APPAREL INTERNSHIP REPORT

MADURA FASHION & LIFESTYLE, ADITYA BIRLA NUVO LTD.

BANGALORE

Department of Fashion Technology

NATIONAL INSTITUTE OF FASHION TECHNOLOGYNEW DELHI

COMPILED BYKUNAL NAKRAMANU SRIVASTAVA(BFT 7)

DECLARATION

I declare that this project report of Apparel Industry Internship & Training at Madura Fashion & Lifestyle, Bangalore is my original work.I also declare that all the data taken and worked upon has been acknowledged by me. I have put in a great amount of effort to complete this internship report successfully.

...[Manu Srivastava]B.Ftech (2011-2015)

ACKNOWLEDGEMENTS

Foremost, we would like to thank our CC Ms. Girija Jha and our mentor Mr. Prabir Jana for supporting us through our summer internship project and helping us at every step to make the project successful.We would like to express our sincere gratitude to Ms. Surbhi Gupta and Ms. Sarita Sharma (HR, Young talent management) for giving us the opportunity to do our projects at Madura Fashion and Lifestyle. I am immensely grateful to my industry mentors Ms. Deepa Chandran (Group manager, PDQA, Mr. Jayant Prasad( Allen Solly ) and other members of PDQA Department at Madura Fashion & Lifestyle with special mention of Mr. Sudhakar (Head,TMC) and Mr. Sudhir Singh (IE, TMC) for their immense guidance, support and training without which the internship would have been unsuccessful.We would also like to appreciate the support given by every staff and employee of Madura Fashion & Lifestyle who took out valuable time for us and helped us in all possible ways.

CONTENTS

1Executive Summary

2Introduction to the company

>History

>Brands

>Organizational structures

>Departments

3Project 1 : Material flow study to reduce the timeline of womens wear pre-

Production Sampling process through standardization

>Project Objective and methodology

>Standard operating procedure

>Department wise process changes and improvisations

4Project 2: Project portfolio identifying projects for rapid prototyping

>Project objective and methodology

5Project 3: Retail based analysis of innovative practices across all brands nationwide of

Madura F&L.

>Project objectives and statistics

6Trade Show

7Learning outcome

8Bibliography

EXECUTIVE SUMMARY

The 14 week Apparel summer internship was pursued at Madura Fashion & Lifestyle, Bangalore starting from 26th May to 31st August 2014. I have worked under the guidance of Ms. Deepa Chandran (Product Development Quality Assurance Dept.) and the details of the three projects assigned and undertaken are as following:1. Reduction of Material flow time in the newly established centralized womens wear Proto sampling unit to reduce the lead time for the process of Sampling and develop a standard operating procedure to achieve optimal time for sampling. (Location : Site 7F, Raj Pinnacle, Doddanekundi Industrial Area, Whitefield, Bangalore)

2. Project Portfolio identifying Projects for rapid prototyping and investment in a year.

3. A retail based study of Kaizen practices across all brands of all regions nationwide of Madura F&L and subsequent organization of an event KAIZEN SPREAD for replication, adoption and spreading of the best innovative practices.

The document also includes a brief report on the trade show, which was a very knowledgeable experience in terms of exposure towards the actual buying process. The duration of work for the trade show was 2 weeks.

INTRODUCTION

HISTORY

Established in 1988 by Madura Coats Limited, Madura Fashion & Lifestyle has its origins in the erstwhile Coats Viyella Plc, Europes largest clothing supplier. In December 1999, Aditya Birla Nuvo, an Aditya Birla Group company, acquired Madura Fashion & Lifestyle to become the undisputed leader in the readymade menswear industry in India. In 2000, the company became a wholly-owned subsidiary of Aditya Birla Nuvo.Madura Fashion & Lifestyle, a division of Aditya Birla Nuvo Ltd, is one of Indias fastest growing branded apparel companies and a premium lifestyle player in the retail sector. After consolidating its market leadership with its own brands, it introduced premier international labels, enabling Indian consumers to buy the most prestigious global fashionwear and accessories within the country.The companys brand portfolio includes product lines that range from affordable and mass-market to luxurious, high-end style and cater to every age group, from children and youth to men and women. Madura Fashion & Lifestyle is defined by its brands Louis Philippe, Van Heusen, Allen Solly, Peter England and People that personify style, attitude, luxury and comfort.The company's lifestyle store, The Collective, offers a unique blend of global fashions, international trends and innovative customer services, to customers in Bangalore, Mumbai, Delhi, Delhi NCR, Chandigarh and Pune.Planet Fashion, the multi-brand, apparel-retailing arm of Madura Fashion & Lifestyle, housing the company's in-house and other brands, is the largest chain of stores of its kind in India.Madura Fashion & Lifestyle reaches its discerning customers through an exclusive network comprising more than 1,300 stores, covering 1.9 million sq ft of retail space, and is present in more than 1,300 premium multi-brand stores and 300+ departmental stores.Madura Fashion & Lifestyle, an IT and web-enabled organisation, is the first-ever apparel company to have successfully implemented the ERP SAP system. It is also the first company globally to integrate Retek ERP with SAP ERP.Recently, the company launched Trendin.com, a one-stop shopping destination for the style conscious. As the official online store showcasing the widest range of merchandise from Louis Phillipe, Van Heusen, Allen Solly, Peter England and People, Trendin.com caters to both men and women. With the best talent in the fields of design, manufacturing and product development,Trendin.combrings contemporary, chic, fashion forward sensibility at price points that work with every budget.Madura Fashion & Lifestyle is one of the fastest growing branded apparel companies, recording a blistering growth rate of over 25 per cent year-on-year.

