National Apprentice & Industrial Training

Authority
Report on Industrial Training
At
OMEGA LINE LTD

Name : D.M.N.N.Dasanayaka

Student Number : RT/FAD/17/0030

Department : Higher National Diploma in Fashion Designing Tec.

Field : Fashion Designing

Period : 06 Months (10th January, 2019-10th July, 2019)

OMEGA LINE LTD produce some of Europe’s most renowned lingerie brands viz.Calzedonia, Intimissmi,
Tezenis & Falconeri. The parent company of omega line is calzedonia which has also invested in four more
companies in Sri Lanka. (Sirio LTD, Alpha apparels, Benji LTD & vavuniya apparels) This five companies export
150 million pieces of garments annually. The omega line group as already started making accessories such as
hooks & eyes, tubes, under wires, bra cups and also operate a dye house.

Brands under the calzedonia group companies under the calzedonia group
o Customer – Calzedonia concentrates on women’s, Men’s inner garments and outer garments.
o Production – Fashionable. High quality materials, unique, simple and elegant
o Retail shops – The collections are sold exclusively within the more than 4600 owned or calzedonia, intimissmi, intimissmi uomo,
Tezenis.Falconeri, signorvino and atelier me present the in the best locations more than 50 different countries.

Priority areas in production management

o We use Toyota Sewing system as our Modular production system.
o Production planning is done using Fast react.
o For finished goods handling, monitoring and for inventory we use a system call SAP.
o For Capacity planning, priority planning, recording and maintaining the cutting department we use an ERP system call Cutting plan.
o SMV calculation, Line balancing and other IE activities we use a System call GSD.
o Efficiency & performance tracking, QC, Attendance, off standards, Incentive, spare parts consumption and machine handling is done
by a real time system call Sabre.
o Other than the above we use machines with the latest technology to reduce the operator handling time and the work load.
o Cutting department use lectra system (CAD system) for cutting function with automatic laying machines.
 Departments I covered under the in plant training period
 Production planning  Sample room
 Inspection  Work study department
 Dye house  Quality audit
 CAD department  Outlet department.
 Cutting department

Production planning

• The planning department is coordinating other all departments, mother company and out side parties such as suppliers. Therefore This department does a
major role for the benefit of the company.
• As well as they are responsible to give a guide line to the other department to do their activities directed to one objective
• The omega line has not a highlighted merchandising department because the omega line almost works under its own mother company. Therefore they do not
need to find the orders. As a results The planning department normally is doing some merchandising activities
• The main duty of the planning department is making the better and delivery oriented production plan for all the placed orders by thinking the type of style and
order delivery
• The FASTREACT, an advance planning tool is used to make production planning by the production planning department. This tool is also being used by other
department to refer the production plan.
• The planning department is mainly received the orders from the styles of bra, fashion and brief under main two bands name. Those are shown below.
• Normally The bra is planned to Omega I and the briefs are planed to Omega II.
• Above mentioned orders are normally placed seasonally and Those are changed season wise. In addition to this There is orders called ‘Basic orders’ which is
the repeating through out the year.
 Inspection

The inspection section is responsible to inspect and give desired decision on the inspected item Therefore they are always responsible to
inspect the item which is need to inspect. But, The Fabric, 3P and Lace are normally inspected by the inspection section.

• The Inspection section has been located in Omega II

• It has 5 Fabric inspection machines, 1 lace inspection machine and 1 light box as well as it has lab facilities also to check fabric.
• In addition to this, The spectrophotometer in dye house also is used to check color shade when they need.
• Currently, 2 Fabric inspection machine for Calzidonia’s fabric and 2 fabric inspection machine for Other fabric have been allocated to do fabric
inspection efficiently.
• Here Fabric for Omega as well as Alpha and Sub factories are also inspected

• 4 Points System
 
Here, the fabric defects are categorized into 4 base on defect size and give different points to each category. As well as defects are identified in different colors as
shown below.
  Color Green Yellow Red
Size of Defect 0.7 cm 7 cm <=15 cm 15 cm <= 22 cm 22 cm <
No of Points 01 points 02 points 03 points 04 points
 
When doing the inspection under 4 points system the inspector should identify the all the defects and enter the desired points to each defects manually to the
system and the system sticks a color sticker which is match to given point. This gives a guide line to identify the defects and the size of the defect when the fabric
is being used.
Common Defects
Fly / Foreign Yarn   Folding Mark   joint
Slub   MC Stropped Mark Color Smudging
Nap / Knot   Shade Line   Poor Registration
Thin / Thick Place   Needle Line   Miss End / Pick
Hole   Tension Line   Dye Patch
Oil / Satin Mark   Missing Yarn   Rubbing Mark
Reed Mark        

Dye house
 
The Omega line has a centralized dye house because this is dying items for the factories situated in Sri Lanka as well as they sends dyed items to calzidonia
also. Generally the following accessories are dyed according to the required shad.
Hooks & Eyes
Sliders
Bar tubes
Rings & loops
The Dye house has main two section to do its work properly. Those are shown below
Dying testing section.
Dyeing section.
•  Spectrophotometer.
This is instrument that runs with a special software. The instrument is used to take sample’s actual color. This is mainly used to check the color variation. As well
as this is used to take recipes for the given color
 Normally there is main two types of dying methods.
• Exhaust method – material % is base to dying process. ( weight of dye is measured accord according to material % ) This is
applied to hooks & Eyes, 8 shapes, sliders and rings dying.)
• Padding method – This is used to dye fabric, lace, tubes etc… The unit is g/L.

Normally dying process needs few kinds of chemicals as shown below

• Dyes
• Acid – Acts as a buffer solution when increasing the temperature
• Leveling agent – Helps to apply dyes to the sample uniformly.
• Fixing agent – Helps prevent color shading.

