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    LT KARLE LT KARLE Document Transcript

    • MANUFACTURERS & EXPORTERS OF READYMADE GARMENTS & TEXTILES (100% EOU) (An ISO 9001:2008 Certified Company) SUMMER INTERNSHIP REPORT BATCH (2008 – 2012) BY: ANOOP SINGH & RAJEEV SHARAN
    • Apparel internship (2008-2012) ACKNOWLEDGEMENTThe presentation of “SUMMER INTERNSHIP REPORT” was possible due to thedirection & help rendered by couple of persons. We take pleasure to remember them.We acknowledge Ms.Jonalee Bajpai ,Course Coordinator B.F.Tech, NIFT, Bangalore.Our profound thanks & indebted gratitude for our mentor Ms. Sweta Jain for herguidance & suggestions given at every stage while bringing out this report.First of all, we would like to thank Mr. Guruprasad, Learning & Development officer, LTKarle, who provided us the brilliant opportunity to be internee at the organisationWe also extend a special thanks to Mr. Vijeindra Joshi, the Assistant General Manager(and my mentor) for taking out time from his busy schedule to provide us with valuableguidance throughout this training period.Further, We would like to extend our regards to Mr.Vijay and Mr.Manjesh, theIndustrial Engineers for providing us with all the necessary information reviews andremarks at all stages of the internship.We would also like to thank Mr. Santhosh, thecutting in-charge and Mr.Rudresh,the QA Head of cutting room for their immensecooperation during our study in the cutting room.Our sincere thanks to all the managers of various departments for guiding us throughoutthe internship.We would also like to thank all staff and workers of LTK -2, for keeping patience andsharing their valuable experience with us. Anoop Singh & Rajeev SharanLT KARLE – ANOOP SINGH & RAJEEV SHARAN 2 NIFT, BANGALORE
    • Apparel internship (2008-2012) OBJECTIVE OF THE INTERNSHIPNational Institute of Fashion Technology, a premier institute in South-east Asia isresponsible for human resource development for apparel industry in India. ApparelProduction department is imparting education in crucial areas of technology in garmentmanufacturing. After completing three years of apparel production, a techno managerialunder graduate degree program at National Institute of Fashion Technology, the studentsare exposed to a eight week industry internship with the leading garment manufacturingorganizations as a part of the course curriculumThe objective of this industry internship is aimed towards blending the classroom studywith industry application. This internship helps the students to analyze the day to dayactivities along with practical application of different principles.The objectives of internship is firstly to gain practical exposure and secondly applicationof knowledge in real life projects.This internship also helps us to learn and improve our interpersonal communication skillswith colleagues, peer group and workers.LT KARLE – ANOOP SINGH & RAJEEV SHARAN 3 NIFT, BANGALORE
    • Apparel internship (2008-2012) Table of ContentsSl No Page no1. COMPANY PROFILE 52. SAMPLING DEPARTMENT 233. SPREADING & CUTTING DEPARTMENT 384. SEWING SECTION 485. FINISHING SECTION 586. QUALITY ASSURANCE 647. MATERIALS DEPARTMENT 678. IE DEPARTMENT 839. CPQAD 10810 PLANNING 11511 HUMAN RESOURCE DEPARTMENT 11812 MERCHANDISING 123 ROLE OF PPM13. IT DEPARTMENT 12514. WASHING DEPARTMENT 12915. SYSTEM & AUDIT DEPARTMENT 13616. EXPORT & IMPORT DEPARTMENT 13917. FINANCE DEPARTMENT 14218. FACILITIES DEPARTMENT 14519. COSTING DEPARTMENT 14820. OBSERVATIONS AND LEARNING 151LT KARLE – ANOOP SINGH & RAJEEV SHARAN 4 NIFT, BANGALORE
    • Apparel internship (2008-2012) COMPANY PROFILELT KARLE – ANOOP SINGH & RAJEEV SHARAN 5 NIFT, BANGALORE
    • Apparel internship (2008-2012)COMPANY PROFILEKarle group is a leading business conglomerate in Apparel, Infrastructure, Life sciences,Properties & Packaging. The group was founded by Late Sri L.T Karle in the year 1972,by opening LT Karle Unit 1 in Yeshwanthpur, Bangalore to manufacture apparel. Sri LTKarle hails from Karle village, 20kms from Hassan in Karnataka. He was a sciencegraduate & had undergone training in advance agriculture in USA .Having gainedknowledge in advanced agriculture; he introduced scientific farming in his Hassan farm.He had a unique aptitude of foreseeing future potential of markets 7 tapping steadily fromtime to time. Besides excelling in business and providing employment to 1000‟s ofpeople, he also dedicated to the public life by occupying various positions to contribute tothe society.With his entrepreneurial skills, he has groomed his sons (Mr. Sudarshan Karle & Mr.Mahendra Karle) to take Karle group into greater heights. Since then, there has been nolook back for the group, with the aggressive forays into other business apart fromApparel. The group has clear vision with in depth knowledge of the market, committedhuman resources, state of the art technology & global associations which have all helpedKarle group to spread its wings.VISION: Nurture passion for innovation & creativity to achieve its goal to become adominant & most admired player in the chosen field.MISSION: To continuously…….attract , develop , retain , innovative and creativepeople , Evolve and upgrade – Knowledge and technology systems , Process , productand services , Encourage organic and inorganic growth initiatives.GOAL: To become dominant and most admired players in the chosen fields.LT KARLE – ANOOP SINGH & RAJEEV SHARAN 6 NIFT, BANGALORE
    • Apparel internship (2008-2012)QUALITY POLICY: We are committed to provide apparel that meet or exceed presentand continual expectations of our customers in terms of : product quality , delivery andcost.ABOUT THE FOUNDERMajor positions held  Joined Indian National Congress 1938  President Malnad Productivity Council  President-Apparel Export Promotion Council (Karnataka)  President-Krishik Samaj  Vice President- Karnataka Pradesh Congress Committee (KPCC)  President: South India Textile Industries Association  Member of Karnataka Legislative Council 1978(MLC)Serial Entrepreneur  Bangalore Crome Tannery 1970  LT Karle and Company (1972)-Bangalore  Bharathi Sales-Bangalore  Machine Component Manufacturing Bangalore  Bharathi Housing Factory- Bangalore  Bharathi Tiles- Hasan  Bharathi Coffee Curing- Hasan  Vijay Kandasari Sugar- Hasan  Bangalore Leather and Leather Craft BangaloreLT KARLE – ANOOP SINGH & RAJEEV SHARAN 7 NIFT, BANGALORE
    • Apparel internship (2008-2012)CHRONOLOGICAL DEVELOPMENTApparel Sector:  1972 LT Karle and Company, Unit 1, Yeshwanthpur  1989 LT Karle Unit 2, Madanayakanahalli  1994 Karle International Unit-1, Nagasandra village  2001 LT Karle Unit 4- Peenya II stage  2007 Karle International Unit-2, MallarabanavadiOther Business Companies  1997-Karle Properties  1998-Cymbio Pharma Pvt Ltd  2005-Karle Health Sciences Pvt Ltd  2007-Karle Infra Projects Pvt Ltd  2007- ETI Karle Klinical Pvt Ltd  2007-Karle Packaging Pvt LtdLT KARLE – ANOOP SINGH & RAJEEV SHARAN 8 NIFT, BANGALORE
    • Apparel internship (2008-2012)DIFFERENT UNITSLT KARLE – ANOOP SINGH & RAJEEV SHARAN 9 NIFT, BANGALORE
    • Apparel internship (2008-2012)HEAD OFFICE and LTK Unit 1KARLE GROUP OF COMPANIES#151, INDUSTRIAL SUBURB,YESHWANTHPUR,BANGALORE - 560022INDIATel: +91-080-23475212, 41285311-15Fax: 91-80-23374729Website: www.karlegroup.comLT KARLE – ANOOP SINGH & RAJEEV SHARAN 10 NIFT, BANGALORE
    • Apparel internship (2008-2012)New Head Office, ETI, KHS and Sampling UnitNO.71 / 72, INDUSTRIAL SUBURB, WARD NO.10, NEAR ULLAS THEATRE, 1STBLOCK RAJAJINAGAR, BANGALORE – 560 010.TEL: +91 – 080-2357 7460, 3250 4549,FAX: +91 – 080 – 23474729LT KARLE – ANOOP SINGH & RAJEEV SHARAN 11 NIFT, BANGALORE
    • Apparel internship (2008-2012)L T KARLE & CO (UNIT II)#SURVEY NO.46/2, SHED NO.4, MADANAYAKANAHALLI TUMKUR ROAD,BANGALORE NORTHTEL: 23712341/23712338LT KARLE – ANOOP SINGH & RAJEEV SHARAN 12 NIFT, BANGALORE
    • Apparel internship (2008-2012)KARLE INTERNATIONAL-1NO. 73, NAGASANDRA VILLAGE TUMKUR ROAD, BANGALORE – 560 073TEL: 28399046/28395161LT KARLE – ANOOP SINGH & RAJEEV SHARAN 13 NIFT, BANGALORE
    • Apparel internship (2008-2012)L T KARLE & CO., (UNIT IV)NO. V 77 & 78, INDUSTRIAL ESTATE, PEENYA 2nd STAGE,BANGALORE - 560 058LT KARLE – ANOOP SINGH & RAJEEV SHARAN 14 NIFT, BANGALORE
    • Apparel internship (2008-2012)KARLE INTERNATIONAL – IISURVEY NO. 26/1, 26/2, 27/2, MALLAR BANAVADI, KUNIGALROAD, NELAMANGALA TALUK,BANGALORE RURAL DISTTEL: 27700493/ 27700568Production CapacityS. No. Facility No of Machines Quantity per month1 KI -I 750 150,0002 KI- II 1100 285,0003 LTK-II 275 73,0004 LTK-IV 350 90,000Total 2475 598,000LT KARLE – ANOOP SINGH & RAJEEV SHARAN 15 NIFT, BANGALORE
    • Apparel internship (2008-2012)CORE COMPETENCE OF KARLE GROUP  Know the Job:- Over 38 years of expertise in Garment Manufacturing  Ensure quality: - All 4 factories are ISO 9001 -2008 certified.  Capacity: - four factories capable of manufacturing 600,000 garments a month.  Integrated manufacturing: All the activities of garment manufacturing are carried out in-house to ensure quality and consistency  Competency: trained manpower to carry out the work.  Customer Satisfaction: More than 80% business come from existing customersCORE VALUES  Deep respect for individuals and ecosystem  Deliver excellent quality to stakeholders and society at large  Be a responsible corporate and social citizen  Commitment to honesty and transparency  Respect for democratic process, change and joy.LT KARLE – ANOOP SINGH & RAJEEV SHARAN 16 NIFT, BANGALORE
    • Apparel internship (2008-2012)KARLE & CO – DEPARTMENTS: APPAREL MANAGING PARTNERS GROUP EXECUTIVE BOARD OPERATIONS PRE PRODUCTION SUPPORT FUNCTIONS KARLE COSTING EXPORTS HUMAN RESOURCES LTK - 1 PRODUCT DEVELOPMENT ADMINISTRATION LTK - 2 SAMPLING COMPLIANCE LTK - 4 MERCHANDISING FINANCE & KI - 1 ACCOUNTS SOURCING & KI - 2 PURCHASE INFORMATION TECH MATERIALS (STORES) SYSTEM & AUDIT RMQA MAINTAINANCE CPQAD & UTILITY M/C MAINTAINANCE EXLM - HO PRODUCTION C&F - MARKETING CHENNAI COST CONTROLLT KARLE – ANOOP SINGH & RAJEEV SHARAN 17 NIFT, BANGALORE
    • Apparel internship (2008-2012) CORPORATE –HR ORGANOGRAM KARLE GROUP OF COMPANIES MANAGING PARTNERS CHIEF PEOPLE OFFICE GENERAL MANAGER HUMAN RESOURCE TALENT TALENT LEARNING & PERSONAL GROUPACQUISITION MANAGEMENT DEVELOPMENT DEVELOPMENT FACILITIES LT KARLE – ANOOP SINGH & RAJEEV SHARAN 18 NIFT, BANGALORE
    • Apparel internship (2008-2012)TOP MANAGEMENTGroup Executive Board Members [GEB]  Mr. Sudharshan Karle – Managing Partner  Mr. Mahendra Karle – Managing Partner  Mr. P.P.Madappa – Senior Group AdvisorCorporate Management Council Members [CMC]  Mr. Chandramowly – Chief People Officer  Mr. Gururaj Bhat – Chief Financial Officer  Mr. Gokal Chittaranjan – Chief Executive  Mr. V.K.Kumar – Chief Financial Officer(Karle Infra Projects)  Dr. M.V.Nagendra – Chief Principal Investigator (ETI Karle Clinical)Business Units & Heads  Apparel Sample Making – Mr. K.S.Prasanna (Partner)  Apparel Production – Mr. Gokal Chittaranjan ( Chief Executive Manufacturing)  Karle Integrated Packaging – Mr. Sunil Betigeri (Head Packaging Unit)  Cymbio Pharma Pvt ltd – Mr. Sadyojatha A.M (Deputy G.M)  Karle Health Sciences Pvt. ltd – Mr. Louis Menezes (Senior Vice President)  ETI Karle Clinical Pvt ltd – Dr. M.V.Nagendra ( Chief Principal Investigator )  Karle Properties – Mr. Srinivas Deshpande (Advisor)  Mr. Gopala Krishna (Senior Executive)  Karle Infra Projects – Mr. Mahlanna Sasalu (Chief Operating Officer) o Mr. V.K.Kumar (Chief Financial Officer)LT KARLE – ANOOP SINGH & RAJEEV SHARAN 19 NIFT, BANGALORE
    • Apparel internship (2008-2012) ORGANIZATION CHART: General Manager Unit Head P.M I.E P.E System Cutting in Finishing in Unit Controller charge charge HR Cutter/ Finishing Layers / supervisor Asst System controller Helpers Checkers / packers/ CAD spot operators/P washers/Bundle Feeding Producti Washin roduction alterationmovers helpers on clerk g helper writers/Em tailors broidery Asst Ironers Panel checking Supervisor Production writter Numbering helper /Recutters/ Sorting helpers/Pan el checkers LT KARLE – ANOOP SINGH & RAJEEV SHARAN 20 NIFT, BANGALORE
    • Apparel internship (2008-2012)CLIENTS:  ABERCROMBIE AND FITCH  LANDS END  ANN TAYLOR  TOMMY HILFIGER  SEARS  AMERICAN EAGLE  HOLLISTER  NIKE  ADIDAS  LEVISMAJOR CLIENTS (for the last year): 32% 39% Eddie Bauer Nordstorm Lands End Ann Taylor 15% 14%LT KARLE – ANOOP SINGH & RAJEEV SHARAN 21 NIFT, BANGALORE
    • Apparel internship (2008-2012)PRODUCT RANGE IN LTK-2  HEAVY JACKETS  LIGHT JACKETS  SKIRTS  TRENCH COATS  CASUAL BLAZERS  WIND SHETTERS Men’s and Women’s wear  L.T LARLE is known for their jackets in the global market and amongst the Indian garment exporters  Ann Taylor has awarded LT Karle NO.1 for their quality and production in Asia.LT KARLE – ANOOP SINGH & RAJEEV SHARAN 22 NIFT, BANGALORE
    • Apparel internship (2008-2012) SAMPLING DEPARTMENTLT KARLE – ANOOP SINGH & RAJEEV SHARAN 23 NIFT, BANGALORE
    • Apparel internship (2008-2012)SAMPLING DEPARTMENTThe sampling department at L. T. Karle is a massive structure where samples for theirmost valuable clients are made. The four main clients that are handled in the samplingunit are:  Ann Taylor  Lands‟ end  Eddie Bauer  NordstromThe sampling department consists of the design team, processes like cad, pattern making,cutting, production, finishing, inspection, fitting of the garment etc.Quality Objectives:  100% sample exit as per buyer requirement of quality and time  100% sample approval within 2 fit rounds  100% correct pattern release to production unit  100% correct pattern release to production unit as per stipulated time  Sample rejection <1.5%  Internal audit performance >90%The different kind of samples made is:  Proto/ concept samples  Fit samples  Pre production sample  Garment package test sample  Size set samples  Salesman sample  Photo shoot sampleLT KARLE – ANOOP SINGH & RAJEEV SHARAN 24 NIFT, BANGALORE
