apparel internship at

8/4/2019 Apparel Internship At

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Presented By:Dipali Modi (07)

Rashmi Kumari(18)

AP VII (2008-12)

NIFT Kolkata

Apparel Internship atCHEERSAGAR


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OBJECTIVES

PRIMARY OBJECTIVE

To gain a full understanding of the working &operations of all departments in an export house with

main focus on quality parameters

SECONDARY OBJECTIVES

To understand each department needs Find ways of minimizing risk factors

Scope of reducing development and company cost


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COMPANY PROFILE

Year of Estd. 1991Annual Turnover (Rs.crore) USD 7.75 millionProprietory/Partner./Pvt. Ltd. ProprietorExport/Doms/Both./100%EOU ExportIn house /Fabrication/Both BothTotal Covered Area Sq. mt. 80,000SQ FTTotal Workforce 1100


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Focus on Ladies High Fashion GarmentsChildren GarmentsAccessories

Policies and certification ISO 9001WRAP CERTIFICATION

Awards State Award for Export Excellence presentedby HonbleChiefMinister for the year 1994-95National Award presented by HonblePresidentof India for the year 1995-96.

State Award for Export Excellence presentedby HonbleChiefMinister for the year 2003-04

Clientele Coolcat, HollandCecil Mcbee, Japan

Anna Sui, Japan Mujirushi, Japan Truworths, South Africa Brendisole, South America Cache Cache, France Eurodiff, France

Mudo, Turkey


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Organizational flow


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Process Flow

Sampling

Fabric Store & Inspection

Cutting

Sewing

Packing & Dispatch

Production planning dept

Merchandising

Finishing
http://process%20flow%20at%20client%20unit.docx/http://process%20flow%20at%20client%20unit.docx/


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PROJECT 1

OPTIMISING SAM AND THEREBYSTITCHING COST BY CLUBINGOF OPERATIONS


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:

To increase the productivity and decrease the stitching cost ofa style running in the sewing line.

METHODOLOGY:

Make operationbreakdown of thestyles

Perform time study

Identify operations thatcan be clubbedtogether
http://project%201.docx/


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PROJECT 2 : OPERATOR TRAINING

FOR FLOATERS


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Unavailability of skilled labour created qualityrelated problems

Absenteeism of the operators caused qualityrelated issues in the production process


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METHODOLOGY Primary Training: Basic Sewing & Machine

Control Training

Secondary Training:Adding on Skills to Existing

Operators & Improving the Efficiency of LowPerforming Operators


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Resources Required

Sewing Machines

One Sewing Instructor

Continuous Availability of Fabric, Thread & Needle

Cupboard of Documentation 1 White Board 4X4 1

Duster - 1, White Board Marker 4, PermanentMarker 1, Measuring Tape 5

Stop Clock -2


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Training Syllabus for Trainee

Operators


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STEP 1

Duration: 1 Day

Theory:

1. General idea of other departments in the factory.

2. Different types of Sewing Machines

3. Sewing Machine and its parts.

4. Threading sequence for different types of SewingMachines (S/N,O/L,D/N,F/L)


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STEP 2Duration: 3 Days

Practical

1. Treadle movement, Treadle Control PART-I

a. Running the machine at high Speedb. Running the machine at low Speedc. Running the machine at very low speed,d. Needle up & Needle down.e. Full speed & stop at stop points.f.Roughing exercises.

2. Different kinds of Stitches.

3. Different kinds of Fabric, and its general use.

4. Different kinds of Needles, Threads and their use.

5. Stitches per Inch (SPI) & Stitches per Cms (SPC) andadjustments.


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STEP 3Duration: 3 Days

Theory

Adjusting Sewing conditions

Needle change, Tension adjustment.

Selection of Needle, Thread and SPI for given Fabric.

Folders, Attachments and their use.Importance of Daily Machine Cleaning and Preventive Maintenance

check-up.

Practical

Fabric Exercises (Single ply) with threaded machine.1. Straight line (single ply)

2. Square (single ply)

3. Triangle (single ply)

4. Curve. (Single ply)

5. Circle or oval shape (single ply)6. Zi za Exercises.


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STEP 4:Duration: 3 Days

Practical

Exercises to improve handling & increase M/c time

Long practice on waste fabric

Practice of Run stitch, Edge stitch, pointed stitch, PrecisionStart & Stop & various

other sewing exercises.

