DORE DOR CASESubmitted By(Grp-1)

Dhananjay Rastogi(Roll-11)Md Harun Rasheed(Roll-24)Prachi Srivastava(Roll-30)

Dore Dore Company BackgroundDore Dore was manufacturer of fashionable Knitted Products.It has two Business UnitHosiery Unit: Socks and Stockings, which contributes 88% of Dore Dore total sale.Knitwear Division: Produce childrens knitwear such as Playclothes,Sweaters and Nightclothes.DD focus on high end of market with regard to Quality and quantityDD has 30-40% market share in High end segment.DD represent 4-5% market in Hosiery Segment and 0.5% in Knitwear Division.

Issues in OperationIt has two Operating location-MERY Plant for Children Knitwear Operation-GRES Complex has Hosiery Factory and HQEach season DD produced each style in two seasons in hosiery and preset production for Knitwear in hosiery and preset production for Knitwear division.Uncertain ForecastHigh Inventory Cost,Many times Items were left UnsoldDore Dore is planning for reduce manufacturing Lead time by tracking demand fluctuationThe company wanted to get into Cellular Design for better Production and Operational Utilization.

Production Cycle for KnitwearCompany is Presently Using Product design layout for Operation Production

Each Worker repeatedly perform single specific task on each batch of items

Same style and same orders were placed every time and delivery is in advance

The Impact of Cellular design process on Hosiery design were studied in consultation with ITF

Main objective to design such a layout to reduce lead time

U Shaped Process Design LayoutA prototype U shaped close knit process design of flexible cell was made operational.It has close knit seven operation for particular batch with six chosen cross trained operatorsBatches of about 200 pieces of same style and color were expected to flow quickly through cell through each operator.

It caused throughput time of garment to dropped from 15 Working day to 1 day.Defect rate also dropped from 5% to 2.5 %IR of factory setup improved resulted in better productivityOther cell, different from first one also placed near tradition line operation.

RESULT AND ADVANTAGE

PRODUCTION CYCLE FOR HOSIERY OPERATION Very High Raw Material Inventory, It generates product of different style, size, color with total of 35000 SKUs.

Production in Batches with same colour and style with multiple sizes.

High Setup time for Knitting Machine ,Toe closing room is noisy, crowded and Windowless

Overall Current production system is rigid and not very Lean

PROPOSED MODIFIACTIONDesign such a layout where minimum possible change is required for Designing the task.All Operation after Knitting to be clubbed together in single roomNew cell design will be based on capacity of two ironing MachinesEach cell is assigned with 36 Workmen in teams of two responsible for production of entire line of hosiery.Teams should not be completely cross trainedIt is expected that Mfg time will drop by 1 week and Inventory would drop by 30-40%

*