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Case Study - I

Apparel Manufacturing
 Large size manufacturer and Exporter of
               Garments
Client’s Brief
• Manager:
  o “Unceasing need to increase production volumes without increasing
    capacity. I need to   constantly measure process
    lead times and monitor productivity. Through this I can focus
    efforts to cut lag where it is most”
Data Sample
Name Date       Time      Process Number Process                    Status    Lot No       Qty        Style        Colour       Remarks
Rajesh 3-19-2012 11:10:16               100 Laying                  Started            1          420 Crigan 3WH            251 Pant material
Rajesh 3-19-2012 16:45:42               100 Laying                  Started            1          438 Crigan 3WH            251 Pant material
Rajesh 3-19-2012 16:45:42               100 Laying                  Completed          1         1904 Crigan 3WH            251 Piping
Rajesh 3-20-2012 9:10:19                100 Laying                  Completed          1          438 Crigan 3WH            251 Pant material
Rajesh 3-20-2012 10:25:12               100 Laying                  Completed          1         1904 Crigan 3WH            251 WB Piping
Rajesh 3-19-2012 13:10:30               110 Sticking & Inspection   Started            1          420 Crigan 3WH            251 Pant material
Rajesh 3-19-2012 14:41:30               110 Sticking & Inspection   Started            1         1904 Crigan 3WH            251 Fusing
Rajesh 3-19-2012 17:03:14               110 Sticking & Inspection   Completed          1         1904 Crigan 3WH            251 Piping
Rajesh 3-20-2012 10:27:05               110 Sticking & Inspection   Completed          1          438 Crigan 3WH            251 Pant material
Rajesh 3-19-2012 14:06:48               120 Cutting                 Started            1          420 Crigan 3WH            251 Pant material
Rajesh 3-20-2012 10:06:21               120 Cutting                 Completed          1         1904 Crigan 3WH            251 Piping
Rajesh 3-20-2012 12:08:58               120 Cutting                 Completed          1          438 Crigan 3WH            251 Pant material
Rajesh 3-19-2012 14:47:17               130 Numbering               Started            1          420 Crigan 3WH            251 Pant material
Rajesh 3-19-2012 16:53:18               130 Numbering               Started            1         1904 Crigan 3WH            251 Pocketing
Rajesh 3-20-2012 13:57:43               130 Numbering               Completed          1          438 Crigan 3WH            251 Pant material
Production Summary
Lead Time
Queue Delay
Stitch Time
                                                                                                                                            Cummulative
Date          Hour       Qty produced        Hourly Performance compared to standard                                        % Performance Qty Produced     Productivity
       21-Mar 1 PM                      35                                      |||||||||||                                         -22.22%             35             3.14
              2 PM                      40                                            ||||||                                        -11.11%             75             6.23
              3 PM                      25                           ||||||||||||||||||||||                                         -44.44%           100              7.87
              5 PM                      55                                                   |||||||||||                             22.22%           155              9.93
       22-Mar 9 AM                      53                                                   |||||||||                               17.78%           208             12.76
              10 AM                     20                     ||||||||||||||||||||||||||||                                         -55.56%           228             14.52
              11 AM                     40                                            ||||||                                        -11.11%           268             15.14
              12 PM                     19                    |||||||||||||||||||||||||||||                                         -57.78%           287             16.23
              1 PM                      51                                                   |||||||                                 13.33%           338             17.03
              2 PM                      12            |||||||||||||||||||||||||||||||||||||                                         -73.33%           350             18.01
              3 PM                      61                                                   ||||||||||||||||||                      35.56%           411             19.21
              4 PM                      25                           ||||||||||||||||||||||                                         -44.44%           436             19.66
              5 PM                      53                                                   |||||||||                               17.78%           489             21.48
       23-Mar 9 AM                      15               |||||||||||||||||||||||||||||||||                                          -66.67%           504             22.22
              10 AM                     49                                                   ||||                                     8.89%           553             23.33
              11 AM                     15               |||||||||||||||||||||||||||||||||                                          -66.67%           568             23.25
              12 PM                     14              ||||||||||||||||||||||||||||||||||                                          -68.89%           582             23.11
              1 PM                      26                            |||||||||||||||||||||                                         -42.22%           608             22.69
              2 PM                      70                                                   ||||||||||||||||||||||||||||            55.56%           678             23.57
              3 PM                      52                                                   ||||||||                                15.56%           730             24.84
              4 PM                      60                                                   |||||||||||||||||                       33.33%           790             26.11
              5 PM                      60                                                   |||||||||||||||||                       33.33%           850             27.38

