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MBA661 - POMS
POMS PROJECT REPORT
Layout Study at Zorba International
SUBMITTED ON 4/29/2012
Chetan Kusram (11125015)
Nitin Bharadwaj (11125036)
Sagar Agarwal (11125047)
Sanjeet Kumar (11125051)
Samreen Jamal (11125049)
Taruna Birthalia (11125062)
Vijayta Fulzele (11125064)
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Contents
Executive Summary ................................................................................................................................ 2
Products: ............................................................................................................................................. 3
Dog Products ................................................................................................................................... 3
Cat Products .................................................................................................................................... 3
Problem Statement .................................................................................................................................. 4
Objective ................................................................................................................................................. 4
Physical Plant Layout .............................................................................................................................. 4
Factors affecting plant layout ............................................................................................................... 5
TYPES OF PLANT LAYOUT ............................................................................................................ 5
Product oriented plant layout ........................................................................................................... 5
Process oriented plant layout (Functional Layout) ............................................................................ 6
Cellular layout ................................................................................................................................. 6Existing Layout ....................................................................................................................................... 7
Precedence DiagramCollars and Belts .............................................................................................. 7
Individual process time .................................................................................................................... 7
Precedence DiagramWhip Process ................................................................................................... 8
Individual Process Time................................................................................................................... 9
Current Layout Design ........................................................................................................................ 9
Processes: ........................................................................................................................................ 9
Assembly Line Diagram .................................................................................................................... 11
Improved Layout ............................................................................................................................... 13
Assembly Line Diagram in New Layout ............................................................................................ 14
Changes In New Layout: ................................................................................................................... 14
Individual Process Time................................................................................................................. 15
Apparel Precedence Diagram ............................................................................................................. 16
Individual Processes ...................................................................................................................... 16
Layout at New Plot ................................................................................................................................ 17
Process layout for Apparels ............................................................................................................... 17
Left side working hall .................................................................................................................... 17
Process layout for Collars, Belts and Whips ....................................................................................... 18
Right side working hall .................................................................................................................. 18
.............................................................................................................................................................. 18
Expected Result ..................................................................................................................................... 19
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Executive Summary
Zorba international was started in 2000 with an aim to create a highly focused company
dedicated to Leather dog Collars. Gupta family owns all the activities of Zorba with their wild
passion for dogs. Dogs became the integral part of their family. Zorba in their four floor first unit
at Krishnapuram, Kanpur manufacture Leather dog accessories which is one of the focused
companies for dogs. Zorba sources best leather skins from different parts of India on a contract
tanning and developing basis thus matching the standards. Zorba gets all ornaments from the
Mumbai a fashion capital of India from our friend who is in women jewellery business since
ages. Zorba develops all hardware in making a collar at their one of metal crafting unit managed
by our relative who is highly specialized in the metal segment.
Figure 1 Figure 2
Comfort is liberation each and every product in Zorba is focused towards comfort which gives
birth to a newdesign. Zorba has 50 to 60 people who are devoted craftsmen and women involved
in their traditional art since years. Subhash gupta and Sudhir gupta being an animal graduate
involved 24x7 answering all the inquiries regarding manufacturing, Custom designing, pricing
and timely shipping, Sanjay gupta having a technical background is highly focused on Quality
control of each and every product which is shipped to our customer friends all over the world.
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Products:
Dog Products
Figure 3: Lamb Leather Collar, Figure 4: Matching Dog Leash,
Cat Products
Figure 4: Crystal Collars
Figure 5: Leash
Figure 6: Harness
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Problem Statement
Studying the current process and suggesting improvements to make it more organized and effective. They are also establishing one more plant for similar products, so by studying process from here
making a process effective layout for the upcoming plant.
ObjectiveThe objectives of this project were as follows:
To study and analyse the manufacturing process of collars, belts, whips, etc. To suggest improvements in the current process To suggest a new layout for the Zorbas new plant
Physical Plant Layout
Plant layout planning includes decisions regarding the physical allocation of the economic
activity centers in a facility. A facility layout is an arrangement of everything needed for
production of goods or delivery of services.
An economic activity center is any entity occupying space.The objective of plant layout planning is a more effective work flow at the facility, allowing
workers and equipment being more productive.
To make a decision about layout planning, 4 different questions must have an answer:
1. Which centers do we have to consider?2. How much space and capacity is required for each center?
If there is not enough space, productivity may be reduced.
Too much space is expensive and may also reduce productivity.
3. How must the space be configured at each center?Space quantity, shape and the elements of the work center are related to each other.
4. Where should each center be located at within the facility?The allocation of the different centers may affect productivity.
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Factors affecting plant layout
Materials
The layout of the productive equipment will depend on the characteristics of the product
to be managed at the facility, as well as the different parts and materials to work on.
Labor
Labor has to be organized in the production .
Material Handling
Material handling does not add value to the product; its just waste.
The building
If it has been already selected, its characteristics will be a constraint at the moment ofdesigning the layout, which is different if the building has to be built.
