Professional Documents
Culture Documents
ON
Submitted to:
Mrs Rupsha Burman
Assistant Professor
Submitted by:
ROHIT SINGH
00514188814
STUDENTS UNDERTAKING
I hereby certify that this is my original work & it has not been submitted elsewhere.
ROHIT SINGH
PROJECT GUIDEs
Faculty Name :- Rupsha Burma
Designation ;- Assistant Professor at Jagannath International Management School
TABLE OF CONTENTS
INDEX
PAGE
TITLE PAGE
ACKNOWLEDGEMENTS
DEDICATION
EVALUATION FORM
EXECUTIVE SUMMARY
COMPANY PROFILE
ABOUT COMPANY
11
PRODUCT DEVELOPMENT
19
MERCHANDISING DEPARTMENT
20
SAMPLING DEPARTMENT
28
30
FABRIC STORE
31
FABRIC INPECTION
34
TRIMS STORE
36
CAD DEPARTMENT
38
SPREADING DEPARTMENT
43
SEWING DEPARTMENT
49
WASHING DEPARTMENT
51
FINISHING DEPARTMENT
52
PACKAGING DEPARTMENT
53
REFERANCE
57
TITLE PAGE:
ACKNOWLEDGEMENT
ACKNOWLEDGEMENT
It is a matter of great satisfaction and pleasure to present my summer internship
report at JJ FABTEX PVT LTD on FUNCTIONING OF AN EXPORT HOUSE.
I further wish to place on record my deep sense of gratitude to Mr. Mayank Dixit
for his excellent guidance and constant encouragement in all the stages of my
project work and for sparing his valuable time for providing me with his
suggestions.
I express my profound gratitude to Mr.Sanjeev Singh for providing help and a
congenial work environment, which was a catalyst for a great learning experience.
I am deeply indebted to Rupsha Mam for their valuable contribution during the
academic session.
Last but not the least, I would like to thank everyone I was associated with, whose
names have remained unmentioned here, but who have contributed by giving me a
sharp and gratifying imminent approach and insight during the course of my
project.
I would like to grab this opportunity to express my sincere gratitude to
Ms.PartibhaKathuria(Merchandiser),Ms.Kanika (Merchandiser) for guiding me
through all the processes involved in the processing of the fabric and was patient
enough to answer all my doubts and queries.
I would specially like to thank all the staff members and workers for helping me
throughout the internship. Without their support, it would have been difficult job to
successfully complete the training.
ROHIT SINGH
EVALUATION FORM
EXECUTIVE SUMMARY
In the past two decades, the Indian textile industry in terms of home textile,
garments and accessories have a witnessed a complete transformation in terms of
quality, market and product development as well as the expansion, In this scenario
export house plays the major role in the growth and conduct of exports. Looking
from this perspective JJ Fabtex Pvt ltdis a very good and important organization in
its work.
Internship at JJ Fabtex Pvt Ltd has been a great exposure for the practical
application of my learning. I gained knowledge about actual work culture of the
company and how to deal with the people at workplace.
I did my internship in Production, Merchandising and Sampling Department.
OBJECTIVE
Objective of the study is to learn about the functioning of export house and
working of various departments particularly production, merchandising and
sampling, earning knowledge about different departments of the company, their
function and information flow during work.
DATA COLLECTION METHOD
I Collected this by following method Personal interview from various departments.
Close observation during work.
Internal data from various departments.
And secondary data was collected from the internet.
COMPANY PROFILE
COMPANY NAME
ADDRESS
A-87,sector-63,Noida-201303
G.B. Nagar(U.P)
TELEPHONE
0120-4307818
fabrics@jjfabtex.com
WEBSITE
YEAR ESTD.
2003
Market
100% EXPORT
OWNER
DIRECTOR
ANNUAL TURNOVER
30 Crores
600
MONTHLY PRODUCTION
150000 pcs
JJ FABTEX PVT.
LTD.
