Summer Internship Report

ACKNOWLEDGEMENT
We would like to express our sincere gratitude to Mr. Subhashish Das ex

H.R.Manager for giving us the opportunity to do the internship at Radnik Exports. We also extend our acknowledgement to Mr Pradeep Industrial

Engineering head for providing guidance as a mentor and analysis for this report. We would also like to thank the support given by the staff and employees of Radnik Exports especially Mrs.Neera and Mr.Rajesh Jaglan for their tireless support and co-operation without which we would not have been able to complete the report. We would also like to thank Mrs.Bhawna Kapur, center co -ordiantor and all my faculties who have always been there for us, and have taught us a lot during these three years with the help of which we were able to understand so much about the industry.

RADNIK EXPORTS, GURGAON

Page 1

Summer Internship Report

INDEX
SL. NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 16 17 18 19 20 21 CONTENT Introduction Merchandising Department Sampling Pre-Production Planning & Control Fabric Store Accessories Store Testing Lab Cutting Room Embroidery/ Adda work Sewing Industrial Engineering Department Finishing Quality Control IT Department HR Department IT Department Project 1 Project 2 Order Tracking Learning Experience PAGE NO. 3 10 15 20 26 31 34 38 48 49 56 62 68 76 78 107 82 91 110 121

RADNIK EXPORTS, GURGAON

Page 2

Summer Internship Report

1. INTRODUCTION
1.1 COMPANY PROFILE
Radnik Exports is one of the India s leading garment export houses today. It is owned by Mr. Vinod Kapoor. Establishes in 1973, it has become one of the booming companies in India. Radnik Exports has 6000 managers leading the company, with manpower of 4000 people. It has customers spread all over the world. Radnik Exports manufactures high fashion ladies apparel, ranging from casual outfits to formal evening wear. Recently they have expanded their range to include men s wear and children s clothing as well. Capacity of the Gurgaon unit is 1.25-1.5 lakhs per month. The turnover is 53 crores per year. For over 30 years, Radnik has built its business on this axiom - Delivering quality fashion apparel to the world s leading buyers and retailers, building relationships that help us anticipate client needs and proactively generate relevant solutions. The management of Radnik Exports is committed to satisfaction of its customer s by providing quality garments at the right time and at the right price. It is also committed to provide healthy work environment for its employees by adhering to health and safety norms and creating an efficient work culture.
RADNIK EXPORTS, GURGAON Page 3

Furthermore. 1. The capacity is 850 machines.Summer Internship Report 1.000 garments per month. RADNIK EXPORTS.2 INFRASTRUCTURE Radnik has six production factories.000 sq. They have established their own offices at these fabric centers to have a better grip on the quality and aesthetics of the fabric.Noida The unit at Gurgaon is forty years old. telephone or fax-24 x 7. In addition other specialized garment manufacturing machines are used extensively throughout their production centres. GURGAON Page 4 . Radnik has several units:. There are two units.Okhla . advanced washing and finishing processes are implemented across all orders. feet with a capacity to handle 500. while synthetics and rayons in all its forms are best sourced from the western regions of India.215 & 294) .Gurgaon (Has two units in Udyog Vihar. covering a total area of 250. Usuage of over 2000 stitching machines in India and Nepal is an important factor in the growth of this compnay. Their on-line office helps their buyers to be in touch with them through e-mail. Moreover.3 FABRIC SOURCING Radnik ensures complete quality in their cottons that come from the south.

4 PRODUCTION Radnik ensures maximum quality and efficiency as their mission. 1. they have a team of quality controllers who constantly monitor production using AQL standards. they are most concerned with this department s functioning. GURGAON Page 5 . Further to focus more closely on the processes.Summer Internship Report they work only with the most quality conscious printing and dyeing mills in the country which are in and around NCR until and unless specified by the buyer. Cycle checks and a team of industrial engineering always look out for ways to increase the productivity and efficiency of the production floor.5 CUSTOMERS o United Kingdom  BHS  Next  Marks & Spencer  Evans  Asda  Debenhams  Dorothy Perkins  River Island RADNIK EXPORTS. 1. These controllers themselves are supervised by technically trained Quality Assurance tam leaders. These fabrics meet all the specified norms before being approved for production. They critically analyse the reasons for delay or low productivity and put them in the da tabase in order to obtain solutions for the same.

GURGAON Page 6 .Summer Internship Report  Miss Selfridges  Littlewoods  Ann Harvey o Sweden  H&M  Lindex  Ahlens  Indiska  Gudrun SJoden o Australia & New Zealand  Morgan Spencer  Pumpkin Patch  Jeanswest RADNIK EXPORTS.

16 L W N A N N H C Me c S Fabric Store Spreading and Cutting Industrial Engineering Se ing Floor Finis ing Final AQL Audit Despatc R IK E P R R  ¨ & % $ #" !  c    ©¨ § planning and c ntroL  © ¥£ ¢ S ¦ £¢¥ ¤ £¢¡¡   n n hip R po AN s P .

cutting master must be informed Comments on visual Appearance of the garment.12 SOP FROM PRE-PRODUCTION TO FINAL FINIS ING Process Remarks Responsible Person To be contacted Deciding the Date and Time for PPM Informing the Departmental Heads Reports from Stores In charge In consultation with Production Manager PPC Head Preparing the comments for the Preproduction Sample Comments from Production Department Fabric Shrinkage. GURGAON . merchandiser needs to take approval from the buyer Need of Notches Deciding the Critical Operations Deciding Special machines and attachments needed In case there is some measurement changes to be done. CSV. etc. special equipments. in-house if the Acc. Twill tape. etc. Quality and Finishing Department Stores In charge Department Heads Comments from Quality Departments Comments from Finishing Department In case of construction changes needed. is still waiting. Thread. etc.Summer Internship Report 1. Expected date of Acc. Reject. Merchandiser Page 8 Size-set RADNIK EXPORTS. Zipper. Button. Problems which may arise in Bulk Discuss all the comments with concerned Production Manager Merchandiser Cutting Head PPC Head Quality Head Finishing Head Procurement Dept. Comments on Construction Quality Deciding the Quality Check-points Stage at which the garment should be sent to finishing room Need of die. From Production. Test Reports. color bleed.

ticket no.Summer Internship Report comments and Proto comments Trim Card Approval departments Documenting the minutes of the meeting for future reference Information of number and size of bar tags. Lindex & The Arcadia Group RADNIK EXPORTS. and size of buttons. thread and other Acc. SGS. zippers Information about critical operations Information about sizes and shade in the style (Shade. GURGAON Page 9 .7 AC IEVEMENTS o ISO 9001:2000 Certification by BVQI o AEPC Awards: Outstanding Performance in Rupee Trade Area Outstanding Performance in Global Export o Certificate of State Award: Outstanding Export Performance (Delhi Administration) Outstanding Export Performance (Department of Commerce) o Corporate Compliance: Factories are compliant under International Code of Conduct Laws and are certified by Price Water House Coopers (USA) Intertek Testing Services. also) Any special instruction for the style Merchandiser PPC HEAD PPM members 1. buttons. H& M. zippers.

Merchandising department has the following objectives: y Arranging meetings with buyers y Costing of the garment to obtain maximum profit. pass on all the concerned details to the production department. lab dip reports. y Coordinating with production department & updating them about various approvals received from buyer to ensure timely delivery. MERCHANDISING DEPARTMENT Merchandising department is the coordinator of the company.Summer Internship Report 2. There are total 5 senior merchandisers & 5 assistant merchandisers who assist their respected senior merchants in handling different buyers and 1 head of the merchandiser whose authorization is production to final shipment. to the store and to the accounts dept y Conducting PP meeting and preparing Time and action calendar and reviewing them on daily basis. TOP samples or gold sealer y Once the orders are finalized. Radnik export has a centralized obtained before submitting costing to the buyer. maintaining file records. There are two office assistants for preparing swatch cards. y Coordinating with the sampling department for all the approvals whether Proto / Fit . planning. RADNIK EXPORTS. and putting them into one envelope. It plays its role right from bringing orders. and for other office work. GURGAON Page 10 . sealer. merchandising department for all other units in Gurgaon. Size Set .

Thus the problem comes into the notice of director. RADNIK EXPORTS.Summer Internship Report y Providing best service to the buyers by taking quick actions and feedback to maintain healthy buyer vendor relationship At Radnik there is practice of having meeting of all heads of different departments every day in the evening so that all the heads can put forward their problems in front of director regarding any bottleneck in their department or in any other department which is hampering productivity of any particular department. this makes the higher authority aware about actual situation of company. In this meeting the merchandiser who has performed well in the day gets clapping as a reward. GURGAON Page 11 .

getting it signed by the company anding over of production file and sealer to the production department for production R IK E P R R C Sending pre.21 C L W: Get tec Pac from the Buyer Discussing pattern details with the pattern master and C Getting Pattern made if approved by or else making re uired changes after discussing with the buyer aking the first protos and sending it to the buyer for approval Receiving comments on the first proto and making second revised proto with changes aking of Fit samples with the help of comments on the second protos aking of size set samples in accordance with the showroom samples comments aking approval on size set from buyer and sending it for A check.production samples to the buyers B A head for the sealer sample 6 6 7 20 5 P 4 ) S A 3 0)2 1 0)(( ' n n hip R po 8 9 D @ 8 .

y Sampling Department: At every stage it is the responsibility of the merchant to get the fabric and the trims arranged for all sample makeups as per the need. y IE Department: If any technical or special requirement is raised by the buyer. y Production Department: Merchandiser has to keep an eye on the progress of an order and ensure that the order is being processed as per the Time and Action Calendar. He maintains the style package and updates it every time the buyer makes any changes. merchandiser discusses it with the IE Department. GURGAON Page 13 . He keeps in constant touch with the buyer and communicates his instructions to the sampling and other departments.Summer Internship Report 2.3 ROLE OF MERC ANDISERS AS COORDINATOR y Fabric and accessory store: Merchandisers have to consult the fabric and accessory store to get cost of the fabrics and trims used in the garment. y Cutting Room: Merchandiser has to discuss with the CAD operator and pattern maker about the average consumption of the fabric. RADNIK EXPORTS.2 MANPO ER: DESIGNATION Merchant Manager Senior Merchants Assistant Merchants Office Assistant Pre production manager+ assistant Total: NUMBER 1 5 5 2 2 15 2.

GURGAON Page 14 . They also has to ensure that required quality level is achieved. merchandising department has to communicate frequently with the shipmen t department.Summer Internship Report y Shipment Department: For proper shipment on time.6 RECORDS MAINTAINED y Merchandiser file o Purchase order(Refer annexure 1) o Cost sheet(Refer annexure 2) o Tech Pack o Accessories demand note(Refer annexure 3) o Packaging instructions o Measurement sheet. design sheet o Comment sheet o Comments on trims and accessories o Color standard o Size label o Embroidery panel o Swatch chart o Marker o Fabric demand note(Refer annexure 4) o CMS labeling and packaging (Refer annexure 5) o Testing Report RADNIK EXPORTS. 2. y Quality Department: Merchandiser has to discuss quality issues in the style that has to be carefully maintained with the Quality department.

