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Acknowledgement
We are thankful to Mr. Lalit Mahajan (Vice President
& Commercial Head), VNGL for allowing us to intern at this prestigious institution. We would also like to thank Mr. Sumit Kharab (Production head, Sewing) and Mr. Nitin Sharma (Manager, P &I.E ) for their utmost support and cooperation during our tenure here. It was their valuable guidance that lighted the way for us. Lastly, we are also grateful to all the staff members and workers for giving us their valuable time.
Introduction
Vardhman entered the Garment Industry with a
joint venture with Nisshinbo Textile Inc. from Japan for production of formal shirts in Ludhiana, Punjab (India) with Vardhman holding 51% stake. The shirts will be sold in India as well as exported to US, Europe & Japan. Vardhman produces yarns & fabrics and will perform liquid ammonia processing with technology cooperation from Nisshinbo and is one of the few industries producing wrinkle free shirts in India..
Market standing
Even after VNGL being a recent endeavour, it has
already started creating a niche in the market due to its specialised product profile, i.e. wrinkle free formal shirts and has already attracted the attention of major buyers in the Indian market which procure orders from us. These companies , to name a few:
Blackberrys Billy Jealousy Arrow Turtle Raymond
operating and managing the production process. The factory has two floors and the departments are divided as under : Ground Floor:
Fabric and Trim Storage Finishing Warehouse Canteen HR and Time office
Sewing Department Administration office CAD Room Sampling MVK
First Floor:
Layout :
Ground Floor
Layout:
First Floor
Issues Noted
shorter, the ply is considered to be end bit. By doing this, the cut quantity is also not achieved sometimes. In order to achieve the rquired cut quantity, the end bit ply is recut for completing the cq. TOO MUCH DEPENDENCE ON RECUTTING:
of rejection and defective panel or sub assemblies and not when actual cut quantity falls short of the required one.
WIP storage
Existing system
more occurences of shirts falling down as the height of WIP rises. More chances of slippage Box is inverted over a frame which is against the purpose of box. Use of pladtics is eliminated
confines the garments in space The straps are made of semi elastic material. Straps sandwitched between the two parallel rods . The three straps will have enough strength to take the load of 200 garments atleast.
KANBAN
for main assembly. Loss of labor hours who are waiting for loading to happen.
much pieces as what is required as input in the subsequent section. Elimination of over time and idle time in cutting and finishing operation. The operators who become idle soon as assembly is loaded can be shifted to other jobs in different sections
advance. Team leader of the earliest target achieving section should ensure that operators are allocated elsewhere.
METHODOLOGY
Assumptions
Production requirements
Operator vs Operation Production Capacity( Cutting-Sewing-Finishing) Method Study Time Study
Assumptions
Production Plan per day will vary for each day.
Production Requirements
Suppose X quantity is planned for a day,
after cutting. Allocation of work to people who become idle after making A no. of pieces. Training of operators in different operations to allocate for floater work.
DEGREE OF LOAD
Degree of loading can be introduced to the
Kanban plan in the Assembly line. For eg> Loading requirement in assembly U: Under Loading <=80% loading F : Full Loading 80%- 120% O: Over Loading >=120 %
of that section. F The required amount of buffer for the given style is achieved . O Over production of the style running in that section.
a degree. The degree of loading will be judged according to the outputs of the sections producing the style running in the assembly. This system can be incorporated into finishing to control WIP coming from Production.
CSBA- Attachment