SAMSONITE

About Samsonite Started in 1910 by Jesse Shwayder

Founded in Denver (USA) - Plants : Belgium, Hungary, India (Nashik)

Etymology : Biblical character Samson, renowned for his strength.

Listed on Honk Kong Stock Exchange

Vision “ To become one of the world’s most highly regarded premium

lifestyle travel brand”

Product Portfolio

BACKGROUND OF NASHIK PLANT

Construction completed in 1996Production – March 1997Plant area – 18 acresTotal staff – 500 employees40% hard luggage manufactured in Nashik plantPower consumption – 4 lakh units per monthRaw material – 300 to 400 tonnes per monthStock hypothecated to SBI,HSBC,HDFC and Indus

Ind Bank

Raw materialThere are primarily three raw materials used for making

the hard Luggage :

1. Polycarbonate(PC) : A thermoplastic polymer, which are easy to mould and can be thermoformed. It is transparent in nature and can undergo deformations without cracking or breaking.

Contd.. 2. Polypropylene (PP): It is thermoplastic, generally

used for packing. It is rugged in nature and resistant to most chemical solvents, bases and acids. It is recyclable in nature.

3. Acrylonitrile butadiene styrene (ABS) : It is one of the most commonly used thermoplastic. It is light weight and has ability to be injection moulded.

Contd..

In terms of strength

Polycarbonate > ABS > Polypropylene

In terms of cost

Polycarbonate > Polypropylene > ABS

Manufacturing processes1.Extrusion: The plastic granules are given shape in an Extruder in which a plastic material is melted and formed in to a continuous profile.The molten material is passed through barrel screw and rollers to give it a desired profile.

2. Vacuum Forming: Vacuum forming is whereby a sheet of plastic is heated to a forming temperature, stretched onto or into a single-surface mold and held against the mold by applying a vacuum between the mold surface and the sheet.

Manufacturing processes3. Pressure forming:  The technique is accomplished by forcing a hot sheet against a mold by applying a hydraulic pressure of 200 tonnes to the back side of the heated sheet.

4. Plastic Injection Molding:Material for the part is fed into a heated barrel, mixed, and forced into a mold cavity using a screw type plunger where it cools and hardens to the configuration of the cavity.

OPERATIONS

Stores : FIFO, Visual Control, 5 Level storageThe inventory turnover is 12 Most of the suppliers were form Nashik which helped

them to follow JIT approach Inventory :

a. 30 Days: For Imported Raw Material

b. 2 Days: For Local/Domestic Material 4 lines making 125 pieces in 8hoursOne direction single flowLean practices were followed

Assembly Process

Contd…Use of a moving line assembly

After the process at each station the bag would be kept on a belt with rollers & pushed to the next station

Multi-skilling of workers

Quality AssuranceSystematic MeasurementComparison with a standardMonitoring of processesAssociated Feedback“Fit for Purpose”“Right first time”Samsonite follows Random Testing

Quality Assurance Testing Tumble Test:50 Revolutions & obstacles :Tumbling the bag in a

tumbler at 50 cycles in a loaded condition. ( Done at -12 degree C for export to regions with extreme climatic conditions)

Drop test:AT 0.9m: Dropping the bag 18 times on the ground at all

corners and sides at atmospheric temperature from 0.9 m height.

The Handle test:3500 Times : Tested by giving jerks to the handle for

3500 times in a loaded condition.

Quality Assurance Testing THE LOCK TEST

PUSH & RELEASE CYCLES: Locks’ durability is checked by operating the lock for 15000 cycles in one go continuously.

WHEEL TEST 32 KMs - Wheel is been carried for 32 kms in a loaded condition to check the wear and tear for wheels.

THE ZIPPER TEST - 15000 times Force is applied to sliders and zippers to test the strength of zippers and pullers.

Key aspectsIn addition to the routine quality assurance testing

annual testing is done to improve the aesthetics of the model

An ISO 9001:2008 certified company

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