PROJECT REPORT ON Streamlining the Sewing Floor Layout

PROJECT REPORT ON

Streamlining the Sewing Floor Layout

Submitted by: Apurv Pranav Kumar BFT-(AP) 2010-14 NIFT-Bangalore

Abstract Facility layout and design is an important component of a business's overall operations, both in terms of maximizing the effectiveness of production processes and meeting employee needs and/or desires.

Facility layout can be defined as the physical arrangement of everything needed for the product or service, including machines, personnel, raw materials, and finished goods. The criteria for a good layout necessarily relate to people, materials (raw, finished, and in process), machines, and their interactions.

This project aims at reducing the man and material movement in the sewing floor lines by rearrangement of the floor. Apart from the material and man movement reduction, it also improvises the streamlined flow of the pieces within the line and the effective utilization of the available space.

The major aspects of the project are: streamlining the operations, automatic material movement and efficient use of the layout.

A successful implementation of the proposed layout changes will help the project achieve its cent percent objective, thereby facilitating the reduction in man and material movement and automatic movement of the pieces.

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Chapter- 3 INTRODUCTION

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3.1 Introduction: One of the oldest activities of the industrial engineer is designing an effective plant layout. It is the activity that deals with the designing of an arrangement of the physical elements of the activity.

A layout design is an arrangement of the physical facilities (equipment, land, buildings, utilities etc.) to optimize the interrelationship among operating personnel, material flow, and the method required in achieving the organizational objectives efficiently, economically and safely.

The overall objective of layout design is to get the inputs (materials, supplies, etc.) into, through and out of each facility in the shortest possible time. In industrial terms, the shorter the amount of time a piece of material spends in the plant, the less opportunity it has to collect labour and overhead charges. The work of a facility design usually starts with an analysis of the product to be made, or the services to be performed, and a consideration of the overall flow of the material or activity. It progresses, step by step, through the detailed planning of the arrangement of equipments for each individual work area. Then the interrelationship between work areas is planned; related areas are coordinated into units, sections, departments, which when are woven into a final layout.

The flow of material usually represents the backbone of a productive facility, and should be very carefully planned and not allowed to grow or develop into an unwieldy octopus of confused traffic pattern.

Effective arrangement of facilities around the material flow pattern results in efficient operation of the various related processes, resulting in minimum production cost and maximum profit. Thus, material flow pattern then becomes the basis for the entire plant design as well as the success of the organisation.

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3.2 Project Brief: The project is to streamline and rearrange the layout of the Sewing Floor of the shirt manufacturing facility of Texport Industries Pvt. Ltd. The rearrangement or change in the layout is needed to increase in Production and Efficiency and reduce WIP and Throughput time, Man movement and Material movement. Also, the layout had to be planned so that the pieces should move automatically from one workstation to another without the help of any external person.

3.3 Locale: Texport Industries Pvt. Ltd., Unit 10 Block No. 3, 106/1 Kenchanahalli, Mysore Road Bangalore- 560059 Karnataka

3.4 Statement of Study: To streamline and rearrange the sewing floor layout to increase in Production and Efficiency and to reduce WIP, Throughput time, Man movement and Material movement.

3.5 Objectives: To rearrange the layout: 

To increase the Efficiency of the Sewing Floor.



To increase the Productivity of the Sewing Floor.



To reduce the WIP.



To reduce the Throughput Time.



To reduce the overall man movement.



To reduce the overall material movement.



To ensure the smooth flow of pieces from one workstation to other.



To effectively utilize the available space.



To track the movement of the WIP.

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3.6 Significance of the Project: The continuous cry of a businessman is to increase productivity and search for ways of reducing cost to offset the ever increasing prices they have to pay for labour and material. One of the prime sources of increasing productivity and cost improvement opportunity is by redesigning the facility, material flow and reducing the material handling time. In spite of the considerable effort that gone into designing the layout, there is no way to guarantee that it is the best or includes all the desirable objectives, criteria and ideas.

With the passage of time, some undesirable changes do occur in the original layout plan because of some on the spot product requirement or some other reasons creating deviation from the original layout plans. So the existing and working layout should also be evaluated to discover improvement opportunities. Audit and evaluation of layout results in increased productivity, smooth material flow, incorporating improvements with changing market and newer technology available, interacting with fresh and unique ideas different from traditional ones. The final result is an updated plant layout filling the gap developed between the present objective and objective specified at the beginning of the layout process and ready to compete with the changing needs of the present scenario.

