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STUDENTS NAME: ABHISHEK KUMAR, MANISH RAJ GUNJAN & BIRJU MURMU
Project Title: AUDIO-VISUAL Operator Training Module Project Guide: Mr.S.S.Ray Background: There exists a scope of visual learning in Apparel Manufacturing Technology education. Visual learning is always better than learning from books. Moreover, an operator training method based on visual learning may be more beneficial as the operator can see the method of performing an operation again and again without actually wasting the raw materials required for demonstration Objective: To development the training material for the sewing operators of the knitwear industry and convert it into audio-visual mode. Methodology: Identify what learners want or need to know and decide what type of training can meet their learning needs. Plan the training so that learning is likely to take place. Deliver the training so that the learning does take place. Evaluate the training so that there is evidence that learning has taken place. Findings: Audio- visual training module prepared for operators, delivered and evaluated. Conclusion: The training module was completed and will now be changed into flash version with local language voice over.
Objective:To develop a comprehensive quality bible aiming at product integrity and overall consistency in all operations.
Methodology: Based on the study of the existing Methods & acting on the difference to achieve the ideal procedures for a zero defect merchandise. Findings:Quality manual developed featuring Product Quality Rating System (PQRS), Defect Library, Quality Index, o AQL, Zero ReWork.
Conclusion: This manual will act as a guideline for all QA Personnel, Garment Vendors & other concerned heads to understand companys standard in line with customers standard in line with customers expectations.
Objective:To apply some of the concepts of lean manufacturing in the organization to eliminate waste assessed in respect of non value added activity in the finishing that would lead to lowering of cost per unit of the item produced.
Methodology:Studying the entire finishing floor and the existing system. Short-listing the faults in the system and highlighting the areas where improvement can be done. Findings:Lean manufacturing, 5s, visual control, productivity implemented in the finishing department of the garment industry.
Conclusion: A systematic approach to identifying and eliminating waste (non-value added activities) through continues improvement by flowing the product at the pull of customer in pursuit of perfection.
Objective:The objective of the project was to develop more profitable relationships with customers and having a 360 degree view of the customer helped. This meant that all touch points-salesperson, call centre agent, field service personnel must have access to the right information to enable them to interact effectively with the customer, whatever the preferred mode of communication-face-to face, phone, fax or email.
Methodology:The first step was learning theories, research works, and ideal conditions, rules about the CRM. The next part was modifying the existing CRM programs keeping in mind the ones used by competitions and considering customers views. Then came the implementation of suggestions and improvements of the program at the personnel and software level and evaluating the changes and their fetched results last part was incorporating the changed frame of CRM into system and getting people adapted to them and tracking down the further problems. Findings:Changes were made in the store ambience, loyalty promotion scheme, customer feedback book. An online link was created for enrollment of new members. A user interface was created for members to check individual account status. Conclusion: Several changes were incorporated starting from the shop floor, the personnel, the policies and even to the software. The aim was to retain best customers, converting good customers into high profit earning customers and dealing with unprofitable customer.
Methodology:Study of Existing Sale and inventory Management software was done. Selection of right options for small retail store were analysed. Effort to make the software economical. Selection of platform independent front end i.e.Java and MS-Access as back end. Findings:Retail Store, Sale Software, Bill, Retail Invoice, Inventory management, Vendor Details, Re-order Point. Conclusion:We are planning to install our softwares in a Delhi based retail setup which is expected to run successfully. It is expected to have an increase in sales, easier inventory handling and reduction in inventory carrying cost in this small span.
Objective:To develop an alternative solution of costing with extrapolation of the existing methods and detailed analysis of the working procedure to help Atraco combat with the existing weak order flow.
Methodology:Extrapolation of the existing working system keeping in mind the changes going to incur and also without a great amount of monetary loss. To develop an alternative costing sheet which can provide a better way to meet the targets. Findings: A new way of calculating costs was developed which enabled to manage the order flow at lower margins and quote the best prices. Since Bangladesh is the biggest threat, this approach helped Atraco to quote at the prices slightly lower than the target price of Bangladesh. Conclusion: Several changes in the costing sheet helped to get orders of around 25,0000 pcs for the new season even in this holocaust situation.
Objective:Reducing the no. of labours in the line because labour is getting costlier than ever.
Methodology: Listing out all the available options and choose the best of them. Make proper use of it and customize it for a special purpose. Findings:Reduction of material wastage, DHU and throughput time. Improved cycle time of button hole stitching and getting the stitch right at the first time. 754 pieces can be produced extra by reducing the total time.
Conclusion: This sewing guide can save the labor force and decrease the throughput time thereby increasing production and saving cost.
Objective:To identify brands/Lobs falling under the Benchmark by calculating return per square foot and recommending a business improvement plan.
Methodology:Based on data obtained from SAP reports and interviews. Findings:A business improvement plan was developed based on the return per square foot, sales per square foot. Based on this parameters bench marks was created and space efficiency and brand performance was studied.
Conclusion: This project helps analyze brands/LoBs to identify under-performers and suggests strategies to bring them above the benchmark.
Conclusion: The purpose of this project lies in lean manufacturing with primary focus on cost cutting by making a visually organized workplace reducing absentism of operators.
Findings: Total time saved for sewing a run stitch on a collar using the over bed trimmer is 3.0 seconds. Total Cost of the device is Rs. 2300/-.
Objective: To reduce the delays in several orders by analyzing the delay factors and giving suggestions for them.
Methodology: To determine the workflow in the merchandising dept. and finding out the reasons for delays in it and then giving suggestions for them so that the delay decreases. Findings: The most of the critical factors of delay is due to pre production activities. So. A merchant can manage the order better by following the planned time and action calendar right the first time.
Conclusion: Made a manual swatch cutter gum sheets & checklist for the merchandising department so as to make work easy for them Numerous suggestions given in respect to the delays found.
Conclusion: VM standard should be up to the mark to attract the customer and ultimately enhancing the sales.
Conclusion: The project therefore helped to make a quantitative evaluation system for suppliers in Prateek Apparels Pvt.Ltd. and made sourcing decisions simpler and logical.