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MAS Intimates Linea-Clothing
Outline
Introduction
Activities and learning outcomes
Research findings
Suggestions
Survey results
Time period: 4th August- Up to now
Assigned Department: MOS
Worked on: Cutting Department
Introduction
Activities participated……
Sessions conducted by Tony and Critt
OBT session & Training school
TL/GL project in the cutting department • STW audits/ deviations
Questionnaire survey in LC/LI and data analysis
Observations in the production floor
Tony’s and Critt’s SessionsAble to gather a wide knowledge about the
STWs Developing BIQ Importance of problem solving TL/GL concept- TL/GL job rolesReduction of safety issues during the
working
OBT Program & Training School
OBT Session– Team work– Leadership– Integrity– Courage– Patience– Self trust & mutual trust
Training School– Sewing– Machine types/ needles – On the job training
» Targets» Time » Patience when damages
happens» Respect to others in the
team» Responsibility
Observed the loading, spreading, cutting and bundling processes Value adding, variations and the periodic variations
Measured the time period for each stepsSTW Audits and found some deviations from
the STWs8 step problem solving - More Andons from
the division 2 Cutting green board preparationCut- training cuts
TL/GL Project in the cutting department
• Got an idea about –The operations of a garment–AQL audits (pass/failure)–SMV –Efficiency calculation–Red box–6S audits
• Other observations– Difficulties- Style changes– Difficulties- graphic printers- due to heatMain learning outcomes- How to deal with people
Environment for learning
Production floor
Research
Research• Title: Factors Affecting adoption of
Standardized Work in LM
• Research Design : Case Study
• Target group : Total population in the cutting department
68 TM- Questionnaire survey/ ObservationsManager & supervisors/staff- Key informant
discussions
• Data analysis tool: SPSS- Chi square & Frequency analysis
• Data presentation : Bar graphs/ pie charts
General Objective: To determine the factors affecting adoption of
standardized work in Lean Manufacturing in the cutting department of MAS Linea-Clothing
Specific Objectives:To identify the individual and organizational
factors affecting adoption of standardized workTo give suggestions to improve the adoption of
standardized work
Objectives
Conceptual framework
Gender
Age
Education level
Working experience
Resource availability
Training and development programs
Performance evaluation and rewards
Clearly defined STW/SOP
Management support
Individual
factors
Adoption of Standardized
Work
Organizational
factors
Success in LM
Results and discussion
Gender Age
Population Characteristics
Male44%
Fe-male56%
Chart Title
20-29 30-39 ≥400
10
20
30
40
50
60
21
14
7
56
2 0
Male Female
Age (years)
Perc
enta
ge
Population characteristics……
Education level Type of jobs
Pass G.C.E.O/L Pass G.C.E. A/L
Graduates0
5
10
15
20
25
30
35
40
45
50 4649
5
Education level
Perc
enta
ge
Loading
Spreading
Cutting
Bundling
Embellishments
Record
ing
Market p
lace
Marker d
rawing0
5
10
15
20
25
30
4
8
27 28
15
6 7
3
Job types
Perc
enta
ge
Knowledge and skill level
Bad Moderate Good Very good0
10
20
30
40
50
60
0
9
54
35
1
27
41
31
Knowledge skill
Knowledge and skill level
Perc
enta
ge
Population characteristics
Less experienced ( ≤ 3 yrs)
Experienced (>3 yrs)0
10
20
30
40
50
60
7068
32
Experience level (years)
Perc
enta
ge
Working experience (years)
Gender Age
Individual Factors
Low adopters High adopters0
10
20
30
40
50
60
45
5555
45
Male Female
Perc
enta
ge
χ2 0.397p 0.481
χ2 0.53p 0.467
Low adopters High adopters0
10
20
30
40
50
60 56
4447
53
Young ( ≤26 years) Old (>26 years)
Perc
enta
ge
Individual factors
Education level Working experience
Low adopters High adopters40
42
44
46
48
50
52
54
56 54
4645
55
Less experience (≤3 years) Experienced (>3years)
Perc
enta
ge
χ2 0.908p 0.341
χ2 0.471p 0.472
Low adopters High adopters0
10
20
30
40
50
60 55
4546
54
G.C.E O/L passG.C.E. A/L pass and above
Perc
enta
ge
Organizational Factors
Resource availability Training and development programs
Low adopters High adopters44
45
46
47
48
49
50
51
52
5353
47
50 50
Not enough Enough
Perc
enta
ge
Low adopters High adopters0
10
20
30
40
50
60
70 62
3843
57
Not satisfied Moderate satisfied
Perc
enta
ge
χ2 0.052p 0.819
χ2 2.274p 0.032
Organizational factors
Performance evaluation and reward system
Existing STW and SOP
Low adopters High adopters0
10
20
30
40
50
6058
42
4852
Disagree Agree
Perc
enta
ge
χ2 0.041p 0.839
χ2 0.699p 0.403
Low adopters High adopters45
46
47
48
49
50
51
52
53 53
48
49
51
Not satisfied Moderately satisfied
Perc
enta
ge
Management support
Organizational factors
χ2 4.963p 0.026
Low adopters High adopters0
10
20
30
40
50
60
7067
3339
61
Moderate Good
Perc
enta
ge
Organizational factors
People who are engaged in development
People who should develop
Development of STW
Supervisors 99%
Team members 1%
Team members 76%
Supervisors 23%
Conclusions
None of the individual factors viz. age, gender, education level, and work experience affect the adoption of standardized work
Out of the organizational factors, only management support, and training and development programs affect the adoption of standardized work
• Grievances of team members
• Criticized areas by the TMs,– Developing STWs– Available training and development programs
Ex: CAD, SAP– Work place troubles
Damaged tables No proper AC, Water tap requirement – Performance evaluation and rewards system
Observations
• Further HR attention towards the TMs in CD
• The training and development programs should be aligned with the SW
• The STWs should be developed by the collaboration of team members
• If they have less knowledge, supervisors can act as mentors to help them by giving instructions
Suggestions
• Develop common STWs for different fabrics, by including important steps
Ex: Speed of the spreading machine1.1. Mesh (……..)1.2. Cotton( .…...)1.3. Lace (……..)
