garment productivity management the purpose of the course is to create ability among the...
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Garment Productivity Management
The purpose of the course is to create ability among the participants to develop productivity improvement plans and their execution.
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Rationale of Studying Garment Productivity
The only way of survival for Pakistan Better Performance of Garment Industry
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Textile Contribution in Economy of Pakistan
Exports 67 % of total exports (US $ 7.5 Billion)
Manufacturing 46% of total manufacturing Employment 38 % of total employment GDP 11 % of total GDP Investment 31% of total investment Market Capitalisation 8% of total market capitalisation Taxes Rs. 4.5 Billion per Annum Salaries and Wages Rs. 44 Billion per annum Contribution to R&D Rs 148 million per annum
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Significance of Garment Industry
Value added
Labour intensive
Use of infrastructure
Foreign exchange earning
Ancillary industry
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Our position in international market
Table One Table Two
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Value added product and our garments Designer wear Ladies Kids wear Formal suiting Formal shirts and trousers Leisure wear Made ups
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What we are exporting?
Made ups
Major share bed sheets
Lowest possible price
Throw away products
Not of high quality
Daily used items
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Why we are Exporting low priced Items?
Technology?
Designing ?
Machinery?
Raw Material?
Quota?
Duties?
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Actual Reasons:
Lack of professionalism Lack of transparency Lack of skilled management Lack of honest traders Lack of commitment Lack of infrastructure
Or Poor productivity
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For improvement:
We have to study productivity since this is the
only way to achieve honorable position
We can do a lot since:
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Scope of Pakistan Textile Industry
Pakistan has 9% share in total world’s cotton production. Pakistan is a major exporter of yarn and enjoying a share of
28 % in the total world yarn trade. Pakistan has a 9.9% share in the total world export of cotton
cloth. Growth rate of clothing exports is quite encouraging. In 1970-
71 clothing export (Bed Wear, Made Ups, Woven and Knitted garments) share was only 1.43% of the total Pakistan exports, which is 38.97% in 2003-04.
There are 64 million people between the age of 20 and 60 capable to work in a Labour-intensive industry And finally Pakistan has no other choice
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Lecture #02
Productivity Fundamentals
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13
Garment Productivity Means?
More productionLess rejectionMore efficient Less labor costLess pollutionMore profitSatisfied customerIn time deliveryHigh price
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Increased output increased productivity Profit and productivity are synonymous Cutting cost improve productivity Profit today and tomorrow are possible Partial productivity improvement is
worthwhile Productivity applies only to production.
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Productivity?
A mind set to produce more with less
An approach to keep planet intact
An effort to keep all stake holders smiling
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Stakeholders
Client
Supplier
Government
Society
Employees
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Confrontation in interests
Government --- more taxes
Customer less rate and quick supplies
Society less pollution, more employment
Owner --- more profits
Employees ---- more benefits
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Target achievable or not achievable
Yes-----yes ---- yes ---
But how
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Through Better Productivity
Productivity is a continuous growth
phenomenon
Growth
Negative or positive
No chance of zero growth
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Control and Growth
Growth is an inevitable phenomenon
One has to control it and make it according to
his or her desires and demands
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Some Classical Productivity Definition
Productivity is the measure of how well resources are
brought together in organizations and utilized for
accomplishing a set of results. Productivity is the
name of reaching the higher level of performance
with the least expenditures of resources
Mali
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Productivity is measured by the goods and
services produced by per unit of national
resources.
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The concept that productivity is a relationship between outputs from a given system during or over a given period in time, and inputs to that system during that same period, should be generic and universal
Sink
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Productivity is a comprehensive measure about how efficiently and effectively organisations satisfy the following five aims: Objective achievements Efficiency of the process Effectiveness- Comparability with other organisations Trend- productivity measured over a period”
Lawlor
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Productivity is about making the most efficient
use of all resources and gaining maximum
added value from them”
Prokopenko & North
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Doing things right at the least possible cost in
least possible time with the highest possible
quality and to the maximum level of
satisfaction of the customers and employees
Ayesha Baig
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Productivity is a road to competitive
enterprises, the economic development of
countries and welfare and well being of
nations
Gharneh
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In a nutshell, productivity reflects results as a function of effort. If productivity improves, it means that more results are being gained from a given amount of effort. In a classical sense, productivity is defined as a ratio such that the output of an effort under investigation is divided by the input required to produce the output.
