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ORIGINAL RESEARCH
1. Introduction
The cement manufacturing sector of Bangladesh is the 40th largest market in the world. Currently, more than 32
cement manufacturing companies, including five multinationals are in operation and produce around 31 Million Metric
Tons (MMT) of cement per year, which is higher than the annual demand of Bangladesh (EBL, 2019). Out of the total
cement consumed in Bangladesh, the individual home sector uses 25%, real estate developers use 30%, and the government
organization uses the rest 45% (ECRL, 2015). Surplus production of cement is exported to the global market; thus, the
cement industry has become an export earning sector of Bangladesh. This sector earned USD 11.50 million export revenues
for the fiscal year 2017-18 compared to USD 10.79 million for the previous fiscal year. Though cement exports witness an
increasing trend throughout the past several years, Bangladesh holds an insignificant share of the global cement market
(BEPB, 2016). Major cement producing and consuming countries, on the other hand, continue to drop their cement
production due to high energy cost, strict trade policy, environmental issues and high labor cost as stated in Supino et al.
(2016), Ray and Pal (2010), and Sharma (2007). Hence, having a high global market demand for cement with cheap labor
and energy availability and flexible trade policy, Bangladesh has the opportunity to earn even more export revenues through
increased production of cement. Also, the prospect of this sector in Bangladesh is exceedingly promising because of
increasing growth in the urbanization as well as the economic sector, and the government's emphasis on massive
infrastructure projects. Although cement industry is a booming sector in Bangladesh with great potentiality, productivity
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Biswas, Kibria, Hasan, & Khan J. Prod. Sys. Manuf. Sci. (2020), 1(2), 0008
barriers in cement industry hinder its growth which can be observed by a large gap between production capacity (54
MMT) and actual production (31 MMT).
Productivity is a crucial component in the production performance of firms and often depends upon various factors.
It also reflects the scenario of an industry or organization how efficiently and effectively it transforms its inputs to outputs
(Syverson, 2011). Previous studies in different industries reveal a broad range of factors that significantly affect productivity.
Dasanayaka and Sardana (2017) tried to identify the factors affecting the productivity of small and medium scale rubber
manufacturing companies in Sri Lanka. They found that technology adoption, innovation, human factors, cost, and quality
of raw materials have a significant effect on rubber manufacturing productivity. Islam and Khadem (2013) investigated the
productivity factors of Oman construction industry and found that professionalism, the fairness of financial transactions,
supervisors’ skill, materials availability, and availability of complete drawing are most significant factors of productivity.
Coito et al. (2005) revealed that production schedule, plant operations, and maintenance, product quality, energy
consumption as well as efficient utilization of resources significantly affect the productivity of California cement industry.
Muthukrishnan (2011) intended to analyze the productivity factors of cement industry in India and revealed the fact that
efficient management, proper capacity, and resource utilization, infrastructure facilities and optimized extraction of labor
resource led to higher productivity and better performance. Capacity utilization, effective use of raw materials,
maintenance, rework, competition, motivation, and skilled labor are also reported as productivity factors of cement
industry in India (Burange and Yamini, 2009; Kumar, 2009; Krishna et al., 2013). Avami and Sattari (2007) showed that the
productivity of Iranian cement industry is greatly affected by energy consumption, production management, and new
technologies. Graisa and Al-Habaibeh (2011) investigated the factors behind low productivity of Libyan cement industry
and found that lack of training and personal development, and low motivation of worker due to lack of a management
strategy and reward structure were the main reason behind this problem. Saifuddoha et al. (2013) studied the supply chain
of cement industries in Bangladesh using value stream mapping and pointed out that elimination of wastes and non-value
adding activities from cement processing can significantly enhance the productivity. Hossain and Moudud-Ul-Huq (2014)
assessed the financial performance of cement industries in Bangladesh using Altman Z Score Model and revealed the fact
that cement manufacturing companies with higher productivity have higher profitability. Hoque et al. (2015) examined the
relationship between working capital management and profitability of cement industry in Bangladesh and concluded that
working capital management was a critical factor for productivity and profitability in this industry.
As seen from the above literature, the cement manufacturing sector in Bangladesh has the potential for meeting the
growing annual demand of Bangladesh. Also, this sector has an opportunity for enhancing the global cement market share
and earning more export revenues. However, productivity barriers in cement industries are hampering its growth. Like
other industries, productivity determinants of the cement industry include social, technological, managerial, financial, and
cultural issues; and widely differ from region to region. Hence, to improve the productivity, proper identification of the
factors affecting the productivity of cement industries in Bangladesh is of great importance. Besides, a systematic study
identifying proper and significant factors affecting the productivity of cement industries in Bangladesh is lacking. This
article, therefore, aims to identify the significant factors and their relationship with the productivity of cement industries
in Bangladesh. This study focuses on:
• Identifying process performance factors, human factors, financial factors, marketing factors, technological factors,
environmental and safety factors, managerial factors, Supply chain related factors, governmental and political
factors critical to the productivity of the cement industries;
• Ranking the identified factors by their contributions to the productivity of the cement industries;
• Reducing ranked factors into highly predictive productivity determinants of the cement industries; and
• Developing a structural equation model (SEM) in quantifying the relationships between the identified highly
predictive determinants and the productivity of the cement industries in Bangladesh.
