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Project Report
The Making operational ready of the Pilot Print Project of X
Clothing

Name:
Unit Title: Project Management

Page 1

Statement of originality of submitted work

I;
Module Name: Project Management

I hereby confirm that the work presented here in this report and in all other associated materials; is
wholly my own work
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Signature:……………………………………
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EXECUTIVE SUMMARY
This assignments aims to provide an insight on a real-life Project Management exercise
proposed to be executed in the apparel manufacturing industry by MAS Holdings
...
This project will revolve around an incumbent
project on setting up an in-house embellishment solution for a cotton brief manufacturing plant
(Linea Clothing)
...
Whilst manufacturing apparels at low cost the firm boasts itself in quality excellence
of its products
...
Thus the firm focuses to
combine and integrate all its value chain activities
...
In order to realize the MAS Vision, the corporate strategy should be able to
deploy its limited pool of resources to projects (tactics) that are capable, efficient and align with
organizational values and beliefs
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In 2009 the lead time from order inquiry to delivery was 60 days
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Diagram 01 – The comparison of leadtimes Source- Author

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The instant undies program brought the order inquiry of the customer to delivery of the
product much closer, thus allowing MAS to have competitive advantage amongst competition
by being flexible enough to respond to customer demand more sensitively
...

The current manufacturing process can be divided in to the following timeline (manufacturing
process of Linea Clothing a MAS Holdings plant, where the pilot project will be implemented)
...
Source- Author
Within the current manufacturing context, the printing of garments or panels are done by third
party contracting organizations
...
Within the current manufacturing process three days are allocated for the
printing operation
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For further reduction in the
lead time, the printing operation needs to be done at the sewing plant itself, thereby reducing
the transportation time and loading and unloading times
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The new heat seal sticker technology obtained from Italy has
many options such as multi-color and glitter printing
...
As a result the plant could be benefitted
from reduced lead times and greater response to manufacturing needs
...
To effectively counter the
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challenges posed by the environment and optimize the internal opportunities at MAS Holdings,
the proposed pilot in-house printing pilot project would be made ready at Linea clothing
...

The project covers the area selection for printing area, procurement of printing equipment
(Heat Sealing Machines), arranging the work place and fitting to start the printing operation and
staffing
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2
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2
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2 Project Objectives and key determinants to success (Critical Success factors)

Objectives

Start operation print area by May 30, 2014
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The section to facilitate the printing operation
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Internal – allocation of staffing, project team

1
...

spandex% fabric)

External – Consistency of print orders

2
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Establish a platform for testing the printing Internal – Success will depend on the testing
technologies which are developed by MAS and trials (on application and durability) done
Holdings
...


If the concept is successful, test on other Internal - The trials need to be done at the lab
fabric compositions (100% Polyester)
...


Table 01 – Objectives and Critical Success factors, source - Author
2
...
3 Project Sponsor
The sponsor for the project is the funds of the pilot plant; Linea Clothing
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2
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4 Key Stake holders of the project
Strategic Customer – Victoria’s Secret
Service Provider – MAS design, MAS Automation team
Project Head – Special Project Manager – Nishan Gunathilake
Core Project Team – Head of Maintenance, Head of Industrial Engineering, Automation
Executive,

2
...
5 Deliverables

Deliverable 01 - Obtaining Director’s approval
-

Prepare proposal for the pilot project

-

Prepare project charter/ A3

-

Present the proposal and charter to Director to for approval

Deliverable 02 – Evaluation of Printing System
-

Identify system requirement from plant end – initial requirement

-

Identify alternative print technologies available (heat seal, heat transfer, screens)

-

Identify the printing devices that are available for printing ( print material/ machinery)

Deliverable 03 – Finance allocation
-

Allocate budget for the purchase of print machinery

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Allocate budget for work place arrangement

Deliverable 04 – Procurement
-

Obtain quotations from several local on available print technologies and suppliers
prices
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1
...
1
...
1
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2 Work Breakdown Structure

The Work Breakdown Structure organizes and defines 100% of the scope of project work to be
accomplished and displays it in a way that relates work elements to each other and to the
project's goals, The Project Management Institute's (PMI)
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It also implies the correlation between activities so that a logical
arrangement of the work order is available for unambiguous execution
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Page 12

2
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1 The Work Break Down Structure of the Pilot Printing Program

Starting operations at the Print Plant

Obtain approval from the Director

Finance
Allocation

System Analysis

Analyse the Suitable
Print Technology/
devices

Analyse the
Plant
Requirement

Clear space from
floor area

Finance
Allocation for
Print Machinea

Finance Allocation
for work place
arrangements

Demarcate and arrange work place
Obtain
Quatations
Utility Fittings

Selection and Staffing
for printing section
Select supplier and
finalize prices

Install Print Machinery

Raise POs
Trail Run

Training
Quality Test on Printed material

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Gantt chart

Page 14

2
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The approach to quality with this project will take three facets; Quality Planning, Quality
Assurance and Quality Control
...
1
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The
quality planning is crucial as this would be the stage that the foundation is laid for quality
management to the entire process
...

