WELCOME EVERYONE !!!

• This is N.NANDHINI doing IV MSC FDM in PSG

COLLEGE OF
TECHNOLOGY,COIMBATORE,TAMILNADU.
• PROJECT CARRIED OUT IN A INDUSTRY : ARVIND
MILLS,BANGLORE
• PROJECT CARRIED OUT IN A PERIOD : MAY – OCT
2018
• PROJECT CARRIED OUT IN A DEPARTMENT :
FINISHING
• INTERNAL GUIDE : DR.NIRMALA VARGHESE
• EXTERNAL GUIDE: MR.VENKATESHA MURTHY
 “I SEE MY LIFE AS AN
UNFOLDING SET OF
OPPORTUNITIES TO AWAKEN”
 INTRODUCTION

• Arvind Limited (formerly Arvind Mills) is a textile manufacturer and the

flagship company of the Lalbhai Group. Its headquarters is in Naroda, Ahmedabad,
Gujarat and India. It has units at Santej (near Kalol).
• State of the art technology and equipment have made Arvind one of the leading
producers of denim in the world, paving the way for the company to emerge as a
global textile conglomerate.
• Today it retails its own brands like Flying Machine, Newport and Excalibur and
licensed international brands like Arrow, Tommy Hilfiger, through its nationwide
retail network. Arvind also runs three clothing and accessories retail chains, the
Arvind Store, Unlimited and Megamart , which stocks company brands.
 COMPANY PROFILE

Arvind.
We are one. 
Yet, we are many.
• They are a fashion powerhouse that is also building new age homes ; they are a global leader in
apparel manufacturing that is also transforming water management;
• Today, the fabric made by Arvind can go around the earth 6 times over.
2 pieces of apparel are sold by an Arvind managed brand, every second in India.
Arvind owns 22 global patents for environmental solutions, and is the largest fire protection
fabric producer in the country.
• History has been witness to the Arvind Group's commitment to excellence, innovation,
perseverance and undying attention to customer and societal needs.
 POLICY

We Are At Arvind Ltd ; Are Focusing On The Delight Of Ultimate

Judge By Our Constructing Solutions To Problems Before They
Occur And Designing Excellence In To A Product Service.

FOR ARVIND

“ QUALITY IS AN INVESTMENT “
 
PROJECT IN DENIM
TROUSERS
IN DENIM FINISHING
• The garment industries are always trying to improve production and the quality of the garments
to sustain in the enormous competitive market. The sustainability and profitability of garment
industry is governed by the productivity of that industry.
 OPERATIONS CARRIED OUT IN
FINISHING
• Loop cutting • Measurement checking
• Trimming • Tagging
• Dusting • Match book
• Leather patch attach • Final checking
• First checking • Folding
• Rivet & shank attach PACKING
• Closing of zipper • Labelling
• Pressing • Insert into polybag
• Topside checking • Closing polybag
• Presentation checking • Final label & final packing
 1
To Redesign the workstation

OBJECTIVE 2
To Implement kaizen
S
3 To Implement method of
standardization

4 To motivate and provide awareness to

employees

5 To Set self-imposed production

capacity deadlines
 • TO REDESIGN THE
1 1.REDESIGNING
WORKSTATION(LAYOUT)
OF

• The importance of a layout would be better appreciated if one understands the influence of
an efficient layout on the manufacturing function: it makes it smooth and efficient.
Operating efficiencies, such as economies in the cost of handling materials, minimization of
production delays and avoidance of bottlenecks all these depend on a proper layout.
 RESULT
• EXISTING LAYOUT
• Existing layout of finishing department
produces 6000 garments per day.
• They had two lines where one line produces
3000 garments.
• Existing layout has some operations in a
centralized one, some spaces which is not in use
and no required space for storing the packed
garments.
• Packing area – 63*46 feet in length
• Operators required - 166
COMPARISON
• PROPOSAL LAYOUT
• Proposal layout can produces 7500 garments per day
• They will have 3 lines where one line produces 2500
garments per day.
• Using capacity study for each person , I had designed the
proposal layout with required people for each operation,
utilized that unwanted spaces and made centralized
operations into single operation for each line.
• Packing area – 73*46 feet in length
• Finally we can get some extra spaces for storing packed
garments and increase of 1500 production.
• Operators required - 179
 OPERATORS
REQUIRED/LINE

