TIME LOSSES IN DURING STYLE CHANGE

Style- 210180( PLS- BI- STRETCH)

Buyer- Pellestrom
Trouser Line-4 (Date-29.01.21)

In between In between
SL NO Operation Name M/C Type Time loss(min) Time loss(sec)

1 Dart Pressing

2 Dart Top stitch Dart press 50 3000

3 Back pocket welting Auto welt 33.25 2005
4 Welt pocket pressing Back pocket press 4.3 270

5 Coin pocket with front pocket attach SNLS 34 2040

6 Side pocket pressing Side pocket press 1 60

7 coin pocket top stitch SNLS 30 1800

8 coin pocket serging 5T overlock 5 300
9 Front pocket top stitch SNLS 15 900
Welt pocket Top stitch with loop
10 marking Snls 2 120
11 Loop atttach on back pocket SNLS 4 240
12 Welt pocket fabric Top stitch SNLS 6.5 410
13 Bartack welt pocket Bartack
14 Button attach on back pocket Button sewer 20 1200
15 Lock Top welt SNLS
16 Back rise binding SNLS
17 Front rise serging 3T O/L
18 Left & right fly attach SNLS 2 120
19 Side seam Join SNCS
20 Inseam Join SNCS
Side & Inseam open
21 Side seam & Inseam pressing press 0.5 30
22 Waistband lining attach SNLS 1 60
23 Waistbad attach SNLS 2 120
24 Zipper fly lining attach SNLS 0.5 30
25 Press Extn, Left & right fly FIT
26 Hook bar attach Hook & bar attach
27 J stitch SNLS
28 Front rise SNLS
29 Top stitch right zipper SNLS
30 Slider & brad attch YKK SLIDER 3.52 232
31 Back rise sew TNCS
32 Press waist band waist band press
33 wash care & size label attach SNLS
 34 Bartack front pocket & fly Bartack 6.07 421
35 Button hole on on waistband Button holer 3 180
36 Button attach on waist band Button sewer 10 600
37 Curtain fell waistband Blind stitch
38 Loops finish Bartack
39 Pintack on waistband Pintack m/c
40 Bottom overlock 3 T overlock
41 Buttom hem Blind stitch
Total(min) 235.6333333

These are activities performed for sewing machines that are already in line, example gauge set, SPI change, folder adjustment or any other similar operation, as
per the requirement of new style. The time taken to complete all the internal activities constitutes the set-up phase.

rnal activities are performed outside the line without disturbing the production inline. For example, pre-setting of a sewing machine for new style or early loading of cut parts without disturb
LE CHANGE
Reason for Time loss
late supply from pressing
M/c setup, pressure foot change
M/c setting, Bobbin Thread change
M/C setup,thread SPI change
Template making & operator not present
Thread change
Template making
Thread & bobbin change
Needle break two time
Thread, bobbin change
m/c setting
Quality checking(waist measurement)
Take Action for time
loss(convert Internal
to External activity)
Need to earlier loding
without disturbing
production
M/c can be setting early
before style change
Template need to make
earlier
Template nee to make earlier
M/c can be setting earlier
 m/c setting
Gauder adjustment, m/c setting M/c can be set earlier

et, SPI change, folder adjustment or any other similar operation, as

nternal activities constitutes the set-up phase.

g of a sewing machine for new style or early loading of cut parts without disturbing the production of running style
 TIME LOSSES IN DURING STYLE CHANGE
BUYER- JCP
STYLE-195470(classic Fit)
LINE-3(05.02.21)
In between Time In between Time
SL NO Operation Name M/C Type loss(min) loss(sec) Reason for Time loss
1 Back pocket welting Auto welt 10 600 M/c setting
2 Welt pocket pressing Back pocket press
Pressure foot change, thread
3 Front pocket attach SNLS 15 900 change
4 Front pocket top stitch SNLS 5.5 350 Thread & bobbin change
5 Welt pocket Top stitch SNLS
6 Button hole Button holer 12.25 745 m/c setting, thread change
7 Back pocket close SNLS
M/c setting, used worng
8 Bartack Bartack 10.2 620 Thread for bartack
9 Button attach Button sewer 1.04 64 Thread & bobbin change

10 wash care label attach SNLS 13.3 810

11 Front pocket top stitch SNLS
12 Front rise overlock 3 T overlock
13 Zipper fly attach SNLS 1.5 110
14 Side seam attach SNCS 1.25 85
15 In seam attach SNCS 1.5 110 guider Adjustment

Side & Inseam open

16 Side seam In seam pressing press 12.2 740 Operator was not present
Waist band marking for
17 loop 8.52 532 For making waistband marking
Front pocket Fabric edge
18 finishing SNLS
19 Loop attach SNLS edge cutter

