Inttern

nship
p Reeporrt onn Maasood
Texxtile Millls Lttd.

1 
 
 In
nternsship Report
R
On
Maasood Textille Millls
Sargod
S dha Road
R F
Faisala
abad
Subm
mitted To:
T
H Deppartmennt
HR
Subm
mitted By:
B
M mmad Addeel Ali
Muham
B
BBA H), Reg. #: 20112-GCU
(H UF-029112
M
MTM: TE2217704
Subm
mission Date:
133-08-2015

Internnship rep
port submmitted inn partial fulfilmen
f nt of thee
requirrement foor the deegree of BBA (H H)

Govvernmeent Colllege Univers

U sity
Faisa
alabad
d, Pakisstan

2 
 
 Taable of
o Con
ntentss
SERII PA
AGE
AL SUB
BJECT
TS NO
O.
NO.
1. Prefaace 7

2. Ackn
nowledggementt 8-99

3. Execcutive Summar
S ry 10

4. Texttile Secttor and Pakistaan 11

5. Brieff Historry of MTM

M 12--13

6. MTM
M Divissions 14

7. Driv
ving Dirrections 15

8. CEO
O Messaage 16

9. Visio
on & Values
V 17--18

10. Busiiness Voolume & 19--20

Profi
file Of Employe
E ees
11. Certiificationns 21--22

12. Custtomers Portfoli

P io 23--24

13. Awaards 25--29

14. Prod
duct Rannge of MTM
M 30--32

3 
 
 15. A Brrief Process at Mill & at Garm
ments 33
Division
16. MTMM Operrations 34--36

17. Man
nagemennt Hieraarchy & Scale in
i MTM
M 37--40

18. Garm
ment Manufactturing Process
P 41--61

19. Lab Testingg in MT

TM 62--64

20. GSM
M (Gram
ms per Square
S M
Meter) 65--66

21. Depaartmentts 67

I. Mark
keting &Merch
& handisinng 68--110

II. Reseearch annd Deveelopmennt Depaartment 1111

III. PPC Departtment 1122

IV. Quallity Conntrol Deepartmeent 1133

V. Quallity Asssurance Departtment 1144

VI. Indu
ustrial Engineer
E ring Departmennt 1155-
1166
VII. Proccuremennts depaartment 1177

VIII. Storees Depaartment 1188

IX. Finisshing Departm

D ment 1199-
1222

4 
 
 X. I T Departm
D ment 1233-
1244
XI. H R Departm
ment 1255

XII. Finance Deppartmennt 1266

XIII. Forw
wardingg Departtment 1277-
1311
22. SWO
OT Anaalysis 1322-
1344
23. My Persona
P al Experrience 1355-
1366
24. Concclusion 1377

5 
 
In th me of ALLA
he nam A AH, the moost
Benefficent, the most
m mercif
m ful

6 
 
 Prrefacee
All praaises to Almighty
A y Allah alone,
a thee Most Merciful
M a the most
and m
Benefiicent and His Holyy Propheet “Muham
mmad” (Peace bee Upon Him)
H
who is forever touch
t of guidance
g and know
wledge foor the hum
manity.

The Business Administr

A ration Deepartmennt of the Governm
ment Colllege
Univerrsity Faisalabad want
w t Students have to know that how
that the w the
theorettical know
wledge is being appplied praactically.

For thiis purpose, I have selected Masood Textile Mills

M Ltdd. Faisalabbad.
It was a golden
n chance for me to enhannce my knnowledgee practicaally.
MTM developeed and shhaped myy capabiliities and skills in the practtical
environnment. Furthermo
F ore durinng this period I obtaineed a lott of
inform
mation. I hope
h this is
i practicaal and valuable.

7 
 
 A
Acknow
wledgeement
The feelicitation
n goes forr me to acknowle
a edge the people,
p w hold the
who
desirabbility for encouragging, praiising, assisting as well as believing
b me
on the tasks of merchand
m dising acttivities what
w I havve workedd throughh my
internsship perio
od.

First of all I wo
ould like to take thhe opporttunity to thanks
t to my teachhers
&my innternship m guidellines, helpp in assisting
p supervissor for prooviding me
my repport.

I also acknowlledge thee loving support of my teeachers, parents, and

friendss. I exprress my honest and sinccerest grratitude to
t the A.M
A
Marketting of MTM,
M M Syed Ahsan
Mr. A Raza, whoo guided me a lott by
ortunity for eye opening in this particular
giving an oppo p r sector and
writingg this reeport in the mosst comprrehensivee mannerr within the
specifiied time frame.
f

I would like to take the opportuni

o ity to thannks Mr. Asif
A Naziir, Markeeting
Managger, of MTM,
M fo proviiding mee time to
for t time informattion,
suggesstion as well
w as proocedures to
t work with
w my toopic.

I also want
w to th
hank to all Merchaandiser off MTM, for
f creatinng a frienndly
environnment.

I will show my
y gratitudde to all the Mannagement & Non-M
Managem
ment
Staffs who
w havee helped me
m duringg the interrnship peeriod.

8 
 
I was bound in
n my theooretical knowledg
k e. It is my
m first experienc
e e to
acquiree knowled
dge in thee practicaal field. So,
S it is naatural thaat there might
m
have some
s misstakes. Foor these reasons, I am reeally sorrry and I beg
pardonn.

Finallyy, numero
ous thanks and graatitude to the Almiighty Allaah for pavving
my waay to successfully finish
f myy report making.
m

9 
 
 Exxecutivve Sum
mmaryy
I joineed Maso
ood Texttile Millss Ltd ass an intternee inn Marketting/
Merchandising departmeent. The motive of
o joining the MTM
M is to have
h
an expposure of
o textile sector and poteential to avail a sound and
promissing careeer. I devoted two months
m too learn about MTM
M, which will
be beneficial to me.

In thesse two mo
onths of innternshipp program
m, I attendded the lectures of key
departm
ments (M C, GGT, Stores, Inndustrial Engineerring,
Merchandiising, PPC
LAB, Procurem
P ment, IT, Forwardin
F M etc.) of this laargest kniitted
ng and Mills
garmennt manufa
facturer off Pakistann which were
w deliivered byy experiennced
managgers of th
hese deppartments.. After attending
a the lecttures, I also
visitedd these dep
partmentss for acquuiring praactical knowledge.

I also learnt ab
bout the organizattional cuulture, theeir valuess, their teeam
workinng and pro
oducts. During
D traaining I allmost visited everyy departm
ment
of MTM
M and strrive to leaarn.

The obbject of th
his reportt is that I observeed the neccessary measures
m that
can help to capiitalize thee strengthhs to overrcome weeaknessess and rem
move
the defficiencies.

10 
 
 Textille Secttor and
d Pakisstan
The Teextile industry
i i
in Pakkistan is the largest manufactur
m ring
industrry in Pakiistan. It has
h traditiionally, after Agricculture, been
b the only
o
industrry that has
h generrated hugge emplooyment for
f both skilled and
unskillled labor.. The Texxtile Induustry conttinues to be the seecond largest
employyment geenerating sector inn Pakistaan. Pakisttan is thee 8th largest
exporteer of Tex
xtile produucts in Asia.
A This sector coontributess 8.5% too the
GDP and
a proviides employment to about 15 millioon people or rougghly
30% of
o the 49 million workforcce of thee Countryy. Pakistaan is the 4th
largestt produceer of cotton with the
t third largest Spinningg capacityy in
Asia after
a Chin
na and Inddia, and contribute
c es 5% too the globbal Spinnning
capacitty. At preesent, theere are 1,221 Ginnning unitss, 442 sppinning unnits,
124 laarge spinn
ning unitts and 425
4 smalll units which
w prooduce texxtile
produccts. Pakistan’s texttile indusstry has about
a 50 large andd 2500 sm
mall
garmennt manuffacturing units. Moreover
M r, it also houses around 600
knitweear-produccing unitss and 4000 towel-prroducing units.

11 
 
 Briief History off MTM
M
Kohisttan Bus Service
S w the fiirst professional step in the life of Ch.
was
Nazir Ahmad father of Mr. Shahid Nazir inn 1973. Afterwaards
Dream
mland Hotel, Sangeeet Cinem
ma, Aizad Beveragees were establishe
e ed in
1978 and
a 1983
3 respectiively. Mrr. Zahid Nazir annd Mr. Shahid
S N
Nazir
helpedd his fath
her in thee formatiion of ann industriial co-opperative bank
b
along with
w the developm
ments of Rabia Trust Hosppital. Kakkakhel Ghee
G
Mills and
a Flying
g Traininng Schoolls were esstablishedd in 1994..

Masoood Textilee Mills waas incorpporated inn 1984 with 4 spinnning millls. It
is a puublic limited comppany withh its regisstered offfice at Faaisalabad and
listed in
i all Stocck Exchannges of Pakistan.
P

It is veertically integrated
i d Textile unit. It has wn Spinning, Knittting,
h its ow
Processing and Stitchingg units. Innitially it was engaaged onlyy in spinnning.
But in 1993 com
mpany chhanged itss strategy in addingg up mostt process and
disposeed off th
hree Spinnning unnits. In 1995
1 com
mpany made
m its own
o
garmennts units with onlly 35 stitcching maachines but
b today it has abbout
5600 stitching
s machiness of diffeerent brannds. All credit off this succcess
goes too visionarry personnality of Mr.
M Shahhid Nazirr, the Chiief Execuutive
of the Company
C y.

They strive
s to lead in creeating, deevelopingg and mannufacturinng of kniitted
apparel products right from
f bassic to higghly fashhioned gaarments thus
t
responnding to emerging trends in the indusstry. Theyy translatte concepptual
12 
 
ideas of
o our cusstomers innto realityy and shaape them through our
o technnical
bent and
a profeessional acumen.
a The team
m here strongly
s b
believes that
Custom
mer satisffaction iss the esseence of business
b today. MTM
M has the
technology wiith expeertise, prroducts with knnowledge and most
m
importtantly the right minndset to achieve
a tootal custom
mer satisffaction.

13 
 
 MTM
M Divisiions

Masood Textilee Mills Limitted

                                                           M

Faisalabad – Pakistan
   

Head Office:
O Jaiil Road, Faisalaba
F d, Pakistaan
Factorry: Saargodha Road,
R Faissalabad, Pakistan
P

Mills: 322 Km, Shiiekhupuraa Road, Faisalabad

F d, Pakistaan

Lahorre Office:: 166/3A, Edeen Homess, Main Gulberg,

G L
Lahore

Phonee: (922-41) 7877931~34, (92-41) 748001~

7 13

Fax: (922-41) 7811361

Web Site:
S w
www.maso
oodtextilee.com

14 
 
 D
Driving
g Direcctions

Mo
otorway & 
Sargodha 
Road

Sattiana  Jaranwala 
Rooad Road

M
MTM

Sheikhu
upura  Samunddri 
Roaad Road

Distan
nce froom Maajor Ciities
Lahoree 134 km
m

Islamaabad 372 km
m

Peshaw
war 519 km
m

Quettaa 1096 km
k

Karachhi 1181 km
k

15 
 
 CEO
O Messaage
Welcom
me to MTM,
M Maasood opeerates thrroughout the worlld with over
o
21,0000 employeees as parrt of our team.

