Factory Monthly KSM

1. 1-0

2. Palmal Group of Industries
KM Monthly Knowledge Sharing Meeting-KSM
(Nov-21 To Jan-22)
Organized by:
Central-IE
Manufacturing Audit & Central Costing
1-1

3. Objectives of the Meeting:
1-2
To review factory last month performance
To understand our present position against
management expectation
To know about the scope of improvement
To set next month performance target

4. Key Discussion points:
1-3
1. Planning, Production & IE KPI:
Monthly Target Vs. achievement status
Monthly Efficiency %
Monthly PCD Hit rate status
Monthly NPT Analysis
Monthly Revenue status
Monthly Profit/Loss status
Monthly Machine utilization %
Operators Skill Matrix Analysis
Monthly Short/excess shipment status
3. Quality Assurance Department KPI:
 Monthly Final inspection pass status
 Monthly OQL% status
Monthly DHU% status
Monthly Top 5 Defects analysis
Fail report analysis against Top 5 Defect
2. Human Resource Department KPI:
 Monthly worker absenteeism status
4. Set next month performance target

5. 1. Planning, Production & IE KPI:
1-4

6. Overview of Performance:
1-5

7. Month wise Plan & Floor Target Vs. Achievement status:
1-6

8. Month wise Machine utilization % :
1-7

9. Month wise efficiency %:
1-8

10. Month wise profit/Loss status (Excluding Abnormal Loss) :
1-9

11. Root Causes Analysis:
1-10

12. Month wise per Machine Plan Vs. Achieve Revenue status:
1-11

13. Month wise Plan Vs. Actual Style Analysis (November-21):
1-12
SMV Type Style Type Style Qty Plan Minute Plan Qty
Avg qty % out of
total Plan Qty
<4.5 Very Basic 7 596283 135230 18.60%
4.51-7.5 Basic 30 2849011 491956 67.65%
7.51-10.5 Semi Critical 16 1041532 92728 12.75%
10.51-15 Heavy Semi Critical 0 0 0 0.00%
15.1-20 Critical 1 121180 7300 1.00%
20.1- >=28 Heavy Critical 0 0 0 0.00%
6.34 Basic 54 4608006 727214 100%
SMV Type Style Type Style Qty
Produced
Minute
Produced Qty
Avg qty % out
of total
Produce Qty
<4.5 Very Basic 7 500523 115035 18.5%
4.51-7.5 Basic 29 2248494 378576 60.9%
7.51-10.5 Semi Critical 8 663138 72499 11.7%
10.51-15 Heavy Semi Critical 8 647381 50965 8.2%
15.1-20 Critical 2 71053 4525 0.7%
20.1- >=28 Heavy Critical 0 0 0 0.0%
6.65 Basic 54 4130589 621600 100.0%

14. Month wise Plan Vs. Actual Style Analysis (December-21):
1-13
SMV Type Style Type Style Qty Plan Minute Plan Qty
Avg qty % out of
total Plan Qty
<4.5 Very Basic 4 364988 81400 10.03%
4.51-7.5 Basic 19 3564897 634740 78.24%
7.51-10.5 Semi Critical 10 876130 95100 11.72%
10.51-15 Heavy Semi Critical 0 0 0 0.00%
15.1-20 Critical 0 0 0 0.00%
20.1- >=28 Heavy Critical 0 0 0 0.00%
5.92 Basic 33 4806015 811240 100%
SMV Type Style Type Style Qty
Produced
Minute
Produced Qty
Avg qty % out
of total
Produce Qty
<4.5 Very Basic 6 521937 119140 17.7%
4.51-7.5 Basic 25 2575336 467748 69.5%
7.51-10.5 Semi Critical 11 462819 53545 8.0%
10.51-15 Heavy Semi Critical 8 423076 32365 4.8%
15.1-20 Critical 0 0 0 0.0%
20.1- >=28 Heavy Critical 0 0 0 0.0%
5.92 Basic 50 3983169 672798 100.0%

