Closure Ceremony of 'Improvement of Productivity - Quality - Cost - Delivery (PQCD) Program at the Site' at the G.I CÁT VẠN LỢI Electric Wire Conduit Factory under the JICA Pride Project, supported from October 2022 to October 2023.

On November 14, 2023, the Japan International Cooperation Agency (JICA), the sole implementing agency for Japan's Official Development Assistance (ODA), organized the Closing Ceremony of the "Improvement of Productivity - Quality - Cost - Delivery (PQCD) Program at the Site" at the G.I CÁT VẠN LỢI Electric Wire Conduit Factory, as part of the JICA Pride Project, supported from October 2022 to October 2023. In the Southern region, JICA selected three exemplary enterprises to participate in the project, concluding with the "CEO Training Program for Enhancing Manufacturing and Business Competencies - Business Networking in the Supply Chain for Japanese Corporations" from September 13-18, 2023, in Nagoya, Japan. This aims to enhance the leadership capabilities of small and medium-sized enterprises in Vietnam, contributing to the development of Vietnam's support industry, which is still in its early stages, and serving as a crucial reference platform for Vietnam's industrial development by 2045.

The summary of the "Improvement of Productivity - Quality - Cost - Delivery (PQCD) Program at the Site" at the G.I CÁT VẠN LỢI Electric Wire Conduit Factory achieved the following improvements:

Production:

• Implemented Industrial Engineering (IE) tools to establish standard production times for products, serving as the basis for evaluating the capabilities and skills of employees. This resulted in a 75% reduction in planning time and delayed deliveries due to incorrect planning.
• Utilized statistical analysis and the 5Why method to identify and address root causes systematically, implementing continuous improvement through the Plan-Do-Check-Action (PDCA) cycle in response to abnormalities or production incidents.
• Reduced the time for changing cable conduit welding molds by 97%, increased labor productivity by 21%, and decreased defects in the welding process.

Quality:

• Established a quality control process covering raw material quality (IQC), in-process production quality (PQC), and finished product quality (OQC).
• Created checklists, inspection guides, and logs to document and analyze errors, applying the 5Why method for systematic thinking and taking preventive and corrective actions based on the continuous improvement PDCA cycle.
• Developed a quality assurance system for the production of EMT connectors and couplings, resulting in a 75% reduction in process defects.

Cost:

• Reduced operation time, saving 29% in labor costs and increasing labor productivity by 20%, leading to a decrease in defects in the production of Pull boxes.
• Cut direct factory labor costs by 5%.

Delivery:

• Implemented product location tracking in the warehouse area to facilitate inventory management and reduce the risk of picking the wrong products.
• Reduced the rate of product mispicks, streamlined inventory management, and optimized inventory levels using the FIFO principle to minimize waste and excess storage costs.
• Created information sheets for transport vehicles (departure time, order number, quantity of orders, location code) and order information sheets (customer name, order number, delivery date, weight, checking personnel). This led to a 50% reduction in time spent loading goods onto trucks.

Basic Site Improvement:

• Initiated the 5S awareness and visual workplace creation and continuous improvement activities (KAIZEN) in the Japanese style at the G.I CÁT VẠN LỢI Electric Wire Conduit Factory for middle management and on-site workers.
• Established a leadership team (3 individuals) to enhance theoretical knowledge, methods, and capabilities in the Japanese manufacturing style (Monozukuri). They participated in the "Enterprise Improvement Diagnosis Consultant for Manufacturing Industries - Shindanshi" course directly conducted by JICA experts from August 2023 to November 2023.

Business Connection with Japanese Enterprises:

• Successfully connected and signed export contracts with Nippon Denka, a company based in Osaka.
• Served as the main supplier of electrical supplies (G.I Electric Wire Conduit & accessories, hanging systems for MEP systems) to Shinryo, the contractor for the Lego factory project in Binh Duong.