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INTERNSHIP REPORT NAVEENA TEXTILE (PVT) LIMITED 1. K.M off Bhoptian Chowk, Raiwind Road Lahore. Telephone: (92-42) 5320062-66 Fax: (92-42)-5320067-68 ADVISOR: MADAM SADAF RAUF (Lecturer) Management Sciences Presented By:

SHOUKAT ALI MBA-FA04-75 COMSATS Institute of Information Technology M.A.Jinnah Campus, Defence Road off Raiwind Road, Lahore Dedications I dedicate this report to my loving parents whose prays, affection and support are always a source of encouragement for me to reach at this destination and a humble icon for others in future. My parent and teachers who give me real eyes that help me to leads myself and others in the dark and cruel world. Acknowledgment At first I am thankful to Almighty ALLAH and the Holy Prophet (P.B.U.H), their blessings have been with me in all good and bad times. Then I am grateful for the thorough support by my advisor MADAM SADAF RAUF and also Mr. NAEEM (Asst.Manager Admin), WAQAR AHMED (Merchandiser), for providing

related information on which this project is based. They were the constant source of inspiration and encouragement that helped in completion of my internship. Executive Summary This report consists of my six weeks internship at NAVEENA exports (Pvt) Ltd. This organization is situated in Lahore. The organization started its business from Karachi since 1967. The salient features of this report are NAVEENAS organizational background, its vision, corporate values and goals of the company. This report focuses its business operations including major suppliers of the company, its overall marketing strategies, Management Information Systems, its dynamic Human Resource, Purchase Merchandising and import & export strategies in special. This report also enhances the organizations challenges in perspective to its domestic and international competitors. The organizations BCG matrix, marketing strategy, competitive strategy and thus the analysis of all these operations is really a fascinating experience of mine. Finally, this report is a nutshell comprises of my practical learning, recommendations and suggestions. .

Company Background Group NAVEENA is a progressive name in the textile industry established in 1967 has become one of the largest manufacturer and exporter of textile in USA and Europe. When started its operations, it was a small dying and embroidery unit in Karachi. Today NAVEENA exports comprises of three independent units, it offer distinctive branded garments, producing six million pieces annually with special emphasis on fashion apparel, NAVEENA apparel, is a broad spectrum of source houses internationally. Bond of Trust Its bond of trust is consistent upon this remarkable notion given below: We are proud to have some of the most reputable name worldwide. This has been achieved over time through the approach of work fast and work smart. The bond of trust has been developed because of our ability to fulfill our commitments to deliver the right product at the right time. Check and balances are placed from the initial stages to eliminate any possibility of

error. Vision of Company The company undertakes to apply the vision in letter and spirit under the following guiding principles: 1. In time action 2. Clear understanding of customers instructions. 3. Clear communication with vendors 4. Clear instructions for production 5. Strict compliance with quality control system. 6. Total devotion maintains first class quality standard. 7. Absolute efforts for in time shipments

8. Career development opportunities for employees MISSION STATEMENT NAVEENAs Mission statement, statement focused on its major commitments i.e. We make clothes that fit well, look good and most importantly feel great when you wear them. We are committed to become number one supplier of causal clothing around the globe. Its Corporate Values Team work Integrity Excellence

 Commitment to buyer. Maintenance of consistent standard Its GOALS Continuous improvement. Customers satisfaction. Quality of product and system. Organizational chart CEO/OWNER Director GM

Merchandising Manager Finance Manager Production Manager Export Manager Quality Manager INTRODUCTION TO DIFFERENT DEPARTMENTS AT NAVEENA Merchandising Flow of Information

Buyers Merchandiser PPC M a t e r i a l P l a n n

i n g T i m e & A c t i o

n P l a n s P r o d u c t i

o n P l a n s

Production Department

o Yarn store o Knitting o Dyeing o Cutting o Stitching o Packing & Finishing o Purchases o Stores Merchandising PURPOSE OF

MERCHANDISING AT NAVEENA Merchandising is a global process through which products are produced, sourced, and sold all over the world. Merchandisers must have leadership for the value chain (developing, distributing, and selling products) in a global market. Merchandisers need to see "the whole process" from product innovation through consumer satisfaction. This requires logical thought processes such as problem solving, decision-making, and resource management. It is a critical need for merchandisers at NAVEENA, which has strong business background, yet it also stays focused on fashion or other products that undergo continuous change in the consumer-driven market. Here, the merchandising department is mainly divided into accounts buyers. This shows that there is individual or a team of merchandising, who takes care of a specific buyer or account. Merchandising serves the following purposes at NAVEENA: Gateway: It acts as a bridge between buyer and the company for communication.

Marketing: Merchandiser has to market his company in order to increase his customers and generate more and more revenue. Costing: Merchandise makes a cost sheet to see if the product is feasible or not in terms of cost and revenue. Merchandiser has to calculate the cost of products including all wastes and accessories to tell the final cost of the product to his customers. Negotiation: Merchandiser must have a negotiating power on the price to convince his buyers on specific price to lessen the chances of loss. Sampling: Merchandiser must send the sample to his buyers for confirmation and satisfaction. At this stage,

Sampling is also done to avoid loss. Information Management: As merchandiser has direct contact with his buyers so the buyers have to give information about their products requirements and if there is any problem the merchandiser has to inform his buyers in return. Implementation: It is the responsibility of merchandiser to prepare the product according to the requirement of buyer. Production Follow Up: Merchandiser must be aware of the quality, packaging and on time delivery. Process of Merchandising The following process describes how merchandising carries out its responsibilities at NAVEENA:

 Initial Inquiry Initial Research & Development Costing Cost Sheet Approval Order Booking Status Management Sampling Process Information Handling & Forwarding Buyer Performance Review Initial Inquiry: An initial inquiry may be a simple fax describing briefly the target price *FOB and product or it may

be detailed package from a buyer describing in detail. Initial Research & Development Initial Research & Development or preliminary discussion is carried out with RESEARCH AND DEVELOPMENT to see if the company has the capability to produce the product in terms of man and machines. Costing: Merchandise makes a cost sheet to see if the product is feasible or not in terms of cost and revenue. For this purpose a cost sheet is prepared, keeping in view the styling and accessories to be used on the product. Approval: After the cost sheet is prepared it is presented to the CEO or any other approving authority for approval. The approval is mainly granted keeping the profit in view.

