Apparel Internship VNGL

By: Kenneth Kikan Siddhant Kaushik

Acknowledgement
We are thankful to Mr. Lalit Mahajan (Vice President

& Commercial Head), VNGL for allowing us to intern at this prestigious institution. We would also like to thank Mr. Sumit Kharab (Production head, Sewing) and Mr. Nitin Sharma (Manager, P &I.E ) for their utmost support and cooperation during our tenure here. It was their valuable guidance that lighted the way for us. Lastly, we are also grateful to all the staff members and workers for giving us their valuable time.

Introduction
Vardhman entered the Garment Industry with a

joint venture with Nisshinbo Textile Inc. from Japan for production of formal shirts in Ludhiana, Punjab (India) with Vardhman holding 51% stake. The shirts will be sold in India as well as exported to US, Europe & Japan. Vardhman produces yarns & fabrics and will perform liquid ammonia processing with technology cooperation from Nisshinbo and is one of the few industries producing wrinkle free shirts in India..

Market standing
Even after VNGL being a recent endeavour, it has

already started creating a niche in the market due to its specialised product profile, i.e. wrinkle free formal shirts and has already attracted the attention of major buyers in the Indian market which procure orders from us. These companies , to name a few:
Blackberrys Billy Jealousy Arrow Turtle Raymond

Shopper Stop, etc, ensure a bright future for VNGL.

Overview of the Industry

The industry is divided into sections for ease in

operating and managing the production process. The factory has two floors and the departments are divided as under : Ground Floor:

Fabric and Trim Storage Finishing Warehouse Canteen HR and Time office
Sewing Department Administration office CAD Room Sampling MVK

First Floor:

Layout :
Ground Floor

Layout:
First Floor

Issues Noted

 On an account of the last ply of lay getting

shorter, the ply is considered to be end bit. By doing this, the cut quantity is also not achieved sometimes. In order to achieve the rquired cut quantity, the end bit ply is recut for completing the cq. TOO MUCH DEPENDENCE ON RECUTTING:

 Recutting should come to picture only in the case

of rejection and defective panel or sub assemblies and not when actual cut quantity falls short of the required one.

WIP storage

Comparison of existing and proposed system

Existing system

One side wheels and the opposite side stationary support

Old and New

Upper surface place, Parabolic shape easily

more occurences of shirts falling down as the height of WIP rises. More chances of slippage Box is inverted over a frame which is against the purpose of box. Use of pladtics is eliminated

confines the garments in space The straps are made of semi elastic material. Straps sandwitched between the two parallel rods . The three straps will have enough strength to take the load of 200 garments atleast.

KANBAN

Need For Kanban

Over loading and under loading.

Over loading causes:

Time loss in counting the pieces. Pieces are likely to be lost.

Unequal supply of sub assemply parts required

for main assembly. Loss of labor hours who are waiting for loading to happen.

 Every individual section should manufacture as

much pieces as what is required as input in the subsequent section. Elimination of over time and idle time in cutting and finishing operation. The operators who become idle soon as assembly is loaded can be shifted to other jobs in different sections

 Target of the section should be given well in

advance. Team leader of the earliest target achieving section should ensure that operators are allocated elsewhere.

METHODOLOGY
Assumptions

Production requirements
Operator vs Operation Production Capacity( Cutting-Sewing-Finishing) Method Study Time Study

Assumptions
Production Plan per day will vary for each day.

Hourly output of each section is going to vary

Production Requirements
Suppose X quantity is planned for a day,

Which is inclusive of A, B and C pieces of three

styles repectively. X = A+B+C

 Per hour production needed in assembly

Lowest output giving section is the anchor section

after cutting. Allocation of work to people who become idle after making A no. of pieces. Training of operators in different operations to allocate for floater work.

DEGREE OF LOAD
Degree of loading can be introduced to the

Kanban plan in the Assembly line. For eg> Loading requirement in assembly U: Under Loading <=80% loading F : Full Loading 80%- 120% O: Over Loading >=120 %

 2 Hrs is the standard buffer time.

U It means we are running short on production

of that section. F The required amount of buffer for the given style is achieved . O Over production of the style running in that section.

 Indication to be given with lights corresponding to

a degree. The degree of loading will be judged according to the outputs of the sections producing the style running in the assembly. This system can be incorporated into finishing to control WIP coming from Production.

CSBA- Attachment