Project -1 - GOOD HOUSE KEEPING

Saving cost through house keeping –

Celebration’s apparel has managed to save a big amount

of money by introducing a simple concept of wearing
slipper on the production floor.

The factory has got the shop floor area of 60,000 sq. feet.
To clean this area we need minimum of 6 House keeping
employees to ensure that the Plant is clean.

The cost of house keeping for the shop floor at present -

Salary of 1 cleaner Rs.3900

Yearly salary of 6 cleaner Rs. 280800

Total cost per year Rs. 280800

After going through the 5 S of KAIZEN – there was change

in the process of House keeping for the shop floor. The
plant decided to buy and give slippers to every body and
developed the habit of cleaning their working area by
themselves. This change in process also incurred some
one time costs. The one time incurred cost for change of
process is followings
Cost of brooms & other Rs. 11000
items
Cost of slippers ( 650 * 50) Rs. 35,500 (Visitors slippers)
Cost to make slipper’s Rs. 15000
storage racks
One time cost Rs.58,500

After the introduction of this system, every employee of

Celebrations gets into the working slipper before walking
onto the production area. Also, they need to clean their
working area before they start the work and after finishing
their work in the evening. The plant maintains the same
system for visitors.

Operators wearing slippers

After introduction of the above said system – there were

reduction in the number of house keeping people required
to maintain the floor area. The new cost is followings
Salary of 2 cleaner’s Rs.3900*2 = Rs7800
Yearly salary of 2 cleaner’s Rs.93600
Total cost per year Rs.108600

Difference between the both the previous cost & the new
cost is

= Rs 280800 – Rs. 108600

= Rs 172200

total saving , cost without using

172200 slipper
cost without cost with slipper
using slipper,
280800 total saving
cost with
slipper, 108600
Conclusions and results:

1. The pie chart clearly depicts that there is net saving of

Rs. 172200.
2. Operators are more cautious about the cleanliness as
they themselves have to clean their working are
3. The buck stops at everybody working and there are
minimum chances that anyone could pass it onto
someone else.
Project -2 REDUCTIONS IN TRANSPORTATION TIME

Saving cost in one of the waste given in 9 waste radar chart

–(Transportation) –

In the company the main store is at the ground floor while all
the other production activities are on the first floor.
Therefore, good amount of time gets wasted if one needs to
go from first floor to the ground floor for any production
need. So we have reduced the distance by making the sub
store on the production floor itself so it saves the –

 Cost
 Energy
 Time
 Increase the production as we have extra minutes

available than earlier for production activities.

This will be more clear by the table which shows our study
done when we reduces the distances after creating the
Sub- Store on the shop floor itself.
Main store chart:

Distance traveled from 157 feets

production floor to main
store
No. of time helper travels 3
to main store
Total waiting time per trip 15 min
Time spent in a trip 8 min
Total time lost in a day 69 min
Monthly wage of worker Rs. 4900
wage of worker per day Rs. 196
wage of worker per hour Rs. 24.50
wage of worker per min Rs.0.41
cost of one trip Rs. 9.43
cost of trips per day Rs.28.29
total cost of 33 trips (11 Rs. 311
team leaders * 3)
cost of trips per month Rs. 7,775
cost of trips per year Rs 93,300
Sub store chart:

Distance traveled from 50 feet

production floor to sub store
No. of time helper travels to 3
sub store
Total waiting time per trip 5 min
Time spent in a trip 4 min
Total time lost in a day 27 min
Monthly wage of worker Rs. 4900
wage of worker per day Rs. 196
wage of worker per hour Rs. 24.50
wage of worker per min Rs. 0.41
cost of one trip Rs. 3.69
cost of trips per day Rs.11.07
total cost of 33 trips ( 11 Rs. 121
leaders * 3)
cost of trips per month Rs.3.025
cost of trips per year Rs36,300

The difference between both the costs will be shown by

the pie chart as given below:

saving,
57000 Main store
Main store, sub store
93,300
sub store, saving
36,300

Conclusion and results:

 As we converted the main stores in to sub store on

the production floor itself, so it saves the time by

reducing the distance and also saves the money.
 Net saving is Rs.57, 000 per year.
 By allocating the subsotres near the production area

we save the time which can be utilize in the

production process which will increase our available
production time for the plant.