    • Apparel internship (2008-2012) ORGANIZATIONAL CHART OF SAMPLING DEPARTMENT HOD Sampling Assistant Mgr Admin & scheduling A TechnicianPattern Makers Sewing QA Coordinators supervisors Pattern assistants Feeding Iron Operators Operators Special helpers machine oprts Cutters Assistant LT KARLE – ANOOP SINGH & RAJEEV SHARAN 25 NIFT, BANGALORE
    • Apparel internship (2008-2012) A Digitizers Sub store Maintenance Assistants Head Maintenance mechanicsSAMPLE MAKING PROCESSObjective: to make the required samples on time as per buyer specificationsScope: this procedure is applicable for making samples for all buyersResponsibilities:  Merchandising department: Furnishing the controlled techpack, sampling indent, materials, trim cards, and shrinkage reports for making samples.  Materials department: Providing raw materials for making samples as per sampling indent.  Sampling department: make samples as per requirement and as per time and action calendar and also provide the necessary information to the production unit.The tech pack received by sampling has the following:  Tech pack description:- The tech pack consists of the following details.LT KARLE – ANOOP SINGH & RAJEEV SHARAN 26 NIFT, BANGALORE
    • Apparel internship (2008-2012)  Style folder description:- All the possible details like brand name development number, style name, fit, pattern number and other minute details are included in this folder.  Details & picture:- The waist cut whether bias or contour with the GARMENT is represent here. The place where maximum stitch is requires this fixing of the other additional trims to be added to be through a diagram.  Fabric details:- The fabric group, main fabric, pocketing fabric is represented with development number & code with the supplier reference. The weight, width, composition quality & size are marked here.  Thread details:- The details of threads used are given with the code number. For e.g.:-, main thread (41), navy thread (120), white thread (122), black thread (125,126). The number‟s given in the bracket are the code numbers for each colors which identifies the particular shade of the color. If the quality specification is number given, it should be identified & conferred with the buyer. e.g.:- thickness (30tkt, 50tkt, 75tkt, 100tkt) 30 thicker, 100 finer, quality cotton, poly, spun poly, rayon, poly-most strength, rayon-poor strength.  Packing details:- The details given here are about box & plastic bag with their respective code number‟s, & RMN description or details.LT KARLE – ANOOP SINGH & RAJEEV SHARAN 27 NIFT, BANGALORE
    • Apparel internship (2008-2012)Different methods of packing:-  Dead man fold.  Stand up pack.  Hanger pack.Zipper & HardwareZipper details include zipper chine zipper slider, zipper top stop, and zipper bottom stopwith their color description. Generally gold & silver would be the preferable colors.  Zipper band.  Zipper teeth.  Puller.  Stopper.For men‟s garments zipper teeth comes in metal but in children‟s GARMENT.It comes in plastic. The advantage is it comes with lock & unlocks system.Comment sheet:-  Additional care label order of destination is attached to addition care label.  Additional text on care label.The made “…………….” (Country of manufacturing) is represented here.It should be numbered that care label for destination should be only in English.  Polish hand tag.The detail specified here are source plant & country. e.g.:-79000 15.-marocco.These arethe following details include waist band button fastener denim with their code numbers &colors.LT KARLE – ANOOP SINGH & RAJEEV SHARAN 28 NIFT, BANGALORE
    • Apparel internship (2008-2012)Labelhandbags & miscellaneous:-This detail includes HPL, woven label leather patch, care label size ticket& style labelwith code number‟s color description & other details. Miscellaneous includes details ofbias tape & fusing tape with their code numbers & color.After Wash Measurements:-The after wash measurements waist, thigh, knee, bottom, inseam, Front rise, back rise.Zip leant mettle, fly opening are given. The after wash measurement increase or decreaseaccording to the type of Fabric.LT KARLE – ANOOP SINGH & RAJEEV SHARAN 29 NIFT, BANGALORE
    • Apparel internship (2008-2012)CHECK LIST OF ITEMS/ REPORTS TO BE SENT ALONG WITHSAMPLES1. Proto/ PPR/ CR1Package offered to Buyer QA  Proto Samples  Measurements and Comments of internal QA  Tech pack  Pattern Tracing  Trim Card  Fabric Shrinkage Report  Samples Review SheetPackage sent to Buyer  Proto Samples  Measurements and Comments of external QA  Tech pack signed by Buyer QA  Pattern Tracing  Sample Review Sheet2. Fit/ PPR/ CR2Package offered to Buyer QA  Fit Samples  Measurements and Comments of internal QA  Tech pack  Pattern Tracing  Pinned Sample  Trim Card  Wash Standard & Wash Recipe  Pattern SuperimposeLT KARLE – ANOOP SINGH & RAJEEV SHARAN 30 NIFT, BANGALORE
    • Apparel internship (2008-2012)  Samples Review SheetPackage sent to Buyer  Fit Samples  Measurements and Comments of external QA  Tech pack signed by Buyer QA  Pattern Tracing  Pinned Sample  Sample Review Sheet3. PPS/ QRS/ Counter SamplePackage offered to Buyer QA  PP Samples  Measurements and Comments of internal QA  Tech pack  Pattern Tracing  Nested Pattern  Buyer agent approved Trim Card  Mini marker  Cut Patterns  Wash Standards & Wash Recipe  GPT Report  Samples Check List  SuperimposePackage sent to Buyer  PP Samples  PPS Report  Pattern Tracing  Sample Check ListPackage sent to the UnitLT KARLE – ANOOP SINGH & RAJEEV SHARAN 31 NIFT, BANGALORE
    • Apparel internship (2008-2012)  Sealed PP Sample  Sealer Report  Pattern Tracing  Sample Check List4. Size SetPackage offered to Buyer QA  Size Set garments  Size Set Report of internal QA  Bulk Shrinkage Report  Pattern Tracing  Approved Wash Standards (Wash Recipe if applicable)  Samples Check ListPackage sent to the Unit  Size Set garments  Size Set report of external QA  Full Set Patterns  Sample Check ListLT KARLE – ANOOP SINGH & RAJEEV SHARAN 32 NIFT, BANGALORE
    • Apparel internship (2008-2012) CAD DEPARTMENT (SAMPLING SECTION) Process Flow: Blocks (sent by Buyer) Measurement & SpecificationsPattern Preparation (Manually- 4 Pattern Preparation On tables are present) CAD system. Digitization Inspection of Patterns Amendments Marker Preparation Inspection of Marker Amendments Cutting (according to Cutting IndentStitching received from Merchandising Dept.) PlottingSample Inspection Sent to Redesign of Commentsagainst Tech pack Buyer Patterns LT KARLE – ANOOP SINGH & RAJEEV SHARAN 33 NIFT, BANGALORE
    • Apparel internship (2008-2012)Applications:  Marker Preparation (done by Pattern Making & Marking Team)  Fabric Costing (done by Fabric Costing Executives- 2 members)Costing (Process Flow): Marker Development Calculation of average fabric consumption for a garment Calculation of different losses Estimation of Fabric Requirement Fabric CostingSoftware Used:Gerber-8.2LT KARLE – ANOOP SINGH & RAJEEV SHARAN 34 NIFT, BANGALORE
    • Apparel internship (2008-2012)Work instructions for the preparation of pattern-making1. Make the initial pattern  Use the sloper/ tech pack/ sketch provided by buyer.  Make pattern to hit specifications given, use how to measure manual to arrive at measurement given in specification sheet.  Check with Bill Of Material (BOM), to make patterns for shell, trims, interlinings, poly-fills etc.  Provide correct sewing margin.  Provide notches, where required and match all seams.  Mark the grain line.  Mark all placements- pockets, labels, embroidery or patch etc.  Make marking pattern.  Check that the pattern is according to construction sheet, sketch and sample.  Prepare the cutters must and compare with BOM (i.e. in case of change between colour ways- should be mentioned in cutters must).  Write style no., size, name of the pattern, cut quantity and pattern-version.  Prepare pattern check report for measurements, seam matching and notches.  Refer to shrinkage reports. In case of shrinkage/ elongation incorporate it as soft/ hard patterns as applicable.  Clarify with technician in case of doubts.2. Do as follows if check report does not meet the buyer’s specifications  Measure the proto garment to find out whether there was an error in measuring as measurement by QA.  Determine whether error is in measurement or in parts that are mismatched.  Compare fabric report with shrinkage & elongation report.  Compare actual fusing, ironing shrinkage/ elongation with lab reports.  Take corrective action.LT KARLE – ANOOP SINGH & RAJEEV SHARAN 35 NIFT, BANGALORE
    • Apparel internship (2008-2012)3. Repeat the process till we get a proto that in all respect is correct and can be sent to buyer for the review. Put the seal of version on the patterns4. Once the buyer gives the comment the first sample the following needs to be done  Study the comments, compare with the proto sample to understand the requirement.  Study the mock sent by buyer and compare with the proto sample.  Compare comments from buyer on specifications with proto and QA audit report.  Study „how to correct‟ instructions from buyer to understand the requirements.  Compare the above comments with P.V.O and identify the area to be corrected.  Develop a new pattern called fit pattern (P.V.I).  Check whether the new pattern made tally with the revised measurement chart & if all the comments have been incorporated, mention it on the comment sheet.  Check P.V.I and pattern check report.  Destroy previous version hard pattern and maintain in soft copy.  Repeat the above process till fit sample is approved.5. After receiving the approval for fit samples (PPS- preproduction samples), the final approved pattern must be graded to cover the size range.  Follow the grade rules specified by buyer in the tech pack.  Grades are the sizes required by buyer.  Make block patterns, if required (depending on fabric report)  Check all the sizes comparing them with each other to see that grading as per grading rule.  Prepare pattern check report for each size to ensure all measurements are tallying with measurement chart.  Write all reference no., pattern version, name of pattern, number of cut, style no, grain line etc.LT KARLE – ANOOP SINGH & RAJEEV SHARAN 36 NIFT, BANGALORE
    • Apparel internship (2008-2012)  Make multiple patterns for wash garments (depending on the % of shrinkage and group of fabric according to shrinkage)LT KARLE – ANOOP SINGH & RAJEEV SHARAN 37 NIFT, BANGALORE
    • Apparel internship (2008-2012) SPREADING & CUTTING DEPARTMENTLT KARLE – ANOOP SINGH & RAJEEV SHARAN 38 NIFT, BANGALORE
    • Apparel internship (2008-2012)CUTTINGCUTTING SECTION AT KI-1The cutting department at KI-1 is stationed at the second floor and it has state of the artgarment spreading and cutting machines. There are 2 types of cutting carried out at KI-1,mainly:  Manual spreading  Machine spreadingLT KARLE – ANOOP SINGH & RAJEEV SHARAN 39 NIFT, BANGALORE
    • Apparel internship (2008-2012)The cutting section also has within it the CAD department, the re-cutting department, ithas sections for checking, numbering, and panel checking and sorting.Cutting is done with the help of the CNC Gerber cutter (automated) and manuallythrough straight knife and band knife systems.LT KARLE – ANOOP SINGH & RAJEEV SHARAN 40 NIFT, BANGALORE
    • Apparel internship (2008-2012)ORGANIZATION CHART Cutting manager Asst Incharge CAD executive CNC technician Heat sealers CAD operator CNC operator Supervisor spreading P. writer CAD assistant Helper CNC spreader Cutter Helper Layer Runner / body embroidery/ printing Supervisor Numbering P. Helper Sorting Re Fusing Cutting helper checking Bundling cutter helper issuer helper helperLT KARLE – ANOOP SINGH & RAJEEV SHARAN 41 NIFT, BANGALORE
    • Apparel internship (2008-2012)CUTTING SECTION AT LTK-2The cutting section consists of the production in charge, cutting supervisor, cutter,damage cutter, lay girls, lay helpers & clerk for record maintenance. The production incharge is the person responsible for the entire cutting department. Objective of cutting isto separate fabric parts as replica of pattern pieces in marker plan.For fulfilling this requirement cutting master plays a vital role. As the major cost of thegarment is in the fabric, accounting to 60 % of the total cost, so it is very essential thatactual usage of fabric is slightly controlled by scientific methods & procedures.Furniture & Fixtures: 1. Fabric laying table 2. Weight 3. Numbering stickers 4. Lay paper sheet 5. Bundle card 6. Clamps 7. Pencil 8. Patterns 9. Scissors 10. Storage- racks & trolleys. 11. Measuring tapeQUALITY OBJECTIVES:100% achievement of planned batch production efficiency.Cost / minute: Rs 1.45/-Wage: Rs 0.874 per attended minute.Compliance audit score > 80%Internal audit performance > 90%Attrition rate = <5%LT KARLE – ANOOP SINGH & RAJEEV SHARAN 42 NIFT, BANGALORE
    • Apparel internship (2008-2012)Stores, spreading and cutting layoutLT KARLE – ANOOP SINGH & RAJEEV SHARAN 43 NIFT, BANGALORE
    • Apparel internship (2008-2012)LT KARLE – ANOOP SINGH & RAJEEV SHARAN 44 NIFT, BANGALORE
