Pay - 400Rs/day

Cutting Manpower Manpower Cost Cost Per Pc Cost Per Pc (inc overheads)
3300 35 14000 4.24 5.09
5000 38 15200 3.04 3.65
5500 38 15200 2.76 3.32
7000 38 15200 2.17 2.61
Pay - 350Rs/day
Cutting Manpower Productivity Cost Per Pc Cost Per Pc (inc overheads)
3300 35 94.29 3.71 4.45
5000 38 131.58 2.66 3.19
5500 38 144.74 2.42 2.90
7000 38 184.21 1.90 2.28
Cutting Cost Analysis
Daily Monthwise Yearly Difference Cutting
3300 85800 1029600
5000 130000 1560000 530400 2710344
7000 182000 2184000 1154400 5898984
Assumptions
Cost 5.11
Daily Cutting Average
Pay - 400Rs/day
Finishing Manpower Manpower Cost Cost Per Pc Cost Per Pc (inc overheads)
2035 104 41600 20.44 28.62
4000 114 45600 11.40 15.96
3185 190 76000 23.86 33.41
4000 111 44400 11.10 15.54
Pay - 350Rs/day
Finishing Manpower Productivity Cost Per Pc Cost Per Pc (inc overheads)
2035 104 19.57 17.89 25.04
4000 114 35.09 9.98 13.97
3185 190 16.76 20.88 29.23
4000 111 36.04 9.71 13.60
Sec-57
Sec-63
Sec-57
Sec-63
Finishing Cost Analysis
Month 1st Floor 2nd Floor
S. No Process Previous Recommended Feb
1 Thread Cutting 33 17 March 1735 1795
2 Initial Checking 18 0 April 1969 2005
3 Pressing 19 16 May 1420 1449
4 Final Checking 13 10 June
5 Quality Check 5 4 July
88 47 41 Average 1708 1750
Month 1st Floor 2nd Floor
S. No Process Previous Recommended Feb
1 Thread Cutting 27 20 March 1753 2039
2 Initial Checking 24 0 April 1777 1995
3 Pressing 25 16 May 1525 2086
4 Final Checking 15 10 June 1741 1938
5 Quality Check 4 4 July
95 50 45 Average 1699 2015
Finishing Manpower
B-16, Sec-57
C-135, Sec-63
Packing Details of both Finishing
Total Manpower
170
3530 154 Annual 635000
3974 150 Monthly 52917
2869 146 Daily 2035
Manpower 104
3458 155 114
Total Manpower
168 Annual 994000
3792 152 Monthly 82833
3772 156 Daily 3186
3611 147 Manpower 190
3679
3714 156 111
Packing Details of both Finishing
Initial Checking 1 Time Study
2 Capacity
3 RFT
Pressing 1 Time Study
2 OTP
3 Energy
Final Checking 1 Time Study
2
Washing
Manpower 1 OTP
2 Initial
3 Measurement
4 Final
5 QC
6 QA
Packing
A) Recommendations
Advance Cutting Plan (First 1 week, then 1 Month, then 6 Months)
Standard Time Implementation on Laying
Incentivize the laying Team for meeting Standard Time
Increase Percentage Utilization of CAD Marker
Cutting will not be done without CAD Marker
B)Implementations
Cutting Plan - 15 days advance plan & Daily table utilization plan
Laying Incentive
CAD Utilization
CAD Marker is to be check by placing all patterns before laying ends.
Width checking & write it on every than
Fabric in-house widthwise
Fabric availability near laying table
Started giving targets to lay team according to their normal speed.
Writing of target on the white board & Finding the gap & gap reason for further
Fabric availability near laying table.
Remove width variation by in-house of fabric in cutting department according to
Incentivize the laying team for achieving the standard Time for laying.
C)Impact
Laying time reduced to 90mins from 300mins.
CAD Utilization percentage increase to 60-70% from 10-20%
Cutting pieces increase to 5500 from 3300.
C)Savings
Cost reduces from 5.11rs per garment to 3.32rs per garment (i.e. 35% reduction of cost)
D)FutureAspects
After increasing Utilization of CAD Marker, we can achieve 7000 daily
A) Recommendations
Advance Cutting Plan (First 1 week, then 1 Month, then 6 Months)
Standard Time Implementation on Laying
Incentivize the laying Team for meeting Standard Time
Increase Percentage Utilization of CAD Marker
Cutting will not be done without CAD Marker
B)Implementations
Cutting Plan - 15 days advance plan & Daily table utilization plan
Laying Incentive
CAD Utilization
CAD Marker is to be check by placing all patterns before laying ends.
Width checking & write it on every than
Fabric in-house widthwise
Fabric availability near laying table
Started giving targets to lay team according to their normal speed.
Writing of target on the white board & Finding the gap & gap reason for further
Fabric availability near laying table.
Remove width variation by in-house of fabric in cutting department according to
Incentivize the laying team for achieving the standard Time for laying.
C)Impact
Laying time reduced to 90mins from 300mins.
CAD Utilization percentage increase to 60-70% from 10-20%
Cutting pieces increase to 5500 from 3300.