Brinkerhoff and Dressler
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Productivity is a measure of the capacity of individuals, firms, industries or entire economies to transform input into output. More specifically productivity is a measure of the rate at which output (of goods and service) are produced from given amount of input.
Industry Commission
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Productivity is an approach, a mindset, and a way
of thinking to do more with less by observing the
business ethics, caring the risk of stakeholders
and keeping the planet clean.
Mushtaq Mangat
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Lecture# 03
Garment Industry Practices
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Garment Productivity Management
A blue print for productivity improvement
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Management of whole process
Input
Process
Output
Feed Back
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Input
Raw material Human Resources Utilities Time Information System Support of society
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Process
Merchandising
Planning
Procurements
Production
Finishing
Packing and export
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Quality assurance
Quality control
Quality checking
Quality departments
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Output
14% rejected garments Every fifth shipment by air Cancellation of order 13 hour average working hour Under pressure Job insecurity No personal life
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A few new industries in last 10 years, where
as many closed down
Delay in salary
Long over due of suppliers
Bank loan problem
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Reason:
Technical
Managerial
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Technical
Not common
Industry is order bases
Order is confirmed after having approval of samples
All technical problems are solved at sample level
But still there are problems
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Sample is ok but bulk production problem
Small quantities are under control where as big quantities are problematic
Parameters are noted properly noted during sampling
Many things are over looked during sampling
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Why so?
Want to get order at any cost
Show efficiency before customer
Do not make customer unhappy
There is a gap in production
Want to meet over heads
Want to achieve scales of economies
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Managerial
Top management
Middle management
Front line management
Workers
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Top Management
CEO
GM
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Top management and low productivity
Duty of top management 1- Resource availability 2- Helping in difficult situation 3- Motivating 4- Monitoring 5- Guiding 6- Leading in difficult situation
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But what they do?
Raw material, Very common --- no cushion of raw
material
Late delivery of accessories
Poor quality of accessories
Short quantity of accessories
Seen many times garments are packed and waiting
for cartons
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Guidance and helping
Helpless Only two person qualified in textile not in
garments Shortage of funds No money for storage Working on zero inventory cost but with poor
relations with suppliers
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Motivation
No long term association
Termination quickly
Harsh wording
No friendship and interaction
No dine together
Lack of trust on employees
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Result:
No feel of participation
Lack of commitment
Looking for other jobs all the times
Back biting very common
No sense of ownership
No work pride
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Middle Management
Not qualified in textile Learned on job Lack of confidence Application of authority Spend more time in office calling people working on
floor No help in work Getting job by order
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Out come
Lack of interaction
No team work
Less trust
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What you can do?
Being employee:
Limited decision power
Limited authority
Limited information
Lack of vision
Lack of trust
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Options
Look and count sinking of ship
Work hard to save it
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Sinking of Ship
Results:
Job lose
Confidence lose
Un-employment
Loss of the nation
More poverty
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Only option
Have to give shoulder to ship How? Keeping company interest first Putting more efforts Working hard Increasing commitment level Being confident Seeking help and guidance from Allah
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Lecture # 04
Productivity and Economic Prosperity
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Productivity and Economic Prosperity
Prosperity is a function of productivity
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Economic Prosperity: ultimate goal
Basic demand of human being Provides comfort Gives leadership A way to get respect Independence Sovereignty provision
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Means of Economic Prosperity
Reach to resources Use of resources Development of resources Provision of resources Getting benefit of resources
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Get work done by others
Economic prosperity depends upon: Knowledge Skill Hard work Use of latest technology Generation of value added products and services
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Developed Countries and productivity
A proof that better productivity is a guarantee of economic prosperity
They achieved through better productivity Resources scarcity did not hinder They used resources more wisely
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Personal Prosperity and Productivity
More knowledge and more gain High skill and better life More hard work and prosperity Prosperity is a function of productivity
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Productivity Measuring Application
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Lecture # 05
Productivity Measurement application
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Application of PM
It is not only an indicator of actual performance, but also of potential areas of improvement
Highlights the degree of efficiency in the use of economic resources and facilities of an organisation and the ability to control these resources and facilities
Helps to clarify linkages between strategic planning, capital allocation, and performance
Offers an opportunity to compare, forecast, analyse and control different operations
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Conti----
Spotting productivity declines for early warning Comparing productivity across individuals, units,
organisations, and industry to make management decisions. Linking management and labour productivity improvement
efforts to build common awareness and responsibilities Demonstrate productivity gains to stakeholders Conducting research and evaluation related to new or
experimental methods Supporting incentives and bonus plans with objective
productivity data
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Conti---
Profit Customer Satisfaction Sales Revenue Market Share Costs Quality, defects Response time Units Produced
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Conti---
For strategic purpose; in order to make a comparison with other firms
For tactical purpose, to enable management to control the performance
For planning purpose; to compare the relative benefit For internal purpose; so that management can take help for
collective bargaining To measure the work content and reward for labour To determine the staffing level For appraisal of management performance To measure the organisation effectiveness
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PM Issues
Data Collection Labour productivity Partial and total productivity Simple and compound productivity Primary and secondary productivity
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Lecture # 06
PM models and approaches
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PM Approaches
The range of measurement approaches and measurement tools is quite large. As with other productivity tools, the choice of an appropriate tool depends on the nature, scale, level and phase of the investigation. There are even ‘political’ considerations.”
