Bata Shoe Organization Term Paper 2011

7/22/2019 Bata Shoe Organization Term Paper 2011

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TERM PAPER

OFOPERATION MANAGEMENT

TOPIC,

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INDEX

1. INTRODUCTION

". PRO#$CT RANGE

%. TRANSFORMATIONA& PROCESS 'I( INP$TS,O$TP$TS AN# PROCESSFO&&O)E# IN CON'ERSION

*. FACI&IT+ &A+O$T

. FACI&IT+ &OCATION

-. PRO#$CTION P&ANNING S+STEM 'I( CAPACIT+ P&ANNING OPERATIONMANAGEMENT SE#$&ING ETC.

7. INVENTORY MANAGEMENT

8. MODEL OF SUPPLY CHAIN MANAGEMENT BEING FOLLOWING


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BRIEF HISTORY OF THE COMPANY

The business that became the Bata Shoe Organization was established on August 24,

1894 in Zlin, zechoslo!a"ia b# Tomas Bata, and included his brother Antonin and

sister Anna$ Although this business was new, the Bata name had been %art o& a

tradition o& shoema"ing &or eight generations, s%anning three hundred #ears$

't was one o& the &irst modern da# shoe (manu&acturers) , a team o& snitchers and

shoema"ers creating &ootwear not *ust &or the local town , but also &or the distant retail

merchants$ This de%arture &rom the centuries old tradition o& the one man cobbler)s

wor"sho% was a brand new conce%t, creating an entirel# new industr#$

The Bata enter%rise re!olutionized the treatment o& em%lo#ees and labor conditions$

Tomas consistentl# maintained a human &ocus, creating o%%ortunities &or de!elo%ment

and ad!ancement, and added com%ensation &or em%lo#ees based on achie!ement$

'n late 198+$ Antonin was dra&ted into the arm# &or com%ulsor# militar# ser!ice and li&t

&amil# shoe business$ Also that #ear, Anna le&t the com%an# to marr#, lea!ing a #oung

Tomas to build the business on his own$

B# 19+ Tomas had ta"en the new enter%rise to 22 %airs o& shoes %er da# , %roduced

b# 2+ em%lo#ees - utilizing resource&ul imaginations , s"illed hands and modern

machiner# to "ee% u% with demand$ .nder this (manu&acturing) s#stem, %roducti!it# was

greater than e!en be&ore$

Bata shoes were e/cellent 0ualit# and a!ailable in more st#les than had been o&&ered

be&ore$ emand grew ra%idl# in the earl# 19s$ es%ite material and man%ower

shortages, cartel and the outbrea" o& orld ar 1, sales continued to increase,

reaching two million %airs %er #ear b# 1913$

As the enter%rise %ros%ered, so did the communities where it o%erated, Tomas belie!ed

that a &ocus on %eo%le and %ublic ser!ice was critical &or business success$ The

enter%rise built housing, schools and a hos%ital near the shoema"ing %lant in Zlin$ 't


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%ro!ided &ood and ine/%ensi!e rent during !er# di&&icult times when there was no hel%

to be &ound$ Bata com%anies alter %ro!ided rail ser!ices, construction, insurance,

%ublishing and tanner# in Zlin$

5ollowing orld ar 1, consumer %urchasing %ower was !er# low Tomas and his

em%lo#ees de!ised a %lan to ad*ust to %ost6war economic di&&iculties and reduced theirshoe %rices$ Bata stores were &looded with bu#ers and industr# c#nics were &orced to

&ollow their lead$

Alread# e/%orting to other 7uro%ean countries, orthern A&rica and the .SA, the

enter%rise began establishing new sales organizations in these mar"ets during the

192s$ om%anies were o%ened in oland, :ugosla!ia, ;olland, enmar", .nited


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more li&est#le6oriented, which has hel%ed change consumer %erce%tions to a largee/tent$

Bata India - Today Sells oer * million pairs o/ /ootwear eer0 0ear Seres oer 1"2,222 !3stomers eer0 da0

Sells t4ro354 oer 1"22 retail stores Operates man3/a!t3rin5 /a!ilities Emplo0s more t4an -622 people

BATAS BUSINESS UNITS

Bata Europe, @ausanne Bata Asia Pacific-Africa, Singa%ore Bata ati! A"erica, e/ico Bata Nort# A"erica, Toronto

