Internship Report and Project Main_Apurv Pranav

8/12/2019 Internship Report and Project Main_Apurv Pranav

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CHAPTER 1

INTRODUCTION

APPAREL INTERNSHIP REPORT ON TEXPORT INDUSTRIES PVT. LTD. | APURV& PRANAV

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1.1 COMPANY OVERVIEW

1.1.1 Introduction:

Texport Industries Pri!te Li"ited #$or"er% Texport '!r"ents( is ! $u%%

seri)e *roup+ ,!sed in Indi!+ ,ui%t on ! p%!t$or" t-!t stries to !)-iee !

sner* t-!t )!nnot ,e )o"p!red to t-e rest+ t-us !%%o proidin* /u!%it

!pp!re%s+ or%dide. Str!te*i)!%% %o)!ted in 0u",!i+ !n*!%ore !nd Tirupur+

t-e 2o"p!n -!rness t-e ,est *eo*r!p-i)!% resour)es !!i%!,%e. TIPL+

! Underriters L!,or!tories )erti$ied ISO 344156444 )o"p!n is ! e%%78non

!nd reputed ,usiness -ouse $or its et-i)!% st!nd!rds !nd )o""it"ent.

2%ose% -e%d , t-e 'oen8! $!"i% sin)e its in)eption in 139:+ TIPL is one o$

t-e "ost e%%78non !nd reputed ,usiness -ouses in t-e *!r"ent industr+ inIndi! !s e%% !s in t-e Intern!tion!% "!r8ets. It is one o$ t-e $irst )o"p!nies in

Indi! to st!rt export oper!tions. ;non $or its /u!%it !nd )o""it"ent to

So)i!% Responsi,i%it+ it is ! pioneer in !%uin* -u"!n re%!tions-ips. TIPL

produ)es in ex)ess o$ 1.< "i%%ion *!r"ents ! "ont- #19 "i%%ion !nnu!%%( $ro"

nineteen dire)t% oned $!)i%ities.

TIPL=s re!% stren*t- %ies in its produ)tion+ produ)t dee%op"ent !nd Ne >or8

presen)e+ it- t-e )o"p!n=s "!n!*e"ent %!in* e"p-!sis on ?UALIT> !nd

PRODU2TIVIT>. T-e )o"p!n !%so -!s -i*-% s8i%%ed !sso)i!tes !nd tr!ined

personne% ensurin* ?UALIT> !t eer %ee%. A %ot o$ !ttention is *ien to

DETAIL. TIPL -ires t-e ,est in t-e industr !nd "!8e no )o"pro"ises -en

it )o"es to -u"!n resour)es. T-e 2o"p!n -!s s8i%%ed !nd te)-ni)!%%

/u!%i$ied personne% "!nnin* t-e "!)-ines !nd pro)esses.

1.1.2 Company:

TIPL is ! "!@or p%!er in t-e re!d"!de *!r"ent industr !)ross t-e *%o,e.

T-e 2o"p!n -!s ! -erit!*e o$ %e!ders-ip to -onour !nd presere.

A /ui)8 oerie5

In)orpor!ted in 139:+ ,!sed in Indi!.

One o$ Indi!=s %!r*est "!nu$!)turer exporter.

Annu!% reenue o$ USD :4 "i%%ion.

13 dire)t% oned+ $u%% e/uipped+ "odern+ "!nu$!)turin* $!)i%ities.


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T-e $!)i%ities !re en*ineered , t-e renoned ;urt S!%"on Asso)i!tes in

!sso)i!tion it- Te)-nop!8.

Spe)i!%iBes in "!nu$!)ture o$ 0ens Co"ens 2-i%dren tops !nd

,otto"s.

An ISO 344156444 )erti$i)!tion , Underriters L!,or!tories.

2!p!)it to produ)e !nd export 1. "i%%ion *!r"ents ! "ont-.

1+444 F e"p%oees.

444 F "!)-ines.

A $u%%7$%ed*ed in7-ouse desi*n te!" )re!tin* !nd dee%opin* ex)itin*

)o%%e)tions e!)- se!son.

Presen)e in N>2+ USA.

TIPL is ! "!@or p%!er in t-e re!d"!de *!r"ent industr !)ross t-e *%o,e

-!in* ! -erit!*e o$ %e!ders-ip to -onour !nd presere.

1.1.2.1 In House Facilities:

6 "!nu$!)turer !nd supp%ier o$ Hi7

G!s-ion !pp!re%s+ e",odin* t-us t-e spirit o$ )o""it"ent !nd -u"!nit.



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1.1.2.3 Mission:

De%ier on7ti"e+ eer ti"e.

An ee on produ)t /u!%it !nd inte*rit.

2o"p% it- t-e needs o$ t-e st!tutor re*u%!tor !ut-orit o$ indiidu!%

)%ients.

Hi*-est produ)tiit+ t-ere, o$$erin* ! )ost !d!nt!*e to !%% our )%ients.

1.1.2.4 Awards:

Texport -!s ,een re)o*niBed , t-e Indi!n 'oern"ent Aut-orities $or its

)ontri,ution to exports $ro" Indi!.

2usto"er Ad"ir!tions $or outst!ndin* per$or"!n)es !nd )re!tiit.

Re)o*nition $ro" N!tion!% Asso)i!tion o$ t-e %ind.

1.1.2.5 etailin!:

Texport is ! %e!din* p%!er in t-e re!d"!de *!r"ent industr !)ross t-e

*%o,e !nd -!s ! -erit!*e o$ %e!ders-ip to -onour !nd presere. Texport -!s !

pre"iu" %!,e% , t-e n!"e o$ ROERT 'RAHA0 !)ross t-e US !nd ot-er

intern!tion!% destin!tions !s e%%.



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1.1.3 "eoples and Values:

T-e ,i**est !sset o$ t-e 2o"p!n is t-eir peop%e. Texport '!r"ents is !

te!" o$ deoted pro$ession!%s -o t!8e pride in t-eir !))o"p%is-"ents. Cit-

t-e s!"e dedi)!ted te!" o$ 8e peop%e or8in* it- t-eir )usto"ers oer t-e

e!rs+ t-e -!e dee%oped ! )%ose p!rtners-ip )!terin* to t-eir spe)i$i)

needs.

Su))ess is seetest -en it is s-!redJ. T-e 2o"p!nKs su))ess !nd

re)o*nition is in p!rt due to t-eir p!ssion $or de%ierin* top /u!%it produ)ts

!nd seri)es to t-eir )usto"ers. T-e 2o"p!n e"p-!siBes er $ir"% on

te!"or8 !nd !re renoned !s ! $!ir ne*oti!tor.

T-e 2o"p!n is "ission drien !nd resu%t oriented+ !nd -en t-e pro"ise+

t-e de%ier. T-e !re 144 pro!)tie !nd /ui)8 to )!pture ne opportunities

in t-e "!r8et. At t-e s!"e ti"e+ t-e !re er !d!ptie !nd t-e "irror t-eoper!tions o$ t-eir )usto"ers to ,est $it t-eir indiidu!% re/uire"ents.

1.1.4 "roducts:

TIPL+ Unit714 "!in% $o)uses on 0enKs oen S-irt.

Produ)ts o$ ot-er units !re57

1. Tops . Po%os

6. Dress s-irts 9. Hoodies

. Deni" s-irts :. ;ids e!r


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1.1.5 In#rastructure:

T-e 2o"p!n is e%% e/uipped it- st!te o$ t-e !rt "!)-ines !nd

sop-isti)!ted te)-no%o* t-!t resu%t in $%!%ess produ)tion o$ /u!%it *!r"ents

!nd opti"iBe e$$i)ien).



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1.1.5.1 $uality Initiati%es:

An ISO 344156444 Underriters L!,or!tories In). )erti$ied )o"p!n+ t-e

)o""it"ent to /u!%it i"proe"ent+ tou)-es eer !spe)t o$ t-e produ)t+

seri)e !nd )usto"er support.

1.1.5.2 &ec'nolo!y Initiati%es:

A te)-no%o* drien )o"p!n+ t-e t!8e inno!tie te)-no%o* initi!ties to

o$$er $inest /u!%it *!r"ents to t-eir )%ients.

1.1.5.3 Compliant Facilities:

A%% t-e $!)i%ities )on$or" to )o"p%i!n)e nor"s o$ indiidu!% )usto"ers )oerin*

so)i!%+ et-i)!% !nd 27TPAT st!nd!rds.

1.1.5.4 Mac'ines:

Texport uses st!te o$ t-e !rt "!)-ines !nd t-e "ost !d!n)ed te)-no%o*ies

in its $!)tories.


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1.1.5.5 &rims:

Top )%!ss tri"s $ro" t-e $o%%oin* intern!tion!% ,r!nds.

1.1.( C):

T-e 2o"p!n re)o*niBes t-e di$$erent% )-!%%en*ed in t-eir e"p%o"ent

!nd *ie t-e" !n e/u!% opportunit to %e!d ! nor"!% %i$e

Gor t-is ende!or+ T-e 2o"p!n !s re)o*niBed , His Ex)e%%en)+ t-e

'oernor o$ t-e St!te o$ ;!rn!t!8!+ Indi!+ !nd !s !!rded on ,e-!%$ o$

t-e N!tion!% Asso)i!tion $or t-e %ind.

T-e 'oen8! $!"i% -!s $%o!ted t-e S"t. S-idei Deipr!s!d 'oen8!

Gound!tionJ -i)- )ondu)ts $ree "edi)!% )!"ps eer /u!rter ,ene$itin*

-undreds o$ p!tients -!in* !rious !i%"ents.

It !%so runs ! $ree -ospit!% !nd *ies "edi)!% tre!t"ent t-!t spe)i!%iBes in

)!t!r!)t oper!tions !nd ot-er !i%"ents. 0ore t-!n $ie t-ous!nd p!tients

-!e ,ene$ited t-us $!r.

T-e 2o"p!n is !%so !sso)i!ted it- t-e Rot!r D.'. 'oen8! %ood

!n8J+ -i)- runs ,%ood don!tion )!"ps eer e!r.

Vo)!tion!% Tr!inin* pro*r!"s !re )ondu)ted it- respe)t to t-e *!r"ent

industr.


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1.1.* +or, Culture:

At Texport+ t-e )-ie$ o,@e)tie is to nurture *rot- !t !%% %ee%s. T-e

2o"p!n stries to !ttr!)t+ or*!niB!tion!% !nd ,usiness *rot- t-rou*-

t!%ented+ en*!*ed !nd )o""itted e"p%oees. To !)-iee t-is t-e $o)us

on %e!rnin*+ )!reer dee%op"ent+ per$or"!n)e "!n!*e"ent+

)o"pens!tion !nd ,ene$its.

T-e 2o"p!nKs ro%e is to ensure t-!t Texport is ! true =%e!rnin* -!,it!t=+

-i)- *roo"s peop%e !nd t-eir t!%ents *iin* t-e" t-e s8i%%s t-e need to

ex)e%. Hen)e+ tr!inin* o$ personne% !t !%% %ee%s o$ or*!niB!tion is !n

essenti!% )o"ponent to !u*"ent. T-eir tr!inin* pro*r!"s !re !%%7per!sie

!nd !re stru)tured to -one t-e spe)i$i) s8i%%s o$ e!)- e"p%oee.

Gin!%%+ t-e 2o"p!n p%!s !n essenti!% ro%e in s-!pin* dee%op"ent

pro)esses t-!t -e%p peop%e !d!n)e t-eir )!reers !s $!r !nd !s $!st !s

t-e )!n. At Texport+ itKs !%% !,out peop%e.

C- TexportM e)!use t-e )re!te !n eniron"ent t-!t no !sso)i!te )!n

i%%in*% !%8 out o$. T-e %o!%t st!,i%it index o$ t-e )o"p!n+ !))ur!te%

re$%e)ts t-e -i*- %ee%s o$ !sso)i!te e"poer"ent it *ener!tes !nd

!sso)i!tes= s!tis$!)tion.

An open+ $%exi,%e or8 eniron"ent.

2-!%%en*es !nd %e!rnin* opportunities t-!t 8eep one !t t-eir )re!tie !nd

)o"petitie ,est.

Per$or"!n)e "e!sure"ent !nd i"!*in!tie re!rd sste"s.

Produ)tiit %in8ed in)enties !nd industr st!nd!rd )o"pens!tion.

0u%tip%e *rot- !enues.

St!te7o$7t-e7!rt in$r!stru)ture to or8 it-.

1.1.- uyers:

TO00> HILGI'ER A0ERI2AN EA'LES LEE

'AP ESPIRIT 'UESS EANS

TO0 TAILOR OLD NAV> ARROC

ER;LE> SHIRTS PEPE EANS ARROCSHIRTS

CALL0ARTS VAN HEUSEN 'UESS

2 PENN> ;I;O0O H & 0


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;HOLS


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1.2 ORGANISATIONAL STRUCTURE

APPAREL INTERNSHIP REPORT ON TEXPORT INDUSTRIES PVT. LTD. | APURV & PRANAV 14


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CHAPTER 2

DEPARTMENTAL OVERVIEW

APPAREL INTERNSHIP REPORT ON TEXPORT INDUSTRIES PVT. LTD. |APURV & PRANAV

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2.1 HR DEPARTMENT

2.1.1 Introduction:

Hu"!n Resour)es 0!n!*e"ent #HR0( is t-e desi*n o$ $or"!% sste"s in !n

or*!niB!tion t-!t ensure t-e e$$e)tie !nd e$$i)ient use o$ -u"!n t!%ent to

!))o"p%is- or*!niB!tion!% *o!%s.

HR is t-e personne% !nd !d"inistr!tion -e!d -i)- is responsi,%e $or pro,%e"

so%in* ,eteen E"p%oee !nd 0!n!*e"ent.

2.1.2 oles o# H /epartment:

2o%%e)tin* d!t! !,out "!n poer re/uire"ent p%!n $ro" IE dep!rt"ent.

HR dis)usses it- 0!n!*e"ent on t-e "!n poer re/uire"ent p%!n !nd

)o"e to !*ree!,%e ter"s on it.

