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REPORT ON PRESITEX ENTERPRISE (PTY) LTD
MASERU,KINGDOM OF LESOTHO
VISHNU JAYAKUMAR, MT-I.E1
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Year of
establishment: 2000
Number of
employees: 2031 ( August 1st 2011)
Area In SQM : 222,500
Sales turnover
(2009 - 2010): $ 94 M
ExportsTurnover : $ 84.6 M
Core Activity : Manufacturer of garments like Jeans, Jacket etc.
Industries
Catered: Textile, Garment Industries
COMPANY PROFILE
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PRODUCT DETAILS
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PROCESS SEQUENCE
FABRIC STORE
ACCESSORY
CUTTING
PATTERNSEWINGSEWING
DRY PROCESS
WASHINGDISPATCH
LOADING
CHEMICAL
PRINTING
SHIPPING
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DATA COLLECTION
TheoreticalTakt Time
Customer LEVIS
PS No 15093Demand/month 440000 garment (Apprx.)
Shop Floor Availability
No of Shifts 1
Shift Hours 10HrsLunch Break 60Min
Available time / Shift 540Min / Shift
Total working days 22days
Total Available Time / month=
11880Min712800Sec
Takt Time =
Total Available
Time / Demand
0.027 min/garment
FabricStore
Accessory
Pattern Cutting SewingDry
ProcessWashin
gDispatc
h
Operation 4 1 1 1 2.5 2 2 2
00.5
1
1.5
2
2.5
3
3.5
4
4.5
Days
Time study
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PROCESS PARAMETERSMachines
OEE(24 hr)Max output / hr / Mc
MTBF (minutes)
Needed Floor Space (sqm)
Connected load in KW
Time (seconds)
process time
changeover time / pc
loading timetakt time / pc
Machine cost (R)
Saler price
recovery period (years)
Labour cost (R)
personal expense/shift & machineemployee
employee's qualification (wage level)
Manufacture
number of work pc/station
Employee analysis
accident rate
For eachindividualoperations interest rate for recovery period
electricity tariff in r/Kwh
shift/day
working hours/shift
wage/hour in rs (high qualified)
wage/hour in rs (normal qualified)
wage/hour in rs (low qualified)
recovery period in years for the
manufacturing system
work days / year
floor space cost in r / hr & sqm
needed floor space for the whole
manufacturing system in sqm)
floor of production hall in sqm
General for all operations
Process Lead
time/garment(days)
Cycle Time / garment (Sec)
Man-Machine Availability
Rejections Ratios
Manual Material handling
between stations(min/bin)
Inspection time(sec/bin)
Inspection frequency(garment)
Quality Check/hour
Setup adjustments
(min/garment)
No. of operators
No. of machines
Mudas-Identification
Line balancing
Thread Consumption
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MATERIAL HANDLING EQUIPMENTS
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SL
No.
OPERATION
1 Arrival of container
2 Uploading to the shop floor
3 Shrinkage cutting 25 * 25 (10%)
4 Shade blanket cutting 8 * 8
5 Inspection 10% from current arrival
6 After wash of shrinkage- measure
length and width
7 After wash of shade changes will
categories into A , B & C etc.
8 Request from cutting department for
fabric and will provide as much
required.
DIVISION MANPOWER
Shrinkage 01
Inspection 02
Issuing 02
Supervisor 01
Unloading etc 09
Total 15
Shop Floor Details
FABRIC STORE9
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Point system-American Standard-Levis
1-point : Defect less than 32-point : Defects exceeding 3 up to 6
3-point : Defect exceeding 6 up to 9
4-point : Defect exceeding 9
Point/100 sq.yard = (Total point * 36 * 100) / (sample yards * cuttable roll width).
If it exceeds 15 the fabric will get rejected.
Fig: Inspection Machine
SL
No.
Length
(Yard)
Width( Yard) Setup Time
(Min)
Inspection
(min)
Point
Calculation
1 138 58.5 5.58 25.34 3
2 104.9 58.5 7.2 25.04 2.56
FABRIC STORE10
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General Ideas
PS NUMBER WASH NAME
P-11002 Medium
P-11003 Dark
P-11006 Relaxed Medium
P-11007 Journey
P-11008 Anthem
P-11009 Rustic
P-11011 Summit
Supply chain Management- Ship Routes
1.India-> Durban -> Lesotho
2.India -> Cape town -> Lesotho
3.Pakistan -> Durban -> Lesotho
Time Average
Total time to reach a fabric to cutting is 3-4days Minimum. In Emergency 2 days.
Time for washing in shade blanket is 1 day. Before that 1day for cutting.
For shrinking washing time is minimum 2hrs and after washing 1hr.
