This document provides information about an internship report submitted by Muhammad Kamran and Farman Ullah at Nishat Mills Limited Apparel Division. It begins with an acknowledgment of those who supported and assisted with the internship orientation. It then provides the mission statement and corporate mission of Nishat Apparel. It includes an organizational chart of the different departments at Nishat Apparel and describes the roles and processes within key departments like merchandising, material procurement, product development and sampling, and production planning and control.

1. NISHAT MILLS LIMITED
(APPAREL DIVISION)
7-KM Nishat Avenue off 22-KM Ferozepur Road Lahore, Pakistan.
NISHAT
INTERNSHIP REPORT
WORKED BY:
MUHAMMAD KAMRAN S/O MIR WALI KHAN
FARMAN ULLAH S/O UMER KHAN
SUBMITTED TO:
MAJOR(R) SYED MUBEEN RAZA
(MANAGER HR & ADMIN)
DATE: 14-March-2014

2. ACKNOWLAGMENT
All praises to Allah Almighty, the one and the only, the Merciful, Beneficent and
Compassionate.!I would like to acknowledge the following people for their support and
assistance with this orientation. FromHR Department to SHIPING in the supervision of our
dears MAJOR. MUBEEN RAZA manager( HR department) ,DEPT manager KHALID MEHMOOD
SANDHU(HR) , SAQIB SHAHZAD (HR) , Mr.KASHIF QAYYUM (PPC department), Mr.WASANTHA
(P.D department) ,(Mr.JAWAD KHALID MMC department), Mr.ABDRUL REHMAN (FABRIC
INSPICTION department), Mr.GULAM MUSTAFA (CAD,ABROIDERY,CUTTING department) Mr.
ZAKIR HUSSAIN (SEWING A department), Mr. SHAFQAT AZIZ (SEWING B department),
Mr.NIMAL and (ENGR IRFAN AKHTAR) IE department) ,Mr. ABDRUL REHMAN (QUALITY
ASSURANCE department) ,Mr. MUHAMMAD NAEEM BUTT( G.W.P department), Mr. IFTAHAR
ALI AWAN (FINISHING AND PICKING department) ,Mr.NIAMAT ULLAH (SHIPPING department).
This report would not have become possible without their help and guidance. Special thanks to
Mr. Khalid Mehmoodsandhu& Mr. SaqibShahzadfor their support and care during the
Orientation Programme. I want to thank Nishat Apparel staff for their cooperation and
constant exchange of information was very satisfactory throughout the time and proved
to be a key to optimizing output with regard to the project goals.! I found this Orientation
Programme to be a very positive experience and a unique opportunity for me to gain some
Textileexperience. !

3. MISSION STATEMENT
At Nishat apparel mills limited we aim to serve the need of our costumer and build value for our
stakeholder by continuing to remain in efficient and profitable company at the same we hope
we are creating an environment where talented and exceptional people want to work we are
committed to proving our employs with opportunity for personal and professional growth that
they can find nowhere else. We are dedicated to our operating our facility with the all most
respect for the community and environment in which we live and work
OUR CORPORATE MASSION
 Put the customer first always
 Be flexible to the customer needs
 Adhere to the highest quality standard
 Thinks innovatively but make informed business decision
 Deliver results
Introduction
Nishat group is one of the leading and most diversified groups in Pakistan with fixed/current
assets of over US $ 5 billion .It is ranked among the top five business houses of Pakistan . The
group has strong presence in three most important business sectors of the region namely
textiles, cement and financial services. In addition, the group also has reasonable market share
in Insurance (Adamjee insurance), Power generation and Aviation business .It also has the
distinction of being one of the largest players in each sector. The group has a remarkable
position in the market as good as any MNC operating locally in terms of its quality of products,
services and management skills.

4. Textiles
Nishat Mills Limited, the flagship company of the group was established in 1951. Its annual
turnover for the year is over US $ 280 million. The following are the main division of NML.
Spinning Division
Weaving Division.
Dyeing & Finishing Division.
Printing & Home Division.
Apparel Division.
The apparel division came into existence in 2007 and ever since never looked back. The
factory has capacity to produce 23,000 pcs of garments per day. There are 22 sewing
lines with 65 machines in each line, so in total there are 1800 stitching machines under
one roof which makes it one of the biggest garment unit of the country.
Nishat Apparel
Nishat Mills Ltd is amongst Pakistan’s oldest and most respected institution in the field of
textile processing. Nishat Apparel certified (WRAP , SA-8000 , C-TPAT , & international buyers
code of conducts etc.) is a state of the art facility of garment making and became part of the
Nishat group in 2007. Ever since aspired towards the same standards of quality and pride in
workmanship which has always distinguished Nishat the world over.
At present, Nishat Apparel has twenty two sewing lines. These lines , each of which hosts up to
sixty five machines terminals are manned by experience and highly trained operators .The
stitching lines currently in service are capable of producing woven / denim bottoms of any kind
.A normal eight hour shift is capable of preparing minimum of 23,000 pcs per day . Nishat
apparel main customers are known brands of US and Europe, at the same time efforts are
underway to explore new markets /customers. The main items produced include:

