performance enhancement proposal for epic vietnam

8/14/2019 Performance Enhancement Proposal for EPIC Vietnam

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PerformancePerformanceEnhancementEnhancement

Proposal for EPICProposal for EPICVietnamVietnam

Raymond ChongRaymond ChongOctober 28 2008October 28 2008


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Scope and AimScope and Aim

EPIC Vietnam is one of theEPIC Vietnam is one of theimportant part in whole EPICimportant part in whole EPIC

Group familyGroup family

Customers Jones New YorkCustomers Jones New York( 60% )( 60% )

Kohls, Costo and NextKohls, Costo and Next

( 40% )( 40% )

Workers 1,500 workersWorkers 1,500 workers

Quantity 250,000 pcs per monthQuantity 250,000 pcs per month

Quality Which is EPIC GroupQuality Which is EPIC Group

tenet for providing service to ourtenet for providing service to our


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Hardware Space (1)Hardware Space (1)

Fabric in Warehouse / CuttingFabric in Warehouse / Cutting

DepartmentDepartmentFabric Fabric

Fabric Relaxation for all StretchFabric Relaxation for all Stretch

FabricFabric

Unroll fabric for cutting both rollUnroll fabric for cutting both roll

end and middle of roll forend and middle of roll for

shrinkage wash testshrinkage wash testSolution Solution

Trolleys and Trays can be optionTrolleys and Trays can be option

for getting more space to relaxfor getting more space to relaxfabricfabric


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Hardware Space (3)Hardware Space (3)

Finishing and Final Audit ( Unit 2 )Finishing and Final Audit ( Unit 2 )Measuring Garment Measuring Garment

QC has no space for measuringQC has no space for measuring

garment and flipping aroundgarment and flipping around

caused low efficiencycaused low efficiency

Cannot get the accurateCannot get the accurate

measurement if garment cannot bemeasurement if garment cannot be

laying flat on the tablelaying flat on the tableSolution Solution

Purchase more Plastic Shelf for thePurchase more Plastic Shelf for the

back log garments after pressingback log garments after pressing

Create more s ace for lettinCreate more s ace for lettin


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Hardware - LogisticHardware - Logistic Between Unit 1 and Unit 2Between Unit 1 and Unit 2Garment lost, damage ( oil stain,Garment lost, damage ( oil stain,

dirt mark ) and wastage due todirt mark ) and wastage due totransportation transportation

Garment lost due to missingGarment lost due to missingcounting in and out from Unit 1 tocounting in and out from Unit 1 toUnit 2Unit 2

Oil stain and dirt mark causedOil stain and dirt mark caused

wastagewastageMistake found in Unit 2 which theMistake found in Unit 2 which theproduction is still continuous inproduction is still continuous inUnit 1Unit 1

Fabric Warehouse should be theFabric Warehouse should be the

d iH d E i /


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Hardware Equipment /Hardware Equipment /

Facility (1)Facility (1)

Textile Pre-Shrink / SpongeTextile Pre-Shrink / Sponge

MachineMachineStretch Fabric Stretch Fabric

Comfort for the end consumerComfort for the end consumer

Popular in the marketPopular in the market

Fabric Shrinkage is unstable in theFabric Shrinkage is unstable in the

marketmarket

Solution Solution

Fabric Relaxation overnightFabric Relaxation overnight

Fabric Shrinkage / Wash TestFabric Shrinkage / Wash Test

Textile Pre-Shrink / SpongeTextile Pre-Shrink / Sponge

d iH d E i t /


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Current Sewing MachineCurrent Sewing MachineOld Chinese stated to do good jobOld Chinese stated to do good job

should have good tools first.should have good tools first.

Efficiency is low because theEfficiency is low because the

machines have to be maintenancemachines have to be maintenancealwaysalways

Some of current sewing machinesSome of current sewing machines

are too old which are not operatedare too old which are not operatedwellwell

Have to be fixed / repaired byHave to be fixed / repaired by

maintenance always caused lowmaintenance always caused low

efficiencyefficiency

H d E i /H d E i t /


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Drill Hole MachineDrill Hole MachineHelp sewing working to haveHelp sewing working to have

accuracy accuracy

By manually folding dart theBy manually folding dart the

placement is up to the sewingplacement is up to the sewingworker whateverworker whatever

By the welt pocket placement is upBy the welt pocket placement is up

to where is the back dartto where is the back dartplacement should beplacement should be

Drill hole machine should be usedDrill hole machine should be used

after cutting right away, no need toafter cutting right away, no need to

have extra work and have accuracyhave extra work and have accuracy

H d E i /H d E i t /


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Needle DetectorNeedle DetectorChild Safety ChildrenwearChild Safety Childrenwear

