Cutting Dept. SPREADING

8/11/2019 Cutting Dept. SPREADING

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ACKNOWLEDGEMENT

First of all, I would like to thank my collage mentor Mr. Ram Mohan for being a greatsupport throughout the duration of my internship, as without his support and

guidance my project would not have been successful. His guidance has made my

internship a knowledgeable and beneficial experience.

I would like to thank Mr. Kaushalendra Narayan (General Manager) & Mr. Hiral

Lakdawala (Plant Manager) for providing me an opportunity to undertake a project .

I would like to thank Ms. Samiksha Bhamra (Cutting Executive), my industry

mentor, I would like to thank her for her kind cooperation and valuable time she has

lent me during the period of my internship.

Last, but not the least, I am highly obliged to the entire Raymond Team who has

directly or indirectly helped me in the successful completion of this project.



Index

Serial no. Topic Page no.

01 Introduction to cutting

02 Process flow of cutting

03 Pre-cutting

04 Cut order planning

05 Marker making

06 Spreading

07 Cutting

08 Numbering

09 Quality check and relaying

10 Fusing

11 Panel inspection and bundling

12 Re-cutting and mis report re-cutting

13 Project



AUTOMATED CUTTING ROOM – PRODUCTION PRACTICES AND

STANDARD OPERATING PROCEDURE

This section provides the framework for the processes involved in cutting section andthe production management practices that are incorporated in the cutting area .

cutting processes are regarded as the most critical process in the garment

manufacturing process. The theory behind this is that here the raw material (fabric is

given a form in the form of cut panels . this means that utmost care must be taken in

each and every process because after cutting most of the times the wrong doing

cannot be rectified.

Cutting is also a direct interface for the pattern department by way of making

markers . A lot of effort is involved in making sure that the markers are provided in

the required manner to eliminate the chances of mistakes. Effort goes into making

sure that every single details of the style is considered while marker making . That is

why cutting plays a vital role in having a correct pattern.

Cutting coasts form a bulk of manufacturing costs . An automated cutting room forms

almost 50% of the stationary , spares , consumables cost . overall , cutting costs

incorporated about 25 % to 30 % of the manufacturing expenses.

Automated cutting room also involves highly accurate CNC machine which run on an

established technology and there by maintenance become very omportant .

preventive maintenance and TPM activities are carried out in a very efficient manner.



OUTLINE PROCESS IN CUTTING SECTION

ORDER RECIEPT – ISSUE FILE , TECH PACK

,SAMPLE , ETC

CUT PLAN PROCESS

FABRIC ISSUE AS PER CUT PLAN

PATTERN ISSUE

MARKER MAKING AND LAY REPORT

GENRATION

ISSUE LAY REPORT TO CUTTING FLOOR

AUTO SPREADING / MANUAL SPREADING /

PINNING





PRE – CUTTING

Pre cutting activities :

Any order processing begins with the issue of a standard file which contains the

following ;

1. Order sheet

2. Bill of material

3. Size breakup ratio sheet

4. Product pack

5. Approved sample

6. Measurement spec sheet

7. Approved patterns – soft copy

8. Hard bound band knife pattern

9. Hard bound making pattern

10. Graded nested patterns

In all of this , BOM sheet is the most referred which will indicate the consumption of

various fabrics and accessories . the size break up sheet will provide the frame work

for planning and this begins the actual stage of cutting process.

Fabric section will provide the approved 10 parameter report.



CUT ORDER PLANNING

Cut order planning is the most critical and important process in the cutting section .

here , actual

order size is planned into no. of lays with the objective being to achieve the given

BOM consumption

While keeping cutting costs to a minimum. The process works in a contradicting

way. As one tries to increase the ply height by planning more no. of plys , the

consumption tends to increase . while planning with lower no. of plies , the

consumption targets can be met, but less no. of plies means more no. of lays to cut ,

which means that cutting costs are increased . the planning must be balanced

keeping in mind the no. of plies and cutting cost.