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Conti---
Control panels The Objectives Matrix -OMAX The Balanced Scorecard Productivity accounting Throughput costing Economic Value Added -EVA. Integrated Business Control - IBC
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Conti---
Growth models attribute increased economic growth either to accumulation of physical or human capital or to increase efficiency of their use
Neoclassical growth models view technical progress as exogenously determined
Endogenous models consider a range of structural and policy variables which contributes to differences in technology endowment, investment, and knowledge accumulation among countries
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Total and Partial Productivity It provides both aggregate (firm level) and detailed
(operational unit-level) productivity indices. It points out which operational units are profit making and
which are not It shows which particular input resources are being utilised
inefficiently so that corrective action can be taken It lends itself to mathematical treatment so that sensitivity
analysis and model validity become easier.
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It is integrated with evaluation, planning, and improvement phases of the productivity cycle. That is to say the TPM offers for the first time, a way of not only measuring but also evaluating, planning and improving the over all productivity of the an organization as a whole and as well as its operation units.
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It offers the advantages of management by exception by providing, a means to more tightly control the total productivity of major operation units, while providing routine control for the less critical operation units.
It provides valuable information to strategic planners in making decisions related to diversification and phase-outs
of product or services.
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Lecture # 07
Garment Productivity Measuring Factors Contributing in Productivity
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Factors
Raw Material Utilities Human Resources Time Capital Infrastructure
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Significance of Factors
Different factors have different share Some factors are controllable Some factors are out of control Some factors easily controllable Some factors have less significant
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Selection of Factors
Most important Most critical Be sensitive in selection the factors Be critical in selection the factors Be wise in selection of factors
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Raw Material
Yarn 40 to 50 % of the cost Dyed Fabric 50 to 60 % -------- Trims 10 to 15%---------- Labour 5 to 15 % ---------- Over Head 10 to 20 % --------- Utility Bills 5 to 10 % ---------- Misc 5 to 10 % ----------
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Raw Material
60 to 70 % of the total cost Minor change in RM consumption can save a
lot Easy to save little How one can save RM? Next Class
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Raw Material
Fabric Trims Accessories
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Fabric
Main fabric Fusing
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Potential Productivity Indicator
What can be produced what has been produced?
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Potential
Potential calculation Problems:
Variation in product Variation in style Variation in quantity Any other change
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How to calculate the Production Potential From previous record By doing experiments Market practice Machine manufacturer’s recommendation
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Production Departments
Cutting Stitching Clipping Pressing Packing
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Develop potential of every department
Keeping in view the product, facilities and skill of the people
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Cutting Department Potential
How much pieces can be cut with same number of people?
What is current level of production? What is the variation level? Why there is a variation? Who is responsible? Workers.. Machines.. System..
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Workers
Lack of skill Lack of motivation Lack of awareness Lack of guidance Lack of commitment No personal growth plan Any other
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System
Poor environment Poor planning Non-availability of material No incentive Less control Poor management Any other
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Machines
Old technology Poor maintenance of machines Less quantity of machines than required No skill to operate the machines Any other
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How you can improve?