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Chapter- 4 REVIEW OF LITERATURE

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4.1 Plant layout: Plant layout refers to the arrangement of physical facilities such as machines, equipment, tools, furniture etc. in such a manner so as to have quickest flow of material at the lowest cost and with the least amount of handling in processing the product from the receipt of raw material to the delivery of the final product.

The efficiency of production depends on how well the various machines; production facilities and employee’s amenities are located in a plant. Only the properly laid out plant can ensure the smooth and rapid movement of material, from the raw material stage to the end product stage. Plant layout encompasses new layout as well as improvement in the existing layout.

It can also be defined as the technique of locating machines, processes and plant services within the factory so as to achieve the right quantity and quality of output at the lowest possible cost of manufacturing. It involves a judicious arrangement of production facilities so that workflow is direct.

4.1.1 Importance of Plant Layout: Plant layout is an important decision as it represents long-term commitment. An ideal plant layout should provide the optimum relationship among output, floor area and manufacturing process. It facilitates the production process, minimizes material handling, time and cost, and allows flexibility of operations, easy production flow, makes economic use of the building, promotes effective utilization of manpower, and provides for employee’s convenience, safety, comfort at work, maximum exposure to natural light and ventilation. It is also important because it affects the flow of material and processes, labour efficiency, supervision and control, use of space and expansion possibilities etc.

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4.1.2 Types of Layout: Plant layout facilitates the arrangement of machines, equipment and other physical facilities in a planned manner within the factory premises. It differs from plant to plant, from location to location and from industry to industry. But the basic principles governing plant layout are more or less same.

4.1.3 Principles of Plant Layout: The principles of plant layout can be stated as:1. Integration of all factors - The plant should integrate all the essential resources of men, machines and materials in order to give an optimum level of production. 2. Minimum Movement - The less the movement of men, machines and materials, the less will be the cost of production. Thus, minimum movement of these resources will provide cost efficiency. 3. Unidirectional flow - All materials should progressively move towards the same direction i.e. towards the stage of completion. Any back-tracking should be avoided here. 4. Efficient space handling - The space used up during the plant work also costs money as more the space required, more will be the floor rent. The materials should be organized in stacks in a proper and recognizable order to maintain space efficiency. 5. Inherent safety - The environment of the plant should be safe for the workers as well as the machines. There should be fire extinguishers and fire exits placed strategically. There should be minimum contact of the labour to toxic chemicals and environment. 6. Maximum observation capacity - The layout of the plant should such that all of its resources and workforce can be observed and evaluated at all points in time. This helps in better supervision of work and helps in increasing both effectiveness and safety. 7. Maximum accessibility - The layout of the plant should ensure that all essential resources are accessible to the labour and machines without any delay. The aisles should be free from obstacles. The materials should be placed as close, to the machines concerned, as possible.

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8. Minimum Handling - The ineffective handling of materials leads to a rise in cost. Materials should be handled in stacks and transferred in one go. Handling of a material twice in the same direction must be avoided. 9. Maximum protection - The layout should ensure the protection of the materials and machines while they are in the working or the storage stage. The security system should be efficient without making too many doors or barriers. 10. Maximum flexibility - The plant layout should not be rigid and permanent. If the need arises, the plant layout should be able to change itself without being expensive.

4.1.4 Layout Design: Layout Design is one of the most critical tasks of the production management. It affects the factory efficiency, quality and costs. If the layout is wrong, it can lead to confused flow patterns, inventories, long process times, inflexible operations and high cost.

Many practical reasons make the changes to layout difficult, one of them is the physical size of equipment and machines that need to be moved. Managers are reluctant to make changes in the factory layout because it can be expensive to carry out and disruptive to production. But at the same time there is pressure to design an effective layout that is right for the factory.

The task of designing the layout of factory involves deciding where to locate resources such as equipment, machines, stores and operators. It also determines the way that materials and parts flow through the factory. Relatively small changes in the position of a machine in the factory can affect the flow of materials. This in turn can affect costs and efficiency of manufacturing.

