SHAHI EXPORTS

PVT. LTD.

Research by:
- Abinash Mohanty
- Vishal Kashyap
(Batch: Fashion Technology, Semester 6)
THE OBJECTIVES 01

THE
OBJECTIVES
The Apparel Internship

14 weeks Observations and

work over

To gain substantial
knowledge and
psychophysical
enlightenment of the
practical aspects of the
working culture in a garment
industry.

To apply the theoritical

knowledge in various
crunches and enigmatic
situations.

To contrive Projects for the

betterment of the industry
THE GIST 02

THE
GIST
We did the Apparel Internship in Shahi Exports PVT. LTD.
In Noida for the period of 14 weeks under sincere
guidance and comfort.

There are two projects that we proposed with constant

explorations and discussions so as to make it more
allusive and concise.
We covered all the departments by thoroughly observing
the macro and the micro levels of the work culture and
technicalities.

The interactions with the Managers of Production,

cutting , industrial engineering and finishing was very
informative and guided us to frame our projects to
absolute knowledge.

Value Stream
Mapping Of
Value Stream Finishing
Mapping Of Department &
Cutting Layout
Department Improvement Of
Checking Tables

PROJECT 1 PROJECT 2
COMPANY 03
PROFILE

COMPANY
PROFILE
Name: Shahi Exports Private Limited
Established: 1974

Website
http://www.shahi.co.in

Industry: Apparel & Fashion

Type: Privately Held
Owner: Mrs. Sarla Ahuja
Managing Director: Mr. Harish Ahuja
Address: Industrial Plot-1, Sector 28 Faridabad, Haryana
Work Force: More than 100,000
Capacity: Over 2 million high quality garments per month
Retail House: At Last & Co. , New York
Fabric Processing: Sarla Fabrics, Ghaziabad
Annual Turnover: INR 4500 crore (Group Turnover)
ABOUT THE 04
COMPANY

ABOUT THE
COMPANY
SHAHI Exports Pvt. Ltd. is engaged in the manufacture
and export of readymade garments in the International
market. It is No 1 .Export house of India having an annual
turnover of 450 million USD.

The Group is into manufacturing of a wide range of

Men’s, Ladies wear, Kidswear and also in Home
products. SHAHI group has all the modern units
equipped with state-of-the-art technology giving the best
to its buyers. It caters to a versatile client base of US &
European market like Walmart, Target, A&F, Hugo Boss,
FCUK, H&M, Liz Claiborne, GAP, CK, Espirit, Zara etc. 

SHAHI Group’s commitment to quality can meet global

quality standards. Its ranking given by J.C.Penney, the
world-renowned departmental stores, is one of the best
in Asia.
ABOUT THE 05
COMPANY

THE COMPANY’S PRODUCT RANGE : T-shirts, casual

wear tops & bottoms, jumpers, dungarees, vests, skirts,
fleece jackets and tracksuits for men and women. It also
manufactures bed & table linen, sheet sets, deck pillows,
bags and fashion accessories under the home furnishing
products segment.
THE UNITS : 51 manufacturing facilities spread Delhi,
Karnataka and TN. The facilities are equipped with
machineries to handle embroidery, washing, garment
dyeing, fabric processing, knitting and printing activities.

INSTALLED CAPACITY : manufacturing around 1 million

pieces of knits and 2 million pieces of woven products
per month.

The company earns its entire revenue from export of

knitting, woven and home furnishing products to its
clients in the US , Asia and Europe.

Shahi Exports is accredited with SA-8000 quality

certification.
ABOUT THE 06
COMPANY

MAJOR BUYERS
ABOUT THE 07
COMPANY

COMPANY POLICIES

Against child Labour

Against forced Labour
Health and Safety
Freedom of Association & Right to Collective Bargaining
Against discrimination
Disciplinary Practices
Working Hours
Remuneration
Outside Communication
Access for Verification
SHAHI EXPORTS 08
PVT.LTD, NOIDA

SHAHI EXPORTS
PVT. LTD. ,NOIDA C 35
YEAR OF ESTD. – July 2012

AREA COVERED – 4038 SQ.MTR

TOTAL WORKFORCE – 2500

The Unit is running with optimum versatility with four

floors to support its management.

The unit is headed and managed by Gen. Manager Mr.

Uday Nair

The Unit has almost the same buyers as the generalized

list suggests.

Spread across a large area it also has Parking space and

canteen of its own.
DISJUNCTURE 09

DISJUNCTURE

Ground , 1st and 2nd floor are

BASEMENT: Reception,
designed such that the
Meeting Room, Cutting
production floor, finishing (with
Department , Fabric & Trim
packaging ) function under one
Store, Dispatch section
roof in each floor

The canteen and maintenance HR department is located on

room is located on the terrace. the ground floor
ORGAINISATION 10
CHART

ORGANISATION CHART

FACTORY HEAD

Production Manager Quality Manager PPC Asst. Manager HR Manager

Floor Bundling Finishing Quality- QA Executive- Maint. Safety

Incharge In-Charge In-Charge Asst.Manager Finishing Manager Offices

Line Jr. Jr.

