Internship SHAHI EXPORTS PVT. LTD.

Faridabad
Submitted by: Puja Kumari Ram
MFM III

National Institute of Fashion Technology, Bangalore

Industry Profile
India is the second largest producer of garments in the world.
Indian garment industry is expected to grow to a size of US$

223 billion by 2021.

Indias apparel exports are rising, because the country is eating

into the shares of neighbouring China and Bangladesh.

Rise in labour cost in China would be a boost to the Indian

exports.

Company Introduction
SHAHI Exports Pvt. Ltd. is engaged in the manufacture and export

of readymade garments in the International market.

It is one of the largest export houses in India.
Company started its operations in the form of a small fabrication

unit with the help of 25 machines.

Its turnover has a turnover of

Rs. 4000 and around 90000

employees spread over 50 locations.

It has manufacturing units in six different states of India viz. Delhi,

Haryana, Uttar Pradesh, Tamil Nadu, Karnataka and Andhra

Pradesh.

 Shahi Exports is into manufacturing of a wide range of Mens

and Ladies wear and also home products.

Shahi

has a well-equipped sampling division where latest

patterns/designs/styles of high standards are developed with the

assistance of experienced designers.
Shahi Exports has its own testing lab.
As regards to quality, SHAHI has been ranked one of the best in Asia

by J. C. Penny, the world-renowned departmental stores.

Company Profile
Name: Shahi Exports Private Limited
Established: 1974
Owner: Mrs. Sarla Ahuja
Managing Director: Mr. Harish Ahuja
Address: Industrial Plot-1, Sector 28 Faridabad, Haryana
Work Force: 90,000
Capacity: Over 2 million high quality garments per month
Retail House: At Last & Co. , New York
Home Brand: Bhane
Fabric Processing: Sarla Fabrics, Ghaziabad
Annual Turnover: INR 4000 crore (Group Turnover)

Company Mission
Exploring new dimensions of excellence. A path, where there

was none.
A new horizon beyond yesterday. Excellence beyond today,

touching tomorrow.
Its mindset, the action, and partners of Shahi are ever reaching

further, never resting on achievements.

Shahi believes that its main strength is its people. The larger
investments made in the manufacturing units will give the
desired results only if backed by a committed human effort.

Corporate Vision
Be the global best in bringing delight to human life by

weaving dreams of fashion & feelings of comfort.

Corporate Values
The company believes in:
High level of honesty and a sense of responsibility.
Two-way communication channel for all purposes of

communication.
In sharing the fruit of growth, prosperity with its partners i.e. the

employees.
In giving each individual room to contribute and grow.

The company firmly believes that team spirit is the hallmark of

success.

Key Strengths
Shahi Exports Private Limited is one of the largest vertically

integrated garment manufacturer and exporter in India.

Shahi is one of the most successful professionally managed

companies in India.
Well qualified trained and committed professionals with a shared

vision.
Highly qualified Design team, Product development skills and a

Design Studio.

 High degree of adoption of advanced manufacturing technology

MIS and IT systems.

All factories and offices are electronically linked to facilitate all

time access to information

Focus on quality and a proven track record :

Short shipment: 0.50%

On time delivery: 98%
Quality claims: Nil.

Product Profile
The following based and operated in NCR
Division

Description

LSD

Ladies Specialty Division

LBAD

Ladies branded Apparel Division

LFD

Ladies Fashion Division ( basically caters to Wal

HFD

Mart)
Home Furnishing Division

Shahis product range is vast as the organization. It covers:

Girls shirt - Formal
Mens and boys shirt casual
Ladies and girls blouses, dresses
Mens and ladies bottoms
3 button polo shirts
Jackets
Loungewear
Golf wear
Sportswear
Sleepwear
Scarfs

LIST OF BUYER
WAL-MART STORES
MAX
J.

INC

MARA (ITALY)

C. PENNY

GAP

INC.

SEARS
REPLAY
SAKS

FIFTH AVENUE

GYMBOREE
LIZ

CLAIBORNE

PHILIP VAN

HEUSEN

TOMMY HILFIGER
NAUTICA KELLWOOD
GYMBOREE
LIZ

CLAIBORNE

PHILIP VAN

HEUSE

TOMMY HILFIGER
MERVYNS
NEXT

(U.K)

CALVIN

KLEIN

DEBENHAMS
ABERCROMBIE

& FITCH

TALBOTS
KOHLS
LANE

BRYANT

DIESEL
GUESS

JEANS

MONSOON
CUTTER

& BUCK

PAPAYA
IMPULSE
GEORGE
HENNES

& MAURITZ

BENETTON
TARGET

Corporate Norms
Shahi emphasizes on some guiding principles, which are indicative
of some basic norms the These are the building blocks for the
organization culture.
They are as follows:
The company believes in the highest level of honesty and sense of

responsibility.
The company believes in two-way communication channel for all

purposes of communication.
The company believes in sharing the fruit of growth and prosperity

with its partners i.e. the employees.

