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.
APPAREL INTERNSHIP PROJECT REPORT ON LAYOUT STREAMLINING | APURV & PRANAV

TEXPORT INDUSTRIES PRIVATE LIMITED| NIFT-BENGALURU | AUGUST 2013
Chapter- 3 INTRODUCTION

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.

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.

Chapter- 4 REVIEW OF LITERATURE

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 employees 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 employees 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.

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.

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 dont 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 firms 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
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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 1 2 3 4 5 6 7 8 Run-stitch Collar Trim & turn collar Iron collar Topstitch collar Hem collar band Attach collar band to collar Turn & iron collar band corner Trim & notch collar SAM 0.650 0.350 0.350 0.450 0.450 0.850 0.550 0.400 Machine Type SNLS SNEC Iron Table SNLS SNLS SNEC Iron table SNEC Template Template Template CR 1/4" Deskilling Devices Profile
6.2.2 Collar Section Details: Total Manpower : 48 26
Total no. of machines :

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6.2.3 Material Movement: Movement 1 2 3 4 5 6 7 8 9 Rack to Run-stitch Collar Run-stitch Collar to Trim & turn collar Trim & turn collar to Iron collar Iron collar to Topstitch collar Topstitch collar to Hem collar band Hem collar band to Attach collar band to collar Attach collar band to collar to Turn & iron collar band corner Turn & iron collar band corner to Trim & notch collar Trim & notch collar to Matching table Total Distance (in Feet) 90 0 12 10 8 24 19 12 48 223
6.3 Back Preparation:
6.3.1 Operation Breakdown and Process Flow: Operation SAM Machine Type Deskilling Devices 1 2 3 4 5 6 Mark & attach label to inner yoke patch Iron inner yoke patch Attach inner yoke patch to back Mark for darts Sew darts on back Attach back to yoke 0.450 0.400 0.450 0.450 0.900 0.650 SNLS Iron Table SNLS Helper Table SNLS SNLS MF 213
6.3.2 Back Section Details: Total Manpower : 38 32

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6.3.3 Material Movement:
Movement 1 2 3 4 5 6 7 Rack to Mark & attach label to inner yoke patch Mark & attach label to inner yoke patch Iron inner yoke patch to Attach inner yoke patch to back Attach inner yoke patch to back to Mark for darts Mark for darts to Sew darts on back Sew darts on back to Attach back to yoke Attach back to yoke to Matching Table Total
Distance (in Feet) 40 0 12 14 64 8 70 208
6.4 Front Preparation:
6.4.1 Operation Breakdown and Process Flow: Operation 1 2 3 Hem button hole placket Hem button placket Mark & sew bust darts SAM 0.650 0.450 0.650 Machine Type Deskilling Devices DNLS SNLS SNLS MF 206, a = 1 1/8" MF 206, a = 1 "
6.4.2 Front Section Details: Total Manpower : 16 16

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6.4.3 Material Movement: Movement Distance (in Feet) 1 2 3 4 Rack to Hem button hole placket Hem button hole placket to Hem button placket Hem button placket to Mark & sew bust darts Mark & sew bust darts to Matching table Total 28 12 2 88 130
6.5 Cuff Preparation:
6.5.1 Operation Breakdown and Process Flow: Operation 1 2 3 4 Hem cuff Run stitch cuff Trim and turn cuff Iron cuff SAM 0.500 1.000 0.550 0.450 Machine Type Deskilling Devices SNLS SNLS SNEC Iron table CR 5/16" Profile
6.5.2 Cuff Section Details: Total Manpower : 33 20
6.5.3 Material Movement: Movement Distance (in Feet) 1 2 3 4 5 Rack to Hem cuff Hem cuff to Run stitch cuff Run stitch cuff to Trim and turn cuff Trim and turn cuff to Iron cuff Iron cuff to Matching Table Total 95 63 8 23 36 225
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6.6 Sleeve Preparation:
6.6.1 Operation Breakdown and Process Flow: Operation 1 2 3 4 Attach & finish lower sleeve placket Tack lower sleeve placket Iron upper sleeve placket Attach & finish upper sleeve placket SAM Machine Type Deskilling Devices MF 219, a=1/2"
0.600 SNLS 0.350 SNLS 0.900 Iron table 0.900 SNLS
6.6.2 Sleeve Section Details: Total Manpower : 37 25
6.6.3 Material Movement: Movement Distance (in Feet) 1 2 3 4 5 Rack to Attach & finish lower sleeve placket Attach & finish lower sleeve placket to Tack lower sleeve placket Tack lower sleeve placket to Iron upper sleeve placket Iron upper sleeve placket to Attach & finish upper sleeve placket Attach & finish upper sleeve placket to Matching Table Total 82 62 16 21 88 269

