Sewing operator grade improvement & assessment-three techniques & comparison report of Apparel
Sharmin Akther Diba
Industrial & Production Engineer
Rajshahi University of Engineering & Technology (RUET)
Email: dibasrmn@gmail.com
LinkedIn: Sharmin Akther Diba
Objectives:
1.
To find out feasible KPI point of assessment.
2.
To identify existing proposed system advantages & disadvantages.
Comparison of final grading policy between three units:
1. KPI Criteria: Operational & HR
KPI’s
1. Performance
2. Absenteeism
3. Lateness
4. Lunch out
5. Disciplinary Action"
Technique: Technique-01
Considering Factor
1. It was done for assessing 6th-grade operator & grade improvement to 5th grade. A-C grade was improved & D grade was proposed for training & re-assessed.
Measurement of Operational Performance
1. Score =100, Operational =60, HR=40.
2. Considering 4 grades; below 30 D grade, 30.01 to 55 C grade, 55.01 to 75 B grade & above 75 A grade.
2. Considering 4 grades; below 30 D grade, 30.01 to 55 C grade, 55.01 to 75 B grade & above 75 A grade.
Example
Name: Mrs. Jali, ID: 50130055
Calculation:
For 5 KPI points, respectively marks= 18.33+6.40+8.40+4.58+5 =48, hence C grade.
She promoted to 5th HR grade.
Advantage of KPI Calculation
1. Fair marking policy.
2. Easy calculation.
3. Easy to brief operators about their performance.
Disadvantages of KPI Calculation
1. For yearly report making the purpose, need manpower for data entry & record keeping.
2. For new operator assessment, only operational performances have to consider.
2. KPI Criteria: Operational & HR
KPI
1. Critical Operation
2. Semi-critical Operation
3. Basic Operation
4. Absenteeism
5. Attitude
Considering Factor
1. It was done for proposing increment, level position & training needed operator selection based on marks.
Measurement of Operational Performance
1. Grading policy: Total marks <=14 :Unskilled,Total marks <=29 :D grade, Total marks <=44 :C grade, Total marks <=58 :B grade, Total marks <=65 :A grade, Total marks <=58 :B grade, Total marks >=96 :A+ grade.
2. If present gross salary= performance grade-wise salary, leveled; if If present gross salary< performance grade-wise salary, increment; if If present gross salary> performance grade-wise salary, skill enhance training needed.
3. Follow the details:
Example
Name: Ayesha Begum, ID: 81440079
Calculation:
For 5 KPI points, respectively marks= 4+18+2+3+3= 30, hence skill grade C.
Her HR grade is 4, subgrade become C1
Present gross salary 9347 BDT, Performance grade salary become 8875 BDT which is less than preset salary; she needs skill training.
Advantage of KPI Calculation
1. Subgrading is the potential for recruiting salary fixation.
Disadvantages of KPI Calculation
1. Considering Efficiency & letting Quality level marking choosing criteria is contradictory.
2. HR KPI attitude marking may be biased, hence sub grading might be biased.
3. For new operator assessment only operational performance has to consider.
KPI Criteria: Operational & HR
KPI
1. Service years
2. Multi m/c skill
3. Multi-process skill
4. Process efficiency
5. Quality performance
6. Attitude & attendance
Considering Factor
1. It was a proposal for increment, level position & training needed operator selection based on marks.
Measurement of Operational Performance
1. Score =100, For six KPI Points marks respectively 5, 10, 10, 50, 20, 5.
2. Based on total marks operator type, operator grade, operator grid & salary will be selected.
3. Follow the details:
2. Based on total marks operator type, operator grade, operator grid & salary will be selected.
3. Follow the details:
Example
Name: Md. Abdul Jolil, ID: 40120002
Calculation:
KPI points marks respectively 5+10+10+46+14+3.7= 88.20
Thus, semi-critical operator type (B1).
Advantage of KPI Calculation
1. Process efficiency marking is easy to calculate.
Disadvantages of KPI Calculation
1. Marking might be biased.
2. Motivational marking policy not established.
3. Considering Efficiency & Quality performance is contradictory as efficiency is calculated considering value-added activities.
