Apparel Internship Final Copy Document Print

Apparel Internship Report
SHIVA TEXYARN LIMITED
Coimbatore, Tamilnadu
Submitted By
R K NAVEENA (BFT/19/692)
T DIVYA (BFT/19/156)
Y NAVINA (BFT/19/658)
Bachelor of Fashion Technology (Apparel Production)
Under the Guidance of
Dr. K RAM MOHAN Sir

Professor, Department of Fashion Technology
2022
Department of Fashion Technology
National Institute of Fashion Technology,
Hyderabad
Internship at Shiva Texyarn Limited, Coimbatore; 2022
SELF-DECLARATION:
This is to certify that this report which is a documentation of the Apparel Internship at Shiva
Texyarn Limited, Coimbatore, Tamilnadu has been made in entirety by the following
students: R.K.Naveena, T.Divya, Y.Navina who are members of the same group and attended
the internship at the same duration from June 6 to July 29, 2022. This project and its report is
a culmination of our own efforts and has not been copied or plagiarised from any other
source, apart from technical specifications written referenced from the company that
manufactures the machinery, along with references, bibliography and definition of terms
collected from secondary research which have been properly and entirely referenced. All
information which have been written in this report are true to our knowledge.
R.K.Naveena T.Divya Y.Navina
Signature of the Mentor
Dr. K Ram Mohan Sir
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ACKNOWLEDGEMENT:
We would like to express our gratitude to Mr. Ravin Kumar sir, AGM at Shiva Texyarn
Limited, for accepting us to pursue internship at their prestigious organization. The internship
helped us gain insights, crucial inputs and overall understand how a textile manufacturing
setup works. We are also extremely grateful to Mr.Vijay Kumar, Senior Production Manager
at Shiva Texyarn Limited for being our Industry Mentor and helping us get acquainted with
the processes, working and teaching us about the various functions in detail. We would also
like to thank him for being patient with us and encouraging and building our confidence as
this was an important internship we were undertaking. We would also like to express our
thanks to all the Department Managers/Masters and every other staff in the organization for
helping us in understanding the process and workflow of the company despite their busy and
hectic schedules. We would also like to specially mention their help and contribution and are
thankful to the organisation for accommodating us. We also thank our college, National
Institute of Fashion Technology, Hyderabad. We would like to express our sincere gratitude
to Director Sir Shri. Vijay Kumar Mantri IAS, Joint Director sir Shri. L Madan kumar Reddy
sir and the CAC, Dr. Mandalika Annaji Sarma sir for giving us this opportunity. We would
like to thank Mr. K.Ram Mohan sir for his valuable guidance and support throughout. He has
been there for us clarifying all our doubts and helping us always understand work. We extend
our gratitude to Dr.Shakeel Iqbal sir, Center Cordinator, Department of Fashion Technology
for clarifying the doubts and encouraging us at all times. We would also like to thank our
department, the Department of Fashion technology, our professors Dr. Rajini Jain ma’am, Ms.
Sharmila Sure ma’am, Mr. TVSN Murthy sir, Mr Anantphani sir, Ms. Srivani Thadepalli
ma’am and Dr.Mohammed Vaseem Chavhan Sir for always supporting us, teaching us,
mentoring and motivating us and for imparting crucial knowledge that enabled us to go and
intern in the apparel industry.
We would like to thank Mr.V.Muthu, who put in a good word for us and helped us get this
internship in the first place. We would like to acknowledge the contribution of our parents for
always supporting us and providing us with the means to complete the internship. We would
also like to special mention our friends and classmates for being there for us, supportive and
critical as and when required. In the end, we would like to extend our heartfelt obligation
towards all persons who have helped us at every stage of our internship. Without all their
support and guidance, we would not have been able to undertake this study and complete the
internship.
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CONTENTS
Self-declaration: ...................................................................................................................................... 2
Acknowledgement: ................................................................................................................................. 6
1 Introduction:.................................................................................................................................... 8
2 Company Profile .............................................................................................................................. 9
3 Divisions......................................................................................................................................... 11
4 In-House Brands ............................................................................................................................ 14
5 Organizational Chart...................................................................................................................... 14
6 Marketing: ..................................................................................................................................... 15
7 Merchandising department: ......................................................................................................... 16
8 Research and development:.......................................................................................................... 18
9 Accounts department:................................................................................................................... 19
10 Sampling department: ............................................................................................................... 20
11 Fabric store: ............................................................................................................................... 21
12 Trims & accessories store: ......................................................................................................... 22
13 HR & Administration: ................................................................................................................ 24
14 Cutting: ...................................................................................................................................... 27
15 Sewing (production): ................................................................................................................. 31
16 Quality control:.......................................................................................................................... 36
17 CAD: ........................................................................................................................................... 39
18 Finishing Department ................................................................................................................ 40
19 Maintenance department: ........................................................................................................ 41
20 Packing Department .................................................................................................................. 43
21 Product Analysis ........................................................................................................................ 45
22 Time study: ................................................................................................................................ 63
23 Production planning: ................................................................................................................. 66
24 Gantt Chart ................................................................................................................................ 67
25 Shiva Texyarn Limited: SWOT Analysis of the Company. .......................................................... 70
26 Project ....................................................................................................................................... 72
27 Learning Experience: ................................................................................................................. 88
28 Appendices ................................................................................................................................ 90
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1 INTRODUCTION:
As part of the mandatory course requirement, we 3 students, R.K.Naveena, T.Divya,
Y.Navina began our Textile Internship which is undertaken at the beginning of the 7th
Semester at Shiva Texyarn Limited, located at Coimbatore District, Tamilnadu. We have got
acquainted with the working of the industry and have understood the practical applications of
the apparel production processes that we have studied about in the previous years. We looked
at the processes and machinery in detail, studied the functions and carried out small tasks
assisting in the functioning of the industry. The Apparel Internship was an extended effort in
order to grasp the concept and methods of how an apparel industry works. Over the duration
of 8 weeks, we were actively involved learning about day to day functioning and technical
processes in the industry. Our industry mentor was instrumental in teaching us and we also
learnt a lot by shadowing others and picking up information from everywhere. It was 8 weeks
of learning insights into a student’s mind to develop the idea of production and finishing and
pre-production stages of apparel manufacturing along with their quality aspects for both
technical and commercial processes. In this report, we have documented each stage of our
learning, various processes that we witnessed first-hand and our understanding about the
functioning of the industry in general. On the 29th of July 2022, we received our certificates
and thereby completed our apparel Internship.
Objective of the Apparel Internship
To study the different strategies of garment manufacturing process and departments in detail
and work on projects given by the industry.
Statement of Study:
To study the garment manufacturing process thoroughly different department functions and
observe their day-to-day functioning. Execution of small projects/assignments as per
organizational need.
Significance of Study:
The study will help to gain hands on experience of various manufacturing processes like
cutting, sewing, finishing, checking, data generation and the use of IT tools in various stages
of garment manufacturing.
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2 COMPANY PROFILE
Shiva Texyarn limited is a multifaceted vertically integrated textile company focusing on
technical textiles and value-added products. They operate in a range of segments from yarn
and fabric to fully confected Textile solutions, both in their brand name and esteemed clients
worldwide. Shiva Texyarn Limited was incorporated in 1980 as a private limited entity in
Coimbatore, Tamil Nadu (India). They are widely acclaimed as a leading manufacturer,
supplier and exporter of Canvas Products, Laminated Sheets, Coated Fabric, Baby Care
Products and Bed Protectors.
The Corporate Identification Number (CIN) of Shiva Texyarn Limited is

L65921TZ1980PLC000945. The registered office of Shiva Texyarn Limited is at 52, East
Bashyakaralu Road R S Puram, Coimbatore, Coimbatore, Tamil Nadu.
Company Details:
Table 1 – Company Details of Shiva Texyarn Limited
CIN L65921TZ1980PLC000945
Company Name Shiva Texyarn Limited
52, East Bashyakaralu Road R S Puram, Coimbatore,

Coimbatore, Tamil Nadu.
Company Category Company limited by Shares
Company Subcategory Non-govt company
Date of Incorporation 28 May 1980
Age of Company 42 years
Products Home textiles, Knit garments, Military and Tactical

DivisIon, Backpacks and Rucksacks, Technical textiles,
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Baby products and garments
In house brands Quick Dry, Quick fit, Q Club, Wulf, Paw Paw, Medicmasks,
Medic Virostat
Brand Collaborations Decathlon, Amazon, Myntra, Sundaram Textiles, Defence

