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Introduction

Raymond Ltd:
The Raymond Group was incorporated in 1925 and within a span of
a few years, transformed from being an Indian textile major to a
global conglomerate.
Today, the Raymond group is vertically and horizontally integrated
to provide customers total textile solutions. Few companies globally
have such a diverse product range of nearly 20,000 varieties of
worsted suiting to cater to customers across age groups, occasions
and styles.
Raymond manufactures for the world the finest fabrics - from wool
to wool-blended worsted suiting to specialty ring denims as well as
high value shirting.
Raymond also have some of the most highly respected fabric and
apparel brands in our portfolio: Raymond, Raymond Premium
Apparel, Park Avenue, Color Plus, Parx, Makers and Notting Hill
Creating the finest suiting in the world

Over time, Raymond has mastered the craft of producing the finest
suiting in the world using super fine wool (with a fine count from
80s to 250s) and blending the same with superfine polyester and
other specialty fibers like Cashmere, Angora, Alpaca, Pure Silk,
Linen etc.

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They also produce and market plush-velvet furnishing fabric in a
wide array of designs and colors for Indian and overseas markets.

Textile manufacturing Facility
World-class facilities

Raymond's manufacturing facilities include three world-class fully
integrated plants in India, deploying state-of-the-art technology
modern quality management systems like ISO 9001 and
Environment Control Systems (ISO 14001). All our plants are self-
sufficient and provide staff welfare measures such as education,
housing, recreation and support systems for employee.
Raymond plants are located in India at the following locations:
Chhindwara in Central India, Vapi in Gujarat, near Mumbai and
Jalgaon in Maharashtra.

Chhindwara Plant
The Raymond Chhindwara plant, set up in 1991, is a state-of-the-
art integrated manufacturing facility located 57 kms away from
Nagpur in Central India. Built on 100 acres of land, the plant
produces premium pure wool, wool blended and polyester viscose
suiting.
This plant has achieved a record production capacity of 14.65
million meters, giving it the distinction of being the single largest
integrated worsted-suiting unit in the world.

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Vapi Plant
Raymond has increased its worsted suiting capacity by 14 million
meters, as part of the second developmental phase of the Vapi
plant.
Modeled to meet international standards, the Vapi plant has been
set up on 112 acres of lush green land with Hi-tech machinery such
as warping equipment from Switzerland, weaving machines from
Belgium, finishing machines, automatic drawing-in and other
machines from Italy.
About The Raymond Industry

Business spreading across manufacturing, Sales-Services,
Distribution and Logistics
1 Head Office Mumbai
2 Regional Office Thane
3 Manufacturing Unit 3
3 Branch network across India 700
4 Group Revenue for operation in 2013-14 (INR) 4593 Cr
5 Manpower over (on rolls) 7500
6 Distributors spread across India 2200
7 Assets deployed (cranes, fork lifts etc.) 15billion



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Process to convert Wool in to fabric

1 Sheep:
Wool comes from sheep. They grow a wool coat and once a year this
wool coat is sheared off the animal. In Wisconsin, this is frequently
done in the early spring shortly before they have their lambs. A
shorn ewe will be more likely to stay out of the wind and bad
weather and protect her newborn lamb if she does not have a thick
wool coat on her.
2 Fleeces:
The shorn wool coat is called a fleece. It is also called "grease wool"
because of all the oil and lanolin in the wool. This fleece must be
cleaned before it can be processed into wool yarn. There is much
vegetable matter, manure and natural oil that must be removed
Sometimes as much as 50% of the weight of the fleece is not wool.






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3. Skirting a fleece:
The wool from the back end of the sheep, their legs and sometimes
their belly is too full of manure to use. These are referred to as
"tags" (as in the phrase "tag end"). These are removed first before
washing the fleece; this process is called skirting, as all the edges of
the wool coat are removed. The fleeces are also sorted into the
various types: fine from coarse and short from long.
In the Raymond the wool import from the Australia and Africa. This
wool comes in Vapi plant for making a fabric.
4. Washing the wool:
The grease must then be removed from the wool. This can be done
using soap or detergent and a lot of water or it can be done by
submerging the wool in an acid bath which dissolves all the
vegetable matter as well as the grease (this is called scouring).







