MBA661 - POMS

POMS PROJECT REPORT

Layout Study at Zorba International
SUBMITTED ON 4/29/2012

Chetan Kusram (11125015) Nitin Bharadwaj (11125036) Sagar Agarwal (11125047) Sanjeet Kumar (11125051) Samreen Jamal (11125049) Taruna Birthalia (11125062) Vijayta Fulzele (11125064)

Contents
Executive Summary ................................................................................................................................ 2 Products: ............................................................................................................................................. 3 Dog Products ................................................................................................................................... 3 Cat Products .................................................................................................................................... 3 Problem Statement .................................................................................................................................. 4 Objective ................................................................................................................................................. 4 Physical Plant Layout .............................................................................................................................. 4 Factors affecting plant layout ............................................................................................................... 5 TYPES OF PLANT LAYOUT ............................................................................................................ 5 Product oriented plant layout ........................................................................................................... 5 Process oriented plant layout (Functional Layout) ............................................................................ 6 Cellular layout ................................................................................................................................. 6 Existing Layout ....................................................................................................................................... 7 Precedence Diagram Collars and Belts .............................................................................................. 7 Individual process time .................................................................................................................... 7 Precedence Diagram Whip Process ................................................................................................... 8 Individual Process Time................................................................................................................... 9 Current Layout Design ........................................................................................................................ 9 Processes: ........................................................................................................................................ 9 Assembly Line Diagram .................................................................................................................... 11 Improved Layout ............................................................................................................................... 13 Assembly Line Diagram in New Layout ............................................................................................ 14 Changes In New Layout: ................................................................................................................... 14 Individual Process Time................................................................................................................. 15 Apparel Precedence Diagram ............................................................................................................. 16 Individual Processes ...................................................................................................................... 16 Layout at New Plot ................................................................................................................................ 17 Process layout for Apparels ............................................................................................................... 17 Left side working hall .................................................................................................................... 17 Process layout for Collars, Belts and Whips ....................................................................................... 18 Right side working hall .................................................................................................................. 18 .............................................................................................................................................................. 18 Expected Result ..................................................................................................................................... 19

Executive Summary
Zorba international was started in 2000 with an aim to create a highly focused company dedicated to Leather dog Collars. Gupta family owns all the activities of Zorba with their wild passion for dogs. Dogs became the integral part of their family. Zorba in their four floor first unit at Krishnapuram, Kanpur manufacture Leather dog accessories which is one of the focused companies for dogs. Zorba sources best leather skins from different parts of India on a contract tanning and developing basis thus matching the standards. Zorba gets all ornaments from the Mumbai a fashion capital of India from our friend who is in women jewellery business since ages. Zorba develops all hardware in making a collar at their one of metal crafting unit managed by our relative who is highly specialized in the metal segment.

Figure 1

Figure 2

Comfort is liberation each and every product in Zorba is focused towards comfort which gives birth to a newdesign. Zorba has 50 to 60 people who are devoted craftsmen and women involved in their traditional art since years. Subhash gupta and Sudhir gupta being an animal graduate involved 24x7 answering all the inquiries regarding manufacturing, Custom designing, pricing and timely shipping, Sanjay gupta having a technical background is highly focused on Quality control of each and every product which is shipped to our customer friends all over the world.

Products:
Dog Products

Figure 3: Lamb Leather Collar,

Figure 4: Matching Dog Leash,

Cat Products

Figure 4: Crystal Collars

Figure 5: Leash

Figure 6: Harness

Problem Statement
Studying the current process and suggesting improvements to make it more organized and effective. They are also establishing one more plant for similar products, so by studying process from here making a process effective layout for the upcoming plant.

Objective
The objectives of this project were as follows:

To study and analyse the manufacturing process of collars, belts, whips, etc. To suggest improvements in the current process To suggest a new layout for the Zorbas new plant

Physical Plant Layout

Plant layout planning includes decisions regarding the physical allocation of the economic activity centers in a facility. A facility layout is an arrangement of everything needed for production of goods or delivery of services. An economic activity center is any entity occupying space.

The objective of plant layout planning is a more effective work flow at the facility, allowing workers and equipment being more productive. To make a decision about layout planning, 4 different questions must have an answer: 1. Which centers do we have to consider? 2. How much space and capacity is required for each center? If there is not enough space, productivity may be reduced. Too much space is expensive and may also reduce productivity. 3. How must the space be configured at each center? Space quantity, shape and the elements of the work center are related to each other. 4. Where should each center be located at within the facility? The allocation of the different centers may affect productivity.

Factors affecting plant layout

Materials

The layout of the productive equipment will depend on the characteristics of the product to be managed at the facility, as well as the different parts and materials to work on.
Labor

Labor has to be organized in the production .

