Tuesday, May 21, 2013

What is Manufacturing First Past Yield (FPY)?


Manufacturing First Past Yield (FPY) – The measure of product that is acceptably completed on the first attempt without requiring remedial action or rework.
To calculate the total manufacturing process FPY, have to multiply all sub section FPY between all sections.
Cutting FPY X Embellishment FPY X Sewing FPY X Washing FPY X Finishing FPY

First Past Yield = Output – Rework – Hold X 100
                                                    Output + Scrap
Note:

* Rework: Any pies which is reworked and returned to the process

* Holds: Input of one process which cant be passed on to the next process ( i.e. Remains as WIP for more than one day) due to lack of trims, awaiting of approvals, or similar problems should be treated as a “Hold” when it passes on to the next process

* Scrap: Any pies which is rejected and not returned to the process.

* Stock lots: If a stock lot is produced to order it should be captured as a part of output, if not it should be treated as Scrap.

hat is First Rejection Rate (FRR) ?


Quality level has calculated in terms of first rejections (FRR) and First Past Yield (FPY) calculation method has given to calculate the future quality levels as recommended.


First Rejection Rate (FRR) - The defects founded at the first time inspections.

Calculation method:
                        FRR = No of defects found X 100
                                     No of pcs checked

What is Financial Productivity?


Financial Productivity The turnover achieved per employee expressed in US$

Calculation method:
                                    Turnover
                                 Total Headcount

Note:

* Express in US$

what is Man to Machine Ratio?

Man to Machine Ratio – The number of Employees per running machine

Calculation method:

                                Total Headcount              
                         Total no of machines used

Note:

* Total no of machines used: The average of the daily no of standard hours (SAH) generating machine operators (MO’s) present during the month

* Total Headcount: Closing Headcount for the month inclusive of casuals

What is Direct to Indirect Ratio?

Direct to Indirect Ratio – The number of Employees per Machine operator

Calculation method:

             Total Headcount - No of Machine operators
                             Total No of operators

Note:

* Total headcount should include the all management staff and workers

* No of operators should calculate including the Training machine operators (TMO) who are working in the sewing floor.

What is Receive to Ship Percentage?

Receive to Ship Percentage – The quantity of fabric shipped (in sq.yds) expressed as a percentage of fabric received (in sq.yds) for the reporting period.

Calculation method:

                            Total Shipped quantity (sq.yds) X 100     
                         Total fabric received for the orders (sq.yds)

Note:

* Express as a percentage
* Ship quantity in yards have to calculate, pcs shipped multiply by consumption
* Received fabrics have to obtain in square yards.

What is Receive to Ship Percentage?

Receive to Ship Percentage – The quantity of fabric shipped (in sq.yds) expressed as a percentage of fabric received (in sq.yds) for the reporting period.

Calculation method:

                                   Total Shipped quantity (sq.yds) X 100       
                                Total fabric received for the orders (sq.yds)


Note:
* Express as a percentage
* Ship quantity in yards have to calculate, pcs shipped multiply by consumption
* Received fabrics have to obtain in square yards.

What is Cut to Ship Percentage?

Cut to Ship Percentage -The quantity shipped (In pcs) Expressed as a percentage of qty cut (in pcs) computed in respect of each delivery / MPO. The objective of this measure is to compute the process loss arising from defects in fabric, cutting, washing, missing garments etc.

Calculation method:
               Total Shipped Quantity (in pcs) X 100
                       Total Cut Quantity (in pcs)


Note:
* Expressed as a percentage Next page
* Obtain shipped and cut quantity in respect of each delivery/MPO

what is Total manufacturing Cycle Time (TCT) ?

Total manufacturing Cycle Time (TCT) – “The time elapsed for a unit of work to move between the start and finish of a process” or “The turnaround time of the manufacturing process expressed in days”.

Calculation method: - The cycle time is measuring “Dynamically”,

Sewing Cycle Time= Beginning work in progress (WIP) + Ending WIP/2
                                                                 (Out’s)

What is Cost Per Minute (CPM)

Cost Per Minute (CPM) – is “The Overhead Cost reported at factory level expressed in US$ Cents per standard minute produced.

Calculation method:

Cost per minute= Direct Labor + Indirect OH + SG&A OH + Finance OH X 100
                                           Total earn standard minute for the same period

Note:

* Expressed in US$
* Overhead cost should exclude Airfreights & Claims
* All the operational activities should include in the overhead (Ex. Subcontracting, Pocket cleaning casual workers etc)
* SG&A OH:  Selling General and Administrative overheads

What is efficiency?

Productivity evaluated in terms of ‘Efficiency’. Bellow mentioning the formula to calculate efficiency, and giving the formula for calculate the Total Cycle Time (TCT) and Cost Per Minute (CPM) for recommended future calculations.

Efficiency of labor is- “The Standard Hours (SAH) generated from the total hours worked during the reporting period”.

