Presented By:ANKIT JAISWAL RAHUL TELANG DFT, SEM VII

COMPANY PROFILE

Established by Mr. Janardhan Agarwal is presently the largest shirt manufacturing company in India. Their fabric manufacturing facilities are 50 million meters per annum. Their garment manufacturing facilities are 35 million pieces per annum.

CENTRAL WARE HOUSE

CENTRAL WARE HOUSE FABRIC WARE HOUSE TRIMS STORE

FABRIC WARE HOUSE

RECIEVE
INSPECT
STORE ISSUE

FABRIC WARE HOUSE

They have huge capacity for fabric storage, around 40 lakh meter fabric. Their total Storage area is 60,000 sq. feet. They have handling capacity of around 16 lakh meter fabric per day. Details on fabric rolls:

GSM Buyer P.O # Length in meters Width in inches

FABRIC WARE HOUSE

After the fabric is in house, 2 pieces of 25x25cms or 50x50cms was cut from each roll. One was sent for shrinkage check and other was checked for shade variation if any. According to shrinkage, changes were made in the pattern in sampling CAD department. And according to shade variation lots were made.

FABRIC WARE HOUSE

There was a lot of fabric wastage due to following reasons:

On top of 3% allowance on fabric that the buyer gave another 5% extra was given by merchandiser and the supplier also added 5% on the ordered fabric. Poor fabric quality

And also due to,

Order reduction Excess lay length

TRIMS STORE
RECIEVE

CHECKING (QUALITY/QUANTITY)

MRN (MATERIAL RECEIPT NOTE)

STORE

ISSUE

SAMPLING
PATTERN MAKING COSTING MARKER GRADING CONFIRMATION OF FABRIC FROM MERCHANDISER ADD SHRINKAGE LOADING DETAIL TO TAILOR

WASHING
QA & FINISHING

SAMPLING

Produced 100-120 garments/day

A+ Operators
Time taken to produce one shirt = 2 hrs Workforce = 142

If less order quantity, production is carried out in sampling department itself.

SAMPLING

Critical areas for checking:

Collar attach and finishing Sleeve attach and finishing Sleeve placket attach and finishing

For check fabric matching was also a criteria Machine adjustment is important for different fabric such as needle, spi, thread, needle gauge, feed dog, etc For eg : For linen fabric as handling was difficult a ball point needle was used.

CAD

The software being used for marker making was of GERBER. Constraints for Marker Making

Size Ratio Dependent Per Garment Consumption Wash Detail Check Matching

Marker Utilization for Shirt

Checks 83-85% Stripes-85-87% Solid-87-90%

CAD

Types of markers being made

CSV Non CSV One Way Group Marker

SPREADING

Total 24 tables, 18 for plaids and plain fabric and remaining 6 for checks fabric. Plaid and plain fabric were spread by automatic spreader with the help of 2 spreaders. While, check fabric spreading was done manually with the help of 4 spreaders. 10 pin tables were also installed for checks but due to bowing problem, spreading was done manually.

SPREADING

GERBER spreader:

Spread length 5.20 m Time taken to spread 19.54 sec 2 spreaders

Manual spreader:

Spread length 5.96 m Time taken to spread 34.38 sec 4 spreaders

CUTTING

Cutting department is responsible to distribute cut pieces to all sewing units in Bangalore, it is spread over 97000 square feet. It has a maximum capacity of cutting 1 lakh pieces per day. It has 8 GERBER automatic cutters and 2 Morgan Razor cutters

CUTTING

GERBER Cutter

Knife- 25.1 cm stone knife Motor- 50 hp Speed min 2650 rpm, max- 4200 rpm Ply height- 7 cm with vacuum

Morgan Razor Cutter

Knife -30.1 cm belt knife Motor -20 hp Speed min 2500 rpm, max 4000 rpm Ply height- 4 cm with vacuum

EMBROIDERY

It is spread in an area of 13500 sq feet with capacity of 4500 pieces per day for pocket and 3600 pieces per day for yoke. There were total 21 machines out of which 10 were of Barudan, 10 of Tajima and 1 of Fieyu for sampling. The cost per 1000 stitches were 80 paisa.

EMBROIDERY

Flat Head Machines

Company Tajima Thread used- Cotton Size of Embroidery-Small Logos Quality-Medium

Round Head Machines

Company-Barudan Thread Used-Silicon Size of Embroidery-Large Logos (writings) Quality-High

QUALITY ASSURANCE

After receiving the fabric shrinkage report, the rolls were sent again for shrinkage rechecking. Then reports were cross checked, if matched then it was approved for bulk production. If not, then it was put on hold and according to shrinkage pattern changes were advised and proceeded to stitching.

SEWING

The stitching unit is spread in an area of 196227 sq feet with a capacity of 22000 pieces per day. There are a total of 2685 machines.

There are 18 lines of Unit Production SystemETON installed for assembly with 33 work station in each line.
Garments produced per day per ETON line is around 800 pieces but its capacity was 1200 pieces/day.

SEWING

Advantages of ETON system:

Less material handling Increased efficiency Increased productivity Increased quality Better space utilization Flexible High cost Suitable for large order quantity Garments containing less components

Disadvantages of ETON system:

SEWING

Time loss on sewing floor:

Loading delay Due to delay in cutting section which happens due to delay in fabric. No feeding Fabric rejection in quality checking or high defect fabric So, 100% panel checking is to be carried out which takes more time than required, which also results in loading delay. Start up loss Operator not at m/c. Sitting idle. No feeding available.

SEWING

During the delay alteration work can be carried out so that operator is not idle. Some other style can be set on the lines if there is no feeding for some days. Feeding from nearby factory can be taken so that there is no idle time and money loss can be avoided. The workers should be made aware of the time loss and the consequent loss in production.

Supervisor to be held accountable for unscheduled breaks and disruptions.

FINISHING

2.5 AQL level is being followed in the organization but it can change as per buyer requirements. Wrapping was done after the button attachment to reduce abrasion with the fabric, hence increasing durability. Garments were sent to another unit for washing which increased the time of finishing by 2 days.

PACKING

Types of packing

Online Ratio Pre Pack Bulk

Carton Details

PO # Style # Color Size Quantity Country of Origin Gross Weight Net Weight Carton Measurement

PACKING

Documents required while shipment

Proforma Invoice Packaging List Bill of Lading Country of Origin

HRM ISSUES

Labor Turnover was high as the operators used to leave after gaining the required skill. As skilled laborers were paid more in other factories. In order to overcome this, a training program was started in the unit.