BRANDS UNDER MADURA F&L

MULTI-BRAND RETAILING

MULTI-BRAND LUXURY STORE

ORGANIZATIONAL STRUCTURE

GENERAL ORGANIZATIONAL STRUCTURE

DEPARTMENTS

Design: This department is responsible for studying trends in the domestic and international markets and designing a range of garments in line with the brand promise and customer expectations. Production: It is responsible for understanding fabric and garment trends and developments, garmenting processes and product creation. Sourcing: This team is responsible for sourcing the appropriate fabric, trims/finished garments at the right cost and right time. Supply Chain: This department is responsible for procuring the right merchandise in full and at the right time. Operations: It is responsible for manufacturing garments as per agreed costs and quality standards. Sales: This department is responsible for sale of garments to achieve brand sales and profitability targets. Retail Operations: This team responsible for sale of garments through retail channels to achieve retail sales and profitability targets. Retail Buying & Allocation: This team is responsible for placing a buy on garments and allocation to right stores at the right time to achieve retail sales and profitability targets. Marketing: It is responsible for generating consumer insights, research, and communication. Visual Merchandising: This team is responsible for retail store look and feel, understanding of global visual merchandising trends and implementation. HR: It is responsible for attracting, developing and retaining talent at Madura Fashion and Lifestyle. IT: It is responsible for enabling the organization to achieve its vision through application of technology. Finance: Responsible for accounting, finance and management information systems

PROJECT 1 Reduction of Material flow time in the newly established centralized womens wear Proto sampling unit to reduce the lead time for the process of Sampling and develop a standard operating procedure to achieve optimal time for sampling.

PROJECT NAME: Material Flow Study to reduce the timeline of the womens wear pre-production sampling process through standardization. Location : TMC Site 7F, Raj Pinnacle, 3rd Floor, Doddanekundi Industrial Area, Whitefield, Bangalore

PROJECT OBJECTIVE: To observe, study and analyze the existing system of material flow in order to identify the areas and operations which can be targeted for improvisation to increase the efficiency, productivity and reduce the overall lead time of the centralized sampling process.

PROJECT METHODOLOGY: Studying the existing process of material flow from stores to warehouse through quantifiable questionnaires, discussions and flow diagrams. Identifying and defining the constraints and challenges. Analyzing the time consumed and accuracy of operations in each department. Analyzing the capacity, productivity and efficiency of each department. Identification of critical areas and suggesting steps for reducing timelines and increasing efficiencies in the material process flow. Developing a standard operating procedure for achieving optimal time for sampling

The SOP consists department wise standardized procedures which are represented through:

TECHNOLOGY MANAGEMENT CENTER: BRANDWISE BREAKUP

TMC PERCENTAGE USAGE BREAKUP

TMC PIECES PER BRAND CONTRIBUTION

GARMENT WISE BREAKUP

OPERATOR PRODUCTIVITY

ABSENTEESM DATA

1. VAN HEUSEN (APRIL JUNE)

2. ALLEN SOLLY (APRIL-JUNE)

For each download, the causes of failures were recorded during the review meetings. The failures were classified into minor/major failures, Qualitative/Quantitative failures, or failures due to design changes. The information from each review meeting was recorded in the following format.

After recording all the information and quantifying the data, critical areas were identified for targeted improvisations in order to reduce the sampling time, increase the efficiency and the quality of work being done. A standard operating procedure was developed for the unit, which clearly and systematically represents the ideal material and process flow that should be adopted to achieve an optimal time for proto sampling.

2014.MADURA FASHION AND LIFESTYLE

STANDARD OPERATING PROCEDURE (SOP)

TECHNOLOGY MANAGEMENT CENTERSite 7F, Raj Pinnacle, 3rd Floor, Doddanekundi Industrial Area,Whitefield, Bangalore -5600048TABLE OF CONTENTS

Introduction

Objectives of TMCPurpose of TMCDeliverables at TMC

TMC Process maps

Material flow process chartInter departmental functional process chart

Workflow, RACI charts, SIPOC Templates

CAD StoreProduction (Cutting and Sewing)Knit Section

Outsourcing

Future scope

Conclusion

General awareness

INTRODUCTION

Technology management is set of management disciplines that allow organizations to manage their technological fundamentals to create competitive advantage.

