Factory Monthly KPI

1. 1-0

2. Palmal Group of Industries
ARKAY-2(Unit-1) Monthly Knowledge Sharing
Meeting-KSM
Organized by:
Central-IE
Manufacturing Audit & Central Costing
1-1

3. Objectives of the Meeting:
1-2
To review factory last five month performance
To understand our present position against
management expectation
To know about the scope of improvement
To set next month performance target

4. Key Discussion points:
1-3
1. Planning, Production & IE KPI:
Monthly Target Vs. achievement status
Monthly Efficiency %
Monthly PCD Hit rate status
Monthly NPT Analysis
Monthly Revenue status
Monthly Profit/Loss status
Monthly Machine utilization %
Monthly Short/excess shipment status
3. Quality Assurance Department KPI:
 Monthly Final inspection pass status
 Monthly OQL% status
Monthly DHU% status
Monthly Top 5 Defects analysis
2. Human Resource Department KPI:
 Monthly worker absenteeism status
4. Set next month performance target

5. 1. Planning, Production & IE KPI:
1-4

6. Month wise target Vs. Achievement status:
1-5

7. Month wise efficiency %:
1-6

8. Month wise profit/Loss status (Excluding Abnormal Loss) :
1-7

9. Month wise per Machine Plan Vs. Achieve Revenue status:
1-8

10. Month wise Plan Vs. Achievement status:
1-9

11. Month wise and SMV wise Product
Category Analysis:
1-10

12. SMV wise Product Category Analysis (Jan-22):
1-11
SMV Type Style Type Style Qty
Produced
Minute
Produced Qty
Avg qty %
out of total
Produce Qty
<4.5 Very Basic 6 455323 105415 21.7%
4.51-7.5 Basic 17 1719011 272000 55.9%
7.51-10.5 Semi Critical 11 851932 100255 20.6%
10.51-15
Heavy Semi
Critical
3 109036 8260 1.7%
15.1-20 Critical 1 7518 310 0.1%
20.1- >=28
Heavy
Critical
0 0 0 0.0%
6.46 Basic 38 3142819 486240 100.0%

13. SMV wise Product Category Analysis (Feb-22):
1-12
SMV Type Style Type Style Qty
Produced
Minute
Produced Qty
Avg qty %
out of total
Produce Qty
<4.5 Very Basic 4 457068 106520 28.4%
4.51-7.5 Basic 13 859524 147390 39.4%
7.51-10.5 Semi Critical 5 663151 76055 20.3%
10.51-15
Heavy Semi
Critical
3 348766 31085 8.3%
15.1-20 Critical 1 325678 13430 3.6%
20.1- >=28
Heavy
Critical
0 0 0 0.0%
7.09 Basic 26 2654187 374480 100.0%

14. SMV wise Product category Analysis (March-22):
1-13
SMV Type Style Type Style Qty
Produced
Minute
Produced Qty
Avg qty %
out of total
Produce Qty
<4.5 Very Basic 5 304940 69299 16.0%
4.51-7.5 Basic 19 1643382 273466 63.2%
7.51-10.5 Semi Critical 10 272764 28850 6.7%
10.51-15
Heavy Semi
Critical
4 677772 60780 14.0%
15.1-20 Critical 1 9846 406 0.1%
20.1- >=28
Heavy
Critical
0 0 0 0.0%
6.72 Basic 39 2908704 432801 100.0%

15. SMV wise Product Category Analysis (April-2022):
1-14
SMV Type Style Type Style Qty
Produced
Minute
Produced Qty
Avg qty %
out of total
Produce Qty
<4.5 Very Basic 0 0 0 0.0%
4.51-7.5 Basic 17 1352646 235950 71.4%
7.51-10.5 Semi Critical 5 104933 11245 3.4%
10.51-15
Heavy Semi
Critical
7 1012784 80776 24.4%
15.1-20 Critical 1 49576 2485 0.8%
20.1- >=28
Heavy
Critical
0 0 0 0.0%
7.63 Basic 30 2519938 330456 100.0%

16. SMV wise Product Category Analysis (May-2022):
1-15
SMV Type Style Type Style Qty
Produced
Minute
Produced Qty
Avg qty %
out of total
Produce Qty
<4.5 Very Basic 0 0 0 0.0%
4.51-7.5 Basic 18 1458599 252469 74.6%
7.51-10.5 Semi Critical 7 642292 70239 20.8%
10.51-15
Heavy Semi
Critical
4 174126 15730 4.6%
15.1-20 Critical 1 0 0 0.0%
20.1- >=28
Heavy
Critical
0 0 0 0.0%
6.72 Basic 30 2275017 338438 100.0%