2. the fabric and trims details. The main objective of this department is to make samples. The buyer sends a specification sheet.Summer Internship Report 3. Quality department and the merchandising department are in sync with the sampling department as they have to be very specific and clear as to what the buyers want and what work is in process. RADNIK EXPORTS. The merchandisers have to supervise and direct the work flow of the sampling department with the kind of output required. which has details like the sketch of the garment. A buying house may send the same to Radnik. SAMPLING There are three ways through which the company gets orders: 1. Samples are prepared by a team. 3. Pattern master makes pattern according to the buyer s specification sheet then the digitizing of those patterns is done with the help of Astra software. GURGAON Page 15 . Radnik may send a rough sketch of the garment(development sample) that is prepared by the Okhla unit to the buyer or the buying house.

Ne t. All re uired washing and packing as instructed is carried on. all are confirmed. second fit samples are prepared rectifying the errors occurred in the first fit sample. it is now ready for bulk production. is the pilot sample (sealer sample . Usually the buyer asks for certain sizes for this stage. In case of any discrepencies. firstly first fit sample is made The sketch of the garment is sent to the pattern master who prepares the pattern with the standard measurements Three samples are sewn by highly skilled operators One of them is sent to the buyer. second to the buying house and third is kept in the e port house This sample is made in ordinary fabric Comments are received from the buyer. This sample is prepared with the e act trims and accessories as asked. Once the buyer is convinced with the sample. In case of any changes. the thread. Once the sample has been sealed by the buyer. In some cases there may be a re uest for a third fir sample.31 C L W: As the file is sent to the sampling department. Three samples are prepared for each size. re uest for the size set samples is put forward. R IK E P R R R R R T T U R PH P G S R T Q HGP I HGFF E n n hip R po S S S . re -pilot is sent considering all comments.

3 MAC INERY: Type of machine SNLS SNLS 3 Thread O/L 5 Thread O/L SNLS-UBT Number 19 1 1 2 1 Make Juki Brother Juki Juki Juki 3.Summer Internship Report 3. Before To rectify Fit. and into the Page 17 Second fit Substitute RADNIK EXPORTS.4 TYPES OF SAMPLES MADE: Following are the various types of samples made at Radnik Export: Sample type First fit sample Material Substitute Stages at which it Purpose is sent Before To finalize confirmation of construction. order converting sketch/design garment. GURGAON .2 CAPACITY OF T E SAMPLING DEPARTMENT: Type Operators Pattern master QA Cutting Master Supervisor Manager Quantity 12+4 3 2 2 1 1 3.

embroidery etc. Pilot sample Fabric and During line setting For buyer s all trims reference. Gold sealer Fabric and If there are To rectify the sample all trims changes to be changes suggested made in the sealer by the buyer. whether the quality and construction is matching to the sealer sample or not. using the comments on the first sample If there are major changes to be made in the second fit. After fit and construction of average size is approved. Sealer sample Fabric and After Size-set for This sample sealed all trims the style has been for the bulk approved. sample.) to be done on the garment. Vendor Page 18 RADNIK EXPORTS. Substitute confirmation.Summer Internship Report sample Third fit sample To incorporate the changes suggested by the buyer for the second fit Size set sample Fabric To check the actual approval for production of all the sizes and also to approve the desired value added work (like printing. changes suggested by the buyer Production (TOP) sample Fabric and all trims To see whether the bulk pieces are coming out alright or not. GURGAON .

GURGAON Page 19 .5 RECORD MAINTAINED y Size Specifications y Daily Production RADNIK EXPORTS. 3.Summer Internship Report always tries to select the best quality pieces to send as TOPs.

It helps in coordinating and supervising the basic workflow. Control means not just setting targets but bringing the actual near to the standard. RADNIK EXPORTS. He controlled the production of both the units in Gurgaon. It knows where the loop holes are find ways to rectify the same. when. GURGAON Page 20 . and w here of an action. The PPC department sends the Production package to the logistics and R&D department. PLANNING AND CONTROL As the name suggests. week. It makes sure that the required product is produced with minimum total cost and time for required delivery. day and hour. PRODUCTION. From the data of the time study conducted by the Production targets are set for the production floor for each month. Accordingly the PPC allocates different styles to different units depending upon the order quantity and delivery date. It gives an aim and a target to achieve on a daily basis.Summer Internship Report 4. PPC monitors every stage of production and it is responsible for deciding an appropriate action that must be taken to change the plan whenever production is behind the planned schedule. this department is for the careful planning and controlling the different manufacturing processes to ensure a timely delivery of the goods. The PPC was headed by only 1 manager with an assistant. The PPC department is the backbone of the company. For this PPC has a huge database of records helps the controllers in following up and telling what. which conducts a time study for the style and give their estimated time of production.

GURGAON Page 21 . y For a perfect flow of production. washing & finishing. in which following information are given: y Date of plan released y Fabric code y Style description y Order quantity y Date of cutting & spreading (with status) y Date of sewing with quantities (with status) y Date of washing with quantities (with status) y Date & status of garments in finishing RADNIK EXPORTS. store. y Set the daily targets for different departments right from spreading to the final dispatch y Keep a check on whether everything is on right track or not.Summer Internship Report Some of the functions of the department are: y Planning of the operations y To ensure that all the resources are being used optimum. y Styles to be prioritized according to their delivery dates. and quality assurance. Every month PPC releases a plan for the production. y PCD was calculated taking a 60% efficiency of the operators. sampling. planning department makes proper balance with all other related departments like sourcing.

42 c h f dc e AN GNA W qd pi N N 1 1 2 B H Assist nt ot l 43 C L W Production package file pepared Package is studied thoroughly by PPC Production package sent to the logistics department Production package sent to the RnD department Time study is conducted for the style Estimated time of production is calculated PPC allocates different styles to different units Targets are set for different units. R IK E P R R aY P X S b YXa ` YXWW V n n hip R po f hg r r g .

cutting master must be informed Comments on visual Appearance of the garment. Awl. is still awaiting. color bleed. Problems which may arise in Bulk Production Manager Merchandiser Cutting Head PPC Head Quality Head Finishing Head Procurement Dept. Button. Twill tape.4 SOP of the PPC Department Process Remarks Responsible Person To be contacted Deciding the Date and Time for PPM Informing the Departmental Heads Reports from Stores Incharge In consultation with Production Manager and Factory Manager PPC Head Preparing the comments for the Preproduction Sample Comments from Production Department Fabric Shrinkage. RADNIK EXPORTS. Thread. For Production.Summer Internship Report 4. CSV. etc. etc. GURGAON Page 23 . Reject. Quality and Finishing Department Stores In charge Department Heads Comments from Quality Departments Comments from Finishing Department In case of construction changes needed. etc. Expected date of Acc. Zipper. merchandiser needs to take approval from the buyer Need of Notches. in-house if the Acc. Comments on Construction Quality Deciding the Quality Check-points Stage at which the garment should be sent to finishing room Need of die. etc. special equipments. Test Reports. Deciding the Critical Operations Deciding Special machines and attachments needed In case there is some measurement changes to be done.

A database is maintained. ticket no. RADNIK EXPORTS. y Lead time is most important factor and daily updates are required over this information. A little training and this software can do all the work.Summer Internship Report Size-set comments and Proto comments Trim Chart Approval Discuss all the comments with concerned departments Merchandiser Information of number and size of bartacks. buttons. thread and other Acc. Functions of the software: y y Planning of cutting . GURGAON Page 24 .sewing and finishing department An auto generated TNA is prepared and all the steps are matched with the current scenario or status.6 SOFT ARE USED To have a better control and planning procedures. This software helps in planning and allocating styles according to their quantity and delivery dates. Radnik has installed FastReact software to do the same. zippers Information about critical operations Information about sizes and shade in the style (Shade. and size of buttons. zippers. also) Merchandiser Documenting the minutes of the meeting for future reference 4.

and required] are some of the statuses. AND OVER DUE are some of the status for cutting sewing and finishing department. light blue(order completes within permissible delay) and dark blue colour(unacceptable delay) y This helps in keeping track of what is going to finish on time and which style require immediate attention to finish on time. MARK COMPLETE .7 RECORDS MAINTAINED y Pre-production meeting notes y Production File description y Measurement Report y Trim card y Bulk component card y Line loading schedule y Monthly shipment plan y Shipment schedule RADNIK EXPORTS. skipped. WAITING . not very critical. GURGAON Page 25 . WIP INVALID .Summer Internship Report y MADE . TOTAL . y Sofware shows the status of the order in grey(order can finish within its delivery date). y For TNA [critical. 4.

There is one field supervisor who looks after for all printing and dying operations. FABRIC STORE Fabric store is controlled by the fabric manager who is responsible for all fabric in house by time at the same width which merchandiser demands. y To get the fabric in-house. y To issue fabric to the cutting room Location system of storage is followed. ROLL NO. Fabric packages are stored in two areas: (a) Checked Fabric and (b) Unchecked Fabric. and demand note and day wise details of fabric. fabric in house date. He is supposed to visit all suppliers for timely and adequate delivery. FABRIC WEIGHT: RADNIK EXPORTS. 5. GURGAON Page 26 . Clerks are to keep all records regarding width.Summer Internship Report 5. y To check the fabric according to the 4 point system for defects and faults. WIDTH: FABRIC SUPPLIER: STYLE NO.1 INFORMATION ON ROLL DATE OF CHECKING: FABRIC DESCRIPTION: LOT NO. y To order greige fabric for printing and dyeing. The job responsibility of supervisor is to get target of checking fabric achieved by checkers. price. y To order printed fabric as specified by the buyer.

bulk fabric is brought in -house Fabric is checked according to the 4 point system fabric is issued to cutting R IK E P R R ‚ € CHECKED B € € METERS xv DEFECT POINTS P u S y vux w vutt s n n hip R po . buyer's name. 5 2 PROC FLOW: Purchase order received by merchandiser fabric in-chare gets to know about the delivery schedule He studies the specification of the goods required.The fabric store issues the fabric for cutting on Challan. instead it is issued as re uired. A list of suppliers is prepared Supplier is finalised First lot is sent for approval after its approval. color. The Challan contains information regarding style no. All fabric is not issued at one go. and quantity to be issued to Cutting Room.

GURGAON ƒ AREA Surat.3 TYPES OF FABRIC y Chiffon y Satin y Corduroy y Linen y Georgette y Cotton o Poplin o Cambric o Voile y Dobby silk y Swiss dot 5.5 FABRIC SUPPLIERS: FABRIC Yarn dyed Poly-chiffon RADNIK EXPORTS.Summer Internship Report 5. Coimbatore Surat Page 28 .4 MANPO ER: DESIGNATION OD Field Supervisor Supervisor Clerk Assistant clerk Checkers TOTAL NUMBER 1 1 1 2 1 4 10 5. Salem.