Future changes
One of the main objectives of plant layout is flexibility.
Its important to forecast the future changes to avoid having an inefficient plant layout in
a short term.
TYPES OF PLANT LAYOUT
The production process normally determines the type of plant layout to be applied to the facility:
Product oriented plant layout
Machinery and Materials are placed following the product path. This type of plant layout is useful when the production process is organized in a
continuous or repetitive way.
Advantages:
Reduced material handling activities. Work In Process almost eliminated. Minimum manufacturing time. Tasks simplification.
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Disadvantages:
No flexibility in the production process. Low flexibility in the manufacturing times. High capital investment. Monotonous work
Process oriented plant layout (Functional Layout)
This type of plant layout is useful when the production process is organized in batches.
Personnel and equipment to perform the same function are allocated in the same area.
Cellular layout
Work cells: Group of equipment and workers that perform a sequence of operations over
multiple units of an item or family of items.
Looks for the advantages of product and process layouts:
Product oriented layout: Efficiency Process oriented layout: Flexibility
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Existing Layout
Precedence DiagramCollars and Belts
Individual process time
A1.5 + 1 = 2.5 min
B0.5 min
C - 1.2 min
D1+1 = 2 min
E1+1.5 = 2.5 min
F1 min
G0.5 min
H1.8 min
I0.5 min
J0.8 min
K1+1.5 = 2.5min
L1+3 = 4min
M1 min
N1min
o- 1.5+1.5 = 3 min
Leather
Cutting - A
Applying
Adhesive - B Folding - C
Roughing
surface - D
Punching - EBead
Attachment - FTape Sticking -
GEdge Shaping -
H
White TapeSticking - I
BacksideLeather - J
collarstitching- K
buckleattachment - L
hole punching- M
Final finishing -N
packaging - o
Figure 7: Precedence Diagram Collars and Belts
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Precedence DiagramWhip Process
Store
Jhallar Cutting - A
Stick Rolling B
Stick Rolling - C
Hand Sewing - D
Knotting - E
Packaging - F
Finished Goods
FirstFloor
Basement
Basement
Figure 8: Precedence Diagram Whips
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Individual Process Time
A1.5 + 1 = 2.5 min
B6 min
C - 6 min
D5 min
E10 min
F1.5 min + 1.5 min = 3 min
Current Layout Design
Processes:
A: Leather Cutting: Here the skin or the leather is cut in order to start the process of collar manufacture.
This is done on 2nd floor. The time taken for this process is 1.5+1 i.e. 2.5 minutes. The extra one minute is
taken to compensate for the time lost in taking the leather ( i.e. the skin used) to the second floor.
B: Adhesive Applying: Here adhesive is applied to the cut leather from process A in order to fold it and
give it the desired shape. Time taken for this process is 0.5 minutes.
Terrace
Collars
D
2nd Floor
A, B, C
E, F, G, H, I, J
L, M, N
1st Floor
Apparel and Accessories
Ground Floor
K
Figure 9: Current Layout Design
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C: Folding: Here the leather is folded and shaped into a collar. Time taken for this process is 1.2 minutes.
D: Roughing surface: Here the surface of leather is roughened using a machine so that it might not create
further problems while sticking. Time taken for this process is 1+1 i.e. 2 minutes. The extra time is added
because this process is being done on the terrace.
E: Punching: This is the stage where the collar is punched in order to attach beads and other such
decorative items to it (done by hand). Time taken for this process is 1+1.5 i.e. 2.5 minutes. Extra time is
added to account for the time taken to bring it back to the previous floor.
F: Bead Attachment: In this process, beads are attached to the collar by hand. Time taken for this process
is 1 minute.
G: Tape sticking: To support the beads and the collar, tape is stuck to the collar. Time taken for this
process is 0.5 minutes.
H: Edge Shaping: The edges of the collar are given a proper shape by scaling. Time taken for this process
is 1.5 minutes.
I: Thick Tape Sticking: A thick tape is stuck to the collar at this stage in order to provide it stiffness and
avoid damage to the stitching done later on. Time taken for this process 0.5 minutes
J: Backside leather sticking: Sticking leather to the backside of the collar. At this stage adhesive is applied
to the backside of the leather and then a second piece of leather is stuck in order to provide it more
strength. Time taken for this process is 0.8 minutes.
K: Collar stitching: This is the process in which the stuck leather at the back of the collar is stitched to
provide it even more strength (by hand). Time taken for this process is 1+1.5 i.e.2.5 minutes. Extra time is
taken into consideration as this process is done on the ground floor
L: In this process, buckle is stitched to the collar by hand. Time taken for this process is 1+3 i.e. 4
minutes.This process is done again on the 2nd
floor, hence time is added.
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M: Holes are punched to the collar using a pattern. Time taken for this process is 1 minute.
N: Final Finishing: In this process, final touch is given by removing the threads and Time taken for this
process is 1 minute.