Merchandising process continues if a specific cost sheet is approved. Order Booking Status: Once an order is received it is mentioned in order booking status. OBS is extensively necessary to maintain the track of records, capacity optimization, and planning further through OBS strategic planning is also carried out. It helps in calculating cash in and out follow. OBS is normally kept confidentially and it is only accessible to predefine personal. Advantages of Establishing OBS(Order Booking Status) Following are the advantages to establish the OBS. Makes order follow up easier Allow better planning Helps in contingency optimization

 Helps in contingency planning Improves time management Improves coordination Helps in financial forecasting This document must be kept confidential as it contains very sensitive information access to be only allowed at a specific level, as per the policy of company. Sampling: It is the complete process through which sampling approvals are taken. It starts from a proto sample and ends at shipment sample depending on the buyer as different buyer have different sampling requirements. Samples may be paid or free depending on the category, quantity, contract with the manufacturer. Information Management & Forwarding:

All information received from the buyer is forwarded to the relevant department in the factory as to PPC package, checklist, accessories etc. information is provided which in terms is processed by the PPC and is forwarded to the relevant departments to start production. Buyer & Country Dependence: It is always better to establish an optimum buyer that dependence on the buyer be balanced so that just dependence on the buyer is also avoided and on the other hand dependence on too many buyer is also not recommended. Updating of OBS: OBS could Management Information Systemlead document in case it is not properly updated. Special checks need to be maintained for proper upgrading of the OBS ad if data on the OBS is incorrect capacity and management could be seriously affected. COST SHEET Style Number: 26898 Fabric: S/Jersey

Season: 1Q 2003 GSM: 225 Buyer: Target Gauge: 24 Division: Mens Consumption of yarn: 5.67Kgs/Dzn 12.50 Lbs/Dzn
Process Yarn Knitting Dyeing Cutting Embroidery Cost/Unit 55 Rs/Lbs 10 Rs/Kgs 65 Rs/Kgs 2.5 Rs/Pc 30 TTL Cost 687.5 56.70 368.55

Flocking Printing Accessories Stitching Inland Freight

6 Rs/Dzn 15 Rs/Pc 120 Rs/Dzn 20 Rs/Kgs 6 1440 120 113.40

2822.14647

Total Cost/Dzn 30 Over Head % Rs 846.6

Mat + OH + Cost Rs 3668.8 25 Profit % Rs 917.2 Mat + OH + Profit Rs 4586.0 58 Exchange Rate TTL USD 79.1 Rs/USD Price per Piece USD/Pc 6.6 Package Package is basically the collection of information given by the buyer regarding to specification, details

and other related information about the specific product that has to be manufactured. Components of a package: Package consists of the following components: 1. Cover Sheet 2. Fabric Mill Sheet 3. Sketch Sheet 4. Accessories Detail 5. Size Specification Sheet 6. Packing Manual 7. Revision History

1. Cover Sheet: It contains the general information about buyer, style #, garment, season, division. 2. Fabric Mill Sheet: It contains the information about fabric for garment and it includes: Division, style, season, type of Fabric, type of yarn, gauge, diameter, GSM, GSM before and after wash, dyeing, details, finishing details and shrinkage etc. 3. Sketch sheet: It contains the information about front and back view. It also includes the stitching type i.e. (overlooks, main stitch, back stitch, folder, and flat lock). 4. Accessories Detail Sheet: It contains the complete information about stitching threads, button material, button color, and button

thread. It also includes the size of button (16, 18, 20 or 22 line.) and that either buttons contain two holes or four. Line is the unit of button. Type of Stitching Over lock Lock stitch Flat lock Folder stitch Labels: It also includes the detail of label with its size specification. There are three kinds of labels; Main labels

 Size labels Care labels Tablet labels COO labels And two main types of labels are as follow; 1. Woven Labels 2. Printed Labels Accessories detail also contains detail about taps. There are three types of tapes. 1. Hearing Bone Tape 2. Plain Tape

3. Fusing Tape Fusing tape further consists of two types; 1. Tear away 2. Non Tear away Fuse able through glue while using iron. Normal width of fusing roll is 40``. Fusing Roll Tear way is fusible while non-tear way is non fusible.
GMT Color Color Code Embroidery Thread + Main Label Code Main Label Source Size Label

Stitching

Thread 10% cotton DTM Red Green Yellow 0020 0030 0040 Red Green Yellow

Code Style #

Code Source

Stucco MD1001 Red MD 1181 White MD 10001

ML101 ML 101 ML 101

Futek Futek Futek

SM-1 SM-1 SM-1

Futek Futek Futek

5. Size Specification Sheet: It contains the size of garments.

Description Chest 1 below arm hole Heam Across Shoulder Cuff Opening Arm Hole

Small 23 23 _ _

Medium 23.5 23.5 _ _

Large 24 24 _ _

X Large 24.5 24.5 _ _

XX Large 25 25 _ _

Tolerance + 0.5 + 0.5 _ _

In SPEC sheet all values are taken in inches while tolerance means acceptable deviation. Buyer gives all sizes. 6. Packing Manual: Packing manual contains the folding details of a garment, printing details, and material to be placed. It also includes hangtags detail, carton dimension details.

Packing Strategies: There are four packing strategies; 1. Solid Color Solid Size 2. Solid Color Assorted Size 3. Assorted Color Solid Size 4. Assorted Color Assorted Size Solid Color Solid Size: According to this strategy all garments are of same size and color. e.g Garments = 42 Color = Red , Size = Small

Solid Color Assorted Size: According to this strategy color of all pieces is same while there is variation in size e.g. Garments = 42 Color = red Size = Small, Medium, and long with ratio 1:2:1. Assorted Color, Solid Size: In this strategy color of garments is different while size is same. Garments = 42 Color = Red & Blue Size = Medium

Assorted Color, Assorted Size: Garments are of different colors and sizes. Garments = 42 Color = Red & Blue Size = small & Medium 7. Revision History: It includes all the changes required by the buyer afterwards e.g. buttons changed 3 to 2 or change in thread. Ti also includes the revision description, date, time and initiating authority. POLY-BAG

1. Types: There are three types of poly bags. I. Individual Poly bag: Individual poly bag contain 1 pc/bag. II. Blister Poly bag: Blister poly bag contain more than 1 pc/bag in a carton. III. Master Poly bag: It contains more than one piece/bag. 2. Dimension: 10``

9`` Flap 3`` Fold Size L W WxLxF 9.5`` x 10.5`` x 3`` 3. Material/Transport/GG: Printing Weight of Carton Instructions Logos

Address Buyers individual idea Carton tape Carton stickers Cartons Solid Color Solid Size: Garments = 42 Color = Red Size = Small Solid Color Assorted Size:

Garments = 42 Color = red Size = Small, Medium, and long Assorted Color, Solid Size: Garments = 42 Color = Red & Blue Size = Medium Assorted Color, Assorted Size: Garments = 42 Color = Red & Blue

Size = small & Medium Information Required For Carton: Following information is required for a carton. Hang tags Tag pins Plastic Clips/Jet clips UVM (Universal Vender Mark) VMT (Vender Mark Ticket) UPC (Universal Product Code Ticket) These above accessories are used 1/pc and only tag pins are used 2/pc and jet clips are used 4/pc.

Types of Carton: Regular slotted Telescopic carton Regular Carton Telescopic Carton 1. Dimensions Flap Height Width Length

LxWxH 28 x 26 x 8 2. Carton Printing Addresses (From & To) Carton Contents (Size, Color) Symbols Weight of Carton (With garments weight) Printing Types 2 Side printing 4 Side Printing

3. Carton Accessories Carton Sticker Carton Tape Carton Strapping Sampling Management Process Management is the process to do work on time, achieve target/goal on time while using All resources (machine, personnel, Human Resource). Sampling is the complete process through which sampling approvals are taken. It starts from a proto sample and ends at shipment sample depending on the buyer as different buyer have different sampling requirements. Samples may be paid or free depending on the category, quantity, contract with the manufacturer.

