1-1

Palmal Group of Industries

KRC(U-3&4) Monthly Knowledge Sharing Meeting-KSM

(May-22 To July-22)

Organized by:
Central-IE
Manufacturing Audit & Central Costing

1-2
Objectives of the Meeting:

To review factory last month performance

To understand our present position against
management expectation
To know about the scope of improvement
To set next month performance target

1-3
 Key Discussion points:
1. Planning, Production & IE KPI:
Monthly Target Vs. achievement status
Monthly Machine utilization %
Monthly Efficiency %
Monthly Profit/Loss status
Monthly Revenue status
On-Time Delivery Status
Monthly Short/excess shipment status
Monthly Style Wise Line Plan Analysis
Monthly PCD Hit rate status
Monthly NPT Analysis
Operators Skill Matrix Analysis

2. Human Resource Department KPI:

 Monthly worker absenteeism status
3. Quality Assurance Department KPI:
 Monthly Final inspection pass status
 Monthly OQL% status
Monthly DHU% status
Monthly Top 5 Defects analysis
Fail report analysis against Top 5 Defect

4. Set next month performance target

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

1-5
Overview of Performance:

1-6
Month wise Plan & Floor Target Vs. Achievement status:

1-7
Month wise Machine utilization % :

1-8
Month wise efficiency %:

1-9
Month wise profit/Loss status (Excluding Abnormal Loss) :

1-10
Month wise per Machine Plan Vs. Achieve Revenue status:

1-11
Month wise On Time Delivery status:

1-12
Month wise short/excess shipment status :

1-13
Root Causes Analysis:

1-14
 Month wise Plan Vs. Actual Style Allocation Analysis (May-22):
ALLOCATION PLAN STYLE ANALYSIS ACTUAL RUNNING STYLE ANALYSIS
Avg qty % out Avg qty % out
Produced Produced
SMV Type Style Type Style Qty Plan Qty of total SMV Type Style Type Style Qty Produced Qty of total
Minute Minute
Produce Qty Produce Qty
<4.5 Very Basic 0 0 0 0.0% <4.5 Very Basic 1 19737 4386 0.7%

4.51-7.5 Basic 25 3401376 628332 86.2% 4.51-7.5 Basic 18 2946501 547901 85.8%

7.51-10.5 Semi Critical 3 813660 87000 11.9% 7.51-10.5 Semi Critical 4 597419 63195 9.9%

10.51-15 Heavy Semi Critical 1 48289 3328 0.5% 10.51-15 Heavy Semi Critical 1 64134 4420 0.7%

15.1-20 Critical 1 173884 10344 1.4% 15.1-20 Critical 3 325182 19035 3.0%

20.1- >=28 Heavy Critical 0 0 0 0.0% 20.1- >=28 Heavy Critical 0 0 0 0.0%

6.09 Basic 30 4437209 729004 100.0% 6.19 Basic 27 3952974 638937 100.0%

1-15
 Month wise Plan Vs. Actual Style Allocation Analysis (June-22):
ALLOCATION PLAN STYLE ANALYSIS ALLOCATION PLAN STYLE ANALYSIS
Avg qty % out Avg qty % out
Produced Produced
SMV Type Style Type Style Qty Plan Qty of total SMV Type Style Type Style Qty Produced Qty of total
Minute Minute
Produce Qty Produce Qty
<4.5 Very Basic 3 309995 69500 6.7% <4.5 Very Basic 4 332628 74549 7.6%

4.51-7.5 Basic 18 4763956 889469 85.6% 4.51-7.5 Basic 19 4490990 835091 85.1%

7.51-10.5 Semi Critical 1 355779 45730 4.4% 7.51-10.5 Semi Critical 2 258906 32089 3.3%

10.51-15 Heavy Semi Critical 1 505287 34500 3.3% 10.51-15 Heavy Semi Critical 1 523155 35720 3.6%

15.1-20 Critical 0 0 0 0.0% 15.1-20 Critical 2 73223 3840 0.4%

20.1- >=28 Heavy Critical 0 0 0 0.0% 20.1- >=28 Heavy Critical 0 0 0 0.0%

5.71 Basic 23 5935017 1039199 100.0% 5.79 Basic 28 5678902 981289 100.0%

1-16
 Month wise Plan Vs. Actual Style Allocation Analysis (July-2022):

