APPAREL INTERNSHIP REPORT

MADURA FASHION & LIFESTYLE, ADITYA BIRLA NUVO LTD.

BANGALORE

Department of Fashion Technology

NATIONAL INSTITUTE OF FASHION TECHNOLOGY
NEW DELHI

COMPILED BY
KUNAL NAKRA
MANU SRIVASTAVA
(BFT 7)

DECLARATION

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

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

ACKNOWLEDGEMENTS

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

CONTENTS

Executive Summary

Introduction to the company

>History
>Brands
>Organizational structures
>Departments

Project 1 : Material flow study to reduce the timeline of

womens wear preProduction Sampling process through standardization
>Project Objective and methodology
>Standard operating procedure
>Department wise process changes and improvisations

Project 2: Project portfolio identifying projects for rapid

prototyping
>Project objective and methodology

Project 3: Retail based analysis of innovative practices across

all brands nationwide of
Madura F&L.
>Project objectives and statistics

Trade Show

Learning outcome

Bibliography

EXECUTIVE SUMMARY

The 14 week Apparel summer internship was pursued at Madura Fashion

& Lifestyle, Bangalore starting from 26th May to 31st August 2014.
I have worked under the guidance of Ms. Deepa Chandran (Product
Development Quality Assurance Dept.) and the details of the three
projects assigned and undertaken are as following:
1. Reduction of Material flow time in the newly established centralized
womens wear Proto sampling unit to reduce the lead time for the
process of Sampling and develop a standard operating procedure to
achieve optimal time for sampling.
(Location : Site
7F, Raj Pinnacle, Doddanekundi Industrial Area, Whitefield,
Bangalore)
2. Project Portfolio identifying Projects for rapid prototyping and
investment in a year.
3. A retail based study of Kaizen practices across all brands of all
regions nationwide of Madura F&L and subsequent organization of
an event KAIZEN SPREAD for replication, adoption and
spreading of the best innovative practices.

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

INTRODUCTION
HISTORY
Established in 1988 by Madura Coats Limited, Madura Fashion & Lifestyle
has its origins in the erstwhile Coats Viyella Plc, Europes largest clothing
supplier. In December 1999, Aditya Birla Nuvo, an Aditya Birla Group
company, acquired Madura Fashion & Lifestyle to become the undisputed
leader in the readymade menswear industry in India. In 2000, the
company became a wholly-owned subsidiary of Aditya Birla Nuvo.
Madura Fashion & Lifestyle, a division of Aditya Birla Nuvo Ltd, is one of
Indias fastest growing branded apparel companies and a premium
lifestyle player in the retail sector. After consolidating its market
leadership with its own brands, it introduced premier international labels,
enabling Indian consumers to buy the most prestigious global fashionwear
and accessories within the country.
The companys brand portfolio
affordable and mass-market to
every age group, from children
Fashion & Lifestyle is defined by

includes product lines that range from

luxurious, high-end style and cater to
and youth to men and women. Madura
its brands Louis Philippe, Van Heusen,

Allen Solly, Peter England and People that personify style, attitude,
luxury and comfort.
The company's lifestyle store, The Collective, offers a unique blend of
global fashions, international trends and innovative customer services, to
customers in Bangalore, Mumbai, Delhi, Delhi NCR, Chandigarh and Pune.
Planet Fashion, the multi-brand, apparel-retailing arm of Madura Fashion &
Lifestyle, housing the company's in-house and other brands, is the largest
chain of stores of its kind in India.
Madura Fashion & Lifestyle reaches its discerning customers through an
exclusive network comprising more than 1,300 stores, covering 1.9 million
sq ft of retail space, and is present in more than 1,300 premium multibrand stores and 300+ departmental stores.
Madura Fashion & Lifestyle, an IT and web-enabled organisation, is the
first-ever apparel company to have successfully implemented the ERP SAP
system. It is also the first company globally to integrate Retek ERP with
SAP ERP.
Recently, the company launched Trendin.com, a one-stop shopping
destination for the style conscious. As the official online store showcasing
the widest range of merchandise from Louis Phillipe, Van Heusen, Allen
Solly, Peter England and People, Trendin.com caters to both men and
women. With the best talent in the fields of design, manufacturing and
product development, Trendin.com brings contemporary, chic, fashion
forward sensibility at price points that work with every budget.
Madura Fashion & Lifestyle is one of the fastest growing branded apparel
companies, recording a blistering growth rate of over 25 per cent year-onyear.

BRANDS UNDER MADURA F&L

Louis Philippe
Van Heusen
Allen Solly
Peter England
People

MULTI-BRAND RETAILING

Plant Fashion

MULTI-BRAND LUXURY STORE

The Collective

ORGANIZATIONAL STRUCTURE

MANAGEMENT TEAM

CEO Apparel Business (Pranab Barua)

CEO MF&L
(Ashish
Dikshit)

CFO
(S.
Vishvanathan)

Chief
Information
Officer (NP
Singh)

Corporate
Strategy &
Business
Excellence
(Anurag
Srivastav)

EXECUTIVE COMMITTEE

Jacob John,
Brand
Head, Louis
Philippe

Vinay
Bhopatkar,
Brand
Head, Van
Heusen

Sooraj Bhat
Brand
Head, Allen
Solly

Kedar
Apshankar ,
COO, Peter
England

GENERAL ORGANIZATIONAL STRUCTURE

Shoaib
Farooqi,
COO,
Planet
Fashion,
Internation
al Business
and Trade
Sales

DEPARTMENTS

 Design: This department is responsible for studying trends in the

domestic and international markets and designing a range of
garments in line with the brand promise and customer expectations.
Production: It is responsible for understanding fabric and garment
trends and developments, garmenting processes and product
creation.
Sourcing:

This team is responsible for sourcing the appropriate

fabric, trims/finished garments at the right cost and right time.

