CUTTING ROOM… A STUDY FOR PROBLEM IDENTIFICATION AND SOLUTION

CUTTING ROOM

P ROCESS FLOW FOR SOLIDS CUTTING CUT PARTS SEND TO WAREHOUSE INSPECTION WORK ON CUT PARTS (OPTIONAL) BUNDLING TICKETING CAM CUTTING SPREADING ON AUTOMATIC SPREADER

P ROCESS FLOW FOR YARN DYED CUTTING SENDING TO WAREHOUSE INSPECTION CUTTING TRACING OF PATTERN ON BLOCK LAYING CUTTING OF BLOCKS OPENING OF FABRIC ROLL

I MPORTANT STEPS & OBSERVATIONS I N C UTTING ROOM

F ABRIC INSPECTION & AUDIT DEPARTMENT OBSERVATIONS :  Fabric inspection is done for each and every roll from a batch. Inspection is done for the fabric faults and to check the width of each roll of fabric. But it was observed that every bundle was not being checked for the width.  Mostly due to workers being uneducated about faults many times roll with faults are passed over to audit department.  Sometimes due to lac of knowledge defected fabric is passed and for the same reason less defected fabric is bundled under defected category.  No humidity and temperature measuring instruments are available.  GSM of fabric is taken without drying it.  No instruction is given to rolling operator about the dimension of fabric to be cut for GSM measurement.  GSM of roll is taken from very localized fabric area i.e. from the same part of roll instead of taking from different areas of roll.

SUGGESTIONS : o Proper lighting should be provided. o Improper inspection table. o Insure fault highlighting stickers are properly sticked to the fabric of roll.

. E ACH AND EVERY FABRIC ROLL MUST BE CHECKED FOR WIDTH AT LEAST TWO TIMES ; AT START OF ROLL AND AT MIDDLE OF IT.

C ORRECT INFORMATION REGARDING ROLL MUST BE FED IN SLIP.

I T MUST BE TRIED TO CHECK THE GSM OF EACH ROLL OF FABRIC. UNDER STRICT SUPERVISION.

E MPLOYEE EDUCATION IS VERY NECESSARY HERE.

S AMPLES OF DEFECTED FABRICS OR PHOTOGRAPHS OF THEM SHOULD BE MADE AVAILABLE TO OPERATOR.

D UE TO EXCESS HUMIDITY AND TEMPERATURE, THERE IS MORE RELAXATION ALLOWANCES FOR WORKER WHICH DECREASES OVERALL ON STANDARD TIME.

D UE TO MOISTURE CONTAMINATION OBSERVED GSM OF FABRIC MAY VARY FROM ACTUAL ONE.

D UE TO UNSPECIFIED DIMENSION OF CUT PART WHICH IS UTILIZED FOR GSM MEASUREMENT LEADS TO FABRIC WASTAGE.

F ABRIC AUDIT DEPARTMENT : OBSERVATIONS :  In fabric audit department 3-4 rolls are checked for width and gsm of the fabric along with the fabric fault.  Many time GSM of the fabric changes from roll to roll and also in the same roll.  Same thing happens with the width of the fabric.  But as each bundle is not checked these faults pass unnoticed to cutting room

S UGGESTION :  Cut part which is choosen for GSM measurement should be taken from different location of fabric roll and avg of different measurement should be marked as GSM of fabric.  Width of the fabric should be taken from different phases of fabric roll ie 1 st check when 15 mts are roll is finish. 2 nd measurement should be taken at middle of rolling process and third at last.

F ABRIC WAREHOUSE OBSERVATIONS :  Fabric comes to warehouse from audit department with audit report.  Fabric is stored according to buyer’s name  There is no check of fabric prior to storage in the warehouse.  Fabric is not segregated according to width or gsm of fabric.  Rolls of fabric do not have ‘width’ and ‘gsm’ information on them

R ELAXATION OBSERVATIONS : No proper relaxation machine. Machine that is used does not have proper attachments. Fabric handle is done manually. This causes fabric disturbance and relaxed fabric gets ruffled.manually. No accountability in this department. No standard way of fabric storage after relaxation processfabric storage

S UGGESTIONS : Spiral rollers should be used instead of plain rollers. Tray should be used in which fabric is collected and loaded to spreading machine along with the tray,in order to avoid distortion in fabric structure. Proper accounting of relaxed rolls should be done.