First identify the problem Then search it solution with the help of people
working Apply Keep an eye during application process
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We know where most of the creativity, the innovation, the stuff that drives productivity lies -- in the minds of those closest to the work. John F. Welch, Jr.
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Time management is life management. Everybody manages time. It's not optional. Some people just do it better than others."
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If you use your head more, you'll use your feet less."
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Do not spend time. Invest it. You spend time in your sleep. Investing time requires conscious thought.”
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Lecture # 08
Resource Productivity
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One learns by asking questions. Author : Ali ibn Abi Talib (r.a)
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Men are born to succeed, not fail."- Henry David Thoreau
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The growth & development of people is the highest calling of leadership."- Harvey S. Fireston
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“I know the price of success: dedication, hard work, and a devotion to the things you want to see happen." - Frank Lloyd Wright
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"Purpose is what gives life a meaning." -- C. H. Parkhurst
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Cares For Consumption Planning
Must be accurate No extra ordinary margins
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Planned Requirement
Planning can lead you to any destination Planed Consumption
Basis for Planned consumption Old record Markers Sampling
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Raw Material
Fabric Selection of fabric supplier Quality checking of fabric Quantity Delivery time And finally price
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Analysis of Consumed RM
Actual verses Planned Variation is possible Reasons of variation
This comparison will help in calculating the reason of variation
Variation may be plus or minus In both cases it is not acceptable
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Variation Reasons
Quantity variation Cost variation
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Quantity Variation Reasons
Quality – more defects in fabric Width variation Length variation Grammage variation Color shading
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Cost variation
Price fluctuation Other cost like transportation , storage Re processing Sorting
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Productivity Indicator
Raw material per garment One has to control During production And has to make a comparison after
competition
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Lecture # 09
Cutting Department Potential Productivity
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Cutting Department Function
Receiving of fabric Checking of quality of fabric Quantity verification Assurance of all required accessories Placing of goods in order Avoiding mixing of goods with other lots
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Laying of fabric
Length of lay decision Proper length Control of wastage Use of margins Avoiding mixing of different rolls Proper bundling
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Cutting Process
Cutting can add faults Cutting can save losses Cutting is irrecoverable Loss is multiplied by high numbers
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Cutting Productivity Parameters
Consumption per garment Number of pieces cut in a shift Rejection of panels and piece percentage Reasons of rejection Analysis of rejections Remedy of rejected panels
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Waste analysis
Large waste Small waste Front and end pieces Panels wastage
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Lecture # 10
Stitching Process
Assembling of Cut pieces
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Receiving from cutting department and induction
Stitching of cut pieces according to design Checking of quality
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Stitching Productivity
Garments per machine Garments per head Garments per square meter
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Productivity per operation
Different machines are used for stitching Productivity of different stitching machines Productivity of different operators Productivity of line checkers
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Re-work enemy of productivity Re-work percentage Reasons of re-work Remedies of re-work Record of re-work
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Finishing Department
Receiving from stitching Clipping Pressing and checking Packing
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Finishing Productivity
Pressing per day Packing per day Percentage of wrong packing Percentage of repacking Packing per person Packing per hour
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Packing problems
Wrong packing Assortment disturbance Mishandling of pieces Addition of stains during packing
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Better Packing can Add Product Value
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Lecture # 11
Garments Quality and Productivity We need quality products with high
productivity
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Nothing in the world can take the place of persistence. Talent will not; nothing is more common than unsuccessful men with talent. Genius will not; unrewarded genius is almost a proverb. Education will not; the world is full of educated derelicts. Persistence and determination are omnipotent. The slogan press on has solved and always will solve the problems of the human race. No person was ever honored for what he received. Honor has been the reward for what he gave.
Author: (John) Calvin Coolidge (1872-1933), 30th US President, Republican
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Quality
Goods as per demand of the customer 1-Time 2-Product 3-Quantity 4- Specification
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Productivity
At minimum cost--- efficiency Maximum Production--- efficiency Minimum Rejection rates--- effectiveness High value ---- performance Optimum production--- maximum capacity
utilization No loss to the nature--- environmental friendly
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Wise use of resources--- resource productivity
Application of latest technology--- less utility and Labour bills
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What we need?
Quality products High productivity
What do you think?
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Quality?
Is it demanded? Is it built in? Can some one compromise? Can we live without it?