HR 0!n!*er p%!s !n i"port!nt ro%e in se%e)tion o$ ! )!ndid!te $or ! @o, !t

t-e ti"e o$ interie.

Person!% $i%es o$ !%% t-e e"p%oees !re "!int!ined $o%%oin* !%% st!tutor

nor"s.

HR -!nd%es ,ot- its su,ordin!tes !s e%% !s -i*-er "!n!*e"ent !t e!se.

HR is ino%ed it- )o"p!n !nd %!,or e%$!re !)tiities.

HR )ondu)ts ne or8ers indu)tion "eetin*.

HR t!8es ! tour o$ t-e $!)tor on re*u%!r ,!sis to )-e)8 -e!%t- !nd s!$et

issues.

Oer ti"e -ours is 8ept it-in t-e %e*!% %i"its+ I$ $ound !n ex)usie o$

oerti"e HR dis)usses it- t-e 0!n!*e"ent.

A%% st!tutor returns !re su,"itted on ti"e %i8e de)%!r!tion $or"s+ "ont-%

returns+ -!%$ e!r% returns !nd !nnu!% returns.

HR )-e)8s t-e !*e re)ord !nd in & out ti"e re)ord o$ e!)- e"p%oee

eer "ont-. C!*e re)ord !nd ti"e re)ord is "!de !!i%!,%e on 14 t-d!

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2.1.3 A0senteeism &urn o%er resol%in!:

To preent t-e e"p%oee turnoer+ t-e $o%%oin* points "ust ,e 8ept in "ind57

Ade/u!te se%e)tion !nd p%!)e"ent.

Testin* s-ou%d se%e)t on% t-e )!ndid!tes t-!t -!e t-e re/uired s8i%%s $or

t-e @o,.

Interies s-ou%d sere !s !n !ddition!% s)reen $or !pp%i)!nts.

C!t)-in* $or turnoer indi)!tors su)- !s57

7Cor8ers -o donKt on ! -ouse.

7Cor8er oun*er t-!n 6.

7Peop%e it- )-i%dren ,e%o < e!rs o$ !*e.

7Peop%e t-!t !re oer% edu)!ted $or t-e position.

7Peop%e t-!t -!e -!d "!n @o,s in ! s-ort period o$ ti"e.

'ood indu)tion pro*r!".

;eepin* ! per"!nent !t)- oer si*ns o$ turnoer su)- !s !,senteeis".

0!8e t-e or8p%!)e $ee% e"poered )-!%%en*ed !nd !))epted , t-e

)o"p!n.


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Design Department

Texports own Development

Obtain information reg. fabrics,

styles, silhouettes, color, etc. from

WGS !Worth Global Style

etwor"#

$uyers %nspiration

&reate 'oo( boar( an( &olor

boar( with Designs, Styles,

Silhouettes, etc. from various

source.

&ollect fabric, (evelop (esigns.

)resentation of the collection to

the buyer.

Develop collection on various

categories in Sampling (ept.

*inalising (esigns by +OD

Deci(es color, fabric, style, etc.

from own inspiration or from

other sites.

Short listing of samples by buyer.

2.2 DESIGN DEPARTMENT


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2.3 SAMPLING DEPARTMENT

2.3.1 asic +or, Flow:

In !n export -ouse+ t-e s!"p%in* dep!rt"ent is one o$ t-e "ost i"port!nt

dep!rt"ents. S!"p%in* is done to see -o t-e produ)t i%% %oo8 %i8e -en

produ)ed in ,u%8 !nd to )-e)8 -et-er t-ere !re !n dis)rep!n)ies in t-e

p!ttern !nd !re "!de !))ordin* to t-e uerKs spe)i$i)!tion. In Texport+

S!"p%in* dep!rt"ent is )entr!%iBed in He!d O$$i)e $or oen.It is di$$erent

$ro" ,u%8 produ)tion !s -ere e!)- t!i%or is "u%ti s8i%%ed !nd "!8es ! )o"p%ete

"!8e t-rou*- *!r"ent.

T-ere !re seer!% st!*es ino%ed in t-e S!"p%in* Dep!rt"ent -i)- ino%es t-e

"!8in* o$ di$$erent tpes o$ S!"p%es !t di$$erent st!*es in t-e industr. A%% t-ese

st!*es !re ,rie$% des)ri,ed !nd exp%!ined ,e%o.

In t-e st!rtin* st!*e+ t-e S!"p%in* Dep!rt"ent re)eies !n indent $ro" t-e

0er)-!ndiser -i)- is si"i%!r to t-e Te)- p!)8 ,ut it does not )ont!in !%% t-e

det!i%s t-!t !re present in t-e Te)- p!)8. T-e det!i%s in t-e indent in)%ude

"e!sure"ents+ %o)!tion o$ tri"s !nd !))essories+ $%!t s8et)- o$ t-e $ront !nd t-e

,!)8 ie+ t-e en%!r*ed $%!t s8et)- o$ t-e !re!s -i)- needs to ,e t!8en )!re o$+

t-e !rious !))essories re/uired !nd t-eir p%!)e"ents in t-e *!r"ent.

As soon !s t-e s!"p%in* dep!rt"ent re)eies t-e indent t-e )-oose t-e

desi*ners -o" t-e $ee% !re *ood $or t-e p!rti)u%!r st%e or expert in t-!t

p!rti)u%!r $ie%d !nd t-en t-e st!rt dee%opin* t-e p!tterns $or t-e st%e. T-e

dur!tion $or t-e re)eipt o$ t-e indent !nd t-e st!rtin* o$ dee%opin* t-e p!ttern is

!,out one to to d!s "!xi"u".

A$ter dee%opin* t-e p!tterns+ t-e S!"p%in* Dep!rt"ent does t-e )ostin* )!d

"!r8er !nd dee%ops S!"p%e si"u%t!neous%.

Costin! cad mar,er5 T-is tpe o$ t-e "!r8er is done prior to t-e order !ppro!%

$or 8noin* t-e ex!)t $!,ri) )onsu"ption $or t-e *ien st%e. Here t-e $!,ri)

uti%iB!tion per)ent!*e is "!xi"iBed , te)-ni)!% "et-ods o$ "!r8er "!8in* usin*

so$t!re.

/e%elop )ample5 In t-is tpe o$ t-e S!"p%e t-e !)tu!% tri"s !nd !))essories !re

not used een t-e $!,ri) is su,stituted !nd t-is is "!de !))ordin* to t-e uerKs

spe)i$i)!tion !nd t-e uer -ere e"p-!siBes on t-e $it !nd t-e s-!pe o$ t-e

*!r"ent ,ein* produ)ed.

T-e ti"e t!8en to *ener!te t-is dee%op S!"p%e is !,out ! ee8 !nd t-e dur!tion


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o$ ti"e $ro" t-e p!ttern dee%op"ent !nd dee%op S!"p%e *ener!tion is !,out

to to t-ree d!s. Dee%op S!"p%e is prep!red o$ t-e ,!si) siBe t-!t -!s ,een

pre$erred $or t-!t p!rti)u%!r st%e.

A$ter *ener!tin* t-is S!"p%e t-ere is ! *!p o$ !,out $i$teen to tent d!s !nd

!$ter -i)- t-e S!"p%in* Dep!rt"ent dee%ops t-e Proto S!"p%e.

"roto )ample5 In t-is S!"p%e ! su,stitute o$ t-e $!,ri)s !nd t-e tri"s is used !nd

!$ter "!8in* t-is S!"p%e t-e )o"p!n #i.e.+ Texport Industries Pt. Ltd.( )!n

su**est !n )-!n*es in t-e *!r"ent to t-e uer. I$ t-e uer !pproes t-en t-e

)-!n*es !re in)orpor!ted e%se it is $o%%oed !s t-e uer spe)i$ies. T-is S!"p%e

is !%so @ud*ed !))ordin* to its desi*n !nd st%e.

A$ter *ener!tin* t-ese S!"p%es+ t-e S!"p%es !re t!8en to t-e 0er)-!ndiser !nd

t-en t-e 0er)-!ndiser )-e)8s t-e S!"p%e i$ it -!s "et t-e spe)i$i)!tions+ i$ t-e

0er)-!ndiser -!s !n )o""ent re*!rdin* t-e produ)tion o$ t-e S!"p%e t-en -e!s8s $or t-e )-!n*es in t-e !re!s -ere t-e S!"p%e -!s not "et t-e uerKs

spe)i$i)!tion+ i$ t-e 0er)-!ndiser -!s no )o""ents t-en t-e -e t!8es t-e

S!"p%es to t-e uer $or -is !ppro!%. Suppose t-e uer -!s !n )o""ents or

)orre)tions t-en -e sends $or t-e re7prep!r!tion o$ t-e S!"p%e , spe)i$in* t-e

!re!s -i)- -!s to ,e "ended. I$ t-e uer !pproes t-e $it S!"p%e+ t-en t-e

uerKs order is )on$ir"ed.

On)e t-e proto S!"p%e -!s ,een !pproed t-e#it )ampleis prep!red !nd t-is is

pure% done on t-e uerKs !ppro!% !nd t-is S!"p%e is "!de to )-e)8 t-e siBe

!nd "e!sure"ent o$ t-e *!r"ent !nd $or t-is S!"p%e eit-er !)tu!% or su,stitute

$!,ri)+ tri"s !nd !))essories !re used.

A$ter t-e !ppro!% o$ t-e $it S!"p%e , t-e uer ! "" "re"roduction )ample

is *ener!ted. Here !)tu!% $!,ri)+ tri"s !nd !))essories !re used. T-e PP S!"p%e

is sent to t-e uer !nd ! S!"p%e is 8ept $or t-e )o"p!n$ir" on% $or t-e

intern!% testin* !nd "!int!inin* t-eir re)ords !nd st!nd!rds.

A$ter t-e PP S!"p%e is !pproed+ ! )ealer )ampleis prep!red. In t-is S!"p%e

!)tu!% $!,ri)+ tri"s !nd !))essories !re used. T-is S!"p%e is sent to t-e %i!ison

o$$i)es.

A$ter t-e !ppro!% o$ t-e se!%er S!"p%e ! )ie )et )ampleis *ener!ted !nd in

t-is tpe o$ s!"p%in* sste" t-e S!"p%es !re *ener!ted not on% $or t-e ,!si)

siBe inste!d t-e S!"p%es !re *ener!ted $or !%% t-e siBes $or -i)- t-e uer -!s

!s8ed $or ex!"p%e i$ t-e uer -!s !s8ed $or ! $or"!% s-irt it- siBes


18/136

)!rried out in t-e si"i%!r "et-od , usin* si"i%!r "!)-ines it-out !%terin* !n o$

t-e pro)edures !nd "!nu$!)turin* is done.

T-e $irst pie)e o$ produ)tion+ 8non !s TOP S!"p%e #Top O$ Produ)tion S!"p%e(

is so"eti"es !s8ed , uer to 8no produ)tion d!te !nd i$ it "!t)-es it-

Se!%er S!"p%e.

Workflow of Sampling Department


19

Tech pac" receive( from merchant

Develop patterns

&osting &D mar"er Develop Sample

Develop fit-proto sample

evise *it-)roto sample )) sample

%f no comments%f any comments

comments

evise )) sample Si/e Set sample


comments

%ncorporate $uyer &omments Sealer sample


comments

%ncorporate $uyer &omments $ul" )ro(uction


comments


19/136

2.3.2 Mac'ines in )amplin! )ection are:

SNLS "!)-ine

DNLS "!)-ine

!rt!)8 "!)-ine

Oer%o)8 "!)-ine

;!ns!i Spe)i!%

i*B!* Lo)8stit)- "!)-ine

%ind stit)- "!)-ine

2.3.3 6arment )ample:

A$ter t-e )on$ir"!tion o$ order+ e!)- S!"p%e sent to t-e uer -!s t-e

$o%%oin* det!i%s !tt!)-ed to it+ it- t-e -e%p o$ ! t!*. It )ont!ins t-e det!i%spert!inin* to ,ot-+ -!t t-e uer -!s de"!nded !nd -!t supp%e"ent

$!,ri)tri" et). t-e -!e used.

Re$ no.

2o%or

G!,ri)

2o"position

Des)ription

?u!ntit

St%e no SiBe

Store


1:


20/136

2.4 MERCHANDISING DEPARTMENT

2.4.1 Introduction:

0er)-!ndisin* is ! pro)ess t-rou*- -i)- produ)ts !re p%!nned+ dee%oped+

exe)uted !nd presented to t-e uer. It in)%udes dire)tin* !nd oerseein* t-e

dee%op"ent o$ produ)t %ine $ro" st!rt to $inis-.

0er)-!ndisin* is t-e )entr!% )oordin!tin* point $or t-e produ)t %ine.

0er)-!ndisin* is t-e p%!nnin* dee%op"ent+ dee%op"ent !nd present!tion o$

produ)t %ine $or identi$ied t!r*et "!r8ets it- re*!rd to pri)es+ !ssort"ents+

st%in* !nd ti"in*. 0er)-!ndisers "! ,e ino%ed in t-e "!teri!%s

"!nu$!)turin*+ !pp!re% "!nu$!)turin* !nd ret!i%in* %ee%s o$ t-e !pp!re%

,usiness.

A))ordin* to Ci%%i!" . Stenton "er)-!ndisin* is de$ined !s Produ)t

p%!nnin* to *et t-e ri*-t produ)t or seri)e to t-e "!r8et !t t-e ri*-t ti"e+ !tri*-t pri)e+ in ri*-t )o%ors !nd siBesJ.

T-e 0er)-!ndiser s-ou%d ,e !,%e to !nser e!)- !nd eer /uestion to t-e

uer+ ,e !,%e to *ie su**estions+ -!nd%e t-e present!tion o$ t-e S!"p%e

)o%%e)tion+ s-ou%d ,e !,%e to "!8e on t-e spot )ostin* !nd *ener!%% ,ui%t ,

)on$iden)e it- t-e uer.

T-e export do)u"ent!tion ino%es t-e prep!r!tion o$ t-e spe)i$ied nu",er o$

)opies o$ t-e pres)ri,ed do)u"ents pert!inin* to t-e di$$erent pro)edures.

