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100 Non-Productive Time (NPT) Problems in Garments (Department-wise)

What is NPT? Any time in which people, machines, or lines are not adding value to the garment (no standard minutes produced) due to waiting, stoppage, rework, or administrative holds.

Simple KPI idea: NPT% = (Total NPT Minutes ÷ Total Available Minutes) × 100

This table lists common Non-Productive Time (NPT) issues in garment factories, divided by departments.

Department	Problems
Cutting	1. Fabric not issued on time 2. Fabric shade variation approval delay 3. Marker not ready 4. Lay planning delay 5. Cutting machine breakdown 6. Bundling/numbering delay 7. Cut panels not received 8. Wrong cutting 9. Fabric shrinkage issue 10. Panel direction mismatch
Sewing Line	11. Late line start 12. Early line stop 13. Operator absenteeism 14. Operator late arrival 15. Helper absent 16. Line balancing issue 17. Machine breakdown 18. Needle breakage 19. Presser foot/attachment missing 20. Gauge set change delay 21. Learning curve of new operators 22. Method not standardized 23. Work aid not ready 24. First piece approval delay 25. Wrong bundle mix-up
Maintenance	26. Machine oiling delay 27. Spare parts shortage 28. Preventive maintenance not scheduled 29. Boiler breakdown 30. Steam leakage 31. Air pressure failure 32. Lighting failure 33. Electrical breakdown 34. Compressor not working 35. Long wait for mechanic
Quality	36. Inline quality inspector not available 37. Rework/repair queue 38. DHU spike investigation 39. PP sample not approved 40. Size set pending approval 41. Measurement spec change 42. QC hold without decision 43. Final QA hold 44. AQL inspection delay 45. Re-inspection after fail
IE (Industrial Engineering)	46. Operation bulletin not released 47. SMV not confirmed 48. Method trial & error 49. Layout change delay 50. Line balancing pending 51. Hourly target not communicated 52. Work study delay 53. Skill matrix not updated 54. Training delay 55. Improper operator allocation
Finishing	56. Iron not heating 57. Steam station breakdown 58. Metal detector not working 59. Shade sorting delay 60. Measurement audit rework 61. Carton shortage 62. Polybag shortage 63. Ticketing/price tag delay 64. Packing approval pending 65. Loading plan change
Trims & Store	66. Trims not issued 67. Wrong trims issued 68. Thread shortage 69. Button shortage 70. Zipper shortage 71. Elastic shortage 72. Interlining shortage 73. Carton not in store 74. Polybag mismatch 75. Barcode label not printed
Admin / HR	76. Strike/labor unrest 77. Excess absenteeism 78. Extended breaks 79. Unplanned meetings 80. Fire/evacuation drill 81. Compliance audit 82. Buyer visit stoppage 83. Training session during production 84. Health screening stoppage 85. Accident/first aid incident
Utility / General	86. Power failure 87. Generator breakdown 88. Voltage fluctuation 89. Compressed air leakage 90. Water shortage 91. Heat/humidity problem 92. Safety alarm false triggers 93. Canteen issue (late food supply) 94. Transport delay 95. ERP/system down
Logistics / Shipment	96. Dispatch vehicle not available 97. Shipping plan change 98. Document not ready 99. Container delay 100. Port strike / external hold

Total: 100 Problems Department-wise