Operation Breakdown and SMV 5 Pockets Long Pant

Operation Breakdown and SMV 5 Pockets Long Pant

5 Pocket pant can be long or short, most commonly manufactured in the apparel industry, 3 pocket in the front side and 2 in the back. Generally, 5 Pocket pant is Slim Fit Skinny Leg types. 5 pocket pants can be made by jeans or non-denim Twill Pant. Nowadays 5 pockets jeans pant is very commonly used garments and it is very popular. This article will help you to know about a list of operation and SMV of 5 pocket long pant. Hopefully, you will understand after reading Operation Breakdown and SMV 5 Pockets Long Pant.

Operation Breakdown and SMV 5 Pockets Long Pant
NO. OPERATION M/C TYPE No. of Machine  SMV TGT in 100% Efficiency
FRONT PART
1 FNT FLY FUSING ATT IRN 1 0.2 300
2 FNT PART KNEE MARK Helper 1 0.25 240
3 S/FLY +D/FLY MAKE+FNT RISE O/L 3 OL 1 0.3 200
4 D/FLY OL +SEAM OL 3 OL 1 0.3 200
5 FNT PKT SEAM  MARK Helper 1 0.3 200
6 COIN PKT ATT TO SEAM SNL 1 0.3 200
7 FNT PKT SEAM + FACING  ATTACH TO PKTING SNL 1 0.3 200
8 FNT PKTING ATTACH TO BODY SNL 1 0.25 240
9 FNT S/FLY ATT +  TOP STC SNL 1 0.3 200
10 FNT S/FLY ZIPPER ATT DNL 1 0.3 200
11  J STC MARK Helper 1 0.2 300
12  J TOP STC DNL 1 0.25 240
13 FNT D/FLY JOIN SNL 1 0.25 240
14 FNT D/FLY BODY CLOSE SNL 1 0.25 240
15 FNT RISE INSIDE TACK+ROLLING SNL 1 0.35 171
16 FNT RISE TOP STC SNL 1 0.3 200
17 FNT RISE 2ND STC WITH DIMOND SNL 1 0.25 240
18 FNT PKT  MOUTH ROLLING WITH PIPING DNL 2 0.55 109
19 FNT PKT HORI+VERTI- TACK SNL 1 0.4 150
20 FNT PKT BAG OL +TURN 3 OL 1 0.3 200
21 FNT PKT BAG 1/4 TOP STC SNL 2 0.4 150
22 LABLE MAKE SNL 1 0.25 240
23 FNT PART LABLE ATT SNL 1 0.3 200
24 FNT PART WAIST MARK Helper 1 0.25 240
25 FNT PART CHECK QC
26 BK PART 
27 BK PART KNEE MARK Helper 1 0.25 240
28 BK YOKE JOIN 3 OL 1 0.3 200
29 BK YOKE JOIN TOP STC FOA 1 0.3 200
30 BK RISE  JOIN 3 OL 1 0.3 200
31 BK RISE TOP STC FOA 1 0.28 214
32 BK PKT + LOOP + YOKE + CORD MARK Helper 2 0.4 150
33 BK PKT MOUTH ROLLING+COIN PKT ROLLING CHIN 1 0.45 133
34 BK PKT OL 3 OL 1 0.3 200
35 BK PKT IRN IRN 2 0.6 100
36 BK PKT ATT SNL 2 0.6 100
37 BK PKT TOP STC SNL 2 0.5 120
38 BK PART CHECK QC
39 ASSEMBLY
40 FR.+BK PART MACHINE Helper 1 0.3 200
41 INSEAM JOIN TOP STC (FOLDER) FOA 2 0.55 109
42 SIDE SEAM O/L 5 OL 2 0.6 100
43 SIDE SEAM SAFT STC SNL 2 0.6 100
44 SIDE SEAM CORD STC SNL 2 0.4 150
45 SIDE SEAM LABLE ATT SNL 1 0.3 200
46 W/BELT SHARING 5 OL 1 0.3 200
47 W/BELT FUSING ATT IRN 1 0.3 200
48 W/BELT MARK Helper 1 0.3 200
49 W/BELT MATCHING Helper 1 0.3 200
50 W/BELT JOIN  TOP STC  ( FOLDER) K-S 2 0.65 92
51 W/B CHECK+IN SIDE CHECK Q.I
52 W/BELT MOUTH CUT+TREAD REMOVE Helper 2 0.45 133
53 W/BELT MOUTH CLOSE SNL 3 0.8 75
54 WAIST LOOP MAKE(FOLDER)+LOOP CUT+MATCHING SNL 1 0.3 200
55 WAIST  LOOP & BELT  IRN IRN 1 0.26 231
56 WAIST LOOP ATT  (5PCS) SNL 2 0.5 120
57 WAIST LOOP CLOSE SNL 1 0.35 171
58 W/BELT LABLE ATT SNL 1 0.3 200
59 BTM HEM ROLLING SNL 2 0.6 100
60 TRIM CUT Helper 2 0.3 200
61 FNT PKT WASH TACK +MOUTH TACK SNL 1 0.3 200
62 BERTECK & BUTTON SECTION
63 LOOP BERTECK (10 pics) BERTEK 2
64 BK PKT BERTECK+CORD STC BERTEK 1
65 FNT PKT BERTECK+FLY BERTEK 1
66 EYELET HOLE HOLE 1
67 FLAP MARK & BODY CARING Helper 1
68 REVEAT ATTACH(10 POINT) SNAP BUTTON 2
69 WAIST BUTTON SNAP BUTTON 1
70 WAIST MARK Helper 1

