new product development using knitting fabric wastage (2)
TRANSCRIPT
Chapter 1Company profile
PREPARED BY SAMUEL G/HERID NO 0502283
Internship report Oct. 2016
BACK GROUND OF ALMEDA TEXTILS PLC.
Is a private company established with a share capital of 180,000,000 Birr in1989.
The factory is located 7 km from the centre of Adwa town on the main road to Axum.
The town of Adwa is located at a distance of 1006kms and 233kms from Addis Ababa and
Mekelle
The factory is directly linked to the main port of Djibouti for Import /Export incident
OBJECTIVE
To produce threads yarns and cloths from various fibers
To produce clothing materials for personnel and house hold uses.
To engage in any other trade necessary to the achievement of its
business.
To engage in agricultural activities where becomes necessary for its
Business.
MISSION To make profit by competing in the global market. To generate foreign exchange by increasing export. To create employment opportunities to the community. To have sustainable production capacity
VISSION
Develop Almeda as a reference for Ethiopian Textile and Garmenting
industry
Create the conditioned that ALTEX can become leader in the
Ethiopian market in terms of export and local market sale
Garment manufacturing process
COMPANYS MAIN CUSTOMER
Local customer Foreign customer
Brand Location Brand Location
Defence of
ministry
Ethiopia Condor ITALY
Regional police “ Bem apparel USA
Federal police “ Edwards USA
Royal foam “ Tsi USA
Guna plc. “ Kopperman GERMANY
Adama garment “ Vitcon plc SUDAN
Victon “ champro USA
COMPANY MAIN PRODUCTE
NEW PRODUCT DEVELOPMENT USING KNITTING FABRIC WASTAGE
BACK GROUD
As fabric cost comprises to 70% of the final production cost, the consumption of fabric is
critical to profitability.
The major are where wastes are highly observed or created is in cutting department those are
Marker loss and
Spreading losses
For better costing of garment, and cost reduction, it is necessary to have understanding of
Fabric utilization and,
various fabric losses that occur during garment production.
PROBLEM STATEMENT
As the apparel production profitability depend on the fabric consumption its fabric
utilization should be critical.
ALTEX as any other company its knitted efficiency is 75% - 85%
o company has 15% - 25% waste fabric.
company profit is much depend on the fabric utilization Wastes are Cause a problem on
profit.
So, we can use those wastes to develop a pcs of garment as contrast and full garment.
OBJECTIVE
General objective
Producing new products from waste knit fabric.
Specific objective
Decreasing fabric wastage by using the waste as value add and for
contrast
Create better product and acquire recognition.
To maximize the fabric utilization and reduce fabric waste
Increasing product and profitability.
Tools and techniques
o Wight measure in M
o Tape measure in Kg
o Fabric
o Table and
o Pai-chart
METHODOLOGY
M• Observe the cutting department
E• Finding the problem
T• Identify the scope of improvement in cutting room
M • Data collection
O • Analysis the data
D • Result and conclusion
Data collection system
Is collected through direct observation and asking questions
is in the form of
Total received fabric in Kg
Remnant, width and marker and other loss are in Meter
As ALTEX gave a grade to the discarded fabric I also set a grade based on the usability and length of the
fabric.
o Remnant loss A Grade
o Width loss B Grade, and
o Marker loss and other losses C Grade
As it varies batch to batch I collect 9 batch's with different colours and styles.
Here is average waste fabric in Kg that we can get from the data collected
B# No Used Kg Remnant Width Marker & other loss
33 389.1 2 25 65
25 397 3 25 62
35 407 3 29 68
36 396.1 3 25 60
27 430 3 27 65
28 407.7 3 22 64
29 408 2 27 51
26 415.7 2 29 50
30 301.3 3 23 47
Total 3551.9 24 232 532
So the average of the waste fabric from the collected data will be
o Received fabric in Kg is = 3551.9/9 394.65Kg
o Remnant fabric in kg is = 24/9 2.7Kg
o Width fabric in Kg is = 232/9 25.8Kg
o Marker & other loss in Kg is = 532/9 59.1
Remnant loss0.68%
Width loss6.54%
Marker loss & other loss
14.98%
utilized fabric77.8%
percent of wasted and utilized fabric
Remnant lossWidth lossMarker loss & other lossutilized fabric
The total Kg is 87.6 Kg per a batch
Data analysis
To determine how much fabric is being wasted in a batch, shift, …….. And year will be
In ALTEX 1 shift work minimum 3batch and 6 batch of knitting fabric per a day to know the wastage per shift
Solution 1 batch = 87.6Kg Z = 3 batch*87.6Kg
3 batch = Z 1 batch
262.8Kg fabric will be wasted per shift
One day has two working shift
Solution 1 day = 2* one shift 525.6Kg fabric will waste per day
. . .
