PROJECT: DETAILED STUDY AND ANALYSIS OF CUTTING DEPARTMENT

SUBMITTED BY:
SOURAV DOLUI
(NIFT, CHENNAI)
DURBAR DASGUPTA
(NIFT, KOLKATA)

ARVIND LTD. (ELECTRONIC CITY, BANGALORE)

CONTENTS

Title

Acknowledgement

Introduction

Objectives

Project Scope

Project Details
o Flow Chart
o Current State Analysis
o Standardise Process and Areas
o New Processes and Mechanism

ARVIND LTD. (ELECTRONIC CITY, BANGALORE)

TITLE PAGE

A report is based on Fourteen weeks internship at Arvind Limited, Electronic City,

Bangalore.

Prepared by Durbar Dasgupta and Sourav Dolui, B F Tech, Sem-VII, National

Institute of Fashion Technology, of Kolkata and Chennai centres respectively.

The project will be in under the guidance of Mr. Prasanth TS.

Date of submission on 24 Aug 2016.

ARVIND LTD. (ELECTRONIC CITY, BANGALORE)

ACKNOWLEDGEMENT

Through this project report we would like to thanks numerous people whose consistent
support and guidance has been the standing pillar in architecture of this project. To begin
with, our sincere thanks to the management of NIFT for giving this opportunity to
experience and learn the processes practiced in Apparel Industry.
For the completion of this document We would like to thank Mr. Russel Trimothy (Head
CEP &Diploma NIFT CHENNAI), Mr. Bibekananda Banerjee (Course Coordinator NIFT
KOLKATA) for being our mentor and our guide throughout the project. we would like to
express my sincere thanks to the Management and staff of Arvind Limited, Bangalore, for
their outstanding support and cooperation in my efforts to gain knowledge about the
practical aspects of Apparel industries during the Internship.
We are thankful to Mr. Prasanth TS (IED Head), for the guidance and planning out the
schedule for the internship.
We would like to grab this opportunity to express my sincere gratitude to Mr.
Sambasivarao Popuri(Production Manager) for guiding me through all the processes
involved and was patient enough to answer all our doubts and queries.
We would specially like to thank all the staff members and workers for helping me
throughout the internship. Without their support, it would have been difficult job to
successfully complete the training.

ARVIND LTD. (ELECTRONIC CITY, BANGALORE)

INTRODUCTION

Value stream mapping is a part of Lean implementation in the factory, to remove the waste
from the current processes and set a standard for all work process, areas etc. so that it will
be suitable for all workers to understand the working process, areas and their job
descriptions. It is also help to gain production with less waste of time and materials.
This project includes various process in cutting department.
The Project starts on 30th June 2016 under the guidance of Mr. Prasanth T.S.

ARVIND LTD. (ELECTRONIC CITY, BANGALORE)

OBJECTIVE
Project covers various objectives and milestones, to simplify this we categorise into three major
objectives under which major part of the project covers:
Standardise the Material Flow Process in Cutting

Implement effective method to calculate safety stock levels that incorporate the accuracy
of required WIP
Correct WIP for schedule - Right material is always available in the right quantity in the
right location

PROJECT SCOPE

Standardise the Material Flow Process in Cutting

Prepare VSM & STW(standard work flow) and analyse:

o Layering, cutting , Bundling Processes
o Audit the Cutting
o RE -CUT

Time Study

Implement WIP boards at cutting tables

Standardized the cutting tables

ARVIND LTD. (ELECTRONIC CITY, BANGALORE)

 Implement effective method to calculate safety stock levels that incorporate the accuracy
of required WIP

Introduce Mechanism to serve the fabric & trims from W/H to cutting table &
module

Optimize the marker Length

Correct WIP for schedule - Right material is always available in the right quantity in
the right location

CURRENT STATEOF CUTTING DEPARTMENT ANALYSIS

Preparation of Value Stream Map:
At the starting of project the first thing that required was Value Stream Map of Current
State. This includes each and every process that takes place with in different departments
of the Factory. Meanwhile every department also prepared VSM for their department.
Also simultaneously VSM for Future State was prepared.
VALUE STREAM MAPPING CURRET STATE (CUTTING DEPARTMENT)