Sampling programmers can be a cost effective, tangible and highly visible method of launching new product, boosting sales or re-educating lapsed users. Sampling programs provide a conduit for consumers to experience product trials. Product samplings and mailings increase brand awareness and result in additional sales. Sampling should be complete on time with resources; Initiate Sampling Process Sampling Budget (To Control Cost) Time & Action Plan of Sampling SAMPLING PROCESS Proto Type Sample: This is the first sample given to the buyer. The sample is prepared according to requirement of buyer

and this is the rough sample. The range of sample is about 1-2 to vary according to the requirement of buyer. Comments on Proto Type: Buyer gives his comments on sample and also recommends the changes in sample. Counter Proto Sample: This sample is based on the comments received from the buyer. For this sample, 2-3 pieces are required. Salesman Sample: Buyer sends the samples in market by salesman to get market feedback from customers it is done on 250-500 pieces or may exceed depending on season and customer. Buyer has to sell these garments to check and view. Samples

Market Feedback Buyers Design Buyers Merchandisers Manufacturers Merchandiser Comments on Salesman Sample: Feedback on ample from customer is send to merchandiser/ manufacturer. Pre-Production Sample (PPS): Manufacturer prepares it. All changes are confirmed on it. 2-3 pieces are required in pre-production sample.

Approval of PPS: It is the stage where a sample may be approved or rejected. If accepted go ahead to next step and if rejected then there will be the process of revision of previous steps. PPC department is also involved at this stage. Once PPC is involved, no change in styling is acceptable. Size Set Sample: 2-3 sets of different size are sending to PPC (planning production and control). Manufacturer keeps one sample himself and one sends to buyer for cutting approval. Its purpose is that buyer will make no change in cutting details. If he makes some changes, he himself will be responsible for any loss/ damage. Fit Sample: No change in stitching is acceptable at this stage. 2-3 garments are used in fit sampling.

Photo Shoot Sample: Now the sample is ready fort shipment. Buyer picks some pieces randomly to test its gauge, GSM, shrinkage. If all these are according to the requirement of buyer then shipment is said to be ok. 15-20 pieces are picked up as a sample to test. Shipment Sample: This stage is the completion of total order. And the garments are sending to shipment. SAMPLING BUDGET It consists of the following data. Sampling budget Knitting plan Dyeing Plan

Accessories Sheet Cutting& Stitching Plan 1. Sampling Budget: It contains the general information about; Buyer: Target Fabric: Mesh Season: 3Q 2003 Pieces: 500 Style #: 295 Division: Mens GMT: S/S Polo with 1x1 Rib DTM body at neck. 2. Knitting Plan: Knitting plan is used for the description of material to be knit.

Description Mesh Rib

Yarn 20 S Carded 20 S Carded

F. Width 36 200

F. Width 26

9 209

Total Width

Total # of Pieces = 500 Mesh for 1 Shirt = 400g Mesh for 500 Shirts = 500 x 400 g = 200,000 g 1000

= 2 Kgs Total # of Pieces = 500 Rib for 1 Shirt = 18g Rib for 500 Shirts = 500 x 18 g = 9,000 g 1000 = 9 Kgs Yarn Requirement: 20 S Carded = 209 = 5 45.36

Dyeing Plan:
Color Red Navy C. Code Mesh Kgs 250 x 400/1000 = 100 250 x 400/1000 = 100 Rib Kgs 250 x 18/1000 = 4.5 250 x 18/1000 = 4.5

Accessories Sheet:
Description Stitching Thread Red Stitching Thread Navy Factor 200m TTL Material 250x200/2286 = 22 250x200/4500 = 12

Main Label Side Label Label Core Label Twill Tape Poly bag Tissues Cartons (24/Pieces/Carton)

1 1 1 1 1m 1 2 500/24

1x500 = 500 1x500 = 500 1x500 = 500 1x500 = 500 1x500 = 500 1x500 = 500 2x500 = 1000 21 cartons

Prepare By: ________ Checked By: _________ Received By: ________ Stitching Thread:

Small Cone = 2286m Large Cone = 4500m 1m = 39.37 Cutting & Stitching Plan:
Color Red Navy Total C. Code 100 100 S M 100 100 200 L 100 25 125 XL 50 25 75 TTL 250 250 500

Time & Action Plan: Pieces = 500

Packing = 200Pcws/DAy Stitching = 150Pieces/DAy Cutting = 1day Dyeing = 2 days Knitting = 3 days Yarn Package = 1 week
Yarn Req. S.D E.D Knitting S.D E.D S.D Dyeing E.D S.D Cutting E.D Stitching S.D E.D Packing S.D E.D Factory Date

28Jul 5Aug 9Aug 12Aug 15Aug 17Aug 20Aug 21Aug 20Aug 24Aug 23Aug 27Aug 7 Sep.

Prepare By: ________ Checked By: _________ Received By: ________ METHODS OF BREAKDOWN Following are the methods of breakdown. 1) Purchase Order 2) Production Summary a. Ratio b. Percentage c. Direct given by buyer RATIO METHOD

S Color Red Green Htr Grey C. Code 1 1/4x1000=250 1/4x2000=500 1/4x3000=750

M 2 2/4x1000=500

L TTL 1 1/4x1000=250 1000 2000 3000

2/4x2000=1000 1/4x2000=500 2/4x3000=1500 1/4x3000=750

PERCENTAGE METHOD
Color Red Green Htr Grey C. Code S (30%) 300 600 900 (M 20%) 200 400 600 (L 50%) 500 1000 1500 TTL 1000 2000 3000

DIRECT METHOD In direct method the buyer gives all values.

Color Red Green Htr Grey C. Code S (30%) 1000 (M 20%) 2000 (L 50%) 3000 5000 6500 TTL 6000 9000 6000

FABRIC CONSUMPTION CALCULATION Following methods are used to calculate the fabric consumption.

Step 1: Identify components of a garment. Step 2: Take finish width available from R & D. Step 3: Layout patterns + optimizes wastages. Step 4: Calculate length of layout. Step 5: Apply formula.

39.37 x 39.37 = 1550 yarn/pc/layout L x W x 2 x GSM = ____________ = ___________ 1550 No. of Pieces/day grams/Pc While 2 = No. Of Layers of Fabric Circular Knit consists of 2 Layers Open width consists of 1 Layer Step 6: Add wastage. Step 7: Calculate / make plans.

