NATIONAL INSTITUTE OF FASHION TECHNOLOGY,

KANGRA

Lean Management
ASSIGNMENT - 2

SUBMITTED TO : SUBMITTED BY:

MR. SAURABH CHATURVEDI DRISHTI
(ASSISTANT PROFESSOR) HARSHITA KHATWANI
ANURAG VERMA
PRIYANKA KAPOOR
SHIVAM BHANDARI
SNIGDHA MAHAJAN
 Acknowledgement
Any attempt at any level cannot be satisfactorily completed without the support of all those
who have directly or indirectly helped me in this assignment. We would like to express my
immense gratitude to Mr Saurabh Chaturvedi who provided us the opportunity to come up
with this assignment.
A special thanks to the all those who rendered their whole hearted support to all times for the
successful completion of this assignment.
 OPERATIONAL BREAKDOWN

Output per
SAM MC operation Operators
Shoulder
Attaching 0.6 SNLS 100 1
Front Placket
Shirt 0.85 HELPER 70.58824 1.5
Front Placket
Attaching 1.05 SNLS 57.14286 2
Front Placket
Finishing 0.55 SNLS 109.0909 1
Pocket Hemming 0.4 SNLS 150 1
Pocket Pressing 0.3 HELPER 200 1
Pocket Attaching 0.6 SNLS 100 1
Check Point 0.35 HELPER 171.4286 1
Collar Attaching 0.7 SNLS 85.71429 1
Collar Tape
Attachment 0.45 SNLS 133.3333 1
Side Seam 0.59 4t O/L 101.6949 1
Sleeve
Attachment 1 4t O/L 60 2
Sleeve Hem 0.8 F/L 75 1.5
Bottom Hem 0.95 F/L 63.15789 1.5
Check Point 0.35 HELPER 171.4286 1

SAM 9.54 18.5

SAM = 9.54 == 10 min

No. of Operations = 16 (including 2 checkpoints)
Output per operations = 60/Sam of Operation
Total workers = 18.5
Pitch time = 88 (i.e. 88 pieces per operation should be made)
Man : Machines = 1.6 : 1
Machines= 100
Therefore man= 160
Longest process time = 0.95 min
Line balancing rate (LBR) = (SAM/ (Longest process time X no. of workers)) X 100
LBR =63%
Output per line per day= (480 X 18 X 70)/ (100 X 10) == 600
No. of lines 5 (since capacity of 99 m/c)
Output per day = 600 X 5 = 30,000 pcs
Button attaching machine= 200 buttons per Hr.
Therefore, for a day = 200 X 8 =1600

CALCULATED OUTPUT BASED ON LINE BALANCING

OPERATION MACHINE NO. OF EXPECTED CALCULATED
WORKERS OUTPUT PER OUTPUT
HOUR
Shoulder Attaching SNLS 1 88 100
Front Placket Shirt HELPER 1.5 88 105
Front Placket
Attaching SNLS 2 88 110
Front Placket
Finishing SNLS 1 88 109
Pocket Hemming SNLS 1 88 150
Pocket Pressing HELPER 1 88 200
Pocket Attaching SNLS 1 88 100
Check Point HELPER 1 88 171
Collar Attaching SNLS 1 88 85
Collar Tape
Attachment SNLS 1 88 133
Side Seam 4t O/L 1 88 101
Sleeve Attachment 4t O/L 2 88 120
Sleeve Hem F/L 1.5 88 120
Bottom Hem F/L 1.5 88 94
Check Point HELPER 1 88 171
PLANT LAYOUT

Fig 1.1 : Plant Layout

CUTTING DEPARTMENT LAYOUT

Fig 2.1 : Layout made using AutoCad

Fig 2.2: Cutting Department layout

SEWING AND FINISHING DEPARTMENT LAYOUT

Fig 3.1 : Sewing Department Layout

 Fig 3.2 : Finishing Department Layout

Note :
In the pictures given above :
1. Yellow box denotes a helper.
2. 4 boxes are button hole and button attaching machine.
3. 10 boxes are Iron tables.
4.8 boxes are inspection table.
5. 6 boxes in placed horizontally are for rework.
6. 1 big box is dispatch.