Line 1

ITEM No.:- M675

operations Neck attachment Neck Finish
Date
11-Jun-11
29
13-Jun-11
22
14-Jun-11
26
15-Jun-11
16-Jun-11
17-Jun-11
18-Jun-11
20-Jun-11
21-Jun-11
22-Jun-11
23-Jun-11
TOTAL

22
13
7
4
5
10
7
5
150

SL.No.
1
2
3
4

Zipper attachment

Zipper finish

side o/l

sleeve fold

Bottom fold

sleeve tacking

dori

27
24
0

25
34
0

21
17
0

7
0
0

7
0
0

3
0
8

13
0
0

0
3
0

10
10
8
6
3
16
6
6
116

5
11
21
12
14
4
12
2
140

0
1
3
15
12
3
7
2
81

3
3
8
0
10
2
6
14
53

0
0
5
0
7
6
0
6
31

6
5
14
4
4
9
2
2
57

160
1400
1200
1000
80
600
400
200
00

0

0
0
5
5
5
5
4
10
37

TOP 4 OPERATION HAVING DEFECTS
OPERATIONS
No. OF DEFECTS
Neck attachment
150
Zipper attachment
140
Neck Finish
116
Zipper finish
81
total
487

total defects= 740
out of 740, 487 are found in 4
operations only…..
i.e. 65.8%

cost for these 4 alters
opereration
time(in min.)
Neck attachment
2.12
Neck Finish
1.22
Zipper attachment
5.54
Zipper Finish
3.04

overhead/time
3.25
3.25
3.25
3.25

Total/pc
6.89
3.965
18.005
9.88

no. of pcs
150
116
140
81

total(in Rs)
1033.5
459.94
2520.7
800.28

13

TOTAL

4814.42

Label attach

TOTAL
0
0
12

132
100
46

TOTAL

18
6
0
12
0
0
9
5
62

64
49
71
58
60
55
53
52
740

TOTAL

Line 1

ITEM No.:- M675

Time taken for rework
SL. No.

Operations
1
2
3
4
5
6
7
8
9
10
11

rework time

Pleat
neck attach
neck finish
side o/l
sleeve fold
Bottom fold
Zipper Attach
Zipper Finish
sleeve tacking
Dori
label attach

0.88
1.4
0.5
1.16
0.98
0.96
4.82
2.32
0.4
0.5
0.8

recheck time endline
0.72
0.72
0.72
0.72
0.72
0.72
0.72
0.72
0.72
0.72
0.72

after poka yoke
time taken by operators to check these operations and cost analysis
SL. No.

Operations
1
2
3
4
5
6
7
8

time(in min)

Overhead/time(in Rs)

total/pc(in Rs)

Pleat
neck attach
neck finish
side o/l
sleeve fold
Bottom fold
Zipper Attach
Zipper Finish

0.4
0.5
0.4
0.45
0.32
0.45
0.6
0.52

3.25
3.25
3.25
3.25
3.25
3.25
3.25
3.25

1.3
1.625
1.3
1.4625
1.04
1.4625
1.95
1.69

9 sleeve tacking
10 Dori
11 label attach

0.36
0.4
0.3

3.25
3.25
3.25

1.17
1.3
0.975

ITEM No.:- M675

me taken for rework
total
1.6
2.12
1.22
1.88
1.7
1.68
5.54
3.04
1.12
1.22
1.52

cost for these 4 alters
opereration
Neck attachment
Neck Finish
Zipper attachment
Zipper Finish

time(in min.) overhead/time
total/pc
2.12
3.25
1.22
3.25
5.54
3.25
3.04
3.25

6.89
3.965
18.005
9.88

cost saved per alter pc of these 4 critical operations
cost before
cost after
reduction
opereration
cost/pc(in Rs) cost/pc(in Rs)
(in Rs)
Neck attachment
6.89
1.625
5.265
Neck Finish
3.965
1.3
2.665
Zipper attachment
18.005
1.95
16.055
Zipper Finish
9.88
1.69
8.19
TOTAL
Savings per line

4009.98

no. of pcs total(in Rs) 150 1033.7 81 800.44 .89 804.94 140 2520.28 TOTAL 4814.8 273 136.5 116 459.42 Final cost (in Rs) 243.75 150.

inline checker 2 Puckering/Pleating/ Roping Broken Stitch Raw edge Run Off Uunbalanced/ Unmatched Smocking Problem Trim problem Wavy Stitch Specs Cutting problem Others 6/11/2011 27 20 0 19 0 0 0 0 0 0 0 6/13/2011 11 19 0 15 9 0 0 0 0 0 0 6/14/2011 13 15 0 21 8 0 0 0 0 0 0 6/15/2011 8 8 0 28 16 0 0 0 0 0 0 100% 90% 80% 70% 60% 50% 40% 30% 20% 10% Puckering/Pleating/ Roping Broken Stitch Raw edge Run Off Uunbalanced/ Unmatched 6/11/2011 13 9 0 0 24 inline checker 1 6/13/2011 8 13 3 6 10 6/14/2011 4 3 5 10 2 6/16/2011 6/15/2011 6/14/2011 6/13/2011 6/11/2011 0% 6/15/2011 8 17 0 7 18 .

Smocking Problem Trim problem Wavy Stitch Specs Cutting problem Others 0 0 9 0 0 1 0 0 0 0 0 0 0 0 11 0 0 0 0 0 0 0 0 0 100% 90% 80% 70% 60% 50% 40% 30% 20% 10% Puckeing/ Pleating/ Roping 11-Jun-11 13-Jun-11 14-Jun-11 15-Jun-11 16-Jun-11 17-Jun-11 18-Jun-11 20-Jun-11 21-Jun-11 22-Jun-11 23-Jun-11 Total Broken Stitch 10 0 0 8 4 14 0 14 7 5 6 68 Raw Edge 6 6 12 0 9 5 0 12 11 0 0 61 Run Off 0 22 3 5 11 24 5 4 12 0 4 90 100% 90% 80% 70% 60% 6/15/2011 6/14/2011 6/13/2011 6/11/2011 0% 14 0 2 6 1 5 19 0 10 3 14 74 .