 The company firmly believes that team spirit is the hallmark of

success.
Besides the dynamic and professional leadership of the promoters,

Shahi is mainly recognized for its excellence in quality, product,

range, service and reliability.

Infrastructure of SHAHI
An innovative team and a mature infrastructure are the pride of any

company in fashion industry.

Shahi Export has diligent merchandisers and a creative team involves

itself in producing brilliant designs and outstanding creations.

There are 18 integrated state-of-the-art garment production centres

with a whopping 4500 sewing machines installed.

The highly advanced fabric-processing unit at Ghaziabad whips out a

daunting 90000 meters of finished fabric a day.

The company has the capacity to produce over 2 million high quality

garments per month.

 The CAM based Cutting Department has a production capacity of

75,000 cuts per day.

The 60 Multi-head Computerized Embroidery Machines have a

capacity of 800 million stitches per day.

Quality at its best

At Shahi, care is taken to ensure only the finest garments get

through.

The

Shahi

manufacturing

facility

incorporates

comprehensive testing at each stage.

Starting with an in-house laboratory for full proof material

testing, ensuring flawless raw material matching STM standards are

used every time.
The Quality Control Department comprises one of the best teams

of all times.
All units follow stringent quality procedures with every shipment

undergoing inspection by an in-house Final Statistical Audit team.

 Timely deliveries are given utmost importance at Shahi.

In order to meet high quality parameters, all fine dyed yarn is

purchased from reputed mills. An in-house facility then inspects

100% fabric in the production centers. Fully equipped to test the
yarn/fabric quality like fastness, shrinkage etc., and these production
centers redefine excellence in their sphere.
Professionally qualified Textile Engineers handle the entire fabric

sourcing and quality control activities.

Customer satisfaction is desired at any cost

Company Hierarchy

Departments
Product & design development
Merchandising department
Sampling department
Order analysis department
Computer aided design department
Production planning and control department
Fabric sourcing department
Purchase & logistics department
Testing laboratory department

Merchandising Department
Merchandiser: A merchandiser is primarily a coordinator. He/she acts

an interface between the buyer and the supplier who has to ensure the
quality of production and timely delivery.

Basic roles of a merchandiser

The major responsibilities can be summarized as follows:
Understanding your customer and your customer's customer
Managing downstream supply chain effectively and
Defining your competencies in terms of customer satisfaction

Classification of merchandising

Merchandising in Apparel Industry can be classified as follows:

Export Merchandising:

a. In an Export Production House

b. In a Buying House
Domestic Merchandising:

a. For the domestic Indian Market

Hierarchy in merchandising department

Profit center head, markeingprofit center head, marketing

Merchandising workflow

Merchandising activities
To get order: Buyer directly communicates with the merchandiser in order

to place the order.

Costing: Costing of the garment in bulk is calculated on the basis of quality

of material and their requirement in the garment. To arrive at a perfect price

to be quoted to the buyer, following points are taken into consideration:
Calculation of consumption of fabric (yields per yard) and threads to

produce one garment

Calculation of cost of fabric per garment
Calculation of cost of trims and threads
Poly bag cost
Cost of carton box

 Sampling: Merchandiser is involved in coordinating with the sampling

department.
Order confirmation: After the approval of the sample, merchandiser

receives PO from buyer and communicates with panning and production

department.
Preparing Time and action plan
Preparing the bill of material
Execution: Merchandising department communicates with the buyer QA

during the production and gets the approval of the quality or any changes
in the garment.
Shipment of goods
File preparation

Sampling Department
Sampling department is a backbone. Sampling department plays most
vital role in an organization.
This department is self sufficient as it had its own:
Fabric store
CAD
Cutting
Stitching
Washing
Thread trimming
Spotting
Ironing
Packing
Quality etc. dedicated for the construction of samples only.

Layout of sampling department

Workflow of sampling room

Merchandiser orders for fabric requisition as per PO

Sampling process
The process of sampling goes through a series of sampling stages each
of them are explained below:
Fit sample
Second fit sample
Proto sample
Pre-production sample
Size-set sample
GPT sample
Salesman sample

Cutting

Thread matching area

Sewing area

Pattern library

Ironing table

Machine embroidery

Hand embroidery

Checking/spotting table

Final checking table

Threading trimming table

Packing

Details attached to the garment sample

The sample made has the following details attached to it, with the help
of a tag:
Reference Number
Color
Fabric
Composition
Description
Quantity
Style no/ Size
Store

Machines in sampling department

Sampling department had 8 lines in total and 165 sewing machines.

