What is Operation Bulletin and its type?

 What is Operation Bulletin?

Operation Bulletin (OB) is a worksheet which is containing complete details of “How exactly going to manufacture the product in the production line.” It is prepared by Industrial Engineer based on style details. Operation bulletin is containing a complete and clear flow process with SMV. Without appropriate cause adding up (or) reducing down on operation bulletin details is inadequate action.

What are the details contain operation bulleting?

Operation bulletin is a package which is containing details for a particular style.  

i.e. Style details, sketch, order details, process breaks down, SMV, target, workstation type, machine description, attachments details, folder details, work station required, manpower required, total machines, total workstation, total SMVs, total manpower required, planned Output, planned worker efficiency, planned workers efficiency, planned global efficiency, planned pieces per machine, planned pieces per workstation, basic pitch time (BPT), lower control limits(LCL), upper control limits(UCL), workstation balancing details, line balance detail, manpower utilization, takt time (TT), pitch diagram, work minute planned estimated SMV, estimated cost of manufacturing (CM), name of IE who prepared the OB, and special comments. All details are belonging the particular style.  

Which is the complete Operation Bulletin?

Most of the garment industries following only sewing section operation bulletin. It is considered only the sewing section process. But that is not a complete operation bulletin. the complete operation bulletin is included the cutting section process, sewing section process, and finishing section process. Let take an example of a particular style-shirt belonging to order A. Order A has two different types of finishing 1. Deadman packing and 2. Stand packing. Here, stand pack SMV is higher than the dead man folding. The same way solid and check cutting SMV will not be the same even though same style.  Based on the above details SMV should be considered for cutting and finishing process.

What are the points that should be considered if we make Operation Bulletin including cutting, sewing, and finishing process?

In the costing prospects, Cutting, and finishing SMV should be considered. Most of the garment factory’s cost arrives at machines used in the sewing section, Not overall. Cutting and finishing section manpower may not include. In these cases, IE has to work arrive cost per manpower.   

Case1: Cost per minute only sewing section

Sewing cost per manpower per minute = (Average cost per day) / Total machine used in sewing section/Work minute -------- (a)

 Note: Average cost is arrived from monthly cost, Total machine used is considered only from sewing section.

Case2: Cost per minute per manpower

The overall cost per manpower per minute = (Average cost per day) / Total the manpower used in Cutting, Sewing, and finishing -------- (b)

 Note: Average cost is arrived from monthly cost, Total manpower used in considered from cutting + sewing + finishing.

Merchant The complete operation bulleting is used case2 cost per minute for calculating CM. At the same time communicating to merchant (or) marketing (or) buyer should be clear. Because they will confuse and think the SMV is high and cost per minute is low. With proper explanation, we can start following the overall SMV and overall cost.

What are the different types of Operation Bulleting?

Operation Bulleting prepared for multiple purposes,

based on the purpose it will be divided as below,

 1. Primary OB is prepared as a base sheet. This is the first version of OB which is prepared followed by the details of style sketch, Product development comments, Style specification, etc. which is often called a tentative worksheet.

2. Costing OB is prepared to calculate the cost of manufacturing (CM). Based on costing OB and its SMV values, the cost of manufacturing will be calculated. The costing OB will be shared with the marketing or buyer upon request and approval from management. This is kept as confidential data of the company. Costing OB is quite higher than production OB and its values. This is a guideline or thumb line sheet for production OB. If work content or SMV increased after costing OB, IE could be raised a point for upcharge the CM with updated OB and clear justification points.

3. Planning OB is prepared for planning purposes. It is prepared followed by the delivery date and production required rate. This OB will be enabled to 1. The total number of lines requirement, 2. Calculate manpower requirements, 3. Machinery requirement, 4. Capacity booking, 5. Capacity balancing, 6. Order distribution, 7. Delivery date calculation for prepone or postpone, etc. The OB format will be allowed to calculate forward and backward calculations. This operation bulletin is prepared based on forecasted and common style.

4. Production OB is prepared exactly to set the production line accordingly. It is considered all kinds of amendments up to preproduction sample. This is crystal-clear OB with all accurate parameters to follow on the production floor. Before finalize and release the production OB, all parameters will be ensured i.e. Final construction, Measurement of folders and gauges, product safety concerns, etc. Followed by this factory IE will be arranged required machinery, attachment, manpower, methods, etc.

5. Post-production OB is updated based on actual production flow and values. This is like renovation or updating process to set accuracy and maintaining for latest methods. Over the period production floor comes up with new methods than production OB and database. So that the forthcoming process could use the updated methods. Post-production OB preparing IE should be open mind to accept the increase or decrease the workmanship. So that it could be considered for further analysis and improvements.

6. ROI analytical OB is prepared for analytic purposes. This is a supporting document for the engineer to review the requirement of new investments. For example, if a company planned to buy a new technology machine or types of equipment. Then IE can be preparing two OBs i.e. (a) OB with present methods, (b) OB with new method if we buy the new technology machine of equipment. From these to OB can create an additional column to compare (a) and (b). The saved SMV will be converted into cost and time. At end of the calculation, we could get an answer for “How long we need to recover (or) return of interment”. If IE giving a proposal to the company to buy new machines or equipment then they could be submitted with ROI analytical OB. This will be more helpful for both ends to take a decision.

7. Methods and optional OB is prepared for clearly understand two or more methods. For example, we have a proposal to make with different methods for the same product. At the time IE could make different optional OB find which one is a better method. This is a supporting document to finalize a better method in a systematic way.

8. Others OB are often prepared followed be requirements,

For example,

a)       Negotiation OB – Based on construction changes to reduce or upcharge the CM.

b)      Project OB – For calculate project required manpower, machinery, inventory, etc.  

c)       General manpower calculation – To calculate overall or organizational manpower requirement.  

d)      Floater’s calculation – To accommodate attrition, absentees, skill shortage, and balancing purpose.

e)      operators training – To identify key process and arrange advanced training for operators, So on. 

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