           Required Stitch Time                                               45 Qty/hr
       Achieved Average Stitch Time                                        38.64 Qty/hr
All results achieved…
                   Using mobile
 Without any                          Collecting data
                 phone & capturing
  software                             directly from
                   data through
 deployment                               source
                       voice




                                      User training in
  No complex     Roll-out in just 3
                                       less than 10
implementation         days
                                         minutes
Call us
         You will be happy you did !!!
              +91-9962908222
     For further details pl. visit www.valgenmobility.com
                Mail us at vijay@valgeninc.com

                      Valgen Group Companies

www.valgen.in           www.valgeninc.com      www.valgenconsulting.com

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Valgen Case Study - Midsized Apparel Manufacturer

  • 1. Case Study - I Apparel Manufacturing Large size manufacturer and Exporter of Garments
  • 2. Client’s Brief • Manager: o “Unceasing need to increase production volumes without increasing capacity. I need to constantly measure process lead times and monitor productivity. Through this I can focus efforts to cut lag where it is most”
  • 3. Data Sample Name Date Time Process Number Process Status Lot No Qty Style Colour Remarks Rajesh 3-19-2012 11:10:16 100 Laying Started 1 420 Crigan 3WH 251 Pant material Rajesh 3-19-2012 16:45:42 100 Laying Started 1 438 Crigan 3WH 251 Pant material Rajesh 3-19-2012 16:45:42 100 Laying Completed 1 1904 Crigan 3WH 251 Piping Rajesh 3-20-2012 9:10:19 100 Laying Completed 1 438 Crigan 3WH 251 Pant material Rajesh 3-20-2012 10:25:12 100 Laying Completed 1 1904 Crigan 3WH 251 WB Piping Rajesh 3-19-2012 13:10:30 110 Sticking & Inspection Started 1 420 Crigan 3WH 251 Pant material Rajesh 3-19-2012 14:41:30 110 Sticking & Inspection Started 1 1904 Crigan 3WH 251 Fusing Rajesh 3-19-2012 17:03:14 110 Sticking & Inspection Completed 1 1904 Crigan 3WH 251 Piping Rajesh 3-20-2012 10:27:05 110 Sticking & Inspection Completed 1 438 Crigan 3WH 251 Pant material Rajesh 3-19-2012 14:06:48 120 Cutting Started 1 420 Crigan 3WH 251 Pant material Rajesh 3-20-2012 10:06:21 120 Cutting Completed 1 1904 Crigan 3WH 251 Piping Rajesh 3-20-2012 12:08:58 120 Cutting Completed 1 438 Crigan 3WH 251 Pant material Rajesh 3-19-2012 14:47:17 130 Numbering Started 1 420 Crigan 3WH 251 Pant material Rajesh 3-19-2012 16:53:18 130 Numbering Started 1 1904 Crigan 3WH 251 Pocketing Rajesh 3-20-2012 13:57:43 130 Numbering Completed 1 438 Crigan 3WH 251 Pant material
  • 7. Stitch Time Cummulative Date Hour Qty produced Hourly Performance compared to standard % Performance Qty Produced Productivity 21-Mar 1 PM 35 ||||||||||| -22.22% 35 3.14 2 PM 40 |||||| -11.11% 75 6.23 3 PM 25 |||||||||||||||||||||| -44.44% 100 7.87 5 PM 55 ||||||||||| 22.22% 155 9.93 22-Mar 9 AM 53 ||||||||| 17.78% 208 12.76 10 AM 20 |||||||||||||||||||||||||||| -55.56% 228 14.52 11 AM 40 |||||| -11.11% 268 15.14 12 PM 19 ||||||||||||||||||||||||||||| -57.78% 287 16.23 1 PM 51 ||||||| 13.33% 338 17.03 2 PM 12 ||||||||||||||||||||||||||||||||||||| -73.33% 350 18.01 3 PM 61 |||||||||||||||||| 35.56% 411 19.21 4 PM 25 |||||||||||||||||||||| -44.44% 436 19.66 5 PM 53 ||||||||| 17.78% 489 21.48 23-Mar 9 AM 15 ||||||||||||||||||||||||||||||||| -66.67% 504 22.22 10 AM 49 |||| 8.89% 553 23.33 11 AM 15 ||||||||||||||||||||||||||||||||| -66.67% 568 23.25 12 PM 14 |||||||||||||||||||||||||||||||||| -68.89% 582 23.11 1 PM 26 ||||||||||||||||||||| -42.22% 608 22.69 2 PM 70 |||||||||||||||||||||||||||| 55.56% 678 23.57 3 PM 52 |||||||| 15.56% 730 24.84 4 PM 60 ||||||||||||||||| 33.33% 790 26.11 5 PM 60 ||||||||||||||||| 33.33% 850 27.38 Required Stitch Time 45 Qty/hr Achieved Average Stitch Time 38.64 Qty/hr
  • 8. All results achieved… Using mobile Without any Collecting data phone & capturing software directly from data through deployment source voice User training in No complex Roll-out in just 3 less than 10 implementation days minutes
  • 9. Call us You will be happy you did !!! +91-9962908222 For further details pl. visit www.valgenmobility.com Mail us at vijay@valgeninc.com Valgen Group Companies www.valgen.in www.valgeninc.com www.valgenconsulting.com

