Question-27: What are the steps of kaizen implementation?

Ans:
Kaizen steps:
1. Clarify the problem
2. Breakdown the problem
3. Set a target
4. Analyze the root cause
5. Develop counter measure
6. See countermeasures through
7. Evaluate both results and processes
8. Standardize successful processes.
Question-35: How to calculate estimated line cost per minute?
(Question asked by Tanveer Nitul, Executive at Experience Textile Ltd.)
Ans:-
Estimated cost per minute of a sewing line:
= (𝑇𝑜𝑡𝑎𝑙 𝑠𝑎𝑙𝑎𝑟𝑦 𝑜𝑓 𝑎 𝑙𝑖𝑛𝑒 𝑓𝑜𝑟 𝑜𝑛𝑒 𝑑𝑎𝑦)/((𝑇𝑜𝑡𝑎𝑙 𝑚𝑖𝑛𝑢𝑡𝑒𝑠 𝑎𝑣𝑎𝑖𝑙𝑎𝑏𝑙𝑒 ∗𝐿𝑖𝑛𝑒 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦%))
= (𝑇𝑜𝑡𝑎𝑙 𝑠𝑎𝑙𝑎𝑟𝑦 𝑜𝑓 𝑎 𝑙𝑖𝑛𝑒 𝑓𝑜𝑟 𝑜𝑛𝑒 𝑑𝑎𝑦)/((𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑡𝑜𝑡𝑎𝑙 𝑙𝑎𝑏𝑜𝑟∗𝐷𝑎𝑖𝑙𝑦 𝑤𝑜𝑟𝑘𝑖𝑛𝑔
ℎ𝑜𝑢𝑟𝑠∗60∗𝐿𝑖𝑛𝑒 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦%))
= 20360/((81∗8∗60∗0.4))
= 1.31 Taka
Here,
-Total Direct labor =81 (55 operator+15 Helper+02 Ironer+05 quality checker 03 line supervisor)
[Per day salary,
01 Operator =250 Taka ; 55 operators=55*250=13750 Taka
01 Helper = 200 Taka ; 15 Helpers =15*200= 3000 Taka
01 Ironer = 230 Taka ; 02 Ironer= 460 Taka
01 Quality checker = 240 Taka ; 05 Quality checker= 1200 Taka
01 Line supervisor = 650 Taka ; 03 Line supervisor= 1950 Taka]
-Total day salary of all direct labors = 20360 taka (13750+3000+460+1200+1950)
-Working Hour =08
-Line efficiency =40%
[Note: Cost per minute of a line is calculated only for direct laborers (operators, helpers, ironer ,
quality checkers, line supervisor).]
Question-29: What are the Seven QC Tools?
Ans: Seven basic tools of Quality:
1. Check sheet or tally sheet
2. Histogram
3. Pareto chart
4. Cause and effect diagram (Fishbone diagram/ Ishikawa diagram)
5. Process flow chart
6. Control chart (C chart)
7. Scatter diagram 
Question-32: How to calculate no. of machines required from operation bulletin.
(Question asked by Atiqur Rahman, IE officer, Skyline Group)
Ans: Please see the standard operation bulletin format I've attached. From this format you can
calculate the no. of machines required for a specific style as per your line target based on your
expected efficiency level.
Question-32: How to calculate no. of machines required from operation bulletin.
(Question asked by Atiqur Rahman, IE officer, Skyline Group)
Ans: Please see the standard operation bulletin format I've attached. From this format you can
calculate the no. of machines required for a specific style as per your line target based on your
expected efficiency level.
 Question-30: What are the steps of 5S?
Ans:
Organize the work area:
1. Sort (eliminate that which is not needed)
2. Set in Order (Organize remaining items)
3. Shine (clean and inspect work area)
4. Standardize (write standards for above)
5. Sustain (regularly apply the standards)
Question-31: How does 5S help?
Ans:
Eliminates waste that results from a poorly organized work area e.g. wasting time looking for a
tool.
Question-19: What are the goals of Lean Manufacturing?
Ans:
Goals to Lean Manufacturing:
1. Highest Quality
2. Lowest cost
3. Shortest Lead Time