DEPARTMENT OF FASHION TECHNOLOGY

STRUCTURED SYSTEM ANALYSIS

AND DESIGN

DATE: 04-05-2010
SUBMITTED TO-

Mr. RAGHURAM JAYARAMAN

COURSE CO-ORDINATOR(F.P)

SUBMITTED BY-

ANADI MISHRA

NEHA DUBEY

SHWETA IYER

VANDANA SINGH
INTRODUCTION

Desi Domain apparels have factories all widespread in India and is renowned in the field of
garment manufacturing. It has given hope and confidence to the Indian manufacturers that they
can prosper and move ahead if they keep up with the changes occurring in garment
manufacturing worldwide and other fashion changes. It also does research in the field of fashion
forecasting and has support of various designers.

Now, it is planning to enter the international market, it is considering the upgradation or change
of its older machinery since now it has to make more pieces per day to supply to satisfaction for
both Indian as well as international customers.

The main area to be concentrated upon will be lesser SAM and more garments to be
manufactured per day. For this, various changes will have to be done in the various departments
of spreading, cutting, inspection, sewing, finishing etc.

The analysis of a specific factory initially in Tamilnadu in Cochin will be initially done on the
basis of which changes and automation requirements will be taken into tasks.

The successful implementation in the Cochin factory and its evaluation for a year will then make
impact for the changes in the other divisions of Desi Domain Apparels.
 BACKGROUND

Desi Domain Apparels have been manufacturing ready to garments past 10years
and have been successful business partners with many International garment
manufacturing names. It has four main divisions which are:-

• East India-Assam

• West India-Gujarat

• North India-Haryana

• South India-Tamil Nadu

The company’s main objectives has been to make garments which are wearable
and for Indians buyers only. Its has alliance with various Indian designers which
keep it informed about latest trends and fashion statements.

Also the company focuses on good quality and moderate price scheme which has
made it popular and in demand.

The annual profit of company in the fiscal year of 2009-2010 has been 1200 crores.

The company is planning to expand its business now and give competition to the
International garment manufacturing companies and dividing to convert all the
factories into exporting houses.

The sole intention of this is to keep its factories update with the latest technologies
as well as boost up the profits by entering the International market.

The company presently has latest equipments in the field of finishing and washing
like:

VIBE MAC-Washing MAC

Hydroextractol dries

Finishing

Crinkling
Requirement Analysis
The company needs certain things to be upgraded and changed for the
enhancement of the company and its progress. The sewing department needs some
changes or up gradation to achieve higher goals and profits.

The some the changes that need to be changed or upgraded are:

• New technology machines

• Less dependence on manual labour

• More machines

• More types of machines and instrument

• Overhead conveyor belt system

In short we want full automation in the sewing department for better progress of
the company and for the profit of the company. The work will be easier and faster
compared to present scenario of the company and it will be able to produce larger
amount of products in lesser time which will attract more company for contract
towards the company. This will in turn increase the overall turnover of the
company and will create a platform for itself in the international level and become
competent to bigger companies present in the company.
Detailed Requirements
• New technology machines-

The company needs new technology machines for faster

and better work. To prove itself in international market it need to produce
the products in lesser time as well as the quality shouldn’t degrade at the
same time. It should include machines with having inbuilt system of telling
any fault in the machine. In short manual work should be reduced and
automation should be done for reducing the errors.

• Less dependence on manual labor-

As described above we demand automation in the sewing

department for better work and for reducing the errors while production. So
implementing this we will have less dependence on manual labour for small
things as the machines will be fully automatic instead of semi-automatic as
now. This will increase the profit of the company as a whole also as
production will be at a greater speed.

• More number of machines-

The company also needs more number of machine as to

compete at an international level it need to produce larger amount of products in
lesser time only then the other companies would give contracts. With more number
of machines we will be able to produce better garments in large quantity in lesser
time and increasing the profit overall.

• More types of machines-

The sewing department needs all such new types of machines

which will be helpful for larger production and also better quality of the
products. For example:

1. Fusing machine

2. Automatic spreader
 3. New overlock machines etc…

These machines will also help in establishing the company on an international

market and increase its profit and give it a good name. the sewing department if
installed with new types of machines it will be very beneficial for the company and
its production, also for its clients. The quality of garments will also be better which
will make the client happy in turn increasing the company’s business.

