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Leather Goods Manufactory Department Distribution Prashant Kumar Ray Designer, FDDI, NOIDA.

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Presentation on theme: "Leather Goods Manufactory Department Distribution Prashant Kumar Ray Designer, FDDI, NOIDA."— Presentation transcript:

1 Leather Goods Manufactory Department Distribution Prashant Kumar Ray Designer, FDDI, NOIDA

2 Technical Departments Sample Department Leather Store Leather Selection Area Leather cutting area Leather Skiving & Splitting Area Lining fabric Store Fabric Cutting Department Metal Accessories Store Other Reinforcement and adhesion Material Store Production department Common Facility Area Finishing Area Packing Area Spare Area for stacking the packed goods

3 Technical Departments Sample Department Leather Store Leather Selection Area Leather cutting area Leather Skiving & Splitting Area Lining fabric Store Fabric Cutting Department Metal Accessories Store Other Reinforcement and adhesion Material Store Production department Common Facility Area Finishing Area Packing Area Spare Area for stacking the packed goods Sampling Department: - The core Department of any leather goods manufactory which is involved into research and development of new samples/Product or designs. Generally Designer or Creative Director of the Company heads this department. After designer, a pattern cutter/master is the main person who cut the 2-d patterns of the design, given either by designer or according to the buyer’s specification sheet. Sample makers are the people who make or construct the bags according to the given instructions by the designer or the pattern maker. There used to be some helping hands to the sample maker in this department who help them for small and easy techniques or steps just to save the time and ease the work, they are called as Helpers. Design are been developed in two different ways in sample department. First is according to Buyer’s Specification and second, Designers develop their own designs and developments as well.

4 Technical Departments Sample Department Leather Store Leather Selection Area Leather cutting area Leather Skiving & Splitting Area Lining fabric Store Fabric Cutting Department Metal Accessories Store Other Reinforcement and adhesion Material Store Production department Common Facility Area Finishing Area Packing Area Spare Area for stacking the packed goods Leather store: - for leather Goods manufactory, leather is the main Raw Material and to store leather precisely and according to their properties. each manufactory should have a Dedicated leather store usually headed by minimum 2-3 manpower, including leather store manager (head), Asst. Store manager, Helper, as leather has it’s plenty types according to their tanning process and finishes thus they need to be kept and stored in appropriate ways and techniques. If it doesn’t happen the quality of the leather degrades and the wastage percentage increases, the head of the leather store is responsible for such storage issues. Again if we talk about measurements of the leather, it is a one of very big and important issue which should be maintained in proper way. The correct and précised measurement either in sq feet or sq DM should be calculated and to be kept by the storekeeper. Leather issuing for cutting department should be followed up by the storekeeper, so that he can ensure that the right leather with right selection is going to be cut according to the buyer’s specification and product style.

5 Technical Departments Sample Department Leather Store Leather Selection Area Leather cutting area Leather Skiving & Splitting Area Lining fabric Store Fabric Cutting Department Metal Accessories Store Other Reinforcement and adhesion Material Store Production department Common Facility Area Finishing Area Packing Area Spare Area for stacking the packed goods Leather selection department: - Generally this department comes under leather store itself, as it is a sub department of the store. The main purpose of this department is to do the right selection process of leather according to the grades, colours, sizes, quality etc. Here a person do the selection process manually and classify the leather with grading system, he should be very much technical and with sharp eyes for leather and fast as well as because this is a manual process and consumes time to find out the defects and to make grading classification. (See CUTTING ENCOUSER book for the details of defects). A big table with a standard size is a minimum requirement for this department the no of table is dependent on the volume of the company and frequency of the work orders. Very good white lighting is an essential requirement to increase the visibility and helps the concern person to ensure and cross check his decision about the leather grading, the positioning of the white light should be over the table and the positioning should cover the light everywhere on the table.

