Productivity action plan

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 Scenario


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%


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 Strategy


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


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


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


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


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)


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)


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


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


TOT training team

ConsultantFull project

PIC team

Out source trainer

LEAN Transformation project


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



4 days 1 month

6 month development plan for each factory

Cost benefit analysis


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


Factory setup stage

Capacity & layout planning

Labor planning

Item knowledge

ROI Analysis



• 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


Awareness seminar

with owner & buyer

Pre Setup

Engineered planning

Short training program

with factory side

Short term strategy


PIP strategy

Collaboration with

International buyer

Collaboration with Donor

agencies

Collaboration with Top

management by means of short

seminar


Branding strategy


Suggestion for further Improvement


Towards Competitive RMG Sector


Productivity action plan

Engineering

productivity team

improvement plan

method improvement

productivity module

bgmea4low productivity

factory training

module breakpic team

team training condition