Modelama Exports - Apparel Manufacturing Internship Presentation

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Modelama Exports - Apparel Manufacturing Internship Presentation by Vinay Prajapati, Atul & Navneet.

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Modelama Exports - Apparel Manufacturing Internship Presentation

  1. 1. Under the Guidance of Presented by Mrs Vasundhara Chaudhary Atul Dwivedi, Navneet Yadav and Associate Professor Vinay Prajapati; M.F.TECH, SEM-III National Institute of Fashion Technology, Gandhinagar19-09-2011 1
  2. 2. COMPANY NAME MODELAMA EXPORTS PVT LTD ADDRESS PLOT NO. 105/106, UDYOG VIHAR, PHASE-1 GURGAON, HARYANA- 122015 HEAD OFFICE B-57 OKHLA INDL. AREA PHASE-1 NEW DELHI- 110020 INDIA TELEPHONE 0124-4008105 FAX 0124-4008108 E MAIL info@modelamaexports.com WEBSITE www.modelamaexports.com YEAR ESTD. 1979 OWNER MR. LALIT GULATI DIRECTORS MR. SANJAY GULATI MR. GAGAN GULATI MR. GAURAV GULATI ANNUAL TURNOVER 60 MILLION (OF ALL FACTORIES) MARKET 100% EXPORT TOTAL COVERED AREA 4,00,000 SQ. FT. TOTAL WORKING FORCE 5500 IN HOUSE/FABRICATION/BOTH BOTH PRODUCTION CAPACITY 8 MILLION/YEAR19-09-2011 2
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  5. 5. VisionModelama will guide its business activities maintaining a balance between ethicalvalues and corporate objectives. The company will strive to achieve its goals byexecuting its strategic plans and caring for the profits of all the stake holders.MissionModelama has a vision to establish itself as a multi-product and multi-servicesbusiness conglomerate. It is committed to expand the spheres of its business activitiesinto newer sectors in the years ahead. The company is confident of building the samebrand image in all areas of its operations that it has in garments and home furnishingsectors19-09-2011 5
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  9. 9. HARYANA184, Udyog Vihar, Phase-I, Gurgaon 105, Udyog Vihar, Phase-I, Gurgaon106, Udyog Vihar, Phase-I, Gurgaon 200, Udyog Vihar, Phase 1,Gurgaon,Mervyns 201, Udyog Vihar,Phase 1 204, Udyog Vihar,Phase 1, Gurgaon660, Udyog Vihar, Phase-V, Gurgaon Plot No-5, IMT Manesar, Sector-4, GurgaonPlot No 7, IMT Manesar, Sector 5,IMTManesar, Plot No 18, IMT Manesar, Sector 5,IMTManesar,Gurgaon GurgaonPlot No 89, IMT Manesar, Sector 8, IMT 529, Phase-I, Bahrhi, Dist. SonipatManesar, GurgaonPlot No 1, Sector 8, Bawal, Dist. RewariCHENNAIPlot No - K 46/47/48/49, Appragel Park , IrunGattukottai. Dist. TairnaturDELHIB-33, Okhla Industrial Area, Phase -1, New Delhi19-09-2011 9
  10. 10. PRODUCT BUYER DEVELOPER MERCHENT SAMPLING FABRIC BUNDILING MARKER CUTTING SPREADING TESTING AND TICKETING PLANNING FINISHING AND PRODUCTION WASHING PACKING DISPATCH PRESSING19-09-2011 10
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  12. 12. A merchant is the person who acts as a link between a buyer and vendor. He is the one who is central or integral part of a garment industry.19-09-2011 12
  13. 13. 1. Chase for fabric/trims prior to PCD date.2. Size sets/PP/TOP samples-Monitoring and delivering.3. Coordinating buying agency QA Inspection. Responsibility19-09-2011 13
  14. 14. This department is not buyer specific and work for all the buyers that companycaters to.19-09-2011 14
  15. 15. PROTO TOP TYPE SIZE SET SAMPLE SAMPLE SAMPLE MADE MADE FIT PP SHIPMENT SAMPLE SAMPLE MADE MADE SAMPLE19-09-2011 15
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  20. 20. SPREADING MARKER LAYERING CUTTING MANUAL/AUTOMATIC TICKETING FUSING CHECKING BUNDLING TRANSFER TO PRODUCTION19-09-2011 20
