Submitted by : Abhishek Reddy

N. Venkat Ramji
Priyal Kaka
Yere Yaswanth Kumar
 CONTENT

• ORGANIZATION STRUCTURE
• CUSTOMER BASE
• INFRASTRUCTURE
• DESIGN MANAGEMENT
• RAW MATERIALS- FABRIC AND TRIMS
• INSPECTION
• MARKETING AND MANAGEMENT
• PLANNING
• MANUFACTURING PROCESS
• FINISHING PROCESS PACKAGING AND SHIPMENT
• IT DEPARTMENT
• GREEN MANUFACTURING
• PROJECT UNDERTAKEN
▪ Aquarelle Group is an international woven shirt manufacturer supplying a homogeneous

upper/middle market segment through 11 production units in Mauritius, Madagascar and

India. With a vertically integrated weaving mill, Aquarelle Group also offers dyeing,
weaving, finishing and washing operations in-house. CEO of Aquarelle Group is Mr.
Nagesh Badida.

Companies:

➢ Consolidated Fabrics Limited (CFL): specialised in manufacturing of fabric

➢ Laguna Clothing: specialised in the production of men’s shirts

➢ Aquarelle Casual: specialised in the production of casual shirts

➢ Pastel Blue: specialised in ladies’ shirts

➢ Workforce: 11,000

➢ Countries: Mauritius, Madagascar and India

➢ Turnover: MUR 6.4BN for the year ended 30 June 2018

USA Levis S PA I N Zara
Do ckers Studio Classic
J.Crew Massimodutti
Express Cortefiel
Dillards
Eddie Bauer DOMESTIC Levis
Lee
UK Ben Sherman Wrangler
Debenhams UCB
Matalan

FRANCE Burton France

Jules
Celio

N O R W AY Dress man
 AQUARELLE INDIA PVT LTD
INFRASTRUCTURE
▪ It is the international shirting manufacturing unit located in Bangalore, Karnataka.

▪ Aquarelle India Private Limited has 4 factories in total in Bangalore. (AIPL-1, AIPL-2, AIPL-6,
AIPL-7).
▪ They have a Sampling unit (AIPL-3) and also warehouse (AIPL-4).

▪ The AIPL-2, one of the production units of Aquarelle Casual, is located at No. 93/25/1 & 24;/2,
Kempanayakanhalli, Bannerughatta Dhakle, Jigani Hobli, Anekal Taluka, Bangalore- 560093.
▪ The total area covered by the AIPL 2 is 14,000 square feet. There are total 350 machines and
670 staffs in total.
▪ It receives orders from various companies and manufactures the same for them.

▪ The head-office consists of a design team, a finance team, a merchandising team and a
marketing team.
▪ The raw materials are either provided by the buyer company or are sourced by the
manufacturer .

Aquarelle India Private Limited 2 plant entrance

 DESIGN MANAGEMENT

When the company receives an order, it goes through an entire process of planning and development.
The steps are :

▪Pre –production : Tech- packs and material sheets are launched which are analyzed in the feasibility
meeting. Samples are made which are sent to the buyer for approval.

▪In-process : 1st bundle is made. Quality check is done. In case of deviation , correction is made.

▪Raw materials delivery : Raw materials like fabric and trims are bought on time and final
production is to be planned.

▪Product development : Bulk production is done. Quality check is done so as to ensure that the
demand is fulfilled. Packaging and shipment is done.
BASIC STEPS FOLLOWED:
❖Design is received from the buyer.

❖Color palette is received from the buyer.

❖CAD samples are done.

❖Handloom samples are developed.

❖Yardage samples are developed and are sent for approval.

❖When approved , feasibility meeting is done.

❖Raw materials are ordered .

❖Prototype is made.

❖Prototype is approved by the buyer.

❖Style check, color check and size check and correction if any
.
❖Bulk production

❖Packaging

❖Shipment
 RAW MATERIALS- FABRIC AND TRIMS
FABRIC : It constitutes 60% of a garment, so sourcing the right fabric plays a very important role.