Project – 3 CUTTING DEPARTMENT

Block cutting: For stripes and Plaids we were using the
ready cutting concept for the fusible collar and cuff for
sewing line. But we found that after doing the time study
that we were wasting time, cost, money & it was resulting
in low productivity. Therefore, we cut down the chain and
eliminated the pinning and ready cutting operation due to
following problems

 If there is bowing in the fabric then it’s very difficult

to remove it during the process of re –laying. As the

fabric has the tendency to come back to its original
shape.
 There may be chances of size change
 Production is low

These are the reasons behind us now cutting the Block

collar & Cuff and sending it to sewing line directly. By
doing this we have totally eliminated the process of re-
laying and other cutting processes. This could be best
described by previous flow chart & new flow chart

Process flow chart for ready cutting (previous

method)

Process chart for block cutting (present method)

Collar block cutting

Collar spot fusing

 Collar fusing

Collar trimming
 The advantages of the new method over the
previous method are followings

 SAM is less for new method compare to old

method.
 Does not depend upon the type of fabric we are

using
 Less chances of error
 Save cost as we don’t need to re-lay in the new
method.
 Saves band knife machine cutting time & therefore
life span of machine.

The following table and chart will clearly show the benefits
of this concept:

By comparing the SAM value we can find that how much

money we can save.

Ready cutting

Operation SAM

Pinning cuff 0.28

Pinning collar 0.324

Ready cut cuff 0.108

Ready cut collar 0.11

Total 0.822
 Block cutting:

Operation SAM

Trim cuff 0.12

Trim collar 0.17

Total 0.29

Difference 0.532

The difference between both the SAM values is 0.532

 Sam

0.9
0.822
0.8
0.7
0.6 0.532
0.5
0.4 Sam
0.29
0.3
0.2
0.1
0
Ready cutting diffrence Block cutting

Total savings chart

Average production in cutting

3500pcs
section
Average production in stripes &
checks 2100pcs
Total minutes saved with reduction
SAM 0.532 1117.2 min
 Total hours saved per day 18.62 hrs
No of operators reduced 3
But in sewing one operator is
required for trimming 1
Total manpower saved 2
Cost of operator per month (CTC) Rs.4900
Cost saved per year/ operator Rs.58800
Total cost saved per year Rs.117600

Total cost saved per year is RS.117600

Conclusion and Results:

1. We increased the production in cutting section as

we have reduced many operations in cutting
department.
2. By this process we reduced 3 operators in cutting
section and had to add only one additional
operation in sewing.
3. By this process we are saved cost of the 2
operators.
4. We reduced re cutting in the cutting section.

Project -4

RE-ENGINEERING OF COLLAR SEWING FOR NON

FUSIBLE INTERLINING.
Method re engineering

We could not follow the same process of sewing for

“Fusible “as well as “Non-fusible” collars.

Therefore, it was pertinent to re-look at the process for run

stitch of Non- fusible collars. It was being extremely
difficult to reduce the quality problem arising out of the
current method and control the re-cutting of collar as a
result of defects.

At this juncture, we decided to re-engineered our process

that has been well explained by the flow charts for
Previous & new methods.

We decided to use profiles for sewing collar with ‘Non-

fusible” interlinings. The profile is polycarbonate sheet –
and then cut into the shapes of collar with groove for
needle movement.

Flow chart (without using profile)

Flow chart (with profile)
 Collar pinning

Collars run stitch with profile

 Collar trimming

Advantages:

 collar run stitch operation is easy by this

process

 In checks and stripes line balancing and mirror image

of collar points are achievable with new process for

non- fusible collar.
 Fabric with bowing defect also can be handled easily

by this method.
 This method de-skill the collar run stitch operation.
Therefore, we are not dependent on skilled operator.

Savings by Reducing the Re-cutting after following the

new process for collar run stitch. This has been shown by
calculating the earlier costs and the new costs.
Cost of trips before implementing the profile
(operators)

Distance traveled from collar section to

1 recutting table 40 feet
No of times helper / supervisor travels
2 to recutting table 15
3 Distance traveled in a trip 80
4 Total distance traveled in a day 1200
5 Time spent in a trip 3 min
6 Total time lost in a day 45 min
7 Monthly wage of worker 4900
8 Wage of worker per day Rs.196
9 Wage of worker per hour Rs.24.5
10 Wage of worker per min Rs..040
11 Cost of one trip Rs.1.22
12 Cost of 15 trips Rs.18.3
13 Cost of trips per day Rs.18.3
14 Cost of trips per month Rs.457.5
15 Cost of trips per year Rs.5490

Cost of the trip before implementing the profile

(supervisor)

Distance traveled from collar

1 section to recutting table 40 feet
No of times helper / supervisor
2 travels to recutting table for rework 15
 3 Distance traveled in a trip 80
4 Total distance traveled in a day 1200
5 Time spent in a trip 3 min
6 Total time lost in a day 45 min
7 Monthly wage of supervisor (CTC) 11000
8 Wage of supervisor per day Rs.458.3
9 Wage of supervisor per hour Rs.57.2
10 Wage of supervisor per min Rs.95
11 Cost of one trip Rs.2.86
12 Cost of 15 trips Rs.42.96
13 Cost of trips per day Rs.42.96
Rs1031.2
14 Cost of trips per month 5
15 Cost of trips per year Rs.12375

Process re –engineering cost:

Description Price
Pressure foot Rs.65
Needle plate Rs.90
Feed dog Rs.90
Polycarbonate
sheet cost Rs.500
Needle cost Rs.27
Total Cost Rs.772

Total saving after implementation of new method is

= Cost of re-work – one time cost of new process

= Rs. 17865 - Rs. 772

= Rs. 17093.

