Process Capability

How many operators can actually run each operation — the answer to every line-balancing and style-change question

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Operations in catalogue

39 critical

Single-point-of-failure

Operations with fewer than 3 qualified operators

Qualified operator slots

2,401

Operators at 70%+, counted per operation

Average efficiency

69.1%

Process-wise skilled operator pool

Grade spread of the operators tested on each operation. Management's line-allocation sheet.

Operation	Category	M/C	SMV	Target/hr	Tested	A+	A	B+	B-	<60	Qualified	Avg eff.
Cargo Pocket Flap Attach & Top Stitch	Critical	SNLS	0.80	75	82	10	10	23	23	16	43	70.5%
Cargo Pocket Attach (Both Side)	Critical	SNLS	1.20	50	68	13	7	20	16	12	40	72.7%
Inseam Join	Critical	5T O/L	0.40	150	73	9	5	26	19	14	40	71.3%
Attach Back/Front patch pocket	Critical	SNLS	0.60	100	64	17	5	17	17	8	39	74.8%
Close Waistband Mouth L/R	Critical	SNLS	0.75	80	62	13	6	17	20	6	36	74.4%
Join Inseam by OL	Critical	OL 5	0.60	100	68	11	9	16	20	12	36	71.2%
Front Rise OL (Single & Double Fly)	Critical	4T O/L	0.50	120	70	13	2	20	18	17	35	70.2%
Join bk rise by folder	Critical	FOA	0.24	250	56	7	8	20	14	7	35	73.4%
Join Side seam by OL	Critical	OL 5	0.75	80	66	7	4	24	13	18	35	69.2%
Side Seam Join	Critical	5T O/L	0.60	100	64	7	7	20	17	13	34	71.0%
Bottom Hem	Critical	SNLS	0.50	120	63	8	3	23	15	14	34	70.2%
Back Rise Join	Critical	FOA	0.35	171	66	11	8	15	18	14	34	71.5%
Top st. Welt pocket bag with fold	Critical	SNLS	1.00	60	54	6	6	21	13	8	33	71.5%
Attach Waistband (Single Folder)	Critical	MNCS	0.40	150	62	12	5	16	18	11	33	71.7%
Attach reinforcement patch to body (Four corner)	Critical	SNLS	0.86	70	61	14	7	12	14	14	33	72.1%
Close collar bottom	Critical	SNLS	0.60	100	64	9	4	20	16	15	33	69.4%
Attach Waistband (Manual)	Critical	SNLS	0.60	100	62	8	7	17	16	14	32	70.3%
Back Pocket Attach	Critical	2NLS	0.75	80	57	5	7	20	17	8	32	71.1%
Attach Welt to body (APW)	Critical	APW	0.35	171	51	5	4	23	11	8	32	70.9%
Close Waistband Top/bottom (Manual Waistband)	Critical	SNLS	0.70	86	50	9	8	15	9	9	32	72.9%
Join Inseam (Folder)	Critical	FOA	0.40	150	54	13	3	16	14	8	32	74.6%
Make Collar With zig pattern	Critical	SNLS	0.40	150	60	2	7	22	22	7	31	69.8%
Bottom Hem	Critical	2NCS	0.75	80	57	6	5	20	18	8	31	71.4%
Waist Band Attach	Critical	K/S	0.50	120	61	8	6	16	19	12	30	70.9%
Attach collar	Critical	SNLS	0.60	100	54	9	9	12	12	12	30	71.9%
Front Pocket Top Stitch With Piping	Critical	2NLS	0.60	100	64	12	4	13	18	17	29	69.9%
Back Yoke Join	Critical	FOA	0.35	171	53	12	2	15	12	12	29	71.5%
Front Rise Join (Fly)	Critical	SNLS	0.40	150	55	6	8	14	14	13	28	69.5%
Bartack body with loop	Critical	Bartak	0.30	200	55	5	3	20	18	9	28	69.7%