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  22. 22. FABRIC IS LOADED ON SPREADING MACHINE PERFORATRED PAPER IS SPREAD ON SPREADING TABLE VACCUME IS TURN -ON IN THE SPREADING TABLE AUTOMATIC/MANUAL SPREADING IS DONE PROPER TENTION IS MAINTAINED WHILE WHEN FINISHED, VACCUME IS TURNED OFF MARKER IS SPREAD OVER IT AND PASTED BY TAPE AIR FLOW IS GIVEN FROM BOTTOM TRANSFERRED TO THE CUTTING TABLE19-09-2011 22
  23. 23. Types of cutting devices:1. 5 fusing machine2. 16 straight knife3. 6 edge cutters4. 2 computer aided machines5. 4 spreader6. 1 round knife19-09-2011 23
  24. 24. Parameters Value Speed 100 m/min Thickness can lay 30- 40 cm Working width 2.5 meter Length 20 meter Suction Tables Roll Weight 150 Kg19-09-2011 24
  25. 25. Parameters Value Speed 100 km/hr Thickness can cut 6-7 cm Cutting width 2.54 mtr Cutting Length 3.5 mtr Suction 4 kg/cm219-09-2011 25
  26. 26. Blade Size (inch) 5 6 7 8 Blade Size (cm) 12.7 15.2 17.7 20.3 Cutting Capacity (inch) 3 1/2 4 1/2 5 1/2 6½ Cutting Capacity (cm) 8.89 11.4 13.9 16.5 Stroke Size (inch) 1 1/8 1 1/8 1/4 1/4 Stroke Size (cm) 8.89 8.89 11.4 11.419-09-2011 26
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  28. 28. MODEL HP-1000LW POWER SUPPLY Three phase HEATER:21.6kw RATED OUTPUT MOTOR:705W FUSHING WIDTH 1,000mm MAX.BELTSPEED 12.7m/min MAX.PRESSURE 5kg/cm2 MAX.TEMPERATURE 198℃ HEATING TIME 6.5~31sec. DIMENSIONS 4,327 X 1,606 X 1,255mm WEIGHT (Approx)1,500kg19-09-2011 28
  29. 29. PATTERN MAKING DIGITIZING STYLE/PATTERN DESCRIPTION GRADING CUT ORDER PLANNING MARKER MAKING PRINTING FOR CUTTING19-09-2011 29
  30. 30. Modaris Main equipment used:This software performs the following functions: •Pattern pieces o Pattern making •Digitizer o Pattern modification •Software o Pattern digitizing •Plotter o Pattern grading  FLY PEN  ALYS-30DiaminoThis software is used for marker making. It can be manual or automatic.Efficiency of marker as decided as per the garment in this seam allowancesare also added.OptiplanThis software is used when buyers send uneven ratios.19-09-2011 30
  31. 31. 1. Significant reduction in lead times.2. Reduction in labour costs for generating new styles & modifying existing ones.3. Achieving significant reductions in fabric utilization.4. Block’s images stored in computer.5. Grading technique replaced by expert system. So that grading is now in the form of tables and auto matched.6. Percentage wasted; computed and displayed for each layout.7. Fabric pattern constraints incorporate in the program.8. Cutters replaced by CAD/CAM.9. Wages reduced.19-09-2011 31
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  33. 33. Production floor follows Bundle system. Following are steps to start a production line: Study the production file. Study operation bulletin and set line accordingly. Manpower – tailors and helpers. Load and feeding lines. Arrange buffer or work-in-progress. Manufacturing. Make daily production and to achieve targets accordingly. Understand bottlenecks stage of production19-09-2011 33
  34. 34. Shrinkage production pattern is issued to production floor from CAD department.Ready patterns are made as per the requirement of production room.Cutting receives from cutting department.Cross checking of cut panels with patterns.Bundling of cut panels is done.Operation wise feeding of cut panel into the line.Inline checkpoints.Output of line.Final checkpoints.Auditing of checked pieces.19-09-2011 34
