how to give ied a friendly face

8/8/2019 How to Give IED a Friendly Face

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How to Give IED a Friendly Face ?

Amit Anand, an alumna of

NIFT (GMT) and SCDL,

Pune (MBA), is currentl

!or"in# as Production

$%ecuti&e !it'

TrendSetters International,

a Gur#aonased e%*ort

'ouse+ Amon# ot'er res*onsiilities, Amit also

loo"s after trac"in# and "ee*in# records

analsin# t'e reasons for lo!er *roducti&it

ma"in# re*orts on atc' *erformance, o*erator

*erformance and factor efficienc+

I$D is one of t'e "e de*artments in an

#arment manufacturin# estalis'ment+ In m

*re&ious article (refer Stitc'-orld Au#ust issue) I'ad em*'asised on t'e &arious functions t'at

t'e I$D *erforms t'at lead to 'i#'er *roducti&it,

o*timum utilisation of resources and t'us

#ro!in# *rofits for t'e or#anisation+ .o!e&er,

t'ere are certain factors, !'ic' if ta"en care of,

!ould 'el* t'e I$D function more effecti&el in a

#arment manufacturin# setu*+ In t'e *resent

article, I intend to 'i#'li#'t some of suc' factors

!'ic', mi#'t loo" &er sim*le ut 'a&e t'e

*otential of affectin# t'e effecti&eness of t'e I$D

to a #reat e%tent+

It/s an undis*uted fact t'at an I$D mana#er needs to e tec'nolo#icall sound ut, esides t'at, 'e

also needs to e an e%cellent communicator, as 'e !ould need to communicate !it' t'e line

su*er&isors and o*erators on t'e one side and on t'e ot'er 'e !ould e re*ortin# to t'e to*most

mana#ement of t'e com*an+ In addition, 'e s'ould also 'a&e a #ood sense of 'uman *sc'olo#

and 'uman e'a&iour+

T'e #arment industr, unli"e an ot'er industr, is 'i#'l laour oriented+ No dout, mac'ines and

tec'nolo# are a must to #et 'i#'er *roducti&it ut it s'ould not e for#otten t'at after all t'e

mac'ines are to e run 'umans+ T'e #arment industr is 'i#'l de*artmentalised and in&ol&es total

team!or"+ T'erefore, t'e 'uman factor ecomes all t'e more im*ortant+ 0nli"e a soft!are firm, t'e

!or" force of a #arment manufacturin# unit elon#s to a different educational and socioeducational

ac"#round and it ma"es it more difficult for t'em to *ut t'eir t'ou#'ts and acts to#et'er and !or" as

a team+ As a result, t'e c'ances of clas'es are more+ For e%am*le, t'e clas' et!een t'e *roduction

de*artment and t'e 1ualit de*artment+ I$D is et anot'er de*artment t'at is al!as *rone to clas'es

!it' t'e *roduction team+

Amon# t'e &arious 2os t'at t'e I$D *erforms, t'e most im*ortant is one *ertainin# to 3!or"

measurement/+ T'e I$D measures t'e time ta"en in t'e *erformance of an o*eration4!or", se*aratin#

t'e effecti&e time from t'e ineffecti&e time+ T'us, !or" measurement 'el*s re&eal t'e e%istence and

nature of t'e ineffecti&e time and is also used to set a standard time for carrin# out an o*eration 4

!or"+ Tar#ets are t'en set on t'e asis of t'e standard time needed to do an o*eration+ No!, 'ere lies

t'e main *rolem+ -or" measurement s'o!s u* t'e e'a&iour of !or" *eo*le and ecause of t'is it is

a*t to meet !it' far #reater resistance t'an an ot'er functions of t'e I$D, sa t'e met'od stud+ It

Amit Anand



must e rememered t'at !or" measurement and in *articular time stud, its/ *rinci*al tec'ni1ue,

'a&e ac1uired a ad re*utation in t'e *ast ecause it !as directed to reducin# t'e ineffecti&e time

!it'in t'e control of t'e o*erati&es settin# *erformance standards for t'em+ Actuall, nood !ants

a tar#et or standard of *erformance to e set for 'im or 'er as once it is set, 'e4s'e is e%*ected to

ac'ie&e t'ose standards+ T'e resistance is more if t'e tar#ets are to e set an ot'er aut'orit or

de*artment+ No!, a**lin# t'is to our #arment industr set u*, I$D does t'e same for t'e *roduction

team+ I$D sets u* t'e tar#ets *er o*erator as !ell as *er atc'4line+ No!, in case an o*erator fails to

meet 'is tar#et, 'e is *ulled u* t'e line su*er&isor and, if a line fails to meet its *roduction tar#et for

t'e da, t'e concerned su*er&isor #ets 1uite an earful from t'e *roduction mana#er+ T'us failure to

ac'ie&e t'e tar#ets s'oots u* a c'ain reaction of re*rimands+ So, e&erod feels 'o! etter life

!ould 'a&e een 'ad t'ere een no tar#ets to ac'ie&e no *erformance le&els to meet+ $&erod

