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Line 1

ITEM No.:- M675

operations Neck attachment Neck Finish


Date
11-Jun-11
29
13-Jun-11
22
14-Jun-11
26
15-Jun-11
16-Jun-11
17-Jun-11
18-Jun-11
20-Jun-11
21-Jun-11
22-Jun-11
23-Jun-11
TOTAL

22
13
7
4
5
10
7
5
150

SL.No.
1
2
3
4

Zipper attachment

Zipper finish

side o/l

sleeve fold

Bottom fold

sleeve tacking

dori

27
24
0

25
34
0

21
17
0

7
0
0

7
0
0

3
0
8

13
0
0

0
3
0

10
10
8
6
3
16
6
6
116

5
11
21
12
14
4
12
2
140

0
1
3
15
12
3
7
2
81

3
3
8
0
10
2
6
14
53

0
0
5
0
7
6
0
6
31

6
5
14
4
4
9
2
2
57

160
1400
1200
1000
80
600
400
200
00

0
0
5
5
5
5
4
10
37

TOP 4 OPERATION HAVING DEFECTS


OPERATIONS
No. OF DEFECTS
Neck attachment
150
Zipper attachment
140
Neck Finish
116
Zipper finish
81
total
487

total defects= 740


out of 740, 487 are found in 4
operations only..
i.e. 65.8%

cost for these 4 alters


opereration
time(in min.)
Neck attachment
2.12
Neck Finish
1.22
Zipper attachment
5.54
Zipper Finish
3.04

overhead/time
3.25
3.25
3.25
3.25

Total/pc
6.89
3.965
18.005
9.88

no. of pcs
150
116
140
81

total(in Rs)
1033.5
459.94
2520.7
800.28

13

TOTAL

4814.42

Label attach

TOTAL
0
0
12

132
100
46

TOTAL

18
6
0
12
0
0
9
5
62

64
49
71
58
60
55
53
52
740

TOTAL

Line 1

ITEM No.:- M675

Time taken for rework


SL. No.

Operations
1
2
3
4
5
6
7
8
9
10
11

rework time

Pleat
neck attach
neck finish
side o/l
sleeve fold
Bottom fold
Zipper Attach
Zipper Finish
sleeve tacking
Dori
label attach

0.88
1.4
0.5
1.16
0.98
0.96
4.82
2.32
0.4
0.5
0.8

recheck time endline


0.72
0.72
0.72
0.72
0.72
0.72
0.72
0.72
0.72
0.72
0.72

after poka yoke


time taken by operators to check these operations and cost analysis
SL. No.

Operations
1
2
3
4
5
6
7
8

time(in min)

Overhead/time(in Rs)

total/pc(in Rs)

Pleat
neck attach
neck finish
side o/l
sleeve fold
Bottom fold
Zipper Attach
Zipper Finish

0.4
0.5
0.4
0.45
0.32
0.45
0.6
0.52

3.25
3.25
3.25
3.25
3.25
3.25
3.25
3.25

1.3
1.625
1.3
1.4625
1.04
1.4625
1.95
1.69

9 sleeve tacking
10 Dori
11 label attach

0.36
0.4
0.3

3.25
3.25
3.25

1.17
1.3
0.975

ITEM No.:- M675

me taken for rework


total
1.6
2.12
1.22
1.88
1.7
1.68
5.54
3.04
1.12
1.22
1.52

cost for these 4 alters


opereration
Neck attachment
Neck Finish
Zipper attachment
Zipper Finish

time(in min.) overhead/time


total/pc
2.12
3.25
1.22
3.25
5.54
3.25
3.04
3.25

6.89
3.965
18.005
9.88

cost saved per alter pc of these 4 critical operations


cost before
cost after
reduction
opereration
cost/pc(in Rs) cost/pc(in Rs)
(in Rs)
Neck attachment
6.89
1.625
5.265
Neck Finish
3.965
1.3
2.665
Zipper attachment
18.005
1.95
16.055
Zipper Finish
9.88
1.69
8.19
TOTAL
Savings per line

4009.98

no. of pcs total(in Rs)


150
1033.5
116
459.94
140
2520.7
81
800.28
TOTAL
4814.42

Final cost
(in Rs)
243.75
150.8
273
136.89
804.44

inline checker 2

Puckering/Pleating/ Roping
Broken Stitch
Raw edge
Run Off
Uunbalanced/ Unmatched
Smocking Problem
Trim problem
Wavy Stitch
Specs
Cutting problem
Others

6/11/2011
27
20
0
19
0
0
0
0
0
0
0

6/13/2011
11
19
0
15
9
0
0
0
0
0
0

6/14/2011
13
15
0
21
8
0
0
0
0
0
0

6/15/2011
8
8
0
28
16
0
0
0
0
0
0

100%
90%
80%
70%
60%
50%
40%
30%
20%
10%

Puckering/Pleating/ Roping
Broken Stitch
Raw edge
Run Off
Uunbalanced/ Unmatched

6/11/2011
13
9
0
0
24

inline checker 1
6/13/2011
8
13
3
6
10

6/14/2011
4
3
5
10
2

6/16/2011

6/15/2011

6/14/2011

6/13/2011

6/11/2011

0%

6/15/2011
8
17
0
7
18

Smocking Problem
Trim problem
Wavy Stitch
Specs
Cutting problem
Others

0
0
9
0
0
1

0
0
0
0
0
0

0
0
11
0
0
0

0
0
0
0
0
0

100%
90%
80%
70%
60%
50%
40%
30%
20%
10%

Puckeing/ Pleating/ Roping


11-Jun-11
13-Jun-11
14-Jun-11
15-Jun-11
16-Jun-11
17-Jun-11
18-Jun-11
20-Jun-11
21-Jun-11
22-Jun-11
23-Jun-11
Total

Broken Stitch
10
0
0
8
4
14
0
14
7
5
6
68

Raw Edge
6
6
12
0
9
5
0
12
11
0
0
61

Run Off
0
22
3
5
11
24
5
4
12
0
4
90

100%
90%
80%
70%
60%

6/15/2011

6/14/2011

6/13/2011

6/11/2011

0%

14
0
2
6
1
5
19
0
10
3
14
74

60%
50%
40%
30%
20%
10%
13/Jun/11

11/Jun/11

0%

150
100
50
0

6/16/2011
14
18
0
14
16
0
0
0
0
0
0

6/17/2011
21
12
0
21
7
0
0
0
0
0
0

6/18/2011
17
15
0
12
17
0
0
0
0
0
0

6/20/2011
15
14
0
11
16
0
0
0
0
0
0

6/21/2011
17
11
0
13
14
0
0
0
0
0
0

6/20/2011
11
6
15
6
8

6/21/2011
8
16
8
21
12

Others
Cutting problem
Specs
Wavy Stitch
Trim problem
Smocking Problem
Uunbalanced/ Unmatched