• The fabric is either supplied by the buyer or is manufactured or imported by the manufacturer.

• The sourcing should be done well ahead of the production time. In Aquarelle India , the fabrics if
not produced then are sourced from Ashima, Vardhman, Blue fabrics, Hemerley/Oswal, Mandhana,
Bombay Rayon fashion Ltd., Moralgi.

TRIMS
THREAD
The quality of thread determines the quality of the garment. Fine count threads increases
the cost of the garment . They are generally available in spool or cone forms.

BUTTONS
These are used to fasten a garment. They are available in every shape, size, colour and
material. Sometimes the brand names or logos are also embossed on them.

LABELS
These are the brand tags which distinguishes one brand from the other. They have the
brand name or logo printed, woven or embroidered over them.

ZIPPERS
These are also used as fasteners. They come in various colour and materials.

INTERLINING
An insulation, padding, or stiffening fabric, either sewn or pressed to the wrong side or the inner side
of the outer shell fabric for extra weight, shape and warmth.
 DEVELOPMENT TASK
• Tech packs(style/specification sheet) are made according to the design.
• Material description sheet is prepared (Trim, Fabric and Wash)
• 1st proto type sample is made.
• Patterns are made in sample room
• Stitching of the garment is done
• Finishing process if any
• Auditor checks the sample and merchandiser prepares the evaluation report.
• The 1st meeting sample is prepared.
• Review is done regarding the style, color and shape.
• Bulk production

FABRIC AND TRIMS INSPECTION

• Fabric Inspection is carried out at Jigani factory.
• 4 point inspection system is used.
• Defects in both warp / fill directions will be assigned points under the following criteria.

Defect Range Points Evaluation

Up to 3 inches 1 Point
> 3 inches < 6 inches 2 Points
> 6 inches < 9 inches 3 Points
>9 inches 4 Points

• The acceptable quality limit (AQL) for trims is 1.5%.

• Once the fabric is inspected in the grey room, it is sent to the cutting department.
• Once the trims are inspected ,they are sent to the purchasing department.
MARKETING AND
MERCHANDISING
This department deals with the entire process of getting an order, executing it and
delivering it to the buyer within the time limit.

TYPES

Design Driven ( samples provided by company)

Jointly (design team & the customer)
Buyer’s requirement (according to the forecast)

ROLE OF MERCHANDISING TEAM

• According to the buyers requirement

• Meeting is fixed
• Issuing of tech pack
• Development of sample
• Comments
• Issuing of order sheet
• Bulk production

ROLE OF A MARKETING PERSON

• Understanding current and potential customers

• Gathers information on product
• Proper pricing of the product
• Customer relationship management
• Managing budgets
• Developing the marketing strategy and plan.
• Management of the marketing mix.
• Ensuring timely delivery.
Spreads Markers Production
It translates customer orders into cutting orders

➢ minimize total production costs

➢ meet deadlines

➢ seek most effective use of labor, equipment, fabric and space

➢ Examining incoming orders and piece goods width and availability

➢ Determining volume, size ratios, and sectioning procedures for marker making

➢ Determining whether file markers are available or new ones are needed

➢ Developing specifications for optimum marker making and fabric utilization

➢ Determine most effective use of spreading and cutting equipment and personnel

➢ Issuing orders for marker making, spreading and cutting

Marker planning Lay planning
➢ Is a diagram of a precise arrangement of pattern pieces for a specific style and the sizes
to be cut from a single spread.

Marker Making
➢ is the process of determining the most efficient layout of pattern pieces for a specified
style, fabric, and distribution of sizes (requires time, skill and concentration)
➢ Marker making is a critical step in the manufacturing process.
➢ By retaining strict control over this critical step, they keep the fabric consumption as low as possible.

➢ It also ensures that the issues that affect quality will be given proper attention. These include placing
patterns on grain, keeping patterns paired, and attending to details such as drill holes and notches.

