Experience has shown that there are real benefits and cost savings from
computerizing the piecework payroll and factory controls. The following
highlights some of the areas where improvements and costs savings can be made:
Savings in the Calculation of the Gross Payroll:
The manual calculation of the gross payroll normally requires one full-time
payroll clerk for each 75 to 100 direct labor operators. The time required to
input the coupons and do the gross payroll will be reduced to one third of the
time required to do it manually.
Savings in Printing Bundle Tickets:
Most apparel factories have a person who spends from 4 to 8 hours per day
printing bundle tickets and maintaining the rates by style (either using type
cages or typed sheets or stencils). The ticket printing is automated which
greatly reduces the work involved in printing bundle tickets.
Improving the accuracy of the data:
With the MAGNAL FA.CT.S manufacturing system there is a check to ensure that the
quantity bundled equals the quantity cut, eliminating errors in the bundle
quantities and the chances of over payments to the operators.
Ability to Change Rates and Quantities per Bundle Quickly and Accurately:
With manual ticket system, changes to piece rates and/or bundle quantities is
both difficult and time consuming. With the MAGNAL FA.CT.S Poduction Control
Software, this can easily be done in the computer ensuring correct payment of
rates and quantities.
Gaining the Lost time between Clocking In/Out and Starting/Finishing Work at
the Work Station:
Everyone is familiar with the line ups to clock in/out and the time required to
travel to and from the work station. By using the operator's gum sheet as
his/her time card, the need for this is eliminated, resulting in a real gain in
productivity of 1% to 2%.
Reduced Work In Process:
With more timely information available, the apparel production management can
react faster to production problems. Work in process inventory levels have
always been a function of the delays of getting data and management's ability to
react and correct problems. Lower levels of work in process are possible by
having the production data available when management requires it.
Improved Employee Motivation:
An important advantage of computerized data collection is the ability to feed
performance data back to the employee on a daily basis. This helps the employees
understand how they are performing and encourages them to maintain a good level
of performance. For trainees it is an excellent motivation tool whereby they can
monitor their performance on a daily basis. Experience has shown that factories
do achieve better performances when information is fed back to the employees.
Improved Planning and Utilization of Factory Capacity:
It is very difficult and costly to do detailed production planning for most sewn
products factories because of the large amount of data which must be calculated
and the need for frequent changes to schedules. Automating the calculations
permits the factory management to quickly analyze production schedules and to
determine where bottlenecks and potential problems exist. In factories, improved
planning has resulted in a 4% to 8% reduction in excess costs.