• CAPACITY CALCULATION.xlsx
 EXISTING LAYOUT OF FINISHING- 1 ST
FLOOR
• The total area of trimming(1st floor) is 107 FT * 26 FT.
• All the operations are centralized one.

EXISTING LAYOUT - 1 ST FLOOR.xlsx

 PROPOSED LAYOUT OF FINISHING-1ST
FLOOR
• The total area of trimming(1st floor) is 142 FT * 26 FT.
• Totally three lines.
• All operations are separate for each line.

PROPOSED LAYOUT-1 ST FLOOR.xlsx

 EXISTING LAYOUT OF FINISHING-GROUND
FLOOR
• The total area of finishing ground floor 220 FT * 78 FT.

EXISTING LAYOUT - GROUND FLOOR.xls

x
 PROPOSED LAYOUT OF FINISHING-GROUND
FLOOR
• The total area of finishing ground floor 220 FT * 78 FT.

PROPOSED LAYOUT-GROUND FLOOR.xlsx

 2 • TO IMPLEMENT
KAIZEN
• KAIZEN: For motivating employees about kaizen , displayed some hand
made posters.
• Found some proposal ideas for bottle neck operations.
1.HAND MADE :
PDCA CYCLE
POSTERS
TEAMWORK
MAJOR THINGS TO AVOID
7 WASTES TO AVOID
 2.PROPOSAL IDEAS FOR BOTTLE NECK
OPERATIONS
3 D EFFECT TRIMMING/LOOP CUTTINGLEATHER PATCH
 Individual lightings  Clockwise trimming  Markings of leather attach
 Standardized fitted rolls  Tightness of scissors  Speed of labors
 Engaging works to labor  Sharpness of scissors  Automatic machine for
 Machine problem  Using the inside edge of trimming the edges
scissor
 Changing of tables
 RESULT

Awareness about kaizen to employees

Can improve bottle neck operations which is a major

task happening in this industry.
 • TO IMPLEMENT
3 METHOD OF -
STANDARDISATION

Utilize operator’s time as much as we can. There is no better alternative than just stopping
operators sitting idle to improve operator productivity. Start eliminating non-productive time
as much as possible.
 RIVET
ATTACHING
• EXISTING:videos\Newfolder\6.RIVET&SHANK\RIVET ATT 2.MP4
• PROPOSAL:videos\Riveting and eyeleting machines_HD.mp4
 TURN IN AND OUT

• EXISTING:videos\Newfolder\TURN IN OUT.MP4
• PROPOSAL:videos\SUPER FULL PANTS-TURNER MACHINE_HD.mp4
 FOLDING

• EXISTING:videos\Newfolder\FOLDING.MP4
• Proposal:videos\Trouser folding machine STP 1000( THERMOTRON).mp4
 3D EFFECT

• EXISTING:images\3 D EFFECT.jpg
• PROPOSAL:videos\Metod Makina 3D Vacuum Machine.mp4
 COMPARISON
OPERATIONS MANUAL( 1 labor) AUTOMATIC

RIVET ATTACHING 12O pcs/hour 1200 pcs/hour

(1 min=2 pcs) (1 min=20 pcs)

TURN IN AND OUT Major problem for every employees. Can satisfy employees

FOLDING 240 pcs/ hour 600 pcs/hour

( 1 min=4 pcs) ( 1 min= 10 pcs)

3D EFFECT 1 mac : 15 pcs /hour 120 pcs/hour

( 4 minutes=1 pc)
6 mac : 90 pcs /hour
 RESULT
• .
Consumption of manpower

Increase of production

Minimizing the machines.