5. Basic 5 pocket Chino trouser
Basic 5 pocket Denim trouser
Ladies jeans
Ladies Capri
Men’s shorts woven/denim
Men’s cargo shorts woven /denim
Ladies 3/4 shorts
At NAL, on average 35,000 meters fabric is cut every day. This work is done with maximum
efficiency in mind, while carefully considering any possible factors related to the fabric being
cut. State of the art software is used to design markers for automatic or manual cutting. Four
Gerber Spreader Machines, capable of spreading eighty layers of fabric in a lay. Two Gerber
high speed heavy duty automatic cutting machines which use air pressure to stabilize the lay
while accurately cutting out any required shape. Two Gerber plotters for printing the cutting
markers.Six Gerber fusing machines to attach linings.In addition to this capability, we also have
machines for manual cutting which can cut through six to ten inches of fabric.
The embroidery facility At NA, possess the capability to produce embroidered design on the
garments. These designs are computer controlled. The shift capacity for our machines is
approximately 4000 pieces each day, depending of course, upon the design. Following
machinery is used to perform this task.Nishat have four Twenty-Head Tajima automatic
embroidery machines in place, totaling eighty terminals. Each terminal is capable of ten
thread/color embroidery design.
At Nishat Apparel, we operate a state of the art washing facilities which perform various tasks, including
finishing, washes and fabrics trimming especially for Denim .Piece dyed washes include:
Softener silicon wash

6. Stone enzyme
Enzyme wash.
Tonello machines from Italy are used for washing. Five dryers are used .fading effect are conducted
manually using sandpaper .Potassium permanganate is sprayed to enhance fading effect .Any wrinkle
/fabric shape setting is performed using curing ovens .The following types of washes for Denim are
available :
Rinse wash (for dark colors)
Enzyme stone wash
Bleach wash
Tint wash
Raisin washes
Garment dyeing.
The finishing facility prepares the garment in their final stage of production. They have ten topper
Naomoto machines, imported from Japan for French and soft pressing. There are also fifty manual irons
for hard pressing. One Ngai garment turning machine and six vertostar thread sucking machines which
automatically clean the garment from any loose threads.
The packaging facility performs three types of packing. We ensure our garment are packed clean and
free of any undesirable contamination. Even the possibility of minute needle fragments in the garment is
not overlooked .every garment is magnetically scanned ensuring the highest safety standards. All same
size garments are packed together. Same color and style garments are packed together.

7. DEPARTMENT LIST FLOW CHART
 MARKETING
 Compliance (HR & EHS )
 FABRIC PRECURMENT
 PRODUCT DEVELOPMENT & SAMPLING
 PRODUCTION PLANING & CONTROL
 MATERIAL MANGMENT MEETING
 GATE OFFICE
 RECEIPT ROOM
 MAIN STORE (Accessory Store)
 FABRIC INSPECTION
 CAD ROOM/AMBROIDERY/CUTTING
 SEWING
 INDUSTRIAL ENGINEERING
 QUALITY ASSURANCE
 GARMENT WET PROCESSING
 FINISHING AND PICKING
 SHIPPING

8. MARKETING/ MERCHANDIZING
Merchandising department is the star of the department among all the working departments in
the APPERAL INDUSTRY , because Merchandising is the only department having maximum
control over the departments and total responsible for Profit and loss of the company.
Merchandise- means goods bought and sold; and trading of goods.
Merchandising- is an activity of selling and promoting the goods.
a. What does a Merchandiser do?
Merchandiser is a person who interacts with the buyer and seller, and also puts efforts into
proper relation between buying offices/ buying agents/ agency and seller/ exporter in terms of
executing an order.
b. Merchandiser in garment industries:
In the field of marketing and services, Merchandiser is at a position of utmost importance, He is
the person who co-ordinates with various departments for a uniform business.
Objects of Merchandising
Merchandising denotes all the planned activities to execute and dispatch the merchandise on
time,
Right Quantity: To dispatch right quantity of product what buyer ordered.
Right Quality: It should be with right quality as accepted both parties.
Right Cost: Everybody wants more from what they are paid.
Right Time: No one wants to wait but Keeping delivery schedule is mandatory.