Bata is one o& the world leading &ootwear retailer and manu&acturer with o%erations

across + continents managed b# 4 regional meaning&ul business units CB.sD$ The

B. a%%roach %ro!ides 0ualit# resources and su%%ort in "e# areas to the com%anies

o%erating in similar mar"ets such as %roduct de!elo%ment, sourcing or mar"eting

su%%ort$ 7ach B. is entre%reneurial in nature, and can 0uic"l# ada%t to changes in

the mar"et %lace and seize %otential growth o%%ortunities$

BataFs strength lies in its worldwide %resence$ hile local com%anies are sel&6go!erning,

each one bene&its &rom its lin" to the international organization &or bac"6o&&ice s#stems,%roduct inno!ations and sourcing$

Although Bata o%erates in a wide !ariet# o& mar"ets, climates and bu#ing %ower Bata

com%anies share the same leadershi% %oints$ Two im%ortant ones are %roduct conce%t

de!elo%ment and constant im%ro!ement o& business %rocesses in order to o&&er

customers great !alue and the best %ossible ser!ice$

$ISION

To grow as a d#namic, inno!ati!e and mar"et dri!en domestic manu&acturer and

distributor, with &ootwear as our core business, while maintaining a commitment to the

countr#, culture and en!ironment in which we o%erate


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MISSION

To be success&ul as the most d#namic, &le/ible and mar"et res%onsi!e organization,

with &ootwear as its core business

BATA BUSINESS

Bata shoe Organization com%anies are in!ol!ed in e!er# &ace o& the business o& shoes$

Throughout the world, Bata com%anies ser!ice customers &rom the store sales &loor to

the &actor# &loor$

PRODUCT RANGE

arie laire

;ush u%%ies

ower

Bubble Iummers

orth Star

Scholl

einbrenner

Prod3!t ran5e starts o/ Bata "778"*77. Bata start ran5e "77 to

lowest ran5e o/ s!4ool s4oe and 4i54est 9rands o/ power : ot4er

prod3!t. Bata prod3!t lowest to 4i54est ran5e aaila9le to

market.

Hus# Puppies % No& i! I!'ia

;ush u%%ies are a &amous shoe brand o& the .SA$ 't

is so &amous and %ioneering that it)s sometimes re&erred to as a legend$

This brand is owned and o%erated as a di!ision b# the ol!erine$$$
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Bata is &orst s#oe "a(er

Bata is the %eo%le who ma"e shoes &or high %rices but with low 0ualit#$ i

bought a %air o& sli%%ers &rom bata named Jcom&itJ &or Ks$ 349H6 on ma#

23$ it is not com%&ortable at all$ The sli%%er is made$$$

Poor )ua*it+ s#oes

' bought one %air o& leather shoes &rom Bata, ochin dealer near adma

*unction one #ear be&ore$ The %roduct was &ormal shoes with laces$ The

shoes cost 'K 1499 &or me$

Bata is &orst s#oe "a(er

Bata is the %eo%le who ma"e shoes &or high %rices but with low 0ualit#$ i

bought a %air o& sli%%ers &rom bata named Jcom&itJ &or Ks$ 349H6 on ma#

23$

Hi,# Price Poorest ua*it+

' *ust ha%%ened to bu# Bata shoes a wee" bac"$ The item ' bought was

ob!iousl# o!er%riced, but going b# the name bata ' bought it at 499$ ithin

a wee"s) usage, the shoe sole was %artiall# ri%%ed o&&L

.TRANSFORMATIONA PROCESS $I/ INPUTS OUTPUTS AN0

PROCESS FOO1E0 IN CON$ERSION.
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'n order to handle the increasing com%le/it# o& distributed industrial manu&acturings#stems, there is a strong demand &or methods and tools that su%%ort the designer in

the anal#sis and o%timisation o& &le/ible in&rastructures &or the automation o& %roduction%rocesses$ e are currentl# in!estigating how emerging standards and ad!ancedsimulation techni0ues can be e/%loited success&ull# in the %roduction o& custom madeshoes$

