ABSTRACT
DINESH Garments, TIRUPPUR initiated the Project. It manufactures clothes designed for women’s, men’s, and children’s clothing. Apparel production, also referred to as garment production, transforms fabric into clothes. “apparel production” is generally used when clothes are produced in factories.
The Project focuses on increasing the efficiency and reducing the cost of Sewing in the section. The focus of the Project is on steps that have been taken to research and eliminate any non-productive tasks in the sewing department to cut time and money and decrease internal processing time. This paper describes the method of better knowledge-based and integrated process control and planning. The results of this research were that an organization could increase its Productivity and profit by eliminating non-productive processes. An overview of this trend is provided in this report.
CHAPTER-1
Introduction to TEXTILE and APPAREL INDUSTRY
It is important to note that the Indian textile industry significantly influences the economic system and the global textile industry. Their contribution to the Indian economy is significant to the manufacturing industry and creates foreign exchange and employment jobs. It is responsible for 20 percent of the industrial production and 9 percent of the excise revenue, and 18 percent of the work in the industrial sector—close to 20 percent of the country’s total export earnings in addition to 4 percent of GDP.
The garment industry in India is characterized by a fragmented structure with many units that can produce small orders. There are a lot of companies with significant investments that are fully integrated.
The world’s apparel industry is among the most significant economic sectors in terms of investment income, trade, and employment production all over the globe. The apparel industry in India is vastly diverse in regional, climate, fiscal and cultural factors. Indian textiles are witnessing tremendous expansion and growth in the industry sector in India and overseas. The importance of the apparel industry is solely built on the impact of industrial efficiency and employment. The entire apparel industry contributes to the GDP of the country following agriculture. The significant segments of the fashion industry include furniture and home decor and clothing and accessories for women, children, and men.
Introduction to the Project:
In most industries, the primary attention is paid to profit. While there are a variety of costs to consider and cost reductions internally employed by the sector by cutting down on waste, eliminating and enhancing the quality of work will increase profits. Ineffective activities indicate that the client does not think the product is worth its price and zigzags because of poor layout and line balancing issues or planning that is not done correctly or used of machines and sharing of work equipment, lack of workers fatigue, etc. One way to reduce wastage is to eliminate non-productive activities that could drop in time, costs, and time to market. It is a fact that can be seen in the famous Russian phrase Time is Money; if the production time is cut down, the business will capitalize on less cash and save more.
COMPANY PROFILE
Modestly established in 2007 in Tirupur, the knitting capital in India, Dinesh Garments has taken considerable strides in becoming an established brand and has an annual sales turnover of over 100 crores.
The clients include Suncityand Suncity France and Major-US Next-UK Sergent.
Mr. Dinesh, the founder-chairman of Dinesh Garments, is an innovator with more than 15 years of experience in knitting. Dinesh Garment’s strength lies in the transparency of its operations, prompt delivery, and exceptional customer service.
Dinesh Garments Dinesh Garments has all departments needed to run an apparel business, such as Knitting, Cutting, Printing, Sewing, labeling and packing, ironing, and labeling.
Objectives of the PROJECT:
- Analyze the process of Sewing using the Time Study method.
- To determine the production status on the line, to determine the reason for the lack of Productivity in the sewing department, and to analyze the price for the item.
- It is implementing the concept to decrease the inefficiency during Sewing. This results in improved productivity in the sewing department and saves time and money for the organization.
REQUIRED FOR The Study:
Dinesh garments are facing the issue with the efficiency of its sewing lines, and the Productivity of its sewing line is not as high as the industry standard. The company’s management declares that the performance reached by this department is not sufficient. Requires an in-depth evaluation of the efficiency of the line and labor performance.
Scope of the STUDY
- The study aids the business in increasing productivity.
- The study assists the company in saving money and time in the sewing department.
REGULATIONS FOR STUDY
- Four different orders have been taken and studied.
- The study was conducted with the current group of workers, and not all workers are protected.
CHAPTER 2
METHODOLOGY
INTRODUCTION:
A study of the time-consuming sewing operation was carried out during the production procedure of the Dinesh garment. The study was conducted on behalf of the children’s clothing made in the business.
Based on the time observed for each Sewing component, the Average Basic Time, Standard Allowable Minute for every procedure, is calculated according to the information in the sections below.
Then, the analysis of the content of the balance of work for the workers in the Sewing Group is carried out to identify opportunities for improvement in Productivity.
Type of Research:
The kind of research conducted is quantitative descriptive research. Descriptive analysis aims to present data and features regarding the person or the phenomenon being investigated. This research studies the amount of time required to perform different essential tasks involved in the sewing process to determine the cause of low productivity.
DATA COLLECTION:
Data collection is an important stage during the research process. The first data needed to conduct this study was collected by TIME study of the various processes involved in sewing garments. The timings are analyzed in the usual procedures used for every Sewing component. The standard method used to conduct a Time Study using a suitable stopwatch is followed for the study.