MTM Collectio
on has a wide
w seleection of quality garments
g includingg T-
shirt, Polo
P shirrt, Jogginng suit, Henley
H s
shirt, Ragglan shirrt, Tank top,
wear. Coompetent professional stafff, a
Bikini,, Shorts, Pants annd Sleepw
team of
o talented merchaandisers, excellentt suppliess & suppport serviices,
and sttate-of-th
he-art tecchnology is the driving force beehind MTM
M
phenom
menal gro
owth in thhe past yeears.

MTM has expanded its operation

o ns to incluude the Innternet, and
a has taaken
advanttage of th
he varietyy of interrnational trade faccilitated by
b the Web.
W
Now MTM
M usees state-oof-the-art client/serrver technnology foor its maarket
inform
mation pro
ocesses too coordinnate its network
n o globall buyers and
of
agents around th
he world..

16 
 
 V
Vision
“To Be
B the World’s
W B Ap
Best pparel Company
C y”

"Our vision
v is of a sustained grow
o continuual improovement and wth, and of a
kers. Whoo are given the beest compensation benefits and
family of work
t regionn? In thiis respectt, MTM continues to
workinng condittions in the
emphaasize the need
n to innvest in and
a develoop its moost preciouus resourrce -
its hum
man capittal. MTM
M continuees to provvide trainning courrses and self-
s
enhanccement op
pportunitiies for alll our workkers".

Our First
F Responsibility

Cuustomerr Satissfactionn

17 
 
 V
Values

R
Respec
ct Inttegrityy Trust

Respecct for the individuual, integrrity, speedd, simpliccity, self--assurednness,

and a 100%
1 com
mmitmennt, our vaalues are non-nego
n otiable; thhey are neever
to be jeettisoned.. For us, our
o values are our well-spriing.

• To de market leadershiip and braand coverrage

T provid
• To
T pursuee technoloogical innnovation
• To
T partnerr with opeerators foor their maximum
m p
productiv
vity
• To
T provid
de virtuouus to ourr custom
mers, empployees, communit
c ties,
a the en
and nvironmennt

18 
 
 B
Busine
ess Vollume
Masoood rank the num
mber onee textile and appparel manufactur
m ring
o annuaal turnoveer and brrand profile,
compaany in Paakistan inn terms of
havingg achieved
d an annuual turnovver US $ 254
2 millioon last yeear.

Turn Over
O In Millions
M

Yearss Value In
n RS I US
In

2015 26980.977 $ 265

2014 25861.011 $ 254

2013 24944.677 $ 245

2012 23824.711 $ 234

2011 22938.922 $ 225.3

19 
 
 Prrofile of
o Emp
ployeess

Yeaars Employees
2015 21000

20144 20119

2013 19400

2012 19000

2011 18500

20 
 
 Certiificatioons
We are
a proud
d being WRAP
P (Worldwide Responsib
R ble Appparel
Producction) cerrtified. Thhe certifiication ennsures thhat sewn products are
producced und
der law
wful, h
humane and ethical conditioons.
Follow
wing are the
t core standards
s s that we strictly follow
f thrroughout our
producction proccess.

• Complliance with Laws and

a Workkplace Reegulationss
• Prohibition off Forced Labor
L
• Prohibition off Child Laabor
• Prohibition off Harassm
ment or Abbuse
• Com
mpensationn and Bennefits
• Hourrs of Worrk
• Prohibition off Discrimination
• Healtth and Saafety
• Freed
dom of Associatio
A on and Coollective Bargainin
B ng
• Envirronment
• Custo
oms Com
mpliance
• Secu
urity

21 
 
MTM has the ISO-90022 Certificcation annd the reggistrationn # 99086699.
We havve the log
go of thrree-accredditation bodies
b

• ANSI
A RAB (USA Based)
B
• U.KAS
U (U
UK Basedd)
• DAR/TAG
D G (Germaany Basedd)
• Conducted
C d by Mooody Internnational

22 
 
 Cu
ustomeers Portfolio
MTM is proud to
t work with
w the world’s
w beest labelss. This expposure too the
brand labels haas been a continuuous learnning expeerience for
fo the enntire
team. Currently
C S. while rest
y, 80% of producttion is exxported to the U.S
20% too Europe. Brands are;
a

Abercrrombie & Fruit of

o the
Adidas Cham
mpion
Fitch Loom
m

Aeropoostale Asiam
m Calvinn Klein Cham
mps

Chaps Dockeers Foot Locker

L Guess

Hanesss Hollister Tomm

my Hilfiger Walm
mart

23 
 
Izod JCpenney Jockey Kohlss

Lee Levis Li & Fung

F Macyys

Nautica NFL Polo Pumaa

Reebokk Sears StJohnnsBay Staffoord

Artisanns Tom Tailor

T Underr Armourr V&D
D

24 
 
 Aw
wards
MTM has a prid
de to win followinng internattional aw
wards;

FTL haas awardeed MTM

Aw
ward 20133

Presideent of Pakistan
P Awards 2010-2011 for Best
B Expport & Best
B
Hosierry

Aw
ward 20111

Faisalaabad Cham
mber of Commerc
C ce

Aw
ward 20099

25 
 
JC Pennney has awarded
a M
MTM Puurchasing Partnershhip

Aw
ward 20077

FTL haas awardeed MTM..

FTL has
h award M "Accuuracy of Informattion and Compliaance
ded MTM
Supplier Award
d.

26 
 
 UBL hass awardedd MTM

MTM is certifieed by the WRAP Certificati

C ion Boardd (2007).

JC Pennney has awarded

a M
MTM "D
Divisional Quality Award"
A ((2005).

27 
 
 Fruit of
o the Loo
om has aw
warded MTM
M "Quuality Conntrol Awaard 2005""

JC Peenney haas awardded MTM

M "Bestt Qualityy Awardd for 20002"
Certificate.

Qualityy Recogn
nition “20001-2002”” Certificate

Russelll Corporration hass awardeed MTM "Global Quality Recogniition

2001-22002"Certtificate.

28 
 
JC Pennney Awaards MTM
M "The best
b suppllier of the region award 20001-
2002". The cereemony waas held inn Singapoore on 17tth July 20002.

Mr.Shaahid Naziir (C.E.O.) receiveed this aw

ward.

29 
 
 Prod
duct Range of MTM
M
• Yarn
• Fabricc
• Long Wear
W
• Activee Wear
• Sleep Wear
W
• Athletic Wear
• Sportss Wear
• Under Wear

30 
 
MTM has categ
gorized itss products in two m
main cateegories whhich are
knownn as;

1. Tops
T
2. Bottoms
B

Tops:
• High
H Neck
k
• Mock
M Necck
• Polo
P Shirtt
• T-
T Shirt
• V-
V Neck
• V-
V Insert
• Raglan
R Sh
hirt
• Rugby
R Shirt
• Hood
H Shirrt
• Full
F Zippeer Hood Shirt
S
• Quarter
Q Ziipper Hoood Shirt
• Tank
T Top

31 
 
Bottooms:
• Pant
P
• Trouser
T
• Short
S
• Boxer
B
• Boxer
B Brief
• Boxer
B Sho
ort
• Leggings
L

32 
 
 A Brrief Pro
ocess at
a Mills& at Garme
G ents Division
n
Mill’s Process Spinningg Knittiing
Process Processs

Cotton
C Process,
P
P
Procurement
t D
Dyeing &
F
Finishing

Start Here
H
Dispatch

Cutting
C
Department
D t

A
Apparel D
Division’s Process (Garment
( ts)

Induction Stitch
hing Finishin
ng
Departtme Depaartment Departmment

End
Packiing &
Shipm
ment

33 
 
 M
MTM O ations
Opera
MTM is one off the few fully verttical textiile mills in
i Pakistaan havingg in-
house Yarn, Knitting,
K Fabric dyeing,
d P
Processing
g, and Laundry
L and
Appareel Manuffacturing facilitiess. The veertically integrated operatiions
help uss in achieeving shoorter lead times annd greaterr flexibilitty to cateer to
the cusstomers’ demand.
d

Spinn
ning:

Spinniing Diivision of
Masoood Textilees is capaable
of producing 60,000 lbss. of
Ring spun
s yarrn every day
(basedd on 20/s count). The
divisioon, equipped w
with
most modern machinnery
from Japan,
J

nd, produuces a vaast range of yarn counts from

Englannd and Switzerlan
S fr
10/s too 40/s. To
o ensure consistennt quality,, spinningg laboratoory has been
b
equippped with latest
l andd most modern
m testing equuipment. 50% of yarn
y
producction is exported
e to Hongg Kong, Japan, Korea,
K M
Malaysia and
r of cappacity is used for in-housee productiion of fabbric,
Thailannd. The rest
converrted subseequently into
i apparrel.

34 
 
Knittting:

Knnitting Deppartment machinees

cappable of making
m Jeersey, Piqque,
Fleeece, Interrlock andd Rib in
t mini jacquard
adddition to the
dessigns of siingle knitt jersey. The
T
gauuge rangees from 9 to 28 for
single knit, 18 to 24 for
f Interloock
andd 15 for Rib
R machiines.

Most of
o the maachines arre equippeed with Spandex
S a
attachmen
nt. Masoood
has addded stripeer machinnes for prooducing feed,
f autoo and engineered
stripe jersey.
j

Moreover, it has
h flat bed
b machhines for collar annd armband makking.
100% productio
p on is insppected andd only ‘A
A’ grade fabric
f is transferre
t d to
the suubsequent operatioons. Massood has a daily knitting capacityy of
95,0000 kg.

35 
 
Dyein
ng, Pro
ocessingg & Lau
undry:

The Prrocessingg Departm

ment
has ann installedd capacityy of
dyeingg 120 Toons per day.
d
Equippped w
with Thhese
dyeingg machhines fr
from
Germaany, it iss capablee of
dyeingg both 1000 % cotton
and Poly-cott
P ton blennded
fabricss.

The machine
m siize selecttion provvides flexxibility inn dye lot size rangging
from 200
2 Kgs to
o 2200 Kgs.
K

The deepartmentt has Sanntex finisshing linees from Switzerlan

S nd includding
hydro extractorrs, dryerss and com
mpactorss for tubuular as well
w as open
o
width fabrics. Moreover
M r state of the art Lampertti sueding equipm
ment
with Nylon
N ushing Teechnologyy makes Masood capable of
Bru o produccing
immacculate and delicatte knit fabrics.
f G
German Technoloogy Monnfort
stanterr and Coriino slittinng machinnes are thhe latest addditions to
t processsing
departm
ment.

A sepaarate testiing Laborratory with latest equipmen

e nt is in plaace to enssure
that thhe processsed fabrric qualityy is maiintained to
t meet the requuired
parameeters of our buyerss.
36 
 
Laundrry divisio
on is caapable off doing garment
g dyeing and
a garm
ment
d ,sodaa wash, ennzyme wash,
washinng includiing pigmeent dyeinng, tie & dye
stone wash
w etc. contributting a goood part toowards vaalue chainn.

Stitch
hing:

With ovver 5,6000 stitchinng machines,

manned with thhe most skilled and
expert opperators, Masood is capable of
7 millioon pieces per
producinng about 7.5
month veersatile gaarments ranging
r frrom

basic to high fashion,, men’s, women’s and kids

k withh maxim
mum
flexibillity in sizze and collor assorttments. The Qualitty controll and Quaality
partments are in place too make sure thee companny’s
Assuraance dep
objectiive of zeero defects. Compputerized Bar codding and Back Trrack
system
ms providee Masoodd 100% prredictabillity and trracking performannce.

