LAYOUT SPA FACTORY 1_ENGLISH
- 1. SCORE PROGRAM Its All Because of Love FIGURE 1 MARIA SATYA PUTRI, OWNER OF SPA FACTORY Back in 2002, Maria SatyaPutri decidedtomove tothe Island of the Gods;Bali. There,she decidedtostart hercareeras a businesswomansellingspaproducts, which are now being soldby a numberof local and international hotelsandresorts. Earlierinher businessjourney,Maria metan acquaintance fromthe United Stateswhohad a dream totransform Bali intoa global pampering destination. Maria,whohad a great passionforspa productsand body scrub,greatlywelcomedthe ideaand decidedtoopena small business producingbodycare products,which she later called:SpaFactory. I am indeedafan andloverof spa and bodyscrub products. My motherwho isfrom Yogyakartais the one who introducedme tothose bodycare products. I have knownthose products froma youngage,Maria said OPPORTUNITIES AND INTERNATIONAL MARKET Marias small business was officially operational in August 2002. At the beginning of her business,she only had one employee and used her own house as a production facility. According to Maria, producing these spa products made her feel like she wasbackinher college years, whenshe spenta lot of time readingandexpanding SPA FACTORYS CASE STUDY TAKING HOUSE SPA TO AN INTERNATIONAL LEVEL THEY SAY As the ownerof the company, I see SCORE program as a much needed training for the employees in my company. They (the employees) often fail to do something not because they do not want to do it, but they do not know how to do it. For example, arranging the objects in the warehouse appropriately, etc. that is the knowledge that they acquire through SCORE. Maria Satya Putri, Spa Factory owner
- 2. 2 SPA FACTORY her knowledge and her insight on beauty products, especially developing spa products. Back in September 2002, the international community was shocked by the tragic Bali Bombing terroristattackwhichclaimedhundredsof lives.This event affected Marias new startup business. However, Maria is a tough businessperson. That is the risk of havinga business,Ihave a strong will and continue to think positively, Maria said. Marias persistence in pioneering her business paid dividends, and eventually one of her friends from France contactedherand expressedherintentionto opena spabusinessinMaldives. Mariaimmediately welcomed this opportunity and started her spa product export to a foreign country. My business is small to medium scale and I am not a businesspersonwithunlimitedcapital,therefore I have to be able to create products whichwill satisfy my consumers;bothnationallyandinternationally, she said. Other than product quality, Maria expressed the importance of innovationandthe abilityto envision and determine the market niche in line with attracting her consumers attention. Offering a private label or customized products became the new focus of her business. We do not have brands forthe productsthat we produce,howeverwemake productsandbuildthe brandimageforotherpeople; these conditions in fact have enabled our company to survive and in fact keep growing, Maria said. WOMAN LEADER Being a woman business leader in spa products productions provides various types of privileges, according to Maria. As a woman, I have a strong maternal instinct; this in fact helps me to embrace my employees and as majority of them are women; we are more open to communication and a cohesive working environment, Maria said. FIGURE 2. DAYCARE FACILITY AT SPA FACTORY One initiative that Maria implemented in order to create conducive workingconditions,wasto opena daycare facility for her female employees. This has positively impacted working conditions, as it provides a sense of comfort and security for the female employees as they know their children are being well looked after when they are at work. I am a mother of two, so I appreciate the security of knowing I am able to work while my children are looked after, Maria explained. Despite fierce business competition, Maria believes that the company will survive because of the strong sense of familyvaluesintheworkplace,aswellasthe highly flexible culture designed to build, and accommodate conducive workingconditionsforher employees. Cooking and having lunch together or goingonfishingtripsare some of the social activities regularly organized by the Spa Factory to improve team morale and encouraging a positive culture in the workplace. These social activitiesinfact create a highsense of belonging among the employees toward this company. Ultimately, this is what will lead to more effective and consumer satisfaction of our products, Maria said.
