5 reasons that fail production plan.

1. Productivity Improvement Through
efficiency improvement & Better
Planning

2.  Recent surveys on cost of manufacturing in Asia have
indicated that a 2% increase in productivity could be
worth $80,000 to $1,60,000 per 1000 sewing
machines per year.

3.  The easiest and most effective way to improve
factory productivity is not to focus on sewing faster
but to make sure that your operators spend more
time sewing without wasting much time.

4.  What are the reasons for idle time and delayed
deliveries.

5.  5 Reasons that fail production plan and cause
shipment delay and biggest reasons for idle time and
lost of precious production lead time in our
organization.

6.  Most of the factories do not consider including
development stage schedule under plan and
industrial engineering.
 It results no control on pre-production processes, and
samples are not made as per the production
requirements and we need to do hit and try on the
shop floor after loading the style on the line, which
causes delays in line setting.
 As a result planned delivery date gets postponed.
Product development and Sampling:

7.  Suppliers fail to send good on time due to too many
uncertainties.
 Sourcing delays also consumed extra time and make it
difficult to start in-house processes on time.
 We have experienced that yet after loading of cutting and
stitching, trims or fabric are yet to be sourced. Partly
stitched garments start piling up in the line and line
supervisor load another style keeping running style aside
from the line until they receive trims.
Delay in sourcing of raw material:

8.  Fabrics, trims and accessories get in-housed at last.
Goods are passed through quality checks before using
in product or cutting.
 It may be shade variation/matching, wrong GSM
quality, low quality print etc.
 If an inferior quality of raw material found, fabrics are
send for re-processing or resourcing. It causes further
day in PCD.
Inferior quality in sourced goods:

9.  Pressure and urgency increases when factory starts
production, as order has already eaten up bigger part of
total time in merchandising and sourcing.
 Not having much time on hand, managers push everything
on fast pace. They even push their whole team on quantity
production. Once they start ignoring standard procedures
they get stuck on stitching quality or related problem rises.
Repair and re-inspection become a main process. These
process increases production time.
Production urgency

10.  We make high fashion product, which have few value
added processes such as panel printing, embroidery, bead
work or dyeing are needed.
 For these value added processes factory normally send
fabric or half stitch garment to sub-contractors for job-
works.
 Sub-contractors also come with their big commitments on
delivery and quality.
 But when factory receives goods, they had to count some
more days on their delays. This happen due to absence of
planning at subcontractor factory.
Delay from Sub-contracting Jobs

11.  Achieving targets doesn’t mean that a factory is achieving
the target cost and making profit.
 For example:
 Unit A is having 400 operators and produced 5000 pcs
with 2 hours OT.
 Productivity is: 400 operators x 10 hours = 4000 hours.
 4000 hours/ 5000 pcs = 48 minutes.
 Hence we can say that factory is taking 48 minutes to
make one garment.
Increased productivity

12.  Factory B is having 400 operators and produced 5000 pcs without OT.
 Productivity is: 400 operators X 8 hours = 3200 hours.
 3200 hours/ 5000pcs = 38.4 minutes.
 So we can say factory is taking 38.4 minutes to produce one garment.
 As per the above calculation both factories have achieved their target
but Factory B is more efficient and making more Profit to the
organization.
 Hence we need to calculate the performance by calculating their
efficiency. If a factory has achieved the target efficiency then the
production target will be met accordingly.

13.  The ability to produce more within the same amount
of time is a company's insurance for survival.
 This ability means that the company can now accept
more work.
 It means that costs can be lowered by avoiding
overtime.
 It means that fixed costs can be spread out over more
units of production.
 It means that profits Improve.
Making more profit through better
efficiency and good planning.

14.  Making a plan and execution of the plan is ‘must do’
task to meet the lead time. As a standard procedure
factories make plans and do extensive follow up of
tasks. Still factories do not meet their target dates for
final inspection and fail to ship good on agreed
shipment date. In this presentation I have explained
the 5 most visible reasons that cause the delay in
shipment.

15. Thank You