Professional Documents
Culture Documents
Apparel Internship 2014: Silver Spark Apparel Limited Doddaballapura, Bengaluru
Apparel Internship 2014: Silver Spark Apparel Limited Doddaballapura, Bengaluru
2014
This unit manufactures suits and formal trousers catering largely to the export markets.
The major market for the firm is USA, and other markets are Japan, Canada and Europe.
The major clients include:
Konaka (Japanese Buyer)
Charles Tyrwhitt
Peerless
Levis
ST Lonia
J C Penny
Calvin Klein
SSAL In Numbers
AREA: 200,000 SQUARE FEET
TOTAL MAN POWER: 2240 OPERATORS AND SUPERVISOR
300 EMPLOYEES
Bundling &
Issue of cut ticket
Fabric is spread as Lay shifted to the Cutting as per Fusing of the cut ticketing issue to
and mini marker to
per the lay report cutting table marker plan part sewing section as
the spreading dept.
per plan
.
Express
Banana Republic
Pellestrom
Looks after the payment, salaries and wages of employees and operators
Part of recruitment team
Training of operators – according to the skill matrix
Medical facilities
Extra - activities
IT Department
The ERP used is STAGE, on which end to end documents are
synchronized. From purchase order till shipment confirmation.
Lining Pink
Canvas Purple
BIN CARD Pocketing Red
Fusing White
Felt Yellow
Sampling Green
Non-moving Orange
8 Parameters
Shade Width
CSV
Report Report
Color 4 Point
Fastness Inspection
4 point system
Inspection parameters
Colour Shade Variations:
Roll to roll variation
Centre to Selvedge Variation
Shrinkage:
Fusing (Heat) Shrinkage
Pressing (Steam) Shrinkage
Warp way shrinkage
Weft way shrinkage
Color Fastness:
Machines :
Fabric.
Merchandising
Quality Control
Cutting
Sewing
Finishing
Trim store
Functions
Maintain records of incoming and outgoing materials
To check material for attribute & variables
To arrange an incoming material in an allocated racks
To issue trims as per production planning & other material as per requirement
To mention a record of incoming & outgoing material
To do audit to check physical inventory.
To inspect quantity and quality of material
Auditing of inventory
Process flow
Check of received material records
Records updated
Trim details
Sewing threads
Suppliers - Gutermann, Amann, Coats, Vardhman
Ticket No.- 30, 70, 75, 80, 100, 120, 150, 160, 180
Buttons
Types – 4 holes button, metal buttons(shank), plastic buttons
Sizes – 24 L - 32 L
Suppliers - Emsig, Tiger
•Finishing department trims
–Poly bag
–Carton box
–Hangers
–Staple pins
–Cello tape
–Hang tags
–Pin tags
Shoulder pads
Suppliers - Hailu, Helsa, Orion
Zipper and slider
Supplier – YKK
Hook and bar
Label
Size
Wash care
Brand
AQL in trim store
Quantity Received Sample Size Pass Fail
0-280 13 0 1
281-500 20 1 2
501-1200 32 2 3
1201-3200 50 3 4
3201-10000 80 5 6
10001-35000 125 7 8
They take care of loading plans for the lines, fabric details plans and the shipment plans.
The department plans the entire production process from the receipt of the fabric, the
cutting plan, the quantity, time of loading, finishing and dispatch.
Efficiency report
Cutting dept.
Headed by – Mr. Praveen Khot
No. of Supervisors – 3 (2 for Jacket, 1 for Trouser)
Also heads CAD dept.
No. of Supervisors – 1
The capacity of the cutting department is approximately 5000 – 6000
pieces per day.
Dept. details and Process Flow
Machine details : Receiving Order Checking Ticketing
Automatic Spreaders: 4
Pin tables : 7
Cut Order Planning
CNC cutters : 4 (Accumark
Fusing Defect checking
Software)
Fusing machines : 4
The operators are to arrange all required pieces in a serial number in trolley.