OBJECTIVE OF TMC

Transforming design Ideas to world class apparel reality with the best usage of manufacturing practices and reduce design product cycle by a continuous learning curve and technical enhancement

THE PURPOSE OF TECHNOLOGY MANAGEMENT CENTRE (TMC)

TMC was formed to reduce the time line and bridge the gap between design ideas to physical product, which was observed over a period of time by the management in the face of technical and technological constraints. The emphasis was on Womens wear which had faster business potential among all the categories in the retail space.

Technical Solution Provider Best in Class Tech Pack Centralized Fit provider Integrated Base Pattern & specification LAB Provide conducive work environment for Internal and External customer Bench marking to Global standards Innovative platform for design team Time line adherence

KEY DELIVERABLES AT TMC

ORGANISATIONAL STRUCTURE

QUALITY CONTROLHOUSEKEEPING TMC HEAD CO-ORDINATOR PATTERN MASTER GARMENT ENGINEER STORE INCHARGE CUTTING INCHARGE SEWING SUPERVISOR STORE HELPER/RUNNER MAINTENANCE OPERATORS FLAT KNITTINGTMC: LAYOUT

PROCESS MAPS

TMC: MATERIAL FLOW PROCESS CHART

INTER- DEPARTMENTAL FUNCTIONAL PROCESS CHART

START

Machine ReadyCut PatternTrim Card &TrimsYarnsFabric & Trim RequirementFabric/Trim Fabric/InterliningSketch/Reference/Sample/spec/Tech PackDOCUMENTATION & DISPATCH TO THE WAREHOUSEFINISHING/QUALITY CHECK/DESIGN REVIEWSAMPLE READYOutsourced: Washing, Embellishments, Printing, and Embroidery etcMAINTENANCESEWINGCUTTINGSTORESpecial Machine(FLAT KNIT)GE/Coordinator/Pattern Master

DESIGN INPUT

NONO

YES

ENDGLOSSARY OF PROCESS ELEMENTSProcesses have been designed to cover Process Maps, Templates and RACI Charts

Process Documentation Scope:

-What analysis formats are used to support the process?- Captures standardized formats of documents used in different process stepsWho plays what role in the execution of the process?Captures roles and responsibilities of the persons directly and indirectly involved-How is the process carried out and by which functions?- Captures the basic operational flow and steps to be followed.SIPOC TemplateRACI ChartsProcess Maps

GLOSSARY OF SHAPES USED IN THIS DOCUMENT

Event

Note (1): Legend Colour coding

R Responsible

A Accountable

C Consulted

I Informed

1. DESIGN DOWNLOADObjective

Provide accurate and elaborate information about the new products for rapid prototyping.

1.1Download Activities The style/Design of the new product is shared in the form of sketches, samples, and/or pictures by the Product & Design team. Measurements along with discussions and clarifications regarding the technical details of the styles are recorded. The fabric and trims requirements for designs are also specified and are subsequently used to prepare trim cards.

1.2Checklist of Activities (Owner- coordinator) The designer, Brand Tech, Garment Engineer, Co-ordinator, Store manager, and Pattern master (if required) are a part of the download meeting.

Check availability of sample/sketch/picture

All the information requirements (Product styling, Technical details, measurements, Fabric & Trim requirements) to be discussed and recorded in the master design sheet during the download meeting.

Check for Fabric and trims availability (Nearest alternative)

Understanding timelines and material requirements

File Compilation and handover

1.3 RACI CHART: DESIGN DOWNLOAD

L1 PROCESS STEPMANAGERCO-ORDINATORBRAND TECHDESIGN/

PRODUCT/ PDQASTORE INCHARGEPATTERN MASTERGE

Discussion of Technical detail of style.

ARCCCCC

Measurements/sample/ TechpackARCCCCC

Fabric and trim requirement specification

ARCCCCC

Check for sample/ picturesARCCCCC

Understanding timelines and material req. ARCCCCC

1.4 PROCESS CHART: DESIGN DOWNLOAD

DESIGN (STYLES/SKETCHES/ SAMPLES/PICTURES)FABRIC & TRIMS SPECIFICATIONS (Shell, Lining, Buttons, zippers etc)BRAND/CENTRAL SOURCING(FABRICS/TRIMS) GE/IE (TECH PACK/MASTER DESIGN SHEET)IE/GE/CO-ORDINATOR (REFRENCE INFORMATION FOR REPETETIVE STYLES)Handover to CAD/ Pattern MasterClarifications Regarding Style/Design/Fabric/Trims/Measurements/ or any other information requiredFile compilation for all styles from the download along with Fabric/Trim Fabric/ Trim samplesChecking Fabric Availability from stores/ Selection of the Fabric (Nearest Alternative)

NOOK

YES

1.5 SIPOC TEMPLATE: DESIGN DOWNLOAD

SUPPLIERINPUTPROCESSOUTPUTCUSTOMER

Design/Product/PDQAProduct Styles/designs/picturesSamples/sketches

Fabric and trim specifications

Fabric and trims

Clarifications/discussions/ Technical detailingConsolidated design/style/technical information

CAD/Pattern Master

Store

Garment technicianMeasurements/tech packClarifications/discussions/ Technical detailing (Tech pack)CAD/Pattern Master

2. CAD Objective

Provide accurate and precise new development patterns with best fit, production friendly and cost effective either derived from sketch, specs, existing style or bench marking references within the stipulated time frame.