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4.1.5 Objectives of Plant Layout: 

Proper and efficient utilization of available floor space



To ensure that work proceeds from one point to another point without any delay



Provide enough production capacity



Reduce material handling costs



Reduce hazards to personnel



Utilise labour efficiently



Increase employee morale



Reduce accidents



Provide for volume and product flexibility



Provide ease of supervision and control



Provide for employee safety and health



Allow ease of maintenance



Allow high machine or equipment utilization



Improve productivity

4.1.6 Advantages of a good layout in terms of:Working Environment 

Lesser number of operations & material handling



Reduction in length of hauls & motions between operations



More labour productivity



More safety & security to workers from accidents



Better working conditions resulting improved efficiency

Manufacturing Costs 

Maintenance and replacement costs are reduced



Loss due to waste and spoilage minimized



Improved quality of product with reduction in handling

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Production Control and Supervision 

Provides more space for production operations



Control & supervision operation are provided at appropriate points



Better and convenient storage facilities



Efficient arrangement for receipt, transportation & delivery of raw material and finished goods



Result in less inspection activity



Cost & efforts in supervision of production process minimized

4.1.7 Features of a good layout: 

Ease of working, grater safety and reduced health hazards for workers



Reduced handling of materials/planned material flow pattern



Straight line flow



Minimum back tracking



Auxiliary flow lines



Straight aisles



Processing combined with material handling



Reduced damage & spoilage of materials



Reduced congestion of materials, machinery & men



Flexibility with regard to changing production conditions



Planned for orderly expansion



Minimum goods & materials in process



Maximum use of all plant levels



Building constructed around plant layout



Proper location of production & employee service facilities



Planned control of noise, dirt, fumes, dust and humidity



Partitions don’t impede material flow



Planned scrap removal



Receiving & shipping in logical locations

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4.1.8 Types of Manufacturing Unit Layouts: In case of manufacturing unit, plant layout may be of four types: (a) Product or line layout (b) Process or functional layout (c) Fixed position or location layout (d) Combined or group layout

4.1.8.1 Product or Line layout: Under this, machines and equipments are arranged in one line depending upon the sequence of operations required for the product. The materials move from one workstation to another sequentially without any backtracking or deviation. Under this, machines are grouped in one sequence. Therefore materials are fed into the first machine and finished goods travel automatically from machine to machine, the output of one machine becoming input of the next, e.g. in a paper mill, bamboos are fed into the machine at one end and paper comes out at the other end. The raw material moves very fast from one workstation to other stations with a minimum work in progress storage and material handling. The grouping of machines should be done keeping in mind the following general principles:a) All the machine tools or other items of equipments must be placed at the point demanded by the sequence of operations. b) There should no points where one line crossed another line. c) Materials may be fed where they are required for assembly but not necessarily at one point. d) All the operations including assembly, testing packing must be included in the line.

Product Layout

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Advantages: Product layout provides the following benefits:a. Low cost of material handling, due to straight and short route and absence of backtracking b. Smooth and uninterrupted operations c. Continuous flow of work d. Lesser investment in inventory and work in progress e. Optimum use of floor space f. Shorter processing time or quicker output g. Less congestion of work in the process h. Simple and effective inspection of work and simplified production control i.

Lower cost of manufacturing per unit

Disadvantages: Product layout suffers from following drawbacks:a. High initial capital investment in special purpose machine b. Heavy overhead charges c. Breakdown of one machine will hamper the whole production process d. Lesser flexibility as specially laid out for particular product

Suitability: Product layout is useful under following conditions:a) Mass production of standardized products b) Simple and repetitive manufacturing process c) Operation time for different process is more or less equal d) Reasonably stable demand for the product e) Continuous supply of materials Therefore, the manufacturing units involving continuous manufacturing process, producing few standardized products continuously on the firm’s own specifications and in anticipation of sales would prefer product layout e.g. chemicals, sugar, paper, rubber, refineries, cement, automobiles, food processing and electronics etc.

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4.1.8.2 Process layout: In this type of layout machines of a similar type are arranged together at one place. E.g. Machines performing drilling operations are arranged in the drilling department, machines performing casting operations be grouped in the casting department. Therefore the machines are installed in the plants, which follow the process layout.