• Overhead conveyor belt system –

Detailed analysis of Overhead Conveyor System-

The movement of work from one place to another can be time consuming, for this
purpose overhead rails now provide the most common method of transportation.
Since they are economical in space, relatively safe and permit garment ports to be
hung with a consequent reduction increasing and case of access.

All these operations are controlled by computerized control system. Main control
computer panel is called as line controller, line controller performs the function of
software / hardware coordination.

It collects information from node stations placed at every work station. After
collecting information it process it and updates it within 30 seconds. In this system
the garment parts are placed in hanger in sequence of operations. So it removes the
process of bundling and ticketing.

It has barcode reader at every workstation which keeps track of all the hanger and
updates information about them to main control panel.

This helps in keeping information about WIP, real time, productivity, target
achieved, time required to achieve the target also.

A Conveyor system is a very common product handling device. Conveyors provide

companies with the ability to move product safely from one location to another
without human intervention.

Overhead Conveyor Systems provide the same basic benefits of the common
conveyor system except they provide exceptional use of floor space by using the
airspace above manufacturing production areas to convey the products to
predetermined pick-up or delivery station.

Overhead conveyors do not require the need for dedicated floor space for travel
paths of the conveyor. By significantly reducing the need for floor space dedicated
to product flow requirements, the overhead conveyor systems will provide the
ability for better and quicker product flow management as well as multiple tier or
level drop-off and pick-up locations.
Applications for Overhead Conveyor Systems are many, but can be limited to
product weight of up to 2,000 lbs. depending on the conveyor design and product
size.

More common applications include: paint lines, progressive assembly, work-in-

progress (WIP), extrusion finishing, castings, trash movers, carton movement, tote
handling, robotic interface, machine-to-machine transfers, aerospace, and hospital /
industrial laundry applications

Automated Handling

Hanging Garment Automation Systems take your distribution

operations to a new level allowing the handling of upwards
of 200,000 garments per day.

Transformer Systems can analyse your current operation & plan your entire
goods flow. Below is a brief introduction to GOH (garment on hanger)
automated handling systems.

Power & Free - Conveyor

Power & Free allows buffering prior to Workstations (such as bagging

machines & steam tunneling) within the DC with the conveyor providing a
constant but controlled delivery of garment to the point. The conveyor has a
capacity of 12000 garments p/hr at 25m/min and is run with plastic dogs.

Pin Conveyor

The pin conveyor allows the transport of high volumes of garments. Capacity
is 12000 garments p/hr at 25m/min. An easy system to add additions to,
drop-offs on the side of conveyor are an option also.

Distribution - Sorter - Conveyor

The distribution and sorter conveyor are the same as the pin conveyors but
can by powered by pneumatic or electric motors and allow sortation to be
simplified by the drop off system which allow multidirectional changes with
no interference in direction. This type of conveyor only allows for 6000
garments p/hr at 25m/min but the distribution and sortation properties mean
that it is ideal for big warehouse with lots of garments being processed in
and out.

Garment Handling

Slickrail
Transformer's Slickrail is a simple trolley-less overhead railing system.

Manual garment on hanger handling system where the hanger travels directly on the rail.

Slick allows the movement of hanging garments throughout a warehouse.

Hanging garments are slid along the 20mm square BZP tube.

Slickrail uses a continuous rail system which gives rapid feed from goods in /
unloading to specific locations. Using switches, booster conveyors and
loading boom sets, systems can be designed to suit any garment handling
requirement.

• Good Stock Control

• Eliminates Double Handling
• Reduces Loading / Unloading Time
• Low Maintenance

Speedrail
Speedrail is a mono rail system, utilising trolleys to efficiently move hanging
garments. Like Slickrail, Speedrail creates a methodical and controlled flow
of hanging goods and is excellent for sortation purposes.

Garment on hanger handling where garments move around the system on trolleys / jets.

Speedrail structures allow integration with various garment processing

practices such as ; pressing, steaming, kimbelling and bagging.

