SILVER SPARK APPAREL LIMITED II

RAYMOND

PRESENTED BY :
ASINE AMON SOY
GYANENDRA KUMAR
INTRODUCTION ABOUT THE COMPANY
 SSAL II (SILVER SPARK APPAREL LIMITED)
GAURIBIDANUR

SSAL II was inaugurated on 24th Oct. 2008.

This is a suit, jacket, waistcoat & trouser manufacturing plant.
The total area is 11 acres and the build up area is 2, 09,953.75 square feet.
The total workforce is 1998. (Including staff)
 Company Name RAYMOND LIMITED
Chairman and Managing Director MR. GAUTAM HARI SINGHANIA.

Raymond Limited

Industry Name Silver Spark Apparel Limited Unit-II,

Address No. - 4/2A, 5/3A, 3B

BASIC INFORMTION Gundapura village , kasba hobli

Gauribidanur taluk, Chikkaballapur dist.
Karnataka, pin- 561208
Tel - +91855-283288

GENERAL MANAGER MR. KAUSHALENDRA NARAYAN

Silver Spark Apparel Limited Unit-II

Type of Manufacturing APPAREL MANUFACTURING

Year of Establishment 24th October, 2008

Area 11 Acres & build up area 209953.75 sq. feet

Core Products Jacket, Trouser, Vest Coat

Manpower 1998

Capacity per day Jacket - 3300

Trouser 2900

Business across the world 55 countries in North America, Europe, and Asia
ORGANISATIONAL STRUCTURE AT RAYMOND :
Industry Layout :
COMPLETE PROCESS FLOW

Order
Order received Product Production
confirmation at
from SSAL Merchandising Merchandising
SSAL

Pre-Production Fabrics &

Cutting Cutting Quality
Sample at Trims
Department Checking
SSAL Department

Finishing
Sewing Sewing Quality Finishing
Quality
Department Checking Department
Checking

Customer
Packing Warehouse Shipment
or Buyer
PATTERN DEVELOPMENT DEPARTMENT :

It is the job of the Pattern Masters in the Pattern

Making Department to prepare the base size
pattern of a style from which samples are
prepared.
These patterns are later modified according to
buyer comments.
The Pattern Masters may either produce the
patterns manually on cardboards or they use the
Software.
This pattern is then used to cut the fabrics in
Sample Production Department.
SAMPLING DEPARTMENT :

OBJECTIVES
Getting approvals from buyers based on the samples
produced.
The Sampling Department produces the base
patterns from which the samples are produced and
send to the buyer for approval.
Checking and analyzing new styles, defining quality
terms of new styles to production department.
FUNCTION
The sampling department also calculates the
consumption of fabric required to produce the
garment.
The sampling department also access for
accessories and thread consumption for that
particular garment.
Based on the sampled garment the costing is been
carried out.
1. Fabric received from the mill

2. Unloading

3. Stacking of goods in the racks

4. Bale opening

5. 4 point inspection

6. Bar-coding

7. 12 parameter preparation
8. Fabric Inspection summary-report
generate
9. Sending the report to CAD department

10. Receive requisition

11.Stage entry and Physically issue with

bin-card updatation
12 PARAMETER INSPECTION CRITERIA:
100% Quality inspection in fabric section is carried out by skilled manpower
for Jackets/Suits and 100% for Trousers also. The system followed for
inspection and rejection of a lot/roll is 4-point system. 12 parameters report is
made
Shade report
Shade band card
Face side approval
Hand feel
Shrinkage report
CSV
Color fastness
Nap direction
Bowing & Skewing
4 point fabric inspection report
Width report
Seam slippage
OBJECTIVE: 1. Incoming
2. Unloading
materials
To receive Incoming material and check
material for attribute & variables
3. Temporary
4. Quantity
To arrange an incoming material in an storage of
check
allocated racks incoming goods

To issue trims as per production

6. GRN entry
planning & other material as per 5. Quality
and storage in
requirement check 2.5 AQL
the racks

To mention a record of incoming & 8. Stage entry

outgoing material 7. Receive and Physically
requisition slip issue with bin-
To do audit to check physical inventory card updatation
DIFFERENT TRIMS
SEWING TRIMS FINISHING TRIMS
Sewing thread Poly Bag
Waist band lining Carton Box
Band Roll: Waist Band, loop Hanger
Fusing: Waist Band, Loop, Jet Clip
Part Staple Pin
Button Tag
Zipper tape Bullet tag pin
Zipper slider Size ring
Stopper wire
Hook & Bar
Labels:
Quality Inspection
All the trims received are checked for quality defects. Acceptable
quality level followed for trims is 2.5.

