Transcript CUTTING ROOM… - textile

CUTTING ROOM…
A STUDY FOR PROBLEM
IDENTIFICATION
AND
SOLUTION
CUTTING ROOM
PROCESS FLOW FOR SOLIDS CUTTING
SPREADING ON AUTOMATIC SPREADER
CAM CUTTING
TICKETING
BUNDLING
WORK ON CUT PARTS (OPTIONAL)
INSPECTION
CUT PARTS SEND TO WAREHOUSE
PROCESS FLOW FOR YARN DYED CUTTING
OPENING OF FABRIC ROLL
CUTTING OF BLOCKS
LAYING
TRACING OF PATTERN ON BLOCK
CUTTING
INSPECTION
SENDING TO WAREHOUSE
IMPORTANT STEPS & OBSERVATIONS
IN
CUTTING ROOM
FABRIC INSPECTION & AUDIT DEPARTMENT
OBSERVATIONS:
Fabric inspection is done for each and every roll from a batch. Inspection
is done for the fabric faults and to check the width of each roll of fabric. But
it was observed that every bundle was not being checked for the width.
Mostly due to workers being uneducated about faults many times roll with
faults are passed over to audit department.
Sometimes due to lac of knowledge defected fabric is passed and for the
same reason less defected fabric is bundled under defected category.
No humidity and temperature measuring instruments are available.
GSM of fabric is taken without drying it.
No instruction is given to rolling operator about the dimension of fabric to
be cut for GSM measurement.
GSM of roll is taken from very localized fabric area i.e. from the same part
of roll instead of taking from different areas of roll.
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.
CORRECT INFORMATION REGARDING ROLL MUST BE FED IN SLIP.
IT MUST BE TRIED TO CHECK THE GSM OF EACH ROLL OF
FABRIC.UNDER STRICT SUPERVISION.
EMPLOYEE EDUCATION IS VERY NECESSARY HERE.
SAMPLES OF DEFECTED FABRICS OR PHOTOGRAPHS OF THEM
SHOULD BE MADE AVAILABLE TO OPERATOR.
DUE TO EXCESS HUMIDITY AND TEMPERATURE, THERE IS MORE
RELAXATION ALLOWANCES FOR WORKER WHICH DECREASES
OVERALL ON STANDARD TIME.
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.
FABRIC AUDIT DEPARTMENT:
OBSERVATIONS:
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 WAREHOUSE
OBSERVATIONS:
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Fabric comes to warehouse from audit department
with audit report.
Fabric is stored according to buyer’s 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:
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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
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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.
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PROPOSED EASING MACHINE VIDEO
process video of ideal spreader machine
Oshima
Serkon
F.N
SPREADING – SOLIDS (AUTOMATIC)
(OBSERVATIONS)
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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.
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More than optimum lay length being laid.
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Lack of attachments in the spreading machine.
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Lack of specific data of rolls leads to off time.
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Improper handling of fabric.
On table no 3 lays are aligned from one side of table only
because of its more width
SPREADING – YARN DYED
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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
SHIFTING OF THE LAY TO CUTTING TABLE:
While shifting of lay from spreading table to the
cutting table air floatation table is not used properly.
 On table number 3 plies are aligned from only one
sideby the operator which causes difference in size of
patterns.
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Suggestions:
DECREASE RUNNING SPEED OF SPREADER TO AVOID TURNING OF
PLIES UPSIDE DOWN.
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.
THE BEGINNING ITSELF.
AT
SPIRAL ROLLERS SHOULD BE USED INSTEAD OF PLANE SURFACE
ROLLERS. TO INSURE EVEN LAY
.
TWO DIFFERENT LAYS OF TUBULAR KNITS CAN BE
SPREAD AT A
TIME TO UTILIZE MAXIMUM WIDTH LAYING CAPACITY OF
SPREADER
CONTINUES…
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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.
CUTTING – SOLIDS & YARN DYED
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All the previous process have an impact on cutting of the fabric.
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Machine stoppage due to lack of feed is high.
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Many times change in the width and gsm of the fabric leads to increase in idle
time of auto cutter.
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Machine stoppage for maintenance is high and frequent.
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Cutting of yarn dyed fabric is done by straight knife & shears
STUDY CONSIDERING WORKER &
OPERATOR
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
NO TEMPERATURE AND HUMIDITY MEASURING INSTRUMENTS IN
FABRIC PROCESS DEPARTMENT.
CLASSES SHOULD BE ORGANIZED TO MAKE WORKERS
AND
OPERATORS REALIZE THAT STAKE OF THEM AND COMPANY IS’NT
DIFFERENT.
MOTIVATIONAL
AND RECREATIONAL CAMPS SHOULD BE
ORGANIZED IF FEASIBLE.
CUT PARTS INSPECTION
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For checking of prints instead of measuring with
tape we can have pattern of print to insure its
right alignment.
print
panel
pattern