2. Palmal Group of Industries
AZMERI Monthly Knowledge Sharing Meeting-KSM
Organized by:
Central-IE (Audit)
Manufacturing Audit & Central Costing
1-1
3. Objectives of the Meeting:
1-2
To review factory last months 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
2. 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
3. Human Resource Department KPI:
Monthly worker absenteeism status
4. Set next month performance target
10. Month wise NPT status :
1-9
Month
No of
Working
days
Non
Productive
Minute
NPT Value in
Tk.
NPT% NPT (Pcs)
NPT (Man-
Hour)
NPT
MC/Day
Total Earning
(Including NPT
Value)
Revenue/M
C (Without
NPT)
November-20 26 152758 Min. 887,524৳ 7.16% 19461 Pcs 2546 10.7 MC 175,574.66
$ BDT 57739
December-20 23 208675 Min. 1,212,402৳ 10.16% 21813 Pcs 3478 17.7 MC 188,820.82
$ BDT 72404
January-21 26 171499 Min. 996,409৳ 5.68% 24122 Pcs 2858 11.8 MC 273,029.37
$ BDT 83997
G. Total 25 532932 Min. 3,096,335৳ 7.39% 65395 Pcs 8882 13.4 MC 637424.846 BDT 71628
17. Operators Skill Matrix Analysis :
1-16
Grade wise
OP
Number of
Operator
OP %
Grade wise
OP
Number of
Operator
U-1,OP %
Grade wise
OP
Number of
Operator
U-2,OP %
Grade wise
OP
Number of
Operator
U-3,OP %
A+ 3 1.01% A+ 1 0.34% A+ 1 0.34% A+ 1 0.34%
A 8 2.68% A 5 1.68% A 1 0.34% A 2 0.67%
B+ 31 10.40% B+ 6 2.01% B+ 6 2.01% B+ 19 6.38%
B 112 37.58% B 38 12.75% B 36 12.08% B 38 12.75%
C+ 0 0.00% C+ 0 0.00% C+ 0 0.00% C+ 0 0.00%
C 144 48.32% C 56 18.79% C 36 12.08% C 52 17.45%
Total Op 298 Total Op 106 Total Op 80 Total Op 112
U-1
All Unit U-2 U-3
Unit wise Operator Grading Summary Month
Number of
New operator
Jan-21 49
Dec-20 0
Nov-20 0
Oct-20 12
Sep-20 15
Aug-20 8
Jul-20 7
Jun-20 3
May-20 7
Apr-20 0
Mar-20 9
Feb-20 8
Jan-20 11
Total 129
18. Line balance Analysis based on skill matrix:
1-17
Red Tape 246 Grade- A 0 0% Date:
WTK-10,23,37 202 Grade- B+ 1 5%
82% Grade- B 13 62%
202 Grade- C 7 33%
Total 21
1 2 3 4 5
1 OP2538 C Shoulder join, Cut & Arrange 26 24 23 26 25 24.8 0.41 145 150 -12 -8%
2 OP2538 C Shoulder join, Cut & Arrange 27 25 28 25 27 26.4 0.44 136 150 -11 -8%
3 OP2515 B Neck join 14 13 16 14 15 14.4 0.24 250 220 1 250 -21 -8%
4 OP2585 C Neck rib tack 15 14 13 15 13 14.0 0.23 257 300 1 257 -21 -8%
5 OP3294 B Neck Rib servicing & t/c 16 15 17 15 14 15.4 0.26 234 260 1 234 -19 -8%
6 OP2119 B Back neck piping & cut 15 14 15 16 13 14.6 0.24 247 273 1 247 -21 -8%
7 OP2453 B Piping end tack & cut 15 14 16 15 16 15.2 0.25 237 300 1 237 -20 -8%
8 OP2594 B Back top stitch with loop & t/c 27 25 24 26 27 25.8 0.43 140 158 -12 -8%
9 OP2581 B Back top stitch with loop 25 26 28 25 26 26.0 0.43 138 158 -12 -8%
10 OP2556 B Slv join 31 29 32 29 28 29.8 0.50 121 125 -10 -8%
11 OP284 B Slv join 32 30 29 33 32 31.2 0.52 115 125 -10 -8%
12 OP3457 B Side join 45 47 46 49 46 46.6 0.78 77 86 -6 -8%