owada#s, man# di&&erent a%%roaches, methodologies and com%uter aided design toolscan be em%lo#ed in the anal#sis and o%timization o& com%le/ industrial s#stems$ As aconse0uence, the selection o& the most a%%ro%riate techni0ues and tools &or a %articulars#stem is critical$ Be&ore ma"ing an# &inal decision, it is necessar# to in!estigate the&unctionalities o&&ered, com%lianc# with e/isting standards, and ca%acit# &orintero%erabilit# with non6%ro%rietar# instruments$ e are currentl# wor"ing on a

methodological a%%roach to the structured design and simulation6based anal#sis ando%timisation o& manu&acturing %lants$ The methods and tools used during the di&&erent%hases o& the design are illustrated with re&erence to an a%%lication in the shoemanu&acturing sector$ 'n %articular, we describe an inno!ati!e %lant &or the %roduction o&customized shoes$ This %lant is located at the 'T'A6K laborator# in ige!ano C'tal#Dand constitutes the %ilot %lant o& a large 7uro%ean research %ro*ect called 7.KOShoe,which began in arch 21 and is scheduled to &inish in Eune 24$


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Figure 1: The InnovativeShoe Manufacturing Plant

7.KO Shoe is a com%le/ and ambitious %ro*ect with thirt#6&i!e academic and industrial%artners &rom ten di&&erent 7uro%ean countries$ 't aims at a dramatic reno!ation o& theconce%t o& shoes as %roducts and o& their %roduction, based on a trans&ormation &rommass6%roduced to mass6customised goods$ This %roduct e!olution goes in %arallel witha trans&ormation o& &ootwear com%anies into distributed and &le/ible enter%rises ca%ableo& handling the com%le/it# that such a radical change in the nature o& the %roductim%lies and o& mastering the associated new technological challenges$ This im%lies acom%lete re!ision not onl# o& the entire manu&acturing %rocess but also o& the tools usedto anal#se and o%timize the resulting inno!ati!e industrial s#stem$

5or the sa"e o& bre!it#, the methods and tools used &or the design, anal#sis ando%timization o& the %lant automation s#stem are outlined with re&erence to the controland su%er!ision o& the trans%ort line$ 'n the shoe manu&acturing %lant that we considerC5igure 1D, an inno!ati!e trans%ort line is used to mo!e the semi6&inished shoes &romone machining station to another according to a %rede&ined o%erating schedule$ 'n%articular, the inno!ati!e molecular structure o& the trans%ort line C5igure 2D strongl#enhances the modularit#, scalabilit#, integrabilit# and recon&igurabilit# o& the %roductions#stem, thus increasing the o!erall &le/ibilit# o& the %lant$


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Figure 2: Layout of the Shoe Plant (left) and ISaGRF Si!ulation Gra"hicalInterface (right)#

At the beginning o& the design li&e c#cle, the control and su%er!ision s#stem o& thetrans%ort line was s%eci&ied b# means o& .@ C.ni&ied odelling @anguageD diagrams

in %articular use6case, class, se0uence and state diagrams were used to s%eci thes#stems modules, their relationshi%s and their d#namic beha!iour$ The s#stemarchitecture and &unctions were designed using the 5unction Bloc" &ormalism de&ined b#the '7 M1499 standard, which integrates ob*ect6oriented conce%ts and discrete e!entmodels to suitabl# su%%ort control so&tware design$ The &unctional model obtained wasanal#sed and o%timized b# means o& closed6loo% discrete e!ent simulations %er&ormedin the Simulin"HState&low en!ironment, where both the controller and the controlled%rocess were modeled and simulated through state charts, as was the beha!iour o& theo!erall s#stem$ 'n this wa#, the correctness and %er&ormance o& the solution %ro%osedcould be e!aluated$ 'n %articular, a bottom u% methodolog# was de&ined and e/%loited tostud# the s#stem according to a modular a%%roach$ This enabled us to sim%li the

o!erall anal#sis %rocess, to !eri the correctness o& the automation &unctionalities easil#and to o%timize the s#stem %er&ormance &rom the !er# &irst %hases o& the design li&ec#cle$ Once the &unctional modules had been !eri&ied, the control and su%er!isionalgorithms were de!elo%ed using the S5 CSe0uential 5unctional hartD &ormalism,which is an ad!anced discrete e!ent modelling gra%hical language, directl# deri!ed &rometri nets, and included in the '7 M11=1 %art = standard, which de&ines %rogramminglanguages &or industrial @s Crogrammable @ogic ontrollersD$ The S5 algorithmswere anal#sed through closed loo% discrete simulations in the 'SaIKA5 en!ironment inorder to !eri their correctness and to o%timize their %er&ormance$ 'SaIKA5 is aAS Com%uter Aided ontrol S#stem esignD tool that allows the automationso&tware to be structured using all &i!e '7 M11=1 languages and su%%orts simulation