Embrroidery
y:

Latest Tajima embroider

e ry machiines, fullyy automaated, 6 coolor 20 heeads
each provide
p Masood
M the flexiibility annd capabbility to cater to the
custom
mer’s requ
uirementss.

37 
 
 Management Hierarrcchy in MTM
Ma

Chie
ef Executive 
Top Manag
M ement: Officer

D
Directors  

Generral Managerss

Midd
dle Man
nagemeent:

Maanagers 

Senior  Depu
uty  Assistant  Officeers 
Officers  Managgers  Managers 

38 
 
Loweer Leveel Manaagemen
nt:

Su
upervisors

Helpers  Foramens 
Operators

39 
 
 Desiggnation
n scalee at MT
TM
Chief Executive
E e Officer

Directoors Level D

Generaal Manager Level G11

Deputyy Generall Manageer Level G44

Senior Managerr Level M1

Managger Level M22

Deputyy Manageer Level M3

Assistaant Manager Level M44

Senior Officer Level M5

Officerr Level M6

Supervvisor Level S11

Assistaant Superrvisor Level S22

Inspecttor Level S33

Packerr Level S44

Helperr Level S55

40 
 
 Ga
arment Manufactu
uring Process
P s

Ginning

Shipmentt S
Spinning

Garment Manufacturing Process

Audit Knitting

Packking Dyeing

Fabric 
Finishing
Finishing

Sewing C
Cutting

Printing & 
Embroidery

41 
 
Ginn
ning:

It is a process
p in
n which cotton
c linnt and othher contam
mination in the cotton
are elim
minated. Purified
P c
cotton is compacte
c ed to balees for com
mmercial use.
u

Spinn
ning:

It is coombinatio
on of all processees which are invollved in conversionn of
fiber innto yarn. In textille when we
w say spinning
s t
then we mean to say
about the
t final process
p inn the transformatioon of fibeer into yarrn.

• Mixing:
M Mixing of
o differennt lots off cotton.
• Blowing
B : Input iss mixed cootton & output
o is “Lap”,
“ likke a sheett of
p
paper rolleed over a steel rodd.
• Carding
C g: Input foor cardingg is lap which
w is obbtained frrom blow
wing
section & output iss “Sliver”, like rope.
• Drawing
D g: Drawinng is a proocess in which
w diffferent slivvers are
c
combined together to producce single sliver. Normally
N 8 slivers are
a
fe behind
fed d one draw
wing macchine andd get an ennd producct in form
m of
single sliv
ver.
• Combing
C g: If fine yarn is required thhen this process
p iss added.
• Simplex
S : Simplexx is almosst the finiishing staage of the spinningg. In
thhe Simpleex processs, sliver is
i fed andd “Rovingg” is mannufacturedd.
F
Finished sliver
s is drafted
d and very low
w twist iss insertedd to form
R
Roving.
42 
 
 • Ring:
R In this sectiion rovingg from sim
mplex secction is tuurned intoo
fi & sop
fine phisticated yarn off differentt counts.
• Auto
A one: The primary objective
Co o of this prrocess is to assembble
a packaged from suuitable forr subsequuent proceedures suuch as
w
weaving and
a knittinng.

Yarn
n Countt:

Count is the fineness of yarn.

y Num
mber of hanks
h per pound iss called coount
(one hank is eq
qual to 8440 yards). We mayy say thaat if one pound
p cootton
makes one han
nk count will be 1.
1 If sam
me weightt of cottoon makess 10
hanks than coun
nt will bee 10 and if
i it makees 20 hannks then count
c willl be
20. Count can be
b measurred by givven formuula;

“Coun
nt = lengtth in han
nks/Weigh
ht in pou
und”

Single yarn hav

ving 20 count can be writteen as 20/1, if 20/22 it meanss 20
doublee, if 20/3,, 20/4, 200/5 it meaan count 20 is thrree ply, four
f ply, five
ply etcc.

Count is coarseer e.g. 122 or 10 then

t yarnn will be thick. Thhe wovenn or
knittedd fabric with
w higheer count will
w be finne and sm
mooth buut may noot be
durablee.

43 
 
Differrent cou
unts of yarn:
y

10 Singlee 222 Single 32 Single

12 Singlee 244 Single 36 Single
16 Singlee 266 Single 40 Single

Counts from 10 single

s to 16
1 single are
a coarserr, from 200 single too 30 singlee are
medium
m and from
m 32 single to 50 single and upw
ward are finne.

Fabrication:

Generaally there are two types

t of fabric.
f

Woveen Fabrric:

Weavinng is defiined as thhe processs of makinng fabric by interlacing yarrns.

Knittted Fab
bric:

Knittinng is a pro
ocess of making
m f
fabric by interlopinng one orr more yaarns,
insteadd of two sets of yarn crossing eacch other in weaving. Tubular
machinne are used
u for knitting. Machine gauge and settting willl be
different for thee differentt fabric tyypes.

44 
 
Typees of Kn
nitting Accord
A ding to Machin
M nes:

• Flat
F Knittiing Machhines
• Circular
C Knitting
K M
Machines

1. Circular
C Knitting
K M
Machines 2. Flat Knitting
K M
Machines

Typees of Knitted
K dAccorrding to
t Fabrric
• Single
S Kn
nit Fabric
• Double
D Kn
nit Fabricc

45 
 
 S
Single K Fabric
Knit

Singlle Jerseey:

• Solid
S Jerseey
• Jersey Spaandex
• Y/D
Y Jersey
• Auto
A Strip
per
• Feed
F Strip
per
• Engineer
E Striper

Piquee:

• Locaste
L Piique
• Honey
H Co
omb Piquee
• Bird
B Eye Pique
P

Frencch Terrry:

• 2 Thread Terry
T
• 3 Thread Terry
T
• Terry
T Spandex
• Y/D
Y Terry
y
• Auto
A Strip
per Terry
• Feed
F Strip
per Terry

46 
 
 • Engineer
E Striper Terry
T

Fleecce:

• 2 Thread Fleece
F
• 2 Thread Fleece
F
• PQ
P Fleecee
• Spandex
S Fleece
F ( Spandex)
S
• 2 Thread Spandex
S F
Fleece
• 2 Thread Spandex
S F
Fleece

D
Double Knit Fabric

Rib:

• 1X1 Rib
• 2X1
2 Rib
• 2X2
2 Rib
• Flat-back
F rib

Interrlock Fa
abric:

• Y/D
Y Interllock
• Innterlock Auto
A Striper
• Innterlock Feed
F Stripper
• Spandex
S Interlock
I

47 
 
 • Spandex
S Interlock
I Auto Striiper
• Spandex
S Interlock
I Feed Striiper

Jacqu
uard Fa
abric:

• Jersey
• Pique
P
• Rib
R
• Innterlock
• Mesh
M
• Waffle
W &T
Thermal etc.
e

The knnitted stitcches that occur in vertical columns

c are calledd Wales, and
ntal rows are calledd coursess.
those in horizon

48 
 
 Types
T of Striipes in
n Garm
ments

Feed Stripes: Those have a sm

mall repeeat of thee stripe design, whhich
generaally fits within 1.9 inches.

Auto Stripe: Those have

h largger repeatts of the stripes i.e.
i more 1.9
inches..

Engin
neered Stripe:
S A design of the sttripes whhich does not repeaated
in the garment again. Thhe size of the repeeat depennds on thhe size off the
garmennt. Wheree one reppeat endss in the fabric
f durring knittted, the next
n
garmennt starts.

Feeed Strip
pe

49 
 
 Autto Strip
pe

Engineeered Sttripe

50 
 
 D
Dyeing
It is thee process of coloriing the faabric accoording to the
t requirred color and
shades through different processees in different stagees such ass;

Singeing: The process by whhich loosee, hairy projectinng fibers are

removeed

De-sizzing: Byy this proccess gumm

my and siize materrials are reemoved.

Scourring: Thhis processs is perfformed foor removving impuurities off the

textile material.

Bleaching: Thhe process removees the natuural colorr of the material.

m

Merceerization: It is an
a additioonal treatment. It increases
i s the strenngth
and lusster of thee materiall.

Typees of Dy
yes

• Direct
D Dyes
• Reactive
R Dyes
D
• Disperse
D Dyes
D
• Sulphur
S Dyes
D
• Vat
V dyes

51 
 
Fabric Finisshing:

In thiss processs, fabric is treatedd with some

s mecchanical or chem
mical
process beforee or afteer dyeingg or priinting too give the
t fabric a
fancy/nnovelty to
ouch to make
m it more
m duraable, flexiible, soft and good in
appearrance & handling.
h

Cuttiing:

Cuttingg is the process

p o converrting fabrric into sew-able
of s cut partss. It
consistts of follo
owing proocesses.

Gettin
ng the Fabric:
F I
Issuance f
from fabrric store.

Spreaading: Manually
M o through computterized sppreading machine.
or m

Patterrn Marking: Manually

M or througgh compuuterized GGT
G patttern
makingg.

ng: Handd cutters or

Cuttin o with modern
m auutomatic cutters.
c

Bundling: Alll cut part according to roll or

o lot.

52 
 
 Priinting and itss Typees

Screeen Prin
nt:

A proccess, where ink is mechaniccally appllied to a surface

s w the use
with u a
screen..

Pigm
ment priint:

These penetratee the fabbric moree and creeate a muuch softeer feel. Also
A
useful for largerr area prinnts wheree texture is
i importaant.

53 
 
Flock
k Print::

This process in
nvolves printing of glue onn the fabrric first, applying the
fiber flock
f on the gel printed
p b keepinng the faabric on special taable
by
(electroo staticallly chargeed).

Disch
harge Print:
P

t print lighter colors onto dark backkground fabrics, they

Used to t workk by
removiing the dy
ye alreadyy present in the gaarment.

54 
 
Foil Print:
P

This printing
p method
m is based on the use
u of metallic
m f
foil paperr of
aluminnum or co
opper one.

Puff Print:
P

An addditive to Plastic sol

s inks which
w raiises the print
p off the garm
ment,
creatinng a 3D feeel.

55 
 
Heat Transffer Prin
nt:

Heat trransfer prrinting iss a methood of trannsferring a desiredd pattern via

heat onnto a subsstrate.

Embrooidery:

Embrooidery is an
a art form
m that uses close or
o overlappping stittches to form
f
intricatte, three--dimensioonal, surfface desiggns to em
mbellish piece
p gooods,
o garmeents. Embbroidery is a flat trim thhat adds interest and
trims or
differentiation to
t a produuct.

Embrooidered deesigns may be appplied directly to piece

p gooods, garm
ment
nished gaarments, or as inddividual emblemss that aree an
compoonents, fin
add-onn type of trim.
t

56 
 
 Seewing
It is the processs of conveerting fabbric cut paarts into garment
g w the help
with h
of diffe
ferent macchines acccording to
t the speecified seeam classses and sttitch
types or
o the pro
ocess in which
w connversion of mensionaal fabrics into
o two dim
three dimension
d nal fabricss is calledd sewing.