Needle detector is the one of mostNeedle detector is the one of most

important if we have to runimportant if we have to run

business for childrenwearbusiness for childrenwear

Next requested to have everyNext requested to have every

garment ( Test Order ) to begarment ( Test Order ) to be

passing through the needlepassing through the needledetector without any metal beforedetector without any metal before

shipmentshipment

PS : Even the childrenwear fromPS : Even the childrenwear from

Kohls is asking for passingKohls is asking for passing

H d T l fH d T l f


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Hardware Tools fromHardware Tools from

Buyer (1)Buyer (1) Construction RuleConstruction RuleJones New York has their ownJones New York has their own

construction rule for garment construction rule for garment Merchandising and CADMerchandising and CAD

department must have a set ofdepartment must have a set ofcopy which is updatedcopy which is updated

Better to print the constructionBetter to print the constructionrule to let everyone know aboutrule to let everyone know about

Translate to Vietnamese and put onTranslate to Vietnamese and put onboard of sewing lineboard of sewing line

Any updated should be choppedAny updated should be choppedthe date, highlighted and replacethe date, highlighted and replace

on board for sewing workerson board for sewing workers

H d T l fH d T l f


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Hardware Tools fromHardware Tools from

Buyer (2)Buyer (2) How to Measure ManualHow to Measure ManualCAD department, QC and FinalCAD department, QC and Final

Audit must have one set which isAudit must have one set which is

updated updated

Pattern maker must follow thePattern maker must follow the

individual manual from differentindividual manual from different

customer to create patterncustomer to create pattern

especially waist circum or hip levelespecially waist circum or hip leveletc.etc.

QC and Final Audit must followQC and Final Audit must follow

individual Manual when measuringindividual Manual when measuring

garmentgarment

H d C tH d C t


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Hardware CorrectHardware Correct

GuidanceGuidance Standard of ProcedureStandard of ProcedureQuality Right 1Quality Right 1stst Time Time

Workers are weak on properWorkers are weak on proper

mindset, and no correct conceptmindset, and no correct concept

and appropriate mentalityand appropriate mentality

Quality Control should followQuality Control should follow

correct guidance to do their jobcorrect guidance to do their job

( not number of piece )( not number of piece )Solution Solution

Leaders should implant workers forLeaders should implant workers for

correct concept as alwayscorrect concept as always

Establish a Standard of ProcedureEstablish a Standard of Procedure

H d Q liH d Q lit


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Hardware QualityHardware Quality

Management SystemManagement System TQM / ISO 9000 / 5-S Principal / 6TQM / ISO 9000 / 5-S Principal / 6

SigmaSigmaQuality Management System canQuality Management System can

help housekeeping, enhancehelp housekeeping, enhance

quality, performance and evenquality, performance and evenself-discipline and self-initiativeself-discipline and self-initiativealsoalsoThough it will be a long process toThough it will be a long process to

get the system to be certifiedget the system to be certifiedThe first thing we have to do is toThe first thing we have to do is tofine tune/ make better progress offine tune/ make better progress ofour systemour system

With Quality Management SystemWith Quality Management System


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S ft Q lit A dS ft Q lit A d


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Software Quality AwardSoftware Quality Award(1)(1)

Quality Award ProductivityQuality Award Productivity

against Qualityagainst QualityEveryone is looking at number ofEveryone is looking at number of

piece as company set-up thepiece as company set-up the

Productivity AwardProductivity AwardQuality Control can get ProductivityQuality Control can get Productivity

Award also which is not right, andAward also which is not right, and

against whose job natural at allagainst whose job natural at all1,200 pcs output with difficult for1,200 pcs output with difficult for

repairing or damage garmentrepairing or damage garment

versus 1,000 pcs without repairingversus 1,000 pcs without repairing

concept must be implantedconcept must be implanted

S ft Q lit A dS ft Q lit A d


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Software Quality AwardSoftware Quality Award(2)(2)

Quality Award ( continuous )Quality Award ( continuous )Solution Solution

Suggest to set-up Quality Award toSuggest to set-up Quality Award to

emerge the importanceemerge the importance

Award any worker who doing goodAward any worker who doing good

job without or less return forjob without or less return for

repairingrepairing

Billboard the monthly QualityBillboard the monthly QualityAward ( if possible ) to let allAward ( if possible ) to let all

workers knowworkers know

Make an announcement and memoMake an announcement and memo

to let all workers understand howto let all workers understand how

S ft P i h tS ft P i h t


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Software PunishmentSoftware PunishmentSchemeScheme