Re)ent% di$$erent $or"s used in t-e export do)u"ent!tion -!e ,eenst!nd!rdiBed !nd !%i*ned. 'oods "! ,e exported to $orei*n "!r8ets , Se!+

Airport+ & L!nd. T-ere !re t-ree ,!si) ter"s o$ p!"ents in intern!tion!%

tr!de. T-e !re !s $o%%os57

!. Do)u"ent o$ !))ept!n)e

,. Do)u"ent !*!inst p!"ent

). Letter o$ )redit


13


21/136

2.4.2 Merc'andisers ,ey responsi0ilities are as #ollows:

Produ)t Dee%op"ent

0!r8et And Produ)t An!%sis

Se%%in* T-e 2on)ept

oo8in* Orders

2on$ir"in* De%ieries

Desi*nin* And S!"p%in* 2oordin!tion

2ostin*

R! 0!teri!%

G%o 0onitorin*

Produ)tion Go%%o Ups

P!"ents

A *ener!% se/uen)e o$ oper!tions $o%%oed in exe)utin* order is s-on ,e%o5

T-e uer sends )ostin* in/uir s-eet.

I$ t-e t!r*et pri)e spe)i$ied , t-e uer is !*reed , t-e 0er)-!ndiser.

L!, dips.

L!, dipss!t)-es !re sent to t-e uer $or !ppro!%.

T-e uer sends pur)-!se orderp%!)e"ent 8it.

Prototpe$it S!"p%e !nd !))essories !re sent to t-e uer $or !ppro!%.

T-e uer *ies instru)tion to t-e 0er)-!ndiser i$ !n )orre)tions !re to

,e "!de.


64


22/136

Pur)-!se orders $or $!,ri)s !nd !))essories !re issued to t-e suit!,%e

"!nu$!)turers $or spe)i$ied /u!ntit !nd /u!%it.

P-oto7S!"p%e sent to t-e uer $or !ppro!%.

Produ)tion o$ t-e *!r"ent !nd $inis-in* o$ t-e *!r"ent.

P!)8in* o$ *!r"ent in po% ,!* !nd $in!%% in )!rtons.

T-e uer *ies t-e spe)i$i)!tion s-eet+ -i)- )ont!ins A to det!i%s o$ t-e

order+ to t-e export !nd !s8s -i" to *ie t-e pri)in*. A$ter studin* t-e order

t-orou*-%+ t-e export )!%)u%!tes t-e $!,ri) )onsu"ption *!r"ent re/uired !nd

t-e pri)e o$ t-e $!,ri). !sed on t-e $!,ri) pri)e !nd )onsu"ption -e

)!%)u%!ted t-e )ost per $!r.

I$ t-e uer !*rees t-e pri)e !nd t-e order is )on$ir"ed t-en t-e $o%%oin*

!)tiities !re )!rried out5

S)rutiniBin* t-e order%etter o$ )redit)-e)8 expir !nd %!st s-ip"ent d!te.

Re%e!sin* t-e order to t-e $!)tor.

Arr!n*in* $or $in!n)e.

Go%%o up to en/uirer exe)ution or order.

Pre7s-ip"ent exe)ution.

E$$e)tin* t-e s-ip"ent.

H!in* !))epted order+ no p%!)e t-e order on our $!)tor+ t-e order s-ou%d

)%e!r% spe)i$ t-e $o%%oin*5

2o"p%ete des)ription o$ t-e produ)t.

2o"p%ete p!)8in* spe)i$i)!tion.

De%ier s)-edu%e spe)i$in* det!i%s o$ d!tes -en t-e "!teri!% s-ou%d ,e

re!d $or disp!t)-.

Det!i%s o$ t-e pre7s-ip"ent inspe)tion+ i$ !n.

T-e d!te , -i)- ou s-ou%d p!)8in* %ist+ inspe)tion )erti$i)!tes !nd !n

ot-er re%e!nt do)u"ent.


61


23/136

An ot-er !%id instru)tions.

A$ter )on$ir"in* t-e order t-e uer so"eti"es *ies S!"p%e o$ t-e *!r"ent

!nd !s8s t-e exporter to su,"it !n ex!)t rep%i)! o$ t-e s!"e in !)tu!% $!,ri)

or in !n !%tern!tie $!,ri) $or t-e st%e !ppro!%. A$ter )-e)8in* t-e p-oto

S!"p%e+ t-e uer *ies )o""ents on it+ i$ !n !nd !s8s t-e exporter to

su,"it t-e siBe set S!"p%es.

T-e uer !%so spe)i$ies t-e det!i%s o$ t-e $!,ri) to ,e used in "!nu$!)ture o$

t-e *!r"ents. T-e exporter "ust 8no -o supp%ies -!t 8ind o$ $!,ri)+ -is

/u!%it+ !nd de%ier ti"e et). A$ter *ettin* t-e *rei*e $!,ri)+ it -!s to ,e sent

$or pro)essin*. e$ore sendin* or st!rtin* pro)essin*+ s! $or ex!"p%e dein*+

%!, dips -!s to ,e )o%%e)ted $ro" t-e pro)essin* unit !nd it -!s to ,e sent $or

!ppro!% to t-e uer. A$ter *ettin* !ppro!% in %!, dip+ t-e ,u%8 $!,ri) -!s to

de.

e$ore st!rtin* t-e )uttin*+ )!re s-ou%d ,e t!8en to see t-!t !%% t-e

!))essories s-ou%d ,e in -ouse !nd it -!s to ,e !pproed , t-e uer. A%%

t-e )o""ents *ien , t-e uer on t-e siBe set S!"p%e -!s to ,e )%e!r%

exp%!ined to t-e produ)tion "!n!*er !nd on !ppro!% S!"p%e !%on* it- !%%

t-e !))essories s-ou%d ,e *ien to t-e $inis-in* in )-!r*e. A$ter $in!%

inspe)tion t-e *oods s-ou%d ,e s-ipped+ to t-e respe)tie port.

2.4.3 78planation o# t'e process in /etail:

Mar,etin! and merc'andisin! department:A te!" o$ 0er)-!ndisers !nd

"!r8eters or8in* to*et-er under ! pro$it )ontro%s -e!d. 0er)-!ndisers

-!nd%e t-e $orei*n uers. T-e te!"s !re "!de !))ordin* to t-e uers

,ein* -!nd%ed.

oles and esponsi0ility o# Merc'andiser:

!. uer )ont!)t !nd )o""uni)!tion5

It is t-e sin*%e "ost i"port!nt $un)tion !t ,ot- pre !nd post s-ip"ent st!*es.

0er)-!ndiser i%% ,e uerKs represent!tie it-in t-e or*!niB!tion !nd !%so+

represents on or*!niB!tion.

,. Produ)t Dee%op"ent5

0er)-!ndiser s-ou%d 8no !nd underst!nd uerKs re/uire"ent )o"p%ete%

!nd t-orou*-% !nd "ust ,e !!re o$ uer )-!r!)teristi)s+ -e or s-e s-ou%d


66


24/136

,e !!re o$ "!r8et se*"ent+ pri)e7points+ !*e7*roups+ $!s-ion pre$eren)es+

)o%or+ trend+ st%es !nd $!,ri)s $ore)!sts. T-e s-ou%d -!e ! t-orou*-%

sour)e "!r8et !nd produ)t 8no%ed*e !nd )o""er)i!% i!,i%it.

). 2ostin* !nd Pri)in*5

0er)-!ndiser "ust -!e t-orou*- !nd !))ur!te 8no%ed*e o$ )urrent "!r8et

r!tes o$ r! "!teri!%s oper!tin*+ )osts+ pri)e+ !nd )o"petition pro$it p!nnin*

et) t-e "ust !%so ,e!r in "ind uerKs pri)e point !nd t-e pur)-!sin* !,i%it

o$ t-e end )usto"er.

d. Se%%in* !nd oo8in* o$ Order5

T-e "ust tr+ *ettin* t-e uer to ,u in ,uin* "eetin*. #Tr!de $!irs+ uer7

se%%er "eets+ et).(.

e. Produ)tion Go%%o7Up5

2%e!n+ det!i%ed produ)tion do)8ets. He or s-e s-ou%d inter$!)e it- ot-er

dep!rt"ents+ espe)i!%% ,eteen s!"p%in* !nd produ)tion !nd s-ou%d 8eep

up7to7d!te in$or"!tion to t-e uer.

$. ?u!%it 2ontro%5

0ust tr to "eet uerKs /u!%it re/uire"ents. R!ndo" /u!%it )-e)8s s-ou%d

,e done !t !rious st!*es o$ produ)tion !nd "ust 8eep in "ind )o""er)i!%

i!,i%it.

*. S-ippin* !nd Do)u"ent!tion5

It ,e*ins it- t-e order )on$ir"!tion !nd ino%es pre7s-ip"ent !nd post

s-ip"ent do)u"ent!tion. It "ust ,e sent to t-e uer on ti"e. Ter"s o$ s!%e+

produ)tion+ s-ip"ent+ et). "ust !%!s ,e 8ept in "ind. Gin!% s-ip"ent %i8e

-en+ -o+ -ere s-ou%d ,e 8ept in "ind. Gin!% s-ip"ent %i8e -en+ -ere

s-ou%d ,e 8ept in "ind.

In !n export -ouse+ "er)-!ndisin* is ! )o",in!tion o$ ,usiness !nd te)-ni)!%

!spe)ts. Senior 0er)-!ndisers -!e responsi,i%ities o$ produ)ts dee%op"ent

!nd )oordin!tin* it- t-e uer+ t-e *!r"ent st%es t-!t "eet uerKs

expe)t!tions in re*!rds to de%ier+ /u!%it+ !nd pri)e point. unior

0er)-!ndisers -!e t-e responsi,i%it o$ -!nd%in* p!per or8 !nd $o%%o up+

det!i%in* it- uers+ oerse!s )o""uni)!tion et). On)e t-e order is p%!)ed

it is t-eir dut to )o"p%ete t-e ne)ess!r p!per or8+ proide ,re!8don

in$or"!tion to !%% ot-er dep!rt"ent !nd *et S!"p%es !pproed $or $it+ )o%or

!nd /u!%it. 2o""uni)!tions it- oerse!s !nd do"esti) supp%iers+ !ppro!%


6


25/136

o$ produ)tion S!"p%es+ !nd dee%op"ent o$ $!,ri) !nd !rns !re !%so in)%uded

in produ)t dee%op"ent+ -i)- !re )o7)oordin!ted it- ot-er dep!rt"ents.

0er)-!ndisers -!e to ne*oti!te it- t-e uers on pri)in*+ or8 out de%ier

s)-edu%es+ !nd inesti*!te $or $uture uers. Oer!%% e )!n s! t-!t

"er)-!ndisin* is t-e )ore dep!rt"ent o$ t-e entire industr.

T-e 0er)-!ndiser !t $irst i%% o,t!in t-e te)- p!)8 $ro" t-e uer or *et ,rie$

ide! o$ t-e st%e !nd !%so t!8es ! S!"p%e $ro" t-e uer o$ t-e ,!se siBe.

On)e t-is is done t-e 0er)-!ndiser i%% -!e to do t-e to "!@or i"port!nt

@o,s+ -i)- !re !s $o%%os57

a Costin!: T-is ino%es t-ree "!@or steps.

Girst%+ t-e !n!%sis o$ t-e $!,ri) )onsu"ption -i)- is )!%)u%!ted usin* t-e

2AD dep!rt"ent. T-e 2AD dep!rt"ent i%% %oo8 t-rou*- t-e st%e !nd desi*n

o$ t-e *!r"ent !nd *ener!%% !,out Q o$ extr! $!,ri) i%% ,e 8ept in "ind

$or t-e entire order /u!ntit in order to )ope up it- t-e !st!*es o$ t-e

$!,ri). T-is )onsu"ption is *ener!%% done $or one ,!si) *!r"ent siBe

su**ested eit-er , t-e uer or t-e 0er)-!ndiser.

Se)ond%+ t-e !n!%Be t-e )ost o$ t-e tri"s !nd $!,ri)s !))ordin* to t-eir

re/uire"ent+ tpe+ /u!ntit+ et). #-ere t-e 0er)-!ndiser -!s to /uote t-e

ex!)t re/uire"ent o$ $!,ri)s !nd tri"s(. T-en t-e "er)-!nts prep!re t-e )ost

s-eet $or t-e S!"p%e *!r"ent -i)- t-e re)eie $ro" t-e uer.

T-ird%+ t-e "er)-!nts o,t!in t-e 'SD #'ener!% Sein* D!t!( $ro" t-e IE

Dep!rt"ent $or t-!t p!rti)u%!r S!"p%e.

0 )amplin!:T-e )ostin* !nd t-e s!"p%in* $or t-e st%e+ t-!t t-e uer

ou%d -!e *ien+ -!ppen si"u%t!neous%. T-e "er)-!nts *ie t-e )op o$t-e te)- p!)8 to t-e S!"p%in* dep!rt"ent !s soon !s t-e *et it $ro" t-e

uer !nd t-en !s8 t-e" to *ener!te ! S!"p%e !s per t-e spe)i$i)!tions

*ien in t-e te)- p!)8 #-ere t-e tri"s !nd t-e $!,ri)s used i%% not ,e t-e

s!"e !s t-!t in t-e ori*in!% S!"p%e *ien , t-e uer(.

A$ter dee%opin* t-e initi!% S!"p%e+ i$ t-e uer !s8s $or t-e proto S!"p%e

t-en t-e proto S!"p%e i%% ,e *ener!ted , t-e s!"p%in* dep!rt"ent. No t-e

0er)-!ndiser -o%ds t-e responsi,i%it to send t-e /uot!tion to t-e uer !s

per t-e )!%)u%!tions -e s-e ou%d -!e done $or t-e st%e t-e uer !nts.

T-is /uot!tion ino%es t-e )ost s-eet !nd t-e S!"p%e -i)- ou%d -!e


6


26/136

,een *ener!ted !nd t-is is done *ener!%% , t-e 0er)-!ndiser -i"se%$ i.e.

t-e "er)-!nts i%% isit t-e uer !nd *ie t-e" t-e /uot!tion or so"eti"es

t-e uer i%% isit t-e $!)tor !nd t!8e t-e".

