An Overview Of

Raymond Limited (Textile

Division)
With Emphasis
On
Supply Chain Management

Presented By:
Mohsin Aziz Baba
Shashanka Shankar Boruah

Objectives
2

Primary:
To study the Supply Chain Management Process of Raymond
(Textile Division).

Secondary:

To get an overview of the textile division of Raymond

Limited.

To understand the process flow of various departments

operating in the Chhindwara unit of Raymond.

Raymond Limited
3

Raymond Limited is one of the largest integrated manufacturer of worsted

fabrics in the world.

It ranks amongst the first three fully integrated manufacturers of worsted

suiting in the world.

Only Company in the world to have a diverse product range of nearly

20000 designs and colors of suiting fabric to suit every age, ocassion and
style.

Products exported to over 55 countries including the US, Canada, Europe

and Middle East.

Company Overview
4

Year of Establishment: 1925

Market Share(for worsted suiting fabrics):

60% of the Indian market

30% share of the world market

Turnover: Rs. 1400 Crores.

Textile Divisions:

Chhindwara

Vapi

Jalgaon

Brands
5

Raymond
Park Avenue
Parx
Manzoni
Be
Premium

Joint Ventures
6

Raymond UCO Denim Pvt. Ltd .

Raymond Zambaiti Pvt. Ltd .

Gas Apparel Pvt. Ltd .

J. K. Ansell Ltd .

Overview Of Chhindwara
Unit
7

Flagship Company of J. K. Groups (Western Division).

Became operational in 1991

Produces high quality PW fabric and PV blends fabric.

The finishing department is the largest of its kinds in Asia,

with a capacity of 40000 mtrs per day.

The work force is adequately skilled, well trained and

competent.

Vital Statistics
8

Present capacity : 45,000 mtrs per day.

Total Production: 153 lacs meters per annum

Installed Capacity:

License capacity: 1500 looms and 50000 spindles.

Total Area:

113 looms and 33528 spindles

100 acre plot

Built-up area:

1,40000 sq meters

Green belt area:

65%.

Vital Statistics
9

Manpower : 3246 Labourers And 415 Staff Members

Power Consumption : 1, 67,000 Unit per day

Water Requirement : 43 Lacs liter per day

Coal Required : 58 Metric tones per day

Out Put : 40,000 mtrs fabric per day

Units Turn Over : Rs. 430 crores approx p.a

Vision for Unit Set Up

10

To manufacture world class polyester-wool and polyester-viscose

blended suiting and furnishing fabrics at competitive prices,

To establish a large-scale unit in a backward area, which needed

accelerated development,

To ensure all- round socio-economic progress of the region and its

hinterland,

To catalyze the industrial potential of smaller towns of the country,

and

To provide additional sources of employment to people in & around

Chhindwara district.

Location Selection Factors

11

Cheap Land.

Labour availability at cheaper cost.

Easy availability of power, fuel and water.

Availability of land for Expansion.

Easy Transportation

Market Proximity.

15% of subsidy on total cost of project subject to maximum of 15

lacs.

Sales Tax exempt for 7 years initially.

Entry Tax exempted for 5 years extended by another five years

due to major expansion.

5% Subsidy in electricity charges subject to a maximum of 10 lacs

per annum.

Organisational
Hierarchy:

Works Director

GM Works

Sr. Manager(HR)
Executive (RMG)
Manager (SCM)
DGM (Dyeing)

Sr. Manager(Plush)

DGM (Finishing)

DGM (Engineering)
DGM (Warehouse)
Manager (Weaving)

Sr. Manager (Accounts)

Sr. Manager (Recombing)

Sr. Manager (Designing)

Manager (Folding)
Sr. Manager (QA)

Sr. Manager (Excise)

Manager (PVSPG)
Sr. Manager(WSPG)
12
Manager (Grey Combing)

Sr. Manager (CPP)

