REPORT ON APPAREL INTERNSHIP AT ORIENT CRAFT LIMITED

( 9K UNIT)

SUBMITTED BY: RIDDHI

MALVIYA

(B.F.TECH VII)

UNDER THE GUIDANCE OF:

ASST. PROFESSOR ANKUR SAXENA

25th May- 28th August

COMPANY PROFILE

• 1997Year established

• Mr. Sudhir DhingraOwners/ Directors

• FOB US$ 225 Million for 2014-15Annual Turnover

• 8000 in-houseNo. of people employed

MERCHANDISING

PRODUCTION PLANNING AND CONTROL

1. Order clarity meeting with marketing team 2. Receive the order

3. Plan to check if there is available capacity in

sewing to achieve the delivery date required

4. Plan to check the available capacity in non-

sewing areas (cut, embroidery; print, wash

and pack)

5. Plan to check sufficient lead time to order and receive fabric, trims,

approve sample, carry out lab tests

6. Confirm delivery date to customer and reserve

capacity

7. Plan Cut Date (PCD) follow-up

8. Communicate plan to sampling, cutting, sewing

and finishing

9. Monitor progress against plan and doing

the follow-up

FABRIC SOURCING AND AUDIT

Entry in excel

Shade segregation

TRIM STORE

ISSUE DEPARTMENT

CENTRAL PLANNING

QUANTITY & QUALITY CHECK

TRIM APPROVAL CARD

DATA ENTRY IN EXCEL SHEET

RECEIVING GOODS AT STORES

GOODS RECEIVED AT GATE

CENTRAL INDUSTRIAL ENGINEERING DEPARTMENT (IED)

Product Analysis(optimum method of

construction )

Product Costing Production Planning(line plan)

Performance Development

(SAM)

Method Engineering(man and material

movement methods)

Operator Training

SAMPLING

CUTTING

SEWING

WASHING DEPARTMENT

FINISHING & PACKING

Tagging

TESTING LABORATORY

•Decreasing alterations in the sewing room

PROJECT

OBJECTIVES

• To estimate the alteration percentage to get a quantitative prospective of problems

• To detect the major defects and its causes • To improve the quality standard from the

current status• To increase the profits which is the major

area of concern for any organization

TRAIN OPERATORS TO THE NEW WAY OF WORKING

Sustaining is as important as implementing

SUGGEST POSSIBLE MEASURES TO REDUCE DEFECTSAfter analysing the cost effectiveness

IDENTIFY THE MAJOR CAUSES OF DEFECTSDiscussing with line managers, using own knowledge

DETECT THE SEWING LINES HAVING MAXIMUM ALTERATIONComparing data from inspection table

Line 1( Day 5) Line 2 ( Day 2) Line 3 ( Day 3) Line 4 ( Day 6) Line 5 ( Day 7)0

200

400

600

800

1000

1200

1400

1600

1800

2000

Total garments produced

Number of alterations

1

• Woven’s Sewing room • Line 2Location

• 558015Style number

• Banana RepublicBuyer

• 10000 piecesOrder quantity

THE PROBLEM

Uneven placket width Problem of puckering, roping

•8-10 minutes per garment ( opening stitch, stitching again with increased focus and time)

Time required

for alteration

•2 workers•Salary = 6000*2 = 12000

Number of workers

involved in alteration

THE SOLUTION:Anti puckering kit

Contains needle plates and feed dogs.

Has a transparent glass guide.

Training provided to the operator on how to use the guide and

needle plate

Cost of anti puckering kit: Rs 180 per kit

( including delivery and basic training)

Day 1 Day 2 Day 3 Day 170

100

200

300

400

500

600

Total garments producedNumber of alterations

2

•Woven’s Sewing room •Line 3Location

•289221Style number

•Banana RepublicBuyer

•5000 piecesOrder quantity

THE PROBLEM

Roping and puckering at the bottom hem Causing unevenness

THE SOLUTION

Add a ‘stay-stitch’ at the hem before doing the final

hemming

Add one operator to the line and train him to do the stay

stitch

Reason for reluctance: adding an extra step?!

CURRENT SAM OF GARMENT : 28 MINUTES

ALTERATION % = 160/230 = 69% !

Thus, adding the alteration time, the final time comes out to be 28+8 = 36 minutes

Number of operators in line = 49 operators + 2 for alterations

Time taken for STAY STITCH= 1 minute 49 seconds

Thus, final SAM = 29 minutes 49 seconds

No extra operator required because one operator from alteration can be replaced here.

Day 3 Day 4 Day 110

50

100

150

200

250

300

Total garments producedNumber of alterations

3

New correct method to sew main label for clean finish from front & back : Nordstorm

Traditional method of attaching main label

In traditional method back side is not very neat after attaching main label and may result in alteration if tried to finish.

Not neat from back

Correct method to sew label for clean finish

• Step 1

Keep needle thread up with hand before starting the operation.

Note: Auto trimming function of sewing m/c need to be disable for labelattaching.

• Step 2

Start the operation and end with keeping the needle thread up.

• Step 3

Same on other side of the label with keeping the needle thread up.

After attaching label

Front side Back side

• Step 4

Finish the label by trimming the extra threads visible on front & back

Final view of label after finishing which is very neat from front and back.

Front. Back.

ComparisonTraditional method Correct method

Back view Back view

Not neat Neat & clean

Not neat Neat & clean

SPECIALIZATION: MERCHANDISING

THANK YOU