Implementation of kaizen for continuous improvement of productivity in garment industry in Bangladesh Saima Akter,a Farasat Raiyan Yasmin,b Md. Ariful Ferdousc KUET— Khulna University of Engineering & Technology Khulna 9203, Bangladesh [email protected] b KUET— Khulna University of Engineering & Technology Khulna 9203, Bangladesh [email protected] c KUET— Khulna University of Engineering & Technology Khulna 9203, Bangladesh a [email protected] Abstract.Kaizen is a continuous improvement of process, often is considered to be the building block of all lean production methods. The ultimate objective of this paper is to increase efficiency and productivity in sewing floor of luggage manufacturing plant through system simplification, process standardization, reducing waste and incremental improvements by using modern techniques like Kaizen. By implementing kaizen, line efficiency has been improved up to 7% and Defect per Hundred units has also reduced. For industries, to remain competitive and retain market share in this global market, continuous improvement of manufacturing system processes has become necessary. Kaizen strives to empower the workers, increase worker satisfaction, facilitates a sense of accomplishment, thereby creating a pride of work. It not only ensures that manufacturing processes become leaner and fitter, but eliminate waste where value is added. Keywords: Kaizen, TPM, 5S, PDCA, POKA-YOKE DHU, SOP, Just-In-Time, Root cause analysis, Continuous Improvement 1 INTRODUCTION All the garments industries are labor intensive, so the best utilization of labors of the industry will assure the highest profit of company. Bangladesh is a country where labors are available at low wages. Many garments have established their company in our country to be benefited. So, improvement in product quality with incremental productivity becomes necessary. Here comes the necessity of best utilization of modern techniques like KAIZEN in garments industry. By implementing Kaizen worker safety, worker satisfaction and pride of work were created which motivate them into work. Through Kaizen strong small, incremental changes are routinely applied and sustain over a long period which results in significant improvement in efficiency, quality as well as productivity. 1.1 Kaizen Kaizen is a Japanese hybrid work. It is a compound word involving two concepts: Kai (change) and Zen (for the better). The term comes from Gemba Kaizen meaning ‘Continuous Improvement’ (CI). Continuous Improvement is one of the core strategies for excellence in production, and is considered vital in today’s competitive environment. It calls for endless effort for improvement involving everyone in the organization. Kaizen requires no or little investment. The principle behind is that, a very large of small improvements are more effective in an organizational environment than a few improvement of large value. This philosophy implies that strong small, incremental changes are routinely applied and sustain over a long period which results in significant improvement. 1.1.1 Function of KAIZEN: Two functions related to the executable work are distinguished in Japan maintenance of the existing condition relying on the operations related to complying with current standard of technology and management, improvement of the existing condition-kaizen, being the function playing the main role while the procedures and instructions are strictly implemented. 1.1.2 Application process of KAIZEN method Application process of kaizen method basically consists of: definition of the improvement area, analysis and selection of the key problem, identification of the cause of improvement, planning the remedial Centre measures, implementation of the improving project, measuring, analyzing and comparison of the results, Standardization. 1.1.3 Techniques connected with KAIZEN There are no strictly defined principles and instruments, which must be used by management and employee, in order to achieve benefits and control the processes of continuous improvement. However, several definitions and techniques are connected with kaizen. These are: TPM TPM aims at maximization of machine utilization, operator, material, energy utilization, reducing losses that that affect the work efficiencies which is extremes of productivity. 