Avg qty % out Avg qty % out

Produced Produced
SMV Type Style Type Style Qty Plan Qty of total SMV Type Style Type Style Qty Produced Qty of total
Minute Minute
Produce Qty Produce Qty
<4.5 Very Basic 3 148586 33740 5.5% <4.5 Very Basic 4 128869 29746 6.2%

4.51-7.5 Basic 12 2244295 421120 68.1% 4.51-7.5 Basic 18 1691691 319402 66.1%

7.51-10.5 Semi Critical 4 671156 86250 14.0% 7.51-10.5 Semi Critical 4 558925 71768 14.8%

10.51-15 Heavy Semi Critical 4 996253 77000 12.5% 10.51-15 Heavy Semi Critical 4 810235 62479 12.9%

15.1-20 Critical 0 0 0 0.0% 15.1-20 Critical 0 0 0 0.0%

20.1- >=28 Heavy Critical 0 0 0 0.0% 20.1- >=28 Heavy Critical 0 0 0 0.0%

6.57 Basic 23 4060289 618110 100.0% 6.60 Basic 30 3189719 483395 100.0%

1-17
 Operators Skill Matrix Analysis :
KRC (U-3&4) Operator Skill Matrix
NO OF PERCENTAGE PERCENTAGE
GRADE GRADING
OPERATOR (%) (%)
A+ 0 0%
A 21 5% A 15%
A- 46 10%
B+ 110 24%
B 138 30% B 73%
B- 90 19%
C+ 30 6%
C 24 5% C 12%
C- 3 1%
D 0 0% D 0%
462 100% 100%

1-18
 STYLE CHANGING ANALYSIS (LINE PLAN VS.EXECUTION COMPARISON OF KRC-U-3)
PLAN STYLE RUNNING HEAT MAP,KRC,U-3 Unit 3
No of
Line 2-Jul 3-Jul 4-Jul 5-Jul 6-Jul 7-Jul 16-Jul 17-Jul 18-Jul 19-Jul 20-Jul 21-Jul 23-Jul 24-Jul 25-Jul 26-Jul 27-Jul 28-Jul 30-Jul 31-Jul
Style
A LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING 1

B LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING 2

C LEGGING LEGGING LEGGING LEGGING T-shirt T-shirt T-shirt 2

D T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt 2

E HOODY HOODY HOODY HOODY HOODY HOODY HOODY HOODY LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING 2

F TANK TOPTANK TOP T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt 2

G JACKET JACKET JACKET JACKET JACKET JACKET JACKET JACKET JACKET JACKET JACKET JACKET JACKET JACKET JACKET JACKET JACKET JACKET JACKET JACKET 2

H TANK TOPTANK TOPTANK TOPTANK TOP 1

Style Running Heat Map- KRC U-3 Unit- 3

Number of No. of
Line 1-Jul 2-Jul 3-Jul 4-Jul 5-Jul 6-Jul 7-Jul 16-Jul 17-Jul 18-Jul 19-Jul 20-Jul 21-Jul 23-Jul 24-Jul 25-Jul 26-Jul 27-Jul 28-Jul 30-Jul 31-Jul styling style
Runned Runned
HOODY HOODY HOODY HOODY HOODY HOODY HOODY HOODY HOODY
A WITH ZIP WITH ZIP WITH ZIP WITH ZIP WITH ZIP WITH ZIP WITH ZIP WITH ZIP WITH ZIP
JACKET JACKET JACKET JACKET JACKET JACKET JACKET JACKET JACKET JACKET JACKET JACKET 2 3

LADIES
B T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT
DRESS
TANK TOP TANK TOP TANK TOP 3 5

C LEGGING LEGGING LEGGING T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT 2 3

C2 LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING - - - - - - - - - - - - - - 1 1

D LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT 2 3

E T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT - LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING JACKET JACKET JACKET - - - - 3 3

E+F - - - - - - - - - - - - - - - - - JACKET JACKET JACKET JACKET 1 1

F TANK TOP TANK TOP LEGGING LEGGING TANK TOP TANK TOP TANK TOP TANK TOP TANK TOP TANK TOP TANK TOP TANK TOP TANK TOP - - - - - - - - 2 4