    • Apparel internship (2008-2012)Cutting department AQL =1.5CUTTING (PATTERN SEPERATION ACCORDING TO SHRINKAGE %) PATTERN COLOUR A B C D E F GThe pattern for easy identification is differentiated with the help of different colouredstickersWhen the fabric swatches are sent for washing the shrinkage % of each lot is observedand depending the shrinkage of each lot and depending on which lot fabric is issuedffrom time to time the cutting QA accordingly gives the patternThis colored sticker method is an in house innovation which is very user friendly and isfollowed till date.FORMATS AVAILABLE IN THE CUTTING DEPARTMENT:  Cutting check list  Laying check list  Bundle identification  Bundle checking or recutting reports  Lay record  Daily production status reportLT KARLE – ANOOP SINGH & RAJEEV SHARAN 45 NIFT, BANGALORE
    • Apparel internship (2008-2012)STAFF IN CUTTING DEPARTMENT  Cutting supervisor  Cutting head  CAD operator  Pattern maker  QA  QA assistant  Production writer  Cutting issuer  Cutters  Re –cutters  Layers  Sorting helpers  Embroidery assistant  Helpers  Panel checkersMachines available in C/S:Machine Model Make QuantityStraight knife Streak -II East man 5Band knife STV-376 Wastema 2End cutters EC-3 East man 4Drilling Dz3-ID Dalian 2Plotter GGT ACCUPLOT Gerber 1 100Fusing machine HBP FA 700 Fiblon 1LT KARLE – ANOOP SINGH & RAJEEV SHARAN 46 NIFT, BANGALORE
    • Apparel internship (2008-2012)Fusing machine (complete automatic)Korea fiblonThe machine is divided into  Belt speed  Temperature  Pressure  ON/OFF main  Upper /lower heat temperature  RegulatorFusing material strength is calculated using fusometerThis is used to check the bond strength The machine is japan‟s obha sikiFor example:Fuse line temperature observed:125 degrees centigradeBond strength :400 gmsDuration :15 secsPressure :3 khrLT KARLE – ANOOP SINGH & RAJEEV SHARAN 47 NIFT, BANGALORE
    • Apparel internship (2008-2012) SEWING DEPARTMENTLT KARLE – ANOOP SINGH & RAJEEV SHARAN 48 NIFT, BANGALORE
    • Apparel internship (2008-2012)SEWINGSewing department is where the actual production takes place. The batch should be setaccording to the style . The batch is set based upon the previous time study. Theproduction target for each day is set according to the time study done by IED in order tomeet the shipment day.The layout set up in this factory was batch & assembly(ETON) layout. The batch layoutis where parts like collar, cuff , front etc are prepared and assembly is where all the batchparts are assembled. As soon as the bundles comes to the sewing section, the productionprocess starts.QUALITY OBJECTIVES:100 % achievement of planned batch production efficiency.Cost / minute = 1.45 /-Wage = Rs 0.874 per attended per minuteCompliance audit score > 80%Internal audit performance > 90%Unauthorized absenteeism < 2%Attrition rate : < 5%LT KARLE – ANOOP SINGH & RAJEEV SHARAN 49 NIFT, BANGALORE
    • Apparel internship (2008-2012)Sewing section layout:LT KARLE – ANOOP SINGH & RAJEEV SHARAN 50 NIFT, BANGALORE
    • Apparel internship (2008-2012)SEWING: Every tailor is graded A=Rs 4500 B=Rs 4000 C=Rs 3800ORGANISATION CHART: AGM Production Finishing Production manager incharge executive Supervisor PE Asst System Floor incharge Pattern maker controller Checker Asst system APM controller Ironer Supervisor Finishing Helper helper Tailor Helper Operator Finishing helper Batch mover Poly packer Production bank asst Spot wash Alt tailor Production writerLT KARLE – ANOOP SINGH & RAJEEV SHARAN 51 NIFT, BANGALORE
    • Apparel internship (2008-2012)PROCESS FLOW CHART: Receipt of production file from PE Preparation of unit PPS Unit PPS approval QAM Receipt of machine layout Internal PPM External PPM Cutting /ROM CS Accessories from stores Batch setting Load pilot run Approval of pilot runs by QAM/CPQAD/BUYER QA Bulk loading Monitor production as per target End line checking Accountings & handover to system controllerLT KARLE – ANOOP SINGH & RAJEEV SHARAN 52 NIFT, BANGALORE
    • Apparel internship (2008-2012) LTK-2 MACHINE LIST Machin TOT e TRAINI AL SEN Tot brought R NG FINISHI IN T al from LINE LINE LINE LINE LINE LINE & SECTI NG/ UNI OU in ALLO other TYPE -1 -2 -3 -4 -5 -6 D ON Cutting T T use TED unit 3 S/N 27 26 30 26 23 26 2 10 8 208 208 587 -379 24 1S/N EC 3 2 1 1 1 1 6 0 0 25 25 93 -68 D/N 16 15 15 10 15 15 0 0 0 86 86 124 -38 D/N CS 1 0 0 0 3 0 1 0 0 2 O/L 1 0 1 6 3 1 8 3 1 44 44 112 -68 BUTTON 0 0 0 0 0 0 0 0 3 3 3 19 -16 B/HOLE 0 0 0 0 0 0 5 0 0 5 5 17 -12 B.TAKE 1 1 2 1 1 1 1 0 1 9 9 28 -19 KEY.HOLE 1 1 1 1 1 0 0 0 0 5 5 7 -2 12/N 2 1 0 2 1 0 5 0 0 11 11 0 11 F/OF ARM 0 1 0 0 1 1 0 0 0 3 3 0 3 BLIND H 0 0 0 0 0 0 0 0 0 0 0 0 0 WELT 0 0 0 0 0 0 0 0 0 0 0 3 -3 XY TACKER 1 1 0 0 0 0 0 0 0 2 2 2 0 FLAT LOCK 1 0 1 0 0 0 1 0 0 3 3 3 0 SNAP 2 0 2 0 0 0 0 0 0 FEGGOTING M/C 0 0 0 0 0 0 5 0 0 LT KARLE – ANOOP SINGH & RAJEEV SHARAN 53 NIFT, BANGALORE
    • Apparel internship (2008-2012)The sewing floor has 6 linesA- Shift batchB- Regular batchC- Regular batchD- Regular batchE- Shift batchF-regular batchShift batch the batch runs for 16 hours in a day6 am to 2pm and 2.30 to 10.30pm2:00 – 2.30 (lunch for shift batch)The other batches run for 8 ½ hrs and lunch is from 1pm – 1.30pmLunch timing for other departments is 1.30-2.00pmA batch is in one line has 46 machinesB batch is divided into two lines in two different places has 44 machinesC batch is divided into two lines in two different places 49 machinesD batch is in one line has 43 machinesE and f are divided into parts n assembly has 50 and 46 machines respectively.After parts stitching before it goes to assembly each line has a parts bank where theystore the parts which will then be loaded into the assembly line which is switch tracksystem.LT KARLE – ANOOP SINGH & RAJEEV SHARAN 54 NIFT, BANGALORE
    • Apparel internship (2008-2012)General Manager  Governs the entire unit  Head of the entire unit  Analysis the monthly reports and directly works with the AGM  Discusses the problems to the development team  Plays an integral role in evaluation meeting of the entire organization  Coordinates with chief executive officer about the progress and the issues  Gets the highest salary in the unitAssistant general manager  Is like a factory manager and has roles of a factory manager  Governs the entire production from top  Starting from procurement to shipment  Target is to reach the shipment date  Production manager addresses to the AGM  Reporting to the GM  Unit monthly planning to be prepared by AGM  Order tracking and discuss about the ppm dates etc  Monthly turnover report to be generated by AGMProduction manager:  To look after the production in terms of quantity  Look after the employees in the batch  Supervise the APM‟S  Making sure the target production is reached at the desired time  Coming up with immediate solutions to problems  Keeping a track on production in all the lines  Making changes in PPM if necessary  Try to reach the unit‟s objectivesLT KARLE – ANOOP SINGH & RAJEEV SHARAN 55 NIFT, BANGALORE
    • Apparel internship (2008-2012)  Approve the daily OVER TIME reports produced by production writersAPM  Direct the supervisors  Head of the entire batch  Have to handle and solve all the problems of the batch  Have to report to the PM  Have to make sure that the batch reaches the required target  Plays an important role in pilot runs  Approves daily DPR  Helps the IE in line balancing  Integral part in PPMSUPERVISORS  Directly interacts to the tailors  First hand experience in batch problems  Always on the floor  Helps in time study  Checks on the production and quality hourly  Takes care of the tailors  Can increase the tailors salary if finds them worth  Rates the tailorsSYSTEM CONTROLLERIt is a department where the system controlling head takes care of movement of  Cutting panels  Parts bank  Finished garmentsLT KARLE – ANOOP SINGH & RAJEEV SHARAN 56 NIFT, BANGALORE
    • Apparel internship (2008-2012)  Cutting panels once it is out of the cutting department the system controller has to the sign the report which has the details of the number of panels coming to the shop floor  And it has to tally to the report generated by the sewing department  Any case of missing panels the system controller has to recheck and analyse or else this department will be held responsible  In case of parts bank it has to keep a track on the parts going from parts batch to assembly  In case of finished goods  It has to keep a track on the finished garments going to the finishing department and from there to washing to the head office if necessaryLT KARLE – ANOOP SINGH & RAJEEV SHARAN 57 NIFT, BANGALORE
    • Apparel internship (2008-2012) FINISHING DEPARTMENTLT KARLE – ANOOP SINGH & RAJEEV SHARAN 58 NIFT, BANGALORE
    • Apparel internship (2008-2012)FINISHINGFinishing section consists of the various operations like trimming, ironing, measurementchecking, folding is carried out. In trimming operation sides of the pocket, seams, cuffs(if any) i.e. tiny extensions of the thread are trimmed to give a uniform and finished lookto the garment. After trimming the general checking is done to see the above processesare carried out correctly or not. Ironing is done to set crease wherever required and toremove unwanted wrinkles. This gives a finished look to the garment. After ironing thegarment is sent for final checking where the garment is finally checked for any flaws anddefects. After the final checking the garments are sent for measurement checking beforethe folding operation, here the garment is checked for its measurements against originals.This step is the last operation in finishing which is folding, this includes fastening of allthe tags in proper fashion and folding the garment as per the buyer‟s requirement.LT KARLE – ANOOP SINGH & RAJEEV SHARAN 59 NIFT, BANGALORE
    • Apparel internship (2008-2012)Finishing section layoutLT KARLE – ANOOP SINGH & RAJEEV SHARAN 60 NIFT, BANGALORE
    • Apparel internship (2008-2012)PROCESS FLOW CHART: FINISHING SECTION Receipt of production file & packing approval Receipt of garments from system controller Middle checking AQL inspection Receipt of poly packing approval De dusting with blower Pressing De dusting & removal of cut thread Presentation checking Measurement checking Folding Tagging Poly bag packing To packing sectionLT KARLE – ANOOP SINGH & RAJEEV SHARAN 61 NIFT, BANGALORE
    • Apparel internship (2008-2012)PROCESS FLOW CHART: PACKING SECTION Receipt of poly packed garment from finishing section Sorting out of garments Cartoning & marking Packed AQL by CPQAD Buyer certification ShipmentLT KARLE – ANOOP SINGH & RAJEEV SHARAN 62 NIFT, BANGALORE
    • Apparel internship (2008-2012)STEP ONE• Checking label forA) Style No.B) PO No.• Affixing the price tag• Folding the garment• Placing folded garment in polythene bag and closing the bag• One bag will have one garment.STEP TWO• All the garments placed in polythene bag will undergo Metal detector test• Tested garments will be segregated size wiseSTEP THREE• Setting up carton box• Mentioning product details on the carton box• Placing the garments into carton box• Closing and sealing the carton box• PACKING COMBINATIONS1) Solid color and solid size2) Solid color and assorted size3) Solid size and assorted color.4) Assorted color and assorted size.LT KARLE – ANOOP SINGH & RAJEEV SHARAN 63 NIFT, BANGALORE
    • Apparel internship (2008-2012)QUALITY ASSURANCEEnsuring the production of the garment with reference to the standard specification isknown as quality control. Quality of the garment is inspected in various stages fromfabric to finished garment.Fabric QualityOnce the fabric is received by the stores, it is checked by quality department by 4 pointsystem. Rejection of fabric should be informed to the supplier before 1 week, in case ofno information from the garment unit, the fabric is considered as accepted by the unit andthe supplier won‟t accept any more rejections. So, quality team should work as soon asfabric in-house happens.Common defects found during 4 point inspection 1. Broken stitches 2. Contamination 3. Double pick 4. Miss weave 5. Miss end 6. Stain 7. Slub 8. Stop mark 9. Miss point 10. Knots 11. Mend markLT KARLE – ANOOP SINGH & RAJEEV SHARAN 64 NIFT, BANGALORE
    • Apparel internship (2008-2012)Marker inspectionThe marker plan is inspected for quality parameters before cutting operation. Theparameters include marker length, number of parts, garment size as per pattern, markingsas per pattern, grain lines, notches, marker matching one way, position of numberingplaces.Lay inspectionThe defects occurring during spreading are inspected after the process. The commondefects obtained are to be minimized and account for the following i.e. lay length, laytension, selvedge edge cut, ply height, number of plies, lay alignment etc.Cut part inspectionComponents of the garments are to be cut with dimension of pattern to ensure bettersewing operation. To enhance it some of the common defects that are inspected arenotches, and frayed edges, cut part to pattern check.Sewing inspectionIn this, inspection is done at several stages which are as follows:  Inline inspection - The sewn parts such as Cuff, sleeve attachment, pocket attachment are inspected.  End – of – line Audit – In this auditing of garment Seams, loops, Cuff attachment, and hems.  Pockets and seams are inspected for defects. The defects identified are: Uneven top stitch, broken or skip stitch, wrong SPI, loose tension, marking mismatch etc.  Label- missing, misplaced, slanted, wrong thread, raw edge, uneven tension etc Pocket- Up-down, raw edge, skip, broken or down stitch, uneven topstitch, shade variation, puckeringLT KARLE – ANOOP SINGH & RAJEEV SHARAN 65 NIFT, BANGALORE
