No. Export Wing, Ministry of Commerce The People's Republic of Bangladesh The Study on Potential Sub-Sector Growth for Export Diversification in the People’s Republic of Bangladesh PILOT PROJECT COMPLETION REPORT March 2009 JAPAN INTERNATIONAL COOPERATION AGENCY UNICO INTERNATIONAL CORPORATION IDD JR 09-014 Abbreviations Abbreviation : English Japanese A APO : Asian Productivity Organization アジア生産性本部 B B2B : Business to Business 企業間取引 BASIS : Bangladesh Association of Software and Information Services バングラデシュ・ソフトウェア・情報サービス協会 BCC : Bangladesh Computer Council バングラデシュ・コンピューター評議会 BIK Japan : Bangladesh IT Kumiai Japan バングラデシュIT組合 BIISS : Bangladesh Institute of International and Strategic Studies バングラデシュ国際戦略研究所 C CAD : Computer Aided Design コンピューター支援設計 CIDA : Canadian International Development Agency カナダ国際開発庁 D DAC : Development Assistance Committee （OECD）開発援助委員会 DANIDA : Danish International Development Assistance デンマーク国際開発援助 E EPB : Export Promotion Bureau （バングラデシュ）輸出振興庁 G GP : Green Productivity 緑の生産性 I IBPC : ICT Business Promotion Council （バングラデシュ）ICTビジネス振興評議会 IE : Industrial Engineering 生産工学 ITES : IT Enabled Service IT対応サービス J JDP : Jute Diversified Products ジュート多様化製品 L LEIC : Local Enterprise Investment Centre ローカル企業投資センター JICA : Japan International Cooperation Agency 国際協力機構 N NPO : National Productivity Organisation 国家生産性本部 O OECD : Organisation for Economic Co-operation and Development 経済協力開発機構 P PDM : Project Design Matrix プロジェクト・デザイン・マトリクス PIC : Productivity Improvement Cell 生産性改善セル Q QC : Quality Control 品質 S SE : System Engineer システム・エンジニア SI : System Integrator システム・インテグレーター T TQM : Total Quality Management 総合的品質管理 Table of Contents Chapter 1 Jute Products Industry 1.1 Design of the Pilot Project ..........................................................................................1 - 1 1.1.1 Design Concept ...................................................................................................1 - 1 1.1.2 Scope of the Project.............................................................................................1 - 2 1.1.3 Organization for Project Implementation............................................................1 - 9 1.1.4 Implementation Schedule....................................................................................1 - 14 1.2 Implementation of the Pilot Project.............................................................................1 - 17 1.2.1 Flow of Activities in the Pilot Project.................................................................1 - 17 1.2.2 Timetable for Mill Visits During the Pilot Project..............................................1 - 19 1.2.3 Description of Methodologies Used for the KAIZEN Activities........................1 - 25 1.2.4 Overall Effects of KAIZEN Activities................................................................1 - 38 1.3 Terminal Evaluation of the Pilot Project.....................................................................1 - 42 1.3.1 Background Data and Information for Evaluation and Examination..................1 - 42 1.3.2 Examination of Project Performance ..................................................................1 - 43 1.3.3 Examination of the Implementation Process.......................................................1 - 43 1.3.4 Evaluation Based on the Five Criteria.................................................................1 - 44 1.3.5 Conclusion, Recommendations, and Lessons Learned .......................................1 - 52 Chapter 2 Computer Software Industry 2.1 Design of the Pilot Project ..........................................................................................2 - 1 2.1.1 Design Concept ...................................................................................................2 - 1 2.1.2 Scope of the Project.............................................................................................2 - 2 2.1.3 Organization for Project Implementation............................................................2 - 7 2.1.4 Implementation Schedule....................................................................................2 - 11 2.2 Implementation of the Pilot Project.............................................................................2 - 14 2.2.1 Output 1: Brochures of Participating Companies................................................2 - 14 2.2.2 Output 2: Brochure for Software/ITES Industry of Bangladesh .........................2 - 16 2.2.3 Output 3: Database of Participating Companies .................................................2 - 18 2.2.4 Output 4: Market needs of Japanese Companies.................................................2 - 22 2.2.5 Output 5: Establishment of Bridge SE System ...................................................2 - 27 2.2.6 Output 6: Seminar ...............................................................................................2 - 30 2.2.7 Output 7: Match-making Mechanism through Bridge SE System......................2 - 33 2.3 Terminal Evaluation of the Pilot Project.....................................................................2 - 40 2.3.1 Background Data and Information for Evaluation and Examination..................2 - 40 2.3.2 Examination of Project Performance ..................................................................2 - 41 i 2.3.3 Examination of the Implementation Process.......................................................2 - 41 2.3.4 Evaluation Based on the Five Criteria.................................................................2 - 42 2.3.5 Conclusion, Recommendations, and Lessons Learned .......................................2 - 50 ii List of Figures and Tables Chapter 1 Jute Products Industry Figure 1.1-1 Pilot Project Concept for Jute Products Industry ........................................1 - 4 Figure 1.1-2 5S Explained by Element ............................................................................1 - 6 Figure 1.1-3 National Productivity Organisation (Organization Chart)...........................1 - 11 Figure 1.1-4 Work Schedule for Pilot Project for Jute Products Industry .......................1 - 16 Figure 1.2-1 Typical Production Process of Jute Mills....................................................1 - 18 Figure 1.2-2 Three-Round Mill Visits .............................................................................1 - 19 Figure 1.2-3 Positioning of the KAIZEN team................................................................1 - 26 Figure 1.2-4 Snap Reading Method .................................................................................1 - 27 Table 1.1-1 5S in Various Language ..............................................................................1 - 5 Table 1.1-2 PDM (Project Design Matrix) .....................................................................1 - 7 Table 1.1-3 KAIZEN Working Group............................................................................1 - 12 Table 1.1-4 Participating Companies in the Pilot Project for Jute Products Industry........................................................................................................1 - 13 Table 1.1-5 「KAIZEN」Team Members.........................................................................1 - 14 Table 1.2-1 Visits to Head Offices and Jute Mills..........................................................1 - 20 Table 1.2-2 6-Day KAIZEN Activities (1st Round).......................................................1 - 20 Table 1.2-3 Visits to Head Offices and Jute Mills..........................................................1 - 22 Table 1.2-4 5-Day KAIZEN Activities (2nd Round) .....................................................1 - 22 Table 1.2-5 Visits to Head Offices and Jute Mills..........................................................1 - 23 Table 1.2-6 5-Day KAIZEN Activities (3rd Round)......................................................1 - 23 Table 1.2-7 Visits the Head Offices and Jute Mills (4th Round)....................................1 - 24 Table 1.2-8 Measurement of Ring Spinning Stoppage...................................................1 - 28 Table 1.2-9 Measurement of Weaving Machine Stoppage.............................................1 - 29 Table 1.2-10 Results of Machine Inspection ....................................................................1 - 31 Table 1.2-11 Causes of Fabric Defects.............................................................................1 - 32 Table 1.2-12 Causes of Weaving Machine Stoppage.......................................................1 - 33 Table 1.2-13 Causes of Troubles in Ring Spinning..........................................................1 - 33 Table 1.2-14 Thread Breakage in Beaming/Sizing...........................................................1 - 34 Table 1.2-15 Sample : Causes and Countermeasures fore Fabric Defects .......................1 - 35 Table 1.2-16 Sample of Job Standard for Model Mill......................................................1 - 37 Table 1.2-17 Summary of Improvement (%)....................................................................1 - 38 Table 1.2-18 -Spinning Process- KAIZEN Target and Actual Figures During Pilot Project (in 2008)..........................................................................................1 - 39 iii Table 1.2-19 -Weaving Process- KAIZEN Target and Actual Figures During Pilot Project (in 2008)..........................................................................................1 - 40 Table 1.3-1 Productivity