MOM - 6S Implementation Progress Review with HOD Lean Process Excellence
Date: Jan 10, 2025
Participants:Miss Roshani ,Muhammad Shoaib, Hamza Khalid, Abu bakar Manzoor, Waqas Ali, Adeel Ghafoor, Alishba Nasir, Awais Ur Rehman, Ali Waqas, Ali Shah, Syed Asif Bukhari
Sr # What Who When
1 Control Mechanism need to be introduced to ensure 6s implementation. ( Written SOP ) Shoaib 7-Feb-25
2 Audit need to be conductted in first half and clear the highlighted NC's in second half with process owner. Shoaib, Asif
3 Steering Committee and Zonal Structural Committee need to be operational. Hamza
4 Zonal Leader Engagment mechanism need to be developed.(Activities + % Criteria) Hamza 7-Feb-25
Strength the Training Processs through attractive curriculum development (creatively articulate for 1 department and engage
5 Hamza
process owner at initial step)
6 Source of Material flow from bundling to embellishmnent need to be define. Adeel, Abu Bakakr 12-Jan-25
8 Hoshin Project need to be started after completion of current projects Shoaib, Abu Bakar, Hamza
10 Restucturing need to done after completion of current Project Miss Roshani , Shoaib
11 Red Tag Area need to be allocated by discussion with Bilal . Shoaib From 15th February
12 Trolley Ordering need to be done Shoaib 28-Feb-25
13 Bin Standard need to be reviewed through analysis and by incorporating process owner view and handling perspective. Abu Bakar
Locator
14 Develop Locator & Bin Standard as per Mr. Aqeel suggestion and check feasibility Abu Bakar, Shoaib
Bin
15 Start Machine cleaning at stitching area and fix the frequency. Hamza , Awais
17 Introduce Audit Mechanism for Machine Cleaning and Admin Cleaning Hamza
18 Develop 6s plan for stitching module and discuss with Khalid. Shoaib, Hamza, Awais 11-Jan-25
MOM - Action Plan based on PAA
GEMBA Highlights
Date: Jan 20, 2025
Participants: Aqeel Ahmad, Miss Roshani, Muhammad Shoaib, Hamza Khalid, Adeel Ghafoor
Agenda Points :
1. Relaxation Area
2. WIP Tracebility
3. 6S
4. Visual
What Who When
6S Steering committee plan on Tuesday (Check available of Mr. Iqbal &
1 Mr. Saeed) and complete the PPT. Hamza 21-Jan
LCD Installation and KPIs Visualization complete in Fabric ( Knitting,
2 Lot making, Dye house, Finishing, Garment Laundry) Shoaib 24-Jan
LCD Installation and KPIs Visualization complete in Garment
3 (Relaxation, Cutting, Printing, Embroidery, Sewing). Shoaib 30-Jan
4 Arrangement of Mini Computer Shoaib
5 Purchase the USB for the LCDs Shoaib 24th jan
5 Arrangement for 43" LCDs. Shoaib 20-Jan
6 Arrnagement of Printer & Portable . Shoaib
7 Kaizen Implementation by PE Team. Shoaib 30-Jan
8 Meeting with Shahnawaz for the Bin Standard Implementation. Shoaib 21-Jan
9 Daily Process Audit of Garment Division 2 Adeel 27-Jan
10 Email to Mr. Ejaz to add TNA in WIP Report. Adeel 27-Jan
11 Develop Process of Online packing.
12 New Directions from Mr. Aqeel.
12 Lean Training program for 5 Modules to make model modules. Roshani 30-Jan
12 Bi-Weekly PE progress review by PAA.
6S Steering committee review should be for all division including active
12 wear.
12 Develop PE Dashboard to share the weekly progress to PAA. Shoaib 31-Jan
Categorize fabric type wise as per families (Relaxation Time and Air
13 Flow). Alishba 25-Jan
Trolley Parking Area (Conditioning Area,Shelf for Stacking,Space
13 Requirement, Feasibility Study). Adeel 30-Jan
Excel Base of Locationing of i. Ready for Relaxation Area [Link] Input
13 [Link] Trolley Parking [Link] Input Area. Adeel 27-Jan
6S Implementation Plan - Phase 1
1- Complete the layout of M1 from induction point to packing output along with Number of Bins require, Demarcati
Pallets, etc
1.1- Calculate total number of bins within M1 area
1.2- Specifi the dimension and area for input area
1.3- Define how many input table area required at each module along with total number of input tables required
1.4- Number of bins required for excess pannel under input table
1.5- Finalize the demarcation location of all modules
1.6- Waste bins require for waste collection along with waste removal process and mechanism within the module
1.7- Bins required for stain and rejects under endline table
1.8- Bins required for accessory (packing) under packing table
1.9- calculate Carton making table required in M1
1.10- Pallets required for packed carton
1.11- Number of bins required for leftover fabric and garments
1.12- Specify area for leftover keeping along with demarcation plan
1.13- Number of bins required for Hold under accessories
1.14- Specify area for hold stock under accessories along with demarcation plan
1.15- Finalize the layout of off line packing area along with input bins required, tables, pallet, etc
1.16- Finalize the layout of after wash module along with racks required at input, tables, along with flow.
