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Approach Plant Startup 11302007
 

Approach Plant Startup 11302007

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    Approach Plant Startup 11302007 Approach Plant Startup 11302007 Presentation Transcript

      • Approach Document
      • Assistance in the Apparel Plant Start up
        • November’ 2007
    • Contents
      • Background 4
      • Objectives and Scope 5
      • Project Work Steps 7
        • Planning and Design 8
        • Selection and Pre-training 13
        • Implementation 15
        • Follow up 23
      • Implementation Schedule 24
      • Project Benefits 25
      • Team and Responsibility 28
      t e c h n o p a k Giza Spinning and Weaving, Co.
    • Background
      • The document discusses the following in detail.
        • Objectives and Scope
        • Methodology
        • Time frame
        • Deliverables
        • Consulting fee
      Background
    • Objectives and Scope
        • To assist in the start-up of an apparel plant
        • Design and plan a model world class building with future expansion plan
        • Achieve efficiency levels comparable to international benchmarks, competitive productivity and quality levels, at low costs of production
        • Selection and implementation of state-of-the-art equipment, as appropriate for local manufacturing conditions
        • Implementation of effective manufacturing management procedures and engineering techniques
        • Selection, training and placement procedures to assure skills necessary at production levels to achieve and maintain competitive performance
      Objectives
    • Objectives and Scope
        • To start a garment facility in specified location.
        • Designing and planning the building, production system, department layouts, MIS, Quality Assurance System etc.
        • Achieve efficiency levels to the tune of 65% after stabilization
        • Technopak’s direct role and involvement will be to start-up first 50% of the sewing machines (TBC).
        • Technopak on-site assistance is planned at 80- 90% of the time for first 3 phases.
        • During the fourth, follow-up phase, on-site assistance will be 25% of the time, over a period of 2 months.
      Scope
    • Project Work Steps Phase 1 Phase 2 Phase 3 Phase 4 Design the production system & layout on the basis of product mix as well as target customers. Plan & design factory specifications, factory control systems, technical requirements and select machine and work-aids etc . Define organization structure & job specifications . Develop shortlist criteria for new positions. Assist in framing advertisement / brief to placement agency & help in selection. Training of merchandisers on Time and Action calendar, Pre-production monitoring and follow up. Conduct class-room training & shop-floor exercises in apparel manufacturing, based on Technopak’s Master Plato® Implement layouts & process design. Establish operator selection procedures and select operator . Training of operators at AAMT centre and Build-up of operator efficiencies through training on the shop-floor . Engineer all garment operations. Implement SAM reduction measures . Build-up of efficiencies through implementation of Production, Industrial Engineering and Quality Assurance procedures . Audit implemented systems to ensure continuity of efficiency build-up . Trouble shoot and support as required, on-site . Monitor & support, through office based support . Duration (Week Number, cumulative) – 0 8 18 38 38+8 t e c h n o p a k Finalize technical specifications based on product and identify equipment. Giza Spinning and Weaving, Co. Planning & Design of the Factory Selection & Pre-Training of Middle Management Implementation Follow-up
    • Phase 1: Planning & Design of the Factory
      • Planning of space, machinery and manpower requirements for the proposed production will be completed in this phase .
      Analysis of the Product Mix and Capacity Planned Design Factory Specifications Design Technical Specifications Define Manpower Requirement Design Management Information System and select the Monitoring Software Design Quality Assurance System Work Steps 1
    • Phase 1: Planning & Design of the Factory
      • Factory Design
        • Building plan and design
        • Future expansion plan
        • Building details such as flooring, colours etc.
        • Utilities plan and design
        • Factory ventilation and cooling system
        • Physical layout plans for manufacturing
        • Electrical plan and load calculation
        • Steam and Pneumatic line plan
        • Production systems
        • Manpower movement plan
        • Material movement plan
      Key Outputs 1
    • Phase 1: Planning & Design of the Factory
      • Production Systems
        • Progressive Bundle Unit
        • Mobile Progressive Bundle Unit
        • Modular Manufacturing
        • Unit Production System
        • Mass Customization
      • Work Handling System
        • Trolleys
        • Movers
        • Carousels
      • Equipment Types
        • Make
        • Model details
        • Supplier Details
      • Storage Systems
        • Racks for different departments
        • Material Transportation system
      • Workplace Attachments
        • Work-aids
        • Folders
        • Work Station Design
        • Labour Saving Devices
      Key Outputs 1
      • Define d Manpower Requirement
        • Detailed manpower requirements for each department
        • Defined job responsibilities for various positions
        • Defined selection criteria
        • Detailed selection plan
        • Design of training and other required equipments
      • Management Information System Design – Design of Technopak Blue Book
        • Assist in standardization, definition, mapping and documentation of production planning and control procedures at the factory level, process descriptions, methods, quality requirements, measures and controls
        • Assist in design of Incentive System for the factory work force.
