IBG JORDAN

Unit 1 Section Packing Date 9-Feb

Manpower Time Available (Min) Current State Future State Daily current Daily Future
Sl # Code Operation Remarks
Exp Local Total Exp Local Current Target SMV Future Target SMV Capacity Capacity

1 P1 Endline Checking 6 3 9 720 480 65 0.92 90 0.67 6240 6840

2 P2 Line Output Count 2 1 3 720 480 300 0.20 300 0.20 9600 9600

3 P3 Reverse Garment 0 2 2 720 480 300 0.20 429 0.14 4800 6857

4 P4 Sticker Removal 0 7 7 720 480 30 2.00 120 0.50 1680 6720 Change Seating Arrangement,
Standardise way of checking,
Do in standing position, More
5 P5 Trimming 0 15 15 720 480 30 2.00 62 0.97 3600 7448 talkative

6 P6 Trimming Count 1 0 1 720 480 600 0.10 600 0.10 7200 7200

7 P7 Blowing 0 2 2 720 480 300 0.20 500 0.12 4800 8000

8 P8 Inseam Ironing 0 6 6 720 480 100 0.60 180 0.33 4800 8640

9 P9 Ironing Count-1 1 0 1 720 480 600 0.10 600 0.10 7200 7200

10 P10 Final check 8 1 9 720 480 65 0.92 72 0.83 6760 6816

11 P11 Final Count 1 0 1 720 480 600 0.10 600 0.10 7200 7200

12 P12 Hand Needle 1 0 1 720 480 600 0.10 600 0.10 7200 7200

13 P13 Damage Repair 1 0 1 720 480 600 0.10 600 0.10 7200 7200

14 P14 M/C Operator 1 0 1 720 480 600 0.10 600 0.10 7200 7200
Poor Performance, talking
15 P15 W/B Ironing 5 1 6 720 480 90 0.67 144 0.42 6120 6552
each other
16 P16 Ironing Count-2 0 1 1 720 480 600 0.10 600 0.10 4800 4800 can manage

17 P17 Button Closing 0 1 1 720 480 600 0.10 600 0.10 4800 4800 Lag Concentration on work

18 P18 Measurement 1 0 1 720 480 600 0.10 600 0.10 7200 7200

19 P19 Appearance 3 0 3 720 480 150 0.40 120 0.50 5400 5400 Have to reduce Trimming

20 P20 Style Seprating + Count 1 0 1 720 480 600 0.10 600 0.10 7200 7200

21 P21 Waist Band Tag 1 0 1 720 480 500 0.12 720 0.08 6000 6000
Need one more machine
22 P22 W/B Helper 1 0 1 720 480 500 0.12 720 0.08 6000 6000
Use additional MP from WB
23 P23 Hand Tag 2 0 2 720 480 250 0.24 720 0.08 6000 6000 tag
24 P24 Size Checking 1 0 1 720 480 500 0.12 500 0.12 6000 6000 can manage

25 P25 Final Ironing Helper 1 0 1 720 480 500 0.12 600 0.10 6000 6000 can manage
26 P26 Final Ironing Checker 1 0 1 720 480 500 0.12 600 0.10 6000 6000 can manage

27 P27 Final Ironing 9 0 9 720 480 55 1.09 72 0.83 5940 5940 Poor Performance, talking
each other
28 P28 Dust Cleaning 0 7 7 720 480 90 0.67 90 0.67 5040 5040 Standardise the way of doing

29 P29 Size Separation 2 0 2 720 480 300 0.20 360 0.17 7200 7200

30 P30 Ratio making 0 1 1 720 480 500 0.12 600 0.10 4000 4800 Need proper supply of sizes

31 P31 Poly Bag 0 2 2 720 480 250 0.24 450 0.13 4000 7200

32 P32 Cello Tape 0 2 2 720 480 250 0.24 333 0.18 4000 5333 Lag Concentration on work

33 P33 Size Sticker 0 2 2 720 480 250 0.24 600 0.10 4000 9600

34 P34 Carton 3 0 3 720 480 200 0.30 200 0.30 7200 7200

35 P35 Carton Writing 2 0 2 720 480 250 0.24 250 0.24 6000 6000 can manage

36 P36 Supervisor-Ironing 1 0 1 720 480 600 0.10 600 0.10 7200 7200

37 P37 Supervisor-Trimming 0 1 1 720 480 800 0.08 800 0.08 6400 6400

38 P38 Supervisor-Floor 1 0 1 720 480 600 0.10 600 0.10 7200 7200

39 P39 Recorder-Trims 1 0 1 720 480 600 0.10 600 0.10 7200 7200

40 P40 Stain Cleaning 1 0 1 720 480 600 0.10 600 0.10 7200 7200

41 P41 Supervisor-Line 1 0 1 720 480 600 0.10 600 0.10 7200 7200

42 P42 Packing Incharge 1 0 1 720 480 600 0.10 600 0.10 7200 7200

TOTAL 61 55 116 13.97 9.65 6047 6762

 MANPOWER
CURRENT
SL# BOTTLE NECK
EXP Local AVG TARGET

1 Trimming 0 15 4000

2 Sticker Removal 0 7 4000

3 Blowing 0 2 4800

4 Inseam Ironing 0 6 4800

5 Button Closing 0 1 4800

6 Appearance 3 0 5400

7 Final Ironing 9 0 5940

8 Dust Cleaning 0 7 5040

9 Ratio making 0 1 4000

10 Cello tape 0 2 4000

11 Poly Bag 0 2 4000

12 Size Sticker 0 2 4000

 Why??? Who? How to improve?

Ensuring Quality at Source (JIDOKA), Ensure full target

Threads from Sewing, Low Operator, Mechanic, from trimmer, Machine need to full adjusted with not
Performance of trimmers Trimmer more than 1 inch thread out, Use thread Cutter in M/C
if possible.

