REPORT ON PRESITEX ENTERPRISE (PTY) LTD

MASERU,KINGDOM OF LESOTHO

VISHNU JAYAKUMAR, MT-I.E

COMPANY PROFILE

Year of establishment Number of employees Area In SQM

2000

2031 ( August 1st 2011)

222,500

Sales turnover (2009 - 2010)

Exports Turnover Core Activity

$ 94 M

$ 84.6 M

Manufacturer of garments like Jeans, Jacket etc.

Industries Catered

Textile, Garment Industries

PRODUCT DETAILS

PROCESS SEQUENCE
FABRIC STORE ACCESSORY CUTTING PRINTING

SEWING

SEWING

PATTERN

DRY PROCESS

LOADING

SHIPPING

CHEMICAL
4

WASHING

DISPATCH

DATA COLLECTION
TheoreticalTakt Time
Customer PS No Demand/month LEVIS
Days 4.5 4 3.5 3 2.5 2 1.5 1 0.5 0

Time study

15093 440000 garment (Apprx.)

Shop Floor Availability

No of Shifts Shift Hours Lunch Break Available time / Shift 1 10Hrs 60Min 540Min / Shift

Fabric Store 4

Access Dry Washin Dispatc Pattern Cutting Sewing ory Process g h 1 1 1 2.5 2 2 2

Operation

Total working days Total Available Time / month =

22days 11880Min 712800Sec

Takt Time =

Total Available Time / Demand 0.027 min/garment

PROCESS PARAMETERS
Machines OEE(24 hr) Max output / hr / Mc MTBF (minutes) For each Needed Floor Space (sqm) individual Connected load in KW

General for all operations

operations

interest rate for recovery period

Time (seconds) process time changeover time / pc loading time takt time / pc

Process Lead time/garment(days)

Cycle Time / garment (Sec) Man-Machine Availability Rejections Ratios Manual Material handling between stations(min/bin)

electricity tariff in r/Kwh

shift/day working hours/shift wage/hour in rs (high qualified)

Machine cost (R) Saler price recovery period (years)

Labour cost (R) personal expense/shift & machine employee employee's qualification (wage level) Manufacture number of work pc/station Employee analysis accident rate

wage/hour in rs (normal qualified) wage/hour in rs (low qualified)

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

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

MATERIAL HANDLING EQUIPMENTS

FABRIC STORE

Shop Floor Details

SL No. 1 2 OPERATION Arrival of container Uploading to the shop floor Shrinkage Inspection 01 02 DIVISION MANPOWER

3
4

Shrinkage cutting 25 * 25 (10%)

Shade blanket cutting 8 * 8

Issuing
Supervisor

02
01

5 6
7 8

Inspection 10% from current arrival After wash of shrinkage- measure length and width After wash of shade changes will categories into A , B & C etc.
Request from cutting department for fabric and will provide as much required.

Unloading etc 09 Total 15

FABRIC STORE

Point system-American Standard-Levis

1-point 2-point 3-point 4-point : Defect less than 3 : Defects exceeding 3 up to 6 : Defect exceeding 6 up to 9 : 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.
SL No. 1 2 Length (Yard) 138 104.9 Width( Yard) Setup Time (Min) 58.5 58.5 5.58 7.2 Inspection (min) 25.34 25.04 Point Calculation 3 2.56

Fig: Inspection Machine

10

FABRIC STORE

General Ideas
Supply chain Management- Ship Routes PS NUMBER WASH NAME

P-11002
P-11003 P-11006 P-11007 P-11008

Medium
Dark Relaxed Medium Journey Anthem

1.India-> Durban -> Lesotho 2.India -> Cape town -> Lesotho 3.Pakistan -> Durban -> Lesotho

P-11009
P-11011
Time Average

Rustic
Summit

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

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.

11

FABRIC STORE

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
12

FABRIC STORE

PATTERN ROOM

13

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.

14

PATTERN

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 as example. So the size issue, because of external issues like shrinkage will always between this.

15

PATTERN

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

16

PATTERN

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 fabric shrinkage 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 stock level in previous production. Printer needs at least 20-30 minutes to make a printout.

Currently in pattern department there are 2 + 1 workers

17

PATTERN

CUTTING

18

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.
19

Current capacity is 20,000 pieces in a day.

