BY :-

ANUJ KUMARM.FTECH (A.P.)

Arvind Ltd. - A flagship company of a diversified $550 million Lalbhai group founded in 1908

Lalbhai Group Businesses are:› Textiles & Clothing's (Core Business)

Manufacturing ( Arvind Ltd., Lifestyle Fabrics & Apparels)

Retail (Megamart Retails)

› Financial Services (Anagram Sec. Ltd.)

› Engineering (Anup Engg. Ltd.)

› Chemicals & Dyes (Atul Ltd., Anil Starch Products Ltd.)

› Telecom & Electronics (Arvind Telecom)

Production Production commencedcommenced

Products Products

CapacityCapacity

Plant locationPlant location

Major end Major end user brandsuser brands

1999-00

Yarn & fabric

30 mmpa

Santej

SHIRTINGSSHIRTINGSSHIRTINGSSHIRTINGS

GAP, BR, M&S

DENIMDENIMDENIMDENIM

1987

Yarn & fabric

120 mmpa.

Naroda

GAP, Levi’s, Lee, JC Penney

1999-00

Garment

12.0 M pcs

Amber, Vadsar & EmBee

KNITSKNITSKNITSKNITS

M&S, Hanes,

Reebok, Adidas

1999-00

Fabric

7200 tons pa

Santej

KNITSKNITSKNITSKNITS

M&S, Hanes,

Reebok, Indian

Retailer

2000-01

Garment

4.8 M shirts

Bangalore

GAP, Tommy,

M&S, Wal-Mart

SHIRTSSHIRTSSHIRTSSHIRTS

Life Style Apparels - Knitwear

KNITS BUSINESS DIVISIONSantej Road, Near Khatrej, Taluka Kalol,

Dist Gandhinagar  Gujarat – 382721. IndiaTel: +91-2764-281100/22Fax: +91-2764-281060Contact Person : Praney Mehtae-mail : praney.mehta@arvind.in

Sportswear, Graphic Tees, Casual Tees, Cut & Sew Tees, Golf Polo shirts, Lounge Wear Casual Polo shirts, Rugby shirts, Joggers ... & many more.

BUYER

Briefing sheet specifies color, trims, sewing trims, buttons, embroidery etc.

MERCHANDISING DEPT

Development (3 – 4 weeks)

BUYER

Review & order placement

MERCHANDISER

Garment Order processing form

Fabric technical hanger along with fabric swatch sent to buyer for approval

SAMPLING

Contract seal prepared which specifies exact construction of the product

MERCHANDISER

Trims and accessories are decided

After approval material order form is prepared

KNP is released

MERCHANDISER

queries for date of fabric availability

Forwarded to sewing floor to get dispatch date

BUYER

Confirms date

Order is placed

MERCHANDISER

yarn requisition is raised

At the same time the trims order is also placed

Receive sample request and material

Verify material / requisition

Receive materials from marketing

Request trims from store

Receive patterns Prepares samples

Internal auditIn case of rejection from marketing Remake sample from first step

Forward sample to marketing

Receives buyers feedback with comments from marketing

If sample approved proceed, else repeat process

Hand over approved sample

TYPES OF SAMPLES◘ PROTO SAMPLE First sample meant for look, actual fabric & trims not required, could be revised as per buyers requirement

◘ FIT SAMPLE (BASE SIZE) For exact construction & measurement, can be alternate fabric, one sample of each color in medium size

◘ SIZE SET SAMPLE Critical stage, decides order confirmation, two samples each in color and size, one for buyer and one for department

◘ PRE PRODUCTION SAMPLE (PPS) / CONTRACT SEAL / GOLD SEAL meant for internal assessment,, 2-3 set in all color & sizes are sent to buyer

◘ RACK SAMPLE a random sample taken from the production line

PLANNING AND IMPROVEMENT

Developing line plansOperation breakdownGSD studySet target for each line

Daily feeding plan forwarded to sewing floor

Device methods for improving productivity

CONTROL

Buyer specific floor merchants

Sends GOPF to all departments

Communicate daily KNP progress with buyer’s merchant

Responsible for timely shipment

TYPES OF GOODS

Open width fabric on card board rolls

Tubular fabric in cutled form

INFRASTRUCTURE

Total floor area = 17.53 m x 22.86m = 400.73m²

Total number of racks 48 - 49

Capacity = 15 – 17 tones

Daily usage = 6 – 7tones

Package typeRolls (open) = 20 – 25 kgRectangular shape (tubular) = approx. 35 kg

FABRIC STORE

Fabric received

Fabric issued

AUTOMATIC SPREADING(2 -3 PERSONS AT EACH TABLE)

MANUAL SPREADING(CONTRACTUAL BASED)

SPREADING OF SOLIDSSPREADING OF SRIPES

SOME TIMES OF SOLID

PROCESS PROCESS

Loading of roll on

to the M/C

Spread perforated

paper

Spreading

Insert stripes to

locate roll

change

Opening of roll

Opening of roll

block cuttingblock

cutting

Match stripesMatch stripes

Spreading of blocksSpreading of blocks

GERBER (AUTO CUTTER)STRAIGHT KNIFE (MANUAL CUTTING)

PROCESS PROCESS

Moving lay to Gerber

table

Spread polythene

sheet over the

lay

Run the loaded

marker plan in the M/C

pieces sorted out

according to the different

rolls

Pattern placement on block

Marking with chalk

Cutting using

straight knife

pieces sorted out

according to the different

rolls

HEAT TRANSFER

Moon patch pieces

received from cutting

Check specs and

selecting appropriate

sticker

Placement using

template

Temporary attachment using hand

iron

Final heat transferring

using HASHIMA HP

Sticker removed

FUSING

Cut the rolls as per width mentioned in KNP sheet & quantity required for shift by using roll cutting machine

