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TABLE OF CONTENTS

Serial No. Topic Pg #01 Group Introduction 03

02 Dedication 04

03 Acknowledgement 05

04 Preface 06

05 Executive Summary 07

Ch. # 1 Company Introduction 08

o Company Name 08

o Slogan & Logo 08

o History 09

o Vision & Mission Statement 11

o Objectives 12

Ch. # 2 Six Sigma Process 15

o DMAIC Process 16

Ch. # 3 Define 18

Ch # 4 Measure 19

o Flow Chart 19

o Process Flow 20

o Prato Diagram 26

o Time Series 27

Ch # 6 Analysis 30

Ch #7 Improvement 31

o Prato Diagram and Time Series 32

Ch # 8 Control 33

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Course name:

“Total Quality Management”

Project Name:

Increasing Employees Efficiency

Submitted To ,

Sir Masood Kalyar.

Submitted By:

Abdullah Shahzad 203

Yahya Amin 205

Mah Gull 223 BBA 6th Morning 2009-2013

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We dedicated this project to our dearest, Parents & Teachers. Who prayed for our success and to all our love ones whom we love from the core of heart.

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A c k n o w l e d g e m e n t :

We wish to acknowledge our regards and indebtedness to our guide and benevolent Sir. Masood Kalyar teaching Total Quality Management in G.C. University Faisalabad. Whose kind and precious suggestions enriched our thoughts and helped us to accomplish this Business plan. We also want to thank our families who supported us. Thanks to Almighty ALLAH for giving us such will and power to complete this business plan on time

A deep sense of appreciation is owed to Mr. Ikram ilahi for his kind attitude and keen interest during my internship.

Last but not least we offer our humble heart felt gratitude and deepest affections to my great

mother and respected father for being inspired for higher ideals of life, supported morally and

financially throughout my studies, and always prayed for glorious success about my pursuits

throughout all of my life.

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P r e f a c e :

We have chosen this Textile Mill to make our project on it. We had a good time while doing the

survey about our problem and gathering the information about solving our problem to increase

employee efficiency through different ways into a project.

The project is basically about the Increasing employee efficiency, skills, knowledge. We also

used the source of internet for gathering information. We think that we have done our job in

solving the problem we hope that

We have given all the complete information required by our teacher, and hope that our hard work pays off.

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Executive Summary:

YAT is the organization that deals in the manufacturing of Lawn and Cotton suits. This organization is innovatory product in the Pakistani market. The organization name is Yasir Afzal Textile Pvt. Ltd.

In the first phase, we had conducted the Organization survey and we found the main problem in organization . The survey was very successful in which we observed all the procedure of manufacturing clothe and different type of machines which helped to produce clothe and then we get sample knowledge about employees their efficiencies, skills and knowledge about their work. In the whole survey the main problem that we found is that there is no sufficient output as there should be. Then with our survey report and knowledge we found the cause of this problem. The cause is that employees are not satisfied from their job. In which we found that there is insufficient salary, lack of commitment, no incentives and working environment which discomforts the employees. Therefore, we decided to solve this problem and increase the efficiency of employees.

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Company Name:

Yasir Afzal Textile Pvt Ltd.

Our Slogan:

“Be Different”

Our Logo:

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Ch # 1:

Introduction & History of Organization:

Yasir Afzal Textile Industries Pvt. Limited Faisalabad is the grooming industry in Faisalabad in

textile. Founded in 1991 by the most famous person, Haji Muhammad Afzal and Haji

Muhammad Islam, is now led by the young Mr. Umer Afzal and Mr. Amir Afzal , a dynamic

second generation leader of Faisalabad textile industry.

Yasir Afzal Textile is one of the largest manufacturer of textile goods in Pakistan. It is

manufacturing high quality products. Its product brand name is “Ashi and Rabi” are amongst

leader in the market. Yasir Afzal Textile has designing, and printing departments. The

bedding and fabric collection of Yasir Afzal Textile are sent to the different parts of the country

such as Lahore Karachi Islamabad and Peshawar.

Yasir Afzal Industry by now is in textile cloth finishing and processing, textile product packing.

