Denim Garment Industry [PDF]

Zitiervorschau

REPORT ON PRESITEX ENTERPRISE (PTY) LTD MASERU,KINGDOM OF LESOTHO

1

VISHNU JAYAKUMAR, MT-I.E

COMPANY PROFILE

Year of establishment

:

2000

Number of employees

:

2031 ( August 1st 2011)

Area In SQM

:

222,500

Sales turnover (2009 - 2010)

:

$ 94 M

Exports Turnover

:

$ 84.6 M

Core Activity

:

Manufacturer of garments like Jeans, Jacket etc.

Industries Catered

:

Textile, Garment Industries

2

PRODUCT DETAILS

3

PROCESS SEQUENCE FABRIC STORE

PRINTING

ACCESSORY CUTTING

SEWING

DRY PROCESS

CHEMICAL 4

WASHING

SEWING

LOADING

DISPATCH

PATTERN

SHIPPING

DATA COLLECTION TheoreticalTakt Time LEVI’S

15093 440000 garment (Apprx.)

Shop Floor Availability No of Shifts Shift Hours Lunch Break Available time / Shift

Total working days Total Available Time / month =

Takt Time =

5

1 10Hrs 60Min 540Min / Shift

22days 11880Min 712800Sec

Total Available Time / Demand 0.027 min/garment

Days

Customer PS No Demand/month

Time study 4.5 4 3.5 3 2.5 2 1.5 1 0.5 0

Operation

Fabric Store 4

Access Dry Washin Dispatc Pattern Cutting Sewing ory Process g h 1

1

1

2.5

2

2

2

PROCESS PARAMETERS Machines OEE(24 hr) Max output / hr / Mc MTBF (minutes) For each Needed Floor Space (sqm) individual Connected load in KW

operations

Time (seconds) process time changeover time / pc loading time takt time / pc

Machine cost (R) Saler price recovery period (years) Labour cost (R) personal expense/shift & machine employee employee's qualification (wage level) Manufacture number of work pc/station Employee analysis accident rate

6

General for all operations

interest rate for recovery period

electricity tariff in r/Kwh shift/day

Process Lead time/garment(days) Cycle Time / garment (Sec) Man-Machine Availability

wage/hour in rs (high qualified)

Rejections Ratios Manual Material handling between stations(min/bin)

wage/hour in rs (normal qualified)

Inspection time(sec/bin)

working hours/shift

wage/hour in rs (low qualified)

recovery period in years for the manufacturing system work days / year floor space cost in r / hr & sqm needed floor space for the whole manufacturing system in sqm) floor of production hall in sqm

Inspection frequency(garment) Quality Check/hour Setup adjustments (min/garment) No. of operators No. of machines Mudas-Identification Line balancing Thread Consumption

MATERIAL HANDLING EQUIPMENTS

7

FABRIC STORE

8

Shop Floor Details SL No. 1

OPERATION Arrival of container

2

Uploading to the shop floor

3

DIVISION

MANPOWER

Shrinkage

01

Shrinkage cutting 25 * 25 (10%)

Inspection

02

4

Shade blanket cutting 8 * 8

Issuing

02

5

Inspection 10% from current arrival

Supervisor

01

6

After wash of shrinkage- measure length and width After wash of shade changes will categories into A , B & C etc.

Unloading etc 09

7 8

9

Total

15

Request from cutting department for fabric and will provide as much required.

FABRIC STORE

Point system-American Standard-Levis •1-point •2-point •3-point •4-point

: Defect less than 3 : Defects exceeding 3” up to 6” : Defect exceeding 6” up to 9” : Defect exceeding 9”

Point/100 sq.yard = (Total point * 36” * 100) / (sample yards * cuttable roll width). If it exceeds 15 the fabric will get rejected. SL No.