Hence, such layouts typically have drilling department, milling department, welding department, heating department and painting department etc. The process or functional layout is followed from historical period. It evolved from the handicraft method of production. The work has to be allocated to each department in such a way that no machines are chosen to do as many different job as possible i.e. the emphasis is on general purpose machine. The work, which has to be done, is allocated to the machines according to loading schedules with the object of ensuring that each machine is fully loaded.

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The grouping of machines according to the process has to be done keeping in mind the following principles:a) The distance between departments should be as short as possible for avoiding long distance movement of materials b) The departments should be in sequence of operations c) The arrangement should be convenient for inspection and supervision

Advantages: Process layout provides the following benefits:a) Lower initial capital investment in machines and equipments. There is high degree of machine utilization, as a machine is not blocked for a single product b) The overhead costs are relatively low c) Change in output design and volume can be more easily adapted to the output of variety of products d) Breakdown of one machine does not result in complete work stoppage e) Supervision can be more effective and specialized f) There is a greater flexibility of scope for expansion Disadvantages: Product layout suffers from following drawbacks:a. Material handling costs are high due to backtracking b. More skilled labour is required resulting in higher cost c. Time gap or lag in production is higher d. Work in progress inventory is high needing greater storage space e. More frequent inspection is needed which results in costly supervision

Suitability: Process layout is adopted when:a. Products are not standardized b. Quantity produced is small c. There are frequent changes in design and style of product d. Job shop type of work is done e. Machines are very expensive APPAREL INTERNSHIP PROJECT REPORT ON LAYOUT STREAMLINING | APURV & PRANAV TEXPORT INDUSTRIES PRIVATE LIMITED| NIFT-BENGALURU | AUGUST 2013

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Thus, process layout or functional layout is suitable for job order production involving non-repetitive processes and customer specifications and non-standardized products, e.g. tailoring, light and heavy engineering products, made to order furniture industries, jewellery.

4.1.8.3 Fixed Position or Location Layout: In this type of layout, the major product being produced is fixed at one location. Equipment labour and components are moved to that location. All facilities are brought and arranged around one work center. This type of layout is not relevant for small scale entrepreneur.

Advantages: Fixed position layout provides the following benefits:a) It saves time and cost involved on the movement of work from one workstation to another. b) The layout is flexible as change in job design and operation sequence can be easily incorporated. c) It is more economical when several orders in different stages of progress are being executed simultaneously. d) Adjustments can be made to meet shortage of materials or absence of workers by changing the sequence of operations.

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Disadvantages: Fixed position layout has the following drawbacks:a. Production period being very long, capital investment is very heavy b. Very large space is required for storage of material and equipment near the product. c. As several operations are often carried out simultaneously, there is possibility of confusion and conflicts among different workgroups.

Suitability: The fixed position layout is followed in following conditions:a. Manufacture of bulky and heavy products such as locomotives, ships, boilers, generators, wagon building, aircraft manufacturing, etc. b. Construction of building, flyovers, dams. c. Hospital, the medicines, doctors and nurses are taken to the patient (product).

4.1.8.4 Combined layout: Certain manufacturing units may require all three processes namely intermittent process (job shops), the continuous process (mass production shops) and the representative process combined process [i.e. miscellaneous shops]. In most of industries, only a product layout or process layout or fixed location layout does not exist. Thus, in manufacturing concerns where several products are produced in repeated numbers with no likelihood of continuous production, combined layout is followed. Generally, a combination of the product and process layout or other combination are found, in practice, e.g. for industries involving the fabrication of parts and assembly, fabrication tends to employ the process layout, while the assembly areas often employ the product layout. In soap, manufacturing plant, the machinery manufacturing soap is arranged on the product line principle, but ancillary services such as heating, the manufacturing of glycerine, the power house, the water treatment plant etc. are arranged on a functional basis.

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4.1.9 Safety Factors for Plant Layout: Plant layout is often a compromise between a number of factors such as:

The need to keep distances for transfer of materials between plant/storage units to a minimum to reduce costs and risks;



The geographical limitations of the site;



Interaction with existing or planned facilities on site such as existing roadways, drainage and utilities routings;



Interaction with other plants on site;



The need for plant operability and maintainability;



The need to locate hazardous materials facilities as far as possible from site boundaries and people living in the local neighbourhood;



The need to prevent confinement where release of flammable substances may occur;



The need to provide access for emergency services;



The need to provide emergency escape routes for on-site personnel;



The need to provide acceptable working conditions for operators.

