Textile & Apparel
Where a sewing floor loses money
Control, not just reports — see what happens when you’re not on the floor, and every site in one window
mama · 7:30 AM
Good morning. Here is your floor yesterday:
Productivity
Sewing floor at 58% efficiency — best day this week
Line 4 waited 45 min for cut panels; 3 operators idle on Line 2 after lunch
Output
3,420 of 3,800 garments packed (90%)
PO 7781 (polos, 12,000 pcs) on track · PO 7790 needs one Saturday shift
Safety
Fire exit near finishing blocked by cartons for 40 min
No needle-guard issues flagged
A sample of your morning summary from Mama
Where the money is on a sewing floor
Four places an owner gains or loses money. Each square opens its own map
This year's profit
Capital and the future
GROW
Make moreOutput from lines you already pay for₹9 lakha year for every 1 point of sewing efficiency, on 500 operators at ₹15,000 a monthTechnopak via Online Clothing Study, 2012: India 36-56% · worked exampleOpen the loss tree →OpportunitiesOrders without a new line₹8.4 lakha month from 5 more points of efficiency, as many pieces as a new 50-operator lineOpportunities breakdown · worked example, 500-operator unitOpen the effort × value map →PROTECT
Spend lessFabric, rework, overtime, energy₹1.2 crorea year from six moves in an assumed 600-person, ₹75 crore unit, close to a quarter of its profitMoSPI ASI 2023-24: materials 49.1% of output · worked exampleOpen the loss Pareto →RisksWhat lands on the owner personally₹1.5 croreif four bad events land in one year: fire, audit hold, key person, night shiftNCRB 2024 · DQS 2025 · Labour Bureau · worked example, 400-worker unitOpen the risk map →Calculator for your floorWhat is 1% of sewing efficiency worth to you?Enter operators and wages — see the ₹ a yearOpen →
More calculators: OEE · Rework & scrap · Changeover cost · Labour cost per piece · Stock ageing · Can we take this order? · Power cuts & DG · Customer PPM complaints · Camera-AI payback · OLE (labour effectiveness) · Overtime · Contract labour · Idle-machine energy · CCTV planner & budget · Keep or replace Hikvision/Dahua · Compare analytics quotes · Cash in WIP · Machine utilisation · Shift-edge leakage · Absenteeism · Third shift payback · Late order cost · Runner & regrind · Women night shift · Energy per unit
Navigators: Improvement Methods Navigator · Factory Incentives Navigator
The six things every floor fights
Pick one to see every article →Downtime & output
Machines stopped, waiting or running below plan — before it costs you the shipment
32 articles ›≈ ₹4.1Llost / wk
People & discipline
Who’s on the line, who’s standing idle, and the churn after every festival
15 articles ›≈ ₹1.8Lidle pay / wk
Waste, theft & cost
Rework, half-finished stock with cash frozen in it, and shrinkage at the gate
19 articles ›≈ ₹2.6Lleaking / wk
Safety & risk
The accident, the fire, the unguarded machine — what lands on you personally
9 articles ›3near-misses / wk
Compliance & audits
Proof the shift ran, guards were on and PPE worn — for inspector and buyer
44 articles ›Readyfor audit
Capacity & growth
Spare machine-hours, the next big order, the extra shift — room to grow
9 articles ›18%spare capacity
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Get a camera plan for your floor
Tell Mama about your plant and Mama will come back with how many cameras you need, where they go, and the retention your state expects — sized to your floor, in ₹. Built for Indian factories.
- How many cameras & exact placement
- Compliance-ready (BIS/STQC, women's night shift)
- Honest ₹ estimate — guard vs camera-AI