Presentation based on 3 Month Internship at

Modelama Exports Ltd.

Under the Guidance of

Presented by

Mrs Vasundhara Chaudhary

Associate Professor

Atul Dwivedi, Navneet Yadav

and
Vinay Prajapati; M.F.TECH,
SEM-III

National Institute of Fashion Technology, Gandhinagar

19-09-2011

Company Profile
COMPANY NAME

MODELAMA EXPORTS PVT LTD

ADDRESS

TELEPHONE

PLOT NO. 105/106, UDYOG VIHAR, PHASE-1

GURGAON, HARYANA- 122015
B-57 OKHLA INDL. AREA PHASE-1
NEW DELHI- 110020 INDIA
0124-4008105

FAX

0124-4008108

E MAIL

info@modelamaexports.com

WEBSITE

www.modelamaexports.com

YEAR ESTD.

1979

OWNER

MR. LALIT GULATI

DIRECTORS

ANNUAL TURNOVER

MR. SANJAY GULATI

MR. GAGAN GULATI
MR. GAURAV GULATI
60 MILLION (OF ALL FACTORIES)

MARKET

100% EXPORT

TOTAL COVERED AREA

4,00,000 SQ. FT.

TOTAL WORKING FORCE

5500

IN HOUSE/FABRICATION/BOTH

BOTH

PRODUCTION CAPACITY

8 MILLION/YEAR

HEAD OFFICE

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Team Modelama

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Corporate Office

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Vision/Mission
Vision
Modelama will guide its business activities maintaining a balance
between ethical values and corporate objectives. The company will
strive to achieve its goals by executing its strategic plans and caring
for the profits of all the stake holders.
Mission
Modelama has a vision to establish itself as a multi-product and
multi-services business conglomerate. It is committed to expand the
spheres of its business activities into newer sectors in the years
ahead. The company is confident of building the same brand image in
all areas of its operations that it has in garments and home furnishing
sectors

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Product Range
APPAREL

HOME
FURNISHING
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Organisation Structure

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Infrastructure

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Production Units
HARYANA
184, Udyog Vihar, Phase-I, Gurgaon

105, Udyog Vihar, Phase-I, Gurgaon

106, Udyog Vihar, Phase-I, Gurgaon

200, Udyog Vihar, Phase 1,Gurgaon,

Mervyns 201, Udyog Vihar,Phase 1

204, Udyog Vihar,Phase 1, Gurgaon

660, Udyog Vihar, Phase-V, Gurgaon

Plot No-5, IMT Manesar, Sector-4, Gurgaon

Plot No 7, IMT Manesar, Sector

5,IMTManesar, Gurgaon

Plot No 18, IMT Manesar, Sector

5,IMTManesar, Gurgaon

Plot No 89, IMT Manesar, Sector 8, IMT

Manesar, Gurgaon

529, Phase-I, Bahrhi, Dist. Sonipat

Plot No 1, Sector 8, Bawal, Dist. Rewari

CHENNAI
Plot No - K 46/47/48/49, Appragel Park , Irun
Gattukottai. Dist. Tairnatur
DELHI
B-33, Okhla Industrial Area, Phase -1, New
Delhi
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Work Flow
BUYER

PRODUCT
DEVELOPE
R

MERCHENT

SAMPLING

FABRIC

BUNDILING
AND
TICKETING

CUTTING

SPREADING

MARKER
PLANNING

TESTING

PRODUCTI
ON

WASHING

FINISHING
AND
PRESSING

PACKING

DISPATCH

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Buyers

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11

Merchandising

A merchant is the person who acts as a

link between a buyer and vendor. He is
the one who is central or integral part of
a garment industry.
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12

Merchandisers Responsibility
1. Chase for fabric/trims prior to PCD date.
2. Size sets/PP/TOP samples-Monitoring and delivering.
3. Coordinating buying agency QA Inspection.

Responsibility

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13

Product Development
This department is not buyer specific and work for all the
buyers that company caters to.