Length (Yard)

Width( Yard) Setup Time (Min)

Inspection (min)

Point Calculation

1

138

58.5

5.58

25.34

3

2

104.9

58.5

7.2

25.04

2.56

Fig: Inspection Machine 10

FABRIC STORE

General Ideas Supply chain Management- Ship Routes PS NUMBER WASH NAME

P-11002

Medium

P-11003

Dark

P-11006

Relaxed Medium

P-11007

Journey

P-11008

Anthem

P-11009

Rustic

P-11011

Summit

1.India-> Durban -> Lesotho 2.India -> Cape town -> Lesotho 3.Pakistan -> Durban -> Lesotho

Time Average

QUALITY ISSUES Barre Holes Biased Jerk In Bow Knots Broken End Misdraw Course Ends Mispick Crack Marks Mote Compactor Marks Needle Lines Creases Off Pattern Double Ends Press Off Dye Streaks Read Marks Ends Out Rope Marks Filling Bands Runs Fine Ends Seam Marks Finger Mark Slub Float Smash Fly Soil

Total time to reach a fabric to cutting is 3-4days Minimum. In Emergency 2 days. Time for washing in shade blanket is 1 day. Before that 1day for cutting. For shrinking washing time is minimum 2hrs and after washing 1hr.

11

FABRIC STORE

Continuous..  Containers

details from Import and export department. Details

including Container number, P/O, quantity, ETA, ETD, YDS, Shipping line. When arrived, the uploading will do only after customs

clearance. Fabric Consumption- 1.34 yard = (Total yard/Cut Quantity) Reports: Stock report and fabric consumption report. Types of Fabric: Canvas- Cotton-Dot type, Cordury & TWILL .

Issuing the fabric to cutting as per cutting plan. They will give request for fabric to issue. Mostly will cut 7% more than order quantity 12

FABRIC STORE

PATTERN ROOM

13

Process details 

Buyer will give design to the management as per their requirement. Through Merchandiser it will transfers to pattern department.



Pattern maker will calculate the total fabric needed for a garment in yards. It always an average of 1.40yards + 2 % allowance.



Management will decide the overall cost of making a garment and will inform to buyer.



If the buyer is not ready to accept the rate, there will also a discussion for cost reduction and may reach as per buyers standard.



For sample piece of garment firstly as per shrinkage report, pattern will make with GEBER Software.

14

PATTERN

Continuous.. 

Sample will send to buyer for verification. After that there might be small changes from buyer will occur. They also will send back to Merchandiser and finally to pattern department.



Pattern department will start pre-production and will make a pattern of three or four size garments with two or three pieces and will undergo all process including quality check in final.



Quality department will note and inform if there any changes and problems in the final product,



Always the utilization of fabric should be more than 90%. And at least like to reach 93%.



In pre-production buyer will always give a tolerance on +5 to -5 as example. So the size issue, because of external issues like shrinkage will always between this.

15

PATTERN

Continuous… 

Calculation for yard needed for a Garment



Example: Marker Length as per software

= 17.26 yard

Converting to yards + 2 % allowance = 17+26/36 + 2% = 17.73 Total number of garments in a marker= 14

Total yard per piece

= 17.73/14= 1.26 yards.

Fig: Plotted drawing 16

PATTERN

Continuous… 

How to make cut plan.



Production sheet contents like PS NO, SAP-PO NO, PRODUCT CODE, ORDER QUANTITY



From the Order Quantity cut plan will make taking Insim and Size as major calculation point of view. With exact number of quantity of each size like 32, 34, 36, 38 etc. Marker count and table count will decide. From the fabric shrinkage report and marker allotment total quantity of fabric will calculate.



Design is making with Geber software and will allot in exact yards with 90% efficiency.



Always make Order quantity with 0-7% extra, with comparison of stock level in previous production.



Printer needs at least 20-30 minutes to make a printout.



Currently in pattern department there are 2 + 1 workers 17

PATTERN

CUTTING

18

Production Plan 

From Cut plan department head will make output plan.



From Marker the quality department will check whether all the pieces of a garment are present or not.



The fabric roll will keep in table with more than 74 layers as per the thickness of garment. May be the capacity will reach about 100.