Supply Chain: This department is responsible for procuring the
right merchandise in full and at the right time.
Operations: It is responsible for manufacturing garments as per
agreed costs and quality standards.
Sales: This department is responsible for sale of garments to
achieve brand sales and profitability targets.
Retail Operations: This team responsible for sale of garments
through retail channels to achieve retail sales and profitability
targets.
Retail Buying & Allocation: This team is responsible for placing a
buy on garments and allocation to right stores at the right time to
achieve retail sales and profitability targets.
Marketing: It is responsible for generating consumer insights,
research, and communication.
Visual Merchandising: This team is responsible for retail store
look and feel, understanding of global visual merchandising trends
and implementation.
HR: It is responsible for attracting, developing and retaining talent
at Madura Fashion and Lifestyle.
IT: It is responsible for enabling the organization to achieve its
vision through application of technology.
Finance: Responsible for accounting, finance and management
information systems

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

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

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

The SOP consists department wise standardized procedures which are

represented through:

Process Maps
-How is the process carried out and by
which functions?
- Captures the basic operational flow and steps
to be followed.

RACI Charts
Who plays what role in the execution of
the process?
Captures roles and responsibilities of the
persons directly and indirectly involved

SIPOC Template
-What analysis formats are used to
support the process?
- Captures standardized formats of documents
used in different process steps

TECHNOLOGY MANAGEMENT CENTER: BRANDWISE BREAKUP

TMC PERCENTAGE USAGE

BREAKUP
37
178

108

68

AS

VH

TMC/KMC

Others

TMC PIECES PER BRAND

GARMENT WISE
BREAKUP

OPERATOR PRODUCTIVITY

18

5.96

16
14

5.37

3.36

12
10

10

10
8

8
6
4
2
0
April

ABSENTEESM DATA

May

June

TMC average pcs /day

Operators

6%

june

9%

6%

may

6%

april

0%

absentism
average standard TMC

5%

3%
2%

4%

6%

8%

1. VAN HEUSEN (APRIL JUNE)

2. ALLEN SOLLY (APRIL-JUNE)

10%

100
50
0

15 7 12
9 4 7
Samples

201515

7 4 6
Rework

22

12
0

14

18

18 3 11

95 91
33

14 5 13

Techpack to finish days

0

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

MADURA
FASHION AND
LIFESTYLE

After
recording
all
the
information and quantifying the
data,
critical
areas
were
identified
for
targeted
improvisations in order to reduce
the sampling time, increase the
efficiency and the quality of work
being done.

A standard operating procedure was developed for the unit, which

clearly and systematically represents the ideal material and process
flow that should be adopted to achieve an optimal time for proto
sampling.

TECHNOLOGY MANAGEMENT CENTER

Site 7F, Raj Pinnacle, 3rd Floor, Doddanekundi Industrial Area,
Whitefield, Bangalore -5600048

TABLE OF CONTENTS

1. Introduction
(1)Objectives of TMC

STANDARD OPERATING
PROCEDURE (SOP)
(2)Purpose of TMC
(3)Deliverables at TMC

2. TMC Process maps

(1)Material flow process chart
(2)Inter departmental functional process chart

3. Workflow, RACI charts, SIPOC Templates

(1)CAD
(2)Store
(3)Production (Cutting and Sewing)
(4)Knit Section

4. Outsourcing
5. Future scope
6. Conclusion
7. General awareness

8.

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

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

THE PURPOSE OF TECHNOLOGY MANAGEMENT CENTRE

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

Technical Solution Provider

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

KEY DELIVERABLES AT TMC

Product consistency

Standard operating procedure and uniformity

Standardization of product specification
Easy product replication at different vendor
locations.

Technical
competency
building

Building databank for womens wear product.

Scientific guideline to sourcing and
manufacturing

Translate into cost

and time
advantage

Immediate conversion of prototype

No iterations
No to and fro of samples between vendors
and designers

ORGANISATIONAL STRUCTURE

TMC HEAD

COORDINATOR

STORE INCHARGE GARMENT ENGINEER

STORE
HELPER/RUNNER

SEWING
SUPERVISOR

CUTTING INCHARGE PATTERN MASTER

MAINTENANCE

OPERATORS

FLAT KNITTING

QUALITY
CONTROL

TMC: LAYOUT

HOUSEKEEPI
NG

PROCESS MAPS

TMC: MATERIAL FLOW PROCESS CHART

INTER- DEPARTMENTAL FUNCTIONAL PROCESS CHART

START

DESIGN
INPUT

GE/Coordinator/Pattern Master
Sketch/Reference/Sa
mple/spec/Tech Pack

Special
Machine
(FLAT KNIT)

Fabric & Trim

Requirement

Cut
Pattern

STORE

CUTTING

Yarn
s

Fabric/Trim
Fabric/Interlining
Trim Card
&Trims

MAINTENANC
E

SEWING

Machine
Ready

Outsourced:
Washing,
Embellishments,
Printing, and

SAMPLE
READY

NO

NO
FINISHING/QUALITY
CHECK/DESIGN REVIEW

YES

GLOSSARY OF

DOCUMENTATION &
DISPATCH TO THE
WAREHOUSE
PROCESS
ELE
END MENTS

Processes have been designed to cover Process Maps, Templates and RACI Charts

Process Documentation Scope:

Process
Maps

-How is the process carried out and by which

functions?
- Captures the basic operational flow and steps to
be followed.

RACI Charts

Who plays what role in the execution of the

process?

Captures roles and responsibilities of

the persons directly and indirectly
involved

SIPOC
Template

-What analysis formats are used to support

the process?
- Captures standardized formats of documents used
in different process steps

GLOSSARY OF SHAPES USED IN THIS DOCUMENT

Eve

Note (1):
Legend Colour coding
R Responsible
A Accountable
C Consulted

1. DESIGN
DOWNLOAD
I Informed

Objective

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

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

1.2Checklist of Activities (Owner- coordinator)

o

The designer, Brand Tech, Garment Engineer, Co-ordinator, Store manager,

and Pattern master (if required) are a part of the download meeting.

Check availability of sample/sketch/picture

All the information requirements (Product styling, Technical details,

measurements, Fabric & Trim requirements) to be discussed and recorded in
the master design sheet during the download meeting.

