Jay jay textile company

Jay jay Textile Company

Project

Prepared by: rahel wondesen

 Jay jay textile company

CHAPTER ONE

COMPANY BACKGROUND PROFILE

Figure 1 Company Profile

Jay Jay textile private limited company was establish in Ethiopian in October 18/10/2013 by
Indian investor with an authorized capital of birr 40 ,million owned by
SriKumarbalasuprayam.The company located at 17 km from center of Addis Ababa in the east
direction of Bole and its specific name is Bole Lemi industry zone. The hand holding area of the
factory is 2700 square meter .The Company has gained an investment license from the
government (EIP-IP/022668/06) for producing children wear. All fabrics and accessories are
sourced from jay jay mills (India) plc. The main products of the company are children’s body
suit and children’s pants body suit and children’s pants. The company planting its mill in India,
Srilanka, Bangladesh, and Ethiopia and exporting products for GCI, TCP, Carter’s, H&M and
new buyer needed.

Initially the total power of the company was 350 and the work force is relatively 90% young
female with basic knowledge skill is to write and read, to operate and maintain the installed
machine and equipment. The company starts its production process by giving training in one
training room (block 9) and the training length period of time takes maximum 21 days and
minimum 16 days. Since the workers were finished their training program, they will directly
transfer to the production line.
 Jay jay textile company

Vision
To be the most trusted baby wear manufacturer in the world.
Mission
 To be best top 3 supplier to the buyers
 To be best work place for employers
 To be the most reliable baby wear manufacturing quality and delivery
 To have good learning system by continually eliminate waste.
Goal
 Turn over percent below 6%
 Achieve 100% delivery on time
 Maintain 0% final AQL failure
 To maintain budgeted cost per min
 Jay jay textile company

Organizational Structure

General
Manager

Deputy
General
Manager

Operational
manager

Maintenan FGS IE QA TPD

Deputy HR Productio
ce executive manager Manager Manager
Manager n manager
manager

Manager of Manager Planning Manager IT

Embroidery and account manager merchandi manager
printing ser

Figure 2 Organization Structure Chart

 Jay jay textile company

Responsibilities of Deputy Manager HR (Human Resource)

E Preparing short term and long term plan of HR and submitted to General Manager
(Operational Manager) for approval.
E Studying the need of different departments for human resource
E Selecting workers through identifying their capabilities based on their identity card, Birth
certificate and Exam (for direct workers).
E Providing awareness for workers about The way how to inform their grievance, Safety
procedures, Leave procedures, Termination and resignation procedure.
 Jay jay textile company

Types of machines
 Over lock
 Flat lock
 Single needle chain stich
 Double needle chain stich
 Double needle lock stich
 Button
 Heat seal
 bar tuck
 button sower
 button hole
 single need side cutter m/c
Types of over lock machine
1. Back lack: used for side seam
2. 4 tread over lock: used for sleeve attach, 1st and 2nd side seam.3tread over lock
for neck binding and shoulder attach.
3. Cylinder bed overlock: used for elastic attach

 The difference with 4 tread over lock is this one can lock the stich after
finishing and 4 thread overlock is under bed.

Types of flat lock machine

Fold type convertible machine:used for binding bottom and neck binding.
Used additional garment

Fold type chain stich m/c: used for sleeve hem

Puller m/c: used for west band

Hem cutter: for bottom binding

Cylindered flat lock m/c: used for leg hem which doesn’t need tuck.
 Jay jay textile company

Heat seal
 We use heat seal for two purpose for tagless label attach and fussing the only
difference is temperature, pressure and time. We use fussing when garment
have embroidery, on the inside of the garment there are treads which is
uncomfortable so to remove that we use net then fuse on the garment.
Single needle lock stich: in jay jay we are using for tucking but with this m/c
we can complete one garment.
Double needle chain stich : used for neck rib binding.
Double needle lock stich: used for denim pocket lay out. In this machine we
can lock the needle during sewing.
Single needle side cutter: this machine can stich and cut at the same time.

Button

Ykk scovila

In jay jay we are using ykk button.

3 types of button
 Opl(female):have color and silver depend on the order
 Socket
 Duo(male):always silver

Size of button
GCI: 14L
Carter and H&M: 15L
Bar tuck; used for tucking on the inseam crotch
Button hole: used for insertion of button
Button sower: used for extra attachment like adidas, Nike.