At Raymond Ltd., a standard cut order planning software provided by morgan

technology is used to cut plan. The below mentioned points are considered in cut

planning –

1. Cut order planning is performed in combination with roll management techiques. It is

mandatory that a person executing cut order planning is trained in marker

management techniques.

2. There are 4 constrains on which the cut plan needs to be done to achieve the dual

objective of optimum consumption and optimum cost

a) Fabric width

b) Shrinkage

c) Shade





MARKER MAKING

This is essentially a process of positioning all the required parts in the usable fabric

width in order to maximize fabric utilization and reduce consumption as much as

possible . the following constraints will have to be considered during marker making

process:

1. Center to selvedge variation : this is the inherent characteristics in the fabric which

will have a different colour at the center and a lighter contrast at the selvedge . a

fabric having CSV will have to be made in a CSV marker.

2. Shrinkages : there will be washing , stream , fusing shrinkage applicable . in case of

washing , stream as well as fusing shrinkage for jackets, the shrinkages are added in

the pattern and a new model is generated . these models are used for specifically

allotted rolls as per roll management techiques .

3. Direction : fabric exhibiting nap direction or one way direction fabric need to be

processed as one way marker . this means all parts of the same garment are to be in

one way direction .

4. Stripes/checks : certain body parts of these fabrics need to be cut as a block (bigger

in size that the original pattern) by considering the repeat of stripes / checks so that

they are matched by relaying process and the required plaid matching is achieved.

All these parameter will have an adverse impact on consumption but these are

regular feature in the fabric which need to be considered . this is the reason , marker

at most of the times (shell fabric , knee lining of the trouser and body lining of jacket)

are processed manually. In case the fabric is free from all these constraints ,

automatic marker generation is used . At Raymond Ltd. A standard marker making

software is utilized to achive the desired result .

Once the marker is ready , they are thoroughly checked for the following points :



a) Fabric utilization

b) Consumption achieved

c) Direction

d) Placement of parts in case of CSV

e) Grainline of parts

f) Any parts missed in the marker

This process is followed with Lay Report Generation .

A lay report generation is a standard document carrying instruction for the next

process , i.e spreading . it consists of order no., style no., lay length , type of lay

(face to face / face up ), fabric width , no. of plies , no. of garment that will be cut .

the lay report will also have a quality para meter checks. Later the marker file is

converted into a cut file to enable automatic cutting process and a protected

wireless transfer is executed between the marker terminal and cutter terminal. In

case of increase in consumption , the same is highlighted to the merchandiser in

writing and futher process is done after written approval from the concerned

marchant.

Also enclosed will be parts bundle ticket which is generated from barcode printer .this process is followed in all automatic cutting operations . this will save the plotter

paper and plotted requirement.



SPREADING

As per the lay report given , specific fabric rolls are taken up for spreading .

Spreading involves laying the fabric as per the given length in meters and cutting .

Table planning is done at the starting and process is executed as per the plan. There

are three types of spreading :

1. Automatic spreading process : this involves usage of automatic spreading machine

in which the parameters are programmed on the machine and it does most of the

jobs. The machine can run in either automatic mode or manual mode. Apart from the

lay report parameters , fabric setting must also be tight , the fabric alignment must be

perfect on all sides , the release tension on the dancer bar must be appropriate and

so on. Automatic spreading machine is useful for fabric which are solid in nature ,have no bowing effect and does not exhibit any stretch qualities . Automatic

spreading becomes meaningful for longer lay lengths , greater no. Of plies and step

lays .

2. Manual spreading : fabric exhibiting bowing and greater stretch cannot be

executed on automatic spreading . Manual laying is the best suited process . Also

the end bit and shorter lay length are better off to be put on manual laying to save

cutting time and cost . Fabric having acceptable percentage of bowing effects are

manually torn at the end of lays and stretched and relaxed to allow the bowing

effects to diminish and then turn the process is continued.