The most important factors of plant layout as far as safety aspects are concerned are those to:

Prevent, limit and/or mitigate escalation of adjacent events;



Ensure safety within on-site occupied buildings;



Control access of unauthorized personnel;



Facilitate access for emergency services.

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Chapter- 5 METHODOLOGY

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5.1 Steps: The project has been done in the following steps:1. Study of the shirt manufacturing process. 2. Mapping the current layout. 3. Study of the flow of material. 4. Mapping the man and material movement. 5. Analyzing the problems/ difficulties in the current layout. 6. Taking the suggestions of the IE Department and the Line Supervisors. 7. Making new layout proposals. 8. Taking references from the IED and supervisors on the proposals. 9. Comparing the two layouts in terms of various parameters. 10. Evaluating the layouts by taking the suggestions from the Production Manager, IE, Maintenance teams and the Operators. 11. Doing a feasibility study from the old and proposed layouts. 12. Outcome of the Project.

5.2 Data Collection Method: 5.2.1 Primary Data: 

The primary data collection is done by making the layouts in Auto-CAD by taking exact measurements of the sewing lines.



Collecting reports from the IE Department.

5.2.2 Secondary Data: The secondary data collection is done by referring various books from the library and through websites.

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Chapter - 6 Proposal of Layout- I Process Layout (Modular System)

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6.1 Layout Details:

Product: FULL SLEEVE SHIRT Style: W CARRIE POLKA DOT Production: 4375 Efficiency: 70% Absenteeism: 10% No. of Lines: 7 Total No. of Machines: 276 Total No. of Workplace (Manpower): 333 Total Distance of Material movement: 1509 Feet

6.2 Collar Preparation:

6.2.1 Operation Breakdown and Process Flow: Operation

SAM

Machine Type

Deskilling Devices Profile

1

Run-stitch Collar

0.650

SNLS

2

Trim & turn collar

0.350

SNEC

3

Iron collar

0.350

Iron Table

4

Topstitch collar

0.450

SNLS

5

Hem collar band

0.450

SNLS

6

Attach collar band to collar

0.850

SNEC

Template

7

Turn & iron collar band corner

0.550

Iron table

Template

8

Trim & notch collar

0.400

SNEC

Template

CR 1/4"

6.2.2 Collar Section Details: Total Manpower

:

48

Total no. of machines :

26

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6.2.3 Material Movement: Distance

Movement

(in Feet)

1

Rack to Run-stitch Collar

90

2

Run-stitch Collar to Trim & turn collar

0

3

Trim & turn collar to Iron collar

12

4

Iron collar to Topstitch collar

10

5

Topstitch collar to Hem collar band

8

6

Hem collar band to Attach collar band to collar

24

7

Attach collar band to collar to Turn & iron collar band corner

19

8

Turn & iron collar band corner to Trim & notch collar

12

9

Trim & notch collar to Matching table

48

Total

223

6.3 Back Preparation:

6.3.1 Operation Breakdown and Process Flow: Operation

SAM

Machine Type Deskilling Devices

1

Mark & attach label to inner yoke patch

0.450

SNLS

2

Iron inner yoke patch

0.400

Iron Table

3

Attach inner yoke patch to back

0.450

SNLS

4

Mark for darts

0.450

Helper Table

5

Sew darts on back

0.900

SNLS

6

Attach back to yoke

0.650

SNLS

MF 213

6.3.2 Back Section Details: Total Manpower

:

38

Total no. of machines :

32

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6.3.3 Material Movement:

Distance

Movement

(in Feet)

1

Rack to Mark & attach label to inner yoke patch

40

2

Mark & attach label to inner yoke patch

0

3

Iron inner yoke patch to Attach inner yoke patch to back

12

4

Attach inner yoke patch to back to Mark for darts

14

5

Mark for darts to Sew darts on back

64

6

Sew darts on back to Attach back to yoke

8

7

Attach back to yoke to Matching Table

70

Total

208

6.4 Front Preparation:

6.4.1 Operation Breakdown and Process Flow: Operation

SAM

Machine Type Deskilling Devices

1

Hem button hole placket

0.650

DNLS

MF 206, a = 1 1/8"