9. Qualities of Merchandiser
COMMUNICATION SKILL: The communication is very much important to promote the
business activity. The merchandiser should remember that communication must be lurid
and should having face to face conversation with the buyer.
1. Planning Capability: Merchandiser should be capable of planning, based on the planning
the order is to be followed. If the planning is not done properly it will directly affect the
delivery time of the order.
For a Merchandiser, decision making power is most important. He should think about the
decision to be taken and to act in a right way.
2. Loyalty: Loyalty is an essential character of human beings. Especially for the business
people like merchandiser it is a must.
3. Knowledge about the field: Merchandiser should have adequate knowledge about the
garments,Computer knowledge, and technical knowledge to communicate with
different people in the business is a must.
4. Co-ordinate & Co-operate: Merchandiser is the person who is actually co-ordinate with
the number of departments. To Co-ordinate with different people in the industry he
should be co- operative.
5. Monitoring ability: Merchandiser should monitor to expedite the orders.
6. Other qualities: Education, Experience, Situational Management, Ability to Evaluate,
Dedication, Knowledge of expediting procedures.
Function of Merchandisers
Developing new samples, execute sample orders
Costing
Programming
Raw materials / Accessories arrangement
Production scheduling (or) route card drafting
Approval of various Process, Pattern and size set

10. Pre production follow up
Meet Inspection Agencies
Production controlling
Identifying shortages and make arrangement for the shortages
Following quality assurance procedures, quality control procedures
Important Duties
Costing or Calculating Garment Price
In many companies, costing is done by costing officer & CEO. But in some places, it is done by
the Merchandisers.
Some important terms in costing
Yarn cost
Process cost
Process loss
CMT (Cutting, Making & Trimming)
Negotiation (getting the best out of a deal)
Commission percentage (%) for Middle man
Shortage
Buyer specification (It is buyers responsibility to specify the quality required)
Quantity
Currency
Mode of Shipment (sea, air)
FOB (Free On Board)
CIF (Cost, Insurance and Freight)
OH (Over head)
Quota(Not applicable nowadays)
Profit (level of %)

11. COMPLINCE (HR &EHS ) DEPARTMENT
WORK OF ENVIRMENTAL HEALTH AND SAFETY
The main work of health and safety is to control the envirment of factory. Envirment of factory
mean that, to protect the factory worker on work place and provide resis against hazard/fire
and maintenance of machine and give instruction to all the labor and management that how
protect yourself and the tools of factory. they warned the department in which there are some
hazard for worker and make sure them that keep the maintenance of that depart with their
specific time duration. this is also the main department of factory because without this no
customer can link with the factory.
FABRICPRECUREMENTS DEPARTMENT
FLOW OF PROCEDURES INVOLVED IN
M.M.C.
( PRECUREMENTS)
MERCHANDISER RAISES
DEMAND
APPROVAL FROM
MERCHANDISER
BULK ORDERING
SAMPLES FROM SOURCES/
VENDORS

12. PROCEDURE
Merchandiser raises demand for the materials required for a work order.
After merchandiser raises demand, MMC starts working for the procurement of fabrics
and accessories.
MMC acquires samples from different vendors. Vendors may be nominated by the
customer or decided by the Manager MMC.
Samples are shown to the merchandiser for approval.
If merchant doesn’t approve any sample than MMC either send instructions to the
vendors for improvement or looks for more samples from different sources. If
merchandiser approves a sample than bulk ordering is done to the most suitable
vendor.
When vendor completes the bulk production, then it sends materials to the factory.
When materials are in-house then Quality Checking is done to ensure if quality of
material matches with our required quality or not.
If Quality of the material is OK then it is sent to store if it is not OK then it is sent back to
vendor/supplier.
IN-HOUSE
If Not OK
SENT BACK TO
VENDOR
If OK
SENT TO STORE
QUALITY CHECK

13. CONCEPT OF MATERIAL MANAGEMENT AND CONTROL
MMC is that department which is responsible for the sourcing of materials required to
construct a garment. It is also known as Procurement or Commercial Department.
Materials used for the construction of garments are basically of two types.
1. Fabric.
2. Trims and Accessories.
FABRIC
Fabric is classified into two types according to the construction of garment.
1. Shell Fabric (used in our factory is mostly twill and piece dyed)
2. Pocketing Fabric.
TRIMS AND ACCESSORIES
Following is the list of most commonly trims used:
Thread
Zippers
Buttons
Rivets
Woven Labels
Leather Patch Labels
Tags
Tag Pins or Chords for tags (e.g. for hang tags)
Fusible
Hangers

14. Poly-bags
Stickers
Tape
Cartons
FACTORS FOR EFFECTIVE PROCUREMENT:
There are three main factors for effective procurement
1. Quality
2. Price
3. Lead Time
For effective and efficient procurement all factors are of great importance. For example if a
supplier is giving you very good quality on a reasonable price but he can not you in time, then
we can not order that vender for our materials. Same is the case with price and quality. Means
we can compromise on quality and price. Only that supplier/vendor is preferred which is
offering best Quality, best price and in time.
Product Development & Sampling Department
What is apparel product development?
• A process that involves creating each individual style within the line.
Duties of an apparel product developer
• Line Development
• Fabric selection
• Create a prototype
• Develop patterns
• Preliminary costing
• Work hand-in-hand with merchandiser
• Be certain that each style that is created is salable

