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Established in 2003

Specialized in export of readymade garments


Business turnover (annual ) 100 crores
Director Dheeraj jha
General manager Manju Walia
Production manager Bishan Singh
Total covered area-1500 sq km
Total working force- 700

Product Ladies casual and urban wear ( in a-28 )


Fabrics All wovens and knitted especially viscose

georgette ,poly chiffon ,silk ,prints and embroidery ,poly


lazor satin ,silk ,poly knitted ,etc.
Units a-26, a-28 (sec-7),c-13, w-14 ,e-80 (sec -6)
Buyers:-

Various departments in the apparel


production industry : Production planning and control
Sampling department
R&D department
I E department
Quality assurance department
Fabric and accessories departments
Embroidery department
Spreading and cutting department
Stitching department
Finishing and packaging department
Shipping dept

PRODUCTION PLANNING AND CONTROL


Job or Task Scheduling
Material Resource Planning (Inventory)
Loading production
Process selection & planning
Facility location
Estimating quantity and costs of production
Capacity planning
Line planning
Follow up and execution

SAMPLING DEPARTMENT
Samples that are made in development stage are as

following Proto Sample


FIT sample
Salesman sample
Purchase order comes after approval os salesman
sample only.
Size set Sample
Pre-production Sample
In production stage factory need to submit few more
samples that includes
Top of Production Sample
Shipment Sample
Average is found. (i:e fabric consumption in one garment
by which merchant calculate total demands of fabric for
the entire order ).

R& D and IE DEPARTMENT


Increasing the production of a company

with minimizing the cost.


Various tasks performed are: Line balancing. To check that product if it is production
feasible or
not before sending final approval to buyer
Calculating thread consumption.
Time study.
Creating operation breakdown.
Find out SMV.
No. of machine
Helpers required
To find out the efficiency of the individual operator and
line.

Calculating daily efficiency of the unit.


Co-ordination with PPC for improving the efficiency.
Fix the target production.
Decide the type of machine and work aids attachment

required for particular operation.

QUALITY ASSURANCE DEPARTMENT


QA is the systematic monitoring andevaluationof the
various aspects of a project, service or facility to
maximize the probability that standards of quality are
being attained by the production process.
Two principles included in Quality Assurance are:
"Fit for purpose", the product should be suitable for the
intended purpose, and
"Right first time", mistakes should be eliminated.

Quality Assurance includes regulation of the


quality of raw materials, assemblies, products and
components, services related to production, and
management, production andinspection processes.

Functions of quality assurance department:Pre-production

Audit:In this stage auditing is mainly done for the stages


which come before the production and that is the sampling stage..
Cutting Audit

Spreading
pattern notches (accuracy of patterns)
Sewing audit

In line audit: Here the garments are checked during their different stages
of manufacturing .

End line audit :-Here the garments are checked after the entire process is
over and the specifications are mainly based on the dimensions of the
garment at the critical positions and then the placements of the labels.

INSPECTION AND TESTING


Garment inspection

Here some of main fabric properties that are taken into


consideration for garment manufacturing for export
basis:
Overall look of the garment.

Right formation of the garment.


Feel and fall of the garment.
Physical properties.
Colour fastness of the garment.
Finishing properties
Presentation of the final produced garment.

There are certain quality related problems in garment


manufacturing that should not be over looked:
Sewing defects -Like open seams, wrong stitching
techniques used, same colour garment, but usage of
different colour threads on the garment, miss out of
stitches in between, creasing of the garment, erroneous
thread tension and raw edges are some sewing defects
that could occur so should be taken care of.
Colour effects -Colour defects that could occur are
difference of the colour of final produced garment to the
sample shown, accessories used are of wrong colour
combination and mismatching of dye amongst the
pieces.

Sizing defects -Wrong gradation of sizes, difference in

measurement of a garment part from other, for


example- sleeves of XL size but body of L size. Such
defects do not occur has to be seen too.
Garment defects -During manufacturing process defects
could occur like faulty zippers, irregular hemming, loose
buttons, raw edges, improper button holes, uneven
parts, inappropriate trimming, and difference in fabric
colours.

Trims inspection -Like garments, trims are not checked


for 100%. Quality inspector only needs to confirm that
bulk trims are sourced as per required standards .
Trims are normally being checked against standards on
the following parameters.
Shade matching
Shrinkage
Color bleeding
Width and thickness
Strength
Number and size
Fiber content
Text content/font/language in labels and tags

FABRIC AND ACCESSORIES DEPARTMENT


Sourcing regions
Suppliers of trims: Zipper (ykk brand) jankson (okhla) , sai impose (govindpur)
Zipper (tex brand) tex carbo ltd (gurguaun)
Button (polypol button ) -govindpur dealers
Shell button (spila brand) ultimate dealers ,repotex from
Bombay
Lace k.gyanchand in sadar market
Needle rajasthan inter gross dealor
Supplier of fabrics: Polyster sarvodaya textiles ,balaji textiles ,gulmohar in
surat
Cotton bhivandi
They order for Yarn dyed in goindpur dealers mainly

Fabric and accessories department is divided into


tthree sections:-

Fabric reconciliation
Fabric reconciliation is a process that is used to do fabric
analysis. It means how the total purchased fabric is used by
a factory. What percentage of the fabric is actually used to
make garments, what percentage of the purchased fabric is
left after shipment as dead stock, and how much fabric is
lost as wastage.