2

Hem button placket

0.450

SNLS

MF 206, a = 1 "

3

Mark & sew bust darts

0.650

SNLS

6.4.2 Front Section Details: Total Manpower

:

16

Total no. of machines :

16

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6.4.3 Material Movement: Movement

Distance (in Feet)

1

Rack to Hem button hole placket

28

2

Hem button hole placket to Hem button placket

12

3

Hem button placket to Mark & sew bust darts

2

4

Mark & sew bust darts to Matching table

88

Total

130

6.5 Cuff Preparation:

6.5.1 Operation Breakdown and Process Flow: Operation

SAM

Machine Type Deskilling Devices

1

Hem cuff

0.500

SNLS

CR 5/16"

2

Run stitch cuff

1.000

SNLS

Profile

3

Trim and turn cuff

0.550

SNEC

4

Iron cuff

0.450

Iron table

6.5.2 Cuff Section Details: Total Manpower

:

33

Total no. of machines :

20

6.5.3 Material Movement: Movement

Distance (in Feet)

1

Rack to Hem cuff

95

2

Hem cuff to Run stitch cuff

63

3

Run stitch cuff to Trim and turn cuff

8

4

Trim and turn cuff to Iron cuff

23

5

Iron cuff to Matching Table

36

Total

225

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6.6 Sleeve Preparation:

6.6.1 Operation Breakdown and Process Flow: Operation

SAM

Machine Type Deskilling Devices

1

Attach & finish lower sleeve placket

0.600 SNLS

2

Tack lower sleeve placket

0.350 SNLS

3

Iron upper sleeve placket

0.900 Iron table

4

Attach & finish upper sleeve placket

0.900 SNLS

MF 219, a=1/2"

6.6.2 Sleeve Section Details: Total Manpower

:

37

Total no. of machines :

25

6.6.3 Material Movement: Movement

Distance (in Feet)

1

Rack to Attach & finish lower sleeve placket

82

2

Attach & finish lower sleeve placket to Tack lower sleeve placket

62

3

Tack lower sleeve placket to Iron upper sleeve placket

16

4

Iron upper sleeve placket to Attach & finish upper sleeve placket

21

5

Attach & finish upper sleeve placket to Matching Table

88

Total

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269

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6.7 Assembly Section:

6.7.1 Operation Breakdown and Process Flow: Operation

SAM

Machine Type Deskilling Devices

cuff

0.450

Helper Table

2

Join shoulders

0.650

SNLS

3

Mark & attach tape at neck

0.600

SNLS

4

Attach collar

0.650

SNLS

5

Close collar

0.900

SNLS

6

Attach sleeve

0.900

SNLS

7

Overlock sleeve

0.700

3TOL

8

Top-stitch arm hole

0.850

SNLS

9

Close sides

0.900

SNLS

10 Overlock sides

0.750

3TOL

11 Prepare & tack w/care label to sides

0.450

SNLS

12 Hem bottom

0.900

SNLS

13 Iron side bottom patch

0.800

Iron table

14 Mark & topstitch on side patch

0.800

SNLS

15 Make sleeve pleat (2 nos.)

0.450

SNLS

16 Attach & finish cuff

0.900

SNLS

17 Top-stitch cuff

0.800

SNLS

1

Match fronts & back, collar, sleeve,

MF 211

MF 503, a= 5/16"

F-224( cuff setter)

6.7.2 Assembly Section Details: Total Manpower:

138

Total no. of machines:

126

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6.7.3 Material Movement: Movement

Distance (in Feet)

1

Matching table to Assembly Line 1

35

2

Matching table to Assembly Line 2

40

3

Matching table to Assembly Line 3

63

4

Matching table to Assembly Line 4

86

5

Matching table to Assembly Line 5

109

6

Matching table to Assembly Line 6

121

Total

454

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Layout (Process Layout) APPAREL INTERNSHIP PROJECT REPORT ON LAYOUT STREAMLINING | APURV & PRANAV TEXPORT INDUSTRIES PRIVATE LIMITED| NIFT-BENGALURU | AUGUST 2013

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Material Flow (Process Layout)