FABRIC STORE11
QUALITY ISSUES
Barre Holes
Biased Jerk In
Bow Knots
Broken End Misdraw
Course Ends Mispick
Crack Marks Mote
Compactor Marks Needle Lines
Creases Off Pattern
Double Ends Press Off
Dye Streaks Read Marks
Ends Out Rope Marks
Filling Bands Runs
Fine Ends Seam Marks
Finger Mark Slub
Float Smash
Fly Soil
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Continuous..Containers details from Import and export department. Details
including Container
number, P/O, quantity, ETA, ETD, YDS, Shipping line.
When arrived, the uploading will do only after customs
clearance.
Fabric Consumption- 1.34 yard = (Total yard/Cut Quantity)
Reports: Stock report and fabric consumption report.
Types of Fabric: Canvas- Cotton-Dot type, Cordury & TWILL .
Issuing the fabric to cutting as per cutting plan. They will give
request for fabric to issue.
Mostly will cut 7% more than order quantity
FABRIC STORE12
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PATTERN ROOM
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Process details
Buyer will give design to the management as per their requirement.
Through Merchandiser it will transfers to pattern department.
Pattern maker will calculate the total fabric needed for a garment in yards.
It always an average of 1.40yards + 2 % allowance.
Management will decide the overall cost of making a garment and will
inform to buyer. If the buyer is not ready to accept the rate, there will also a discussion for
cost reduction and may reach as per buyers standard.
For sample piece of garment firstly as per shrinkage report, pattern will
make with GEBER Software.
PATTERN14
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Continuous..
Sample will send to buyer for verification. After that there might be small
changes from buyer will occur. They also will send back to Merchandiser
and finally to pattern department.
Pattern department will start pre-production and will make a pattern of
three or four size garments with two or three pieces and will undergo all
process including quality check in final.
Quality department will note and inform if there any changes and problems
in the final product,
Always the utilization of fabric should be more than 90%. And at least like
to reach 93%.
In pre-production buyer will always give a tolerance on +5 to -5 asexample. So the size issue, because of external issues like shrinkage will
always between this.
PATTERN15
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Continuous
Calculation for yard needed for a Garment
Example:
Marker Length as per software = 17.26 yard
Converting to yards + 2 % allowance = 17+26/36 + 2% = 17.73
Total number of garments in a marker= 14
Total yard per piece = 17.73/14= 1.26 yards.
Fig: Plotted drawing
PATTERN16
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Continuous
How to make cut plan.
Production sheet contents like PS NO, SAP-PO NO, PRODUCT CODE,
ORDER QUANTITY
From the Order Quantity cut plan will make taking Insim and Size as major
calculation point of view. With exact number of quantity of each size like 32,
34, 36, 38 etc. Marker count and table count will decide. From the fabricshrinkage report and marker allotment total quantity of fabric will
calculate.
Design is making with Geber software and will allot in exact yards with
90% efficiency.
Always make Order quantity with 0-7% extra, with comparison of stocklevel in previous production.
Printer needs at least 20-30 minutes to make a printout.
Currently in pattern department there are 2 + 1 workers
PATTERN17
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CUTTING
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Production Plan
From Cut plan department head will make output plan.
From Marker the quality department will check whether all the pieces of a
garment are present or not.
The fabric roll will keep in table with more than 74 layers as per the
thickness of garment. May be the capacity will reach about 100.
There are 12 line of cutting table. 6 tables with 19 and 6 tables with 21. After cutting there will be a quality checking for whether there any more
excess cut is made or any other wrong cut is made. They will mark in error
piece bundles for rework.
After that numbering will do in all pieces of bundles. And they will make
bundles of garments together. There also a quality checks after numbering.
After all the line feeders in sewing department will take the bundles to
respective area.
Current capacity is 20,000 pieces in a day.
CUTTING19
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Shop floor details
Manpower: 71 workers + 2 Supervisors excluding qualitydepartment
Target
Maximum
20,000 piecesper day
SL.
No
OPERATION: LAYERING MANPOWER
1 Keeping cutting machine to the
place 2
2 Layering in sequence as per
style2
3 Keeping bundle in to the
position 2
4 Quality check in each layers 1
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PLANNING
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General ideas
Merchandiser will provide Projection Order to Planning department.
Planning will do 55 days before the production.
Always make a buffer of 7 days for shipping.
Cutting plan will make and will provide to fabric, accessory, pattern and
cutting department.
Garment fabric length taken as 1.4 m for a garment and 0.17m for lining. Container size maximum of 30,000 Jeans supply.
505- Straight fit and 550- Relax Fit
PLANNING22
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Continuous
1-2-3 and interaction with import
Mainly deals with fabric quantity, accessory needed, date of order and
arrival
Production Planning
Production is well planned as per the day of shipping as final designation
with proper date and allocating works in proper Line. Quantity Control
Number of garments in each operation is well controlled to get proper
output with less WIP in each level of production.
