Internship report, Brandix internship project unit-1 Apparel production floor

1. Brandix
Presented by Suman Chowdhury(MFT/21/79)

2. About
Brandix Lanka Limited was founded in 1972 and is based in Colombo, Sri Lanka. The company was
formerly known as Lux Shirts (Pvt.) Ltd. The company has manufacturing locations in Sri Lanka, India, and
Bangladesh
Brandix Lanka limited is a well-known garment manufacturing company which has South Asia’s largest
apparel group, providing integrated solutions covering the entire value chain, from product design,
development, manufacturing and raw-material supply. Because of that reason, clients are being provided
best what clients can be satisfied. They are doing the best for their customers, so they have been given lot of
orders from foreign branded company. Because of that reason Brandix is one of the largest exporters of
apparel in Sri Lanka. As the holding company of the Brandix Group of companies, it is engaged in
developing, manufacturing and marketing end-to-end apparel solutions to global fashion super brands.

3. Overview
Overview
Plant Head- Mr. Senthooran Sivasubramaniam
Single largest exporter of underwear from India
4200 Employees
Two shift operation
Products produced: Bikini, Boy Shorts, Thongs, V-Strings, Hip Huggers and Hipsters
Land Area: 13.5 Acres
Built Up Space: 146,000 sq. ft.
Producing 4.5 million pcs/month in a two-shift operation.
Current Customers- Victoria's Secret LOGO & Victoria's Secret PINK

4. Factory cost

5. sampling
Reference Sample: This sample is sent by Brandix Lanka to create a black seal sample.
Black Seal Sample: This sample is stitched by the technician. Original fabric and trims
are used to stitch it. Out of the 5 samples stitched, 2 best samples are sent to the front
end to get assurance on construction and measurement. Once approved, Brandix India
can start with the bulk production.
Keep Sample: One of the black seal samples which is kept to be used as reference in
future is known as the keep sample.
Green Tag Sample: Black seal sample received from Brandix Lanka after approval
from Technical Head of Brandix Essential limited is known as the green tag sample.
Red Tag Sample: The black seal sample received from Brandix Lanka after approval
from the buyer is known as the red tag sample.

6. Sourcing

7. Water Spiders Day In ALife Alignment
Trims Reconciliation progress &Visual control
Label storage &deviationcontrol

8. Water Spiders Day InALife
Alignment

9. Water spider is a term that refers to the specific person whose main role is to take
care of the tasks that are issued such as supplying materials to the workstation.
Water spiders classification for each section:
Trims waterspider-1
Label water spider-1
Block input water spider- 4 (for blocksA,B,C,D)
WATERSPIDER

10. TRIMSCOLLECTIONFLOWCHART

11. LABELSCOLLECTIONFLOWCHART

12. INPUTBUNDLECOLLECTIONFLOWCHART

13. Checking IMS/TMS/RMS of the modules.
Put input request for TMSand get necessary input based on the module requirement.
Collect the cut bundles from the cutting section, counting the bundles and put
signature in the cutting operators book.
According to the WIPin the sewing module, input quantity is arranged in the input
area.
[Trims are issued and arranged in total quantity, cut bundles are arranged for next 2-
3hrs]
Lace relaxation isdone.
Elastic is arranged (provided in bins).
Issuing the input to the operators.
Cleaning the input area of sewing module.
Placing the trims in the return trims area (when the style is closed)
INPUTWATERSPIDER JOBROLE

14. INPUTWATERSPIDER DAYIN ALIFE

15. SECTION1(BLOCK-B)
•Check the input and arrange the
bundles in input area =15mins
•Arrange trims in input area and clear
the trimboxes =5 mins
•Put trims request for modules = 5
mins
•Check RMS and note down the
required =5mins
• Arrange thread cones in return area
=5 mins
•Collecting cut bundles from RMS,
sorting them according to the size,
counting plies and bundles, storing in
IMS=60 mins
•Serving trims input to modules = 10
mins
SECTION2(BLOCK-C)
• Check input in the modules =5mins
•Noting down the IMS and input left
in the modules =5 mins
• Put trims request =10mins
•Collecting cut bundles from RMS,
sorting them according to the size,
counting plies and bundles, storing in
IMS=45 mins
•Remove the return trims from the
input area and arrange those trims in
return area=30 mins
•Arranging new thread cones to stand,
remove the balance thread cones and
storing =10mins
SECTION4 (BLOCK-A)
• Check input area=15mins
•Check IMS balance and bundle input
in modules =60mins
• Put trims request =10mins
•Arrange thread and clean the input
area =15mins
• Return trims =20mins
• Lace relaxation =5mins
• Elastic relaxation =30mins
•Collecting cut bundles from RMS,
sorting them according to the size,
counting plies and bundles, storing in
IMS=45 mins
•Arrange lace to the lace stand = 10
mins
• Collecting gussets =20min
SECTION WISEOBSERVATIONS