15. Month wise Plan Vs. Actual Style Analysis (January-2022):
1-14
SMV Type Style Type Style Qty Plan Minute Plan Qty
Avg qty % out of
total Plan Qty
<4.5 Very Basic 3 242840 54000 8.04%
4.51-7.5 Basic 31 2456909 432670 64.38%
7.51-10.5 Semi Critical 14 2021974 185370 27.58%
10.51-15 Heavy Semi Critical 0 0 0 0.00%
15.1-20 Critical 0 0 0 0.00%
20.1- >=28 Heavy Critical 0 0 0 0.00%
7.03 Basic 48 4721723 672040 100%
SMV Type Style Type Style Qty
Produced
Minute
Produced Qty
Avg qty % out
of total
Produce Qty
<4.5 Very Basic 3 181648 41211 6.5%
4.51-7.5 Basic 32 2562586 436473 69.2%
7.51-10.5 Semi Critical 12 909568 110697 17.5%
10.51-15 Heavy Semi Critical 11 581261 42582 6.7%
15.1-20 Critical 0 0 0 0.0%
20.1- >=28 Heavy Critical 0 0 0 0.0%
6.71 Basic 58 4235063 630963 100.0%

16. Month wise facts analysis :
1-15
SMV 1st
day 2nd
day 3rd
day 4th
day 5th
day 6th
day 7th
day 8th
day 9th
day 10th
day
<4.5 45% 60% 70% 75% 85% 85% 85% 85% 85% 85%
4.51-7.5 40% 55% 65% 70% 75% 75% 75% 75% 75% 80%
7.51-10.5 35% 45% 55% 60% 65% 65% 65% 70% 70% 70%
10.51-15 35% 45% 50% 55% 60% 60% 60% 65% 65% 65%
15.1-20 25% 35% 45% 50% 55% 55% 55% 55% 55% 60%
20.1-28 25% 35% 40% 45% 50% 50% 50% 55% 55% 55%
>=28.1 10% 20% 30% 35% 40% 45% 45% 45% 45% 50%
Efficiency Requirement
Month Factory
Noof
Working
days
No.
Style
Running
No.
Styling
No.of
Avg.
Line
Run
days/Styling
/Line
Expected
Efficiency
Achieved
Efficiency%
November-21 KM 26 54 10 15 38days 74.0% 59.8%
December-21 KM 25 50 9 16 45days 70.0% 57.0%
January-22 KM 26 58 8 16 51days 68.0% 56.3%
G.Total 26 162 27 46 44days 70.7% 57.7%

17. Style Allocation Analysis (November-21):
1-16
StylingGroup GrpWiseStyleQty
GrpWise
Production
Qty
Item
A 2 24651 Bottomshort
C 1 9320 Bottom-Long
D 4 50695 Legging
E 27 425680 T-Shirt
H 1 2200 Jacket
I 2 5686 Tank-Top
K 1 3120 Jogger
L 4 30161
Hoody
WithoutZip
M 11 68682 Sweat-Shirt
N 1 1405
HoodyWith
Zip
10 54 621600
SMV Type Style Type Style Qty
Produced
Minute
Produced Qty
Avg qty % out
of total
Produce Qty
<4.5 Very Basic 7 500523 115035 18.5%
4.51-7.5 Basic 29 2248494 378576 60.9%
7.51-10.5 Semi Critical 8 663138 72499 11.7%
10.51-15 Heavy Semi Critical 8 647381 50965 8.2%
15.1-20 Critical 2 71053 4525 0.7%
20.1- >=28 Heavy Critical 0 0 0 0.0%
6.65 Basic 54 4130589 621600 100.0%