Order Reconciliation
It will shows clear idea of all sewing quantity , washing quantity, Input to
dispatch, sewing reject, washing reject, cutting reject , shipping quantity,
Leftover etc. All management staffs will get a clear view report after Order
reconciliation.
PLANNING23
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Departmental capacity
Example Sewing department:
Lead time = 21.32 minutes
Total time availability = 9 * 60
Number of Manpower = 110
Machine hour = 110 * 9 * 60 = 59400 minutes
Target Efficiency = 85%
Line target in a shift = (59400 * 0.85) / (21.32) = 2368 nos.
Production per hour = 263 nos.
Production in 5 lines = 2368 * 5 = 11841 nos.
PLANNING24
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Basic Production Process
PROCESS DAYSFabric Store 4
Trims 1
P.P Approvals 1
Pattern 1
Cutting 1
Sewing 2.5
Dry Process 2
Washing 2
Dispatch 2
Total
15.5
days
PLANNING25
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ACCESSORY STORE
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Accessories
Main label
Pocket label
Care Label
Leather patch
Zipper
Fusing
Threads
Buttons
Rivets
Waist tag
PKT tags
Size Sticker
Poly Bags
Cartons
Brown paper
Double sided Clear type
Tag pin
Plastic stables
ACCESSORY27
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Suppliers
Sl.No Item Country
1 Zipper Swaziland
2 Thread Hongkong
3 LeatherPatch (RT)
Mauritius
4 Leather
Patch
(Denizen)
Hongkong
Will get Production sheet
from merchandiser.
Cutting report from
department.
Invoice from supplier.
Quality and quantity check
mostly 10 % in all supplies if
the lot is more. If it is less ofnumber will do 100%. Mostly
Zipper count will do 100%
checks in all arrival.
ACCESSORY28
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Continuous..
Accessory sheet will make for all checking in each arrival
Always provides 5-7% allowance in supply to production.
Provided a person for all supplies in a line. He will name bundle no, size,
Line no, cut no etc.
TRIM CARD is made for reference of each style.
Zipper Size as per size 31- 16, 32-16.5, 33-17, 36-19 From PO will get what type of label needed and prepare with printing
machine. Model will sent by Levis. 3000 pieces/hr
ACCESSORY29
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SPARE PARTS
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General Ideas
Spare parts are categories into different variety and kept inside spare part
store.
As per the Mechanic and Head Mechanic request spare parts will get
issued.
Some consequent replacing parts have Minimum Inventory Level.
Company have monthly budget for purchasing spare parts. Asitha is the incharge and having more than five regular suppliers. Some parts are supply
from Hongkong.
Issues are Not getting the spare parts from suppliers. So there is issue
when a part is to be replaced as soon.
SPARE PARTS31
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Common spare parts..
Upper knife clamp
JointLower knife
Oring
Worm wheel
Spring
Connection
Needle bar bushing
Bushing assembly
Shaft
Ring
Connection
Cover
Upper looper holder
assemblyCrank shaft
Oil distributor complete
Tube
Upper knife
GasketUpper looper holder
assembly
Lower looper holder
assembly
Lower looper holder
Block
Main feed bar
Lever
Connection
Holder
Looper holder
Spring
WopmThread take up
Thread eyelet
Thread eyeletThread eyelet
Thread retiner
Tread guard
connection
Thread guide
Thread take up
Thread guide
Thread guide
Thread guide
Thread guide
Thread guide
Thread guide[right]
Needle guideFlat knife
Needle guard
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PR-SEWING
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Shop floor..
Currently 5 lines in working out of 6.
Line feeder will feed line.
Reports to/from PR
Cut plan report from Cutting department.
Feeding report.
Production Planning control report.
Current Situation
Total number of workers is 110 + 4 supervisors + 1 Line manager + 9
Quality checkers + 1 Line feeder + 1 Score lady in each line. Total of 126
workers in a line.
126 * 5 = 630 total in a PR.
Average production Target in a line = 250 pieces/hr. Total of 2340 pieces in
day
Target 2340
pieces/9hour
PR-SEWING34
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Operation Bulletin
OPERATION BULLETIN LSS (levis
signature).xls
PR-SEWING35
http://localhost/var/www/apps/conversion/tmp/scratch_6/OPERATION%20BULLETIN%20LSS%20(levis%20signature).xlshttp://localhost/var/www/apps/conversion/tmp/scratch_6/OPERATION%20BULLETIN%20LSS%20(levis%20signature).xlshttp://localhost/var/www/apps/conversion/tmp/scratch_6/OPERATION%20BULLETIN%20LSS%20(levis%20signature).xlshttp://localhost/var/www/apps/conversion/tmp/scratch_6/OPERATION%20BULLETIN%20LSS%20(levis%20signature).xls7/22/2019 Denim Garment Industry
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PG-SEWING
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Shop floor..
Current three sewing lines out of 6 in working
Got three bulletins of garment with SMV.
