“SUMMER INTERNSHIP REPORT APPAREL PRODUCTION & MANAGEMENT PDF

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SUMMER INTERNSHIP REPORT APPAREL PRODUCTION &MANAGEMENT A Dissertation Submitted to Sponsored By SANGAR OVERSEAS Submitted by : Preeti Rani Msc.APM–II 1 TABLE OF CONTENTS INDEX PAGE TITLE PAGE ..........................................................................................................

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“SUMMER INTERNSHIP REPORT APPAREL PRODUCTION &MANAGEMENT” A Dissertation Submitted to

Sponsored By SANGAR OVERSEAS

Submitted by :

Preeti Rani Msc.APM–II

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TABLE OF CONTENTS INDEX

PAGE

TITLE PAGE ............................................................................................................................................................... 3 ACKNOWLEDGEMENTS ........................................................................................................................................ 4 DEDICATION...............................................................................................................................................................5 SUMMER INTERNSHIP CERTIFICATE ............................................................................................................... 6 EVALUATION FORM ............................................................................................................................................... 7 EXECUTIVE SUMMARY ......................................................................................................................................... 8 COMPANY PROFILE................................................................................................................................................ 9 ABOUT COMPANY ................................................................................................................................................. 11 PRODUCT DEVELOPMENT ................................................................................................................................ 19 MERCHANDISING DEPARTMENT ..................................................................................................................... 20 SAMPLING DEPARTMENT ................................................................................................................................. 28 FABRIC SOURCING DEPARTMENT .................................................................................................................. 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

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TITLE PAGE:

 A report is based on Six week internship at Sangar Overseas, Gurgaon, Haryana.

 Prepared by Prreti Rani, APM, Sem-II, Institute of Apparel Management, Gurgaon.  The project will be in under the guidance of Mrs. Neera Chandra, professor and course coordinator of APM, Institute of Apparel Management.  Date of submission on 12 Aug 2015.

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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

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DEDICATION

I dedicate my dissertation work to my family and many friends. A special feeling of gratitude to my loving husband Surender Nain whose words of encouragement and push for tenacity ring in my ears. I also dedicate this dissertation to my many friends who have supported me throughout the process. I will always appreciate all they have done. I dedicate this work and give special thanks to my wonderful daughter Erica Nain for being there for me throughout the entire summer internship program. You have been my best cheerleader.

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SUMMER INTERNSHIP CERTIFICATE

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EVALUATION FORM

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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.

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COMPANY PROFILE

COMPANY NAME

SANGAR OVERSEAS PVT LTD

ADDRESS

SANGAR OVERSEAS PLOT NO 304, PHASE – 4,UDYOG VIHAR GURGAON, HARYANA 122016

TELEPHONE

Ph: 0124-4738800 (10 Lines) fax: 0124-4013018

E-MAIL

[email protected]

WEBSITE

http://www.sangaroverseas.com

YEAR ESTD.

1984

Market

100% EXPORT

OWNER

Mr.RAJEEV SANGAR

DIRECTOR

Mr.RAJEEV SANGAR

ANNUAL TURNOVER

40 Crores

TOTAL WORKING FORCE

600

MONTHLY PRODUCTION

150000 pcs

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SANGAR OVERSEAS MANUFACTURER & EXPORTER OF READYMADE GARMENTS

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ABOUT THE COMPANY With a strong hold on varied market segments across the world SANGAR OVERSEAS are recognized as a reputed garment manufacturing company. Incepted in the year 1984, they have acquired immense design expertise that helps us in meeting the diverse requirements of their global clientele. They are manufacturers, exporters and suppliers of exclusively designed & fabricated Ladies, Girls & New Born apparel Woven and Knits. They have state-of-the art facilities comprising in-house computer embroidery facility, washing facilities and a sophisticated array of machinery. These facilities assist us in producing a quality assured range of garments for their valued clients. Ever since its inception, Sangar Overseas has never looked back. Growing with Strength as well as value it has achieved the production capacity of 150000 PCS. Garments per Month.

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• Product Categories –Ladies-wear (60%) and girls wear – NB, Infant, Toddler, 4-14 (40%). • Fabrics – 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. They 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. • Factory Capacities – They operate 500 machines, approx. 125,000 – 150,000 pcs per month with in-house computer embroidery with sequin attachment (60 heads) & complete laundry facilities (enzyme/bleach/silicon/bio/softener wash, perc (petrol-free) machine for dry cleaning). They have complete in-house cut to pack facilities, including a highly capable product development and sampling department.

• Buyer for Ladies-wear •

Bon prix – Germany

•

George – UK

• Cia Hering – Brazil • Tema – Turkey • Ali & Kris-USA • Adrienne Papelle – USA • Anotah – UAE • Tape a l Oeil – France 12

•

Foschini – South Africa

• Rene Derhy-France. • Buyer for kids-wear – • George-UK •

Morrison’s – UK

•

Baby shop-UAE

•

Bon Prix – Germany

•

Disney (for baby Shop and George, since we are a FAMA certified Disney facility).

• Social Compliance – The factories are Sedex certified, BSCI approved, Disney & Wal-Mart certified, CT-PAT compliant. • Design and Product Development – They believe in investing in best talent available creative talent in the market to get something on the table for our principals as our own initiative and hence, we have a full-fledged in-house design, product development and sampling department .they assure you that you shall get fresh ideas and bodies from us every season. QUALITY CONTROL The Factory is equipped with “STATE-OF-THE-ART” Imported Stitching and washing machines. The internal quality control systems ensure that Goods of highest quality are shipped to their customers.