There are 12 line of cutting table. 6 tables with 19” and 6 tables with 21”.



After cutting there will be a quality checking for whether there any more excess cut is made or any other wrong cut is made. They will mark in error piece bundles for rework.



After that numbering will do in all pieces of bundles. And they will make bundles of garments together.



There also a quality checks after numbering.



After all the line feeders in sewing department will take the bundles to respective area.



Current capacity is 20,000 pieces in a day.

19

CUTTING

Shop floor details Manpower: 71 workers + 2 Supervisors excluding quality department



SL. No 1

OPERATION: LAYERING Keeping cutting machine to the place

2

Layering in sequence as per style Keeping bundle in to the position Quality check in each layers

3 4

MANPOWER

2

Target Maximum 20,000 pieces per day

2 2 1

20

CUTTING

PLANNING

21

General ideas 

Merchandiser will provide Projection Order to Planning department.



Planning will do 55 days before the production.



Always make a buffer of 7 days for shipping.



Cutting plan will make and will provide to fabric, accessory, pattern and cutting department.



Garment fabric length taken as 1.4 m for a garment and 0.17m for lining.



Container size maximum of 30,000 Jeans supply.



505- Straight fit and 550- Relax Fit

22

PLANNING

Continuous… 

1-2-3 and interaction with import



Mainly deals with fabric quantity, accessory needed, date of order and arrival



Production Planning



Production is well planned as per the day of shipping as final designation with proper date and allocating works in proper Line.



Quantity Control



Number of garments in each operation is well controlled to get proper output with less WIP in each level of production.



Order Reconciliation



It will shows clear idea of all sewing quantity , washing quantity, Input to dispatch, sewing reject, washing reject, cutting reject , shipping quantity, Leftover etc. All management staffs will get a clear view report after Order reconciliation. 23

PLANNING

Departmental capacity 

Example



Sewing department:



Lead time

= 21.32 minutes



Total time availability

= 9 * 60



Number of Manpower = 110



Machine hour

= 110 * 9 * 60 = 59400 minutes



Target Efficiency

= 85%



Line target in a shift

= (59400 * 0.85) / (21.32) = 2368 nos.



Production per hour

= 263 nos.



Production in 5 lines

= 2368 * 5 = 11841 nos.

24

PLANNING

Basic Production Process PROCESS Fabric Store Trims P.P Approvals Pattern Cutting Sewing Dry Process Washing Dispatch

Total

DAYS 4 1 1 1 1 2.5 2 2 2 15.5 days

25

PLANNING

ACCESSORY STORE

26

Accessories 

Main label



PKT tags



Pocket label



Size Sticker



Care Label



Poly Bags



Leather patch



Cartons



Zipper



Brown paper



Fusing



Double sided Clear type



Threads



Tag pin



Buttons



Plastic stables



Rivets



Waist tag

27

ACCESSORY

Suppliers… Will get Production sheet Sl.No

Item

Country

1 2 3

Zipper Thread Leather Patch (RT)

Swaziland Hongkong Mauritius

Leather Patch (Denizen)

Hongkong

4

from merchandiser.

Cutting report from department. Invoice from supplier.

Quality and quantity check mostly 10 % in all supplies if the lot is more. If it is less of

number will do 100%. Mostly Zipper count will do 100% checks in all arrival.

28

ACCESSORY

Continuous.. 

Accessory sheet will make for all checking in each arrival



Always provides 5-7% allowance in supply to production.



Provided a person for all supplies in a line. He will name bundle no, size, Line no, cut no etc.



TRIM CARD is made for reference of each style.



Zipper Size as per size 31- 16, 32-16.5, 33-17, 36-19



From PO will get what type of label needed and prepare with printing machine. Model will sent by Levis. 3000 pieces/hr

29

ACCESSORY

SPARE PARTS

30

General Ideas 

Spare parts are categories into different variety and kept inside spare part store.



As per the Mechanic and Head Mechanic request spare parts will get issued.



Some consequent replacing parts have Minimum Inventory Level.



