Production function is basically concerned with the production/manufacturing of goods and services for the satisfaction of wants of consumers. Production involves movement of information, instructions and materials from one position to the next one in a logical order.
The circulatory flow of materials, information’s and instructions in the production process is called the “PRODUCTION CYCLE”. The production cycle starts and ends with the customer. Production is always as per the needs, requirements and expectations of customers. Companies conduct marketing research activities and find out the product, which consumers need. Thereafter, the market demand is estimated through sales forecasting. Production planning is necessary and useful for the conduct of production activity in an order manner. The whole production activity moves continuously till the production activity is completed. Here, one production cycle comes to an end.
The goods produced are marketed thereafter. In due course of time, once again the same exercise is repeated. The new production cycle starts with the study of consumer expectations, possible demand and so on. This suggest/justifies the statement that production cycle starts and ends with the customer. The sales department studies the reactions of consumers to the products available in the market and the extent to which the consumers are satisfied with them. The marketing research will be also conducted in order to find out the possible reaction and support of consumers to the new product which the company desires to introduce and which can act as the base of the whole production cycle to be introduced. The conclusions drawn from the research work will be used for decision-making in the subsequent stages of production cycle. The details collected (data collected) by the sales department and the market research department will be used as the base by the sales department in order to find out the acceptability of the product by the customers and the extent of such acceptability.
This information will be submitted to the top-level management for decision on the production to be conducted in the proposed production cycle. The sales forecast prepared will be used for preparing production budget by the finance department. The final decision is taken by the management as regards the annual or semiannual quantity to be produced by the production department. This production quantity decided will act as base for future steps in the production cycle. Soon after deciding the production quantity, the engineering department will be instructed to prepare detailed drawings, parts list and specifications of the proposed product. In addition, the department will have to check and modify existing parts, if required. Vice president production or head of the production department will be authorized to start with the production target decided by the top management. the engineering department will submit the same at the appropriate management level and will be passed on to the production planning and control department for follow up steps.
The production planning and control department will have verify and inform about the availability of materials for the new production cycle to be undertaken and also the expected delivery dates of materials already ordered. Detailed production schedules are also prepared by production planning and control department in this stage of production cycle. The inventory levels of materials are checked in order to determine the placement orders for new procurement of materials and standard parts. Materials will start coming and the purchase department has to make necessary arrangements for inspection of materials prior to acceptance. The accepted materials will be stored in stores. The production planning section sends complete data on methods, machine loading, production schedules, etc. to the production control section for dispatching purpose. This prepares proper background for production control operations. The production control section will release orders for materials, tools, fixtures, and etc. to respective section for production purpose.
The orders are issued to the shop in regard to materials and production work. Detailed Production orders are prepared and sent by the production control section to the shop. Actual progress of production is constantly compared with the planned schedules.
This facilitates introduction of suitable modifications for rectification of shortfalls, if
Noticed. This facilitates quick and correct flow of information and instruction between control section and manufacturing departments. Inspection work for quality control is undertaken. Inspection orders are released. The purpose of quality control during the production process is to see that specifications as laid down are confirmed with. Final inspection of parts is made before the product leaves the shop and moves to the finished parts or products store.
Inspection reports are prepared after the evaluation. Such reports form the basis for corrective measures/actions in the processes/methods and even for modifications in the specifications of raw materials, if required. The production planning and control department submits the reports on the progress of the work to the vice-president, in charge of manufacturing. The control section also evaluates data obtained from the shops about operation times, idle time of men and machines, causes and effects of breakdowns, etc. Action initiated by the control section (as a result of such reports) has to be followed up. Its evaluation should also be reported to the vice president, in charge manufacturing. The vice-president, in charge manufacturing submits interim and final reports on the production activity undertaken. Top-level management receives such reports for evaluation. The top-level management also receives a report from the financial department on the production work undertaken. Final evaluation is done by the management on the basis of both the reports. The finished product (duly inspected) is transferred to stock for marketing.
