What is Line Ranking?
Answer: Line Ranking is an production development system by considering the best line.
Garments MIS Software consider Garments sewing line ranking depending
on total mark on following 7 criteria:
1. Efficiency
2. Right Fast Time
3. Style Change
4. Throughput Time
5. Absenteeism
6. COC & Compliance Status
7. Effort in maintaining machines
For more details please see following Marking system:
1. Efficiency:
Efficiency = (Production * SMV) / (Total Worker * Working Hour * 60) *100%
Efficiency depend on following three option:
(a) Total Production
(b) Total Time
(c) Total Worker
- If Total Worker and Total Time will same, but Total Production increase than Efficiency will increase.
- If Total Production same but Total Worker or Total Time less than Efficiency will increase.
Mark: Mark as much as the Efficiency of a line.
Data input system for mark: If you enter daily Efficiency in Garments MIS Software than mark for efficiency will calculate automatically in this software.
2. Right First Time:
Total percentage of QC pass body is Right First Time percentage. Mark will given according to the following formula based on the Right First Time percentage of the whole month.
Total Mark = (RFT - 90) * 1.5
- If RFT less than 90 than mark will negative.
Example:
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%
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Mark
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|
82 |
-12 |
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84 |
-9 |
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88 |
-3 |
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90 |
0 |
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93 |
4.5 |
|
95 |
7.5 |
|
96 |
9 |
|
98 |
12 |
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Continuing |
Data input system for mark: If you enter daily alter quantity in Garments MIS Software than mark for RFT will calculate automatically in this software.
3. Style Change:
Mark for style change will add based on operation change percentage comparing previous style when style change with following system.
Operation Change Percentage = (Total Operation Change / Previous style total operation) * 100
|
Operation Change percentage |
Mark
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Blow 5 |
0 |
|
Below 10 |
.15 |
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Below 15 |
.30 |
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Below 20 |
.45 |
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Below 25 |
.60 |
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Below 30 |
.75 |
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Below 35 |
.90 |
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Below 40 |
1.05 |
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Below 45 |
1.20 |
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Below 50 |
1.35 |
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Below 55 |
1.50 |
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Below 60 |
1.65 |
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Below 65 |
1.80 |
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Below 70 |
1.95 |
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Below 75 |
2.10 |
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Below 80 |
2.25 |
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Below 85 |
2.40 |
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Below 90 |
2.55 |
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Below 95 |
2.70 |
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Below or equal 100 |
2.85 |
Data input system for mark: If you add value of Operation change percentage at data entry form than mark will calculate automatically in this software.
4. Throughput Time:
Throughput Time is time between new style first input and new style first output. Garments MIS Software consider a standard Throughput Time based on SMV. Following is the mark distribution system:
|
Throughput Time |
Mark
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More than 50% from Standard Throughput Time |
-2 |
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More than 40% from Standard Throughput Time |
-1 |
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More than 30% from Standard Throughput Time |
0 |
|
More than 20% from Standard Throughput Time |
1 |
|
Below 20% from Standard Throughput Time |
2 |
Data input system for mark: If you add value of Throughput Time (min) at data entry form than mark will calculate automatically in this software.
5. Absenteeism:
Mark will given according to the following formula based on the total absenteeism percentage of the whole month:
Total Mark = (5 - Absenteeism Percentage) * 1.65
|
Absenteeism% |
Mark
|
|
1 |
6.6 |
|
2 |
4.95 |
|
3 |
3.3 |
|
4 |
1.65 |
|
5 |
0 |
|
6 |
-1.65 |
|
7 |
-3.3 |
|
8 |
-4.95 |
* The lowest mark -10.
Data input system for mark: If you add Monthly Appointment manpower at data entry form than mark will calculate automatically in this software.
6. COC & Compliance Status:
Total mark for
COC & Compliance Status is 10. Factory Compliance Department will daily audit about following subject and give mark. For every subject marks will 2. Problem found in 1/2 subject mark will 1, problem found in 3 subject mark will 0 or problem found more than 3 subject mark will -2.
If no problem found than mark will 2. From daily mark average will monthly total mark. Following are the subject details:
(a) PPE (Use of Mask, Gloves, Glass etc.).
(b) Machine Safety (Use of Eye guard, Needle guard, Motor cover, paddle mats etc.).
(c) Aisle & Extinguisher (Aisle & Extinguisher management).
(d) Use of Equipment
(Scissors, Cutters Management, Knife, broken parts, extra needle management).
(e) Cleanness, Discipline.
* The lowest mark -10.
COC and Compliance audit Format:
MARKS OF OBSERVATION ON COC & COMPLIANCE
Date:
Audited By: Sign:
|
Line |
PPE |
M/C Safety |
Aisle & Extinguisher |
Use of Equipment |
Cleanness, Discipline |
Remarks |
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- There would be one HR Officer fixed for one floor. Any particular floor will not be audited by the designated officer in that floor. There will by cross audit among the officers.
Data input system for mark: Input above format marks into the software data entry form daily.
7. Effort in maintaining machines:
Total mark for Effort in maintaining machines is 10. Factory Maintenance Department will daily audit about following subject and give mark. For every subject marks will 2. Problem found in 1/2 subject mark will 1, problem found in 3 subject mark will 0 or problem found more than 3 subject mark will -2.
If no problem found than mark will 2. From daily mark average will monthly total mark. Following are the subject details:
(a) Idle machine management (M/C switch off, Needle open, M/C cover, M/C cleanness, Garments on M/C, Without layout m/c in line etc.).
(b) Running m/c management (M/C switch off after leave, Needle down, M/C cover, M/C oil etc.).
(c) Machine cleanness (Daily m/c clean by m/c operator).
(d) Stain pad (Use of pad under presser foot).
(e) Wiper (Use of Wiper in automatic trimming m/c).
- The lowest mark -10.
Maintenance audit Format:
MARKS OF OBSERVATION ON M/C MAINTENANCE
Date:
Audited By: Sign:
|
LINE |
IDLE M/C |
RUNNING M/C |
M/C CLEAN |
STAIN PAD |
WIPER |
REMARKS |
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- Maintenance Dept. needs to provide above data.
Data input system for mark: Input above format marks into the software data entry form daily.
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