Size in unit Sample size Max N` defectives

51-90 13 0
91-150 20 1
151-280 32 2
281-500 50 3
501-1200 80 5
1201-3200 125 7
3201-10000 200 10
10001-35000 315 14
35001 and more 500 21
The spreading is done
manually as well as with the
help of automatic spreader. Fabric Store Panel
Fusing
It is spread manually in case Department Inspection
there is a high probability of
occurrence of bowing or Fabric
Numbering Bundling
Receipt
skewing problem in the
fabric, mostly when it is a Issue to
CAM
stripes fabric. Laying
Cutting
Sewing
Department
Sewing departments function is the crucial and most vital job in
a garment industry. This is the place where actual production
takes place. After the fabric is released from cutting, it is passed
on to the sewing department for the sewing. The various parts
are stitched together to form the garments.

The sewing section is comprised of:

1. Trouser Lines
2. Jacket Lines
SEWING DEPARTMENT :
Preparatory Assembly
Front and Back
 Breast Lapel, Armhole
Pckt & Canvas, Side Panel tape Side panel
Auto-dart
Front Dart bottom Attach Attachme Press
Mark marking nt

Fuse Dart Breast Front Breast

Welt pocket
and side pocket Flap stich Pocket pocket
Panel stich welting press
press

Breast Breast
Front Front Front
pocket Pocket Attach
Pocket Pocket Pocket bag
Attach & canvas
Zig zag pressing Bag attach Close
Close

Front Armhole
Side seam Side seam Bottom
Block Canvas Basting
attach Press press
press Cut

Shoulder Shoulder Shoulder

attach press pad Attach
Wing Facing Facing Saddle Pocket Welt Pocket
Facing Press
Attach Stitch Welting Press

Pocket Facing Main Label Fit Label Label Attach@

D-Bar tack
attach Attach Attach Facing

Label Pocket Flap Pocket

Side seam Side Seam
Bag Attach & Bag Attach & Collar Attach
attach press
Close Close

Shoulder
Facing Blind-
Attach + Neck Collar Press
hem
band Stitch
 COLLAR SECTION

Collar Collar Band Chain Stitch Collar Felt

Fuse Collar
Marking attach @ Collar felt Attach

Collar Turn &

Corner Lock Press Collar

CANVAS READY & FLAP READY

Bridle tape
Canvas Felt attach to
Attach to
Ready Canvas
Canvas
 Sham hole Elbow seam
Elbow seam Cuff press
mark & sew press

Elbow seam Lining attach to

Vent Lock Press Button attach
lining shell

Sleeve inseam Sleeve bottom

Inseam close Elbow tacking
press press
 Front Edge
Pairing Pick Attach Collar Zig Zag Basting
Stitch

Front Edge Front Edge

Bottom Close Pick press Bottom Press
Trim Seam Open

Arm hole
Sleeve head Sleeve head
lapel Press Sleeve attach Seam Open &
making Attach
Press

Button hole
Button hole Button hole
Arm hole close Vent close sew /flower
marking bar tack
hole sew

trimming
A customers interest in a garment is evoked by the final
presentation of it in any store. The finishing department does just
that, in the sense that it ships neatly packed goods.

The objectives of finishing are:

o Improve the appearance of the garments
o Improve the drape by pressing
o Improve the durability of the garments
o Packing for dispatch
 Spot Sleeve Back Front
Washing Pressing Pressing Pressing

Shoulder Collar Elbow

Nipping
Pressing Pressing Pressing

Wrappin
Lining Button
Blocking g&
Pressing Attach
Knotting

Lapel Quality
Touch-up Auditing
Pressing Check

Packing
A ware house is a
Sorting done PO
commercial building for wise then Color
storage of goods. and size wise

The main purpose of Packing in Box or

Hanger
Pairing
warehouses was the Containers then
Shipment
packing, checking,
labelling and packing of
Dusting and
goods for exports Covering
Inspection
FLOW :
PROJECTS :
 IMPLEMENTATION OF BEST
FEASIBLE PRACTICES

INDUSTRY MENTOR PROJECT BY- ASINE AMON SOY

Mr. ANKIT SHARMA BFT-VII
(Jacket line 6, line executive) NIFT- HYDERABAD
PROJECTS :-
WORK AIDS (IMPLEMENTATION OF LASER IN ADDITONAL LABEL)
BREAST POCKET PIN BOARD
VSM ( VALUE STREAM MAPPING )
REDUCE THE SAM OF OPERATIONS OF LINE 6
5S

Proposed solutions :-
KAIZEN (WAX PENCIL)
LAYOUT
1. DATA COLLECTION:

BEFORE AFTER TIME STUDY.xlsx

2. V.S.M (VALUE STREAM MAPPING)

FINAL JURY VSM.xlsx

1. WORK AIDS (IMPLEMENTATION OF LASER IN
ADDITONAL LABEL)
BEFORE : A pattern was used for making the point manually for the additional label .
 AFTER:
Laser light was put in the operation . It reduced the handling time as now the operator
did not mark the points manually ,laser was used as a guide ,as a result time was
reduced and productivity was increased .