15. • Approaches to Development
• Fabric-driven: select fabrics, create silhouette
• Silhouette-driven: design silhouette, select fabric
• Both end in the same result
The apparel product developer is involved through the entire process from concept to
delivery.PD dept. re-engineer and re-create every customer manufacturing specs on Nishat
Apparel standardized format , including operation wise thread charts , operational details of
sewing and finishing while taking into consideration customer specifications , comments and
approval process .
Nishat Apparel Tech Pack consists of:
Style Brief
Fabric and wash detail
Trims and Sundries detail
Thread and Construction detail
Information Flow Chart in PD Dept
PD Dept.
Design Cell sampling Tech. services
Styling &embellishments sample development wash recipe
Collection Development constructional queries wet process routing
Pattern analysis
Garment consumptions

16. Process flow chart of Sampling Dept
Sample request & Tech pack received from Merchant (Merchandising Dept.)
Develop Patterns
Costing / CAD Marker
Develop fit/Proto sample
Pre production sample
Size set sample
Sealer sample (final)

17. PRODUCTION PLANNING AND
CONTROL
INTRODUCTION
Production is a process whereby raw material is converted into finished products and
thereby adds to the value of utility of products, which can be measured as the difference
between the value of inputs and value of outputs.
Production function encompasses the activities of procurement, allocation and utilization of
resources. The main objective of production function is to produce the goods and services
demanded by the customers in the most efficient and economical way. Therefore efficient
management of the production function is of utmost importance in order to achieve this
objective.
PRODUCTION MANAGEMENT
Production system is a system whose function is to convert a set of inputs into a set of
desired outputs. Production system is depicted under with help of chart
Production management involves the managerial decisions regarding design of the product
and design of the production system i.e. determination of production processes and
production planning and control.
INPUTS CONVERSION PROCESS OUTPUTS
CONTROL

18. TYPES OF PRODUCTION SYSTEM
Broadly one can think of three types of production systems which are mentioned here
under:-
1. Continuous production
2. Job or unit production
3. Intermittent production
1. CONTINUOUS PRODUCTION:
It refers to the production of standardized products with a standard set of process and
operation sequence in anticipation of demand. It is also known as mass flow production or
assembly line production. This system ensures less work in process inventory and high
product quality but involves large investment in machinery and equipment.
2. JOB OR UNIT PRODUCTION:
It involves production as per customer's specification each batch or order consists of a small
lot of identical products and is different from other batches. The system requires
comparatively smaller investment in machines and equipment. It is flexible and can be
adapted to changes in product design and order size without much inconvenience. This
system is most suitable where heterogeneous products are produced against specific orders.
3. INTERMITTENT PRODUCTION:
Under this system the goods are produced partly for inventory and partly for customer's
orders. e.g. components are made for inventory but they are combined differently for
different customers.

19. MANUFACTURING PROCESS
The nature of the process of production required by these three different types ofproduction
system are distinct and require different conditions for their working.
Selection of manufacturing process is also a strategic decision as changes in the same are
costly. Therefore the manufacturing process is selected at the stage of planning a business
venture. It should meet the basic two objectives i.e. to meet the specification of the final
product and to be cost effective.
PRODUCTION PLANNING AND INVENTORY CONTROL
Once the management has taken the decisions regarding the product design and production
processes and system, its next task is to take steps for production planning and control, as
this function is essentially required for efficient and economical production.
Planned production is an important feature of the industry. The management possessing the
ability to look ahead, organize and coordinate and having plenty of driving force and
capacity to lead and ability to supervise and coordinate work and simulates his associates by
means of a program of human relation and organization of employees, it would be able to
get the best outcome
Production planning without production control is like a bank without a bank manager,
planning initiates action while control is an adjusting process, providing corrective measures
for planned development. Production control regulates and stimulates the orderly how of
materials in the manufacturing process from the beginning to the end.
BENEFITS OF PPC
Production planning and control can facilitate in thefollowing ways
(1) Optimum Utilization of Capacity:
With the help of Production Planning and Control [PPC] an organization can schedule its
tasks and production runs and thereby ensure that his productive capacity does not remain

20. idle and there is no undue queuing up of tasks via proper allocation of tasks to the
production facilities. No order goes unattended and no machine remains idle.
(2) Inventory Control:
Proper PPC will help to resort to just- in- time systems and thereby reduce the overall
inventory. It will enable him to ensure that the right supplies are available at the right time.
(3) Economy in Production Time:
PPC will help reduce the cycle time and increase the turnover via proper scheduling.
(4) Ensure Quality:
A good PPC will provide for adherence to the quality standards so that quality of output is
ensured.
To sum up we may say that PPC is of immense value incapacity utilization and inventory
control. More importantly it improves response time and quality. As such effective PPC
contributes to time, quality and cost parameters of organizational succes
PRODUCTION PLANNING AND
CONTROL
PRODUCTION PLANNING PRODUCTION CONTROL
Planning
Routing
Scheduling
Loading
Dispatching
Following Up
Inspection
Corrective