Company have monthly budget for purchasing spare parts. Asitha is the in charge and having more than five regular suppliers. Some parts are supply from Hongkong.



Issues are Not getting the spare parts from suppliers. So there is issue when a part is to be replaced as soon.

31

SPARE PARTS

Common spare parts.. Upper knife clamp Joint Lower knife Oring Worm wheel Spring Connection Needle bar bushing Bushing assembly Shaft Ring Connection Cover Upper looper holder assembly Crank shaft Oil distributor complete Tube

32

Upper knife Gasket Upper looper holder assembly Lower looper holder assembly Lower looper holder Block Main feed bar Lever Connection Holder Looper holder Spring Wopm Thread take up

Thread eyelet Thread eyelet Thread eyelet Thread retiner Tread guard connection Thread guide

Thread take up Thread guide Thread guide Thread guide Thread guide Thread guide Thread guide[right] Needle guide Flat knife Needle guard

SPARE PARTS

PR-SEWING

33

Shop floor.. 

Currently 5 lines in working out of 6.



Line feeder will feed line.

Reports to/from PR 

Cut plan report from Cutting department.



Feeding report.



Production Planning control report.

Target 2340 pieces/9hour

Current Situation 

Total number of workers is 110 + 4 supervisors + 1 Line manager + 9 Quality checkers + 1 Line feeder + 1 Score lady in each line. Total of 126 workers in a line.



126 * 5 = 630 total in a PR.



Average production Target in a line = 250 pieces/hr. Total of 2340 pieces in day 34

PR-SEWING

Operation Bulletin

OPERATION BULLETIN LSS (levis signature).xls

35

PR-SEWING

PG-SEWING

36

Shop floor.. 

Current three sewing lines out of 6 in working



Got three bulletins of garment with SMV.



Line efficiency in each line is studied.

Target Efficiency = 80% 

Formula:



Front = (present front manpower * 60 *9) / (front Total SMV * 85%)



Back = (present back manpower * 60 *9) / (back Total SMV * 85%)



Assembly = (present Assembly manpower * 60 *9) / (Assembly Total SMV * 85%)



Line Target= (present line manpower * 60 *9) / (Line Total SMV * 85%)



Line balancing is observed as per the availability of manpower and work.

37

PG-SEWING

Bonus calculation SL No.

Efficiency (%)

Workers (R)

1 2 3 4

80-90 91-100 101-110 111 and above

10 15 18 21

SL No. 1 2 3 4

38

Efficiency (%) 80-90 91-100 101-110 111 and above

Supervisor (R) 25 35 45 55

Line Manager (R) 50 60 70 80

PG-SEWING

Continuous.. 





In pre-production, all management will group together for the new garment. It includes the rate for all kinds of utilization include threads, manpower, electricity, space, machine etc. and will go for sample production. Product safety is very important in quality check. There should not be any harmful material or sharp edge parts are in the garment. Quality persons have to do thorough check up regarding this issue. Operation Bulletin is attached.

39

PG-SEWING

INDUSTRIAL ENGINEER

40

General Ideas.. 

Standard Minute Value: The taken for completing an operation. It also called as cycle time.



Machine Capacity: The maximum number of products that a machine can perform during an hourly based production



Thread Consumption: Done thread consumption practical study with the help of a Jeans (Denizen)



Production Efficiency in each operation /section



Total Number of workers in IE Department Bonus calculator-1, IE clerk-1, Score ladies-6. Total of 8 workers.



General Production Issue • Mainly thread wastage. • Loop wastage. • Time delay between operations. • Waiting for successive operation. • Line is not balanced

41

INDUSTRIAL ENGINEER

Thread Consumption example

thread consumption.pdf

42

INDUSTRIAL ENGINEER

DRY PROCESS

43

Operation SORTING

MARKING FRONT

MARKING BACK

TURNING 1st

TURNING 2nd

BLOWING

TRIMMING

WHISKER Target Maximum 10,000 pieces per day

HAND SAND

WASHING

CHEVERON

GRINDERS

44

P.P.SPRAY

DRY PROCESS

Availability 

 

 

Currently having 106 machines in working. Having 6 grinding machines. Having 15 P.P.Spray machines. Two blowing machine Two Turning machine

P.P.Spray

Whisker pattern 45

Whisker area

Chevron Area DRY PROCESS

Manpower SL.NO.

