© 2014, VIYELLATEX Group, All rights reserved.RESTRICTED
ISS Projects for VTL
VIYELLATEX group ISS
2 © 2014, VIYELLATEX Group, All rights reserved.RESTRICTED
ISS Focus Area.• Business Monitoring & Controlling
– Identifying gray areas of the business processes , standardizing flow of work, restricting unusual transaction for better and smoother business operation.
• Process Automation– The focus here was to automate the
business processes for faster and accurate execution of tasks thus enabling business to thrive for more
• Go Paperless– Converting paper base activities into a
systematic one for saving paper, man hour and achieving control at the same time.
3 © 2014, VIYELLATEX Group, All rights reserved.RESTRICTED
H o s p i t a l I n f o rm a t i o n M a n a g e m e n t S y s t e m
Previous Process & Issues: Manual entry in register for
patient history & medicine stock No reporting & analyzing of injury
& seasonal diseases & medicine issues
New Process & Benefits:
System generated prescription for patient entry & automated medicine Inventory
Disease & Injury trend analyzing
Medicine issue track Report visibility for
management
87% Reduction in Injury from Jan to May
January February March April May0
50000
100000
150000
200000
250000
300000
20132014
34% Reduction in Medicine cost than Jan to May of 2013
4 © 2014, VIYELLATEX Group, All rights reserved.RESTRICTED
S a m p l e Tr a c ke r
Previous Process & Issues: Manual process for sample
development so visibility of task missing
No proper reporting & analyzing of data
Maintained Excel Document
1123 pc of Sample creation of 13 Buyer from Jan - May
Soliver Puma M&S NEXT PVH Esprit Olymp0
50
100
150
200
250
300
350
400
6788
55
10
112 108
9
103
364
117 125155 145
18
Number of Order Con-firmedNo. of Sample De-veloped
New Process: & Benefits End to end automated Sample
development Process Buyer wise production
confirmation report against each sample creation
Analyzing on fabric issue for future use
Report visibility for management
Auto mail to MM, DPD
42% sample order confirmed
5 © 2014, VIYELLATEX Group, All rights reserved.RESTRICTED
S a m p l e Tr a c ke r
M&S Esprit Olymp DK P&C Saccor Puma Next PVH Soliver0
100
200
300
400
500
600
700
800
900
83129
7314 1 18
773
92 66106
56 49 413 1 0 21 8
49 35
No of Sample Input in System
System Input Not in System
M&S Esprit Olymp DK P&C Saccor Puma Next PVH Soliver0%
20%40%60%80%
100%120%
40% 28% 36%18%
50%
0% 3% 8%43%
25%
60% 72% 64%82%
50%
100% 97% 92%57% 75%
Sample Tracker Usage %
%of Not Use Usage %
84%
16%
Overall Sample Tracker Usage
System InputNot in System
6 © 2014, VIYELLATEX Group, All rights reserved.RESTRICTED
Re c h e c k Tr a c ke r ( Fi n a l I n s p e c t i o n )
Previous Process: & Issues Manual Entry in register of
inspection status Excel Reporting & Manipulation of
data possible No reporting , monitoring & data
Analyzing
New Process & Benefits: Automated inspection tracking
system of finished products No Excel sheet use & Paper
wastage Finding out the root cause of
rejection & recheck reason of finished products
Reporting & Analyzing of system data (Buyer wise, defect category wise, unit wise..etc)
11% Reduction in Defects quantity from Jan to May
Jan Feb Mar Apr May2100
2200
2300
2400
2500
2600
2700
2800
2900
No. of De-fects
7 © 2014, VIYELLATEX Group, All rights reserved.RESTRICTED
I n l i n e Re c h e c k Tr a c ke rPrevious Process: & Issues
Manually maintained number & type of defects per sewing & finishing line wise
Excel report maintained Multiple QI report in each line &
manipulation possible No reporting & visibility of process
to management
New Process & Benefits Tracking defects line, floor, unit, buyer
wise Easily updating QM information to SAP Reduction of defects & recheck
number in pre-final & final inspection Analyzing system & reporting to
management Taking action against increasing of
DefectsOil Spot % Dirt Spot % Stitching Problem %
0.00%
1.00%
2.00%
3.00%
4.00%
5.00%
6.00%
3.60%
2.45%
4.16%3.91%
2.89%
5.40%
AprilMay
8 © 2014, VIYELLATEX Group, All rights reserved.RESTRICTED
Pro d u c t i o n Tr a c k i n g S y s t e m ( P T S )
Existing Process & Issues: Supervisors fill up the PTR
sheet & send leftover & rejected garments to PTR Team
PTR team sends them to LMS weekly basis by SAP challan
No visibility of PTR report to management
Manipulation possible PTR Team is under Production
dept.
New Process & Benefits: An automated end to end system
(cutting to finishing dpt.) An Independent PTR team will
take input from cutting, sewing & finishing separately & will post the data to the system except data of incomplete goods
Goods will be segregated and packed in PTR room & send to LMS for selling
Visibility of PTR to management & tracking missing garments
Proper grading will ensure proper price of garments for selling
9 © 2014, VIYELLATEX Group, All rights reserved.RESTRICTED
Wa s t a g e M a n a g e m e n t ( W M )Existing Process & Issues:
No standard process/SOP for wastage declaration so individual methods for each units or departments
Mixed wastage item are measured by weight & send to wastage store but wastage store receives without measuring weight
No visibility on movement of wastage to management
No monitoring & wastage control not properly utilized
New Process & Benefits: An automated system by following SOP
for managing waste for Knitting, Dyeing, Garments
Cross checking while sending & receiving goods
Proper item segregation & items are standardized as left over & wastage
Visibility of wastage movement & selling to management by reporting
Properly history maintaining of sold items
Microsoft Office Word Document
10 © 2014, VIYELLATEX Group, All rights reserved.RESTRICTED
N e e d l e Tr a c ke rPrevious Process & Issues:
Manual register entry for needle usage & issuing
Update in SAP was done cost center wise
No Reporting & instant visibility of needle usage to line or individual person wise
Manipulation possibleNew Process & Benefits:
System keeps records of needle usage unit, floor, line, machine, size & person wise
Visibility of needle usage ensured to management & save cost
Historical data analysisJanuary February March April May0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
Monthly Needle Usage
Monthly Needle Usage
11 © 2014, VIYELLATEX Group, All rights reserved.RESTRICTED
H o u r l y P ro d u c t i o n M o n i t o r i n g ( H P M ) ( V T L , I S M L )
Existing Process & Issues: PIS team manually update the
data & excel reporting is maintained
System update is done from that excel sheet which is kept on shared drive
Manipulation possible & no size wise & real time visibility of hourly production input
PIS team is under production dept.
New Process & Benefits:
An independent team will collect the data every hour and update in system to see live update on dashboard
Target will be set by IE concern & System will show target VS. actual hourly performance in graphical interface
Visibility of hourly production status & Target Vs. Actual hourly production to management
Reduce data entry people
ISML floor wise hourly production report
Production Summary - Last Working Day (Date: 06.07.2014)
Target Output Achievement
Sewing Summary of ( ISML1 + ISML2 ) 38302 36570 95.48 %
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