Internship Report and Project Main - Apurv Pranav

CHAPTER 1 INTRODUCTION
APPAREL INTERNSHIP REPORT ON TEXPORT INDUSTRIES PVT. LTD. | APURV & PRANAV
1.1 COMPANY OVERVIEW
1.1.1 Introduction: Texport Industries Pri !te Li"ited #$or"er%& Texport '!r"ents( is ! $u%% ser i)e *roup+ ,!sed in Indi!+ ,ui%t on ! p%!t$or" t-!t stri es to !)-ie e ! s&ner*& t-!t )!nnot ,e )o"p!red to t-e rest+ t-us !%%o. pro idin* /u!%it& !pp!re%s+ .or%d.ide. Str!te*i)!%%& %o)!ted in 0u",!i+ 1!n*!%ore !nd Tirupur+ t-e 2o"p!n& -!rness t-e ,est *eo*r!p-i)!% resour)es ! !i%!,%e. TIPL+ ! Under.riters L!,or!tories )erti$ied ISO 344156444 )o"p!n& is ! .e%%78no.n !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%%78no.n !nd reputed ,usiness -ouses in t-e *!r"ent industr&+ in Indi! !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. ;no.n $or its /u!%it& !nd )o""it"ent to So)i!% Responsi,i%it&+ it is ! pioneer in !%uin* -u"!n re%!tions-ips. TIPL produ)es in ex)ess o$ 1.< "i%%ion *!r"ents ! "ont- #19 "i%%ion !nnu!%%&( $ro" nineteen dire)t%& o.ned $!)i%ities. TIPL=s re!% stren*t- %ies in its produ)tion+ produ)t de e%op"ent !nd Ne. >or8 presen)e+ .it- t-e )o"p!n&=s "!n!*e"ent %!&in* e"p-!sis on ?UALIT> !nd PRODU2TIVIT>. T-e )o"p!n& !%so -!s -i*-%& s8i%%ed !sso)i!tes !nd tr!ined personne% ensurin* ?UALIT> !t e er& %e e%. A %ot o$ !ttention is *i en 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 preser e. A /ui)8 o er ie.5 In)orpor!ted in 139:+ ,!sed in Indi!. One o$ Indi!=s %!r*est "!nu$!)turer A exporter. Annu!% re enue o$ USD :4 "i%%ion. 13 dire)t%& o.ned+ $u%%& e/uipped+ "odern+ "!nu$!)turin* $!)i%ities.
T-e $!)i%ities !re en*ineered ,& t-e reno.ned ;urt S!%"on Asso)i!tes in !sso)i!tion .it- Te)-nop!8. Spe)i!%iBes in "!nu$!)ture o$ 0ens A Co"ens A 2-i%dren tops !nd ,otto"s. An ISO 344156444 )erti$i)!tion ,& Under.riters L!,or!tories. 2!p!)it& to produ)e !nd export 1.D "i%%ion *!r"ents ! "ont-. 1E+444 F e"p%o&ees. D444 F "!)-ines. A $u%%7$%ed*ed in7-ouse desi*n te!" )re!tin* !nd de e%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 preser e.
1.1.2.1 In House Facilities: 6<4 -e!ds o$ )o"puteriBed E",roider& "!)-ines produ)in* si"p%e !nd )o"p%ex e",roideries. 144 st!tions o$ )o"p%ex -!nd e",roider&. Auto"!ti) *!r"ent )rus-in*. 2o"puteriBed G!,ri) 2uttin* S&ste". L!ser 2uttin*. 2ir)u%!r !nd G%!t ;nittin* "!)-ines "!8in* spe)i!% 8nit $!,ri)s. Auto"!ted p!ne% printin*.
1.1.2.2 Vision: To ,e re)o*niBed !s ! pre"ier ?UALIT> "!nu$!)turer !nd supp%ier o$ Hi7 G!s-ion !pp!re%s+ e",od&in* t-us t-e spirit o$ )o""it"ent !nd -u"!nit&.
1.1.2.3 Mission: De%i er on7ti"e+ e er& ti"e. An e&e 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$ indi idu!% )%ients. Hi*-est produ)ti it&+ t-ere,& o$$erin* ! )ost !d !nt!*e to !%% our )%ients.
1.1.2.4 Awards: Texport -!s ,een re)o*niBed ,& t-e Indi!n 'o ern"ent Aut-orities $or its )ontri,ution to exports $ro" Indi!. 2usto"er Ad"ir!tions $or outst!ndin* per$or"!n)es !nd )re!ti it&. Re)o*nition $ro" N!tion!% Asso)i!tion o$ t-e 1%ind.
1.1.2.5
etailin!:
Texport is ! %e!din* p%!&er in t-e re!d&"!de *!r"ent industr& !)ross t-e *%o,e !nd -!s ! -erit!*e o$ %e!ders-ip to -onour !nd preser e. Texport -!s ! pre"iu" %!,e% ,& t-e n!"e o$ RO1ERT 'RAHA0 !)ross t-e US !nd ot-er intern!tion!% destin!tions !s .e%%.
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1.1.3 "eoples and Values: T-e ,i**est !sset o$ t-e 2o"p!n& is t-eir peop%e. Texport '!r"ents is ! te!" o$ de oted pro$ession!%s .-o t!8e pride in t-eir !))o"p%is-"ents. Citt-e s!"e dedi)!ted te!" o$ 8e& peop%e .or8in* .it- t-eir )usto"ers o er t-e &e!rs+ t-e& -! e de e%oped ! )%ose p!rtners-ip )!terin* to t-eir spe)i$i) needs. ISu))ess is s.eetest .-en it is s-!redJ. T-e 2o"p!n&Ks su))ess !nd re)o*nition is in p!rt due to t-eir p!ssion $or de%i erin* top /u!%it& produ)ts !nd ser i)es to t-eir )usto"ers. T-e 2o"p!n& e"p-!siBes er& $ir"%& on te!".or8 !nd !re reno.ned !s ! $!ir ne*oti!tor. T-e 2o"p!n& is "ission dri en !nd resu%t oriented+ !nd .-en t-e& pro"ise+ t-e& de%i er. T-e& !re 144L pro!)ti e !nd /ui)8 to )!pture ne. opportunities in t-e "!r8et. At t-e s!"e ti"e+ t-e& !re er& !d!pti e !nd t-e& "irror t-e oper!tions o$ t-eir )usto"ers to ,est $it t-eir indi idu!% re/uire"ents.
1.1.4 "roducts: TIPL+ Unit714 "!in%& $o)uses on 0enKs .o en S-irt. Produ)ts o$ ot-er units !re57 D. Po%os 9. Hoodies :. ;ids .e!r
1. Tops 6. Dress s-irts H. Deni" s-irts
<. Crin8%e $ree s-irts !nd ,%ouses 3. 2!r*o s-orts E. 1otto"s )!su!% .e!r 14. Ni*-t .e!r
1.1.5 In#rastructure: T-e 2o"p!n& is .e%% e/uipped .it- st!te o$ t-e !rt "!)-ines !nd sop-isti)!ted te)-no%o*& t-!t resu%t in $%!.%ess produ)tion o$ /u!%it& *!r"ents !nd opti"iBe e$$i)ien)&.
1.1.5.1 $uality Initiati%es: An ISO 344156444 Under.riters L!,or!tories In). )erti$ied )o"p!n&+ t-e )o""it"ent to /u!%it& i"pro e"ent+ tou)-es e er& !spe)t o$ t-e produ)t+ ser i)e !nd )usto"er support.
1.1.5.2 &ec'nolo!y Initiati%es: A te)-no%o*& dri en )o"p!n&+ t-e& t!8e inno !ti e te)-no%o*& initi!ti es to o$$er $inest /u!%it& *!r"ents to t-eir )%ients.
1.1.5.3 Compliant Facilities: A%% t-e $!)i%ities )on$or" to )o"p%i!n)e nor"s o$ indi idu!% )usto"ers )o erin* so)i!%+ et-i)!% !nd 27TPAT st!nd!rds.
1.1.5.4 Mac'ines: Texport uses st!te o$ t-e !rt "!)-ines !nd t-e "ost !d !n)ed te)-no%o*ies in its $!)tories.
1.1.5.5 &rims: Top )%!ss tri"s $ro" t-e $o%%o.in* intern!tion!% ,r!nds.
1.1.( C) : T-e 2o"p!n& re)o*niBes t-e di$$erent%& )-!%%en*ed in t-eir e"p%o&"ent !nd *i e t-e" !n e/u!% opportunit& to %e!d ! nor"!% %i$e Gor t-is ende! or+ T-e 2o"p!n& .!s re)o*niBed ,& His Ex)e%%en)&+ t-e 'o ernor o$ 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 1%ind. T-e 'oen8! $!"i%& -!s $%o!ted t-e IS"t. S-i de i De ipr!s!d 'oen8! Gound!tionJ .-i)- )ondu)ts $ree "edi)!% )!"ps e er& /u!rter ,ene$itin* -undreds o$ p!tients -! in* !rious !i%"ents. It !%so runs ! $ree -ospit!% !nd *i es "edi)!% tre!t"ent t-!t spe)i!%iBes in )!t!r!)t oper!tions !nd ot-er !i%"ents. 0ore t-!n $i e t-ous!nd p!tients -! e ,ene$ited t-us $!r. T-e 2o"p!n& is !%so !sso)i!ted .it- t-e IRot!r& D.'. 'oen8! 1%ood 1!n8J+ .-i)- runs ,%ood don!tion )!"ps e er& &e!r. Vo)!tion!% Tr!inin* pro*r!"s !re )ondu)ted .it- respe)t to t-e *!r"ent industr&.
1.1.* +or, Culture: At Texport+ t-e )-ie$ o,@e)ti e is to nurture *ro.t- !t !%% %e e%s. T-e 2o"p!n& stri es to !ttr!)t+ or*!niB!tion!% !nd ,usiness *ro.t- t-rou*t!%ented+ en*!*ed !nd )o""itted e"p%o&ees. To !)-ie e t-is t-e& $o)us on %e!rnin*+ )!reer de e%op"ent+ per$or"!n)e "!n!*e"ent+ )o"pens!tion !nd ,ene$its. T-e 2o"p!n&Ks ro%e is to ensure t-!t Texport is ! true =%e!rnin* -!,it!t=+ .-i)- *roo"s peop%e !nd t-eir t!%ents *i in* t-e" t-e s8i%%s t-e& need to ex)e%. Hen)e+ tr!inin* o$ personne% !t !%% %e e%s o$ or*!niB!tion is !n essenti!% )o"ponent to !u*"ent. T-eir tr!inin* pro*r!"s !re !%%7per !si e !nd !re stru)tured to -one t-e spe)i$i) s8i%%s o$ e!)- e"p%o&ee. Gin!%%&+ t-e 2o"p!n& p%!&s !n essenti!% ro%e in s-!pin* de e%op"ent pro)esses t-!t -e%p peop%e !d !n)e t-eir )!reers !s $!r !nd !s $!st !s t-e& )!n. At Texport+ itKs !%% !,out peop%e. C-& TexportM 1e)!use t-e& )re!te !n en iron"ent t-!t no !sso)i!te )!n .i%%in*%& .!%8 out o$. T-e %o&!%t&A st!,i%it& index o$ t-e )o"p!n&+ !))ur!te%& re$%e)ts t-e -i*- %e e%s o$ !sso)i!te e"po.er"ent it *ener!tes !nd !sso)i!tes= s!tis$!)tion. An open+ $%exi,%e .or8 en iron"ent. 2-!%%en*es !nd %e!rnin* opportunities t-!t 8eep one !t t-eir )re!ti e !nd )o"petiti e ,est. Per$or"!n)e "e!sure"ent !nd i"!*in!ti e re.!rd s&ste"s. Produ)ti it& %in8ed in)enti es !nd industr& st!nd!rd )o"pens!tion. 0u%tip%e *ro.t- ! enues. St!te7o$7t-e7!rt in$r!stru)ture to .or8 .it-.
1.1.- .uyers: TO00> HILGI'ER 'AP TO0 TAILOR 1ER;LE> SHIRTS SHIRTS CALL0ARTS N2 PENN> A0ERI2AN EA'LES ESPIRIT OLD NAV> PEPE NEANS VAN HEUSEN ;I;O0O H&0
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LEE 'UESS NEANS ARROC ARROC 'UESS
;HOLS
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1.2 ORGANISATIONAL STRUCTURE
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CHAPTER 2 DEPARTMENTAL OVERVIEW
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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"!% s&ste"s in !n or*!niB!tion t-!t ensure t-e e$$e)ti e !nd e$$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* ,et.een E"p%o&ee !nd 0!n!*e"ent.
2.1.2
oles o# H /epartment:
2o%%e)tin* d!t! !,out "!n po.er re/uire"ent p%!n $ro" IE dep!rt"ent. HR dis)usses .it- 0!n!*e"ent on t-e "!n po.er re/uire"ent p%!n !nd )o"e to !*ree!,%e ter"s on it. HR 0!n!*er p%!&s !n i"port!nt ro%e in se%e)tion o$ ! )!ndid!te $or ! @o, !t t-e ti"e o$ inter ie.. Person!% $i%es o$ !%% t-e e"p%o&ees !re "!int!ined $o%%o.in* !%% st!tutor& nor"s. HR -!nd%es ,ot- its su,ordin!tes !s .e%% !s -i*-er "!n!*e"ent !t e!se. HR is in o% ed .it- )o"p!n& !nd %!,or .e%$!re !)ti ities. 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. O er ti"e -ours is 8ept .it-in t-e %e*!% %i"its+ I$ $ound !n& ex)usi e o$ o erti"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%o&ee e er& "ont-. C!*e re)ord !nd ti"e re)ord is "!de ! !i%!,%e on 14 t- d!& o$ e er& "ont-.
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2.1.3 A0senteeism 1 &urn o%er resol%in!: To pre ent t-e e"p%o&ee turno er+ t-e $o%%o.in* 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,. Inter ie.s s-ou%d ser e !s !n !ddition!% s)reen $or !pp%i)!nts. C!t)-in* $or turno er indi)!tors su)- !s57 7Cor8ers .-o donKt o.n ! -ouse. 7Cor8er &oun*er t-!n 6E. 7Peop%e .it- )-i%dren ,e%o. < &e!rs o$ !*e. 7Peop%e t-!t !re o er%& 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)- o er si*ns o$ turno er su)- !s !,senteeis".
0!8e t-e .or8p%!)e $ee% e"po.ered )-!%%en*ed !nd !))epted ,& t-e )o"p!n&.
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2.2 DESIGN DEPARTMENT
Design Department
$uyers %nspiration
Texports own Development
&reate 'oo( boar( an( &olor boar( with Designs, Styles, Silhouettes, etc. from various source.
Obtain information reg. fabrics, styles, silhouettes, color, etc. from WGS !Worth Global Style etwor"# Deci(es color, fabric, style, etc. from own inspiration or from
&ollect fabric, (evelop (esigns.
other sites. *inalising (esigns by +OD Develop collection on various categories in Sampling (ept.
)resentation of the collection to the buyer.
Short listing of samples by buyer.
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2.3 SAMPLING DEPARTMENT
2.3.1 .asic +or, Flow: In !n& export -ouse+ t-e s!"p%in* dep!rt"ent is one o$ 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 1u&erKs spe)i$i)!tion. In Texport+ S!"p%in* dep!rt"ent is )entr!%iBed in He!d O$$i)e $or .o en. It is di$$erent $ro" ,u%8 produ)tion !s -ere e!)- t!i%or is "u%ti s8i%%ed !nd "!8es ! )o"p%ete "!8e t-rou*- *!r"ent. T-ere !re se er!% st!*es in o% ed in t-e S!"p%in* Dep!rt"ent .-i)- in o% es t-e "!8in* o$ di$$erent t&pes o$ S!"p%es !t di$$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)ei es !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)ei es 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 de e%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$ de e%opin* t-e p!ttern is !,out one to t.o d!&s "!xi"u". A$ter de e%opin* t-e p!tterns+ t-e S!"p%in* Dep!rt"ent does t-e )ostin* )!d "!r8er !nd de e%ops S!"p%e si"u%t!neous%&. Costin! cad mar,er5 T-is t&pe o$ t-e "!r8er is done prior to t-e order !ppro !% $or 8no.in* t-e ex!)t $!,ri) )onsu"ption $or t-e *i en st&%e. Here t-e $!,ri) uti%iB!tion per)ent!*e is "!xi"iBed ,& te)-ni)!% "et-ods o$ "!r8er "!8in* usin* so$t.!re. /e%elop )ample5 In t-is t&pe o$ t-e S!"p%e t-e !)tu!% tri"s !nd !))essories !re not used e en t-e $!,ri) is su,stituted !nd t-is is "!de !))ordin* to t-e 1u&erKs spe)i$i)!tion !nd t-e 1u&er -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 de e%op S!"p%e is !,out ! .ee8 !nd t-e dur!tion
APPAREL INTERNSHIP REPORT ON TEXPORT INDUSTRIES PVT. LTD. | APURV & PRANAV 1E
o$ ti"e $ro" t-e p!ttern de e%op"ent !nd de e%op S!"p%e *ener!tion is !,out t.o to t-ree d!&s. De e%op S!"p%e is prep!red o$ 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 t.ent& d!&s !nd !$ter .-i)- t-e S!"p%in* Dep!rt"ent de e%ops t-e Proto S!"p%e. "roto )ample5 In t-is S!"p%e ! su,stitute o$ 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 P t. Ltd.( )!n su**est !n& )-!n*es in t-e *!r"ent to t-e 1u&er. I$ t-e 1u&er !ppro es t-en t-e )-!n*es !re in)orpor!ted e%se it is $o%%o.ed !s t-e 1u&er spe)i$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 $or t-e )-!n*es in t-e !re!s .-ere t-e S!"p%e -!s not "et t-e 1u&erKs spe)i$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 1u&er $or -is !ppro !%. Suppose t-e 1u&er -!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 1u&er !ppro es t-e $it S!"p%e+ t-en t-e 1u&erKs order is )on$ir"ed. On)e t-e proto S!"p%e -!s ,een !ppro ed t-e #it )ample is prep!red !nd t-is is pure%& done on t-e 1u&erKs !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 1u&er ! "" 2"re3"roduction4 )ample is *ener!ted. Here !)tu!% $!,ri)+ tri"s !nd !))essories !re used. T-e PP S!"p%e is sent to t-e 1u&er !nd ! S!"p%e is 8ept $or t-e )o"p!n&A$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 !ppro ed+ ! )ealer )ample is 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 ! )i5e )et )ample is *ener!ted !nd in t-is t&pe o$ s!"p%in* s&ste" 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 1u&er -!s !s8ed $or ex!"p%e i$ t-e 1u&er -!s !s8ed $or ! $or"!% s-irt .it- siBes <4+ <6+ <<+ <D+ <: t-en S!"p%e is t!8en out o$ e!)- pre$erred siBe !nd t-en produ)ed it to t-e 1u&er. A$ter t-e siBe set S!"p%e is !ppro ed ,& t-e 1u&er t-en t-e 1u&er sends ! re/uest to t-e 0er)-!ndiser $or t-e ,u%8 produ)tion !nd t-en t-e produ)tion is
APPAREL INTERNSHIP REPORT ON TEXPORT INDUSTRIES PVT. LTD. | APURV & PRANAV 1D
)!rried out in t-e si"i%!r "et-od ,& usin* si"i%!r "!)-ines .it-out !%terin* !n& o$ t-e pro)edures !nd "!nu$!)turin* is done. T-e $irst pie)e o$ produ)tion+ 8no.n !s TOP S!"p%e #Top O$ Produ)tion S!"p%e( is so"eti"es !s8ed ,& 1u&er to 8no. produ)tion d!te !nd i$ it "!t)-es .itSe!%er S!"p%e.
Tech pac" receive( from merchant Develop patterns
&osting &,D mar"er
Develop Sample Develop fit-proto sample
%f any comments comments
%f no comments
.evise *it-)roto sample