60% 50% 40% 30% 20% 10% 13/Jun/11 11/Jun/11 0% 150 100 50 0 .

6/16/2011 14 18 0 14 16 0 0 0 0 0 0 6/17/2011 21 12 0 21 7 0 0 0 0 0 0 6/18/2011 17 15 0 12 17 0 0 0 0 0 0 6/20/2011 15 14 0 11 16 0 0 0 0 0 0 6/21/2011 17 11 0 13 14 0 0 0 0 0 0 6/20/2011 11 6 15 6 8 6/21/2011 8 16 8 21 12 Others Cutting problem Specs Wavy Stitch Trim problem Smocking Problem Uunbalanced/ Unmatched Inline checker 2 6/16/2011 0 15 4 32 7 6/23/2011 6/22/2011 6/21/2011 6/20/2011 6/18/2011 6/17/2011 Run Off Raw edge Broken Stitch Puckering/Pleating/ Roping 6/17/2011 12 5 8 0 22 6/18/2011 14 16 0 12 8 .

0 0 4 0 0 0 0 0 8 0 0 2 0 0 0 0 0 0 0 0 14 0 0 0 0 0 0 0 0 0 Others Cutting problem Specs Wavy Stitch Trim problem Smocking Problem Uunbalanced/ Unmatched Run Off 6/23/2011 6/22/2011 6/21/2011 6/20/2011 6/18/2011 6/17/2011 6/16/2011 6/15/2011 Raw edge Broken Stitch Puckering/Pleating/ Roping inline checker 1 Unbalanced/Unmatched Smocking Problem 0 8 26 3 15 5 8 25 5 7 15 102 Trim Problem 0 0 0 0 0 0 0 0 0 0 0 0 Wavy Stitch Specs 0 0 0 0 0 0 0 0 0 3 5 8 0 16 3 24 5 12 14 5 4 27 8 118 OT CP SP 0 0 0 4 3 0 2 0 0 0 0 9 .

SP WS TP SM 23/Jun/11 22/Jun/11 21/Jun/11 20/Jun/11 18/Jun/11 17/Jun/11 16/Jun/11 15/Jun/11 14/Jun/11 UM RO RE Broken S End line checker defects Puckering Problem+D390 Broken Stitch Raw Edge Run Off Unbalanced/ Unmatched Smocking Problem .

6/22/2011 6/23/2011 0 9 24 21 0 0 19 16 12 15 0 0 0 0 0 0 0 0 0 0 0 0 6/22/2011 6/23/2011 7 14 11 8 10 13 11 4 9 17 .

0 0 6 0 0 0 Cutting Problem 0 0 0 0 0 0 0 0 0 0 0 0 0 0 9 0 0 0 .

M675 inline checker 1 DATE operations 11-Jun-11 Neck attachmemt Neck Finish Total DHU PP BS RE 5 4 8 5 13 9 23.45783 24.638554 14.5 35 30 0 3 3 7.786 DHU 21.07 CP 0 0 0 0 OT total total checked pcs 0 1 29 132 0 0 27 0 1 56 0 1.9697 20.21 16.09639 .Line 1 ITEM No.45455 42.42424 50 11-Jun-11 40 30 Total 20 DHU 10 0 PP DATE operations 13-Jun-11 Neck attachmemt Neck Finish Total DHU PP BS 3 5 8 20 BS RE 5 8 13 32.:.5 RE RO UM SM defects RO UM 4 2 6 15 TP SM 4 6 10 25 WS TP 0 0 0 0 SP CP WS 0 0 0 0 OT SP 0 0 0 0 CP 0 0 0 0 OT 0 0 0 0 0 0 0 0 total total checked pcs 16 166 24 40 13-Jun-11 25 20 15 Total 10 DHU DHU 9.07 0 0 0 0 defects RO UM SM 0 10 0 14 0 24 0 42.86 TP 0 0 0 0 WS SP 0 9 0 0 0 9 0 16.

78431 13.83333 29.5098 .57 5.43 8.72549 24.714 TP WS TP 0 0 0 0 SP CP OT WS SP 0 11 0 0 0 11 0 31.43 CP 0 0 0 0 35 OT 0 0 0 0 0 0 0 0 total total checked pcs 16 120 19 35 DHU 13.33333 15.15 DHU 10 5 0 PP DATE operations 14-Jun-11 Neck attachmemt Neck Finish Total DHU PP BS BS RE 0 0 5 4 3 0 4 3 5 11.29 RE RO UM SM defects RO UM SM 0 0 10 2 10 2 28.571 14.16667 14-Jun-11 30 25 20 Total 15 DHU 10 5 0 PP DATE operations 15-Jun-11 Neck attachmemt Neck Finish Total DHU PP BS 2 6 8 16 BS RE RE 10 7 17 34 0 0 0 0 RO UM SM defects RO UM 0 7 7 14 TP SM 10 8 18 36 WS SP TP 0 0 0 0 CP WS 0 0 0 0 OT SP 0 0 0 0 CP 0 0 0 0 OT 0 0 0 0 0 0 0 0 total total checked pcs 22 204 28 50 DHU 10.

19 6.452 RE RO UM SM defects RO UM SM 0 4 32 3 32 7 51.41667 25.40 15-Jun-11 35 30 25 20 Total 15 DHU 10 5 0 PP DATE operations 16-Jun-11 Neck attachmemt Neck Finish Total DHU PP BS BS RE 0 5 0 0 10 4 0 15 4 0 24.452 CP 0 0 0 0 OT 0 0 0 0 60 total total checked pcs 0 13 240 0 49 0 62 0 DHU 5.83333 16-Jun-11 50 40 30 Total 20 DHU 10 0 PP DATE operations 17-Jun-11 Neck attachmemt PP BS 10 RE 0 BS RE RO UM SM defects RO UM SM 0 0 10 TP WS TP 0 SP CP WS 0 OT SP 0 CP 0 OT 0 2 total total checked pcs 22 585 DHU 3.760684 .29 TP WS TP 0 0 0 0 SP CP WS OT SP 0 4 0 0 0 4 0 6.61 11.416667 20.

