Raymond

The comp complet lete e Man Man  Sinc Since e 1925 PRESENTED BY Amrita Tiwari(01) Ishan Chawla(08)

CONTENTS 1.Raymond 1.Raymond  Since 1925 ABOUT RAYMOND GROUP HR Policy Company Profile Locations of Manufacturing Facilities Milestones Group Companies Joint Ventures Branded fabric and retail- core focus focus Achievements         

2. Vapi Vapi plant plant Hierarchy Site Map Plant Layout Location Advantage Plant Workforce Modern Infrastructure Infrastructure Competitive Advantage Due to Technical Progress SWOT Analysis        

CONTENTS 1.Raymond 1.Raymond  Since 1925 ABOUT RAYMOND GROUP HR Policy Company Profile Locations of Manufacturing Facilities Milestones Group Companies Joint Ventures Branded fabric and retail- core focus focus Achievements         

2. Vapi Vapi plant plant Hierarchy Site Map Plant Layout Location Advantage Plant Workforce Modern Infrastructure Infrastructure Competitive Advantage Due to Technical Progress SWOT Analysis        

3.    

Process Flow: Various Departments SCM Department Department Design Department Quality Department Department Production Department Department  ±  ±  ±  ±  ±  ±  ±  ±  ±  ±

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Scouring Grey Combing Dyeing Recombing Spinning Yarn Room Weaving Mending Finishing Folding

Costing/Accounting Costing/Accounting Department Department

4.Projects undertaken undertaken 5. Bibliography Bibliography

Overview - Eight decades decades old group, group, in operation operation since 1925 - One of India's largest largest branded branded fabric fabric and fashion fashion retailer - Market Market leader in the worsted worsted fabrics business with over over 60% market market share - Second largest largest branded branded apparel business in India - Owns prestigious award award winning brands brands like like Raymond, Park Avenue, Avenue, Colorplus, Parx - Amongst the earliest earliest direct retail chains in India - One of the largest exclusive exclusive retail retail networks in the the textile and fashion space in India - Large India India focus, with more more than three three fourth of revenues revenues from domestic market - Raymond Ltd, Ltd, the flagship company company of the group, is listed listed on BSE and NSE

HR POLICY HR VISION "Raymond the most Desired Workplace for Top Talent" HR MISSION They commit to the HR vision of making "Raymond the most Desired Workplace for Top Talent". They will strive to weave in the core Raymond values namely Quality, Trust, Leadership, and Excellence in all our actions & HR processes so as to make every Raymondite a Complete Man. HR VALUE  Trust  Quality  Leadership  Excellence    

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COMPANY PROFILE 

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Name of the company : - Raymond Limited (Textile division) Address of Registered Office : - Plot 156/H No. 2, Zadgaon Ratnagiri,415 612,TelNo: +9123524921917Fax: +91 2352 492 3851

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Year of Establishment : - 2005

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Year of commencement of Business : - 2005

Business Activities : - Manufacturing Process of Fibre to Fabric Principle Bankers : (1) Bank of India (2) Bank of Maharashtra (3) Bank of America (4)Central Bank of India (5) City Bank N.A. (6) HDFC Bank Limited (7) The Hongkong and Shanghai Banking Co-operation Limited (8) Standard Chartered Bank Auditors : - Dalal & shah Website : - www.raymondindia.com 

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LOCATION OF MANUFACTURING FACILITIES

India Operations 

Vapi

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Thane

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Nasik

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Jalgaon

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Yavatmal

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Aurangabad

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Ratnagiri

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Chiplun

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Kolhapur

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Chhindwara

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Bangalore(3 plants)

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Chennai

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Kolkata

Overseas Operations 

Indonesia

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Romania

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Belgium

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Portugal

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United States of America

GROUP COMPANIES There are 10 Companies in Raymond Group. 

Raymond Ltd.

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Raymond Apparel Ltd.

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Color Plus Fashions Ltd.

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Silver Spark Apparel Ltd.

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Regency Textile Portuguesa Ltd

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Ever Blue Apparel Ltd.

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Celebrations Apparel Ltd.

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J.K. Files & Tools

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Ring Plus Aqua Ltd.

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J.K. Helene Curtis Ltd.