It is sent out to dealers in due course for giving delivery to customers. The finished product is sold to customer for actual use. The customer compares the features and plus points of the said product with those of its competitors and also with his needs and expectations. Views of customers are important and useful as they prepare sound background/foundation for the next production cycle of the company.
RAYMONDS APPAREL LIMITED
VISIT ANALYSIS: -
(A) Research and Development: -
The R and D department of Raymond’s starts planning one year in advance. They take around 3 months for the research, 3 months for the market survey, 2 months for the developing, 2 months for the sample testing. Eventually there is a conference for the sample testing, feedback from the customers; remaining 2 months are utilized for the modification of the product, if needed.
(B) PRODUCTION CYCLE: -
There are mainly three stages in the production cycle:
1. Research: -The kind of fabric required, quantity and quality of the fabric is decided
a year advance. Similarly the market demand, consumers preference are also taken
into consideration.
2. Design: - Then as per the survey done by the Research and Development Department, and also taking into consideration the customers demand and overall market demand,
Customers type of cloth and design requirements, the designing process starts. The fabric is then given proper design and then with verification they are passed on to the CAD dept.
3. CAD: -In CAD, new styles are developed and modified according to consumers needs.
There is a design studio, to display final product to customers. There is a scoop-up at
Every stage
(C) UNITS PRODUCED: -
Samples are taken from dealers regularly. Based on the season and demand the number of units produce is considered. E.g. In a winter season, more blazer or jackets are produced.
1Price Structure: - The overall cost depends upon actual cost, overheads and brand value of the product. About 90% of fabric is manufactured at Raymond remaining 10% is imported.
2. Size: - The average height of a person is considered while making any suits, shirts, trousers or blazers. The height considered is 5 feet 9 inches.
3. Workers: - Employment depends upon output, process, season, demand in market etc. The Thane branch of workers has around 300 workers. Workers work for 8 hours daily having a break for ½ hour.
(D) PRODUCTION PROCESS:
There are many stages in production process. All the designs, styling, markings for the cutting of the fabric are computerized. Steps taken are as follows: -
1. Cutting stage: - The machine used for cutting the fabric is gold-knife cutting machine. It is a very dangerous machine if not handled properly. The machine cuts the different parts of fabric i.e. the sleeves, collar, body etc. After different parts are cut every part is numbered according to size, model number etc.
2. Fudging: - In the stage thin white cloth is stuck inside the sleeves. This is to make the material more comfortable for the person who wears it.
3. Sorting: - Different parts of a suit are given different numbers. In the sorting stage all the needed parts are brought together.
4. Back and front: - In this stage the back and front part of the suit or blazer is stitched. Proper measurements are taken and it is hand cut.
5. Pocket: - In this stage the pockets are made. The pocket does not have a flap. Proper measurements are taken with the help of the machines.
6. Lining of the pockets: - The pockets are measured and thin cloth is stitched in the pockets.
7. Batch label: - In this process the label is given to the cloth. A batch label machine does it.
8. Pocket bag: - In this stage a proper pocket is created on both sides of the blazer.
9. Pocket batch: - Here, the pockets a batched with different numbers and codes so that they can be differentiated properly.
10. Piping: - In this stage the pocket is folded with a thin line above the pocket.
11. Lapel: - Then the pockets are lapelled, i.e. - ironing of the pockets take place to give it a define shape.
12. Pasting with heated iron: - After the lapel stage the material is pasted with hot iron. It is ironed neatly to give a neat look.
13. Body shaping: - Raymond has a special machine for the body shaping. This machine gives a proper shape to the fabric.
14. Bottom fold: - In this stage the lower part of the fabric is given a fold. This is also done by using the machine.
15. Shoulder pad: - The shoulder pad is now attached to the shoulders. It’s put for better shape of the shoulders.
16. Collar machine: - After shoulder pad is attached the materials is sent to the zigzag or collar machines. Here the collar is stitched carefully to every blazer.
17. Lapel processing: - Lapel processing means collar pressing. The collar is pressed with hot iron to give it a define shape.
18. Botton pressing with lining: - In this stage the blazer is heated. The lower part is pressed with iron with low temperature to keep the shape intact.