➢ Depending on the relative efficiency of each marker produced, the company may save
or waste thousands of dollars a year.
 Computerized marker
Manually produced
making (CAD)
 Area of patterns in the marker plan / Total area of the marker plan X 100%

➢ It is determined for fabric utilization

➢ Minimum waste

Factors affecting marker efficiency

➢ Fabric characteristics (fabric width, length of design repeat etc.)

➢ Shape of Pattern pieces (large pieces –less flexibility)

➢ Grain requirements
 MANUFACTURING PROCESS

PATTERN MAKING

It is one of the earliest steps in the development of a garment.

For shirting pattern they create standard patterns either by photographing or
scanning existing patterns or by modifying one of the standard blocks supplied
with fashion cad.

LAYING AND SPREADING

Laying out your pattern on the fabric to prepare for cutting is an important step.
The laying tables specially are made as air floatation tables which ensured easy
sliding of fabric. The long length of the tables made the fabrics easy to spread and
cut.

CUTTING

The process of cutting different parts of the shirt using straight knife cutting
machine. It can generally cut 150-200 layers depending upon its efficiency.
 Power system

Handle

Sharpening

Cutting blade

Blade guard
Up and down movement
One way thrust as the circular
blade makes contact with the
fabric

Base plate
Ticketing Bundles
Ticketing
➢ Tickets carry details : style no, size,
ply no, bundle no., date issued
➢ Operations may be incorporated for
payment purposes, control of work
and facilitating quality control
Bundling
➢Small batches of garments move from one work station to another in a
controlled way
➢ Tens, dozens, 2 dozens, etc.
➢ If ticketing is not done, a top ply labeling system is done

Bundle ticket consists of :

▪ Order no. 6015
▪ Bundle no. 1430
▪ Quantity 12
▪ Style no. 3145
▪ Size 12
▪ Section collar
FUSING
The process of attaching cloth/paper fusing to the fabric so as to enhance its
Strength, shape and look of the garment.

SEWING

Sleeve attachment ( 2 side sleeve attachment and laser sleeve placket folding)

1. Back ( Ironing , making back pleat and yoke stitch)

2. Collar ( Joining collar, trimming collar and inserting collar band)

3. Cuff ( Hemming, sewing and trimming cuff , Ironing )

4. Front ( Front placket, bottom hem, pocket attachment and side tag )

5. Assembly ( All parts of the shirt are attached together to complete the process)

6. Inspection ( Measurement check, stitch check, thread trimming )

 COSTING
• Fabric constitutes 60% of the cost a shirt.

• The fabric cost generally includes :

• fabric cost + trims cost + washing cost + supporting material cost + embroidery or printing cost
+ finance cost + standard minute value + profit = final cost

• The fabric cost is calculated according to the total fabric used x the price of the fabric per
metre.

• Different trims have different values and may include trims like buttons, tapes

• zippers, tags, wash care labels and many more.

➢ Finishing is the last stage of garment production where garment gets its final look.

➢ In this department each garment undergoes different finishing processes.

➢ It undergoes for quality check for several number of time which sets the garment free
from defects.

➢ Buyer specifications and instructions are strictly maintained.

Operations performed at finishing stage

➢ Thread cutting: Uncut threads affect the presentation of finished and packed garments. Therefore, it
is necessary to cut and trim the loose and uncut threads.

➢ Stain removal: Removal of the following type of stains:

➢ Oil, yellow, black and paint spots, stains due to color bleeding, ink, rust, tracing marks, yellow stains,
and hard stains

➢ Seam ironing: Ironing of garments using steam ironing tables with vacuum boards.

➢ Final finishing: The entire garment is finished using various finishing equipments.
➢ Tagging and packing: The pass pieces are brought to the tagging and packing section. It is the
responsibility of the packing supervisors to provide the tagging operators with the appropriate
price and brand tags. He also instructs the tagging operator as to where and how the tag has to be
placed. The most important thing to be kept in mind while placing the tag is to match the size
mentioned on the main label and the size on tag.
Presentation checking and carton packing

➢ Tags and price stickers are as per specification.

