improvement in marker efficiency

EXPORTS

NATIONAL INSTITUTE OF FASHION TECHNOLOGY

PRESENTED BY : HIMANI SAINI & SATENDRA BURNWAL DFT-VII

GARMENT INTERNSHIP AT

Tuesday, April 18, 2023

OVERVIEW

COMPANY PROFILE

DEPARTMENT WISE WORKFLOW

STYLES COVERED

PROJECT UNDERTAKEN

ANNEXURES

COMPANY PROFILE

CLASSIC MENSWEAR LINE (CML-UNIT)

MADURA GAREMNTS EXPORTS

ADITYA BIRLA NUVO

ADITYA BIRLA NUVO LTD

Powered by an intellectual capital of over 37,000 employees and an

optimum mix of revenue and profit streams, the company is a

diversified conglomerate and the platform that has launched many new

businesses for India’s premier business house, the Aditya Birla

Group.

Aditya Birla Nuvo has a balanced portfolio of traditional and new age

businesses under its fold, ranging from textiles to life insurance

MADURA GARMENTS EXPORTS

•Madura Garments Exports ,wholly owned subsidiary of Aditya Birla Nuvo

focusing on garment exports.

• Integrated player in the apparel industry with interest in manufacturing

exports of woven, knits and Full Service Provider business.

•The company has modern manufacturing facilities and caters to customers

like Marks & Spencer, Next and Menswear House

•Madura Garments is one of the leading export company based at Bangalore.

THE UMBRELLA OF MADURA EXPORT COMPANIES

MADURA GARMENTS EXPORTS

CLASSICC MENSWEAR

(CML)

RAMANAGRAM UNITEUROPA UNIT

CLASSIC MENSWEAR LINE(CML-UNIT)

Factory Name Madura Garments Exp Ltd (CML)

Address 288/8,Dodda Begur

City BangaloreState Karnataka

Postal Code 560068

Year of Establishment Nov-92

Factory Licence # MYB-8244Registration # MYB-8244Factory Land aria 153039.11 sq ft

Total Area Built Sq.Ft 123,432 sft

Nearest Airport - FOB BIA

Nearest Seaport - FOB CHENNAI

Regular # of working days in a WeekMonday to Saturday - 6days, 8.30AM to

5.00PM

Total # of Employees 1409

Ratio of male and female workers F-72%,M-28%

Total # Male Employees 225

Total # of female Employees 525

Total # of Staff 55

Maximum capacity (number of pieces produced per month) 80000 p/m

Minimum Wage 141.32 P/Day

Mode of payment Cash & Bank

Deductions PF,Canteen,Proffessional Tax

How many shifts are there One Shift

Total # of toilets 59

Total # of ladies toilets 40

Total # of gents toilets 19

Ratio of toilets per Male/female workers 25:01:00

What is the minimum hiring age of this facility? Above 18 yrs

Total # of Fire Extinguishers 109

Total # of First Aid Boxes 24

Toatal # of Fire Alarms 22Total # of Emergency lights 12

No of Emergency Exits 12

Factory Manager Mr. Shivaramakrishnan KWelfare Officer Ms.Sanju Cheriyan.Labour Turnover Rate(%) 5.00%

Committees

Canteen Committee, Prevention of Sexual Harassment Committee, Health

and Safety committee, Grievance / Workman Committee.

Factory Timings 8:30 am to 5:00 pmAverage wage paid 150/ dayPayment Date 7thSettlement Date 20th to 25thType of chemicals stored on-site: Acid,Rust Remover,Aciton.

•Calvin Klein

•TMW (Joseph and Feiss)

•Dockers

•Perry Ellis

•Diesel

•John miller

•Arrow

Clientele

•Factories Act, 1948

•Gratuity Act, 1972

•ESI Act,1948

•Pf and miscellaneous provision act, 1952

•Maternity benefit, 1954

•Child labor prohibition and regulation, 1986

•Minimum wages, 1948

•Payment of wages, 1936

ABIDED LABOUR LAWS

•Environment, Policy Health & Safety

•Freedom of Association & Collective Bargaining Policy

•Prohibition of Child Labour Policy

•Forced Labour Policy

•Sharp Tool Policy

•Broken Needle

•Personal Protective Equipment

•Compensation & Benefits

COMPANY POLICIES

•Policy on Non-Discriminations

•Working Hours

•Security Policy

•Prevention of Sexual Harassment

•Leave Policy

•Policy for Pregnant Women

•Employee Grievance Redressal Policy

•Policy & Product Discrepancy

•Policy on Safety in Warehouse

•Policy on Delay in Transit

PLANT LAYOUT(MACRO VIEW)

GROUND FLOOR

FIRST FLOOR

SECOND FLOOR

DEPARTMERNT WISE

WORKFLOW

THERE ARE 13 DIFFERENT DEPARTMENTS

• MARKETING AND MERCHANDISING

DEPARTMENT (Controlled From The Head Office For All Units)

