Académique Documents
Professionnel Documents
Culture Documents
STYLE: MATALAN
DATE TOTAL NO QUANTITY TOTAL NO OF % OF ALTERATION
CHECKED DEFECTS
17-mar 2800 561 20
18 2910 562 19.3
19 ---- ---- ----
20 2802 529 18.9
21 2710 457 16.9
22 3610 694 19.2
23 4705 784 16.7
24 5705 834 14.9
25 6320 898 14.2
26 ---- ---- ----
27 5790 800 13.8
28 5210 701 13.5
7000
6000
5000
4000
3000
2000
1000
0
1 2 3 4 5 6 7 8 9 10
NO OF DAYS
30
25
20
15
10
0
1 2 3 4 5 6 7 8 9 10
NO OF DAYS
Average alteration=16.2%/day
3050
3000
2950
2900
2850
2800
2750
2700
2650
2600
1 2 3 4 5 6 7 8 9 10
NO OF DAYS
Average production=2900/day
35
30
25
20
15
10
0
1 2 3 4 5 6 7 8 9 10
NO OF DAYS
Average alteration=18.5%/day
Using formulas
% of alteration= (Total no of defects/total no of quantity
checked)*100
Before Implementation
Production = 30000pieces
Alteration = 18.5%
After Implementation
Production = 42000pieces
Alteration =16.2%
Fault measurement.
MEASUREMENT
Broken Stitch
Open seams
Raw edges
Un cut thread
Size jump
Wrong stitch
EMD problem
Roping hem
% OF DEFECTS
6,690
26.0
Cumulative_Frequency
4,460
15.7
14.6
12.0
9.7
2,230 7.9 7.9
3.1 3.0
TYPE OF DEFECTS
Sewing section
After receive the garments components from cutting section, all
the garments parts are joined and sewn as sequentially.
Obviously all the components are sewn respects on buyer
requirement. So, sewing section is the most important
department of a garment manufacturing industry. Sewing
machines of different types are arranged as a vertical line to
assemble the garments. Sequence of types of sewing machine
arrangement depends on sequence of assembling operations.
Problem Definition
1. High alteration rate
OBJECTIVES
Improve quality
Improve visual management
Reduce lead time
Reduce wastage
Improve worker performance
Conclusion
Traffic light system is a system that can be implemented in any
garment manufacturing company and it will help to improve the
quality status, reduced the cost, reduced the lead time and
thus strengthen the supply chain performance without
increasing the resource.
From this study we have seen that after implementing the lean
traffic light system the quality status was improved and thus
supply chain was strengthen through the reduced lead time. So
it can be said that, it is an urgent for the factories to adopt lean
in the supply chain.
DEPARTMENT OF INDUSTRIAL ENGINEERING AND MANAGEMENT
Karthik.p (1ms13im404)
Ajaykarthi.m (1ms14im401)
Murali.s (1ms14im407)
Sharanabasava (1ms14im410)
AVG ALTERATION=125.63/6=21%
AVG ALTERATION=119.7/6=20%
AVG PRODUCTION=3323/6=554
AVG ALTERATION=102.4/6=17.1
AVG ALTERATION=82.6/6=13.77%
AVG PRODUCTION=3709/6=618
AVG ALTERATION=59.8/6=10%
25
20
15
10
0
1 2 3 4
NO OF WEEK
10
NO OF WEEKS
25
20
15
10
0
1 2 3 4
NO OF WEEKS
=660*2.87
= RS 1897.5
POST IMPLEMENTATION
ALTERATION PROFIT
Weeks No of altered Total alteration Alteration benefit
pieces/week cost
PRODUCTION PROFIT
Weeks Raise in Operational Production
production cost/piece benefit
1st 49 9.2 450.8
nd
2 168 9.2 1545.6
3rd 288 9.2 2649.6
th
4 554 9.2 5076.8
TOTAL PRODUCTION BENEFIT=9742.8