Week 7_Internship report 2_Apperal production and management

EXECUTIVE SUMMARY In the past two decades, the Indian textile industry in terms of home textile, garments and accessories have a witnessed a complete transformation in terms of quality,

“SUMMER INTERNSHIP REPORT APPAREL PRODUCTION &MANAGEMENT”

TABLE OF CONTENTS

TITLE PAGE 3

ACKNOWLEDGEMENTS 4

DEDICATION 5

SUMMER INTERNSHIP CERTIFICATE 6

EVALUATION FORM 7

EXECUTIVE SUMMARY 8

COMPANY PROFILE 9

ABOUT COMPANY 11

PRODUCT DEVELOPMENT 19

MERCHANDISING DEPARTMENT 20

SAMPLING DEPARTMENT 28

FABRIC SOURCING DEPARTMENT 30

FABRIC STORE 31

FABRIC INPECTION 34

TRIMS STORE 36

CAD DEPARTMENT 38

SPREADING DEPARTMENT 43

SEWING DEPARTMENT 49

WASHING DEPARTMENT 51

FINISHING DEPARTMENT 52

PACKAGING DEPARTMENT 53

REFERANCE 57

ACKNOWLEDGEMENT

Through this project report I would like to thanks numerous people whose consistent support and guidance has been the standing pillar in architecture of this project To begin with, my sincere thanks to the management of IAM for giving this opportunity to experience and learn the processes practiced in Apparel Industry

For the completion of this documentI would like to thanksMs.Neera Chandra (Course Coordinator APM) for being my mentor and my guide throughout the project I would like to express my sincere thanks to the Management and staff of SangarOverseas Gurgaon for their outstanding support and cooperation in my efforts to gain knowledge about the practical aspects of Apparel industries during the Internship

I am thankful to Mr.Hari Shankar Rajput (Sr Production Manager), Mr.Keshav Kumar, Mr.Kuldeep Singh (Sr HR Manager) for the guidance and planning out the schedule for the internship

I would like to grab this opportunity to express my sincere gratitude to Ms.PartibhaKathuria(Merchandiser),Ms.Kanika (Merchandiser) for guiding me through all the processes involved in the processing of the fabric and was patient enough to answer all my doubts and queries

I would specially like to thank all the staff members and workers for helping me throughout the internship Without their support, it would have been difficult job to successfully complete the training

Preeti Rani

DEDICATION

I dedicate my dissertation work to my family and many friends A special feeling

of gratitude to my loving husband Surender Nain whose words of encouragement and push for tenacity ring in my ears

I also dedicate this dissertation to my many friends who have supported me

throughout the process I will always appreciate all they have done

I dedicate this work and give special thanks to my wonderful daughter Erica Nain for being there for me throughout the entire summer internship program You have

been my best cheerleader

SUMMER INTERNSHIP CERTIFICATE

EVALUATION FORM

EXECUTIVE SUMMARY

In the past two decades, the Indian textile industry in terms of home textile, garments and accessories have a witnessed a complete transformation in terms of quality, market and product development as well as the expansion, In this scenario export house plays the major role in the growth and conduct of exports Looking from this perspective Sangar Overseas is a very good and important organization in its work

Internship at Sangar Overseas has been a great exposure for the practical application of my learning I gained knowledge about actual work culture of the company and how to deal with the people at workplace

I did my internship in Production, Merchandising and Sampling Department

OBJECTIVE

Objective of the study is to learn about the functioning of export house and working of various departments particularly production, merchandising and sampling, earning knowledge about different departments of the company, their function and information flow during work

DATA COLLECTION METHOD

I collectedthis by following method-

 Personal interview from various departments

 Close observation during work

 Internal data from various departments

 And secondary data was collected from the websites of Sangar Overseas

COMPANY PROFILE

PLOT NO 304, PHASE – 4,UDYOG VIHAR

MONTHLY PRODUCTION 150000 pcs

SANGAR OVERSEAS

MANUFACTURER & EXPORTER OF READYMADE GARMENTS

ABOUT THE COMPANY

With a strong hold on varied market segments across the world SANGAR

OVERSEAS are recognized as a reputed garment manufacturing company

Incepted in the year 1984, they have acquired immense design expertise that helps

us in meeting the diverse requirements of their global clientele

They are manufacturers, exporters and suppliers of exclusively designed &

fabricated Ladies, Girls & New Born apparel Woven and Knits

They have state-of-the art facilities comprising in-house computer embroidery facility, washing facilities and a sophisticated array of machinery

These facilities assist us in producing a quality assured range of garments for their valued clients

Ever since its inception, Sangar Overseas has never looked back Growing with Strength as well as value it has achieved the production capacity of 150000 PCS Garments per Month

• Product Categories –Ladies-wear (60%) and girls wear – NB, Infant,

Toddler, 4-14 (40%)

• Fabrics – predominantly woven fabrics – solids & printed voiles, cambric,

poplin, yarn dyed (mainly auto-loom & mill-made), complete range of

polyester fabrics, viscose, mill made twill, canvas, denims They are also doing woven knit combo wherein top is mainly woven and bottom leggings

in s/l ctnlycra + poly s/j linings for see through dresses & tops in polyester

• Factory Capacities – They operate 500 machines, approx 125,000 –

150,000 pcs per month with in-house computer embroidery with sequin attachment (60 heads) & complete laundry facilities