ARVIND LTD. (ELECTRONIC CITY, BANGALORE)

Analysis of Current Processes:

After preparation of VSM focused on the various process with in different Process or
operation which includes the flow of materials and can be responsible for the wastage of
materials and time. The department and process that includes in the project are given
below:

Cutting Section Process

o Spreading
o Cutting- Straight Knife
o Cutting- Band Knife
o Bundling
o Trims & lining Cutting
o Quality Audit
o Cutting Input Issue

Time Study of Current Processes:

After selecting and analysing the required processes team decided to conduct a time study as
well as method studies for all these process, so that we can know about the process time and
duration of each steps.
This study helped us to find wastage in all the process such as:
1. Unnecessary work process,
2. Duplication of work,
3. Idle Time
4. Misunderstanding between workers

ARVIND LTD. (ELECTRONIC CITY, BANGALORE)

5. No Standard working process

Eliminate Waste from Current Processes:
The wastes that found during the method studies of the processes were eliminate and
improved the working procedure.

Requisite data:
BUYER:

S OLIVER

COLOR

39N7

STYLE

2285

FABRIC STORE:
Fabric received report
DATE

FABRIC QUANTITY

CUMULATIVE TOTAL

9/6/2016

2674.4 meters

2674.4 meters

14/6/2016

155.00 meters

2829.4 meters

18/6/2016

4719.60 meters

7549.00 meters

20/6/2016

1222.40 meters

8771.4 meters

20/6/2016

67.00 meters

8838.4 meters

ARVIND LTD. (ELECTRONIC CITY, BANGALORE)

RECORD OF ISSUED FABRIC ROLL FOR 1ST LOT:

ROLL DESCRIPTION

FABRIC QUANTITY

3261

23

5500

150

5479

150

5496

150

5483

150

5488

150

5504

150

5491

124

5497

150

5484

150

5498

150

5358

91

RECORD OF FIRST LOT:

ARVIND LTD. (ELECTRONIC CITY, BANGALORE)

LOT NO

01

SIZE RATIO

S ,M,L ,XX , 2X
7.00 METERS

BUYER

S.OLIVER

LAY LENGTH

STYLE
NO.

2285

FABRIC WIDTH
MARKER
WIDTH

148 cm

NO OF PLIES

113

SPREAD BY

PUSHPA

PONO.
FABRIC
COLOR

624RCHARCOLE

COLOR
CODE

LINING

WAYS

MARKED BY

S. NO.

ROLL
NO

SHAD
E

ISSUED
QUANTITY(M
TS)

NO. OF CUML
PLIES TOTAL

5491

s-7

124

17

17

4.00

5045

s-7

150

21

38

2.00

4975

s-7

150

21

59

2.00

4845

s-7

150

21

80

2.00

4985

s-7

150

21

101

2.00

4885

s-7

150

21

113

NEW IMPLEMENTATION:
ARVIND LTD. (ELECTRONIC CITY, BANGALORE)

END
BITS
(MTS)

Change the roll size of the fabric roll:

Current status:
What fabric rolls are being used are 150 200 meters of rolls.
So at the time of spreading of 113plies, fabric roll has to be changed at least 6 times.

S ,M,L ,XX , 2X

LOT NO

01

BUYER

S.OLIVER

STYLE NO.

2285

PONO.
FABRIC
COLOR

624R
CHARCOLE

COLOR
CODE

LINING

S. No.
WAYS

Roll no4

Shade

Issued
quantity(mt
s)

No. Of
plies

Cuml
total

End bits
(mts)

SIZE
1 RATIO
5491

s-7

124

17

17

4.00

LAY
2 LENGTH
5045

s-77.00 METERS
150

21

38

2.00

FABRIC
WIDTH
3
4975

s-7

150

21

59

2.00

MARKER
WIDTH
4
4845

s-7148 cm

150

21

80

2.00

No5of plies 4985

s-7113

150

21

101

2.00

Spread
by 4885
6

s-7PUSHPA 150

21

113

66 mts
balanced

Marked by

NOTE: 66 meters balanced fabric will be used in next lot spreading.

