Recently, i have been sharing ideas where this topic came up, Shall we start double shift operation in sewing section to maximize the capacity and utilization of our resources. The catchy argument for that is to utilize the most of our fixed investments (Machinery, Facility resources, Factory rents etc.). These looks a promising idea, however, in my opinion i think we can do so much more before we start double shifts in RMG. The reasons are as below.
1. We would be needing double amount of skilled workers, supervisors, PM, IE for double shifts. These resources are very difficult to find and also difficult to maintain because of worker migrations. Also, its very difficult to ensure all the compliance required.
2. Secondly , we may increase the capacity of RMG portion by starting two different shift, but we also have to increase the capacity for all of the supporting operations (Knitting, dyeing, printing, embroidery, washing etc.) to balance out. All of the knitting and dyeing plants are already running on 24/7 basis, so no chance of increasing that capacity by increasing shift That's a huge investment to consider.
3. Marketing team also has to fill up these added sewing capacity by taking on more orders. More order means more complexity to handle in whole supply chain. so its highly unlikely the same manpower can manage the marketing, procurement, imports and export for the added work throughout the whole SCM. Companies need to hire more merchants, Purchase people, IE, import export c&f etc. to support the increased capacity.
4. Most of the factory at Bangladesh are running at 25%- 45% efficiency level at GSD Benchmark. we are already losing around 60-70% of paid minutes. Doubling the shift wont do anything about it, it will probably double the loss minutes also or maybe more due to increased complexity. Plus its also difficult to train double amount of supervisor and workers also for the IE team.
5. So whats the solution? To me, productivity depends on three key criteria.
Speed, Performance and utilization.
To help with speed we will be needing better design and cost engineering, better machinery with added folder and guides.
To increase performance, workers has to be trained in best way (which is difficult in 2 shifts), they should be get motivated (also challenging for 2 shifts), and better planningwith these complex SCM (difficult in 2 shifts for added complexity).
To get better utilization, We need to optimize the scheduling (Match products/orders to lines, reduce style change)
Better Pre-Production Control( Ensure samples, approvals, patterns etc. are ready to start as optimized schedule)
Materials & Trims Supply (Ensure materials & trims etc. ready to start as optimized schedule)
Process Management (Ensure process capacity, special machines WIP in place to feed line)
Reduce firefighting (Plans and promises must be realistic and achievable to last minute rushes to keep production and delivery on time.)
Line balancing (Optimize individual worker/operation balance hour to hour. )
Quality Issues (minimizes losses to poor quality and rework)
Machine Breakdown (minimizes losses to machine breakdown)
If we can achieve these, we should be able to increase around 15-20% efficiency without any additional labor cost, secondary capacity increment cost, increased management staff cost, any bank interest, only with their existing resources.
Ayan Barua is currently working with Coats Digital as Business Development Manager for Bangladesh . He has worked in Four H Group, Fakir Fashion and Epyllion Group in IE and Supply Chain Department. He is an Industrial Engineer Graduate From Shahjalal University Of Science and Technology.
Linkedin: https://www.linkedin.com/in/ayan-barua
Facebook: https://www.facebook.com/ayan.crusherix
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