Compensation system of an industrial organization a case study of ananta appa...
TOYO lean presentation
1. TOYO COMPOSITE
KNIT GARMENTS LTD.
PRESENTED BY:
MOHAMMED ZAHIR
Lean start on MARCH 2009
Now we are in 2014
PROGRESS MEETING
SUMMARY
Prepared by IE & Planning Dept.
PRODUCTIVITY IMPROVEMENT
AND
SOCIAL ENHANCEMENT PROJECT
2. 1. COMPANY NAME: TOYO COMPOSITE KNIT GARMENTS
LTD.
2. LOCATED IN: 1,SARDAR COMPLEX, SOUTH KAMLAPUR,
DHAKA.
3. CONTACT: TEL 9333629
FAX 9340747
EMAIL: joy@toyopureknit.com
4. ESTABLISHMENT: 1990
5. OWNER: MD. RAFIQUL HAQUE
6. AREA OF FACILITY: 45000 SQ FT
7. CONTACT PERSON: MD. MAHABUB- UL- HAQUE
MD. ZAHIR JOY
8. NO. OF EMPLOYEE: 500
3. ALL SORTS OF KIDS ITEMS
MEN’S T-SHIRT
WOMEN’S T-SHIRT
JOGGING SETS
JACKETS
MEN’S POLO SHIRTS
WOMEN’S KNIGHT GOWNS
ANY OTHER CRITICAL KNIT ITEM
4. TO IMPROVE THE PRODUCTIVITY &
QUALITY
REDUCE LEAD TIME
DEVELOP LIVING STANDARD OF THE WORK-
FORCE
Enhance skill of the workers by means of imparting
knowledge and participation
Downsizing the current bigger layout to reduce
change-over time and to ensure balanced flow
6. TO SYNCHRONIZE CUTTING, SEWING AND FINISHING BY RE-ALLOCATING
THE DEPARTMENTS WHERE NECESSARY
ELIMINATE ‘NUMBERING OF THE PRINTING PARTS’
ARRANGE ERGONOMIC WORK-AIDS AND ATTACHMENTS FOR ALL THE
WORKSTATIONS
ELIMINATE THREAD SACKER MACHINE
ELIMINATE EXCESS TRANSPORTATION
ELIMINATE EXCESS MOTION
REMOVE WAITING TIME
REDUCE SPACE
7. After Lean we Eliminated some unnecessary and
extra process like Thread Sucker Machine
35. LEARNED STEPS PRIOR TO
IMPLEMENTATION:
JUST IN TIME AND PULL PRODUCTION
IMPACT OF WASTE ON THE SUPPLY
CHAIN
HOW TO IDENTIFY AND TROUBLESHOOT
WASTE
HOW TO IMPLEMENT NEW IDEAS VIA
KAIZEN EVENT
37. A PULL PRODUCTION SYSTEM IS BASED ON
CUSTOMER DEMAND.
THE OPERATOR WILL SEW ONLY WHEN THE
NEXT WORK-STATION HAS A DEMAND OF
PRECEDING OPERATION
38. To identify wastes in any process we
use VSM (Value Stream Mapping) tool
Then eliminate the wastes through
Kaizen events
39. IDENTIFY THE ROOT CAUSE ASKING AT LEAST
FIVE QUESTIONS STARTING WITH WHY
(5WHY’S)
SEEK IDEA FROM ANY ONE DEFINE SAMPLE
SOLUTIONS
RE-EVALUATE FIXED IDEAS
CHOOSE SOLUTION NOT NECESSARILY TO BE
PERFECT ONE
40. •INCENTIVE
•LESS WORK-HOUR WITHOUT HAMPERING
EARNINGS
•BETTER WORK-ENVIRONMENT
•EXCELLENT INTERPERSONAL RELATIONSHIP
•IMPROVED BASIC DISCIPLINE
•UNREST WILL NOT BE HAPPENED
41. A system by which employees receive
a share of the profits of a business
enterprise.
In profit sharing, company leadership
designates a percentage of annual
profits as a pool of money to share
with employees, or a portion of
employees such as executives.
42. * Toyo Knit Composite Garments Ltd also
share profit yearly with the all employee
using a formula for distribution. Our
factory shared 5% annual profit with all
employees.
43. Our Factory also delivered the monthly
profit(incentives) to the workers according to their
efficiency.
Before LEAN this system were not established.
45. A fund into which the employer and the employee both
pay money regularly, so that when the employee retires
or leaves the company, he or she receives a sum of
money.
Under a provident fund, the full amount of the benefit
available at retirement may be taken as a lump sum cash
payment, irrespective of whether the benefit is
calculated on a defined benefit or a defined contribution
basis.
46. Generally 8% salary deducted per month for
provident fund
After three years or above if any employee
wants to withdraw money from their provident
fund, factory will provide 100% benefit to them.
Before LEAN there was no provident fund and
employees was deprived from this facilities.
47. Before LEAN there was no worker
welfare fund
After successfully LEAN establishment
we set up welfare fund for the worker
If any worker face any problem like
Building house they will get money from
welfare fund.
For any occasion like marriage
ceremony they also will get money from
this fund.
48. A concept whereby companies integrate
social and environmental concerns in their
business operations and in their interaction
with their stakeholders on a voluntary basis.
Corporate Social Responsibility is the
continuing commitment by business to
behave ethically and contribute to economic
development while improving the quality of
life of the workforce and their families as
well as of the local community and society
at large.
49. Caring for company staff and their families:
Our company influence worker to draw an
insurance for their better future.
Social activities benefiting the local
community: Various social activities done by
our company like
50. Public awareness of birth control
Health & safety of a pregnant women
Check up of a pregnant women time to time
and how to take care of them
Help poor children for their education etc.
Different types of drama showing to worker
about public awareness.
51. 5S implementation is our main CSR
Mohammad Zahir is management
representative of Toyo Composite Knit
Garments Ltd. Who is the pioneer of
5S implementation in Toyo Composite
Knit Garments Ltd including society.
He and his IE team worked to develop
of 5S system and successfully change
the outlook of the factory and society.
52. Toyo implement 5S system that can
change ones as well as societies life
style.
Dialogue of 5S is clean home clean
city. By this philosophy if anyone
maintain 5S in home automatically it
affect in his city or his society. Our
factory obtain this and change all
workers life style.
53. Some benefits of 5S
implementation
After maintaining 5S now we are clean, safe
and progressive.
Quality of our factory environment is
improved.
Wastages are reduced
We are now safe in our work place from
various hazards.
Prevent the disease such as
malaria,diarrhoea
By this system we can influence others as
“carry lean and change your life”.
54. After 5S we ensure that our factory has no
harmful impact on environment.
We control air pollution and sound pollution
Now we proudly say that by controlling
environmental pollution, we are in a green
world.
