SUB: FM2 STENTER PLANNING & FINISHING PROJECT

It will be nearly 4 years since I have been transferred to fm2. And I can say there has been many changes from(planning to finishing) in a positive way under the full freedom / support given by the management. Without support maybe we would not have achieved these things. We’re still an improving team which always aims for faster system / strategy & success. There is still alot to do with the arrival of new machine (Bruckner / Open compactor steamer / Double blade slitting / inspection machines )& the training of our full finishing team. We want to take full control of the fm2 finishing section & provide a better service which has never existed before.

o New/faster strategy set up / Planning.

o Sample

o Fabric feeding.

o Parameters

o Production.

o Quality control / Technical follow-up.

o Operational & Machine condition.

o Training & Manpower.

o Housekeeping & Health / safety.

FM2 STENTER PLANNING DEPT1. The FM2 stenter planning consists of four parts of planning and is done manually on excel. The four parts is (Thermofix / Heatset / sample / wet )

planning. (time consuming). The backload of heatset / thermo fix normally on average is more than 100Tons for orders only.

2. With the arrival of new Bruckner / open compactor machine, this will add more pressure on us for feeding & follow-up. We’ll require at least 25Tons fabric feeding daily with available parameters for both MF4 / Bruckner.

3. Daily floor backload.

4. Our main feeding source, Preparation / Slitting / Kalator / open compactor steamer planning (very important).

5. Fm2 stenter planning is responsible for giving target delivery date to fm1 / fm2 dyeing team for heatset fabric. A master planning is done for that & make us think a lot (time consuming).

6. The flow & feeding of heatset fabric throughout warehouse to finishing is constantly looked by fm2 stenter planning. (Knitting / warehouse / preparation / slitting).

7. The follow-up and measuring of greige fabric prior to include on planning is done & control purely by the FM2 stenter planning .

8. All parameter for thermofix / heatset & sample thermofix is put by myself / Rishi. For new fabric type , a test (1 job) is done prior to launch volume production & is follow by myself/Rishi.

9. Sku follow-up.

10. A new request by Mr Cougen for the follow-up of scanning HT in finishing. I must say right now its fm2 stenter planning who is checking the routing job by job prior to include in planning. That is for time being routing ST5 is created & release by us if not available. And if template has not been correctly been released , an informative mail is send. (time consuming).

11. Stenter production evolution progressive report.

12. Handing over meeting is done twice daily with operators. (AM / PM).

13. The kalator machine & two indian team player is supervise personally by me. (Preparation of sample / lycra fabric & reprocess fabric).

14. Stenter production will always depend on planning dept.

15. Open compact steamer machine planning / control gate prior for heat setting.

Requirements & request: A data entry girl & a Pc need to be recruited. There is a lot of data entry work / analyse & reporting needs to be done. This will also spare me

more time to spent in high profile meeting & overview the whole system.

In overall to run the Stenter planning dept smoothly, only 3 person is required.

Myself (Overall planner)

Satyam (Second hand planner)

Data entry

Proposal stenter manpower for MF4 & BRUCKNER. (To seek Approval from Mr Cougen)

We intend to use 1 main operator / 1 assistant operator & 3 packer to run both MF4 & Bruckner per shift.

Task list as follows:

Operator• Set parameter.

• Recording weight for heatset process.

• Monitoring of operational process:

( Heatset process / Glue / Staining / Migration / Roll presentation / Bowing / Etc).

• Enable & push for production.

• Monitoring machine condition.

• Monitoring of utilities & equipment in finishing.

• Ensuring Housekeeping machine / stenter area.

• Training of our finishing Indian team workers.

• Reporting.

Packer 1 – Assistant operator

1] Act as an alternative to operator.

2] His task list will be similar to an operator.

Packer 2

1] will be responsible for feeding / over locking of both stenter .

2] Housekeeping in front stenter area .

Packer 3

1] will be responsible for fabric coming out from MF4.

2] sample procedure. (1 meter to cut after heatset).

3] Informing operator on heatset weight / quality issue.

4]Ensuring housekeeping behind machine.

Packer 4

1] will be responsible for fabric coming out from Bruckner.

2] Ensuring we have enough pallet / trolley to put fabric for both stenter.

3] Informing operator on quality issue.

4]Ensuring housekeeping behind machine.

FINISHING SECTION: STENTER

FINISHING SECTION: OPEN COMPACT STEAMEROpen compact steamer is a gate to our problem concerning heat setting & will reduce at some point the number of

discrepancies found on greige fabric but will not solve the issue of overweight / underweight 100%. We are already preparing ourselves to be in full operation in the coming weeks.

o It will help us to highlight discrepancies found within batches / jobs & alert us to review our heat setting parameters.

o Both orders / samples lycra will be steamed.

Shyam has already requested to run the machine on shift to be able to meet feeding / priorities.

Task list as follows:

Operator – Right now Ravindra Kumar is operating as day worker operator.

o Set parameter.

o Recording & updating steaming control sheet.

o Reporting.

o Ensuring fabric is well plastic strap on pallet after steaming.

o Ensuring machine condition & Housekeeping near machine area.

