Bangladesh Knitwear Manufacturers & Exporters Association
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  BKMEA’s Productivity Improvement Program (PIP)  
 
 
 
In the context of fierce global market competition, product prices are declining and buyers are requesting shorter lead times. To facilitate its members, Bangladesh Knitwear Manufacturers and Exporters Association (BKMEA) initiated the “Productivity Improvement Program” (PIP) in collaboration with the German Technical Cooperation (GTZ).

The aim of the program is to accomplish overall productivity improvements within the existing manufacturing system without major capital investments. The approach is to implement Lean Production systems to eliminate waste (non value added) and facilitate value added work. The PIP program is being implemented by the BKMEA’s Productivity Improvement Cell (PIC).

   
 

Activities of PIC

   
 
  • Provides Consultancy services to member factories for Productivity Improvement
  • In house training to create professionals on lean production
   
1. PIC Consultancy Services
   
2. PIC Current Projects
   
3. PIC Training Course
   

     Seminar on Productivity Improvement through Lean Manufacturing  

PIC Consultancy Services

Implementation of Lean Production

Lean implementation is divided into five phases allowing sufficient time for factory staff to adopt and master the changes undertaken during the improvement process. The phases are:
 
Phase I - Lean Assessment
In this phase, value stream mapping (VSM), process mapping and operations scanning are conducted for existing data collection and to draw a comprehensive picture of the existing status of the enterprise. All value added and non value added activities are to be identified at this stage.

Phase II – Awareness Development Training Program

Training is provided to the factory management and the production floor staff (workers, floor supervisor, production manager, general manager, etc.). The training focuses on lean culture, methods of identification of value added versus non value added activities and tools required to eliminate waste such as 5S workplace, pull system, Kanban etc.

Phase III - Setting up 1st Pilot Run

The new production concept, as per the assessment, is designed during this stage.  One production line is selected for implementing all the changes as per the new concept. The BKMEA consultants, jointly with the factory team, implements the changes and improvements within the selected line from fabric acquisition till the finished product.

Phase IV – Support Concept

At this stage, all activities related to management and engineering are established.

 Phase V - Global Changes

Once the first trial has been successfully implemented, global changes will be designed, and activities will be set with agreed time lines covering the overall changes and implementation across the factory.

  BKMEA's Productivity Engineer is Guiding Worker during Production Process   

PIC Current Projects

Lean initiatives have been undertaken in Niagara Textiles Ltd., Knit Zone Mode Pvt. Ltd., Southern Knitwear Ltd., Fatullah Apparels, Reedisha Knitex Ltd. NAZ Bangladesh Ltd. Karooni Knit Composite Ltd. Active Composite Mills Ltd. S. M. Knitting Industries Ltd. The Productivity Improvement Team is providing services to the factories on first come first serve basis. Interested member companies are requested to enlist their names at the PIC, BKMEA.

   Poster 7 types of waste: Unwraped by Mr. Abdul Hai Sarkar, President, BTMA   

PIC Training Course

 
 
 

Certificate Course on “Lean Manufacturing and Engineering”

PIC is also providing training to create professionals on lean production. The three broad areas covered in this course are:

Basics of Textile Technology

  • Fibers
  • Fabrics- knit woven
  • Dyeing
  • Finishing
  • Printing

    • Industrial & Production Engineering

  • Production & Productivity
  • Capacity Define & Planning
  • Process Selection, Plan & Analysis
  • Facility Layout
  • Scheduling
  • Inventory Management
  • Work Study
  • PMTS

    • Lean Manufacturing

  • Lean History
  • Toyota Principles
  • Waste Identification & Elimination
  • Value Stream Mapping (VSM)
  • Cellular Manufacturing
  • Lean tools (KAIZEN, KANBAN, Pull production, Quick Changeover etc).
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