74359 17-Jun-11 40 30 Total 20 DHU 10 0 PP DATE operations 18-Jun-11 Neck attachmemt Neck Finish Total DHU PP BS 4 10 14 28 BS RE 8 8 16 32 0 0 0 0 RE RO UM SM TP WS SP defects RO UM 0 12 12 24 SM 6 2 8 16 TP 0 0 0 0 CP OT WS 0 0 0 0 SP 0 0 0 0 CP 0 0 0 0 OT 0 0 0 0 0 0 0 0 total total checked pcs 18 525 32 50 18-Jun-11 35 30 25 20 Total 15 DHU 10 5 0 PP BS RE defects RO UM SM TP WS SP CP OT DHU 3.982906 9.772 14.509 50 35 57 585 5.05 8.04 0 0 0 12 22 38.428571 6.Neck Finish Total DHU 2 5 8 12 5 8 21.095238 9.52381 .04 0 0 0 0 0 0 2 0 3.6 0 0 0 0 8 0 8 0 14.

33 CP 0 0 0 0 OT 0 0 0 0 30 0 0 0 0 total total checked pcs 16 480 44 60 DHU 3.166667 12.583333 13.62 12.33 BS RE 6 0 6 10 RO 0 15 15 25 UM 0 6 6 10 SM 1 7 8 13.31 35 RE RO UM SM defects RO UM SM 0 0 21 12 21 12 32.958333 9.333333 9.31 24.5 20-Jun-11 25 20 15 Total 10 DHU 5 0 PP DATE operations 21-Jun-11 Neck attachmemt Neck Finish Total DHU PP BS BS RE 8 11 0 0 5 8 8 16 8 12.46 TP WS TP 0 0 0 0 SP CP WS 0 0 0 0 OT SP 0 0 0 0 CP 0 0 0 0 OT 0 0 0 0 0 0 0 0 total total checked pcs 19 480 46 65 21-Jun-11 30 25 20 15 10 5 0 Total DHU DHU 3.31 18.DATE operations 20-Jun-11 Neck attachmemt Neck Finish Total DHU PP 9 2 11 18.33 TP 0 0 0 0 WS SP 0 0 0 14 0 14 0 23.54167 .

41379 22-Jun-11 20 15 Total 10 DHU 5 0 PP DATE operations 23-Jun-11 Neck attachmemt Neck Finish Total DHU PP BS BS RE 4 8 0 10 0 13 14 8 13 21.96 20.37 16.137931 8.53763 13.15 TP TP 0 0 0 0 WS SP CP WS SP 0 4 0 5 0 9 0 13.11 0 0 0 0 SP CP OT CP 0 0 0 0 OT 0 0 0 0 25 0 0 0 0 total total checked pcs 18 435 36 54 DHU 4.85 OT CP 0 0 0 0 OT 0 0 0 0 23-Jun-11 0 0 0 0 total total checked pcs 16 465 49 65 DHU 3.97849 .154 26.31 20 30 RE RO UM SM defects RO UM SM 0 0 4 17 4 17 6.54 12.67 TP WS TP WS SP 0 6 0 0 0 6 0 11.37 18.52 RE RO UM SM defects RO UM SM 0 0 11 9 11 9 20.275862 12.44086 10.0 PP DATE operations 22-Jun-11 Neck attachmemt Neck Finish Total DHU PP BS BS RE 7 5 0 0 6 10 7 11 10 12.

85 BS 12 6 0 13 12 19 19.81 11.11111 total total checked pcs 0 20 585 0 42 0 62 0 DHU 3.076923 8.034188 11.29 DEFECT LIST PP BS RE RO PUCKERING/PLEATING/ROPING BROKEN/INSECURE/SKIP/UNTIDY JOINT RAW EDGE RUN OFF TP WS SP TP 0 0 0 0 WS 0 0 0 0 TP 0 0 0 0 CP SP 0 0 0 0 WS 0 0 0 0 OT CP 0 0 0 0 SP 0 0 0 0 OT 0 0 0 0 CP 0 0 0 0 OT 0 0 0 0 total total checked pcs 18 585 47 65 DHU 3.418803 7.46 18.30 25 20 Total 15 DHU 10 5 0 PP DATE operations 24-Jun-11 Neck attachmemt Neck Finish Total DHU PP DATE operations 25-Jun-11 Neck attachmemt Neck Finish Total DHU PP BS BS RE 12 6 0 0 6 9 12 12 9 18.46 13.59829 0 0 0 0 .35 30.179487 10.92 defects RO UM SM 0 2 16 5 16 7 25.65 RE 0 8 8 12.31 16.9 RE RO UM SM defects RO UM SM 0 0 21 11 21 11 32.

UM SM TP WS SP CP OT UNBALANCED/UNMATCHED SMOCKING PROBLEM TRIM PROBLEM WAVY STITCH SPECS CUTTING PROBLEM OTHER .

.

