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K. M. Hasan Ripon
K. M. Hasan Ripon

This document provides an overview of productivity improvement techniques that can be applied in the footwear industry. It defines productivity and discusses how to measure and improve various factors of productivity, including labor, materials, machines, and capital. Japanese productivity improvement techniques like Jidoka, Heijunka, Kaizen, 5S, muda elimination, poka-yoke, SMED, just-in-time, and kanban are explained. The key is to reduce waste and continuously improve processes through small, incremental changes by workers at all levels of the organization.

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Presentation By KMHasan Ripon, Director-BSDI & Afzal Hossain,Chairman, IDEA Technology TRAINING ON APPLICATION OF PRODUCTIVITY IMPROVEMENT TECHNIQUE IN FOOTWEARINDUSTRY
KMHasan Ripon Director, BSDI & CEO, Jobsbd ILO Certified Master Trainer and Industry Assessor Fellow TAFE, Australia Fellow SIDA (Stockholm University) KAIZEN & SCORE Practitioner TrainerToday
Ground Rules
What do we mean Productivity?
Productivity & Productivity Improvement: CONCEPT  Productivity is the ratio between Output and Input  Relationship between output and one or all associated inputs  Quantitative relationship between what we produce and what we have spent to produce.  Productivity is nothing but reduction in wastage of resources like Men, Material, Machine, Time, Space, Capital etc.
Productivity: Definition Productivity means that more is produced with the same expenditure of resource i.e. at the same cost in terms of land, materials, machine, time or labour etc.
Improving productivity means increasing or raising productivity with the help of using same amount of materials, machine time, land, labour or technology.
Part s of Shoe
LEATHERDEFECTS
Productivity improvement slide share
Key steps toward improving productivity by WilliamJ. Stevenson  Develop productivity measures for all operations.  Look at the system as a whole in deciding which operations are most critical  Develop methods for achieving productivity improvement, such as soliciting ideas from workers in all levels
Key steps toward improving productivity by WilliamJ. Stevenson (Cont.)  Establish reasonable goals for improvement  Make it clear that management supports and encourages productivity improvement. Consider incentives to reward workers for contributions.  Measure improvements and publicize them  Don't confuse productivity with efficiency
Productivity improvement slide share
Factors of Productivity Improvements  capital investments in production  capital investments in technology  capital investments in equipment  capital investments in facilities  workforce knowledge and skill resulting from training and experience  Procedures  Systems  quality of products  quality of processes  quality of management  general levels of education  social environment  geographic factors
Productivity Improvement Keys  Labor Productivity can be higher or lower depending on factors like availability of work load, material, working tools, availability of power, work efficiency, level of motivation, level of training, level of working condition (comfortable or poor) etc. Can be increased by increasing efficiency of labourand
Productivity Improvement Keys  Material productivity plays important role in cost of production. Material productivity depends upon how material is effectively utilized in its conversion into finished product. Material productivity depends upon percentage of rejection, creation of scrap, level of spoilage, obsolescence, work wastage etc. Material productivity can be increased by using skilled workers, adequate machine tools, good design of product etc.
Productivity Improvement Keys  Machine Productivity: Production system converts raw material into finished product through mechanical or chemical process with the help of machines and equipment's. Machine productivity depends upon availability of raw material, power, skill of workers, machine layout etc.
Productivity Improvement Keys  Capital productivity: For any production set- up, facilities of machines, tools, land etc. are required which are assets of organization. Capital is needed for such assets. As huge capital is locked in assets, their effective utilization is absolutely necessary. Capital productivity depends on how effectively assets are utilized.
Japanese Productivity Improvement Techniques:  JIDOKA is a Toyota concept. The JIDOKA way of working consists of following three principles- Do not make defects, Do not pass on defects, Do
Japanese Productivity Improvement Techniques:  HEIJUNKA focuses on achieving consistent levels of production. Heijunka has the capability of reducing lead times by minimizing time losses due to frequent
Japanese Productivity Improvement Techniques:  KAIZEN Techniques (Continuous improvement) is a management supported employee driven process where, employees make a great number of continuous improvement
KAIZEN Techniques FIVE SS: A structured approach to achieve clean and orderly workplace by fixing place foreverything. Five Ss is an abbreviation forthe Japanese words which means  SEIRI- getting rid of unnecessary items  SEITON- Arranging items (materials, tools, gauges) systematically foreasy retrieve.  SEISO- Keeping workplace scrupulously clean.  SEIKETSU - Scheduling regularcleaning and clearing out operations. SHITSUKE - Making all the above taskmeet agreed standards at agreed intervals.
KAIZEN Techniques  MUDA ELIMINATION: Muda means „Waste‟. Here muda elimination implies an „on going‟ and systematic reduction or elimination of waste.  There are seven kinds of major waste: Overproduction Muda, Stock Muda, Transport Muda, Defects Muda, Delay Muda, Motion Muda, Over processing Muda.
KAIZEN Techniques  Poka-Yoke: It is powerful and comprehensive method of „error proofing‟. A work process to eliminate inadvertent errors to ensure quality products and services.  It helps in defect prevention and defect detection
KAIZEN Techniques  SMED: Single Minute Exchange of Die (SMED) is a technique of performing a set up operation in lesser amount of time .It affects a machinery setup for change over from job to another in less than 10 minutes expressed as a single digit.  It helps in reduced Work-in-progress, better average daily production, increased capacity and faster delivery to customers.
KAIZEN Techniques  Just-In-Time: JIT is a management philosophy aimed at eliminating waste from every aspect of manufacturing and its related activities.  The term JIT refers to producing only what is needed, when it is needed and in
KAIZEN Techniques  Kanban is a manual production scheduling technique controlled by a process or machine operator. Kanban means card in Japanese, ia attached to given number of parts or products in the production line instructing the delivery of given quantity.