!ould 'a&e een free of an oli#ation of meetin# standards and e&erod/s life !ould 'a&e een

more 'asslefree+ So, 1uite naturall, t'e I$D ecomes an ee sore, es*eciall for t'e o*erators and

line su*er&isors, !'o unfortunatel don/t understand t'e im*ortance of !or" measurement e%ercise+

T'e al!as feel t'at t'e I$D "no!in#l sets a tar#et t'at is unrealistic for t'em+ It is t'e i##est

c'allen#e efore an I$D mana#er to !in t'eir confidence and con&ince t'em t'at I$D is not t'ere to

'arm t'eir interest ut to 'el* t'em *erform etter+

Case Study

T'e *rimar dut of I$D mana#er is to remo&e all t'e fears of t'e !or"ers and #i&e t'em a etter

understandin# of t'e entire *rocess of tar#et settin#+ So, 'e started a**roac'in# t'e o*erators

encoura#ed t'em to e%*ress t'eir douts and made t'em understand t'e *rocess !'ic' t'e I$D

used to set tar#ets for t'em (of course, in t'e sim*lest and la man/s terms)+ .e 'i#'li#'ted t'e

follo!in# *oints durin# t'e course of 'is delierations !it' t'em5

T'e *erson on !'om time stud !as *erformed !as also 'uman 2ust li"e t'em and not a mac'ine

and if 'e can *erform an o*eration in a *articular amount of time, so can t'e+ In fact o*erators 'ad

more ad&anta#e in t'e sense t'at t'e *erform t'e same o*eration in t'e se!in# line for a lon# *eriod

of time (as !e run lar#e 1uantit orders) unli"e t'e o*erator on !'om time stud !as *erformed+ T'us,

t'e 'ad t'e o**ortunit of #ettin# more and more *erfection !it' t'e o*eration, as t'eir learnin#

cur&e s!elled !it' time and 'ence t'e could 'a&e not onl met t'e tar#et ut e&en eaten t'em+

-'ile settin# tar#ets t'e I$D !ould ta"e a minimum of 67 readin#s *er o*eration, t'us de&elo*in#

a *ool of data, so t'at it could arri&e at an a&era#e fi#ure and ne#ate an c'ance of relin# on a

ma%imum or minimum &alue+ T'e !ere informed aout t'e t*e of allo!ances t'at !as #i&en to t'em and !ere con&inced t'at

all t'eir natural needs !ere ta"en care of !'ile settin# tar#ets for t'em+

A c'an#e in t'eir e'a&iour !as 1uite *al*ale soon, as more and more o*erators !ere #i&en an

insi#'t into t'e !'ole *rocess+ T'e o*erators sto**ed com*lainin# aout t'e tar#ets ein# &er 'i#' or

unrealistic+ T'e !ere no! more o*en !it' t'e I$D team and !ould s'are !it' t'em if t'e faced an

difficult in *erformin# an o*eration and #ettin# t'e tar#ets+ T'e I$D !as no! a 8foe turned friend9 for



t'em+

If an I$D mana#er t'in"s 'is !or" is o&er !it' fi%in# tar#ets for t'e *roduction de*artment, 'e is

#rossl mista"en+ :at'er, once t'e tar#ets are set, t'e I$D s'ould coordinate !it' t'eir *roduction

counter*arts and find out !'et'er t'e tar#ets !ere ein# ac'ie&ed on t'e *roduction floor+ It s'ould tr

to find out t'e o*erations !'ere t'e tar#ets 'ad remained elusi&e for t'e *roduction team+ It s'ould

also tr to loo" into t'e factors res*onsile for it+ It !ould ser&e t!o *ur*oses5

It !ould 'el* narro!in# t'e !ed#e et!een t'e *roduction and t'e I$ de*artment as t'e

*roduction team !ould also feel t'at t'e I$D is not rela%in# after #i&in# t'em tar#ets to meet ut also

'el*in# t'em to ensure t'at t'e tar#ets are met are on t'e floor+ T'is !ould remo&e t'e sus*icion from

t'eir mind t'at t'e I$D delieratel sets an unrealistic tar#et for t'em+

Generall t'e *roduction team is so us 'andlin# core *roduction related c'allen#es, it doesn/t

#et an time to in&esti#ate dee*l into t'e reasons for lo!er *roduction+ So, I$D can e%tend a 'el*in#

'and analsin# !'at it is t'at ma"es t'e tar#ets unac'ie&ale for t'e !or"ers on t'e floor+ If ano*erator is deficient, t'ere could e a numer of reasons e'ind it and t'e can e roadl

cate#orised as5

Prolem related to men5 o*erators efficienc didn/t matc' !it' t'e efficienc le&el re1uired t'e

o*eration+ For e%am*le, !'ile t'e o*eration needed to e *erformed an 3A/ #rade o*erator, it !as

ein# done a 3B/ #rade o*erator+

Prolem related to mac'ine5 eit'er t'e mac'ine !as not runnin# *ro*erl or !as #ettin# fre1uent

rea"do!ns+ It "illed t'e o*erator/s *roducti&e time+

Prolem related to material5 !as t'e cuttin# *ro*er or !as t'e line alanced and t'e o*erator !as