3 defects RO UM SM 0 10 0 0 9 0 0 0 0 0 19 0 0 28.15152 12.78 16.19 40 35 30 25 20 defects RO UM SM 0 9 5 0 6 0 0 0 4 0 15 9 0 27.72727 12.M675 TP 0 0 0 0 0 WS 0 0 0 0 0 SP 0 0 0 0 0 CP 0 0 0 0 0 50 OT 0 0 0 0 0 total 0 0 0 0 0 total checked pcs 25 21 20 66 165 DHU 15.Line 1 inline checker 2 DATE operations 11-Jun-11 Zipper Attach Zipper Finish Side attach Total DHU PP BS 7 0 20 27 40.37 35.67 TP 0 0 0 0 0 WS 0 0 0 0 0 SP 0 0 0 0 0 CP 0 0 0 0 0 OT 0 0 0 0 0 13-Jun-11 Total total 0 0 0 0 0 total checked pcs 25 17 12 54 245 DHU 10.04082 .20408 6.897959 22.79 0 ITEM No.12121 40 11-Jun-11 40 30 Total 20 DHU 10 0 PP BS RE RO UM SM TP WS SP CP OT DATE operations 13-Jun-11 Zipper Attach Zipper Finish Side attach Total DHU PP BS RE 0 11 11 0 0 8 11 19 20.:.909 RE 8 12 0 20 30.938776 4.

25 20 15 10 5 0 Total DHU PP DATE operations 14-Jun-11 Zipper Attach Zipper Finish Side attach Total DHU PP BS RE 8 9 0 0 5 6 13 15 22.32 BS RE RO UM SM defects RO UM SM 0 13 0 0 8 8 0 0 0 0 21 8 0 36.313725 22.67213 .868852 19.35294 Total DHU BS 0 8 0 8 OT 14-Jun-11 PP DATE operations 15-Jun-11 box pleat attach sleeve attach center sleeve attach Total CP RE 0 8 0 8 BS RE RO UM SM defects RO UM SM 0 7 8 0 5 0 0 16 8 0 28 16 TP WS TP 0 0 0 0 SP CP WS 0 0 0 0 SP 0 0 0 0 CP 0 0 0 0 OT 0 0 0 0 total 0 0 0 0 total checked pcs 15 21 24 60 305 DHU 4.27451 4.807 26.04 TP WS SP TP 0 0 0 0 0 CP WS 0 0 0 0 0 OT SP 0 0 0 0 0 0 0 0 0 0 40 35 30 25 20 15 10 5 0 PP 0 0 0 0 0 total 0 0 0 0 0 total checked pcs 30 16 11 57 255 DHU 11.918033 6.76471 6.885246 7.84 14.

58 25.67 0 0 0 0 50 0 0 15-Jun-11 40 30 Total 20 DHU 10 0 PP DATE operations 16-Jun-11 box pleat attach sleeve attach center sleeve attach Total DHU PP BS BS RE 4 11 0 7 10 0 14 18 22.797468 15.581 29.67 26.81 WS SP TP 0 0 0 0 0 CP OT WS 0 0 0 0 0 SP 0 0 0 0 0 35 CP 0 0 0 0 0 OT 0 0 0 0 0 16-Jun-11 30 25 20 Total 15 DHU 10 5 0 PP BS RE RO UM SM TP WS SP CP OT total 0 0 0 0 0 total checked pcs 15 32 15 62 395 DHU 3.DHU 13.03 RE RO UM SM TP defects RO UM SM 0 0 0 0 9 16 0 5 0 0 14 16 0 22.333 13.6962 .797468 8.101266 3.33 0 46.

352941 5.268041 4.426 19.490196 4.0 PP DATE operations 17-Jun-11 box pleat attach sleeve attach center sleeve attach Total DHU BS RE RO UM SM TP defects RO UM SM 0 0 7 0 5 0 0 16 0 0 21 7 0 34.869 24.773196 12.67 27.57732 DHU 6 0 0 15 11 0 17 15 27.48 PP BS RE 4 0 5 12 12 0 21 12 34.96078 .87 TP WS SP TP 0 0 0 0 0 CP OT WS 0 0 0 0 0 SP 0 0 0 0 0 CP 0 0 0 0 0 OT 0 0 0 0 0 18-Jun-11 total 0 0 0 0 0 total checked pcs 12 28 21 61 510 DHU 2.43 11.67 WS SP TP 0 0 0 0 0 CP OT WS 0 0 0 0 0 SP 0 0 0 0 0 40 35 30 25 20 15 10 5 0 PP 20 total checked pcs 11 22 28 61 485 DHU 2.117647 11.536082 5.59 25 total 0 0 0 0 0 Total BS 30 OT 0 0 0 0 0 17-Jun-11 PP DATE operations 18-Jun-11 box pleat attach sleeve attach center sleeve attach Total DHU CP 0 0 0 0 0 RE BS RE RO UM SM defects RO UM SM 0 6 0 0 6 7 0 0 10 0 12 17 0 19.

578313 13.217391 4.786 RE 6 0 8 14 25 BS RE RO UM SM defects RO UM SM 0 0 5 0 11 0 0 0 11 0 11 16 0 19.20 15 Total 10 DHU 5 0 PP DATE operations 20-Jun-11 box pleat attach sleeve attach center sleeve attach Total DHU PP BS 0 15 0 15 26.173913 5.49398 20-Jun-11 25 20 15 Total 10 DHU 5 0 PP DATE operations 21-Jun-11 box pleat attach sleeve attach center sleeve attach PP BS 5 0 12 BS RE 0 11 0 RE RO UM SM TP defects RO UM SM 0 0 5 0 13 0 0 0 9 WS SP CP TP 0 0 0 OT WS 0 0 0 SP 0 0 0 CP 0 0 0 OT 0 0 0 total 0 0 0 total checked pcs 10 24 21 460 DHU 2.64 28.565217 .650602 6.57 TP WS SP TP CP OT WS 0 0 0 0 0 0 0 0 0 0 SP 0 0 0 0 0 CP OT 0 0 0 0 0 30 0 0 0 0 0 total 0 0 0 0 0 total checked pcs 11 26 19 56 415 DHU 2.26506 4.