Haji Muhammad Afzal the present Chairman of the Industry, the creative and courageous man,

latter joined by second generation, making a blend of experience and modern business

knowledge, managed the business growth and development with assistance of highly qualified

team of professionals. Faith in Almighty Allah and in their own abilities & commitment to the

cause, untiring efforts and leadership qualities of the family, established the industry, which now

stands amongst Leading Industrial Industry of the Country, under the Chairmanship of Haji

Muhammad Afzal.

The daily production round about 1 lac meter and the parties of YAT are in Lahore, Karachi, Faisalabad, and Multan through the different parties they export cloth in different Asian countries like Seri Lanka, India, Malaysia and Thailand. Via Karachi they send cloth to Dubai. For many years YAT working with Maria B Designer. They manufacture Maria B Lawn on order which have many outlets inside the country Karachi, Lahore, Faisalabad etc and outside the country like Dubai.

They start with one rotary Machine and then expand the business with the passage of time and now working with 3 rotary machines. Start business with personal manufacture and sold their cloth through outlet in market and later on manufacture cloth on order .Now many domestic trader prepare their cloth from YAT on order.

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Vision:

“To become one of the Best brands in the country”

Mission:

“Satisfying our customers by providing them best qualitative stuff and Unique designs keeping in view their comforts and excellence”Excellence in quality and improved efficiency at lower operating cost by Utilizing blend of state

of art technologies.

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Our Objectives:

There are two types of objectives

1-Non-Financial Objectives:

To be among the top ten favorite brands.

Yasir Afzal Textile is the growing Organization in the Textile

Sector

ISO certified Company

Having a Qualified and Experienced Staff

Proper Utilization of Human Resources

Having a latest Machinery to Compete Globally

Friendly Environment

2-Financial Objectives:

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To maintain an inflation growth in earning per year at a rate of 12%.

To obtain a return on equity of at least 30%.

Providing stitching facilities to other boutiques in 2010 which are Lacking this facility.

BRIEF HISTORY OF ORGANIZATION

Yasir Afzal Textile Industries Pvt. Limited Faisalabad is the grooming industry in Faisalabad in

textile. Founded in 2005 by the most famous person, Haji Muhammad Afzal and Haji

Muhammad Islam, is now led by the young Muhammad Umer and Muhammad Amir , a

dynamic second generation leader of Faisalabad textile industry.

Yasir Afzal Textile is one of the largest manufacturers of textile goods in Pakistan. It is

manufacturing high quality products. Its product brand name is “Ashi and Rabi” are amongst

leader in the market. Yasir Afzal Textile has designing, stitching, and printing departments. The

bedding and fabric collection of Yasir Afzal Textile are sent to the different parts of the country

such as Lahore Karachi Islamabad and Peshawar.

Yasir Afzal textile is one of the largest manufacturers of textile in Pakistan. Specializing in home

textiles, printed, dyed, bleached fabrics, an apparel and fashion garment, Yasir afzal is delivering

quality to virtually all parts of the country. With latest “State-of-the-art” machinery and

equipment, it is a complete printing, dyeing, finishing and stitching plant. Three huge spinning

mills, a high caliber weaving unit and a made-up / garment unit is working under one roof. The

unit is capable of producing high quality with a capacity of 75000 meters of finished cloth every

day.

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Yasir Afzal textiles industries private limited has proudly maintaining its leadership in 100

percent pure cotton products along with the man made fiber. The product range in pure cotton is

available as sateen both in mono cotton and poly cotton, bed sheets, pillow, quilt covers, aprons,

boxer shorts, and ready made garments are available in most exotic and fascinating designs.

A sizeable percentage of Yasir Afzal textiles, daily textile production by the meter are converted

in-house into a ready, saleable retail product. There “Cut & Sew” division enjoys the cutting

edge in assembling and sewing of bed sheets and sets, quilt covers, curtains, table linen, bed

spreads, comforter covers, pillow cases, kitchen linen and ready made garments as per the specs

defined by the customers.

From a fiber to a finished product, nothing gets spared from our ultra-sensitive, extra vigilant

laboratory. Equipped with the most modern and precision equipment, products are frequently

subjected to tests against most relevant international standards at every stage of manufacture.

