Progress 26.11.14
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- The document discusses improvements made to human resources, productivity, quality, and methods at a garment factory over several months. - Key human resources initiatives included an induction system, buddy system, and appraisal system, which helped reduce absenteeism and turnover. Productivity improvements such as data tracking helped reduce defects and losses. - Graphs show decreases in absenteeism, defects, and losses, as well as increases in efficiency, productivity, and profits over the months that the new systems and initiatives were implemented.
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Progress 26.11.14
- 1. SHANGU GROUP. Farseeing knit composite ltd. A sister concern of, Prepared By, S.M. Abedin Kader Manager(IE) Farseeing Knit Composite Ltd. Fareedpur, Telihati,Sreepur,Gazipur.
- 3. Summary: *06 Zero Defect Operators. *A very simple and well defined guideline to start Industrial Engineering activities. *A proper guideline for Qualified Production Management
- 4. Summary: *Very strong Team work forming guideline. *A pace to change the Culture. *Well structured HR work way. *Very specific to reduce Worker Turnover.
- 6. 1. Induction System 2. Buddy System 3. HR Trackers 4. HR Visions 5. Responsibilities of HR Manager, Welfare Officer and Buddy 6. Responsibilities of Sewing Supervisors 7. Appraisal System 8. Training Need Assessment KEY POINTS.
- 7. What worked well & how? Induction System. Except month the of September, this system worked well. Worker Turnover was reducing gradually. We are focusing on this system because we believe that it will help us to achieve our target.
- 8. Where do you find difficulties? describe, why? A fully dedicated welfare officer is needed to continue the system.
- 9. Summary of Human Resource Improvements: Months Absenteeism (Pilot) Absenteeism (Factory) Turnover (Factory) Avg. pay (BDT) per Hour (Statistical) May 3.24 % 12.69 % 04 % 30.6 June 2.07 % 10.82 % 05 % 32.9 July 0.36 % 5.16 % 01 % 34.5 August 1.80 % 7.20 % 04% 33.00 September 1.38 % 5.85 % 01% 32.90 October % % %
- 10. Graphical Representation 3.23% 2.07% 0.36% 1.80% 1.38% 1.89% 2.30% 0.00% 0.50% 1.00% 1.50% 2.00% 2.50% 3.00% 3.50% May June July August September October November ABSENTEEISM (PILOT LINE)
- 11. Graphical Representation 12.69% 10.82% 5.16% 7.20% 5.85% 8.31% 6.54% 0.00% 2.00% 4.00% 6.00% 8.00% 10.00% 12.00% 14.00% May June July August September October November FACTORY ABSENTEEISM
- 12. Graphical Representation Absenteeism (Pilot Line VS Others) 3.23% 2.07% 0.36% 1.80% 1.38% 1.89% 2.30% 12.69% 10.82% 5.16% 7.20% 5.85% 8.31% 6.54% 0.00% 2.00% 4.00% 6.00% 8.00% 10.00% 12.00% 14.00% May June July August September October November Absentism (Pilot Line) Total
- 13. Graphical Representation 4% 5% 1% 4% 2% 7% 0% 1% 2% 3% 4% 5% 6% 7% 8% MAY JUNE JULY AUGUST SEPTEMBER OCTOBER Turnover (Factory)
- 16. Key Points: 1. Performance Calculation 2. Time Study 3. Method Study 4. Line Balancing 5. Zero Defect Operator 6. Problem Solving Methodology 7. 7 Wastages 8. 5 S
- 17. What worked well & how? Data Tracking and Monitoring System. Such as Cut to Ship loss and DHU Trackers. It helps and guides us in every step to make improvements by analyzing root causes in detail.
- 18. Where do you find difficulties? describe, why? ï‚—To involve the supervisor into data tracking system as there are so many trackers. ï‚—Actually the supervisors are not used to do such type of paper job.