        • System for application of machine breakdown and preventive maintenance
        • Evaluation of suitable software s available
      • Quality Assurance System Design
        • Design the Quality Assurance system which emphasises producing raw material and garments of the desired quality
      Phase 1: Planning & Design of the Factory Key Outputs 1
    • Phase 1: Planning & Design of the Factory
      • Factory MIS Requirement Design– Design of Technopak Green Book
        • MIS reports designed on the basis of framed process
        • Aimed at providing information about all activities in the factory
        • Help take better decisions on a day to day and on long term basis
      • Compliance Policies Framework – Technopak Red Book
        • Technopak will help factory frame policies on the following:
          • Health and safety requirement
          • Remuneration
          • Daily housekeeping procedures
      • Project Feasibility
        • Execution of the detailed project plan with key numbers of efficiency and costs to extrapolate a 5 year revenue and costs.
        • Calculating the Cost/SAM and the ROI for a 5 year tenure on an yearly basis
      • Project Scheduling and Time Frame
        • Scheduling of all activities developed and a time frame for execution finalized
      Key Outputs 1
    • Phase 2: Selection & Pre-Training
      • Project Team Formation
        • Determination of team requirement
        • Define the organization structure
        • Identify selection centers
        • Release job responsibilities in the press
        • Co-ordinate with selection firm for candidates
        • Initial short-listing of CVs - Fit with pre-defined criteria, based on Technopak’s Short Master program
        • Aptitude level (judged by an entry level aptitude test administered by Technopak)
        • Performance interviews
        • Job offers
      • Key Positions to be selected
        • Factory Manager, Production Manager, Department Managers, Industrial Engineers, Merchandisers, Production Executives, Quality Executives, Operator Trainers
      2 Team Selection
    • Phase 2: Selection & Pre-Training
      • Training for Manufacturing
      • This team will be trained through class-room and on the shop floor activities, to develop strong manufacturing and management skills and tools. The training will be based on Technopak’s MasterPlato ® course, for manufacturing management.
      • The topics covered in this training would be:
        • Apparel engineering, apparel management techniques, and operator training concepts
        • Quality assurance (specifications, inspection and audit procedures)
        • Productivity measurements (metrics, production, efficiencies)
        • Goal setting and line management
        • Line balancing (maintaining optimum utilization levels of workforce and equipment)
        • Cost controlling and Incentive Plans (control of excess costs and waste)
        • Operator Training through AAMT ®
        • Human resources development and change management (attendance, counseling)
      • Once trained, the team will be able to work with the line management on the floor to improve performance.
      2 Pre-Training
    • Phase 3: Implementation
      • Activities in this phase will include:
      •  
        • Install Layouts and Process design
        • Engineer all garment operations and work place design
        • Implement AAMT® Operator Training program
        • Implement Industrial Engineering functions
        • Install Quality Assurance systems
        • Train Middle management and Supervisors
        • Engineer Cutting and Finishing
        • Implement Factory Control Systems and MIS
        • Install direct incentive scheme for workers, in-direct and middle management
        • Build up of Efficiency and Production
      3 Activities
    • Phase 3: Implementation
      • Layouts and Process Design Installation
      • The process design specifications are implemented. The production format is designed in the planning stage in terms of required production volumes, style-flexibility needs, space utilization and cycle time needs thereby defining the following:
        • Production system – Assembly line size, level of flexibility required, level of multi-skilling, etc.
        • Layout
        • Bundle size and WIP level
        • Material Handling System
        • Throughput time
      • Engineer Garment Operations and Work Place Design
      • Each operation will be engineered so as to minimize the non-sewing time in the operation
        • Work places and work-aids will be designed for each operation
        • Methods and standards will be defined for all operations on core styles
        • Production methods and standards will be implemented as defined
      3 Layout and Engineering
    • Phase 3: Implementation
      • Introduction to AAMT ® (Advanced Analytical Method of Training ® )
      • A large number of apparel companies do not train their operators in ‘Best Practices’. Inefficient employee training can be very expensive, especially when accompanied by high labour turnover. The cost to train an operational employee to a productive work level is often estimated at several thousands of Rupees, considering trainee wages, overhead s , payroll cost, effective work produced and other factors.
