Standard Operation Procedure (SOP)

Work Study/ Industrial Engineering – SOP’s

1. At Style inquiry
Submit Estimated SMV, Outputs and efficiency levels for pre-costing
Analyze and comment on potential of doing the orders inquired.
Attend for the product development meeting and provide proactive input
Attend to do the mock ups for approvals on required construction changes with the evaluation of saving
and benefits
Calculate and submit thread consumption to the merchandising

2. At Production Planning
Submit Estimated SMV, Outputs and efficiency levels for Production planning
Provide proactive input for production scheduling
Check and approve production schedules
Make Line wise details production plan

3. At Pre-production
Testing and preparation for the confirmed orders – Methods, attachments
the samples to submit and comments after receive
Operation bulleting and SMV.
bulleting with Production and technical staff
Attend for line sample
Confirm operation bulleting
Prepare line layouts and discuss and confirm with production and technical staff
manpower allocation for layouts
Prepare skill inventory and requirement for each style
and attend on skill development for style based critical operations (Training in advanced)
Critical path analyses.
Prepare and attend on general skill development plan
fresher training manual
Supervise fresher training and training centre activities
Prepare machine, attachment and manpower requirements based on latest production schedules
Make and follow line feeding plan
Risk analyses before style feeding

4. Line feeding/New style introduction

Attend in new style introduction
Instruct and train workers on correct methods as motion sequence include in desired SMV
for best work place arrangements as method desired on SMV with maintaining a style check list.
Explain the SMV, Targets and plan efficiency and Incentive levels to each and every worker
Play a active roll on reducing line feeding losses (Through put time)
Optimum utilization of machine and equipment
Attend for style first bundle meeting

5. At Running Production and day to day

Capacity study of all layout/Operations at two to three days after feeding
SMV revision and confirmation with comparing the capacity after complete the capacity study
Make potential plans after capacity study
1st line layout re-balancing based on actual capacities and as per potential plan
Attend in daily line pocket meeting
Attend on daily line balancing
the bottle necks, technical and quality issues and attend to solve with addressing to the responsible
persons
Interval capacity study and line layout re-balancing once a every two weeks time in first month and
once a month after first month
Plan and attend in Continuous Training of workers
Attend in Continuous method improvements and SMV reductions
Organize and conduct daily efficiency meeting with production staff
Improving individual efficiencies with monitoring and making sure that the efficiency reports are
accurate
Monitor and record individual and line off standard times (lost time) and take necessary actions to
reduce the lost times. Address and discuss with management on off standard times
Achieve the maximum potentials of individuals and sections and maintain the minimum capacity gaps
Achieved planed production targets and line efficiencies
 6. Post Production
Style reconciliation of technical (SMV, Efficiency, Production output, Thread consumption, Production
plan, Bottlenecks)
Monitor the style reconciliation of received to ship
Monitor the post costing

7. General
Performance evaluation of workers and factory staff. Do the grading
Introducing and monitoring incentive schemes/Motivation tools
Plan and monitor the skill upgrade program
Management update on latest management concepts, Technology, systems and procedures, methods,
tools and attachments.
Maintain and achieve the targets of key productivity indicators (KPI) and do the comparison with other
industries for management information
Maintain all filing and document systems
Special tasks/Projects assign by management
Attend for management meeting and give proactive input
training and maintain records of achievements

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