Information at your finger tips RFID tracking system on the sewing floor

Sabre Technologies (Pvt.) Ltd., is an IT company that is focusing on developing productivity improvement systems for the apparel industry. Its flagship product RAPTOR, which encompasses software as well as proprietary data capture units, is a Real Time Production Floor Management System that facilitates the adoption of a process focused operating model by apparel manufacturers. The product covers the entire production process from cutting to finished goods and also encompasses ancillary processes such as quality and machine management.

RAPTOR in itself can be described as a RFID (Radio Frequency Identification)-aided effective production monitoring tool which helps count and track items flowing through the main segments of the supply chain, upstream, mid-stream and downstream. RAPTOR helps manage workstation-wise WIP by eliminating the wastes of waiting through multi-unit coordination, waste of transportation through electronic transfer of data and waste of overproduction through real-time WIP information. On the whole RAPTOR plays a pivotally important role in driving the shop floor towards a lean one which contributes to maximize flow and eliminate waste on the shop floor. This article details a hypothetical proposal to implement the system for 13 production lines to track either line wise performance (meaning work centre wise tracking) or operator wise performance (meaning workstation wise tracking).

By RFID tracking the information generated is available on a real time basis (up-to-minute vs. up-to-date) and is geared to be delivered to all levels of employees starting from the MO (machine operators) and mechanics up to senior management (enterprise information vs. management information). The objective is to empower employees at all levels to take responsibility for their sphere of activity through pro-active decision making.

The financial proposal for the project is based on the following hypothetical assumptions at any manufacturing organization:

Data Capturing process

Each Machine Operator will be given an RFID tag to report their presence. Operator should tag into Odyssey DCU (RFID Device Controller Unit) once reported to the Work Centre and tag out when going out or moving from that work centre. WIP Tracking, Bundle movements, Produced minutes will be tracked either at each work centre or each work station. RFID tag will be attached to each bundle through a “Tag Allocation” process in ‘Bundle handling area’. Bundles will be issued to relevant work area through a “Bundle Issue” Application in the system. Off Standard Time (downtime) reporting will be tracked either for each work centre or each workstation.

Each Supervisor will be given two RFID tags to report Off Standard Time for machine-related and general downtime recording. Each mechanic will be given a RFID tag to respond to machine related breakdowns. Downtime should be reported by Line Supervisor by tagging in the relevant tag into the relevant workstation given for the downtime type. Mechanic should respond to the reported downtime by tagging in to the relevant workstation and should tag out once the job is completed. Mechanic’s actions are confirmed by the Supervisor by tagging out the relevant downtime in the workstation.

Endline Quality Check functionality uses the Odyssey DCU with a numeric keypad to capture the related quality information at final inspection. Data will be captured for each bundle and with the pre-defined quality defects/rejects codes against a sewing operation. The details of the equipments are given in Tables 1 and 2.

Project Implementation

A project team headed by a Project Manager for the implementation of the system would need to be formed. The team composition of the project recommended includes besides one person from Work Study/Production on a full-time basis to act as a Project Manager, some people on a part-time basis to carry out specific tasks that include one person each from IT, Cutting and the Quality team.

The Manager in-Charge of Production would need to be available for weekly progress meetings. All personnel attached to the project would have to be given time off from their regular duties to be trained on the use of the RAPTOR. Total No. of days for Server Setup, Network Testing, Master Data Setup, Installation will be 11 days for line wise implementation and 8 days for operation wise implementation. Training & Implementation of 520 Sewing Work Stations will be 13 days and Roll out and Live run would take another 4 days. Thus total time frame for project implementation would be from 25 to 28 days.

Training

While Sabre will provide train-the-trainer training to a lead batch of power users selected from different disciplines on the use of the system, the customer will be required to organize user-to-user training for the rest of the staff.

Project investment

The total investment for the selected modules of the RAPTOR, including   proprietary hardware and implementation services supplied by Sabre is mentioned in Tables 3 and 4.

Total cost of the Raptor system is US $ 1,08,131/- for operator wise  performance tracking and US $ 19,982 for line wise performance tracking.

Return on investment and payback period

The return on investment and payback period is calculated as follows:

Number of Operators = 520

Chargeout rate = US $ 5.23 per hour per operator

At current efficiency of 42%, earning capacity per month = US $ 1,64,481.41

(520 operators x 8 hours a day x 18 days a month x USD 5.23 x 42% efficiency)

With an increase of 2% efficiency, earnings per month = US $ 1,72,313.86/- per month

(520 operators x 8 hours a day x 18 days a month x USD 5.23 x 44% efficiency)

Therefore the Return on Investment = US $ 7,832.45/- per month

Total cost of the Raptor system = US $ 1,08,131/- (for operator wise performance) or US $ 19,982 (for line wise performance)

Therefore, the payback period = 14 months (US $ 1,08,131/ US $ 7,832.45) for operator wise performance tracking, and 3 months (US $ 19,982/ US $ 7,832.45) for operator wise performance tracking.

With additional 2 months of implementation and training, the total payback period will be from  months to 16 months.

Why invest in RFID?

The typical apprehension of a garment manufacturer is the cost of any RFID implementation and the extra value for money that one is realizing. A measurable improvement plan will help to realize the benefit faster. RFID or any passive wireless communication device is relatively foolproof method of tracking inventory. The unique advantage of RFID being work in process (WIP) related information can be retrieved by authorized user regardless of where they are physically based. Secondly, RFID ensures non-evasive and non-intrusive but accurate tracking of any style from the piles of WIP in the shop floor which is typical characteristics of any PBU sewing system. The other advantages of using RFID over bar code being the increased amount of data for each bundle that can be stored, and the wash proof, water proof, virtually non-destructible tags are ideal for rugged shop floor practice of any garment manufacturing enterprise.