    • Apparel internship (2008-2012)  Hem- Improper overlap stitch, roping, puckering, seam mismatch, broken, skip , tension, raw edge  Side Seam- Raw edge, puckering, SPI wrong, uneven stitch, wrong thread, broken, skip, down stitchThese are mostly occurring defects in garment production. An hourly report is maintainedand accordingly settings are kept in production line. In the final inspection AQLStandards (according to buyer requirement ) is adopted to maintain quality.Accepted quality levelIt is the maximum quality level with tolerance within which the product can be acceptedfor its quality, beyond which the product can be rejected. The following chart is used toaccess quality: AQL Lot Size Sample Size 1.5 2.5 4.0 A R A R A R 2-8 2 0 1 0 1 0 1 9-15 3 0 1 0 1 0 1 16-25 5 0 1 0 1 0 1 26-50 8 0 1 0 1 1 2 51-90 13 0 1 1 2 1 2 91-150 20 1 2 1 2 2 3 151-280 30 1 2 2 3 3 4QUALITY OBJECTIVES:Failed audits % = <5%End line defects % = < 10%Cost of poor quality = < 2% of wage billShort shipment % = < 0.3%LT KARLE – ANOOP SINGH & RAJEEV SHARAN 66 NIFT, BANGALORE
    • Apparel internship (2008-2012) MATERIALS DEPARTMENTLT KARLE – ANOOP SINGH & RAJEEV SHARAN 67 NIFT, BANGALORE
    • Apparel internship (2008-2012)MATERIALS DEPARTMENTResponsible for  Receipt,  Storage,  Distribution,  Record keeping and  Identifying surplus and deficient quantities of materials. 1. RECEIPT OF MATERIAL When the materials reach the concerned factories, the inward clerk of material department check the purchase order, invoice, packing slip etc., to ascertain style number, quantity ordered and received, and other specifications of the material. Variations if any between ordered material and received will be brought to the notice of concerned merchandiser to sort out the matter. 2. STORING OF MATERIAL After receipt the material will be stored properly in the respective stores. Before issuing the material for production they have got to be checked/ tested by Raw Material Quality Assurance (RMQA) department. Therefore the material to be given for RMQA will marked with orange colour sticker. After RMQA test the material will be marked with green colour sticker. 3. ISSUING MATERIAL Materials checked by RMQA will be issued to production department for cutting. Sometimes material is issued from one factory to another depending upon the factory in which a particular style is manufactured. For this purpose the dispatch clerk has to prepare delivery challen (DC) and enter in the security counter.LT KARLE – ANOOP SINGH & RAJEEV SHARAN 68 NIFT, BANGALORE
    • Apparel internship (2008-2012) 4. SURPLUS/ DEFICIENT MATERIAL STATUS Materials department is also responsible for detecting surplus / deficient quantity of materials. It will prepare surplus quantity status and advice merchandising department to plan for extra garments. In case of deficiency it will follow up with import, sourcing and merchandising department to ensure that remaining quantity is brought at right time. 5. PROCEDURE FOR IMPORTED MATERIAL Apart from the procedure mentioned above additional formalities have to be completed in respect of imported material. When the material arrives at the respective factories the security department will break open the seal of consignment. Important documents like packing slip, invoice, bill of entry etc., will be checked by inward clerk of materials department. For each imported consignment get a bond number allotted by customs department through EXIM department. The bond number has to be entered in the inward register.LT KARLE – ANOOP SINGH & RAJEEV SHARAN 69 NIFT, BANGALORE
    • Apparel internship (2008-2012)STORESEOUDTA  EXPORT ORIENTED UNITS ARE o LTK-4 o KI-2  DUTY TARRIF AREA o LTK-2 o KI-1DTA pays duties entirely and gets the fabricEOU does not pay the duties and get the fabric; it is as if the fabrics are with customsdeptDTA cannot give fabric to EOUEOU can give fabrics to DTAEOU – export oriented unitDTA – domestic traffic areaFabric storesThe fabric is issued, stored and inspected here. The fabric is only stored, relaxed andissued to the production floor after cutting. The inspection of the fabric is done here.The fabric is inspected using 4 – point defects system. Here 100% fabric inspection isdone.The formula used to calculate total points are:A – Total defect points observed.Net points = (A x 10000)/ (width in cms x length in meters).If this value is greater than 22, than the roll is rejected.LT KARLE – ANOOP SINGH & RAJEEV SHARAN 70 NIFT, BANGALORE
    • Apparel internship (2008-2012)Trims storesThe store maintains both capital and non-capital requirements of the factory. The capitalrequirements of the factory are concerned with the files for maintenance records, datastorage devices, and computers etc. The non-capital requirements are the products usedfor the garment production. The products are sewing threads, labels, zippers, accessories,trims, rivets, fasteners etc. these materials are to be sourced / acquired as per buyer‟srequirement before the actual production.Furniture & Fixtures a) Store Racks b) Trim Storing Racks c) Fabric Inspection MachineQUALITY OBJECTIVES:  100% of time materials issued to sampling with in the stipulated time.  100% of the time submission of trim cards with in the stipulated time.  100% upto date maintenance of store records.  100% submission of counting report with in the stipulated time. Head office team ; Clearance of materials shortage and rejections for all the counting reports within the stipulated time. 100% time stock confirmation with in the stipulated time from the left out bonds. DTA units : 100% of times submission of counting reports with in the stipulated time. 100% planning of extra garments in stage 3. Zero % production loss due to materials departmentLT KARLE – ANOOP SINGH & RAJEEV SHARAN 71 NIFT, BANGALORE
    • Apparel internship (2008-2012) EOU units : 100% of time submission of counting reports within the stipulated time. 100% planning of extra garments in stage 3 100% updation of regulatory and statutory records. Zero % production loss due to material departments.NIKESampling plan chartWoven fabrics yards/mts Inspection quantityless than 2000 yards One roll or 10% which ever is >(1,800mts)2001 to 20,000 yds 10%(1,801-18,000mts)20001-50000 yds 5%(18001-46000mts)Over 50000 yds 3%(46001 mts)Knit fabrics Inspection quantityless than 2000 yards One roll or 10% which ever is >(1,800mts)2001 to 5000 yds 10%(1,801-4600mts)Over 2000yds 3%LT KARLE – ANOOP SINGH & RAJEEV SHARAN 72 NIFT, BANGALORE
    • Apparel internship (2008-2012)Nike acceptable pointFabric type Ind roll pts/100 yds Shipment pointsWoven fabric 20 20Warp knit 20 20Knit fabric 25 20(open or tubular)Acceptance criteria TommyFabric type Roll point /100 yds Shipment pointsWoven fabric 28 20Knits 36 30L.T KARLE sampling planFABRIC ROLL POINT SHIPMENT POINTWoven /knitted 20 20LT KARLE – ANOOP SINGH & RAJEEV SHARAN 73 NIFT, BANGALORE
    • Apparel internship (2008-2012) ORGANISATION CHART: HOD STORES EXECUTIVE STORES JUNIOR EXECUTIVE DOCUMENTATION PLANNING TEAM TEAMComputeroperator Senior assistant Senior fabric and assistant DC & accessories Annexure Senior stock assistant Material issues Senior assistant inwardAssistant fieldwork Helpers Senior Senior assistant assistant fabric accessories Assistant Assistant accessories fabric LT KARLE – ANOOP SINGH & RAJEEV SHARAN 74 NIFT, BANGALORE
    • Apparel internship (2008-2012)PROCESS FLOW CHART – INWARD PROCESS: Stores Receipt Order Status Receipt of Bill Of Materials - QAMS Prepare material Requirement Plan Receipt Of Consignment Inward Process Package verification against Supplier Invoice / Packing Unit Inhouse Status Report Lab Test Forward counting report to merchandising Trim card through HO materials Pass Fail Inspection process Approved Rejected Quality check Pass Fail Generation of counting Report Conditionally approved by Rejected RMQAM / Buyer Forward counting report Inform to purchase executive to HO Storage in rejected area Send it back to Storage of passed materials suppliers Disposal after 6 monthsLT KARLE – ANOOP SINGH & RAJEEV SHARAN 75 NIFT, BANGALORE
    • Apparel internship (2008-2012) Updated MRP Balance material status follow up Forward bills to account for payment Issues to sub stores with issue slip Issue of fabric to cutting section Issues of trims to production based on lay record based on MRS Receipt of end bits from cutting Receipt of left out materials from section production Recutting process OCR OCRLT KARLE – ANOOP SINGH & RAJEEV SHARAN 76 NIFT, BANGALORE
    • Apparel internship (2008-2012)PROCESS FLOW CHART – IUT Stores Receipt of loading schedule from HO Receipt of Bill Of Materials - QAMS Update status to production Receipt Of Materials Inward Process Package verification against packing list for weight & no of packages Materials received with ispection Materials received without inspection Generate in house status report Lab test Trim card for accessories Storage of materials Forward ISI to In style wise house unit & Yes No pass materials - HO Rejected To be inspected Inspection processLT KARLE – ANOOP SINGH & RAJEEV SHARAN 77 NIFT, BANGALORE
    • Apparel internship (2008-2012) Inspection pass Inspection fail Quality checking Conditionally approved by Rejected buyer Counting report Storage in rejected Area Forward CR to materials Dpt – HO – CC to inhouse unit Send the materials to inhouse unit with counting report Storage of passed material Updated MRP BMS follow up Update status to production Issues to sub store with issue slip Issues of fabric to cutting Issues of trims to production section based on lay record based on MRS Receipt of end bits from Receipt of left over cutting section materials from production Recutting process OCR OCRLT KARLE – ANOOP SINGH & RAJEEV SHARAN 78 NIFT, BANGALORE
    • Apparel internship (2008-2012)StoresObjective: Receipt, storage and issue of raw materials and packing materials in order toensure smooth productionScope:This procedure is applicable for receipt storage and issue of all types of raw materialsResponsibility:  merchandising department  Import department  Raw material quality assurance  Materials departmentMaterials department: depending on the documents from merchandiser through materialsdepartment HO on receipt of order statusBased on BOM stores planning team shall prepare the following documents  MRP  Running length material work sheet  Thread work sheetLT KARLE – ANOOP SINGH & RAJEEV SHARAN 79 NIFT, BANGALORE
    • Apparel internship (2008-2012)IUT PROCESSProduction unit shall collect the following documents from-HO materials department onreceipt of loading schedule  Production file  Carton box work sheet  Poly bag work sheetMRP and thread worksheet shall be prepared by the unitStorage of accepted items Storage if failed items (identified by blue sticker) Storage of conditionally approved items (C.A on the blue sticker) Storage of rejected items (red sticker) Once in 6 months review for decision on disposalLT KARLE – ANOOP SINGH & RAJEEV SHARAN 80 NIFT, BANGALORE
    • Apparel internship (2008-2012)PROCESS FLOW CHART – TRIMS Receipt of trims consignment in material department Collect PO & packaging list from materials Dpt Send samples to lab & proceed inspection Trim card – send to merchandiser Go for inspection – AQL Metal detection & heat transfer test Pick samples for inspection as per AQL norms Fail Do inspection as per laid out instruction If fail in any test Check lab test report & merchandiser If no approval report If yes Do not proceed further inform HOD & act as per Make inspection report instruction Pass AQL fail Pass quantity – store in pass Do 100% inspection inspection area / counting Rejected quantity – store in rejected area Inform HOD for further actionLT KARLE – ANOOP SINGH & RAJEEV SHARAN 81 NIFT, BANGALORE
    • Apparel internship (2008-2012)PROCESS FLOW CHART – FABRICS: Receipt of fabric consignment in material department Collect PO & packaging list from materials Dpt Send samples to lab Wash program Swatch cutting non wash program Send swatches from 100% rolls to lab for shrinkage test Shade band & colour Run card Fabric relaxation projection 100% relaxation / ironing & fusing shrinkage Center to selvedge colour verification Width measurement Fabric quality inspection as per 4 point system Inform HOD & Fail act as per Check lab test report instruction Summary report Take decision about acceptance / rejection by head of RMQALT KARLE – ANOOP SINGH & RAJEEV SHARAN 82 NIFT, BANGALORE
    • Apparel internship (2008-2012) IE DEPARTMENTLT KARLE – ANOOP SINGH & RAJEEV SHARAN 83 NIFT, BANGALORE
    • Apparel internship (2008-2012)INDUSTRIAL ENGINEERINGIndustrial Engineering Department is one of most important department in the industry.It helps in up gradation of the production department with different types of studies in thedepartment like capacity, time, production, motion study. To improve the production &achieve target in time it is setup in batch & SAM (standard allotted minute) is calculated.IED follows the GENERAL SEWING DATA (GSD) systemProductivity = the ratio of output produced to the input resources utilized in theproduction.QUALITY OBJECTIVES:100% of time actual SMV shall match with costed SMV with +/- 5% variation (monthly)100% of time actual thread consumption shall match with costed thread consumptionwith +/- 5% variation (monthly).Preparation for the styles so as to reach learning curve targets min of 95%.Maintain helper numbers in sewing line as per SMV‟s (with 5% max variation)Functions of IE department at Karle:Industrial Engineering (IE) department in Karle Group is located in new head office. Ithas two wings. Each of the wings has two teams namely development team working fromhead office and Implementation team working at our apparel factories. The departmentuses specialized software called GSD (general sewing data). 1) Feasibility study: The development team studies the tech pack and determines whether a particular style is possible to manufacture in our organization considering the facilities/resources we have. This information will help the organization to decide whether to accept or reject a particular business proposal.LT KARLE – ANOOP SINGH & RAJEEV SHARAN 84 NIFT, BANGALORE