877551 3.460 Total DHU 17 30.45 0 0 0 0 0 0 0 0 35 0 0 0 0 55 11.95652 21-Jun-11 30 25 20 Total 15 DHU 10 5 0 PP DATE operations 22-Jun-11 box pleat attach sleeve attach center sleeve attach Total DHU PP BS BS RE 0 11 0 5 0 8 0 24 0 43.22449 .061224 11.909 11 20 0 0 13 14 23.285714 3.55 21.64 25.82 WS SP TP 0 0 0 0 0 CP OT WS 0 0 0 0 0 SP 0 0 0 0 0 CP 0 0 0 0 0 50 45 40 35 30 25 20 15 10 5 0 OT 0 0 0 0 0 22-Jun-11 Total DHU PP BS RE RO UM SM TP WS SP CP OT total 0 0 0 0 0 total checked pcs 21 19 15 55 490 DHU 4.64 RE RO UM SM TP defects RO UM SM 0 10 0 0 9 5 0 0 7 0 19 12 0 34.

23 24.84211 23-Jun-11 35 30 25 20 Total 15 DHU 10 5 0 PP DATE operations 24-Jun-11 box pleat attach sleeve attach center sleeve attach Total DHU PP BS 0 0 8 0 0 10 8 10 12.842105 3.87 45 40 35 30 BS RE RE RO UM SM TP defects RO UM SM 0 8 6 0 17 0 0 0 14 0 25 20 0 39.754 34.333333 14 .75 WS SP TP 0 0 0 0 0 CP OT WS 0 0 0 0 0 SP 0 0 0 0 0 CP 0 0 0 0 0 OT 0 0 0 0 0 24-Jun-11 total 0 0 0 0 0 total checked pcs 14 25 24 63 450 DHU 3.368421 12.59 WS SP TP 0 0 0 0 0 CP OT WS 0 0 0 0 0 SP 0 0 0 0 0 CP 0 0 0 0 0 40 OT 0 0 0 0 0 total 0 0 0 0 0 total checked pcs 22 23 16 61 475 DHU 4.43 RE RO UM SM TP defects RO UM SM 0 0 15 0 9 0 0 7 0 0 16 15 0 26.631579 4.68 31.111111 5.698 15.555556 5.PP DATE operations 23-Jun-11 box pleat attach sleeve attach center sleeve attach Total DHU BS PP BS RE 0 7 9 5 0 9 9 21 14.

76471 .67 36.35 30 25 20 15 10 5 0 Total DHU PP DATE operations 25-Jun-11 box pleat attach sleeve attach center sleeve attach Total DHU PP BS BS RE RO UM SM TP defects RO UM SM 0 0 9 0 7 0 0 12 13 0 19 22 0 31.137255 4.67 RE 0 10 9 0 0 0 9 10 15 16.67 WS SP TP 0 0 0 0 0 CP WS 0 0 0 0 0 OT SP 0 0 0 0 0 CP 0 0 0 0 0 OT 0 0 0 0 0 40 25-Jun-11 35 30 25 20 Total 15 DHU 10 5 0 PP DEFECT LIST BS RE RO UM SM TP WS SP CP OT total 0 0 0 0 0 total checked pcs 19 16 25 60 510 DHU 3.901961 11.72549 3.

PP BS RE RO UM SM TP WS SP CP OT PUCKERING/PLEATING/ROPING BROKEN/INSECURE/SKIP/UNTIDY JOINT RAW EDGE RUN OFF UNBALANCED/UNMATCHED SMOCKING PROBLEM TRIM PROBLEM WAVY STITCH SPECS CUTTING PROBLEM OTHER .

M675 Endline checker DATE 11-Jun-11 operations inline Pleat checker neck attach neck finish side o/l sleeve fold Bottom fold Zipper Attach Zipper Finish sleeve tacking Dori label attach Total DHU PP 0 0 0 7 0 3 0 0 0 0 0 10 33.Line 1 ITEM No.666667 0 0 7.888889 3.66667 .333 BS RE 0 0 0 0 0 0 0 0 6 0 0 6 20 defects RO UM 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 7 0 0 0 7 0 0 14 46.:.67 SM 0 0 0 0 0 0 0 0 0 0 0 0 0 TP 0 0 0 0 0 0 0 0 0 0 0 0 0 WS 0 0 0 0 0 0 0 0 0 0 0 0 0 SP CP 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 OT 0 0 0 0 0 0 0 0 0 0 0 0 0 total 0 0 0 0 0 0 0 0 0 0 0 0 0 total checked pcs 0 0 0 7 7 3 0 0 13 0 0 30 50 11-Jun-11 45 40 35 30 25 Total 20 DHU 15 10 5 0 PP endline checker BS RE RO UM SM TP WS SP CP OT 180 DHU 0 0 0 3.222222 0 0 16.888889 1.

284768 0 0.DATE 13-Jun-11 operations inline Pleat checker neck attach neck finish side o/l sleeve fold Bottom fold Zipper Attach Zipper Finish sleeve tacking Dori label attach Total DHU PP BS 0 0 0 0 0 0 0 0 0 0 0 0 0 6 0 0 0 0 0 0 0 0 0 6 0 11.538 defects RE RO UM SM 0 0 0 5 0 3 0 0 0 0 0 2 0 0 0 16 0 0 1 0 0 0 0 0 0 0 0 0 0 3 0 0 0 22 0 8 42.21854 13-Jun-11 40 35 30 25 Total 20 DHU 15 10 5 0 PP BS RE RO UM SM TP WS SP CP OT endline checker DATE 14-Jun-11 operations inline Pleat checker PP BS 0 RE 0 defects RO UM SM 0 0 0 TP 0 WS 0 SP 0 CP 0 OT 0 total 0 total checked pcs 0 DHU 0 286 .298013 2.38 TP 0 0 0 0 0 0 0 0 0 0 0 0 0 WS 0 0 0 0 0 0 0 0 0 0 0 0 0 SP 0 14 0 0 0 0 2 0 0 0 0 16 30.77 CP 0 0 0 0 0 0 0 0 0 0 0 0 0 OT 0 0 0 0 0 0 0 0 0 0 0 0 0 45 total 0 0 0 0 0 0 0 0 0 0 0 0 0 total checked pcs 0 22 0 2 0 16 9 0 0 3 0 52 302 DHU 0 7.993377 0 17.308 0 15.980132 0 0 0.662252 0 5.