2.1 CAD FunctioningCAD area converts raw ideas by designers into a visual reality template. Here, a sloper or a block pattern is created and its related activities take place such as muslins, digitization, grading, etc. As complete development follows the baseline structure of CAD, hence it is very important that the accuracy level from this department is of highest level.

2.2 L1 Process Workflow

Pattern master part of Download meetingDevelopment of pattern based on inputsPlotting the Pattern /digitizing Interaction with design, tech and sourcing on design & construction Check for pattern correctnessMake changes to pattern as per comments and corrections

2.3 Checklist of Activities

Check correctness for Sample/design/sketch/Spec Check for construction, grading and shrinkage incorporation. Check Pattern Correctness for 1. Measurements2. Styling3. Seam to seam and panel to panel match4. Notch point 5. Ready parts. Correction of pattern based on proto/fit comments. Pattern Plotting for internal and external requirement need based.

2.4 CAD management team:

CAD/Patterning : Will overall lead for the Development related to pattern, shrinkage, slopers, body block creations, specs( if not provided by tech), Spec verification if provided by tech, plotting, cross check physical pattern to spec and corresponding activities.

Manager (TMC) : Will initiate with CAD/Pattern team and align to Overall requirement of the design, production and customer/clients and oversee the Department operations on day-to-day basis.

Garment Engineer : Will work in framework of consulting CAD regarding Technical inputs and pass on the critical inform to quality/ cutting and sewing line.

Brand Tech: Will provide specs as per the design and slop.

Quality Assurance: would assist directly with Pattern master in cross checking critical specs on pattern and its correctness, the information in turn will be passed on to with Cutting and Sewing line.

2.5 Work flow of CAD

2.6 RACI CAD

L1 PROCESS STEPMANAGERASST MANAGERBRAND TECHDESIGN/SOURCING/PRODUCTPDQAQUALITYCAD

Pattern development & fitACCCCR

Plotting for internal and externalACCR

Pattern Digitizing and GradingACCR

Pattern Check for variationACCR

2.7 CAD: SIPOC SUPPLIERINPUTPROCESSOUTPUTCUSTOMER

Design/product/SourcingSpecification/design/block referenceClarification/digitizing & pattern creationReady pattern archive - soft /hardGE/IE/Cutting

TMC storesFabric design - repeat/ flow/face/designBase pattern grading and balancingBase pattern - soft/hard with fabric inputsCutting

IE/GEReference sample( if any)/ construction detailsPattern developmentReady and cut pattern issue to cuttingCutting

Design techSpec/ style detailsEvaluation & fit verificationPattern specification and constructionGE/IE/QA

CoordinatorFabric shrinkage - Thermo & washShrinkage advise to patternShrinkage added in patternQA

Central sourcingRatio - size range/ specificationDigitizing/gradingReady pattern plottingExternal vendors

3. STORE

Objective:

Systemized data capturing, recording, bar-coding, storing and material reconciliation. Simple and faster way to source sample material as one stop solution provider to design and product team, adhering to design , colour, quality and quantity needs.

3.1 Store Functioning:Store has a critical role in faster process movement of overall activities though out the TMC. Material store plays the role of start point of all activities in TMC as well as terminating point of activities with respect to development.

3.2 L1 Process Workflow

Inventory Stock Grid of Fabric & trims availability

Procure the Fabric & Trims from FCL&CCL locationCheck for quality of raw materials and reject if not meeting required quality standardsSample input of Fabric and Trims from Design/Product/SourcingSwatches of Fabric & Trims to be made available to design for reference Fabric & trim if not used for more than 60 days to be send back & reconcile

Special Fabric & Trims procurement from Local vendor

3.3 Checklist of Activities All procurement of Fabric & trims to be carried out within 1week of Download. Check the availability of materials from available stock. New Procurement of Materials via PI from suppliers & material sourcing. Subsequent PO rising for the new procurement fabric and trims through CCL/FCL/ Suppliers. Procurement of fabric via fabric sourcing and trims via trims sourcing team Matching of all trims to fabric base and organizing as per specification all trims like thread tkt, tape/lace width &designs, cords, fusing etc. Machinery and office stationary stocking and inventory maintaining. Pre shrinkage of all the fabrics either wash or relaxation to arrest abnormal shrinkages. Codification / Bar-coding of fabric and trims samples in PLM. Bar-coding of the Samples completed and dispatch to PE warehouse All documentation and material ownership maintenance. Reconciliation of all inward and outward from system Materials Fusing data bank & history.