Check for Fabric and trims availability (Nearest alternative)

Understanding timelines and material requirements

File Compilation and handover

1.3 RACI CHART: DESIGN DOWNLOAD

L1
PROCESS
STEP

Discussion
of Technical
detail of
style.
Measuremen
ts/sample/
Techpack
Fabric and
trim
requirement
specification
Check for
sample/
pictures
Understandi
ng timelines
and material
req.

DESIGN/

MANAGER

COORDINATO
R

BRAND
TECH

STORE
INCHARGE

PATTERN
MASTER

GE

1.4 PROCESS CHART: DESIGN DOWNLOAD

PRODUCT/
PDQA

DESIGN
(STYLES/SKETCHE
S/
SAMPLES/PICTUR
ES)

FABRIC & TRIMS

SPECIFICATIONS
(Shell, Lining,
Buttons, zippers
etc)

BRAND/CENTRAL
SOURCING
(FABRICS/TRIMS)

GE/IE
(TECH
PACK/MASTER
DESIGN SHEET)

Clarifications Regarding Style/Design/Fabric/Trims/Measurements/ or any other

information required
Checking Fabric Availability from stores/ Selection of the Fabric (Nearest
Alternative)

NO

OK
YES

File compilation for all styles from the download along with Fabric/Trim Fabric/ Trim
samples

Handover to CAD/ Pattern Master

1.5 SIPOC TEMPLATE: DESIGN DOWNLOAD

IE/GE/COORDINATOR
(REFRENCE
INFORMATION
FOR REPETETIVE
STYLES)

SUPPLIER

INPUT
Product
Styles/designs/pictu
res
Samples/sketches

Design/Product/PDQA

Fabric and trim

specifications

PROCESS

Clarifications/discu
ssions/ Technical
detailing

OUTPUT

CUSTOMER

Consolidated
design/style/technic
al information

CAD/Pattern
Master
Store

Fabric and trims

Garment technician

Measurements/tech
pack

Clarifications/discu
ssions/ Technical
detailing

(Tech pack)

CAD/Pattern
Master

2. CAD

Objective
Provide accurate and precise new development patterns with best fit, production friendly and
cost effective either derived from sketch, specs, existing style or bench marking references

within the stipulated time frame.

2.1 CAD Functioning
CAD area converts raw ideas by designers into a visual reality template. Here, a sloper or a
block pattern is created and its related activities take place such as muslins, digitization,
grading, etc.
As complete development follows the baseline structure of CAD, hence it is very important
that the accuracy level from this department is of highest level.
2.2 L1 Process Workflow

Pattern master part of Download meeting

Check for patter

Development of pattern based

Plotting
on inputs
the Pattern /digitizing

Interaction with design, tech and sourcing on design & construction

2.3 Checklist of Activities

o Check correctness for Sample/design/sketch/Spec
o Check for construction, grading and shrinkage incorporation.

Make changes to pattern as pe

o Check Pattern Correctness for

1. Measurements
2. Styling
3. Seam to seam and panel to panel match
4. Notch point
5. Ready parts.
o Correction of pattern based on proto/fit comments.
o Pattern Plotting for internal and external requirement need based.

2.4 CAD management team:

o CAD/Patterning : Will overall lead for the Development related to pattern, shrinkage,
slopers, body block creations, specs( if not provided by tech), Spec verification if
provided by tech, plotting, cross check physical pattern to spec and corresponding
activities.
o Manager (TMC) : Will initiate with CAD/Pattern team and align to
Overall requirement of the design, production and customer/clients and oversee the
Department operations on day-to-day basis.
o Garment Engineer : Will work in framework of consulting CAD regarding
Technical inputs and pass on the critical inform to quality/ cutting and sewing line.

o Brand Tech: Will provide specs as per the design and slop.
o Quality Assurance: would assist directly with Pattern master in cross checking critical
specs on pattern and its correctness, the information in turn will be passed on to with
Cutting and Sewing line.

2.5 Work flow of CAD

2.6 RACI CAD

L1
PROCESS
STEP

MANAGER

ASST
MANAGER

BRAND
TECH

DESIGN/
SOURCING/
PRODUCT

PDQA

Pattern
developme
nt & fit
Plotting for
internal and
external
Pattern
Digitizing
and
Grading
Pattern
Check for
variation

QUALITY

CAD

2.7 CAD: SIPOC

SUPPLIER

INPUT

PROCESS

OUTPUT

CUSTOMER

Design/product/
Sourcing

Specification/design/
block reference

Clarification/digitizin
g & pattern creation

Ready pattern archive

- soft /hard

GE/IE/Cutting

TMC stores

Fabric design - repeat/

flow/face/design

Base pattern grading

and balancing

Base pattern - soft/hard

with fabric inputs

Cutting

IE/GE

Reference sample( if
any)/ construction
details

Pattern development

Ready and cut pattern

issue to cutting

Cutting

Design tech

Spec/ style details

Evaluation & fit

verification

Pattern specification
and construction

GE/IE/QA

Coordinator

Fabric shrinkage Thermo & wash

Shrinkage advise to
pattern

Shrinkage added in
pattern

QA

Ratio - size range/

specification

Digitizing/grading

Ready pattern plotting

External vendors

Central sourcing
3. STORE

Objective:

Systemized data capturing, recording, bar-coding, storing and material reconciliation. Simple
and faster way to source sample material as one stop solution provider to design and product
team, adhering to design , colour, quality and quantity needs.
3.1 Store Functioning:
Store has a critical role in faster process movement of overall activities though out the TMC.
Material store plays the role of start point of all activities in TMC as well as terminating point
of activities with respect to development.
3.2 L1 Process Workflow

Inventory Stock Grid of

Fabric & trims
availability

Sample input of Fabric

and Trims from
Design/Product/Sourcin
g

Procure the Fabric &

Trims from FCL&CCL
location

Special Fabric & Trims

procurement from Local
vendor

Check for quality

of raw materials
and reject if not
meeting required
quality standards

Fabric & trim if

not used for more
than 60 days to be
send back &
reconcile
Swatches of Fabric
& Trims to be made
available to design
for reference

3.3 Checklist of Activities

o All procurement of Fabric & trims to be carried out within 1week of Download.

o Check the availability of materials from available stock.