Process flow of Department

13

Polyester
Viscose-Fiber
Dye
Dyeing

Polyester ViscosePiece Dye

Spinning / O/s Yarn

Grey Combing

Grey Combing

Spinning
Yarn Room

Yarn Room
Warping Weaving

Dyeing
Recombing

Recombing
Spinning

Warping
Weaving
Mending

Mending

Spinning

Yarn Room

Finishing
Finish Mending
Folding
Warehouse

Polyester Wool- Polyester Wool-Piece

Top Dye
Dye

Finishing(Pretreatmen
Yarn Room
Warping Weaving
t)
Dyeing
Warping Weaving
Mending
Finishing(Post
treatment)
Folding
Warehouse

Mending

Finishing(Pretreatment
)
Finishing
Dyeing
* Finish Mending
Finishing(Post
treatment)
Folding
Folding

14

Working of the
Departments

Raw Material Godown

15

Receives Raw material from outside party

Receives materials from in-house departments

Deliver as per the requirement with care.

Stores the raw material with proper order,

Receives waste from various departments,

Dispatches the waste material.
Sections:

1. Raw material godown (RMG)

2. Top godown

3. Waste godown

Process Flow:
Raw Materials from Suppliers

Making of lots and allotment of lot numbers

Stacking as per different materials (bins/blocks)

Samples sent to laboratory to verify quality according to
specifications

Waiting for Requisition from various departments-Scouring,

Convertor, Combing and Dyeing-and sent accordingly

Received by Top Godown

16

Depending and as per Requisition, its sent to Dyeing/Recombing

Wool Scouring
17

Objective :

To remove all the above mentioned impurities without damaging the fiber.
The dirt and sand in the wool are removed during scouring by mechanical
agitation.
In scouring there is loss in weight amounting to about 40%.

Types Of Impurities In Raw Wool:

Natural

Acquired

Applied

Grey Combing
18

Lubrication:

Wool is lubricated

Carding:

Convert criss-cross and tuff forms of bulk to rope

like shape which is known as sliver.

Gilling:

Parallelize fibres and increase evenness.

Combing:

Remove smaller fibres.

Converter
19

Raw material is polyester (Synthetic fibre)

Converter : cut filament into desired length.

Gilling:

make sliver more parallel and even

Dyeing
20

Sample dyeing:

For colour matching on spectrometer.

Top dyeing:

Wool and polyester are dyed separately.

Hydro-extractor:

Removal of moisture by centrifugal action.

RF drier:

To remove left over moisture.

Recombing
21

Defelter: seperates closely clinged wool

fibres.

Blender: mixes wool and polyester.

Gilling: increase evenness.

Combing: remove smaller fibres.

Spinning
22

Gilling: reduce mass per length and diameter of silvers.

Roving: reduce weight per length & impart required twist.

Ring frame spinning: twisting the yarn to impart strength.

Streaming: reducing snarling tendency and set twist

Auto-winding: remove various faults like neps, slubs, thick & thin
places etc.

23

Ply winding: 2 yarns are wound together without twist.

Twisting: imbibe twist by maintaining required tension.

Steaming: is done to reduce snarling tendency.

[the yarn is put in autoclave to set the twist].

Yarn Room: stores yarn till required by warping section and

maintains all necessary data about the yarn produced.

Yarn is weighed

Data entry is done

Warping
24

Rewinding: supply sufficient number of packages in the

form of cheese.

Sectional Warping: loading packages on reel.

Waxing: make warp yarns smooth to reduce breakage on

looms.

Drawing-in & denting

Weaving:
25

Primary motions: shedding, peaking , beating up.

Secondary motions: let off, take up.
In Rapier looms, the weft insertion element resembles a rapier
or a thin bladed straight sword
There are many varieties of Rapier systems such as single,
double, flexible, rigid, telescopic and two phased.
The rapier may also be of the rigid rod type or flexible, made of
metal or plastic tapes.

