Browsing by Author "Ermias, Tesfaye (PhD)"

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    Assembly Operation Productivity Improvement for Garment Production Industry through the Integration of Lean and Work-Study A Case study in Bahir Dar Textile Share Company, in Garment
    (Addis Ababa University, 2021-10) Mequanent, Ewnetu; Ermias, Tesfaye (PhD); Fitsum, Getachew (Mr.) Co-Advisor
    Productivity improvement is a very important issue for manufacturing industries to survive in the global competition. A nation’s effort on productivity-improving is mandatory and its achievement of productivity is one of the major weapons to attain cost, time, and quality advantages for competition. Ethiopian garment industries are not competitive in the global market share. The primary reason is low productivity. This study tries to investigate both internal & external productivity factors of the garment industry and proposed genuine solutions using integrated techniques of lean & work-study. So, this paper aims to provide the users are understanding easily the main productivity factors of the garment industry and present the way how to develop a solution using these integrated techniques. The main objective of the research is to enhancing productivity using integrated techniques of lean & work-study for the Ethiopian garment industry, specifically in the case company. To accomplish this objective a literature review has been conducted to get a realistic understanding. The existing productivity status, improvement practices, experience, and productivity factors of the garment industry have been assessed using open interviews and secondary data from the sector. To make this study practical and realistic, a case study has been conducted on the Bahir-dar textile share company in, garment. And the data was collected using interviews, direct observation, recording, measuring, questionnaires, and secondary data. The existing result indicates that the productivity of the Ethiopian garment industry and the case garments is much lower than the government plan and their production targets as well as compared with other best practice garment industries. Due to this, the garment industry has been faced multidimensional productivity factors related to human, method, control, process, and product. To enhancing the overall productivity improvement of the garment industry that has been using the combined techniques & tools of lean and work-study, due to, the nature of garment industry productivity factors are multidimensional as a result a single tool or model hasn’t boosted a significant change. Consequently, to solve the garment industry productivity factors that should be used an integrated techniques & tools for enhancing a significant productivity improvement of the case company and these integrated techniques has been answered the research question.
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    Developing Structural Relationship of Motivational Factors and Their Impact on Labor’s Relative Efficiency: A Case GMM Garment PLC
    (AAU, 2018-07) Yordanos, Zewdu; Ermias, Tesfaye (PhD)
    Creating motivated employee is one way of optimizing labor efficiency in any industrial sector. Employee motivation can be enhanced either by external or internal factors. Now a day’s Ethiopian apparel industry is one path for export earnings. The government facilitates industry parks to attract potential foreign investors. Manufacturers in the industry park raised the issue of recruiting, employee turnover, and worker demotivation as a key concern. This paper aims to identify theoretical relationship of motivation factors and to analyze their impact on labor relative efficiency at GMM Garment PLC. Structured questionnaire, informal interview, data records and related literatures are used as a data collection tools. Structural Equation Modeling is used for confirmatory factor analysis. The finding show extrinsic motivation factor such as monetary incentive, non-monetary incentives, job related incentives and company related motivational factors are highly significant factor for productivity. Fuzzy expert system is also used for ranking motivation factors. The result is similar to confirmatory factor analysis which is extrinsic motivation factors have high significant impact on productivity. Data envelopment analysis used to measure operator’s relative efficiency and motivational factors are considered as input and output variables. The result shows that both intrinsic and extrinsic motivation factors have significant impact on labor’s relative efficiency. Sensitivity analysis result indicates monetary incentive is the highest significant factor among the other identified motivation factors.
