PERIOD

DOMAIN

BUSINESS HEALTH DIAGNOSIS

FINANCIALS

SKILL MATRIX

MARKETING

RECRUITMENT

ORGANISATION DEVELOPMENT

PRODUCTION EFFICIEENCY
LEAN & SIX SIGMA

QUALITY

ERP

MIS

BUSINESS PROCESS IMPROVEMENTS

O1-JAN-14 TO 31-DEC-14
PROCESS DESCRIPTION FROM

Analysis and diagnosis of the Business health - Review the data of the
past 12 months. 1-Jan-14
Identifying the concluding the CURRENT STATE - of all Key parameters.
Including Cost per Minute & MOPS 1-Feb-14

Defining the FUTURE STATE 1-Mar-14

Publishing the FY 14/15 FISCAL BUDGET 15-Mar-14
Establishing Systems to monitor and control :-
COGS
CONTRIBUTION
DAILY COST REPORT (Tracking of Per pc cost,MMR,Cost/Min) 15-May-14
WEEKLY BUDGET TRACKER 15-May-14

Product Analysis - To Find skill set required 1-Jun-14

Skill Test of Exiting M/Pwr -To find right people for right operation 1-Jun-14

Fill the Gap of Required Skill Vs Available Skill with Systematic Selection 15-Jun-14
Skill Development & Training Programme 1-Jul-14

Product Costing - Revised Methodology 1-Aug-14

Product - Pricing strategies 1-Aug-14
Customer wise Sales Plan to match Business Targets 1-Aug-14

Recruitment of IE,PPC,MIS,Financial, Production, Quality and Other

Personnel.

Re-engineering of Organizational Structure 1-Mar-14

Introduction of Short term Reward System (Attn Bonus, etc)
KRA Definition for all level of Management /Design Accountability
System of Indivitual 1-Jul-14
Performance Management & Appraisal 1-Nov-14
Fuel Consumption Management (FCC) 1-Jun-14

Performance based Compensation System Development (BSC based) 1-Nov-14

Set up & Training IE/PPC Dept 1-Jan-14

Efficiency Monitoring System - Hourly-Daily-Weekly-Monthly 2-Feb-14
Efficiency Improvement Through Lean Tools 1-Apr-14

Daily Reason analysis for Lower performance and plug the reason
Macro /Micro Planning 1-May-14
Planning Monitoring, Alerts/reminder for pendency 1-May-14

Six Sigma Tools Analysis - Fish bone, Pareto Analysis 1-Jul-14

Lean Tools Implementation
FMEA 1-Jul-14
SMED 1-Jul-14
CELL Manufacturing / "U"Shape Layout 1-Jul-14
TPM/TQM 1-Jul-14
5S (External Consulting would be needed) * 1-Jul-14
KAIZEN 1-Jul-14
Visual Factory 1-Jul-14
Value Stream Mapping 1-Jul-14
Balance Score Card 1-Dec-14

Quality System Improvement 1-Jul-14

Inputs on ERP ( requirement based customization to improve

productivity)
Find and implement best Suited ERP - Attendance and Payroll 1-Mar-14

Monthly Budget Vs Actual Expenses

Customer wise/Stylewise Actual Contribution
Pre & Post -Contribution Comaprison
Fabric Cost Variance From Pre & Post
Trims Cost Variance From Pre & Post
All months
Short Shipment Analysis
Rejection Analysis
Cut to Ship Ratio Analysis
Order Closing Report
Any other, as suited to the Organisation needs and process.

