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MODERN TECHNOLOGICAL TOOL IN AID OF
LEAN MANUFACTURING:GARMENT UNIT CASE STUDY
Prof. P.B. JhalaResearch Advisor
National Institute of DesignGandhinagar-382 007
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LEAN PRODUCTION SYSTEM: MODEL
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NEED FOR LEAN IN GARMENT UNIT
Low Technology Labour IntensiveLow ProductivitySewing Time 20%Handling Time 80%
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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
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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
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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
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Process Unit
Description
Washing 9 Ramsons Washing Machine.
2 Japanese Hydro Extractor.
3 Ramsons Tumbler
1 Thermotech Boiler.
Finishing 4 Ramsons Steam Press.
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SYSTEM CONFIGURATION
SUPPLY FROM CUTTING ROOM
COLLECTION OF FINISHED GOODS
INSPECTION HOSTCOMPUTER
SERIAL CABLE
SINGLE BOARD COMPUTER
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SYSTEM BLOCK DIAGRAM16 Char, 2 LinesLCD Display
4 x 4Matrix
Keyboard
Optical Sensor
64K RAM
64K EPROM
RS 485
Real Time Clock
80C535
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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
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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
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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
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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.
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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
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ATIRA-ITCTI MONOGRAPH
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Thank You