&unctionalities &or testing %ur%oses, as well as automatic code generation &acilities &ordi&&erent industrial s#stems$ 'n order to %er&orm the closed loo% simulations, sim%li&iedmodels o& the %lant de!ices ha!e been re%resented in 'SaIKA5 b# means o& suitableS5 modules and data structures$ oreo!er, to sim%li the anal#sis o& the simulationresults, a sim%le 2 gra%hic animation was realized in 'SaIKA5 C5igure 2D$ Simulationsha!e been %er&ormed b# considering t#%ical o%erating conditions, ie, t#%ical %roductionorders, and the results obtained show that the s#stem is deadloc" &ree and that the%lant is well balanced, ie its resources are all used e&&ecti!el#$ A&ter !eri&ication ando%timization o& the automation &unctions and algorithms, the corres%onding code wasgenerated and im%lemented on the target industrial de!ices$ e &ound that thesimulation6based anal#sis techni0ues reduced the %lant rum%6u% times and costs andim%ro!ed o!erall s#stem %er&ormance$ 5uture wor" will concern the e/%loitation o& thestandards, methods and tools %ro%osed &or other industrial %lants and their integrationwithin an ad!anced AS tool &or manu&acturing s#stems


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MANUFACTURIN2

Tomas Bata)s re!olutionar# business conce%t was to industrialize the shoema"ing

%rocess o& that da#$ That t#%e o& thin"ing has been the dri!ing &orce behind the Bata

Shoe Organization success$

The Bata Shoe Organization has been as inno!ator in the manu&acturing o& shoes o!er

the #ears$ Bata %ersonnel ha!e made im%ortant ad!ances in Cirect ulcanization

rocessD, , athletic &ootwear %roduction and slush - molded &ootwear %roduction$

1. Raw Material Stock

T4e raw material w4i!4 in!l3des t4e !4emi!als 3sed /or makin5 !ement

ad4esie,r399er late; and sole


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T4e !ement ad4esie and r399er late; are t4e main !4emi!als 3sed to paste

to5et4er t4e di//erent part o/ a s4oe, are man3/a!t3red in t4e plant itsel/.

Bot4 t4ese materials are prod3!ed keepin5 in mind t4e e;a!t re3irements

and also t4e !orre!t spe!i/i!ation, w4i!4 is t4e ri54t mi; o/ !4emi!als to

make it t4e 9est pastin5 element and 5et t4e desired 3alit0.

1. Sole Pull Manufacturing:

The inner an !"#er $h!e re%"ire in #he $h!e are a&$! 'r!"(e in)h!"$e. H"*e r"++er$hee#$ ,ea$"rin* -#./0#. ha1in* a #hi(2ne$$ ! a''r!/. 0 (,$. are ir$# hea#e #! hi*h

#e,'era#"re an #hen '&a(e in a ("rin* (ha,+er !r 8 ,in"#e$ 3here #he4 are a*ain

'r!(e$$e a# hi*h #e,'era#"re ! ar!"n 576!C. A# $"(h a hi*h #e,'era#"re #he $hee#$e/'an an #hen $en# !r 1"&(ania#i!n 3here i# i$ 'r!(e$$e !r - hr$. #! $e# #he

$hrin2in* &i,i# ! r"++er. The$e $hee#$ (an +e ("# !n&4 a#er #3! 3ee2$ ! 1"&(ania#i!n.

Thi$ i$ 2n!3n a$ $ea#in* 'r!(e$$.

2. Making Binding:

A +inin* i$ re%"ire !n #he !"#er ! #he $h!e #! +in #he e*e$ ! (&!#h "''er. Thi$+inin* ,a#eria& i$ a&$! ,ae 3i#hin #he '&an# "$in* (&!#h. I# i$ ,a(hne $#i#(he !n#! #he

(&!#h "''er.