MANUFACTURER & EXPORTER OF
READYMADE GARMENTS
10
11
13
FACTORY LAYOUT
FLOORS
DEPARTMENTS
BASEMENT
Stitching
a. Fabric Store
GROUND
b. Trim Store
c. Cutting Department
d. Human Resource
a.CEO office
ST
b. Showroom
c. Director office
d. Merchandising
e. Stitching
f. Sampling
g. Quality
h. IT & Accounts
2ND
Finishing&Packing
3RD
Washing
14
1
5
Work flow
BUYER
PRODUCT DEVELOPER
MERCHANT
SAMPLING
FABRIC
TESTING
MARKER PLANNING
SPERADING
CUTTING
BUNDLING
RESEARCH& DEVELOPMENT
PRODUCTION
WASHING
FINISHING&PRESSING
PACKING
16
LIST OF MACHINERY
1) BROTHER SINGLE NEEDLE HIGH SPEED LOCKSTITCH MACHINE
400
20
04
04
04
04
25
02
01
10
02
04
01
14) HYDRO
03
17
03
20
20
02
02
02
12
02
02
02
02
82
02
02
02
04
02
02
02
18
PRODUCT DEVELOPMENT
PRODUCT DEVELOPMENT
INTERNAL DESIGNING
EXTERNAL DESIGNING
TECH PACK
OWN DESIGN
LINE
INSPIRATIONAL
19
MECHANDISING DEPARTMENT
Merchandising is a specialized management functions within the fashion industry.
It is the business that moves the world fashion from designers showroom to retail
sales floor and in to the hands of consumers. It is the internal planning that takes
place within a retail organization in order ensures adequate amount of
merchandise are on hand to be sold at prices that the consumers are willing to pay
to profitable operation.
Following are the responsibilities of merchandisers which gives importance to
them
1. Internal& external communication,
2. Sampling,
3. Lab dips,
4. Accessories& trims,
5. Preparing internal order sheets,
6. Preparing purchase orders,
7. Advising and assisting production,
8. Advising quality department about quality level,
9. Mediating production and quality departments,
10.Giving shipping instructions and following shipping,
11.Helping documentation department,
12.Taking responsibility for inspections and Following shipment.
20
ORDER CONFORMATION
BUDGETING
WITH BUYER
INTERNAL
RE SAMPLE /PROTO
MATERIAL INDENT
TYPE APPROVAL
(TRIMS DETAILS)
(FABRIC DETAILS)
FPT APPROVAL
PP SAMPLE
GPT SAMPLE
21
PURCHASE ORDER
1. Delivery date
6. Terms if sale
2. FOB
7. Currency
8. L/C
4. Destination
9. Quantity
5. Ship mode
Communication:
It communicate
is one of the foremost
functions
of of
merchandiser
the
merchandiser
has to
with different
levels
people in hisbecause
day to day
activities.
Planning & Programming: A merchandiser has to check the order requirement,
planning for the given order, programming for various activities, proper allocation
of work to the assistants.
Follow ups: It includes sending of samples at various stages of order, buyer and
buyer house for sample and other approvals.
Decision making: A merchandiser has to make several decisions during the order
processing like giving approvals like fabrics, color, design, accessories, and
packing, selection of suppliers and vendors, selection of buyers, sometimes time
extensions for order shipment.
Sourcing & Purchasing: A merchandiser may have to do sourcing and purchasing
for raw materials and accessories, suppliers and vendors, new designs, new buyers.
Controlling: This is the crucial activities for any merchandiser. A merchandiser
has to make sure that all the activities are carried out as per the planning and
even if there is any deviation, he/she should make the alternatives measures.
given and
period.
Both the controlling
and the
coordinating
activities complement each
other
a merchandiser
has to adopt
both accordingly,
Negotiation: It is the activity of convincing, compromising and cooperation which
would benefit the both parties involved in the negotiation.
Costing: It is the process of estimating the expenditure of a given product and the
subsequent price. It is another crucial function because mostly order
conformation depends on the price offered to the buyers. The merchandiser
should know the current prices and rates of various products and processes to do
the accurate costing.
Meeting: There are two types of meeting a merchandiser has to be involved. First
type, a merchandiser has to conduct the meeting with the concern department in
charges to discuss about the proceedings and the status of the running order. In
second type, a merchandiser has to attend the meeting with the superiors or buyers
or business people in giving reporting or participation or discussion.
Forecasting: Forecasting is the activity of predicting the future happenings or
problems. A merchandiser has to predict the future uncertainties in the current
order or industry so that alternative actions or corrective measures can be taken
in advance this also includes giving suggestion or ideas about new technologies
or new products or latest industry trends.