ARVIND LTD. (ELECTRONIC CITY, BANGALORE)

NON VALUE ADDED ACTIVITY TIMES:

Roll changing time taken by the operator 34.12 sec

Roll unrolling time taken by the operators 1.11 min
Data entry time - 35.54 sec
Face side checking time 20.82 sec
End bits collection 30.07 sec
End bits tearing time 13.76 sec
Total NVA time = (34.12+35.54+20.82+20.82+30.07+13.76+ 71)
= 205.31 sec
= 3.42 minutes (for every roll changing)
Total end bits collected in lot 1 = (4+2+2+2+2) meters
= 12 meters

FUTURE STATUS:
Big roll of fabric (consumption should be 1000 meters)
Non value added time 3.42 minutes will be eliminated.
Roll changing fatigue will reduce.
End bits loss will be eliminated.

SEMI AUTOMATIC SPREADING PROCESS:

CURRENT STATUS:

ARVIND LTD. (ELECTRONIC CITY, BANGALORE)

What process for spreading for spreading is followed is manual. Spreading is done in a 4
steps process
1. Pull the fabric end to another end of spreading.
2. Align the fabric end & keep the weight.
3. Go back to the starting point and & make a slit by using scissors
4. Tearing the fabric end & finish spreading.
Non value added time taken by the operator
= (9.39+5.82+10.78+7.26) sec
=33.25 sec

CUTTING WIP BOARD:

CURRENT STATE:
No WIP is being calculated at the time of spreading and cutting.
Future state:
On format will be filled daily by feeding helper so WIP will be transparent and daily updated.
The format is

ARVIND LTD. (ELECTRONIC CITY, BANGALORE)

CHANGE MARKER LENGTH:

CURRENT STATE:
Now lay length is around 7 meters
Problem- end bits are collected and stored.

FUTURE STATUS:
Lay length will be decided according to the fabric consumption of any roll.
So end bits consumption will be less.

EMBROIDERY MACHINE
CURRENT STATE:
White pencil mark is done for embroidery and after bundling it is send to NAGNATHPURA.
And it received after 1 day. Then bundling is done and those parts are sent to cut pats storage.
Non value added times Minimum time is 1 day.

FUTURE STATE:
1 embroidery machine should be there for embroidery if required.

IMPLEMENT LARGER TICKETING ROLL:

CURRENT STATE: Normal size ticket roll which are used for numbering are small in size so
there at the time of numbering frequent roll change is required. So it takes average
time
to change the roll.

ARVIND LTD. (ELECTRONIC CITY, BANGALORE)

So these can be called as a non-value added time.

NON VALUE ADDED TIME: Time takes to change the roll 26 sec
Time takes for wrong numbering 270 sec

FUTURE STATE:
If roll size is bigger than normal size then no need of frequent changes of roll so it will reduce
the time of numbering.

PIN TABLE TIME STUDY:

STARTING TIME: 10.53 AM

CYCLE TIME: 3.50, 3.00, 2.34, 2.20, 2.57, 2.19, 2.30, 2.33, 2.49
P& FA: 15%
ENDING TIME: 11.38 AM
Total time taken for lying of 15 plies: 45 minutes
End bits collection time: (cycle time): 1.162 minutes
Preparation time: 1.43 minutes
ARVIND LTD. (ELECTRONIC CITY, BANGALORE)

Checking by tearing the marker: 5 minutes

Delay: 22 minutes
Pin bet set: 18 minutes
Delay: 6
Straight knife cutting :( 2+5+7+18+14+6) minutes
=52 minutes

VALUE STREAM MAPPING OF THE FUTURE STATE OF CUTTING DEPARTMENT

ELIMINATING THE NON-VALUE ADDED ACTIVITIES

ARVIND LTD. (ELECTRONIC CITY, BANGALORE)