Download - Smart Jacket - corrected one
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What is Cost ???• An amount that has to be paid or given up
in order to get something.• In business, cost is usually a monetary
valuation of (1) effort, (2) material, (3) resources, (4) time and utilities consumed, (5) risks incurred, (6) opportunity for gone in production and
delivery of a good or service.
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What is Wastage ???
Loss time resulting from breakage of machinery, handling, double handling etc.
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Method of Increase the EfficiencyCreate a happy work place
Discipline
Lay out
Utilize the
existing machinery
Create a team work
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Use of Maximum Resources
Before After
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Profit Formula
Effort
Efficiency
Usage of existing
equipment
Technical development
Proper follow up
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Changes In Working ProcedureMorning meeting with all concern people and find out the issues and solve it with better ideas.
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Now we will see the difference what we made in Smart Jacket
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Cutting Section
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Change of formats in cutting
Before After
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Cutting Production follow up Hourly Chart
For every one awareness now its follow in chart which is easy to monitor :
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Machine Down time Chart
Before After
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Fabric Spreading Area
Before With 4 Person After With 2 Person
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Some Technical Changes To Make The Process Easier
Before After
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House Keeping Changes in Cutting Section
Before After
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Spreading Area
Before After
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Fusing Section
Before With 9 Person After with 3 Person
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New Tools To Make Things Easier
Before After
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Resource use To Make Things Easier
Before After
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Replace Panel Box Sharp Tool Keeping Box
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Fabric Relax Table
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Closely Monitor in cutting section
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Cost Reduce in cutting area
Before Total People was in cutting -101 person,Now total people in cutting after new Procedure-50 Person.
We save around 50% manpower and production also better then before. Day by day its increasing also.
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Production Comparison in cutting section
First Week Second Week
14000 26000
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Cutting Department Cost Savings
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Production bonusBefore Now Plan
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Finishing Area
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Some Compliance Issues
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Some Compliance Issues
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Changes in Process
Before Thread cut 16 Person After Thread Cut 10 Person
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Before Snap Button Attach 2 machine use 2 operator
After Snap Button Attach 2 machine join together use 1 operator
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Before Folding & Poly area use 9 Person After : Folding & Poly area use 4 Person
Double Handling New Method start & finish process
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Finishing Production Chart
Before After
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Finishing Cost Reduce
• Before Total People was in finishing -188 person, Now total people in finishing after new Procedure- 115 Person.
• Still the set up is running. Once we fix the quality team there then we will get the final summary of manpower in finishing area.
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Finishing Department Cost savings
Manpower Production/Day Cost in $/Month0
5000
10000
15000
20000
25000
BeforeAfter