PRESENTED BY: 1

RITU RAJ
DIVYA
DEEKSHA BARGUJAR
 Incorporated in 1925  Products:
 Jacket
 Raymond Ltd.  Trouser
Gauribidanur was  Vest coat

inaugurated on 24th  Major buyers:

Oct. 2008  Pellestrom
 Peerless
 The total area is 11  J.C Penney
acres and the  Moods of Norway
buildup area is 2,  Haggar
 Express
00,000 square feet
 3M

2
 Fabric stored in separate racks - shell, lining, pocketing,
canvas, felt and fusing
 Material details are stored in Stage
 Supermarket: The materials are stored in advance to be
issued for cutting for easy tracking
 Inspection done based on 12 parameters:
 4point system  Color fastness
 Shade band card  Hand feel
 Face side approval  Bowing & skewing
 Shrinkage  Sponging
 Nap  CSV
 Width report  Seam slippage

3
 Trims are arranged and stored in racks,
rejected ones separately
 The value of materials stored is around
2.5 crores.
 30 days inventory is stored in trims store
 Issue trims as per production planning &
other material as per requirement
 Trims are checked based on AQL 2.5
system
 Labels are counted, defects in weave are
checked
 Buttons are checked for defects: shade
variation and broken buttons

4
 Spreading lines – 7 for jacket, 2 for trouser
 Manual spreading is done for shell fabric to avoid bowing and skewing
 Auto spreader is used for lining
 Face to face spreading is done
 Generally 50 plies are laid at a time, but it varies according to the
requirement
 Pinning table is used for matching checks
 Scope of improvement:
 Use of thread within the pins of pinning table itself, to save time of threading
and knotting

5
 Cutting machines:
 5 CNC cutters
 6 band knives
 3 straight knives

 In jacket –
 All parts are ready cut in CNC cutters and sent for 100% inspection for solid
fabric
 Back, lapel and collar are block cut and then re-cut in band knife
 There are 7 fusing machines in fusing section
 50 garment parts are fused in 1 hour

6
 Jacket line is divided into:
 Front section
 Lining, collar, sleeve
 Assembly

 Jacket line Layout

 U shaped for front section
 2 parallel straight lines for lining, collar and sleeve
 U shaped line for assembly of shell

 Unit production system is used in which the parts are moved using
conveyor
 Trouser line uses straight line layout

7
 6 jacket lines, 5 trouser lines
 Jacket line output- 2400 pieces per day
 Total manpower – 136
 27 workstations consisting of 17 operations
 Packing is done according to buyer’s requirement
 Maximum 6 pieces in one carton

8
 1950 Machines CRITICAL MACHINES
 Preventive
Maintenance  Auto dart machine
 Andon system to  Arm hole tape attach
indicate  Breast pocket welting
1. Breakdown in
 Sham hole
critical machines  Blind hem
 Zig-zag
2. Quality issues
 Front edge machine
 Material tracking &  Sleeve attach
stacking system in  Button hole
store

9
 Planning layouts
 Monitoring Production flow system
 Decide the machines and attachments for all style
 Monitoring and improve the operator performance
 Operator training
 Production control system
 Quality control
 Develop wage and salary administration systems and job evaluation
programs
 Rate and update skill matrix

10
 Quality assurance is done at every stage
 In case of defects, the garments are sent for alteration or re-cutting
accordingly
 Inspection is of 2 types:
 Stationary and roaming
 TLS audit, internal audit and external audits are done to ensure
quality of products

11
 SILVER SPARK APPAREL LTD., UNIT-II

12
PRESENTED BY-
RITU RAJ
B.F.TECH.
BFT/14/870
1 • Observation

2 • Problem Identification

3 • Plan of Action

4 • Implementation

5 • Result

6 • Scope of Improvement
13
1

 Movement of material is more

 Operations are not in straight flow direction
 Line wise separate trolley not used
 Hourly output was not tracked
 Movement of operators from lines to preparatory for bundles is
more
 Frequent m/c breakdown and mechanics attained time is more
 Operation wise target not clear to operators
 Workstation was not properly designed.

14
 BEFORE

15
 PROBLEMS FACED IN PREPARATORY(BEFORE)-
 Movement of material, manpower was more
 Time consuming for every operations
 Material moves from trolley to machine after that pressing table after that WIP trolley

 BENEFITS (AFTER)-
 From this string diagram we can save time of operators
 Movement of material become less
 From this new layout we can increase productivity from auto facing m/c because in
this for six lines we are using four auto facing m/c for front pocket facing attach and
for back pocket facing attach, SNLS m/c are used.

