Manpower Optimization 10 % Plan

OT EMPLOYEE
Month Dec'18 Jan'19 Feb'19
26-Nov Need Reduction 4% 3% 3%
Estimat Estimat
Current
Section Sub Section MPW % MPW ed MPW ed MPW
Onroll
Onroll Onroll
Cutting Assistant 95 6% 4 91 3 88 3
Input Man 19 1% 1 18 1 18 1
Operator 9 1% 0 9 0 8 0
Quality 14 1% 1 13 0 13 0
Sewing Assistant 174 11% 7 167 5 162 5
Input Man 19 1% 1 18 1 18 1
Iron Man 66 4% 3 63 2 61 2
Operator 752 46% 30 722 22 700 21
Quality (RQC+QI) 66 4% 3 63 2 61 2
Finishing Assistant 144 9% 6 138 4 134 4
Folding Man 17 1% 1 16 0 16 0
Input Man 8 0% 0 8 0 7 0
Iron Man 46 3% 2 44 1 43 1
Operator 35 2% 1 34 1 33 1
Quality 54 3% 2 52 2 50 2
Repair 5 0% 0 5 0 5 0
Packing Packing Loader 9 1% 0 9 0 8 0
Packing Man 27 2% 1 26 1 25 1
Sample Sample Man 34 2% 1 33 1 32 1
General Cleaners 49 3% 2 47 1 46 1
TOTAL OT EMPLOYEE 1642 100% 66 1576 47 1529 46

Current- Jan'19 Feb'19

Section 26-Nov'18 Dec'18 Onroll +/- Onroll +/- Onroll +/-

Cutting 123 118 -5 115 -4 111 -3

Sewing 1011 971 -40 941 -29 913 -28
Finishing 255 245 -10 237 -7 230 -7
Packing 36 35 -1 34 -1 33 -1
Quality 134 129 -5 125 -4 121 -4
Sample 34 33 -1 32 -1 31 -1
General 49 47 -2 46 -1 44 -1
1642 1576 -66 1529 -47 1483 -46

NON OT EMPLOYEE
Factory CUT+EMB+TECH 41 14%
Electrician 11 4%
Factory Mgnt 13 4%
Final Auditor 12 4%
LC+Sample 21 7%
 Mechanics 15 5%
Quality Controller 39 13%
Store 15 5%
Supervisor 37 13%
Office ACT+PUR+PMD 4 1%
HR+CSR 10 3%
IT Section 1 0%
Merchandising 12 4%
Others Cleaners 2 1%
Security 21 7%
Transport 7 2%
Utility 28 10%
NON OT EMPLOYEE 289 100%
Feb'19
3%
Estimat
ed
Onroll
86
17
8
13
157
17
60
679
60
130
15
7
42
32
49
5
8
24
31
44
1483
 MBM GARMENTS LTD
MANPOWER OPTIMIZATION & EFFICIENCY IMPROVEMENT PLAN-Nov'18

MANPOWER OPTIMIZATION PALN-SEWING Plan Optimization % 2% 4% 4%

Plan Optimization MPW
Current Proposed 1-Mar 1-Apr 1-May Plan Way of Optimization
Total Producti Process
TGT/ Wor Target vity
T# Style Order
Hr k HR Produc Produ Reducti increase MPW Efficien MPW Efficien MPW Efficien develop Layout Innovati Capital Remarks Quality
SMV OP SF IR Total Effi % SMV OP SF IR Total Effi % Reducti Reducti Reducti Investme
tivity ctivity on d on cy % on cy % on cy % ment/M Change on nt
ethod
A5 Chino long Pant 74650 120 12 1440 38.0 66.0 12.0 8 86.0 88% 16.744 38.00 65 9 7 81 94% 17.78 -5.0 6.2% 5 75% 9 77% 8 80%

B5 Cargo Short 23251 110 12 1320 44.0 74.0 16.0 4 94.0 86% 14.043 44.00 72 14 4 90 90% 14.67 -4.0 4.4%
C5 Short Slv shirt 1482 75 12 900 26.0 37.0 6.0 2 45.0 72% 20 26.00 32 6 2 40 81% 22.5 -5 12.5%
177.0 34.0 14 225.0 82% 211 -14.0 5 9 8
A6 Chino Short 52438 120 12 1440 38.0 70.0 17.0 5 92.0 83% 15.652 38.00 72 15 5 92 83% 15.65 0 0.0% 5 75% 10 77% 9 80%

