Garment tracking from Fabric Rolls to carton packing

Supplier/Mills attach RFID tags on each Role

Rolls tracking-factory gate and ware house

Rolls tracking using RFID tags and antennas
Auto ASN/ GRN / Packing List at entry gate

Rolls tracked- storage racks; inspection and cutting

Fabric laying; Cutting and bundling

Numbering Bundle tracking in cutting Using RFIDs on every

bundle
Re bundling

Assign and attach PROCON I tags to each bundle during Re bundling Issue bundle to sewing lines

Packing
Tracked using
special trolleys
at gate
End Table- Remove I tags and assign
Remove RFID tag from garment Finishing Washing
passive RFID Tag to each garment
Sewing line production tracking- ProCon
System
Attach I tags to bundle in cutting Scan I tags at bundle start and end

I tags Reader on each Sewing m/c Operator punch his I card for identity, login In and Out time

Key features

• Real time production, efficiency vs targets – line wise,

operator wise, PO wise, style wise
• Online operator wise and Line wise WIP tracking
• Auto preparation and up dation of skill matrix I tags
• SMS alert for machine breakdown etc
• Real time line balancing and line analysis
• Rejection and alteration visibility
• Operator idle time, machine breakdown time non
production time tracking I tag Reader
• Order status reports Line display board
 RFID COST SUMMARY WITHOUT PROCON SYSTEM OTC ARC
Total Cost
Sr. No Development (Factory F-1) Quantity Rate Type Of Cost Total Amount ARC %
(min)
Customized software development (One time- Can be replicated
1 1300000 OTC INR 1,300,000
across 50 Factories without any additional cost)

1 Additional Software cost per Factory 1 26000 OTC 26000

2 Development Of Android app 1 100000 OTC 200000

3 Development of IOS app 1 100000 OTC 100000
4 Software AMC 15% ARC 15% 48900
Total Software cost 326000 48900

5 RFID reader per factory 20 55000 OTC 1100000

6 Antenna 20 12000 OTC 240000
7 RFID Antenna & Readers Installation cost 1 100000 OTC 100000
8 Cost of Passive tags (Shelf life of 20 years) 50000 25 OTC 1250000 25% 312500
9 Cost of Barcode printer 5 12000 OTC 60000
10 Customization for HHT 1 100000 OTC 100000
11 Hand held terminal 5 49500 OTC 247500
12 Colour code Printing machine 2 15300 OTC 30600
13 Smart Trolley for Washing count 2 500000 OTC 1000000
14 OP (RFID Output Port) Installation 100000 OTC 100000
15 Installation per warehouse/factory 100000 OTC 100000
16 Procon Hardware Device cost
17 PROCON IT Add on Infrastructure cost 10% OTC 0
 Total Cost
Sr. No Development (Factory F-1) Quantity Rate Type Of Cost Total Amount ARC %
(min)
18 LED screen 36 20000 OTC
19 Manpower cost per year 20 ARC 12000 2880000
20 Electricity Cost ARC
21 Procon AMC Cost ARC 17% 0
22 AMC for LED screen ARC 15%
23 RFID Hardware Maintenance and Damage ARC 15% 251715

Total hardware cost

52,54,100.00 34,93,115.00
Grand Total ( In Lacs) 55.80 35.42
Cost per garment 1.16 0.74
Cost % of sales (in paisa) 0.29 0.18

Cost Incurred Yearly ( Possible Savings Amount

In Lacs) Min Max Remarks Min. Max.
1 Factory Cost 0% 0% Efficiency Gain 0 0
7,200.00
Fabric
2 Fabric Cost ( RFID On Fabric Roll) 0.20% 0.50% 21.6 54
10,800.00 Optimization
3 Lost Garment Cost 15.00% 25.00% Theft Detection 12 20
80.00
Total Saving yearly (In lacs) 33.60 74.00
Min Max
ROI on investment 0.6 1.3
Converted in years(months) 20 9
 Benefits- RFID based Only
Tangible Benefits (Fabric roles) -: Tangible Benefits (Sampling) -:
- Real time Fabric shipping & - Sample fabric store
production visibility. regularization.
- Automated ASN, GRN, Packing - Swatch, Tec pack and marker
list, Inspection report. tracking.
- Seamless finished garment back - Finished sampling garment theft
tracking from parent roll. control.
Tangible Benefits (Production) -:
- Optimal fabric utilization.
- Better cutting/marking output.
- WIP bundle tracking.
- Washing productivity
measurement.

