The document provides an internship report for Kay & Emms pvt Ltd prepared by Muhammad Qasim. It summarizes the company's operations including its vision, core values, and major departments like merchandising, sampling, costing, cutting, stitching, printing, embroidery, quality control, finishing, packing and major customers. It analyzes different types of production systems used in the apparel industry and their impact on cost, quality and productivity. The conclusion emphasizes that selecting an efficient production system is important for reducing defects and increasing productivity in the sewing department.

1. INTERNSHIP REPORT
Kay & Emms pvt Ltd
Supervised by: Sir falik sher
Prepared By: Muhammad Qasim
16-NTU-1303
Semester:7th
Date of Submission:20-09-2019
National Textile UniversityFaisalabad

2. Dedications
Dedications I dedicate this report to my loving parents whose prays, affection and
support are always a source of encouragement for me to reach at this destination
and a humble icon for others in future. My parent and teachers who give me real
eyes that help me to leads myself and others in the dark and cruel world. My
parent and teachers who give me real eyes that help me to leads myself and
others in the dark and cruel world.

3. Acknowledgement
The credit for the completion of reportgoes to a number of peoples. First of all
I thankfulto Allah Almighty, for providingmestrength and resources to carry
out the research. Then I wantto thank my parentswho provided mewith
unconditional loveand moralsupportso I became able to do this in an
efficient way. I wish to thank all who helped me in makingthis report. I am
very thank fullto Mr. ‘SadaqatRasool’ theGeneralManger of HR department
in KAY & EMMSFaisalabad, who madeKAY & EMM Successable for me. I am
thankfulto Mr. ‘WaseemSafdar’ the Manger of PPC & I.E who helped me and
guided my effortsin the right direction. I am also very thankfulto all people
who helped me and worked with me in KAY& EMMS.

4. Abstract
Through critical and deep study, this reportexamines the types of production
systems that are used in apparelindustry of Pakistan. It shows the analysis
and comparison of production systemswith respect to cost, quality and
productivity. Sincethe function of sewing departmentmainly dependson the
typeof production system, its selection needs to be done carefully. This study
is based on the analysisof the handlingtime required to complete the
operationsof a polo shirt, as the needletime is constant in all typesof
systems. This thesis also focuses on the positive and negative aspects of
production systems. It demonstratesthat the industry hasmade significant
progresstowardscomprehendingthe necessity of proper production system
which has implications on the overall productivity of an apparelmill.

5. Introduction
Established in 1990, today Kay & Emms(Pvt) Ltd is one of the leading
manufacturersof knitted apparelin Pakistan. With the experience of more
than21 yearsin the industry, Kay & Emmshave served several differentmajor
brandsand labels in the US and Europe. Kay & Emmsis capable of producing
differentstyles of men, ladies and children from basic to high fashion with
extensive embellishments. Kay& Emmsdeals in 100% cotton and cotton-
blended fabrics. Fleece, interlocks, Ribs and cotton-spandexfabrics are
strengths of Kay & Emms and severalother programslike Jerseys, Piquesand
thermals are also manufactured every year. Thevertically integrated
operationshelp Kay & Emmsto achieve shorter lead times and greater
flexibility to cater to the customers’demand and their satisfaction. As a
businesswe can produce70,000 piecesper week. The factories are producing
a range of knitted jersey topsand bottoms with heavy embellishments for
Children’s, Ladies and Menswear.

6. BOARD OF DIRECTORS
Mr. Sharif Tariq (chairman)
Mr. khurram Tariq (chief Executive Officer)
Mr. Moazzam Tariq ( Director Operations)

7. Vision:
To be “the best of the knits” through culture & excellence and be a
meaningful contributor to Society.
Mission:
“Sustainable organic growth through amazing customer experience,
vendor partnership, innovation, quality and commitment, providing
exceptional value to all of its stake holders.”
Stakeholders include
1- Customers 2- Employees 3 – Vendors 4 – Shareholders 5 – Society
Core Values
1- Trust
2- Agility
3- Service
4- Coordination
5- Ownership
6- Truthful Information Sharing

8. MERCHANDISING
Merchandisingis a process through which productsareplanned, developed,
executed and presented to the buyer. It includesdirecting and overseeingthe
developmentof productlinefrom start to finish. Marketing and
merchandisingdepartment: A team of merchandisersand markets work
together under aprofit controls head. Merchandisershandlethe foreign
buyers. The teams are makingaccording to the buyersbeing handled.
Two typesof merchandisingdonein garment exports.
1) Marketingmerchandising.
2) Productmerchandising.
Marketing Merchandising
Main function of market merchandisingis
 ProductDevelopment
 Costing
 Ordering
Marketingmerchandisingis to bring orderscostly products
developmentand ithas direct contact with the buyer.
Product Merchandising:
Productmerchandisingis donein the unit. This includesall the
responsibilities from sourcingto finishingi.e. first sample onwards, the
productsmerchandisingwork start and endstill shipment.
Merchandiser’s key responsibilities are as follows...
 Product Development
 Market and product Analysis
 Selling the concepts
 Booking order
 Confirming Deliveries
 Costing

