NISHAT MILLS

LIMITED
(APPAREL DIVISION)
7-KM Nishat Avenue off 22-KM Ferozepur Road
Lahore, Pakistan.

NISHAT
INTERNSHIP REPORT
WORKED BY:
MUHAMMAD KAMRAN S/O MIR WALI
KHAN
FARMAN ULLAH S/O UMER KHAN
SUBMITTED TO:
MAJOR

(R)

SYED MUBEEN RAZA

(MANAGER HR & ADMIN)

DATE: 14-March-2014
ACKNOWLAGMENT
All praises to Allah Almighty, the one and the only, the Merciful,
Beneficent and Compassionate. !I would like to acknowledge the following
people for their support and assistance with this orientation. From HR
Department to SHIPING in the supervision of our dears MAJOR. MUBEEN
RAZA manager( HR department) ,DEPT manager KHALID MEHMOOD
SANDHU(HR) , SAQIB SHAHZAD (HR) , Mr.KASHIF QAYYUM (PPC department),
Mr.WASANTHA (P.D department) ,(Mr.JAWAD KHALID MMC department),
Mr.ABDRUL REHMAN (FABRIC INSPICTION department), Mr.GULAM MUSTAFA
(CAD,ABROIDERY,CUTTING department) Mr. ZAKIR HUSSAIN (SEWING A
department), Mr. SHAFQAT AZIZ (SEWING B department), Mr.NIMAL and
(ENGR IRFAN AKHTAR) IE department) ,Mr. ABDRUL REHMAN (QUALITY
ASSURANCE department) ,Mr. MUHAMMAD NAEEM BUTT( G.W.P department),
Mr. IFTAHAR ALI AWAN (FINISHING AND PICKING department) ,Mr.NIAMAT
ULLAH (SHIPPING department) . This report would not have become
possible without their help and guidance. Special thanks to Mr. Khalid
Mehmood sandhu & Mr. Saqib Shahzad for their support and care during the
Orientation Programme. I want to thank Nishat Apparel staff for their
cooperation and constant exchange of information was very satisfactory
throughout the time and proved to be a key to optimizing output with
regard to the project goals.! I found this Orientation Programme to be a
very positive experience and a unique opportunity for me to gain some
Textile experience. !

MISSION STATEMENT
At Nishat apparel mills limited we aim to serve the need of our costumer and
build value for our stakeholder by continuing to remain in efficient and
profitable company at the same we hope we are creating an environment
where talented and exceptional people want to work we are committed to
proving our employs with opportunity for personal and professional growth
that they can find nowhere else. We are dedicated to our operating our
facility with the all most respect for the community and environment in
which we live and work
OUR CORPORATE MASSION

Put the customer first always

Be flexible to the customer needs
Adhere to the highest quality standard
Thinks innovatively but make informed business decision
Deliver results

Introduction
Nishat group is one of the leading and most diversified groups in Pakistan
with fixed/current assets of over US $ 5 billion .It is ranked among the top
five business houses of Pakistan . The group has strong presence in three
most important business sectors of the region namely textiles, cement and

financial services. In addition, the group also has reasonable market share in
Insurance (Adamjee insurance), Power generation and Aviation business .It
also has the distinction of being one of the largest players in each sector. The
group has a remarkable position in the market as good as any MNC operating
locally in terms of its quality of products, services and management skills.

Textiles
Nishat Mills Limited, the flagship company of the group was established in
1951. Its annual turnover for the year is over US $ 280 million. The following
are the main division of NML.

Spinning Division

Weaving Division.

Dyeing & Finishing Division.

Printing & Home Division.

Apparel Division.
The apparel division came into existence in 2007 and ever since never
looked back. The factory has capacity to produce 23,000 pcs of
garments per day. There are 22 sewing lines with 65 machines in each
line, so in total there are 1800 stitching machines under one roof which
makes it one of the biggest garment unit of the country.

Nishat Apparel

Nishat Mills Ltd is amongst Pakistans oldest and most respected institution
in the field of textile processing. Nishat Apparel certified (WRAP , SA-8000 , CTPAT , & international buyers code of conducts etc.) is a state of the art
facility of garment making and became part of the Nishat group in 2007.
Ever since aspired towards the same standards of quality and pride in
workmanship which has always distinguished Nishat the world over.
At present, Nishat Apparel has twenty two sewing lines. These lines , each of
which hosts up to sixty five machines terminals are manned by experience
and highly trained operators .The stitching lines currently in service are
capable of producing woven / denim bottoms of any kind .A normal eight
hour shift is capable of preparing minimum of 23,000 pcs per day . Nishat
apparel main customers are known brands of US and Europe, at the same
time efforts are underway to explore new markets /customers. The main
items produced include:

