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Apparel Internship | B.F.Tech | NIFT
- 1. Silver Spark ApparelLtd Ipshita Patra Sem- VII
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- 3. SSAL • It isawholly ownedsubsidiaryofthe Textile andApparelmajor RaymondLimited. • This unitmanufacturessuitsandformaltrouserscatering largely tothe exportmarkets. • The majormarketfor thefirm is USA,andothermarketsare Japan,CanadaandEurope. The majorclients include: • Konaka(JapaneseBuyer) • CharlesTyrwhitt • Peerless • Levis • STLonia • J CPenny • Calvin Klein
- 4. Departments Marketing and Merchandising Department PurchaseDepartment Pre-Production Department PlanningDepartment CuttingDepartmentSewing DepartmentFinishingDepartmentWarehouse IndustrialEngineering Department QualityAssurance MaintenanceDepartment Accountsand Finance Department InformationTechnology Department MTM (Made toMeasure) Department
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- 8. Sampling Proto Sample Fit Sample Photoshoot sample Size Set Pilot-Production Sample Top of Production Sample Shipment Sample • Stages of Sampling SamplingIs DoneFor Procurement oforders Order confirmation Finallookof thegarment For knowingthe critical areas For knowingcostof production Operations required Numberof workers required Accessoriesrequired etc.
- 9. Planning & Purchase Dept •PROCESS FLOW OF PURCHASE DEPT Process Flow
- 10. Fabric Store • Functionincludes: Issuefabric tospreading department as perplan Receive theend bits from thecutting department 4-pointsystemfollowed 10% random inspectionfor trouser fabric. 100%inspectionfor jacketfabric. Spongingand24hr. relaxation isdone for Preventing fabric shrinkage. Process Flow
- 11. Cutting Department •Processflow chart(CAD) Markerefficiency: • Jacket:–88–90% • Trouser:–85 –87% Software used: Gerber Accumark Processflow chart(Patternmaking)
- 12. Spreading Dept Types oflayingmethods: • Manual spreading • Automatic spreading Process Flow
- 13. Cutting • Machine details: • Automatic Spreaders:4 • Pin tables : 7 • CNCcutters: 4+1(band knife) • Fusing machines: 5 • Manpower: 144 Process Flow
- 14. Stickering/Numbering The numbering ofeach part in a particular lay is to be done in order to avoid the problem of shade variation in anygarment during Sewing and also to assure that different parts for a single garment are from the same layer of the fabric. In addition it helps the operators to have a perfect count of the parts and thus, helps in avoiding the misplacement of parts.
- 15. SewingDept (Jkt) • Jacketproduction is forte of SSAL. • Known for its world class jacket manufacturing. • Price range of jacket –Rs8000– Rs9,00,000 • Major buyers – • Calvin klein, • DKNY, • Charles tyrwhitt • Peerless • Konaka(japan) Jacket line Installed capacity Actual Budjet 1 600 470 2 600 470 3 600 410 4 600 410 5 600 370 HMS 30 30
- 16. Process flowchart • TheSAM for a basic jacketis approx. 70-85 minand that for japanese (konaka) jacketis approx. 90-105 min. • The material moves on pneumaticallycontrolled overhead hangers, whichuses the principleof gravity beautifully
- 17. Finishing Dept • Improvetheappearanceofthe garments •Improvethedrapebypressing • Improvethedurabilityof the garments • Packingfor dispatch Thefinishingdepartmentat SSAL has theexclusivelicensetousethe“SI-RO- SET chemical”forpermanentcrease setting. Process flow chart
- 18. Quality Dept • Quality hierarchyin SSAL •TASKOF QUALITYDEPARTMENT • Quality parametersdiscussion in PP meeting • Quality Check before sending the samples to the buyer • Trainingthe quality inspectors • Maintaining all inspection reportsfrom store towarehouse. • Final audit before shipment
- 19. Industrial Enginerring Dept CalculateSAMof garmentfreshly orderedto calculatedifferent consumptions Work measurementofa newconfirmed order Toadvice production departmenton garmentSAM and linelayout Day today activity Tocalculateline efficiency Tocalculate operators efficiency Grade changeof operators Time andmethod study Linebalancing Checkfor work aid and compliances Preparationof incentivescheme • . Oncethe customersplace the orderthe merchandisedepartment forwardsthe orderto the industrial engineering department forthe processing. • Theythen preparethe CMcost (cut make cost). Thisincludes: SAM (standard allocated minute) for each individual operation Cost per machine houris calculation
- 20. Maintenance Dept Carriesout preventiveand correctivemaintenance Line setup during stylechange
- 21. Warehouse •Buyer wise •Po wise •Sizewisesegregation •2types of container •20ft –40ft
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- 24. Work Station Improvement Jacket line– 3 Front Section
- 25. Workstation should beimprovised according to the operator’s ease whichwillgive access to do the workin minimum amount of timeand withless physical fatigue.