On)e t-is is done t-e entire !ppro!% or t-e re@e)tion o$ t-e order %ies in t-e

-!nds o$ t-e uer. I$ t-e /uot!tion or t-e S!"p%e is not !pproed t-en t-e

)ost s-eet or t-e S!"p%e -!s to ,e or8ed !*!in !nd i$ it is !pproed+ t-!t is

i$ t-e order is )on$ir"ed t-en t-e 0er)-!ndiser -!s to $o%%o $urt-er steps.

T-e 0er)-!ndiser -!s to )!%% $or t-e "eetin* -i)- i%% ino%e !rious

dep!rt"ents %i8e t-e p%!nnin*+ sour)in*+ pur)-!sin*+ !s-in*+ $inis-in*+

e",roider !nd t-e IE dep!rt"ents. Durin* t-is "eetin* seer!% /uestions i%%

,e so%ed !nd t-e $%o o$ t-e order i%% ,e dis)ussed !"on*st !%% t-e

dep!rt"ents.

Girst%+ t-e Planning departmentor8s on t-e $o%%oin* det!i%s57

P2D #P%!n 2ut D!te(

Sein* %ine ,!t)- -i)- i%% ,e suit!,%e $or t-e p!rti)u%!r st%e.

2!p!)it7ise p%!nnin* t-e !%%o)!tion o$ t-e st%e to t-e ,!t)-.

Re/uire"ents o$ "!)-ines in order to "!nu$!)ture t-e *!r"ent.

An spe)i!%iBed "!)-ines i$ re/uired.

T-e %ine ,!%!n)in* det!i%s et).

Se)ond%+ t-e Sourcing and the Purchasing department or8 on t-e

$o%%oin* det!i%s57

T-e d!te $or orderin* t-e tri"s $!,ri) $ro" t-e supp%ier.

T-e ,re!8 Q up o$ /u!ntit $or -i)- t-e dep!rt"ents s-ou%d p%!)e t-e

order. Spe)i$i)!tions o$ t-e $!,ri)s !nd tri"s i%% ,e dis)ussed.

0ode o$ p!"ent.

T-ird%+ the Washing, Embroidery and Finishing departments.

I$ t-e st%e de"!nds $or !n tpe o$ e",roider or8 t-en t-e )!p!)it !nd

t-e !!i%!,i%it o$ t-e e",roider dep!rt"ent -!s to ,e )-e)8ed. T-e !s-in*

dep!rt"ent -!s to )on$ir" i$ it )!n $u%$i% t-e spe)i$i)!tions on ti"e !s re/uired


6


27/136

, t-e uer. T-e !!i%!,i%it o$ t-e !s-in* !nd t-e $inis-in* dep!rt"ent is

er i"port!nt !s t-e !s-in* unit is t-e )entr!%iBed dep!rt"ent.

Gin!%%+ t-e IE department+

T-e -!e to *ie t-e det!i%s o$ t-e tpes o$ or8ers%!,orers -o -!e to,e used $or t-e p!rti)u%!r st%e in t-e sein* $%oor.

T-e *ie t-e r!tio o$ t-e t-ree *r!des o$ t-e or8ers -i)- !re to ,e

uti%iBed $or t-e st%e.

T-e "ention t-e !!i%!,i%it !nd t-e )!p!)it o$ t-e oper!tors.

O,t!in t-e 'SD $or t-e st%e.

T-e 0er)-!ndiser )o%%e)ts !%% t-e det!i%s $ro" !%% t-e !,oe "entioned

dep!rt"ents !nd t-en t!,u%!tes t-e" or*!niBes t-e" !s per t-eir

re/uire"ent !nd enters !%% t-e det!i%s in t-e so$t!re. Hen)e+ t-e exe)ution o$

t-e !pproed order ,e*ins. Eer uer i%% -!e -is on ter"ino%o*ies $or

t-e S!"p%es+ t-e "er)-!nts -!e to *o !))ordin* to t-e uerKs )-oi)e o$

tpe !nd t-e nu",er o$ S!"p%es !nd proide t-e" !s !nd -en t-e re/uire

it.

On)e !%% t-e S!"p%es !s per t-e uer re/uire"ent is done+ -i)- t!8es

!,out 1 Q 64 d!s+ t-en t-e "er)-!nts -!e to !it $or t-e uerKs !ppro!%

o$ t-e S!"p%e. I$ t-e uer re@e)ts t-e" t-en t-e re!sons $or t-e re@e)tion isre)eied $ro" t-e uer in t-e $or" o$ )o""ents !nd !%% t-!t i%% ,e

in)orpor!ted !nd t-e "ist!8es i%% ,e re)ti$ied !nd t-e S!"p%es i%% ,e "!de

!*!in !s per t-e reised re/uire"ents. A$ter t-is t-e S!"p%es -!e to ,e

!pproed , t-e uer !*!in.

Suppose t-e S!"p%es !re !pproed , t-e uer t-en t-e 0er)-!ndiser

-o%ds ! PP #Pre Q Produ)tion( "eetin* it- t-e p%!nnin* !nd IE dep!rt"ent.

In t-is PP "eetin* seer!% issues !re dis)ussed %i8e+

Line p%!n ,!sed on t-e SA0 !%ue.

!sed on t-e %ine p%!n+ t-e /u!ntit t-!t -!s to ,e pro)essed e!)- d!.

A$ter t-e PP "eetin* t-e %o!din* is done to t-e ,!t)- !nd t-e )uttin* is !%so

)!rried out. On)e t-e exe)ution o$ t-e ,u%8 order ,e*ins+ !t $irst+ t-e ,!t)- i%%

-!e ! dur!tion o$ !,out Q < d!s $or t-e ,!t)- settin* in -i)- t-e entire

,!t)- is *ien ti"e to *et !d@usted to t-e ne st%e !nd !t t-is ti"e !%% t-e

oper!tors !re *ien ! proper tr!inin* !nd t-e !re !%so edu)!ted !,out t-e

proper "et-od t-!t t-e !re supposed to $o%%o in order to $inis- t-eir @o, it-

e!se. A$ter t-e ,!t)- settin* is done !nd t-e st%e is under proper produ)tion+


6


28/136

it -!s to ,e $o%%oed , !%% t-e units o$ t-e produ)tion dep!rt"ent !nd t-en

t-e -!e to upd!te it to t-e uer. T-e produ)tion !nd "er)-!ndisin*

dep!rt"ent -!s to su,"it t-e re/uired do)u"ents to t-e do)u"ent!tion

dep!rt"ent.

On)e t-e $irst set o$ $inis-ed *!r"ents !re out+ t-e -!e to ,e sent $or t-e

$in!% inspe)tion -i)- is done !))ordin* to t-e uerKs spe)i$i)!tions !nd

ter"s. T-e *!r"ents !re !*!in )-e)8ed , t-e uer ?2 !nd t-en s-ipped

!nd sent to t-e uer. A$ter t-e *!r"ents !re sent to t-e uer+ t-e

0er)-!ndiser -!s to $o%%o up t-e p!"ents $or t-e tru)8ed *oods.

2.4.4 /ocuments Maintained y Merc'andisers:

S!"p%e st!tus $i%e

Tri"s !ppro!%

Testin* re/uire"ent $or $!,ri) !nd tri"s

L!, !ppro!%

2ostin* s-eet

Pur)-!se order $or $!,ri) !nd tri"s

Git )o""ents

0!int!inin* s!t)- )!rd

0!int!inin* st%e re/uire"ent s-eet

Ti"e !nd !)tion )!%end!r

Produ)tion st!tus

S-ip"ent do)u"ents

Gin!% !udit report

Gi%e o$ tri" st!tus


69


29/136


6:


30/136

Start

Obtain tech pac" from buyer

Sampling

naly/e fabric

consumption from &D

naly/e cost of trims

an( fabric

Obtain general sewing

(ata from %0D

)repare cost sheet from

Sample

Develop sample as per the

Tech pac"

Develop proto sample

&ost sheet 1 Sample sent to $uyer for approval

pproval

&ost sheet

rewor"e(

&onfirmation of

or(er

Obtain )&D 1 (etails

from pro(uction unit

Source Trims 1 *abric

from concerne( (ept.

$oo" Washing 1 0mbroi(ery

capacity if re2uire(

Obtain GSD from

%0D

0xecution of or(er

)repare Sample as per $uyer re2uirements

*orwar( the Sample to $uyer for approval

pproval

&omments receive( from $uyer

shoul( be incorporate( an( *it

Sample rewor"e(

+ol( pre3pro(uction

meeting with the

)ro(uction unit

0xecute

bul" or(er

&osting

*ollow up with

pro(uction

(epartments 1

up(ate the buyer

Submit re2uire(

(ocuments to

(ocumentation (ept.

Offer garments for

final inspection.

Truc" out

*ollow up on

the payments

for goo(s

0n(

o4es

o4es


63


31/136

Flowchart of Merchandising Process

2.5 FABRIC DEPARTMENT

2.5.1 Fa0ric )tore:

T-e $!,ri) store is responsi,%e $or issuin* $!,ri) to t-e )uttin* se)tion !s per

D2PO #Di$$erent )ountr pur)-!se order(. e$ore st!rt o$ produ)tion o$ !n

order t-e He!d o$$i)e #HO( sends ! p!)8!*e to t-e unit #TIPL714(. T-is

p!)8!*e )onsists o$ t-e $o%%oin* do)u"ents5

o, )!rd

Pur)-!se Order #PO(

Pre7produ)tion "ini "!r8er

Pre7produ)tion S!"p%e

?u!%it )o""ents

Audited te)- p!)8

'r!ded Spe) s-eet

2o"p%ete tri" )!rd et).

I$ t-ere !re !n )-!n*es or )orre)tions to ,e "!de in t-ese do)u"ents t-e

unit )o""uni)!tes it- t-e "er)-!ndisin* diision in HO+ e%se t-e pro)eed

it- t-e det!i%s *ien. G!,ri) )onsu"ption $or ! p!rti)u%!r order is )!%)u%!ted

, !ddin* 67 o$ extr! $!,ri) !s per uer re/uire"ents. T-en HO p%!)es

order $or t-e re/uired $!,ri). On)e t-e $!,ri) re!)-es t-e !re-ouse it is sent

$or testin* in Texport %!,or!tor in t-e 'odon. A$ter t-e $!,ri) is tested it is

sent to t-e $!,ri) store o$ t-e unit.

A$ter re)eiin* t-e $!,ri) in store+ t-e store in7)-!r*e )-e)8s $or t-e $!,ri)

)ode+ )o%or+ !rd!*e !s "entioned+ no. o$ ro%%s !nd ot-er det!i%s on t-e $!,ri)

p!)8!*e. T-en t-e $!,ri) is inspe)ted r!ndo"% $or de$e)ts !nd t-en $!,ri) is

se*re*!ted s-!de7ise !nd idt-7ise in to di$$erent %ots. T-ese %ots !re

issued to t-e )uttin* dep!rt"ent.


4


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2.5.2 &'e asic Functions o# t'e Fa0ric )tore:

2-e)8 $or t-e !ri!tions in t-e $!,ri).

P-si)!% testin* $or de$e)ts+ s-!des !nd idt- !ri!tions.

Appro!%+ re@e)tion or su, st!nd!rdiB!tion o$ $!,ri) %ot.

2%!ssi$i)!tion o$ $!,ri) in !rious s-!des

Prep!r!tion o$ s!t)-es "entionin* s-!des !nd t-eir respe)tie /u!ntit.

T-e G!,ri) Audit dept. supp%ies t-e $!,ri) $or s-rin8!*e )-e)8.

Girst o$ !%% t-e 0er)-!ndiser sends t-e Pur)-!se order #PO( s-eet to t-e

$!,ri) su, store -e!d. T-e re/uired nu",er o$ pie)es #*!r"ents( is *ien

in t-e s-eet.

A$ter t-is t-e G!,ri) 2uttin* 2-!rt is re)eied $ro" t-e 2uttin* se)tion

-e!d. In t-is )-!rt t-e "eters o$ $!,ri) re/uired , t-e )uttin* roo" is

*ien.

Next t-e in7)-!r*e re)eies t-e G!,ri) ?u!%it Inspe)tion Su""!r. T-is

)ont!ins t-e inspe)tion det!i%s o$ t-e $!,ri). T-e in7)-!r*e t-en re)eies

t-e 0ini 0!r8er $ro" t-e 0er)-!ndiser. T-is s-eet )ont!ins t-e /u!ntit o$

$!,ri) re/uired per *!r"ent.

!sed on t-is t-e in7)-!r*e prep!res ! )-!rt. T-is )-!rt )ont!ins t-e $!,ri)

det!i%s #S!t)-+ 2o%or+ Order ?u!ntit !nd t-e /u!ntit re/uired(. T-e in7

)-!r*e )!%)u%!tes t-e /u!ntit o$ $!,ri) re/uired !$ter !ddin* t-e !ste

per)ent!*e.

6 is !dded !s ! !ste per)ent!*e $or $!,ri). is !dded $or t-e

re@e)tion o$ *!r"ents. Hen)e+ ! tot!% o$ o$ t-e order /u!ntit is !dded.

T-is is t-e tot!% /u!ntit o$ t-e $!,ri) re/uired to ,e ordered $ro" t-e "!in

stores.

T-is )-!rt is sent to t-e 0er)-!ndiser !nd t-e re/uired /u!ntit o$ t-e

$!,ri) is ordered.

Prep!r!tion o$ G2R #$!,ri) )onsu"ption report(.

2.5.3 6oods ecei%in!:


1


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He!d o$$i)e )!%)u%!tes t-e $!,ri) )onsu"ption $or t-e p!rti)u%!r @o, order !nd

p%!)e t-e order $or $!,ri) it- extr! $!,ri) in )!se o$ so%id !nd in )!se

o$ )-e)8s. T-e -e!d o$$i)e te%%s t-e $e!ture o$ $!,ri) to t-e supp%ier !s per

uer re/uire"ent. T-e $!,ri) supp%ier sends t-e $!,ri) $or %!, testin* to !n

testin* unit.