Basic 5 pocket Chino trouser

Basic 5 pocket Denim trouser

Ladies jeans

Ladies Capri

Mens shorts woven/denim

Mens cargo shorts woven /denim

Ladies 3/4 shorts

At NAL, on average 35,000 meters fabric is cut every day. This work is done
with maximum efficiency in mind, while carefully considering any possible
factors related to the fabric being cut. State of the art software is used to
design markers for automatic or manual cutting. Four Gerber Spreader
Machines, capable of spreading eighty layers of fabric in a lay. Two Gerber

high speed heavy duty automatic cutting machines which use air pressure to
stabilize the lay while accurately cutting out any required shape. Two Gerber
plotters for printing the cutting markers. Six Gerber fusing machines to
attach linings. In addition to this capability, we also have machines for
manual cutting which can cut through six to ten inches of fabric.
The embroidery facility At NA, possess the capability to produce embroidered
design on the garments. These designs are computer controlled. The shift
capacity for our machines is approximately 4000 pieces each day, depending
of course, upon the design. Following machinery is used to perform this task.
Nishat have four Twenty-Head Tajima automatic embroidery machines in
place, totaling eighty terminals. Each terminal is capable of ten thread/color
embroidery design.
At Nishat Apparel, we operate a state of the art washing facilities which perform
various tasks, including finishing, washes and fabrics trimming especially for
Denim .Piece dyed washes include:

Softener silicon wash

Stone enzyme

Enzyme wash.

Tonello machines from Italy are used for washing. Five dryers are used .fading effect
are conducted manually using sandpaper .Potassium permanganate is sprayed to
enhance fading effect .Any wrinkle /fabric shape setting is performed using curing
ovens .The following types of washes for Denim are available :

Rinse wash (for dark colors)

Enzyme stone wash

Bleach wash

Tint wash

Raisin washes

Garment dyeing.

The finishing facility prepares the garment in their final stage of production. They
have ten topper Naomoto machines, imported from Japan for French and soft
pressing. There are also fifty manual irons for hard pressing. One Ngai garment
turning machine and six vertostar thread sucking machines which automatically
clean the garment from any loose threads.
The packaging facility performs three types of packing. We ensure our garment are
packed clean and free of any undesirable contamination. Even the possibility of
minute needle fragments in the garment is not overlooked .every garment is
magnetically scanned ensuring the highest safety standards. All same size
garments are packed together. Same color and style garments are packed together.

DEPARTMENT LIST FLOW

CHART

MARKETING
Compliance (HR & EHS )
FABRIC PRECURMENT
PRODUCT DEVELOPMENT & SAMPLING
PRODUCTION PLANING & CONTROL
MATERIAL MANGMENT MEETING

GATE OFFICE
RECEIPT ROOM
MAIN STORE (Accessory Store)

FABRIC INSPECTION
CAD ROOM/AMBROIDERY/CUTTING
SEWING
INDUSTRIAL ENGINEERING
QUALITY ASSURANCE
GARMENT WET PROCESSING
FINISHING AND PICKING
SHIPPING

MARKETING/ MERCHANDIZING
Merchandising department is the star of the department among all the
working departments in the APPERAL INDUSTRY , because Merchandising is
the only department having maximum control over the departments and
total responsible for Profit and loss of the company.

Merchandise- means goods bought and sold; and trading of goods.

Merchandising- is an activity of selling and promoting the goods.
a. What does a Merchandiser do?
Merchandiser is a person who interacts with the buyer and seller, and also
puts efforts into proper relation between buying offices/ buying agents/
agency and seller/ exporter in terms of executing an order.

b. Merchandiser in garment industries:

In the field of marketing and services, Merchandiser is at a position of utmost
importance, He is the person who co-ordinates with various departments for
a uniform business.
Objects of Merchandising
Merchandising denotes all the planned activities to execute and dispatch the
merchandise on time,

Right Quantity: To dispatch right quantity of product what buyer

ordered.

Right Quality: It should be with right quality as accepted both parties.

Right Cost: Everybody wants more from what they are paid.

Right Time: No one wants to wait but Keeping delivery schedule is

mandatory.

Qualities of Merchandiser
COMMUNICATION SKILL: The communication is very much important to
promote the business activity. The merchandiser should remember that
communication must be lurid and should having face to face conversation
with the buyer.
1. Planning Capability: Merchandiser should be capable of planning,
based on the planning the order is to be followed. If the planning is not
done properly it will directly affect the delivery time of the order.
For a Merchandiser, decision making power is most important. He should
think about the decision to be taken and to act in a right way.
2. Loyalty: Loyalty is an essential character of human beings. Especially
for the business people like merchandiser it is a must.

3. Knowledge about the field: Merchandiser should have adequate

knowledge about the garments,Computer knowledge, and technical
knowledge to communicate with different people in the business is a
must.
4. Co-ordinate & Co-operate: Merchandiser is the person who is
actually co-ordinate with the number of departments. To Co-ordinate
with different people in the industry he should be co- operative.
5. Monitoring ability: Merchandiser should monitor to expedite the
orders.
6. Other qualities: Education, Experience, Situational Management,
Ability to Evaluate, Dedication, Knowledge of expediting procedures.

