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Apparel Internship at Shahi Exports

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vijayshree vs

on 14 January 2015

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Transcript of Apparel Internship at Shahi Exports

DEPARTMENTS OVERVIEW
PROJECT UNDERTAKEN
PRODUCTIVITY IMPROVEMENTS
Just in time
Apparel Internship at Shahi Exports Pvt.Ltd.
AGENDA
Company Profile
Departments Overview
Summary
Project Undertaken
Findings & conclusions
Recommendations
Bibliography
COMPANY PROFILE
Name: Shahi Exports Private Limited
Established: 1974
Owner: Mrs. Sarla Ahuja
Managing Director: Mr. Harish Ahuja
Work Force: 70,000
Annual Turnover: INR 3500 crore (Group Turnover)
SUMMARY
One of its main production units is located in E 10, Noida,
Started in the year 1993.
The factory head is Mr. Neeraj Harjani.
Total workforce is 1550
Capacity of 1.7-2 Lakhs per month
Annual turnover is 70 Crore.
Total covered area of 5021 sq.m with well equipped and modern machines.

Departments
M/C
Workforce
Cutting
Sewing
Finishing
Packing
25
860
21
3
60
1020
350
38
E 10 , Noida
QUALITY COMMITMENT
The price is long forgotten but quality is remembered forever.
Strong human resource
Welfare department
Perks/Promotions
Motivation
Excellent Workforce
By- Vijayshree
DFT, Nift, Chennai
2011-2015

Time study and follow ups were taken to compare and calculate the efficiencies of operators


Findings & Conclusions
Recommendations
Bibliography
www.shahi.co.in/
www.shahi.co.in/home.htm
http://www.intouch-quality.com/services/product-inspections-in-china/pre-production-inspections/
http://www.indiamart.com/cq-systems-services/apparel-production-management-services.html
http://textilelearner.blogspot.in/2011/08/quality-control-system-in-garments_2589.html
http://www.theseus.fi/bitstream/handle/10024/34405/Paneru_Naresh.pdf?sequence=1
http://www.onlineclothingstudy.com/2012/02/20-ways-to-improve-productivity-in.html


Ergonomic Interventions to improve work environment.
Chair replacement
Install music system
Flexible production & Multi skilling
Provide solution to skill shortages
Providing operators different operations

OBJECTIVE
Continuous improvement which eliminate the non value added operations and reduce the manpower
AREA CHOSEN
1. CUTTING
2. SEWING
1.1 Sticker placement
1.2 Fabric rolls are separated by waste fabric to avoid shade variation
1. IMPLEMENTATIONS IN CUTTING DEPARTMENT
1.3 Ticketing tags are replaced by printed stickers.
Before
After
Stickers were removed by the quality checkers in the assembly lines while checking the defects. And sometimes, extra workers are assigned for sticker removal which led to:
• Delay in the fabric inspection on sewing floor.
• Workmanship of two extra workers in each line for sticker removal.
• The glue of the stickers is so hard that it leaves stain on fabric after sticker removal.
• Leaves patch, if not removed completely.
• Extra softner is used for stain remover during washing which increases the cost.
• Even after washing, if stain is not gone then, it is removed by using chemicals in the finishing department.
• One spotter is assigned in each line in the finishing area. There are total 9 lines.

Changes made in the marker by adding extra space (gauge) in each part of a garment to eliminate removal of stickers. The gauge is drawn on the marker so that it can automatically be trimmed during stitching. For e.g., it is given at the bottom side seam of the front part of the ladies top, so that it could easily be cut off during side seam over lock stitch. This way the stickers can be removed from all the parts during stitching.
1.1 sticker placement
RESULTS
• Cost effective.
• Eliminates the workmanship in sewing, finishing departments especially assigned for sticker and its stain removal.
• Saves time and man power.
• Improves the quality.
• No investment.
• Increases productivity.

Comparison
Before
After
1.2 FABRIC ROLLS ARE SEPARATED BY WASTE FABRIC TO AVOID SHADE VARIATIONS
Before
Fabric spreading is done by the process of unwinding large rolls of fabric, onto long, wide tables. Rolls were laid on spreading table without separating one roll from another fabric rolls. Which is why, stickers are used on each parts of the garment to avoid shade variation. The height of the layer is kept up to 2.5 inches. No of layers in a lay differs from fabric to fabric according to their thickness. For e.g. in a 100% cotton fabric, no of layers is 250 at the height of 2.5 inches.
Comparison
Before
Results
• No shade variations in a lot of fabric.
• No requirement of sticker on small parts.
• Reduces the man power, involved in numbering with sticker gun.
• Eliminate wastes, increases productivity
• No investment.