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Chapter- 7 Proposal of Layout-II Product Layout (Progressive Bundle System)

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7.1 Layout Details: Product: FULL SLEEVE SHIRT Style: W CARRIE POLKA DOT Production: 3750 Efficiency: 70% Absenteeism: 10% No. of Lines: 6 Total No. of Machines: 252 Total No. of Workplace (Manpower): 306 Total Distance of Material movement: 1281

7.2 Line Section: 7.2.1 Operation Breakdown and Process Flow: Operation

SAM

Machine

Deskilling Devices

Type 1

Run-stitch Collar

0.650

SNLS

Profile

2

Trim & turn collar

0.350

SNEC

3

Iron collar

0.350

Iron Table

4

Topstitch collar

0.450

SNLS

5

Hem collar band

0.450

SNLS

6

Attach collar band to collar

0.850

SNEC

Template

7

Turn & iron collar band corner

0.550

Iron table

Template

8

Trim & notch collar

0.400

SNEC

Template

9

Hem cuff

0.500

SNLS

CR 5/16"

10 Run stitch cuff

1.000

SNLS

Profile

11 Trim and turn cuff

0.550

SNEC

12 Iron cuff

0.450

Iron table

0.450

SNLS

0.400

Iron Table

CR 1/4"

13 Mark & attach label to inner yoke patch 14 Iron inner yoke patch

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15 Attach inner yoke patch to back

0.450

16

SNLS Helper

Mark for darts

0.450

Table

17 Sew darts on back

0.900

SNLS

18 Attach back to yoke

0.650

SNLS

MF 213

19 Hem button hole placket

0.650

DNLS

MF 206, a = 1 1/8"

20 Hem button placket

0.450

SNLS

MF 206, a = 1 "

21 Mark & sew bust darts

0.650

SNLS

22 Attach & finish lower sleeve placket

0.600

SNLS

23 Tack lower sleeve placket

0.350

SNLS

24 Iron upper sleeve placket

0.900

Iron table

0.900

SNLS

25 Attach & finish

MF 219, a=1/2"

upper sleeve

placket 26 Match fronts & back, collar, sleeve, cuff

Helper 0.450

Table

27 Join shoulders

0.650

SNLS

28 Mark & attach tape at neck

0.600

SNLS

29 Attach collar

0.650

SNLS

30 Close collar

0.900

SNLS

31 Attach sleeve

0.900

SNLS

32 Overlock sleeve

0.700

3TOL

33 Top-stitch arm hole

0.850

SNLS

34 Close sides

0.900

SNLS

35 Overlock sides

0.750

3TOL

36 Prepare & tack w/care label to sides

0.450

SNLS

37 Hem bottom

0.900

SNLS

38 Iron side bottom patch

0.800

Iron table

39 Mark & topstitch on side patch

0.800

SNLS

40 Make sleeve pleat (2 nos.)

0.450

SNLS

41 Attach & finish cuff

0.900

SNLS

42 Top-stitch cuff

0.800

SNLS

MF 211

MF 503, a= 5/16"

F-224 ( cuff setter )

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7.2.2 Single Line Details: Total Manpower

:

306

Total no. of machines :

252

7.2.3 Material Movement: Movement

Distance (in Feet)

1

Rack to Assembly Line 1

105

2

Rack to Assembly Line 2

83

3

Rack to Assembly Line 3

74

4

Rack to Assembly Line 4

93

5

Rack to Assembly Line 5

115

6

Rack to Assembly Line 6

188

7

Assembly Line Feeding End to Collar ( x 6 Lines )

8

Collar to Cuff ( x 6 Lines )

147

9

Cuff to Back ( x 6 Lines )

87

10

Back to Front ( x 6 Lines )

380

11

Front to Sleeve ( x 6 Lines )

7

12

Sleeve to Assembly ( x 6 Lines )

2

Total

0

1281

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Layout (Product Layout)

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Material Flow (Product Layout) APPAREL INTERNSHIP PROJECT REPORT ON LAYOUT STREAMLINING | APURV & PRANAV TEXPORT INDUSTRIES PRIVATE LIMITED| NIFT-BENGALURU | AUGUST 2013

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Chapter– 8 Analysis of the Proposed Layouts

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8.1 Comparison between Layouts:

Sl.