16
 AFTER

17
LAYOUT
PROBLEMS
 Operations in preparatory was not in straight flow direction
 Line 4,5 work was done in line 1 & 2.
 For eg.- Line 4,5 front pkt. facing o/l done in line 4, this creates problem for production
tracking of individual line .
 Movement of material was more
 Time consuming for operators

BENEFITS
 After changing layout movement of material and manpower reduced.
 It saves time of operators

18
 Line 2 FIT is interchanged
with line 2 pressing table (for
reducing the movement of
material)

 Pressing table is used for

pressing all ready parts for
trolley (pocket, fly, waistband,
crotch)

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LINE 1 AFTER AUTOFACING
M/C O/L M/C EDGE
CUTTER FRONT PKT.
POINTED FRONT PKT.
POINTED C BACK POCKET
FACING LABEL ATTACH

20
 Line 6 Auto facing
m/c and fit is
interchanged with
line 4 o/l machine &
SNLS.

21
 BEFORE  AFTER

AFTER

This type of format was not clear Output of front pkt., Waist band, fly for
for others 8 hrs.
In this format output was shown  Line wise is clear to others
as whole (sum of all lines)  Visible for others
Line wise output was not clear  In this format target and achieved
Time consuming for team leaders target is clear 22
BENEFIT-
 From this format hourly
output can be visible to
others
 Line wise production output
is clear
 Auto facing m/c output is
visible
 This format is not time
consuming

23
 BEFORE  AFTER

PROBLEMS BENEFITS
After m/c breakdown operator or After implementation of ANDON light the time of
team leader had to go to the calling mechanics is reduced
mechanic for solution Sound alarm is for calling mechanics
This was too much time consuming Three types of colour light is used
Attended time is more 24
 When Red light is on then mechanics who are in the line can understand there is
some critical problem on machine and machine is not working
 When orange light is on- it indicates that there is some small problems in machine
and mechanic has to attend the machine.
 When green light is on- it indicates that there is no problem and the machine is
running in proper way.
 From this needle time increases and idle time decreases.
 After implementation of Andon light in critical machines 3 minutes time
saved for calling mechanics.

25
 WORK STATION
REDESIGN IN PREPARATORY
LAYOUT

26
ZIPPER ATTACH M/C

PROBLEMS (BEFORE)- BENEFITS (AFTER)-

Left fly zipper not properly arranged After using bin left fly zipper have a proper placement for storing them
There is not proper placement for fly with zipper Floor becomes clean from fly parts
Fly spread on floor in very mismanaged way 5S followed by operators
5S not followed by operators
Hourly 5 minutes saved as there is no chances of
knotting of fly bundle and capacity increased is
27
250 pieces per day
CONTD....

PROBLEMS (BEFORE)- BENEFITS (AFTER)-

There was not proper place for keeping fused fly after After attachment of stand in zipper attach m/c time of
fusing m/c finding fly from the fusing m/c is reduced
Operators kept fly on sewing table that was not good Visibility becomes managed way
for sewing. Idle time is reduced
Bundle allowance time reduced is 5
minutes per hour 28
CROTCH OVERLOCK M/C

PROBLEMS (BEFORE)- BENEFITS (AFTER)-

There was not proper placement for crotch After attaching bin to the sewing table
after over lock. crotch don’t touches the floor
The crotch touches the floor after passing There become a proper placement for
through machine. crotch

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W.B. FUSING M/C

BEFORE PICTURE
AFTER PICTURE

30
 PROBLEMS-  BENEFITS-
 There is not proper placement  After implementing band roll stand
for Band Rolls (fusing) used the haphazard way of placing rolls is
during waist band fusing abolished.
 As we can see from fig. the
band rolls spreads on the floor  From this implementation they follow
this is not the right way of 5S
placing anything on floor  This we can see from fig. The band
 Operators faced problem rolls are not kept on floor
during picking band rolls from
floor because they are under  Fusing machine’s upper part become
the fusing machine. clear from band rolls.
 Sometime operators kept rolls  This shows a managed way of placing
on upper part of Fusing anything.
 The average time saving of operator
machine that shows the
haphazard way of placing rolls. per hour is 16 minutes and capacity
 There was not proper increased 96 pieces per hour
placement for keeping waist
band pieces join for fusing
under fusing machine.
 Operators kept waist band
pieces on the floor for fusing.

