Process Loss Reduction: Implementing Process Management System Through Digitization using a Web-Based Application

Abstract

This research identifies problem in Ethiopian denim trouser manufacturing unit between cut to ship, resulting in material loss. The area of study is chosen from the cutting to the packing of the unit. The study investigates the various process losses and their causes. A web-based application that uses a QR code to track bundle movement is attached with bundles which will also generate production, Quality, Machine breakdown, recut, and WIP reports. The design and system developed can track Real-time material movement throughout the process and generate real-time insightful and actionable data. Using real-time tracking, planning, and insightful data provides a vision for this project. The significance of the research is immense as Reliance on the data is raised, planning becomes more manageable and effective, monitoring is improved, WIP is controlled, Gap Mitigation (Capacity to Performance) is streamlined and above all, "Transparency" of the floor becomes sharper.