FINISHING DEPARTMENT

Introduction
Finishing is the last stage of garment production where garment gets its final look. In this department each garment undergoes different finishing processes. It undergoes for

quality check for several number of time which sets the garment free from defects. Buyer specifications and instructions are strictly maintained.

Hierarchy of flow

Supervisor (Manager) (Executive) Supervisor Supervisor

FINISHING DEPARTMENT LAYOUT

GENERAL MEASUREME NT

GENERAL VISUAL CHECKING

THREAD CUTTING

GENERAL MEASUREMENT

GENERAL VISUAL CHAECKING

TAGGING

FINAL MEASUREMENT

FINAL VISUAL CHECKING

FOLDING AND PACKING

FINAL MEASUREMENT

FINAL VISUAL CHECKING

FOLDING AND PACKING

OFFICE

REPRES SING 4

REPRE SSING 3

REPR ESSIN G2

REPRESSI NG 1

EXIT

EXIT

Material flow

Batch Receiving

Washing and drying

Labelling

Initial Checking

Spotting

Thread cutting

Visual checking

Measurement checking

Pressing

Packing

Procedure followed 1. Receiving Batches The batches are received from the sewing floor.Three different registers are maintained here. Daily Production Register: details maintained Style no, sizes (recd), total, grand Total. As soon as the batches are received the entry is done in this book. (daily basis). Cutting Received Register: This register contains the details as to how many pieces have been fed in the lines of the sewing floor and how much is recd here. The balance as to how many yet to receive is also calculated. This is maintained size-wise. Batch Production Received Register: this register contains the details of the pieces received from every batch. That is, this register maintains the details of the pieces recd batch-wise and date-wise. Also calculates the cumulative number of pieces received.

2.Washing and drying The batches are sent for washing followed by tumble drying. 3.Labelling After washing garment are sent for labelling. Three heat set labelling machines are available. 3.Initial Checking In this process, they remove paper of heat-set label. They check for the spots in the garment or if any stitch is open. 150 pieces are checked per hour per checker.

4.Spotting After initial checking if any spot found, the garment is sent for spotting where spot is removed with the help of solvent(white petrol) .

5. Thread cutting Unwanted threads are cut from armholes,seams and hem.

40-50 pieces undergo this process per hour per worker. 6. Visual checking After the thread cutting process, visual checking is done in which the garment is put on the table and is checked to see if any remarkable difference from original. 7. Measurement checking In this process the garment is checked with a measuring tape. There are 20 worker for this job who checks the 6 main areas for measurements: 8. Tagging Here, the price ticket or the price tag is attached to the pieces with the attaching gun. The tags are attached size wise. There are 5 worker assigned for tagging the garment. Waist Hip Chest Bottom Seam length Length

9. Pressing The pieces are then received for ironing after checking and tagging process. In this, the pieces are given final ironing. All the creases are removed and the garment are sent for packaging. 10. Packing After all the above processes are carried out, the pieces are sent into the Packing Section. The processes followed inside are:

11. Garment Folding The garment folding is done. Folds are made according to the type of garment. Folding is done in accordance to the dimensions of the packaging bag.

12. Poly bag packing The folded up form of the garment is put into a poly bag. And this bag is sealed.The dimension of the poly bag is given by the buyer.

Garment inside poly bag

13. Carton Packing Then the packed garments are put into cartons. They are packed into the cartons shade wise. Each carton has garments of the same shade. They are packed into the carton as per the size ratio that is ordered by the buyer. There are few cartons which are marked as ODD cartons. For example, if there are 65 pieces of size L are left and the buyer requirement is 40 pieces per carton. After packing 40, 25 pieces would be left. These pieces would be put in a carton and marked as ODD with a red marker. This process is followed by shipment of cartons.

After the shipping process is complete, the Daily Production Auditing Report is filled in by the finishing section in-charge. This gives the details of the pieces gone for each processes and number of pieces rejected. Details of the sheet: buyer name, style, color, Finishing Recd Qty, Wash sent, Wash Recd, Packed Qty, Shipped Qty and balance qty.