Calculation Method :

Efficiency =(Standard Hours Produced (SAH) / Total worked (used) hours)×100

Note:
* Expressed as a percentage (%)
* SAH = (Output in pieces X Standard Minute Value / 60 min)
* Total working Hours = Normal Hours + Overtime Hours, of all workers

Efficiency Benchmark is 70% at the South Asian countries

Saturday, May 18, 2013

Special Concept of process development and improve productivity

The six lines of attack 
At this stage, now that the major influences at work have been very broadly examined, it is possible to formulate positive lines of action. These can be summarized under six headings which have come to be known as ‘the six lines of attack’ to improve productive efficiency, and since they were first enunciated by ICI they have proved their value on the national scale as well as on the basis of the individual firm-

1) Improve basic process by research and development (Long term –Will require capital) 
2) Provide more , and improved , physical means of producing 
3) Simplify and improve the product and reduce the verity (Intermediate-May require capital) 
4) Improve methods of operations 
5) Improve organization , planning and control (Short term- Will require little or no capital) 
6) Increase manpower effectiveness at all levels 

Improve basic processes by research and development Provide more, and improved, physical means of producing :
There is an essential difference between the first two lines of attack and the others. These two will require considerable capital expenditure and are necessarily long-term projects. 

They entail investment in highly trained technical staff and in buildings, plant and equipment, as well they demand all those facilities which go with technical and engineering research and development especially as applied to the creation of new products and the design of new plants. Work study is now making a significant contribution here; a modern trend is for all technical staff to be given appreciation in the principles and to have all trained work study specialist in development and design teams 

Simplify and improve the product and reduce the Variety 
The third line of attack may be considered an intermediate term policy which may or may not require the expenditure of capital, to improve technical efficiency or make other changes, but the significance of expenditure will depend on the particular circumstances of each case. 

In most cases, however, a grade deal of negotiation and co-operation will be required, and the planned changes will take time. There are great economic benefits to be gained from standardization and the range of products to a reasonable minimum. In all these work study techniques have their part to play, in simplifying the problem and in assess in the economics of various alternatives. 

The remaining three lines of attack described bellow represent the short-term campaign which is essentially concentrated in the operational field where work study can be widely and immediately applied. Little or no capital expenditure is required,. But again progress can be handicapped unless there is an appreciation of the potentialities of work study and the trained staff to put these potentialities to work. Either from a national or individual point of view it is important to remember that it is from the savings resulting from these lines of attack that the capital becomes available for the long-term measures mentioned above. 

Improve methods of operation 
By an analytical and intensive study of the details of operation of existing plant, many firms, great and small, have found unexpected and still growing fields for improvement. The general approach and the techniques of work study are essential to success in such an approach provided they are adequately integrated with technical consideration. 

Improve organization, planning and control 
To suggest improvements in planning and organization sounds obvious and elementary and there are few readers of this note could not claim to be able to do somebody else’s job better. The work study attitude of mind turns this critical attitude towards ones own organization. Who would claim his job could not be better planned? How many fully realize that manpower is the most valuable of all our resource and that the cost of human effort is increasing relatively faster than any other? The fundamental facts revealed by work study have been proved beyond a doubt to be a far better basis for executive judgment then inspiration or misguided experience. 

Increase manpower effectiveness at all levels 
This last line of attack should be considered in the broadest possible terms and should include everybody from the most exalted executive to the most recently joined apprentice. As Sir Ewart Smith once put it.
Whatever thinking may have been in the past, we have found the impact of work study traveling steadily away from the shop floor to the board room. We now regard it as symbolizing the analytical and progressive attitude of mind which is mainly concerned with making management manage better, rather than getting the work man to work harder. 

In each of the forgoing fields, then, work study has obvious applications:
In regard to the last three factors referred to, work study can play a major role. For some years now It has been widely recognized that work study applied to an existing plant and to proposals for Its modernization or extension can reduce the amount of capital required, or perhaps even postpone the necessity for such expenditure, and because shout- term movement are always desirable , and are normally within the scope of all sizes and types of organization, work study has come in to favor particularly as an attractive and useful means of improving productivity during and between changes of more far reaching nature.

Factors affecting productivity

Nature and quality of raw materials: 
In the world we have heard too much in the past about our disadvantages in the relative lack of many raw materials and far too little of the compensations we enjoy by the ‘short hauls’ which permit economical and costal transport services or get our materials where we need them. 
Both factors demand better method to eliminate the woeful waste which is evident in the use of our natural resources and to provide for their efficient handling. 

Basic nature of process employed 
In respect of scientific research to improve the process and procedures we use this countries has almost unequalled resources in the manpower of its chemists, engineers, physicists, accountant etc. here the drive for better methods in using what is possibly the most unable of any nations resource demands that our technologist should be used o the best advantages in constantly improving our processes. Too often in the researches and the development fields we find technologist would be used to the best advantage in constantly improving our processes. Too often in the research and development fields we find the technologist and we are dangerously short of them- doing all sorts of pedestrian work which could be done by less qualified people or by machines. 