(enzyme/bleach/silicon/bio/softener wash, perc (petrol-free) machine for dry cleaning) They have complete in-house cut to pack facilities, including a highly capable product development and sampling department

• Buyer for Ladies-wear

• Bon prix – Germany

• George – UK

• Cia Hering – Brazil

• Tema – Turkey

• Ali & Kris-USA

• Adrienne Papelle – USA

• Anotah – UAE

• Tape a l Oeil – France

• Foschini – South Africa

• Bon Prix – Germany

• Disney (for baby Shop and George, since we are a FAMA certified Disney facility)

• Social Compliance – The factories are Sedex certified, BSCI approved,

Disney & Wal-Mart certified, CT-PAT compliant

• Design and Product Development – They believe in investing in best talent

available creative talent in the market to get something on the table for our principals as our own initiative and hence, we have a full-fledged in-house design, product development and sampling department they assure you that you shall get fresh ideas and bodies from us every season

QUALITY CONTROL

The Factory is equipped with “STATE-OF-THE-ART” Imported Stitching and washing machines The internal quality control systems ensure that Goods of highest quality are shipped to their customers

LIST OF MACHINERY

1) BROTHER SINGLE NEEDLE HIGH SPEED LOCKSTITCH MACHINE 400 2) BROTHER DOUBLE NEEDLE LOCKSTITCH SPLIT FEED MACHINE 20

3) BROTHER COMPUTERISED BARTECK MACHINE 04

4) BROTHER BUTTON HOLE MACHINE 04

5) BROTHER COMPUTERISED CROSS-STITCH LOCKSTITCH BUTTONING MACHINE 04

6) WAIST BAND ATTACHMENT MACHINE 04

7) 5 THREAD OVERLOCK MACHINE 25

8) EASTMAN CUTTING MACHINE 02

9) BAND KNIFE CUTTING MACHINE WITH AIR CUSHION TABLE 01

10) AUTOMATIC SNAP FASTNER WITH COMPRESSOR 10

11) FUSING PRESS (HASIMA-CONTINOUS FEED) 02

12) ENZYME WASHERS – NGAI SHING 04

13) RAMSONS – 200 KG CAPACITY WASHER 01

14) HYDRO 03

15) DRYING TUMBLER – NGAI SHING 03

17) STEAM PRESSES – NGAI SHING 20

18) THREAD SUCKING MACHINE 02

24) CINTEX & LOCK NEEDLE DETECTOR M/Cs 02

25) SPOTTING STATION MACHINE 02

33)SIRUBA/KANSAI 12 NEEDLE SMOCKING MACHINE 02

PRODUCT DEVELOPMENT

in the context of garment export business normally product development is handled

by design department But where there is no design team, merchants are

responsible for whole production development process In export houses sampling department is considered as product development department

CLASSIFICATION

PRODUCT DEVELOPMENT

EXTERNAL DESIGNING INTERNAL DESIGNING

TECH PACK

MECHANDISING DEPARTMENT

Merchandising is a specialized management functions within the fashion industry

It is the business that moves the world fashion from designers showroom to retail sales floor and in to the hands of consumers It is the internal planning that takes place within a retail organization in order ensures adequate amount of merchandise are on hand to be sold at prices that the consumers are willing to pay to profitable operation

Following are the responsibilities of merchandisers which gives importance to them

1 Internal& external communication,

2 Sampling,

3 Lab dips,

4 Accessories& trims,

5 Preparing internal order sheets,

6 Preparing purchase orders,

7 Advising and assisting production,

8 Advising quality department about quality level,

9 Mediating production and quality departments,

10 Giving shipping instructions and following shipping,

11 Helping documentation department,

12 Taking responsibility for inspections andFollowing shipment

PROCESS FLOW OF MERCHANDISING DEPARTMENT

TECH PACK COMES FROM BUYER

INITIAL SAMPLING AND COSTING

GET ORDER FROM THE BUYER

ORDER CONFORMATION

BUDGETING

MATERIAL INDENT (TRIMS DETAILS)

RE SAMPLE /PROTO TYPE APPROVAL

FAVRIC PROGARAM (FABRIC DETAILS)

FIT SAMPLE APPROVAL

PURCHASE ORDER

PO is an external document which is issued by buyer in the name of Sangar

Overseas Export Pvt.Ltd; it is an evidence as well as support of order confirmed in the favour of company

Po include the following information-

1 Delivery date 6 Terms if sale

3 Ship cancel date 8 L/C

4 Destination 9 Quantity

5 Ship mode 10 Size break up / colour break up

SANGAR OVERSEAS USE WFX ERP SOFTWARE –

In company employee work on WFX ERP software for making challan, purchase order, indent etc it’s very simple and useful software

Apparel export merchandising may be defined as ‘all the planning &

activities involved right from the buyer communication & order receiving till the execution or shipment of the order by fulfilling the following factors (Six Rights):