➢ Packing is secured or not if specified.

➢ Poly bags should not be soiled and torn.

➢ Hangers are there or not if specified.

➢ Garment has been folded as per specification etc.

➢ Number of garments to be packed in one carton.

➢ Ratio asked for example S:M:L=2:1:1

➢ Packing the garments in the cartons as per specified.

➢ Closing the cartons with cello tape.

➢ Sealing the cartons with plastic cord.

➢ Writing on carton information like: Store or buyer name, buyer's address, ratio, net weight of

the carton etc.

 I.T
DDBMS (Digital Database Management System):

The DDBMS is the most innovative part of Aquarelle India. It is an in-house software developed by the
company itself. The DDBMS is used to keep track of the hourly production in the shop floor.
Process of DDBMS:

Enter the no. of machinist present

Choose the styles to be cut/sewed

Bundle sheet is generated

SMV stickers are generated

The bundles are scanned every hour

Unmatched bundles are noted DDBMS Interface

Efficiency of each operator, line and section is known

At the end of the day, WIP report is generated Working
VAS Software:

This is a database used by Aquarelle which gives details about the following:

This software has various phases.

PHASE 1-Video data analysis and SMV calculation.

PHASE 2-OB generation and Thread CU calculation.

PHASE 3- Skill matrix

Focussed training on the use of VAS.

VAS Interface
SMV of each operation is derived.

CU i.e. the thread calculation for each garment is derived using appropriate formulae.

The operation breakdown format is there in the software according to Aquarelle standards.

Video data analysis is done to find out elapsed time for each operation.
GREEN AREAS

About 20 percent of the site area has been developed as green area using native plantation, thus
considerably reducing the landscaping water demand. All the empty and free spaces in the industry
will have plantations and even in the parking area and free spaces, gardens which will also have a
good green impact towards the industry. Open space planted with trees and flowering plants and
rainwater fed pond.

CARBON NEUTRAL

providing alternative transportation solutions to associates in the industry they are able to reduce
emissions, and planting trees to offset carbon emissions, will become carbon neutral in the long run.
All the departments are in the walkable distance and thus there would be no need of any fuel
intensive vehicles.

ELECTRICITY: SOLAR
Water Management in Green Manufacturing

•Minimizing water usage can be achieved by installing greywater and rainwater catchment systems that
recycle water for irrigation or toilet flushing; water-efficient appliances, such as low flow showerheads,
self-closing or spray taps; low-flush toilets, or waterless composting toilets. Installing point of use hot
water systems and lagging pipes saves on water heating

Rainwater harvesting

•Rainwater harvesting (RWH) can be defined as the collection, conveyance, and storage of rainwater for
an intended use. Roof Rain Water Harvesting (RRWH) is the practice of capturing the rainfall from roofs,
diverting it through gutters and drains, and storing the water in tanks of various sizes for later use.

•Rainwater may be collected from any kind of roof. Tiled or iron sheets are easier to use and produce the
cleanest water. The only common roof not suitable for roof catchment is that of lead flashings or those
painted with lead based paints. Roofs made of asbestos can be used if fibres chips have not been
detached from damaged areas

WATER SUPPLY, DRAINAGE & SANITATION

•An underground water storage of capacity 1,00,000 l for fire safety and cooling system will be there in
the planned industry. Rainwater harvesting pond of capacity 20000 l is attached with terrace pump of
pumping power 900 l/min
EFFLUENT TREATMENT

Effluent refers to the wastewater (treated or untreated) that flows out of a treatment plant, sewer, or
industrial outfall.

There are generally treated by a combination of physical-chemical and biological treatments. The
steps are as follows:

Preliminary Treatment:

removes materials that could damage plant equipments.

Primary Treatment :
Removes settle able and floatable solids by electro-coagulation.

Secondary Treatment: Removes dissolved and colloidal suspended materials by biological action.

Disinfection: Removes microorganisms to reduce or eliminate the possibility of diseases.

