CUTTING ROOM…

A STUDY FOR PROBLEM

IDENTIFICATION
AND
SOLUTION
CUTTING ROOM
PROCESS FLOW FOR SOLIDS CUTTING
PROCESS FLOW FOR YARN DYED
CUTTING
IMPORTANT STEPS & OBSERVATIONS

IN

CUTTING ROOM
 FABRIC INSPECTION & AUDIT DEPARTMENT

OBSERVATIONS:
Fabric inspection is done for each and every roll from a batch. Inspection is done for
the fabric faults and to check the width of each roll of fabric. But it was observed that
every bundle was not being checked for the width.
Mostly due to workers being uneducated about faults many times roll with faults are
passed over to audit department.
Sometimes due to lac of knowledge defected fabric is passed and for the same
reason less defected fabric is bundled under defected category.
No humidity and temperature measuring instruments are available.
GSM of fabric is taken without drying it.
No instruction is given to rolling operator about the dimension of fabric to be cut for
GSM measurement.
GSM of roll is taken from very localized fabric area i.e. from the same part of roll
instead of taking from different areas of roll.
 SUGGESTIONS:

oProper lighting should be provided.

oImproper inspection table.
oInsure fault highlighting stickers are properly sticked to the fabric of roll.
EACH AND EVERY FABRIC ROLL MUST BE CHECKED FOR
WIDTH AT LEAST TWO TIMES; AT START OF ROLL AND AT
MIDDLE OF IT.
CORRECT INFORMATION REGARDING ROLL MUST BE FED
IN SLIP.
IT MUST BE TRIED TO CHECK THE GSM OF EACH ROLL OF
FABRIC.UNDER STRICT SUPERVISION.
EMPLOYEE EDUCATION IS VERY NECESSARY HERE.
SAMPLES OF DEFECTED FABRICS OR PHOTOGRAPHS OF
THEM SHOULD BE MADE AVAILABLE TO OPERATOR.
DUE TO EXCESS HUMIDITY AND TEMPERATURE, THERE IS
MORE RELAXATION ALLOWANCES FOR WORKER WHICH
DECREASES OVERALL ON STANDARD TIME.
DUE TO MOISTURE CONTAMINATION OBSERVED GSM OF
FABRIC MAY VARY FROM ACTUAL ONE.
DUE TO UNSPECIFIED DIMENSION OF CUT PART WHICH IS
UTILIZED FOR GSM MEASUREMENT LEADS TO FABRIC
WASTAGE.
 FABRIC AUDIT DEPARTMENT:

OBSERVATIONS:

In fabric audit department 3-4 rolls are checked for width and gsm
of the fabric along with the fabric fault.
Many time GSM of the fabric changes from roll to roll and also in
the same roll.
Same thing happens with the width of the fabric.
But as each bundle is not checked these faults pass unnoticed to
cutting room
 SUGGESTION:

Cut part which is choosen for GSM measurement should be

taken from different location of fabric roll and avg of different
measurement should be marked as GSM of fabric.
Width of the fabric should be taken from different phases of
fabric roll ie 1st check when 15 mts are roll is finish. 2nd
measurement should be taken at middle of rolling process and
third at last.
 FABRIC WAREHOUSE
OBSERVATIONS:
 Fabric comes to warehouse from audit department with
audit report.
 Fabric is stored according to buyer’s name
 There is no check of fabric prior to storage in the
warehouse.
 Fabric is not segregated according to width or gsm of fabric.
 Rolls of fabric do not have ‘width’ and ‘gsm’ information
on them
 RELAXATION
OBSERVATIONS:

 No proper relaxation machine.

 Machine that is used does not have proper attachments.
 Fabric handle is done manually. This causes fabric
disturbance and relaxed fabric gets ruffled.
 No accountability in this department.
 No standard way of fabric storage after relaxation process
 SUGGESTIONS:

 Spiral rollers should be used instead of plain rollers.

