Control / Co-ordinate

Production and operations monitoring system that works

The Challenge

Did you know that almost 50% of operating personnel time is spent on tracking completion, material, and manpower?

Even as production managers spend considerable time on these items, every production unit face three major problems:

  • Increasing WIP inventory
  • Discrepancies in fixed rate of throughput
  • Unmanageable rate of rework and rejections

The reason behind the lack of accuracy often includes the inefficient process of production distribution across lines that reduces the rate of throughput thus increasing inventory that is work-in-progress. Without data to understand each worker’s performance level, the rate of rejections also increase over time.

Thus, managers do not have the entire picture of the production floor to create a productive plan for execution due to the following reasons.

  • Lack of visibility of actual outputs or cycle time
  • Work assigned solely on availability of capacity without target consideration
  • Measuring rejections with parameters other than lost time, capacity or output
  • Failure to optimise productivity

The Story

8 / 10 line managers spend significant time and effort to create a production plan.

However, the current operations that are conducted across many departments work at SILOS focused on individual objectives. Each department sets their own objective for the product line and use a rule of thumb for line planning.

To end this process, did the management ever feel a holistic system could revolutionise the manufacturing unit of the business? A single application with 360-degree view of the floor with the flexibility to monitor all aspects including materials availability, quality check, rejections monitor, workers’ performance. A solution that can transform the operations to become more responsive.

Success of POMS

One of India's largest footwear manufactures catering to European markets implemented POMS across 18 assembly lines in 3 factories Result - Increased operational efficiency by 16% width optimal deployment of man and machines.

One of Asia's top five fashion leather goods manufacturer based in India producing approximately 2.5 million units of leather fashion products to top global brands implemented POMS for optimising production cost result - cost per unit of production reduced by 12%

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Product Overview

Production and Operations Monitoring System, POMS, was engineered to resolve time management and stop-gaps in the production line. A robust application offered by Peritus, POMS transforms the approach to line balancing based entirely on production target and workers’ performance. Controlling all aspects of product flow from capacity monitoring to capacity utilisation, POMS is a single dashboard that reduces personnel time and effort by 50% with real-time visibility at both managerial and operational levels. The system conveniently allows line managers to handle multiple orders across several lines of production and easily lets managers to plan each line to the fullest capacity.

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Production Monitoring System allows apparel, footwear and discrete manufacturers (where the production is highly resource dependent) with a plethora of facilities including:

  • Real time visibility on their day-to-day operations on customer and work order status (including delays and expected time to completion)

  • Instant production planning with available workmen/machine capacity with expected output, rejection/rework levels across different production lines using a simple bar code based software

  • Efficient line balance by industrial engineering team in less than 15 minutes from the shift start. The system ensures productive deployment of workers based on operation skills and allocating them to different lines.

  • Operations standardisation with SAH/Cycle times based on actual utilisation of capacity, resources and time.


Fashion & Apparel