AS PER BUSINESS REQUIREMENTS - NOT LIMITED TO THE ABOVE. 1-Jan-14

DURATION TO

30 31-Jan-14 Click Here

25 26-Feb-14

15 16-Mar-14
30 14-Apr-14

Click Here

30 14-Jun-14
30 14-Jun-14

30 1-Jul-14

60 31-Jul-14 Click Here

60 14-Aug-14
60 30-Aug-14

60 30-Sep-14
60 30-Sep-14 Click Here
60 30-Sep-14

Click Here
All months

120 29-Jun-14

60 30-Aug-14
Click Here
60 31-Dec-14
15 16-Jun-14

58 29-Dec-14

60 2-Mar-14
30 4-Mar-14
90 30-Jun-14
Click Here
All months
 60 30-Jun-14
60 30-Jun-14

90 29-Sep-14

90 29-Sep-14
88 27-Sep-14
88 27-Sep-14
88 27-Sep-14
89 28-Sep-14 Click Here
90 29-Sep-14
89 28-Sep-14
90 29-Sep-14
30 31-Dec-14

90 29-Sep-14 Click Here

Click Here
90 30-May-14

Click Here

All Months 30-Dec-14

 TOTAL IBG -JORDAN
CURRENT STATE - 31-03-14

Month Details (Figure in USD) JAN'13 FEB'13 MAR'13 APR'13 MAY'13

Sale - Value (in lacs) 24.37 21.35 17.07 23.43 25.95

Sale - Qty (in pcs) 407452 398569 288911 361518 383933
Average Unit Price 6 5 6 6 7
Cost Of Goods Sold (COGS) 15.33 13.20 10.39 14.66 16.58
Duty Drawback (Govt Incentive) 0.0 0.0 0.0 0.0 0.0
Contribution - Value (Incl Drawback ) 9.04 8.15 6.68 8.77 9.36
Contr per pc 2 2 2 2 2
Contribution - % 37% 38% 39% 37% 36%
Manufacturing Expenses 8.32 8.15 7.59 8.14 8.45
Manufacturing Expenses Per Pc 2.04 2.04 2.63 2.25 2.20
Manufacturing Expenses as % of Sales 34% 38% 44% 35% 33%
Profit / (Loss) 1 0 (1) 1 1

Exp Total Total Total Total Total

Expense Head Expenses Expenses Expenses Expenses Expenses
Type (in Lacs) (in Lacs) (in Lacs) (in Lacs) (in Lacs)

A.Employee Cost
Var OverTime 0.85 0.54 0.22 0.52 0.61
Var Provision For Bonus/Settlement/Leave 0.11 0.11 0.11 0.11 0.11
Var Provision For Visa/Air Ticket 0.42 0.42 0.43 0.42 0.49
Fix Salaries & Incentives 3.22 3.24 3.22 3.25 3.25
Fix Security Expenses 0.15 0.15 0.15 0.15 0.15
Fix Staff Welfare Exp 0.03 0.02 0.01 0.01 0.02
Fix Staff Uniform 0.00 0.00 0.00 0.00 0.00
Fix Admin Expenses - Hiring 0.12 0.12 0.12 0.12 0.13
A.Employee Cost Total 4.90 4.60 4.26 4.58 4.77

B.Power & Fuel

Var Diesel + Genset 0.39 0.39 0.34 0.37 0.25
Var Electricity 0.24 0.26 0.23 0.20 0.20
B.Power & Fuel Total 0.62 0.65 0.58 0.57 0.45

C.Repair & Maintenance

Building/Office Maintenance/ IT & Network
Fix Maintainance 0.05 0.03 0.01 0.01 0.02
Fix Factory Maintenance 0.10 0.08 0.09 0.09 0.13
Fix Machine Maintenance 0.04 0.04 0.09 0.04 0.05
Fix Repair & Maintenance General 0.02 0.03 0.02 0.02 0.02
Var Consumable Stores (Spare Parts)
C.Repair & Maintenance Total 0.22 0.18 0.21 0.17 0.23