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6.7 Assembly Section:
6.7.1 Operation Breakdown and Process Flow: Operation 1 Match fronts & back, collar, sleeve, cuff 2 3 4 5 6 7 8 9 Join shoulders Mark & attach tape at neck Attach collar Close collar Attach sleeve Overlock sleeve Top-stitch arm hole Close sides 0.450 0.650 0.600 0.650 0.900 0.900 0.700 0.850 0.900 0.750 0.450 0.900 0.800 0.800 0.450 0.900 0.800 Helper Table SNLS SNLS SNLS SNLS SNLS 3TOL SNLS SNLS 3TOL SNLS SNLS Iron table SNLS SNLS SNLS SNLS F-224( cuff setter) MF 503, a= 5/16" MF 211 SAM Machine Type Deskilling Devices
10 Overlock sides 11 Prepare & tack w/care label to sides 12 Hem bottom 13 Iron side bottom patch 14 Mark & topstitch on side patch 15 Make sleeve pleat (2 nos.) 16 Attach & finish cuff 17 Top-stitch cuff
6.7.2 Assembly Section Details: Total Manpower: Total no. of machines: 138 126

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6.7.3 Material Movement: Movement 1 2 3 4 5 6 Matching table to Assembly Line 1 Matching table to Assembly Line 2 Matching table to Assembly Line 3 Matching table to Assembly Line 4 Matching table to Assembly Line 5 Matching table to Assembly Line 6 Total Distance (in Feet) 35 40 63 86 109 121 454

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Layout (Process Layout)

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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 Type 1 2 3 4 5 6 7 8 9 Run-stitch Collar Trim & turn collar Iron collar Topstitch collar Hem collar band Attach collar band to collar Turn & iron collar band corner Trim & notch collar Hem cuff 0.650 0.350 0.350 0.450 0.450 0.850 0.550 0.400 0.500 1.000 0.550 0.450 SNLS SNEC Iron Table SNLS SNLS SNEC Iron table SNEC SNLS SNLS SNEC Iron table Template Template Template CR 5/16" Profile CR 1/4" Profile Deskilling Devices
10 Run stitch cuff 11 Trim and turn cuff 12 Iron cuff 13 Mark & attach label to inner yoke patch 14 Iron inner yoke patch
0.450 0.400
SNLS Iron Table

