This Training slide was meant for FCI Group's Line Managements to enlighten them regarding their Job responsibilities and day to day work flow. This training was given by FCI Group's Lean Management Trainers to the line management to make sure they are well aware about the company's change of style in production management.

1. Production Floor Management Training
Session - 1

2. Line Management basic
Responsibility

3. The very basic responsibility for every Operations
Personnel:
1. Entering the factory at least 10-15 minutes before
line starting. (6:45-6:50 AM)
2. Conducting Morning Meeting with all the operators.
3. Completing Morning meeting at least 5 minutes
before line starting. (6:55 AM)
4. Starting the whole line at sharp 7:00 AM.
5. End of the day organizing respective zone/line/floor
for tomorrow’s operation with proper housekeeping
and 5S.

4. Are we really following this?

5. Scenario 1: More than 50% operators are still sitting
around at 7:06 (Date- 19- November-2022)

6. Scenario 2: Empty Workstations after 7:10 AM

7. Scenario 3: Line hasn’t started even at 7:09 AM.

8. Scenario 4: maintaining Proper 5S after line closing.

9. How to be A good Line
Management?

10. 1. Achieving Hourly Target with good quality
each hour based on available capacity.
Why we are failing here?
A. Lack of initiative by Line Managements to identify and analyze
bottlenecks. Escalating 90% problem to next level leaders.
B. Lack of teamwork between Line chief, supervisors and Quality
Supervisors to solve repetitive quality problems.
C. Not having the “ Wining as a TEAM” mindset in the Line Level and
Zone Level Teams. (Production, Quality, IE, Maintenance and
Technical)
D. Lack of control over own team member as a team leader.
E. Lack of respect of for each other, company’s SOP and basic
disciplines.

11. 2. Achieving 1st three hour Production target
Why we are failing here? What can we do better?
A. Forecasting list of probable absenteeism in the next few days and
making a plan for that with the help of Line IE, Zone APM and PM.
B. Motivating the team members to take leave instead of
absenteeism
C. Incase of any sudden absenteeism zone supervisor has to
communicate with his seniors and IE and sit on that process until
IE allocate operator for that process.
D. Making sure the output area isn’t dried out the next day by
ensuring the available capacity from each workstation, every
hour.
E. Achieving the previous day target within the planned hours.
*All Absenteeism issue has to be solved within 15
minutes. (Line IE and Zone APM)

12. Zone APM
Line
No
17-Nov
19-Nov
20-Nov
21-Nov
Average
L- 1 78% 62% 70% 94% 76%
L-2 75% 67% 71% 61% 69%
L- 3 27% 68% 44% 46% 46%
L- 4 41% 64% 68% 50% 56%
L- 5 60% 67% 84% 36% 62%
L- 6 0% 18% 20% 38% 19%
L- 7 64% 64% 74% 120% 81%
L- 8 74% 61% 70% 72% 69%
L- 9 108% 45% 92% 96% 85%
L- 10 66% 46% 64% 92% 67%
L- 11 85% 82% 75% 71% 78%
L- 12 100% 78% 88% 98% 91%
L- 13 103% 114% 96% 107% 105%
L- 14 89% 69% 63% 114% 84%
L- 15 93% 48% 59% 60% 65%
L- 16 109% 97% 108% 93% 102%
L- 17 76% 47% 48% 70% 60%
L- 18 84% 79% 90% 100% 88%
L- 19 88% 67% 65% 70% 72%
L- 20 81% 82% 82% 83% 82%
L- 21 0 0 0%
Total 75% 66% 72% 79% 73%
1st 3 hour Summary-
November
Zone
-
4
Zone
-5
Ali
Billal
Zone
-
3
Sahabu
ddin
Zone
-
1
Riaz
Zone-2
Rakib

13. 3. Achieving First Day Efficiency by
following QCO
Need to achieve first day efficiency by doing my part
to ensure successful implementation QCO procedure.
Why we are failing here?
A. Not finishing previous styles on time. Mainly due to
rejection, recut and defect repairing delay.
B. Lack of production follow up in the backside area.
C. Failure to provide pre-trained operator to Specific
processes due to unplanned absenteeism and leave.
D. Lack of involvement during feeding time following the
Company’s Changeover Standard Procedure.