17. Month wise Machine utilization % :
1-16

18. Month wise facts analysis :
1-17
SMV 1st
day 2nd
day 3rd
day 4th
day 5th
day 6th
day 7th
day 8th
day 9th
day 10th
day
<4.5 45% 60% 70% 75% 85% 85% 85% 85% 85% 85%
4.51-7.5 40% 55% 65% 70% 75% 75% 75% 75% 75% 80%
7.51-10.5 35% 45% 55% 60% 65% 65% 65% 70% 70% 70%
10.51-15 35% 45% 50% 55% 60% 60% 60% 65% 65% 65%
15.1-20 25% 35% 45% 50% 55% 55% 55% 55% 55% 60%
20.1-28 25% 35% 40% 45% 50% 50% 50% 55% 55% 55%
>=28.1 10% 20% 30% 35% 40% 45% 45% 45% 45% 50%
Efficiency Requirement
Month Factory
Noof
Working
days
No.Style
Running
No.
Styling
No.of
Avg.Line
Run
days/Styl
ing/Line
Expected
Efficiency
Achieved
Efficiency
%
January-22 ARKAY-2(U-1) 27 38 16 11 19days 68% 64.3%
February-22ARKAY-2(U-1) 23 26 13 13 24days 66% 63.5%
March-22 ARKAY-2(U-1) 25 39 16 15 24days 69% 63.0%
April-22 ARKAY-2(U-1) 24 30 13 17 31days 66% 56.7%
May-22 ARKAY-2(U-1) 21 46 15 16 22days 68% 58.9%
G.Total
ARKAY-2(U-
1) TOTAL
24 179 73 73 24days 67.4% 61.3%

19. PCD HIT RATE:
1-18

20. Month wise NPT status :
1-19
Non
Productive
Minute
NPT Value
NPT Value in
Tk.
NPT% NPT (Pcs)
NPT (Man-
Hour)
NPT
MC/Day
Total Earning
(Including NPT
Value)
Revenue/MC
(Without NPT)
28925 Min. 2,024.75
$ 168,054৳ 0.59% 4475 Pcs 482 1.8 MC 294,892.84
$ BDT 98298
0 Min. -
$ -৳ 0.00% 0 Pcs 0 0.0 MC 242,399.71
$ BDT 97490
0 Min. -
$ -৳ 0.00% 0 Pcs 0 0.0 MC 269,216.48
$ BDT 102917
0 Min. -
$ -৳ 0.00% 0 Pcs 0 0.0 MC 247,239.38
$ BDT 96559
0 Min. -
$ -৳ 0.00% 0 Pcs 0 0.0 MC 223,172.29
$ BDT 98899
28925 Min. 2,024.75
$ 168,054.3৳ 0.13% 4475 Pcs 482 0.4 MC 1,276,920.70
$ BDT 98838

21. Month wise On Time Delivery status:
1-20

22. Month wise short/excess shipment status :
1-21

23. 2. Human Resource Department KPI:
1-22

24. Month wise worker absenteeism status :
1-23

25. Factors influencing on efficiency %:
1-24
1. Style Analysis : Allocating the styles in such a way that
maximum line days can be achieved.
2. PCD hit Rate : Ensure PCD to ensure right style line feeding at
right time.
3. Set a standard Target : Target has to be as per feasibility
learning curve to get expected efficiency.
4. Production Monitoring : Ensure process wise production which
leads to target achievement of full line.
5. Line Balancing : Set right person at right place to get maximum
utilization of manpower and get output.
6. Operators Skill Matrix : Identify the right person as per process
& requirement.
7. Operators Availability : Reduction of absenteeism to ensure
operators availability as per requirement.

26. 3. Quality Assurance Department KPI:
1-25

27. 1-26
Month wise Final inspection status:

28. 1-27
Month wise Final inspection OQL status :

29. 1-28
Month wise Sewing DHU status :

30. 1-29
TOP 5 DEFECTS OF LAST 5 MONTHS
SL NO Month
UNCUT
THREAD
BROKEN
STITCH
PLEAT
SKIPPED
STITCH
UP &
DOUN
OPEN
SEAM
1 Jan-22 33% 10% 9% 8% 8%
2 Feb-22 29% 10% 9% 9% 9%
3 Mar-22 28% 11% 9% 10% 9%
4 Apr-22 35% 8% 9% 10% 9%
5 May-22 30% 9% 8% 11% 9%
31% 10% 9% 9% 9% 9%
Month wise Top 5 Defects of Arkay-2(Unit-1)
Average %

31. 1-30
Root cause & Action plan of Uncut thread

32. 1-31
Root cause & Action plan of Broken stitch

33. 1-32
Root cause & Action plan of Skip stitch

34. Thank You