)) sample
%f no comments
.evise )) sample
Si/e Set sample

%f no comments
%ncorporate $uyer &omments

Sealer sample
%f no comments
%ncorporate $uyer &omments
$ul" )ro(uction
Workflow of Sampling Department
19
2.3.2 Mac'ines in )amplin! )ection are:3 SNLS "!)-ine DNLS "!)-ine 1!rt!)8 "!)-ine O er%o)8 "!)-ine ;!ns!i Spe)i!% Oi*B!* Lo)8stit)- "!)-ine 1%ind stit)- "!)-ine
2.3.3 6arment )ample: A$ter t-e )on$ir"!tion o$ order+ e!)- S!"p%e sent to t-e 1u&er -!s t-e $o%%o.in* det!i%s !tt!)-ed to it+ .it- t-e -e%p o$ ! t!*. It )ont!ins t-e det!i%s pert!inin* to ,ot-+ .-!t t-e 1u&er -!s de"!nded !nd .-!t supp%e"ent $!,ri)Atri" et). t-e& -! e used. Re$ no. 2o%or G!,ri) 2o"position Des)ription ?u!ntit& St&%e noA SiBe Store
1:
2.4 MERCHANDISING DEPARTMENT
2.4.1 Introduction: 0er)-!ndisin* is ! pro)ess t-rou*- .-i)- produ)ts !re p%!nned+ de e%oped+ exe)uted !nd presented to t-e 1u&er. It in)%udes dire)tin* !nd o erseein* t-e de e%op"ent o$ produ)t %ine $ro" st!rt to $inis-. 0er)-!ndisin* is t-e )entr!% )oordin!tin* point $or t-e produ)t %ine. 0er)-!ndisin* is t-e p%!nnin* de e%op"ent+ de e%op"ent !nd present!tion o$ 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 in o% ed in t-e "!teri!%s "!nu$!)turin*+ !pp!re% "!nu$!)turin* !nd ret!i%in* %e e%s o$ t-e !pp!re% ,usiness. A))ordin* to Ci%%i!" N. Stenton "er)-!ndisin* is de$ined !s IProdu)t p%!nnin* to *et t-e ri*-t produ)t or ser i)e to t-e "!r8et !t t-e ri*-t ti"e+ !t ri*-t pri)e+ in ri*-t )o%ors !nd siBesJ. T-e 0er)-!ndiser s-ou%d ,e !,%e to !ns.er e!)- !nd e er& /uestion to t-e 1u&er+ ,e !,%e to *i e su**estions+ -!nd%e t-e present!tion o$ 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$iden)e .it- t-e 1u&er. T-e export do)u"ent!tion in o% es t-e prep!r!tion o$ 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 ,een st!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 $o%%o.s57 !. Do)u"ent o$ !))ept!n)e ,. Do)u"ent !*!inst p!&"ent ). Letter o$ )redit
13
2.4.2 Merc'andisers ,ey responsi0ilities are as #ollows: Produ)t De e%op"ent 0!r8et And Produ)t An!%&sis Se%%in* T-e 2on)ept 1oo8in* Orders 2on$ir"in* De%i eries Desi*nin* And S!"p%in* 2oordin!tion 2ostin* R!. 0!teri!% G%o. 0onitorin* Produ)tion Go%%o. Ups P!&"ents
A *ener!% se/uen)e o$ oper!tions $o%%o.ed in exe)utin* order is s-o.n ,e%o.5 T-e 1u&er sends )ostin* in/uir& s-eet. I$ t-e t!r*et pri)e spe)i$ied ,& t-e 1u&er is !*reed ,& t-e 0er)-!ndiser. L!, dips. L!, dipsAs.!t)-es !re sent to t-e 1u&er $or !ppro !%. T-e 1u&er sends pur)-!se orderAp%!)e"ent 8it. Protot&peA$it S!"p%e !nd !))essories !re sent to t-e 1u&er $or !ppro !%. T-e 1u&er *i es instru)tion to t-e 0er)-!ndiser i$ !n& )orre)tions !re to ,e "!de.
64
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 1u&er $or !ppro !%. Produ)tion o$ t-e *!r"ent !nd $inis-in* o$ t-e *!r"ent. P!)8in* o$ *!r"ent in po%& ,!* !nd $in!%%& in )!rtons.
T-e 1u&er *i es t-e spe)i$i)!tion s-eet+ .-i)- )ont!ins A to O det!i%s o$ t-e order+ to t-e export !nd !s8s -i" to *i e t-e pri)in*. A$ter stud&in* 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). 1!sed on t-e $!,ri) pri)e !nd )onsu"ption -e )!%)u%!ted t-e )ost per $!r.
I$ t-e 1u&er !*rees t-e pri)e !nd t-e order is )on$ir"ed t-en t-e $o%%o.in* !)ti ities !re )!rried out5 S)rutiniBin* t-e orderA%etter o$ )reditA)-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%%o.in*5 2o"p%ete des)ription o$ t-e produ)t. 2o"p%ete p!)8in* spe)i$i)!tion. De%i er& 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
An& ot-er !%id instru)tions.
A$ter )on$ir"in* t-e order t-e 1u&er so"eti"es *i es 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!ti e $!,ri) $or t-e st&%e !ppro !%. A$ter )-e)8in* t-e p-oto S!"p%e+ t-e 1u&er *i es )o""ents on it+ i$ !n& !nd !s8s t-e exporter to su,"it t-e siBe set S!"p%es.
T-e 1u&er !%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%i er& ti"e et). A$ter *ettin* t-e *rei*e $!,ri)+ it -!s to ,e sent $or pro)essin*. 1e$ore sendin* or st!rtin* pro)essin*+ s!& $or ex!"p%e d&ein*+ %!, dips -!s to ,e )o%%e)ted $ro" t-e pro)essin* unit !nd it -!s to ,e sent $or !ppro !% to t-e 1u&er. A$ter *ettin* !ppro !% in %!, dip+ t-e ,u%8 $!,ri) -!s to d&e. 1e$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 !ppro ed ,& t-e 1u&er. A%% t-e )o""ents *i en ,& t-e 1u&er 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 *i en 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)ti e 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 1u&ers. T-e te!"s !re "!de !))ordin* to t-e 1u&ers ,ein* -!nd%ed.
oles and
esponsi0ility o# Merc'andiser:
!. 1u&er )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 1u&erKs represent!ti e .it-in t-e or*!niB!tion !nd !%so+ represents o.n or*!niB!tion. ,. Produ)t De e%op"ent5 0er)-!ndiser s-ou%d 8no. !nd underst!nd 1u&erKs re/uire"ent )o"p%ete%& !nd t-orou*-%& !nd "ust ,e !.!re o$ 1u&er )-!r!)teristi)s+ -e or s-e s-ou%d
APPAREL INTERNSHIP REPORT ON TEXPORT INDUSTRIES PVT. LTD. | APURV & PRANAV 66
,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$itP p!nnin* et) t-e& "ust !%so ,e!r in "ind 1u&erKs pri)e point !nd t-e pur)-!sin* !,i%it& o$ t-e end )usto"er. d. Se%%in* !nd 1oo8in* o$ Order5 T-e& "ust tr&+ *ettin* t-e 1u&er to ,u& in ,u&in* "eetin*. #Tr!de $!irs+ 1u&er7 se%%er "eets+ et).(. e. Produ)tion Go%%o.7Up5 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!%%& ,et.een s!"p%in* !nd produ)tion !nd s-ou%d 8eep up7to7d!te in$or"!tion to t-e 1u&er. $. ?u!%it& 2ontro%5 0ust tr& to "eet 1u&erKs /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 in o% es pre7s-ip"ent !nd post s-ip"ent do)u"ent!tion. It "ust ,e sent to t-e 1u&er 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 de e%op"ent !nd )oordin!tin* .it- t-e 1u&er+ t-e *!r"ent st&%es t-!t "eet 1u&erKs expe)t!tions in re*!rds to de%i er&+ /u!%it&+ !nd pri)e point. Nunior 0er)-!ndisers -! e t-e responsi,i%it& o$ -!nd%in* p!per .or8 !nd $o%%o. up+ det!i%in* .it- 1u&ers+ o erse!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+ pro ide ,re!8do.n in$or"!tion to !%% ot-er dep!rt"ent !nd *et S!"p%es !ppro ed $or $it+ )o%or !nd /u!%it&. 2o""uni)!tions .it- o erse!s !nd do"esti) supp%iers+ !ppro !%
APPAREL INTERNSHIP REPORT ON TEXPORT INDUSTRIES PVT. LTD. | APURV & PRANAV 6H
o$ produ)tion S!"p%es+ !nd de e%op"ent o$ $!,ri) !nd &!rns !re !%so in)%uded in produ)t de e%op"ent+ .-i)- !re )o7)oordin!ted .it- ot-er dep!rt"ents. 0er)-!ndisers -! e to ne*oti!te .it- t-e 1u&ers on pri)in*+ .or8 out de%i er& s)-edu%es+ !nd in esti*!te $or $uture 1u&ers. O er!%% .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 1u&er or *et ,rie$ ide! o$ t-e st&%e !nd !%so t!8es ! S!"p%e $ro" t-e 1u&er o$ t-e ,!se siBe. On)e t-is is done t-e 0er)-!ndiser .i%% -! e to do t-e t.o "!@or i"port!nt @o,s+ .-i)- !re !s $o%%o.s57 a4 Costin!: T-is in o% 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 H Q EL 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 1u&er 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+ t&pe+ /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)ei e $ro" t-e 1u&er. T-ird%&+ t-e "er)-!nts o,t!in t-e 'SD #'ener!% Se.in* D!t!( $ro" t-e IE Dep!rt"ent $or t-!t p!rti)u%!r S!"p%e. 04 )amplin!: T-e )ostin* !nd t-e s!"p%in* $or t-e st&%e+ t-!t t-e 1u&er .ou%d -! e *i en+ -!ppen si"u%t!neous%&. T-e "er)-!nts *i e 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 1u&er !nd t-en !s8 t-e" to *ener!te ! S!"p%e !s per t-e spe)i$i)!tions *i en 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 *i en ,& t-e 1u&er(. A$ter de e%opin* t-e initi!% S!"p%e+ i$ t-e 1u&er !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 1u&er !s per t-e )!%)u%!tions -e A s-e .ou%d -! e done $or t-e st&%e t-e 1u&er .!nts. T-is /uot!tion in o% es t-e )ost s-eet !nd t-e S!"p%e .-i)- .ou%d -! e
APPAREL INTERNSHIP REPORT ON TEXPORT INDUSTRIES PVT. LTD. | APURV & PRANAV 6<
,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 1u&er !nd *i e t-e" t-e /uot!tion or so"eti"es t-e 1u&er .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 1u&er. I$ t-e /uot!tion or t-e S!"p%e is not !ppro ed t-en t-e )ost s-eet or t-e S!"p%e -!s to ,e .or8ed !*!in !nd i$ it is !ppro ed+ 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%% in o% 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* se er!% /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 department .or8s on t-e $o%%o.in* det!i%s57 P2D #P%!n 2ut D!te( Se.in* %ine A ,!t)- .-i)- .i%% ,e suit!,%e $or t-e p!rti)u%!r st&%e. 2!p!)it&7.ise 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%%o.in* det!i%s57 T-e d!te $or orderin* t-e tri"s A $!,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& t&pe 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
6E
,& t-e 1u&er. 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 *i e t-e det!i%s o$ t-e t&pes o$ .or8ersA%!,orers .-o -! e to ,e used $or t-e p!rti)u%!r st&%e in t-e se.in* $%oor. T-e& *i e 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 !,o e "entioned dep!rt"ents !nd t-en t!,u%!tes t-e" A 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 !ppro ed order ,e*ins. E er& 1u&er .i%% -! e -is o.n ter"ino%o*ies $or t-e S!"p%es+ t-e "er)-!nts -! e to *o !))ordin* to t-e 1u&erKs )-oi)e o$ t&pe !nd t-e nu",er o$ S!"p%es !nd pro ide t-e" !s !nd .-en t-e& re/uire it. On)e !%% t-e S!"p%es !s per t-e 1u&er re/uire"ent is done+ .-i)- t!8es !,out 1E Q 64 d!&s+ t-en t-e "er)-!nts -! e to .!it $or t-e 1u&erKs !ppro !% o$ t-e S!"p%e. I$ t-e 1u&er re@e)ts t-e" t-en t-e re!sons $or t-e re@e)tion is re)ei ed $ro" t-e 1u&er 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 re ised re/uire"ents. A$ter t-is t-e S!"p%es -! e to ,e !ppro ed ,& t-e 1u&er !*!in. Suppose t-e S!"p%es !re !ppro ed ,& t-e 1u&er 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* se er!% issues !re dis)ussed %i8e+ Line p%!n ,!sed on t-e SA0 !%ue. 1!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 H Q < d!&s $or t-e ,!t)- settin* in .-i)- t-e entire ,!t)- is *i en ti"e to *et !d@usted to t-e ne. st&%e !nd !t t-is ti"e !%% t-e oper!tors !re *i en ! 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, .ite!se. A$ter t-e ,!t)- settin* is done !nd t-e st&%e is under proper produ)tion+
it -!s to ,e $o%%o.ed ,& !%% t-e units o$ t-e produ)tion dep!rt"ent !nd t-en t-e& -! e to upd!te it to t-e 1u&er. 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 1u&erKs spe)i$i)!tions !nd ter"s. T-e *!r"ents !re !*!in )-e)8ed ,& t-e 1u&er ?2 !nd t-en s-ipped !nd sent to t-e 1u&er. A$ter t-e *!r"ents !re sent to t-e 1u&er+ 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:3 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
6:
Start
Obtain tech pac" from buyer
&osting
Sampling
,naly/e fabric consumption from &,D
,naly/e cost of trims an( fabric
Obtain general sewing (ata from %0D
Develop sample as per the Tech pac"
)repare cost sheet from Sample
Develop proto sample
&ost sheet 1 Sample sent to $uyer for approval
&onfirmation of or(er
4es ,pproval
&ost sheet rewor"e(
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 +ol( pre3pro(uction meeting with the )ro(uction unit 4es ,pproval o &omments receive( from $uyer shoul( be incorporate( an( *it Sample rewor"e(
0xecute bul" or(er
*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(
63
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(. 1e$ore st!rt o$ produ)tion o$ !n& order t-e He!d o$$i)e #HO( sends ! p!)8!*e to t-e unit #TIPL714(. T-is p!)8!*e )onsists o$ t-e $o%%o.in* do)u"ents5 No, )!rd Pur)-!se Order #PO( Pre7produ)tion "ini "!r8er Pre7produ)tion S!"p%e ?u!%it& )o""ents Audited te)- p!)8 'r!ded Spe) s-eet 2o"p%ete tri" )!rd et).
I$ t-ere !re !n& )-!n*es or )orre)tions to ,e "!de in t-ese do)u"ents t-e unit )o""uni)!tes .it- t-e "er)-!ndisin* di ision in HO+ e%se t-e& pro)eed .it- t-e det!i%s *i en. G!,ri) )onsu"ption $or ! p!rti)u%!r order is )!%)u%!ted ,& !ddin* 67EL o$ extr! $!,ri) !s per 1u&er re/uire"ents. T-en HO p%!)es order $or t-e re/uired $!,ri). On)e t-e $!,ri) re!)-es t-e .!re-ouse it is sent $or testin* in Texport %!,or!tor& in t-e 'odo.n. A$ter t-e $!,ri) is tested it is sent to t-e $!,ri) store o$ t-e unit. A$ter re)ei in* t-e $!,ri) in store+ t-e store in7)-!r*e )-e)8s $or t-e $!,ri) )ode+ )o%or+ &!rd!*e !s "entioned+ no. o$ ro%%s !nd ot-er det!i%s on t-e $!,ri) p!)8!*e. T-en t-e $!,ri) is inspe)ted r!ndo"%& $or de$e)ts !nd t-en $!,ri) is se*re*!ted s-!de7.ise !nd .idt-7.ise in to di$$erent %ots. T-ese %ots !re issued to t-e )uttin* dep!rt"ent.
H4
2.5.2 &'e .asic Functions o# t'e Fa0ric )tore:3 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)ti e /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 *i en in t-e s-eet. A$ter t-is t-e G!,ri) 2uttin* 2-!rt is re)ei ed $ro" t-e 2uttin* se)tion -e!d. In t-is )-!rt t-e "eters o$ $!,ri) re/uired ,& t-e )uttin* roo" is *i en. Next t-e in7)-!r*e re)ei es t-e G!,ri) ?u!%it& Inspe)tion Su""!r&. T-is )ont!ins t-e inspe)tion det!i%s o$ t-e $!,ri). T-e in7)-!r*e t-en re)ei es 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. 1!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 L is !dded !s ! .!ste per)ent!*e $or $!,ri). H L is !dded $or t-e re@e)tion o$ *!r"ents. Hen)e+ ! tot!% o$ E L 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!:
H1
He!d o$$i)e )!%)u%!tes t-e $!,ri) )onsu"ption $or t-e p!rti)u%!r @o, order !nd p%!)e t-e order $or $!,ri) .it- HL extr! $!,ri) in )!se o$ so%id !nd EL in )!se o$ )-e)8s. T-e -e!d o$$i)e te%%s t-e $e!ture o$ $!,ri) to t-e supp%ier !s per 1u&er re/uire"ent. T-e $!,ri) supp%ier sends t-e $!,ri) $or %!, testin* to !n& testin* unit. T-e 1u&er re/uired testin* "!in%& $or57 Di"ension!% st!,i%it& to .!s-in*. Appe!r!n)e !$ter .!s-. 2o%or $!stness to %!underin*+ %i*-t+ )ro)8in* !nd non7)-%orine ,%e!)-. Tensi%e stren*t-. Te!r stren*t-.
T-e& "!t)- t-e resu%t .it- s)!%e .-i)- in ,et.een 17E. E7 Ex)e%%ent+ <7 er& *ood+ H7 A er!*e+ 67poor+17 Ver& poor.
2.5.4 "'ysical &estin! 1 Inspection: G!,ri) is inspe)ted ,& usin* ! < point s&ste". It is ! pro@e)tion o$ tot!% de$e)ts ,!sed on t-e tot!% nu",er o$ de$e)ts $ound durin* inspe)tion o$ ! S!"p%e !s ! ,!sis $or !))ept!n)eAre@e)tion )riteri!. In t-is point inspe)tion s&ste" pen!%t& points !re !ssi*ned ,!se on t-e st!nd!rd $!u%t. Gor e er& t&pe o$ $!u%t )o%or sti)8ers !re put+ to identi$& serious de$e)ts in t-e su,se/uent pro)ess.
4 "oint )ystem: T-is "et-od is .ide%& !dopted in t-e industr&. In t-is s&ste" t-e points !re *i en $or t-e de$e)ts in t-e $!,ri) dependin* on t-e siBe o$ t-e $!,ri). De$e)ts in Len*t- Cise !nd Cidt- Cise57 /7F7C&) 1. Up to HKK 6. O er HKK7DKK H. O er DKK73KK <. O er 3KK "9I:&) 4ne T.o T-ree Gour
H6
A$ter notin* do.n t-e points t-e pointsA 144 s/. &!rd is )!%)u%!ted usin* t-e $or"u%!+ PointsA144 s/. &d.RTot!% pointsS#144S 144(A#tot!% nu",er o$ "etersS.idt- o$ $!,ri)(
4 Point System
Fabric width The rule for this system is to give points to each defect found in a fabric role/than.
(p 3'' 36'' 36''
$p
%''
36''
points are based on following criteria : Fault less than 3'' ( .!cm" in length Fault up to 3''&6'' ( .!&$!cm " in length Fault up to 6''&''' ($!&%3cm" in length Fault over ''' (%3cm" in length
# $ point # % points # 3 points # ( points
%p 6''
36''
)ole si*e less than or e+ual to $'' )ole si*e more than $''
# % point # ( point
(p
%'' hole $,''
36''
The ma-imum number of points for any linear yard (36''.fabric width " can not be more than ( points.
Here t-e pointAs/. &d. is $ound out & t-e resu%t )!n ,e interpreted !s i$ t-e pointAs/. &d. is ,e%o. <4 points t-e $!,ri) is )onsidered !s $irst /u!%it&. <4 points As/. &d. is not ! $ixed st!nd!rd !nd !r& dependin* up on 1u&erA2ountr& or t&pe o$ $!,ri). A%% t-e $!,ri)s !re inspe)ted !s per t-e Gour Point inspe)tion s&ste". Under t-e Gour Point s&ste" pen!%t& points !re !ssi*ned ,!sed on t-e st!nd!rd $!u%t siBe #intern!tion!%%& !))epted( $or e er& t&pe o$ $!u%t+ )o%ored sti)8ers !re put to identi$& serious de$e)ts in t-e su,se/uent pro)ess.
2.5.5 "'ysical &ests "er#ormed 9n Fa0ric: S-rin8!*e test A$ter .!s- e$$e)t 2o%or $!stness to .!s-in* 2o%or $!stness to )ro)8in* !nd st!inin*
HH
2o%or $!stness to %i*-t Di"ension!% st!,i%it& Tensi%e stren*tTe!r stren*t2ount+ EPI+ PPI+ !nd .idt-
)'ade .atc'in!: He!ds ends !pproxi"!te%& DJ %on* .i%% ,e )ut $ro" e er& inspe)ted ro%% !nd t-is .i%% ,e used to deter"ine s-!de !ri!tion !t t-e ,e*innin*+ "idd%e !nd t-e end o$ t-e ro%%+ side to side s-!de !ri!tion )-e)8s !re )!rried out !t t-is st!*e ,& )o"p!rin* t-e t.o sides o$ t-e $!,ri) ro%% )%oser to t-e se% ed*e. Ro%%s .it- ! )onsistent s-!de .it-in .i%% t-en ,e )-e)8ed ro%% to ro%% s-!din* usin* t-e -e!d ends. I$ si*ni$i)!nt !ri!tions in s-!des !re $ound !t t-is st!*e+ ro%%s inspe)ted .i%% ,e ,!t)-ed !))ordin* to t-e nu",er o$ t-e "!@or s-!des+ ro%% inspe)ted .i%% ,e ,!t)-ed !))ordin* to t-e nu",er o$ "!@or s-!des *roups !nd t-is in$or"!tion too .i%% ,e re)orded in t-e inspe)tion report !%on* .its.!t)-es representin* e!)- s-!de *roup. +idt' .atc'in!: E!)- inspe)ted ro%% .i%% ,e "e!sured $or t-e )ut t!,%e .idt- !t t-e ,e*innin*+ )enter !nd t-e .idt- o$ t-e ro%% !nd t-e "e!sure"ent t-us o,t!ined .i%% ,e re)orded in t-e sp!)e pro ided in t-e inspe)tion report. T-e n!rro.est .idt.i%% ,e )onsidered !s t-e )ut t!,%e .idt-. I$ t-e !ri!n)e in t-e )ut t!,%e is "ore t-!n 1L t-en ?u!%it& Assur!n)e 0!n!*er .i%% de)ide on .-!te er !ddition!% )-e)8s dee"ed ne)ess!r&. An& %oss !risin* $ro" )ut t!,%e .idt,ein* s-orter t-!n in oi)ed .idt- is noti$ied to t-e "er)-!ndisin* dep!rt"ent $or t-e $urt-er !)tion. T-e stores .i%% ,e "e!surin* t-e $!,ri) .idt- o$ !%% t-e pie)es *oods t-e& re)ei ed. 144L .i%% ,e done $or !%% t-e )onsi*n"ents. T-en it .i%% ,e *rouped .idt-.ise+ tot!% &!rd!*e o$ t-e e!)- .idt- *roup .it- ! p!)8in* %ist is su,"itted to t-e p%!nnin* dep!rt"ent !$ter t-e inspe)tion $or t-e purpose o$ t-e "!r8er re/uire"ent in di$$erent .idt-s. )'rin,a!e &est: R!ndo" se%e)tion o$ 14L o$ t-e ro%%s is tested $ro" e!)- %otA,!t)-. T.o pie)es o$ t-e $!,ri) ID4SD4)"J is )ut & E4SE4)" is "!r8ed !nd sin*%e need%e stit)- on "!r8in*. A te"p%!te -!s ,een prep!red to en!,%e A))ur!te "!r8in* points )o erin* t-e %en*t- !nd t-e .idt- o$ t-e $!,ri) !t ! predeter"ined
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dist!n)e o$ E4)". .-en t-e $!,ri) returned $ro" t-e .!s-in* t-ese points !re "e!sured !nd t-e .!rp !nd t-e .e$t s-rin8!*e ! er!*e is )!%)u%!ted in to ! per)ent!*e. I$ t-e s-rin8!*e !ri!tion is "ore t-!n EL .it-in ! ,!t)- t-en ! 144L test is per$or"ed. T-e test resu%ts !re re)orded !nd $or.!rded to t-e ?. A. Dep!rt"ent !nd .-o .i%% %i!ise .it- p!ttern "!8er $or ne)ess!r& !%%o.!n)e. I$ t-e di$$erent )o%orsAd&e %ots s-o. di$$erent s-rin8!*e+ di$$erent p!tterns .i%% ,e "!de !))ordin*%&.
)'rin,a!e 6roupin!: I$ !n extre"e s-rin8!*e r!te o))urs t-en ! test on e er& ro%% .i%% ,e per$or"ed. T-e resu%ts )o%%!ted !nd sep!r!ted into s-rin8!*e *roups o$ ! FA71.EL r!n*e. Sep!r!te p!tterns .i%% ,e "!de $or e!)- *roup. T-e s-rin8!*e !%%o.!n)e o$ e",roider& is )!%)u%!ted !t t-e S!"p%e "!8in* st!*e. T-e p!ttern "!8er .i%% !dd t-e ne)ess!r& !%%o.!n)e to t-e p!tterns !t t-is point !nd )o""uni)!te to t-e ?.A dep!rt"ent.
2.5.( Fa0ric Maintenance 'P? )-e)8 %ist
eports:
?u!%it& )o""ents $ro" 1u&er G!,ri) s-rin8!*e reports Test report #Di"ension!% st!,i%it&+ 2o%or $!stness to .!s-in*+ )ro)8in* !nd st!inin*+ G!,ri) )onstru)tion+ 2ount+ G!,ri) .idt-( No, )!rd Pre7produ)tion 0ini 0!r8er S-!de ,!nd !ppro !% $or"s 1u%8 !ppro !% $or" #G!,ri) det!i%s+ 1od& $!,ri) !nd Tri" $!,ri) !ppro ed s.!t)-es+ 1u&er det!i%s et).( G2R #G!,ri) )onsu"ption report(
2.5.* &ypes o# Interlinin!s:3 Co en