Material Handling

Material handling does not add value to the product; its just waste.
The building

If it has been already selected, its characteristics will be a constraint at the moment of designing the layout, which is different if the building has to be built.
Future changes

One of the main objectives of plant layout is flexibility. Its important to forecast the future changes to avoid having an inefficient plant layout in a short term.

TYPES OF PLANT LAYOUT

The production process normally determines the type of plant layout to be applied to the facility:
Product oriented plant layout

Machinery and Materials are placed following the product path. This type of plant layout is useful when the production process is organized in a continuous or repetitive way.

Advantages:

Reduced material handling activities. Work In Process almost eliminated. Minimum manufacturing time. Tasks simplification.

Disadvantages:

No flexibility in the production process. Low flexibility in the manufacturing times. High capital investment. Monotonous work

Process oriented plant layout (Functional Layout)

This type of plant layout is useful when the production process is organized in batches. Personnel and equipment to perform the same function are allocated in the same area.
Cellular layout

Work cells: Group of equipment and workers that perform a sequence of operations over multiple units of an item or family of items. Looks for the advantages of product and process layouts: Product oriented layout: Efficiency Process oriented layout: Flexibility

Existing Layout
Precedence Diagram Collars and Belts
Leather Cutting - A Applying Adhesive - B Folding - C Roughing surface - D

Edge Shaping H

Tape Sticking G

Bead Attachment - F

Punching - E

White Tape Sticking - I

Backside Leather - J

collar stitching- K

buckle attachment - L

packaging - o

Final finishing N

hole punching -M

Individual process time A 1.5 + 1 = 2.5 min B 0.5 min C - 1.2 min D 1+1 = 2 min E 1+1.5 = 2.5 min F 1 min G 0.5 min H 1.8 min I 0.5 min J 0.8 min K 1+1.5 = 2.5min L 1+3 = 4min M 1 min N 1min o- 1.5+1.5 = 3 min

Figure 7: Precedence Diagram Collars and Belts

Precedence Diagram Whip Process

Store

Figure 8: Precedence Diagram Whips

Basement First Floor Basement Stick Rolling - C

Jhallar Cutting - A

Stick Rolling B Hand Sewing - D

Knotting - E

Packaging - F

Finished Goods Inventory

Individual Process Time A 1.5 + 1 = 2.5 min B 6 min C - 6 min D 5 min E 10 min F 1.5 min + 1.5 min = 3 min

Current Layout Design

Terrace

Collars D

2nd Floor

A, B, C E, F, G, H, I, J L, M, N

Apparel and Accessories

1st Floor

K
Ground Floor

Figure 9: Current Layout Design

Processes:

A: Leather Cutting: Here the skin or the leather is cut in order to start the process of collar manufacture. This is done on 2nd floor. The time taken for this process is 1.5+1 i.e. 2.5 minutes. The extra one minute is taken to compensate for the time lost in taking the leather ( i.e. the skin used) to the second floor.

B: Adhesive Applying: Here adhesive is applied to the cut leather from process A in order to fold it and give it the desired shape. Time taken for this process is 0.5 minutes. 9

C: Folding: Here the leather is folded and shaped into a collar. Time taken for this process is 1.2 minutes.

D: Roughing surface: Here the surface of leather is roughened using a machine so that it might not create further problems while sticking. Time taken for this process is 1+1 i.e. 2 minutes. The extra time is added because this process is being done on the terrace.

E: Punching: This is the stage where the collar is punched in order to attach beads and other such decorative items to it (done by hand). Time taken for this process is 1+1.5 i.e. 2.5 minutes. Extra time is added to account for the time taken to bring it back to the previous floor.

F: Bead Attachment: In this process, beads are attached to the collar by hand. Time taken for this process is 1 minute.

G: Tape sticking: To support the beads and the collar, tape is stuck to the collar. Time taken for this process is 0.5 minutes.

H: Edge Shaping: The edges of the collar are given a proper shape by scaling. Time taken for this process is 1.5 minutes.

I: Thick Tape Sticking: A thick tape is stuck to the collar at this stage in order to provide it stiffness and avoid damage to the stitching done later on. Time taken for this process 0.5 minutes

J: Backside leather sticking: Sticking leather to the backside of the collar. At this stage adhesive is applied to the backside of the leather and then a second piece of leather is stuck in order to provide it more strength. Time taken for this process is 0.8 minutes.

K: Collar stitching: This is the process in which the stuck leather at the back of the collar is stitched to provide it even more strength (by hand). Time taken for this process is 1+1.5 i.e.2.5 minutes. Extra time is taken into consideration as this process is done on the ground floor

L: In this process, buckle is stitched to the collar by hand. Time taken for this process is 1+3 i.e. 4 minutes.This process is done again on the 2nd floor, hence time is added.

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M: Holes are punched to the collar using a pattern. Time taken for this process is 1 minute.

N: Final Finishing: In this process, final touch is given by removing the threads and Time taken for this process is 1 minute.