Tests are conducted to control shrinkage (dimensional change), pilling resistance, and abrasion,

color fastness and washing fastness etc.

Much of their wide success and popularity is attributed to there technically being ahead in there

printing. There printing staff and design teams combine years of practical experience in printing

with top-of-the-range Austrian J. Zimmer rotary printing machines producing 280 cm finished

width up to 12 colors per design and maximum repeat of 91 cm. Flat bed printing facility

comprised Reggiane machine with 320 cm working width and 320 cm repeat.

Thanks to their modern and sophisticated facility, processing to finishes like chintz, silicon,

scotchgard, fire retardant down proof and raisin etc, is invariably a pleasure. With YASIR

AFZAL, their clients gets quick quality sampling on Austrian J. Zimmers latest rotary strike off

machine facilitating production of strike offs up to 15 meter length

CH # 2:

SIX SIGMA PROCESS

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What is six sigma?

Six sigma is a customer based approach realizing that defects are expensive. Fewer defects mean lower costs and improved customer loyalty. The lowest cost, high value producer is the most competitive provider of goods and services. Six sigma is a way to achieve strategic business results.

Six Sigma is a business management strategy, originally developed by Motorola, USA in 1986. Six Sigma became well known after Jack Welch made it a central focus of his business strategy at General Electric in 1995, and today it is widely used in many sectors of industry.

Six Sigma seeks to improve the quality of process outputs by identifying and removing the causes of defects (errors) and minimizing variability in manufacturing and business processes. It uses a set of quality management methods, including statistical methods, and creates a special infrastructure of people within the organization ("Black Belts", "Green Belts", etc.) who are experts in these methods. Each Six Sigma project carried out within an organization follows a defined sequence of steps and has quantified financial targets (cost reduction and/or profit increase).

The term Six Sigma originated from terminology associated with manufacturing, specifically terms associated with statistical modeling of manufacturing processes. The maturity of a manufacturing process can be described by a sigma rating indicating its yield, or the percentage of defect-free products it creates. A six sigma process is one in which 99.99966% of the products manufactured are statistically expected to be free of defects (3.4 defects per million). Motorola set a goal of "six sigma" for all of its manufacturing operations, and this goal became a byword for the management and engineering practices used to achieve it.

DMAIC Process

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1-D= DEFINE : Define the problem, the voice of the customer, and the project goals, specifically. The objective of this phase is to define opportunities for improvement. Defining the problem answers the questions such as "what are the problems?"

Define is the first step in our six sigma approach of DMAIC. DMAIC first asks leaders to define our core process. It is important to define the selected project scope, expectations, resources and timelines . The definition step in the six sigma approach identifies specially what is part of the project and what is not, and explains the scope of the project .

2-M=MEASURE: Measure key aspects of the current process and collect relevant data. Many think when they start a journey the most important thing to know is where they are going. while we agree knowing where you want to go is very important, we believe some of the first information you need before starting any journey is your current location. The six sigma approach asks the black belt project manager to quantify and benchmark the process using actual data. At a minimum consider the mean or average performance and some estimate of the dispersion or variation.

3-=ANALYSIS have been considered. Seek out root cause of the defect under investigation. Analyze the data to investigate and verify cause-and-effect relationships. Determine what the relationships are, and attempt to ensure that all factors Once the project is understood and the baseline performance documented and verified that there is real opportunity, it is time with the six sigma approach to do an analysis of the process . in this step , the six sigma approach applies statistical tools to validate root causes of problems. Any number of tools and tested can be used .The objective is to understand the process at a level sufficient to be able to formulate options for improvement. We should be able to compare the various options with each other to determine the most promising alternatives.

4-I=IMPROVE : During the improve step of the six sigma approach ideas and solutions are put to work. the six sigma black belt has discovered and validated all known root causes for the existing opportunity. the six sigma approach requires black belt to identify solutions. few ideas or opportunities are so good that all are an instant success. as part of the six sigma approach there must be checks to assure that the desired results are being achieved. some experiments and trails may be required in order to find the best solution. when making trails and experiments it is important that all project associates understand that these are trails and really are part of the six sigma approach.