Function of Merchandisers

Developing new samples, execute sample orders

Costing

Programming

Raw materials / Accessories arrangement

Production scheduling (or) route card drafting

Approval of various Process, Pattern and size set

Pre production follow up

Meet Inspection Agencies

Production controlling

Identifying shortages and make arrangement for the shortages

Following quality assurance procedures, quality control procedures

Important Duties
Costing or Calculating Garment Price

In many companies, costing is done by costing officer & CEO. But in some
places, it is done by the Merchandisers.
Some important terms in costing

Yarn cost

Process cost

Process loss

CMT (Cutting, Making & Trimming)

Negotiation (getting the best out of a deal)

Commission percentage (%) for Middle man

Shortage

Buyer specification (It is buyers responsibility to specify the quality

required)

Quantity

Currency

Mode of Shipment (sea, air)

FOB (Free On Board)

CIF (Cost, Insurance and Freight)

OH (Over head)

Quota(Not applicable nowadays)

Profit (level of %)

COMPLINCE (HR & EHS ) DEPARTMENT

WORK OF ENVIRMENTAL HEALTH AND SAFETY
The main work of health and safety is to control the envirment of
factory. Envirment of factory mean that, to protect the factory worker on

work place and provide resis against hazard/fire

and maintenance of

machine and give instruction to all the labor and management that how
protect yourself and the tools of factory. they warned the department in
which there are some hazard for worker and make sure them that keep the
maintenance of that depart with their specific time duration. this is also the
main department of factory because without this no customer can link with
the factory.

FABRIC PRECUREMENTS
DEPARTMENT
FLOW OF PROCEDURES INVOLVED IN
M.M.C.
( PRECUREMENTS)
MERCHANDISER RAISES
DEMAND

SAMPLES FROM
SOURCES/ VENDORS

APPROVAL FROM
MERCHANDISER

BULK ORDERING

IN-HOUSE

QUALITY CHECK

If Not OK
SENT BACK TO
VENDOR

If OK

PROCEDURE
Merchandiser

raises demand for the materials required for a work

order.
After

merchandiser raises demand, MMC starts working for the

procurement of fabrics and accessories.
MMC

acquires samples from different vendors. Vendors may be

nominated by the customer or decided by the Manager MMC.
Samples are shown to the merchandiser for approval.
If
merchant doesnt approve any sample than MMC either send
instructions to the vendors for improvement or looks for more samples
from different sources. If merchandiser approves a sample than bulk
ordering is done to the most suitable vendor.
When vendor completes the bulk production, then it sends materials to
the factory.
When materials are in-house then Quality Checking is done to ensure if
quality of material matches with our required quality or not.
If Quality of the material is OK then it is sent to store if it is not OK then
it is sent back to vendor/supplier.

CONCEPT OF MATERIAL MANAGEMENT AND CONTROL

MMC is that department which is responsible for the sourcing of materials

required to construct a garment. It is also known as Procurement or
Commercial Department.
Materials used for the construction of garments are basically of two types.

1. Fabric.
2. Trims and Accessories.

FABRIC
Fabric is classified into two types according to the construction of
garment.
1. Shell Fabric (used in our factory is mostly twill and piece dyed)
2. Pocketing Fabric.

TRIMS AND ACCESSORIES

Following is the list of most commonly trims used:
Thread
Zippers
Buttons
Rivets
Woven Labels
Leather Patch Labels
Tags
Tag Pins or Chords for tags (e.g. for hang tags)
Fusible
Hangers
Poly-bags

 Stickers
Tape
Cartons

FACTORS FOR EFFECTIVE PROCUREMENT:

There are three main factors for effective procurement
1. Quality
2. Price
3. Lead Time
For effective and efficient procurement all factors are of great importance.
For example if a supplier is giving you very good quality on a reasonable
price but he can not you in time, then we can not order that vender for our
materials. Same is the case with price and quality. Means we can
compromise on quality and price. Only that supplier/vendor is preferred
which is offering best Quality, best price and in time.

Product Development
Department

&

Sampling

What is apparel product development?

A process that involves creating each individual style within the line.
Duties of an apparel product developer
Line Development
Fabric selection
Create a prototype
Develop patterns
Preliminary costing
Work hand-in-hand with merchandiser

 Be certain that each style that is created is salable

Approaches to Development
Fabric-driven: select fabrics, create silhouette
Silhouette-driven: design silhouette, select fabric
Both end in the same result
The apparel product developer is involved through the entire process from
concept to delivery.PD dept. re-engineer and re-create every customer
manufacturing specs on Nishat Apparel standardized format , including
operation wise thread charts , operational details of sewing and finishing
while taking into consideration customer specifications , comments and
approval process .
Nishat Apparel Tech Pack consists of:

Style Brief

Fabric and wash detail

Trims and Sundries detail

Thread and Construction detail

Information Flow Chart in PD Dept

PD Dept.