Bhiwandi Faridabad. This implies If the length of defected piece is: 0-3 3-6 6-9 <9 1 point 2 point 3 point 4 point Description Length Width Defects Sample size 100% 3 places at each piece 100% Acceptance criteria +/. corduroy) Grey fabric Dyeing of fabric China. RADNIK EXPORTS. GURGAON Page 29 . and 60 pts for lining The department has to maintain different records for each and every type of fabric as all possess different type of defects and require specific treatment. Ahmedabad.1 40 pts per 100mtr.1 cm +/. Hong Kong South.6 FABRIC C ECKING 4 point system was being followed. Jodhpur 5.Summer Internship Report Imported fabric( Stretch silk.

Summer Internship Report 5. Cracks Cracks 5.5 REPORTS GENERATED y Fabric Demand Note(Refer annexure 4) y Fabric Purchase Order Form(Refer annexure 1) y Dyeing fabric order form y Fabric Issue Challan RADNIK EXPORTS. Weaving. GURGAON Page 30 .7 DEFECTS IN DIFFERENT FABRIC Fabric GEORGETTE SILK Defects Thickness.

6. He then sourced the trims and accessories and made it available for the sampling and production. ACCESSORIES STORE The accessories store was headed by the manager. Lead time of the order depended on the comple ity of the order. Order quantity for trims included wastage of 5 %. y Order placement as per the requirement of the style y Ensure that it is in-house for sampling and production y Check whether the quality is well within acceptance limits y Issue the same to other departments 6 1 PROC FLOW: Demand note is issued to the accessory store by the merchandiser Order placemement Checking of the trims that are in -house Placed in cabinets according to the style number Issue of challans for sampling and production R IK E P R R P “ Some of the functions of this department are ’ ‰‡ † S ‘  ‡†‰ ˆ ‡†…… „ n n hip R po . sually it was 5-7 days. He was given a PO order by the merchandiser showcasing the requirements of the order.

neck tape.2 MANPO ER: DESIGNATION Store manager Store In-charge Store Assistant Clerk Checkers Runner elpers TOTAL NUMBER 1 1 1 2 2 2 2 11 6. 1% rejection leads to rejection of lots. time label. Transfer prints RADNIK EXPORTS. Unique Price Code tickets. loop label. ribbons and laces: Shoulder tape. Snap buttons. Trims like buttons that may be pigment dyed require prior approval from the export house. country of origin label. y Embroidery patches. Velcro tape etc. GURGAON Page 32 ” . y Interlining and Fusing material: shoulder pad. y Buttons and fasteners: Available in different sizes and material. hooks. wash care label. European standards follow lead. mobilon tape.Summer Internship Report Note: in case the trims require dying. satin laces. it is either requested to the buyer or is done in house. 6. License Hang :ags. braids etc. content label. logo transfer etc.3 TYPES OF TRIMS y Labels and tags: Main label. elastic ribbons. nickel abd iron free trims. twill tape. y Sequins and beads: Embroidery accessory in variety of shapes and colors y Threads: Sewing and embroidery threads. size label. carton stickers. paper foam etc y Tape.

Noida Hangers: Marity. vendor etc. Usually 5% more than required trims are procured as they are subjected to defects.Summer Internship Report y Needles y Zippers y Packing Material: Poly bags. Gurgaon. cartons. 6.5 SOURCING REGIONS Labels: SMN. Hong Kong (Both are otherwise buyer specific) Zipper: YKK. style no. leading to rejection. hangers. Ideal Tax 6. Max Trade. adhesive tape. color.6 RECORDS MAINTAINED y Accessory Demand Note(Refer annexure 3) y Accessory Purchase Order Form RADNIK EXPORTS. This trim sheet is handed over to purchase department by the merchandiser. tissue paper y Stationery like Cad Roll paper. record books 6. GURGAON Page 33 . It also states the size and content of the trims. buyer. Wastage of trims is also high. alteration stickers.4 INFORMATION ON TRIMS CARD The trims card other than trims contains information like quantity.

TESTING LAB Lab functions under fabric department only. y Shrinkage o Warp length o Weft length y Tear strength y Count (warp. Lab assistant must know about all the standards given by buyer so that the testing can be done accordingly. Lab assistant keeps record of all type of testing. 7. weft) y Construction (warp. Lab assistant takes care of all machines and inform the senior authority for any repairing or any other issues related to machine. Count. o Color change o Color staining. o Self staining.1 OBJECTIVES: The lab performs the following tests as per the buyer s requirements: y Colorfastness to crocking y Colorfastness to washing. construction.Summer Internship Report 7. weft) y GSM y GLM RADNIK EXPORTS. GURGAON Page 34 . and GSM etc are done internally however FPT and other major test are done at SGS and Intertek.

durability.3 MANPO ER: DESIGNATION Lab assistant Charak checker elpers Total NUMBER 1 1 2 4 7. 2. GURGAON • To determine the 1 tearing strength To checkthe button 1 strength To weigh the samples 1 . Color fastness to light Color fastness to water Page 35 RADNIK EXPORTS.Summer Internship Report 7. FPT is done to check fabric for shrinkage. seam strength. tensile strength and color fastness: 1.4 MAC INES: Type of machine Senator washing machine ashing fastness tester Conditioning chamber Motorised crockmeter Tearing strength tester Button snap pullout tester eighing machine GSM cutter Purpose To test washing fastness To test washing fastness To condition the sample pieces To check the color fastness ro crocking Number 1 1 1 1 Make IFB Ramp Ramp Ramp Ramp Ramp Ramp – – Cuts samples to 1 determine the GSM of samples When fabric is sent to buyer for approval it is sent with fabric processing test report.

acetate and so on. Yarn: assembly of fiber .e. Yarn numbering systems are used to express a relationship between unit length and weight of yarns either meters per gram or yards per pound. nylon. The yarn count system which is used for all spun yarns Count: number of hanks in each 840 yards or 1 pound yarn . which is used for all filame nt yarns. This is because a yarn of low weight per unit of length would be finer than a yarn with a higher weight per equal unit of length. acrylic. cotton. There are two main numbering systems in use: 5. Color fastness to washing Color fastness to rubbing For color fastness to washing the fabric is washed with multi fiber strip which usually have 6-8 different fibers i. GURGAON Page 36 .1 YARN NUMBERING SYSTEMS Yarn are bought and sold by the pounds. The garment is washed with this strip and checked which fiber does absorb color most or least. polyester. The relationship between unit length and weight also reflects the diameter or thickness of a yarn. wool. 6. The denier system. The formula for calculating yarn count is Length of threads *number of threads*.4. 4.590 (constant) 100*weight RADNIK EXPORTS.Summer Internship Report 3. 7.

The formula for calculat ing flat GSM is given below: Weight Length*breath For actual GSM the special machine is used. Pick glass 7.4. 7. RADNIK EXPORTS. The length of yarns are multiplied by number of threads and by .Summer Internship Report For yarn count. y Supplier manual should be there in the lab for quick reference.warp per inch. EPI: Ends per inch. GURGAON Page 37 . Flat GSM (gram per square meter): A piece is cut then measured and weighed on weighing balance machine. y The reports should be maintained in box files of at least last 4 months. flat GSM is always more than actual GSM as this is the short cut method for calculation. then for weft count.weft per inch.590(which is constant) then divi ded by 100(to convert centimeters into meters) and by weight. This formula is used twice first for warp count. PPI: Pick per inch.2 CONSTRUCTION Construction: For yarn construction warp and weft are counted in 1inch length of fabric with help of pick glass. some yarns either warp wise or weft wise of same length are taken out then they are weighed on weighing machine. So it can be easily recognized that which side is what. Along the selvage usually yarns are more than the weft side.6 SUGGESTIONS: y The lab should be air conditioned.

RADNIK EXPORTS. There are four activities carried out in the cutting department: y Grading and marker making through CAD y Spreading y Cutting y Ticketing and bundling Cutting Manager is responsible for giving productivity of 6000 pcs/day. there are racks where cut parts as well as end bits are stored. It forms an important and integral part of apparel production. it could lead to a critical garment defect. CUTTING DEPARTMENT Cutting department was in the basement along with the fabric and accessories store. y Beside tables. So special care should be taken to cut the fabric. If the fabric is not cut as per the guidelines. The cutting in-charge has to keep eye on layer men and cutters so that the layering could be done properly and cutting pieces could be up to the measurements. The end bits are categorized according to their length and placed in different shelves. This will eventually lead to its rejecti on. Layer men are to lay the fabric. GURGAON Page 38 . which is done manually.Summer Internship Report 8. Some of the features were: y There are ten tables in the cutting room.

etc. total pieces cut. y Different fabric takes different time for layering and cutting. table number. buyer name. GURGAON Page 39 .Summer Internship Report y There is a display board at one end of the room which keeps record of pieces cut per day. While making time and action calendar. depends on its properties. the merchandiser should remember the properties of the fabric. lay number. RADNIK EXPORTS. target. It has details like style number.

8. marker planning according to the order ratio in CAD Issue of fabric through challan Spread fabric lay as planned Place marker on lay and also pin it if required to avoid slippage Cut solids if required and block cut for stripe and checks matching Band knife for small components Ticketing f defects found. part change Bundling R IK E P R R fd P ™ S g d™f e d™˜˜ — n n hip R po .1 PROC FLOW Manual Pattern making Digitization of the patterns Grading.

2 PROCESS OF SPREADING Before layering of the fabric a brown paper is used to spread on the table. All the patterns have information like: RADNIK EXPORTS. cutter and 2 helpers. two sides are taken as references for the layering of the fabric.3 CUTTING Round blade end cutters are used to cut plies at the end.Make sure if the fabric is very slippery. This ensures that the piece cut in that part requires recutting. From the four side of brown paper. includes paper or cotton cloth in between piles to avoid slippage.Summer Internship Report 8. .Flagging id done on the layers that denotes the defects on the fabric. The various defects that one looks out for during spreading are: y Weaving defects y Incorrect cuts y Stains y Holes y Torn fabric Spreading Precautions: . cotton is placed after every ten plies) .Marker is stuck on the top layer with the help of cellotape. .(in case of georgette. Each style/fabric is dealt among three people. GURGAON Page 41 . Big components and blocks are cut using straight knife while band knives are used for cutting smaller components.Spicling is done for single piece cutting 8.