Controlo Monitoring of steaming process is operationally very important.

o Measurement of greige will be re-taken after steaming job by job prior to include on planning / heat setting.

o Any anomaly / discrepancies found , will be hold & an informative mail will be sent.

Improvemento Right now am studying the parameters for steaming process along with Frederic / Rishi. Upon approval in the coming month from technical team , I will

be independent to issue parameter for steaming process.

FINISHING SECTION :SAMPLE FOLLOW-UPSAMPLE:Sample heatset has become such an important part in our daily follow-up at fm2. There is so much pressure being link from Phx up to fabric mills. A

decision was taken last year (2012), to prepare sample directly in finishing on kalator to enable us to move / attack quickly prior for heat setting / thermo fixing. I can say in overall the strategy is working & everyone has seen the result. Now a new process is being added in our sample follow-up (steaming process) & I believe we can cope with this changed.

SAMPLE (HEATSET / THERMOFIX) STRATEGY & ROUTING AT FM2KNITTING Delivery from knitting should be fast

WAREHOUSE All sample received from knitting is checked by warehouse team players before sending directly to finishing floor.

FINISHING Sample preparation is done on kalator in finishing & normally start at 7.30 to noon. Sample received (afternoon) is either prepared at 7pm to 11pm or preparation is plan for next day.

PROCEDURESwatch & 1 meter (before process) need to be cut in each job & is send to technical team.

SLITTING Measurement of greige fabric is done on slitting by same finishing team player.

PLANNING Planning is done after all details have been collected. (greige measurement & details / swatch send to technical team) & is then mail to technical team for analysis / parameter.

New process : For all Heatset sample – steaming process to be done prior for heat setting. Measurement of greige will be done after steaming process.

PROCESS PROCESSUpon receivable of parameter. Sample is re-prepared on kalator depending on width & temperature being used to

enable us to push for production. All heatset sample is normally plan during the day for close follow-up / monitoring by technical team & thermo fix process is plan for night shift.

PROCEDURE AFTER1 meter need to be cut (After process) job wise for hanger for technical team.

DELIVERY Normally we do not have any transport issue for transferring sample to FM1 after heatset.

FINISHING SECTION: KALATORKalator play an important role in our finishing department & is a value added machine to our process & production

factor. Both indian team player is honestly trustfully & most of the time technical work are assign to them.

MANPOWER:

Task list as follows: TASK1. Sample preparation . (See previous page for sample follow-up).

2. lycra orders / provisional also is prepare on kalator. This enables Gopee to concentrate on planing & bulk production.

2. The measurement of greige for orders (Roll / tubular after slitting) also is done by the same team player.

3. Measurement of greige after steaming.

4. Finishing reprocess .

Future New project to be assign to kalator team player

Both team player will receive a packer training & will contribute in our finishing logistical follow-up & housekeeping project.

Requirements & request: One inventor need to be added on machine as right now the machine is running slowly. Thus we are both losing time / production in a way.

Indent to be sent to Mr Cougen for approval.

FINISHING SECTION : SLITTING

The slitting area consist of two slitting machine.Avinash was supervising & monitoring the basic procedure on both slitting , but right now his time is limited with issuing parameter for

wet fabric. We’ll review the situation with Mr Shyam asap.

• BIANCO(Schedule to process wet fabric only)

• CORINO (Schedule to process greige fabric (thermofix only)

• DOUBLE BLADE SLITTING (Schedule to process both wet & greige fabric)

Machine not yet received. Manpower still to be define.

Requirements: NEW SYSTEM & IMPROVEMENT NEEDS TO BE DEFINE:• Space issue highlighted - A big parking area / layout need to be define.

• Monitoring of round bac & chasing for trolleys.

• Control (Checklist) & housekeeping improvement.

• Built new trolleys & more round bac required.

• Old trolleys to be repair & paint.

FINISHING SECTION: PARAMETER / TECHNICAL FOLLOW-UP

WET PARAMETERSAvinash / Rajesh is responsible of issuing wet parameters at fm2. Right now Rajesh is following FM2 priorities for

finishing in fm1. As soon as Bruckner start running he will have to be back to basic at fm2 & continue his work with Avinash.

TECHNICALRishi is responsible for following technical fabric on stenter (Order / Sample) (Stripe / Quilt fabric , mesh , etc.). All

heatset test is personally done by him & overview all heatset parameters along with me.

FINISHING SECTION: MANPOWER

ManpowerSantosh is doing a great work in overall concerning manpower / housekeeping / priorities. Helping in the production /

priorities / machine condition. With his presence at odd hours , we are able to meet our priorities. We shall continue along with his good work.

FINISHING SECTION: EQUIPMENT & UTILITIESEQUIPMENT & UTILITIES

Our main headache in finishing is trolley follow-up.1] Pallet play an important part in our daily operational. Due to lack of trolleys, we are using mostly plastic pallet in our

operation on stenter / kalator / open compact & sometimes on slitting. It is more practical & easy to move around. Thus we shall continue using pallet & daily follow-up of pallet is required.

2] Most of our trolley is broken.