5 WHY Basic for kaizen and at the same time the simplest organizing technique simultaneously, captivated in motto “when you find a problem, ask why five times”; it ask so many times as you will find the deepest reason of problem. PDCA Process of kaizen idea application is closed in PDCA cycle, Where: plan (P) refers to establishing the aim for improvement, do (D) is connected with implementing the plan, check (C) defines determining whether the implementation has brought the planned improvement, Act (A) characterizes standardizing as the preventing recurrence of the original problem or setting goals for the new improvement. 7 INSTRUMENTS OF THE QUALITY CONTROL Pareto diagram, reasons and results diagram (so called Ishikawa diagram), histogram, scheme, punctual diagram, check card most often with x-R diagram, POKA-YOKE (ERROR PROOF) poka-yoke solutions find application in stable processes and enable to drop of frequency of defects for six sigma level, 5S The basis of kaizen are constituted by 5s concept, seiri-(selection); proper (suitable) preparation of a workplace, with the elimination of everything useless. seito-order (systemic); tidiness in a workplace, tools in the manner enabling simple and quickly utilization, seiso-clearness (cleaning); order in a workplace allowing on increase of safety . seiketsu-consolidation (standardization); reminding employees about their duties in the aspect of care of used tools and equipment and about keeping the workplace order, 1.2 OBJECTIVES To improve line efficiency. To reduce waste. To reduce DHU. To increase 5S score. To apply standard operation procedure (SOP) for all operators by eliminating non-value added activities 1.3 METHODOLOGY Total summarization of Kaizen implementation is given below: Collecting existing data including taking time calculation of existing line. Balancing line by reducing non-value added activities Identifying top 5 defects of current sewing line by root cause analysis and taking corrective action to reduce these top 5 defects. Auditing 5S of existing layout, taking corrective action. Auditing 5S after Kaizen implementation. Calculating the improvement in line efficiency and defect reduction after implementing continuous corrective action known as Kaizen through 5days of observation. 2 LITERATURE REVIEW Kaizen originated in Japan in 1950 when the management and government acknowledge that there was a problem in the current confrontational management system and a pending labor shortage . First, it was been introduced and applied by Imai in 1986 to improve efficiency, productivity and competitiveness in Toyota, a Japanese carmaker company in the wake of increasing competition and the pressure of globalization. Since then, Kaizen has become a part of the Japanese manufacturing system and has contributed enormously to the manufacturing success (Ashmore, 2001). Kaizen forms an umbrella that covers many techniques including Kanban, Total Productive maintenance, six sigma, automation, just-in-time, suggestion system and productivity improvement, etc. (Imai, 1986) in figure 1 . Fig. 1: The Kaizen Umbrella According to Imai (1986), Kaizen is a continuous improvement process involving everyone, managers and workers alike. Broadly defined, Kaizen is a strategy to include concepts, systems and tools within the bigger picture of leadership involving and people culture, all driven by the customer. Watson (1986) says that the origin of Plan-Do-Check-Act (PDCA) cycle or Deming cycle can be traced back to the eminent statistics expert Shewart in the 1920s. Shewart introduced the concept of PDCA. The Total Quality Management (TQM) guru Deming modified the Shewart cycle as: Plan, Do, Study and Act. The Deming cycle is a continuous quality improvement model consisting of a logical sequence of these four repetitive steps for Continuous Improvement (CI) and learning. The PDCA cycle is also known as Deming Cycle, the Deming wheel of CI spiral. Suzaki (1987) explains that CI is a philosophy widely practiced in manufacturing and quality circles. Teian (1992) describes that Kaizen is more than just a means of improvement because it represent the daily struggles occurring in the workplace and the manner in which these struggles are overcome. Kaizen can be applied to any area in need of improvement. Hammer et al. (1993) explain that Kaizen generates process-oriented thinking since processes must be improved before better results are obtained. Deniels (1995) explains that the way to achieve fundamental improvement on the shop floor is to enable operators to establish their own measures, to align business strategies and to use them to drive their Kaizen activities. Yeo et al.