Size: the size to which that component belongs to.Serial(denotes components from 1 ply) RADNIK EXPORTS. If there is some defect that has to be removed.Lot number .4 TICKETING After the parts are cut. . ‡ It is placed on the extra amount of fabric that is saved aside for partchange ‡ A whole new pattern is cut manually ‡ Sticker is removed from the defective part and stuck onto the new component ‡ New part is replaced in the bundle. all the patterns that have been cut are inspected to see whether an extra bit of fabric which signifies that there may be a defect in the pattern which needs to be rectified. 8. then part change is done as follows: ‡ Pattern is removed from the bundle. In the Cutting Department.Summer Internship Report y Style y Size y Name of component During part-change. there are 5 part-change checkers. GURGAON Page 42 . they are transferred to a different table and tickets are stamped on the fabric that bears information like .

pressure and time are set as per lining RADNIK EXPORTS. Lay wise 3. they are done in the cutting department only. Serial number 8. Barcoding is also done to keep a track of the efficiency during production. Bundle number 7. Color wise 2. Care needs to be taken to send all the components of the style together Bundling is done 1. GURGAON Page 43 .5 BUNDLING After the parts get their tickets and defective parts have been changed. Size 4. After the parts have been cut in blocks they are taken to the fusing machine.6 FUSING In cases where parts need to fused. Lot number 5. Total pieces 8. Color 3. Style number 2.Summer Internship Report 8. Machine temperature. Bundling information consists of: 1. Size wise 10 pieces were bundled together. Part name 6. they need to be bundled to be sent to the Sewing Floor.

p o mk P j S n kjm l kjii h n n hip R po rrq . Manual patterns developed in the sampling department by the pattern masters are digitized using the digitizer. it is tied and disposed on trolley. Post fusing. In the CAD room after the patterns have been made the marker is plotted and then sent to the cutting room. Transfer the piece to machine bed.1 P ROC FLOW IN CA : Size is specified. Alteration and grading of patterns on computer.7 CA Marker efficiency in patterns depends upon the difficulty of the style. 8.specification.7. R IK E P R R s 8. Marker making as per the requirement. A quality check is very important as a little mistake in the collar fusing could lead to its rejection or visibility of fusing material. the parts are re-cut with band knife. After bundle is over. Creation of data for marker Plotting of markers. after placing lining on fabric properly. sually it is tried to keep marker efficiency not less than 85%. or inadequate fusing could be a critical defect. Collecting and inspecting the fused parts at the other end of the machines the ne t step.

pleats. 2.No. 14. S. stretch. 12.  RADNIK EXPORTS. 8.2 ANALYZING USAGE OF VA RIOUS FUNCTIONS IN THE CAD SYSTEMS. 7. Criteria Digitization On screen pattern construction Notches option Dart manipulation Always Sometimes/ Occasionally Rarely Never Additional Comment     As and when required 5. 11. cut.Summer Internship Report 8. 10. trace. GURGAON Page 45 . Rotate pattern. flip. combine. 4. Grading tools Size correspondence Specification sheet development Piece assembly Variant tools Marker planning Plotting Piece rotation Measurement capabilities Pattern Design functions. 6.7. 3. 1. 13. shrink. Removing and adding patterns   Given by the buyer    15. 9.Darts.

8 MANPO ER: DESIGNATION Cutting Manager Cutting Incharge Assistant Incharge Cutters Layer men Bundling supervisor elpers NUMBER 1 1 1 3 4 1 6 8.9 MAC INERY Type machine Digitizer of Purpose To digitize the paper patterns and convert them to digital form. GURGAON t 1 4 Allys Graphtec Eastman 629X 1 4 2 Toniy Eastman Eastman DZ-1 EC-900 Page 46 . To plot the marker on paper Cutting of blocks and big components and marking notches Cutting of smaller components Cutting plies at the end To mark points (dart point.Summer Internship Report 8. pocket) through drilling Number 1 Make Accumark Model 16 digit mouse Plotter Straight Knife Band Knife End Cutters Driller RADNIK EXPORTS.

11 RECORDS MAINTAINED y Production File y Spreading and Cutting Checklist y Lay Slip y Cutting Plan y Ticket Register y Part Change Record y Bundling Information Record y Copy of challan received from fabric room and sent to sewing room y Cutting Record y Daily Cutting Report y Daily Cutting Quality Audit Report RADNIK EXPORTS.10 RELATIONS IP IT OT ER DEPARTMENTS y Quality Department: Quality Department takes care of the cut pieces quality in terms of quality. sewing room cannot start its operations.Summer Internship Report 8. y Sewing Department: Cutting Department feeds the sewing room. y Merchandising Department: Merchandisers need to be updated with the progress of the styles. smooth edges and measurement. y Production Planning Department: The PPC department provides the cutting room with cut plans and targets. GURGAON Page 47 . 8. Without the cut pieces.

K EMBROIDERY 9. GURGAON Page 48 . EMBROIDERY HAND WORK Radnik Exports outsources the embroidery work from small time vendors in and around Delhi.3 INSTRUMENTS USED IN ADDA y y y y y y y y y Frame Sequence Needle of MUTTHI ADDA SAMSERAK Thread Butter paper Colgate paste Elastic ORK RADNIK EXPORTS.Summer Internship Report 9. 9.1 NOMINATED VENDORS FOR EMBROIDERY y CHANDANI HAND EMBROIDERY y SABNAM y ASHIQUE ZARI WORK y R.2 NOMINATED VENDORS FOR AND ORK y MAHA LAXMI HAND WORK y MUSKAN HAND WORK y VARUN HAND WORK 9. When the embroidered pieces are brought in -house they are checked and inspected thoroughly before going into the production line.

Details are as follows: Production Unit Production Floor I (Floor I) Production Floor II (Floor II) Number of lines 4 4 (3 production lines + 1 sampling line) 10. RADNIK EXPORTS. Here. GURGAON Page 49 . the raw material in the form of fabric and accessories is converted into the final garment. Radnik Exports owns a well planned and efficient sewing floor.1 OBJECTIVES: y To stitch the cut pieces into garments as per the buyers specifications. SEWING Sewing Room is the heart of every export house. Unit 294 has two production units consisting of seven production lines and one sampling line.Summer Internship Report 10.

2 PROC FLOW: Receive bundles from Cutting section Bundle opening and counting of pieces Feeding to sewing line In-Line inspection.10. Assembly section Trimming End-line Inspection Garment sent to Finishing Department R IK E P R R zx P w S { xwz y xwvv u n n hip R po .

10.3 PROC FLOW: Lin s ttin Pre Production Meeting Decision Making: Line Selection Allocation of the operation to the operator according to the Operation bulletin Attachment set to the M/C according to the operation Cut Fabric and trims issued to the section Mock operation shown to the respective operator Operation is getting done by respective operator approval is taken from the A If approved. production starts If not approved. operator is trained or replaced R IK E P R R ƒ  P ~ S ‚ ~ € ~}} | n n hip R po .

GURGAON .Summer Internship Report 10.5 MAC INES: Type of machine SNLS(Single Needle Lockstitch) SNLS(Single Needle Lockstitch) SNLS with UBT DNLS(Double Needle Lockstitch) 3 Thread O/L Fusing machine Embroidery machine Flat lock Thread cutter Beads Feed up m/c Number 110 170 31 11 45 2 1 2 7 2 1 Make Juki Brother Juki Brother Juki + Yamato+Pegasis Hashima Local Brother Cleantag Juki Brother 2 2 Kansai Juki Page 52 Model DDL 8700-7 Sequin attachment Sequin attachment machine Button holing RADNIK EXPORTS.4 MANPO ER: DESIGNATION Production Manager Floor in-charge Line in-charge Operators(including floaters) Clerk Button holing and sewing operators NUMBER 1 2 8 361 2 10 10.

The stitching floor head in consultation with the supervisors and the tailors decides this target. Every hour production & defective pieces are record.Summer Internship Report Button sewing Button sewing(snap button) Smocking Elastic attachment 4 Juki 2 Kansai 10.6 FEATURES OF T E SE ING DEPARTMENT y Production System: Progressive Bundle System is used. y Inline quality checking: The process of stitching and checking of the stitched garments is carried out simultaneously. y Machine Layout: Zig zag flow: Material flow is in zig zag form. Checking ensures production of defect free garments and hence reduces the transfer of defects from the stitching department to the next department. RADNIK EXPORTS. y Pilot Run: Before starting of actual production a pilot run is run on lines. After approval of pilot run actual production starts. Every hour production & target is display in front of each sewing line on board. which is going to use the output of stitching department as its input. GURGAON Page 53 . y Target Setting: Each line has a target to achieve by the end of the day.

many barcode stickers are put on a card and the card is tied to the bundle. Those garments which are passed. Information is easily fed into the system and the production report is generated automatically. alter and reject.Summer Internship Report y Bar-code System: A sheet is provided to each operator and is maintained by the IE department for accountability of bundles and output calculation at the end of the day. GURGAON Page 54 . Every two hours. RADNIK EXPORTS. When an operator completes an operation on one bundle. Easy tracking of bundles 2. find place in accept shelf. Each barcode sticker corresponds to each operation to be done on the bundle. IE department uses the barcode reader to read information from the sticker. Automatic generation of production report 3. he takes off the sticker corresponding to the operation and puts it on his sheet. The hourly production report is prepared every two hours. When components are bundled together. Easy assessment of operator performance y End line quality checking: There is an end line quality checking table which has three shelves: accept. Advantages of bar code system: 1. The alter shelf has those garments that have defects that are to be mended by the operators and reject shelf has those garments which cannot be mended at that time but will be attended later.

Summer Internship Report 10. y Production Planning Department: Production Planning Department schedules the functioning of sewing department. 9.8 RECORDS MAINTAINED IN T E DEPARTMENT y Needle Issue Record y Material Record y Hourly Production Report y Daily Production Report y Daily Unit Report y Batch Production Report y Line Bottleneck Recording y Job Operator Card y Operation Specification Sheet y Daily Audit Report y Final Audit Report y Cutting Feedback Report y Mobile Inspection Report y Measurement Control Chart RADNIK EXPORTS. GURGAON Page 55 . y Finishing Department: Completed garments are sent to the finishing department.7 RELATIONS IP IT OT ER DEPARTMENTS y Quality Department: Quality Department takes care of the quality at each stage of sewing. y Cutting Department: Sewing Department receives its raw material from cutting department.

This department is responsible for the company s success to a large extent.Production Meeting Notes y Design Work Sheet y Fabric Reference Sample y Fabric Test Report y Garment Accessories Test Report y Accessories and Trim Card y Purchase Order Sheet y Fabric Order Sheet RADNIK EXPORTS. The industrial engineer determines which is the best machine to be used for a required process an also which is the best method for using the machine and training the operator to achieve maximum production efficiency. Once the Production. Along with the approved Pre Production sample. it instructs the IE department to prepare for setting up a new line on the floor.Summer Internship Report 11. INDUSTRIAL ENGINEERING Radnik s Industrial Engineering department is known to be the strongest part of the Export House. planning and control department gets the order file from the merchandiser. GURGAON Page 56 . the file is forwarded to this department with important documents like: y Production File Description y Pre.

