Productivity improvement and efficient utilization of manpower are the most suitable solutions for the sustained growth of the Bangladeshi apparel industry, considering the adverse impact of the recent wage hike. Foreseeing the need to improve the utilization of both the resources of manpower and machinery, Dhaka-based Finery and Rhymer Apparel Ltd. has implemented the SewEasy SMV calculation system for optimising the overall operations of the industrial engineering department and is today reaping the benefits.
Established by two bankers, Finery and Rhymer is a two-decade old company manufacturing shirts, blouses and kidswear for US and European buyers, including Charter House and Vivarte Group. With a 1000 strong workforce and turnover of US $ 9 million, the ISO 9001-2000 certified company manufactures 2,50,000 pieces per month.
Just 5 months into the implementation, based on SewEasy’s work load estimation of each sewing machine, led to higher daily output from 10% sewing operators and improved workflow within the sewing lines contributed to further 10% improvement in the overall output. Delighted with the improvements Mamanul Huq, Managing Director of the company shares, “These optimizations were done in our existing manufacturing unit keeping in mind our upcoming manufacturing facility.” Thanking the Brandix i3 Process Excellence consultants in Dhaka for recommending SewEasy for innovation orientation, Mamanul Huq is open to address queries of any apparel manufacturer regarding SewEasy.
[bleft] Just 5 months into the implementation, based on SewEasy’s work load estimation of each sewing machine, led to higher daily output from 10% sewing operators and improved workflow within the sewing lines contributing to further 10% improvement in the overall output. [/bleft]
Production management teams easily grasped the functioning of SewEasy and advanced training was provided to the IE Team for further improvements towards accurately estimating SMVs as well as better balancing of sewing lines. “We achieved all this by on-site training of the already employed Bangladesh personnel of the company and did not hire any foreign expat in the industrial engineering department,” avers Keerthi Abe, CEO, SewEasy, boosting his company’s 2nd successful implementation in Bangladesh after Fakir Knitwear.
Another highlight of the implementation was the introduction of the web-based project management system along with SewEasy to the company, which increased focus
and visibility of the efficiency improvement effort.
In recent developments, the SewEasy SMV estimation system has been adopted by global apparel brands such as Walmart for “Sustainable Labour Costing”. Enabling apparel manufacturers to benefit from productivity improvement and cost reduction techniques, a pre-determined motion time study system SewEasy makes available to an apparel manufacturer the variance in the sewing times from the standard which consequently affects the costing of the product, TnA calendar, production, wages and the overall manufacturing capability of the sewing department.