- 3. 3 SPA FACTORY IMPROVEMENTS IN THE COMPANY TO ENHANCE EFFECTIVENESS IN THE WORKPLACE Spa Factory interaction with ILOs SCORE program took place on January 2015. SCORE establishes collaborationwithaprivate trainingprovider,BEDO, to organize enhancingperformance trainingof small to medium scale enterprises in Bali. WhenI firstattendedSCOREtraining,Iencouraged my employees to be more active in taking part in discussions and performing issue mapping. I think it is essential as this training actually places the employees as the agent of change; thus when a change is deemed necessary, the initiative should originate from the employees, Maria said. SCORE trainingis notdull,as it is so much different from the trainings we attended in the past, Mauliana Soliha, Head of Production at Spa Factory said. Upon returningfromthe SCORE training,employees and management of Spa Factory demonstrated a commitment to transforming their company. The mass signing of the SCORE banner by all employees and management indicated a strong consensus of improving the workplace together. In conjunction with cleaning up the companys internal organization; 5S, the employees identified issues and saw that they needed to engage in organizational activities especially within the companyswarehouse.Thisstepwasfollowedbythe formationof anEnterprise ImprovementTeam(EIT). One of the duties of the EIT is to ensure the sustainability of 5s activities in the company as well as maintain the 5s passion and approach within the entire production line. Mauliana also expressed: There is only limited space in our office and our warehouse is seriously disorganized. All objects are mixed-upand there is no proper room organization nor consistent identification of existing objects, Mauliana said. ThoyibunRiki MatHora, AssemblingSupervisor,also adds that due to these complexities and the disorganization, including the lack of labels on objects, an absent employee for a particular department results in confusion among other employees in the management of the objects. Mauliana also describes the R&D room, where she works, as chaotic. Work files were scattered everywhere. Iwasso embarrassed.Now myroom is very organized, thanks to 5s, Mauliana added. FIGURE 3. MAULINA SOLIHA PROUD BECAUSE R&D ROOM BECOME SO CLEAN AND ORGANIZED Jeff Kristianto, one of the trainers of BEDO who accompaniedthe SCOREprogramimplementationat Spa Factory, statedthat: The establishedEITshows a high level of enthusiasm toward the SCORE program implementation. They always attend the meetings and actively discuss with trainers from BEDO to receive professional feedback in conjunction with improved collaboration and implementation of 5s; therefore the organization and clean up activities which were originally done only in the warehouse, finally expanded to production and office areas, Jeff said with a wide grin. Other than 5s, Spa Factory also experienced some improvements in terms of communication and collaboration. We used to blame each others unit
- 4. 4 SPA FACTORY when a mistake occurred. Now we focus more on identifying the issues and look for solutions. This is made possible due to regular meetings held in the late afternoon among division heads and inventory units to discuss various issues such as orders received, Mauliana explained. Additionally, they alsoholdweeklymeetingsthatinvolvealldivisionsin the company,includingthe salesdepartment. Thisis necessary in order to avoid production mistakes. FIGURE 4. REGULAR MEETING AMONG ALL DIVISION IMPROVED COOPERATION IN THE WORKPLACE Thoyibun has also noticed improvements in the communication system. It used to be that our communication system was greatly informal; this situationisdue tothe locationof ourcompanywhich isinthe middleof aresidentialarea,hence wedonot feel that it is necessary to prepare a request for goods in writing, normally we simply shout out a request for such goods; and we shall receive the requested goods. With the introduction of SCORE, we have learned to build a better communication system. Nowwe havetohave coverletterswhenwe request goods from the warehouse. This helps facilitate a correct audit of stock inventory. SpaFactory hasalsostartedto maximizethe use of a bulletin board to ensure that employees receive sufficient information regarding relevant company matters. Additionally,there isalsoaplatformwhich enablesthe employeestoprovide feedbackonways to improve work effectiveness, as well as other topics. Through the commitment and hard work demonstrated by this company, in a relatively short period of time from January to March 2015, there are improvements in communication which has led to improvedcollaboration.Thishastriggeredafairly significantimprovementinthe productionfrontline: the percentage of defective productsatthe frontline fell from4.12% to 0%. Meanwhile atthe endof the production line, the percentage of defective products which was 2%, and at some point even reached 2.8%, has now dropped to 0%. BECOMING EVEN BETTER As the headof Spa Factory,Maria admittedthatthis small to medium enterprise is the type of business which is vulnerable to changes and development taking place out there. Majorityof Small to MediumEnterprisesstartwith the interestof theownertowardaparticularsubject, hence often times these Small to Medium Enterprisesdonotkeepagoodmanagementsystem; hence their businesses start to disintegrate when their businesses should be growing, Maria said. Maria further added that SCORE is a training program that meets the needs of Small to Medium Enterprise entrepreneurs in this country. I honestlyfeel supportedbythe SCORE program as this program was introduced at the right time. Moreover,whenwe had to move from our previous location to the new location we occupy now, there were plenty of aspects associated with the proper workflow, organization, and tidiness of our workplace whichhashelpedusduringthe relocation of our workplace, Maria said.