Mending
26

Objective: weaving and spinning defects are found and

corrected as far as possible.

Selvedges: stop outside ends from fraying from the

body of the cloth.

Grey Perching: visible inspection of fabric.

Finishing
27

Batching: to obtain sufficient length of cloth.

Pre-scouring: washing process.

Drying & heat setting

Singeing: burning loose fibres.

Rope scouring, opening and drying.

Shearing: cutting left protruding fibres.

28

Semi- perch: manual check of finished fabric.

Relaxing m/c: removes crease of fabric.

Damping & Pressing

Formula 1: improves dimensional stability & lustre of the

fabric

Kier decasting(TMT): steam and pressure is applied

simultaneously for wool setting.

Folding
29

Grey sample making: for future use.

Sample matching: with standard fabric sample.

Inspection & perching: defects are checked for manually.

Flagging: Flags are put according to faults.

Double fold/Rolling/Lapping: on grey board or paper

tube the fabric is folded.

30

Supply Chain Management

SCM
31

SCM is all about effective integration of right product, at

right place, at right quantity at the right time and at the
right value.

SCM is the management of network of interconnected

businesses involved in the ultimate provision of goods and
services required by the end customer .

It spans all movement and storage of raw materials, work-inprogress inventory and finished goods from point of origin to
point of consumption.

Organizational Chart of SCM Department

Works Director

Manager SCM
HOD

Manager SCM

Assistant
Manager(2)

Executive(4)

32

Officers(2)

Responsibilities
33

Checking for the programs in SAP and Vector System/Mail for

the programs

To ensure timely delivery of the fabric to the warehouse

Preparedness Meeting

Buffer Meeting

Overall Responsibility of Yarn Room & SCM

WIP and Inventory Control

NPD Activity

34

WIP/Inventory Control

Export Market Follow up and reporting

To look after the activity of furnishing, yarn order and follow up

Yarn Room of Furnishing

CD Yarn planning and follow up

Warping Order Issue and follow-up with weaving as per VDD

and color priority.

Check for the lead time and spread time

PW Route plans follow up

35

Outside Yarn Follow up

To look after Polyester Viscose Route Plans

Monthly reports preparation

Preparedness activity of plans and follow up

Raw Material PSF/VSF Order Placement and follow up

All Daily and Fortnightly report Preparation

Keeping account of Grey Fabric Receipts

Distribution of necessary documents to the concerned

Process Flow of SCM

Department
36

Check RMG stock and inform to Central

SCM and commercial. Based on preparedness
for plan created in SAP

Check for CCR load

Order Receipt in Vector Flow

Keeping necessary follow-up with concerned

departments in flow meeting/ Jalgaon /
Outside to ensure timely delivery(OTIF)

Lead Period for Each

Department
37

Department

Lead Time-days

Dyeing

5-6

Recombing

1-6

Worsted Spinning

12-14

P/V Spinning

14-16

Weaving

7-10

Mending

2(If no major faults)

Finishing

5-6

Folding

1-2

Types of Markets
38

Civil

Export

Exotic

RAL(Raymond Apparel Limited)

Exclusive

Institutional

Stock Lot

RMG

Theory of Constraints
39

Definition of Theory of Constraints in one

single word is focus.

Focus on things which are supposed to be

done.

Pre-TOC Way of Working:

40

Focus more on Production & Efficiency targets & less on flow of

material.

Picking by choice by Production Departments.

Higher Manufacturing Lead Time (80-90 days) leading to lost sales &
customer dissatisfaction whereas touch time is very less.

While some orders get late, some get completed much ahead of their
required date.

High Inventory across production departments leading to tied capital.

Focusing Steps of TOC

41

Step 1:

IDENTIFY the system constraint (the Weakest

link)

Step2:

system

Step3:

Decide how to EXPLOIT(and not waste) the

Constraint
SUBORDINATE everything to the above

decision.

Step4:

Elevate the Constraint.