19. Sleeves attach: - here, the sleeves are finally attached to the blazer. It now gets a complete look.
20. Miscellaneous: - Here all minor mistakes are checked, if any. E.g. the sleeves, collars etc are attached properly.
21. Buttons: - The buttons are now fixed. There are2 types of buttons- metal and plastic. It is attached to the front and sleeves of the blazer. All buttons are brought from central mumbai.
22. Thread finishing: - The extra thread is cut and proper finishing touch is given to the blazer.
23. Shoulder press: - The sleeve (from the shoulders) is pressed with hot iron. Pressing of the blazer again ensures that it looks neat.
24. Sleeves press: - There is a sleeve-pressing machine. Here the sleeves are pressed from left to right.
25. Front lapping pressing: - In this stage the body of the blazer is pressed using the body-pressing machine. It also gives a definite shape to the blazer.
26. Miscellaneous: - Here details such as are buttons proper, is proper thread used everywhere, shoulder pad at right place etc are looked into.
27. Final quality control: - In this stage the team of final quality control checks each and every blazer or trouser. If any errors found it is sent to the manufacturing process. If not the goods are dispatched.
(E) DEFECTS: -
After a fabric is completed there maybe many defects such as;
1. Fabrication defect
2. Manufacturing defect
3. Fabric defect
4. Color defect
If the fabric is rejected by final quality control department then the product are called STAMP. There are sold in market with 20% to 30% discount and are considered as seconds. But the defect even in such a case is so minor that only the experts and not any customer could detect it.
(F) MACHINE: -
All the machines are imported from places like ITALY, GERMANY, and JAPAN. Complete manufacturing of a blazer takes around 120 minutes whereas trousers take up to 60 minutes. The machines used are mostly fully automatic and some machines require human assistance.
FUTURE PLANS OF THE COMPANY: -
RAYMONDS have been world leaders as far as textiles are concerned. There aim now is to be world-class stitching manufacturer by 2010. They believe in perfection and every fabric quality is checked and rechecked by the quality control experts. 90% of the raw materials come from Raymond whereas remaining 10% is taken from the dealers.
The circulatory flow of materials, information’s and instructions in the production process is called the “PRODUCTION CYCLE”. The production cycle starts and ends with the customer. Production is always as per the needs, requirements and expectations of customers. Companies conduct marketing research activities and find out the product, which consumers need. Thereafter, the market demand is estimated through sales forecasting. Production planning is necessary and useful for the conduct of production activity in an order manner. The whole production activity moves continuously till the production activity is completed. Here, one production cycle comes to an end.
The goods produced are marketed thereafter. In due course of time, once again the same exercise is repeated. The new production cycle starts with the study of consumer expectations, possible demand and so on. This suggest/justifies the statement that production cycle starts and ends with the customer. The sales department studies the reactions of consumers to the products available in the market and the extent to which the consumers are satisfied with them. The marketing research will be also conducted in order to find out the possible reaction and support of consumers to the new product which the company desires to introduce and which can act as the base of the whole production cycle to be introduced. The conclusions drawn from the research work will be used for decision-making in the subsequent stages of production cycle. The details collected (data collected) by the sales department and the market research department will be used as the base by the sales department in order to find out the acceptability of the product by the customers and the extent of such acceptability.
This information will be submitted to the top-level management for decision on the production to be conducted in the proposed production cycle. The sales forecast prepared will be used for preparing production budget by the finance department. The final decision is taken by the management as regards the annual or semiannual quantity to be produced by the production department. This production quantity decided will act as base for future steps in the production cycle. Soon after deciding the production quantity, the engineering department will be instructed to prepare detailed drawings, parts list and specifications of the proposed product. In addition, the department will have to check and modify existing parts, if required. Vice president production or head of the production department will be authorized to start with the production target decided by the top management. the engineering department will submit the same at the appropriate management level and will be passed on to the production planning and control department for follow up steps.