HE
Non7.o en 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%%o.in* %i*-ts57 D7DE5 D!& %i*-t 2CG5 2oo% C-ite G%uores)ent Li*-t UVH4445 ;OHLKs Pri"!r& Li*-t IN2A5 Tun*sten Li*-t UV5 U%tr! io%et Li*-t
HD
E!)- 1u&er re)o""ends t.o %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)& dri e in erter $or pre)ise speed )ontro% !nd proxi"it& sensors to )ontro% t-e uni$or"it& o$ ed*es.
*amsons
checkmate Model +o& *FI$%E
T-is "!)-ine is used to )-e)8 di$$erent 8inds o$ de$e)ts "entioned !,o e. T-e $!,ri) is )-e)8ed !nd sent to t-e $!)tor& $ro" t-e -e!d o$$i)e. So on%& 14L 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.
H9
Process Flowchart of Fabric Department
H:
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)ei in* 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)ei es 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 $or" )ont!ins d!t! %i8e57 Order no. 1u&er St&%e Order /u!ntit&#no. o$ pie)es( S-!de ?u!ntit& to ,e ordered Vendor De%i er& d!te+ et).
T-e 0er)-!ndiser t-en *i es 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:

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L!,e%s Pri)e t!* Se.in* T-re!d E",roider& T-re!d Gusin* 1uttons Oipper Inter%inin* 0o,i%on t!pe H!n*er Po%& ,!* St&%e ID 2!rtons Dr!. )ords 1u)8%es Stoppers Ve%)ro T!pes
2.(.3 )u03types o# &rims: T-re!ds 1uttons 5 2otton+ Po%&ester+ 64s+ H4s+ <4s+ E4s+ D4s up to 644s. 5 Sn!p ,uttons+ Nor"!% ,uttons+ 1<L+ 1DL+ 1:L+ 64 L+ 66L+ 6<L+ 6DL+ 6:L+ H4L+ H6L+ H<L.
1utton Ho%e 5 Nor"!% 8!@!+ Rise 8!@!. Oippers 5 Vision+ 2oi%ed )oi%+ 0et!%.
<4
Dr!. )ords 5 E%!sti)+ Nor"!%. Stoppers H!n*ers -!n*er. L!,e%s P!)8in* Po%%& ,!* 2!rtoon 5 2&%indri)!%+ Pi* nose+ 1e%%+ 1!%%. 5 S-irt -!n*er+ 2%ip -!n*er+ N!)8et -!n*er+ He! & .ei*-t 5 0!in %!,e%+ SiBe %!,e%+ 2ontent %!,e%+ 2ountr& ori*in C!s- )!re %!,e%+ Spe)i!% %!,e%. 5 H!n*er p!)8+ P%!te p!)8+ St!nd p!)8. 5 Indi idu!%+ 0!ster po%& ,!*. 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 $!)tor& pur)-!se order or t-e 1u&er )uttin* ti)8et. A store st!tus report is )re!ted+ in )!se o$ "u%tip%e re)eipts+ upd!ted report to ,e *ener!ted !t %e!st e er& .ee8 i$ not on e!)- re)eipt. 1!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)-!ndiserA,u&in* 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& $or !rious tri"s. T-e tri"s store .i%% inspe)t 14L o$ 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 !d ise t-e "er)-!nts !nd !.!it instru)tions in ter"s o$ return to t-e supp%ier+ order !ddition!% tri"s o$ )o er $or re@e)tions !nd !pportion"ent o$ t-e )ut ti)8et ti%% ,!%!n)e o$ t-e tri"s !re re)ei ed. 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.
<1
Start .e2uisition of Trims
Or(er Trims
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(
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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 $!,ri)+ .-i)- is !))ountin* to D4794L o$ t-e tot!% )ost. It is t-ere$ore essenti!% t-!t !)tu!% us!*e o$ $!,ri) s-ou%d ,e )ontro%%ed
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$or e)ono"i)!% produ)tion. A .e%%7desi*ned )uttin* pro)ess .i%% &ie%d !n ex)e%%ent resu%t in t-e o er!%% per$or"!n)e o$ oper!tions. T-e )uttin* dep!rt"ent is !n essenti!% p!rt o$ !n& *!r"ent7"!nu$!)turin* unit+ ,e)!use t-e $!,ri) is one r!. "!teri!%+ .-i)- )onstitutes to "ore t-!n E4L o$ t-e tot!% )ost o$ t-e *!r"ent !nd it -!s to ,e )ut into p!tterns !nd ! %ot is on st!8e+ i$ !n& pro,%e" !rises in t-is se)tion t-en it )!n !$$e)t t-e order dr!sti)!%%&. T-e $irst st!*e in t-e "!nu$!)ture o$ t-e *!r"ents is t-e )uttin* o$ t-e "!teri!%s into t-e ne)ess!r& p!ttern s-!pes. T-ese !re t-en @oined to*et-er ,& "e!ns o$ se!"s to )re!te t-ree7di"ension!% *!r"ents. C-ere %!r*e /u!ntities o$ ! *!r"ent st&%e "ust ,e )ut+ ! %!& is )re!ted .-i)- )onsist o$ "!n& p%ies o$ $!,ri) spre!d one !,o e t-e ot-er. Gro" t-is+ !%% t-e *!r"ent pie)es $or !%% t-e siBes t-!t -! e ,een p%!nned $or t-!t %!& !re )ut. T-e p!ttern s-!pes $or t-ese *!r"ents !re dr!.n !s to t-eir s-!pe !nd position+ .-i)"!& ,e -e%d .it-in ! )o"puter+ to ,e p%otted si"i%!r%& on t-e p!per "!r8er. T-e )uttin* dep!rt"ent !t Texport Industries P t. Ltd.+ TPIL714 unit is ! )o",ined se)tion $or spre!din* )uttin* !nd ti)8etin* .Spre!din* is done "!nu!%%& in t-e )o"p!n&. 2uttin* dep!rt"ent -!s str!i*-t 8ni$e+ ,!nd 8ni$e+ end )utter !nd $usin* "!)-ine. Tot!% "!npo.er o$ )uttin* roo" is 91.
2.*.2 90;ecti%es o# Cuttin!: To sep!r!te $!,ri) p!rts !s rep%i)!s o$ t-e p!ttern pie)es in t-e "!r8er. 2uttin* o$ *!r"ent p!rts !))ur!te%& !nd e)ono"i)!%%& !nd in su$$i)ient o%u"e !nd to 8eep t-e se.in* roo" supp%ied .it- .or8.
2.*.3 "rocedure: Spre!din* is one o$ t-e "ost i"port!nt st!*e in )uttin*+ ?2 -!s to )on$ir" t-e %!& %en*t- & -!s to )-e)8 $or %ooseness & tension o$ t-e %!&s. No to%er!n)e o$ "inus in spre!din* !s !*!inst t-e "!r8ed %en*t-. L!&s s-ou%dnKt %e!n on one !not-er & s-ou%d ,e str!i*-t 1e$ore )uttin*+ t-e ?2 .i%% )on$ir" t-!t !%% t-e p!rts o$ t-e *!r"ents !re t-ere in t-e "!r8er ,e$ore )uttin* & t-e s!"e .i%% ,e re)orded.
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A$ter )uttin*+ t-ree p!ne%s # top+ )entre & ,otto" ( o$ e er& p!rt .i%% ,e )-e)8ed !*!inst t-e -!rd p!ttern $or s-!pe+ not)-+ "is7)ut+ siBe & t-en .i%% ,e !%%o.ed $or nu",erin* #siBe & %otT( .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* $or stripes !s per re/uire"ent #"eterin*Anon7 "eterin*(+ ,!%!n)in* & p%!)e"ent o$ not)-es. Gusin* o$ p%!)8ets A )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 $or !uditin*. 1e$ore %o!din* to Se.in*+ 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 & %otAs-!de7.ise t!*s .i%% ,e issued !%on* .it- e er& ,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!*erA"!ster *ets ! do)8et .-i)- )ont!ins r!tio )o%or .ise+ /u!ntit& ,re!8do.n+ st&%e .ise )uttin* !nd ot-er det!i%s o$ t-e $!,ri)P -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)ei ed $ro" t-e stores t-rou*- re/uisition !nd stored in ! $!,ri) ,u$$er !re! .-ere t-e $!,ri) is re%e!sed !nd t-e .idt- o$ t-e $!,ri) is )-e)8ed. T-e "!n!*erA"!ster issues ! %!&er $or"!t to t-e %!&"!n+ .-i))ont!ins t-e %en*t- !nd .idt- o$ t-e $!,ri)+ nu",er o$ %!&ers to ,e %!id. T-e %!&er "!n !))ordin* to t-e $or"!t %!id t-e $!,ri)+ ,e$ore %&in* o$ t-e $!,ri) ! ,ro.n p!per is spre!d !nd stu)8 to t-e t!,%e to "ini"iBe s%ipp!*e o$ t-e $!,ri). A$ter t-e %!&in* is o er "!r8er re)ei ed $ro" )!d is spre!d o er t-e pi%es %!id $or )uttin* o$ p!tterns or p!tterns !re "!nu!%%& "!r8ed $or )-e)8 $!,ri)s !nd t-en t-e pins !re inserted $or sti$$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 t.ent& pie)es !re ,und%ed in
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,und%in* se)tion t-en $in!% !uditin* is )!rried out. Here+ e!)- p!rts !re )-e)8ed !))ordin* to A?L 6.E s&ste" !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 1!nd 8ni$e )utter Gusin* "!)-ine
2.*.* Formats used in t'e Cuttin! /epartment: No, order D!i%& )uttin* report
<D
Issue 2-e%!n 2uttin* nu",erin* re*ister Order .ise )uttin* re*ister 144L p!rt )-e)8in* report 0inusin* re)ord
<9
Process Flowchart of ,utting Department
<:
2.*.- &ools and 7<uipments: a. )trai!'t =ni#e T-e e%e"ents o$ ! str!i*-t 8ni$e )onsist o$ ! ,!se p%!te+ usu!%%& on ro%%ers $or e!se o$ "o e"ent+ !n upri*-t or ! st!nd!rd )!rr&in* ! str!i*-t+ erti)!% ,%!de .it- !r&in* ed*e )-!r!)teristi)s !nd !n e%e)tri) "otor !,o e it+ ! -!nd%e $or t-e )utter to dire)t t-e ,%!de+ !nd ! s-!rpenin* de i)e. T-e ,!se p%!te on its ro%%ers s%ides under t-e *%!Bed p!per+ .-i)- is spre!d ,e%%o.+ t-e ,otto" p%& o$ $!,ri) in ! %!&. T-e *re!ter t-e ,%!de "o e"ent+ t-e $!ster t-e ,%!de )uts t-e $!,ri) !nd t-e "ore r!pid%& !nd e!si%& t-e oper!tor )!n pus- t-e "!)-ine. Initi!% )uttin* is done ,& t-e str!i*-t 8ni$e )utter+ .-i)is $urt-er used $or re7)uttin* o$ ,i**er !nd )ur !)eous *!r"ent p!rts+ t-!t is di$$i)u%t to ,e done on t-e ,!nd 8ni$e. T-e ,%!de -ei*-t is !round :J+ t-ere$ore t-e "!xi"u" %!&s !re p%!nned !))ordin*%&+ not to ex)eed <J.
0. .and =ni#e A ,!nd 8ni$e )o"prises ! series o$ t-ree or "ore pu%%e&s+ po.ered ,& !n e%e)troni) "otor .it- ! )ontinuous%& rot!tin* stee% ,%!de "ounted on t-e". One ed*e o$ t-e ,%!de is s-!rpened. T-e ,!nd 8ni$e p!sses t-rou*- ! s%ot in t-e )uttin* t!,%e in ! $ixed position !nd t-e se)tion o$ t-e %!& to ,e )ut is "o ed p!st it. 1!nd 8ni es !re used .-en ! -i*-er st!nd!rd o$ )uttin* !))ur!)& is re/uired t-!n )!n ,e o,t!ined .it- ! str!i*-t 8ni$e+ ,ut )uts t-e str!i*-ter p!rts "ost%&. One -!s to .e!r "et!% *%o es $or s!$et& purpose.
<3
c.
ound =ni#e
Round ;ni$e is ,!si)!%%& used $or ed*e )uttin* .-i%e t-e "!nu!% %!&in* or spre!din* is t!8in* p%!)e. It is 644 "" in di!"eter !nd -!s ! %i"it!tion $or not )uttin* pre)ise !t t-e )ur e !nd t-us is used $or ed*e )uttin* !s it *i es ! pre)ise str!i*-t %ine )ut. It is used $or )uttin* t-e p%!in !nd stripe $!,ri)+ ,ut stri)t%& not $or )uttin* t-e ed*e o$ t-e )-e)8 $!,ri) ,e)!use it )!uses t-e pro,%e" o$ ,o.in* i$ t-e )-e)8 $!,ri) *ets !n o$$7*r!in )ut.
d. /rillin! Mac'ine
E4
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 sendsAissues 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%& retrie ed.
0. )preadin! 9# &'e ?ay

