Sisira Kumara is the Managing Director of SK POLYPACK in Sri Lanka, which produces printed polythene bags. The company started in 2008 as a subcontractor with only a cutting machine. In 2008, they bought an extruder machine to produce polythene, and after 6 months bought a printing machine. Their growth was slow with no guidance. In 2010, they joined the Kaizen Entrepreneurs Project and learned productivity concepts from the National Productivity Secretariat. This helped change employee attitudes, build confidence, reduce costs and increase revenue. Employee numbers grew from 2 to 15 from 2009-2014 as turnover increased from 0.08 million to 3.4 million rupees. Future plans include close

1. Sisira
Kumara
Managing Director
SK POLYPACK
Sri Lanka

2. APO International
Productivity Showcase
& Best Practice Networking
Forum on SMEs

3. Product – Printed Polythene
bags
Started on – 2008/01/01
Started as a subcontractor
Intermediate person
At first we bought only a cutting
machine
Later we bought an Extruder
Machine to produce polythene
(2008 Dec)
After 6 months we bought a printing
SK Polypack

4. Product – Printed Polythene
bags
Started on – 2008/01/01
Started as a subcontractor
Intermediate person
At first we bought only a cutting
machine
Later we bought an Extruder
Machine to produce polythene
(2008 Dec)
After 6 months we bought a printing
SK Polypack

5. Our growth was very slow.
No one to guide us.
We continue only with the past
experience.
(I have been working in awaloka
Polythene Factory since 1991 )
Before 2010

6. We joined Kaizen Entrepreneurs Project
In 2010 Mach

7. Productivity concepts were introduced
to us.
We were guided by Productivity
Promotion Officers of National
Productivity Secretariat .
We learned theories of productivity and
practical training .
After 2010

8. On time Delivery
Direct customer care
Investment only with the profit
(without bank loans)
Learn about productivity concepts
(Mrs Yamuna learns productivity in
Kaizen Managers Training Program in
Gampaha District))
Usage of recycled raw materials
Recycling of polythene waste
Best Practice

9. 9
Changed
Employees
Attitudes
Built up the
Confidence
Reduced
Production
Cost
Increased
Revenue
Results

10. Employee Analysis ………
2
3
7
10
15
0
2
4
6
8
10
12
14
16
2009 2010 2011 2012 2013/2014
No.ofEmployees
Year No. of Employees
Started Year
of Kaizen
10

11. Turnover (Rs. Mn)…………
0.08 0.2
0.9
1.7
2.5
3.4
0
0.5
1
1.5
2
2.5
3
3.5
4
2008/09 2009/10 2010/11 2011/12 2012/13 2013/14
Turnover-Mn
Year
Started Year
of Kaizen
11

12. Close supervision and training of staff to
minimize defects.
Changes of work floor to minimize
unnecessary waiting ,transportation ,
movements
Unnecessary inventory and unnecessary
overproduction is a problem at present but
their future plan is to have a proper Purchase
Order Form to minimize errors
Wasting of dye is another problem at present
– future plan is to get the proper
measurement of the amount of dye needed
for a specific production and apply that
data when necessary
Change MD’s room to have a close
Future Plans