TOPIC: Product Traceability and Real time Information
Sharing
OBJECTIVE: TO FIND THE BEST COST EFFICENT SOLUTION FOR LIVE TRACKING OF GARMENTS
METHODOLOGY: TO STUDY THE EXISTING METHODS OF TRACKING AND BRAINSTROM

WHAT IS A BARCODE?

Barcodes are those thin black lines on a label

accompanying a product in a store, and the person
manning the check-out counter scans it. This displays
the product information and price.

Barcodes are machine-readable information present

on a surface that one can scan using special scanners.
Barcodes are also called “Universal Product Codes”
(UPCs), and they help in faster check-out, managing
inventory, keeping track of items, etc.
▪ Businesses use barcode scanning software to scan barcodes and capture information for
further processing. Such software sends the contents of barcodes to the relevant computer
systems of the company.
▪ Barcode scanning systems are quite advanced now, therefore, most barcode scanners
operate in plug-and-play mode. Organizations operating them don’t need to install any
software separately since it comes bundled with the scanner.

WHY DOES BARCODE SCANNING SOFTWARE MATTER?

▪ Barcodes and barcode scanning software have made a big difference to the world of
business, and their advantages are as follows:
▪ The check-out process in stores was slow and manual, however, barcodes have changed that.
▪ Barcodes and barcode scanners have reduced human errors.
▪ Employees need less training, thanks to barcodes and barcode scanning software.
▪ Businesses can use labels with barcodes on almost anything, e.g., merchandise, envelopes,
packages. This improves the business processes in nearly all functions.
▪ Above factors result in improved operations, therefore, businesses reduce their costs
significantly.
▪ Barcodes also help in complying with regulations. Heavily regulated industries like pharma
or shipping have stringent labeling requirements, and barcodes make it easy to meet these.
▪ The cost estimation will depend on several factors, e.g., the number of features, geography,
local labor market, tools, platforms, etc. In this article, I will describe the variables for cost
estimation, so that you can plug in your exact requirements and arrive at a cost estimate.
▪ The variables are as follows:
▪ The cost of manpower: This is the labor cost for the software development team. I
will estimate the person-months you need, subsequently, you need to apply the
labor rate to arrive at the manpower cost.
▪ The IT infrastructure cost: I will explain how you can get a pricing plan from a
cloud services provider, and you need to determine the pricing tier you need.
▪ Tools cost: This could include “Software Development Kits” (SDKs), “Application
Programming Interfaces” (APIs), project management tools, and any other relevant
tools. I will show how you can get the pricing plans, following which, you need to
choose the pricing tier.
▪ Administrative costs: This could include hiring costs, travel, etc. These costs depend on your
geography, labor market, etc.

BARCODE SCANNNER BARCODES

▪ Barcode systems can be easy to implement in small scale retail environments

▪ Barcodes can be easily printed in house on cheap materials, such as paper or plastic

▪ It’s much cheaper to use a barcode system, as opposed to RFID technology

▪ The accuracy of barcodes is generally thought to be better than RFID

▪ Barcodes are a universal technology and can be read from basically any scanner
▪ The key disadvantage for barcodes is that they require a line of sight in order to be read.

▪ Barcode scanners usually have to be within 15 feet of the barcode in order to read its data.

▪ Barcodes are typically printed on paper or plastic, which makes them easy to damage. A
damaged barcode can’t be read by a scanner.
▪ Items must be scanned individually if you’re using barcode technology.

▪ Barcodes can be easily counterfeited or replicated.

▪ Only the type of item will be contained on a barcode, whereas RFID provides a code for
every individual item.
▪ Barcodes contain only basic information relating to the product.

▪ Barcodes are read only and information cannot be updated or added.