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14

Sampling

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PROTO
TYPE
SAMPLE
MADE

TOP
SAMPL
E
MADE

SIZE
SET
SAMPL
E

FIT
SAMPL
E
MADE

PP
SAMPL
E
MADE

SHIPME
NT
SAMPLE

15

Machine Details in Sampling Department

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16

Process Flow of Fabric Store

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17

Inspection

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Defect Categorisation

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Spreading & Cutting

SPREADING

MARKER LAYERING

CUTTING MANUAL/AUTOMATIC

TICKETING

FUSING

CHECKING

BUNDLING

TRANSFER TO PRODUCTION
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Spreading

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Spreading Flow
FABRIC IS LOADED ON SPREADING MACHINE

PERFORATRED PAPER IS SPREAD ON SPREADING

TABLE
VACCUME IS TURN -ON IN THE SPREADING TABLE

AUTOMATIC/MANUAL SPREADING IS DONE

PROPER TENTION IS MAINTAINED WHILE

WHEN FINISHED, VACCUME IS TURNED OFF

MARKER IS SPREAD OVER IT AND PASTED BY TAPE

AIR FLOW IS GIVEN FROM BOTTOM

TRANSFERRED TO THE CUTTING TABLE

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Spreading Flow
Types of cutting devices:
1.
2.
3.
4.
5.
6.

5 fusing machine
16 straight knife
6 edge cutters
2 computer aided machines
4 spreader
1 round knife

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Lectra Automatic Spreader

Parameters

Value

Speed

100 m/min

Thickness can lay

30- 40 cm

Working width

2.5 meter

Length

20 meter

Suction Tables
Roll Weight

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150 Kg

24

Lectra Victor Automatic Cutter

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Parameters

Value

Speed

100 km/hr

Thickness can cut

6-7 cm

Cutting width

2.54 mtr

Cutting Length

3.5 mtr

Suction

4 kg/cm2

25

Straight Knife Cutter

Blade Size (inch)

Blade Size (cm)

12.7

15.2

17.7

20.3

Cutting Capacity 3 1/2

(inch)
Cutting Capacity 8.89
(cm)
Stroke Size (inch) 1 1/8

4 1/2

5 1/2

11.4

13.9

16.5

Stroke Size (cm)

8.89

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8.89

1 1/8

1/4
11.4

1/4
11.4

26

Fusing Machine

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27

Fusing Machine Specification

MODEL
POWER SUPPLY
RATED OUTPUT
FUSHING WIDTH
MAX.BELTSPEED
MAX.PRESSURE
MAX.TEMPERATURE
HEATING TIME
DIMENSIONS
WEIGHT

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HP-1000LW
Three phase
HEATER 21.6kw
MOTOR 705W
1,000mm
12.7m/min
5kg/cm2
198
6.5 31sec.
4,327 X 1,606 X 1,255mm
(Approx)1,500kg

28

Computer Aided Design

PATTERN MAKING
DIGITIZING
STYLE/PATTERN DESCRIPTION
GRADING
CUT ORDER PLANNING
MARKER MAKING
PRINTING FOR CUTTING

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CAD Software
Modaris
This software performs the
following functions:
o Pattern making
o Pattern modification
o Pattern digitizing
o Pattern grading

Main equipment
used:
Pattern pieces
Digitizer
Software
Plotter
FLY PEN
ALYS-30

Diamino
This software is used for marker making. It can be
manual or automatic. Efficiency of marker as decided
as per the garment in this seam allowances are also
added.
Optiplan
This software is used when buyers send uneven ratios.
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CAD Advantages
1. Significant reduction in lead times.
2. Reduction in labour costs for generating new styles &
modifying existing ones.
3. Achieving significant reductions in fabric utilization.
4. Blocks images stored in computer.
5. Grading technique replaced by expert system. So that
grading is now in the form of tables and auto matched.
6. Percentage wasted; computed and displayed for each
layout.
7. Fabric pattern constraints incorporate in the program.
8. Cutters replaced by CAD/CAM.
9. Wages reduced.