16. UPGRADEDINPUTWATERSPIDER DAYIN ALIFE

17. Root Cause:
Not being present at the input
areas when cleaning music plays.
They are facing difficulties while
arranging the balance style trims
and running style trims and cut
bundles at the same place.
Empty carton boxes are left in the
input area.
maintained
Problem:
Input areas are not
organized by water spider.
1.Problems Observed
Before

18. Suggestion:
They have to come and clean
input area of their respective
blocks when the cleaning music
play.
Balance style trims and new style
trims have to be stored separately.
Empty boxes have to be folded
and thrown in the blue bins.
After

19. Problem:
Thread cones issue in thread stand and
return area
Root Cause:
Even if the thread cones are provided
with a plastic cover, the covers were
missing after placing them in the
input area.
Balance style threads are left
uncovered.
The thread cones are also not sorted
according to the cone type
(160T,160s,120) in returnarea.
2.Problems Observed

20. Suggestion:
The new style thread cones
have to be placed along with
cover provided and the
balance style thread cones
have to be arranged separately.
Thread cones have to be sorted
colour wise.
Before
After

21. Trims Reconciliation progress &
Visual control

22. TRIMSRECONCILIATION
Trims reconciliation is a process that is used to do the analysis of trims
consumption.
What percentage of trims are used for one style, what percentage of trims is
left after production, what is the percentage of trims wastage is calculated.
Trims reconciliation helps to understand the required quantity and arrange it
in the sewing module.

23. TRIMSRECONCILIATIONFLOWCHART

24. Main reason:
1.Improper usage/Shortage of trims in the sewing modules.
2.Cutting operators not following the exact cut length in spreading of bindings fabric
3.Not using exact size binding roll to that size of garment ,because when there is a shortage of
binding in the previous cut number, they are using binding of next cut number( in some
cases)
Sub reasons:
1.Issue in the operator skills/Improper stitching in the module.
2. Defect in the function of sewing machine.
Effect:
3.Over usage of binding and elastic is observed.
4.Labels and heat-seals required for IMSbalance garments are deviated.
5.Trims like elastic, binding, lace, labels and heat-seals are getting wasted.
WHYDOES ITOCCUR?

25. Problem:
The elastic given in the bins is
getting tangled.
Root Cause:
If the quantity of elastic required for
one style is 120 yards, when each box
contains only 200 yards, then 120
yards elastic is taken from the box and
issue it in bins when the trims water
spider collect it from RMWH and
handover to input water spider, it is
getting tangled.
PROGRESS IN TRIMSRECONCILIATION

26. Suggestion:
The elastic provided in the bins have to be
packed tight in a cover to avoid movement
inside the pack and overtime taken in the
sewing module
Before After

27. DAILYTRIMSRECONCILIATION SHEET
The quantity of the respective cut no. trim is calculated by Technician.
The module with the same cut quantity mentioned in the trims reconciliation format with that
of size wise output is marked green.
The module with that differs in the cut quantity mentioned in the trims reconciliation format
with that of size wise output is marked red.

28. Style no.:200883
Module 50- Size S
Waist Cut Length=48"
No. of pieces=2
There is no wastage in the binding for that
particular size. The joint in the binding is
exactly sufficient for 2pieces.
Style no. :200883
Module 50- Size S
LegCut Length=62"
No. of pieces=1.5
There is no wastage in the binding for
that particular size. The joint in the
binding is exactly sufficient for 1.5pieces.

29. Style no.:200883
Module 32- Size M
Waist Cut Length=55"
No. of pieces=2
5"-6"of wastage isobserved.
Style no. :200883
Module 32- Size M
LegCut Length=55"
No. of pieces=1
Shortage in the leg binding has been
observed. Under monitoring, there is no such
issue ofshortage.

30. Proper skill operator should be considered for that particular operation of binding and elastic.
Respective trims should be used for that respective garment style and size only.
Cutting operators have to spread the fabric with exact measurement.
Under monitoring, the wastage can be controlled.
VISUALCONTROL

31. Label storage &Deviation
control

32. Root Cause:
Some modules are not having boxes to keep
labels and some modules are not using
boxes. In this case, the labels are missing in
the modules.
Label lockers are not secured.
Problem:
Label and Heat-seal shortage in the sewing
modules

33. Suggestions:
Operators involved in Label attach
and heat-seals should be allotted
fixed boxes andtrays.

34. Foldable desk on side-facing of
the Labellocker.
Easy folding and space saving.
Label W
ater Spider can place
the labels and heat-seals for the
quantity checkingpurpose.
Length =10"
width =16"

35. Current labellockers
Section 1 Section 4
Section 3
Section 2

36. Measurements of current label locker
71"
35"
63/8"
53/8"
Running
style
labels
Nextcut
labels
Running
style
labels
IMS
Balance
labels

37. Proposal for new label locker
80"
50"
8"
71/2"
Running stylelabels
IMS
Balance
labels
Nextcut
labels

38. THANKYOU!