INTERNSHIP REPORT ON

MERCHANDISING IN PEARL GLOBAL

PVT LTD

PREPARED BY:
ASHMA AGARWAL -1877007
8th SEMESTER
BATCH-2018-22
KIIT SCHOOL OF FASHION TECHNOLOGY
 LETTER OF TRANSMITTAL

Prof. Bauri Raula

Head of Department
KIIT SCHOOL FASHION TECHNOLOGY
BHUBANESHWAR, ODISHA

Subject: Internship report on merchandising department in export house.

Dear sir,
With great pleasure, here I submit my internship report on Merchandising in
Export house (Pearl Global PVT LTD) that you have approved and assigned as a
compulsory requirement. I have tried my level best to bring out the original
scenario of Pearl group with full of effectiveness & efficiency. I have really
learned a lot and have gained valuable experience and knowledge while
collecting information for the report .It was certainly a great opportunity for
me to work on this real life project to actualize my theoretical knowledge of
this course in the practical arena and some more which is out of this course .I
hope that this project paper has been to your expectation, if you come across
any questions & quarries regarding these cases, it will be my pleasure to clarify
your questions.

Sincerely,
Ashma Agarwal
1877007
KIIT SCHOOL OF FASHION TECHNOLOGY
BHUBANESHWAR, ODISHA ,INDIA.
CONTENTS
Acknowledgement
Executive summary of Pearl Global
Introduction
Objectives
Methodology
Scopes
Limitations
PART-01
Organization Part
Brief history of Pearl Global
Garment Merchandising
Garments trims/accessories
Activities of merchandising department
Kinds of garment industry
PART-02
Main report part
Name of the buyers of Pearl Global
Fabric supplier of Pearl Global
Trims supplier of Pearl Global
Store of Pearl Global
Job responsibility of Merchandiser
Essential Duties and Responsibilities
Threads,Interlining,Label,Buttons,Zippers,Elastic
Services of Merchandising team to buyers
Execution process of Export orders
Sampling facilities
Quality Assurance
Quality control and inspection procedures
Sourcing services
Factory Evaluation
PART-03
Quality Procedure
Quality depends on some Factors
Quality on sewing
Types of quality checkers
Quality in washing
Checklist for auditing cartoon
Cost of failure
Remarks
Quality control
Definition of quality
Dimension of quality
The great value of quality
Controlling quality
In-line inspection
Section supervisor
Quality procedures
Quality drills
Points to be checked:Cutting section,Spreading,Cutting,others
Sewing section
Finishing section
Fabric inspection
Grading system
Garments Defect
Classification of defects
Possible garment defect:Fabric cleanliness,Pressing,stitching,Button
hole,Button sewing,Waistband,Belt loop,Hem,Pockets,zipper, Fly area, Labels
Final inspection of garment
Garment checking
Quality planning
Transportation for shipment
PART-04
Conclusion
References
 ACKNOWLEDGEMENT

A warm felicitation goes for me to acknowledge the people, who hold the
desirability for encouraging, praising, assisting as well as believing me on the
tasks of Merchandising activities what I have worked through my internship
period. First of all I would like to take the opportunity to thank my courses
coordinator of KIIT & my internship supervisor for providing me guidelines,
help in assisting my report. He was constantly supporting me with his inspiring
personality. I will always be thankful for his extraordinary reinforcement.

I would like to take the opportunity to thank Mr. Surender Singh, MM, Pearl
Global PVT LTD for being my on-site supervisor & providing me time to time
information, suggestion as well as procedures to work with my topic. I also
want to thank Mrs. Renu Dhaka, MM of Pearl Global PVT LTD for being so
cooperative in my work.

Finally I will show my gratitude to all the management & non-management

staffs who have helped me during the internship period and the entire persons
who somehow have impact on me in completing my report.
 EXECUTIVE SUMMARY
Founded by Mr. Deepak Seth in 1987, Pearl Global is a multinational apparel
manufacturing company that provides end-to-end supply chain solutions to
brands across the globe.We develop apparel for people pf all ages, genders,
locations, and style preferences by using sustainable means.
Pearl was established with the aim to transform the way fashion is created
across the globe.By empowering people and preserving the environment, we
create a win-win situation by giving way to a circular economy.
With an annual turnover of over $450 Million worldwide and an employee
strength of over 32,000 people, we are one of the few apparel companies
listed in the Indian stock Exchanges.
Started in 1987, Pearl global is an end-to-end clothing vendor and supplier with
a presence across the globe.We provide complete apparel solutions to leading
fashion brands across categories.Our processes begin from product inception
and end with on-time deliveries in stores.
With a sustainable approach in our ecosystem, as one of the best clothing
vendors, we craft environmentally-conscious clothes through tech, innovation,
and talent.Our competencies lie in combining sustainable technology with
design in order to create customized solutions for our clients.
We have established our presence in India, Bangladesh, Vietnam, Indonesia,
Hong Kong, Spain, UK and USA.
70 Mil+ units produced annually.With consistent performance annually, we
create fashion for some of the biggest names in the industry.
 INTRODUCTION
Pearl Global manufacturing units are especially designed to create quality bulk
output.As a clothing and apparel manufacturer, we are at the forefront of
textile innovation and sustainability.All our machines are highly scalable in
terms of performance and delivery, ensuring that demands are met on time.

