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AT
TEXPORT SYNDICATE INDIA LTD
BY
SREYASI DAS (1527954)
Company Profile
Texport Syndicate: is a firm leader in the Apparel export space in India over the
past 30 years and is well equipped to handle woven and knit products under one umbrella.
1. Incorporated in 1976 headquartered in Mumbai India.
2. One of India's largest manufacturer / exporters.
3. 16 fully equipped, modern, manufacturing factories based across Bangalore, Mumbai,
Hyderabad, Tirpur.
4. Specialized in manufacture of Shirts, Tops, Sleepwear, Polos, Sweatshirts.
5. OEKOTEX Certified
6. Capacity to produce and export 1.5 million garments a month.
7. 11,000 employees.
CLIENTS
Secondary objectives:
Improve current practice of 5S.
Problem Statement:
Productivity and Efficiency improvement by implementation of Line
balancing in Texport Syndicate.
Project Methodology
A garment order is chosen which was started in the line knowing total
amount of order, style description and SAM.
In addition to that we have calculate the takt time, labor productivity, line
efficiency and bench mark capacity.
Equations used
Line efficiency = Total no. of output per day per line * SAM
Total manpower per line X Total minutes per day
* 100%
Target/ hr. =
252 (100% efficiency)
201 (80% efficiency)
Labor productivity = 40
300
250
200
150
Capacity/hr
100
50
0
0
5 10 15 20
process
Bottlenecks
Line Balancing
300
250
200
capacity/hr
150
100
50
0
0 5 10 15 20
process
Analysis of Data:
5s
Frequency of waste
Frequency of Occurence
18
16
14
12
10
Occurence
8
6
4
2
0
Machine Defect
Delay Reasons
Other Waste
Pareto analysis
QC tools:
Waiting waste in Sewing department:
200
180
160
140
120
100
80
60
40
20
0
100
90
80
70
60
50
40
30
20
10
0
Minutes
Cumilative %
Pareto analysis
Major Sewing defects:
45
100
40
90
80
35
70
30
60
25
50
20
40
15
30
10
20
10
0
Broken stich
Loose thread
Open seam
Wavy stich
Incorrect stich
Slipped stich
defect
defect %
Findings
Suggestions
Suggestion
THANK
YOU