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Sewing Room Production Management

PEPGI: Promoting Employment & Productivity in Garment Industry

IndustrialEngineering

Consulting GuidelinesArtistic Apparels

November 09, 2013

PEPGI: Promoting Employment & Productivity in Garment Industry

Contents

1Objectives & Methodology

2Technopak Gap Analysis

3Observations and Recommendations

4IE Activities

5Follow up Schedule6Activities Already Started

PEPGI: Promoting Employment & Productivity in Garment Industry

Association with PEPGI provides the participating companies, a unique experience through consulting guideline in one of the chosen area from the following topics:

Fabric & Cutting Room ManagementSewing Room Production Management(SRPM)Industrial EngineeringQuality management systemBusiness process mapping

Artistic Apparel has chosen Industrial Engineering for enhancing the performance in this area. On the basis of assessment study, the various gaps are identified which will be filled by companys employees through consulting guidelines, followed up and monitored by Technopak Advisors and UNDP team.Why Consulting Guidelines Required?

PEPGI: Promoting Employment & Productivity in Garment Industry

ObjectivesAssess the sewing operations at Artistic Apparel Unit # 01 (Stitching Line # 5), in terms of Productivity and Efficiency, based on observation of the entire operations and a comprehensive Technopak Gap Analysis.

Compare performance data and results from gap analysis to industry benchmarks. Determine areas of improvement.

Put forward the observations pertaining to sewing floors and share recommendations.

Identify the need gaps for performance improvement and suggest a roadmap based on Industrial Engineering, to the management for bridging these gaps.

Highlight the advantages and benefits of having Industrial Engineering department .

PEPGI: Promoting Employment & Productivity in Garment Industry

Identify current performance levels in Capacities, Utilization, Using Methods, and productivity.Productivity level was evaluated from 5 perspectives:

Workers CapacityEvaluation of existing capacities of sewing operators & their ability to meet their capacities.Training Requirement Requirement of training based on Workers capacity.Workers Utilization How well are the operators being utilized.Methodology Terms Evaluation of methodology of doing operations for the product profile being manufactured.Efficiency terms Evaluation of production data recorded for the current month.General observations

Methodology

PEPGI: Promoting Employment & Productivity in Garment Industry

Technopak Gap AnalysisEfficiency GapHow efficient is the work ?

PEPGI: Promoting Employment & Productivity in Garment Industry

Sewing Room Capacity/Training GapCapacity Gap - Difference between achievable production capacity of operators based on their sewing pace & the actual output produced by them.

Methodology - Single cycle time was taken for randomly chosen operators to calculate their sewing capacity and their actual output recorded over a production day, under standard conditions.

Result:Capacity Gap: 42%

Training Gap - Difference between achievable efficiency of operators based on their sewing pace and their actual efficiency.

Methodology - Operators actual capacities are compared with targets and the gaps calculated.

Result: Training Gap: 12%

PEPGI: Promoting Employment & Productivity in Garment Industry

Sewing Room - Capacity/Training Gap

CAPACITY AND TRAINING GAP ANALYSISFactory: Artistic ApparelLine #: 05Style: Jade Grey28-10-13S.No.OperationMachineOperator (Name)SAMAllowances(MD+PF)Target/hr @ 100%Target SCTActual SCTCapacity (%)CapacityActual O/PCapacity Gap %Training GAP %Btn Tag & Fly O/L3T-O/LNoshad0.2514.502430.200.2385.0020618012.7915.00Zipper Attach (on fly)DNLSSajjid Ali0.1425.004320.100.1095.0041118056.185.00Zipper cuttingHelperAnwer0.1311.004750.100.1282.0039018053.8318.00Label Making (3 lable attach)SNLSShakeela0.2820.002140.220.2587.0018612035.4013.00Facing MarkingHelperErum0.2411.002540.200.2290.0022811051.8310.00Facing AttachFlat LockNazia0.4816.501240.400.4785.001061005.4715.00Facing CuttingHelperKoser0.1311.004520.100.1287.0039310074.5913.00Linning Closing3T-O/LNoshaba0.3414.501790.280.3092.001641508.698.00Linning TopSNLSAqsa0.3620.001650.290.3386.001429036.5114.00Linning TopSNLSNasreen0.3920.001540.310.3784.001299030.4316.00Linning Attach on Front PKTSNLSRukhsana0.7420.00810.600.6790.00736510.9310.00Linning Attach on Front PKTSNLSShoaib0.6020.001000.490.5391.00917517.259.00Front Pannel O/L3T-O/LNazia0.3225.001890.240.2789.0016914016.9811.00Mouth Top (with piping)DNLSAli0.2925.002100.210.2585.001798552.4015.00Mouth Top CuttingHelperNiqab0.1811.003370.140.1595.003208573.435.00Mouth Top (with piping)DNLSSajjad0.3025.001990.230.2590.001799049.7910.00Mouth Top CuttingHelperGulzara0.2211.002680.180.2092.002469063.448.00Fly pressHelperAyaz0.1511.004120.110.1385.0035018048.5415.00Fly AttachSNLSShan0.1820.003360.130.1588.0029617042.5612.00Fly TopSNLSSaleem0.2520.002380.210.2390.0021417020.6710.00