Our factories are equipped with resources that perform tasks like knitting,
washing, and drying fabric that has been sourced from some of the most
strategic locations.These resources enable us to make all kinds of garments
catering to women, men and kids.

While technology is important for crafting world-class apparel, it’s the team at
Pearl that truly makes the processes seamless.Our workforce is our biggest
strength and they play a key role in getting our production and delivery
right.We are a clothing manufacturing company with skilled personnel.

For clothing suppliers, Keeping up with the trend is crucial.We combine the
scalability of our technology with the adaptability and skills of our people into
the perfect amalgamation of efficiency.Our manufacturing process and
operational excellence help us deliver bulk production to some of the biggest
clients in the fashion industry globally.We achieve this process through
technology, innovation, talent, planning, cross operations and
communication.Hence, manufacturing at Pearl global is truly sustainable and
efficient because as apparel manufacturers, we strive to refine this
performance with changing trends.
 OBJECTIVES
Objective means the purpose of this report.The objectives of this report are as
follows:
. To know detail about PGIL sector.
.Information gathers about commercial.
.Getting idea about shipping procedure.
.Concept develop about knitting.
.Comparison between class room learning and practical learning.
.Knowledge gather about PGIL sector related other organization.
.To achieve new idea about knit garments manufacturing process.
.To know about the management and technical process of apparel industry.
.To know about the management procedure in Garments Industry.
.To mark a comment over the whole Internship Report.
.To focus on the valuable part of Internship Report.
.To have skill labor for quality product.
.To study the present market composition for the Indian garment product
about Market diversification.
.Opportunity of behavioral theory practice in our garments sector.
.Regularly behavioral theory practice in garments industry.
.Identifying the the trade agreements that might affect the export growth.
.To do a merchandising practice in the factory.
.To identify merchandising and total production system.
.To relate the use of groupware and collaborative systems with future trends in
roles and responsibilities.
METHODOLOGY
Methodology defines how we go through all the processes of research and
how I have proceeded on.Here includes the steps of conducting the report and
the explanation of the sources of data.
.Factory
.Different Organization
.Books
.Discussion
.Internet
.Class Lecture
.Library
.Annual Report
.To collect information what I am seeing in practical in my internship program.
.To collect information what I did in practical what has by me for my practical
knowledge.
.To make a comment over the project we have to understand the whole
project.

SCOPES
Scope means how many uses for completing this report space.The scopes are
given below-
.Factory
.Buying House
.Discussion
.Internet
.I can collect information through various books and relevant paper what
related with apparel industry.
LIMITATIONS
Limitations refers the obstacles I have to face for completing this report and
what I couldn’t cover for this limitation.
. Time Constraint
. Merchandiser doesn’t have enough time to give the information elaborately.
. Short time visit in different work stations.
. Lack of organizing chain of command.
. Lack of instruction book, and any change.They are following traditional
business.
. I may have to suffer for lack of supply chain management.
. Due to high employee turnover rate and lack of good reporting practices in
the factor, problems with collecting data have been faced.
PART-01

ORGANISATION PROFILE CONTACTS

Head office
Plot No.-51,
Pearl Tower,Sector-32,
Gurugram,Haryana-122001

Factory Address
16-17, Udyog Vihar, Phase VI, Khandsa,
Gurgaon - 122004
Haryana - India

446, Udyog Vihar, Phase-V,

Gurgaon - 122016
Haryana - India

Plot No.73, Udyog Vihar, Phase-1,

Gurgaon - 122016
Haryana - India

Plot No.274, Udyog Vihar, Phase-II,

Gurgaon - 10016
Haryana - India

751, Pace City II, Sector 37, Khandsa,

Gurgaon - 122004
Haryana - India

No.of Employees- 962

OUR PRODUCTS-
1. Knits
2. Woven
3. Denim
4. Outerwear
5. Activewear & Athleisure
6. Sleepwear & Lounge
7. Children wear
GARMENTS MERCHANDISING
The term ‘merchandising’ is well known to the persons specially involved in
garment trade.The term merchandising has been derived from the term
merchandise.Merchandise means good that are bought & sold.
The term “merchandiser” may be defined as the person who merchandises the
goods.Garments merchandising means buying raw materials & accessories,
producing required garments, maintaining required quality level and exporting
the garments within time frame.
Marketing can do everything but he can’t do everything directly is called
merchandiser.
From the above definition, we can assume that a person involved in garments
merchandising need a wide range of knowledge & skill to perform his job
successfully a merchandiser should possess the following basic knowledge and
skill.Are:-
A. Good command of English and adequate knowledge of technical terms for
accurate and efficient communication.
B. Good knowledge of yarn, fabric, and dyeing, printing, finishing, dyes color
fastness garments production,etc.
C. Clear conception of usual potential quality problems in the garments
manufacturing.
D. Good knowledge of raw materials inceptions systems & garments inspection
systems.
E. When an export order is given to a merchandiser, he has to schedule the
following main function to execute the export order perfectly in time.Are:-
1.Fabric requirement calculations.
2.Accessories requirement calculations(Thread,Button,Interlining label polybag,
main label, knit label, fit label,cartoon, heat transfer, size band, etc.)
3.Sources of fabric
4.Sources of trims
5.Possible date of arrival of fabrics & trim in the garments factory.
6.Costing
7.Garments production planning
8.Pre shipment inspection schedule
9.Shipment document
10.Have to make TNA