Intangible Benefits -:
Intangible Benefits-:
- Theft reduction at all levels.
- Optimal material utilization.
- Material visibility at all stages
- Error proofing Input vs Output.
- Level scheduling to reduce lead
- Incoming/ Outgoing challan
time
adherence.
- Real time bottle neck/ Constraint
- Realistic OCR realization.
identification
 RFID COST SUMMARY WITH PROCON SYSTEM OTC ARC
SI No. Development (Factory F-1) Quantity Rate Type Of Cost Total Amount ARC % Total Cost (min)
Customized software development (One time- Can be replicated
1 1300000 OTC INR 1,300,000
across 50 Factories without any additional cost)

1 Additional Software cost per Factory 1 26000 OTC 26000

2 Development Of Android app 1 100000 OTC 200000

3 Development of IOS app 1 100000 OTC 100000
4 Software AMC 15% ARC 15% 48900
Total Software cost 326000 48900

5 RFID reader per factory 20 55000 OTC 1100000

6 Antenna 20 12000 OTC 240000
7 Installation cost 1 100000 OTC 100000
8 Cost of Passive tags (Shelf life of 20 years) 50000 25 OTC 1250000 25% 312500
9 Cost of Barcode printer 5 12000 OTC 60000
10 Customization for HHT 1 100000 OTC 100000
11 Hand held terminal 5 49500 OTC 247500
12 Colour code Printing machine 2 15300 OTC 30600
13 Smart Trolley for Washing count 2 500000 OTC 1000000
14 OP Installation 100000 OTC 100000
15 Installation per warehouse/factory 100000 OTC 100000
16 Procon Hardware Device cost 1500 5500 OTC 8250000
17 PROCON IT Add on Infrastructure cost 10% OTC 825000
SI No. Development (Factory F-1) Quantity Rate Type Of Cost Total Amount ARC % Total Cost (min)
18 LED screen 36 20000 OTC 720000
19 Manpower cost per year 20 ARC 12000 2880000
21 Electricity Cost ARC 100000
22 Procon AMC Cost ARC 17% 1402500
23 AMC for LED screen ARC 15% 108000
RFID Hardware Maintenance and Damage ARC 15% 251715

Total hardware cost

1,50,49,100.00 51,03,615.00
Grand Total ( In Lacs) 153.75 51.53
Cost per garment 3.20 1.07
Cost % of sales (in paisa) 0.80 0.27

Cost Incurred Yearly ( Possible Savings Amount

In Lacs) Min. Max. Remarks Min. Max.
1 Factory Cost 2% 3% Efficiency Gain 144 216
7,200.00
Fabric
2 Fabric Cost 0.20% 0.50% 21.6 54
10,800.00 Optimization
3 Lost Garment Cost 15.00% 25.00% Theft Detection 12 20
80.00
Total Saving yearly (In lacs) 177.60 290.00
Min Max
ROI on investment 1.2 1.9
Converted in years(months) 10 6
 Benefits- With Procon + RFID

Worker Incentive Scheme -:

- Operator can see their earned
incentive.
- Incentive would be distributed
transparently on nos.
- This shall result in increase in
productivity per factory.
Real time production count -:
- Output against the feeded input
per line can easily be tracked.
- Better line monitoring and
individual performance tracking.
Tangible Benefits -:
- Efficiency Gain.
- Better production control.
- Better Inventory management.
- Raw material visibility.

Optimization aspects-: Utilization enhancement -:

- On time & accurate OCR closure. - Increased Fabric utilization.
- Authentic delivery challan. - Material consumption visibility
- Production writer reduction. - Wastage/ loss realization
- Department wise productivity. - No scope of data fudge
 Major Implementation challenges

Department wise
SOPs

Skilled Manpower Defined Entry/exit

deployment gates

False reporting in Control system

greed of incentive should be defined
THANK YOU