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

3.4 Store management activities:

o Store In charge: Planning the feeding activity, inward, outward, fabric & trims
procurement, maintain minimum stock levels, and other office related miscellaneous
items requirement.
PO and PI raising, PLM and SAP updating
o Reconciliation closure and MIS, Follow-up with fabric/trims sourcing and updating to
design.
o Store help: Upkeep of store, material issue & receipt to cutting, sewing & office. Trim
card preparation, thread winding, fabric and trim checking for quality and quantity.
Barcode printing, label printing, shrinkage bits preparation, dying of trims or fabric,
document preparing and track of all the day today material movements.

3.5 RACI STORES

L1 PROCESS
STEP

MA
NAG
ER

STOR
ES

GE/
IE

COORDINAT
OR

CAD

CUT
TING

SEWIN
G

DESI
GN
&
PRO
DUC
T
C

FAB/
TRIMS
SOURCI
NG

FABRIC
AND
TRIMS
WARE
HOUSE

FG
WARE
HOUSE

Fabric availability,
storage,
and issue
Trims availability,
storage
and issue

PI/PO

PLM (Material)

SAP

Reconciliation/
Documentation &
dispatch ready
garments

3.6 WORK FLOW OF STORES

I
C

3.7 STORE: SIPOC

SUPPLIER

INPUT
-Fabric

Design/product

External vendor
suppliers

GE/IE

Sewing /finishing

Coordinator

PROCESS

-Trims

-Inward and outward of

material
-Quality check of input
receipt and replace

-Accessories
-Machinery spare &
folders
-Office & cad stationery

-Material staging
-Weekly material
planning
- Minimum level stock

-Trim fabric

Interlining &
consumption calculation

Ready garment

Tech pack / Down load

Running length trim

organizing
-Tape
-Laces
-Belts etc
-Barcode codification Individual garment wise
data visibility on input &
output
-Reconcile
-Trim card preparation
-Fabric and trims dying if
required
-Inter departmental input
movement &
coordination

OUTPUT

CUSTOMER

PO/ PI/
Invoicing/
Documentation

Sourcing/PDQA/
CCL/FCL

Quality raw
material
outward to
Inter-dept
updated
-Trim card
-Kit

-Coordinator
-Cutting
-Maintenance
-Cad
-Sewing line

Finished sample
outward &
document
Reconciliation
closure

PE-warehouse/
Design/Product

-Trim card
- DTH fabric/
trims
- Readiness of
the fabric/trims

-Sewing
-Cutting

4. PRODUCTION: CUTTING AND SEWING

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

4.1. Production Functioning:

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

4.2. L1ProcessWorkflow
Pattern, ready pattern,
measurement sheets, tech
pack, construction,
machinery and work aids
details hand over

Work study and time line

for completion & quality
parameters

Parts preparation
and Assembly
closure

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

Work order release from

SAP Fabric, Trim & trim
card (BOM) hand over
from stores to cutting
and sewing line.

Cutting, recutting,
checking, numbering,
fusing, outsourcing
bundling and issue to
line

Sample Quality
review corrections
and send to store
For Sap closure

4.3. Checklist of Activities

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

o Manager (TMC): will overlook the day to day activity on quality and productivity with
the team members.
o Asst. Manager (TMC): will provide all relevant tech pack and construction details and see
to that standard adhered to achieve the desired sampling standard.
o Pattern Master : Providing sampling pattern with all relevant details on pattern margins,
notchs, fit, ready pattern, understanding of critical construction, spec verification,
garment balancing, etc to cutting, sewing and QA.
o Cutter: Pattern understanding and verification, cutting, panel checking, re-cutting,
numbering, bundling and physical pattern storage.
o Machine Maintenance: Up keep of all Machines, preparedness of attachments, folder and
jigs arrangement, reduce down time of m/c setting, training special machine skills and
skill matrix up gradation.
o Co-coordinator: Planning, co-ordination, time line and execution of activity between
store, production and outsourced jobs.

L1 PROCESS
STEP

Discussion of
Technical
detail of style
Fabric and trim
Procurement
from store
Cutting and recutting,
numbering,
fusing,
checking and
bundling
Cutting issued
to Sewing Line
Machine
setting as per
Styling, fabric
nature and
thread quality
Tech-pack
study with
pattern and
cutting
Part and
Assembly
preparation
Sending
Sample for
outsource Job
Quality & spec
check of
Sample
Sample
Handover

MANAGE
R

GE/IE

CAD

STORE
S

SUPERVISIO
R/QA/FLAT
KNIT
PROGRAMM
ER

MAIN
TANC
E

CUTTIN
G

COORDINA
TOR

4.5. RACI Production

4.6. Work flow of Cutting

GE DOWNLOAD ON
FABRIC WAY, CUTTING,
AND GRAIN

CAD CUTTING
PATTERN

STORES FABRIC
AND TRIM FABRIC

CO-ORDINATOR TECH
PACK & FILE HAND OVER
AND MOM

Download Tech
Pack
- and Sample (If available)
rnPatte
check for >Grainlines >Margins >Notches and >No. of Parts.

Fabric Process
Relaxation

and checking for defect Marking

Steaming (silk / chiffon / georgette)
Washing (Knits, washed sample, Denim)
Fabric way

Fabric cut plan (marker making)

Fabric
attern
p matching Identification
Marker planning and consumption

NO

OK
YES

Fabric Tearing (Remove bowing / skewingwoven)

Fabric Laying, Patten Balancing, Marking, Selvage Tearing, Block and ready cutting, Trim Fabric
cutting, Lining, Interlining, Binding, Notches

Embroidery
& Printing

Sorting, Numbering, Panel Checking, cutting,

Re
Bundling

NO
QA
CHECK
YES

CUTTING READY

NO

OK
YES

Garment finished, Packed and hand over to stores

4.7. Work flow of Production

4.8. PRODUCTION: SIPOC

A) CUTTING:
SUPPLIER

INPUT

CAD

Ready and cut

pattern

GE/IE

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

PROCESS
- Pattern check
-Cut planning
-Part check to
pattern Grain,
-Marking notches and
margins
Sample to pattern
check
Pattern to tech pack
check
Consumption check