Stitch
hes & Seams:
S

Stitch: Is a formation of
o thread for the purpose
p o makinng a seam
of m or
stitchinng / a loo
op of thrread or yaarn resultting from
m a singlee momennt of
needle in sewing or knittting is callled stitchh.

Typees of Stiitches:

There are
a two basic
b typees of stitchhes.

1. Lock Stitch: (Examplles for locck stitch are

a zigzagg & buttoon hole).

2. Chaain Stitch
h:(Exampples for chhain stitcch are oveer lock & flat Lock &
usuallyy used lop
ppers).

57 
 
 m: Consissts of a seeries of sttitches ussed to joinn two or more
Seam m pliees of
materiaal / fabricc.

They are
a classiffied into following
f g types.

ms: Seam
Superr Imposed Seam ms in whiich two or
o more plies of faabric
are supperimposeed on eacch other

ms: Seam
Lappeed Seam ms in which
w o fabric are
twoo or morre plies of
superim
mposed and/or
a foldded on eaach other

Bound ms: Seam

d Seam p of fabbric is seewn over the
ms in which one ply
edge of two or more
m pliees of fabriic

Flat Seams:
S Seams inn which two or more
m pliees of fabrric are seewn
togetheer at the edges
e

mental Seams: Ornamenntal stitchhing is stittches sew

Ornam wn on onee ply
of fabrric.

m: Fabricc edge is finished with

Edge Neateniing Seam w stitcching.

58 
 
Machine Types
T B
Being U
Used In
n Garm
ment Flow
F

Lock
k Stitch:

There is one bobbin

b annd one bobbin caase in thiis machinne. In sinngle
needle lock stittch, one needle
n is used. Att one tim
me two neeedles cann be
used inn double needle
n locck stitch machine.
m Machinees under this
t type are;
a

• Single
S Needle Lockk Stitch Machine
M
• Double
D Neeedle Locck Stitch Machine
• Button
B Ho
ole Machiine
• Button
B Atttach Macchine
• Bar
B Take Machine
M
• Embroider
E ry Machiine
• Zigzag
Z Maachine
• Over
O Lock
k Machinne
• Flat
F Lock Machinee

59 
 
Finishing:

In this process stitched

s g
garments are inspeected for further puurificationn of
defectss occurred
d in the seewing proocess.

Inspecction of S/S
S Crew Neck

60 
 
Pack
king

In this the stagee finished garmentss (after fiinishing) are packeed accordding
to the buyer’s
b reequirement using different
d p
packing a
accessorie
es and
different quantitties in thee carton.

Interrnal Au
udit-Extternal (Buyer’
( ’s)

In is thhe stage of m inspecttion of thee finishedd packed goods reeady

o random
for shippment eitther by innternal Q.A (pre-ffinal or finnal) or byy the buyyer’s
d party inspector inn case of any ambiiguity.
auditorrs or third

Shipm
ment Move
M If OK Ottherwisse Re-S
Screen

If the shipmen
nt is ok then
t it is movedd. Otherw
wise it will
w be 1000%
recheckked to meeet the required quuality stanndard.

61 
 
 Laab Testting in MTM
M

Cond
ditionin
ng:

Condittioning iss essentiaal for eacch test. Condition

C ning room
m is makking
with 21°
2 tempeeratures and
a 60° humidityy. Conditiioning raacks mustt be
with crross air. Time
T is reequire forr that 4 Hoour beforre and afteer test.

Shrin
nkage Test:
T

Shrinkkage is th
he processs in whiich a fabbric becoomes smaaller thann its
originaal size, ussually throough the process of
o laundryy.

Burstting Strrength Test:

Burstinng strengtth test is to test hoow much the strenngth of the fabric is.
i It
is donee on a speecific machine on which meter
m is shhowing thhe strengthh of
the fabbric in Lbs. It is naamed Mulllen USA.

Wash
hing Teest:

Washinng test iss for the bleeding

b of dyed fabric.
f Faabric wasshed withh the
white fabric
f and
d the effe w the standard and
fect on whhite is coompared with
decidedd to give the approopriate pooints. (1-55)

62 
 
Crocking Teest:

Dyed fabric
f is rub
r with white fabbric on a specific machine and coloor of
changeed white is
i match with stanndard as thhe resultss the repoort is writtten.
About 3-4 is accceptable in
i wet annd 4-5 is acceptable
a e in dry crocking
c t
test.

Pilingg Test:

Piling testing machine

m iss to test thhe pile onn the fabrric after same
s timee. A
wooden box is rotated having fabric
f in it specifiically stittched on the
rubber pipe. Then the fabbric is cheecked.

PH Test:
T

The pH
H of the fabric is tested thhrough a procedure
p e. Fabric is dippedd in
water and
a boileed 4-5 miinutes. The water is cooledd and phh is testedd by
two meethods.

1- PH strips aree dip in thhat water and comppared witth given standards
s and
1-7 poiints are decided
d onn comparison.

2- PH testing eq
quipmentt is to testt the ph value
v of fabric,
f thee glass rod of
ph metter is dipped in thhe fabric water
w andd the valuue is apppeared onn the
screen of ph tessting instrrument. Ph
P 6-9 is acceptable for thee customeer in
most cases.

63 
 
Shad
de Varia
ation:

Light Box
B is usse for cheecking thhe shade variation
v with the standardd we
check this
t fabricc in differrent typess of lightss for the shade
s maatching.

Buttoon Pull Test:

mine the holding strength between the

Buttonn pull testt is used to determ
button and the fabric too which it is attaached. Hoolding strrength is the
force required
r to
o separatee the buttton from the
t materrial (fabriic / garmeent).

Torq
que:

Deviattion of th
he wale & coursees of thee fabric from
f 90°° angle after
a
washinng, it is caalled torqque.

The D-shape
D o fabric after waashing is called Torque.
of T T %agee of
The
Torquee can be checked
c b
by,

= Totaal deviatio
on of fabrric from original
o pllace x 1000 /Total shrink
s lenngth

64 
 
 GS
SM (G
Grams per
p Sqquare Meter)
M )

GSM
M Cutterr Sheett:

This iss a special rubber sheet

s on which
w fabbric lay down & cuut with GSM
G
cutter

GSM
M Cutterr:

GSM cutter
c help
ps to cut the fabricc in roundd shape.

There are
a very sharp
s bladdes fixedd inside thhe body of this cuttter whichh cut
the fabbric in rou
und shapee.

65 
 
GSM
M Weigh
ht Scalee:

GSM weight
w sccale weigght the faabric in grams.
g Thhe round shape faabric
lay at this
t mach
hine for weight.
w

M Finding Method
GSM M ds

With
h Cutterr

Multipply the weeight of sample

s by 100 to calculatee the GSM
M of sam
mple
fabric.

With
hout Cu
utter

If you don’t hav

ve a rounnd cutter, you can measure fabric GSM by ussing
followiing formu
ula.

66 
 
 Depaartmeents
MTM is consistting of thee followinng departtments;

1. Marketting &Meerchandisiing
2 Researcch and Deevelopmeent Deparrtment
2.
3 Production, Plannning andd control Departme
3. D ent (PPC))
4 Quality
4. y Control Departm
ment
5 Quality
5. y Assurannce Deparrtment
6 Industrial Enginneering Deepartmennt
6.
7 Procureements deepartmentt
7.
8 Stores Departme
8. D ent
9 Finishin
9. ng Deparrtment
10. I T Departme
D ent
11. H R Departm
ment
12. Finaance Depaartment
13. Forw
warding Departmen
D nt

67 
 
 1. Marrketing
g &Merchand
dising Deparrtmentt
The main
m objecctive of Marketing
M g departm
ment is to attract thhe custom
mers
by assuuring quaality with competittive pricee, sound back
b trackk system and
total cuustomer satisfactio
s on.

MTM’s merchandising departm

ment is very
v activve. It allso perfoorms
marketting functtions. As MTM iss a markeeting oriented com
mpany so this
ment hass to playy a vital role in companyy. Basic objectivee of
departm
merchaandising departme
d ent is to taake orderrs from exxisting cuustomers and
to attraact new customers
c mer by advertisem
s. It locattes the neew custom ment
in maggazines, exhibitions and by
b providding sam
mples to the
t potenntial
mers. It is most im
custom mportant responsibi
r ility is too satisfy customers
c s by
providiing qualitty produccts and tim
mely delivvery.

Mercchandissing:

Merchaandising is a buusiness onn marketting activvities ressponsible for

ensurinng a prod Merchandising
ducts desccription booth qualitty and quuantity. M
means total resp
ponsibilityy of a Merrchandiserr.

Duty of
o mercha
andiser describes
d s himselff like this;

A mann who collects

c o
order froom custoomer souurcing raaw materrials
producction on tiime with quality annd maintaains lead time.

68 
 
Garmeents mercchandising means buying raw matterials & accessorries,
produccing garm
ments, maaintainingg required qualityy level annd exporrting
the garrments wiithin scheeduled tim
me.

If anybbody hass to be deesignatedd as Mercchandiserr then thee word ittself

demannds some qualities from thatt individuual, now let us seee what alll are
the hiddden mean
nings therre in the word
w “M
MERCHA
ANDISER
R”

M- Shoould havee good Manageria

M al capacitty.

ficient in both
E- Effi b Engglish writtten and sppoken.

R- Haaving high
h sense off Respon
nsibility.

C- Alw
ways keep
p Commiitment.

H- Leaads honesst life.

A- Atttitude sho
ould alwaays be possitive in resolving
r any probblem.

N-Nevver does any

a arguee with buyyers and seniors.
s

D- Fully devoteed to his service.

s

I- Alw
ways well Informed
d about his
h all ordders.

S- Sinccere in offfice and daily worrks.

E- Entthusiasticc in naturre.

R- Reggular in e-mail
e corrrespondeence.

69 
 
Typees of Meerchand
dising:

Two tyype of meerchandisiing done in garmeent exportts

1. Marrketing merchandissing.

2. Prodduct mercchandisingg.

Mark
keting Mercha
M andisin
ng:

Main function
f of
o marketting merchhandisingg is

1. Prodduct Deveelopment

2. Costting

Orderinng Mark
keting meerchandisiing is to bring orrders cosstly produucts
development an
nd it has direct
d conntact with the buyeer.

Product Meerchand
dising:

Producct merch
handising is donee in the unit. This
T incluudes all the
responnsibilities from souurcing to finishingg i.e. firstt sample onwards, the
produccts merchandising work starrt and endds till shippment.

70 
 
Key respons
r sibilitiees of meerchand
diser arre as foollows;

• Market
M an
nd Producct Analysiis
• Product
P Developm
D ent
• Designing
D g and Sam
mpling
• Costing
C
• Confirmin
C ng Price
• Innternal & Externall Commuunication
• Booking
B Orders
O
• Preparing
P Purchasee Orders
• Raw
R Mateerial
• Preparing
P internal Order
O Sheeets
• Lab
L Dips
• Accessori
A es & Trim
ms
• Mediating
M g Productiion and Quality
Q Departmennts
• Advising
A and
a Assissting Prodduction
• Advising
A Quality
Q D
Departmen
nt About Quality Level
L
• Sampling
S
• Production
P n Follow Ups
• Taking
T Reesponsibility for Innspections
• Helping
H Document
D tation Deppartment
• Giving
G Sh
hipping Innstructionns and Folllowing Shipping,
S
• Following
F g up the Shipment
S
71 
 
 • Payments
P Follows

Most importan
i nce thinggs for a Merchanndiser arre;

c
commu
unicatio
on

Pllannin
ng

Pro
oductio
on 
Folllow U
Up 

72 
 
The reesponsib
bilities off a smartt Merchaandiser are handdling ordder
at fourr stages.