Basic Terms: Open Pattern Close Pattern One Garment Components Calculations: Rib = 26 Fabric = 30 30 x 60 x 2 x 200 = 464.5 1550 2

= 233g/Pc Neck Calculation: Neck = 3 x 26 x 220 x 2 = 23 = 7.3g/Pc 1550 3 Cuff Calculation: Cuff = 3.5 x 26 x 220 x 2 = 25.832 = 12.9g/pc 1550 2
Fabric = Neck = Cuff = 233 8 13

Total

254

Including small wastages 254 x 12 x 2.2046 = 6.72lbs/Dzn 1000 TYPES OF WASTAGES Cutting: It includes; Excess planning Small wastage 5 % included in layout Large wastage 3 %

Dyeing: It includes; Dyeing wastage 6-9% normally for fleece Finishing wastage Knitting: It includes; Knit 2-2.5% wastage that is left over yarn wastage Yarn Dyeing: It includes 5-7% Yarn dyeing wastage

WASTAGE ADDITION METHOD There are two methods used for waste addition. I. Progressive/ Step By Step Method II. Direct Method Calculation for Yarn Consumption: Length = 60 Width = 25 No. Of Pieces = 2 GSM = 220

60 x 25 x 2 x 220 = 425.80g 1550 425.80 = 212.90g/pieces 2 Calculation for Rib: Length = 5 Width = 30 GSM = 250 5 x 30 x 2 x 250 = 48.50g 1550

48.50 = 12.10g/pc 4 Wastages: = 5.95 x 1.05 x 1.03 x 1.06 x 1.02 = 6.95Lbs/Dzn RESEARCH AND DEVELOPMENT Research and development or RESEARCH AND DEVELOPMENT is related with product development. Concerned Merchandiser forwards the Fabrication Info to the Product Library and will get the exact match. If there is required match, Documentation and Planning is done, Merch is developed

and PD Plan is made by the PD center. If there is no exact match, Technical evaluation (Pricing), Documentation and Planning is carried out. RESEARCH AND DEVELOPMENT starts working here. After that PD Plan is made by the PD center. RESPONSIBILITIES OF THE RESEARCH AND DEVELOPMENT MANAGER She decides the fabric styling, finishing Routes. He submits the fabric in the Lab. He compiles the results. He sends the results to the buyer. If OK for the results, Data is inserted into the computer for making the file. If result is not OK, we refinish the fabric. RESEARCH AND DEVELOPMENT sends the developed samples to the P.I. Lab, for the quick wash and sees the results after the 3 washes and required GSM is produced.

After the quick wash, 20-30 g (weight) of the fabric is reduced just because of chemicals and detergents. Maximum sample weight is 10 Kg but is according to the merchandisers requirement. Yarn Count, Single Knit/Double Knit, Width and GSM is calculated and observed in RESEARCH AND DEVELOPMENT. PRODUCT DEVELOPMENT PLAN It issues the work order, tells about the style, design, counts, gauges, fabric finishing routes and fabric dyes. PD plan is send to the three departments; RESEARCH AND DEVELOPMENT, SAMPLING, Sewing and ACCOUNT. One copy remains with the Merchandiser. One copy remains with the PD- Officer. QUALITY PLAN

 Quality Product Requisition (QPR) is made in RESEARCH AND DEVELOPMENT. Within three days Quality Plan is issued from RESEARCH AND DEVELOPMENT. Quality planning includes the Consumption Sheet or Pattern Efficiency that is 85% required.. Quality Planning also includes the Garments to Kg concept, that shows that how much garments can be abstracted from the 1 Kg of fabric. An independent and vertically integrated product development and research center is one of its own kinds. It is a 35000 sq ft facility, largest in Asia, designed to achieve the following Fulfilling Designers Dreams A facility where an idea can be accurately converted in to product in quickest turnover rate.

 Continuously developing and innovating new and exciting fabrics, garments and finishes in line with ever changing trends in knitwear world. Ensuring reproducibility and predictability of new products for production. Meeting Merchandizing Requirement Delivery of all types of samples with speed, accuracy, quality and competitive pricing. Prototype samples in 3-4 days in actual fabric and color. Sales man samples in 2-4 weeks at actual production parameters MANAGEMENT INFORMATION SYSTEM Department MANAGEMENT INFORMATION SYSTEM department more than 100 hardware computers in factory. He is responsible the maintenance and hardware related problem. Look after of these computers.

Only available recourses are planned. Softwares: The softwares that are being used in NAVEENA Textiles are: Inventory management Fixed assets system Salary system software Piece rate related software Engineering system Attendance system Security:

Login is provided to every user and password is provided, he can change according to his convenience. In all organization we provide three types of login. 1. Home directory 2. Department share 3. Care drive Home Directory: Home directory the user can build folders, files. He is only responsible for compiling and security for this data. Departmental share: The departments can share data with each other. Care drive:

In care drive the departments can read only. Write facility is not provided because security purpose. Future plan: In future plan they will implement the E Commerce for update the status of the garments. They also plan to implement ERP step by step. They are using SQL because this provides more security and cheaper than database. HUMAN RESOURCE DEPARTMENT Human resource department is responsible for Recruiting Training Compensation Performance appraisal

 Firing Recruiting In NAVEENA for management hiring three interviews are conducted if they are experienced. If they fresh graduate then first written test is done after this initial interview, and then final interview is conducted. This process is done for management trainees. For workers and officer level the head of department hire. His criteria will accord job requirements. Training On the job training is mostly provided. But sometimes for management we conduct seminars; in LUMS some lectures are scheduled. Some mangers they visit to foreign countries for getting training. Compensation For management trainees they provide Rs.12000 and other according to job requirement and skills of the employee. They also compensate according market going situation.

For workers they are providing minimum Rs. 3000 according to government rolls. For officers the G.M decide how much salary will be provided. This depends on the nature of the job and skills, experience of the employees. Firing the employees If any employee is not doing his job very well then the Head of the department fire the concern employee. PRODUCTION PLANNING AND CONTROL Production Planning and Control (PPC) is the nervous system of the organization and its basic task is to receive information from the merchandiser and link it to the production. It involves the PreProduction Analysis to ensure quality and reproducibility. PPC has two further branches A) Material Resource Planning

B) Production Planning and Monitoring MATERIAL RESOURCE PLANNING Material Resource Planning is done for the material procurement, like sundries, yarn and fabric. It is basically done to analyze that how much is needed, what is needed, when is needed, what is the cost of the material and how to acquire the resources. PRODUCTION PLANNING It includes the planning like the Sewing Plan (we can also call it as the Master Plan). Back Ward Production Planning is done and this Production Time Line involves whens and whats of the production. Date Wise Plans are made from work order to delivery. MONITORING It is the different entity. Monitoring is done for the whole production process and in this we check out the planning implementation. If the planning is failed, re-planning is done for that. Off- the- track and On-the- track planning is also done by the PPC.

DOCUMENTS RECEPTION IN PPC Two types of the documents are received by the in the PPC from RESEARCH AND DEVELOPMENT and Cutting. RESEARCH AND DEVELOPMENT PPC receive Quality Plan from the RESEARCH AND DEVELOPMENT. In this Quality Plan specification, quality, width, weight, dyes, gauges and counts are mentioned. Cutting PPC receive Fabric Consumption Patterns from the Cutting department and plans that how much fabric must be used. DOCUMENTS GENERATION IN PPC Store Plan