IE department conducts time study and finds out the root cause.Hourly.1 OBJ C IV : y Making the Operation Bulletin y Conduct Time and Motion study y Prepare floor layout y Generate machine population report y Sale and purchase of machines y Monitor production control reports. Daily and weekly reports y Monitor finishing report y Monitor running cost y Monitor PERC report y Monitor needle report 11. R IK E P R R ‰‡ P † S Š ‡†‰ ˆ ‡†…… „ n n hip R po .11.2 PROC FLOW: Study of the approved sample Development of operation bulletin Line setting and line balancing If there is any problem in the production.

how much time is consumed in the start RADNIK EXPORTS.3 MAKING OF OPERATION BULLETIN: An operation bulletin comprises of: y Breakdown of operations y Number of machines y Number of operators and helpers y Types of machines used for each operation At the end of each day. This is done to keep track of the orders being made and to see how much production has been completed for different orders and how much is still left. requirement of more machinery etc.Summer Internship Report 11. a production report is generated on a daily basis. daily and monthly basis. Production scores are maintained on hourly. It is also done if the production department puts in a request for extra machines and at times when the production output of that particular style is not meeting the set targets.) 11. 11. Time study is done to determine how much time is consumed to do a particular operation in the garment.4 PRODUCTION REPORT IE Department also keeps record of the production that takes place in the different production units headed by different Floor -in-charges.g.5 TIME AND MOTION STUDY Time and Motion study is conducted when buyers ask for it or when an unknown style garment comes in for production. The production figures are compared with the production targets set for them by PPC and if the target is not being achieved then the reason for it is ascertained (for e. GURGAON Page 58 .

trims and accessories consumption Revise average of thread and trims 4.6 PROCEDURE FOLLO ED FOR LINE PLANNING AND SAMPLE MAKING 1. how much time is being wasted by the operators in eating. ii. iv. GURGAON . ii. drinking. 11. of lines for style Deciding the cutting start date Deciding the input date Per day production and cutting plan for meeting the shipment date 2.Summer Internship Report up losses and fatigue losses. Making pre-production sample i. Procurement of cut fabric and accessories Stitching of pilot sample Checking of pilot sample 3. operators and helpers required Page 59 RADNIK EXPORTS. Finalization of thread. iii. chatting. iii. going to toilets etc. Production plan for line (Planning manager) i. ii. Deciding the style Deciding no. and thus minimize these losses and hence increase the efficiency. Finalizing the sequence of processes in the style Deciding the number of machines. Calculating the manpower and machine requirements i. v.

v. Receiving pcs. iii. GURGAON Page 60 . vi. Production i. Production Machine setting according to operation breakdown and layout with allotted man power 6. v. iv. Button attachment i.7 RECORDS MAINTAINED y Production Report y Operation Bulletin RADNIK EXPORTS. To washing/finishing 11. Transfer to button attachment dept. Cutting 200 pc. cut after PPM 7. Line setting Feedback report for bulk cutting Ensure the cutting is ok or not in every lot Checking of output pcs.in line checking Audit after 100 or 200 pcs. ii. ii. 8. Pcs. iv. Button attachment Sent pcs. Calculating the SAM of the style Deciding the rate of pay for specialised operation Deciding the line in which the production will be done 5. iii.Summer Internship Report iii.

GURGAON Page 61 .Summer Internship Report y Thread Consumption Report y Deviation Report y Output and Input Sheet y Running Cost y Efficiency Report RADNIK EXPORTS.

y To check the measurements of the garments. FINISHING AND PACKAGING Finishing is the final process in the production cycle. y To trim threads. It is used to impart the desired look to the garment.12.2 PROC FLOW: Washing to remove spots and improve the feel of the garment Thread trimming Spotting Initial checking Ironing Measurement and final checking Tagging and folding Packing R IK E P R R P Ž  S ‘ Ž  ŽŒŒ ‹ n n hip R po . 12.1 OBJ C IV : y To impart the final look of the garment. y To attach different kinds of labels. 12. y To remove stains acquired during production.

GURGAON .Summer Internship Report 12.3 MANPO ER: DESIGNATION Manager Supervisors ashing workers Spotting workers Thread cutting workers Pressing workers Taggers Initial checkers Measurement checkers Final checkers Total NUMBER 1 4 7 2 19 12 4 7 2 2 59 ’ ’ “ 12.4 MAC INES: Type of machine Pressing Machines Purpose Make Ramsons Fabcare Renzacci Fabcare Fabcare Number 12 2 1 2 2 1 1 1 3 Page 63 Used for garment pressing ashing machine Used for removing (150 kg) spots Dry cleaning Used for washing using machine(18 kg) solvent ydroextractor(50 kg) Used for extracting excess water Tumbledryer(100 kg) Used for drying clothes Tumbledryer(100 kg) Spotting machine Boiler Used for drying clothes Ramsons Used for spotting Crest Thermax RADNIK EXPORTS.

In first cycle.Summer Internship Report Needle Detector Air Hashima Avero System 1 3 12.3 % : 5-7% : 10 -15% 12. garments are washed with plain water with silicon for 5 minutes.c For Polyester fabric : 2. There are spotting guns and spotting machines also which can be used for carrying out the above mentioned operation.0% for 10-20 min. In second cycle. Silicon Light weight fabric Medium weight fabric Heavy weight fabric Tumble Dryer Temperature: 50-60 . RADNIK EXPORTS.5 -1. The chemicals used for spotting are amyl.4 12.5 SPOTTING Spotting is done for stains which cannot be removed easily.4.c For cotton fabric 45-50 . garment is washed with non ionic detergent (surf excel) 0. WASHING CYCLE Washing generally is a process involving two cycles . GURGAON ” ashing AS ING Page 64 .1. acetone and solmet.

12. GURGAON Page 65 . They are hanged or folded and kept into plastics. 12. 325 mm wide. 428 mm high y Half-height.7. 12.1 CARTON SIZE AND WEIGHT The commonly used carton sizes are: y Full height.2 CARTON SEALING The following two methods of sealing of cartons is followed:y Using tape of not less than 7 cm. Garments are folded according to the buyer specifications. RADNIK EXPORTS. They must also offer proper protection to the garments during shipment.560mm long. y Cold or hot gluing.Summer Internship Report The chemicals are applied by local application .7. 12. Now-a-days the stain removers are applied through spray guns on the stained part. wide.560mm long. Stain remover is applied on the stain itself and rubbed with soft fabric. 325 mm wide. 214 mm high 15 kgs is the standard weight of all the cartons.6 TAGGING AND FOLDING The garments are tagged using the tagging guns and the labels are also attached as per the requirements of the specific garment.7 PACKING The product must be supplied in adequate cartons which are appropriate according to the style and fulfill the purpose.

8 AQL ROOM The AQL room is the last and one of the most important steps in the finishing process. Then the garments are checked according to AQL level of 2.5 2.9 REPORTS GENERATED y Final Packing List y Weekly Rejection Report y Packing list y Shipment Record y Needle Calibration record y Packing Record RADNIK EXPORTS.5. the garments are passed through a needle detector machine. From here the garments are finally dispatched.5 0 0 0 1 1 1 1 2 2 3 3 5 5 7 4.0 1 1 2 3 5 7 10 AQL room is a metal free zone and no metal objects are allowed inside. 12. Single sampling method is used and the following is the AQL table:- Lot Size 2-50 51-90 91-150 151-280 281-500 501-1200 1201-3200 Sample Size 8 13 20 32 50 80 125 Acceptable Quality Level 1.Summer Internship Report 12. GURGAON Page 66 . Here. The garments are sent for checking if metal is detected in the garment.

Summer Internship Report y Requisition for polybag y Daily finishing of line inspection Report(Refer annexure 6) RADNIK EXPORTS. GURGAON Page 67 .

inspections at various le vels of production and at other stages is followed. QUALITY Quality is the utmost important thing to be taken care of. In this process. For this. Defective pieces involve undoing and redoing processes which involve the unnecessary use of the following resources:  Manpower  Time  Material  Money  Power/machinery 13.1 OBJECTIVE: Quality department is responsible for the correct methods of producing garments. No process can achieve the level expected by the customer without taking quality into account. it is their responsibility to rectify it. Quality assurance plays a vital role in the economic production while the goods are being produced right first time. RADNIK EXPORTS.Summer Internship Report 13. GURGAON Page 68 . quality department people have to inspect each & every step involved in the production and if they find any discrepancies.

Checking of lay. R IK E P R R š˜ P — S › ˜—š ™ ˜—–– • n n hip R po . Inspection of fabric after dyeing or printing. marker and patterns before cutting.13.2 PROC FLOW: Greige fabric checking.

Summer Internship Report

13.4 MANPO ER:
DESIGNATION Quality ead Finishing QA Sewing QA Cutting QA Line Quality Controller Checkers Total NUMBER 1 (for both unit) 1 1 1 (for both units) 9 25 38

13.4.1 QUALITY ASSURANCE OFFICER:

y In charge of the quality issues that occur on every floor y Decides where the critical points are and what could be the possible areas of defects along with the floor in-charge. y Supervises the Quality Controllers as well as the Inline and Endline checkers. y Performs Daily Audit Report on finished garments of all the styles on a regular basis. y Necessary actions are taken if the defect % is high.

13.4.2 QUALITY CONTROLLER: y Looks over the quality issues of his line. y Fills in the cutting feedback in The Cutting Feedback Report each time he receives garment bundles from the Cutting Room. y Fills in the basic details about the style (style no, color, number of bundles, number of pieces received, etc). If any mistak es are found which need to be rectified, he gives his remarks in the Correction in
RADNIK EXPORTS, GURGAON Page 70

œ

Summer Internship Report

Cutting column. This report helps in avoiding confusions and misinterpretations between the Cutting and Sewing Rooms. y Performs the mobile/ random inspection and checks the q uality of goods being made by the operators. He fills a Mobile Inspection Report for this. y The stitched garments are collected from each operator and checked for defects. The defective piece found is returned back to the operator who stitched it so that he learns from his earlier mistake and produces goods RFT (Right First Time).
13.4.3 QUALITY C ECKERS:

y Perform inspections y Check for defects and fill the formats. y Present at the end of the line on the sewing floor.

13.6 RADNIK S QUALITY POLICY
The Management of Radnik Exports is committed to the satisfaction of its customers by providing quality garments at the right time and at the right price.

It is also committed to provide a healthy work environment for its employees by adhering to health and safety norms and by creating an efficient work culture. To be a reliable partner to our clients, working closely with them to deliver quality that is just right, in style on time.