O: Packaging: this is the final process where the final sorting of collar and the packaging is done in order to send the product for final shipping. Time taken for this process is 1.5+1.5 minutes. This process is done in the basement.

Assembly Line Diagram

A,B,C4.2 min

D2min

E,F 3.5 min

G,H,I,J 3.6min

K2.5min

L,M,N6min

O-3 min

Figure 10: Assembly Line Diagram

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Total flow time = 4.2 + 2 + 3.5 + 3.6 + 2.5 + 6 + 3 = 24.8 min Estimated cycle time = No. Of working hours * 60 / Total production per day of collars Here we have No. Of working hours = 8 hrs. ( as approximated by zorba) Total production per day of collars = 100 So, Estimated cycle time = 8*60/ 100 = 4.8 min Now, Efficiency of the current layout = Total flow time / No. Of workstations * estimated cycle time = 24.8/(8*4.8) = 64.6 %

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Improved Layout

Terrace

Apparels and Accessories

2nd Floor

1st Floor

collars A, B,C, D E, F, G, H, I,J

Collars & Whips, Office K Ground Floor L, M, N

Basement

Inventory & Invoicing O

Figure 11: Improved Layout

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Assembly Line Diagram in New Layout

A, B, C, D- 4.7 min

E, F, G, H, I, J4.8 min

K- 3.5 min

L, M, N- 4 min

O3 min

Figure 12: Assembly Line Diagram in New Layout

Changes In New Layout:

We have moved apparel section from Ist floor to 2nd floor to keep it separate since it is not related to collar making process. We have moved process D i.e. Rouging process from terrace to 1 st floor to reduce the time in shifting unfinished goods to and fro from 2nd floor to terrace. We have moved collar making process (A, B, C and E, F, G, H, I,J) altogether to 1 st floor to reduce the timing of moving inventory from basement to 2nd floor. Processes L, M,N are moved from 2 nd floor to ground floor and this will make the space of keeping Rough surface making machine which is shifted from terrace to 1st floor. And utilizing the free space available in ground floor where just whip making process is going on. There are no change in packaging and inventory keeping since it is little a private materials of Zorba which they want to keep it secured. 14

Individual Process Time This individual process time excludes the time it takes for a part to move between floors. A 1+1= 2 min B- 0.5 min C- 1.2 min D- 1min E- 1 min F- 1 min G- 0.5 min H- 1 min I 0.5 min J- 0.8 min K- 0.5 +3 = 3.5 min L 2 min M 1 min N 1 min O- 1+1.5 =2 min

Total flow time = 4.7 + 4.8 + 3.5 + 4 + 3 = 20 min

Estimated cycle time = No. Of working hours * 60 / Total production per day of collars

Here we have No. Of working hours = 8 hrs. (as approximated by Zorba) Total production per day of collars = 100 So, Estimated cycle time = 8*60/ 100 = 4.8 min Now, Efficiency of the new layout = Total flow time / No. Of workstations * estimated cycle time = 20/(5*4.8) = 83.33 %

Hence, new layout has more efficiency as compared to current layout.

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Apparel Precedence Diagram

Cutting

Stitching

Finishing

Figure 13: Apparel Precedence Diagram

The entire apparel stitching process is performed on the first floor right from cutting of cloth uptil final packaging. This floor also houses some of the various accessories that Zorba International provides. Few examples are dog shoes, raincoats, jackets, ties, bathrobes, towels , etc.

Individual Processes 1) Cutting In this process the cloth for apparel is cut into a proper shape using a pattern with accurate dimensions. This process is done by hand using scissors. This process takes around 10 min 2) Stitching The stitching process comes next. Here the entire cloth piece which was previously cut is stitched into nice apparel for pets. This is done on electric sewing machines. Time taken for this process is around 20 minutes. 16

3) Finishing The final finishing of the apparel involves removal of threads, stitching the Zorba tags and packing it .This process takes around 5 minutes.

Layout at New Plot

As seen in the new plot layout in picture we put all apparel section on left side working hall while all belts, collars and whips making section on right side working hall. In picture below we show the magnified look at left side working.

Process layout for Apparels

Left side working hall 27 Feets

Stitching

Finishing Cutting 74 Feets

Inventory Entry

Finished Goods Inventory

Figure 14: Process layout for Apparels

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Process layout for Collars, Belts and Whips

Right side working hall

37 Feets

Inventory

Finished Good Inventory

27 Feets A O 7 Feet

B
C

37 Feets

M D L E F G H Entry I K J

5 Feet

18 Figure 15: Process layout for Collars, Belts and Whips

Expected Result
With above suggestion to the current process it is expected that the process transfer time and cost will reduce and overall efficiency of the system will increase. With the suggested new layout optimized process flow can be achieved at minimum changes to the current process flow.

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