- 5. 5 SPA FACTORY FIGURE 5. SPA FACTORY IS NOW OCCUPIED A NEW BUILDING IN UNGASAN AREA Effective April 2015, Spa Factory, whichwas located on Toyaning Street, Kuta-Bali, now occupies a new location in the Ungasan area. Occupying an area of 1,450 meters,SpaFactoryisnowproudlyshowingits presence. Inside her workspace, filled with an aroma of lemongrassandmintleaves,Mariastatedthatshe is a passionate personwhenitcomesto spas,and she isoftenpreoccupiedwiththeideaonhowtodevelop this ideal business of hers. However, she admitted that whatever happens behind the doors of Spa Factory becomes another challenge. Workflows which involves various work units often times present problems, therefore communication and collaboration is a critical aspect, in addition to 5s. FIGURE 6. MARIA MET UP WITH SCORE IN HER CLEAN AND ORGANIZED OFFICE I do not have sufficient knowledge of how to run a factory,butnowItrulyhave achance tolearnitfrom SCORE,Maria said.Asthe ownerof the company,I see the SCOREprogramas muchneededtrainingfor the employees in my company. They (the employees) often fail to do something not because they do not want to do it, but because they do not know how todoit.Forexample,effectivelyarranging the objectsinthe warehouseappropriately,etc.That is the knowledge that they have now acquired through SCORE, Maria said. Accordingto her,the businessownersoftenassume that the employees should know of various aspects that enable the company to work more effectively and efficiently, however not all employees have sufficient knowledge and experience. Maria considers that a common business owners mistake is that they do not provide sufficient training and guidelines for their employees. When the employees have acquired knowledge from SCORE training,theywill be passionate tolead changes in their workplace and will truly feel the benefits of them, Maria said. The success of Spa Factory in implementing the SCORE program in the company has enhanced the workingspiritsof the employees.Thisisindicatedby the reduction in employee absenteeism from 3% in January down to 1% in March 2015. Thoyibun from the assembling unit said, Since the workplace is now clean and orderly, the workflow and communication work well, I sometimes dont realize whattime itisasitgoesbysoquickly,andall of suddenitis time to go home. I feel at home here and this is like a second home for me.
- 6. 6 SPA FACTORY FIGURE 7. R&D ROOM BEFORE IMPLEMENTATION OF SCORE: PREVIOUS BUILDING FIGURE 9. R&D ROOM IS ORGANIZED AND CLEAN NEW BUILDING FIGURE 8. R&D ROOM AFTER SCORE IMPLEMENTATION TRANSITION PERIODE BEFORE MOVE OUT TO THE NEW BUILDING THEY SAY Work files were scattered everywhere. I was so embarrassed. Now my room is highly organized, thanks to 5s, - Mauliana Soliha, Head of Production, Spa Factory THEY SAY Since the workplace now is clean and orderly, the workflow and communication work well, I sometime am not aware as time goes by so quickly, all of sudden it is time to go home. I feel at home here and this is like a second home forme. Thoyibun RikiMat Hora, Assembling Supervisor.