14. What is Line Management’s Role in QCO?
Responsible Responsibiliti
Before Line loading Need to make the sample and take approval
Select Team member properly before line loading and for training
with APM advise
Bring required sewing pattern to line before layout start
Ensure all input material has been available in line before start
Allocate helper for machine transportation
Feeding the line with Sewing technician
Ensure Operator providing on time in feeding process as per allocation
Ensure Bobin case supply on time in feeding process
Follow the area where feeding Completed for quality and productivity
Follow up and ensure the target of new style with the support of APM
Production Supervisor-
2
Follow the old style target and ensure on time finish as plan with
support of APM
Line Chief
Production Supervisor-1

15. •Each Zone APM need to Lead the
Changeover with the Zone
Technician and IE.
•Zone APM need to make sure his
line management is performing his
respective role in the changeover.

16. Single Piece flow Benefits and
Mechanism

17. Why Single Piece Flow is Better
1. Better FTT%
2. Better P2P% by solving problems hidden in the
system for long time.
3. Faster response to any kind of problem from the
support team
4. Better housekeeping and safety and workforce
morale.

18. What are the disadvantages of
more WIP?
ইনপুট
(input)
আউটপুট
(Output)
মেশিন
সেসযা
(Machine
Problem)
হাউজ শিশপিং
ঠিি নাই(Poor
Housekeeping)
লাইন ব্যাললন্স
হয় নাই(Line is
not Balanced)
অনুপশিশি
(Absenteeism)
মিায়াশলঠট
সেসযা
(Quality
Issue )
ম াগাল াগ সেসযা
(Communication
Problem) মব্িী মসটাপ টাইে
(More Setup Time)

19. What are the disadvantages of more WIP?
(বেশি কাজ জমান ার অসুশেধা শক শক?)
ইনপুট
(input)
আউটপুট
(Output)
মেশিন
সেসযা
(Machin
e
Problem
)
হাউজ শিশপিং
ঠিি নাই(Poor
Housekeeping)
লাইন ব্যাললন্স
হয় নাই(Line is
not Balanced)
অনুপশিশি
(Absenteeism)
মিায়াশলঠট
সেসযা
(Quality
Issue )
ম াগাল াগ সেসযা
(Communication
Problem) মব্িী মসটাপ টাইে
(More Setup Time)

20. Mechanism: Standard WIP and
Input Kanban
1. Component area – 5 pcs for all components area
operator
2. Single Piece area - 2 Pcs for all single piece flow
area.
3. End line and Inline Quality Table , Get up Table
and Finishing Iron- 5 pcs for each team member.
4. Total Standard WIP will be calculated based on
Layout Simulation and Mock up
5. If Line’s WIP is within Standard WIP, it will get it’s
last hours sewing output as Input.

21. 5 Pcs Defect Card and Defect
Repairing:
1. In every line for every checker 5 pcs defect card will
be provided. 5 Cards will be marked as 1 to 4 and one
card as "STOP".
2. For every piece of defect that comes to the table,
one defect card will be attached to the body for
sending back to the line for repairing.
3. Defect has to be repaired one by one. Taking 5 pcs
defect at once would be unacceptable.
4. If 5 pcs defect card is on the line and no card is left to
attach to the defect body, the checker will stop the
checking and hang the stop card from the table.

23. Sewing Defects from Get Up and
Reject/Recut
1. Line Chief and Quality Supervisor has to bring sewing
defect from Get up table every half and hour.
2. Quality supervisor need to make sure no sewing
defect is passed through End line by proper Checker’s
STW follow up and maintaining 7/0 procedure.
3. Everyday rejects has to be reviewed in the rejection
meeting by Zone APM, Zone AQM and proper
resolution has to be taken to stop it from the source.
4. Yesterday’s rejection need to be repaired within
today.

