laundry operations - lavale

7/29/2019 Laundry Operations - Lavale

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LAUNDRY SERVICEAT LAVALEPROCESS ANALYSISAND

IMPROVEMENTS


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PROCESSMAPPING

Work Break Down

Structure Duration Start Time Finish Time

Laundry Process 2846.3 min 28-09-2009 19:26 30-09-2009 18:52

Cloth Collection

906.3 min 28-09-2009 19:26 29-09-2009 10:32

Collection of clothes at

counter 1.5 min 28-09-2009 19:26 28-09-2009 19:28

Making Cash Memo &

Handing over Cash

memo to student 1.8 min 28-09-2009 19:28 28-09-2009 19:29

Tagging(indicating room

no , total cloth & bill no)

on one cloth in a lot 1 min 28-09-2009 19:29 28-09-2009 19:30

Tie a knot on the lot 1 min 28-09-2009 19:30 28-09-2009 19:31

Accumulate the clothes

of all student at one

place 1 min 28-09-2009 19:31 28-09-2009 19:32

Wait for Transportation 900 min 28-09-2009 19:32 29-09-2009 10:32

Work break down for a bundle of 10 clothes ordered for washing:


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PROCESSMAPPING..CONTD

Work Break Down


Transportation from

Lavale to Katraj

90 min 29-09-2009 10:32 29-09-2009 12:02

Loading of accumulated

clothes on APE 30 min 29-09-2009 10:32 29-09-2009 11:02

Transportation (25 Km)

to Washing location

(katraj) 60 min 29-09-2009 11:02 29-09-2009 12:02

Activities in Katraj

64 min 29-09-2009 12:02 29-09-2009 13:06

Wait for Processing to

start 60 min 29-09-2009 12:02 29-09-2009 13:02

Marking of room no on

each cloth of each lot 2 min 29-09-2009 13:02 29-09-2009 13:04

Segregation based on

Colour and Type 1 min 29-09-2009 13:04 29-09-2009 13:05

Assigning of tag on

cloth where it is not

easy to mention

marking 1 min 29-09-2009 13:05 29-09-2009 13:06


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Work Break Down


Washing Activities at

Katraj

1274 min 29-09-2009 13:06 30-09-2009 10:20

Making of lot (around 50)to be loaded in washing

machine 2 min 29-09-2009 13:06 29-09-2009 13:08

Starting of washing

machine by adding

Washing powder 10 min 29-09-2009 13:08 29-09-2009 13:18

Washing of clothes in a lot

of 50 30 min 29-09-2009 13:18 29-09-2009 13:48

Taking out of clothes from

washing machine 10 min 29-09-2009 13:48 29-09-2009 13:58

Putting clothes in Hydro-

spinner for rinsing 15 min 29-09-2009 13:58 29-09-2009 14:13

Rinsing Process 15 min 29-09-2009 14:13 29-09-2009 14:28

Taking out of clothes from

hydro-spinner to Dryer 10 min 29-09-2009 14:28 29-09-2009 14:38

Dryer Run 2 min 29-09-2009 14:38 29-09-2009 14:40

Putting Clothes for Drying

in an Open Area 10 min 29-09-2009 14:40 29-09-2009 14:50

Clothes Drying Process &

Waiting for Pick up 1140 min 29-09-2009 14:50 30-09-2009 09:50

Accumulation of all dried

clothes in mixed condition 30 min 30-09-2009 09:50 30-09-2009 10:20


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Work Break Down


Transportation from

Katraj to Lavale

90 min 30-09-2009 10:20 30-09-2009 11:50

Transportation ofdried clothes in mixed

condition to college 60 min 30-09-2009 10:20 30-09-2009 11:20

Unloading the clothes

from tempo to

Laundry in hostel 30 min 30-09-2009 11:20 30-09-2009 11:50


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Work Break Down


Front end activites in

Lavale

420 min 30-09-2009 11:50 30-09-2009 18:50

Segregation of clothes

according to the floor

series 20 min 30-09-2009 11:50 30-09-2009 12:10

Segregation of clothes

according to the roomno. 10 min 30-09-2009 12:10 30-09-2009 12:20

Ironing of clothes 25 min 30-09-2009 12:20 30-09-2009 12:45

Keeping the pressed

clothes on shelf for

delivery 2 min 30-09-2009 12:45 30-09-2009 12:47

Waiting for Delivery 360 min 30-09-2009 12:47 30-09-2009 18:47

Delivery of clothes

against producing the

receipt by student 3 min 30-09-2009 18:47 30-09-2009 18:50

Payment collection 2 min 30-09-2009 18:50 30-09-2009 18:52


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PROCESS DOCUMENTATION

Over The Counter Operations:

Collection of Clothes:

General scanning of the cloth by the person to ensure

the condition (torn parts, hard strains, decoloured areas,

etc.) of an incoming order

Checking for any articles in the pockets or otherwise

Checking for the type of incoming clothes from the

bundle (say no. of shirts, trousers, jeans, etc.)