Incharge Executive Executive
House
keeping Welfare Executive
In- Officer H.R
charge

Checking TC Press Packing

In-charge In-charge In-charge In-charge
ORGAINISATION 11
CHART
DEPARTMENTS 12

DEPARTMENTS

Fabric & accessories stores

Industrial engineering
Sampling department
CAD section
Cutting section
Sewing section: in-line finishing
Quality assurance
Human Resources
Maintenance Department
THE GIST 13

DEPARTMENTS

STUDY &
OBSERVATION

PROCESS
FLOW

INFORMATIONS
HUMAN RESOURCE 14
DEPARTMENT

HUMAN RESOURCE
DEPARTMENT
Human resource department plays a vital role in the
working of any organization.

It is the only department who is responsible for building

the company’s work environment by placing the right
person for the right job.

Shahi exports pvt. Ltd. Noida has a time office and HR

fraternity under Mr. Manoj Tiwari, HR Manager.
HUMAN RESOURCE 15
DEPARTMENT

HR
Planning

Recruitment, Labor
selection & relations
introduction

Personnel
administration
HRM Succession
& Career
planning

Training & Talent

development management

Performance
& reward
management
FABRIC 16
STORE

FABRIC
STORE
The fabric store records data regarding the inward and
outward movement of the fabric in the specified quantity,
both to and from the departments.

Fabric is stored in such a way so as to make the

identification of the fabric rolls easy and the person
issuing the rolls does not waste time searching for them.

Remaining fabric are sent to Okhla OCR (Other Cost

Returning).

In the store there are 42 racks within 5 rows .Fabric lot are
arranged according to style number, GRN number, and
shrinkage or shade variation according to the buyer.
PROCESS FLOW 17
OF FABIRC STORE

PROCESS FLOW OF THE FABRIC STORE

- Gate entry
FABRIC - Fabric chalaan to store manager
RECIEVING - Register entry
- Fabric unloading

- Width checking
RACK
- Length checking
SELECTION
- Segregate according to grn number , shrinkage , shades

- Fabric Inspection
INSPECTION - Centre to Selvedge Variation
- Shade Batching for the whole lot
- Stocking of inspection rolls to the alloted racks

FABRIC - Fabric requisition form from cutting

ISSUE - Fabric issue
- Data entry
RECORDS 18
MAINTAINED IN
THE STORE

SWATCH STATUS
BOARD BOARD

Records
Maintained in
the sotre

STOCK GOODS RECEIVED

REPORT NOTE COPY
TRIM STORE 19

TRIM
STORE
This is the place where all the trims and accessories are
stored before and after their use.

All the materials used by different departments are

segregated accordingly.

Trims and accessories store consist of 6-7 people.

PROCESS FLOW IN 20
TRIM STORE

PROCESS FLOW IN THE TRIM STORE

Material Delivery Material Quantity checking

Schedule from Received against the packing
Merchandiser list and Invoice

Report of variance in Goods Receive Trims Inspection

quantity to the supplier note to Merchandiser

Stocking of the material Material Requisition Issue

according to Slip from the Material
category and Order different Departments
TRIM STORE 21

REPORTS MAINTAINED
IN TRIM STORE
Material Delivery Schedule

Copy of packing List

Inspection Report

Material Requisition Slip copy

Excel sheet report

SAMPLING 22
DEPARTMENT

SAMPLING
DEPARTMENT
The Sampling Department works out to make the required
samples with the given specifications supplied by the
buyer.

The merchandising team for the particular buyer

coordinates the sample development process.

The samples are developed on the initial of the bulk.

All the buyers and all the styles do not require the same
types and same number of samples.
SAMPLING 23
PROCESS

SAMPLING PROCESS
Mr. Devender Singh: Sampling head

Material Delivery Material Quantity checking

Schedule from Received against the packing
Merchandiser list and Invoice

Report of variance in Goods Receive Trims Inspection

quantity to the supplier note to Merchandiser
HUMAN RESOURCE 24
DEPARTMENT

SAMPLING
ROOM
Cutting is done manually with patterns.

Size set is done in sampling

MACHINES:14 SNLS , 2o/l , 1foa, 1dnls, 2 press

14 operator 1 cutting master, 1 quality assurance, 1

technician.

File contains: cutting document, marker, tech pack,

sketches, fabric report, garment report, test report, trim
card, SGC
CAD 25

CAD

The CAD department is functional at a number of stages,

in coordination with many departments as and when
required which is mainly at the time of sampling, along
with the pattern making department.