Design Cell
Tech. services
Styling &embellishments
wash recipe
Collection Development
wet process routing

sampling
sample development
constructional queries

Pattern analysis
Garment consumptions

Process flow chart of Sampling Dept

Sample request & Tech pack received from Merchant (Merchandising Dept.)

Develop Patterns

Costing / CAD Marker

Develop fit/Proto sample

Pre production sample

Size set sample

Sealer sample (final)

PRODUCTION PLANNING AND

CONTROL
INTRODUCTION
Production is a process whereby raw material is converted into finished products and
thereby adds to the value of utility of products, which can be measured as the difference
between the value of inputs and value of outputs.
Production function encompasses the activities of procurement, allocation and utilization of
resources. The main objective of production function is to produce the goods and services
demanded by the customers in the most efficient and economical way. Therefore efficient
management of the production function is of utmost importance in order to achieve this
objective.

PRODUCTION MANAGEMENT
Production system is a system whose function is to convert a set of inputs into a set of
desired outputs. Production system is depicted under with help of chart

INPUTS

CONVERSION PROCESS

CONTROL

OUTPUTS

Production management involves the managerial decisions regarding design of the product
and design of the production system i.e. determination of production processes and
production planning and control.

TYPES OF PRODUCTION SYSTEM

Broadly one can think of three types of production systems which are mentioned here
under:1. Continuous production
2. Job or unit production
3. Intermittent production

1. CONTINUOUS PRODUCTION:
It refers to the production of standardized products with a standard set of process and
operation sequence in anticipation of demand. It is also known as mass flow production or
assembly line production. This system ensures less work in process inventory and high
product quality but involves large investment in machinery and equipment.

2. JOB OR UNIT PRODUCTION:

It involves production as per customer's specification each batch or order consists of a small
lot of identical products and is different from other batches. The system requires
comparatively smaller investment in machines and equipment. It is flexible and can be
adapted to changes in product design and order size without much inconvenience. This
system is most suitable where heterogeneous products are produced against specific orders.

3. INTERMITTENT PRODUCTION:
Under this system the goods are produced partly for inventory and partly for customer's
orders. e.g. components are made for inventory but they are combined differently for
different customers.

MANUFACTURING PROCESS
The nature of the process of production required by these three different types of production
system are distinct and require different conditions for their working.
Selection of manufacturing process is also a strategic decision as changes in the same are
costly. Therefore the manufacturing process is selected at the stage of planning a business
venture. It should meet the basic two objectives i.e. to meet the specification of the final
product and to be cost effective.

PRODUCTION PLANNING AND INVENTORY CONTROL

Once the management has taken the decisions regarding the product design and production
processes and system, its next task is to take steps for production planning and control, as
this function is essentially required for efficient and economical production.
Planned production is an important feature of the industry. The management possessing the
ability to look ahead, organize and coordinate and having plenty of driving force and
capacity to lead and ability to supervise and coordinate work and simulates his associates by
means of a program of human relation and organization of employees, it would be able to
get the best outcome
Production planning without production control is like a bank without a bank manager,
planning initiates action while control is an adjusting process, providing corrective measures
for planned development. Production control regulates and stimulates the orderly how of
materials in the manufacturing process from the beginning to the end.

BENEFITS OF PPC

Production planning and control can facilitate in the following ways

(1) Optimum Utilization of Capacity:
With the help of Production Planning and Control [PPC] an organization can schedule its
tasks and production runs and thereby ensure that his productive capacity does not remain
idle and there is no undue queuing up of tasks via proper allocation of tasks to the
production facilities. No order goes unattended and no machine remains idle.
(2) Inventory Control:
Proper PPC will help to resort to just- in- time systems and thereby reduce the overall
inventory. It will enable him to ensure that the right supplies are available at the right time.
(3) Economy in Production Time:
PPC will help reduce the cycle time and increase the turnover via proper scheduling.
(4) Ensure Quality:
A good PPC will provide for adherence to the quality standards so that quality of output is
ensured.
To sum up we may say that PPC is of immense value in capacity utilization and inventory
control. More importantly it improves response time and quality. As such effective PPC
contributes to time, quality and cost parameters of organizational succes

PRODUCTION PLANNING AND

CONTROL

PRODUCTION PLANNING

PRODUCTION CONTROL

Planning

Dispatching

Routing

Following Up

Scheduling

Inspection

Loading

Corrective

1. Production Planning
Production planning may be defined as the technique of foreseeing every step in a long
series of separate operations, each step to be taken at the right time and in the right place and
each operation to be performed in maximum efficiency. It helps to work out the quantity of
material manpower, machine and money requires for producing predetermined level of
output in given period of time.
Routing:
Under this, the operations, To perform these operations the proper class of machines and
personnel required are also worked out. The main aim of routing is to determine the best and
cheapest sequence of operations and to ensure that this sequence is strictly followed.
Routing procedure involves following different activities.
1. An analysis of the article to determine what to make and what to buy.
2. To determine the quality and type of material
3. Determining the manufacturing operations and their sequence.
4. A determination of lot sizes
5. Determination of scrap factors
6. An analysis of cost of the article
7. Organization of production control forms.
Production schedule: The main aim is to schedule that amount of work which can easily be
handled by plant and equipment without interference. Its not independent decision as it takes
into account following factors.
(1) Physical plant facilities of the type required to process the material being scheduled.
(2) Personnel who possess the desired skills and experience to operate the equipment and
perform the type of work involved.
(3) Necessary materials and purchased parts.

