The document summarizes a monthly knowledge sharing meeting for Palmal Group of Industries. Key discussion points included the previous month's performance on planning, production, quality assurance, and human resources KPIs. Data on production targets vs achievement, efficiency percentages, defects analysis, and worker absenteeism was reviewed. The group analyzed root causes for shortfalls and set new targets for the coming month. Style-wise production plans and actual outputs were compared through heat maps for two factory units.

1. 1-0

2. Palmal Group of Industries
KRC(U-3&4) Monthly Knowledge Sharing Meeting-KSM
(May-22 To July-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 (May-22):
1-12
SMV Type Style Type Style Qty
Produced
Minute
Produced Qty
Avg qty % out
of total
Produce Qty
<4.5 Very Basic 1 19737 4386 0.7%
4.51-7.5 Basic 18 2946501 547901 85.8%
7.51-10.5 Semi Critical 4 597419 63195 9.9%
10.51-15 Heavy Semi Critical 1 64134 4420 0.7%
15.1-20 Critical 3 325182 19035 3.0%
20.1- >=28 Heavy Critical 0 0 0 0.0%
6.19 Basic 27 3952974 638937 100.0%
ACTUAL RUNNING STYLE ANALYSIS
SMV Type Style Type Style Qty
Produced
Minute
Plan Qty
Avg qty % out
of total
Produce Qty
<4.5 Very Basic 0 0 0 0.0%
4.51-7.5 Basic 25 3401376 628332 86.2%
7.51-10.5 Semi Critical 3 813660 87000 11.9%
10.51-15 Heavy Semi Critical 1 48289 3328 0.5%
15.1-20 Critical 1 173884 10344 1.4%
20.1- >=28 Heavy Critical 0 0 0 0.0%
6.09 Basic 30 4437209 729004 100.0%
ALLOCATION PLAN STYLE ANALYSIS

14. Month wise Plan Vs. Actual Style Analysis (June-22):
1-13
SMV Type Style Type Style Qty
Produced
Minute
Plan Qty
Avg qty % out
of total
Produce Qty
<4.5 Very Basic 3 309995 69500 6.7%
4.51-7.5 Basic 18 4763956 889469 85.6%
7.51-10.5 Semi Critical 1 355779 45730 4.4%
10.51-15 Heavy Semi Critical 1 505287 34500 3.3%
15.1-20 Critical 0 0 0 0.0%
20.1- >=28 Heavy Critical 0 0 0 0.0%
5.71 Basic 23 5935017 1039199 100.0%
ALLOCATION PLAN STYLE ANALYSIS
SMV Type Style Type Style Qty
Produced
Minute
Produced Qty
Avg qty % out
of total
Produce Qty
<4.5 Very Basic 4 332628 74549 7.6%
4.51-7.5 Basic 19 4490990 835091 85.1%
7.51-10.5 Semi Critical 2 258906 32089 3.3%
10.51-15 Heavy Semi Critical 1 523155 35720 3.6%
15.1-20 Critical 2 73223 3840 0.4%
20.1- >=28 Heavy Critical 0 0 0 0.0%
5.79 Basic 28 5678902 981289 100.0%
ALLOCATION PLAN STYLE ANALYSIS