Comparison of KPI & marking policy between three units
Sl.
|
KPI Criteria
|
KPI
|
Technique
|
1
|
Operational
|
Performance
|
Technique-01
|
2
|
Operational
|
Critical Operation
|
Technique-02
|
3
|
Operational
|
Semi-critical Operation
|
Technique-02
|
4
|
Operational
|
Basic Operation
|
Technique-02
|
5
|
Operational
|
Multi M/C Skill
|
Technique-03
|
6
|
Operational
|
Multi Process Skill
|
Technique-03
|
7
|
Operational
|
Process Efficiency
|
Technique-03
|
8
|
Operational
|
Quality Performance
|
Technique-03
|
9
|
HR
|
Absenteeism
|
Technique-01
|
HR
|
Absenteeism
|
Technique-02
| |
10
|
HR
|
Lateness
|
Technique-01
|
11
|
HR
|
Lunch out
|
Technique-01
|
12
|
HR
|
Disciplinary Action
|
Technique-01
|
13
|
HR
|
Attitude
|
Technique-02
|
14
|
HR
|
Service Years
|
Technique-03
|
15
|
HR
|
Attitude & Attendance
|
Technique-03
|
Comparison of KPI & marking policy between three units:
1. KPI Criteria: Operational
KPI: Performance
Considering Factors:
1. Out of 100 assessment marks, 60 marks allocated
2. Types of operation (basic, medium, critical operation)
3. Number of operations performed (no of different operations)
4. Operation wise efficiency (different operations wise efficiency)
5. Minimum number of operations -03 (an operator must attain min 03 different operations)
Measurement of Operational Performance
1. Basic: Level (41% to 100%, below 40% =0, mark per efficiency=1, total 60 marks
2. Medium: Level (31% to 90%, below 30% =0, mark per efficiency=1, total 60 marks
3. Basic: Level (26% to 85%, below 25% =0, mark per efficiency=1, total 60 marks
Example
Name: Mrs. Jali, ID: 50130055
Calculation:
Label Make/ attach (Basic)-43% (03 Marks)
Inner & Outter tack (Basic)-32% (00 Marks)
Hanger Loop attaches (Medium)-82% (52 Marks)
Total= (03+00+52)=55 Marks, 03 processes,
Avg=55/3= 18.33 Marks for Performance
Advantage of KPI Calculation
1. All performance criteria covered including efficiency, quality as well as expertise of operation.
2. Easy to calculate as well as fair for operator assessment because every single efficiency improvement has taken into consideration.
3. Easy to define & motivate operators about their performance & necessary improvement.
Disadvantages of KPI Calculation
1. For yearly report making the purpose, need manpower for data entry & record keeping.
2. KPI Criteria: Operational
KPI: Critical Operation
Considering Factors:
"1. Considered as per set-up marking
3. If QA Level & Eff% does not match choose minimum criteria for marking"
Measurement of Operational Performance
"1. Efficiency: Above 75%, QA Level 1%, Marks 4
2. Efficiency: 61% to 74%, QA Level 2%, Marks 3
3. Efficiency: 51% to 60%, QA Level 2%, Marks 2
4. Efficiency: 40% to 50%, QA Level 2%, Marks 1"
Example
"Name:Ayesha Begum, ID: 81440079
Calculation:
Pocket join/ Patch label join: Match measurement option 03 & get marks= 2
Attach & lose tape to slit on bottom hem: Match measurement option 03 & get marks= 2
Total Marks: 2+2= 4"
Advantage of KPI Calculation
1. All performance criteria covered including efficiency, quality as well as expertise of operation.
Disadvantages of KPI Calculation
"1. Considering Efficiency & letting Quality level being a mark choosing criteria is contradictory.
2. Marking might be biased by changing the Quality level.
3. Efficiency level is not considered from micro-level, for example, 61% eff operator 74% eff operator getting the same marks. This might causes operator dissatisfied."
3. KPI Criteria: Operational
KPI: Semi-critical Operation
Considering Factors:
"1. Considered as per set-up marking.
