ACKNOWLEDGEMENT

First of all, I would like to thank my collage mentor Mr. Ram Mohan for being a great
support 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 and
the 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


























AUTOMATIC CUTTING / STRAIGHT KNIFE
CUTTING


NUMBERING


RELAYING
CUT PANEL DEFECT CHECKING

FUSING
CUT PARTS PANEL INSPECTION
BUNDLING
ISSUE TO SEWING LINES





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
d) Roll length
3. Two types of lays are practiced
a) Face- up (solid fabric for trousers , pocketing , body lining and other trims)
b) Face to face (solid , checks and stipes for jackets )
4. Combination of sizes is worked out to achieve the best fit to achieve marker
utilization so that the consumption are primarily met. At the same time , efforts are
made to maximize the ply height to achieve optimum cutting cost.
5. Once the plan is ready , the numbering sequence generator is utilized to
predetermine the ply numbering sequence.
6. For each lay , specific fabric rolls are allotted and the basis for allotting depends on
one or a combination of the following factors:
a) Width
b) Shrinkage
c) Share
d) Roll length
e) Fabric utilization
7. The generated cut plan is thoroughly checked by the authorized personal and
forwarded for marker procedure






















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 dont 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 by
straight 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. Buyers 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

LARGE
PARTS
Lift two plies
at a time;
number both
on the
wrong side.

SMALL
PARTS
Lift two plies
at a time;
number both
on the
wrong side.
Separate
and remove
the mirror
parts.
LINING

LARGE
PARTS
Arrange the
parts in a
step wise
manner with
the help of
fingernails,
and then
stamp one
after the
other.
SMALL
PARTS
Small parts
arranged in
different
ways: flower
like
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
lay
Marking
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 Position for
numbering
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
6. Small Parts Top

7. Collar Felt Middle



11. Check the numbering after completing one bundle to check:
i. All the components are numbered; no numbering jump.
ii. Correct numbering is done.
iii. Numbering is done at the correct position.

2.1. GLOSSARY
1. Cut Sticker: Cut stickers are generated in the CAD office, using the software, E-
Matters.
The input required to generate a cut sticker is:
i. buyers name
ii. order number
iii. style number
iv. sizes
v. quantity for each size
vi. type of lay (shell, body lining, body fusing, knee lining etc.)
These are put and the software generates a template that can be directly used to
print on the stickers.
The cut sticker has information of the buyer, the style number, lay number, size and
garment number.
2. Summary Sheet: A summary sheet has information of the buyer, order number, total
order quantity, lay number, colour, size, quantity and numbers of the pieces
segregated size wise. It is a very important document generated in the CAD office
using the Morgan Software. It helps in numbering. Any errors in the summary sheet
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. Temperature
2. 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, in- seam
,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
parameters
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 the
operators 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
3
CUTTING 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.
2. Fusing feeder operator was instructed to bring the fusing material according to need
i.e according to summary sheet importantly body fusing. Fusing feeder will check for
the fusing supply at the interval of two hours.
Before
Fusing was keep in inappropriate manner . Below picture will clear the scenario

Figure 6:fusing keep on the table

Figure 7:fusing kept under the table



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
parameters
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 and
match 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.


F
O
R

2
5

P
L
I
E
S


1
2

P
A
I
R

O
F

F
/
F

L
A
Y
I
N
G



F
O
R

2
5

P
L
I
E
S


1
2

P
A
I
R

O
F

F
/
F

L
A
Y
I
N
G



ISSUE:
The table planner didnt 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