CUTTING

Shop floor details

Manpower: 71 workers + 2 Supervisors excluding quality department

OPERATION: LAYERING Keeping cutting machine to the place Layering in sequence as per style Keeping bundle in to the position Quality check in each layers MANPOWER Target Maximum 20,000 pieces per day

SL. No 1

2 3 4

2 2 1

20

CUTTING

PLANNING

21

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

22

PLANNING

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.
23

PLANNING

Departmental capacity

Example
Sewing department:
Lead time
Total time availability Machine hour

= 21.32 minutes
= 9 * 60 = 110 * 9 * 60 = 59400 minutes

Number of Manpower = 110 Target Efficiency

Line target in a shift Production per hour

= 85%
= (59400 * 0.85) / (21.32) = 2368 nos. = 263 nos.

Production in 5 lines

= 2368 * 5 = 11841 nos.

24

PLANNING

Basic Production Process

PROCESS Fabric Store Trims P.P Approvals Pattern Cutting Sewing Dry Process Washing Dispatch DAYS 4 1 1 1 1 2.5 2 2 2 15.5 days

Total

25

PLANNING

ACCESSORY STORE

26

Accessories

Main label

PKT tags Size Sticker Poly Bags Cartons Brown paper

Pocket label
Care Label Leather patch Zipper Fusing

Double sided Clear type

Tag pin

Threads
Buttons

Plastic stables

Rivets
Waist tag

27

ACCESSORY

Suppliers
Will get Production sheet Sl.No 1 2 3 Item Zipper Thread Leather Patch (RT) Country Swaziland Hongkong Mauritius from merchandiser.

Cutting report from

department. Invoice from supplier.

Quality and quantity check Hongkong

mostly 10 % in all supplies if the lot is more. If it is less of

Leather Patch (Denizen)

number will do 100%. Mostly Zipper count will do 100%

checks in all arrival.

28

ACCESSORY

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

29

ACCESSORY

SPARE PARTS

30

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 in charge 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.

31

SPARE PARTS

Common spare parts..

Upper knife clamp Joint Lower knife Oring Worm wheel Spring Connection Needle bar bushing Bushing assembly Shaft Ring Connection Cover Upper looper holder assembly Crank shaft Oil distributor complete Tube Upper knife Gasket Upper looper holder assembly Lower looper holder assembly Lower looper holder Block Main feed bar Lever Connection Holder Looper holder Spring Wopm Thread take up Thread eyelet Thread eyelet Thread 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 guide Flat knife Needle guard

32

SPARE PARTS

PR-SEWING

33

Shop floor..

Currently 5 lines in working out of 6.

Line feeder will feed line.

Cut plan report from Cutting department. Feeding report. Production Planning control report. 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.
Target 2340 pieces/9hour

Reports to/from PR

Current Situation

126 * 5 = 630 total in a PR.

Average production Target in a line = 250 pieces/hr. Total of 2340 pieces in day
34

PR-SEWING

Operation Bulletin

OPERATION BULLETIN LSS (levis signature).xls

35

PR-SEWING

PG-SEWING

36

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. Formula: Front = (present front manpower * 60 *9) / (front Total SMV * 85%)

Target Efficiency = 80%

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.

37

PG-SEWING

Bonus calculation
SL No.
1 2 3 4

Efficiency (%)
80-90 91-100 101-110 111 and above

Workers (R)
10 15 18 21

SL No. 1 2 3 4

Efficiency (%) 80-90 91-100 101-110 111 and above

Supervisor (R) 25 35 45 55

Line Manager (R) 50 60 70 80

38

PG-SEWING

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 the garment. Quality persons have to do thorough check up regarding this issue. Operation Bulletin is attached.

