Implementation of Lean Principle- Pull System

1. Company Profile
1. Company- Celebrations Apparel
Ltd.
2. Product- Formal/Semi formal
Shirts
3. Location- Hoskote, Bangalore
4. Daily Production- _000 shirts
5. Layout: Combined
CELEBRATIONS APPAREL LTD…(A Unit of Raymond)
*None of the data points mentioned here are
indicative of the actual numbers. These have been
changed to protect the actual info

2. Objective
Throughput Time
CELEBRATIONS APPAREL LTD…(A Unit of Raymond)
Process Time
+
Inspection time
+
Move time
+
Queue time
+
Waiting Time
=
TOOL-1PULL SYSTEM(IMP.) TOOL-2SMED (PROPOSED)

3. IMPLEMENTATION OF PULL
SYSTEM
CELEBRATIONS APPAREL LTD…(A Unit of Raymond)
Through Visual ManagementIn Sewing Floor

4. Original System
CELEBRATIONS APPAREL LTD…(A Unit of Raymond)
IMBALANCES Brand X Brand Y Brand Z
Cut-parts
To Assembly Ready
4 days 2 days 3 days
Wait for Parts (days) 2.6 out of 4 days 1 out of 2 days 2 out of 3 days
Ʃ order size= 1000/line

5. Research Process
CELEBRATIONS APPAREL LTD…(A Unit of Raymond)
Recording Data/Obs.
Analyzing Data/Obs.
Problem Segregation
1. Macro-Level study (Link to data
is removed)2. Micro-Level Study Results
Problem exclusive to section Detail Problems Common to all Parts’ Detail
Solution Proposed Floor Plan Step-by-step Solutions
Proposed and Implemented
Visual Controls Pics
Parts to produce acc. To
Assembly Requirement. Soln
Cutting to cut acc. to
Parts’ Requirement Soln.
Cutting Loading
Prioritization Graphs

6. Results
1. Decrease in Average WIP/Day = 13%Avg.
Waiting Time saved/W.S/Shift= 6%
2. Reduction of idol-operators in Morning (Back
Section) = 12.6%
3. Cost saved on Overtime = 76%*
*This project has a significant contribution in total reduction in over time cost.
CELEBRATIONS APPAREL LTD…(A Unit of Raymond)
Month Production(pcs.) Man-Power
June Pre-Implementation --- ----
August Post-Implementation --- -----
Graphical Analysis

7. CELEBRATIONS APPAREL LTD…(A Unit of Raymond)
Before After

8. CELEBRATIONS APPAREL LTD…(A Unit of Raymond)
AfterBefore

9. Further Scope of Study
• To plan for the cross-sectional training for
Parts’ operators.
• To study the factors to be considered while
dynamically deciding the Sequence of feeding
• To train the supervisors to calculate the
performance in terms of efficiency.
CELEBRATIONS APPAREL LTD…(A Unit of Raymond)

10. CHANGE OF MINDSET….
CELEBRATIONS APPAREL LTD…(A Unit of Raymond)
B

11. Thank You
Presented By:
Anushka Sharma
B.F.Tech (Sem-VII)
NIFT Bangalore
CELEBRATIONS APPAREL LTD…(A Unit of Raymond)
Mr. Vinay,
Production Manager,
Celebrations Apparel Ltd.
Under Guidance of:
Mr. Jayanta Roy,
Sr. Manager,
( Product Dev. And
Quality)
Celebrations Apparel Ltd.