13 OP3494 C Side join 43 45 47 45 43 44.6 0.74 81 86 -7 -8%
14 OP163 B Side join 46 44 43 46 47 45.2 0.75 80 86 -7 -8%
15 OP1641 C Care label attach & fold tack & t/c 27 25 29 27 29 27.4 0.46 131 158 -11 -8%
16 OP2439 C Care label attach & fold tack & t/c 25 28 25 27 28 26.6 0.44 135 158 -11 -8%
17 OP2395 B+ Bottom Hem 15 17 16 14 13 15.0 0.25 240 250 1 240 -20 -8%
18 OP2576 B Slv hem 32 34 32 31 33 32.4 0.54 111 150 -9 -8%
19 OP3524 B Slv hem 32 31 29 31 30 30.6 0.51 118 150 -10 -8%
20 OP3462 B Front Neck top stitch 16 14 15 16 14 15.0 0.25 240 333 1 240 -20 -8%
21 OP2354 C Heat seal 18 17 19 18 17 17.8 0.30 202 250 1 202 -17 -8%
21
3 238
FS
Target/Hr
.
2 282
2 236
2 278
Total
2 267
2 229
Capacity Study
Minimum Target
220
Capacity
Gap
Gap %
SL
Oparator Name
or IDNO
Operation
Cycle time
2nd floor
C
Floor:
Line
Name of Supv.
Prepaired By (IE)
Average
Input date:
Order Qty:
Style:
Buyer:
Combine
capacity
Allocated
Manpowe
r
Capacity/
Hr.
Cap SMV
Operator
Grade as per
Skill Matrix
SPT
BPTTarget
Line Balance
BNT
47. 1-46
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.
50. Proposal for Month factory overall house keeping
status :
1-49
Color Meaning
Green Maintain
Yellow Need to improve
Red Alarming
Discredit marks %
If marks is >20%
If marks is 10% to 20%
If marks is <10%
SL FOCUS POINTS
NO OF
CHECKED
ITEMS
NO OF
DEFECTS
DISCREDIT
POINTS
REMARKS
1 The work area and all tables are clean 10 2 20%
2 The Idle machine is covered by machine cover 20 5 25%
3 All tools and scissors are attached to the equipment (avoiding touching the floor) or attached workers wrist 10 1 10%
4 All fabrics rolls are poly bagged and identified & All trims are stored properly and identified 5 0 0%
5 Aisle are free from any object 10 1 10%
6 Fabrics and Trims in Quanrantine areas must be placed on pallets 20 3 15%
7 Empty Basket / Trolley are stationed in designated area 5 1 20%
8 Sewing Machines and Tables are in right place and position 10 2 20%
9 Alter Materials are kept in Rework, Rejected ,spot clean boxes 10 3 30%
10 Iron shoe & palet are being used during ironning 15 1 7%
11 Fire fighting tools are kept in right place 10 1 10%
12 All cartoon, boxes and unusable goods are kept in designated area 5 1 20%
13 Finished carton areas are kept as well organized 10 1 10%
14 Rejection garments management system is well organized 5 1 20%
145 23 16%
Factory HR KPI Dash Board.
Total
51.
52. 4. Set next month target:
1-51
Final Inspection Pass % 100.00%
DHU% <5.00%
OQL % <3.50%
Quality
Expected Plan Actual Plan
Planned Machine 270 270
Working days 26 26
Avg. Working Hour 10.00 10.00
Avg. SMV 9.39 9.39
Target Efficiency % 65.00% 58.76%
Target Hour 59319 53627
Target Qty 379053 342680
Target Achievement % 100.00% 100.00%
Machine utilization % 98.00% 98.00%
Excess shipment % 0.50% 0.50%
AZMERI
PPC, IE &
Production
Criteria
Dept.