1. Sourrcing for future ordders/Buyers

2. New
w Order

3. Connfirmed Order
O

4. Runnning Ord
der

73 
 
 Busin
ness Devel
D opmeent Prrocedu
ure
MTM specialized in Méélange Yaarn, Knittted Fabriccs, Dyeinng, Garments
and a lot moree. Run byy an elitte qualityy managiing team,, it enjoyys a
favorabble reputaation amoong oversseas custoomers wiith soundd creditability
and supperb quallity.

Appareel manuffacturer inn Textilee industryy must bee developped with the
trend of
o markett otherwisse they cannot
c exttend theirr businesss. To colllect
new buuyer and business
b with them
m a comppany mustt follow thhe proceddure
of busiiness deveelopmentt. Buyers have beeen chosenn by two ways.
w Firsstly,
Buyer chooses the suppllier and the
t seconnd one soometimes,, MTM want
w
to workk with a particularr buyer and
a then contact
c w them accordinng to
with
that. The
T MTM
M follow the
t proceedure of business
b d ment, this are
developm
given below;
b

Buyer 
B Meeting  Samppling 
Seelection with buyyer  Stage

Kno
ow about  Offer to bu
O uyer 
Price 
the buyer  for visit th
he 
Companyy Negotiation
n
nature

Collect au
C udit  Price 
Firstt Email to
o 
pass repoort  ma and 
confirm
b
buyer
from buyyer order place 

74 
 
First email to
t buyeer for business
b s develoopmentt:

For new busineess develoopment seellers havve to com

mmunicatee with buuyer.
Email is the eassiest and swift wayy of comm
municatioon so wheen seller will
contracct first tim
me with buyer
b by email
e at thhat time have
h to mention
m soome
importtant inform
mation abbout com
mpany. Which
W kindd of thinggs shouldd be
includiing here this
t are;

• Innformatio
on about You
Y and Your Com
mpany.
• Products
P Informati
I on about Your Company.
• Capacity
C and
a Produuctivity.
• Innform Ab
bout Certiification.
• Which
W Bu
uyers Worrk With You.
Y
• Attachmen
A nt a Beauutiful Sam
mple Photograph.
• Waiting
W fo
or Feedbaack.

This kiind of infformationn should be includded in thiis email. On the other

o
hand thhis email will be minimum
m word andd maximuum comm
municationn.

75 
 
Samp
ple of fiirst email:

Dear Sir,
S

I am Adeel
A Maalik Mercchandiserr of Masoood Textiile Mills.. We are the
manufa
facturer & exporrter of Apparels
A , Fabrics in Euuropean and
Americcan Mark
kets. Knitting cappacity iss 95 ton per dayy and sittting
capacitty is 2000
000 piecees per dayy.

We aree specialiized in Yarn,

Y Fabric, Lounngewear, Athletic,, Sportsw
wear,
Underw
wear, Acctive weear, Sleeppwear ettc. Run by an elite quaality
managging team
m, it enjjoys a favorable
f reputatiion among oversseas
custom
mers with sound creeditabilityy and supperb qualiity.

We aree working
g with woorldwide brands
b whhich are

Aberrcrombie &
Adidas Fruit of the Loom Champion
Fitch

Aeropostale Asiam Calvin

n Klein Champs

Chaps Dockers Foot Locker Guess

76 
 
  

Haness
H Hollister Tommy
y Hilfiger Walmart

Izod JCpeney Joc

ckey Kohls

Lee Levis Li & Fung Macys

Nautica
N NFL Polo Puma

Reebok
R Sears StJoh
hnsBay Stafford

Artisans
A Tom Tailorr Under Armour V&D

We are
a prou
ud beingg WRAP
P (Worlddwide Responsib
R ble Appparel
Producction) cerrtified andd also hass the ISO--9002 & AATCC Certificaation
and thee registraation # 99908699. We
W have the logo of two-accreditaation
bodies
77 
 
 • ANSI RAB (Ameriican Natioonal Stanndards Insstitute)
A
• U
U.KAS (U
United Kinngdom Accreditat
A tion Serviice)

For furrther information visit

v www w.masooddtextile.coom

Your kind
k co-op
peration would
w be highly apppreciated.

Thank
ks & Bestt Regards

Adeel Malik
M

Faisalabbad Pakistaan

Adeelm
malik526@y
yahoo.com
m

Samp
ple Pictu
ure

78 
 
Feed –back from buyer
b in
n respoonse to first
f em
mail:

Dear Sir,

I am pleased
p ab
bout youur companny, so I want
w to make
m a business
b w
with
you. Soo you sho
ould sendd some oriiginal sam
mple incluude with FOB pricce.

Best Regards,
R

ABC

This iss happeneed in case of chooosing buyyer by MTM

M itsellf but moostly
the buyyer choosse the suppplier and in that case theyy send a product tack
t
pack first
f and
d then suupplier send
s the productt accordiing to their
t
requireement.

79 
 
Samp
ple:

Sendinng quality
y samplees to new
w buyerr for bettter understandingg of
workm
manship of the facttory. Sam
mples playy a vital role to gett new ordders.
y samplee supplierrs cannott developp a new business, so
Withouut quality
samplee should be
b better quality
q beefore bulkk producttion.

Typees of Samples:

Broadlly garmen
nt samplees are cateegorized as;
a
• Developm
D ment Samp
ples 
• Productio
P n Samplees 
Samplees that arre made in development stage are aas followin
ng: 
• Proto
P Sam
mple
• FIT
F samplle
• Salesman
S Sample/P
Photo shoot Samplee
• Size
S Set Sample
S
• Pre-Produ
P uction Sam
mple

In prodduction sttage factoory needs to submiit few moore samplees that

includees

• Top
T of Pro
oduction Sample
• Shipment
S Sample

80 
 
Protoo Samp
ple:

Proto sample
s is type of new
n desiggn createdd by desiggners. Thhis is the first
samplee in pro
oduct devvelopmennt stage.. Proto sample is madee to
commuunicate th
he designn of a style
s or a line orr to pressent garm
ment
structuure. In pro
oto samplles fit andd fabric deetailing iss not beenn consideered.

Fit Saample:

Once proto saample is approveed, FIT is beingg made with acctual

measurrement. Modificat
M ion on thee pattern is done too get desiired fit off the
garmennt. FIT is one of thhe most im
mportant factor too be consiidered durring
samplee develop T samplee is beingg tested onn live moodel or Dress
pment. FIT
form foor to verify garmennt fit andd fall.

Salessman Sa
ample

Salesm
man samp
ples are made
m p on diisplay in the retail showrooom.
to put
man sample (SMS)) are displlayed for assessingg customeer's feedbback
Salesm
and acccording to custoomers response buyers
b foorecast demand
d o a
of
particuular style. Sales sam
mples aree made with a trims and
w actuaal fabric and
accessoories. Buy
yer pays for salesm
man sampples to thee developper.

81 
 
Size Set
S Sam
mple:

The puurpose off the sizee set is too check fit

f of thee garmentt in diffeerent
sizes. In
I this staage factorry developps samplees in mulltiple sizees. Generaally,
buyers ask sizee set sam
mple in juump sizess, like S, L, and XXL. Buuyer
check size
s set saample and give feeedback too factory if anythinng need too be
correctted.

Pre-P
Producttion Saample:

All thee above samples

s a made in samppling depaartment. Buyer wants
are
b made in actuaal production
pre-prooduction sample (PP sampple) to be
line, soo that opeerators knnow whatt they are going to make. Thhis samplle is
made with ual fabric, trims annd accessoories and made byy sewing line
w actu
tailors.. PP saample muust be approved
a by buyyer or buuying hoouse
merchaants (tech
hnical perrsons) prioor to procceeding actual
a production.

Top of
o Prod
duction Samplle (TOP
P Samp
ple):

Once productio
p n is onlinne, few pieces are taken ouut in the middle
m off the
oduction pieces arre sent to
producction. Pro t buyer as TOP sample. All
buyers do not ask
a for TOP
T sampple. Purppose is to cross-chheck wheether
factoryy is follow
wing PP sample
s sppecificatioon or not.

82 
 
Shipm
ment Sa
ample:

When style is being

b finiished andd packed for
f shipm
ment, 2-3 finished and
packedd pieces with all packing details are
a kept for futurre referennce.
Shipment sample is keptt by factory merchhants and buyers merchant.
m The
ment is seent directtly to waarehouse and mercchants at the
approvved shipm
buyer do not get garmeent out off the shippment. Thhat is whhy they keep
k
shipmeent samplle for futuure reference.

83 
 
 Gettting Pu
urchasse Order
A purcchase order (PO) is a comm
mercial doocument and
a first official offer
o
issued by a buy
yer to a seller,
s inndicating types, quuantities, and agrreed
prices for prod
ducts or services.
s Acceptannce of a purchasee order by
b a
seller forms
f a co
ontract beetween thhe buyer and
a sellerr, so no coontract exxists
until thhe purchaase order is acceptted. It is used
u to control
c thhe purchassing
of prodducts and
d services from external supppliers.

Those items aree includedd in P.O. This

T are;

• PO
P Numb
ber.
• Style
S Num
mber.
• Order
O Quaantity.
• Product
P Description
D n.
• Size
S Break
kdown.
• Supplier
S Bank
B Adddress.
• Buyer
B Dettails.
• Country
C of
o Origin.
• Payment
P Terms.
T
• Carton
C Maarks.
• Fabric
F Constructionn.
• Accessori
A es
• Care
C Labeel Instructtion.

84 
 
 • P
Port of Lo
oading etcc

Sa
ample of KIK
K Purcchase Order

85 
 
 86 
 
 87 
 
Sending Pro
o Form
ma Invoiice to Buyer:
B

Pro Foorma Invo

oice is a document
d that's sennt to a buuyer quotiing/accepting
price and
a mentiioning terrms and condition
c s of paym
ment, shippment etcc. so
that buuyer can open
o LC according to the Pro
P Form
ma Invoicee. Pro Forma
Invoicee is not a real invvoice – itt's merelyy a docum
ment that declares the
seller’ss commitm
ment to supply
s thee productts or serviices fixedd to the buuyer
at certaain prices. Follow
wing is a specimenn Pro Forrma Invooice for clear
c
understanding.

88 
 
 L/C
C Open
ning byy Buyerr

Letteer of creedit:

A letteer of cred
dit is a doocument from a bank
b guarranteeing that a seeller
yment in full as loong as ceertain deliivery connditions have
will reeceive pay h
m In the event thhat the buuyer is unnable to make
been met. m payyment onn the
purchaase, the baank will cover
c the outstandiing amouunt.

a often used in internationnal transaactions too ensure that

They are t paym
ment
will bee received a sellerr may nott know eaach other and
d where thhe buyer and
n differentt countriees. In thiss case thee seller is exposed to a
are opeerating in
numbeer of riskss such as credit riskk, and leggal risk  caaused by the distannce,
differinng laws and
a difficculty in knowing
k e
each partty personaally. A leetter
of creddit provid
des the seeller withh a guaranntee that they willl get paidd as
long as certain delivery conditioons have been mett. For thiis reason the
use of
o letterss of creedit has becomee a verry imporrtant asppect
of interrnational trade.

