Production lead time improvement by implementing operation management strategies in a zipper and button manufacturing company

Abstract

YKK Bangladesh Pte. Ltd. is a part of the giant multinational fastener manufacturing company YKK Corporation, originated in Japan, which was founded by Tadao Yoshida in 1934. This company mainly manufactures zippers, snap & button and other fastener items for Ready Made Garments (RMG). This company has very enriched management principle, policies and culture. The production capacity of this company is around 45,00,000 pieces of zipper and 13,00,000 pieces of Button per day. There are several departments like HR, Compliance, Safety, Product Development, Production, IT, Accounts, Export-Import, Sales, Marketing, Planning and Operation, Maintenance and so on. The Planning and Operation team works dynamically to optimize the production processes, allocating the resources effectively, making production flow efficient, ensuring raw materials and improving the overall productivity. In this report, a brief overview of YKK Bangladesh Pte. Ltd. is given and the operation management activities are analyzed. Lead time is the time that is required to produce a final product from the raw materials through various manufacturing processes. It is a critical issue for operation management. In this study lead time perfection by implementing the operation management knowledge and skills in maintaining production and delivery, lead time was the main focus.