Professional Documents
Culture Documents
A DISSERTATION SUBMITTED TO
SUBMITTED BY:
MUKES RAJAK
MFM - II
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TABLE OF CONTENTS
INDEX PAGE
ACKNOWLEDGEMENTS ........................................................................................................................................ 4
DEDICATION………………………………………………………………………………………………………...5
TRIMS STORE.......................................................................................................................................................... 31
REFERENCE ............................................................................................................................................................ 52
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TITLE PAGE:
• The project will be in under the guidance of Mr. Geetendra Singh (M.M.)
and Mr. Devesh Kumar (PPC Head) of Paragon Apparels Pvt. Ltd.
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ACKNOWLEDGEMENT
Through this project report I would like to thanks numerous people whose
consistent support and guidance has been the standing pillar in architecture of this
project. To begin with, my sincere thanks to the management of NIFT for giving
this opportunity to experience and learn the processes practiced in Apparel
Industry.
For the completion of this document I would like to thanks Mrs. Lipsa Mohapatra
(Course Coordinator MFM) for being my mentor and my guide throughout the
project. I would like to express my sincere thanks to the Management and staff of
Paragon Apparels Pvt. Ltd. for their outstanding support and cooperation in my
efforts to gain knowledge about the practical aspects of Apparel industries during
the Internship.
I am thankful to Mr. Geetendra Singh (Merchant Manager), Mr. Devesh Kumar
(PPC Head) for the guidance and planning out the schedule for the internship and
guiding me throughout the course.
I would like to grab this opportunity to express my sincere gratitude to Mr. Salman
Saifi (Asst. Merchant), Mr. Neeraj Kumar (Planning team) for guiding me through
all the processes involved in the processing of the Planning and Sampling and was
patient enough to answer all my doubts and queries.
I would specially like to thank all the staff members and workers for helping me
throughout the internship. Without their support, it would have been difficult job to
successfully complete the training.
Mukes Rajak
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DEDICATION
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Executive Summary
In the past two decades, the Indian textile industry in terms of home textile,
garments and accessories have witnessed a complete transformation in terms of
quality, market and product development as well as the expansion. In this scenario
export house plays the major role in the growth and conduct of exports. Looking
from this perspective Paragon Apparels Pvt. Ltd. is a very good and important
organization in its work.
Internship at Paragon Apparels Pvt. Ltd. has been a great exposure for the practical
application of my learning. I gained knowledge about actual work culture of the
company and how to deal with the people at workplace.
I did my internship in Production, Merchandising and Sampling Department.
OBJECTIVE
Objective of the study is to learn about the functions of export house and working
of various departments particularly production, merchandising and sampling,
earning knowledge about different departments of the company, their function and
information flow during work.
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COMPANY PROFILE
E-MAIL info@paragonapparels.co.in
WEBSITE www.paragonapparels.co.in
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PARAGON APPARELS
MANUFACTURER & EXPORTER OF READYMADE GARMENTS
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ABOUT THE COMPANY
With a strong hold on varied market segments across the world, PARAGON
APPARELS is recognized as a reputed garment manufacturing company. Incepted
in the year 1999, they have acquired immense design expertise that helps us in
meeting the diverse requirements of their global clientele.
They have a Printing unit too which helps them to deliver on time and at the
same time it produces high quality prints with faster speed.
Having a own fabric mill can be the best thing for a garment manufacturing
company. They have their own fabric mill in UNA Himachal Pradesh, which
produces quality fabrics on demand for the mill and thus makes the process
more easy to handle.
These facilities assist them in producing a quality assured range of garments for their
valued clients.
Ever since its inception, Paragon Apparels has never looked back. Growing with
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• Product Categories – Men’s wear (70%) and Women’s wear (20%),
Kid’s wear (10%).