Function of the quality control department can vary widely. But most common
function of quality control depart are as follows
Testing of of raw material: Quality control department does not conduct testing
of raw materials but they send sample to testing lab for testing physical and
chemical test. Once factory receive test report, quality control team get
assurance whether raw material to accept or not.
26
Preparatory work inspection: In high fashion garment, lot preparatory work are
outsourced like, printing, machine embroidery, bead work, special decoration on
garments etc. Before feeding this outsourced goods, quality department checks
and approve for further process (sewing process).
Finishing Process: Finally quality personnel checks finished and packed goods
and do auditing prior to handover shipment to external inspector.
Quality System Development
To make quality product throughout the garment manufacturing process, factories
need to develop quality system. Quality Control Department is responsible for
setting quality system for the factory.
27
SAMPLING DEPARTMENT
In an export house, the sampling department play vital role in the up- lifting of a
unit. This department directly coordinates with the merchandising dept. and
production dept. sampling is done to see how the product will look when
produce in bulk and to check discrepancies in the pattern are.
28
STEP OF SAMPLING
PP SAMPLE MADE
TOP SAMPLE
29
Fabric sourcing means souring the right kind of fabric which fulfils the
specification. Fabric sourcing department is quite important as more than 90%of
garment is fabric and approximately 70% cost of garment is due to the fabric cost.
Selecting the right quality of the fabric as per the buyers specification otherwise it
may lead to cancellation or rejection of the whole order given by the buyer. The
fabric sourcing department gets the fabric sample from the vendor. These samples
are tested before sending to buyer for approval. After the buyer approves the
sample, the fabric is order for bulk production.
TYPE OF FABRIC
Predominantly woven fabrics solids & printed voiles, cambric, poplin, yarn dyed
(mainly auto-loom & mill-made), complete range of polyester fabrics, viscose,
mill made twill, canvas, denims.
We are also doing woven knit combo wherein top is mainly woven and bottom
leggings in s/l ctnlycra + poly s/j linings for see through dresses & tops in
polyester.
30
Fabric storehouse actual are where the fabric for production is receive or
dispatched for processing. Beside storage the fabric store department is also
responsible for the inspection of good receives by it.
31
FABRIC RECIVING
SOLID /YARN
DYED
/PRINTED
GRIEGEFABRIC
32
STORAGE
Rack system of storage is followed i.e. packages are stored in two areas:
1. Check fabric
2. Unchecked fabric
They are further segregated on the basic of style no. and lot wise. The fabric
rolls are put in rack manual way. Such systematic maintenance of the store
makes it easy to make the fabric whenever needed in future.
The fabric via transport trucks comes in various packages like rolls, book fold etc.
each consignment comes in with an invoice having details like quantity, color,
GSM, and weight. The goods are weighted and other detailed are reconfirmed
before they store.
33
FABRIC INSPECTION
The fabric being the main contribution to development of our final product i.e. the
garment, it is very important to control its quality indicated by the no. of faults and
various present in it. Identification of these objectionable variations and faults right
at the initial stage to reduce the production time. So once the fabric is in- house it
is immediately sent on a pilot and trolley assembly to inspection.
4 POINT SYSTEM:
4 Point system for fabric inspection is widely used in apparel industry for fabric
quality inspection.
1. Fabric inspection method or preparation.
2. Criteria of giving penalty points based on defects and defect length.
3. Calculation method of total penalty points for total defects found in a fabric
roll.
4. A Check sheet or format for recording data.
5. Knowledge of different types of defects (how a defect looks and
its appearance).
Criteria for giving penalty points
The penalty evaluation points have been given for different length of fabric defect
and dimension of holes.
34
SIZE OF DEFECT
PENALTY
POINTS
4
Holes and openings(largest dimension)
1 inch or less
Over 1 inch
Example: A fabric roll 120 yards long and 46 inch wide contains
following defects.
35
4x1
4 points
3X2
6 points
2X3
6 points
1X4
4 points
1X4
4 points
24 Points
Therefore,
= 24*3937/109.72*46
= 18.72 points
TRIMS STORE
Trims store as the name suggests is a department, which acts as a storehouse for
accessories. It is the place where all the accessories required in an export house,
are stored. Right from sewing thread, needles to packaging material mike poly
bags and taps etc. all are stored in the accessories store.