RADNIK EXPORTS, GURGAON



Page 71

Summer Internship Report

13.7 QUALITY INSPECTIONS
13.7.1 FABRIC AND TRIMS INSPECTION The fabric is received in the form of rolls and folds. First of all, shade segregation (lotting) is done (in case of dyed or printed). Then, 100% inspection is done. There are three types of stickers used for marking defects. y Green : defects that can be mended y Yellow: stain y Red: defects that cant be mended 4 point system is used for fabric inspection:

Size of defect 3 inches or less Over 3, but not over 6 Over 6, but not over 9 Over 9

Penalty 1 2 3 4

Major defects are classified as follows: Major woven fabric defects are slubs, hole, missing yarn, conspicuous yarn variation, end out, soiled yarn, wrong yarn, dye or printing defects, dye spots, burr mark slackness, open reed, smash, contrast yarn, bowing crease mark, streaks, skews etc. Once the trims are in housed, a random checking is done. First, the sizes and specifications of the trims are matched with the ones on the trims card. Then samples of each type of trims are checked for quality as well as quantity. The quantity of the trims is also checked. Lab testing (like testing button pull
RADNIK EXPORTS, GURGAON Page 72

the operator is informed and instructed and the operation is inspected every hour until there is no fault in continuation. 13. GURGAON Page 73 . If it is not correct. lay length and spreading way is checked. These rejected pieces are sent back to the vendor for debit or replacement. QC does random inspection for all the operations in whole day. and correct placement of panels. At least one time inspection is mandatory for each operation in every hour. marker and patterns are checked.Summer Internship Report strength. Markers are checked for number of patterns. 13.7. There are three bins below the inspection table: Accept. The checkers put the garments after RADNIK EXPORTS. width of the plies. regularity and proper size ratio. Inspection is carried out at top ply. Then a physical checking of the whole lot takes place where each individual piece is physically checked for defects.4 E ND LINE INSPECTION After stitching. 5 pieces are checked each time. Lay height. If an operation is ok. balance. symmetry.2 CUT P ARTS CHECKING The lay.7. There are two checkers per line who inspect all garments for proper stitching. it is checked after an interval of two hours. middle & at bottom ply. After cutting. 13. every component from a lay is inspected for measurement & notch size. Alter and Reject.3 INLINE INSPECTION One QC is employed for one sewing line. Trims that do not meet the acceptance level are rejected and separated from the rest.7.) is also done if specified by the buyer. snap fastener testing and thread testing etc. there is 100% inspection of all garments.

Alter bin has those garments that are having sewing defects.5 0 0 1 1 2 3 5 Acceptable Quality Level 2. These defects are corrected by the operators in the line only when they are idle or waiting for next bundle. Defects are corrected in the department only. Most common defect encountered during this stage is stain. stains are spotted.0 1 1 2 3 5 7 10 RADNIK EXPORTS. It is mainly done to find out if there is any defect acquired during the finishing processes.5 F INISHING INSPECTION This is the last 100% checking carried out in the export house. GURGAON Page 74 . Accept bin has all those garments that are flawless and have passed the checking.5 Lot Size 2-50 51-90 91-150 151-280 281-500 501-1200 1201-3200 Sample Size 8 13 20 32 50 80 125 1. staining and other minor defects that are easily repairable.6 AQL INSPECTION Single Sampling method is used. 13.5 0 1 1 2 3 5 7 4. The AQL level followed at Radnik Exports is 2.7. Reject bin has garments that need part change.Summer Internship Report checking in suitable bins. 13.7. and weaving defects are mended. There are operators for correcting the sewing defects.

13. Most common faults are open seams and uncut thread.Summer Internship Report If the audits fail to pass the required AQL. GURGAON Page 75 .8 REPORTS MAINTAINED y Fabric inspection record y Daily cutting quality audit report y Quality audit report y Daily mobile/inline checking record y End line reports (Refer annexure 7) RADNIK EXPORTS. then the whole lot is rechecked.

1 OBJECTIVE: y Purchase of new equipments related to computers. IT DEPARTMENT ERP system is customized service which helps in maintaining central information system where. y Talking and negotiation with the vendors and updating of software called TEX NET NIRYAT y Ensuring the proper functioning and maintenance of FastReact. 14. GURGAON ž Page 76 . if any communication betwe en any department happens it passes through the server database and a copy of it is stored and can be retrieved when required. There is a server room in unit 294 which takes care of the software and inter departmental communications of both the units. 14. scanners and cartages.2 MANPO ER: DESIGNATION OD Assistant Manager Staff Total NUMBER 1 1 4 6 RADNIK EXPORTS.Summer Internship Report 14. UPS. y Maintenance and ordering of any computer related accessories.

y All the computers are connected through LAN and any communication is processed at the server room. GURGAON Page 77 . One is for department. and third copy is for the vendors. y Annual maintenance charges are paid for the yearly maintenance of software. RADNIK EXPORTS.Summer Internship Report y 3 copies of the purchase order are prepared. y FASCINATION INFO situated in Noida had provided the customized software according to requirements of Radnik group and if there any addition of columns or instruction is done the vendors are consulted for this act. another is with guards.

3840. GURGAON Page 78 .2. The minimum wage of the factory is Rs.1 THE 5 S S:  Seiri (SORTING) Role: -Get rid of unwanted items -Decide what to keep & what to discard Key Technique: Red Tagging  Seiton (ORGANISE) Role: -Everything has a place and everything in its place RADNIK EXPORTS. 15.Summer Internship Report 15. ensure adherence to standards and foster the spirit of continuous improvement.2 5S The 5S s are a group of techniques to promote workplace organization. 15.1 OBJECTIVES y Interviews y Induction y Record Maintenance y Performance Management y Training and Development 15. HR DEPARTMENT HR department is responsible for the care of the employees of the organization at a personal level.

Key Technique: Visual Management (Indicators & Controls)  Shitsuke (SUSTAIN) Role: -To sustain improvements and make further improvements by effective use of PDCA (Plan.2 5 S ROADMAP ‡ Divide the factory into small Zones ‡ Choose Zone Leaders ‡ Establish a 5S policy & display RADNIK EXPORTS. Check.2. GURGAON Page 79   Ÿ . Act) Cycle Key Techniques: . Do.Continual 5S promotional activities .Summer Internship Report -Locations and quantities clearly marked Key Technique: Sign Boarding  Seiso (S INE & S EEP) Role: -Clean and discover abnormalities Key Technique: Physical sweeping and cleaning  Seiketsu (STANDARDISE) Role: -Consolidate first 3S by establishing standard procedures -Determine the best work practices and ensure that everyone does it the Best way.Auditing -Reward & Recognise -Training 15.

A few of the questions frequently asked are: y Employee s record. ‡ Develop a suggestion scheme ‡ Develop draft 5S implementation plan and agree resources.3 COMPLIANCE The HR department looks after the compliance requirements of the buyer . y Factory regulations. 15.Signboard strategy team ‡ Develop zone specific 5S improvement plan ‡ Prepare Audit sheets & Do Fixed point photography ‡ Identify the problems ‡ Make radar charts for assessment of zone ‡ Make improvement plan ‡ Start 5S story board.Summer Internship Report ‡ Establish the company objectives from 5 S ‡ Establish a Steering group ‡ Give training on 5S to senior management. The team informs the buyer about the various practices.Disposal of documentation . y Attendance record. RADNIK EXPORTS.Disposal of equipment . There are various aspects which the buyer wants to enquire. GURGAON Page 80 . policies and infrastructure of the company. ‡ 5S Zone leader training ‡ Determine and agree scope of activities ‡ Develop 5S sub-advisory group for : .

y Worker s right. fire. GURGAON Page 81 . 15. y Business registration. y Safety (building. first aid). y Organization chart with the number of workers in each section. y Factory conditions. y Child labour.4 RECORDS MAINTAINED y Employee list y Absenteeism list y Wages list y Overtime list RADNIK EXPORTS. y Environment departments approval. y Wages and working hours. y Local legal minimum wages. y Production machine list. y Housing conditions (factory provided accommodation) y Environment.Summer Internship Report y Insurance certificate.

Summer Internship Report 16.1.1 OBJECTIVE To Standardize the process of the sampling department in order to utilize its total capacity 16.1. GURGAON Page 82 .3 SAMPLEA sample is the representation of the bulk which the factory produces 16.1.4 SAMPLINGy The process of making the representation is called sampling RADNIK EXPORTS.1.2 MET ODOLOGYy Listing the as is process y Obtaining sampling data for inference y Determine the to be process y Implementation of the new process y Inspection of the new process 16.1 PROJECT 1 16. PROJECTS 16.

Manufacturing difficulties.6 TYPES OF SAMPLESy Proto Sample /Development Sample y Pre Salesman Sample y Sales Sample y Fit Sample y Pre Production Sample y Sealer Sample y Photo shoot/Advertisement Sample y Size Set Sample RADNIK EXPORTS.5 IMPORTANCE OF SAMPLINGy Samples decide the ability of an exporter y It is equivalent to a Research & Development department in a unit y Exporter can estimate 1. GURGAON Page 83 .1. 4.Summer Internship Report y It maybe done by selecting items from a production lot for samples after the production starts 16.1. Optimize the processing parameters for mass production 16. Fabric consumption 2. Idea on costing 3.

1.8 A IS PROC SS B ING FOLLOW DEPARTMENT B i f p o ss flo R IK E P R R © ¨ Operators(16 Pattern masters(3) ¦¤ Sampling incharge A(2) Cutting masters(2) £ S § ¤£¦ ¥ ¤£¢¢ ¡ n n hip R po IN SA PLING P .y Top Sample y Shipment Sample 16.7 WORKFORC Sampling coordinator 16.1.

Merchandiser gives sample requisition form to the Sampling In-charge and Co-ordinator Sampling Incharge and Sampling Co-ordinator plan the Sampling Process and Needs Pattern Master makes the basic with the specifications given in the tech pack which goes for buyer approval Samples are sent back to the Merchandiser for buyer approval with suggestions and changes(if any) Samples reviewed by the Sampling A Approved patterns are cut.harge y Gets complete details and raw materials from the respective merchant y Receives sampling priorities from the AGM/Planner and acts accordingly y Responsible for the planning of lines for sampling production y Receives complete production details which has to be conducted in the sampling department y Represents the sampling department in pre-production meetings R IK E P R R ± ¯­ P ¬ S ° ­¬¯ ® ­¬«« ª n n hip R po . sewing (washing.9 ROLES & RESPONSIBILITIES OF SAMPLING IN-CHARGE AND CO-ORDINATOR Samplin In. . printing .embroidery outsourced if needed) 16. feeding cutting .1.

GURGAON Page 86 . "what" and "how" of washing and follows it up with the washing/ printing/embroidery company y He makes the delivery chalan for the garments to be sent for washing.1.Summer Internship Report Sampling co-ordinator y Gets complete details and raw materials from the respective merchant y Reverts back to the merchant if any details are missing in the sample requisition form y Helps out in the planning of lines for sampling production y Collects all the information regarding "when". printing.10 FLA S IN T E AS IS PROCESS y NO standardized process flow y NO visibility of the month s plan or the available capacity y NO defined owner(decision maker) present at any stage RADNIK EXPORTS. embroidery Flaws in Roles of Sampling In-Charge and Co-ordinator y Duplication of responsibilities y No organized bifurcation of their responsibilities y Working in tandem with No particular assigned authority responsible for sampling department 16.

4 705. GURGAON ² ³ ³ ³ Current plan 1.16 26 23.11 EVALUATION OF T E CURRENT SAMPLING PROCESSCurrent sampling plan Total Number of days Total Number of orking days Average Tailors Present Total Man ours ( Regular + Overtime) Total Man ours Tailors ( Regular + Overtime) Total Man ours Tailors ( Regular) Total Pieces generated Total Pieces generated in regular hours by tailors Productivity (Sampling pieces per Tailor per day) 30 26 23.16 Page 87 .4 26 23.34 Our capacity 2.3398295 1.4 1460.Summer Internship Report y NO clear definition of the roles and responsibilities of the Sampling In Charge and Co-ordinator 16.159335683 16.1.4 7807 4926 3608 963 705.12 A COMPARISON Pieces per tailor per day Total working days Average tailor present Pieces produced in regular hours RADNIK EXPORTS.1.