2. Methodology
2.1 Formulation and administration of questionnaire
Based on the critical factors reported in the relevant published literature, a structured questionnaire was prepared
and later modified using experts’ opinion from managerial adroit personnel and academic expert. There were two parts in
the questionnaire. First part included demographic variables like age, job responsibility, and length of service of the
respondents. The second part included the factors affecting productivity of the cement industry in Bangladesh. As can be
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seen in Table 1, a set of fifty-six factors was identified from the published literature under ten broad categories namely
process performance factors, human factors, financial factors, marketing factors, technological factors, environmental and
safety factors, managerial factors, supply chain related factors, government and political factors.
Table 1: Critical productivity determinants identified from literature review
Category Productivity Determinants Sources
Process Performance Change in cycle time Istvan (1992), Zhao and Chua (2003), Bloom and Van
Factors Effective use of raw materials Reenen (2007), Lee et al. (2007), Feng at al. (2007),
Machine stoppage Shafeek (2012), Vilasini et al. (2014), Hoque et al.
Product quality (2015).
Proper utilization of capital
Rework
Unnecessary activities (movement, recheck etc.)
Financial Factors Inflation Huselid (1995), Kilic and Okumus (2005), Greenaway
Profits reinvestment et al. (2007), Butler and Cornaggia (2011), Doong et al.
Rate of interest (2011), Valderrama et al. (2012), Ray (2012).
Value addition through R&D
Marketing Factors Competition in the market Tsekouras and Daskalopoulou (2006), Noche and
Expenses on marketing Elhasia (2013), Chicu (2013), Backus (2019).
Market condition (product)
Marketing policy of the country
Product branding and promotion
Human Factors Change in employee cost Levine (1991), Datta et al. (2005), Egger and Egger
Employment generation (2006), Gong et al. (2009), Jiang et al. (2012).
Motivation
Shortage of skilled labor
Skill enhancing training
Corporate Social Community attitude Kim (2000), Doong et al. (2011), Sun and Stuebs
relation Factors Regional development (2013).
Social responsibilities
Technological Automation Xu (2000), Guellec et al. (2002), Fried et al. (2008),
Factors New product delivery mode Avila and Evenson (2010), Cassiman et al. (2010),
New technology Kromann et al. (2011), Syverson (2011).
On-site recycling and reuse
Product innovation
R&D implementation
Sustainable development
Environmental and Availability of personal protection equipment Blank and Valdmanis (2010), Iqbal et al. (2010),
Safety Factors Managerial policy for safety (insurance, medical Hamidi et al. (2012), Valderrama et al. (2012).
allowance)
Training on safety
Safety in the workplace
Worker attitude to safety
Workstation environment
Management Factors Culture of promoting knowledge sharing to the Bloom and Van Reenen (2007), Birdi et al. (2008),
subordinates Mojahed and Aghazadeh (2008), Syverson (2011),
Flexible and adaptable rules Noche and Elhasia (2013), Bender et al. (2018).
Instantaneous and independent decision making
Managerial skill
Strategic alliance (share resources to undertake a
specific, mutually beneficial project)
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Supply Chain related Application of lean tool Boyd and Pang (2000), Rasul et al. (2005), Li et al.
Factors Efficient plant operation (2006), Utlu et al. (2006), Alsyouf (2007), Hasanbeigi
Energy availability et al. (2010), Graisa and Al-Habaibeh (2011), Doloi et
al. (2012), Ray and Reddy (2012), Madlool et al.
Energy price
(2013).
Maintenance delay
Material availability
Pricing of raw materials
Supply chain management
Transportation cost
Variation of product
Government and Change in government rules Medina et al. (2003), Pandey and Dong (2009),
Political Factors Overall GDP of the country Bandara and Karunaratne (2010), McMillan and
Political stability Rodrik (2011).