Research and Development Organisation- India, DMART
Annual Turnover 500 Crores
No of workers 320
The company has the following certifications.
● SA8000
● FIVE S (Workspace management system)
● Oeko - Tex 100 certification
● WRAP certification
● Affiliation certification (Textile sector skill council)
Timeline:
1980 - Commenced business as a non-banking financial company.
1985 - Went public.
1989 - Spinning mills Unit 1 at Dindigul district started.
1994 - Windmill division at Munduvelampatti started.
2002 - Finance business and spinning division merged.
2006 - Lamination division at Karanampettai started.
2009 - Spinning mills Unit 2, Garment division, and Knitting division at Karanampettai
started.
2012 - Technical textile division at Ganeshapuram started.
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2012 - Processing division at Sipcot, Perundurai started.
2013 - Coating division at Ganeshapuram started.
2014 - Bag division at Ganeshapuram started.
2015 - Garment division 2 (NBC) at Karanampettai started.
2016 - Garment division 3 at Karanampettai started.
3 DIVISIONS
The company has the following divisions, the garment division is one among them where we
completed our apparel production internship.
Spinning mill:
The company makes some of the finest cotton yarns in the market and have an experience of
more than 25 years in the spinning industry. Their raw materials comes from select ginners of
India and from International sources in West Africa, Australia and the United States. Low
imperfection rate and negligible contamination, outstanding fabric drape and consistency have
made them a name to reckon with in this field in India.
They make combed, carded and compact yarns, slub yarns and fancy yarns.
Specifications:
● 52000 spindles
● 2-stage online contamination cleaner/ PP scanner in blow room.
● Linkconer equipped with the latest quantum yarn clearers.
● Online ring data system.
Processing division:
They have facilities for specialized, performance fabrics processing, including high fastness,
moisture wicking properties as well as for the processing of delicate fabrics. Their Processing
division supports their raising, brushing and shearing operation where they can create a range
of specialized fabrics.
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Lamination Division:
Lamination technology is one of the most innovative technologies used in textile innovation
and product creation. The most advanced Textile lamination system in the world is the
Reactive Polyurethane (PUR) technology and Shiva Texyarn was the first to introduce this
technology to India in 2005 and they are the only Indian company to have more than a decade
of experience in this field with millions of metres produced over the years. Their two lines
can produce approximately 600,000 metres per month.
Application Examples:
● Breathable, waterproof membrane lamination.
● Fleece to Fleece.
● Paper to Fabric.
● Flat fabric to raised fabric.
● Knit to woven.
Uses
● Outdoor clothing fabric (breathable shells).
● Mattress protectors.
● Medical textiles.
● Industrial applications.
● Military applications.
Coating Division:
They have a material handling capability of 9 lakh metres/month and the coating division is
capable of a versatile range of coating applications that produce.
● Acrylic coated products
● PU Coating
● Art canvas & Digital canvas products.
They offer a range of finishes in its coated products that include:
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● Fire retardant
● Water repellent
● Soil and stain resistant
● Anti-microbial
● Oil resistant
● Crease resistant and wrinkle free finishes.
Coated Products:
● Digital canvas
● Art canvas
● Q-Print media
Garment Division:
● Home Textiles
● Bedding Range
● Towels and Bath
● Kitchen Articles
● Garments
● Knitwear
● Outerwear
● Military and tactical gear
Bag Division:
Shiva Texyarn Limited sports is a bag division ranging school bags, exclusive girls range and
a professional range for camping and photography, WULF bags are popular with varied age
groups and professionals.
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4 IN-HOUSE BRANDS
 Quick Dry
 Q-Club
 Wulf
 Quick Fit
 PawPaw
5 ORGANIZATIONAL CHART
Figure 1: Organizational Chart of Shiva Texyarn Garment Division.
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DEPARTMENTS:
6 MARKETING:
The marketing department in a garment company is responsible for marketing products made
in the factory, product marketing and bringing in new orders for the company. Its headed by
the Marketing manager and supported by a core marketing team. The marketing team is
responsible for discussing prospects with existing buyers and showcasing the factory’s ability
for developing new designs.
The most common marketplace is garment exhibitions and buyer meetings. The department is
also important for maintaining good relations and PR as well as retaining customers, both
B2BandB2C.
Objective:
 Build awareness of the brand
 Target new customers
 Improve relationship with stakeholders
Marketing
Manager
Client In-House
Marketing Marketing
Manager Manager
Marketing Marketing
Assitant Assistant
Figure 2: Organizational chart of Marketing Department

Table 2- Activities of the Marketing Department
S.No. Activity Responsibility Requirements

1 Reach out to customers Marketing Manager
2 Create content Client/Inhouse Past sales data
Marketing Managers
3 Advertising & distribution Marketing Assistant Contact marketing agencies
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7 MERCHANDISING DEPARTMENT:
In merchandising department, an apparel merchandiser will have to deal with many
departments while merchandising a product. They will follow up with the order right from the
beginning till the order gets shipped. The merchandiser will also calculate the account
profitability.
Objective:
 To mediate between marketing and production departments.
 Increase sales.
 To purchase and maintain the inventory that customers are expecting or requiring.
 To reach the company's goals, which can only be done when the inventory is sold,
such as profit, growth, etc.
Costing:
Costing is the process of calculating and then figuring out the whole cost of making a
garment, which includes the cost of the materials, labour, and transportation as well as the
general costs of running the business. The merchandiser needs to be well-versed in costs.
There are several circumstances in which cost is a key factor. The costing is primarily done
by the merchandiser for two reasons.
 Prising of the garment
 Order acceptance
Pricing:
If the garment is sold directly to the end customer by the manufacturer, it’s mandatory to
estimate the cost very carefully and accurately. Pricing is basically done by adding estimated
mark-up profit % to manufacturing cost. The profit might vary upto 60% depending on the
product. If the garment is made for an order from the buyer or a retailer, the profit % set by
the manufacturer might vary from 30-60 % .
Order acceptance:
If the garment has to be exported by the manufacturer, then costing is the base of the business.
After estimating cost of manufacturing including wages, operating expenses, transportation
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and freight charges, the merchandiser takes the negotiation with the buyer with the cost of
unit garment and decides whether to accept the order or not.
Organisational chart:
Merchandising
department
Merchandiser
1
Asst.
merchandiser
1
Figure 3: Organizational chart of the Merchandising department
Table 3- Activities of the Merchandising department

1. Communicating with buyers Merchandiser Previous order samples
2. Sending the developed garment Assistant merchandiser
sample to the buyer
3. Product costing Merchandiser
4. Scheduling of activities Assistant merchandiser Time & action plan
5. BOM preparation ERP head BOM
6. Sourcing raw material Merchandiser
7. Approval of quality Senior production
manager
8. Preparing tech pack Merchandiser
9. Conducting pre-production Merchandiser
meeting
10. Order execution Assistant merchandiser
11. Following up throughout the order Merchandiser
12. Maintaining a good relationship Merchandiser
with the buyer in long term
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Figure 4 – Amazon Solimo’s Tech Pack
8 RESEARCH AND DEVELOPMENT:

Objective:
 Innovate and introduce new products and services.
 Focuses on development of in-house products.
R&D
Head
Assistant
Figure 5: Organizational chart of the Research and Development department
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Table 4 – Activities of the Research and Development department

1. Product research R & D head, assistant Product
development project
2. Product development R & D head, assistant Product
development project
3. Product updates R & D head Product
development project
4. Quality control R & D head, Quality control head Quality guidelines
5. Market research R & D head, Marketing manager
9 ACCOUNTS DEPARTMENT:
The accounts department tracks and records customers cash payments for supplied items and
services provided. It manages bills. It also sends polite reminders to customers to make sure
they pay their invoice on time.
Objective:
 Record transactions
 Sort & analyse them
 Prepare financial statements
 Assessing financial position
Accounts
department
Senior
accountant
1
Assistant Staff
2 3
Figure 6: Organizational chart of the Accounts department
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Table 5- Activities of the Accounts department

1. Pay salary Assistant
2. Manage company’s accounts Senior accountant
3. Recompensate company’s payments Senior accountant
for production cost or make advance
payments
4. Collection of debts from buyers Assistant Data
5. Preparing profit reports Staff Current production &
sales data
10 SAMPLING DEPARTMENT:
The sampling process is the very first stage in garment production. Also, through sampling,
one can arrive at manufacturing cost, timing, manpower etc.
Objective:
 To get approval of the buyer.
 To check fit.
 To determine the entire cost of production
 Making high quality samples may attract other buyers in the future.
Sampling
department
Sampling head Pattern master

1 1
Tailor
2
Figure 7: Organizational chart of the sampling department
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Table 6 – Activities of the sampling department

1. Receive tech pack from merchant Pattern master
2. Develop patterns with available Pattern master Specification
trims & accessories sheet
3. Develop fit samples Tailor Pattern
4. Get approval from buyer Sample head
5. Develop pattern with specified Pattern master Specification
trims, accessories and fabric sheet & pattern
6. Get approval Sample head
7. Shrinkage test is done if necessary Washing department staff
8. Develop pre-production sample Tailor Specification
sheet & pattern
11 FABRIC STORE:
Fabric is stored in the fabric store and it is distributed respectfully to the cutting department.
The primary duty of the fabric store department is to store all the raw materials, particularly
the fabric, required to make clothing.
Objective:
 To store fabric.
 To inspect fabric.
Fabric store
Store manager
1
Assistant Staff
2 3
Figure 8: Organizational chart of the stores department
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Table 7 – Activities of the stores department

1. Follow up with factory’s fabric Store manager
needs
2. Receive & store fabric in bulk Assistant
3. Manage fabrics inventory record Store manager BIN card
4. Supply necessary fabric to the Staff
factory
12 TRIMS & ACCESSORIES STORE:

The trims and accessories store also operates similar to the fabric store.
Trims- Threads, buttons, lining, Interlining, zippers, labels, care labels, etc.
Accessories- Polybag, elastic bag, mini polybag, master carton, inner carton, collar stand,
safety pin, etc.
Store
Store Assistant
manager and ERP
Figure 9: Organizational chart of the trims and accessories stores department
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Process flowchart:
Figure 10: Flow Chart of the stores department