Store Plan can also be called as Accessories Plan. It involves all the documentation about the sundries being used in the production of the order. It also involves the information about Threads, Buttons, Sewing and Labels. Store Plan is basically a Quantity Plan. Dyeing Plan It is related with the Dyeing of the fabric that how much fabric is required for an order, and then it is converted in to the Acro fabric. It plans for how much dyes and chemicals are required. For the procurement of the materials, PPC goes for the purchase department. EXTRA PLANNING 3-5% extra planning is done for the losses. There are some visible losses and some invisible losses. Visible losses occur from cutting to shipment. Invisible losses are being made in Dyeing process and Finishing Process. Any extra planning requires extra cost. So for the additional planning and additional cost, PPC managers have to go for the Chief Executive. The Production Planning and Control is the nervous system of our organization and undoubtedly it is our key success factor. The nucleus of NAVEENA and Sarahs remarkable success has been its

impeccable system. PPC conducts detailed pre-production analysis to ensure quality and reproducibility. PURCHASE DEPARTMENT Every aspect of organization for the manufacturing of the product like sundries, stationary, parts of machineries that can be available locally, chemicals and dyes etc. have to be purchase locally from the local markets. These are usually the general items, involve local purchase for the purchase of machines machinery that is not available in the local market, import department involves in such purchases. This whole import department is concerned with the high involvement machinery. They whole purchase department is do not work the work order or purchase order. Things are purchased according the buyer demand. No buying is done without the order. As such no inventory level is maintained for such goods as these goods are utilized immediately and plan is made for the minimum for the week. Three most important documents are used in the purchase department. Store Plan Store plan comes from the Store and purchase Requisition; It comes from the warehouse. Buyer provides purchase Order and according to this the store department make plan. It is made for one supplier only at one time only. Demand of the supplier is mentioned in the purchase order. These

documents are used all over department. MPR: Material Procurement Recognition Every department issues this then the purchase department is responsible for procurement. MRP: Material Requirement and Planning This document is used within factory for issuing the material. EXPORT DEPARTMENT EXPORT PROCEDURE Purchase order is received from buyer through the merchandizing department. A fax message is send to buying house/buyer for opening L/C. Expected Audit date/time received and go-head is taken from concerned unit (manager) to carry shipment. Arrangements are made for the transportation to move the consignment by the road/train/air as per plan.

Funds arrangement for the transportation and custom clearance charges. Shipment moves for the Karachi through the following ways. Eg. Truck, Train, and Air. Rates are as per shipment volume. Cargo lifting advice is fixed to custom clearing agent/ Forwarder/ Transportation. Forwarder / clearing agent make arrangements for the custom clearance and booking of the space at earliest vessel. Following documents are required for the custom clearance. Detail is given following; INVOICE In Invoice following criteria is required. Consignee and Applicant Addresses Garment Description Garment Price and Total Invoice value

 Net and Gross Weight of Garments PO (purchase order) no. Freight Terms; FOB/ C&F/ CIF/ Ex-Work Pakistan. From # & Date L/C. #(letter of credit) PACKING LIST There are following details in the packing list required as per buyers instruction or mentioned in L/C. Consignee and applicant addresses Product description Garment Style and color

 Net and Gross weight of Garments No. Of Pieces in the Carton and Carton Dimension also other necessary information, which gives help for the custom clearance. Export-FORM E-FORM is issued and attested by the concerned bank. VALUATION FORM It is for the custom purpose to inform the value of the consignment to the State Bank of Pakistan. BILL OF ENTRY Applicable only in case of the imported material used in the manufacturing of the garments for the export purposes. SHIPPING BILL

The forwarder prepares shipping bill. After the sub Management Information Systems ion of the custom docs, by the forwarder, custom authorities check the docs. And examine the shipment accordingly. They write the report on the backside of the shipping bill and allow the shipment for the export from the Pakistan. All these docs are then returned to the export department. QUOTA PROCEDURE Arrangement of the quota for the exporting the above goods or the garments as per category. Quota purchase from the open market/ EPB (export promotion bureau) VISA PROCESS After receiving the Docs from the forwarder, Export Department prepares the Visa docs, which are required for the export of garment to the following countries; USA, CANADA, EUROPEAN countries. The set of Visa with required docs is presented to P.H.M.A. for the issuing/ entering of the Passbook and the given serial numbers.

After this P.H.M.A. pass the Visa to the E.B.P. for the Visa issuance. Then after the checking of the docs Visa is signed and stamped by the Director of the E.P.B (textile section). All original docs are returned to the export department. NEGOTIATION / COLLECTION After the completion of the Visa process, we submit the docs in the Bank for the negotiation/ collection. The docs are prepared according to the L/C. or the buyer requirement. DOCUMENTS FOR THE BUYER Export department also prepare documents for the buyer for the custom clearance of the shipment at the destination. PAYMENT PROCEDURE After the negotiation/ collection procedure of the docs, bank dispatches the same to L/C opening bank, to realize the payment. Foreign bank is bound to realize the same within the 10 to 15 days. After realization of the payment, our bank is bound to issue the PRC within the working days.

REBATE CLAIM After receiving the PRC, export department claims the duty draw back (rebate) from the customhouse in Karachi or Lahore. COMMERCIAL INVOIVCE In the commercial invoice all the details are mentioned required under conditions of L/C for the custom clearance and other necessary purposes. PACKING LIST It consists of color, weight, product code/other, coding numbers, no. of cartons, carton dimension, and carton packing. BILL OF LADING/ AIRWAY This is according to the L/C terms and conditions.

SHIPPING CERTIFICATE In this certificate the shipping line intimates that the vessel /flight is not affected buy on Indian or the Israeli Flag vessel. BENEFICIARYS CERTIFICATE It is according to per buyer requirement. INVOICE: It is custom attached and details of the imported material are also given, that is used in the manufacturing of the garment. SHIPPING BILL: It is provided by the clearing agent and attested by the custom authorities. BILL OF LADING: in it all the required information is provided which is needed for the custom clearance. BILL OF ENTRY: We need detailed information like Description, Foreign Exchange Rate, Insurance, H.S Code, Weight, Custom and sales tax duties and etc.

Business Operation Management: The management team of NAVEENA comprises of dedicated and highly motivated individuals, laying much emphasis on teamwork and interdependency, which brings synergetic results. They bring with them, experience in the knitwear industry and diverse educational backgrounds, both local and international. NAVEENA has tried to develop a company culture where quality is given the top priority, innovation is encouraged, system are followed and fool proof inspection procedures at every stage of production and carried out. Quality Standers: Continuity in quality is an integral part of this organization. there is team of professionals who head this department .their work starts from yarn till the end product .strict quality control measures are implemented from the beginning and at all subsequent levels to maintain standards .

