FAILURE MODES AND EFFECTS

ANLAYSIS (FMEA) OF TIME LOST/ IDLE

VIJIT SAHU
GP PROJECT
2017

Industry Mentor College Mentor

Suryakanta Dr Amar Tiwari
Mohapatra
Associate
I.E Manager Professor
Arvind - TPD NIFT Gandhinagar
 INTRODUCTION
Garment manufacturing units are having many
problems in their cutting, sewing and finishing
sections due to which their efficiency lie between
40-50% and the reason behind it is practicing
huge amount of non-value activities.

The present work is an attempt to reduce non-

value added time by identifying all possible the
failure modes within the factory and carefully
avoiding certain Failure Modes observed and
recorded by the author
 PROBLEM DEFINITION
In garment industry, one of the major problems
faced by manufacturers are optimising non-
productive time which directly contributes to loss
of standard time.

By controlling the non-productive time, one

industry can eliminate its wasteful practices and
can save the standard time thus increase the
output and the efficiency of the factory.
 NEED OF THE PROJECT
In an ever increasing competitive world economy,
manufacturers must have a solid grasp on their
production capacity, lower their cycle times, and
must find ways to eliminate idle and lost time in all
its forms.

It amounts to capturing idle time, identifying actual

work time and setting the stage to eliminate the
root causes of downtime and delays.
 OBJECTIVE
The main objective of this project is to decrease
time lost/ idle (non-productive time) of the plant
through Failure Modes and Error Analysis.
 RESEARCH
METHODOLOGY
Studying the existing system

Research on the topic

Preparing list of activities to be monitored for

measuring time lost/ idle
Take readings for a span of time of various activity
causing time lost/ idle

preparing report for the various activities

contributing to idle time/ time lost

Analysing report and finding out main activity

contributing to max time lost/ idle

Performing Root Cause Analysis

 Performing FMEA

Preparing the solutions and implementing them

Report the decrease in time idle/ lost

Document the process and the result

LIST OF ACTIVITIES MORNITORED
lost/ idle
Machine Breakdown

Power Failue

Air Supply
Mainten
ance Steam Supply

Trims Quality Issues

Audit Failure Rescreen

Quality Pending Decision

 No Plan

Trims Unavailable

Style File Unavailable

Plannin
g PP Meeting Not Done

Workaid Unavailable

I.E. OB Not Available

Cutting Quality issues

Feeding Not Available

Cutting Fabric Quality issues

 Rework
Line Absenteeism

ER Meeting

ER ER Activities

Line Meeting

Pending Decision

Manage
ment
 1st Hour 2nd Hour 3rd hour 4th Hour 5th Hour 6th Hour 7th Hour 8th Hour
TOTAL

Machine Breakdown

Power Failue

Air Supply

Maintenance Steam Supply

Trims Quality Issues

Audit Failure Rescreen

Quality Pending Decision

No Plan

Trims Unavailable

Style File Unavailable

Planning PP Meeting Not Done

Style Changeover

I.E. OB Not Available

Cutting Quality issues

 OBSERVATION
35.00%

30.00%

25.00%

20.00%

15.00%

10.00%

5.00%

0.00%

Trims unavailable, Feeding not available and Line

meeting constitutes to 62.7 % of the total time lost

This observation is Result.xl

drawn from
PROBLEMS
 TRIMS UNAVAILABLE

Unavailability of labels
[17th Feb Reliance khakhi , 14th -15th Feb
UTOC Jackets]
[ 17th Feb all styles, 7th Feb
Radium could not arrive on time
SRM Coverall, 6 -7 Feb Arjyle
th th

Jackets]
Trim Store take much time to procure trims
[ 11th Feb UTOC
Jackets ]

This observation is LINE_1.xlsx LINE_2.xlsx

drawn from
LINE_3.xlsx
FEEDING NOT AVAILABLE
Preparatory not done [13th ,15th Feb Reliance
khakhi ]
Fabric not Available [10th , 16th Feb Reliance
khakhi ]
Embroidery panel received late (back [10
patch)
th
- 17th Feb Reliance
khakhi ]
Marking done wrong [16th Feb UTOC Jacket]

This observation is LINE_1.xlsx LINE_2.xlsx

drawn from
LINE_3.xlsx
ANALYSING SOLUTIONS
 Can
Man delegate Supervisor
other work to be
soon Active

Materials
Minimise
Waiting
FRC label not label itself not for work
ready from the available from
mill buyer

Unavailability Workers Sitting idle

of label

Label
arrived
late

Label
attachment
done at last Communicated
to merchant

2 day delay for

Method
FRC label
 UNAVAILABILITY OF LABEL

SOLUTIONS

Strong External Strong Internal

Communication Communication
Needs to be clear as Maintaining transparency
possible Access to order status
Clear timeline for all to Generating common folder
be specified in shared document which
should have entire status