More Related Content

Productivity improvement slide share

  • 1. Presentation By KMHasan Ripon, Director-BSDI & Afzal Hossain,Chairman, IDEA Technology TRAINING ON APPLICATION OF PRODUCTIVITY IMPROVEMENT TECHNIQUE IN FOOTWEARINDUSTRY
  • 2. KMHasan Ripon Director, BSDI & CEO, Jobsbd ILO Certified Master Trainer and Industry Assessor Fellow TAFE, Australia Fellow SIDA (Stockholm University) KAIZEN & SCORE Practitioner TrainerToday
  • 4. What do we mean Productivity?
  • 5. Productivity & Productivity Improvement: CONCEPT  Productivity is the ratio between Output and Input  Relationship between output and one or all associated inputs  Quantitative relationship between what we produce and what we have spent to produce.  Productivity is nothing but reduction in wastage of resources like Men, Material, Machine, Time, Space, Capital etc.
  • 6. Productivity: Definition Productivity means that more is produced with the same expenditure of resource i.e. at the same cost in terms of land, materials, machine, time or labour etc.
  • 7. Improving productivity means increasing or raising productivity with the help of using same amount of materials, machine time, land, labour or technology.
  • 11. Key steps toward improving productivity by WilliamJ. Stevenson  Develop productivity measures for all operations.  Look at the system as a whole in deciding which operations are most critical  Develop methods for achieving productivity improvement, such as soliciting ideas from workers in all levels
  • 12. Key steps toward improving productivity by WilliamJ. Stevenson (Cont.)  Establish reasonable goals for improvement  Make it clear that management supports and encourages productivity improvement. Consider incentives to reward workers for contributions.  Measure improvements and publicize them  Don't confuse productivity with efficiency
  • 14. Factors of Productivity Improvements  capital investments in production  capital investments in technology  capital investments in equipment  capital investments in facilities  workforce knowledge and skill resulting from training and experience  Procedures  Systems  quality of products  quality of processes  quality of management  general levels of education  social environment  geographic factors
  • 15. Productivity Improvement Keys  Labor Productivity can be higher or lower depending on factors like availability of work load, material, working tools, availability of power, work efficiency, level of motivation, level of training, level of working condition (comfortable or poor) etc. Can be increased by increasing efficiency of labourand
  • 16. Productivity Improvement Keys  Material productivity plays important role in cost of production. Material productivity depends upon how material is effectively utilized in its conversion into finished product. Material productivity depends upon percentage of rejection, creation of scrap, level of spoilage, obsolescence, work wastage etc. Material productivity can be increased by using skilled workers, adequate machine tools, good design of product etc.
  • 17. Productivity Improvement Keys  Machine Productivity: Production system converts raw material into finished product through mechanical or chemical process with the help of machines and equipment's. Machine productivity depends upon availability of raw material, power, skill of workers, machine layout etc.
  • 18. Productivity Improvement Keys  Capital productivity: For any production set- up, facilities of machines, tools, land etc. are required which are assets of organization. Capital is needed for such assets. As huge capital is locked in assets, their effective utilization is absolutely necessary. Capital productivity depends on how effectively assets are utilized.
  • 19. Japanese Productivity Improvement Techniques:  JIDOKA is a Toyota concept. The JIDOKA way of working consists of following three principles- Do not make defects, Do not pass on defects, Do
  • 20. Japanese Productivity Improvement Techniques:  HEIJUNKA focuses on achieving consistent levels of production. Heijunka has the capability of reducing lead times by minimizing time losses due to frequent
  • 21. Japanese Productivity Improvement Techniques:  KAIZEN Techniques (Continuous improvement) is a management supported employee driven process where, employees make a great number of continuous improvement
  • 22. KAIZEN Techniques FIVE SS: A structured approach to achieve clean and orderly workplace by fixing place foreverything. Five Ss is an abbreviation forthe Japanese words which means  SEIRI- getting rid of unnecessary items  SEITON- Arranging items (materials, tools, gauges) systematically foreasy retrieve.  SEISO- Keeping workplace scrupulously clean.  SEIKETSU - Scheduling regularcleaning and clearing out operations. SHITSUKE - Making all the above taskmeet agreed standards at agreed intervals.
  • 23. KAIZEN Techniques  MUDA ELIMINATION: Muda means „Waste‟. Here muda elimination implies an „on going‟ and systematic reduction or elimination of waste.  There are seven kinds of major waste: Overproduction Muda, Stock Muda, Transport Muda, Defects Muda, Delay Muda, Motion Muda, Over processing Muda.
  • 24. KAIZEN Techniques  Poka-Yoke: It is powerful and comprehensive method of „error proofing‟. A work process to eliminate inadvertent errors to ensure quality products and services.  It helps in defect prevention and defect detection
  • 25. KAIZEN Techniques  SMED: Single Minute Exchange of Die (SMED) is a technique of performing a set up operation in lesser amount of time .It affects a machinery setup for change over from job to another in less than 10 minutes expressed as a single digit.  It helps in reduced Work-in-progress, better average daily production, increased capacity and faster delivery to customers.
  • 26. KAIZEN Techniques  Just-In-Time: JIT is a management philosophy aimed at eliminating waste from every aspect of manufacturing and its related activities.  The term JIT refers to producing only what is needed, when it is needed and in
  • 27. KAIZEN Techniques  Kanban is a manual production scheduling technique controlled by a process or machine operator. Kanban means card in Japanese, ia attached to given number of parts or products in the production line instructing the delivery of given quantity.