Production- labor, stockroom and standards

Question 1

Describe the TruCount Process.

Question 2

Explain the benefit of TruCount to our customers.

Question 3

What are the Quality Audit expectations for the rental division?

Question 4

What are the most common defects noted in the Product Quality Audit?

Answer 4

Holes, buttons, emblems, holes in mats and linen

Question 5

What can you, as a Plant Manager, do to improve quality in your location?

Answer 5

Make sure partners have the proper training and work enviroment to focus on quality. Develop awareness with the partners. Determine the root causes of product issues. Bi weekly quality audits. Stay on schedule.

Question 6

What gets poly wrapped?

Answer 6

Press garments. Customer requests. Executive garments. White cotton

Question 7

How are garment repairs handled?

Answer 7

Pin repairs initiated by SSR. Pin repairs are washed each night and hung first thing in the morning. This allows them to go straight to mending allowing time to complete the repair/order emblems and get the garment back with its route.

Question 8

How are “pressed” accounts handled?

Answer 8

Press garments are separated by the SSR on the truck, unload gives them to the wash alley to wash in the pony washer. Press is given to the press operator to press and blended back to route

Question 9

How are late pieces injected?

Answer 9

2nd sort checks the mender rail and late rail in order to pull them into the process. Audit does a finial check of the late rail for final audit.

Question 10

What defect percentage standards should you be achieving at your location, and what is your defect rate?

Answer 10

Garments- <2.5 Bulk- <2.5 Mats- <8.0

Question 11

What are your locations standards for Shakeout, Sorts, Wrapout, Press, Bulk, and Mats?

Question 12

What are you doing to improve your locations standards without sacrificing quality?

Question 13

Discuss the set up and purpose of the Production Labor Audit (PLA). What is needed to do so and what is the importance of the labor audit?

Answer 13

To allow you to see your partner head count in each department and what is actually needed for each department. • Need current roster/ washalley poundage • To see how much work needs to be processed and the amount of people needed in each department to process that product.

Question 14

Explain in depth what each criteria for Production Manager PEAK is and what they can do to get better.

Question 15

Why is controlling labor costs so important?

Answer 15

Increase labor cuts into profits. Next to material cost labor is the largest production cost

Question 16

When is the correct time to use overtime?

Answer 16

Only permitted if it will negatively impact the customer or business. Maintenance needing to be done on off hours

Question 17

What are the reasons that overtime should only be used as a last resort?

Answer 17

Partners can get used to it and start to rely on it. Causes fatigue. Is expensive

Question 18

Why is overtime particularly troublesome in our industry?

Answer 18

It is a sign of poor management. Our business is predictable and we should be able to see ahead and know what we will need to get the work done on time

Question 19

When is the correct time to use to use temporary labor from a staffing agency?

Answer 19

Never • Traditional hiring practices are not generating fast enough or no good quality candidates.

Question 20

What are the reasons that staffing agencies should only be used as a last resort?

Answer 20

If we are not able to support the business. We want to hire long term partners that fit our culture. Staffing agency gets a premium. Usually don’t find good long term partners. Causes lower partner engagement with current partners

Question 21

What are the five components of an effective reliability program?

Answer 21

Proper staffing. Well executed PM program. Good work order sysetm (Emaint). Effective execution of repairs and long term projects. Communication between PM & maintenance

Question 22

What are some consequences to delaying a repair on a piece of equipment?

Answer 22

Breakdown of equipment. Excessive wear and tear. Unsafe environment. Increase in expenses. Decrease in partner engagement

Question 23

What are some conditions that cause our equipment to break down prematurely or unexpectedly?

Answer 23

PMs not being completed. Delaying repairs. Dust or lint build up in the baring or electrical components. Water in contact with uncovered electrical components

Question 24

How can an effective PM program prevent these conditions?

Answer 24

Can spot issues before major breakdowns. Cleaning and inspecting equipment on regular basis

Question 25

What are the 4 "buckets" of material cost on the WOR? Explain each and how MC is allocated.

Answer 25

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Question 26

How is material cost calculated?

Answer 26

Money spent (cost of garments purchased)/Rental revenue (amortized) The lower the better

Question 27

What is your location’s current Existing Material Cost percentage?

Answer 27

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Question 28

Do you believe the Production Department has a major role in controlling material cost? If yes, explain.

Answer 28

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Question 29

What is the importance of physical inventory accuracy in regard to material cost?

Answer 29

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Question 30

What is a GRF?

Answer 30

Garment request form. Generated to request garments from the stockroom/DC

Question 31

What factors impact a location's stockroom OWT?

Answer 31

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Question 32

Explain the benefits in inventory sharing (stock transfer) between locations.

Answer 32

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Question 33

What % of the stockroom should be inventoried weekly?

Answer 33

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Question 34

What is a short-pick and what are the 4 reasons they occur?

Answer 34

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Question 35

What are some factors that can increase a location’s pull percentage?

Answer 35

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Question 36

How can a location improve their scrap rate of OOS garments?

Answer 36

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Question 37

What impact does grading have in material cost management?

Answer 37

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Question 38

What are the major functions of the stockroom?

Answer 38

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Question 39

Explain A, C, S, and D grade garments.

Answer 39

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Question 40

Explain the Stockroom’s role in preventing duplicate orders:

Answer 40

Making sure we are hitting our OWT. Good communication with SSR's on back orders. Run the shortage report and find all garments on the list. Look into any garments missing for shipping dates.

Question 41

What is the purpose of the standard product line?

Answer 41

This is the most commonly used items. Easy to fufill orders. Doesn't requre GM approval.

Question 42

Name 10 of the Material Cost 20 Keys:

Answer 42

·    Rail organization