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    Efficiency Analysis and Performance Improvement of Bottling Production Line (Case on: East Africa Bottling Share Company)
    (2018-10) Teklay, Araya; Ermias, Tesfaye (PhD); Hileluaule, Mamo (Mr.) Co-Advisor
    In response to today's highly competitive business environment, companies are forced to analyze and improve their existing manufacturing system continuously to minimize production losses due to production disturbances that hinder the system efficiency, performance and reduce profitability. The major problems of the case production line are related with low throughput, high inefficiency losses, and higher raw material cost etc. As a result, over all equipment efficiency of the production line is blow target (management plan) and it was challenged to fulfilling the expected production plan (volume). Therefore, the purposes of this study are to evaluate line efficiency and improve performance of the bottling production line. Researches in relation to production line, productivity, efficiency losses, OEE analysis, improvement, simulation modelling has been reviewed, primary and secondary data have been collected from the case company through direct observations, check sheets. Also, different tools such as OEE, Pareto chart, fish bone diagram, Arena simulation has been utilized, and root cause analysis, brainstorming sessions has been conducted in analysis and improvement process. Efficiency analysis of line is has been done using OEE, as a result the disturbances that results production losses are studied, major efficiency losses are identified, focus of improvement areas with associated challenges and their root causes has been investigated, then corrective actions, counter measures and action plans has been suggested as strategy for improvements. Also, model of the real production line has been developed Using Arena software, and validated. After analyzing the production line model, line behavior, disturbances, efficiency losses under varying set of circumstances were studied and performance measures quantified. Also, a number of problems including; short stops, starvation and blockage were identified as problems. Then a set of changes and modifications on the actual system simulation model has been suggested. Finally, an improved model was proposed where line availability and performance can be enhanced by 11%, line OEE increased by 21.4% and raw material loss and cost reduced. Therefore, the achieved results in the proposed model can be easily adapted after similar studies and the company's targets can be achieved and profitability, competitiveness can be improved significantly.
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    Enhancing Productivity of Mixed-Model Assembly Line in Tikur Abbay Shoe S.Co
    (Addis Ababa University, 2018-10) Menbere, Tilahun; Ermias, Tesfaye (PhD)
    Tikur Abbay shoe S. Co is one of leather industry in Ethiopia, which produces a variety of shoe model for local and export markets. The research is mainly focus on the export product, men shoe (HARBER) model, production condition has different problem not good working environment and less production efficiency this means the company not satisfies internal and external customer interest such as quality, delivery time and work environment problem. Footwear assembly tasks are very repetitive and provide the operators with little opportunity for rest. Many operators perform only one operation with no job rotation. The repetitive nature of the job caused work overload and that was made worse by other workers delivering unfinished shoes to the operators. The general objective to enhance productivity and increase competitiveness of company by export product to meet international quality and workplace ergonomically comfortable, improve work environment and safety requirement. The methodologies for the study follows are discussion with target group, direct observation, face-to-face interview and distribute questioner to collect ergonomic problem fact and observe production section to record working environment problem this all use to collect the research useful data. Data analysis is interpreted through a descriptive method by using MS–Excel 2016 software, were used to present data in pie chart, Minitab 16.2.4 software were used to prioritized shoes model and MS-Visio were used to draw root causes analysis of work load and to illustrate the processes layout. The finding of the study shows that about 33.6 % of defected product is caused by operators due to work overload in the production stations and due to existing layout problem 28 m distance which is unnecessary movement and ergonomic problems. Therefore, improving human ergonomics problem is used to reduce work overload and worker health problem, improve work condition and improve chair and table design. If proposed layout of production area implemented and ergonomics problem is solved the output of company increased by 38 pieces of shoe per day and 33.6 % of defected products are solved and the production efficiency is increased by 28.19 % which is 88.95%.