      • Many firms experience high training costs and even higher disappointing results, but these can be avoided by carefully choosing and implementing the most appropriate approach to employee training. Technopak has used the AAMT ® training method across a broad product spectrum to make improvements to the tune of :
        • 50% to 60% reduction in the time required to train an employee to the productive level
        • 50% to 75% reduction in the cost per successful trainee
        • 300% increase in the number of successful trainees
        • 25% to 30% increase in trainee productivity during the training process
      • Such improvements have been made over a wide range of product applications such as apparel, textiles, carpets and rugs, footwear, furniture, health care, and hospitality (food and lodging).
      • The following pages throw light on the steps involved in implementation of a AAMT ® programme at a new facility.
      3 Operator Training
    • Phase 3: Implementation
      • The team for this module will be headed by a senior person to act as the AAMT® Training Coordinator
      • Operator Trainers would have been recruited as a part of the earlier phase.
      Trainers’ Training Recruit Trainers & form Team Operator Selection and Training
      • Operator Trainers will be trained on the AAMT® principles (classroom and shop floor training) including:
      • Group orientation and instruction
      • AAMT® methodology
      • Basic sewing and manual skills development.
      • Trainers’ training will continue throughout the course of the project.
      • Their development will continue as they work with operators in the Training Centre and on the floor.
      • Operators will be selected based on Technopak tests:
      • KSD-A (manual dexterity)
      • KSD-B (finger dexterity)
      • KSP (visual perception)
      • Color Blindness Test
      • Operator training will be performed by Operator Trainers and directed by Technopak
      • Training will be carried out in the Training Centre and on the production floor, during commercial production.
      Operator Training Work steps 3
    • Phase 3: Implementation
      • Implementation of Industrial Engineering Functions
      • The following Industrial Engineering functions will be implemented:
        • Garment engineering, Method engineering, Workplace design
        • Work-aids design and development
        • Operation Bulletins and Time Standards
        • Factory Control Systems
        • New Style start-up procedures
        • Operator Performance Monitoring systems
      • Industrial Engineering Department will review all designs with actuals on the production floor, so as to ensure that the methods, operation bulletins, etc. that are developed do not remain a theoretical exercise but yield the desired improvements also.
      • The Engineering Cell should also be equipped with a software for:
        • Bundle Ticketing Printing
        • Operator and Plant Performance Monitoring
        • Work-in-Process Control
        • Incentive Scheme Implementation and Calculation
      • For implementation of all software based systems, Technopak’s role will be limited to providing domain/ functional expertise. Software implementation responsibility will lie with the vendor (if external) and Client Project Team.
      3 Industrial Engineering
    • Phase 3: Implementation
      • Quality Assurance Systems Installation
      • From the pool of middle management, personnel will be deputed to the Quality Team. Activities in this module include:
        • Define Quality requirements for the factory
        • Develop Technopak Quality System for specific needs of the factory
        • Introduce Quality systems on the floor
        • Monitor performance and quality of output
        • Fine tune and remove bottle-necks
      • Middle Management, Senior Management & Supervisor Training
        • Middle management that has undergone pre-training during Phase 2 will be further trained
        • Senior Factory management will be trained on details of all factory systems implemented
        • Supervisors will be trained on areas related to line management, operator performance monitoring, incentive schemes, etc.
      • Engineering of Cutting and Finishing Room
      • Cutting and Finishing Room will be engineered to include:
        • Layouts and Process Design
        • Material handling systems and work flow
        • Operation sequences and time standards
        • Work place engineering and design
      3 Quality Assurance
    • Phase 3: Implementation
      • Factory Control Systems Implementation
      • The factory control systems implemented would include:
        • Work-study data management (PDTMS system – GSD, other)
        • Work ticket printing – define the process of work ticket printing for the cutting, sewing and finishing room.
        • Factory loading – define the steps to be followed during the loading of a style in the factory
        • Line balancing – usage of hourly controls, production monitoring and skills matrix
        • WIP control – define the ideal work in process level and the system to maintain it
        • Direct labour cost control – achieved by continuous monitoring of productivity per person
      • Installation of Incentive Based Payroll System
      • Incentive based payroll systems will be defined and finalized for the factory during planning. This part of the implementation will involve the following:
        • Implementation of systems necessary to start the incentive scheme
        • Implementation and stabilisation of incentive system
      3 MIS and Incentive
    • Phase 3: Implementation
      • Efficiency and Production Build-up
      • Production build-up follows after the implementation of all systems and operator training. Technopak along with the project team will monitor the productivity growth and works towards attaining the projected production and efficiency build up. At this point, the focus is on ensuring smooth functioning of all implemented systems. The work steps shall be:
        • Build up supervisor skills and operator efficiencies
        • Build up of efficiencies and ensure utilisation of capacity
        • Documentation of training, work methods, quality assurance and production planning systems
      3 Efficiency Build Up
    • Phase 4: Follow-up
      • The Follow-up module after implementation would involve:
        • Audit all implemented systems to ensure continuity of efficiency build-up
        • Trouble shoot and support as required, on-site
        • Monitor through office based support
      • The follow-up phase would be perceived as a Retainership Program, in which Technopak would be involved in the performance improvement of the facility for a duration of 2 months after the end of Phase 3 at 25% On-site involvement throughout the module.