Editor's Notes

  1. Custom animation effects: fly-in and shrink lines, stretch rectangles(Intermediate)To reproduce the first vertical line on this slide, do the following:On the Home tab, in the Slides group, click Layout, and then click Blank.On the Home tab, in the Drawing group, click Shapes, and then under Lines click Line. On the slide, press and hold SHIFT, and then drag to draw a straight, vertical line.UnderDrawing Tools, on the Format tab, in the Size group, in the Shape Width box, enter 4.5”.On the Home tab, in the bottom right corner of the Drawing group, click the Format Shape dialog box launcher. In the Format Shape dialog box, click Line Color in the left pane, select Gradient fill in the Line Color pane, and then do the following:In the Type list, select Linear.Click the button next to Direction, and then click Linear Right (first row, fourth option from the left).In the Angle box, enter 0°.Under Gradient stops, click Add or Remove until three stops appear in the drop-down list.Also under Gradient stops, customize the gradient stops that you added as follows:Select Stop 1 from the list, and then do the following:In the Stop position box, enter 0%.Click the button next to Color, select More Colors, and then in the Colors dialog box, on the Custom tab, enter values for Red: 148, Green: 172, and Blue: 208.In the Transparency box, enter 100%.Select Stop 2 from the list, and then do the following: In the Stop position box, enter 50%.Click the button next to Color, select More Colors, and then in the Colors dialog box, on the Custom tab, enter values for Red: 148, Green: 172, and Blue: 208.In the Transparency box, enter 0%.Select Stop 3 from the list, and then do the following:In the Stop position box, enter 99%.Click the button next to Color, select More Colors, and then in the Colors dialog box, on the Custom tab, enter values for Red: 148, Green: 172, and Blue: 208.In the Transparency box, enter 100%.Also in the Format Shape dialog box, click Line Style in the left pane. In the Line Style pane, in the Width box, enter 6 pt.To reproduce the first rectangle on this slide, do the following:On the Home tab, in the Drawing group, click Shapes, and then under Rectangles click Rectangle (first option from the left). On the slide, drag to draw a rectangle.Select the rectangle. Under DrawingTools, on the Format tab, in the Size group, do the following:In the ShapeHeight box, enter 2”.In the ShapeWidth box, enter 2”.Under Drawing Tools, on the Format tab, in the bottom right corner of the ShapeStyles group, click the FormatShape dialog box launcher. In the FormatShape dialog box, click Fill in the left pane, select Gradient fill in the Fill pane, and then do the following:In the Type list, select Linear.Click the button next to Direction, and then click Linear Up (second row, second option from the left).In the Angle box, enter 270°.Under Gradient stops, click Add or Remove until three stops appear in the drop-down list.Also under Gradient stops, customize the gradient stops that you added as follows:Select Stop 1 from the list, and then do the following:In the Stop position box, enter 0%.Click the button next to Color, click More Colors, and then in the Colors dialog box, on the Custom tab, enter values for Red: 44, Green: 93, and Blue: 152.In the Transparency box, enter 0%.Select Stop 2 from the list, and then do the following: In the Stop position box, enter 80%.Click the button next to Color, click More Colors, and then in the Colors dialog box, on the Custom tab, enter values for Red: 60, Green: 123, Blue: 199.In the Transparency box, enter 0%.Select Stop 3 from the list, and then do the following:In the Stop position box, enter 100%.Click the button next to Color, click More Colors, and then in the Colors dialog box, on the Custom tab, enter values for Red: 58, Green: 124, Blue: 203.In the Transparency box, enter 0%.Also in the Format Shape dialog box, click Line Color in the left pane. In the Line Color pane, select No line. Also in the Format Shape dialog box, click 3-D Format in the left pane, and in the 3-D Format pane, do the following:Under Bevel, click the button next to Top, and then under Bevel click Circle (first row, first option from the left). Next to Top, in the Width box, enter 5 pt, and in the Height box, enter 2 pt.Under Surface, in the Angle box, enter 20°.On the slide, right-click the rectangle and then click Edit Text.Enter text in the text box and select the text. On the Home tab, in the Font group, do the following:In the Font list, select Calibri.In the Font Size list, select 32.Click the button next to Font Color, and then under Theme Colors click White, Background 1 (first row, first option from the left).On the slide, press and hold CTRL, and then select the line and the rectangle.On