OUTPUT

CUSTOMER

Pattern ready to cut

Sample ready for

cutting process and
indent for fabric
required from stores
SEWING LINE

Stores

Coordinator

-Actual fabric/trim
fabric/ Interlining
- Fabric width
-Fabric shrinkage
thermo & wash
-Sample size
required
-Outsourced
requirement

B) SEWING:

Fabric width, flaws,

-fabric/interlining/
Trim fabric
-Checking

Sample cutting
Panel checking for
fabric defects/re
cutting
Sorting/numbering/
bundling/fusing

Cutting shrinkage bits/

shade blankets
preparation
Embroidery/printingcutting/
marking/excess fabric
attach

Readiness of
shrinkage bitsembroidery/printing/
or other value
addition

SUPPLIER

INPUT

Maintenance

Sewing machinery
attachments/ folders
Specialized machinery

TMC cutting

Ready fabric cutting

TMC stores

IE/GE
CAD
Co-ordinator

Sewing trim kit

Ready trims
Tech packs( construction
details) & specs
Ready pattern
Critical construction
inputs
Ref sample
embellishments
Washed garments

5. FLAT KNIT MACHINE

PROCESS
Machine setting
Folder and attachment
usability
Threading
Cutting preparedness for
loading ( main, trim and
interlining non fusible)
Running length checking
Requirement & quantity
verification
Against receipt
Constructing seams
Ready marking

Garment finishing

OUTPUT

CUSTOMER

-machine
ready and
availability Finished
sample
Application on
the sample
Parts &
assembly
ready
Parts ready
Parts ready

Designer
Brand
Sourcing

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

5.1. Flat knitting functioning:

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

5.2. L1 process work flow

Post and
Knitting
and Work study and time line for completion &Looping,
quality parameter
label attac
Knitting Structure
programming

Download to be provided by the Design/ Product (Design, sketch, speck & sample)

Sample Quality review corre

Work order release from SAP Yarn hand
Pre Knitting and shrinkage test
For Sap closure

5.3. Checklist of Activities

o The entire Download for Design, would be discussed with Knitting Engineer &
Coordinator along with the Product ID.
o PLM updation of construction and shrinkage
o Internal down load to looping team and QA
o Work order will be released by stores for Yarns
o Pre-Knitting, washing, post-knitting, looping and final quality check will
be carried out and the approved sample will be handed over to stores.
5.4. Flat knitting management team:

o Manager (TMC): will overlook the day to day activity on quality and productivity.
o Flat knitting engineer: will provide programming for knit structure and all relevant
Construction, see to that standard adhered to achieve the desired sampling standard.
o Machine Maintenance : Up keep Machines like flat knit, rewinding and linking
machine, reduce down time of m/c setting, training on special machine skills
o

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

o Linking operator: Running the Linking and rewinding machine on day today basis
Without any break down and rework on finished sample.
L1
PROCESS
STEP

Discussio
n of
Technical
detail of
style
Coordinat
ion b/w
store and
knitting
Linking
of ready
knitted
panels
Machine
Maintance
Quality &
spec
check of
Sample
Sample
Handover

MANAGER

FLAT KNIT
PROGRAMME
R

STORE

QA

MAINTANC
E

LINKING
OPERATO
R

COORDINAT
OR

o Quality: Make sure the sample meets the entire design, spec and quality requirement
to meet the set standards.
o Stores: Make sure the Yarn procurement and spare availability at all times.

5.5. RACIFLAT KNITTING

5.6. SIPOC: FLAT KNITTING

SUPPLIER
Design/product/sourc
ing

INPUT
Specification/design/
Block reference/
Reference sample
( if any)

PROCESS

OUTPUT

CUSTOMER

Clarification &
design creation

Ready design archive

- soft

Flat knit programm

Flat knit operator

TMC stores

Yarn and threads

Procurement
Storage
And supply of yarns

Base pattern soft/hard with fabric

inputs

Design tech

Spec/ Style details

Evaluation & fit

verification

Specification and
construction

Flat knit programm

Coordinator

Panel shrinkage Thermo & wash

Shrinkage washing
in washing machine
and

After wash spec

Flat knit programm

Linking

Knitted panels for

linking

Gauge setting and

linking

Finished flat knit

sample

6. OUTSOURCING

OBJECTIVE:

Design/
product/PDQA

To leverage the external expertise to give the required or desired value addition input in to the
sample within the agreed time lines
6.1. Outsourcing functioning:
Sending and receiving the Trims, fabric, pre-cut panel, post-semi finished or fully finished
sample for value addition to outsourced vendor base either for embroidery, printing,
embellishments, washing, dying etc. The entire activity will be coordinated by coordinator
making sure the desired quality, quantity and time lines are meeting.
6.2. L1 Process work chart

Coordinator plans,
instruct and clarify
outsource
requirements

Stores Shrinkage
bits- dying fabric
and trims

Runner carries or
picked up by
outsource vendors

Quality check
for the
inward
receipt

Cutting Cut
panels

Sewing Semi
finished garments
or full finished
garments

Send to
respective
departments

6.3. Checklist of Activities

o The entire Download for the respective department should be understood and clear.
o Marking to be done based on the requirements like 50 cm x 50 cm for denim
shrinkage with a standard template, for embroidery and embellishment placement
marking
o Internal down load to looping team and QA
o Work order will be released by stores for Yarns
o Pre-Knitting, washing, post-knitting, looping and final quality check will be
carried out and the approved sample will be handed over to stores.
7. FUTURE SCOPE:

1. Monthly forecasting & collection on womens wear.

2. One stop solution for Design, product and manufacturing in field of Technical
inputs, risk analysis study, method & work study.
3. Product Research and bench marking in kids wear, ethnic wear, outerwear, suits
and denim.
4. All New fit development.
5. Create complete Data bank on specs, pattern and construction for future product
bench marking study.

6.

Build awareness of product and services to exemplify strong back end operations
support in terms of creating innovative merchandise.

