Real-time Production Tracking System - All that You will Get from Scanning Bundle Tags

A real-time production tracking system has the capability to capture bundle start time (with timestamp) and bundle end time at each operation for each bundle and units. ( I am talking about the system for readymade garment manufacturing). You can capture workers standard work time, idle time, and non-productive time against various non-productive categories. All these trackings are done at the operator's terminal by operators.

The objective of a real-time system is getting accurate information at the right time. So that line supervisors and the work-study team can act for managing the line and sewing floor. In a bigger object, managing orders and reducing labour cost. You can’t imagine the depth of data you can have through bundle scanning.

All that you will get from an RFID based real-time system.

Cycle time of each operation as system captures start and stop time for each bundle (or each individual unit)

SAH produced by individual workers and by the line

Standard hours worked (attended) by employees

Non-productive time of individual operators

You can track most critical non-productive items and total hours spent on non-productive work.

You can track WIP in between operations in a line (style) and in between sections

You can track WIP in between sections (garment parts) and departments

You can make a line balancing graph with actual production data against each operation (and workstation)

You get produced garment quantity of each employee from each operation on real-time

Operators skill data will be built up automatically

From the actual operation cycle time, you can compare your operation standard time (SAM/SMV) to the average operation cycle time.

You can use the operation cycle time as time study data. The system keeps a record of bundle start and bundle stop time. In time study, you need that bundle completion time.

You can do operator wise capacity study using cycle time data

Initial line balancing and line layout can be made using historical data (operator skill level)

You can develop production reports as per your custom requirement

You can track at what time an operator starts working on a bundle. You can track how much time operators are working on their job.

You can measure accurate on-standard efficiency of your employees

You can identify your low skilled operators and high performers from the system data

You can map the learning curve of a style

You can measure new operators learning curve

You can compare actual operations cycle time of different operators working on the same operations

You can calculate accurate employee earning

Bonus amount calculation and distribution of bonus will be easier, as all the performance data are available and accurate

You can stop and reduce missing of garments from the bundle

You will have historical data for all kind of data analysis. – employee efficiency, line efficiency, lost-time, order completion date, production data, WIP etc.

You can motivate your workers by showing them their actual performance and giving them a chance to improve their performance

The real-time product tracking systems come with standard report sets. You can develop as many custom reports as you need from the database.

The listed above items are available when data capturing is designed for capturing bundle scan timestamp and bundles are scanned correctly without missing scanning at the workstation.

The most important thing is, by using an RFID based real-time production tracking system, you will have information and data for real-time as well as historical data analysis. With the available data, you can view data in many ways as you can.

production tracking system
A real-time production tracking system

Prasanta Sarkar

Prasanta Sarkar is a textile engineer and a postgraduate in fashion technology from NIFT, New Delhi, India. He has authored 6 books in the field of garment manufacturing technology, garment business setup, and industrial engineering. He loves writing how-to guide articles in the fashion industry niche. He has been working in the apparel manufacturing industry since 2006. He has visited garment factories in many countries and implemented process improvement projects in numerous garment units in different continents including Asia, Europe, and South Africa. He is the founder and editor of the Online Clothing Study Blog.

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