Then why some one discuss it?
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Just to remind
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Productivity
Can one live with low productivity? Was in past it was less important? Can we hire a less productive manager? Price of slaves in ancient times mainly depends upon
his or her productivity? People move one area to other area based on
productivity of land Command, authority, leadership depends upon
productivity
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What is your Answer?
Productivity Quality Or Both Then How? It is the question needs your answer
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Only growth can ensure your success and happiness
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Lecture # 12
Resource Productivity
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Post Shipment Analysis
This will help you in finalizing the strategies
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Planned and Consumed
Post shipment analysis Reasons of variation Remedied for variation Future planning Record of previous shipments Meeting on order closing
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Involvement of whole team Distribution of information to all persons
concerned
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Significance of Post shipment analysis
In most of the cases orders are accepted which have profit margin
It is very rare that orders are accepted for loss… might be some hidden agenda
But In most of the cases there is a loss after
completion of order---------- Reasons?
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Reasons Identification
Most significant process Needs to avoid such loss in future To have more profit in future To reduce price for better marketing To know the potential loss
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Steps in post shipment analysis
Identification of most significant factors Classification of factors on the basis of their
origin Comparison of actual verses plan Reasons of variation Cause and affect diagram
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Results Analysis
Discussion about outcome with other team members
Fixing the responsibilities on departments not on persons
Estimating share of different departments Conclusion
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Lecture # 13
Productivity is a comparison Phenomenon Evaluation and comparison
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Evaluation
What we have done? What was our capacity? How many resources we have used? What could be done? For this we have to compare
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Comparison
With potential With competitors With market With old record With trail run
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How to compare
For comparison
1- Maximum similarity
2- High players of the market
3- In a simplest way
4- Frequently
5- Periodically
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Evaluation Level
Personnel Department Firm Industry Country World
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Who can evaluate?
Must have knowledge about the process Must have experience to measure Must have the ability to correlate different
factors Must be able to understand affect of any
factor
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When to Measure?
Before start During After completion Or
??????
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Conclusion
May be biased May be not true May be misleading Can lead to some way far
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Explanation of results
Much important Much crucial Must be done with lot of care
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Actions should be based upon results
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The intelligent man is whoever knows how to be happier today than yesterday
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He is honoured who frequents the intelligent
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No one who possesses intelligence is ever reduced to poverty
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Application of Evaluation in Textiles
Evaluate yourself before you are evaluated by customers
Early evaluation will help you in improving Late evolution just intimation of failure Better evaluate yourself every day and every
moment
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Internal audit is better than audit by the customer
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Lecture # 14
Productivity Planning
Third Step of Productivity Cycle
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Planning Objective
For Better Productivity
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Micro Planning
Major Areas
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Stop the leakage
Most important Much crucial No development is possible You can’t fill the glass with a hole in the
bottom
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Rejection Reduction Planning
Rejection measurement Rejection is a symptom not reason Reason is some where else
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Identification of reasons
It is difficult to assess difference between reason and symptom
No improvement is possible with out addressing symptom
This needs a skill and quite clear vision Spend maximum time at this step
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Addressing of symptom
Involve people Take their observation Ask them for solution Encourage their participation Encourage to have experiments Help in experimentation Give support for difficult decisions
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Lecture # 15
Productivity Application
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Implementation – the fourth step
Apply your decisions Gradually and be vigilant in assessing the results Give extra time and resources to your team during
implementation Do not resist for change during implementation Celebrate minor and major success
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Actions will be judged according to intentions Muhammed PCBH
The world will be your best counselor, if you follow its advice Hazrat Al
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Lecture # 16
Productivity Reviewing
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More Coming Soon ... We are working on this category.
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Productivity Reviewing
Change is an ever last phenomenon
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Why Review
Have to improve targets Environment has changed Demands have been changed Culture has been changed Technology has been changed
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How to Review
Compare targets and achievements Analyze the out come Do micro analysis Consult the relevant people Make graphic representation Intimate to every one about results Do not hide the truth
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Reviewing and Planning
Reviewing is not the target Objective is to make base for next planning Planning needs some basis
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Lecture # 17
Personal Productivity
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PERSONAL PRODUCTIVITY and Organizational Performance
Productivity Concept and meaning Doing more with less
Ratio of output to input Doing right first time Less wastage More yields More wise use of resources Helping increased productivity of others
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In one’s lifeOutput Work Result Gain Develop Grow Increased in knowledge Helpful for others
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InputTimeResourcesWealthOthers timePlaceMaterial (books, food, energy etc)
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Process Doing things Reading Learning Writing Listening Having meetings Remembering Results are directly proportional to the
level of self organising
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Self-organising Only to have more with less How in can be increased?