Line efficiency in each line is studied.
Target Efficiency = 80%
Formula:
Front = (present front manpower * 60 *9) / (front Total SMV * 85%)
Back = (present back manpower * 60 *9) / (back Total SMV * 85%)
Assembly = (present Assembly manpower * 60 *9) / (Assembly Total SMV * 85%)
Line Target= (present line manpower * 60 *9) / (Line Total SMV * 85%)
Line balancing is observed as per the availability of manpower and work.
PG-SEWING37
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Bonus calculation
SL No. Efficiency (%) Workers (R)
1 80-90 10
2 91-100 15
3 101-110 18
4 111 and above 21
SL No. Efficiency (%) Supervisor (R) Line Manager (R)
1 80-90 25 50
2 91-100 35 60
3 101-110 45 70
4 111 and above 55 80
PG-SEWING38
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Continuous..
In pre-production, all management will group together for the
new garment. It includes the rate for all kinds of utilization
include threads, manpower, electricity, space, machine etc. and
will go for sample production.
Product safety is very important in quality check. There should
not be any harmful material or sharp edge parts are in thegarment. Quality persons have to do thorough check up
regarding this issue.
Operation Bulletin is attached.
PG-SEWING39
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INDUSTRIAL ENGINEER
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General Ideas.. Standard Minute Value: The taken for completing an operation. It also called
as cycle time. Machine Capacity: The maximum number of products that a machine can
perform during an hourly based production
Thread Consumption: Done thread consumption practical study with the
help of a Jeans (Denizen)
Production Efficiency in each operation /section
Total Number of workers in IE Department Bonus calculator-1, IE clerk-1,
Score ladies-6. Total of 8 workers.
General Production Issue
Mainly thread wastage. Loop wastage.
Time delay between operations.
Waiting for successive operation.
Line is not balancedINDUSTRIAL ENGINEER41
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Thread Consumption example
thread consumption.pdf
INDUSTRIAL ENGINEER42
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DRY PROCESS
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Operation
SORTING MARKING
FRONT
MARKING
BACK
TURNING 1st
TRIMMINGTURNING 2nd
WHISKER
HAND SAND
P.P.SPRAY
WASHING
BLOWING
CHEVERON
GRINDERS
Target
Maximum
10,000 pieces
per day
DRY PROCESS44
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Availability
Currently having 106 machines in working.
Having 6 grinding machines.
Having 15 P.P.Spray machines.
Two blowing machine
Two Turning machine
P.P.Spray
DRY PROCESS
Whisker pattern Whisker area Chevron Area
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Manpower
SL.NO. OPERATION MANPOWER TARGET METHOD
1 Sorting 3 - Checking size/Inseam and grouping
2 Marking Front 6 150 Vary from size
3 Marking Back 3 300 Vary from size
4 Turning 1st 2 - Using Turning machine
5 Trimming 3 120 Removing excess threads
6 Blowing 2 - Vacuum machine to remove threads
7 Turning 2nd 2 - Using Turning machine
8 Whisker 10 20Using Mould whisker will make
9 Chevron 7 50 Marking in near knee
10 Grinding 4 Using grinders
11 Crinkle - -
Using resin with Owen in 140 degree
Celsius for 15 minutes.
12 Hand sand 58 50
Using sand paper with hand sand
machine in horizontal
13 P.P.Spray 11 45
Using KMnO4 (300gm/10litre water) for
making lighter the color.
Supervisor PPC 1
Score Lady 3
Score Lady whisker 2
Supervisor Whisker 1
QC Table 6
Trolley Boy 1
TOTAL 125
DRY PROCESS46
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Safety Equipments
Mask Finger guards
Ear plug
Gloves for PP spray
Overall gown
Two filter respirator
Sand Paper Types
P-60Lighter
P-240- More delegate
P-150- standard
P-400- Sheet paper typeFig: Sand paper
Inventories
Role Rubber
300 pieces tug
3kg of resin
4 roll of sandpaper for each day
DRY PROCESS47
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Quality checking
DRY PROCESS48
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Time study
SL.NO. OPERATION TIME
STUDY
(sec/piece)
1 Sorting
2 Marking Front 20.1
3 Marking Back 9.8
4 Turning 6.35 Trimming 35.9
6 Blowing 12
7 Whisker Marking 12.55
8 Whisker 70
9 Chevron Marking 33.8
10 Chevron 65
10 Grinding- Bottom 28.2
11 Grinding- pocket 45
12 Hand sand (31 * 32) 153
13 P.P.Spray 560
DRY PROCESS49
Causes for Defects in garment
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Causes for Defects in garment
Preliminary view Production Rate increase
New workers recruit
Not having Job rotation
Mentality setup
DRY PROCESS50
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WASHING
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Shop Floor..