• Fast Handling
 • Aids Continuous Stock Control
• Maximise Handling Capacity

Garment Racking
Hanging garment storage, simple adjustable racking. Can be integrated with our handling
systems.

Automated Handling
Automated & semi-automated hanging garment handling; goods in, movement, sortation &
delivery.

Mobile Garment Rails

Super simple garment on hanger transportation, we cater for both retail & warehousing
requirements.

Slickwax
A wax specially designed to reduce friction for garment hangers on our slickrail system.

Garment Set Carriers

A carrier allowing problem hangers & bundles to be successfully moved around our slickrail
system.

Garment Racking
Garment Racking is specifically designed for the storing & picking of
garments in warehouses, D.C.s, and stockrooms. A modular system, it comes
in a wide range of sizes and layouts are draughted to suit clients
requirements.

Transformer's Garment Storage is easily adjusted and added to. It can also
be converted to accommodate cartons / boxes as well as hanging garments
through the simple addition of shelving.
Hanging Garment Storage Racking can also be developed into a multi-tier
systems with walkways.

• Easy Access & Improved Picking Times

• High Density Storage
• Adjustable

BENEFITS:

• Line balancing
• Elimination of bundling time
• Overall improvement efficiency which can be achieved
• Reduction in handling and external time
• Operators attendance monitoring
• Updates about current production against targets
• WIP can be brought down to operational level
• Reduction in throughout time
• More accurate product job costing
• Increase in order bookings
• Improved impression to the clients

ABOUT THE SYSTEM:

THE STRUCTURE OF THE SYSTEM

CONTROLLING UNIT

The computer controls the whole system and the controlling unit is given
different name in different brands like in Eton it is called as Eton Line
Controller or ELC unit.

The elc system is electronic control part of the Eton system. The PC based
software SOFTPro/ Soft uses the elc system to capture the data from the
production and to distribute messages to the operators.

The system consists of a main unit, the elc station controllers and workplace
terminals. The station controllers are connected to the elc in a network.
The workplace terminals are on an Eton line connected to the station
controllers, but can (outside an Eton line) be connected directly to the elc
network.

Each workstation is controlled by a station controller.

The station controllers on each workstation controls outputs, such as

unloading, loading arms etc. and sense inputs such as micro switches and
other sensors. The workplace terminals are used to enter information and
display messages to the operators.

It is incharge of all the addressing and controlling of the Eton line. All
parameters and setup needed for the system to work are stored in ELC. The
ELC handles the communication to each station controller and keeps track of
where the clamps are in the system.

It is sealed enclosure, which consists of a main CPU with RAM memory the
Host Card, and two controller cards called the net cards. The memory on the
host card has an internal battery backup. The ELC unit has a built in power
supply to internally power up the cards.

STATION CONTROLLER

At every workstation there is a station controller, which is placed above each

of the workstations, on top of the headline. This is equipped with the two
cards- the upper one is I/O card and the lower one is node controller card.

All these station controllers are incharge of the intelligence on the

workstations itself i.e. feeding chain, barcode reader etc. the station
controller also handles all the information for all the inputs and outputs of the
station.

NETWORK CONNECTION BOX:

Every station has a network connection box which facilitates the connection
between all the stations and the ELC.

HEADLINE:

This is the main conveyer on which hangers or clamps or product carrier

move from one workstation to another
 SCOPE DOCUMENT

GOAL: To expose the Desi Domain Apparels to international markets and to automate this
garment industry by introducing the latest softwares of overhead conveyer system.

PROJECT SUMMARY:

PROBLEM STATEMENT:

1. Transportation problem within the departments.

2. Creates confusion

3. Mixed up the garment parts

4. Lead times i.e. less work in process is more

5. Less productivity

6. No quality monitoring

REWORKS ARE DUE TO:

Shade difference

Loose stitches

Puckering
Stains on the garments

Smell contamination
 Size variations and others

Early identification throughput

BUNDLE SYSTEM:

• Parts are bundled together and kept on the table.only a small part is visible and shade
differences are not visible.

• Garments are bundled and crushed and easy to catch stains.