Odd carton

PACKAGING ROOM LAYOUT

SPACE USED TO KEEP CARTOONS

EXIT

OFFICE

Audit
Guidelines for Final Audit Check the carton dimension, marker sticker. Check the price sticker, hangtag, prepack. Check the packing. Check the folding size. Check the ratio and shade wise packing. Check the fabric defect and poor pressing. Check the shade wise packing. Check the button placement and insecured button. Check the shape of garment. Check the joint stitch, broken stitch, open stitch, uncut stitch. Check the outlook of the garment, Check the measurement.

Final audit AQL 2.5 Lot shipment Sample size 13 20 32 50 80 125 300 0 0 0 0 0 0 0 1 1 1 1 1 1 1 0 1 2 3 5 7 17 1 2 3 4 6 8 15 1 3 5 7 10 14 21 2 4 6 8 11 15 22 Critical defects Pass Fail Major Pass Fail Minor Pass Fail

size by color 0 to 280 281 to 500 501 to 1200 1201 to 3200 3201 to 10000 10001 to 35000 35001 & above

Audit reference

INDUSTRIAL ENGINEERING

HIERARCHIAL FLOW

(Executive)

(Junior Executive)

Trainees (Total = 02)

INTRODUCTION Industrial Engineering is concerned with design, improvement and installation of integrated system of people, material, equipment and energy. It draws specialized knowledge in mathematical, physical and social science together with principles and method of engineering analysis and design to specify, predict and evaluate the results to be obtained from such systems. The Industrial Engineer not only does the time study and capacity study, he also develops the line plan keeping in mind the constraints such as availability of machines and the annual budget of the company. He tries to identify the problem areas and tries to smooth not only the material flow but also the operation by providing the operator with some work aid and attachments and thus actually helping in reducing SAM and the Throughput time of the garment being produced.

Work Flow
Order Enquiry from buyer

Merchandiser calculates the cost

Gives the thread calculation to the IE

Calculates the Thread Consumption and includes wastage

Pre Production Meeting Happens

IE starts calculating the Capacity that can be produced in one day and accordingly make a line plan on the basis of GSD and other PMTS tools

Calculates time to time the capacities and SAM and make changes in the line accordingly

QUALITY

HIEARCHY OF FLOW

(Manager)

Testing Lab Assistant

(Manager) Quality supervisors Quality Checkers

INTRODUCTION Quality, can be defined as something which is right the first time, or can be said as following the standards been developed by making the specifications and documenting them in such a way that they can be communicated to all the employees of the organization. Quality department in RICHA GLOBAL not only keep a watch on what the factory is producing but also keep an eye on the vendors whom the order is been given and a quality auditor constantly keep visiting the factories from where the order is been outsourced. The quality checkers are trained as soon as the new style comes in the factory as to how they have to check the garment.

Check Points:1. Stores - At this stage a small blanket of the fabric been sourced is cut and then taken for testing in the testing lab. 2. Cutting - At this stage while laying the operator herself check the lay and as the markers are developed on the CAD and transferred directly to the CAM thus operator does not have to check the marker. 3. Bundling and Ticketing - At this stage the bigger part of the garments are checked and send for recutting if any fault is found. 4. Sewing - In sewing, a 100 % inspection is done inline as well as end of line because the operators are new and are not consistent in the quality produced. 5. Washing - Before washing normally the quality check is not done as it is done before dry processing and thus this quality check ensure the quality of good coming to washing, after washing the shade are matched according to the shade band prepared and if the shade is not matching to the band or is not lying in the range then it is rejected. 6. Finishing - This section has most number of quality checking point starting from the middle checking wherein the garment is checked from inside as well as outside, then it goes for a final check wherein the quality is checked by looking at the top side of the garment and giving it for the alteration if required.. Lastly the garment is checked for its presentation and packed. 7. Final Audit - Final Audit is done internally(by quality auditor) as well as externally (by buyer's QC). They use statistical Quality Control as their tool as check few pieces so as to get the idea of the lot.