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15 Attach inner yoke patch to back 16 Mark for darts 17 Sew darts on back 18 Attach back to yoke 19 Hem button hole placket 20 Hem button placket 21 Mark & sew bust darts 22 Attach & finish lower sleeve placket 23 Tack lower sleeve placket 24 Iron upper sleeve placket 25 Attach & finish placket 26 Match fronts & back, collar, sleeve, cuff 27 Join shoulders 28 Mark & attach tape at neck 29 Attach collar 30 Close collar 31 Attach sleeve 32 Overlock sleeve 33 Top-stitch arm hole 34 Close sides 35 Overlock sides 36 Prepare & tack w/care label to sides 37 Hem bottom 38 Iron side bottom patch 39 Mark & topstitch on side patch 40 Make sleeve pleat (2 nos.) 41 Attach & finish cuff 42 Top-stitch cuff upper sleeve
0.450
SNLS Helper
0.450 0.900 0.650 0.650 0.450 0.650 0.600 0.350 0.900
Table SNLS SNLS DNLS SNLS SNLS SNLS SNLS Iron table MF 219, a=1/2" MF 213 MF 206, a = 1 1/8" MF 206, a = 1 "
0.900
SNLS Helper
0.450 0.650 0.600 0.650 0.900 0.900 0.700 0.850 0.900 0.750 0.450 0.900 0.800 0.800 0.450 0.900 0.800
Table SNLS SNLS SNLS SNLS SNLS 3TOL SNLS SNLS 3TOL SNLS SNLS Iron table SNLS SNLS SNLS SNLS
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MF 211
MF 503, a= 5/16"
F-224 ( cuff setter )

7.2.2 Single Line Details: Total Manpower : 306 252
7.2.3 Material Movement: Movement 1 2 3 4 5 6 7 8 9 10 11 12 Rack to Assembly Line 1 Rack to Assembly Line 2 Rack to Assembly Line 3 Rack to Assembly Line 4 Rack to Assembly Line 5 Rack to Assembly Line 6 Assembly Line Feeding End to Collar ( x 6 Lines ) Collar to Cuff ( x 6 Lines ) Cuff to Back ( x 6 Lines ) Back to Front ( x 6 Lines ) Front to Sleeve ( x 6 Lines ) Sleeve to Assembly ( x 6 Lines ) Total Distance (in Feet) 105 83 74 93 115 188 0 147 87 380 7 2 1281

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Layout (Product Layout)

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Material Flow (Product Layout)

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Chapter 8 Analysis of the Proposed Layouts

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8.1 Comparison between Layouts:
Sl. No. Particulars 1 Material Movement 2 Manpower 3 No. of M/c 4 Production 5 Space Availability 6 Line Balancing 7 Order Tracking 8 WIP 9 Quality Inspection 10 Visibility 11 Maintenance 12 Control & Supervision 13 Material Flow 14 Throughput time 15 Report Generation 16 Safety 17 Machine Utilisation 18 Effect of Absenteeism Modular System 1509 ft. 333 276 4375 Less Easy Difficult Huge Difficult Random Difficult Difficult Slow & Back Tracking Huge Difficult Lesser Excellent Can be balanced
Progressive Bundling System 1281 ft. 306 252 3750 More Difficult Easy Less Easy Streamlined Easy Easy Straight line Less Easy Better Efficient Difficult to balance

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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 43

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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PROJECT REPORT ON Streamlining The Sewing Floor Layout

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PROJECT REPORT ON Streamlining The Sewing Floor Layout

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Drepturi de autor:

