One of BDCs previous projects the USAID-Funded Tatweer Project Redesigns a Factory and Enhances Business

One month after the General Manager of The International Co. for Jewelry Manufacturing attended the 5S training workshop organized by the USAID- funded Tatweer Project, the company’s production time and production cost have been reduced and each product is now compared to a standard set by management to ensure a high level of quality.

The International Co. for Jewelry Manufacturing was established by a well-experienced entrepreneur in 1982, and this jewelry making factory has been providing the local market with high quality items for twenty-seven years. The company mass produces particular traditional items specifically for the local market, and it also customizes items for export markets.

After attending the 5S workshop the General Manager appreciated the importance of the 5S techniques that were presented and realized the significance of applying them in every department. In addition, Tatweer decided, to send a consultant to the factory for a full day to help suggest ways to implement the 5S techniques presented in the workshop.

Mr. Al-Lama’, the company’s General Manager, stated that "The USAID-funded Tatweer Project has improved our factory in many ways. Previously the warehouse was unorganized, untidy, and the layout was poor. Now the warehouse is tidy and clean which helped us minimize cost as we now know the exact quantity of stock available . More importantly we have stopped buying things we don't need because everything is arranged properly”. Many of the goals, such as, eliminating waste, reducing search times, reducing stress, and improving safety measures have been met and the factory was even able to gain extra income from selling the unwanted dies.

Changes have been made in three areas of the company:

1) Inventory Store:

The inventory store was un-organized and untidy. Workers placed materials and supplies anywhere they found an empty space.

The store before the 5s workshop

 

     

The store after the 5s workshop

 

2) Dies Shelf:

Space was limited on the dies shelf due to many unused dies that were stored there. In order to identify the unwanted and useless items, a technique called Red Tagging was used, where unwanted items are moved to a storage area, thrown out or sold.

 

The un-used dies that were removed and ready to be sold or stored.

 

3) Faceting Department:

The Faceting department is the final stage of the production process. Diamond tools are used to cut and finish the bangles to their final shapes and due to the large variety of bangles produced, there is an assortment of cutting diamond tools which are replaced after they are used a certain amount of times. Previously the company wasted crucial production time finding the right cutting diamond, in some cases work was paused for a couple of hours to find the right diamond cutters and in other cases workers discovered that the required tool was finished and it was necessary to re-order the tool from the supplier. The consultant recommended a simple solution; to create a board to hold the cutting diamonds and label each holder with type and size of the cutting diamond. It was also recommended that a marker was put on each holder to signify when it was time to re-order the cutting diamond in order to avoid running out of these tools.

     

Cutting diamond holder

Each holder shows the size and kind of each cutting diamond and the Re-Order point.

Another suggestion was a “Shadow Box Board” which would reduce the time searching for the required production tool and hence reduce the overall production time.
Mr. Al-Lama’ is pleased with the results as the workers no longer waste time looking for tools. At the end of the day the supervisor is required to see if any tools are missing and is responsible for putting them back in their place.















The last addition made was a Shadow board which shows the different types of bangles produced and is visible to the workers.

This ensures a control attribute in the department and that the products are compared to standards set by the management.



The changes made have not only benefited the factory economically, the workers now have a professional and efficient environment to work in, which is safer. As a result of this improved atmosphere they employees are now more motivated, efficient and happy.

“The 5S program helped improve the workers' mentality, they now try to find easier ways to get the task done which also improved the communication level between them and the management”, said Mr. Al-Lama’.

"We are also planning to apply all of the 5s techniques to all departments, however, this will take time, effort and support from Tatweer. We are really grateful for the role the USAID-Funded Tatweer Project played in upgrading our factory and providing us with the technical assistance we need to enhance our competitiveness" added Mr. Al-Lama'

TATWEER is an economic development project funded by the United States Agency for International Development-USAID, and managed by the Business Development Center-BDC; with a main objective of enhancing competitiveness of Jordanian Enterprises and creating jobs, through export development and facilitating technical assistance and capacity building services.