15. Month wise Plan Vs. Actual Style Analysis (July-2022):
1-14
SMV Type Style Type Style Qty
Produced
Minute
Plan Qty
Avg qty % out
of total
Produce Qty
<4.5 Very Basic 3 148586 33740 5.5%
4.51-7.5 Basic 12 2244295 421120 68.1%
7.51-10.5 Semi Critical 4 671156 86250 14.0%
10.51-15 Heavy Semi Critical 4 996253 77000 12.5%
15.1-20 Critical 0 0 0 0.0%
20.1- >=28 Heavy Critical 0 0 0 0.0%
6.57 Basic 23 4060289 618110 100.0%
SMV Type Style Type Style Qty
Produced
Minute
Produced Qty
Avg qty % out
of total
Produce Qty
<4.5 Very Basic 4 128869 29746 6.2%
4.51-7.5 Basic 18 1691691 319402 66.1%
7.51-10.5 Semi Critical 4 558925 71768 14.8%
10.51-15 Heavy Semi Critical 4 810235 62479 12.9%
15.1-20 Critical 0 0 0 0.0%
20.1- >=28 Heavy Critical 0 0 0 0.0%
6.60 Basic 30 3189719 483395 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
No.Style
Running
No.
Styling
No.of
Avg.Line
Run
days/Stylin
g/Line
Expected
Efficiency
Achieved
Efficiency%
May-22 KRC(U-3&4) 22 8 16 42days 75.0% 60.5%
June-22 KRC(U-3&4) 27 7 16 59days 75.0% 67.8%
July-22 KRC(U-3&4) 21 9 16 37days 75.0% 54.8%
70 24 48 45days 75.0% 61.0%
Total

17. PLAN STYLE RUNNING HEAT MAP,KRC,U-3 Unit 3
Line 2-Jul 3-Jul 4-Jul 5-Jul 6-Jul 7-Jul 16-Jul 17-Jul 18-Jul 19-Jul 20-Jul 21-Jul 23-Jul 24-Jul 25-Jul 26-Jul 27-Jul 28-Jul 30-Jul 31-Jul
No of
Style
A LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING 1
B LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING 2
C LEGGING LEGGING LEGGING LEGGING T-shirt T-shirt T-shirt 2
D T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt 2
E HOODY HOODY HOODY HOODY HOODY HOODY HOODY HOODY LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING 2
F TANK TOPTANK TOP T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt 2
G JACKET JACKET JACKET JACKET JACKET JACKET JACKET JACKET JACKET JACKET JACKET JACKET JACKET JACKET JACKET JACKET JACKET JACKET JACKET JACKET 2
H TANK TOPTANK TOPTANK TOPTANK TOP 1
Style Running Heat Map- KRC U-3 Unit- 3
Line 1-Jul 2-Jul 3-Jul 4-Jul 5-Jul 6-Jul 7-Jul 16-Jul 17-Jul 18-Jul 19-Jul 20-Jul 21-Jul 23-Jul 24-Jul 25-Jul 26-Jul 27-Jul 28-Jul 30-Jul 31-Jul
Number of
styling
Runned
No. of
style
Runned
A
HOODY
WITH ZIP
HOODY
WITH ZIP
HOODY
WITH ZIP
HOODY
WITH ZIP
HOODY
WITH ZIP
HOODY
WITH ZIP
HOODY
WITH ZIP
HOODY
WITH ZIP
HOODY
WITH ZIP
JACKET JACKET JACKET JACKET JACKET JACKET JACKET JACKET JACKET JACKET JACKET JACKET 2 3
B T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT
LADIES
DRESS
TANK TOP TANK TOP TANK TOP 3 5
C LEGGING LEGGING LEGGING T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT 2 3
C2 LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING - - - - - - - - - - - - - - 1 1
D LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT 2 3
E T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT - LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING JACKET JACKET JACKET - - - - 3 3
E+F - - - - - - - - - - - - - - - - - JACKET JACKET JACKET JACKET 1 1
F TANK TOP TANK TOP LEGGING LEGGING TANK TOP TANK TOP TANK TOP TANK TOP TANK TOP TANK TOP TANK TOP TANK TOP TANK TOP - - - - - - - - 2 4
G HOODY
WITH ZIP
HOODY
WITH ZIP
HOODY
WITH ZIP
JACKET JACKET JACKET JACKET JACKET JACKET JACKET JACKET JACKET JACKET JACKET JACKET JACKET JACKET JACKET JACKET JACKET JACKET 2 3
H LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING 1 2
STYLE-WISE LINE PLAN VS.EXECUTION COMPARISON OF KRC-U-3