3. Pinning: for fabric required plaid matching (stripes and checks ) , spreading is done

on pinning tables. Pinning table is essentially consist of intermediate rows and



columns of needles /pins which are so placed that they can be removed in rows

along the length by the means of hand wheel. This enables the spreader to adjust

the setting are required . There will be indications in the marker about the places

where the plaid matching is required and length from zero position will be given . The

spreader will at first organize the pin rows accordingly and then proceed with

spreading . Here the fabric lay are passed through a series of pins . Care should be

taken to make sure that the pins don’t damage the fabric but only displace the yarn .

After the spreading process is complete the lay is transported to cutting process .

During transportation , the fabric lays are held together by means of end clip to

make sure that the alignment remains same . Table blower are utilized to help in

easy transportation.



CUTTING

This process cut down the lays into parts referred as cut parts . Cutting is done by

the following :

1. Automatic cnc cutting : cutting is done by machine oriented cutter . This process

substantially reduces human skill , errors , greatly increase accuracy and precision

and considerable saves time . The respective cut files are opened once the lay

reached the cutter beam is straight . Cutting process is enabled to the use of high

level vacuum level , knife speed , drop frequency , sharpening frequency , traverse

speed and so on. After cutting process , the cut parts are trans ported for numbering

. During the cutting process , bundle tickets are placed on the cut parts by visually

seeing the mini markers. This will eliminate the requirement of lay plotting.

2. Manual /straight knife cutting: this is the traditional way of cutting. The spreading

process is the same but when it comes to cutting , it is executed manually bystraight knife machine. This process involves high degree of human skill and on an

average is of lower accuracy. Here either the marker plotted paper is placed on the

top of the lay and cut manual or in the absence of marker, individual block pattern

are placed on the top of the lay till the consumption and utilization are achieved and

taken forward for cutting . Although this process is not all that accurate and requires

more time , in terms of cost , this process will cost lesser in comparison with

automated cutting.



NUMBERING

Numbering process is esstential giving identity to the indivisual parts . Two types of

numbering is done :

1. Sticker placement : a standard sticker machine is used in which roller scale and

number is placed as per the number sequence given from CAD.

2. Ink stamping : this is mechanical machine in which ink pad are placed on the

number generator roll and the setting is made as per the number sequence given

from CAD. Repeat of numbers can also be set by means of a linear scale which will

be converted into rotary action by number movement.

Numbering is an important process in the cutting room. It is the process of giving all

the components of a garment a unique number, so that they can be paired together

while sewing. For shell, collar felt and sleeve lining, stickers are put using the sticker

machine, whereas for body lining, the numbers are stamped using a stamping

machine.

Problems that can occur due to wrong numbering are enlisted below:

1. Shade variation.

2. Assembly of face side and wrong side.

3. Different size components assembled together.

The input for the numbering section is the output of the cutting machine. The parts

(shell, lining, collar felt) cut at the cutter are brought to numbering tables.

At the numbering tables, these points must be checked:



1. Cut sticker must be present on all the components. Any missing cut sticker would

lead to wastage of time in finding out the details of the unnamed components.

2. Check Summary Report to see if correct details are mentioned on the cut stickers

before starting with numbering. Buyer’s name, style number, colour, lay number, size

and quantity are checked.

3. Before starting with numbering first time in the day, clean the stamp with white petrol

and cloth to make sure there is no paint. This ensures that the numbers stamped are

clear and easy to read. The stamping machine should be taped as well.

4. Refill the paint in the stamping machine. Squeeze out the paint from the bottle onto

the refill pad.

5. Put new sticker roll in the sticker machine.

6. The parts are arranged in a manner to ease the process of numbering. This

arrangement differs for:

i. Shell (spread face up face down or face to face for jackets)

ii. Lining (spread face up)

iii. Small Components

iv. Large components



SHELL

LARGEPARTS

Lift two plies

at a time;

number both

on the

wrong side.

SMALL

PARTS

Lift two plies

at a time;

number bothon the

wrong side.