▪ There’s so much data to manage, process, and analyse that it becomes difficult to do it manually.
Manually collecting data takes a lot of time, effort, and energy. However, choosing an ERP system is
not enough. Your system might still expose inefficiencies. facing problems like:
▪ Increased inventory overstock issues

▪ Poor customer service

▪ Imbalanced incoming and outgoing records

▪ Increased office expenses

▪ Manual errors in inventory stocking and dispatching

▪ Barcode technology is the proven solution for many of your manufacturing, inventory, and
distribution woes. It is currently the most used and accessible method to track the “stuff” in your
warehouse.
▪ A barcode can transform your business from being inefficient and slow to productive and
streamlined when integrated with an ERP system like Dynamics ERP.
▪ The success and growth of an apparel manufacturing business depend on how well cross-
department production information is delivered, handled and executed in real-time. What is
required is a reliable platform to fulfil all these aspects of the business.

▪ RFID (Radio-frequency identification) technology is the call of the hour to improve the
operational flow in such a complex environment of apparel production business. It collects and
analyses production data during the entire production workflow on a real-time basis. This
specifically deals with common production problems encountered on the shop floor.
▪ The process flow of the system has been explained in the following:

▪
Data preparation: Data preparation consists of tasks such as a listing of operations for the style
Assigning of SAM for each operation. Listing of employees, supervisors Listing of machine type
and class. Create bundles for each cut (lay).
▪ Assigning job/operation to the terminal: In the line, each operator would perform the specific
job. Prior to start work on the workstation, operation is assigned to the terminal (workstation).
Assigning of job can be done by using job cards or entering the job number manually to the
terminal.
▪ Issuing card: According to the bundling done by the cutting department, RFID cards are
scanned by RFID scanner to assign bundle number to the cards. Assigned cards are issued to the
cutting department. These cards refer to the bundle numbers created on the computer. Bundle
numbers includes information such as quantity of garment, size, color etc. Bundle cards are then
attached to the bundles.
▪ The primary objective of an RFID based real-time production tracking system is capturing
real-time data and viewing the report in real-time.
▪ Improving process visibility and transparency. Accuracy in production data.

▪ Data capturing and getting data automatically through scanning RFID tags in the
workstation. Once you have captured data from the desired activity in the pre-defined
parameters, you can play with the data and build reports and KPIs as you need.
▪ Each factory is unique, and different garment factories view daily production reports in
different formats. The inbuilt reports in a real-time production tracking system are limited.
In case the factory wants additional report matching with their existing excel reports,
suppliers can develop the customized report with/without additional charges.
▪ The involvement of the line supervisors, line leaders and sewing operators is essential for
a successful implementation. Sometimes questions come – why operators should spend
time on scanning RFID and follow the new system if they are getting any benefits from this
system (in the salaried environment).
▪ real-time production tracking systems is used as standalone software and not integrated
with the ERP and payroll systems. Engineers become the lead for the system installation
and maintaining the system. When an IE leaves the factory, factory face issues in
maintaining the system.
▪ During the implementations, factories develop many custom reports. But after a few
months, they used to view and track only a few reports.
▪ Most of the factories do not have a database team (IT team having knowledge of SQL DB
and report preparation from SQL database) for developing reports internally. In such a
situation, factories can’t utilize the data they captured.
1. Equipment Costs
In a typical manufacturing setting, RFID readers are needed at all entries and exits, as well as in
common material storage areas. If a tagged item is placed in an area where readers are not present,
the item cannot be located. The location could possibly be inferred by the last seen entry/exit event
or by manually “hunting” for the tag using a handheld reader. The use of handheld inventory “guns”
is especially common in Aerospace RFID.
2. Installation Costs
Passive RFID installation must be done by an expert who is well versed in tuning the equipment,
directing the antennas, running the necessary connectivity tests, and configuring settings and
networking details. The readers are generally connected via a LAN network to a central server, which
is typically on site and processes all of the RFID data.
3.Tag Costs
One of the primary benefits of passive RFID is the low cost of tags, which usually run for much less
than a dollar. One exception is if you need to tag a metal object, in which case the tags will be
slightly more expensive because regular passive RFID tags won't perform appropriately. There are
other highly specialized RFID tags for laundry or autoclaves that can run even higher.
4.Software Costs
Passive and active RFID readings are useless without asset management software—and this kind of
software can run you a pretty penny. You can learn more about the capabilities to look for in real-time
location system (RTLS) software.
Generally, the complexity and specialization of the software drive the cost. A basic tag reading
software could be an open-source project, whereas an integrated RFID to ERP enterprise application
could cost hundreds of thousands of dollars to maintain.
5. Ongoing License Costs
While active RFID licensing costs are typically bundled with the software, passive RFID technologies
often require ongoing licensing costs that go toward support and software upgrades. These can be
quite expensive, so be sure to account for this cost before you select a passive RFID technology.
6.Maintenance Costs
As mentioned above, passive readers are more complex than active readers due to their extensive
cabling, antennas, etc. And because the passive readers are fairly large, they’re at a greater risk of
being snagged or bumped, which could lead to costly maintenance issues over time.
7.Integrator Costs
If you choose to purchase an active or passive RFID solution from an integrator, you’ll likely pay a
premium over what you would pay if you were to go directly to the technology solution provider. That
said, integrators often have teams of experts available to help you select the best technology to fit your
problem, which could make the additional expense worth it.
 TABS INSTALLED IN A WORKPLACE TO COLLECT DATA