21. 1. Production Planning
Production planning may be defined as the technique of foreseeing every step in a long
series of separate operations, each step to be taken at the right time and in the right place and
each operation to be performed in maximum efficiency. It helps to work out the quantity of
material manpower, machine and money requires for producing predetermined level of
output in given period of time.
Routing:
Under this, the operations, To perform these operations the proper class of machines and
personnel required arealso worked out. The main aim of routing is to determine the best and
cheapest sequence of operations and to ensure that this sequence is strictly followed.
Routing procedure involves following different activities.
1. An analysis of the article to determine what to make and what to buy.
2. To determine the quality and type of material
3. Determining the manufacturing operations and their sequence.
4. A determination of lot sizes
5. Determination of scrap factors
6. An analysis of cost of the article
7. Organization of production control forms.
Production schedule: The main aim is to schedule that amount of work whichcan easily be
handled by plant and equipment without interference. Its notindependent decision as it takes
into account following factors.
(1) Physical plant facilities of the type required to process the material beingscheduled.
(2) Personnel who possess the desired skills and experience to operate theequipment and
perform the type of work involved.
(3) Necessary materials and purchased parts.
Master Schedule: Scheduling usually starts with preparation of master schedulewhich is
weekly or monthly break-down of the production requirement for eachproduct for a definite
time period, by having this as a running record of totalproduction requirements the

22. entrepreneur is in better position to shift theproduction from one product to another as per
the changed production requirements.
Manufacturing schedule: It is prepared on the basis of type of manufacturing process
involved. It is very useful where single or few products are manufactured repeatedly at
regular intervals. Thus it would show the required quality of each product and sequence in
which the same to be operated
Scheduling of Job Order Manufacturing:
Scheduling acquires greater importance in job order manufacturing. This will enable the
speedy execution of job at each center point.
Scheduling is of utmost importance asit brings out efficiency in the operations and reduces
cost price. The organization four types of schedules to have a close scrutiny ofall stages
namely an enquiry schedule, a production schedule, a shop schedule andan arrears schedule
out of above four, a shop schedule is the most important mostsuited to the needs of an
apparel organization.
1. The total load on any section
2. The operational sequence
3. The stage, which any job has reached.
2. Production control (W.I.P)
Production control is the process of planning production inadvance of operations,
establishing the extract route of each individual item partor assembly, setting, starting and
finishing for each important item, assembly orthe finishing production and releasing the
necessary orders as well as initiating thenecessary follow-up to have the smooth function of
the organization. The productioncontrol is of complicated nature in small industries. The
production planning andcontrol department can function at its best in small scale unit only
when the workmanager, the purchase manager, the personnel manager and the
financialcontroller assist in planning production activities. The production controllerdirectly
reports to the works manager but in small scale unit, all the threefunctions namely material
control, control starts with dispatching and ends upwith corrective actions.
GATE OFFICE

23. Work and Procedure
The main work of gate office is to control the inward gate pass of Goods and
the outward gate pass of Goods.
The inward gate pass mean that the delivery of the Goods which is perchesd by factory .and for
entrance the transport required permission from gate office and security office. the transporter
show the delivery slip list. when gate office conform that this delivery is ordered by any
department of factory they cheeked that order in orical through P.O number and also conform
from the department. After conformation they send the driver to the security office. security
officer also checked the P.O number and quantities and then verified them. when they
complete their process then they allow the driver with container and after when they enter into
the factory then again one person of gate office will check all the Goods and passed them
through receipt room.
Outward gate pass(OGP)
Two type of outward gate pass
1. Non-Returnable Goods
2. Returnable Goods
Non-returnable Goods mean that, the Goods which is out from the factory that Goods cannot
come back to the factory again.
Returnable Goods mean that, the material which is out from the factory that Goods can come
back to the factory this Goods is the property of the factory.
RECIPET ROOM
When Goods receive the receipt room they check the Goods. Mean the Goods quantity and
also check the each item that its fine or its been broken also some Goods which is demand by
any department that is measurable they measure them with some digital scale. In receipt room
there is also a quality person who check the quality of every accessories that is demand by the

24. department with their P.O number they check their label size , label quality and also other
accessories. then they forward the Goods to the main store.
MAIN POINT
Receipt Room
G.R.I.N (goods receipt inspection
report) it is ensured that goods we
have received are of required quality
MAIN STORE
When they received the Goods from the receipt room they store them in the different Racks
with identification and marks with the quantities. If the Goods that’s received the main store is
more then the ordered Goods then they store that’s Goods in store when ever again they
required they give it to them again.
MAIN POINT
FABRIC INSPECTION
when fabric is come to this department they check the fabric roll they check the roll number
and order number with all specification after that they cut two pieces from the roll one is small
Issue the items as per demand to
the specific department by taking
S.I.R (Store Issue Requisition)
form the person who will come to
receive the item