D.Factory Over Heads

Var Advertisement Exp 0.00 0.00 0.00 0.00 0.00
Var Cartage & Freight
Var Chemical
Fix ETP & Water Charges 0.24 0.23 0.28 0.27 0.29
Var Printing & Stationary Exp 0.01 0.01 0.01 0.01 0.01
Fix Rent 0.30 0.31 0.30 0.30 0.30
Fix Service Tax 0.00 0.00 0.00 0.00 0.00
Var Short / Excess Recovery 0.00 0.00 0.00 0.00 0.00
Fix House Keeping Exp (Material) 0.00 0.00 0.00 0.00 0.00
Fix Canteen Expenses 0.37 0.37 0.36 0.35 0.36
Fix Direct Insurance 0.05 0.04 0.06 0.06 0.05
Fix Indirect Insurance 0.00 0.00 0.00 0.00 0.00
Var Sundry Expenses 0.06 0.08 0.06 0.06 0.06
D.Factory Over Heads Total 1.04 1.04 1.07 1.04 1.08

E.Freight & Forward

Var Freight & Forwarding Charges 0.34 0.44 0.33 0.32 0.35
E.Freight & Forward Total 0.34 0.44 0.33 0.32 0.35

E1.Sales Commission
Var Sales Commission 0.00 0.00 0.00 0.09 0.09
E1.Sales Commission Total 0.00 0.00 0.00 0.09 0.09

F.Customer Service
Var Quality Claims & Discounts 0.00 -0.02 0.00 0.00 0.00
F.Customer Service Cost Total 0.00 -0.02 0.00 0.00 0.00

G.Bad Debts written off

Var Old expense written off 0.18 0.18 0.18 0.18 0.18
G.Sampling Total 0.18 0.18 0.18 0.18 0.18

H.Travelling /Conveyance
Var Foreign Travel 0.02 0.00 0.01 0.04 0.01
Var Local Travel
Fix Vehicle Fuel/Conveyance/Maintn 0.07 0.06 0.06 0.06 0.08
H.Travelling /Conveyance Total 0.09 0.06 0.07 0.11 0.08
I.Communication Exp
Var Courier Charges
Fix Mobiles 0.01 0.01 0.00 0.01 0.00
Fix Telephone Expenses 0.02 0.03 0.00 0.02 0.02
Var Postage Expenses 0.00 0.00 0.00 0.00 0.00
Fix Telex/Fax/Internet
I.Communication Exp Total 0.02 0.04 0.01 0.03 0.03
J.Other S&GA

Var Quality Control Exp/ External agency Testing

Fix Entertainment Exp
Var Sales Promotion /Professional Charge 0.04 0.22 0.04 0.28 0.35
J.Other S&GA Total 0.04 0.22 0.04 0.28 0.35

K.Financial Charges
Var Bank Charges 0.33 0.27 0.32 0.31 0.35
K.Financial Charges Total 0.33 0.27 0.32 0.31 0.35

L.Jobwork Charges
Var Job work Charges 0.00 0.01 0.03 0.00 0.00
Var Stitching J/Work (Garment)
L.Job work Charges Total 0.00 0.01 0.03 0.00 0.00
Non Cash Expenses
Fix Depriciation 0.53 0.47 0.50 0.47 0.49
Fix Corporate Services Expenses share 0.00 0.00 0.00 0.00 0.00

M.Corporate Expenses Total 0.53 0.47 0.50 0.47 0.49

TOTAL BUDGET 8.32 8.15 7.59 8.14 8.45

Type Description Mfr Mfr Mfr Mfr Mfr

Fix Fixed Expenses 5.33 5.23 5.28 5.24 5.39
Var Variable Expenses 2.99 2.92 2.31 2.91 3.07

SUMMARY - COST/MINUTE WORKING

Current Current Current Current Current
Average Running Machines 516 516 516 516 516
Available Minutes/day/Machine 692 692 558 678 692
No of Working Days/Month 25 22 26 24 24

Total Minutes Available /Month ( in Lacs) 89.28 78.57 74.86 83.96 85.71
Total Expenses/Month (in Lacs) 8.32 8.15 7.59 8.14 8.45

Cost /Minute (Available Minutes) 0.09 0.10 0.10 0.10 0.10

Average Pcs Production/Month 407452 398569 288911 361518 383933

Avg SAM of the Product 15.626 15.626 15.626 15.626 15.626
Total Minitues Produced (in Lacs) 63.67 62.28 45.15 56.49 59.99