39

PG-SEWING

INDUSTRIAL ENGINEER

40

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 balanced

41

INDUSTRIAL ENGINEER

Thread Consumption example

thread consumption.pdf

42

INDUSTRIAL ENGINEER

DRY PROCESS

43

Operation
SORTING MARKING FRONT

MARKING BACK

TURNING 1st

TURNING 2nd

BLOWING

TRIMMING

WHISKER Target Maximum 10,000 pieces per day

HAND SAND

CHEVERON

WASHING

GRINDERS

P.P.SPRAY

44

DRY PROCESS

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

Whisker pattern
45

Whisker area

Chevron Area DRY PROCESS

Manpower
SL.NO. OPERATION MANPOWER TARGET 150 300 METHOD Checking size/Inseam and grouping Vary from size Vary from size

1
2 3 4

Sorting
Marking Front Marking Back Turning 1st

3
6 3 2

5 6
7 8 9 10 11 12 13

Trimming Blowing
Turning 2nd Whisker Chevron Grinding Crinkle Hand sand P.P.Spray Supervisor PPC Score Lady Score Lady whisker Supervisor Whisker QC Table Trolley Boy

3 2
2 10 7 4 58 11 1 3 2 1 6 1

120 20 50

Using Turning machine Removing excess threads

Vacuum machine to remove threads Using Turning machine Using Mould whisker will make

50 45

Marking in near knee Using grinders Using resin with Owen in 140 degree Celsius for 15 minutes. Using sand paper with hand sand machine in horizontal Using KMnO4 (300gm/10litre water) for making lighter the color.

46

TOTAL

125

DRY PROCESS

Safety Equipments

Mask
Finger guards

Sand Paper Types

P-60 Lighter

Ear plug
Gloves for PP spray

P-240- More delegate

P-150- standard P-400- Sheet paper type

Overall gown
Two filter respirator

Fig: Sand paper

Inventories
Role Rubber 300 pieces tug 3kg of resin 4 roll of sandpaper for each day

47

DRY PROCESS

Quality checking

48

DRY PROCESS

Time study
SL.NO. OPERATION TIME STUDY (sec/piece)
20.1 9.8 6.3 35.9 12 12.55 70 33.8 65 28.2 45 153 560 DRY PROCESS

1 2 3 4 5 6 7 8 9 10 10 11 12 13
49

Sorting Marking Front Marking Back Turning Trimming Blowing Whisker Marking Whisker Chevron Marking Chevron Grinding- Bottom Grinding- pocket Hand sand (31 * 32) P.P.Spray

Causes for Defects in garment Preliminary view

Production Rate increase

New workers recruit

Not having Job rotation Mentality setup

50

DRY PROCESS

WASHING

51

Shop Floor..

Machine availability
Sl.No Machine Number Workers
Target 23000 pieces /24 hr

Washing Machine 800 P=25,

700 P=11

2 3 Total

Hydro Extractors Dryer

200 P=1 10+2 26 75

200 (full fledge)

52

WASHING

Current State
Sl.No Operation count Maximum Capacity per machine 33 pieces at a time

Tumble dryer Hydro Extractors

40 pieces,80 degree, 30 minutes maximum 100 pieces, 30-45 minutes

35kg

Washing
capacity

23000-25000
pieces/24 hour

147kg per loading

(40% of 800 pounds)

53

WASHING

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)

54

WASHING

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 reduction

Test 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% 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%.

Enzyme or stoning process

55

WASHING

CHEMICAL STORE

56

Chemical Names..
Sl.No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 57 33 CHEMICAL NAME Maxiclean Caustic soda Cellex (50) Indilite (50) Aqua Persulphate Denclean Denlube Oxalic acid Acetic acid Thiosulphate X-brite Salt Pretex P.permaganet Exclore Garmensoft Indisoft Soda-ash Bleach (25) Bleach (45) Bleach (50) Nanotin Peires cat Orange Brown 8rl Black Violet Brown Brr Brown Gxl Brown Bl Indigo 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.

DISPATCH

58

Operation

Cut Loop

Trimming

Final QC

Blowing

Rivets

Buttons

Repair Checking Rivets & Buttons

Size Label

Waist Tag

Pairing

Measurement

Pressing

Check Shade

Folding

Scan Pack

Loading

TARGET/SHIFT 10K-21K

59

DISPATCH

Current Scenario

C:\Documents and Settings\VishnuCGM\Desktop\CAPACITY STUDY DISPATCH.xls

60

DISPATCH

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 get confirmation from shipping department.

Final Audit
Check the size, waist length, rivet position and button strength.

