The complete Man – Since 1925

PRESENTED BYAmrita Tiwari(01)Ishan Chawla(08)

CONTENTS

1.Raymond – Since 1925• ABOUT RAYMOND GROUP• HR Policy• Company Profile• Locations of Manufacturing Facilities• Milestones• Group Companies• Joint Ventures• Branded fabric and retail- core focus • Achievements 2. Vapi plant• Hierarchy• Site Map• Plant Layout• Location Advantage• Plant Workforce• Modern Infrastructure• Competitive Advantage Due to Technical Progress• SWOT Analysis

3. Process Flow: Various Departments• SCM Department• Design Department• Quality Department• Production Department

– Scouring– Grey Combing– Dyeing– Recombing– Spinning– Yarn Room– Weaving– Mending– Finishing– Folding

• Costing/Accounting Department

4.Projects undertaken5. Bibliography

Overview- Eight decades old group, in operation since 1925- One of India's largest branded fabric and fashion retailer- Market leader in the worsted fabrics business with over 60% market

share- Second largest branded apparel business in India- Owns prestigious award winning brands like Raymond, Park Avenue,

Colorplus, Parx- Amongst the earliest direct retail chains in India- One of the largest exclusive retail networks in the textile and fashion

space in India- Large India focus, with more than three fourth of revenues from

domestic market- Raymond Ltd, the flagship company of the group, is listed on BSE and

NSE

HR POLICY• HR VISION• "Raymond the most Desired Workplace for Top Talent"• HR MISSION• They commit to the HR vision of making "Raymond the most

Desired Workplace for Top• Talent". They will strive to weave in the core Raymond values

namely Quality, Trust,• Leadership, and Excellence in all our actions & HR processes so as

to make every Raymondite• a Complete Man.• HR VALUE• • Trust• • Quality• • Leadership• • Excellence

COMPANY PROFILE• Name of the company : - Raymond Limited

(Textile division)• Address of Registered Office : - Plot 156/H No.

2, Zadgaon Ratnagiri,415 612,TelNo: +9123524921917Fax: +91 2352 492 3851

• Year of Establishment : - 2005• Year of commencement of Business : - 2005

• Business Activities : - Manufacturing Process of Fibre to Fabric

• Principle Bankers : - (1) Bank of India(2) Bank of Maharashtra(3) Bank of America(4)Central Bank of India(5) City Bank N.A.(6) HDFC Bank Limited(7) The Hongkong and Shanghai Banking Co-operation

Limited(8) Standard Chartered Bank• Auditors : - Dalal & shah• Website : - www.raymondindia.com

LOCATION OF MANUFACTURING FACILITIES

GROUP COMPANIESThere are 10 Companies in Raymond Group.• Raymond Ltd.• Raymond Apparel Ltd.• Color Plus Fashions Ltd.• Silver Spark Apparel Ltd.• Regency Textile Portuguesa Ltd• Ever Blue Apparel Ltd. • Celebrations Apparel Ltd.• J.K. Files & Tools• Ring Plus Aqua Ltd.• J.K. Helene Curtis Ltd.• J.K. Investo Trade (India) Ltd.

JOINT VENTURES• Raymond UCO Denim Pvt. Ltd.• Raymond Zambaiti Pvt. Ltd. • Raymond Woolen Outerwear Ltd. • Gas Apparel Pvt. Ltd. • J.K. Ansell Ltd. • J.K. Talabot Ltd.

ACHIEVEMENTS• Images Fashion Awards 2009 - Most Admired

Textile Brand of the Year • Reader's Digest - Platinum Trusted Brand,

2008 • Lycra Images Fashion Awards 2008 - Most

Admired Textile Brand of the Year • Lycra Images Fashion Awards 2008 - Most

Admired Suiting Brand of the Year • CNBC Consumer Award 2007 - The Best

Branded Readymade Garment and Textile

VAPI PLANT

Site OverviewLand – 112.61 Acres

Industrial – 94.43 Acres Resi – 18.18 Acres

(a) Factory Building:

• Ware House (Finished goods store) : 5,025 sq. mtr.• Folding Dept. + (AWT) : 1,730 sq. mtr• Process & Finishing Plant : 5,797 sq. mtr.• Passage : 144sq.mtr.• Weaving plant + (AWT) : 7,000 sq. mtr.• Boiler House : 1,080 sq. mtr.• Substation (HT/LT/Com/ workshop) : 1,430 sq. mtr.• Switch yard : 2,652 sq. mtr

(b)Miscellaneous Structures:

• Security room : 47 sq. mtr.• Time office / Disp. /Creche : 450 sq. mtr.• Engineering Office & stores : 460 sq. mtr.• WTP and Raw water tank : 1,245 sq. mtr. (40 lac ltr)• ETP plant : 1,350 sq. mtr.• Over head tank : 8 lac ltr cap. • Over head tank : 8 lac ltr cap.

III Phase site overview: The company has started a new plant

PLANT LAYOUT

LOCATION ADVANTAGE

• Situated in Gujarat- known for its good governance• Situated on NH no.8 and near to industrial Hub• Well connected by Rail & Road• Proximity to Mumbai/Thane• Accessibility of skilled manpower• Continuous availability of water• Urbanized and literate people• Multi- culture community with communal harmony

PLANT WORKFORCE• Human resource department is devoted to providing

effective policies, procedures, and people-friendly guidelines and support within companies.

Following types of person are employed/ engaged at site:

• Management staff• Workmen• Fixed period employees• Contract labors• Job contract• Labor contract

SWOT AnalysisStrengths• • Location Advantage• • Water availability• • Raw material Availability• • Modern world class machineries• • Skilled labour at low costWeaknesses• • Current Scenario of market• • Effect of government policiesOpportunities• • Increase focus on product development• • 100% capacity utilization• • Increase foreign market businessThreats• • Competition in Domestic and International market• • Ecological & social awareness• • Regional Alliances

VARIOUS DEPARTMENT

PROCESS FLOW: VARIOUS DEPARTMENTSINTRODUCTION• Production is the functional area responsible for

turning inputs into finished outputs through a series of production processes.

• The production and planning department will set standards and targets for each section of the

production process.• The quantity and quality of products coming off a

production line will be closely monitored. In businesses focusing on lean production, quality will be monitored by all employees at every stage of production, rather than at the end as is the case for businesses using a quality control approach.

NAME OF THEDEPARTMENTS

• SCM Department• Design Department• Quality Department• Production Departmento SCOURINGo GREY COMBINGo CONVERTERo RECOMBINGo DYEINGo SPINNINGo WEAVINGo FINISHINGFOLDINGo WAREOUSE• Costing/Accounting Department

1.SUPPLY CHAIN MANAGEMENT DEPARTMENTINTRODUCTION• SCM REFERS TO SUPPLY CHAIN MANAGEMENT• SCM is the core Department which mainly deals

with the planning & control activities of each plan. It provides link between departments.

• Strategy & Analysis.• Supply Chain Planning• Core Processes

2.QUALITY CONTROL

Central laboratory works in association with R & D and Q.C. departments.

• The basic function of Central lab is to check the final product. Also it carries out testing of faults and complaints in the fabric.

• The central laboratory mainly functions for all kinds of testing, both physical and chemical. Testing of the material is done in the fiber, yarn and fabric stages.

• Decentralization of the department is done into the departmental laboratories i.e.

• 1. Combing laboratory.• 2. Spinning laboratory.• 3. Finishing laboratory.

COMBING LABORATORY• The combing lab is a division of the central lab in the combing department.

Various tests carried out in this lab on the material in the filter stage.Chemical tests carried out in Combing Laboratory• 1. Blend composition.• 2. Moisture contents.• 3. Residual grease contents.Physical tests carried out in Combing Laboratory• Mean fiber length testing

Instrument – Almeter.• Fiber fineness measurements. Instrument– A)WIRA Fineness Meter B) Projection Microscope• Measurements of the crimps.• Measurement of the denier of polyester.• Visual assessment of vegetable matter, Slubs, clusters etc.