Master Schedule: Scheduling usually starts with preparation of master schedule which is
weekly or monthly break-down of the production requirement for each product for a definite
time period, by having this as a running record of total production requirements the
entrepreneur is in better position to shift the production from one product to another as per
the changed production requirements.
Manufacturing schedule: It is prepared on the basis of type of manufacturing process
involved. It is very useful where single or few products are manufactured repeatedly at
regular intervals. Thus it would show the required quality of each product and sequence in
which the same to be operated
Scheduling of Job Order Manufacturing:
Scheduling acquires greater importance in job order manufacturing. This will enable the
speedy execution of job at each center point.
Scheduling is of utmost importance as it brings out efficiency in the operations and reduces
cost price. The organization four types of schedules to have a close scrutiny of all stages
namely an enquiry schedule, a production schedule, a shop schedule and

an arrears

schedule out of above four, a shop schedule is the most important most suited to the needs of
an apparel organization.
1. The total load on any section
2. The operational sequence
3. The stage, which any job has reached.
2. Production control (W.I.P)
Production control is the process of planning production in advance of operations,
establishing the extract route of each individual item part or assembly, setting, starting and
finishing for each important item, assembly or the finishing production and releasing the
necessary orders as well as initiating the necessary follow-up to have the smooth function of
the organization. The production control is of complicated nature in small industries. The
production planning and control department can function at its best in small scale unit only
when the work manager, the purchase manager, the personnel manager and the financial
controller assist in planning production activities. The production controller directly reports

to the works manager but in small scale unit, all the three functions namely material control,
control starts with dispatching and ends up with corrective actions.

GATE OFFICE
Work and Procedure
The main work of gate office is to control the inward gate pass of
Goods and the outward gate pass of Goods.
The inward gate pass mean that the delivery of the Goods which is perchesd
by factory .and for entrance the transport required permission from gate
office and security office. the transporter show the delivery slip list. when
gate office conform that this delivery is ordered by any department of
factory they cheeked that order in orical through P.O number and also
conform from the department. After conformation they send the driver to the
security office. security officer also checked the P.O number and quantities
and then verified them. when they complete their process then they allow
the driver with container and after when they enter into the factory then
again one person of gate office will check all the Goods and passed them
through receipt room.

Outward gate pass(OGP)

Two type of outward gate pass
1. Non-Returnable Goods
2. Returnable Goods
Non-returnable Goods mean that, the Goods which is out from the factory
that Goods cannot come back to the factory again.
Returnable Goods mean that, the material which is out from the factory that
Goods can come back to the factory this Goods is the property of the factory.

RECIPET ROOM

When Goods receive the receipt room they check the Goods. Mean the Goods
quantity and also check the each item that its fine or its been broken also
some Goods which is demand by any department that is measurable they
measure them with some digital scale. In receipt room there is also a quality
person who check the quality of every accessories that is demand by the
department with their P.O number they check their label size , label quality
and also other accessories. then they forward the Goods to the main store.

MAIN POINT
Receipt Room
G.R.I.N (goods receipt inspection
report) it is ensured that goods we
have received are of required quality

MAIN STORE
When they received the Goods from the receipt room they store them in the
different Racks with identification and marks with the quantities. If the Goods
thats received the main store is more then the ordered Goods then they
store thats Goods in store when ever again they required they give it to
them again.

MAIN POINT
Issue the items as per demand to
the specific department by taking
S.I.R (Store Issue Requisition)
form the person who will come to
receive the item

FABRIC INSPECTION
when fabric is come to this department they check the fabric roll they check
the roll number and order number with all specification after that they cut
two pieces from the roll one is small size and the other one Is little large from
the first one they measure that pieces before the wash and after the wash to
check the shrinkage if the shrinkage is down or up from the required
shrinkage if this shrinkage is control during the last washing then they pass
the fabric to the other process to complete the fabric inspection if not then
they send the fabric roll to the fabric store. The next process in the fabric
inspection is to check the whole fabric of roll if the fabric is damage or any
fault they note the faults place and then if the percentage of this faults
places is over the required faults

then they send back the roll of fabric.

Some faults are like (nods, slabs, selvage cut, broken faults, weaving faults,
starting marks, weaving marks etc.)

