This guide is tailored for Production Managers in the garment manufacturing industry using the Garment IO Platform. It provides detailed instructions on managing production processes, setting up system preferences, and monitoring performance.
Overview of Role and Responsibilities
As a Production Manager, your primary responsibilities include:
- Understanding how employee time is allocated across various tasks.
- Understanding the different efficiencies calculated by the system.
- Understanding the different stages of production orders and the progress of batches within the production process.
- Managing requests made by employees when they are idle.
- Understanding the different processes involved in garment manufacturing and the time it takes to complete a specific task.
- Getting Started with the Platform
Before diving into specific tasks, ensure you are familiar with the basic navigation and features of the platform. Log in with your credentials and explore the platform, menu options, and settings.
Before diving into specific tasks, ensure you are familiar with the basic navigation and features of the platform. Log in with your credentials and explore the platform, menu options, and settings. Main Concepts
Set Up Initial Data
- Set up factory settings:
- Decide whether to allow employees in the factory to request idle time.
- Determine whether to integrate fingerprint devices with Garment IO.
- Decide whether the factory will use batch grouping.
- Choose the preferred view in the device for employees, including how to display production and target, and in which language the device should be.
- Decide on the minutes that can be used as tolerance between shifts, determining which shift should be added if the employee arrives early or leaves late.
- Set the maximum allowable missing processes on batches before the device starts sending error messages (recommend between 3 and 5).
- Set the maximum number of days allowed on orders without any progress before the system automatically changes the order status to stopped.
Monitoring Tasks
Hourly Monitoring:
- Pinpoint bottleneck processes in real-time and take actions to resolve them to ensure daily targets are met and no process is overloaded.
- Monitor the hourly throughput of each process, employee, and style to maintain a balanced line.
- Review section/line performance cards to determine if an overtime shift is needed and notify the management team and workers early.
- Check pieces ready for production on each process inside the section using the WIP report to pinpoint bottleneck processes.
- Check lines efficiency and the styles they have worked on so far.
Daily Monitoring:
- Compare yesterday's wasted time with today's to identify any progress.
- Check yesterday's worker efficiency to motivate employees and determine if additional training is needed.
- Assess the number of pieces under the target and take actions for the next day to ensure the production target is met.
- Identify pieces still in repair and take immediate action to avoid extended delays.
- Evaluate section/line throughput with order details and plan how to increase it the next day.
- Check a specific employee's timeline to know what they have done each day with detailed information.
- Review a specific production order's information, including production details, quality details, and a detailed costing report.
- Analyze the reasons behind accepted idle times to minimize them the next day and increase operational efficiency.
Weekly Monitoring:
- Assess improvements or declines in wasted durations using the wasted duration report.
- Review the Gantt Chart plan to know upcoming orders and determine if training is required for new styles and processes.
- Identify common idle reasons and work on reducing idle time.
- Pinpoint common machine issues and collaborate with the maintenance team to minimize downtime.
- Evaluate collective metrics to determine if employees are overperforming or underperforming using the employee scorecard.
- Analyze quality defects found in inline and station inspections to reduce them in the future.
Monthly Monitoring
Assess overall performance metrics for the month to identify top and underperforming employees using the
employee efficiency page.Compare actual performance against the plan on the
Gantt chart and make decisions to ensure future orders meet planned targets.
Troubleshooting and Support
For any issues or questions, refer to the troubleshooting section or contact support for assistance.
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