5S SYSTEM

The 5S system is a lean manufacturing tool that

improves workplace efficiency and eliminates
waste. There are five steps in the system, each
starting with the letter S:

By providing a systematic framework for

organization and cleanliness, 5S helps facilities
avoid lost productivity from delayed work or
unplanned downtime.
STEPS OF 5S
5S was created in Japan, and the original “S”
terms were in Japanese, so English translations
for each of the five steps may vary. The basic
ideas and the connections between them are
easy to understand, though.

Step Name Japanese term Explanation

1. Sort Seiri (tidiness)Remove unnecessary
items from each area
2. Set In Order Seiton (orderliness) Organize
and identify storage for efficient use
3. Shine Seiso (cleanliness) Clean and
inspect each area regularly
4. Standardize Seiketsu (standardization)
Incorporate 5S into standard operating
procedures
5. Sustain Shitsuke (discipline) Assign
responsibility, track progress, and continue the
cycl
3M [WASTE MANAGEMENT]
Toyota has developed its production system around
eliminating three enemies of Lean: Muda (waste),
Muri (overburden) and Mura (unevenness) (Liker,
2004).
Muda is the direct obstacle of flow. As written below,
there are 8 distinctive types of muda which all lead to
waiting times, and therefore longer lead times in a
process. Simply taking out the muda does not work.
Usually, there is a reason why the muda is there and
this reason often has to do with the other two
enemies: muri and mura. This means the three
enemies of Lean are interrelated and should
therefore be taken into account simultaneously.

The three enemies of lean can be found in both

production and office processes. I even dare to say
that they can be found more in office processes than in
production processes. One reason for this is that
production processes are visible. Everybody who walks
through a factory can see the inventory waiting to be
worked on. In the office environment however,
processes are often hidden inside our computers, in
mailboxes and IT-systems.
Though it is the goal of lean to reduce all three
enemies of Lean, it might not be possible to
completely remove all of them (Panneman, 2017).
In terms of muda, unless your factory is placed next to
your customer, there will always be some sort of
transport necessary to get the product to your
customer. We should focus on reducing the transport
time and costs as much as we can, but 100% reduction
is not realistic.
The same holds for muri. There can always be a time
where machines or people have to give that little extra
effort or time to make sure the customer demand is
fulfilled. There is nothing wrong with this when you
can thereby get a huge order of extra products or win
over a new client. The problem exists when you are
expecting this from your machines or people all the
time, up to a point where a machine will burn down or
a colleague burns out.
Finally, even mura cannot always be reduced with
100%. When you are producing different products,
they are bound to require different materials, a
different way of working or even different process
times. This is even more so in project work,
where every project is different, or in the financial
world, where a financial report needs to be
delivered at the end of each month.
 JOB CARD
HOW TO USE JOB CARD

A job card is a detailed description of work that is

performed for a work order.
These specify planning and scheduling information
that can be used by your production facility‟s digital
machines.
They can have a number of specifications such as
capability, class, and category.
There are a variety of job cards, the functions of which
sometimes overlap depending upon the production and
the preferences of the company producing it and they
don‟t necessarily have to be physical cards.
The basic idea is that job cards are a timing method in
monitoring a job to be done within a specified time
frame.
HOW TO JOB CARDS IN PRODUCTION PROCESSES
Job cards have found popularity in businesses dealing
with production and also other industries such as
electrical contracting, plumbing, and facilities
management.
They are used to send the details of jobs to workers
out in the field and to receive the information back
about the work done each job.
It is a good way to save time for the administration
department as the details are just printed out and
handed to an engineer for him or her to fill out the job
card by hand once all the relate d work is done.
 S.O.P [STANDARD OPERATING PROCEDURE]
In garments & textile industry SOP is popular word &
new concept in this sector: In modern ages
manufacturing company widely maintain SOP for
smoothly production process.
SOP means “standard operating procedure”. It is the
management tools of garments industry. It is
indicates the every task how to operate smoothly. It is
one kind of operating proceeding of particular job.
SOP is the checklist of particular task. Standard
operating procedure is the success method of
managing tools.
Basically, it is the written instructions of a particular
task. An operator can operate the particular task
maintain SOP in his department. Standard operating
procedure is the complex task & need a written draft
before final implementation. Every department in
garment & textile sector has own SOP so they can
operate smoothly every task for successful operating.
It is the effective & efficiency way to successful
operation of any organization.
INSPECTION REPORT

The simple steps of involved in making quality

inspection report:
Design quality inspection format(s)
Record quality inspection data while inspecting goods
- online or off the line

Analyse data and make a summary of the reports

SIMPLE METHOD -1:

To measure percentage defectives of a garment lot you need
to follow the below procedure. A sample format is shown in
the following for data collection.

Employ one quality checker at the end of the line (at the end
of the process). Checker needs to check 100% garments
coming out from the line.

Record total number of pieces checked by the checker during

the day

Record total defective (including rejected garments)

garments kept aside while checking garments

Calculate percentage defective garment in the production lot.

SIMPLE METHOD -2:
To measure total number of defects or Defect per Hundred
Units (DHU) of a garment lot you need to follow below
procedure. A sample format is shown in the following for data
collection.Record numbers of defects found in checked
garments. You can extend this format for recording number of
defects for defect wise.