GARMENT TRIMS
Garment trims means all items used in the garment except the basic is called
garments trims.There are hundreds of items used to manufacture the
garments which are used as trims.
A list of few important trims is mentioned here.
1. Sewing thread
2. Interlining
3. Label
4. Button
5. Zipper
6. Lining
7. Shoulder fad
8. Elastic
9. River
10. Poly bag
11. Hanger
Quality of trims as well as proper selection of trims is very important;
otherwise the garments may be rejected returned by the customers.
ACTIVITIES OF MERCHANDISNG DEPARTMENT:
Communication with buyers
A. Procure order & order confirmation
B. Costing
CONSUMPTION
A. Price quoting
B. Sample control & approval
C. Potential sourcing of materials & approvals fabric, trims, accessories
D. Lab dipping & approval
E. Purchasing of materials
F. Testing
G. Factory scheduling/Planning
H. Order followup: all steps of production & quality
I. Ensure on time delivery
J. Liaision with the customer during design, sourcing, production & shipping
K. Conduct coordination meeting with other departments/pre production
meeting
L. Attend buyers meeting
M.Ensure customer satisfaction
N. Product development etc.
Various departments/ sections of pearl global are as folows:
1. Store
2. Sample
3. Pattern
4. CAD/CAM/DESIGN
5. Cutting
6. Sewing
7. Finishing & packing’
8. Merchandising /Marketing
9. Quality control/Assurance
10. Purchase/Procurement
11. Maintenance

