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Kaizen - Celebrity Fashions Pvt. Ltd.

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  • 1. Profile … Apparel/Readymade garments Manufacturing. 3 million Garments per year Product range from scarf to jacket 4 factories with Employee strength of 3500. 380 crores in combined turnover Own Domestic brand manufacturing + retailing Established 25 year ago in 1988.
  • 2. Challenges that the apparel sector faced.Celebrity Fashions : Narayanapuram Rising manufacturing costs Skilled manpower shortage. Poaching of employees by other sectors likeretail, electronics, real estate and auto industrygiants. A weaker rupee. Rise of lower cost hubs like Bangladesh,Indonesia, Egypt etc. Higher compliance standards . Reduction in incentives from the governing
  • 3. Celebrity Fashions : Narayanapuramof Kaizens
  • 4. Celebrity Fashions : Narayanapuram
  • 5. “Pay me half of what we spend and I shall showthem that Leans not possible here.” 25 year old baggage Reluctance to change I know it all Paradigms/Barriers. Whats in it for me ? No focus on improvements or the future." Lean ? U mean single piece flow, no breakdown ofmachine, no abseentism, ridiculous system,Are you joking, no way that this can be done in our
  • 6. BEGINING….not from the Books.. Started with 5s as the foundation. Awareness regarding the need for change Training and empowerment of middlelevel managers. Learnt from our Mistakes. Inspired by Employees Ideas Encouraged ideas for progressAnd thus came kaizens
  • 7. Operational Problems that needattention.. Abseentism Attrition Rework/Rejections Production Losses Higher style startup time Inventory pileups Higher Leadtimes Higher Manufacturingcost
  • 8. Kaizen-Initiative-Practice-Culture
  • 9. Sustaining the culture 2% of manhours every month is spenton training Incubator line formed for explainingnew comers the best practices Training school with respectivefunctional Heads guest lectures One point lessons as a manual/WorkInstructions. TWI : Best in class employee as trainer-Job based Connecting career growth with “Best Practices”adherence
  • 10. One Point lessons - Examples
  • 11. One Point lessons - Examples
  • 12. PDCACelebrity Fashions : NarayanapuramProblemeliminated forgood.
  • 13. PDCA29 PDCAscompleted inpast 2 years.
  • 14. Celebrity Fashions Limited
  • 15. Nursing Kaizen Environment Pre-recorded messages on kaizen subject via PAsystem, Cross functional Panel to invite and execute ideasinstantly. A dedicated day 3rd Friday of everymonth Cash awards and certificate of recognition. Newsletter for spreading recent progress/Ideas. A patrol team to monitor the progress of the kaizensimplemented across all Factories Senior managements dedication
  • 16. 3rd Friday – The Kaizen TabloidCelebrity Fashions : Narayanapuram
  • 17. Successful completion of 13editionsCelebrity Fashions : Narayanapuram
  • 18. CADD /Cutting Dec ‘2011PRODQLTYCOSTSFTYDELSMORLPandirajan/AnuFor Gerber plotter GT 100 : about 8-10 cartridge penseach costing 600 rs was used every month, summing up aminimum expense of 6000 rs a mnthThe earlier optionrequired anexpense of 6000rs a month +ordering / followups/receipts/couriercharges etcthis kaizen beingthe very first one,led to a lot ofencouragementamong others tocontribute ideasEmpphotograph To overcome this cost factor, a ball point refill was fixedinto an empty cartridge pen & tried out. The result afterthis trial showed promising outcomes, leading to a savingof 72000/annumTangibleBenefitsValue/unitProdnTimeQualityMaterialOthers 7000070000 rs/annPre kaizenscenarioPost kaizenscenarioSTATUS:ImplementedFew Kaizen Eg: Usage of Ball point refill instead of Cartridgepen
  • 19. Ironing dept June ‘2012PRODQLTYCOSTSFTYDELSMORLThe Measurements of a garment during the finishingprocess is checked during ironing by using a cardboardpattern which is made for every size & styleThe preparationeffort, time & costinvolved is higherfor the earlierpractice.Higher output ,less handling isone advantagebeside the costsaved due toelimination ofcard board usageKaizen panelIn order to overcome this, a measurement grading similarto our measuring tape is printed on the ironing table clothitself, both vertically & horizontally.TangibleBenefitsValue/unitProdn 60 pcs/dayTime 4 secs /pcQuality Eradicatesmeasuremntissues.MaterialElectricityPre kaizenscenarioPost kaizenscenarioSTATUS:ImplementedElimination of measurement patterns usage during ironing atfinishingStanley
  • 20. Few More Kaizen Examples Couriering Socks to retail stores instead logisticsmode. Bringing only 50 mts Initial yardage of fabric by airin only one color. RO plant installation instead of procuringpackaged water Usage of stock threads for fresh lots (avoidsprocuring) Sending back packaging accessories to factoriesfrom stores
  • 21. Kaizen CountHUB Quality Prod Cost Safety Morale TotalFactory 49 137 81 32 28 327Product Development 7 6 10 23Merchandising 16 16Purchase 3 3Laundry 2 2 4 1 9Retail 14 14Human Resources 4 5 37 46Warehouse 4 41 45Total 58 149 169 41 66 483020406080100120140160Quality Prod Cost Safety MoraleKaizen CountFactoryProduct DevelopmentMerchandisingPurchaseLaundryRetailHuman ResourcesWarehouse
  • 22. Kaizen SavingsHUB Cost SavedFactory 19261910Product Development 63272Merchandising 2214860Purchase 4344264Laundry 36800Retail 217066Human Resources 1408040Warehouse 6794418Total sum 3,43,40,63056%0%6%13%0%1%4%20%Savings via KaizensFactoryProductDevelopmentMerchandisingPurchaseLaundryRetailHumanResourcesWarehouse
  • 23. Celebrating Fun at workCelebrity Fashions : Narayanapuram
  • 24. Celebrity Fashions : Narayanapuram
  • 25. PRESENT STATE… OUT OF BOX THINKING TEAMWORK EMPLOYEEINVOLVEMENT EMPOWERMENT CLEANLINESS & ORDER MOTIVATEDWORKFORCE PROACTIVE APPROACH PRE-PLANNEDEXECUTION FUN /JOY ATWORKPLACE CAREER GROWTH TRAINED WORKFORCETHINGSSET INORDERCELEBRATING WORK