Separate

and remove

the mirror

parts.

LINING LARGE

PARTS

Arrange theparts in a

step wise

manner with

the help of

fingernails,

and then

stamp one

after the

other.



SMALLPARTS

Small parts

arranged in

different

ways: flowerlike

arrangement

for

sweatshield.

7. The face side of the components is checked to ensure that numbering is not done

there. If not taken care of, this could result in quality issues: wrong side and face side

could be assembled together.

In a bundle, WT (pink sticker) depicts wrong side of the topmost layer and WB (blue

sticker) represents wrong side of the last layer in a bundle of components.

S.No.Type of

layMarking

1.Face to

face



2.Face up

face

down

3.Face one

way

8. The number to be put is tallied against the summary sheet and set on the stamp

machine using a pin. In case stickers are being used, it is set on the sticker gun.

9. The frequency of change is set. For stamp machine, the following options are

available:

S.No. Option Function

1. 0 No change; Repeat.

2. 1 Numbers change in a sequence. (e.g. 101, 102,

103…)

3. 2 Numbers would change after every second time

(e.g. 101, 101, 102, 102, 103, 103…)



4. 3 Thrice the same number would be repeated (e.g.

101, 101, 101, 102, 102, 102, 103, 103, 103…)

5. 4 The same number would get stamped four times

(e.g. 101, 101, 101, 101, 102, 102, 102, 102, 103,103, 103, 103…)

For sticker gun, three options are available:

S.No. Options Function

1. 1 Numbers would change one after the other; in a

sequence. (e.g. 101, 102, 103…)

2. 2 One number would be repeated twice. (e.g. 101,

101, 102, 102, 103, 103…)

3. R No change; Repeat. (e.g. 101, 101, 101, 101…)

10. Numbering must be done at the correct place. Numbering positions for the large

parts of shell is given below:



S.No. Parts Posit io n for

number ing

Visual

SHELL

1. Front Bottom

2. Back Across-back,middle.



3. Lapel Numbering

position

4. Side Panel Top

5. Top Sleeve Crown



6. In Sleeve Below the crown

7. Collar Centre

8. Collar Neck

Band

Centre

9. Small Parts

(Flap,

Bone,

Breast

pocket,

Pocket

facing, )

Centre

LINING

1. Front Bottom



2. Back Bottom

3. Side Panel Bottom

4. Top Sleeve Crown

5. In sleeve Below the crown





can lead to wrong numbering which can affect quality of the garments being

produced.

QUALITY CHECKING AND RELAYING

Quality checking is a essential process for checking for visual defects in parts

concentrated on weaving defects . 100 per cent checking is done except small parts

like bone , flap ,etc

RELAYING

Parts which are cut as bigger blocks in pinning are brought here and matched

against each other to make sure that the plaid matching is achieved . the plaid

matching is essential for standard features of any stripe/ checks garment . as in

pinning , there will be under neath needle which are set at the desired position and

the parts can be adjusted as per the plaid repeat requirement. After the requirement

parts are matched , they are tied together by means of knotting . then ready patterns

are placed over the bulk plies and bound by means of end clips . care should be

taken here to make sure that the grain line remains the same while placing the

ready patterns.

After this, the parts are taken for band knife cutting on band knife machine . band

knife machine essentially consists of a revolving knife placed on pulleys run by motor

. the knife generate a vibrating movement which will enable cutting process. Hand



gloves are mandatory while operating this machine . the bigger bolcs are trimmed at

ends / edge to bring the parts to the required dimensions . notches as required are

also made on this machine .

