WORKFLOW IN DEPARTMENTS

The business is headed by Plant Head who, further, has functional heads supporting him:

 Production Merchandising Head

 Production Head (Jacket & Trouser)
 Finishing Head (Jacket & Trouser)
 Quality Head
 HR/Admin Head

The respective managers of Trims Store, Cutting Department, Industrial Engineering, Sewing Department,
Quality, Finishing & Maintenance department directly report to the Plant Head. The head of department
has an indirect reporting responsibility to the Merchandising Department. The Merchandising Department
has a major role to play and is involved in every stage of the product development. The Head of
Merchandising heads the activities in the three departments namely merchandising, purchase department
and fabric department. The Head (HR/Admin) heads the activities of the HR department, Admin
department and the IT department.

The Plant Head reports to the General Manager for the various activities and major decision making in the
departments.

The work flow of SSAL Unit-ll is a planned and coordinated effort from all the departments. Giving the
importance to quality and precision, checks are performed at every stage of Manufacture right from pre-
production to post-production. There are 18 different departments in Raymond Ltd. They are

Departments
Human Resourse
Marketing & Merchandising
Production Planning & Control
Fabric & Trims Stores
Sampling Section
Pattern Dept.
Cutting Section
Trouser Quality
I.E
Jacket Sewing Lines
Jacket Finishing
Trouser Sewing Lines
Trouser Finishing
Trouser I.E & Maintenance
Jacket &Trouser Quality
Warehouse
Training Department
Utility Department
 All these departments are directly or indirectly related to the process of production. The following
flowchart will explain the working of departments, which are directly involved for the process of
production right from receipt and conformation of order to purchase than production to final
finishing processes.

Note: In SSAL Unit - II, there is no separate department for marketing/merchandising. Thus the marketing
and merchandising activities are being carried out at Head Office and then coordinated. SSAL-II has its in-
house Production merchandising Department which takes care of the availability of materials and trims
required for production. Thus, SSAL-II procures materials required for production from Head Office.

INFRASTRUCTURE

The unit is ASIA’s LARGEST SINGLE FLOOR SUIT MANUFACTING UNIT IN ASIA. Raymond
Group is equipped with many manufacturing units in Banglore, Dadballapur, Gauribidnaur, Vapi, Mumbai,
Chinwarda. The Group is all set to establish more and more manufacturing unit near Hindupur (near
Gauribidnaur). It will further enhance the production capacity of the Group. Offices strategically located all
over India are operating with a commitment to excel. Ultramodern technologies lead the Group ahead of
the competitors. It plays the key role in producing the products of superior quality. The unique blend of
modern technologies from all over the world has enabled Raymond Group to maximize its capability. The
latest highlighted-tech machinery is used at every stage, from - designing (CAD), Cutting (Digitizers, Plotters
& Automated Cutting Machines) to Fusing.

CUTTING-The cutting section is equipped with the Gerber & morgan spreader and cutter that ensure 100%
perfection. It improves turnaround times and expedites the cutting process with minimal waste and cost.
The section also has Band Knife machine and Fusing machines. Most modern CAD systems from Gerber,
Interlocutor and Lectra are employed for Computerized Precision Pattern Making, Grading and Marking
System. The facility also has 5 CNC cutters. Advanced designing system and elaborate matching processes
are employed to achieve intricate patterns and sophisticated illustration. Both machine and manual
methods are employed for cutting and spreading.

STITCHING-With its wide range of advanced machinery & proficient labor capable of producing stylized
garments with perfection & finesse, the sewing section has a hi-tech infrastructure. The production lines
are UPS based. The production lines are fully integrated and operational with various types of powered
sewing machines from Brother, Juki, Pegasus, Pfaff, DA, & special machines like Computerized Welt
Pocketing Machine, Belt Loop Attachment Machines, Multi Needle Kansai Special Machines & Special
sleeve attaching machine.

Finishing-Hi-tech machinery and cutting edge technology facilitate high quality wrinklefree finishing.
Various pressing machines and heat transferring machines are available to ensure improvement in high
functional performance of the garment through specialty finishing. There are 13 types of buck pressing
machine for perfect finish.