36
The merchandiser as per buyer specifications order the purchase dept. to buy the
accessories that are used in a particular style of that buyer. Merchandiser prepares a
swatch card containing all the accessories and their quantity in a cycle. These
accessories used in the swatch card are as per the quality and color mentioned and
approve by the buyer. The purchase dept. with help of swatch card prepared by the
merchandiser purchase the required quantity of accessories. The accessories are
purchased 10 15% extra then the required, as the wastage in case of accessories is
more. The receiving dept. then receives these accessories from the vendor and then
checking and testing of these accessories are done. They are checked quality and
color. The accessories like buttons are tested with help of button snap tester.
After all accessories are checked and tested as per the buyers specification then
an accessories approval card is prepared.
After the accessories are received they are stored in the accessory store. The
accessories are stored in different racks. The accessories of a single buyer are
stored in one rack but the different accessories are stored separately from each
other in the same rack. The accessories store also houses the stationary required in
export house.
Now, whenever the production starts the accessories required in production are
issued to the production dept. through an internal channel. A stock register is used
for maintaining records. Thus an accessory store function as a store house for
accessories where all accessories are assembled and kept and also issued to
sampling and production dept. for the garment manufacture.
37
CAD DEPARTMENT
Computer Aided Design (CAD) becomes an essential tool for pattern making and
related jobs in garment industry. In apparel industry CAD Software is used for
pattern making, Grading of pattern, marker making and digitizing manual patterns.
CAD system involves any type of design activities which use of to develop
analyses or modify any engineering or garment design.
TUKA CAD Software which is used for computer aided designing in SANGAR
OVERSEAS.
TUKAcad is an innovative apparel pattern making software that is perfect for
manufacturers and designers of any size. Operating under Microsoft Windows,
TUKAcad allows the user to accurately builds patterns, grade rules and markers for
single styles or entire lines. It is the advanced pattern making, grading and marker
making system that will streamline your production process and reduce operating
expenses.
Fabric Matching
Engineer pattern pieces according to fabric prints, stripes, or plaids. Fabric
print can be transferred to Marker Making for perfect matching. TUKAcad even
accomodates the flaws in warp control.
38
G R AD I N G
Build block libraries with "master grading." Changes made to base pattern are
automatically reflected in entire size range eliminating need to recalculate grade
rules. Easily insert size in between current sizes and the system will
automatically divide the grading in half.
E X P O R T I N G F I L E F O R M AT S
Within TUKAcad, users have the ability to export to multiple file formats.
TUKAcad files can be exported to DXF, AAMA, or ASTM.
39
MARKER MAKING
A marker is a diagram of precise arrangement of pattern pieces for size of specific
style that are to be cut from a single spread.
Marker making is a process of developing a diagram which is superimposed on
the top of a ground of superimposed piles as a guide for cutting these plies.
It determines the most efficient layout of pattern pieces for a specific style fabric
and distribution sizes.
40
SPREADING
LAYERING
CUTTIN G MANUAL/
AUTOMATIC
TICKETING
FUSING
CHECKING
BUNDLING
TRANSFER TO PRODUCTION
42
SPREADING DEPARTMENT
Spreading is the process of smooth layering of fabrics in superimposed layers
of specified length. After fabric is received it is issued to spreading department
for further processing. Spreading is done with the type of fabric, print of fabric
and marker issued by CAD dept.
PROCESS FLOW OF SPRADING
FABRIC IS LOADED ON SPREADING MACHINE
43
CUTTING DEPARTMENT
Cutting means to separate out different garment process from the lay of fabric with
the help of cutting template and devices. It is done to get required shape in
different no. or as a whole to make a complete product. The first stage in the
manufacture if garment is the cutting of material into the necessary pattern shapes.
These patterns are joined to form a garment when large amount of garment style
has to be cut, a lay is created, which consist of many piles of fabric spread one
above the other. Now all the pattern pieces for all sizes are from this lay. The main
objective of the cutting dept. is the cutting of garment parts accurately and
economically and in sufficient value to keep the sewing room supplied with work.
Objective:
To maintain the quality of the cut components.
To cut the raw material in required shape and quality.
Availability of cut components on time.
