Process Improvement from cut to sew
PARAMOUNT PRODUCTS PRIVATE LIMITED
Paramount Products Pvt. Ltd has been a pioneer in the field of garment export from India since its launch in 1973.The company exports to brands in the United Kingdom, Germany, France, Spain, Sweden, Norway, and Denmark.
They specialize in women’s and kids wear, and the 45 years of experience has provided with a strong supply chain of fabric, materials.
COMPANY PROFILE
Company operates out of 5 units situated in Okhla and
Noida with a capacity of 600,000 units per month..
Head Office: A-55, Okhla Industrial Area Phase-II,
New Delhi-110020
PROJECTS
PROJECT – 1 Process Improvement from cut to sew
Problems Faced –
1. More waiting Time at the loading table in production line.
2. More Number of Alterations due to Colour variation.
The following Data represents the number of pieces produced and number of pieces given for alterations
Average of variation (for 4 days) = (Total variations/ Total pieces Produced) *100
Average of variation = (450/1723) *100 =26.1
Which means around 26 % of the production is sent for alteration due to color Variation.
Solutions –
Implementation Of Traffic Light System
• Traffic Light system in Fabric store-
The Fabric Store earlier did not implement the use of traffic Light System, due to which the storage was not proper and it was difficult to differentiate among the inspected and non- inspected lots of fabric.
After implementing this system, the fabric storage was well organised and was easy to transport the required lot when needed for cutting.
Traffic Light system in Fabric store-
Traffic system in Final line inspection
Traffic system was made to be implements at the final check point of a line so that no Piece with any alteration should go for further processes which are finishing, washing and packaging.
Setting the things in order from cutting to load table
Earlier the transportation of cutting panels was done manually by hands and we could not transport a greater number of panels due to which waiting time was more.
A trolley system was introduced for setting the cutting panels in order so that the movement of cutting panels is easy and also the waiting time at the loading table is reduced.
Manpower was also reduce.
Implementing the Use of Different label stickers for different lots
A specific colour code was used to a Lot of Fabric, and when the spreading was done the checker used to match the colour of label which was given on the fabric roll and the label card given to him.
Introduction of Recutting table on the cutting floor
Implementing basket system in line
Before-
In most of the cases the ticket number on the panels did not match the chances of colour variations were very high, so to solve this issue the basket system was used.
After-
Chances of joining a panel of a ticket number ‘x’ with the panel with ticket number ‘y’ becomes negligible so the chances of color variation alterations also decrease
Observations and Results
After Implementation of all these steps the number of colour variations were reduced and also the waiting time at the loading table was reduced. An observation was made that prior to bucket system the operators had to figure out that where they kept the panel with the same ticket number and in most of the cases, they used to take the ticket number of other panel and used to paste it onto the another for their convenience. Which made the Colour Variation alteration.
Average of variation (for 4 days) = (Total variations/ Total pieces Produced) *100
Average of variation = (200/1684) *100 = 11.8
Which means around 12 % of the production is sent for alteration.
