It finally gave us one clear picture of our production floor.
For years, PBK Apparels ran its production lines on Excel workbooks. The operation breakdowns, dividing plans, hourly output sheets and costing sheets were all separate files kept by different people. By the time a problem on the line reached my desk, the day was usually over, and we were explaining yesterday’s shortfall instead of fixing today’s.
This system changed that. Our industrial engineer now imports the buyer’s OB sheet directly, plans the manpower from pitch time, and sets up the line on a map that looks exactly like our floor: every machine, every operator, and who is doing which operation. When a line is out of balance, the system suggests a plan for the people we actually have that day, and it does so the way our supervisors would: the same machine, the next job in the same section, nobody walking across the line. Our IEs trust the suggestions because they make sense on the floor.
Our recorders enter each operator’s output every hour, with a reason whenever someone is below target, and the day’s cutting at the end of the shift. From the dashboard I can see every line’s efficiency, the bottleneck, the reasons for lost hours, and exactly how far each order has to go, from cutting through to packing. I no longer wait for the evening report. I can see it as it happens, even from my phone.
The printed sheets matter just as much to us. The operation breakdown, the line map for the supervisor, the workstation cards at each machine and the costing sheet we send to buyers all come straight from the system, consistent and ready to sign. Our costing is now based on real pitch times, and our quotes go out faster and with more confidence.
Since we moved to the system, hours lost without a reason have become rare, changeovers are planned rather than improvised, and our meetings start from the same numbers instead of arguing about whose spreadsheet is right.
What I value most is that it was built around how a Sri Lankan garment factory really works, by people who listened. Every piece of feedback from our IEs, recorders and managers was turned into an improvement, quickly. It has become part of how we run PBK Apparels every day.
Harsha Nissanka
CEO,
PBK Apparels