18. Style Allocation Analysis (December-21):
1-17
StylingGroup GrpWiseStyleQty
GrpWise
Production
Qty
Item
A 3 20519 Bottomshort
B 1 1400 Women'sTop
D 1 44610 Legging
E 23 411440 T-Shirt
G 2 7393 Polo
I 7 135509 Tank-Top
K 1 1298 Jogger
L 5 23572
Hoody
WithoutZip
M 7 27057 Sweat-Shirt
9 50 672798
SMV Type Style Type Style Qty
Produced
Minute
Produced Qty
Avg qty % out
of total
Produce Qty
<4.5 Very Basic 6 521937 119140 17.7%
4.51-7.5 Basic 25 2575336 467748 69.5%
7.51-10.5 Semi Critical 11 462819 53545 8.0%
10.51-15 Heavy Semi Critical 8 423076 32365 4.8%
15.1-20 Critical 0 0 0 0.0%
20.1- >=28 Heavy Critical 0 0 0 0.0%
5.92 Basic 50 3983169 672798 100.0%

19. Style Allocation Analysis (January-2022):
1-18
StylingGroup GrpWise Style Qty
GrpWise
Production
Qty
Item
A 4 4880 Bottomshort
B 1 6300 Women'sTop
C 1 27545 Bottom-Long
E 31 358316 T-Shirt
G 1 4889 Polo
I 5 167704 Tank-Top
L 7 29578
Hoody
WithoutZip
M 8 30101 Sweat-Shirt
SMV Type Style Type Style Qty
Produced
Minute
Produced Qty
Avg qty % out
of total
Produce Qty
<4.5 Very Basic 3 181648 41211 6.5%
4.51-7.5 Basic 32 2562586 436473 69.2%
7.51-10.5 Semi Critical 12 909568 110697 17.5%
10.51-15 Heavy Semi Critical 11 581261 42582 6.7%
15.1-20 Critical 0 0 0 0.0%
20.1- >=28 Heavy Critical 0 0 0 0.0%
6.71 Basic 58 4235063 630963 100.0%

20. PCD Hit & Fail Status (Nov-21):
1-19

21. PCD Hit & Fail Status (Dec-21):
1-20

22. PCD Hit & Fail Status (Jan-22):
1-21

23. Month wise NPT status :
1-22
Non
Productive
Minute
NPT Value
NPT Value in
Tk.
NPT% NPT (Pcs)
NPT (Man-
Hour)
NPT
MC/Day
Total Earning
(Including NPT
Value)
Revenue/MC
(Without
NPT)
46236 Min. 3,236.52
$ 268,631৳ 0.67% 6958 Pcs 771 3.1 MC 348,860.82
$ BDT 80122
76646 Min. 5,365.22
$ 445,313৳ 1.10% 12946 Pcs 1277 5.3 MC 338,936.70
$ BDT 78553
103524 Min. 7,246.68
$ 601,474৳ 1.38% 15424 Pcs 1725 6.7 MC 367,955.53
$ BDT 81083
226406 Min. 15,848.42
$ 1,315,419৳ 1.06% 35328 Pcs 3773 5.0 MC 1,055,753.05
$ BDT 79940

24. NPT status (November-2021):
1-23
MAINTENANNCE , 0,
0%
MERCHANDISING,
1800, 4%
PRODUCTION,
11640, 25%
QUALITY, 0, 0%
PLANNING,
32796, 71%
HR & ADMIN, 0,
0%
Department Wise NPT%
MAINTENANNCE MERCHANDISING PRODUCTION QUALITY PLANNING HR & ADMIN

25. NPT status (November-2021):
1-24

26. NPT status (December-2021):
1-25
MAINTENANNCE , 0,
0%
MERCHANDISING,
3360, 4%
PRODUCTION,
19010, 25%
QUALITY, 3240,
4%
PLANNING,
38796, 51%
HR & ADMIN,
12240, 16%
Department Wise NPT%
MAINTENANNCE MERCHANDISING PRODUCTION QUALITY PLANNING HR & ADMIN

27. NPT status (December-2021):
1-26

28. NPT status (January-2022):
1-27

29. NPT status (January-2022):
1-28

30. Operators Skill Matrix Analysis :
1-29
A+ 0 0.00%
A 25 7.00%
B+ 26 7.28%
B 224 62.75%
C+ 82 22.97%
C 0 0.00%
D 0 0.00% D 0.00%
Total 357 100.00% 100.00%
A+,A 7.00%
B+,B 70.03%
C+,C 22.97%
KMOperatorsSkillMatrix
Grade
NoOf
Operator
Percantage Grading (%)

