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 .

feet. Details on fabric rolls:       GSM Buyer P. They have handling capacity of around 16 lakh meter fabric per day.O # Length in meters Width in inches . Their total Storage area is 60. around 40 lakh meter fabric.FABRIC WARE HOUSE    They have huge capacity for fabric storage.000 sq.

According to shrinkage.    . 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. And according to shade variation lots were made. changes were made in the pattern in sampling CAD department.FABRIC WARE HOUSE  After the fabric is in house.

  Order reduction Excess lay length . Poor fabric quality  And also due to.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.

TRIMS STORE RECIEVE CHECKING (QUALITY/QUANTITY) MRN (MATERIAL RECEIPT NOTE) STORE ISSUE .

SAMPLING PATTERN 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.

spi.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.   . 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 was done manually.SPREADING  Total 24 tables. While. 18 for plaids and plain fabric and remaining 6 for checks fabric. 10 pin tables were also installed for checks but due to bowing problem. Plaid and plain fabric were spread by automatic spreader with the help of 2 spreaders.    . check fabric spreading was done manually with the help of 4 spreaders.

96 m Time taken to spread – 34.SPREADING  GERBER spreader:    Spread length – 5.54 sec 2 spreaders  Manual spreader:    Spread length – 5.20 m Time taken to spread – 19.38 sec 4 spreaders .

It has 8 GERBER automatic cutters and 2 Morgan Razor cutters   . It has a maximum capacity of cutting 1 lakh pieces per day. it is spread over 97000 square feet.CUTTING  Cutting department is responsible to distribute cut pieces to all sewing units in Bangalore.

CUTTING  GERBER Cutter     Knife.1 cm stone knife Motor.1 cm belt knife Motor -20 hp Speed –min 2500 rpm. max 4000 rpm Ply height.7 cm with vacuum  Morgan Razor Cutter     Knife -30. max.25.4 cm with vacuum .4200 rpm Ply height.50 hp Speed – min 2650 rpm.

10 of Tajima and 1 of Fieyu for sampling.   . There were total 21 machines out of which 10 were of Barudan.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. The cost per 1000 stitches were 80 paisa.

Cotton Size of Embroidery-Small Logos Quality-Medium  Round Head Machines     Company-Barudan Thread Used-Silicon Size of Embroidery-Large Logos (writings) Quality-High .EMBROIDERY  Flat Head Machines     Company –Tajima Thread used.

then it was put on hold and according to shrinkage pattern changes were advised and proceeded to stitching.   .QUALITY ASSURANCE  After receiving the fabric shrinkage report. if matched then it was approved for bulk production. the rolls were sent again for shrinkage rechecking. Then reports were cross checked. If not.

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. Garments produced per day per ETON line is around 800 pieces but its capacity was 1200 pieces/day.   There are 18 lines of Unit Production SystemETON installed for assembly with 33 work station in each line.  .

SEWING  Advantages of ETON system:       Less material handling Increased efficiency Increased productivity Increased quality Better space utilization Flexible High cost Suitable for large order quantity Garments containing less components  Disadvantages of ETON system:    .

 Sitting idle.  No feeding  Fabric rejection in quality checking or high defect fabric  So. Start up loss Operator not at m/c. .  No feeding available. 100% panel checking is to be carried out which takes more time than required.SEWING  Time loss on sewing floor:   Loading delay Due to delay in cutting section which happens due to delay in fabric. which also results in loading delay.

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. 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.SEWING  During the delay alteration work can be carried out so that operator is not idle.

hence increasing durability.5 AQL level is being followed in the organization but it can change as per buyer requirements. Garments were sent to another unit for washing which increased the time of finishing by 2 days.   . Wrapping was done after the button attachment to reduce abrasion with the fabric.FINISHING  2.

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 .

In order to overcome this.   . a training program was started in the unit.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.

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