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Samar Kamal Fazli. Assistant Professor.
Muhammad Jamil BHATTI. CIIT/Spo5-MBA-062/LHR.
August 28, 2006
COMSATS institute of information technology, JINNAH Campus, Defence Road off Raiwind Road, Lahore Ph No. 5321090, 9203101 Ext. 215
The internee Muhammad Jamil Bhatti Acknowledgements
All the praises are for the almighty, Allah who bestowed me with the ability and potential to complete this Internship. I also pay my gratitude to the Almighty for enabling me to complete this Internship Report within due course of time. Words are very few to express enormous humble obligations to my affectionate Parents for their prayers and strong determination to enabling me to achieve this job. I take this opportunity to record my deep sense of gratitude and appreciation to my Internship Advisor Mr. Samar Kamal Fazli, Department of Management
Sciences, COMSATS Institute of Information Technology Lahore for his constant encouragement and inspiring guidance with his Wisdom. I also appreciate the cordial co-operation from all my concern Managers in the different departments of Nishat Mills Ltd especially Capt. M Nasir (CSO) Mr. Asif Javaid GM Spinning Mr. Abdur Rehman, DSM Spinning Unit#3, Mr. Nadeem Ashraf Marketing Executive and Admin & HR management for providing me requisite information and knowledge for compilation of my complete Internship.
I dedicate this to my Beloved Parents for all their love & attention which has made it possible for me to make it up to this point and as well as the Internship Advisor Mr. Samar Kamal Fazli, who bestowed me with the courage, the commitment and the awareness to follow the best possible route, by his unmatchable style and by best possible training.
Table of Contents
The internee 2
Acknowledgements 3 Dedication 4 Table of Contents 5 Executive Summary 6 Vision 7 Mission 8 Quality Policy 9 Textile Vision 2006 10 Introduction 11 IMPORTS textile machinery 12 EXPORTS of Textile 13 Nishat Group 15 The Company 18 Business operations 23 MARKETING STRATEGY 46 Marketing process 50 SWOT Analysis 51 Detail of SWOT Analysis 52 PEST Analysis 55 Learning as internee 57 Conclusion 58 Recommendations 59 Annexure 60 .
The difference between the success & failure is doing things right and doing things nearly right. Executive Summary Nishat has grown from a cotton export house into the premier business group of Pakistan with 5 listed companies. & NML has always tried for success & that is why it is known to be one of the leading organizations in Pakistan. I recently have done my internship in Nishat Mills Limited. in which I got training from each of its department. Cement. In this report I have given a very brief review of what I have seen during our internship I have mentioned all these as I have made an internship as according to the schedule. the style of working & the commitment of the employees in NML is really exemplary. I have all my practical efforts in the form of this manuscript that’s the asset for my future career. Vision . concentrating on 4 core businesses. The system. Today. Then I have discussed about my learning in the whole internship that is all about the Textile Terminologies and process of the productions. I have made it possible to write each and every thing that I have learnt there. I have noticed a few areas where the improvement can really increase the efficiency of NML. I also mentioned about the Textile industry in Pakistan and vision of its industry. Then I have done a detailed SWOT analysis as well as PEST Analysis. Nishat is considered to be at par with multinationals operating locally in terms of its quality products and management skills. Irrespective of all these positive points of Nishat Mills Limited. Banking and Power Generation. Textiles. The internship basically revolved around the product knowledge training.
Mission To provide quality products to customers and explore new markets to promote/expand sales of the company through good governance and foster a sound and dynamic team. To transform the company into a modern and dynamic power generating company with highly professionals and fully equipped to play a meaningful role on sustainable basis in the economy of Pakistan. . cloth and processed cloth and finished product manufacturing company with highly professionals and fully equipped to play a meaningful role on sustain able basis in the economy of Pakistan. To transform the company into a modern and dynamic yarn.
Textile Vision 2006 An open market driven. textile made-ups and garments with an attempt to maintain the market share in each individual market. Globally Competitive Fully equipped to exploit the opportunities created by the MFA Phase out and this enables Pakistan to be amongst the Top Five Textile Exporting Countries not only in Asia all over the world with the tremendous Textile companies Low Road Scenario represented a situation where only the historic export growth rates in textile sub-sectors were maintained.so as to achieve optimum prices of products of the company for sustainable and equitable growth and prosperity of the company. innovative & dynamic Textile Sector which is:Internationally Integrated. Quality Policy We work together as a team for implementation and continual improvement of total quality system in order to achieve satisfaction of our internal and external customers. Do-Able Scenario envisaged increase in unit price realization of yarn. The overall average export growth for the textile sector after analysis was finalized at 6% per annum. fabric. It also suggested penetration in the non-quota markets along with increased .
Introduction The Textile Industry: Over the years. fabrics and garments. foreign exchange earnings. During the year exports were controlled from falling and significant investment was made in value-added expansion and in Balancing-Modernization. woven garments. investment and revenue generation altogether placed the textile industry as the single largest determinant of the economic growth of the country. The overall export growth in this scenario was estimated at 12% per annum. Besides broadening of export product portfolio with extra push in synthetic and man-made fibers. Its share in the economy. employment. High Road Scenario the most ambitious of the scenarios that not only adopted the apparel sector as the engine of textile export growth but also recommended diversification in products that hold greatest potential but unfortunately have been neglected e. . Pakistan is said to be the single crop economy i. fabrics and garments. in terms of GDP. exports.share of synthetic and blended yarns. the implementation of WTO's agreement.g. and women wear. specialized industrial garments. Pakistan's textile industry has weathered the storm by coming out of the international crisis in a very positive manner.e. sports wear. cotton and textile that claims the lion's share in terms of the contribution in the national economy of Pakistan. various bilateral agreements have been signed and implemented. Despite efforts to bring in diversification in country's overall economic get-up the textile sector continues to be the most important segment of the national economy. Despite harsh and hard international economic conditions. Besides fall out of the events of September 11.Replacement (BMR).
have now established compact units adding state-of-the-art finishing units and knitting machines to add value to their products. who earlier concentrated on Spinning and Weaving. At present. Textile is the only sector where investment has been substantial and regular during past three years. The entrepreneurs. investment pattern and fiscal and monetary policies were significantly changed. besides increasing the volume of fabrics and quality garments exports from the country. It is expected that an additional Rs10 billion would be required for Balancing.As a result global scenario has changed. The latest addition to this is the setting up of denim cloth producing units. the export competitiveness of the textile industry can be improved by aggressive marketing techniques and quality improvements which have to be taken care of micro-level that is each textile unit should make its own independent efforts to sell its products in different international markets. In the last five years more than Rs9 billion have been invested for the import of spinning machinery. IMPORTS textile machinery Import of textile machinery and equipment has picked up since 1997-98 when a bumper cotton crop was harvested and the Textile Industry reaped massive profits due to lower input cost. exports of textile manufactures increased from $5.8 billion in 2001-02. Nishat is one of the major customers in terms of importing Textile Machinery from almost all developed countries. These facilities would improve value-addition in fabrics. All the individual textile units should implement the ISO 9001 program for quality standard and ISO 14000 for environmental standards to counter the threat of globalization. The encouraging . Modernization and Replacement (BMR) in the spinning sector during the next three years for producing superior quality yarn besides several units are in various stages of installation in Karachi also. EXPORTS of Textile Despite sluggish trends in the international markets. So. Government and the corporate textile sector adjusted their policies to achieve maximum benefits of free trade.75 billion in 2000-2001 to $5. local structure of the corporate culture. The most encouraging factor of this investment is diversity.
The textile quota exports to the United States. The share of value-added products in total textile exports from Pakistan this year was 57. The textile export figures for the first ten months of the current year released by the Export Promotion Bureau revealed that the textile quota exports to the US improved by 24 per cent while the increase in exports to EU countries at the end of October 2002 registered an increase of 16. Readymade Garments improved by 7 per cent to $882 million from$827 million. 101 million square meters worth $28 million.1 billion during 2000-2001. The highest amount of increase of 55 per cent in quota exports followed by US 29 per cent and EU 12 per cent. European Union imported 1058-million square meter worth $509 million. Silk/Synthetic Textile and other manufactures declined during the period. while towels exports increased by 12 per cent to $270 million against 242 million. indicating an increase of 9. The only increase 0. European Union. Tents. .e. exports grew by 30 per cent to Turkey and 13 per cent to the EU. whereas Made-up articles increased by 6 per cent to $351 million as compared to $331 million. Exports to Canada declined by 21 per cent in quantity. earned $ $911 million.6 per cent for the EU and 16 per cent in case of Turkey.03 billion in 2000-01. In terms of value. showing growth of 23 per cent. Exports declined in case of Canada by 29 per cent and 9 per for the US. The average unit price of Pakistan's textile quota exports dropped considerably i.6 per cent in terms of value and 13 per cent in terms of quantity. Cotton cloth export also increased to $1. 30 per cent in case of US. The exports of bed-wear fetched $918 million against $745 million.13 per cent as compared to 54 per cent last year. Cotton Yarn.e. The total exports to the US were 420 million square meters worth $481 million.21 per cent was recorded in average unit price of exports to EU. Canvas/Tarpaulin. 9. Cotton yarn.factor was the increase in the exports of value-added items.13 billion during this period as compared to $1. Canada and Turkey grew by over 18 per cent with nominal increase in value during the first seven months of the calendar year 2002 compared to the same period last year. Art. Canada imported 16 million square meters worth $18 million and Turkey.7 per cent. The WTO agreement provides for making textile trade completely free from 2005. The exports of five sub-groups i. which earned $1. knitwear.
the State Bank of Pakistan has introduced three facilitating schemes for the exporters namely. he witnessed by the momentous changes that swept the Indo-Pak subcontinent. 6th in 1990 and Number 1 in 1997. . Nishat Group *The Nishat Group* Mian Muhammad Mansha Yaha is the captain of this splendid ship having around 30 companies on board. is now setting up a billion rupee ($ 17 m) paper sack project too. chemicals and insurance. Nishat Group was country's 15th richest family in 1970. courage and integrity. who owns the Muslim Commercial Bank as well. Mansha is on the board of nearly 50 companies. Chinioti by clan. all out efforts are needed to boost textile exports and increase access to the international markets. Mansha. He died in 1969. In 1947 when he was running leather business in Calcutta. He is one of the richest Pakistanis around. cement. Foreign Currency Export Financing Scheme (FCEFS). when Mian Muhammad Yahya founded Nishat Mills Limited. If Mansha was bitten by Bhutto's nationalization stint of 1970. cotton and jute textiles.CHALLENGE: To get maximum benefit from quota free regime. The bank would provide 210 days credit facility to exporters for South America as compared to 120 days credit facility to other markets. He could have bought the United Bank too. He has had his share of luck on many occasions in life and has recently been awarded Pakistan's highest civil award by President Musharraf. at the age of 51 having achieved so much in so short time. This is story of success through sheer hard work and an undaunted spirit of enterprise. but then who doesn't have adversaries. There is no stopping Mansha and he is still on the move! The history of Nishat Group dates back to 1951. He is deemed to have made investments in many bourses. To boost the exports. Mian Mohammad Yahya was born in 1918 in Chiniot. insurance and management companies. Beginning with a cotton export house. he soon branched out in to ginning. his friends think he was compensated by Nawaz Sharif's denationalization programme to a very good effect. This man of vision. Political Risk Guarantee Scheme (PRGS) and the Export Guarantee Scheme (EGS). He was elected Chairman of all Pakistan Textile Mills Association. Nishat Group of comprises of textiles. Mansha is married to Yousaf Saigol's daughter. currency and metal exchanges both within and outside Pakistan. leasing.
000 new spindles. 740 looms and dyeing and finishing capacity of 5 million meters. Nishat group is among the leading business houses of the country and ranks among the top 5 groups in terms of assets and sales revenue. 1 has a capacity of 2.G Khan Cement Company Limited (DGKCC) from the second largest project of the group and is ideally located in the heart of the country. Nishat setup the first power generation unit in the private sector in 1995. An addition of 20. BANK . Nishat Group acquired D. for more then decade! POWER GENERATION Nishat group has also been a pioneer in power generation in the private sector of the country. A new unit heaving the capacity of 3. DGKCC unit No. With the addition of unit No. The group has its roots firmly planted into four core business namely Textiles Power Generation Banking Cement TEXTILES The textile business is further subdivided into 2-textile division: Nishat Faislabad Nishat Chunian The textile capacity of the group is the largest in the country.200 tons per day. CEMENT In 1992. DGKCC has become the largest manufacturer of cement in Pakistan.After almost half a century of undaunted success.300 tons was setup in 1997. International Finance Corporation and common Wealth Development Corporation have financed this unit.2. The largest exporters of textile products from Pakistan.000 spindles. with easy access to transportation all over Pakistan. 100 new air jet looms and new dyeing plants has increased the existing capacity of 242.
dyeing. selling and otherwise dealing in yarn. 1984) and listed on Stock Exchanges in Pakistan Nishat Mills Nishat Mills Limited (“Nishat”) is a public company incorporated in Pakistan and listed on all three Pakistani stock exchanges. and to generate. 1913(Now Companies Ordinance. The Company is engaged in the business of textile manufacturing and of spinning. stitching. weaving. linen. bleaching. MCB has a network of over 1200 branches employing over 12. Company is providing quality products to its customers within the Pakistan and outside the Pakistan. combing. weaving. accumulate. buying. bleaching. The Company Nishat Mills Limited is a public Limited Company incorporated in Pakistan under the Companies Act. MCB has grown ever since and is now the largest bank in the private sector. distribute and supply electricity. buying. cloth and other goods and fabrics made from raw cotton. Nishat Group ventured into the financial sector through the acquisition of Muslim commercial Bank. synthetic fiber and cloth. synthetic fiber and cloth.000 people. Presently company is exporting its all kinds if apparel products. combing. cloth and other goods including fabrics made from raw cotton. and printing. Major competitors Nishat competitors are Crescent . Which involves spinning. dyeing printing. and selling of textiles? They deal with yarn. linen.In 1991. Nishat is engaged in textile manufacturing. stitching.