Table 8 – Activities of the stores department
S.No. Activity Responsibility Co-ordinated Requirements

department
1. Indent is raised from the Merchandiser Merchandising Rough purchase
store order
2. Purchase order is made Merchandiser Merchandising
3. PO is sent to the supplier Store manager Merchandising, Purchase order
ERP
4. Lead time is decided Merchandiser & Merchandising Time & Action
Store manager calendar
5. Goods are checked for Store assistant ERP Quality
damages inspection and
record
maintenance
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sheet, ERP
6. Preparation of inventory Store manager & BIN Card
record (BIN card) Store assistant
7. Supply of necessary Store assistant ERP and every Product
goods to the factory department requirement
sheet from
every
department
13 HR & ADMINISTRATION:
Objective:
 Keeping a good relationship with employees and managing their talents
 Taking care of training and development
 Organising awareness programs and looking after compliance and sustainability etc.
HR &
Administration
Human
Resource
Manager
Assistant Assistant
Figure 11: Flow chart of the HR Department
HR Employment process:
The workers are paid on a daily wages basis. The attendance is taken through biometrics and
automatically fed on the ERP. The workers are given incentives based on their attendance
percentage and rewarded accordingly. All the staffs are given a leave of 7.5 days after a
probation period of 3 months. After a year, a leave of 10 days is allowed. The company has
also initiated a training and development program.
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Certification:
SA 8000 2014 (Social accountability)
PF & ESI
Education:
They also provide education and coaching to the staff and workers of the company where
transportation and 50% of educational expenses are covered by the company. They provide
UG, PG courses like BBA, B.com, Nursing etc.
Committees:
 ICC Committee
 Work committee
 Health & safety committee
 Covid awareness committee
 Grievance committee
 SA 8000-2014 committee
HR ERP:
 Bank details
 PF & VAN
 ESI/IP
 Employee personal information
 Personnel file
 Reports
 Costing
 Hostel
 Private van
 ID
 Payslip
 PF/EEI
 Commission
 Token
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CSR Activities:
SPORTS:
 Coimbatore trail run.
 Vers marathon.
EXPOS AND FAIRS:
 Tex fair - 2018.
 Children baby maternity expo, Shanghai - 2019.
 Global Textile expo - 2019.
SEMINARS:
 Seminar programme on Industrial safety.
 HR Conclave on Next gen HR practices - Dec,2017 in Firebird institute.
HEALTH:
 Medical camps.
 Insulin pump donation.
Table 9 – Activities of the HR Department

department
1. Recruit new employees HR Manager Assistant Offer letter, ERP
General manager
2. Maintaining record of old HR Assistant ERP Data excel sheets,
& current employees ERP
3. Taking care of labour HR Manager, HR AGM, Senior Data excel sheets,
issues assistant production registers , ERP
manager
4. Receiving feedback & HR assistant Every Registers
acting accordingly department
5. Guiding new employees HR manager, Training Offline
assistant (TASMA)
6. Organise programs & HR manager Every
manage unions department
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14 CUTTING:
Objective:
 Cutting fabrics for garment orders.
 Feeding the sewing department with cuttings.
Cutting
department
Spreading
Cutting master CAD Master
master
Spreading Cutting
assistant assistant
2 2
Figure 12: Flow chart of the cutting department.
Marker making procedure:
CAD Software used - Tukatech (TUKACAD)
It is a fashion CAD pattern making software with advanced functions process engineering to
empower accurate pattern making, grading and marker making for every style created. The
software makes it easy to create various types of notches, darts, pleats, seams, drill holes and
internal contours. Changes to one (base) pattern are automatically mirrored throughout the
whole size range, removing the need to recalculate the grading rules. Grade rules are
immediately applied to the new style pattern when existing pattern blocks or reference
patterns with grading are used to generate new styles, removing the requirement to reapply
grade rules on new developments. It also has the ability to work with other CAD data. For
data exchange with other cad systems, TUKAcad imports and exports data in industry
standard formats such as ASTM.dxf and AAMA.dxf. Automatic data backups, scheduled at
predefined intervals, ensure that work is not lost. Backs are made for all open files if multiple
files are open. Pattern files, marker, plot and cut files are automatically zipped for emailing
thorough MS office integration. It has a built in video/ audio help demonstrating every tool
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and function. Videos run one minute or less describing how to use a tool or perform a
function. Data and photos can be uploaded to current PLM and PDM systems or saved in
designated network files. Fabric Buyers, Production Engineers, Costing, and Product
Merchandisers will have quick access to information.
Role of cutting department:

Table 10: Activities of the cutting department
department
1 Receive fabric from store Cutting master
2 Relaxation of fabric Cutting assistant
3 Cut order planning Cutting master CAD Master Estimate of
total
production
4 Fabric spreading Spreading master
5 Marker making CAD Master Marker plan
6 Cutting fabric Cutting CAD Master Marker plan
department
7 Inspecting cut components Cutting assistant
8 Sorting panels Cutting assistant
9 Re-cutting panels Cutting assistant
10 Fusing garment Cutting assistant
components
Machinery used:
Spreading:
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Figure 13: Spreading Machine

Table 11: Details of machinery used in spreading
Type of machine Company name Model Count
Roll Loader machine Morgan Tecnica Morgan Tecnica- 330 1
Fabric spreading (lay) Morgan Tecnica Morgan Tecnica Fox 200 2

machine
Roll Loader machine
● Roll storage and handling, a ten-roll motorized carousel is used.

● The storage space is made up of two conveyorized platforms that are stacked on top of
each other.
● The bottom platform is for roll pre-loading, done at random since the proper spreading
sequence is determined by the control panel, which is equipped with an interactive PC
Touch and dedicated advanced software that is both intuitive and user-accessible.
● The upper one collects the used rolls, which are automatically unloaded after
spreading.
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Fabric Spreading (lay) machine
● Ideal for high-volume production.

● WIFI-enabled computer with Windows OS
● Solid belt cradle improves quality.
● Boost reliability with an auto-diagnosis system.
Automatic cutting:
Table 12: Details of the automatic cutting machines
Type of machine Company name Model Count
Automatic high ply Morgan Tecnica Morgan Tecnica Next 2 Δ 1

fabric cutting m/c
Automatic band knife San-V San-V SK 900 1

cutting m/c (Special
143)
● Artificial Intelligence allows procedures like sharpening cycles and real-time speed
control to be handled as efficiently as possible.
● This automatic cutter can also self-detect any operating anomaly through its auto-
diagnosis mechanism, reducing machine pauses and breaks.
● Band Knife Cutting Machines is suitable for exact cutting of small parts with air table.
according to the type of material.
● Inverter speed control system provides smooth cutting. provides easy cutting without
collapsing the pile of Fabrics.
Manual cutting:
Table 13: Details of manual cutting machines
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Type of Machine Company name Model Count
Straight Knife cutting Sakae KS-AUH Heavy duty 3

m/c (Special 141) KM 8" Straight knife
cutter 220V CE
Band Knife cutting m/c San-V San-V SK 700 2

(Special 147)
End cutting m/c Eastman Eastman EC-6NL 5
Rotary cutting m/c 1
Cutting table 5
● Straight knife m/c cutting efficiency is higher than round knife. In this machine, the
fabric can be cut at any angle.
● Band knife cutting m/c is used for cutting the fabric rolls without a cardboard inner
tube.
● End cutters are a set of pliers with a cutting edge designed to help cut through material
with a flush finish.
● Rotary m/c is used to cut large and medium-size components of simple shape from
low-fabric spreads or to cut single articles from one or two material plies.
15 SEWING (PRODUCTION):
Sewing department is the heart of the whole production and manufacturing of every company,
it is the department that is responsible to set and meet daily production targets and finish
assembly of cut parts. The garments take shape and come to life here. At Shiva Texyarn
Limited, there were 11 production lines in total, each handling a different operation. Each line
usually is set up with 22 machines, adding or removing machines as per requirement of the
garment. Each line has its own supervisor. The production targets and line operations are set
daily.
Objective:
 Record maintenance of cutting received from cutting department.
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 Making reports of everyday production on line-wise basis and manpower.

 Meeting Production targets while ensuring garment quality is maintained.
 Rework and repairing if required.
Set a target for Set up machine

Product Analysis
production layout
QC check of the Set up operator

Line Balancing
Product layout
Distribution of
Line Setup Receiving cut parts
process
Distribution of cut
Complete garment
End Checking parts to tailor and
making
helper
Couting and Repair and Rework

checking with Final Quality Check if required or its
target finished.
Figure 14: Process flow of sewing department
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Senior
Production
Manager
Asst
Production Industrial
Production
Planner engineer
Manager
Production Asst
Production
Quality Production
Incharge
Manager Planner
Production
Inspector
Floor
Production In-
Charge
Line
Supervisor
Tailor
Helper
Figure 15: Organizational chart of Sewing department

Table 14 – Activities of the sewing department

1. Style analysis Production incharge
2. Estimating labor costs Industrial Engineer
3. Planning and scheduling floor level Industrial Engineer
production
4. Setting the line Production Inspector
5. Stitching the garments Tailor
6. Balancing the assembly line Floor production
33
incharge
7. Making parts Tailor
8. Ironing garment components Helper
9. Checking stitched garments Staff
10. Documentation Line supervisor
Machinery used in the sewing department:

Table 15 – Machines in the sewing deparment
Sewing Department
Sewing Number Make/Model

Machine
Single Needle 195 Juki DDL 9000C, Brother S-7300A 403P, Juki DDL 900A S,
UT Juki 8700B-7, Brother S-7200-403, Juki DDL 8100 E
Single Needle 79 Juki DDL 8700
Ordinary
SN Edge Cutter 8 Juki DLM 5200 N
4 Thread 62 Juki mo-6814 D, Yamato CZ612545DF
Overlock
5 Thread 15 Juki 6MO-6816 D, Yamato AZF8120ST-YDF, Pegausus
Overlock M952-52H
FlatLock 32 Pegausus W500PV Flatbed, Yamato CF-2300M-156M
Flatbed, Juki MF-7523D Flatbed
Bartack 23 Juki LK-1900BN, Brother KE-430FS-05J,Typical GT-6430G
Button 2 Juki LK-190BAS, Brother BE-438FX
Machine
Pattern Taker 6 Brother BAS-3266G-02A, Juki AMS-221EN
Kaja Hole 2 Brother HE800B2, Juki LBH-1790A-S
Keyhole Kaja 2 Juki MEB3810NJ
Snap Button 9 Orbito OBP 90-P, Air Snap OS 2808, Wellnown 1959
Double 15 Juki DU1181N, Typical GCO33ODB
Pressure Foot
34
Machine
Durkopp 7 Juki Durkopp LS-1341, Durkopp 669
Bonding
Double Needle 15 Brother T-8422C-403, Juki LH-3588A
Lock Sticth
Double Needle 3 Juki MH-380
Chain Stitch
Feed Off 4 Juki MS-1261M, Brother DA-92703
Machine
ZigZag 2 Juki LZ-2290ASS7
Machine
Piping 1 Durkopr adler
Machine
Trimming 5 Without Number
Machine
Seam Sealing 19 H&H A1-118, Fabcare FB-2721
Rib Cutting 5 Dino LU-933, SCM-1.35M
Weighing 2 NIL
Scale
Special 21
Machines
Quilting 4 Chinese Machinery
Machine
Total 538
35
Figure 16: Sewing department
16 QUALITY CONTROL:
It is the department concerned with planning, raw data compilation, investigation and
implementing changes to ensure quality in all aspects. Quality is crucial to ensure that bulk
orders don’t get rejected therefore preventing the industry from suffering huge losses. In the
industry a dedicated quality team ensures, that by stage by stage monitoring, the expected
quality is assured and production is completed within target time.
Objective:
Improving the product by identifying the bugs and issues
36
Quality
Manager
Assistant Inspection
Quality and Testing
Manager Manager
In-Line/End- General
Line Quality Quality
Head Supervisor
Figure 17: Organizational chart of Quality control department