Inline checker 2

6/16/2011
0
15
4
32
7

6/23/2011

6/22/2011

6/21/2011

6/20/2011

6/18/2011

6/17/2011

Run Off
Raw edge
Broken Stitch
Puckering/Pleating/ Roping

6/17/2011
12
5
8
0
22

6/18/2011
14
16
0
12
8

0
0
4
0
0
0

0
0
8
0
0
2

0
0
0
0
0
0

0
0
14
0
0
0

0
0
0
0
0
0

Others
Cutting problem
Specs
Wavy Stitch
Trim problem
Smocking Problem
Uunbalanced/ Unmatched
Run Off

6/23/2011

6/22/2011

6/21/2011

6/20/2011

6/18/2011

6/17/2011

6/16/2011

6/15/2011

Raw edge
Broken Stitch
Puckering/Pleating/ Roping

inline checker 1

Unbalanced/Unmatched

Smocking Problem
0
8
26
3
15
5
8
25
5
7
15
102

Trim Problem
0
0
0
0
0
0
0
0
0
0
0
0

Wavy Stitch

Specs

0
0
0
0
0
0
0
0
0
3
5
8

0
16
3
24
5
12
14
5
4
27
8
118

OT
CP
SP

0
0
0
4
3
0
2
0
0
0
0
9

SP
WS
TP
SM

23/Jun/11

22/Jun/11

21/Jun/11

20/Jun/11

18/Jun/11

17/Jun/11

16/Jun/11

15/Jun/11

14/Jun/11

UM
RO
RE
Broken S

End line checker

defects
Puckering Problem+D390
Broken Stitch
Raw Edge
Run Off
Unbalanced/ Unmatched
Smocking Problem

