DENIM PRODUCTION PROCESS CHART

DENIM FABRIC RAW

FABRIC INSPECTION CUTTING OF FABRIC
MATERIAL

WASHING THREADING STITCHING

BUTTONING / PRESSING PACKING AND

RIVETS FINAL INSP.
G OF FABRIC

TCHING

ING AND
AL INSP.
ESTIMATED WORKER AND STAFFING COST FOR 1000 PCS DENIM LINES
EXPECTED OUTPUT 800 PCS ON PLANNED CAPACITY

FABRICS DEPARTMENT
MANPOWER POSITIONS SALARY**/ MONTS
FABRIC STORE INCHARGE 1 10000
FABRIC CHECKER 1 4800
HELPERS 2 4000
4
COST WEIGHT ON UNIT PIECE ( RUPEES ) 1.10

CUTTING DEPARTMENT
MANPOWER POSITIONS SALARY**/ MONTS
CUTTING SUPERVISOR 1 12000
HELPER 2 4000
CUTTER 1 6500
LAYMAN 4 4500
WRITER 1 4300
FUSING MACHINE OPERATOR 1 4000
SORTING / BUNDLING 2 4300
NUMBERING/ STICKERING 2 4300
14
COST WEIGHT ON UNIT PIECE ( RUPEES ) 3.37

STITCHING DEPARTMENT
MANPOWER POSITIONS SALARY**/ MONTS

PRODUCTION INCHARGE 1 15000

PRODUCTION SUPERVISORS 2 10000

WRITER 1 4500

OPERATORS 80 6500

HELPERS 5 4000

PRESSMEN 2 4500

THREAD CUTTERS 3 4000

94
COST WEIGHT ON UNIT PIECE ( RUPEES ) 28.87

PRESSING AND PACKING DEPARTMENT

MANPOWER POSITIONS SALARY**/ MONTS
FINISHING INCHARGE 1 12000
PRESSMEN 4 4500
HELPERS 6 4300
CHECKERS 1 4000
FINAL CHECKERS 1 5500
WRITER 1 4500
REWETING AND BUTTONING 3 5000
ALTERMAN 2 4500
19
COST WEIGHT ON UNIT PIECE ( RUPEES ) 4.51

MISCELLENIOUS STAFF
MANPOWER POSITIONS SALARY**/ MONTS
QUALITY INCHARGE 1 16000
STITCHING CHECKER 2 4800
LINE Q.C 1 7500
CUTTING CHECKER 1 4800
ELECRICIAN 1 5000
FITTER 1 8000
PLANNING OFFICER 1 15000
PLANNING ASST 1 6500
STORE KEEPER 1 6500
10
COST WEIGHT ON UNIT PIECE ( RUPEES ) 3.79
NIM LINES

TOTAL SALARY
10000
4800
8000
22800

TOTAL SALARY
12000
8000
6500
18000
4300
4000
8600
8600
70000

TOTAL SALARY

15000

20000

4500

520000

20000

9000

12000
600500
TOTAL SALARY
12000
18000
25800
4000
5500
4500
15000
9000
93800

TOTAL SALARY
16000
9600
7500
4800
5000
8000
15000
6500
6500
78900
ESTIMATED RAW MATERIAL COST

RAW MATERIAL CONSUMPTION / UNIT

Denim fabric (meter) 1.3
Pocket lining (meter) 0.2
Stitching thread (meter) 350
Button 1
Zipper 1
Main label 1
Washcare / size label 1
Washing cost **
Rewet/unit 6
Packing cost ** ( MATERIAL COST)

TOTAL ESTIMATED COST (rupees)

** ARE FIX COSTS

DEPARTMENTAL COST

DEPARTMENT EST.** COST (Rupee)

FABRIC DEPARTMENT 1.1

CUTTING DEPT. 3.37

STITCHING DEPT. 28.87

PRESSING AND FINISHING 4.51

MISC. STAFF 3.79

TOTAL STAFFING COST 41.64
RATE/UNIT (RUPEE) TOTAL COST
175 227.5
70 14
10 10
3 3
15 15
5 5
2 2
30 25
1.5 9
15 12

322.5