    • Apparel internship (2008-2012) 2) Time study: The development team studies the time required for manufacturing a particular style. For this purpose the various operations involved in a style are segregated and time required for performance of each operation is calculated. By adding all these time requirements the basic minutes is derived. Another 15% to 20% time is added as human fatigue to determine the time required for manufacturing a garment which is called standard minute value (SMV). This information is required by costing, production planning and production departments. 3) Calculating thread consumption: The development team determines the requirements of thread for manufacturing a style. This information is required for the (a) costing department to arrive at the price to be quoted for the buyer, and (b) merchandising department to decide the quantity of thread to be purchased. 4) Simplifying the style process: The development team works with technicians of sampling department to simplify the construction of a garment at the product development stage itself. 5) Making a sample piece at the factory: After the pre production meeting and before the pilot run production, the implementation team at the unit will prepare a sample piece of the garment to understand the technicalities involved in a style. Difficulties if any found at this level will be resolved by discussing with development team and sampling department. 6) Skill matrix for tailors: The implementation team is responsible for preparing skill matrix of all the tailors working in the unit. This will help the industrial engineers to understand the skill level of each and every tailor so that they can be deployed at appropriate places in the production line. 7) Batch Setting: Before loading a style to production line, the implementation team has to ensure that the number of production lines is available, all machines are in proper condition and there is sufficient number of trained people to handle all the critical operations. 8) Line Balancing: The implementation team has to study the process involved, the time required for each operations, the competent tailors to be placed at eachLT KARLE – ANOOP SINGH & RAJEEV SHARAN 85 NIFT, BANGALORE
    • Apparel internship (2008-2012) machine of the production line, and the tasks to be performed by each tailors so that all the tailors in the line get the work properly distributed. 9) Actual time study: The SMV calculated by development team is only an estimate done in controlled condition at head office The implementation team will actually do the time study at the factory after a style is loaded for mass production. This will help the I.E. department to ascertain the variation between the SMV calculated by development team and the actual time consumed for making a garment. It will also help the production planning department to fix the daily production targets for the production functionaries. 10) Daily production report: The implementation team prepares the daily production report for each style and sends it to production planning department.Role of IEPre productionAnalyze the garmentSee the 3 M‟s: MAN MATERIAL AND MACHINE requirement for the particulargarment and quantityThis includes  Operation break down  Thread consumption report  Machine list  Machine layoutDuring productionLine balancing  Theoretical balancing :based on the SMV values  Dynamic balancing: practical one based on the absenteeismLT KARLE – ANOOP SINGH & RAJEEV SHARAN 86 NIFT, BANGALORE
    • Apparel internship (2008-2012)Post productionAfter the production is over the IE has to report to the development team if there has tobe any changes or any kind of problems faced during the production so that thoseproblems don‟t repeat.Data analysis is done based on the reports generatedOn efficiency, minute, cost, man and machine etcThread consumptionInstruction 1. List down the operation of the garment and enter the type of ink used as per GSD.style bulletin in the operations and machine consumption separately. 2. Measure the scam length of each oper cms using a calibrated measuring tape by excluding the margin. 3. Per each operation add 5cms allowance to the scan length on either side of the scan for scan margin and wastage in threading and enter the values in scan length 4. Enter the number of scans for each operation in frequency collumn. 5. Refer the ratio chart and enter the ratio for each type of machine / stich type used for the operation in the “ratio column. 6. Calculate thread consumption for each operation by formula given below: Thread consumption in cms =SEAM LENGTH X FREQUENCY X RATIO 7. Add the thread consumption for all operations to obtain total thread consumption for garment in cms. 8. Categorise thread consumption machine wise. 9. Calculate thread consumption in meters and enter in thread deatails. 10. Compare thread type colour/quality/stich/density with instructions given in style file. 11. Refer the calculations done and the thread details table to categorise the consumption for each thread type enter the values in thread summary. THREAD RATIOS AND CONSUMPTION Single needle SPi needle bobbin Total ratio 10-12 1.25 1.25 1:2.5 12-14 1.5 1.5 1:3LT KARLE – ANOOP SINGH & RAJEEV SHARAN 87 NIFT, BANGALORE
    • Apparel internship (2008-2012) Single needle top stitch-thicker thread. Spi needle bobbin Total ratio 7 1.5 1.5 1:3 8 1.6 1.4 1:3 Double needle Spi needle bobbin Total ratio 10-12 2.5 2.5 1:5 12-14 3 3 1:6 Chain stich Spi needle looper Total ratio 10-12 2 4 1:6 12-14 2 4 1:6 14-16 3 4 1:7 3 thread overlock Sp1 needle looper Total ratio 10-12 5 15 1:20 12-14 5 17 1:22 14-16 7 19 1:26LT KARLE – ANOOP SINGH & RAJEEV SHARAN 88 NIFT, BANGALORE
    • Apparel internship (2008-2012) 5thread overlock Spi needle looper Total ratio 10-12 5 15 1:20 12-14 5 17 1:22 14-16 7 19 1:26 Single needle No.of plys needle looper Total ratio 4 ply 2 1.4 1:3.4 2ply 1.6 1.4 1:32 needle flat lock (top and bottom cover) Spi Needle 1 Needle 2 Top looper Bottom Total looper 12 2.5 1.5 4 8.25 1:16.25 4 12.252 needle flat lock (top and bottom cover ) spi Needle 1 Needle 2 Top looper Btm looper total 12 3 4 6.4 10 1:23.4 7 16.43 needle flat lock(top and bottom cover ) Spi Needle 1 Needle 2 Needle top btm Total 3(center) 12 2.75 2.5 3.5 7.75 11.5 1:284 needle flat lockSpi Needle 1 Needle 2 Needle 3 Needle 4 Top Btm total looper loop12 2 2.5 2.75 2.25 6.25 14.25 1:30 20:5 9.54 thread over lockSpi Needle1 Needle 2 toploop Btm loop total10 2 1.5 5.5 6.25 1:15.2514 3.5 2.5 7 8 1:21 6 15LT KARLE – ANOOP SINGH & RAJEEV SHARAN 89 NIFT, BANGALORE
    • Apparel internship (2008-2012)Example of thread worksheet of LT KARLE FO IE/F RM M/0 L.T.KARLE NO 2 THREAD CONSUMPTION CALCULATION & Co RE V.N 02 O MERCHANDISIN DA TO DEPT G TE GI 9/1/2011 DEVELOPMENT INDUSTRIAL FROM DEPT VE TEAM ENGG N STYLE NO 1J1245 BASED ON PPS DESCRIPTI Jacket SIZE M ON BUYER A&F SEAM PART T RA OPERA MACHI SP LENGT FREQU S E TI CONSUMP TIONS NE I H IN ENCY NAME X O TION CMS Hood 10 1.2 panels att snt 60 - 74 2 185 5 fell seam 12 10 1.2 snb 40 - 74 2 185 5 12 Hood 15 8- panels att tmncs 81 4 3 972 0 10 FOA 8- bmncs 80 81 4 4 1296 Hood 10 Hood 10 1.2 btm pnls snt 60 - 34 2 85 5 att shell 12 10 1.2 snb 40 - 34 2 85 5 12 Hood 15 8- btm pnls tsn 41 2 1.6 131.2 0 10 att top st bsn 80 8- 41 2 1.4 114.8LT KARLE – ANOOP SINGH & RAJEEV SHARAN 90 NIFT, BANGALORE
    • Apparel internship (2008-2012) 10 Hood 10 1.2 lining snt 60 - 74 2 185 5 pnls att 12 10 1.2 snb 40 - 74 2 185 5 12 Hood in 10 1.2 out pnls snt 60 - 94 1 117.5 5 att 12 10 1.2 snb 40 - 94 1 117.5 5 12 Hood in 15 8- out att tsn 101 2 1.6 323.2 0 10 top st dn 8- bsn 80 101 2 1.4 282.8 10 Tape att 10 1.2 to hood snt 60 - 102 1 127.5 5 lining 12 10 1.2 snb 40 - 102 1 127.5 5 12 Tape att 15 8- to hood tsn 111 1 1.6 177.6 0 10 finsh 8- bsn 80 111 1 1.4 155.4 10 Tapr att 15 8- to tsn 74 2 1.6 236.8 0 10 neckline 8- bsn 80 74 2 1.4 207.2 10 10 Prepare snt 60 - 30 1 3.2 96 loop 12 10 snb 40 - 30 1 2.8 84 Hanger 12 loop Center 15 8- stitch tdn 30 1 3.2 96 0 10 loop 8- bdn 80 30 1 2.8 84 10LT KARLE – ANOOP SINGH & RAJEEV SHARAN 91 NIFT, BANGALORE
    • Apparel internship (2008-2012) 10 Tack snt 60 - 13 4 1.6 83.2 loop 12 10 snb 40 - 13 4 1.4 72.8 12 Runstitch 10 1.2 cuff with snt 60 - 104 2 260 5 intl 12 10 1.2 snb 40 - 104 2 260 5 12 Attach button 15 8- tsn 68 2 1.6 217.6 patch on 0 10 cuff 8- bsn 80 68 2 1.4 190.4 10 10 Run 1.2 snt 60 - 47 2 117.5 stitch tab 5 12 10 1.2 snb 40 - 47 2 117.5 5 12 Cuff top stitch 15 8- tsn 54 2 1.6 172.8 section tab 0 10 8- bsn 80 54 2 1.4 151.2 10 attach 10 1.2 inner snt 60 - 57 2 142.5 5 cuff 12 10 1.2 snb 40 - 57 2 142.5 5 12 Close and 15 8- tsn 64 2 1.6 204.8 finish 0 10 cuff 8- bsn 80 64 2 1.4 179.2 10 Cuff top 15 8- tdn 64 2 3.2 409.6 stitch 0 10 8- bdn 80 64 2 2.8 358.4 10 Sleeve Sew 15 8- tsn 40 1 1.6 64 Section deco 0 10LT KARLE – ANOOP SINGH & RAJEEV SHARAN 92 NIFT, BANGALORE
    • Apparel internship (2008-2012) stitch around label 8- bsn 80 40 1 1.4 56 10 Attach 15 8- label to tsn 37 1 2 74 0 10 sleeve 8- bsn 80 37 1 1.6 59.2 10 Join sleeve 10 1.2 panels snt 60 - 77 2 192.5 5 (One 12 side) 10 1.2 snb 40 - 77 2 192.5 5 12 Top stitch 15 8- tmncs 84 4 3 1008 sleeve 0 10 panels 8- bmncs 80 84 4 4 1344 10 Join sleeve 10 1.2 panels snt 60 - 77 2 192.5 5 (Other 12 side) 10 1.2 snb 40 - 77 2 192.5 5 12 Top stitch 15 8- tmncs 84 4 3 1008 sleeve 0 10 panels 8- bmncs 80 84 4 4 1344 10 Runstitch 10 1.2 flap with snt 60 - 0 5 intl 12 Flap 10 1.2 section snb 40 - 0 5 12 Sew 15 8- tdn 37 7 3.2 828.8 tarpunto 0 10LT KARLE – ANOOP SINGH & RAJEEV SHARAN 93 NIFT, BANGALORE
    • Apparel internship (2008-2012) stitch on inner flap 8- bdn 80 37 7 2.8 725.2 10 10 Runstitch 1.2 snt 60 - 63 2 157.5 flap 5 12 10 1.2 snb 40 - 63 2 157.5 5 12 Top 15 8- stitch tdn 70 2 3.2 448 0 10 flap 8- bdn 80 70 2 2.8 392 10 10 Flap 1.2 snt 60 - 30 2 75 ready st 5 12 10 1.2 snb 40 - 30 2 75 5 12 10 1.2 Flap att snt 60 - 30 2 75 5 12 10 1.2 snb 40 - 30 2 75 5 12 Flap top 15 8- tdn 37 2 3.2 236.8 st 0 10 8- bdn 80 37 2 2.8 207.2 10 10 Prepare 1.2 snt 60 - 36 1 45 welt 5 12 10 1.2 snb 40 - 36 1 45 5 12 Welt 10 attach 1.2 pocket snt 60 - 25 1 31.25 welt 5 12 10 1.2 snb 40 - 25 1 31.25 5 12 Lock 10 1.2 snt 60 25 1 31.25 welt ends - 5LT KARLE – ANOOP SINGH & RAJEEV SHARAN 94 NIFT, BANGALORE
    • Apparel internship (2008-2012) 12 10 1.2 snb 40 - 25 1 31.25 5 12 Welt att 10 1.2 to K side snt 60 - 30 2 75 5 pkt bag 12 10 1.2 snb 40 - 30 2 75 5 12 P side 10 1.2 pkt bag snt 60 - 30 2 75 5 att 12 10 1.2 snb 40 - 30 2 75 5 12 10 Pkt bag 1.2 snt 60 - 208 2 520 close 5 12 10 1.2 snb 40 - 208 2 520 5 12 Binding 10 1.2 att to pkt snt 60 - 156 2 390 5 bag sides 12 10 1.2 snb 40 - 156 2 390 5 12 10 Binding 1.2 snt 60 - 156 2 390 finish 5 12 10 1.2 snb 40 - 156 2 390 5 12 10 Prepare 1.2 snt 60 - 47 2 117.5 welt 5 12 10 Lower 1.2 snb 40 - 47 2 117.5 welt 5 12 side 15 8- 1.2 pocket Welt att tsn 34 2 85 0 10 5 8- 1.2 bsn 80 34 2 85 10 5 Attach snt 60 10 30 2 1.6 96LT KARLE – ANOOP SINGH & RAJEEV SHARAN 95 NIFT, BANGALORE
    • Apparel internship (2008-2012) binding - to the 12 welt 10 snb 40 - 30 2 1.4 84 12 Finish 15 8- 1.2 tsn 30 2 75 binding 0 10 5 8- 1.2 bsn 80 30 2 75 10 5 P side 10 facing att 1.2 snt 60 - 27 2 67.5 tp pkt 5 12 bag 10 1.2 snb 40 - 27 2 67.5 5 12 P side 10 pkt bag 1.2 snt 60 - 27 2 67.5 tack on 5 12 top 10 1.2 snb 40 - 27 2 67.5 5 12 10 Pkt prns 1.2 snt 60 - 34 2 85 seam att 5 12 10 1.2 snb 40 - 34 2 85 5 12 Pkt prncs 15 8- tsn 41 2 1.6 131.2 seam ts 0 10 8- bsn 80 41 2 1.4 114.8 10 10 lock welt 1.2 snt 60 - 13 2 32.5 ends 5 12 10 1.2 snb 40 - 13 2 32.5 5 12 close 10 1.2 pokcet snt 60 - 156 2 390 5 bag 12 10 1.2 snb 40 - 156 2 390 5 12LT KARLE – ANOOP SINGH & RAJEEV SHARAN 96 NIFT, BANGALORE
    • Apparel internship (2008-2012)Operation bulletin -Time studyAN EXAMPLEOF TIME STUDY DONE IN LTK-2 I E / FORM F NO MTIME STUDY / 1 0 REV.N 0 O 31J1245/ JKT LOADING DATE 17-FebAnF REPORTING DATE 24-FebBnF UNIT LTK - 2 TIME STUDY READING AV ER GS AG AVE MD % D E RAG WITH DIFF OF GSD TIM TIM E Allo ERE DIFOPERA TIME E IN E IN TIME wanc Capa NCE* FER RETOR MACHIN IN SE SE IN e* city/ (GSD EN MANAME E TYPE* MINS CS* T1 T2 T3 T4 T5 CS MINS (6%) Hr - TS) CE* RKSRAMACHANDR SNLSANC UBT 0.475 29 29 32 31 32 31 31 0.52 0.55 116 -0.07 -7%PREMA SNLS -R UBT 1.115 67 69 68 69 70 68 68.8 1.15 1.22 52 -0.10 10%K.N.MA SNLSNJULA UBT 0.854 51 50 51 52 50 49 50.4 0.84 0.89 71 -0.04 -4%RAMACHANDR SNLSANC UBT 0.510 31 33 32 31 33 34 32.6 0.54 0.58 110 -0.07 -7%SAVITH SNLSRAMMA UBT 0.991 59 58 57 56 58 59 57.6 0.96 1.02 63 -0.03 -3%MANJULA.S foa 0.981 59 60 61 62 60 61 60.8 1.01 1.07 59 -0.09 -9%Basavar SNLSaju UBT 0.858 51 49 50 51 48 49 49.4 0.82 0.87 73 -0.01 -1%JAYALAKSHMAMMA DNLS.R.S std 0.897 54 55 57 56 54 53 55 0.92 0.97 65 -0.07 -7%NIRMAL SNLSA UBT 0.783 47 48 47 48 49 46 47.6 0.79 0.84 76 -0.06 -6%NIRMAL SNLSA UBT 0.644 39 40 42 39 41 40 40.4 0.67 0.71 89 -0.07 -7%GAYAT SNLSHRI.H.N UBT 0.494 30 28 29 27 28 30 28.4 0.47 0.50 127 -0.01 -1%GAYAT SNLSHRI.H.N UBT 0.822 49 50 48 49 51 50 49.6 0.83 0.88 73 -0.05 -5%H.D.MA SNLSNJULA UBT 1.354 81 79 80 78 79 81 79.4 1.32 1.40 45 -0.05 -5%VISHAL SNLSAMMA UBT 1.101 66 65 67 68 64 65 65.8 1.10 1.16 55 -0.06 -6%SUJAT SNLSHA.N.T UBT 1.018 61 59 60 61 58 59 59.4 0.99 1.05 61 -0.03 -3%SHANT SNLSHA .K.G UBT 0.948 57 59 57 56 55 57 56.8 0.95 1.00 63 -0.06 -6%LT KARLE – ANOOP SINGH & RAJEEV SHARAN 97 NIFT, BANGALORE