Clients - Reebok
Adidas
Hummel
Levis’s
Lifestyle
Kappa
Alcis
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Orchestra
Reliance
Callaway
MAX
Waste2Wear
TJX
Bugatti
Skechers
Best Seller
Knight Riders
RCB
NBA
Pune City
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Awards and Achievements: Times Award Finalist 15-16
Awarded by AEPC
Awarded by NAEC
13-14)
13, 13-14)
12-13, 13-14)
(2013-2014)
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FACTORY LAYOUT
FLOORS DEPARTMENTS
a. Finishing Department
b. CEO office
GROUND
c. Cutting Department
d. Human Resource
e. Designer Cabin
a) Production unit 3
1ST
b) Merchandising and CAD Department
c) Production GM cabin
d) Quality Lab
e) Conference room
f) PPC Department
g) Finishing Department
h) Spotting room
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PRODUCT DEVELOPMENT
CLASSIFICATION
PRODUCT DEVELOPMENT
TECH PACK
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MECHANDISING DEPARTMENT
2. Sampling
3. Lab dips
4. Accessories& trims
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PROCESS FLOW OF MERCHANDISING DEPARTMENT
TECH PACK COMES FROM BUYER
ORDER CONFORMATION
BUDGETING
(FABRIC DETAILS)
MATERIAL INDENT
(TRIMS DETAILS)
LOT APPROVAL
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PURCHASE ORDER
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Apparel export merchandising may be defined as ‘all the planning &
activities involved right from the buyer communication & order receiving till the
execution or shipment of the order by fulfilling the following factors (Six Rights):
Right Merchandise: Retailers must fill their shelves with the merchandise that
customer wants.
Right Time: Much merchandise is seasonal in nature and must be on hand when it
is most needed.
Right Price: Merchandiser must arrive at a price that is high enough to give the
store profit and yet low enough to meet the competition and customers
expectations.
Right Promotion: Right balance between the investment and the appeal created
for the customers.
The successful execution of any garment export order depends on the work
performance of a merchandiser. Merchandiser is the person who plans and
coordinates all the activities right from the order procuring and till the shipment
order. A merchandiser should have the comprehensive knowledge of his work
procedures and responsibilities so that he could perform his job efficiently and
effectively. In the apparel export industry, a merchandiser has to perform the
following functions;
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Communication: It is one of the foremost functions of merchandiser because the
merchandiser has to communicate with different levels of people in his day to day
activities.
Follow ups: It includes sending of samples at various stages of order, buyer and
buyer house for sample and other approvals.
Decision making: A merchandiser has to make several decisions during the order
processing like giving approvals like fabrics, color, design, accessories, and
packing, selection of suppliers and vendors, selection of buyers, sometimes time
extensions for order shipment.
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given period. Both the controlling and coordinating activities complement each
other and a merchandiser has to adopt the both accordingly,
Costing: It is the process of estimating the expenditure of a given product and the
subsequent price. It is another crucial function because mostly order conformation
depends on the price offered to the buyers. The merchandiser should know the
current prices and rates of various products and processes to do the accurate
costing.
Meeting: There are two types of meeting a merchandiser has to be involved. First
type, a merchandiser has to conduct the meeting with the concern department in
charges to discuss about the proceedings and the status of the running order. In
second type, a merchandiser has to attend the meeting with the superiors or buyers
or business people in giving reporting or participation or discussion.
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QUALITY CONTROL DEPARTMENT
Paragon Apparels processes export orders in factories. While raw materials are
converted into garments, there are possibilities to make errors, like making
defective garment components and defective garment. Making defective garment is
a cost to the company. So to make sure garments are made as per customer
requirement and whatever raw materials are sourced must meet the factory
standards, factory establish Quality Control Department.
Function of the quality control department can vary widely. But most common
function of quality control depart are as follows
Testing of raw material: Quality control department does not conduct testing of
raw materials but they send sample to testing lab for testing physical and
chemical test. Once factory receive test report, quality control team get assurance
whether raw material to accept or not.
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Inspection of Sample: Visual inspection and measurement checking is done prior
to sending sample to respective buyers.
Cutting room inspection: Quality department also inspects work done by cutting
room. Like, layering of fabrics on cutting table, cut layer inspection, cut component
inspection, Bundle inspection etc.