Load the fusing roll on machine stand

Place the cut on the on the machine bed

Align the fusing of fabric feed to conveyer

Trim the fused of fabric using tied scissors in exit the rear end

Receive instruction sheet

and pattern

Receipt of cut panels

and trims

marking as per

placement given

instruction sheet

Load framing with canvas/fusing

Floppy transfer to embroidery to machine

load the machine with framed panels

Carry out embroidery operations

Thread/canvas/fusing

cutting checking

There are 3 BARUDAN LTD. Embroidery machines2 machines with 20 heads &

1 machine with 12 head

Positive is prepared referring

spec sheet

on polyester mesh (frame)

photo emulsion coating is done, turns to screen

after passing from test the panels are arranged with bundles and sent

to embroidery or sewing sections

then online inspection

the printed panel goes to check as for placement of print and print

quality

in the machine itself after printing

there light emulsion which tends to dry the

printing

the screen is dryed

attached with printing machine

washing as for removing wet area

(black area)

assembly goes to photo camera

device machine where assembly gets exposing of

light

positive is mounted on the

screen

For single colorEfficiency is about 90%

And max. no of pieces they can print is 5000

AMBER PLANT 7 lines capacity approx 4500 garments / dayVADSAR PLANT 11 lines ( 9 PBS& 2 UPS ) capacity approx. 12000 garments / day

PROCESS FLOW IN SEWING

PROCESS FLOW IN FINISHING

Receipt of sewing plan from PPC

Sewing operations

Supervision and application of correct methods in sewing

Inline inspection

After inline inspection

ironing

Final inspection

folding

Packing in polybagFinal inspection

Sent to audit

Line out

Special finish(if any)

Dead man fold

Button attaching

Pre press checking

Lot making

tagging

Final checking

pressing

Alteration(if any)

audit

folding

polybagging

Check for metal

contamination

Carton making and packing

Dispatch

External audit

storage

Online audit

AQL LEVEL OF BUYERS

MARKS & SPENCER : 2.5OUTER BANK : 2ADIDAS & REEBOK : 1.5

Online audit

Final internal audit

External audit

AUDITING PROCESS

AUDIT

failed

Final inspection

passed

Online audit

TWO CONCEPT PRODUCTION FACILITIES

• VADSARVADSAR - Designed for producing Casual wear / Cut & Sew Tee's & Polo's

• AMBAR- Designed Specifically for producing Premium High End Golf-wear and Sportswear

OBSERVATION

Following steps in lay planning

Study on different formats used in the lay planning

Taken an random example of lot wise cut program

Observing the manual way of filling formats

Problems can arise due to not properly filling the formats

METHODOLOGY

Generating Fabric Requisition Generating Cut Program Generating Cut Numbers Issuing Cut Program and Fabric

Requisition Generating and Issuing Lay Information

Slip

It consists of the total amount of fabric that is needed for a particular Lot wise Cut Program.

The various rolls that are issued to fulfill the fabric required are listed according to their weights.

The roll no. of the fabric rolls is used to identify the rolls for a particular lot no.

It consists of the K&P, style and lot numbers.

It includes the fabric consumption per garment and the various size ratios

The cut no. generation program is generated by the system and it clearly states the number of plies and

marker length of each lay.

This has to be filled by the worker who is laying a particular cut no.

It includes the roll no, roll width, roll weight and the no. of plies that were spread from a particular roll for 1 cut no.

This sheet helps us to keep a record of all the rolls were used for all the cut programs.

A random lot wise cut program was selected and all the required formats of that program were checked to see if the total fabric that is issued was actually used or not and whether the entries done in the formats against the system laid down in the manual were correct or not.

A total of 31 fabric rolls were issued in the fabric requisition sheet

A total of 31 fabric rolls were issued in the fabric requisition sheet

While the lay information slips showed :

While the lay information slips showed :

While the lay information slips showed :

While the lay information slips showed :

While the lay information slips showed :

That only 24 fabric rolls were actually used

Only 24 rolls were used compared to the 31 rolls that were actually issued. Therefore 7 rolls were missing…….

When the total fabric consumption for the garment pieces actually cut was

calculated, it matched with the total fabric actually issued.

This leads to the conclusion that the workers have spread more than 1 fabric roll together and have done entry of only 1 roll. Therefore the rolls do not have any record in the lay information slip and hence seem to be missing.

Due to this mistake of entering information of only 1 roll in place of 2 or more in the lay information sheet, there can be problem of shade variation in the cut parts if there is roll to roll shade variation. Since the bundle card is made on the basis of the lay information slip, now 1 bundle will contain cut parts of more than 1 roll. Hence shade variation in the cut parts and hence more rejections.

Due to this mistake, there will be problem if an external auditor comes and checks as this shows that the system entries are not properly being followed.

The same roll was entered in the lay information slip for 2 different lays which is not possible.

Taking attention to the CUT NO. 43, there are ROLL NO ‘14’ & ROLL NO ‘9’ with other roll no.Then in CUT NO. 45 (I), here once again there is ROLL NO ‘14’Also in CUT NO. 45 (II), here also again there is ROLL NO ‘9’

Means,

The same roll was entered in the lay information slip for 2 different lays which is not possible.Overall there was due to the carelessness of the workers. There is shade variation in the cut parts hence more rejections, which is not good in the companies point of view.

Provided the SOP to every worker & machine,

Making aware to the workers about importance of quality,

Unskilled or untrained workers should not be placed as an operator in case of absenteeism,

Supervisor must Check the formats time to time and must keep the record,

There should be random inspection audits to check formats filling,

Indiscipline should be handled with stricter action,

All mobile phones should be banned on the work floor.

THANK YOU