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

8 273 136.89 804.no.75 150.94 140 2520. of pcs total(in Rs) 150 1033.28 TOTAL 4814.42 Final cost (in Rs) 243.7 81 800.44 .5 116 459.

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 .

86 TP 0 0 0 0 WS SP 0 9 0 0 0 9 0 16.45455 42.21 16.:.786 DHU 21.5 35 30 0 3 3 7.07 CP 0 0 0 0 OT total total checked pcs 0 1 29 132 0 0 27 0 1 56 0 1.5 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 9.09639 .9697 20.638554 14.Line 1 ITEM No.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 32.45783 24.07 0 0 0 0 defects RO UM SM 0 10 0 14 0 24 0 42.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.

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 10.78431 13.43 CP 0 0 0 0 35 OT 0 0 0 0 0 0 0 0 total total checked pcs 16 120 19 35 DHU 13.714 TP WS TP 0 0 0 0 SP CP OT WS SP 0 11 0 0 0 11 0 31.5098 .29 RE RO UM SM defects RO UM SM 0 0 10 2 10 2 28.43 8.571 14.15 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 11.72549 24.33333 15.57 5.83333 29.

41667 25.19 6.452 RE RO UM SM defects RO UM SM 0 4 32 3 32 7 51.83333 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 3.61 11.416667 20.452 CP 0 0 0 0 OT 0 0 0 0 60 total total checked pcs 0 13 240 0 49 0 62 0 DHU 5.760684 .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 24.29 TP WS TP 0 0 0 0 SP CP WS OT SP 0 4 0 0 0 4 0 6.

Neck Finish Total DHU 2 5 8 12 5 8 21.772 14.428571 6.52381 .04 0 0 0 0 0 0 2 0 3.982906 9.04 0 0 0 12 22 38.05 8.6 0 0 0 0 8 0 8 0 14.509 50 35 57 585 5.095238 9.74359 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.

62 12.54167 .31 18.31 24.33 BS RE 6 0 6 10 RO 0 15 15 25 UM 0 6 6 10 SM 1 7 8 13.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 23.31 35 RE RO UM SM defects RO UM SM 0 0 21 12 21 12 32.46 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 3.333333 9.166667 12.5 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 12.33 CP 0 0 0 0 OT 0 0 0 0 30 0 0 0 0 total total checked pcs 16 480 44 60 DHU 3.958333 9.583333 13.

154 26.85 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 3.11 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 4.97849 .96 20.37 16.67 TP WS TP WS SP 0 6 0 0 0 6 0 11.31 20 30 RE RO UM SM defects RO UM SM 0 0 4 17 4 17 6.15 TP TP 0 0 0 0 WS SP CP WS SP 0 4 0 5 0 9 0 13.37 18.53763 13.0 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 12.54 12.41379 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 21.52 RE RO UM SM defects RO UM SM 0 0 11 9 11 9 20.137931 8.275862 12.44086 10.

418803 7.85 BS 12 6 0 13 12 19 19.29 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 3.076923 8.31 16.46 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 18.179487 10.9 RE RO UM SM defects RO UM SM 0 0 21 11 21 11 32.81 11.65 RE 0 8 8 12.11111 total total checked pcs 0 20 585 0 42 0 62 0 DHU 3.034188 11.92 defects RO UM SM 0 2 16 5 16 7 25.46 13.59829 0 0 0 0 .35 30.

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

.

79 0 ITEM No.Line 1 inline checker 2 DATE operations 11-Jun-11 Zipper Attach Zipper Finish Side attach Total DHU PP BS 7 0 20 27 40.938776 4.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 15.20408 6.15152 12.67 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 10.909 RE 8 12 0 20 30.78 16.3 defects RO UM SM 0 10 0 0 9 0 0 0 0 0 19 0 0 28.12121 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 20.897959 22.72727 12.:.04082 .19 40 35 30 25 20 defects RO UM SM 0 9 5 0 6 0 0 0 4 0 15 9 0 27.37 35.

918033 6.868852 19.84 14.807 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 11.35294 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 4.67213 .885246 7.76471 6.313725 22.25 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 36.27451 4.

33 0 46.81 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 3.03 RE RO UM SM TP defects RO UM SM 0 0 0 0 9 16 0 5 0 0 14 16 0 22.DHU 13.67 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 22.101266 3.333 13.58 25.797468 15.6962 .67 26.797468 8.581 29.

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 11.352941 5.0 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 34.59 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 19.773196 12.67 27.87 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 2.536082 5.43 11.490196 4.869 24.57732 DHU 6 0 0 15 11 0 17 15 27.426 19.96078 .268041 4.48 PP BS RE 4 0 5 12 12 0 21 12 34.

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 28.26506 4.173913 5.565217 .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 2.650602 6.578313 13.786 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 26.217391 4.