PART-02
NAME OF THE BUYERS OF PEARL GLOBAL PVT LTD
1. KOHL’S
2. MACY’S
3. NORDSTORM
4. BELK
5. GAP
6. BERSHKA
7. MANGO
8. AMERICAN EAGLE
9. PRIMARK
10. NEXT
11. RALPH LAUREN
12. WALMART
13. SAM’S CLUB
FABRIC SUPPLIERS OF PERAL GLOBAL PVT. LTD
INDIA:_
1. Global attire (Tirupur)
2. BRFL textile (Maharashtra)
3. Gimi Filament (Uttar Pradesh)
4. Karma fabric (Faridabad)
5. SSVT sidhi vinayak (Sonipat)
6. Bir horizin (Noida)
CHINA:-
1. Shaooxing shanghao
2. Shaoxing Ivan
3. Changzhao lason
4. Fountain set
5. Nice dyeing
6. Siris holding group
7. Camhing
TRIMS SUPPLIER OF PEARL GLOBAL PVT. LTD
1. Manohar Filaments private limited (Label & Washcare)
2. Colour stitch limited (Thread)
3. Mainetti private limited (Hanger)
4. Kohinoor Ribbon Factory Pvt. Ltd. (Embroidery Patches)
5. Jain Narrow Fabrics (Elastic)
JOB RESPOSIBILITY FOR A GAMENTS MERCHANDISER:
The ideal candidate plays nicely with others ans a proven track record of
success leading a team of graphic artists, an understanding of screen-print and
with merchandising.Specific responsibilities include managing daily operations
including providing supervision to employees as well as managing vendors,
departmental communications, stylistic direction and managing associated
budgets.
ESSENTIAL DUTIES AND RESPONSIBILITIES:
1. Develop and maintains a clearly defined strategy in support of company’s
mission, vision and objectives.
2. Works closely with key individuals and teams to integrate strategic
opportunities into the prioritized workflow.Ensure cross-organizational
support and extraordinary results for customers and partners.
3. Responsible for day-to-day operations including managing employees,
vendors, communications, stylistic direction and associated budgets.This
position will also provide support to customer service, marketing and product
development.
4. Carries out supervisory responsibilities in accordance with the organization’s
policies and applicable laws.
5. Manages and direct all pre-launch sampling and distribution of samples to
sales & customers.
6. Work with sales teams and design staff to provide cost estimates.
7. Coordinates all aspects of tradeshow
8. Develops business internally by participating in merchandising team.
1. SEWING THREAD:There are various types of sewing threads, which are used
in the garments manufacturing industries.100% cotton, 100% polyester, nylon,
viscose, mono filament, textured, mesh, OPD, amd solid thread especially
finished thread etc.
2. INTERLINING: The fabric which is used between two plies of garments basic
fabric with an intention to make certain parts attractive, strong & retain those
shapes for long times called interlining.Interlinings are of two types non-fusible
and fusible interlining.At present days non-fusible interlinings are not used
commonly.Types of fusible interlining are available & price varies considerably.
Polyethylene coated interlining- Water wash
Polyethylene coated interlining-Water wash
Polyethylene coated interlining-Dry wash
 PVC coated interlining-All types of wash, costly
PVA coated interlining-Mild water wash
Care should be taken during selection of interlining otherwise there may be a
great problem.
A. Shrinkage of interlining should be less than the fabric shrinkage
B. Color of interlining should not affect the color of garments in the fused area.
3. LABEL:Label is a common accessory, which is to use in each garments.Within
each garment no.of label to be used more than one because there are various
types of label to be used for various information.In the garment label you will
get some information.
Main label-Name of the company
Size label-Garments size
Price label tag- Cost of garments
Composition label- fiber composition
Care label- ironing & washing, dying come
There sometimes also some components used outside/face side of the
garment to increase the beauty or fashion of the garments is called motif.A
sometimes motif bears the symbol, trademark etc.Labels are available with
various types, qualities & prices.
4. BUTTONS:It is also common accessories used in the garments.It may work as
functional part as well as decorative item, buttons are made from nylon
polyester ,wood bone, metal,etc.It may have two or four holes with shank.
Attaching of button in the garments is very important, usually it is attached by
the button attach machine.If lock stitch type button attaching machine.It looks
stitch type button a size also varies.To express the button size the term line is
used.
5. ZIPPERS: In the pant, trouser and jacket is a common component Metal or
plastic-Teethes are used on narrow tapes of polyester or Nylon & those two
series of teethes locked by a slider.Sometimes two sliders are used within a
single zipper.
Usually zippers do not shrink after wash but increase of garments, which may
shrink a wash then the sipper area may look wavy.
6. ELASTIC:Elastics are available in many sizes,shapes,stretched.The force
required to stretch the elastic also various depending on types of elastic
used.The elastic used in the bottom waistband of a jacket, vest or pull over
shirt etc should consider using the elastic with more tractability.For pants
shorts, skirts (all buttons)the elastic should be of medium stretch ability.Elastic
suppliers usually sell elastics by gross unit, but if you measure one gross length
you may get 140 yds.In most cases.
7. MERCHANDISING:Our merchandising team is committed to complete
customer satisfaction.Our merchandising department consists of highly
qualified team of merchandisers whose prime aim is to provide full satisfaction
to our customer starting from the fabric procurement stage to shipment and
reporting the status of the order to the buyers regularly.
The services our merchandising team provides to our clients are:
Systematic follow-up on each stage of production and execution of order on
time.Monitoring new trends in fabric, fashion and design.
Locating new reliable sources to meet the customer with regard to fashion and
design.Introducing new sample buyers to enable them to expand their
business.
Educate the customer about the characteristics of variety of fabrics, dyes,
dyeing and printing process, and their positive and negative points and caution
the buyers about the pitfalls involved.
Liasion between the customer and our factories and follow-up.
Guiding the supplier in preparation of the range to meet the customer’s
requirements with regard to fashion and design and negotiation.
EXECUTION PROCESS FOR A GARMENT
EXPORT ORDER IN A FACTORY (IN BRIEF)
1. Order enquiry from buyer to factory:Merchandiser sits with production
manager for ship date planning.Enquiry on price (sometimes the target price is
also given) enquiry on ship date I.e. whether it can be shipped in due date?
2. Approval of order from buyer, as per the costing given by the merchandiser:
Merchandiser makes TNA contain the details of the action be taken as per
fixed date, in order to execute the shipment on the date as committed to
buyer.
3. Fit sample sent to buyer for the fit approval: Merchandiser co-ordinates