Clear goals Priorities Daily plan Elimination of Procrastination Avoiding Personal disorganisation Looking for Perfectionism Avoiding Interruption
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Goal pyramid Long term- medium rang and short term Be realistic when setting your goals Be realistic about your expectations Do not give up very easily Prefer those areas that offer the best chance for
improvement Monitor your achievements And resetting your goals
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Organising Study Life --------------------learning is life
Create study environment Study group Where you should study- library, home, and
friends home When you should study
Study when you are best Consider your sleep habits Study when you can
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Evaluate your study area
Have a drinkTurn down the heatShake a legChange your schedule
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Be selective in study
Why study What to study How much to study After study
Remember Take notes Put notes properly for future references
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Your Productivity is Organizational Prosperity Direct link between your performance and
company performance Company performance is sum of individual
performance It is the duty of company to improve personal
performance And it is the duty of individuals to improve
company performance
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Interest is common Threat is common Goals are common Targets are common Duties are different
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Your personal improvement will help you in your personal growth
Be selfish in personal productivity
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Lecture 18
Application of Productivity Improvement Program
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We Have Studied
Productivity Cycle Measure Evaluate Plan Action
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This lecture will cover
Guideline to start productivity program in a firm
Discussion about possible confrontations Issues related to this program Support required Cost and benefit analysis Win-Win position
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Justification of Productivity Program
Low profits Heavy loss More stress on management Quick change of customers Always in hurry Spoil personal life of management No good name in market
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Are these rationale are significant?
supposed to be some where else should be market leader have a credit in market should earn more profits should have a balance in business and
personal life should have time for prayers
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Convinced Team--- Basic Requirement for Change How you can Convince team?
By telling them the truth…. May be they are thinking that situation is quite healthy
By sharing secret--- so called secrets with them By gaining their confidence By telling them successful stories of winners By showing them worst scenario--- if there is no
improvement By promising for a better share of fruits
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Be Ready for Confrontation
You may face severe confrontation; like, Criticism Mistrust Working alone No action on your advice Blames Discriminated behavior
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Issues Might Come
No data is available Wrong reporting Double reports Fake figures Hidden agenda Taking personal grudge Using your office for personal gains Any thing ----
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You Need
Support Authority
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Support Required From
Top management Middle Management Front line management Workers
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Support is not your Right
But you need it: How you can get it?
A big question?
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Qualities Required:
Interpersonal skills Be fair Be trustworthy Do not indulge in their private and personal matters Be neutral Focus on your own job Do not be part of any group Do not be personal
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Cost and Benefit Analysis
Need of funds for improvement never appreciated
Start such activities where no money is required
Prove that you are saving some thing Plan to invest part of savings Be conscious in investing money
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Who will Be benefited?
Firms Society Government Community Or employees themselves
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Who will get Benefit First?
Employees
Elaborate this phenomenon
This is the motivation point
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Productivity--- unending process
Never stop productivity program It is for ever since
Competition is for ever
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Lecture # 19
Productivity Measurement
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Measurement
We have studied the significance of productivity measurements and methods to measure productivity. Now we will measure change in productivity indicators
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TFP is a sum of partial productivity
Example:
Total Pieces Produced 25890
Total Pieces Rejected 2356
Rejected Due to Knitting Faults
650
Rejected Due to Dyeing Faults
560
Rejected Due to Stitching faults
1050
Misc 96
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Small Holes 150
Needle line 250
Press off 50
Oil stain 150
Double stitch 50
Detail of Knitting Faults
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Calculate:
If needle line problem improve 50% what will be the impact on total rejection %
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Lecture 20
Productivity Measurement and its analysis
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Analysis
For Improvement For addressing the weak areas Finalizing increment Hiring and firing decisions Making strategic decisions Forming policies
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Un attended
If results are not derived and action actions are not taking --- then people will ignore its importance
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Analysis and People Involvement
Development depends upon the level of people involvement