Table 16 – Activities of the Quality department
S.No Activity Responsibility Requirements

1 Identify defects if present Staff Tools
2 Verification of product General quality
supervisor
37
Quality Pre Production

Size Set
Process Process
First Output Pre Production

Pilot Cutting
Evaluation Meeting
Pilot If Ok, Bulk In Line

Evaluation Cutting Inspection
Final
Inspection and End Inspection
Packing
Figure 18: Quality control flow chart

In order to maintain quality, the quality assurance department undertakes their job in the
following stages.
Daily Quality control:
Daily Quality control meetings are conducted line wise and total pieces are checked in-line as
well as endwise.
Weekly Quality Control:
In weekly quality control meetings, the defect data is collected and compiled to identify top
defects and the Defect per Hundred Units or DHU is calculated.
Upper control Limits are defined for the DHU of every department.
Cutting – 4%
Stitching – 10%
Washing – 5% (for denim)
38
Finishing - 2%
After this the corrective/preventive actions are taken according to methods defined by the
department.
17 CAD:
In the CAD department, the markers are checked for their shade and shrinkage preferences.
Cutting Audit:
In the cutting stage, which is the most critical where no rework can be done, the following
measures are carried out.
 Quality check for marker

 100% in-line checking while spreading
 Marker and lay checking
 100% checking of cut pieces.
 Notches and other parameters
A.Q.L Audit system for cutting and sewing
Table 17: AQL standards and defects
Inspection samples quantity and acceptability criteria
Offer Quantity Size of No of defects in No of Defects in

sample cutting (AQL 1.5) Garment (AQL 2.5)
Pass Fail Pass Fail
51 to 90 13 0 1 0 1
91 to 150 20 1 2 0 1
151 to 280 32 1 2 0 1
280 to 500 50 2 3 0 1
500 to 1200 80 3 4 1 2
1201 to 3200 200 5 6 1 2
3201 to 10000 315 7 8 2 3
39
Sewing Audit:
In sewing process, the inspection is done in two areas.
In-Line checking – Here the garments are checked during their different stages of
manufacturing.
End-Line checking – In this, the garments are checked after the entire process is over and the
dimensions are also checked.
For denim, quality checking is done before and after wash to ensure right shades.
Reports maintained for quality:
The following reports are maintained for quality.
 Size set report

 Spreading lay report
 Cutting report
 Inline and Endline checking report
 In-Process measurement report
 Washing report
 Final statistical audit report
18 FINISHING DEPARTMENT
The finishing department carries out the following steps.
 Trimming involves the removal of the extra threads from the garment from the
stitched areas.
 Ironing is done after the garment has been completely inspected and the garments are
ironed on the basis of their folding. Diaper and knit garments are not ironed.
 After pressing, the garment is measures and verified according to buyer specification.
 Final checking is done before packing.
 Inspection is carried out according to AQL but if the buyer asks for 100% inspection
then it’s done as well.
40
 Detection of needles and other metallic parts is also done, especially for baby
products.
Finishing
manager
Trimming QC
Ironing Master
Checker
Measurement
Checking
Figure 19 :Organizational chart of Finishing department

1. Trimming of threads Trimming QC
Checker
2. Checking for threads Trimming Checker
3. Ironing of garments Ironing Master Iron box
4. Garment measurement Measurement
checker
5. Verification according to buyer Finishing Manager
specifications
6. Final Checking Finishing Manager
7. Inspection Finishing Manager
19 MAINTENANCE DEPARTMENT:
Objective:
 Repair machines
 Follow up with monthly maintenance of machines
 Inspection
 Procurement
41
 Planning and implementing expansion of factory
Maintenance
department
Mechanic head
1
Mechanical
Helper 1
assistant 1
Figure 20 : Organizational chart of Maintenance department
Table 18 – Activities of the maintenance department

1. Repairing machines Mechanic Tools
2. Regular inspection of machines Assistant Maintenance record
3. Planning & execution Mechanic
42
Figure 21: Machine maintenance progress

record
20 PACKING DEPARTMENT
In the packing department, garments are tagged and the final labels are attached including
miscellaneous labels if required by the buyer. After the tagging is over, and final garment tags
are attached, the garments are then folded according to buyer requirement and packed into
boxes that are then packed into cartons and shipped.
Packing can be done in three ways, solid packing, ratio packing or mixed packing.
Packing
Master
Folding Packaging and

Incharge Label Incharge
43
Figure 22 :Organizational chart of packing department
Table 19 – Activities of the packing department

1. Tagging of garments Packaging/Label
Incharge
2. Folding of garments according to Folding Incharge
requirement
3. Checking of folding, final inspection Quality department
4. Packing of garments into boxes Folding Incharge
5. Delivery Challan Finishing Manager Delivery challan
Figure 23 : Packing floor
44
PART –II
21 PRODUCT ANALYSIS
Product- Diaper with reusable pad
Figure 24: PAW PAW Diaper

Merchandising Department:
PAW PAW Diaper is an in-house brand and it is developed by the Research and Development
team of Shiva Tex Yarn ltd. Then the developed product ideation is sent to Managing director
for approval. Tech pack is developed by the merchandiser as it is an house brand. Sample is
made with the actual fabric and fabric testing is done for children’s safety.
The Consumer Product Safety Improvement Act (CPSIA) is a United States Government
law restricting levels of hazardous materials in products imported or made within the
US, especially those for children.
Time and action calendar:

Table 20 – TNA Calendar
1 Development of product by R&D team 06-10-2021
2 Approval sent to managing director 07-10-2021
3 Approval received 11-10-2022
4 Bill of Materials prepared 15-10-2022
45
5 Preparation of costing sheet sent 18-10-2021

7 Pattern Making 20-10-2021
8 Proto sample submission 22-10-2021
9 Proto Sample Approval 23-10-2021
10 Confirmation of Order 25-10-2021
11 Request for sample of trims and fabric 26-10-2021
12 Sample lot of trims received by the manufacturer 1-11-2021
13 Meeting with sampling and other department 3-11-2021
14 Fabric Package Test Sample Approved 5-11-2021
15 Fabric In House 12-06-2022
16 Trims in House 12-06-2022
17 Fabric and Trims Quality and Quantity Check 13-06-2022
18 Marker Making 25-10-2022
19 Cutting Issue 13-06-2022
20 Start of Cutting 13-06-2022
21 Pilot Run 15-11-2021
22 Pre Production Meeting 15-11-2021
23 Pre Production sample sent 15-11-2021
24 Approval of PP Sample 10-05-2022
25 Production Start 10-05-2022
26 Production second slot start 15-06-2022
27 Finishing 1-06-2022-
28 Quality inspection 3-06-2022
29 Packaging 5-06-2022
30 Quality Audit 4-06-2022
31 Shipment Dispatch 8-06-2022
32 Order Delivery -
As it is an inhouse product, the product was developed before 2022 and second slot
production was going on between 1-06-2022 to 1-08-2022
Sampling and sourcing:
After finalizing the fabrics and trims for diaper, the pattern master makes the pattern for the
product with maximum efficiency to calculate the fabric consumption.
Fabric:
Micro fleece- 210 gsm
Single jersey cotton fabric- 120 gsm
46
Bill of Materials
Then the Bill of materials is made with approximation and the cost is quoted. 3% to 5% buffer
is added to items and cost.
Sourcing
Snap Buttons – Thirumurugan traders, Coimbatore
Sewing thread- Renuga yarn threads, Peelamedu
Micro Fleece Fabric- RKSD Fabric, Ludhiana
Single jersey cotton fabric – Tehsil Ludhiana
Elastic – Prema elastic, Coimbatore
Velcro – Ram enterprises, Coimbatore
The sourcing is done within 5 to 6days maximum as it is in-house and recurrent product in
production and the vendors are well known and familiar.
Store:
After the delivery of fabrics and trims they are qualitatively and quantitatively inspected and
stored in the fabric and trims store. It is issued according to the requirement daily. All the
records are fed in ERP software (Prime ERP- software used in Shiva Tex-yarn ltd.)
Cutting:
CAD:
Tukatech software is used for making the marker plan
Machine: Orbitech inkjet plotting machine
47
Figure 25: Marker plan of diaper
Figure 26: Marker plan of diaper
48
Spreading:
Fabric: Printed
NAP: N/O/W
Spreading mode – F/O/W
Machine used – Morgan Tecnica Fox 200
Automatic cutting:
Automatic cutting is used for cutting Fleece fabric and single jersey fabric.
Machine used: Morgan Tecnica Next 2∆
Sam Value
Paw Paw Diaper

