denim garment industry

7/22/2019 Denim Garment Industry

1/98

REPORT ON PRESITEX ENTERPRISE (PTY) LTD

MASERU,KINGDOM OF LESOTHO

VISHNU JAYAKUMAR, MT-I.E1


2/98

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

2


3/98

PRODUCT DETAILS

3


4/98

PROCESS SEQUENCE

FABRIC STORE

ACCESSORY

CUTTING

PATTERNSEWINGSEWING

DRY PROCESS

WASHINGDISPATCH

LOADING

CHEMICAL

PRINTING

SHIPPING

4


5/98

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

5


6/98

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

6


7/98

MATERIAL HANDLING EQUIPMENTS

7


8/98


9/98

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


10/98

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


11/98

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


12/98

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


13/98

PATTERN ROOM

13


14/98

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


15/98

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


16/98

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


17/98

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


18/98

CUTTING

18


19/98

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


20/98

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

CUTTING20


21/98

PLANNING

21


22/98

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


23/98

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


24/98

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


25/98

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


26/98

ACCESSORY STORE

26


27/98

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


28/98

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


29/98

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


30/98

SPARE PARTS

30


31/98

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


32/98

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

SPARE PARTS32


33/98

PR-SEWING

33


34/98

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


35/98

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).xls


36/98

PG-SEWING

36


37/98

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


38/98

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


39/98

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


40/98

INDUSTRIAL ENGINEER

40


41/98

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


42/98

Thread Consumption example

thread consumption.pdf

INDUSTRIAL ENGINEER42
http://localhost/var/www/apps/conversion/tmp/scratch_6/thread%20consumption.pdfhttp://localhost/var/www/apps/conversion/tmp/scratch_6/thread%20consumption.pdf


43/98

DRY PROCESS

43


44/98

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


45/98

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

45


46/98

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


47/98

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


48/98

Quality checking

DRY PROCESS48


49/98

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


50/98

Causes for Defects in garment

Preliminary view Production Rate increase

New workers recruit

Not having Job rotation

Mentality setup

DRY PROCESS50


51/98

WASHING

51


52/98

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


53/98

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


54/98

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


55/98

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


56/98

CHEMICAL STORE

56


57/98

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.

57


58/98

DISPATCH

58


59/98

Operation

CutLoop

Trimming Final QC Blowing Rivets

PressingMeasurement

Buttons

CheckingRivets &Buttons

Pairing

FoldingCheckShade

Repair

WaistTag

SizeLabel

ScanPack

Loading

TARGET/SHIFT

10K-21K

DISPATCH59


60/98

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.xls


61/98

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

61


62/98

QUALITY

62


63/98

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


64/98

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-


65/98

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


66/98

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

66

General points..


67/98

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

67

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..

70 REJECT STORE

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

72

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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81

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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84

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..

85 IMPORT

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

C i


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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..

87

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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90

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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92

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.

94 WATER TREATMENT

C ti


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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.

95 WATER TREATMENT

Snaps


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Snaps..

96 WATER TREATMENT


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97

MERCHANDISING


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