The primary objective is to produce Operator, Line, Divisional, and Factory Efficiency figures, and to provide total Work in Progress control. This is done by the introduction of a Bar-Coded bundle ticket system, which ensures that data collection is quick, accurate and easy. Scanning tickets produces all the efficiency and WIP reports. Pro-Man will serve as the base for future installations of our fully integrated production control systems.
Advantages of Pro-Man
- Management decisions based on the current situation not history
- Reduction of data collection personnel:
- Freeing supervisors and Managers to manage
- Control of Labour ratios to ensure accurate recoveries
- Part of a totally integrated production control system
- Links and other applications
- Better and more efficient data flow between systems and departments
- Better trained and more informed personnel
- Quicker reaction to customers needs
- Improved customer satisfaction
- Improved communication
- Total Work in Progress Control
- Control of rejects and theft
- Speedy operation breakdowns for costing purposes
- Easy to read graphs
- Assistance with Line balancing
- Simple for operators to understand
Quick and accurate
All of the above points lead to better management control and considerable cost savings, but these savings are intangible and not easily quantified. Daily profit and loss reporting per factory, per department, per line Automatic emails to head office. Print what you require only, it may be the case that some of the reports are used intermittently. Transport information into Spread sheet applications
Methods Workshop
Methods Workshop was founded in 1981, The company develops systems specifically for the clothing industry. Have dedicated team of consultants with combined industry experience of over 150 years, have over 250 users in various countries, Have offices in Cape Town, Colombo, Delhi, software support and updates via Modem, we are adding to the system constantly, keeping up with the latest technologies.
Training
It is essential that everyone in the organisation is fully conversant with the outputs available, and how to use the information properly. We therefore recommend the following:
Management Training
Detailed discussion and explanation to all management covering:
Principals of Pro-Man, bundle systems and the disciplines required.
What should be expected from the system?
Work in progress controls, Bonus structures Supervisory Training
Detailed discussion and explanation to all first line supervision covering:
Bar-coded tickets, Thermal printing.
Personnel Management
All relevant details, including address, next of kin and the operator’s function are captured. As information is scanned into the system skills and performance against those skills are accumulated automatically. Records of absenteeism, late coming, warnings, and counselling are maintained. This information is captured daily, thus it is always available at the touch of a button.
Styles and Quality
Style and operation information is captured directly into Pro-Man. The user can scan a picture, Photo or Technical Drawing of the style and of the operation into the system this allows for Quality control information to be available for every operation and reduces the need for samples on the factory floor. All operations are captured into a specially designed four-tier database system (Fabric, Garment, Garment Part, and operation type) for ease of retrieval, thus improving the accuracy and speed of labour costing.
Orders
Bundle information is entered directly after laying-up, simply enter the sizes and the number of times they have been marked in the lay, the number of plies per colour or shade and the bundle list is automatically generated.
If Pro-Cut (Fabric Reconciliation system) is being used, these details are automatically available and no bundle entry is necessary. There are no restrictions on the number of lays that the system will accept. There is a check to stop bundle tickets being generated if they do not match the cut quantity exactly.
Bundle numbers are continuous throughout the order, irrespective of the number of lays the order may require. It is also possible to “Reconcile” each lay, thus minimising shortages and highlighting theft during the production process.
Bundle Tickets
There are currently 4 different bundle ticket layouts to select from. Information on the ticket includes: Style number, Order number, Garment Part, Bundle Number, Colour, Size, Quantity, and Minutes for the Bundle, Lay Number, Shade and the target for one hour.
Peel and stick tickets are also now available, these reduce bundle handling time significantly and thus are economically viable.
Barcode Scanning
You can scan as often as you wish, we recommend four times a day. Thus 2 hours after work has commenced management knows exactly where the problems are, and can take corrective action. The information gathered is “Live” and can be available on the manager’s desk immediately after the scanning process. Each direct operator must be scanned every scanning period. All information is captured including produced minutes, absent time, lost time, off standard time and overtime. Lost time (time that the operator looses through no fault of their own) is captured against a reason, thus highlighting areas that need attention.
After scanning, all work done by the operator is held in an audit trail and can be tracked back, tickets cannot be scanned twice, and this effectively “Seals” the operator’s ability to “Cheat” the system. “Missing” tickets become a thing of the past as operators learn that when a ticket has been scanned an audit trail exists.
Work in Progress
There is comprehensive work in progress tracking within the system. When the operation sequence is created certain operations are identified as progress points. There are up to 10 progress points available. These are “Soft Coded” so can be named to suit you
It is intended that these points are allocated to the relevant operation; e.g. the “On line” progress point ticket is allocated to the first sewing operation, when this tickets are scanned, the bundle is moved automatically in the work in progress section, adjusting the balance still being held as “Cut Work Stock” and the balance “on line”, this is automatic, no human intervention is necessary. As the order progresses various reports are available to assist supervisors, Management and production chasers. You are also able to get WIP values for all departments when you need it
Incentive Structures
There are a number of bonus structures available, Individual, Group, a combination of Individual and group; piecework and stepped. It is also possible to print the money value of the work completed on the bar-coded ticket instead of the target. This lets the operator calculate exactly how much she/he has earned as during the day/week.
Skills Matrix
The system will automatically build a skills matrix for every operator, showing what operation types he/she can do and the efficiency that has been reached on the various operations. This information is invaluable when balancing lines, and during the installation of new styles, and is also very necessary to produce training plans to show you where insufficient skills are available.
System Configuration and Implementation
The number of stations required will depends on the size of the company. We recommend one station for every 120 operators for scanning purposes. Over and above this the Factory manager, Personnel department and other management staff may need the system available on their workstations. Implementation is commenced by setting up a database to suit your company’s specific requirements. Dependent on whether you have used a bundle system before it may be necessary to spend some time in the cutting room training staff how to set up bundles.
Computer Hardware
Will be specified at the time of quoting, and once we know your requirements.
Reports
There are more than 40 reports available. This is a listing of some of them together with an explanation of their use. |
