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A REPORT ON THE VISIT TO


SCORPIO.
By Samay Grover

Abstract
The Document gives an overview of my observation and what I learnt from my visit to Scorpio
Production House
Introduction
Garment Manufacturing is an assembly line activity
Requires a huge range of raw materials, production volumes and
technology along with infrastructure and skill based manpower
Scorpio as a sole manufacturer produced for Monsoon but also
Whitestuff and Bonpoint among other buyers
Manufacturing Workflow
Meet with with buyers and planning to order fabric
Fabric order placement
Receipt of fabric
Fabric inspection
Check physical appearance and properties)

Marker Planning
(For bulk production)
Sampling
Spreading & Cutting
Pre-sewing operations
Fusing, embroidery - if required in style)
Bundling
Feeding in lines
(As per production plan)

Finishing
Packing
Warehousing
Packing and dispatch
1. Pre- Production Meeting (PPM)
The following things are analyzed in a PPM
Stitch Types The variety of seams required for an optimum workflow

Machine Types The ideal use of technology to maximize output and


deciding what all machines are to be used in its production

Outsourcing Deciding if any services are to be outsourced from out of the


factory

Fabric Requirement - Fabric is more than 65% of the garment cost


Therefore is significant to monitor and if the engineering is done properly
one can save fabric and reduce consumptions.

Cutting- The process of cutting requires precision hence every detail is


discussed

Finishing- Finishing is the last link of the value chain which is essential for
performance point of view.

2. Receiving Tech Pack (CAD)

Tech Pack is received from the buyer which displays all essential
specification of the garment and a basic pattern is made in one size
i.e (trims, cut, color etc)

Pattern is digitized in a computer software


Grading - proportionally increase or decrease the size of a pattern,
while maintaining shape, fit, balance and scale of style details in
different sizes on a software.

CAD
Tech pack template

3. Fabric Inspection
The following things are checked once fabric is received

Stains
Misprints
Selvages (side to side)
Tears and Weaves
o Abrasion Mark: A place in the fabric where the surface has been
damaged due to friction or abnormally weakened by any operation
through which it has been passed.
o Misprint: In printed fabrics, either missed, or partially missed, or
incorrectly positioned relative to each other.
o Oil Stain: Oil mark on the fabric.
o Hole: A breakage of yarns in the fabric involving more than two yarns.
o Skew: Distortion in the construction of the fabric i.e. in the yarn that
constitute the fabric.
o Crease: A fabric defect across the fabric width usually caused by a sharp
fold.
o : An area of discoloration due to uneven absorption of colorant.
o Color Separation: The appearance of a colored separation line in a
printed design.
Holes

Warp Defect

4. Trim Receival
After receival and checking of trims a trim card is made specific to the style

Different kinds of trims


- Buttons
- Hooks
- Badges
- Zippers
- Collar pick bone
- Tags : brand name, collection name and fit type
- Labels : wash care, size and fit, brand
- Fusible labels
- Leather patches
- Packing materials: hangers, collar stand, brand label, packing box,
polybag

5. SPREADING AND CUTTING


Spreading
- Spreading is the process of unwinding large rolls of fabric onto long,
wide tables and laying them in superimposed plies of specified length.
- The number of lays depends upon the number of garments desired and
the fabric thickness
- The cutting marker is laid on the topmost layer by a worker as a guide
on how much is to be cut from where.

Cutting
Usually a white chalk or a white color pencil is used to mark the dimensions for
cutting

Cutting parameters:
- Precision in cutting: To ensure the cutting of fabric - accurately
according to the line drown of the marker plan.
- Clean edge: By avoiding the fraying out of yarn from the fabric edge.
Cutting edge must be smooth clean. Knife must be sharp for smooth or
clean edge.
- Consistency in cutting: All the sizing safe of the cutting parts should be
same of knife should be operated of the right angle of the fabric lay.

Types of cutting equipments:


- Scissors
- Straight knife

Preparation for sewing:


1) Position marking : tucks, pocket positions etc
2) Shade marking: each component is marked with a unique no. printed
on a small sticker stuck on the component.
3) Bundle making: according to size, color, quantity
4) Bundle tickets: to identify each bundle to size, lot, style and color
wise.
5) Fusing parameters: There are different types of fusings depending
upon the end use and type of fabric

Type Heat Pressure Time


Microdot 150 degree 2.5 13 sec
Semi fusing 140 degree 1.5 15 sec
Woven fusing 175 degree 3 18 sec
6. EMBROIDERY DEPARTMENT

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