DEFECTS CLASSIFICATION LIST

FRONT GMT NO FLAT LOCK SKIP STITCH MISSING LABEL WRONG LABEL FRT RISE SKIP/BROKEN POCKET FACING RAW EDGES/LOOSE STITCH J-FLY BROKEN /LOOSE STITCH DOWN STITCH BACK LOOSE/BROKEN ATTACH YOKE SKIP STITCH/RAW EDGES BACK EDGES JOINT MISMATCH BROKEN STITCH NEEDLE MARKS RISE SKIP STITCH /RAW STITCH @PKT

STYLE NO :

SHADE VARIATION DOWN STITCH MISSING BARTACK MISPLACED BARTACK PKT PLACEMENT VARIATION FAB DEFECTS DAMAGES LOOSE STITCH MISALIGNED BACK PANELS ASSEMBLY SKIP STICH /RAW EDGES @ INSEAM JOINT MISMATCH @ INSEAM NEEDLE MARKS FRT/BACK MISBALANCED SKIP STITCH @ OVERLOCK STITCH @ DECORATIVE

BROKEN STITCH @ SEAMS RAW EDGES @ SEAMS DOWN STITCH @ S/S TOPSTITCH PIPING @ S/S TOP STITCH SKIP/BROKEN STITCH @ W/B LOOSE STITCH @ W/B

MISALIGNED @ W/B ENDS SKIP/BROKEN HEM ROPING @ BOTTOM HEM PLEATS @ BOTTOM HEM MISALIGNED LOOPS MISSING BARTACK GMT SENT FOR ALTERATION GMT RCVD FROM ALTERATION STITCH @ BOTTOM

Research and Development

As further diversification of its extensive manufacturing capabilities, the group is coming up with a knitwear plant at Manesar and a plant for bottoms at Bangalore. Poised to reach the pinnacle and resolute to mark its presence globally, the Richa Group is constantly moving ahead in their endeavor to be the global leader in the readymade garments industry.

Also company is buying and working upon a software named EFIT SIMULATOR BY TUKA.

3D Virtual Prototyping and Sample Making

e-fit Simulator by TUKA makes it easy for designers, pattern makers and apparel manufacturers to present style decisions, test the fit of a garment or share fit comments with others around the globe. If you are spending too much time making, shipping and checking samples, now is the time to check out e-fit Simulator software. Create accurate and visually stunning samples in less time and share them instantly, without expensive sewing and shipping costs. e-fit Simulator is packed with features to show off your designs in true 3D, bringing your sketches to life.

Digital sample making A digital sample is a prototype on your computer that shows you how a garment is going to look and fit before it is actually sewn. e-fit Simulator turns patterns into digital samples that can be sent around the world through e-mail to enhance communication, get feedback and deliver quality samples in less time. e-fit Simulator's digital samples do not require any fabric or sewing machine, and can be sent instantly, at the speed of email, to anyone around the world.

How e-fit works e-fit Simulator software takes a digital (CAD) pattern and a set of fabric values (such as stretch, weight, etc) and creates for you a digital sample of the garment, draped on a 3D virtual fit model, using the latest in cloth simulation technology. Users of e-fit Simulator provide the software with the pattern, the type of fabric and the measurements and shape of the fit model, and the system will accurately create the sample. The system is designed with users in mind, and is easy to learn and use. Users can create many samples in much less time than it would take to sew and deliver a real garment.

How e-fit can help... Designers E-fit Simulator gives designers the flexibility to modify their designs without disrupting their delivery timelines by giving a first-look sample as soon as the pattern is drafted. Fit corrections and style line changes can be made much earlier in the apparel development process, giving designers more time to bring their creative ideas to life.

Flat sketches often aren't able to truly explain a designer's vision to the development team or potential buyers. e-fit Simulator's digital samples make it possible for users to see the garment from any angle in a static pose or even in motion. Pictures or movies can be made in the software and used for creating dynamic storyboards or explicitly detailed construction instructions. e-fit Simulator also lets designers have 'virtual fit sessions' online, in real time.