Formate disponibile

PROJECT REPORT ON

Streamlining the Sewing Floor Layout

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

APPAREL INTERNSHIP PROJECT REPORT ON LAYOUT STREAMLINING | APURV & PRANAV

APPAREL INTERNSHIP PROJECT REPORT ON LAYOUT STREAMLINING | APURV & PRANAV

APPAREL INTERNSHIP PROJECT REPORT ON LAYOUT STREAMLINING | APURV & PRANAV

APPAREL INTERNSHIP PROJECT REPORT ON LAYOUT STREAMLINING | APURV & PRANAV

APPAREL INTERNSHIP PROJECT REPORT ON LAYOUT STREAMLINING | APURV & PRANAV

Chapter- 4 REVIEW OF LITERATURE

APPAREL INTERNSHIP PROJECT REPORT ON LAYOUT STREAMLINING | APURV & PRANAV

APPAREL INTERNSHIP PROJECT REPORT ON LAYOUT STREAMLINING | APURV & PRANAV

APPAREL INTERNSHIP PROJECT REPORT ON LAYOUT STREAMLINING | APURV & PRANAV

APPAREL INTERNSHIP PROJECT REPORT ON LAYOUT STREAMLINING | APURV & PRANAV

APPAREL INTERNSHIP PROJECT REPORT ON LAYOUT STREAMLINING | APURV & PRANAV

APPAREL INTERNSHIP PROJECT REPORT ON LAYOUT STREAMLINING | APURV & PRANAV

APPAREL INTERNSHIP PROJECT REPORT ON LAYOUT STREAMLINING | APURV & PRANAV

APPAREL INTERNSHIP PROJECT REPORT ON LAYOUT STREAMLINING | APURV & PRANAV

APPAREL INTERNSHIP PROJECT REPORT ON LAYOUT STREAMLINING | APURV & PRANAV

APPAREL INTERNSHIP PROJECT REPORT ON LAYOUT STREAMLINING | APURV & PRANAV

APPAREL INTERNSHIP PROJECT REPORT ON LAYOUT STREAMLINING | APURV & PRANAV

APPAREL INTERNSHIP PROJECT REPORT ON LAYOUT STREAMLINING | APURV & PRANAV

APPAREL INTERNSHIP PROJECT REPORT ON LAYOUT STREAMLINING | APURV & PRANAV

APPAREL INTERNSHIP PROJECT REPORT ON LAYOUT STREAMLINING | APURV & PRANAV

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

APPAREL INTERNSHIP PROJECT REPORT ON LAYOUT STREAMLINING | APURV & PRANAV

6.1 Layout Details:

6.2 Collar Preparation:

6.2.2 Collar Section Details: Total Manpower : 48 26

Total no. of machines :

APPAREL INTERNSHIP PROJECT REPORT ON LAYOUT STREAMLINING | APURV & PRANAV

6.3 Back Preparation:

6.3.2 Back Section Details: Total Manpower : 38 32

Total no. of machines :

APPAREL INTERNSHIP PROJECT REPORT ON LAYOUT STREAMLINING | APURV & PRANAV

6.3.3 Material Movement:

Distance (in Feet) 40 0 12 14 64 8 70 208

6.4 Front Preparation:

6.4.2 Front Section Details: Total Manpower : 16 16

Total no. of machines :

APPAREL INTERNSHIP PROJECT REPORT ON LAYOUT STREAMLINING | APURV & PRANAV

6.5 Cuff Preparation:

6.5.2 Cuff Section Details: Total Manpower : 33 20

Total no. of machines :

APPAREL INTERNSHIP PROJECT REPORT ON LAYOUT STREAMLINING | APURV & PRANAV

6.6 Sleeve Preparation:

0.600 SNLS 0.350 SNLS 0.900 Iron table 0.900 SNLS

6.6.2 Sleeve Section Details: Total Manpower : 37 25

Total no. of machines :

APPAREL INTERNSHIP PROJECT REPORT ON LAYOUT STREAMLINING | APURV & PRANAV

6.7 Assembly Section:

APPAREL INTERNSHIP PROJECT REPORT ON LAYOUT STREAMLINING | APURV & PRANAV

APPAREL INTERNSHIP PROJECT REPORT ON LAYOUT STREAMLINING | APURV & PRANAV

Layout (Process Layout)

Material Flow (Process Layout)

APPAREL INTERNSHIP PROJECT REPORT ON LAYOUT STREAMLINING | APURV & PRANAV

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

APPAREL INTERNSHIP PROJECT REPORT ON LAYOUT STREAMLINING | APURV & PRANAV

SNLS Iron Table

APPAREL INTERNSHIP PROJECT REPORT ON LAYOUT STREAMLINING | APURV & PRANAV

0.450 0.900 0.650 0.650 0.450 0.650 0.600 0.350 0.900

F-224 ( cuff setter )

APPAREL INTERNSHIP PROJECT REPORT ON LAYOUT STREAMLINING | APURV & PRANAV

7.2.2 Single Line Details: Total Manpower : 306 252