FINISHING SECTION: OPERATIONAL• ALI Ali is the big future proposal project on operational follow-up. I want to introduce & used Ali as an important major

force in our finishing department. He is such an honest guy & hard worker. His reporting & execution of priorities is absolutely perfect & his vision quality fabric & on heat setting level is even perfect . His production sheet is always on high score. With such person on board ,we don’t fear to run the finishing. I rate him no1 in CMT in terms of operators / housekeeping. Our finishing is becoming big & we need someone on floor monitoring the basic operational process . It’s a decision Mr. Cougen need to approve . Right now we are managing but if the question arise we’ll sent the proposal to Mr Cougen.

(Ali is the only operator I give maximum heatset at night)

Future Task list for ALI:

• Monitoring of our machine condition. (MF4 / Bruckner / open compact).

• Training of our finishing Indian team workers.

• Enable & push for production.

• Monitoring of heatset / steaming process.

• Monitoring of wet process. (Glue / staining / migration / roll presentation / Etc)

• Monitoring of utilities & equipment in finishing.

• Reporting.

FINISHING SECTION: CONTROL• CONTROL & INSPECTION machine will be our next working

project.

SUB: HEATSETTING CONTROL PROJECT IN FM2

Recently we have notice a rise in density issue at heat setting level in FM2. Unfortunately many things have contributed to that rise but we won’t comment or look for excuses. We’re very concern with that , & definitely action needs to be taken for improvement. We’re very confident we can improve & provide a much better follow-up. This is now a project work we want to promote aiming for improvement. 60% of my time will be invest in heat setting control as soon as data entry assistance is given to support Satyam in planning.

o Knitting / Planning.

o Greige / Boil test. (Orders v/s sample)

o Steaming process.

o parameter .

o Heat setting process & Machine condition monitoring.

o Tumble dry test

o Stamp Released / Doubtful batch prior for dyeing.

o Build Matrix & keep updating / Record.

HEATSETTING ROUTINGHEATEST CONTROL PROJECT

KNITTING 1] Boil test need to be available (Both order / sample) .[Preetam / Kailash]

2] Identical Ref Sample need to be available. (If not available , request will be made) [Nicolas]

3] A copy of Knitting greige matrix / boil test matrix to be given to heatset team [Preetam / Swaraj / Nicolas]

4] As far as possible to use same lycra / dia / gauge for additional or repeats [Nicolas]

5] Knitting to tighten control on lycra / pet fabric to avoid unnecessary pressure on finishing team. [France]

FINISHING (Part1) 1] Greige / Boil test: orders will be compare first to Ref sample. (Any anomaly found - informative mail to be sent)

2] All VLX , SLX (Except 100pet) , SLS to be steam prior for heatsetting.

3] Measurement of greige prior for steaming parameter.

4] Measurement of greige after steaming process to be done job wise. (Any discrepancies being found job by job - informative mail to be sent)

FINISHING (Part2) 1] Test / First job to be monitor & heatset by Rishi / myself prior to launch bulk production.

2] Operators / Packer to ensure basic procedure is respected during heatsetting.

3] Heatset Set target weight to be monitor by Operator / Packer. (Any anomaly found - Heatsetting to be stop)

FINISHING (Part3) 1] Cross-checked weight & Tumble dry test to be done after heatsetting job wise prior to release for dyeing.

2 Stamp for release / doubtful batch.

FINISHING (Part4) 1] Build/ updating Matrix for heatsetting parameters.2] In future heatsetting to be plan in day shift only for better monitoring.

HEATSETTING CONTROL SHEET

1 indian team player need to be given to me for the cross-checked weight & tumble dry test job wise. (Permanent team player required)

Upon of result obtain we will be able to highlight 100% if heatsetting done in condition required & as such we can rel fabric for dyeing.

Failure & doubtful batch shall be hold for reprocessing or further investigation to be done to determine causes of failure.

MATRIX

The most important things in our heatsetting planning is PARAMETERS to be used. This week I will sit with our finishing technician, to start building up & standardize our Matrix for heatsetting parameters per fabric type. It might take months for doing that as we don’t have relevant data due to steaming process.

KNITTING Delivery from knitting should be fast.

WAREHOUSEAll sample received from knitting is checked by Mahen before sending directly to

finishing floor.

FINISHING

Sample preparation is done on kalator in finishing & normally start at 7.30 to noon.

Sample received (afternoon) is either prepared at 7pm to 11pm or preparation is plan for

next day.

PROCEDURE

Swatch & 1 meter (before process) need to be cut in each job & is send to technical

team.

SLITTING Measurement of greige fabric is done on slitting by same preparation team player.

PLANNINGPlanning is done after all details have been collected. (greige measurement & details /

swatch send to technical team) & is then mail to technical team for analysis / parameter

PROCESS

PROCESS

Upon receivable of parameter. Sample is re-prepared on kalator depending on width &

temperature being used. All heatset sample is normally plan during the day for close

follow-up / monitoring by technical team & thermo fix process is plan for night shift.

PROCEDURE AFTER

1 meter need to be cut (After process) job wise for hanger for technical team.

DELIVERY Normally we do not have any transport issue for transferring sample to FM1 after

heatset.

THE ENDTHANKS YOU