APPAREL INTERNSHIP REPORT ON TEXPORT INDUSTRIES PVT. LTD. | APURV & PRANAV E1
1ro.n p!per is spre!d ,e%o. t-e $!,ri) %!&. 0!r8er %en*t- !nd no o$ pie)es to ,e )ut is de)ided ,& t-e unit re )-e)8 t-e "!r8er %en*t- !nd "!r8er+ i$ t-ere is !n& di$$eren)e in t-e d!t! t-en t-e& in$or" t-e -e!d o$$i)e !,out it e%se t-e& *o !s per t-e p%!n. A$ter $inis-in* o$ e er& ro%%+ ! strip .!s %!id on t-e p%ies to "!r8 t-e de"!r)!tion o$ t-e ro%%s !nd ! )-!rt .!s sti)8 to t-e %!st p%& .-i)- -!d in$or"!tion !,out ro%% no.+ siBe r!tio + & no o$ pie)es o$ ! p!rti)u%!r siBe + n!"e o$ oper!tor. L!&in* is done 0!nu!%%& %!&in* .!s used $or t-e stripe $!,ri) !nd so%id $!,ri) oper!tors -! e t-e %!&in* )-!rt in .-i)- %!& %en*t- !nd nu",er o$ p%ies to ,e %!& is *i en !))ordin* to it oper!tors %!& t-e p%ies. T.o oper!tors !re used in t-e %!&in*.
c. .undlin! )ection T-e !rious steps in t-e ,und%in* se)tion !re !s $o%%o.s7 d. )ortin! 2ut p!rts !re sorted in re/uired nu",er o$ ,und%es. It e!ses t-e 0!teri!% G%o.+ ! ri*-t siBe o$ ,und%e is de)ided in t-is st!*e so t-!t t-e $%o. o$ "!teri!% re"!ins s"oot- !nd t-e CIP neit-er in)re!ses nor de)re!ses ,et.een t-e oper!tions. T-e ,und%e siBe is de)ided ,& 8eepin* in "ind t-e t&pe o$ t-e $!,ri) desi*n. I$ t-e $!,ri) is so%id+ t-en t-e s-!de !ri!tion is "ore+ so+ t-e ,und%e siBe is 8ept %o.+ i.e. *ener!%%& E4 !nd not !,o e E4 in !n& )!se. 1ut $or t-e )-e)8s !nd stripes+ .-ere t-e s-!de !ri!tion is not t-!t $re/uent+ t-is ,und%e siBe *ener!%%& depends on t-e nu",er o$ %!&s !nd )!n ,e !s "u)- !s t-e nu",er o$ %!&s+ .-i)- )!n ,e !s "u)- !s H44. e. :um0erin! As soon !s t-e )ut pie)es !re )-e)8ed+ t-e& !re nu",ered. Nu",erin* is done "!nu!%%&. Nu",erin* is done in su)- ! "!nner t-!t !%% pie)es o$ one p!rti)u%!r *!r"ent -! e one t-e s!"e nu",er. #. "anel C'ec,in! P!ne% )-e)8in* is done !$ter nu",erin* to $ind out t-e $!,ri) de$e)ts. It is espe)i!%%& done !$ter )uttin* !nd nu",erin*+ to ! oid !n& 8ind o$ de$e)t t-!t "!& o))ur in t-e p!rts !nd so t-!t t-e p!rt )!n ,e rep%!)ed ,e$ore+ it is ,und%ed .it- t-e %ot. !. .undlin!
E6
T-e )-e)8ed )ut pie)es !re t-en ,und%ed up .it- ! t!*+ .-i)- )ont!ins t-e entire des)ription !,out t-!t p!rti)u%!r p!ttern needed ,& t-e se.in* oper!tors. T-is des)ription in)%udes57 '. St&%e Nu",er 1u&er N!"e Order Nu",er S-!de Nu",er Lot Nu",er Nu",er o$ Pie)es N!"e o$ t-e P!rt elay
In t-is se)tion t-e )ut p!rts !re )-e)8ed. In )!se o$ striped !nd )-e)8s $!,ri) pie)es !re !%i*ned proper%&+ )-e)8ed $or !%i*n"ent o$ )-e)8s !nd stripes !nd )ut. A%so s"!%% p!rts %i8e po)8ets !re !%i*ned !nd )ut.
2.*.1@ Formats Ased in t'e Cuttin! /epartment: "roduction "lan #or t'e wee,: To )o""uni)!te t-e st&%es runnin*+ order /u!ntit&+ siBe .ise ,re!8 up+ )o%or .ise ,re!8 up+ de%i er& d!tes. 6)M record s'eet: No st!nd!rd $or"!t existin* no.. Used to p!ste ,e$ore .!s- !nd !$ter .!s- s.!t)-es o$ $!,ri)s !%on* .it- t-eir 'S0 !%ues. ?ay ecord: 0u%tipurpose $or"!t. Used $or "!int!inin* ,itin* re)ords $or e!)- st&%e+ used $or issuin* to spre!din* oper!tors in$or"in* t-e nu",er o$ p%ies to %!& !nd t-e %en*t- o$ t-e %!& $or t-e p!rti)u%!r st&%e !nd !%so used $or "!int!inin* t-e si*n!tures o$ !%% t-e spre!din* !nd )uttin* oper!tors .-o .or8ed on t-!t $!,ri). Hourly "roduction .oo,: Used $or "!int!inin* e!)- oper!torKs -our%& produ)tion $or !%% !)ti ities. )preadin! and Cuttin! eport: Used $or $i%%in* up t-e det!i%s !$ter t-e p!ne% inspe)tion o$ t-e )ut ,und%es $ p!ne%s. Used to "ention !%% t-e
EH
re.or8 !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 $or !%% t-e d!&s !nd e er& d!& t-e pie)es re"!inin* to ,e )ut !re "entioned on t-e top o$ t-e p!*e. Hen)e t-e n!"e ICutting MinusingJ /aily "roduction eport #or Cuttin! section: Used $or "!int!inin* t-e d!i%& produ)tion $or e!)- order $or e!)- st&%e.
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2.8 SEWING DEPARTMENT
2.-.1 Introduction: T-e do"in!nt pro)ess in *!r"ent "!nu$!)ture is se.in*. T-e o,@e)ti es o$ se.in* !re t-e )onstru)tion o$ se!"+ .-i)- )o",ines t-e re/uired st!nd!rd !ppe!r!n)e & per$or"!n)e+ .it- !n !ppropri!te %e e% o$ e)ono"& in )onstru)tion. Per$or"!n)e o$ se!"s "e!ns t-e !)-ie e"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 !)-ie ed .-en p%!nnin* *!r"ent produ)tion ,et.een 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 $%oor .i%% re)ei e t-e det!i%s %i8eP T-e st&%e or t-e *!r"ent+ Nu",er o$ 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 $or e!)- d!& 1re!8up o$ t-e produ)tion /u!ntit&.
A$ter re)ei in* !%% 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 $or t-e ne. st&%e. 1e$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 $or !,out H Q < d!&s. A$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 E4 pie)es $or t-e entire d!& !nd t-en t-e produ)tion *r!du!%%& in)re!ses $ro" E4 Q 144 Q 1E4 !nd so on+ t-is .i%% "!8e
APPAREL INTERNSHIP REPORT ON TEXPORT INDUSTRIES PVT. LTD. | APURV & PRANAV EE
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)ei ed $ro" t-e )uttin* !nd sortin* se)tion t-en t-e p!rts !re prep!red !nd !sse",%ed !))ordin* to t-e %ine t-!t is p%!nned. A$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 t.o t&pes o$ )-e)8in*+ t-e& !re In7pro)ess )-e)8in*. End %ine )-e)8in* Q 1ot- A?L !udit !nd nor"!% )-e)8in* exists.
T-e *!r"ent "!8in* is di ided into t-ree di$$erent st!*es !nd !t t-ese t-ree st!*es t-e )-e)8in* is done. T-e $%o. o$ "!teri!% in t-e produ)tion $%oor is t-rou*- t-e ,und%e s&ste" !nd e!)- oper!tor *ets ! ,und%e )ont!inin* si"i%!r pie)es !nd t-ere .i%% ,e !,out 1E Q 64 pie)es in e!)- ,und%e !nd t-e oper!tor )o"p%ete%& $inis-es t-e @o, !nd sends it to t-e next oper!tor to do t-e next oper!tion on t-e". E!)- ,und%e .i%% )ont!in s!"e )o"ponent o$ di$$erent *!r"ents. T-e "o e"ent o$ t-e "!teri!%s .it-in t-e oper!tors in t-e ,!t)-A%ine is *ener!%%& Bi*QB!* "otion. T-e )-e)8in* person .i%% ,e present !t ! position .-ere t-e *!r"ent is p!rti!%%& $inis-ed !nd it is !s "entioned )-e)8ed t-ri)e in t-e %ine !nd so"eti"es "ore t-!n t-ree !nd t-is depends on t-e 1u&er !s .e%% !s t-e nu",er o$ )o"ponents present in t-e *!r"ent.
2.-.3 .atc' )ystem: In ,!t)- s&ste" t-e .or8 is di ided into di$$erent oper!tions !nd e!)oper!tion is )!rried out ,& ! p!rti)u%!r t!i%or .t-is s&ste" is !%so re$erred to !s ,!nd s&ste" or !sse",%& %ine+ t-ou*- t-ere is ! $ine di$$eren)e ,et.een t-ese t-ree . T-is s&ste" is suit!,%e $or "ediu" !nd %!r*e s)!%e industr&.
2.-.4 .atc' )ettin!: 1!t)- settin* is ! pro)ess o$ !rr!n*in* t-e "!)-ines+ !%%ottin* t-e "!)-ines+ di idin* 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"ootrunnin* to.!rds t!r*eted output !nd is )!%%ed !n ide!% ,!t)- settin*.
ED
1!t)- settin* is ,!sed on t-e $o%%o.in* $!)tors57 St&%e Produ)tion re/uired A !i%!,i%it& o$ "!)-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 super isor p%!&s ! it!% ro%e in t-e produ)tion $%oor. HeAs-e "!n!*es t-e entire ,!t)- .-i)- is ,een !%%o)!ted to t-e" !nd t-e& -! e t-e $o%%o.in* $un)tions to per$or"57 1. T-e& -! e to )on e& 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. H. 2-e)8 i$ t-e entire oper!tor in t-e ,!t)-A%ine is ,us& .it- t-e .or8 ,ein* !%%o)!ted to t-e". <. I$ t-e oper!tor does not -! e !n& "!teri!% to .or8 on t-en t-e super isor -!s to *et -i"A-er t-eir "!teri!% !nd !s8 t-e" to .or8. E. 2o"p%!in t-e produ)tion "!n!*ers i$ t-e oper!tors !re not per$or"in* t-eir ,est.
E9
D. H! e to "!int!in ! proper )o""uni)!tion ,et.een 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%% %e e% .-ene er !s8ed $or. :. C-en !n& oper!tor is on %e! e t-en t-e super isor -!s to "!8e sure .-o )!n ,e ! ,etter person to $it into t-!t !)!nt p%!)e. 3. At ti"es t-e super isor -i"se%$ sits !nd per$or"s t-e oper!tion i$ ne)ess!r&. 14. T-e super isor 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.
E:
Process Flowchart of Sewing Department
E3
2. FINISHING DEPARTMENT
2.>.1 Introduction: In t-is se)tion t-e *!r"ent is proper%& $inis-ed !nd p!)8ed ,& *i in* t-e re/uired $inis- $or t-e *!r"ent. T-e *!r"ents $ro" se.in* 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"o e 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 se.in* se)tion.
D4
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 indi idu!% po%& ,!*s !s spe)i$ied ,& t-e 1u&er. T-e *!r"ents !re t-en p!)8ed in t-e )!rton ,oxes !))ordin* to t-e spe)i$i)!tion o$ 1u&er.
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%%o.in* steps57 &rimmin!:
T-is in o% 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.E s&ste" !nd so"eti"es it depends on t-e 1u&er !%so i.e.+ i$ t-e 1u&er e"p-!siBes $or ! 144L 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*.
D1
&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 1u&er. On)e t-e t!**in* is done t-e *!r"ents !re $o%ded !))ordin* to t-e 1u&erKs spe)i$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 1u&erKs spe)i$i)!tions !*!in. T-e p!)8in* "!teri!%+ P21 det!i%s+ nu",er o$ siBe r!tios t-!t !re supposed to ,e put in !re !%% su**ested ,& t-e 1u&er !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 se er!% )riteri! $or t-e p!)8in* o$ t-e *!r"ents t-e& !re !s $o%%o.s. T-ere !re *ener!%%& t.o .!&s o$ p!)8in* t-e *!r"ent57 i. T-e *!r"ent is indi idu!%%& p!)8edA.r!pped in t-e po%& ,!* .-ose desi*n .i%% ,e spe)i$ied ,& t-e 1u&er 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%%o.ed in e!)- )!rton ,ox !s !%re!d& "entioned is done in di$$erent .!&s .-i)- is !s $o%%o.s5 )olid "ac,in!: In t-is "et-od o$ p!)8in*+ t-e )!rton ,ox .i%% in)%ude *!r"ents o$ sin*%e )o%or !nd s!"e siBe. Gor ex!"p%e+ 64 s-irts o$ ! si"i%!r )o%or s!& n! & ,%ue !nd t-e siBe s!& S .i%% ,e put in one )!rton ,ox. atio "ac,in!: In t-is "et-od t-e )!rton ,ox in)%udes *!r"ents o$ s!"e )o%or ,ut o$ di$$erent siBes !))ordin* to t-e r!tio. Gor ex!"p%e+ S 5 0 5 L 5 XL R E 5 9 5 9 5 E
APPAREL INTERNSHIP REPORT ON TEXPORT INDUSTRIES PVT. LTD. | APURV & PRANAV D6
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 *odo.nAstores unti% t-e 1u&er sends t-e 1u&er ?2 $or t-e inspe)tion purpose ,e$ore de%i erin* t-e" !nd on)e t-e ?2 !rri es+ -eAs-e .i%% )-e)8 t-e" !))ordin* to t-e 6.E A?L %e e% !nd t-en see i$ t-e *!r"ents -!s to ,e !))epted or re@e)ted.
'!r"ent Re)eipt $ro" Se.in* C!s-in* 1utton Ho%e 1utton Att!)1!r T!)8 Tri""in* 0idd%e 2-e)8 T-re!d Su)8in* Pressin* 1utton 2%osin* Gin!% 2-e)8 Go%din* P!)8in* Process Flowchart of Finishing Department
DH
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 1!r )ode sti)8ers
2.>.( "ressin! 7<uipment: H!nd iron5 ?u!%it& depends up on t-e s8i%% o$ t-e oper!tor .it- ,u%8 !rr!n*e"ents. Ste!" press5 Depends on t-e t&pe o$ t-e *!r"ent produ)ed. Here t-e *!r"ent to ,e pressed is s!nd.i)-ed ,et.een t-e t.o p%!tes & -e!ted ,& t-e p!ssin* ste!". Gor" press5 C-ere no need o$ )re!se "!r8s "!in%& used in @e!n & suit. Hot !ir or ste!" is supp%ied. Tunne% $inis-er5 E"p%o&ed .-ere -!nd%in* o$ *!r"ent s-ou%d ,e ! oided+ e"p%o&ed $or suit. Per"!nent Press5 Anti7.rin8%e+ )re!se $ree )urin* U te"per!ture ste!"ed resin .it- -i*- te"per!ture is used. er& -i*-
2.>.* Foldin!: T&pes o$ $o%din*57 G%!ts De!d "!n H!%$ de!d "!n
D<
Here $%!t is used in $in!% p!)8in*P -!%$ 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%orAso%id siBe So%id )o%orA!ssorted siBe Assorted )o%orAso%id siBe Assorted )o%orA!ssorted siBe
DE
2.1! IE DEPARTMENT
2.1@.1 Introduction: T-e IED dep!rt"ent -!s to .or8 .it- "!n& ot-er dep!rt"ents !s t-is dep!rt"ent *i es 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%% %e e% )!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. 2.1@.2 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 8no.in* 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)ti it& o$ t-e *i en st&%e $or t-e initi!% )ostin* !nd !%so )!%)u%!tes or )ounts t-e !))essories )onsu"ption ,& t-e st&%e !nd *i es !%% 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 *i es 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!% Se.in* D!t! prep!re t-e st&%e ,u%%etin .-i)- in)%udes t-e di$$erent t&pes 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 t&pes o$ stit)-es t-!t -!s to ,e )!rried out !t di$$erent p%!)es o$ t-e *!r"ent !s per t-e 1u&ers spe)i$i)!tions !nd !ppro !%. T&pes o$ t-re!d #.-i)- is t-e TEX(+ !re! o$ p%!)e"ent o$ t-e tri"s !nd !))essories !nd its %o)!tion di$$erent 8inds 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 "!npo.er !nd t-eir s8i%% %e e% .-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 *i e t-e t!r*et to e!)- oper!tor ,!sed on
APPAREL INTERNSHIP REPORT ON TEXPORT INDUSTRIES PVT. LTD. | APURV & PRANAV DD
-isA-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 ! $i%e .-i)- is t-e DPR #D!i%& Produ)tion Report(+ in t-is report t-e& upd!te t-e ,!t)- nu",er+ st&%eAite" nu",er+ !)tu!% output+ )o""itted output+ SA0 !%ue o$ 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)& !)-ie ed+ 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$or"!tion !,out t-e ,!t)- settin* prior to t-e "!ss produ)tion+ et).+ !%% t-is .i%% ,e "entioned in t-is DPR.
2.1@.3
oles and
esponsi0ilities o# an I7:
On re)eipt o$ produ)tion p!)8!*e !nd stud& t-e 2IED O1 !%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 re ie.+ !rr!n*e t-e st&%e st!rtup "eetin* .it- 2IED + Gin!%iBe t-e 0A2 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$$i)ient%& to "eet t-e %ine ,!)8 %o!din* d!tes. 0!8e sure t-e ,!t)- settin* !s per t-e 2IED !ppro ed %!&out .)orre)t s8i%% oper!tors -! e to p%!)e !s per t-e s8i%% "!trix. 0ust !$$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 1i-our%& on Lo. output oper!tors .it- t-e -e%p o$ %ine in )-!r*es !nd i"pro e t-e oper!tions on d!i%& ,!sis !nd *i e upd!tes to Super isors !s .e%% !s P0 on -our%& A,i-our%& ,!sis. IE -e!d is responsi,%e !%% produ)tion reports.
D9
0!8e sure !%% ;SA s&ste"s in p%!)e in e!)- dep!rt"ent.
2.1@.4 ?ine .alancin!: Line ,!%!n)in* is ! pro)ess exer)ise ,& .-i)- ! produ)tion super isor )!n ,!%!n)e output & input. T-e su))ess !nd $!i%ure o$ super isors & "!n!*er depends on -is or -er 8no.%ed*e !,out produ)tion %ine ,!%!n)in*. 'ood super isor .-o -!s ! *ood 8no.%ed*e o$ !,out %ine ,!%!n)in* )!n en@o& s-op $%oor+ in ot-er -!nd ! super isor .-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%%o.in* e$$e)ti e p%!nnin* s-ou%d ,e )%e!r in t-e "ind o$ produ)tion super isor57 ;no.%ed*e o$ *!r"ent "!nu$!)turin*. Crite do.n se/uen)e o$ p!rti)u%!r st&%es. 'r!din* o$ oper!tion. Re/uire"ent o$ %!,or. 'r!din* o$ %!,or !))ordin* to oper!tion *r!din*. 0!)-ines re/uire"ent !))ordin* to st&%e. Se/uen)e o$ "!)-ine on t-e s-op $%oor+ !))ordin* to se/uen)e oper!tion o$ *!r"ent. Tr!i% produ)tionApi%ot stud& ! !i%!,%e $!,ri). Se)tion!%iB!tion o$ ,!t)- %ines #i$ re/uired(. Identi$i)!tion o$ ,ott%ed ne)8 oper!tion. Cor8 stud& st!rtin* initi!% produ)tion s-ou%d ,e )%e!r ,e$ore. T-e st!nd!rd ti"e *i es ti"e re/uired $or e!)- oper!tion. A%%o)!tion o$ oper!tion on t-e ,!sis o$ e$$i)ien)& !nd s8i%%ed %e e% o$ oper!tor. Line ,!%!n)in* -e%ps in )ontinuous $%o. o$ ,und%e .it- "ini"u" in entor&.
D:
2.1@.5 ?a0or Allotment: L!,or !%%ot"ent depends up on t-e nu",er o$ oper!tions+ "!)-ines to ,e used+ !nd "!teri!% $%o. ,et.een t-e "!)-ines+ %ine ,!%!n)in* & )!p!,i%ities o$ t-e %!,ors. 1!sed on t-e oper!torKs per$or"!n)e .-i)- .ou%d -! e ,een o,ser ed $or ! spe)i$ied period o$ ti"e+ t-e dep!rt"ent .i%% !%%o)!te ! *r!de to t-e oper!tor .-i)- is !s $o%%o.s57 ),ill type A 1 2 6rade Hi*-%& s8i%%ed S8i%%ed Se"i7s8i%%ed
T-e oper!tors $or e!)- ,!t)- !re t!8en in ! r!tio o$5 Hi*-%& S8i%%ed S8i%%ed Se"i7s8i%%ed 5 64L 5 6EL 5 E4L
T-is is done irrespe)ti e to !n& st&%e !nd 1u&er !nd t-e )o"p%i)!tion o$ 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. 1e)!use o$ "!int!inin* t-is re)ord t-e& 8eep in tr!)8 o$ t-e oper!torKs s8i%% !nd -is e$$i)ien)&+ .or8in* "et-od !nd !$ter ! p!rti)u%!r sp!n o$ ti"e t-e& upd!te t-e re)ord. Suppose ! ne. oper!tor @oins !nd -e is )o"p%ete%& un!.!re o$ stit)-in* t-en ! tr!inin* $or !,out <E Q E4 d!&s is *i en to -i"A-er !nd t-en ,!sed on t-eir %e!rnin* !nd *r!spin* )!p!)it& ! *r!de is ,een !%%o)!ted to t-e" pri"!ri%&. Suppose t-e oper!torAne. e"p%o&ee 8no.s or -!s ! pre ious .or8 experien)e in ! *!r"ent industr& t-en -e is @ust ,een !s8ed !,out -is @o, .-i)- -eAs-e .ou%d -! e done in t-e pre ious $!)tor& !nd t-en -eAs-e is @ust *i en !n -ourKs test to 8no. -is s8i%%s !nd t-en *r!de is ,een !%%o)!ted.
APPAREL INTERNSHIP REPORT ON TEXPORT INDUSTRIES PVT. LTD. | APURV & PRANAV D3
E er& d!& t-e IED te!" t-ere .i%% ,e ! "eetin* .-ere in .-i)- t-e& spe!8 !,out t-e "!inten!n)e o$ e$$i)ien)& o$ t-e ,!t)- in t-e produ)tion $%oor. T-e& !%so )ondu)t ! produ)tion re ie. "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 pre ious%& p%!nned $%o. is not *i in* t-e esti"!ted e$$i)ien)& !nd output t-en t-e& .i%% t-in8 o$ )-!n*in* t-e %ine p%!n !nd re ie. it !nd %!ter $o%%o. t-e ri*-t one.
94
Start
Training, selection 1 (evelopment Selection of Operators, +elpers, Supervisors, &hec"ers, 6&, etc.
Wor" 'easurement
Systems (evelopment
Time Stu(y
'etho( Stu(y
O)D ,nalysis
7ine $alancing
S"ill 'atrix
$atch 7ayout
Style $ulletin
$atch )erformance
0n(
Process Flowchart of I- E- Department
91
2.1@.( Acti%ities "er#ormed In 7ac' )ection: a. AAM& &rainin! section: 7Oper!tor se%e)tion pro)edures5 T-e pro)edure "entioned $or t-e se%e)tion o$ oper!tors "ust ,e "!int!ined. 7Tr!inin* pro)edures5 Spe)i$i) AA0T tr!inin* pro)edures s-ou%d ,e used. 7Oper!tor s-i$tin* pro)edure5 A%% AA0T tr!iners -! e to t!8e oper!tor re/uisition $ro" e!)- ,!t)- on .ee8%& ,!sis. 7Tr!inin* pro*ress st!tus5 T-is st!tus s-ou%d ,e upd!ted e er& d!& !nd s-ou%d ,e disp%!&ed in t-e AA0T dep!rt"ent.
0. Cuttin! /epartment: 7Oper!tion 1u%%etin5 O1 is re/uired to de)ide t!r*ets & "!npo.er !%%o)!tion. 72uttin* )-e)8 %ist5 T-is is ,!si) re/uire"ent in )uttin* se)tion to 8no. -o. to )ut + .-ere not)-es .i%% )o"e & .-ere dri%% -o%e "!r8in* is re/uired & to de)ide p%!)e"ent o$ p%& nu",erin* !s per stit)-in* O1 re/uire"ent 7E$$i)ien)& Report5 E$$i)ien)& report -!s to ,e prep!red usin* SA0s o$ ne. st&%es. 7In)enti e St!te"ent5 It s-ou%d ,e "!de $or e!)- oper!tor ,!sed on upd!ted in)enti e s)-e"es. 7T!,%e p%!nnin*5 T!,%e p%!nnin* is "ust $or spre!din* & %!&out & ,& t-is .e )!n uti%iBe )uttin* t!,%e proper%&. 7L!& s%ip5 It is i"port!nt to 8no. t-e ti"in* !nd ot-er det!i%s o$ spre!din* !nd )uttin*. T-ese det!i%s !re "entioned in L!& s%ip. 7'u" s-eet5 'u" s-eets s-ou%d ,e upd!ted on -our%& ,!sis. 7Hour%& T!r*et ,o!rds5 Hour%& produ)tion !nd t!r*et re/uired s-ou%d ,e "entioned on t-e ,o!rd. 7L!& inspe)tion5 E er&d!& P0+ ?A0 & 2uttin* In)-!r*e need to )-e)8 t-is report.
96
c. )ewin! /epartment: 7Oper!tion 1u%%etin5 O1 is re/uired to de)ide t!r*ets & "!npo.er !%%o)!tion. 7L!&out5 T-e %ine %!&out s-ou%d ,e "!de !nd do)u"ented $or t-!t p!rti)u%!r st&%e. 7Per$or"!n)e "onitorin* s&ste"5 Geed,!)8 on oper!tor per$or"!n)e s-ou%d ,e *i en to e!)- oper!tor+ !nd t-en .e )!n !)-ie e ,etter e$$i)ien)&. 7G%!* S&ste"5 0ust use $%!*s $or oper!tor per$or"!n)e.
9H
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%& e en 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$$erent st!*es o$ "!nu$!)turin* !nd t-ere !re )%!ssi$ied into $our "!@or *roups .-i)- !re !s $o%%o.s.
a. "re3production Audit: In t-is st!*e !uditin* is "!in%& done $or t-e st!*es .-i)- )o"e ,e$ore t-e produ)tion !nd t-!t is t-e s!"p%in* st!*e. Here t-e !uditin* is done $or !%% S!"p%es !nd pre)ise%& $or t-e siBe set S!"p%es !nd !%so $or t-e pi%ot produ)tion *!r"ents. T-e siBe set S!"p%es !re *i en i"port!n)e to ,e)!use t-e& !re "!in%& !s8ed ,& t-e 1u&er $or )-e)8in* t-e di"ensions o$ t-e *!r"ent -en)e !n extr! stress is *i en to t-ese S!"p%es !nd t-e !uditin* $or t-e" is "!in%& done $or t-e "e!sure"ents o$ t-e *!r"ent !nd t-e "e!sure"ents !re )-e)8ed !t !%% t-e )riti)!% !re!s in t-e *!r"ent. Gor ex!"p%e5 i$ it is ! trouser t-en t-e "e!sure"ents !re )-e)8ed !t t-e !re!s %i8e t-e %en*t- o$ t-e trouser+ .!ist "e!sure"ents+ inse!" "e!sure"ents+ t-e dist!n)e o$ t-e ,e%t %oops+ et).+ Gor t-e pi%ot run produ)tion !%so+ t-e *!r"ents !re )-e)8ed $or t-e di"ensions !nd !%so $or t-e p%!)e"ent o$ t-e !))essories !nd tri"s. $or ex!"p%e+ t-e %!,e% !tt!)-"ent !re!s+ et).
0. Cuttin! Audit: In t-e )uttin* st!*e+ .-i)- is t-e )riti)!% st!*e o$ t-e *!r"ent produ)tion t-e !uditin* is $urt-er di ided into "!n& ot-er dep!rt"ents .-i)- !reP 1. Spre!din* 6. Re%!& )ut H. 1!nd 8ni$e <. S-!de
APPAREL INTERNSHIP REPORT ON TEXPORT INDUSTRIES PVT. LTD. | APURV & PRANAV 9<
E. H!rd p!ttern c. )ewin! Audit: In se.in* pro)ess t-e inspe)tion is done in t.o !re!s+ t-e& !re57 i. In Q %ine !udit5 Here t-e *!r"ents !re )-e)8ed durin* t-eir di$$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 t.o 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 do.n into st!*es %i8e+ t-e $inis- o$ $ront+ $inis- i$ ,!)8+ s%ee e !tt!)- $inis- !nd t-en t-e entire s-irt. In t-is )!se t-e s-irt is ,ein* )-e)8ed !t e!)- st!*e !nd t-e !uditin* personne% .i%% ,e pro ided ,& )ert!in spe)i$i)!tions !nd !%so t-e to%er!n)e %i"its ,!sed on .-i)- -e )-e)8s t-e *!r"ent. Here e er& sin*%e *!r"ent is )-e)8ed. ii. End Q %ine !udit5 Here t-e *!r"ents !re )-e)8ed !$ter t-e entire pro)ess is o er !nd t-e spe)i$i)!tions !re "!in%& ,!sed on t-e di"ensions o$ t-e *!r"ent !t t-e )riti)!% positions !nd t-en t-e p%!)e"ents o$ t-e %!,e%s.
d. Finis'in! Audit: In t-is !re! t-e !uditin* is "!in%& done ,& t-e oper!tor -i"se%$ !s t-e @o, is %i"ited+ it is @ust ,utton !tt!)-"ent t-!t -!s to ,e done !nd t-e oper!tor does it -i"se%$ !s !nd .-en -e $inis-es -is p!rt o$ t-e @o, .it- t-e *!r"ent !nd t-e oper!tor .i%% ,e *i en or t!u*-t !,out t-e spe)i$i)!tions $or t-e *!r"ent to !tt!)- t-e ,uttonA "!8in* t-e ,utton -o%es. A$ter t-e !uditin* is done in e!)- !nd e er& st!*e t-e de$e)ts+ $indin*s !nd ot-er re%!ted in$or"!tion .i%% ,e re)orded ,& t-e )on)erned dep!rt"ents in t-eir o.n $or"!ts !nd t-e& .i%% ,e sent to t-e respe)ti e dep!rt"ents $or re)ti$i)!tion.
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2.11.2 $.C Hourly: Re@e)ted *!r"ents !re sep!r!ted in t-ree "!in *roups57 0!nu$!)turin* $!u%ts G!,ri) de$e)ts C!s-in*Aprintin*Ae",roider& $!u%ts
T-e do)u"ent!tion is 8ept on -our%& ,!sisP t-e in$or"!tion is )o%%e)ted ,& ?u!%it& 2ontro%%er !nd in)orpor!tes t-is in to d!i%& /u!%it& report.
2.11.3 7nd &a0le
eports:
?.2Vs %!,e% nu",er s-ou%d ,e entered in t-e $ront side. Sti)8er s-ou%d ,e put up on t-e de$e)ts & entered in t-e $or". De$e)ts !re .ritten on t-e .!ste *!r"ent !nd it is t!**ed to t-e -!n*er %oop. 1!t)- super isor s-ou%d si*n on t-e report. I$ t-ere is !n& pendin* pie)e. ?2 %!,e% nu",er s-ou%d ,e entered in t-e Re"!r8 )o%u"n.
2.11.4 $C s'ould c'ec, t'e #ollowin!: R!ndo" )-e)8in* Seri!% .ise nu",er )-e)8in* Pie)es s-ou%d ,e )-e)8ed .-i)- is p!ssed ,& )-e)8ers It is t-e "!teri!% used to *i e sti$$ness in )o%%!r+ )u$$+ & ot-er p!rts.
2.11.5 &o maintain !ood <ualityC operators s'ould do t'e #ollowin!: Se%$7)-e)8in*
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Se%$7tri""in* Se%$7si*nin* .it- nu",erin* t!* or sti)8er
2.11.( Important points to c'ec, in t'e was'ed !arment: T-e "e!sure"ent !$ter .!sT-e -!nd $ee% T-e )o%or or s-!de !$ter .!sT-e pu)8erin* on se!"s i$ !s8ed ,& t-e 1u&er
2.11.* Important points to c'ec, in a "ac,ed !arment: T-e present!tion o$ .or8 o$ t-e *!r"ent is i"port!nt Po%& ,!* to ,e ne!t+ not d!"!*ed '!r"ent to ,e ,!%!n)ed on ,ot- sides T!*s to ,e in t-e ri*-t p%!)e T!*s not to ,e d!"!*ed No un)ut t-re!ds & st!ins !))ept!,%e Ensure proper de7dustin*.
2.11.- Accessory Inspection B A$? 2.5: C-en t-e !))essories !rri e+ ! S!"p%e o$ e!)- ite" is *i en to t-e "er)-!ndisin* dep!rt"ent .-o .i%% )on$ir" i$ t-is ite" is )orre)t !))ordin* to .-!t .!s ordered. On)e t-e ite" -!s ,een eri$ied 0er)-!ndiser .i%% in$or" to pro)eed .it- !ppropri!te testin*. A%% t-e !))essories !re *i en !n initi!% inspe)tion o$ 14L r!ndo" inspe)tion t-is inspe)tion is )ondu)ted $o%%o.in* t-e *uide%ines st!ted in t-e A))essories )-e)8in* t!,%e. To test s-!de !ri!tion !nd t-e )o%or !ri!tion !*!inst t-e ,u%8 it is er& i"port!nt t-!t t-e !))essories )on$or" to t-e 1u&ers re/uire"ents+ t-ere$ore "e!sure"ents to spe)i$i)!tion+ %!,e%%in* !))ur!)&+ I )ode nu",ers+ %etterin* or )!re$u%%& ex!"ined.
