Weaving Excellence in Apparel Manufacturing- The Success Story of Pee Empro Exports Pvt Ltd

Pee Empro Exports Pvt Ltd is a well-established woven apparel manufacturer with a rich history in the textiles business. With a strong customer base including renowned brands like Gap, Old Navy, Anthropologie, and more, the company has a significant presence in both the US and EU markets. With a monthly capacity of 700,000 units that includes a diverse mix of adult and kids’ clothing, with a specialization in dresses, tops, skirts, and shorts.

Pee Empro Exports Pvt Ltd had been utilizing a prominent system, but encountered certain challenges along the way. In search of an alternative solution that could overcome these shortcomings, they eagerly adopted Stitch. This decision proved to be a game-changer as Stitch effectively addressed numerous issues, leading to exceptional results and significant progress for the company.

Pee Empro Exports faced significant challenges in their manufacturing processes, primarily due to the absence of digitisation and real-time insights. This led to inefficiencies in vital areas like inventory management, centralized planning board, machine maintenance, and resource allocation. Let’s explore each challenge separately:

1. Inventory Management- Pee Empro Exports faced critical inventory challenges with their previous system, lacking real-time visibility into stock levels, demand patterns, and supplier data. The combination of excessive carrying costs, frequent stockouts, and production delays resulted in significant impacts on their operations, including deadstock, completed orders, and aging of fabric.
2. Planning Board- Pee Empro Exports encountered significant challenges resulting from the absence of a centralized planning board. This lack hindered their visibility into critical aspects such as tracking of purchase orders, monthly capacity, resource allocation, line-wise planning, accurate hour scheduling, real-time delay tracking, and pre-production insights.
3. Operator Production Tracking- Monitoring and tracking individual operator performance on the production floor have been a manual and time-consuming process at Pee Empro Exports leading to difficulties in identifying skill gaps and performance bottlenecks.
4. Scheduled Maintenance- Pee Empro Exports has experienced unexpected machine breakdowns, resulting in unplanned downtime and increased maintenance costs. Reactive maintenance practices have hindered productivity and led to production disruptions.
5. Auto Cut Plan Generation- Pee Empro Exports faces material wastage and higher production costs due to manual cutting plans. There was a lack of a system that could reduce fabric consumption, meet optimum production requirements, and cutting constraints, resulting in limited cost savings and sustainability.

1) Efficient Inventory Management- With Stitch, Pee Empro Exports gains real-time visibility into stock levels, demand patterns, and supplier data, enhancing inventory management. The optimized system minimizes excessive carrying costs, stockouts, and production delays, ensuring efficient and cost-effective inventory control.

2) Enhanced Planning Efficiency with Planning Board- Pee Empro Exports now enjoys seamless resource management, purchase order tracking, monthly capacity planning, resource allocation, line-wise scheduling, accurate hour planning, real-time delay tracking, and pre-production insights, all made possible through our well-organized & centralized planning board.

3) Easy Performance Monitoring- With Stitch, operator performance tracking on the production floor is automated, offering real-time insights into productivity and efficiency. Prompt identification of skill gaps and performance bottlenecks allows Pee Empro Exports to implement targeted training programs and incentives, boosting operator performance and productivity.

4) Smart Maintenance- Stitch facilitated maintenance, ensuring that Pee Empro Exports can proactively address unexpected machine breakdowns. By leveraging machine learning algorithms and IoT sensors, the system anticipates potential failures, enabling timely maintenance, and minimizing unplanned downtime, ultimately improving overall productivity.

5) Auto Cut Plan Generation- Stitch optimized the cut plan generation process for Pee Empro Exports, considering material dimensions, production requirements, and cutting constraints. This reduces material wastage and production costs, promoting sustainability and cost savings.

1) Goodbye to unexpected breakdowns- Stitch machine learning and IoT magic anticipate potential failures, empowering Pee Empro to conduct timely maintenance and minimize unplanned downtime.

2) Improved Workforce Productivity- Stitch helped Pee Empro Exports to unleash the true potential of their workforce by offering real-time insights into productivity and efficiency that helped them to swiftly identify skill gaps and performance bottlenecks.

3) Enhanced Visibility with Stitch Planning Board- Thanks to the Stitch planning board, Pee-Empro gains comprehensive insight into all factory facilities and their available resources. With clear visibility into total booked capacity, available capacity, and total capacity, they now have a holistic view of their production capabilities.