T-e uer re/uired testin* "!in% $or57

Di"ension!% st!,i%it to !s-in*.

Appe!r!n)e !$ter !s-.

2o%or $!stness to %!underin*+ %i*-t+ )ro)8in* !nd non7)-%orine ,%e!)-.

Tensi%e stren*t-.

Te!r stren*t-.

T-e "!t)- t-e resu%t it- s)!%e -i)- in ,eteen 17. 7 Ex)e%%ent+


34/136

A$ter notin* don t-e points t-e points 144 s/. !rd is )!%)u%!ted usin* t-e

$or"u%!+

Points144 s/. d.Tot!% points#144 144(#tot!% nu",er o$ "etersidt- o$

$!,ri)(

Here t-e points/. d. is $ound out & t-e resu%t )!n ,e interpreted !s i$ t-e

points/. d. is ,e%o


35/136

2o%or $!stness to %i*-t

Di"ension!% st!,i%it

Tensi%e stren*t-

Te!r stren*t-

2ount+ EPI+ PPI+ !nd idt-

)'ade atc'in!:

He!ds ends !pproxi"!te% J %on* i%% ,e )ut $ro" eer inspe)ted ro%% !nd

t-is i%% ,e used to deter"ine s-!de !ri!tion !t t-e ,e*innin*+ "idd%e !nd t-e

end o$ t-e ro%%+ side to side s-!de !ri!tion )-e)8s !re )!rried out !t t-is st!*e

, )o"p!rin* t-e to sides o$ t-e $!,ri) ro%% )%oser to t-e se%ed*e.

Ro%%s it- ! )onsistent s-!de it-in i%% t-en ,e )-e)8ed ro%% to ro%% s-!din*

usin* t-e -e!d ends. I$ si*ni$i)!nt !ri!tions in s-!des !re $ound !t t-is st!*e+

ro%%s inspe)ted i%% ,e ,!t)-ed !))ordin* to t-e nu",er o$ t-e "!@or s-!des+

ro%% inspe)ted i%% ,e ,!t)-ed !))ordin* to t-e nu",er o$ "!@or s-!des *roups

!nd t-is in$or"!tion too i%% ,e re)orded in t-e inspe)tion report !%on* it-

s!t)-es representin* e!)- s-!de *roup.

+idt' atc'in!:

E!)- inspe)ted ro%% i%% ,e "e!sured $or t-e )ut t!,%e idt- !t t-e ,e*innin*+

)enter !nd t-e idt- o$ t-e ro%% !nd t-e "e!sure"ent t-us o,t!ined i%% ,e

re)orded in t-e sp!)e proided in t-e inspe)tion report. T-e n!rroest idt-

i%% ,e )onsidered !s t-e )ut t!,%e idt-. I$ t-e !ri!n)e in t-e )ut t!,%e is

"ore t-!n 1 t-en ?u!%it Assur!n)e 0!n!*er i%% de)ide on -!teer

!ddition!% )-e)8s dee"ed ne)ess!r. An %oss !risin* $ro" )ut t!,%e idt-

,ein* s-orter t-!n inoi)ed idt- is noti$ied to t-e "er)-!ndisin* dep!rt"ent

$or t-e $urt-er !)tion.

T-e stores i%% ,e "e!surin* t-e $!,ri) idt- o$ !%% t-e pie)es *oods t-e

re)eied. 144 i%% ,e done $or !%% t-e )onsi*n"ents. T-en it i%% ,e *rouped

idt-ise+ tot!% !rd!*e o$ t-e e!)- idt- *roup it- ! p!)8in* %ist is

su,"itted to t-e p%!nnin* dep!rt"ent !$ter t-e inspe)tion $or t-e purpose o$

t-e "!r8er re/uire"ent in di$$erent idt-s.

)'rin,a!e &est:

R!ndo" se%e)tion o$ 14 o$ t-e ro%%s is tested $ro" e!)- %ot,!t)-. To

pie)es o$ t-e $!,ri) 44)"J is )ut & 44)" is "!r8ed !nd sin*%e need%e

stit)- on "!r8in*. A te"p%!te -!s ,een prep!red to en!,%e A))ur!te "!r8in*

points )oerin* t-e %en*t- !nd t-e idt- o$ t-e $!,ri) !t ! predeter"ined



36/136


37/136

Non7oen

Gusi,%e

Non7$usi,%e

2.5.- In#rastructure:

a. Color Matc'in! Ca0inet

Paramount !n IS" #$$%&'$$$ group

Spectra (ision color matching booth)

G!,ri) )!n ,e "!t)-ed under $o%%oin* %i*-ts57

D75 D! %i*-t

2CG5 2oo% C-ite G%uores)ent Li*-t

UV4445 ;OHLKs Pri"!r Li*-t

IN2A5 Tun*sten Li*-t

UV5 U%tr!io%et Li*-t



38/136

E!)- uer re)o""ends to %i*-ts in -i)- t-e $!,ri) -!s to ,e "!t)-ed+

pri"!r !nd se)ond!r %i*-t.

0. Fa0ric Inspection Mac'ine

It )onsists o$ ! st!te7 o$7 t-e7 !rt !ri!,%e $re/uen) drie inerter $or pre)ise

speed )ontro% !nd proxi"it sensors to )ontro% t-e uni$or"it o$ ed*es.

*amsons checkmate Model +o& *FI$%E

T-is "!)-ine is used to )-e)8 di$$erent 8inds o$ de$e)ts "entioned !,oe.

T-e $!,ri) is )-e)8ed !nd sent to t-e $!)tor $ro" t-e -e!d o$$i)e. So on%

14 o$ $!,ri) is )-e)8ed in t-e $!)tor !nd t-e rest is @ust re%!xed !nd sent to

t-e )uttin* se)tion.


9


39/136

Process Flowchart of Fabric Department


:


40/136

2.6 ACCESSORIES DEPARTMENT

2.(.1 &rims )tora!e:

Tri" stor!*e is used to store !%% t-e tri"s !nd !))essories $or t-e order t-!t is

)urrent% ,ein* pro)essed !nd $or t-e ones t-!t !re next in turn. On re)eiin*

t-e $in!% P.O t-e 0er)-!ndiser su,"its ! re/uest $or !%% t-e re/uire"ents $or

t-!t p!rti)u%!r order. T-e 0er)-!ndiser te%%s !,out t-e re/uire"ents $or

p!rti)u%!r order+ !s soon !s t-e order is )on$ir"ed. T-e store dep!rt"ent

pro)ures t-e desired "!teri!% i.e. tri"s+ !))essories+ et). !nd stores it in tri"

!nd st!tion!r dep!rt"ent. T-e tri"s !nd !))essories $or e!)- order !re 8ept

in t-e p%!)e !%%otted $or t-!t order nu",er.

T-e dep!rt"ent re)eies t-e 0!teri!% Order Gor" $ro" t-e 0er)-!ndiser+-i)- -!s !%% t-e det!i%s o$ t-e "!teri!% to ,e ordered $or ! p!rti)u%!r order in

)!se o$ t-e tri"s !nd !))essories o$ t-e *!r"ents.

T-e 0!teri!% order $or" )ont!ins d!t! %i8e57

Order no.

uer

St%e

Order /u!ntit#no. o$ pie)es(

S-!de

?u!ntit to ,e ordered

Vendor

De%ier d!te+ et).

T-e 0er)-!ndiser t-en *ies t-e Pur)-!se Re/uest to t-e "!teri!% ,!sed on

-i)- t-e prep!re t-e PO #pur)-!se order(. T-e order is p%!)ed !))ordin* to

t-is !nd t-en t-e "!teri!%s !nd stores prep!re ! 0!teri!% Re)eipt -i)-

)ont!ins t-e det!i%s %i8e /u!ntit+ p!rt+ et). T-is is prep!red $or t-e !))ounts

dep!rt"ent so t-!t )!n t!8e t-e p!"ents !t t-e ri*-t ti"e.

2.(.2 &ypes o# &rims:


3


41/136

L!,e%s

Pri)e t!*

Sein* T-re!d

E",roider T-re!d

Gusin*

uttons

ipper

Inter%inin*

0o,i%on t!pe

H!n*er

Po% ,!*

St%e ID

2!rtons

Dr! )ords

u)8%es

Stoppers

Ve%)ro

T!pes

2.(.3 )u0types o# &rims:

T-re!ds 5 2otton+ Po%ester+ 64s+ 4s+


42/136

Dr! )ords 5 E%!sti)+ Nor"!%.

Stoppers 5 2%indri)!%+ Pi* nose+ e%%+ !%%.

H!n*ers 5 S-irt -!n*er+ 2%ip -!n*er+ !)8et -!n*er+ He! ei*-t

-!n*er.

L!,e%s 5 0!in %!,e%+ SiBe %!,e%+ 2ontent %!,e%+ 2ountr ori*in C!s- )!re

%!,e%+ Spe)i!% %!,e%.

P!)8in* 5 H!n*er p!)8+ P%!te p!)8+ St!nd p!)8.

Po%% ,!* 5 Indiidu!%+ 0!ster po% ,!*.

2!rtoon 5 Inner 2!rton+ Outer 2!rtoon.

2.(.4 "rocedure #or &rims Inspection:

On re)eipt o$ t-e tri"s+ ! )ount !))ur!) )-e)8 s-ou%d ,e done !*!inst

t-e $!)tor pur)-!se order or t-e uer )uttin* ti)8et.

A store st!tus report is )re!ted+ in )!se o$ "u%tip%e re)eipts+ upd!ted report

to ,e *ener!ted !t %e!st eer ee8 i$ not on e!)- re)eipt.

!sed on t-e tri"s %ist o$ t-e )usto"er+ tri" )!rds !re )re!ted in 9 sets.

T-e )on)erned 0er)-!ndiser,uin* o$$i)e i%% si*n o$$ !n !ppro!% !nd

send it ,!)8 to t-e store it- t-e 0TL test report i$ !n $or !rious tri"s.

T-e tri"s store i%% inspe)t 14 o$ t-e tri"s !nd *ener!te ! report it-

)%osure on /u!ntities !nd /u!%it.

On -i*-er re@e)tion per)ent!*e o$ t-e tri"s+ t-en t-e tri"s store -!s to

!dise t-e "er)-!nts !nd !!it instru)tions in ter"s o$ return to t-e

supp%ier+ order !ddition!% tri"s o$ )oer $or re@e)tions !nd !pportion"ent o$

t-e )ut ti)8et ti%% ,!%!n)e o$ t-e tri"s !re re)eied.

T-e tri"s store -!s to "!int!in ! st%e $i%e $or e!)- st%e.

T-e stor!*e o$ t-e tri"s -!s to ,e st%e ise it- its tri" $i%e e!si%

!))essi,%e it- ,in )!rd upd!ted it- e!)- issue.



43/136

Start

Trims receipt by +O

5erify materials against invoice- Delivery &hallan 1 pac"ing list

&arry out 2uality 1 2uantity inspection as per 67 8.9

llocation of trims base( on the nature of the item

)repare (elivery &hallan 1 "eep trims

rea(y to issue to the factories

Trims receive( by the *actory an(

%nspection is (one before issuing for

pro(uction

0n(

e2uisition of Trims

Or(er Trims



44/136

Process Flowchart of !ccessories Department

2.7 CUTTING DEPARTMENT

2.*.1 Introduction:

T-e $irst st!*e in t-e "!nu$!)ture o$ t-e *!r"ent is )uttin* o$ t-e "!teri!% into

re/uired s-!pes. T-e !re o$ten @oined , "e!ns o$ se!" to )re!te ! t-ree

di"ension!% *!r"ent. 2uttin* pro)ess p%!s ! it!% ro%e in ! *!r"ent industr.

T-e "!@or )ost o$ *!r"ent is $!,ri)+ -i)- is !))ountin* to 4794 o$ t-e tot!%

)ost. It is t-ere$ore essenti!% t-!t !)tu!% us!*e o$ $!,ri) s-ou%d ,e )ontro%%ed



45/136


46/136

A$ter )uttin*+ t-ree p!ne%s # top+ )entre & ,otto" ( o$ eer p!rt i%% ,e

)-e)8ed !*!inst t-e -!rd p!ttern $or s-!pe+ not)-+ "is7)ut+ siBe & t-en

i%% ,e !%%oed $or nu",erin* #siBe & %ot( it- di$$erent )o%ors o$ sti)8ers

$or di$$erent siBes.

A$ter nu",erin* ?2 -!s to )on$ir" $or t-e !))ur!) o$ t-e s!"e.

A$ter nu",erin*+ t-e p!ne%s i%% ,e )-e)8ed $or $!,ri) de$e)ts+ proper

nu",erin*+ ,!%!n)in* $or stripes !s per re/uire"ent #"eterin*non7

"eterin*(+ ,!%!n)in* & p%!)e"ent o$ not)-es.

Gusin* o$ p%!)8ets )o%%!rs is ,ein* done in t-e $usin* "!)-ine & t-e

s!"e is ,ein* re)orded it- t-er"ost!ti) strips.

0!r8in* $or p%!)8ets & e",roider p%!)e"ents is ,ein* done ,e$ore

,und%in*.

As per t-e re/uire"ent+ !%% t-e p!rts i%% ,e ,und%ed !%on* it- ,und%in*

ti)8et & su,"itted $or !uditin*.

e$ore %o!din* to Sein*+ t-e ,und%es i%% ,e !udited $or s-!pe+ not)-es+

siBe+ nu",erin*+ no. o$ pie)es !*!inst t-e ,und%e ti)8et & %ots-!de7ise

t!*s i%% ,e issued !%on* it- eer ,und%e $or identi$i)!tion o$ s-!des

-i%e !s-in* & to se*re*!te s-!de ise p!)8in* in !s-ed pro*r!""e.