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PROCESS DOCUMENTATION.CONTD.

Cash Memo for the receipt of Clothes: Prepare a Cash Memo indicting the Room No., type of clothes,

the amount to be charged and date of order placement

Tagging of Lot:

Tagging is done on the cloth which is used to tie the bundle. Tag is marked with Room No., Code to indicate Boys Hostel as

BH and Ladies Hostel as LH and also an additional code toidentify that clothes are from Lavale Campus.

Permanent marker is used for tagging and this is doneimmediately after cash memo and before he takes up newcustomer order so that there are no mistakes in tagging and

bundling.

Aggregation of the clothes: The clothes received for washing are all put on a pile so that they

can all be bundled for transportation to the washing area.


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Transportation from Lavale to Katraj:

The washing activity is done at Katraj which is at 25 km from

Lavale.

A tempo (APE) comes to Lavale from Katraj once daily with

washed clothes coming from Katraj and unwashed bundlesare taken from here.

The clothes from the ladies hostel are also brought in to make

bundles.

Generally 4-5(max) bundles are loaded on the APE.

Approximately 450-500 clothes are sent daily.

The only person manning is the driver who is employed by

the Laundry. The two people at the boys hostel and 1 at girls

hostel help in loading and unloading.

It takes approx. 1hr in travelling from Katraj to Lavale and 30

min in loading and unloading process.


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Activities in Katraj:

Details about Katraj The total area in Katraj is about 2700 sq. feet. Ground floor is about 1000 sq. feet which is

used for sorting and washing. First floor is also around 1000 sq. feet and is used mainly fordrying the Clothes. At a time around 300-400 cloth can be dried in this place. Second flooris around 700 sq. feet which is an open space and this is also used for drying Clothes.

Around 150-200 Clothes can be dried in this place at a time.

Washing Machine: There are 2 washing machine one hydro spinner and one dryer in the washing area.

Maximum capacity of one of the machine is 120 Clothes and that of the other is 50Clothes. However the safe working load for each one of them is 60-70 and 30-40respectively.

Segregation based on type and colour:

Bundles are opened and room no. is marked on every cloth

Clothes are segregated based on type (jeans, t-shirt, shirt, trouser) and colour

Wherever it is difficult to mark, tags are put on the cloth



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Washing Activities

Clothes are bundled in the group as per the safe working load. These bundling isdone based on colour. Similar colour Clothes are bundled together.

Washing machine is started by adding washing powder (Tide in the case).

A lot of cloth is added to the machine and the machine is started. It takes around 40to 45 minutes to wash the Clothes in the machine.

Once the washing is done Clothes are taken out for drying. The lot is put in the hydro spinner for drying. Water is drained from the spinner in this

area and then finally the cloth is taken in open area for drying.

Clothes are put in the open area for drying.

Once the Clothes are dried they are again collected and bundled together to be sentto college. Clothes are collected in mixed condition and segregation is not done inthis place.

Transportation from Katraj to Lavale

Bundle of dry Clothes are taken and put in Ape which has capacity of around 450-500 Clothes.

The transportation time from katraj to lavale is around an hour.

Once the cloth reaches the hostel its unloaded from the Ape and taken to the BH.



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Receiving of Washed Clothes from Katraj: Washed clothes arrive typically by afternoon to Lavale.

All clothes are first received at the boys hostel.

These are unbundled and sorted for LH and BH.

The Ladies hostel guy takes care of the clothes for the LH at

the LH counter.

Segregation of clothes: The tags on each clothes are read and sorted by the Floor no.

series on the floor. Heaps are made on the floor and areready for ironing. There are 2 person involved in the ironing

process at BH. Ironing and stacking of clothes of w.r.t. the room no. is done

while ironing. The device used here is Electric Metal Press.

The role of the person who does ironing is also to stack theclothes as per room no. and place accordingly on the racksfor disbursal.


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Delivery to the Customers:

On the show of the cash memo indicating room no. and date

of order, the delivery boy lets the customer know whether his

clothes are ready or not.

If he is aware that the clothes for that days lot have arrived,he checks on the delivery rack and on finding them there, he

delivers it and accepts cash.

The person on the counter also takes a note of the amount

cash collected in a separate register.

For the instances where a customer is not having the cash

memo of the order, he asks for the room no. from him and

then writes in a register the name of the person so that he

can track the outgoing clothes or any wrong deliveries.

In case the clothes of a customer is not in the incoming pile

then, he postpones his delivery date to next date.


