CHAPTER-1: INTRODUCTION

1.1 Background Title

In the garment industry, the fabric is the backbone of the industry. It is very important that the
use of fabric should be done carefully because the cost of fabric is too high from other factors. .

Generally, in an industry the main target is on the profits of the company.Despite the fact that
there are various costs engaged to decrease internal cost invested by a companyonfinding out the
wastage, forestalling or redressing inadequate work. Non value added activities comprises of all
the movement that consumeris ready to pay for.

Non-value added activities depict that the buyer does not analyze as increasing the value of his
item (for ex:-holding up time, review time, no legitimate arranging, inappropriate machine use,
lack of workers, laborers' weariness and so on.) One of the way to minimize wastage can be
disposal of non-value added activities that can result in a decrease in time and cost. It differs with
the end goal of determination. As it is realized that time is cash, if additional time is needed in
goods more cash is included. By responding speedier to prepare an item according to buyer
requirement,the organization will contribute inferior money and much preserving. Hence, an
investigation was completed in an article of apparel industry situated at Jharmajri, Himachal
solan, named Gini and Jony at a cutting area about the procedure stream to recognize Non-value
added activities in order to dispense with them for sparing time, cost and improve inside
throughput time.

1.2 Problem Identification

 Work has been done in the Gini & Jony, manufacturing into woven and knits products i.e.
T-Shirt, shirts, trousers, jeans, Capri, dungarees, top, Jackets, dresses, etc. and many
more articles related to woven and knits. The overall production capacity is of 8000 -
10000 pieces per day. However, it’s been observe during the production survey
conducted to reduce the defects and non- value added process in cutting which causes the
overall cost of manufacturing and replicated the finishes of the final pieces produced.
Some of the problem faced in the cutting department of Gini& Jony is as follows.
 1. Unequal layer cutting
2. The Manual Spreading process are taken lots of time
3. Fabrics are not equal in spreading
4. Cutting the wrong size ratio
5. Wrong spreading of fabric
6. Mismatching of checks and strips during cutting
7. Wastage of fabric during face to face layer cutting
8. Wrong marking on the layer
9. Double pattern marking

Table 1.1: Different Problems that have been identified

Sr. Problem identified Explanation
no.
1 The Manual Spreading
process are taking lots of
time
2 Fabric spreading are not
equal

3 By mistake double pattern

marked

4 - Cutting the wrong size

ratio
5 :- The Wrong spreading of
fabric

6 -figure shows the unequal

cutting of fabric layers.
Because of damaging the
electric layer cutter

7 - Mismatching of checks
and strips during cutting
The above table ( Table 1.1) shows different kinds of problems that have been identified like
fabric spreading are not equal, double pattern marking, mismatching of checks and stripes etc.

1.2.1.Objectives

 Save cost and time

 Reduce non value added activities
 Proper utilization of manpower
 1.3 Company Profile

1.3.1Introduction Of Gini & Jony Pvt.Ltd

Gini & Jony Pvt. Ltd brand sells apparel through a mix of company-owned and franchised
outlets and is currently present in 106 cities with 1200 exclusive brand outlets and other large
format multi-brand stories, like shopper stop, lifestyle stories,pantaloons, etc.” while the
promoter group holds the majority stake in the organization, the company is partially owned
(22%)by Anil Ambani reliance capital.

GINI & JONY PVT.LTD.

Table 1.2: Overview of Gini & Jony PVT.LTD.

Industry textile apparel and luxury goods

Founded 1980

Founder Prakash Lakhani, Jay Lakhani, Anil Lakhani

Headquarters Mumbai, Maharashtra India.

Key People Prakash Lakhani (Chairman), Jaikrishan H.

Lakhani, (Executive Director).