797203 0 0 0 0 4.52 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 3 0 0 0 0 0 3 6.195804 16.285714 2.inline checker neck attach neck finish side o/l sleeve fold Bottom fold Zipper Attach Zipper Finish sleeve tacking Dori label attach Total DHU 0 0 0 0 0 0 0 0 0 0 0 0 0 0 3 0 0 0 0 0 0 0 0 0 0 0 0 0 12 0 0 12 3 0 26.714286 .5217 0 26 0 0 0 0 0 0 2 0 0 0 0 0 0 0 0 0 0 0 2 26 4.348 56.857143 0 1.08392 14-Jun-11 50 40 30 Total DHU 20 10 0 PP inline operations DATE 15-Jun-11 checker Pleat neck attach neck finish side o/l sleeve fold Bottom fold PP BS 0 8 0 0 0 0 RE 0 0 0 0 0 0 BS RE RO UM defects RO UM SM 0 0 0 0 0 0 0 6 0 0 0 3 0 0 0 0 0 0 SM TP TP 0 0 0 0 0 0 WS WS 0 0 0 0 0 0 SP CP SP 0 0 0 0 0 6 OT CP 0 0 4 0 0 0 OT 0 0 0 0 0 0 total 0 0 0 0 0 0 total checked pcs 0 8 10 3 0 6 350 DHU 0 2.087 6.857143 0.522 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 60 26 0 0 0 8 0 0 0 0 12 46 286 9.090909 0 0 0 2.

339286 .669643 0 1.142857 14.28571 60 15-Jun-11 50 40 30 Total DHU 20 10 0 PP DATE 16-Jun-11 operations inline Pleat checker neck attach neck finish side o/l sleeve fold Bottom fold Zipper Attach Zipper Finish sleeve tacking Dori label attach PP BS 0 0 4 0 0 0 0 0 0 0 0 RE 0 0 0 3 0 0 0 0 0 0 6 BS RE RO UM defects RO UM SM 0 0 0 0 0 12 0 0 0 0 0 0 0 0 0 5 0 0 6 0 3 0 1 0 0 0 0 0 0 0 0 0 0 SM TP TP 0 0 0 0 0 0 0 0 0 0 0 WS WS 0 0 0 0 0 0 0 0 0 0 0 SP SP 0 0 3 0 0 0 2 0 0 0 0 CP OT CP 0 0 3 0 0 0 0 0 0 0 0 OT 0 0 0 0 0 0 0 0 0 0 0 total 0 0 0 0 0 0 0 0 0 0 0 total checked pcs 0 12 10 3 0 5 11 1 0 0 6 448 DHU 0 2.428571 0 0 0 5.678571 2.455357 0.350 Zipper Attach Zipper Finish sleeve tacking Dori label attach Total DHU 0 0 0 0 0 8 16 0 0 0 0 0 0 0 5 0 0 0 0 5 10 0 0 0 0 0 6 12 0 0 0 0 0 3 6 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 18 24 48 0 0 0 0 0 4 8 0 0 0 0 0 0 0 0 0 0 0 0 0 0 5 0 0 0 18 50 1.223214 0 0 1.232143 0.116071 2.

25 0 0 0 0 48 10.45614 3.75 22.14 CP SP OT CP 0 0 0 0 0 0 0 0 0 0 0 0 0 OT total 0 0 0 0 0 0 0 0 0 5 0 0 0 0 0 0 0 0 0 0 0 0 0 5 0 7.917 1 15 2.877193 2.Total DHU 4 8.684211 0.403509 0.877193 0 12.143 7.286 7.052632 1.083 31.143 SM RE TP WS TP 0 0 0 0 0 0 0 0 0 0 0 0 0 SP WS 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 3 0 0 0 7 0 0 2 0 12 17.25 0 0 0 0 5 10.403509 1.1429 40 BS RE RO UM defects RO UM SM 0 0 0 0 0 0 0 0 5 0 0 0 0 0 0 12 0 0 12 2 0 0 3 0 0 0 0 0 0 0 0 0 0 24 5 5 34.3333 9 11 18.2807 .71429 35 16-Jun-11 30 25 20 Total 15 DHU 10 5 0 PP DATE 17-Jun-11 operations inline Pleat checker neck attach neck finish side o/l sleeve fold Bottom fold Zipper Attach Zipper Finish sleeve tacking Dori label attach Total DHU PP BS 0 0 6 0 0 0 8 0 0 0 0 2 0 0 0 0 0 0 0 3 0 0 14 5 20 7.1429 17-Jun-11 total checked pcs 0 6 8 8 5 14 21 3 0 5 0 70 570 DHU 0 1.526316 0 0.42 3 6.

3333 31.71429 .40 17-Jun-11 35 30 25 20 Total 15 DHU 10 5 0 PP DATE 18-Jun-11 operations inline Pleat checker neck attach neck finish side o/l sleeve fold Bottom fold Zipper Attach Zipper Finish sleeve tacking Dori label attach Total DHU PP BS BS 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 RE RO UM SM defects RE RO UM SM 0 0 0 0 0 4 0 0 4 0 0 0 0 0 0 0 6 0 0 2 0 0 11 0 0 0 0 5 0 0 0 0 0 5 19 8 8.142857 10.892857 2.3333 OT 0 0 0 0 0 0 0 0 0 0 0 0 0 total 0 0 0 0 0 0 0 0 0 0 12 12 20 35 18-Jun-11 30 25 total checked pcs 0 4 6 0 0 6 12 15 0 5 12 60 560 DHU 0 0.142857 2.714286 1.67 13.33 TP WS TP 0 0 0 0 0 0 0 0 0 0 0 0 0 SP CP OT WS 0 0 0 0 0 0 0 0 0 0 0 0 0 SP CP 0 0 0 0 0 2 0 0 0 0 0 0 10 0 4 0 0 0 0 0 0 0 14 2 23.678571 0 0.33 3.071429 2.071429 0 0 1.