পি এমপ্রো এক্সপোর্টস প্রাইভেট লিমিটেড একটি সুপ্রতিষ্ঠিত বোনা পোশাক প্রস্তুতকারক এবং টেক্সটাইল ব্যবসায় সমৃদ্ধ ইতিহাস রয়েছে।
গ্যাপ, ওল্ড নেভি, অ্যানথ্রোপোলজি এবং আরও অনেক বিখ্যাত ব্র্যান্ড সহ একটি শক্তিশালী গ্রাহক বেস সহ, কোম্পানিটি মার্কিন যুক্তরাষ্ট্র এবং ইইউ উভয় বাজারেই উল্লেখযোগ্য উপস্থিতি রাখে। মাসিক ৭০০,০০০ ইউনিট ধারণক্ষমতা সহ, যার মধ্যে প্রাপ্তবয়স্ক এবং শিশুদের পোশাকের বৈচিত্র্যময় মিশ্রণ রয়েছে, পোশাক, টপস, স্কার্ট এবং শর্টসের ক্ষেত্রে বিশেষীকরণ সহ।

পি এমপ্রো এক্সপোর্টস প্রাইভেট লিমিটেড একটি বিশিষ্ট সিস্টেম ব্যবহার করে আসছিল, কিন্তু পথে কিছু চ্যালেঞ্জের সম্মুখীন হয়েছিল। এই ত্রুটিগুলি কাটিয়ে উঠতে পারে এমন একটি বিকল্প সমাধানের সন্ধানে, তারা আগ্রহের সাথে স্টিচ গ্রহণ করেছিল। এই সিদ্ধান্তটি একটি গেম-চেঞ্জার হিসাবে প্রমাণিত হয়েছিল কারণ স্টিচ কার্যকরভাবে অসংখ্য সমস্যা সমাধান করেছে, যার ফলে ব্যতিক্রমী ফলাফল এবং কোম্পানির জন্য উল্লেখযোগ্য অগ্রগতি হয়েছে।

পি এমপ্রো এক্সপোর্টস তাদের উৎপাদন প্রক্রিয়ায় উল্লেখযোগ্য চ্যালেঞ্জের সম্মুখীন হয়েছে, যার প্রধান কারণ ডিজিটাইজেশন এবং রিয়েল-টাইম অন্তর্দৃষ্টির অভাব। এর ফলে ইনভেন্টরি ব্যবস্থাপনা, কেন্দ্রীভূত পরিকল্পনা বোর্ড, মেশিন রক্ষণাবেক্ষণ এবং সম্পদ বরাদ্দের মতো গুরুত্বপূর্ণ ক্ষেত্রগুলিতে অদক্ষতা দেখা দিয়েছে। আসুন প্রতিটি চ্যালেঞ্জ আলাদাভাবে অন্বেষণ করা যাক:

1. ইনভেন্টরি ব্যবস্থাপনা- পি এমপ্রো এক্সপোর্টস তাদের পূর্ববর্তী সিস্টেমের সাথে গুরুত্বপূর্ণ ইনভেন্টরি চ্যালেঞ্জের সম্মুখীন হয়েছিল, স্টক স্তর, চাহিদার ধরণ এবং সরবরাহকারীর ডেটাতে রিয়েল-টাইম দৃশ্যমানতার অভাব। অতিরিক্ত বহন খরচ, ঘন ঘন স্টকআউট এবং উৎপাদন বিলম্বের সংমিশ্রণের ফলে তাদের কার্যক্রমের উপর উল্লেখযোগ্য প্রভাব পড়ে, যার মধ্যে রয়েছে ডেডস্টক, সম্পূর্ণ অর্ডার এবং কাপড়ের বয়স।
2. পরিকল্পনা বোর্ড- পি এমপ্রো এক্সপোর্টস একটি কেন্দ্রীভূত পরিকল্পনা বোর্ডের অনুপস্থিতির ফলে উল্লেখযোগ্য চ্যালেঞ্জের সম্মুখীন হয়েছে। এই অভাব ক্রয় আদেশ ট্র্যাকিং, মাসিক ক্ষমতা, সম্পদ বরাদ্দ, লাইন-ভিত্তিক পরিকল্পনা, সঠিক ঘন্টা সময়সূচী, রিয়েল-টাইম বিলম্ব ট্র্যাকিং এবং প্রাক-উৎপাদন অন্তর্দৃষ্টির মতো গুরুত্বপূর্ণ দিকগুলিতে তাদের দৃশ্যমানতাকে বাধাগ্রস্ত করেছে।
3. অপারেটর উৎপাদন ট্র্যাকিং- উৎপাদন তলায় পৃথক অপারেটরের কর্মক্ষমতা পর্যবেক্ষণ এবং ট্র্যাক করা Pee Empro Exports-এ একটি ম্যানুয়াল এবং সময়সাপেক্ষ প্রক্রিয়া, যার ফলে দক্ষতার ঘাটতি এবং কর্মক্ষমতার বাধাগুলি সনাক্ত করতে অসুবিধা হচ্ছে।
4. নির্ধারিত রক্ষণাবেক্ষণ- Pee Empro Exports অপ্রত্যাশিত মেশিন ভাঙ্গনের সম্মুখীন হয়েছে, যার ফলে অপরিকল্পিত ডাউনটাইম এবং রক্ষণাবেক্ষণ খরচ বৃদ্ধি পেয়েছে। প্রতিক্রিয়াশীল রক্ষণাবেক্ষণ অনুশীলনগুলি উৎপাদনশীলতাকে বাধাগ্রস্ত করেছে এবং উৎপাদন ব্যাহত করেছে।
5. অটো কাট প্ল্যান জেনারেশন- Pee Empro Exports ম্যানুয়াল কাট পরিকল্পনার কারণে উপাদানের অপচয় এবং উচ্চ উৎপাদন খরচের সম্মুখীন হচ্ছে। এমন একটি সিস্টেমের অভাব ছিল যা কাপড়ের ব্যবহার কমাতে পারে, সর্বোত্তম উৎপাদন প্রয়োজনীয়তা এবং কাটিংয়ের সীমাবদ্ধতা পূরণ করতে পারে, যার ফলে সীমিত খরচ সাশ্রয় এবং স্থায়িত্ব ঘটে।