24. How are we being Monitored
Zone APM
Line
No
1-Nov
2-Nov
3-Nov
5-Nov
6-Nov
7-Nov
8-Nov
9-Nov
10-Nov
12-Nov
13-Nov
14-Nov
15-Nov
16-Nov
17-Nov
Total
Average
APM
Total
Picture Per
line for
APM
L- 1 1 0 0 2 2 1 1 3 2 1 1 3 0 4 3 24 1.6
L-2 0 0 0 0 1 1 2 4 3 1 4 5 3 2 4 30 2.0
L- 3 0 0 0 0 1 0 1 3 0 2 3 1 3 0 3 17 1.1
L- 4 4 5 5 0 3 5 1 3 1 2 3 4 2 0 4 42 2.8
L- 5 0 2 0 0 0 0 0 2 1 3 5 3 1 2 1 20 1.3
L- 6 7 10 8 4 4 8 1 2 1 2 5 1 0 1 5 59 3.9
L- 7 4 4 5 3 5 0 1 3 1 3 8 0 0 1 2 40 2.7
L- 8 0 0 0 0 4 2 1 0 3 1 0 2 1 2 1 17 1.1
L- 9 3 0 1 1 0 2 1 1 1 4 5 1 4 2 1 27 1.8
L- 10 1 2 1 4 6 2 2 1 1 2 4 3 1 3 3 36 2.4
L- 11 0 0 2 4 4 1 1 2 1 4 0 3 3 0 3 28 1.9
L- 12 1 0 1 5 3 0 1 1 1 3 2 3 1 2 3 27 1.8
L- 13 6 5 0 1 1 1 1 2 3 3 0 1 2 3 0 29 1.9
L- 14 1 3 7 0 4 3 1 3 3 4 6 3 3 3 3 47 3.1
L- 15 1 0 1 5 2 4 3 5 4 5 8 2 2 2 3 47 3.1
L- 16 2 0 0 4 0 2 0 0 0 0 2 4 3 4 2 23 1.5
L- 17 4 6 0 1 1 1 4 3 1 5 10 5 3 6 4 54 3.6
L- 18 1 3 5 5 3 0 0 0 1 6 2 1 2 3 2 34 2.3
L- 19 4 8 6 0 1 3 3 6 4 5 6 2 0 0 0 48 3.2
L- 20 9 11 17 4 10 1 6 3 4 3 10 4 2 3 3 90 6.0
L- 21 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.0
Total 49 59 59 43 55 37 31 47 36 59 84 51 36 43 50 739 49.3
2.381
17-Nov Single PC Flow Lines' Avg.
Line Wise WIP Picture Summary- November
226
173
Zone
-
4
3.0
Zone
-5
Ali
Billal 2.3
108
119
Zone
-
3
Sahabu
ddin
1.8
113 1.9
2.6
Zone
-
1
Riaz
Zone-2
Rakib

25. How are we being Monitored
24
30
17
42
20
59
40
17
27
36
28 27
29
47 47
23
54
34
48
90
0
0
10
20
30
40
50
60
70
80
90
100
L- 1 L-2 L- 3 L- 4 L- 5 L- 6 L- 7 L- 8 L- 9 L- 10 L- 11 L- 12 L- 13 L- 14 L- 15 L- 16 L- 17 L- 18 L- 19 L- 20 L- 21
Total

26. How are we being Monitored

27. How to Sustain Single Piece flow?

28. The 23 Sustainability Points:

29. Proper Monitoring of the
Sustainability Points is the key

31. General Housekeeping Rules

32. Rule : 1:
Everything needs to be kept in their
designated places.

37. Rule No: 2:
Before leaving the factory make sure the
line/Zone is organized for the next day

39. Last but not Least
1. The SOP’s and Standards are there for a reason.
2. We are here to manage our juniors. We are not
here to get managed by them.

40. Thank You