OPERATION

MANPOWER

TARGET

METHOD

1

Sorting

3

-

Checking size/Inseam and grouping

2

Marking Front

6

150

Vary from size

3 4

Marking Back Turning 1st

3 2

300 -

Vary from size

5

Trimming

3

120

Using Turning machine Removing excess threads

6

Blowing

2

-

Vacuum machine to remove threads

7

Turning 2nd

2

-

Using Turning machine

8 9 10

Whisker Chevron Grinding

10 7 4

20 50

Using Mould whisker will make

11

Crinkle

-

-

12

Hand sand

58

50

13

P.P.Spray

11

45

Supervisor PPC Score Lady

1 3

Score Lady whisker

2

Supervisor Whisker QC Table Trolley Boy

1 6 1

TOTAL

125

46

Marking in near knee Using grinders Using resin with Owen in 140 degree Celsius for 15 minutes. Using sand paper with hand sand machine in horizontal Using KMnO4 (300gm/10litre water) for making lighter the color.

DRY PROCESS

Safety Equipments 

Mask

Sand Paper Types



Finger guards

P-60 – Lighter



Ear plug



Gloves for PP spray

P-240- More delegate



Overall gown



Two filter respirator

P-150- standard P-400- Sheet paper type

Fig: Sand paper

Inventories Role Rubber 300 pieces tug 3kg of resin 4 roll of sandpaper for each day

47

DRY PROCESS

Quality checking

48

DRY PROCESS

Time study SL.NO.

OPERATION

1 2 3 4 5 6 7 8 9 10 10 11 12 13

Sorting Marking Front Marking Back Turning Trimming Blowing Whisker Marking Whisker Chevron Marking Chevron Grinding- Bottom Grinding- pocket Hand sand (31 * 32) P.P.Spray

49

TIME STUDY (sec/piece) 20.1 9.8 6.3 35.9 12 12.55 70 33.8 65 28.2 45 153 560 DRY PROCESS

Causes for Defects in garment – Preliminary view 

Production Rate increase



New workers recruit Not having Job rotation

 

Mentality setup

50

DRY PROCESS

WASHING

51

Shop Floor.. 

Machine availability Sl.No

Machine

Number

1

Washing Machine 800 P=25,

Workers

Target 23000 pieces /24 hr

700 P=11

52

2

Hydro Extractors

3 Total

Dryer

200 P=1 10+2 26 75

200 (full fledge)

WASHING

Current State Sl.No Operation

count

Maximum Capacity per machine 33 pieces at a time

1

Tumble dryer

40 pieces,80 degree, 30 minutes maximum

2

Hydro Extractors

100 pieces, 30-45 minutes

35kg

3

Washing

23000-25000

147kg per loading

capacity

pieces/24 hour

(40% of 800 pounds)

53

WASHING

General Ideas.. 

The washing Head will get the Washing plan for each day. Mostly it varies from each day to day. The washing plan is as per PPC chart



Weighing of garment is very important:



Liquid ratio 1Kg/10 Liter.



Chemical and dye depend on weight of garment.



Consistency



Ideal loading of machine is 40% of total capacity of machine. (100-120kg)

54

WASHING

Operation Procedure 

PPC- Involved with operator, weighing and counting of garment.



Loading- Inside the machine. 1.Proper way-(creak mark to avoid) 2.Rotation of machine should be balance in and out and vice versa. 3.Rotation of drum- 28-30 revolution/minute



Desizing : sizing denim- starch reduction Test 1: Iodine Test





Alpha-Amylase (not reacts with fiber, react with starch).

 

Temperature- 60 degree. Oscillation with lubricant Reducing friction. Tungle of garment will reduce.