Actual Cost/Minute (Produced Minutes) 0.13 0.13 0.17 0.14 0.14

Production Efficiency 71% 79% 60% 67% 70%
JORDAN

JUNE'13 JULY'13 AUG'13 SEP'13 OCT'13 NOV'13 DEC'13 TOTAL

25.68 25.03 26.27 26.45 15.78 26.29 29.54 ### 287.21 287.21
376465 346260 374365 387096 232453 426212 469121 4452354
7 7 7 7 7 6 6 6
16.13 14.98 17.20 16.99 10.60 16.98 18.99 182 182.01
0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
9.55 10.05 9.07 9.47 5.18 9.31 10.56 105.19 105.19
3 3 2 2 2 2 2 2
37% 40% 35% 36% 33% 35% 36% 36.6%
8.51 8.69 8.47 8.63 7.10 8.92 9.51 100.5 100.49
2.26 2.51 2.26 2.23 3.05 2.09 2.03 2
33% 35% 32% 33% 45% 34% 32% 35.0%
1 1 1 1 (2) 0 1 4.71 4.71

Total Total Total Total Total Total Total

Expenses Expenses Expenses Expenses Expenses Expenses Expenses
(in Lacs) (in Lacs) (in Lacs) (in Lacs) (in Lacs) (in Lacs) (in Lacs)

0.66 0.67 0.69 0.70 0.73 0.63 1.03 7.85

0.11 0.11 0.07 0.07 0.07 0.07 0.00 1.07
0.42 0.43 0.42 0.42 0.41 0.42 0.40 5.12
3.34 3.32 3.33 3.48 3.63 3.44 3.56 40.26
0.15 0.15 0.15 0.15 0.15 0.15 0.16 1.85
0.01 0.02 0.01 0.01 0.01 0.02 0.01 0.19
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.15 0.15 0.09 0.13 0.12 0.13 0.15 1.50
4.85 4.85 4.76 4.96 5.13 4.86 5.31 57.84

0.00
0.27 0.25 0.28 0.34 0.34 0.33 0.50 4.07
0.18 0.22 0.19 0.22 0.22 0.24 0.22 2.62
0.45 0.47 0.47 0.56 0.56 0.57 0.71 6.69

0.01 0.01 0.02 0.03 0.02 0.02 0.05 0.28

0.09 0.09 0.12 0.10 0.10 0.13 0.10 1.24
0.05 0.05 0.07 0.10 0.05 0.08 0.09 0.75
0.02 0.02 0.03 0.04 0.02 0.02 0.02 0.29
0.00
0.16 0.18 0.24 0.27 0.19 0.25 0.26 2.56

0.00
0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.06
0.00
0.00
0.28 0.30 0.31 0.27 0.25 0.24 0.24 3.22
0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.08
0.29 0.29 0.30 0.30 0.30 0.29 0.29 3.57
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.36 0.38 0.37 0.35 0.37 0.36 0.39 4.38
0.05 0.05 0.05 0.05 0.05 0.06 0.05 0.64
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.06 0.13 0.08 0.10 0.07 0.07 0.08 0.92
1.06 1.17 1.12 1.09 1.06 1.03 1.06 12.86

0.00
0.28 0.86 0.58 0.60 0.10 1.27 1.09 6.53
0.28 0.86 0.58 0.60 0.10 1.27 1.09 6.53

0.00
0.59 0.07 0.10 0.13 0.05 0.04 0.07 1.23
0.59 0.07 0.10 0.13 0.05 0.04 0.07 1.23

0.14 0.10 0.00 0.18 0.00 -0.25 0.00 0.15

0.14 0.10 0.00 0.18 0.00 -0.25 0.00 0.15

0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.91

0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.91

0.00 0.00 0.01 0.00 0.00 0.00 0.00 0.08

0.00
0.06 0.06 0.06 0.07 0.08 0.07 0.07 ### 0.79
0.06 0.06 0.06 0.07 0.08 0.07 0.07 0.88