The quality planning could be done through the following steps during the planning stage
...
At MAS point of
view, this stipulates a Total Quality Management approach to the project, where each process
step needs to ensure that it ensures the expected quality levels
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The scope statement describes the boundaries that the project could operate and lays out the
frame work for the project team to create schedules for work through the expected outcomes/
objectives and deliverables
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The
initial testing’s would be on cotton panties”
...

Further as a project objective, a project completion date of making the printing area
operationally ready has been mentioned
...

The product description; briefs styles that are currently running at Linea Clothing, is a key to
set boundary on print testing effort for the trail run which would be followed at a later stage
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This would be a comparison of technical
skills, technological capability and design of print solutions at a leading embellishment supplier
...
An
advantage of this method is that, this allows exposure to tried and proved methods of practices
at a successful plant
...
1
...

The following elements are included in quality assurance;
 Quality Management Plan

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 Quality Measurements / Quality Standards
 Operational instructions – Work Standards
 Process Audits
Quality Management plan
The quality management plan should strive to assimilate the new process in to the existing
quality management framework of the existing process
...
Another important
aspect to cover is the compliance of the project activities and the subsequent work processes
laid out with existing firm standards such as ISO 9001:2008 and OSHAS health and occupational
safety standards
...
If the quality standards in the current
manufacturing process and the printing process do not comply together it will impact the
overall First Time Through rates of the plant
...

For example, the current quality standard at the sewing modules is AQL (Acceptable Level of
Quality) 0
...
Ideally
from the activity the trail run onwards the same quality standards should be applied in the
printing section as well
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The standardized work for any operation is the best agreed method to
do a task or action and may be in the following forms;

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Type
Type One

Description
Structured / Routine

Type two

Structured/ nonroutine
Unstructured/ nonroutine

Type Three

Standard to be followed
Standard Work Sheet
work Instruction
Standard Operation
Procedure

Example
Sewing
Mechanic repairing
equipment
Commercial approval for
a color shade

Table 03 – Types of work, Source - Author
It is the responsibility of the quality department to make sure that these STWs and work
instructions are provide parallel to the training of the staff selected for the printing operations
...


Process Auditing- Kamishibai

The progress of the project could be evaluated through a Kamishibai method
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The same standard could be
applied after the printing process is operational
...
1
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If the processes are in place and does not provide the desired results, then
this would be a problem to the purpose of establishment of the pilot printing section
...
The closer
the control to the abnormality, the lesser time and effort would be to bring it again to the right
direction
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The following could be considered as quality controls;

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Results – Whether the expected results/ outcomes are achieved with the project
Deliverables – the deliverables could be measured against the schedule of activities
Cost – the forecasted cost against the actual expenditure

TASK 04
Risk Management Plan
Risk is a state or an event that may have a positive or negative impact on the project
...
The process of
identifying and risk planning starts prior to the initiation of the project
...
include activities such as external members from the
project team to handle risk, budgets for risk, scoring and interpretations for which thresholds
would be predetermined so that risks will be or will not be acted upon or given response
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1 Risk Identification

Here the potential and actual risks relevant to the project will be identified and documented
...
These may be
– Technical, quality or performance risks – Failed to hit printing takt times
– Project management risks- failure of project completion on schedule
– Organizational risks- the potential damage of relationships with print suppliers
– External risks- government and BOI policies

The information gathering techniques for this exercise would be brain storming’s, The Delphi
technique (Experts from the printing industry) and interviews with the plant teams
...
The quantification of risk can create a threshold for response or for non-response
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2 Risk response planning

At this stage primary and secondary strategies are formulated to counter risks by all parties
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i
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With the type of risk that is being addressed the response strategies that will be used will differ
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Source - Author

4
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5 Risk Monitoring and Control

Here the following will be taken in for consideration
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Changes to the project plan – have any time deviations or resource deviations happened to the
project plan, if so whether contingencies are place
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Take note and action upon through the risk
response plan
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Include this in the risk management plan
and take reference in future project
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The dissemination of information needs to be done
through the use of different modes of communication
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The communication plan for the pilot printing project is as following;
Communication

Description

Participants/

Medium

requirement

Communication

audience

Presentation

To the

Process Owner

Frequency

Build awareness
on the plant
team on the

Managers,

Special Project

One Week prior

Communication

project
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Source - Author

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References
Online Resources
[ONLINE] Available at http://www2a
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gov/cdcup/library/pmg/concept/wbs_description
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blogspot
...
html[Accessed on 20th February]
[ONLINE] Available at http://www
...
org/2012/05/organisational-capability-analysis

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