6/22/2011 6/23/2011
0
9
24
21
0
0
19
16
12
15
0
0
0
0
0
0
0
0
0
0
0
0

6/22/2011 6/23/2011
7
14
11
8
10
13
11
4
9
17

0
0
6
0
0
0

Cutting Problem
0
0
0
0
0
0
0
0
0
0
0
0

0
0
9
0
0
0

Line 1
ITEM No.:- M675

inline checker 1
DATE
operations
11-Jun-11 Neck attachmemt
Neck Finish
Total
DHU

PP

BS

RE

5
4
8
5
13
9
23.21 16.07

0
0
0
0

defects
RO
UM
SM
0
10
0
14
0
24
0 42.86

TP
0
0
0
0

WS
SP
0
9
0
0
0
9
0 16.07

CP
0
0
0
0

OT
total total checked pcs
0
1
29
132
0
0
27
0
1
56
0 1.786

DHU
21.9697
20.45455
42.42424

50

11-Jun-11

40
30

Total

20

DHU

10
0
PP

DATE
operations
13-Jun-11 Neck attachmemt
Neck Finish
Total
DHU

PP

BS
3
5
8
20

BS

RE
5
8
13
32.5

35
30

0
3
3
7.5

RE

RO

UM SM

defects
RO
UM
4
2
6
15

TP

SM
4
6
10
25

WS

TP
0
0
0
0

SP

CP

WS
0
0
0
0

OT

SP
0
0
0
0

CP
0
0
0
0

OT
0
0
0
0

0
0
0
0

total total checked pcs


16
166
24
40

13-Jun-11

25
20
15

Total

10

DHU

DHU
9.638554
14.45783
24.09639

15

DHU

10
5
0

PP

DATE
operations
14-Jun-11 Neck attachmemt
Neck Finish
Total
DHU

PP

BS

BS

RE

0
0
5
4
3
0
4
3
5
11.43 8.571 14.29

RE

RO UM SM

defects
RO
UM
SM
0
0
10
2
10
2
28.57 5.714

TP

WS

TP
0
0
0
0

SP

CP

OT

WS
SP
0
11
0
0
0
11
0 31.43

CP
0
0
0
0

35

OT
0
0
0
0

0
0
0
0

total total checked pcs


16
120
19
35

DHU
13.33333
15.83333
29.16667

14-Jun-11

30
25
20

Total

15

DHU

10

5
0

PP

DATE
operations
15-Jun-11 Neck attachmemt
Neck Finish
Total
DHU

PP

BS
2
6
8
16

BS

RE

RE
10
7
17
34

0
0
0
0

RO UM SM

defects
RO
UM
0
7
7
14

TP

SM
10
8
18
36

WS

SP

TP
0
0
0
0

CP

WS
0
0
0
0

OT

SP
0
0
0
0

CP
0
0
0
0

OT
0
0
0
0

0
0
0
0

total total checked pcs


22
204
28
50

DHU
10.78431
13.72549
24.5098

40

15-Jun-11

35
30

25
20

Total

15

DHU

10
5

0
PP

DATE
operations
16-Jun-11 Neck attachmemt
Neck Finish
Total
DHU

PP

BS

BS

RE

0
5
0
0
10
4
0
15
4
0 24.19 6.452

RE

RO UM SM

defects
RO
UM
SM
0
4
32
3
32
7
51.61 11.29

TP

WS

TP
0
0
0
0

SP

CP

WS

OT

SP

0
4
0
0
0
4
0 6.452

CP
0
0
0
0

OT
0
0
0
0

60

total total checked pcs


0
13
240
0
49
0
62
0

DHU
5.416667
20.41667
25.83333

16-Jun-11

50
40
30

Total

20

DHU

10
0
PP

DATE
operations
17-Jun-11 Neck attachmemt

PP

BS
10

RE
0

BS

RE

RO UM SM

defects
RO
UM
SM
0
0
10

TP

WS

TP
0

SP

CP

WS
0

OT

SP
0

CP
0

OT
0

total total checked pcs


22
585

DHU
3.760684

Neck Finish
Total
DHU

2
5
8
12
5
8
21.05 8.772 14.04

0
0
0

12
22
38.6

0
0
0

0
8
0
8
0 14.04

0
0
0

0
0
0
2
0 3.509

50

35
57

585

5.982906
9.74359

17-Jun-11

40
30

Total

20

DHU

10
0
PP

DATE
operations
18-Jun-11 Neck attachmemt
Neck Finish
Total
DHU

PP

BS
4
10
14
28

BS

RE
8
8
16
32

0
0
0
0

RE RO UM SM TP WS SP

defects
RO
UM
0
12
12
24

SM
6
2
8
16

TP
0
0
0
0

CP

OT

WS
0
0
0
0

SP
0
0
0
0

CP
0
0
0
0

OT
0
0
0
0

0
0
0
0

total total checked pcs


18
525
32
50

18-Jun-11

35
30
25
20

Total

15

DHU

10
5
0
PP

BS

RE

defects

RO UM SM TP WS SP

CP

OT

DHU
3.428571
6.095238
9.52381

DATE
operations
20-Jun-11 Neck attachmemt
Neck Finish
Total
DHU

PP
9
2
11
18.33

BS

RE
6
0
6
10

RO
0
15
15
25

UM
0
6
6
10

SM

1
7
8
13.33

TP
0
0
0
0

WS
SP
0
0
0
14
0
14
0 23.33

CP
0
0
0
0

OT
0
0
0
0

30

0
0
0
0

total total checked pcs


16
480
44
60

DHU
3.333333
9.166667
12.5

20-Jun-11

25
20
15

Total

10

DHU

5
0
PP

DATE
operations
21-Jun-11 Neck attachmemt
Neck Finish
Total
DHU

PP

BS

BS
RE
8
11
0
0
5
8
8
16
8
12.31 24.62 12.31
35

RE

RO UM SM

defects
RO
UM
SM
0
0
21
12
21
12
32.31 18.46

TP

WS

TP
0
0
0
0

SP

CP

WS
0
0
0
0

OT

SP
0
0
0
0

CP
0
0
0
0

OT
0
0
0
0

0
0
0
0

total total checked pcs


19
480
46
65

21-Jun-11

30
25

20
15
10
5
0

Total
DHU

DHU
3.958333
9.583333
13.54167

PP

DATE
operations
22-Jun-11 Neck attachmemt
Neck Finish
Total
DHU

PP

BS

BS

RE

7
5
0
0
6
10
7
11
10
12.96 20.37 18.52

RE

RO UM SM

defects
RO
UM
SM
0
0
11
9
11
9
20.37 16.67

TP

WS

TP

WS
SP
0
6
0
0
0
6
0 11.11

0
0
0
0

SP

CP

OT

CP
0
0
0
0

OT
0
0
0
0

25

0
0
0
0

total total checked pcs


18
435
36
54

DHU
4.137931
8.275862
12.41379

22-Jun-11

20

15
Total
10

DHU

5
0
PP

DATE
operations
23-Jun-11 Neck attachmemt
Neck Finish
Total
DHU

PP

BS

BS
RE
4
8
0
10
0
13
14
8
13
21.54 12.31
20

30

RE

RO

UM

SM

defects
RO
UM
SM
0
0
4
17
4
17
6.154 26.15

TP

TP
0
0
0
0

WS

SP

CP

WS
SP
0
4
0
5
0
9
0 13.85

OT

CP
0
0
0
0

OT
0
0
0
0

23-Jun-11

0
0
0
0

total total checked pcs


16
465
49
65

DHU
3.44086
10.53763
13.97849

30
25
20

Total

15

DHU

10
5
0
PP

DATE
operations
24-Jun-11 Neck attachmemt
Neck Finish
Total
DHU

PP

DATE
operations
25-Jun-11 Neck attachmemt
Neck Finish
Total
DHU

PP

BS

BS
RE
12
6
0
0
6
9
12
12
9
18.46 18.46 13.85

BS

12
6
0
13
12
19
19.35 30.65

RE
0
8
8
12.9

RE

RO UM SM

defects
RO
UM
SM
0
0
21
11
21
11
32.31 16.92

defects
RO
UM
SM
0
2
16
5
16
7
25.81 11.29

DEFECT LIST
PP
BS
RE
RO

PUCKERING/PLEATING/ROPING
BROKEN/INSECURE/SKIP/UNTIDY JOINT
RAW EDGE
RUN OFF

TP

WS

SP

TP
0
0
0
0

WS
0
0
0
0

TP
0
0
0
0

CP

SP
0
0
0
0

WS
0
0
0
0

OT

CP
0
0
0
0

SP
0
0
0
0

OT
0
0
0
0

CP
0
0
0
0

OT
0
0
0
0

total total checked pcs


18
585
47
65

DHU
3.076923
8.034188
11.11111

total total checked pcs


0
20
585
0
42
0
62
0

DHU
3.418803
7.179487
10.59829

0
0
0
0

UM
SM
TP
WS
SP
CP
OT

UNBALANCED/UNMATCHED
SMOCKING PROBLEM
TRIM PROBLEM
WAVY STITCH
SPECS
CUTTING PROBLEM
OTHER

Line 1

inline checker 2
DATE
operations
11-Jun-11 Zipper Attach
Zipper Finish
Side attach
Total
DHU