T-e )uttin* roo" "!n!*er"!ster *ets ! do)8et -i)- )ont!ins r!tio )o%or

ise+ /u!ntit ,re!8don+ st%e ise )uttin* !nd ot-er det!i%s o$ t-e $!,ri) -e

prep!res ! )ut p%!n ,!sed on t-e do)8et !nd issue to t-e in )-!r*e. A))ordin*

to t-e )ut p%!n $!,ri) is re)eied $ro" t-e stores t-rou*- re/uisition !nd stored

in ! $!,ri) ,u$$er !re! -ere t-e $!,ri) is re%e!sed !nd t-e idt- o$ t-e $!,ri)

is )-e)8ed. T-e "!n!*er"!ster issues ! %!er $or"!t to t-e %!"!n+ -i)-

)ont!ins t-e %en*t- !nd idt- o$ t-e $!,ri)+ nu",er o$ %!ers to ,e %!id. T-e

%!er "!n !))ordin* to t-e $or"!t %!id t-e $!,ri)+ ,e$ore %in* o$ t-e $!,ri) !

,ron p!per is spre!d !nd stu)8 to t-e t!,%e to "ini"iBe s%ipp!*e o$ t-e

$!,ri).

A$ter t-e %!in* is oer "!r8er re)eied $ro" )!d is spre!d oer t-e pi%es %!id

$or )uttin* o$ p!tterns or p!tterns !re "!nu!%% "!r8ed $or )-e)8 $!,ri)s !nd

t-en t-e pins !re inserted $or sti$$ness. 2utter does )uttin* "!nu!%% !nd issue

t-e )uttin* to t-e nu",erin* se)tion -ere nu",erin* is done on e!)- )ut

p!rts !))ordin* to t-e siBes. T-en t-e p!rts t-!t re/uire $usin* !re $used in !

$usin* "!)-ine. T-en+ t-e )ut p!rts !re )-e)8ed , )-e)8ers !nd it is p!ssed

to sortin* se)tion -ere sortin* is done !nd tent pie)es !re ,und%ed in



47/136

,und%in* se)tion t-en $in!% !uditin* is )!rried out. Here+ e!)- p!rts !re

)-e)8ed !))ordin* to A?L 6. sste" !nd t-en )ut p!rts !re disp!t)-ed to

!rious units !))ordin* to t-e re/uire"ents.

2.*.4 Met'ods o# Mar,er "lannin!:

0!nu!% "!r8er p%!nnin* it- $u%% siBe p!ttern in ! $u%% siBe "!r8er

2!r,on dup%i)!tin*

2o"puteriBed "!r8er p%!nnin*

P-oto*r!p-i) "et-od

2.*.5 Met'ods o# )preadin!:

Spre!din* , -!nd

Spre!din* usin* ! tr!e%in* "!)-ine

2.*.( Mac'ines used in Cuttin! /epartment:

Spre!din* "!)-ine

End )utters

Str!i*-t 8ni$e )utters

!nd 8ni$e )utter

Gusin* "!)-ine

2.*.* Formats used in t'e Cuttin! /epartment:

o, order

D!i% )uttin* report



48/136

Issue 2-e%!n

2uttin* nu",erin* re*ister

Order ise )uttin* re*ister

144 p!rt )-e)8in* report

0inusin* re)ord



49/136

Process Flowchart of utting Department



50/136

2.*.- &ools and 7


51/136

c. ound =ni#e

Round ;ni$e is ,!si)!%% used $or ed*e )uttin* -i%e t-e "!nu!% %!in* or

spre!din* is t!8in* p%!)e. It is 644 "" in di!"eter !nd -!s ! %i"it!tion $or not

)uttin* pre)ise !t t-e )ure !nd t-us is used $or ed*e )uttin* !s it *ies !

pre)ise str!i*-t %ine )ut. It is used $or )uttin* t-e p%!in !nd stripe $!,ri)+ ,ut

stri)t% not $or )uttin* t-e ed*e o$ t-e )-e)8 $!,ri) ,e)!use it )!uses t-e

pro,%e" o$ ,oin* i$ t-e )-e)8 $!,ri) *ets !n o$$7*r!in )ut.

d. /rillin! Mac'ine


4


52/136

T-e E!st"!n )%ot- dri%%er )!n dri%% -o%es t-rou*- nu"erous %!ers o$ $!,ri)+

indi)!tin* ,utton -o%es+ d!rts+ po)8ets !nd ot-er !tt!)-"ent points. T-is is

per$e)t $or use on %oose% 8nit+ ,u%8 or /ui%ted spre!ds -ere ! "!r8 is

needed.

2.*.> Acti%ities o# t'e Cuttin! /epartment:

a. Issue 9# Fa0ric

G!,ri) t-!t is re/uired $or ! p!rti)u%!r order is t!8en $ro" t-e store dep!rt"ent-e!d o$ )uttin* issues ! s%ip to t-e Store In)-!r*e -i)- )ont!ins $u%%

in$or"!tion order no+ st%e no+ %ot no + s-!de + ro%% no+ et). ,!sed on t-is t-e

store In)-!r*e sendsissues t-e $!,ri) ro%%s to t-e )uttin* se)tion. T-e Store

In)-!r*e $eeds !%% t-e in$or"!tion in t-e )o"puter so t-!t !n in$or"!tion

!,out ! p!rti)u%!r ro%% )!n ,e e!si% tr!)ed out. A%so ide! !,out sto)8 in store

)!n ,e e!si% retrieed.

0. )preadin! 9# &'e ?ay


1


53/136


54/136


55/136

reor8 !nd re7)uttin* re/uired to ,e done on t-e )ut p!ne%s !nd t-e

re!sons $or t-!t.

Cuttin! Minusin! oo,: 0!int!ined !s re*ister. Used $or "entionin* t-e

pie)es )ut $or e!)- st%e+ $or !%% t-e )o%ors. T-is is $i%%ed up $or !%% t-e d!s

!nd eer d! t-e pie)es re"!inin* to ,e )ut !re "entioned on t-e top o$

t-e p!*e. Hen)e t-e n!"e Cutting MinusingJ

/aily "roduction eport #or Cuttin! section: Used $or "!int!inin* t-e

d!i% produ)tion $or e!)- order $or e!)- st%e.



56/136

2.8 SEWING DEPARTMENT

2.-.1 Introduction:

T-e do"in!nt pro)ess in *!r"ent "!nu$!)ture is sein*. T-e o,@e)ties o$

sein* !re t-e )onstru)tion o$ se!"+ -i)- )o",ines t-e re/uired st!nd!rd

!ppe!r!n)e & per$or"!n)e+ it- !n !ppropri!te %ee% o$ e)ono" in

)onstru)tion. Per$or"!n)e o$ se!"s "e!ns t-e !)-iee"ent o$ stren*t-+

e%!sti)it+ dur!,i%it+ se)urit o$ )o"$ort & t-e "!inten!n)e o$ !n spe)i!%iBed

$!,ri). Properties su)- !s !ter7proo$in* or $%!"e proo$in*+ et). ! ,!%!n)e

"ust ,e !)-ieed -en p%!nnin* *!r"ent produ)tion ,eteen t-e de"!nds

o$ t-e end use o$ t-e *!r"ent+ its pri)e & t-e "!)-iner !!i%!,%e $or its)onstru)tion.

2.-.2 Functions:

T-e produ)tion $%oor i%% re)eie t-e det!i%s %i8e

T-e st%e or t-e *!r"ent+

Nu",er o$ oper!tors re/uired+

T-e ,!t)- $or -i)- t-e st%e -!s to ,e inst!%%ed+

An extr! 8inds o$ "!)-ines t-!t !re to ,e used $or t-e p!rti)u%!r st%e+

T!r*et $or e!)- d!

re!8up o$ t-e produ)tion /u!ntit.

A$ter re)eiin* !%% t-ese det!i%s t-e send ! re/uest $or t-e )ut p!rts $ro" t-e

)uttin* !nd sortin* se)tion !nd t-e re/uest is sent to t-e !))essor stores $or

!%% t-e !))essories t-!t !re re/uired $or t-e p!rti)u%!r st%e t-en t-e st!rt t-e

produ)tion $or t-e ne st%e.

e$ore st!rtin* t-e proper produ)tion+ t-e produ)tion $%oor does ! pro)ess o$

,!t)-7settin* $or t-e $%oor -i)- is tr!inin* t-e oper!tors $or t-e ne st%e t-!t

-!s to ,e produ)ed ,u%8+ t-is te!)-in* session i%% *o on $or !,out Q < d!s.

A$ter t-is ,!t)- settin* pro)ess t-e produ)tion $or t-e next d! st!rts it- !

s"!%%er )o""it"ent i.e.+ "! ,e $or 4 pie)es $or t-e entire d! !nd t-en t-e

produ)tion *r!du!%% in)re!ses $ro" 4 Q 144 Q 14 !nd so on+ t-is i%% "!8e



57/136

t-e oper!tors %e!rn s%o% !nd pre)ise% !,out t-e pro)esses t-!t -!s to ,e

)!rried out $or t-e p!rti)u%!r st%e.

On)e t-e )ut p!rts is re)eied $ro" t-e )uttin* !nd sortin* se)tion t-en t-e

p!rts !re prep!red !nd !sse",%ed !))ordin* to t-e %ine t-!t is p%!nned. A$ter

t-e !sse",%in* o$ t-e p!rts is done+ t-ere i%% ,e %ine )-e)8in*+ -ere t-e

s-!de "!t)-in* !nd t-e "e!sure"ents !re )-e)8ed !nd sent.

Durin* t-e pro)ess o$ *!r"ent "!8in* t-ere exists to tpes o$ )-e)8in*+

t-e !re

In7pro)ess )-e)8in*.

End %ine )-e)8in* Q ot- A?L !udit !nd nor"!% )-e)8in* exists.

T-e *!r"ent "!8in* is diided into t-ree di$$erent st!*es !nd !t t-ese t-reest!*es t-e )-e)8in* is done. T-e $%o o$ "!teri!% in t-e produ)tion $%oor is

t-rou*- t-e ,und%e sste" !nd e!)- oper!tor *ets ! ,und%e )ont!inin* si"i%!r

pie)es !nd t-ere i%% ,e !,out 1 Q 64 pie)es in e!)- ,und%e !nd t-e oper!tor

)o"p%ete% $inis-es t-e @o, !nd sends it to t-e next oper!tor to do t-e next

oper!tion on t-e". E!)- ,und%e i%% )ont!in s!"e )o"ponent o$ di$$erent

*!r"ents. T-e "oe"ent o$ t-e "!teri!%s it-in t-e oper!tors in t-e

,!t)-%ine is *ener!%% Bi*QB!* "otion. T-e )-e)8in* person i%% ,e present !t

! position -ere t-e *!r"ent is p!rti!%% $inis-ed !nd it is !s "entioned

)-e)8ed t-ri)e in t-e %ine !nd so"eti"es "ore t-!n t-ree !nd t-is depends

on t-e uer !s e%% !s t-e nu",er o$ )o"ponents present in t-e *!r"ent.

2.-.3 atc' )ystem:

In ,!t)- sste" t-e or8 is diided into di$$erent oper!tions !nd e!)-

oper!tion is )!rried out , ! p!rti)u%!r t!i%or .t-is sste" is !%so re$erred to !s

,!nd sste" or !sse",% %ine+ t-ou*- t-ere is ! $ine di$$eren)e ,eteen t-ese

t-ree . T-is sste" is suit!,%e $or "ediu" !nd %!r*e s)!%e industr.

2.-.4 atc' )ettin!:

!t)- settin* is ! pro)ess o$ !rr!n*in* t-e "!)-ines+ !%%ottin* t-e "!)-ines+

diidin* t-e or8 !nd p%!nnin* t-e nu",er o$ "!)-ines !nd t!i%ors re/uired

.T-e ,!t)- settin* !ries $ro" one produ)tion "!n!*er to !not-er .T-ere !re

no -!rd ru%e !nd $!st ru%es $or ,!t)- settin* ,ut on% t-in* to ,e t!8en )!re is

t-!t+ t-ere s-ou%d not ,e !n ,ott%e ne)8 !t !n st!*e .T-is ensures s"oot-

runnin* to!rds t!r*eted output !nd is )!%%ed !n ide!% ,!t)- settin*.



58/136

!t)- settin* is ,!sed on t-e $o%%oin* $!)tors57

St%e

Produ)tion re/uired

A!i%!,i%it o$ "!)-ines

A!i%!,i%it o$ s8i%%ed %!,ors

Sp!)e

P%!nners

T-e ot-er studies re/uirin* $ruition !re5

Ti"e stud

Produ)tion per s-i$t oper!tion per s-i$t

St%e stud

2.-.5 ole o# )uper%isor:

T-e superisor p%!s ! it!% ro%e in t-e produ)tion $%oor. Hes-e "!n!*es t-e

entire ,!t)- -i)- is ,een !%%o)!ted to t-e" !nd t-e -!e t-e $o%%oin*

$un)tions to per$or"57

1. T-e -!e to )one t-e proper stit)-in* "et-od to t-e oper!tors.

6. 'uide t-e oper!tors -en t-e $!)e di$$i)u%t in "!8in* !n oper!tion !nd

te!)- t-e" t-e "ost suit!,%e !nd !n e!s "et-od o$ per$or"in* t-e t!s8.

. 2-e)8 i$ t-e entire oper!tor in t-e ,!t)-%ine is ,us it- t-e or8 ,ein*

!%%o)!ted to t-e".


59/136

. H!e to "!int!in ! proper )o""uni)!tion ,eteen t-e oper!tors !nd t-e

"!n!*e"ent.

9. S-ou%d ,e in ! position to te%% t-e "!n!*er !,out e!)- oper!torKs s8i%% %ee%

-eneer !s8ed $or.

:. C-en !n oper!tor is on %e!e t-en t-e superisor -!s to "!8e sure -o

)!n ,e ! ,etter person to $it into t-!t !)!nt p%!)e.

3. At ti"es t-e superisor -i"se%$ sits !nd per$or"s t-e oper!tion i$

ne)ess!r.

14.T-e superisor s-ou%d ,e in *ood ter"s it- !%% t-e oper!tors , -!in* !

$riend% !ppro!)- to t-e" !nd !%so "ust "!8e sure t-!t none o$ t-e"

)re!te !n trou,%e $or t-e $!)tor !t !n ti"e.

