Apparel Internship: A Case Study of Production Optimization in the Garment Industry, Study notes of Reporting and Production

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APPAREL INTERNSHIP

27th May - 31st August 2019

APURVA NIDHI

MONICA RAJU

RITIKA PATHANIA

BFT VII

CONTENT

TOPIC SLIDE NO.

Company Profile 3

Department Overview 4

RFT Improvement 9

Other Projects 29

Deluxe Coffee Drinks

● Planning ● RM (Raw Material) ● MQA (Material Quality Assurance) ● PCU (Production Control Unit) ● Cutting

DEPARTMENTS

TECHNICAL/ PPA PRODUCTION FINISHED GOODS

● BPU (Brand Protection Unit) ● Logistics ● Quality ● Lean enterprise ● IE (Industrial Engineering)

OTHERS

● Training School ● Time & Security

OPERATIONS SUPPORTING

TRAINING

Induction

● HR Policies & procedures ● Quality & product knowledge ● MOS- Mas Operating Standards

Basic M/c skill area

● Fundamentals ● Auxiliary ● Foundational ● Operational

Advanced M/c skill area

● Advance machine knowledge ● Critical operations

Dancing and Yamazumi

● Modular layout (multiskilled, Line balancing)

Ideal Profile

● Multi-skilled ● Dancing & yamazumi knowledge ● Lean practices ● Quality FTT mindset ● Basic product knowledge

CUTTING

● PHASE 1 Straight knife cutting

● PHASE 2 Band knife cutting/ Automatic Cutter

● PHASE 3 Bundling process

CAD

● For all the sizes the patterns are received from the MDS Sri Lanka ● Factories try to improve the marker plan with greater efficiency

PRODUCTION

● Total of 64 cells following the Modular production system

● WIP of 5 pieces between two operations

● TL/GL Concept

DEFECT PERCENTAGE

11156655 Cell-45 11156960 Module-15 11156655 Cell-

DEFECT PERCENTAGE

11156965 Cell-

11156965 Cell-

NEEDLE POINT FTT

11156965 Cell-

11156965 Cell-

REWORK

Cell-

Cell-

Module-

AQL %

Cell-

11156655 Cell-

11156960 Module-

AQL %

11156965 Cell-

11156965 Cell-

COUNTER-MEASURE MATRIX

S.NO. PROBLEM MAJOR CAUSE SOLUTIONS

1 Uneven fringes Blade problem ● Machine blade check 2 times/ shift to ensure

blade sharpness & working properly

2 Thread pullout Horizontal tacking ● Tacking should be done vertically & not

horizontally

● Team members should be made aware of the

process

● Visualization for proper method can be put in the

machine

● Videos can be made and put in the tab for

reference and training by the TL and TMs

S.NO. PROBLEM MAJOR CAUSE SOLUTIONS

3 Gusset loose ● Method unawareness

● Uneven gusset attachment

● Improper gusset tacking

● Proper handling the panels while feeding and using

one hand for feeding while holding the gusset panel

and the other hand for simultaneously flattening

the panel during the process

● Not accepting the defective parts from the previous

operation.

4 Waist center

off/Waist wavy

● Untrained operator (o/l

operator made to do ringer

operation)

● Ringer dia setup problem

● Training the operator before hand, as it wastes the

material as well as time & also leads to

demotivation of the operator

● Addition of visual for the display of ringer diameter

sizewise and stylewise in order for the easy setup of

the machine

● Proper placement of the panel, matching the

Centre Back of the panel to the Center Back of the

waist band.