BASIC WORK FLOW
Cutting department receives the order for cutting a garment style from the
production manager. Cutting order is an authorization by the production manager
to cut a given amount of styles, from the spreads. It comes in from of a package
file that carries the following details:
44
Cutting average = Area of one piece in the marker (cm square)* GSM of the fabric
10,000
45
Cutting average is used to determine the cost of raw material that is fabric for
each garment. Hence it is very important that it is maintained airing the bulk
cutting also. The cutting manager finds out his actual cutting averages before the
bulk cutting and tries to keep it close as possible to average predicted by the CAD.
TICKETING
Once the pattern pieces are cut by the cutting machine, they are then ticketed.
Cut components are group together as per their sizes and taken to the checking
table. Here the cut components are inspected for any error. It is very important to
take care that pieces cut from two different bolts of fabric are not mixed up. This
is because within lot there bolt to bolt variation in colour shade.
46
FUSING
Fusing is also carried out in the cutting room itself. The parts to be fused are
separated from the bundle. The fusing material (like interlining) is cut according to
size of the component to be fused. The component along with the cut fusing
material are kept between to paper sheets and the pack is passed through the
fusing machine by means of temperature and pressure fusing takes place at
particular speed and for a particular time. The pack comes out at the other end on
conveyors and the pieces are removed and re-bundled.
Parameters affecting the fusing process:
47
CHECKING
The ticked panels are now sending to the checking are for inspection of every
individual pieces for any objectionable faults. Panels having faults like wrong
grain line, in appropriate size, incorrect shape and any fabric defects likes holes,
cut , shade, variation etc. That are not within the acceptable quality parameters, are
removed from the cut lay. A cutting component checking report is filled for the
total quantity cut, checked and approvals. The rejected pieces are sent back and
equal no of trash panel are separately cut, replaced in the set and ticketed with the
same no. as the rejected once. Other mend able faults are marked with an alteration
sticker and passed on. These will be spotted out during garment finishing or
washing.
BUNDLING
The checked components of one style and in one size are now clubbed and
bundled using tie. The size of bundle depends upon the requirements of the
production plant. Each bundle will contain pieces of same style and same size
only. These pieces are stored in racks made beneath the cutting table. The cutting
department issues the amount required by the production dept. as and when ask
for. The cut component may be issued in instalment or all at once as the needs of
the production dept. against the job order.
48
SEWING DEPARTMENT
The basic aim of an export house is to deliver value satisfaction of the customer
at the profit level.
Production is an act of producing i.e. quantity obtained by multiplying two
quantities to gather by making use available resources.
To deliver quality with the quantity the ratio between input resources or material &
output good and service is known as productivity are reciprocally related to each
other. Therefore an increase in production leads to fall in the cost per unit & rise in
profit.
The production department is spread in two floors, ground floor and first floor is
for jacket, blazer and basic garment. Both floors have common cutting dept. so
all the sizes of bundles are received from there only.
Production floor follows assembly line system. Following are steps to start a
production line.
To study the production file.
To study operation bulletin and set line accordingly.
Manpower operators, checkers, quality controller and helper.
49
WASHING DEPARTMENT
Garments pass through various handling processes, which may render them dirty
and stain, thereby reducing their aesthetic appeal. To restore this aesthetic value,
they are subjected to cleansing process like washing and dry cleaning. Garments are
sent for washing by the production department as per the buyers requirement.
Normally the fabrics are not asked to go for wash by the buyer. Whether the fabric
department may internally sent it a number of other reasons.
51
WASHING FACILITIES:
ENZYME,
STONE WASHING,
OVERDYEING ETC
FINISHING DEPARTMENT
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.
52
WASHING
THREAD CUTTING
ALTERATION
REIRONING
FINAL CHECKING
PRESENTATION/FINAL IRONING
MEASUREMENT
Final thread cutting minute thread like those of labels, bar tack etc. are
trimmed off to give the neat look. Thread loosely sticking to the garments is
also shed off, both in and out by jerking the garment before it goes for
pressing.
Pressing pressing in general is shaping the assemble material with
pressure, with/ without heat and moisture, for further processing. In case of
knits, this is important but not as significant as in the case of woven
because of their property of excellent recovery and fit.
Measurement and final checking this is the final and most stringent done for
garment measurement, appearance, labels, trim etc to study the final look and
shape the final look and shape of the product produced. Measurements are done
according to the specification sheets and recording are made for any variations in
the measurement chart. This gives an overall idea about the quality of the
garment being produced.
PACKAGING DEPARTMENT
55
IT IS THEN FOLDED
CARTON IS SEALED
56
57