Lean · Kaizen
Sewing Process Kaizen Programme
Method improvements on hoodie, long pant and polo styles: removing marking steps and merging operations so fewer people do the same work in less time.
17manpower freed
18–57%time reduction
Tk 2.35 lakhsaving, 5 projects
Project results
| Project | MP before → after | Sec before → after | Improvement | Saving (Tk) |
|---|
| Kangaroo pocket join without mark | 8 → 4 | 54 → 38 | 29.6% | 52,000 |
| Body mark for pocket join, no middle mark | 12 → 6 | 23 → 18 | 21.7% | 78,000 |
| Hood servicing with tuck (2 ops → 1) | 8 → 4 | 30 → 22 | 26.7% | 60,000 |
| Label & loop join combined | 4 → 2 | 35 → 15 | 57.1% | 30,000 |
| Placket close & top stitch combined | 4 → 3 | 44 → 36 | 18.2% | 15,000 |
| Total | 17 freed | | | 2,35,000 |
How
- Time study before and after on running lines, video of both methods.
- Eliminated non-value marking, combined adjacent operations on one machine.
- Savings calculated over each style's run (26–30 days).
Time studyMethod studyPowerPointExcel tracker
Manpower · Costing
Helper Reduction & Piece-Rate Analysis
A contractual-operator knit-dress factory ran with a 42–45% helper share. I built the case to cut helpers through small devices and operator-side task changes, with a piece-rate offer to keep operators on side.
13lines in scope
3improvement cases
1 / linehelper removed per case
The three cases
- Shoulder join: a trimming device on the overlock removes the trimming helper on all 13 lines.
- Back tape piping: operator cuts the piping, removing one helper per line on 9 lines.
- Sleeve join: operator folds the body, removing one helper per line on 13 lines.
Deliverable
- Formula-driven workbook for MD, Chairman and Director: executive summary, inputs, one sheet per case, piece-rate sensitivity, risk and manpower view.
- Operator incentive range modelled through a piece-rate increase to manage contractor resistance.
Excel modellingSensitivity analysisLine study
Analytics · Power BI
Machine Health Analytics
A machine-health dashboard for a multi-plant group, built from AMS-R101 fleet data, so maintenance can see which machines and plants need attention first.
5plants
Fleetmachine-level data
Power BIwith DAX measures
What it does
- Cleans and models fleet data across five plants into one model.
- DAX measures for machine health and status, conditional formatting to flag problem machines.
- Custom navy theme for management reporting.
Power BIDAXData modelling
Strategy · Business case
IE Department Proposal
A proposal to build a dedicated IE team for 1,300 sewing machines across 48 lines, with cutting and finishing in scope, where no time study, line balancing or layout work was being done.
55.5% → 65%efficiency target
$1.8M+yearly value of the gap
3hiring phases
The case
- Mapped the current workload: daily SMV for 20–25 styles, input-ensure data chasing 3–4 hours a day, manual line checks.
- Valued the efficiency gap using ERP capacity and CM figures.
- Phased recruitment: one experienced IE per floor, the rest trained freshers.
- Delivered as a PowerPoint deck and a Word proposal for the MD.
Capacity analysisBusiness caseOrg planning