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Skill matrix

Productivity Improvement Tools

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Skill matrix

  1. 1. Abruan Group Mohammad Kamruzzaman Head of Industrial Engineering & Planning Temakaw Fashion Ltd. Trainer: Effective tool to boost productivity in apparel Industry Training on…..
  2. 2.  Skill matrix is a table that shows skills of individuals in a team and any gaps between the skills of employees and the job roles they have. It is also known as a competency framework.  Operator's Skill Matrix is the database which maintains the record of each operator, who can do what type of operation and at what rating.  It is very important to keep this database updated as over the time, operator acquire skills for most of the new operations as well as improve performance in existing operations.
  3. 3.  It is an integral part of our Visual Management System (VMS).  It is a simple visual tool to aid in the management, control & monitoring of skill levels  It displays all tasks & skills required to work in an area or team.  It displays all current team members. For each team member it displays current competency/ability levels for each task  It is a simple tool to aid resource planning.
  4. 4.  It keeps record of all operators with their efficiency of different operations carried out by taking the number of trials.  With the use of skill matrix an engineer's or line supervisors needs very list time to find out and select most efficient operator for a particular operation from the pull of operation.  It helps the line supervisor for balancing the line with particular skilled operators according to the work content.
  5. 5. Material and method Preparation of operator Skill Inventory (Skill Matrix): A standard work minute library is developed by measuring the amount of time taken by a good worker to do various tasks, measured by the stopwatch as given in the following Table 1. Once the skill matrix has been developed, for the setting of production line with respect to new style the pattern maker decides the production type, production steps in the sequence and the amount of work for each production step. Then he uses the standard work minute library to determine the number of standard work minute needed for each tasks.
  6. 6.  What is Line Balancing?  Line Balancing is the distribution of work on the line in such a way that everyone gets the same output of work in terms of time.  Objectives of line Balancing.  To minimize the no. of workstation on line.  To minimize the cycle times.  To maximize the workload smoothness.  To minimize the frequency of tools change.  To maximize the efficiency & effectiveness.
  7. 7. Allocation of Operator's (Line Balancing): Appropriate allocation of the skill operators for particular operations is the keystone for any line balancing in the garment industry. Allocation also depends on type of balance required. One approach of allocation is to find the closest match between operators required and operators available. This type of allocation results in intrinsic balance of line. Another approach is the effective utilization of operator's skill so far he can do the best, this approach results in dynamic balance of line.
  8. 8. From the Tables 2 and 3 for a setting the operators are selected as B-A-D because the operational efficiencies of these operators are as per the required for the particular jobs which will have the effective use of all operators' skills.
  9. 9. Results and discussion In this study the authors have produced a garment of 'Jegging without Pocket' and for this production they took the production of line number 14 before implementation of skill matrix, and then they selected the required operators with the use of skill matrix with respect to the operation which is as shown in the Table 4. In this study the authors have conducted for the production of number of pieces for the selected line number 14 before and after the implementation of the skill matrix. According to the prepared skill matrix the operators are selected with respect to their skill reports stored from the database. The Table 5 shows the results of before and after the implementation of the skill matrix.
  10. 10. The Figures 1 and 2 reveal that, the number of pieces produced per day after the implementation of the skill matrix is found to have increased by 30% to 40%, which is due to the effective utilization of manpower at the proper place. For one day it is found to be only 8% since on the same day a particular operative was absent and so far the percentage increase was less on the same day. By the statistical analysis it is confirmed that, the 'P' value for both the production levels of before and after implementation of the skill matrix is 4.12E-05 which is less than 0.05, reflecting that there is a significant difference in both the production levels. Therefore it can be concluded that with the use of skill matrix the production level of the garment industry can be effectively improved.
  11. 11. 1. The record keeping of all operations with respect to the particular operator has been found to be possible which in turn is useful for further line execution, which leads to improving the efficiency level in each operation. 2. The statistical analysis proves that the use of skill inventory (skill matrix) is very much essential for the garment industries for enhancing the productivity. 3. For the engineers or line supervisors require less time to find and select most efficient operators for a particular operation from the pull of operators. 4. For line balancing, operators can be selected according to work content. For example – where an operation is required 50% less time than pitch time, engineers can select an operator whose efficiency level is 50% on that operation. 5. When operation clubbing is required (for less work content works), skill inventory gives the information on what type of operation is to be given to an operator. 6. When someone is absent, supervisor can easily find a suitable person from the skill inventory table for replacement. 7. A skill matrix can be made in spread sheet. Or real time shopfloor data tracking system can be used for skill matrix development. In the skill matrix, a user can do sorting of operator performance in various operations and other way in an operation how many operator are there who had earlier worked on and their efficiency levels.
  12. 12. System : How to develop skill Matrix
  13. 13. Untrained Work Instruction Skill Task No experience of
  14. 14. Learner Being taught the  Skill  Task  Work instruction
  15. 15. Practitioner  Can carry out the skill/task/work instruction/package Safely.  To the correct quality standards at first time  To 1.5 times the standard cycle time i.e. is still not up to speed.
  16. 16. Developer  Can improve the skill/task/work instruction/package: Safely.  To the correct quality standards, first time.  Work to the standard cycle time.
  17. 17. Coach Someone who has the skill level of a Developer, but can train & develop others in carrying out the skill/task/work instruction/package:  Safely.  To the correct quality standards, first time.
  18. 18. Can perform efficiently Can perform as a Master Symbol Skill Description Can not perform the task Familiar with eliments of the job Can perform
  19. 19. Date: 20th August,11 32 20 32 17 32 16 32 21 32 15 Prepared By: Dekko Designs Ltd. 11 20 Skill Lavel Key Line No: 2 20 11 20 10 20 Sabina Shamim Nasima Industrial Engineering Department OperatorScore 2020 20 9 Ashraf Untrained Learner Developer Coach 141510 Practitioner Skill Score Operation Name CardNo/Name Salma MTCS SIDESEAMUSINGFOLDER FOA 20 6 Skill Matrix Sample- DDL COLLARJOINT SNLS BOTOMHEM(PANT) SNLS/DNLS SIDESEAM OL5 INSEAM OL5 BOTOMHEM(SHIRT) SNLS/DNLS COLLARBANDJOIN SNLS WAISTBANDJOINT
  20. 20. Abruan Group Line-12 Temakaw Fashions Ltd.
  21. 21. Operation Bulletin of Jacket before Balancing
  22. 22. Breakdown of Plain Machine before arrangement Breakdown of Plain Machine after arrangement
  23. 23. Breakdown of Over lock Machine before arrangement Breakdown of Over lock Machine after arrangement
  24. 24. Breakdown of Flat lock Machine before arrangement Breakdown of Flat lock Machine after arrangement
  25. 25. Operation Breakdown of Jacket after arrangement
  26. 26. Final Practical output after sharing of work