ROI FOR BASIC LEVEL AND HIGEST LEVEL OF TECHNOLOGY “PANEL SERGING MACHINE FOR TROUSERS” Presented By: Neha Samdani Prajjwal Dewaskar M.F.tech 3rd SEM

Panel serging A serger is a machine that creates the finished seam you see on the seams of ready made garments such as side seams in trousers,jeans,sweat shirts and tee shirts. Due to industrial influences, you will hear people refer to what home sewers have come to know as serging by many different terms, Overlock and Merrow (named after the Merrow Sewing Machine Company) are just a few.

Panel serging 3 thread O/L 2 thread O/L 1 thread O/L

Basic Level of Technology The basic level of technology for trouser panel serging is : A 2/3/4- thread overlock machine with manual handling of fly wheel for lifting the needle. The operators can be skilled or semi-skilled. Placement of fabric on machine bed should be at correct width position. Operator needs to pay more attention while sewing to maintain required and consistent width.

Machine Used SUPPLIER: JUKI COST: $499 SUPPLIER: BRAITHWAITE

Features Sewing Speed max. 1,500 spm Needle household machine size 11 or 14 Overlock Width standard, 4 mm; rolled hem, 1.0 - 1.5 mm Stitch Length 1 – 3 mm (standard: 2.5 mm) Tension industrial type dial / 1 rotation Built-In Rolled Hemming 2 or 3 thread

Features Universal Presser Foot tape, ribbon, narrow elastic application Presser Foot Lift 5 mm 2 Thread for Overcastting Easiest Built In Rolled Hemming No need to change needle plate Adjustable Stitch Length and Cutting Width Overlock Serger and Overlocker No Differential Feed on this Model

Intermediate level of technology The intermediate level of technology for trouser panel serging is: A 2/3/4- thread overlock machine with motor driven system for lifting the needle. It reduces work content for operator and fatigue as the speed of machine is higher and no manual handling of fly wheel for lifting needle.

Intermediate level of technology The operators can be skilled or semi-skilled. Placement of fabric on machine bed should be at correct width position. Operator needs to pay more attention while sewing to maintain required and consistent width.

Machine Used MO-6900S Series MO-6900R Series (variable top-feed)

Specification

Supplier HOSEKI brand by GEMSY 757G Super High-Speed Overlock Sewing Machines Series SUPPLIER: GEMSY 757G COST: $799

Specifications 757G 2 5 3mm 5mm 3.6mm 0.7-2 5.5mm DCx27 #11-#18 Model 757G No. Of needles 2 No. Of threads 5 Needle gauge 3mm Stitch width 5mm Stitch length 3.6mm Differential ratio 0.7-2 Height of presser foot 5.5mm Needle DCx27 #11-#18 Motor 3450 r.p.m. clutch motor Sewing speed 7500 s.p.m.

Highest Level Of Technology Automatic Serging Machine: An automatic single head or double head work station with or without computer programming. An automatic machine with or without knee lining. The machine performed serging according to the material used. Flexible cloth guide can easily be adjusted in height according to the material to be used.

Highest Level Of Technology A dust extractor is equipped as standard in the upper looper arm section where dust is likely to gather.it helps prevent dust from accumulating inside the cloth chip cover. The machine comes with an air-blow table,which issues a jet of air from its air nozzles at three locations to contribute to smoother handling of material.

Highest Level Of Technology The operator simply places the fabric on the machine, and starts the machine. The operators can be semi skilled, no need of skilled operators.

Supplier: JUKI ASN-690 series

Specification Model name ASN-690 Machine head MO-6904S (super high speed,1needle overlock m/c) Application Serging of pants , skirts , jeans etc Max. sewing speed 8,000 sti/min Stitch length 0.8 to 4 mm Over edging width (mm) 4.0,4.8,5.6 Differential feed ratio For gathering 1:2 (max 1:4),for stitching 1:0.7 (max 1:0.6) Needle DC x 27 (#11) #9,#14 Thread trimming device Exclusive pneumatic side cutter Lubrication Automatic Lubrication oil ISO VG 18 Compressed air 0.5 Mpa Power consumption 590 VA Power requirement Single-phase 200 to 240V,3-phase 200 to 380V Machine Weight Long table-160kg,short table-110kg

Supplier: DURKOPP ADLER 1365-5-2

ROI for Basic and Highest level of Technology The decision of which machine to purchase depends on the size of orders that a manufacturer gets and the kind of labor that is available. The higher we move up in the levels of technology for any operation, greater is the productivity and consistency of quality.

Basic Level of Technology We assume: Target production-1600trousers/day Cost of labor = Rs 3000 per month SAM value for serging both the front panels = 0.75 min Production = 640 trousers per day (shift of 480 mins.) Labor cost per day = 3000/ 26 = Rs 115.40 (month of 26 working days) Labor cost per trouser = 115.40/ 640 = Rs 0.18 Cost of Machine= $ 499/- (rs.24950/)

ROI for Basic and Highest level of Technology Using advanced machinery also results in deskilling of labor; more is the automation, lesser is the skill required by an operator. Keeping all this in mind, we can calculate the ROI for the highest level of technology and find out how effective it is for an industry

Basic Level of Technology We assume: Target production-1600trousers/day Cost of labor = Rs 3000 per month SAM value for serging both the front panels = 0.75 min Production = 640 trousers per day (shift of 480 mins.) Labor cost per day = 3000/ 26 = Rs 115.40 (month of 26 working days) Labor cost per trouser = 115.40/ 640 = Rs 0.18 Cost of Machine= $ 499/- (rs.24950/)

Highest Level of Technology We assume: Target production-1600trousers/day Cost of labor = Rs 3000 per month SAM value for serging both the front panels = 0.30 min Production = 1600 trousers per day (shift of 480 mins.) Labor cost per day = 3000/ 26 = Rs 115.40 (month of 26 working days) Labor cost per trouser = 115.40/ 1600 = Rs 0.07 Cost of Machine= $ 30000- (rs.1500000/)

ROI calculations for Basic and Highest level of Technology Formulas to be used: Depreciated Value(DV) = NBV/{1+DR/100}n where NBV = Net Book Value; DR = Depreciation rate n = Number of years ROI for any year= [CM Price from total machine - total operator salary till that year] ÷ Depreciated value of total machine, expressed as a percentage

Description Basic level of technology Highest level of technology SAM value of per trouser 0.75min. 0.30min. Production per day 640 1600 Production per annum 640x12x26=199680pcs (26 working days in a month) 1600x12x26=499200pcs Production target 1600pcs No. of machines required to meet the target 2.5~3 1 Salary per operator per annum 36000 Total salary(A) 108000 Cost of machine Rs.24950/ Rs.1500000/ Annual Depreciation 15% CM price per trouser Rs.1.44/ Yearly CM price per machine Rs.71884.8 Rs.718848 Yearly CM price(B) 71884.8x3=215654.4 Rs. 718848 Effective CM price constant [71884.8x3]-[36000x3]=107654.4/- 718848-36000=682848/-

CALCULATION OF ROI Description Basic level of technology Highest level of technology Year 1Depreciated value ( c ) Rs.65087/ Rs.1304347.8/ ROI[(B-A)/C] 7.6% 32% Pay Back 14 years 4 years

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