3. Time period: 4th August-
Up to now
Assigned Department: MOS
Worked on: Cutting Department
Introduction
4. Activities participated……
Sessions conducted by Tony and Critt
OBT session & Training school
TL/GL project in the cutting department
• STW audits/ deviations
Questionnaire survey in LC/LI and data
analysis
Observations in the production floor
5. Tony’s and Critt’s Sessions
Able to gather a wide knowledge about the
STWs
Developing BIQ
Importance of problem solving
TL/GL concept- TL/GL job roles
Reduction of safety issues during the
working
6. OBT Program & Training School
OBT Session
– Team work
– Leadership
– Integrity
– Courage
– Patience
– Self trust & mutual
trust
Training School
– Sewing
– Machine types/ needles
– On the job training
» Targets
» Time
» Patience when damages
happens
» Respect to others in the
team
» Responsibility
7. Observed the loading, spreading, cutting and
bundling processes
Value adding, variations and the periodic variations
Measured the time period for each steps
STW Audits and found some deviations from
the STWs
8 step problem solving - More Andons from
the division 2
Cutting green board preparation
Cut- training cuts
TL/GL Project in the cutting department
8. • Got an idea about
–The operations of a garment
–AQL audits (pass/failure)
–SMV
–Efficiency calculation
–Red box
–6S audits
• Other observations
– Difficulties- Style changes
– Difficulties- graphic printers- due to heat
Main learning outcomes- How to deal with people
Environment for learning
Production floor
10. Research
• Title: Factors Affecting adoption of
Standardized Work in LM
• Research Design : Case Study
• Target group : Total population in the cutting
department
68 TM- Questionnaire survey/ Observations
Manager & supervisors/staff- Key
informant discussions
• Data analysis tool: SPSS- Chi square &
Frequency analysis
• Data presentation : Bar graphs/ pie charts
11. General Objective:
To determine the factors affecting adoption of
standardized work in Lean Manufacturing in the
cutting department of MAS Linea-Clothing
Specific Objectives:
To identify the individual and organizational
factors affecting adoption of standardized work
To give suggestions to improve the adoption of
standardized work
Objectives
12. Conceptual framework
Gender
Age
Education level
Working experience
Resource availability
Training and development
programs
Performance evaluation and
rewards
Clearly defined STW/SOP
Management support
Individual
factors
Adoption of
Standardized
Work
Organizational
factors
Success in LM
22. Organizational factors
People who are engaged in
development
People who should develop
Development of STW
Supervisors 99%
Team members 1%
Team members 76%
Supervisors 23%
23. Conclusions
None of the individual factors viz. age, gender,
education level, and work experience affect the
adoption of standardized work
Out of the organizational factors, only
management support, and training and
development programs affect the adoption of
standardized work
24. • Grievances of team members
• Criticized areas by the TMs,
– Developing STWs
– Available training and development programs
Ex: CAD, SAP
– Work place troubles
Damaged tables
No proper AC, Water tap requirement
– Performance evaluation and rewards system
Observations
25. • Further HR attention towards the TMs in CD
• The training and development programs
should be aligned with the SW
• The STWs should be developed by the
collaboration of team members
• If they have less knowledge, supervisors can
act as mentors to help them by giving
instructions
Suggestions
26. • Develop common STWs for different fabrics, by
including important steps
Ex: Speed of the spreading machine
1.1. Mesh (……..)
1.2. Cotton( .…...)
1.3. Lace (……..)
• There should be a proper performance
evaluation method which align with SW
performances.
Suggestions………………….
27. • Reward system should be aligned with
performances through SW
• Rewards
–Financial , According to quantity cut,
bundled
–Non Financial
Employee of the month/Year,
Promotions for the bundlers as well
as spreaders
Suggestions………………….
28. • OBT programs after the placement of TM in
the teams
–To enhance the team cohesiveness
–To identify new leaders
Suggestions………………….
29.
30. • Aim : To identify the needs of the team
members to develop business strategies
• Target population: Female team members in
the LC & LI
• Data collection tool: Questionnaire survey
• Data analysis tool: SPSS
Survey……….
31. • Reasons for joining
• Requirement of a Day Care Centre
• No of years, TMs are going to stay within the
organization
• Marital status and the future state
• Family conditions
– Husband, Children, Houses ( ownership)
• Salary / Savings
• Hobbies/ interests
• Type of help for further education
• Troubles (mentally/ physically) and type of help
required from the plant
• Sports
Major concerned areas
33. Survey Results…………
0
10
20
30
40
50
60
70
80
Single Married Divorce Widow
76.2
21.8
1.2 0.8
58.6
38.7
1.3 1.4
Percentages
Maritial status and requirement of
day care
req. day care do not want
Want
87%
Do not
want
13%
Necessity of a day care
34. Survey Results…………
0
10
20
30
40
50
60
70
80
90
100
GAQ Charted Diploma
95.3
1.6 3.1
Percentage
Type of following higher education
programs
63.3
18
9.3 9.3
0.01
0
10
20
30
40
50
60
70
Money leaves books Library other
Percentage
Expect from the plant for the
higher education
35. Survey Results…………
0
10
20
30
40
50
60
70
Extra classes English
training
programs
practically
use while
working
65
16
19
Percentage
What do you expect from the plant
to improve English?
0
10
20
30
40
50
60
70
80
90
100
yes no
93
7
Percentage
Do you want to learn English
further?
37. Suggestions
• Day Care Centre – Management can reduce
the LTO after their marriages
• More considerations for their further
education
– Loan facilities
– Weekend releases
38. “Some changes look negative on their surface
but you will soon realize, that space is being
created in your life for something new to
emerge……………….”.
-Eckhart Tolle-
39.
40.
41. 8 Steps Problem Solving
1. Clarify the problem
2. Break down
3. Set targets
4. Root cause analysis (5 Why and fish bone
diagram)
5. Develop countermeasures
6. Implement countermeasures
7. Evaluation
8. Standardization