SHRINKAGE TEST
METHOD
Take a piece of fabric with 60 cm length and 60 cm width from the fabric roll
in a way that length is along the grain line. Draw boundaries of 5cm on all
sides of the fabric and well get a square area of 50cm x 50cm in the fabric.
Stitch the fabric from both sides along with the 50 cm lines using a single
needle operation. Over lock the fabric from all sides except one side that is
parallel to the weft. Over lock this side in a way that it becomes like a pillow
cover and send the fabric for washing. After required wash is done:
Calculate the following measurements.
1. Width after wash
2. Length after wash

FORMULA OF SHRINKAGE
SHRINKAGE =

MEASUREMENT AFTER WASH - MEASUREMENT BEFORE WASH X 100%

MEASUREMENT BEFORE WASH

Note: Shrinkage is always shown as (LxW) %.

Diagram

5CM
50cm
50cm
60CM

60CM

CAD ROOM DEPARTMENT

Cad room is the main department of apparel industry because without cad
room the fabric cannot enter into the garments departments mean to cut
and then to stitching.

WORK OF CAD ROOM

The work of cad room is to make the pattern marker through required size.
but the main work of CAD ROOM is that, that the pattern is accurate and will
marker and also the marker will made to be perfect through which the fabric
loss is much lower. When they complete the pattern marker then they print
that pattern of marker and send to the cutting department.

CUTTING DEPARTMENT
After inspection of fabric by FID (fabric inspection dept.) it is handed over to
cutting dept.The Gerber Garment Technology (GST) is used to perform the
marker making, spreading and cutting functions. GST is an American
technology; based on Accu Mark software system .This software is used to
make computerized pattern in PDS. Pattern making is the process of creating
templates of a garment parts that are to be stitched to create a complete
garment. Pattern are also made manually from size chart .First basic pattern
is created .This master pattern is than graded for different sizes.
Marker making through software is more accurate and provide the greatest
opportunity for pattern manipulation, marker efficiency, reuse of previously
made markers .Best fabric utilization depends on how tightly the pattern
pieces are fit together within the marker .This dept. calculates the fabric
consumption per garment and reverts to PPC

Process flow chart is as

below
Marker Making

Fabric Spreading as per shade and shrinkage report

Placing marker paper on to the fabric lay

Auto cutting / Manual cutting

All parts are checked and reports are made

Folding and Numbering

Ready to be send to Sewing dept.

EMBROIDERY DEPARTMENT
After cutting , the WIP people sends the pieces that need embroidery to
above department .The in house embroidery facility allows to rapidly
translate designs onto fabric guaranteeing prompt and reliable service to the
customers .
Equipped with eighty terminals of the high-tech Twenty-Head Tajima
automatic embroidery machines, the embroidery facility can produce

approximately 4000 pieces a day. Each terminal is capable of ten thread

/color embroidery design. The design cell in the PD dept uses this facility
while making new development / collections.

SEWING DEPARTMENTS
In nishat apparel the sewing department is divide into to section swing A and
swing B with line. there are 20 line in swing A and swing B.in each line their
65 machine. They are working under the 4 supervisor and 1 in charge of
each line. There are four section in the swing department which is also
mention in the above table but here also,

Back section
Front section
Assembly 1
Assembly 2

In every section they have different machine adjustment for different

operation to make a complete garment.
There are different machine such as under below.

Operation Description

Machine Type

Coin Pocket Hemmig

Coin pocket attachment on facing
Facing attachement on pocketing
Pocket bag closing
Top stitch on Pocket Bag
Back pocket hemming
Over lock left & right fly
Make Left & right fly
Attach Zipper to right fly
Make loops

D.N.L.S
D.N/S.N
Cover stitch
Safety
S.N.L.S
D.N.L.S
Over Lock
S.N.L.S
S.N.L.S
Flat Lock

Fly attachment with front panel

J-Stitch on fly
Fly top Stitch/Edge Stitch
Fron Rise/Crotch Stitch
Front Pocket attachment with Front Panel
Top stitch on front pocket opening
Secure Stitch

S.N.L.S
D.N.L.S
S.N.L.S
2N-Feedo
S.N.L.S
D.N.L.S
S.N.L.S

Safety Stitch on Yoke & Back Panel

Top Stitch on yoke
Safety Stitch on Back rise
Top Stitch on Back Rise
Back Pocket attachment

Safety
3N-Feedo
Safety
3N-Feedo
D.N.L.S

Safety on Inseam
Top Stitch on Inseam

Safety
3N-Feedo

Small Parts
1
2
3
4
5
6
7
8
9
10

Front
11
12
13
14
15
16
17

Back
18
19
20
21
22

Assembly-1
23
24

25
26
27

Safety on Side seam

Top Stitch on Side seam
Waist Band attachment

Safety
2N-Feedo
Waist Band m/c

Waist Band closing

Loop Attach
Bartack on fly, back pockets & S.S
Button Hole
Bottom Hemming

S.N.L.S
Bartack m/c
Bartack m/c
Eye-let m/c
S.N.L,S

Assembly-2
28
29
30
31
32

Machine Type
1) Single Needle Lockstitch (Auto)
2) Double Needle Lockstitch (Auto)
3) Double Needle Chain stitch
4) 6 Thread Over-lock (Auto)
5) Waistband Attach Machine
6) Feed Of Arm (Auto)
7) Bar-tack (Auto)
8) Cover Stitch (Auto)
9) Zigzag Stitch Machine
10)