877551 3.95652 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 43.82 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 4.061224 11.22449 .64 RE RO UM SM TP defects RO UM SM 0 10 0 0 9 5 0 0 7 0 19 12 0 34.55 21.64 25.45 0 0 0 0 0 0 0 0 35 0 0 0 0 55 11.460 Total DHU 17 30.285714 3.909 11 20 0 0 13 14 23.

368421 12.555556 5.631579 4.23 24.754 34.842105 3.75 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 3.333333 14 .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.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 14.111111 5.43 RE RO UM SM TP defects RO UM SM 0 0 15 0 9 0 0 7 0 0 16 15 0 26.698 15.59 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 4.68 31.87 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.

72549 3.76471 .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 3.67 36.901961 11.35 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.

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 .

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.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.:.66667 .666667 0 0 7.888889 1.888889 3.222222 0 0 16.333 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.

308 0 15.662252 0 5.38 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 30.538 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 42.284768 0 0.993377 0 17.21854 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.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 11.77 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 7.980132 0 0 0.

857143 0 1.714286 .285714 2.087 6.857143 0.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 26.522 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 9.5217 0 26 0 0 0 0 0 0 2 0 0 0 0 0 0 0 0 0 0 0 2 26 4.195804 16.52 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 6.08392 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 2.090909 0 0 0 2.797203 0 0 0 0 4.348 56.

669643 0 1.350 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 1.142857 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 2.455357 0.678571 2.223214 0 0 1.339286 .232143 0.116071 2.428571 0 0 0 5.

526316 0 0.Total DHU 4 8.052632 1.75 22.877193 0 12.25 0 0 0 0 48 10.877193 2.917 1 15 2.1429 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 18.71429 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 7.286 7.42 3 6.143 7.1429 17-Jun-11 total checked pcs 0 6 8 8 5 14 21 3 0 5 0 70 570 DHU 0 1.25 0 0 0 0 5 10.403509 0.45614 3.2807 .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 17.083 31.684211 0.14 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 7.403509 1.

714286 1.33 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 23.892857 2.142857 2.071429 2.33 3.71429 .071429 0 0 1.40 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 8.67 13.3333 31.3333 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 10.678571 0 0.

892857 0.6667 0 41.714286 2.25 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 23.535714 1.71429 .785714 1.67 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 8.892857 0 10.25 0.333 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 6.333 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 0.142857 0 0.5 2.

818 18.540541 0 0.882883 0.801802 2.36036 1.900901 0 9.081081 1.90991 .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 7.909 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 1.18 9.720721 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 21.273 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 10.621622 0.25 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.

584087 .084991 0 0.361664 2.265823 0 0.169982 1.66 CP SP OT CP 0 5 3 0 0 0 8 7 0 4 0 27 50.66 13.723327 1.094 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 1.265823 1.434 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 5.627486 9.084991 1.21 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 9.94 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.

536232 1.811594 0.362319 0.905797 1.538 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 7.086957 2.362319 0 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 9.92 28.362319 0.6923 26.38 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.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 11.086957 0.905797 9.615 WS SP CP 0 0 0 0 6 0 2 0 0 0 0 8 15.42029 .

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.

21854 Total extra time Total extra time for the style Extra cost incurred 12 46 286 16.:. 1 2 3 4 5 6 7 Operation In line checker 1 (pleat.M675 Alter checked Pcs Date Sl 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 16.0839161 .Line 1 ITEM No.66666667 52 302 17.

71429 .:.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 14.28571 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.ITEM No.2807 6 12 15 12 60 560 10.71429 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.

42029 .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.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 10.90991 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 9.584087 4RO+2PP 10UM+4PP WS RE 2 WS 2 RE 5 TP 52 552 9.

) SL.M67 actual SAM (in min.14 2.) 0.45 1.6 .98 0.78 0.84 0. No.2 0.34 time for rework (in min.65 0.8 1.19 0.4 0.) 1.16 1.8 1.96 4.1 2.4 0.Line 1 ITEM No.4 0. 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 1.35 0.4 0.5 0.6 1.52 observed SAM (in min.28 1.54 0.5 0.8 1.82 2.36 1.77 1.:.2 0.5 0.2 0.

01 8.95 1.72 0.09 5.51 3.72 0.) 0.89 Checking after rework (in min.) 2.37 4.72 0.95 0.72 0.67 2.42 3.72 0.95 0.4 3.95 0.72 0.72 0.95 0.23 4.95 Total (in min.29 2.72 0.7 3.72 0.:.) 3.95 0.57 1.95 0.89 4.9 2.ITEM No.95 0.55 1.) 0.95 0.73 9.95 0.62 3.68 2.72 Total (in min.27 2.61 5.61 .72 0.95 0.M675 Checking time (per gmt in min.

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