5 2.785714 1.892857 0.333 CP OT SP CP 0 0 0 0 0 0 0 0 0 0 0 0 0 OT total 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 45 40 20-Jun-11 35 30 25 20 Total total checked pcs 0 5 3 10 7 4 14 12 0 5 0 60 560 DHU 0 0.71429 .6667 0 41.333 0 0 0 0 0 0 4 5 0 3 0 12 20 RE RO UM SM defects RE RO UM SM 0 0 0 0 0 5 0 0 0 0 0 10 0 0 0 4 0 0 0 0 10 0 0 0 0 0 0 0 0 0 0 0 0 4 0 25 6.25 20 Total 15 DHU 10 5 0 PP DATE 20-Jun-11 operations inline Pleat checker neck attach neck finish side o/l sleeve fold Bottom fold Zipper Attach Zipper Finish sleeve tacking Dori label attach Total DHU PP BS BS 0 0 3 0 7 0 0 4 0 0 0 14 23.142857 0 0.25 0.892857 0 10.535714 1.714286 2.67 TP WS TP 0 0 0 0 0 0 0 0 0 0 0 0 0 SP WS 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 3 0 2 0 5 8.

621622 0.727 RE RO UM SM defects RO UM SM 0 0 0 0 0 5 0 5 0 0 0 0 0 0 0 9 0 0 0 0 0 3 0 0 0 0 0 0 5 0 0 0 0 12 10 5 21.18 9.909 0 10 16 2 6 9 4 3 0 5 0 55 21-Jun-11 20 15 Total 10 5 total checked pcs DHU 555 DHU 0 1.720721 0.801802 2.36036 1.900901 0 9.25 Total 20 DHU 15 10 5 0 PP DATE 21-Jun-11 operations inline Pleat checker neck attach neck finish side o/l sleeve fold Bottom fold Zipper Attach Zipper Finish sleeve tacking Dori label attach Total DHU PP BS 0 5 0 2 0 0 0 0 0 0 0 7 12.273 CP OT SP CP 0 0 0 0 0 0 0 0 0 0 0 0 0 OT total 0 0 0 0 0 0 0 0 0 6 0 0 0 0 0 0 0 0 0 0 0 0 0 6 0 10.882883 0.90991 .091 TP RE 0 0 11 0 0 0 0 0 0 0 0 11 20 25 BS WS TP 0 0 0 0 0 0 0 0 0 0 0 0 0 SP WS 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 4 0 0 0 0 4 7.081081 1.540541 0 0.818 18.

66 CP SP OT CP 0 5 3 0 0 0 8 7 0 4 0 27 50.434 BS RE 0 0 0 0 0 0 0 0 0 0 0 0 0 RE RO UM SM defects RO UM SM 0 0 0 0 0 0 0 3 0 0 0 3 0 0 0 0 0 0 0 0 4 0 0 0 0 0 0 0 0 0 0 0 0 0 3 7 0 5.21 TP TP 0 0 0 0 0 0 0 0 0 0 0 0 0 WS SP WS 0 0 0 0 0 0 0 0 0 0 3 3 5.0 PP DATE 22-Jun-11 operations inline Pleat checker neck attach neck finish side o/l sleeve fold Bottom fold Zipper Attach Zipper Finish sleeve tacking Dori label attach Total DHU PP BS 0 2 0 3 0 0 0 0 0 0 0 5 9.66 13.094 60 22-Jun-11 50 40 30 Total DHU 20 10 0 PP BS RE RO UM SM TP WS SP CP OT total checked pcs 0 7 6 6 0 2 12 7 0 4 9 53 553 DHU 0 1.94 0 0 0 0 0 0 0 0 0 0 0 0 0 OT total 0 0 0 0 0 0 0 0 0 0 0 2 0 0 0 0 0 0 0 0 0 6 0 8 0 15.265823 0 0.169982 1.627486 9.084991 1.084991 0 0.361664 2.584087 .265823 1.723327 1.

086957 2.615 WS SP CP 0 0 0 0 6 0 2 0 0 0 0 8 15.086957 0.362319 0.811594 0.6923 26.905797 9.DATE 23-Jun-11 operations inline Pleat checker neck attach neck finish side o/l sleeve fold Bottom fold Zipper Attach Zipper Finish sleeve tacking Dori label attach Total DHU PP BS 0 0 2 4 0 0 0 0 0 0 0 6 11.92 28.536232 1.905797 1.85 TP 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 5 5 9.362319 0.38 0 0 0 0 0 0 0 0 0 0 0 0 0 35 OT 0 0 0 0 0 0 0 0 0 0 0 0 0 total 0 0 0 0 0 0 0 0 0 0 0 0 0 23-Jun-11 30 25 20 Total 15 DHU 10 5 0 PP BS RE RO UM SM DEFECT LIST PP BS RE RO UM PUCKERING/PLEATING/ROPING BROKEN/INSECURE/SKIP/UNTIDY JOINT RAW EDGE RUN OFF UNBALANCED/UNMATCHED TP WS SP CP OT total checked pcs 0 5 6 14 6 2 2 2 0 10 5 52 552 DHU 0 0.538 0 0 0 0 0 0 0 0 0 0 0 0 0 defects RE RO UM SM 0 0 0 0 0 5 0 4 0 0 0 10 0 0 0 2 0 0 0 0 0 2 0 0 0 0 0 0 10 0 0 0 0 4 14 15 7.42029 .362319 0 1.