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Front-end Counters (Lavale)Boys

Hostel

Girls

Hostel Activities

Area (Sq ft) 500 500 Managing Counter, Sorting,

Ironing and TransportingRent (Rs ) 5000 5000

Washing and Drying Area (Katraj)

Area Purpose Capacity

Ground floor 1000 sq ft

Sorting,

Washing

First Floor 1000 sq ft Drying 300-400 clothesSecond floor(open to sky) 700 sq ft Drying 150-200 clothes

FACILITIES AVAILABLE AT LAUNDRY


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Max Capacity Safe Loading Cost(Rs)

Washing Machine 1 120 clothes per lot 60-70 clothes per lot 250000

Washing Machine 2 50 clothes per lot 30-40 clothes per lot 120000

Hydro Spinner 25000

Dryer 60000

WASHING MACHINE DETAILS AT KATRAJ


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RESOURCE USAGE:

Resources No. of Persons Rate

Counter Operation 2 5000

Ironing 3 1 per piece

Washing 3 3000Ape 1 On Contract

Electricity 2500 per month


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RATE CHARTOF LAUNDRY:

Sl No. Item Rate (Rs.)

1 Formal Shirt 7

2 T- Shirt 7

3 Formal Paint 7

4 Jeans Pant 8

5 Waist 7

6 Underwear 57 Socks 5

8 Handkerchief 5

9 Bed sheet 15

10 Pillow Cover 711 Tie 7

12 Coat 25

13 Sweat Shirt 15

14 Towel 10

15 Blanket 50


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COST ANALYSIS:Revenue Structure

No. of Clothes Per Month Avg. Rate Revenue

Lavale(1000/2*1*30) 15000 8 120000

Infosys(500) 500 5 2500

Hotels 900 8 7200

Total 129700Expense Structure

Item Head Amount Total per Month

Rent 15000

Ironing 18000

Transportation 12000

Electricity 2500

Manpower 19000Materials 6000

Water 2000

Misc. Expenses 10000

84500

Depreciation of Assets

Washing Machine 1 250000

Washing Machine 2 120000Hydro Spinner 25000

Dryer 60000

Net CAPEX 455000

Appropriated over 60 months 7583

Preventive & Breakdown Maint. 2500 10083

WACC @ 15% 937769 15629

Total Expenses 110213

Net Monthly Profit 19487


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CAUSESFORBADSERVICELEVELINLAUNDRY Increased Order fill time (OFT):

Since the process is not mechanised, loss in productivity can causebackorders and piling of clothes at the Counter or Washing Area either dueto controllable factors (issues due to manpower, bad scheduling, bundlemishandling, and transportation) or uncontrollable factors (bad weather,intermittent power cuts)

Sudden spike in customer orders (due to bad weather, after a longweekend, some college activity, exam time) will cause a piling ofclothes since the capacity (washing/ironing) is just matching tomeet the demand.

There is NO system to ensure that piles of clothes received in aday are washed and stacked together so that misplacing of clothesis avoided at Katraj facility.

Power cut while washing can cause over soaking and the clothescolour may get damaged.

Washing of soft clothes with heavy items can damage the textureover a period of time.

There is NO system to customize washing for a particular clothwhich has dark stains. The laundry on student complaints re-takeswashing of the same cloth in the same way as bulk washing isdone, which makes it no better.


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SUGGESTIVE PROCESS IMPROVEMENTSINTHE

EXISTING LAUNDRY:

The two separate counters at Boys and Ladies Hostel

could be replaced by a single counter at a common areathereby reducing manpower by 1 and rent of facility by say50% if a combined counter is of larger size and rent is7500 pm.

Ironing process may not be outsourced and the people

can be hired on wage basis rather than by piece basis.This leads to both increases in customer service levels aswell as reduced cost of the laundry owner. Even If 3people are hired for this purpose assuming 5000 perperson per month, it will lead to a saving of 36,000 per

year increasing the profit by 15 percent. The clothes should go to drying as soon as they are out of

the process from hydro dryer so that the capacity ondrying can be increased to face a peak order. It will lead toformation of a capacity buffer at the drying process.


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SUGGESTIVE PROCESS IMPROVEMENTSINTHE

EXISTING LAUNDRY............CONTD.

The marking of clothes needs to be improved to includedifferent marks for different people staying in the sameroom so that Order fill accuracy (OFA) can be improved.

The room wise sorting can be done at the facility atKatraj in the morning once the clothes have been driedand then they can be separated according to roomnumbers. It leads to more capacity at ironing as well ascustomer service counter.

Some amount of value added service like minor stitchrepairs, button fixing, zipper change, hemming, etc. canbe done at the front end counter by the ironing personand this will be added revenue at no extra cost otherthan a sewing machine and having a ironing person withbasic stitching skills.


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laundry operations - lavale

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