Here,

  • IRN- Iron Machine
  • SNL- Single needle lock stitch
  • 3 OL- 3 thread overlock
  • VERT- Vertical Machine
  • DNL- Double needle lockstitch machine
  • K-S – Kansai machine
  • FOA- Feed of the arm

Operation Breakdown and SMV 5 Pockets Long Pant

Operation Breakdown and SMV 5 Pockets Long Pant excel

Written by

A.M. Amirul Islam (Washim)
Email: [email protected]

Linkedin: A.M. Amirul Islam

Operation Breakdown and SMV of Men’s Long Sleeve Shirt

Operation Breakdown and SMV of Men’s Long Sleeve Shirt

Operation Breakdown for Garments ManufacturingOperation breakdown is a list of processor operation in sequence wise with SMV or SAM and machine Helper list. Style-wise operation breakdown is done by an industrial engineer in an excel chart. Operation breakdown report help to set the line layout of every style. For your better understanding, I made an Operation Breakdown and SMV of Men’s Long Sleeve Shirt in an excel sheet.

Operation Breakdown Report Includes

  1. List of operation
  2. Operation wise needed sewing machine list
  3. Operation wise number of  sewing machine
  4. SMV or SAM of every operation
  5. Production target of every operation

Operation Breakdown and SMV of Men’s Long Sleeve Shirt

OPERATION M/C TYPE Number of Machine Needed SMV Target Production in 100% Efficiency(Pcs) Target Production in 80% Efficiency(Pcs)
MAKE SECTION-SMALL PARTS
COLLER FUSING IRN 2 0.25 240 192
COLLAR MAKE MARK + MATCH HELPER 1 0.25 240 192
COLLAR MAKE WITH HELPER THREAD SNL 2 0.45 133 213
COLLAR ALLOWANCE CUT HELPER 1 0.25 240 192
COLLAR TURN + THREAD REMOVE HELPER 1 0.25 240 192
COLLAR TOP 1/4 STC SNL 2 0.32 188 300
COLLAR + BAND MATCH HELPER 1 0.3 200 160
BAND JOIN SNL 2 0.55 109 175
COLLAR ALLOWANCE NOSE  CUT + SERGING 3 OL 1 0.35 171 137
BAND TOP (MIDDLE)  STC SNL 1 0.3 200 160
COLLAR  MARK SHOULDER PSN HELPER 1 0.3 200 160
FLAP IRN IRN 2 0.45 133 213
FLAP MAKE SNL 2 0.6 100 160
FLAP TOP STC SNL 2 0.55 109 175
FLAP PEN POINT MARK+ROLLING SNL 3 0.4 150 360
MARK FOR CUFF MAKE HELPER 1 0.35 171 137
CUFF MAKE SNL 1 0.5 120 96
CUFF MAKE VERT 1 0.4 150 120
CUFF TOP STC SNL 2 0.6 100 160
BACK PART
BACK PART DART MAKE SNL 1 0.25 240 192
MAIN + FIT LBL ATT WT BACK YK SNL 2 0.3 200 320
BACK YK ATT 3 PARTS SNL 2 0.28 214 343
BACK YK TOP STC SNL 1 0.4 150 120
CARE LBL ATT SNL 1 0.3 200 160
BACK NECK TRIMMING HELPER 1 0.5 120 96
BACK PART CHECK QC
FRONT PART
BOX PLATE MAKE K-S 2 0.55 109 175
THREAD CUT HELPER 1 0.2 300 240