8. CONCLUSION

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

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

GENERAL AWARENESS

Access to operators will be to their designated work area only.

MFL/MGL visitors need to enter visitor ledger and will be accompanied by TMC staff
if required.

Outsourced vendor need to report to security at reception and will not be allowed
admission inside the TMC, in case they need to visit the floor, then concerned TMC
staff need to accompany them with a valid reason for visit.

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

Over time will be need based.

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

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

No smoking allowed in the premises.

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

All Food plates need to be cleaned after lunch hours.

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

Fire exit need to be maintained as per norms.

TMC TIMMINGS:
TMC office timing will:
- Start: 8.30 am
- Machine cleaning: 10 minutes
- 1sttea break: 10.30 am-10.40 am
- Lunch break: 1.00 pm- 1.30 pm
- 2ndtea break: 3.30 pm- 3.40 pm
- Closing: 5.30 pm.
- Total working hours 8 hrs.
ATTENDENCE:

(Morning and evening)

(10 minutes)
(30 minutes)
(10 minutes)

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

Attendance punching is mandatory.

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

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

HOUSE KEEPING:

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

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

Reception and Pantry area 9.00 am to 10.30 am daily

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

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

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

END

Overlock-4thread Variable

Overlock-4thread cylinder bed

Flatlock Bottom hemming

Flatlock Binding machine

Flatlock Cover stitch machine

Flatlock machine with side cutter

Flat Knitting

Linking mc

24

25

26

27

28

29

30

31

Flat Ironing tables

Flat Ironing tables

Ramsons Veit Dress Board Table

Online table

boiler

Compressor

Dryer

Washing M/c

Washing& Dry Cleaning

TOTAL

Online table

Rivet & snap attach

Spotting station & gun

49

Heat transfer machine

Rib cutting machine

Thread winder

Finishing

TOTAL

35

34

33

Winder

Overlock -4thread

32

Overlock with gathering device

23

Overlock-3thread baby for rolled

Overlock-5thread variable top feed

Overlock - 6 Thread

Zig Zag

22

21

20

19

18

saddle Stitch

Edge folding

16

17

Blind Hem

15

DN - SPLIT BAR

DNCS

13

14

Buttoning

Bartack - M/H

Bartack - L/M

Keyhole

FOA -M/H

FOA - L/M

Kansai -M/H

Kansai - L/M

SNLS - Denims & Heavy Fabrics

SNLS - Shirt & Trousers fabrics

SNLS-variable top and bottom feed

SNLS - For light weight fabric

Fusing Machine

12

11

10

Sewing

TOTAL

2
panel

Tops,Dress,Small parts andFusing Machine

KANNIEGIESSER
AX 450

JUKI

with puller

LK-1900ANHS (JUKI)

all kind of garments

single thread blindstitch machine

Strobel

pin point saddle stitching m

Juki
achine

EX5114-04
W664-35BC

machinefour
variable
2needle
thread overlock
Pegasus
machinecylinder
3
needle Flatlock machine Pegasus

linking machine

flat knitting machine

Rib cutting for knits

For binding /rib cutting for flatlock machine for armhole and neckline area in knit garments(3/4
knits top and dress
inch-1 1/2 inch)

General purpose drying machine for washed garment

General purpose drying machine for washed garment

Sound proof and auto cut air suction compressor for better usablility and power saving

Electric boiler with auto cut steam level

Used for pressing and steaming small panel during production process with buck

Used for pressing and steaming small panel during production process

Used for shape pressing in garment in semi stitched panel for pressing and shaping

Ironing table for garment finishing

Ironing table for garment finishing

For riveting and snap attaching in denims, trouser, dress etc

all kind of garments

all kind of garments

all kind of garments

all kind of garments

all kind of garments

all kind of garments

all kind of garments

all kind of garments

all kind of garments

denims, trouser etc

NAGI SHING

RAMSON

Impress

Impress

IIGM

NS-47U ( NGAI SHING )

CL4

HW-40C

Domestic washing machineIFB

Dryer for washing machineIFB

Maxi dry cleaner

MR 27
boiler-27KWA with water softerner
RAMSON30 liter
ENO7
7.5HP
ELGI

RON 006

RV 4235
dress board with sucking blowing
RAMSON
seam leang
th 45 inch
RON 006
onine table with press
RAMSON

flat with suction blowing with

RAMSON
flat with light
4425-80

onine table with press withRAMSON

Buck

Flatlock machine with side cutter to cut extra area in knits garments

For coverstitch process in knits. Pegasus machine best in class

For binding process in knits. Pegasus machine best in class

For hemming process in knits. Pegasus machine best in class

For attaching Cuff and kids garment directly

For Better control on fabric layer to sew

Pegasus overlock better for chainstitch operation

For gather process majorly in women's wear

Washing machine

dryer for washing machine

Compressor

Boiler for ironing table

Ironing table to be used by operators

Ironing table to be used by operators

Dress finishing iron table

Ironing Table for garment finishing

Ironing Table for garment finishing

Snap button attaching machine

Spotting machine for stain removal

Transfer priniting

Rib cutting for knits

For rewinding of thread spool for better usgae and avoid thread wastage

Yarn re winding machine

CMS 530 HP Multi Gauge (INTARSIA), Gaugemulti gauge flat knitting machine
linking machine
8gg and 12gg machine for linking knits

W562-05SB

W1562N-01G

flat with suction blowing with

RAMSON
buck with4425-80
light

Rivet & snap attach

all kind of stain and dressSpotting station & gun

used for heat transfer label and stitchless garments tape(temp :50-250 c)(2-6 kg square) tops, shirts, denims etc Transfer priniting