Quality Emphasis: The organization has already achieved ISO 9002 certification and has acquired various quality certificates and awards. Laboratory Testing: The organization have a comprehensive lab to check dye lots .its the organizational routine to check fabric for shrinkage, lot to lot shade continuity, color fastness to corking etc. Among other equipment the most noted are the data colors, spectra flash, tumbler and washing. Major Clients: The organization is working with leading multinational companies and believes in developing long term, sustainable relationships rather then one time commercial contract. Organizational buyers are recognized and respected names in the international apparel industry, including the followings, Factory Facility

Factory area KHI 12000sq.yards covered area 175000sq .FT Factory area LHR 5375sq. yards covered area 150000sq FT No. Of employees-KHI 2500 No. Of employees LHR 1500 Govt departments involve with organization: There are many departments, which are involved in term of Govt intervention in the textile industry, which are followings, CBR Ministry of labor and manpower Ministry of excise and taxation

Custom department Quality standards assurance organization State bank of Pakistan Structure and design of organization: Structure of the organization is flat and functional. And it is to some extend is a mechanistic organization. But it is due to its mass production .The organization along with its functional structures has horizontal linkage which is most necessary thing in garment industry because of high quality consciousness. Plant and Equipment: The organizations most of the plant and equipment is procured internationally, configured to generate optimal production at all stages and to ensure high quality. In term of knitting

Type Model Gauge Diameter No. Auto striper (terrot) s4f-248 18 30 5 Auto striper (terrot) s4f-248 20 30 2 Auto striper (fuquhara) s4f-248 18 30 2Auto striper (fuquhara) s4f-248 20 30 1 Mini jacquard (terrot) s3p4f-148 18 20 1 Feed stripe (Mayer & cie) 1mv4 11 20 30 1 Feed stripe (Mayer & cie) 1mv4 11 20/24 30 1 Feed stripe (Mayer & cie) 1ml-bf 20 30 1 Eight lock double knit t130-9621 18 30 2 RIB (pai-lung) t130-9621 16 34 1

Flatbed machines: Make Origin Gauge length Number Matsuya Japan 14 80cm 16 Matsuya Japan 14 56 05 Dying Yarn dyeing: Description make capacity number fongs yarn dyeing H.K 30kg 1 Atyc yarn dyeing H.K 90kg 1 fongs yarn dyeing H.K 200kg 1

fongs yarn dyeing H.K 300kg 3 fongs yarn dyeing H.K 750kg 1 atyc yarn dyeung H.K 850kg 1 fongs yarn dryer H.K 300kg 1 these machinbes are wiuth a capacity of four batches. Fabric dyeing: fongs 2t soft flow H.K 300Kg 1 Fong 3t soft flow H.K 500-600kg 2 Atyc ht 4t soft flow SPAIN 900kg 1 Atyc ht soft flow SPAIN 165kg 1

Winding machines: SSM cone winder Switzerland 2000kg 4 Re-winder local 9000kg 6 Garment washing: Suit lick washing machine H.K 4000/day 2 Finishing: hyadro extractor local 60kg 1 Hydro extractor Taiwan 60kg 1 Tumbler (askmer) H.K 30kg 8 Tumbler (sutlick) H.K 30kg 2

tumbler (askmer) H.K 30kg 8 Tumbler china 60kg 1 Dryer (sanatax) Switzerland 5 ton/day 1 Stenator Italy 15ton/day 1 Fabric slitter local 500kg 1 Squeezer Switzerland 6000kg 1 Corino (slitting machine) Italy 12000kg 1 Monforts (6chamber stenter Italy 15000kg 1 With graving system) Gravimeter system raising machine china 3000kg 1

Cutting /Embroidery: Electric cutting machine KM (Japan) 12 heads 5 Embroidery machine tajima 6needles 1 Band knife nagi shing 1 Stitching 480 sewing machines comprising along with 5 uni8ts having capacity of 22000 dozen garments /month. Auxiliary equipment: The organization has an in house repair, maintenance and development facility classified under electrical and mechanical department. Currently the following equipments are installed on the preManagement Information Systems.

Equipment Made Specification Number Boiler England 5.50ton/hr 1 Generator USA 375KVA 1 Generator USA 300KVA 1 Compressor Japan 1580lbs 4 The organization has a strong capacity of production, which also works as competitive advantages in term of technology. The brands which the organization is currently using all are of well named in industry. Which also work for attracting the buyers towards organization, and helpful for obtaining order and fulfilling it on time. NAVEENA Dying The dyeing process starts from the sample swatches that are sent by the Buyer.

Lab Functions: Samples are prepared according to the needs of the buyer and the process is called lab dipping. After the buyer then the dyeing approves the samples people follow the production plan provided by the PPC. Dyeing Process: There are two types of dyeing 1. Yarn Dyeing 2. Fabric Dyeing There are two Methods 1. Hi-Temperature dyeing 2. Atmospheric Dyeing.

Machinery: In Yarn dyeing all machines are of Hi-Temperature. The capacities of the machines are as following. 1. Machine 1 is 800kg 2. Machine 2 is 90 kg 3. Machine 3 is 30 kg 4. Machine 4 is 200kg 5. Machine 5+6+7 is 300kg each 6. 8th in line is only drier of 800kg. In fabric dyeing three machines are hi-temperature and rest is atmospheric. The capacity of the machines is as following.

1. Machine 1 is 700 kg 2. Machine 2 is 150 kg 3. Machine 3+4 is 550 kg 4. Machine 5 is 350 kg 5. Machine 6 is 50 kg and is named as winch machine. 6. Machine 7 is 20 kg and is also winch machine. After the dyeing fabric is transferred to finishing. Reasons for dyeing: For attractive purpose For uniformity

Shade variation controlling Color gives: More comfort More satisfaction Process flow: Singeing To remove protruding fibers De Sizing To remove the size for uniform dyeing (over dry) Scouring

To remove added and natural impurities Detergents To remove soil and keep it suspended in Water. So they dont penetrate again in the fabric. Bleaching Removing of color Changing absorbency Mercerization Length of fiber Fineness of fiber

Types of dyes: Reactive dyes make covalent bond Disperse dyes make a penetration Vat dyes make a trapping Sulphur dyes Direct dyes make a overlapping Component of dyeing: Temperature Salt Machines

Factor effect the cost: q Labor q Raw material q Machinery q Maintenance q Electricity q Transportation q Dyes q Chemical q Gas

General requirements by buyers Strong color bonding No bleeding & staining After twenty washes no change in color No absorption affect on garment after twenty washes Recommendations for cost control in dyeing house:

1. Compare the cost with competitors 2. Before selecting the product consider followings; q Price q Quality q Availability q Performance q Packing q Storage q Concentration q Final cost

q Compatibility q Environmental factors Required expertise: Electric and electronic work Mechanical work Machine / work knowledge Responsibility: Maintenance Manager / Knitting Manager Benefits: a. Less stoppage

b. More production c. High quality NAVEENA Knitting There are two kinds of knitting: Flat knitting Circular knitting. These both categories of knitting are being performed at NAVEENA 2 facility. Lets take a brief over view how it is done. Flat Knitting: The purpose of flat knitting is to prepare collars and coughs. They are given the fabric by circular knitting department and after that the technician at the flat knitting machine feeds the designs

according to the demand of the buyer. They are given a complete production plan by the PPC department, which they need to follow to get the desired result. Machinery: For the purpose of flat knitting NAVEENA 2 facility flat knitting department is equipped with 21 automatic flat knitting machines. Three operators one helper and a master manage them. The capacity of each machine is 250 sets in 24 hours, and according to the statement of machine operators they are easily achieving the maximum capacity on regular basis. All the machines are 14 gauge machines, which mean every machine can have 14 needles per inch. The more the gauge better will be the quality. Common error is that of needle break, which spoils the whole fabric if not detected at once. Setting the needles in the machine according to the requirement is an art and the master has to be the master in this art to get the desired result and to avoid error. Maintenance: There is a separate maintenance department present but there is no concept of preventive maintenance, only break down maintenance is done which costs the organization much more than the preventive maintenance.

