Tan Phuong Company: Improves the product quality and competitiveness

Tan Phuong Co., Ltd., located in Phuong La craft village, Thai Binh province, is one of the enterprises selected to participate in the project “Supporting craft village enterprises to apply Kaizen improvement tools to improve quality and productivity” of Foreign Trade University. Tan Phuong specializes in manufacturing towels, napkins, cotton towels for domestic and export markets.

The production process of the Company is carried out with the following stages: importing and distributing yarn, weaving carpentry towels, importing carpentry towels, bleaching and dyeing, cutting sewing (including vertical sawing, vertical cutting, horizontal cutting, horizontal sewing and thread press), sorting, needle checking, finished product packaging.

Initially, the project implementation team conducted a survey to evaluate the current situation, find opportunities for improvement to improve productivity and product quality of the Company. At the time of the survey, the percentage of defective products of Tan Phuong was quite high, leading to an increase in production costs and frequent rejections of orders by customers, affecting the company’s brand name. The main reason for the above conditions is that the management team as well as the workers have not been trained in the management system and the quality control and inspection tools.

On that basis, the project implementation team detailed advice to businesses on the application of the following improvement tools:

– With the cutting area: Analyze the employee’s operation to reduce redundant action, propose an improvement plan to improve the productivity of the horizontal and vertical section. In addition, reallocate the ground to reduce moving waste.

– For the sewing sector: Analyze the workers’ operations, record errors, propose solutions to overcome errors to improve productivity, quality and reduce waste of sewing workshops.

– Make a rule to limit employees from bringing food and personal belongings into the workshop to ensure hygiene in production;

– Develop and apply a mechanism to care and encourage employees to create labor motivation for employees.

After 03 months of implementing the model applying innovative tools in production, Tan Phuong has obtained the following results:

– Cutting area: 25% cycle time reduction of cross section for TTXK towel 36x 80;

– Sewing area: Eliminate 50% of wasted time traveling on the sewing line and sorting;

2.33 times more errors detected thanks to improved operations and overcoming waste on the line;

– Increase 2.6 times the number of workers working in groups to emulate productivity and general hygiene practices.

– Workshop rules are strictly enforced by workers, down by nearly 20%; Five times more notifications on the Rules to remind Kaizen adoption and building corporate culture.

– Protection of the quality management system: 100% of employees voluntarily abide by the rules and follow the process of ensuring quality standards of exported products;

– Regarding the motivational mechanism for employees: 100% are provided with 02 sets of labor protection free of charge per year to ensure labor health; 100% of employees committed to regular long-term work will sign a labor contract and will enjoy the policies according to the Labor Law; 100% of employees are entitled to rest when sick and visit when sick; The fathers of the father and mother were visited when seriously ill and died.

Under the consultation and support of the project implementation team, Tan Phuong’s staff have made efforts to improve and obtained very encouraging results. This will be a premise for Tan Phuong to continue to maintain continuous improvement activities at the Company in the coming time.

Productivity and Quality Office