T-e Produ)tion 0!n!*ers -e%p t-e p%!nnin* dep!rt"ent durin* p%!nnin* or

!%%o)!tin* ! p!rti)u%!r %ine $or t-e st%e , te%%in* t-e" t-e )!p!)it o$ t-e %ine

!nd !%so te%%in* t-e" !,out t-e s8i%%s o$ t-e oper!tors.


:


60/136

Process Flowchart of Sewing Department


3


61/136

2. FINISHING DEPARTMENT

2.>.1 Introduction:

In t-is se)tion t-e *!r"ent is proper% $inis-ed !nd p!)8ed , *iin* t-e

re/uired $inis- $or t-e *!r"ent. T-e *!r"ents $ro" sein* se)tion !re t!8en

$or ,utton -o%in* !nd ,utton pro)ess !nd !re t-en ,rou*-t to $inis-in* se)tion.

2.>.2 "rocess in%ol%ed in #inis'in! o# !arments:

Tri""in*

C!s-in*

2-e)8in*

A%ter!tion

Ironin*

0e!sure"ents

T!**in*

P!)8in*

Disp!t)-

2.>.3 "rocedure:

Girst% t-re!d )uttin* is done to )ut t-e t-re!ds t-!t !re $r!in* !nd

ent!n*%ed.

T-e *!r"ents !re sent $or !s-in* i$ re/uired.

Spottin* *un7usin* so%ent does spottin* !nd petro% or !n ot-er )-e"i)!%s

re/uired to re"oe t-e sti)8er "!r8s !nd st!ins.

T-e *!r"ent is $u%% pressed -i)- is )!%%ed *ener!% pressin*.

T-en *ener!% )-e)8in* is done -ere t-e -o%e *!r"ent is )-e)8ed !nd i$

t-ere !re !n $!u%ts in t-e *!r"ent t-e !re sent $or !%ter!tion to t-e

sein* se)tion.


4


62/136

An "inor !%ter!tion is done in t-e $inis-in* itse%$.

Gin!% )-e)8in* is done.

Gin!% pressin* is done , ste!" iron.

T!**in* is done.

T-e *!r"ents !re $o%ded !nd p!)8ed in indiidu!% po% ,!*s !s spe)i$ied

, t-e uer.

T-e *!r"ents !re t-en p!)8ed in t-e )!rton ,oxes !))ordin* to t-e

spe)i$i)!tion o$ uer.

2.>.4 Functions:

T-e $inis-in* dep!rt"ent is t-e dep!rt"ent -i)- )o"es !$ter !%% t-e

dep!rt"ents !nd it p%!s !n e/u!%% i"port!nt ro%e in t-e $in!% !ppe!r!n)e o$

t-e *!r"ent. T-is dep!rt"ent in)%udes "!@or% o$ t-e $o%%oin* steps57

&rimmin!:

T-is ino%es t-e re"o!% o$ t-e extr! t-re!ds $ro" t-e *!r"ent !t t-e stit)-ed

!re!s.

Inspection5

T-e inspe)tion )!rried out -ere is !))ordin* to t-e A?L 6. sste" !nd

so"eti"es it depends on t-e uer !%so i.e.+ i$ t-e uer e"p-!siBes $or !

144 inspe)tion t-en t-e )o"p!n -!s to do !s spe)i$ied.

)emi B "ressin!:

T-is -!ppens -en ! *!r"ent is di$$i)u%t to inspe)t in t-e )rus-es "!nner !s

it )o"es $ro" t-e !s-in* dep!rt"ent -en)e+ t-e do ! p!rti!% pressin* $or

t-e *!r"ents !nd t-en inspe)t it !nd tri" it !nd t-en send it to t-e )o"p%ete

pressin* pro)ess.

"ressin!:

T-e pressin* is done !$ter t-e *!r"ent -!s ,een )o"p%ete% inspe)ted !nd

t-e *!r"ents !re pressed on t-e ,!sis o$ -o t-e i%% ,e $o%ded durin*

p!)8in*.


1


63/136

&a!!in! )ection:

On)e t-e *!r"ents !re ,een done it- t-e inspe)tion !nd )o"p%ete pressin*

t-en t-e !re sent $or t!**in* t-e %!,e%s !nd t-e %!,e%s in)%ude t-e siBe %!,e%s+

pri)e t!*s !nd "is)e%%!neous %!,e%s i$ !n re/uired , t-e uer. On)e t-e

t!**in* is done t-e *!r"ents !re $o%ded !))ordin* to t-e uerKs spe)i$i)!tion

!nd !%so t-e !re eit-er $o%ded p%!in% or so"eti"es t-e !re $o%ded !$ter t-e

!re put to t-e -!n*ers !s per t-e uerKs spe)i$i)!tions !*!in.

T-e p!)8in* "!teri!%+ P2 det!i%s+ nu",er o$ siBe r!tios t-!t !re supposed to

,e put in !re !%% su**ested , t-e uer !nd t-e p!)8in* is done !))ordin* to

t-ese spe)i$i)!tions.

"ac,in!:

T-e p!)8in* is !%!s done in t-e )!rton ,oxes !nd t-ere !re seer!% )riteri!

$or t-e p!)8in* o$ t-e *!r"ents t-e !re !s $o%%os.

T-ere !re *ener!%% to !s o$ p!)8in* t-e *!r"ent57

i. T-e *!r"ent is indiidu!%% p!)8edr!pped in t-e po% ,!* -ose desi*n

i%% ,e spe)i$ied , t-e uer i.e.+ eit-er it- t-e -!n*er !tt!)-ed or p%!in po%

,!* p!)8in* !nd t-en t-e entire *!r"ents #!s per t-e p!)8in* )riteri!( is

!rr!n*ed in t-e )!rton ,ox.

ii. T-e ot-er "et-od is t-!t t-e *!r"ents !re @ust $o%ded !nd !rr!n*ed in t-e

)!rton ,oxes it-out puttin* t-e" in t-e po% ,!*. T-e p!)8in* )riteri!

$o%%oed in e!)- )!rton ,ox !s !%re!d "entioned is done in di$$erent !s

-i)- is !s $o%%os5

)olid "ac,in!:

In t-is "et-od o$ p!)8in*+ t-e )!rton ,ox i%% in)%ude *!r"ents o$ sin*%e)o%or !nd s!"e siBe.

Gor ex!"p%e+ 64 s-irts o$ ! si"i%!r )o%or s! n! ,%ue !nd t-e siBe s!

S i%% ,e put in one )!rton ,ox.

atio "ac,in!:

In t-is "et-od t-e )!rton ,ox in)%udes *!r"ents o$ s!"e )o%or ,ut o$

di$$erent siBes !))ordin* to t-e r!tio.

Gor ex!"p%e+ S 5 0 5 L 5 XL 5 9 5 9 5


6


64/136

Mi8ed "ac,in!:

In t-is "et-od t-e )!rton ,ox in)%udes *!r"ents o$ di$$erent )o%ors ,ut

o$ s!"e siBe or *!r"ents it- di$$erent )o%ors !nd di$$erent siBes in !

p!rti)u%!r r!tio $or".

A$ter t-e p!)8in* is done t-e *!r"ents !re 8ept in t-e *odonstores

unti% t-e uer sends t-e uer ?2 $or t-e inspe)tion purpose ,e$ore

de%ierin* t-e" !nd on)e t-e ?2 !rries+ -es-e i%% )-e)8 t-e"

!))ordin* to t-e 6. A?L %ee% !nd t-en see i$ t-e *!r"ents -!s to ,e

!))epted or re@e)ted.

Process Flowchart of Finishing Department


'!r"ent Re)eipt $ro" Sein*

C!s-in*

utton Ho%e

utton Att!)-

!r T!)8

Tri""in*

T-re!d Su)8in*

Pressin*

utton 2%osin*

Go%din*

P!)8in*

Gin!% 2-e)8

0idd%e 2-e)8


65/136

2.>.5 &'e 0o8 contains t'e #ollowin! in#ormation:

Nu",er o$ pie)es in e!)- )!rton ,oxes

St%e nu",er

SiBe r!tio !nd )o%or r!tio

Pur)-!se order nu",er

Address

!r )ode sti)8ers

2.>.( "ressin! 7.* Foldin!:

Tpes o$ $o%din*57

G%!ts

De!d "!n

H!%$ de!d "!n



66/136

Here $%!t is used in $in!% p!)8in* -!%$ de!d is used -ere $urt-er pro)ess -!s

to ,e "!de+ de!d "!n on% $or tr!nsport!tion.

2.>.- "ac,in!:

G%!t p!)8

St!nd7up p!)8 on% $or $or"!% s-irts

H!%$ de!d & de!d p%!ster p!)8 or ,u%8 p!)8in*

H!n*er p!)8 Q*!r"ents not $o%ded e.*. suit trousers

T-e purpose o$ p!)8in* is to s!$e*u!rd t-e *!r"ent+ to "!8e t-e present!tion

ne!t+ to "!8e t-e *!r"ent re!d $or s!%e.

2.>.> Carton "ac,in!:

T-is is t-e $in!% p!)8in* done in $our !s t-e !re57

So%id )o%orso%id siBe

So%id )o%or!ssorted siBe

Assorted )o%orso%id siBe

Assorted )o%or!ssorted siBe



67/136

2.1! IE DEPARTMENT

[email protected] Introduction:

T-e IED dep!rt"ent -!s to or8 it- "!n ot-er dep!rt"ents !s t-is

dep!rt"ent *ies t-e entire ide! o$ t-e *!r"ent )onstru)tion !nd t-e t-re!d

!nd tri"s )onsu"ption )riteri!+ oper!tors s8i%% %ee% )!te*oriB!tion !nd ot-er

re%!ted !spe)ts -en)e t-e p%! ! it!% ro%e in deter"inin* t-e )ost o$

produ)in* ! sin*%e pie)e o$ t-e *!r"ent !nd t-e !%so )!%)u%!te t-e )ost o$ t-e

$!)tor $or t-!t p!rti)u%!r st%e o$ *!r"ent.

[email protected] Functions:

T-e IED dep!rt"ent -e%ps t-e p%!nnin* dep!rt"ent to 8no t-e ti"e re/uired

$or t-e produ)tion o$ t-!t p!rti)u%!r st%e o$ t-e *!r"ent , )!%)u%!tin* t-e

SA0 !%ue $or it !nd t-e !%so -e%p in 8noin* t-e )!p!)it o$ t-e $!)tor

,!sed on -i)- t-e p%!nnin* dep!rt"ent t!8es ! de)ision i$ t-e -!e to

pro)eed it- t-e ite" or not. T-e IED )!%)u%!tes t-e SA0 !%ue $or t-e

*!r"ent+ )!%)u%!tes t-e produ)tiit o$ t-e *ien st%e $or t-e initi!% )ostin* !nd

!%so )!%)u%!tes or )ounts t-e !))essories )onsu"ption , t-e st%e !nd *ies

!%% t-ese det!i%s to t-e "er)-!ndisin* dep!rt"ent $or t-e )ostin* purpose

,e)!use t-e entire )ostin* )riteri! depends on t-ese !spe)ts !nd t-e IED !%so*ies t-e "er)-!nts su**estions re*!rdin* t-e redu)tion o$ t-e )ost o$

"!nu$!)turin* t-e *!r"ent , "odi$in* !n o$ t-e steps !nd t-e "et-od o$

doin* it.

T-e IED peop%e usin* t-e #'SD( 'ener!% Sein* D!t! prep!re t-e st%e

,u%%etin -i)- in)%udes t-e di$$erent tpes o$ se!"s !nd stit)-es t-!t -!s to ,e

done $or t-e *!r"ent !nd it !%so in)%udes t-e %en*t- o$ t-e se!"s !nd t-e

tpes o$ stit)-es t-!t -!s to ,e )!rried out !t di$$erent p%!)es o$ t-e *!r"ent

!s per t-e uers spe)i$i)!tions !nd !ppro!%. Tpes o$ t-re!d #-i)- is t-e

TEX(+ !re! o$ p%!)e"ent o$ t-e tri"s !nd !))essories !nd its %o)!tion di$$erent8inds o$ %!,e%s t-!t !re supposed to ,e p%!)ed+ t-e )riteri! under -i)- t-e

$inis-ed *!r"ent -!s to ,e )-e)8ed+ t-e ti"es !t -i)- t-e inspe)tion -!s to

,e )!rried out i%% !%so ,e "entioned in t-e st%e ,u%%etin+ t-is ,u%%etin i%% ,e

si"i%!r to t-e Te)- P!)8 ,ut )ont!ins "ore te)-ni)!% d!t! t-!n t-!t.

T-is dep!rt"ent i%% !n!%Be !nd esti"!te t-e "!npoer !nd t-eir s8i%% %ee%

-i)- is re/uired $or t-e produ)tion o$ t-e *!r"ent+ t-e !%so set ! t!r*et to

t-e ,!t)- $or !n -our+ $or ! s-i$t !nd $or ! "ont- -i)- i%% -e%p t-e" to

"!int!in t-eir outputs !nd !%so -e%ps in ti"e% )o"p%etion o$ t-e order or

so"eti"es e!r%ier. T-e i%% !%so *ie t-e t!r*et to e!)- oper!tor ,!sed on



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-is-er )!p!)it !nd s8i%% in order to -e%p t-e" $inis- t-eir pie)e o$ or8 on

ti"e !nd !%so "!int!in t-e /u!%it o$ t-eir or8.

A$ter settin* t-e t!r*ets $or ! ,!t)- !nd !%so $or e!)- oper!tor t-en t-e i%%

)!%)u%!te t-e e$$i)ien). T-is e$$i)ien) is pure% ,!sed on t-e d!i% output o$

t-e ,!t)- !s e%% !s t-e sin*%e oper!tor !nd t-en t-e )o"e up it- t-e

"ont-% output , t-e p!rti)u%!r ,!t)-.