(1995) describe the viewpoints of various traditional quality management gurus on the concept of ‘zero defects’ and ‘do it better each time’ that these strategies are the important ways to improve quality continuously. Williams (2001) highlights that CI techniques are the recognized way of making significant reduction to production costs. Quality Function Deployment (QFD) is a wellknown technique for translating customer requirements for a product into functional specification. Abdolshah and Jahan (2006) describe how to use CI tools in both quantitative and qualitative tools in different life periods of an organization have been discussed. 3. KAIZEN IMPLEMENTATION Before implementing Kaizen the existing data and layout were analyzed. The time study sheet for a sewing line named line 13 and SMV are listed in the following table 3.1. Here 10% allowance is considered. ISO specifies minimum 10% allowance for the entire operator. Table 1: Time study for different workers SL no. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Name Shopna Tania nipa Rina Aklima Nahar Jorina Rajia Lima Bina Rita Majeda Josna Khaleda Maya Machine 2NDL SM SM SM SM 2NDL SM SM SM SM SM SM SM 2NDL SM Observed time (sec) 1.75 1.80 1.58 1.66 1.77 1.52 1.95 1.93 2.05 1.88 1.54 1.58 1.60 1.60 1.65 Allowance 10% 10% 10% 10% 10% 10% 10% 10% 10% 10% 10% 10% 10% 10% 10% SMV (min) 1.93 1.90 1.74 1./83 1.95 1.67 2.15 2.12 2.25 2.07 1.69 1.74 1.76 1.76 1.82 3.1 Plan-Do-Check-Act Cycle Plans were made to improve operation, the problems were identified and ideas were made to solve those problems. Some changes were implemented on small scale. By checking through Data check sheets and graphical analysis we were confirmed that plan and action will bring desired result. Then we act promptly to implement the changes though process standardization. Fig. 2: The PDCA Cycle. 3.2 Standard operation procedure (SOP) Implementation of Standard operation is necessary because of making it possible to identify and eliminate variation in operator work to sustain gains achieved from past Kaizen activities, to provide baseline for future Kaizen activities. Creating Standard Operation: 1. 2. 3. 4. Conducts cycle time analysis Check documents each standard operation Display the document Ensures that all operators are trained The objective of SOP is to prepare standard operation sheet for all operation and machine. To standardize operation procedure time study is require observing the existing method of processes. Then analyzing the processes slowly and eliminate the unnecessary movement to standardized the method of processes. A standard method of process was analyzed by the line supervisor. Then the ways or methods of processing were documented. If the operators follow those methods properly, the non-value added time will be reduced as well as the cycle time within taken time. 3.3 Cycle time balancing After implementing SOP the non-value added activity is reduced as a result the process becomes standardized. Before analyzing the existing layout the taken time of the line 13 was calculated. Taken time is the time which is precisely matches production to customer demand. Taken time = net operating time buyer demand Here, order quantity by buyer= 6000 pcs & day in hand is 20 days=20*8*60 minutes. Taken time = 20 ∗ 8 ∗ 60 6000 = 1.6 minute Total cycle time limit (TTL) = Total value added activity (VA) + Total non-value added activity Table 2: Cycle time balancing by kaizen SL no. Name Machine Taken time (min) Cycle time (before) Cycle time (after) 1 Shopna 2NDL 1.6 1.75 1.70 2 Tania SM 1.6 1.80 1.77 3 Nipa SM 1.6 1.58 1.59 4 Rina SM 1.6 1.66 1.64 5 Aklima SM 1.6 1.77 1.70 6 Nahar 2NDL 1.6 1.52 1.51 7 8 Jorina Rajia SM SM 1.6 1.6 1.95 1.93 1.94 1.85 Kaizen Implementation Reduce unnecessary movement, rearrange of material keeping. Reduce unnecessary movement Reduce unnecessary movement Reduce unnecessary movement rearrange of material keeping Reduce unnecessary movement Allocate worker Reduce unnecessary material 9 Lima SM 1.6 2.05 1.95 10 Bina SM 1.6 1.88 1.84 11 Rita SM 1.6 1.54 1.44 12 Majeda SM 1.6 1.58 .51 13 Josna SM 1.6 1.60 . 55 14 15 Khaleda Maya 2NDL SM 1.6 1.6 1.60 1.65 .60 .50 Rearrangements of necessary equipments Reduce unnecessary movement Reduce unnecessary movement of worker rearrange of material keeping rearrange of material keeping Periodic cleaning Reduce bundle quantity 3.4 Existing 5s score 5S is a process and method of creating and maintaining a safe, organized, clean and high performance workplace. In the following table the 5S score evaluation & scoring criteria are that five or more than five problems are scored as zero. Similarly four, three, two, one and zero problem are considered as one, two, three, four and five score respectively. Table 3: 5s score sheet before kaizen implementation SL no 1 2 3 4 Factor Unnecessary items Safety Material Storage cleaning Description Unnecessary items are not present in the workplace. No items are on top of machines, cabinets or equipment. Work areas are free of safety hazards. Firefighting and other emergency/ first aid equipment are unobstructed and correctly stored in a correctly color-coded area. Boxes, containers and materials are necessary and stored neatly in clearly labeled shelves of cabinet Machines and equipments are clean, windows and work surface are clean. Floors are cleaned minimum once a day Score (0-5) 3 3 Defective level need for improvement 1. Rework products are present, unnecessary fabric, thread are present. 