with sampling section, for the fit sample and get it approved from the buyer
for fit and measurement.
4. Pre-production sample submitted to buyer with original accessories and
fabric:P.P sample to be made from the production line.PP sample approval
from buyer means merchandiser takes approval on style, original fabric &
original accessories.
5. Fabric and trims to be in housed on due time as per time and action
plan:Inventory to be monitored by merchandiser so that there is no problem in
quality or shortage of quantity in fabric and accessories.If there is anything
wrong prompt action to be taken by merchandiser.
6. Pilot production to be started as per time and action plan:Or initial
production mean consists of 100 to 200 Pcs. Production managers and quality
team should check very carefully about.The style & quality of the garment.The
measurement needs to follow as per buyers spec sheet.
7. On line inspection by buyers QC certifies the quality of the garment: Buyer
QC gives suggestion where the quality defects are and how to improve on that.
8. Bulk production to be started as per the TNA plan: Buyers QC monitor on
the production and quality of garments.Production manager and supervisor
need to be very careful to meet. The production target, to meet the ship date
on time.
9. In the mean time commercial section prepares the shipping documents:
Contact with shipping line for the booking of vessels.
10. Final inspection as per TNA plan: Buyer’s QC. Do random inspection
during final inspection.Only if buyer’s QC certifies the quality is satisfactory
then only we can ship out the goods.
11. Goods are made ex-factory: Goods send to seaport.Goods sent to airport.
12. Goods handed over to the shipping line: NOTE: NOW IN ANY CASE WE
FAIL TO SHIP THE GOODS ON TIME AS PER THE DATE, BUYER WILL CANCEL THE
GOODS OR WILL ASK AIR FREIGHT I.E. THE ORDER WAS IN SEA SHIPMENT.
SAMPLING FACILITIES
Besides nearly 1,000 sorts of fabric samples, we have in house sampling
department with modern machines and equipped with state of the art
technologies for the development of samples for our customers.Our sample
makers have over 10 years experience in sample development. Our sample
makers have developed the expertise of producing excellent quality of sample
as per the need and requirements of the customers.
We encourage our potential buyers to ask us for the samples so that they can
have an idea of the product and its workmanship.We can provide our potential
customers with sample of our own designs from our collection.
In addition, we are very much willing to do the development of our clients own
designs and fabrics.Our philosophy is to provide superior customer services to
our valued clients in order to satisfy their needs a step further than the market.
QUALITY ASSURANCE
At Bureau, we are committed to quality requirements of the highest standard.
We do not sacrifice on quality. We make sure quality is adhered to throughout
our operation from sampling to final shipment.We take extra effort in ensuring
the suppliers comply with strict quality control. Quality assurance is an
inherent part of our services and we ensure that our customers donot face any
problem at any stage.
Quality control and Inspection procedures.
OUR QUALITY CONTROL AND INSPECTION PROCEDURE INCLUDES THE
FOLLOWING FUNCTION:
Our quality assurance department checks all the fabric/ accessories to ensure
that quality/color etc conforms to the order/style.
Our quality assurance and merchandising team goes to factory location to
evaluate pre-production sample, patterns, etc to approve for trial production.
Quality assurance team evaluates trial production and then finally approves for
bulk production.
As bulk production starts, our quality assurance team goes for inline
inspection.This inline inspection during production is performed on daily basis.
At the middle stage of production if result is acceptable / good then we go for
pre - final inspection. Here we check the case pack, carton quality shipping
mark, assortment, presentation etc.
If the pre-final result is acceptable then we go for final inspection and if it
passes, we approve for the final shipment.
To ensure quality of the highest standard , we inspect at every stage of the
production process.The following quality & inspection steps are being currently
employed in sourcing and manufacturing.
-Accessories inspection
-Knitted inspection
-Measurement spec checking
-Accessories inspection testing
-Accessories color matching checking
-Daily cutting checking
-Fabric inspection
-Lap dip testing
-Washing fabric testing
SOURCING SERVICES
Proper sourcing is the key to success in Textile/garments business.Keeping this
in mind, besides our own factories, Bureau sources products from reliable
vendors with a careful assessment of price and quality.We have built up an
extensive sourcing network of dedicated manufacturers and exporters from all
around China.In addition, we have reliable sources of raw material such as
fabric, trim & accessories from many countries.
Sourcing is our core strength , which distinguishes us from the rest of the
market.We offer a complete sourcing package from design to delivery.Our
sourcing department ensures great measures to evaluate the most suitable
manufacturer and supplier for our client’s requirements.
Factory Evaluation:
At Pearl Global we take an extra step to source the most appropriate vendor
for our customers.Before selection we thoroughly evaluate Factory on the
basis of the following assessment:
1. Factory design
2. Financial performance
3. Factory equipment & machinery
4. Factory productivity
5. Quota export performance
6. Prevalent working procedures
7. Factory past performance
8. Technical competency
9. Factory personnel competency
In addition, we have formulated a factory evaluation form, which is filled out
for every factory and then based on the physical, and financial assessment
includes creation of a rating grade to the factory.This rating grade can
determine the quantity of garments it can manufacture as well as whether it
has adequate production capacity.These services can be further extended in
locally reliable fabric sources, dyes and printers, which ultimately promote
quality of merchandise.This is an important process as no factory should be
over booked, which causes delays in delivery and impacts production quality
negatively.
Factory assessments are ongoing process.It is constantly in investing time and
effort in finding new factories, which can meet the requirements of client in
terms of fashion and price.
SHIPPING/DOCUMENTATION
Being a supply chain service provider, we have the knowledge and expertise to
provide total logistic and transportation solutions to our customers. Our
qualified personnel work in close association with leading freight forwarders,
air and shipping lines at various locations.In addition, we can provide you
specific value added services by pre advising all shipments on a regular basis
with tentative arrival dates.
PART-03