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T-e "!xi"u" $!u%t r!tes $or t-e 14L inspe)tion !re 6L.i$ t-e nu",er o$ $!u%ts ex)eeds t-is !"ount t-en !not-er 14L inspe)tion is per$or"ed. 1otinspe)tions !re )!re$u%%& re)orded in t-e !))essories inspe)tion report. 2.11.> Mar,er Inspection: It is responsi,i%it& o$ t-e p!ttern "!ster to )-e)8 t-e !%% "!r8ers issued to t-e )uttin* dep!rt"ent prior to t-e )uttin*. T-is )-e)8 .i%% )on$ir" t-!t !%% )o"ponents !re )orre)t%& p%!)ed !nd !%% t-e )o"ponents re/uired !re in)%uded in t-e "!r8er. I$ !n& "!r8er is $ound to -! e )o"ponents "issin* or in)orre)t%& p%!)ed in t-e "!r8er is !d ised to )!d roo" in )-!r*e t-rou*p!ttern "!ster.
2.11.1@ Cut &a0le Inspection: A t!,%e inspe)tion is per$or"ed durin* t-e )uttin* pro)ess. E er& )ut ,%o)8 is )o"p!red to t-e produ)tion p!ttern ,o!rds. Gro" e er& )ut ,%o)8 t-e $irst+ "idd%e+ !nd %!st pie)e is used to )-e)8 )on$or"it& to s-!pe+ )ut "!r8in* !re *i en !nd positioned )orre)t%&. I$ !n& pie)e $ound to ,e un!))ept!,%e t-!t )uttin* is in$or"ed !nd !ppropri!te !)tion is t!8en. L!&ers .i%% ,e responsi,%e $or $%!**in* o, ious de$e)ts durin* t-e %!&in* pro)essP de$e)ti e pie)es .i%% ,e rep%!)ed ,e$ore *oin* to produ)tion !%% resu%ts !re re)orded in t-e )uttin* t!,%e inspe)tion report. T-e r!ndo" s!"p%in* inspe)tion ! )ut ,%o)8 is seen to -! e d!"!*es ex)eedin* t-e st!ted !"ountP !n !ddition!% $e. pie)es !re inspe)ted. 2uttin* ?u!%it& 2ontro%%er .i%% !ssess t-e %e e% o$ d!"!*es !nd de)ide i$ )!n ,e re)ti$ied t-e ,%o)8 .i%% ,e )orre)ted ,& eit-er re )uttin* or rep%!)in* t-e p!ne%s.
2.11.11 Cut "anel Inspection: C-en t-e )ut ,%o)8s !re re!d& $or produ)tion !not-er inspe)tion is per$or"ed ,& )-e)8in* EL o$ t-e )onsi*n"ent )o erin* !%% t-e siBes !nd t-e )o%ors+ t-is inspe)tion id per$or"ed )o"p!re t-e )ut p!ne%s to t-e p!ttern ,o!rd to identi$&in* !n& dis)rep!n)& ,e$ore *oin* to produ)tion. I$ t-e re@e)tion is "ore t-!n HL+ 144L inspe)tion is done.
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2.11.12 )ewin! $uality Inspections: In%ine inspe)tion5 T-e in%ine inspe)tion is used to "onitor t-e /u!%it& o$ t-e produ)t t-rou*- its !rious produ)tion st!*es. It is ne)ess!r& $or dete)tin* $!u%ts !nd identi$& !rious pro,%e"s durin* t-e produ)tion pro)esses e!)- ti"e !n in%ine inspe)tion is per$or"ed !n in%ine inspe)tion report is )o"p%eted. T-e $re/uen)& o$ in%ine inspe)tion .i%% depend upon t-e t&pe o$ "er)-!ndise ,ein* produ)ed. End %ine inspe)tion5 To est!,%is- !n !*ree"ent on /u!%it& re/uire"ent on e!)- *!r"ent t-e ?u!%it& Assur!n)e Dep!rt"ent .i%% deter"ine t-e !%%o.!,%e to%er!n)es !%% t-e ?u!%it& 2ontro%%ers .i%% .or8 !))ordin* to t-!t st!nd!rds !nd *uide%ines. So t-ere .i%% ,e no di$$eren)es in t-e %e e% o$ /u!%it&. A%% t-e end %ine ?u!%it& 2ontro%%er inspe)tors *i e ! $u%% inspe)tion o$ e er& *!r"ent+ ex!"inin* )%ose%& )o%or "!t)-in*+ )on$or"it& to s-!pe+ .or8"!ns-ip+ !nd siBe spe)i$i)!tion. An& *!r"ents $ound .it- d!"!*es .i%% ,e re)orded in t-e end %ine inspe)tion report .it is responsi,i%it& o$ t-e produ)tion "!n!*er to "onitor t-e e er& end %ine inspe)tion report !nd ensure )orre)t !)tion to ,e t!8en i$ needed.
Gin!% Audit5 It is t-e sep!r!te dep!rt"entP t-e& .i%% "!8e t-e $in!% inspe)tion .-en :4L o$ t-e order is p!)8ed in t-e )!rtons. Audit .i%% ,e on r!ndo"%& se%e)ted *!r"ents !nd is di ided in t-ree se)tions !s $o%%o.in*57 !. Inter"edi!te !udit ,. Cor8"!ns-ip !udit ). 0e!sure"ent !udit
93
2.11.13 /i##erent types o# de#ects:3 7m0ellis'ment de#ect !. ,. ). d. e. $. *. -. i. @. 8. %. ". Unr! e%in* Pee%in* & )r!)8in* Poor )o er!*e Poor re*istr!tion Poor !d-esion I"proper ,!)8in* re"o !% In)orre)t )o%or In)orre)t siBe In)orre)t p%!)e"ent In8 s"e!r P%!te "!r8s E",e%%is-"ent "issin* E",e%%is-"ent not !s spe)i$ied !. ,. ). d. e. "ac,in! de#ects In)orre)t in$or"!tion po%& ,!* In)orre)t siBe po%& ,!* In)orre)t )!rtoon )ontent O er p!)8 under p!)8 )!rtoon 0issA in)orre)t u. o.8. sti)8er o,@e)ts pins st!p%es
$. Gorei*n need%es *. -.
Open or d!"!*e po%& ,!* 0ixed siBes
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)titc'in! de#ects !. ,. ). d. e. $. *. -. i. @. 8. %. ". n. o. p. /. r. s. S;IPAdropA,ro8en stit)R!. ed*es $r!&ed se!"s Open se!" O er run stit)In)orre)t tension Un e en .! & stit)-in* 0issin*Ainse)ure )o"ponent Need%e -o%e Need%e )-e. T.isted ropin*A une en -e" 2onspi)uous rep!ir 2onstru)tion not !s spe)i$ied In)orre)t in)onsistent stit)S-!din* .it- in *!r"ents In )orre)t )o%or )o",in!tion Hi*-A%o. po)8et s-ou%der Do.n stit)Loose stit)>!rn pu%%in* !. ,. ). d. e. $. *. -. i. @.
Fa0ric de#ects Ho%e ;not St!in Go%d "!r8 Une en pe!)Gorei*n &!rn 0iss .e! e 0iss %ine S%o, D&e stre!8s
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2.12 MAINTENANCE DEPARTMENT
2.12.1 Introduction: Ap!rt $ro" -! in* /u!%it& s&ste" !nd t-e ,est pr!)ti)es+ V0!)-ine 0!inten!n)eK !%so -!s ! it!% ro%e in o,t!inin* V/u!%it&K produ)ts. Un!))ept!,%e /u!%it& o$ten resu%ts in i%%7"!int!ined "!)-ines. 1re!8do.n !nd pre enti e "!inten!n)e is pri"!ri%& !i"ed to.!rds redu)ed do.nti"e !nd in)re!sed %i$e respe)ti e%&. Proper "!)-ine "!inten!n)e is ne)ess!r& to ! oid )!su!%ties !t t-e $%oor. T-e $un)tion o$ 0!inten!n)e in)%udes t-e $o%%o.in*57 2!re o$ t-e $ittin*s Ad@ustin* settin*s Oi% )-!n*in* 'r!p- "!inten!n)e Out.!rdAin.!rd reports Need%e .ee8%& reports. 0!)-ine )on$i*ur!tion )-!rt L!ser sto)8 Histor& )!rd Need%e %o* )!rds.
2.12.2 )er%icin! Areas: 'ener!tors 2o"pressors Se.er!*e tre!t"ent p%!nt Pu"p -ouse 2!nteen e/uip"ent 1oi%ers A Iron t!,%es
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Spre!din* 0!)-ines Gusin* 0!)-ines St!in re"o er "!)-ines Need%e dete)tor "!)-ines 2uttin* "!)-ines 1!nd 8ni$e "!)-ines G!,ri) inspe)tion "!)-ines 2o%or ,ox Li$tin* t!,%es Li*-t Gittin*s Se)urit& Li*-ts 2o"puter
2.12.3 )a#ety: 0et!% A Need%e )ontro%%in* pro)edures .i%% ,e i"p%e"ented. S!$et& e/uip"ent $or t-e .or8ers .i%% ,e identi$ied. Tr!inin* .i%% ,e pro ided to t-e entire st!$$ on $ire e !)u!tion. G!)tor& te!" .i%% ,e edu)!ted on $ire dri%% & $ire7$i*-tin* tr!inin*. Gire dri%% te!" .i%% ,e identi$ied !"on* t-e st!$$. Gire extin*uis-er p%!)in* points .i%% ,e identi$ied. Gire e !)u!tion p!t-s .i%% ,e identi$ied & "!r8ed inside t-e $!)tor&.
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2.13 SHIPPING DEPARTMENT
2.13.1 Introduction: I"ports !nd exports !re t-e t.o i"port!nt )o"ponents o$ ! $orei*n tr!de. Gorei*n tr!de is t-e ex)-!n*e o$ *oods !nd ser i)es ,et.een t-e t.o )ountries+ !)ross t-eir intern!tion!% ,orders. VI"ports= i"p%& t-e p-&si)!% "o e"ent o$ *oods into ! )ountr& $ro" !not-er )ountr& in ! %e*!% "!nner. It re$ers to t-e *oods t-!t !re produ)ed !,ro!d ,& $orei*n produ)ers !nd !re used in t-e do"esti) e)ono"& to )!ter to t-e needs o$ t-e do"esti) )onsu"ers. Si"i%!r%&+ =exports= i"p%& t-e p-&si)!% "o e"ent o$ *oods out o$ ! )ountr& in ! %e*!% "!nner. It re$ers to t-e *oods t-!t !re produ)ed do"esti)!%%& in ! )ountr& !nd !re used to )!ter to t-e needs o$ t-e )onsu"ers in $orei*n )ountries. T-us+ t-e i"ports !nd exports -! e "!de t-e .or%d ! %o)!% "!r8et. T-e )ountr& .-i)- is pur)-!sin* t-e *oods is 8no.n !s t-e i"portin* )ountr& !nd t-e )ountr& .-i)- is se%%in* t-e *oods is 8no.n !s t-e exportin* )ountr&. T-e tr!ders in o% ed in su)- tr!ns!)tions !re i"porters !nd exporters respe)ti e%&. T-is is !n i"port!nt dep!rt"ent in t-e !pp!re% industr& sin)e orders -! e to ,e )ontinuous%& exported to t-e )ountries .-ere t-e 1u&er spe)i$ies. A%so so"eti"es r!. "!teri!%s !re i"ports. Hi*- /u!%it& $!,ri) or tri"s !s re/uired ,& t-e 1u&er -! e to ,e i"ported.
2.13.2
esponsi0ilities:
I"portAexport "!n!*ers ensure t-e s"oot- de%i er& o$ *oods to t-eir intended destin!tions to or $ro" ! )ountr&. 0!8in* !rr!n*e"ents $or i"port !nd export o$ *oods !nd o erseein* t-e de%i er& o$ *oods !re p!rt o$ t-e responsi,i%ities o$ !n i"portA export "!n!*er. I"portAexport "!n!*ers $un)tion !s inter"edi!ries $or or*!niB!tions !nd indi idu!%s i"portin* $ro" or exportin* to !rious *eo*r!p-i)!% %o)!tions. An i"portAexport "!n!*er is )-!r*ed .it- responsi,i%it& $or ensurin* t-!t *oods !re s!$e%& !nd e$$i)ient%& tr!nsported+ "!8in* sure t-!t )ost7e$$e)ti e "e!sures !re t!8en into !))ount. Dependin* on t-e t&pe o$ *oods !nd t-e )usto"ersK needs+ i"port Aexport "!n!*ers .i%% ,e re/uired to or*!niBe t-e ,est "e!ns o$ tr!nsport+ ,e it ,& !ir+ ro!d+ r!i% or s-ip. Tr!nsport!tion !nd )%ient needs .i%% !%so !r& .it- t-e siBe !nd t&pe o$ or*!niB!tion .it- .-i)- t-e i"portAexport "!n!*er is .or8in*.
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I"portAexport "!n!*ers !re responsi,%e $or p%!nnin* tr!nsport routes !nd "e!ns. T-e& !re+ t-ere$ore+ re/uired to rese!r)- t-e ,est tr!nsport!tion "e!ns+ routes !nd !n& spe)i!% re/uire"ents in t-e -!nd%in* !nd )!re o$ *oods under tr!nsport. T-e "!n!*er ensures t-!t *oods !re p!)8!*ed !ppropri!te%&+ !nd -e ne*oti!tes )ontr!)ts $or tr!nsport!tion !nd -!nd%in*. It is t-e "!n!*erKs responsi,i%it& to o,t!in+ prep!re !nd )-e)8 !%% ne)ess!r& do)u"ents re/uired to ensure t-!t t-e do)u"ents "eet t-e re/uire"ents o$ n!tion!% )usto"s !ut-orities or !n& ot-er re*u%!tor& ,od&. T-e "!n!*er o ersees t-e de%i er& o$ *oods in !))ord!n)e .it- )usto"er spe)i$i)!tions !nd ensures t-!t de!d%ines !re "et. T-e i"portAexport "!n!*er de!%s .it- !%% t-ird p!rties in o% ed in t-e oper!tion !s .e%% !s "!8es !nd )o%%e)ts p!&"ents on ,e-!%$ o$ t-e )usto"er.
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2.14 SUGGESTIONS
2.14.1 6eneral: Pro idin* up to d!te edu)!tion+ tr!inin* to t-e 0!inten!n)e Dep!rt"ent personne% on "!)-iner&+ !tt!)-"ents !nd .or87!ids. Pro idin* edu)!tion+ tr!inin* on intern!tion!% st!nd!rd s!$et& pro)edures to t-e entire $!)tor& .or8 $or)e to "eet 1u&ers re/uire"ent.
2.14.2 +are'ouse: To est!,%is- !nd "!int!in ! pro)edure $or re)ei in*+ -!nd%in*+ stor!*e+ issuin* !nd prep!r!tion sto)87t!8in*. Pro)edures o$ tr!ns$errin* !%% t-e ne)ess!r& $!,ri)+ !))essories !nd ot-er re/uired ite"s to t-e su, stores. Edu)!tin* on "!int!inin* o$ p-&si)!% in entories !nd re)on)i%i!tion. Edu)!tin* on t-e )ontro% o$ !))essories $ro" re)ei in* to issuin* .itdo)u"ent!tion. Edu)!tin* & tr!inin* t-e .!re-ouse st!$$ on s&ste"s & pro)edures to $o%%o. $ro" t-e ti"e o$ *oods !rri in* in port to t-e $in!% s-ip"ent & t-ere!$ter.
2.14.3 Cuttin!: Assist & edu)!te t-e )uttin* roo" personne% on s&ste"s & pro)edures to est!,%is- t-e dep!rt"ent $or )ontinuin* *ood )uttin* !nd e%i"in!te t-e se.in* de$e)ts+ ex)ess rep!irs !nd %oss in produ)tion. Ensure ! s&ste" to "!int!in proper spre!din* !nd )uttin* o$ $!,ri) to pre ent "iss7siBin*+ distortion !nd "ini"iBe t-e .!st!*e !nd pre ent $ro" st!in "!r8s durin* )uttin*. Tr!inin* t-e personne% on )o%%e)tin* !nd re)ordin* o$ !%% t-e produ)tion !nd /u!%it& d!t!.
:D
Tr!inin* t-e personne% on "!int!inin* o$ !%% routine !nd t-e pre enti e "!inten!n)e s&ste"s $or e/uip"entKs .-i)- !re usin* in t-e )uttin* dep!rt"ent. Tr!inin* t-e personne% on "!int!inin* o$ *ood /u!%it& %e e%s !nd s&ste"s t-rou*-out t-e )uttin* dep!rt"ent.
2.14.4 )ewin!: T-e stress !nd .or8 %o!d on e!)- oper!tor "ust ,e redu)ed !nd t-e nu",er o$ oper!tors "ust ,e in)re!sed !t t-e ,ott%e ne)8 points in t-e ,!t)-. Si%i)on oi%s "ust ,e used to ! oid ex)essi e t-re!d ,re!8!*es. Need "ore .e%% tr!ined & e$$i)ient .or8ers. E!)- oper!tor s-ou%d ,e pre$er!,%& !,%e to -!nd%e !t%e!st t-ree pro)ess. T-e se.in* "!)-ine oper!tor s-ou%d ,e !,%e to iron !nd i)e ers!. T-e %o)8 stit)- se.in* "!)-ine oper!tor s-ou%d ,e !,%e to run o er %o)8 "!)-ine.
2.14.5 Finis'in!: Tr!inin* & edu)!tion )!n ,e pro ided to t-e $inis-in* dept. te!" on ,uttonin*+ ironin*+ !nd p!)8in* to $in!% s-ip"ent. Tr!inin* o$ -o. to iron ! *!r"ent+ tr!inin* on -o. to $o%d & p!)8 ! *!r"ent. Tr!inin* on iron A ste!" & te"per!ture )ontro%%in*. Tr!inin* on -o. to use !tt!)-"ents on irons. Tr!inin* on )orre)t "et-ods o$ po%& ,!**in*. Tr!inin* on e$$e)ti e t!**in*. Tr!inin* on *o p!)8in*. Tr!inin* on $o%din* "et-ods & $%!t p!)8in* "et-ods.
:9
Tr!inin* on ,ox "!8in*. Tr!inin* on siBe sortin*. Tr!inin* on r!tio "!8in*. Tr!inin* on ,ox p!)8in* & str!ppin*.
2.15 CONCLUSION
T-e Indi!n *!r"ent industr& in t-e present s)en!rio is !t t-e *ro.in* st!*e. A %ot o$ opportunities %ie in t-e )-!n*es t-!t !re *oin* to t!8e p%!)e in t-e $uture. Indi!n $ir"s -! e t-e opportunit& to )!pit!%iBe on t-ese )-!n*es !nd extend t-eir produ)ts !nd ser i)es to *%o,!% "!r8ets. T-e 8e& in est!,%is-in* ! stron* position in *%o,!% "!r8ets re/uire 0!n!*e"ent !nd "!n!*in* -u"!n !nd inte%%e)tu!% pro)ess re7stru)turin*. T-ese !re ne. too%s in t-e ,ox !nd !re *oin* to !)t !s %i$e %ine $or !n& $ir"s in t-e ne. e)ono"&. T-ere$ore+ )o"p!nies need to )!re$u%%& dr!$t t-ese str!te*ies 8eepin* in ie. .it- t-e )-!%%en*es un$o%din* ,e$ore t-e" in t-ese d&n!"i)!%%& )-!n*in* "!r8ets.
Go%%o.in* t-ese points )ou%d -e%p t-e 2o"p!n& *ro. ,i**er !nd ,etter57 Undert!8e t-e Tot!% 0!n!*e"ent responsi,i%ities o$ t-e or*!niB!tion. Re7stru)turin* & stre!"%inin* o$ t-e )o"p%ete pro)esses .it- its )o & Supportin* pro)esses #$ro" 0er)-!ndiBin* to t-e Gin!% S-ip"ent o$ t-e produ)ts(. 2ost redu)tion & e)ono"& "!n!*e"ent. In)re!sin* t-e G!)tor& E$$i)ien)& A Produ)ti it& Le e%s to t-e Industr& St!nd!rds. Pro idin* support+ en)our!*e"ent to !%% t-e personne% )on)ern !nd en)our!*e te!".or8. Ensurin* ! -i*- /u!%it& produ)t is de%i ered to t-e )usto"er. 2re!tin* ! ne. )u%ture ,& introdu)in* t-e N!p!nese VEKsK+ V?u!%it& 2ir)%eK+ VLe!nK& V;!iBenK )on)epts to "oti !te t-e entire .or8$or)e on dis)ip%ine+ te!".or8 & unit& to !)-ie e t-e industr&Ks -i*-est st!nd!rds o$ /u!%it& & produ)ti it&.
::
It is .it- )!utious opti"is" .e ,e%ie e t-!t Indi!n $ir"s -! e t-e )!p!,i%ities to $or"u%!te !nd i"p%e"ent str!te*ies to en!,%e t-e" to ,e su))ess$u% "u%tin!tion!%s o$ t-e $uture. Go%%o.in* t-e ri*-t steps .ou%d %e!d t-e" to su))ess in Indi! !nd !,ro!d.
PRO#ECT REPORT ON
A$%&'()$* +, D),,-.-$/ S-0)$* F&++. L%'+1/2
:3
A32/.%4/
G!)i%it& %!&out !nd desi*n is !n i"port!nt )o"ponent o$ ! ,usiness=s o er!%% oper!tions+ ,ot- in ter"s o$ "!xi"iBin* t-e e$$e)ti eness o$ produ)tion pro)esses !nd "eetin* e"p%o&ee needs !ndAor desires. G!)i%it& %!&out )!n ,e de$ined !s t-e p-&si)!% !rr!n*e"ent o$ e er&t-in* needed $or t-e produ)t or ser i)e+ in)%udin* "!)-ines+ personne%+ r!. "!teri!%s+ !nd $inis-ed *oods. T-e )riteri! $or ! *ood %!&out ne)ess!ri%& re%!te to peop%e+ "!teri!%s #r!.+ $inis-ed+ !nd in pro)ess(+ "!)-ines+ !nd t-eir inter!)tions. T-is pro@e)t !i"s !t redu)in* t-e "!n !nd "!teri!% "o e"ent in t-e se.in* $%oor %ines ,& re!rr!n*e"ent o$ t-e $%oor. Ap!rt $ro" t-e "!teri!% !nd "!n "o e"ent redu)tion+ it !%so i"pro ises t-e stre!"%ined $%o. o$ t-e pie)es .it-in t-e %ine !nd t-e e$$e)ti e uti%iB!tion o$ t-e ! !i%!,%e sp!)e. T-e "!@or !spe)ts o$ t-e pro@e)t !re5 stre!"%inin* t-e oper!tions+ !uto"!ti) "!teri!% "o e"ent !nd e$$i)ient use o$ t-e %!&out. A su))ess$u% i"p%e"ent!tion o$ t-e proposed %!&out )-!n*es .i%% -e%p t-e pro@e)t !)-ie e its )ent per)ent o,@e)ti e+ t-ere,& $!)i%it!tin* t-e redu)tion in "!n !nd "!teri!% "o e"ent !nd !uto"!ti) "o e"ent o$ t-e pie)es.
34
C5%6/-.7 3 INTRODUCTION
31
3.1 I$/.+814/)+$9
One o$ t-e o%dest !)ti ities o$ t-e industri!% en*ineer is desi*nin* !n e$$e)ti e p%!nt %!&out. It is t-e !)ti it& t-!t de!%s .it- t-e desi*nin* o$ !n !rr!n*e"ent o$ t-e p-&si)!% e%e"ents o$ t-e !)ti it&. A %!&out desi*n is !n !rr!n*e"ent o$ t-e p-&si)!% $!)i%ities #e/uip"ent+ %!nd+ ,ui%din*s+ uti%ities et).( to opti"iBe t-e interre%!tions-ip !"on* oper!tin* personne%+ "!teri!% $%o.+ !nd t-e "et-od re/uired in !)-ie in* t-e or*!niB!tion!% o,@e)ti es e$$i)ient%&+ e)ono"i)!%%& !nd s!$e%&. T-e o er!%% o,@e)ti e o$ %!&out desi*n is to *et t-e inputs #"!teri!%s+ supp%ies+ et).( into+ t-rou*- !nd out o$ e!)- $!)i%it& in t-e s-ortest possi,%e ti"e. In industri!% ter"s+ t-e s-orter t-e !"ount o$ ti"e ! pie)e o$ "!teri!% spends in t-e p%!nt+ t-e %ess opportunit& it -!s to )o%%e)t %!,our !nd o er-e!d )-!r*es. T-e .or8 o$ ! $!)i%it& desi*n usu!%%& st!rts .it- !n !n!%&sis o$ t-e produ)t to ,e "!de+ or t-e ser i)es to ,e per$or"ed+ !nd ! )onsider!tion o$ t-e o er!%% $%o. o$ t-e "!teri!% or !)ti it&. It pro*resses+ step ,& step+ t-rou*- t-e det!i%ed p%!nnin* o$ t-e !rr!n*e"ent o$ e/uip"ents $or e!)- indi idu!% .or8 !re!. T-en t-e interre%!tions-ip ,et.een .or8 !re!s is p%!nnedP re%!ted !re!s !re )oordin!ted into units+ se)tions+ dep!rt"ents+ .-i)- .-en !re .o en into ! $in!% %!&out. T-e $%o. o$ "!teri!% usu!%%& represents t-e ,!)8,one o$ ! produ)ti e $!)i%it&+ !nd s-ou%d ,e er& )!re$u%%& p%!nned !nd not !%%o.ed to *ro. or de e%op into !n un.ie%d& o)topus o$ )on$used tr!$$i) p!ttern.
36
E$$e)ti e !rr!n*e"ent o$ $!)i%ities !round t-e "!teri!% $%o. p!ttern resu%ts in e$$i)ient oper!tion o$ t-e !rious re%!ted pro)esses+ resu%tin* in "ini"u" produ)tion )ost !nd "!xi"u" pro$it. T-us+ "!teri!% $%o. p!ttern t-en ,e)o"es t-e ,!sis $or t-e entire p%!nt desi*n !s .e%% !s t-e su))ess o$ t-e or*!nis!tion. 3.2 "ro;ect .rie#: T-e pro@e)t is to stre!"%ine !nd re!rr!n*e t-e %!&out o$ t-e Se.in* G%oor o$ t-e s-irt "!nu$!)turin* $!)i%it& o$ Texport Industries P t. Ltd. T-e re!rr!n*e"ent or )-!n*e in t-e %!&out is needed to in)re!se in Produ)tion !nd E$$i)ien)& !nd redu)e CIP !nd T-rou*-put ti"e+ 0!n "o e"ent !nd 0!teri!% "o e"ent. A%so+ t-e %!&out -!d to ,e p%!nned so t-!t t-e pie)es s-ou%d "o e !uto"!ti)!%%& $ro" one .or8st!tion to !not-er .it-out t-e -e%p o$ !n& extern!% person. 3.3 ?ocale: Texport Industries Pvt. Ltd., Unit 10 Block No. 3, 10 !1 "enc#$n$#$lli, M%sore &o$d B$ng$lore' ( 00() "$rn$t$k$ 3.4 )tatement o# )tudy: To stre!"%ine !nd re!rr!n*e t-e se.in* $%oor %!&out to in)re!se in Produ)tion !nd E$$i)ien)& !nd to redu)e CIP+ T-rou*-put ti"e+ 0!n "o e"ent !nd 0!teri!% "o e"ent. 3.5 90;ecti%es: To re!rr!n*e t-e %!&out5 To in)re!se t-e E$$i)ien)& o$ t-e Se.in* G%oor. To in)re!se t-e Produ)ti it& o$ t-e Se.in* G%oor.
3H
To redu)e t-e CIP. To redu)e t-e T-rou*-put Ti"e. To redu)e t-e o er!%% "!n "o e"ent. To redu)e t-e o er!%% "!teri!% "o e"ent. To ensure t-e s"oot- $%o. o$ pie)es $ro" one .or8st!tion to ot-er. To e$$e)ti e%& uti%iBe t-e ! !i%!,%e sp!)e. To tr!)8 t-e "o e"ent o$ t-e CIP.
3.( )i!ni#icance o# t'e "ro;ect: T-e )ontinuous )r& o$ ! ,usiness"!n is to in)re!se produ)ti it& !nd se!r)$or .!&s o$ redu)in* )ost to o$$set t-e e er in)re!sin* pri)es t-e& -! e to p!& $or %!,our !nd "!teri!%. One o$ t-e pri"e sour)es o$ in)re!sin* produ)ti it& !nd )ost i"pro e"ent opportunit& is ,& redesi*nin* t-e $!)i%it&+ "!teri!% $%o. !nd redu)in* t-e "!teri!% -!nd%in* ti"e. In spite o$ t-e )onsider!,%e e$$ort t-!t *one into desi*nin* t-e %!&out+ t-ere is no .!& to *u!r!ntee t-!t it is t-e ,est or in)%udes !%% t-e desir!,%e o,@e)ti es+ )riteri! !nd ide!s. Cit- t-e p!ss!*e o$ ti"e+ so"e undesir!,%e )-!n*es do o))ur in t-e ori*in!% %!&out p%!n ,e)!use o$ so"e on t-e spot produ)t re/uire"ent or so"e ot-er re!sons )re!tin* de i!tion $ro" t-e ori*in!% %!&out p%!ns. So t-e existin* !nd .or8in* %!&out s-ou%d !%so ,e e !%u!ted to dis)o er i"pro e"ent opportunities. Audit !nd e !%u!tion o$ %!&out resu%ts in in)re!sed produ)ti it&+ s"oot- "!teri!% $%o.+ in)orpor!tin* i"pro e"ents .it- )-!n*in* "!r8et !nd ne.er te)-no%o*& ! !i%!,%e+ inter!)tin* .it- $res- !nd uni/ue ide!s di$$erent $ro" tr!dition!% ones. T-e $in!% resu%t is !n upd!ted p%!nt %!&out $i%%in* t-e *!p de e%oped ,et.een t-e present o,@e)ti e !nd o,@e)ti e spe)i$ied !t t-e ,e*innin* o$ t-e %!&out pro)ess !nd re!d& to )o"pete .it- t-e )-!n*in* needs o$ t-e present s)en!rio.
3<
C5%6/-.7 4 REVIEW OF LITERATURE
3E
4.1 "lant layout: P%!nt %!&out re$ers to t-e !rr!n*e"ent o$ p-&si)!% $!)i%ities su)- !s "!)-ines+ e/uip"ent+ too%s+ $urniture et). in su)- ! "!nner so !s to -! e /ui)8est $%o. o$ "!teri!% !t t-e %o.est )ost !nd .it- t-e %e!st !"ount o$ -!nd%in* in pro)essin* t-e produ)t $ro" t-e re)eipt o$ r!. "!teri!% to t-e de%i er& o$ t-e $in!% produ)t. T-e e$$i)ien)& o$ produ)tion depends on -o. .e%% t-e !rious "!)-inesP
produ)tion $!)i%ities !nd e"p%o&eeKs !"enities !re %o)!ted in ! p%!nt. On%& t-e proper%& %!id out p%!nt )!n ensure t-e s"oot- !nd r!pid "o e"ent o$ "!teri!%+ $ro" t-e r!. "!teri!% st!*e to t-e end produ)t st!*e. P%!nt %!&out en)o"p!sses ne. %!&out !s .e%% !s i"pro e"ent in t-e existin* %!&out. It )!n !%so ,e de$ined !s t-e te)-ni/ue o$ %o)!tin* "!)-ines+ pro)esses !nd p%!nt ser i)es .it-in t-e $!)tor& so !s to !)-ie e t-e ri*-t /u!ntit& !nd /u!%it& o$ output !t t-e %o.est possi,%e )ost o$ "!nu$!)turin*. It in o% es ! @udi)ious !rr!n*e"ent o$ produ)tion $!)i%ities so t-!t .or8$%o. is dire)t. 4.1.1 Importance o# "lant ?ayout: P%!nt %!&out is !n i"port!nt de)ision !s it represents %on*7ter" )o""it"ent. An ide!% p%!nt %!&out s-ou%d pro ide t-e opti"u" re%!tions-ip !"on* output+ $%oor !re! !nd "!nu$!)turin* pro)ess. It $!)i%it!tes t-e produ)tion pro)ess+ "ini"iBes "!teri!% -!nd%in*+ ti"e !nd )ost+ !nd !%%o.s $%exi,i%it& o$ oper!tions+ e!s& produ)tion $%o.+ "!8es e)ono"i) use o$ t-e ,ui%din*+ pro"otes e$$e)ti e
uti%iB!tion o$ "!npo.er+ !nd pro ides $or e"p%o&eeKs )on enien)e+ s!$et&+ )o"$ort !t .or8+ "!xi"u" exposure to n!tur!% %i*-t !nd enti%!tion. It is !%so i"port!nt ,e)!use it !$$e)ts t-e $%o. o$ "!teri!% !nd pro)esses+ %!,our e$$i)ien)&+ super ision !nd )ontro%+ use o$ sp!)e !nd exp!nsion possi,i%ities et).
4.1.2 &ypes o# ?ayout: P%!nt %!&out $!)i%it!tes t-e !rr!n*e"ent o$ "!)-ines+ e/uip"ent !nd ot-er p-&si)!% $!)i%ities in ! p%!nned "!nner .it-in t-e $!)tor& pre"ises. It di$$ers $ro" p%!nt to p%!nt+ $ro" %o)!tion to %o)!tion !nd $ro" industr& to industr&. 1ut t-e ,!si) prin)ip%es *o ernin* p%!nt %!&out !re "ore or %ess s!"e. 4.1.3 "rinciples o# "lant ?ayout: T-e prin)ip%es o$ p%!nt %!&out )!n ,e st!ted !s57 1. Inte!ration o# all #actors 7 T-e p%!nt s-ou%d inte*r!te !%% t-e essenti!% resour)es o$ "en+ "!)-ines !nd "!teri!%s in order to *i e !n opti"u" %e e% o$ produ)tion. 6. Minimum Mo%ement 7 T-e %ess t-e "o e"ent o$ "en+ "!)-ines !nd "!teri!%s+ t-e %ess .i%% ,e t-e )ost o$ produ)tion. T-us+ "ini"u" "o e"ent o$ t-ese resour)es .i%% pro ide )ost e$$i)ien)&. H. Anidirectional #low 7 A%% "!teri!%s s-ou%d pro*ressi e%& "o e to.!rds t-e s!"e dire)tion i.e. to.!rds t-e st!*e o$ )o"p%etion. An& ,!)87tr!)8in* s-ou%d ,e ! oided -ere. <. 7##icient space 'andlin! 7 T-e sp!)e used up durin* t-e p%!nt .or8 !%so )osts "one& !s "ore t-e sp!)e re/uired+ "ore .i%% ,e t-e $%oor rent. T-e "!teri!%s s-ou%d ,e or*!niBed in st!)8s in ! proper !nd re)o*niB!,%e order to "!int!in sp!)e e$$i)ien)&. E. In'erent sa#ety 7 T-e en iron"ent o$ t-e p%!nt s-ou%d ,e s!$e $or t-e .or8ers !s .e%% !s t-e "!)-ines. T-ere s-ou%d ,e $ire extin*uis-ers !nd $ire
APPAREL INTERNSHIP REPORT ON TEXPORT INDUSTRIES PVT. LTD. | APURV & PRANAV 39
exits p%!)ed str!te*i)!%%&. T-ere s-ou%d ,e "ini"u" )ont!)t o$ t-e %!,our to toxi) )-e"i)!%s !nd en iron"ent. D. Ma8imum o0ser%ation capacity 7 T-e %!&out o$ t-e p%!nt s-ou%d su)- t-!t !%% o$ its resour)es !nd .or8$or)e )!n ,e o,ser ed !nd e !%u!ted !t !%% points in ti"e. T-is -e%ps in ,etter super ision o$ .or8 !nd -e%ps in in)re!sin* ,ote$$e)ti eness !nd s!$et&. 9. Ma8imum accessi0ility 7 T-e %!&out o$ t-e p%!nt s-ou%d ensure t-!t !%% essenti!% resour)es !re !))essi,%e to t-e %!,our !nd "!)-ines .it-out !n& de%!&. T-e !is%es s-ou%d ,e $ree $ro" o,st!)%es. T-e "!teri!%s s-ou%d ,e p%!)ed !s )%ose+ to t-e "!)-ines )on)erned+ !s possi,%e. :. Minimum Handlin! 7 T-e ine$$e)ti e -!nd%in* o$ "!teri!%s %e!ds to ! rise in )ost. 0!teri!%s s-ou%d ,e -!nd%ed in st!)8s !nd tr!ns$erred in one *o. H!nd%in* o$ ! "!teri!% t.i)e in t-e s!"e dire)tion "ust ,e ! oided. 3. Ma8imum protection 7 T-e %!&out s-ou%d ensure t-e prote)tion o$ t-e "!teri!%s !nd "!)-ines .-i%e t-e& !re in t-e .or8in* or t-e stor!*e st!*e. T-e se)urit& s&ste" s-ou%d ,e e$$i)ient .it-out "!8in* too "!n& doors or ,!rriers. 14. Ma8imum #le8i0ility 7 T-e p%!nt %!&out s-ou%d not ,e ri*id !nd per"!nent. I$ t-e need !rises+ t-e p%!nt %!&out s-ou%d ,e !,%e to )-!n*e itse%$ .it-out ,ein* expensi e. 4.1.4 ?ayout /esi!n: L!&out Desi*n is one o$ t-e "ost )riti)!% t!s8s o$ t-e produ)tion "!n!*e"ent. It !$$e)ts t-e $!)tor& e$$i)ien)&+ /u!%it& !nd )osts. I$ t-e %!&out is .ron*+ it )!n %e!d to )on$used $%o. p!tterns+ in entories+ %on* pro)ess ti"es+ in$%exi,%e oper!tions !nd -i*- )ost. 0!n& pr!)ti)!% re!sons "!8e t-e )-!n*es to %!&out di$$i)u%t+ one o$ t-e" is t-e p-&si)!% siBe o$ e/uip"ent !nd "!)-ines t-!t need to ,e "o ed. 0!n!*ers !re re%u)t!nt to "!8e )-!n*es in t-e $!)tor& %!&out ,e)!use it )!n ,e expensi e to )!rr& out !nd disrupti e to produ)tion. 1ut !t t-e s!"e ti"e t-ere is pressure to desi*n !n e$$e)ti e %!&out t-!t is ri*-t $or t-e $!)tor&.