2. If QA Level & Eff% does not match choose minimum criteria for marking"
Measurement of Operational Performance
"1. Efficiency: Above 75%, QA Level 1%, Marks 1
2. Efficiency: 61% to 74%, QA Level 2%, Marks 2
3. Efficiency: 51% to 60%, QA Level 2%, Marks 2
Example:
"Name:Ayesha Begum, ID: 81440079
Calculation:
4 operations: Match measurement option 01 & get marks= 3+3+3+3= 12
3 operations: Match measurement option 02 & get marks= 2+2+2= 6
Total Marks: 12+6= 18"
Advantage of KPI Calculation
Disadvantages of KPI Calculation
Same as previous
KPI Criteria: Operational
KPI: Basic Operation
Technique: Technique-02
Considering Factor
1. Considered as per set-up marking.
2. If QA Level & Eff% does not match choose minimum criteria for marking
2. If QA Level & Eff% does not match choose minimum criteria for marking
Measurement of Operational Performance
1. Efficiency: Above 75%, QA Level 1%, Marks 2
2. Efficiency: 61% to 74%, QA Level 2%, Marks 1
2. Efficiency: 61% to 74%, QA Level 2%, Marks 1
Example
Name:Ayesha Begum, ID: 81440079
Calculation:
1 operations: Match measurement option 01 & get marks= 2
Total Marks: 2
Calculation:
1 operations: Match measurement option 01 & get marks= 2
Total Marks: 2
Advantage of KPI Calculation
Same as previous
Disadvantage of KPI Calculation
Same as previous
KPI Criteria Operational
KPI: Multi M/C Skill
Technique Technique-03
Considering Factor
1. Out of 100 assessment marks, 10 marks allocated
Measurement of Operational Performance
1. If an operator can operate 3 or more machines, he/she will get 10
2. If an operator can operate 2 machines, he/she will get 7
3. If an operator can operate 1 machine, he/she will get 5
2. If an operator can operate 2 machines, he/she will get 7
3. If an operator can operate 1 machine, he/she will get 5
Example
Name: Md. Abdul Jolil, ID: 40120002
Calculation:
Operated S/L, O/L & F/L m/c; thus 03 m/c & match measurement option 01 & get marks= 10
Calculation:
Operated S/L, O/L & F/L m/c; thus 03 m/c & match measurement option 01 & get marks= 10
Advantage of KPI Calculation
1. Easy to calculate.
The disadvantage of KPI Calculation
1. Adding extra calculation because it may be overlapped with multi-process; thus making calculation lengthy.
KPI Criteria: Operational
KPI: Process Efficiency and performance
Technique: Techniques: 1/2/3
Considering Factor:
1. Out of 100 assessment marks, 50 marks allocated
2. Out of 100 assessment marks, 20 marks allocated
3. Out of 100 assessment marks, 20 marks allocated
4. Negative marking is allowed & will be cumulate with marks calculation
5. Maximum allowable mark 5
6. Out of 100 assessment marks, 10 marks allocated
7. Negative marking is allowed & will be cumulated with marks calculation
8. Out of 100 assessment marks, 5 marks allocated
9. Negative marking is allowed & will be cumulated with marks calculation
10. Out of 100 assessment marks, 5 marks allocated
11. Negative marking is allowed & will be cumulated with marks calculation
12. Necessary action was taken as per HR rule
13. Hypothetical/ observation based
14. Out of 100 assessment marks, 5 marks allocated
15. Out of 100 assessment marks, 5 marks allocated
Measurement of Operational Performance
1. If an option can do critical process then he/she will get the mark out 25 based on his/her efficiency (avg. efficiency of his/her critical process), also if the same opt can do semi critical & easy process then he/she will get the mark out 15 for semi critical and 10 for easy process based on his/her efficiency, (avg. efficiency of his/her semi critical & easy process). Suppose an Opt's critical process avg. efficiency-78%, Semi critical process avg. efficiency-83%, and easy process efficency-88%, then his/her marks will be=(25*78%)+(15*83%)+(10*88%)=
