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1.Raymond Since 1925 ABOUT RAYMOND GROUP HR Policy Company Profile Locations of Manufacturing Facilities Milestones Group Companies Joint Ventures Branded fabric and retail- core focus Achievements 2. Vapi plant Hierarchy Site Map Plant Layout Location Advantage Plant Workforce Modern Infrastructure Competitive Advantage Due to Technical Progress SWOT Analysis
3. Process Flow: Various Departments SCM Department Design Department Quality Department Production Department
± ± ± ± ± ± ± ± ± ± Scouring Grey Combing Dyeing Recombing Spinning Yarn Room Weaving Mending Finishing Folding
4.Projects undertaken 5. Bibliography
- Eight decades old group, in operation since 1925 - One of India's largest branded fabric and fashion retailer - Market leader in the worsted fabrics business with over 60% market share - Second largest branded apparel business in India - Owns prestigious award winning brands like Raymond, Park Avenue, Colorplus, Parx - Amongst the earliest direct retail chains in India - One of the largest exclusive retail networks in the textile and fashion space in India - Large India focus, with more than three fourth of revenues from domestic market - Raymond Ltd, the flagship company of the group, is listed on BSE and NSE
They will strive to weave in the core Raymond values namely Quality.HR POLICY HR VISION "Raymond the most Desired Workplace for Top Talent" HR MISSION They commit to the HR vision of making "Raymond the most Desired Workplace for Top Talent". Leadership. and Excellence in all our actions & HR processes so as to make every Raymondite a Complete Man. Trust. HR VALUE Trust Quality Leadership Excellence .
415 612.2005 .2005 Year of commencement of Business : . Zadgaon Ratnagiri.Plot 156/H No.Raymond Limited (Textile division) Address of Registered Office : .TelNo: +9123524921917Fax: +91 2352 492 3851 Year of Establishment : .COMPANY PROFILE Name of the company : . 2.
Business Activities : .www.Dalal & shah Website : .raymondindia.A.Manufacturing Process of Fibre to Fabric Principle Bankers : (1) Bank of India (2) Bank of Maharashtra (3) Bank of America (4)Central Bank of India (5) City Bank N. (6) HDFC Bank Limited (7) The Hongkong and Shanghai Banking Co-operation Limited (8) Standard Chartered Bank Auditors : .com .
LOCATION OF MANUFACTURING FACILITIES India Operations Vapi Thane Nasik Jalgaon Yavatmal Aurangabad Ratnagiri Chiplun Kolhapur Chhindwara Bangalore(3 plants) Chennai Kolkata Overseas Operations Indonesia Romania Belgium Portugal United States of America .
GROUP COMPANIES There are 10 Companies in Raymond Group.K. J.K. J. Raymond Ltd. Investo Trade (India) Ltd. Celebrations Apparel Ltd. Silver Spark Apparel Ltd. Helene Curtis Ltd. Color Plus Fashions Ltd. . J. Regency Textile Portuguesa Ltd Ever Blue Apparel Ltd. Files & Tools Ring Plus Aqua Ltd.K. Raymond Apparel Ltd.
Raymond Woolen Outerwear Ltd.JOINT VENTURES Raymond UCO Denim Pvt. J. . J. Ltd. Ansell Ltd. Ltd.K.K. Ltd. Gas Apparel Pvt. Raymond Zambaiti Pvt. Talabot Ltd.
Most Admired Suiting Brand of the Year CNBC Consumer Award 2007 .The Best Branded Readymade Garment and Textile . 2008 Lycra Images Fashion Awards 2008 .Most Admired Textile Brand of the Year Reader's Digest .ACHIEVEMENTS Images Fashion Awards 2009 .Platinum Trusted Brand.Most Admired Textile Brand of the Year Lycra Images Fashion Awards 2008 .
VAPI PLANT .
Site Overview Land ± 112.43 Acres Resi ± 18.18 Acres .61 Acres Industrial ± 94.
7. 1. 2. mtr. mtr.080 sq.025 sq. mtr. mtr 5. + (AWT) Process & Finishing Plant Passage Weaving plant + (AWT) Boiler House Substation (HT/LT/Com/ workshop) Switch yard . mtr Ware House (Finished goods store) Folding Dept. 144sq.430 sq.(a) Factory Building: : : : : : : : : 5. 1.730 sq.mtr.797 sq. mtr. mtr.652 sq.000 sq. 1.
Over head tank : 8 lac ltr cap. mtr. 450 sq. mtr. mtr. 460 sq. . /Creche Engineering Office & stores WTP and Raw water tank (40 lac ltr) ETP plant Over head tank : : : : : : 47 sq.245 sq. 8 lac ltr cap.350 sq. 1. 1.(b)Miscellaneous Structures: Security room Time office / Disp. mtr. mtr.
III Phase site overview: The company has started a new plant .