১) দক্ষ ইনভেন্টরি ব্যবস্থাপনা- স্টিচের সাহায্যে, Pee Empro Exports স্টক স্তর, চাহিদার ধরণ এবং সরবরাহকারীর ডেটাতে রিয়েল-টাইম দৃশ্যমানতা অর্জন করে, ইনভেন্টরি ব্যবস্থাপনা উন্নত করে। অপ্টিমাইজড সিস্টেমটি অতিরিক্ত বহন খরচ, স্টকআউট এবং উৎপাদন বিলম্ব কমিয়ে দেয়, দক্ষ এবং সাশ্রয়ী ইনভেন্টরি নিয়ন্ত্রণ নিশ্চিত করে।

২) পরিকল্পনা বোর্ডের মাধ্যমে বর্ধিত পরিকল্পনা দক্ষতা – পি এমপ্রো এক্সপোর্টস এখন নিরবচ্ছিন্ন সম্পদ ব্যবস্থাপনা, ক্রয় আদেশ ট্র্যাকিং, মাসিক ক্ষমতা পরিকল্পনা, সম্পদ বরাদ্দ, লাইন-ভিত্তিক সময়সূচী, সঠিক ঘন্টা পরিকল্পনা, রিয়েল-টাইম বিলম্ব ট্র্যাকিং এবং প্রাক-উৎপাদন অন্তর্দৃষ্টি উপভোগ করে, যা আমাদের সুসংগঠিত এবং কেন্দ্রীভূত পরিকল্পনা বোর্ডের মাধ্যমে সম্ভব হয়েছে।

৩) সহজ কর্মক্ষমতা পর্যবেক্ষণ – স্টিচের সাহায্যে, উৎপাদন তলায় অপারেটর কর্মক্ষমতা ট্র্যাকিং স্বয়ংক্রিয়, উৎপাদনশীলতা এবং দক্ষতার মধ্যে রিয়েল-টাইম অন্তর্দৃষ্টি প্রদান করে। দক্ষতার ফাঁক এবং কর্মক্ষমতা বাধাগুলির দ্রুত সনাক্তকরণ পি এমপ্রো এক্সপোর্টসকে লক্ষ্যযুক্ত প্রশিক্ষণ প্রোগ্রাম এবং প্রণোদনা বাস্তবায়ন করতে দেয়, অপারেটর কর্মক্ষমতা এবং উৎপাদনশীলতা বৃদ্ধি করে।

৪) স্মার্ট রক্ষণাবেক্ষণ – স্টিচ সুবিধাযুক্ত রক্ষণাবেক্ষণ, নিশ্চিত করে যে পি এমপ্রো এক্সপোর্টস অপ্রত্যাশিত মেশিন ভাঙ্গনগুলিকে সক্রিয়ভাবে মোকাবেলা করতে পারে। মেশিন লার্নিং অ্যালগরিদম এবং আইওটি সেন্সর ব্যবহার করে, সিস্টেম সম্ভাব্য ব্যর্থতাগুলি পূর্বাভাস দেয়, সময়মত রক্ষণাবেক্ষণ সক্ষম করে এবং অপরিকল্পিত ডাউনটাইম কমিয়ে দেয়, পরিণামে সামগ্রিক উৎপাদনশীলতা উন্নত করে।