Step5:

If the constraint was removed in previous steps,

GO

BACK to Step 1.

Drum-Buffer-Rope:
42

It increases the flow of materials through the shop floor by

bringing the production lead time to be as close to the touch
time as possible.

DBR envisages to achieve this by:

Restricting the release of material to shop floor . This reduces the

inventory

Reduction in inventory leads to lower queue time which reduces

production lead times.

43

Drum:
Its the list of customer orders. All the resources should
be managed so that the customer order can be fulfilled
on time in full.

Buffer :
In order to protect the operation against damages
created by Murphy the constraints must have the right
work available even if upstream resource run into
unexpected problem.

Rope:
Tying the rope is the act of chocking the release of
material in accordance with the drum and the buffer.

Planned load system:

44

Plans are released based on the output of CCR (Capacity

Constraint Resource). In the case of Raymonds, it is the

output of Spinning.

Based on the output the plans are released in the vector flow.

Expected Benefits:

Prevents unnecessary Workflow in the system

Planning based on shop floor reality

CCR should deliver orders in the middle of Yellow.

Window

of

protective

capacity

post

CCR

expediting/recovering delays as and when required.

should

help

in

TOC-NPD
45

Steps involved in the Theory of Constraint for New Product

Development.

Impact of Bad multi tasking

WIP rules are set for design team

Controlled release of new work

New role of master scheduler

Design team has been soft dedicated for APC and Collection

Daily flow meeting process started

Managing inventory through TOC way of stock replenishment

TOC-MTA
46

MTA is a concept which orders daily and replenishes

frequently. It reduces inventory and increases sale of
new developed qualities in addition to regular qualities
.It retains brand value and there is less or no chance of
stock out situation.

Advantages of MTA
47

Raymond will hold inventory as per the norm at its plants

warehouse for the selected SKU. The basic formula to

determine inventory levels are:

Maximum consumption within the replenishment time factored by

unreliability of resupply.

Replenish only what is sold

Order daily, replenish frequently

Rate of consumption over time will be constantly monitored to adjust

the buffer of safety inventory

Buffer Management
48

The buffer is divided into three equal zones of 15 days

each.

Black Color: 1st Priority

Red Color: 2nd Priority

Yellow Color: 3rd Priority

Green Color: 4th Priority.

Plush Weaving
49

Plush is a special type of fabric weaving by which we

can produce piled fabric.
Raymond ltd. produces warp piled fabric.

The main purpose :to produce furnishing fabric for

automobile industries as well as for interior decoration.

Sub departments:
Weaving
Finishing

50

Designing studio creates and selects the designs for

furnishing fabrics.

In flat furnishing 100 % polyester is used while in

aviation, viscose blends are used.

In auto furnishing, OEM is used fabric, foam and

screen.

Yarn suppliers :Grasim, RSM( Rajasthan Spinning

Mill),PSM, Ventura

New Developments
51

The Summer of Wool collection by Raymond is a first

of its kind, unique collection designed especially for

Indian summers that offers a smart made comfortable

range of fabrics, which includes 100% pure Merino Wool
as well as innovative blends of Merino Wool with natural

fibers like cotton and Linen amongst others.

52

Kapok by Raymond is a unique fusion of superior fibre ,

technology and expertise in innovation with excellent design
and colors that make it a world class product. It uses Kapokthe lightest cellulosic natural fiber in the world that is six times
lighter than cotton, which has an inherent property of thermo
regulation.

Royal Magic from Raymond is another world class

innovation having three distinct features namely stretch,

moisture management and UV Protection in a single product.
It is observed that generally the product lose one of these

Yarn Room
53

Two yarn rooms

Old Double Yarn Room(for PV blend yarn )

New Double Yarn Room(for PW blend yarns)

Yarns are given entry in the yarn room according to the

correct shade number, lot number etc. They are weighed and
its particulars are entered into the computer with specified

quantity.