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J.K. Investo Trade (India) Ltd.

JOINT VENTURES 

Raymond UCO Denim Pvt. Ltd.

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Raymond Zambaiti Pvt. Ltd.

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Raymond Woolen Outerwear Ltd.

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Gas Apparel Pvt. Ltd.

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J.K. Ansell Ltd.

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J.K. Talabot Ltd.

ACHIEVEMENTS Images Fashion Awards 2009 - Most Admired Textile Brand of the Year Reader's Digest - Platinum Trusted Brand, 2008 Lycra Images Fashion Awards 2008 - Most Admired Textile Brand of the Year Lycra Images Fashion Awards 2008 - Most Admired Suiting Brand of the Year CNBC Consumer Award 2007 - The Best Branded Readymade Garment and Textile 

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VAPI PLANT

Site Overview Land ± 112.61 Acres

Industrial ± 94.43 Acres

Resi ± 18.18 Acres

(a) 

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Ware

Factory Building:

House (Finished goods store) Folding Dept. + (AWT) Process & Finishing Plant Passage Weaving plant + (AWT) Boiler House Substation (HT/LT/Com/ workshop) Switch yard

: : : : : : : :

5,025 sq. mtr. 1,730 sq. mtr 5,797 sq. mtr. 144sq.mtr. 7,000 sq. mtr. 1,080 sq. mtr. 1,430 sq. mtr. 2,652 sq. mtr

(b)Miscellaneous Structures: 

Security room

:

47 sq. mtr.

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Time

office / Disp. /Creche

:

450 sq. mtr.

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Engineering Office & stores

:

460 sq. mtr.

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WTP

:

1,245 sq. mtr.

and Raw water tank

(40 lac ltr) 

ETP plant

:

1,350 sq. mtr.

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Over head tank

:

8 lac ltr cap.

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Over head tank

:

8 lac ltr cap.

III Phase site overview: The company has started a new plant

PLANT LAYOUT

LOCATION ADVANTAGE

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Situated in Gujarat- known for its good governance Situated on NH no.8 and near to industrial Hub Well connected by Rail & Road Proximity to Mumbai/Thane Accessibility of skilled manpower Continuous availability of water Urbanized and literate people Multi- culture community with communal harmony

PLANT WORKFORCE Human resource department is devoted to providing effective policies, procedures, and people-friendly guidelines and support within companies. 

Following types of person are employed/ engaged at site: Management staff  Workmen Fixed period employees Contract labors Job contract Labor contract      

SWOT Analysis Strengths  Location Advantage  Water availability  Raw material Availability  Modern world class machineries  Skilled labour at low cost Weaknesses  Current Scenario of market  Effect of government policies Opportunities  Increase focus on product development  100% capacity utilization  Increase foreign market business Threats  Competition in Domestic and International market  Ecological & social awareness  Regional Alliances     

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VARIOUS DEPARTMENT

PROCESS FLOW: VARIOUS DEPARTMENTS INTRODUCTION Production is the functional area responsible for turning inputs into finished outputs through a series of  production processes. The production and planning department will set standards and targets for each section of the production process. The quantity and quality of products coming off a production line will be closely monitored. In businesses focusing on lean production, quality will be monitored by all employees at every stage of production, rather than at the end as is the case for businesses using a quality control approach. 

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NAME OF THE DEPARTMENTS    

o o o o o o o o o 

SCM Department Design Department Quality Department Production Department SCOURING GREY COMBING CONVERTER RECOMBING DYEING SPINNING WEAVING FINISHINGFOLDING WAREOUSE Costing/Accounting Department

1.SUPPLY CHAIN MANAGEMENT DEPARTMENT INTRODUCTION 

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SCM REFERS TO SUPPLY CHAIN MANAGEMENT SCM is the core Department which mainly deals with the planning & control activities of  each plan. It provides link between departments.

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Strategy & Analysis.

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Supply Chain Planning

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Core Processes

2.QUALITY CONTROL 

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Central laboratory works in association with R & D and Q.C. departments. The basic function of Central lab is to check the final product. Also it carries out testing of faults and complaints in the fabric. The central laboratory mainly functions for all kinds of testing, both physical and chemical. Testing of the material is done in the fiber, yarn and fabric stages. Decentralization of the department is done into the departmental laboratories i.e. 1. Combing laboratory. 2. Spinning laboratory. 3. Finishing laboratory.

