REDUCE THE FABRIC CONSUMPTION BY
IMPLEMENTATION OF PROPER PINNING
PROCESS AS PER SOP
BY
HASAN NUFAIS M L
PROJECT INTERN TRAINEE
GUIDED BY
Mr. JAYAKUMAR PALLATH MENTORED BY
Mr. GANDHI GANESHAN
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To increase fabric consumption
Typology: Summaries
2020/2021
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REDUCE THE FABRIC CONSUMPTION BY
IMPLEMENTATION OF PROPER PINNING
PROCESS AS PER SOP
BY
HASAN NUFAIS M L
PROJECT INTERN TRAINEE
GUIDED BY
Mr. JAYAKUMAR PALLATH
MENTORED BY
Mr. GANDHI GANESHAN
PROJECT GANTT CHART ACTIVITY/TIME LINE February March APRIL 3rd week 4th week 1st week 2nd week 3rd week 4th week 1st week EGL Process flow from "store to cutting"study study on Importance of Pinning Process in EGL Trouble shoot the pinning table Collection of past consumption data for fabrics Analysis of Avg consumption for different fabrics PIN IT software training to Marker makers Study on where the most fabric wastage occurs Lterature study for the solution to the problem Brainstorming the importance of PIN IT Software Implement the new plan Brainstorming the operators about the new plan Data collection& result analysis for the implemented process Power point Presentation
OBJECTIVES OF THE PROJECT
To study on current cutting process in EGL
To identify the methods to reduce fabric wastage in cutting
To implement the methods identified
To analyze the final results
METHODOLOGY Study on Current process
- (^) Observation of Laying in EGL
- (^) Observation of Laying for Checked & Striped Fabrics Problem identification in current process - (^) Fabric wastage is more - (^) More Relaying Implement new process &Validate the results - (^) Made Pinning marker & reduce in fabric consumption - (^) Proper use of PIN IT Software
FABRIC CONSUMPTION ANALYSIS CHECK FABRIC PINNING MARKER
- (^) Marker buffer =5mm
- (^) Utilization = 79.26%
- (^) Consumption =140cm
FABRIC UTILIZATION BEFORE
Not using Pinning
Table For checks
1. PIN IT software is not properly
utilized.
3. Operators didn’t follow the PIN IT
sheet.
4. The process of SOP for Pinning is
not at all followed
5. Marker buffer is more
Line matching
is not there
Cutting Process Flow for
Checks & Stripes without
Proper Pinning
Cutting Process flow for
Checks & Stripes with
Pinning
Ready Cut Line Matching & Relaying Block Cut
Laying
Marker planning
Fabric received from store
Ready Cut Pinning & Laying with Line matching Marker Planning Fabric received from the store Benefits:
- (^) Proper Pinning Process as per SOP
- (^) Line Matching of Fabrics
- (^) Relay Operators Can be reduced
- (^) Time saving and Quality improvement
S.N
O
CAUSES REASON STEPS TAKEN TO
RESOLVE
IMPROVEMENTS AUTHORIZED
PERSON
1 Pins and Pin holder were damaged and Blunt & Insufficient use of PIN IT Software Improper maintenance of Pin Table
- Request maintenance team to trouble shoot the table
- Empty needle bar Pins has been changed - Improved performance of Pin table - Material handling became easy for Operators Mr. Maruthi 2 PIN Software &PIN sheet has not been followed and Pins were set by using Marker Lack of awareness about PIN IT Software& not been used
- PIN IT Software training has been given to CAD People
- Given awareness to the operator about the PIN sheet
- PIN IT software has been utilized
- PIN sheet has been followed for pinning work order Mr. Raja 3 Line matching for checks & stripes are not Proper SOP for Pinning and PIN sheet has not been followed
- SOP is followed for before & after Marker making
- Repeat size has been checked as per SOP and based on that PIN sheet has been issued
- Fabric consumption has been reduced
- Fabric Parts has been Ready cutted Mr. Sampath, Mr. Narayanan
SAVING OF COST AND MANPOWER REDUCTION Man power reduction
- (^) Relay operators reduction in batch processing ( 4 operators to 2 operators ).
- (^) Ready cut of lays
- (^) Improved quality of garments.
- (^) Fabrics on an average 2-3cm can be saved
- (^) PIN table target = 800pcs/day
- (^) Fabric savings Per table= 800*3= 2400cm /table