2. If an operator get green mark then he will get 20 marks out of 20
3. If an operator gets 1 to 3 yellow and 1 red then he will get 18 marks out of 20
4. If an operator gets 1 to 3 yellow and 1 to 2 red then he will get 15 marks out of 20
5. If an operator gets 8 to 10 yellow and 1-2 red then he will get 10 marks out of 20
6. If an operator get 11 to 13 yellow and 1-2 red then he will get 5 marks out of 20
7. If an operator gets more than 13 yellow or total 3 red then he will get 0 marks out of 20
8. N.B. This policy applies for every individual month, for yearly review avg. marks of that year will be added.
9. Consideration: 25 days/year, marks deduction 0.80 for 1 day
10. For absenteeism 0%, 1%, 2%, 3%, above 3%; marks consecutively 1, 2, 3, 4, 5.
11. Consideration: 25 days/year, marks deduction 0.40 for 1 day
12. Consideration: 12 days/year, marks deduction 0.42 for 1 day
13. Consideration: 2 letters/year, marks deduction 2.50 for 1 letter
14. Consideration: Best, very good & good; marks 3, 2, 1 consecutively
15. If an operator experienced 5 years or more, he/she will get 5
16. If an operator experienced 4 Years, he/she will get 4
17. If an operator experienced 3 Years, he/she will get 3
18. If an operator experienced 2 Years, he/she will get 2
19. If an operator experienced 1 Year, he/she will get 1"
20. Considering grading system A, B, C, D with marks 4 to above, 3, 2, 1 respectively.
21. Marks deduction for specific activities like absent, late, lunch out, warning letter, suspension & verbal warning are 1, 0.50, 1, 1, 2, 1 consecutively.
22. Out of 100 marks, KPI points are Attendance, Behavior Act, Interpersonal Relationship, Punctuality, Disciplinary, Loyalty, Response for betterment marks respectively 60, 20, 5, 5, 3, 3, 4
23. Total score/20 = points =grade"
Some Example
1. Name: Md. Abdul Jolil, ID: 40120002
Calculation:
Critical Operation: Avg efficiency= 92%, marks =.92 * 25 =23
Semi-critical Operation: Avg efficiency= 90%, marks =.90 * 15 =13.50
Basic Operation: Avg efficiency= 90%, marks =.90 * 10 =9
Total marks= 23+13.50+9= 45.50= 46
2. Name Md. Abdul Jolil, ID: 40120002
Calculation:
From Relevant department data, obtained marks= 14
3. Name: Mrs. Jali, ID: 50130055
Calculation:
Absent: 17 days, Marks= 20- (17 * 0.80) = 6.40
4. Name: Ayesha Begum, ID: 81440079
Calculation:
Absenteeism 2%, marks=3
5. Name: Mrs. Jali, ID: 50130055
Calculation:
Late: 04 days, Marks= 10- (4 * 0.40)= 6.40
6. Name: Mrs. Jali, ID: 50130055
Calculation:
Lunch out: 01 day, Marks= 5- (1 * 0.42)= 4.58
7. Name: Mrs. Jali, ID: 50130055
Calculation:
Disciplinary Action: N/A, Marks= 5
8. Name: Mrs. Jali, ID: 50130055
Calculation:
Observer rated mark= 3 (Best)
9. Name Md. Abdul Jolil, ID: 40120002
Calculation:
From the HR Database, total yr of experience: 5.53 yr. Hence obtained marks= 5
10. Name Md. Abdul Jolil, ID: 40120002
Calculation:
KPI points Attendance, Behavior Act, Interpersonal Relationship, Punctuality, Disciplinary, Loyalty, Response for betterment marks respectively 42+16+4+4+2+3+3= 74
74/20 =3.7 =grade B
Advantage of KPI Calculation
1. Easy to calculate.
2. Easy to get data as provided by the relevant department.
3. Easy to calculate.
4. Fair marking help operator to avoid absenteeism."
5. Easy to calculate.
6. Easy to calculate.
7. Fair marking help operator to avoid lateness."
8. Easy to calculate.
9. Fair marking help operator to avoid lunch out tendency."
10. Easy to calculate.
11. Fair marking help operator to avoid malicious act."
12. Easy to calculate.
Disadvantages of KPI Calculation
1. Multi-process & multi m/c can be mixed with these criteria.
2. Considering Efficiency & Quality performance is contradictory as efficiency is calculated considering value-added activities.
3. Marking might be biased by changing the Quality level."
4. Motivational marking policy not established.
5. Lack of marking justification."
6. KPI point implies the bad culture of the company.
7. KPI point implies bad culture of the company.
8. Marking might be biased.
9. Motivational marking policy not established."
10. Might demotivate an efficient operator with less working experience.
11. Marking might be biased.
12. Transparent marking policy is not visible to the operator.