SHANGU GROUP.

Farseeing knit composite ltd. A sister concern of,

Prepared By,S.M. Abedin KaderManager(IE)Farseeing Knit Composite Ltd.Fareedpur, Telihati,Sreepur,Gazipur.

Productivity & quality

Summary:

*06 Zero Defect Operators. *A very simple and well defined guideline to start Industrial Engineering activities.

*A proper guideline for Qualified Production Management

Summary:

*Very strong Team work forming guideline.

*A pace to change the Culture.

*Well structured HR work way.

*Very specific to reduce Worker Turnover.

Human Resource

1. Induction System2. Buddy System 3. HR Trackers 4. HR Visions 5. Responsibilities of HR Manager, Welfare

Officer and Buddy 6. Responsibilities of Sewing Supervisors 7. Appraisal System8. Training Need Assessment

KEY POINTS.

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.

Where do you find difficulties? describe, why?

A fully dedicated welfare officer is needed to continue the system.

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 % % %

Graphical Representation

May June July August September October November0.00%

0.50%

1.00%

1.50%

2.00%

2.50%

3.00%

3.50%3.23%

2.07%

0.36%

1.80%

1.38%

1.89%

2.30%

ABSENTEEISM (PILOT LINE)

Graphical Representation

May June July August September October November0.00%

2.00%

4.00%

6.00%

8.00%

10.00%

12.00%

14.00%

12.69%

10.82%

5.16%

7.20%

5.85%

8.31%

6.54%

FACTORY ABSENTEEISM

Graphical Representation Absenteeism

(Pilot Line VS Others)

May June July August September October November0.00%

2.00%

4.00%

6.00%

8.00%

10.00%

12.00%

14.00%

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%

Absentism (Pilot Line) Total

Graphical Representation

MAY JUNE JULY AUGUST SEPTEMBER OCTOBER0%

1%

2%

3%

4%

5%

6%

7%

8%

4%

5%

1%

4%

2%

7%

Turnover (Factory)

Graphical Representation

April May June July August September October28.00

29.00

30.00

31.00

32.00

33.00

34.00

35.00

31.40

30.60

32.90

34.50

33.00

32.90

Avg.Pay(BDT)/Hour

Production & Quality

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

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.

Where do you find difficulties? describe, why?

To involve the supervisor into data tracking system as there are so many trackers.

Actually the supervisors are not used to do such type of paper job.

Summary of Productivity Improvements:

Months Pilot line efficiency

Pilot line productivi

ty 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%

Graphical Representation

May june July August September October0

2

4

6

8

10

12

0

0.05

0.1

0.15

0.2

0.25

0.3

5

2

4

3 3 3

9.88

9.88

98

Style Changes Avg. SMV Pilot Line Efficiency Of Pilot Line

Graphical Representation

May June July August September October0

10

20

30

40

50

60

70

58 58 58 58 58 58

12.5 14.66 15.51 15.71 15.85

Avg.Person Pilot Line Productivity Per person per 8 hrs(Pilot Line)

Graphical Representation

June July August September October0.00%

0.50%

1.00%

1.50%

2.00%

2.50%

3.00%

3.50%3.30%

3.30%

3.20% 3.30%

2.70%

Lost Time Persantage(Pilot Line)

Lost Time Persantage(Pilot Line)

Considered:No-Input

Supply ProblemM/C Break Down

Line SettingRepair/Alteration

Not startedOthers/Operator

Graphical Representation

May June July August September October0.00%

0.50%

1.00%

1.50%

2.00%

2.50%

3.00%

3.50%

2.53%

3.32%

2.63%

2.08%

1.15%1.43%

Factory Cut Ship Loss Ratio(%)

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%

Graphical Representation

May June July August September October 0

1

2

3

4

5

6

7

8

9

6.58

7.976.4

6.426.49

4.27

DHU of Sewing Line (Pilot Line)

Graphical Representation

May June July August September October 0.00%

1.00%

2.00%

3.00%

4.00%

5.00%

6.00%

5.24%5.69%

4.25%

4.43%

4.37%

4.75%

Percentage Defective of Sewing Line (Pilot Line)

Graphical Representation

May June July August September October 0123456789 8.360000

000000017.56 7.23

5.62 5.54

6.83

DHU of Finishing (Pilot Line)

Graphical Representation

May June July August September October 0.00%

0.50%

1.00%

1.50%

2.00%

2.50%

3.00%

3.50%

4.00%

4.50%

5.00%

3.50%

4.56%

3.45%

2.87%

1.58%

3.25%

Percentage Defective of Finishing (Pilot Line)

Summary of Method Improvements:

Operation Description

Cycle time

before & after

Average cycle time reduction

%

No. of manpo

wer reduced

Average hourly output

improved

Videodocumenta

tion 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

Cost Savings

Month Ship Qty

Cut to Ship Loss

Improvement %

Extra Shipped

Profit Gain @ $ 0.90

In BDT @ 78

Conversion 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

September

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)

Cost Savings

Month Produce Qty

Efficiency

Base line

Efficiency

Improved

Extra Produce

d

Extra Earn@$

.02

In BDT @ 78

Conversation 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)

Initiatives: 5 S

Great Achievement!!!

Zero Defect

Operator

October

October SeptemberSeptember August

July

Any Query Please……….

Thank You.