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Evaluation Phase
1.
2.
3.
4.
5.
6.
House Keeping
Factory Current Efficiency Level
Factory Current Defect Rate
Material Handling
Space Utilization
Style Change Over Analysis
1- House Keeping-before
House Keeping-before
House Keeping-before
2. Factory Efficiency
Following were the major steps taken for calculating factory current
efficiency level:
1. SAM Calculation of major products
2. Calculation of Over time
3. Data Collection from Bundle induction to sewing lines
4.
5.
2. Factory Efficiency
22%
3. Defect Rate
Data collection by introducing appropriate format's.
Data collection at end line and finishing stage.
Appointed end line checkers.
After collection of data for one month an average of
35-40%
840 Ft
Implementation Phase
5S
Before
After
5S in Store
Before
After
Savings of
machinery
Assignment Sheet
Back Rise OL
Bk yoke edge
OL
Side seam OL
Button hole
Bartack 4
pts
Inseam att
In seam OL
W.B elastic mkg, Side label
att, Elastic att at W.B, Main
label att
Bottom hem
Store Room
W.B TS
Style: Short
Time: 10:30
328 Ft
Items
Description
Items
Description
1,000,000
1,000,000
100,000
100,000
225
325
5625
8125
18
12.31
Quality
ControlHourly
System
Introduced
Basis Reports
End Line
Finishing
Check Sheets Major Defects
ISSUES:
Reports could not be properly filled due to large buddle size
Operators were not submitting small bundles on time
Low DHU is Key Factor for running model line, therefore immediate action
must be taken to properly fill the Q.C Reports
Defect Rate
DR reduces Upto 5%
Results
Sr.
No
KPI
Before
After
Percentage
improvement
Efficiency
22%
32%
45%
Defect Rate
35%
5%
85 %
Material Handling
840 ft
328 ft
61%
Space Utilization
0 sq ft
1254 sq ft
100%
3 days
1 day
66%
18 Rs
12.31 Rs
31%