HOODY HOODY HOODY

G WITH ZIP WITH ZIP WITH ZIP
JACKET JACKET JACKET JACKET JACKET JACKET JACKET JACKET JACKET JACKET JACKET JACKET JACKET JACKET JACKET JACKET JACKET JACKET 2 3

H LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING 1 2
 STYLE CHANGING ANALYSIS (LINE PLAN VS.EXECUTION COMPARISON OF KRC-U-4)
PLAN STYLE RUNNING HEAT MAP,KRC,U-4 Unit 4
No of
Line 2-Jul 3-Jul 4-Jul 5-Jul 6-Jul 7-Jul 16-Jul 17-Jul 18-Jul 19-Jul 20-Jul 21-Jul 23-Jul 24-Jul 25-Jul 26-Jul 27-Jul 28-Jul 30-Jul 31-Jul
Style
A T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt 2

B T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt 2

C T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt 2

D T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt 3

LADIES LADIES LADIES
E DRESS DRESS DRESS
T-shirt T-shirt T-shirt T-shirt TANK TOPTANK TOPTANK TOPTANK TOPTANK TOPTANK TOP 2

F T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt 1

G T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt T-shirt JOGGER JOGGER JOGGER JOGGER JOGGER JOGGER JOGGER JOGGER JOGGER JOGGER 2

Style Running Heat Map- KRC U-4 Unit- 4

Number of No. of
Line 1-Jul 2-Jul 3-Jul 4-Jul 5-Jul 6-Jul 7-Jul 16-Jul 17-Jul 18-Jul 19-Jul 20-Jul 21-Jul 23-Jul 24-Jul 25-Jul 26-Jul 27-Jul 28-Jul 30-Jul 31-Jul styling style
Runned Runned

A T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT 1 4

B T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT 1 3

C T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT - - - - - - - - - - 1 2

C2 - - - - - - - - - - - - - - - - - - - - - 0 0

D T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT 1 4

E JOGGER JOGGER JOGGER JOGGER JOGGER T-SHIRT T-SHIRT - - JOGGER JOGGER T-SHIRT LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING LEGGING 3 4

E+F - - - - - - - - - - - - - - - - - - - - - 0 0

F T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT T-SHIRT 1 1

LADIES LADIES LADIES SHORT SHORT LADIES

G DRESS DRESS DRESS PANT
T-SHIRT
PANT
T-SHIRT T-SHIRT
DRESS
JOGGER JOGGER JOGGER JOGGER JOGGER JOGGER JOGGER JOGGER JOGGER T-SHIRT T-SHIRT T-SHIRT 4 6

H - - - - - - - - - - - - - - - - - - - - - 0 0
PCD Hit & Fail Status (May-22):

1-21
PCD Hit & Fail Status (June-22):

1-22
PCD Hit & Fail Status (July-22):

1-23
 Month wise NPT status :
Non Total Earning
NPT Value in NPT (Man- Revenue/MC
Productive NPT Value NPT% NPT (Pcs) NPT MC/Day (Including NPT
Tk. Hour) (Without NPT)
Minute Value)

63205 Min. $ 4,424.35 367,221৳ 0.97% 10216 Pcs 1053 5.2 MC $ 343,893.84 BDT 86562

136475 Min. $ 9,553.25 792,920৳ 1.63% 23582 Pcs 2275 9.1 MC $ 473,161.80 BDT 92624

62182 Min. $ 4,352.74 361,277৳ 1.07% 9424 Pcs 1036 5.6 MC $ 271,491.04 BDT 69293

261862 Min. $ 18,330.34 1,521,418৳ 1.26% 43222 Pcs 4364 6.6 MC $ 1,088,546.67 BDT 83739

1-24
NPT status (MAY-2022):

1-25
NPT status (JUNE-2022):

1-26
NPT status (JULY-2022):

1-27
2. Human Resource Department KPI:

1-28
Month wise worker absenteeism status :

1-29
 Factors influencing on efficiency %:
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.

1-30
 SUMMARY OF TODAY DISCUSSION :
Order Execution Flow Chart

Order Confirmation

Fabric Delay
Sample Approval Planning Fabric & Accessories planning

File Handover PCD delay

Style Analysis during size set & PP Meeting

Cutting Plan

Print/Emb. Plan

Sewing Start Plan

Productivity Loss
Sewing Production

FRI Plan
1-31
3. Quality Assurance Department KPI:

1-32
Final Inspection Pass Status

1-33
Thank You