improvement in marker efficiency
DESCRIPTION
apparel internship report on improving marker efficiencyTRANSCRIPT
EXPORTS
NATIONAL INSTITUTE OF FASHION TECHNOLOGY
PRESENTED BY : HIMANI SAINI & SATENDRA BURNWAL DFT-VII
GARMENT INTERNSHIP AT
Tuesday, April 18, 2023
OVERVIEW
COMPANY PROFILE
DEPARTMENT WISE WORKFLOW
STYLES COVERED
PROJECT UNDERTAKEN
ANNEXURES
COMPANY PROFILE
CLASSIC MENSWEAR LINE (CML-UNIT)
MADURA GAREMNTS EXPORTS
ADITYA BIRLA NUVO
ADITYA BIRLA NUVO LTD
Powered by an intellectual capital of over 37,000 employees and an
optimum mix of revenue and profit streams, the company is a
diversified conglomerate and the platform that has launched many new
businesses for India’s premier business house, the Aditya Birla
Group.
Aditya Birla Nuvo has a balanced portfolio of traditional and new age
businesses under its fold, ranging from textiles to life insurance
MADURA GARMENTS EXPORTS
•Madura Garments Exports ,wholly owned subsidiary of Aditya Birla Nuvo
focusing on garment exports.
• Integrated player in the apparel industry with interest in manufacturing
exports of woven, knits and Full Service Provider business.
•The company has modern manufacturing facilities and caters to customers
like Marks & Spencer, Next and Menswear House
•Madura Garments is one of the leading export company based at Bangalore.
THE UMBRELLA OF MADURA EXPORT COMPANIES
MADURA GARMENTS EXPORTS
CLASSICC MENSWEAR
(CML)
RAMANAGRAM UNITEUROPA UNIT
CLASSIC MENSWEAR LINE(CML-UNIT)
Factory Name Madura Garments Exp Ltd (CML)
Address 288/8,Dodda Begur
City BangaloreState Karnataka
Postal Code 560068
Year of Establishment Nov-92
Factory Licence # MYB-8244Registration # MYB-8244Factory Land aria 153039.11 sq ft
Total Area Built Sq.Ft 123,432 sft
Nearest Airport - FOB BIA
Nearest Seaport - FOB CHENNAI
Regular # of working days in a WeekMonday to Saturday - 6days, 8.30AM to
5.00PM
Total # of Employees 1409
Ratio of male and female workers F-72%,M-28%
Total # Male Employees 225
Total # of female Employees 525
Total # of Staff 55
Maximum capacity (number of pieces produced per month) 80000 p/m
Minimum Wage 141.32 P/Day
Mode of payment Cash & Bank
Deductions PF,Canteen,Proffessional Tax
How many shifts are there One Shift
Total # of toilets 59
Total # of ladies toilets 40
Total # of gents toilets 19
Ratio of toilets per Male/female workers 25:01:00
What is the minimum hiring age of this facility? Above 18 yrs
Total # of Fire Extinguishers 109
Total # of First Aid Boxes 24
Toatal # of Fire Alarms 22Total # of Emergency lights 12
No of Emergency Exits 12
Factory Manager Mr. Shivaramakrishnan KWelfare Officer Ms.Sanju Cheriyan.Labour Turnover Rate(%) 5.00%
Committees
Canteen Committee, Prevention of Sexual Harassment Committee, Health
and Safety committee, Grievance / Workman Committee.
Factory Timings 8:30 am to 5:00 pmAverage wage paid 150/ dayPayment Date 7thSettlement Date 20th to 25thType of chemicals stored on-site: Acid,Rust Remover,Aciton.
