MANUFACTURING

EXCELLENCE
MODULE 2:
PREPARE FOR PRODUCTION

Product Type Loading

PRODUCT
TYPE LOADING
 PRODUCT TYPE LOADING-
Product Type loading is the process of planning & executing
Definition
Production orders in the production lines to gain highest process
efficiency.
Considering:
 Customer Demand
 Order profile
 Product type

 What can be consider from Process side ?

 Line wise capability w.r.t

1. Product wise Efficiency
2. Good Quality consistency
PRODUCT TYPE LOADING-
Objectives

 Improve production planning &

execution to achieve highest
efficiency.
 Reduce changeover time
 Reduce re-training / Learning curve
 Consistent quality
 PRODUCT TYPE LOADING ANALYSIS
1. Categorized the Products types
2. DATA Collection
 Data collection/Line/Product type/season
 Analyze Line & Product type wise highest efficiency achieved
3. Set each line product type loading priority (1st, 2nd & 3rd ) w.r.t
highest efficiency achieved
4. Update the highest efficiency per product every season.
5. Provide the updates to Planning and Production.

 Build KPI for improvement and follow-up (1st Priority Correct Allocation)
 Product Group by family/type
We may group the products by following four criteria

Fabric –
Knit/Wove
n

Style
Variations

Complexit
y
/SMV

Machine
Types
Collect historical data per line: identify
highest efficiency reached per product type

1st Priority 2nd Priority 3rd Priority

Line
Product Eff. Product Eff. Product Eff.
1General Jacket 82% Skirt 54% Top 53%
2 Skirt 86% General Jacket 82% Top 65%
3 Pants 73% T-shirt 68% Skirt 65%
4 Pants 82% Skirt 69% T-shirt 65%
5 Top 73% General Jacket 70% Tight 66%
Provide the allocation priority per line
to planning and production Planning
Allocation

Line 1 HIGHEST
TS EFFICIENCY
PT 0
T.shirt
Pants
TS
PT
60%
46%
RECORDED
9387
77%
2780
23% 0%

Line 2
65%
Allocate
PL
5537
the product
TS
type0
per
Polo PL 2338
T.shirt TS 37% line
70%according30%to the highest
0%
efficiency
Line 3 TS SW 0
T.shirt TS 44% 12965 0
Sweatshirt SW 33% 100% 0% 0%

Line 4 PT TS JK
Pants PT 59% 5219 1822 2395
T.shirt TS 50% 55% 19% 25%
Jacket JK 48%
 KPI: 1st Priority Allocation: Correct Allocation

# LINES 1ST PRIPRITY ALLOCATED

CORRECT ALLOCATION
ALLOCATION
TOTAL LINES (PRODUCING adidas)

# of lines
Monthly Correct with Total of
Efficiency Grouping correct adidas lines
allocation
Jan-17 62.5% 81% 66 81
Feb-17 60.4% 74% 62 84
Mar-17 64.2% 85% 71 84
Apr-17 68.0% 89% 75 84
 KPI: 1st Priority Allocation: Correct Allocation
Product Type Loading
Efficiency vs Correct Allocation

Monthly Efficiency Correct Grouping

89%
81% 85%
74%

60.4% 64.2% 68.0%

62.5%

Jan-17 Feb-17 Mar-17 Apr-17

SET UP YOUR BASELINE AND CONTROL THE KPI ON MONTHLY BASIS

 PRODUCT TYPE LOADING- Steps

Group products by family/type

Collect historical data per line: highest

efficiency reached per product type

Identify the 1st, 2nd and 3rd priority of

allocation for each line

Provide the allocation priority per line to

planning and production

Collect how many lines are being allocated

with the 1st priority product type per
month: correct allocation
 Product type loading exercise
LINE WISE PRIORITY FIRST 15DAYS ORDER QUANTITY
Line 1st Priority 2nd Priority 3rd Priority Sr.# Product type SMV Available days Order quantity Produce Mins. Target
No. DL Product Eff. Product Eff. Product Eff. 1 General Jacket 15 13 14000 210,000
1 30 General Jacket 82% Skirt 54% Top 53% 2 Skirt 8 13 9600 76,800
2 25 Skirt 86% General Jacket 82% Top 65% 3 Pants 12 13 10500 126,000
3 20 Pants 73% T-shirt 68% Skirt 65% 4 Top 10 13 4200 42,000
4 20 Pants 82% Skirt 69% T-shirt 65% 5 T-shirt 8 13 7200 57,600
5 25 Top 73% General Jacket 70% Tight 66% 6 Tight 6 13 3750 22,500

 What do you think, what info. Required for planning

NO. OF AVAILABLE DAYS
LINE # VARIABLES
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
DL 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30
Shift time 480 480 480 480 480 480 480 480 480 480 480 480 480 480 480
Over time - - - - - - - - - - - - - - -
Total available Mins. 480 480 480 480 480 480 480 480 480 480 480 480 480 480 480
LINE NO. 1

Efficiency 82% 82% 82% 82% 82% 82% 82% 82% 82% 82% 82% 82% 82% 82% 82%
Product type Gen. Jacket Gen. Jacket Gen. Jacket Gen. Jacket Gen. Jacket Gen. Jacket Gen. Jacket Gen. Jacket Gen. Jacket Gen. Jacket Gen. Jacket Gen. Jacket Gen. Jacket Gen. Jacket Gen. Jacket
Booked Minutes 11808 11808 11808 11808 11808 11808 11808 11808 11808 11808 11808 11808 11808 11808 11808
THANK YOU