Manufacturing process at Bata India

1. Raw Material Stock:

Raw materials consisted of were the chemicals which were used for making cement adhesive,
rubber latex and sole, cloth which was used for making the upper part, binding materials,
thread and the packing cartons were stocked in the warehouse. All the raw materials were
properly maintained with the help of a “material stock position”.
Every department was allocated with a maximum stock limit beyond which they cannot store
the raw material. After every fortnight the stock and the usage were reviewed. The transfer of
raw materials from the stock warehouse to its respective departments were recorded
accordingly and the same process was followed between various departments as well. All the
data was available for review to all departments.

2. Cement and Latex Manufacturing:

Cement adhesive and rubber latex were the main chemicals which were used to paste together
the different parts of a shoe. Both these cement adhesive and rubber latex were produced
keeping in mind the exact requirement and correct specifications which was the right mix of
chemicals and to make it the best pasting element so that the desired quality was obtained.

3. Sole Pull Manufacturing:

Inner and outer shoe required in the shoe were produced with the help of rubber sheets which
was measured around 3 ft. x 2 ft. which had a thickness of approximately 2 centimetres. This
rubber sheets were first heated to high temperature and were then placed in a curing chamber
for approximately 8 minutes where they ere again processed at a high temperature of around
170oc. Such high temperature resulted to expand the sheets and were then sent for
vulcanization.

4. Making Binding:
Binding was required on the outer part of the shoe to bind the edges of the upper cloth. This
Binding Material was also made in the plant itself using a cloth. It was machine stitched onto
the upper cloth.

5. Folding, Cutting and Stamping:

Cloth for the upper part of the shoe was produced by Bombay Dyeing. It was first folded into
huge lots and then cut into pieces of uniform sizes as per the different size lots. These cloth
pieces were then stamped with what was called as a batch number and the shoe size. After the
stamping was done the upper part of the shoe was then sent for stitching.

6. Stitching:
The stitching process basically started with the folding of the piece and stitching It in a
designated fashion to give a proper shape. After this it was sent for stitching the binding onto
the edges of the shoe. After the binding is done, the shoe was then transferred further where
lace holes and flips were used. The Last Step in the Stitching Process was to insert the laces
into the shoe which was done by hands.

7. Assembly:
The Assembly Process included a dual level conveyor belt. Fully Assembled Shoes were then
hand-picked from the conveyer belt at a particular point on the belt. It was indeed a very well
organized and systematic assembly line configuration wherein none of the employee sat idle
at any given point of time, thereby minimizing the idle time losses.

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 8. Vulcanization:
After the assembly process the next step was of vulcanization. Though the shoes were ready
but they were still very sticky and were not set for the usage. Therefore, this vulcanization
step was present to harden the shoe and to ensure that were pasted properly and whether the
chemicals were dried up or not.

9. Quality Control:
Once the vulcanization process was completed the shoes were all set to be packed but before
that there was an important step which was to check the quality also known as quality control.
At Bata India every shoe was checked manually by a quality check inspector and ratings were
assigned accordingly.

10. Packaging:
Once the quality control was done, the shoes were then packed very carefully to protect the
shoe from any kind of possible damage which may happen. Each pair of the shoe was first
rolled inside paper sheets and then those were put into cardboard boxes. These small boxes of
the shoes were then put into large cartons for the transportation purposes.

EXHIBIT TN-2: CALCULATION FOR TIME TAKEN IN EACH PROCESS

Setup
Process Labour time Run time(Hour) Total
(Hour) time

1. Cement and latex manufacturing 2 0.5 1 1.5

2. Sole pull manufacturing 3 0.30 2.2 2.5

3. Making binding 3 0.10 2 2.10

4. Folding. cutting, stamping 1 0.2 1 1.2

5. Stitching (Stitching, Laces holes and 4 0.75 2.7 3.45

laces)
6. Assembly 3 0.25 2 2.25

7. Vulcanization 1 0.7 2.1 2.8

8. Packing 5 0 1.8 1.8

Total 2.8 14.8 17.6

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 Raw Binding
Compound Chemical Shoe Thread
material cloth

Making Sole
Folding
pull
Making
Binding
Cutting

Stamping

Cement

Latex

Stitching

Assembly

Vulcanizing

Controlling

Packaging

Process flow chart of Bata shoes production

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