0.00
0.01 0.00 0.01 0.00 0.01 0.00 0.01 0.06
0.02 0.02 0.03 0.02 0.02 0.02 0.02 0.25
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.01
0.00
0.02 0.03 0.04 0.02 0.03 0.03 0.03 0.33

0.00
0.00
0.04 0.05 0.27 0.05 -0.79 0.04 0.04 0.61
0.04 0.05 0.27 0.05 -0.79 0.04 0.04 0.61

0.36 0.34 0.32 0.30 0.30 0.33 0.20 3.74

0.36 0.34 0.32 0.30 0.30 0.33 0.20 3.74
 0.00 0.02 0.00 0.00 0.00 0.30 0.29 0.67 ok
0.00
0.00 0.02 0.00 0.00 0.00 0.30 0.29 0.67

0.49 0.49 0.49 0.38 0.40 0.39 0.40 5.49 ok

0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.27
0.00
0.49 0.49 0.49 0.38 0.40 0.39 0.40 5.49

8.51 8.69 8.47 8.63 7.10 8.92 9.51 100.49

Mfr Mfr Mfr Mfr Mfr Mfr Mfr

5.37 5.43 5.44 5.49 5.58 5.41 5.59 64.77
3.13 3.26 3.03 3.14 1.52 3.50 3.92 35.72

0.00
0.00
0.00

Current Current Current Current Current Current Current

516 516 516 516 516 516 516 516
692 692 692 692 692 704 704 682
25 27 24 26 24 24 26 24.75

89.28 96.42 85.71 92.85 85.71 87.15 94.41 86.99

8.51 8.69 8.47 8.63 7.10 8.92 9.51 8.37

0.10 0.09 0.10 0.09 0.08 0.10 0.10 ### 0.10

376465 346260 374365 387096 232453 426212 469121 371029.52

15.626 15.626 15.626 15.626 15.626 15.626 15.626 15.626
58.83 54.11 58.50 60.49 36.32 66.60 73.30 57.98

0.14 0.16 0.14 0.14 0.20 0.13 0.13 ### 0.14

66% 56% 68% 65% 42% 76% 78% 67%
 287.21
4452354.20

182.01

105.19

100.57

4.62
0.27 0.27 0.27 0.27 0.27 0.27 0.27 0.27 0.27
0.27 0.27
 INTERNATIONAL BRITISH GARMENTS
SKILL MATRIX ANALYSIS
Operator Name: Shamila Priyadars Grading Awarded
Card no. : 203974 Production line Assigned :
Trained Machine : Single Needle Date of Joining:
Evaluator Name : Sajid
OPERATION PROCESS DATE Trail - 1 Trail - 2 Trail -3 Average
1. TROUSER OPERATION EXERCISES
Exercise - 1 Target (Hr) 135 135 135 135
A. Welt Attach Actual (Hr) 82 81 80 81
Exercise - 2 Target (Hr) 150 150 150 150
B. Tack back Pocket Actual (Hr) 135 140 125 133
Exercise - 3 Target (Hr) 75 75 75 75
C. Blind Hem Actual (Hr) 62 57 52 57
Exercise - 4 Target (Hr) 80 80 80 80
D. Outseam/Inseam Overlock Actual (Hr) 59 62 72 64
EVALUATION SCORE CARD
RATING % RESULT REMARKS
OPERATION PROCESS
TARGET ACHIEVED
1. TROUSER OPERATION EXERCISES 20 6 30% C POOR

TOTAL EVALUATION SCORE 20 6 30% C POOR

 C
on line Assigned : A
9-Jun

% Rating

60% 1

89% 3

76% 1

80% 1

REMARKS

POOR

POOR
 UNIT I FCC REPORT- IBG JORDAN
ELECTRICITY CONSUMPTION
DATE MULTIPLY KVAH READING AVG UNITS UNIT
CONSUMPTION
FACTOR START END CONSMD RATE
7-Jul N/A N/A N/A N/A 47797.00 0.07

