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.

What is Wastage ???

Loss time resulting from breakage of machinery, handling, double handling etc.

Method of Increase the EfficiencyCreate a happy work place

Discipline

Lay out

Utilize the

existing machinery

Create a team work

Use of Maximum Resources

Before After

Profit Formula

Effort

Efficiency

Usage of existing

equipment

Technical development

Proper follow up

Changes In Working ProcedureMorning meeting with all concern people and find out the issues and solve it with better ideas.

Now we will see the difference what we made in Smart Jacket

Cutting Section

Change of formats in cutting

Before After

Cutting Production follow up Hourly Chart

For every one awareness now its follow in chart which is easy to monitor :

Machine Down time Chart

Before After

Fabric Spreading Area

Before With 4 Person After With 2 Person

Some Technical Changes To Make The Process Easier

Before After

House Keeping Changes in Cutting Section

Before After

Spreading Area

Before After

Fusing Section

Before With 9 Person After with 3 Person

New Tools To Make Things Easier

Before After

Resource use To Make Things Easier

Before After

Replace Panel Box Sharp Tool Keeping Box

Fabric Relax Table

Closely Monitor in cutting section

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.

Production Comparison in cutting section

First Week Second Week

14000 26000

Cutting Department Cost Savings

Production bonusBefore Now Plan

Finishing Area

Some Compliance Issues

Some Compliance Issues

Changes in Process

Before Thread cut 16 Person After Thread Cut 10 Person

Before Snap Button Attach 2 machine use 2 operator

After Snap Button Attach 2 machine join together use 1 operator

Before Folding & Poly area use 9 Person After : Folding & Poly area use 4 Person

Double Handling New Method start & finish process

Finishing Production Chart

Before After

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.

Finishing Department Cost savings

Manpower Production/Day Cost in $/Month0

5000

10000

15000

20000

25000

BeforeAfter