20 Waist band lining attach SNLS 12.5 772

21 Waist band attach SNLS

operator was working on another

22 Zipper fly lining attach SNLS 20 1200 line product

23 Press Extn, Left & right fly FIT 1 60 operator was not there
24 Hook & bar attach Hook & bar attach 5.11 311 Delay due to operator
25 J stitch SNLS 2 120
26 Front rise SNLS
27 Top stitch right zipper SNLS
28 slider & brad attach YKK slider 1.08 68
29 Back rise sew TNCS 1.11 71 Thread bobbin change
Press waist band & back Waist band measurement & quality
30 rise check
31 Bartack Bartack 20.3 1230 Operator was not there
32 Button hole Button holer 6.09 369

33 Button attach Button sewer 10 600 M/c layout change, M/c setting
34 Bartack on Belt loop Bartack
35 Curtain fell waistband Blind stitch
36 Belt loop finish Bartack
37 Pintack Pintack m/c
38 Bartack on crotch Bartack 13.08 788 Bobbin needle thread change
39 Button serging 3 T overlock
40 Blind hem on Buttom Blind stitch
Total(min) 187.6
 TIME LOSSES IN DURING STYLE CHANGE
Buyer-
Style- philips -F20
Line-2(05.02.21)
#REF! Welt pocket pressing
#REF! Front pocket attach 1 60
#REF! Front pocket pressing
#REF! Front pocket Top stitch 13 780
#REF! Welt pocket fabric Top stitch 6.35 395
#REF! Button hole on welt pocket 23.06 1386
#REF! Back stitch
#REF! Back pocket close

#REF! Bartack 26 1560

#REF! Button attach
#REF! Waist position Top stitch
#REF! Serging top stitch
#REF! Attach Zipper fly
#REF! Side seam 3.04 186
#REF! In seam
#REF! Side seam in seam pressing
#REF! Side pocket finishing
#REF! Waist band lining attach
#REF! Waist band attach 3.04 184
#REF! Loop attach
#REF! Zipper fly lining attach 30 1800

#REF! Press Extn, Left & right fly

#REF! Hook & Bar attach
#REF! J stitch
#REF! Front rise 4.38 278
#REF! Top stitch right Zipper 8 480
#REF! slider & brad attach
#REF! Back rise
#REF! Press waist band & back rise
#REF! Wash care label attach 27.27 1647
#REF! Bartack 7.3 450
#REF! Curtain fall waistband
#REF! Button hole on waist band 2.57 177
#REF! Button attach 3.45 225
#REF! Bartack on Loop
#REF! Pintack on waist
#REF! Fabric attach on crotch 17 1020
#REF! Bartack on crotch
#REF! Overlock on bottom hem
#REF! Blind hem in bottom
Total(min) 177.133333333
CHANGE

M/c layout, Bobbin thread change

M/c setting, Needle break

M/C setting, Needle issue, Thread bobbin change

Due to alteration

Quality check(waist measurement)

pressure foot change

Due to alteration, waist measurement

M/c setting

m/c layout
 TIME LOSSES IN DURING STYLE CHANGE
Buyer-Raymond
Style-
Line-6(09.02.21)
In between Time In between Time
SL NO Operation Name M/C Type loss(min) loss(sec)
1 Front Back serging
2 Back Dart 5
3 Pairing 30

4 Back pocket Welting 133

5 Welt pocket pressing
6 Front pocket attach
7 Front pocket pressing
8 Welt pocket Fching stitch 5
9 Button hole on welt pocket 30
10 Back pocket stitch stitch 10
11 Bartack on welt pocket 5
12 Back pocket close
Brand label attach
13
14 Front pocket Top stitch 3
15 Pocket stay stitch
16 Serging front rise
17 Attach Zipper fly
18 Side seam
19 In seam 16
20 Side seam in seam pressing
21 Marking for loop on waist band 5
22 Belt lopp atach
23 Waist band with lining attach
24 Inner pocket close
25 Waist band close
26 Zipper fly lining attach 5
27 Press Extn, Left & right fly 10
28 Hook & Bar attach 6
29 J stitch 10
30 Front rise
31 Ziper Top stitch
32 Slider bar attach
33 Back rise attach
34 Press waist band & back rise
35 Bartack on pocket edge
36 Button hole 5
37 Button attach
38 Bartack on loop
39 Curtain fall waistband 4
40 Loop finish
41 Crotch guard attach
42 Bartack on crotch guard
43 Pintack on waist postion
44 Bottom Hem
Total(min) 282
GE

