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Table-1: Factor analysis table for losing accuracy in trims and accessories management | |||||||
S/L | Types of Delay | Causes | Responsibilities | ||||
1 | Man | Machine | Management | Materials | Others | ||
Manufacturing Delay | 1. Trims and accessories Late approval | yes | yes | ||||
2. Lack of follow-up and creatin pressure on supplier | yes | yes | |||||
3. Raw materials unavailability | yes | yes | |||||
2 | Supply-Cain | 1.Single sourcing | yes | ||||
2.Poor plant layout | yes | yes | |||||
3.Poor understanding | yes | ||||||
3 | Store-Management | 1.Counting mistake | yes | ||||
2.Overlook notification | yes | yes | |||||
3.Manual data managing sheet | yes | yes | yes | ||||
4.Communication gap | yes | Yes | |||||
5.Memory issues | yes | yes | |||||
6.Mis-understanding with supplier and Production manager | yes | yes | |||||
4 | Communication Delay | 1.Manual TNA | yes | ||||
2. Lack of live and real-time data flow | yes | yes | |||||
3. Frequent Load Shedding (internet connection loss) | yes | ||||||
4.Delay mailing | yes | ||||||
5.Memory loss | yes | ||||||
5 | Technology | 1. Tendency to not accepting new technology | yes | yes | yes | ||
2. Lack of Training to cope up with new technology | yes | yes | |||||
3. Complexity of the user module | yes | yes | |||||
6 | Documentation | 1. P/O delay | yes | ||||
2. Faulty processing | yes | ||||||
3. Overlook | yes | ||||||
4. Poor skill | Yes |
Table-2: ‘Trims and accessories management accuracy Index’ data table before implementing DMAIC, the 5S concept with Demo of live data stream technology (MS excel synched with google sheet.) | ||||||
S/L no. | Title | Availability (0) | Low (1) | Moderate (2) | High (3) | Excellent (4) |
1 | Communication Skill | yes | ||||
2 | Human Efficiency | yes | ||||
3 | Supply Chain Efficiency | yes | ||||
4 | Data management efficiency | yes | ||||
5 | ERP Management | No ERP software | ||||
6 | Modern Technology base TNA management | NO | ||||
7 | Auditing accuracy | yes | ||||
8 | Strategic Management skill | yes | ||||
9 | Change acceptance mentality | yes | ||||
10 | Data safety | no |
Table-3: Rating Scale | |
Rating | Percentage |
Very Below standard | 1-30 % |
Below Standard | 31-60% |
Standard | 61-80% |
Excellent | 81-100% |
Calculation of data from table-2 | |||
Attained Point | Total Point | Percentage | Rating Status |
14 | 40 | 35% | Below Standard |
Table 4: Solution for all major problems with its causes | ||
Area | Causes | Solution |
Man | Lack of interest | Improve supervision |
Lack of skill | Arrange training and skill improvement session | |
Lack of knowledge and motivation | Arrange motivation sessions and increase incentives | |
Unwillingness to accept new and updated technology | Grooming | |
Machine | Information gap and communication gap | Add ERP software |
Load shedding (internet down) | Use a high power generator | |
Poor data management policy | Use MS excel synching with google sheet | |
Poor tracking and follow-up mechanism of the current status of the materials and processing | Use ERP | |
Management | High dependency on a single supplier for trims and accessories | Change the strategy of the supply chain. Subscribe multi-sourcing |
Manual communication and data management | Use live stream data flow technology | |
Poor planning strategy | Recruit planning manager | |
Unhealthy documentation process in the order procedure | Recruit factory account officer | |
Materials | Having faulty raw materials by the supplier for producing trims and accessories | Ensure strict quality control |
Poor quality materials supply | Ensure better dealings with the supplier |
Calculation of data from table-2: | |||
Attained Point | Total Point | Percentage | Rating |
29 | 40 | 72.5 | Standard |
Table-5: ‘Trims and Accessories Management Accuracy Index’ data table after implementing DMAIC, the 5S concept with Demo of live data stream technology (MS excel synched with google sheet) | ||||||
S/L no. | Title | Availability (0) | Low (1) | Moderate (2) | High (3) | Excellent (4) |
1 | Communication Skill | yes | ||||
2 | Human Efficiency | yes | ||||
3 | Supply Chain Efficiency | yes | ||||
4 | Data management efficiency | yes | ||||
5 | ERP Management | No ERP software | ||||
6 | Modern Technology base TNA management | yes | ||||
7 | Auditing accuracy | yes | ||||
8 | Strategic Management skill | yes | ||||
9 | Change acceptance mentality | yes | ||||
10 | Data safety | yes | ||||
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