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5. Picking:
The washed and dried wool is then "teased" or "picked" which is the
beginning of the process of opening up the locks of wool and
turning it into a consistent web. The wool is put through a picker,
which opens the locks and blows the fluffy wool into a room. At the
same time a special spinning oil is added which helps the wool
fibers slide against each other but also helps them stick together as
a fine web through the processing.

6. Carding:
The wool fibers are then put through a series of combing steps
called carding. This can be done with small hand cards that look
much like brushes. It can also be done on a larger scale with
machine driven drums covered with "card cloth" which combs the
wool many times by transferring it back and forth from one drum to
the other as it is passed down the series of drums. We have "woolen
cards which produce a wool web with the fibers coming off in
random alignment. This is in contrast to "worsted" combing those
lines up all the fibers (as you would see in thread).




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7. Roving

The final step in the carding process divides the web into small
strips called pencil rovings. These are collected on large spools on
the end of the card. These spools of pencil roving will be placed on
the spinning frame to make yarn. Pencil roving is too delicate to be
handled much, so when proccessing fiber for handspinners the
roving is taken off the machines earlier and wound into balls





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8. Spinning:
The roving as it comes off the card has no twist. It is held together
by the oil and natural hooks that exist on the surface of the wool
fibers. The spinning frame will put the actual twist on the roving
and turn it into yarn. This is collected on wooden bobbins. The
frame we have is small but it can spin up to 90 threads at one
time. This only spins one ply yarn (single stranded), which is not as
sturdy as most prefer. In order to make two or more ply yarn the
strands are twisted together on the plyer, from several cones onto
fewer spools.


9. Wind and/or skeining:
When the wooden bobbins are full of yarn, they are placed on a
cone winder and the yarn is transferred to paper cones for use in
weaving and knitting machines. It could also be put into skeins of
yarn which are the form that knitters like to use.




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10. Weaving:
The yarn is woven into fabric on looms, computerized machines
that work at high speeds to interlace horizontal and vertical sets of
threads, forming a flat cloth. A set of parallel warp (vertical) threads
are held taut by the loom while weft (horizontal) threads are held in
a shuttle. The loom lifts the warp threads up and down in
sequence, creating a space between them that the shuttle passes
through at high speed; several shuttles can be used
simultaneously. This action weaves the two sets of threads together
at right angles and creates fabric.
Different patterns are created by lifting the warp threads in different
sequences and by using different colored yarns. Types of fabric
made from wool include broadcloth, gabardine, herringbone,
hounds tooth and tweed.
Weaving Machine



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11. Dyeing and finishing:.
Wool can be dyed before carding or after being spun into yarn, or
the finished fabric can be dyed. Fabric is treated with heat,
moisture and friction to tighten the weave and shrink the fabric. To
make the fabric fleecy, it is brushed to raise the nap, giving a fluffy
finish. Chemical finishes can be applied to make the fabric
washable by coating it with a resin film.



12. Storage in Warehouse:
Once the fabric is making the material will be stored in companys
warehouse as per location is given by SAP (Raymond Software) And
material should be dispatched as per order comes from sales team.



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Raymond Plant Layout (Vapi Plant):


Spinning Wind and/or skeining


Roving Weaving


Carding/Dyeing Dyeing


Picking Finishing


Scouring Storage in Warehouse

START END

Main Gate (Entry/Exit)


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Production Planning in Vapi plant

gi Different branch



2.



The above fig shows the Production outcome in each process in vapi
plant. It shows maximum capacity for weaving process is 10 ton per
day but output of the spinning process is 7 ton per day. So it will
create deficit between this two processes so their will necessary to
outsourced remaining (i.e. 3 ton per day) from different vendor.
After weaving of 10 ton per day dying is being done and it will be
preceded for Finishing. Finishing is done at 20 ton per day and out
of which 10 ton is being outsourced.
So our project is to analysis Lead-time between order given to the
different vendor and time required to complete this order to vendor.
There are approximately 50 registered vendors to manufacture Yarn
for Raymond. We analyzed the data of last 6 months, suggested
them which vendor is more suitable for which material, In which
Quarter which material come late from vendor, determine relation
between Quantity of material is to ordered and lead time.


Wool
scoring 14
ton/day
Polyester
converter
-7
ton/day


Dyeing
process-14
ton/day
Recombing
process 14
ton/day
Spinnin
g Yarn 7
ton/day
Different
branch/vendor
Weaving
10
ton/day
Remaining 3
outsourced
from different
Vendor

Finished
Fabric
20
ton/day
Remaining
10
outsourced