Quality Parameters: The quality checkers inspect the flat knitted fabric on the basis of Wales and courses. They check whether the whales and courses per inch meet buyer requirement or not. Wastage of 2 % is allowed. Circular Knitting: They again get their line of action from the PPC department. The purpose of the circular knitting is to convert yarn into fabric. Machinery: There are total 15 machines 9 of them are computerized and called auto machines. These machines are capable of making maximum stripes on a fabric while using four colors at a time. The auto machines are mostly used for the preparation of fabric of dark colors and having stripes or repeat. The remaining six machines are called feeder machines. They cannot make a stripe more than 2.5 inches on a fabric. Mostly they are used for simple fabrics of white and light colors. Each machine is capable of producing 150 kg per day. A total of 192 cones of yarn can be added to a single machine of four different colors, 48 cones belong to each color. One person handles each auto machine and two feeder

machines are under one person. There is a supervisor and a master present to keep check on the things. The machinery is not capable of producing French terry and fleece fabric. Any order of these two fabrics is outsourced. All the machines have flexible gauge facility, which is set according to the buyer requirement. Quality Parameters: After the fabric is prepared it is checked by the quality personnel on a machine called clatter machine, using the 4 point system. This machine enables the quality personnel to detect various defects in the garment, after detecting the error they mark it and send for appropriate corrections. The errors, which cannot be removed, are then cut off in a way that their effect should not be on the finished garment. Finishing: The finishing can be termed as the process for drying the fabric. First of all the fabric is transferred to hydro machine which squeezes the water out of fabric. Then the fabric whose rate of shrinkage is more is sent for tumbling which is the traditional approach for drying and the other fabrics are transferred to tenter fesaro + compactor machine, where fabric is straightened. The machine is hi-tech and fully

computerized. Then the fabric is transferred to slitting and squeezing machine. After that comes in the stenter machine having six chambers. After that the fabric goes through the erasing machine which smoothens the fabric mostly fleece is erased. Now fabric is ready and is transferred to NAVEENA 1. All the machines are of hi-technology and produce great results. A dryer is in the process of being set up and will soon be functional increasing the efficiency of the finishing section. Quality Parameters: The quality personnel check the quality after the erasing and the main concentration is upon the variation of shades. If the fabric shade varies then it is sent back for re dyeing. The sophisticated fabric in whom there are more chances of shade variation it is even checked during the dyeing process by the quality personnel. Cone WINDING: It is of two types: Soft winding

 Re winding Soft winding: The yarn when firstly come is hard .the cone winding department re wind it to make it soften. Then it become easy to dye and the dye quality become higher. Re winding: After dyeing of the yarn it is re winded and is transferred from spring wind to the paper wind. The biggest draw back is that there are no control checks what so ever in the cone-winding department. If any thing Management Information Systems the eye of supervisor then any error can easily go through Major Suppliers Din spinning

Sapphire Ejaz spinning Azgard9 Dewan Mills Nishat Mills Hussain Mills Factors Affecting on Organization in Term of External Environment There are factors which are currently affecting the organization and are as follow: Govt policies As the policy of Govt changes it directly effects organization because there are many factors, which

entice the organization with Govt Tax policy Rebate Quota Industrial policy of Govt in term of garments manufacturer. Subsidies from Govt. Labor policy Brands Side out High sierra

Antigua Cherokee Amc stores Aeropostale Phat farm Roots Hard rock caf Hollister Brake water Perry Ellis Wal-Mart

The company devotes considerable time and effort to consolidate its present relationships and develop new ones, agin, with the goal of establishing relationships, which are long term and diversify the company client base. Suppliers of organization: The company also has the list of compatible suppliers and includes them in term of stakeholders and used to facilitate them with the maximum beneficial way to develop long-term relationship with them. The supplier side is although most critical aspect of the organization in term of quality and quantity because of the large-scale production in NAVEENA. Organizational Culture NAVEENA consider its employees to be its biggest assets. Adequate facilities exist and are constantly upgraded to improve the social environment. The organization has following statement for their social culture We strictly, under all cost, forbid child labor and forced labor

Competition There is a big competition between industry .in term of taking orders and the main aspect is price of manufacturing garments. There is less innovation and differentiation in products. So, because the commodity is same and due to witch there is cost factors which is very high and directly effect organization. Domestic competition M as oo d te xti le

 A m m ar te xti le Le isu re te xti les

Irf an te xti le Sh ah ka m te xti le A

ng or a te xti le Co m bi ne d fa br ics

Co mf or t te xti les Mi an so ns These are all major competitors of the organizations, and all are Lahore based. International Competition The overseas competition is now a days very less but it will become very high after the remove of

ATC .the organization has to develop its self from now to be in market in future. Because in that huge dynamic e4nvironment there will be more dimensions in organization to meet with uncertainty. It can be come from: Singapore Bahrain (because the USA made a contract with UAE) China Bangladesh Thai-land Honk Kong Malaysia

Technology: Technology is also a key sector in term of external environment for garments industry. Because the technology is also working as a substitute for man power with more efficiency. The industrialist has a solid point that it also saved cost i9n term of Error reduction Les labor cost In order to compete internationally the organization must have to depend on new and advanced technology. Although the technology, which NAVEENA is using not very low but there is no end in business. Structure and design of organization: The structure of organization is functional with horizontal linkage. The organization has mechanistic design and which is working on the basis of efficiency, which means

more production, maximum out put from least input. SWOT ANALYSIS OF NAVEENA During my internship I observe some strengths, weaknesses, opportunities and threats for Naveena are given below. STRENGHTS Big buyers from market Well known strong suppliers Strong departmental structure MANAGEMENT INFORMATION SYSTEM department Quality Provider

WEAKNESSES Not a big player in market Low integration between departments Too much decentralized the departments. No RESEARCH AND DEVELOPMENT No marketing research OPPORTUNITIES In WTO(World Trade Organization) implement quota will free this will be opportunity for especially NAVEENA because he can produce much more. Many brands we can start like sports garments.

 Expansion of business Diversification In term of open trade Capture local market THREATS New entries in the market like small level unit after WTO implementing. China and India is big threat when quota will free Differentiation Switching of buyers No Isolation

 Persistent quality Low price from other countries BCG MATRIX FOR NAVEENA Boston Consulting Group Matrix (BCG MATRIX) The BCG matrix measure market attractiveness by market growth rate and it assesses the firm ability to compete by, its relative market share. The BCG matrix assumes the causal relationship between market share and profitability. Stars Questionmark Cash cows Dogs

There is a huge slum in garments industry, after the incident of 9/11. This is directly and indirectly affecting the whole market. But NAVEENA is the organization working quite well, even in this situation and earning from international market. Thats the sign due to which I analyze that the NAVEENA is a cash cow in term of BCG matrix. Competitive Strategy In garment washing different effects is provided to customer. Value added products are provided. Pull and push strategy is adopted Performance is better. Marketing Strategy The product improvement will be marketing strategy.