Conclusion and result-

1. By using profile output from collar run stitch is

increased by 65 pcs to 120 pcs/hr.
2. We found that there is 100% line balancing in checks
and stripes.
3. There is almost 0% of re - work with new process.

Project -5

Waste management in Maintenance

Department:

1. Air handling unit (AHU)

Re- Scheduling the timing of Air Handling Unit Working

AHU DETAILS:

1) AHU 8no. of 20000cfm

2) Ducts 14no spiral ducts.
3) Fresh Air Louvers with volume control dampers
16no per spiral ducts.
4) Fixed Louvers 24no (for out going Air).
5) Motor power 15KW ( 20Hp)
6) Cost per unit Rs.5/-
7) Working Area 110mts X 54mts,
8) Used working area = 70mts x 54mts
9) Factory Timing = 8.10am to 4.40pm.
 Initially all the 8 no of AHU was working for the
complete factory timing from 8.10am to 4.40PM in
the months of February to September, and the cost
was Rs.998400/-

Now we have Re-scheduled the time of workings i.e.,

from 9.30am to 12.30PM, and post lunch 1.30pm to
4.30PM.

We have also stopped Running two AHU, one in

Cutting section due to displacement of laid fabric,
another one AHU in Assembly section it is non
utilized area.
Present saving from re-scheduling of AHU working is
Rs. 436800.

Conclusion and result

1. Re scheduling of AHU not affected normal working
condition.
2. Yearly cost saving of Rs. 436800.

Project – 6

CAM CUTTING WIYHOUT PLOTTER PAPER

The Marker which is made on the CAD marker making

software for production is converted to the cut file to be
cut on the CUTTER ( CAM) and as well plotted in plotter of
2mts using Plotter Paper of 64inches, as reference marker
to be placed on the laid fabric and then is feed to the
cutter to cut.
In the present scenario we are not using the plotted
marker Paper on the laid fabric, instead a mini marker at a
visible level is printed either on A4 / A3 sheet, and as soon
the part are cut in the Cutter (CAM) the size stickers which
are written / printed will be stuck on to the cut part as per
the
Mini marker. This saves Plotter Paper, Plotter INK and
Running / Maintenance cost.

Fabric is feed to CAM without plotter paper

Fabric cutting by CAM

 Size and part identification by stickering

Production cost of cutting by CAM:

Previous procedure:

Descriptio Unit Usage/da Cost/day monthly yearly

n cost y
Plotter 800 1.roll 800 19200 230400
paper
Plotter 1200 10% 120 2880 26460
cartridge

Current procedure:

Descriptio Unit Usage/da Cost/day monthly yearly

n cost y
Sticker 1.5 100 150 3900 46800

Man power 1 4900 58800

Total saving per year = Rs. 159360

Conclusion and result:

1. We are able to save paper cost, cartridge cost and

plotter running cost.

2. There is no need to wait for plotter paper and now

cutting can start instantly.

Project - 7

Boiler: REDUCING THE OPERATING COST OF

BOILER

We will see how we can save fuel by using waste

condense steam.
Thermax diesel boiler of 200 kg which can produce 200kg
of steam per hour,
To produce 200kg steam / hr it utilizes 12lts of diesel / hr
Our utilization of the boiler is 75%, therefore per day
diesel consumption for 9hr is 74lts.

With our old procedure of working, we used to allow the

condense steam in to the waste water drain, form the by
pass steam strap.

In the new procedure we have change the feed water tank

form the Plastic sintex tank to MS tank, which was
presently used for diesel storage and was under utilized.
Then connected the condense steam through a pipe of
1/2” to the feed water tank.
During Boiler in working the pipe carrying the condense
steam would transfer the steam temperature to the feed
water which increase the water temperature form normal
room temperature to desirable temperature of 50 to 60
degree centigrade which results in reducing burning time,
As result of this, low consumption of fuel.
Due to this there is a savings of 6 liter of diesel per day.