Sum up total pieces checked and total defects found in those

checked pieces

Calculate Defects per Hundred Units (DHU)

SIMPLE METHOD -3: MEASUREMENT

CHECKING
Garment measurement checking is required to
ensure the fit of the garment. For measurement
checking use following procedure.
Design format with a list of measurement points, size-
wise measurement specified by buyer/designer,
allowance (+/-)
Record actual measurements while you are
checking garment measurements
Verify actual measurement with buyer
specified measurements and tolerance level.

ADVANCED METHOD
Design detailed data collection format - it should
include defects categories, total defects, total defective
pieces, accepted pieces etc.
While checking garments (stitching division) record
defects found under defect categories, record total
defective pieces found.
Sum up number of defects in each defect categories
an
d
ca
lc
ul
at
e
to
ta
l
de
fe
ct
s.
Calculate DHU and Percentage Defective of the
inspected garment lot
List down defects in descending order of number
of defect found. You can also make bar graph
(Pareto chart) with total defects in each
categories. See following figure-3 for example of
Pareto chart.
 INDUSTRIAL TRAINING REPORT
ON

MANUFACTURING OF “INDUSTRIAL UNIFORMS”

“AUTOMOBILES & CHAIR UPHOLSTERY”

SUBMITTED TO: SUBMITTED BY:

SHIVAM GOSWAMI, PAWAN JOSHI TANYA

K-2 CLOTH / K-2 INDUSTRIES B.F.D

126-127, SECTOR IIDC,

SIDCUL,HARIDWAR
 COMPANY PROFILE

Company Name : k2 Cloth

Add 126,127, sector IIDC

SIDCUL haridwar 249403

Telephone : 9897249697, 7055500302,

7055500307

E – Mail : K2haridwar@gamil.com

K2himesh@gmail.com

Year ESTD : 2005

Market : Export/Domestic

Annul Turnover : 15,crores

Total Working Force : 150

Monthly Production : 12000

M.D. : Mr. Himesh Kapoor

Director : Mrs. Ritika kapoor

Manager : Mr. Shivam Goswami

Quality head: Mr. Pawan Joshi

DISPATCH
It is to decide the best order of an operation in
the process, and make instructions to workers.
All of the operation order which reached a
certain process do not have the same priority.
Some can be delayed, some are urgent and are
required to be handled first. The main functions
of dispatching are to determine the priority, to
set the best order, to make instructions, and to
control the process.
CAD
• Computer-aided design (CAD) is the use of computer

systems to assist in the creation, modification, analysis, or

optimization of a design.

• CAD software is used to increase the productivity of the

designer, improve the quality of design, improve

communications through documentation, and to create a

database for manufacturing.

• CAD output is often in the form of electronic file for print,

machining, or other manufacturing operations.

. Commonly used software used for CAD are AUTO CAD,

MSVISIO, Smart draw etc.

. We are using style CAD software.

CAM
• Computer-aided manufacturing (CAM) is the use of

computer software to control machine tools and

related machinery in the manufacturing of work

pieces.

• CAM may also refer to the use of a computer to assist in all

operations of a manufacturing plant, including planning,
management, transportation and storage.
HAR GHAR TIRANGA

Har Ghar Tiranga‟ is a campaign under the aegis

of Azadi Ka Amrit Mahotsav to encourage people
to bring the Tiranga home and to hoist it to
mark the 75th year of India‟s independence. Our
relationship with the flag has always been more
formal and institutional than personal. Bringing
the flag home collectively as a nation in the 75th
year of independence thus becomes symbolic of
not only an act of personal connection to the
Tiranga but also an embodiment of our
commitment to nation-building. The idea behind
the initiative is to invoke the feeling of
patriotism in the hearts of the people and to
promote awareness about the Indian National
Flag.
The Indian National Flag represents free India,
evoking patriotism in the hearts of the masses.
One can proudly associate the „Tricolor‟ with
the many brave souls who dedicated, even gave
up their lives, so that the National Flag could fly
high. From the moment it was first hoisted, it
has symbolized all our victories as a nation.

The National Flag of India (in its present

design) was adopted in the meeting of the
Constituent Assembly on 22nd July 1947, days
before India gained Independence on 15th
August 1947.The colors of the National Flag of
India hold great significance and were chosen
distinctively to portray the spirit of India.
Saffron indicates strength and courage, white
indicates peace and truth and green stands for
fertility and growth. The Chakra present in the
center of the Flag symbolizes motion, progress,
and advancement. The dignity of the National
Flag of India is governed by the Flag Code of
India and its amendments. It describes the
conventions, practices, and instructions for the
display of the National Flag.
„Har Ghar Tiranga‟ campaign under Azadi Ka
Amrit Mahotsav

„Har Ghar Tiranga‟ is a campaign under the

aegis of Azadi Ka Amrit Mahotsav to encourage
people to bring the Tiranga home from 13th -
15th August 2022. Our relationship with the flag
has always been more formal and institutional
rather than personal. Bringing the flag home
collectively as a nation in the 75th year of
independence thus becomes symbolic of not
only an act of personal connection to the Tiranga
but also an embodiment of our commitment
to nation-building. The idea behind the initiative
is to invoke the feeling of patriotism in the
hearts of the people and to promote awareness
about the Indian National Flag.