- 26. • From BundletoPiece Movement • Handling • Ergonomics • Productivity • Holding Materialand Equipment • Storage andCapacity of Ministorage • Folders to be attached • Workstation Equipment and Method
- 27. Panels Movement Front panelsare being carried by the operators tothe longer distance. Its not according to the properbundle.
- 28. 1. Forfront panels availabletrolley / bin trolleys are not feasible to use. Problems
- 29. Frontand back panelsare of length 82 cm. Reasons It is too big for tomove in the line without affecting the walking space. 1 1. No wheels ,so no ease movement. 2. Dueto rod folded panelscannotbekept properly inthebin. 3. Iftried tohung,due to displayrod not possible 4. Horizontallength is 61cmwhichis less than82 cm. 4
- 30. From Dart markingworkstation to Dart Making workstation 01 Operatorwill turnin twice to get the right ticketed panel. 02 It takes 4-7mins in which novaluable process is performed. 03 Due toheavy bundle sometimes 2 operators are engaged 04 Thedistance between the two workstation is less than7 mts.
- 31. Panels are lyingimproperlyin the bin at the floor.
- 32. Afterasking to workers theoperators wantedsomeeasy andfeasible transportationsystem There attheDart Makingworkstation spaceis notmanaged.
- 33. At Marking • Pieceswerebeing kept on the rack made on the table on front. • This actually created fatigue because the operator has to lean on to the table to keepthe panel up. • Since it’s a repeated action by the end of the day they suffer from muscoskeletal problemon shoulder.
- 34. 1. Thisinverted “u”shaped small handlewill help to keep the panels hanging. 2. Thedart marking operator can directly keep the panels after making 3. Theoperator doesn’t have to turn twice the panels. 4. It coversvery less space so can be easily moved. 5. Canbe made out of scrap. 6. Operatorcan easily pull this. 7. It can be used in the sewing line Solution Table Height 50cm Wheels for ease movement Time saved : 10 to 12 mins
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- 37. Front Dart AndBreast Pocket Marking • Table Width is 72”. • Maximum size of the panelis 43” • Catch is at same time 2 panels are being placed for marking on the same table by two different operators for marking Front Dart and Breast Pocket • Thus space req = 43”+43” = 86”(min.) for properspreading of the panels. • Contrary part we may see for breast pocket marking only upper part is reqso no full alignment. • But, due to collision of the panels sometimes the panel is movedby the other aligned panels
- 38. • Solution canbe the extension of the table by 86”-72”= 14” • Or implement separate tables. Solution
- 39. • Bottleneck operationwhen its checks. • Due to improper handling, pieces go missing. • Due to piece missing, it goes for re- cutting which generates WIP. • Some times operator wastes10 mins in searching. • Operator should take 40 secsbut due to searching she takes 3-4 mins for each panel. • Sometimes due topreparation of pkts of different no createsfuss Breast Pocket Attachment
- 40. • Sometimes two2operators are engaged either for helping the main operator or herself attaching the breast pocket to prevent WIP.
- 41. It can bepreventedby segregating the pieces into small bundle either by bundling it with the help of rubberbands or putting them into the section of box. But while trying for bundling with rubberband it was not feasible as at last after unbundling it again mixed with the other panels
- 42. Loading BreastPkt Preparation BreastPktattachment • 30 pcs target for 30 mins taken Sam : 25 sec Sam : 40 sec Solution
- 43. Want big impact? Usebig image Herewith bundle no will be written , thushelping the operator to searchthe part Boxat the breastpkt preparation Boxat the breastpkt attachment
- 44. Almost Helped • Makingcost: made out of leftover smallplies • Time saved : upto 5 min for eachpart searching • Benefit: debottlenecked
- 45. Stitch and TrimCanvas at Armhole • Bottle neck operation • SAM for completing this operation is 48 secs. • But either a helper is requiredto cut of the extra canvas by scissor or the operator herself will cut the panel by scissor taking 120 to 140 secs.