Auto Welt

11)

Button Hole - Straight (Auto)

12)

Button Hole - Eye Let (Auto)

13)

Snap Machine

14)

Auto Loop Machine

15)

Mock Machine

16)

Auto Bottom Hem Machine

17)

Make Loops

18)

Button Attach Machine (Auto)

INDUSTRIAL ENGINEERING DEPARTMENT

Industrial engineering is a branch of engineering that concerns the
development, improvement, implementation and evaluation of integrated
systems of people, money, knowledge, information, equipment, energy,
material and process. Industrial engineering draws upon the principles and
methods of engineering analysis and synthesis, as well as mathematical,
physical and social sciences together with the principles and methods of
engineering analysis and design to specify, predict and evaluate the results
to be obtained from such systems. In lean manufacturing systems, Industrial
engineers work to eliminate wastes of time, money, materials, energy, and
other resources.
Industrial engineering is also known as operations management, systems
engineering,

production

engineering,

manufacturing

engineering

or

manufacturing systems engineering; a distinction that seems to depend on

the

viewpoint

or

motives

of

the

user.

Recruiters

or

educational

establishments use the names to differentiate themselves from others. In

healthcare, industrial engineers are more commonly known as management
engineers or health systems engineers.
Where as most engineering disciplines apply skills to very specific areas,
industrial engineering is applied in virtually every industry. Examples of

where industrial engineering might be used include shortening lines (or

queues) at a theme park, streamlining an operating room, distributing
products worldwide (also referred to as Supply Chain Management), and
manufacturing cheaper and more reliable products. Industrial engineers
typically use computer simulation, especially discrete event simulation, for
system analysis and evaluation.
The name "industrial engineer" can be misleading. While the term originally
applied to manufacturing, it has grown to encompass services and other
fields as well. Similar fields include Operations Research, Management
Science, Financial Engineering, Supply Chain, Manufacturing Engineering,
Engineering

Management,

Overall

Equipment

Effectiveness,

Systems

Engineering, Ergonomics, Process Engineering, Value Engineering and

Quality Engineering.
There are a number of things industrial engineers do in their work to make
processes more efficient, to make products more manufacturable and
consistent in their quality, and to increase productivity.
1. Resources
2. Space

RESOURCES
resources mean that the machinery and tools of these machine which
is required and the main work of Industrial engineering department
their is to use the machinery very well.and other resoures which is
required here.

SPACE
Space mean that how much worker can work in this place and how many
machinery can be adjust their.nad the main work of industrial engineering

is that to maintain the large number of machinery adjust at that place

that give the great production to the factor.

BASIC TERMS USED IN INDUSTRIAL ENGINEERING:

Basic Minute Value time taken by an operator to complete one
cycle into observed rating
of that operator.
Standard Minute Value can be calculated by adding Allowances in
basic minute value.
Single Cycle means one complete operation from picking the
material to sew and up to dispose.
Cycle Time means time taken by an operator to complete one cycle
or operation.

BASIC FORMULAE USED IN INDUSTRIAL ENGINEERING:

S.A.M=
B.M.V+ Allowances (m/c Allowance, Contingencies Allowances,
Material Handling Allowance etc.)

B.M.V=
S.M.V Allowances
(m/c
Allowances, Material Handling Allowance etc.)

Allowance,

Contingencies

Relaxed Single Cycle (R.S.C) = Av. Single C.T + Allowances (m/c Allowance,
Contingencies Allowances, Material Handling Allowance etc.)

Single Cycle Performance =

No. of Pcs. x S.A.M

x 100

Observed Time
Efficiency

No. of Pcs. x S.A.M

x 100

On Stitching Time
Performance

No. of Pcs. x S.A.M

x 100

Shift Time

QUALITY ASSURANCE
DEPARTMENT

in quality assurance department the garment will check during the

stitching .its

mean that the quality person in each section of stitching

department will check the each piece of garment which is stitch in garment
stitching department. That quality person check the different operation
which is done during the stitching. If there is fault in the stitching which is
not the requirement of the customer they reject that garment piece to do
again the process. If there is no fault then they proceed that garment to then
next operation.
Some faults are below shown
1. Wrong style(size)
2. Wrong thread
3. Damage
4. Hole
5. Cut
6. Wrong label attach
7. Fabric fault
8. Stain marks
9. Raw edge
10.
Missing operation
11.
Joint out
12.
Needle chew
13.
Open seam (fold)
14.
Wrong matching
15.
Shaded parts
16.
Miss alignments
17.
Un even stich
18.
slanted loop or eye let
19.
Needle gauge
20.
Joint seam

21.
Notches out
etc .
these are the major faults which is come during the stitching of
garments
and the every 1 hour one quality officer while save the record in the
final section checking reports.