Types of Needle
 Jay jay textile company

1. Sharp needle: used for woven fabric

2. Ball point: used for knitted fabric
3. Heavy: used for heavy fabric like denim

Jay jay uses light ball point needle type

Size of needle
75, 70,65,60---------European

11, 10, 9, 8-------Asian

Needle prossiger
1. First thing we do when needle breaks we stop the machine
2. Collecting the garment before and after stich.
3. Then taking the garment with plastic bag in AQL
4. AQL there is metal detector machine during checking when we find the
needle we can get the replacement of the needle but if there is no needle found
in the garment we must return to the m/c
5. Then we search the needle by using ground magnet for 1-1:30hr still if we
can’t find the needle
6. We must go to the needle center and get the investigation form and
operational manager, quality manager…….. Will sign on it and we can get the
replace needle then call the mechanic then fix the machine.

Needle type
 Jay jay textile company

DBx1……………………..single needle
DCx27…………………….over lock
UYx128…………………..flat lock
UYx163……………………Pico
DPxk5…………………….embroidery
DBx5………………………bar tuck
Dpx17……………………button
Operation for TCP (T-shirt)
Heat seal…………… sleeve hem………shoulder attach………neck
rib make…….neck rib attach……….1st side seam……….2nd side
seam……….bottom hem……..tuck….ironing ……cheaking ……
packing.

Operation for GCI

Heat seal……sleeve hem….neck binding……sleeve attach….1st side
seam…….bottom binding……2nd side seam……end tuck…botton
attach.
During the production of GCI iron is not needed

Operation for bike short

Back rise and front rise attach...……heat seal……leg hem…..side
seam…elastic attach….label tuck…west band…..leg
tuck….checking…..joker tack….ironing….packing.
Operation for carter
Heat seal……sleve hem…..neck binding…..sleve attach….1st side
seam……2nd side seam….bottom…..twill tape…..button attach.

Types of foot
 Jay jay textile company

Single
 Narrow foot
-normal: for medium fabric
-heavy: for heavy duty
 Zipper foot
-left: for zip outline
-right: for zip attach
 Gauge foot(CR&CL): for special outline like shoulder(one side sewing the
garment the other press)
 Gauge foot: for special outline
 Heming fet:one foot is bigger
 Teflon: a foot with plastic
 Double needle chain stich foot;have gauge and the needle hole is different
 Uptail feet with small hole:for less gsm fabrics

Over lock foot

 For 4tread:short
 3 tread over lock: thin and long

Flat lock
 For bottom hem: have gauge
 Sleeve hem: have hole
 For neck bottom binding: flat without gauge.

Planning

Capacity offering
 Jay jay textile company

mercendizer contact with buyer

ISO standard will be checked by

the buyer

first po will forcast to the

mercendizer

mercendizing prepare po for

the 1st accessary

pcd(plan cut date)

tna(time and action)

until mercendizingfulfill all the accessarys @ the same time plannining will do
–what type of m/c is needed
-how many machine is needed
-How many day we needed to finish the order

Job creation
Linking the job

Start production

Follow production
Fig 3 planning flow chart

Types of mercendizing
1. Market: head of mercendizer which have directly connection with
the buyer and doing the costing also.
2. Supply chain: have connection with supplier
 Jay jay textile company

3. Sample mercendiser: follow sample

4. Production mercendiser: follow production, start production.
During sample making there are 5 steps
1. Lap dep: these lap dep is received from cirilanka from supplier by
color cad
Then balk pg: by seeing from the cad bulk pg (bulk garment is
prepared)
2. Developing sample: with any kind of garment they send the
buyers see only the construction.
3. Fit sample: after developing sample fit sample will send to the
buyer now they will see both construction and measurement.
4. pp sample: after approving fit sample pp sample will send at this
time actual measurement, actual construction and accessary will be
checked.
5. Top sample: after approving pp sample the final step will be top
sample after approving we start production and finally shipment.