Right Merchandise: Retailers must fill their shelves with the merchandise that

customer wants

Right Place: The location of the merchandise is of prime importance since it

decides the accessibility Much merchandise is seasonal in nature and must be on hand when it is most needed

Right Time: Much merchandise is seasonal in nature and must be on hand when it

is most needed

Right Quantity: A profitable balance between volume of sales and amount of

inventory is the desired goal

Right Price: Merchandiser must arrive at a price that is high enough to give the

store profit and yet low enough to meet the competition and customers

expectations

Right Promotion: Right balance between the investment and the appeal created

for the customers

The successful execution of any garment export order depends on the work

performance of a merchandiser Merchandiser is the person who plans and

coordinates all the activities right from the order procuring and till the shipment order A merchandiser should have the comprehensive knowledge of his work procedures and responsibilities so that he could perform his job efficiently and effectively In the apparel export industry, a merchandiser has to perform the

following functions;

Communication: It is one of the foremost functions of merchandiser because the

merchandiser has to communicate with different levels of people in his day to day activities

Planning & Programming: A merchandiser has to check the order requirement,

planning for the given order, programming for various activities, proper allocation

of work to the assistants

Follow ups: It includes sending of samples at various stages of order, buyer and

buyer house for sample and other approvals

Decision making: A merchandiser has to make several decisions during the order

processing like giving approvals like fabrics, color, design, accessories, and

packing, selection of suppliers and vendors, selection of buyers, sometimes time extensions for order shipment

Sourcing & Purchasing: A merchandiser may have to do sourcing and purchasing

for raw materials and accessories, suppliers and vendors, new designs, new

buyers

Controlling: This is the crucial activities for any merchandiser A merchandiser

has to make sure that all the activities are carried out as per the planning and even

if there is any deviation, he/she should make the alternatives measures

Coordination: Merchandiser has to coordinate in such way to reduce the

uncertainties and difficulties and if there is a problem arises, the merchandiser has

to support and lend helping hand in order to complete the task successfully in the

given period Both the controlling and coordinating activities complement each other and a merchandiser has to adopt the both accordingly,

Negotiation: It is the activity of convincing, compromising and cooperation which

would benefit the both parties involved in the negotiation

Costing: It is the process of estimating the expenditure of a given product and the

subsequent price It is another crucial function because mostly order conformation depends on the price offered to the buyers The merchandiser should know the current prices and rates of various products and processes to do the accurate

costing

Meeting: There are two types of meeting a merchandiser has to be involved First

type, a merchandiser has to conduct the meeting with the concern department in charges to discuss about the proceedings and the status of the running order In second type, a merchandiser has to attend the meeting with the superiors or buyers

or business people in giving reporting or participation or discussion

Forecasting: Forecasting is the activity of predicting the future happenings or

problems A merchandiser has to predict the future uncertainties in the current order or industry so that alternative actions or corrective measures can be taken in advance this also includes giving suggestion or ideas about new technologies or new products or latest industry trends

QUALITY CONTROL DEPARTMENT

Sangar Overseas processes export orders in factories While raw materials are converted into garments, there are possibilities to make errors, like making

defective garment components and defective garment Making defective garment is

a cost to the company So to make sure garments are made as per customer

requirement and whatever raw materials are sourced must meet the factory

standards, factory establish Quality Control Department

Function of the quality control department can vary widely But most common function of quality control depart are as follows

Quality Inspection of Internal Processes and Outsourced work

Inspection of raw material: Checking of raw materials to ensure there is no

defective or abnormal goods

Testing of of raw material: Quality control department does not conduct testing

of raw materials but they send sample to testing lab for testing physical and

chemical test Once factory receive test report, quality control team get assurance whether raw material to accept or not

Inspection of Sample: Visual inspection and measurement checking is done prior

to sending sample to respective buyers

Cutting room inspection: Quality department is also inspects work done by

cutting room Like, layering of fabrics on cutting table, cut layer inspection, cut component inspection, Bundle inspection etc

Preparatory work inspection: In high fashion garment, lot preparatory work are

outsourced like, printing, machine embroidery, bead work, special decoration on garments etc Before feeding this outsourced goods, quality department checks and approve for further process (sewing process)

Sewing process: In sewing there are multiple checking process is practiced by

exporters, like, Inline inspection, end of line inspection, stitching quality audit etc

Finishing Process: Finally quality personnel checks finished and packed goods

and do auditing prior to handover shipment to external inspector

Quality System Development

To make quality product throughout the garment manufacturing process, factories need to develop quality system Quality Control Department is responsible for setting quality system for the factory

Quality Awareness development

They are also responsible to bring quality awareness among the workers and all employees

SAMPLING DEPARTMENT

A sample is a proto type of a product to be manufactured in future course of

production It is also called mock up of a product and is made to check the design effectiveness and fit of the garment Sampling is a set of the procedure follow to produce various sample style It contains activities like making of the pattern for proto type according to measurement of the sample with the help of machinery and getting buyers approvals for sample produce

In an export house, the sampling department play vital role in the up- lifting of a unit This department directly coordinates with the merchandising dept and

production dept sampling is done to see how the product will look when produce

in bulk and to check discrepancies in the pattern are