Capacity Planning

Establish capacity for each production section, remove holidays, add overtime, use your current efficiencies and absentee levels and your capacity is instantly available. Capacity is established for 300 days in advance, it maintains these days by adding a new day at the end day.

You can: Reserve capacity for special customers, Change the capacity of sections as it suits your sales.

Pre-Production Planning

The system will tell you by which date all the necessary pre-production functions must be complete if the style is to start feeding onto the line on the planned date. Those pre-production functions that are late show on the screen in red. The individual company according to their needs and experience sets lead times.

Audit Trail

An Audit trail is in place to allow Management to monitor the actions taken by those responsible to ensure that pre- production functions are completed in time. Actions taken are date recorded and the date the action was taken can neither be changed nor deleted. To view audit action simple double-click on the style the information is required for.

Pictures

The facility is provided to insert pictures of styles into the system. No more looking for samples, click on the style and the picture is there, click on the picture to get a full screen image.

Style Entry

Enter style details including:

Special instructions, minute value, outwork types, trims, fabrics, special machines required, and style costs.

Outwork and CMT

Monitors outwork and CMT, you enter date sent and expected lead-time, it reports to you and reminds you of outstanding and late deliveries.

Orders

As orders are received they are entered and any special requirements are recorded. Requested delivery date, whether or not the style is going out to CMT if the order is for export, which vessel and departure date is applicable.

Planning

Orders are planned onto the section that can best make them. The orders are arranged in the best sequence for customer delivery, Push the “Compile “ button and the dates that the order will be complete is compared to the “Requested Delivery date” and the number of days early or late is displayed. Orders can be re-arranged, transferred to other lines, sent out to CMT, overtime or short time, can be planned and the effects of these changes can be seen immediately.

Booking Production

If this system is used in conjunction with our Pro-Man system, booking production is automatic, otherwise daily production figures are entered and the plan recompiled to see the effect of today’s production on the expected completion date.

Scenario Planning

It is possible to plan several different “Scenarios”, IE “What if” situations, these can be “Compiled”, reviewed and the best alternative chosen, or go back to the original situation.

REPORTS AVAILABLE

Production Schedule

Listing of all allocated orders in priority order by section: This report shows the start and end date, the requested delivery date and the “Play” (early or late) for every order.

It also shows the situation with regard to the pre-production functions.

Production Report:

This is the daily profit or loss of the whole factory based on today’s output.

Planned Production Value:

Predicts the value of monthly turnover, section by section:

Outwork

A complete listing of all styles that are waiting for outwork to be completed, showing whether the outwork is on schedule or not

Factory Loading

Indicates the available capacity monthly, and shows the factory loading against this capacity.

And many more including
Work in Progress
Special Machine requirements
Customer Reports
Linked Styles
Audit Trail
Styles to clear

General Comments

Production planning is the “soul” of the business, can be the difference between success and failure.

It is a discipline that requires constant monitoring, done properly it informs everyone what is happening in every department, and allows everyone to work on the same priorities.

Report

Information

Who should use it

Operator efficiency after every 2 hours per section

Supervisor and Workstudy officer

Section Efficiency

Summary of section efficiencies per division.

Line and Production manager

Division and Factory Efficiency

Overall Efficiencies reflecting the bottom line of each Section efficiency

Management

Piece Work earnings

List of all operators, their wage rates and earnings for a specific period

Management, Wages department

Graphs

These can be previewed as and when required

All

Lost Time

This is a summary of the time lost by operators which is not their fault. It is a guide to Supervisory and management efficiency.

Supervisors, Managers

Tickets Produced per operation

To determine lost tickets and cheating, no need to print

Workstudy, Supervisor

Operators below %

Summary of operators below a certain efficiency levels. Used to improve performances

Work-Study

Bonus Earnings

If a bonus system is in place this indicates bonus earnings for each operator.

Supervisors, Managers, Wages,

Score sheet

Units produced per scanning period and the efficiency attained.

Supervisor, W/S

Production Report

The total garments that have been produced for each operation during a scanning period

Manager, Supervisor

Work-slip

Individual operator feedback on their days production. This was designed to indicate to operators their daily earnings and production output.

Management, Operators, Supervisors

Work in progress

Shows the status of all orders in the factory at various important production points. Eg Cut, On line, Off line ect, and is used to monitor the progress of all orders

Management, Planning , Sales, Dispatch, Merchandising

WIP between progress points

Indicates the amount of garments between 2 progress points

As above

Units produced per operation

Number of garments produced at every operation regardless of the number of operators on that operation

Supervisors, Manager

Units produced by sub-section

Number of garments produced through the last operation of all the subsections – Valuable when making garment sub sections simultaneously.

Supervisors, Managers, W/S staff.

Work Distribution

Quantity produced on every operation in the style and the buffer qty between operations. Used for a  stock take and Line Balancing

Supervisor, Manager

Work in progress by colour and size

Quantities produced per colour and size on any operation in the style.

Manager, Planning, Sales, Dispatch

Profit / Loss

Shows the daily recovery against operating costs, works in conjunction with the costing module

Manager and Supervisors

Daily Line Recovery

Cost feedback on an order on any progress point. Compares the value recovered against the selling price

Management

Rejects and Garments removed

Quantity of rejected garments by reason, colour and size

Management

Operation  Sequence

Listing of all operations in a style

Workstudy and Supervision

Cut Summary

Qty cut per colour and size

Cutting Room, Dispatch

Bundle List

List of all bundle in the lay with sequence numbers

Numbering operators and bundling girls, Supervisors line feeders, Dispatch

Operators Personal Records

Feedback on absenteeism, warnings, Skills, Efficiencies etc. information should be captured regularly

Personnel department and Manager

Operators Skills Analysis

Feedback on the skills accumulated by operators in the factory

Supervisors, Manager, Training Department, Personnel

Scanning Control Sheet

Used to check the operators on the section prior to the first scan

Supervisor and Scanning operator

Machine Requirements

List of operations and the machine type needed for each operation

Supervisor and Mechanic

Operations, Machines and Work aids

Listing of each – for reference purpose

Workstudy

Late Tickets

List of all tickets that have not been scanned in every order in the system

Workstudy, Supervisor

Budgeted Operators

This is intended to help to keep the ratio of Machinists to non machinists in check, it give a comparison between budgeted and actual employees

Management

Personnel

Operator Skills analysis

This is a skills matrix, it is built automatically

Supervisors,  managers, personnel

Scanning control sheet

This is a list of the operators who are allocated to the section, it is printed daily and the scanner must check the actual people on the line

Scanner

Late bundles

This report shows a list of the bundles that have not moved for a predetermined number of days.

Progress chaser

Management