Naz Mansha BOARD OF DIRECTORS: Mrs. Naz Mansha Mian Raza Mansha Mian Hassan Mansha .Chenab Arzoo Alkarms Sitara Kohinoor Amtex But main competitors of Nishat Mill are “Crescent Textile Mills” “Chenab Textile” company profile: CHIEF EXECUTIVE: Mrs.
Ashraf Ali Raza Mr.Badar Rauf Mr.Masood Akhtar Mr. Faisal Ehsan Ellahi Mr.Mudassar Mr.Inam Mr.Mr.Usman Bajwa Mr.Zulufiqar AUDIT COMMITTEE: .Shehzad Malik (G. Khalid Qadeer Qureshi (Chief FinancialOfficer) Mr.M) Mr.Asad Iqbal Mr. Muhammad Nawaz Tishna (NIT) Mr.Nawaz Mr. Rana Muhammad Mushtaq FINANCE DEPARTMENT: Mr. Muhammad Azam Mr.
Khalid Mahmood Chohan AUDITORS: Riaz Ahmed & Company Chartered Accountants LEGAL ADVISOR: Mr.waseem ul Haque Osmani Chairman Mian Hussan Mansha Member Mr. Chamber No. 6. Advoca te.Mr. Faisalabad. Muhammad Azam Mr. Aftab Ahmed Khan Member HEAD OF INTERNAL AUDIT: Mr. Aurang zeb Khan. M. BANKERS TO THE COMPANY: .Khalid Kabeer CORPORATE DEPARTMENT: Mr. District Court.
A Deu tsche Bank Fays al Bank .AB N AMRO Bank Allie d Bank of Pakista n Limite d Ame rican Expres s Bank Limite d Ask ari Comme rcial Bank Limite d Cre dit Agrico Citi bank N.
C Mee zan Bank Limite d Nati onal Bank of Pakista n Stan dard Charte red Bank Grindl ays .G.Limite d Hab ib Bank Limite d Hab ib Bank A. Zurich Mas hreq Bank P.S.
These units are equipped with the latest machines in all of their departments. In the spinning units the fiber is converted into yarn.The Hong Kong & Shanga i Ban king Corpor ation Limite d Uni on Bank Limite d Unit ed Bank Limite d Business operations Spinning Department: Nishat Textile Limited has seven spinning units situated in Faisalabad. Spinning Weaving . and as this the quality of yarn is very important in the textile sector so spinning units have a lot of importance.
Grey Room PROCESSING Singeing Desizing Scouring Bleaching Printing Dyeing Finishing Folding .
Finally after passing through the auto cone the yarn comes in the packing department. For the carded portion the drawing breakers & drawing finishers are used to prepare the fiber to a certain level so that the process on the simplex machine can be carried out. Generally the spinning mills mechanism is very similar. & after that it goes through the combing machine. After going through a process it is taken to the card room for the next process. after passing through the PC drawing & Drawing finisher goes to the simplex machine. in the combed portion. after the drawing breaker the cotton goes through the lab former. The combed yarn is of better quality and its process is a bit bigger than the other one. As this process is very important so there are some common parameters on which the quality of yarn is judged. In NML the process of Ultra Violet Checking is also practiced to ensure the quality of the yarn. These parameters have been listed as below: Important Parameters of Yarn & Fiber: Important Parameters of the Fiber: • Length • Strength . It starts from the mixing department where the bales of cotton are mixed and at that section the most visible impurities are taken out. This mixed cotton is then taken to the blow room by a machine. where the comer noil and comber sliver are separated. The product that comes from the simplex machine is then taken to the Ring section where the yarn is to be made. On the other hand. The comber sliver. After the card room the route is taken by keeping in view that whether carded yarn is the end product or the combed yarn.
. the weaving units of NML are really very well equipped with the latest machinery to make the best possible product for the customer to gain the customer satisfaction.• Micronaire value • Color grade • Neps / gram • Trash percentage Important Parameters of Yarn: • Yarn count • Strength LCSP • U percentage • Thin Places • Thick Places • Neps • IPI (Imperfection) Yarn Elongation (Flexibility) • Single Yarn Strength • TPI • Twist Multiplier Weaving Department: Very similar to the spinning units.
The D grade fabric is either used in the B grade sale or in gathering of the fresh pieces. quality is the main purpose of the NML people. where a lot of quality check is done. near Sheikhupura. NML Bhikhi has 389 looms for preparing the greige. The end product of the spinning unit is the starting point of the weaving unit. then it is taken to the inspection department. After the drawing inn the beams of the yarn is then taken to the Sulzer Looms so that the yarn is converted into the weaved product. The A grade fabric after mending. Out of these 389 machines 96 are Sulzer Ruti of Switzerland. . i. it is then taken to the warping zone in which the beams are prepared. After sizing the process of drawing inn is applied so that the yarn could be converted into fabric. When the cones of the yarn are brought to weaving unit. These beams are then taken to the sizing section where the different chemicals are applied to the yarn so that the weaving of the fabric can be done with the minimum breakage of yarn. from where it is taken to the rechecking machines.e. while other machines are the latest Air Jet machines of Japan origin. When the greige is made. As far as the looms are concerned. During all the above process. After rechecking either the greige is rolled or folded & packed according to requirements of the buyer. In the sizing section the NML Bhikhi has 5 machines. In the warping section NML Bhikhi has 5 Benninger Machines which are of Switzerland origin. This Unit is equipped with the later Air Jet looms. While the process of A grade fabric is a bit longer. goes to the checking machines. At the first step the fabric is classified into two types. The weaving units of NML check the product quality as under: NML (Four Weaving Units) BHIKHI NML has one of the largest weaving setups in Bhikhi. The variety level of the product is very good. A grade & D grade.Most of the machines in the weaving unit of NML are of new technology & NML has a very good check on the quality of fabric produced by its Quality Control department.
Finally in the folding section checks are applied at every step of the folding process. The weaving units of NML are known to be the best producers of greige product in Pakistan. Following checks are made at different departments: Checks while Printing: . Quality Control Department: First of all the people of NML checks the quality of yarn before taking it into the process.The Bhikhi unit of NML is specially very well known for its product in all over the country. quality control lab ensures that every work has done according to the standards of NML. QUALITY CONTROL LAB: During the production. Following are the yarn characteristics that are checked before taking it into the process: • Count Testing • Strength Testing • TPI • Hairiness Testing • Thick & Thin bases At the warping section the following characteristic is checked: • Breakage Report When the sizing process is applied. the following two tests are applied: • Abrasion Test • Strength Test After completion of the greige the g/sm test is applied so that to have the best customized product.
Rubbing Washing Dry Cleaning Chlorine Test Checks after Curing: Rubbing Washing Checks after Stenter Process: Light Fastness Shrinkage Rubbing Washing (Optional) Pilling Checks after Raising: Quality check The purpose of all these checks is to ensure the Quality of the end product. QUALITY CONTROL LAB MACHINES: • Crock Meter: • Pilling Machine: • Garment Washing Machine: • Dura Wash: .
• Wascator Machine • Thumble Dryer • Light Box • Auto Wash • Curing Machine • Pader • Light Fastner Tester • Air Permea-meter • Data Color Visco Meter The above are the machine which is used in the Quality Control Lab to ensure the quality at every step. The processing unit of NML comprises of the following department: Bleaching Department Finishing Department Printing Department Dyeing Department Folding Department . Processing Department: Processing Unit of every textile mill has a paramount importance because it actually provide the finish fabric product which is either sent to customer either as a piece good or as made up after converting the fabric into the required stitched product.
A brief overview on the Processing capacity of NML has been discussed as follow: Bleaching Department: The bleaching department of NML is equipped with the latest machinery to compete with the market. Bleaching department has the following machines: Singeing & De-sizing: L-Box: Mercerizing: Emerizing: Jiger: Water Mangle: The above are the machines & a very brief overview of the machines. . The Quality Control people ensure the Quality of work in the Bleaching to fulfill the collective goal.Quality Control Lab Digital Design Studio & Engraving Department Sample Room Production & Planning Department The operations of Production & Planning Department are to work as a bridge between the marketing team and the processing people. The bleaching department is like a back bone of the processing unit. The finishing department is also very important because it is the center of operations held in the processing unit. the fabric is brought to the bleaching department where it is prepared on the above machines so as to be prepared for the Printing or Dyeing. After weaving mill. so this department has the prime importance. All of the communication which is held between the processing & the export people is done through this department.
then the fabric will be taken to first of all Ager Machine & then Goller Soaper Washing. There is a mini sampling machine for the sampling section to facilitate their work. the route of the fabric depends on the dye class. If the reactive dyes have been used. This includes three machines. The specification & general points about these rotaries are as under: Reggianni Machine: Zimmer Machine: Stork Machine: The Printing department of NML is working at its best & producing really good stuff. then to Stenter finish & finally to the calendar. On the other hand the fabric treated with pigment dye is taken to the curing machine & from there it is taken to the calendar after the required stenter finish. These machines have been identified & discussed as below: Pad Thermosol: Pad Steam: . we’ll see the specifications of the Curing & Ager Machines: Curing Machine: Ager & Curing Machine: Dyeing Department: The dyeing department is a major department of NML processing. Zimmer & Stork. Along with theses three rotaries. Reggianni. i. the printing department has three sampling tables to fulfill the sample need of the customers of NML.Printing Department: The Printing department of Nishat Mills Limited comprises of three rotaries. Now in the following line. After the printing from the rotaries.e.
Goller Soaper Washing: So above is a bird’s eye view on the dyeing department of NML. Finishing Department: Finishing department of any textile mill has a very significant importance because it acts like a hub in the Processing. Almost every fabric which goes through processing unit, it has to be passed through the finishing department. The finishing department of NML Processing unit is famous for its quality work. It comprises of many latest machines which includes Stenters, Cylinders, Raising Machines & Sanforizing Machine. Types of Finishes: There are two major types of finishes: Chemical Finishes Mechanical Finishes The finishes in which no chemical is used is called the mechanical finish, a very good example of mechanical finish is Calender Finish. On the other hand the finishes through stenter are known to be the chemical finish. The finishes are of the following types: Normal Soft Super Soft Chintz Anti Pilling Anti Wrinkle Water Proof Easy Care Soil Repellent
Sanforizing Machine: The Sanforizing machine is used for relaxing the shrinkage of warp. The machine possessed by NML has a workable width of 114”. It is basically used either on customer demand or in case of Garments. The standard is 5%. NML has one Sanforizing machine in its processing unit. Raising Machine: This basically means to raise the fibers from the surface of the fabric. The machine possessed by the finishing department of NML has a workable width of 114”. NML has one raising machine in its processing unit. Calender: NML has 2 Cylinders. The basic purpose of calendaring is to have the shine & to have better hand feel. These Cylinders are of two different lengths, the workable width of the Cylinders is 100” & 111” respectively. The above is a brief introduction of the Finishing department of NML. Folding Department: The folding department of the NML has a daily production of 1,00,000m. The folding department is the last department of the Processing Unit. After the folding unit the fabric is transferred to GSC. The folding department has two kinds of machines; the kind is rolling machine while the other kind is of folding machines. It depends on the requirement that which kind of machine would be used. In the folding department of NML latest 4 score method is used for the inspection purposes. Quality checks are made at every step of processing unit. Engraving Department: The Engraving Department of Nishat Textile Mills Limited is equipped with the latest machinery along with the manual machinery for the process of exposing. In the Engraving Department of NML, the screens are generally prepared which are then used in the printing process.
Sizes of the Screens: Following are the three repeats of screens which are used in the Engraving Department: 640mm 820mm 914mm Similarly the widths of the screens are of the following five kinds: 3030mm 2650mm 1850mm 1620mm 1280mm The fifth width is currently not in the use of Engraving department and that are not in used in NML now. The first four kinds are basically in use in the NML. The selection of the screens depends on the design requirement of the print. The most important thing which should be kept in mind is that only one screen should be used for one color that means the number of screens will be equal to the number of colors which will be used during the printing process. Process: 1. Coating Stage: The first step which is taken in the formation of the screens is to coat the screen with SCR 100. This coating is done for the purpose of blocking the meshes of the screen so that the required king of design can be made through the screen. The coating of the screen takes almost 8-9 minutes.