- 19. Summary of Productivity Improvements: Months Pilot line efficiency Pilot line productivity per person per 8 hours Pilot Line’s cut to ship Loss ratio Loss time in percentage (Pilot Line) Factory’s cut to ship loss ratio June 19.91% 12.50 3.25% 3.3% 3.32% July 23.73% 14.66 1.50% 3.3% 2.63% August 23.78% 15.51 2.60% 3.2% 2.08% September 25.29% 15.71 1.90% 3.3% 1.15% October 26.98% 15.85 1.25% 2.75% 1.43%
- 20. Graphical Representation 5 2 4 3 3 3 9.8 8 9.8 8 9 8 0 0.05 0.1 0.15 0.2 0.25 0.3 0 2 4 6 8 10 12 May june July August September October Style Changes Avg. SMV Pilot Line Efficiency Of Pilot Line
- 21. Graphical Representation 58 58 58 58 58 58 12.5 14.66 15.51 15.71 15.85 0 10 20 30 40 50 60 70 May June July August September October Avg.Person Pilot Line Productivity Per person per 8 hrs(Pilot Line)
- 22. Graphical Representation 3.30% 3.30% 3.20% 3.30% 2.70% 0.00% 0.50% 1.00% 1.50% 2.00% 2.50% 3.00% 3.50% June July August September October Lost Time Persantage(Pilot Line) Lost Time Persantage(Pilot Line) Considered: No-Input Supply Problem M/C Break Down Line Setting Repair/Alteration Not started Others/Operator
- 23. Graphical Representation 2.53% 3.32% 2.63% 2.08% 1.15% 1.43% 0.00% 0.50% 1.00% 1.50% 2.00% 2.50% 3.00% 3.50% May June July August September October Factory Cut Ship Loss Ratio(%)
- 24. Summary of Quality Improvements: Months DHU of Sewing Line (Pilot Line) Percentage Defective of Sewing Line (Pilot Line) DHU of Finishing (Pilot Line) Percentage Defective of Finishing (Pilot Line) May 6.58 5.24% 8.36 3.5% June 7.97 5.69% 7.56 4.56% July 6.40 4.25% 7.23 3.45% August 6.42 4.43% 5.62 2.87% September 6.49 4.37% 5.54 1.58% October 4.27 4.75% 6.83 3.25%
- 25. Graphical Representation 6.58 7.97 6.4 6.42 6.49 4.27 0 1 2 3 4 5 6 7 8 9 May June July August September October DHU of Sewing Line (Pilot Line)
- 26. Graphical Representation 5.24% 5.69% 4.25% 4.43% 4.37% 4.75% 0.00% 1.00% 2.00% 3.00% 4.00% 5.00% 6.00% May June July August September October Percentage Defective of Sewing Line (Pilot Line)
- 27. Graphical Representation 8.36 7.56 7.23 5.62 5.54 6.83 0 2 4 6 8 10 May June July August September October DHU of Finishing (Pilot Line)
- 28. Graphical Representation 3.50% 4.56% 3.45% 2.87% 1.58% 3.25% 0.00% 0.50% 1.00% 1.50% 2.00% 2.50% 3.00% 3.50% 4.00% 4.50% 5.00% May June July August September October Percentage Defective of Finishing (Pilot Line)
- 29. Summary of Method Improvements: Operation Description Cycle time before & after Average cycle time reduction % No. of manpowe r reduced Average hourly output improved Video documentatio n available (Yes / No) Box Plate Facing Lining Fusing Before- 28 After-10 64.28% 1 42 Yes Pocket Attach Before- 69 After-54 22.00% --- 14 Yes Collar TS With Neck Tape Before- 105 After-72 31.42% --- 13 Yea
- 30. Cost Savings Month Ship Qty Cut to Ship Loss Improvem ent % Extra Shipped Profit Gain @ $ 0.90 In BDT @ 78 Conversio n Rate May 195465 2.53% Considering Base Line June 43678 3.62% -1.09% -477 -429.3 -33485.4 July 88338 2.63% -0.1% -88 -79.2 -6177.6 August 71555 2.08% 0.45% 321 288.9 22534.2 Septemb er 101100 1.15% 1.38% 1395 1255.5 97929 October 78336 1.43% 1.10% 862 775.8 60512.4 Total(Excluding June & July Month) 141312.60 Factory (Gain due to Cut to Ship Loss Reduction)
- 31. Cost Savings Month Produce Qty Efficienc y Base line Efficienc y Improved Extra Produced Extra Earn@$ .02 In BDT @ 78 Conversat ion Rate June 19362 19.9% 19.90% Considering Base Line July 19362 23.7% 3.8% 2400 48.00 $ 3744 August 22137 24.8% 4.9% 22165 443.30 $ 34577.4 September 21850 25.3% 5.4% 20855 417.10 $ 32533.8 October 19690 27.00% 7.3% 12785 255.70 $ 19944.6 Pilot Line(Gain Due to Efficiency Improvement)
- 32. Initiatives: 5 S
- 35. Thank You.