OPERATIONS MANAGEMENT

Individual Assignment Process Mapping at Raymond Ltd.

Tata Institute of Social Sciences

By Aditi Yadav (2011HR004)

Date: March 9, 2012

About Indian Textile Industry

Indian Textile Industry is one of the leading textile industries in the world. Though was predominantly unorganized industry even a few years back, but the scenario started changing after the economic liberalization of Indian economy in 1991. The opening up of economy gave the much-needed thrust to the Indian textile industry, which has now successfully become one of the largest in the world. India textile industry largely depends upon the textile manufacturing and export. It also plays a major role in the economy of the country. India earns about 27% of its total foreign exchange through textile exports. Further, the textile industry of India also contributes nearly 14% of the total industrial production of the country. It also contributes around 3% to the GDP of the country. India textile industry is also the largest in the country in terms of employment generation. It not only generates jobs in its own industry, but also opens up scopes for the other ancillary sectors. India textile industry currently generates employment to more than 35 million people, which is second largest after agriculture in the country. India has the potential to increase its textile and apparel share in the world trade from current level of 4.5 % to 8% and reach US$ 80 billion by 2020.

About the company: Raymond

Incorporated in 1925, Raymond Group is one of India's largest branded fabric and fashion retailers. It is one of the leading, integrated producers of worsted suiting fabric in the world, with a capacity of producing 31 million meters of wool & wool-blended fabrics. The Group owns apparel brands like Raymond, Raymond Premium Apparel, Manzoni, Park Avenue, ColorPlus, Parx & Notting Hill. All the brands are retailed through The Raymond Shop (TRS) - One of the largest networks of over 600 retail shops spread across India and overseas, in over 240 cities.

There is a range of Merchandise offered at The Raymond Shop:

Fabrics
Suiting Shirting

Readymades
Raymond Premium apprael Park Avenue Parx Colorplus

Others
Accessories (Belts, Ties, Handkerchiefs, Toiletries, Cufflinks) Men's Grooming Essentials (Deodorants, Shaving Cream, Soaps etc.)

Services
Custom Tailoring Made-to-Measure (MTM)

CORE PROCESS
Manufacturing of Suiting
Raymond is the world's largest producer of worsted suiting fabrics commanding over 60% market share in India. With a capacity of 31 million meters, it is among the few companies in the world, fully integrated to manufacture worsted fabrics, wool & wool blended fabrics. They also convert these fabrics into suits, trousers and apparels that are exported to over 55 countries in the world including European Union, USA, Canada, Japan and Australia amongst others. Raymond has created the worlds finest worsted suiting fabric from the finest wool ever produced in the world the Super 240s fabric made of 11.6 micron wool. Today it is recognized as a pioneer in manufacturing worsted suiting in India, producing nearly 20,000 designs and colors of suiting fabrics, which are retailed through over 3,000 stores in over 400 towns across India. Raymond's manufacturing facilities include three world-class fully integrated plants in India (Chhindwara in Central India, Vapi in Gujarat, near Mumbai and Jalgaon in Maharashtra), deploying state-of-the-art technology modern quality management systems like ISO 9001 and Environment Control Systems (ISO 14001). The process of manufacturing suiting at all the three plants of Raymond is standardized and flows through various Departments before going to the Warehouses:

Cetralized design team works on the desings of entire fabric range Design required for further manufacturing of garments also made

Supply Chain Management

Plans & controls activities of each Dept. Supply Chain Planning The complete process of converting wool into fabrics. Explained in detail below.

Quality Control
Checks the final product with Physical and Chemical Testing Testing of faults and complaints in the fabric

Budgeting Product Costing Cost audit Profit planning Inventory valuation

Design

Production

Costing/ Accounting

Detailed Production Process

Wool is imported from Aurtalia directly to factory locations. Polyester is procured domestically. Wool Fibre

Washing

The wool fibre is washed with alkaline solutions for removal of dirt and greece. It is then dried by means of warm air and followed by opening and cleaning the loose stock. Oiling to improve the processing characteristics.

Seperating individual fibres by removing the remaining impurities.

Carding

Drawing In

This process involves doubling of slivers and stretching them to improve regularity of the fibres.

Combing

Short fibres are combed out. In woolen fibres combing is not necessary but is essential in the case of worsted fabrics. After combing, it goes for final drawing where again drawing of slivers and stretching is done to further improve regularity.

Top

After the main draw frame, the contents of the cans are compressed and these "Bumped Tops" are ready for Top Dyeing.

Dyeing

The ready 'Bumped Tops' are dyed. This is known as Top Dyeing. Dyeing is also done at the yarn stage or fabric stage.

Blending

The Blending of Wool and Polyester is done in silver form using a grill box. The thickness of the silvers is gradually reduced and it is called Roving frame. The product from the Roving frame is called Roving Ribbon.

Spinning

The Roving ribbon is mounted on the Spinning machines where the final single thread with required thickness is made. The single thread is doubled on doubling machine. this is followed by twisting the thread to get the final yarn.

Weaving

The Yarn obtainied is then woven. In Raymond, this is done on a shuttle-less looms. The piece length woven is over 100 meters. Each piece is checked completely for any flaw/ defect and if found, it is sent to the mending department.

Finishing

Divided into 3 sections - Grey House, Wet FInish and Dry Finish. Grey House - all the grey material after perching and mending comes here for Grey Scouring, Heat setting and Singeing. Wet Finish - all the treatments carried out on the material are in wet form that includes rescouring and chemical treatment. Dry Finish - fabric is treated in dry form throughout to enhance its look shine and feel under influence of pressure and steam

Folding

In the last stage, the fabric goes for ironing, where shine is imparted to the fabric. The fabric is checked again for any kind of flaws, if it has gone un-noticed. Finally, the piece-length is cut to 15 metres & is ready for dispatch as per requirements.

SUPPORT PROCESS
Visual Merchandising - A Silent Salesman
Visual-merchandising is an art of displaying merchandise in an attractive and effective manner. The correct merchandising and display helps answer all the questions of the customer. A Raymond shop window attracts shoppers to the store and enforces the Raymonds brand image. Whether a window is large, small or a modest one in size, each needs to be carefully planned and executed. Importance of Visual Merchandising:
Increases buying

Increases buying

Improves Store Image

Visual Merchandising
Makes products accessible to customers Educates the customer

Promotes brand image

Detailed Process of a VM Campaign

References

Raymond Induction Manual Interview data from employees of Production and Visual Merchandise Departments Www.Raymondindia.com http://business.mapsofindia.com/india-industry/textile.html http://www.cci.in/pdf/surveys_reports/indian-textile-industry.pdf