The work done through the digital design studio is done through this automatic machine. so the operator can access any of the prepared design in the studio. Then the lighting process is done i. the presence of machine operator is very important. Exposing Stage: Nishat Textile Mills Limited has two exposing machines. Irrespective of these facts the importance of this machine is still there. Heating Stage: These screens are then heated in the ovens so that to carry out the process in the best possible manner. otherwise the time for each screen will be higher than the original one. The process at this machine does not effect because of the presence of the operator. Basically the manual machine is used for the word of design studio. The automatic machine is the “wax jet”.2. The process of exposing stage is different for both the machines. The result of this process is that the place where only coating is there and there is no wax. one of them is manual and the other is fully automatic. at these places the coating got fixed in such a way that the meshes are . The heat is provided to the screens so that to fix the SCR 100 so that the exposing stage should be started. Earlier most of the work was done through this machine but now the major load has been shifted to “was jet”. In this machine. When the screens are heated in the proper way then they are taken to the exposing machines. the screen goes through high power light. The “Wax Jet” machine is fully automatic. The mechanism of this machine is that the machine is linked with the digital design studio. The exposing is being done through the wax on this machine that is why it has such a name. The speed of exposing through this machine is relatively higher than the manual machine because there is not such need of operator at every stage of the exposing. In the process of Manual Machine. it is quite a time taking process.e. Then the wax is applied on the screen in such a way that the wax is applied on that place from where the operator want to open the meshes. All sizes and widths of the screens can be prepared through this machine. 3.
blocked in a better way. After this Exposing stage the screen is taken to the next stage. NML has ordered for “ink jet” machine which will enhance the production capability of the engraving department. 4. Washing Stage: The screens are then taken from the exposing machines to the washing area. This is the area where the screens are washed so that the black portion can be washed from the screens. This is also called the Developing Stage. The screens are then kept on the light stand to see that whether the results are satisfactory or not. When the staff feels that the design is satisfactory then they send this screen to the heating machine for curing. 5. Curing Stage: The curing is being done through an oven. The screens are kept about 20-25 minutes in the oven. This heat fixes the design on the screen so that after the final touch the screen can be sent to the next department. 6. Endring Stage: During this stage the ring type iron is fixed on both the sides of the screens so that the screens could be taken to the printing department for printing. 7. Touching Stage During the touching stage the final work is done. In this stage if there is any extra patch on the screen, then they are blocked with SCR52 so that the correct effect can be drawn on the fabric. This is the final stage of Engraving Department. After this step, the screens are then taken to printing department. Design Studio The design studio is a very important department of Processing Unit. The importance of design studio is because of the reason that without its right work nothing correct can be done. The presence of good design studio is very important for any good textile export organization. The buyer sends the desired design in the following forms:
Through Sketches Through Fabric Sample Through CD swages Now after having the concept of design, it is then the responsibility of design department to make the screen design, to select the sizes of the screen, to select the repeats of the screens and most importantly to make the films and designs so that to have the same designs during the printing process as required by the buyer. In the digital design studio the work is being done through the latest machineries and software and dedicated and educated persons are there for the purpose carrying out the process. All of the work in this studio is done on the latest machines and the work can be accessed through the Wax Jet machine. In the other design studio, the work is being done through the experienced persons. In that studio the guideline is the first thing which is made at the start. After this step, there comes a chain in the design studio such as to separate the colors up to making the and preparing the films which can be used in the engraving department. Stitching Department: NML has two stitching units. 1: One is situated in Faisalabad 2: The other is situated in Lahore. The bedding section is concentrated in Faisalabad while the Lahore unit is a complete unit which is involved in all kinds of stitching. CUTTING DEPARTMENT. The cutting department is the first department of GSC, which takes the fabric. The fabric, which is to be stitched, is brought from the folding department to the cutting department. In this department the fabric is cut according to the
specifications & need. From the cutting department the fabric is transferred to the store from where the fabric is issued on the required floor according to the freezing plan.
The cutting department objectives • Quality control • Cutting • Minimize Wastage So cutting department was performing these responsibilities. Mr. Arif the Cutting supervisor who shared the rules of cutting that is the foundation of the complete stitching department. Those are
One: LENTH FOR LENGTH (L*L) Two: WIDTH FOR LENGTH (W*L)
The Process flow of cutting department is as below SAMPLE PROGRAMME CUTTING
Stitching Department (GSC) Stitching department is one of the well equipped machines department in the field of the Textile in Pakistan that’s why there are most of the loyal customers of the Nishat from all over the world specially WALL MART, TARGET and TARGET. These are the major have chain of stores around the world. 724 helpers are daily wages working as quality checker in the whole stitching department. 400 stitching machines in the whole stitching unit. Every machine operator has a unique no to find out the any type of the fault.
The objectives of the stitching department are ◊ The cost minimization and ◊ To minimize wastage ◊ Best utilization of time
Work force is use for loading or shipping in container. Container Type: ◊ Twenty fitter lengths ◊ Forty STD 8. ◊ WORK STATION ◊ Blind stitch ◊ Over lock ◊ Flat lock Dispatch Department Dispatch department is performing two functions ◊ WARE HOUSE. Dispatch Department has a continual liaison with Marketing Department and to fix stickers according to the customer demand on the cartoons. Maximum container capacity is to six containers per day. ◊ TWIN NEEDLE. ◊ CHAIN STITCH. Dispatch department is to pack and dispatch report preparation the prime responsibility is to make maid-ups dispatch Report. It depends on the marketing department when it should be dispatched.◊ Quality control by line checker Types of stitching ◊ LOCK STITCH.5 feet length . ◊ MAID-UP DISPATCH Dispatch department is responsible to dispatch all types of Export after packing. Its not necessary to dispatch daily. The dispatch report also send to the head office and as well as customer.
insert card. So the above is the brief overview of some of the NML operations. It is the duty of the commercial department to arrange all the equipment needed in the stitching unit for every bulk order. Quality is most important consideration while production in NML. As the stitching department is the last department before the dispatch of goods so a lot of responsibility comes on its shoulders. A freezing plan is made every month so as to maintain & systemize the production process.5 height. Acceptance Quality Level 2. there is another important depart named as commercial department.◊ Forty STD = 9. Then they issue a demand order through their Purchase Department. they see whether it is a new order or a repeat order. size stickers. From cutting to dispatch process is as below Cutting stitching Packing dispatch COMMERCIAL DEPARTMETN: Along with the cutting section. The products which are the responsibility of the commercial department includes label. stiffener. The working of commercial department starts from receiving the stitching programs. identification sticker. The stitching units of NML have latest and number of machines to fulfill the customer need & requirements. Total number of helpers in on daily wages in the whole stitching unit is 724. security codes etc. poly bag. stickers.5 & AQL 4. First of all. There are 400 machines in the GSC (general stitching company).0 is under practice. polyester rope. The Nishat Sewing Lahore is a certified for quality level from many organizations. This shows that the Quality checks in Nishat Sewing Units are of international standards. In Nishat Sewing Lahore. fusing. barcodes. . Now we’ll discuss the chances of further improvement in NML. . There are sample rooms in the stitching units so as to fulfill the sample stitching requirement for different markets to ensure customer satisfaction. This is why the quality checks in stitching department are of very good level.
This department starts working from getting purchase order to deliver the shipment to the buyer. Shipment of Yarn. Every region has a different Export Manager and its whole staff. Grey cloth & Processed Fiber . This department is responsible for the export of yarn. That’s why Managers visit to new Markets around the world. This department has to fulfill all the legal requirements and prepare important documents involved in the export of yarn. The marketing responsibility is not only to just sales and marketing it has also to find out new horizons and new ways. NML Marketing has a very strong liaison with their customers around the world. grey cloth and processed fiber.Export Marketing Department: The export department of Nishat Mills Limited is known to be the best marketing department in the whole textile industry because of the commitment and dedication of employees. The export department performs 3 major functions. That’s why NML has different segments on the basis of different regions like North America. Australia and Europe. the determination of work & the best management system. HAM TEX FAIR Hamtex is a fair of textile held in Germany on every January of the year in which all over the world well established organizations make their display centers to attract new customers. grey cloth and processed fiber.
.After receiving packing list from shipping department. It is also called documentary credit defined as. “A written undertaking by the bank of importer i. It usually prepares the following documents to ensure the timely shipment. issuing bank at the request of buyer or importer to make payments at sight or at determinable future date upto stated sum of money within prescribed time against stipulated documents”. export departments starts its main functions. The most commonly documents which export department has to prepare and deal with are: Letter of Credit (L/C) Bill of Exchange Commercial Invoice Export Declaration Form Certificate of Origin Packing List Customs Invoice Textile Declaration Form Inspection Certificate Shipping Bill/Bill of lodging/Air Way Bill Manufacture's Certificate Letter of Credit Letter of credit is the conditional undertaking on the request of the importer/buyer.e.
672 spinning has also commenced. Then NML local bank sends documents to the buyer bank and foreign bank release payment to NML bank with the permission of the buyer. buyers bank.e. cheaper and better raw materials and machinery.S. beneficiary.FNML parties are involved in the payment of the goods. Taiwan. MARKETING STRATEGY The past year has been tough for the textile industry as competition is steadily and margin of profits is becoming smaller day-by-day. After clearance of the export documents. Government allocate quota to third world. Indonesia. . A new spinning unit of 21. Countries like China. Market for Yarns and Grey fabrics was diversified to increase the customer base and reduce dependency on the Far East. Korea. L. QUOTA SYSTEM Most of the customers are American and U. UK and South America was initiated in case of Yarns. Infect quota is a quantitative restriction and more than that can't be shipped to America from a particular country CLAIM FOR REBATE Rebate is actually a "Duty Draw Back". then government pays back some of its part. India and Bangladesh played an active role in the fabric market. which caters to the weaving units in Sheikhupura. The duty which an importer pays to government for the product that is re-exported after some process. In this effort business with Malaysia. Improvement in quality and production capability was the main area of concentration.. the buyer.C. advising bank. export department negotiate the papers with bank receive payments from the bank. Our competitors from Asia have come up in a big way with lower prices resulting from lower overhead. This pay back of duty is called rebate. i.
Japan.In case of Grey Fabric market business was initiated in South Africa. The export of processed fabric and made-Ups has shown market improvement as compared to last year. Nishat has established its name in new markets be creating specialized fabrics. It has placed us successfully in the middle to upper end of the market. it’s a new market for it after breaking up the exclusive arrangement with our previous sale set-up. North America. The quota is . replacing old machines with new ones upgrading the existing set-up. Keeping in view demand of the World market. different finishes and embellished products. Leaving behind the traditional way of doing business and in our journey towards excellent it has consistently expanded its buyer base and explored the different markets around the world. Bedford Cords. leading to better efficiencies and quality products. In Europe. North America is the star market for Nishat. Nishat Mills Limited worked towards the achievement of its goal of future increasing its capability in value addition. Nishat Mills Ltd pursued its strategy of value addition and reducing the dependency on Grey Fabrics and Grey Yarn. and Cavairy Twills and stretch fabrics were developed which are being sold at premium prices. Our strength in Europe is the curtain division. designs and also by providing our customers with efficient service and excellent quality. The plan is to continue with this winning strategy and at the same time we are trying to find new clients in the high end. France. NML has constantly updated our machinery. Fancy and special items like Dobby Designs. Product range was also increased to cater to the differing needs of the buyers. Having the foresight to assess that in coming year’s value addition will be the thing of the future. and Sri Lanka etc. We are also exploring business opportunities in countries like Spain and France where Nishat has very little business at the moment. Nishat has made the most growth in the year 1999. engineered confections. Italy. This included yarn dyed dobbies.
Nishat is also taking up the social accountability issues very seriously. Nishat has achieved the highest sales in 1999-2002 for North America market. which is helping us to maintain our print volumes. They have successfully broken the ground and we have very strong faith that these markets will give us good volumes in the near future. which has started its production. as Nishat Mills Ltd moves towards becoming a more vertically integrated organization. we have to review and analyze them very thoroughly to associates with the right people in the long run. and Jordan etc. In the short term we are building a small amount of quota. which will give us recognition as a bedding supplier. Saudi Arabia. Nishat is very strong in non-quota categories like curtain and table linen. Bedding is the bulk of the home textile business. Lot of big brand US companies have visited us and are discussing the possibilities of a joint venture. The opportunities are limitless. The latest addition is the most ambitious Apparel Dyeing plant setup near Lahore. We are also targeting printed apparel business for the first time. which are so dear to the American consumers. Despite economic problems in that region. This market is a good design source for other markets. Nishat has dedicated new staff with fresh energy for the emerging market. In business terms it is our “cash cow” market. Egypt. Middle East market is composed of South Africa and the new emerging markets like the UAE. On top Nishat has developed more direct and closer relationship with our end customers. it has maintained our sales figures in the year under review. The effectiveness and productivity of this plant will be further enhanced. Nishat will coordinate the effort for NPD by all markets to optimize results. Nishat is in the process of updating its machinery to cater the needs of the wider width fabric requirement for USA bedding business. These categories are best served with new product development (NPD). Oceanic has been our most lucrative and mature marker. Primarily due to being a non-quota market it had no real limitations in this market. .coming down in 2005 and we have started to prepare for it internally as well as for the external environment.
Its marketing and production teams co-ordinance at all times and it focus remains on maintaining its position as the market leader in the textile sector of Pakistan. procuring better raw material and most importantly kept a very close association with its costumers. Nishat has provided its staff with better working environment and facilities. All of the above mentioned points led to strengthened relationship with its business partners making it very difficult for its competition to penetrate into its market share. It is being exported to some of the leading brands of the world. which enhanced efficiency and out put. Marketing process Inquiry costing quote to customer Check Greige Processing cost per delivery . At Nishat. it is prospering due to our professional commitment toward excellence and giving the best results at all times and against all odds. It visits its business partners frequently and provides them with the best service possible. Nishat has increasing its profitability by working efficiently.Our dyed fabric has already established its name in the market.