And second, when the bulk production starts.

It performs a variety of functions such as:

- Digitizing
- Pattern Design System
- Cut order planning
- Marker making
- Marker plotting etc.
PRODUCTION 26
PLANNING & CONTROL
DEPT.

PRODUCTION PLANNING
&CONTROL DEPARTMENT
The planning department has the responsibility of
converting the orders booked by the merchant, to the
production team for the easy execution of the order.

Based on the TNA and the availability of the line the PPC
team allocates the order on the production floor as which
process has to be done at what time.

The operators are dedicated to the each operation as per

the capacity planning and delivery date of the order.
INDUSTRIAL 27
ENGINEERING DEPT.

INDUSTRIAL ENGINEERING
DEPARTMENT
The Central IE department is responsible for the
preparation of the

Operation Breakdown

SMV analysis

Improvement of work Methods

Operator Grade Change on the basis of time study

Thread Consumption sheet

Style analysis and work aid requirements

ACTIVITIES 28
FOLLOWED

ACTIVITIES
FOLLOWED
Study of sample or Tech Pack received from buyer and to
make observation sheet.

Feasibility study of sample with sewing head for

availability of folders, attachments, templates, collar/cuff
dies, seams & stitches etc.

Preparation of time & action plan of orders (after their

confirmation) keeping in mind the available resources of
floor.

Forwarding the requirements (e.g.: folders, dies,

templates etc.) to the stores/marketing for any particular
order.
ACTIVITIES 29
FOLLOWED

Preparation of instruction/detailing sheet.

Preparation of complete order files which includes

comment sheet, order quantity, cut quantity, BOM,
instruction sheet, fabric swatches and distributing it to
cutting, sewing, finishing, cad & sampling, planning and
production manager.

Distribution of paper patterns (ready) to all the parts

sections for checking of in process production.

Conducting pre-production meetings before start of every

new order.

Monthly Time study of all the operators, efficiency

graph/comparison of operators, recommendation for
grade change and promotion with consulting production
team.
SPREADING & 30
CUTTING

SPREADING &
CUTTING
Cutting production consist of all the process activities
involved in reducing the bulk material used in apparel in to
the component parts making up the apparel.

The cutting room is a combined section for spreading

cutting, ticketing/ bundling and fusing. There are 6
spreading tables .

The lay is cut by straight knife on the same table and the
blocks are transferred to other table and then to band
knife for final cutting and then to numbering table.
THE WORKPLACE 31

THE
WORKPLACE
Spreading Tables = 6
Straight Knife = 8
Band Knife = 1
Workforce = 105 ( including 5 checkers)
Ticketing machines = 14
Table for bundling = 4
Table for audit = 2
Table for ticketing = 2
There is separate section for bundling and sorting.
PROCESS 32
INFORMATION

PROCESS
INFORMATION
Fabric issues by requisition form signed by cutting head.

The cutting department receives fabric and fusing from

the stores, while referring to the width and shade lot
report.

Along with the fabric, the cutting department also

receives CAD markers from the CAD department, which
includes the spreading report and the ratio details. Marker
gives an idea about the lay length.
PROCESS 33
FLOW

PROCESS FLOW

SAMPLING
CAD
SEWING

FABRIC READY TO ISSUE

STORE

BUNDLING
SPREADING

SORT
BLOCK CUT

CUTTING

TICKETING

TICKETING FUSING RE SPREAD RE CUT

SEWING DEPARTMENT 34

SEWING
DEPARTMENT
Production Department is one of the most important
department of any apparel industry, where cut parts are
stitched together to make garments.

This is the department where maximum number of

manpower is required.

There are three floors for production consisting of 18 lines

along with a straight line manufacturing system with a
manual carriage system.
THE WORKING 35
INFORMATION

THE WORKING
INFORMATION
Capacity of the factory : 15000 Garments
Number of lines :18
Total number of floors :3
Total number of operators :950
No of machines per line: 44-50
No. of helping tables including pressing : 13
Software used for information storage : movex
THE WORKING 36
INFORMATION

Each floor is equipped with loading section and end

tables for final inspection.

There are 3 inline check tables along with tables for

helpers.

The finishing tables for quality check are located nearby

inside the floor for efficient flow.

The production system followed is PBS (Progressive

Bundle System)

PPC develops load plan for Feeders along with Cut plan to
be followed in lines.
THE WORKING 37
INFORMATION

One piece flow is

Feeder provides Bundle of 18-20 pieces followed till garment
bundle bag to line is followed generally reaches completion.

Progressive Assembly
Loading bundle flow section

End table Transport to

checking sequential checking

Final checking table Hourly output is

provided to line transported further
PRODUCTION 26
PLANNING & CONTROL
DEPT.

PRODUCTION PLANNING
&CONTROL DEPARTMENT