Clarify the problem

• Stock distribution (December 2020)

Clarify the problem
• Output cutting
DATE PLAN QTY ACTUAL QTY MENIT MENIT effisiensi
OUTPUT OUTPUT PLAN ACTUAL

01-Dec 35,938 36,545 40,726 45,288 99%

02-Dec 42,285 46,028 45,227 50,664 111%
03-Dec 35,494 38,296 44,657 43,932 96%
04-Dec 40,319 47,066 43,571 48,349 106%
07-Dec 49,531 33,690 53,917 40,868 90%
08-Dec 43,878 48,594 50,596 52,474 115%
10-Dec 79,700 33,617 82,453 40,526 89%
11-Dec 58,137 40,414 64,303 43,958 96%
14-Dec 43,885 44,469 47,587 46,394 102%
15-Dec 42,351 46,599 42,351 56,038 123%
16-Dec 44,839 43,519 44,839 48,963 107%
17-Dec 21,675 37,161 26,224 45,411 115%
18-Dec 13,677 44,436 15,805 52,192 125%
21-Dec 40,210 46,611 48,865 51,614 129%
22-Dec 33,592 36,524 33,485 40,164 110%
23-Dec 25,463 32,012 30,901 36,696 101%
28-Dec 33,504 37,313 42,271 41,386 113%
29-Dec 43,856 36,285 47,292 43,833 120%
30-Dec 66,360 24,385 51,357.00 33,446 92%
 Clarify the Problem
• Distribution request pull forward plan cutting date
Date 1-Dec 3-Dec 7-Dec 8-Dec 10-Dec 11-Dec 14-Dec 18-Dec 21-Dec 22-Dec 23-Dec 28-Dec 29-Dec 30-Dec
PO 11 15 11 13 4 11 7 6 7 7 10 14 5 7
Qty Order (Pcs) 5,963 20,778 18,151 8,612 3,207 3,932 1,805 17,666 10,090 30,494 51,606 14,549 4,452 5,691
Initial Problem Perception
• High WIP or Stock in distribution, High Output cutting, but everyday
distribution Request pull forward plan cutting date to fulfill sewing
need.
Clarify the Problem
What actually happen
• Stock distribution over than 5
days
• Not all output cutting is same as
with needed
• Distribution request pull forward
for cutting plan to fulfill sewing
need
What should be happen
• Stock distribution Distribution
Stock ready 2 days and stock
unready 3 days.
• Output cutting should be the
same as with sewing needed
Breakdwon
• PPCM Release every two weeks, every PPCM release there are
changes plan to start sewing. if the start to sewing is pull back, it
would increase work in process or stock at distribution, while if the
start to sewing is pulled forward it would make pull forward for plan
cutting date. And once it happens it would be made unsmooth
process between cutting and distribution.
Tabel jumlah maju mundur ppcm, table
jumlah pull forward pcd
Real Problem
• The changes every PPCM release caused a high stock in distribution
and led to unsmooth process between distribution and cutting
Point of Cause (PoC)
• Locate Area
Flow process

Based on trackback, the PoC is PPCM, the caused of this problem is

inconsistency PPCM
Point of Cause (PoC)
• Grasp situation at PoC
Point of Cause (PoC)
• Direct cause