SEWING PROCESS IMPROVEMENT IN JACKET

Student Name: SANJITH PANDEY (2008 12)

Background:
Improving processes is paramount for businesses to stay competitive in
todays marketplace. Over the last 10 to 15 years companies have been
forced to improve their processes because we, as customers, are demanding
better and better products and services.
Garment manufacturers who are basically export oriented are facing the
problem of efficient manufacturing of great number of different models in
small series. The reason for this is that foreign buyers are looking for
partners capable of producing high quality in greater range and in small
quantities, short delivery dates. As a result it has become necessary for the
companies to improve the existing production process.

Objectives of the project:

To reduce the cost of production by reducing total cyclic time and

number of operators where possible.

To identify need of work aid developments in jacket line to aid the

operators and to analyze their effects on the operation.

To reduce the number of loading points and excess man and material
movement.

Methodology:

Literature Survey of the topics related to project

Study of the existing jacket line operations in a detailed manner.

Cyclic time study of the whole line.

Calculation of pitch time for the line and selection of operation for
improvement based on pitch time.

Application of following below mentioned concepts to improve the selected

operations:-

Method improvement

Workstation design

Ergonomic consideration

Material Handling Reduction

Reduction of excessive motion.

Suggestion for modification of selected operations to improve the process.

Implementation of changes in the line.

Study of effect of these changes on the production of the line and on the
operator for reducing material handling and movements.

Preparation of report and report submission to the company.

Discussion & Analysis:

To analyze the current sewing process, Cyclic time study, pitch analysis and string
diagram of the whole line were done. As a result various suggestions were given
and implemented like automatic tape un-winder, modification of layout to improve
material movement, development and implementation of new work aids.

Conclusion:

The main aim of the project was improvement in the process and to make the
line sustainable for the higher production.

There was strong effort taken for reducing the handling time and extra
movement of operators.

The production of the line at the start of project was 436 jackets/day. After
the changes done, it grew up to 485 jackets/day. So there was an increase of
49 jackets/day i.e. 11.3%in the production.