B6 5-Pkt Pant 514 210 12 2520 25.0 75.0 16.0 10 101.0 87% 24.95 25.00 75 13 7 95 92% 26.53 -6 6.3%
C6 Long Slv Shirt 67893 60 12 720 40.0 37.0 13.0 5 55.0 73% 13.091 40.00 39 13 5 57 70% 12.63 2.0 -3.5%
182.0 46.0 20 248.0 81% 244 -4 5 10 9
A8 Chino long Pant 67973 120 12 1440 36.0 70.0 13.0 1 84.0 86% 17.143 36.00 66 11 1 78 92% 18.46 -6 7.7% 5 75% 11 77% 10 80%
B8 5-Pkt Pant 29507 210 12 2520 22.0 71.0 19.0 6 96.0 80% 26.25 22.00 65 15 6 86 90% 29.3 -10 11.6%
C8 Cargo Pant 72797 80 12 960 56.0 72.0 15.0 5 92.0 81% 10.435 56.00 70 13 5 88 85% 10.91 -4 4.5%

213.0 47.0 12 272.0 82% 252 -20 5 11 10

A9 5-Pkt Pant 56790 210 12 2520 25.0 77.0 20.0 10 107.0 82% 23.551 25.00 77 16 10 103 85% 24.47 -4.0 3.9% 4 75% 8 77% 7 80%
B9 Chino Short (Check ) 52438 120 12 1440 36.0 69.0 16.0 4 89.0 81% 16.18 36.00 65 16 4 85 85% 16.94 -4 4.7%

146.0 36.0 14 196.0 81% 188 -8.0 4 8 7

Sew Inputman 19.0 16 -3
Sewing Floater 3.5 % 33.0 32.0
Sewing Others 18.0 18.0
ub Total 718.0 163.0 60 1011 82% 18.00 36.96 961 86% 19.08 -49.0 5.3% 19 75% 37 77% 35 80% 0 0 0

MANPOWER OPTIMIZATION PALN-FINISHING

Current Proposed Dec'18 Jan'19 Feb'19 Plan Way of Optimization Remarks Quality
Producti
Total Process
TGT/ Wor Target vity MPW MPW MPW Capital
T# Style Order Efficie Produc Produ Reducti increase Efficien Efficien Efficien develop Layout Innovati
Hr k HR SMV OP SF IR Total ncy % tivity SMV OP SF IR Total Efficiency ctivity on Reducti cy % Reducti cy % Reducti cy % ment/M Change Investme
d on
on on on nt
ethod

A2 Mens Chino 74650 250 12 3000 6.14 2.0 26.0 8 36 71% 83.3 6.14 2.0 23.0 8 33 78% 90.91 -3 9.1% 7 2 3
B2 5- PKT Pant 514 300 12 3600 5.53 2.0 28.0 8 38 73% 94.7 5.53 2.0 23.0 8 33 84% 109.1 -5 15.2% 2 3
C2 Shirt 19587 200 12 2400 8.10 1.0 28.0 9 38 71% 63.2 8.10 1.0 26.0 9 36 75% 66.67 -2 5.6% 2
A3 5- PKT Pant 56790 300 12 3600 5.55 2.0 28.0 8 38 73% 94.7 5.55 2.0 23.0 8 33 84% 109.1 -5 15.2% 2 3
B3 5- PKT Pant 514 300 12 3600 5.55 2.0 28.0 8 38 73% 94.7 5.55 2.0 23.0 8 33 84% 109.1 -5 15.2% 2 3
2nd Quality All 12 7 7 0
Button Section+Alteration All 12 36 30 -6
Repair All 12 5 5 0
Spot Remove All 2 2 0
Packing+Packing Loader All 36 3.0 33 -3
2nd Quality Fin All 0 0
Finishing Inputman All 8 5.0 5 -3
Rejection Repair All 0 0 3
Fin Quality All 57 57 0
Fin Floater 3.5 % All 7 7 0
346.0 72% 314 81% -32.0 7 0 0

