Welcome To The Presentation

TOPICThe Factory Performance Evaluation Status & Scope Of Further Improvement By Focusing

On The Key Performance Indicators

Presented ByIE TEAM

IndexImplementation & Initialization of IE Tools & TechniquesGeneration Of Key Performance Indicators

Current Factory Status Based On KPI’s

Comparison Of KPI’s In Recent Months

Continued…………

Loss Calculation Based On NPT & Cut to Ship RatioScope Of Further Improvements By implementing IE Tools & TechniquesPerformance assessment based on KPI(month of March)

Questionnaires

Implementation & Initialization of IE Tools & Techniques

Implemented IE Tools:

Operation Bulletin Line Balancing Target setting based on manpower & line balancing Manpower utilization report Non Productive Time collection & root cause

analysis behind the NPT Hourly Production Study Sewing WIP assessment

Continued....

Initiated IE Tools:

Individual Production & Quality board for operators

Skill matrix of all operatorsLine WIP assessment

Generation Of Key Performance Indicators

Key Performance Indicator:

Efficiency= Earned minute/Available minute

Productivity= Production/Man/HourAverage SMVAverage Working HourNPTPerformance= Earned minute/(Available

minute-NPT)

Continued….

Cut to Ship loss ratio=Total Shipment/Total Cutting

Absenteeism

Current Factory Status Based On KPI’s

1st 2nd 3rd Fac-tory Summary

0.001.002.003.004.005.006.007.008.009.00

10.00

9.52 8.77

5.35

7.88

Average SMV(March)

Overall Avg. SMV

SMV

1st 2nd 3rd Fac-tory Summary

0.00%

5.00%

10.00%

15.00%

20.00%

25.00%

30.00%

35.00%

40.00% 0.356 0.3721

0.2861

0.351300000000001

Efficiency(March)

Avg. Efficiency

Eff.%

1st 2nd 3rd Fac-tory Summary

64.00%66.00%68.00%70.00%72.00%74.00%76.00%78.00%80.00%82.00%84.00%

0.826000000000001

0.822800000000001

0.709000000000001

0.8029

Avg. Target Ach.% (March)

Avg. Target Ach.%

Perc

enta

ge

1st 2nd 3rd Fac-tory Summary

2.70

2.80

2.90

3.00

3.10

3.20

3.30

3.40

3.50

2.983.06

3.44

3.16

Productivity(March)

Avg. Productivity

Prod

uctiv

ity

1st 2nd 3rd Fac-tory Summary

10.00

10.20

10.40

10.60

10.80

11.00

11.20

10.59

10.38

11.06

10.6766666666667

Average Working Hour(March)

Avg. W.H

Hou

r

1st 2nd 3rd Fac-tory Summary

050000

100000150000200000250000300000350000400000450000500000

169169

264817

39300

473286

Total NPT(Man min.)M

inut

e

1st 2nd 3rd Fac-tory Summary

0.00%5.00%

10.00%15.00%20.00%25.00%30.00%35.00%40.00% 0.362800000000

0010.3857

0.295

0.3616

Performance (March)

Avg. Per%

Per.%

Comparison of KPI’s In Recent Three Months

Factory Efficiency is Trends to get Higher

January February March0.00%5.00%

10.00%15.00%20.00%25.00%30.00%35.00%40.00%

27.93%30.27%

35.13%Efficiency

Effi-ciencyLinear (Effi-ciency)

Target Achievement is trends to get higher

January February March0.00%

10.00%

20.00%

30.00%

40.00%

50.00%

60.00%

70.00%

80.00%

90.00%

59.39%65.81%

80.29%

Target Achievement

Target Achievement

Linear (Target Achievement)

Factory productivity trends to get higher

January February March0.00

0.50

1.00

1.50

2.00

2.50

3.00

3.50

2.18

2.833.16

Productivity

ProductivityLinear (Productiv-ity)

Average SMV Trends to get lower

January February March0.001.002.003.004.005.006.007.008.009.00

10.00 9.12

7.027.88

Average SMV

Average SMVLinear (Av-erage SMV)

Factory Average working hour trends to get lower

January February March9.50

10.00

10.50

11.00

11.50

12.00

12.50

13.00

11.78

12.64

10.67

Working Hour

Working HourLinear (Working Hour)

Non Productive Time trends to get higher

January February March0

50000100000150000200000250000300000350000400000450000500000

0 0

473286NPT (Non Productive Time in minute)

NPT (MIN.)Linear (NPT (MIN.))