The baank that writes

w thee letter off credit will
w act on behalf of the buuyer
and maake sure that
t all deelivery coonditions have beeen met beefore makking
the payyment to the selleer. Most letters off credit are
a governned by ruules
promullgated by
b the Innternationnal Cham
mber off Commerce  knoown
as Unifform Cusstoms and Practicce for Doocumentarry Creditts. Letters of
credit are typ
pically ussed by importinng and exporting
e g compannies

89 
 
particuularly for large puurchases and will often neegate the need by the
buyer to
t pay a deposit
d beefore delivery is made.
m

The paarties to a letter of crediit are thee supplieer, usually called the
"benefficiary", "the
" issuiing bank"", of whoom the buyer
b is a client, and
sometiimes an ad
dvising bank,
b of whom
w the beneficiaary is a cllient. Alm
most
all letters of creedit are irrrevocablle, i.e., caannot be amendedd or canceeled
withouut mutual consent of
o all partties.

Kind
ds of Letters off Crediit (L/C)):

• Revocable
R e Letter Of
O Credit
• Irrrevocablle Letter Of
O Creditt
• Confirmed
C d Letter Of
O Credit..
• Confirmed
C d and Irreevocable Letter
L Off Credit
• Transferab
T ble or Divvisible Leetter Of Credit
C
• Back
B To Back
B Lettter Of Creedit
• Red
R Clausse Letter Of
O Creditt
• Sight
S Lettter Of Creedit
• Revolving
R g Letter Of
O Credit
• Stand-By
S Letter Off Credit

90 
 
 Sam
mple- Letterrs of Crredit

Samplee- Letters of
o Credit (L/C) Pagge-1

91 
 
Samplee- Letters of Credit (L/C) Pagge-2

92 
 
Samplee- Letters of Credit (L/C) Pagge-3
93 
 
Samplee- Letters of Credit (L/C) Pagge-4

94 
 
 L/C Amendm
A ment

Sometiimes it’s found thhat some clauses of

o the L//C are contrary to the
interest of buyeer and suupplier. Inn this situuation, MTM
M askeed to chaange
the clauuses to make
m a favvorable buusiness deal for alll.

Sending Pree-produ
uction Sample
S e to Buyyer:

Pre- Production
P n Samplee When material for bulkk producttion arrivved;
factoryy makes a samplee with thhe actual material and sennds to buuyer.
Buyer wants to
o be asssured thaat correctt materiaal is souurced & line
workm
manship conformedd to the quality
q leevel. Folloow-up wiith the buuyer
for proompt deliv
very of prre-producction sam
mple maxim
mum 2 daays.

Obtainn 4 sets of pre-production samples

s f
from the productio
p on. One send
s
to buyer, one for
fo the saample storre room, one for the qualiity controol &
one forr the , meerchandiseers for futture referrences.

Pre-prooduction sample in all size

s sets should be availlable to the
merchaandisers at
a least 5 days befoore the staart of actuual produuction.

Upon receipt of
o samplees from the buyeer, matchh these against buuyer
specifiications.

Thorouughly cheeck the styling,

s m
measurem
ment, stitching, quuality of the
fabric, fabric co
onstructioon/GSM, hand feeel, washinng standaard, finishhing
of the sample
s & accessorries. .

95 
 
Pre-p
producttion Saample Approva
A al:

In any discrete period of time, whenever

w it requireed any reevision inn the
samplee, a new sample is made (sometime
( es swatchhes send to buyerr) as
per neew specification. It is sent to buuyer for his apprroval of the
mity that-the revission is done correcctly.
conform

SIZE SET:
S Con
nsists of 1 pc from
m each sizze for eachh color coombinatioon.

hes: Any
Swatch y part of the
t garm
ment to maake for particular
p purpose, not
compleete garm
ment Pre- Producttion Sam
mple Wheen materrial for bulk
b
ved; factoory makes a samplle with thhe actual material and
producction arriv
sends to
t buyer.

After getting
g thee approvaal from buuyer movves for buulk producction

Production::

Usuallyy after getting pp approoval orgganizationn moves for fabbrics

producction. Thee usual diifference between PP approoval and Productio
P on is
30 to 45
4 days.

Once sampling
s is compleeted Headd of concern Mercchandiser forwardss the
order file
f to the Head of Quality Control
C allong withh the apprroved sam
mple
& a copy
c of projectedd producttion scheedule. Make
M suree the filee is
forwarrded at leaast 5 dayss before start
s of acctual prodduction.

96 
 
A meeeting should be conductedd betweenn the Heead of Merchandis
M sing
Departtment, Co
oncern Merchandis
M ser, Headd of Qualiity Contrrol & Quaality
Controol Officer (Producttion) discuussing alll the detaails of ordder.

Obtainn an instrruction shheet coveering all the

t required inforrmation from
fr
the quaality conttrol officeer & apprrove. Makke sure anny new commentss are
added into the instructionn sheet. Regular
R f
follow upp should be
b made with
w
the buyyer & Qu
uality Conntrol regarrding the status off production. .

Obtainn daily pro

oduction status froom Qualitty Controol & forw
ward the saame
to IT for
fo updatin
ng the Web
W Site laatest by 11:00 everry morninng.

Obtainn reports of all the

t inspeections conducted
c d i.e. Faabric Quaality
Testingg, ILC, IP
PC, and MPC
M & FRI
F for evvery order from quuality conntrol
& keepp a copy for
f recordd.

Updatee Order Checklist,

C format ennclosed.

Updatee the statu

us sheet according
a ly, formaat encloseed. (Dailyy basis)

Producction mon
nitoring system with
w supppliers forr smoothh deliveryy of
fabricss & accessories:

Sourcinng differeent types of threadds and othher materiials.

Storage of cotto
on and yarrns needeed for prooduction.

Other than
t this the
t store looks afteer issuingg materiall for outsoourcing.

Raisingg purchasse orders for materrials needded in prooduction/ssampling..

97 
 
Arrangge timely delivery from supppliers, to avoid production delay.

hecking is done with suppervisionn from thhe store,, as

Cottonn/yarn ch
rejected goods are
a returnned to the supplier..

If anyy producttion proccess has been outsourced,, goods after

a enteered
factoryy premisees, are chhecked foor shortagges, damaage etc beefore issuuing
to prodduction / finishing.
f .

Good raw mateerials aree the keyy to succeessful prooduction,, minimizzing

rejectioons and ensuring
e smooth productio
p on runs. Fabrics
F a testedd for
are
color fastness
f sttandards and fabriic strengthh. A sepaarate bookklet of faabric
swatchhes can bee made avvailable, offering
o i
insight intto the rannge of fabbrics
availabble. We have goood fabricc sourcinng in the country. All testing
methodds confirm
m to ISO & AATC
CC if Buyyer requirre.

Prepaaration
n of Prooduction Files for Prooductioon
Startting:

• Approval
A Sample
• Order
O Sheeet
• Measurem
M ment Sheeet
• Assortmen
A nt
• Fabric
F Qu
uantity
• Packing
P List
L
• Carton
C Meeasuremeent
98 
 
Sendiing Proccedure of
o Pre-productioon Samp
ples App
proved by
Buyerrs, Prod
duction File
F & Pattern
P t Masteer of Faactory:
to

Collectt approveed samplle, produuction file and appproved pattern

p fr
from
buyer. Merchan
ndiser arrrange meeeting wiith produuction maanager. Give
G
clear iddea aboutt approveed samplee, production file and
a approoved patttern.
Than handover
h these item
ms to PM
M.

Prepaaration
n & Con
nductin
ng of Prre-prod
duction
n Meetin
ng
in Faactory Require
R ed forP
Producttion Plaanning in
Factoory:

Productiion Meeting– once

Pre-P o pree-producttion (PP)) samplee is
approvved (also called seealer sampple) and most of the
t trims are sourcced,
merchaants or production
p n planninng departtment coonduct prre-production
meetinng with productio
p n team, quality team
t andd sourcingg team. All-
A
importtant comm
ments, prroceduress to be followed,
f does annd don’ts are
discusssed. Scheeduling of
o PCD (pplanned cut
c date) and shippment datte is
a teams. Producttion planns, Materiial plannning and line
announnced to all
planninng – to start prooduction on time and shipp the orrder on time
t
planninng is must. Planniing is neeeded for material sourcingg, production
capacitty, line planning. Schedulinng of jobbs and ressponsibiliity is defiined
at this stage.

99 
 
This meeting
m should be
b conduucted dirrectly affter the merchandise
managger approves the concept for development. The purrpose of the
meetinng is to reeview the preliminnary produuct and package
p s
specificati
ions
and to ensure that
t the supplier
s i aware of the coompany’ss quality and
is
producct develop
pment proocedures. The meeeting shoould be of
o a technnical
fore, the supplierr shouldd bring to the meeting
nature.. Therefo m the
approppriate rep
presentatiion from
m their staff.
s Exxpect to discuss the
manufa
facturing process
p inn detail and
a addresss any pootential manufactur
m ring
concerrns or lim
mitations in regardd to mannufacturinng the paarticular item
i
being discussed
d. In thiss meetingg, the suupplier shhould be providedd an
initial specificaation filee with details
d off the gaarment thhat is to be
manufa
factured. The
T supplier shoulld be requuested wiithin a shhort periodd of
time too formally
y acknow
wledge theeir undersstanding of
o the reqquirementts. It
is a good idea to
o obtain this
t in wriiting.

100 
 
Patteern Ma
aking:
There at
a least 2 Pattern are
a markeed

First Pattern:

First paattern is the

t first physical
p v
version off any garm
ment as peer the
artworkk done by
y designeer and for developeer.

Humann Mind → Sketch → Paper Pattern → Sample

Purpoose: See the Desiggn Work & Test thhe Fitting

Statuss: Nothinng Specifi

fic

Materrial: Avaailable

Price: Not Connfirmed

Quanttity: 1 (fo
or Custom
mer) + 1 (ffor Merchhandiser)

Deliveery: As Peer Urgenccy

101 
 
Secon
nd Patttern:

Usuallyy designeer /developer alw

ways ask for somee changess to the first
patternn. Second
d pattern is made ass per com
mments.

Proto Sample:

Where first patttern is made

m on designerss artworkk, Proto sample is to
make not
n on deesigner's artwork,
a has to foollow anoother sam
mple givenn by
the meerchandiseer.

Purpoose: See the Workkmanshipp & Test the

t Factorry Skill

Statuss: Nothinng Specifi

fic

Materrials: Avvailable

Price:: Not Connfirmed

ntity: 1 (ffor Customer) + 1 (Self-Keeping)

Quan

Deliveery: As Peer Requesst

102 
 
Swatch:

Swatchh is a pressentation of all thee materialls is usedd for any specific

s s
style
/order. Usually small piiece of faabric and each pieece of acccessories are
attacheed in bo
oard paper in a systemaatic mannner. Swaatch is very
v
importtant for productio
p on line too make the correect consttruction of
o a
garmennt and QC
C departm
ment ensuures it. Concernedd merchanndiser shoould
confirm
m/approve the swaatch.