MANPOWER OPTIMIZATION PLAN-CUTTING

Dec'18 Jan'19 Feb'19 Plan Way of Optimization Remarks Quality
Current
Short Ses B. S. TTL Prod Total Producti
Process
MPW Efficien MPW Efficien MPW Efficien develop
MPW Pkt, Re- Bend Fabric vity Layout Innovati Capital
Group Bulk Table-1+2+3+4 Cuttin siori Card MO SF IR Dir/Lin Efficiency uctivi Reducti Reducti Reducti Reducti Investme
(Day+Nig int Cut knife relx on
increase on cy %
on
cy %
on
cy % ment/M Change on
nt
g ng writter e ty d ethod
ht shift)
Layman 22 2 1 1 4 -4 2 5 5
Cutterman 12 0 0
Recut 7 2 2 -2
Numbering 9 1 1 -1
Bundling 29 2 2 -2
Pktng Print 4 0 0
Fusing 20 0 0
Inputman 17 3 3 -3
Loading 3 0 0
S.Total 123 0 0 0 12 -12 0 2 5 5 0 0

MANPOWER OPTIMIZATION PALN - UNMEASURED AREA

Planned timeline Dec'18 Jan'19 Feb'19 Plan Way of Optimization Remarks Quality

Current Total
Producti
MPW MPW MPW
Process
Capital
Ttl Produ Reducti vity Reducti Efficien Reducti Efficien Reducti Efficien develop Layout Innovati Investme
Group Manpowe Lines MO SF IR Efficiency
Direct ctivity
on
increase
on
cy %
on
cy %
on
cy % ment/M Change on
nt
r d ethod

Sample 34 1 1 -1
Quality 134 0 0
General 49 0 0
S.Total 463 0 0 0 403 -57 0 0 0
1943.0 28 75% 42 77% 40 80%
 MBM Finishing Manpower Reconciliation

upto 17-
26-Nov 29-Dec +/- 31-Jan +/-
Feb
Finishing Assistant 144 144 0 141 -3 151
Folding Man 17 17 0 16 -1 17
Input Man 8 8 0 8 0 8
Iron Man 46 45 -1 44 -1 50
Operator 35 35 0 34 -1 34
Quality 54 57 3 58 1 66
Repair 5 5 0 5 0 5
Packing Packing Loader 9 8 -1 8 0 9
Packing Man 27 27 0 26 -1 26
345 346 1 340 -6 366

N.B: February'19 Newly recruited 26 Manpower to Start new Finishing Line.

Current Onroll
Previous OB Requirement Current OB Requirement
Status
Team Prdn Quality Prdn Quality +/- Prdn Quality
A2 35 8 33 10 0
B2 29 12 33 10 2
C2 40 12 33 10 -9
A3 40 11 36 10 -5
B3 41 10 33 10 -8
C3 (New) 20 7 27
300 66
Button & Alteration 37 35 -2
Packing 38 35 -3
Floater & Others 11 11 8 8
Repair 5 5 0
2nd Quality 2 2 0
Inputman 8 8 0
286 53 284 65 10 300 66
339 349 366
 +/-

10
1
0
6
0
8
0
1
0
26

Remarks

New line started

5 Button working in SRT but showing in MPW report

6 QI people working in other section

 Stylewise Over Capacity Operation

Practical
Team Order No. Style Name of the Operation OB Allocation
Allocation
A5

0
B5

0
C5

0
A6

0
B6
 Practical
Team Order No. Style Name of the Operation OB Allocation
Allocation

0
C6

0
A8 67973 Chino Long Pant Frt Pkt Facing 2 2.5
S.Fly Piping + WB Piping 1 1.5
Bottom Hem 2 2
Edge Stc. Frt Pkt mouth 0 1
D.fly O/L 1 1
Frt raise & T/S 1 1
Zipper Attach 1 1
Bk Part Mark for Belt Join 1 1