      Follow-up 4
    • Implementation Schedule t e c h n o p a k Giza Spinning and Weaving, Co. Illustrative
    • Project Benefits
        • Performance to defined standards of quality, productivity, cost and flexibility.
        • Resultant lower and more competitive costs of manufacturing.
        • Technopak will deliver a factory that will achieve upwards of 65% efficiency levels on stabilization (24 to 36 months from start-up) as compared to average apparel factories at 40 to 45% efficiency levels.
        • Achievement of Operator Build-up of 50 – 60 operators a month.
        • Achievement of the efficiency levels as specified below
          • By project month 12, the factory is estimated to achieve 35-40% weekly sewing efficiency, with the first sewing lines achieving 50-55% weekly efficiency.
          • By month 18 of operation, the factory will achieve 45-50% weekly sewing efficiency.
      Quantitative Benefits
    • Project Benefits
        • Planning and Design of the factory, to ensure the factory is planned as per “best practices” and future expansion plan .
        • Establishing benchmarks in Denim Apparel Manufacturing across the world.
        • Experience in developing competitive levels of productivity and throughput at the manufacturing facility.
        • Work study department capable of undertaking engineering of any style given, after the conceptual training and practice on specific product groups. Well engineered operations and processes resulting in reduced training time and improved quality.
        • Access to Technopak’s methodology and knowledge database to develop effective apparel manufacturing management. World-class facilities require development of world-class human resources to manage state-of-the-art assets.
        • Acquisition of process, methodology and training tools to leverage other start ups and manufacturing improvement efforts.
        • Quality Assurance System to ensure desired quality.
        • Technopak helps in setting apparel manufacturing businesses and not just apparel factories. Technopak methodology ensure overall development of business.
      Qualitative Benefits
      • Technopak shall create a Project Team to work jointly with client . Active participation from client management is envisaged for taking key decisions.
      • The Technopak project team will comprise of consultants experienced in apparel manufacturing and sourcing.
      Project Team and Responsibility Coordination Team * : Proposed Lead Consultant Staff Consultants Subject Matter Expert, If required Project Manager TBD* Project Manager TBD Steering Group Project Director TBD TBD* Technopak Project Team I. E. Quality Technical Project Team (rep.) Production H.R.
    • Technopak Team and Responsibility
      • Project Manager
        • Will be the lead contact for the project and will have responsibility for:
          • Co-ordination within the team members and with the Client’s organisation
          • Resource planning and scheduling. Quality of work delivered
          • Will have 15-20% on-site involvement and will provide office based support.
      • Lead consultant and Staff consultant
        • Will be the on-site consultants and will be responsible for:
          • Delivery of the defined program of work
          • Analysis and research required to define the manufacturing unit
          • Technical inputs to the project team as required; co-ordination with wider resources
          • Daily liaison with the local project management regarding all aspects of the project.
          • Will have 85-90% on-site involvement
      Technopak Team
    • Client Team and Responsibility
      • Client project team positions will be specified during Phase 1 – Planning and Design for the factory. Broad requirements are as below:
        • Project Manager – Shall be interacting with the machinery suppliers, carpenters and other external suppliers for development of equipment. Will take the lead role in continuance of systems and build-up of efficiencies after completion of active Technopak involvement.
        • Factory Manager – Support the organization in coordinating, supervising and monitoring all activities so as to achieve production targets, quality, performance and cost targets, shipment deadlines, pre-production activities etc.
        • Production Manager – Carry out all production related activities including coordinating, supervising and implementing all production related requirements from cutting through to finishing.
        • Technical Expert – Shall be the technical sewing expert from the client team. Will be required to demonstrate sewing operations to operators, work on finalising sewing methods, and assist with technical and fit related areas.
        • Industrial Engineer Head – Shall need to have Garment Engineering skills and will have the responsibilities of execution and formalisation of methods devised by the Technical Expert whose role is primarily development.
        • Quality Assurance Manager – Responsible for the development of the Quality System. He shall have a team of quality controllers under him who shall do the inspections at various stages of manufacturing.
        • Operator Trainers – Responsible for the training of the operators. These set of people will be trained by technopak and these in turn will train the operators under the supervision of Technopak consultants. These are normally hired in the ratio of 1:4 to start with then are graduated to the ratio of 1:8. The ratio is higher in the beginning because the operator trainers are also learning while they are training the operators.
      Client Team