Join bk yoke by folder	Critical	DNCS	0.30	200	63	9	4	14	18	18	27	69.3%
Waist Band Edge Close	Critical	SNLS	0.75	80	65	6	9	11	21	18	26	68.5%
Inseam Join	Critical	FOA	0.40	150	60	9	3	14	23	11	26	70.0%
J-Round Top Stitch With Mark	Critical	2NLS	0.35	171	59	8	7	11	19	14	26	69.9%
Attach cargo pocket	Critical	SNLS	1.00	60	52	7	2	16	20	7	25	71.0%
Attach Waistband (Double Folder)	Critical	MNCS	0.50	120	44	5	4	15	12	8	24	70.3%
Attach Welt to body (Manual)	Critical	DNLS	0.60	100	61	7	2	15	16	21	24	66.7%
Attach sleeve after side seam by OL	Critical	OL 5	0.65	92	55	7	4	12	17	15	23	69.1%
Join bk rise along with front rise (Folder)	Critical	FOA	0.50	120	56	9	4	10	18	15	23	68.5%
Back Pocket Attach With Reinforce	Critical	SNLS	0.80	75	54	5	7	8	22	12	20	67.1%
Top st. at inseam	Semi-critical	FOA	0.40	150	77	9	12	21	23	12	42	72.0%
Top st. at welt pocket top	Semi-critical	SNLS	0.60	100	69	9	12	15	22	11	36	71.2%
Front Pocket Mouth Top Stitch	Semi-critical	2NLS	0.50	120	69	15	6	15	14	19	36	70.4%
Cargo Pocket Box Pleat Make	Semi-critical	SNLS	0.70	86	67	10	4	20	19	14	34	70.3%
Attach sleeve before side seam by OL	Semi-critical	OL 5	0.45	133	62	10	4	20	17	11	34	71.3%
Inseam Safety Stitch	Semi-critical	SNLS	0.35	171	65	9	10	14	12	20	33	70.0%
Flap Join with 1/16"–1/4" Top Stitch	Semi-critical	SNLS / 2NCS	0.70	86	74	5	9	19	20	21	33	68.5%
Attach cuff	Semi-critical	SNLS	0.75	80	70	6	7	20	21	16	33	69.8%
Front Part Panel Top Stitch	Semi-critical	2NCS	0.40	150	59	3	6	23	19	8	32	70.4%
J Round	Semi-critical	DNLS	0.24	250	64	6	8	18	15	17	32	70.5%
Zipper Join with Single Fly T/S	Semi-critical	SNLS	0.40	150	56	11	4	16	11	14	31	70.1%
Flap Join	Semi-critical	SNLS	0.50	120	69	5	7	18	20	19	30	69.1%
Side Seam Top Stitch	Semi-critical	FOA	0.40	150	59	10	7	13	20	9	30	71.7%
Attach D/fly,Join & top st. front left right	Semi-critical	SNLS	0.35	171	57	6	4	20	19	8	30	69.7%
Thigh Pocket Attach with Corner Tack	Semi-critical	SNLS	1.50	40	73	9	2	18	24	20	29	67.7%
Join back rise along with front rise	Semi-critical	OL 5	0.45	133	57	9	3	17	18	10	29	70.5%
Top st. at front pocket mouth	Semi-critical	DNLS	0.50	120	68	3	6	20	20	19	29	67.9%
Attach loop to waist	Semi-critical	SNLS(VRT)	0.45	133	63	5	6	18	20	14	29	68.2%
Front Pocket Bag Close	Semi-critical	3T O/L	0.30	200	62	7	5	17	21	12	29	70.2%
Cargo Pocket Velcro (Value) Attach	Semi-critical	SNLS	0.75	80	63	5	3	21	15	19	29	67.5%
Make flap/cuff with zig pattern	Semi-critical	SNLS	0.75	80	61	3	7	19	20	12	29	68.9%
Back Part Dart Make & Top Stitch	Semi-critical	SNLS	0.70	86	55	7	3	18	15	12	28	69.5%
Front Pocket Attach	Semi-critical	SNLS	0.35	171	59	6	3	19	16	15	28	68.6%
Front Pocket Bag Turn & T/S	Semi-critical	SNLS	0.35	171	55	6	6	15	15	13	27	69.7%
Welt Facing Attach	Semi-critical	SNLS	0.40	150	62	7	5	15	19	16	27	68.1%