  35. 35. To restore this aesthetic value, they are subjected to cleansing process like washing.19-09-2011 35
  36. 36. Normal WashDesize WashEnzyme WashStone WashSoftenerBleachAcid WashMonkey WashSand Wash19-09-2011 36
  37. 37. Normal Wash Softener WashProcess Time Process TimeDesizing 30 min Desizing 20 minEnzyme 30-60 min Washing 30 minSoftener 20- 30 min Stone WashEnzyme Wash Process TimeProcess Time Desizing 30 minDesizing 30 min Enzyme 30-60 minEnzyme 30-60 min Stone 20 minhypo chloride 30 min hypo chloride 30 minNeutralization 30 min Neutralization 30 minSoftener 20 min Softener 20 min19-09-2011 37
  38. 38. After assembly, the garments now come for finishing- a key stage of garment manufacturing process. Finishing is done to prepare the final garment according to the quality standards of the buyer before packing it for shipment19-09-2011 38
  39. 39. GARMENT SENT FOR COMES FROM PACKING PRODUCTION washing ALTERATION REIRONING MEASUREMENT INITIAL PERSENTATION THREAD CHECKING FINAL /FINAL CUTTING AND CHECHING IRONING SPOTTING19-09-2011 39
  40. 40. Finishing Machines No. of Machines Vacuum Table 60 Up Steam Table 5 Stain Removing Gun 13 Stain Removing W/S 3 Form Finisher 219-09-2011 40
  41. 41. Packing is the last stage where the finished garments are primed, organized,geared up for the shipment to the buyer, the entire process from the way agarment will be folded to the final labelling of the cartons is dictated by thebuyer’s specifications.19-09-2011 41
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  43. 43. 1. All garments packed in individual poly bags.2. Poly bag sticker on poly bags, which may be printed by the factory3. Order must be completed (packed, ready for shipment) prior to bulk orders.4. Order must be inspected and audited by the factory 100%.5. Order must be of first quality, no repair or ungraded garments should be in license shipments.6. Order must be shipped 100% complete otherwise notified.7. The packed goods are now ready to be passed through19-09-2011 43
  44. 44. AQL Chart No. of Cartons Sample Size Pass Fail 5-15 3 0 1 16-50 8 0 1 51-150 20 0 1 151-500 50 1 2 501-1200 80 1 2 1200-up 125 2 319-09-2011 44
  45. 45. 1. Incorrect quality2. Carton labeling error3. Incorrect Prepackaging4. Carton not as per specified size5. Use of wire of metallic strap19-09-2011 45
  46. 46. Shipment Size Sample Size Gap AQL (2.5) Old Navy AQL Level (4.10) Level Pass/Fail Pass/Fail 0-500 20 1/2 2/3 501-1200 32 3/2 3/4 1201-3200 50 3/4 5/6 3201-10000 80 5/6 7/8 10100-35000 125 7/8 10/11 35000 > 200 10/11 14/1519-09-2011 46
  47. 47. Working of IE is as follows: Calculating SMV Making Operation Bulletin Calculation of thread consumption Designing of work aid devices; Folders, Guide & Profiles Update SMV and finalize report Prepare work station layout Line setup Capacity check analysis and feedback Production study and increased efficiency19-09-2011 47
  48. 48. MONITORING OF LOST TIME & OPERATOR PERFORMANCE19-09-2011 48
  49. 49. During the project we observed that initially most of the times were going waste inextra other activities like drinking water etc.It was observed the operators were not flexible to work in the new line setup that’swhy their performance was not up to the mark.With the Help of this project the IE department of the Modelama exports put somepressure on the operator not to waste the time on other activities and increased theaverage performance of Operator from 23.9 to 26%.19-09-2011 49
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