Transcript
PIC Action Plan
©Productivity Improvement Cell,BGMEA
Developed by :
Saad Bin A.RashidProductivity Improvement Cell,BGMEA
Outline
•PRODUCTIVITY Scenario.• Improvement Strategy.•PIC team training condition & further
improvement plan.•Working strategy.
©Productivity Improvement Cell,BGMEA
Productivity Scenario
©Productivity Improvement Cell,BGMEA
0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
Bangladesh
India
Vietnam
Pakistan
Cambodia
Bangladesh India Vietnam Pakistan Cambodia
Productivity 77% 92% 90% 88% 68%
©Productivity Improvement Cell,BGMEA
Low productivity Less labor efficiency.
Less skill mid level management
No Productivity team( IE, Work study)
Top management lack of awareness about productivity
Low Supply Chain Efficiency – increase lead time
©Productivity Improvement Cell,BGMEA
Productivity Improvement Strategy
©Productivity Improvement Cell,BGMEA
Productivity Improvement phase plan
• GSD based training
• Zero defect operator training
• SOP development
Worker eff. training
• Production management Training
• PL development
Mid mgt PL program
Capacity plan development
Factory Setup support
Direct factory consultation
Implement
©Productivity Improvement Cell,BGMEA
PIC cell Action plan Fa
cto
ry s
et u
p s
tage Capacity
calculation, production layout design, ROI analysis, Item knowledge
Pro
du
ctio
n s
tage Direct factory
consultation by their training & practical improvement
Sho
rt c
ou
rse
on
ski
ll d
evel
op
men
t
Short course offered to develop Mid management officer for factory.
Top
man
agem
ent
& b
uye
r at
tach
men
t se
min
ar Short seminar about productivity improvement to ensure smooth business & better growth for RMG Sector
©Productivity Improvement Cell,BGMEA
Production Leader (PL) development Program
Floor level position
(OJT)
• Supervisor & line chief, Floor in charge people can have very specific idea about efficient production system by On job Training (OJT)
• They are very related to floor , so they should learn to train up multiskilling operator
Mid level management
• Mid level management(production management, Industrial Engineering, quality) may be trained by module to have efficient production system.
• This program can be further institutionalized by collaboration with training center & Garmenting institution.
Top management
• Top management might be keep in touch to know how about modern production Technology.
• we can promote our activity by short seminar /fair/ gathering
©Productivity Improvement Cell,BGMEA
Production Leader (PL) development Program
OJT
Time studyCapacity
calculation
Efficiency calculation
Production planning&
design
Line balanceWIP
reduction
Method improvement
Motion study
Quality improvement
Inventory Control
©Productivity Improvement Cell,BGMEA
70
-80
% E
ffic
ien
cy
leve
l
Work Measurement Technique ( NPT , SAM, Time study,
skill matrix)
Motion & Method Engineering (micro motion,
method improvement, human factor engineering)
Efficient Production system design(Production layout,
capacity , target, WIP reduction, Waste reduction)
Quality control Engineering
Kaizen, 5s tools
Cutting Fabric optimization Technique
Phase -1( standard)
©Productivity Improvement Cell,BGMEA
90
-10
0%
eff
icie
ncy
leve
l
LEAN Manufacturing ( VSM , TQM, TPM, Pull production
System, SMED, OEE, ANDON, Kanban )
Flexible Manufacturing System(Cellular manufacturing,
Group technology)
RFID & BARCODE based production
SIX Sigma Approach
KPI Benchmarking for Factory (benchmark
performance indicator for all department)
Phase -2( Global Standard)
©Productivity Improvement Cell,BGMEA
PIC Team continuing project
• In total 6 months project with almost 24 factories.
• It covers Productivity module 1,2,3 followed by HR module, fire & safety.
•PIC team to have practical work during each module break
•PIC team need to develop own module within the short term of training for factory training.BBW
•This program mostly related to practical implementation.
•We need to develop our basic module before attending the program.
•PIC team need to mix up experience to implement it successfully & make success story.PSES•We need special TOT for PIC team , follow by intense practical session by them
•Training material needs to be provided to PIC ( video, presentation soft copy ) for further implementation.
•PIC team have to develop own module based on that training for factory implementationUNIDO
©Productivity Improvement Cell,BGMEA
PIC Team Standing
PHASE -11. Work Measurement
2. Method Engineering
3. Motion analysis
4. Production system design
5. Quality control
6. Cutting fabric optimization
7. Inventory planning
PHASE-28. LEAN Manufacturing
9. Flexible Manufacturing system
10. RFID & Barcode based production
11. Six sigma approach
12. KPI benchmarking
Professional training
• ERP Software training ( Fast react or similar software)
• GSD training
• Marker software( Lectra, Garber)
• Professional Excel training( VBA, Macro)
• Cost benefit analysis
After P
SES & B
BW
pro
gram
©Productivity Improvement Cell,BGMEA
TOT training team
ConsultantFull project
PIC team
Out source trainer
LEAN Transformation project
©Productivity Improvement Cell,BGMEA
PIC Cell Factory consultation
Set Assessment
Diagnose improvement
scope
Develop factory PL team
OJT-1for PL
Action plan
Factory implementation( PIC team with PL
)
OJT-2
Set pilot line & global change
Follow up
1 day 3 day 7 day 4 day 15 day 3 month
In house mini workshop-1
In house mini workshop-2
In house mini workshop-3
4 days 1 month
6 month development plan for each factory
Cost benefit analysis
©Productivity Improvement Cell,BGMEA
Systematic approach of Implementation
Floor Data collection
Analysis the data
Standardize the data
PMTS format development
Optimize layout design
WIP analysis Bottleneck Balance lineSet standard production
system
Productivity Improvement Cell,BGMEA
©Productivity Improvement Cell,BGMEA
Factory setup stage
Capacity & layout planning
Labor planning
Item knowledge
ROI Analysis
©Productivity Improvement Cell,BGMEA
©Productivity Improvement Cell,BGMEA
• Competitive cost• High Quality
• Smooth production run• Right delivery time• Flexibility• CSR, safety & compliance
• Profit• Sustainable business growth• repeat business
Bu
yer
Factory O
wn
er
PIPproductivity improvement program
Cost optimization system development
Factory productivity system development
©Productivity Improvement Cell,BGMEA
Awareness seminar
with owner & buyer
Pre Setup
Engineered planning
Short training program
with factory side
Short term strategy
©Productivity Improvement Cell,BGMEA
PIP strategy
Collaboration with
International buyer
Collaboration with Donor
agencies
Collaboration with Top
management by means of short
seminar
©Productivity Improvement Cell,BGMEA
Branding strategy
©Productivity Improvement Cell,BGMEA
Suggestion for further Improvement
©Productivity Improvement Cell,BGMEA
Towards Competitive RMG Sector
©Productivity Improvement Cell,BGMEA
top related