Approval received Lab dips/strike sample P.O received/Sales Contract sent Greige booking Dying/printing program issue Fabric processed Shipment sample dispatched for approval Shipment sample approved Shipment dispatched .
• Tremendous market positioning • Highly qualified and skilled management • Highly Motivated Workforce • Adequate financial resources • Competitive advantage • Equipped with MIS System • Own power generation plant Weaknesses: • High cost of production • Centralized decision making • Weak image in the international market • Small international market share • Less promotional activities • Lack of benefits and rewards for the employees .SWOT Analysis Strengths: • ISO 9001-2000: • Strong Security System • High quality product • Latest mechanized machinery.
Opportunity: • Organization Can expand product lines • Organization Can capture new market segments around the world • Organization Can reduce the cost by proper utilization of resources • Organization Can hire more welleducated and experienced person Threats: • New Entry of competitors • Buyer needs demands changes • Political instability • Changed of government policies • Globally Economic instability Detail of SWOT Analysis Strengths: • ISO 9001-2000: Nishat textile is certified under ISO 9001-2000 and so it meets the requirement of international standard and has a value in the mind of concern people. .
They are using modern looms which they have purchased from Japan and France. • Highly qualified and skilled management The management of Nishat is skilled they have hired the foreign graduate people in their management and also experienced people from all over the country. • High quality product Nishat textile limited using advance technology like they have modern machinery by which the quality of product produced is very high. • OKTEX 100: Nishat is also Oktex 100 certified its mean that Nishat is satisfied to not using hazard chemical using. • Highly Motivated Workforce They are providing better pay to their employees and also bonus to them which motivate the workforce and they are doing well at work setting. There are different hidden security cameras which capture the all moments. • Tremendous market positioning Nishat textile is one of the pioneer textiles in the Pakistan so it got the position in the mind of its customer. • Latest mechanized machinery. • Adequate financial resources The owner of the Nishat is one of the richest persons of the Pakistan and they have more plant and investment in other industries like cement. They have adequate financial resources to meet their requirements. And by using that latest machinery the productivity of the employees are very high. Bank.• Strong Security System Nishat textile limited has a greater security system. . Nishat has a better position in the mind of its customers. And being an old textile company people are loyal with it.
• Equipped with MIS System They have a management information system by which the departments and employees are connect with each other and they have a data ware house by which they can share their resources easily. Bangladesh etc the international image in the textile sector is very weak. • Own power generation plant They have own power generation plant and Nishat is the pioneer in the private organization who start the power generation.• Competitive advantage Because it is an old textile and it has still keep its position in the textile market on all others competitors in the nation wide which is its competitive advantage. Those countries providing cheap product to the market then Pakistan’s textile industries. • Centralized decision making The decisions are made by the upper management which is weakness of the Nishat because they have no proper idea about the situation and their decision can be not fruitful for the company. And also selling to the WAPDA its produced power. and Bangladesh etc . • Small international market share Although Nishat has very strong in the national wide but it has small market share in the global textile industry due to the sound competitors like china. • Weak image in the international market Because of the other textile specialized countries like China. Weaknesses: [ • High cost of production The production cost is high because of not properly utilization of its resources.
• Organization Can reduce the cost by proper utilization of resources If the cost of different matters which is not utilizing properly is controlled by the Nishat management they can produce more in a few costs.[ • Less promotional activities The advertising and promotional cost of the Nishat textile is very low it can take advantage for more turnouts. fresh and energetic staff for their betterment. And they also have better market repute. Opportunity: [ • Organization Can expand product lines Currently the Nishat not dealing in knitwear they can expand their product line by producing knitwear. • Organization Can hire more well-educated and experienced person They can take advantages by hiring more skilled people and they should hire young. Threats: • Buyer needs demands changes . They have plants and the extra cost for the production will be low for Nishat. • Lack of benefits and rewards for the employees Some facilities that other providing to their employees like Transport and medical fee etc Nishat not providing to their employees because of which the productivity of the employees decrease. It has to develop a further systematic process for controlling and managing resources.
Due to the rapid change in the Government every government sets its own new trade policies. • Political instability Political instability effects the Nishat because of the quota system the company can be restrict by the government to export. The political situation of Pakistan is not satisfactory. Dumping system which is rising on daily basis in the world can create many problems for the company and any uncertainty in the world like 9/11 may affect also the overall export. PEST Analysis Political Instability. • Globally Economic instability Because of the economic instability the Nishat affected a lot. should apply sustainable policies for the beneficial of the exporters as well as the investors. Social situation: . Economic situation: The economic condition of Pakistan can also affect the foreign investors increasing inflation rate make the cost of production high and thus reduce the profit margin of the investor.Because of the research and development the design and the product of Nishat is just satisfactory as compare to competitors in the globally and they are not fulfilling the demand of customer. Govt. • Changed of government policies Government policies are changing day to day so it is a threat for the Nishat to survive in such a changeable situation.
The change in the lifestyle of the people affects the growing demand of the NTM products. Learning as internee It was a tremendous experience that I have availed with devotion and commitment. The change in the lifestyle and needs in different demographics also affect the demand of the customers. Technological factor: Technological advancement in all the sectors of the country has changed the entire socio-economic environment. • I learnt that every problem is solved with a systematic process like from the root of the problem. Especially in the textile sector there is a lot of technological development. NTM Excellent computerized machines and devices are installed in the NTM \has made extension in its present setup by installation of well advanced technology imported from Japan China and France. . Yoshifumi Nariyama the sales representative of KANAI from JAPAN who came to introduce some new products in NML. Here I am sharing some of my learning regarding my internship in different departments. Ie to target your customer after knowing needs with product solution of the customer need. • First I met Mr. Due to all these changes NTM is performing excellent for the excellence organization as well as for the customer. • In the spinning unit I have learnt about the yarn construction and the yarn specification and the process of cotton to yarn. I discussed about the marketing practices going on in the international Textile market. I have an interest in textile industry that’s because Textile is the back bone of the economy of the country. But one thing I want to share its not easy that looks it has a great toughness and complications in its process but the overall it was nice and great.
This comment leads to the conclusion that the Information Sharing Process should really be improved. • During my internship I learnt about the value that customer is the only who come first. All the record is saved. the policies & decentralized decision making environment is really remarkable. • I learnt about the HR policies that how many types of hiring Nishat textile limited is using. • I learnt about the marketing procedure and required of the documents and dealing with customers. the “Information” is the key to success in the business. . This means that the successful businessman will be who will have the right information at the right time. In this era of technology. • I learnt that in the textile sector the cutting and stitching based on two rules o (Length) (Length) o (width) (Length) Conclusion Nishat Mills Limited is one of the leading groups in Pakistan. The fulfillment of the demand of customer is our basic motive. • The quality control as well inception in the textile department should be parallel.• I also performed some task in the spinning department like how to calculate the no of frames for a specific order and how many days are require for a specific order. the management style. And what are the procedures of the Nishat about HR matters. This report is basically an attempt to identify the areas which need to be improved. The system.
. The effectiveness of its management. this all contributes to the very much improved and sound position of company. • Medical facilities are given in mill but such facilities should also be given to management. The overall analysis is indicating that the company’s progress has mainly attained through dedication of employees. • Special incentives should also be given to Head on Eid and on other special days should be given to the workers. This will create the easiness for workers and reduce the wastage of time. • Employees should be paid extra for the work which they done after working hours. their willingness to take advantage of opportunities and face challenges of changing economic picture. • Different training courses should be arranged for the up lifting and improving the quality of work for employees • They provide transportation facility to only female employees I think male should also be provided with conveyance convenience. This is really appreciable for the devotion and hard work of all the employees of the company Recommendations Recommendations for Improvements are: • At present facility of bonus is given only to production staff but such incentives should also be given to Head office Staff. • There is also a problem of work overload for the employees and it should be control properly so that the employees are motivated.
Annexure FORM OF PROXY I/We______________________________________________________________ of________________________________________________________________ being a member of Nishat Mills Limited. hereby appoint _________________ ______________________________________________________________________ _ of ________________________________________________________________ or failing him/her ___________________________________________________ of ________________________________________________________________ Member of the Company. as my/our proxy in my/our absence to attend and vote for Me/us and on my/our behalf at the Annual General Meeting of the Company to be held on .
at Nishat House.m. As witness may hand this ________________day of ________ 2005 Signed by the said member _________________________________ In presence of _____________________________________________ Signature of witness Signature(s) of Member(s INTERNSHIP REPORT NAVEENA TEXTILE (PVT) LIMITED 1. 31 October.M off Bhoptian Chowk.A. Lawrence Road. 2005 at 11:30 a. Lahore. Lahore .Jinnah Campus.Monday. Raiwind Road Lahore. 53A. Telephone: (92-42) 5320062-66 Fax: (92-42)-5320067-68 ADVISOR: MADAM SADAF RAUF (Lecturer) Management Sciences Presented By: SHOUKAT ALI MBA-FA04-75 COMSATS Institute of Information Technology M. Defence Road off Raiwind Road. K.
NAEEM (Asst.B.U. their blessings have been with me in all good and bad times. My parent and teachers who give me real eyes that help me to leads myself and others in the dark and cruel world. Then I am grateful for the thorough support by my advisor MADAM SADAF RAUF and also Mr. . for providing related information on which this project is based.Dedications I dedicate this report to my loving parents whose prays. They were the constant source of inspiration and encouragement that helped in completion of my internship. affection and support are always a source of encouragement for me to reach at this destination and a humble icon for others in future.H). Acknowledgment At first I am thankful to Almighty ALLAH and the Holy Prophet (P.Manager Admin). WAQAR AHMED (Merchandiser).
The organization’s BCG matrix. its overall marketing strategies. . recommendations and suggestions. competitive strategy and thus the analysis of all these operations is really a fascinating experience of mine. The salient features of this report are NAVEENA’S organizational background. corporate values and goals of the company. this report is a nutshell comprises of my practical learning. This organization is situated in Lahore. marketing strategy. Management Information Systems. its dynamic Human Resource. Purchase Merchandising and import & export strategies in special. Finally. Executive Summary This report consists of my six weeks internship at NAVEENA exports (Pvt) Ltd. . The organization started its business from Karachi since 1967. This report focuses its business operations including major suppliers of the company. its vision. This report also enhances the organization’s challenges in perspective to its domestic and international competitors.
Check and balances are placed from the initial stages to eliminate any possibility of error. Bond of Trust It‘s bond of trust is consistent upon this remarkable notion given below: “We are proud to have some of the most reputable name worldwide. This has been achieved over time through the approach of work fast and work smart. Company Background Group NAVEENA is a progressive name in the textile industry established in 1967 has become one of the largest manufacturer and exporter of textile in USA and Europe. Vision of Company . it offer distinctive branded garments. Today NAVEENA exports comprises of three independent units. it was a small dying and embroidery unit in Karachi. When started it’s operations. is a broad spectrum of source houses internationally. The bond of trust has been developed because of our ability to fulfill our commitments to deliver the right product at the right time. NAVEENA apparel. producing six million pieces annually with special emphasis on fashion apparel.
Clear understanding of customer’s instructions. In time action 2.The company undertakes to apply the vision in letter and spirit under the following guiding principles: 1. Absolute efforts for in time shipments 8. Career development opportunities for employees MISSION STATEMENT NAVEENA’s Mission statement. 3. statement focused on its major commitments i. Total devotion maintains first class quality standard. Clear instructions for production 5. Strict compliance with quality control system. 7. Clear communication with vendors 4. Ø We are committed to become number one supplier of causal clothing around the globe. Ø We make clothes that fit well. look good and most importantly feel great when you wear them. .e. 6.
Ø Maintenance of consistent standard It’s GOALS Ø Continuous improvement.It’s Corporate Values Ø Team work Ø Integrity Ø Excellence Ø Commitment to buyer. Organizational chart CEO/OWNER Director . Ø Quality of product and system. Ø Customer’s satisfaction.
GM Merchandising Manager Finance Manager Production Manager Export Manager Quality Manager INTRODUCTION TO DIFFERENT DEPARTMENTS AT NAVEENA .
Merchandising Flow of Information Buyers Merchandiser PPC · Material Planning · Time & Action Plans · Production Plans Production Department o Yarn store o Knitting o Dyeing o Cutting o Stitching o Packing & Finishing o Purchases o Stores .
This requires logical thought processes such as problem solving. Marketing: Merchandiser has to market his company in order to increase his customers and generate more and more revenue. It is a critical need for merchandisers at NAVEENA. Merchandisers must have leadership for the value chain (developing. who takes care of a specific buyer or account. Merchandisers need to see "the whole process" from product innovation through consumer satisfaction. Merchandising serves the following purposes at NAVEENA: Gateway: It acts as a bridge between buyer and the company for communication. which has strong business background. Merchandiser has to calculate the cost of products including all wastes and accessories to tell the final cost of the product to his customers. This shows that there is individual or a team of merchandising. the merchandising department is mainly divided into accounts buyers. yet it also stays focused on fashion or other products that undergo continuous change in the consumer-driven market. Merchandising PURPOSE OF MERCHANDISING AT NAVEENA Merchandising is a global process through which products are produced. and sold all over the world. and resource management. Here. . Costing: Merchandise makes a cost sheet to see if the product is feasible or not in terms of cost and revenue. decision-making. and selling products) in a global market. sourced. distributing.