T-is dep!rt"ent "!int!ins ! $i%e -i)- is t-e DPR #D!i% Produ)tion Report(+

in t-is report t-e upd!te t-e ,!t)- nu",er+ st%eite" nu",er+ !)tu!% output+

)o""itted output+ SA0 !%ue o$ t-e *!r"ent #,ot- !)tu!% !nd t-!t p!rti)u%!r

d!s SA0 !%ue(+ tot!% produ)tion ti%% d!te+ !er!*e e$$i)ien) o$ t-e ,!t)- ti%%

d!te+ pe!8 e$$i)ien) !)-ieed+ i$ t-e )o"p!n !s or8in* t-!t d! or not+ i$

t-ere !s ! de%! o$ produ)tion t-en t-e re!son ,e-ind it+ in$or"!tion !,out

t-e ,!t)- settin* prior to t-e "!ss produ)tion+ et).+ !%% t-is i%% ,e "entioned

in t-is DPR.

[email protected] oles and esponsi0ilities o# an I7:

On re)eipt o$ produ)tion p!)8!*e !nd stud t-e 2IED O !%on* it- t-e

)orre)t S!"p%e underst!nd t-e oper!tions !nd re/uire"ent o$ Go%der+

!tt!)-"ents !nd s8i%% re/uire"ent o$ oper!tions !%on* it- produ)tion

te!" !nd P%!n t-e L!out.

A$ter t-e st%e reie+ !rr!n*e t-e st%e st!rtup "eetin* it- 2IED +

Gin!%iBe t-e 02 L!out !nd t!r*et !%on* it- P0.

0!8e sure t-e ,!)8 %o!din* on ti"e " $or t-!t )%ose% or8 it- P0 $or !%%

S!"p%e !ppro!%s.

P%!n t-e )uttin* dept. "ore e$$i)ient% to "eet t-e %ine ,!)8 %o!din* d!tes.

0!8e sure t-e ,!t)- settin* !s per t-e 2IED !pproed %!out .)orre)t s8i%%

oper!tors -!e to p%!)e !s per t-e s8i%% "!trix.

0ust !$$ix t-e t!r*et sti)8ers !nd oper!tors s-ou%d underst!nd t-e t!r*et o$

t-eir oper!tions.

Ensure 2orre)t CIP is "!int!ined in %ine durin* )ourse o$ produ)tion.

Go%%o up Hour% or i-our% on Lo output oper!tors it- t-e -e%p o$ %ine

in )-!r*es !nd i"proe t-e oper!tions on d!i% ,!sis !nd *ie upd!tes to

Superisors !s e%% !s P0 on -our% ,i-our% ,!sis.

IE -e!d is responsi,%e !%% produ)tion reports.


9


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0!8e sure !%% ;SA sste"s in p%!)e in e!)- dep!rt"ent.

[email protected] ?ine alancin!:

Line ,!%!n)in* is ! pro)ess exer)ise , -i)- ! produ)tion superisor )!n

,!%!n)e output & input. T-e su))ess !nd $!i%ure o$ superisors & "!n!*er

depends on -is or -er 8no%ed*e !,out produ)tion %ine ,!%!n)in*. 'ood

superisor -o -!s ! *ood 8no%ed*e o$ !,out %ine ,!%!n)in* )!n en@o s-op

$%oor+ in ot-er -!nd ! superisor -o does not on% 8no !,out %ine ,!%!n)in*

)!nnot sit $or ! "inute in t-e s-op $%oor.

So+ to ,!%!n)e %ine t-e $o%%oin* e$$e)tie p%!nnin* s-ou%d ,e )%e!r in t-e "ind

o$ produ)tion superisor57

;no%ed*e o$ *!r"ent "!nu$!)turin*.

Crite don se/uen)e o$ p!rti)u%!r st%es.

'r!din* o$ oper!tion.

Re/uire"ent o$ %!,or.

'r!din* o$ %!,or !))ordin* to oper!tion *r!din*.

0!)-ines re/uire"ent !))ordin* to st%e.

Se/uen)e o$ "!)-ine on t-e s-op $%oor+ !))ordin* to se/uen)e oper!tion

o$ *!r"ent.

Tr!i% produ)tionpi%ot stud !!i%!,%e $!,ri).

Se)tion!%iB!tion o$ ,!t)- %ines #i$ re/uired(.

Identi$i)!tion o$ ,ott%ed ne)8 oper!tion.

Cor8 stud st!rtin* initi!% produ)tion s-ou%d ,e )%e!r ,e$ore.

T-e st!nd!rd ti"e *ies ti"e re/uired $or e!)- oper!tion.

A%%o)!tion o$ oper!tion on t-e ,!sis o$ e$$i)ien) !nd s8i%%ed %ee% o$

oper!tor.

Line ,!%!n)in* -e%ps in )ontinuous $%o o$ ,und%e it- "ini"u" inentor.


:


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[email protected] ?a0or Allotment:

L!,or !%%ot"ent depends up on t-e nu",er o$ oper!tions+ "!)-ines to ,e

used+ !nd "!teri!% $%o ,eteen t-e "!)-ines+ %ine ,!%!n)in* & )!p!,i%ities o$

t-e %!,ors. !sed on t-e oper!torKs per$or"!n)e -i)- ou%d -!e ,een

o,sered $or ! spe)i$ied period o$ ti"e+ t-e dep!rt"ent i%% !%%o)!te ! *r!de to

t-e oper!tor -i)- is !s $o%%os57

T-e oper!tors $or e!)- ,!t)- !re t!8en in ! r!tio o$5

Hi*-% S8i%%ed 5 64

S8i%%ed 5 6

Se"i7s8i%%ed 5 4

T-is is done irrespe)tie to !n st%e !nd uer !nd t-e )o"p%i)!tion o$ t-e

st%e.

A re)ord is "!int!ined in -i)- t-e s8i%%s o$ oper!tors !re upd!ted on ti"e%

,!ses. e)!use o$ "!int!inin* t-is re)ord t-e 8eep in tr!)8 o$ t-e oper!torKss8i%% !nd -is e$$i)ien)+ or8in* "et-od !nd !$ter ! p!rti)u%!r sp!n o$ ti"e t-e

upd!te t-e re)ord.

Suppose ! ne oper!tor @oins !nd -e is )o"p%ete% un!!re o$ stit)-in* t-en

! tr!inin* $or !,out


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Eer d! t-e IED te!" t-ere i%% ,e ! "eetin* -ere in -i)- t-e spe!8

!,out t-e "!inten!n)e o$ e$$i)ien) o$ t-e ,!t)- in t-e produ)tion $%oor. T-e!%so )ondu)t ! produ)tion reie "eetin*s it- t-e oper!tion te!" in -i)-

t-e dis)uss !,out t-e %ine !nd t-e oper!tion )!rried out in t-e ,!t)- suppose

t-e preious% p%!nned $%o is not *iin* t-e esti"!ted e$$i)ien) !nd output

t-en t-e i%% t-in8 o$ )-!n*in* t-e %ine p%!n !nd reie it !nd %!ter $o%%o t-e

ri*-t one.


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Process Flowchart of I- E- Department


91

Start

Training, selection 1

(evelopment

Wor" 'easurement Systems (evelopment

Selection of Operators, +elpers,

Supervisors, &hec"ers, 6&, etc.

Time

Stu(y

'etho(

Stu(y

O)D

nalysis

7ine

$alancing

S"ill

'atrix

$atch

7ayout

Style

$ulletin

$atch

)erformance

0n(


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2.1@.( Acti%ities "er#ormed In 7ac' )ection:

a. AAM& &rainin! section:

7Oper!tor se%e)tion pro)edures5 T-e pro)edure "entioned $or t-e se%e)tion o$

oper!tors "ust ,e "!int!ined.

7Tr!inin* pro)edures5 Spe)i$i) AA0T tr!inin* pro)edures s-ou%d ,e used.

7Oper!tor s-i$tin* pro)edure5 A%% AA0T tr!iners -!e to t!8e oper!tor

re/uisition $ro" e!)- ,!t)- on ee8% ,!sis.

7Tr!inin* pro*ress st!tus5 T-is st!tus s-ou%d ,e upd!ted eer d! !nd

s-ou%d ,e disp%!ed in t-e AA0T dep!rt"ent.

0. Cuttin! /epartment:

7Oper!tion u%%etin5 O is re/uired to de)ide t!r*ets & "!npoer !%%o)!tion.

72uttin* )-e)8 %ist5 T-is is ,!si) re/uire"ent in )uttin* se)tion to 8no -o to

)ut + -ere not)-es i%% )o"e & -ere dri%% -o%e "!r8in* is re/uired & to

de)ide p%!)e"ent o$ p% nu",erin* !s per stit)-in* O re/uire"ent

7E$$i)ien) Report5 E$$i)ien) report -!s to ,e prep!red usin* SA0s o$ nest%es.

7In)entie St!te"ent5 It s-ou%d ,e "!de $or e!)- oper!tor ,!sed on upd!ted

in)entie s)-e"es.

7T!,%e p%!nnin*5 T!,%e p%!nnin* is "ust $or spre!din* & %!out & , t-is e

)!n uti%iBe )uttin* t!,%e proper%.

7L! s%ip5 It is i"port!nt to 8no t-e ti"in* !nd ot-er det!i%s o$ spre!din* !nd

)uttin*. T-ese det!i%s !re "entioned in L! s%ip.

7'u" s-eet5 'u" s-eets s-ou%d ,e upd!ted on -our% ,!sis.

7Hour% T!r*et ,o!rds5 Hour% produ)tion !nd t!r*et re/uired s-ou%d ,e

"entioned on t-e ,o!rd.

7L! inspe)tion5 Eerd! P0+ ?A0 & 2uttin* In)-!r*e need to )-e)8 t-is

report.


96


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c. )ewin! /epartment:

7Oper!tion u%%etin5 O is re/uired to de)ide t!r*ets & "!npoer !%%o)!tion.

7L!out5 T-e %ine %!out s-ou%d ,e "!de !nd do)u"ented $or t-!t p!rti)u%!r

st%e.

7Per$or"!n)e "onitorin* sste"5 Geed,!)8 on oper!tor per$or"!n)e s-ou%d

,e *ien to e!)- oper!tor+ !nd t-en e )!n !)-iee ,etter e$$i)ien).

7G%!* Sste"5 0ust use $%!*s $or oper!tor per$or"!n)e.


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2.11 "UALITY ASSURANCE DEPARTMENT

2.11.1 Introduction:

?u!%it is t-e "!@or )riteri! $or !n produ)t !nd t-e s!"e ru%e !pp% een to

*!r"ent industries !%so. In order to "!int!in /u!%it t-e /u!%it !ssur!n)e

dep!rt"ents -!s sp%it up t-eir @o, into di$$erent st!*es o$ "!nu$!)turin* !nd

t-ere !re )%!ssi$ied into $our "!@or *roups -i)- !re !s $o%%os.

a. "reproduction Audit:

In t-is st!*e !uditin* is "!in% done $or t-e st!*es -i)- )o"e ,e$ore t-e

produ)tion !nd t-!t is t-e s!"p%in* st!*e. Here t-e !uditin* is done $or !%%

S!"p%es !nd pre)ise% $or t-e siBe set S!"p%es !nd !%so $or t-e pi%ot

produ)tion *!r"ents. T-e siBe set S!"p%es !re *ien i"port!n)e to ,e)!use

t-e !re "!in% !s8ed , t-e uer $or )-e)8in* t-e di"ensions o$ t-e

*!r"ent -en)e !n extr! stress is *ien to t-ese S!"p%es !nd t-e !uditin* $or

t-e" is "!in% done $or t-e "e!sure"ents o$ t-e *!r"ent !nd t-e

"e!sure"ents !re )-e)8ed !t !%% t-e )riti)!% !re!s in t-e *!r"ent.

Gor ex!"p%e5 i$ it is ! trouser t-en t-e "e!sure"ents !re )-e)8ed !t t-e!re!s %i8e t-e %en*t- o$ t-e trouser+ !ist "e!sure"ents+ inse!"

"e!sure"ents+ t-e dist!n)e o$ t-e ,e%t %oops+ et).+

Gor t-e pi%ot run produ)tion !%so+ t-e *!r"ents !re )-e)8ed $or t-e

di"ensions !nd !%so $or t-e p%!)e"ent o$ t-e !))essories !nd tri"s. $or

ex!"p%e+ t-e %!,e% !tt!)-"ent !re!s+ et).

0. Cuttin! Audit:

In t-e )uttin* st!*e+ -i)- is t-e )riti)!% st!*e o$ t-e *!r"ent produ)tion t-e

!uditin* is $urt-er diided into "!n ot-er dep!rt"ents -i)- !re

1. Spre!din*

6. Re%! )ut

. !nd 8ni$e


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. H!rd p!ttern

c. )ewin! Audit:

In sein* pro)ess t-e inspe)tion is done in to !re!s+ t-e !re57

i. In Q %ine !udit5

Here t-e *!r"ents !re )-e)8ed durin* t-eir di$$erent st!*es o$ "!nu$!)turin*.

Here t-e entire "!nu$!)turin* pro)ess $or ! p!rti)u%!r *!r"ent is sp%it into t-e

re/uired nu",er o$ p!rts "! ,e to Q t-ree !nd t-en !t t-e end o$ e!)-

st!*e t-e inspe)tion is )!rried out , t-e person -ose "!in @o, is !uditin*.

Gor ex!"p%e i$ t-e *!r"ent t-!t is ,ein* "!nu$!)tured is ! s-irt t-en t-e

entire "!nu$!)turin* pro)ess is ,ro8en don into st!*es %i8e+ t-e $inis- o$

$ront+ $inis- i$ ,!)8+ s%eee !tt!)- $inis- !nd t-en t-e entire s-irt. In t-is )!se

t-e s-irt is ,ein* )-e)8ed !t e!)- st!*e !nd t-e !uditin* personne% i%% ,e

proided , )ert!in spe)i$i)!tions !nd !%so t-e to%er!n)e %i"its ,!sed on

-i)- -e )-e)8s t-e *!r"ent. Here eer sin*%e *!r"ent is )-e)8ed.

ii. End Q %ine !udit5

Here t-e *!r"ents !re )-e)8ed !$ter t-e entire pro)ess is oer !nd t-e

spe)i$i)!tions !re

Internship Report and Project Main_Apurv Pranav

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Transcript of Internship Report and Project Main_Apurv Pranav