CUTTING ROOM

A STUDY FOR PROBLEM

IDENTIFICATION
AND
SOLUTION

CUTTING ROOM

PROCESS FLOW FOR SOLIDS

CUTTING

PROCESS FLOW FOR YARN DYED

CUTTING

IMPORTANT STEPS & OBSERVATIONS

IN
CUTTING ROOM

FABRIC INSPECTION & AUDIT

DEPARTMENT
Fabric inspection is done for each and every roll from a batch. Inspection is
done for the fabric faults OBSERVATIONS:
and to check the width of each roll of fabric. But it
was observed that every bundle was not being checked for the width.
Mostly due to workers being uneducated about faults many times roll with
faults are passed over to audit department.
Sometimes due to lac of knowledge defected fabric is passed and for the
same reason less defected fabric is bundled under defected category.
No humidity and temperature measuring instruments are available.
GSM of fabric is taken without drying it.
No instruction is given to rolling operator about the dimension of fabric to
be cut for GSM measurement.
GSM of roll is taken from very localized fabric area i.e. from the same part of
roll instead of taking from different areas of roll.

SUGGESTIONS:
oProper lighting should be provided.
oImproper inspection table.
oInsure fault highlighting stickers are properly sticked to the fabric of roll.

.
EACH AND EVERY FABRIC ROLL MUST BE CHECKED
FOR WIDTH AT LEAST TWO TIMES; AT START OF ROLL
AND AT MIDDLE OF IT.

CORRECT INFORMATION REGARDING ROLL MUST BE

FED IN SLIP.

IT MUST BE TRIED TO CHECK THE GSM OF EACH

ROLL OF FABRIC.UNDER STRICT SUPERVISION.

EMPLOYEE EDUCATION IS VERY NECESSARY HERE.

SAMPLES OF DEFECTED FABRICS OR PHOTOGRAPHS

OF THEM SHOULD BE MADE AVAILABLE TO
OPERATOR.

DUE TO EXCESS HUMIDITY AND TEMPERATURE,

THERE IS MORE RELAXATION ALLOWANCES FOR
WORKER WHICH DECREASES OVERALL ON STANDARD
TIME.

DUE TO MOISTURE CONTAMINATION OBSERVED GSM

OF FABRIC MAY VARY FROM ACTUAL ONE.

DUE TO UNSPECIFIED DIMENSION OF CUT PART

WHICH IS UTILIZED FOR GSM MEASUREMENT LEADS
TO FABRIC WASTAGE.

FABRIC AUDIT DEPARTMENT:

OBSERVATIONS:
In fabric audit department 3-4 rolls are checked for width
and gsm of the fabric along with the fabric fault.
Many time GSM of the fabric changes from roll to roll and
also in the same roll.
Same thing happens with the width of the fabric.
But as each bundle is not checked these faults pass
unnoticed to cutting room

SUGGESTION:
Cut part which is choosen for GSM measurement should
be taken from different location of fabric roll and avg of
different measurement should be marked as GSM of
fabric.
Width of the fabric should be taken from different phases
of fabric roll ie 1st check when 15 mts are roll is finish. 2nd
measurement should be taken at middle of rolling process
and third at last.

FABRIC WAREHOUSE
OBSERVATIONS:

Fabric comes to warehouse from audit department

with audit report.
Fabric is stored according to buyers name
There is no check of fabric prior to storage in the
warehouse.
Fabric is not segregated according to width or gsm
of fabric.
Rolls of fabric do not have width and gsm
information on them

RELAXATION
OBSERVATIONS:

No proper relaxation machine.

Machine that is used does not have proper
attachments.
Fabric handle is done manually. This causes fabric
disturbance and relaxed fabric gets ruffled.

No accountability in this department.

No standard way of fabric storage after relaxation
process

SUGGESTIONS:
Spiral rollers should be used instead of plain
rollers.
Tray should be used in which fabric is collected
and loaded to spreading machine along with the
tray,in order to avoid distortion in fabric
structure.
Proper accounting of relaxed rolls should be done.