6 Technical Departments Sample Department Leather Store Leather Selection Area Leather cutting area Leather Skiving & Splitting Area Lining fabric Store Fabric Cutting Department Metal Accessories Store Other Reinforcement and adhesion Material Store Production department Common Facility Area Finishing Area Packing Area Spare Area for stacking the packed goods Leather cutting: - once the selection process is done, leather moves to the cutting department which comes under a cutting head/in charge in the manufactory. He gets the cutting patterns of the article/product from the pattern master of sample department. As we know that the cutting process can be done generally by two ways, either by hand or by various machines (see CUTTING ENCOUSER book for the details). So usually our industry prefers hand cutting method for bigger pattern of the bag and clicking machine for smaller patters and leather components, for hand cutting the cutting in charge is responsible to make the replica of the pattern given by the pattern maker into TIN. And for the clicking machine method (if applicable) he needs the dye to be made as the machine required dies for cutting. Hand cutting method can also cut small patterns as well, but it consume time so the company prefers to keep at least one clicking machine in their cutting department.

7 Technical Departments Sample Department Leather Store Leather Selection Area Leather cutting area Leather Skiving & Splitting Area Lining fabric Store Fabric Cutting Department Metal Accessories Store Other Reinforcement and adhesion Material Store Production department Common Facility Area Finishing Area Packing Area Spare Area for stacking the packed goods Proper lay out while cutting is the biggest issue not only for the cutting department but it is very important for the company, because this is directly proportionate to the profit and loss from the relevant work order. While cutting if proper lay outing is not done the waste percentage will increase and will affect the consumption. So the in charge is very much responsible and should ensure about this process while cutting (for the detailed information about lay out and waste percentage please see the CUTTING enclosure) After this cutting process the parts which has been cut should be bundled in very proper manner to avoid any miss-match issue while stitching and assembling

8 Technical Departments Sample Department Leather Store Leather Selection Area Leather cutting area Leather Skiving & Splitting Area Lining fabric Store Fabric Cutting Department Metal Accessories Store Other Reinforcement and adhesion Material Store Production department Common Facility Area Finishing Area Packing Area Spare Area for stacking the packed goods Leather skiving and splitting: - all the bundles should move to the skiving and splitting room to compete the production process and according to the specification sheet of the article there are some part / leather components which need skiving or splitting technically (for details please see the enclosure BASIC CONSTRUCTION) there is a fixed person who may be headed by the cutting department in charge itself who do the skiving and splitting. The quality and specific skiving way or splitting thickness should be ensured by the person before sending these to next step, here again the re – bundling will be done as some parts may not need this treatment

9 Technical Departments Sample Department Leather Store Leather Selection Area Leather cutting area Leather Skiving & Splitting Area Lining fabric Store Fabric Cutting Department Metal Accessories Store Other Reinforcement and adhesion Material Store Production department Common Facility Area Finishing Area Packing Area Spare Area for stacking the packed goods Lining or fabric store: - similar to leather store there should be a lining/fabric store, as almost a handbags and goods have the lining inside and it is an essential raw material in leather goods industry. To keep the fabric record while production and issuing to the production department this store should have a store in charge that is responsible for the in and out process, proper stacking of the fabric and quantity management. Fabric Cutting Room: - this department comes under Fabric Store department and should manage by the Fabric store manager and their assistants if required. The fabric cutting department should be kept very much clean and tidy because it affects the dirt and stains on fabric. For light colour of fabric it is most important as it looks very dirty after exposure to the dirt. The cutting process of fabric is done mostly by the hand operated fabric cutting machine. This is very economic machine and can be handed easily. After proper lay out making on many layers of the fabric the cutting process is done. It is called layer cutting. The wastage control is again a very important issue here too.

10 Technical Departments Sample Department Leather Store Leather Selection Area Leather cutting area Leather Skiving & Splitting Area Lining fabric Store Fabric Cutting Department Metal Accessories Store Other Reinforcement and adhesion Material Store Production department Common Facility Area Finishing Area Packing Area Spare Area for stacking the packed goods Metal Accessories Store: - A bag usually is made with leather and fabric and added by metal accessories. There are lot of metal accessories in many kind of finishes are available and to be used in leather goods according to the styles and designs. Shapes can vary so the accessories store is a very essential department in any manufacturing department and should be headed separately by one in charge along with their required assistants. The persons who are into the Metal Accessories store should understand different types of finishes and qualities of accessories. This department should avoid any kind of damp around, so that it should not affect the quality and durability as well. While issuing the accessories the proper quantity calculation is necessary to avoid the wastage and this should be done by the helping hands. The Shelves and Plastic crates are basic requirement of this department to keep the Accessories separately according to their colour and finishes.