11
B8
 Practical
Team Order No. Style Name of the Operation OB Allocation
Allocation

0
C8+C9

0
A9

0
B9 52438 Chino Short Coin pkt Join Without Mark 0 1
Tack zipper at body & mark panel top 1 2

3
Total
 Stylewise Indirect Manpower Optimization Plan (Targe

Operation
Team Buyer Order No. Style Name of the Operation Current MPW Forecast MPW
Type
A5 2262 Long Slv Shirt Placket Mark HP 1
Front Match & Cut HP 1
Pkt join Mark HP 1
Dechain after Box plate make HP 1
Pkt join Mark HP 1
Culf Match HP 1
Slv Match HP 1
Dechain Side seam (FOA) HP 2
Trim Bottom Extra part HP 1
Body Turn HP 1
Collar Iron Iron 2
Culf Iron Iron 1
Placket Iron Iron 2
PKt Iron Iron 2
Flap Iron Iron 1
19
B5 69805 Mens Chino Chort Bone Mark HP 1
Bone Cut & Corner Cut HP 2
Mark Waist Band HP 1
Turn Frt pkt Bag after close HP 1
Match Frt & Back HP 1
Match Waist Belt HP 1
Body Mark for Belt Join HP 2
Loop join Mark HP 1
Dechain WB after KS HP 3
Body Tun HP 1
Press Coin Pkt Iron 1
Press Bottom Hem Iron 1
16
C5 65824 Long Slv shirt Dechain HP 1
Placket Mark HP 1
Placket Mark extra HP 1
Mark for bottom Hem HP 1
Slv Match HP 1
Collar Match HP 1
Dechain Side seam HP 2
Body Turn & sticker remove HP 2
Plkt Iron Iron 1
Pkt Iron Iron 1
Collar Iron Iron 1
13
A6 23251 Cargo Short Thigh pkt Press Iron 1
Bone Mark HP 1
Flap Turn HP 1
Bone Join Mark HP 1
Bone Join Mark & Corner cut HP 2
Frt & BK Match HP 1
Loop & Belt Match HP 1
Body Mark for Belt Join HP 1
Thigh Pkt Join Mark HP 2
Thigh Pkt & Flap Match HP 1
Press Waist Belt Mouth Iron 1
Dechain WB after join HP 3
Waist Belt mark for Loop Join HP 1
Mark Bottom Before btm Hem HP 1
Dechain Inseam after join HP 1
Press Loop Iron 1
Press Inner Reinforcement Iron 1
21
B6 514 5-Pkt Pant ( Cord) Sticker Remove Output HP 2
Leather Match HP 1
Body Turn for Top side HP 1
 Operation
Team Buyer Order No. Style Name of the Operation Current MPW Forecast MPW
Type
Dechain after inseam & turn HP 2
Inseam Sessioring HP 1
Body Mark for Loop join HP 1
Dechain After WB Attach HP 1
Body Mark for WB Attach HP 2
Match Frt & Back HP 2
Match Waist Belt HP 1
Match Loop HP 1
Waist Belt Mark HP 1
Mark for Bk pkt Join HP 2
Dechain S.fly HP 1
Turn Frt Pkt Bag HP 1
Loop Iron & Cut Iron 3
Press Bk Pkt Iron 2
Press Frt Pkt mouth Iron 1
Press Watch Pkt Iron 1
27
C6 56539 Long Slv shirt Slv Cut HP 1
PLkt Extra mark HP 1
Cuf Extra Cut HP 1
Culf Match HP 1
Dechain Side seam HP 1
Sticker remove HP 2
Bottom Cut HP 1
Plkt Iron Iron 1
Culf Iron Iron 1
Yoke Iron Iron 1
Pkt Iron Iron 1
12
A8 21181 Chino Short Dechain WB After Kansai HP 3
Bone join Mark HP 1
Bone Cut & Corner cut HP 2
Mark for Waist Belt Attach HP 1
Frt pkt Bag Turn HP 1
Frt & bk Match HP 1
WB & Loop Match HP 1
Loop Join Mark HP 1
WB join Mark HP 1
WB Mark HP 1
Watch Pkt Join Mark HP 1
Body Turn for Inseam HP 1
Thread Trim Output HP 1
Attach Zipper to S.fly HP 1
Fusing Attach @ Back Rise Iron 1
Fusing Attach @ Inseam Iron 1
Press WB mouth for Kansai Iron 1