3.4 Store management activities:

Store In charge: Planning the feeding activity, inward, outward, fabric & trims procurement, maintain minimum stock levels, and other office related miscellaneous items requirement. PO and PI raising, PLM and SAP updating

Reconciliation closure and MIS, Follow-up with fabric/trims sourcing and updating to design.

Store help: Upkeep of store, material issue & receipt to cutting, sewing & office. Trim card preparation, thread winding, fabric and trim checking for quality and quantity. Barcode printing, label printing, shrinkage bits preparation, dying of trims or fabric, document preparing and track of all the day today material movements.

3.5 RACI STORES

L1 PROCESS STEPMANAGERSTORESGE/IECO-ORDINATORCADCUTTINGSEWINGDESIGN& PRODUCTFAB/TRIMS SOURCINGFABRIC AND TRIMS WAREHOUSEFG WAREHOUSE

Fabric availability, storage, and issueARCCCCCC

Trims availability, storage and issueARCCCCC

Reconciliation/ Documentation & dispatch ready garmentsARCCCCC

PI/PO ARICC

PLM (Material)ARCI

SAPARCCC

3.6 WORK FLOW OF STORES

3.7 STORE: SIPOCSUPPLIERINPUTPROCESSOUTPUTCUSTOMER

Design/product-Fabric-Trim fabric-Trims -Inward and outward of material-Quality check of input receipt and replace-Material staging-Weekly material planning- Minimum level stockPO/ PI/ Invoicing/ Documentation Sourcing/PDQA/CCL/FCL

External vendor suppliers-Accessories-Machinery spare & folders-Office & cad stationeryQuality raw material outward to Inter-deptupdated-Trim card-Kit-Coordinator-Cutting -Maintenance-Cad-Sewing line

GE/IEInterlining & consumption calculation

Running length trim organizing -Tape-Laces-Belts etc

Sewing /finishingReady garment -Barcode codification - Individual garment wise data visibility on input & output-ReconcileFinished sample outward & documentReconciliation closurePE-warehouse/ Design/Product

CoordinatorTech pack / Down load-Trim card preparation-Fabric and trims dying if required -Inter departmental input movement & coordination-Trim card- DTH fabric/ trims- Readiness of the fabric/trims-Sewing-Cutting

4. PRODUCTION: CUTTING AND SEWINGObjective:

The processes and methods used to transform design via tangible inputs (raw materials, semi-finished goods, subassemblies) and intangible inputs (ideas, work aids, techniques, information, knowledge) into apparel sample . Resources are used in this process to create an output that is best in the industry.

4.1. Production Functioning:The primary purpose of the production function is to address efficiency in the use of factor inputs in production and the resulting distribution of Quality samples, while abstracting away from the technological problems of achieving technical efficiency.

4.2. L1ProcessWorkflow

Parts preparation and Assembly closure Work study and time line for completion & quality parametersPattern, ready pattern, measurement sheets, tech pack, construction, machinery and work aids details hand over

Download to be provided by the GE/IE(Design, sketch & sample)

Sample Quality review corrections and send to store For Sap closureWork order release from SAP Fabric, Trim & trim card (BOM) hand over from stores to cutting and sewing line. Cutting, recutting, checking, numbering, fusing, outsourcing bundling and issue to line

4.3. Checklist of Activities

The entire Download for Design, would be discussed together with TMC Team (GE/IE, Pattern Master, Coordinator) along with the Product ID. PLM updation of BOM, Construction details and special tech usage on folders, etc Internal down load will be given once the pattern and materials are ready to cutting, sewing line and QA. Work order will be released by stores for Fabric and trims issue. Cutting, sewing and final quality check will be carried out and the approved sample will be handed over to store.4.4. Production management team:

Manager (TMC): will overlook the day to day activity on quality and productivity with the team members.

Asst. Manager (TMC): will provide all relevant tech pack and construction details and see to that standard adhered to achieve the desired sampling standard.

Pattern Master : Providing sampling pattern with all relevant details on pattern margins, notchs, fit, ready pattern, understanding of critical construction, spec verification, garment balancing, etc to cutting, sewing and QA.

Cutter: Pattern understanding and verification, cutting, panel checking, re-cutting, numbering, bundling and physical pattern storage.

Machine Maintenance: Up keep of all Machines, preparedness of attachments, folder and jigs arrangement, reduce down time of m/c setting, training special machine skills and skill matrix up gradation.

Co-coordinator: Planning, co-ordination, time line and execution of activity between store, production and outsourced jobs.

