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Productivity Benchmarking Study Evaluation Seminar (on 23-06-2011 at karachi )

Productivity Benchmarking Study Evaluation Seminar (on 23-06-2011 at karachi ). Background.

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Productivity Benchmarking Study Evaluation Seminar (on 23-06-2011 at karachi )

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  1. Productivity Benchmarking Study Evaluation Seminar (on 23-06-2011 at karachi)

  2. Background • On request of textile and apparel industry, Ministry of Textile Industry got approved necessary funds from EDF Board for conducting productivity benchmarking study of various sub-sectors of textile industry in 2006. • M/s Werner International Consultants, USA were appointed as consultants for conducting this study. • APTMA signed TORs with consultants and coordinated study for the sub-sectors like Spinning & Weaving. • Study for other sub-sectors was coordinated either by respective association or Werner had contacted the willing companies directly.

  3. Purpose of Benchmarking Study • To identify the benchmarking data which forms the optimum targets to be achieved under the present operating conditions within a product mix. • Comparison of the companies’ performance with their main competitors and with best international practices. • Provision of quantifiable measure for the parameters in terms of present and expected performance. • To conduct survey to measure the operational and labour performance of the companies. Contd………

  4. To do SWOT analysis of companies resulting in a strategic profile for them. • To use the benchmarking analysis for seeking answers of the most important questions and to identify the opportunities to improve the operational performance of each company i.e. productivity efficiency, labour force, quality, product development and use of technology. • Provision of detailed analysis regarding manufacturing capabilities and potentials to companies for improvement of their performance.

  5. Scope of Study • Benchmarking study of 10 sub-sectors was to be conducted and 08 factories were to be included in each sub-sector. • The names of mills were provided by the respective associations. • Study of six sub-sectors has been completed and study of four sub-sectors is yet to be done:- • Spinning • Weaving • Knit wear(processing and making-up) • Woven garments • Towel(weaving and processing ) • Denim • Processing • Ginning • Home textile • Hosiery • Total 48 companies/factories of six sub-sectors were benchmarked under this study.

  6. Method of Study • Werner adopted the following method to investigate the actual performance of the industry:- • On-site visit (3 days for each mill). • Management workshop. • Benchmark and Data Analysis. • After conducting the study of a sub-sector, consultants gave a presentation first to the respective association and then to MINTEX where participating factories were also invited. • Thereafter, a sector-wise report on the study was submitted by the consultants both to the respective association/mills and MINTEX.

  7. Findings of the Report • The Sector-wise report submitted by consultants contain findings on the following:- • Plant Layout, • Organizational chart, • Ratio of Direct/Indirect personnel, • Training, • Product Specifications, • Standard times, • Production control, • Production planning, • Method of work, • Line balancing, • Plant Efficiency, • Quality • Maintenance etc.

  8. Required Feed Back from the Participants • Process/Methodology adopted by Consultant. • Whether recommendations of the study have been implemented by the units and if so, to what extent? • Action taken by the association on report of the consultants. • Impact/outcome of the study in quantifiable terms, on individual units/sub-sectors. • Way forward/future road map.

  9. Thank You

  10. Benchmarking Methodology

  11. Summary of benchmarks (Towel Sector)

  12. Summary of benchmarks (Towel Sector)

  13. The benchmarks (Knitwear Sector)

  14. benchmarks (Knitwear Sector)

  15. benchmarks (Knitwear Sector)

  16. Dyeing and finishing (Knitwear Sector) Contd…………

  17. Dyeing and finishing (Knitwear Sector)

  18. Recommendations and road map

  19. Benchmarking Project: Towel Results (Processing) • Suggested Road map • Labour: • Structure Supervisory and Operative Training • Too many intermediate levels: streamline the organization chart • Dyes utilization and Consumptions: • Start using quality dyes and chemicals • Environmental care: • Install to Effluent Treatment Plant (share ETP with others) • Customers will soon ask for certifications (OEKOTEX 100, ISO14000...) • Energy, water and steam usage should be reduced • Machines • Full automatic machines should be preferred

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