25. size and the other one Is little large from the first one they measure that pieces before the
wash and after the wash to check the shrinkage if the shrinkage is down or up from the
required shrinkage if this shrinkage is control during the last washing then they pass the fabric
to the other process to complete the fabric inspection if not then they send the fabric roll to the
fabric store. The next process in the fabric inspection is to check the whole fabric of roll if the
fabric is damage or any fault they note the faults place and then if the percentage of this faults
places is over the required faults then they send back the roll of fabric. Some faults are like
(nods, slabs, selvage cut, broken faults, weaving faults, starting marks, weaving marks etc.)
SHRINKAGE TEST
METHOD
Take a piece of fabric with 60 cm length and 60 cm width from the fabric roll in a way that
length is along the grain line. Draw boundaries of 5cm on all sides of the fabric and we’ll get a
square area of 50cm x 50cm in the fabric. Stitch the fabric from both sides along with the 50 cm
lines using a single needle operation. Over lock the fabric from all sides except one side that is
parallel to the weft. Overlock this side in a way that it becomes like a pillow cover and send the
fabric for washing. After required wash is done:
Calculate the following measurements.
1. Width after wash
2. Length after wash
FORMULA OF SHRINKAGE
SHRINKAGE =MEASUREMENT AFTER WASH - MEASUREMENT BEFORE WASH X 100%
MEASUREMENT BEFORE WASH

26. Note: Shrinkage is always shown as (LxW) %.
Diagram
CAD ROOM DEPARTMENT
Cad room is the main department of apparel industry because without cad room the fabric
cannot enter into the garments departments mean to cut and then to stitching.
WORK OF CAD ROOM
50cm
50cm
5CM
60CM
60CM

27. The work of cad room is to make the pattern marker through required size. but the main work
of CAD ROOM is that, that the pattern is accurate and will marker and also the marker will
made to be perfect through which the fabric loss is much lower. When they complete the
pattern marker then they print that pattern of marker and send to the cutting department.
CUTTING DEPARTMENT
After inspection of fabric by FID (fabric inspection dept.) it is handed over to cutting dept.The
Gerber Garment Technology (GST) is used to perform the marker making, spreading and cutting
functions. GST is an American technology; based on Accu Mark software system .This software
is used to make computerized pattern in PDS. Pattern making is the process of creating
templates of a garment parts that are to be stitched to create a complete garment. Pattern are
also made manually from size chart .First basic pattern is created .This master pattern is than
graded for different sizes.
Marker making through software is more accurate and provide the greatest opportunity for
pattern manipulation, marker efficiency, reuse of previously made markers .Best fabric
utilization depends on how tightly the pattern pieces are fit together within the marker .This
dept. calculates the fabric consumption per garment and reverts to PPC
Process flow chart is as below
Marker Making
Fabric Spreading as per shade and shrinkage report
Placing marker paper on to the fabric lay

28. Auto cutting / Manual cutting
All parts are checked and reports are made
Folding and Numbering
Ready to be send to Sewing dept.
EMBROIDERY DEPARTMENT
After cutting , the WIP people sends the pieces that need embroidery to above department
.The in house embroidery facility allows to rapidly translate designs onto fabric guaranteeing
prompt and reliable service to the customers .
Equipped with eighty terminals of the high-tech Twenty-Head Tajima automatic embroidery
machines, the embroidery facility can produce approximately 4000 pieces a day. Each terminal
is capable of ten thread /color embroidery design. The design cell in the PD dept uses this
facility while making new development / collections.
SEWING DEPARTMENTS
In nishat apparel the sewing department is divide into to section swing A and swing B with line.
there are 20 line in swing A and swing B.in each line their 65 machine. They are working under
the 4 supervisor and 1 in charge of each line. There are four section in the swing department
which is also mention in the above table but here also,

29.  Back section
 Front section
 Assembly 1
 Assembly 2
In every section they have different machine adjustment for different operation to make a
complete garment.
There are different machine such as under below.