Sampling: Merchandiser must send the sample to his buyers for confirmation and satisfaction. Implementation: It is the responsibility of merchandiser to prepare the product according to the requirement of buyer. At this stage.Negotiation: Merchandiser must have a negotiating power on the price to convince his buyers on specific price to lessen the chances of loss. Process of Merchandising The following process describes how merchandising carries out its responsibilities at NAVEENA: § Initial Inquiry § Initial Research & Development § Costing § Cost Sheet Approval § Order Booking Status Management . Production Follow Up: Merchandiser must be aware of the quality. Information Management: As merchandiser has direct contact with his buyers so the buyers have to give information about their product’s requirements and if there is any problem the merchandiser has to inform his buyers in return. Sampling is also done to avoid loss. packaging and on time delivery.
and planning further through OBS strategic planning is also carried out. capacity optimization. Merchandising process continues if a specific cost sheet is approved. Costing: Merchandise makes a cost sheet to see if the product is feasible or not in terms of cost and revenue. OBS is normally kept confidentially and it is only accessible to predefine personal. Order Booking Status: Once an order is received it is mentioned in order booking status. Advantages of Establishing OBS(Order Booking Status) Following are the advantages to establish the OBS. Approval: After the cost sheet is prepared it is presented to the CEO or any other approving authority for approval. Initial Research & Development Initial Research & Development or preliminary discussion is carried out with RESEARCH AND DEVELOPMENT to see if the company has the capability to produce the product in terms of man and machines. . For this purpose a cost sheet is prepared. It helps in calculating cash in and out follow.§ Sampling Process § Information Handling & Forwarding § Buyer Performance Review Initial Inquiry: An initial inquiry may be a simple fax describing briefly the target price *FOB and product or it may be detailed package from a buyer describing in detail. keeping in view the styling and accessories to be used on the product. The approval is mainly granted keeping the profit in view. OBS is extensively necessary to maintain the track of records.
contract with the manufacturer. Special checks need to be maintained for proper upgrading of the OBS ad if data on the OBS is incorrect capacity and management could be seriously affected. checklist. It starts from a proto sample and ends at shipment sample depending on the buyer as different buyer have different sampling requirements. Samples may be paid or free depending on the category. information is provided which in terms is processed by the PPC and is forwarded to the relevant departments to start production. quantity. . Buyer & Country Dependence: It is always better to establish an optimum buyer that dependence on the buyer be balanced so that just dependence on the buyer is also avoided and on the other hand dependence on too many buyer is also not recommended. Sampling: It is the complete process through which sampling approvals are taken.Ø Makes order follow up easier Ø Allow better planning Ø Helps in contingency optimization Ø Helps in contingency planning Ø Improves time management Ø Improves coordination Ø Helps in financial forecasting This document must be kept confidential as it contains very sensitive information access to be only allowed at a specific level. Updating of OBS: OBS could Management Information Systemlead document in case it is not properly updated. as per the policy of company. accessories etc. Information Management & Forwarding: All information received from the buyer is forwarded to the relevant department in the factory as to PPC package.
55 .70 368.50 Lbs/Dzn Process Yarn Knitting Dyeing Cutting Embroidery Flocking Printing Cost/Unit 55 Rs/Lbs 10 Rs/Kgs 65 Rs/Kgs 2.67Kgs/Dzn 12. COST SHEET Style Number: 26898 Fabric: S/Jersey Season: 1Q 2003 GSM: 225 Buyer: Target Gauge: 24 Division: Men’s Consumption of yarn: 5.5 Rs/Pc 6 Rs/Dzn 6 30 TTL Cost 687.5 56.
6 Mat + OH + Cost Rs 3668.Accessories Stitching Inland Freight 15 Rs/Pc 120 Rs/Dzn 20 Rs/Kgs 1440 120 113. Cover Sheet .2 Mat + OH + Profit Rs 4586.6 Package Package is basically the collection of information given by the buyer regarding to specification.1 Rs/USD Price per Piece USD/Pc 6.40 2822.0 58 Exchange Rate TTL USD 79.14647 Total Cost/Dzn 30 Over Head % Rs 846.8 25 Profit % Rs 917. details and other related information about the specific product that has to be manufactured. Components of a package: Package consists of the following components: 1.
Line is the unit of button. 3.2. type of yarn. Type of Stitching Ø Over lock Ø Lock stitch Ø Flat lock Ø Folder stitch . main stitch. Cover Sheet: It contains the general information about buyer. Sketch Sheet 4. (overlooks. and flat lock). Accessories Detail Sheet: It contains the complete information about stitching threads.) and that either buttons contain two holes or four. GSM before and after wash. Sketch sheet: It contains the information about front and back view. season. 20 or 22 line. Revision History 1. It also includes the stitching type i. style #. button color. garment. folder. season. 18. Packing Manual 7. Fabric Mill Sheet 3. 2. dyeing. Accessories Detail 5. Fabric Mill Sheet: It contains the information about fabric for garment and it includes: Division. gauge. 4. division. Size Specification Sheet 6. diameter. finishing details and shrinkage etc. style. It also includes the size of button (16. button material. type of Fabric. details. and button thread. back stitch. GSM.e.
There are three kinds of labels. 1. Printed Labels Accessories detail also contains detail about taps. 1. 1. Non Tear away Fuse able through glue while using iron. There are three types of tapes. Normal width of fusing roll is 40``. Woven Labels 2. Hearing Bone Tape 2. Ø Main labels Ø Size labels Ø Care labels Ø Tablet labels Ø COO labels And two main types of labels are as follow.Labels: It also includes the detail of label with its size specification. Fusing Tape Fusing tape further consists of two types. Tear away 2. Plain Tape 3. .
Fusing Roll Tear way is fusible while non-tear way is non fusible. Size Specification Sheet: It contains the size of garments.5 _ .5 + 0. Description Chest 1” below arm hole Heam Across Shoulder Cuff Opening Small 23 23 _ Medium 23.5 _ Large 24 24 _ X Large 24.5 24.5 _ XX Large 25 25 _ Tolerance + 0. Stitching Thread GMT Color Color Code 10% cotton DTM Red Green Yellow Embroidery Thread + Code Style # Stucco MD1001 Red MD 1181 White MD 10001 ML101 ML 101 ML 101 Futek Futek Futek SM-1 SM-1 SM-1 Futek Futek Futek Main Label Code Main Label Source Size Label Code Source Red Green Yellow 0020 0030 0040 5.5 23.
It also includes hangtags detail. Packing Strategies: There are four packing strategies. e. Buyer gives all sizes. Solid Color Assorted Size 3. Garments = 42 . carton dimension details. 6.g.Arm Hole _ _ _ _ _ _ In SPEC sheet all values are taken in inches while tolerance means acceptable deviation. 1. Assorted Color Assorted Size Solid Color Solid Size: According to this strategy all garments are of same size and color. Packing Manual: Packing manual contains the folding details of a garment. printing details. Solid Color Solid Size 2. and material to be placed. Size = Small Solid Color Assorted Size: According to this strategy color of all pieces is same while there is variation in size e. Assorted Color Solid Size 4.g Garments = 42 Color = Red .
Assorted Size: Garments are of different colors and sizes. Solid Size: In this strategy color of garments is different while size is same. Assorted Color. I. Medium. Garments = 42 Color = Red & Blue Size = small & Medium 7. and long with ratio 1:2:1. time and initiating authority. Revision History: It includes all the changes required by the buyer afterwards e. buttons changed 3 to 2 or change in thread. II. Blister Poly bag: . Individual Poly bag: Individual poly bag contain 1 pc/bag. Types: There are three types of poly bags. POLY-BAG 1.g.Color = red Size = Small. Garments = 42 Color = Red & Blue Size = Medium Assorted Color. date. Ti also includes the revision description.
Dimension: 10`` 9`` Flap 3`` Fold Size L W WxLxF 9.5`` x 3`` 3. Master Poly bag: It contains more than one piece/bag. III. Material/Transport/GG: Printing Weight of Carton Instructions Logos Address Buyer’s individual idea Carton tape Carton stickers Cartons Solid Color Solid Size: . 2.Blister poly bag contain more than 1 pc/bag in a carton.5`` x 10.
Solid Size: Garments = 42 Color = Red & Blue Size = Medium Assorted Color. Assorted Size: Garments = 42 Color = Red & Blue Size = small & Medium Information Required For Carton: Following information is required for a carton. Ø Hang tags Ø Tag pins Ø Plastic Clips/Jet clips Ø UVM (Universal Vender Mark) Ø VMT (Vender Mark Ticket) . Medium.Garments = 42 Color = Red Size = Small Solid Color Assorted Size: Garments = 42 Color = red Size = Small. and long Assorted Color.
Types of Carton: · Regular slotted · Telescopic carton Regular Carton .Ø UPC (Universal Product Code Ticket) These above accessories are used 1/pc and only tag pins are used 2/pc and jet clips are used 4/pc.
Telescopic Carton 1. Dimensions Flap Height Width Length LxWxH 28 x 26 x 8 2. Color) Ø Symbols Ø Weight of Carton (With garments weight) Printing Types Ø 2 Side printing . Carton Printing Ø Addresses (From & To) Ø Carton Contents (Size.
Carton Accessories Ø Carton Sticker Ø Carton Tape Ø Carton Strapping Sampling Management Process Management is the process to do work on time. Ø Initiate Sampling Process Ø Sampling Budget (To Control Cost) Ø Time & Action Plan of Sampling SAMPLING PROCESS Proto Type Sample: . quantity. Samples may be paid or free depending on the category. Sampling is the complete process through which sampling approvals are taken. Product samplings and mailings increase brand awareness and result in additional sales. Sampling programs provide a conduit for consumers to experience product trials.Ø 4 Side Printing 3. tangible and highly visible method of launching new product. Sampling programmers can be a cost effective. It starts from a proto sample and ends at shipment sample depending on the buyer as different buyer have different sampling requirements. contract with the manufacturer. boosting sales or re-educating lapsed users. achieve target/goal on time while using All resources (machine. personnel. Sampling should be complete on time with resources. Human Resource).
23 pieces are required. The range of sample is about 12 to vary according to the requirement of buyer.This is the first sample given to the buyer. All changes are confirmed on it. For this sample. Samples Market Feedback Buyer’s Design Buyer’s Merchandisers Manufacturer’s Merchandiser Comments on Salesman Sample: Feedback on ample from customer is send to merchandiser/ manufacturer. Approval of PPS: It is the stage where a sample may be approved or rejected. Counter Proto Sample: This sample is based on the comments received from the buyer. Pre-Production Sample (PPS): Manufacturer prepares it. The sample is prepared according to requirement of buyer and this is the rough sample. Salesman Sample: Buyer sends the samples in market by salesman to get market feedback from customers it is done on 250-500 pieces or may exceed depending on season and customer. . 2-3 pieces are required in pre-production sample. Buyer has to sell these garments to check and view. Comments on Proto Type: Buyer gives his comments on sample and also recommends the changes in sample.
If he makes some changes. Size Set Sample: 2-3 sets of different size are sending to PPC (planning production and control). shrinkage. PPC department is also involved at this stage. SAMPLING BUDGET It consists of the following data. Its purpose is that buyer will make no change in cutting details. he himself will be responsible for any loss/ damage. 15-20 pieces are picked up as a sample to test. 2-3 garments are used in fit sampling. Once PPC is involved. Sampling budget Knitting plan Dyeing Plan .If accepted go ahead to next step and if rejected then there will be the process of revision of previous steps. GSM. no change in styling is acceptable. Buyer picks some pieces randomly to test its gauge. And the garments are sending to shipment. Shipment Sample: This stage is the completion of total order. If all these are according to the requirement of buyer then shipment is said to be ok. Fit Sample: No change in stitching is acceptable at this stage. Manufacturer keeps one sample himself and one sends to buyer for cutting approval. Photo Shoot Sample: Now the sample is ready fort shipment.
Knitting Plan: Knitting plan is used for the description of material to be knit. Sampling Budget: It contains the general information about. Width 26’’ 9’’ 209’’ Total # of Pieces = 500 Mesh for 1 Shirt = 400g Mesh for 500 Shirts = 500 x 400 g = 200. 2.Accessories Sheet Cutting& Stitching Plan 1. Width 36’’ 200 F.000 g 1000 = 2 Kgs Total # of Pieces = 500 Rib for 1 Shirt = 18g . Buyer: Target Fabric: Mesh Season: 3Q 2003 Pieces: 500 Style #: 295 Division: Men’s GMT: S/S Polo with 1x1 Rib DTM body at neck. Description Mesh Rib Yarn 20 S Carded 20 S Carded Total Width F.
36 Dyeing Plan: Color Red Navy C. Code Mesh Kgs 250 x 400/1000 = 100 250 x 400/1000 = 100 Rib Kgs 250 x 18/1000 = 4.5 250 x 18/1000 = 4.5 Accessories Sheet: Description Stitching Thread Red Stitching Thread Navy Main Label Side Label Label Core Label Twill Tape Poly bag Factor 200m 1 1 1 1 1m 1 TTL Material 250x200/2286 = 22 250x200/4500 = 12 1x500 = 500 1x500 = 500 1x500 = 500 1x500 = 500 1x500 = 500 1x500 = 500 .000 g 1000 = 9 Kgs Yarn Requirement: 20 S Carded = 209 = 5 45.Rib for 500 Shirts = 500 x 18 g = 9.