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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 16

LIST OF MACHINERY 1) BROTHER SINGLE NEEDLE HIGH SPEED LOCKSTITCH MACHINE

400

2) BROTHER DOUBLE NEEDLE LOCKSTITCH SPLIT FEED MACHINE

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3) BROTHER COMPUTERISED BARTECK MACHINE

04

4) BROTHER BUTTON HOLE MACHINE

04

5) BROTHER COMPUTERISED CROSS-STITCH LOCKSTITCH BUTTONING MACHINE

04

6) WAIST BAND ATTACHMENT MACHINE

04

7) 5 THREAD OVERLOCK MACHINE

25

8) EASTMAN CUTTING MACHINE

02

9) BAND KNIFE CUTTING MACHINE WITH AIR CUSHION TABLE

01

10) AUTOMATIC SNAP FASTNER WITH COMPRESSOR

10

11) FUSING PRESS (HASIMA-CONTINOUS FEED)

02

12) ENZYME WASHERS – NGAI SHING

04

13) RAMSONS – 200 KG CAPACITY WASHER

01

14) HYDRO

03

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15) DRYING TUMBLER – NGAI SHING

03

16) HEATED VACUUM TABLES – NGAI SHING

20

17) STEAM PRESSES – NGAI SHING

20

18) THREAD SUCKING MACHINE

02

19) REECE KEY HOLE BUTTON HOLE MACHINE

02

20) FEED OF THE ARM

02

21) AUTOMATIC STICKERING MACHINE

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22) CARTON STRAPPING AUTOMATIC MACHINE

02

23) PERC DRY CLEANING MACHINE

02

24) CINTEX & LOCK NEEDLE DETECTOR M/Cs

02

25) SPOTTING STATION MACHINE

02

26) COMPUTERIZED EMBROIDERY MACHINE

82

27) THREAD WINDING MACHINE

02

28) LAYER DRILLING MACHINE

02

29) FLAT LOCK MACHINE

02

30) FOUR THREAD OVERLOCK MACHINE

04

31) FLAT LOCK WITH TRIMMER

02

32) YKK NEWMAX SNAP ATTACHING MACHINE

02

33)SIRUBA/KANSAI 12 NEEDLE SMOCKING MACHINE

02

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PRODUCT DEVELOPMENT

in the context of garment export business normally product development is handled by design department. But where there is no design team, merchants are responsible for whole production development process. In export houses sampling department is considered as product development department.

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. 20

PROCESS FLOW OF MERCHANDISING DEPARTMENT TECH PACK COMES FROM BUYER

INITIAL SAMPLING AND COSTING

GET ORDER FROM THE BUYER

ORDER CONFORMATION

BUDGETING

INTERNAL

WITH BUYER

MATERIAL INDENT

RE SAMPLE /PROTO

(TRIMS DETAILS)

TYPE APPROVAL

FIT SAMPLE APPROVAL

FAVRIC PROGARAM (FABRIC DETAILS)

FPT APPROVAL

PP SAMPLE

GPT SAMPLE

TOP SAMPLE APPROVAL LOT APPROVAL SIZE SET SAMPLE APPROVAL

SHIPMENT INSPECTION AND FINAL SHIPPING 21

PURCHASE ORDER

PO is an external document which is issued by buyer in the name of Sangar Overseas Export Pvt.Ltd; it is an evidence as well as support of order confirmed in the favour of company.

Po include the following information-

1. Delivery date

6. Terms if sale

2. FOB

7. Currency

3. Ship cancel date

8. L/C

4. Destination

9. Quantity

5. Ship mode

10. Size break up / colour break up

SANGAR OVERSEAS USE WFX ERP SOFTWARE –

In company employee work on WFX ERP software for making challan, purchase order, indent etc. it’s very simple and useful software.

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Apparel export merchandising may be defined as ‘all the planning & activities involved right from the buyer communication & order receiving till the execution or shipment of the order by fulfilling the following factors (Six Rights): Right Merchandise: Retailers must fill their shelves with the merchandise that customer wants. Right Place: The location of the merchandise is of prime importance since it decides the accessibility. Much merchandise is seasonal in nature and must be on hand when it is most needed. Right Time: Much merchandise is seasonal in nature and must be on hand when it is most needed. Right Quantity: A profitable balance between volume of sales and amount of inventory is the desired goal. Right Price: Merchandiser must arrive at a price that is high enough to give the store profit and yet low enough to meet the competition and customers expectations. Right Promotion: Right balance between the investment and the appeal created for the customers. The successful execution of any garment export order depends on the work performance of a merchandiser. Merchandiser is the person who plans and coordinates all the activities right from the order procuring and till the shipment order. A merchandiser should have the comprehensive knowledge of his work procedures and responsibilities so that he could perform his job efficiently and effectively. In the apparel export industry, a merchandiser has to perform the following functions;

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Communication: It is one of the foremost functions of merchandiser because the merchandiser has to communicate with different levels of people in his 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.

Coordination: Merchandiser has to coordinate in such way to reduce the uncertainties and difficulties and if there is a problem arises, the merchandiser has to support and lend helping hand in order to complete the task successfully in the 24

given period. Both the controlling and coordinating activities complement each other and a merchandiser has to adopt the ...