QUALITY
INTRODUCTION:
In manufacturing, quality is the concept of making products fit for a purpose
and with the fewest defects.Many different techniques and concepts have
been tried to minimize defects in products.
QUALITY ASSURANCE:
The establishment and maintenance of all activities and functions concerned
with the attainment of requisite quality.
QUALITY CONTROL:
The systems required for programming and co-ordinating the efforts of the
various groups in an organization to maintain the requisite quality.As such
quality control is seen as the agent of quality assurance or total quality control.
SPECIFICATION:
Quality control requires the establishment of adequate specification tolerances
correctly the first time.
OBJECTIVE:
To maximize the production of goods with in the specified tolerances correctly
the first time.
By considering such information it can be decided what requires to be
monitored. Monitoring the process is the essence of quality control.
Total quality of a garment depends on the following factors:
1. Quality of fabrics
2. Quality of accessories
3. Quality of cutting
4. Quality of machines
5. Quality of sewing
6. Quality of washing
7. Quality of finishing
In each stage there are quality controlling with quality checkers or
controllers.Quality manager is responsible for total quantity of a
product.Quality controlling in different stages described below:
Quality of Fabric: There are some fabric inspectors, who check the fabric
defects with fabric inspection machine.
Quality of accessories: Trim inspection bay at main store inspects the trim and
accessories for quantity and quality.
Quality in cutting: In cutting section there are 3 types of quality checkers. They
are
A. MARKER CHECKING QC: Marker checking QC checks the marker used for
cutting for any type of mistake or defect. He checks for the following things:
1. Style, size, color and type of marker
2. Any drawing defects on marker
3. Any overlapping of parts
4. All parts present on marker
5. Ratio of marker is correct
6. Check with hard pattern provided by technical manager if needed.
B. TABLE OR LAY QC: Table QC checks for lay defect and correct procedure for
lay.He checks for the following things-
1.Marker length and lay length and proper allowance for lay length
2.Any fabric defect
3.Pile of fabric is correct
4.Tension of fabric
5.Salvage of fabric is outside the marker
6.Fabric nap is correct
C.BUNDLE CHECKING QC:He checks for total parts in a bundle.He checks the
bundle with JC Penney 3 piece system.In this system he collects 3 pieces from
the bundle and checks them for any fabric defect, size and shape and proper
cutting.
QUALITY IN SEWING:
Maximum quality controlling is in sewing lines as maximum defects occurred
during sewing. Some common defects are:
1. Thread tension
2. Broken stitch
3. Raw edge
4. Wrong back tack
5. Puckering
6. Open seam
7. Skip stitch
8. Joint stitch
9. Fabric defects
10. Shading
11. Stains
12. Un-even shape
13. Down stitches
14. Updown
15. Center out
16. Gap difference
17. Poor ironing
18. Holes and damages
19. Slanted
20. Missing bar tack
QUALITY IN WASHING:
Shading is the main quality problem in washing.There is a quality checker who
matches the garments with approval shade after each wash.
QUALITY IN FINISHING:
For better quality there are several quality posts in finishing.First step in
process wise inside checking, then process wise out side checking and last step
is final quality checking. And there are also two audits in finishing:
They are-
1. Hourly audit (Internal)-They audit randomly any 7 pieces in each hour from
a line.If they find any major defect in any 1 piece than audit goes to fail and
whole garments in that line have to check again.Otherwise audit pass and
garments goes to cartoon packing.
2. Cartoon audit (External)-They audit any 3 cartoons from each line.They
check for external matters like tag, size, ratio, color, etc.If find any major
defects in any piece of any carton, the audit fail and all carton have to check
and pack again.
NOTE- After passing the external audit garments are ready for shipment.
CHECKLIST FOR AUDITING CARTON:
The following we have to check while auditing a carton.
1. Barcode/Shipping mark
2. Assortment
3. Size label
4. Match box
5. Sticker
6. Shade
7. Ratio
8. Also for size, presentation of garments, looseness or tightness, folding,
dimension, etc.
COST OF FAILURE:
The main costs of failure due to poor quality are-
1. Losses due to faulty and spoilt work
2. Examiners records
3. Reprocessing-Additional materials, Extra labor, Disruption of production
4. Administrative costs-Reaching agreement with customers and replacing
defectives or complaint adjustments.
REMARKS:
1. Better quality makes the production rate better and also satisfied customer
or buyer. If quality is poor then we need much time to repair the altars, which
decrease the overall production rate.
2. Roving auditor using red card for poor quality of an operator.He also can use
a green card for better quality of an operator, which will inspire him and others
for better quality.
DEFINITION OF QUALITY:
Quality has been with us since the drawn of civilization; however science, after
second world war it has been used more as a competitive weapon or
competitive advantage.
Eight dimensions of quality
1. Performance
2. Features
3. Reliability
4. Conformance
5. Durability
6. Servicability
7. Aesthetics
8. Perceived quality
Sometime hard to imagine that one skipped stitch can cause customer
dissatisfaction please recognize that, if something is not as specified, it is
defective.Defects are a waste!Let’s see what happens to defective garments in
the factory.If a defective unit is found you have two possibilities.That is can be
repaired,that it can’t. Seconds are sold at a loss by the factory. Units to be
repaired are also an extra cost because extra cost are incurred in
1. Handling the unit before repair,
2. Extra labor and materials in repairing and
3. Extra handling to get it back with the first goods.
The time consumed on repairing defective goods can always be used to
produce first class goods. In all cases defective units are costs for the
factory.”Do it right the first time” is the key to success.
To ensure quality we need to do number of things:
1. Recognize who the customer is
2. Build processes that anticipate and prevent defects
3. Make a plan to achieve the desired quality level.
4. Set up ways to measure our progress
5. Work as a team to achieve the goal.
A good plan requires:
1. A clearly defined objective
2. Goals or expected results
3. The activities needed to achieve the desired results
4. Defined roles and responsibilities for the activities
5. Dates for the begin and completion of each activity
6. An analysis of potential problems.
Measurements are a vital part of any quality improvement program.Anything
that is not measure does not improve.We need to establish these standard
measures and measure the progress periodically.