After
Fabric spreading is done by the same process of unwinding large rolls of fabric, onto long, wide tables. Rolls were laid on spreading table and after each rolls, one layer of waste fabric is laid to separate one roll from another fabric roll. And fabric lot is made in such a way that one lot will have pieces from one fabric roll to avoid shade variations and hence stickers would not be required for small parts.
After
Comparison
Before
1.3 TICKETING TAGS ARE REPLACED BY PRINTED STICKERS.
After
Manually filled tags were replaced by computerized printed stickers which, not only eliminates the extra non value added work but also saves time. One person is assigned to note down all the details on a notepad which automatically feeds the data in the computer and the same can be printed out as a sticker.
Before
Every bundle has a tag which contains the entire description of the garment. It contains:

• TAG NUMBER
• ORDER NUMBER
• STYLE NUMBER
• COLOR
• SIZE
• PART
• LOT NUMBER
• NUMBER OF PCS
• DATE
• CHECKED
The above mentioned details were filled manually. Four persons were assigned for filling the details.

Results
• Eliminates non value added work
• Saves manpower and time
• Work of 4 persons can be done only by one

After
2.1 Change the existing method of sleeve tab making
2.2 Tab attach at sleeve is done by tracking
2.3 Placket finishes in continuation for left & right front panel.
2.4 Using template for pressing flaps
2.5 Using binder instead of manual pressing of belt loop.

2. IMPLEMENTATIONS IN SEWING DEPARTMENT
2.1 Change the existing method of sleeve tab making
After
A new technique is used for tab making which involves lesser steps as compared to earlier one. In this the sleeve tab is folded into two parts and small tucking is done at the center. Then, the required shape is obtained using both the fingers. And top stitch is given.
comparison
Before
Results
• Time reduced: 24.64 Seconds
• Minimizes the no. of operation
• Saves time
• Productivity increases

Before
The sleeve tab is made by stitching two plies together and by inserting thread to get the sharp point. Then the tab is turned, pressed and top stitch is given.
Details
• Line no: 11
• Buyer: Bonita
• Style no: 19641
• Item no: Z-933
• Color: Jewel Blue
• Quantity: 5726 Pcs
After
Comparison
2.2 TAB ATTACH AT SLEEVE IS DONE BY TRACKING
• Line no: 11
• Buyer: Bonita
• Style no: 19641
• Item no: Z-933
• Color: Jewel Blue
• Quantity: 5726 Pcs

Comparison
2.3 PLACKET FINISHES IN CONTINUATION FOR LEFT & RIGHT FRONT PANEL
• Line no: 4
• Buyer: Wal- mart
• Style no: HFGL24431ST
• Item no: Z-848
• Color: Blue Blaze

Time study
2.4 USING TEMPLATE FOR PRESSING FLAPS
Before:
For making flap, first marking is done and then it is folded and creased manually by iron, which takes a lot of time.

Time Study
2.5 USING BINDER INSTEAD OF MANUAL CREASING OF BELT
Before:
Belt is creased manually with the help of template.

After:
Belt is creased using binder. This process is faster than the earlier one, by reducing the time taken for creasing

Push & pull system
Reduce line setting time
Results
• Reduced time:49.5 Seconds
• Reduces manpower
• Increases productivity
• Provides better quality
• Reduces the no. of defective pieces.

After:
To save time and to improve quality and productivity, a template of flap’s size is used for pressing. This method not only eliminates manual marking but also results in better productivity

Results
• Reduces time: 4.62 Seconds
• Operators involved are less
• Utilize man power in value added works.
• Increases productivity.

Before:
For placket finish, both left and right part of front is done one by one. So the Pick Up and disposal time for one garment increases.

After:
To minimize the Pick Up and disposal time for both parts one by one it is suggested not to trim the threads which, joins both the parts in the prior operation (placket edge stitch). This way the Pick Up and disposal time would reduced by half by picking up and disposing both the parts together.

Before
After
Before:

Tab is attached at the sleeve manually by using single needle lock stitch machine. A box is made manually using SNLS machine.

After:

The tab making is done automatically, which is also called as tracking, by setting computerized XY tracking in a bartack machine and changing the plate according to the required size. It consumes very less time as compared to the earlier method and gives very neat finish and maintains the quality.

Time study
Results
• Time reduced: 44.88 Seconds
• Saves man power
• Saves time
• Provides better quality
• Increases productivity

Before
After
Time Study
Total time reduced: 123.74 seconds
The main focus was on ‘cost effective production’ to sustain, thus the basic resources are being utilized effectively.
R & D was done at every stage to maintain the quality
Reduction in the non value added works , helps to contribute in increasing productivity.
No Investment
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