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    Labor Productivity Analysis and Factors Affecting Oromia Credit and Saving Share Company
    (Addis Ababa University, 2018-10) Jifara, Mirkena; Ermias, Tesfaye (PhD); Wogene, Tesfaye (Mr.) Co-Advisor
    Now day’s productivity is an issue of any organization that they talk about it and give emphasis to survive and compete in the dynamic market. Among other partial productivities, several research works indicated that the productivity of labor is the prime concern and it is considered as the engine of any kind. Because much of the success of any organization relies up on the productivity of its workforce and for many businesses the most significant cost is labor, all efforts are focused on improving workforce productivity. Never the less the Oromia Credit and Saving Share company has been indicating reasonable growth in the first decade of its operation, its staff productivity was very low as compared to the resource allocated for the performance of its huge workforce. In an attempt to improve this, this study aims to analyze the staff productivity of OCSSCO and identify the factors affecting it. The study chosen labor productivity based on the results found from secondary data of the company and includes an analysis of statistical correlation of primary data between the factors affecting labor productivity. The study used productivity index concept to identify which partial productivity adversely affecting OCSSCO’s productivity and confirmatory factor analysis to identify the vital factors affecting the staff productivity of it. The findings of this thesis indicated that, the significantly factors impacting staff productivity of OCSSCO are motivation and commitment, staff retention and working environment factors. Even though the impact of leadership and staff training results investigated on labor productivity of OCSSCO were not significantly supported, these two factors are strongly correlated with the other three left factors which their effects directly influence these factors. The developed conceptual frame work model helps the company to use human resource efficiently and effectively by improving the vital factors.
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    Multiobjective Resource-Constrained, Project Scheduling Problem In Habsha Cement Share Company
    (Addis Ababa University, 2017-06) Hiwot, Wubishet; Eshtie, Berhan (PhD); Ermias, Tesfaye (PhD)
    In construction industry project, Project Manager usually manages and executes multiple objectives simultaneously within their portfolio. This involves sharing of limited resources such as funds, equipment, work force, and others among different projects, which increases the complexity of the scheduling process. The allocation of scarce resources then becomes a major objective of the problem and several compromises should make to solve the problem to the desired level of optimality. In such cases, contractors are generally concerned with optimizing a number of different objectives, often conflicting among each other. Thus, the main objective of this research is to develop a multiple objective project-scheduling model under resource constraints. Objectives include time, cost, and resource balancing. The model aims to help project manager in devising schedules that obtain optimal/near optimal tradeoffs between different projects’ objectives, namely: duration of projects, total cost, and resource fluctuations. Moreover, the model offers the flexibility in selecting the desired set of objectives to optimize. Management model built in order to achieve the main objective, which involves the development of: (1) a scheduling model that establishes optimal/near optimal schedules for construction industry projects. Management models linked with the designed optimization model, which consequently performs operations of the elitist Multi-objective Genetic algorithm (MOGA) technique, in three main phases: (1) population initialization; (2) fitness evaluation; and (3) generation evolution. The optimization MMMOGA model tested using large scale of cement industry project presented to demonstrate the practicality and efficiency of the proposed model and optimization. Finally, an automated tool using C++ language programming built with a friendly graphical user interface to facilitate solving multi-objective scheduling optimization problems for project manager and practitioners.
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    Presented in Partial Fulfilment of The Requirement for The Degree of Master of Science in Mechanical Engineering (Industrial Engineering Stream)
    (Addis Ababa University, 2018-10) Adem, Tadesse; Ermias, Tesfaye (PhD)
    This main concern of this study is to improve the productivity of the factory by LEAN approach. The purpose of lean in production is to increase productivity, improve product quality, reduce lead time and eliminate manufacturing waste. The study has been conducted on C&H Garment factory that produces different men’s and women’s garment products, located in Bole Lemmi industry park Addis Ababa. On an earlier stage, a literature review on lean was conducted, from the creation of the concept of LEAN to its main tools and techniques. Valuable data has been collected from the case study (C&H Garment Company) by observation, and interview from management body. The collected data has been analyzed according to the relevant time. For this purpose MS-excel, statistical tools, MS-Visio have been applied; in addition to these, industrial or lean tools were considered. The research approach considers the existing factory manufacturing culture and the lost events with respect to lean tools and techniques, to determine the lean tool gap the main waste of lean are identified with case company. Besides waste of lean absenteeism is one crucial event on factory productivity, included on study. Finally, lean productivity improvement methods were propose. But in practical validation of lean tool 5why methods have been exercised to improve rework and defects , based on the average defect rate ,production rate, cycle time, production costs were improve by 40.91%,50.85%,13%,40.91%, respectively. Cellular manufacturing and other approaches have not been implemented, although the company has been left prepared for an implementation in the future.
