By :Anuj Kumar m.ftech (a.p.)
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Transcript of By :Anuj Kumar m.ftech (a.p.)
BY :-
ANUJ KUMARM.FTECH (A.P.)
Arvind Ltd. - A flagship company of a diversified $550 million Lalbhai group founded in 1908
Lalbhai Group Businesses are:› Textiles & Clothing's (Core Business)
Manufacturing ( Arvind Ltd., Lifestyle Fabrics & Apparels)
Retail (Megamart Retails)
› Financial Services (Anagram Sec. Ltd.)
› Engineering (Anup Engg. Ltd.)
› Chemicals & Dyes (Atul Ltd., Anil Starch Products Ltd.)
› Telecom & Electronics (Arvind Telecom)
Production Production commencedcommenced
Products Products
CapacityCapacity
Plant locationPlant location
Major end Major end user brandsuser brands
1999-00
Yarn & fabric
30 mmpa
Santej
SHIRTINGSSHIRTINGSSHIRTINGSSHIRTINGS
GAP, BR, M&S
DENIMDENIMDENIMDENIM
1987
Yarn & fabric
120 mmpa.
Naroda
GAP, Levi’s, Lee, JC Penney
1999-00
Garment
12.0 M pcs
Amber, Vadsar & EmBee
KNITSKNITSKNITSKNITS
M&S, Hanes,
Reebok, Adidas
1999-00
Fabric
7200 tons pa
Santej
KNITSKNITSKNITSKNITS
M&S, Hanes,
Reebok, Indian
Retailer
2000-01
Garment
4.8 M shirts
Bangalore
GAP, Tommy,
M&S, Wal-Mart
SHIRTSSHIRTSSHIRTSSHIRTS
Life Style Apparels - Knitwear
KNITS BUSINESS DIVISIONSantej Road, Near Khatrej, Taluka Kalol,
Dist Gandhinagar Gujarat – 382721. IndiaTel: +91-2764-281100/22Fax: +91-2764-281060Contact Person : Praney Mehtae-mail : [email protected]
Sportswear, Graphic Tees, Casual Tees, Cut & Sew Tees, Golf Polo shirts, Lounge Wear Casual Polo shirts, Rugby shirts, Joggers ... & many more.
BUYER
Briefing sheet specifies color, trims, sewing trims, buttons, embroidery etc.
MERCHANDISING DEPT
Development (3 – 4 weeks)
BUYER
Review & order placement
MERCHANDISER
Garment Order processing form
Fabric technical hanger along with fabric swatch sent to buyer for approval
SAMPLING
Contract seal prepared which specifies exact construction of the product
MERCHANDISER
Trims and accessories are decided
After approval material order form is prepared
KNP is released
MERCHANDISER
queries for date of fabric availability
Forwarded to sewing floor to get dispatch date
BUYER
Confirms date
Order is placed
MERCHANDISER
yarn requisition is raised
At the same time the trims order is also placed
Receive sample request and material
Verify material / requisition
Receive materials from marketing
Request trims from store
Receive patterns Prepares samples
Internal auditIn case of rejection from marketing Remake sample from first step
Forward sample to marketing
Receives buyers feedback with comments from marketing
If sample approved proceed, else repeat process
Hand over approved sample
TYPES OF SAMPLES◘ PROTO SAMPLE First sample meant for look, actual fabric & trims not required, could be revised as per buyers requirement
◘ FIT SAMPLE (BASE SIZE) For exact construction & measurement, can be alternate fabric, one sample of each color in medium size
◘ SIZE SET SAMPLE Critical stage, decides order confirmation, two samples each in color and size, one for buyer and one for department
◘ PRE PRODUCTION SAMPLE (PPS) / CONTRACT SEAL / GOLD SEAL meant for internal assessment,, 2-3 set in all color & sizes are sent to buyer
◘ RACK SAMPLE a random sample taken from the production line
PLANNING AND IMPROVEMENT
Developing line plansOperation breakdownGSD studySet target for each line
Daily feeding plan forwarded to sewing floor
Device methods for improving productivity
CONTROL
Buyer specific floor merchants
Sends GOPF to all departments
Communicate daily KNP progress with buyer’s merchant
Responsible for timely shipment
TYPES OF GOODS
Open width fabric on card board rolls
Tubular fabric in cutled form
INFRASTRUCTURE
Total floor area = 17.53 m x 22.86m = 400.73m²
Total number of racks 48 - 49
Capacity = 15 – 17 tones
Daily usage = 6 – 7tones
Package typeRolls (open) = 20 – 25 kgRectangular shape (tubular) = approx. 35 kg
FABRIC STORE
Fabric received
Fabric issued