Taxation
To rank the impact of identified productivity factors, a 5-point Likert scale was used and labeled as: 1= very low, 2=
low, 3= average, 4= high, and 5= very high. Moreover, in this study, Cronbach’s alpha was used to measure the internal
consistency of the questionnaire utilized. Voluntary nature of participation in this study and confidentiality of responses
was assured with an introductory letter. The questionnaires were sent to the respondents randomly. The questionnaires
completed were returned to the authors in a sealed condition. The questionnaires were filled while the respondents were
at their workplaces. They were asked not to take too much time to answer a question. Also, they were requested to always
adhere to the first spontaneous answer that came to their mind.
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Table 2: Reliability statistics for different categories of productivity components.
Component Category Number of Items Cronbach’s alpha (Cα)
Corporate social relation factors 3 0.604
Environmental and safety factors 6 0.614
Financial factors 4 0.667
Government and political factors 4 0.778
Human factors 5 0.672
Management factors 5 0.705
Marketing factors 5 0.725
Process performance factors 7 0.770
Supply chain related factors 10 0.791
Technological factors 7 0.651
As shown in Table 2, values of Cronbach’s alpha for process performance factors, human factors, financial factors,
marketing factors, technological factors, environmental and safety factors, managerial factors, supply chain related factors,
government and political factors are found satisfactory and hence, data can be analyzed further to conclude the results.
3.2 Demographics characteristics
From Table 3 showing the summary statistics of the demographic characteristics of the respondents, it is found
that job categories of the respondents were distributed as engineering (31.9%), administrative (17%), human resource
(12.8%), marketing (12.8%), production (14.9%) and finance (10.6%). Of 204 respondents, 63.9% were identified as early
middle age (31-40 years), 17% as a young adult (24-30 years), and 14.9% as late middle age (41-50 years). Moreover, 72.3%
of the respondents had at least five years of work experience in cement industries, while 27.7% of them were working for
less than five years at the time of the study.
Table 3: Demographic characteristics of the respondents
Demographic variable Category Percentage
Job category Administrative 17.0
Engineering 31.9
Finance 10.6
Human resource 12.8
Marketing 12.8
Production 14.9
Age group 24 – 30 yrs. 17.0
31 – 35 yrs. 51.1
36 – 40 yrs. 12.8
41 – 50 yrs. 14.9
Over 50 yrs. 4.50
Length of service 1 – 4 yrs. 27.7
5 – 10 yrs. 40.4
10 – 14 yrs. 14.9
Over 15 yrs. 17.0
This ranking suggests that productivity of the cement industries in Bangladesh is mostly affected by the issues
related to process performance, managerial skill and human factors, unavailability of skilled labor, skill enhancement
training facilities, automation, and new advanced technology. However, productivity is perceived to be least affected by
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changes in government policies, marketing strategy adopted by the companies, corporate social relationship, and financial
factors.
As shown in Table 5, five principal components – also termed as highly predictive components – were retained in
PCA for this productivity determinants analysis. Together these five principal components accounted for 56.3% of the
variation in the original fifty-six variables included in this study. The first principal component (PC1) was heavily loaded
on the effective use of raw material, proper utilization of capital, and product quality. The second component (PC2) was
loaded heavily on the price of raw material, availability of material, competition, and country marketing policy. The third
component (PC3) was loaded on the managerial skill, R&D implementation, job planning, and new technology — the
fourth component (PC4) on motivation, PPE availability, profit reinvestment, and managerial policy to safety. Finally, the
fifth component (PC5) was loaded on flexible and adaptable rules, changes in governmental rules, and stability of the
government. For ease of interpretability, these principal components were termed as “Process performance factors” (PC1),
“Marketing and supply chain factors” (PC2), “Management and technological factors” (PC3), “Human and safety factors”
(PC4) and “Government and political factors” (PC5). However, it should be noted that these do not represent any
categories; instead, they show the dominant indicators that define each of the five retained principal components and
hence, the five distinct determinants of productivity of cement industries in Bangladesh.
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between the identified principal components (PCs) and the productivity of the cement industries. Before developing SEM,
the linearity of the model was tested using a scatter plot and found it fit for SEM development.
Fig. 1 Structural equation model of the principal components influencing the productivity of cement industries
Fig. 1 demonstrates the causal relationship between the identified principal components and productivity of the
cement industries in Bangladesh. The indices of the model developed were Incremental Fit Index (IFI) = 0.949, Non-
Standard Fit Index (NNFI) = 0.894, Comparative Fit Index (CFI) = 0.929, Approximate Root Mean Square Residual
(RMSEA) = 0.033, P-value = 0.05, and Chi-square = 70.016 with the degrees of freedom = 14 indicating the model fitness.