COMBING LABORATORY The combing lab is a division of the central lab in the combing department. Various tests carried out in this lab on the material in the filter stage. Chemical tests carried out in Combing Laboratory 1. Blend composition. 2. Moisture contents. 3. Residual grease contents. Physical tests carried out in Combing Laboratory Mean fiber length testing Instrument  Almeter. Fiber fineness measurements. Instrument A)WIRA Fineness Meter B) Projection Microscope  Measurements of the crimps.  Measurement of the denier of polyester.  Visual assessment of vegetable matter, Slubs, clusters etc. 

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SPINNING LABORATORY The spinning lab is a branch of the central lab in the spinning department. Tests carried out in Spinning Laboratory 1. Count measurements. 2. Single yarn stage measurements. 3. Twist measurements 4. Testing of the roving frame as well as rubbing of the rubbing frame. 5. Hairiness testing. 6. Tensile strength measurement.

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FINISHING LABORATORY After weaving, the properties of the fabric are checked in the finishing laboratory. Tests carried out in Finishing Laboratory 1. Relaxation shrinkage percentage. 2. Piling resistance (sample size  24 cm * 10 cm). 3. Color fastness to water (sample size 10cm* 4cm). 4. Crock fastness. 5. Wet fastness. 6. Dry cleaning and steaming shrinkage test.

CENTRALIZED LABORATORY Most of the physical and chemical tests are carried out in centralized laboratory. The samples tested are of Raymond as well as those received from out side parties. Tests carried out in Central Laboratory 1. Light fastness. 2. Twist testing. 3. Elongation testing. 4. Seam slippage testing. 5. Yarn testing. 6. Drape testing. 7. Fabric tensile testing. 8. Tensile strength testing. 9. Abrasion testing. 10. Crease recovery testing. 

3.PRODUCTION

DEPARTMENT

Bales

SCOURING OBJECTIVE It is a process of removing grease and other impurities with hot water, soda ash and detergent. It is a chemical process carried out in a series of bowls where the wool is washed thoroughly. thoroughly. The impurities present in wool are  Natural Natural impurities oil, o il, fats, secreted by sebaceous glands of  animal skin (wool fat)  Acquired impurities- sand, dust, and and vegetable matter matter..  Applied impurities- raw wool contents contents 24 to 25 % of impurities WOOL SCOURING:  Capacity of the machine is to feed 950 kg of wool per hr.  Clean wool yield: 60 to 65% that depends up on wool quality. quality.  We are getting 3 to 4 % more yield than the standard recommended value. 

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GREY COMBING CARDING OBJECTIVE 

Opening of individual fibers

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Elimination of impurities (80-95%)

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Elimination of dust from the materials.

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Disentanglement of neps.

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Elimination of short fiber.

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Fiber blending, blending , orientation & sliver formation

GILLING OBJECTIVE Parallelisation of fibers. Reduction in weight per unit length of sliver. Improving uniformity of sliver material by using multiple passages. To prepare a sliver of required wrapping for further processing To lay the sliver into can. TYPES OF GILL BOXES Open gill box has a single set of fallers. Intersecting gill box has multiple sets of fallers. Rotary gill box has 6 rollers (3 / 3) each having spiked rings. Line C is for Blending  Recombing  Gilling. DEFECTS The defects in gilling are as follows: Inadequate pressure on roller Broken pins or improper density Improper feelers and improper gilling. Production  180-240 Kgs/hr     

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PROCESS FLOW 

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Recombing Blender Gill Box - 1 Gill Box - 2 Gill Box - 3 Comber Gill Box - 4 Gill Box - 5

COMBING Combing is a process followed after the gilling in the grey scouring section for the following reasons, 

To

remove short fibers from the material

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To

remove all vegetable (foreign) matter

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To

straighten and parallelise the fiber

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To

remove the neps and

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To

lay the sliver into cans.