L1 PROCESS STEPMANAGERGE/IECADSTORESSUPERVISIOR/QA/FLAT KNIT PROGRAMMERMAINTANCECUTTINGCO-ORDINATOR

Discussion of Technical detail of style

IRCAAAA

Fabric and trim Procurement from store

ICACCR

Cutting and re-cutting, numbering, fusing, checking and bundling

ICCCCCA

Cutting issued to Sewing Line

ICCCRA

Machine setting as per Styling, fabric nature and thread quality

IACRC

Tech-pack study with pattern and cutting

IACRC

Part and Assembly preparation

ACRCC

Sending Sample for outsource Job

ACIR

Quality & spec check of Sample

ACR

Sample Handover

ICRA

4.5. RACI Production

4.6. Work flow of Cutting

GE DOWNLOAD ON FABRIC WAY, CUTTING, AND GRAIN CAD CUTTING PATTERN STORES FABRIC AND TRIM FABRIC CO-ORDINATOR TECH PACK & FILE HAND OVER AND MOM Download Tech-Pack and Sample (If available) Pattern check for >Grainlines >Margins >Notches and >No. of Parts. Fabric Process Relaxation and checking for defect Marking Steaming (silk / chiffon / georgette) Washing (Knits, washed sample, Denim) Fabric way Fabric cut plan (marker making) Fabric pattern matching Identification Marker planning and consumption Fabric Tearing (Remove bowing / skewing woven) Fabric Laying, Patten Balancing, Marking, Selvage Tearing, Block and ready cutting, Trim Fabric cutting, Lining, Interlining, Binding, Notches OK NO YES Sorting, Numbering, Panel Checking, Re-cutting, Bundling QA CHECK CUTTING READY OK YES YES NO NO Garment finished, Packed and hand over to stores Embroidery & Printing 4.7. Work flow of Production

4.8. PRODUCTION: SIPOC

A) CUTTING:SUPPLIERINPUTPROCESSOUTPUTCUSTOMER

CADReady and cut pattern- Pattern check-Cut planning-Part check to pattern Grain,-Marking notches and marginsPattern ready to cutSEWING LINE

GE/IEReference sample( if any)-Specs-Tech pack-Fabric design-Repeat/ flow

Sample to pattern checkPattern to tech pack checkConsumption check Sample ready for cutting process and indent for fabric required from stores

Stores-Actual fabric/trim fabric/ Interlining- Fabric widthFabric width, flaws, -fabric/interlining/Trim fabric -CheckingSample cuttingPanel checking for fabric defects/re cuttingSorting/numbering/ bundling/fusing

Coordinator-Fabric shrinkage thermo & wash-Sample size required -Outsourced requirement

Cutting shrinkage bits/ shade blankets preparationEmbroidery/printing- cutting/ marking/excess fabric attachReadiness of shrinkage bits-embroidery/printing/ or other value addition

B) SEWING:

SUPPLIERINPUTPROCESSOUTPUTCUSTOMER

MaintenanceSewing machinery attachments/ foldersSpecialized machineryMachine setting Folder and attachment usabilityThreading

-machine ready and availability -DesignerBrandSourcing

TMC cuttingReady fabric cutting Cutting preparedness for loading ( main, trim and interlining non fusible)Finished sample

TMC storesSewing trim kit Ready trimsRunning length checkingRequirement & quantity verificationAgainst receiptApplication on the sample

IE/GETech packs( construction details) & specsConstructing seamsParts & assembly ready

CADReady patternCritical construction inputsReady marking

Parts ready

Co-ordinatorRef sample embellishmentsWashed garmentsGarment finishingParts ready

5. FLAT KNIT MACHINE

OBJECTIVE: To get 3 D knitting topologies that were more difficult or impossible to create at vendor bases and give option to explore for creativity.

5.1. Flat knitting functioning: Be a supportive function to design and product by having a data bank of design capabilities in knitting technology and give a complete solution to compete with international benchmarking.

5.2. L1 process work flow

Download to be provided by the Design/ Product (Design, sketch, speck & sample)Knitting Structure and programming Post Knitting and Work study and time line for completion & quality parametersWork order release from SAP Yarn hand Looping, label attach and finishing Sample Quality review corrections and send to store For Sap closurePre Knitting and shrinkage test

5.3. Checklist of Activities

The entire Download for Design, would be discussed with Knitting Engineer & Coordinator along with the Product ID.

PLM updation of construction and shrinkage

Internal down load to looping team and QA

Work order will be released by stores for Yarns

Pre-Knitting, washing, post-knitting, looping and final quality check will be carried out and the approved sample will be handed over to stores.

5.4. Flat knitting management team:

Manager (TMC): will overlook the day to day activity on quality and productivity.

Flat knitting engineer: will provide programming for knit structure and all relevant Construction, see to that standard adhered to achieve the desired sampling standard.

Machine Maintenance : Up keep Machines like flat knit, rewinding and linking machine, reduce down time of m/c setting, training on special machine skills

Co-coordinator : Planning & co-ordination between store and production

Linking operator: Running the Linking and rewinding machine on day today basis Without any break down and rework on finished sample.

