Professional Documents
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Asin
Asin
RAYMOND
PRESENTED BY :
ASINE AMON SOY
GYANENDRA KUMAR
INTRODUCTION ABOUT THE COMPANY
SSAL II (SILVER SPARK APPAREL LIMITED)
GAURIBIDANUR
Raymond Limited
Manpower 1998
Business across the world 55 countries in North America, Europe, and Asia
ORGANISATIONAL STRUCTURE AT RAYMOND :
Industry Layout :
COMPLETE PROCESS FLOW
Order
Order received Product Production
confirmation at
from SSAL Merchandising Merchandising
SSAL
Finishing
Sewing Sewing Quality Finishing
Quality
Department Checking Department
Checking
Customer
Packing Warehouse Shipment
or Buyer
PATTERN DEVELOPMENT DEPARTMENT :
OBJECTIVES
Getting approvals from buyers based on the samples
produced.
The Sampling Department produces the base
patterns from which the samples are produced and
send to the buyer for approval.
Checking and analyzing new styles, defining quality
terms of new styles to production department.
FUNCTION
The sampling department also calculates the
consumption of fabric required to produce the
garment.
The sampling department also access for
accessories and thread consumption for that
particular garment.
Based on the sampled garment the costing is been
carried out.
1. Fabric received from the mill
2. Unloading
4. Bale opening
5. 4 point inspection
6. Bar-coding
7. 12 parameter preparation
8. Fabric Inspection summary-report
generate
9. Sending the report to CAD department
Breast Breast
Front Front Front
pocket Pocket Attach
Pocket Pocket Pocket bag
Attach & canvas
Zig zag pressing Bag attach Close
Close
Front Armhole
Side seam Side seam Bottom
Block Canvas Basting
attach Press press
press Cut
Shoulder
Facing Blind-
Attach + Neck Collar Press
hem
band Stitch
COLLAR SECTION
Bridle tape
Canvas Felt attach to
Attach to
Ready Canvas
Canvas
Sham hole Elbow seam
Elbow seam Cuff press
mark & sew press
Arm hole
Sleeve head Sleeve head
lapel Press Sleeve attach Seam Open &
making Attach
Press
Button hole
Button hole Button hole
Arm hole close Vent close sew /flower
marking bar tack
hole sew
trimming
A customers interest in a garment is evoked by the final
presentation of it in any store. The finishing department does just
that, in the sense that it ships neatly packed goods.
Wrappin
Lining Button
Blocking g&
Pressing Attach
Knotting
Lapel Quality
Touch-up Auditing
Pressing Check
Packing
A ware house is a
Sorting done PO
commercial building for wise then Color
storage of goods. and size wise
Proposed solutions :-
KAIZEN (WAX PENCIL)
LAYOUT
1. DATA COLLECTION:
AFTER :
This increased the production by 13 pieces hourly and in 8 hour
shift production was increased by 104 pieces.
COSTING :
Every piece of the breast pocket was maually marked and cut.
Which gives a total of 54 seconds that is consumed to ready one piece of breast pocket.
NEW CONCEPT ABOUT THIS
BOARD :
In this 30 to 40 pieces are pinned together matching the checks by the lines on the board.
then it is clamped together and cut with the ban knife using the pattern .
OPERATIONS
TARGETED:
First operator :
taking of 2 welt pockets (left and right).
- closing the breast pocket.
- attaching the breast pocket.
-Closing the breast pocket.
Second operator:
attach the pocket to 2 the welt pockets.
Third operator:
closing the 2 welt pockets.
-close the 2 welt pocket bag.
SOLUTION :
One operator from the pocket bag attach was removed. The work of the first pocket
bag attach operator was divided into the zig zag machine before her and the other
two pocket bag attach operator ahead her.
Here 1 operator was saved.
The division of work was done as :
Zig zag operator did :
- the zig zag
- closing the breast pocket opening.
-attaching the breast pocket.
First pocket bag operator :
- taking of 2 welt pockets (left and right).
- attach the pocket to 2 the welt pockets.
Second operator did:
closing the 2 welt pockets opening.
-close the 2 welt pocket bag.
-Closing the breast pocket bag.
The SAM was reduced ,now the waiting time of the operation ahead was reduced.
WELT POCKET PRESS :
Before -Work done by the welt press operator was to cut the bone of both left and
right panel and press the welt of left and right.
The iron used for pressing and the table need repair as the steam and vacuum of
the table was not working properly. This caused over work and added to non value
added time.
SOLUTION:
As in the before lay out the welt pocket press was before breast pocket attach, the
lay out was changed and the work done by the welt pressing operator was divided
to the breast pocket press.
Now in the new layout the welt pressing had to cut only one bone by herself the.
BOTTOM HEM & FLAP PRESS :
PROBLEM :
1.In flap press, when ever there was a rework the operator had to cover a long
distance to the iron table .
2.On the other hand even the operator for bottom hem had to travel lot ,to the FIT
in case there was any rework.
SOLUTION:
The FIT behind flap marking table was brought beside flap press machine ,this
reduced the distance that both the operators had to cover before .
This reduced time consumed.
4. KAIZEN : WAX PENCIL
PROBLEM :
Pencil marks made during the matching of checks , on the welt pocket flap
and the breast pocket ,which are visible on the front .Which is later
removed in the finishing department using solvent (white petrol).
A shipment lot of quantity 10,000 was sent back for rewashing (rework) as
the marks of white pencil were still there .
SOLUTION :
How is it helpful ?
It is renewable .
Its saves operator of washing in finishing
department.
SUGGESTED LAYOUT :