raymond visit report

8/11/2019 Raymond Visit Report

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Introduction

Raymond Ltd:

The Raymond Group was incorporated in 1925 and within a span ofa few years, transformed from being an Indian textile major to aglobal conglomerate.

Today, the Raymond group is vertically and horizontally integratedto provide customers total textile solutions. Few companies globallyhave such a diverse product range of nearly 20,000 varieties of

worsted suiting to cater to customers across age groups, occasionsand styles.

Raymond manufactures for the world the finest fabrics - from woolto wool-blended worsted suiting to specialty ring denims as well ashigh value shirting.

Raymond also have some of the most highly respected fabric andapparel brands in our portfolio: Raymond,Raymond PremiumApparel,Park Avenue,Color Plus,Parx,Makers andNotting Hill

Creating the finest suiting in the world

Over time, Raymond has mastered the craft of producing the finestsuiting in the world using super fine wool (with a fine count from80s to 250s) and blending the same with superfine polyester andother specialty fibers like Cashmere, Angora, Alpaca, Pure Silk,Linen etc.
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They also produce and market plush-velvet furnishing fabric in awide array of designs and colors for Indian and overseas markets.

Textile manufacturing Facility

World-class facilities

Raymond's manufacturing facilities include three world-class fullyintegrated plants in India, deploying state-of-the-art technologymodern quality management systems like ISO 9001 andEnvironment Control Systems (ISO 14001). All our plants are self-sufficient and provide staff welfare measures such as education,housing, recreation and support systems for employee.

Raymond plants are located in India at the following locations:Chhindwara in Central India, Vapi in Gujarat, near Mumbai and

Jalgaon in Maharashtra.

Chhindwara Plant

The Raymond Chhindwara plant, set up in 1991, is a state-of-the-art integrated manufacturing facility located 57 kms away fromNagpur in Central India. Built on 100 acres of land, the plantproduces premium pure wool, wool blended and polyester viscose

suiting.

This plant has achieved a record production capacity of 14.65million meters, giving it the distinction of being the single largestintegrated worsted-suiting unit in the world.


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Vapi Plant

Raymond has increased its worsted suiting capacity by 14 millionmeters, as part of the second developmental phase of the Vapi

plant.

Modeled to meet international standards, the Vapi plant has beenset up on 112 acres of lush green land with Hi-tech machinery suchas warping equipment from Switzerland, weaving machines fromBelgium, finishing machines, automatic drawing-in and othermachines from Italy.

About The Raymond Industry

Business spreading across manufacturing, Sales-Services,Distribution and Logistics

1 Head Office Mumbai

2 Regional Office Thane

3 Manufacturing Unit 3

3 Branch network across India 700

4 Group Revenue for operation in 2013-14 (INR) 4593 Cr

5 Manpower over (on rolls) 7500

6 Distributors spread across India 2200

7 Assets deployed (cranes, fork lifts etc.) 15billion


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Process to convert Wool in to fabric

1 Sheep:

Wool comes from sheep. They grow a wool coat and once a year thiswool coat is sheared off the animal. In Wisconsin, this is frequentlydone in the early spring shortly before they have their lambs. Ashorn ewe will be more likely to stay out of the wind and badweather and protect her newborn lamb if she does not have a thickwool coat on her.

2 Fleeces:

The shorn wool coat is called a fleece. It is also called "grease wool"because of all the oil and lanolin in the wool. This fleece must becleaned before it can be processed into wool yarn. There is muchvegetable matter, manure and natural oil that must be removedSometimes as much as 50% of the weight of the fleece is not wool.


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3. Skirting a fleece:

The wool from the back end of the sheep, their legs and sometimestheir belly is too full of manure to use. These are referred to as"tags" (as in the phrase "tag end"). These are removed first before

washing the fleece; this process is called skirting, as all the edges ofthe wool coat are removed. The fleeces are also sorted into thevarious types: fine from coarse and short from long.

In the Raymond the wool import from the Australia and Africa. Thiswool comes in Vapi plant for making a fabric.

4. Washing the wool:

The grease must then be removed from the wool. This can be done

using soap or detergent and a lot of water or it can be done bysubmerging the wool in an acid bath which dissolves all thevegetable matter as well as the grease (this is called scouring).