AUTOMATIC SPREADING(2 -3 PERSONS AT EACH TABLE)
MANUAL SPREADING(CONTRACTUAL BASED)
SPREADING OF SOLIDSSPREADING OF SRIPES
SOME TIMES OF SOLID
PROCESS PROCESS
Loading of roll on
to the M/C
Spread perforated
paper
Spreading
Insert stripes to
locate roll
change
Opening of roll
Opening of roll
block cuttingblock
cutting
Match stripesMatch stripes
Spreading of blocksSpreading of blocks
GERBER (AUTO CUTTER)STRAIGHT KNIFE (MANUAL CUTTING)
PROCESS PROCESS
Moving lay to Gerber
table
Spread polythene
sheet over the
lay
Run the loaded
marker plan in the M/C
pieces sorted out
according to the different
rolls
Pattern placement on block
Marking with chalk
Cutting using
straight knife
pieces sorted out
according to the different
rolls
HEAT TRANSFER
Moon patch pieces
received from cutting
Check specs and
selecting appropriate
sticker
Placement using
template
Temporary attachment using hand
iron
Final heat transferring
using HASHIMA HP
Sticker removed
FUSING
Cut the rolls as per width mentioned in KNP sheet & quantity required for shift by using roll cutting machine
Load the fusing roll on machine stand
Place the cut on the on the machine bed
Align the fusing of fabric feed to conveyer
Trim the fused of fabric using tied scissors in exit the rear end
Receive instruction sheet
and pattern
Receipt of cut panels
and trims
marking as per
placement given
instruction sheet
Load framing with canvas/fusing
Floppy transfer to embroidery to machine
load the machine with framed panels
Carry out embroidery operations
Thread/canvas/fusing
cutting checking
There are 3 BARUDAN LTD. Embroidery machines2 machines with 20 heads &
1 machine with 12 head
Positive is prepared referring
spec sheet
on polyester mesh (frame)
photo emulsion coating is done, turns to screen
after passing from test the panels are arranged with bundles and sent
to embroidery or sewing sections
then online inspection
the printed panel goes to check as for placement of print and print
quality
in the machine itself after printing
there light emulsion which tends to dry the
printing
the screen is dryed
attached with printing machine
washing as for removing wet area
(black area)
assembly goes to photo camera
device machine where assembly gets exposing of
light
positive is mounted on the
screen
For single colorEfficiency is about 90%
And max. no of pieces they can print is 5000
AMBER PLANT 7 lines capacity approx 4500 garments / dayVADSAR PLANT 11 lines ( 9 PBS& 2 UPS ) capacity approx. 12000 garments / day
PROCESS FLOW IN SEWING
PROCESS FLOW IN FINISHING
Receipt of sewing plan from PPC
Sewing operations
Supervision and application of correct methods in sewing
Inline inspection
After inline inspection
ironing
Final inspection
folding
Packing in polybagFinal inspection
Sent to audit
Line out
Special finish(if any)
Dead man fold
Button attaching
Pre press checking
Lot making
tagging
Final checking
pressing
Alteration(if any)
audit
folding
polybagging
Check for metal
contamination
Carton making and packing
Dispatch
External audit
storage
Online audit
AQL LEVEL OF BUYERS
MARKS & SPENCER : 2.5OUTER BANK : 2ADIDAS & REEBOK : 1.5
Online audit
Final internal audit
External audit
AUDITING PROCESS
AUDIT
failed
Final inspection
passed
Online audit
TWO CONCEPT PRODUCTION FACILITIES
• VADSARVADSAR - Designed for producing Casual wear / Cut & Sew Tee's & Polo's
• AMBAR- Designed Specifically for producing Premium High End Golf-wear and Sportswear
OBSERVATION
Following steps in lay planning
Study on different formats used in the lay planning
Taken an random example of lot wise cut program
Observing the manual way of filling formats
Problems can arise due to not properly filling the formats
METHODOLOGY
Generating Fabric Requisition Generating Cut Program Generating Cut Numbers Issuing Cut Program and Fabric
Requisition Generating and Issuing Lay Information
Slip
It consists of the total amount of fabric that is needed for a particular Lot wise Cut Program.