3. Folding, Cutting And Staming:

The (&!#h #ha# !r,$ #he $h!e "''er i$ 'r!"(e r!, B!,+a4 D4ein*. I# i$ ir$# !&e

in#! h"*e &!#$ an #hen ("# in#! 'ie(e$ ! "ni!r, $ie$ a((!rin* #! #he ieren# $ie

&!#$.The$e (&!#h 'ie(e$ are #hen $#a,'e 3i#h 3ha# ,a4 +e (a&&e a +a#(h n",+er an #he

$h!e $ie. An e/a,'&e ! a +a#(h n",+er ,a4 +e 9F)-058:00;. In #hi$ (!e F re're$en#$'&an# (!e ! #he Faria+a a(#!r4 -05 i$ #he (!e ! #he 'ar#i("&ar 3!r2$#a#i!n an

a$$e,+&4 &ine 8 re're$en#$ #he 4ear ! ,an"a(#"rin* :0 #he 3ee2 an 0 $i*niie$ #he a4

! #he 3ee2 in 3hi(h 'r!"(#i!n ha$ +een !ne.Thi$ $#a,'in* 'ar#i("&ar&4 he&'$ i #herei$ a ee(# !"n !"# in #he $h!e a#er $a&e. A#er $#a,'in* i$ !ne #he "''er i$ $en# !r

$#i#i(hin*.


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:. Stitc!ing 'r!(e$$ $#ra#e*4?(. @"a&i#4 ! 3!r2 &ie >h",an re$!"r(e $#ra#e*4?. B"i&in* an $i#e (!n$#rain#$ >&!(a#i!n $#ra#e*4?

Ba"ic la$out form":a. Pr!(e$$ La4!"#

+. Pr!"(# La4!"#

(. C!,+ina#i!n La4!"#. Fi/e '!$i#i!n La4!"#


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Fi*ed+Po"ition la$outIn i/e)'!$i#i!n &a4!"#$ #he i#e, +ein* 3!r2e !n re,ain$

$#a#i!nar4 an 3!r2er$ ,a#eria&$ an e%"i',en# are ,!1e a$

neee. Fi/e)'!$i#i!n &a4!"#$ are 3ie&4 "$e !r ar,in*

irei*h#in* r!a +"i&in* h!,e +"i&in* re,!e&in* an

re'air an ri&&in* !r !i&+"i&in*$ $hi'$ air(ra#$.

Factor" in etermining &a$out and e"ign:

S,a&& +"$ine$$ !3ner$ nee #! (!n$ier ,an4 !'era#i!na& a(#!r$ 3hen

+"i&in* !r ren!1a#in* a a(i&i#4 !r ,a/i,", &a4!"# ee(#i1ene$$. The$e

(ri#eria in(&"e #he !&&!3in*$in*&e)'r!"(#?'r!"(#i!n ra#e$.

0. Flow of mo)ementThe a(i&i#4 e$i*n $h!"& re&e(# a

re(!*ni#i!n ! #he i,'!r#an(e ! $,!!#h 'r!(e$$ &!3. In #he (a$e !

a(#!r4 a(i&i#ie$ #he '&an 3i&& $h!3 #he ra3 ,a#eria&$ en#erin* 4!"r

'&an# a# !ne en an #he ini$he 'r!"(# e,er*in* a# #he !#her. The&!3 nee n!# +e a $#rai*h# &ine. Para&&e& &!3$ U)$ha'e 'a##ern$ !r

e1en a i*)a* #ha# en$ "' 3i#h #he ini$he 'r!"(# +a(2 a# #he

$hi''in* an re(ei1in* +a4$ (an +e "n(#i!na&. H!3e1er +a(2#ra(2in*

i$ #! +e a1!ie in 3ha#e1er 'a##ern i$ (h!$en. When 'ar#$ an

,a#eria&$ ,!1e a*ain$# !r a(r!$$ #he !1era&& &!3 'er$!nne& an 'a'er3!r2 +e(!,e (!n"$e 'ar#$ +e(!,e &!$# an #he a##ain,en# !

(!!rina#i!n +e(!,e$(!,'&i(a#e.

-. Material" !andling S,a&& +"$ine$$ !3ner$ $h!"& ,a2e (er#ain

#ha# #he a(i&i#4 &a4!"# ,a2e$ i# '!$$i+&e #! han&e ,a#eria&$ >'r!"(#$

e%"i',en# (!n#ainer$ e#(.? In an !rer&4 ei(ien#an 'reera+&4 $i,'&e

,anner.