Quality: Make sure the sample meets the entire design, spec and quality requirement to meet the set standards.

Stores: Make sure the Yarn procurement and spare availability at all times.

5.5. RACIFLAT KNITTING

L1 PROCESS STEPMANAGERFLAT KNIT PROGRAMMERSTOREQAMAINTANCELINKING OPERATORCO-ORDINATOR

Discussion of Technical detail of styleIRCCCA

Coordination b/w store and knittingICAR

Linking of ready knitted panelsIACCCR

Machine MaintanceIACRC

Quality & spec check of SampleACR

Sample HandoverIACR

5.6. SIPOC: FLAT KNITTINGSUPPLIERINPUTPROCESSOUTPUTCUSTOMER

Design/product/sourcingSpecification/design/Block reference/ Reference sample( if any)Clarification & design creationReady design archive - soft Flat knit programmer

TMC storesYarn and threadsProcurementStorageAnd supply of yarns Base pattern - soft/hard with fabric inputsFlat knit operator

Design techSpec/ Style detailsEvaluation & fit verificationSpecification and constructionFlat knit programmer

CoordinatorPanel shrinkage - Thermo & washShrinkage washing in washing machine and After wash spec Flat knit programmer

LinkingKnitted panels for linking Gauge setting and linking Finished flat knit sampleDesign/ product/PDQA

6. OUTSOURCINGOBJECTIVE:

To leverage the external expertise to give the required or desired value addition input in to the sample within the agreed time lines6.1. Outsourcing functioning:Sending and receiving the Trims, fabric, pre-cut panel, post-semi finished or fully finished sample for value addition to outsourced vendor base either for embroidery, printing, embellishments, washing, dying etc. The entire activity will be coordinated by coordinator making sure the desired quality, quantity and time lines are meeting.

6.2. L1 Process work chart

Quality check for the inward receiptRunner carries or picked up by outsource vendorsStores Shrinkage bits- dying fabric and trims

Coordinator plans, instruct and clarify outsource requirements

Send to respective departmentsSewing Semi finished garments or full finished garmentsCutting Cut panels

6.3. Checklist of Activities

The entire Download for the respective department should be understood and clear.

Marking to be done based on the requirements like 50 cm x 50 cm for denim shrinkage with a standard template, for embroidery and embellishment placement marking

Internal down load to looping team and QA

Work order will be released by stores for Yarns

Pre-Knitting, washing, post-knitting, looping and final quality check will be carried out and the approved sample will be handed over to stores. 7. FUTURE SCOPE:

1. Monthly forecasting & collection on womens wear.2. One stop solution for Design, product and manufacturing in field of Technical inputs, risk analysis study, method & work study. 3. Product Research and bench marking in kids wear, ethnic wear, outerwear, suits and denim. 4. All New fit development.5. Create complete Data bank on specs, pattern and construction for future product bench marking study.6. Build awareness of product and services to exemplify strong back end operations support in terms of creating innovative merchandise.

8. CONCLUSION

Technology management centre will bring high-quality clothing and value to womens wear business and the most significant competitive advantage providing an approachable atmosphere with top-notch customer service.

The nomenclature will mirror the current ideas articulated throughout the Proto typing: Style, Concierge and About. The overall strategy of TMC will to be providing a clear and simple architecture that allows the user to convert all the ideas simply and easily.

GENERAL AWARENESS

Access to operators will be to their designated work area only. MFL/MGL visitors need to enter visitor ledger and will be accompanied by TMC staff if required. Outsourced vendor need to report to security at reception and will not be allowed admission inside the TMC, in case they need to visit the floor, then concerned TMC staff need to accompany them with a valid reason for visit.

All machine need to be kept neat after usage and all the material used to be returned back to stores.

Over time will be need based.

Housekeeping timing will start at 7 and all other office timing will be maintained as above.

Uniform is mandatory for all sewing, cutting, maintenance and housekeeping staff during working hours.

No smoking allowed in the premises.

All lights and Air conditioners need to be switched off during breaks and office hours.

All Food plates need to be cleaned after lunch hours.

Avoid any path way hindrance: Keep material within marked yellow lines on the floor.

Fire exit need to be maintained as per norms.

TMC TIMMINGS:

TMC office timing will:

- Start: 8.30 am- Machine cleaning: 10 minutes (Morning and evening)- 1sttea break: 10.30 am-10.40 am (10 minutes)- Lunch break: 1.00 pm- 1.30 pm (30 minutes)- 2ndtea break: 3.30 pm- 3.40 pm (10 minutes)- Closing: 5.30 pm.- Total working hours 8 hrs.

ATTENDENCE:

TMC Working days: Monday to Saturday of every month of the calendar years, Sunday weekly off and all Government holidays as per norms.

Attendance punching is mandatory.

Monthly twice 15 minutes will be allowed for late coming, but above it, half day salary will be deducted from that months salary.