PLANT LAYOUT .
LOCATION ADVANTAGE Situated in Gujarat.known for its good governance Situated on NH no.8 and near to industrial Hub Well connected by Rail & Road Proximity to Mumbai/Thane Accessibility of skilled manpower Continuous availability of water Urbanized and literate people Multi.culture community with communal harmony .
procedures. and people-friendly guidelines and support within companies. Following types of person are employed/ engaged at site: Management staff Workmen Fixed period employees Contract labors Job contract Labor contract .PLANT WORKFORCE Human resource department is devoted to providing effective policies.
SWOT Analysis Strengths Location Advantage Water availability Raw material Availability Modern world class machineries Skilled labour at low cost Weaknesses Current Scenario of market Effect of government policies Opportunities Increase focus on product development 100% capacity utilization Increase foreign market business Threats Competition in Domestic and International market Ecological & social awareness Regional Alliances .
VARIOUS DEPARTMENT .
The production and planning department will set standards and targets for each section of the production process. The quantity and quality of products coming off a production line will be closely monitored. .PROCESS FLOW: VARIOUS DEPARTMENTS INTRODUCTION Production is the functional area responsible for turning inputs into finished outputs through a series of production processes. quality will be monitored by all employees at every stage of production. In businesses focusing on lean production. rather than at the end as is the case for businesses using a quality control approach.
NAME OF THE DEPARTMENTS o o o o o o o o o SCM Department Design Department Quality Department Production Department SCOURING GREY COMBING CONVERTER RECOMBING DYEING SPINNING WEAVING FINISHINGFOLDING WAREOUSE Costing/Accounting Department .
SUPPLY CHAIN MANAGEMENT DEPARTMENT INTRODUCTION SCM REFERS TO SUPPLY CHAIN MANAGEMENT SCM is the core Department which mainly deals with the planning & control activities of each plan. Supply Chain Planning Core Processes . It provides link between departments. Strategy & Analysis.1.
QUALITY CONTROL Central laboratory works in association with R & D and Q. Combing laboratory. 3. yarn and fabric stages.C. 1. Testing of the material is done in the fiber. Also it carries out testing of faults and complaints in the fabric. Decentralization of the department is done into the departmental laboratories i.e. Finishing laboratory. The central laboratory mainly functions for all kinds of testing. The basic function of Central lab is to check the final product. . 2.2. both physical and chemical. departments. Spinning laboratory.
Chemical tests carried out in Combing Laboratory 1. Measurement of the denier of polyester. 3. Various tests carried out in this lab on the material in the filter stage. Visual assessment of vegetable matter. Slubs. Fiber fineness measurements. Blend composition. 2. . Physical tests carried out in Combing Laboratory Mean fiber length testing Instrument Almeter. Instrument A)WIRA Fineness Meter B) Projection Microscope Measurements of the crimps. Residual grease contents.COMBING LABORATORY The combing lab is a division of the central lab in the combing department. clusters etc. Moisture contents.
6. Testing of the roving frame as well as rubbing of the rubbing frame. Count measurements. Tests carried out in Spinning Laboratory 1. 3. Twist measurements 4. Single yarn stage measurements. Hairiness testing. 2. Tensile strength measurement. . SPINNING LABORATORY The spinning lab is a branch of the central lab in the spinning department. 5.
Crock fastness. Dry cleaning and steaming shrinkage test. 4. 2. Piling resistance (sample size 24 cm * 10 cm). Relaxation shrinkage percentage. Wet fastness. Color fastness to water (sample size 10cm* 4cm). 6. 3. FINISHING LABORATORY After weaving. 5. . Tests carried out in Finishing Laboratory 1. the properties of the fabric are checked in the finishing laboratory.
7. Fabric tensile testing. Seam slippage testing. Twist testing. Light fastness. The samples tested are of Raymond as well as those received from out side parties. Tests carried out in Central Laboratory 1. Abrasion testing.CENTRALIZED LABORATORY Most of the physical and chemical tests are carried out in centralized laboratory. 4. 9. Yarn testing. 10. 5. 3. Drape testing. Tensile strength testing. Elongation testing. 6. 8. . Crease recovery testing. 2.
PRODUCTION DEPARTMENT .3.
OBJECTIVE It is a process of removing grease and other impurities with hot water, soda ash and detergent. It is a chemical process carried out in a series of bowls where the wool is washed thoroughly. The impurities present in wool are Natural impurities oil, fats, secreted by sebaceous glands of animal skin (wool fat) Acquired impurities- sand, dust, and vegetable matter. Applied impurities- raw wool contents 24 to 25 % of impurities WOOL SCOURING: Capacity of the machine is to feed 950 kg of wool per hr. Clean wool yield: 60 to 65% that depends up on wool quality. We are getting 3 to 4 % more yield than the standard recommended value.