The Executive’s job related to quality:

These are two separate areas of dealing with quality that an executive
becomes involves in:
1. Handling repairs- Getting repairs corrected and work back into the
production flow.
2. Preventing repairs- Working with operators to prevent repairs.
TO CONTROL QUALITY
1. Have the proper approach toward operators
2. Approach operator with defective garment
3. Train operators to sew with good quality from the beginning
4. Know quality specification and tolerance. Be sure you understand what
constitutes good and poor quality.
5. Be consistent in your decisions toward quality.
6. Comment on both good and bad qualify.We all have a tendency to be silent
during good times and vocal during the bad.
7. Use a checklist- do not rely on memory of specs.
8. Do not rely on inspectors to tell you the quality level of your operators.
9. Never give the impression that you think work is OK but inspector will not
pass.
In-Line Inspection:
During the production of garments the operator’s finished work is audited in
an in-line inspection.A quality inspector move’s from one operator to another
at random inspecting a predetermined number of parts from a finished bundle.
In-process inspector:
If the in-line inspector finds a defect and a part he is inspecting he should:
1. Take defective part/parts out of the bundle.
2. Take part to the operator’s immediate supervisor.
3. Give the part to the supervisor to examine while inspector explains the
defect found.
4. Decide with the supervisor whether it is actually a defective part send if
defective the supervisor should return the part to the operator.
5. Go back to the operator and mark the bundle as rejected with a red card or
cloth and fill in the appropriate paperwork for the inspection and mark the
workstation with quality banner to signal that follow up bundles have not been
cleared.
6. Continue to the next operator selected randomly from the list of operator
and perform the inspection based on the approved sampling plan.
7. If an operator has a bundle rejected then all bundles coming from that
operator are going to be checked by the quality inspector until three
consecutive bundles are free of defects.
8. The quality banner helps the inspector remember to inspect the follow-up
bundles from that operator and also helps the supervisor identify what
operators are having quality problems.
9. Make sure that only the defined number of units is inspected.No more, no
less.
SECTION SUPERVISOR:
If a quality inspector approaches the supervisor with a defective unit he or she
should:
1. Greet the inspector do not ignore him/her. Inspect the part according to the
quality specifications.
2. If it is defective let the inspector know you understand it is a defective part
and you are going to address the part with the operator.
100% inspection:
At the end of a section there will be an inspection made to all parts existing the
section.The inspection should be effective in identifying all defects in a
garment.To ensure all seams and quality characteristics are inspected in a
short period of time a defined inspection method should be followed.
The inspection operators should have their forms filled out correctly.A good
source of information to determine the quality performance of the section is
the point of 100% inspection.The section supervisor should check the quality
level at the point of 100% inspection periodically.
From the 100% inspection forms the supervisor should analyze what are the
operators with the highest defect frequency.For these operations the
supervisor should identify the type of defects found most often, the cause, and
the frequency at which the type of defects happen. With this information the
supervisor should address the problems, correct the possible causes and make
plans to prevent them.
FINAL AUDIT:
A final audit should be performed on packed items.When the boxes are ready
to be shipped a certain number of units should be inspected.
Determining how many garments need to be inspected.Randomly select a
number of boxes from the lot that contain the determined amount of units to
be inspected.
After entering all the information into the final audit form, the final inspector
should determine if the lot was accepted or not. Any rejected lots should be
addressed promptly to minimize the chance of having a late order.
Quality procedures in the cutting area
During the cutting process the factory should ensure quality by having a
spreading inspection, a cutting inspection and a final audit.
SAMPLE:
Quality control personnel must check sample before sending it to the buyer.
Important points to be checked:
Whether the samples are as per buyers specifications or not, such as style
description, sketch measurement sheet, photograph, etc. And workman ship
has to be checked with reference sample or related documents provided by
the buyer.Report to be submitted to the merchandiser as well as to the
superior.
CUTTING SECTION:
Pattern marker:Pattern and marker must be checked by the quality control
personnel check points are as follows:
1. Measurement
2. Gradation
3. Allowances
4. Pattern parts missing
5. Mixed parts
6. Pattern shape
7. Direction of pattern in the marker
8. Pattern alignment with respect to the grain line
9. Poor line marking
10. Marker too wide than fabric width
11. Notches and drills marks omitted
12. Mismatch checks and strips
13. Overlapping
14. Too thick line or double line marking
15. Invisible line marking
16. Marker incorrectly positioned on the lay
SPREADING:
During spreading following should be checked:
1. Fabric relaxation
2. Incorrect tension of plies
3. Wrong direction of plies
4. Unacceptable damages found
5. Mismatching of checks and strips
6. Narrow fabric
7. Shaded fabric
8. Misalignment of plies
CUTTING:
During cutting the following points should be checked:
1. Inappropriate cutting
