Organization
- Define the right organogram.
- Recruit with an effective methodology.
- Train at every level.
- Plan incentives.
Apparel factory set-up consultants
The BENCI Engineered Factory: a turnkey apparel factory, designed to perform.
An engineered apparel factory has trained manpower, optimum technology, ideal infrastructure and rationally designed processes. BENCI designs and builds all four together, so the factory performs from the first production day.
Designed together
One factory, four pillars
Technology
- Select the right machinery and the right software.
- Use work-aids and attachments well.
Infrastructure
- Build the right infrastructure.
- Plan the physical layout to the product mix.
- Plan utilities.
Processes
- Design and implement department-wise SOPs.
- Set up quality control, industrial engineering, training and MIS.
- Implement the software systems.
What goes wrong
Seven mistakes the Engineered Factory avoids
- Flawed factory design and machinery layout
- Over or under investment in technology
- Ignorance of modern industrial engineering and quality control methods
- Wrong hiring, poor training and overstaffing
- Absence of information capture and communication
- Excessive working capital due to poor planning
- Absence or underutilization of the right software
For a 250 machine set-up, these mistakes mean a loss of
2.5 lakh pieces of production
and Rs. 2.5 crore in profits
every year.
Benchmarks
Key features of an Engineered Factory
| Feature | Benchmark |
|---|---|
| Man-to-machine ratio | 2.0 or less |
| Operator efficiency | Up to 40% within 6 weeks of training |
| Floor space | About 20% saved by a high performance layout compared with a conventional layout |
| Line efficiency | 55–60% within a year |
| Inventory | About 50% lower through lean manufacturing tools |
| Cut-to-ship ratio | 99% for standard products |
| Changeover | Quick, for flexibility in product mix |
| Cost | Maximum use of low cost automates and work-aids |
| Information | An MIS that captures the right data for decisions |
| Compliance | Fully compliant with Safety, Health and Environmental norms |
Engagements
How we deliver it
-
Start-up assistance
Start-up assistance builds the factory from scratch on a turnkey basis.
-
Re-engineering
Re-engineering brings an existing factory closer to the Engineered Factory.
-
Tailored modules
Tailored modules cover one area at a time.
What is an Engineered Factory?
An apparel factory with trained manpower, optimum technology, ideal infrastructure and rationally designed processes, designed together as one system.
How fast can operators reach target efficiency?
Individual operators reach up to 40% efficiency within 6 weeks of training, and lines reach 55 to 60% within a year.
What factory sizes has BENCI worked with?
Factories from 150 to 6,000 machines, in India, Bangladesh, Vietnam and Ethiopia.
Can BENCI help with an existing factory?
Yes. Re-engineering brings an existing factory closer to the Engineered Factory, and tailored modules cover one area at a time.