13 SUGGESTED PROCESS Standard Sampling Plan y Inputs by merchants/planners the Co-ordinator. GURGAON Page 88 . y Sampling processes arranged priority wise Visibilityy Standard sampling plan provides visibility of the sampling schedule to the In-charge y Available capacity can be allotted to the production department.Summer Internship Report Difference in Pieces Produced1460 705 = 755 sampling pieces Result of this Differencey Wastage of Sampling Capacity y Monetary loss due to more Overtime y Delaying of Samples y Production suffers as well 16. y Made with the knowledge of the sampling capacity .1. RADNIK EXPORTS. y The Co-ordinator ensures the plans are received a month in advance y Schedule for the coming month devised. y To be designed by the In-charge.

Summer Internship Report y In case the In-charge feels that the workforce is insufficient to carry out the sampling plan he can approach the H R department.1.1 To be Role of Sampling Co-ordinatorMAIN FUNCTION y Sampling Co-ordinator keeps the sampling capacity 100% utilized all the time y Plays the link between the merchant/planner/factory head and the sampling in-charge SUB-FUNCTIONS y Ensures that the plan for the new styles are received at least a month earlier failing which he reports to the marketing head/AGM y Gets Plans in case of Size Set(which maybe received from the merchant) y Gives the details received from merchant and reverts back to the respective merchant in case of missing data y Asks for production pieces that can be undertaken in Sampling Department as a result of excessive sampling capacity available y Reports to him in case of overlapping schedules to get priorities 16.2 To be Role of Sampling Incharge y Gets the Work Order from the him and informs him in case of available capacity or any other problems in sampling RADNIK EXPORTS.1.13. GURGAON Page 89 . y Overtime can be decided by the In-charge if required y In case of overlapping schedules the PPC department can be informed 16.13.

decides the needs for Overtime y Informs them in case of a shortage of man power for completion of work y Manages the material to what . where and how for the samples to be sent for washing. printing and embroidery 16.y Responsible for the planning of sample production on the basis of capacity and priority.1.1.13. This can be done by allotting separate and distinct roles and responsibilities to the sampling incharge and the co-ordinator. The sampling R IK E P R R » ¹· P ¶ S º ·¶¹ ¸ ·¶µµ ´ n n hip R po .3 Defined Owner at each Stage y Sampling In-charge and Co-ordinator follow their listed roles and responsibilities y Sampling Head: Oversees the proper e ecution of their roles and responsibilities 16.14 CONCL SION The analysis of the capacity of the sampling department and its comparison with the present productivity shows that the sampling department will start producing around 750 pieces per month more if it starts working to the full of its capacity.

2 PROJECT 2 . manufacturing costing. its rate. if went through these changes. y Comparison of pre and post costing of a particular style y Obtain solutions in case of heavy losses (if any) y Help the company to decide upon the cost of the garment prior to its production y Gives a clear idea of where exactly measures have to be taken to ensure maximum profit 16. will surely be able to utilize its resources to the best of its capacities.e Marks & Spencer to have a clear view y Study of the fabric.COMPARISON OF PRE AND POST COSTING OF DIFFERENT STYLES AND CALCULATION OF ASTAGE 16. being a bit unorganized. consumption will give us the fabric cost RADNIK EXPORTS.2 MET ODOLOGY: y Preparation of excel sheets showcasing the fabric costing. GURGAON Page 91 . 16. wastage and a comparison of pre and post costing y The styles studied were of the same buyer i. trims costing.2.1 OBJECTIVE: y To study 4 styles of the same buyer and calculate the losses incurred due to wastage in the different manufacturing processes.2.Summer Internship Report department.

damage. its bulk rate will lead us to the total trims cost.ECT 155 : it was a dress of fabric type cotton dobby white. etc. y Cost incurred due to stitching. GURGAON Page 92 .2. This waste could occur due to mishandling. embroidery. washing. quality checks. inappropriate completion. It was embroidered in the front with shell buttons.3 STYLES STUDIED: . Fabric Costing RADNIK EXPORTS. 16. finishing(CMT cost) y Finally the quantity which is received after every process finishes gives us the cost incurred due to waste.Summer Internship Report y Various trims used per garment.

GURGAON Page 93 .Summer Internship Report Costing of Trims RADNIK EXPORTS.

Manufac uring Cost R IK E P R R Á¿ P ¾ S  ¿¾Á À ¿¾½½ ¼ n n hip R po à .

Summer Internship Report Calculation of wastage during the Manufacturing processes: RADNIK EXPORTS. GURGAON Page 95 .

Summer Internship Report

Pre V/s Post Costing Sheet

Graph showing the pre and post costing

RADNIK EXPORTS, GURGAON

Page 96

Summer Internship Report

Style- C DR 12 Fabric Costing

Trims Costing

RADNIK EXPORTS, GURGAON

Ä

Page 97

Summer Internship Report

Manufacturing Cost

RADNIK EXPORTS, GURGAON

Page 98

Summer Internship Report Wastage Calculation: Pre V/s Post Costing Sheet RADNIK EXPORTS. GURGAON Page 99 .

Summer Internship Report Plotting the same on Graph Style BBDR 10 Fabric Costing RADNIK EXPORTS. GURGAON Page 100 .

Summer Internship Report Manufacturing Cost RADNIK EXPORTS. GURGAON Page 101 .

GURGAON Page 102 .Summer Internship Report Trims Costing RADNIK EXPORTS.

Summer Internship Report Wastage: Pre and post costing RADNIK EXPORTS. GURGAON Page 103 .

Summer Internship Report Graph: Style AG 237 Fabric Costing RADNIK EXPORTS. GURGAON Page 104 .

Tri s Costing R IK E P R R ÊÈ P Ç S Ë ÈÇÊ É ÈÇÆÆ Å n n hip R po Ì .

GURGAON Page 106 .Summer Internship Report Manufacturing cost: Wastage: RADNIK EXPORTS.

Summer Internship Report Pre and post costing Graph: RADNIK EXPORTS. GURGAON Page 107 .

Summer Internship Report 16. y Special training should be given to those workers to obtain maximum efficiency. They did not segregate the cost of stitching. y In case the order is delivered through ship and pre costing has been according to shipment through air. Due to its color bleeding it lead to maximum wastage.4 CONCLUSION: y The maximum advantage that Radnik got was taking the CMT cost as Rs. RADNIK EXPORTS. It spoiled the entire garment which lead to big losses for the company. finishing and cutting differently.2. They never manipulated or hinder that cost in their pre costing sheets which were sent to the buyer. Special care had to be taken to e nsure better productivity and quality from the laborers. Precautions should have been taken in the testing of the lace before stitching it to the garment. this also adds ups to the profit that the company can have. y Though it was seen that the embroidery and beading had a lot of wastage. They had accumulated all that cost. 135. y Profit can be calculated by subtracting the total pre cost of the order from post cost of the order. y In style CHDR 12 which had a lace works in the front. GURGAON Page 108 .

RADNIK EXPORTS. We got an idea which area was the most beneficial of all. both pre and post. GURGAON Page 109 .Summer Internship Report Through this project we got a clear idea as to how costing is done. which department brought maximum profit and we could identify which areas needed solutions to avoid wastage.

It is of lurex brown color from coats (I9680). 2010 through mail stating the following: .1. .Trim information: 80s sateen 184 X 104.Target price: 4.Fabric information: yarn dyed check 2/80 X40/104X72. (Refer annexure 8) SAM 7045 Country of buyer buyer Garment description: Fabric details .05 euros . SAM 7045 17. Trim should be matchin g the check. ORDER TRACKING: 17. A specification sheet was attached with a digital photograph of the garment.Summer Internship Report 17.Knits/wovens/solid dyed/yarn dyed/print* Fabric description: Order quantity/original delivery date: United Kingdom NEXT Ladies shirt 100 % cotton yarn dyed yarn dyed check 2/80X40/104X72 7600 pcs Date RADNIK EXPORTS.Order quantity: 7600 pcs .1 MERCHANDISING DEPARTMENT The order was received on 21 st April.1. GURGAON Page 110 .

Summer Internship Report Activity Description Date buyer meeting (sampling request+specifications received) Date FIT samples were sent to the buyer Date comment (approval/rejection) received from the buyer Date Order Confirmation (Col+Qty+Delv+Price) Date size set were sent to buyer Date comment on size set from buyer Date of revised size set sent to the buyer Duration of size set 2nd iteration (steps 5 .8) Duration of lab dip 2nd iteration(steps 7 .8) Date first lot finished fabric received in store Date bulk fabric (from first lot) sent to buyer for colour approval Date bulk fabric colour (approval/rejection) received from buyer Date of embroidery thread sent for approval Date of accessories order placed Date of twill tape approval Date of approval of price tags Date of labels approved RADNIK EXPORTS.6) Date lab dip were sent to the buyer Date comment (approval/rejection) on lab dip from buyer Duration of lab dip 1st iteration(steps 7 . GURGAON On 21st April 10 Remarks 5th may 7th may 15th may 17th may 19th may 22nd may 3rd may 6th may 19th may 20th may 15th june Late reply from the buyer 4th may 18th may 31st may 14th june 28th june Page 111 .

Summer Internship Report Duration cutting Duration Sewing Duration washing (if applicable) Date production piece sent to buyer Date goods out of factory (in exporting country) 2nd july 15th july 3rd july-22th july 5th july 28th july 17.1.1 m) Fabric package type Rolls No. of pins used 2 Use of pins No Use of paper between layers No Table height 38 Table width 60 Table length 12 m Table top type wooden Working condition Lights per sq. m 4 Fans per sq.2SPREADING DEPARTMENT Fabric Yarn dyed check cotton Fabric width 113(Total) 110(Cuttable) Yarn dyed Fibre content 100% cotton Nap Either way Spreading mode FEW NEW Lay Length Size 12-14(8. of clamps used 2 No. m 4 Height of light from cutting table RADNIK EXPORTS. GURGAON 10 Page 112 .