• There should be a proper performance evaluation method which align with SW performances.
Suggestions………………….
• Reward system should be aligned with performances through SW
• Rewards
–Financial , According to quantity cut, bundled
–Non Financial Employee of the month/Year,
Promotions for the bundlers as well as spreaders
Suggestions………………….
• OBT programs after the placement of TM in the teams–To enhance the team cohesiveness–To identify new leaders
Suggestions………………….
Survey……….
• Aim : To identify the needs of the team members to develop business strategies
• Target population: Female team members in the LC & LI
• Data collection tool: Questionnaire survey
• Data analysis tool: SPSS
Survey……….
• Reasons for joining• Requirement of a Day Care Centre• No of years, TMs are going to stay within the
organization• Marital status and the future state• Family conditions
– Husband, Children, Houses ( ownership)
• Salary / Savings• Hobbies/ interests• Type of help for further education• Troubles (mentally/ physically) and type of help
required from the plant• Sports
Major concerned areas
Survey Results
income diffi
culties
wages
hostel fa
cilities
transp
ort fac
ilities
good w
ill
future
succe
ss
work
experie
nces
Furth
er educati
on job
like to
LC0
10
20
30
40
50
60
70
80
Reasons for joining with the plant
Reason for joining
Perc
enta
ge
0 0.1 0.7 1.5 2.5 4 6 8 150.00
5.00
10.00
15.00
20.00
25.00
30.00
Years of Staying
Years
Perc
enta
ge
Survey Results…………
Single Married Divorce Widow0
10
20
30
40
50
60
70
80 76.2
21.8
1.2 0.8
58.6
38.7
1.3 1.4
Maritial status and requirement of day care
req. day care do not want
Perc
enta
ges
Want87%
Do not want13%
Necessity of a day care
Survey Results…………
GAQ Charted Diploma0
10
20
30
40
50
60
70
80
90
100 95.3
1.6 3.1
Type of following higher education programs
Perc
enta
ge
Money leaves books Library other0
10
20
30
40
50
60
70
63.3
18
9.3 9.3
0.01
Expect from the plant for the higher education
Perc
enta
ge
Survey Results…………
Extra cl
asses
English tr
aining progra
ms
practi
cally
use w
hile w
orking
0
10
20
30
40
50
60
70 65
16 19
What do you expect from the plant to improve English?
Perc
enta
ge
yes no0
10
20
30
40
50
60
70
80
90
100
93
7
Do you want to learn English further?
Perc
enta
ge
Survey Results…………
Netball
Cricket
Elle
Basket b
all
badminton
athletics
chess
0
5
10
15
20
25
30
35
28
11.5
17.4
0.4
33.2
6.3
3.2
Other sport choices
Perc
enta
ge
For f
oods
Childre
n's acti
vities
for c
lothes
for e
ducation
for s
iblings
beauticultu
re
medicines
for p
arents
0
5
10
15
20
25
30
3534
10
7.6
18.5
12.2
1.1
3.4
12.9
Way of spending the salary
Perc
enta
ge
Suggestions
• Day Care Centre – Management can reduce
the LTO after their marriages
• More considerations for their further education
– Loan facilities– Weekend releases
“Some changes look negative on their surface but you will soon realize, that space is being
created in your life for something new to emerge……………….”.
-Eckhart Tolle-
8 Steps Problem Solving
1. Clarify the problem2. Break down3. Set targets4. Root cause analysis (5 Why and fish bone
diagram)5. Develop countermeasures6. Implement countermeasures7. Evaluation8. Standardization
Efficiency calculation
• Efficiency = SMV* Output( pieces) No of team members* 420