Two ply attaching by Run stitch, Turn & stitchpointed or edge (kinari).

Theory

Structure and Principle of Assembly of Cloths.

Sewing Defects, Cause and Effect diagram, Trouble shooting.

Importance of Alignment while stitching and its importance toQuality.


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STEP 5:

Duration: 2 Days

Practical

1. Consolidate all the above steps.2. Common Operations in Garmenting of Different

Styles

a. Collar operation

b. Sleeve operations

c. Hemming Operations

3. Quality Exercises


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STEP 6: Released to Production Line & Follow up

Paper Exercise

Machine Exercise

Fabric Exercise


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PROJECT 3 : Control over needlebreakage/damage so as to reducemachine idle time


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Objective:

to study and analyze the probable reasons for theneedle damage and controlling it by providingprobable solutions to it and the safety measures

Time Duration: 2 Weeks


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Methodology:

Study for 5 consecutive days to find out the variousreasons which lead to the breakage of the needles.

Kept a record of all the needles that were broken duringthis period.

provided the linemen with a format that contained thedetails about the breakage ,operator name, machinetype, needle type, buyer, style no., supervisor name ,broken needle

After the observations were made for 5 days ,thesuggestions were passed onto the linemen and the linesupervisors to be implemented on the floor.

The observations again were made this time as to howmany needles broke due to avoidable reasons.


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Cause andEffect Diagram

Needle Breakage

Needle is insertedincorrectly

Needle clamp screw isloose

Bent needle beingused

Upper or lower threading is notcorrect

Upper thread tension is set too tight/high

Bobbin case not inserted correctly


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ObservationsREASON FOR BREAKAGE NO. OF NEEDDLES

DBX

1DCX1 UYX128 TQX1 TOTAL

Needle is inserted incorrectly 20 6 0 0 26Needle clamp screw is loose 21 7 3 0 31

Bent needle being used 9 5 0 1 15Upper or lower threading is not correct 11 3 2 0 16

Upper thread tension is set too tight/high 22 9 1 0 32Bobbin case not inserted correctly 18 4 0 1 23

TOTAL 91 34 6 2 154


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Broken Needle Control Procedure(hand and machine)

locate ALL pieces of the broken needle

Use of magnet

new needles to be issued on receipt of the old oneby authorized personnel.

The machine settings should be checked at randomfor any faults leading to needle breakage.


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Used Needle Control Procedure(hand and machine)

The factory must identify a person who will be responsible for theissue of needles.

All needles even if not broken must be checked regularly by the

supervisor to ensure that they are in good working condition.

No sewing operator should be in the possession of any spareneedles, used or new.

All spare sewing needles must be kept accessible only byauthorized personnel.

Hand sewing needles must have a control system were arecord is kept for issue and return of the needles at thebeginning and end of every shift.


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NEEDLES PRE AND POSTSUGGESTION

DB X 1 DC X 1 UY 128 TQ X 1

PRE-

SUGGESTION 91 34 6 2POST-

SUGGESTION 67 25 5 4


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GENERAL PROBLEMS IN THEDIFFERENT DEPARTMENTS ANDTHEIR SOLUTIONS...

DEPARTMEN PROBLEMS SUGGESTIONS


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DEPARTMENT

PROBLEMS SUGGESTIONS

Cutting Contract basis of cutting Abolishment of thecontract systemEmphasis on use of CAD

Sewing Absenteeism: Leads to a hugeefficiency loss.Lack of skilled operators

Reward schemesEmphasis on trainingoperators

Qualitycontrol

Average alteration % identified is 20%.There are no Pro Active decisions onquality taken.The Quality parameters are not clearlydefined.Quality records are not kept for styles

that were over

The processes should bemeasured using statisticalprocess control techniques todetermine current andpotential quality issues.There can be held zero-

defect days which wouldencourage the operators toproduce without defects.Employee communicationwith the management shouldbe encouraged about

obstacles to quality


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THANK YOU!!!

apparel internship at

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