General Production Issues

Repairs

Accessory lag.
Rivet problems

Workers are lazy Waiting for previous Operator Unnecessary Motion Improper Feeding DISPATCH

Machine problems
Human error
61

QUALITY

62

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

63

QUALITY

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, double and 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 generally single and double normal sampling plans are applied.
64

QUALITY

4-Point system-American StandardLevis

1-point 2-point 3-point 4-point

: Defect less than 3 : Defects exceeding 3 up to 6 : Defect exceeding 6 up to 9 : 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.

65

QUALITY

General points..
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.

Inspection Issues in Fabric store

66

Levis Standard
QUALITY

General points..
Final Audit Internal audit will take care by QA. Carton Marking Pocket accuracy Shade checking Measurement

Fig 1:Metal Detector Product Safety

Fig 2: Pull Test Machine

Check all safety levels in garments. Especially metallic safety. Check needle presence. And rivet and button strength. Having Metal detector and pull test machine.

67

QUALITY

REJECT STORE

68

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.

69

REJECT STORE

General points..
Category Specification Good Garments of leftover Good 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 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 D
70

Small hole noticeable at hemming or waistband, big stains Damage but still wearable (fix) Big Holes and Bursting but still wearable (fix) REJECT STORE

COMPLIANCE AND SAFETY

71

Safety Equipment List

Equipment Fire Extinguisher Safety goggles Safety gloves Replacement 6 months 12 months

Apron Safety Shoes Winter Jacket Emergency Alarm Safety Mask Ear Muffs Safety Gown

12 Months

1 Month 12 months

Having Safety Marking with different colours 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

72

COMPLIANCE AND SAFETY

Snaps

73

COMPLIANCE AND SAFETY

PERSONAL WAGES

74

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. Maternity leave-2 weeks.

Direct Dismissal: Stealing, Assault, Fraud, Damaging Company property, Fighting.

75

PERSONAL WAGES

Continuous..

Direct Dismissal: Stealing, Assault, Fraud, Damaging Company property, Fighting.

Notice Period: 1 week for 6month experience. 2 weeks for above 6 months, 1 month 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
Unskilled Trained Exp >1
76

Rand
3.99 4.3 4.76

PERSONAL WAGES

WAGES

77

General Procedures..

Contract Period: Daily, Weekly, Biweekly, and Monthly.

Temporary contract for 3 months. Casual labour will get permanent if she/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.
Contract Daily Wage (R) 4.55 Contract 1 year Colour of paper white

Weekly
Biweekly

4.31
4.31

2 year
3 year

Blue
Yellow

Monthly

3.99

ID cards will provide in the evening of date Joined with photo in lamination.
78

WAGES

Wages per day

Usual Days (R 3.99 as rate) Time Rate(Rand)/hour Total 7:00- 17:00 9*3.99 35.91 17.00-19:00 19:00-21:00 2*3.99*1.25 2*3.99*1.31 Night shift 19:00-5:00 9*2.06*3.99 73.9746 9.975 10.4538

Saturday and Sunday 7:00-15:00 7*2*3.99

55.86

79

WAGES

Discharge

3 days continuous absent:- Immediate Termination.

Greater than 1 year experience:- 90hr severance.

Greater than 6 month:- 12 days leave Increment <1 year- 2%, (R 4.43) <2 year-4% (R4.47).

Operation
Casual Bonus

Payment Day
Friday Thursday

Query
Casual OT

Wednesday
Tuesday

Discharge

Monday

80

WAGES

IMPORT

81

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.

82

IMPORT

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.

83

IMPORT

Accessory List for Import

IMPORT-ACCESSORY LIST ITEM DESCRIPTION A4 Copy pare White Board Marker Stapler Pin Paper Clips File Fastener Permanent Marker Pen Pencil Highlighter Pencil Sharpener Pencil Rubber Eraser Correction fluid Arch & Regina File Glue Stick Computer Continuous Paper Tailor & White Long Chalk White Pencil Nylon Rope Face Mask Transmission Belt Gloves Textile Gloves Rubber Safety Shoes Over all out fit Ribbon & Toners Printing Ink 84 DUTY (%) 15 15 20 20 20 15 15 20 15 15 15 FREE 15 FREE 15 FREE 20 22 20 15 30 20 30 40 15 FREE VAT 14% 14 14 14 14 14 14 14 14 14 14 14 14 14 14 14 14 14 14 14 14 14 14 14 14 14 14