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5. Picking:

The washed and dried wool is then "teased" or "picked" which is thebeginning of the process of opening up the locks of wool andturning it into a consistent web. The wool is put through a picker,

which opens the locks and blows the fluffy wool into a room. At thesame time a special spinning oil is added which helps the woolfibers slide against each other but also helps them stick together asa fine web through the processing.

6. Carding:

The wool fibers are then put through a series of combing steps

called carding. This can be done with small hand cards that lookmuch like brushes. It can also be done on a larger scale withmachine driven drums covered with "card cloth" which combs thewool many times by transferring it back and forth from one drum tothe other as it is passed down the series of drums. We have "woolencards which produce a wool web with the fibers coming off inrandom alignment. This is in contrast to "worsted" combing thoselines up all the fibers (as you would see in thread).


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7. Roving

The final step in the carding process divides the web into smallstrips called pencil rovings. These are collected on large spools on

the end of the card. These spools of pencil roving will be placed onthe spinning frame to make yarn. Pencil roving is too delicate to behandled much, so when proccessing fiber for handspinners theroving is taken off the machines earlier and wound into balls


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8. Spinning:

The roving as it comes off the card has no twist. It is held togetherby the oil and natural hooks that exist on the surface of the woolfibers. The spinning frame will put the actual twist on the roving

and turn it into yarn. This is collected on wooden bobbins. Theframe we have is small but it can spin up to 90 threads at onetime. This only spins one ply yarn (single stranded), which is not assturdy as most prefer. In order to make two or more ply yarn thestrands are twisted together on the plyer, from several cones ontofewer spools.

9. Wind and/or skeining:

When the wooden bobbins are full of yarn, they are placed on acone winder and the yarn is transferred to paper cones for use inweaving and knitting machines. It could also be put into skeins ofyarn which are the form that knitters like to use.


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10. Weaving:

The yarn is woven into fabric on looms, computerized machines

that work at high speeds to interlace horizontal and vertical sets of

threads, forming a flat cloth. A set of parallel warp (vertical) threads

are held taut by the loom while weft (horizontal) threads are held in

a shuttle. The loom lifts the warp threads up and down in

sequence, creating a space between them that the shuttle passes

through at high speed; several shuttles can be used

simultaneously. This action weaves the two sets of threads together

at right angles and creates fabric.

Different patterns are created by lifting the warp threads in differentsequences and by using different colored yarns. Types of fabric

made from wool include broadcloth, gabardine, herringbone,

hounds tooth and tweed.

Weaving Machine


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11. Dyeing and finishing:.

Wool can be dyed before carding or after being spun into yarn, or

the finished fabric can be dyed. Fabric is treated with heat,moisture and friction to tighten the weave and shrink the fabric. To

make the fabric fleecy, it is brushed to raise the nap, giving a fluffy

finish. Chemical finishes can be applied to make the fabric

washable by coating it with a resin film.

12. Storage in Warehouse:

Once the fabric is making the material will be stored in companys

warehouse as per location is given by SAP (Raymond Software) And

material should be dispatched as per order comes from sales team.


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Raymond Plant Layout (Vapi Plant):

Spinning Wind and/or skeining

Roving Weaving

Carding/Dyeing Dyeing

Picking Finishing

Scouring Storage in Warehouse

START END

Main Gate (Entry/Exit)


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Production Planning in Vapi plant

gi Different branch

2.

The above fig shows the Production outcome in each process in vapiplant. It shows maximum capacity for weaving process is 10 ton perday but output of the spinning process is 7 ton per day. So it willcreate deficit between this two processes so their will necessary tooutsourced remaining (i.e. 3 ton per day) from different vendor.

After weaving of 10 ton per day dying is being done and it will bepreceded for Finishing. Finishing is done at 20 ton per day and outof which 10 ton is being outsourced.

So our project is to analysis Lead-time between order given to thedifferent vendor and time required to complete this order to vendor.

There are approximately 50 registered vendors to manufacture Yarnfor Raymond. We analyzed the data of last 6 months, suggestedthem which vendor is more suitable for which material, In which

Quarter which material come late from vendor, determine relationbetween Quantity of material is to ordered and lead time.

Wool

scoring 14

ton/day

Polyester

converter

-7

Dyeing

process-14

ton/day

Recombing

process 14

ton/day

Spinnin

g Yarn 7

ton/day

Different

branch/vendor

Weaving

10

ton/day

Remaining 3

outsourcedfrom different

Vendor

Finished

Fabric

20

Remaining

10

outsourced

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