 Tray should be used in which fabric is collected and
loaded to spreading machine along with the tray,in order
to avoid distortion in fabric structure.
 Proper accounting of relaxed rolls should be done.
PROPOSED EASING MACHINE VIDEO
 process video of ideal spreader machine

Oshima
Serkon
F.N
 SPREADING – SOLIDS (AUTOMATIC)
(OBSERVATIONS)

 Used speed of machine is very low in the range of 7m/min;

running speed being higher.
 Target is not achieved even after excess operators being implied
on spreader.
 More than optimum lay length being laid.
 Lack of attachments in the spreading machine.
 Lack of specific data of rolls leads to off time.
 Improper handling of fabric.
 On table no 3 lays are aligned from one side of table only because
of its more width
SPREADING – YARN DYED
 Excessive manpower allocated in this department.
 Hand shears is used instead of end cutters leading to increase
of manpower need.
 In yarn dyed spread length is generally for a single piece of
shirt leading in the need of excessive manpower for laying
SHIFTING OF THE LAY TO CUTTING TABLE:

 While shifting of lay from spreading table to the cutting

table air floatation table is not used properly.
 On table number 3 plies are aligned from only one sideby
the operator which causes difference in size of patterns.
Suggestions:
DECREASE RUNNING SPEED OF SPREADER TO AVOID
TURNING OF PLIES UPSIDE DOWN.
KEEP LENGTH OF SPREAD BETWEEN 7-8M. THIS WILL HELP
IN FASTER AND PRECISE LAY.
ONE OPERATOR SHOULD ALWAYS TRAVEL ALONG WITH
THE MACHINE TO FIX ANY BLOCKAGE IN THE PASSAGE OF
LAYING. AT THE BEGINNING ITSELF.
SPIRAL ROLLERS SHOULD BE USED INSTEAD OF PLANE
SURFACE ROLLERS. TO INSURE EVEN LAY
.
TWO DIFFERENT LAYS OF TUBULAR KNITS CAN BE SPREAD
AT A TIME TO UTILIZE MAXIMUM WIDTH LAYING CAPACITY
OF SPREADER
CONTINUES…
 Spreading operator have no data about width of roll which causes
spreading of rolls with different widths ,this will createloss of fabric
as marker is made according to roll of minimum width.
Due to this sometimes whole plies related to one role has to be taken
off which decreases efficiency of spreader
 Replace hand shears with end cutters. This will decrease labor
requirement from 4 to 2.and will also increase efficiency of lay.
 Instead of laying for single piece one can make a block for two
piece and after laying block can be cut and operated separately.
 Beforeshifting of lay make sure that air flotation is on and running
at highest level. This will decrease tension in lay due to pulling and
also distortion in lay.
CUTTING – SOLIDS & YARN DYED
 All the previous process have an impact on cutting of the fabric.

 Machine stoppage due to lack of feed is high.

 Many times change in the width and gsm of the fabric leads to increase in idle time of auto
cutter.
 Machine stoppage for maintenance is high and frequent.

 Cutting of yarn dyed fabric is done by straight knife & shears

STUDY CONSIDERING WORKER
& OPERATOR
1st/ Improper water supply. ie chilled water is not
available which sometime increases relaxation
allowance and worker rating decreases so as
production.
UNHYGIENIC CONDITION NEAR WAREHOUSE AND WORKER
PLACE OF EATING WHICH INCREASES ABSENTEEISM % DUE
TO FREQUENT DISEASES DUE TO URINALS IN VICINITY
NO TEMPERATURE AND HUMIDITY MEASURING
INSTRUMENTS IN FABRIC PROCESS DEPARTMENT.
CLASSES SHOULD BE ORGANIZED TO MAKE WORKERS AND
OPERATORS REALIZE THAT STAKE OF THEM AND COMPANY
IS’NT DIFFERENT.
MOTIVATIONAL AND RECREATIONAL CAMPS SHOULD BE
ORGANIZED IF FEASIBLE.
CUT PARTS INSPECTION

 For checking of prints instead of measuring with tape we

can have pattern of print to insure its right alignment.

print

panel

pattern