    • Apparel internship (2008-2012)ZAMEER DNLSPASHA std 0.985 59 57 58 60 59 58 58.4 0.97 1.03 62 -0.05 -5%MAHALAKSHM SNLSI.L UBT 1.055 63 64 62 63 62 64 63 1.05 1.11 57 -0.06 -6%BHAGY SNLSA.M UBT 0.653 39 40 38 39 41 40 39.6 0.66 0.70 91 -0.05 -5%BHAGY SNLSA.M UBT 0.729 44 46 45 42 43 44 44 0.73 0.78 82 -0.05 -5%SUNITHABAI.K. SNLSD UBT 0.874 52 52 53 54 52 53 52.8 0.88 0.93 68 -0.06 -6%MUJASSIM SNLSBANU UBT 0.911 55 54 58 57 56 55 56 0.93 0.99 64 -0.08 -8%PRABHAKARA. SNLSB.C UBT 0.700 42 43 40 41 42 44 42 0.70 0.74 86 -0.04 -4%SUBRA SNLSMANI.V UBT 1.117 67 67 65 66 68 70 67.2 1.12 1.19 54 -0.07 -7%PRABHAKARA. SNLSB.C UBT 0.751 45 47 46 45 44 47 45.8 0.76 0.81 79 -0.06 -6%MANJUNATH. SNLSM.G UBT 0.690 41 42 40 41 39 40 40.4 0.67 0.71 89 -0.02 -2%MANJUNATH. SNLSM.G UBT 0.759 46 47 46 45 44 46 45.6 0.76 0.81 79 -0.05 -5%GOWR SNLSAMMA UBT 0.553 33 34 35 34 32 33 33.6 0.56 0.59 107 -0.04 -4%SAVITH DNLSA .B split 1.270 76 78 75 76 75 77 76.2 1.27 1.35 47 -0.08 -8%GOWR SNLSAMMA UBT 0.658 39 40 41 39 38 40 39.6 0.66 0.70 91 -0.04 -4%DEVI DNLS.V.T std 0.840 50 49 48 50 51 50 49.6 0.83 0.88 73 -0.04 -4%DEVI SNLS.V.T UBT 0.845 51 52 53 49 49 50 50.6 0.84 0.89 71 -0.05 -5%VISHWANATH DNLS.H.S std 0.929 56 55 57 58 56 57 56.6 0.94 1.00 64 -0.07 -7%BHAKTHARAJ. DNLSG std 0.746 45 44 46 47 45 46 45.6 0.76 0.81 79 -0.06 -6%GEETH SNLSA.G UBT 1.16 70 72 70 69 71 72 70.8 1.18 1.25 51 -0.09 -9%M.H.SH SNLSANTHA UBT 1.117 67 68 67 68 70 69 68.4 1.14 1.21 53 -0.09 -9%BHAKTHARAJ. SNLSG UBT 0.72 43 43 42 41 42 43 42.2 0.70 0.75 85 -0.03 -3%C.SHOBH SNLS -A UBT 1.017 61 64 62 63 64 63 63.2 1.05 1.12 57 -0.10 10%NARAYANAPPA .J /SUJAT SNLS 12 12 12 119. -HA .P UBT 1.666 100 115 0 4 1 118 6 1.99 2.11 30 -0.45 45%SUJAT SNLSHA .P UBT 0.671 40 38 40 42 41 39 40 0.67 0.71 90 -0.04 -4%SARASWATHI DNLS 0.734 44 42 46 45 47 45 45 0.75 0.80 80 -0.06 -6%LT KARLE – ANOOP SINGH & RAJEEV SHARAN 98 NIFT, BANGALORE
    • Apparel internship (2008-2012).M stdAMARE SNLSSH UBT 0.948 57 57 58 56 58 59 57.6 0.96 1.02 63 -0.07 -7%B.S.SA DNLSVITHA std 0.985 59 60 61 62 59 60 60.4 1.01 1.07 60 -0.08 -8%SARASWATHI SNLS.M UBT 0.364 22 20 19 18 21 22 20 0.33 0.35 180 0.01 1%MANJU SNLSLA .V UBT 0.319 19 15 18 19 20 21 18.6 0.31 0.33 194 -0.01 -1%YOGEE SNLSSH UBT 1.096 66 67 64 65 63 65 64.8 1.08 1.14 56 -0.05 -5%M.S.UM SNLSESH UBT 1.003 60 59 60 62 64 62 61.4 1.02 1.08 59 -0.08 -8%NAGENDRAPP SNLSA UBT 0.937 56 57 58 56 57 56 56.8 0.95 1.00 63 -0.07 -7%MANJU SNLSLA .V UBT 0.837 50 49 50 51 52 50 50.4 0.84 0.89 71 -0.05 -5%Nethrav SNLSathi.B.H UBT 0.831 50 52 53 49 48 50 50.4 0.84 0.89 71 -0.06 -6%Nethrav SNLSathi.B.H UBT 0.733 44 42 43 42 45 46 43.6 0.73 0.77 83 -0.04 -4%KAMAL SNLSA .N.S UBT 0.949 57 57 56 54 56 56 55.8 0.93 0.99 65 -0.04 -4%ASHMA SNLSJABHIN UBT 0.893 54 53 57 56 55 54 55 0.92 0.97 65 -0.08 -8%Sowmy SNLSa UBT 0.949 57 60 59 58 57 59 58.6 0.98 1.04 61 -0.09 -9%Bhagera SNLSthi UBT 0.804 48 46 47 45 44 43 45 0.75 0.80 80 0.01 1%Bhagera SNLS -thi UBT 0.496 30 35 37 38 36 34 36 0.60 0.64 100 -0.14 14%PARIJA DNLSTHA.T std 0.743 45 43 45 44 45 46 44.6 0.74 0.79 81 -0.04 -4%DANAN DNLSJAYA std 0.973 58 59 58 57 58 59 58.2 0.97 1.03 62 -0.06 -6%SUMIT SNLSHRA.V UBT 1.155 69 70 69 68 71 72 70 1.17 1.24 51 -0.08 -8% SNLS -RAVI.K UBT 1.115 67 68 69 70 68 69 68.8 1.15 1.22 52 -0.10 10%GIRISH DNLS.K.B std 1.243 75 75 76 74 75 73 74.6 1.24 1.32 48 -0.07 -7%PARIJA DNLSTHA.T std 0.466 28 27 28 29 27 26 27.4 0.46 0.48 131 -0.02 -2%HEMALATHA.H SNLS.G UBT 1.031 62 64 62 61 63 62 62.4 1.04 1.10 58 -0.07 -7%GAJENDRA.R. SNLSS UBT 0.564 34 37 35 36 33 32 34.6 0.58 0.61 104 -0.05 -5%GAJENDRA.R. SNLSS UBT 0.489 29 27 28 30 29 31 29 0.48 0.51 124 -0.02 -2%VEENA SNLS.H.R UBT 1.458 87 89 86 87 86 87 87 1.45 1.54 41 -0.08 -8%SAVITHRAMM SNLSA UBT 0.681 41 42 43 40 41 42 41.6 0.69 0.73 87 -0.05 -5%SAVITHRAMM SNLSA UBT 0.758 45 46 47 46 47 48 46.8 0.78 0.83 77 -0.07 -7%GIRISH SNLS 0.783 47 48 49 50 47 48 48.4 0.81 0.86 74 -0.07 -7%LT KARLE – ANOOP SINGH & RAJEEV SHARAN 99 NIFT, BANGALORE
    • Apparel internship (2008-2012).V.S UBTSHOBHA .L /LAKSH SNLS 14 14 14 -MI DEVI UBT 2.314 139 150 8 7 2 143 146 2.43 2.58 25 -0.27 27%MANJU SNLSNATH H UBT 1.134 68 65 67 65 64 69 66 1.10 1.17 55 -0.03 -3%GIRISH SNLS.V.S UBT 0.431 26 24 25 26 24 25 24.8 0.41 0.44 145 -0.01 -1%SUNITHA .V/ANNAP DNLS 10 10 10 104.URNA std 1.758 105 107 5 3 2 104 2 1.74 1.84 35 -0.08 -8%SUGUN SNLSA .K.P UBT 1.002 60 59 60 62 61 62 60.8 1.01 1.07 59 -0.07 -7%MANJU SNLSLA .A UBT 1.012 61 59 60 62 61 60 60.4 1.01 1.07 60 -0.06 -6%SUGUN SNLSA .K. UBT 0.761 46 45 46 47 45 46 45.8 0.76 0.81 79 -0.05 -5%RAJU SNLS.G UBT 1.445 87 87 89 87 87 85 87 1.45 1.54 41 -0.09 -9%HANUMANTHARAYAP SNLSPA .K.C UBT 0.479 29 27 28 30 28 29 28.4 0.47 0.50 127 -0.02 -2%HANUMANTHARAYAP SNLSPA .K.C UBT 0.722 43 45 42 43 41 42 42.6 0.71 0.75 85 -0.03 -3%J.MAHAMODSALEE SNLSM UBT 0.565 34 34 33 35 34 32 33.6 0.56 0.59 107 -0.03 -3%J.MAHAMODSALEE SNLSM UBT 0.751 45 46 42 43 45 42 43.6 0.73 0.77 83 -0.02 -2%KUMA SNLSR .G UBT 0.392 24 24 23 22 24 25 23.6 0.39 0.42 153 -0.02 -2%KUMA SNLSR .G UBT 0.741 44 46 42 43 45 42 43.6 0.73 0.77 83 -0.03 -3%PADAMAVATH DNLSI std 0.935 56 54 53 56 54 56 54.6 0.91 0.96 66 -0.03 -3%MANJUNATH.S /HANUMANTH SNLS 12 12 12 127. -A. UBT 2.134 128 125 9 7 8 130 8 2.13 2.26 28 -0.12 12%HANUM SNLSANTHA UBT 0.51 31 30 31 30 29 28 29.6 0.49 0.52 122 -0.01 -1%SUNAN SNLSDA UBT 1.012 61 60 62 61 60 59 60.4 1.01 1.07 60 -0.06 -6%MANJUNATHA SNLS.B.M UBT 0.787 47 47 46 45 47 48 46.6 0.78 0.82 77 -0.04 -4%MANJUNATHA SNLS.B.M UBT 0.826 50 49 48 50 51 52 50 0.83 0.88 72 -0.06 -6%LT KARLE – ANOOP SINGH & RAJEEV SHARAN 100 NIFT, BANGALORE
    • Apparel internship (2008-2012)PUTTAPPA SNLS.N.K UBT 0.479 29 27 28 29 30 28 28.4 0.47 0.50 127 -0.02 -2%PUTTAPPA SNLS.N.K UBT 0.722 43 45 42 43 42 40 42.4 0.71 0.75 85 -0.03 -3%D.G.MANJUNA SNLSTH UBT 0.565 34 34 36 35 34 33 34.4 0.57 0.61 105 -0.04 -4%D.G.MANJUNA SNLSTH UBT 0.392 24 24 23 25 26 24 24.4 0.41 0.43 148 -0.04 -4%GANGA SNLSMMA UBT 0.741 44 43 46 45 42 43 43.8 0.73 0.77 82 -0.03 -3%GANGA DNLSMMA std 0.720 43 40 46 45 43 42 43.2 0.72 0.76 83 -0.04 -4%MANJU SNLSNATH.T UBT 0.941 56 57 56 57 56 55 56.2 0.94 0.99 64 -0.05 -5%Radhika DNLS.P std 1.102 66 65 66 67 64 63 65 1.08 1.15 55 -0.05 -5%CHANDRASHEKA SNLSR UBT 0.298 18 15 14 16 15 17 15.4 0.26 0.27 234 0.03 3%MANGALA SNLS.M.M. UBT 1.055 63 64 63 62 63 62 62.8 1.05 1.11 57 -0.05 -5%SHASHI SNLSKALA.V UBT 0.926 56 54 56 56 55 57 55.6 0.93 0.98 65 -0.06 -6%CHANDRASHEKA SNLSR UBT 0.435 26 24 23 25 26 27 25 0.42 0.44 144 -0.01 -1%YAMUN SNLSA .R UBT 0.830 50 49 50 52 51 50 50.4 0.84 0.89 71 -0.06 -6%BHAGY SNLSA. M UBT 0.971 58 57 58 56 55 54 56 0.93 0.99 64 -0.02 -2%UMA.S. SNLSG UBT 0.624 37 37 35 36 38 38 36.8 0.61 0.65 98 -0.03 -3%UMA.S. SNLSG UBT 0.501 30 29 30 31 32 30 30.4 0.51 0.54 118 -0.04 -4%LT KARLE – ANOOP SINGH & RAJEEV SHARAN 101 NIFT, BANGALORE
    • Apparel internship (2008-2012)AN EXAMPLE OF LINE BALANCING DONE IN LTK-2Line balancing:Line balancing can be done two ways:  Theoretical balancing  Dynamic balancing FORM IE/FM/12 NOLT KARLE & CO LINE BALANCING REV NO 1 BUYEUNIT LTK-2 ANF DATE R 16-Feb-2011 STYLBATCH B&F E/DES 1J1245/Jkt C EXCESS /STA COMP. / S Ca M/C SHORTTIO OPERATION M/C REMARKS ON PART M p/h ALLO QN DESCRIPTION TYPE BALANCING AREA V r TED T TIMENO Y Tab Interlining Stay Stitch - SNLS 0.4 12 9.61 Section All around UBT 75 6 0.5 20 Tab ready (round shape SNLS 1.1 54 12.12 )2 nos UBT 15 1 11 Round cnr tab -both SNLS 0.8 70 23.33 sides edge st UBT 54 1 27 SNLS 0.5 11 8.14 Tab attach 2 nos UBT 10 8 0.5 16 Sleeve Slv pnls att- fell seam- SNLS 0.9 61 17.45 Section SNLS UBT 91 1 18 0.9 61 17.86 TS- Slv pnls- FOA foa 81 1 18 SNLS 0.8 70 23.17 Slv sides close - sls UBT 58 1 27 Top sew sleeve joint / DNLS 0.8 67 21.48 Dn- 1 seam std 97 1 24 BAL WITH Attach twill tape to slv SNLS 0.7 77 -3.7 SLEEVE SIDE9 panel - One side panel UBT 83 0.5 -5 CLOSE Rectangular patch att to SNLS 0.6 93 2.310 sleeve- SNLS UBT 44 0.5 4 SNLS 0.4 12 8.811 Sleeve facing pnls att UBT 94 1 0.5 18 Stay stch on Cuff with SNLS 0.8 BAL WITH PREV 73 -5.312 Interlining UBT 22 0.5 -7 OPRN Attach sleeve facing - SNLS 1.3 44 1.813 SNLS UBT 54 1 1 Edge stitch sleeve facing SNLS 1.1 54 12.714 -SNLS UBT 01 1 11 Close sleeve facing - SNLS 1.0 59 16.215 SNLS UBT 18 1 16 Front SNLS 0.9 Princess seam att -SN 63 19.216 Section UBT 48 1 20 Princess seam att - DNLS 0.9 61 17.617 DNTS std 85 1 18 Attach armhole patch - SNLS 1.0 57 14.618 SNLS UBT 55 1 14 Slant Pocket Stay stitch on pocket SNLS 0.6 92 1.919 Section facing with - interlining UBT 53 0.5 3 Facing attach to pkt SNLS 0.7 BAL WITH PREV 82 -1.320 bag-palm& knuckle side UBT 29 0.5 -2 OPRN K.side pkt bag att to frt- SNLS 0.8 69 22.421 slash pkt UBT 74 1 26LT KARLE – ANOOP SINGH & RAJEEV SHARAN 102 NIFT, BANGALORE
    • Apparel internship (2008-2012) Edge st @pkt opening- SNLS 0.9 66 20.822 slash pkt UBT 11 1 23 Top sew pocket opeing - SNLS 0.7 86 -0.123 L shape UBT 00 0.5 0 SNLS 1.1 54 12.024 pkt bag close - pointed UBT 17 1 11 Welt pocket SNLS 0.7 80 -2.3 BAL WITH PREV25 section Sew flap tarpanto stitch- UBT 51 0.5 -3 OPRN Deco stitch on flap - SNLS 0.6 87 0.326 SNLS UBT 90 0.5 0 SNLS 0.7 BAL WITH NEXT 79 -2.627 Attach pull tabs to flap UBT 59 0.5 -3 OPRN Flap ready -v - shape - SNLS 0.5 10 6.228 profile UBT 53 8 0.5 11 D/n top st on flap - flap DNLS 1.2 47 5.429 is creased after ready split 70 1 4 Pkt flap att to ft (2 Flaps SNLS 0.6 91 1.730 )- Gr.st UBT 58 0.5 3 BAL WITH PKT WELT ATT TO 71 -6.1 DNLS 0.8 BODY ( ADD 131 top st@ flap att-DN std 40 0.5 -7 M/C) Welt ready w? interning SNLS 0.8 BAL WITH WELT 71 -6.332 -2 welts UBT 45 0.5 -7 PKT END TACK Pkt welt att to body DNLS 0.9 65 20.133 panel std 29 1 22 welt pkt . Bag attach to DNLS 0.7 BAL WITH PREV 80 -2.134 body panel std 46 0.5 -3 OPRN SNLS 1.1 52 10.135 Welt pkt - ends tack UBT 6 1 9 SNLS 1.1 54 12.036 Attach welt patch -SNLS UBT 17 1 11 Welt pkt kinari ( top SNLS 0.7 BAL WITH NEXT 83 -1.037 side)/ no Ubt UBT 2 0.5 -1 OPRN Welt pkt kinari (Bttm SNLS 1.0 59 16.338 side)/ no Ubt UBT 17 1 16 Attach Pocket binding at close- One side SNLS 1.6 36 18.439 Precreased UBT 66 1.5 11 Back SNLS 0.6 89 1.140 Section Back yoke att - lap seam UBT 71 0.5 2 BAL WITH Top stitch on back yoke DNLS 0.7 82 -1.6 PRINCESS SEAM41 - dnls std 34 0.5 -2 T/S SNLS 0.9 63 19.242 Princess seam att - SN UBT 48 1 20 Princess seam att - DNLS 0.9 61 17.643 DNTS std 85 1 18 Hanger loop rdy - flat SNLS 0.3 16 14.344 lock UBT 64 5 0.5 39 SNLS 0.3 18 16.345 Hanger loop att UBT 19 8 0.5 51 SNLS 1.0 55 12.946 Main label attach - snls UBT 96 1 12 SNLS 1.0 60 16.947 Label att A&f UBT 03 1 17 SNLS 0.9 64 19.748 Label att- A&f UBT 37 1 21 SNLS 0.8 72 -6.049 Label att - A&f UBT 37 0.5 -7 SNLS 0.8 - BAL WITH PREV 72 -8.750 Label att - A&f UBT 31 0.45 11 OPRN Attach poly cover to the SNLS 0.7 82 1.551 main label UBT 33 0.55 2 Hood Att hood shell pnls - SNLS 0.9 63 19.252 Section SNLS UBT 49 1 2053 Hood pnls att top stitch SNLS 0.8 67 1 24 21.6LT KARLE – ANOOP SINGH & RAJEEV SHARAN 103 NIFT, BANGALORE
    • Apparel internship (2008-2012) UBT 93 Att hood lining pnls - SNLS 0.9 63 19.254 SNLS UBT 49 1 20 SNLS 0.8 BAL WITH PREV 75 -4.655 Hood pnls att top stitch UBT 04 0.5 -6 OPRN Decorative st.- SN/ 12 square - single square/ SNLS 0.4 8.7 156 snls UBT 96 0.5 17 Attach hood facing to DNLS 0.7 BAL WITH NEXT 81 -1.957 lining - SNLS std 43 0.5 -3 OPRN Attach tape to lining at DNLS 0.9 62 18.258 facing - SNLS std 73 1 19 SNLS 1.1 52 10.359 Hood sh & ling close UBT 55 1 9 SNLS 1.1 54 12.160 Final close @ hood UBT 15 1 11 Hood finishing from top DNLS 1.2 48 6.661 side - DNLS std 43 1 5 Attach binding to snap DNLS 0.4 12 10.062 patch -DNLS std 66 9 0.5 21 Lock snap patches at SNLS 1.0 58 15.763 ends -SNLS UBT 31 1 15 Attach snap patch to SNLS 0.5 10 5.764 hood UBT 64 6 0.5 10 Top stitch snap patch SNLS 0.4 12 9.065 attach - SNLS UBT 89 3 0.5 18 SNLS 1.4 BAL WITH PREV 41 -2.766 Box stitch & cross st UBT 58 1 -2 PRN Assembly SNLS 0.6 88 0.767 Section Shoulder join UBT 81 0.5 1 SNLS 0.7 79 -2.668 Shoulder pointed / UBT 58 0.5 -3 SNLS 0.7 BAL WITH NEXT 77 -3.769 Arm hole serging UBT 83 0.5 -5 OPRN Stay st SLV & Att to SNLS 2.3 26 20.570 body - SN ubt new UBT 14 2 9 Attach binding at SNLS 1.1 53 11.271 armhole - SNLS Folder UBT 34 1 10 Slv binding kuruk / SNLS 0.4 13 11.572 UBT UBT 31 9 0.5 27 DNLS 1.7 34 14.473 Arm hole top st /snls std 58 1.5 8 SNLS 1.0 60 16.974 Under arm gusset att- sn UBT 02 1 17 Ft.Zipper att. To body - SNLS 1.0 59 16.575 one side UBT 12 1 16 SNLS 0.7 79 -2.776 Frt facing pointed - SN- UBT 61 0.5 -4 SNLS 1.4 BAL WITH NEXT 42 -2.177 facing attach - all round UBT 45 1 -1 OPRN Right SNLS 0.4 12 9.478 Side Interlining att to placket UBT 79 5 0.5 20 Run stitch round placket SNLS 0.7 BAL WITH PREV 83 -1.079 - single placket UBT 22 0.5 -1 OPRN Top stitch round placket SNLS 0.5 10 5.780 - single placket /snls UBT 65 6 0.5 10 Trapunto stch on SNLS 0.7 BAL WITHIN THE 80 -2.381 placket UBT 51 0.5 -3 OPERATION SNLS 0.3 15 13.182 Ready stitch on plkt UBT 92 3 0.5 34 placket attach / new - pre SNLS 0.7 BAL WITHIN THE 81 -1.983 - ironed UBT 41 0.5 -3 OPERATION Attach gross grain tape- DNLS 0.9 64 19.884 dnls std 35 1 21 Box stitch on placket- SNLS 2.1 BAL WITH NEXT 28 -1.885 placket /snls UBT 34 1.5 -1 OPRN Frt hidden plkt att - one SNLS 0.5 11 8.186 Left Side side UBT 1 8 0.5 16LT KARLE – ANOOP SINGH & RAJEEV SHARAN 104 NIFT, BANGALORE