Punishment SchemePunishment SchemePunish any worker if they didPunish any worker if they did

many mistakesmany mistakesSet-upSet-up Verbal Warning SystemVerbal Warning System forfor

certain number of Minor Mistakescertain number of Minor Mistakesreturn for repairing ( E.g. morereturn for repairing ( E.g. morethan 3% )than 3% )

Set-upSet-up Written Warning SystemWritten Warning System forfor

Major Mistake occurred causedMajor Mistake occurred causeddamage garment or high wastagedamage garment or high wastage( E.g. only 1 time )( E.g. only 1 time )

By the end of the year, number ofBy the end of the year, number of

warnings will count into thewarnings will count into the


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Software Accuracy (2)Software Accuracy (2)

Information provide from HKInformation provide from HKmerchandisingmerchandisingQuality Right 1Quality Right 1stst Right is fromRight is from

accurate informationaccurate information

HK merchandising should alwaysHK merchandising should always

be specific when writing e-mailbe specific when writing e-mail

with details informationwith details information

Factory always need clear detailsFactory always need clear detailsand instruction to processand instruction to process

E-mail should be better point byE-mail should be better point by

point in Bullets and Numbering topoint in Bullets and Numbering to

rovide clear informationprovide clear information


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Software Accuracy (2)Software Accuracy (2) Fabric Shrinkage / HandlingFabric Shrinkage / HandlingFabric is the most expensive in aFabric is the most expensive in a

garmentgarment

Fabric Department should getFabric Department should get

involved for fabric inspection wheninvolved for fabric inspection whenshipment is ready from mill notshipment is ready from mill not

until problem found in factoryuntil problem found in factory

Factory should pull the roll end andFactory should pull the roll end andmiddle roll of fabric for shrinkagemiddle roll of fabric for shrinkage

wash testwash test

Unroll the fabric for relaxationUnroll the fabric for relaxation

properly without die creaseproperly without die crease


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Software Accuracy (3)Software Accuracy (3) Shrinkage build-in method ( CADShrinkage build-in method ( CAD

department )department )How build-in shrinkage withoutHow build-in shrinkage without

distort the fit is an acknowledgedistort the fit is an acknowledge

Pattern maker used their own wayPattern maker used their own way

to build-in shrinkage on patternto build-in shrinkage on pattern

The way is not correct method andThe way is not correct method and

will be distorted the fit as whatwill be distorted the fit as whatbuyer approvedbuyer approved

Suggest to use the function in theSuggest to use the function in the

CAD system provided for build-inCAD system provided for build-in

the shrinkage based on fabric form,the shrinkage based on fabric form,


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Software Accuracy (5)Software Accuracy (5) Sewing DepartmentSewing DepartmentMarking / Sewing and NotchMarking / Sewing and Notch

matching is the next step tomatching is the next step toachieve Quality Right 1achieve Quality Right 1stst TimeTime

Any mis-cut panel should beAny mis-cut panel should bereturned to cutting department toreturned to cutting department tore-cut or re-trim, do not startre-cut or re-trim, do not startsewingsewing

Marking / Sewing must be accurateMarking / Sewing must be accurateusing the actual pattern with seamusing the actual pattern with seamallowance consistenceallowance consistence

Sewing must be followed allSewing must be followed all

notches matching provided fromnotches matching provided from


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Software Accuracy (6)Software Accuracy (6) Washing DepartmentWashing DepartmentShrinkage built-in on pattern andShrinkage built-in on pattern and

marker is based on approved washmarker is based on approved wash

standardstandard

Should conduct Pilot Run ofShould conduct Pilot Run ofwashing before bulk washing towashing before bulk washing to

see the result is stablesee the result is stable

Any measurement discrepancy isAny measurement discrepancy isfound should inform CADfound should inform CAD

department to adjust the patterndepartment to adjust the pattern

and marker for the following cutand marker for the following cut

Any dirt mark or oil stain is foundAny dirt mark or oil stain is found


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Software Accuracy (7)Software Accuracy (7) Pilot Run VS ShrinkagePilot Run VS ShrinkagePilot Run has to make sure allPilot Run has to make sure all

preparation is donepreparation is done

Used the approval PPS Pattern toUsed the approval PPS Pattern to

cut the Pilot Run for building incut the Pilot Run for building inshrinkage for bulk is riskyshrinkage for bulk is risky

Suggest to make 2Suggest to make 2ndnd round if the 1round if the 1stst

round Pilot Run is too far away onround Pilot Run is too far away onmeasurementmeasurement

