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Absenteeism Effecting on Production capacity : Findings and Solution

• Absenteeism effecting in Production capacity: Findings and Solution  In garment sector our absenteeism bench mark is 3%. But it is very difficult to keep in track. Most of the factories absenteeism is 8% to 10% . Definitely high absenteeism create less production. Less production means lose the production capacity. Now the question is how we keep our capacity on track? It’s a million dollar question. Ok , now let’s see the capacity equation. Capacity = Direct strength x Working minute x Plant Av.Efficiency x (1-Ab%) / SMV Based on this equation we can compare two different absenteeism how acting with capacity. Let’s see  below :- Case 1 : For 3% Absenteeism a)       Factory Direct strength – 90 b)       Factory Average efficiency – 55% c)       SMV – 22.03 Minute Then capacity for one hour = 90X60X55X(1-3%) / 22.03X100                                                 = 130 Pcs Case 2 : For 10% absenteeism a)      , b) and c) – All Information is same as above Then capacity for one hour = 90X60X55X(1-10%) / 22.03X100                                                  = 121 Pcs Based on two cases – if absenteeism increase from 3% to 10% then  production will be  loses for one hour = 130-121 = 9 Pcs ð  Per day loses = 90 pcs ð  Per month loses = 2340 pcs It is just Mathematically findings . But everybody knows how difficult to manage 10% absenteeism in production floor. So far it is very tough to manage Extra Feed of the arm and Kansai m/c operator. Still our factory not have enough strong Human resource department.  Maximum people does not know how to motivate the worker based on Maslow’s Hierarchy of needs in absenteeism cases or Migration cases or any other cases . Every employee should right to get Human motivation , Management training  and Personal development. They have not enough knowledge  about the X-Y Theory. So, we can’t go by this way. Then how we can balance the production floor at the time of abnormal absenteeism ? Yes we can control . But first of all we need  some multy skilled operator to make Reserve strength. Normal absenteeism time we will use this reserve strength at sample section . In our country sample section always rush- They can easily get more benefit to use this buffer. To make Reserve strength – we can use our industrial engineers to develop operators for much more operations and deferent machines. This is called Skill Inventory . By this Skill inventory list we can pick our required strength to make reserve Strength . In absenteeism time  we can easily use this strength to balance the production line. But we need to paid money to this extra strength  - From capacity equation we have found that every day we have lose 90 pcs . If per pcs C&M is 95 taka then per day lose = 95 x 90 = 8550 taka. ----------------------------ref-1 If Machine operator is 65 then for 10% absenteeism we need 6 more operator to balance the line . if per operator monthly salary is 9000 taka then per day salary is 350 taka. For this 6 extra strength per day need = 350 x 6 = 2100 taka --------------------------ref-2 From reference 1 and 2 we have found that if we not use Reserve Strength to balance the absenteeism then per day we have lose 8550 taka. If we use this strength to get capacity from production then we have to paid 2100 taka  but we will get 8550 taka .So balance is ( 8550 – 2100 ) = 6450 taka i.e. we can earn more 6450 taka by using reserve strength. It is only one thing but the main thing is we can take our production capacity on track which we have committed to buyer , we can produce our product on time, Goods shipment going  on time after all no air freight – no losing the money.   Thanks Tabassum Hasan Ahmad Manager – I.E. & Planning Misami Garments LTD. Cell # 01782492634

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