CASE ANALYSI 1 ::

Order: J C Penny waist coat B 699

Initial allotment: 16443 mts

Area of allotment: Raymond ltd Gauribidnaur

Area of problem: Lining

Other details :

Buyer order no-JCP 156 CDE

Style no :JCP-156 CDE

Taffeta lining

Problem statement :

Initially following the BOM issued by merchandiser the store from SSAl issued 16443 mts taffeta interlining for the order as mentioned above .Along with the interlining other materials were also issued which includes shell fabric ,trims etc .This calculation was made keeping in mind that interlining consumption is 0.96 mts per garment .

However, after sometime re order of around 9387 mts fabric was made …..

Possible reasons :

1. Poor accountability

2. Poor pattern planning

3. Poor order planning

4. Poor checking procedure

5. Poor store management

6. Basic errors by merchandiser in making BOM

Problem faced :

Once the ssal was informed about the problem they have to act immediately because if the problem is not solved quickly the production can stop at Raymond ltd .

Possibilities :

1. If the problem occurs once more and the fabric is not in house……Then some serious problem can occur

Reaction time analysis (SSAL)

Date :4 June 2012

Confirmation of problem: 1057 hours

Updating process by merchandiser: 1115 hours

Issuing of material and DC: 1145 hours

Loading in truck: 1215 hours

Despatching for Gauribidnaur:1245 hours

Truck arrival time (Gauribidnaur ):1430 hoursTotal cycle time : 4 1/2 hours

CASE ANALYSIS 2 ::

Thread Inspection

Thread Type : Gutterman sewing thread

Asked Quantity: 660 spools

Area of allotment :Raymond Apparel Limited ,Gouribidnaur

Method of inspection: Physical inspection

Result : On physical inspection 720 spools of thread were found i.e around 60 spools of thread were found extra

Reasons for error :1. Improper checking

2. Laid back attitude of workers

3. No proper inspection of checking procedure

Case Analysis 3 :

DC no: T1335,T1501

Order Ref. no: HO/11-12/JCP1335/1074

Problem Trims: Imitation horned buttons

Problem Statement : As per outward(DC) the total number of buttons going to Raymond Ltd were around 7858 when counted physically the total number of buttons founded were around 78580.A difference was around 70000.After crosschecking it from the work order it was founded that original requirement in Raymond ltd was actually 78580.Hence the mistake was in outward

Reason: The reason of this problem was the typing error by the operator

Impact: 100% physical checking of material is done at Raymond ltd but sometimes the GRN(Goods Receipt Note) is made on the basis of outward only .Thus 70000 buttons could have lost as their won’t be any record in the inventory.