Progressive Bundling

No. Particulars

Modular System

System

1509 ft.

1281 ft.

2 Manpower

333

306

3 No. of M/c

276

252

4 Production

4375

3750

5 Space Availability

Less

More

6 Line Balancing

Easy

Difficult

7 Order Tracking

Difficult

Easy

Huge

Less

Difficult

Easy

10 Visibility

Random

Streamlined

11 Maintenance

Difficult

Easy

12 Control & Supervision

Difficult

Easy

Slow & Back Tracking

Straight line

Huge

Less

Difficult

Easy

Lesser

Better

Excellent

Efficient

Can be balanced

Difficult to balance

1 Material Movement

8 WIP 9 Quality Inspection

13 Material Flow 14 Throughput time 15 Report Generation 16 Safety 17 Machine Utilisation 18 Effect of Absenteeism

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8.2 Pros and Cons of Modular System (Layout 1):

8.2.1 Pros:     

Lesser Machine requirement Easy to balance the line in case of Absenteeism Line balancing is easy Machine utilization is excellent Lesser effect of absenteeism

8.2.2 Cons:        

Huge WIP Difficulty in tracking the status of Production Inline Quality Inspection Material movement is more Greater requirement of Manpower More number of Machine requirement Order tracking is difficult Control & supervision is difficult

8.3 Pros and Cons of Progressive Bundling System (Layout 2):

8.3.1 Pros:        

Lesser Manpower requirement Lesser Material movement Order tracking is easy WIP is lesser Throughput time is lesser Quality inspection is easy Visibility is streamlined Control & supervision is easy

8.3.2 Cons:  

Lesser production Line balancing is difficult in case of Absenteeism

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Chapter – 9 Outcome of the Project

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Depending upon the need of the Organisation and facilities available, we would suggest the Management to implement Modular System. The suggestion is purely based on the findings of our Project and discussion with the IED on the feasibility of implementing the Layout.

As in our analysis we found that with the Process system or Modular layout, the sewing floor can be utilized more and production can be increased as compared to the Product layout.

In the production unit where we did our analysis, due several reasons the Product System or Single Line system is not as productive as compared to Process layout. The reasons are as follows:

Absenteeism



Variation in products



High iteration rate



Very less multiple skilled operators

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BIBLIOGRAPHY



www.texportgarments.com



Industrial Engineering and Management



Dr. O. P. Khanna, Dhanpat Rai Publications, New Delhi



Management -James A. F. Stoner, R. Edward Freeman(6th edition)



Management of Textile Industry - Dr. Dudeja Textile Trade Press, 1981



Magazines: -The Indian textile journal. -Clothes line. -Global crossing A Turnaround. -Apparel Marketing and Merchandising, Ruth. A. Clarke -Motion and time study, Gerald Dodler -Marketing research, Peter M. Chisnall -Materials handling in industry, British Electrical Development Association



Text book, Management Development Course, Juki corp.



Federation of India chamber of commerce & Industry, FICCI quality forum.



Productions and Operations Management (5th edition)



Apple, J. M. (1977). The Facilities Design Function. In J. M. Apple, Plant Layout and Material Handling (pp. 1-24). John Wiley & Sons.



Apple, J. M. (n.d.). Plant Layout and Material Handling.



Health and Safety Executive. (n.d.). Plant Layout. Retrieved March 16, 2013, from Health and Safety Executive: http://www.hse.gov.uk/comah/sragtech/techmeasplantlay.htm



Kumar, A. (n.d.). Retrieved March 16, 2013, from www.du.ac.in: http://www.du.ac.in/fileadmin/DU/Academics/course_material/EP_07.pdf



Majumdar, S. (2009, September 20). The Principles of a Plant Layout. Retrieved March 16, 2013, from Indiastudychannel.com: http://www.indiastudychannel.com/resources/87244-The-Principles-Plant-Layout.aspx

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

Plant Layout. (n.d.). Retrieved March 16, 2013, from Web-Su-kat: http://www.websukat.com/PAOM-plant-layout.htm



Plant Layout, Types of Plant Layouts. (n.d.). Retrieved March 16, 2013, from http://www.websukat.com: http://www.websukat.com/PAOM-plant-layout.htm

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