Advance notice for leave is to be applied at least 1 week ahead in case of planned leave, In case of emergency leaves, Your immediate reporting superior must be informed one day in advance The leaves are needed to be captured in the leave form and approval of the immediate superior is mandatory.

HOUSE KEEPING:

Production floor, Stores, special m/c area and staff area cleaning morning 7 am to 8.30 am daily

Toilets twice in a day 8.30 am to 9.00 am and 2.30 pm to 3.00 pm

Reception and Pantry area 9.00 am to 10.30 am daily

Brainstorm, VH, Allen solly showroom area 9.00 am to 12.30 pm on Saturday and if any meeting scheduled.

Machinery cleaning every day 9.00 am to 12.30 pm. 1.30 pm to 3.00 pm.

All cutting and paper waste need to be bagged on hourly basis.

END

Machinery listDEPARTMENT WISE IMPROVISATIONS1. PRE PRODUCTION MASTER MEASUREMENT SHEET

2. PRE PRODUCTION MASTER MEASUREMENT SHEET (TROUSERS)

3. FABRIC & TRIM REQUIREMENT SPECIFICATIONS SHEET

4. TRIM CARD

5. CUT AUDIT REPORT

6. PRODUCTION AUDIT REPORT

7. WEEKLY TIME & ACTION CALENDAR

8. MEASUREMENT VARIATION (SHIRTS)

9. MEASUREMENT VARIATION SHEET ( WOMENS TOP)

10. MEASUREMENT VARIATION SHEET (TROUSERS)

11. MEASUREMENT VARIATION SHEET ( WOMENS TROUSERS)

12. MEASUREMENT VARIATION SHEET (OUTERWEAR)

13. PATTERN QUALITY GRADING SHEET

14. OPERATOR QUALITY GRADING SHEET

15. THROUGHPUT TIME CALENDAR AND FILE CHECKLIST

16. FINISHING REQUIREMENT SHEET

PROJECT 2Creating a Project Portfolio identifying Projects for rapid prototyping and investment in a year.PROJECT OBJECTIVE: To identify and funnel critical areas for innovations based on market need, and develop a project portfolio for rapid prototyping and investment for the next year.

PROJECT METHODOLOGY: Defining Innovation, types of innovations, Innovation funnels, and the process of innovation funnelling. Studying innovation models (Technology push, market pull, Coupling model, fugal innovation process model etc. A study of how innovation happens in textiles across the world. A study of how innovation happens at Madura. Case studies and reports on best done and marketed innovations. Identifying market need through research Research incorporating market trends Research on new available technologies Research on competitive landscape Short listing Innovation ideas (funnelling), generation of new ideas based on need and market opportunities. Screening of the concepts ( Creating a portfolio of projects that will meet the business objective of the organization)

PROJECT 3A retail based study of Kaizen practices across all brands of all regions nationwide of Madura F&L and subsequent organization of an event KAIZEN SPREAD for replication, adoption and spreading of the best innovative practices.PROJECT OBJECTIVE:To acknowledge, motivate and appreciate the retail best practices and Kaizen initiatives undertaken across all the retail outlets of all the Brands of Madura F&L across the nation and to organize an event KAIZEN SPREAD for displaying these practices for replication and adoption of best innovative practices.

TRADE SHOW

The trade show provided a real time exposure to the actual buying process. It is an exhibition for companies to showcase their new products and services. These conferences have been developed in order to give retail owners, buyers and managers the opportunity to meet existing suppliers, conduct business meetings, network with others in retail and investigate new products.Duration: July 15 August 4

LEARNING OUTCOME

The Apparel summer internship at Madura Fashion & Lifestyle was extremely beneficial and has provided a unique learning experience through its summer internship program. Working in the PDQA (Product Development Quality Assurance department) has been knowledgeable in terms of product development process, vendor selection and evaluation criteria, Quality assurance and benchmarking, and sourcing strategies. A research based project in innovation has helped me learn in large about what drives innovations in companies and how companies in textiles specifically target innovation and development. The project on centralized sampling in the new sampling unit has taught me both project and people management. The standard operating procedure that was developed was audited twice externally, which has been a very new insightful experience. The retail based project has provided an exposure virtually to all the 961 retail stores of Madura and the best innovative practices adopted by them. The trade show has also been a learning experience regarding the buying and selling for the season. My personal learning would include Professional ethics, project management and handling, people management and team working, leadership and decision making. The confidence and ability to interact and gain knowledge where ever possible.

BIBLIOGRAPHY

http://www.maduragarments.com/ (Accessed on 17th august 11:30 am)http://www.london.edu/programmes/executiveeducation/makinginnovationhappen.htmlhttp://www.indiantextilejournal.com/articles/FAdetails.asp?id=5457www.jeffdegraff.com (Innovation you: steps to drive innovation)Joe Atkinson, Preparing for the unknown: An emerging approach toward risk resilience