• Sweat and dirt are picked up from operators and helpers. No possibility for free air to
pass through garment parts.

• Only mass verification at the end of the line possible.

• Throughput time is too long. Defects are noticed only when the full garment is
finished. By the time the issue is noticed ; many parts are stitched necessating rework.

OVERHEAD CONVEYER SYSTEM:

• Garment parts are hanged and easily visible to operators and supervisors and shade
difference, loose stitches and puckering are noticed and immediately action taken.

• Minimum handling and no crushing of garment parts. Freshness of fabric is maintained.

• Contaminations are removed as hanged parts are exposed to air and light.

• Possibility for easy verification at every station avoids size variation and other quality
issues.

• Throughput time is very short and hence quality issues in fully finished garments are
highlighted, well in time.

BENEFITS:

Summary of benefits:

Pick up work Eliminated

Prepare work Eliminated

Administration Reduced

Stains and cleaning Reduced

Pressing Reduced

Operator fatigue Reduced

Momentum Increased

ULTIMATE BENEFITS:

Improved space utilization

Increased productivity
Direct labor costs are reduced
Improved ergonomics
Additional garments at no extra cost= improved profitability
Improved quality control= increased customer confidence
Quicker throughput= easier to meet delivery target
WHY OVERHEAD CONVEYER SOLUTIONS??

 Totally flexible layout

 Maintenance free

 Quick installation per production line(1-2 days)

 Layout proposals provided

 System training

 On going technical support

 Upgrade possibilities

a. Re configuration of system

b. Real time data collection

THE ETON SYSTEM:

Eton’s objective is to offer over-all productivity improvements based on the implementation

of the Eton Unit Production System.

The Eton system is a computerized overhead conveyer with individually addressable

workstations. The system eliminates manual transportation between workplaces as well as
non-productive operator time. It is built from modules, which makes it very easy to adjust for
every customer’s specific needs.
 FEASIBILITY STUDY
Needs for Implementation of Overhead Conveyor System:-
1. Faster stitching: - Since the overhead conveyor system does not allow any idle
time the workers are kept busy and engaged which helps in completing the order fast
since they stitch faster.

2. Faster Information Retrieval: - Any problem which crops up can be easily

traced back to its originating workpod and hence can be rectified accordingly.

3. Records Workers’ Efficiency: - The system keeps a record on the number of

pieces stitched by a particular worker and hence helps in evaluating the efficiency of
the workers.

4. Easy Fault Handling: - An important advantage of the overhead conveyor

system is that we can check for faults and can send it back to the specified operator
directly to rectify it.

5. Fast work Pace: - The overall work moves at a fast pace since less time is taken
for stitching and troubleshooting.

6. Line Balancing:- The tedious process of line balancing is reduced.

7. Updated Information:- It provides updated information about current production

against targets.

8. Costing: - More accurate product costing can be achieved.

9. Improves Impression:- The clientele is more impressed and they provide more
orders.
 10. Saves Floor Space: - The whole setup of the system can be accommodated in
very less space as compared to a convectional assembly line thus saving essential
floor space.

Cost Benefit Analysis:-

Hardware Cost: - The overall cost which is required to setup and run the overhead system is
the hardware cost which is required.

Number of workpods required = 20

Main alluminium stand =1

Pulleys =5

Hangers =250

Flat Belt Suitable for the above conveyor

Total cost= Rs. 7,00,000

Machine requirements:-

Snls machines= 12

Dnls machine=3

Overlock machines= 3
Button Hole machine=1

Button attaching =1

Total machine cost= Rs. 5,00,000

Total hardware cost= Rs.12,00,000

Facility Cost: - These costs include the price required to arrange for the required floor
space and for operations like wiring, lightening, air-conditioning etc. These are one time costs.

Tube-lights required= 20

Fans required= 15

Stools required = 20

Air-conditioners required=5

Total cost = Rs. 1,25,000

Operating Cost: - These costs include all the costs involved in the day to day operations
of the system. These depend on the number of shifts, nature of operation and the caliber of the
working staff.