SM TP WS SP CP OT SMOCKING PROBLEM TRIM PROBLEM WAVY STITCH SPECS CUTTING PROBLEM OTHER 11-Jun-11 13-Jun-11 14-Jun-11 15-Jun-11 16-Jun-11 17-Jun-11 18-Jun-11 20-Jun-11 21-Jun-11 22-Jun-11 23-Jun-11 Total PuckeringBroken Problem+D390 Stitch Raw EdgeRun Off Unbalanced/ Smocking Unmatched Trim Problem Problem Wavy Stitch Specs 10 6 0 14 0 0 0 0 0 6 22 0 8 0 0 16 0 12 3 2 26 0 0 3 8 0 5 6 3 0 0 24 4 9 11 1 15 0 0 5 14 5 24 5 5 0 0 12 0 0 5 19 8 0 0 14 14 12 4 0 25 0 0 5 7 11 12 10 5 0 0 4 5 0 0 3 7 0 3 27 6 0 4 14 15 0 5 8 68 61 90 74 102 0 8 118 100% 90% 80% 70% 60% 50% 0 0 0 4 3 0 2 0 0 0 0 9 Cutting Problem Others 0 0 0 0 0 0 0 0 0 0 0 5 0 0 0 0 0 6 0 8 0 0 0 19 Others Cutting Problem Specs Wavy Stitch Trim Problem 40% Smocking Problem 30% 20% Unbalanced/Unmatche d Run Off 10% Raw Edge 0% Broken Stitch .

0 Others Cutting… Specs Wavy Stitch Trim… Smocking… Unbalance… Run Off Raw Edge Broken… Puckering… 150 100 50 Run Off 23/Jun/11 22/Jun/11 21/Jun/11 20/Jun/11 18/Jun/11 17/Jun/11 16/Jun/11 15/Jun/11 14/Jun/11 13/Jun/11 11/Jun/11 0% defects Puckering Problem+D390 Broken Stitch Raw Edge Broken Stitch Puckering Problem .

Line 1 Sl. No.M675 CRITICAL OPERATIONS 1 front pintuk making 2 Collar finish 3 Zipper attachment 4 Zipper finish 5 Hemming DEFECTS Pinch Unstitched Insecure stitch Inside ply visible uneven curve Misstitch Uneven width Pinch Improper allignment Loose stitch Loose stitch Raw edge Unfinished Wavy hem Raw edge MAN Y Y Y y y y y y y y y y y y CAUSES MACHINE MATERIAL Y METHOD Y Y y y Y y y Y y y Y .:. ITEM No.

:. 1 2 3 4 5 6 7 Operation In line checker 1 (pleat.66666667 52 302 17.M675 Alter checked Pcs Date Sl No.21854 Total extra time Total extra time for the style Extra cost incurred 12 46 286 16.0839161 .Line 1 ITEM No. neck attach) In line checker 2 (neck finish) Side o/l Sleeve Hem Bottom Hem Sleeve fold taki Dori 11-Jun-11 Type 7 7 3 13 PP RO PP 6BS+7RO 13-Jun-11 Type 5RO+14WS+ 22 3UM 14-Jun-11 26 2 UM 16 RE 8 3 UM 6BS+1RE+2 9 WS 8 Zipper attach 9 Zipper finish 10 Label attach TOTAL ALTER TOTAL CHECHED DHU % 30 180 16.

71429 17-Jun-11 Type 6 PP 18-Jun-11 4 3WS+5UM PP OT 12RE+2BS 6 5 2WS+3BS 12RE+7WS 21 +2RO 5 8 8 5 14 3 RO 70 570 12.71429 .ITEM No.:.2807 6 12 15 12 60 560 10.28571 16-Jun-11 Type 12 UM 3WS+4PP 10 +3SP 3 BS 5 RE 3UM+2WS 11 +6RE 1 RO 6 BS 48 448 10.M675 Type UM 15-Jun-11 Type 8 PP 10 4SP+6RO 3 UM 3RE+2RO+3WS 6 WS 5 RE BS 18 WS 50 350 14.

71429 21-Jun-11 Type 22-Jun-11 Type 10 5UM+5PP 7 2PP+5WS 16 2 6 9 6 3RO+3WS 6 3UM+3PP 5RO+11BS PP OT RE 5 RO 4 WS 3 RO 55 555 9.42029 .584087 4RO+2PP 10UM+4PP WS RE 2 WS 2 RE 5 TP 52 552 9.90991 23-Jun-11 Type 5 UM 2 OT 6 14 6 2 4 WS 10 RO 12 8WS+2UM 7 WS 9 TP 53 553 9.Type UM 4UM+2SP RO RE 10WS+2RO 11RO+4WS OT 20-Jun-11 Type 5 UM 3 10 7 4 PP UM PP RE 5 BS 14 10UM+4BS 3WS+4PP+ 12 5BS 60 560 10.

M67 actual SAM (in min.5 0.8 1.) SL.45 1.35 0.) 1.Line 1 ITEM No.6 1.34 time for rework (in min.2 0.4 0.77 1.:.52 observed SAM (in min. 1 2 3 4 5 6 7 8 9 10 11 operations pintuck making neck attach neck finish side o/l sleeve Hem Bottom Hem Zipper Attach Zipper Finish sleeve tacking loop label attach 1.82 2.2 0.65 0.) 0.8 1.4 0.16 1.2 0.4 0.8 1.19 0.36 1.5 0.54 0.5 0. No.4 0.78 0.28 1.98 0.84 0.6 .96 4.1 2.14 2.

72 0.72 0.) 2.95 1.72 0.61 5.) 3.23 4.95 0.72 0.72 0.:.95 0.72 0.62 3.95 0.) 0.ITEM No.37 4.01 8.89 4.4 3.95 0.95 0.95 0.29 2.67 2.73 9.72 0.27 2.) 0.51 3.72 0.95 0.61 .68 2.57 1.72 0.95 0.9 2.89 Checking after rework (in min.7 3.95 Total (in min.95 0.72 Total (in min.09 5.72 0.M675 Checking time (per gmt in min.42 3.55 1.95 0.

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