Table 21 – Elemental Breakdown of PawPaw Diaper
S.No Operation Machine Operators Pieces Cycle Cycle Average Basic SAM
(per 1 2 time(in Time (cyle time
hour) seconds) (80% plus
) allowance
17%)
1 Button (8) Button 2 80 41 43 45 0.6 0.702

attaching
machine
2 Panel SNLS 2 70 53 50 51.6 0.688 0.8342

attach
with
Velcro
3 L/R small SNLS 1 100 39 35 37 0.493 0.576

pouch
49
4 Pouch Overlock 1 300 15 13 14 0.186 0.217

overlock
5 Pouch SNLS 1 200 19 17 17.3 0.230 0.269

Ready
6 Pouch L/R SNLS 2 200 16 19 17.6 0.234 0.273

attach
7 Elastic SNLS 1 150 25 24 24 0.32 0.374

stitch
8 Elastic SNLS 2 150 22 25 23.67 0.31 0.36

Attach
9 Piping, SNLS 2 60 59 62 59.3 0.79 0.92

Folding
label
10 Tag SNLS 1 150 21 25 23 0.30 0.35
11 Final Button 1 100 34 36 34 0.45 0.526

Button attaching
machine
12 Trimming 1 150 25 26 24.6 0.32 0.374
SMV = Basic time + Allowance

= (Cycle time × Rating) + (allowances)
= 371.07 × 0.70 + 17%
=259.749+ 5.057
=264.806
=4.4 mins
50
1A
1B
Button
Button
2A
2B
Flap, side
Flap, side
3A
3B
Panel, Velcro attach
Panel, Velcro attach
4A
4B
Panel, Velcro attached
Panel, Velcro attached
with diaper side
with diaper side
5A
6A
Over lock (side & below)
Over lock (pouch)
A
7A
7B
Elastic
Elastic
8A
8B
Attachment
Attachment
(Overlock, elastic)
(Overlock, elastic)
9A
9B
Elastic
Elastic
10A
10B
Sizing (cutting extra pieces)
Sizing (cutting extra pieces)
11A
11B
Folding & attaching label
Folding & attaching label
12A
13A
Finishing/closing button
Peak attach
LINE SETTING
51
A & B Indicates workers performing actions
Number indicates the tasks performed by them
ERP Production Details:
Figure 27 – Production details
Trimming:
No of workers- 3
The excess threads are trimmed and pencil marks are removed using soap oil
Inspection:
As diaper is a baby product, metal detector is used to find any sharp objects like needle inside
the stitched pouches and also they check the overall product by examining it.
Rejection rate- 10 pcs per 1000 pcs
52
Packing:
Figure 28: PAW PAW Diaper package
The diaper is placed inside the thick paper printed package directly without poly bag.
The total production data is updated in the ERP and then it is placed in the delivery section for
shipment.
Shipment:
The product is shipped after quality auditing and it is fed is ERP. The delivery challan is
provided. As it is an in-house product the payment is made within the different factory
branches itself.
53
PRODUCT ANALYSIS- JEANS
Merchandising:
Merchandiser team receives purchase order enquiry from Pepe Jeans. Tech pack with required
specifications is sent to the merchandiser. After analyzing all the requirements from the
buyer, the order is discussed with the general manager and the BOM is made according to the
requirements. The costing sheet is sent for approval. After receiving approval, proto sample is
made and sent to the buyer for confirmation
Then the order is confirmed. Merchandiser simplifies the requirements in layman words for
easy understanding and conducts meeting with the production workers.
Tech pack-
Figure 29: Tech pack of Jeans
54
Bill of Materials:
 Denim Fabric- Mahishi fabric, East Delhi (gsm- 230)

 Pocket bag fabric – Salecha sons, Ludhiana
 Sewing Thread- Prerna threads, Ghaziabad
 Topstitch thread- Prerna threads, Ghaziabad
 Metal zipper- Ningbo LY, China
 Metal button- Dongguan Hingye Button Products
 Metal rivet- Anjali enterprise, Mumbai
 Main label- Sneha printing, Peelamedu
 Wash care tag- Sneha printing, Peelamedu
 Poly bag- VS Enterprises
Sampling & Sourcing:
Pattern master makes the pattern for jeans in efficient way to maximize the production and the
consumption of fabric and trims is identified for the required order. Then the final BOM is
made and the fabric is finalized after the sample approval.
Figure 30: Jeans sample
Table 22 – TNA of Denim Jeans
55
Time & Action Calendar:
1 Receives purchase order enquiry 12-05-2022

2 Consultation with production team and sales contract sent to the 13-05-2022
buyer
3 Codified system entries (ERP) 13-05-2022
4 Bill of Materials prepared 15-05-2022
5 Costing sheet sent to the buyer 15-05-2022
7 Pattern Making 18-05-2022
8 Proto sample submission 19-05-2022
9 Proto Sample Approval 20-05-2022
10 Confirmation of Order 22-05-2022
11 Request for sample of trims and fabric 25-05-2022
12 Sample lot of trims received by the manufacturer 1-06-2022
13 Meeting with sampling and other department 1-06-2022
14 FIT Sample sent to the buyer 2-06-2022
15 Approval of FIT Sample 3-06-2022
16 Purchase Order raised by the buyer 5-06-2022
17 PO from the manufacturer 5-06-2022
18 Size Set Sample Sent 7-06-2022
19 Size Set Sample Approved 8-06-2022
20 Fabric In House 13-06-2022
21 Trims in House 13-06-2022
22 Fabric and Trims Quality and Quantity Check 13-06-2022
23 Fabric Shrinkage Test 15-06-2022
24 Pattern Manipulation 16-06-2022
25 Marker Making 18-06-2022
26 Pre Production Meeting 19-06-2022
27 Start of Cutting 20-06-2022
28 Pilot Run 23-06-2022
29 Production Start 25-06-2022 (start)
56
30 Denim Washing 27-06-2022 (start)

31 Trims and Accessories Attachment 7-06-2022(start)
32 Cargo Booking
33 Finishing
34 Packaging
35 Buyer's Quality Audit
49 Shipment Dispatch 8-07-2022 (approx.)
50 Order Delivery
Approx lead time- 88 days
STORE:
After the delivery of fabrics and trims they are qualitatively and quantitatively inspected and
stored in the fabric and trims store. It is issued according to the requirement daily. All the
records are fed in ERP software (Prime ERP- software used in Shiva Tex-yarn ltd.)
Shrinkage test is done for the fabric and it is separated according to the shrinkage level and
placed in different lots.
Shrinkage test:
Step 1: Prepare the wash test sample

Cut fabric from the roll and take fabric specimen of 110 cm X 110 cm (length X width). If
you have multiple lots of fabrics rolls, take a sample from each lot.
Step 2: Measure before washing
Mark a square of 100 cm X 100 cm (You can only mark + at the corner of the square.). Use a
fabric marker to mark the fabric. This is before wash measurement of fabric length and width.
Step 3: Wash the fabric sample
Wash the specimen following dip wash or machine wash as needed. Follow washing
instruction provided by your buyers. Or follow the standard washing method to find the
shrinkage percentage for washing.
Step 4: Dry the sample after washing
Dry the fabric specimen as specified. Do line dry or tumble dry as specified in the test
method.
57
Lay the specimen on a flat table. Remove creases but don't stretch the fabric. Measure the
fabric length and width following marking points and note it.
After washing measurement are as following
 Lengthwise measurement =95 cm
 Width wise measurement = 97 cm
Fabric shrinkage %= (length before washing- length after washing)*100/ length before
washing
Fabric Shrinkage
Length wise= (100 - 95)/100 = 0.05 that is 5%
Width wise = (100-97)/100= 0.03 that is 3%
Cutting Department:
CAD:
Tukatech software is used for making the marker plan
Machine: Orbitech inkjet plotting machine
Figure 31 – Marker plan for denim jean
58
Spreading:
Fabric: Printed
NAP: N/O/W
Spreading mode – F/O/W
Machine used – Morgan Tecnica Fox 200
Automatic cutting:
Automatic cutting is used for cutting denim fabric.
Machine used: Morgan Tecnica Next 2∆
Production:
Approx- 3000 pcs
Size-28 to 40
Sam Value:
Table 23 – Elemental breakdown of Denim Jean
S.No. Operation Machinery Pieces No. of Cycle 1 Cycle Average Basic SAM
used (per operators 2 time in Time
hour) seconds
1 Fly piece SNL 12 4 289 305 304.6 5.076 5.9397
stitching
2 Fly piece SNL 12 3 276 294 294 4.9 5.733
attachment
0 0
IN-LINE CHECKING
3 Front SNL 10 7 369 345 362.3 6.0383 7.06485
pocket
(L&R)
4 Back yoke 3TOL 50 1 77 70 71.67 1.1945 1.397565
join
5 Back yoke FOA 50 1 69 80 73 1.216 1.4235
59
top stitch
6 Back raise 3TOL 40 1 98 86 91.67 1.5278 1.787565
join
7 Back raise FOA 40 1 96 90 90 1.5 1.755
top stitch
8 Back pocket SNL 25 1 151 142 143 2.383 2.7885
attachment
0 0
IN-LINE CHECKING
9 Side seam 5TOL 60 2 65 57 59 0.9833 1.1505
overlock
(L&R)
10 Side seam FOA 100 2 362 358 358.3 5.9716 6.98685
top stitch
(L&R)
0 0
IN-LINE CHECKING
11 In- Seam OL 40 1 95 87 91 1.516 1.7745
Join
12 In-Seam top FOA 40 2 88 85 87.67 1.4611 1.709565
stitch
13 Bottom hem SNL 40 2 92 87 90.67 1.5111 1.768065
join
14 Waist band WBAM 15 2 243 229 239.67 3.9945 4.673565
attachment
15 Waist band WBAM 15 3 221 258 240.6 4.01 4.6917
closing
16 Loop Bartack, 50 1 69 71 68.34 1.139 1.33263
attachment ABLA
17 Key hole Keyhole 50 2 79 64 72 1.2 1.404
making
18 Trimming 50 5 75 81 75.3 1.255 1.46835
0 0
60
CHECKING
0 0
WASHING
19 Bartack Bartack 30 1 114 132 118.67 1.977 2.314065
20 Rivet and Button 60 1 54 63 61.34 1.02233 1.19613
Kaaj button attach
placing
2992.8 49.88 58.3596
FINAL INSPECTION
SMV = Basic time + Allowance