Number of shifts=2

Number of workers per shift= 20

Worker wage per day= Rs. 200

Total cost= Rs. 8000 per day

Justification:-
Non-financial Justification:-
1. Benefit of Mechanization

2. Improved Productivity

3. Consistent quality

4. Reduced Labor Cost

 5. Deskilling Jobs

6. Better utilization of Materials

Financial Justification:-
1. Direct Labor Cost savings

2. Increased profitability by virtue of increased productivity.

REQUEST FOR PROPOSAL

SCOPE OF PROPOSAL

The Proposals would be evaluated on the basis of the evaluation criteria set out in this RFP
document in order to identify the successful Bidder for the Project (hereinafter referred to as
“Successful Bidder”).

SELECTION CRITERIA

In order to fulfill the mentioned requirements the following selection criteria must be
fulfilled:

• The goals and end results needed has been stated and the profits and benefits the
company will yield has been explained clearly and precisely.All bodies are invited
which can demonstrate their potential in the field of implementation of overhead
conveyor system and related software and machineries in the sewing department.
 • The body taking up for the technical requirement section should initially discuss with
the company’s Implementation and Automation committee what they intend to do so
while satisfying the technical requirements.
• The concerned bodies should present their worth and status in the current business
scenario as well as quality according to which they would be appointed for the
implementation if the concerned bodies have all desired requisites needed towards
meeting the aim.
• The project needs a solid bse as it is going to deal with large scale manufacturing so
bodies who have made a mark in their related fields are only invited.
• The body taking up architectural requirements should discuss with the Committee for
positioning and allocation for the space needed for machinery.
• The basic requirements are the primary requirements which need to be implemented
with full care and attention since any changes in sewing department will directly
affect the production rate and hence the profits and yields of the company.
• The technical ,architectural and basic requirements should fulfilled in fixed span and
negotiation related to pay-offs and sourcibg in machinery should be discussed ahead
of starting the project
• It is the responsibility of body/bodies taking up the project to look after during post
implementation for period of 6 years and guarantee maintanence if required whenever
needed.

ELIGIBILE BIDDERS

The bidders who are eligible for participating should come into anyone of the two categories
which are:

• Minimum stay in the field for 10 years and been in competition with counterparts for 4 years
with completion capacity within allowed span of time.
• The bidder should have taken order from other garment manufacturing companies in the past
with success results of nearly 98%.
Any entity which hs beenprohibited by the government or facing any legal proceedings or
conflicts is not eligible to submit the proposal if it remains till the Proposal Due Date.
 NUMBER OF PROPOSALS

Each bidder can submitmaximum of 2 propasals relating to different requirements in response to

the Request For Proposal.Any bidder submittingas a joint venture with another bidder will be
disqualified but will be allowed if they have previous alliance based business running presently.

VALIDITY OF PROPOSAL

The proposal will remain valid for a period of not less than 15 weeks from the Proposal Due
Date.Desi Domain reserves right to reject any proposal which does not meet its requirements.

PROPOSAL PREPARATION COST

The body of bidders shall be responsible for all the costs associated with the preparation and its
participation in the bidding process.Desi Domain will be not responsible for any such costs
regardless it is as the outcome of the proposal’s requirements.

PROPOSAL DETAILS

PROPOSAL SHALL COMPRISE THE FOLLOWING:

1.Technical proposal
• A brief description of the Bidder’s organization and an outline of recent experience on
assignment of similar nature.
• The composition of the proposed Professional team, the tasks, which would be assigned to
each one of them.
• Estimates of the total time (person x months) for each professional staff.

2. Financial Proposal
a. Quotation
 • In Figures
• In words
Note: In case of difference in amount quoted in figures and words, the higher value would be
considered for evaluation.

Send along the financial proposal format form as in Appendix E

b. The budget should also cover cost of, preparation of reports, and other related expenses.

3. Details of all the requirements mentioned above.

4. Performa for Notice of Intent to Bid

5. Bank guarantee

6. Proof of registration of the company

7. Covering Letter

8. Qualification Proof

FORMAT AND SIGNING OF PROPOSAL

The proposal and other correspondence and documents should be in English.The documents to
be given in support and printed literature furnished by the Bidder with proposal having
translations.

