IMPROVISATION OF THE

PRODUCTIVITY OF MORGAN
TECNICA CUTTING MACHINE
objectives
To study and increase total cutting room efficiency
To improvise the productivity of automatic cutting
machine.
To devise another shift to reach an output of 10000 pieces
Allocation of Manpower to this shift.
Implementation of New shift.
Reduction Off standard time.
Maximum utilization of automatic cutting system.

Technical Specifications
Max cutting thickness 7 cm
Window Size 17500
Power plants 7 Kw + 15 Kw (single pump)
Average power consumption approx. 11 Kw
Standard cutting window 180 cm.
Available width 180 - 220 cm
Standard 4500 rpm - HM 6000 rpm
Environment temperature from 10 to 40
Humidity from 30% to 80% without condense
Voltage 400 V 3Ph 50/60 Hz
Current Facts
Cost of the machine- 1.5 crore.
Average lay length 8.56 meters.
Average number of plies- 37
Average lay thickness- 3.53 cm.
Current output(average) - 3111.
Targeted output 5000 pieces/Shift or 10000/day.
Working hours 11 hours. (9.30-8.30)
Marker making software- GERBER accumark explorer.
Current Output Report. ..\cutting.xlsx
Off standard
Time
Breakdown
Maintenance
Unnecessary
Stoppages
Cutting Less
than capacity
Less Output
Reasons for off standard time

Problem with the machine, maintenance not done in time.
Power cut
Cut parts not removed from the area.
Next lay not ready.
Waiting for the next pattern to upload in the software.


Off standard time
There were many reasons because of which there was an increase in off
standard time, more number of pieces could have been cut if this off standard
time could be reduced.



6/06/14 9/06/14 10/06/14 11/06/14
Off standard
time
1.02 hours 1.51 hours 4.21 minutes 2.48 hours.
Lays which
could have
been cut in
the off
standard time
30-40 60-70 5-10 90-100
Pieces 350 650 70 950
Current output 2860 2968 3546 3760
Increase in
output
3210 3618 3616 4710
Off Standard Time (9/6/2014)
Reason Time
Discussion with the cutting manager 2.45+3.27+1.33+37+40+1.44+30+1.
30+45= 13.51 minutes
Next lay not ready 69.12 minutes
Operator not present 8.45 minutes
Total off standard time 1.51 hours.
Off Standard Time (10/6/14)
Reasons Time
Work Area not cleared 2.15 minutes+ 34 sec. + 36 sec +
48 sec
Total 4.21 minutes
Off Standard Time (11/06/14)
Reasons Time
Delay to approval 30 minutes
Air compressor Problem 1.15 hrs
Operator not present 50 minutes
Total 2.48 hours
Cutting less than capacity
One of the major reason for the less output is cutting plies less than
capacity.

Cutting ply quantity of less than 50 is not ideal for this machine. As
cutting of even 30 plies takes the same amount of time as cutting of 49
plies.

Any less number of plies if there should be cut manually and not on this
machine.

Increasing the ply quantity for a particular marker is one of the major
recommendation for increasing the output.


Break Down Maintenance
Instead of following preventive or scheduled maintenance,
breakdown maintenance was being followed on the
machine which resulted in off standard time when ever the
machine had some problem.

More over for each of the small problems technician was
being called and machine was stopped, therefore resulting
in no output in the required period.

Many of the machine parts required daily maintenance and
weekly maintenance which would help the machine to work
continuously without any errors.

Even when the screen was showing some sort of problem
to be checked, the operator wasnt responding to it.
REDUCTION IN OUTPUT WHEN MACHINE BREAK DOWN
INCREASED
OUTPUT
Cutting
Ideal
Plies
Increasing
Number of
lays
Lay Length
Pre Planning
Following
Maintenance
Cutting Ideal Plies
This is a very important factor which is often ignored while trying to get the right
mix ratio of the order.

According to the specification of the machine, the maximum it can cut in 7cm of
thickness, but here only a maximum of 4.5 cm is cut, it can be therefore
improved.


4.5cm = 50 plies
1cm = 50/4.5 plies
7cm= 50/4.5 * 7 = 77.77

Therefore ideal number of plies that could be cut on this machine is around 70.

Also to cut ideal number of plies is very important.
Ideal plies= Order qty./ Maximum Pieces allowed in marker.

Any ply cut extra then the ideal plies result in more wastage of fabric and
increase in time.


LESS NUMBER OF PLIES
QUANTITY CAN BE INCREASED
IDEAL PLIES
Number of ways in a marker
For getting an output of 5000, the ideal number of ways that need to be
included in a marker is always 10 or more than that.

If the number of ways is less than 10 it will result in less number of pieces
getting cut and more amount of time getting wasted.

See the excel sheet. ..\cutting.xlsx

In the case of H & M slim low, the number of ways are kept close to 10 always
therefore it resulted in getting more close to ideal plies getting cut.

