Muhammad Dimas Firmanda DEVELOPMENT OF TRAINING MODULES AND INFRASTRUCTURES
FOR PRODUCTION AREA AT GERMAN AUTOMOTIVE MANUFACTURING COMPANY
By
Muhammad Dimas Firmanda 11507002
BACHELOR’S DEGREE in
INDUSTRIAL ENGINEERING
FACULTY OF ENGINEERING AND INFORMATION TECHNOLOGY
SWISS GERMAN UNIVERSITY
The Prominence Tower
Jalan Jalur Sutera Barat No. 15, Alam Sutera Tangerang, Banten 15143 - Indonesia
July 2019
Revision after Thesis Defense on 10th of July 2019
Muhammad Dimas Firmanda
STATEMENT BY THE AUTHOR
I hereby declare that this submission is my own work and to the best of my knowledge, it contains no material previously published or written by another person, nor material which to a substantial extent has been accepted for the award of any other degree or diploma at any educational institution, except where due acknowledgement is made in the thesis.
Muhammad Dimas Firmanda
____________________________________________
Student Date
Approved by:
Ir. Setijo Awibowo, MM
____________________________________________
Thesis Advisor Date
Dr. Tanika Dewi Sofianti, S.T, MT.
____________________________________________
Thesis Co-Advisor Date
Dr. Maulahikmah Galinium, S.Kom, M.Sc.
____________________________________________
Dean of Faculty of Engineering & IT Date
Muhammad Dimas Firmanda
ABSTRACT
DEVELOPMENT OF TRAINING MODULES AND INFRASTRUCTURES FOR PRODUCTION AREA AT GERMAN AUTOMOTIVE
MANUFACTURING COMPANY
By
Muhammad Dimas Firmanda Ir. Setijo Awibowo, MM, Advisor Dr. Tanika Dewi Sofianti, ST.MT, Co-Advisor
SWISS GERMAN UNIVERSITY
German Automotive Manufacturing Company is an international automotive company that has been established since the 19th century in Germany. The company is renowned for making high quality automotive cars that has been distributed to all parts of the world. In 1970s, German Automotive Manufacturing Company have the first manufacturing plant in Wanaherang Bogor which is around 50 km from Jakarta. The manufacturing plant that located in Wanaherang, Bogor is mostly focusing on assembly vehicle parts that came from Stuttgart, Germany and has been certified and declared by TUV-Rheinland as an Eco-Industry.
The situation that the factory area currently has inside the factory is that there is no proper production training center for every types of worker in the factory. These can lead to many problems such as the learning curve of the workers during in the factory area are longer than it needs to be. Therefore, production training center for the German Automotive Manufacturing Company are very much needed in order to give learning time for new workers, and also refreshment training for existing workers.
Keywords: Training Handbooks, E-Learning, ADDIE Model, Learning Process, Training Methods
Muhammad Dimas Firmanda
© Copyright 2019
by Muhammad Dimas Firmanda All rights reserved
Muhammad Dimas Firmanda
DEDICATION
I dedicate the thesis
To God who gave me spiritual wisdom To my parents for their utmost support
To my professors and lectures who taught me many knowledges And to all my friends and colleagues who went through tough times with me
Muhammad Dimas Firmanda
ACKNOWLEDGEMENTS
First and foremost, the author would like to give his utmost gratitude to Allah SWT, who are always give me with help and blessing with completing the thesis. Without God’s blessing, the author will not complete the thesis.
The author also expresses his profound gratitude towards Ir. Setijo Awibowo, Dr.
Tanika Dewi Sofianti, S.T, MT, and Wahyu Ricardo S.T, who their role as the author’s supervisors will not be forgotten. Their endless support and motivation have guided the author to finish the thesis.
Nevertheless, the author would like to express his biggest gratitude towards his mother, Ir. Dias Nurrahmi Widiastuti, father, Agus Wahyu Widodo, S.E, and grandfather, Ir.
Slamet Widodo who always give the author their kindness to drive the author to make the thesis as best as possible.
Furthermore, the author would like to mention his thankful towards Audrelia Maretha Putri S. Ked, who always gave the author many encouragement and support to give the author the motivation to work his hard to complete the thesis. The author also gives his many thanks to Rezky Dwimarsya S.T, B. Eng and Andreas who helped the author throughout the thesis development for the past six months.
