Thai Garment Industry
Overview of Thai Garment Industry
Important Statistics
Items Value
Total Thai garment export value Approx. 3,200 million USD
Total Thai garment Domestic value Approx. 5,000 million USD
Total number of garment factories in Thailand 2,200 (90% are SMEs)
Number of local brand Approx. 1,000 brands
Number of people working in Thai garment industry
Approx. 900,000 people
SMEsOEM
(Own Equipment Manufacturing)
SMEsODM
(Own Development Manufacturing)
SMEsOBM
(Own Brand Manufacturing)
How SHARE helps Thai SMEs
Government
Mar, 2011
Thai Garment Development FoundationThai Garment Development Foundation
Corporate Profile & ObjectivesCorporate Profile & Objectives
Thai Garment Development Foundation or SHARE is formed in November 1994 by government and private sector
The organization running under the concentration on delivering competitiveness solution
MissionMission
To Strengthen Thai Fashion and Apparel SMEs to ASEAN
by creating value-added and reducing cost.
What we do What we do To serve and increase competitiveness of Thai Apparel
Industryby creating value-added and reducing cost.
Human Resource Development
Human Resource Development
Continuous Development• Knowledge, Skill,
Attitude and competencies development•All level(Operator,Middle,Top management)• Industrial competency standard
Education Resources Management
Education Resources Management
Sustainable Development• Education Sector Collaboration
(Vocational , University)
Productivity DevelopmentProductivity
Development
Reducing Cost.
Creating Value-Added
Productivity improvement
Product
Development
ProductDevelopment
ProductDevelopment
What is SHARE Business Network ?What is SHARE Business Network ?
Human Resource Development
Human Resource Development
Education Resources Development
Education Resources Development
2010
4 projects
5 projects
5 projects
371,170,000 million baht / year
18 projects 190 companies Increase value /
reducing cost for industry
Product DevelopmentProduct Development 4 projects
Productivity DevelopmentProductivity Development
Our past projects and performance
Best Practices II
Sustainable Productivity Improvement
55 companies
8 companies
1 company
TPM
LEAN THTI 4 companies
Cost reduced by 8.96 million baht / year
Cost reduced by 359.50 million baht / year
68 companies
Our past projects and performance
Cost reduced by 2.71 million baht / year
Product Development
Pattern Workshop Training 2 Courses
36 people
2 Companies
Fashion Muslim
Product Developing
-Under wear / Swimmer- Lady wear
Best Practices (Sample Room) 5 Companies
19 Companies
Our past projects and performance
Organization Behavior Development
Garment Skills Development
Competency Assessment Test
1 Companies
254 people
1 Time
- ACP Apparel Co., Ltd.- MCAP Erawan Co., Ltd.
Human Resource Development
Human Resource Development
In-house Training4 Courses
12 Companies
Career Development 78 people
- 20 courses 65 companies
-Garment Merchandiser Competency Test from23 companies 74 candidates
- Sustainable Improvement- Motivate to work happily for an entire organization-Self inspection for production dept. (sewing)- Waste reduction
103 companies
2 Courses
1 Time - Cooperative study project with RMUTK
Education Resources Management
Education Resources Management
2 Times
Career CenterCareer Center
1 Time
VQ: Vocational Qualification
Cooperative study
New skilled labors recruitment for the industry
Teaching Media
Development
Teaching Media
Development1 Topic
- Bachelor degree of engineering - Bachelor degree of industrial engineering at RMUTSV
The Project of Best PracticesExample
Sponsored by Department of Industrial Promotion
Best PracticeBest Practice conceptconcept
“Help each other, exchange and learn together”
Best Practices Modules
Production Planning and Control
Sample Room and Prototype Improvement
Material Utilization
Lean Manufacturing
Multi Skill Development
Japanese Advanced Production System
Best Practice Success caseBest Practice Success case
Productivity Improvement and Cost Reduction by Multi-skills
Grand Knit Wear Co., Ltd.
A medium size company with approximately 300 machines
BeforeBeforeAfterAfter
• Space consuming
• Long production line
• Double work
• Time consuming
• Production line was rearranged by sitting next to each other so that workers can see the works amount of their teammates.
• Quality control was brought in place at the line’s end for immediate inspection.
Result in Sewing line Result in Sewing line improvement improvement
Star
tSt
art
Fini
shFi
nish
ResultsResults
Topic Target Before After
Efficiencyincrease ≥ 10%
80 pieces
160 pieces (100%)
Reworkdecrease
≤ 5%30
pieces10 pieces (200%)
WIPdecrease
≥ 20%132
pieces70 pieces (88.5%)
Improving StagesImproving Stages
1. Adjustment of production from work process focused to goods produced focused.
2. Reduction of Work-In-Process by changing from bundle system to one-piece-flow system.
3. Revision of workers’ compensation system.4. Changing workers’ attitude.5. Supervisors focus only production alone.6. Prepare sewing manual for common products.7. Determine group compensation.