IMPORT

Charges..
BAF BAS CCL CTO DDF DHC EMF ERS EXP FFC IHI IMP ODF OHC PAE PIO POS PSE PSS SER TCE CHARGE TYPE Bunker Adjustment Factor Basic Ocean Freight Container Cleaning Container terminal Order Documentation Fee-Designation Handling Charge- Designation Equipment Management Fee Emergency Risk Surcharge Export Service charge Freight Forwarder Commission Inland Haulage Import Import Service charge Documentation fee-Origin Handling charge-Origin Port additional- Export Pick-up/Drop off Equipment Positioning Surcharge Port Security Charge-Export Peak Season Surcharge Carrier Security Charge Temporary Customs Export

85

IMPORT

Continuous..
Contract No: 530298 INLAND/LOCAL CHARGES (RAND) ROAD INDIA DOCUMENTAION Durban 20 40 Port Elizabeth 20 40 250 250 20 40

SAFMARINE ORGIN CHARGES (USD $)

OCEAN FREIGHT BAF

275 510

575 1020

275 510

575 1020

INLAND HAULAGE CONTAINER CLEANING CTO FEE HANDLING CHARGE IMPORT SERVICE CHARGE PICK UP/DROP OFF

13669 75 120 1073 300 1500

16295 100 120 1586 450 3300

EMERGENCY RISK CHARGE SECURITY CHARGE

90 9

180 9

90 9

180 9 TOTAL CHARGES 16987 22101

TOTAL CHARGES

884 1784

884

1784

86

IMPORT

Charges..
COST PER COUNTRY (US $) TRAVEL (Rand)

INDIA
20 40

PAKISTAN
20 40

HONG KONG
20 40

YANITAN
20 40

DALIAN
20 40

SHANGHAI
20 40

QINGDAO
20 40

ROAD
20 40

RAIL
20 40

SAFMARINE

884 1784

909 1809 1074 2139 1074 2139 1124 2239 1074 2139 1124 2239 16987 22101 9561 18424

MAERSK
MOL

859 1709

904 1779 1044 2069

949 1889 1039 2069

924 1839 1146 2281 16987 22101 8676 14449

1596 3286 1334 2662 1521 3036 1471 2936 1421 2853 1471 2936 1471 2936 14123 15766 11048 19688

87

IMPORT

EXPORT

88

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

89

EXPORT

MAINTENANCE

90

Boiler

Operating Procedure

Basic Ideas
Currently have two boilers

JOHN THOMPSON AFRICA Design Gauge Pressure 1034 kPa

Design Temperature Shop Test Pressure Site Test Pressure Max.Permissible Operating Pressure Operating Pressure Operating Temperature Capacity (Flooded)

250 C 1551 kPa 1293 kPa 1034 kPa 960 kPa 183 C 34 m3

Fig: Boiler

Sl.No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

PARAMETERS Steam Pressure Water Flow Feed pump CO2 Gas Exit Temp Coal Bed Depth Stoker Speed Steam Flow Fuel Trim ID Fan control Blow down secs Gauge glasses blow down Mobrey blow down Soot blowes Fuel ash LR Chem dosing tank

91

MAINTENACE

WATER TREATMENT

92

Process Diagram
PAC WASTE WATER 150 cub.m/ h NaOH POLYMER AUTO MIXING MACHINE

GRIT BASIN: 3 COMPARTMENTS

EQUALIZATION BASIN

NEUTRALIZATION BASIN 1

DAF SYSTEM

SEDIMENTATION BASIN

NEUTRALIZATION BASIN 2

BIO TREATMENT BASIN: 5

COAGULATION BASIN

SLUDGE DEWATERING MACHINE

THICKENIN G

MUD

A.C.FILTER 3 CYLINDERS

EFFLUENT BASIN

RECYCLED WATER

WATER TREATMENT

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 enough quantity of Oxygen. Currently having a five chamber of 2500 cubic meter water storing.

94

WATER TREATMENT

Continuous..

In one final compartment there will be purification process. Here also there is a mixing of polymer negative is 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..

96

WATER TREATMENT

MERCHANDISING

97

98

MERCHANDISING