Cone winder

Multi purpose machine for stain removing in parts and garments

BTM

STOLL

3 needle Flatlock machine Pegasus

3 needle Flatlock machine Pegasus

W1562N-026

EX5214-83BA

machinefour thread overlock

2needle
Pegasus

3 needle Flatlock machine Pegasus

M852-13

4 degree and 6 degree thread

RE-WINDER (SINGLE SIDED), PEASS
MODEL VERSA-C V1 WITH 6 SPINDLES
PS-SCHLAFHORST VERSA
cone winding

Flat knit top, dress

Flat knit top, dress

knits top and dress

knits top and dress

knits top and dress

knits top and dress

knits top and dress

knits top and dress

MO-6716S-DE4-42H/E35/S161

machine
2
-needlewith
four gather
thread overlock
Pegasus

for rolled hemming process in women's garment

knits top and dress

2- needl five thread overlock

JUKI

In Woven Stitch formation is better in JUKI overlock Whereas Life and wear tear less in Pegasus

4 cone multi rewinding of spools and thread

For Thread winding at 6 degree and 4 degree to use in flat knit machine

For linking Flat knit garment at side and sleeve and panel together

Flat kniting of garment with multi float design in 8gg and 12 gg

1- 10 mm cutting at side with chainstitch

6 -14 SPI for coverstitch at panels

1/4 inch biniding at neckline and armhole and single needle chainstitch usage

1/8 -1/4 inch bottom hemming in knits

4th overlock machine for sleeve rib attaching (7mm bite width)

4th overlock machine with top feed control with differential feed (7mm bite width)

4thn overlock machin with 7mm bite width for knits and jersey panel sewing

In Woven Stitch formation is better in JUKI overlock Whereas Life and wear tear less in Pegasus

spare part and availiblity, Machine performance and feed mechanism better

In Branded JUKi only making it

Strobel is better for usage and performace than maier

Table stand and motor to be purchased seperatley

serging of all woven garment

1 needle overlock machine for
JUKIrolled hemm
MO-6704S
ing
-OA5-150
panel

5th overlock machine with gather function available at lower ply with6-10 mmbite width woven top and dress

3th Overloc machine with 6 mm bite width

MO-6743S

LZ-2290ASR-7WB/SC916/IP110D

MP-200 (JUKI)

Strobel is better for usage and performace than maier

Table stand and motor to be purchased seperatley

Better performance ,direct drive,semi dry head

Better to have 2 needle Chainstitch , can convert to single chainstitch

For button attaching process in garments(lockstitch)

Bartcak for Heavy duty garment like denim

JUKI better for Lighter garments

Excellent stitch formation due to state-of-theart sewing kinematics

Better feed mechanism and prevention against puckering,higher stroke

3 needle can be used as 2 needle by conversion Better feed mechanism and prevention against puckering,lighter stroke

Better in maintenance and spare part availbilty

Better in maintenance and spare part availbilty

Patented light stroke technology for no marks with thread nipper

Patented light stroke technology for no marks with thread nipper

All light and difficult to sew

2 needle overlock machine with
JUKI safety stitch
MO-6916R-DE4-40H
material

Multi usage overlock machine to be converted in all type of overlock based on requirment(
Denim
10sm
and
m) woven garments
3 needle overlock machineJUKI

for scaplloping hem at tops,

For zig zag operation with reverse type option with 22 design ( single step,2 step, 3 step) used for
welt pocket at suit, and
decorative and conceal area purpose
deorative design in denims1 needle,direct drive zig zagJUKI
machine

5th overlock machine with top feed control with diffferential feed ( 8mm bite width)

103-180 (STROBEL)

LH3568ASF

Hem finish of top and dress

single thread blindstitch machine
Strobelfor rolled
103-254F
hemming
(STROBEL)

For decorative straight saddle stitch in denims, trouser and tops etc(1 mm-6mm saddle form
Denim
ations, tops, dress

1/8 rolled hem(single step and double step)

single step and double step( 5/8 - 3 inch fold hem) and single hem across two fabrics

Double needle operation in dress, top , shirt (1/8, 3/16 ,1/4 inch gauge available)

Direct Drive, Semi-Dry Head,2

Can be used for shirt collar ,
needle lockstitch machine with
Back pocket dress etc
JUKI
split bar

Can sew 2 Chain stitch parallel in light to medium fabric garments,(armhole area) (1/4,3/8
Shirt,inch)
top, dress, trouser, denim
2-needle ,flat bed double chain
JUKIstitch machine
MF-380FU

Shirt, top, dress, trouser, denim

computer controlled buttoning
JUKImachine LK-1903ANSS ( JUKI)

JUKI

LK-1900ANSS (JUKI)

computer controlled key buttonhole

Durkopp m
Adler580-141-01
achine

3-needle,feed of the arm chain

JUKIstitch machine
MS-1261-VO45S (JUKI) with puller

stitch machine

JUKI

To Sew button in shirt and top ( 16 patterns)

DFB-1404PSF ( KANSAI)

4- needle ,flat bed double chainsticth

KANSAI
machine
DLR-1508P ( KANSAI)
3 needle ,feed of the arm chain
MS-1261VO46R ( JUKI)

4- needle ,flat bed chainsticth

KANSAI
machine

computer controlled
To conceal & reinforce stress point for medium to heavy fabric trouser, denims etc ( 1/8- 1 inch
Denim
length)(width-2m
, trouser, etc m)
bartacking machine

Denim , trouser, etc

Denim , trouser, etc

Shirts, tops etc

waistband etc

computer controlled
To conceal & reinforce stress point for light to medium weight Shirts, tops and dress ( 1/8Shirt,
7/8
light
inch
weight
length)(width-2m
tops, dress m)
bartacking machine

For keyhole in trouser, Denims and suits( 16 -24 mm length)(1- 2.5 mm width one side)

Lap seam operation ( inseam , back yoke) for Denims( 1/4 inch)( 1/8 inch* 2 inch) gauge

Lap seamoperation (side seam ) for shirts and tops(1/4 inch)(1/8 inch* 2inch) gauge

chainstitch(1/4 _1 _1/4 inch)

Mutli needle chainstitch machine used for Mediumto hevy duty fabric for waist band andFor
mutli
denim and trouser

Patented light stroke technology for no marks with thread nipper

Fusing machine best in class.Made in germany

Machine required for light and diffuclt to feed material

WB/H062/Z061/SC910NKS/M91/1P110C/KT01A

DLU-5494NBB-7-

Direct Drive, Semi-Dry Head,1

281-140342-02
medium weight top , dress, shirt
Durkopp Adler
needle lockstitch machine with
Direct Drive, Semi-Dry Head,1
281-160362-02
Denim, trouser, etc
Durkopp Adler
needle lockstitch machine