2. Work in process products are not arranged. 1. Large items i.e. boxes , trays are arranged incorrectly 2. No specific point for emergency equipment. 1. 3 2. 1. 3 2. Defect garments are stored in a tray. Unnecessary material such as: threads, fabrics, zipper are stored. Periodic cleaning is not exercised. Unnecessary threads, fabrics and yarns are present No specific place for broom. 5 6 Equipment maintenance 5S Control All machines and equipments are painted neatly. Safety guards and signs are correctly installed. No fluid leaks and frayed electrical cords. 1. 2 weekly audits completed, results graphed, sustain those improvements Total 5s score 2 Equipments are stored far from the workplace which increases the downtime and interrupt the production. 2. dust in equipment 3. oil leakage in equipment 1.1 Only 2S (sorting and shine) are followed. 16 16/6=2.67 3.5 Corrective action plan for existing 5s score The existing 5S score of the sewing floor was 2.67. To increase the working environment as well as 5S score some corrective action was taken. These corrective actions are listed below: 1. 2. 3. 4. 5. 6. 7. Remove unnecessary items Material storage review Stretcher not to be blocked Easy access to first aid box Floor cleaning Clean machine 5S audit Table 4: 5s score sheet after kaizen implementation SL no Factor Description Score (0-5) Defective level need of improvement 1 Unnecessary items Unnecessary items are not present in the workplace. No items are on top of machines , cabinets or equipment 4 1. Rework products are present 2 Safety 4 1. No specific point for emergency equipment. 3 Material Work areas re free of safety hazards. Fire fighting and other emergency/ first aid equipments are unobstructed and correctly stored in a correctly color-coded area. Boxes, containers and 3 1. Defect garments Storage 4 5 6 materials are necessary and stored neatly in clearly labeled shelves of cabinet Cleaning Machines and equipments are clean, windows and work surface are clean. Floors are cleaned minimum once a day Equipment All machines and maintenance equipments are painted neatly. Safety guards and signs are correctly installed. No fluid leaks and frayed electrical cords. 5S Control weekly audits completed, results graphed, sustain those improvements Total 5s Score 2. are stored in a tray. Unnessary material such as: threads, fabrics, zipper are stored. Unnecessary threads, fabrics and yarns are present but less in amount. 4 1. 4 1. Equipments are stored far from the workplace 4 1. 3S are followed(sorting, shine, standardization ) 23 23/6=3.83 3.6 Reducing waste The main objective of lean is to reduce wastes. If sewing floor defective garments are regarded as wastes. So, if defects are reduced wastes are also reduced. It also improves quality and efficiency of garments. There are different types of defects in sewing floors. Some defects are given below: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. Stitch density uneven Down stitch Open stitch Wrinkle Uneven stitch Piping damage Wrong insertion of puller Binding damage Bad thread tension Webbing damage Pleat Broken stitch Zipper waviness over stitch Stitch on bending head. Loose thread 17. 18. 19. 20. Pinch Needle mark Oil spot Fabric damage Fig. 3. Faulty display board. 3.6.1Root cause analysis Fig. 4. Fish bone diagram for wrinkle problem 3.6.2 Corrective action for Defects Table 5. Top five problems in sewing section Quality issues Action taken 1.Wrinkle 2. Zipper waviness 3. Wrong puller insertion 4.Broken stitch 5.Uneven stitch 1. Parts should be joint carefully. 2. Heating of fabric from a specific distance can be effective. 1. Zipper joint with fabric should be done correctly. 