Productivity action plan

PIC Action Plan
©Productivity Improvement Cell,BGMEA
Developed by :
Saad Bin A.Rashid
Productivity 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 planFactorysetupstage
Capacity
calculation,
production
layout design,
ROI analysis,
Item knowledge
Productionstage
Direct factory
consultation by
their training &
practical
improvement
Shortcourseonskill
development
Short course
offered to
develop Mid
management
officer for
factory.
Topmanagement&buyer
attachmentseminar
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 study
Capacity
calculation
Efficiency
calculation
Production
planning&
design
Line
balanceWIP
reduction
Method
improvement
Motion study
Quality
improvement
Inventory
Control

70-80%Efficiency
level
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)

90-100%efficiencylevel
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 implementation
UNIDO

PIC Team Standing
PHASE -1
1. Work Measurement
2. Method Engineering
3. Motion analysis
4. Production system design
5. Quality control
6. Cutting fabric optimization
7. Inventory planning
PHASE-2
8. 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
AfterPSES&BBWprogram

TOT training team
Consultant
Full project
PIC team
Out source
trainer
LEAN Transformation project

PIC Cell Factory consultation
Set
Assessment
Diagnose
improvement
scope
Develop factory
PL team
OJT-1
for 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

Systematic approach of Implementation
Floor Data
collection
Analysis the
data
Standardize
the data
PMTS format
development
Optimize
layout design
WIP analysis Bottleneck Balance line
Set 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
Buyer
FactoryOwner
PIP
productivity 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

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