Final Inspection-Silver spark has an efficient Final Inspection Department equipped with the latest
equipments. This section plays the most crucial role in ensuring 100% perfection of all the products. It is
inspected that all the features demanded by the clients are designed or not. The experts thoroughly check
all the products to make sure that the perfect products are delivered to the client. The products carry the
brand image of the company. That’s why utmost care has been taken in this section to ensure that all the
products are faultless

COMPLETE PROCESS FLOW

 Trims Store:

SOP for Trims Store

 1st thing is physically counting of the no. of packages received e.g. No. Carton / Bales / Sacks
received.
 Then compare the quantity mentioned on the packs multiplied with number of packs, with the the
quantity mentioned on packing list or invoice. Any loss, damage or open boxes is informed to
commercial dept, purchase dept and merchandiser.
 Store Keeper prepares and signs a Goods received note or GRN in which Name of the item, actual
quantity received is clearly mentioned and also he mentions the identification mark of the shortage
i.e. Carton No., Bale no. etc. and gives a copy to commercial dept.

Garment Trims and Accessories

1. Sewing thread
2. Button, Snap button, Shank button, Eyelet button, Rivet button
3. Eyelet washer, it is used inside the eyelet
4. Interlining, it is used in collar/ cuffs/ front placket and waist band etc.
5. Padding, it is used in padding jacket
6. Collar bone / stay, it is used inside the collar point
7. Zipper, to fasten garments.
8. Lace, it is used at the top or bottom of any garments
9. Shoulder tape, it is used inside at shoulder seam
10. Woven tape/ twill tape, it is used at side seam of pant
11. Hook, it is used inside of waist band
12. Stopper, end of drawstring/zipper
13. Shoulder pad, inside of shoulder of Jacket
14. Velcro tap craves, inside of flaps and pocket for opening and closing
15. Lining, inside of fabric
16. Rip, used in neck/ bottom/sleeve/ collar
17. Brass pin, folding pinup
18. Al- pin, folding pinup
19. Boll pin, folding pin
20. Tag pin, used for handing the hangtag and price tag
21. Label, Elastic, Badge, Size finder
22. Gum tape, for closing the carton
23. Scotch tape, for closing the poly bag or blister poly bag
24. Collar stand/ collar insert. It is used for proper neck, saves it stay around the neck circumference
25. Poly bag
26. Inner carton, for safety
27. Divider, for dividing the garment in carton
28. Hanger, to hang garments
29.Sticker, identify the alter or defect
30. Price sticker shows price of the garment.
31. Barcode sticker, shows measure of garment
32. UPC label, outside of master carton or export carton etc.
SOP Of Trims Inspection
 Trim Card : before starting inspection, QC in the store collects Merchandiser Approved Trim Card*
and compare the Trims with Trim Card
 Trim Card is a collection of all the trims used in a particular style pasted together in a card board
for approval and referance.
 First QC checks and compares the trims with trim chart she checks the style no. Auto no. etc.
 QC Randomly takes 10% of the trims and transfers to the trims inspection bin where QC is doing
the inspection for quality of the trims.She compares the quality with merchandiser’s trim chart.
 And prepares a quality inspection report duly signed by Store Manager and QA Manager.
 If it is approved from the merchandiser then 6 pcs of each item is sent to merchandiser to prepare
Trim chart for Production reference. And all the trims goes to inventory.
 If the inspection is rejected re-inspection is done for 100% trims.If pass goes to inventory if not the
whole lot is rejected and report is sent to merchandiser.

Quality Checks for Sewing Trims

o Zipper – color, length, puller, working condition etc
o Label – print quality, color, size etc
o Button – broken, without hole, color, size, thickness etc
o Thread – color, no. of ply, tkt no. etc
o Elastic – width, stretchability
o Twill Tape – width, weave structure, color

Quality Checks for Packing Trims

o Labels – size,color,print quality
o Hang Tags – size,color,print, string
o Stickers – gum strength, color, size print quality etc
o Sizer – Print quality, size.
o Polybag – measurement, print quality

Quality Check for Accessories

 Belt – length, width, color buckle quality etc. On receipt of goods they prepares inspection shortage
report in case of no discrepancy in quantities is observed the inspection shortage report shall show
the variance as nil. And forward the inspection shortage report to commercial and also to the
concern merchandiser.

