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.
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