How to select the best employees in garment industry?

1. OBJECTIVES:

Identify and motivate the best performance employee and team, which may enable the employees to work happily to achieve good quality and better efficiency.

2. SCOPE:

The scheme is applicable to all core-production and supporting employees to be a part of the healthy-competition.

3. PROCESS WONER:

Primary: Production Manager & IEP Manager

Secondary: HRD, CORE TEAM & MIS Audit

4. PROCESS INPUTS

Efficiency report of the line

In-line inspection, End line inspection and finishing rework due to sewing defects reports of the line,

Attendance report of the line,

Replace Panel due to sewing section’s error,

Loading and transfer ratio report of the line,

Work place safety & Housekeeping of the line – Audit report from safety / HR officer.

5. PROCESS DECRIPTION

1.       Provide best performance award in every month

a)       Best line => (Supervisor + Operator + Helper + Checker) ~ 45

b)       Best operators => Each line 2-person x 6 lines = 12 person

c)       Best Cutting operators => 2-person

d)       Best Finishing operators => 2-person,

e)       Store Fabric, Store accessories & Maintenance -  1-person, and others.

f)        Total estimated person is around ~ 70 person

2.       Initially we may arrange a start-up value items which is 50 to 100 rupees per person. (Based on the efficiency we could add slab-value on that). This also could be explained to them. (Here, we have to explain the employees, the award is more valuable than its price).

a)       Estimated cost/employees per month = 100 Rupees (~assumed)

b)       Total person planned (max) = 70 person

c)       Total forecast value per month => 70 x Rs.100 = Rs. 7,000

 5.1 Calculation to Identify the best performance line

The authenticated reports will be collected from concern department by IED.

Example:

5.1.1. Efficiency report: It is the primary information to identify the best performance line (BPL). The highest efficiency produced line will be nominated to check below parameters. The details will be considered from monthly report. The origin of reports is 1. Finished garment transferred to finishing (or) washing from dispatch recorder, 2. Attendance (employees) report from HRD and 3. SMV details from IED. All the input details will be verified by MIS-Audit to ensure the accuracy of the details / data.

 

Calculation method,

 

Efficiency = (Production X SMV) / (No of employee x 480) x 100 --------------------- (a)

 

Criteria for efficiency,

Efficiency > Other lines --------------------------------------------------------------------------- (a’)

[‘.’ over time also will be considered in the calculation]

Best operator will be considered from individual efficiency report of the month which is calculated based on daily work sheet details.

5.1.2. End line, In-line & finishing defects due to sewing error reports: These three report will be considered for secondary information. Which should be produced less than 8% (collectively)

 

Calculation method,

Defect rate = (Quantity Defect / Quantity inspected) x 100 --------------------------- (b)

 

Criteria for qualify,

Defect rate > 8% ---------------------------------------------------------------------------------- (b’)

Note: Above 8% will be changed to 5% after 6 months from the implementation of scheme. If any reject in final inspection due to sewing defects, then that the line will be withheld to qualify. 

[‘.’ The same will be followed in 1. In-line inspection, 2. End line inspection and 3. Finishing section, the average will be considered as overall defects rate]

 

5.1.3. Attendance report of the line: Employee attendance report will be considered for additional information for individual employees from the qualified line. The operators / employees who not absent less than 2 days, they will be considered to nominate. Also will be considered the reprimand of employees to nominate.

 

Calculation method,

Employee absent = (No of day absent / total working days) x 100 ------------------ (c)

 

Criteria for attendance,

Individual-Employee absented days < 2days ---------------------------------------------- (c’)

 

[‘.’ The compensated absent days will not be considered as absent, upon the authentication from HRD]

 

5.1.4. Replace Panel due to sewing section’s error: The replace panel / re-cutting report will be considered as additional information to qualification to receive the award.

 

Calculation method,

Re-cutting rate = (Total re-cut quantity due to sewing defect / total input quantity) x 100 ----------- (d)

 

Criteria for replace panel rate,

Re-cutting rate < 2 %------------------------------------------------------------------------------------------------------ (d’)

 

[‘.’ Re-cutting due to fabric and cutting error will be exempted from consideration, unless the rate is less than 2.5%]

 

5.1.5. Loading and transfer ratio report of the line: The output of the line will be considered from finished and quality garment transferred from sewing section to finishing (or) washing. If any process of sewing is not completed, then it will not be considered. Except running order, all order loading and output will be considered to qualify the line.

 

Calculation method,

Loading and output ration = (Total loading / total output) x 100 ------ (e)

 

Criteria for loading to output ratio,

Loading and output ration = 0%------------------------------------------------ (e’)

[‘.’ If there is any acceptable reason which is not due to sewing, then it will be considered for further reviewing of qualify]

 

5.1.6. Work place safety & Housekeeping of the line – Audit report from safety / HR officer: The work place housekeeping and safety audit will be contacted by HRD safety-officer. The safety of the employees and safety of the product will be considered as additional information qualify the line.

i.e. Housekeeping in and around work place, safety of work place, sharp material / tool control, needle policy, hazard preventive maintenance, so on.

 

Calculation method,

Audit score = 1-(Findings of abnormal / Total observation) x 100 ------------------------- (f)

 

Criteria for work place safety and housekeeping,

Audit score = 80%--------------------------------------------------------------------------------------- (f’)

 

[‘.’ If there is any acceptable CAP raised from the line against of finding, then it will be considered for further reviewing of qualify]

 

5.2. Limit of the scheme  

5.2.1. Calculation Period: The calculation will be done in monthly basis. The time line is 1^st date of the month to last date of the month.

5.2.2. Best performance award issuing time line: Every month 5^th will be issued the BPL award. The date will be fall next working day if any holiday or leave day.

5.2.3. Employee qualify for nomination: The operators, helper, supporting employees, and checkers only will be considered from the qualified line.

5.2.4. the rights of the scheme: The Core team and top management are authenticated to withheld the scheme at any times, if found any uncertainty or ineffective of the scheme.

5.3. Responsible 

5.3.1. Responsible for calculation and prepare report: The industrial Engineering department is primary responsible to collect the authenticate details from origin of source. The calculation will be done in monthly basis. The time line is 1^st date of the month to last date of the month. The details will be dually verified and ensured its accuracy. The report will be generated and processed for necessary approval from Production, HRD, MIS-Audit and the final approval from the Managing Director. The approved report will be send to HRD & Accounts for further process. The time line is 3-working days from last working days of the month.

5.3.2. The authentication of the scheme: The HRD & MIS is authenticated to verify the details.

5.4. validity of the scheme

5.4.1. Validity: The scheme is validity for 6-moths from the date of implemented.

5.5. Authority:

5.4.1. Authority to change, update or any required action on the scheme: The primary responsible to review, assess and provide updating points is liable to IED. The IED will be observe closely the scheme execution, effective and other relevant details. The details will be highlighted and bring to the core team review and discussion. The outcome of core team discussion will be carried to management with formal-proposal. The final authority of the scheme 1. Update, 2. Change, 3. Re-design, etc. are liable to top management and the Managing Directors.  

6. PROCESS OUTPUT

Self-motivation to achieve efficiency, quality and systems.

7. PROCESS MEASURABLE

After 3-months, the overall improvement will be measured.

8. DOCUMENTS / RECORDS

Efficiency report

Quality Report

Attendance report

Replace Panel

Loading report

Garment transfer report

Housekeeping and safety Audit report