Machine availability
Sl.No Machine Number Workers
1 Washing Machine 800 P=25,
700 P=11
200 P=1
2 Hydro Extractors 10+2
3 Dryer 26
Total 75 200 (full
fledge)
Target 23000
pieces /24 hr
WASHING52
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Current State
Sl.No Operation count Maximum
Capacity per
machine
1 Tumble
dryer
40 pieces,80 degree,
30 minutes maximum
33 pieces at a time
2 HydroExtractors
100 pieces, 30-45minutes
35kg
3 Washing
capacity
23000-25000
pieces/24 hour
147kg per loading
(40% of 800
pounds)
WASHING53
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General Ideas..
The washing Head will get the Washing plan for each day. Mostly it varies
from each day to day. The washing plan is as per PPC chart
Weighing of garment is very important:
Liquid ratio 1Kg/10 Liter. Chemical and dye depend on weight of garment.
Consistency
Ideal loading of machine is 40% of total capacity of machine. (100-120kg)
WASHING54
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Operation Procedure
PPC- Involved with operator, weighing and counting of garment.
Loading- Inside the machine.
1.Proper way-(creak mark to avoid)
2.Rotation of machine should be balance in and out and vice versa.
3.Rotation of drum- 28-30 revolution/minute
Desizing : sizing denim- starch reductionTest 1: Iodine Test
Alpha-Amylase (not reacts with fiber, react with starch).
Temperature- 60 degree. Oscillation with lubricant Reducing friction.
Tungle of garment will reduce.
Anti-black strain- 0.25%, 0.1%, 0.5% (if good).
Anti cleaning- 1%
Enzyme or stoning process
1.Enzyme is effective at 35-40 degree Celsius. Ideal effect at 50 degree Celsius.
2.Concentration 1kg for 100Kg garment i.e. 0.1%.
WASHING55
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CHEMICAL STORE
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Chemical Names..Sl.No CHEMICAL NAME
1 Maxiclean
2 Caustic soda3 Cellex (50)
4 Indilite (50)
5 Aqua
6 Persulphate
7 Denclean
8 Denlube
9 Oxalic acid
10 Acetic acid
11 Thiosulphate
12 X-brite13 Salt
14 Pretex
15 P.permaganet
16 Exclore
17 Garmensoft
18 Indisoft
19 Soda-ash
20 Bleach (25)
21 Bleach (45)
22 Bleach (50)23 Nanotin
24 Peires cat
25 Orange
26 Brown 8rl
27 Black
28 Violet
29 Brown Brr
30 Brown Gxl
31 Brown Bl
32 Indigo
33 Stone
1. Chemical utilization will update each day as per the
consumption in washing department.
2. Chemicals are mainly from India and south Africa.
3. New arrivals are checked properly and handled with safety
precautions.
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DISPATCH
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Operation
CutLoop
Trimming Final QC Blowing Rivets
PressingMeasurement
Buttons
CheckingRivets &Buttons
Pairing
FoldingCheckShade
Repair
WaistTag
SizeLabel
ScanPack
Loading
TARGET/SHIFT
10K-21K
DISPATCH59
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Current Scenario
C:\Documents and Settings\Vishnu-CGM\Desktop\CAPACITY STUDY
DISPATCH.xls
DISPATCH60
http://c/Documents%20and%20Settings/Vishnu-CGM/Desktop/CAPACITY%20STUDY%20DISPATCH.xlshttp://c/Documents%20and%20Settings/Vishnu-CGM/Desktop/CAPACITY%20STUDY%20DISPATCH.xlshttp://c/Documents%20and%20Settings/Vishnu-CGM/Desktop/CAPACITY%20STUDY%20DISPATCH.xlshttp://c/Documents%20and%20Settings/Vishnu-CGM/Desktop/CAPACITY%20STUDY%20DISPATCH.xlshttp://c/Documents%20and%20Settings/Vishnu-CGM/Desktop/CAPACITY%20STUDY%20DISPATCH.xlshttp://c/Documents%20and%20Settings/Vishnu-CGM/Desktop/CAPACITY%20STUDY%20DISPATCH.xlshttp://c/Documents%20and%20Settings/Vishnu-CGM/Desktop/CAPACITY%20STUDY%20DISPATCH.xlshttp://c/Documents%20and%20Settings/Vishnu-CGM/Desktop/CAPACITY%20STUDY%20DISPATCH.xlshttp://c/Documents%20and%20Settings/Vishnu-CGM/Desktop/CAPACITY%20STUDY%20DISPATCH.xlshttp://c/Documents%20and%20Settings/Vishnu-CGM/Desktop/CAPACITY%20STUDY%20DISPATCH.xlshttp://c/Documents%20and%20Settings/Vishnu-CGM/Desktop/CAPACITY%20STUDY%20DISPATCH.xlshttp://c/Documents%20and%20Settings/Vishnu-CGM/Desktop/CAPACITY%20STUDY%20DISPATCH.xlshttp://c/Documents%20and%20Settings/Vishnu-CGM/Desktop/CAPACITY%20STUDY%20DISPATCH.xlshttp://c/Documents%20and%20Settings/Vishnu-CGM/Desktop/CAPACITY%20STUDY%20DISPATCH.xlshttp://c/Documents%20and%20Settings/Vishnu-CGM/Desktop/CAPACITY%20STUDY%20DISPATCH.xls7/22/2019 Denim Garment Industry
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Continuous Solid pack
The pack consists of 6 pieces or 20 pieces accordingly as per buyers requirement. Scan Pack
Check size, check quantity, Scan UVM barcode and enter the P-style and count the garment.