Amount of plant and equipment employed 
It should be remembered that the physical effort a man him self can give is only about ½HP whereas the average power used in industry per man today is very much greater. Broadly speaking, therefore, it is highly uneconomical from productivity point of view for a man to do any physical work at all which could reasonably be done by mechanical equipment. Far too much of the countries plant equipment and buildings is obsolete and ill designed. This is due to a failure to plough back enough capital for modern equipment for future profit. Many whole industries stand indicated on this. It must also be remembered that even when there are plenty of funds to invest in new plant and equipment, it is still necessary to ensure that capital resource are used to the best advantage for productive efficiency. 

Efficiency of the plant and equipment employed 
This factor partly depends on an adequate supply of technologists; but equally it demands eagerness and action at all levels in a firm to obtain the best from existing resources. To make this eagerness effective, information on production, performance and cost must be available to all concerned. 

Volume, continuity and uniformity of production 
Standardization of products, resulting in longer and more economical runs, depend upon finding out the best and most simple product to fill the markets needs and the best method of making it. Some ‘customer education’ may be necessary, but this should not be difficult if the product offered is cheap and satisfied. 

Utilization of manpower 
Manpower – brain as well as brawn – is the fundamental resource. Our countries are not any disadvantage in quality at any level and, hence, there is real need to see that both general planning and detailed methods of work are not wasteful of effort and productive of avoidable fatigue and frustration.

Productivity


Productivity is a important terms of industrial engineering. It is the heart term of any productive industry. Productivity is the term that has number of different meanings although it is most commonly associated with labor effectiveness in industry. In a broad sense productivity is the ratio of output to some or all of the resources used to produce the output. Productivity = Output / Input. Labor productivity may be defined as “Output per unit of time” or “Output per labor hour” of a production oriented industry. 

We are concerned with all factors effecting productivity, great emphasis will be placed on the effectiveness of labor, the efficient operation of machine, equipment, and facilities and the economical use of materials. All those factors relate to the cost of the product. 

Productivity in its vast concept is the quantitative relationship among what we produce and the resources which we use. There is clear and distinct difference between production and productivity. Actual number of production is truly possible to increase but yet productivity will decrease. In seeking higher  efficiency, productive therefore, we are concerned, not simply with increasing output, but with increasing output from the same or smaller use of resource of all kinds. 

Productivity is an overall conception which is difficult to express or to measure. It is, however, possible to consider productivity in terms of various basic resources used in industry. Thus it is sometimes expressed in terms of the output from labor, or from services, or from the capital invested. Whilst these partial expressions do not necessarily give an accurate picture of the overall position, they may be very useful in that they show trends and broad movements. 

In the long term it is only through advance in productivity that employees can hope to obtain an increase in real wages, shareholders an increase in the purchasing power of their dividends, and customers lower real prices. It is equally true that the future economic strength of the nation in a competitive world depends on management’s success in achieving this aim, wherever the provision of goods or services is involved. With the increase in scientific knowledge and the development of better management techniques this advance should not only be continuous, but should take place at an ever- increasing pace. Here it is as well to remind ourselves of a well-known definition of management: the organization and control of human activity directed to specific ends. 


Factors affecting productivity:

Since national problems may be considered as the sum of individual problems, the best way of improving the national level of productivity would seem to lie in improving that of the individual concern. Clearly, if one can devise way of improving the productivity of the individual concern, one has gone a long way towards solving the problem on a national level. The starting- point is to consider the factors affecting productivity.

Industrial Engineering


Objective of the site:          


Entire program is design to extract the system deficiencies lies with “S-Suhi Industrial Park Ltd.” in terms of productivity and technological concepts.

  1. Educate technical staff and management on possible improvements that can be take place in the technical system.
  2. Introduce basic fundamental industrial engineering concepts to technical staff in order to emphasize on the impotency of following such systems in the industry.
  3. By identifying the needs for improvement and based on the findings giving the recommendations to the management.
Areas to be covered by the system analyze;
Ø  Present technical operational system
Ø  Positive and negative impacts
Ø  Present opportunity Gaps
Ø  Possibility of improvements
Ø  System sustainability

Methodology


Methodology has been defined to analyze actual present scenario of “S-Suhi Industrial Park Ltd.” and to find out opportunity Gap and emphasize on possibilities of improvement.

·         Evaluating the historical Data
·         Evaluating the current performances
·         System Gap Evaluation;
o   Systems
o   Activities
o   Procedures
·         Opportunity Gap analysis has done in terms of;
o   Capacity Gap
o   Utilization Gap
o   Methods Gap
o   Quality Gap
o   Human resource Gap
·         Training module.
o   On job practical session to provide evidence of  possible improvements
o   Educate staff on industrial engineering and productivity improvement basic principles and past and present knowledge capacity improvements

This is the basic part of my site:

I will discuss Briefly about bellow Subject:

1. Planning 
2. Supply chain management 
3. Report Oriented development
4. Productivity and Efficiency impoverishment
5. Target and result oriented output