BTN PLATE MAKE SNL 1 0.5 120 96
FRONT NECK TRIMMING HELPER 1 0.3 200 160
ASSEMBLY
BACK + FRONT PART MATCH HELPER 1 0.2 300 240
SHOULDER JOIN SNL 2 0.3 200 320
SHOULDER T/S DNL 1 0.25 240 192
POCKET + FLAP MARK HELPER 2 0.45 133 213
POCKET ROLLING SNL 1 0.2 300 240
POCKET IRN IRN 2 0.2 300 480
PLACKET IRN IRN 2 0.5 120 192
POCKET MATCH HELPER 1 0.25 240 192
POCKET JOIN SNL 2 0.6 100 160
POCKET 1/4 SNL 2 0.55 109 175
FLAP MATCH HELPER 1 0.2 300 240
FLAP JOIN DNL 2 0.5 120 192
NECK SHARING SAFETY STC SNL 1 0.25 240 192
COLLAR + BODY ASSEMBLY HELPER 1 0.25 240 192
COLLAR JOIN SNL 2 0.45 133 213
COLLAR CLOSE  TOP STC SNL 3 0.65 92 222
SLEEVE PLACKET OPEN MARK + CUT HELPER 1 0.3 200 160
GANBLE JOIN( FOLDER) SNL 1 0.35 171 137
GANBLE TACK + EXCESS CUT SNL 1 0.3 200 160
PLACKET JOIN + EDGE TOP STC SNL 2 0.4 150 240
CUFF JNS PSN MARK HELPER 1 0.25 240 192
SLEEVE MATCHING HELPER 1 0.2 300 240
SLEEVE JOIN 3 OL 2 0.5 120 192
SLEEVE INSIDE ALLOWANCE CUT HELPER 1 0.25 240 192
ARMHOLE TOP STC ( FOLDER) DNL 2 0.6 100 160
THEAD CUT + ALLOWANCE CUT 3OL 1 0.35 171 137
SIDE SEAM TOP STC FOA 2 0.45 133 213
CUFF  JOIN PSN MARK HELPER 1 0.35 171 137
CUFF JOIN SNL 3 0.8 75 180
BOTTOM HEM SNL 2 0.45 133 213
COMFORT LBL JOIN SNL 1 0.4 150 120
FINAL THREAD CUT HELPER 2 0.4 150 240

Here,

  • IRN – Iron Machine
  • SNL – Single needle lock stitch
  • 3 OL – 3 thread Overlock
  • VERT – Vertical Machine
  • DNL – Double needle lockstitch machine
  • K-S – Kansai machine
  • FOA – Feed of the arm

Operation Breakdown and SMV of Men’s Long Sleeve Shirt excel

Written by

A.M. Amirul Islam (Washim)
Email: [email protected]

Linkedin: A.M. Amirul Islam

Job Responsibility of IE in Apparel Industry

Before appointing an industrial engineer for the apparel industry, you have to keep in mind the Job Responsibility of IE in Apparel Industry. Here IE means Industrial Engineering. The world has limited resources but day by day we need to produce more and more product. The challenge is to increase productivity by using the least amount of resources. Garments industry is very much competitive. So in this competitive industry, it is a big challenge for Bangladesh or any other country to survive. We are looking for a solution where we will get more productive technology with lower cost. Industrial Engineering is all about optimization of limited resources. Generally, Optimization, Planning, and Process Control is the core work in apparel for the industrial engineering department.