FUSING

Fusing process is one of the most important processes in cutting department. Fusing

materials essentially provide strength , stiffness and stability to the garment and

adds to the presentation of the garment . there are various types of fusing

depending on the application . the most three parameter in fusing are :

1. Temperature2. Pressure

3. Fusing time

Different types of fusing have different setting of parameter . the fusing machine

must be set as per the required parameters for particular fabrics and fusing . a

standard guideline about the fusing setting will be given from fabric section . another

important process here is FUSE line BOND testing . bond testing is a process of

mechanically testing the fuse line pressure (in kgs) by means of mechanical weight

scale . the process is performed at starting of any new style and the same same

displayed alongside the machine. Also the fusing machine are tested for temperature

manually by means of temperature thermo strips twice a day to make sure

temperature calibration is intact , since the machine is influenced by outside weather

and climate.



Standard fusing guidelines for different parts will be provided for ease of placements

of fusing pieces on the shell fabric.

Fusing Technology in Garment Industry:-

The most important area of garment construction where an alternative process has

significantly taken over from sewing is in the attachment of interlinings. When

interlinings are sewn in, it can be difficult on parts such as collars to avoid a wrinkling

of the interlining inside the collar and pucker around the edge. On large parts such

as jacket fronts, the attachment of interlinings by sewing is expensive and requires a

skill if a high standards is to be achieved. The alternative process which has been

developed is that of fusing. Fusing technology whereby the interlining is bonded to

the outer fabric by means of a thermoplastic resin. The term fusible interlining is

used to describe a base fabric coated on one side with a thermoplastic adhesive

resin which can be bonded to another fabric by the controlled application of heat and

pressure. These materials, generally called fusible, provide the designer with a

number of properties which can enhance the appearance of finished garments.

Following are the fusible parts of different garment:-



Advantages of Interlining :

support.

drape better compared to non-interlined garments.

the additional manufacturing time involved.

drapes and

consequently often exposed to direct light. Delicate fabrics like silk and velvet can



suffer from sun damage if hung with a liner alone, and most drapers recommend the

use of an interlining for the life of the fabric.

offers an extra bit of fluffiness, along with warmth in the

winter.

Major Challenges in Fusing Technology:-

1. Modern fashion fabrics and interlinings are more delicate.

2. Fabrics are generally finer and lighter.

3. They are more sensible to temperature and pressure.

4. They have more tendencies to shrinkage under temperature.

5. Many fabrics are elastic, some in both directions.

6. Textile finish with softeners can effect fusing.

7. Modern fusible interlinings are lighter and thinner. 8. There is more chance of

strike back of fusing.

Interlinings used in Raymond, Gauribidanur:- Raymond Gauribidanur is a jacket,

waistcoat & trouser manufacturing plant established on 24th Oct. 2008. Jacket is one

of the heaviest garments and hence requires interlining like fusing, canvas and felt.

Fusing used in Raymond, Gauribidanur :Three types of fusing are used in this plant:

1. Body Fusing- They are basically a woven fusing, which is fused at front panel of the

jacket and also sometimes at lapel, depending upon buyer requirement. They are

generally white or black in color.

2. Part Fusing-They are basically non-woven fusing, which is fused at different part of

the panels like collar, shoulder, side seam, inseam, arm-hole ,bottom line, dart,

pocket, bone, flap etc. They are generally white or charcoal in color.

3. NR Fusing- They are so called because of presence of nylon thread in non-woven

fusing. They are used to strengthen the seams and are fused at side seam, inseam

,collar & shoulder .They are generally white or black in colour.

4. White fusing – This fusing is named after its colour . It is used in few parts of panel

which are as buyer requirement .

FUSING MACHINES:

There are seven fusing machines used for jacket fusing



Machine type .No. of machine

Kannegiesser 5

Weishi 1

Reliant Cool stream 1

Men-Power for Fusing: There are 10 operators for feeding the parts and 3

operators for collecting these parts. The distribution for each parts are as follow :

Feeding:

– 3 Operators

Back and top-sleeve – 3 Operators

-panel and In-sleeve – 1 Operator each

– 1 Operator

– 1 Operator

Collecting:

– 1 Operator

-Sleeve and Small parts – 1 Operator

-panel and In-sleeve – 1 Operator

Note-Small parts includes Collar, Neck band, Welt, Bone and Flap.