DYEING DYEING: ( Bellini ) TOP DYEING Top dyeing is carried out after the first round gilling and combing operations are over for the sample. In top dyeing at first, sample dyeing is done in which 5 kg of  material is dyed in the laboratory and then after increasing proportions of the chemicals dyes entire bulk required for dyeing. Dyes used for wool are modified metal complex, 1:2 Metal Complex, acid milling dyes,chrome dyes. PET is always dyed with disperse dyes. 

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GENERAL INFORMATION Capacity Of Machine  Minimum 5Kgs And Maximum 400Kgs Temperature (Oc)  98 For Wool And 135 For Polyester Material To Liquor Ratio  1: 20 Time Required Light Shade - Wool-3 Hr, Poly-4 Hr Medium Shade - Wool-4 Hr, Poly-5 Hr Dark Shade -Wool- 5hr, Poly-6 Hr Extra Dark Shade- Wool- 6 Hr, Poly-7hr Each dyeing machine is connected with a microprocessor in which various dyeing programmes are fed as per the material and shade. 

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RECOMBING Main function of this process is to proper blending of polyester & wool according to given proportion & at the same time maintaining the shade by proper mixing of component, General processes:  55% Poly & 45% wool  65% Poly & 35% wool  38 % wool & 62 % wool These are the commonly used blends. According to blend dept decides & calculate feeding of  poly & wool. 

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SPINNING TOP STORAGE 

When

the tops coming from combing dept they are stored for conditioning in the trolley.

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The

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The

conditionings room is enclosed one and humidifiers are installed for conditioning of  tops. conditioning time is around 24 hrs. After conditioning material is taken for spinning process.

ROVING FRAME The

main objectives of the roving frame are as follows 

Attenuation of material

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Preparation of suitable package for ring frame.

RING FRAME The rubbing and roving frame bobbins are brought to ring frame dept. the roving is converted into yarn by drafting and twisting. The objectives of the ring frame are as follows  Attenuation and  Twisting and winding on the bobbin. Factors to be considered in promoting good spinning are as follows  Count of yarn  Position of spindle rail  Correct type travelers and  Satisfactory spindle speed.

WEAVING SECTIONAL WARPING OBJECTIVE To produce weavers beam. To wind the warp end with equal tension on each and every end. To produce different colour patterns. To produce a compact beam (without valleys and ridges). Sectional warping is done when one needs to produce some design i.e. beam contain some different colours of yarn then sectional warping is used. In sectional warping, the warp threads are wound on the warping drum sectionally. After winding on drum it is then taken on weavers beam.  

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WARPING FAULTS 1. Yarn cone of wrong size. 2. Wrong built of cone 3. Tension variation during warping. 4. Count mix during creeling. 5. Broken ends improperly repairs.

LOOM SHED INTRODUCTION Weaving is the basic department for preparing a fabric by interlacement of warp and weft yarns. There are various looms for weaving available in the textile industry. In RAYMONDS LTD., there are two types of loomsProjectile (SULZER RUTI) and Rapier looms (RIGID /FLEXIBLE RAPIER). About 225OO meters of linear fabric is produced per day. There are total 112 looms working in three shifts. That means each loom is producing about 92 meters of fabric per shift. 

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MENDING OBJECTIVE OF MENDING 

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To

remove mend able spinning & weaving the defects from the fabric like neps , slubs , Missing end, loose pick etc After the mending fabric is delivered to Finishing

FINISHING Finishing department in Raymond is divided into 3 sections viz.  Grey House,  Wet Finish  Dry Finish GREY HOUSE This section is called grey house because all the grey material from the weaving department after perching and mending is being sent to grey house. It includes grey scouring,heat setting and singeing.

WET FINISH This section is known as wet finish section because all the treatments that are carried out on the material are in wet form that includes rescouring and chemical treatment. DRY FINISH This section is called the dry finish section as here the fabric is treated in dry form throughout. Only mechanical operations are rendered to the fabric in order to enhance its look shine and feel. This treatment is generally under the influence of  pressure and steam 

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FOLDING In this department checking of the fabric, cutting and packing take place.  Finish of the fabric approved as per the approved hanger from the product department Shade checking is done as per the booking hanger There are two markets Domestic :- Civil, Exclusive and Stock Lot Export , RAL, RMG & Institutional CIVIL Visual inspection 5 TYPES OF GRADING 1. Good, 2. Second A, 3. Second B, 4. Second C, 5. Second D. 

