MODERN TECHNOLOGICAL TOOL IN AID OF

LEAN MANUFACTURING:GARMENT UNIT CASE STUDY

Prof. P.B. JhalaResearch Advisor

National Institute of DesignGandhinagar-382 007

LEAN PRODUCTION SYSTEM: MODEL

NEED FOR LEAN IN GARMENT UNIT

Low Technology Labour IntensiveLow ProductivitySewing Time 20%Handling Time 80%

Unavoidable losses Avoidable losses

Machine Set-up Time. Balancing Bottleneck Operation.

Material Handling. Waiting for Maintenance Diagnostic.

Personal Break Time. Late Starts, Early Stops, Low Speed,

Inspection and Clean-up. Extensive Breaks.

Rethreading, Bobbin Change, Needle Change.

 

PRODUCTIVITY LOSSES

GARMENT UNIT PROFILEProducts : Readymade Garments

in Bottom WeightsArticles : Trousers, Shorts,

BermudasCapacity :Cutting, Stitching, Finishing

: 12,000 pcs/month

Washing Unit : 70,000 pcs/monthStaff : Managerial Worker

: 878

Turnover : US $ 4,00,00/annum

Process Unit Description

Cutting 4 15m x 2m Cutting Table

  2 8" Brute Straight Knife Power Driven Cloth Cutting Machine

  1 Brute Cloth Drill Machine.

Stitching 20 Juki Single Needle Lock Stitch Machine.

  1 Juki Bartack Machine.

  3 Juki Overlock Machine.

  1 Kansai Sp. Belt Machine.

  2 Juki Two Needle Lock Stitch Machine.

  1 Kansai Sp. Loop Making Machine.

  1 Kansai Sp. Pocket Facing Machine.

  1 Kashyap Fusing Machine.

LIST OF MACHINES

Process Unit

Description

Washing 9 Ramsons Washing Machine.

  2 Japanese Hydro Extractor.

  3 Ramsons Tumbler

  1 Thermotech Boiler.

Finishing 4 Ramsons Steam Press.

SYSTEM CONFIGURATION

SUPPLY FROM CUTTING ROOM

COLLECTION OF FINISHED GOODS

INSPECTION HOSTCOMPUTER

SERIAL CABLE

SINGLE BOARD COMPUTER

SYSTEM BLOCK DIAGRAM16 Char, 2 LinesLCD Display

4 x 4Matrix

Keyboard

Optical Sensor

64K RAM

64K EPROM

RS 485

Real Time Clock

80C535

DATA GENERATION Machine and Operator

Work in Process (WIP) at Various Stagesof Manufacture

Traceability of Various Bundles in Sewing Room

Productive Time Handling Time Down Time Rework Time

Form for Entry of Employee Code, Time Tolerances, WIP of Regular or Rework for a Machine.

Form for Entering Information to Generate theWork Flow Diagram.

Form for Entering the Details of all the Employees into the Database.

Form for Entering the Order Details.

FORMS FOR SUPERVISORS USE

Daily Productivity Report showing Supervisor Code, Machine Code, Employee Code, Productive Time, Handling Time, Rework Time, Down Time.

  Work in Progress Report (WIP) showing Daily

Progress for the Entire Month.

WIP Current Status Report with Various Alarms toindicate Underflow/Overflow of Material at each Station.

  Skill Matrix Chart showing Operation Code, SAM per

Unit, Output per hour (at 100% Performance), Operator Performance (%), Floater Performance.

Process Flow Chart of a Product.

REPORT GENERATION

BENEFITS Achieving SAM Value of Operation.  Reduce WIP Level of the Shop Floor. Increased Productive Time and Reduced Handling

Time. Improved Efficiency of Operator. Identification and Correcting Problematic Area in Short Time. Reduced Delivery Time for the Order. Greater Transparency in Production System On-line Information of the Shop Floor through Internet.  Data Generation for Standardising the Allowance and Creating Benchmarks.

PAPER PUBLICATION IT Based Sewing Room Data for Improved

Performance of SMEs’ in Garment Sector

C.S. Vora, M.G. Solanki, P.B. Jhala (ATIRA) Pavan Godiawala (NIFT-G) Verghese Paul

(NIRMA)

Proceedings of 43rd Joint Technological Conference Jointly Organised by ATIRA, BTRA, SITRA & NITRA

March 02-03, 2002

ATIRA-ITCTI MONOGRAPH

Thank You