Note:
• The MS Tank was used to store diesel, which was
under utilized, used as Feed water tank to Boiler.
• Only pipe was purchased, modification was done In-
house

Flow of R.O water to the boiler (old process)

New process flow :
Thermax 200 KG diesel boiler
 PER DAY IN
LITERS

Cost for Rate Saving

implementing Old New / lts Old New in Rs

of
Proces Proces diese Proces
s s l Process s

PIPE 1/2" 5 mts

+ ball Valve =
Rs 600/-

Per day 74 68 37 2738 2516 222

equals Rs. 600

Consum
ption

Per month 1924 1768 37 71188 65416 5772

Consumptio
n

78499
Per Year 23088 21216 37 854256 2 69264

Consumptio
n
Conclusion and result:

1. We identify the waste and able to convert it in to

useful resources.
2. We use condensed steam for pre heating of water

that helps to reduce the burning time and hence

save consumption of the fuel.

Project - 8
Segregating different types of waste:

Celebrations Apparel Ltd generates various types of

wastes some of them are fabric pieces, interling pieces,
papers, plastic papers, threads, buttons, carton boxes,
thermocoal, etc. Earlier we used to dump these wastes
together into our waste container. We were selling this
waste at Rs.2. Then we realized that if we segregate the
wastes separately our selling price of waste will go high.
Therefore, we made the waste disposal container into
separate partitions to dump fabric and interling one side
and paper and carton boxes one side.

Before separating the waste

Sl.No Waste Price/Kg Avg Total Total amount / Year
material kg/Month amount/Month

1 All waste Rs.2 5500 kg Rs.11000 Rs.132000

After implementing the partition in the waste

container
Sl.N Waste Price/K Avg Total Total amount /
o material g kg/Month amount/Mont Year
h
1 Fabric Rs.2.5 3000 kg Rs.75000 Rs.90000
waste

2 Paper & Rs.3 1000kg Rs.3000 Rs.36000

carton
boxes

3 Others Rs.2 1500Kg Rs.3000 Rs.36000

Total earning per year is Rs.162000

Total savings per year by separating the waste is

Rs.30000

Conclusion & Results

It is a lesson for each one of us in terms of contribution of

even waste material into earning of an organization.

Project - 9
WASTE WOOD MANAGEMET:

We have had enough waste wood coming as a packing

material along with imported machines. We had kept
these woods for long and not sure what should be done
with it. Since it requires a huge space for storage so the
easiest way out was to sell it off as a waste. This was the
time when our internal requirements of Tables and racks
arise. At this juncture we took a conscious decision of
hiring a carpenter on company roll. And convert these
waste woods into required shapes as per our need.

The below excel sheet will give the details of items

prepared from waste wood as and the incurred cost of in-
house manufacturing compare to outsourced prices.

Waste wood

Materials
Market Total used other
Quantit
Description price per Market than wood Saving
y
unit price
Price
 Cutting section
Manual pinning table for cutting
section 4 2000 8000 1000 7000
Die storage rack in cutting section 1 1000 1000 50 950
Table for printer in CAD with
drawer 1 750 750 150 600
Table for pattern section with
drawer 2 9000 18000 2000 16000
Sewing Section
Loadind table for sewing section 5 3000 15000 1600 13400
Inspection table 3 2000 6000 750 5250
Chute for collar finih machine 1 2000 2000 250 1750
Legs for fusing machine table 1 1200 1200 180 1020
Cuff turning table 4 1000 4000 360 3640
Finishing Section
Trims storage rack for finishing 1 1000 1000 50 950
Pinning table for finishing section
with shelf 2 9000 18000 1850 16150
Legs for measurement checking
table 8 1500 12000 2000 10000
Attachment for trimming table 24 100 2400 210 2190
Stores
Fabric roll width checking table 1 3000 3000 400 2600
Table for thread shade cabinet 1 2000 2000 250 1750
Stands for fabric inspection
machine 2 1000 2000 300 1700
Tables for stores 3 3000 9000 1100 7900
Maintenance
Maintenance table for grinding
machine, vice 1 3000 3000 100 2900
Storage rack for maintenance 1 4000 4000 125 3875
General
Support stands for notice board 20 350 7000 500 6500
Conference table 2 2000 4000 500 3500
Table with drawer for boiler room 1 4000 4000 350 3650
Table with drawer for creche 1 3250 3250 450 2800
Table for security 1 3000 3000 300 2700
Telephone stand for office 2 1500 3000 350 2650
Notice board for canteen 2 1500 3000 300 2700
12412
Total 139600 15475 5
 Loading table

Interlining storage rack

 Conference table

Notice board supporter

Conclusion & Results

 Carpenter is an employee of celebration Apparel Ltd

and CTC of the carpenter is Rs.7500 per month

 The above work is done in a period of 5 months.

 Total cost of the carpenter for 5 months is Rs.37500

 Total cost saved in 5 months is Rs.124125

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