Performance trends to get higher

January February March0.00%

5.00%

10.00%

15.00%

20.00%

25.00%

30.00%

35.00%

40.00%

27.93%30.27%

36.16%Performance

Per-for-manceLinear (Per-formance)

Absenteeism trends to get lower

January February March0.00%

5.00%

10.00%

15.00%

20.00%

25.00%

9.86%

19.61%

8.18%

Absenteeism%

Absen-teesmLinear (Absen-teesm)

Loss Calculation Based on NPT(Non Productive Time) of Month March

Floor wise total NPT on month of March

1st floor 2nd floor 3rd floor Total0

50000

100000

150000

200000

250000

300000

350000

400000

450000

500000

169169

264817

39300

473286NPT(Man minute)

Floor wise Loss of Production due to NPT

1st floor 2nd floor 3rd floor Total0

5000100001500020000250003000035000

13357 14023

2907

30288

Loss in Production (pcs.)

Floor wise Loss in FOB due to NPT

1st floor 2nd floor 3rd floor Total $-

$10,000 $20,000 $30,000 $40,000 $50,000 $60,000 $70,000

$28,018 $31,769

$433

$60,221

Loss in FOB

Responsible Sections for NPT(Non Productive Time) for Month March

Production17%

Supply chain60%

Qual-ity2%

Cutting2%

Textile2%

Mainten-ance3%

Mer-chandiser7%

Ab-sen-tism1%

Store6%

Responsible sections for NPT

Reasons Behind The Non Productive Time

FABRIC DELAY 

CUTTING DELAY

CUTTING MISTAKE

MACHINE BREAK DOWN

RE-WORK

APPROVAL DELAY

MACHINE DELAY

ACCESSORIES DELAY SUPPLYER

ACCESSORIES DELAY STORE

Continued….WRONG CONSUMPTION 

EMBROIDEREY DELAY

PATERN MISTAKE

DECISION MAKING DELAY-QD

DECISION MAKING DELAY-PM

PLANNING-DELAY

PRINTING DELAY

FEEDING  DELAY

POWER FAILURE

Loss Calculation Based on Cut to Ship Loss Ratio

Factory Internal Supply Chain Status(Based on Order Closing Status for Month of March)

Total Cutting Total Sewing Total Packing Total Shipment

510000

520000

530000

540000

550000

560000

570000

580000

590000

600000

589663

557966

538484 537848

Loss Ratios between the Stages of Factory Internal Supply Chain

Cut to Sew Loss ratio

Sew to pack Loss ratio

Cut to Ship Loss ratio

0%1%2%3%4%5%6%7%8%9%

10%

5%

3%

9%

Loss Ratio

Loss Ra-tio

Poly-nomial (Loss Ratio)

Loss in FOB due to Cut to Ship Loss

Loss in FOB(cut to sew)

Loss in FOB(Sew to Pack)

Total Loss in FOB(Cut to ship)

$-

$20,000.00

$40,000.00

$60,000.00

$80,000.00

$100,000.00

$120,000.00

$140,000.00

$160,000.00

$180,000.00

$94,269

$57,131

$153,358

Loss in FOB

Loss in FOB

Polynomial (Loss in FOB)

Scope Of Further Improvements By implementing IE Tools &

Techniques

Generation of SMV/SAM for cutting production

Evaluation of cutting Efficiency based on SMV/SAM

Generation of cutting & Pre- production SOPSystem development in cutting section ( elimination of replace cutting system)Process elimination & standardization of cutting working procedureData recording & systematic analysis for continuous improvement in cutting sectionProcess elimination & standardization of sewing processes

Changeover time record & analysis

Finding root cause behind changeover time

Changeover time efficiency calculation

Establishment of preventive maintenance

Calculation of Overall equipment effectiveness(OEE)

Visual Management in Cutting, Sewing & Finishing section

Establishment of Kanban system to minimize the lead time of supply chain Establishment of 5S technique allover the factory to minimize the unnecessary movement