EVALUATION OF MATERIAL FLOW IN ALOK

INDUSTRIES GARMENTS DIVISION

SUBJECT :- Plant Layout

COMPILED AND SUBMITTED BY:

ASHISH KUMAR ANNEPU (7)
LALIT KISHORE SINGH (14)
 LAYOUT OF SPREADING AND CUTTING -2
RACKS CUT PIECE STORAGE RACKS
BUNDLI
NG AND
TICKETI
BUNDLING AND TICKETING TABLE
NG/SOR
TING

ST
AIR
BUNDLING AND TICKETING TABLE S

END BIT STORAGE FOR PIPING EXI

KNITS MANUAL SPREADING TABLE T
BUN
DLIN
PIPING STORAGE RACKS

FUSI
G
NG
AND
FUSING SORTING M/C
KNITS MANUAL SPREADING TABLE TICKE
TING
/SOR
PIPIN
TING
G
PRINTING PIECE SORTING EMBROIDERY PIECE SORTING FOLD
PIPING M/C ER

FUSI
DISPATCH TO PRINTING DISPATCH TO EMBROIDERY BAND NG
PIPING TABLE
M/C
KNIFE

OFFICE
PRINTING

FROM EMBROIDERY
PANEL REPLACEMENT
PATTERN TABLES

PATTERN
TABLES

PANEL RACKS

TO EMBROIDERY /SEWING VIA LIFT

CAD
 LAYOUT OF SEWING AND FINISHING

CUT
WOVEN GARMENT SEWING LINE (SINGLE PIECE MOVEMENT AND BUNDLE SYSTEM) PIECES

PRESSING

CUT
PIECE
STORA
FINAL INSPECTION AND GE
PACKAGING TABLES KNIT GARMENT SEWING LINE (SINGLE PIECE MOVEMENT) RACKS
BOILER

TO PACKAGING
STICKERING TABLES

BOILER
STICKERING TABLES

PRESSING
 LAYOUT OF FABRIC STORE Unlo
Unlo
ading
ading
bay
Sam Accessory TO BE bay
pling inspection INSPECTED
Office area fabri
Exit Exit
c

DISPATCH

EXIT

Quality
Fabric inspecti
on area Fabric
Insp
storage ectin
g
storage
Fabric storage m/c

Fabric storage Fabric

storage
CUTTI
NG CUTTI
DEPT NG
DEPT

Fabric storage
 Dispatch Dept
LAYOUT OF SPREADING AND CUTTING -1

END BITS

Exit
STORAGE RACKS
Fabric store

WOVEN SPREADING TABLE

Woven inspection Table

BAND KNIFE
WOVEN SPREADING TABLE

folder m/c
Knits Inspection table
GERBER CUTTER
GERBER SPREADING TABLE
END BITS RACKS

Piping
Fusing m/c
GERBER SPREADING TABLE
Fabric store

END BITS

KNITS SPREADING TABLE (MANUAL)

Office area

PIPING FROM END BITS Bundling and ticketing section

 FLOOR LAYOUT OF PRODUCTION FLOOR (Garments Division)
STAIRS SAMPLING DEPARTMENT STAIRS MAINTAINENCE LIFT
PACKAGING AREA
LIFT
AQL AREA

WOVEN LINES (5)

FINISHING
DISPATCH SPIRAL VENT

CONTROL
STAIRS
ROOM

ND
PRODUCTION FLOOR (2 FLOOR) CUTTING
ISSUE
RECORDER

PRODUCTION / SEWING
SPOTTING ROOM

WATERCOOLER
STAIRS
CHEMICAL STORE

QUALITY DEPT
ACCESSORY DEPT
WORKER GENTS TOILET

KNITS LINE (15)

STAIRS
WATERCOOLER
E
M
STAIRS B
R
OI
WORKER STAFF STAFF Production office
STAIRS STAIRS
GENTS GENTS LADIES REJECTION ROOM (IE, PPC.GM, VP, MECHANDISING)
TOILET TOILET TOILET
WATERCOOLER
 ENTRY ENTRY ENTRY
FLOOR LAYOUT OF GROUND FLOOR (Garments Division)
SHIPMENT LOADING BAY

