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CUTTING ROOM
CUTTING OF BLOCKS
LAYING
CUTTING
INSPECTION
SENDING TO WAREHOUSE
SUGGESTIONS:
oProper lighting should be provided. oImproper inspection table. oInsure fault highlighting stickers are properly sticked to the fabric of roll.
. EACH AND EVERY FABRIC ROLL MUST BE CHECKED FOR WIDTH AT LEAST TWO TIMES; AT START OF ROLL AND AT MIDDLE OF IT.
IT MUST BE TRIED TO CHECK THE GSM OF EACH ROLL OF FABRIC.UNDER STRICT SUPERVISION.
DUE TO MOISTURE CONTAMINATION OBSERVED GSM OF FABRIC MAY VARY FROM ACTUAL ONE.
DUE TO UNSPECIFIED DIMENSION OF CUT PART WHICH IS UTILIZED FOR GSM MEASUREMENT LEADS TO FABRIC WASTAGE.
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
SUGGESTION:
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 1st check when 15 mts are roll is finish. 2nd measurement should be taken at middle of rolling process and third at last.
Fabric comes to warehouse from audit department with audit report. Fabric is stored according to buyers 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
RELAXATION
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.
No accountability in this department. No standard way of fabric storage after relaxation process
SUGGESTIONS:
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.
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.
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
Suggestions:
KEEP LENGTH OF SPREAD BETWEEN 7-8M. THIS WILL HELP IN FASTER AND PRECISE LAY.
ONE OPERATOR SHOULD ALWAYS TRAVEL ALONG WITH THE MACHINE TO FIX ANY BLOCKAGE IN THE PASSAGE OF LAYING. AT THE BEGINNING ITSELF.
SPIRAL ROLLERS SHOULD BE USED INSTEAD OF PLANE SURFACE ROLLERS. TO INSURE EVEN LAY
SPREAD AT A TIME
CONTINUES
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. Due to this sometimes whole plies 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.
1st/ Improper water supply. ie chilled water is not available which sometime increases relaxation allowance and worker rating decreases so as production.
UNHYGIENIC CONDITION NEAR WAREHOUSE AND WORKER PLACE OF EATING WHICH INCREASES ABSENTEEISM % DUE TO FREQUENT
DISEASES DUE TO URINALS IN VICINITY
MOTIVATIONAL FEASIBLE.
For checking of prints instead of measuring with tape we can have pattern of print to insure its right alignment.
panel
pattern