frontier textiles pvt ltd

8/7/2019 FRONTIER TEXTILES PVT LTD

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Presented by:

Ankita Guha

Sanghamitra KalitaApparel production

Batch(2007-11)


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COMPANY PR

OFILE

y Company name: Frontier Textiles Pvt. Limited

y Business Type: Exporter/Manufacturer

y Established in 1993

y Accreditations: ISO 9001:2000 certified

Quality management system certified

Social responsibilities:y Theyhave special training programs for the underprivileged

y Theyhave set up a training centre under the auspices of the West BengalGovernment

y Theyhave embarked on a plan of employing physically challenged people


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Products

Leisure wear Work wearIndustrial clothing


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Industrial clothing:

y Coveralls

y Bib Trousers

y Trousers

y Short Jacket

y Long Coat

y Detachable Trousers

y Bermudas

Fabric Used

y 100% Cotton, in a variety of weights from 140 GSM for Shirts to 430 GSM

y Polyester/Cotton in various blends and weaves, from Twill, Drill, Plain weave

mat, Canvas, Duck etc

y CVC in the above variety of weavesy Denims from 9oz to 16oz

y Other blended fabrics with a variety of blends in cotton, polyester, acrylic,

viscose etc


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Fig. 1 Coverall

Fabric:290 GSM 100% cotton

Fig. 2 Coverall



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Fig. 3 Short Jacket

Fabric:140 GSM Polyester Tricot

Fig. 4 Coverall



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Work wear:

y uses specialty fabrics catering to adverse environmental conditions fall

under protective wear

Protective Clothingcomprises:

y Protection from wind, water, snow.

y Protection from sparks, fire.

y Protection from Chemicals, acids

y Protection from Static charge.

y Protection from cut, abrasion, shrapnel

y Pilots suit for high altitude flying including G-Suits.y Diving Suits in freezing water.


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These cater to a widerange of Industries like:

y Refineries

y Mining Industries

y Steel Plants

y Casting Industries

y Army

y Air force

yDrilling Rigs

y Electronic Laboratories

Fabrics/Productsused for these categories of work wear include:

y Cotton coated with chemicals for fire retardant, acid repellant

y Finishes for anti microbial, anti fungal, oil and water repellent with coatings forbreathability and heat resistance.

y Special fibers like mod acrylic, Meta Aramid, carbon core.


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y

Oth

er fire retardant fibers like viscose, polyester,

y Special blends like wool/viscose for metal splash protection.

y Special crackle proof breathable coating for high altitude clothing with downfilling

y IRRprinted clothing for the military/police.

y Proximity suits meeting all international stipulations for fire fighting.

y G-Suits made of Meta Aramid fabric for usage in air force.

y Chainsaw protection chaps and trousers for the lumber industry


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Fig. 1a

Fabric: 220 GSM Kermel, Fire Retardant

Fig. 2a

Fabric: 290 GSM 100% cotton, FlameRetardant


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Institutions usingtheiruniforms:

y Hospitals

y Hotels

y Retail Chains

y Supermarkets

y Corporate Gifts

y Event Management Companies

TheirLeisurewearcomprises:

y Leisure at work: Polo shirts, chinos, drill trousers, shirts, sweat shirts,

moleskin canvass jackets

y Leisure at sports: Polo shirts, Bermudas, detachable trousers, vests, fishing

jackets, trekking clothes


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Process flow in the industry


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Project 1:

Suggestions toimprove daily production

Methodology followed:

y Calculation of daily productivity of the existing line set up

y Conducting a time study for every operation

y From the Time study we found out the SAM value for the garment in thecurrent line

y Analysis of the causes of low production & suggestions given

Suggestions toincrease productivity:

y

Proper preproduction planningy Improvement or change in the current the material transfer

y A specification sheet of the entire garment should be made

y Use of fusing machine

y Use of left and right hand chart should be implemented


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Project 2

SWOT

analysisStrength:

y Quality products

y Established name

y Good financial resources

y Timely deliveryy Competitive prices

y Enormous capacity

y Buyer loyalty

y Loyal and experienced personnel

y Effective buyer communication


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Weakness

y Unprofessional work culture

y Labour absenteeism

y Lack of planning

y Improper infrastructure

y Poor hygienic facilities

Opportunities

y Scope for expansion

y Scope for modernization

y Domestic foray

Threats

y Companies working with cheap labour

y Reduction in duty drawbacks


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SWOT analysis of spreading and cutting room