Anti-black strain- 0.25%, 0.1%, 0.5% (if good).



Anti cleaning- 1%

Enzyme or stoning process 1.Enzyme is effective at 35-40 degree Celsius. Ideal effect at 50 degree Celsius. 2.Concentration 1kg for 100Kg garment i.e. 0.1%. 55

WASHING

CHEMICAL STORE

56

Chemical Names.. Sl.No

CHEMICAL NAME

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 57 33

Maxiclean Caustic soda Cellex (50) Indilite (50) Aqua Persulphate Denclean Denlube Oxalic acid Acetic acid Thiosulphate X-brite Salt Pretex P.permaganet Exclore Garmensoft Indisoft Soda-ash Bleach (25) Bleach (45) Bleach (50) Nanotin Peires cat Orange Brown 8rl Black Violet Brown Brr Brown Gxl Brown Bl Indigo Stone

1. Chemical utilization will update each day as per the consumption in washing department. 2. Chemicals are mainly from India and south Africa. 3. New arrivals are checked properly and handled with safety precautions.

DISPATCH

58

Operation

Cut Loop

Trimming

Final QC

Blowing

Rivets

Buttons

Repair

Size Label

Check Shade

Waist Tag

Folding

Pairing

Scan Pack

Checking Rivets & Buttons

Measurement

Pressing

Loading

TARGET/SHIFT 10K-21K

59

DISPATCH

Current Scenario

C:\Documents and Settings\VishnuCGM\Desktop\CAPACITY STUDY DISPATCH.xls

60

DISPATCH

Continuous… 

Solid pack

The pack consists of 6 pieces or 20 pieces accordingly as per buyer’s requirement. 

Scan Pack

Check size, check quantity, Scan UVM barcode and enter the P-style and count the garment. 

Loading plan From import/Export department Loading Memo will get. It contains container info, Security check etc. Arrange as per the memo and seal the container with shipping seal. And will get confirmation from shipping department.



Final Audit Check the size, waist length, rivet position and button strength.



General Production Issues



Repairs



Accessory lag.



Rivet problems



Machine problems

Unnecessary Motion



Human error

Improper Feeding

61

Workers are lazy Waiting for previous Operator

DISPATCH

QUALITY

62

General Ideas Quality Analysis [QA] - Preventive maintenance, Root cause Analysis, Corrective Action plan  Quality Control [QC] - 100% check on daily basis.  Rolling QC: Randomly checking in bundles in Sewing line  Station QC: 100% checking  End line QC: Assembled final check 

63

QUALITY

AQL- Acceptable Quality Level 

Acceptable quality Level: In general cases the buyer will determine which sampling plan and what AQL to adopt. The AQL 1.5 is applied when severe inspection conditions are required on high-class expensive items. The AQL 2.5 is applied when textiles of normal/good quality are involved. There are three types of sampling plans: i.e. single, double and multiple sampling plans. Each sampling plan can be performed at three levels, i.e. normal, tightened and reduced, depending on inspection requirements and quality of the products. In the garments industry generally single and double normal sampling plans are applied. 64

QUALITY

4-Point system-American StandardLevis  

 





1-point 2-point 3-point 4-point

: Defect less than 3 : Defects exceeding 3” up to 6” : Defect exceeding 6” up to 9” : Defect exceeding 9”

Point/100 sq.yard = (Total point * 36” * 100) / (sample yards * cuttable roll width). If it exceeds 15 the fabric will get rejected.

65

QUALITY

General points.. Internal PP Meeting Arrange with Merchandiser, all department head, and factory Manager to review PP sample. Conclude to one decision for buyer’s requirement with technical support.

Inspection Issues in Fabric store 66

Levi’s Standard QUALITY

General points.. Final Audit •Internal audit will take care by QA. •Carton Marking •Pocket accuracy •Shade checking •Measurement

Fig 1:Metal Detector

Fig 2: Pull Test Machine

Product Safety Check all safety levels in garments. Especially metallic safety. Check needle presence. And rivet and button strength. Having Metal detector and pull test machine.