O: Packaging: this is the final process where the final sorting of collar and the packaging is done in order
to send the product for final shipping. Time taken for this process is 1.5+1.5 minutes. This process is done
in the basement.
Assembly Line Diagram
A,B,C-
4.2min
D -
2min
E,F -
3.5min
G,H,I,J
-3.6min
K-
2.5min
L,M,N-
6min
O-3
min
Figure 10: Assembly Line Diagram
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Total flow time = 4.2 + 2 + 3.5 + 3.6 + 2.5 + 6 + 3 = 24.8 min
Estimated cycle time = No. Of working hours * 60 / Total production per day of collars
Here we have
No. Of working hours = 8 hrs. ( as approximated by zorba)
Total production per day of collars = 100
So,
Estimated cycle time = 8*60/ 100 = 4.8 min
Now,
Efficiency of the current layout = Total flow time / No. Of workstations * estimated cycle time
= 24.8/(8*4.8)
= 64.6 %
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Improved Layout
Terrace
2nd Floor
Apparels and Accessories
1st Floor
collars
A, B,C, D
E, F, G, H, I,J
Ground Floor
Collars & Whips, Office
K L, M, N
Basement
Inventory & Invoicing
O
Figure 11: Improved Layout
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Assembly Line Diagram in New Layout
Changes In New Layout:
We have moved apparel section from Ist floor to 2nd floor to keep it separate since it is notrelated to collar making process.
We have moved process D i.e. Rouging process from terrace to 1st floor to reduce the time inshifting unfinished goods to and fro from 2
ndfloor to terrace.
We have moved collar making process (A, B, C and E, F, G, H, I,J) altogether to 1st floor toreduce the timing of moving inventory from basement to 2nd floor.
Processes L, M,N are moved from 2 nd floor to ground floor and this will make the space ofkeeping Rough surface making machine which is shifted from terrace to 1 st floor. And utilizing
the free space available in ground floor where just whip making process is going on.
There are no change in packaging and inventory keeping since it is little a private materials ofZorba which they want to keep it secured.
A, B, C,
D- 4.7
min
E, F, G,
H, I, J-
4.8 min
K- 3.5
min
L, M,
N- 4
min
O-
3 min
Figure 12: Assembly Line Diagram in New Layout
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Individual Process Time
This individual process time excludes the time it takes for a part to move between floors.
A1+1= 2 min
B- 0.5 min
C- 1.2 min
D- 1min
E- 1 min
F- 1 min
G- 0.5 min
H- 1 min
I0.5 min
J- 0.8 min
K- 0.5 +3 = 3.5 min
L2 min
M1 min
N1 min
O- 1+1.5 =2 min
Total flow time = 4.7 + 4.8 + 3.5 + 4 + 3 = 20 min
Estimated cycle time = No. Of working hours * 60 / Total production per day of collars
Here we have
No. Of working hours = 8 hrs. (as approximated by Zorba)
Total production per day of collars = 100
So,
Estimated cycle time = 8*60/ 100 = 4.8 min
Now,
Efficiency of the new layout = Total flow time / No. Of workstations * estimated cycle time
= 20/(5*4.8)
= 83.33 %
Hence, new layout has more efficiency as compared to current layout.
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Apparel Precedence Diagram
The entire apparel stitching process is performed on the first floor right from cutting of cloth uptil final
packaging. This floor also houses some of the various accessories that Zorba International provides. Few
examples are dog shoes, raincoats, jackets, ties, bathrobes, towels , etc.
Individual Processes
1) CuttingIn this process the cloth for apparel is cut into a proper shape using a pattern with accurate
dimensions. This process is done by hand using scissors. This process takes around 10 min
2) StitchingThe stitching process comes next. Here the entire cloth piece which was previously cut is
stitched into nice apparel for pets. This is done on electric sewing machines. Time taken for this process is
around 20 minutes.
Cutting Stitching Finishing
Figure 13: Apparel Precedence Diagram
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3) FinishingThe final finishing of the apparel involves removal of threads, stitching the Zorba tags and
packing it .This process takes around 5 minutes.
Layout at New Plot
As seen in the new plot layout in picture we put all apparel section on left side working hall while all
belts, collars and whips making section on right side working hall. In picture below we show the
magnified look at left side working.
Process layout for Apparels
Left side working hall
tr
InventoryFinished Goods Inventory
Cutting
Stitching
Finishing
27 Feets
74 Feets
Figure 14: Process layout for Apparels
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Process layout for Collars, Belts and Whips
Right side working hall
37 Feets
Inventory
27 Feets
Finished Good Inventory
A
B
C
D
E
F
B
C
D
E
H I
K
L
M
N
O
F
G J
A
7 Feet
5 Fe37 Feets
try
Figure 15: Process layout for Collars, Belts and Whips
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Expected ResultWith above suggestion to the current process it is expected that the process transfer time and cost will
reduce and overall efficiency of the system will increase. With the suggested new layout optimized
process flow can be achieved at minimum changes to the current process flow.