FLOW CHART

Order information from

production file

Marker Making



Fabric issue report

Issue of fusing rolls from

fabric store

Storage of rolls in cutting

section

Spreading

Cutting

Issue to fusing area

Segregation

Collection of shell parts from

panel checking

Fusing starts

Check machine

arameters

Reset Machine

INCORRECT

Bundling



PANEL INSPECTION AND BUNDING

PANEL INSPECTION

This is essential a quality department process in which cut panel in random are

checked for the dimensional accuracy by placing the top, middle , and bottom ply of

Continue Production

Panel checking

Bundling

Issue to sewing

CORRECT

CORRECT

RE- CUTTING



any bulk parts on graded nested patterns . this process is usually performed to make

sure that after cutting process and fusing , the part dimensions are intact . any defect

found here is sent for re-cutting , where parts are cut manually.

BUNDLING

This is a process in which individual parts are clubbed together in bunches and

made ready for the process of issue to line . the bunding process is usually done lay

wise and a standard numbering sequence generator is provided for bundling and theoperators make sure that they arrange the different parts according to the required

lays and make it ready to issue to lines in material handling trolleys . here , the

arrangement is made section wise .

After bundling . the cut parts are issued to sewing lines by means of issue slip.

RE-CUTTING AND MIS REPORT RE-CUTTING

Apart from the regular process , a service requirement from cutting is re- cutting

which is essentially a manual hand cutting process to cut parts which are either

found defective in cutting inspection or brought from sewing section as damaged



parts . here , a record is kept in which the parts has been cut or at least the shade of

the parts is matched before re- cutting .

A separate area for rejected parts/ panels is designated to ease in identify and for

futher transactions.

MIS REPORTS

Final cut report

(FCR)

This report give the size wise cut quantities

across each order and indicate short close or

extra quantities of any size. This report is

distributed to all the departments to make sure

that they are geared up for all eventualities .

Fabric consumption

report

Essentially indicates the amount of fabric

consumed , the quantity cut and the fabric left

over in roll and end bit and individual garment

consumption.

Order completion

report

A part of the required is OCR , for which

cutting will provide cut quantities , fabric

consumed ,fabric returned and cutting rejects .

Daily production

report

Daily production report as a part of MIS

requirement is provided as per proman

software.

PROJECT FOR IMPLEMENTATION AND IMPROVEMENT

Improvement 1: canvas and pocketing fabric was layed on single stand which took

42 seconds to lay 1 meter of canvas .



Before

Figure 1:canvas laying on single stand

After

Figure 2:laying of canvas on two stand

Result : Now in 42 seconds 2 ply of same 1 meter can be layed.

BEFORE :

To lay 1 ply of 1 meter 42 seconds is required



Therefore ,

To lay 50 plies = 50 *42 seconds

= 2100 seconds.

AFTER :

Now to lay 2 ply of 1 meter same 42 seconds is required

Therefore,

To lay 50 plies = 42 /2 seconds

= 1050 seconds.

Time saved : 1050 seconds per 50 plies of canvas.

i.e . 17.5 minute per 50 plies of canvas.

Summary : Project was to solve the issues for productivity hurdles of the fusing .i.e

to increase the productivity of fusing. For this time study is been done and top

problem were seen for its solution.



Implementation : Top five problems of were listed out in 4800 minutes and are

categorized into MAN , MATERIAL , METHOD , MACHINARY , MONEY which is

as follows below:

Total time wasted = 549 minutes

= 9 hours of 80 hours is been wasted in upper listed problems.

Figure 3:occurance time line graph

S.no. Problem

Occurance

Time

Time

Wasted(in

mins) Category

1

SEARCHING FOR CORRECT PART

SIZE FUSING 23 257 METHOD

2 FUSING OVER NOTCH MARKS 10 67 METHOD

3CUTTING OF FUSING MATERIAL TO

ACHIEVE CORRECT SIZE 16 110 MACHINE

4 WRONG CUTTER STICKER 3 35 MAN

5 MACHINE BREAKDOWN 5 80 MACHINE



Figure 4:TIME WASTAGE GRAPH

Figure 5:SEGRIGATION OF 10PERCENT WASTAGE TIME

PROBLEM 1. Manual search for the needed fusing part is the top most problem of

the fusing productivity hurdles.

