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Welcome A presentation about on yearly progress 2015 & future plan 2016 (Newage Apparels Ltd-Unit 1 ) -Safiqul islam sujan

Factory yearly improvement presention

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Page 1: Factory yearly improvement presention

Welcome A presentation about on yearly progress 2015 & future plan 2016

(Newage Apparels Ltd-Unit 1 )

-Safiqul islam sujan

Page 2: Factory yearly improvement presention

Unit Profile

In knit unit 2

production floor

1 finishing section 2 cutting section

18 sewing line

Total operator -

669Total Hp+IM-

330Finishing -

195

Unit efficiency -

48.76%

Sewing Production per month – 631867

pcsTotal

manpower -1756

Cutting - 102

Staff- 167

Page 3: Factory yearly improvement presention

Efficiency 2014 43.73% Efficiency 2015 48.76%

Yearly efficiency growth-

2014 201541.00%42.00%43.00%44.00%45.00%46.00%47.00%48.00%49.00%50.00%

43.73%

48.76%

Sewing Efficiency Improvement 2015

11.50%

Page 4: Factory yearly improvement presention

0.00%

10.00%

20.00%

30.00%

40.00%

50.00%

60.00%

70.00%

58%

42%

55%54%

44%50%53%

59%53%51%

45%40%

49%43%

51%

42%

52%53%

Yearly unit

2015

Line wise efficiency growth 2015 2014

Page 5: Factory yearly improvement presention

0.00%

10.00%

20.00%

30.00%

40.00%

50.00%

60.00%

70.00%63%

47%

60%59%

49%55%58%

64%58%56%

50%45%

54%48%

56%

47%

57%58%

Baseline

Effi-ciency 55%

Line wise avg. in-crease 5%

Yearly growth 11.34%

Sewing Efficiency progress Plan – 2016

Page 6: Factory yearly improvement presention

Avarage production per

month/ unit

631867

Avarage SMV/ per style

12.20

Avarage manpower / per line

49

Unit production – 7582405

3RD FLOOR -3944320

2nd floor -3638058

Production progress 2015

Page 7: Factory yearly improvement presention

Avarage production per

month/ unit

686812 pcs

Average SMV 12.20

Avarage manpower / per line

47.5

Production progress plan 2016

Yearly production plan

8241744 pcs

Excess production plan

659339 pcs

Yearly production

growth 8.70 %

Page 8: Factory yearly improvement presention

                      2015                                              

Month/15Floor-02 Floor-03  

Grade Skill OP Grade Skill OP  

6 5 4 3 Total 6 5 4 3 Total  

Jan-15 2 2 7 1 12 - 6 14 1 21  

Feb-15 1 7 12 4 24 2 11 33 3 49  

Mar-15 - 4 7 - 11 - 2 20 3 25  

Apr-15 2 5 14 - 21 - 3 27 5 35  

May-15 - 6 14 3 23 - 14 24 2 40  

Jun-15 - 5 10 - 15 1 2 4 - 7  

Jul-15 - 2 4 - 6 - - - - -  

Aug-15 - 15 25 1 41 1 20 31 5 57  

Sep-15 - - - - - - - 3 - 3  

Oct-15 - 15 30 2 47 1 17 47 4 69  

Nov-15 - 6 13 1 20 - 3 9 - 12  

Dec-15 - 1 1 - 2 - 3 5 3 11  

Total 5 68 137 12 222 5 81 217 26 329  

551                      

    Floor-3 / Finishing 15              

                                              

Skill Test Achievement 2015

Grade (3)- 38Grade (4) -

354

Grade (5)- 149

Grade (6) - 10Finishing -

15

Total-566

Page 9: Factory yearly improvement presention

Grade 3 4 5 6

Existing 88 348 153 63

Proposed plan

72 252 180 108

Skill Test & Recruitment Plan 2016

Grade allocation/per line Grade 3 – 4Grade 4 – 14Grade 5 – 10Grade 6 – 6

Manpower-47.5SMV – 12.20

OP- 34Hp-13.5

Page 10: Factory yearly improvement presention

Previous summary Present summary Improvement

Moon attach – 1 operator Moon close – 1 operator

Moon attach & close – 1 operator

Reduce 1 operator

Body fold – 1 iron man Body mark – 1 helper

Body fold & body mark – 1 helper

Reduce 1 iron man

Placket attach – 1 operator Placket mid psn scissoring – 1 helper

Placket attach & mid psn scissoring – 1 operator

Reduce 1 helper

Neck join - 1 operator Neck servicing – 1 operator

Neck join & servicing - 1 operator

Reduce 1 operator

Shoulder join – 1 operator Trim at do psn - 1 helper

Shoulder join & trim – 1 operator

Reduce 1 helper

Care label attach – 1 operator Side seam – 1 operator

Side seam insert care label - 1 operator

Reduce 1 operator

Fly attach - 2 operator Fly attach – 1 operator ( reduce excess motion )

