APPAREL PRODUCTION SKILL GAP OVERVIEW

In the apparel industry, line production is a method where the garment-making process is broken into smaller steps. Each worker or machine is responsible for one step, like stitching a sleeve or attaching buttons. The garment moves from one worker to the next until it’s finished. This system helps make clothes faster and in large quantities. It also makes it easier to check for quality at each step.

One major challenge in line production in the apparel industry is managing the absenteeism and attrition of skilled workers. This often happens without prior notice. This issue is compounded by a shortage of skilled workers in the industry. The industry operates based on strict time requirements. It also has efficiency requirements. Daily production targets are set for an 8-hour workday (480 minutes).

Each worker’s target is determined by the Standard Allowed Minutes (SAM) for each task. The SAM is calculated based on the cycle time in seconds and other factors. This system highlights the critical importance of time in apparel production. Meeting production goals relies on having enough skilled workers who can complete their tasks efficiently within the set time limits.

Now Let’s dive into the solution using Power Platform Components

Solution Overview: Addressing Absenteeism

Background: LK Fashions(not a real company) operates 25 production lines and plans to expand by adding 10 new lines. However, the factory faces challenges with absenteeism and attrition, impacting the efficiency and productivity of the production lines.

Challenges:

Absenteeism: Uninformed leaves disrupt production and reduce efficiency. Despite awareness training, employees continue to take uninformed leaves.

Attrition: The lack of skilled operators for the new production lines due to high attrition rates.

Data Required:

Daily Absenteeism Data: Information on who is absent, including reasons for absence.

Existing Workers Skill Matrix: Current skills and qualifications of the existing workforce.

Fixed Operators : List of Fixed Operator in the production line if company follows.

Proposed Solution:

1. Capturing Absenteeism Data:

Method: Implement an IVR (Interactive Voice Response) system for capturing absenteeism data. Employees can call in and record their absenteeism using an automated phone system.

Technology: Utilize Azure Communication Services to build the IVR system. This service offers integration, scalability, flexibility, and cost-effectiveness.

2. Storing Absenteeism Data:

Storage: Use Microsoft Dataverse to store the absenteeism data.

• Data Capture: The IVR system captures data like the dialed phone number, entry reason for leave, and timestamp.
• Integration: Power Automate will trigger a flow. This flow will add records to the Dataverse table. This happens whenever new IVR call data is received.
• Example Data Table:
  • PhoneNumber: Text
  • LeaveReason: Text
  • Timestamp: DateTime

3. Notification and Data Utilization:

Notification to HR and IE Department:

• Timing: Set up a Power Automate scheduled flow. This flow will send an email to the HR and Industrial Engineering (IE) departments. The email will be sent every morning at 8:45 AM.
• Content: The email will include the list of uninformed absences. It will provide the HR and IE teams with the information needed to address absenteeism. This helps them make decisions to mitigate productivity loss.

Benefits:

Efficiency: Automated data capture reduces manual entry and errors, improving the accuracy of absenteeism records.

Timeliness: Daily email notifications give HR and IE departments timely information to take necessary actions before the production day starts.

Scalability: The IVR system and Dataverse integration are scalable to handle increasing data volume as the factory expands.

In the following blog, we will explore the advanced features of Skill GAP IVR Solution with captured data. We will discuss solutions for managing the shortage of skilled operators for new styles. LK Fashions is expanding to 10 additional production lines.

Stay tuned for more insights and solutions!