FIRST DATA RELIABLE:
The most crucial information sources include:
- Time observation during the process of executing an element of a sewing procedure
Sample Size:
Based on the previous experiences and the company’s practice, a sample size of the elementary operation is selected. For each of the components involved in Sewing a casual shirt of wills club, ten readings were made to determine the timing of the process.
CALEURATION OF AM THROUGH TIME Custody:
step 1: Choose one of the operations you would like for SAM calculation.
Step 2: Stopwatch. Begin by the side with the person who is operating. Take a picture of the cycle time for the operation. (cycle duration – the amount of time needed to perform the work required to finish one task, i.e., time from picking up the piece of the first piece to picking up the next article). Conduct a time study over five cycles. Remove if you find unusual or not value additional time for any of the cycles. Calculate the average of five cycles. The time study is known as cycle time. Convert this cycle time to real-time by multiplying cycle time by the operator score.
The Basic Time is the Cycle Time divided by performance.
Step 3: Performance evaluation. Now, you must rate the worker on what degree he was performing the job, taking note of his movements and work speed.
Standard Allowed Minutes (SAM) equals (Basic minutes plus bundle allowances plus personal allowances and machine). Include bundle allowances (10 percent) and personal and device allowances (20 percent) to the basic. The standard time they were allowed, or SAM has been calculated for all tasks associated with the above clothes style. The calculation of SAM includes and excludes non-productive time. The productive and non-productive actions in each step discovered were identified in the above procedure for each type, and the SAM or SMV in minutes were recorded. Then the final SMV variation was determined.
CALIBRATIONS FOR PRODUCTION
The production day is calculated using the calculated SAM and the total work hours per day for the company, as shown below.
Total production time
Production per day =……………………………….X Efficiency
SAM
The time of production total is not. of the operator X Time
The formula above is used to calculate the Project.
GROOMING COSTS:
Calculated according to the following
- Production / day ……………………
- Production/ month…………………..
- Production/year……………………
- Cost/garment………………………..
- Total cost = No of cost of process X/ garment
Elements of OPERATIONS Involved in the SEWING PROCESS BASIC LEGGING, INCLUDING:
- Front rise attached
- Back rise attached
- Lace ironing
- Lace attached
- Lace finishing
- The elastic label is attached to the waistband.
- Inside the finishing
- Care label attached
- Hemming waistband
- Top of crotch and bottom of the legging
CHAPTER 3
Analyze and Interpretation
Estimation of Standard ALLOWED MINUTE (SAM) In INCLUDING/EXCLUDING NON-PRODUCTIVITY (NP) Activities:
SAMPLE-1
| S.No | Operation | Sam includes NP activities | Sam should be excluded NP activities | Number of Operators | m/c |
| 1 | Front rise attached | 0.2366 | 0.2093 | 2 | O/L |
| 2 | Back rise attached | 0.2002 | 0.1820 | 2 | O/L |
| 3 | Lace ironing | 0.0910 | 0.1820 | 1 | – |
| 4 | Lace attached | 0.0780 | 0.0650 | 1 | F/L |
| 5 | Lace finishing | 0.0650 | 0.0520 | 1 | F/L |
| 6 | Elastic label | 0.2275 | 0.2002 | 1 | F/L |
| 7 | Elastic label with finished | 0.1170 | 0.0910 | 1 | O/L |
| 8 | Inside the finishing | 0.2730 | 0.2356 | 2 | O/L |
| 9 | Care label attached | 0.0910 | 0.0780 | 1 | F/L |
| 10 | Hemming to waistband | 0.1365 | 0.1092 | 1 | F/L |
| 11 | The bottom of the leggings has a peak. | 0.1638 | 0.1274 | 2 | O/L |
| TOTAL | 2.4796 | 2.2277 | 15 |
Table-4.1 Data collection sample-1
SAMPLE-2
| S.No | Operation | Sam is included in NP activities. | Sam is excluded from NP activities. | Number of Operators | m/c |
| 1 | Front rise attached | 0.2266 | 0.2193 | 2 | O/L |
| 2 | Back rise attached | 0.2102 | 0.2020 | 2 | O/L |
| 3 | Lace ironing | 0.0910 | 0.0880 | 1 | – |
| 4 | Lace attached | 0.0780 | 0.0750 | 1 | F/L |
| 5 | Lace finishing | 0.0650 | 0.0620 | 1 | F/L |
| 6 | Elastic label | 0.2275 | 0.2102 | 1 | F/L |
| 7 | An elastic label that is finished | 0.1170 | 0.0910 | 1 | O/L |
| 8 | Inside the finishing | 0.2630 | 0.2556 | 2 | O/L |
| 9 | Care label attached | 0.0910 | 0.0880 | 1 | F/L |
| 10 | Hemming to waistband | 0.1365 | 0.1192 | 1 | F/L |
| 11 | A peek at the bottom of the leggings. | 0.1638 | 0.1474 | 2 | O/L |
| TOTAL | 2.4696 | 2.3577 | 15 |
Table-5.1.2 Revisionized Data Collection sample 3
SAMPLE-3