Implementation criteria :

1. Wooden shelf is installed for the segregation of fusing cut material according to part

wise like side panel , top sleeve , in sleeve , etc.





AFTER IMPLEMENTATION:

1.A trolley is provided to fusing feeder operator who will keep the fusing parts on the

trolley after cutting instead of keeping under the fusing table which confuses the

fusing operator.

2.wooden shelf was installed over the table which segregates the fusing according

to parts wise of the garment.



Figure 8: Segrigation of fusing part wise

IMPROVED SOP :

Order information from

production file

Marker Making



Fabric issue report

Issue of fusing rolls from

fabric store

Storage of rolls in cutting

section

Spreading

Cutting Bundling (part wise)

Issue to fusing area

Segregation(part wise)

Collection of shell parts from

panel checking

Fusing starts

Check machine

arameters

Reset Machine

RE- CUTTING

CORRECT

INCORRECT



PROBLEM 2.

Summary: Notches were not visible during stitching process as superimposed seam

is used at side seam and operator could not see the shell notch, so to attach andmatch notch marks should be visible which was a great problem.

Issue 2:

Operator did wrong placement of fusing on shell fabric due to which Notches were

not clearly visible in the sewing section which creates problems and sometimes also

led to re-cutting.

STYLE QUANTITY DEFECTED

PIECES

OCCURANCE

AREA

PL- 1415 974 25 SIDE PANEL

PL- 1415 974 8 LAPEL

PL- 1416 523 19 FRONT ,BACK

JCP- 367(BLACK) 6261 12 SLEEVE

NAVADA -331 794 21 YOKE

PL-1541 300 19 BACK

PL-1541 300 8 FLAP , BONE

Continue Production

Panel checking

Bundling

Issue to sewing



Implementation:

Training was given by the cutting supervisor and cutting quality supervisor to the

operators describing the actual placement of the fusing and importance of notches.

Panel checking were advised to check the panels carefully before issuing it to

sewing to avoid any problem.

Figure 9:training given by quality supervisor

BEFORE TRAINING MOCK



Figure 10:previous mock without notch

After improvement

Figure 11:new mock for training

Importance to notch mark , grain line , and number placement is given in English as

well as in kannda. This will guide the fusing operator in their work as well the new

recruits.



Result :

Figure 12:occurance time after improvement

IMPROVEMENT 3.



Summary : Raymond is been installed with 600 pieces per day capacity but due to

low efficiency of human behaviour Raymond achieves only half of its capacity.

Production board was maintained but not in a appropriate manner.

Problem : correct format for production sheet was not appropriate .

BEFORE

Figure 13:fusing report before



AFTER

Figure 14:fusing report after implementation

RESULT: This format were given to operator after in which the production number

has to be written tallying with the summary sheet. It was most effective as operator

cannot show fake production per hour.

IMPROVEMENT 4:



BEFORE : laying was done in a following manner

F / F

PAIR 1

This type of laying doesnot make pair for sandwich fusing .

AFTER

The first ply is made into pair of F / F . This makes the work of operator easier .

IMPROVEMENT : 4.

FOR25PLIES

12PAIROFF/FLAYING

FOR25PLIES

12PAIROFF

/FLAYING



ISSUE:

The table planner didn’t had a hard copy compilation to know how many laying is

been layed till the new table plan is planned. Table planner have to refer each table

to see the lay report number.

SOLUTION :

A laying checklist was made to track down the number of layed . This helped the

table planner to access the details of laying number at once for each line .

Figure 15: FORMAT OF LAYING CHECKLIST

Documents

Cutting Dept. SPREADING