ISS Projects for VTL June 2014_md_jahidur_rahaman

© 2014, VIYELLATEX Group, All rights reserved.RESTRICTED

ISS Projects for VTL

VIYELLATEX group ISS

2 © 2014, VIYELLATEX Group, All rights reserved.RESTRICTED

ISS Focus Area.• Business Monitoring & Controlling

– Identifying gray areas of the business processes , standardizing flow of work, restricting unusual transaction for better and smoother business operation.

• Process Automation– The focus here was to automate the

business processes for faster and accurate execution of tasks thus enabling business to thrive for more

• Go Paperless– Converting paper base activities into a

systematic one for saving paper, man hour and achieving control at the same time.


H o s p i t a l I n f o rm a t i o n M a n a g e m e n t S y s t e m

Previous Process & Issues: Manual entry in register for

patient history & medicine stock No reporting & analyzing of injury

& seasonal diseases & medicine issues

New Process & Benefits:

System generated prescription for patient entry & automated medicine Inventory

Disease & Injury trend analyzing

Medicine issue track Report visibility for

management

87% Reduction in Injury from Jan to May

January February March April May0

50000

100000

150000

200000

250000

300000

20132014

34% Reduction in Medicine cost than Jan to May of 2013


S a m p l e Tr a c ke r

Previous Process & Issues: Manual process for sample

development so visibility of task missing

No proper reporting & analyzing of data

Maintained Excel Document

1123 pc of Sample creation of 13 Buyer from Jan - May

Soliver Puma M&S NEXT PVH Esprit Olymp0

50

100

150

200

250

300

350

400

6788

55

10

112 108

9

103

364

117 125155 145

18

Number of Order Con-firmedNo. of Sample De-veloped

New Process: & Benefits End to end automated Sample

development Process Buyer wise production

confirmation report against each sample creation

Analyzing on fabric issue for future use

Report visibility for management

Auto mail to MM, DPD

42% sample order confirmed


S a m p l e Tr a c ke r

M&S Esprit Olymp DK P&C Saccor Puma Next PVH Soliver0

100

200

300

400

500

600

700

800

900

83129

7314 1 18

773

92 66106

56 49 413 1 0 21 8

49 35

No of Sample Input in System

System Input Not in System

M&S Esprit Olymp DK P&C Saccor Puma Next PVH Soliver0%

20%40%60%80%

100%120%

40% 28% 36%18%

50%

0% 3% 8%43%

25%

60% 72% 64%82%

50%

100% 97% 92%57% 75%

Sample Tracker Usage %

%of Not Use Usage %

84%

16%

Overall Sample Tracker Usage

System InputNot in System


Re c h e c k Tr a c ke r ( Fi n a l I n s p e c t i o n )

Previous Process: & Issues Manual Entry in register of

inspection status Excel Reporting & Manipulation of

data possible No reporting , monitoring & data

Analyzing

New Process & Benefits: Automated inspection tracking

system of finished products No Excel sheet use & Paper

wastage Finding out the root cause of

rejection & recheck reason of finished products

Reporting & Analyzing of system data (Buyer wise, defect category wise, unit wise..etc)

11% Reduction in Defects quantity from Jan to May

Jan Feb Mar Apr May2100

2200

2300

2400

2500

2600

2700

2800

2900

No. of De-fects


I n l i n e Re c h e c k Tr a c ke rPrevious Process: & Issues

Manually maintained number & type of defects per sewing & finishing line wise

Excel report maintained Multiple QI report in each line &

manipulation possible No reporting & visibility of process

to management

New Process & Benefits Tracking defects line, floor, unit, buyer

wise Easily updating QM information to SAP Reduction of defects & recheck

number in pre-final & final inspection Analyzing system & reporting to

management Taking action against increasing of

DefectsOil Spot % Dirt Spot % Stitching Problem %

0.00%

1.00%

2.00%

3.00%

4.00%

5.00%

6.00%

3.60%

2.45%

4.16%3.91%

2.89%

5.40%

AprilMay


Pro d u c t i o n Tr a c k i n g S y s t e m ( P T S )

Existing Process & Issues: Supervisors fill up the PTR

sheet & send leftover & rejected garments to PTR Team

PTR team sends them to LMS weekly basis by SAP challan

No visibility of PTR report to management

Manipulation possible PTR Team is under Production

dept.

New Process & Benefits: An automated end to end system

(cutting to finishing dpt.) An Independent PTR team will

take input from cutting, sewing & finishing separately & will post the data to the system except data of incomplete goods

Goods will be segregated and packed in PTR room & send to LMS for selling

Visibility of PTR to management & tracking missing garments

Proper grading will ensure proper price of garments for selling


Wa s t a g e M a n a g e m e n t ( W M )Existing Process & Issues:

No standard process/SOP for wastage declaration so individual methods for each units or departments

Mixed wastage item are measured by weight & send to wastage store but wastage store receives without measuring weight

No visibility on movement of wastage to management

No monitoring & wastage control not properly utilized

New Process & Benefits: An automated system by following SOP

for managing waste for Knitting, Dyeing, Garments

Cross checking while sending & receiving goods

Proper item segregation & items are standardized as left over & wastage

Visibility of wastage movement & selling to management by reporting

Properly history maintaining of sold items

Microsoft Office Word Document


N e e d l e Tr a c ke rPrevious Process & Issues:

Manual register entry for needle usage & issuing

Update in SAP was done cost center wise

No Reporting & instant visibility of needle usage to line or individual person wise

Manipulation possibleNew Process & Benefits:

System keeps records of needle usage unit, floor, line, machine, size & person wise

Visibility of needle usage ensured to management & save cost

Historical data analysisJanuary February March April May0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

Monthly Needle Usage

Monthly Needle Usage


H o u r l y P ro d u c t i o n M o n i t o r i n g ( H P M ) ( V T L , I S M L )

Existing Process & Issues: PIS team manually update the

data & excel reporting is maintained

System update is done from that excel sheet which is kept on shared drive

Manipulation possible & no size wise & real time visibility of hourly production input

PIS team is under production dept.

New Process & Benefits:

An independent team will collect the data every hour and update in system to see live update on dashboard

Target will be set by IE concern & System will show target VS. actual hourly performance in graphical interface

Visibility of hourly production status & Target Vs. Actual hourly production to management

Reduce data entry people

ISML floor wise hourly production report

Production Summary - Last Working Day (Date: 06.07.2014)

Target Output Achievement

Sewing Summary of ( ISML1 + ISML2 ) 38302 36570 95.48 %


Thanks

ISS Projects for VTL June 2014_md_jahidur_rahaman

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