31
AUTOZIG M/C

PROBLEMS (BEFORE)-
BENEFITS (AFTER)-
waist band cut pieces have not proper
After implementing waist band stand for
place for keeping them
waist band cut pieces there becomes a proper
Time consuming in finding waist band line
placement for waist band fused pieces
wise
 Cycle time reduced per piece is 2
Re -cutting waist bands are less in no. that’s
second
why it has more chance to replace.
 Capacity increase is 60 pieces per hour
Wastage of time is 15 minutes per hour 32
CONTD....

PROBLEMS (BEFORE)- BENEFITS (AFTER)-

There is not proper place for storing After implementing waist band stand for waist band cut
extension after comes from fusing m/c pieces there becomes a proper placement for waist band
Operators take pieces/ bundle from the fused pieces
fusing m/c after place them on machine Easy for Auto zig operator to work in bundle
This is difficult for doing work with all In stand waist band placed according to line from this way
bundles and all on machine it is time saving for Auto zig operator
There is a separate segregation for re cutting waist bands.
Material is easy to access and time saving is 5
33
minutes per hour
LABEL ATTACH M/C

PROBLEMS (BEFORE)- BENEFITS (AFTER)-

There was no proper placement for labels After attaching labels box with label attach machine there
storing become a proper placement for labels
Lots of Labels scattered across the label attach From this attachment there is no label scatter across the
machine that looks like a lot of mismatches. machine
Ergonomically right for operators to do work
Time consuming for finding different types of There is separation in the label box for different type of labels (
labels from one place size, main, fit )
 Cycle time is reduced 8 seconds (51 second to 43
seconds) per pieces
 Capacity increased is 13 pieces per hour 34
FLY BINDING M/C

BEFORE
PICTURE
AFTER PICTURE

35
 PROBLEM-  BENEFITS-
 In fly binding machine there was not  After adding roller stand in fly binding
proper placement for keeping binders machine the WIP trolley become vacate.
 Operators placed them in WIP trolley that  Fly binding machine become more
was not right place for placing them spacious.
 From this WIP trolley saw always  Easy access of the rolls and hourly
overloaded, because of this the place for time saving is 4 minutes.
placing small parts in WIP trolley
reduced.
 Some of them placed on fly binding
machine. From this the sewing area on
table reduced.

36
AUTO BOBBIN WINDER FOR LOOP
LOOP M/C

Bobbin for Air motor for loop

loop binding binding

37
 PROBLEM-  BENEFITS-
 There was not proper space for loop  After implementing loop binder the work
after loop ready machine, from this flow becomes easy to operate
floor becomes very unclean  Time saving for line operators
 Time consuming for operators who  Loop is binded in bobbin as line wise
come in preparatory from lines, they
first clear the knots from loop after that  There are total 12 bobbins for loop
they rolled in hand for save loop from binding 6 for lines and 6 for preparatory
knotting.
 The total capacity of one bobbin is for
 Fusing machine bin were always full 160 pcs. Trousers
with loops, it is not easy to find out line
wise loop after fusing machine.  This implementation is automatic that’s
why it takes less time
 From loop floor in front of blind hem
machine becomes very messy.  Air motor is attached with loop ready
machine from this when the machine
moves the loop binder moves with the
same speed of loop ready machine.
 Easy to feed material to lines as
Bobbin winded form
 There is no chances of Loop knotting
 Rework time for unknotting by
operator is saved upto 12 minutes per
hour
38
SL No Improvement Area Before After
capacity/day Capacity/da
y
1 Auto Facing machine(per machine) 800 960

2 Zipper Attach 2800 3050

3 WB Fusing 2900 3668

4 WB Extension Sew(for 4 line) 1984 2630

5 Label Attach(for 1 line) 564 670

6 Fly Binding 2880 3170

7 Loop Sew machine 2880 3456 39

2

 Autofacing machine output is less than the target

 Requirement of multiskill operators in few operations for

absenteeism cover

 Layout is not as per material flow

 There was not proper segregation for small parts in trolleys.

