Defining Operational Improvements to Increase On-Time-In-Full/On-Time-Delivery Performance for a Mid-Sized Textile Manufacturer
Background and Challenge
The client was a mid-sized textile manufacturer and a leading player in premium shirtings' manufactured custom designed fabrics for global and domestic brands. However, the manufacturing operations were unable to cope with the high volume of DLS (Desk Loom Sample) requirements. There were significant delays in deliveries of DLS/ bulk orders due to the following issues:
- Ineffective capacity utilisation
- Planning systems were inadequate due to the following reasons:
1) Absence of structured planning/ scheduling
2) Inadequate information for monitoring progress and decision making
3) Communication gaps due to lack of defined processes (DLS preparation)
Lack of adherence to manufacturing standard operating procedures (SOP’s) led to quality issues. Thus, the client turned to UC to improve its operations and processes to sustain the growth of the company.
Approach and Recommendations
To improve the operations and processes of the company, UC adopted the following approach:
- Defined and implemented SOPs and an MS Excel based tracking/ management information system (MIS) tool for both the marketing department at the head office and the design studio at the factory
- Identified bottlenecks and implemented improvement initiatives for lead time reduction in DLS preparation, which led to a 40 percent reduction in lead time
- Analysed, defined and implemented a SOP adherence audit process across various production departments
- Developed a MS Excel based tool to optimise dyeing vessel capacity utilization, reducing the lead-time by 7 to 10 days and improving throughput by10 percent
- Developed a production planning and monitoring tool to enable effective planning, scheduling and tracking of order
- Initiated daily production planning meetings to improve co-ordination and effectiveness of planning.
The client benefited with an improvement in its operations with regards to the capacity utilisation, planning and quality issues of the system.