Reason for Time loss

M/c setting, Back pocket facing loading late

from cutting

M/c setting
Operator was not there , m/c setting

m/c setting, m/c layout

Brand label attach wrong

Thread change
Delay due to some alter pics

M/c setting, M/c layout

 TIME LOSSES IN DURING STYLE CHANGE
Buyer-Raymond
Style- RMT0008912
Line-3(10.02.21)
In between In between
Time Time
SL NO Operation Name M/C Type loss(min) loss(sec) Reason for Time loss
1 Front Back serging
2 Back Dart
3 Pairing 19 1140
4 Back pocket Welting 3.29 209
5 Welt pocket pressing
6 Front pocket attach
7 Front pocket pressing
8 Front pocket Top stitch 4 240 m/c Layout
9 Welt pocket Fching stitch
10 Button hole on welt pocket 10 600 M/c setting
11 Back pocket stitch
12 Bartack on welt pocket 11.5 710 m/c setting, quality chechk
13 Button attach 6 360 m/c setting, Button late issue
14 Back pocket close
Brand label attach 8 480
15 m/c setting, wrong attach
16 Pocket stay stitch
17 Serging front rise 7 420 Thread change
18 Attach Zipper fly
19 Side seam 20.2 1220 pukring,m/c setting
20 In seam
21 Side seam in seam pressing
22 Marking for loop on waist band 15 900 marker making for loop
23 Belt lopp atach
24 Waist band with lining attach
25 Inner pocket close 6 360 needle change,m/c setting
26 Waist band close
27 Zipper fly lining attach 10 600 zipper fly marker making
Press Extn, Left & right fly
28
29 Hook & Bar attach 1.4 100 Delay due to the operator
Thread, bobbin change,, pattern making, main delay
30 J stitch due to the pattern making
31 Front rise
32 Zipper Top stitch
33 Slider bar attach
34 Back rise
35 Press waist band & bback rise 10 600 Quality check

36 Bartack on pocket edge

37 Button hole 12 720 m/c setting
38 Button attach
39 Bartack on loop 11 660 m/c setting
40 Inner pocket Top stitch
41 Curtain fall waistband
42 Loop finish
43 Crotch guard attach 10 600 m/c setting, layout change
44 Bartack on crotch guard
45 Pintack on waist postion
46 Bottom Hem serging
Total min 165.3
 TIME LOSSES IN DURING STYLE CHANGE
Buyer-Raymond
Style-
Line-1(11.02.21)

SL NO Operation Name M/C Type In between Time In between

loss(min) Time loss(sec) Reason for Time loss
1 Front Back serging
2 Back Dart
3 Pairing
4 Back pocket Welting 120 7200 M/c problem, M/c setting
5 Welt pocket pressing 10 600
6 Front pocket attach 10.5 650 Front pocket late loading
7 Front pocket pressing
8 Front pocket Top stitch
9 Welt pocket Fching stitch
10 Button hole on welt pocket
11 Back pocket stitch 10 600 Needle issue late

12 Bartack on welt pocket 40 2400 late due to bobbin and needle

13 Button attach
14 Back pocket close
Brand label attach
15
16 Pocket stay stitch
17 Serging front rise 10 600 Thread change, thread late issue
18 Attach Zipper fly
19 Side seam 40 2400 M/c problem
20 In seam 6 240
21 Side seam in seam pressing
22 Marking for loop on waist band 10 600 marker making
23 Belt lopp atach
24 Waist band with lining attach 5 300 Thread bobbin change
25 Inner pocket close
26 Waist band close
27 Zipper fly lining attach
28 Press Extn, Left & right fly

29 Hook & Bar attach

30 J stitch 10 600 Quality check
31 Front rise
32 Zipper Top stitch 9.2 560 waist band measurement
33 Slider bar attach
34 Back rise
35 Press waist band & bback rise
36 Bartack on pocket edge 11.5 710 M/c setting
37 Button hole 15 900 M/c setting
38 Button attach
39 Bartack on loop
40 Inner pocket Top stitch
41 Curtain fall waistband
42 Loop finish
43 Crotch guard attach 15 900 M/c problem, M/c setting
44 Bartack on crotch guard
45 Pintack on waist postion
46 Bottom Hem serging
Total 321
 Suggestion Way of imporvment

1 Machines of running styles by Green, Yellow, Red card. Green- Machine will be in position,
Yellow Machine will be in line but in different position and the future position will be
mentioned, Red- Machine will be removed from line
Machines will be adjusted before bringing in the line as per new style's process and fabrics.
2
3 Arrange m/c setting Part & component before style change
Making template for waistband loop marking, J stitch, Waist band lining attching template
4 before style change
Quality supervisor and Quality checker are trained before changeover so that they are well
5 known about required quality
6 Can be use Carrier tool box for m/c setting part & component
If extra m/c is availble for button hole & welt pocket making, can be setting the
7 m/c for new style before style change
8