Products Apparel

No of employers 580

Area 9800 sq. ft belt up area (9800×3) =29400

Annual turnover 300 Corers

Website www.giniandjony.com

Brands Palm Tree, GJ Baby Dreams, GJ Jeans,

Freedom wear, GJ Gold

Sizes I (12M, 18M, 24M) , K(2, 4, 6, 8), Y(10,12,

14,16)

Styles GIRLS & BOYS KIDS WEAR

PRODUCTS T-Shirt, shirts, trousers, jeans, coordinates,

Capri, Dungarees, top, Jackets, dresses, etc.
Accessories: socks, belt, bags, caps

Timing: 8: AM to 4:30 PM
The above table (Table 1.2) shows basic information of GINI&JONY PVT. LTD. where the
research process has been done. It includes information like name of company, infrastructure,
etc.

Head office

Gini & Jony apparel pvt.ltd (head office) A/601, city

point building, Andheri East, Mumbai -40059 (Next to hotel Kohinoor continental) In 2005 the
company also constructed two manufacturing units at plat 2d and plot no. 47 at Epip, Jharmajari,
Baddi Dist. Solan, H.P.

Production capacity and sourcing

The total capacity of over 12 million garments p.a. 0.9 million manufactured at Daman and about
0.3million manufactured at the Baddi unit. Apart from that, they also outsource approximately 2
million garments P.A. from the dedicated production unit in various parts of the world.

DESIGN STRENGTH

Introducing area 700 designs with 2 collections in a year Spring-Summer, and Autumn-Winter.
 CHAPTER- 2: LITERATURE REVIEW

2.1 Current Status of Research

A.T. M. Mohibullah, Umme Magreba Takebira (2017) this study worked on reducing the
non-value added process in time utilization at cutting area. Its concentration on the cutting area
of the garment industry for description and removal of non-valuated procedure of cutting.

Parthraj Puranik, Saloni Jain (2017) focused on the marker plan to reduce the avoided
wastage by choosing the best suitable procedure of planning by using computer-aided marker
planning
Elmira Dumishllari, Genti Guxho (2016) focused on suggesting solutions like good weight age
efficiency and low consumption by using Gemini CAD for the purpose of lay plan combination.

Md Nazumul Haque (2016) this study worked on marker efficiency by using software like
pattern modification and designed Lectra Modaris V6R 1.6.1 and marker making using Lectra
diamino fashion V6 software. So that more efficient marker with less fabric consumption can be
obtained.
Elmira Dumishllari, Genti Guxho (2015) experimented with the number of markers to get,
different marker efficiency on cut plan efficiency and its consumption and suggested solutions of
the cut plan with high efficiency and low length.

Md. Mazedul Islam, Adnan Maroof Khan (2013) worked on it steps has been taken to
examine and reduction of wastages, that is, non-productive activities in sewing area so as to save
time and cost and decrease internal procedure time. In this work, a way to deal with more
information based and incorporated procedure planning and control is displayed. The result of
this perception shows that industry may increase higher production efficiency and gainfulness by
reducing non-profitable activities.
W.K. Wong et. al. (2005) worked on an optimization model for manual fabric cutting process
based on Genetic Algorithm by using manual spreading and cutting method fulfillment rate was
improved for both cut pieces required and the makesplan fabric cutting department.

W.K Wong et.al. (2000) many research has been conducted from machines scheduling and flow
shop sequencing problem use GA is applied for line balancing problem in the garment
manufacturing industry. This application has only being confined to the sewing operation it was
observed that industry adopted SCS model using GA to solve the sequencing problem. The result
obtains between the actual production cycles under the proposed model using GA.

C.L Hui Patrick, et. al. (2000) this study has been carried out investigated in spreading by GA
(genetic algorithm) and explains, however, the matter of roll coming up with will be developed
for GA to unravel. The result of the study shows that associate best role coming up with being
found out by victimization GA approach. It is done for able to avoid wasting a substantial
quantity of cloth once the most effective roll coming up with is employed for the assembly.

2.2 Concluding Remarks

It has been concluded that these literatures are very effective for cutting and spreading section.
With the help of all these literature reviews, we can do better work in our research work. They
are very helpful in practical life. They give the idea about different technologies used for cutting
and spreading in the garments industry. All literatures are related to the cutting and spreading of
the fabric and non-value added process of the apparel industry. We can use all these reviews as
guidance for our report. These literature reviews provides the proper information about value
added and non-value added processes which are extensively used in planning of cutting process
till bundling of cut panels.