The author also would like to give his thanks to all of the author’s friends from Industrial Engineering SGU 2015 who went through this journey together with the author. The four years of college experience cannot be more fulfilled without the friends that the author have throughout college life.
Last but not least, the author would like to say his thanks to Hakim, Aldi, Haikel, Fikri, Arel, and others who are not mentioned. Thank you for giving the author the motivation and strength to inspire the author to finish the thesis.
Muhammad Dimas Firmanda
TABLE OF CONTENTS
STATEMENT BY THE AUTHOR ... 2
ABSTRACT ... 3
DEDICATION ... 5
ACKNOWLEDGEMENTS ... 6
TABLE OF CONTENTS ... 7
LIST OF FIGURES ... 10
LIST OF TABLES ... 11
CHAPTER 1 – INTRODUCTION ... 12
1.1. Background ... 12
1.2. Research Problem ... 13
1.3. Research Objectives ... 13
1.4. Research Limitation ... 13
1.5. Thesis Structure ... 13
CHAPTER 2 – LITERATURE REVIEW ... 15
2.1 Change Management ... 15
2.2 Training and Skills Development ... 15
2.2.2. On-the-job Training ... 16
2.2.3. Off-the-job Training ... 17
2.3 Training Process ... 20
2.3.1. Analysis Phase ... 21
2.3.2. Design Phase ... 23
2.3.3. Development Phase ... 24
2.3.4. Implementation Phase ... 26
2.3.5. Evaluation Phase ... 27
2.4 Learning Outcomes... 27
2.5 E-Learning ... 29
Muhammad Dimas Firmanda
2.6 Knowledge Management ... 30
2.7 Concept of Knowledge in Knowledge Management ... 31
2.8 The SECI Model of Knowledge ... 32
2.9 Likert Scale ... 33
CHAPTER 3– RESEARCH METHODOLOGY ... 36
3.1. Analysis ... 37
3.2. Design ... 37
3.3. Development ... 38
3.3.1. Training Center Materials ... 39
3.3.2. Training Infrastructure ... 39
3.4. Implementation ... 39
3.5. Evaluation ... 40
3.5.1. Result and Discussion ... 40
3.5.2. Conclusion and Recommendation ... 40
CHAPTER 4– RESULT AND DISCUSSION ... 41
4.1. Company Profile ... 41
4.2. Analysis ... 41
4.2.1. Problem Identification ... 42
4.2.2. Literature Review ... 42
4.2.3. Define Solution ... 42
4.3. Design ... 43
4.3.1. Identify the Process of Assembly Vehicle ... 43
4.3.2. Design Courses for Each Processes ... 46
4.4. Development ... 49
4.4.1. Training Center Materials ... 49
4.4.2. Training Center Infrastructure ... 55
4.5. Implementation ... 61
4.5.1. Pre-Test ... 61
Muhammad Dimas Firmanda
4.5.2. Theoretical Training ... 63
4.5.3. Practical Training ... 64
4.5.4. Post-Test ... 64
4.6. Evaluation ... 66
4.6.1. Respondents ... 66
4.6.2. Calculation using Likert Scale ... 67
CHAPTER 5– CONCLUSION AND RECOMMENDATION ... 76
5.1. Conclusion ... 76
5.2. Recommendation ... 77
REFERENCES ... 78
APPENDIX A – Handbook of Tightening ... 79
APPENDIX C – Handbook of E-Learning ... 157
APPENDIX D – Handbook of Gluing ... 171
APPENDIX E – Handbook of Checking and Setting ... 192
APPENDIX F – Training Tool Design: Push-Pull Non-Electrical Connection ... 218
APPENDIX G – Training Tool Design: Tightening ... 223
APPENDIX H – Training Tool Design: Push-Pull Electrical Connection ... 227
APPENDIX I – Training Tool Design: Gluing ... 230
APPENDIX J – Training Tools: Checking and Setting ... 232
APPENDIX K – Training Pre/Post-Test Example: Tightening ... 235
APPENDIX L – Training Development Questionnaire ... 248
CURRICULUM VITAE ... 255