9.  Raw Material
 Flow Monitoring
 Production Follow Ups
 Payments Follows
Sampling:
Sampling is the Research and Development section of the garment
industry. In this department the replicas of the bulk is produced.
The samples are produced according to the spec sheet in single size
and sent for buyer approval; the sample is the representative of the
whole bulk. This initiates the actual production. Sampling process is
responsible to monitor quality at minimum cost. The samples
garment is prepared in the sampling department with great care
because these samples represent the capability of the company and
in order to procure orders to the company. This is done very
cautiously checking every minute thing getting the sample to
perfection as per the buyer’s requirements in the spec sheet.
Costing
Costing includes all the activities like purchase of raw materials and
accessories, knitting fabrics, processing and finishing of fabrics,
sewing and packing of garments, transport and conveyance,
shipping, over heads, banking charges and commissions, etc. The
method of making costing will vary from style to style. As there are
many different styles in garments, it is not possible here to discuss
about all the styles. Hence let us take some following styles as
examples which are in regular use.

10. We have to find out following things.
 Fabric consumption
 Gross weight of other components of garment.
 Fabric cost per kg.
 Fabric cost per garment.
 Other charges (print, embroidery, etc.)
 Cost of trims (labels, tags, badges, twill tapes, buttons, bows,
etc.
Cutting
Cutting is the very first process in garment manufacturing. The
cutting department receives the fabric from the fabric department
after inspection.
Objectives of the department
 Cutting according to the master patterns with 100% accuracy.
 Ensuring 100% quality in cutting.
 100% issue of all the parts to sewing section.
The cutting floor is a combined unit for spreading, cutting, ticketing
and bundling. The work of cutting department starts right from the
point of order being received from the buyer by the merchandising
department.
Types of cutting
Auto cutting
Automation is justified only if it is used to the fullest extent. The
intention is to de-skill and increase production, and wherever

11. possible economize on cost. All the three purposes should be
achieved; otherwise the advantage of automation may not be one
hundred percent. Use laser for cutting, cutting is done by machines,
using command system.
Manual Cutting
Here cutting and spreading is done by manual method, skill level is
most important factor in the manual cutting and spreading.

12. INDUCTION
 After cutting 100% inspection of cut panels is done.
 Rejected pieces are replaced so that it may not disturb
stitching.
 In induction quantity of the cut panels is making sure.
 In induction quality of cut panels is checked to reduce human
errors.
 In induction bar codes are generated against related work
order.
 Re-bundling is done according to work order detail.

13. Stitching
What is Stitching?
This is the main assembly stage of the production process, where
sewers stitch fabric pieces together, and a garment is assembled.
What is Machine?
Combination of different mechanical parts, which reduces the
human effort to achieve target.
There are several types of machines for stitching but usually use.
1) Flat Lock
2) Over Lock
3) Lock Stitch
1. Flat Lock
The machine in which we can use three or multi needles, mostly we
use three-needle machine. There are two lopper, spreader set lower
lopper. Here we use five threads. It can be run without cloth and
complete the stitch but in other machines, this is not possible.

14. 2) Over Lock
An over lock stitch sews over the edge of one or two pieces of cloth
for edging, hemming or seaming. Usually an over lock sewing
machine will cut the edges of the cloth as they are fed through (such
machines are called ‘sergers’ in North America), though some are
made without cutters. The inclusion of automated cutters allows
over lock machines to create finished seams easily and quickly.
An over lock sewing machine differs from a lockstitch sewing
machine in that it uses loppers fed by multiple thread cones rather
than a bobbin.
Loppers serve to create thread loops that pass from the needle
thread to the edges of the fabric so that the edges of the fabric are
contained within the seam. Over lock sewing machines usually run
at high speeds, from 1000 to 9000 rpm, and most are used in
industry for edging, hemming and seaming a variety of fabrics and
products.