Mercendizing flow process

Mercendizers communicate with

buyers
 Jay jay textile company

Po received

After order received check capacity

Sample making

Bom (bill of material)

Po released to supplier

Check actual grn and received grn

Supply payment check

pp meeting

Production follow

Production process

Risk analysis meeting

After one week pp meeting

Order receive
 Jay jay textile company

IE make lay out

Mockup sample

Allocating operators

Fabric in put

Fabric check

Follow production
Fig4 production flow chart

Fabric inspection

Receive packing list and invoice from store

Select the fabric roll based on lot no, rollno, qty &
fabric type & width

Select 10 from the packing list

 Jay jay textile company

Take the selected roll to inspection

Clean and switch on the machine

Start inspection with approved shade

card/sample check fabric width
Ok not ok

Calculate the point for each defect Inform to QA and tpd manger

Pass fail

Pass 20point send the roll to the 20 reject roll and store in
same location rejected area

Accessory store

Receiving package in
receiving area

Check accessary by using in

voice

Grn (good reciving note)

 Jay jay textile company

Racking based on
 Item wise
 Color wise
 Size wise

Job preparation based on pick lest

Release to issue

Dc (delivery channel)

Fig 5 fabric inspection process

Cutting flow chart

 Jay jay textile company

production The required Marker the

The roll fabric spread
order format fabric type master pattern
according to the
receive from receive from on a single
required amount
the production the store fabric
manager

The Single
Sorting and
fabric which is
Cut the spread Numbering the bundling
marker placed
fabric cutted pieces according to
at the top of the
size
spread

Issuing the
pieces to
sewing
department
 Jay jay textile company

IE (wok study)
Responsibility of iE
 Lay out making
 Balancing
 Improvement(multi skill) of operators
 Increase productivity by reducing man power
 Increase salary
 Forecast
 Prepare operation break down(what kind of operation is needed)
 Kayzen system

IE

Work method measurement method

(By observing) (By measurement time study)
Smv(standard minute value):means in how much minute one pis of garment
finished.
SMV=(basic time *allowance)+basic time
Basic time= observe*rating
For example observe rate
45……..100%
40……..90%
30………80%
During obeseving when if one grl is 45,the second girl is40,the tird is 30 we
give the first one 100% rating the second 90 the tird 80.after that we take the
highest among the three Then we can calculate the basic time and smv.
 Jay jay textile company

SMV=45+ (45*10%)
HOURLY TARGET= time (3600sec)
SMV
Individual efficiency =number of pies*SMV
Time
Line efficiency=number of pies*SMV
Number of carder*time
Or we can use this formula eff=SAH
TIME*SMV
n Nam operatio Sm 100 1 2 3 4 5 Averag Allowanc No Efficienc
o e n v %targe e e of y
t 12% pcs
1 Heat seal 0.20 300 1 1 8 1 1 10 11 32 109%
0 1 0 1 7
2 Shoulder 0.30 200 2 2 2 2 2 24.2 27 13 66.5%
attach 2 8 4 3 4 3
3 Neck rib 0.20 300 2 2 2 2 2 23.6 26 13 46%
make 3 2 4 5 4 8
4 Neck 0.45 133 4 3 3 3 3 34.6 39 92 69%
attach 1 1 2 5 4
5 Neck 0.35 171 2 2 2 2 2 22.6 25 14 84%
binding 0 0 2 3 8 4
6 Sleeve 0.55 109 2 2 2 2 2 25.2 28 12 117%
attach 3 4 7 8 4 8
7 1st side 0.30 200 1 2 1 2 2 20.2 23 15 96%
seam 9 1 7 3 1 6
8 2nd side 0.35 171 2 2 2 2 2 24.6 27 13 77%
seam 6 3 4 2 8 3
9 Bottom 0.50 120 2 3 3 2 3 30.2 32 11 93%
hem 6 0 6 6 3 2
10 tuck 0.20 300 2 2 2 2 2 24 27 13 77%
3 2 3 5 7 3
11 ironing 0.45 133 3 3 3 2 3 30.3 34 10 78%
2 0 1 9 1 5
12 packing 0.60 100 1 1 1 1 1 11 12 30 300%
2 0 0 1 2 0
 Jay jay textile company

350

capacity chart 300

300

250

200

156
150 133 133 133
128
112
105
100

50

0
Category 1 Category
Series 1 2
Series 2 Category
Series 3 3 Category 4

Bottle neck area is 92 so in this time we can balance one girl which
have high capacity and increase the capacity to 120 and improve
there effecinecy.
Type of production system
Bundle system: work by bundle like when sewing 12 bundle then pass 12
bundle to the next operation.
Pcs movement system: sewing one pcs then after pass the pcs to the next
operation.
Section wise: after sewing three pcs then pass.
 Jay jay textile company