3:
T-e t!s8 o$ desi*nin* t-e %!&out o$ $!)tor& in o% es de)idin* .-ere to %o)!te resour)es su)- !s e/uip"ent+ "!)-ines+ stores !nd oper!tors. It !%so deter"ines t-e .!& t-!t "!teri!%s !nd p!rts $%o. t-rou*- t-e $!)tor&. Re%!ti e%& s"!%% )-!n*es in t-e position o$ ! "!)-ine in t-e $!)tor& )!n !$$e)t t-e $%o. o$ "!teri!%s. T-is in turn )!n !$$e)t )osts !nd e$$i)ien)& o$ "!nu$!)turin*.
4.1.5 90;ecti%es o# "lant ?ayout: Proper !nd e$$i)ient uti%iB!tion o$ ! !i%!,%e $%oor sp!)e To ensure t-!t .or8 pro)eeds $ro" one point to !not-er point .it-out !n& de%!& Pro ide enou*- produ)tion )!p!)it& Redu)e "!teri!% -!nd%in* )osts Redu)e -!B!rds to personne% Uti%ise %!,our e$$i)ient%& In)re!se e"p%o&ee "or!%e Redu)e !))idents Pro ide $or o%u"e !nd produ)t $%exi,i%it& Pro ide e!se o$ super ision !nd )ontro% Pro ide $or e"p%o&ee s!$et& !nd -e!%tA%%o. e!se o$ "!inten!n)e
33
A%%o. -i*- "!)-ine or e/uip"ent uti%iB!tion I"pro e produ)ti it&
4.1.( Ad%anta!es o# a !ood layout in terms o#:3 +or,in! 7n%ironment Lesser nu",er o$ oper!tions & "!teri!% -!nd%in* Redu)tion in %en*t- o$ -!u%s & "otions ,et.een oper!tions 0ore %!,our produ)ti it& 0ore s!$et& & se)urit& to .or8ers $ro" !))idents 1etter .or8in* )onditions resu%tin* i"pro ed e$$i)ien)&
Manu#acturin! Costs 0!inten!n)e !nd rep%!)e"ent )osts !re redu)ed Loss due to .!ste !nd spoi%!*e "ini"iBed I"pro ed /u!%it& o$ produ)t .it- redu)tion in -!nd%in*
"roduction Control and )uper%ision Pro ides "ore sp!)e $or produ)tion oper!tions 2ontro% & super ision oper!tion !re pro ided !t !ppropri!te points 1etter !nd )on enient stor!*e $!)i%ities E$$i)ient !rr!n*e"ent $or re)eipt+ tr!nsport!tion & de%i er& o$ r!. "!teri!% !nd $inis-ed *oods Resu%t in %ess inspe)tion !)ti it& 2ost & e$$orts in super ision o$ produ)tion pro)ess "ini"iBed
144
4.1.* Features o# a !ood layout: E!se o$ .or8in*+ *r!ter s!$et& !nd redu)ed -e!%t- -!B!rds $or .or8ers Redu)ed -!nd%in* o$ "!teri!%sAp%!nned "!teri!% $%o. p!ttern Str!i*-t %ine $%o. 0ini"u" ,!)8 tr!)8in* Auxi%i!r& $%o. %ines Str!i*-t !is%es Pro)essin* )o",ined .it- "!teri!% -!nd%in* Redu)ed d!"!*e & spoi%!*e o$ "!teri!%s Redu)ed )on*estion o$ "!teri!%s+ "!)-iner& & "en G%exi,i%it& .it- re*!rd to )-!n*in* produ)tion )onditions P%!nned $or order%& exp!nsion 0ini"u" *oods & "!teri!%s in pro)ess 0!xi"u" use o$ !%% p%!nt %e e%s 1ui%din* )onstru)ted !round p%!nt %!&out Proper %o)!tion o$ produ)tion & e"p%o&ee ser i)e $!)i%ities P%!nned )ontro% o$ noise+ dirt+ $u"es+ dust !nd -u"idit& P!rtitions donKt i"pede "!teri!% $%o. P%!nned s)r!p re"o !% Re)ei in* & s-ippin* in %o*i)!% %o)!tions
141
4.1.- &ypes o# Manu#acturin! Anit ?ayouts: In )!se o$ "!nu$!)turin* unit+ p%!nt %!&out "!& ,e o$ $our t&pes5 #!( Produ)t or %ine %!&out #,( Pro)ess or $un)tion!% %!&out #)( Gixed position or %o)!tion %!&out #d( 2o",ined or *roup %!&out 4.1.-.1 "roduct or ?ine layout: Under t-is+ "!)-ines !nd e/uip"ents !re !rr!n*ed in one %ine dependin* upon t-e se/uen)e o$ oper!tions re/uired $or t-e produ)t. T-e "!teri!%s "o e $ro" one .or8st!tion to !not-er se/uenti!%%& .it-out !n& ,!)8tr!)8in* or de i!tion. Under t-is+ "!)-ines !re *rouped in one se/uen)e. T-ere$ore "!teri!%s !re $ed into t-e $irst "!)-ine !nd $inis-ed *oods tr! e% !uto"!ti)!%%& $ro" "!)-ine to "!)-ine+ t-e output o$ one "!)-ine ,e)o"in* input o$ t-e next+ e.*. in ! p!per "i%%+ ,!",oos !re $ed into t-e "!)-ine !t one end !nd p!per )o"es out !t t-e ot-er end. T-e r!. "!teri!% "o es er& $!st $ro" one .or8st!tion to ot-er st!tions .it- ! "ini"u" .or8 in pro*ress stor!*e !nd "!teri!% -!nd%in*. T-e *roupin* o$ "!)-ines s-ou%d ,e done 8eepin* in "ind t-e $o%%o.in* *ener!% prin)ip%es57 !( A%% t-e "!)-ine too%s or ot-er ite"s o$ e/uip"ents "ust ,e p%!)ed !t t-e point de"!nded ,& t-e se/uen)e o$ oper!tions. ,( T-ere s-ou%d no points .-ere one %ine )rossed !not-er %ine. )( 0!teri!%s "!& ,e $ed .-ere t-e& !re re/uired $or !sse",%& ,ut not ne)ess!ri%& !t one point. d( A%% t-e oper!tions in)%udin* !sse",%&+ testin* p!)8in* "ust ,e in)%uded in t-e %ine.
APPAREL INTERNSHIP REPORT ON TEXPORT INDUSTRIES PVT. LTD. | Product Layout APURV & PRANAV
146
Ad%anta!es: Produ)t %!&out pro ides t-e $o%%o.in* ,ene$its57 a. Lo. )ost o$ "!teri!% -!nd%in*+ due to str!i*-t !nd s-ort route !nd !,sen)e o$ ,!)8tr!)8in* b. S"oot- !nd uninterrupted oper!tions c. 2ontinuous $%o. o$ .or8 d. Lesser in est"ent in in entor& !nd .or8 in pro*ress e. Opti"u" use o$ $%oor sp!)e f. S-orter pro)essin* ti"e or /ui)8er output g. Less )on*estion o$ .or8 in t-e pro)ess h. Si"p%e !nd e$$e)ti e inspe)tion o$ .or8 !nd si"p%i$ied produ)tion )ontro% i. Lo.er )ost o$ "!nu$!)turin* per unit /isad%anta!es: Produ)t %!&out su$$ers $ro" $o%%o.in* dr!.,!)8s57 !. Hi*- initi!% )!pit!% in est"ent in spe)i!% purpose "!)-ine ,. He! & o er-e!d )-!r*es ). 1re!8do.n o$ one "!)-ine .i%% -!"per t-e .-o%e produ)tion pro)ess d. Lesser $%exi,i%it& !s spe)i!%%& %!id out $or p!rti)u%!r produ)t )uita0ility: Produ)t %!&out is use$u% under $o%%o.in* )onditions57 !( 0!ss produ)tion o$ st!nd!rdiBed produ)ts ,( Si"p%e !nd repetiti e "!nu$!)turin* pro)ess )( Oper!tion ti"e $or di$$erent pro)ess is "ore or %ess e/u!% d( Re!son!,%& st!,%e de"!nd $or t-e produ)t e( 2ontinuous supp%& o$ "!teri!%s
14H
T-ere$ore+ t-e "!nu$!)turin* units in o% in* )ontinuous "!nu$!)turin* pro)ess+ produ)in* $e. st!nd!rdiBed produ)ts )ontinuous%& on t-e $ir"Ks o.n spe)i$i)!tions !nd in !nti)ip!tion o$ s!%es .ou%d pre$er produ)t %!&out e.*. )-e"i)!%s+ su*!r+ p!per+ ru,,er+ re$ineries+ )e"ent+ !uto"o,i%es+ $ood pro)essin* !nd e%e)troni)s et). 4.1.-.2 "rocess layout: In t-is t&pe o$ %!&out "!)-ines o$ ! si"i%!r t&pe !re !rr!n*ed to*et-er !t one p%!)e. E.*. 0!)-ines per$or"in* dri%%in* oper!tions !re !rr!n*ed in t-e dri%%in* dep!rt"ent+ "!)-ines per$or"in* )!stin* oper!tions ,e *rouped in t-e )!stin* dep!rt"ent. T-ere$ore t-e "!)-ines !re inst!%%ed in t-e p%!nts+ .-i)$o%%o. t-e pro)ess %!&out. Hen)e+ su)- %!&outs t&pi)!%%& -! e dri%%in* dep!rt"ent+ "i%%in* dep!rt"ent+ .e%din* dep!rt"ent+ -e!tin* dep!rt"ent !nd p!intin* dep!rt"ent et). T-e pro)ess or $un)tion!% %!&out is $o%%o.ed $ro" -istori)!% period. It e o% ed $ro" t-e -!ndi)r!$t "et-od o$ produ)tion. T-e .or8 -!s to ,e !%%o)!ted to e!)dep!rt"ent in su)- ! .!& t-!t no "!)-ines !re )-osen to do !s "!n& di$$erent @o, !s possi,%e i.e. t-e e"p-!sis is on *ener!% purpose "!)-ine. T-e .or8+ .-i)- -!s to ,e done+ is !%%o)!ted to t-e "!)-ines !))ordin* to %o!din* s)-edu%es .it- t-e o,@e)t o$ ensurin* t-!t e!)- "!)-ine is $u%%& %o!ded.
14<
T-e *roupin* o$ "!)-ines !))ordin* to t-e pro)ess -!s to ,e done 8eepin* in "ind t-e $o%%o.in* prin)ip%es57 !( T-e dist!n)e ,et.een dep!rt"ents s-ou%d ,e !s s-ort !s possi,%e $or ! oidin* %on* dist!n)e "o e"ent o$ "!teri!%s ,( T-e dep!rt"ents s-ou%d ,e in se/uen)e o$ oper!tions )( T-e !rr!n*e"ent s-ou%d ,e )on enient $or inspe)tion !nd super ision Ad%anta!es: Pro)ess %!&out pro ides t-e $o%%o.in* ,ene$its57 !( Lo.er initi!% )!pit!% in est"ent in "!)-ines !nd e/uip"ents. T-ere is -i*- de*ree o$ "!)-ine uti%iB!tion+ !s ! "!)-ine is not ,%o)8ed $or ! sin*%e produ)t ,( T-e o er-e!d )osts !re re%!ti e%& %o. )( 2-!n*e in output desi*n !nd o%u"e )!n ,e "ore e!si%& !d!pted to t-e output o$ !riet& o$ produ)ts d( 1re!8do.n o$ one "!)-ine does not resu%t in )o"p%ete .or8 stopp!*e e( Super ision )!n ,e "ore e$$e)ti e !nd spe)i!%iBed $( T-ere is ! *re!ter $%exi,i%it& o$ s)ope $or exp!nsion /isad%anta!es: Produ)t %!&out su$$ers $ro" $o%%o.in* dr!.,!)8s57 !. 0!teri!% -!nd%in* )osts !re -i*- due to ,!)8tr!)8in* ,. 0ore s8i%%ed %!,our is re/uired resu%tin* in -i*-er )ost ). Ti"e *!p or %!* in produ)tion is -i*-er d. Cor8 in pro*ress in entor& is -i*- needin* *re!ter stor!*e sp!)e e. 0ore $re/uent inspe)tion is needed .-i)- resu%ts in )ost%& super ision )uita0ility: Pro)ess %!&out is !dopted .-en57
APPAREL INTERNSHIP REPORT ON TEXPORT INDUSTRIES PVT. LTD. | Process layout showing movement of two products APURV & PRANAV 14E
!. Produ)ts !re not st!nd!rdiBed ,. ?u!ntit& produ)ed is s"!%% ). T-ere !re $re/uent )-!n*es in desi*n !nd st&%e o$ produ)t d. No, s-op t&pe o$ .or8 is done e. 0!)-ines !re er& expensi e T-us+ pro)ess %!&out or $un)tion!% %!&out is suit!,%e $or @o, order produ)tion in o% in* non7repetiti e pro)esses !nd )usto"er spe)i$i)!tions !nd non7 st!nd!rdiBed produ)ts+ e.*. t!i%orin*+ %i*-t !nd -e! & en*ineerin* produ)ts+ "!de to order $urniture industries+ @e.e%%er&. 4.1.-.3 Fi8ed "osition or ?ocation ?ayout: In t-is t&pe o$ %!&out+ t-e "!@or produ)t ,ein* produ)ed is $ixed !t one %o)!tion. E/uip"ent %!,our !nd )o"ponents !re "o ed to t-!t %o)!tion. A%% $!)i%ities !re ,rou*-t !nd !rr!n*ed !round one .or8 )enter. T-is t&pe o$ %!&out is not re%e !nt $or s"!%% s)!%e entrepreneur.
Ad%anta!es: Gixed position %!&out pro ides t-e $o%%o.in* ,ene$its57 !( It s! es ti"e !nd )ost in o% ed on t-e "o e"ent o$ .or8 $ro" one .or8st!tion to !not-er. ,( T-e %!&out is $%exi,%e !s )-!n*e in @o, desi*n !nd oper!tion se/uen)e )!n ,e e!si%& in)orpor!ted. )( It is "ore e)ono"i)!% .-en se er!% orders in di$$erent st!*es o$ pro*ress !re ,ein* exe)uted si"u%t!neous%&.
d( Ad@ust"ents )!n ,e "!de to "eet s-ort!*e o$ "!teri!%s or !,sen)e o$ .or8ers ,& )-!n*in* t-e se/uen)e o$ oper!tions.
/isad%anta!es: Gixed position %!&out -!s t-e $o%%o.in* dr!.,!)8s57 !. Produ)tion period ,ein* er& %on*+ )!pit!% in est"ent is er& -e! & ,. Ver& %!r*e sp!)e is re/uired $or stor!*e o$ "!teri!% !nd e/uip"ent ne!r t-e produ)t. ). As se er!% oper!tions !re o$ten )!rried out si"u%t!neous%&+ t-ere is possi,i%it& o$ )on$usion !nd )on$%i)ts !"on* di$$erent .or8*roups. )uita0ility: T-e $ixed position %!&out is $o%%o.ed in $o%%o.in* )onditions57 !. 0!nu$!)ture o$ ,u%8& !nd -e! & produ)ts su)- !s %o)o"oti es+ s-ips+ ,oi%ers+ *ener!tors+ .!*on ,ui%din*+ !ir)r!$t "!nu$!)turin*+ et). ,. 2onstru)tion o$ ,ui%din*+ $%&o ers+ d!"s. ). Hospit!%+ t-e "edi)ines+ do)tors !nd nurses !re t!8en to t-e p!tient #produ)t(. 4.1.-.4 Com0ined layout: 2ert!in "!nu$!)turin* units "!& re/uire !%% t-ree pro)esses n!"e%& inter"ittent pro)ess #@o, s-ops(+ t-e )ontinuous pro)ess #"!ss produ)tion s-ops( !nd t-e represent!ti e pro)ess )o",ined pro)ess Wi.e. "is)e%%!neous s-opsX. In "ost o$ industries+ on%& ! produ)t %!&out or pro)ess %!&out or $ixed %o)!tion %!&out does not exist. T-us+ in "!nu$!)turin* )on)erns .-ere se er!% produ)ts !re produ)ed in repe!ted nu",ers .it- no %i8e%i-ood o$ )ontinuous produ)tion+ )o",ined %!&out is $o%%o.ed. 'ener!%%&+ ! )o",in!tion o$ t-e produ)t !nd pro)ess %!&out or ot-er )o",in!tion !re $ound+ in pr!)ti)e+ e.*. $or industries in o% in* t-e $!,ri)!tion o$ p!rts !nd !sse",%&+ $!,ri)!tion tends to e"p%o& t-e pro)ess %!&out+ .-i%e t-e !sse",%& !re!s o$ten e"p%o& t-e produ)t %!&out.
149
In so!p+ "!nu$!)turin* p%!nt+ t-e "!)-iner& "!nu$!)turin* so!p is !rr!n*ed on t-e produ)t %ine prin)ip%e+ ,ut !n)i%%!r& ser i)es su)- !s -e!tin*+ t-e "!nu$!)turin* o$ *%&)erine+ t-e po.er -ouse+ t-e .!ter tre!t"ent p%!nt et). !re !rr!n*ed on ! $un)tion!% ,!sis. 4.1.> )a#ety Factors #or "lant ?ayout: P%!nt %!&out is o$ten ! )o"pro"ise ,et.een ! nu",er o$ $!)tors su)- !s57 T-e need to 8eep dist!n)es $or tr!ns$er o$ "!teri!%s ,et.een p%!ntAstor!*e units to ! "ini"u" to redu)e )osts !nd ris8sP T-e *eo*r!p-i)!% %i"it!tions o$ t-e siteP Inter!)tion .it- existin* or p%!nned $!)i%ities on site su)- !s existin* ro!d.!&s+ dr!in!*e !nd uti%ities routin*sP Inter!)tion .it- ot-er p%!nts on siteP T-e need $or p%!nt oper!,i%it& !nd "!int!in!,i%it&P T-e need to %o)!te -!B!rdous "!teri!%s $!)i%ities !s $!r !s possi,%e $ro" site ,ound!ries !nd peop%e %i in* in t-e %o)!% nei*-,our-oodP T-e need to pre ent )on$ine"ent .-ere re%e!se o$ $%!""!,%e su,st!n)es "!& o))urP T-e need to pro ide !))ess $or e"er*en)& ser i)esP T-e need to pro ide e"er*en)& es)!pe routes $or on7site personne%P T-e need to pro ide !))ept!,%e .or8in* )onditions $or oper!tors.
T-e "ost i"port!nt $!)tors o$ p%!nt %!&out !s $!r !s s!$et& !spe)ts !re )on)erned !re t-ose to57 Pre ent+ %i"it !ndAor "iti*!te es)!%!tion o$ !d@!)ent e entsP Ensure s!$et& .it-in on7site o))upied ,ui%din*sP 2ontro% !))ess o$ un!ut-oriBed personne%P
14:
G!)i%it!te !))ess $or e"er*en)& ser i)es.
C5%6/-.7 5 METHODOLOGY
143
5.1 )teps: T-e pro@e)t -!s ,een done in t-e $o%%o.in* steps57 1. Stud& o$ t-e s-irt "!nu$!)turin* pro)ess. 6. 0!ppin* t-e )urrent %!&out. H. Stud& o$ t-e $%o. o$ "!teri!%. <. 0!ppin* t-e "!n !nd "!teri!% "o e"ent. E. An!%&Bin* t-e pro,%e"sA di$$i)u%ties in t-e )urrent %!&out. D. T!8in* t-e su**estions o$ t-e IE Dep!rt"ent !nd t-e Line Super isors. 9. 0!8in* ne. %!&out propos!%s. :. T!8in* re$eren)es $ro" t-e IED !nd super isors on t-e propos!%s. 3. 2o"p!rin* t-e t.o %!&outs in ter"s o$ !rious p!r!"eters. 14. E !%u!tin* t-e %!&outs ,& t!8in* t-e su**estions $ro" t-e Produ)tion 0!n!*er+ IE+ 0!inten!n)e te!"s !nd t-e Oper!tors. 11. Doin* ! $e!si,i%it& stud& $ro" t-e o%d !nd proposed %!&outs. 16. Out)o"e o$ t-e Pro@e)t. 5.2 /ata Collection Met'od: 5.2.1 "rimary /ata: T-e pri"!r& d!t! )o%%e)tion is done ,& "!8in* t-e %!&outs in Auto72AD ,& t!8in* ex!)t "e!sure"ents o$ t-e se.in* %ines. 2o%%e)tin* reports $ro" t-e IE Dep!rt"ent.
114
5.2.2 )econdary /ata: T-e se)ond!r& d!t! )o%%e)tion is done ,& re$errin* !rious ,oo8s $ro" t-e %i,r!r& !nd t-rou*- .e,sites.
C5%6/-. 7 6 P.+6+2%& +, L%'+1/7 I P.+4-22 L%'+1/ :M+81&%. S'2/-;<
111
(.1 ?ayout /etails: Produ)t5 GULL SLEEVE SHIRT St&%e5 C 2ARRIE POL;A DOT Produ)tion5 <H9E E$$i)ien)&5 94L A,senteeis"5 14L No. o$ Lines5 9 Tot!% No. o$ 0!)-ines5 69D Tot!% No. o$ Cor8p%!)e #0!npo.er(5 HHH Tot!% Dist!n)e o$ 0!teri!% "o e"ent5 1E43 Geet (.2 Collar "reparation: (.2.1 9peration .rea,down and "rocess Flow: 9peration 1 6 H < E D 9 : Run7stit)- 2o%%!r Tri" & turn )o%%!r Iron )o%%!r Topstit)- )o%%!r He" )o%%!r ,!nd Att!)- )o%%!r ,!nd to )o%%!r Turn & iron )o%%!r ,!nd )orner Tri" & not)- )o%%!r )AM 4.DE4 4.HE4 4.HE4 4.<E4 4.<E4 4.:E4 4.EE4 4.<44 Mac'ine &ype SNLS SNE2 Iron T!,%e SNLS SNLS SNE2 Iron t!,%e SNE2 /es,illin! /e%ices Pro$i%e
2R 1A<Y Te"p%!te Te"p%!te Te"p%!te
116
(.2.2 Collar )ection /etails: Tot!% 0!npo.er 5 5 <: 6D Tot!% no. o$ "!)-ines
(.2.3 Material Mo%ement: Mo%ement 1 6 H < E D 9 : 3 R!)8 to Run7stit)- 2o%%!r Run7stit)- 2o%%!r to Tri" & turn )o%%!r Tri" & turn )o%%!r to Iron )o%%!r Iron )o%%!r to Topstit)- )o%%!r Topstit)- )o%%!r to He" )o%%!r ,!nd He" )o%%!r ,!nd to Att!)- )o%%!r ,!nd to )o%%!r Att!)- )o%%!r ,!nd to )o%%!r to Turn & iron )o%%!r ,!nd )orner Turn & iron )o%%!r ,!nd )orner to Tri" & not)- )o%%!r Tri" & not)- )o%%!r to 0!t)-in* t!,%e &otal /istance 2in Feet4 34 4 16 14 : 6< 13 16 <: 223
(.3 .ac, "reparation: (.3.1 9peration .rea,down and "rocess Flow: 9peration )AM Mac'ine &ype 1 6 H < E D 0!r8 & !tt!)- %!,e% to inner &o8e p!t)Iron inner &o8e p!t)Att!)- inner &o8e p!t)- to ,!)8 0!r8 $or d!rts Se. d!rts on ,!)8 Att!)- ,!)8 to &o8e 4.<E4 4.<44 4.<E4 4.<E4 4.344 4.DE4 SNLS Iron T!,%e SNLS He%per T!,%e SNLS SNLS /es,illi n! /e%ices
0G 61H
11H
(.3.2 .ac, )ection /etails: Tot!% 0!npo.er 5 5 H: H6 Tot!% no. o$ "!)-ines
(.3.3 Material Mo%ement: /istance 2in Feet4 <4 4 16 1< D< : 94 2@-
Mo%ement 1 6 H < E D 9 R!)8 to 0!r8 & !tt!)- %!,e% to inner &o8e p!t)0!r8 & !tt!)- %!,e% to inner &o8e p!t)Iron inner &o8e p!t)- to Att!)- inner &o8e p!t)- to ,!)8 Att!)- inner &o8e p!t)- to ,!)8 to 0!r8 $or d!rts 0!r8 $or d!rts to Se. d!rts on ,!)8 Se. d!rts on ,!)8 to Att!)- ,!)8 to &o8e Att!)- ,!)8 to &o8e to 0!t)-in* T!,%e &otal
(.4 Front "reparation: (.4.1 9peration .rea,down and "rocess Flow: 9peration 1 6 H He" ,utton -o%e 4.DE4 4.<E4 4.DE4 DNLS SNLS SNLS 0G 64D+ ! R 1 1A:Y 0G 64D+ ! R 1 Y )AM Mac'ine &ype p%!)8et He" ,utton p%!)8et 0!r8 & se. ,ust d!rts /es,illin! /e%ices
(.4.2 Front )ection /etails: Tot!% 0!npo.er 5 5 1D 1D Tot!% no. o$ "!)-ines
11<
(.4.3 Material Mo%ement: Mo%ement 1 6 H < R!)8 to He" ,utton -o%e p%!)8et He" ,utton -o%e p%!)8et to He" ,utton p%!)8et He" ,utton p%!)8et to 0!r8 & se. ,ust d!rts 0!r8 & se. ,ust d!rts to 0!t)-in* t!,%e &otal /istance 2in Feet4 6: 16 6 :: 13@
(.5 Cu## "reparation: (.5.1 9peration .rea,down and "rocess Flow: 9peration 1 6 H < He" )u$$ Run stit)- )u$$ Tri" !nd turn )u$$ Iron )u$$ )AM 4.E44 1.444 4.EE4 4.<E4 Mac'ine &ype SNLS SNLS SNE2 Iron t!,%e /es,illin! /e%ices 2R EA1DY Pro$i%e
(.5.2 Cu## )ection /etails: Tot!% 0!npo.er 5 5 HH 64 Tot!% no. o$ "!)-ines (.5.3 Material Mo%ement: Mo%ement 1 6 H < E R!)8 to He" )u$$ He" )u$$ to Run stit)- )u$$ Run stit)- )u$$ to Tri" !nd turn )u$$ Tri" !nd turn )u$$ to Iron )u$$ Iron )u$$ to 0!t)-in* T!,%e &otal /istance 2in Feet4 3E DH : 6H HD 225
11E
(.( )lee%e "reparation: (.(.1 9peration .rea,down and "rocess Flow: 9peration 1 6 T!)8 %o.er s%ee e p%!)8et H < Iron upper s%ee e p%!)8et Att!)- & $inisupper s%ee e p%!)8et (.(.2 )lee%e )ection /etails: Tot!% 0!npo.er 5 5 H9 6E Tot!% no. o$ "!)-ines (.(.3 Material Mo%ement: Mo%ement 1 6 H < E R!)8 to Att!)- & $inis- %o.er s%ee e p%!)8et Att!)- & $inis- %o.er s%ee e p%!)8et to T!)8 %o.er s%ee e p%!)8et T!)8 %o.er s%ee e p%!)8et to Iron upper s%ee e p%!)8et Iron upper s%ee e p%!)8et to Att!)- & $inisupper s%ee e p%!)8et Att!)- & $inisupper s%ee e p%!)8et to 0!t)-in* T!,%e &otal /istance 2in Feet4 :6 D6 1D 61 :: 2(> Att!)p%!)8et & $inis%o.er s%ee e )AM 4.D4 4 4.HE 4 4.34 4 4.34 4 SNLS SNLS Iron t!,%e SNLS 0G 613+ !R1A6Y Mac'ine &ype /es,illin! /e%ices
11D
(.* Assem0ly )ection: (.*.1 9peration .rea,down and "rocess Flow: 9peration 1 6 H < E D 9 : 3 1 4 1 1 1 6 1 H 1 < 1 E 1 D 1 9 0!t)$ronts & ,!)8+ )o%%!r+ 4.<E4 4.DE4 4.D44 4.DE4 4.344 4.344 4.944 4.:E4 4.344 4.9E4 4.<E4 4.344 4.:44 4.:44 4.<E4 4.344 4.:44 He%per T!,%e SNLS SNLS SNLS SNLS SNLS HTOL SNLS SNLS HTOL SNLS 0G He" ,otto" Iron side ,otto" p!t)0!r8 & topstit)- on side p!t)0!8e s%ee e p%e!t #6 nos.( Att!)- & $inis- )u$$ Top7stit)- )u$$ SNLS Iron t!,%e SNLS SNLS G766<# SNLS SNLS setter( )u$$ EA1DY E4H+ !R 0G 611 )AM Mac'ine &ype s%ee e+ )u$$ Noin s-ou%ders 0!r8 & !tt!)- t!pe !t ne)8 Att!)- )o%%!r 2%ose )o%%!r Att!)- s%ee e O er%o)8 s%ee e Top7stit)- !r" -o%e 2%ose sides O er%o)8 sides Prep!re & t!)8 .A)!re %!,e% to sides /es,illin! /e%ices
(.*.2 Assem0ly )ection /etails: Tot!% 0!npo.er5 Tot!% no. o$ "!)-ines5 1H: 16D
119
(.*.3 Material Mo%ement: Mo%ement 1 6 H < E D 0!t)-in* t!,%e to Asse",%& Line 1 0!t)-in* t!,%e to Asse",%& Line 6 0!t)-in* t!,%e to Asse",%& Line H 0!t)-in* t!,%e to Asse",%& Line < 0!t)-in* t!,%e to Asse",%& Line E 0!t)-in* t!,%e to Asse",%& Line D &otal /istance 2in Feet4 HE <4 DH :D 143 161 454
11:
113
.ayout /Process .ayout0 APPAREL INTERNSHIP REPORT ON TEXPORT INDUSTRIES PVT. LTD. | APURV & PRANAV
164
Material Flow (Process Layout) APPAREL INTERNSHIP REPORT ON TEXPORT INDUSTRIES PVT. LTD. | APURV & PRANAV 161
C5%6/-.7 7 P.+6+2%& +, L%'+1/7II P.+814/ L%'+1/ :P.+*.-22)=- B1$8&- S'2/-;<
166
*.1 ?ayout /etails: Produ)t5 GULL SLEEVE SHIRT St&%e5 C 2ARRIE POL;A DOT Produ)tion5 H9E4 E$$i)ien)&5 94L A,senteeis"5 14L No. o$ Lines5 D Tot!% No. o$ 0!)-ines5 6E6 Tot!% No. o$ Cor8p%!)e #0!npo.er(5 H4D Tot!% Dist!n)e o$ 0!teri!% "o e"ent5 16:1 *.2 ?ine )ection: *.2.1 9peration .rea,down and "rocess Flow: 9peration 1 6 H < E D 9 : 3 1 4 1 1 1 6 1 H 1 < 1 E Run7stit)- 2o%%!r Tri" & turn )o%%!r Iron )o%%!r Topstit)- )o%%!r He" )o%%!r ,!nd Att!)- )o%%!r ,!nd to )o%%!r Turn & iron )o%%!r ,!nd )orner Tri" & not)- )o%%!r He" )u$$ Run stit)- )u$$ Tri" !nd turn )u$$ Iron )u$$ 0!r8 & !tt!)- %!,e% to inner &o8e p!t)Iron inner &o8e p!t)Att!)- inner &o8e p!t)- to ,!)8 )AM 4.DE4 4.HE4 4.HE4 4.<E4 4.<E4 4.:E4 4.EE4 4.<44 4.E44 1.444 4.EE4 4.<E4 4.<E4 4.<44 4.<E4 Mac'ine &ype SNLS SNE2 Iron T!,%e SNLS SNLS SNE2 Iron t!,%e SNE2 SNLS SNLS SNE2 Iron t!,%e SNLS Iron T!,%e SNLS
16H
/es,illin! /e%ices Pro$i%e
2R 1A<Y Te"p%!te Te"p%!te Te"p%!te 2R EA1DY Pro$i%e
1 D 1 9 1 : 1 3 6 4 6 1 6 6 6 H 6 < 6 E 6 D 6 9 6 : 6 3 H 4 H 1 H 6 H H H < H 0!r8 $or d!rts Se. d!rts on ,!)8 Att!)- ,!)8 to &o8e He" ,utton -o%e p%!)8et He" ,utton p%!)8et 0!r8 & se. ,ust d!rts Att!)- & $inis- %o.er s%ee e p%!)8et T!)8 %o.er s%ee e p%!)8et Iron upper s%ee e p%!)8et Att!)- & $inisupper s%ee e p%!)8et 0!t)- $ronts & ,!)8+ )o%%!r+ s%ee e+ )u$$ Noin s-ou%ders 0!r8 & !tt!)- t!pe !t ne)8 Att!)- )o%%!r 2%ose )o%%!r Att!)- s%ee e O er%o)8 s%ee e Top7stit)- !r" -o%e 2%ose sides O er%o)8 sides 4.<E4 4.344 4.DE4 4.DE4 4.<E4 4.DE4 4.D44 4.HE4 4.344 4.344 4.<E4 4.DE4 4.D44 4.DE4 4.344 4.344 4.944 4.:E4 4.344 4.9E4
He%per T!,%e SNLS SNLS DNLS SNLS SNLS SNLS SNLS Iron t!,%e SNLS He%per T!,%e SNLS SNLS SNLS SNLS SNLS HTOL SNLS SNLS HTOL
16<
0G 61H 0G 64D+ ! R 1 1A:Y 0G 64D+ ! R 1 Y
0G 613+ !R1A6Y
0G 611
E H D H 9 H : H 3 < 4 < 1 <
Prep!re & t!)8 .A)!re %!,e% to sides He" ,otto" Iron side ,otto" p!t)0!r8 & topstit)- on side p!t)0!8e s%ee e p%e!t #6 nos.( Att!)- & $inis- )u$$ 4.<E4 4.344 4.:44 4.:44 4.<E4 4.344 4.:44 H4D 5 6E6 SNLS SNLS Iron t!,%e SNLS SNLS G766< # )u$$ setter SNLS SNLS ( 0G E4H+ !R EA1DY
6 Top7stit)- )u$$ *.2.2 )in!le ?ine /etails: Tot!% 0!npo.er 5 Tot!% no. o$ "!)-ines *.2.3 Material Mo%ement: Mo%ement 1 6 H < E D 9 : 3 14 11 16 R!)8 to Asse",%& Line 1 R!)8 to Asse",%& Line 6 R!)8 to Asse",%& Line H R!)8 to Asse",%& Line < R!)8 to Asse",%& Line E R!)8 to Asse",%& Line D
/istance 2in Feet4 14E :H 9< 3H 11E 1:: 4 1<9 :9 H:4 9 6 12-1
Asse",%& Line Geedin* End to 2o%%!r # x D Lines ( 2o%%!r to 2u$$ # x D Lines ( 2u$$ to 1!)8 # x D Lines ( 1!)8 to Gront # x D Lines ( Gront to S%ee e # x D Lines ( S%ee e to Asse",%& # x D Lines ( &otal
16E
16D
.ayout /Product .ayout0
169
16:
Material Flow (Product Layout)
C5%6/-.> 8 A$%&'2)2 +, /5- P.+6+2-8 L%'+1/2
163
-.1 Comparison 0etween ?ayouts:
)l. :o . 1 6 H < E D 9 : 3 14 11 16 1H 1< 1E 1D 19 "articulars 0!teri!% 0o e"ent 0!npo.er No. o$ 0A) Produ)tion Sp!)e A !i%!,i%it& Line 1!%!n)in* Order Tr!)8in* CIP ?u!%it& Inspe)tion Visi,i%it& 0!inten!n)e 2ontro% & Super ision 0!teri!% G%o. T-rou*-put ti"e Report 'ener!tion S!$et& 0!)-ine Uti%is!tion E$$e)t o$ Modular )ystem 1E43 $t. HHH 69D <H9E Less E!s& Di$$i)u%t Hu*e Di$$i)u%t R!ndo" Di$$i)u%t Di$$i)u%t S%o. & 1!)8 Tr!)8in* Hu*e Di$$i)u%t Lesser Ex)e%%ent 2!n ,e ,!%!n)ed "ro!ressi%e .undlin! )ystem 16:1 $t. H4D 6E6 H9E4 0ore Di$$i)u%t E!s& Less E!s& Stre!"%ined E!s& E!s& Str!i*-t %ine Less E!s& 1etter E$$i)ient Di$$i)u%t to ,!%!n)e
1: A,senteeis"
-.2 "ros and Cons o# Modular )ystem 2?ayout 14: -.2.1 "ros:
APPAREL INTERNSHIP REPORT ON TEXPORT INDUSTRIES PVT. LTD. | APURV & PRANAV 1H4
Lesser 0!)-ine re/uire"ent E!s& to ,!%!n)e t-e %ine in )!se o$ A,senteeis" Line ,!%!n)in* is e!s& 0!)-ine uti%iB!tion is ex)e%%ent Lesser e$$e)t o$ !,senteeis"
-.2.2 Cons: Hu*e CIP Di$$i)u%t& in tr!)8in* t-e st!tus o$ Produ)tion In%ine ?u!%it& Inspe)tion 0!teri!% "o e"ent is "ore 're!ter re/uire"ent o$ 0!npo.er 0ore nu",er o$ 0!)-ine re/uire"ent Order tr!)8in* is di$$i)u%t 2ontro% & super ision is di$$i)u%t
-.3 "ros and Cons o# "ro!ressi%e .undlin! )ystem 2?ayout 24: -.3.1 "ros: Lesser 0!npo.er re/uire"ent Lesser 0!teri!% "o e"ent Order tr!)8in* is e!s& CIP is %esser T-rou*-put ti"e is %esser ?u!%it& inspe)tion is e!s& Visi,i%it& is stre!"%ined
1H1
2ontro% & super ision is e!s&
-.3.2 Cons: Lesser produ)tion Line ,!%!n)in* is di$$i)u%t in )!se o$ A,senteeis"
C5%6/-. > O1/4+;- +, /5- P.+?-4/
1H6
Dependin* upon t-e need o$ t-e Or*!nis!tion !nd $!)i%ities ! !i%!,%e+ .e .ou%d su**est t-e 0!n!*e"ent to i"p%e"ent 0odu%!r S&ste". T-e su**estion is pure%& ,!sed on t-e $indin*s o$ our Pro@e)t !nd dis)ussion .itt-e IED on t-e $e!si,i%it& o$ i"p%e"entin* t-e L!&out. As in our !n!%&sis .e $ound t-!t .it- t-e Pro)ess s&ste" or 0odu%!r %!&out+ t-e se.in* $%oor )!n ,e uti%iBed "ore !nd produ)tion )!n ,e in)re!sed !s )o"p!red to t-e Produ)t %!&out. In t-e produ)tion unit .-ere .e did our !n!%&sis+ due se er!% re!sons t-e Produ)t S&ste" or Sin*%e Line s&ste" is not !s produ)ti e !s )o"p!red to Pro)ess %!&out. T-e re!sons !re !s $o%%o.s57 A,senteeis" V!ri!tion in produ)ts Hi*- iter!tion r!te Ver& %ess "u%tip%e s8i%%ed oper!tors
1HH
BIBLIOGRAPHY