Improve or optimize the current process based upon data analysis using techniques such as design of experiments, poke yoke or mistake proofing, and standard work to create a new, future state process. Set up pilot runs to establish process capability.

5-C=CONTROL: Control the future state process to ensure that any deviations from target are corrected before they result in defects. Implement control systems such as statistical process control, production boards, visual workplaces, and continuously monitor the process.

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Many people believe the best performance you can ever get from a process is at the very beginning. Over time there is expectancy that slowly things will get a little worse until finally it is time for another major effort towards improvement. Contrasted with this is the kaizen approach that seeks to make everything incrementally better on a continuous basis. The sum of all these incremental improvements can be quite large. As part of the six approach performance tracking mechanism and measurement are in place to assure, at a minimum, that the gains made in the project are not lost over a period f time.

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CH # 3 Define

PROJECT: Yasir Afzal Textile Pvt. Ltd.

PROJECT INFORMATION :

Leader: Mah Gul

Black belt : Abdullah Shahzad

Green Belt : Yahya Amin

Project start: 28 April 2012

Project end : 28th may 2012

Cost of poor quality:10,000-20,000 Meter.

TEAM MEMBERS :

SPONSOR: Yasir Afzal Textile (PVT LTD).

BLACK BELT: Abdullah Shahzad, identification of problem is the main responsibility of Abdullah Shahzad.

GREEN BELT: Yahya Amin collection , analysis of data and implementations are the responsibilities of Yahya Amin

PROCESS PROBLEM :

Problem is that no output from employees and no efficiency level .there are many reasons behind this but we took main reasons that environment is not suite able, 2nd employees are not satisfied, 3rd lack of motivation

PROJECT IMPORTANCE:

This project is about the increase the employees efficiencies and increase the output of employees & through which increase the production.

PROCESS START /STOP

START POINT: enter the grey into factory END POINT: Manufacture the cloth and Dispatched

PROJECT TIME FRAME :

MILESTONE: visit and identified the problem Data collection ANALYSIS

DATE: 28-04-12 30-04-12 07-05-12

MILESTONES: MAKE THE SOLOUTIONS IMPLIMENTATION STUDIED THE OUTCOMES

10-05-12 13-05-12 25-05-12

Critical to Quality:

Provide the cloth to customer on time and increase the daily production.

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Ch # 4

2- Measurement

No

Yes

Dying

printing

Yes

Grey

Entry in System

Mending

Is Grey Be good

Refuses Order

check Inventory

Jigger Machine

Standard Machine

Rotary & Boozer Machine

Ager Machine

Finishing Department

Super Machine

Checker

Packing

Calendar or Press

Folding

bleaching

Wait

Resize

Mercerize

Care

Printing or Dying

1 or 2 Hours

Dispatched

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For manufacturing cloth 1st of all receive grey in factory then enter inventory of grey in record then check the fault about grey and if defect in grey then reject the grey but in case of acceptation then send for bleaching in which three steps involve

Bleaching:-

Bleaching improves whiteness by removing natural coloration and remaining trace

impurities from the cotton; the degree of bleaching necessary is determined by the

required whiteness and absorbency. Cotton being a vegetable fiber will be bleached using

an oxidizing agent, such as dilute sodium hypochlorite or dilute hydrogen peroxide. If the

fabric is to be However, for white bed sheeting and medical applications, the highest

levels of whiteness and absorbency are essential. dyed a deep shade, then lower levels of

bleaching are acceptable.

Desizing:-

Depending on the size that has been used, the cloth may be steeped in a dilute acid and has been used, the cloth may be steeped in a dilute acid and then rinsed, or enzymes may be used to break down the size. Then rinsed, or enzymes may be used to break down the size.

Mercerize:-

A further possibility is mercerizing during which the fabric is treated with caustic soda

solution to cause swelling of the fibres. This results in improved lustre, strength and dye

affinity. Cotton is mercerized under tension, and all alkali must be washed out before the

tension is released or shrinkage will take place. Mercerizing can take place directly on

grey cloth, or after bleaching.