#ettin# t'e *ieces from t'e *recedin# o*eration in ade1uate numer;

It !ould 'el* t'e *roduction team to identif t'e ottlenec"s and #ettin# a!a !it' t'em+ For e%am*le,

if an o*erator failed to ac'ie&e 'is tar#et ecause 'e #ot fault cuttin#s from t'e cuttin# section and 'e

!as re1uired to recut t'e *ieces on t'e mac'ine ed, t'e *rolem didn/t lie !it' t'e o*erator ut !it'

t'e material made a&ailale to 'im+ So, as a solution, a 'el*er s'ould e *ro&ided to recut and 2ustif

t'e *ieces, so t'at t'e o*erator can utilise 'is mac'ine time to full+

To re&ise t'e #rade of o*erators from time to time is et anot'er 2o t'at t'e I$D must *erform+ I 'a&e

come across cases !'ere an o*erator 2oined a com*an fi&e ears ac" as a 3C/ #rade o*erator and

e&en after all t'ese ears !as still ein# considered as a 3C/ #rade o*erator, t'ou#' in t'ese fi&e ears

s'e 'ad *erfected man ne! o*erations, 'ad #ained more control on t'e 'and and mac'ine

mo&ements and !as no! ale to *erform e&en t'ose o*erations t'at !ere ein# *erformed an 3A/

#rade o*erator on t'e same se!in# floor+ But t'an"s to t'e callousness of t'e I$D, s'e !as still

#ettin# a salar t'at !as meant for a 3C/ #rade o*erator+

It o&iousl ma"es t'e o*erator un'a** and 'e4s'e feels totall de2ected+ Suc' a demoti&ated !or"

force can ne&er deli&er t'e est 1ualit or *roducti&it+ T'e I$D must re&ise t'e #rades of o*erators



from time to time+ T'us, t'ere are &arious smaller t'in#s !'ic' if ta"en care of !ould 'el* t'e I$D

function more effecti&el+ Suc' measures !ould 'el* t'e I$D estalis' cordial relations !it' t'e

*roduction team and !or"ers, t'us minimisin# t'e c'ances of clas'es and s'o!do!ns t'at 'inder t'e

o&erall #ro!t' of an or#anisation+

Industry Reactions on How can IED be made more

effective in the garment industry?

Neeraj Verma, Vice President (Marketing & Operations), Shahi Exports — 8For ac'ie&in#

ma%imum *roducti&it !it'out minimum *rocess time loss and *erfection in t'e 1ualit of t'e

*roduct, t'e follo!in# are a must < B draftin# met'od stud, o*eration analsis similar to GSD

(asseml line *roduction), *roducti&it ac'ie&ement !it' reference to 1ualit, time stud of a

*roduct, tools and attac'ment ma"in# and selectin# and !or"er/s s"ill matri%+9

Venkatesh Murth, !echnica" and #ona" Manager, $% Mohan — 8To ma"e I$D stron# and

effecti&e, I t'in" t'e !or"in# culture s'ould c'an#e in our industr+ T'ere is deart' of educated

*eo*le in t'e industr+ T'e industr s'ould 'ire *roduction s*ecialists and *ut t'em on asseml

lines and not ma"e t'em sit in t'e office+ Ada*tation of t'e latest tec'nolo# and ne! met'ods

are t'e need of t'e era+ Production Mana#ers and Su*er&isors are t'e "e *eo*le and t'e

s'ould e o*en to ne! ideas and tec'nolo# and if t'e are o*en t'en automaticall it *ercolates

do!n+9

a'id, Vice President (Operations), Orientcrat td% — 8T'ere are a numer of !as t'at t'e

industrial en#ineerin# de*artment (I$D) can e made more effecti&e in t'e #arment industr+ For

one, tools suc' as GSD i+e General Se!in# Data 'el* in analsin# e%actl 'o! an o*erator

s'ould se! to increase o&erall *roducti&it+ Additionall t'e I$D s'ould #i&e t'e !or" stud

de*artment more o!ners'i* to t'e ac'ie&ement of on standard efficienc+ =ne must understand

t'at t'ere is mar"ed difference et!een on standard efficienc and o&erall efficienc+ -'ile t'e

former is a means to measure t'e o*erator *roducti&it, t'e latter is t'e com*an>s ailit to

su**l t'e o*erator+ A**lin# ot' t'ese means to#et'er ensures 'i#'er and etter *roducti&it+

Additionall, t'e I$ de*artment needs to measure t'emsel&es on t'e results t'at t'e rin# dail,

measured a#ainst a !orld standard tar#et < not an internal enc'mar"+ Gi&in# t'e I$>s t'e

*o!er of line mana#ement, ta"es t'em a!a from 'o! t'e are usuall *ercie&ed as a 3ser&ice/

and #i&in# t'is o!ners'i* a real force of moti&ation+

But if Indian Manufacturers continue to utilise laour in t'e arc'aic !a of contractors, no len#t'

of I$ in&ol&ment !ill add &alue+9

how to give ied a friendly face

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