Job Responsibility of IE in Apparel Industry

Nowadays IE playing the key role in the apparel industry. Industrial Engineering Job is not an easy job, always engineers need to take on the challenge and bring a complete solution. The person who is responsible for industrial engineering is considered as an industrial engineer. I made a list of industrial engineering activities in the apparel industry.

Job Responsibility of IE in Apparel Industry

Major Work of Industrial Engineering in Garments

Industrial Engineering deals with the following activities:

  1. Time Study, Motion study
  2. Taking the capacity study of full-line and line balancing for clean-up bottleneck area.
  3. Methods developments & analysis as a side of quality & quantity.
  4. Follow-up the low performing Operators.
  5. Operation breakdown, Operation Bulleting / Layout
  6. SMV calculation by time study.
  7. Operator skill Summery.
  8. Train up production staff on efficiency.
  9. Process-wise operator skill development.
  10. Nonproductive time (Loss Time) record and reduce.
  11. Hourly Production Monitoring & Achieve the line Target.
  12. Prepare Man machine report.
  13. 5s implementation, Training, and Auditing
  14. Work on 7 QC tools to minimize defect.
  15. Statistical analysis for continuous quality improvement.
  16. Production Planning and control, Planning Calculations
  17. Capacity Study
  18. Production Study
  19. PDCA Cycle
  20. 7 Wastage reduce
  21. Manpower Budget Planning
  22. CPM, CM Calculation
  23. Line Cost Calculation, Floor capacity calculation
  24. SPM, EPM, PCL Calculation
  25. Reduce WIP (Work in Process)
  26. Operator, Line and floor efficiency Calculation
  27. Follow up KPI (Key Performance Indicator) and Report
  28. Inventory Control in all section
  29. Implementation lean manufacturing tools and Six Sigma
  30. Provide Incentive for operator and Production staffs
  31. Manpower requisition and set up
  32. Eliminating excess manpower
  33. Improving Productivity through detailed analysis of the process by process
  34. Smooth supply chain management from raw material to output
  35. Helping to launch the TQM (Total Quality Management) system in a factory
  36. Implement traffic light system on the floor & reduced sewing defect percentage
  37. Co-ordination with merchandising
  38. Fabric & thread consumption.
  39. Garments analysis & style development for reducing costing.

Please mention in the comment box if I missed any point.

Written by

A.M. Amirul Islam (Washim)

Facebook: Amirul Islam Washim

Phone:+8801929643301
E-mail: [email protected]

7 QC Tools in Apparel Industry

7 QC (Quality Control) tools are very effective for apparel or any other types of the factory to solve almost every type of problem in a factory operation. These are the tools of troubleshooting quality issues, based on numeric value. 7 QC tools in apparel industry is a set of data analysis tools used to support continuous quality improvement efforts. If you can use these seven fundamental tools, then definitely quality control will be effective for your company.

7 QC Tools in Apparel Industry

  1. Histogram
  2. Check Sheet (Tally Sheet)
  3. Cause-and-Effect Diagram
  4. Pareto Chart
  5. Scatter Diagram
  6. Control Chart
  7. Stratification

7 QC Tools in Apparel Industry

Benefits of 7 QC Tools

  • Improve management decision making skills
  • Collect, present, Identify and analyses data
  • Implement Six Sigma
  • Control cost of poor quality
  • Reduce variations and improve quality
  • Reduce defects and improve production
  • Reduce cycle time and improve efficiency
  • Continuous quality improvement
  • Encourages teamwork and confidence
  • Enhances customer satisfaction through improved quality product

Explanation of 7 QC Tools for Apparel Industry

  1. Histogram

Histogram is also a bar chart. It is a graphical chart based on numeric value for showing frequency distribution of database. People become confused among Histograms and Bar Charts. A histogram is used for continuous data, where the bins represent ranges of data, while a bar chart is a plot of categorical variables. Some authors recommend that bar charts have gaps between the rectangles to clarify the distinction.