Strength:

y Fabric store is adjacent to it

y Proper lighting and ventilation helps in better performance

y Specific and proper records maintained

Weakness:

y Spreading is manual

y Excessive time loss due to manual spreading and cutting

y More workforce is required

y Maximum 2 spreading can be done at the same time involving 3 workers

eachy Limited cutting equipments

y No proper storage system followed for the cut parts

y Worker absenteeism

y Worker inefficiency


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Weakness:

y Improper indexing and storage

y Lack of space

Opportunities:


Threats:

y Confusion and misplacement of materials due to improper storage

y Reordering of raw materials

y Wastage of raw materials


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SWOT analysis of sewing room:

Strength:

y Sewing quality products

y Adjacent location of trim store

y Constant supervision

Weakness:

y Worker absenteeism and inefficiency

y Constant line setup for every order

y Specification sheet not provided to every worker

y Tables placed between the lines for material transfer

y Working aids or accessories not used


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Opportunities:

y Scope for modernisation

y Use of trolleys or rails for movement of material instead of tables


Threats:

y Reduction in production

y Time loss

y Delay in delivery

y SWOT analysis of finishing room:Strength:

y

Sufficient work forceWeakness:

y Lack of space

y Not all finishing activities are carried out

y Inadequate machineries


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Opportunities:


y Scope for improvement in mechanization

Threats:

y Inadequate machineries mayhinder better finishing

y SWOT analysis of the inspection room:Strength:

y Sufficient work force present for inspection

y All the checks are performed

y Records maintained for the quality standards

y Thorough checking done and defective products sent for repairing

Weakness:

y Manual checking

y No needle detectors or detectors for broken button and sharp objects


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Opportunities:

y

Scope for using better automated equipments for detectionThreats:

y Hazardous or a very small but vital fault may be overseen

y Rejection of order

SWOT analysis of the packaging room:Strength:

y Sufficient work force present

y Hygienic work area

y Use of proper packaging material

Weakness:y Manual ironing

y Manual folding

y Time loss

y Manual packaging is not perfect


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Opportunities:

y Scope for using better automated equipments for ironing

y Reduction of man power with the use of automated ironing and packagingequipments

Threats:

y Hazardous or a very small but vital fault may be overseen

y Rejection of order


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Project 3:

To control the needle breakage on the production floor (Sewing

floor)

Need:

Even after using good quality needles, needle breakage rate was found to be veryhighwhich cost a lot the company.

Methodology followed :

y Past data of four months from maintenance department was studied

y Operators were interviewed to find the various causes of needle breakage

y Causes of needle breakage was found with their frequencies

y R

emedies were given


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Graphical representation of Needle breakage analysis for 4 months:

DPx5 602 687 630 669

TVx5 56 67 66 71

DCx27

308 341 333 356

0

100

200

300

400

500

600

700

800

january february march april

DPx 5TVx 5

DCx 27


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Code Reason DPx5 TVx5 DCx27

1 Improper needle bar height 58 4 8

2 Improper needle fixing 19 7 16

3 Improper needle hook timing 7

4 Improper needle to hook clearance 7

5Improper threading 19 8 35

6 Improper thread tensions 29 9 48

7 Needle fabric compatibility 12 6 3

8 The bobbin is not rotating smoothly 57

9 The needle is to ching the throat plate 15 2

10 The thread thickness does not match with the

needle size

35 59

11 Too m ch thread is wo nd aro nd the bobbin 62

320 34 179


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Needle-reason graph

code

Needle

broken

71 45 7 7 68 89 21 59 17 94 64

0

10

20

30

40

50

60

70

8090

100

1 2 3 4 5 6 7 8 9 10 11

needle broken


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Remedies and suggestions based on thestudy:

y Operators should be trained about basic functioning of the machines

y Maintenance department should be alert. All the machines should bethoroughly inspected at least twice a week

y Operators should inform their respective supervisors as soon as they observe

any kind of problem regarding working of the machine

y Operators should remain careful enoughwhile filling their bobbins, threadingthe needle and fixing the machine

y

Operators should do a primary check every time they sit on the machine inwhich the needle is positioned

y Thread tension should be set at an optimum level the workers start working onthe machines

y Thread-needle compatibility should be tested before starting the production


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frontier textiles pvt ltd

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