These solutions is drawn FMEA_sol.xl

from
 Trims stucked at
custom dept.
Materials

No
Radium
available

Radium could
not arrive on Workers sitting idle
time
No tracing
of
common
trims
No
reminder if
it finishes
from the Last minute order for
store radium from nearby
supplier

Delay in
receiving the
Method radium tape
 RADIUM NOT ARRIVE ON TIME

Common trims have no tracking hence

It happens that after it get finished,
merchant get the update
SOLUTIONS

1 packet / 500 pieces

must be kept as a
reserve and trim store
personnel should convey
the shortage to merchant

These solutions is drawn FMEA_sol.xl

from
 Man Difficult
and time
taking
process
Takes time to find
the style of a
Boxes kept are
particular style
piled up

trim store
take much Workers sitting idle
time to
procure trims

Takes much
time

Finds
carton and
check if it
has the
required
trims
Method
 TRIM STORE TAKE MUCH TIME TO PRECURE TRIMS

SOLUTIONS

Build a Board Update the SOP to keep

Location of Trims the board maintained

These solutions is drawn FMEA_sol.xl

from
 BOARD

LOCATION OF TRIMS
 UPDATED SOP
STEP 1: MATERIAL RECEPT
STEP 2 : MATERIAL UNLOADING AND STORAGE
STEP 3 : QUANTITY CHECK
STEP 4 : SWATCH PREPARATION
STEP 5 : VISUAL INSPECTION/ QUALITY CHECK
STEP 6 : STORAGE IN THE RACKS
STEP 7 : UPDATE THE BOARD LOCATION OF TRIMS
STEP 8 : ISSUING OF MATERIALS
STEP 9 : RETURNS

SCHEDULE FOR SUSTAINANCE

Extracted SOP_Trims.pp
from
UPDATED BIN CARD

Before After
 Man No Work
Variation in in the
seam assembly
allowance
MACHINE

Worker
sitting idle
Plotter in not
calibrated

Preparatory Workers sitting idle

Not Done

No proper
SOP

No rechecking is done

Method
 PREPARATORY NOT DONE

SOLUTIONS

To avoid shade Plotter Calibration

variation, Central problem and no
Selvage cutting is checking done
already done

Maximum prevention is
already done Daily Checking of
Calibration of the plotter
and SOP implementation

These solutions is drawn FMEA_sol.xl

from
Daily Checking of Calibration of
the plotter
 SOP OF CAD
DEPARTMENT
STEP 1: RECEIVE TECH PACK / SAMPLE
STEP 2 : MAKE PATTERNS
STEP 3 : PROCUREMENT OF TRIMS AND FABRIC
STEP 4 : VISUAL INSPECTION / QUALITY CHECK
STEP 5 : CUTTING OF SAMPLE FABRIC
STEP 6 : CONSTRUCTION OF SAMPLE
STEP 7 : FINISHING OF THE SAMPLE
STEP 8 : MARKER MAKING

SCHEDULE FOR SUSTAINANCE

Extracted SOP_CAD.pp
from
 Supplier unable
to provide on
time
Materials

Fabric
came late

Fabric not
Available
Workers sitting idle

Reliance
brand is given
priority

Priority
wise
planning

Method
 FABRIC NOT AVAILABLE

SOLUTIONS

Strong External Strong Internal

Communication Communication
Needs to be clear as Maintaining transparency
possible Access to order status
Clear timeline for all to Generating common folder
be specified in shared document which
should have entire status

These solutions is drawn FMEA_sol.xl

from
 No
checking
or
Man supervisio
n

Marking
done
wrong

Marking
Done Wrong Delay in Production

Marking pattern
given without
instructions
No
demonstratio
n

Method
 MARKING DONE WRONG

Unable to give proper

explanation No Demonstration

SOLUTION

Production Masterji

giving demonstration for new

style and Make sure that workers
way of marking is correct

These solutions is drawn FMEA_sol.xl

from
 Separate
Man workers
needed for
Embroidery gone emb.
late : Delay in attach
Materials production

Extra
Work and
extra time
Fabric came
late

Embroidery
panel Workers sitting idle
received late
(back patch)

Embroidery patch
requirement is high
then vendor capacity

Method
 EMBROIDERY PANEL RECEIVED LATE

Fabric came late Supplier unable to meet

our demand

SOLUTION

Supplier has pre- 1 more supplier to be

informed indulged for the purpose

These solutions is drawn FMEA_sol.xl

from
 CONSTRAINTS
Due to a short time limit, Reading were taken for 15 days
All possible downtime are listed, but can be possibility that
some point are missed
Embroidery unavailable is listed in Feeding not Available
because embroidery is out-sourced and embroidery cannot
be sent before cutting the fabric
Time taken in the reading is approximately true
Sewing Rework is only considered
THE
END