37’’ Cutting & Stitching Plan: Color Red Navy Total C. Code 100 100 S M 100 100 200 L 100 25 125 XL 50 25 75 TTL 250 250 500 Time & Action Plan: Pieces = 500 Packing = 200Pcws/DAy Stitching = 150Pieces/DAy Cutting = 1day Dyeing = 2 days Knitting = 3 days Yarn Package = 1 week Yarn Req. Knitting Dyeing Cutting Stitching Packing Fac D .Tissues Cartons (24/Pieces/Carton) 2 500/24 2x500 = 1000 21 cartons Prepare By: ________ Checked By: _________ Received By: ________ Stitching Thread: Small Cone = 2286m Large Cone = 4500m 1m = 39.
S. Percentage c. Code 1 1/4x1000=250 1/4x2000=500 1/4x3000=750 2 2/4x1000=500 1 1/4x1000=250 1000 2000 3000 M L TTL 2/4x2000=1000 1/4x2000=500 2/4x3000=1500 1/4x3000=750 PERCENTAGE METHOD Color C.D S. 1) Purchase Order 2) Production Summary a. Code S (30%) (M 20%) (L 50%) TTL . Ratio b. Direct given by buyer RATIO METHOD S Color Red Green Htr Grey C.D E.D S.D 28Jul 5Aug 9Aug 12Aug 15Aug 17Aug 20Aug 21Aug 20Aug 24Aug 23Aug 27Aug 7 S Prepare By: ________ Checked By: _________ Received By: ________ METHODS OF BREAKDOWN Following are the methods of breakdown.D E.D S.D S.D E.D E.D S.D E.D E.
Step 4: Calculate length of layout. Step 3: Layout patterns + optimizes wastages. Step 2: Take finish width available from R & D.Red Green Htr Grey - 300 600 900 200 400 600 500 1000 1500 1000 2000 3000 DIRECT METHOD In direct method the buyer gives all values. Color Red Green Htr Grey C. Step 1: Identify components of a garment. Code S (30%) 1000 (M 20%) 2000 (L 50%) 3000 5000 6500 TTL 6000 9000 6000 FABRIC CONSUMPTION CALCULATION Following methods are used to calculate the fabric consumption. .
of Pieces/day grams/Pc While 2 = No. Step 7: Calculate / make plans. 39.Step 5: Apply formula. Basic Terms: Ø Open Pattern Ø Close Pattern Ø One Garment Ø Components Calculations: Rib = 26’’ Fabric = 30’’ 30 x 60 x 2 x 200 = 464. Of Layers of Fabric Circular Knit consists of 2 Layers Open width consists of 1 Layer Step 6: Add wastage.5 .37 = 1550 yarn/pc/layout L x W x 2 x GSM = ____________ = ___________ 1550 No.37 x 39.
2046 = 6.72lbs/Dzn 1000 TYPES OF WASTAGES Cutting: .832 = 12.9g/pc 1550 2 Fabric = Neck = Cuff = Total 233 8 13 254 Including small wastages 254 x 12 x 2.1550 2 = 233g/Pc Neck Calculation: Neck = 3’’ x 26’’ x 220 x 2 = 23 = 7.3g/Pc 1550 3 Cuff Calculation: Cuff = 3.5 x 26 x 220 x 2 = 25.
Progressive/ Step By Step Method II. Knit 2-2. Direct Method Calculation for Yarn Consumption: Length = 60’’ Width = 25’’ . I.5% wastage that is left over yarn wastage Yarn Dyeing: It includes 5-7% Yarn dyeing wastage WASTAGE ADDITION METHOD There are two methods used for waste addition. Excess planning Small wastage 5 % included in layout Large wastage 3 % Dyeing: It includes. Dyeing wastage 6-9% normally for fleece Finishing wastage Knitting: It includes.It includes.
Of Pieces = 2 GSM = 220 60 x 25 x 2 x 220 = 425. .80 = 212.10g/pc 4 Wastages: = 5.95Lbs/Dzn RESEARCH AND DEVELOPMENT Ø Research and development or RESEARCH AND DEVELOPMENT is related with product development.05 x 1.02 = 6.50g 1550 48.06 x 1.80g 1550 425.03 x 1.90g/pieces 2 Calculation for Rib: Length = 5’’ Width = 30’’ GSM = 250 5 x 30 x 2 x 250 = 48.95 x 1.50 = 12.No.
Data is inserted into the computer for making the file.Ø Concerned Merchandiser forwards the Fabrication Info to the Product Library and will get the exact match. Ø He sends the results to the buyer. After that PD Plan is made by the PD center. gauges. RESEARCH AND DEVELOPMENT starts working here. design. PRODUCT DEVELOPMENT PLAN Ø It issues the work order. Merch is developed and PD Plan is made by the PD center. finishing Routes. Single Knit/Double Knit. Lab. tells about the style. Maximum sample weight is 10 Kg but is according to the merchandiser’s requirement. 20-30 g (weight) of the fabric is reduced just because of chemicals and detergents. Ø If OK for the results. Ø He compiles the results. we refinish the fabric. for the quick wash and sees the results after the 3 washes and required GSM is produced. He submits the fabric in the Lab. Documentation and Planning is carried out. Technical evaluation (Pricing). Width and GSM is calculated and observed in RESEARCH AND DEVELOPMENT. RESPONSIBILITIES OF THE RESEARCH AND DEVELOPMENT MANAGER Ø She decides the fabric styling. Documentation and Planning is done. Ø If there is no exact match. . counts. After the quick wash. SAMPLING. fabric finishing routes and fabric dyes. Ø If there is required match. Ø One copy remains with the Merchandiser. RESEARCH AND DEVELOPMENT. Sewing and ACCOUNT. Ø PD plan is send to the three departments. Yarn Count.I. If result is not OK. Ø RESEARCH AND DEVELOPMENT sends the developed samples to the P.
largest in Asia. accuracy. designed to achieve the following Fulfilling Designer’s Dreams § A facility where an idea can be accurately converted in to product in quickest turnover rate.. garments and finishes in line with ever changing trends in knitwear world. Ø Quality Planning also includes the “Garments to Kg concept”.Officer. QUALITY PLAN Ø Quality Product Requisition (QPR) is made in RESEARCH AND DEVELOPMENT. § Ensuring reproducibility and predictability of new products for production. § Sales man samples in 2-4 weeks at actual production parameters . § Continuously developing and innovating new and exciting fabrics. It is a 35000 sq ft facility. § Prototype samples in 3-4 days in actual fabric and color. Ø An independent and vertically integrated product development and research center is one of its own kinds.Ø One copy remains with the PD. Ø Within three days Quality Plan is issued from RESEARCH AND DEVELOPMENT. Ø Quality planning includes the “Consumption Sheet or Pattern Efficiency” that is 85% required. Meeting Merchandizing Requirement § Delivery of all types of samples with speed. that shows that how much garments can be abstracted from the 1 Kg of fabric. quality and competitive pricing.
. Home directory 2. 1. Software’s: The software’s that are being used in NAVEENA Textiles are: Ø Inventory management Ø Fixed assets system Ø Salary system software Ø Piece rate related software Ø Engineering system Ø Attendance system Security: Login is provided to every user and password is provided. files. Care drive Home Directory: Home directory the user can build folders.MANAGEMENT INFORMATION SYSTEM Department MANAGEMENT INFORMATION SYSTEM department more than 100 hardware computers in factory. Only available recourses are planned. He is only responsible for compiling and security for this data. Departmental share: The departments can share data with each other. he can change according to his convenience. In all organization we provide three types of login. Look after of these computers. He is responsible the maintenance and hardware related problem. Department share 3.
Future plan: In future plan they will implement the E Commerce for update the status of the garments. This process is done for management trainees. His criteria will accord job requirements. If they fresh graduate then first written test is done after this initial interview. and then final interview is conducted. For workers and officer level the head of department hire. HUMAN RESOURCE DEPARTMENT Human resource department is responsible for Ø Recruiting Ø Training Ø Compensation Ø Performance appraisal Ø Firing Recruiting In NAVEENA for management hiring three interviews are conducted if they are experienced.Care drive: In care drive the departments can read only. Training . Write facility is not provided because security purpose. They also plan to implement ERP step by step. They are using SQL because this provides more security and cheaper than database.
For workers they are providing minimum Rs. But sometimes for management we conduct seminars. PRODUCTION PLANNING AND CONTROL Production Planning and Control (PPC) is the nervous system of the organization and its basic task is to receive information from the merchandiser and link it to the production. This depends on the nature of the job and skills. what is needed. yarn and fabric. in LUMS some lectures are scheduled. It is basically done to analyze that how much is needed. like sundries. .M decide how much salary will be provided. when is needed. For officers the G. Firing the employees If any employee is not doing his job very well then the Head of the department fire the concern employee. They also compensate according market going situation. experience of the employees. Compensation For management trainees they provide Rs. Some mangers they visit to foreign countries for getting training.On the job training is mostly provided. PPC has two further branches A) Material Resource Planning B) Production Planning and Monitoring MATERIAL RESOURCE PLANNING Material Resource Planning is done for the material procurement. It involves the Pre-Production Analysis to ensure quality and reproducibility.12000 and other according to job requirement and skills of the employee. what is the cost of the material and how to acquire the resources. 3000 according to government rolls.
DOCUMENTS GENERATION IN PPC Store Plan Store Plan can also be called as Accessories Plan. and then it is converted in to the Acro fabric. In this Quality Plan specification.PRODUCTION PLANNING It includes the planning like the Sewing Plan (we can also call it as the Master Plan). It also involves the information about Threads. It plans for how much dyes . Buttons. Date Wise Plans are made from work order to delivery. Back Ward Production Planning is done and this Production Time Line involves when’s and what’s of the production. weight. Monitoring is done for the whole production process and in this we check out the planning implementation. dyes. width. DOCUMENTS RECEPTION IN PPC Two types of the documents are received by the in the PPC from RESEARCH AND DEVELOPMENT and Cutting.track and On-the. quality. Dyeing Plan It is related with the Dyeing of the fabric that how much fabric is required for an order. gauges and counts are mentioned. If the planning is failed. replanning is done for that. MONITORING It is the different entity.track planning is also done by the PPC.the. RESEARCH AND DEVELOPMENT PPC receive Quality Plan from the RESEARCH AND DEVELOPMENT. Off. Cutting PPC receive Fabric Consumption Patterns from the Cutting department and plans that how much fabric must be used. Sewing and Labels. It involves all the documentation about the sundries being used in the production of the order. Store Plan is basically a Quantity Plan.
Store Plan Store plan comes from the Store and purchase Requisition. They whole purchase department is do not work the work order or purchase order. So for the additional planning and additional cost. Three most important documents are used in the purchase department. Things are purchased according the buyer demand. Buyer provides purchase Order and according to this the store department make plan. There are some visible losses and some invisible losses. import department involves in such purchases. parts of machineries that can be available locally. stationary. EXTRA PLANNING 3-5% extra planning is done for the losses. involve local purchase for the purchase of machines machinery that is not available in the local market. chemicals and dyes etc. It comes from the warehouse. The nucleus of NAVEENA and Sarah’s remarkable success has been its impeccable system. No buying is done without the order. For the procurement of the materials. PPC managers have to go for the Chief Executive. PURCHASE DEPARTMENT Every aspect of organization for the manufacturing of the product like sundries. Any extra planning requires extra cost. PPC goes for the purchase department. These documents are used all over department. These are usually the general items. This whole import department is concerned with the high involvement machinery. As such no inventory level is maintained for such goods as these goods are utilized immediately and plan is made for the minimum for the week.and chemicals are required. The Production Planning and Control is the nervous system of our organization and undoubtedly it is our key success factor. MPR: Material Procurement Recognition . PPC conducts detailed pre-production analysis to ensure quality and reproducibility. Invisible losses are being made in Dyeing process and Finishing Process. It is made for one supplier only at one time only. Demand of the supplier is mentioned in the purchase order. Visible losses occur from cutting to shipment. have to be purchase locally from the local markets.
Expected Audit date/time received and go-head is taken from concerned unit (manager) to carry shipment. Following documents are required for the custom clearance. MRP: Material Requirement and Planning This document is used within factory for issuing the material. Train. Rates are as per shipment volume. Cargo lifting advice is fixed to custom clearing agent/ Forwarder/ Transportation. Arrangements are made for the transportation to move the consignment by the road/train/air as per plan. Funds arrangement for the transportation and custom clearance charges. Forwarder / clearing agent make arrangements for the custom clearance and booking of the space at earliest vessel. Truck. Eg. Shipment moves for the Karachi through the following ways. and Air.Every department issues this then the purchase department is responsible for procurement. EXPORT DEPARTMENT EXPORT PROCEDURE Purchase order is received from buyer through the merchandizing department. A fax message is send to buying house/buyer for opening L/C. Ø Consignee and Applicant Addresses Ø Garment Description Ø Garment Price and Total Invoice value Ø Net and Gross Weight of Garments . INVOICE In Invoice following criteria is required. Detail is given following.