PROPOSED EASING MACHINE

VIDEO

process video of ideal spreader machine

Oshima
Serkon
F.N

SPREADING SOLIDS (AUTOMATIC)

(OBSERVATIONS)

Used speed of machine is very low in the range of

7m/min; running speed being higher.
Target is not achieved even after excess operators being
implied on spreader.

More than optimum lay length being laid.

Lack of attachments in the spreading machine.

Lack of specific data of rolls leads to off time.

Improper handling of fabric.

On table no 3 lays are aligned from one side of table only
because of its more width

SPREADING YARN DYED

Excessive manpower allocated in this department.

Hand shears is used instead of end cutters leading to
increase of manpower need.
In yarn dyed spread length is generally for a single
piece of shirt leading in the need of excessive
manpower for laying

SHIFTING OF THE LAY TO CUTTING

TABLE:
While shifting of lay from spreading table to the
cutting table air floatation table is not used properly.
On table number 3 plies are aligned from only one
sideby the operator which causes difference in size of
patterns.

Suggestions:

DECREASE RUNNING SPEED OF SPREADER TO AVOID

TURNING OF PLIES UPSIDE DOWN.

KEEP LENGTH OF SPREAD BETWEEN 7-8M. THIS WILL

HELP IN FASTER AND PRECISE LAY.

ONE OPERATOR SHOULD ALWAYS TRAVEL ALONG

WITH THE MACHINE TO FIX ANY BLOCKAGE IN THE
PASSAGE OF LAYING. AT THE BEGINNING ITSELF.

SPIRAL ROLLERS SHOULD BE USED INSTEAD OF

PLANE SURFACE ROLLERS. TO INSURE EVEN LAY

.
TWO DIFFERENT LAYS OF TUBULAR KNITS CAN BE
SPREAD AT A TIME TO UTILIZE MAXIMUM WIDTH
LAYING CAPACITY OF SPREADER

CONTINUES

Spreading operator have no data about width of roll which

causes spreading of rolls with different widths ,this will
createloss of fabric as marker is made according to roll of
minimum width.
Due to this sometimes whole plies related to one role has to
be taken off which decreases efficiency of spreader
Replace hand shears with end cutters. This will decrease
labor requirement from 4 to 2.and will also increase
efficiency of lay.
Instead of laying for single piece one can make a block for
two piece and after laying block can be cut and operated
separately.
Beforeshifting of lay make sure that air flotation is on and
running at highest level. This will decrease tension in lay
due to pulling and also distortion in lay.

CUTTING SOLIDS & YARN DYED

All the previous process have an impact on cutting of the fabric.

Machine stoppage due to lack of feed is high.

Many times change in the width and gsm of the fabric leads to increase in idle
time of auto cutter.

Machine stoppage for maintenance is high and frequent.

Cutting of yarn dyed fabric is done by straight knife & shears

STUDY CONSIDERING
WORKER & OPERATOR

1st/ Improper water supply. ie chilled water is

not available which sometime increases
relaxation allowance and worker rating
decreases so as production.

UNHYGIENIC CONDITION NEAR WAREHOUSE AND

WORKER PLACE OF EATING WHICH INCREASES
ABSENTEEISM % DUE TO FREQUENT DISEASES DUE
TO URINALS IN VICINITY

NO TEMPERATURE AND HUMIDITY MEASURING

INSTRUMENTS IN FABRIC PROCESS DEPARTMENT.

CLASSES SHOULD BE ORGANIZED TO MAKE WORKERS

AND OPERATORS REALIZE THAT STAKE OF THEM AND
COMPANY ISNT DIFFERENT.

MOTIVATIONAL AND RECREATIONAL CAMPS SHOULD

BE ORGANIZED IF FEASIBLE.

CUT PARTS INSPECTION

For checking of prints instead of measuring with

tape we can have pattern of print to insure its
right alignment.

print

panel

pattern