18. PLAN STYLE RUNNING HEAT MAP,KRC,U-4 Unit 4
Line 2-Jul 3-Jul 4-Jul 5-Jul 6-Jul 7-Jul 16-Jul 17-Jul 18-Jul 19-Jul 20-Jul 21-Jul 23-Jul 24-Jul 25-Jul 26-Jul 27-Jul 28-Jul 30-Jul 31-Jul
No of
Style
A T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt 2
B T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt 2
C T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt 2
D T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt 3
E
LADIES
DRESS
LADIES
DRESS
LADIES
DRESS T-shirt T-shirt T-shirt T-shirt TANK TOPTANK TOPTANK TOPTANK TOPTANK TOPTANK TOP 2
F T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt 1
G T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt JOGGER JOGGER JOGGER JOGGER JOGGER JOGGER JOGGER JOGGER JOGGER JOGGER 2
STYLE-WISE LINE PLAN VS.EXECUTION COMPARISON OF KRC-U-4
Style Running Heat Map- KRC U-4 Unit- 4
Line 1-Jul 2-Jul 3-Jul 4-Jul 5-Jul 6-Jul 7-Jul 16-Jul 17-Jul 18-Jul 19-Jul 20-Jul 21-Jul 23-Jul 24-Jul 25-Jul 26-Jul 27-Jul 28-Jul 30-Jul 31-Jul
Number of
styling
Runned
No. of
style
Runned
A T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT 1 4
B T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT 1 3
C T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT - - - - - - - - - - 1 2
C2 - - - - - - - - - - - - - - - - - - - - - 0 0
D T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT 1 4
E JOGGER JOGGER JOGGER JOGGER JOGGER T-SHIRT T-SHIRT - - JOGGER JOGGER T-SHIRT LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING 3 4
E+F - - - - - - - - - - - - - - - - - - - - - 0 0
F T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT 1 1
G LADIES
DRESS
LADIES
DRESS
LADIES
DRESS
SHORT
PANT
T-SHIRT
SHORT
PANT
T-SHIRT T-SHIRT
LADIES
DRESS
JOGGER JOGGER JOGGER JOGGER JOGGER JOGGER JOGGER JOGGER JOGGER T-SHIRT T-SHIRT T-SHIRT 4 6
H - - - - - - - - - - - - - - - - - - - - - 0 0

19. PCD Hit & Fail Status (May-22):
1-18

20. PCD Hit & Fail Status (June-22):
1-19

21. PCD Hit & Fail Status (July-22):
1-20

22. Month wise NPT status :
1-21
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)
63205 Min. 4,424.35
$ 367,221৳ 0.97% 10216 Pcs 1053 5.2 MC 343,893.84
$ BDT 86562
136475 Min. 9,553.25
$ 792,920৳ 1.63% 23582 Pcs 2275 9.1 MC 473,161.80
$ BDT 92624
62182 Min. 4,352.74
$ 361,277৳ 1.07% 9424 Pcs 1036 5.6 MC 271,491.04
$ BDT 69293
261862 Min. 18,330.34
$ 1,521,418৳ 1.26% 43222 Pcs 4364 6.6 MC 1,088,546.67
$ BDT 83739

23. NPT status (MAY-2022):
1-22

24. NPT status (JUNE-2022):
1-23

25. NPT status (JULY-2022):
1-24

26. Operators Skill Matrix Analysis :
1-25
GRADE
NO OF
OPERATOR
PERCENTAGE
(%)
GRADING
PERCENTAGE
(%)
A+ 0 0%
A 21 5%
A- 46 10%
B+ 110 24%
B 138 30%
B- 90 19%
C+ 30 6%
C 24 5%
C- 3 1%
D 0 0% D 0%
462 100% 100%
KRC (U-3&4) Operator Skill Matrix
A
B
C
15%
73%
12%

27. Month wise On Time Delivery status:
1-26

28. Month wise short/excess shipment status :
1-27

29. 2. Human Resource Department KPI:
1-28

30. Month wise worker absenteeism status :
1-29

31. Factors influencing on efficiency %:
1-30
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.

32. SUMMARY OF TODAY DISCUSSION :
1-31
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

33. Thank You