Of Pieces in the Carton and Carton Dimension also other necessary information. They write the report on the . by the forwarder. which gives help for the custom clearance. Ø From # & Date Ø L/C. VALUATION FORM It is for the custom purpose to inform the value of the consignment to the State Bank of Pakistan. After the sub Management Information Systems ion of the custom docs. § Consignee and applicant addresses § Product description § Garment Style and color § Net and Gross weight of Garments § No. Export-FORM E-FORM is issued and attested by the concerned bank. And examine the shipment accordingly. BILL OF ENTRY Applicable only in case of the imported material used in the manufacturing of the garments for the export purposes. #(letter of credit) PACKING LIST There are following details in the packing list required as per buyer’s instruction or mentioned in L/C. Ø Freight Terms.Ø PO (purchase order) no. FOB/ C&F/ CIF/ Ex-Work Pakistan. SHIPPING BILL The forwarder prepares shipping bill. custom authorities check the docs.
to realize the payment.P. PAYMENT PROCEDURE After the negotiation/ collection procedure of the docs.H. bank dispatches the same to L/C opening bank. All original docs are returned to the export department. USA.A.M. our bank is bound to issue the PRC within the working days.A. QUOTA PROCEDURE Ø Arrangement of the quota for the exporting the above goods or the garments as per category. NEGOTIATION / COLLECTION After the completion of the Visa process. for the issuing/ entering of the Passbook and the given serial numbers. After this P. REBATE CLAIM .P. we submit the docs in the Bank for the negotiation/ collection. After realization of the payment. Ø Quota purchase from the open market/ EPB (export promotion bureau) VISA PROCESS After receiving the Docs from the forwarder.backside of the shipping bill and allow the shipment for the export from the Pakistan.B. The docs are prepared according to the L/C.B (textile section). for the Visa issuance. Then after the checking of the docs Visa is signed and stamped by the Director of the E. CANADA.H. or the buyer requirement. pass the Visa to the E. The set of Visa with required docs is presented to P. All these docs are then returned to the export department. Export Department prepares the Visa docs. which are required for the export of garment to the following countries. DOCUMENTS FOR THE BUYER Export department also prepare documents for the buyer for the custom clearance of the shipment at the destination.M. EUROPEAN countries. Foreign bank is bound to realize the same within the 10 to 15 days.
S Code. BENEFICIARY’S CERTIFICATE It is according to per buyer requirement. § SHIPPING BILL: It is provided by the clearing agent and attested by the custom authorities. and carton packing. PACKING LIST It consists of color. § INVOICE: It is custom attached and details of the imported material are also given. BILL OF LADING/ AIRWAY This is according to the L/C terms and conditions. § BILL OF ENTRY: We need detailed information like Description. no. H. that is used in the manufacturing of the garment. SHIPPING CERTIFICATE In this certificate the shipping line intimates that the vessel /flight is not affected buy on Indian or the Israeli Flag vessel. § BILL OF LADING: in it all the required information is provided which is needed for the custom clearance. export department claims the duty draw back (rebate) from the customhouse in Karachi or Lahore. of cartons. weight. product code/other.After receiving the PRC. carton dimension. Custom and sales tax duties and etc. Foreign Exchange Rate. . coding numbers. Weight. Insurance. COMMERCIAL INVOIVCE In the commercial invoice all the details are mentioned required under conditions of L/C for the custom clearance and other necessary purposes.
Business Operation Management: The management team of NAVEENA comprises of dedicated and highly motivated individuals.strict quality control measures are implemented from the beginning and at all subsequent levels to maintain standards .their work starts from yarn till the end product . They bring with them. system are followed and fool proof inspection procedures at every stage of production and carried out. Quality Standers: Continuity in quality is an integral part of this organization. innovation is encouraged. experience in the knitwear industry and diverse educational backgrounds. there is team of professionals who head this department . NAVEENA has tried to develop a company culture where quality is given the top priority. both local and international. Quality Emphasis: . laying much emphasis on teamwork and interdependency. which brings synergetic results.
The organization has already achieved ISO 9002 certification and has acquired various quality certificates and awards. lot to lot shade continuity. spectra flash. yards covered area 150000sq FT No. sustainable relationships rather then “one time” commercial contract. Among other equipment the most noted are the data colors. including the followings. Laboratory Testing: The organization have a comprehensive lab to check dye lots . CBR Ministry of labor and manpower Ministry of excise and taxation Custom department . Of employees-KHI 2500 No. which are involved in term of Govt intervention in the textile industry. which are followings.FT Factory area LHR 5375sq. Organizational buyers are recognized and respected names in the international apparel industry. Of employees LHR 1500 Gov’t departments involve with organization: There are many departments. Factory Facility Factory area KHI 12000sq. color fastness to corking etc.yards covered area 175000sq .its the organizational routine to check fabric for shrinkage. tumbler and washing. Major Clients: The organization is working with leading multinational companies and believes in developing long term.
Plant and Equipment: The organization’s most of the plant and equipment is procured internationally. Auto striper (terrot) s4f-248 18 30 5 Auto striper (terrot) s4f-248 20 30 2 Auto striper (fuquhara) s4f-248 18 30 2Auto striper (fuquhara) s4f-248 20 30 1 Mini jacquard (terrot) s3p4f-148 18 20 1 Feed stripe (Mayer & cie) 1mv4 11 20 30 1 Feed stripe (Mayer & cie) 1mv4 11 20/24 30 1 Feed stripe (Mayer & cie) 1ml-bf 20 30 1 Eight lock double knit t130-9621 18 30 2 RIB (pai-lung) t130-9621 16 34 1 . And it is to some extend is a mechanistic organization. But it is due to its mass production . In term of knitting Type Model Gauge Diameter No. configured to generate optimal production at all stages and to ensure high quality.The organization along with its functional structures has horizontal linkage which is most necessary thing in garment industry because of high quality consciousness.Quality standards assurance organization State bank of Pakistan Structure and design of organization: Structure of the organization is flat and functional.
K 850kg 1 fong’s yarn dryer H.K 300Kg 1 .K 300kg 1 these machinbes are wiuth a capacity of four batches.K 300kg 3 fong’s yarn dyeing H.K 750kg 1 atyc yarn dyeung H.K 90kg 1 fong’s yarn dyeing H.K 30kg 1 Atyc yarn dyeing H. Fabric dyeing: fong’s 2t soft flow H.Flatbed machines: Make Origin Gauge length Number Matsuya Japan 14 80cm 16 Matsuya Japan 14 56 05 Dying Yarn dyeing: Description make capacity number fong’s yarn dyeing H.K 200kg 1 fong’s yarn dyeing H.
K 4000/day 2 Finishing: hyadro extractor local 60kg 1 Hydro extractor Taiwan 60kg 1 Tumbler (askmer) H.K 30kg 2 tumbler (askmer) H.K 30kg 8 Tumbler china 60kg 1 Dryer (sanatax) Switzerland 5 ton/day 1 Stenator Italy 15ton/day 1 Fabric slitter local 500kg 1 Squeezer Switzerland 6000kg 1 Corino (slitting machine) Italy 12000kg 1 Monforts (6chamber stenter Italy 15000kg 1 With graving system) .K 500-600kg 2 Atyc –ht 4t soft flow SPAIN 900kg 1 Atyc –ht soft flow SPAIN 165kg 1 Winding machines: SSM cone winder Switzerland 2000kg 4 Re-winder local 9000kg 6 Garment washing: Suit lick washing machine H.Fong 3t soft flow H.K 30kg 8 Tumbler (sutlick) H.
50ton/hr 1 Generator USA 375KVA 1 Generator USA 300KVA 1 Compressor Japan 1580lbs 4 The organization has a strong capacity of production. Equipment Made Specification Number Boiler England 5. Currently the following equipments are installed on the pre-Management Information Systems. which also works as competitive advantages in term of technology. Auxiliary equipment: The organization has an in house repair. The brands which the organization is currently using all are of well named in industry.Gravimeter system raising machine china 3000kg 1 Cutting /Embroidery: Electric cutting machine KM (Japan) 12 heads 5 Embroidery machine tajima 6needles 1 Band knife nagi shing 1 Stitching 480 –sewing machines comprising along with 5 uni8ts having capacity of 22000 dozen garments /month. and helpful for obtaining order and fulfilling it on time. NAVEENA Dying . Which also work for attracting the buyers towards organization. maintenance and development facility classified under electrical and mechanical department.
Machine 1 is 800kg 2. Dyeing Process: There are two types of dyeing 1. Machinery: In Yarn dyeing all machines are of Hi-Temperature. Machine 5+6+7 is 300kg each 6. Atmospheric Dyeing. Machine 3 is 30 kg 4. Yarn Dyeing 2. 8th in line is only drier of 800kg. Hi-Temperature dyeing 2. Fabric Dyeing There are two Methods 1. Lab Functions: Samples are prepared according to the needs of the buyer and the process is called lab dipping. After the buyer then the dyeing approves the samples people follow the production plan provided by the PPC. The capacities of the machines are as following. The dyeing process starts from the sample swatches that are sent by the Buyer. . 1. Machine 4 is 200kg 5. Machine 2 is 90 kg 3.
Machine 1 is 700 kg 2. Machine 7 is 20 kg and is also winch machine. Machine 2 is 150 kg 3. 1. 6. Machine 5 is 350 kg 5. Reasons for dyeing: For attractive purpose For uniformity Shade variation controlling Color gives: More comfort More satisfaction Process flow: Singeing To remove protruding fibers De –Sizing To remove the size for uniform dyeing (over dry) Scouring . After the dyeing fabric is transferred to finishing. The capacity of the machines is as following. Machine 6 is 50 kg and is named as winch machine. Machine 3+4 is 550 kg 4.In fabric dyeing three machines are hi-temperature and rest is atmospheric.
Bleaching Removing of color Changing absorbency Mercerization Length of fiber Fineness of fiber Types of dyes: Reactive dyes make covalent bond Disperse dyes make a penetration Vat dyes make a trapping Sulphur dyes Direct dyes make a overlapping Component of dyeing: Temperature Salt Machines Factor effect the cost: q L .To remove added and natural impurities Detergents To remove soil and keep it suspended in Water. So they don’t penetrate again in the fabric.
a b o r q R a w m a t e r i a l q M a c h i n e r y q M a i n t e n a n .
c e q E l e c t r i c it y q T r a n s p o r t a ti o n q D y e s q C h e m i .
c a l q G a s General requirements by buyers · Strong color bonding · No bleeding & staining · After twenty washes no change in color · No absorption affect on garment after twenty washes Recommendations for cost control in dyeing house: 1. Before selecting the product consider followings. q Price q Quality q Availability q Performance q Packing q Storage q Concentration q Final cost q Compatibility . Compare the cost with competitors 2.
Let’s take a brief over view how it is done. High quality NAVEENA Knitting There are two kinds of knitting: · Flat knitting · Circular knitting. Flat Knitting: The purpose of flat knitting is to prepare collars and coughs. They are given the fabric by circular knitting department and after that the technician at the flat knitting machine feeds the designs according to the demand of the buyer. More production c. Less stoppage b. These both categories of knitting are being performed at NAVEENA 2 facility.q Environmental factors Required expertise: Electric and electronic work Mechanical work Machine / work knowledge Responsibility: Maintenance Manager / Knitting Manager Benefits: a. They are .
Setting the needles in the machine according to the requirement is an art and the master has to be the master in this art to get the desired result and to avoid error. They cannot make a stripe more than 2. Mostly they are used for simple fabrics of white and light colors. Three operator’s one helper and a master manage them. The purpose of the circular knitting is to convert yarn into fabric. Circular Knitting: They again get their line of action from the PPC department. The more the gauge better will be the quality. Common error is that of needle break. They check whether the whales and courses per inch meet buyer requirement or not. Each machine is capable of producing 150 kg per day. which they need to follow to get the desired result. only break down maintenance is done which costs the organization much more than the preventive maintenance. The capacity of each machine is 250 sets in 24 hours. Machinery: For the purpose of flat knitting NAVEENA 2 facility flat knitting department is equipped with 21 automatic flat knitting machines. Quality Parameters: The quality checkers inspect the flat knitted fabric on the basis of Wales and courses. Machinery: There are total 15 machines 9 of them are computerized and called auto machines. The remaining six machines are called feeder machines. A total of 192 cones of yarn can .given a complete production plan by the PPC department. These machines are capable of making maximum stripes on a fabric while using four colors at a time. which mean every machine can have 14 needles per inch.5 inches on a fabric. The auto machines are mostly used for the preparation of fabric of dark colors and having stripes or repeat. which spoils the whole fabric if not detected at once. and according to the statement of machine operators they are easily achieving the maximum capacity on regular basis. Maintenance: There is a separate maintenance department present but there is no concept of preventive maintenance. All the machines are 14 gauge machines. Wastage of 2 % is allowed.