Regular yarns are put in the trolley the remaining ones are

Precautions
54

Correct shade of yarn should be issued to the warping

as well as weaving dept.

Along with the shade the twist of the yarn should be

checked

Checking of stains, oil marks, shade variation,

contaminants etc. with the help of UV rays.

55

Problems in Various
Departments

Yarn Room
56

Storage time of yarn increases due to non delivery of

one or more yarn components required in the respective
orders.

Generation of RT (Returned) Yarn.

Low consumption of Lycra Yarns against Minimum order

quantity:

Solutions
57

Spinning department should take care to manufacture all the

components required for a particular order in one go. This will

reduce the waiting time for yarn components delivered to
yarn room which will ultimately reduce the time span for

storage of yarn and will help in reducing the inventory in the

yarn room.

Yarn room personals should take care to collect all

components for a particular order and also maintain a track of

the pending components and handover the entire lot as soon
as weaving orders are issued.

58

In cases where RT yarns are lying in the Yarn Room, the

storage time can be reduced by quick coordination with the

designing department, wherein seeing the blend and the
count of the yarns, they develop new designs.

It can be quickly intimidated to the Warping department

whereby if there is any such shade requirement, it can be
quickly supplied and thus reducing the storage days in the

Yarn Room.

Further such RT yarns can be sold in the market when they

have no usage in the design and warping departments.

Raw Material Godown

59

After

much

surveillance

we

felt

that

the

housekeeping of raw material godown was not

satisfactory.

Waste material was not conglomerated properly

and were seen lying randomly.

Raw material being one of the less tedious and

less effort involving department was neglected in
many regards.

Suggested Solutions
60

Housekeeping department visits should be conducted

periodically to check the hygiene and working conditions of
raw material department. Compressed bales should be kept
at a particular fixed place which would avoid any confusion or
ineffective time.

The quality of lycra and other higher value blends can

deteriorate over a period of time. Its tensile strength and
fineness can get affected, if its not being utilized in due
course of time. So, these Lycra yarns need to be utilized

within a quick period of time.

61

Primarily, plant can coordinate with the central

SCM and the marketing department to see if there
are any Lycra blend orders so that the remaining

yarns get utilized as soon as possible and theres

no wastage.

Otherwise, Raymond can sell it to outside local

parties.

Key Findings
62

The Probable reasons identified:

Lack of Efficiency of the Marketing and Sales Department

Availability of substitutes at lower prices

Easier availability of plush to the distant buyers in their nearby

areas

Lack of Proper advertising

Suggested solutions for the problem:

Proper advertising should be done

Procurement of raw materials at cheaper prices

Conclusion
63

Raymond Ltd, Chhindwara has well trained and qualified human

resource.

With the introduction of Theory of constraint(TOC) in 2010 the flow of

work in the departments have been stream lined and the buffer days

have been shortened with the use of color coding during its stages in
production.

This has resulted in optimum utilization of the available resources

and has led to maximum production. It also has helped in identifying

the weakest link i.e spinning and accordingly the other departments
have to be synchronised.

64

Supply chain management department plays a pivotal

role in implementing the TOC and in facilitating the work
flow of various departments. In the buffer meeting the
flaws in the production and the deviation of any
department from their schedule buffer days are

questioned and reasons are noted down which helps in

proper movement of goods from the raw material godown
to the warehouse.

Learning
65

Interdependence between the various

departments and their coordinated efforts in
meeting the expected buffer period.
SCM department playing a pivotal role in
meeting customer deadlines.
Cash Flow increases with the quick increase in
product delivery by quick profit earning by an
efficient operation of SCM.

References
66

Fiber to - fabric. Bernard P Cobman

Raymondindia.com

Goldratt,Eliyahu M.- Theory of constraint(The Goal)

Financialexpress.com

Indiaprwire.com

SCM Department manual(As per ISO 9001:2008)

67

Thank You