The production planning and control department will have verify and inform about the availability of materials for the new production cycle to be undertaken and also the expected delivery dates of materials already ordered. Detailed production schedules are also prepared by production planning and control department in this stage of production cycle. The inventory levels of materials are checked in order to determine the placement orders for new procurement of materials and standard parts. Materials will start coming and the purchase department has to make necessary arrangements for inspection of materials prior to acceptance. The accepted materials will be stored in stores. The production planning section sends complete data on methods, machine loading, production schedules, etc. to the production control section for dispatching purpose. This prepares proper background for production control operations. The production control section will release orders for materials, tools, fixtures, and etc. to respective section for production purpose.
The orders are issued to the shop in regard to materials and production work. Detailed Production orders are prepared and sent by the production control section to the shop. Actual progress of production is constantly compared with the planned schedules.
This facilitates introduction of suitable modifications for rectification of shortfalls, if
Noticed. This facilitates quick and correct flow of information and instruction between control section and manufacturing departments. Inspection work for quality control is undertaken. Inspection orders are released. The purpose of quality control during the production process is to see that specifications as laid down are confirmed with. Final inspection of parts is made before the product leaves the shop and moves to the finished parts or products store.
Inspection reports are prepared after the evaluation. Such reports form the basis for corrective measures/actions in the processes/methods and even for modifications in the specifications of raw materials, if required. The production planning and control department submits the reports on the progress of the work to the vice-president, in charge of manufacturing. The control section also evaluates data obtained from the shops about operation times, idle time of men and machines, causes and effects of breakdowns, etc. Action initiated by the control section (as a result of such reports) has to be followed up. Its evaluation should also be reported to the vice president, in charge manufacturing. The vice-president, in charge manufacturing submits interim and final reports on the production activity undertaken. Top-level management receives such reports for evaluation. The top-level management also receives a report from the financial department on the production work undertaken. Final evaluation is done by the management on the basis of both the reports. The finished product (duly inspected) is transferred to stock for marketing.
It is sent out to dealers in due course for giving delivery to customers. The finished product is sold to customer for actual use. The customer compares the features and plus points of the said product with those of its competitors and also with his needs and expectations. Views of customers are important and useful as they prepare sound background/foundation for the next production cycle of the company.
RAYMONDS APPAREL LIMITED
VISIT ANALYSIS: -
(A) Research and Development: -
The R and D department of Raymond’s starts planning one year in advance. They take around 3 months for the research, 3 months for the market survey, 2 months for the developing, 2 months for the sample testing. Eventually there is a conference for the sample testing, feedback from the customers; remaining 2 months are utilized for the modification of the product, if needed.
(B) PRODUCTION CYCLE: -
There are mainly three stages in the production cycle:
1. Research: -The kind of fabric required, quantity and quality of the fabric is decided
a year advance. Similarly the market demand, consumers preference are also taken
into consideration.
2. Design: - Then as per the survey done by the Research and Development Department, and also taking into consideration the customers demand and overall market demand,
Customers type of cloth and design requirements, the designing process starts. The fabric is then given proper design and then with verification they are passed on to the CAD dept.
3. CAD: -In CAD, new styles are developed and modified according to consumers needs.
There is a design studio, to display final product to customers. There is a scoop-up at
Every stage
(C) UNITS PRODUCED: -
Samples are taken from dealers regularly. Based on the season and demand the number of units produce is considered. E.g. In a winter season, more blazer or jackets are produced.
1Price Structure: - The overall cost depends upon actual cost, overheads and brand value of the product. About 90% of fabric is manufactured at Raymond remaining 10% is imported.
2. Size: - The average height of a person is considered while making any suits, shirts, trousers or blazers. The height considered is 5 feet 9 inches.
3. Workers: - Employment depends upon output, process, season, demand in market etc. The Thane branch of workers has around 300 workers. Workers work for 8 hours daily having a break for ½ hour.
(D) PRODUCTION PROCESS:
There are many stages in production process. All the designs, styling, markings for the cutting of the fabric are computerized. Steps taken are as follows: -
1. Cutting stage: - The machine used for cutting the fabric is gold-knife cutting machine. It is a very dangerous machine if not handled properly. The machine cuts the different parts of fabric i.e. the sleeves, collar, body etc. After different parts are cut every part is numbered according to size, model number etc.