Loading plan
From import/Export department Loading Memo will get. It contains container info, Security
check etc. Arrange as per the memo and seal the container with shipping seal. And will getconfirmation from shipping department.
Final Audit
Check the size, waist length, rivet position and button strength.
General Production Issues
Repairs
Accessory lag.
Rivet problems
Machine problems
Human error
DISPATCH
Workers are lazy
Waiting for previous Operator
Unnecessary Motion
Improper Feeding
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QUALITY
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General Ideas
Quality Analysis [QA] - Preventive maintenance, Root
cause Analysis, Corrective Action plan
Quality Control [QC] - 100% check on daily basis.
Rolling QC: Randomly checking in bundles in Sewing line
Station QC: 100% checking End line QC: Assembled final check
QUALITY63
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AQL- Acceptable Quality Level
Acceptable quality Level: In general cases the buyer will
determine which sampling plan and what AQL to adopt.
The AQL 1.5 is applied when severe inspection conditions
are required on high-class expensive items. The AQL 2.5 is
applied when textiles of normal/good quality are involved.
There are three types of sampling plans: i.e. single, doubleand multiple sampling plans. Each sampling plan can be
performed at three levels, i.e. normal, tightened and
reduced, depending on inspection requirements and
quality of the products. In the garments industry generallysingle and double normal sampling plans are applied.
QUALITY64
4-Point system-American Standard-
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Levis
1-point : Defect less than 3
2-point : Defects exceeding 3 up to 6
3-point : Defect exceeding 6 up to 9
4-point : Defect exceeding 9
Point/100 sq.yard = (Total point * 36 * 100) / (sampleyards * cuttable roll width).
If it exceeds 15 the fabric will get rejected.
QUALITY65
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Inspection Issues in Fabric store
Internal PP Meeting
Arrange with Merchandiser, all department head,
and factory Manager to review PP sample.
Conclude to one decision for buyers
requirement with technical support.
QUALITY
Levis Standard
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General points..
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QUALITY
Final Audit
Internal audit will take care by QA.
Carton Marking
Pocket accuracy
Shade checking
Measurement
Product Safety
Check all safety levels in garments. Especially metallic safety. Check needle presence. And
rivet and button strength. Having Metal detector and pull test machine.
Fig 1:Metal Detector Fig 2: Pull Test Machine
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General points..
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REJECT STORE
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General points..
All garments that all categories as not as per buyers
requirement will taken to reject store.
In reject store separation of garment will take place.
It will divide into A, B, C, and D categories.
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General points..
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Category Specification
A
Good Garments of leftoverGood Garments of overrun
Good Garments from PP Sample with non conformity,
washing , construction or measurement
Good Garments without of shade band
Good garments with wrong pocket placements
B
Shading within the garment
Fabric flaws
Small stains within 1" diameter area and not more than 3
points
Sewing defects mainly at waist band and HEM area
C Small hole noticeable at hemming or waistband, big stains
DDamage but still wearable (fix)
Big Holes and Bursting but still wearable (fix)
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COMPLIANCE AND SAFETY
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Safet Equipment List
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Safety Equipment List
Having Safety Marking with differentcolours in shop floor.
Fire and safety training in each 3
months.
Safety Inspection in regular time. Drinking water is allotted in regular
places by the government
COMPLIANCE AND SAFETY
Equipment Replacement
Fire Extinguisher 6 months
Safety goggles 12 months
Safety gloves
Apron 12 Months
Safety Shoes
Winter Jacket
Emergency Alarm
Safety Mask 1 Month
Ear Muffs 12 months
Safety Gown
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Snaps
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Snaps
COMPLIANCE AND SAFETY73
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PERSONAL WAGES
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General Ideas..
Total of 9hour in a day. 45hr/week. 195hr/month.
Regular basic wage is R 3.99/hr. R 1.25/hr for overtime. DDPI- Directorate of dispute Prevention and Resolution will discuss about
Dismissal problems.
After three warning labour will call for DDPI for further questioning with an
representative called as shop steward.
DDPI will send the labour to Labour Court for final decision. Union FAWU, UNITE.