….Cont.
o One year has 295 working days
Solution 1 day = 525.6Kg F =295 days*525.6Kg
295 days = F 1 day
155,052Kg fabric will be wasted per year
o Based on their GSM and other process ALTEX sold their product 45-40 birr per t-shit and
for contrasted t-shirt maximum 50 birr per t-shirt
Based on the given grade the current wastage per t-shirt and per cost is
Given
Remnant loss in t-shirt = 10 t-shirt
Cost of t-shirt = 35birr per t-shirt
Solution 1 t-shirt = 35birr R = 10 t-shirt*45birr
10 t-shirts = R 1 t-shirt
350birr/t-shirt
….Cont.
Parameter
KG
Percent %
Wastage per t-
shirt
Cost incurred Birr per
t-shirt
Remnant loss 2.43 0.68 10 350
Width loss 12.9 6.54 53 1855
Total loss 15.33 7.22 63 2205
ALTEX sold the discarded fabric
For grade B sold by 8.4 birr per Kg and
Remnant loss
Width loss Marker & Other loss
For grade c sold by 2.03 birr per Kg,
To know the amount of money ALTEX found from the current waste
Solution: for grade B in a batch
1Kg = 8.4 birr S = 8.4 birr*87.6Kg
87.6Kg = S 1Kg
87.6 Kg per batch
current waste cost per batch, day,……year will be
….Cont.Parameter Kg Percent % In cost (birr)
REMNANT LOSS
8.1/shift 0.68 68.04
16.2/day 0.68 136.08
97.2/week 0.68 816.48
421.2/month 0.68 3538.08
4779/year 0.68 40143.6
WIDTH LOSS 77.4/shift 6.54 650.16
154.8/day 6.54 1300.32
928.8/week 6.54 7801.92
4024.8/month 6.54 33808.32
45666/year 6.54 383594.4
MARKER AND
OTHER LOSS
177.3/shift 14.98 1489.32
354.6/day 14.98 2978.64
2127.6/week 14.98 17871.84
9219.6/month 14.98 77444.64
14607/year 14.98 878698.8
TOTAL 1302436.8/year
current waste cost per batch, day,……year will be .
NEW PRODUCT DEVELOPMENT
New Product
Cut and sew discarded fabric
Discarded fabric
Is a process of bringing new product to a market.
Is a critical cornerstone of the firm’s success.
……Cont.
PROCESS STRUCTURE
Every new product will pass through a series of stages
How can we develop the new product ?
Waste fabric 1 Analysis 2 Ideation 3 screening 4 design objective
……Cont.
Analysis: The idea is to generate a basis for the ideation work to follow.
Ideation: the aim is to come up with previously unknown ways of using it.
Screening: This phase is for deciding which to discard and which to keep.
Photo of the product sample
AFTER NEW PRODUCT APPLIED
It doesn’t mean that all the wastes are to be used
90 % of 2.7 Kg Remnant loss, it becomes 2.43 Kg per batch
50 % of 25.8 Kg of Width loss it becomes 12.9 Kg per batch
To know the amount of money ALTEX will gate after using the wastes for product will be
Solution: 0.245 Kg = 1 t-shirt W = 29.55 Kg*1 t-shirt 7.29 Kg = W 0.2468Kg
30 t-shirt
After new product applied per cost……cont.
Parameter Kg Percent (%) In t-shirt In cost (birr)
REMNANT LOSS
7.29/SHIFT 0.68 30 1050
14.58/Day 0.68 60 2100
87.48/Week 0.68 357 12495
379.08/Month 0.68 1719 60165
4301.1/Year 0.68 17556 614460
WIDTH LOSS 38.7/shift 6.54 157 5495
77.4/day 6.54 314 10990
464.4/week 6.54 1882 65870
2012.4/month 6.54 8153 33035
22833/year 6.54 92516 3238060
TOTAL 19142.55/year 77562 t-shirt/year 3852520birr/year
Result
S/N Key performance
point (KPIS)
Before
(birr per year)
After
(birr per year)
Improvement
Rate (%)
1 Cost 1,302,436.8 3,624,593.2 64%
Key performance point
(KPIS)
Before
(pcs per year)
After
(pcs per year)
Improvement
rate (%)
2 Production 236,000 313,562 24.7%
Conclusion
In order to remain competitive on market a company should gate profit from its product.
As we can see in the data collected
The current cost ALTEX found from discarded fabric is 1,302,436.8 birr/year
And the cost after new product applied is 3,624,593.2 birr/year
So, ALMEDA must be implement new product using the discarded knitting fabric.
RECOMMENDATION
The management may give to employees aware ness about the discarded fabric
The operators should cut discarded fabric considering that they are usable
fashion group should be created
Employee shouldn't use discarded fabric for their personal use
Optimally use the available resources.
THANK YOU