৫) অটো কাট প্ল্যান জেনারেশন – স্টিচ উপাদানের মাত্রা, উৎপাদন প্রয়োজনীয়তা এবং কাটিংয়ের সীমাবদ্ধতা বিবেচনা করে পি এমপ্রো এক্সপোর্টসের জন্য কাট প্ল্যান জেনারেশন প্রক্রিয়াটি অপ্টিমাইজ করেছে। এটি উপাদানের অপচয় এবং উৎপাদন খরচ কমায়, স্থায়িত্ব এবং খরচ সাশ্রয় বাড়ায়।

১) অপ্রত্যাশিত ভাঙ্গনকে বিদায় – স্টিচ মেশিন লার্নিং এবং আইওটি ম্যাজিক সম্ভাব্য ব্যর্থতাগুলি পূর্বাভাস দেয়, পি এম্প্রোকে সময়মত রক্ষণাবেক্ষণ পরিচালনা করতে এবং অপরিকল্পিত ডাউনটাইম কমাতে সক্ষম করে।

১) অপ্রত্যাশিত ভাঙ্গনকে বিদায় – স্টিচ মেশিন লার্নিং এবং আইওটি ম্যাজিক সম্ভাব্য ব্যর্থতাগুলি পূর্বাভাস দেয়, পি এম্প্রোকে সময়মত রক্ষণাবেক্ষণ পরিচালনা করতে এবং অপরিকল্পিত ডাউনটাইম কমাতে সক্ষম করে।

৩) স্টিচ প্ল্যানিং বোর্ডের মাধ্যমে দৃশ্যমানতা বৃদ্ধি – স্টিচ প্ল্যানিং বোর্ডের জন্য ধন্যবাদ, পি-এম্প্রো সমস্ত কারখানার সুবিধা এবং তাদের উপলব্ধ সংস্থান সম্পর্কে ব্যাপক অন্তর্দৃষ্টি অর্জন করে। মোট বুকিং ক্ষমতা, উপলব্ধ ক্ষমতা এবং মোট ক্ষমতা সম্পর্কে স্পষ্ট দৃশ্যমানতার সাথে, তারা এখন তাদের উৎপাদন ক্ষমতা সম্পর্কে একটি সামগ্রিক দৃষ্টিভঙ্গি অর্জন করেছে।

Pee Empro Exports Pvt Ltd adalah produsen pakaian tenun yang mapan dengan sejarah panjang di bisnis tekstil. Dengan basis pelanggan yang kuat, termasuk merek-merek ternama seperti Gap, Old Navy, Anthropologie, dan lainnya, perusahaan ini memiliki kehadiran yang signifikan di pasar AS dan Uni Eropa. Dengan kapasitas bulanan sebesar 700.000 unit yang mencakup beragam pakaian dewasa dan anak-anak, dengan spesialisasi gaun, atasan, rok, dan celana pendek.

Pee Empro Exports Pvt Ltd telah menggunakan sistem yang unggul, tetapi menghadapi beberapa tantangan di sepanjang prosesnya. Dalam upaya mencari solusi alternatif yang dapat mengatasi kekurangan ini, mereka dengan antusias mengadopsi Stitch. Keputusan ini terbukti menjadi pengubah permainan karena Stitch secara efektif mengatasi berbagai masalah, yang menghasilkan hasil yang luar biasa dan kemajuan yang signifikan bagi perusahaan.

Pee Empro Exports menghadapi tantangan signifikan dalam proses manufaktur mereka, terutama karena kurangnya digitalisasi dan wawasan waktu nyata. Hal ini menyebabkan inefisiensi di area vital seperti manajemen inventaris, papan perencanaan terpusat, perawatan mesin, dan alokasi sumber daya. Mari kita bahas setiap tantangan secara terpisah:

1. Manajemen Inventaris – Pee Empro Exports menghadapi tantangan inventaris yang krusial dengan sistem mereka sebelumnya, yaitu kurangnya visibilitas waktu nyata terhadap tingkat stok, pola permintaan, dan data pemasok. Kombinasi biaya penyimpanan yang berlebihan, seringnya kehabisan stok, dan penundaan produksi mengakibatkan dampak signifikan pada operasional mereka, termasuk stok mati, pesanan yang telah selesai, dan penuaan kain.
2. Papan Perencanaan – Pee Empro Exports menghadapi tantangan signifikan akibat tidak adanya papan perencanaan terpusat.

   Ketiadaan ini menghambat visibilitas mereka terhadap aspek-aspek penting seperti pelacakan pesanan pembelian, kapasitas bulanan, alokasi sumber daya, perencanaan lini demi lini, penjadwalan jam kerja yang akurat, pelacakan penundaan secara real-time, dan wawasan pra-produksi.

