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JAKARTA INDONESIA

INDUSTRIAL

ENGINEERING

COMMUNITY

Department : Management Service Team

Title : Operation Breakdown

Effective date :

Reversion No : 1

Issued date :

The contents of this manual have been issued, audited and approved by the following authorities. Contents

should not be changed unless approved by the same authorities.

Name Signature Date

Issued by

Originator

Management Service

Team

Audited by

Immediate Superior

Approved by

Dept. Manager

Production Manager

Technical Consultant

Distribution to

Consultant

Production Manager

Production Executive

Production Planning Control

Cutting

Merchandising

Technician

Document No: Revision: Page 1 of

Manual Contents

Index No Title Page No Total Pages

1 Purpose 3 1

2 Scope 3 1

3 Equipment 3 1

4 Reference 3 1

5 Flow Chart 4 1

6 Procedure

7 Appendix

Document No: Revision: Page 2 of

Title Operation Breakdown Procedure

1. Purpose Define the system which must be followed when producing operation

breakdowns.

2. Scope This standard operating procedure applies to all garments produced by.

3. Equipment Electronic decimal stop watch

Time study sheet

Measuring tape

Computer

Calculator

Synthetic data base

Sample garment

4. Reference

Document No: Revision: Page 3 of

5. Flow Chart (optional)

OC form Sketch

Reference sample

&

Worksheet

Estimated

daily target

for

PPC

Predefine

operation

breakdow

Trial Sample Time Study

Approval Sample

Modify predefine

operation

beakdown

Machine layoutSewing

specification

Operation

breakdown

Document No: Revision: Page 4 of

6. Procedure

1. Obtain order confirmation form from the merchandising office

2.

From the sketch on the order confirmation form decide if the style has been manufactured by

PCCS previously.

If the style has been manufactured previously: -

1. Refer to the historical data in the operation breakdown file.

2. Photocopy the operation breakdown for use with the new order.

3. Return the original operation breakdown to the operation breakdown file and give the photocopy to PPC.

3.

If the style has not been manufactured previously: -

Referring to the order confirmation form analyze the sketch.

a. Using the sketch as a guide, break the style down into operations and record them on the order confirmation form.

b. Using synthetic data and estimates calculate the operation target’s and enter them into the order confirmation form.

c. Using the targets, calculate the standard minutes and enter them into the order confirmation form.

d. Using the operation targets, calculate the daily team targets and enter them on the order confirmation form.

e. After completing the order confirmation form take one photocopy and enter one copy into the order confirmation file and give one copy to PPC.

4.

Receive work sheet (specification) from merchandising.

a. Take operation sheet from MST operation breakdown file.

b. Receive reference sample from merchandising

c. Analyze the reference sample and record operation breakdown on new

operation breakdown sheet.

d. Identify operations which do not have standard minutes.

e. Go to the sample room and take a time study for the operations which do not

have standard minutes.

f. Insert new standard minutes into the operation breakdown form.

g. Using the operation targets, calculate the daily team targets and enter them on

the order confirmation form.

h. Enter the machine layout into the operation breakdown form

i. Enter the ‘points to watch’ into the operation breakdown form

j. Place the operation breakdown form into the file.

Receive the approved sample from merchandising

a. Compare the first sample and the approved sample to detect any differences

effecting the operation breakdown.

b. Correct any differences on the operation breakdown form.

c. Arrange a production meeting.

Document No: Revision: Page 5 of

7. Appendix / Attachment

1.

2.

3.

4.

5.

6.

7.

OC form

sketch

worksheet

predefined operation breakdown

final operation breakdown & piece rate

machine layout

sewing specification

Document No: Revision: Page 6 of

Department

:

Title :

Effective date :

Issued date :

Revision Change Item Reason for change

Name Signature Date

Issued by

Originator

Immediate Superior

Production Manager

Technical Consultant

Distribution to

Document No: Revision: Page 7 of

Department Code : ( max 3 alphabet/00198 )

Production

Cutting

Sewing

Finishing

Dipping

Washing

Pattern Room

- CUT

- SEW

- FIN

- DIP

- WAS

- PPR

Administration

Accounts

MIS

Purchasing

Shipping

Gen Adm.

Security

HR

Store

- ACC

- MIS

- PUR

- SHP

- ADM

- SEC

- HR

- STR

Service

Quality

AAMT

IE

CMD

MU

Laboratory

PPC

Maintenance

- QUA

- AMT

- IE

- CMD

- MU

- LAB

- PPC

- MAN

Document No: Revision: Page 8 of