Once the initial set up has been produced the day-to-day maintenance of a balanced section becomes the responsibility of the line supervision and can be monitored using another aspect of the program.
There are 3 main facilities available:
A: Maximise the output from a given number of operators.
B: Maximise the efficiency of the operators to produce a given number of garments over a certain period.
C: Maintain a good, well-balanced section whilst producing the order.
The program offers the following facilities
1. Skills Matrix.
The first requirement, is to build a skills matrix for the complete Labour force, this will be done in conjunction with our Pro-Man system. All operations are given a skill code, when an operator works on the skill, the efficiency achieved will be averaged with previously stored efficiency information to give an up to date efficiency figure for this operator on this skill. A complete skills matrix is available for all operators and is displayed for every operator showing what operations she/he can do and at what level of efficiency. A second display indicates how many operators can do each skill, this information should be interpreted to create a training needs analysis. One can also search the database to see who can perform a particular operation or skill this functionality can be used to find replacements for absentees.
2. Line set up.
Operation sequences for new styles are built up from the operation database developed in Pro-Man, all of the operations used will have a skills code.
The system will calculate the number of operators required for each operation according to the number of operators available on the line chosen to produce the order.
Operations are combined where necessary to enable the correct and most economical use of the available operators.
Once this has been done the “bottleneck” operation and the “line balance efficiency” is calculated.
From the skills listing the best operators can be chosen for each operation
The operators can now be arranged to facilitate the most suitable line layout
The line layout plan can be printed, various layouts options exist, i.e. with centre table, in a straight line, in a U shape.
Arrows, superimposed on the layout will indicate work flow
A “Drag and Drop” facility exists to further improve the workflow.
3. Running the Line.
When the line balance has been produced, and the line set up to perform as required, the system is set to monitor the workflow to minimise bottlenecks.
This is done in conjunction with the Pro-Man system as follows.
- After each scan, the exact Work in Progress between each operation is established.
- Management can set an optimum level of minutes of work required between each operator for the smooth performance of the line, not too little and not too much.
- The optimum number of minutes if WIP will be shown on the screen as a straight line across the screen.
- The work in progress is shown in the form of a histogram, showing the WIP between each operation, either over or under the line.
- Different skills are shown in different colours, bottlenecks are easily identified and work can be moved to other operators on the line who have the skills (same colour) to perform the operation.
- The supervisor will choose which operator she feels is best to change according to the current situation and give work from the bottleneck operation to the chosen operator.
- At the next scan the supervisor can review the situation as a result of her changes and see what has happened.
- The system will report “output efficiency” on the screen each period. The supervisor will be able to see whether or not the efficiency is rising or falling as a result of her actions.
4. Maintenance Department:
Because of the ability of the system to produce “Line Layouts” the maintenance department are advised in advance of equipment and attachments required and through Pro-asset they will be able ensure availability.
It is therefore possible to have the equipment prepared and ready in advance, thereby reducing “Down Time” or “Set-up Time” for new orders.
5. Reports
- Line layout plan
- Line balance, which operator will do which operation
- Skills matrix
- Skills training Plan
- Machinery and attachments list
6. System Setup
Each company’s circumstances are taken into account as follows:
- Number of production lines
- Amount of training necessary to get the desired results.
- The positioning of the screens to ensure ease of use.
- Positioning of screen in production manager’s office
7. Pictures
Pictures of styles will be available in the database to assist in the preparation of the line layouts. These pictures will avoid the necessity for sample to be found and will help to ensure that the correct style is being worked on.
8. Implementation
The company will need to have set-up and run the Pro-Man system for some time to have the procedures in place to collect the skill information vital to the running of this system. |