GREY COMBING CARDING OBJECTIVE Opening of individual fibers Elimination of impurities (80-95%) Elimination of dust from the materials. Disentanglement of neps. Elimination of short fiber. Fiber blending, orientation & sliver formation
To prepare a sliver of required wrapping for further processing To lay the sliver into can. Reduction in weight per unit length of sliver. Intersecting gill box has multiple sets of fallers. DEFECTS The defects in gilling are as follows: Inadequate pressure on roller Broken pins or improper density Improper feelers and improper gilling. Rotary gill box has 6 rollers (3 / 3) each having spiked rings. Line C is for Blending Recombing Gilling. TYPES OF GILL BOXES Open gill box has a single set of fallers. Improving uniformity of sliver material by using multiple passages. Production 180-240 Kgs/hr .GILLING OBJECTIVE Parallelisation of fibers.
1 Gill Box .2 Gill Box .PROCESS FLOW Recombing Blender Gill Box .3 Comber Gill Box .5 .4 Gill Box .
COMBING Combing is a process followed after the gilling in the grey scouring section for the following reasons. To remove short fibers from the material To remove all vegetable (foreign) matter To straighten and parallelise the fiber To remove the neps and To lay the sliver into cans. .
Dyes used for wool are modified metal complex. sample dyeing is done in which 5 kg of material is dyed in the laboratory and then after increasing proportions of the chemicals dyes entire bulk required for dyeing. In top dyeing at first.DYEING DYEING: ( Bellini ) TOP DYEING Top dyeing is carried out after the first round gilling and combing operations are over for the sample.chrome dyes. acid milling dyes. 1:2 Metal Complex. PET is always dyed with disperse dyes. .
Poly-7hr Each dyeing machine is connected with a microprocessor in which various dyeing programmes are fed as per the material and shade.Wool-3 Hr. Poly-6 Hr Extra Dark Shade.Wool.5hr.Wool-4 Hr.6 Hr. Poly-5 Hr Dark Shade -Wool. .GENERAL INFORMATION Capacity Of Machine Minimum 5Kgs And Maximum 400Kgs Temperature (Oc) 98 For Wool And 135 For Polyester Material To Liquor Ratio 1: 20 Time Required Light Shade . Poly-4 Hr Medium Shade .
According to blend dept decides & calculate feeding of poly & wool.RECOMBING Main function of this process is to proper blending of polyester & wool according to given proportion & at the same time maintaining the shade by proper mixing of component. . General processes: 55% Poly & 45% wool 65% Poly & 35% wool 38 % wool & 62 % wool These are the commonly used blends.
After conditioning material is taken for spinning process. .SPINNING TOP STORAGE When the tops coming from combing dept they are stored for conditioning in the trolley. The conditioning time is around 24 hrs. The conditionings room is enclosed one and humidifiers are installed for conditioning of tops.
ROVING FRAME The main objectives of the roving frame are as follows Attenuation of material Preparation of suitable package for ring frame. .
the roving is converted into yarn by drafting and twisting. . Factors to be considered in promoting good spinning are as follows Count of yarn Position of spindle rail Correct type travelers and Satisfactory spindle speed. The objectives of the ring frame are as follows Attenuation and Twisting and winding on the bobbin.RING FRAME The rubbing and roving frame bobbins are brought to ring frame dept.
To produce a compact beam (without valleys and ridges). . After winding on drum it is then taken on weavers beam. To produce different colour patterns. To wind the warp end with equal tension on each and every end. In sectional warping.WEAVING SECTIONAL WARPING OBJECTIVE To produce weavers beam. beam contain some different colours of yarn then sectional warping is used.e. the warp threads are wound on the warping drum sectionally. Sectional warping is done when one needs to produce some design i.
4.WARPING FAULTS 1. . 2. Broken ends improperly repairs. Wrong built of cone 3. 5. Yarn cone of wrong size. Tension variation during warping. Count mix during creeling.
there are two types of loomsProjectile (SULZER RUTI) and Rapier looms (RIGID /FLEXIBLE RAPIER). In RAYMONDS LTD. There are various looms for weaving available in the textile industry.. About 225OO meters of linear fabric is produced per day. That means each loom is producing about 92 meters of fabric per shift.LOOM SHED INTRODUCTION Weaving is the basic department for preparing a fabric by interlacement of warp and weft yarns. There are total 112 looms working in three shifts. .
Missing end. slubs .MENDING OBJECTIVE OF MENDING To remove mend able spinning & weaving the defects from the fabric like neps . loose pick etc After the mending fabric is delivered to Finishing .
Wet Finish Dry Finish GREY HOUSE This section is called grey house because all the grey material from the weaving department after perching and mending is being sent to grey house. Grey House.FINISHING Finishing department in Raymond is divided into 3 sections viz.heat setting and singeing. . It includes grey scouring.