Multi needle Chain stitch machine used for Shirt placket and light weight fabric multi chainstitch(
Shirt, Skirt, Tops
1/4/_1_1/4) inch ) ,(1/4 _7/8_ 1/4 inch),( 1/4 *6 ) gauge set. Maximum 1 1/2 inch can be done

used for heavy weight fabric garments

Used for medium duty fabric garments

Used for light weight fabric and diffcult to sew fabric.Can control feed amount in top as well
1 needle ,bottom and variable
Top , dress, light weight shirt
JUKI
lower ply
top feed with automatic thread

trimmer,wiper

Direct Drive, Semi-Dry Head,1

281-140342-02
Used for light weight fabric dress with Feed dog with fine teeth and small needl hole plate
Top , dress, light weight shirt
needle lockstitch machine with
Durkopp Adler

smaller areas on larger fabric pieces. The working width of 450 mm / 17.72 inch

Machinery
list

DEPARTMENT WISE IMPROVISATIONS

1. PRE PRODUCTION MASTER MEASUREMENT SHEET

2. PRE PRODUCTION MASTER MEASUREMENT SHEET

(TROUSERS)

3. FABRIC & TRIM REQUIREMENT SPECIFICATIONS

SHEET

4. TRIM CARD

5. CUT AUDIT REPORT

6. PRODUCTION AUDIT REPORT

Style No.

Season:

Fabricdetail:

Target Date:

(Fabric/Trims)

ready

addition ready

ready

Warehouse

Download Date
Materials Ready
Folders & attatchments
Pattern ready
Cutting ready
Outsourced value
Stitching ready
Finishing/Packing
Dispatch to
Deviation/ Rem

Product Detail:

TMCTIME AND ACTION CALENDAR (WEEKLY)

7. WEEKLY TIME & ACTION CALENDAR

8. MEASUREMENT VARIATION (SHIRTS)

9. MEASUREMENT VARIATION SHEET ( WOMENS TOP)

10. MEASUREMENT VARIATION SHEET (TROUSERS)

11. MEASUREMENT VARIATION SHEET ( WOMENS

TROUSERS)

12. MEASUREMENT VARIATION SHEET (OUTERWEAR)

13. PATTERN QUALITY GRADING SHEET

14. OPERATOR QUALITY GRADING SHEET

15. THROUGHPUT TIME CALENDAR AND FILE

CHECKLIST

GARMENTFINISHING STANDARDS

9Proper ironingequipment to used(Flatbeds, bucks, )

8In which sequence to bepressed (shirts/ trousers/dresses)

7Clockwise/anticlockwisepressingstandard tobe followed. (Refer Appendix )

6split seampressing requiredasper garment construction.

5Dead/unwanted creasesshouldbe removed

4Garment must not beover-pressedand glazing-shining/scorching, or burn markseffectsmust not beevident on thegarment.

3Presswith thegrain of the fabric wherever possible and becareful not to stretch the seams.

2Check the garment'sreaction towardssteamingand moisturizing.

1Garmentsshall bepressed or steamedasper the standard required

Garment PressingStandard

5Garment should befreeof any staining/soiling/dirt marks

4Garmentsshall befreeof clip or clampmarks.

3Garment shall befreeof odor.

removed.

2All tape or stickersother than inspection stickersinsidethe garment shall be

Comments/Remarks

(B)

Garment FinishingStandard

(A)
1All residuesfromcleaningfluidsshould beremoved.

Standard

No.

16. FINISHING
REQUIREMENT
SHEET

PROJECT OBJECTIVE:
To identify and funnel critical areas for innovations based on
market need, and develop a project portfolio for rapid
prototyping and investment for the next year.

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

PROJECT OBJECTIVE:
To acknowledge, motivate and appreciate the retail best
practices and Kaizen initiatives undertaken across all the retail
outlets of all the Brands of Madura F&L across the nation and to
organize an event KAIZEN SPREAD for displaying these
practices for replication and adoption of best innovative
practices.

KAIZEN ALL INDIA ALL BRANDS

ANALYSIS
All india Brands
300
250

283
238
212

200
No of Kaizen
150
100

85

76

43

50

5
0
VH

LP

AS

PE

PF

People

TC

TRADE SHOW

The trade show

provided a real time
exposure to the actual buying process. It is an exhibition for
companies to showcase their new products and services.
These conferences have been developed in order to give retail
owners, buyers and managers the opportunity to meet existing

suppliers, conduct business meetings, network with others in

retail and investigate new products.
Duration: July 15 August 4

LEARNING OUTCOME

The Apparel summer internship at Madura Fashion & Lifestyle

was extremely beneficial and has provided a unique learning
experience through its summer internship program.
Working in the PDQA (Product Development Quality Assurance
department) has been knowledgeable in terms of product

development process, vendor selection and evaluation criteria,

Quality assurance and benchmarking, and sourcing strategies.
A research based project in innovation has helped me learn in
large about what drives innovations in companies and how
companies in textiles specifically target innovation and
development.
The project on centralized sampling in the new sampling unit
has taught me both project and people management. The
standard operating procedure that was developed was audited
twice externally, which has been a very new insightful
experience.
The retail based project has provided an exposure virtually to
all the 961 retail stores of Madura and the best innovative
practices adopted by them.
The trade show has also been a learning experience regarding
the buying and selling for the season.
My personal learning would include Professional ethics, project
management and handling, people management and team
working, leadership and decision making. The confidence and
ability to interact and gain knowledge where ever possible.

BIBLIOGRAPHY

http://www.maduragarments.com/ (Accessed on 17th august 11:30 am)

http://www.london.edu/programmes/executiveeducation/makinginnovationhappen.html
http://www.indiantextilejournal.com/articles/FAdetails.asp?id=5457

www.jeffdegraff.com (Innovation you: steps to drive innovation)

Joe Atkinson, Preparing for the unknown: An emerging approach toward risk
resilience