Welt Top Stitch (Upper & Lower)	Semi-critical	SNLS	1.00	60	61	5	10	11	19	16	26	68.9%
Cargo Pocket Flap Top Stitch	Semi-critical	2NCS	0.50	120	60	9	4	12	17	18	25	67.8%
Top st. at welt pocket bottom	Semi-critical	SNLS	0.50	120	54	6	6	12	21	9	24	68.9%
Cargo Pocket Top Stitch	Semi-critical	2NCS	0.60	100	57	8	7	9	18	15	24	69.1%
Top st. at waist	Semi-critical	MNCS	0.45	133	67	6	3	15	25	18	24	66.3%
Tack front pocket side & waist	Semi-critical	SNLS	0.40	150	58	7	5	11	14	21	23	67.7%
Facing Attach	Semi-critical	SNLS	1.20	50	60	7	4	12	18	19	23	67.2%
Single fly t/s with zipper attach	Semi-critical	SNLS	0.35	171	59	7	2	14	15	21	23	67.3%
Bartack at body	Semi-critical	Bartak	0.30	200	69	4	2	17	24	22	23	65.9%
Two Part Close with Double Fly	Semi-critical	SNLS	0.40	150	53	5	6	9	19	14	20	67.3%
Attach front pocket facing with fold 4*	Semi-critical	SNLS	0.75	80	60	2	4	13	22	19	19	64.2%
Sew second st. at bk pocket	Semi-critical	SNLS	0.50	120	57	2	2	15	22	16	19	65.0%
Top st. bk yoke	Basic	DNCS	0.30	200	26	3	5	7	5	6	15	70.4%
Back Flap Attach & Top Stitch	Basic	SNLS	1.00	60	22	1	·	9	6	6	10	66.1%
Top st. bk rise	Basic	FOA	0.24	250	20	1	2	6	6	5	9	68.4%
Close back/front pocket bag with turn	Basic	LO 3	0.30	200	23	3	1	5	5	9	9	66.4%
Belt Loop Attach	Basic	SNLS	0.40	150	20	1	2	6	6	5	9	68.5%
Waist Band Loop Tack	Basic	SNLS	0.35	171	16	2	2	5	3	4	9	70.3%
Top st. at back/front pocket bag (Pre overlocked)	Basic	SNLS	0.45	133	23	1	1	7	7	7	9	65.4%
Tack & top st. at front rise	Basic	SNLS	0.35	171	14	2	2	4	5	1	8	73.6%
Thigh Pocket Pleat Top Stitch	Basic	2NLS	0.75	80	18	4	1	3	4	6	8	69.2%
Eyelet Hole	Basic	B/T	0.20	300	20	2	1	4	6	7	7	64.7%
Label Join	Basic	SNLS	0.24	250	21	1	1	5	5	9	7	63.0%
Attach & top st. flap	Basic	DNLS	0.60	100	18	3	1	3	6	5	7	69.2%
Loop Bartack 10*	Basic	B/T	0.50	120	14	1	·	5	3	5	6	67.5%
Thigh Flap Attach	Basic	SNLS	0.40	150	18	2	·	2	10	4	4	65.7%
Join bk rise	Basic	LO 5	0.24	250	18	1	·	3	6	8	4	62.8%
Body Bartack 10*	Basic	B/T	0.40	150	19	1	1	2	11	4	4	65.7%
Serge front rise,Single fly, Double fly	Basic	OL 4	0.40	150	15	2	1	1	4	7	4	62.8%
Top st. at side seam (Full?Up to hip)	Basic	FOA	0.45	133	9	·	1	2	3	3	3	61.5%
Join bk yoke	Basic	LO 5	0.30	200	17	·	2	1	5	9	3	62.3%
Belt Loop Make	Basic	F/L	0.30	200	12	1	·	·	6	5	1	63.9%

“Qualified” means the operator has recorded 70% or better on that operation at least once. Target/hr = 60 ÷ SMV.

Machine-wise capability

Average efficiency by machine type

Machine operator pool

M/C	Ops	Tested	Qualified
SNLS	45	1222	671
FOA	10	436	229
OL 5	5	285	148
2NLS	5	244	122
2NCS	4	221	107
DNLS	4	201	88
MNCS	3	169	79
5T O/L	2	134	71
Bartak	2	119	50
DNCS	2	89	42
4T O/L	1	70	35
SNLS / 2NCS	1	74	33
APW	1	51	32
K/S	1	61	30
SNLS(VRT)	1	63	29
3T O/L	1	62	29
B/T	3	49	16
LO 3	1	23	9
LO 5	2	35	7
OL 4	1	15	4
F/L	1	12	1