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