= (Cycle time × Rating) + (allowances)
= 2992.8 × 0.80 + 17%
=2394.24 + 406.98
=2801.22
=46 mins
Washing:
The denim fabric is given for washing to respective laundry warehouses and received after 3
days. It is located in out skirts of Coimbatore. Washing effects are also given here like stone
washing.
61
Elemental break down- Jeans
Figure 32: Elemental breakdown of Jeans
Trimming:
No of workers- 3
The excess threads are trimmed and pencil marks are removed using soap oil
Inspection:
Final inspection includes examining final products from the buyer's perspective, taking size
measurements, form fitting (placing clothing on the appropriate size manikins to check that it
62
fits as described on the label), and, if necessary, live modelling (again to see if the garments
properly fit the labelled sizes).
Packing:
Deadman folding is done for the pant and it is placed in poly bags. Each carton box has 5
denim pant and it is sealed properly. The box number along with the delivery details is
mentioned in it.
Shipment:
The product is shipped after quality auditing and it is fed is ERP. The delivery challan is
provided. Delivery is taken care by the buyer.
22 TIME STUDY:
Determination of sample size:
Using the formula of the statistical method for sample size determination from the book,
Introduction to Work study by ILO, and by using 5 observations at preliminary level, The
sample size is obtained.
The sample size obtained for the product (cushion cover) is 49.
Thus, a total of 30 observations are taken to perform time study.
Calculation of relaxation allowance:

From the book, Introduction to work study by ILO,
By considering all factors concerning relaxation allowance, the relaxation allowance is
arrived at 17%.
First five observations are given in the tabulation to avoid confusion. A total of 30
observations are taken.
Table 24 – Time study of Cushion Cover
63
El.No. Element description Observed time Total Average R B.T

O.T O.T (s) (s)
1 2 3 4 5 (s)
(s)
1. Overlock 17 20 19 18 17 554 18.47 125 23
2. Zip attachment 57 59 61 60 59 1713 57.1 125 71.4
3. Side closing & label 37 39 39 38 39 1117 37.2 125 46.5
4. Overlock 34 38 37 35 33 1062 35.4 125 44.25
5. Trimming 27 29 32 30 29 877 29.2 125 36.5
Total 177.37 221.65
The averages are taken from all the 30 observations.
Total Observed time = 177.37 seconds
=2.95 minutes.
Standard time = Observed time x Allowance
= 2.95 x 1.7
Standard time = 5.015 minutes.
Table 25 – Elemental description
Observations Element description
No. Overlock Zip Side closing Overlock Trimming

attachment & label
1. 17 57 37 34 27
2. 20 59 39 38 29
3. 19 61 39 37 32
4. 18 60 38 35 30
5. 17 59 35 33 29
6. 17 58 37 35 29
7. 20 58 33 34 33
64
8. 18 58 38 33 26
9. 19 57 39 36 25
10. 17 59 39 37 29
11. 19 57 37 33 27
12. 18 59 38 34 30
13. 17 60 39 38 29
14. 19 61 38 35 32
15. 19 60 39 33 33
16. 17 57 37 34 27
17. 20 59 39 38 29
18. 19 61 39 37 32
19. 20 58 35 36 26
20. 17 59 37 38 27
21. 18 60 36 39 30
22. 19 58 39 37 32
23. 20 59 38 36 32
24. 17 56 36 33 33
25. 19 59 37 35 32
26. 20 60 39 36 29
27. 18 63 33 33 30
28. 20 61 36 32 27
29. 17 60 35 36 26
30. 19 58 36 37 25
65
PART III
23 PRODUCTION PLANNING:
Capacity planning:
Production planning analyses whether a factory has adequate materials and labour to meet
production demands, which requires them to determine a firm's production capacity. They
don't take over capacity orders if the order capacity is reached for the entire year because
doing so would be more expensive. In contrast, if the capacity order is not full, they must wait
for more orders to do so; otherwise, the factory would incur finance losses. In order for
management and merchandisers to advise buyers of orders, the production planning
department informs them of predicted capacity orders.
Time and Action:
The planning department follows each style in accordance with the timeframe. Every
purchase has a due date and is completed on schedule. Every style is adhered to from product
development to shipment. As a result, the planning section keeps track of actions in a very
stylish and timely manner.
Scheduling:
The production planning division decides when a style is added to the production line.
Alongside the retail department and the merchandising department, they schedule fabric and
trims. If everything arrives inside on time, it can all be added to the line. On the other hand,
the line design can be altered to reduce costs if fabric and trims are not received on time.
Production planning meeting:
The store and merchandising department and the production planning department discuss the
condition of trims and fabric. They work closely with all pertinent departments, including
merchandising, production, stores, cutting, finishing, quality, and buyer reps, once all
products and approvals have been done, to make sure that a certain style is understood for
manufacture. Before the PP meeting, they can review the production file, trim card, and ready
size set.
66
Order Allocation:
For each style, the planning department is in charge of order allocation. They must assign a
line plan when they receive an order from a buyer. Without a line plan, an order cannot be
produced efficiently. Order allocation is therefore essential for the planning department.
Manpower and M/C allocation:
The production planning division determines the number of operators needed for a particular
output style. They can select a line layout for a certain design. Determine the number of
machines needed to run the line. Informed choices about productivity for a particular style can
then be made.
Execution of tasks:
The planning department must carry out every task for good planning. Smooth production is
impossible without efficient execution. They have to execute every style, from order
placement to shipment, as a result.
Materials planning and in-house:
To enable pre-planning to the effective line planning date, the planning department must
follow up with the store and merchandising departments on fabric and trims.
24 GANTT CHART
Table 26 – Gantt Chart
Week 1
Day 1 Day 2 Day 3 Day 4 Day 5
Introduction to Overview of CSR Activities Stock keeping and Overview of the

the company the undertaken by store procedures for costing process
and briefing departments the organization fabric, trims and and
about the and and accessories. marketing/buyer
organization. introduction to organizational
each structure. Plant
department. layout and
demonstration.
67
Week 2
Learnt about the Solimo Learnt time and Made a curtain Undertook an
procedures Cushion cover- action calendar, mockup for a buyer, assignment to
followed by the Sourcing, tech BOM and predicted best make buyer
merchandising pack and production selling colours PPT.
department production plan planning using using Pantone shade
Solimo cards.
Cushions.
Week 3
Made a Shadowed the Developed Negotiated buying Overview of

catalogue for Merchandising BOM for process between the Time to Action
each product, team and PawPaw manufacturer and calendar from
using the 4Ps of understood the Diaper. the buyer for denim the
Marketing for process. jacket. Merchandising
an B2B PPT. Department.
Week 4
Sample Fit sample Sample Sourcing and Overview of the

development analysis. development Market visit with cutting room
process. Assisted for the and prototype BIN Card Issue. and automatic
fit of the denim of the hair cap. machinery.
jacket.
68
Week 5
Production plan Time Study for Time Study for Time Study for Pattern
and Sewing Diaper Diaper Diaper and manipulation
Floor Study Accounts and HR and testing for
department study. denim
according to
rolls.
Week 6
Operation Procurement of Denim Washing Quality and Buyer Meetings

Breakdown and Trims and stock sent. Control/Compliance and preparation
analysis of Accessories for Stock Keeping. Processes. of colour
jeans. denim. catalogue
Week 7
Brainstorming Observation for Colour Coding Checking and Shipment

of project. Project. of Diapers and Packing Delivery
its effect on Departments. Challan.
Production Folding.
Line.
Week 8
Compilation of Production Administration, ERP and Certificate and

projects and Line analysis Salary and other information Documents.
report. and line HR records. management.
balancing
69
25 SHIVA TEXYARN LIMITED: SWOT ANALYSIS OF THE COMPANY.

Strength:
1. Technical expertise and resources to handle wide variety of fabrics and products
ranging from baby, high fashion, military, technical and medical products.
2. Faster adaptation to style changes, capacity to train and adapt human resources to
match evolving styles.
3. High Production capacity. Trims and Accessories are easily accessible, thereby
reducing lead times. Located near industrial and manufacturing hub of Tirupur.
4. Pattern development and CAD department that aids in the design and development of
products along with buying houses.
5. Wide horizontal of different products therefore minimizing losses in production.
6. In-house products reduce dependency of the manufacturing unit on outside orders
therefore ensuring that production happens throughout the year.
7. Hostel facilities for workers reduce absenteeism from average of 30% in the garment
industry to under 10%.
8. Work with well-known brands like Decathlon, HRX, Amazon, Indian Army, Arvind
Lifestyle, Future Retail, ABFRL amongst others.
Weaknesses:
1. Lesser order quantities leading to frequent style changes and subsequently increasing
the time for production.
2. In-house brands are less risky but occupy more space in the production line.
3. Some technical products like masks face intense competition from outside and
therefore aren’t profitable.
4. Wide array of styles and knowledge means that the company is not rooted in
experience in any one domain.
5. More focus required on the marketing of in-house product since they sell well but are
not marketed enough.
70
Opportunities:
1. Skilled workforce and the gap in the high fashion industry.