the Home tab, in the Drawing group, click Arrange, point to Align, and then do the following:Click Align Selected Objects.Click Align Left.With the line and rectangle still selected, drag them to the left side of the slide. To reproduce the animation effects for the first vertical line and rectangle on this slide, do the following:On the Animations tab, in the Animations group, click CustomAnimation. On the slide, select the line. In the CustomAnimation task pane, do the following:Click AddEffect, point to Entrance, and then click MoreEffects. In the AddEntranceEffect dialog box, under Basic, click FlyIn.Select the first animation effect (fly-in effect for the line), and then under Modify: Fly In,do the following:In the Start list, select WithPrevious.In the Direction list, select FromTop.In the Speed list, select Fast.On the slide, select the line. In the CustomAnimation task pane, do the following:Click AddEffect, point to Emphasis, and then click MoreEffects. In the AddEmphasisEffect dialog box, under Basic, click Grow/Shrink.Select the second animation effect (grow/shrink effect for the line). Click the arrow to the right of the effect, and then click Effect Options. In the Grow/Shrink dialog box, do the following:On the Effect tab, do the following:In the Size list, select Tiny. Also in the Size list, select Vertical.On the Timing tab, do the following:In the Start list, select WithPrevious.In the Delay box, enter 0.5.In the Speed list, select 1 seconds (Fast).On the slide, select the rectangle. In the CustomAnimation task pane, do the following:Click AddEffect, point to Entrance, and then click MoreEffects. In the AddEntranceEffect dialog box, under Moderate, click Stretch.Select the third animation effect (stretch effect for the rectangle), and then under Modify: Stretch,do the following:In the Start list, select AfterPrevious.In the Direction list, select FromLeft.In the Speed list, select Fast.To reproduce the other shapes with animation effects on this slide, do the following:On the slide, press and hold CTRL, and then select the rectangle and the line. On the Home tab, in the Clipboard group, click the arrow under Paste, and then click Duplicate. On the slide, drag the second line and rectangle to the center of the slide. With the second line and rectangle still selected, on the Home tab, in the Clipboard group, click the arrow under Paste, and then click Duplicate. On the slide, drag the third line and rectangle to the right side of the slide. On the slide, press CTRL+A to select all the objects. On the Home tab, in the Drawing group, click Arrange, point to Align, and then do the following:Click Align to Slide.Click Align Middle. Click the text in each of the duplicate rectangles, and then edit the text.On the slide, select the second (middle) line. On the Home tab, in the bottom right corner of the Drawing group, click the Format Shape dialog box launcher. In the Format Shape dialog box, click Line Color in the left pane, select Gradient fill in the Line Color pane, and then do the following:In the Type list, select Linear.Click the button next to Direction, and then click Linear Right (first row, fourth option from the left).In the Angle box, enter 0°.Under Gradient stops, click Add or Remove until three stops appear in the drop-down list.Also under Gradient stops, customize the gradient stops that you added as follows:Select Stop 1 from the list, and then do the following:In the Stop position box, enter 0%.Click the button next to Color, select More Colors, and then in the Colors dialog box, on the Custom tab, enter values for Red: 154, Green: 181, Blue: 228.In the Transparency box, enter 100%.Select Stop 2 from the list, and then do the following: In the Stop position box, enter 50%.Click the button next to Color, and then under Theme Colors click White, Background 1, Darker 25% (fourth row, first option from the left).In the Transparency box, enter 0%.Select Stop 3 from the list, and then do the following:In the Stop position box, enter 99%.Click the button next to Color, and then under Theme Colors click White, Background 1, Darker 25% (fourth row, first option from the left).In the Transparency box, enter 100%.On the slide, select the second (middle) rectangle. On the Home tab, in the bottom right corner of the Drawing group, click the Format Shape dialog box launcher. In the Format Shape dialog box, click Fill in the left pane, select Gradient fill in the Fill pane, and then do the following:In the Type list, select Linear.Click the button next to Direction, and then click Linear Up (second row, second option from the left).In the Angle box, enter 270°.Under Gradient stops, click Add or Remove until three stops appear in the drop-down list.Also under Gradient stops, customize the gradient