Summer Internship Report

Lay no. 2 Lay height 4 cm No. of fabric layers 100 Marker type CAD Time duration in min 1 hr 30 min No. of layers 100 Spreading operators 3

17.1.3 CUTTING DEPARTMENT

Marker mode 2-way No. of patterns per garment 31 Marker length Size 12-14 (2.98 m) Size 6-20 (3.14 m) Type of cutting machine Straight knife, Band knife (Fusing) Model Blue Streak 2 Blade length 8 Type Straight Average blade life 2 days Block cutting Table height 38 Table length 12 m Table width 60 Table top type wooden Lay no. 2 Lay height 4 cm No. of fabric layers 100 Marker type CAD Time duration in min. 240 min No. of patterns cut 62
RADNIK EXPORTS, GURGAON Page 113

Summer Internship Report

No. of notches 30 Cutting master 1

17.1.4 TIME STUDY:
S.N O 1 2 3 4 Operation Machine 1 47 59 58 50.3 2 50 67 60 50 Time 3 49 62 59 50 4 47 65 63 50 5 43 60 62 50 total Avg Time 47.20 60.60 60.40 50.3 SAM

Mark collar collar Trim collar Turn and edge stitch at collar Pick stitch at collar Crease mark collar band Attach band to collar Mark flap for R/S R/S flap with insert loop Turn nailing flap T/S flap Zig Zag at Flap Joint and recutting piping Sew waist cord Gather at pocket opening attach piping at pocket & close piping Tack dori at front side Sew princess seam at bottom Sew empire seam at bottom Attach side panel to center panel(back) o/l attaching (back) o/l attaching (front)

manually Single needle edge cutter manual UBT

236 302 302 251.5

.79 1.01 1.01 .84

5 6 7 8 9 10 11 12 13 14 15

P/S/M/C manual S/N/E/C manual S/N/E/C manual S/N Zig ZAg S/N/E/C snls snls

24 65 105 68 59 70 76.3 37 56.1 26.6 157. 6

24 63 101 67 60 69 76.3 37 56.1 26 150

22 60 110 66 63 70 76.3 36 56.1 26.4 155

25 61 108 68 61 68 76.3 38 56.1 25.1 154

23 63 106 70 59 72 76.3 37 56.1 25 157

118 312 530 339 302 349 381.5 185 280.5 133 788

23.6 62.4 106 67.8 60.4 69.8 76.3 37 56.1 26.6 157.6

.39 1.04 1.77 1.13 1.006 1.16 1.27 .62 .94 .44 2.63

16 17 18 19 20

UBT Snls snls snls o/l

84 115 116 88 32 60

80 102 112 90 34 63

77 113 115 85 36 62

79 114 111 83 37 61

82 108 113 87 35 60

402 552 567 433 174 306

80.40 110.4 113.4 86.6 34.8 61.2

1.34 1.84 1.89 1.44 .58 1.02

RADNIK EXPORTS, GURGAON

Page 114

Summer Internship Report

21 22 23

24 25 26 27 28 29 30

31 32 33 34 35 36 37 38 39 40 41 42 43 44 45

46

47

t/s at princess & empire seam t/s at lower panel (back) Pick stitch at back lower Pick stitch at front yoke Pick stich at princess & empire seam Att front yoke o/l front yoke Gather at front frill Gather at sleeve top Attach placket at front E/S and close plkt Pick stitch at front plkt Pick stich @shoulder & back yoke Att back yoke at back Crease and press pocket Att pkt AT FRONT Att pkt @front Join shoulder Trim collar for attc Attch collar @ neck Finish collar T/S @ back yoke T/S @ shoulder Att sleeve Overlock @ sleeve Sew side seam Tack elastic @sleeve Close sleeve Att tunnel front + back Finish tunnel Att tunnel front & back Finish tunnel Attch w/c label & tack front loop

D/N D/N P/S/M/C

110 45 44 25

116 41 44 22 75 36 25 28 37 135 172 62 54 54 127 285 242 90 78 111 128 56 93 64 85 98 114 270

112 42 43 20 106 32 24 24 36 139 170 72 58 58 140 280 250 92 86 113 130 54 91 66 88 100 114 265

115 41 45 23 81 35 26 26 37 130 160 68 58 58 135 287 246 88 85 118 124 53 95 70 91 98 116 268

113 40 45 24 75 33 25 27 36 130 165 70 58 58 130 278 245 95 87 123 125 55 92 67 90 101 112 263

566 209 221 114 418 172 125 134 184 662 835 342 283 283 662 1406 1235 452 430 595 626 272 463 331 444 493 566 1328

113.2 41.8 44.2 22.8 83.6 34.4 25 26.8 36.8 132.4 167 68.4 56.6 56.6 132.4 281.2 247 90.4 86 119 125.2 54.4 92.6 66.2 88.8 98.6 113.2 265.6

1.89 .70 .74 .38 1.39 .57 .42 .45 .61 2.21 2.78 1.14 .94 .94 2.21 4.69 4.12 1.51 1.43 1.98 2.09 .91 1.54 1.1 1.48 1.64 1.89 4.43

P/S/M/C UBT 3 thread D/N Snls UBT D/N P/S/M/C Snls Snls manual UBT Snls Snls S/N/E/C Snls Snls Dnls Snls 5 thread 5 thread snls Snls Snls

81 36 25 29 38 128 168 70 55 55 130 276 252 87 94 130 119 54 92 64 90 96 110 262

Snls

237

238

235

240

239

1189

237.8

3.96

Snls

85

80

83

84

81

413

82.6

1.38

RADNIK EXPORTS, GURGAON

Page 115

(Refer annexure 9) 17. GURGAON Date On/From 12/11/09 03/03/10 26/03/10 To Page 116 . ironed and packed.Knits/wovens/solid dyed/yarn dyed/print* Fabric description: Order quantity Marks & Spencer Women s check shirt with belt Yarn dyed Poly Georgette 100% polyester 12082 Activity Description 1 Date buyer meeting (sampling request+specifications received) 2 Date FIT samples were sent to the buyer 4 Date Order Confirmation (Col+Qty+Delv+Price) RADNIK EXPORTS.29 17.2. Only one garmen t could be in the polybag with 50 garments packed in a carton of size 15X10X12 size. The packing details were followed as prescribed by the buyer.1 MERCHANDISING DEPARTMENT Buyer Garment description: Fabric details .1.Summer Internship Report TOTAL M/C= 44 TARGET/HR= 34 PCS TOTAL SAM 75. The garments were to be packed flat in a polybag.5 FINISHING AND PACKAGING After sewing.2 ECT-158 17. the garments were finished.

2. Liability charged.Summer Internship Report 5 5 6 7 6 7 8 9 Fabric demand note Date first lot finished fabric received in store Sealer sample-comments received Approval Duration cutting Duration Sewing Date production piece sent to buyer Date goods out of factory (in exporting country) 01/04/10 24/04/10 28/04/10 06/05/10 17/05/10 18/05/10 01/06/10 15/06/10 30/05/10 10/06/10 y Fabric Average 1. y Buttons were changed to shell buttons.80 (based on buying sample) 1.50 y Order delayed due to late reply from buyer regarding fit samples (Refer annexure 10 for techpack).55 (actual) 1.2 SPREADING DEPARTMENT Fabric Poly Georgette Fabric width 155(Total) 139(Cuttable) Yarn dyed Fibre content 100% polyester Nap Either way Fabric detail 100% polyester yarn dyed check georgette (blue mix) Spreading mode FEW NEW RADNIK EXPORTS. y Belt was removed. y Retail price tag changed from £35 to £24. 17.77 (due to fabric rejection) y Style changed to full sleeve. GURGAON Page 117 .

Band knife (Fusing) Model Blue Streak 2 Blade length 8 Type Straight Average blade life 2 days Block cutting Table height 38 Table length 12 m RADNIK EXPORTS.3 CUTTING DEPARTMENT Marker mode 4-way No. of patterns per garment 16 Marker length Size 12-14-16-18 (7. of clamps used 2 No.Summer Internship Report Lay Length Size 12-14-16-18 (7.084 m) Type of cutting machine Straight knife. of pins used 2 Use of pins No Use of paper between layers No Table height 38 Table width 60 Table length 12 m Table top type wooden Lay no. of fabric layers 100 Marker type CAD Time duration in min 1 hr 40 min No.2. 2 Lay height 4 cm No. GURGAON Page 118 . of layers 100 Spreading operators 3 17.084 m) Fabric package type Rolls No.

67 142.33 85. of fabric layers 100 Marker type CAD Time duration in min.91 2.Summer Internship Report Table width 60 Table top type wooden Lay no.No OPERATION MAC INE 1 318 94 143 73 64 130 107 87 70 56 125 80 127 2 316 90 145 74 60 128 114 86 72 58 120 87 125 3 312 88 140 70 61 134 110 89 69 50 122 89 123 AVG.08 Page 119 .42 2. TIME 315.33 125.18 1. GURGAON Í S.12 0.67 130.67 110.67 122.21 1.04 1.33 90.51 2.03 2.33 61.33 87.4 TIME STUDY CYCLE TIME 1 2 3 4 5 6 7 8 9 10 11 12 13 SEW PINTUCK * 14 MARK FOR DESIGN STITCH MARK FOR DESIGN STITCH FRONT R/S COLLAR ATT PLACKET FRONT FINISH PLKT FRONT FINISH COLLAR ATT COLLAR TAPE B SEW FRONT DART GATHER SLV OPENING SEW BOTTOM HEM ATT CUFF SLV OPENING FINISH CUFF SLV OPENING SNLS SNLS SNLS SNLS SNLS SNLS SNLS SNLS SNLS SNLS SNLS SNLS SNLS RADNIK EXPORTS. 240 min No.38 1.67 72. of patterns cut 64 No.2.26 1. of notches 26 Cutting master 1 17. 2 Lay height 4 cm No.33 67.84 1.00 SAM 5.00 54.46 1.

67 88.5 FINISHING AND PACKAGING Care Labels Care label KBF/551 Fibres & compositions-TCA1 Care instructions-100% polyester Made in (Country codes)-India IN Corporate packaging Women labels-PW1752 Indigo Mitre Barcode & price labels & tickets-UPC/G3666 Hanger & hook size labels-Size pips Frames/Hangers/Hooks & loops-Top 2 (42 cm) & Top 3(44 cm) Tops RADNIK EXPORTS.34 5.47 2.40 5.40 17.Summer Internship Report 14 15 16 17 18 19 ATT YOKE WITH BACK E\S BACK YOKE SEW PINTUCK * 14 SEW PINTUCK * 14 MARK FOR DESIGN STITCH SEW DESIGN STITCH FRONT SNLS SNLS SNLS SNLS SNLS SNLS TOTAL 60 83 320 315 93 142 64 85 319 323 85 147 62 82 323 318 87 144 62.00 84.31 1. GURGAON Page 120 .2.33 144.00 320.33 1.67 318.41 41.03 1.

sampling. The projects undertaken by us in the industry further helped us to increase our knowledge in the specific departments. The actual scenario of the garment industry could be grasped by us in its true and practical sense. We could practically learn about all the departments from merchandising. The whole procedure of the placement of ord er to its shipment was studied in detail which helped in knowing the working of an export house quite well. It was an enriching experience throughout the internship period an d we could increase our knowledge base to a large extent. spreading.Summer Internship Report LEARNING EXPERIENCE The Summer Internship experience. finishing and packaging. GURGAON Page 121 . at Radnik Exports has been a knowledgable RADNIK EXPORTS. The complications of the industry. sewing. The learning of how the garments that we wear and that we buy from different stores are actually made and how that particular quality level is achieved for which we pay the high price. was an experience in itself. cutting. quality departments etc. the achievement of the required finish and the quality level in a highly complicated garment was really interesti ng to know.

GURGAON Page 122 .Summer Internship Report RADNIK EXPORTS.

Summer Internship Report RADNIK EXPORTS. GURGAON Page 123 .

Sign up to vote on this title
UsefulNot useful