P ROPOSED E ASING M ACHINE VIDEO

process video of ideal spreader machine Oshima Serkon F.N

S PREADING – SOLIDS ( AUTOMATIC ) ( OBSERVATIONS ) Used speed of machine is very low in the range of 7m/min; running speed being higher. Target is not achieved even after excess operators being implied on spreader. More than optimum lay length being laid. Lack of attachments Lack of attachments in the spreading machine. Lack of specific data of rolls leads to off time. Improper handling of fabric. On table no 3 lays are aligned from one side of table only because of its more widthone side of table only

S PREADING – YARN DYED Excessive manpower allocated in this department. Hand shears is used instead of end cutters leading to increase of manpower need. In yarn dyed spread length is generally for a single piece of shirt leading in the need of excessive manpower for laying

S HIFTING OF THE LAY TO CUTTING TABLE : While shifting of lay from spreading table to the cutting table air floatation table is not used properly. On table number 3 plies are aligned from only one sideby the operator which causes difference in size of patterns.

Suggestions:

D ECREASE RUNNING SPEED OF SPREADER TO AVOID TURNING OF PLIES UPSIDE DOWN.

K EEP LENGTH OF SPREAD BETWEEN 7-8 M. T HIS WILL HELP IN FASTER AND PRECISE LAY.

O NE OPERATOR SHOULD ALWAYS TRAVEL ALONG WITH THE MACHINE TO FIX ANY BLOCKAGE IN THE PASSAGE OF LAYING. A T THE BEGINNING ITSELF. BLOCKAGE

S PIRAL ROLLERS SHOULD BE USED INSTEAD OF PLANE SURFACE ROLLERS. T O INSURE EVEN LAY

. T WO DIFFERENT LAYS OF TUBULAR KNITS CAN BE SPREAD AT A TIME TO UTILIZE MAXIMUM WIDTH LAYING CAPACITY OF SPREADER

C ONTINUES … Spreading operator have no data about width of roll which causes spreading of rolls with different widths,this will createloss of fabric as marker is made according to roll of minimum width.different widths loss of fabric Due to this sometimes whole plies related to one role has to be taken off which decreases efficiency of spreaderplies related to one role has to be taken off which decreases efficiency of spreader Replace hand shears with end cutters. This will decrease labor requirement from 4 to 2.and will also increase efficiency of lay. Instead of laying for single piece one can make a block for two piece and after laying block can be cut and operated separately. Beforeshifting of lay make sure that air flotation is on and running at highest level. This will decrease tension in lay due to pulling and also distortion in lay.

C UTTING – SOLIDS & YARN DYED All the previous process have an impact on cutting of the fabric. Machine stoppage due to lack of feed is high. Many times change in the width and gsm of the fabric leads to increase in idle time of auto cutter. Machine stoppage for maintenance is high and frequent. Cutting of yarn dyed fabric is done by straight knife & shears

S TUDY CONSIDERING WORKER & OPERATOR

1 st / Improper water supply. ie chilled water is not available which sometime increases relaxation allowance and worker rating decreases so as production.

U NHYGIENIC CONDITION NEAR WAREHOUSE AND WORKER PLACE OF EATING WHICH INCREASES ABSENTEEISM % DUE TO FREQUENT DISEASES DUE TO URINALS IN VICINITY

N O TEMPERATURE AND HUMIDITY MEASURING INSTRUMENTS IN FABRIC PROCESS DEPARTMENT.

C LASSES SHOULD BE ORGANIZED TO MAKE WORKERS AND OPERATORS REALIZE THAT STAKE OF THEM AND COMPANY IS ’ NT DIFFERENT.

M OTIVATIONAL AND RECREATIONAL CAMPS SHOULD BE ORGANIZED IF FEASIBLE.

C UT PARTS INSPECTION For checking of prints instead of measuring with tape we can have pattern of print to insure its right alignment. panel print pattern