    • Apparel internship (2008-2012) Ft.Zipper att. To body - SNLS 1.0 59 16.587 one side UBT 12 1 16 SNLS 0.7 BAL WITH PREV 76 -3.888 Zipper finish UBT 87 0.5 -5 OPRN Trapunto stch on SNLS 0.8 BAL WITH NEXT 73 -5.589 placket - dnls UBT 26 0.5 -7 OPRN SNLS 0.4 12 9.490 Interlining att to placket UBT 79 5 0.5 20 Run stitch round placket SNLS 0.7 BAL WITH NEXT 83 -1.091 - single placket UBT 22 0.5 -1 OPRN Top stitch round placket SNLS 0.5 10 5.792 - single placket /snls UBT 65 6 0.5 10 SNLS 0.3 15 13.193 Ready stitch on plkt UBT 92 3 0.5 34 placket attach / new - pre SNLS 0.7 BAL WITH PREV 81 -1.994 - ironed UBT 41 0.5 -3 OPRN BAL WITH Top stitch placket attach DNLS 0.7 83 -1.0 COLLAR TRIM95 - dnls std 20 0.5 -1 TAPE ATT SNLS 0.9 64 19.596 Hood attach to body UBT 41 1 21 collartrim tape attach DNLS 1.1 54 12.697 /dnls std 02 1 11 SNLS 0.2 20 17.298 Bottom facing pcs att UBT 98 1 0.5 58 SNLS 1.0 57 14.699 Bottom facing att UBT 55 1 14 SNLS 0.9 65 20.2100 Bottom facing att kinari UBT 26 1 22 SNLS 0.4 13 11.3101 Btm corners close UBT 35 8 0.5 26 Trapunto st on btm hem - 2 stitches top and SNLS 0.8 72 24.3102 bottom UBT 30 1 29 Bottom hem - manual SNLS 0.9 62 18.2103 fold / SN (100CM) UBT 71 1 19 Zipper puller ready n SNLS 0.6 96 3.2104 tack UBT 24 0.5 5 SNLS 0.5 12 8.5105 loop tack to puller UBT 01 0 0.5 17 90. 61 1 80TOTAL SMV 90.611 LI NNO.OF MACHINES IN LINE (PLANNED) 80 E O U T P 53 UPITCH TIME (in Minutes) 1.13 T A T 10 0 %HOURLY PITCH TARGET @100 % 53HOURLY PITCH TARGET @ 85 % 45 81.2HOURLY PITCH TARGET @ 80 % 42LT KARLE – ANOOP SINGH & RAJEEV SHARAN 105 NIFT, BANGALORE
    • Apparel internship (2008-2012)ORGANIZATION CHART: Head of IE Development team Implementation team Industrial engineers (GSD practitioners) Senior IE (LTK-2) Senior IE (LTK-1) IE ( batch cutting section / finishing IE section) Time study Time study assistant assistantLT KARLE – ANOOP SINGH & RAJEEV SHARAN 106 NIFT, BANGALORE
    • Apparel internship (2008-2012)PROCESS FLOW : Receipt & updation of tech packs / sample Analysis of tech pack or interaction with sampling department Review of style & process simplification using GSD Study and analysis of style Line balancing exercises & calculations Assessment of available manpower using man power approval formats Study & analysis of cutting section process Time study of finishing section process Co ordination & arrangement of men / machine requirements Time study & method analysis Collection of data – analysis & feedbackLT KARLE – ANOOP SINGH & RAJEEV SHARAN 107 NIFT, BANGALORE
    • Apparel internship (2008-2012) CPQA DEPARTMENTLT KARLE – ANOOP SINGH & RAJEEV SHARAN 108 NIFT, BANGALORE
    • Apparel internship (2008-2012)CENTRAL PRODUCT QUALITY ASSURANCE DEPARTMENT(CPQAD):Quality of the garment is audited in various stages from fabric to finished garment inorder to ensure that the quality of the product as per buyer requirements before releasingshipments.QUALITY OBJECTIVES:1. Zero value loss / Delay in shipment because of not ensuring implementation of buyerrequirements.2. 100% pass rate of final shipment from buyer QA (Monthly)3. Zero customer complaint relating to garment quality4. Zero customer return because of garment quality5. QMS internal audit performance > 90%Data analysis shall be done on monthly basis.MAJOR FUNCTIONS1. QRS Audit – Quality Reference Sample Audit.To ensure that QRS samples meet buyer requirements2. Size Set AuditTo ensure the correctness of the pattern before releasing the same for the Production.3. Quality AuditTo check & ensure that quality of the products conforms (Pilot run & regular prod) tobuyer requirements.4. End line AuditTo check & ensure that the garments are stitched as per the requirement specification.5. Washing unit auditTo ensure that washed / dry processed garments meet the required standards.6. Customer wash test for Addidas.To ensure that washed garment meets the buyer standardsLT KARLE – ANOOP SINGH & RAJEEV SHARAN 109 NIFT, BANGALORE
    • Apparel internship (2008-2012)7. Handling of customer quality complaintsTo analyze the customer quality complaints & take proper CA / PA in order to avoid re-occurrence of the same.8. Calibration of Inspection & measuring Instruments.To ensure accuracy of measuring instruments.9. Control of recordsTo properly maintain records, ensure legibility (readability), easy identification &retrieval.ORGANISATIONAL CHART: HOD Team EDI operator System Embroidery Washing leader operator QA QA QALT KARLE – ANOOP SINGH & RAJEEV SHARAN 110 NIFT, BANGALORE
    • Apparel internship (2008-2012)PROCESS FLOW CHART: Pilot run audit Sample selection for pilot run Check tech pack Metal detection (if applicable) Check BOM Check against PP sample Auditing of packed garment Reporting Cutting section audit Audit – layering & marking Sample selection Cut part to pattern auditing Notches against to pattern auditing Auditing of sobering , bundling & sorting materials ReportingLT KARLE – ANOOP SINGH & RAJEEV SHARAN 111 NIFT, BANGALORE
    • Apparel internship (2008-2012) Endline audit Sample selection Metal detection (if applicable) Visual audit Measurement audit Reporting Review of corrective action Online audit during batch setting Line walk Inspection of sample against PP sample Cross check of sample against tech pack Cross check of sample against BOM Reporting Review of corrective actionLT KARLE – ANOOP SINGH & RAJEEV SHARAN 112 NIFT, BANGALORE
    • Apparel internship (2008-2012) Online audit during finishing process Line walk Inspection of sample against PP sample Cross check of sample against tech pack Cross check of sample against BOM Measurement audit Reporting Review of corrective action First pack audit Sample selection Metal detection check ( if applicable) Initial check Trim verification Visual audit Measurement audit ReportingLT KARLE – ANOOP SINGH & RAJEEV SHARAN 113 NIFT, BANGALORE
    • Apparel internship (2008-2012) Interim audit Carton selection Sample selection Metal detection ( if applicable) Visual audit Measurement audit Reporting Final audit Destination verifying against PO copy Carton selection Packing / ratio auditing Sample selection Metal detection ( if applicable) Visual audit Measurement audit ReportingLT KARLE – ANOOP SINGH & RAJEEV SHARAN 114 NIFT, BANGALORE
    • Apparel internship (2008-2012) PRODUCTION PLANNING DEPARTMENTLT KARLE – ANOOP SINGH & RAJEEV SHARAN 115 NIFT, BANGALORE
    • Apparel internship (2008-2012)PLANNINGPlanning department is in the corporate office 1 which is headed byMr. George who controls the entire organization‟s planning with the help of FASTREACT softwarePlanning department has a planning head and 2 assistants who do the clerical workPlanning head directly reports to the managing director and the GM and AGM of variousunitsRole  Planning is department where all the order details comes from the costing and the merchandising department  Then the planning department plans the production taking in account  The availability of capacity  Brand, whether it can be done in a particular unit for e.g.: Nike gives orders only to KI-2  Certification of the units and various other factorsFunctions  Understand quantity and time schedule  Identify available production capacity  Release the load,  Monitor the production daily  Revise plan on practical aspects  Shipment follow-upBasis for capacity booking  Determine peak efficiency or achievable minutes as under  Eton (automatic movement of pieces) 85%  Switched track 80%  Bundle movement 80%LT KARLE – ANOOP SINGH & RAJEEV SHARAN 116 NIFT, BANGALORE
    • Apparel internship (2008-2012)Understand Learning Curve (for totally new product)• First day 10%• Second day 30%• Third day 40%• Fourth day 60%• Fifth day 80%• Sixth day peak (100%)Understand Learning Curve (for similar product)• First day 30 %• Second day 50%• Third day 75%• Fourth day peak (100%)LT KARLE – ANOOP SINGH & RAJEEV SHARAN 117 NIFT, BANGALORE
    • Apparel internship (2008-2012) HR DEPARTMENTLT KARLE – ANOOP SINGH & RAJEEV SHARAN 118 NIFT, BANGALORE
    • Apparel internship (2008-2012)HUMAN RESOURCE DEPARTMENTIn any organized sector, human resources are the most significant of all resources atcommand & are a critical factor in the success or failure, in effective utilization of allother resources. Its optimal development is the key to success.Human resource development conceptually starts with man power planning on normativeperceptions, keeping in view the specific requirements & problems faced by theparticular sector. It extends in domain to constantly updating the technical knowledge,skill 7 competence of working people,compatible with the trade requirements, training istaking as the prime mover of development of total collective potential of personneldirected towards a set of sectoral objectives.Essential Components: 1. Man Power 2. Selection 3. Training & Development 4. Personnel Appraisal 5. Salary Administration 6. Career development 7. Counseling 8. Organizational development 9. Industrial RelationsLT KARLE – ANOOP SINGH & RAJEEV SHARAN 119 NIFT, BANGALORE
    • Apparel internship (2008-2012)Human resource Unit (authorities reporting) flow Human resource manager head office Human resource manager UNIT-LTK2 Security Head nurse Fire fighting Training centre supervisor head head Securities Fire fighters of Trainees Nurses of each each (tailors) department department Canteen head House keeping headLT KARLE – ANOOP SINGH & RAJEEV SHARAN 120 NIFT, BANGALORE
    • Apparel internship (2008-2012)Pre production meetingObjective: to get full clarity about manufacturing details, quality requirements and inputmaterial status of a particular styleScope: covers all styles of all buyersResponsibility: production executiveProduction executive shall coordinate PPM with necessary production file, patterns,PPS/PRS/QRS/ cross check status of fabric and accessories with merchandiser and recordand circulate minute of meetingPRS: Production reference sampleQRS: Quality reference samplePrerequisites for the meeting:P.E should ensure that the following is available for the meeting:  Production file containing PO copies ,tech pack, FPT- GPT reports, shrinkage reports, interlining test report, trim test reports, fabric width and shade reports, approved minimarker, approved fabric defect standards, approved trim chart, approved print and embroidery standard, size set patterns and unit PPS  In case of urgency, if a few non critical reports are not available the unit head may give approval to proceed with PPMLT KARLE – ANOOP SINGH & RAJEEV SHARAN 121 NIFT, BANGALORE
    • Apparel internship (2008-2012)LIST OF PARTICIPANTS  P.E-To ensure that all required matters are discussed and clarified also takes minutes of meeting and close the issue before PCD  Merchandiser –only for external PPM however external PPM if not there have to sit for internal PPM  Sampling technician: only for external PPM however external PPM if not there have to sit for internal PPM Shall appraise production certificates to production staff and explain status of garment  Production manager:shall discuss about bulk production problems if any regarding change of pattern /construction based on unit PPS report  QAM (Quality assurance manager)- shall ensure production file is understood and discuss any probable quality problems that may rise based on unit PPS inspection  Cutting in charge: problems in cutting  APM: discuss problems in sewing  Stores in charge shall ensure updated status of fabric and accessories are available during PPM  Industrial engineer: shall ensure all critical operations are achievable and explain the same to all and issue thread worksheet  Head mechanic: machine setting, Machine SPI etcLT KARLE – ANOOP SINGH & RAJEEV SHARAN 122 NIFT, BANGALORE
    • Apparel internship (2008-2012) MERCHANDISING DEPARTMENTLT KARLE – ANOOP SINGH & RAJEEV SHARAN 123 NIFT, BANGALORE
    • Apparel internship (2008-2012)MERCHANDISING  This department is in the corporate office #2  Each brand has its own merchandising team  Every merchandiser takes care of his brand and the style allotted to him by the senior merchandiser  For eg: AnF has only 3 merchandisers  Whereas lands end has 32 merchandisersRole:  Merchandiser‟s role starts only after the costing department has decided on the price i.e. the FOB price of the garment  Purchase and sourcing department works at the pace of merchandiser as they get the approval from the costing department and they start sourcing and within 2 days of the approval by merchandiser the fabric order must be placed.  The merchandiser is part of external PPM that is held in the unit  Merchandiser has to prepare trim chart one for buyer and one for unit  Merchandiser must follow up the order and make sure the unit is following all the buyers conditions  Every brand have their own web based software where the merchandisers have an ID and password with which they login and get all the details regarding the brand and the order that they are followingLT KARLE – ANOOP SINGH & RAJEEV SHARAN 124 NIFT, BANGALORE
    • Apparel internship (2008-2012) IT DEPARTMENTLT KARLE – ANOOP SINGH & RAJEEV SHARAN 125 NIFT, BANGALORE