GARMENTS WET PROCESSING

At nishat apparel we operate a stat of the art washing facility which
performs various tasks ,including finishing washing and fabric trimming
, especially for denim.
While the following washes are available in a variety of possible
combination.
The type of washes available at Nishat apparel for denim.
Rinse for( dark color)
Enzymes stone (rubbing)
Enzyme wash (rubbing)
Bleach wash (light color)
Super bleach( very light color)
Reduser wash(usually for black to grey color fading)
Tint wash
Raisin washes for very dark shade.
Over dyeing(dirct dyeing)/garment dyeing
Piece dyed washes
a) Softerner silicon wash
b) Stone enzyme
c) Enzyme wash
The following machine are use

Tonello machine for washing (for higher capacity)

Model (5-10 model,(2 lower capacity) 4-20 model machine.
Fading effect are conducted manually using sand paper
5 driver are used
(3) tonello (2)mino machine
(2) barrel washing machine and one drier for sampling
Potassium per magnate is sprayed to enhance fading
Any wrinkle fabric shape setting is performed using a curing oven

FINISHIG AND PACKING DEPARTMENTS

Procedures involved in Finishing Department:

1. Receiving garments from G.W.P (Garments Wet Processing)

Counting the received quantity in finishing.

Problems we are facing during this process are
a. We dont know size-wise quantity at this stage.
a. Garments received from washing are not in an order.

2. Clipping/Trimming:

Extra threads protruding from the garment surface or seams are

trimmed during this process.
Main problems we are facing in this department are
a. Improper trimming.
b. Damage of pieces due to untrained workers.
c. Garments provided to the workers are not in an order.
d. Workers clean their hands, shoes or face with the
garments and garments are stained.

3. First Quality Check:

It is the first quality check point after construction of garment.

Only trimming and basic construction of garment is checked.
If okay then sent for attachments and if not okay then sent to
rework or rejection.
As attachments are done after the quality so attachments miss
one quality checkpoint before packing.

4. Attachments:

After wash trims are attached during this process like buttons,
rivets, hooks and bar, patch label, draw chords etc.

 Attachments section must be before the clipping and first quality

as some garments having very long threads during attachment
can reach packing.
Proper marking color and pencils should be used so that marks
are not visible on eyelet or any where on waistband.

5. Pressing Section:

Garments are pressed/ironed as per customer requirement for

the good look of garment.
It is also helpful for better folding of garment.
Garments must be pressed properly because pressing enhances
the aesthetics of a garment.

6. Final Quality:

It is the final quality check point.

Each and everything of a garment is checked like construction,
specifications, trimming, pressing etc.
Presentation of the garment is also focused.
Final quality check should be after the attachment of all
accessories of a garment so that everything of a garment can be
checked before garments being packed.
OK garments are sent to packing.
Garments which can be reworked or mended are sent to
rework/alteration section.
Garments having major faults are rejected.

7. Receiving in Packing:

Packing receives OK garments from final quality and counts it.

Sensor labels are attached.
Size-wise distribution of garments and counting the size-wise qty.
Tagging with Dennison then tagging with tag guns.
Every operation which requires needle or any metallic thing is
done till this opera ion.

8. Metal Detection:

All the garments are passed through metal detection machine to

ensure that not any garment having needle or fragment of
needle is packed in the cartons.

All the needle work must be finished before this process because
after this process garments are sent to needle free zone.

9. Packing:

After metal detection garments are first hanged on hangers then

sizers are placed.
Then garments are folded and packed in polythene bags and prepack numbers according to the sizes are pasted on the front side
of the bags.
Garments are packed in cartons ratio-wise or size-wise.

10.

External Audit:

External auditor is called fro audit.

He selects the cartons randomly.
Then checks the garments completely in selected cartons.

 If he approves that garments are OK for shipment then

arrangements for shipment.
Otherwise garments are re-screened or re-checked.

Shipping Department

Once the garment is ready from production, the next important step is to
ship it out timely .This is where the above mentioned dept. comes into
action. The merchandising dept. gives there ex-mill dates to shipping
department and ensure that they receive the packed goods on time from
production. The shipping department than load the goods on the container to
send to port. They work out the best options with the shipping lines so
shipment can reach there destination in the minimum possible time.
The merchandising department gives the:

Sales contract

Packing list

To the shipping people and on the basis of this commercial invoice is made at
the company head office. The shipping dept. also follows the customer
payments through there people in the Head office. There are different
payments terms settled with customers mainly it include:

Advance payment
L/C at sight
L/C at 30/60/90 days
Cash against Document (CAD)
The following sets of documents are usually required to release payment
from bank:

Signed commercial invoice

Packing list showing net & gross weight

Original of certificate GSP Form A

Certificate of origin issued by the chamber of commerce & industry

Bill of lading ( sea shipment ) & Airway bill ( air shipment )

THE
END