3. Pelacakan Produksi Operator – Pemantauan dan pelacakan kinerja masing-masing operator di lantai produksi selama ini merupakan proses manual dan memakan waktu di Pee Empro Exports, sehingga menyebabkan kesulitan dalam mengidentifikasi kesenjangan keterampilan dan hambatan kinerja.
4. Pemeliharaan Terjadwal – Pee Empro Exports telah mengalami kerusakan mesin yang tidak terduga, yang mengakibatkan waktu henti yang tidak direncanakan dan peningkatan biaya pemeliharaan. Praktik pemeliharaan reaktif telah menghambat produktivitas dan menyebabkan gangguan produksi.
5. Pembuatan Rencana Pemotongan Otomatis – Pee Empro Exports menghadapi pemborosan material dan biaya produksi yang lebih tinggi karena rencana pemotongan manual.

   Terdapat kekurangan sistem yang dapat mengurangi konsumsi kain, memenuhi persyaratan produksi optimal, dan kendala pemotongan, sehingga mengakibatkan terbatasnya penghematan biaya dan keberlanjutan.

1) Manajemen Inventaris yang Efisien – Dengan Stitch, Pee Empro Exports mendapatkan visibilitas real-time terhadap tingkat stok, pola permintaan, dan data pemasok, sehingga meningkatkan manajemen inventaris. Sistem yang dioptimalkan meminimalkan biaya penyimpanan yang berlebihan, kehabisan stok, dan penundaan produksi, memastikan pengendalian inventaris yang efisien dan hemat biaya.

2) Peningkatan Efisiensi Perencanaan dengan Papan Perencanaan – Pee Empro Exports kini menikmati manajemen sumber daya yang lancar, pelacakan pesanan pembelian, perencanaan kapasitas bulanan, alokasi sumber daya, penjadwalan per lini, perencanaan jam kerja yang akurat, pelacakan penundaan real-time, dan wawasan pra-produksi, semuanya dimungkinkan melalui papan perencanaan kami yang terorganisir dengan baik & terpusat.

3) Pemantauan Kinerja yang Mudah – Dengan Stitch, pelacakan kinerja operator di lantai produksi diotomatisasi, menawarkan wawasan real-time tentang produktivitas dan efisiensi.

Identifikasi cepat terhadap kesenjangan keterampilan dan hambatan kinerja memungkinkan Pee Empro Exports menerapkan program pelatihan dan insentif yang terarah, sehingga meningkatkan kinerja dan produktivitas operator.

4) Perawatan Cerdas – Stitch memfasilitasi perawatan, memastikan Pee Empro Exports dapat secara proaktif mengatasi kerusakan mesin yang tidak terduga. Dengan memanfaatkan algoritma pembelajaran mesin dan sensor IoT, sistem mengantisipasi potensi kegagalan, memungkinkan perawatan tepat waktu, dan meminimalkan waktu henti yang tidak direncanakan, yang pada akhirnya meningkatkan produktivitas secara keseluruhan.

5) Pembuatan Rencana Pemotongan Otomatis – Stitch mengoptimalkan proses pembuatan rencana pemotongan untuk Pee Empro Exports, dengan mempertimbangkan dimensi material, persyaratan produksi, dan kendala pemotongan. Hal ini mengurangi pemborosan material dan biaya produksi, sehingga mendorong keberlanjutan dan penghematan biaya.

1) Selamat tinggal kerusakan tak terduga – Pembelajaran mesin Stitch dan keajaiban IoT mengantisipasi potensi kegagalan, memberdayakan Pee Empro untuk melakukan perawatan tepat waktu dan meminimalkan waktu henti yang tidak direncanakan.

2) Peningkatan Produktivitas Tenaga Kerja – Stitch membantu Pee Empro Exports memaksimalkan potensi tenaga kerja mereka dengan menawarkan wawasan real-time tentang produktivitas dan efisiensi yang membantu mereka mengidentifikasi kesenjangan keterampilan dan hambatan kinerja dengan cepat.

3) Visibilitas yang Ditingkatkan dengan Papan Perencanaan Stitch – Berkat papan perencanaan Stitch, Pee-Empro mendapatkan wawasan komprehensif tentang semua fasilitas pabrik dan sumber daya yang tersedia. Dengan visibilitas yang jelas tentang total kapasitas yang dipesan, kapasitas yang tersedia, dan total kapasitas, mereka kini memiliki gambaran holistik tentang kemampuan produksi mereka.

Pee Empro Exports Pvt Ltd, tekstil sektöründe zengin bir geçmişe sahip köklü bir dokuma giyim üreticisidir. Gap, Old Navy, Anthropologie ve daha birçok tanınmış markayı içeren güçlü bir müşteri tabanına sahip olan şirket, hem ABD hem de AB pazarlarında önemli bir varlığa sahiptir. Yetişkin ve çocuk giyiminde çeşitlilik gösteren bir ürün yelpazesi sunan ve elbiseler, üstler, etekler ve şortlarda uzmanlaşmış olan şirket, aylık 700.000 adetlik bir kapasiteye sahiptir.