PP

BS

7
0
20
27
40.909

RE
8
12
0
20
30.3

defects
RO
UM
SM
0
10
0
0
9
0
0
0
0
0
19
0
0 28.79
0

ITEM No.:- M675


TP
0
0
0
0
0

WS
0
0
0
0
0

SP
0
0
0
0
0

CP
0
0
0
0
0

50

OT
0
0
0
0
0

total
0
0
0
0
0

total checked pcs


25
21
20
66

165

DHU
15.15152
12.72727
12.12121
40

11-Jun-11

40
30
Total

20

DHU

10
0
PP BS RE RO UM SM TP WS SP CP OT

DATE
operations
13-Jun-11 Zipper Attach
Zipper Finish
Side attach
Total
DHU

PP

BS

RE

0
11
11
0
0
8
11
19
20.37 35.19
40
35
30
25
20

defects
RO
UM
SM
0
9
5
0
6
0
0
0
4
0
15
9
0 27.78 16.67

TP
0
0
0
0
0

WS
0
0
0
0
0

SP
0
0
0
0
0

CP
0
0
0
0
0

OT
0
0
0
0
0

13-Jun-11

Total

total
0
0
0
0
0

total checked pcs


25
17
12
54

245

DHU
10.20408
6.938776
4.897959
22.04082

25
20
15
10
5
0

Total
DHU

PP

DATE
operations
14-Jun-11 Zipper Attach
Zipper Finish
Side attach
Total
DHU

PP

BS

RE

8
9
0
0
5
6
13
15
22.807 26.32

BS

RE

RO UM SM

defects
RO
UM
SM
0
13
0
0
8
8
0
0
0
0
21
8
0 36.84 14.04

TP WS

SP

TP
0
0
0
0
0

CP

WS
0
0
0
0
0

OT

SP
0
0
0
0
0

0
0
0
0
0

40
35
30
25
20
15
10
5
0

PP

0
0
0
0
0

total
0
0
0
0
0

total checked pcs


30
16
11
57

255

DHU
11.76471
6.27451
4.313725
22.35294

Total

DHU

BS
0
8
0
8

OT

14-Jun-11

PP

DATE
operations
15-Jun-11 box pleat attach
sleeve attach
center sleeve attach
Total

CP

RE
0
8
0
8

BS

RE

RO UM SM

defects
RO
UM
SM
0
7
8
0
5
0
0
16
8
0
28
16

TP

WS

TP
0
0
0
0

SP

CP

WS
0
0
0
0

SP
0
0
0
0

CP
0
0
0
0

OT
0
0
0
0

total
0
0
0
0

total checked pcs


15
21
24
60

305

DHU
4.918033
6.885246
7.868852
19.67213

DHU

13.333 13.33

46.67 26.67

50

15-Jun-11

40
30
Total

20

DHU

10

0
PP

DATE
operations
16-Jun-11 box pleat attach
sleeve attach
center sleeve attach
Total
DHU

PP

BS

BS

RE

4
11
0
7
10
0
14
18
22.581 29.03

RE

RO UM SM

TP

defects
RO
UM
SM
0
0
0
0
9
16
0
5
0
0
14
16
0 22.58 25.81

WS

SP

TP
0
0
0
0
0

CP

OT

WS
0
0
0
0
0

SP
0
0
0
0
0

35

CP
0
0
0
0
0

OT
0
0
0
0
0

16-Jun-11

30
25
20
Total

15

DHU

10
5
0
PP

BS

RE

RO UM SM

TP

WS

SP

CP

OT

total
0
0
0
0
0

total checked pcs


15
32
15
62

395

DHU
3.797468
8.101266
3.797468
15.6962

0
PP

DATE
operations
17-Jun-11 box pleat attach
sleeve attach
center sleeve attach
Total
DHU

BS

RE

RO UM SM

TP

defects
RO
UM
SM
0
0
7
0
5
0
0
16
0
0
21
7
0 34.43 11.48

PP

BS
RE
4
0
5
12
12
0
21
12
34.426 19.67

WS

SP

TP
0
0
0
0
0

CP

OT

WS
0
0
0
0
0

SP
0
0
0
0
0

40
35
30
25
20
15
10
5
0

PP

20

total checked pcs


11
22
28
61

485

DHU
2.268041
4.536082
5.773196
12.57732

DHU

6
0
0
15
11
0
17
15
27.869 24.59

25

total
0
0
0
0
0

Total

BS

30

OT
0
0
0
0
0

17-Jun-11

PP

DATE
operations
18-Jun-11 box pleat attach
sleeve attach
center sleeve attach
Total
DHU

CP
0
0
0
0
0

RE

BS

RE

RO UM SM

defects
RO
UM
SM
0
6
0
0
6
7
0
0
10
0
12
17
0 19.67 27.87

TP

WS

SP

TP
0
0
0
0
0

CP

OT

WS
0
0
0
0
0

SP
0
0
0
0
0

CP
0
0
0
0
0

OT
0
0
0
0
0

18-Jun-11

total
0
0
0
0
0

total checked pcs


12
28
21
61

510

DHU
2.352941
5.490196
4.117647
11.96078

20
15

Total

10

DHU

5
0
PP

DATE
operations
20-Jun-11 box pleat attach
sleeve attach
center sleeve attach
Total
DHU

PP

BS

0
15
0
15
26.786

RE
6
0
8
14
25

BS

RE

RO UM SM

defects
RO
UM
SM
0
0
5
0
11
0
0
0
11
0
11
16
0 19.64 28.57

TP

WS

SP

TP

CP

OT

WS

0
0
0
0
0

0
0
0
0
0

SP
0
0
0
0
0

CP

OT

0
0
0
0
0

30

0
0
0
0
0

total
0
0
0
0
0

total checked pcs


11
26
19
56

415

DHU
2.650602
6.26506
4.578313
13.49398

20-Jun-11

25

20
15

Total

10

DHU

5
0
PP

DATE
operations
21-Jun-11 box pleat attach
sleeve attach
center sleeve attach

PP

BS
5
0
12

BS

RE
0
11
0

RE

RO UM SM

TP

defects
RO
UM
SM
0
0
5
0
13
0
0
0
9

WS

SP

CP

TP
0
0
0

OT

WS
0
0
0

SP
0
0
0

CP
0
0
0

OT
0
0
0

total
0
0
0

total checked pcs


10
24
21

460

DHU
2.173913
5.217391
4.565217

460
Total
DHU

17
30.909

11
20

0
0

13
14
23.64 25.45

0
0

0
0

0
0

0
0

35

0
0

0
0

55

11.95652

21-Jun-11

30
25
20

Total

15

DHU

10

5
0
PP

DATE
operations
22-Jun-11 box pleat attach
sleeve attach
center sleeve attach
Total
DHU

PP

BS

BS

RE

0
11
0
5
0
8
0
24
0 43.64

RE

RO UM SM

TP

defects
RO
UM
SM
0
10
0
0
9
5
0
0
7
0
19
12
0 34.55 21.82

WS

SP

TP
0
0
0
0
0

CP

OT

WS
0
0
0
0
0

SP
0
0
0
0
0

CP
0
0
0
0
0

50
45
40
35
30
25
20
15
10
5
0

OT
0
0
0
0
0

22-Jun-11

Total
DHU

PP

BS

RE

RO

UM

SM

TP

WS

SP

CP

OT

total
0
0
0
0
0

total checked pcs


21
19
15
55

490

DHU
4.285714
3.877551
3.061224
11.22449

PP

DATE
operations
23-Jun-11 box pleat attach
sleeve attach
center sleeve attach
Total
DHU