Press Coin pkt & D.fly Iron 1
Press Loop Iron 1
22
B8 505 5-Pkt pant Match Frt Part Left & Right (Cord) HP 1
Frt pkt Bag Turn after Make HP 1
Coin Pkt Mark HP 1
Frt Facing Pair & Sticker Attach HP 1
Waist Belt Mark HP 1
BK Pkt Mark HP 2
Waist Belt Match HP 1
Loop Match HP 1
Frt & bk Match HP 2
Body Mark for Waist Belt join HP 2
Waist belt Dechain (KS HP) HP 3
Loop join Mark HP 1
Inseam Sessioring HP 1
Turn garments after Inseam Join HP 2
Body Turn for Top side after inside che HP 1
 Operation
Team Buyer Order No. Style Name of the Operation Current MPW Forecast MPW
Type
Leather match HP 1
Thread Trim Output HP 1
Press Loop Iron 3
Press Bk Pkt Iron 1
Press Watch Pkt Iron 1
27
C8+C9 72797 Cargo Pant Bone Mark HP
Body Turn Output HP 1
Bone Cut & Corner Cut HP 2
Cargo Pkt Mark HP
Cargo Pkt Join Mark HP 2
Match Frt & mack + Loop HP 1
Dechain after Inseam HP 1
Match Cargo pkt & Flap HP 1
Mark for Loop Join HP 1
FOA HP HP
Drawstring Cut HP 1
Buckle Tie for Wash Send HP 1
Press Cargo Pkt Iron 2
Press Cargo Pkt Flap Iron 1
Press Waist Belt for Closing Iron 1
Press Loop & Cut Iron 1
16
A9 56790 5-Pkt Pant Thread trim Output HP 2
Body Turn after heming HP 1
Dechain after Inseam & turn HP 2
Inseam Sessioring HP 1
Body Mark for Loop Attach HP 1
Dechain after WB Attach HP 3
Body Mark for WB Attach HP 2
Match Frt & Back HP 2
Loop match HP 1
Waist Belt Match HP 1
Body Mark for Bk Pkt Attach HP 2
Waist Belt mark HP 2
Turn Frt Pkt Bag HP 1
Mark for Watch pkt Join HP 1
Loop Cut & Press Iron 3
Press Frt pkt Mouth Iron 1
Fusing Attach Inseam Iron 2
Fusing Attach Bk Raise Iron 1
Press Bk Pkt Iron 2
Press Watch Pkt Iron 1
32
B9 69810 Chino Short(check) Zipper join thread cut HP 1
Frt pkt facing match with frt part HP 1
Frt pkt facing mark with check match HP 3
Bone Cut & Corner cut HP 2
Bone Mark HP 1
Mark for Bone join & bk Dart HP 1
Body mark WB Attach HP 1
Waist Belt Mark with Check Match HP 1
Frt & bk Match HP 1
WB & Loop Match HP 1
Frt pkt bag Dechain after Make & turn HP 1
Frt Part Top Sessioring HP 1
Loop Join Mark HP 1
Body Turn Output HP 1
Press Frt pkt Bag with Check match Iron 1
Press Frt Pkt Top facing & mark Iron 1
Press Waist Belt for Check match Iron 2
21
Total
 MBM Improvement action Plan (IAP) -Sewing

Order Current New save

S/L Section Team Product Type Operation Old Method New Method Video Date status Remarks
No. MPW MPW mpw

1. BK pkt marking pattern merge with yoke pattern

1 Sewing A9 6421 5-Pkt Pant Body Mark for Waist Belt att. 2 Body mark frt & Bk yoke for WB att. 0 2
2. Frt coin pkt marking pattern correction

2 Sewing A9 6421 5-Pkt Pant Waist Belt mouth opening 3 Waist Belt Mouth opening by 3 Helper Waist Belt mouth opening by 2 Helper 2 1
3 Sewing A9 6421 5-Pkt Pant Loop Join Mark 1 Loop Join Mark Loop Join with gauge set in machine 0 1
4 Sewing A9 6421 5-Pkt Pant Waist Belt Press for label positi 1 Waist Belt Press for label positioning Waist belt press remove 0 1