The various rolls that are issued to fulfill the fabric required are listed according to their weights.
The roll no. of the fabric rolls is used to identify the rolls for a particular lot no.
It consists of the K&P, style and lot numbers.
It includes the fabric consumption per garment and the various size ratios
The cut no. generation program is generated by the system and it clearly states the number of plies and
marker length of each lay.
This has to be filled by the worker who is laying a particular cut no.
It includes the roll no, roll width, roll weight and the no. of plies that were spread from a particular roll for 1 cut no.
This sheet helps us to keep a record of all the rolls were used for all the cut programs.
A random lot wise cut program was selected and all the required formats of that program were checked to see if the total fabric that is issued was actually used or not and whether the entries done in the formats against the system laid down in the manual were correct or not.
A total of 31 fabric rolls were issued in the fabric requisition sheet
A total of 31 fabric rolls were issued in the fabric requisition sheet
While the lay information slips showed :
While the lay information slips showed :
While the lay information slips showed :
While the lay information slips showed :
While the lay information slips showed :
That only 24 fabric rolls were actually used
Only 24 rolls were used compared to the 31 rolls that were actually issued. Therefore 7 rolls were missing…….
When the total fabric consumption for the garment pieces actually cut was
calculated, it matched with the total fabric actually issued.
This leads to the conclusion that the workers have spread more than 1 fabric roll together and have done entry of only 1 roll. Therefore the rolls do not have any record in the lay information slip and hence seem to be missing.
Due to this mistake of entering information of only 1 roll in place of 2 or more in the lay information sheet, there can be problem of shade variation in the cut parts if there is roll to roll shade variation. Since the bundle card is made on the basis of the lay information slip, now 1 bundle will contain cut parts of more than 1 roll. Hence shade variation in the cut parts and hence more rejections.
Due to this mistake, there will be problem if an external auditor comes and checks as this shows that the system entries are not properly being followed.
The same roll was entered in the lay information slip for 2 different lays which is not possible.
Taking attention to the CUT NO. 43, there are ROLL NO ‘14’ & ROLL NO ‘9’ with other roll no.Then in CUT NO. 45 (I), here once again there is ROLL NO ‘14’Also in CUT NO. 45 (II), here also again there is ROLL NO ‘9’
Means,
The same roll was entered in the lay information slip for 2 different lays which is not possible.Overall there was due to the carelessness of the workers. There is shade variation in the cut parts hence more rejections, which is not good in the companies point of view.
Provided the SOP to every worker & machine,
Making aware to the workers about importance of quality,
Unskilled or untrained workers should not be placed as an operator in case of absenteeism,
Supervisor must Check the formats time to time and must keep the record,
There should be random inspection audits to check formats filling,
Indiscipline should be handled with stricter action,
All mobile phones should be banned on the work floor.
THANK YOU