Pee Empro Exports Pvt Ltd, köklü bir sistem kullanıyordu, ancak bu süreçte bazı zorluklarla karşılaştı. Bu eksikliklerin üstesinden gelebilecek alternatif bir çözüm arayışında, Stitch’i hevesle benimsediler. Bu karar, Stitch’in birçok sorunu etkili bir şekilde ele alması ve şirket için olağanüstü sonuçlar ve önemli ilerlemeler sağlaması nedeniyle oyunun kurallarını değiştiren bir karar oldu.

Pee Empro Exports, üretim süreçlerinde, özellikle dijitalleşme ve gerçek zamanlı içgörü eksikliğinden kaynaklanan önemli zorluklarla karşı karşıyaydı. Bu durum, envanter yönetimi, merkezi planlama panosu, makine bakımı ve kaynak tahsisi gibi hayati alanlarda verimsizliklere yol açtı. Her bir zorluğu ayrı ayrı inceleyelim:

1. Envanter Yönetimi – Pee Empro Exports, önceki sistemlerinde stok seviyeleri, talep kalıpları ve tedarikçi verilerine ilişkin gerçek zamanlı görünürlük eksikliği nedeniyle kritik envanter sorunlarıyla karşı karşıyaydı. Aşırı taşıma maliyetleri, sık sık stok tükenmeleri ve üretim gecikmelerinin birleşimi, ölü stok, tamamlanan siparişler ve kumaşların eskimesi gibi operasyonları üzerinde önemli etkilere yol açtı.
2. Planlama Kurulu – Pee Empro Exports, merkezi bir planlama kurulunun olmamasından kaynaklanan önemli zorluklarla karşılaştı. Bu eksiklik, satın alma siparişlerinin takibi, aylık kapasite, kaynak tahsisi, hat bazında planlama, doğru saat planlaması, gerçek zamanlı gecikme takibi ve üretim öncesi içgörüler gibi kritik konularda görünürlüklerini engelledi.
3. Operatör Üretim Takibi – Pee Empro Exports’ta üretim sahasındaki bireysel operatör performansının izlenmesi ve takibi manuel ve zaman alıcı bir süreçti ve bu da beceri eksikliklerini ve performans darboğazlarını belirlemede zorluklara yol açtı.
4. Planlı Bakım – Pee Empro Exports, beklenmedik makine arızaları yaşadı ve bu da plansız duruşlara ve artan bakım maliyetlerine neden oldu. Reaktif bakım uygulamaları, üretkenliği engelledi ve üretimde aksaklıklara yol açtı.
5. Otomatik Kesim Planı Oluşturma – Pee Empro Exports, manuel kesim planları nedeniyle malzeme israfı ve daha yüksek üretim maliyetleriyle karşı karşıya kaldı. Kumaş tüketimini azaltabilecek, optimum üretim gereksinimlerini ve kesim kısıtlamalarını karşılayabilecek bir sistem eksikliği vardı ve bu da sınırlı maliyet tasarrufu ve sürdürülebilirlik sağlıyordu.

1) Verimli Envanter Yönetimi – Stitch ile Pee Empro Exports, stok seviyeleri, talep kalıpları ve tedarikçi verilerine gerçek zamanlı görünürlük kazandırarak envanter yönetimini geliştiriyor. Optimize edilmiş sistem, aşırı taşıma maliyetlerini, stok tükenmelerini ve üretim gecikmelerini en aza indirerek verimli ve uygun maliyetli envanter kontrolü sağlıyor.

2) Planlama Panosu ile Gelişmiş Planlama Verimliliği – Pee Empro Exports artık kusursuz kaynak yönetimi, satın alma siparişi takibi, aylık kapasite planlaması, kaynak tahsisi, hat bazında planlama, doğru saat planlaması, gerçek zamanlı gecikme takibi ve üretim öncesi içgörülerden yararlanıyor; tüm bunlar, iyi organize edilmiş ve merkezi planlama panomuz sayesinde mümkün oluyor.

3) Kolay Performans İzleme – Stitch ile üretim katındaki operatör performans takibi otomatikleştirilerek, üretkenlik ve verimlilik hakkında gerçek zamanlı içgörüler sunuluyor. Beceri eksikliklerinin ve performans darboğazlarının hızlı bir şekilde belirlenmesi, Pee Empro Exports’un hedefli eğitim programları ve teşvikler uygulamasına olanak tanıyarak operatör performansını ve üretkenliğini artırmasını sağlar.