67

QUALITY

REJECT STORE

68

General points.. 

 

All garments that all categories as not as per buyers requirement will taken to reject store. In reject store separation of garment will take place. It will divide into A, B, C, and D categories.

69

REJECT STORE

General points.. Category

A

B

Specification Good Garments of leftover Good Garments of overrun Good Garments from PP Sample with non conformity, washing , construction or measurement Good Garments without of shade band Good garments with wrong pocket placements Shading within the garment Fabric flaws Small stains within 1" diameter area and not more than 3 points

Sewing defects mainly at waist band and HEM area C D 70

Small hole noticeable at hemming or waistband, big stains Damage but still wearable (fix) Big Holes and Bursting but still wearable (fix) REJECT STORE

COMPLIANCE AND SAFETY

71

Safety Equipment List Equipment

Replacement

Fire Extinguisher

6 months

Safety goggles

12 months

Safety gloves

Apron

12 Months

 

Safety Shoes Winter Jacket



Emergency Alarm



Safety Mask

1 Month

Ear Muffs

12 months

Having Safety Marking with different colours in shop floor. Fire and safety training in each 3 months. Safety Inspection in regular time. Drinking water is allotted in regular places by the government

Safety Gown

72

COMPLIANCE AND SAFETY

Snaps…

73

COMPLIANCE AND SAFETY

PERSONAL WAGES

74

General Ideas.. 

Total of 9hour in a day. 45hr/week. 195hr/month.



Regular basic wage is R 3.99/hr. R 1.25/hr for overtime.



DDPI- Directorate of dispute Prevention and Resolution will discuss about Dismissal problems.



After three warning labour will call for DDPI for further questioning with an representative called as shop steward.



DDPI will send the labour to Labour Court for final decision.



Union FAWU, UNITE.



Contract Casuals: 3months, 2months, 1month etc.



Probation 3 months.



Benefits: Bonus + Sick leave-12 days/ year with salary. If more than 12days half the salary will get cut. Clinic 3 days. Personal leave end of year 12 days paid. Maternity leave-2 weeks.



Direct Dismissal: Stealing, Assault, Fraud, Damaging Company property, Fighting.

75

PERSONAL WAGES

Continuous.. 

Direct Dismissal: Stealing, Assault, Fraud, Damaging Company property, Fighting.



Notice Period: 1 week for 6month experience. 2 weeks for above 6 months, 1 month for 1 year and above.



Termination for poor performance: 1 month notice period.



In public holiday if the worker is present for a work means double the payment.



Education Leave only when the company is allowed.



Minimum age limit is 18.



Accident Insurance as per workmen’s Compensation Act.

76

Experience

Rand

Unskilled

3.99

Trained

4.3

Exp >1

4.76

PERSONAL WAGES

WAGES

77

General Procedures.. 

Contract Period: Daily, Weekly, Biweekly, and Monthly.



Temporary contract for 3 months. Casual labour will get permanent if she/he working more than three months in the company. Passport is necessary to sign the contract.



After three month contract the same person can come to company as a casual labour after a period of one month.



Contract

Wage (R)

Contract

Colour of paper

Daily

4.55

1 year

white

Weekly

4.31

2 year

Blue

Biweekly

4.31

3 year

Yellow

Monthly

3.99

ID cards will provide in the evening of date Joined with photo in lamination. 78

WAGES

Wages per day Usual Days (R 3.99 as rate) Time Rate(Rand)/hour Total 7:00- 17:00 9*3.99 35.91 17.00-19:00

2*3.99*1.25

9.975

19:00-21:00

2*3.99*1.31

10.4538

Night shift 19:00-5:00

9*2.06*3.99

Saturday and Sunday 7:00-15:00 7*2*3.99

79

73.9746

55.86

WAGES

Discharge 

3 days continuous absent:- Immediate Termination.



Greater than 1 year experience:- 90hr severance.



Greater than 6 month:- 12 days leave



Increment