Transcript Mr. Jehan Jayasuriya – Apparel Sector

Enhancing Productivity
The Apparel Case Study
Presented by: Jehan Jayasuriya
Economic Summit: 10th July 2013
Industry Background
Sri Lankan Perspective
Industry Size : $4Bn
Direct Employment: 300,000
Percentage of Exports: 40%
4,500.00
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3,500.00
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The Transition…
Generic
Value Add
3
The Elements…
What is Productivity?
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Apparel Productivity: Building Blocks
Lean
Design
Technology
Collaboration
People
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Product Design
“Some people think design means how it looks. But of
course, if you dig deeper, it's really how it works” :
Steve Jobs
Aesthetic Appeal
Comfort
Manufacturability
Performance
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Technology
“Every generation's breakthroughs are proven false by
the next generation's technology”
Dan Brown
Energy Efficiency
Product Development
Fabric Cutting
Sewing
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People
“The essence of competitiveness is liberated when
we make people believe what they do is important and then get out of their way while they do it”
Jack Welch
Competitiveness
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Equality
Recognition
Empowerment
Collaboration
“Alone we can do so little; together we can do so much” : Helen Keller
MAS Rapid case study
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Built on strength of partnerships across the
value chain
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Revolutionized industry through crashing
lead times by 80%
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Minimum write downs for the customer
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Minimum stockholding within supply chain,
more productive space
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Built on the principles of Lean
Proximity map of MAS Rapid Supply Chain
Partners
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Lean Principles
“A relentless barrage of “why’s” is the best way to prepare your mind to pierce the clouded veil
of thinking caused by the status quo. Use it often.” : Shigeo Shingo
Achievements in selected key metrics through MOS
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Reduced total inventory levels by 26%
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Space saving leading to freeing up capacity – 73,000 sq.ft
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Reduction in style change over time from 18 hrs to 3hrs
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Reduction in Raw Material write offs by 48%
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Reduction in cost per hour
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Reduction in dock to dock time from 58 days to 25 days
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Synopsis
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Productivity is no longer about output, the main focus
should be on value
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Productivity starts well before the product is in the
factory. Design is the make or break of productivity
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Adopt new technologies fast or risk being left behind
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People are the most critical enabler of productivity in apparel. Culture is what
drives them. Invest in it.
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Optimum productivity cannot be derived in isolation. It only happens when the
whole value chain comes together
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The true potential of lean can only be seen when instilled across all functions of
the value chain