Operational Excellence

in Textile Industry

Case Study
East Africa

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Faber Infinite Consulting and must
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without the prior written approval
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About Client:
Client is one of the leading textile manufacturers based in
Africa, with reach across African region and a significant
share of the East African market. Major products are Yarn,
Sweaters, Blankets, Masai, Baby Shawls, Scarves, Kikoys,
knitwear, etc.
The client is also one of the leading suppliers to various
schools for sweaters.

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 Analysis. Approach.
Project Implementation.

Analysis

Faber Infinite identified five significant opportunities and

set targets to:

Objectives • Reduce wastages across the processes

• Improve machine productivity
• Need of proper customer complaints monitoring
and improvement mechanism
Reduction in Wastages • Improve employee skills
• Reduce Machine Breakdown
To improve Equipment
Performance & Reduce Approach
Breakdown
Project Initiation
To improve employee • Projects were identified and at a large ceremonious
productivity event, the reward and recognition scheme for
achievement of project targets was announced
To improve the customer
• A dedicated steering team was set up to improve the
feedback mechanism processes, initiate actions and monitor progress
Improve overall employee • On the job client team orientation was conducted to
satisfaction understand the manufacturing constraints and
operational excellence tools

• Each team was assigned with clear roles and

responsibilities to achieve the set targets

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Project Implementation Results
Results Delivered
Delivered
Waste Reduction: Production
Productivityimproved
improvedbyfrom
Conducted Cause and Effect Analysis for all the 20%
2 compressors per shift to 3
wastages across the process, finding the exact root
compressors
Soft per shiftby more
waste reduced
cause and taking appropriate countermeasures to
prevent waste generation than
Work80%
content reduced by
Breakdown Reduction: 40% waste reduced by
Hard
Reduced the breakdown at all the key machines by more than 88%
Total labor cost reduced by
restoring the basic condition of machine using 50%
Breakdown in machines
Autonomous Maintenance pillar
reduced by 50%
Productivity improved by
Employee Skill Development:
50%Index improved from
Skill
Provided on the job training using Training Within
Industry (TWI) framework, along with tutorials for
35% to 75%total 10 work
Designed
continually improving skills, which will not only help at station layout as per
the Gemba but to manage the work life balance ergonomic design
Customer Complaint Resolution & Feedback Mechanism: Sustenance
Sustenance
Designed & rollout of structured system to capture
feedback from each customer, which in turn will Implemented results shall be
trigger the customer complaints resolution, reduction The implemented
sustained over a results are
period
in complaints and improving overall quality sustaining
using over a period
Systematic Auditof &
time by implementation
Improvement Loop (SAIL) of &
Productivity Improvement:
Daily Work
Daily Workmanagement
Management
Root causes for low productivity were identified and (DWM)
worked upon via various Problem-Solving tools to
minimize the issues and improve the productivity

Visit Faber at www.faberinfinite.com for more information and a

complete list of regional contacts or send us e-mail:
consulting@faberinfinite.com

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