CAD Room
Functions of cad room
CAD department is responsible for the following functions:
Determining cutting average for costing
Making the most efficient cutting marker
Development and alteration of patterns
Development of size set pattern by grading
Embroidery graphics making
Digitizing the pattern

Work process flow of CAD

Fabric Sourcing
Fabric Store:
The capacity of the store is about 100,000Mts
The Sourcing of Fabric is being done mainly from:
Yarn Dyed Salem & Tirupur
Printed Fabric Ghaziabad (Shahi own Mill)
Denim fabric Arvind Mills, Ashima Textile
Imported Fabric According to buyers specification from China, Hong Kong

etc.
Fabric department is divided into five teams:
Grieg
Finished / processing
Yarn dyed
Polyester
China

Fabric Sourcing

Purchasing Department
Purchase department in India it is divided in six teams which include:
Beads, sequin, artwork, and tape
Thread
Button, elastic, label, washcare, and tag
Zipper (India and China both)
Fusing
Packaging

For china one person is involved of sourcing.

Workflow of the Purchase Department

Requirement send by merchandiser

Lab Testing
A TRF form is to be filled and the sample is to be sent for testing to

the lab. Fiber content, GSM, Color fastness etc can be tested inhouse only.
Some of the test is also done from Bureau Veritas which is located in

Bangalore. In Bureau Veritas for testing charges is less for four

working days. If the test report is required on urgent basis than
charges is high.

Workflow of Testing Lab

Merchandiser give A4 fabric swatch to testing lab

Washing Department
Washing department has two divisions:
1. Woven: In this garment, fabric in meter and swatches can be given. This are the
following washes which is done in washing department:
Softener: Softener is done to give soft hand feel to fabric or garment.
Silicon softener: Silicon softener is done to keep fabric or garment very soft.
Tide wash: Tide wash is detergent wash.
Water dip: Water dip is done before fabric cutting to remove the shrinkage of the fabric.
Enhancer Wash: Enhancer wash is done to improve the effect of the print.
Red softener: Red softener is done to improve the color of the print.
Yellow softener: Yellow softener is done is to give pale look.
Solvent wash: solvent wash is also known as HCL wash. Solvent wash is used to remove

stain marks.

2. Denim: denim wash is generally done according to the given sample or

standard. This are the following washes which is done in washing
department:
Desiger: It is done to remove starch and to give shine to the fabric.
Bleach: Generally bleach done according to the given standard by

buyer.
PP spray: PP spray is Potassium Permanent spray which is used to give

faded effect to garment.

Crackle wash: Crackle wash is done to give uneven effect of bleach.
Overdye: Overdye is used to give colored effect.
Stone wash: stone wash is done to give whiteness effect to the garment.

Order Analysis Department

The Order Analysis Department (OAD) acts as the bridge between the
merchandising and the production functions of the unit. This department gives
technical support to the production team.

OAD receives complete file containing all the details and documents
from the concerned merchant. File consists follwing details:
Purchase Order (PO) contains order quantity, colour and size ratio,

destination, delivery date etc

Product Style Details (PSD) contains details about the fabric (count,

construction, colour), thread, labels, accessories, buttons, fusing etc.

Final mini marker (for interlinings as well if applicable)

 Tech Pack (updated) containing garment measurements with all the

fit comments by the buyer.

Sealed sample (buyer approved)
Embroidery design with the placement and type of thread to be

used
Swatches of fabric, fusing, threads etc
Operational breakdown of the style
Thread consumption report
Base patterns
Washing, ironing and packing instructions

Production

Planning

and

Control

Department

This department has two parts: production planning and production control.

Production planning
The production planning department at Shahi Exports, Faridabad is a
centralized planning department for all the units in the NCR. So, primarily the
planning of the following six units takes place here:
Faridabad
Faridabad 2
Sarai
Okhla
A-5
E-10

The number of lines and number of machines per line in each of the six
units are as follows:

Unit

Number of lines

Machines/Line

21

40

Faridabad 2 (LFD)

22

40

Sarai

33

Okhla

12

40

A-5

45

Faridabad
LSD& HFD (all H&M and Target
orders executed here only)

Production Control
Production control has five teams in this department segregated buyer
wise. These people are responsible for the execution of order in the
unit. The roles and responsibilities of production control people are:
To supervise smooth execution of the order in the unit.
Organizing a pre-production meeting prior to production to discuss

critical issues.
Complete fabric follow up with merchant and the fabric store.
Complete accessory follow up with merchant and sub store.
Supervising the entire production process to ensure timely execution

of the order.