11 Technical Departments Sample Department Leather Store Leather Selection Area Leather cutting area Leather Skiving & Splitting Area Lining fabric Store Fabric Cutting Department Metal Accessories Store Other Reinforcement and adhesion Material Store Production department Common Facility Area Finishing Area Packing Area Spare Area for stacking the packed goods Other Reinforce and Adhesion material Store: - After leather, Lining fabric and Metal accessories, reinforcement materials are the basic raw material in a Leather Bag making process. So we need a dedicated place to store it properly. Reinforcement Store is the place to store it. In some companies this used to come under The Accessories store increase but if the volume of the production is higher than the Person in charge should be a different person. Iron Pallets are the requirement for stacking and keeping the reinforcement material. To stick two leather or lining component, adhesives are being used in different types of treatment while production process. To keep these adhesive materials safe without any inappropriate exposure and to avoid wastage there is place and this can be at reinforce material store or separate as well.

12 Technical Departments Sample Department Leather Store Leather Selection Area Leather cutting area Leather Skiving & Splitting Area Lining fabric Store Fabric Cutting Department Metal Accessories Store Other Reinforcement and adhesion Material Store Production department Common Facility Area Finishing Area Packing Area Spare Area for stacking the packed goods Production Department: - A Place with NOS. Of tables and stitching machines where the assembling is done to make leather goods complete. Here a group of people work to complete this process. Adhesion, Stitching, making seams and closing are the basic treatments which are done in this process under the premises. This department has maximum of work force. Depending on the volume at the production area decides that how many production supervisors will be kept to the floor. Here the bundles of the cut component comes in a proper manner may be in crates with other materials like lining, accessories and etc. Then the group of people work to assemble and make leather goods in bulk.

13 Technical Departments Sample Department Leather Store Leather Selection Area Leather cutting area Leather Skiving & Splitting Area Lining fabric Store Fabric Cutting Department Metal Accessories Store Other Reinforcement and adhesion Material Store Production department Common Facility Area Finishing Area Packing Area Spare Area for stacking the packed goods Common Facility Room: - existence of this department depends on the volume of the company and volume of the production technicalities. This is a place where some heavy duty machines and the machines are been kept which can be used for specific treatments like bulk strap cutting, post bed stitching, Cylinder Arm stitching etc. To use and work on these machines there are some specific person required who are skilled to use them. As these machines are costly and their maintenance is very much required separately unlike normal stitching machines thus there should be a separate room or place to keep them and use. Finishing Room: - Once the volumes of goods are made, they need to travel to a department where the cleaning and finishing will be done and the department is called Finishing Room/Department. A most cleaned and tidy area is the basic requirement of this Department. This area should be damp free, so that any kind of moisture issues can be controlled. A finishing in charge with their helping hands are the required manpower that do these cleaning & finishing work on the made leather goods.

14 Technical Departments Sample Department Leather Store Leather Selection Area Leather cutting area Leather Skiving & Splitting Area Lining fabric Store Fabric Cutting Department Metal Accessories Store Other Reinforcement and adhesion Material Store Production department Common Facility Area Finishing Area Packing Area Spare Area for stacking the packed goods Packing Room: - Right after the Finishing and cleaning process there is an closed area which again should be very clean, where the finished good are kept is Packing Room. According to The work order there used to be some specific packing instruction for all leather goods and the person in charge here is responsible to do the process in right and appropriate manner. Paper Stuffing, Air Bag Stuffing, inner packing, Outer Packing etc s the basic process which take place at packing room by the sub-ordinates of the Packing In charge? Spare department for stacking the packed goods: - The Open/closed area where all packed good are to be kept and stacked properly so that there should no harm on goods inside the packet. This area should be near the exit area of the factory so that the movement for shipment do take lesser time and can get the exit process easily.


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