3. Summary:
*06 Zero Defect Operators.
*A very simple and well
defined guideline to start
Industrial Engineering
activities.
*A proper guideline for
Qualified Production
Management
4. Summary:
*Very strong Team work
forming guideline.
*A pace to change the
Culture.
*Well structured HR work
way.
*Very specific to reduce
Worker Turnover.
6. 1. Induction System
2. Buddy System
3. HR Trackers
4. HR Visions
5. Responsibilities of HR Manager, Welfare
Officer and Buddy
6. Responsibilities of Sewing Supervisors
7. Appraisal System
8. Training Need Assessment
KEY POINTS.
7. 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.
8. Where do you find difficulties?
describe, why?
A fully dedicated welfare officer is needed to
continue the system.
9. 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 % % %
12. Graphical Representation Absenteeism
(Pilot Line VS Others)
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%
0.00%
2.00%
4.00%
6.00%
8.00%
10.00%
12.00%
14.00%
May June July August September October November
Absentism (Pilot Line) Total
16. 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
17. 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.
18. 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.
19. Summary of Productivity
Improvements:
Months Pilot line
efficiency
Pilot line
productivity
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%
20. Graphical Representation
5
2
4
3 3 3
9.8
8
9.8
8
9
8
0
0.05
0.1
0.15
0.2
0.25
0.3
0
2
4
6
8
10
12
May june July August September October
Style Changes Avg. SMV Pilot Line Efficiency Of Pilot Line
21. Graphical Representation
58 58 58 58 58 58
12.5
14.66 15.51 15.71 15.85
0
10
20
30
40
50
60
70
May June July August September October
Avg.Person Pilot Line Productivity Per person per 8 hrs(Pilot Line)
24. 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%
29. Summary of Method Improvements:
Operation Description Cycle time
before &
after
Average
cycle time
reduction %
No. of
manpowe
r reduced
Average
hourly
output
improved
Video
documentatio
n
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
30. Cost Savings
Month Ship Qty Cut to Ship
Loss
Improvem
ent %
Extra
Shipped
Profit
Gain @ $
0.90
In BDT @
78
Conversio
n 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
Septemb
er
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)
31. Cost Savings
Month Produce
Qty
Efficienc
y
Base line
Efficienc
y
Improved Extra
Produced
Extra
Earn@$
.02
In BDT
@ 78
Conversat
ion 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)