2. Technical textiles expertise can be used to set up production of technology enabled
wearables.
3. Frequent changes and less order quantity per style leads to skill training and building a
skilled workforce that’s ready to tackle style challenges.
4. Expanding production capacity and automation to increase production per day.
5. Apparel and its allied areas as well as product design.
Threats:
1. Competition from other geographical locations

2. Production depends a lot on in-house brands
3. Current production involves defense goods, and production for which high quality
standards have to be maintained.
4. Heavy skill-based work, still dependent on manpower.
5. Bulk and Mass quantity production houses.
71
PART IV
26 PROJECT
Project 1
Redesigning the Paw-Paw Diaper
Objectives:
There have been complaints that have been received from the customers, that the sales
department passed on to manufacturing, regarding the placement of buttons and the difficulty
in understanding their placement for fit and size issues for the diaper.
Age Group – 0 to 3 years
Fit Issue – Anthropological difference between the fit of girls and boys, but product
differentiation not understandable to the public.
Project Methodology –
Identification Proposed
Product Study Brainstorming
of Problem Solution
Test
Production Questionnaire Testing
Production
Market Mass
Survey Production
Figure 33: Project methodology flow chart
72
Process:
Step 1: Product Study - We did a detailed study and analysis of the product, and had to
spend many hours sitting and looking at the product, the diaper to figure out and understand
the details of how to use the 12 buttons placed for FIT. And 16 buttons to ensure size.
Step 2: Identification of Problem - After researching and asking the whole production team,
as well as the sales/marketing team, we found out that the problem was people getting
confused between the fit and size buttons and lack of clear demarcation for busy parents who
generally don’t spend a lot of time in reading packaging.
Step 3: Brainstorming – After looking at all the options including but not limited to
changing packaging, an instruction card, we finally arrived at the option of coloured buttons
after talking to customers at the store.
Step 4: Proposed Solution – A proposed solution was given which was the colour coding of
only pink buttons to minimize cost and maintain ease of production.
Step 5: Test Production – Samples were manufactured, a total of 100 samples were
manufactured.
Step 6: Testing – After a sample size calculation, new parents who were workers at Shiva
Texyarn and Bannari Amman group were given the product to test the product.
Step 7: Questionnaire – A questionnaire was made after calculating the sample size among
the users of the paw paw diaper at the factory of Shiva Texyarn and Bannari Amaan group to
people who used the product and the usefulness was tested and asked.
Figure 34 – Sample size calculation Formula
73
A sample size was calculated using 95% confidence level, 10000 population size and the
margin of error of 10%.
After calculating a sample size of 96 was chosen.
Step 8: Production – As a trial run 500 products of the new PawPaw diaper was
manufactured and sent to retailers to obtain market perception and analysis. We completed
our internship at this stage.
Step 9: Market Survey – Through the sales representatives at factory run stores data was
collected, and perceptions received from consumers about the perception and willingness to
buy the product before mass production began.
Step 10: Mass Production – The mass production of the new PawPaw diaper was expected
to begin in October 2022.
Figure 35: The older version of the diaper
74
Figure 36: The new improved diaper with pink buttons.
Table 27 – Sourcing and costing of buttons
Sourcing and costing:
Older Version New Version
Number of white presser 4 4

buttons
Number of white under 16 16

buttons for size
Number of white under 12 6

buttons for fit
Number of pink under 0 6

buttons for fit
Cost per pink button (over +0.18 rupees * 6 = +1.08

and above white ones) rupees per diaper.
75
PAWPAW DIAPER
Design Modification Study
Please take a few minutes to fill the survey, to redesign the pawpaw diaper to make it more
user friendly.
1. On a scale from 1 (very difficult) to 5 (very easy), how would you rate the easiness of
using the product at present?
□ 1
□ 2
□ 3
□ 4
□ 5
2. On a scale from 1(difficult to use) and 5 (easy to use), how would you rate the
understandability of product usage, including buttons?
□ 1
□ 2
□ 3
□ 4
□ 5
3. Do you agree, on a scale from 1(don’t agree) to 5 (completely agree), that colour
coding buttons will make it easier for you to use the product for your girl child?
□ 1
□ 2
□ 3
□ 4
□ 5
4. Do you think that this modification will help new parents to easily understand the
product at one glance, thus make you buy?
□ 1
□ 2
□ 3
76
□ 4
□ 5
5. On a scale from 1( not so much) to 5 (very much), do you think this design
modification is required?
□ 1
□ 2
□ 3
□ 4
□ 5
Figure 37: Question 1
77
78
Project 2
Developing a Hair Cap with size adjustments.
Objectives:
To develop a sample/product prototype for a hair cap, which can utilize fabric scrap and still
be a useful product to dry hair faster and be comfortable enough to wear and be efficient.
Demographics – Girls/Women but anyone with shoulder length hair
Age Group – All age groups
79
Fit Issue – Hair length fit issues since the cap worked well for smaller hair length but
wouldn’t work well for longer hair length. Fabric scraps had to be sorted accordingly and two
sizes to be developed which would work well for the hair length in all spectrum.
Project Methodology –
Identification Proposed
Product Study Brainstorming
of Problem Solution
Sample testing Raw Material

Finalizing sizes Questionnaire
of Product Analysis
Production
Figure 42: Project methodology flow chart
Step 1: Product Study – After an Indepth study/analysis of the product, we understood the
product and its usage.
Step 2: Identification of Problem – After using it, we could first hand realise what the
problem was, there was a problem with the button placement and fit issues according to the
size of the cap and the length of the hair.
Step 3: Brainstorming – After talking to the management and the sampling team, the need
for two sizes to accommodate users with short and long hair was realised as well as the shift
in placement of buttons from inside to the edge, for the hair cap to fit the user correctly.
Step 4: Proposed Solution – We zoomed in on the two sizes, one that was 15 inches long
(the original) and the second that was 23 inches long (for longer hair).
Step 5: Questionnaire and survey – We calculated the sample size of the population and
arrived at a sample size of 82 woman workers in the factory.
Step 6: Raw Material Analysis - All the scraps were analysed and categorised once more
before finalizing the sizes.
80
Step 7: Finalizing sizes –
Step 8: Sample testing of the product – Once the prototype was ready the product, a sample
run was conducted and tested and then the product was ready for the market.
Step 9: Production – After final checking and the approval of the marketing team, the
product was now ready for the market.
Deliverables:
1. Two size recommendations for the hair cap instead of one, one for short hair and one for
long hair
2. Design and product development of hair cap
3. Upgrading of the product in the final stage of sampling.
HAIRCAP SAMPLE
Design Modification Survey
Please take a few minutes to fill the survey, to redesign the hair cap to make it more user
friendly.
1. On a scale from 1 (very difficult) to 5 (very easy), how would you rate the easiness of
using the product at present?
□ 1
□ 2
□ 3
□ 4
□ 5
2. On a scale from 1(difficult to use) and 5 (easy to use), how would you rate the
usefulness of the product to dry hair faster and more efficiently?
□ 1
□ 2
□ 3
□ 4
81
□ 5
3. Do you agree, on a scale from 1(don’t agree) to 5 (completely agree), that having two
sizes one for long hair and one for short hair will help fit your hair better?
□ 1
□ 2
□ 3
□ 4
□ 5
4. Do you think that this modification will help the product better, and thus make you
buy this in the market? On a scale of 1(don’t agree) to 5(strongly agree).
□ 1
□ 2
□ 3
□ 4
□ 5
5. On a scale from 1( not so much) to 5 (very much), do you think size modification is
required?
□ 1
□ 2
□ 3
□ 4
□ 5
82
83
84
Project 3
Amazon Solimo Curtains.
Objectives:
To develop a product for Amazon’s solimo brand with colours that were expected to sell for
the AW Collection.
Demographics – Indian Homes
Project Methodology – Search Research Analysis of the most searched colours of curtains
and designing a product for the Indian market. Fashion Forecasting using data from Amazon.
Requirements:
7 ¼ inches + top and bottom basic measurement of wall
Length – 94 inch + 7 ¼ inch (top and bottom hem)
Width – 65 inch + 3 inch
Product developed: Attached in next page.
85
86
Figure 48 - Curtain designs
87
PART V
27 LEARNING EXPERIENCE:
In the industry we had a first-hand experience of a production shop floor and ground level
realities of the foundation of modern capitalism. We saw last minute rush of meeting
deadlines and the tension/panic of having to meet production targets, but one single incident
that stood out throughout the internship was the fact that disasters happed but eventually
everything did happen and targets were met. We learnt resilience and hardwork in the
industry.
Our Internship at Shiva Texyarn Limited, Garment Unit has been very enriching and a
positive learning experience. We got familiarised and learnt the various phases of handling of
an order/ production from the sampling to production and shipping. It was humbling to know
how much effort, scheduling and accuracy at each stage is required to turn fabric into a
functional product.
We as a team were amazed by two processes, especially the automated cutting, the precision
and accuracy, and spent hours watching the blade cut through the fabric.
One thing that we learnt was how, there was a maintenance issue one day, due to the
breakdown of multiple machines, and due to maintenance issues production could not take
place for the reminder of the day, it happened in the late afternoon.
We learnt about the importance of maintenance and preventive maintenance that day and how
a breakdowns and power shutdowns can cause issues. We were also told that things could and
would go wrong and that what was important was to quickly chart out plans to fix it. We also
learnt life lessons in the industry.
But the next morning, it was fixed and production could resume again, and it was a huge
relief to see that the order was on time, and there wasn’t any significant delay in production.
We also went to each and every department and were given a chance to interact with the
directors of the company. Sometimes there are delays in production but they do try to be as
punctual as possible. The pandemic had disrupted the whole supply chain process, but in July
2022 things were slowly getting back to normal.
88
The apparel internship presented us with an opportunity to apply our classroom knowledge in
the form of posable questions and finding applications in an actual industry. It has helped
broaden our horizons and has helped us to be a part of the industry and gain firsthand
experience on all the processes.
Figure 49: With our Industry Mentors: Mr. Vijay Kumar (Senior Production manager) & Mr.
Ravin Kumar (Assistant General manager) at Shiva Texyarn limited.
89
28 APPENDICES
Appendix II- Machineries used in factory
Appendix III-Spreading
Appendix IV- Cutting
Appendix VII- CAD Department
Appendix IX- Plant layout
Appendix X- Sample deffects
90
APPENDIX – II
Machine Details
Stitching machinery:
Sewing Department
Sewing Number Make/Model