2. Notches-Misplaced, too deep, angled, omitted or wrong type
3. Drills- marks -wrong drill, omitted angled
4. Knife cut- garment parts damaged by careless use of knife
5. Frayed edges scorched or feud edges caused by faulty knife.
6. Slits opened inaccurately or omitted.
OTHERS:
1. Bundling with bundle card,
2. Numbering
3. Cut panel checking
4. Wrong size in the bundle
5. Fused parts checking
6. Cleanliness
7. Proper raking/storing
8. Proper issuing
9. Prefer test cutting than bulk cutting
10. Reporting
SEWING SECTION:
QUALITY CONTROL SYSTEM FOR SEWING SECTION:
There are some systems are in practice in the sewing floor are as follows:
1. Traditional system
2. Macy system
3. Traffic light system
In-line checking criteria:
1. As per pre-production meeting some critical process too be checked in the
sewing
2. Each and every process must be checked
3. Auditing/ Monitoring
4. Cleanliness
5. Reporting
End line checking criteria:
1. Inspector will check all process of a garment.Sample may be picked
randomly or 100%
2. Reporting
Other:
1. Transportation
2. Proper Machine
3. Maintenance
4. Proper attachment each
5. Cleanliness (floor, line, work place)
Finishing section
1. Ironing
2. Folding
3. Tagging
4. Packing
Importance of fabric inspection:
1. Improved product quality
2. Minimize waste
3. Reduce the cost
4. Avoid short shipment
5. Increase productivity
CLASSIFICATION OF DEFECTS
1. CRITICAL DEFECT- A defect that is likely to result in hazardous or unsafe
condition for an individual in consuming or using the product, or that is
contravenes any mandatory regulations.
2. MAJOR DEFECT- A defect that is likely to result in failure, reducing the
usability or serviceability of the product. Any obvious appearance of defect will
affect the sale ability of the product.Most of the cases garments are rejected.
3. MINOR DEFECT-A defect that does not reduces the consumption or sale of
the product is nevertheless a workmanship error beyond the quality standards.
POSSIBLE GARMENT DEFECTS
MATERIALS/FABRIC:
1. Hole or surface haw that could develop into hole.
2. Slues that is easily distiinguishable
3. Distinctive shading
4. Dye spots misprints
5. Cut, tears or visible surface repairs
6. Bow or skew exceeding
7. Plaids ,checks or individual stripes
CLEANSLINESS:
1. Soil, spots, stains or dust
2. Attached thread clusters
PRESSING:
1. Burn or scorch marks
2. Glaring shine marks
3. Press marks
4. Absence of pressing camps
5. Products packaged moist after steam pressing
6. Improper pressing
7. Seams not lined up
8. Loops twisted after pressing
9. Pressed increases uneven
SEAMS AND STITCHING:
1. TWISTED, ROPED OR PUCKERED SEAMS
2. Open or broken stitches
3. Raw edges when covered edges are specified
4. Seams not back stitched
5. Irregular or uneven top stitching
6. Scam grin through
7. Any exposed drill holes
8. Label is not correctly attached
BUTTON HOLE:
1. Size within specs
2. Ragged edges
3. Uncut buttonhole
4. Out of alignment
5. Stitch depth too narrow or wide
Sequence of final inspection of garments:
Before start the final inspection we have to check the final status of the lot
with P.O. sheet and packing list.
1. Quantity
2. Color
3. Size
4. Packing
1. Inspection preparation:
1. Sufficient space
2. Sufficient light
3. Inspection table
4. Clean, noise free environment
5. Sufficient helping hand
Required tools and equipments:
6. Packing list
7. Measuring tape
8. Arrow sticker
9. Marker pen
10. Highlight pen
11. Weight scale
12. Purchase order sheet
13. Quality spec sheet
14. Reference sample
15. Pick glass
16. Approved swatches
17. Finding and reporting format
Carton checking:
18. Quantity
19. Quality
20. Ply
21. Size
22. Strength
23. Color
24. Shipping marks
25. Main mark
26. Side mark
27. Merchandise description
28. Strapping/ trapping
Garment checking:
1. Appearance
2. Materials conformance
3. Conformity of style
4. Color shade
5. Logos
6. Workmanship
7. Finishing
8. Cleanliness
9. Damages
10. Weight
11. Fitness
12. Record of defects non-conformances
13. Measurement checking
14. Defective sample draw for reference
15. Carton fill up
16. Sticker and signature
17. Reporting
 Flat Store
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Fabric ROC- Head checked fabric
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Shrinkage (old navy cap-100%, Other buy-10%)
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B. S.V (Center Celvage Velodic) 10% all buy
C. L.V
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End to end 10%
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Bowing 10%
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Handfeel
GSM CALCULATOR
LAB DIP PHOTOS IN D65 & U30

FLATS & DRAPE

WASHING CENTER
PATTERN CUTTING

SHRINKAGE INSTRUCTION
STRIKE OFFS COMPARISON
PART-04
CONCLUSIONS
In conclusion I can say that this internship report is really essential for every
student of design studies to get idea about textile industry.By completing this
report I have got overall idea of this sector and these may be helpful to know
about the technical and management knowledge of garments industry also
these sector related organizations. This is a huge sector and yet to discover the
whole.

I want to thank my department head for giving me this opportunity of learning.

This internship program will help me in the further challenges of life. I try my
best to make this project enriched with lots of apparel related documents.
Pearl global pvt ltd is really a good experience for me because every person of
there is so much helpful and gave me the proper methods of practical learning.
So, at last, there is a hope of eradicating all the obstacles and become the
leader of garment industries in near future.

References:
https://www.pearlglobal.com/

https://www.slideshare.net/aasif19bd1/internship-report-on-garments-
merchandising-43630429
INTERNSHIP CERTIFICATE