 • TO MOTIVATE AND PROVIDE
4 AWARENESS TO EMPLOYEES

Motivation Is
Simply Mean Like
 IN WHAT WAYS MOTIVATION IS
GOING TO PLAY A ROLE IN THIS
INDUSTRY?

• As The Production Is Completely Based On Manpower , Motivating Each And Every

Employee Plays An Important Role For The Management Improvement.
• Nowadays, Employing New Ones For Getting Production Increased Is Being A Very Big
Task For HRM Which Aware Us To Be Smart In Maintaining The Existing Employees.
• This Shows Us That Employees With Satisfactory Salary Will Not Be Much Enough To
Keep People Stay With Industry Works Where World Is Running Behind Many Easy
Ways Of Jobs.. So Making People To Get Interest In Their Works Is Too Important Which
Is Possible Only Through MOTIVATION…
 BEST WAY OF MOTIVATION

Making People To Work With Competition Among Other

Employees…that Happens In Ways Like
• Even We All Differ From Each Other We Are All Being In
Common As HUMAN BEINGS… So 80% Of Peoples Will
Have Their Sense To Be Proud Among Others…that I Hope This
Method Can Be The First Step To Make People Gets Activated.
• They Should Know That Doing A Job Is Not Much Great Than
Doing A Perfect Job.
• No One Will Do Something Without Some Expectations Or
Benefit…so We Can Make Some Motivating Benefits For The
Best Worker.
 THIS PROCESS
GETS
CHANGED FOR
EVERY WEEK MONITOR THE
SO THAT ALL EMPLOYEES
EMPLOYEES WORKS
GET THEIR
OPPORTUNITIE
S

TYPE OF
MOTIVATION TO BE
DONE
PRIZE THEM
IDENTIFY THE
INFRONT OF
BEST AND
ALL
PERFECT
EMPLOYEES IN
WORKER
A MEET

FIX THE
SELECTED
PEOPLES
SNAPS IN
FRONT OF ALL
IN A BOARD
FOR THE
WHOLE WEEK
 CRITERIA FOR SELECTING THE BEST
EMPLOYEE ?

Punctual in Completing the

Being
presence standard
discipline
(attendance production

RESU People get competition between other employees

and can expect at least 50% of improvement with
them.
LT
 • TO SET SELF-IMPOSED
5 PRODUCTION CAPACITY
DEADLINES

• Instead of giving an over target to all operators working in a line, give a common target
considering overall operators skill level and capacity that can be done. Take care of operators
who are under target.Monitor the operator’s improvement and further give training if needed to
reach the imposed capacity deadline.
 PRODUCTION DEADLINES FOR EACH
OPERATION PER HOUR

S.NO OPERATION LIMIT/ HOUR S.NO OPERATION LIMIT/HOUR

1 LOOP CUTTING 160 14 SHADE DIVIDE 400

2 TRIMMING 40 15 FOLDING 250

3 DUSTING 180 16 CLOSING ZIPPER(ONLY BIGSTAR) 130

4 LEATHER PATCH 140 17 LABEL INSERT 600

(ONLY BIGSTAR)

5 FIRST CHECKING 50 18 APPLY GUM&ATT LABEL(ONLY 700

BIGSTAR)

6 RIVET&SHANK ATT 110(R) 350(S) 19 HEATING (ONLY BIGSTAR) 200

7 IRONING 70 20 METAL DETECTOR 1000

8 TOPSIDE CHECK 120 21 PACKING TAGGING 250

9 MEASUREMENT 250 22 POLYBAG INSERT 500

CHECK

10 PRESENTATION CHECK 150 23 POLYBAG CLOSING 350

12 TAGGING 500 24 FINAL LABEL 500

13 MATCH BOOK 500 25 FINAL PACKING 30

 RESULT
Production target of an hour can be followed
correctly.

Employees participation in working can be

found.

Easy to allocate no.of operators needed each

operation.
THE END
THANK YOU !!!!!!!