    • Apparel internship (2008-2012)INFRASTRUCTURE  About 400+ Computers  10 Servers  10 Member IT Team  Distributed Location of IT Infrastructure  All the Locations are connected by network (Leased Lines)  Different Software being used e.g. QAMS, FASTREACT, GSD, Intelliview, SALS Payroll, Zimbra, ETON, Norton AntivirusSOFTWARE USED:  StoresIn house software called QAMS,MICROSOFT OFFICE ENTERPRISE  Cutting sectionGERBER for CADMICROSOFT OFFICE ENTERPRISE  Sewing sectionMICROSOFT OFFICE ENTERPRISEGSD  Finishing sectionMICROSOFT OFFICE ENTERPRISE  MerchandisingCARTS (CLIENT SOFTWARE BY LEVIS)EMAIL SUITEMICROSOFT OFFICE SUITEMORE WEB BASED SOFTWARES PROVIDED BY CLIENTS  PlanningFAST REACT  IEGSD(GENERAL SEWING DATA)LT KARLE – ANOOP SINGH & RAJEEV SHARAN 126 NIFT, BANGALORE
    • Apparel internship (2008-2012)DEPARTMENTAL STRUCTUREPROPOSED EXPANSION  ERP System soon  For CRO –implementing Oracle Clinical  Also going in for ISO 27000 & 21 CFR Part 11 certification for CRO(For Security purposes).SAP YET TO BE COMPLETELY IMPLEMENTED BUT ALL THE MODULESARE AVAILABLETraining for specific employees happens twice in a week in the corporate officeThere is a SAP department which governs the training and implementationThis is an expensive set up and the training for the employees which is free happens inthe corporate office which is really expensive and it would take a long time for thecompany to recover the investmentThe company is trying to link all the departments and make the whole process faster thanbefore and since the company being one of the very few who have bought SAP amongstthe garment industries is a big challenge for them to implement it and get the returns.LT KARLE – ANOOP SINGH & RAJEEV SHARAN 127 NIFT, BANGALORE
    • Apparel internship (2008-2012)PROBLEMS  Machine layout limit was exceeding all lines  Switch track system was not utilized properly as the station was only for 40 machines and there were 45 machines  Sweat shop  Untidiness  Too much burden on IE  Lack of helpers  Lack of tailors  Competition between the units sometimes becomes a de merit  Too many sub divisions  Area constraint  Dependence on KI -2 for machinesSECURITY POLICY  Use of external storage device is strictly prohibited, unless authorized by IT team e.g. USB Drive, CD Drive, Floppies  Do not disclose your login credentials  You have to lock ( Ctrl + Alt + Del ) When you are away from your desk  Non standard software to be installed only after you get the approvals from Manager & with IT teamLT KARLE – ANOOP SINGH & RAJEEV SHARAN 128 NIFT, BANGALORE
    • Apparel internship (2008-2012) WASHING DEPARTMENTLT KARLE – ANOOP SINGH & RAJEEV SHARAN 129 NIFT, BANGALORE
    • Apparel internship (2008-2012)WET AND DRY PROCESSING UNIT  Located in LTK-1 premises  Capable of washing 8000 garments a day  Works in two shiftsSTAFF  Mr. Dev Daniel is GM (Wet & Dry process)  Senior operators- 4  Operators- 6  Helpers- 10WET PROCESSESWASHING  Subjecting the garment to water and other chemicals  For appropriate shades  For hand feel  For customized finishDYING  Subjecting the garment to liquid colours so as to give  Appropriate shadesPURPOSE AND STEPS OF WASHINGPURPOSE  To add special finish to the apparelSTEPS  Washing  Hydro extracting  Tumble dryingLT KARLE – ANOOP SINGH & RAJEEV SHARAN 130 NIFT, BANGALORE
    • Apparel internship (2008-2012)TYPES OF WASHING  Softener wash using softener, silicon and water  Rubber ball wash for good feel  Enzyme wash using enzyme for wash down effect  Enzyme stone wash for more wash down effectLT KARLE – ANOOP SINGH & RAJEEV SHARAN 131 NIFT, BANGALORE
    • Apparel internship (2008-2012)WASHING MACHINES  2 side loading machines of 60 Kg each  1 side loading machine of 150 Kg  2 front loading machines of 100 Kg each  2 side loading machines of 200 KGs each  AVERAGE WASHING TIME- 30 minutes to 3.5 hoursHYDRO EXTRACTORMACHINES  1 machine of 100 Kg capacity  1 machine of 50 Kg Capacity  1 machine of 150 KgsTIME REQUIRED FOR HYDRO EXTRACTING  3 to 5 minutesLT KARLE – ANOOP SINGH & RAJEEV SHARAN 132 NIFT, BANGALORE
    • Apparel internship (2008-2012)OBJECTIVE OF HYDRO EXTRACTING  To extract the water from wet clothesTUMBLE DRYINGMACHINES  2 machines of 125 Kg each  3 machines of 60 Kg each  4 machines of 150 KG eachTIME REQUIRED FOR TUMBLE DRYING  50 minutes approximatelyTHE OBJECTIVE TUMBLE DRYING  to dry the wet clothLT KARLE – ANOOP SINGH & RAJEEV SHARAN 133 NIFT, BANGALORE
    • Apparel internship (2008-2012)DRY PROCESSES“Subjecting garments to value addition processes to give special look.”Sand BlastingBlasting specific areas of the garment with high pressure sand to get it faded look.LT KARLE – ANOOP SINGH & RAJEEV SHARAN 134 NIFT, BANGALORE
    • Apparel internship (2008-2012)GrindingDamaging the garment to give vintage look.SprayingSpraying colour for bleaching/ colouring.StainingStaining the garment with colour / grease to give a vintage look.LT KARLE – ANOOP SINGH & RAJEEV SHARAN 135 NIFT, BANGALORE
    • Apparel internship (2008-2012) SYSTEMS &AUDIT DEPARTMENTLT KARLE – ANOOP SINGH & RAJEEV SHARAN 136 NIFT, BANGALORE
    • Apparel internship (2008-2012)RESPONSIBLE FOR:  Establish, document, implement and Maintain QMS in the Karle group of companies.  Implementation of other process improvement tools like Six sigma.ISO 9001 CERTIFICATION  Following have been certified for ISO 9001-2008 QMS std : o Apparel division (Corporate office, all units – LTK4,KI1,KI2 and LTK2) o Karle Integrated Package Pvt ltd (KIPL)REQUIREMENTS OF QMS IMPLEMENTATION  Documenting, organization structure, job specification and job description for each and every position in each and every dept.  Establishing quality objectives  Documenting process flow charts and process interaction charts for each and every dept.  Documenting standard operating procedures (SOPs) for each and every depts/ processes  Documenting work instructions wherever applicable.  Preparing quality manualTRAINING AND EDUCATION FOR IMPLEMENTATION  Group leaders will be selected and trained.  Each group leader will in turn train about 15 to 20 people around him.  Pick and speak programme every Saturday morning.INTERNAL AUDIT  Train a group of people selected from different departments as auditors.  Audit each department at 3-6 months interval based on the importanceLT KARLE – ANOOP SINGH & RAJEEV SHARAN 137 NIFT, BANGALORE
    • Apparel internship (2008-2012)  Identify and report non conformities.  Non-Conformities (NC‟s) will be rectified by the HOD‟s  Management Review meeting once in 3 months to review progress in the matter.QMS DOCUMENTS REVIEW  After each internal audit, QMS documentation will be reviewed with concerned HODs to ensure continual suitability.Quality Objective Review Meetings (QORM)  Conducted once in a month  Attended by all HODs and chaired by the CEO  To discuss the quality objectives achievements  HODs to forward the data of objectives met latest by 10th of every month  Meeting to be held by 15th of every month.LT KARLE – ANOOP SINGH & RAJEEV SHARAN 138 NIFT, BANGALORE
    • Apparel internship (2008-2012) EXPORT & IMPORT DEPARTMENTLT KARLE – ANOOP SINGH & RAJEEV SHARAN 139 NIFT, BANGALORE
    • Apparel internship (2008-2012)IMPORTS AND EXPORTS DEPARTMENT  Headed by Mr.Ramu  Located in New Head Office  Has a office in Chennai also.Major Responsibilities  Importing raw materials and capital goods required for use in our business.  Exporting of finished goods to buyer destinationsAdvisory roleThis department advises the management whether DTA scheme or 100% EOU scheme isappropriate in each case.  Export Oriented Unit (EOU) (KI-2 & LTK-4 – EOU)  Domestic Tariff Area (DTA) (KI-1 & LTK-2 – DTA)Import related functions  Nominating freight and forwarding agency in foreign country  Customs clearance of imported material  Bonding activities for 100% EOUsExport related functions  Understanding Buyer/ Consolidator SOPs for different countries.  Arranging transportation to the port  Customs Clearance  Handing over goods to buyer‟s consolidatorDocumentation functions 1. PRE-SHIPMENT DOCUMENTS  Invoice (commercial information of the goods),  Packing list (number of pockets, contents etc), andLT KARLE – ANOOP SINGH & RAJEEV SHARAN 140 NIFT, BANGALORE
    • Apparel internship (2008-2012)  Certificate of origin issued by local chamber of commerce like FKCCI (Federation of Karnataka chamber of commerce Industries) or BCIC(Bangalore Chamber of Industry Commerce) 2. BUYER DOCUMENTS  Another set of similar documents to be sent to buyer to enable him take delivery of goods. 3. PAYMENT RELATED DOCUMENTS  letter of credit,  invoice,  packing list,  certificate of origin,  Cargo bill/ bill of lading etc.Miscellaneous functions  Payment follow-up to freight forwarders.  Closure of statutory books  Returns submission  Liaisoning with customs department  Follow-up for duty drawback and export incentivesImportant organizations in foreign trade  Director General of foreign trade  Customs department  Reserve Bank of India (Monitor & control price of Indian rupee against foreign currency)  Apparel export promotion councilLT KARLE – ANOOP SINGH & RAJEEV SHARAN 141 NIFT, BANGALORE
    • Apparel internship (2008-2012) FINANCE DEPARTMENTLT KARLE – ANOOP SINGH & RAJEEV SHARAN 142 NIFT, BANGALORE
    • Apparel internship (2008-2012)FINANCE DEPARTMENTHeaded by  Mr.Gururaja Bhat, Chief Finance Officer with a Team 42 people.Role of Finance Department  Planning  Sourcing and  ManagingMonetary issue of the companyMajor functions  Receipts and payments  Cost control  Treasury- cash, forex and Hedging (Value against Indian rupee)  Insurance  Recovering dues from buyers  Taxation  Accounting / book keeping  Returns submission  Licenses and approvals  Legal aspects  General purchases  Gen Administration- Civil, Electrical and securityLT KARLE – ANOOP SINGH & RAJEEV SHARAN 143 NIFT, BANGALORE
    • Apparel internship (2008-2012)Organization ChartLT KARLE – ANOOP SINGH & RAJEEV SHARAN 144 NIFT, BANGALORE
    • Apparel internship (2008-2012) FACILITIES DEPARTMENTLT KARLE – ANOOP SINGH & RAJEEV SHARAN 145 NIFT, BANGALORE
    • Apparel internship (2008-2012)FACILITIES DEPARTMENT  It is located in old head office  Headed by Mr. Sai Ram  Serves all the companies in Karle groupOrganizational StructureMajor functionsMaintenance of buildingsMaintenance of machinesProtecting people and property of Karle groupHelping in compliance issues- safety, health etc.TransportationLT KARLE – ANOOP SINGH & RAJEEV SHARAN 146 NIFT, BANGALORE
    • Apparel internship (2008-2012)Maintenance of buildingsCivil worksElectricalSewagePlumbingPaintingWater servicePower generatorsBoilersCarpentryAny other allied servicesEffluent/Sewage Treatment Plant (ETP/STP)Maintenance of MachinesInstallation of machinesRepairing / servicing of machinesHiring of machinesProcuring of spare partsTransportationMaintenance of company vehiclesHiring and managing driversProviding transportation services to group companiesProtecting people and property of Karle groupRecruitment and selection of security personnelTraining and development of security personnelMonitoring movement of people in Karle groupMonitoring movement of goods in Karle groupHousekeeping servicesCleaning and upkeep of both head officesLT KARLE – ANOOP SINGH & RAJEEV SHARAN 147 NIFT, BANGALORE
    • Apparel internship (2008-2012) COSTING DEPARTMENTLT KARLE – ANOOP SINGH & RAJEEV SHARAN 148 NIFT, BANGALORE
    • Apparel internship (2008-2012)COSTING DEPARTMENTThere will be enquiry from prospective buyerCosting department is responsible for quoting correct price for manufacturinggarments to prospective buyers in the shortest possible time.Collecting cost inputs from many departmentsData to determine the price is collected fromIndustrial engineeringSamplingFinanceExport-importSourcingInformation from Industrial engineering deptStandard minute valueThread consumptionFeasibility- is this order/ style possible for KarleSpecial machines required to do this styleInformation from Sampling deptFabric requirement by preparing patterns from the tech pack detailsCost of accessories to be used.Information from Sourcing deptPrice and Supplier informationInformation from Finance dept.Labour and other costs per machineForeign exchange rateLT KARLE – ANOOP SINGH & RAJEEV SHARAN 149 NIFT, BANGALORE
    • Apparel internship (2008-2012)Information from Export & Import dept.Freight chargesClearance chargesDuty drawbacks for domestic tariff area (DTA)(KI-1 & LTK-2 – DTA)(KI-2 & LTK-2 – EOU)Preparation of cost sheetCompute the data collected from other depts.Add wastage costAdd profitScrutinize the price it signed by CEO GetSubmit to the prospective buyerOrder review before style confirmationConfirm the orderHandover the files to MerchandisingLT KARLE – ANOOP SINGH & RAJEEV SHARAN 150 NIFT, BANGALORE
    • Apparel internship (2008-2012)OBSERVATION AND LEARNING 1. Insight into the working of Garment Industry. 2. It was a bridge between the theoretical knowledge and practical application. 3. Understood the difference or the variation in handling of different type of fabrics and its effect on the work process in the cutting department. 4. Developed inter-personal communication skills and learnt how it varies as one moves down or up the hierarchy. 5. Developed the understanding of the thinking process of a worker and how it should be dealt with in the best interests of the organization. 6. Lastly, realized how each entity of a factory, be it worker, machine or managers, work together to attain the goals of a company.LT KARLE – ANOOP SINGH & RAJEEV SHARAN 151 NIFT, BANGALORE