....texport*!r"ents.)o" Industri!% En*ineerin* !nd 0!n!*e"ent Dr. O. P. ;-!nn!+ D-!np!t R!i Pu,%i)!tions+ Ne. De%-i 0!n!*e"ent 7N!"es A. G. Stoner+ R. Ed.!rd Gree"!n#Dt- edition( 0!n!*e"ent o$ Texti%e Industr& 7 Dr. Dude@! Texti%e Tr!de Press+ 13:1 0!*!Bines5 7T-e Indi!n texti%e @ourn!%. 72%ot-es %ine. 7'%o,!% )rossin* A Turn!round. 7App!re% 0!r8etin* !nd 0er)-!ndisin*+ Rut-. A. 2%!r8e 70otion !nd ti"e stud&+ 'er!%d Dod%er 70!r8etin* rese!r)-+ Peter 0. 2-isn!%% 70!teri!%s -!nd%in* in industr&+ 1ritis- E%e)tri)!% De e%op"ent Asso)i!tion
Text ,oo8+ 0!n!*e"ent De e%op"ent 2ourse+ Nu8i )orp. Geder!tion o$ Indi! )-!",er o$ )o""er)e & Industr&+ GI22I $oru". Produ)tions !nd Oper!tions 0!n!*e"ent #Et- edition(
App%e+ N. 0. #1399(. T-e G!)i%ities Desi*n Gun)tion. In N. 0. App%e+ Pl$nt L$%out $nd M$teri$l *$ndling #pp. 176<(. No-n Ci%e& & Sons. App%e+ N. 0. #n.d.(. Pl$nt L$%out $nd M$teri$l *$ndling. He!%t- !nd S!$et& Exe)uti e. #n.d.(. Pl$nt L$%out. Retrie ed 0!r)- 1D+ 641H+ $ro" He!%t- !nd S!$et& Exe)uti e5 -ttp5AA....-se.*o .u8A)o"!-Asr!*te)-Ate)-"e!sp%!nt%!&.-t" ;u"!r+ A. #n.d.(. Retrie ed 0!r)- 1D+ 641H+ $ro" ....du.!).in5 -ttp5AA....du.!).inA$i%e!d"inADUAA)!de"i)sA)ourseZ"!teri!%AEPZ49.pd$
/u!%it&
1H<
0!@u"d!r+ S. #6443+ Septe",er 64(. T#e Principles o+ $ Pl$nt L$%out. Retrie ed 0!r)- 1D+ 641H+ $ro" Indi!stud&)-!nne%.)o"5 -ttp5AA....indi!stud&)-!nne%.)o"Aresour)esA:96<<7T-e7Prin)ip%es7P%!nt7 L!&out.!spx Pl$nt L$%out. #n.d.(. Retrie ed 0!r)- 1D+ 641H+ $ro" Ce,7Su78!t5 -ttp5AA.....e,su8!t.)o"APAO07p%!nt7%!&out.-t" Pl$nt L$%out, T%pes o+ Pl$nt L$%outs. #n.d.(. Retrie ed 0!r)- 1D+ 641H+ $ro" -ttp5AA.....e,su8!t.)o"5 -ttp5AA.....e,su8!t.)o"APAO07p%!nt7%!&out.-t"
1HE

