SUMMER INTERNSHIP

AT
TEXPORT SYNDICATE INDIA LTD
BY
SREYASI DAS (1527954)

Company Profile
Texport Syndicate: is a firm leader in the Apparel export space in India over the
past 30 years and is well equipped to handle woven and knit products under one umbrella.
1. Incorporated in 1976 headquartered in Mumbai India.
2. One of India's largest manufacturer / exporters.
3. 16 fully equipped, modern, manufacturing factories based across Bangalore, Mumbai,
Hyderabad, Tirpur.
4. Specialized in manufacture of Shirts, Tops, Sleepwear, Polos, Sweatshirts.
5. OEKOTEX Certified
6. Capacity to produce and export 1.5 million garments a month.
7. 11,000 employees.

CLIENTS

Objectives And Problem Statement

Objectives:
Primary Objectives:
Study the current production methodology in Texport Syndicate.
To improve line efficiency by implementing line balancing method .

Secondary objectives:
Improve current practice of 5S.

Problem Statement:
Productivity and Efficiency improvement by implementation of Line
balancing in Texport Syndicate.

Project Methodology

The Industrial Engineering Department (IED) receives Operation Bulletin

(OB) from General Sewing Department (GSD).

The OB talks about the number of workplaces, total SAM (Standard

Allotted Minute), machine SAM, SAM for each operation.

It is the responsibility of IE Department to prepare batch layout

considering Operation Bulletin.

A garment order is chosen which was started in the line knowing total
amount of order, style description and SAM.

In addition to that we have calculate the takt time, labor productivity, line
efficiency and bench mark capacity.

Equations used

Takt time= Net available time to work

Demand

Labor Productivity = total no. of output per day per line

No. of operators

Line efficiency = Total no. of output per day per line * SAM
Total manpower per line X Total minutes per day

Target/hr. = No. of operators* working hours *100

SAM

* 100%

Style no # SW 909, George

No. of operators = 27
Working hours = 10
Total output per day = 1100
Total SAM= 6.42

Takt time = .445

Target/ hr. =
252 (100% efficiency)
201 (80% efficiency)

Labor productivity = 40

Line efficiency = 44%

300
250
200
150
Capacity/hr
100
50
0
0

5 10 15 20

process

Bottlenecks

Line Balancing

After balancing the line

No. Of operators = 24
Working hours = 10
Total output per day = 1200
Total SAM= 6.42
Takt time = .408
Target/ hr. =
224 (100% efficiency)
180 (80% efficiency)
Labor productivity = 50
Line efficiency = 53%

300
250
200

capacity/hr

150
100
50
0
0 5 10 15 20
process

Problems Identified and Analysis of

Data

Less control of supervisor on the line.

Operators are given specific jobs, so the operator knows one or few more
operations only.
Workload function among operators is another problem, because one
operator is given one operation at a time.

Analysis of Data:

Comparing number of operators

Comparisons of Information and Material flow
Operator Skill Improvement
Comparing Labor productivity and Line efficiency
Operator Motivation

5s

Frequency of waste
Frequency of Occurence
18
16
14
12
10
Occurence

8
6
4
2
0

Change in Batch layout

Delay from cutting dept

Machine Defect

Delay Reasons

Other Waste

Pareto analysis
QC tools:
Waiting waste in Sewing department:
200
180
160
140
120
100
80
60
40
20
0

100
90
80
70
60
50
40
30
20
10
0

Minutes
Cumilative %

Pareto analysis
Major Sewing defects:
45

100

40

90
80

35

70

30

60

25

50
20

40

15

30

10

20

10

0
Broken stich

Loose thread

Open seam

Wavy stich

Incorrect stich

Slipped stich

defect
defect %

Cause and effect

Findings

The current process of methodology in Texport Syndicate was studied.

The efficiency of line balancing is currently 44%.
The scope for 5S was understood
Work process can be simplified by proposed layout.

Suggestions

Supervisors should be given some personality development coaching so

that they can interact in a better way with the people around them.
The line which performed well should be announced at the end of the day.
This could motivate the employees to perform better.
Traffic light system or flag system should be practiced in stores department
for easy material handling. QC can assign the flag depend on the
performance of operator after every 2 hours. It will be a 3 color flag
(green, blue and red).
Industrial Engineering Department (IED) should be provided for the good
batch planning i.e. effective production planning.
When a particular style is running in production, it is suggested to display
the seam types in that style, the threads used, types of needles etc. written
in common languages to be understood by all the workers.

Suggestion

Training has to be provided for the workers to enhance work efficiency.

Batch layout changes should not be done during working hours. It should
be done previous day (overtime), this is to make sure there is continuous
flow of material and by analyzing it is found that efficiency can be
increased to 53%.

THANK
YOU