31. Month wise On Time Delivery status:
1-30

32. Month wise short/excess shipment status :
1-31

33. 2. Human Resource Department KPI:
1-32

34. Month wise worker absenteeism status :
1-33

35. Factors influencing on efficiency %:
1-34
1. Style Analysis : Allocating the styles in such a way that
maximum line days can be achieved.
2. PCD hit Rate : Ensure PCD to ensure right style line feeding at
right time.
3. Set a standard Target : Target has to be as per feasibility
learning curve to get expected efficiency.
4. Production Monitoring : Ensure process wise production which
leads to target achievement of full line.
5. Line Balancing : Set right person at right place to get maximum
utilization of manpower and get output.
6. Operators Skill Matrix : Identify the right person as per process
& requirement.
7. Operators Availability : Reduction of absenteeism to ensure
operators availability as per requirement.

36. SUMMARY OF TODAY DISCUSSION :
1-35
OrderConfirmation
Sample Approval Planning Fabric& Accessoriesplanning
File Handover
CuttingPlan
Print/Emb.Plan
SewingStartPlan
SewingProduction
FRIPlan
Order Execution Flow Chart
Style Analysisduringsize set& PPMeeting
Fabric Delay
PCD delay
Productivity Loss

37. 3. Quality Assurance Department KPI:
1-36

38. KPI SUMMARY
No of
Inspection
No of Pass Pass % No of Fail Fail % DHU % OQL %
64 62 96.9% 2 3.1% 5.03% 3.35%

39. Meeting Agenda
• DHU% for the month of December
• Top 3 Defects: Root cause analysis and Action taken.
• Weekly Final Inspection Pass/Fail summary report.
• FRI Fail report submit for review.
• OQL summary report.
• CHO Quality Organogram.
• Factory Quality Organogram.
• GPQ Activities and the best way to detecting fabric defects at the initial
stage.

40. DHU DATA- JANUARY
Total Check 688049
QC Pass 638556
Alter 34614
AVG DHU % 5.03%
Uncut Thread 4294 pcs 12.4%
Broken Stitch 3544 pcs 10.2%
Point up-down 2762 pcs 8.9%
QC Pass Alter AVG DHU %
638556
34614 5.03%
Total Check Qty-688049

41. TOP 3 DEFECTS FOR THE MONTH OF JAN-22
•UNCUT THREAD
•BROKEN STITCH
•POINT UP-DOWN

42. TOP 3 DEFECTS FOR THE MONTH OF JAN-22

43. Root cause & Action plan of Uncut thread
Root Cause Action Plan
• Operator didn’t clean his own process
threads properly.
• Should be operator trained and alert to
do proper trimming on own process.
Identified non perform operator and
make them understand the impotency.
• Used Manual Sewing Machine without
auto trimmer.
• Auto trimmer machine should be proper
utilized.
• Improper trained helper • Trained helper to proper trimming and
give a proper guideline with.
• No available compressor line with O/L
machine.
• Should be Set all compressor line with O/L
machine.
• Lack of attention. • Should be monitor each process and bring
attention relevant operator or helper to avoid
thread ends.

44. Root cause & Action plan of Broken stitch
Root Cause Action Plan
Lack of proper training of operator. Trained up operator for proper machine
controlling.
Poor Overlaping stitch. Should be carefully when given Overlaping
stitch.
Don’t use proper thread trimming method. Trained for proper trimming.
Poor thread quality. Should be check thread quality strength
before production according fabric base.

45. Root cause & Action plan of Point up-down
Root Cause Action Plan
Lack of Proper machine adjustment. Machine RPM adjusted properly as per IE target
and machine feed dog set base on operation to
avoid the misplacement as well as improve the
operator handling.
Operator Handling Problem Should be improve Operator handling.

