Production data collected through daily production reports for different departments prepared manually are cumbersome and prone to errors. How daily production reports are prepared in your factory – Manually in a printed format fed into a computer or is there a computer program for this purpose? Who has the responsibility of preparing, updating and foolproofing these reports and how? If someone wants to access these reports, what is the procedure?

Vertical integration is considered as a way to increase competitiveness in the apparel and textile business. What are the perceived advantages of vertical integration – Cheaper products? Better quality? Quicker delivery? While only a few organizations treat every department together as a single business entity, maximum treat them as separate business entities. Can the perceived advantages be achieved if all are treated as separate entities or as a whole? Is vertical integration the way ahead for striving in the future…

Earlier machine suppliers were selling generic machines and garment manufacturers had to pick and choose right combinations from multiple brands necessary for a particular product line. Now leading brands are selling complete set of machines specific to a product like Vibemac for casual trouser or jeans, CF Italia for lingerie, Duerkopp for suits, etc. Do you find the new approach better or does the garment manufacturer run a risk of putting all the eggs in one basket?

Cost of manufacturing: How do you calculate the cost of running a factory? Cost per minute per sewing machine? Cost per day per sewing machine? What all expenses you include in the calculation? Older companies will have advantage over newer companies as cost of land/building/equipments may have depreciated already and not adding to cost of manufacturing operation.

Skill matrix or skill inventory, what term do you use? Do you maintain skill matrix in your organization? What are the criteria which forms the basis to rate an operator into different categories: A, B or C? How does skill matrix benefit your organization in productivity improvement, quality maintenance, efficiency levels, etc.?