Histogram for Apparel Industry

Download: Histogram Template (excel 31kb)

  1. Check Sheet (Tally Sheet)

The Check Sheet/Tally sheet is a simple document that is used for collecting data in real time and at the location where the data is generated. The document is typically a blank form that is designed for the quick, easy, and efficient recording of the desired information, which can be either quantitative or qualitative. When the information is quantitative, the check sheet is sometimes called a tally sheet. A tally sheet to collect data on frequency of occurrences which custom designed by user.

Check Sheet or Tally Sheet

Download: Tally-sheet-template (excel 75kb)

  1. Cause-and-effect diagram (Ishikawa Diagram / Fishbone Diagram)

Cause-and-effect diagram is look like a fish that’s why it’s called Fishbone Diagram, also called Ishikawa diagram, herringbone diagrams or Fishikawa diagrams, a visualization tool for categorizing the potential causes of a problem in order to identify its root causes. Causal diagrams created by Kaoru Ishikawa that show the causes of a specific event. Dr. Kaoru Ishikawa developed the “Fishbone Diagram” at the University of Tokyo in 1943.To break down (in successive layers of detail) root causes that potentially contribute to a particular effect. This diagram is used in process improvement methods to identify all of the contributing root causes likely to be causing a problem.

How to Work on Fishbone

If you find a problem and want to make fishbone diagram. First need brainstorming about the defect to find out types of causes based on 6 basic things. These are:

  • Machine
  • Manpower
  • Environment
  • Method
  • Materials
  • Measurement

Brainstorm all the possible causes of the problem. Ask: “Why does this happen?” As each idea is given, the facilitator writes it as a branch from the appropriate category. Causes can be written in several places if they relate to several categories. For example you can see fishbone in the below:

Fishbone Diagram of QC Tools

Download: Cause and Effect diagram Template (excel 34kb)

4. Pareto Chart (80/20 Rule)

A Pareto chart is a bar graph. The lengths of the bars represent frequency or cost (time or money), and are arranged with longest bars on the left and the shortest to the right. In this way the chart visually depicts which situations are more significant.

The Pareto principle

The Pareto principle (also known as the 80–20 rule, the law of the vital few, and the principle of factor sparsity) states that, for many events, roughly 80% of the effects come from 20% of the causes. More generally, the Pareto Principle is the observation (not law) that most things in life are not distributed evenly. In apparel industry, you can see the data in the below that first 5 defects covered 50% of total defect. So 80-20 rules will not cover all-time 80% problem for 20% causes. It can mean all of the following things:

  • 20% of the defects number cumulate 80% of the total defects
  • 20% of the operator produce 80% of the defects
  • 20% of the customers create 80% of the revenue

Pareto for Apparel Industry

Pareto Chart of Cutting Defects

Download: Pareto Chart Template (excel 25kb)

5. Scatter Diagram

The scatter diagram graphs pairs of numerical data, with one variable on each axis, to look for a relationship between them. If the variables are correlated, the points will fall along a line or curve. The better the correlation, the tighter the points will hug the line. The scatter diagram Collect pairs of data where a relationship is suspected.

Scatter Diagram

6. Control Chart (Shewhart Chart)

Control charts, also known as Shewhart charts or process-behavior charts, are a statistical process control tool used to determine if a manufacturing or business process is in a state of control. A control chart shows how data frequency changes, defects trends and compares with previous time record. Control chart monitor process and hypothetical prediction. Apparel industry need to reduce defect frequency to get quality improvement.