30. Operation Description Machine Type
Small Parts
1 Coin Pocket Hemmig D.N.L.S
2 Coin pocket attachment on facing D.N/S.N
3 Facing attachement on pocketing Cover stitch
4 Pocket bag closing Safety
5 Top stitch on Pocket Bag S.N.L.S
6 Back pocket hemming D.N.L.S
7 Over lock left & right fly Over Lock
8 Make Left & right fly S.N.L.S
9 Attach Zipper to right fly S.N.L.S
10 Make loops Flat Lock
Front
11 Fly attachment with front panel S.N.L.S
12 J-Stitch on fly D.N.L.S
13 Fly top Stitch/Edge Stitch S.N.L.S
14 Fron Rise/Crotch Stitch 2N-Feedo
15 Front Pocket attachment with Front Panel S.N.L.S
16 Top stitch on front pocket opening D.N.L.S
17 Secure Stitch S.N.L.S
Back
18 Safety Stitch on Yoke & Back Panel Safety
19 Top Stitch on yoke 3N-Feedo
20 Safety Stitch on Back rise Safety
21 Top Stitch on Back Rise 3N-Feedo
22 Back Pocket attachment D.N.L.S
Assembly-1
23 Safety on Inseam Safety
24 Top Stitch on Inseam 3N-Feedo
25 Safety on Side seam Safety
26 Top Stitch on Side seam 2N-Feedo
27 Waist Band attachment Waist Band m/c
Assembly-2
28 Waist Band closing S.N.L.S
29 Loop Attach Bartack m/c
30 Bartack on fly, back pockets & S.S Bartack m/c
31 Button Hole Eye-let m/c
32 Bottom Hemming S.N.L,S

31. Machine Type
1) Single Needle Lockstitch (Auto)
2) Double Needle Lockstitch (Auto)
3) Double Needle Chain stitch
4) 6 Thread Over-lock (Auto)
5) Waistband Attach Machine
6) Feed Of Arm (Auto)
7) Bar-tack (Auto)
8) Cover Stitch (Auto)
9) Zigzag Stitch Machine
10) Auto Welt
11) Button Hole - Straight (Auto)
12) Button Hole - Eye Let (Auto)
13) Snap Machine
14) Auto Loop Machine
15) Mock Machine
16) Auto Bottom Hem Machine
17) Make Loops
18) Button Attach Machine (Auto)
INDUSTRIAL ENGINEERING DEPARTMENT
Industrial engineering is a branch of engineering that concerns the development, improvement,
implementation and evaluation of integrated systems of people, money, knowledge,
information, equipment, energy, material and process. Industrial engineering draws upon the
principles and methods of engineering analysis and synthesis, as well as mathematical, physical
and social sciences together with the principles and methods of engineering analysis and design
to specify, predict and evaluate the results to be obtained from such systems. In lean
manufacturing systems, Industrial engineers work to eliminate wastes of time, money,

32. materials, energy, and other resources.
Industrial engineering is also known as operations management, systems engineering,
production engineering, manufacturing engineering or manufacturing systems engineering; a
distinction that seems to depend on the viewpoint or motives of the user. Recruiters or
educational establishments use the names to differentiate themselves from others. In
healthcare, industrial engineers are more commonly known as management engineers or
health systems engineers.
Where as most engineering disciplines apply skills to very specific areas, industrial engineering
is applied in virtually every industry. Examples of where industrial engineering might be used
include shortening lines (or queues) at a theme park, streamlining an operating room,
distributing products worldwide (also referred to as Supply Chain Management), and
manufacturing cheaper and more reliable products. Industrial engineers typically use computer
simulation, especially discrete event simulation, for system analysis and evaluation.
The name "industrial engineer" can be misleading. While the term originally applied to
manufacturing, it has grown to encompass services and other fields as well. Similar fields
include Operations Research, Management Science, Financial Engineering, Supply Chain,
Manufacturing Engineering, Engineering Management, Overall Equipment Effectiveness,
Systems Engineering, Ergonomics, Process Engineering, Value Engineering and Quality
Engineering.
There are a number of things industrial engineers do in their work to make processes more
efficient, to make products more manufacturable and consistent in their quality, and to
increase productivity.
1. Resources
2. Space

33. RESOURCES
resources mean that the machinery and tools of these machine which is required and
the main work of Industrial engineering department their is to use the machinery very
well.and other resoures which is required here.
SPACE
Space mean that how much worker can work in this place and how many machinery can be
adjust their.nad the main work of industrial engineering is that to maintain the large
number of machinery adjust at that place that give the great production to the factor.
BASIC TERMS USED IN INDUSTRIAL ENGINEERING:
Basic Minute Value time taken by an operator to complete one cycle into observed rating of
that operator.
Standard Minute Value can be calculated by adding Allowances in basic minute value.
Single Cycle means one complete operation from picking the material to sew and up to dispose.
Cycle Time means time taken by an operator to complete one cycle or operation.
BASIC FORMULAE USED IN INDUSTRIAL ENGINEERING:
S.A.M= B.M.V+ Allowances (m/c Allowance, Contingencies Allowances, Material
Handling Allowance etc.)
B.M.V= S.M.V -Allowances (m/c Allowance, Contingencies Allowances, Material Handling
Allowance etc.)
Relaxed Single Cycle (R.S.C) = Av. Single C.T + Allowances (m/c Allowance, Contingencies
Allowances, Material Handling Allowance etc.)