BS

PP

BS
RE
0
7
9
5
0
9
9
21
14.754 34.43

RE

RO

UM

SM

TP

defects
RO
UM
SM
0
0
15
0
9
0
0
7
0
0
16
15
0 26.23 24.59

WS

SP

TP
0
0
0
0
0

CP

OT

WS
0
0
0
0
0

SP
0
0
0
0
0

CP
0
0
0
0
0

40

OT
0
0
0
0
0

total
0
0
0
0
0

total checked pcs


22
23
16
61

475

DHU
4.631579
4.842105
3.368421
12.84211

23-Jun-11

35
30
25
20

Total

15

DHU

10
5
0
PP

DATE
operations
24-Jun-11 box pleat attach
sleeve attach
center sleeve attach
Total
DHU

PP

BS

0
0
8
0
0
10
8
10
12.698 15.87
45
40
35
30

BS

RE

RE

RO

UM SM

TP

defects
RO
UM
SM
0
8
6
0
17
0
0
0
14
0
25
20
0 39.68 31.75

WS

SP

TP
0
0
0
0
0

CP

OT

WS
0
0
0
0
0

SP
0
0
0
0
0

CP
0
0
0
0
0

OT
0
0
0
0
0

24-Jun-11

total
0
0
0
0
0

total checked pcs


14
25
24
63

450

DHU
3.111111
5.555556
5.333333
14

35
30
25
20
15
10
5
0

Total
DHU

PP

DATE
operations
25-Jun-11 box pleat attach
sleeve attach
center sleeve attach
Total
DHU

PP

BS

BS

RE

RO

UM SM

TP

defects
RO
UM
SM
0
0
9
0
7
0
0
12
13
0
19
22
0 31.67 36.67

RE

0
10
9
0
0
0
9
10
15 16.67

WS

SP

TP
0
0
0
0
0

CP

WS
0
0
0
0
0

OT

SP
0
0
0
0
0

CP
0
0
0
0
0

OT
0
0
0
0
0

40

25-Jun-11

35

30
25
20

Total

15

DHU

10
5
0

PP

DEFECT LIST

BS

RE

RO UM SM

TP

WS

SP

CP

OT

total
0
0
0
0
0

total checked pcs


19
16
25
60

510

DHU
3.72549
3.137255
4.901961
11.76471

PP
BS
RE
RO
UM
SM
TP
WS
SP
CP
OT

PUCKERING/PLEATING/ROPING
BROKEN/INSECURE/SKIP/UNTIDY JOINT
RAW EDGE
RUN OFF
UNBALANCED/UNMATCHED
SMOCKING PROBLEM
TRIM PROBLEM
WAVY STITCH
SPECS
CUTTING PROBLEM
OTHER

Line 1
ITEM No.:- M675

Endline checker
DATE
11-Jun-11

operations
inline Pleat
checker neck attach
neck finish
side o/l
sleeve fold
Bottom fold
Zipper Attach
Zipper Finish
sleeve tacking
Dori
label attach
Total
DHU

PP
0
0
0
7
0
3
0
0
0
0
0
10
33.333

BS

RE
0
0
0
0
0
0
0
0
6
0
0
6
20

defects
RO
UM
0
0
0
0
0
0
0
0
0
0
0
0
0

0
0
0
0
7
0
0
0
7
0
0
14
46.67

SM
0
0
0
0
0
0
0
0
0
0
0
0
0

TP
0
0
0
0
0
0
0
0
0
0
0
0
0

WS
0
0
0
0
0
0
0
0
0
0
0
0
0

SP

CP

0
0
0
0
0
0
0
0
0
0
0
0
0

0
0
0
0
0
0
0
0
0
0
0
0
0

OT
0
0
0
0
0
0
0
0
0
0
0
0
0

total
0
0
0
0
0
0
0
0
0
0
0
0
0

total checked pcs


0
0
0
7
7
3
0
0
13
0
0
30

50

11-Jun-11

45
40
35
30
25

Total

20

DHU

15
10
5
0
PP

endline checker

BS

RE

RO

UM

SM

TP

WS

SP

CP

OT

180

DHU
0
0
0
3.888889
3.888889
1.666667
0
0
7.222222
0
0
16.66667

DATE
13-Jun-11

operations
inline Pleat
checker neck attach
neck finish
side o/l
sleeve fold
Bottom fold
Zipper Attach
Zipper Finish
sleeve tacking
Dori
label attach
Total
DHU

PP

BS
0
0
0
0
0
0
0
0
0
0
0
0
0
6
0
0
0
0
0
0
0
0
0
6
0 11.538

defects
RE
RO
UM
SM
0
0
0
5
0
3
0
0
0
0
0
2
0
0
0
16
0
0
1
0
0
0
0
0
0
0
0
0
0
3
0
0
0
22
0
8
42.308
0 15.38

TP
0
0
0
0
0
0
0
0
0
0
0
0
0

WS
0
0
0
0
0
0
0
0
0
0
0
0
0

SP

0
14
0
0
0
0
2
0
0
0
0
16
30.77

CP
0
0
0
0
0
0
0
0
0
0
0
0
0

OT
0
0
0
0
0
0
0
0
0
0
0
0
0

45

total
0
0
0
0
0
0
0
0
0
0
0
0
0

total checked pcs


0
22
0
2
0
16
9
0
0
3
0
52

302

DHU
0
7.284768
0
0.662252
0
5.298013
2.980132
0
0
0.993377
0
17.21854

13-Jun-11

40
35
30
25

Total

20

DHU

15
10
5
0
PP

BS

RE

RO

UM

SM

TP

WS

SP

CP

OT

endline checker
DATE
14-Jun-11

operations
inline Pleat
checker

PP

BS
0

RE
0

defects
RO
UM
SM
0
0
0

TP
0

WS
0

SP
0

CP
0

OT
0

total
0

total checked pcs


0

DHU
0

286

inline
checker neck attach
neck finish
side o/l
sleeve fold
Bottom fold
Zipper Attach
Zipper Finish
sleeve tacking
Dori
label attach
Total
DHU

0
0
0
0
0
0
0
0
0
0
0
0
0
0
3
0
0
0
0
0
0
0
0
0
0
0
0
0
12
0
0
12
3
0 26.087 6.5217