Only mechanical operations are rendered to the fabric in order to enhance its look shine and feel. DRY FINISH This section is called the dry finish section as here the fabric is treated in dry form throughout.WET FINISH This section is known as wet finish section because all the treatments that are carried out on the material are in wet form that includes rescouring and chemical treatment. This treatment is generally under the influence of pressure and steam .
RAL. 2. 4. Second B . 5. Exclusive and Stock Lot Export . 3.Civil. cutting and packing take place. Second A . . Second C .FOLDING In this department checking of the fabric. Finish of the fabric approved as per the approved hanger from the product department Shade checking is done as per the booking hanger There are two markets Domestic :. Good. Second D . RMG & Institutional CIVIL Visual inspection 5 TYPES OF GRADING 1.
variable expenses Product costing Cost audit Profit planning Inventory valuation MIS report (Management Information System) .COSTING / ACCOUNTING DEPARTMENT OBJECTIVES OF COSTING DEPT Budgeting Fixed expenses.
By considering following costs the total costing is carried out DIRECT VARIABLE COST (DVC): - In DVC following things are considered Raw material cost Dyes and chemical cost Combing cost Spinning cost Conversion cost .
In conversion cost there are various process cost are included Weaving cost Dyeing cost Wet Finishing cost Dry Finishing cost Doubling (for double yarn) .
measuring jar. WASHING FASTNESS :OBJECT : To check out the washing fastness of the given sample. These tests are as follows : 1.Projects PROJECT 1: OBJECTIVE: TESTING OF TOP DYED WOOL There are various tests performed to determine various quality parameters of top dyed wool. scissors. Detergent used : Surf excel Result : No staining or change in colour occurs. Atmospheric conditions : 70 to 90 0F Apparatus used : Washometer. required adjacent fabric (for covering the sample). . Reading on grey scale is 4/5.5. grey scale. etc.
Apparatus used : Air oven. MOSTURE CONTENT :OBJECT : To determine the percentage of moisture content present in the top dyed wool sample. weighing balance (to the accuracy of 0. etc. .01).2.
). .RESULT : It s average value is found to be 14 % (approx.
container.3. of the sample in gms W2 = Container wt. Chemical used : Methanol (50 mL) Where. hot plate. Apparatus used : Oil extractor. W1 = Initial wt. etc. OIL CONTENT :- OBJECT : To determine the oil content (%) in the top dyed wool sample.(empty) in gms W3 = Container wt.03 = Error correction .(with Oil) in gms 0. weighing balance.
42 %. .RESULT : It¶s average value is found to be 0.
24. 17. Uniperol FBSE SHADE: Light shade of 0. .5 Mic DYE USED :ISOLAN YELLOW 2S 2GLN CHEMICALS USED :Green acid.5 Mic 2.0 Mic 3.0 Mic 4. Opticid PB IN Liq.PROJECT 2: EFFECT OF FINENESS ON SHADE OBJECT : To observe the variation in shade according to the fineness of given wool sample.5%. MATERIALS REQUIRED : Samples of wool of various fineness as : 1. 21. 19.
lighter the shade it produces at same dyeing condition. RESULT : Finer the material. Therefore.e. . have more number of fibres in it considering equal amount of sample weight as compared to that of those coarser ones. REASON FOR THE VARIATION : Since the material of lesser micron i. finer one. the finer the sample the lighter the shade it will produce for the same recipe.
three main issues must be decided. provide the accuracy desired in the estimate . frequency study. however .Project 3: Deriving a Time Standard Using Work Sampling Work Sampling : A technique to measure work activity as related to delays consisting of intermittent observations of actual work and delays. What level of statistical confidence is desired in the results? Hoe many observations are necessary? Precisely when should the observations be made? . Observing an activity 100 times may not . ratio delay study. Also known as activity sampling. To refine this estimate .
The three primary application for work sampling are Ratio delay to determine the activity-time percentage for personnel or equipment . a measure of performance is developed. This is related to the quantity of output. however. When the amount of work time is related to the quantity of output . management may be interested in the amount of tine a machine is running or idle. the observer must be experienced because he or she must attach a performance rating to the observations. For example. This is useful for periodic performance evaluation. a measure of performance is developed. . Performance measurement to develop a performance index for workers. When work sampling is used for this purpose. Time standards to obtain the standard time for a task.
machine is on work) (0.machine is on hold) . Standard time per piece= (((Total time in minutes)*(Working time proportion)*(Performance index))/(Total number of pieces produced))*(1/(1Allowences)) (1.
9412+175. average standard time per piece = (168.5882 )/5 =168.Result: So.2353+183.2353 minutes .5294+152.8824+160.
Bibliography Apparel standard and quality specifications By S.raymondindia. Jacob Fiber to Fabric Raymond machine manuals www.com .6.
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