 Product innovation We make reasonable price against market. Outlook of garment is very smart and excellent. This is accepted in the market. Targeting the young people and using price strategy to satisfy them. Marketing Analysis The structure of organization is quite well but the design is not. Because the coming trends are moving very fast. And in the end of this year the environment that is now-a-days stable will become dynamic. Then there will be need of Differentiation Added features Effectiveness Quick response to changes

More flexibility More complexity Competitive edges not one but more then that. Its a big process, which cant be achieved in days .It take lot of time to enhance theses capabilities in organization. Either to sit a side and looking on trends changing the organization has to do a lot. Practical learning ECRU YARN STORE AND CONE WINDING . At first I get the information about Ecru Yarn Store that how after the order of buyer a company bye the ecru yarn and store it according to W/O. After that I got the information about Cone Winding that how it works and what are the functions of cone winding. YARN DYING / LAB AND CIRCULER KNITTING AND FLAT KNITTING

I learn about the yarn dying that how an ecru yarn dyed and after dying process how it preserves. Then I attached with the process of circular knitting and flat knitting and learn about these two processes and its importance. ECRU FABRIC STORE / LAT MAKING AND FABRIC DYING/ PI LAB I learn about the process of maintaining ecru fabric store and lat making. After this knows about the process of fabric dying and then there was a difficult and main process of approval and rejection of fabric in PI lab. NAVEENA following the international standards of approving and rejecting the dyed fabric. DYING FINISHING AND DYED FABRIC STORE Today I learn about the process of finishing the dyed fabric and how the fabric get ready for the next process and after this after all quality checks the fabric is ready to next process and for this it preserve or store in dyed fabric store. PPC DEPARTMENT (PLANING PRODUCTION AND CONTROLLING)

.It is one of the major department of any textile Industry without having god professional it can not work so knowledge about PPC is very much useful. PRODUCTION SHEET Production sheet is given from buyer and buyer tell his requirements actually all the specs is given in this sheet, so according to this sheet we develop the required garment for approval and also we analyze the cost as well. RESEARCH AND DEVELOPMENT (RESEARCH AND DEVELOPMENT) In RESEARCH AND DEVELOPMENT we analyze and finalize the root of fabric that how it will complete and in finishing how it approaches the buyer requirements, actually we get all the lengths and get the information of cost as well and other things about the roots. CONSUMPTION After getting the all the lengths of garments we know about the consumption and it is known by the defined formula of body and sleeve. we get the sum of body and sleeve and get the consumption of

garments. ASSESRIES In this we plan about how much accessories will be used in garment and also wastage factor will be added in it. COSTING In this process we added all the consumptions and compare it with the buyer rate if it is less than the buyer rate then it will be accepted otherwise not. CONTROLLING We the plan is accepted than according to due date every day PPC check that how much process is completed and how much time remaining will take. So process is checked at every stage. Merchandising Department

I join the merchandising department and get the whole information and briefing about the merchandising department and its functions that are done under merchandising. I learn about the basic functions of merchandising that how after the order of a buyer it works and what are the basic function like reading of spec sheet and other information about the specs. PROTO SAMPLE AND COSTING I learn that how to make a proto sample and how define the costing of that proto sample. After making a proto sample and costing merchandising department send the sample for approval. FIT SAMPLE After getting the information merchant made a fit sample and sends it to the buyer for the final approval. It is a core process and I today I learn about this process. SALE SAMPLE I learn about the process of sale sample the how this process is occur and one thing that is learning in it

that the price of sale sample is doubled than the other garments. It is not the requirement of all the buyers but few buyers get the sale sample. CONFIRMATION OF ORDER I learn about that what happen after confirmation of order, after confirmation of order merchant demand to buyer to give accessories detail so that he can start the production. SCHEDULE ABOUT TESTING I learn that how get the schedule of testing the garments. Actually it is necessary to know about the schedule because after confirmation the order it is 1st requirement that have to fulfill first and after this bulk production is started. SIZE SET AND PRODUCTION Today I known that what is the importance of size set before stating the bulk production. Merchant made all sizes and gets the confirmation of all sizes from buyer then starts the next step.

These days I spent with the merchandiser that how he works when order is confirmed and how the whole process is completed. Actually it was a practical learning and no documentation was involved in these days Issues and Suggestions Suggestions and recommendations for knitting and dyeing There should be a preventive maintenance scheduled program. Effective maintenance is also important to get maximum utilization of machinery. In flat knitting department the quality inspection machine is not working. That should be repaired. Keeping high quality is not only the responsibility of quality department, but it should be embedded in each employees mind. Every employee should take it as personal responsibility.

 There is only one hydro machine in dyeing; it must be two .So the lot loaded on trolleys doesnt have to wait for long time. There should be clearly written standard about the demand of buyers requirements about the production. Quality measures should be clearly defined, written and hang on the departmental walls. Raw material should be properly stored, because theyre hazardous if stored in knitting department. Common error of fluff, which is only due to the noncleanliness of the production floor. And due to which a lot of quality problems are occurring which increase both the time and cost. Issues and Suggestions, regarding production, planning and control:

The biggest draw back in the time and action plans of PPC in NAVEENA is that there is no contingency planning in advance it is a general rule that while planning production some cushion is given for activities such as machine break down or any other extraneous variables that can take place. The problem is addresses only when it occurs. There should be planning in advance for that in order to minimize the effects of a problem that has occurred. Issues and Suggestions, regarding time and action plan: The most common issue is of coordination Management Information System takes that lead to enormous losses at the end of the day. According to PPC personnel due to some Management Information System takes by merchants in providing production summary they end up making garment, which was not required at all. In order to avoid this kind of scenarios the merchants need to be absolutely sure what is required and the PPC personnel should clear any ambiguities before going for production and should recheck with the merchant the basic requirements. Although there is a co-ordination manager present but still personal interest of all the departments is required in order to make the coordination free of any doubts. There should be clear lines of communication established between the departments. Every concerned person should know what is

going on and what was required so that controlling should not only limit to the PPC department. From Knitting to Finishing every responsible person should have a clear idea what he needs his team to do. Limitations: Buyer due to the fact that the merchant cannot forward the purchase order gives Some times the coordination gap to PPC, as it is a secret. Only production summary is prepared and is given to PPC so if merchant makes a Management Information System take in interpreting the PO there is no way PPC can come to know about if there are any ambiguities in the production summary? Sometimes the merchant delays in forwarding information as it arrives to him resulting in delay to initiate the production process. Conclusion Form my experience of six weeks in this organization I have learnt many things. The most important is that practical professional life is very hectic, competitive and tough. The best thing, which I am able to find out, is that the stronger the culture of the organization better will be the productivity. In textile sector the thing of immense importance is how well the organizational personnel

communicate with each other. There is no room for personal grudges because each and every one depends on each other if any one screw up the whole organization suffers. BIBLIOGRAPHY Company profile I got the information regarding vision statement, core values. SWOT information gets from Senior Managers. HRD information get form HR Officer. Export related data gather from Export Manager. Import related data gets from Import manager. Merchandising related data from merchandising manager. Process related data collect from different departmental heads.

GLOSSARY GSM: Stands for Gram Square per meter. MMC: Stands for material Management and Control MPR: This means Material Procurement Requisition MIR: This stand for Material Issue Requisition GPR: This means Gate Pass Requisition GRN: Stands for Goods Received Notes BRS: Stands for Bank Reconciliation Statement SAN: It means Sales Notes OGP: Stands for Outward Gate Pass

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