▪ Unlike barcode scanning using scanners and RFID and using tabs to collect and analyze data in
the centralized database is simple but sophisticated and a costly one.
▪ Barcode scanning requires scanning of barcodes every hour to update the data which requires
some labor and hard work in return of nothing to the company or the worker. And also, the
barcodes may get damaged or lost and false info may get updated.
▪ Where as RFID is mostly used in bigger industries where RFID tags gets scanned to update data
this also requires a good base to develop this model and requires a lot of training to the
employees and labors to get this model started. This requires a large investment in return for
nothing. It is an investment just to collect data easily.
▪ SO, Usage of digital tabs is a better method to collect and analyze data easily by each and every
worker and employee.
 COST

INDUSTRIAL TAB
Minimum price: 19,999 rupees
For example, there is need to establish 400 tabs at the work stations
19,999 x 100 = 19,99,600 (20 lakhs approximately)
•And also, to maintain and train employees is a need.
▪ Through the use of touch display equipment in each clothing manufacturing scene, the data of the
whole production process from cutting machine to delivery can be grasped in real-time.
▪ At the same time, it can return to MES production management system and manage the real-time
production progress, production balance, product quality, flow direction of semi-finished products,
factory efficiency, worker efficiency, IE operation data, IE data analysis, etc. through data analysis, it not
only shortens the auxiliary processing time of clothing manufacturing, greatly improves production
efficiency, reduces the defective rate and raw material waste, but also reduces the area of semi-finished
products, ensures the quality of products, and reap the dividends of intelligent clothing manufacturing.
▪ Data can be checked at regular intervals
▪ Quotas can be pre-set in advance to avoid any mismatch within panels

▪ By programming logical checks in advance, any logical errors in data can be avoided
▪ Since data will be directly inputted by the interviewer in the program, it removes possibility of errors
during data punching
▪ Closed ended data can be made available within 36 hours of fieldwork completion in comparison to
48-60 hours currently
▪ Supplementation of interviews with audio recordings, photos, and videos
▪ Get geolocation of the interviews
▪ Set quotas within the systems – better quota controls
▪ Modification of surveys at any time – even just before use or while a study is ongoing
 ▪ Barcode scanning is used in many industries till today compared to RFID and using
tabs because these other 2 methods are very costly in terms of money to implement.
▪ So, barcode scanning is perfectly implemented in industry now a days but there
comes disadvantages also using this method and also for perfection there is a need
to used Tabs but money and investment matters to do that.
▪ After brainstorming for different low cost and perfect method we can up with an idea
which we can say a mixture of barcode and tab method I’m going to explain the best
method which can be implemented in the manufacturing units as a best process to
collect and analyze data.
▪ We came up with an idea of QR code scanning which can also be called as Quick
response scanning where QR scanners are used but not the normal ones. we
changed and programmed the old QR scanners because there is need of security,
location tracking, continuous input of information of the work done by the worker.