Samplee of Swattch

103 
 
Trim
ms:

Trims cover alll the item

ms used in
i the garrment exxcept the basic fabbric.
There are hund
dreds of ittems used to mannufacture the garm
ments, Prooper
selectioon of trrims andd its quaality are very im
mportant for stylling,
otherw m be rejected or returned
wise the gaarment may r b the customers.
by

Folloowing iss a partt of list that coovers soome names of

the trrims:

• Pocket
P
• T
Twill Tape
• B
Buttons
• D
Draw Corrd
• E
Embroider ry
• L
Lace
• L
Lining & interlininng
• P
Piping
• Z
Zip

104 
 
Hourrly daily
y & moonthly producction report

105 
 
Inven
ntory Report

106 
 
Prepaaration
n of Shiipping Sample
S es & Seending to
t Buyeer
throu
ugh Pro
oper Paacking & Docu
umentaation:

ping: Thee proceduure of traansportingg an item

Shipp m, usuallyy throughh the
email. Shipmen
nt is a very basic, commonn way of getting an
a item from
fr
one plaace to ano
other, or from onee person to
t anotherr. This prrocess cann be
done physically
p y or by trransportinng comm o cargo by land, air,
modities or
and sea. Shippiing sample is preppared beffore shipm
ment but it is sendd to
buyer when
w finaal inspecttion is com
mpleted. This is ann importaant samplle to
buyer that’s
t wh
hy samplee departm
ment take extra
e caree to makee it. It is send
s
to buyeer by air for
f going early.

Sending Pro
oceduree of Shiipping Samplee:

• Making
M According
A g to the Measureme
M ent Sheet.
• Quality
Q Ch
heck.
• Irroning.
• Labeling.
L
• Poly
P Bagg
ging.
• Forwardin
F ng Letter.
• Measurem
M ment Sheeet.
• Finally
F Ree-Check.
• Send
S to Bu
uyer by Courier
C

107 
 
Prepaaration
n of Paccking List
L afteer Finall Inspecction

Here are many kind

k of paacking syystem is used
u in Appparel Inddustry.
Some packing
p name
n giveen below::

1. Flatt packing
g

2. Stanndard paacking

3. Hannger paccking

The back side of the packing some sppecificatioons are included for
attractiing the buyer. In
I the store
s rooom is ussed AMS. In AMS
A
inform N Ordeer No, Sttyle No, and
mation is included such as Buyer No,
Fabric Qty. In the
t packaaging secttion while packingg the appparel induustry
follow these asssortmentss;

• Assort
A collor assort size
• Assort
A collor solid size
s
• Solid
S or solid size
colo
• Solid
S colo
or Assort size

108 
 
Invitaation to
o Third
d Party like Buureau Veritas
V
Conssumer Product
P ts Servvices
For Final
F Innspectioon

Dear Sir,
S

Thankss, recently
y we havve compleeted one order
o from
m US Buyyer. Now
w we
are reaady for fin
nal inspection. Acccording to
t our buuyer requiirement need
n
organizzation fin
nal inspecction certtificate. So
S pleasee come too our facttory
and finnal inspecction thiss order annd give thhe conforrmation date
d for final
f
inspecttion.

Best Regards
R s

Adeel Malik

Merchandiser

MTM

109 
 
Docu
uments that caan be Prresenteed for Paymen
P nt:

To receive paym
ment, an exporter or shippeer must present
p thhe documents
requireed by thee LC. Typpically, thhe payeee presentss a docum
ment provving
wing the actual goods. The
the gooods were sent instead of show
originaal bill of lading
l (B/L) is norrmally the documeent acceppted by baanks
oods havve been shipped. However,
as prooof that go H , the list and form
m of
docum
ments is open
o to negotiatio
n on and might
m conntain requuirementss to
presentt documeents issueed by a neeutral thirrd party evidencin
e ng the quaality
of the goods sh
hipped, orr their plaace of oriigin or pllace. Typpical typees of
ments in su
docum uch contraacts incluude;

Man
nifest:
• Bill
B of Exchange
• Pro
P Formaa Invoice
• Packing
P List
L
• Innsurance Certificaate
• Commerc
C ial Invoicce
• Origin
O Certificate
• Innspection
n Certificaate
• Bill
B of Lad
ding
• Forwarder
F r Cargo Receipt
R

110 
 
 2. Reseearch and Develop
pment Depart
D tment
A veryy aggresssive and creative R&D departmen
d nt is alw
ways busyy in
exploriing innov
vative prooduct deveelopmentt enablingg MTM too be aheaad of
many in the fieeld. Our keen, exxtensive and
a aggreessive Merchandis
M sing
team comprising experieenced andd trained MBA’s
M fuunctions with
w the core
c
objectiive of ren
ndering ultimate
u customerr satisfacction throough prodduct
development an
nd smoothh executioon of ordeers. Theyy are capaable and keen
k
to meeet an averaage 4~5 days
d lead time for proto sam
mples.

Expeerienced
d Profeessionall Managementt:

The MTM
M Team
T comprises a balannced bleend of experiennced
professsionals including
i g over 700
7 MBA’s, Texxtile Enngineers and
Industrrial Engin
neers. Coontinuouss training and developmentt keeps thhem
abreastt with mo
odern tecchnical annd managgement toools. MTM is WR
RAP
certifieed and ISO
O 9002 certified
c a well.
as

111 
 
 3. Produc
P ction, Planni
P ing and
d contrrol
Deparrtmentt (PPC
C)
As thee name off departm
ment show
ws that thhese peopple are ressponsiblee for
managgement off production. Thiis departtment, affter merchandiser get
approvval for bullk producction, starrts planninng the prooduction..

PC deparrtment plaans everyything acccording too the Tecck-Pack. The

The PP
planninng includ
des that in
i how much
m me period we havee to ship the
tim
producction. Thee planningg includes;

Accesssories Planniing:

Here they
t plan
n about the buttoons threaad and suuch kindd of indiirect
materiaal for the productioon.

Fabric Plan
nning:

Here thhey plan about thee fabric quantity,

q q
quality annd lead tiime in whhich
they shhould hav
ve fabric to
t make garments.
g

Under both acccessories and fabrric planniing they chose

c thoose supplliers
who prrovide theem qualitty productts at rightt time at lower
l cossts.

Controlling:

They plan
p that how muuch workkers, machines andd time iss requiredd to
producce certain production.
112 
 
 4. Qua
ality Coontrol Deparrtmentt
Qualityy Control Departm
ment cann be said as an aggent from
m MTM side
which checks th
he requireed param
meters andd recomm
mends soluution at each
e
level of
o processs. It has tw
wo sectionns;

Greyy Section:

Whichh checks th
he fabric for faultss, attaches bar codde clearannce numbeer.

Line Section
n:

This seection checks the finished and dyedd fabric for

fo faults according to
requireements.

113 
 
 5.. Qualiity Asssurancee Depa
artmen
nt
This departmen
d nt is alsoo responssible for making the prodducts quaality
orienteed. This departmeent auditts the gaarments according
a g to miliitary
standarrds. On completin
c ng the auddit this deepartmentt issued different
d t
type
of slipss to the co
oncern unnit. Thesee slips incclude;

Green Slip:

This slip
s is issued when the packing
p a
and finishhing is according
a g to
requireements.

Yelloow Slip::

This slip
s is isssued whhen theree is any discrepaancy in the packking
requireements.

Pink Slip:

This slip
s is isssued whhen there is any discrepaancy in the
t finishhing
requireements.

This isssuance of
o slips does
d not have
h any effect onn the apppraisal off the
concerrn departm
ment but these sliips surelyy affect thhe respecct of conccern
departm
ment. So
ometimes if there is big difference
d e in the product and
requireements th b impossed on the concernn production
hen penallty may be
unit.

114 
 
 6. In
ndustriial Enggineeriing Deepartm
ment
“Brancch of eng
gineering to increaase produuctivity by
b using all resourrces
i.e. hum
man, capiital, land and entreepreneurship”

I.E bellieves in that theree should be place for everyything annd everythhing
in placce.

I.E has threee Divissions:

IND
DUSTRIA AL 
ENGGINEERIING

TR
RAINING
G  PROCESSS 
MAC
CHINE SSHOP
C
CENTER
R ROVEMEENTS
IMPR

I.E perrforms fo
ollowing function
ns:

Stand
dard Allowed Minutes (SAM
M):

This iss the timee which is requireed to perrform speecificationn. This iss an
importtant task because
b i tells thaat in how much tim
it me produuction willl be
producced.

115 
 
 S
SAM is caalculated as follow
w

SAM = (Avg. siingle timee * Rating)/Basic Time + (P

Person annd Machine
Delay)) +Bundlee Handlinng Time (B
BHT)

Meassuring Efficien
E ncy:

Efficieency of workers is measuredd as follows:

(((Output * SAM) / Shifts Minutes

M N of Machines) * 100
* No.

Meassuring Perform
P mance:

mance off worker is calculatted as follows:

Perform

(((Output * SAM) / (Clock Time

T * Noo of Machhines))*100

116 
 
 7. Pro
ocurem
ments depart
d ment
It is thhe acquisition of goods
g annd servicees at the best possible cosst of
he right quuantity att the rightt time in the right place forr the
ownersship in th
direct benefits
b of
o the orgganizationn.

Funcctions of procu
uremen
nt deparrtment:

• Receive
R PPC
P sheett from stoore
• Take
T acqu
uisition
• Price
P nego
otiation
• Order
O placce
• Shipment
S of goods
• Time
T line
• Follow
F up
p tools
• A
Accessories
• Payments
P of purchaased goodds

117 
 
 8.. Stores Depa
artmen
nt
• Main
M storee
• Fabric
F store (Stockk pledge)
• Shipment
S store
• Main
M Storre

There are
a two ty
ypes of thhings, whhich comee under main
m Storee.

I. G
General:

Stationnary, macchine partts, mainteenance and sentry etc

e

II. A
Accessori
ies:

Buttonns, thread,, zips, labbels, and needles

n etc

118 
 
 9. Finishi
F ng Dep
partmeent
Main Finishing
F Checks:

1: Stain

2: Darningg

3: Re Stitchh

partment differentt activitiees are perrformed. This is very

In finishing dep v
importtant deparrtment beecause frrom here the garm
ments aree dispatchh to
shipmeent. Afterr sewing the garm
ment goes to clippinng departtment, whhere
om fabric cuts. Aftter clippinng the gaarment haas checked to
extra thhread fro
find ouut the staain and spots.
s Thhe garmennt which has stains sends for
removiing stain to separaate table where
w diffferent chhemicals are usingg for
removiing the stains.
s Thhere is 100% cheecking off measureement off the
garmennt by finaal inspecttors, whicch is alsoo anotherr check onn the quaality
of the garment. Here som
me underr quality garment
g a sendss to operaators
are
for alteeration an a rejecteed. There is a
nd the garrments thhat not eveen alter are
separatte sheet for
fo rejecteed garmennt. Finishhing in chaarge randdomly cheecks
the garrment. Fin
nally the ok garmeent sends to packinng table, where whhole
garmennt is checked 1000% beforre packinng. Then garmentss are paccked
a poly bag paccked in carton pacckaging and
into pooly bag and a sends to
shipmeent departtment.