Contract Casuals: 3months, 2months, 1month etc.
Probation 3 months.
Benefits: Bonus + Sick leave-12 days/ year with salary. If more than 12days half the
salary will get cut. Clinic 3 days. Personal leave end of year 12 days paid. Maternityleave-2 weeks.
Direct Dismissal: Stealing, Assault, Fraud, Damaging Company property, Fighting.
PERSONAL WAGES75
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Continuous..
Direct Dismissal: Stealing, Assault, Fraud, Damaging Company property, Fighting.
Notice Period: 1 week for 6month experience. 2 weeks for above 6 months, 1month for 1 year and above.
Termination for poor performance: 1 month notice period.
In public holiday if the worker is present for a work means double the payment.
Education Leave only when the company is allowed.
Minimum age limit is 18.
Accident Insurance as per workmens Compensation Act.
Experience Rand
Unskilled 3.99
Trained 4.3
Exp >1 4.76
PERSONAL WAGES76
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WAGES
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General Procedures..
WAGES
Contract Period: Daily, Weekly, Biweekly, and Monthly.
Temporary contract for 3 months. Casual labour will get permanent ifshe/he working more than three months in the company. Passport is
necessary to sign the contract.
After three month contract the same person can come to company as a
casual labour after a period of one month.
ID cards will provide in the evening of date Joined with photo in
lamination.
Contract Colour of paper
1 year white
2 year Blue
3 year Yellow
Contract Wage (R)
Daily 4.55
Weekly 4.31
Biweekly 4.31
Monthly 3.99
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Wages per day
Usual Days (R 3.99 as rate)
Time Rate(Rand)/hour Total7:00- 17:00 9*3.99 35.91
17.00-19:00 2*3.99*1.25 9.975
19:00-21:00 2*3.99*1.31 10.4538
Night shift
19:00-5:00 9*2.06*3.99 73.9746
Saturday and Sunday
7:00-15:00 7*2*3.99 55.86
WAGES79
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Discharge
3 days continuous absent:- Immediate Termination.
Greater than 1 year experience:- 90hr severance.
Greater than 6 month:- 12 days leave
Increment
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IMPORT
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General Process
Collect documents from suppliers: Invoice, Packing List, Bill of lading/telex,
Country of Origin, Beneficiary etc. Send to clearing Agent to process any duties and entry (Bill of Entry)
Follow up with clearing agent or shipping Line about the arrival of
containers.
Update the incoming document you have received,
Follow up any outstanding documents from suppliers
Follow up payment if any (factory or shipping Line)
When entry stamped, payment for duties (if any) is done push for the
released of container to avoid penalty.
When Container at factory, ask for inspection before offloading container,offload fast to avoid penalty.
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Continuous..
Lead Time varies from 14-25 days + or
By Road the maximum allowance is 30 tones in container.
By Train the maximum allowance is 36 tones, but it takes more time to
reach.
CBM, the capacity for a container will calculate.
Two types of Package: 1] FOB: - Free on Board 2] CIF: - Cost Insurance &Freight.
FOB will give the permission to supplier to take care the container till
reaching the designation port.
In CIF the company is responsible for handling Container from the Import
port to designation.
* *make follow up call from shipping line or clearing agent about the status of the vessel,documents and the container to avoid late charges for submitting documents or any charges.
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IMPORT-ACCESSORY LIST
ITEM DESCRIPTION DUTY (%) VAT 14%A4 Copy pare 15 14
White Board Marker 15 14
Stapler Pin 20 14
Paper Clips 20 14
File Fastener 20 14
Permanent Marker 15 14
Pen 15 14
Pencil 20 14
Highlighter 15 14Pencil Sharpener 15 14
Pencil Rubber Eraser 15 14
Correction fluid FREE 14
Arch & Regina File 15 14
Glue Stick FREE 14
Computer Continuous Paper 15 14
Tailor & White Long Chalk FREE 14
White Pencil 20 14
Nylon Rope 22 14
Face Mask 20 14
Transmission Belt 15 14
Gloves Textile 30 14
Gloves Rubber 20 14
Safety Shoes 30 14
Over all out fit 40 14
Ribbon & Toners 15 14
Printing Ink FREE 14
Accessory List for Import
IMPORT
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Charges..
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CHARGE TYPE
BAF Bunker Adjustment Factor
BAS Basic Ocean Freight
CCL Container Cleaning
CTO Container terminal Order
DDF Documentation Fee-Designation
DHC Handling Charge- Designation
EMF Equipment Management Fee
ERS Emergency Risk SurchargeEXP Export Service charge
FFC Freight Forwarder Commission
IHI Inland Haulage Import
IMP Import Service charge
ODF Documentation fee-Origin
OHC Handling charge-Origin
PAE Port additional- Export
PIO Pick-up/Drop off
POS Equipment Positioning Surcharge
PSE Port Security Charge-Export
PSS Peak Season Surcharge
SER Carrier Security Charge
TCE Temporary Customs Export
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Continuous..