•Calvin Klein
•TMW (Joseph and Feiss)
•Dockers
•Perry Ellis
•Diesel
•John miller
•Arrow
Clientele
•Factories Act, 1948
•Gratuity Act, 1972
•ESI Act,1948
•Pf and miscellaneous provision act, 1952
•Maternity benefit, 1954
•Child labor prohibition and regulation, 1986
•Minimum wages, 1948
•Payment of wages, 1936
ABIDED LABOUR LAWS
•Environment, Policy Health & Safety
•Freedom of Association & Collective Bargaining Policy
•Prohibition of Child Labour Policy
•Forced Labour Policy
•Sharp Tool Policy
•Broken Needle
•Personal Protective Equipment
•Compensation & Benefits
COMPANY POLICIES
•Policy on Non-Discriminations
•Working Hours
•Security Policy
•Prevention of Sexual Harassment
•Leave Policy
•Policy for Pregnant Women
•Employee Grievance Redressal Policy
•Policy & Product Discrepancy
•Policy on Safety in Warehouse
•Policy on Delay in Transit
PLANT LAYOUT(MACRO VIEW)
GROUND FLOOR
FIRST FLOOR
SECOND FLOOR
DEPARTMERNT WISE
WORKFLOW
THERE ARE 13 DIFFERENT DEPARTMENTS
• MARKETING AND MERCHANDISING
DEPARTMENT (Controlled From The Head Office For All Units)
• FABRIC DEPARTMENT
• TRIM STORE
• PLANNING DEPARTMENT
• CAD DEPARTMENT
• CUTTING DEPARTMENT
• SEWING DEPARTMENT
• FINISHING DEPARTMENT
• QUALITY ASSURANCE DEPARTMENT
• INDUSTRIAL ENGINEERING DEPARTMENT
• MAINTENANCE DEPARTMENT
• ACCOUNTS AND FINANCE DEPARTMENT
• HUMAN RESOURCE & ADMINISTRATION
DEPARTMENT
MERCHANDISING
ROLE OF MERCHANDISING
•Generation of orders depending on production capacity
• Sample approvals
• Purchase co-ordination
• Generation of BOM
• Delivery of shipment
• Time & Action calendar
•Buyer Communication
WORKFLOW
Customers For Business Costing
Negotiate The Buyer For
Price
Sample Construction For Buyers
Send Samples For Approval
Order Booking
Raise B.O.M For Trims
And Accessories
Arrange Sampling Yardage
Make Proto Sample
Send Proto And Wait For
ApprovalMake Test Fit
Send And Follow Up
For Approval
Check For Fabric And
Trims
Make Pre-production
Sample
Send And Follow Up
For Approval
Issue Work Order Sheet
Follow Up With
Purchase
PRODUCTION
PLANNING Coordination REGARDIN
G LINE PLANDaily Follow
Up With Production Department
Work With Documentation Department And Arrange
For Cargo For Delivery
Dates
Ensure Timely
Shipment Of Production
Follow Up For Payments
SAMPLING
WORKFLOW
Sampling Indent Received
Depending On The Buyer Requirements,
Fabric Is Used( Actual Or
Available
Development Sample
1st Proto SampleFit SampleSize Set Sample
Pre-production Sample
Top Sample Or Ruck Sample Shipment Sample
MAN & MACHINE
TYPE NUMBER
SNLS 13
BARTACK 2
5 THREAD OVERLOCK 3
4-THREAD OVERLOCK 1
3-THREAD OVERLOCK 1
PATTERN CUTTING TABLE 2
IRONING TABLES 2
MANPOWER : 20
FABRIC STORE
Capacity Of 1.5 Lakhs Meter Fabric
100% cotton
Polyester cotton Polyester viscose
Polyesters viscose + lycra 100% cotton + lycra Polyester wool
Pocketing fabric
MANPOWER : 17
WORKFLOW
Fabric Received From The Mill Unloading
Temporary Storage For
Incoming Goods
Width Checking
Visual Inspection
Sending Report To CAD
Department
Receive Requsition
Issue Materials
Sample of BIN CARD used for Tagging of Fabric Rolls
PLANNING
Objectives of the planning department:
• Effective utilisation of production capacity
• Minimum start up losses
•To plan the entire department works and timing those in such a way that the goal that is shipments at right time should be carried out.
•To make cutting plan
•To decide the capacity of different lines and load accordingly
•To rework the plan if previous plans fail to meet
•Alarm the corresponding section when they start failing to meet the plan
CAD
Receive hard pattern
Digitise
Grading
• Average marker efficiency for all the brands is around 87%.
•Software used is GERBER Version 8.08
Summary Of Fabric Inspection Report(Issued from Fabric Dept to CAD Dept)
TRIM STORE
• Store Capacity 2.5 Lakhs apprx
• Maintain a 60 Days Stock
•Pocket flasher
•Hang tag
•Barcode tag( UPC,
unit price cost tag)
•Joker tag
•Plastic clips
•Metal clips
•Hanger
•Poly bags
•Tissue paper
•Threads
•Labels
•Buttons
•Zippers
•Carton boxes
•Barcode stickers
•Size stickers
•Tack pins
•Loop pins
•Pack support
MANPOWER : 12
WORKFLOW
Incoming goods Unloading
Temporary storage of incoming
goods
Quantity check
Quality check
Storage in racks
Issue when required
Accept returns from
sewing and finishing
Advice purchase
and merchandi
sing department
Sample Of Trims Approval Card
CUTTING DEPARTMENT
TOTAL NO. OF LAYING TABLES: 4
WIDTH OF LAYING TABLES: 1.86 meters
Table 1= 17 meters
Table 2= 14 meters
Table 3= 25 meters
