Module Line

Project
Prepared by: Department of IE-Talisman-01
Contents
1. Product categories

2. Skill gap analysis

3. Symbol layout

4. Machine requirement

5. Space Requirement

6. Indirect manpower for layout model

7. Challenges for this project

 [Link] categories
SL NO. Product SMV Picture SL NO. Product SMV Picture

1 5 pocket 23.14 3 Basic with 1 pcs belt 19.06

Basic with elastic

2 Basic with Fake welt 21.68 4 26.24
belt
 [Link] categories
SL NO. Product SMV Picture SL NO. Product SMV Picture

Basic with mock Basic with Functional

5 18.92 7 25.36
without loop Welt

Tchibo-Without Basic with binding

6 11.3 8 25.72
pocket belt
 [Link] categories
SL NO. Product SMV Picture SL NO. Product SMV Picture

9 Basic with mock ply 20.16 11 Basic Blouse 27.44

10 Arket Blouse 28.62

 [Link] Gap Analysis
SL Allocated No of
Required skill level
NO. Product line Manpower SMV
need to train
1 5 pocket 9,10 38 23.14 45

2 Basic with Fake welt 11,12 36 21.68

3 Basic with 1 pcs belt 18 10 19.06 122
40

4 Basic with elastic belt 14,15 16 26.24

5 Basic with mock without 13,26 12 18.92

loop
72
6 Tchibo-Without pocket 6,7,8 45 11.3
7 Basic with Functional Welt 16,17 34 25.36
8 Basic with binding belt 21 ,22 32 25.72 Skill at 55%
9 Basic with mock ply 23 20 20.16 Skill at 45%
10 Arket Blouse 24,25 16 28.62 Skill at 65%
11 Basic Blouse 24,25 16 27.44
New skill need to train
Total 279
 [Link] Layout
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112

2 Back part Assembly Finishing Get-up Packing

3

4
Tabl
Table Table
IRON

IRON

IRON
IRON

IRON

IRON
e
5 Table
Walk
INPUT TROLLY

way Table
6
Table
IRON

IRON
IRON

IRON
Table Table Table Table
7

9 W/B Front Part Assembly Finishing Get-up Packing

10

11

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112
[Link] Requirement
[Link] Available [Link]
S/L Machine Type Available Machines Required Variation S/L Machine Type Required Variation
machines Machines machines

1 SNLS 1090 1262 -172 19 F/L Flat bed 22 34 -12

2 SNLS Cut 140 215 -75 20 F/L Narrow bed 13 21 -8
3 DNLS FB 52 80 -28 21 F/L rawedge cut 0 2 -2
4 DNLS SB 48 56 -8 22 SBL/S 31 49 -18
5 CHAIN STC 90 114 -24 23 DBL/S 17 19 -2
6 5TOL 255 279 -24 24 Ascolete(Elestic thead with heat) 6 7 -1
7 4TOL 108 114 -6 25 IRON Narrow 57 73 -16
8 3TOL 0 103 -103 26 IRON Flat 286 321 -35
9 FOA 18 36 -18 27 APW 8 15 -7
10 B/A 62 85 -23 28 Pattern Tracker 1 4 -3
29 Heat Seal 4 2 2
11 B/H 22 42 -20
30 Collar/ Cuff Turning 6 0 6
12 E/H 18 30 -12
13 B/T 70 95 -25 4TOL Top & Bottom
31 3 0 3
Feed
14 Sleeve Setter 16 14 2
FL/R.E.C. Top &
15 Shoulder pad 8 9 -1 32 12 0 12
Bottom Feed
16 Kansai 27 42 -15 33 Shoulder Press 4 5 -1
17 Kansai (Loop) 7 12 -5 34 Snap Button 40 56 -16
18 F/L Cylinder bed 3 2 1 35 Wrapping/Louver-Cotton tread 7 16 -9
Grand Total 2551 3214 -663
[Link] Requirement
Required machines Category
51
22 SNL

DND
271
176 O/L

Heavy machines

Special Machines

133 36 Iron tables

[Link] Requirement
Required Space
SL NO. Product SMV (Feet)
1 5 pocket 23.14 102
2 Basic with Fake welt 21.68 100
3 Basic with 1 pcs belt 19.06 98
4 Basic with elastic belt 26.24 102
5 Basic with mock without loop 18.92 86
6 Tchibo-Without pocket 11.3 77
7 Basic with Fun Welt 25.36 110
8 Basic with binding belt 25.72 112
9 Basic with mock ply 20.16 95
10 Arket Blouse 28.62 112
11 Basic Blouse 27.44 110

Required Space (2module) 224

Available Space 204 20

0 50 100 150 200 250

 6. Indirect manpower requirement
New New
Indirect Cadre Variance Department Name Cadre Variance
Module Module
1 Sewing Indirect others 37 47 10 1 Sewing Direct 2039 1985 -54
2 Cutting 322 297 -25
2 Jumper Line 26 41 15
3 Cutting Quality 28 31 3
Total Direct 2112 2073 -39
4 Finishing Quality 170 176 6
5 Sewing Quality 132 149 17
Quality Total 354 380 26 Factory Summary
6 Finishing 159 209 50
New
7 Finishing Others 23 36 13 Cadre Variance
Module
8 Packing 175 201 26
22 24 2 1 Total Direct 2112 2073 -39
9 Loader,Packing
10 Cannibalizing 8 12 4 2 Total Indirect 1755 1879 124
Packing & Finishing Total 487 582 95 3 Total Factory 3867 3952 85
11 Pilot Run 42 50 8 Ratio 0.83 0.91 7.5%
12 QCO & Feeder 37 45 8
13 Pattern-Production 6 8 2 Grand Total 4,139 4,224 85
Management 201 219 18
Total indirect (Production) 1401 1525 124
Total indirect (Non production) 354 354 0
Total Indirect 1755 1879 124
7. Challenges for this Project

[Link] need to fix according to product category

[Link] Skill gap need to fill

[Link] machines will increase

[Link] manpower will Increase

[Link] will increase

[Link] production activities will increase

Thank You