Now fabric is ready and is transferred to NAVEENA 1. The machinery is not capable of producing French terry and fleece fabric. using the 4 point system. If the fabric shade varies then it is sent back for re dyeing.be added to a single machine of four different colors. This machine enables the quality personnel to detect various defects in the garment. Quality Parameters: After the fabric is prepared it is checked by the quality personnel on a machine called clatter machine. which is set according to the buyer requirement. A dryer is in the process of being set up and will soon be functional increasing the efficiency of the finishing section. After that the fabric goes through the erasing machine which smoothens the fabric mostly fleece is erased. There is a supervisor and a master present to keep check on the things. are then cut off in a way that their effect should not be on the finished garment. which cannot be removed. The machine is hi-tech and fully computerized. One person handles each auto machine and two feeder machines are under one person. Then the fabric is transferred to slitting and squeezing machine. after detecting the error they mark it and send for appropriate corrections. The errors. All the machines are of hi-technology and produce great results. Cone WINDING: . Quality Parameters: The quality personnel check the quality after the erasing and the main concentration is upon the variation of shades. The sophisticated fabric in whom there are more chances of shade variation it is even checked during the dyeing process by the quality personnel. where fabric is straightened. After that comes in the stenter machine having six chambers. Then the fabric whose rate of shrinkage is more is sent for tumbling which is the traditional approach for drying and the other fabrics are transferred to tenter fesaro + compactor machine. 48 cones belong to each color. Finishing: The finishing can be termed as the process for drying the fabric. All the machines have flexible gauge facility. Any order of these two fabrics is outsourced. First of all the fabric is transferred to hydro machine which squeezes the water out of fabric.
the cone winding department re wind it to make it soften. Re winding: After dyeing of the yarn it is re winded and is transferred from spring wind to the paper wind. If any thing Management Information Systems the eye of supervisor then any error can easily go through Major Suppliers Din spinning Sapphire Ejaz spinning Azgard9 Dewan Mills Nishat Mills Hussain Mills Factors Affecting on Organization in Term of External Environment There are factors which are currently affecting the organization and are as follow: Gov’t policies . The biggest draw back is that there are no control checks what so ever in the conewinding department.It is of two types: Ø Soft winding Ø Re winding Soft winding: The yarn when firstly come is hard . Then it become easy to dye and the dye quality become higher.
· Labor policy Brands Side out High sierra Antigua Cherokee Amc –stores Aeropostale Phat farm Roots Hard rock café . which entice the organization with Gov’t · Tax policy · Rebate · Quota · Industrial policy of Gov’t in term of garments manufacturer. · Subsidies from Gov’t. As the policy of Gov’t changes it directly effects organization because there are many factors.
Organizational Culture NAVEENA consider its employees to be its biggest assets. So. The organization has following statement for their social culture “We strictly. forbid child labor and forced labor” Competition There is a big competition between industry . Adequate facilities exist and are constantly upgraded to improve the social environment. because the commodity is same and due to witch there is cost factors which is very high and directly effect organization. under all cost. Suppliers of organization: The company also has the list of compatible suppliers and includes them in term of stakeholders and used to facilitate them with the maximum beneficial way to develop long-term relationship with them. with the goal of establishing relationships. agin. There is less innovation and differentiation in products.in term of taking orders and the main aspect is price of manufacturing garments.Hollister Brake water Perry Ellis Wal-Mart The company devotes considerable time and effort to consolidate its present relationships and develop new ones. which are long term and diversify the company client base. Domestic competition · Masood . The supplier side is although most critical aspect of the organization in term of quality and quantity because of the large-scale production in NAVEENA.
and all are Lahore based. Because in that huge dynamic e4nvironment there will be more dimensions in organization to meet with uncertainty.· Ammar · Leisure · Irfan te · Shah – textile · Angora · Combin fabrics · Comfor · Mian s These are all major competitors of the organizations. It can be come from: · Singapore · Bahrain (because the USA made a contract with UAE) · China · Bangladesh · Thai-land · Honk –Kong · Malaysia . International Competition The overseas competition is now –a –days very less but it will become very high after the remove of ATC .the organization has to develop its self from now to be in market in future.
Because the technology is also working as a substitute for man power with more efficiency. Structure and design of organization: The structure of organization is functional with horizontal linkage. which means more production. SWOT ANALYSIS OF NAVEENA During my internship I observe some strengths. opportunities and threats for Naveena are given below. The organization has mechanistic design and which is working on the basis of efficiency. which NAVEENA is using not very low but there is no end in business. STRENGHTS Ø Big buyers from market Ø Well known strong suppliers Ø Strong departmental structure . Technology: Technology is also a key sector in term of external environment for garments industry. Although the technology. maximum out put from least input. The industrialist has a solid point that it also saved cost i9n term of · Error reduction · Les labor cost In order to compete internationally the organization must have to depend on new and advanced technology. weaknesses.
Ø MANAGEMENT INFORMATION SYSTEM department Ø Quality Provider WEAKNESSES Ø Not a big player in market Ø Low integration between departments Ø Too much decentralized the departments. Ø No RESEARCH AND DEVELOPMENT Ø No marketing research OPPORTUNITIES Ø In WTO(World Trade Organization) implement quota will free this will be opportunity for especially NAVEENA because he can produce much more. Ø Many brands we can start like sports garments. Ø Expansion of business Ø Diversification In term of open trade Ø Capture local market THREATS Ø New entries in the market like small level unit after WTO implementing. Ø China and India is big threat when quota will free Ø Differentiation
Ø Switching of buyers Ø No Isolation Ø Persistent quality Ø Low price from other countries BCG MATRIX FOR NAVEENA Boston Consulting Group Matrix (BCG MATRIX) The BCG matrix measure market attractiveness by market growth rate and it assesses the firm ability to compete by, its relative market share. The BCG matrix assumes the causal relationship between market share and profitability. Stars Questionmark Cash cows Dogs There is a huge slum in garments industry, after the incident of 9/11. This is directly and indirectly affecting the whole market. But NAVEENA is the organization working quite well, even in this situation and earning from international market. That’s the sign due to which I analyze that the NAVEENA is a cash cow in term of BCG matrix. Competitive Strategy
Ø In garment washing different effects is provided to customer. Ø Value added products are provided. Ø Pull and push strategy is adopted Ø Performance is better. Marketing Strategy § The product improvement will be marketing strategy. § Product innovation § We make reasonable price against market. § Outlook of garment is very smart and excellent. This is accepted in the market. § Targeting the young people and using price strategy to satisfy them. Marketing Analysis The structure of organization is quite well but the design is not. Because the coming trends are moving very fast. And in the end of this year the environment that is now-a-days stable will become dynamic. Then there will be need of Differentiation
It’s a big process. ECRU FABRIC STORE / LAT MAKING AND FABRIC DYING/ PI LAB I learn about the process of maintaining ecru fabric store and lat making. Then I attached with the process of circular knitting and flat knitting and learn about these two processes and its importance. At first I get the information about Ecru Yarn Store that how after the order of buyer a company bye the ecru yarn and store it according to W/O. NAVEENA following the international standards of approving and rejecting the dyed fabric. After this knows about the process of fabric dying and then there was a difficult and main process of approval and rejection of fabric in PI lab. Either to sit a side and looking on trend‘s changing the organization has to do a lot. which can’t be achieved in day’s .It take lot of time to enhance theses capabilities in organization. . YARN DYING / LAB AND CIRCULER KNITTING AND FLAT KNITTING I learn about the yarn dying that how an ecru yarn dyed and after dying process how it preserves.Added features Effectiveness Quick response to changes More flexibility More complexity Competitive edges not one but more then that. Practical learning ECRU YARN STORE AND CONE WINDING . After that I got the information about Cone Winding that how it works and what are the functions of cone winding.
so according to this sheet we develop the required garment for approval and also we analyze the cost as well. PRODUCTION SHEET Production sheet is given from buyer and buyer tell his requirements actually all the specs is given in this sheet.It is one of the major department of any textile Industry without having god professional it can not work so knowledge about PPC is very much useful. actually we get all the lengths and get the information of cost as well and other things about the roots. CONTROLLING .DYING FINISHING AND DYED FABRIC STORE Today I learn about the process of finishing the dyed fabric and how the fabric get ready for the next process and after this after all quality checks the fabric is ready to next process and for this it preserve or store in dyed fabric store. ASSESRIES In this we plan about how much accessories will be used in garment and also wastage factor will be added in it. we get the sum of body and sleeve and get the consumption of garments. PPC DEPARTMENT (PLANING PRODUCTION AND CONTROLLING) . COSTING In this process we added all the consumptions and compare it with the buyer rate if it is less than the buyer rate then it will be accepted otherwise not. RESEARCH AND DEVELOPMENT (RESEARCH AND DEVELOPMENT) In RESEARCH AND DEVELOPMENT we analyze and finalize the root of fabric that how it will complete and in finishing how it approaches the buyer requirements. CONSUMPTION After getting the all the lengths of garments we know about the consumption and it is known by the defined formula of body and sleeve.
FIT SAMPLE After getting the information merchant made a fit sample and sends it to the buyer for the final approval. It is a core process and I today I learn about this process. It is not the requirement of all the buyers but few buyers get the sale sample. after confirmation of order merchant demand to buyer to give accessories detail so that he can start the production.We the plan is accepted than according to due date every day PPC check that how much process is completed and how much time remaining will take. CONFIRMATION OF ORDER I learn about that what happen after confirmation of order. PROTO SAMPLE AND COSTING I learn that how to make a proto sample and how define the costing of that proto sample. So process is checked at every stage. SALE SAMPLE I learn about the process of sale sample the how this process is occur and one thing that is learning in it that the price of sale sample is doubled than the other garments. SCHEDULE ABOUT TESTING . After making a proto sample and costing merchandising department send the sample for approval. Merchandising Department I join the merchandising department and get the whole information and briefing about the merchandising department and its functions that are done under merchandising. I learn about the basic functions of merchandising that how after the order of a buyer it works and what are the basic function like reading of spec sheet and other information about the specs.
That should be repaired. Actually it is necessary to know about the schedule because after confirmation the order it is 1st requirement that have to fulfill first and after this bulk production is started. Ø In flat knitting department the quality inspection machine is not working. Ø Effective maintenance is also important to get maximum utilization of machinery. Merchant made all sizes and gets the confirmation of all sizes from buyer then starts the next step. Ø There is only one hydro machine in dyeing. but it should be embedded in each employees mind. it must be two .I learn that how get the schedule of testing the garments. These days I spent with the merchandiser that how he works when order is confirmed and how the whole process is completed. Actually it was a practical learning and no documentation was involved in these days Issues and Suggestions Suggestions and recommendations for knitting and dyeing Ø There should be a preventive maintenance scheduled program. SIZE SET AND PRODUCTION Today I known that what is the importance of size set before stating the bulk production. Every employee should take it as personal responsibility. . Ø Keeping high quality is not only the responsibility of quality department.So the lot loaded on trolleys doesn’t have to wait for long time.
There should be clear lines of communication established between the departments. In order to avoid this kind of scenarios the merchants need to be absolutely sure what is required and the PPC personnel should clear any ambiguities before going for production and should recheck with the merchant the basic requirements. because they’re hazardous if stored in knitting department. The problem is addresses only when it occurs. Issues and Suggestions. Every concerned person should know what is going on and what was . regarding time and action plan: The most common issue is of coordination Management Information System takes that lead to enormous losses at the end of the day. Ø Quality measures should be clearly defined. which was not required at all. planning and control: The biggest draw back in the time and action plans of PPC in NAVEENA is that there is no contingency planning in advance it is a general rule that while planning production some cushion is given for activities such as machine break down or any other extraneous variables that can take place. regarding production. And due to which a lot of quality problems are occurring which increase both the time and cost. According to PPC personnel due to some Management Information System takes by merchants in providing production summary they end up making garment. Although there is a co-ordination manager present but still personal interest of all the departments is required in order to make the coordination free of any doubts. Issues and Suggestions. which is only due to the non-cleanliness of the production floor. Ø Common error of fluff. written and hang on the departmental walls. There should be planning in advance for that in order to minimize the effects of a problem that has occurred.Ø There should be clearly written standard about the demand of buyers’ requirements about the production. Ø Raw material should be properly stored.
. Conclusion Form my experience of six weeks in this organization I have learnt many things. core values. From Knitting to Finishing every responsible person should have a clear idea what he needs his team to do. is that the stronger the culture of the organization better will be the productivity. In textile sector the thing of immense importance is how well the organizational personnel communicate with each other. as it is a secret. · SWOT information gets from Senior Managers. BIBLIOGRAPHY · Company profile I got the information regarding vision statement. There is no room for personal grudges because each and every one depends on each other if any one screw up the whole organization suffers. The best thing. which I am able to find out.required so that controlling should not only limit to the PPC department. competitive and tough. The most important is that practical professional life is very hectic. Only production summary is prepared and is given to PPC so if merchant makes a Management Information System take in interpreting the PO there is no way PPC can come to know about if there are any ambiguities in the production summary? Sometimes the merchant delays in forwarding information as it arrives to him resulting in delay to initiate the production process. Limitations: Buyer due to the fact that the merchant cannot forward the purchase order gives Some times the co-ordination gap to PPC.
GLOSSARY GSM: Stands for Gram Square per meter.· HRD information get form HR Officer. · Merchandising related data from merchandising manager. MMC: Stands for material Management and Control MPR: This means Material Procurement Requisition MIR: This stand for Material Issue Requisition GPR: This means Gate Pass Requisition GRN: Stands for Goods Received Notes BRS: Stands for Bank Reconciliation Statement SAN: It means Sales Notes OGP: Stands for Outward Gate Pass . · Import related data gets from Import manager. · Process related data collect from different departmental heads. · Export related data gather from Export Manager.
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