Preparatory work inspection: In high fashion garment, lot preparatory work are
outsourced like, printing, machine embroidery, bead work, special decoration on
garments etc. Before feeding this outsourced goods, quality department checks and
approve for further process (sewing process).
Finishing Process: Finally quality personnel checks finished and packed goods
and do auditing prior to handover shipment to external inspector.
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Quality Awareness development
They are also responsible to bring quality awareness among the workers and all
employees.
SAMPLING DEPARTMENT
In an export house, the sampling department play vital role in the up- lifting of a
unit. This department directly coordinates with the merchandising dept. and
production dept. sampling is done to see how the product will look when produce
in bulk and to check discrepancies in the pattern are.
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STEP OF SAMPLING
PP SAMPLE MADE
TOP SAMPLE
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FABRIC STORE
Fabric storehouse actual are where the fabric for production is receive or
dispatched for processing. Beside storage the fabric store department is also
responsible for the inspection of good receives by it.
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PROCESS FLOW OF FABRIC STORE
FABRIC RECIVING
KEPT IN STORE
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STORAGE
Rack system of storage is followed i.e. packages are stored in two areas:
1. Check fabric
2. Unchecked fabric
They are further segregated on the basic of style no. and lot wise. The fabric rolls
are put in rack manual way. Such systematic maintenance of the store makes it
easy to make the fabric whenever needed in future.
The merchant receives the purchase order from the buyer. On the basis of this
purchase order, the fabric source prepares a requisition for fabric as per the
demand of the buyer and raises it to the fabric vendors in the market. The best deal
and the vendor are finalized and the order is placed. The factory may send the yarn
from the store to the fabricator for fabric production, buy greige for dyeing or
directly order processed fabric to the vendors. Once the fabrics development
receives the approval for the fabric, the vendor send it from of lot within the
specified the time period and the fabric is made in house in the fabric store. About
5% extra goods are supplied by the vendor.
The fabric via transport trucks comes in various packages like rolls, book fold etc.
each consignment comes in with an invoice having details like quantity, color,
GSM, and weight. The goods are weighted and other detailed are reconfirmed
before they store.
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FABRIC INSPECTION
The fabric being the main contribution to development of our final product i.e. the
garment, it is very important to control its quality indicated by the no. of faults and
various present in it. Identification of these objectionable variations and faults right
at the initial stage to reduce the production time. So once the fabric is in- house it
is immediately sent on a pilot and trolley assembly to inspection.
4 POINT SYSTEM:
4 Point system for fabric inspection is widely used in apparel industry for fabric
quality inspection.
The penalty evaluation points have been given for different length of fabric defect
and dimension of holes.
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SIZE OF DEFECT PENALTY
POINTS
Defects up to 3 inches 1
1 inch or less 2
Over 1 inch 4
Example: A fabric roll 120 yards long and 46 inch wide contains following
defects.
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4 defects up to 3 inch length 4x1 4 points
Therefore, = 24*3937/109.72*46
TRIMS STORE
Trims store as the name suggests is a department, which acts as a storehouse for
accessories. It is the place where all the accessories required in an export house,
are stored. Right from sewing thread, needles to packaging material mike poly
bags and taps etc. all are stored in the accessories store.
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The merchandiser as per buyer specifications order the purchase dept. to buy the
accessories that are used in a particular style of that buyer. Merchandiser prepares
a swatch card containing all the accessories and their quantity in a cycle. These
accessories used in the swatch card are as per the quality and color mentioned and
approve by the buyer. The purchase dept. with help of swatch card prepared by the
merchandiser purchase the required quantity of accessories. The accessories are
purchased 5 – 10% extra than the required, as the wastage in case of accessories is
more. The receiving dept. then receives these accessories from the vendor and
then checking and testing of these accessories are done. They are checked quality
and color. The accessories like buttons are tested with help of button snap tester.
After all accessories are checked and tested as per the buyer’s specification then an
accessories approval card is prepared.
After the accessories are received they are stored in the accessory store. The
accessories are stored in different racks. The accessories of a single buyer are
stored in one rack but the different accessories are stored separately from each
other in the same rack. The accessories store also houses the stationary required in
export house.