But in the case of other 2 styles, the number of ways is always made less,
which resulted in cutting extra number of plies, therefore increasing time and
fabric wastage

Also, the morgan spreading machine can lay a maximum of 12 meters of
fabric, which is not utilized.
Pre- Planning
This is the most crucial activity and this alone can result in increase in output.

Pre planning the cut plan for the next day will result in achieving the desired
output.

For example:

Time taken to cut 50 plies- 1hr. 20min.(80 min.)
working Hours 11 hours (660 min.)
Number of lays that can be cut in a day= 660/80 = 8.25 ~ 8 (adding the
allowances)
therefore, ideally 8 lays can be cut each day of 50 plies.

Now the time taken to cut 50 plies or 60 plies or 70 plies is the same.

So if 8 lays of 50 plies of lay length 10 meter each having 10 ways is cut every
day then output is: ..\cutting.xlsx
Same way if 60 plies are cut and if 70 plies are cut then the output will be.
Following Maintenance
The Following parts needed daily maintenance:

X-axis
Y-axis
Air filter
Convey Bed
Bowl roller
Knife sensor
Slipping Assembly
Emergency Buttons
Software Functions in PC
Sharpening Devices and belts
Knife
Sharpening Adjustments.

Part Needing weekly maintenance:

Greasing of bearings.
Maintenance Card has been prepared in order to check the daily and weekly
maintenance.
Fluctuation in the output from 3
rd
June to 19
th
June.
Average output- 3111
0
500
1000
1500
2000
2500
3000
3500
4000
4500
5000
Series1
DEVSING ANOTHER SHIFT TO
REACH AN OUTPUT OF 10000
From the flow process chart it can be seen that crucial
activities are:

Bring the fabric rolls from the stores.
Load the roll to the Morgan spreading machine.
Spread the fabric.
Move the fabric towards the cutting machine.
Laying marker paper on the lay.
Cutting of the lay.
Collecting the cut pieces for bundling.
Removal of the waste from the work area.



ACTIVITY Number of Workers Remarks
Bring the roll from the
stores
0 Rolls can be brought up in
the morning shift.
Load the fabric roll onto the
machine
2 ( 1 helper + 1 spreader) Helper is required because
only 1 person cannot
handle the roll alone
Spreading fabric 1 spreader
Moving the lay Helper and spreader will do
this work too
Marker Making 0 Marker will be made in the
previous shift.
Laying the marker on lay 1 Cutting operator
Cutting the fabric Same man
Removing the cut parts 1 helper
Removal of waste from
workplace
1 helper.
Total manpower
requirement
5
Requirements for the new SHIFT
Time of the shift 1- 9.30 am to 8.30 pm. (Working hours-11)

Time of the shift 2 9.30 pm to 8.30 am.

Number of rolls that need to be bring in for the shift- 35-40.

Rolls for a shift need to be brought up from the stores 2 days prior to its
cutting.

Marker for the next shift need to be made in the previous shift.

Cut parts will be kept in the racks and sorting will be done in the morning
shift.

Implementation of the Shift
New operator was called in on 25
th
of June.

From 25
th
June to 1
st
July the new operator was in the learning phase.

Permanent New Shift for the machine began from 2
nd
on the July.

Shift timings being 9pm to 7am.
OUTPUT AFTER THE BEGINNING OF NEW SHIFT
Output after implementing new shift
0
1000
2000
3000
4000
5000
6000
7000
8000
9000
10000
2-Jul 3-Jul 4-Jul 5-Jul 6-Jul 7-Jul 8-Jul
0
1000
2000
3000
4000
5000
6000
7000
8000
9000
10000
9-Jul 10-Jul 11-Jul 12-Jul 13-Jul 14-Jul 15-Jul
Week 1
Week 1
0
1000
2000
3000
4000
5000
6000
7000
8000
9000
16-Jul 17-Jul 18-Jul 19-Jul 20-Jul 21-Jul 22-Jul
0
1000
2000
3000
4000
5000
6000
7000
8000
9000
10000
23-Jul 24-Jul 25-Jul 26-Jul 27-Jul 28-Jul 29-Jul
Week 4 Week 3
6400
6600
6800
7000
7200
7400
7600
7800
8000
8200
30-Jul 31-Jul 1-Aug 2-Aug 3-Aug 4-Aug 5-Aug
Week 5
The average output in 5 weeks after implementation of new shift is 6391.

The output increased from 3111 to 6391, showing an increase of 105%.

Conclusion
After implementing the following suggestions the industry
gets the following benefits:
Reducing the stoppage time of the Automatic Cutting
Machine increases the overall quality of product.
Operator learning is improved.
Total cutting room efficiency is increased.
Output of automatic cutting machine is increased from
3111 to 9000 cut pieces per day.
Implementation of New shift.

THANK YOU