The currency will be in Indian Rupee .Exchange rate going on currently will be considered.

The bidder should provide information as per Request For Proposal with required format and
complete in all aspects. Each proposal shall be having the following:

PART -1 :SUBMISSION

• Covering letter in Appendix A

• Details of bidder in format in Appendix B
• Copy of certificate of registration issued by concerned authority.
• Power of Attorney as in Appendix C
• Proof of Qualification in Appendix D
• Proof of purchase of Request For Proposal for Rs 15,000 or download from site
www.DesiDomainApparels.com

SUBMISSION-PART-2

• Financial proposal as per Appendix-F for supply of machinery,softwares and other

equipments.
• There should be 2 copies of proposal ,one being original and other being copy for
verification purpose for the company
• Both copies should be signed and initialized by the bidding body.
• Modification of Proposal is subject to rights solely dependent on Desi Domain.

PROPOSAL EVALUATION

Proposal will be considered responsive if it fulfills the following conditions:

• Received by Proposal Due Date.

• Signature, Seal ,Marked
• Contains information in specific format
• Mentions proposal validity period.
For technical and architectural requirements,Desi Domain might request the bidder for
alterations and modifications.
 CRITERIA FOR DISQUALIFICATION

• Bidder is not prompt and does not supply the additional information needed.
If any disqualification or rejection occurs after the bidder has been selected for the
work then:

• Next best bidder shall be considered.

• Rebidding
• Invitation to the most appropriate bidder for negotiation.

REQUEST FOR TECHNOLOGY

TENDER NOTICE
 APPENDIX A

COVERING LETTER:

Date:

To:

Implementation and Automation Committee,

Desidomain Apparels,

Hjhjkkl

Cochin,

Tamil Nadu

Phone Number:048-45234568

Fax :487989097980

Ref:Supply of machinery

Sir,
Being duly authorizes to represent and act on behalf of___________(bidder),reviewed and
fully understood specific proposal requirement and information collected with original copy.

Confirmation of proposal and undertaking.

Yours faithfully,

For and behalf(name of bidder),

Duly signed by Authorized Signatory of bidder,

(Name:

Title:

Address:

APPENDIX B

1.) DETAILS OF BIDDER

ON THE LETTERHEAD:

(a) Name of Bidder

(b) Address of the office
(c) Date of commencement of business
2.) Description in short of mainline business

3.)Details of individuals who will serve as point of contact

a) Name

b) Designation

c) Company

d) Address
e) Telephone Number

f) Email Address

g) Mobile Number

4.) Name,Designation,Address,Phone number of Authorizes signatory Bidder

APPENDIX C

It contains the Power of attorney

We (name, address of registered office) do constitute to appoint and

authorize________(Name and Address) presently employed with us and holding position as
attorney on our behalf in all deeds and acts.

We agree to ratify all acts; deeds lawfully done by our said Attorney and said by Attorney
will be done by us.

Date:_______Day of_________2010

For:

(Name and Designation of person

On behalf of bidder)

Accepted
 _____________ (Signature)

Name,Title,Addres of Attorney

Date:

Legal note:

APPENDIX D

PROOF OF QUALIFICATION

Qualification criteria:

Bidder must satisfy the following:

• Operating and dealing with assignments of more than 15 crores.

• Minimal stay in working area for 8 years
• Specific supplier as per requirement
Financial capability:

Financial capability of bidders will be judged on basis of their net worth in financial in
fiscal year 2009-2010.

Audited financial statements of the bidder should be present

 APPENDIX E

Format for Submission Of Financial Proposal From Bidders

To,

Developing Officer,

Desi Domain Apparels,

Cochin-

Tamil Nadu-

Fax- 44-1234567

Office-045-3456272
Dear Sir,

1 We have understood the instructions and the terms and conditions mentioned in the
RFP Document and have thoroughly examined the RFP Document and

are fully aware of the scope of work required. We are hereby submitting our “Financial
Proposal” as per prescribed format in a separate sealed envelope.

2 The amount of consultancy fees quoted is Rs. _______

For and on behalf of:

Signature:

(Authorised Signatory)

Name of the Person :

Designation :