Reduce 1 operator

Cartoon making , sticker inserting – 4 worker

Cartoon making , sticker inserting- 3 worker

Reduce 1 worker

Button hole – 1 operator Button hole psn mark – 1 helper

Button hole & marking – 1 operator

1 helper

Method & Process Development 2015

Page 11: Factory yearly improvement presention

Skill matrix

Line graph -

240

Working Field – 2015

Operator database

NPT database

Line balancing

- 150

Needle report

Production study – 82

Daily target provide

Layout - 230

IE Department progress field 2015

Page 12: Factory yearly improvement presention

Line Graph progress 2015Line no

Total

graph

1 10

2 11

3 16

4 11

5 11

6 12

7 8

8 11

9 14

Line no

Total

10 12

11 10

12 15

13 14

14 13

15 12

16 1217 1318 14

1. Bottle neck find out 2. Line balancing

3. Productivity gap tracking

4. Line production capacity measure

5. Operator capacity sharing

Line graph benefits

3rd floor 2nd floor

Total – 219

Database

Page 13: Factory yearly improvement presention

Line Graph plan 2016Line no

Total

graph

1 13

2 13

3 14

4 13

5 13

6 14

7 13

8 13

9 13

Line no

Total

10 12

11 12

12 14

13 14

14 13

15 13

16 1317 1418 14

3rd floor 2nd floor

Total – 238

Database

Page 14: Factory yearly improvement presention

Appraisal & Promotion Activities 2015

Up-skill Unable to up-skill Up-skill Unable to

up-skill7 6 5 4 3 Total Total 7 6 5 4 3 Total Total

Jan-15 - - - - - - - 3 3 - - - 3 -

Feb-15 - - - - - - - - - - - - - -

Mar-15 - - - - - - - - - - 1 - 1 (1)

Apr-15 - - - - - - - - - - - - - -

May-15 - - - - - - - 1 1 - - - 1 -

Jun-15 - - - - - - - - - - - - - -

Jul-15 - - - - - - - 1 1 - - - 1 -

Aug-15 - - - - - - - - - - - - - -

Sep-15 - - - - - - - - - - - - - -

Oct-15 - - - - - - - - - - - - - -

Nov-15 - - - - - - - - - - - - - -

Dec-15 - - - - - - - - - - - - - -

Total - - - - - - - 5 5 - 1 - 6 (1)

6 -1

Grade GradeMonth/15

Floor-02 Floor-03

Promotion Sewing – 6

Finishing - 3

Page 15: Factory yearly improvement presention

To effective use of manpower

To reduce rework ,reject & cost minimization

To process develop & motion analysis

Other Activities 2015

Not use Operator

track

Cut to ship loss track

Video database

Page 16: Factory yearly improvement presention

Time study –Iron hangtag folding packing section

Iron section Folding section Hangtag section Packing section

2014

no

work

2015

startin

g

SMV Generat

e

Workers Databa

se

Efficiency generate

Month Efficiency (%)

Baseline -April

33.35

November

47.54

December

46.84

Progress

Finishing Department Activities & Progress 2015

Progress to be

continue

Growth -40.44%

Page 17: Factory yearly improvement presention

There is no significant achievement on cutting department in this year . Our IE department starting on cutting observation through time study. We are successfully completed 20 cutting study & one officer is fully involve on cutting section to better analysis & result .

Cutting Department activities 2015

Page 18: Factory yearly improvement presention

Layout provide NPT Reduce Process development Skill matrix Update Operator database update Wastage reduction

SMV bank Worker database Worker skill matrix Process development

SMV Generate Worker database Target Set Efficiency Calculation

Plan 2016

Sewing

Finishing

Cutting

Page 19: Factory yearly improvement presention

Last year our unit migration was very high . Approx. Average 50 workers

Absenteeism frequently occur at last year . Our absenteeism was 8.5 % (approx.)

Frequently style change damage higher productivity

Lack of proper planning

Argument with floor , lack of executive action

New employment & their train up

Our challenge 2015

Workers migration- Absenteeis

m Style

change

Planning

Argument

Employment

Page 20: Factory yearly improvement presention

Thanks to all