%ACILIT& LOCATION

ontact erson$ Address, Bata;ouse - 418H2, Iurgaon ahrauli Koad, Sector 13$ Iurgaon1222$

Haryana$ it#, Iurgaon$ State, Haryana$ hone, 124 4121

1$Bata agar 5actor# Batanagar, estBengal


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2$ Kubber urchasing e%t$


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Bata roduction i!ision is going e/tra miles to meet e!er growing %roduction

re0uirements o& . direct %ouring and other &ootwear to cater the needs o& our

worth# customers$ uring the current season, the o!erall %roduction is going

12N against estimates and 1=N against last #ear$ Similarl# in the area o&

. direct %ouring, 12=N %roduction has been achie!ed against the estimates

and 24N against last #ear$

This milestone in %roduction has been a result o& restructuring o& ara"a and

Kubber 5actories$ A better %roduction %lanning, ma/imum utilization o& human

resources and teamwor" - all ha!e been %ut together strategicall# to achie!e

com%etiti!e ad!antage in >Bata? %roducts o!er the com%etition in the area o&

0ualit#, %rices and sales a%%eal

PROCESS OF PANIN2 OPERATION SYSTEM3

Their %rocess consists o& three %arts$

Ma!ufacturi!,

'n manu&acturing are, all the raw materials are brought together and the raw material is

cut into the sha%es o& the re0uired %roducts$ All the %ieces are cut here &or the s%eci&ic

%roducts$

Stitc#i!,

The cut %ieces o& raw material are stitched here together to gi!e the sha%e o& the shoe$

The sole is also attached to the u%%er %ortion o& the shoe and all the %ieces are *oined

together to gi!e it the sha%e o& shoe$

Fi!is#i!,

The %roduct is then mo!ed to &inishing de%artment where the rough loo" o& shoe is

con!erted in to a &inished %roduct$ The shoe is %olished, cleaned and all the unwanted

materials are remo!ed &rom it to gi!e it a %ro%er sha%e$ The color and shine o& theshoes are &inalized here and the %roduct coming out o& this de%artment is read# &or use$


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Retre!c#"e!t 4Firi!,5

As we "now that Bata is a biggest &irm around us and the# hire the %erson who ha!e the

s"ills and abilit# to do wor" &or a long time $The# mainl# &ire %eo%le on the serious reacho& agreement, misconduct, %unctualit# and u%on not achie!ing their gi!en targets and

once the management has decided to &ire a %erson the# gi!e one month %rior notice to

the res%ecti!e em%lo#ee and once the em%lo#ee is &ired can ne!er be hired again$

oreo!er the# do not conduct an# e/it inter!iew$ The# do not belie!e in e/tending the

out%lacement &acilit# to their em%lo#ees$

UAITY SYSTEM3

A! i"porta!t c#oice

A choice o& more than =, itemsG &ootwear, clothing, bags and accessories, &or

men, women, children and s%orts$

A 6er+ perso!a* ser6ice

Their %ro&essional s%ecialized sta&& is there to hel% #ou ma"e the best choice

Pro'uct prese!tatio!

All the items are clearl# mar"ed with the %rice, size and descri%tion o& the materials

used to ma"e the %roduct, thus sa!ing #ou time and ma"ing #our choice easier$

Your purc#ase is ,uara!tee'

:ou ha!e the guarantee to re%lace the %urchased item i& it is still intact and

accom%anied b# the till recei%t$

IN$ENTORY MANA2EMENT


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S"+e(# ,a##er e/'er# an (!"r$e &eaer ean)Pa"& Wai$,an r!, #he E"r!'ean

Gr!"' 3i#h #he $"''!r# ! V&ai,ir S'e&a r!, Cen#ra& E"r!'e an A&ain Gr!e&&4

r!, S3i#er&an a(i&i#a#e #he E"r! Fa$# Tra(2 Mer(hani$in* ,!"&e in I#a&4 r!,

"ne -r #! 5=#h. 5: E"r!'ean 'ar#i(i'an#$ #!!2 'ar# in #he #rainin*.

The (!"r$e !+e(#i1e$ 3ere a$ !&&!3$

Bata Shoe Organization Term Paper 2011

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