The main thing iE do is less man power with the same target
No of carder Pcs 8hr efficiency
13 200 1600 85%
12 200 1600 92%
11 200 1600 100%

Operator evaluation
Proceger
1. Every 3 month once, they eligible for evaluation
2. three month absenteeism percentage should be less than 3%this is done by
hr department.
Operator grading
a) 1800 birr
b) 1650 100 birr in every level
c) 1550
d) 1450
e) 1350
Ap3-1350
Ap2-1270 without evaluation
Ap1-1200

When they finish the 3 month evaluation in E grade level after evaluation if
they pass they will move to the next level which is d grade. If they fail after
one month they will evaluate again.
A, B, C [skill operators]
D, E [semi skill operator]
Grade minimum requirement
A……………………..2/4
B……………………..3/5
C…………………….2/4
 Jay jay textile company

D……………………..2/3

Operation skill point defn

Skill 3x /skill/intermidet+basic/3basic
Intermidet 2x intermidet +2basic
Basic 1x basic

Efficiency=achieve target
Set target
OB (operation break down): is prepared in sirilanka
 Based on buyer the construction vary
 Based on construction smv vary
Ob consists of
 What kind of m/c is needed
 Time
 m/c operation
 smv

During time study we don’t consider this

 m/c breakage
 trimming
 waiting
 thread breakage
 record trick
 bundle handling
 Owen repair
 We are not considering this kind of things because there are easy to eliminate
and we don’t know when it will happen.
forecast
 Within half an hour must be completed
 forecast based on capacity of line
Before forecast
 check balance
 check absentism
 Jay jay textile company

 balance check capacity

SAH (standard achieved hour) =number of pcs*SMV

60m

Incentive calculation
 to get more production the company gives incentive to the worker
 incentive is not your right
 incentive gives for motivation in order to increase production
For new style
 1st three days factory gives efficiency
 After three days incentive gives based on their efficiency
Types of incentive
 Individual
 Team
 Factory
The main advantageous is team incentive because line production
will increase team work will develop.
Lay out
1. Line with center table and operates facing same direction
2. Line with center table and operates facing opposite direction
3. Side by side
In jay jay u-shape lay out is used
Operation class code
1. Ol-over lock
2. Sn-single needle
3. Dn- double needle
4. Fl- flat lock
5. Fs-flat seam
6. Pc- pico
7. Sb-snap button
8. Hs-heat seal
9. Ir-iron
 Jay jay textile company

10.Btk-bar tack
11.Sp-spicial machine
Basic operation
1) Sn- tack label
2) Sn-sleeve tack
3) sn-neck tack
4) Sn-button tack
5) Sn-foot tack
6) Sn-tack operation others
7) sn-shoulder tack
8) ol-sleeve rib tack
9) ol-croch attach
10) ol-top foot attach
11) ol-front and back rise
12) ol-ring attach
13) fl-sleeve binding
14) pc-picco stich
15) hs-heat seal operation
16) rc-rib cutting
17) ir-gusset ironing and gusset with planket
18) sb-button attach single side
19) btk-bar tack
intermedet operation
1) SN-arm hole tack
2) SN-tab make
3) SN-attach label
4) SN-shoulder planket close
5) SN-sew dart(on rapil pant)
6) SN-tack bottom end(focling,planket)
7) SN-frill attach
8) SN-elastic attach
9) SN-gazering operation
10) DN-elastic out line
11) FL-sleeve hem
12) FL-front and back neck binding
13) FL-top stich
14) Ol-side seam
 Jay jay textile company

15) Ol-merrow over lock

16) OL-inseam
17) IR-full garment pressing
18) OL-shoulder joint

Skill operation
1. SN-zipper attach
2. SN-front facing attaching
3. SN-pocket attach
4. DN-pocket attach
5. SN-collar attach
6. SN-tab attach
7. OL-foot attach
8. OL-sleeve attach
9. OL-sleeve attach with arm hole
10.OL-side in inseam
11.OL-cuff ataach
12.OL-rib attach
13.OL-elastic attach
14.FL-sew sleeve hem
15.FL-neck bindig
16.FL-sew binding body around
17.FL-neck binding
18.FL-bottom binding
19.FL-bottom hem
20.FL-wast elastic attach
21.FL-arm hole binding
22.FL-out line opertation
23.FL-waste band band attach
24.FL-elastic attach
25.FL-flat seam operation
26.SB-button attach gusse and shoulder shink planket
 Jay jay textile company

