Productivity & Quality Improvement Initiatives

The Client:

The client is a Delhi based womens wear exporter in business for over 25 years. It has a production capacity of over 03 million pieces per year and employs over 1000 people. Their key customers include high street retailers in U.K., Ireland, France, Germany, Australia etc. The customers see rapid product development and understanding of fashion trends as a key strength of the company. This project was initiated on behalf of one of their key customers from UK with the objective of improving productivity, strengthening quality systems while improving the social standards. 

The Challenge:

Low productivity

High rework and rejection levels effecting product quality

Limited interdepartmental co-operation for achieving common goals

Absence of scientific methods to determine production standards


The intervention by RBC consultants involved: 

Industrial Engineering Department was established.

Extensive training was provided to the IE and production teams on productivity improvement techniques.

RBC IT based productivity tools were introduced.

Factory teams were trained in the concept of Internal Customer-Supplier Chain with institutionalization of feedback mechanism.

Quality system was strengthened through companywide training and implementation support.

Business Impact:

The productivity improvement ranging from 30% to 57% was achieved in the pilot production lines during the project implementation.

The percentage defective rate reduced by 50.5% thus reducing rework and improving quality.

The interdepartmental co-operation improved substantially.The learning and implementation was spread over in 10 lines by internal team.

The projected monthly cost benefit was estimated at INR 550000.00 to INR 600000.00.

Road maps for the future were chalked out and provided to the factory team for next level of improvement.

The renewed energy and participation in the improvement process displayed by the factory team was highly appreciated by the international buyer.