0
26
0
0
0
0
0
0
2
0
0
0
0
0
0
0
0
0
0
0
2
26
4.348 56.52

0
0
0
0
0
0
0
0
0
0
0
0

0
0
0
0
0
0
0
0
0
0
0
0

0
0
0
0
3
0
0
0
0
0
3
6.522

0
0
0
0
0
0
0
0
0
0
0
0

0
0
0
0
0
0
0
0
0
0
0
0

0
0
0
0
0
0
0
0
0
0
0
0

60

26
0
0
0
8
0
0
0
0
12
46

286

9.090909
0
0
0
2.797203
0
0
0
0
4.195804
16.08392

14-Jun-11

50
40
30

Total
DHU

20
10
0
PP

inline operations
DATE
15-Jun-11 checker Pleat
neck attach
neck finish
side o/l
sleeve fold
Bottom fold

PP

BS
0
8
0
0
0
0

RE
0
0
0
0
0
0

BS

RE

RO

UM

defects
RO
UM
SM
0
0
0
0
0
0
0
6
0
0
0
3
0
0
0
0
0
0

SM

TP

TP
0
0
0
0
0
0

WS

WS
0
0
0
0
0
0

SP

CP

SP
0
0
0
0
0
6

OT

CP
0
0
4
0
0
0

OT
0
0
0
0
0
0

total
0
0
0
0
0
0

total checked pcs


0
8
10
3
0
6

350

DHU
0
2.285714
2.857143
0.857143
0
1.714286

350
Zipper Attach
Zipper Finish
sleeve tacking
Dori
label attach
Total
DHU

0
0
0
0
0
8
16

0
0
0
0
0
0
0

5
0
0
0
0
5
10

0
0
0
0
0
6
12

0
0
0
0
0
3
6

0
0
0
0
0
0
0

0
0
0
0
0
0
0

0
0
0
0
18
24
48

0
0
0
0
0
4
8

0
0
0
0
0
0
0

0
0
0
0
0
0
0

5
0
0
0
18
50

1.428571
0
0
0
5.142857
14.28571

60

15-Jun-11
50
40
30

Total
DHU

20
10
0
PP

DATE
16-Jun-11

operations
inline Pleat
checker neck attach
neck finish
side o/l
sleeve fold
Bottom fold
Zipper Attach
Zipper Finish
sleeve tacking
Dori
label attach

PP

BS
0
0
4
0
0
0
0
0
0
0
0

RE
0
0
0
3
0
0
0
0
0
0
6

BS

RE

RO

UM

defects
RO
UM
SM
0
0
0
0
0
12
0
0
0
0
0
0
0
0
0
5
0
0
6
0
3
0
1
0
0
0
0
0
0
0
0
0
0

SM

TP

TP
0
0
0
0
0
0
0
0
0
0
0

WS

WS
0
0
0
0
0
0
0
0
0
0
0

SP

SP
0
0
3
0
0
0
2
0
0
0
0

CP

OT

CP
0
0
3
0
0
0
0
0
0
0
0

OT
0
0
0
0
0
0
0
0
0
0
0

total
0
0
0
0
0
0
0
0
0
0
0

total checked pcs


0
12
10
3
0
5
11
1
0
0
6

448

DHU
0
2.678571
2.232143
0.669643
0
1.116071
2.455357
0.223214
0
0
1.339286

Total
DHU

4
8.3333

9
11
18.75 22.917

1
15
2.083 31.25

0
0

0
0

5
10.42

3
6.25

0
0

0
0

48

10.71429

35

16-Jun-11
30
25
20
Total
15

DHU

10
5
0
PP

DATE
17-Jun-11

operations
inline Pleat
checker neck attach
neck finish
side o/l
sleeve fold
Bottom fold
Zipper Attach
Zipper Finish
sleeve tacking
Dori
label attach
Total
DHU

PP

BS
0
0
6
0
0
0
8
0
0
0
0
2
0
0
0
0
0
0
0
3
0
0
14
5
20 7.1429
40

BS

RE

RO

UM

defects
RO
UM
SM
0
0
0
0
0
0
0
0
5
0
0
0
0
0
0
12
0
0
12
2
0
0
3
0
0
0
0
0
0
0
0
0
0
24
5
5
34.286 7.143 7.143

SM

RE

TP

WS

TP
0
0
0
0
0
0
0
0
0
0
0
0
0

SP

WS
0
0
0
0
0
0
0
0
0
0
0
0
0

0
0
3
0
0
0
7
0
0
2
0
12
17.14

CP

SP

OT

CP
0
0
0
0
0
0
0
0
0
0
0
0
0

OT

total

0
0
0
0
0
0
0
0
0
5
0
0
0
0
0
0
0
0
0
0
0
0
0
5
0 7.1429

17-Jun-11

total checked pcs


0
6
8
8
5
14
21
3
0
5
0
70

570

DHU
0
1.052632
1.403509
1.403509
0.877193
2.45614
3.684211
0.526316
0
0.877193
0
12.2807

40

17-Jun-11

35
30
25
20

Total

15

DHU

10
5
0
PP

DATE
18-Jun-11

operations
inline Pleat
checker neck attach
neck finish
side o/l
sleeve fold
Bottom fold
Zipper Attach
Zipper Finish
sleeve tacking
Dori
label attach
Total
DHU

PP

BS

BS
0
0
0
0
0
0
0
0
0
0
0
0
0

0
0
0
0
0
0
0
0
0
0
0
0
0

RE

RO

UM

SM

defects
RE
RO
UM
SM
0
0
0
0
0
4
0
0
4
0
0
0
0
0
0
0
6
0
0
2
0
0
11
0
0
0
0
5
0
0
0
0
0
5
19
8
8.3333 31.67 13.33

TP

WS

TP
0
0
0
0
0
0
0
0
0
0
0
0
0

SP

CP

OT

WS
0
0
0
0
0
0
0
0
0
0
0
0
0

SP
CP
0
0
0
0
0
2
0
0
0
0
0
0
10
0
4
0
0
0
0
0
0
0
14
2
23.33 3.3333

OT
0
0
0
0
0
0
0
0
0
0
0
0
0

total
0
0
0
0
0
0
0
0
0
0
12
12
20

35

18-Jun-11
30
25

total checked pcs


0
4
6
0
0
6
12
15
0
5
12
60

560

DHU
0
0.714286
1.071429
0
0
1.071429
2.142857
2.678571
0
0.892857
2.142857
10.71429

25
20
Total
15

DHU

10
5
0
PP

DATE
20-Jun-11

operations
inline Pleat
checker neck attach
neck finish
side o/l
sleeve fold
Bottom fold
Zipper Attach
Zipper Finish
sleeve tacking
Dori
label attach
Total
DHU