After dyed the sample quantity It is checked with the sample using both light box and spectrophotometer. If it is not match with the original
sample. The operator is done testing again doing small adjustment. This process is being done until the dyed sample match with the original
sample. Checking the dyed sample in light box with mother company given light is very essential.
Cutting department & CAD
Omega Line has a centralized cutting department. It cuts fabric for Omega I, Omega II and Alpha factories therefore there are main two cutting procedure for
Omega and Alpha. There are few section in cutting department to do cutting process efficiently.
• Fabric Issuing section
• Fabric Loading and spreading section
• Fabric cutting section
• Fringe cutting section
• Free shape & molding section
• Shorting section
• Final bundling section
• Additionally there is another partially linked section which is called Piping. This is making piping
• In addition to this section CAD center is also directly linked with cutting department.
• The Cutting machines of the Cutting department has been allocated separately to Omega and Alpha. (Ex-There are six spreading machines in Cutting
Department. Three of them for omega and another three for Alpha )

The Basic procedure of cutting department.

 
• Making cut order plan & dockets
• Making allocation note
• Fabric issuing
• Fabric loading and laying
• Create marker according to cut sheet & docket
• Fabric cutting
• Cut pieces shorting
• Cut pieces bundling & sending for production
 
Cutter types
 Work study department

• This is one most important department in Omega Line. Because this mainly involves to increase the production efficiency.
• The main responsibilities of this department are increase the production efficiency, work place arrangement, making machine lay out, module balancing
and achieving & maintaining desired production target.
• The works study departments always try to keep the production target in desire level by regular monitoring the line out put.
• These kinds of duties are normally done by the work study officer who is the responsible person for few modules regarding all work study activities.
• Generally the work study department is studying the type of garment to be produced next, the number of operation in garment and the types of operation
with the main objective of introducing suitable techniques or method to increase the efficiency of production.

Basic procedure of the work study department.

 
• Making line balance sheet.
• Calculate thread consumption.
• Line balance.
• Work place arrangement.
• Increasing and maintaining production target.
Production
 
Brief Introduction.
•  
• There are two parts of production section in omega line ltd. One is in Omega I and other is in Omega II. In most of time both are working independently.
• These two parts usually are used to produce different types of garment (Omega I is mainly used to produce bra and Omega ii is mainly for brief )
• The production section has been further divided to manage in efficient manner. As well as the production section has a audit section to check the finished
goods.
• The main responsibilities of the production section are Machine breakdown, Quality of the garment, Line input, Operator’s turnover & absenteeism,
Order delivery and style feeding.
• The basic unit of the production section is called ‘Module’ and the module is responsible to produce complete garments.
• Every modules have desired lay out like ‘U’ shape as shown below.

The machines in one module can be differ with each other The
types of machines in one module are mainly depend on the type
of operations of the garment. Following machines are mainly
used in production section.
• Double needle machine.
• Single needle machine
• Bar tack machine.
• Flat lock machine.
• Over Lock machine.
• Piping flat lock machine.
The number of machines and number of operators in one module
can be differ in accordance with the number of operations of the
garment.
 Quality checking department

Final auditing steps No Defects garments

• Open poly-bag, check poly-bag sticker and marketing label. • Replace all original internal
• Remove garment packaging materials.
• Lay flat on table Face up collar on top sleeves extended flat • RE-fold garment to original state.
• Give front of garment an overall visual examination check for • Replace into poly-bag.
fabric defects, shading, and soil. • Reseal poly-bag.
• Check hang tags
Defective Garments
Garment Defects Classification • Mark Defect.
• Fold garment neatly defect mark up.
• Critical Defect: A serious defect that can cause harm or injury to the user • Remove from work surface to defect storage.
and/or result in a hazardous condition. • Repeat Process for all garments in sample lot
• Major defects: A defect that falls to meet the mandatory regulations
directly affecting the usability, salability, safety and value of the
merchandise or as specified by customer buyer are considered as major
defects and are generally non repairable for example fabric hole, shading
among panel, wrong measurement, foreign yarn, dye patches etc. The
measurement tolerate level may vary from customer to customer.
• Minor Defects: A defect that does not adversely affect the usability of the
product but does consists of a deviation from the original sample, and
may affect the sale of the product.
Outlet department
After finished the original orders, sometimes materials (fabric, trims and accessories) are remaining in the stores ( all plants) of the all
factories in omega group. There after the new concept fashion designer Ms. jenny will come to omega line factor for design new
collections with outlet team.
Procedure of outlet department
• Style packet creation
Based on the materials available in material reference books. Style packets will be created.in style packets, materials will be sourced and matched to the
maximum level possible. This includes main materials, trims and accessories. However threads will not matched at the designing phase.
Style section,BOM consumption calculation SMV check ,material composition and MDL compatibility check Central outlet team involved in above tasks
during designer visits.
• NM material file updating
During the visit as the designer creates style packets, the related plant planners should mark the relevant material usage in the NM material files that they
send to the central outlet team before the visit.
• Design book copy.
• Lead time for sample and order from arrangements
• Sample and order from approvals.
• Local BOM preparation, thread and missing materials purchasing
Local plants should prepare the require local BOM, also they should purchase other required materials from internal plants and local suppliers if marked in
the design packet .thread should be matched and purchased by the relevant plant.
• Sub contract production plants.
• Pricing and order allocation
Pricing can be done by the local plant when the materials are transferred to sub-contractor. However the minute value should not exceed 0.04 USD.
• Raw material transferring
• Production plan follow up
• Finish good inspections
• Finish good shipments
• Pending order position files update.
Thank you!