The operators have to maintain the alignment of the pieces so that cut pieces are
not disturbed.
The Issuing operator is to note down pieces to be issued as per cut summary
details in issue slip.
The operators are to cross check-recutting pieces has been put into bundle
before issuing to sewing section.
Industrial Engineering
dept.
Work Flow
Calculate SAM of
To advice production
garment freshly ordered Work measurement of a
department on garment Day to day activity
to calculate different new confirmed order
SAM and line layout
consumptions
• The industrial engineering department is responsible for all the factory operations. Once
the customers place the order the merchandise department forwards the order to the
industrial engineering department for the processing.
• They then prepare the CM cost (cut make cost). This includes:
SAM (standard allocated minute) for each individual operation
Cost per machine hour is calculated
Standard achievable efficiency, etc. are calculated and forwarded back to the
merchandise department.
Sewing Department
(Jacket)
Introduction
Installed Average Daily
• Jacket production is forte of SSAL. Line No.
Capacity Prod.
• Known for its world class jacket
manufacturing. Line 1 500 450
• Peerless
• Konaka (japan) HMS 30 30
Sections
Each jacket line is composed of 7 sections except line-2 and HMS:
• Front
• Lining
• Sleeve
• Assembly - 1
• Assembly - 2
• Small parts
• Pocket bag
• Flap chest
• Canvas
• Welt pocket
• Facing
• Collar
The SAM for a basic jacket is approx. 70-85 min and that for japanese (konaka)
jacket is approx. 90-105 min.
The jacket line follows the ups system of production. The material moves on
pneumatically controlled overhead hangers, which uses the principle of gravity
beautifully.
The finishing department at SSAL has the exclusive license to use the “SI-RO-SET
chemical” for permanent crease setting.
Operations of finishing department
JACKET FINISHING
Trouser section
Trouser Types
Double Single
Flat front
pleated pleated
Trouser Line
There were 5 lines for Trouser manufacturing.
Trouser line1,2,3,5 : Export
Trouser line 4: Konaka
The material handling and movement in the preparatory and front & back sections is on waterfall
trolleys and
The assembly lines are based on UPS system.
The material flow is on manually controlled overhead hangers.
The SAM of the trouser is approx 30 - 35 min.
Installed Average Daily
Line No.
Capacity Prod.
• The concept behind made-to-measure is to provide the customer a tailored fit garment with high
quality like readymade garments, with the fabric, trims, style & design according to the need of
the customer.
Drops available:
Drop 2: (11 sizes)
Drop 4: (11 sizes)
Drop 6: (11 sizes)
Drop 8: (12 sizes)
Drop 0: (14 sizes)
Order placement in MTM
• Taking measurements of the customer.
• Getting the closest try on garment and trying that on the garment.
• Pinning the trial garment according to the need and fit of the customer
• Taking the pictures to help the pattern master to understand the fit requirement and to
work on intuition.
• Selection of the fabric, style by the customer
• Conveying all the collected data to the manufacturing unit
• Selecting the base size and doing the alteration according to the need of the customer
• Developing the customized garment
Process flow of MTM
Order received
• Client form: original form or scan copy
• Client photo with the form.
• Days correct information regarding the order booked.
• Responsible person to receive order, down load photo & scan print outs.
Order analysis:
• Requirement:
• Correct information to be filled.
• Measurement
• Style
• Fabric details
• Generate track sheet (Color coding)
• Alterations of pattern by CAD
• Fabric swatch crosscheck
• Track sheet print
• Barcode print
• Order track sheet dispatch to Store and CAD for ready cutting patterns
Production floor
• Laying of fabric
• Cutting
• Numbering
• Fusing
• Ready cutting
• Sewing
• Finishing
• Packaging
• Dispatched
Advancement
They are planning to replace masters from MTM stores because there has been lots
of problem faced due to measurement mistake.