PP

BS

BS

0
0
3
0
7
0
0
4
0
0
0
14
23.333

0
0
0
0
0
0
4
5
0
3
0
12
20

RE

RO

UM

SM

defects
RE
RO
UM
SM
0
0
0
0
0
5
0
0
0
0
0
10
0
0
0
4
0
0
0
0
10
0
0
0
0
0
0
0
0
0
0
0
0
4
0
25
6.6667
0 41.67

TP

WS

TP
0
0
0
0
0
0
0
0
0
0
0
0
0

SP

WS
0
0
0
0
0
0
0
0
0
0
0
0
0

0
0
0
0
0
0
0
3
0
2
0
5
8.333

CP

OT

SP

CP
0
0
0
0
0
0
0
0
0
0
0
0
0

OT

total

0
0
0
0
0
0
0
0
0
0
0
0
0

0
0
0
0
0
0
0
0
0
0
0
0
0

45
40

20-Jun-11

35
30
25
20

Total

total checked pcs


0
5
3
10
7
4
14
12
0
5
0
60

560

DHU
0
0.892857
0.535714
1.785714
1.25
0.714286
2.5
2.142857
0
0.892857
0
10.71429

25
Total

20

DHU

15
10
5
0
PP

DATE
21-Jun-11

operations
inline Pleat
checker neck attach
neck finish
side o/l
sleeve fold
Bottom fold
Zipper Attach
Zipper Finish
sleeve tacking
Dori
label attach
Total
DHU

PP

BS

0
5
0
2
0
0
0
0
0
0
0
7
12.727

RE

RO

UM

SM

defects
RO
UM
SM
0
0
0
0
0
5
0
5
0
0
0
0
0
0
0
9
0
0
0
0
0
3
0
0
0
0
0
0
5
0
0
0
0
12
10
5
21.818 18.18 9.091

TP

RE
0
0
11
0
0
0
0
0
0
0
0
11
20

25

BS

WS

TP
0
0
0
0
0
0
0
0
0
0
0
0
0

SP

WS
0
0
0
0
0
0
0
0
0
0
0
0
0

0
0
0
0
0
0
4
0
0
0
0
4
7.273

CP

OT

SP

CP
0
0
0
0
0
0
0
0
0
0
0
0
0

OT

total

0
0
0
0
0
0
0
0
0
6
0
0
0
0
0
0
0
0
0
0
0
0
0
6
0 10.909

0
10
16
2
6
9
4
3
0
5
0
55

21-Jun-11

20
15
Total
10
5

total checked pcs

DHU

555

DHU
0
1.801802
2.882883
0.36036
1.081081
1.621622
0.720721
0.540541
0
0.900901
0
9.90991

0
PP

DATE
22-Jun-11

operations
inline Pleat
checker neck attach
neck finish
side o/l
sleeve fold
Bottom fold
Zipper Attach
Zipper Finish
sleeve tacking
Dori
label attach
Total
DHU

PP

BS
0
2
0
3
0
0
0
0
0
0
0
5
9.434

BS

RE
0
0
0
0
0
0
0
0
0
0
0
0
0

RE

RO

UM

SM

defects
RO
UM
SM
0
0
0
0
0
0
0
3
0
0
0
3
0
0
0
0
0
0
0
0
4
0
0
0
0
0
0
0
0
0
0
0
0
0
3
7
0
5.66 13.21

TP

TP
0
0
0
0
0
0
0
0
0
0
0
0
0

WS

SP

WS
0
0
0
0
0
0
0
0
0
0
3
3
5.66

CP

SP

OT

CP

0
5
3
0
0
0
8
7
0
4
0
27
50.94

0
0
0
0
0
0
0
0
0
0
0
0
0

OT

total

0
0
0
0
0
0
0
0
0
0
0
2
0
0
0
0
0
0
0
0
0
6
0
8
0 15.094

60

22-Jun-11
50
40
30

Total
DHU

20
10
0
PP

BS

RE

RO

UM

SM

TP

WS

SP

CP

OT

total checked pcs


0
7
6
6
0
2
12
7
0
4
9
53

553

DHU
0
1.265823
1.084991
1.084991
0
0.361664
2.169982
1.265823
0
0.723327
1.627486
9.584087

DATE
23-Jun-11

operations
inline Pleat
checker neck attach
neck finish
side o/l
sleeve fold
Bottom fold
Zipper Attach
Zipper Finish
sleeve tacking
Dori
label attach
Total
DHU

PP

BS

0
0
2
4
0
0
0
0
0
0
0
6
11.538

0
0
0
0
0
0
0
0
0
0
0
0
0

defects
RE
RO
UM
SM
0
0
0
0
0
5
0
4
0
0
0
10
0
0
0
2
0
0
0
0
0
2
0
0
0
0
0
0
10
0
0
0
0
4
14
15
7.6923 26.92 28.85

TP
0
0
0
0
0
0
0
0
0
0
0
0
0

0
0
0
0
0
0
0
0
0
0
5
5
9.615

WS

SP

CP

0
0
0
0
6
0
2
0
0
0
0
8
15.38

0
0
0
0
0
0
0
0
0
0
0
0
0

35

OT
0
0
0
0
0
0
0
0
0
0
0
0
0

total
0
0
0
0
0
0
0
0
0
0
0
0
0

23-Jun-11

30
25
20
Total

15

DHU

10
5
0
PP

BS

RE

RO

UM

SM

DEFECT LIST
PP
BS
RE
RO
UM

PUCKERING/PLEATING/ROPING
BROKEN/INSECURE/SKIP/UNTIDY JOINT
RAW EDGE
RUN OFF
UNBALANCED/UNMATCHED

TP

WS

SP

CP

OT

total checked pcs


0
5
6
14
6
2
2
2
0
10
5
52

552

DHU
0
0.905797
1.086957
2.536232
1.086957
0.362319
0.362319
0.362319
0
1.811594
0.905797
9.42029

SM
TP
WS
SP
CP
OT

SMOCKING PROBLEM
TRIM PROBLEM
WAVY STITCH
SPECS
CUTTING PROBLEM
OTHER

11-Jun-11
13-Jun-11
14-Jun-11
15-Jun-11
16-Jun-11
17-Jun-11
18-Jun-11
20-Jun-11
21-Jun-11
22-Jun-11
23-Jun-11
Total

