DORE DOR CASE

Submitted By(Grp-1)
Dhananjay Rastogi(Roll-11)
Md Harun Rasheed(Roll-24)
Prachi Srivastava(Roll-30)

Dore Dore Company

Background
Dore Dore was manufacturer of fashionable Knitted
Products.
It has two Business Unit
Hosiery Unit: Socks and Stockings, which
contributes 88% of Dore Dore total sale.
Knitwear Division: Produce childrens knitwear such
as Playclothes,Sweaters and Nightclothes.
DD focus on high end of market with regard to
Quality and quantity
DD has 30-40% market share in High end segment.
DD represent 4-5% market in Hosiery Segment and
0.5% in Knitwear Division.

Issues in Operation
It has two Operating location

-MERY Plant for Children Knitwear Operation

-GRES Complex has Hosiery Factory and HQ

Each season DD produced each style in two seasons

in hosiery and preset production for Knitwear in
hosiery and preset production for Knitwear division.
Uncertain Forecast
High Inventory Cost,Many times Items were left
Unsold
Dore Dore is planning for reduce manufacturing
Lead time by tracking demand fluctuation
The company wanted to get into Cellular Design for
better Production and Operational Utilization.

Production Cycle for

Knitwear

Company is Presently Using Product design layout for

Operation Production

Each Worker repeatedly perform single specific task on each

batch of items

Same style and same orders were placed every time and
delivery is in advance

The Impact of Cellular design process on Hosiery design were

studied in consultation with ITF

U Shaped Process Design

A prototype U shapedLayout
close knit process design of flexible

cell was made operational.

It has close knit seven operation for particular batch with
six chosen cross trained operators
Batches of about 200 pieces of same style and color were
expected to flow quickly through cell through each
operator.

RESULT AND ADVANTAGE

It caused throughput time of garment to dropped from 15
Working day to 1 day.
Defect rate also dropped from 5% to 2.5 %
IR of factory setup improved resulted in better productivity
Other cell, different from first one also placed near
tradition line operation.

PRODUCTION CYCLE FOR HOSIERY

OPERATION

Very High Raw Material Inventory, It generates product of

different style, size, color with total of 35000 SKUs.
Production in Batches with same colour and style with multiple
sizes.
High Setup time for Knitting Machine ,Toe closing room is noisy,
crowded and Windowless

PROPOSED MODIFIACTION
Design such a layout where minimum possible
change is required for Designing the task.
All Operation after Knitting to be clubbed
together in single room
New cell design will be based on capacity of two
ironing Machines
Each cell is assigned with 36 Workmen in teams
of two responsible for production of entire line of
hosiery.
Teams should not be completely cross trained
It is expected that Mfg time will drop by 1 week
and Inventory would drop by 30-40%