Now, whenever the production starts the accessories required in production are
issued to the production dept. through an internal channel. A stock register is used
for maintaining records. Thus an accessory store function as a store house for
accessories where all accessories are assembled and kept and also issued to
sampling and production dept. for the garment manufacture.
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CAD DEPARTMENT
Computer Aided Design (CAD) becomes an essential tool for pattern making and
related jobs in garment industry. In apparel industry CAD Software is used for
pattern making, Grading of pattern, marker making and digitizing manual patterns.
CAD system involves any type of design activities which use of to develop
analyses or modify any engineering or garment design.
TUKA cad is an innovative apparel pattern making software that is perfect for
manufacturers and designers of any size. Operating under Microsoft Windows,
TUKA cad allows the user to accurately builds patterns, grade rules and markers
for single styles or entire lines. It is the advanced pattern making, grading and
marker making system that will streamline your production process and reduce
operating expenses.
Fabric Matching
Engineer pattern pieces according to fabric prints, stripes, or plaids. Fabric print
can be transferred to Marker Making for perfect matching. TUKA cad even
accommodates the flaws in warp control.
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GRADING
Build block libraries with "master grading." Changes made to base pattern are
automatically reflected in entire size range eliminating need to recalculate grade
rules. Easily insert size in between current sizes and the system will automatically
divide the grading in half.
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MARKER MAKING
It determines the most efficient layout of pattern pieces for a specific style fabric
and distribution sizes.
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Cut order planning determines:
PATTERN ENGINEERING
An examination of the seam location to ensure the possible placement of
pattern in marker
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WORK FLOW OF SPREADING AND CUTTING
SPREADING
LAYERING
CUTTIN G MANUAL/
AUTOMATIC
TICKETING
FUSING
CHECKING
BUNDLING
TRANSFER TO PRODUCTION
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SPREADING DEPARTMENT
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CUTTING DEPARTMENT
Cutting means to separate out different garment process from the lay of fabric with
the help of cutting template and devices. It is done to get required shape in
different no. or as a whole to make a complete product. The first stage in the
manufacture if garment is the cutting of material into the necessary pattern shapes.
These patterns are joined to form a garment when large amount of garment style
has to be cut, a lay is created, which consist of many piles of fabric spread one
above the other. Now all the pattern pieces for all sizes are from this lay. The main
objective of the cutting dept. is the cutting of garment parts accurately and
economically and in sufficient value to keep the sewing room supplied with work.
Objective:
Cutting department receives the order for cutting a garment style from the
production manager. Cutting order is an authorization by the production manager
to cut a given amount of styles, from the spreads. It comes in from of a package
file that carries the following details:
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1. Sampling average, weight of garment (base fabric consumption only) and
other trims averages.
2. Measurement sheet
3. Design worksheet of the garment
4. Purchase order
5. Fabric requisition sheet
6. CAD mini marker
7. Marker planning length of lay etc. size ratio and colours in which the
patterns are to be cut.
CUTTING AVERAGE
The cutting department duties are not limited to mare cutting of the fabric. It is
responsible for keeping control over the total consumption of fabric per garment
piece cut this consumption is more specifically defined in terms of cutting average.
During marker planning, the CAD rule sends theoretical consumption of fabric as
per its marker, which is calculated as following:
Cutting average = Area of one piece in the marker (cm square)* GSM of the
fabric 10,000
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Cutting average is used to determine the cost of raw material that is fabric for each
garment. Hence it is very important that it is maintained airing the bulk cutting also.
The cutting manager finds out his actual cutting averages before the bulk cutting and
tries to keep it close as possible to average predicted by the CAD.
TICKETING
Once the pattern pieces are cut by the cutting machine, they are then ticketed. Cut
components are group together as per their sizes and taken to the checking table.
Here the cut components are inspected for any error. It is very important to take
care that pieces cut from two different bolts of fabric are not mixed up. This is
because within lot there bolt to bolt variation in colour shade.
