Loom Efficiency Scorecard for Woven Sack Factories

Most woven sack factory owners know when a loom has broken down. Very few know which looms are quietly underperforming every single day.

Answer these 6 questions honestly. Each one reveals a gap that could be costing you money right now.

Question 1: Loom-Wise Output Tracking

When your shift supervisor hands over at the end of a shift, does he report output per loom or just total shift output?

• Per loom, every shift
• Total shift output only
• Depends on the supervisor

Why it matters: If you only see total output, a loom running at 70% efficiency is invisible. You only find out something is wrong when the monthly numbers do not add up.

Question 2: Rejection Tracking at the Machine

When a quality checker rejects a batch of bags, is the rejection recorded against the specific loom that produced it?

• Yes, always recorded loom-wise
• Sometimes, not consistently
• No, rejections are recorded as a daily total

Why it matters: Without loom-wise rejection data, the same loom can cause repeated rejections across multiple shifts before anyone connects the dots.

Question 3: Tape Consumption vs Loom Output

Does your system match the tape consumed by each loom against the fabric it produced in the same shift?

• Yes, matched automatically
• Done manually at month end
• Not tracked at this level

Why it matters: Unmatched tape consumption is one of the biggest sources of unexplained raw material loss in woven sack factories. A loom consuming more tape than it should will show up in your wastage number but nobody will know which loom is responsible.

Question 4: Maintenance History Linked to Performance

When a loom's output drops or rejections spike, can your team check whether a missed or delayed maintenance cycle happened around the same time?

• Yes, maintenance and production data are connected
• Maintenance is tracked separately in a register
• Maintenance is done when something breaks, not on a schedule

Why it matters: Most unexpected loom breakdowns are preceded by small warning signs in production data. Without connecting maintenance history to output data, these signs are invisible until it is too late.

Question 5: Loom Stoppage Recording

When a loom stops mid-shift for any reason, whether for a mechanical issue, tape break, or operator error, is the stoppage time and reason recorded immediately?

• Yes, recorded on the system immediately
• Written in a register at the end of the shift
• Not consistently recorded

Why it matters: Unrecorded stoppages create a false picture of loom efficiency. A loom that stops for 45 minutes every shift looks fully productive on paper but is actually running at 80% capacity.

Question 6: Real-Time Loom Dashboard

At any point during the day, can you or your production manager see which looms are running, which are stopped, and what each one has produced so far in the shift?

• Yes, available on a screen or phone
• Available but requires asking the supervisor
• Not available in real time

Why it matters: Real-time visibility allows problems to be caught and fixed within the same shift instead of the next day or week.

Your Score

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• 5 to 6: Your loom tracking is strong. Small refinements could still improve efficiency and reduce wastage.
• 3 to 4: There are meaningful gaps in your loom data. Some wastage and rejection losses are happening that your current system is not catching.
• 0 to 2: Significant loom performance data is missing. Wastage, rejections, and downtime are costing you money that you cannot currently see or measure.

What Fixing These Gaps Looks Like

A woven sack factory with 20 looms running two shifts a day generates a large amount of floor data every 24 hours. When this data is captured digitally and automatically, the factory owner can see:

• Which loom produced the most wastage this week
• Which shift has the highest rejection rate
• Which loom is due for maintenance before it causes a breakdown
• Where tape consumption does not match fabric output

None of this requires changing how the floor team works. It only requires capturing the same data they already record, digitally instead of on paper.

TCB Infotech helps woven sack manufacturers set up loom-wise digital tracking without disrupting floor operations.