2. marking on zipper should be effective 1. Advice operators to put more attention while inserting puller 2. Alter operators for reducing monotonous 1.Tension of bobbing cage and needle thread is adjusted 2. Advice to trim thread attentively 1. A little more attention can solve this problem partially 3.7 Efficiency calculation Efficiency is the comparison of what is actually produced or performed with what can be achieved. In general efficiency is the percentage of output by input. In sewing floor the equation for efficiency is given bellow: Efficency = Total output per line per day ∗ SMV Total man power per line ∗ Total operating minute per day Table 6. Day by day observed output of the line Day Output 1 350 2 355 3 365 At Day 1: Total output per line per day=350 SMV=28 Total manpower=30Total working minute per day= 10 hour =10*60 minutes By using equation, Efficency = 350 ∗ 28 30 ∗ 10 ∗ 60 = 54% At Day 5(after implementing Kaizen): Total output per line per day=360 SMV=28 Total manpower=30 4 370 5 390 Total working minute per day=10*60 minutes By using equation Efficency = 390 ∗ 28 30 ∗ 10 ∗ 60 = 61% Table 7. Efficiency after implementing kaizen Day Output Efficiency (%) 1 350 54 2 355 55 3 365 57 4 370 58 5 390 61 Fig. 5. Observed efficiency day by day. Here, this bar chart shows that the efficacy of the process increased day by day 3.8 DHU calculation Defects per hundred units (DHU) are the total no of defects found in all the inspected garments in hundred units. DHU is considered as the total n of defected point of all defect garments. DHU means that what are the defects points of per 100 defects. The equation is given bellow: DHU = Total number of defect of inspected product Number of inspected product Table 8. DHU chart of existing data Day No. of defect point 1 379 2 358 3 384 4 340 5 329 No. of inspected product DHU 350 355 365 370 390 108 101 105 92 84 Fig. 6. Observed DHU day by day Here, this bar chart shows that the defect per hundred units reduced. 4 RESULTS AND DISCUSSIONS Kaizen implies that strong small, incremental changes are routinely applied and sustain over a long period which results in significant improvement. At first, the plant layout, machine tool arrangement, production flow, labor skill, work environment of the sewing floor was taken into observation. Table 9. Results for before kaizen implementation and after kaizen implementation with comparative results SL no. 1 Objectives Before kaizen implementation 54 After kaizen implementation 61 108 84 2 Line efficiency(%) DHU 3 5S score 2.67 3.83 4 SOP Non-Value added Value added for some operations Results 7% increased 24 unit reduced 1.16 unit increased Process standardized For the quality improvement in above categories, the basic kaizen techniques PDCA, SOP, 5S scoring, root cause analysis was used by us. By applying PDCA, whole improvement process were planned sequentially, the required corrective action were taken. Those actions were checked, calculated and analyzed that it can be implemented for improvement. By applying SOP the process were standardized and cycle time were balanced by reducing non-value added activities. Thus working environment and job safety were improved. After implementing kaizen 5S scoring was increased by 1.16. The performance of output is highly dependent on working environment. Improving the working environment by making it clean and worker friendly the operators were self-motivated to the works. So, the output was increased day by day. For high quality product defect elimination is necessary. Root cause analysis was performed to identify top defects and corrective actions were taken. After implementing kaizen DHU reduced from 108 to 84. As defects were reduced waste were reduced which helps to reduce unnecessary cost. Hence, Kaizen improves the quality and reduce cost. By implementing Kaizen worker safety, job satisfaction and labor recognition were imparted to workers. It motivate them into work, facilitates a sense of accomplishment, thereby creating a pride of work, increase working skill, inspiration, confidence. If there is extra intensive for good performance, proper training, labor motivation to work will increase. Line efficiency was improved 7% after implementing Kaizen. Hence Kaizen improves productivity along with the improvement of quality and reduction of waste. 5 CONCLUSIONS The main motive of kaizen is to increase overall productivity, efficiency, quality. The result of kaizen implementation for five days was very fruitful. After implementing kaizen the efficiency improves from 54% to 61%, DHU reduces from 108 pieces to 84 pieces. 