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Capacity Building

With below solution proposals and necessary software and hardware support, we help enterprises to increase their capacity by reducing production lead time, improving bottleneck, decreasing energy consumption & production cost, increasing production efficiency, decreasing employee working time and increasing enterprise’s profit. With capacity building, the enterprises can build production & management module and environment that is harmonious,environmentally friendly, socially responsible and sustainable, so as to achieve the win-win of enterprises and clients.

 

This is real solution!

 

1. General Processes of Solution Proposals:

 

1.1 Training

Training is the first step and efficient way to build capacity, including management knowledge and system, construction of management system, LEAN production, 6 Sigma, project management, KPI management and supply chain management etc.

1.2 Assessment

Comparing with benchmark, help enterprise to dig out enterprise’s potential, and draw the improvement path through interview, on-site inspection and document review. Assessment aspects cover strategy, operation (market division, customer requirement, design and development, supply chain, production, transportation, sales, customer feedback), policy, finance and SWOT analysis etc.

1.3 Construction of Management System

The two cores of management system construction: value management and team motivation

1.4  5S, Total Production Maintenance & Total Quality Management

5S, TPM and TQM are the base of implementation of lean production and lean 6 sigma: tidy site and staff accomplishment, OEE (Overall Equipment Efficiency) and RTY (Rolled Throughput Yield)

1.5 Standard Work Time & Industry Engineering

Standard work time and industry engineering can standardize operation, scientize work time, eliminate waste and realize balance.

1.6 LEAN Production Consultancy

Improve the competitiveness through LEAN production: identifying problem, eliminating all forms of waste, improving productivity & quality, minimizing cost, adopting flexible production mode and shortening delivery time.

1.7 6 Sigma Consultancy

6 Sigma can achieve excellent customer value by eliminating the process variation( so as to greatly improve the quality of products or services) and optimizing process( so as to promote service standard).

1.8 Manufacturing Executive System

Manufacturing Executive System collects full and accurate real-time data:

To monitor material/part supply, process/line balance, quality performance, material and labor consumption;

To settle bottle-neck, improve quality and delivery performance, greatly increase efficiency

To downsize material receiver, data input clerk, material tracking clerk, to harmonize management and workers’ relationship;

To eliminate Queuing time, increase effective working time;

1.9 Supply Chain Management

Analyze material flow and information flow, suggest improvement solution, and consult the implementation and effect assessment for marketing, customer requirement and expectation, design and development, purchasing, inventory, inspection, material and parts internal flow, production, sales and customer feedback.

1.10 ERP(Enterprise Resource Planning)

ERP integrates enterprise’s human, finance, material resource and information flow, controls supply chain by its planning and value functions: production plan, material requirement, purchasing plan, sales plan, finance plan and human resource plan.

1.11 Cleaner Production

Cleaner production to achieve energy saving, material consumption decreasing, pollution minimizing and profit increasing by taking efforts from product lifetime design, material and energy consumption, technic, equipment, process control, management, employee and waste discharging and recycle.

1.12 One Stop Solution of Sustainable Development

Through training, management system construction, lean improvement and cleaner production, enterprise can improve profit, environment and social Responsibility. Additionally, enterprises can upgrade competitiveness of hard power. Additionally, enterprises can also improve soft power and image through announcing its sustainable development report.

 

2. A real capacity building case in a underwear plant 

 

 

Item

Measures

Benefits

1

Efficiency

Manufacturing Executive System+Productivity bonus

Production efficiency improved by 15% 

2

Headcount of Assistant Persons

  1. Reduce receiving and issuance persons by 60%
  2. Reduce merchandising person by 50%
  3. Reduce by piece calculation person by 100%

Totally 50 assistant person headcount reduced for a plant with 1000 employees

3

Work Time

Reduce working time by increasing production efficiency and productivity

Average monthly working hours reduced by 13%. Now it's 250-260

4

Worker’s Income

Increase worker income by increasing their efficiency and productivity

Average salary increased by 18%, to RMB 3300 per month

5

Employee & Management Relationship

Reduce the conflict and unnecessary communications between employees and management by employee autonomous management

Increase satisfaction rate by 20% and reduce turnover rate by 30%

6

Clock in/out

Reduce the waiting time for swiping in/out cards by replacing card swiping machines at gates with card swiping facility at workstations. On average 30 minutes for each employee each day is saved.

Effective working time increased by 5%