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COSTING / ACCOUNTING DEPARTMENT OBJECTIVES OF COSTING DEPT Budgeting Fixed expenses, variable expenses Product costing Cost audit Profit planning Inventory valuation MIS report (Management Information System) 

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By considering following costs the total costing is carried out DIRECT VARIABLE COST (DVC): -

In DVC following things are considered Raw material cost Dyes and chemical cost Combing cost Spinning cost Conversion cost 

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In conversion cost there are various process cost are included 

Weaving

cost

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Dyeing cost

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Wet

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Dry Finishing cost

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Doubling (for double yarn)

Finishing cost

5.Projects PROJECT 1: OBJECTIVE: TESTING OF TOP DYED WOOL  There are various tests performed to

determine various quality parameters of top dyed wool. These tests are as follows :

1. WASHING FASTNESS :OBJECT : To check out the washing fastness of the given sample. Atmospheric conditions : 70 to 90 0F  Apparatus used : Washometer, measuring jar, scissors, grey scale, required adjacent fabric (for covering the sample), etc.  Detergent used : Surf excel Result :  No staining or change in colour occurs.  Reading on grey scale is 4/5. 

2. MOSTURE CONTENT :OBJECT : To determine the percentage of moisture content   present in the top dyed wool sample. 

Apparatus used : Air oven, weighing balance (to the accuracy of 0.01), etc.

RESULT : Its average value is found to be 14 % (approx.).

3. 

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OIL CONTENT :-

OBJECT : To determine the oil content (%) in the top dyed wool sample. Apparatus used : Oil extractor, hot plate, weighing balance, container, etc. Chemical used : Methanol (50 mL)

Where, = Initial wt. of the sample in gms W2 = Container wt.(empty) in gms W3 = Container wt.(with Oil) in gms 0.03 = Error correction W1

RESULT : %.

It¶s average value is found to be 0.42

PROJECT 2: EFFECT OF FINENESS ON SHADE 

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OBJECT : To observe the variation in shade according to the fineness of  given wool sample. MATERIALS REQUIRED : Samples of wool of various fineness as :

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1. 17.5 Mic

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2. 19.0 Mic

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3.

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4. 24.5 Mic

21.0 Mic

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DYE USED :ISOLAN YELLOW 2S 2GLN

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CHEMICALS USED :Green acid, Opticid PB IN Liq, Uniperol FBSE

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SHADE: Light shade of 0.5%.

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RESULT : Finer the material, lighter the shade it   produces at same dyeing condition. REASON FOR THE VARIATION : Since the material of  lesser micron i.e. finer one, have more number of  fibres in it considering equal amount of sample weight as compared to that of those coarser ones. Therefore, the finer the sample the lighter the shade it will produce for the same recipe.

Project 3: Deriving a Time Standard Using Work Sampling 

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Work Sampling : A technique to measure work activity as related to delays consisting of intermittent observations of  actual work and delays. Also known as activity sampling; frequency study; ratio delay study. Observing an activity 100 times may not , however , provide the accuracy desired in the estimate . To refine this estimate , three main issues must be decided.

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What

level of statistical confidence is desired in the results?

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Hoe many observations are necessary?

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Precisely when should the observations be made?

The 

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three primary application for work sampling are

Ratio delay to determine the activity-time percentage for personnel or equipment . For example, management may be interested in the amount of tine a machine is running or idle. Performance measurement to develop a performance index for workers. When the amount of work time is related to the quantity of output , a measure of performance is developed. This is related to the quantity of output, a measure of  performance is developed. This is useful for periodic performance evaluation. Time

standards to obtain the standard time for a task. When work sampling is used for this purpose, however, the observer must be experienced because he or she must attach a performance rating to the observations.

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Standard time per piece= (((Total time in minutes)*(Working time proportion)*(Performance index))/(Total number of pieces produced))*(1/(1Allowences))

(1- machine is on work) (0- machine is on hold)

Result: 

So, average standard time per piece = (168.2353+183.5294+152.9412+175.8824+160.5882 )/5 =168.2353 minutes

6.Bibliography

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Apparel standard and quality specifications

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By S. Jacob

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Fiber to Fabric

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Raymond machine manuals

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www.raymondindia.com