• SPINNING LABORATORY The spinning lab is a branch of the central lab in

the spinning department.• Tests carried out in Spinning Laboratory 1. Count measurements. 2. Single yarn stage measurements. 3. Twist measurements 4. Testing of the roving frame as well as rubbing

of the rubbing frame. 5. Hairiness testing. 6. Tensile strength measurement.

• FINISHING LABORATORY After weaving, the properties of the fabric are

checked in the finishing laboratory.• Tests carried out in Finishing Laboratory 1. Relaxation shrinkage percentage. 2. Piling resistance (sample size – 24 cm * 10 cm). 3. Color fastness to water (sample size 10cm*

4cm). 4. Crock fastness. 5. Wet fastness. 6. Dry cleaning and steaming shrinkage test.

CENTRALIZED LABORATORY• Most of the physical and chemical tests are carried out in

centralized laboratory. The samples tested are of Raymond as well as those received from out side parties.

Tests carried out in Central Laboratory 1. Light fastness. 2. Twist testing. 3. Elongation testing. 4. Seam slippage testing. 5. Yarn testing. 6. Drape testing. 7. Fabric tensile testing. 8. Tensile strength testing. 9. Abrasion testing. 10. Crease recovery testing.

3.PRODUCTION DEPARTMENT

Bales

SCOURINGOBJECTIVE• It is a process of removing grease and other impurities with hot

water, soda ash and detergent. It is a chemical process carried out in a series of bowls where the wool is washed thoroughly.

• The impurities present in wool are • Natural impurities –oil, fats, secreted by sebaceous glands of

animal skin (wool fat) • Acquired impurities- sand, dust, and vegetable matter. • Applied impurities- raw wool contents 24 to 25 % of impuritiesWOOL SCOURING: • Capacity of the machine is to feed 950 kg of wool per hr. • Clean wool yield: 60 to 65% that depends up on wool quality. • We are getting 3 to 4 % more yield than the standard

recommended value.

GREY COMBINGCARDING OBJECTIVE• Opening of individual fibers• Elimination of impurities (80-95%)• Elimination of dust from the materials.• Disentanglement of neps.• Elimination of short fiber.• Fiber blending, orientation & sliver formation

GILLINGOBJECTIVE• Parallelisation of fibers.• Reduction in weight per unit length of sliver.• Improving uniformity of sliver material by using multiple passages.• To prepare a sliver of required wrapping for further processing• To lay the sliver into can.TYPES OF GILL BOXES• Open gill box has a single set of fallers.• Intersecting gill box has multiple sets of fallers.• Rotary gill box has 6 rollers (3 / 3) each having spiked rings.• Line C is for Blending – Recombing – Gilling.DEFECTS

The defects in gilling are as follows:• Inadequate pressure on roller• Broken pins or improper density• Improper feelers and improper gilling.• Production – 180-240 Kgs/hr

PROCESS FLOW • Recombing• Blender• Gill Box - 1• Gill Box - 2• Gill Box - 3• Comber• Gill Box - 4• Gill Box - 5

COMBINGCombing is a process followed after the gilling in

the grey scouring section for the following reasons,• To remove short fibers from the material• To remove all vegetable (foreign) matter• To straighten and parallelise the fiber• To remove the neps and• To lay the sliver into cans.

DYEINGDYEING: ( Bellini )TOP DYEING• Top dyeing is carried out after the first round gilling and

combing operations are over for the sample. In top dyeing at first, sample dyeing is done in which 5 kg of material is dyed in the laboratory and then after increasing proportions of the chemicals dyes entire bulk required for dyeing.

• Dyes used for wool are modified metal complex, 1:2 Metal Complex, acid milling dyes,chrome dyes. PET is always dyed with disperse dyes.