If we have to make a 2If we have to make a 2ndnd round Pilotround Pilot

Run it has to be doneRun it has to be done

The orders we have going forwardThe orders we have going forward


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Software Accuracy (8)Software Accuracy (8) Measurement ( Before WashMeasurement ( Before Wash

Garment )Garment )Due to Group Marker from variousDue to Group Marker from various

shrinkageshrinkage

Within 2% for Missy and PetiteWithin 2% for Missy and Petite

stylestyle

Within 1% for Women styleWithin 1% for Women style

Even measurement is perfect, theEven measurement is perfect, thefinal measurement is still variedfinal measurement is still varied

due Group Markerdue Group Marker

CAD / Pattern Department mustCAD / Pattern Department must

rovide the shrinka e atternrovide the shrinka e attern


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Software Efficiency (1)Software Efficiency (1) CAD DepartmentCAD DepartmentPattern Makers should be trainedPattern Makers should be trained

the same vision for fittingthe same vision for fitting

requirementrequirement

Fitting is on the mannequin or liveFitting is on the mannequin or livemodel in 3 dimensions, not flatmodel in 3 dimensions, not flat

pattern in 2 dimensionspattern in 2 dimensions

Should not trace the number ofShould not trace the number ofmeasurement as provided as it canmeasurement as provided as it can

be revised from buyer as always.be revised from buyer as always.

How to control the fit after PPSHow to control the fit after PPS

sample is approved, number ofsample is approved, number of


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Software Efficiency (2)Software Efficiency (2) Communication and UpdatedCommunication and Updated

InformationInformationFace to Face touch-base is veryFace to Face touch-base is very

importantimportant

Suggest HK merchandising teamSuggest HK merchandising team

should visit factory monthly toshould visit factory monthly to

have more communicationhave more communication

Suggest daily regular phone callSuggest daily regular phone call( E.g. Skype ) should be need to( E.g. Skype ) should be need to

clear up any pending issueclear up any pending issue

Any updated should beAny updated should be

communicated each other to avoidcommunicated each other to avoid


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Software Efficiency (3)Software Efficiency (3)

Communication DifficultyCommunication DifficultyDifferent LanguageDifferent Language

Difficulty of communicationDifficulty of communication

between leader and local workersbetween leader and local workers

Message from management cannotMessage from management cannot

be reached to the bottom due tobe reached to the bottom due to

different languagedifferent language

Suggest to have 1 worker or leaderSuggest to have 1 worker or leaderin each sewing line who is familiarin each sewing line who is familiar

of English for betterof English for better

communication to avoid confusioncommunication to avoid confusion


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Software Efficiency (4)Software Efficiency (4)

Communication GapCommunication GapSome error or mistake occurredSome error or mistake occurred

due to communication problemdue to communication problem

between departmentsbetween departments

As leader who should make sureAs leader who should make sure

the communication to bethe communication to be

throughout to another departmentthroughout to another department

to get job well doneto get job well doneBy assumption or guessing is notBy assumption or guessing is not

the appropriate action as a leaderthe appropriate action as a leader

To take proactive initiative to leadTo take proactive initiative to lead

as a leader Training is needas a leader Training is need


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Software Self DisciplineSoftware Self Discipline LeadershipLeadershipMust be theMust be the ParagonParagon for thefor the

workers how to do the good job inworkers how to do the good job in

the factory the factory

Should be responsible to spreadShould be responsible to spreadout the same message fromout the same message from

management to the bottommanagement to the bottom

Should take properShould take proper Time andTime andActionAction of corrective action planof corrective action plan

when management raise up anywhen management raise up any

issueissue

Should take note ofShould take note ofTo Do ListTo Do List


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Software HeadcountSoftware Headcount Pattern Maker Pattern Maker

Suggest to have 1 ~ 2 more patternSuggest to have 1 ~ 2 more patternmakers to ease up their workload. Then,makers to ease up their workload. Then,have extra time to train up same eye forhave extra time to train up same eye forfit requirement adoptionfit requirement adoption

Technical Manager Technical Manager Should have an experienced technicalShould have an experienced technicalperson to oversee the technical aspect /person to oversee the technical aspect /solution. Provide any garmentsolution. Provide any garmentengineering advise for increasing higherengineering advise for increasing higher

productivity without style changeproductivity without style change Checkpoint QC ( Buttoning )Checkpoint QC ( Buttoning )

There is only 1 checkpoint QC forThere is only 1 checkpoint QC forbuttoning, and who is only pullingbuttoning, and who is only pullingrandom check onlyrandom check only

Suggest to have 1 more QC to ensureSuggest to have 1 more QC to ensure


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performance enhancement proposal for epic vietnam

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