Internship Report and Project Main - Apurv Pranav

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CHAPTER 1 INTRODUCTION

1.1 COMPANY OVERVIEW

1. Tops 6. Dress s-irts H. Deni" s-irts

LEE 'UESS NEANS ARROC ARROC 'UESS

1.2 ORGANISATIONAL STRUCTURE

CHAPTER 2 DEPARTMENTAL OVERVIEW

2.2 DESIGN DEPARTMENT

Texports own Development

&ollect fabric, (evelop (esigns.

)resentation of the collection to the buyer.

Short listing of samples by buyer.

2.3 SAMPLING DEPARTMENT

Tech pac" receive( from merchant Develop patterns

&osting &,D mar"er

Develop Sample Develop fit-proto sample

%f any comments comments

.evise *it-)roto sample

Si/e Set sample

%ncorporate $uyer &omments

%ncorporate $uyer &omments

Workflow of Sampling Department

2.4 MERCHANDISING DEPARTMENT

An& ot-er !%id instru)tions.

Obtain tech pac" from buyer

,naly/e fabric consumption from &,D

,naly/e cost of trims an( fabric

Obtain general sewing (ata from %0D

Develop sample as per the Tech pac"

)repare cost sheet from Sample

Develop proto sample

&ost sheet 1 Sample sent to $uyer for approval

&ost sheet rewor"e(

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

)repare Sample as per $uyer re2uirements

0xecute bul" or(er

*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

Flowchart of Merchandising Process

2.5 FABRIC DEPARTMENT

# $ point # % points # 3 points # ( points

%'' hole $,''

2.5.( Fa0ric Maintenance 'P? )-e)8 %ist

2.5.* &ypes o# Interlinin!s:3 Co en

Non7.o en Gusi,%e Non7$usi,%e

2.5.- In#rastructure: a. Color Matc'in! Ca0inet

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

Spectra (ision color matching booth)

checkmate Model +o& *FI$%E

Process Flowchart of Fabric Department

2.6 ACCESSORIES DEPARTMENT

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

Start .e2uisition of Trims

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

Process Flowchart of !ccessories Department

2.7 CUTTING DEPARTMENT

Process Flowchart of ,utting Department

Se%$7tri""in* Se%$7sinin .it- nu",erin* t!* or sti)8er

Open or d!"!e po%& ,! 0ixed siBes