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- 47. • Cutter mechanismused • In place of Scissor, cutter will cut the extra canvas without stitching Solution
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- 50. • Thereare upto9 size segregation on the canvas. • At a time, operator mayhave to stitch different sized canvas. • No of pieces required to stitch a sleeve head are 5 parts
- 51. Machine Protruded bars to keep thefinished shoulder heads in place Shoulder head and canvas box 4 part segregation for canvas 48” 37” Solution
- 52. 2 size segregation box •Prepared slv head andfelt keeping place • Itsnot stuckso canbeused at other workstations • Protruded bars not implemented as it would hinder the operation.
- 54. Multiskilling Jacket line –3 Front section
- 55. Target To have 80%of total operators to be multi-skilled in front section Front Section total operators: 32 80 % of operators : 25 operators To become multi-skilled at least 2 critical operations and 1 difficult operation should be known.
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- 57. BreastPocket Attach Matching Accuracy A-zonedefectarea CanvasArmhole Cutting Skill CentreBack attach Skill Matching A-zonedefect Side seamattach Accuracy Matching Side Seam Pressing Time taking
- 58. Problems with the Operators •Since there is no job rotation, they are not able to increase efficiency in the other operations. • Operators don’t know the English numericals resulting in mismatching of the panels • Notwilling to learn newoperations • No motivation for increasing efficiency • In general working on 50-60 % efficiency • Absenteeism is 5% to 8% in general
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- 60. Steps Taken •Time TablesMade •Job alteration Done
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- 63. Piece tracking Jacket line– 3 Front Section
- 64. Reasons fordry lineand lessproduction Improper Loading Missing Parts at assembly Ineadequate WIP
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- 66. 1st Attempt • Triedto track the piece byhanging boards tobe filledday wise bythe team leaders • It willbe atthe loading • The bundles must be checked for the missingpanels
- 67. Section:JacketIII Missing partsTracking Date: Style: Monday Tuesday Wednesday Thursday Friday Saturday Loading 9:30 12:30 3:30 9:30 12:30 3:30 9:30 12:30 3:30 9:30 12:30 3:30 9:30 12:30 3:30 9:30 12:30 3:30 Front Pcs Loaded Missing pcs Sleeve Pcs Loaded Missing pcs Lining Pcs Loaded Missing pcs Collar Pcs Loaded Missing pcs Section:JacketIII Missing parts Trackingat Pairing Date: Style: Monday Tuesday Wednesday Thursday Friday Saturday Loading 9:30 12:30 3:30 9:30 12:30 3:30 9:30 12:30 3:30 9:30 12:30 3:30 9:30 12:30 3:30 9:30 12:30 3:30 Front Missing pcs Lining Missing pcs Sleeve Missing pcs
- 69. FailedNo one filleditor maintainedit due to time factor Loading was not timelygiven
- 70. 2nd attempt • Thistimefocused for the assembly. • Main problem was the production was done not according tothe ticket no in the sections. • For ex: ifin front sectionproduction is done from 1-100numbered bundle then in lining it is done from 100-200numbered bundle • To abolish this : • raymondprojectstracking.xls
- 71. Partially successful • Teamleaders filledthese formats and tried to be intrack with each other. • But due to improper loading the coordination was not maintained. • Time factor was one of the issue
- 72. 3rd Attempt • Toabolish the problem happening due toimproper number loading tried to keep track with the new made format raymondprojectsut tracing.pdf • The feeding helper willmaintain this
- 73. Almost Helped • Unlessanduntillproper loading is not done didn’t accept the loading • It helped somehow forthe assembly
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- 75. Jigs • Calculating thetop defects in the front section from 1st May to 16th June weget • 1. Vent up and down(192) • 2. Breast Pocket Open(102) • 3. Flap Lining Out(94) • 4. Bottom Folding Uneven(62) Alter processused are • Vent up and down – Pressing • Flap Lining Out – Recutting • Bottom Folding Uneven – Pressing
- 76. Proposals • Bottom FoldingPressing Machine optimization can be done byintroducing Jigs. • Forbottom folding the foldable jig can be preparedwhich will reducetime. • Instead of folding at different parts , at single time only it can be folded. • Repeated adjustments can be avoided.
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- 79. • They areusing chains which weighs upto 250 gm and handling is difficult. • Due to its length, the pieces touch the ground and movement is not smooth. • Since the pieces are downwardhanging, the WIP is not visual from distant place. • Springed hangers can be used withclips that is usedin trouser line, but due to its weight and force requiredto pull the piece is not feasible.
- 80. Proposed • It isrecoiling mechanism which will help to keepthe panel held at visual position and the operations can be carried out without any pressure.
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