Poor performance Helper Need to do Inline Sticker Removal

No input Trimmer Making Trimming Productive

No input Trimmer Making Trimming Productive

Required Dedication in work, Do Line Balancing from

Poor performance, Time
Helper Sewing After 4:30, Keep Minimum Inventory for
Constrain
Smooth Flow
Need to ensure that fully trimmed garments from
Using Time for Trimming Trimmer
Trimmer
Ironer, Packing Standardisation, Motivation & Dedication. Analysis
Poor Performance
Incharge Hourly Target of each Ironer to Improve

Need Balancing of line in Standardise the Working Enviroment & Need

Overtime Hours Packing Incharge Motivation to worker

Need Balancing of line in Standardise the Working Enviroment & Need

Packing Incharge
Overtime Hours Motivation to worker

Need Balancing of line in Standardise the Working Enviroment & Need

Packing Incharge
Overtime Hours Motivation to worker

Need Balancing of line in Standardise the Working Enviroment & Need

Packing Incharge
Overtime Hours Motivation to worker

Need Balancing of line in Packing Incharge Standardise the Working Enviroment & Need
Overtime Hours Motivation to worker
 IBG JORDAN
Unit 1 Section Packing 9-Feb
Manpower Current State Daily current Daily Future
Sl # Code Operation Remarks
Exp Local Total Current Target SMV Capacity Capacity

1 P1 Endline Checking 6 3 9 75 0.80 7200 7560

2 P2 Line Output Count 2 1 3 300 0.20 9600 9600

3 P3 Reverse Garment 0 2 2 450 0.13 7200 6857

4 P5 Trimming 0 22 22 42 1.43 7392 10924

5 P6 Trimming Count 1 0 1 600 0.10 7200 7200

6 P7 Blowing 0 2 2 450 0.13 7200 8000

7 P8 Inseam Ironing 0 6 6 180 0.33 8640 8640

8 P9 Ironing Count-1 1 0 1 600 0.10 7200 7200

9 P10 Final check 8 1 9 70 0.86 7280 7296

10 P11 Final Count 1 0 1 600 0.10 7200 7200

11 P12 Hand Needle 1 0 1 600 0.10 7200 7200 142.857142857143

12 P13 Damage Repair 1 0 1 600 0.10 7200 7200

13 P14 M/C Operator 1 0 1 600 0.10 7200 7200

Poor Performance, talking
14 P15 W/B Ironing 5 1 6 100 0.60 6800 7152
each other
15 P16 Ironing Count-2 0 1 1 600 0.10 4800 4800 can manage

16 P17 Button Closing 0 1 1 600 0.10 4800 4800 Lag Concentration on work

17 P18 Measurement 1 0 1 600 0.10 7200 7200

18 P19 Appearance 3 0 3 200 0.30 7200 7200 Have to reduce Trimming

19 P20 Style Seprating + Count 1 0 1 600 0.10 7200 7200

20 P21 Waist Band Tag 1 0 1 600 0.10 7200 7200
Need one more machine
21 P22 W/B Helper 1 0 1 600 0.10 7200 7200
Use additional MP from WB
22 P23 Hand Tag 2 0 2 300 0.20 7200 7200
tag
23 P24 Size Checking 1 0 1 600 0.10 7200 7200 can manage

24 P25 Final Ironing Helper 1 0 1 650 0.09 7800 7800 can manage

25 P26 Final Ironing Checker 1 0 1 650 0.09 7800 7800 can manage
Poor Performance, talking
26 P27 Final Ironing 9 0 9 55 1.09 5940 5940
each other
27 P28 Dust Cleaning 0 7 7 90 0.67 5040 5040 Standardise the way of doing

28 P29 Size Separation 2 0 2 300 0.20 7200 7200

29 P30 Ratio making 0 1 1 500 0.12 4000 4800 Need proper supply of sizes

30 P31 Poly Bag 0 2 2 250 0.24 4000 7200

31 P32 Cello Tape 0 2 2 250 0.24 4000 5333 Lag Concentration on work

32 P33 Size Sticker 0 2 2 250 0.24 4000 9600

Daily current Capacity
33 P34 Carton 3 0 3 200 0.30 7200 7200
12000

34 P35 Carton Writing

10000 2 0 2 300 0.20 7200 7200 can manage
8000
35 P36 Supervisor-Ironing 1 0 1 600 0.10 7200 7200
6000
36 P37 Supervisor-Trimming
4000 0 1 1 800 0.08 6400 6400

37 P38 2000
Supervisor-Floor 1 0 1 600 0.10 7200 7200
0

Size Separation
Final check

Damage Repair
M/C Operator

Final Ironing Helper

Final Ironing Checker

Carton
W/B Helper

Size Sticker

Supervisor-Floor
Line Output Count
Reverse Garment

Final Count

Measurement
Ironing Count-1

Ironing Count-2
Trimming Count

Hand Needle

Appearance
Style Seprating + Count

Cello Tape

Supervisor-Line
Packing Incharge
Blowing

Supervisor-Ironing
Supervisor-Trimming

Recorder-Trims
Endline Checking

Trimming

Inseam Ironing

W/B Ironing

Waist Band Tag

Hand Tag
Size Checking

Final Ironing
Dust Cleaning

Ratio making

Stain Cleaning
Button Closing

Poly Bag

Carton Writing
38 P39 Recorder-Trims 1 0 1 600 0.10 7200 7200

39 P40 Stain Cleaning 1 0 1 600 0.10 7200 7200

40 P41 Supervisor-Line 1 0 1 600 0.10 7200 7200

41 P42 Packing Incharge 1 0 1 600 0.10 7200 7200

TOTAL 61 55 116 10.44 6788 7169