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    Productivity Improvement of Anbessa shoes S.C through Lean Tools
    (Addis Ababa University, 2021-07) Etabezu, Nemera; Ermias, Tesfaye (PhD); Ashenafi, Adugna (Mr.) Co-Advisor
    Ethiopian footwear manufacturing companies have limitations to compete in the global market. This sector is considered to play major role in increasing country’s economy especially in export. But it is not competitive in the international market due to various internal and external factors. This study was a case analysis on the development of an improved model that works to enhance productivity in the selected shoe factory. The procedures include literature survey, data gathering, and interview with the experts and factory observation to assess the existing work flow. The data analysis was done using Pareto analysis, Cause and effect diagram, lean maturity, value stream mapping and an AutoCAD. Lean manufacturing is to remove waste, decrease the lead time, increase the PCE and rise the profit and productivity .This work addresses the implementation of lean tools by selecting a gentle man shoe model known as SAWA Lafric and observed its production activity then evaluate Process Cycle Efficiency (PCE), Value Added (VD), Non Value Added (NVD) activities, lead time and takt time. The current state and after the implementation of lean tools, the PCE, takt Time and lead Time is 7.79%, 61,234sec, 14.05sec/pair and 17.08%, 27,949sec, 11.16sec/pair respectively. Lean maturity of the case company assessed and Color codes were assigned for the maturity level and the assigned color codes were Green: Above industry baseline, Yellow: At or near industry baseline and Red: Below industry baseline. The green , yellow and red code for existing lean maturity were 0,17 & 3 respectively and after the implementation of lean tools the code became 11,9 & 0 respectively. By this study the lean wastage was evaluated; the existing machine layout was assessed and new machine layout is proposed using AutoCAD. After all the production flow was rearranged by minimizing several NVD times such as transportation, waiting, inspection, etc. a productivity improvement model was proposed. This model is significant as it can resolve the identified problems in awareness Creation on management and manpower, improvement strategies, future VSM, as well as continual improvement of the process.
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    Simulation based Inventory Management Analysis: The Case of GMM Garment
    (Addis Ababa University, 2021-11) Samson, Tesfaye; Ermias, Tesfaye (PhD)
    The aim of this research is to develop discrete simulation model of inventory management system with the help of Arena software, identify the existing problem within inventory management system of the factory, and finally propose a better remedial solutions. This research is a case study on GMM Garment Factory that located in Addis Ababa, and producing different clothing items for foreign markets, by importing most of its raw material inputs. The questions set to provide answer to this research were “how the current inventory management system of the factory operates”, and “how the identified problem of the system be resolved so as to operate the system at a minimum cost”. This study is a cross sectional research, utilized discrete dynamic simulation-modeling methods to address the issues of stochastic nature of demand and supply sides of the factory. The sample selection was purposive from the record of the warehouse, and in-depth interview with the personnel of the factory. The items selected for this study were from both raw materials inputs and finished products. The finding of the study is that GMM garment factory has been facing problem of stock out and capital tied up. Because of stock out, the factory has lost about Birr 2,987,410 revenue in May 2019, and also lost about Birr 1,785,078 revenue from foreign customers in August 2020. There is a capital tied up worth of Birr 445,675 that resulted from unplanned procurement of raw material inputs for the production of protection masks for COVID 19 pandemic. The stock out and capital tie problems of the factory emanated from poor inventory management system which can be resolved through introducing inventory management system model, and be able to reduce total inventory cost from Birr 847,003 to Birr 597,915 of which difference could increase the factory’s revenue and profit from the initial one by about 29%. Therefore, this improvement in revenue and profit of the factory can happen by simply decreasing stock-out, waiting time and avoiding tied up working capital so that inventory cost of the factory can decrease to a minimum level.