Factory Monthly KPI

1. 1-0

2. Palmal Group of Industries
ACCL-1(Unit-2) 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 2 82129 18499 3.1%
4.51-7.5 Basic 37 3242054 501735 85.0%
7.51-10.5 Semi Critical 6 268344 30779 5.2%
10.51-15 Heavy Semi Critical 7 371739 31259 5.3%
15.1-20 Critical 3 139172 8205 1.4%
20.1- >=28 Heavy Critical 0 0 0 0.0%
6.95 Basic 55 4103437 590477 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 3 409877 95837 15.7%
4.51-7.5 Basic 27 2684828 415489 68.1%
7.51-10.5 Semi Critical 10 665320 79743 13.1%
10.51-15 Heavy Semi Critical 3 226477 18985 3.1%
15.1-20 Critical 0 0 0 0.0%
20.1- >=28 Heavy Critical 0 0 0 0.0%
6.53 Basic 43 3986502 610054 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 2 107788 25067 4.0%
4.51-7.5 Basic 23 2787457 455673 72.4%
7.51-10.5 Semi Critical 15 1089651 131813 20.9%
10.51-15 Heavy Semi Critical 2 140328 11717 1.9%
15.1-20 Critical 1 80732 5030 0.8%
20.1- >=28 Heavy Critical 0 0 0 0.0%
6.68 Basic 43 4205955 629300 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 1 6020 1400 0.3%
4.51-7.5 Basic 20 1720682 296197 57.7%
7.51-10.5 Semi Critical 11 1208602 149408 29.1%
10.51-15 Heavy Semi Critical 5 862295 65156 12.7%
15.1-20 Critical 1 23490 1450 0.3%
20.1- >=28 Heavy Critical 0 0 0 0.0%
7.44 Basic 38 3821088 513611 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 28 1764586 321226 70.6%
7.51-10.5 Semi Critical 9 565592 67894 14.9%
10.51-15 Heavy Semi Critical 7 714887 56914 12.5%
15.1-20 Critical 4 175435 9108 2.0%
20.1- >=28 Heavy Critical 0 0 0 0.0%
7.08 Basic 48 3220499 455142 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/Sty
ling/Line
Expecte
d
Efficienc
y
Achieve
d
Efficienc
y%
January-22 ACC-1(U-2) 27 55 20 11 15days 67% 60.4%
February-22 ACC-1(U-2) 23 43 17 13 18days 63% 64.3%
March-22 ACC-1(U-2) 26 46 18 15 21days 61% 62.8%
April-22 ACC-1(U-2) 25 38 17 16 24days 65% 64.3%
May-22 ACC-1(U-2) 21 48 16 16 21days 64% 63.0%
G.Total
ACC-1(U-2)
TOTAL
24 230 88 71 20days 64.1% 62.9%

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)
22242 Min. 1,556.94
$ 129,226৳ 0.33% 3201 Pcs 371 1.3 MC 441,208.31
$ BDT 110667
16898 Min. 1,182.86
$ 98,177৳ 0.27% 2586 Pcs 282 1.2 MC 307,021.60
$ BDT 90348
56140 Min. 3,929.80
$ 326,173৳ 0.84% 8400 Pcs 936 3.7 MC 409,701.14
$ BDT 106654
0 Min. -
$ -৳ 0.00% 0 Pcs 0 0.0 MC 368,913.38
$ BDT 99916
0 Min. -
$ -৳ 0.00% 0 Pcs 0 0.0 MC 333,879.00
$ BDT 108257
95280 Min. 6,669.60
$ 553,576.8৳ 0.31% 14186 Pcs 1588 1.3 MC 1,860,723.44
$ BDT 103358

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
Month
Uncutt
Threads
Open
Seam
Without
Bartack
Skipped
Stitch
Up &
Down
Pleat
Uneven
Stitch
Raw
Edge
Broken
Stitch
Jan-22 50% 15% 10% 8% 6%
Feb-22 50% 8% 15% 10% 6%
Mar-22 50% 6% 8% 18% 11%
Apr-22 48% 8% 11% 6% 18%
May-22 50% 5% 19% 8% 13%
AVG 49.6% 10.2% 7.8% 7.7% 12.8% 8.1% 11.8% 10.5% 15.8%
Top 5 Defects of Last 5 months

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 Raw-edge

34. 1-33
Root cause & Action plan of Skip stitch

35. Thank You