King Garments, Sivaganga

The factory knew its fabric cost and its selling price, but not its real labour cost per order. Operator output was recorded on paper bundle cards, tallied at shift end, and reconciled for piece-rate wages days later, which led to disputes and guesswork. Because no one could see output per operator during the shift, an underperforming line or a slow operation only became visible after the order was already behind. Running expense and manpower cost per style stayed invisible until the books closed.

Fleek put operator-level logging on every workstation: each operator logs completed bundles per operation from an Android phone as the work happens. Output is now visible per operator, per operation, per hour, feeding both the live line dashboard and accurate piece-rate calculation. Labour cost is attributed to each style and order from real logged output, so management finally sees true manpower cost alongside material cost on every order.

• True labour cost now visible per order and per style, alongside material cost and not weeks later
• Operator-level output tracking ended piece-rate wage disputes, since wages are calculated from logged data
• Underperforming operations spotted within the shift instead of after the order slipped
• Paper bundle cards and shift-end tallies gone, with production captured digitally at source
• Management reviews now start from real numbers: output, labour cost, and efficiency by line