QUALITY IN TRIMS AND PACAKGING DEPARTMENT

The points inspected in all trims are:
• Trim broken.
• Incorrect color.
• Incorrect size.
• Trim not as specified.
• Trim bleeding/ migration
• Miscellaneous trim defects
• Trims length
• Uniformity of trims
The Quality criteria is AQL 2.5
All the trims received are checked for quality defects. Acceptable quality level followed for trims is as
follows

Quantity Received Sample Size Accepted Rejected

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
35001 and above 300 14 15
 Process Flow of Trims Store
PURCHASE/SUPPL
SECURITY MERCHANDISING TRIMS STORE Sewing Department FINISHING DEPARTMENT
IER

MATERAILS MATERIAL
SENT

DC/INVOICE

MATERAILS
UNLOADING

MATE
INFORM TO RAILS
CONFI
STORAGE AT
INCOMING GOODS

INFORM TO
PURCHASE PHY.
TEAM FOR QUANT
NECESSARY

APPROVED I/H
I/HTRIMS
TRIMSCARDS
CARDS
APPROVED BY
BY
MERCHANT MAKING
MAKING
MERCHANT

KEEP IN QUALIT
REJECTIONAR INFORM TO Y
EA & INFORM MERCHANDISE AUDIT
TO SUPPLIER

GRN MAKING AS
PER PHYSICAL QTY.
SUPPLIE
RS
CONFER
MATION MATERAILS PHY
FOR SHIFT TO

SEWING/
FINISHING/

RETURN TO
SUPPLIER
BIN CAED
UPDATON

PREPARE BUYER REQUISTION FROM

WISE TRIMS CARD FINISHING LINE

STAGE ISSUE
REQUISTION FROM
AGAINST
SEWING LINE
REQUSITION/ WORK

PHYSICAL
MATERAIL ISSUE
AGANIST STAGE

PHYSICAL ISSUED
Bin Card PER DAY
REQURIMENT TO

STACKING OF ISSUE
MATERAIL IN SUPER
MATERAIL AREA

PHYSICAL SHOULD PER

DAY REQURIMENT TO
Trims Tracking System
 A & B:- Thread
 C:- Zipper
 D:- Common trims
 E & F:- Waistband lining
 G & H:- Label
 I & J:- Button
 K, L, M, N, O, P, Q:- Shoulder Pad
 R & S:- Size Ring
 T, U, V, W:- Joker Tag
 X:- JCP Trouser Joker Bag
 Z:- Packing Trims

TRIMS & ACCESSORIES DETAILS (FOR Trouser)

 Main label
 Add label
 Size label
 Washcare label
 Band roll
 Waistband Lining
 Button- 4(24L)
 Hook & Bar
 Head Tape
 Zipper & Slider
 Stopper wire
 Joker Tag
 Hand Tag
 Size Ring
 Hanger
 Polybag
 Carton types[(20”x20”x6.5”)(30”x18”x7.5”)(115”x75”x25”)}

TRIMS & ACCESSORIES DETAILS (FOR JACKET)

• Shoulder pad
• Thread
• Satin tape
• Size label
• Neck label
• Content/Care label
• Sleeve label
• Main label or brand label
• Bridle tape Felling tape
• Besom tape
• Armhole tape
 • Double sided fusing with paper
• Double sided fusing without paper
• Poly bag
• Hanger

Different ticket no thread using different panel:

Thread Types & End Uses

Gutermann
Thread Tex Tkt No. Length(m) Composition Filament
Blind Heming 8 360 5000 100% Polyster Continuous Filament
Pocket 14 120 1000 100% Polyster Sewing Thread Cone Yarn
Button Hole 40 180 5000 100% Polyster Continuous Filament
Lining 150 1000 100% Polyster Sewing Thread Cone Yarn
First Pocket 19 160 1000 100% Polyster Sewing Thread Cone Yarn
Pocketing 180 5000 100% Polyster Sewing Thread Cone Yarn
Zig Zag 30 300 100% Polyster Sewing Thread Cone Yarn
Zig Zag 70 7000 100% Polyster Continuous Filament
Zig Zag 35 80 2400 100% Polyster Continuous Filament
Zig Zag 40 80 800 100% Polyster Continuous Filament
Zig Zag 25 120 1000 100% Polyster Sewing Thread Cone Yarn
Zig Zag 20 150 1000 100% Polyster Sewing Thread Cone Yarn

SPACE INVENTRY LEVEL STORED:

Space Inventry level stored
SR
No. SECTION L(M) W(M) AREA(M) SQ FT
1 Fabric 68.9 21.7 1495.13 16095.27
2 Trims 31.3 23.3 729.29 2392
3 Warehouse 36.36 49.28 1791.84 1791.84
4 Maintenance 9.9 5.7 56.43 607.096
Wood storage
5 outside 12.5 6.3 78.43 847.06
Wood storage
6 room 12 10.1 121.2 1303.6
7 Packing store 2816.352 9240
Total Storage Area 47380.231 sq ft Total area
Total Constraction Area 209953.75 sq ft used to 23%
store
Total Company Area 425991.43 sq ft inventry 11%