LIFT
AQL ROOM OFFICE OFFICE
STAIRS STAIRS
LIFT

OFFICE
SPREADING AND CUTTING ENTRY

CONTROL ROOMTHREAD STORE

DEPARTMENT

DISPATCH
DEPT
GROUND FLOOR
STAIRS

CAD
FABRIC
STORE
TOILETS

STAIRS
FABRIC UNLOADING BAY
OFFICE
STAIRS STAIRS
TOILETS

TO PRINTING FABRIC UNLOADING BAY/TO CUTTING ACCESORY UNLOADING POINT

`
OVERALL PLANT LAYOUT OF ALOK INDUSTRIES LTD (Garments and Made ups Division)

MAIN GATE 2
PERSONNEL
DEPARTMENT
ANNEX BLOCK

GARMENTS DIVISION GATE

PARKING

WARE
HOUSE
PARKING
SAFETY
SAFETY ASSEMBLY AREA 1
SECURITY
ASSEMBLY
AREA 2
SECURITY

MAIN GATE
Garment Loading Point P
GARDEN A
GARMENTS MADE UPS R
K
Fabric unloading point
I
N
WAREHOUSE

ADMIN BLOCK G

ANNEX BUILDING OPEN SPACE

EVALUATION OF OVERALL MATERIALFLOW
BOILE
R
ROOM

FABRIC UNLOADED AT FABRIC STORE

 FABRIC ISSUED FOR CUTTING AFTER INSPECTION

SPREADING

CUTTING

TICKETING
PRINTING
EMBROIDERY
SORTING PIECES FOR PRINTING, EMBROIDERY, FUSING
FUSING

REBUNDLING

ISSUE TO SEWING ACCESSORY STORE

(ACCESSORY)
THREAD STORE
(THREAD) ISSUE TO SEWING LINE

SEWING GARMENT PARTS (ONE PIECE

MOVEMENT)

PRODUCTION ACCOUNTING AND SIZE SORTING

REMOVAL OF TICKETS (STICKERING)

PRESSING
 INSPECTION AND MENDING

TAGGING

FOLDING

PRODUCT PACAKGING

FINAL INSPECTION
1. FABRIC STORE
 The fabric is received in the mill and unloaded at the unloading bay.

REPACKING
The fabrics are kept in the “TO BE INSPECTED” area before inspections.
 After performing necessary inspections the fabrics are kept in space meant for storage.
 Issue of fabric is done to the cutting on required indent.
CARTON PACKAGING

2. CUTTING AND SPREADING

 The cutting and spreading department is divided into two parts
SEND TO DISPATCH

SHIPMENT
  Part1 contains tables for spreading and cutting
 Part 2 contains tables for auxiliary purposes such as bundling and ticketing.
 The fabric from the store is issued to the Part 1 where the fabrics are spread on the spreading tables.
 Cutting is done for knits using automatic Gerber cutter which covers 3 tables on rails.
 Woven are cut using straight knives on tables itself.
 Separate inspection tables are there for woven and knit for after cutting inspection.
 The cut pieces are transported from inspection tables to the Part 2 section wherein first ticketing is done for all parts.
 After ticketing if any part requires fusing, printing, embroidery it is separated and transported to a different table.
 Different tables are available for dispatching and receiving material to and from printing, embroidery and fusing.
 After the auxiliary processes are executed pieces are received back.
 Rebundling of pieces is done to form bundles.
 These bundles are either stored on rack or transported to the sewing floor via a lift.

3. SEWING
 The cut pieces are issued to the sewing floor.
 Then indivual lines responsible for production are issued with the cut pieces.
 Simultaneously thread and accessories are also issued to the line.
 Production system followed is of single piece moving type.
 All garment parts are rolled into one roll and moved ahead in the aisle space on the right hand on the line.
 Each operation is performed on each part of the garment and sent ahead the aisle space.
 Each work station performs one operation on 1 piece at a time.
 The produced garments are hourly collected at end line which is inspected before being sent to finishing.
 The rejected garments or garments to be sent for washing are sent to the rejection room.
 After receiving from washing the garments are directly to finishing from rejection room.