| S.No | Operation | Sam is included in NP activities. | Sam is excluded from NP activities. | The number of operators | m/c |
| 1 | Front rise attached | 0.2466 | 0.2493 | 2 | O/L |
| 2 | Back rise attached | 0.2002 | 0.1920 | 2 | O/L |
| 3 | Lace ironing | 0.1010 | 0.0980 | 1 | – |
| 4 | Lace attached | 0.0980 | 0.0950 | 1 | F/L |
| 5 | Lace finishing | 0.0750 | 0.0720 | 1 | F/L |
| 6 | Elastic label | 0.2175 | 0.2102 | 1 | F/L |
| 7 | An elastic label that is finished | 0.1570 | 0.1410 | 1 | O/L |
| 8 | Inside the finishing | 0.2830 | 0.2756 | 2 | O/L |
| 9 | Care label attached | 0.0910 | 0.0880 | 1 | F/L |
| 10 | Hemming the waistband to the waist | 0.1565 | 0.1492 | 1 | F/L |
| 11 | The bottom of the leggings has a peak. | 0.1738 | 0.1674 | 2 | O/L |
| TOTAL | 2.5996 | 2.5377 | 15 |
Table-5.1.3 Revised Data collection sample 4
SAMPLE-4
| S.No | Operation | Sam includes NP activities. | Sam is excluded from NP activities. | The number of operators | m/c |
| 1 | Front rise attached | 0.2366 | 0.2293 | 2 | O/L |
| 2 | Back rise attached | 0.2002 | 0.1920 | 2 | O/L |
| 3 | Lace ironing | 0.1000 | 0.0980 | 1 | – |
| 4 | Lace attached | 0.0880 | 0.0850 | 1 | F/L |
| 5 | Lace finishing | 0.0750 | 0.0680 | 1 | F/L |
| 6 | Elastic label with attached | 0.2175 | 0.2002 | 1 | F/L |
| 7 | An elastic label that is finished | 0.1470 | 0.1410 | 1 | O/L |
| 8 | Inside the finishing | 0.2730 | 0.2656 | 2 | O/L |
| 9 | Care label attached | 0.0910 | 0.0880 | 1 | F/L |
| 10 | Hemming to waistband | 0.1565 | 0.1392 | 1 | F/L |
| 11 | A peek at the bottom of the leggings. | 0.1738 | 0.1574 | 2 | O/L |
| TOTAL | 2.5586 | 2.4637 | 15 |
Table-5.1.5 Revised data collection sample 5
SAMPLE-5
OBSERVATION:
The revised SAM figure includes nonproductivity results, which indicate that on average, 2.48 SAM and corresponding production per hour for employees who work at 60%, 70%, or 80% and 90% efficiency would be 218,253,289,326.
OBSERVATION:
The updated observed SAM value is not inclusive of nonproductivity results, which indicate that the average 2.37 SAM and corresponding production per hour for employees who work at 60%, 70%, or 80% and 90% efficiency would be 227,265,303,341.
5.2.2 A REVISED PRODUCTION CHART VARIABLE
Revised production analysisTable5.2.2 Revised production analysis chart 5.2.2 Revised production analysis chart Revised production analysisChart5.2.2 Revised production analysis chart 5.2.2 New production analysis.
OBSERVATION:
The revised production analysis results indicate that with an efficiency between 60, 70, 70, 80, and 90, the difference in production between excluding and including the NP output/hour would be 9 12, 14, and 15, respectively.
5.2.3 Revisions FINANCIAL CALCULATION
M.S.Kaarthikeyan clothing is priced at an average CM cost for the style mentioned above is RS60 per piece.
Revised financial calculationTable5.2.3 Revised financial calculationChart 5.2.3 Revisionized financial calculation Revised financial calculationChart5.2.3 Revised financial calculationChart 5.2.3 Revisionized financial calculation
OBSERVATION:
The financial results above indicate the production fluctuation in output/hours 9 12, 14, and 15, resulting in losses of 1684800, 2246400and, 2620800, and 280800 for the year.
5.3 SUGGESTIONS:
A few of the recommendations given to decrease the time spent on non-productive tasks include efficient production planning, the proper application of industrial engineering an experienced and well-trained operator, a good layout plan, no Rework, efficient running of the machine, appropriate line balancing, the right time for applying oil to sewing machines and ensuring high-quality production. Enough working aids could be made available for seamless operation. Stickers can be used to mark the fabric the correct shade variations and width, length, etc. the material must be determined with proper identification, an appropriate allocation of resources is required, books for recording production to be distributed as one ordinary book is utilized to ensure quality with minimal delay between inspection and waiting and a reduced zigzag motion. These suggestions were made to the department of Sewing.
5.4 CONCLUSION:
The suggested tools created within this Project encompass an extensive array of factors that will help reduce time and cost in the sewing department of the apparel industry by ensuring high-quality production. It was discovered that time was conserved, and time-related costs were efficiently utilized (reduced by removing non-productive tasks). The study clearly shows that by eliminating non-productive processes in the sewing area, time and money are saved, which has a significant impact on the overall economy of the factory.