• FABRIC DEPARTMENT

• TRIM STORE

• PLANNING DEPARTMENT

• CAD DEPARTMENT

• CUTTING DEPARTMENT

• SEWING DEPARTMENT

• FINISHING DEPARTMENT

• QUALITY ASSURANCE DEPARTMENT

• INDUSTRIAL ENGINEERING DEPARTMENT

• MAINTENANCE DEPARTMENT

• ACCOUNTS AND FINANCE DEPARTMENT

• HUMAN RESOURCE & ADMINISTRATION

DEPARTMENT

MERCHANDISING

ROLE OF MERCHANDISING

•Generation of orders depending on production capacity

• Sample approvals

• Purchase co-ordination

• Generation of BOM

• Delivery of shipment

• Time & Action calendar

•Buyer Communication

WORKFLOW

Customers For Business Costing

Negotiate The Buyer For

Price

Sample Construction For Buyers

Send Samples For Approval

Order Booking

Raise B.O.M For Trims

And Accessories

Arrange Sampling Yardage

Make Proto Sample

Send Proto And Wait For

ApprovalMake Test Fit

Send And Follow Up

For Approval

Check For Fabric And

Trims

Make Pre-production

Sample

Send And Follow Up

For Approval

Issue Work Order Sheet

Follow Up With

Purchase

PRODUCTION

PLANNING Coordination REGARDIN

G LINE PLANDaily Follow

Up With Production Department

Work With Documentation Department And Arrange

For Cargo For Delivery

Dates

Ensure Timely

Shipment Of Production

Follow Up For Payments

SAMPLING

WORKFLOW

Sampling Indent Received

Depending On The Buyer Requirements,

Fabric Is Used( Actual Or

Available

Development Sample

1st Proto SampleFit SampleSize Set Sample

Pre-production Sample

Top Sample Or Ruck Sample Shipment Sample

MAN & MACHINE

TYPE NUMBER

SNLS 13

BARTACK 2

5 THREAD OVERLOCK 3

4-THREAD OVERLOCK 1

3-THREAD OVERLOCK 1

PATTERN CUTTING TABLE 2

IRONING TABLES 2

MANPOWER : 20

FABRIC STORE

Capacity Of 1.5 Lakhs Meter Fabric

100% cotton

Polyester cotton Polyester viscose

Polyesters viscose + lycra 100% cotton + lycra Polyester wool

Pocketing fabric

MANPOWER : 17

WORKFLOW

Fabric Received From The Mill Unloading

Temporary Storage For

Incoming Goods

Width Checking

Visual Inspection

Sending Report To CAD

Department

Receive Requsition

Issue Materials

Sample of BIN CARD used for Tagging of Fabric Rolls

PLANNING

Objectives of the planning department:

• Effective utilisation of production capacity

• Minimum start up losses

•To plan the entire department works and timing those in such a way that the goal that is shipments at right time should be carried out.

•To make cutting plan

•To decide the capacity of different lines and load accordingly

•To rework the plan if previous plans fail to meet

•Alarm the corresponding section when they start failing to meet the plan

CAD

Receive hard pattern

Digitise

Grading

• Average marker efficiency for all the brands is around 87%.

•Software used is GERBER Version 8.08

Summary Of Fabric Inspection Report(Issued from Fabric Dept to CAD Dept)

TRIM STORE

• Store Capacity 2.5 Lakhs apprx

• Maintain a 60 Days Stock

•Pocket flasher

•Hang tag

•Barcode tag( UPC,

unit price cost tag)

•Joker tag

•Plastic clips

•Metal clips

•Hanger

•Poly bags

•Tissue paper

•Threads

•Labels

•Buttons

•Zippers

•Carton boxes

•Barcode stickers

•Size stickers

•Tack pins

•Loop pins

•Pack support

MANPOWER : 12

WORKFLOW

Incoming goods Unloading

Temporary storage of incoming

goods

Quantity check

Quality check

Storage in racks

Issue when required

Accept returns from

sewing and finishing

Advice purchase

and merchandi

sing department

Sample Of Trims Approval Card

CUTTING DEPARTMENT

TOTAL NO. OF LAYING TABLES: 4

WIDTH OF LAYING TABLES: 1.86 meters

Table 1= 17 meters

Table 2= 14 meters

Table 3= 25 meters

Table 4= 25 meters

Spreading is done manually & follow FOW NOW mode

LAYING CARD CUTTING QUALITY REPORT CUTTING ISSUES REPORT

MATERIAL FLOW

Fabric Store Department Fabric Receipt

SpreadingCutting

Numbering

Panel inspection:

Fabric defect, size, shape,

notches

Re-cuttingFusing

Bundling Issued to sewing lines

WORKFLOW

NAME MAKE QUANTITY MODEL BLADE TYPE

Straight knife hand

cutter

EASTMAN

Speed - 2850 rpm

10 BLUE STRAEK-

II

Straight knife

Band knife EASTMAN 4 EC - 700 Continuous

blade

End cutter EASTMAN 6 EC - 3 Round blade

Drilling machine EASTMAN 3 CD - 3 -

Flat bed fusing

machine

HERBERT 2 CE-RPC-200 -

Continuous bed

fusing machine

RELIENT 4 EC – RPSL – 400 -

Die machine - 2 - -

MANPOWER :56

MAN AND MACHINE

SEWING DEPARTMENT(TROUSER LINE)

• TAILORS-58• HELPERS-14• IRONERS-5• CHECKERS-5

LINE-1


LINE-2


LINE-3


LINE-4• TAILORS-55• HELPERS-15• IRONERS-6• CHECKERS-5

LINE-5


LINE-6

MACHINE CAPACITY

Double Pleated Single Pleated Flat Front

Trouser with Knee Lining Trouser Without Lining Trouser With Bottom Cuff

Trouser with Normal Bottom Hem Casual Trouser

MATERIAL FLOW

REPORTS GENERATED

•In-line Inspection Report

•In-line Check Points Checker Report

•WIP Report

•Production Report

•Efficiency Report

•Absenteeism Report

IE DEPARTMENTCalculate SAM of

the garment ordered to calculate different

consumptions

Work measurement of a new confirmed

order

To advice production

department on garment SAM and

line layout

Day to day activity

To calculate line efficiency

To calculate operator efficiency

Time and method study

Line balancing

Check for work aids and compliances

Batch setting

Multi Skill Matrix Grade Sheet

FINISHING

Garments received

Parts ironing

Full manual ironing

MACHINES LIST

WRINKLE FREEGarments received

Weighed and tested

Wrinkle free is done

Weighed and tested again

Final finishing

Sent to dispatch

TECHNOLOGY USED

•Pre-cure

•Post-cure

•Garment-dip

•Spray(metered) application

•Vapor phase

MACHINES LIST MANPOWER-52

On each carton box, there is a barcode sticker which contains the following details :

BUYER DETAILS

BRAND NAME

COUNTRY

Each shipment is sent to the buyer along with a Packing List or Container Loading

Clip, and Order Completion Report.

PACKING & DISPATCHTypes of packaging done are:

•Simple packing

•Hanger packing

•Clipboard packing

Warehouse Capacity =30000 - 35000 Garments.

Requirement of packing:

•Remove dust

•Folding

•Price tag and back pocket flasher, size slip

•Put chip board for support

•Clip

•Poly bag

•Size wise packing

•Issue for ware house

QUALITY ASSURANCE

INSPECTION AREAS•Fabric & trim inspection

•Cut parts checked for measurement and notches

•In-line inspection

•End line inspection

•Dry process inspection before wash

•Dry and wet process inspection after wash

•In-line finishing inspection

•Final inspection

ROLE OF THE MAINTENANCE DEPARTMENT:

•Servicing of machine

•Checking of Boilers for steam

•Electricity supply—if power is gone then starting of generator

•Building maintenance

•Oil change

•Replacement of defective parts

•Servicing of Motor

•Checking of Motor

MAINTENANCE DEPARTMENT

PROJECT

ON

MARKER EFFICIENC

Y

STYLE COVERED

TMW29BJ0058

VH216

•TECH PACK•TNA•OPERATION BREAKDOWN•THREAD CONSUMPTION•TIME STUDY•CUTTING•SPREDING

•OPERATION BREAKDOWN& TIME STUDY

•TNA•CUTTING•SPREADING

ANNEXURES

• COMPANY PROFILE

• CAD EVALUATION

• SOFTWARE EVALUATION

• ORDER TRACKING SHEET

LEARNING OUTCOME•Understanding of the different departments working at the factory

•Inevitable constraints for any operation

•Understanding the importance of workforce and results of absenteeism on

production

•The process flow of Merchandising Department and the steps involved in

sample approvals.

•The above areas of understanding made us more aware of the sewing floor

operations, finishing floor operations and cutting and spreading room

operations.

•The learning experience was also a helping tool in making us aware of our role

as policy makers at the ground zero, level one or senior level manager level.

REFERENCES

MR SHIVRAM (FACTORY MANAGER)

MR PARTHIBAN (PRODUCTION MANAGER, CML-UNIT)

MR RAM MOHAN (PROJECT TEAM MEMBER, EUROPA UNIT)

MR KAUSHAL NAIR (QUALITY HEAD, EUROPA UNIT)

BOOKS

TECHNOLOGY OF CLOTHING MANUFACTURING BY CARR & LATHAM

APPAREL MANUFACTURING BY JACOB SOLINGER

LINKS

http://www.indo-gulf.com/maduragarments/index.aspx

http://www.indo-gulf.com

http://www.indo-gulf.com/maduragarments/index.aspx

http://www.indo-gulf.com/

Thank You

improvement in marker efficiency

Documents

Transcript of improvement in marker efficiency