PuckeringBroken
Problem+D390
Stitch
Raw EdgeRun Off Unbalanced/
Smocking
Unmatched
Trim
Problem
Problem
Wavy Stitch
Specs
10
6
0
14
0
0
0
0
0
6
22
0
8
0
0
16
0
12
3
2
26
0
0
3
8
0
5
6
3
0
0
24
4
9
11
1
15
0
0
5
14
5
24
5
5
0
0
12
0
0
5
19
8
0
0
14
14
12
4
0
25
0
0
5
7
11
12
10
5
0
0
4
5
0
0
3
7
0
3
27
6
0
4
14
15
0
5
8
68
61
90
74
102
0
8
118
100%
90%
80%
70%
60%
50%

0
0
0
4
3
0
2
0
0
0
0
9

Cutting Problem
Others
0
0
0
0
0
0
0
0
0
0
0
5
0
0
0
0
0
6
0
8
0
0
0
19

Others
Cutting Problem
Specs
Wavy Stitch
Trim Problem

40%

Smocking Problem

30%
20%

Unbalanced/Unmatche
d
Run Off

10%

Raw Edge

0%

Broken Stitch

0
Others

Cutting

Specs

Wavy Stitch

Trim

Smocking

Unbalance

Run Off

Raw Edge

Broken

Puckering

150

100
50

Run Off

23/Jun/11

22/Jun/11

21/Jun/11

20/Jun/11

18/Jun/11

17/Jun/11

16/Jun/11

15/Jun/11

14/Jun/11

13/Jun/11

11/Jun/11

0%

defects
Puckering
Problem+D390

Broken Stitch

Raw Edge

Broken Stitch

Puckering Problem

Line 1
Sl. No.

ITEM No.:- M675


CRITICAL OPERATIONS

front pintuk making

Collar finish

Zipper attachment

Zipper finish

Hemming

DEFECTS
Pinch
Unstitched
Insecure stitch
Inside ply visible
uneven curve
Misstitch
Uneven width
Pinch
Improper allignment
Loose stitch
Loose stitch
Raw edge
Unfinished
Wavy hem
Raw edge

MAN
Y
Y
Y
y
y
y
y
y
y
y
y
y
y
y

CAUSES
MACHINE

MATERIAL
Y

METHOD

Y
Y
y
y
Y
y
y
Y
y
y

Line 1

ITEM No.:- M675


Alter checked Pcs
Date

Sl No.
1
2
3
4
5
6
7

Operation
In line checker 1 (pleat,
neck attach)
In line checker 2 (neck
finish)
Side o/l
Sleeve Hem
Bottom Hem
Sleeve fold taki
Dori

11-Jun-11 Type

7
7
3
13

PP
RO
PP
6BS+7RO

13-Jun-11 Type
5RO+14WS+
22 3UM

14-Jun-11
26

2 UM
16 RE

3 UM
6BS+1RE+2
9 WS

8 Zipper attach
9

Zipper finish
10 Label attach
TOTAL ALTER
TOTAL CHECHED
DHU %

30
180
16.66666667

52
302
17.21854

Total extra time

Total extra time for the style


Extra cost incurred

12
46
286
16.0839161

ITEM No.:- M675

Type
UM

15-Jun-11 Type
8 PP
10 4SP+6RO
3 UM

3RE+2RO+3WS

6 WS

5 RE

BS

18 WS
50
350
14.28571

16-Jun-11 Type
12 UM
3WS+4PP
10 +3SP
3 BS
5 RE

3UM+2WS
11 +6RE
1 RO
6 BS
48
448
10.71429

17-Jun-11 Type
6 PP

18-Jun-11
4

3WS+5UM
PP
OT
12RE+2BS

5 2WS+3BS
12RE+7WS
21 +2RO

8
8
5
14

3 RO
70
570
12.2807

12
15
12
60
560
10.71429

Type
UM
4UM+2SP

RO
RE
10WS+2RO
11RO+4WS
OT

20-Jun-11 Type
5 UM
3
10
7
4

PP
UM
PP
RE

5 BS
14 10UM+4BS
3WS+4PP+
12 5BS
60
560
10.71429

21-Jun-11 Type

22-Jun-11 Type

10 5UM+5PP

7 2PP+5WS

16
2
6
9

6 3RO+3WS
6 3UM+3PP

5RO+11BS
PP
OT
RE

5 RO
4 WS
3 RO
55
555
9.90991

23-Jun-11 Type
5 UM

2 OT

6
14
6
2

4 WS

10 RO

12 8WS+2UM
7 WS
9 TP
53
553
9.584087

4RO+2PP
10UM+4PP
WS
RE

2 WS
2 RE
5 TP
52
552
9.42029

Line 1

ITEM No.:- M67

actual SAM
(in min.)
SL. No.
1
2
3
4
5
6
7
8
9
10
11

operations
pintuck making
neck attach
neck finish
side o/l
sleeve Hem
Bottom Hem
Zipper Attach
Zipper Finish
sleeve tacking
loop
label attach

1.28
1.35
0.4
0.8
1.2
0.8
1.36
1.2
0.4
0.65
0.52

observed SAM
(in min.)
1.14
2.2
0.45
1.16
1.77
1.1
2.6
1.19
0.84
0.5
0.34

time for rework


(in min.)
0.8
1.4
0.5
0.4
0.98
0.96
4.82
2.54
0.78
0.5
0.6

ITEM No.:- M675

Checking time
(per gmt in min.)
0.95
0.95
0.95
0.95
0.95
0.95
0.95
0.95
0.95
0.95
0.95

Total
(in min.)
2.89
4.55
1.9
2.51
3.7
3.01
8.37
4.68
2.57
1.95
1.89

Checking after rework


(in min.)
0.72
0.72
0.72
0.72
0.72
0.72
0.72
0.72
0.72
0.72
0.72

Total
(in min.)
3.61
5.27
2.62
3.23
4.42
3.73
9.09
5.4
3.29
2.67
2.61

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