119 
 
All thhe inforrmation regardinng shippment annd garment attacched
throughh the labeel.

Labeels:

Main Label
L

Size Laabel

Care Label
L

GMT
T Speccificatioon of garmen
g nts
• Straight
S Shoulder
• Across
A Sh
houlder
• Sleeve
S Op
pening
• Sleeve
S Insseam
• Sleeve
S Length
• Sleeve
S Length from
m HPS
• Sleeve
S Heem Heighht
• Upper
U Arm
m
• Across
A Ch
hest
• Chest
C
• Side
S Seam
m
• Bottom
B
• Neck
N Back
k Drop

120 
 
 • Arm
A Holee Straight
• Arm
A Holee Curve
• Neck
N fron
nt Drop
• Sleeve
S Length from
m CBN
• Shoulder
S Slope
S
• Waist
W
• Collar
C Ban
nd Widthh
• Placket
P Op
pening
• Placket
P Leength
• Waist
W Ban
nd Width
• Side
S Seam
m Excludiing Waistt Band
• Side m Includinng Waist Band
S Seam
• Leg
L Opening
• Leg
L Hem Height
• Fly
F Openiing
• Crotch
C Seam
• Thai
T
• Hip
H

121 
 
Pack
king Pro
ocess:

After stitching
s the
t garmeents are forward
f fo packinng. Chain flow is used
for u
for paccking onee person checks the
t produuct, otherr attach stickers,
s t
then
puttingg in Polly
y bags annd then shifting to
t cartonns. Every person who
w
done any
a operaation on the
t garmeent take a barcodee slip. Annd last sliip is
attacheed with th
he garmennts. This bar
b code is feed inn a compuuter progrram.
And caan be useed for bacck trackinng if necessary. Then
T thesee cartons are
shiftedd to shipm
ment storee for furthher proceeedings.

122 
 
 100. I.T
T Depaartmen
nt
IT Deppartment is very sttrong in thhe MTM. In MTM
M everythhing is onnline
which is maintaained by I.T depaartment. Competen
C nt staff haas develooped
their ow
wn system
ms like;

• Human
H Reesource Managem
M ment Systeem (HRM
MS)
• Apparel
A Manageme
M ent System
m (AMS))
• Apparel
A Costing
C Syystem (AC
CS)
• Fabric
F Maanagemennt System
m (FMS)
• Innventory Managem
ment Systtem (IMS
S)
• Vehicle
V Manageme
M ent System
m (VMS))
• Gate
G Management System (GMS)
• Organizat
O ional Plannning & Developm
D ment (OPD)

I.T perrforms maany otherr functionns in the MTM

M whiich are ass under;

• Card
C Scan
nning
• Bar
B Code on Finishhed Produuct
• Bar
B Code on Packeed Producct
• Catering
C
• Making
M Gate
G Pass

123 
 
BACK TRA
ACK SY
YSTEM
M:
Masoood Textilee Mills is
i the onnly textilee mill inn Pakistann with laatest
compuuterized Barcode
B S
System thhat assures quality in every operationn of
producction from
m spinninng to packking. Prodducts of each
e depaartment carry
bar cooded sticckers, whhich bearr all thee details and hisstory of the
operatiions of th m is reporrted, one can
hat produuct. Hencce if any problem
trace back
b the root
r of thhe problem
m and ennable to prevent
p o
occurrence
e of
the sam
me in futu
ure.

Scan Card

MTM
M also issue
i me scan card foor in/ou
ut.

Pictu
ures of my
m scan
n card..

124 
 
 111. HR
R Departmen
nt
HR Departmen
D nt in MT
TM is innvolved in differrent typees of hum
man
resourcce related
d activitiees. Here are
a the acctivities of
o HR devvelopmennt in
MTM as follow
ws:

• Recruitme
R ent
• Training
T and
a Devellopment
• Compensa
C ation
• Performan
P nce Appraaisals
• Employee
E e Welfare
• Rewards
R and
a Punisshments
• Retiremen
R nt and Terrminationn Benefitss

125 
 
 12. Finaance Deepartm
ment
The main objecctive of finnance deppartment of MTM
M is to maanage finaance
in suchh way thaat maximuum output is takenn by minim
mum inpuut.

MTM’s financiial adminnistrationn is very strict inn giving informattion.

Compaany rules are very strict forr it. Follow
wing are the mainn functionns of
financee departm
ment.

Finan
ncial Managem
M ment:
It deals with the cash inflow
ws and cashh outflows.

Majoor cash inflowss:

• Sales
S Colllection
• Innterest off Depositss
• Sales
S of Leftover
L
• Capital
C Gaains

Majoor outflows:

• Purchase
P of
o Raw Material
M
• Purchase
P of
o Packinng Materiaals
• Purchase
P of
o Fuel
• Wages,
W Saalaries annd Paymennts
• Duties
D and
d Taxes

126 
 
 13. F
Forwa
arding Deparrtmentt
Organiize the saafe and efficient
e movemennt of gooods throuugh diffeerent
mode of transp
portation.. We use the moost effecctive andd econom
mical
methodds of tran
nsport for goods that
t mighht be thee servicess of shippping
lines, airlines or road and raiil freighht operatoors. Thee forwardding
departm
ment play
y very im
mportant role
r for shhipment of
o garmeent to variious
countriies with using
u of many
m docuumentatioon.

They use
u contaiiner to traansfer of garments
g like 20ftt, 40ft andd 40 ft HC
C.

They use
u the following formulas
f t calculaate the CB
to BM.

L * W * H// 61023 * No. of cartons

c

F Air
For

L * W * H// 366 * No.

N of carttons

L=lenggth

W=widdth

H=heigght

127 
 
Funcctions of Forwarding Deparrtment:

• Research
R and
a plannning of apppropriatee route foor shipment
• Obtaining
O g, checkinng and preeparing documenta
d ation to meet
m custooms
a insuraance requuirements..
and
• Arranging
A g air transsport for urgent
u bassis.
• Working
W closely
c w custoomer and third parrties to innsure smoooth
with
o
operations
s to deadllines.
• Maintainin
M ng currennt knowlledge of relevant legislatiion, polittical
a other factors thhat could be affectted.
situation and
• Transmitti
T ing data by
b interneet and traccing of shhipment

Modee of Tra
ansportation

• Road
R Tran
nsportatioon
• Rail
R Transsportationn
• Air
A Transp
portation
• Sea
S Transportationn

128 
 
Docu
umentss

Bill of
o leadin
ng:

A doccument which
w esttablishes the term
ms of a contract between the
shipperr and tran
nsportatioon companny

The foollowing
g heads includees;

• Shipper
S Name
N
• Consignee
C e
• Notify
N parrty
• Export
E Reeference Numbers
N
• Agent’s
A Name
N
• Vessel
V Nu
umber
• Port
P of Diischarge
• Place
P of Delivery
D
• Final
F Desttination
• Descriptio
D on of Gooods

129 
 
Air way
w billl:

An airr way biill is a document

d tary prooof of the contractt of carriiage
betweeen the shipper and the carrieer.

It inclludes th
he follow
wing;

• Supplier
S Name
N
• Consignee
C e
• Form
F Exp
port Numbber
• Innvoice Number
• Notify
N Parrty
• Airport
A off Dischargge
• Airport
A off Receipt
• Airport
A off Loadingg
• Descriptio
D on of Gooods
• Gross
G /Neet Weight
• L.C
L Numb
ber

130 
 
Comm
mercia
al invoicce:

The coommerciaal invoice made byy the forw

warding deepartmentt.

It incluudes the following

f ;

• Innvoice Number
• Shipper
S Name
N
• Consignee
C e Name
• Notify
N Parrty
• Agent
A Nam
me
• Export
E Reegistrationn Numberr
• Payments
P Terms
• Discretion
D n of Goodds

131 
 
 SWOT
T Anallysis
SWOT
T analysiis is a tool foor auditinng an organizati
o ion and its
environnment. It is the first stage of
o planninng and hellps markeeters to foocus
on keyy issues.

T stands for
SWOT f strenggths, weakknesses, opportuni
o ities, and threats.

STREN
NGTHS
S WEAK
KNESS
SES

• ISO 9002 Certificaation. • Inncreased employee

e turnoverr
• AATCC
A Certified.
C • Hiigh cost of
o production.
• Vertically
V y integrateed. • Loow produuction cappacity.
• High
H quality produucts. • Dee-motivatted Staff.
• Excellent
E market im
mage in • Noon-Corpoorative cuulture.
thhe local and
a internnational • Innsufficientt benefitss for the
m
market. em
mployees..
• Highly
H qu
ualified
m
manageme
ent.
• Adequate
A financiall
reesources.
• Competiti
C ive advanntage.
• Adopting
A informatiion
teechnology
y.

132 
 
 • Recruitme
R ent on meerit.
• Loyal
L custtomers.
• Skilled
S Laabor.
• Broad
B and
d motivatiional
v
vision.
• Back
B Tracck System
m

OP
PPORT
TUNITIIES THR
REATS
S

• Can
C expan
nd its diviision • Enntry of neew compeetitors jusst
suuch as en
ntering in likke China, India& Banglades
B sh.
w
weaving sector
s alsoo. • Buuyer needd and dem
mand
• Can
C introd
duce its own
o chhanges.
omestic as well in
laabel in do • Poolitical instability.
innternation
nal markeet • Chhanging geopolitic
g cal situation.
• Can
C captu
ure new market
m • Chhange of government policiies.
segment. • Loow price offered
o byy compettitor
• Full
F poten
ntial of • Gllobalizatiion.
e
entertainin
ng the loccal
m
market.

133 
 
 • Can
C reduce the cost byy proper
u
utilization of
o resourcees.
• End
E of quotta restrictioons by
thhe end of year
y 2004.
• Can
C hire weell experiennced
sttaff.

134 
 
 My Person
nal Exp
perien
nce

Dutiees Acco
omplish
hment:

There are no hard

h dutiees or respponsibilitties like other em
mployee. The
work is providin
ng to me was to taake the coomplete working
w k
knowledg
ge of
all the departments of MTM
M andd the proccesses whhich are being
b flow
wed
in thosse departm
ments. Fiirst of alll a bird’s eye view
w is givess to meabbout
nt and theen I used to send in
each departmen i that every deparrtment to see
the woork. I sp m time in Markketing Merchandis
pent moost of my M sing
departm d I avaiiled the opportuunity to learn merchandis
ment and m sing
functioons.

Lean
nings:

nternee I have a great oppportunityy to see the bookkish

Learninng as in
knowleedge is im
mplementted real tiime in a business
b e
environm
ment and how
h
the bigg businesssmen ruun in the world. I availed this chaance fullyy to
polish my know a to grooom my personallity likelyy to thinkk as
wledge and
entreprreneurs.

Achieevemen
nt:

New knowledge
k e which I gained from
f this prestigioous internnship metthod
g a worthh in my real life to thinkk over soome businness
is really having
135 
 
planninng. After this interrnship I have
h some knowhoow and complete idea
i
about a textile in
ndustry thhat how they
t are running
ru inn Pakistann

136 
 
 Con
nclusioon
Masoood Textilee Mills Limited is one of thhe leadinng groupss in Pakisstan.
The syystem, thee managem
ment stylle, the pollicies & decentrali
d ized decission
makingg environ
nment is really
r rem
markable.

137