Training on…..
Effective tool to boost productivity
in apparel Industry
Trainer:
Mohammad Kamruzzaman
Head of Industrial Engineering & Planning
Temakaw Fashion Ltd.
Abruan Group
Skill matrix is a table that shows skills of individuals
in a team and any gaps between the skills of
employees and the job roles they have. It is also
known as a competency framework.
Operator's Skill Matrix is the database which maintains
the record of each operator, who can do what type of
operation and at what rating.
It is very important to keep this database updated as over
the time, operator acquire skills for most of the new
operations as well as improve performance in existing
operations.
It is an integral part of our Visual Management
System (VMS).
It is a simple visual tool to aid in the management,
control & monitoring of skill
levels
It displays all tasks & skills required to work in an
area or team.
It displays all current team members. For each team
member it displays current competency/ability levels
for each task
It is a simple tool to aid resource planning.
It keeps record of all operators with their
efficiency of different operations carried out by
taking the number of trials.
With the use of skill matrix an engineer's or
line supervisors needs very list time to find out
and select most efficient operator for a
particular operation from the pull of operation.
It helps the line supervisor for balancing the
line with particular skilled operators according
to the work content.
Material and method
Preparation of operator Skill Inventory (Skill Matrix):
A standard work minute library is developed by measuring the amount of time
taken by a good worker to do various tasks, measured by the stopwatch as
given in the following Table 1.
Once the skill matrix has been developed, for the setting of production line
with respect to new style the pattern maker decides the production type,
production steps in the sequence and the amount of work for each production
step. Then he uses the standard work minute library to determine the number
of standard work minute needed for each tasks.
What is Line Balancing?
Line Balancing is the distribution of work on
the line in such a way that everyone gets the
same output of work in terms of time.
Objectives of line Balancing.
To minimize the no. of workstation on line.
To minimize the cycle times.
To maximize the workload smoothness.
To minimize the frequency of tools change.
To maximize the efficiency & effectiveness.
Allocation of Operator's (Line Balancing):
Appropriate allocation of the skill operators for particular operations is the
keystone for any line balancing in the garment industry. Allocation also depends
on type of balance required. One approach of allocation is to find the closest
match between operators required and operators available. This type of
allocation results in intrinsic balance of line. Another approach is the effective
utilization of operator's skill so far he can do the best, this approach results in
dynamic balance of line.
From the Tables 2 and 3 for a setting the operators are selected as B-A-D
because the operational efficiencies of these operators are as per the required
for the particular jobs which will have the effective use of all operators' skills.
Results and discussion
In this study the authors have produced a garment of 'Jegging without Pocket'
and for this production they took the production of line number 14 before
implementation of skill matrix, and then they selected the required operators
with the use of skill matrix with respect to the operation which is as shown in the
Table 4.
In this study the authors have conducted for the production of number of
pieces for the selected line number 14 before and after the implementation of
the skill matrix. According to the prepared skill matrix the operators are
selected with respect to their skill reports stored from the database. The Table 5
shows the results of before and after the implementation of the skill matrix.
The Figures 1 and 2 reveal that, the
number of pieces produced per day
after the implementation of the skill
matrix is found to have increased by
30% to 40%, which is due to the
effective utilization of manpower at the
proper place. For one day it is found to
be only 8% since on the same day a
particular operative was absent and so
far the percentage increase was less on
the same day.
By the statistical analysis it is confirmed
that, the 'P' value for both the production
levels of before and after implementation
of the skill matrix is 4.12E-05 which is
less than 0.05, reflecting that there is a
significant difference in both the
production levels. Therefore it can be
concluded that with the use of skill
matrix the production level of the
garment industry can be effectively
improved.
1. The record keeping of all operations with respect to the particular operator
has been found to be possible which in turn is useful for further line execution,
which leads to improving the efficiency level in each operation.
2. The statistical analysis proves that the use of skill inventory (skill matrix) is
very much essential for the garment industries for enhancing the productivity.
3. For the engineers or line supervisors require less time to find and select most
efficient operators for a particular operation from the pull of operators.
4. For line balancing, operators can be selected according to work content. For
example – where an operation is required 50% less time than pitch time,
engineers can select an operator whose efficiency level is 50% on that operation.
5. When operation clubbing is required (for less work content works), skill
inventory gives the information on what type of operation is to be given to an
operator.
6. When someone is absent, supervisor can easily find a suitable person from
the skill inventory table for replacement.
7. A skill matrix can be made in spread sheet. Or real time shopfloor data
tracking system can be used for skill matrix development. In the skill matrix, a
user can do sorting of operator performance in various operations and other
way in an operation how many operator are there who had earlier worked on
and their efficiency levels.
System : How to
develop skill Matrix
Untrained
No experience of
Skill
Task
Work Instruction
Learner
Being taught the
Skill
Task
Work instruction
Practitioner
Can carry out the skill/task/work
instruction/package
Safely.
To the correct quality standards at first
time
To 1.5 times the standard cycle time i.e. is still
not up to speed.
Developer
Can improve the skill/task/work
instruction/package:
Safely.
To the correct quality standards, first
time.
Work to the standard cycle
time.
Coach
Someone who has the skill level of a
Developer, but can train & develop
others in carrying out the
skill/task/work
instruction/package:
Safely.
To the correct quality standards,
first time.
Symbol Skill Description
Can not perform the task
Familiar with eliments of the
job
Can perform
Can perform efficiently
Can perform as a Master
Date: Line
20th August,11 Skill Matrix Sample- DDL No: 2
Operation Name
Card No/Name
SIDE SEAM USING FOLDER
SNLS / DNLS
SNLS / DNLS
Operator Score
BOTOM HEM (SHIRT)
COLLAR BAND JOIN
BOTOM HEM (PANT)
WAIST BAND JOINT
SNLS
MTCS
SNLS
OL 5
OL 5
FOA
COLLAR JOINT
SIDE SEAM
Salma
INSEAM 32
20
32
Ashraf
17
32
Sabina
16
32
Shamim 21
32
Nasima 15
20 20 20 20 20 20 20 20
Skill Score 11 10 11 10 6 15 9 14
Skill Lavel Key
Untr aine d Le ar ne r Pr actitione r De ve lope r Coach
Prepared By:
Industrial Engineering Department
Dekko Designs Ltd.
Abruan Group
Line-12
Temakaw Fashions Ltd.
Operation Bulletin of Jacket before Balancing
Breakdown of Plain Machine before arrangement
Breakdown of Plain Machine after arrangement
Breakdown of Over lock Machine before arrangement
Breakdown of Over lock Machine after arrangement
Breakdown of Flat lock Machine before arrangement
Breakdown of Flat lock Machine after arrangement
Operation Breakdown of Jacket after arrangement
Final Practical output after sharing of work