GENERAL INFORMATION• Capacity Of Machine – Minimum 5Kgs And Maximum

400Kgs• Temperature (Oc) – 98 For Wool And 135 For Polyester• Material To Liquor Ratio – 1: 20• Time Required Light Shade - Wool-3 Hr, Poly-4 Hr

Medium Shade - Wool-4 Hr, Poly-5 HrDark Shade -Wool- 5hr, Poly-6 HrExtra Dark Shade- Wool- 6 Hr, Poly-7hr

• Each dyeing machine is connected with a microprocessor in which various dyeing programmes are fed as per the material and shade.

RECOMBING• Main function of this process is to proper

blending of polyester & wool according to given proportion & at the same time maintaining the

shade by proper mixing of component,• General processes:• 55% Poly & 45% wool• 65% Poly & 35% wool• 38 % wool & 62 % wool• These are the commonly used blends. According

to blend dept decides & calculate feeding of poly & wool.

SPINNINGTOP STORAGE• When the tops coming from combing dept

they are stored for conditioning in the trolley.• The conditionings room is enclosed one and

humidifiers are installed for conditioning of tops.

• The conditioning time is around 24 hrs. After conditioning material is taken for spinning process.

ROVING FRAMEThe main objectives of the roving frame are as follows

• Attenuation of material• Preparation of suitable package for ring frame.

RING FRAMEThe rubbing and roving frame bobbins are brought to ring

frame dept. the roving is converted into yarn by drafting and twisting.

The objectives of the ring frame are as follows• Attenuation and• Twisting and winding on the bobbin. Factors to be considered in promoting good spinning are as

follows• Count of yarn• Position of spindle rail• Correct type travelers and• Satisfactory spindle speed.

WEAVINGSECTIONAL WARPINGOBJECTIVE• To produce weavers beam.• To wind the warp end with equal tension on each and

every end.• To produce different colour patterns.• To produce a compact beam (without valleys and ridges).• Sectional warping is done when one needs to produce some

design i.e. beam contain some different colours of yarn then sectional warping is used. In sectional warping, the warp threads are wound on the warping drum sectionally. After winding on drum it is then taken on weavers beam.

WARPING FAULTS1. Yarn cone of wrong size.2. Wrong built of cone3. Tension variation during warping.4. Count mix during creeling.5. Broken ends improperly repairs.

LOOM SHEDINTRODUCTION• Weaving is the basic department for preparing a

fabric by interlacement of warp and weft yarns. There are various looms for weaving available in the textile industry.

• In RAYMONDS LTD., there are two types of looms-

Projectile (SULZER RUTI) and Rapier looms (RIGID /FLEXIBLE RAPIER).• About 225OO meters of linear fabric is produced

per day. There are total 112 looms working in three shifts. That means each loom is producing about 92 meters of fabric per shift.

MENDINGOBJECTIVE OF MENDING• To remove mend able spinning & weaving the

defects from the fabric like neps , slubs , Missing end, loose pick etc

• After the mending fabric is delivered to Finishing

FINISHING Finishing department in Raymond is divided into

3 sections viz. • Grey House, • Wet Finish • Dry FinishGREY HOUSE This section is called grey house because all the

grey material from the weaving department after perching and mending is being sent to grey house. It includes grey scouring,heat setting and singeing.

WET FINISH• This section is known as wet finish section

because all the treatments that are carried out on the material are in wet form that includes rescouring and chemical treatment.

DRY FINISH• This section is called the dry finish section as here

the fabric is treated in dry form throughout. Only mechanical operations are rendered to the fabric in order to enhance its look shine and feel. This treatment is generally under the influence of pressure and steam

FOLDING• In this department checking of the fabric, cutting and

packing take place.• Finish of the fabric approved as per the approved hanger

from the product department Shade checking is done as per the booking hanger

• There are two markets Domestic :- Civil, Exclusive and Stock Lot Export , RAL, RMG & Institutional• CIVIL Visual inspection• 5 TYPES OF GRADING 1. Good, 2. Second “A”, 3. Second “B”, 4. Second “C”, 5.

Second “D”.

