Professional Documents
Culture Documents
Sponsored By
SANGAR OVERSEAS
Submitted by :
Preeti Rani
Msc.APMII
TABLE OF CONTENTS
INDEX
PAGE
TITLE PAGE:
ACKNOWLEDGEMENT
Through this project report I would like to thanks numerous people whose
consistent support and guidance has been the standing pillar in architecture of this
project. To begin with, my sincere thanks to the management of IAM for giving
this opportunity to experience and learn the processes practiced in Apparel
Industry.
For the completion of this documentI would like to thanksMs.Neera Chandra
(Course Coordinator APM) for being my mentor and my guide throughout the
project. I would like to express my sincere thanks to the Management and staff of
SangarOverseas Gurgaon for their outstanding support and cooperation in my
efforts to gain knowledge about the practical aspects of Apparel industries during
the Internship.
I am thankful to Mr.Hari Shankar Rajput (Sr. Production Manager), Mr.Keshav
Kumar, Mr.Kuldeep Singh (Sr. HR Manager) for the guidance and planning out the
schedule for the internship.
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.
Preeti Rani
DEDICATION
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 Sangar Overseas is a very good and important organization in
its work.
Internship at Sangar Overseas 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 collectedthis by following method Personal interview from various departments.
Close observation during work.
Internal data from various departments.
And secondary data was collected from the websites of Sangar Overseas.
COMPANY PROFILE
COMPANY NAME
ADDRESS
SANGAR OVERSEAS
PLOT NO 304, PHASE 4,UDYOG
VIHAR
GURGAON, HARYANA 122016
TELEPHONE
sales@sangaroverseas.com
WEBSITE
http://www.sangaroverseas.com
YEAR ESTD.
1984
Market
100% EXPORT
OWNER
Mr.RAJEEV SANGAR
DIRECTOR
Mr.RAJEEV SANGAR
ANNUAL TURNOVER
40 Crores
600
MONTHLY PRODUCTION
150000 pcs
SANGAR OVERSEAS
MANUFACTURER & EXPORTER OF READYMADE GARMENTS
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George UK
Rene Derhy-France.
Buyer for kids-wear
George-UK
Morrisons UK
Baby shop-UAE
Disney (for baby Shop and George, since we are a FAMA certified Disney
facility).
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FACTORY LAYOUT
FLOORS
DEPARTMENTS
Stitching
BASEMENT
a. Fabric Store
GROUND
b. Trim Store
c. Cutting Department
d. Human Resource
a.CEO office
1ST
b. Showroom
c. Director office
d. Merchandising
e. Stitching
f. Sampling
g. Quality
h. IT & Accounts
2ND
Finishing&Packing
3RD
Washing
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Work flow
BUYER
PRODUCT DEVELOPER
MERCHANT
SAMPLING
FABRIC
TESTING
MARKER PLANNING
SPERADING
CUTTING
BUNDLING
RESEARCH& DEVELOPMENT
PRODUCTION
WASHING
FINISHING&PRESSING
PACKING
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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
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PRODUCT DEVELOPMENT
CLASSIFICATION
PRODUCT DEVELOPMENT
INTERNAL DESIGNING
EXTERNAL DESIGNING
TECH PACK
OWN DESIGN LINE
INSPIRATIONAL
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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 andFollowing shipment.
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ORDER CONFORMATION
BUDGETING
INTERNAL
WITH BUYER
MATERIAL INDENT
RE SAMPLE /PROTO
(TRIMS DETAILS)
TYPE APPROVAL
FAVRIC PROGARAM
(FABRIC DETAILS)
FPT APPROVAL
PP SAMPLE
GPT SAMPLE
PURCHASE ORDER
1. Delivery date
6. Terms if sale
2. FOB
7. Currency
8. L/C
4. Destination
9. Quantity
5. Ship mode
In company employee work on WFX ERP software for making challan, purchase
order, indent etc. its very simple and useful software.
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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.
given period. Both the controlling and coordinating activities complement each
other and a merchandiser has to adopt the both accordingly,
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.
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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.
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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.
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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.
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STEP OF SAMPLING
PP SAMPLE MADE
TOP SAMPLE
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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.
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FABRIC STORE
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.
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FABRIC RECIVING
GRIEGEFABRIC
KEPT IN STORE
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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.
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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.
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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.
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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.
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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.
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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.
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GRADING
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.
Within TUKAcad, users have the ability to export to multiple file formats.
TUKAcad files can be exported to DXF, AAMA, or ASTM.
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MARKER MAKING
It determines the most efficient layout of pattern pieces for a specific style fabric
and distribution sizes.
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PATTERN ENGINEERING
An examination of the seam location to ensure the possible placement of
pattern in marker
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SPREADING
LAYERING
CUTTIN G MANUAL/
AUTOMATIC
TICKETING
FUSING
CHECKING
BUNDLING
TRANSFER TO PRODUCTION
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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
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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.
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CUTTING AVERAGE
The cutting department duties are not limited to mare cutting of the fabric. It is
responsible for keeping control over the total consumption of fabric per garment
piece cut this consumption is more specifically defined in terms of cutting average.
During marker planning, the CAD rule sends theoretical consumption of fabric as
per its marker, which is calculated as following:
Cutting average =
fabric
10,000
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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.
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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:
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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.
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SEWING DEPARTMENT
The basic aim of an export house is to deliver value satisfaction of the customer at
the profit level.
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.
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.
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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.
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WASHING
THREAD CUTTING
ALTERATION
REIRONING
FINAL CHECKING
PRESENTATION/FINAL IRONING
MEASUREMENT
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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
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IT IS THEN FOLDED
CARTON IS SEALED
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REFERANCE
http://www.sangaroverseas.com/
http://www.textiletoday.com.bd/
http://www.fibre2fashion.com/
http://garmentsproduction.blogspot.in/
textilelearner.blogspot.com
google.com
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