PEPGI: Promoting Employment & Productivity in Garment Industry

Usual reasons identified for capacity gap:

Inappropriate line balancingUnstable behavior of OperatorsOff standard time No WIP (Waiting Time) Sewing Room Capacity/Training Gap

PEPGI: Promoting Employment & Productivity in Garment Industry

Sewing Room Capacity/Training GapOff Standard TimeNo WIPUnstable behavior of Operators

PEPGI: Promoting Employment & Productivity in Garment Industry

Recommendations to fill the Capacity Gap:

Review the operations and use the concept of clubbing of operations where SAMs are low.Effective line balancing through Operation Bulletins.Measurement and subsequent reduction in off standard time of operators.Making the operators more disciplined and responsible.Sewing Room Capacity/Training Gap

PEPGI: Promoting Employment & Productivity in Garment Industry

Sewing Room - Utilization GapUtilization Gap - Difference between available time & used productive time of operators based on their activity sampling.

Methodology - Activity sampling was done for a sample size of 78 operators over one full working day , to calculate their utilization levels.

Result: Utilization Gap: 25%

PEPGI: Promoting Employment & Productivity in Garment Industry

Sewing Room - Utilization Gap

UTILIZATION ANALYSISFactory: Artistic ApparelDate: 28-10-13Sample Size: 78 Activity Sampling occasions:Line/Lines: 05S.NoActivityTaskOccasionsAs Percentage of total timeAs Percentage of Sewing timeStandard1Normal Productive WorkSew and Handle25341%Shears345%Total28746%100%100%2Bundle Handling / Parts layout17027%59%15%3Machine DelayTB, CC, BC, NC122%4%2%4Machine Breakdown61%2%1%5Personal and Fatigue569%20%3%6Waiting Time599%21%1%7OthersRepair, talk with supervisor & others, looking around345%12%3%TOTAL624100%Total opportunity for Improvement25%MB, P &F, Waiting time, others Achievable Improvement 9%Estimated

PEPGI: Promoting Employment & Productivity in Garment Industry

Sewing Room - Utilization GapMachine Break DownExcessive & Uncontrolled movement

PEPGI: Promoting Employment & Productivity in Garment Industry

Sewing Room - Utilization Gap Usual reasons identified for utilization gap:

Improper line balancingWaiting time for WIPExcessive & Uncontrolled movement Personal And Fatigue

Recommendation to fill the Utilization Gap:

The Utilization Gap of 25 % suggests an estimated improvement potential of (09-10)% by reducing the wastage of productive work time and with preventing measures to avoid above mentioned reasons.

PEPGI: Promoting Employment & Productivity in Garment Industry

Off Standard Time

PEPGI: Promoting Employment & Productivity in Garment Industry

Off Standard Time

PEPGI: Promoting Employment & Productivity in Garment Industry

Methods GapPotential for increasing operator productivity by improving the way an operation is performed.

Methodology - Methods of randomly selected operators/workers were reviewed and potential for improvement studied. A study was conducted to analyze the current methods being used and the timings taken. The methods were then analyzed for engineering possibilities and some basic improvements done. The timing on the new methods was again taken and compared with the timings taken on the methods before engineering.

Result:Method Gap: 15.68 %

Sewing Room - Method Gap

PEPGI: Promoting Employment & Productivity in Garment Industry

Sewing Room - Method Gap

METHODS GAP ANALYSISFactory: Artistic Apparel DepartmentDate: 28-30 October, 2013Style: Jade GreyLine No. 05S.No.OperationCycle Time Before EngineeringEngineering PossibilitiesCycle Time After EngineeringSavings in MinutesSavings in Percentage1Linning Attach Before Front Rise Over Lock0.53Both front panels over lock together before lining attach due to which numbering will not disarranged0.400.1324.532Label Making (3 or 4 labels attach togather), use poly beg for each label in top of machine bed. 0.25Use a fabric poach fixed side the machine bed. 0.220.0312.003Fly top, Front bundle put on the leg after sew one by one pcs then dispose and arrange the side table.0.23Use some extension of machine bed over the le

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