From Fig. 1, it is evident that the ‘marketing and supply chain’ factor was the most significant factor – β value of
0.99 – affecting the productivity of cement industries in Bangladesh. Dominant marketing and supply chain issues were
the availability and pricing of raw material, competition, and marketing policies. Since clinker – 80.0% of the total raw
materials of cement – is currently imported (EBL, 2017), pricing decisions in the cement industries operating in Bangladesh
largely depend on the price and availability of the raw materials. Hence, following the considerable contribution of raw
materials in the cost structure, any movement in the price and availability of clinker and other raw materials eventually
affects the profitability as well as productivity of the cement manufacturing industries. Moreover, cement industries need
to reduce manufacturing cost and hence, the price of the cement through improving their productivity to remain
competitive in the regional and global market.
The second significant factor affecting productivity was ‘process performance’, with a β value of 0.65. Dominant
process performance issues were the effective use of raw materials, proper utilization of capital, and product quality. To
enhance the productivity through maximizing the raw material utilization, the need for innovative total productive
maintenance (TPM) strategy and usage of lean manufacturing tools are critical for cement industries; this finding matches
with Graisa and Al-Habaibeh (2011), Panwar et al. (2015), and Amrina and Lubis (2017). Again, Quayyum (2011), and
Hoque et al. (2015) also observed that proper working capital management has a significant positive relationship with the
productivity of cement industries in Bangladesh. Besides, according to Terziovski (2006), the productivity of
manufacturing industry increases with product quality. Hence, cement manufacturing industries should emphasize more
on quality management practices to gain high productivity.
‘Management and technological’ factor was the third significant factor having a positive effect on the productivity
of the cement industries with a β value of 0.48. Dominating issues were managerial skill, research and development (R&D)
implementation, job planning, and new technology. Managerial factors are found to have the most significant influence on
productivity compared to other potential factors, as also identified by Bloom and Van (2007). Avila and Evenson (2010)
showed that productivity varies with the use of technological equipment. Hence, adaptation of new technology along with
R&D implementation has a tremendous positive impact on the productivity of cement industries.
‘Human and safety’ factor was found as the fourth significant factor – β value of 0.30 – affecting the productivity of
cement industries in Bangladesh. Dominant issues were motivation, availability of personal protecting equipment,
managerial policy of safety, and worker attitude of safety. Safety enhancement program was found to have a positive effect
on productivity by Hamidi et al. (2012). Besides, motivation has a direct influence on improving productivity in a
manufacturing company as stated in Prasada Rao (2006), and Awan and Tahir (2015).
The least significant factor affecting productivity positively was ‘government and political’ factor with a β value of
0.20. Dominant issues were flexible and adaptable rules, changes in government’s rules, and political stability. Government
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and political factor play a significant role in the productivity of cement industries in Bangladesh. This result rhymes with
Bandara and Karunaratne (2010). Political instability discourages foreign investment, while the adaptable capability of
existing public policies significantly affect productivity. Hence, creating public policies to promote cement industries can
considerably increase the productivity of cement in Bangladesh.
4. Conclusion
This study was conducted with a view to identify the significant determinants and their relationships with the
productivity of cement industries in Bangladesh. Based on the results and discussion, the following conclusions can be
drawn:
• Out of fifty-six significant productivity determinants identified from the published literature, top seven factors
critical to productivity are effective use of raw material, managerial skill, motivation, and shortage of skilled labor,
skill-enhancing training, automation, and new technology. On the other hand, government rules, new product
delivery mode, expenses on marketing, marketing policy of the country, regional development, community attitude,
and inflation are perceived to be the bottom seven factors affecting the productivity of the cement industries.
• Process performance, marketing and supply chain, management and technological, human and safety, and
government and political factors are identified as highly predictive determinants of productivity of cement
industries.
• The productivity of the cement industries varies positively with the identified principal determinants. Of five
principal determinants, ‘marketing and supply chain’ is the most significant factor affecting the productivity of
cement industries followed by ‘process performance’ factor.
Moreover, similar research can be carried out in such industrial sectors as small and medium enterprises (SMEs),
garments and apparel industries, textile and leather industries, and food industries in Bangladesh, where productivity
management is still considered to be a critical issue, and a specific productivity growth needs to be maintained to remain
competitive in the global market.
Authors Contribution Research planning, questionnaire formulation, data analysis, editing and overall supervision: Dr.
Mohammad Muhshin Aziz Khan; Data collection, data analysis, writing: Pronob Kumar Biswas; Data
collection and literature review: Mehedi Hasan Kibria, and Jahid Hasan.
Acknowledgement The authors are grateful to the Department of Industrial and Production Engineering, Shahjalal University
of Science and Technology for providing their administrative support to conduct this research work. The
help extended by chief executives and experts of different organizations at questionnaire formulation and
data collection stages are sincerely acknowledged.
Disclaimer The content and claims presented in this journal are of the authors only and do not necessarily represent the
views of the editors and publisher.
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