Machine
Single Needle 195 Juki DDL 9000C, Brother S-7300A 403P, Juki DDL 900A S,
UT Juki 8700B-7, Brother S-7200-403, Juki DDL 8100 E
Single Needle 79 Juki DDL 8700
Ordinary
SN Edge Cutter 8 Juki DLM 5200 N
4 Thread 62 Juki mo-6814 D, Yamato CZ612545DF
Overlock
5 Thread 15 Juki 6MO-6816 D, Yamato AZF8120ST-YDF, Pegausus
Overlock M952-52H
FlatLock 32 Pegausus W500PV Flatbed, Yamato CF-2300M-156M
Flatbed, Juki MF-7523D Flatbed
Bartack 23 Juki LK-1900BN, Brother KE-430FS-05J,Typical GT-6430G
Button 2 Juki LK-190BAS, Brother BE-438FX
Machine
Pattern Taker 6 Brother BAS-3266G-02A, Juki AMS-221EN
Kaja Hole 2 Brother HE800B2, Juki LBH-1790A-S
Keyhole Kaja 2 Juki MEB3810NJ
Snap Button 9 Orbito OBP 90-P, Air Snap OS 2808, Wellnown 1959
Double 15 Juki DU1181N, Typical GCO33ODB
Pressure Foot
Machine
Durkopp 7 Juki Durkopp LS-1341, Durkopp 669
Bonding
Double Needle 15 Brother T-8422C-403, Juki LH-3588A
91
Lock Sticth
Double Needle 3 Juki MH-380
Chain Stitch
Feed Off 4 Juki MS-1261M, Brother DA-92703
Machine
ZigZag 2 Juki LZ-2290ASS7
Machine
Piping 1 Durkopr adler
Machine
Trimming 5 Without Number
Machine
Seam Sealing 19 H&H A1-118, Fabcare FB-2721
Rib Cutting 5 Dino LU-933, SCM-1.35M
Weighing 2 NIL
Scale
Special 21
Machines
Quilting 4 Chinese Machinery
Machine
Total 538
Cutting Machinery :
Cutting Department
Cutting Machine Number Model/Make
Laser Cutting 1 Lazer cutting machine CMA1610-Y
Fabric Inspection 3 Ramson RF101EC, San-V Fabric inspection
machine F-2.4M
End Cutter 10 San-V SanV-1, DMC DMCD108, Eastman
EC-3N
92
Straight Knife 11 DMC 7009-850W, Glory, SanV-3A,KM KS-

AVH, Brutue-627
Band Knife 4 SAN-V SK-900
Lay Spreader and 1
Automatic Cutter
GSM Cutter 1
GSM Scale 1
Total 32
Finishing Machinery:
Finishing and Packing Department

Finishing and Packing Number
Machines
Steam ironing 12 Ramson Ironing steam tapule
Needle Detector 2 Eastman HD-650-C, Enntech HD-760-CE
Thread Sucking 1 Ramson
Palette Machine 1 Penguin
Three Layer Mask 1
Machine
Vacum Packing Machine 3 Saurabh
Box Strapping Machine 2 Signode
Mask Welding Machine 6
Stain Removing Machine 5 Ramson-CL 7
Portable Boiler 3 Ramson boiler 6KV
Roll Packing Machine 1
Total 37
Storage Department
Store Machine Number Model/Make
93
Velcro Cutting 2 Cutex 8" TBC-50

Webbing Cutting 6 Mecanor, Cutex TBC-50LH, Orbito OTC-126,
Machine Kaiyu KAI-13-120H
Cone Winding Machine 1
Total 9
Special Machinery
Special Machines Number Model Make
Embossing Machine 1
Single Head Quiling 2
Multi Head Quilting 1
Auto Fabric Slider 2
Auto Cutting CAD 1
Wading Pilling 1
Cut Pocket APW 1 Juki LH-895N
Supreme Laser Pattern Taker 1 SP-S608-HIJ
Auto loop Attaching 1 Juki LK-1960
Denim Pocket Ironing Machine 1 ADT-MI65
Astron Multi Needdle Machine 1
Kansai Multi Needle Machine 4 DFB-1404P
Bottom Hemming Machine 1 Juki leg bottom
DLN-6390-7
Total 18
Fushing Machines
Embosing Machine 5 Chola C-1620
Roll Fusing Machine 1 Hashima HP 450MS
Roler Fusing Machine 1 SA-450
94
APPENDIX-III
Denim fabric:
Loop knit:
95
Fleece:
100% Polyester:
96
Polyester Microfibre:
97
APPENDIX IV
Denim:
Loop knit:
98
Polyester:
Fleece:
99
Polyester solid- solimo:
100
101
102
103
104
APPENDIX IX – PLANT LAYOUT
105
TOTAL AREA OF THE PLANT:

2.96 acres
1,28,877 sq.ft
INSPECTION:
6,478 sq.ft
STORES:
7,485 sq.ft
ADMIN OFFICE:
1,153 sq.ft
SEWING:
25,826 sq.ft
106
APPENDIX X
PRODUCT DEFECTS CORRECTIVE MEASURES
Hair drying 1. Very tight button. The button was stitched a little
towel loose giving enough space for
The button was very tight and attached too the loop to sit.
close to the fabric which did not help the
loop to sit around the button.
2. Button was placed in the wrong place. Button was placed on the edge.
3. Inconvenient size. Size options were added.
The sample fits very well on short hair but

when tried on long or voluminous hair, it
slipped.
Cushion 1. Zipper The zipper was stitched in a

cover manner the cushions could be
The zipper wasn’t stitched properly. It was inserted easily.
hard to insert the cushions.
2. Improper dimensions. It was rectified.
It is seen while the cover is put on the

cushion.
Paw-paw 1. Velcro Velcro was replaced by buttons.

diaper
When Velcro was used, it was easily
detached by babies.
107
2. Leakage A side pouch was added which

helps store excess urine and
The diaper had leakage issues which was avoids leakage.
the major concern.
Denim jacket
1. Improper waist band fit The measurements were re-
evaluated and rectified.
2. Button holes were too tight. Button holes were made bigger.
Jeans Shade was mismatched Washing process was done

properly
29 REFERENCES:
1. Functions of Production Planning and Control (PPC) Department in Apparel
Manufacturing. (2022). Retrieved 4 September 2022, from
https://www.onlineclothingstudy.com/2011/12/functions-of-production-planning-
and.html?m=1
2. Different Departments in a Garment Factory and Their Functions. (2022). Retrieved 4
September 2022, from https://www.onlineclothingstudy.com/2018/11/different-
departments-in-garment.html?m=1
3. Shiva Texyarn Limited - An Integrated Textile Company. (2022). Retrieved 4
September 2022, from https://shivatex.in/
4. International Labour Office. (1992). Introduction to work study. Geneva. - Book
108

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Apparel Internship Report

SHIVA TEXYARN LIMITED

Bachelor of Fashion Technology (Apparel Production)

Under the Guidance of

Dr. K RAM MOHAN Sir

R.K.Naveena T.Divya Y.Navina

Signature of the Mentor

Dr. K Ram Mohan Sir

Objective of the Apparel Internship

The Corporate Identification Number (CIN) of Shiva Texyarn Limited is

Table 1 – Company Details of Shiva Texyarn Limited

Company Name Shiva Texyarn Limited

52, East Bashyakaralu Road R S Puram, Coimbatore,

Company Category Company limited by Shares

Company Subcategory Non-govt company

Date of Incorporation 28 May 1980

Age of Company 42 years

Products Home textiles, Knit garments, Military and Tactical

Baby products and garments

Brand Collaborations Decathlon, Amazon, Myntra, Sundaram Textiles, Defence

Annual Turnover 500 Crores

The company has the following certifications.

● FIVE S (Workspace management system)

● Oeko - Tex 100 certification

● Affiliation certification (Textile sector skill council)

1985 - Went public.

1989 - Spinning mills Unit 1 at Dindigul district started.

1994 - Windmill division at Munduvelampatti started.

2002 - Finance business and spinning division merged.

2006 - Lamination division at Karanampettai started.

2012 - Technical textile division at Ganeshapuram started.

2012 - Processing division at Sipcot, Perundurai started.

2013 - Coating division at Ganeshapuram started.

2014 - Bag division at Ganeshapuram started.

2015 - Garment division 2 (NBC) at Karanampettai started.

2016 - Garment division 3 at Karanampettai started.

● 2-stage online contamination cleaner/ PP scanner in blow room.

● Linkconer equipped with the latest quantum yarn clearers.

● Online ring data system.

● Breathable, waterproof membrane lamination.

● Flat fabric to raised fabric.

● Outdoor clothing fabric (breathable shells).

● Acrylic coated products

● Art canvas & Digital canvas products.

They offer a range of finishes in its coated products that include:

● Soil and stain resistant

● Crease resistant and wrinkle free finishes.

● Towels and Bath

● Military and tactical gear

Figure 1: Organizational Chart of Shiva Texyarn Garment Division.

Figure 2: Organizational chart of Marketing Department

S.No. Activity Responsibility Requirements

Figure 3: Organizational chart of the Merchandising department

Table 3- Activities of the Merchandising department

S.No. Activity Responsibility Requirements

Figure 4 – Amazon Solimo’s Tech Pack

8 RESEARCH AND DEVELOPMENT:

Figure 5: Organizational chart of the Research and Development department

Table 4 – Activities of the Research and Development department

S.No. Activity Responsibility Requirements

Figure 6: Organizational chart of the Accounts department

Table 5- Activities of the Accounts department

S.No. Activity Responsibility Requirements