Sr No
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
Tasks
KPIs Digitalization process with proper Standup meeting structure in Garment & Fabric Divisions
Arrange Mini Computers for the LCDs
Develop PE Dashboard to share the weekly progress to PAA
Trolley Availability inhouse ( 50% of Trolley order Quantity )
Support PE Team in Implementation & overcoming the Implementation Challenges
PE LSW Meeting Process
6S Audit random audit for critical areas & Train the auditors
Ensure the 6S Audit being Conducted in Fabric and Garment div. and Share with the Plant heads
Trolley Availability in Induction ( Trolley Availability process )
Basic Standard Document should be developed in Stitching Area with proper Controls Rule & Comm
Agreement with Process Owners. e.g. Layout, Polybag, Material handling, Empty Carton,
Kaizen Collection and Review Process from PE Team , Practitioners programs, Process owner.
6S Practitioner Program Initiation in Stitching Floor 2.
PDCA Certification Format need to be completed and three certificate need to be printed for the ce
Hamza , Imran)
Develop the list of Process Standards that should be followed by every person in Induction Factory
Develop the list of Process Standards that should be followed by every person in Stitching Floor
OK and Not OK Picture in Stitching floor ( foot on wall, no garment area, induction keeping way, Pa
make Video to communicate the standards
Complete 6S Practitioner program trainings in Stitching Floor 1.
100% implementation of Module Standards in Stitching Floor 1
100% demarcation of input, output and empty Carton in Stitching Floor 1
100% Implementation of dust bins/ waste bin standards in Stitching Floor 1
100% Implementation of dust bins/ waste bin standards in Stitching Floor 2
100% implementation of area demarcation, Racks, Customer Pockets, labelling of trollies and bins
factory
Implement 5 Kaizen
Implementation of 6S Practitioner Program
100 % training of Induction factory NEs on 5S & Machine Cleaning
Implement 5 Kaizen in Induction
6S Audits of garment div. / Fabric Div.
PR generation & follow-up for garment & Fabric Div.
Clearing the 6S repeating NCs with Process Owners.
Implement Office Standard in all the areas in Garment and Fabric Division of Plant 2.
Kaizen Implementation Process Development.
6s Reward Mechanism Need to be Defined as per Mr Aqeel Suggestion
Complete 6S Practitioner program trainings in cutting
Introduce Audit Mechanism for Machine Cleaning and Admin Cleaning
Follow-up and Ensure the Implementation & Capture the Challenges
Everyone should update their own slides on daily basis and share with hamza on weekly basis
6S Audit Mechanism in Fabric Div. & Start Weekly Audit and share with stakeholders
6S Audit of Fabric Division
Daily WIP report
Finishing WIP reduction to achieve the Target WIP
WIP Tacking project implementation complete In Garment.
WIP Tacking project implementation complete In Fabric.
Daily Process Audit in Garment Start from 10 Feb.
Develop LAB Action Plan & Support in implementation and Follow-up
Relaxation process Streamline
100 % implementation of 6S Standards
Cleaning Process implementation process on 100% machines ( Videos, SWS, Frequency, Time )
WIP Tacking project implementation complete In Garment
WIP Tacking project implementation complete In Fabric
Relaxation process Streamline
Relaxation process audit Daily
Follow – up actions & check evidence and weekly share with HOD & Team
Process Audit of Fabric Division.
Team Initiatives in February - Weekly Progress
Name Week-5
Shoaib
Shoaib
Shoaib
Shoaib
Shoaib
Shoaib
Shoaib
Shoaib
Shoaib
Abu Bakar
Abu Bakar
Abu Bakar
Abu Bakar
Abu Bakar / Adeel / Umer
Abu Bakar / Adeel / Umer
Awais / Abu Bakar
Awais
Umer & Awais
Umer & Awais
Umer & Awais
Umer & Awais
Umer
Umer
Talha
Talha
Talha
Asif
Asif
Asif
Asif
Hamza
Hamza
Hamza
Hamza
Hamza
Hamza
Hamza / Ali Waqas
Ali Waqas
Ali Waqas
Ali Waqas / Adeel
Adeel
Adeel
Adeel
Adeel
Adeel
Ali Shah
Ali Shah
Alishba
Alishba
Alishba
Alishba
Alishba
Waqas
ly Progress
Week-6 Week-7
Week-8 Legends
Completed
Not Completed
In-Progress
MOM - Current Project Progress Review Meeting with Lean HOD.