Control Chart for Apparel

Download: Control Chart Template (excel 17kb)

7. Stratification (Divide and Conquer), can be alternative of flow chart or run chart

Stratification is a method of dividing data into subcategories and classify data based on a group, division, class or levels that helps in deriving meaningful information to understand an existing problem. The main purpose of Stratification is to divide the data and conquer the meaningful information to solve a problem. The visual nature of the chart makes patterns jump out.

Implementation of 7 QC Tools

To implement these tools in your industry, you must have to do Pareto, Fishbone for every section. Result publishes visibly in each line or area in board. People will be conscious to reduce defect. There improvement tracking on control chart also visible for each line/area. You have to find root cause from the root level for cause and effect diagram. Data and data collection must be accurate. Every section has to be taken corrective action based on quality data. Every section must do a quality meeting to take new decision for quality control at least once per month.

Written by

A.M. Amirul Islam (Washim)

Facebook: Amirul Islam Washim

Phone:+8801929643301
E-mail: [email protected]

KPI Factors of Garments

KPI stands for Key Performance Indicator. This is the era of competition and we have to survive with a global challenge in the apparel industry. If you carefully work with Key points that is KPI Factors of Garments then surely Garments business will flourish. The management team should focus on KPI for their industry. KPI report will help you to look into the actual condition of your garments.

KPI Factors of Garments

There are many KPI factors which are directly and indirectly related to garments, especially in factory operations.

KPI Factors of Garments

KPI for Garments Cutting

Cutting Efficiency

Cutting efficiency one of the most important factor. If an efficiency increase in the cutting section then production will increase by using a minimum number of workforce.

Month Wise Cutting EfficiencyCutting Production

Cutting production is another important factor as like Cutting efficiency. Cutting production is related to Spreading, cutting, numbering and bundling.

Month Wise Cutting Production

DHU (Defect per Hundred Units) in Cutting

In cutting, there is no way to repair the defect, must replace panel as per marker with shade matching. So if DHU is high, you will be needed to rework.

Cutting Delay/Input Delay in Sewing Line

Sometimes cutting and sewing does not start as per plan. Only two reasons behind this. If PP/Size Set or pilot run sample fail to buyer QC to meet the quality standard, apparel manufacturers have remake sample and submit again to buyer QC to pass sample and get cutting approval. Sewing can be delayed for Trims and accessories delay receive from the supplier.

Month Wise Input Delay Status

KPI for Sewing

Line Wise Sewing Efficiency

Sewing makes the whole garments, so sewing efficiency is an important factor for the garments industry.

Efficiency Calculation

An operator was doing an operation of SAM (Standard Allowed Minute) 0.60 minutes. In 10 hours day, he produces 600 pieces. So according to the efficiency calculating formula, that operator’s overall efficiency is as follows:

Efficiency (%) = [Total minute produced by an operator/Total minute attended by him *100]

Efficiency (%) = [(Total piece made X SAM of the operation)/ (Total working hour X 60) * 100]
= [(400 x 0.60) / (10 X 60)*100%]
= 240/600*100%
= 40.00%

Last Month Sewing Efficiency

Production/Hour/Manpower/Machine

The ratio among production/hour/manpower/machine is to be optimal. Every factory has self-study to reduce manpower, keeping less helper with the best possible production outcome.

Month Wise Production Plan of Actual Sewing

Machine Trouble/Machine Downtime

Because of Machine trouble production is stopped. Machine maintenance department has to do their best effort to reduce machine downtime. An electrical problem also can be the cause of Machine trouble/machine downtime.

DHU in Sewing

Defects rate also a key point in garments manufacturing. Factory has to rework for repairing defects. Defect generation reduces the operator’s efficiency. Factory wants to keep defects as low as possible for per hundred units.

Absenteeism

Operator absenteeism hampers sewing production, create the bottleneck. Every factory target employee absenteeism rate is zero % but sometimes it may not possible to keep this percent.

No. Style Change

Style change effect on productivity, efficiency, and quality. So garments manufacturer wants big lot order more rather than small quantity order for any lot.

Plan vs Actual Production Ratio

All factories have planning department to make a plan for cutting, sewing, finishing and shipment to meet buyer required shipment date. The gap between plan and actual production is the reason for not meeting on time delivery.