5S improves from 2.67 to 3.83. It can be easily realized that, if a 5 days implementation of Kaizen can bring 7% improvement in line efficiency then, what it will be the effect of implementing Kaizen throughout the life of an industry. But it is very unfortunate for us that most the garments industries don’t follow and implement Kaizen. They even don’t know that Kaizen needs no or little investment. Bangladeshi garments industries have the lowest labor cost but they can’t make the highest profit for not exercising lean, kaizen, 5s and other quality tools. The importance of implementing kaizen or continuous improvement in every industries are knows no bound. 5.1 Recommendations Motive plans providing incentives, training could be prepared to increase operator’s performance Operators recognition can be very effective to provide an operator job satisfaction Entertainment of operator while working can help to release from boredom Alter jobs of the operators (as their skill) in which they are interested. Pictorial SOP can be made for providing easy understanding of operator at every working line The visualization system should be monitored properly For team based working team leader can be introduced and rewarded for good work. Acknowledgement The authors are grateful to the most merciful Allah who helps to complete the project successfully with his grace and mercy. First of all, the authors would like to thank their project supervisor, Dr. Tarapada Bhowmick, Professor & Head, department of Industrial Engineering and Management, for his continual support and encouragement throughout the project period. He maintained an ideal balance among us to work with freedom to develop our own ideas and also provided valuable advice when needed. The authors are particularly grateful to VIP Industries Bangladesh Private Ltd. Mongla EPZ, Mongla, Bagerhat 9351, Bangladesh for their cordial assistance in this project study. Especially thanks to Mr. Monjur Ahamad, head of production department, Mr. Asim Poddar, Mr. Selim Reja for provided us facilities and assistance to make possible to complete the project work. The authors would like to thanks all other teachers of the Department of Industrial Engineering and Management, Khulna University of Engineering and Technology for their direct and indirect assistance at several times. References Abdolshah M and Jahan A (2006), “How to Use Continuous Improvement Tools in different Life Periods of Organization”, IEEE International Conference on Management of Innovation and Technology, Vol. 2, pp. 772-777, Singapore. M. Imai, Gemba kaizen. A commonsense, low-cost, approach to management, Kaizen Institute, Warsaw, 2008. M. Imai, Kaizen: The Key to Japan's Competitive Success, Random House Published New York, 1986. R. Kraszewski, Quality management – conceptions, methods and tools used by the world’s business leaders, Scientific society of management Published, ToruĔ, 2005. Pieczonka, A. Tabor, Quality Vademecum, Center of Training and of Quality Systems of Cracow Technical University Published, Cracow, 2003. S. Wawak, Quality management. Theory and practice, Onepress Published, Warsaw, 2004. H. Suzuki, Practical kaizen for productivity facilitators, Japan Productivity Published, Tokyo, 1993. Center J. Michalska, D. Szewieczek, The 5s methodology as a tool for improving, Journal of Achievements in Materials and Manufacturing Engineering 24/2 (2007) 211214. Jagdeep Singh and Harwinder Singh. Kaizen Philosophy: A Review of Literature Saima Akter is graduated from Khulna University of Engineering & Technology (KUET). She received her B.Sc. degree in Industrial & Production Engineering from Department of Industrial Engineering and Management(IEM) from Khulna University of Engineering & Technology (KUET) in 2015.Her current research interest is in-plant recycling in garment industries of Bangladesh. She is currently a member of IEM association. Farasat Raiyan Yasmin is graduated from Khulna University of Engineering & Technology (KUET). She received her B.Sc. degree in Industrial & Production Engineering from Department of Industrial Engineering and Management(IEM) from Khulna University of Engineering & Technology (KUET) in 2015.Her current research interest is in-plant recycling in garment industries of Bangladesh. She is currently a member of IEM association. Md. Ariful Ferdous is graduated from Khulna University of Engineering & Technology (KUET). He received his B.Sc. degree in Industrial & Production Engineering from Department of Industrial Engineering and Management(IEM) from Khulna University of Engineering & Technology (KUET) in 2015.His current research interests are inspection system software development,quality control, artificial neural network. He is currently a member of IEM association.
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