4) Akıllı Bakım – Stitch, bakımı kolaylaştırarak Pee Empro Exports’un beklenmedik makine arızalarını proaktif bir şekilde ele almasını sağlar. Makine öğrenimi algoritmaları ve IoT sensörlerinden yararlanan sistem, olası arızaları öngörerek zamanında bakım yapılmasını ve plansız duruş sürelerinin en aza indirilmesini sağlar ve sonuç olarak genel üretkenliği artırır.

5) Otomatik Kesim Planı Oluşturma – Stitch, malzeme boyutlarını, üretim gereksinimlerini ve kesim kısıtlamalarını dikkate alarak Pee Empro Exports için kesim planı oluşturma sürecini optimize etti. Bu, malzeme israfını ve üretim maliyetlerini azaltarak sürdürülebilirliği ve maliyet tasarrufunu destekler.

1) Beklenmedik arızalara elveda – Stitch makine öğrenimi ve IoT sihri, olası arızaları öngörerek Pee Empro’nun zamanında bakım yapmasını ve plansız duruş sürelerini en aza indirmesini sağlar.

2) Gelişmiş İş Gücü Verimliliği – Stitch, Pee Empro Exports’un üretkenlik ve verimlilik konusunda gerçek zamanlı bilgiler sunarak iş gücünün gerçek potansiyelini ortaya çıkarmasına yardımcı oldu. Bu bilgiler, beceri eksikliklerini ve performans darboğazlarını hızla tespit etmelerine yardımcı oldu.

3) Stitch Planlama Panosu ile Gelişmiş Görünürlük – Stitch planlama panosu sayesinde Pee-Empro, tüm fabrika tesisleri ve mevcut kaynakları hakkında kapsamlı bir içgörü elde ediyor. Toplam rezerve kapasite, mevcut kapasite ve toplam kapasite hakkında net bir görünürlük sayesinde, artık üretim kapasitelerinin bütünsel bir görünümüne sahipler.

Công ty TNHH Pee Empro Exports là một nhà sản xuất hàng may mặc dệt may lâu đời với bề dày lịch sử trong ngành dệt may. Với lượng khách hàng hùng hậu bao gồm các thương hiệu nổi tiếng như Gap, Old Navy, Anthropologie, v.v., công ty hiện diện đáng kể tại cả thị trường Hoa Kỳ và EU. Với công suất hàng tháng 700.000 sản phẩm, bao gồm nhiều loại quần áo người lớn và trẻ em, chuyên về váy, áo, váy ngắn và quần short.

Công ty TNHH Pee Empro Exports đã và đang sử dụng một hệ thống nổi bật, nhưng gặp phải một số thách thức trong quá trình triển khai. Trong quá trình tìm kiếm một giải pháp thay thế có thể khắc phục những thiếu sót này, họ đã nhanh chóng áp dụng Stitch. Quyết định này đã chứng minh là một bước ngoặt khi Stitch giải quyết hiệu quả nhiều vấn đề, mang lại kết quả vượt trội và tiến bộ đáng kể cho công ty.

Pee Empro Exports đã phải đối mặt với những thách thức đáng kể trong quy trình sản xuất, chủ yếu là do thiếu số hóa và thông tin chi tiết theo thời gian thực. Điều này dẫn đến sự thiếu hiệu quả trong các lĩnh vực quan trọng như quản lý hàng tồn kho, bảng kế hoạch tập trung, bảo trì máy móc và phân bổ nguồn lực. Hãy cùng tìm hiểu từng thách thức riêng biệt:

1. Quản lý hàng tồn kho – Pee Empro Exports đã phải đối mặt với những thách thức nghiêm trọng về hàng tồn kho với hệ thống trước đây, thiếu khả năng hiển thị theo thời gian thực về mức tồn kho, mô hình nhu cầu và dữ liệu nhà cung cấp. Sự kết hợp giữa chi phí lưu kho quá mức, tình trạng thiếu hàng thường xuyên và chậm trễ sản xuất đã gây ra những tác động đáng kể đến hoạt động của họ, bao gồm hàng tồn kho, đơn hàng đã hoàn thành và vải bị lão hóa.
2. Ban Kế hoạch – Pee Empro Exports đã gặp phải những thách thức đáng kể do thiếu một ban kế hoạch tập trung. Sự thiếu hụt này đã cản trở khả năng giám sát của họ đối với các khía cạnh quan trọng như theo dõi đơn đặt hàng, công suất hàng tháng, phân bổ nguồn lực, lập kế hoạch theo dây chuyền, lập lịch trình giờ chính xác, theo dõi độ trễ theo thời gian thực và thông tin chi tiết trước khi sản xuất.
3. Theo dõi Sản xuất của Người vận hành – Việc giám sát và theo dõi hiệu suất của từng người vận hành trên sàn sản xuất là một quy trình thủ công và tốn thời gian tại Pee Empro Exports, dẫn đến khó khăn trong việc xác định khoảng cách kỹ năng và các điểm nghẽn hiệu suất.
4. Bảo trì theo lịch trình – Pee Empro Exports đã gặp phải sự cố máy móc bất ngờ, dẫn đến thời gian ngừng hoạt động ngoài kế hoạch và tăng chi phí bảo trì. Các hoạt động bảo trì phản ứng đã cản trở năng suất và dẫn đến gián đoạn sản xuất.
5. Tạo Kế hoạch Cắt Tự động – Pee Empro Exports phải đối mặt với tình trạng lãng phí vật liệu và chi phí sản xuất cao hơn do kế hoạch cắt thủ công. Thiếu một hệ thống có thể giảm mức tiêu thụ vải, đáp ứng các yêu cầu sản xuất tối ưu và hạn chế cắt giảm, dẫn đến việc tiết kiệm chi phí và tính bền vững bị hạn chế.