15. 3) Lock Stitch
A lock stitch sewing machine binds cloth together with two spools of
thread and a needle with the eye at its base. Distinct from a chain
stitch machine, a lockstitch sewing machine makes strong, straight
seams. It was the first kind of commercial sewing machine to secure
a patent, enter manufacturing, and place automatic sewing in the
hands of millions of households. The machine in which we can use
single needle, there is no lopper. Here we use shuttle for other
thread. In the shuttle, there is bobbin. It may be double needle but
mostly we use single needle lock stitch machine. Here we use two
thread one for needle and other from shuttle. Stitch of this machine
is strong from the other machines.

16. Stitching machines detail

17. Printing
• Embellishment adds value to the garment. We have our own
printing machines and tables complete print set up which
successfully adding features to our products.
• Installed with brand “John Zimer” maxm 8 colors rotary for
printing which can do all design repeats production.

18. Embroidery
• The embroidery division is equipped with latest and
computerized machines.
• The embroidery division is also equipped with 3 “Borodin”
SWF 2 machines computerized embroidery machines. This
division is playing a major role in the growth of export sales.
Supported by top of the line multi heads, 20 heads & 9 colors,
Kay & Emms Equipped with 12 head channel Embroidery.
• Daily production approx. 5,000 pcs
•

19. QualityControl (Q.C)
Introduction
Quality means customer needs is to be satisfied. Failure to maintain
an adequate quality standard can therefore be unsuccessful. But
maintaining an adequate standard of quality also costs effort. From
the first investigation to find out what the potential customer for a
new product really wants, through the processes of design,
specification, controlled manufacture and sale.
There are a number of factors on which quality fitness of garment
industry is based such as - performance, reliability, durability, visual
and perceived quality of the garment. Quality needs to be defined in
terms of a particular framework of cost.
Objectives
To maximize the production of goods within the specified tolerances
correctly the first time. To achieve a satisfactory design of the fabric
or garment in relation to the level of choice in design, styles, colors,
suitability of components and fitness of product for the market.
Quality Control
Quality is of prime importance in any aspect of business. Customers
demand and expect value for money. As producers of apparel there
must be a constant endeavor to produce work of good quality. The
systems required for programming and coordinating the efforts of
the various groups in an organization to maintain the requisite
quality". As such Quality Control is seen as the agent of Quality
Assurance or Total Quality Control. In the garment industry quality
control is practiced right from the initial stage of sourcing raw

20. materials to the stage of final finished garment. For textile and
apparel industry product quality is calculated in terms of quality
and standard of fibers, yarns, fabric construction, color fastness,
surface designs and the final finished garment products. However
quality expectations for export are related to the type of customers
and the retail outlets. Quality control and standards are one of the
most important aspects of the content of any job and therefore a
major factor in training.
Quality Related Problems in Garment Manufacturing
 Sewing defects
 Coloreffects
 Sizing defects
 Garment defects

21. FINISHING & PACKING
Finishing is done before packing. It is been carried out before or
after washing as per the buyer requirement or dependent on the
fabric. The garments from the production section are sent for
washing by segregating them on the basis of sizes, shades. The main
objective of finishing is to finish the garment as per buyer
requirement and present more effectively. Packing is the final stage
of garment industry for shipment of goods. The main objective of
packing is easy transportation of goods. It is also done to maintain
the quality norms of the garment. Packing of the garment is done
depending on the buyer requirement.
In-process flow in finishing
Unwashed Garments
Garments received from the batch audit
Quality and measurement inspection
Button section
Segregation
Trimming

22. Thread sucking
Rough ironing
Final quality and measurement check
Final ironing
Presentation checking
Folding as per the buyers specifications
Packing
Pack audit & Shipment

23. Finishingmachinery detail
List of major Defects
 Brand, care or size
 label missing
 Shading
 Wrong color
 Fabric flaw defect
 Hole in fabric
 Damage
 Conspicuous repair
 Poor construction
 Conspicuous soil age (inside or outside)
 Conspicuous abrasion marks from wash process
 High/ low pockets

24.  Exposed zipper tape
 Buttons, snap defect
 Button hole raveling, incomplete, not cut properly/ miss
aligned
 Sizing problem
 Poorly trimmed garment threads
 Broken stitches
 Skipped stitches
 Open seam

25. Major costumers of KAY & EMMS

26. CONCLUSION
After critical and deep study of all types of production systems that
are used in apparel industry and comparison of production systems
with respect to productivity were allied the importance of a good
production system in sewing unit. An efficient production system
can be used to reduce the off standard performance and increase the
on standard performance. Since the function of sewing department
mainly depends on the type of production system, its correct choice
cannot be further emphasized. Handling time is the major part of
sewing operation which can be minimized as the needle time
remains constant in all types of systems. Production systems are the
key success factor for every company to reduce the cost and boost
the efficiency and productivity of sewing unit.