stops that you added as follows:Select Stop 1 from the list, and then do the following:In the Stop position box, enter 0%.Click the button next to Color, click More Colors, and then in the Colors dialog box, on the Custom tab, enter values for Red: 118, Green: 149, Blue: 53.Select Stop 2 from the list, and then do the following: In the Stop position box, enter 80%.Click the button next to Color, click More Colors, and then in the Colors dialog box, on the Custom tab, enter values for Red: 115, Green: 195, Blue: 72.Select Stop 3 from the list, and then do the following:In the Stop position box, enter 100%.Click the button next to Color, click More Colors, and then in the Colors dialog box, on the Custom tab, enter values for Red: 156, Green: 199, Blue: 70.On the slide, select the third (right) line. On the Home tab, in the bottom right corner of the Drawing group, click the Format Shape dialog box launcher. In the Format Shape dialog box, click Line Color in the left pane, select Gradient fill in the Line Color pane, and then do the following:In the Type list, select Linear.Click the button next to Direction, and then click Linear Right (first row, fourth option from the left).In the Angle box, enter 0°.Under Gradient stops, click Add or Remove until three stops appear in the drop-down list.Also under Gradient stops, customize the gradient stops that you added as follows:Select Stop 1 from the list, and then do the following:In the Stop position box, enter 0%.Click the button next to Color, and then underTheme Colorsclick Aqua, Accent 5, Lighter 40% (fourth row, ninth option from the left).In the Transparency box, enter 100%.Select Stop 2 from the list, and then do the following: In the Stop position box, enter 50%.Click the button next to Color, and then underTheme Colorsclick Aqua, Accent 5, Lighter 40% (fourth row, ninth option from the left).In the Transparency box, enter 0%.Select Stop 3 from the list, and then do the following:In the Stop position box, enter 99%.Click the button next to Color, and then underTheme Colorsclick Aqua, Accent 5, Lighter 40% (fourth row, ninth option from the left).In the Transparency box, enter 100%.On the slide, select the third (right) rectangle. On the Home tab, in the bottom right corner of the Drawing group, click the Format Shape dialog box launcher. In the Format Shape dialog box, click Fill in the left pane, select Gradient fill in the Fill pane, and then do the following:In the Type list, select Linear.Click the button next to Direction, and then click Linear Up (second row, second option from the left).In the Angle box, enter 270°.Under Gradient stops, click Add or Remove until three stops appear in the drop-down list.Also under Gradient stops, customize the gradient stops that you added as follows:Select Stop 1 from the list, and then do the following:In the Stop position box, enter 0%.Click the button next to Color, select More Colors, and then in the Colors dialog box, on the Custom tab, enter values for Red: 39, Green: 135, Blue: 160.Select Stop 2 from the list, and then do the following: In the Stop position box, enter 80%.Click the button next to Color, select More Colors, and then in the Colors dialog box, on the Custom tab, enter values for Red: 54, Green: 177, Blue: 210.Select Stop 3 from the list, and then do the following:In the Stop position box, enter 100%.Click the button next to Color, select More Colors, and then in the Colors dialog box, on the Custom tab, enter values for Red: 52, Green: 179, Blue: 214.To reproduce the background effects on this slide, do the following:Right-click the slide background area, and then click Format Background. In the Format Background dialog box, click Fill in the left pane, select Gradient fill in the Fill pane, and then do the following:In the Type list, select Radial.Click the button next to Direction, and then click From Center (third option from the left).Under Gradient stops, click Add or Remove until three stops appear in the drop-down list.Also under Gradient stops, customize the gradient stops that you added as follows:Select Stop 1 from the list, and then do the following:In the Stop position box, enter 33%.Click the button next to Color, and then under Theme Colors click White, Background 1 (first row, first option from the left).Select Stop 2 from the list, and then do the following: In the Stop position box, enter 67%.Click the button next to Color, select More Colors, and then in the Colors dialog box, on the Custom tab, enter values for Red: 228, Green: 233, Blue: 236.Select Stop 3 from the list, and then do the following: In the Stop position box, enter 100%.Click the button next to Color, select More Colors, and then in the Colors dialog box, on the Custom tab, enter values for Red: 178, Green: 186, Blue: 210.