King Garments, Sivaganga

The challenge

What the floor looked like before

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.

What was set up

On FleekERP

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

Results

What the customer reports

• True labour cost visible per order and per style, alongside material cost, as the order runs.
• Operator-level output ended piece-rate wage disputes, since wages are calculated from what each operator logged.
• Underperforming operations spotted within the shift instead of after the order slipped.
• Paper bundle cards and shift-end tallies gone. Production is captured at the station.
• Management reviews start from real numbers: output, labour cost and efficiency by line.