46. BUYER WISE SELF & BUYING QC/3RD PARTY PASS FAIL PERCENTAGE-JANUARY-22
Month Buyer
Total
Ins
Self
pass
Self pass
%
Self
fail
Self fail
%
QC/3rd
Party
pass
QC/3rd
Party pass
%
QC/3rd
Party fail
QC/3rd
Party fail
%
Overall Pass
%
Overall fail
%
JANUARY-22
Carrefour 26 12 100% 0 0% 14 100% 0 0% 100% 0%
Bestseller 21 19 95% 1 5% 1 100% 0 0% 95.23% 4.77%
Landmark 2 2 100% 0 0% 0 0 0 0% 100% 0%
Red tape 15 0 0% 0 0% 14 93.33% 1 6.66% 93.33% 6.66%
Total 64 33 97.% 1 3% 29 96.7% 1 3.3% 96.9% 3.1%

47. FINAL INSPECTION PERFORMANCE FOR THE
MONTH OF JANUARY-22

48. FINAL INSPECTION FAIL SUMMARY-JANUARY-22
MONTH
TOTAL
INSPECT
ION
PASS FAIL
AQC +
CCQC
ITS+BS
QA+QC
FAIL STYLE FAIL REASON
JANUARY-22 64 62 2 34 30
1.12205914
2. WOMEN'S R.NECK WITH
LOGO
1.AQL BEYOND LIMIT
2. Due to oil spot

49. 3RD PARTY/BUYING QC OQL SUMMAY-JANUARY-22
MONTH
INSPECTED BY 3RD
PARTY
TOTAL
INSPECTED QTY
INSPECTED
SAMPLE QTY
TOTAL
DEFECT QTY
AVERAGE OQL %
Jan-22 30 190812 5415 5415 3.38%

50. SELF OQL SUMMAY-JANUARY-22
MONTH
INSPECTED BY
SELF
TOTAL
INSPECTED QTY
INSPECTED
SAMPLE QTY
TOTAL
DEFECT QTY
AVERAGE OQL %
Jan-22 34 146376 4913 163 3.31%

51. OQL SUMMAY-JANUARY-22
MONTH
INSPECTED
STYLE
TOTAL
INSPECTED QTY
INSPECTED
SAMPLE QTY
TOTAL
DEFECT QTY
AVERAGE OQL %
Jan-22 64 337188 10328 346 3.35%

52. Fabric GPQ Activities:
• Receiving Fabric booking sheet from the fabric audit/merchant team.
• Fabric quality follow-up at fabric mills (dyeing/finishing).
• From each color /combo (1st lot fabric/rib/collar/cuff) approval will be
provided by the concern merchandiser. Rest of the lots approval will be
done by fabric GPQ.
• GSM record (100% rolls) should be made by the fabric mill in front of fabric
GPQ.
• Fabric test report should be carried out from the fabric mill’s lab for each
lot.
• 4.0 Fabric inspection report should be carried out 20% rolls from each lot.
• Fabric check and test related all docs should be submitted to the cutting
units through the mail.

53. CHO QA ORGANOGRAM

54. KM QUALITY ORGANOGRAM

55. 4. Set next month target:
1-54
Expected Plan Actual Plan
Planned Machine 400 370
Working days 20 20
Avg. Working Hour 10.00 10.00
Avg. SMV 10.36 10.36
Target Efficiency % 60.0% 47.4%
Target Hour 62400 45583
Target Qty 361390 263995
Target Revenue/MC/Month BDT 89051 BDT 65052
Target Achievement % 100.00% 100.00%
Machine utilization % 98.00% 98.00%
Excess shipment % 0.50% 0.50%
Dept. Criteria
KM
PPC, IE & Production
Merchandising PCDHit Rate 90.00%
Final Inspection Pass % 100.00%
DHU % <5.50%
OQL % <4.00%
Quality
HR Worker absenteeism % <3.00%

57. If One Of Us Fail, We All Fail.
The End

58. Thank You