4. FINISHING
 The garments received from sewing lines are sorted size wise and counted for production accounting.
 After the counting it is sent to the snickering tables at the end of the floor where tickets from all but 1 part is removed.
 After the stickering the garments are sent for pressing, where pressing is done.
 After pressing, garments are sent to the checking table where final inspection is done.
 After the final inspections garments requiring spotting/mending are sent to spotting room and rest is sent for tagging.
 The buyer tags are attached to the garments in tagging.
  The garments are then folded for packaging purposes.
 Preliminary packaging is one after folding for single product only.
 After prelimnary packaging final third party inspection is done.
 This inspection is destructive in nature.
 Repackaging is done after inspection.
 Carton packaging is done in the packaging area.
 All preliminary packaging’s are packed into cartons.
 These cartons after packaging are then transported to the dispatch department with the help of a circular spiral vent on the floor that travels spirally down to the ground
floor dispatch department
 The cartoons are pushed and stacked on this vent to slide down without effort and with help of gravity

5. DISPATCH
 The dispatch receives the cartons in a sequential order and stacked them respectively.
 Then these cartons are transported to the sealing area where various cartons are sealed using thick plastic sheet wrap for shipment purposes.
 The plastic wrap is a tertiary packaging and helps in transporting the goods safely.
 After completing the packaging, lots ar readied for shipping and loading on to containers from the “loading bay”.
 The containers are loaded and shipped as required.

IDENTIFICATION OF FLAWS IN MATERIAL FLOW AND SUGGESTING REMEDIAL SOLUTIONS

1. Major problems faced in material flow seen in the finishing department where there is back track and overlapping
movements observed.

a. Observation
It has been observed that garments after end line are brought to the inspection tables in the finishing where production accounting is done.
After the counting the garments are sent to tables at the end of the floor at a considerable distance from the inspection tables for stickering purpose.
After the stickering the garments move in opposite direction towards the pressing area for pressing (back track). The pressed garments are transported back
to inspection tables for inspection purposes ,thus overlapping the previous processes.

b. Suggestions
 To avoid back track and overlapping movement it would be preferable if garments moved in a straight line through processes.
 In order to attain this objective helpers can be provided at each end line point of sewing lien for removing tickets (stickering).
 It would also be advisable inspection tables are shifted to the end of the floor nearing to the packaging area in order to lessen distance travelled for
transporting packed goods.
 If possible, each line could be installed with its own pressing station, this would help the pressers perform better as collective pressing area heats up a
lot and makes it uncomfortable to work.
 The person responsible for stickering can also perform the production accounting by sorting sizes as he /she removes stickers thus no need to
transport hourly the garments to inspection tables for accounting purpose.
c. Proposed Benefits
 Elimination of wasteful back track and overlapping motions.
 Better working condition for presser with enhanced performance.
 Removal of stickering tables at floors end.
 Proximity of packaging area to inspection tables, thus least effort for transport.
 Confusions on unclaimed alterations after pressing can be avoided between different sewing lines.

2. Distance and placement of fusing machine with respect to tables meant for fusing piece sorting

a. Observation
 After ticketing pieces requiring fusing are transferred to the fusing piece table placed at one end of the spreading and cutting floor while the machines for fusing
are placed are directly opposite positions and also in the next section of the department .
b. Suggestions
 It is suggested to place all machines in proximity with the table.
 .the table must be placed in between the machines so as to cater to both machines; the piping folder machine can be placed in the other section with
the second piping folder machine as there is ample amount of space available in section -2 near the piping folding m/c.

c. Proposed Benefits
 Proximity to machines.
 Easy operation performing.
 Less chance of misplacing pieces in bundles due to transport.
 Optimum use of extra space.
 Proximity to bundling, thus to and fro transport is less.