AFTER :
 This increased the production by 13 pieces hourly and in 8 hour
shift production was increased by 104 pieces.

COSTING :

1 leaser light =Rs.1200

2. BREAST POCKET PIN BOARD
BEFORE :

Every piece of the breast pocket was maually marked and cut.

12 sec to mark one piece

20 sec to cut one piece
22 sec to iron one piece

Which gives a total of 54 seconds that is consumed to ready one piece of breast pocket.
NEW CONCEPT ABOUT THIS
BOARD :

It is a double needle board.

It has checks made on the board

which helps the operator visually
,and makes it easier for matching
checks.
 AFTER :

In this 30 to 40 pieces are pinned together matching the checks by the lines on the board.
then it is clamped together and cut with the ban knife using the pattern .

It reduces handling time. and also increase the productivity by 57 pieces.

COSTING :

2 Acrylic sheet (12x12x3mm) =Rs.230*2=Rs.460

2 Needles =30*2=Rs.60
1 marker = Rs.10
1 Glue = Rs.5
1 Ruler=Rs.20
Total amount =Rs.555
3. REDUCE THE SAM
OF OPERATIONS BY
CHANGING LAYOUT:

OPERATIONS
TARGETED:

POCKET BAG ATTACH

WELT POCKET PRESS

BOTTOM HEM ,FLAP PRESS

POCKET BAG
ATTACH
BEFORE: This operation was done by 3 operators.

First operator :
taking of 2 welt pockets (left and right).
- closing the breast pocket.
- attaching the breast pocket.
-Closing the breast pocket.

Second operator:
attach the pocket to 2 the welt pockets.

Third operator:
closing the 2 welt pockets.
-close the 2 welt pocket bag.
SOLUTION :
One operator from the pocket bag attach was removed. The work of the first pocket
bag attach operator was divided into the zig zag machine before her and the other
two pocket bag attach operator ahead her.
Here 1 operator was saved.
The division of work was done as :
Zig zag operator did :
- the zig zag
- closing the breast pocket opening.
-attaching the breast pocket.
First pocket bag operator :
- taking of 2 welt pockets (left and right).
- attach the pocket to 2 the welt pockets.
Second operator did:
closing the 2 welt pockets opening.
-close the 2 welt pocket bag.
-Closing the breast pocket bag.
The SAM was reduced ,now the waiting time of the operation ahead was reduced.
 WELT POCKET PRESS :

Before -Work done by the welt press operator was to cut the bone of both left and
right panel and press the welt of left and right.

The iron used for pressing and the table need repair as the steam and vacuum of
the table was not working properly. This caused over work and added to non value
added time.
SOLUTION:

As in the before lay out the welt pocket press was before breast pocket attach, the
lay out was changed and the work done by the welt pressing operator was divided
to the breast pocket press.

Now in the new layout the welt pressing had to cut only one bone by herself the.
 BOTTOM HEM & FLAP PRESS :
PROBLEM :

1.In flap press, when ever there was a rework the operator had to cover a long
distance to the iron table .

2.On the other hand even the operator for bottom hem had to travel lot ,to the FIT
in case there was any rework.

SOLUTION:
The FIT behind flap marking table was brought beside flap press machine ,this
reduced the distance that both the operators had to cover before .
This reduced time consumed.
4. KAIZEN : WAX PENCIL
PROBLEM :

Pencil marks made during the matching of checks , on the welt pocket flap
and the breast pocket ,which are visible on the front .Which is later
removed in the finishing department using solvent (white petrol).

A shipment lot of quantity 10,000 was sent back for rewashing (rework) as
the marks of white pencil were still there .
 SOLUTION :

I made a wax pencil by melting wax chalk. This

pencil could be sharpen which makes it easier to get
a pointed edge for marking dots .

How is it helpful ?

As it is made up of wax it goes off with steam.

It is renewable .
Its saves operator of washing in finishing
department.

It saves solvent(white petrol) used for washing .

The processing time of finishing department.

NEW V.S.M (VALUE STREAM MAPPING)

FINAL JURY VSM.xlsx

 BEFORE
RESULT :

Before : 4457 sec

After : 4311 sec

Decrease of VAT( Value added time) : 146

sec
AFTER
 5S:

BAG FOR THE FUSING

1 : BEFORE
AFTER :
LAYOUT
PRESENT LAYOUT :
PRESENT LAYOUT :

SUGGESTED LAYOUT :