HOW QR CODE SCANNING IS USUALLY DONE A QR SCANNER

 PROCESS
▪ First of all, we are going to generate a QR code for the ERP software.

▪ Then we are going to provide the QR codes for the bundles and update the info of the bundles in the
database.
▪ Once the bundles after cutting QR is attached to them where the info about them is updated and sent it to the
workers of different sections.
▪ There the workers scan the QR’s with the modified version of the QR code scanners and they should provide
their finger prints then the page is opened in the touch screen display LED placed in the work stations which
is connected to the QR code scanners.
▪ The New QR code scanner which is placed in the workstations to update the data of the work comes with
GPS module and finger print sensor.
▪ Numbers are given to the QR scanners which are placed in the workstations and through GPS module in the
QR scanners we know which QR scanner is placed in which workstation.
▪ So, the details of QR codes numbers and their GPS details is also updated in the database so we will know
which scanner scanned which QR code attached to the bundle at which workstation and also which
employee updated the data through his finger print
▪ If an employee is facing issues or doesn’t have any prior knowledge about QR code scanning can be
trained which cannot be a burden on the industry.
▪ We will start giving these modified QR scanners to different workstations in the industry based upon the
machinery and workstations starting from Cutting section.
▪ Follows to loading sections where this modified QR scanner replaces his work manually entering the data.

▪ Then for example where 300 workstations are there we are going to establish 100 modified QR scanners in
the industry.
▪ Cutting, sewing, assembly, loading, unloading, finishing, packing gets these modified QR scanners where
location tracking is easy and precise data is put into the data base immediately after finishing one”s work.
▪ Once the QR scanning and finger print scanning is done employee details and work station details are
updated and when the work is done we can confirm by pressing the green tick option that is displayed in the
display monitor.
▪ Data can be checked at regular intervals

▪ Quotas can be pre-set in advance to avoid any mismatch within panels

▪ By programming logical checks in advance, any logical errors in data can be avoided

▪ Since data will be directly inputted by the interviewer in the program, it removes
possibility of errors during data punching
▪ Closed ended data can be made available within 36 hours of fieldwork completion in
comparison to 48-60 hours currently
▪ Supplementation of interviews with audio recordings, photos, and videos

▪ Get geolocation of the interviews

▪ Set quotas within the systems – better quota controls

▪ Modification of surveys at any time – even just before use or while a study is ongoing
▪ By making the modified version of barcode scanner like POS machine to scan the QR code to
feed the data by employee by confirming his identity through finger print scanner.

▪ location can be easily known whenever the employee scans the QR code and it automatically
saves the location. Also, if the bundle is lost and found or misplaced by scanning the QR code we
can know

▪ Also, usage of the modified QR scanners system tracks the efficiency of each line, tracks the
performance of each sewing machine and each worker. Most importantly it detects the source of
the problem in real-time. It shows who is working in which bundle, fast resolution of bottlenecks
and rapid tracing of quality issues to their source.

▪ So, through this we can understand that with proper modifications, time, training, with the help of
IT department we can successfully use our solution to replace barcodes, tabs, RFID.
▪ https://leanstitch.com/

• https://dfcentre.com/economic-and-social-sustainability-of-the-garment-
industry-possible-strategies/

• https://www.advantech.com/products/industrial-tablet-pc/sub_1-2kwkn0

• https://www.getapp.com/operations-management-software/enterprise-resource-
planning-erp/f/barcode-scanning/

• https://www.intech-systems.com/integration-of-barcode-scanner-and-erp-
system/

• https://www.sensrtrx.com/how-do-you-turn-excel-data-into-a-manufacturing-
dashboard/

• https://www.coursera.org/lecture/advanced-manufacturing-process-
analysis/data-collection-in-different-manufacturing-settings-RnPtH