Date: Jan 24, 2025
Participants:Miss Roshani ,Muhammad Shoaib, Hamza Khalid, Abu bakar Manzoor, Adeel Ghafoor, Alishba Nasir , Talha Ghafoor , Muhammad Umer
Agenda Points :
1. Relaxation Area
2. WIP Tracebility
3. 6S
4. Visual
What Who When
LCD Installation and KPIs Visualization complete in Fabric ( Knitting, Lot making,
1 Shoaib 25-Jan
Dye house, Finishing, Garment Laundry)
LCD Installation and KPIs Visualization complete in Garment (Relaxation, Cutting,
2 Shoaib 27-Jan
Printing, Embroidery, Sewing).
3 Develop PE Dashboard to share the weekly progress to PAA. Shoaib 28-Jan
4 Kaizen Implementation by PE Team. Shoaib 30-Jan
Control Mechanism need to be introduced to ensure 6s implementation. (Written
5 Shoaib 7-Feb
SOP )
Abu Bakar,
6 Develop Locator & Bin Standard as per Mr. Aqeel suggestion and check feasibility 10-Feb
Shoaib
7 Red Tag Area Need to be Defined and Operatoinal by discussion with Bilal Shoaib 15-Feb
8 Arrangement of Bin Standard Implementation with Shahnawaz Shoaib 17-Feb
9 Arrangement of Trolley Through Ordering Shoaib 28-Feb
10 Arrangement of Mini Computer Shoaib 24-Mar
11 Arrnagement of Printer & Portable . Shoaib 24-Mar
12 Introduce Audit Mechanism for Machine Cleaning and Admin Cleaning Hamza 7-Feb
13 Zonal Leader Engagment mechanism need to be developed.(Activities + % Criteria) Hamza 10-Feb
14 Start Machine cleaning at stitching area and fix the frequency. Hamza 14-Feb
Excel Base of Locationing of i. Ready for Relaxation Area [Link] Input
15 Adeel 29-Jan
[Link] Trolley Parking [Link] Input Area.
Process Owner verfication on WIP Tracebility Plan from FFS Issuance to Cutting
16 Adeel 29-Jan
Output.
Calculate manpower of CTEX Machine Area as per Loading /Unloading, CTEX
17 Adeel 30-Jan
Operater, CTEX Supervisor.
Location Induction Area Induction Area
Category Cut Panels Module Waste
Storage Mode Bin Waste Bin
1. Plastic Waste
2. Paper Waste
1. WIP team will keep induction of 4 Hrs
3. Admin team will collect the
2. Unload the bins infront of the module
Method waste 3 times a shift
3. Bins will be stacked at demarcated input
i. 10:30 - 10:45
area
ii. 01:15 - 01:30
iii. 04:30 - 05:00
Qty/Module 15 2
Qty for M1 420 56
Area Required (Sq Ft) 672
95
7.91666666666667
8
2.75
Induction Table Machines area Endline Table Pressing Measurement
Excess Panel Basic Rejection/Stain Garment for Pressing NA
Bin Machines Bin Work Aid Table
1. Extra panels
1. 17 sewing 1. Rejected/Stain
2. Damage
machines for basic Garments will place in 1. 6 pcs Wip for
Panels
articles (Tee, Tank designated bin pressing
3. Extra Fabric
Top, Sweat)
1 17 2 2
28 483 56 56
8064 10
5
Final Inspection Packing Table Output Carton Stacking
NA Packing Accessory Loose Carton Packed Carton
Bin Pallets Pallets
1. Accessories Bin
2. Accessroies
return bins
1. Loose [Link]
[Link] bin
carton carton
4. Empty carton
(without bin under
the table)
3 1 2
84 28 56
336 672
Sewing Modules
Item Dimesnion Qty/Module Total (28 Modules)
Input Bins 8' x 2' 15 405
Input Table 4' x 4' 1 27
Leftover Holding Area 13' x 2' 16 for five modules 96
WIP Pending at Packing Accessory 13' x 2' 16 for five modules 96
Pallets 4' x 3' 3 84
After wash Module
Input Racks for After wash Module 7' x 3' 4 4
Trimming Machines 4' x 1.5' 6 6
Size wise tables 8' x 4' 2 2
HTL machines 3' x 1.5' 4 4
Sewing machines 4' x 1.5' 7 7
Endline tables 8' x 4' 3 3
Touching table 8' x 4' 1 1
Offline Packing Module
Input Bin for Offline Packing 8' x 2' 30 30
Packing Table for Offline Packing 6' x 4' 4 4
Pallets for Offline Packing 4' x 3' 8 8