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Production Floor

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Sewing Department
Production floor follows Bundle system. Following are steps to
start a production line:
Study the production file.
Study operation bulletin and set line accordingly.
Manpower tailors and helpers.
Load and feeding lines.
Arrange buffer or work-in-progress.
Manufacturing.
Make daily production and to achieve targets accordingly.
Understand bottlenecks stage of production

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Working: Production Department

Shrinkage production pattern is issued to production floor from CAD
department.
Ready patterns are made as per the requirement of production room.
Cutting receives from cutting department.
Cross checking of cut panels with patterns.
Bundling of cut panels is done.
Operation wise feeding of cut panel into the line.
Inline checkpoints.
Output of line.
Final checkpoints.
Auditing of checked pieces.
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Laundry
To restore this aesthetic value, they are subjected to cleansing
process like washing.

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Type of Washes
Normal Wash
Desize Wash
Enzyme Wash
Stone Wash
Softener
Bleach
Acid Wash
Monkey Wash
Sand Wash

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Washes
Normal Wash

Softener Wash

Process

Time

Process

Time

Desizing

30 min

Desizing

20 min

Enzyme

30-60 min

Washing

30 min

Softener

20- 30 min

Enzyme Wash

Stone Wash
Process

Time

Process

Time

Desizing

30 min

Desizing

30 min

Enzyme

30-60 min

Enzyme

30-60 min

Stone

20 min

hypo chloride

30 min

hypo chloride

30 min

Neutralization

30 min

Neutralization

30 min

Softener

20 min

Softener

20 min

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Finishing
After assembly, the garments now come for finishing- a key stage of
garment manufacturing process. Finishing is done to prepare the
final garment according to the quality standards of the buyer before
packing it for shipment

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Process Flow: Finishing

GARMENT
COMES
FROM
PRODUCTI
ON

SENT FOR
PACKING

washing

ALTERATION

REIRONIN
G

MEASUREMEN
T

THREA
D
CUTTIN
G

INITIAL
CHECKING
AND
SPOTTING

FINAL
CHECHING

PERSENTATI
ON/FINAL
IRONING

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Finishing Machine Details

Finishing Machines

No. of Machines

Vacuum Table

60

Up Steam Table

Stain Removing Gun

13

Stain Removing W/S

Form Finisher

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Packaging
Packing is the last stage where the finished garments are
primed, organized, geared up for the shipment to the buyer,
the entire process from the way a garment will be folded to
the final labelling of the cartons is dictated by the buyers
specifications.

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Process Flow: Packaging

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Packing Norms
1. All garments packed in individual poly bags.
2. Poly bag sticker on poly bags, which may be printed by the
factory
3. Order must be completed (packed, ready for shipment)
prior to bulk orders.
4. Order must be inspected and audited by the factory 100%.
5. Order must be of first quality, no repair or ungraded
garments should be in license shipments.
6. Order must be shipped 100% complete otherwise notified.
7. The packed goods are now ready to be passed through

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AQL Parameters
AQL Chart
No. of
Cartons

Sample
Size

Pass

Fail

5-15

16-50

51-150

20

151-500

50

501-1200

80

1200-up

125

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Shipment Rejection Reasons

1.
2.
3.
4.
5.

Incorrect quality
Carton labeling error
Incorrect Prepackaging
Carton not as per specified size
Use of wire of metallic strap

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Visual Audit Standard

Shipment
Size

Sample
Size

Gap AQL
(2.5)
Level
Pass/Fail

Old Navy
AQL
(4.10)
Level
Pass/Fail

0-500

20

1/2

2/3

501-1200

32

3/2

3/4

1201-3200

50

3/4

5/6

320110000

80

5/6

7/8

1010035000

125

7/8

10/11

35000 >

200

10/11

14/15

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IE/R&D
Working of IE is as follows:

Calculating SMV
Making Operation Bulletin
Calculation of thread consumption
Designing of work aid devices; Folders, Guide & Profiles
Update SMV and finalize report
Prepare work station layout
Line setup
Capacity check analysis and feedback
Production study and increased efficiency

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Project
MONITORING OF LOST TIME & OPERATOR PERFORMANCE

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Project Outcome
During the project we observed that initially most of the times were
going waste in extra other activities like drinking water etc.
It was observed the operators were not flexible to work in the new
line setup thats why their performance was not up to the mark.
With the Help of this project the IE department of the Modelama
exports put some pressure on the operator not to waste the time on
other activities and increased the average performance of Operator
from 23.9 to 26%.

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Thank You
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50