EMBROIDERY DEPARTMENT
In apparel manufacturing unit; embroidery is special types
of task. It is done according to the buyer requirement
Process Flow of Embroidery: Embroidery is done according
to the following sequence in a A.S .FASHIONS .PVT .LTD
At first designed the buyer design by CAD software

The design software install into the machine

The fabric clamped by the clamp board

Then run the machine until finished the design

Then the fabric collects for delivery

SPREADING DEPARTMENT
Objects of Fabric Spreading:
To place the number of fabric plies to the length of the marker plan
correctly aligned as to the length and width.
To cut garments in large scale and saving fabric through the use of
multi garments marker plan and the saving in cutting time per
garment that result from cutting many piles at the same time.
To make every ply flat and plane.
At correct tension.
Cutting spread are classified by three factors.

T he linear factor of the material


The direction of the material surface with respect to the cutting
table surface
The direction of the surface nap or design with respect to the
ends of tread.

CUTTING DEPARTMENT

A cutting department of a garment manufacturing unit


includes following sub-processes
Fabric relaxation
Fabric spreading / layering on cutting table
Marker making
Cutting - manual cutting (using scissors), machine cutting,
automatic cutting.
Numbering of garment plies (parts)
Shorting and Bundling
Inspection of cut components
Shorting of printed and embroidery panels
Re-cutting of panels
Fusing garment components

Example of one style in as fashion ( for spreading


, laying and cutting):Style no-646130 , colour index 163
In one lay there are 200 layers( and even one lyer
in one lay in single jersey that curls at edges ) .

SEWING DEPARTMENT
Sewing department is the heart of a manufacturing
unit. Cut components are assembled in sewing
department in assembly line.
Manufacturing system used PBS
List of sub-processes those are done in sewing
department includes.
Making garment parts
Sewing full garment
Making garment accessories like dori, tabs, cords etc.
Checking of stitched garments
Alteration work of defective garments

Pre sewing functions


Before the actual task of sewing begins, there are
certain other tasks that have to be taken care of which
can be termed as fabric handling functionsPly separation;
Placing the fabric on working table;
Guiding the fabric towards sewing needle;
and tension control of fabric during the sewing process.
Planning of sewing process: Sequence of seams to be
stitched is determined before the sewing starts. Which
part will be joined first, what stitches will follow one
another, etc. are decided. However, some stitches have
to be necessarily done before or after another stitch.

Sewing Fabrics
The sewing process consists of mainly three functionsguiding fabric towards needle;
sewing of the fabric edge;
and rotation around the needle.
Significant Aspects of Sewing
Thread tension and consumption: Correct balancing of the stitch
and the tension given to the threads is very important for quality
stitch formation. Thread consumption, which is closely associated
with correct stitch.
Presser- foot displacement and compressing force: If this system is
not efficient then it results into irregular seams and many other
defects, especially when running on high speed.
Needle penetration force measurement -Needle penetration force
is one of the variables whose measurement is important for the
analysis of quality problems or "sewability testing" and also quality
monitoring

FINISHING AND PACKGING


DEPARTMEENT
Washing of garment
Buttoning and button holing
Thread trimming
Checking of washed / unwashed garments
Stain removingby tipol ,spotter.
Ironing or Pressing
Final checking of garments after ironing
Mending / repair work( ex- hand embroidery work and

buttoning that breaks in washing )


Tagging
Folding and packing

EXPORT DEPARTMENT
This department is responsible for export related
documentation ,dispatching goods to ports, and communicating
with buyers warehouse and distribution centre.
Different types of price quotation in export trade
Ex-factory or local Price quotation -This type of quotation
represents the simplest arrangement. The importer is presumed
to have bought the goods right at the exporters factory. All
costs and risks from thereon become the buyers problem. The
ex-factory.
Free Alongside ship (FAS) price quotation-The use of this term in
the quotation means that the exporter to be responsible for the
goods until they are placed alongside the ship. All charges
incurred up to that point must be borne by the seller. F.A.S. price
is slightly higher than the ex-factory price, since the exporter
undertakes to transport the goods to the point of shipment.