40
OBSERVATIONS
 Autofacing m/c output- capacity of Auto facing m/c is 150pcs./Hr but output comes 90-
105 pcs./Hr
 Operators skill- operators are not Multi skilled that creates problem during more
absenteeism.
 Absenteeism on workstations
 FREQUENT M/C BREAKDOWN
 PROBLEMS

 CAPACITY OF PREPARATORY-
CAPACITY= MANPOWER * EFFICIENCY * SHIFT TIME/SAM
 Calculation:
 Manpower: 34
 Expected Efficiency: 80%
 Shift Time: 480 minutes
41
Capacity = 35*80*480 /5.2*100
 SOLUTION
1) AUTOFACING M/C ELEMENTAL BREAKDOWN REPORT
 Problem- bundle loading time
 Solution- reduced bundle loading time after implementing
stickers after per 50 pc.
 Trolley arrangement according to parts

42
 BENEFIT OF TROLLEY AND ITS SEGREGATION ACCORDING TO
SMALL PARTS-
 Visible for others where the small parts are kept according to line.
 This reduces bundle loading time of Auto facing m/c operators.
 Maximum time for bundle loading for operators is 3-4 min. from this it becomes
1min.
 Before this implementation pkt. Bag was kept one upon another bundle of 50 pcs.
 From this same serial no. pkt. bag is placed in opposite column of trolley and
facing is placed in the upper part of trolley.
 There are 4 rows and 3 columns in trolley two lines are divided for one line .

43
STICKERS AFTER
EACH 50 PCS. IN
POCKET BAG

STICKERS AFTER EACH

50 PCS IN FACING
44
 BENEFITS
 After implementing sticker system bundle loading time is reduced from 3-4 min. to
20 sec.
 This time is added in needle time of Auto facing M/c
 The Capacity of Auto facing output increased by 8 piece per hour per
machine. So the total capacity 32 piece per for four machines

45
PROBLEMS (BEFORE)- BENEFITS (AFTER)-
After segregation of trolley according to parts, visibility of
WIP trolley was not segregated according to parts
WIP becomes more clear for everyone.
Line 1-6 trolleys segregation was not matched with each
It saves time of line operators
other.
Line operators takes time for finding small parts. From this line 1-6 parts arrangement looks similar.
The searching time for parts and the serial no is The searching time reduced from 2 minutes to 10
more than 2 minutes. seconds for finding correct parts 46
3

OPERATION BULLETIN
SKILL MATRIX
PITCH DIAGRAM
TIME STUDY & BALANCE CHART
MULTI SKILL
7 DAYS WORKING DAY PLAN

47
48
4

 Reduced bundle loading time after implementing stickers after per 50 pc.
 Trolley arrangement according to parts
 Segregation of WIP trolley parts wise
 Layout

49
 5  From this data we can find the output of
Auto Facing machine per week. In
Preparatory section Auto facing machine
AUTOFACING REPORT-JUNE
is the critical machine and it was the main
2000
source for output of front pocket bag
1800  There were 4 auto facing machine in
1600
preparatory, from each machine there
were a set target of 120 pcs./ hr. And the
1400
output came approx. 80-90 pcs. /hr.
1200
P
I 1000 AUTOFACING
E 800 REPORT-JUNE

C
600
E
S 400
200

0
1ST WEEK 2ND WEEK 3RD WEEK 4TH WEEK

50
REPORT
  After implementing sticker system
AUTOFACING REPORT - JULY
2120
for bundle loading, 3 minutes of time
reduced and adding ANDON light in
Auto Facing machine, 10 minutes
2100
time reduced, from this the output of
Auto Facing machine increased day
P 2080 by day. This implementation is done
I in July 3rd week and the output came,
E we can differentiate with the output
2060
C of June month and can find the
E difference.
S 2040

2020 AUTOFACING
REPORT JULY

2000
1ST WEEK 2ND WEEK 3RD WEEK 4TH WEEK

51
 AUTOFACING REPORT- AUGUST  In august report we can see the
2300 production incensement as
compared to June and July month
2200
 The auto facing machine output
will come 110 pcs/hr. from this
2100
type of implementation.
P
I
E 2000

C
AUTOFACING
E 1900
REPORT- AUGUST
S
1800

1700
1ST WEEK 2ND WEEK 3RD WEEK 4TH WEEK

52
6

 CONVEYOR TRAY IN PREPARATORY FOR BUNDLE MOVEMENT

 Conveyor belt should be installed in preparatory section for easy and quick
bundle movement .
 After layout change operations are flowing straight so we can pass conveyor belt
from mid of two lines, and the bundles from one operation to next operation can
move In very less time.

Conveyor belt for

passing bundles
from one
workstations to the
other one 53
 Gerber GTXL Manual.
 Industry Observation and Findings.

54
55