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FUSING
Fusing is also carried out in the cutting room itself. The parts to be fused are
separated from the bundle. The fusing material (like interlining) is cut according to
size of the component to be fused. The component along with the cut fusing
material are kept between to paper sheets and the pack is passed through the fusing
machine by means of temperature and pressure fusing takes place at particular
speed and for a particular time. The pack comes out at the other end on conveyors
and the pieces are removed and re-bundled.
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CHECKING
The ticked panels are now sending to the checking are for inspection of every
individual pieces for any objectionable faults. Panels having faults like wrong
grain line, in appropriate size, incorrect shape and any fabric defects likes holes,
cut, shade, variation etc. That are not within the acceptable quality parameters, are
removed from the cut lay. A cutting component checking report is filled for the
total quantity cut, checked and approvals. The rejected pieces are sent back and
equal no of trash panel are separately cut, replaced in the set and ticketed with the
same no. as the rejected once. Other mend able faults are marked with an alteration
sticker and passed on. These will be spotted out during garment finishing or
washing.
BUNDLING
The checked components of one style and in one size are now clubbed and bundled
using tie. The size of bundle depends upon the requirements of the production
plant. Each bundle will contain pieces of same style and same size only. These
pieces are stored in racks made beneath the cutting table. The cutting department
issues the amount required by the production dept. as and when ask for. The cut
component may be issued in instalment or all at once as the needs of the
production dept. against the job order.
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SEWING DEPARTMENT
The basic aim of an export house is to deliver value satisfaction of the customer at
the profit level.
To deliver quality with the quantity the ratio between input resources or material &
output good and service is known as productivity are reciprocally related to each
other. Therefore an increase in production leads to fall in the cost per unit & rise in
profit.
Production floor follows assembly line system. Following are steps to start a
production line.
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Load and feeding line.
• To arrange buffer or work – in – progress.
Manufacturing.
To make daily production and to achieve target accordingly.
To understand bottlenecks stage of production.
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They generate report for broken needle
Complete assembly is divided in 6 parts, in end of every part there was a
record sheet, which show early target input, actual input, target output and
actual output, according to this can find out bottleneck area.
WASHING DEPARTMENT
Garments pass through various handling processes, which may render them dirty
and stain, thereby reducing their aesthetic appeal. To restore this aesthetic value,
they are subjected to cleansing process like washing and dry cleaning. Garments
are sent for washing by the production department as per the buyer’s requirement.
Normally the fabrics are not asked to go for wash by the buyer. Whether the fabric
department may internally sent it a number of other reasons.
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1. To control uneven shrinkage
2. To remove bowing
3. To lighten colour shade
4. To improve hand
5. To even out colour shade variations
WASHING FACILITIES:
ENZYME,
STONE WASHING,
OVERDYEING ETC…
FINISHING DEPARTMENT
After assembly, the garments now come for finishing – a key stage of garment
manufacturing process. Finishing is done to prepare the final garment according
to the quality standards of the buyer before packing it for shipment.
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PROCESS FLOW OF FINISHING
WASHING
THREAD CUTTING
ALTERATION
REIRONING
FINAL CHECKING
PRESENTATION/FINAL IRONING
MEASUREMENT
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BASIC WORK FLOW
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• Final thread cutting – minute thread like those of labels, bar tack etc. are
trimmed off to give the neat look. Thread loosely sticking to the garments is
also shed off, both in and out by jerking the garment before it goes for
pressing.
• Pressing – pressing in general is shaping the assemble material with
pressure, with/ without heat and moisture, for further processing. In case of
knits, this is important but not as significant as in the case of woven because
of their property of excellent recovery and fit.
Measurement and final checking – this is the final and most stringent done for
garment measurement, appearance, labels, trim etc to study the final look and
shape the final look and shape of the product produced. Measurements are done
according to the specification sheets and recording are made for any variations in
the measurement chart. This gives an overall idea about the quality of the garment
being produced.
PACKAGING DEPARTMENT
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PROCESS FLOW OF PACKING
IT IS THEN FOLDED
CARTON IS SEALED
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REFERENCES
• Personal Interviews
• www.paragonapparels.co.in
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