C)Savings
Cost reduces from 5.11rs per garment to 3.32rs per garment (i.e. 35% reduction of cost)
D)FutureAspects
After increasing Utilization of CAD Marker, we can achieve 7000 daily
Pay - 400Rs/day
Cutting Manpower Manpower Cost Cost Per Pc Cost Per Pc (inc overheads)
3300 35 14000 4.24 5.09
5000 38 15200 3.04 3.65
5500 38 15200 2.76 3.32
7000 38 15200 2.17 2.61
Pay - 350Rs/day
Cutting Manpower Productivity Cost Per Pc Cost Per Pc (inc overheads)
3300 35 94.29 3.71 4.45
5000 38 131.58 2.66 3.19
5500 38 144.74 2.42 2.90
7000 38 184.21 1.90 2.28
Cutting Cost Analysis
A) Recommendations
Recording RFT at Initial Checking (2 Manpower deployed - 1 at each floor for Recording)
Thread cutting at the end of production line before End line checker (Target for 1 Manpower - 50 pieces per hour)
Thread Cutting of Kaaz-Button on machine itself
One Time Pressing (Initial Checking -> Button Closing-> One Time Pressing-> Final Checking-> Quality Check-> Quality Audit)
B)Implementations
Deployed 2 Manpower at each production line before production end line checker
Thread Cutting of Kaaz-Button on machine itself
One Time Pressing (No repressing of garment)
C)Impact
1) Thread Cutting at production floor
Thread Cutting Manpower reduces from 33 to 16 in sec-57 unit and 30 to 20 in sec-63 unit.
Initial Checking Time reduces from 3-3.5min to 1-2min because of thread cutting in production line.
Space of thread cutting at washing area got free completely because of thread cutting in production line.
2) One Time Pressing
Manpower will reduce to apprx. 70% of present
Energy cost will reduce to apprx. 70% of present
Space
C)Savings
D)FutureAspects
One Time Checking (Final Checking->One Time Pressing->Quality Check->Quality Audit)
A) Recommendations
Recording RFT at Initial Checking (2 Manpower deployed - 1 at each floor for Recording)
Thread cutting at the end of production line before End line checker (Target for 1 Manpower - 50 pieces per hour)
Thread Cutting of Kaaz-Button on machine itself
One Time Pressing (Initial Checking -> Button Closing-> One Time Pressing-> Final Checking-> Quality Check-> Quality Audit)
B)Implementations
Deployed 2 Manpower at each production line before production end line checker
Thread Cutting of Kaaz-Button on machine itself
One Time Pressing (No repressing of garment)
C)Impact
1) Thread Cutting at production floor
Thread Cutting Manpower reduces from 33 to 16 in sec-57 unit and 30 to 20 in sec-63 unit.
Initial Checking Time reduces from 3-3.5min to 1-2min because of thread cutting in production line.
Space of thread cutting at washing area got free completely because of thread cutting in production line.
2) One Time Pressing
Manpower will reduce to apprx. 70% of present
Energy cost will reduce to apprx. 70% of present
Space
C)Savings
D)FutureAspects
One Time Checking (Final Checking->One Time Pressing->Quality Check->Quality Audit)
Thread cutting at the end of production line before End line checker (Target for 1 Manpower - 50 pieces per hour)
One Time Pressing (Initial Checking -> Button Closing-> One Time Pressing-> Final Checking-> Quality Check-> Quality Audit)
Pay - 400Rs/day
Finishing Manpower Manpower Cost Cost Per Pc Cost Per Pc (inc overheads)
2035 104 41600 20.44 28.62
4000 114 45600 11.40 15.96
3185 190 76000 23.86 33.41
4000 111 44400 11.10 15.54
Pay - 350Rs/day
Finishing Manpower Productivity Cost Per Pc Cost Per Pc (inc overheads)
2035 104 19.57 17.89 25.04
4000 114 35.09 9.98 13.97
3185 190 16.76 20.88 29.23
4000 111 36.04 9.71 13.60
Finishing Cost Analysis
Sec-57
Sec-63
Sec-57
Sec-63
Date Finishing Production Finishing Manpower Productivity Cost
20-Jul-13
22-Jul-13 2454 192 12.78 27.38
23-Jul-13 3389 199 17.03 20.55
24-Jul-13 4382 186 23.56 14.86
25-Jul-13 4396 197 22.31 15.68
26-Jul-13 3757 196 19.17 18.26
27-Jul-13
29-Jul-13 2288 162 14.12 24.78
30-Jul-13 2900 184 15.76 22.21
31-Jul-13 2105 195 10.79 32.42
1-Aug-13 2549 169 15.08 23.21
2-Aug-13 2704 183 14.78 23.69
3-Aug-13
5-Aug-13 3028 204 14.84 23.58
AVG 3086.55 187.91 16.38 22.42
Cost of manpower in the month at average 190 workmen for 26 days 1,709,972.73
1.91
Date Finishing Production Finishing Manpower Productivity Cost
20-Jul-13 5516 180 30.64 11.42
22-Jul-13 2454 192 12.78 27.38
23-Jul-13 3389 199 17.03 20.55
24-Jul-13 4382 186 23.56 14.86
25-Jul-13 4396 197 22.31 15.68
26-Jul-13 3757 196 19.17 18.26
27-Jul-13 4448 202 22.02 15.89
29-Jul-13 2288 162 14.12 24.78
30-Jul-13 2900 184 15.76 22.21
31-Jul-13 2105 195 10.79 32.42
1-Aug-13 2549 169 15.08 23.21
2-Aug-13 2704 183 14.78 23.69
3-Aug-13 5320 200 26.60 13.16
5-Aug-13 3028 204 14.84 23.58
AVG 2896.24 189.21 18.54 20.51
Cost of manpower in the month at average 190 workmen for 26 days 1,729,000.00