Bangladesh boosts garment productivity with SewEasy System for industrial engineering
Thursday, 30 January 2014 00:00
Using only the information derived from SewEasy Industrial Engineering (IE) software The Finery Ltd. and Rhymer Apparel Ltd. increased resource utilisation leading to earning better profits on garment exports.
The sewing teams who were Bangladesh garment industry workers have responded by fully cooperating and participating with the management in efficiency and improvement in effort since August 2013.
Most of the workers and management staff count decades of service with this same group of companies who specialise in sewing shirts, blouses and jackets for export to the UK and other countries.
Based on SewEasy work load estimation at each sewing machine, the accuracy improved, which led to higher daily output by most machine operators, approximately by about 10%. Improved workflow within the sewing lines contributed to further 10% improvement gradually within the past few months; to the delight of owners who have assured workers of sharing the gains.
Production management teams easily grasped the SewEasy system operation and both the companies were able to ship more garments to USA and European buyers with same resources.
Visiting the factories in November 2013, advanced training was provided to the IE Team for further improvements towards accurately estimating SMVs as well as better balancing of lines.
Managing Director Mamanul Huq would be happy to explain more, to any prospective factory should they choose to contact him about SewEasy system.
ISO certified Finery and Rhymer Apparel Ltd. supply to many US and European buyers including Charter House and Vivarte Group, France. They installed the SewEasy IE System for SMV estimation in August 2013 in the Mirpur area of Dhaka, Bangladesh. A garment sewing and exporting business started by two bankers, Finery and Rhymer Apparel Ltd. made their first exports shipment to UK in 1988 with one sewing line.
Finery and Rhymer Apparel Ltd. are fully compliant factories employing over 1,200 people. New multi-story buildings are being built on the same premises to cater to increased buyer requirements in 2014.
The Finery and Rhymer Apparel Ltd. are thankful to Brandix i3 Process Excellence consultants in Dhaka for recommending SewEasy for innovation orientation.
Keerthi Abe of SewEasy Ltd., Sri Lanka provided on-site training to the company staff, as per requirements agreed by Mamunul Huq, the Managing Director of Finery and Rhymer Apparel Ltd.
Keerthi preferred to train existing production team rather than recruiting new IE experts from Bangladesh or Sri Lanka much to the surprise of the company. A web-based project management system was introduced along with SewEasy by Keerthi to the factories which increased focus and visibility of the efficiency improvement effort.
SewEasy SMV estimation system is featuring in the working papers of 2013 global production networks summit; which is published by Manchester University UK. The said global summit, known as ‘Capturing The Gains’ was an effort for economic and social upgrading in global production networks. Details are at http://www.capturingthegains.org/publications/workingpapers/wp_201314.htm. Fashion, buying practices, living wage, labour costing, efficiency, standard minute values, and freedom of association are themed in this publication.
SewEasy SMV estimation system has been recently adopted by global apparel brand owners such as Wal-Mart for “Sustainable Labour Costing.” SewEasy Ltd. is serving large and medium garment producers especially in Asia, enabling the manufacturers to benefit from simplified productivity improvement and cost reduction techniques. SewEasy has specialised in blending the IE with Six-Sigma, Lean and Ergonomic concepts for setting sustainable competitive direction for enterprises across Asia, Africa, Europe and Oceania over the decades.
Quick training of existing IE teams and rapid rollout are hallmarks of the SewEasy strategy. Users of the SewEasy SMV estimation system benefit from the apparel industry best practices to gain visibility and establish KPIs, which are based on globally accepted benchmarks, thereby increasing profits while promoting industrial harmony. As SewEasy automates the industrial engineering (work study) functions, the labour content and costs are immediately available for marketing and professional line planning.
By automating IE work using SewEasy, the management teams can apply more time and effort towards optimising in-house “workflow”, the balancing of lines, comforting workplace arraignments (ergonomics), and thereby improving efficiency day by day.
The SewEasy SMV estimation system, established on PMTS technology serves factories since 1996, and is based on MTM.