Many other chemical treatments may be applied to cotton fabrics to produce low

flammability, crease resist and other special effects but four important non-chemical

finishing treatments

Care :-

This step use for whiteness of cloth

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Drying:-

After the step of bleaching the grey send for drying

Printing or Dying

Printing:-

Printing, on the other hand, is the application of color in the form of a paste or ink to the

surface of a fabric, in a predetermined pattern. It may be considered as localized dyeing.

Printing designs on to already dyed fabric is also possible.

problem occur in our printing department due to defect in machinery and machinery is

stop for 1 or 2 hours and it is effect on efficiency of employees and production.

20%-25% production decrease due to defect in machinery and Total daily production is 1,30,000 Meter

Dying:-

Finally, cotton is an absorbent fiber which responds readily to coloration processes.

Dyeing, for instance, is commonly carried out with an anionic direct dye by completely

immersing the fabric (or yarn) in an aqueous dye bath according to a prescribed

procedure. For improved fastness to washing, rubbing and light, other dyes such as vats

and reactive are commonly used. These require more complex chemistry during

processing and are thus more expensive to apply.

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Ager Machine

Ager machine use for dry the cloth through heating. Depending on the size that has been used, the cloth may be steeped in a dilute acid and then rinsed, or enzymes may be used to break down the size

Super Machine

It use for washing the cloth

Finishing department:-

For finishing the cloth use standard machine and problem can be occur in finishing

Department and may be delay the production

Calendaring:-

Calendaring is the third important mechanical process, in which the fabric is passed

between heated rollers to generate smooth, polished or embossed effects depending on

roller surface properties and relative speeds.

Folding :-

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Folding machine use for rolling the cloth on role

Checker:-

After preparing the cloth then check for overview about defects.

Packing:-

After the checking and clearance of clothe then we will pack the cloth.

Dispatched:-

Dispatching is the last step of the manufacturing cloth.

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Problem is that there is no output of employee and no efficiency of employee, and there are three main causes

Defect in machinery Environment is not suite able for employee Employee not satisfied from job

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Prato Diagram

Daily Production =130,000 Meter Problem=10,000

Following are the problem in % of 10,000

working environment 5000 m, Employee Dissatisfaction 3000 m, Defect in Machinery 2000 m

Employee Inefficiency0%

10%

20%

30%

40%

50%

60%

50%

30%

20%

Working EnvironmeentEmployee Dis SatisfactionDefect in Machinery

Problem: Employees are not satisfied from job.

Y-axis: Percentage of problem

X-axis: Causes of problem

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Time Series

Employee Inefficiency

Day 1 Day 2 Day 3 Day 4 Day 5 Day 6 Day 70%

10%

20%

30%

40%

50%

60%

Working EnvironmentEmployee inefficiencyDefect in machinery

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Ch # 5 3-Analysis

Skills Competition

Laziness Prejudice

Drug addiction Politics

Top management Load shedding

Communication Financial problem

Human Resource

Employees Environment

Commitment Resources

Employees are not satisfied from job

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Ch # 6:

Improvementwe discussed many causes above that were reason of inefficiency of employees and employees not showing performance so we think that delay in printing department

due to defect in printing machine so we repaired our machinery and replaced our machinery then problem is minimized

for maintain and providing good environment to employees we delivered lecture on cooperation, collaboration and mutual understanding and it is helpful for good environment.

for the satisfaction of employees we give incentives to employees and increase the satisfaction level

we appreciate and motivate the employees work and performance

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After the implementation, the improvement in production and deficiency in error.

Day 1 Day 2 Day 3 Day 4 Day 5 Day 60%

5%

10%

15%

20%

25%

Working environmentEmployee Dis SatisfactionDefect in Machinery

employees inefficiency0%

5%

10%

15%

20%

25%

20%

15%

7%

working enviorenmentemloyee dis satisfactiondefect in machinery

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Control:After implementing the solution, we concluded that improvement implementation brought significant benefit to YAT. That is why, we standardized these solutions to further avoid such problems.

Standardized Solution:

Repair and replace our machinery and install some new plants and machinery that works more efficiently.

Put emphasis on co-operation and collaboration in the organization to make environment friendly.

Provide incentives and allowances to satisfy employees.

Appreciate employees to increase motivation.