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TRANSCRIPT
Presented By:-
ANKIT JAISWAL
RAHUL TELANG
DFT, SEM VII
COMPANY PROFILE
Established by Mr. Janardhan Agarwal is presently the largest shirt manufacturing company in India.
Their fabric manufacturing facilities are 50 million meters per annum.
Their garment manufacturing facilities are 35 million pieces per annum.
CENTRAL WARE HOUSE
CENTRAL WARE HOUSE
FABRIC WARE HOUSE TRIMS STORE
FABRIC WARE HOUSE
RECIEVE
INSPECT
STORE
ISSUE
FABRIC WARE HOUSE They have huge capacity for fabric storage,
around 40 lakh meter fabric. Their total Storage area is 60,000 sq. feet. They have handling capacity of around 16 lakh
meter fabric per day.
Details on fabric rolls: GSM Buyer P.O # Length in meters Width in inches
FABRIC WARE HOUSE After the fabric is in house, 2 pieces of
25x25cms or 50x50cms was cut from each roll.
One was sent for shrinkage check and other was checked for shade variation if any.
According to shrinkage, changes were made in the pattern in sampling CAD department.
And according to shade variation lots were made.
FABRIC WARE HOUSE There was a lot of fabric wastage due to
following reasons: On top of 3% allowance on fabric that the buyer
gave another 5% extra was given by merchandiser and the supplier also added 5% on the ordered fabric.
Poor fabric quality
And also due to, Order reduction Excess lay length
TRIMS STORE
RECIEVE
CHECKING (QUALITY/QUANTITY)
MRN (MATERIAL RECEIPT NOTE)
STORE
ISSUE
SAMPLINGPATTERN MAKING
COSTING MARKER
GRADING
CONFIRMATION OF FABRIC FROM MERCHANDISER
ADD SHRINKAGE
LOADING
DETAIL TO TAILOR
WASHING
QA & FINISHING
SAMPLING Produced 100-120 garments/day
A+ Operators
Time taken to produce one shirt = 2 hrs
Workforce = 142
If less order quantity, production is carried out in sampling department itself.
SAMPLING Critical areas for checking:
Collar attach and finishing Sleeve attach and finishing Sleeve placket attach and finishing
For check fabric matching was also a criteria
Machine adjustment is important for different fabric such as needle, spi, thread, needle gauge, feed dog, etc
For eg : For linen fabric as handling was difficult a ball point needle was used.
CAD The software being used for marker making
was of GERBER.
Constraints for Marker Making Size Ratio Dependent Per Garment Consumption Wash Detail Check Matching
Marker Utilization for Shirt Checks – 83-85% Stripes-85-87% Solid-87-90%
CAD Types of markers being made
CSV Non CSV One Way Group Marker
SPREADING Total 24 tables, 18 for plaids and plain fabric
and remaining 6 for checks fabric.
Plaid and plain fabric were spread by automatic spreader with the help of 2 spreaders.
While, check fabric spreading was done manually with the help of 4 spreaders.
10 pin tables were also installed for checks but due to bowing problem, spreading was done manually.
SPREADING
GERBER spreader: Spread length – 5.20 m Time taken to spread – 19.54 sec 2 spreaders
Manual spreader: Spread length – 5.96 m Time taken to spread – 34.38 sec 4 spreaders
CUTTING Cutting department is responsible to
distribute cut pieces to all sewing units in
Bangalore, it is spread over 97000 square feet.
It has a maximum capacity of cutting 1 lakh pieces per day.
It has 8 GERBER automatic cutters and 2 Morgan Razor cutters
CUTTING GERBER Cutter
Knife- 25.1 cm stone knife Motor- 50 hp Speed – min 2650 rpm, max- 4200 rpm Ply height- 7 cm with vacuum
Morgan Razor Cutter Knife -30.1 cm belt knife Motor -20 hp Speed –min 2500 rpm, max 4000 rpm Ply height- 4 cm with vacuum
EMBROIDERY It is spread in an area of 13500 sq feet
with capacity of 4500 pieces per day for pocket and 3600 pieces per day for yoke.
There were total 21 machines out of which 10 were of Barudan, 10 of Tajima and 1 of Fieyu for sampling.
The cost per 1000 stitches were 80 paisa.
EMBROIDERY Flat Head Machines
Company –Tajima Thread used- Cotton Size of Embroidery-Small Logos Quality-Medium
Round Head Machines Company-Barudan Thread Used-Silicon Size of Embroidery-Large Logos (writings) Quality-High
QUALITY ASSURANCE After receiving the fabric shrinkage report,
the rolls were sent again for shrinkage rechecking.
Then reports were cross checked, if matched then it was approved for bulk production.
If not, then it was put on hold and according to shrinkage pattern changes were advised and proceeded to stitching.
SEWING The stitching unit is spread in an area of
196227 sq feet with a capacity of 22000 pieces per day.
There are a total of 2685 machines.
There are 18 lines of Unit Production System- ETON installed for assembly with 33 work station in each line.
Garments produced per day per ETON line is around 800 pieces but its capacity was 1200 pieces/day.
SEWING Advantages of ETON system:
Less material handling Increased efficiency Increased productivity Increased quality Better space utilization Flexible
Disadvantages of ETON system: High cost Suitable for large order quantity Garments containing less components
SEWING Time loss on sewing floor:
Loading delay- Due to delay in cutting section which happens due to
delay in fabric. No feeding Fabric rejection in quality checking or high defect
fabric So, 100% panel checking is to be carried out which
takes more time than required, which also results in loading delay.
Start up loss- Operator not at m/c. Sitting idle. No feeding available.
SEWING During the delay alteration work can be carried out
so that operator is not idle.
Some other style can be set on the lines if there is no feeding for some days.
Feeding from nearby factory can be taken so that there is no idle time and money loss can be avoided.
The workers should be made aware of the time loss and the consequent loss in production.
Supervisor to be held accountable for unscheduled breaks and disruptions.
FINISHING 2.5 AQL level is being followed in the
organization but it can change as per buyer requirements.
Wrapping was done after the button attachment to reduce abrasion with the fabric, hence increasing durability.
Garments were sent to another unit for washing which increased the time of finishing by 2 days.
PACKING Types of packing
Online Ratio Pre Pack Bulk
Carton Details PO # Style # Color Size Quantity Country of Origin Gross Weight Net Weight Carton Measurement
PACKING Documents required while shipment
Proforma Invoice Packaging List Bill of Lading Country of Origin
HRM ISSUES Labor Turnover was high as the
operators used to leave after gaining the required skill.
As skilled laborers were paid more in other factories.
In order to overcome this, a training program was started in the unit.