F.O.B. (Free on Board) Price Quotation-F.O.B. Price includes

actual placement of goods abroad the ship. The F.O.B price will
includes F.A.S. price plus costs of shipping and boarding on ship.
Ex-ship Price Quotation: This means that the exporter agrees to

meet all expenses to forward the goods to destination port of


the importer. But the expenses towards taking delivery of the
goods from the port authorities and expenses to be incurred
thereafter will be met out by the importer.
Duty paid Price Quotation or Delivery Duty-paid Quotation:
Under this, the exporter bears complete responsibility for the
delivery of goods at a particular destination in the importers
country. He makes arrangement of taking delivery of the goods
at the foreign port, pays necessary duties/taxes and handling,
and provides for further inland transportation in the importers
country.

SOFTWARES
ERP :- Technosoft is the erp used in a.s. fashions
.pvt.ltd .This software is in use since 2013. Various
usages of erp are: Accounting In accounting it is used to keep record of all
expenses and profit .
Logistics
Updates of each departments
It has made easy to get all informations ( ex- in which
stage is style ?, how many expenses are going in
respective departments ) of a style just by selecting
style no .

CAD:-Tukacad is the cad used by a.s.fashions . It is


user friendly . tucacad provides online facility also for
grading and marker making. Various usages of CAD are: it provides the facility of PGM ( pattern making ,
grading , marker making )
waste% is low in cad .
very less time in sample making
a.s.fashions use cad in pattern making and grading
not in marker making because the order they get are
mostly single jersey ,chiffon ,poly chiffon , weightless
georget in which which width vary in each plies but
printout of cad marker cant adjust in varied width .

MERCHANT
Merchandiser is the BRIDGE between the industry and the

buyer.
He has to look after every job like buying the raw material
which is required to finish the product, making the
garment, finishing the garment, documentation, finally
shipping. He is the responsible person to make the
product.
Merchant is a trader, an exporter or importer of a garment
he is basically a employee of a vendors company who is
being responsible to the buyer and coordinate the full
manufacturing process of garment right from getting the
order, approving the design, ordering fabric, cutting,
production and up to the shipment of the order i.e., he is
the whole sole of the company.

Core responsibilities of merchants are: Internal & external communication,


Sampling,
Lab dips,
Accessories & trims,
Preparing internal order sheets,
Preparing purchase orders,
Making cost sheet
Advising and assisting production,
Advising quality department about quality level,
Mediating production and quality departments,
Givingshipping instructions and following shipping,
Helping documentation department,
Taking responsibility forinspectionsand
Following shipment.

SPECIALLY FOCUSED AREA


Project title- To increase productivity by reducing lead
time
Project duration 7 weeks
Project mentor- Ms Aboli Naik
Background-In a world where timeline is everything ,on
time time delivery becomes a critical component of each
success story to meet customer requirement.
The Indian garment industry has a major problem in the
recent economical scenario.
I analyzed the lead time in a.s fashions pvt.ltd and tried to
find out where the waste exists so that it can be eliminated .
Objectives- To be able to understand the delays and its
causes and propose a system by which delays can be
curtailed

Methodology :In start three weeks I did work study of cutting


,embroidery and stitching and finishing department and
found that are as follow: In stitching department ,I observed that in start 15 days
of manufacturing : Needle stoppage was there .( off standard time was
there)
Rate of mostly operator was 80 only .
While in reverse in last 15 days of production there
were: Least off standard time
Rate of mostly operators was almost 100

In the next 4 weeks I came to the actual cause behind off


std time and low rate in stitching department and suggested
a solution that was also implemented.
After analyzing and talking with operators and supervisors I
came to know that
The causes behind the problems were: Line Balancing was done once in a day only, where as in the
style where only 5 days of manufacturing were left
supervisors had to report production manager after every 1
hour and then accordingly rebalancing was done.
Operators wanted to do overtime and so they did not pay
attention in daily clock time and they can get overtime only
when the schedules go behind .
They did not have target to stitch fixed amount of garments
in a day .

After talking with production manager and analyzing the


style of which only 3-5 days were left to go I came to the
solution that are as follow : Supervisors should take work reports even in start 15
days of manufacturing after every 3 hours and balance
the operators then if required.
Give targets to operators and offer money reward to
whom who do more than the target once in a week.
I gave the problems and solutions to production manager
and to production planning control department and they
approved this ,but made changes in bonus scheme
.

This system was applied in other style of which production


was in initial stage
Findings (In 30 days of manufacturing):Reduce three days in sewing since the rate of operators
were 100 even in start days of manufacturing.
Conclusion:Almost in every garment industry they are facing the
problem of late deliveries of goods . By reducing lead time
(specially in stitching department ) we save time in
particular order and can deliver few days earlier which also
saves inventory .

THANK YOU !