Production process
 Production process is converting raw material in to final finished goods.
 Main department of the company others are supporting department.
6th sigma or 5m
 Man power
 Machine
 Material
 Method
 Money
By using this 5m we can convert material into final goods

TPD
Accessory
planning store
FABRIC STORE

Production
line MENTENANCE
HR

FGS
MERCENDIZ
ING

 Production process 100%use managing way to utilize 100%capacity

(leadership) when handing the people.
 Leadership: action to manage people or group leadership is very
important in the production floor.
 Discipline
 Personal reaction
 Personality must be good it helps to build
the group
 Jay jay textile company

 Being part of the team

 Take care of our people
 Build friendship with the team

Time management
 Arranging thing to do some activity
 Organizing and bujeting time with purpose of some activity this is a
key to increase our efficiency.

Time management

Task

To do

Priority

Project

plan

Achievement
 Jay jay textile company

Recut
 Before recut we need some rejection…..un repairable garment
 Recut slip fill by quality supervisor and contains
-item number
-line number
-style number
-time
-damage part
-quantity
-size
-fabric
-reason code
 Before last hour the slip must fill.
 Writing the reject in the packing book need to ask excess
fabric >2% in this process they need a db report.
2%QTY=Order QTY*2%
Assume order quantity is 1000
1000*0.02
20pcs
FABRIC2%=2%QUANTITY*CONSUMPTION FOR 1GMT
=20*0.25
= 9.4M
Calculating missing
For e.g balance =160
In line =10pcs
Reject avaliable Missing pannal Recut
Full 5 10 45 0
 Jay jay textile company

Back 40 25 125 80
Front 35 45 105 60
Sleeve 60/2 120 180 90

Reconcelltion
 This report is used to know how much balance we have
Order quantity=1000pcs
FGS send=815
Balance =125pcs
Result =full 70
=back 55
Recut%=reject *100%
Order quantity
 During reconciliation we consider 6 sleeve as one garment and 2
panel as one garment.
Back panel 30 before heat seal

20 after heat seal

In line requirement
Heat seal 35 90
Label 125 -

Back 55/2=27
Recut full garment =70+27=97pcs
Fabric 2%=97*0.45
=44meter
Difference 44m-9.4=35m (excess) more than 2%
For example if the balance is 130 and when we see the rejection it is
125 and the 5 is missing.
 Jay jay textile company

reject requirement
full 60 0
back 10 10 front
front 40 40 back
sleeve 15 115 sleeve
125
Accessary reconciliation
Reject In hand required balance
Heat seal 5 14 19 5
label 0 19 19 0
Price ticket 0 19 19 0

Production plan

Planning department make the production plan egards to production

After po required planning department divided the job for each line
wich is arranged by planning department.

Process
1. Release 1st po
2. Prepare plan then divide to line per pcs
During line distribution –how much days
-shipment plan
3. Make shipment plan and know when shipment is going
planning department is prepared 6 month then dived in to
month
Monthly: -determine material required (machine)
 Jay jay textile company

-weather the current machines are used for the

plan or not
-type of machine
6month plan will give to the head of the shed then he will
distribute month plan to the lines and the lines are doing daily
plan to achieve the target.

 Full fill the the required detail properly in order to finished

the order until the shipment date.
 If the performance of a particular line is low it has own effect
like :
-not complete the required order on time
-it will be burden for other line
-the line cannot have enough time for the next shipment.
Advantage
N.b: main advantage is having plenty of time to arrange recut
2. Send (shipment) on time
3. Having time to train operator in other machine
4. Can start the next month plan
Production claiming
 After issue note writing then send to AQL then send to FGS we must
full fill the issue note because we are following atom system. Then
issue note convert to dc paper so by using this detail information
inter to the system then deduct from the system. The selected item is
inters to the system the atom will accept but if its d/f the atom will not
accept b/c planning department link particular pej and sej.