86 IMPORT
INLAND/LOCAL CHARGES (RAND)
ROAD 20 40
DOCUMENTAION 250 250
INLAND HAULAGE 13669 16295
CONTAINER CLEANING 75 100
CTO FEE 120 120
HANDLING CHARGE 1073 1586
IMPORT SERVICE CHARGE 300 450
PICK UP/DROP OFF 1500 3300
TOTAL CHARGES 16987 22101
Contract No: 530298
SAFMARINEORGIN CHARGES (USD $)
INDIA
Durban Port Elizabeth
20 40 20 40
OCEAN FREIGHT 275 575 275 575
BAF 510 1020 510 1020
EMERGENCY RISK CHARGE 90 180 90 180
SECURITY CHARGE 9 9 9 9
TOTAL CHARGES 884 1784 884 1784
Ch
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Charges..
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COST PER COUNTRY (US $) TRAVEL (Rand)
INDIA PAKISTAN HONG KONG YANITAN DALIAN SHANGHAI QINGDAO ROAD RAIL
20 40 20 40 20 40 20 40 20 40 20 40 20 40 20 40 20 40
SAFMARINE 884 1784 909 1809 1074 2139 1074 2139 1124 2239 1074 2139 1124 2239 16987 22101 9561 18424
MAERSK 859 1709 904 1779 1044 2069 949 1889 1039 2069 924 1839 1146 2281 16987 22101 8676 14449
MOL 1596 3286 1334 2662 1521 3036 1471 2936 1421 2853 1471 2936 1471 2936 14123 15766 11048 19688
IMPORT
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EXPORT
G l P
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General Process
Booking Information like PO, Order List etc.
Arrange Booking by SAEL Forwarder.
Will get Confirmation from Shipping Department.
Check VISA, Certificate of Origin and Commercial
Document. Always contact Merchandiser for all updates.
Currently using FOB for export activities
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MAINTENANCE
B il
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Boiler Operating Procedure
Basic Ideas Currently have two boilers
91 MAINTENACE
Sl.No. PARAMETERS
1 Steam Pressure
2 Water Flow
3 Feed pump
4 CO2
5 Gas Exit Temp
6 Coal Bed Depth
7 Stoker Speed
8 Steam Flow
9 Fuel Trim
10 ID Fan control
11 Blow down secs
12 Gauge glasses blow down
13 Mobrey blow down
14 Soot blowes
15 Fuel ash LR
16 Chem dosing tank
JOHN THOMPSON AFRICA
Design Gauge Pressure 1034 kPa
Design Temperature 250 C
Shop Test Pressure 1551 kPa
Site Test Pressure 1293 kPa
Max.Permissible Operating Pressure 1034 kPa
Operating Pressure 960 kPa
Operating Temperature 183 C
Capacity (Flooded) 34 m3
Fig: Boiler
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WATER TREATMENT
Process Diagram
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Process Diagram
GRIT BASIN:
3 COMPARTMENTS
NEUTRALIZATION
BASIN 1
DAF SYSTEM
BIO TREATMENT
BASIN: 5
NEUTRALIZATION
BASIN 2
COAGULATIONBASIN
SEDIMENTATION
BASIN
A.C.FILTER
3 CYLINDERSEFFLUENT BASIN
WASTE WATER
RECYCLED WATER
PAC NaOHPOLYMER AUTO
MIXING
MACHINE
THICKENIN
G
SLUDGE
DEWATERING
MACHINE
MUD
EQUALIZATION
BASIN
150 cub.m/ h
WATER TREATMENT
O ti P d
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Operation Procedure
Grit Basin: will collect all water from Presitex and CGM.
Having filters in each compartments and separate thread and stone. Equalization base will collect the water from Grit Basin and pump the
water into the neutralization Basin 1.
In Neutralization Basin 1 having a supply of NaOH, Poly Aluminium
chloride, Polymer negative.
From Basin 1 water will supply to DAF system. In DAF system the Indigo
dye will get separated much more using collector.
Collected dye will sent to sludge dewatering machine for further squeezing.
Water from DAF system will pass to Bio Treatment process.
In Bio Treatment Process Bacteria will act to purify the water with enoughquantity of Oxygen. Currently having a five chamber of 2500 cubic meter
water storing.
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Continuous..
In one final compartment there will be purification
process. Here also there is a mixing of polymer negativeis doing for indigo dye filtering.
Through pumps water is then passed to Sedimentation
tank. Here continuous 3 hour sedimentation will do.
Impurities will sediment in down and will remove.
After sedimentation filtering of water will take place in
three cylinders with coconut and coal. And the purified
water is sent back to each department for usage.
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Snaps
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Snaps..
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MERCHANDISING
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