1) Quản lý Hàng tồn kho Hiệu quả – Với Stitch, Pee Empro Exports có thể theo dõi theo thời gian thực về lượng hàng tồn kho, mô hình nhu cầu và dữ liệu nhà cung cấp, từ đó nâng cao hiệu quả quản lý hàng tồn kho. Hệ thống được tối ưu hóa giúp giảm thiểu chi phí lưu kho quá mức, tình trạng hết hàng và chậm trễ sản xuất, đảm bảo kiểm soát hàng tồn kho hiệu quả và tiết kiệm chi phí.

2) Nâng cao Hiệu quả Lập kế hoạch với Bảng Lập kế hoạch – Pee Empro Exports hiện có thể quản lý nguồn lực liền mạch, theo dõi đơn đặt hàng, lập kế hoạch năng lực hàng tháng, phân bổ nguồn lực, lập lịch trình theo dây chuyền, lập kế hoạch giờ chính xác, theo dõi độ trễ theo thời gian thực và thông tin chi tiết trước sản xuất, tất cả đều có thể thực hiện được thông qua bảng lập kế hoạch được tổ chức tốt và tập trung của chúng tôi.

3) Giám sát Hiệu suất Dễ dàng – Với Stitch, việc theo dõi hiệu suất của người vận hành trên sàn sản xuất được tự động hóa, cung cấp thông tin chi tiết theo thời gian thực về năng suất và hiệu quả. Việc xác định nhanh chóng các thiếu sót về kỹ năng và các điểm nghẽn về hiệu suất cho phép Pee Empro Exports triển khai các chương trình đào tạo và khuyến khích có mục tiêu, giúp nâng cao hiệu suất và năng suất của người vận hành.

4) Bảo trì Thông minh – Stitch hỗ trợ bảo trì, đảm bảo Pee Empro Exports có thể chủ động xử lý các sự cố máy móc bất ngờ. Bằng cách tận dụng các thuật toán học máy và cảm biến IoT, hệ thống dự đoán các sự cố tiềm ẩn, cho phép bảo trì kịp thời và giảm thiểu thời gian ngừng hoạt động ngoài kế hoạch, từ đó cải thiện năng suất tổng thể.

5) Tự động tạo kế hoạch cắt – Stitch đã tối ưu hóa quy trình tạo kế hoạch cắt cho Pee Empro Exports, xem xét kích thước vật liệu, yêu cầu sản xuất và các hạn chế về cắt. Điều này giúp giảm lãng phí vật liệu và chi phí sản xuất, thúc đẩy tính bền vững và tiết kiệm chi phí.

1) Tạm biệt các sự cố bất ngờ – Học máy Stitch và công nghệ IoT dự đoán các sự cố tiềm ẩn, cho phép Pee Empro thực hiện bảo trì kịp thời và giảm thiểu thời gian ngừng hoạt động ngoài kế hoạch.

2) Nâng cao Năng suất Lao động – Stitch đã giúp Pee Empro Exports khai thác tiềm năng thực sự của lực lượng lao động bằng cách cung cấp thông tin chi tiết theo thời gian thực về năng suất và hiệu quả, giúp họ nhanh chóng xác định các khoảng cách kỹ năng và các điểm nghẽn về hiệu suất.

3) Nâng cao khả năng hiển thị với Bảng lập kế hoạch khâu – Nhờ bảng lập kế hoạch khâu, Pee-Empro có được cái nhìn toàn diện về tất cả các cơ sở nhà máy và nguồn lực sẵn có của họ. Với khả năng hiển thị rõ ràng về tổng công suất đặt trước, công suất khả dụng và tổng công suất, giờ đây họ có cái nhìn toàn diện về năng lực sản xuất của mình.