2. Fudging: - In the stage thin white cloth is stuck inside the sleeves. This is to make the material more comfortable for the person who wears it.
3. Sorting: - Different parts of a suit are given different numbers. In the sorting stage all the needed parts are brought together.
4. Back and front: - In this stage the back and front part of the suit or blazer is stitched. Proper measurements are taken and it is hand cut.
5. Pocket: - In this stage the pockets are made. The pocket does not have a flap. Proper measurements are taken with the help of the machines.
6. Lining of the pockets: - The pockets are measured and thin cloth is stitched in the pockets.
7. Batch label: - In this process the label is given to the cloth. A batch label machine does it.
8. Pocket bag: - In this stage a proper pocket is created on both sides of the blazer.
9. Pocket batch: - Here, the pockets a batched with different numbers and codes so that they can be differentiated properly.
10. Piping: - In this stage the pocket is folded with a thin line above the pocket.
11. Lapel: - Then the pockets are lapelled, i.e. - ironing of the pockets take place to give it a define shape.
12. Pasting with heated iron: - After the lapel stage the material is pasted with hot iron. It is ironed neatly to give a neat look.
13. Body shaping: - Raymond has a special machine for the body shaping. This machine gives a proper shape to the fabric.
14. Bottom fold: - In this stage the lower part of the fabric is given a fold. This is also done by using the machine.
15. Shoulder pad: - The shoulder pad is now attached to the shoulders. It’s put for better shape of the shoulders.
16. Collar machine: - After shoulder pad is attached the materials is sent to the zigzag or collar machines. Here the collar is stitched carefully to every blazer.
17. Lapel processing: - Lapel processing means collar pressing. The collar is pressed with hot iron to give it a define shape.
18. Botton pressing with lining: - In this stage the blazer is heated. The lower part is pressed with iron with low temperature to keep the shape intact.
19. Sleeves attach: - here, the sleeves are finally attached to the blazer. It now gets a complete look.
20. Miscellaneous: - Here all minor mistakes are checked, if any. E.g. the sleeves, collars etc are attached properly.
21. Buttons: - The buttons are now fixed. There are2 types of buttons- metal and plastic. It is attached to the front and sleeves of the blazer. All buttons are brought from central mumbai.
22. Thread finishing: - The extra thread is cut and proper finishing touch is given to the blazer.
23. Shoulder press: - The sleeve (from the shoulders) is pressed with hot iron. Pressing of the blazer again ensures that it looks neat.
24. Sleeves press: - There is a sleeve-pressing machine. Here the sleeves are pressed from left to right.
25. Front lapping pressing: - In this stage the body of the blazer is pressed using the body-pressing machine. It also gives a definite shape to the blazer.
26. Miscellaneous: - Here details such as are buttons proper, is proper thread used everywhere, shoulder pad at right place etc are looked into.
27. Final quality control: - In this stage the team of final quality control checks each and every blazer or trouser. If any errors found it is sent to the manufacturing process. If not the goods are dispatched.
(E) DEFECTS: -
After a fabric is completed there maybe many defects such as;
1. Fabrication defect
2. Manufacturing defect
3. Fabric defect
4. Color defect
If the fabric is rejected by final quality control department then the product are called STAMP. There are sold in market with 20% to 30% discount and are considered as seconds. But the defect even in such a case is so minor that only the experts and not any customer could detect it.
(F) MACHINE: -
All the machines are imported from places like ITALY, GERMANY, and JAPAN. Complete manufacturing of a blazer takes around 120 minutes whereas trousers take up to 60 minutes. The machines used are mostly fully automatic and some machines require human assistance.
FUTURE PLANS OF THE COMPANY: -
RAYMONDS have been world leaders as far as textiles are concerned. There aim now is to be world-class stitching manufacturer by 2010. They believe in perfection and every fabric quality is checked and rechecked by the quality control experts. 90% of the raw materials come from Raymond whereas remaining 10% is taken from the dealers.