Mochiko Shoes

Closing And cutting operation takes place in this branch

In cutting system, there was no such conveyor used.
For cutting they are using beam press because it is best suitable for PU
and Mesh and it is a slow process as compared to travelling head beam
press(as it is not suitable for mesh)

Daily Process of Mochiko

1. Layering
2. Cutting
3. Printing and welding
4. Closing
5. Preparation
They do layering in different layers depending upon the
material:
PU: 6 Layers
Mesh: 6 Layers
Lining: 8 Layers
Fancy Punch: 2 Layers
Currently, they are working on the article Flo velero for kids
(Adidas).

LAYOUT OF THE COMPANY

Ground Floor and First Floor both have same type of setup
On Ground Floor, there were four lines and stitching process
was going on
In one line there were 26 Machines on which the operation was
going on.

On Ground floor they are using Flat System that is

MANUAL CONVEYOR; it was proceeding in a zig zag
manner.

Machine 1

Machine 2

Machine 3

Machine 5

Machine 4

Machine 7

Machine 6

Machine 8

Daily Production by Flat system is 400 Pairs.

The timing of 2 pairs is 15 minutes, with manpower of
40 people in one line.
This timing is for FLO kids (Adidas).
At the same time they are making Reebok shoes and
the timing for 2 pairs is 12 minutes.

On First Floor, they are using basket conveyor system.

In one line, there were 38 machines some were single
needle and some of them were double needle.

In this conveyor, starts with 6 pairs and the workers put

into basket for next process.
In one hour 60 pairs are made. And manpower required
is 38 persons per line.
The advantage of this system is more feeding than
other conveyors. The production per day in Basket
Conveyor is 500 Pairs per day.

Machi
ne 1

Worki
ng
table

Basket 1

Qualit
y
Check
Table

Machi
ne 2

Basket 2

Machi
ne 8

Machi
ne 7

Machi
ne 3

Basket 3

Worki
ng
Table

Machi
ne 4

Worki
ng
table

Basket 4

Machi
ne 6

The operator of Machine No.1 will put a new basket

after Basket 1.
The sitting position is different As compared to flat
system.

Machi
ne 5

There are 3 Light system attached in front of every line.

1. Green
2. Yellow
3. Red
Green and yellow are for calling the supervisor.
Red is used for calling the machine technician

Transportation System
As we know in the factories various transportation
systems are used as per the capacity of the factories.
We have to transfer raw material, Work in progress and
finished goods from one place to another or from one
operation to another operation.
TRANSPORTATION SYSTEM USED IN CLOSING
DEPARTMENT
Basket/Bin System
Trolleys System
Conveyor System
Basket/Bin Systems
In this basket/bins are used to move the material from
one workstation to another. We put the batch of 10-12
pairs in one basket. In this a full time feeder is required
to move the basket to different workstation that collect
the basket from the operator when he finishes his
operation and then move it to another operator for the
next operation.
The main feature of this system is:
In this system we can arrange the machines in any
order; however it is best to have some sort of
sequence.
Baskets are inexpensive.
We make the batch size of 10-12 pairs which
determine the basket size.
Baskets are heavy to carry around. Both supervisor
and the operators become tired by the end of the
day.

 In this system there is a chance of missing any one

of tray during processing.
In this system more than one style can be loaded.
TROLLEYS:
For transporting the goods from one workstation to
another trolley are used. Transporting the goods with
the help of trolleys is very easy and one trolley can
contain several trays.
As we know in one basket we can pout 10-12 pairs. It
should be remembered in one trolley we should put one
style of upper .Trolleys are moved to different
workstation after the completion of work at one
workstation.
In one trolley we can put three trays, and in one
tray we can put 10-12 pairs, thus in one trolley we
can put 30-36 pairs.
The footwear being processed should have a
sequence card made for each individual style. This
is placed on the side of each trolley. Only that style
of footwear could be loaded on that particular
trolley.
In this system supervisor and operator do not feel
tired by the end of day.
Handling frequency is less than that of the basket
system.in this system operator completes30-36
pairs before trolley is moved on.

Conveyor System:

In the basket and trolley system require too much of

manual movement which causes too much wastage of
time and loss of production.to overcome this type of
difficulty in handling of the goods gravity conveyors or
powered conveyors are now commonly used in many
factories. Material can be moved from one operation to
another under the flow of gravity or through a powered
conveyor.
Gravity Conveyor:
This is the best method of transporting the goods from
one place to another. In this system power is not used.
This type of conveyor can be easily installed. Material is
moved from operation to another under gravity flow by
manual push. Gravity conveyor can have skate wheels
or roller to convey the material under gravity flow. This
type of conveyor can be installed according to the
production requirement and according to the needs like
light, medium & heavy weight. This conveyor can have
variety of length and width.
In closing Section such conveyor can be classified as
feeder operator feeder as feeder just feeds the work
initially then operator himself moves the work by
manual push to next operator after completion of work
FEEDER-OPERATOR-OPERATOR
In this type feeder is concerned only with initial placing
of work on the transporter, and with removing it on
completion. In this type operators are responsible for
the routing of the work, they must be given clear
instruction on the operational sequence.

Advantages:
A full time feeder is not required.
Less expensive than the motorized type.
Disadvantage:
In this system operator are responsible for the
routing of work can lead to errors.
Accurate work loading, which is not always possible
with fluctuations in styles
Bottlenecks & Shortages are hard to see.
It is hard to control
In this system machines are arranged in a
sequence.
Operator has the advantage to be selective about
their job lots.
Motorized Transporter:
Such transporter requires power driven roller or belt.
This type of conveyor can handle heavier load and can
be driven at various speed. These roller and bells also
provides a solid surface for people working .This type of
transporter in Closing Section requires a full time
feeder who feeds the work to different operators and
receive the finished work through the powered belt. In
this conveyor we use the Feeder operator Feeder
System.
Feeder operator Feeder system:
In this system conveyor belt is used for transferring the
goods from dispatching point to the workstation. A
series of workstation are situated on either side of the
conveyor belt whose distance in between is determined

by the size of tables as well as size of the boxes. In this

system motorized continuous moving belt that allows
for the return of the boxes to the feeder position. Two
boxes are feed at one time, one being worked on and
the other in reserve. The main advantages and
disadvantages of this system are:
Advantages:

In this system we can reduce the work in progress.

Process time is shorter than other system
Operators productivity is increased by this system.
More than one style can be loaded at one time.
Bottlenecks can be identified easily.
Complete control over the progress of work.
Operator can leave there workstation without
upsetting the workflow.
A supervisor can inspect the work from every
operation at one central sposition.
Disadvantages:
In this system a full time feeder is required.
It is very expensive than gravity Conveyor.