Idle Time/Machine

Idle time is also known as loss time. For any type of reason, operators are not working is considered as loss time. Common reasons for idle time are; using a new layout, machine trouble, no work etc.

Operator Wise Efficiency

The best way of efficiency calculation is to calculate individual operator efficiency every day, show report weekly and train up lower efficient operator for improvement which ultimately increases the operational efficiency.

Process Improvement

Industrial engineering (IE) department do time study, motion study and work study to find out SMV (Standard Minute Value), to minimize unnecessary motion for sewing operations. By this way, the factory saves SMV time for garments manufacturing.

Operator Turnover Rate

Since sewing is the key process of apparel, sewing operator turnover percentage is important. Turnover means the number of employees got fired or left from the job and replaced at the workplace by a new operator. If the turnover rate is lower in the factory then it will be better for the company.

Monthly turnover % = (Employees separated/Average number of employees during the month) *100

Example, If Employees separated = 21, Average number of employees during the month= 950

So, Monthly Turnover % = (21/950) × 100 = 2.21%

KPI for Trims and Fabrics

Claim Amount vs. Recovery Amount

According to the buyer quality standard, garments manufacture has to reject fabrics, trim if there is any quality issue. So, the maker must claim for compensation by replacing or giving back their money.

Claim and Recovery Amount

KPI for Finishing, Final Audit, and Shipment

Cut to Ship Quantity

As PO wise buyer order quantity cutting department try to cut extra as much as possible. It could be from 2% to 5%. GMTS reject due to a different quality issue. Below data will give an idea about GMTS (Garments) production flow.

Cut to Ship Quantity

Month Wise Cut to Ship Percent

Reject Percentage

For some critical quality problems like wash damage, measurement out of tolerance, work hole, and unrepeatable problems GMTS rejected by finishing the quality team.

DHU in Finishing

Defects rate also a key point in garments manufacturing. Factory has to rework to repair defects. Finishing team has to repair whatever defect come from sewing or finishing they found. Factory wants to keep defects per hundred units as low as possible. If too many products are defected then to rework the garments may add extra cost to the product which to totally unexpected.

Final Audit Pass Rate

Final Audit pass rate is the number 1 KPI factor for Garments Quality. For some buyer final audit, if fail once any PO in final Audit, Factory has to give a penalty for that. Any PO fail in final audit, a factory has rechecked full quantity of goods again. Could imagine how much cost need to recheck, and it also does hamper running production as well.

Month Wise Final Inspection Pass Rate

Finishing Production

Finishing is the last step of apparel manufacturing. On time delivery, sea or air shipment mainly depends on finishing of production.

Finishing Efficiency

Finishing efficiency is also very important key factory. If efficiency increases, production will increase with minimum manpower and ultimately it will increase profit for the company.

Last Month Floor Wise Average Finishing Efficiency Plan

Order and Ship Ratio

Order and ship ratio should be equal at least or ship quantity could be more than order quantity since cutting quantity is more than 2% or 3% of the order quantity by reducing reject %.

Last Month Shipment Analysis

Year Wise Excess Shipment Quantity

Month Wise Order to Shipment Percent

Air Ship Quantity

Two reasons are cause for air shipment. One, If Garments maker cannot meet on-time delivery date then the maker have to ship goods by air at his own cost. GMTS suffer huge financial loss for air shipment because the rate is more for air shipment. Number two would be merchandising reason for not sourcing raw material on time.

Month Wise Air Shipment

Templates and KPI Dashboard Presentation

You may need to present your factory KPI data with Top management or may need to report them. Here I am sharing you a complete presentation and Excel database for your convenience for free. I hope these would help you to work with KPI smoothly.

  1. KPI Presentation-Apparel and Garments (PowerPoint) (1mb)
  2. Summary of KPI report (Excel) (1.3mb)

Written by

A.M. Amirul Islam (Washim)

Facebook: Amirul Islam Washim

Phone:+8801929643301
E-mail: [email protected]