DIESEL CONSUMPTION
TOTAL FUEL
ITEM POWER START TIME STOP TIME RUNNING HRS RUNNING CONSUMED
HOURS
BOILER 1 500 KG 5:00 19:00 14:00 14:00
0:00
0:00 350.00
0:00

BOILER 2 250 KG 5:00 20:00 15:00 15:00

0:00
0:00
375.00
0:00

TOTAL 0.00 725.0

GRAND TOTAL
IBG JORDAN
ENERGY OTHER TOTAL EB GARMENTS ELECTRICITY
AMOUNT AMOUNT AMOUNT PRODUCED RATE / GRMT
3,345.79 N/A 3,345.79 5550 0.60

AVG CONS / FUEL GARMENTS FUEL RATE /

HOUR RATE/LTR AMOUNT PRODUCED GRMNT

25.00 0.68 236

5550 0.09

25.00 0.68 253

489.4 5550 0.09

3835.17 5550 0.69

 QA DEPARTMENT SOP

1 ALL LINE QA HAS TO MAKE A STYLE ANALISIS REPORT AND PATTERN CHECKING REPORT AND SUBMITT
2 DIFFECT CLASSIFICATION TO BE DISLAYED
3 PREPARE A FILE WITH SIZE SET COMMENTS,IPPM MINUTS,SHADE CARDS,TRIM CARDS &MESUREMENT
4 DISPLAY HOW TO CHECK SKETCH(CLOCK WISE) AND HOW TO MEASURE SKETCH.
5 LINE QA TO BE AUDIT ALL THE OPERATIONS AND HIGHLIGHT THE QUALITY ISSUES TO THE RESPONSIBL
6 DEFECT PIECES BUNDLES TO BE TIED WITH RED TAPES
7 MAINTAINE THE INLINE AUDIT REPORT AND DHU CARD FOR ALL OPERATIONS
8 DAILY LINE QA MUST CHECK THE MESUREMENTS 3 GARMENTS PER CUT NO :WISE/SIZE WISE/SHRINKAG
9 ENDLINE QC HAS TO CHECK ALL OUT PUT PIECES INCLUDE RANDOME CRITICAL MSMT AND REPORT TO
10 INLINE/ENDLINE REPORT HOURLY SINGNED BY BATCH QA AND SUPRWISER FOR IMMEDIATE CORRECT
11 END LINE PASS GARMENTS TO BE AUDITED BY QA AND PASS LOTS ONLY MOVE TO THE DISPACH SECT
12 PERFORM THE MEETING FOR NEW STYLE ANLYSIS, WEEKLY QUALITY ISSUES AND FOR THE QA'S/ QC'S
MAKE THE DAILY DHU GRAF AND WEEKLY/ MONTHLY BAR DIAGRAM OF DEFECTS OCCURANCE AREA .
KEEP ALL REPORTS IN QA FILE WTH RESPONSIBLE PERSONS SIGNED OFF.
14 QA SHOULD HAVE KNOLEDGE OF PATTERN CHECKING,FABRIC QUALITY,CUTTING QUALITY.
DAILY DHU GRAPH & WEEKLY DEFECT OCCURANCE AREA BAR GRAPH TO BE DISPLAYED.
 REPORT AND SUBMITT TO QAM BEFORE STARTING THE PRODUCTION

ARDS &MESUREMENT CHARTS (SHRINKAGE WISE)

S TO THE RESPONSIBLE PERSONS.

SE/SIZE WISE/SHRINKAGE WISE.

MSMT AND REPORT TO BE MAINTAINED-
R IMMEDIATE CORRECTIVE ACTION.
TO THE DISPACH SECTION WITH SIZE WISE BUNDLES.
ND FOR THE QA'S/ QC'S TRAINING PROGRAMME &RECORD TO BE MAINTAINED
TS OCCURANCE AREA .

G QUALITY.