Table 4= 25 meters
Spreading is done manually & follow FOW NOW mode
LAYING CARD CUTTING QUALITY REPORT CUTTING ISSUES REPORT
MATERIAL FLOW
Fabric Store Department Fabric Receipt
SpreadingCutting
Numbering
Panel inspection:
Fabric defect, size, shape,
notches
Re-cuttingFusing
Bundling Issued to sewing lines
WORKFLOW
NAME MAKE QUANTITY MODEL BLADE TYPE
Straight knife hand
cutter
EASTMAN
Speed - 2850 rpm
10 BLUE STRAEK-
II
Straight knife
Band knife EASTMAN 4 EC - 700 Continuous
blade
End cutter EASTMAN 6 EC - 3 Round blade
Drilling machine EASTMAN 3 CD - 3 -
Flat bed fusing
machine
HERBERT 2 CE-RPC-200 -
Continuous bed
fusing machine
RELIENT 4 EC – RPSL – 400 -
Die machine - 2 - -
MANPOWER :56
MAN AND MACHINE
SEWING DEPARTMENT(TROUSER LINE)
• TAILORS-58• HELPERS-14• IRONERS-5• CHECKERS-5
LINE-1
• TAILORS-59• HELPERS-13• IRONERS-7• CHECKERS-4
LINE-2
• TAILORS-61• HELPERS-13• IRONERS-6• CHECKERS-5
LINE-3
• TAILORS-56• HELPERS-15• IRONERS-7• CHECKERS-5
LINE-4• TAILORS-55• HELPERS-15• IRONERS-6• CHECKERS-5
LINE-5
• TAILORS-42• HELPERS-9• IRONERS-3• CHECKERS-3
LINE-6
MACHINE CAPACITY
Double Pleated Single Pleated Flat Front
Trouser with Knee Lining Trouser Without Lining Trouser With Bottom Cuff
Trouser with Normal Bottom Hem Casual Trouser
MATERIAL FLOW
REPORTS GENERATED
•In-line Inspection Report
•In-line Check Points Checker Report
•WIP Report
•Production Report
•Efficiency Report
•Absenteeism Report
IE DEPARTMENTCalculate SAM of
the garment ordered to calculate different
consumptions
Work measurement of a new confirmed
order
To advice production
department on garment SAM and
line layout
Day to day activity
To calculate line efficiency
To calculate operator efficiency
Time and method study
Line balancing
Check for work aids and compliances
Batch setting
Multi Skill Matrix Grade Sheet
FINISHING
Garments received
Parts ironing
Full manual ironing
MACHINES LIST
WRINKLE FREEGarments received
Weighed and tested
Wrinkle free is done
Weighed and tested again
Final finishing
Sent to dispatch
TECHNOLOGY USED
•Pre-cure
•Post-cure
•Garment-dip
•Spray(metered) application
•Vapor phase
MACHINES LIST MANPOWER-52
On each carton box, there is a barcode sticker which contains the following details :
BUYER DETAILS
BRAND NAME
COUNTRY
Each shipment is sent to the buyer along with a Packing List or Container Loading
Clip, and Order Completion Report.
PACKING & DISPATCHTypes of packaging done are:
•Simple packing
•Hanger packing
•Clipboard packing
Warehouse Capacity =30000 - 35000 Garments.
Requirement of packing:
•Remove dust
•Folding
•Price tag and back pocket flasher, size slip
•Put chip board for support
•Clip
•Poly bag
•Size wise packing
•Issue for ware house
QUALITY ASSURANCE
INSPECTION AREAS•Fabric & trim inspection
•Cut parts checked for measurement and notches
•In-line inspection
•End line inspection
•Dry process inspection before wash
•Dry and wet process inspection after wash
•In-line finishing inspection
•Final inspection
ROLE OF THE MAINTENANCE DEPARTMENT:
•Servicing of machine
•Checking of Boilers for steam
•Electricity supply—if power is gone then starting of generator
•Building maintenance
•Oil change
•Replacement of defective parts
•Servicing of Motor
•Checking of Motor
MAINTENANCE DEPARTMENT
PROJECT
ON
MARKER EFFICIENC
Y
STYLE COVERED
TMW29BJ0058
VH216
•TECH PACK•TNA•OPERATION BREAKDOWN•THREAD CONSUMPTION•TIME STUDY•CUTTING•SPREDING
•OPERATION BREAKDOWN& TIME STUDY
•TNA•CUTTING•SPREADING
ANNEXURES
• COMPANY PROFILE
• CAD EVALUATION
• SOFTWARE EVALUATION
• ORDER TRACKING SHEET
LEARNING OUTCOME•Understanding of the different departments working at the factory
•Inevitable constraints for any operation
•Understanding the importance of workforce and results of absenteeism on
production
•The process flow of Merchandising Department and the steps involved in
sample approvals.
•The above areas of understanding made us more aware of the sewing floor
operations, finishing floor operations and cutting and spreading room
operations.
•The learning experience was also a helping tool in making us aware of our role
as policy makers at the ground zero, level one or senior level manager level.
REFERENCES
MR SHIVRAM (FACTORY MANAGER)
MR PARTHIBAN (PRODUCTION MANAGER, CML-UNIT)
MR RAM MOHAN (PROJECT TEAM MEMBER, EUROPA UNIT)
MR KAUSHAL NAIR (QUALITY HEAD, EUROPA UNIT)
BOOKS
TECHNOLOGY OF CLOTHING MANUFACTURING BY CARR & LATHAM
APPAREL MANUFACTURING BY JACOB SOLINGER
LINKS
http://www.indo-gulf.com/maduragarments/index.aspx
http://www.indo-gulf.com
Thank You