MAS-Linea Clothing

MAS Intimates Linea-Clothing

Outline

Introduction

Activities and learning outcomes

Research findings

Suggestions

Survey results

Time period: 4th August- Up to now

Assigned Department: MOS

Worked on: Cutting Department

Introduction

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

Tony’s and Critt’s SessionsAble to gather a wide knowledge about the

STWs Developing BIQ Importance of problem solving TL/GL concept- TL/GL job rolesReduction of safety issues during the

working

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

Observed the loading, spreading, cutting and bundling processes Value adding, variations and the periodic variations

Measured the time period for each stepsSTW Audits and found some deviations from

the STWs8 step problem solving - More Andons from

the division 2 Cutting green board preparationCut- training cuts

TL/GL Project in the cutting department

• 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 heatMain learning outcomes- How to deal with people

Environment for learning

Production floor

Research

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/ ObservationsManager & supervisors/staff- Key informant

discussions

• Data analysis tool: SPSS- Chi square & Frequency analysis

• Data presentation : Bar graphs/ pie charts

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 workTo give suggestions to improve the adoption of

standardized work

Objectives

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

Results and discussion

Gender Age

Population Characteristics

Male44%

Fe-male56%

Chart Title

20-29 30-39 ≥400

10

20

30

40

50

60

21

14

7

56

2 0

Male Female

Age (years)

Perc

enta

ge

Population characteristics……

Education level Type of jobs

Pass G.C.E.O/L Pass G.C.E. A/L

Graduates0

5

10

15

20

25

30

35

40

45

50 4649

5

Education level

Perc

enta

ge

Loading

Spreading

Cutting

Bundling

Embellishments

Record

ing

Market p

lace

Marker d

rawing0

5

10

15

20

25

30

4

8

27 28

15

6 7

3

Job types

Perc

enta

ge

Knowledge and skill level

Bad Moderate Good Very good0

10

20

30

40

50

60

0

9

54

35

1

27

41

31

Knowledge skill

Knowledge and skill level

Perc

enta

ge

Population characteristics

Less experienced ( ≤ 3 yrs)

Experienced (>3 yrs)0

10

20

30

40

50

60

7068

32

Experience level (years)

Perc

enta

ge

Working experience (years)

Gender Age

Individual Factors

Low adopters High adopters0

10

20

30

40

50

60

45

5555

45

Male Female

Perc

enta

ge

χ2 0.397p 0.481

χ2 0.53p 0.467


10

20

30

40

50

60 56

4447

53

Young ( ≤26 years) Old (>26 years)

Perc

enta

ge

Individual factors

Education level Working experience


42

44

46

48

50

52

54

56 54

4645

55

Less experience (≤3 years) Experienced (>3years)

Perc

enta

ge

χ2 0.908p 0.341

χ2 0.471p 0.472


10

20

30

40

50

60 55

4546

54

G.C.E O/L passG.C.E. A/L pass and above

Perc

enta

ge

Organizational Factors

Resource availability Training and development programs


45

46

47

48

49

50

51

52

5353

47

50 50

Not enough Enough

Perc

enta

ge


10

20

30

40

50

60

70 62

3843

57

Not satisfied Moderate satisfied

Perc

enta

ge

χ2 0.052p 0.819

χ2 2.274p 0.032

Organizational factors

Performance evaluation and reward system

Existing STW and SOP


10

20

30

40

50

6058

42

4852

Disagree Agree

Perc

enta

ge

χ2 0.041p 0.839

χ2 0.699p 0.403


46

47

48

49

50

51

52

53 53

48

49

51

Not satisfied Moderately satisfied

Perc

enta

ge

Management support


χ2 4.963p 0.026


10

20

30

40

50

60

7067

3339

61

Moderate Good

Perc

enta

ge


People who are engaged in development

People who should develop

Development of STW

Supervisors 99%

Team members 1%

Team members 76%

Supervisors 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

• 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

• 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

• Develop common STWs for different fabrics, by including important steps

Ex: Speed of the spreading machine1.1. Mesh (……..)1.2. Cotton( .…...)1.3. Lace (……..)

• There should be a proper performance evaluation method which align with SW performances.

Suggestions………………….

• 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


• OBT programs after the placement of TM in the teams–To enhance the team cohesiveness–To identify new leaders


Survey……….

• 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……….

• 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

Survey Results

income diffi

culties

wages

hostel fa

cilities

transp

ort fac

ilities

good w

ill

future

succe

ss

work

experie

nces

Furth

er educati

on job

like to

LC0

10

20

30

40

50

60

70

80

Reasons for joining with the plant

Reason for joining

Perc

enta

ge

0 0.1 0.7 1.5 2.5 4 6 8 150.00

5.00

10.00

15.00

20.00

25.00

30.00

Years of Staying

Years

Perc

enta

ge

Survey Results…………

Single Married Divorce Widow0

10

20

30

40

50

60

70

80 76.2

21.8

1.2 0.8

58.6

38.7

1.3 1.4

Maritial status and requirement of day care

req. day care do not want

Perc

enta

ges

Want87%

Do not want13%

Necessity of a day care


GAQ Charted Diploma0

10

20

30

40

50

60

70

80

90

100 95.3

1.6 3.1

Type of following higher education programs

Perc

enta

ge

Money leaves books Library other0

10

20

30

40

50

60

70

63.3

18

9.3 9.3

0.01

Expect from the plant for the higher education

Perc

enta

ge


Extra cl

asses

English tr

aining progra

ms

practi

cally

use w

hile w

orking

0

10

20

30

40

50

60

70 65

16 19

What do you expect from the plant to improve English?

Perc

enta

ge

yes no0

10

20

30

40

50

60

70

80

90

100

93

7

Do you want to learn English further?

Perc

enta

ge


Netball

Cricket

Elle

Basket b

all

badminton

athletics

chess

0

5

10

15

20

25

30

35

28

11.5

17.4

0.4

33.2

6.3

3.2

Other sport choices

Perc

enta

ge

For f

oods

Childre

n's acti

vities

for c

lothes

for e

ducation

for s

iblings

beauticultu

re

medicines

for p

arents

0

5

10

15

20

25

30

3534

10

7.6

18.5

12.2

1.1

3.4

12.9

Way of spending the salary

Perc

enta

ge

Suggestions

• Day Care Centre – Management can reduce

the LTO after their marriages

• More considerations for their further education

– Loan facilities– Weekend releases

“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-

8 Steps Problem Solving

1. Clarify the problem2. Break down3. Set targets4. Root cause analysis (5 Why and fish bone

diagram)5. Develop countermeasures6. Implement countermeasures7. Evaluation8. Standardization

Efficiency calculation

• Efficiency = SMV* Output( pieces) No of team members* 420

Documents

MAS-Linea Clothing