COSTING / ACCOUNTING DEPARTMENT

OBJECTIVES OF COSTING DEPT• Budgeting • Fixed expenses, variable expenses• Product costing• Cost audit• Profit planning• Inventory valuation• MIS report (Management Information System)

By considering following costs the total costing is carried out

DIRECT VARIABLE COST (DVC): - In DVC following things are considered• Raw material cost• Dyes and chemical cost• Combing cost• Spinning cost• Conversion cost

In conversion cost there are various process cost are included

• Weaving cost • Dyeing cost • Wet Finishing cost • Dry Finishing cost • Doubling (for double yarn)

5.Projects PROJECT 1: OBJECTIVE: TESTING OF TOP DYED

WOOL There are various tests performed to determine various quality parameters of top

dyed wool. These tests are as follows :

1. WASHING FASTNESS :-OBJECT : To check out the washing fastness of the given sample.

Atmospheric conditions : 70 to 90 0F Apparatus used : Washometer, measuring jar, scissors, grey scale, required

adjacent fabric (for covering the sample), etc. Detergent used : Surf excelResult : No staining or change in colour occurs. Reading on grey scale is 4/5.

2. MOSTURE CONTENT :-

OBJECT : To determine the percentage of moisture content present in the top dyed wool sample.

• Apparatus used : Air oven, weighing balance (to the accuracy of 0.01), etc.

RESULT : It’s average value is found to be 14 % (approx.).

3. OIL CONTENT :-

• OBJECT : To determine the oil content (%) in the top dyed wool sample.

• Apparatus used : Oil extractor, hot plate, weighing balance, container, etc.

• Chemical used : Methanol (50 mL)

Where, W1 = Initial wt. of the sample in gms W2 = Container wt.(empty) in gms W3 = Container wt.(with Oil) in gms 0.03 = Error correction

RESULT : It’s average value is found to be 0.42 %.

PROJECT 2: EFFECT OF FINENESS ON SHADE

• OBJECT : To observe the variation in shade according to the fineness of given wool sample.

• MATERIALS REQUIRED : Samples of wool of various fineness as :• 1. 17.5 Mic • 2. 19.0 Mic• 3. 21.0 Mic • 4. 24.5 Mic• DYE USED :ISOLAN YELLOW 2S 2GLN• CHEMICALS USED :Green acid, Opticid PB IN Liq, Uniperol FBSE• SHADE: Light shade of 0.5%.

• RESULT : “Finer the material, lighter the shade” it produces at same dyeing condition.

• REASON FOR THE VARIATION : Since the material of lesser micron i.e. finer one, have more number of fibres in it considering equal amount of sample weight as compared to that of those coarser ones. Therefore, the finer the sample the lighter the shade it will produce for the same recipe.

Project 3: Deriving a Time Standard Using Work Sampling

• Work Sampling : A technique to measure work activity as related to delays consisting of intermittent observations of actual work and delays. Also known as activity sampling; frequency study; ratio delay study.

• Observing an activity 100 times may not , however , provide the accuracy desired in the estimate . To refine this estimate , three main issues must be decided.

• What level of statistical confidence is desired in the results?• Hoe many observations are necessary?• Precisely when should the observations be made?

The three primary application for work sampling are• Ratio delay to determine the activity-time percentage for

personnel or equipment . For example, management may be interested in the amount of tine a machine is running or idle.

• Performance measurement to develop a performance index for workers. When the amount of work time is related to the quantity of output , a measure of performance is developed. This is related to the quantity of output, a measure of performance is developed. This is useful for periodic performance evaluation.

• Time standards to obtain the standard time for a task. When work sampling is used for this purpose, however, the observer must be experienced because he or she must attach a performance rating to the observations.

• Standard time per piece= (((Total time in minutes)*(Working time proportion)*(Performance index))/(Total number of pieces produced))*(1/(1-Allowences))

• (1- machine is on work)• (0- machine is on hold)

Result: • So, average standard time per piece =

(168.2353+183.5294+152.9412+175.8824+160.5882)/5

=168.2353 minutes

6.Bibliography • Apparel standard and quality specifications • By S. Jacob • Fiber to Fabric• Raymond machine manuals• www.raymondindia.com