Productivity Improvement and Cost Reduction by Production Planning & Control
Heart & Mind Co., Ltd.A medium size company with approximately 300 machines
Best Practice Success caseBest Practice Success case
BeforeBeforeAfterAfter
• Space consuming
•Time consuming
• Reducing time by giving out fabric according to more precise calculation
• Better on-time delivery of fabric to production dept. due to process reduction
Result in Fabric Result in Fabric inventory improvement inventory improvement
Use the whole lot of fabric
Receiving withdrawal card
Giving fabric as stated in the card
Restocking the left-over fabric
Receiving withdrawal card
Use the fabric as stated in the card
Giving fabric as stated in the card
ResultsResults
Topic Target Before After
Efficiencyincrease
≥ 5%59%
62.5% (5.9%)
Lead Time
decrease≤ 5%
39 days37 days (5.1%)
OTPincrease≥ 20%
55.2% 69% (25%)
Improving StagesImproving Stages
1. Reducing Lead-time in fabric inventory department by redo the process of giving and restocking fabric, reducing the process of withdrawing fabric for cutting, reducing time for fabric inspection.
2. Reducing production cost by reducing the percentage of sewing accessories purchasing,
Productivity Improvement and Cost Reduction by Lean Production
Central Garment Factory Co., Ltd.
A medium size company with approximately 300 machines
Best Practice Success caseBest Practice Success case
BeforeBefore
AfterAfter
Result in Process line Result in Process line improvement improvement
• The length of work flow is 20.5 meters.
• The length of work flow is reduced to 10 meters (46.3%)
ResultsResults
Topic Target Before After
Productivity
increase ≥ 10%
4,480 pieces
6,780 pieces (51%)
Costdecrease
≤ 10%
43.54 Baht/pie
ce
23.54 Baht/pieces
(45%)
WIPdecrease
≥ 20%2,216 pieces
706 pieces (68.8%)
Improving StagesImproving Stages
1. Adjustment of production line process.2. Search and improve for 3 wastes, production, waiting time and motion.3. Connection of Boxer cutting dept. to sewing dept. and control of work and
equipment using Kamban system with Andong system for failure detection.4. Self-inspection of work in each process.5. Setting up a standard of procedures (SOP).
Productivity Improvement and Cost Reduction by Sample Room Development
Neo Apparel Co., Ltd.A medium size company with approximately 300 machines
Best Practice Success caseBest Practice Success case
BeforeBefore
AfterAfter
Result in Sample room Result in Sample room improvement improvement
Late sample delivery
Long Lead Time
Not Right First Time
No Standard
of Procedure
• Prepared sample plan/status for follow up• Prepared sample production plan• Prepared a form for purchasing sample
• Creating Prototype Standard pattern• Creating Pattern Manual• Improved size spec form• Creating Prototype Pattern for embroidery
• Improved sample order card• Creating manual for correct cutting• Creating sewing technique manual and critical point• Etc.,
ResultsResults
Topic Target Before AfterOn Time Sample Delivery
increase ≥ 10%
38% 48.28%
Lead Time
Reduction
decrease≤ 10%
13 days7.5
days(42.3%)
Not Right First Time
decrease≥ 30%
93% 31%
Improving StagesImproving Stages
1. Prepare work flows by applying lean manufacturing concept to reduce waste.2. Prepare Master Plan and Load Analysis.3. Implement Design Engineering based on actual production and cost according
to the need of customers.4. Implement Risk Assessment.5. Prepare Master Pattern.6. Re-organize for a friendly environment layout .
Skills Development projectFor 10 careers in apparel industry in operator and
supervisor levels
Sponsored by OSMEP
CareersCareers
Operator / Supervisor level1. Production Planning and Control2. Merchandiser / Retail3. Purchasing4. Pattern technician5. Cutting6. Sewing7. Sample room management8. Quality Control9. Sewing machine mechanic10.Trainer for industrial sewing machine
Pre-Test TrainingPost-Test
On-the-job
evaluation
Result in skills Result in skills improvementimprovement
Before After
Average Test Score = 48%
From 254 candidates in 10 careers From 254 candidates in 10 careers
Average Test Score = 75%
SHARE activities SHARE activities
Teacher’s Training Session
Teacher’s Training Session
SHARE SHARE activitiesactivities
Best Practices & TPM
Best Practices & TPM
68 Factories participated
Total Cost reduced by $12 Million / year
SHARE SHARE activitiesactivities
Productivity Improvement for SMEs
Productivity Improvement for SMEs
Skills Improvement for SMEs
Skills Improvement for SMEs
25 Factories participated
Total Cost reduced by $1.8
Million / year
Over 250 personnels
participated
Over 80% satisfaction rate from employers
SHARE SHARE activitiesactivities
Fashion MuslimFashion Muslim
100 personnels
participated
Networking between
manufacturers and community
SHARE SHARE activitiesactivities
Pattern WorkshopsPattern Workshops
SHARE ForumsSHARE Forums
• Swim wear• Under wear• Lady wear
• Once a month• Topics variety• Well-known guest speakers
SHARE SHARE activitiesactivities
Corporate Social Responsibility (CSR)
Corporate Social Responsibility (CSR)
• Education segment• Apparel focused
SHARE executives SHARE executives & staff& staff
Future Multi National Projects for SMEsFuture Multi National Projects for SMEs
Experts Exchange and Study Visit• Merchandiser• Pattern Technician• Productivity Improvement• Competencies Improvement
Targeted Countries• China, South Korea, Russia, UAE, India and etc.
International SMEs Networking• Collaboration• Annual conference• Etc.,
Targeted Countries• Russia, India, China, South Korea, Etc.,
Future Multi National Projects for SMEsFuture Multi National Projects for SMEs
Thank YouThank You
Q&AQ&A www.share-apparel.orgwww.share-apparel.org
[email protected]@share-apparel.org