Human Resource
The Personnel department is centralized for all the units in Delhi and
NCR. This department is responsible for recruitment, training and
deciding the organizational HR policies. It also takes care of wages and
salaries of all the employees.
The main functions of Personnel department are:
Manpower Planning

Sourcing

Recruitment

Salary

Induction

Administration

Training

Motivation

Discipline

Welfare Activities

Weekly Learning:
Week 1:
Joined the company, on 1st June 2015.
Introduced to the company and the team members comprising a Marketing

Manager (Ms. Pallavi Singh), (Ms. Akansha Joshi, Ms. Shalini Kumari)
Merchandiser, Assistant merchandisers (Mr Sumit Mehta) and sample coordinator
(Ms Preeti)
Week 2:
Learnt the sampling procedure. It primarily consists of:
Sampling
Coordination

 Sourcing

Also learnt filing of style entry, patterns requisition entry, purchase order
in-work and pre stitching process involve in sample making.
Week 3:
Learnt to make fabric programme according to buyers specification to

order the fabric which is given to fabric department. In that count,

construction and GSM are mentioned and if prints then CAD and
pantone colors are given.
Simultaneously, trims are also ordered according to the specification

sheet through trim purchasing department.

Week 4:
Stitched sample is moved to finishing department. In first round of

checking if any alteration is found then sample will move to alteration

line.
Spotting and thread trimming is done.
Measurement checking is done, measurements are set with the help of

steam iron.
After alteration (if any), spotting, and thread trimming sample moved

to final checking table.

Final checking is done move to packing table.
Strike - off is send to buyer for approval.

Week 5:
If buyer sends approval for strike-off then it is preceded for SMS (salesman

sample) yardage development.

After getting approval for proto sample TOP (top of production) is made

by following SMS techpak and sent to buyer.

Trims received from purchase department.

Week 6:
Approval for Top is received from buyer.
SMS in-work is done which includes issuing SMS yardage from fabric store,

then fabric move for cutting, stitching, finishing, packaging, and shipment.
Some no. of SMS quantity is developed extra which is kept as counter for

future reference of the team.

Week 7:
SMS yardage/ garment are sent to either internal lab or bureau veritas

for FPT (fabric package test) and GPT (garment package test).
Test report are shared with buyer in proper excel format called call out

chart (in which all the failures are mentioned) and physical parameter
(count, construction GSM and content) are contracted for bulk in that
excel.
Color cards are sent in following way 2 mtr. for buyer, 2 mtr. for buying

house and 1 mtr. kept with the merchant.

Week 8:
SMS handover to buyer.
Receive bulk order for same, merchandiser handover the style to

production merchandiser.
Merchandiser provides production merchandiser sample of the style for

which bulk order is received, fabric card, and trim card.

Learning Outcomes
Key Learning Experience
Merchandiser plays an important role in export house. Merchandiser

plays intermediary role between buyer and sampling department. If any

changes or alteration is required by a buyer communication is done
through merchandiser. Also observed the role of a merchant in various
departments.
The most complex stage is getting the approval from the buyer on fabric,

shades, print and fit.

How to prepare BOM (bill of material), PO (purchase order), challan

etc.

 Since the lead time is less, therefore any delay at any stage can delay

the entire order. So regular follow-up is required until the sample gets
packed.
The operators in the sampling department are very experienced and

highly skilled. They are explained the construction of any new sample
by the pattern master and the supervisor.
The average FOB is $10 - $13.
The sampling department as a whole doesnt work on TNA calendar.
The maximum time is spent in the procurement and approval of trims

and fabric.

Suggestions
The team in sampling department should work-out a TNA plan in

order to efficiently manage time and submit samples without delay.

They should work according to a proper plan so that the work flow

will be smooth and the employees wouldnt be overloaded.

There was communication gap between departments relating to a

particular order and within the team, hence that can be avoided.
All the proper information should be given to sampling department,

so that it can avoid delay in completion of sample.

Conclusions
Learnt about the working of this industry through this

internship.
The work involved in an export house is very tedious and

requires a great amount of knowledge regarding the fabrics

and also time management.
Without a TNA plan, it can be very stressful and inefficient.
The whole process flow of pre-production and production

stage of United Colors of Benetton at Shahi Faridabad was

studied during the internship.

Submitted by: Puja Kumari Ram

MFM III