34. Single Cycle Performance= No. of Pcs. x S.A.M x 100
Observed Time
Efficiency = No. of Pcs. x S.A.M x 100
On Stitching Time
Performance = No. of Pcs. x S.A.M x 100
Shift Time
QUALITY ASSURANCE DEPARTMENT
in quality assurance department the garment will check during the stitching .its mean that the
quality person in each section of stitching department will check the each piece of garment
which is stitch in garment stitching department. That quality person check the different
operation which is done during the stitching. If there is fault in the stitching which is not the
requirement of the customer they reject that garment piece to do again the process. If there is
no fault then they proceed that garment to then next operation.
Some faults are below shown
1. Wrong style(size)
2. Wrong thread
3. Damage
4. Hole
5. Cut
6. Wrong label attach
7. Fabric fault
8. Stain marks

35. 9. Raw edge
10. Missing operation
11. Joint out
12. Needle chew
13. Open seam (fold)
14. Wrong matching
15. Shaded parts
16. Miss alignments
17. Un even stich
18. slanted loop or eye let
19. Needle gauge
20. Joint seam
21. Notches out
etc .
these are the major faults which is come during the stitching of garments
and the every 1 hour one quality officer while save the record in the final section
checking reports.
GARMENTS WET PROCESSING
At nishat apparel we operate a stat of the art washing facility which performs various
tasks ,including finishing washing and fabric trimming , especially for denim.
While the following washes are available in a variety of possible combination.
The type of washes available at Nishat apparel for denim.
 Rinse for( dark color)
 Enzymes stone (rubbing)
 Enzyme wash (rubbing)
 Bleach wash (light color)
 Super bleach( very light color)

36.  Reduser wash(usually for black to grey color fading)
 Tint wash
 Raisin washes for very dark shade.
 Over dyeing(dirct dyeing)/garment dyeing
 Piece dyed washes
a) Softerner silicon wash
b) Stone enzyme
c) Enzyme wash
The following machine are use
 Tonello machine for washing (for higher capacity)
 Model (5-10 model,(2 lower capacity) 4-20 model machine.
 Fading effect are conducted manually using sand paper
 5 driver are used
 (3) tonello (2)mino machine
 (2) barrel washing machine and one drier for sampling
 Potassium per magnate is sprayed to enhance fading
 Any wrinkle fabric shape setting is performed using a curing oven
FINISHIG AND PACKING DEPARTMENTS
Procedures involved in Finishing Department:
1. Receiving garments from G.W.P (Garments Wet Processing)
 Counting the received quantity in finishing.
 Problems we are facing during this process are
a. We don’t know size-wise quantity at this stage.
a. Garments received from washing are not in an order.

37. 2. Clipping/Trimming:
 Extra threads protruding from the garment surface or seams are trimmed during
this process.
 Main problems we are facing in this department are
a. Improper trimming.
b. Damage of pieces due to untrained workers.
c. Garments provided to the workers are not in an order.
d. Workers clean their hands, shoes or face with the garments and
garments are stained.
3. First Quality Check:
 It is the first quality check point after construction of garment.
 Only trimming and basic construction of garment is checked.
 If okay then sent for attachments and if not okay then sent to rework or
rejection.
 As attachments are done after the quality so attachments miss one quality
checkpoint before packing.
4. Attachments:
 After wash trims are attached during this process like buttons, rivets, hooks and
bar, patch label, draw chords etc.
 Attachments section must be before the clipping and first quality as some
garments having very long threads during attachment can reach packing.
 Proper marking color and pencils should be used so that marks are not visible on
eyelet or any where on waistband.

38. 5. Pressing Section:
 Garments are pressed/ironed as per customer requirement for the good look of
garment.
 It is also helpful for better folding of garment.
 Garments must be pressed properly because pressing enhances the aesthetics of
a garment.
6. Final Quality:
 It is the final quality check point.
 Each and everything of a garment is checked like construction, specifications,
trimming, pressing etc.
 Presentation of the garment is also focused.
 Final quality check should be after the attachment of all accessories of a garment
so that everything of a garment can be checked before garments being packed.
 OK garments are sent to packing.
 Garments which can be reworked or mended are sent to rework/alteration
section.
 Garments having major faults are rejected.
7. Receiving in Packing:
 Packing receives OK garments from final quality and counts it.
 Sensor labels are attached.
 Size-wise distribution of garments and counting the size-wise qty.
 Tagging with Dennison then tagging with tag guns.
 Every operation which requires needle or any metallic thing is done till this opera
ion.
8. Metal Detection:

39.  All the garments are passed through metal detection machine to ensure that not
any garment having needle or fragment of needle is packed in the cartons.
 All the needle work must be finished before this process because after this
process garments are sent to needle free zone.
9. Packing:
 After metal detection garments are first hanged on hangers then sizers are
placed.
 Then garments are folded and packed in polythene bags and pre-pack numbers
according to the sizes are pasted on the front side of the bags.
 Garments are packed in cartons ratio-wise or size-wise.
10. External Audit:
 External auditor is called fro audit.
 He selects the cartons randomly.
 Then checks the garments completely in selected cartons.
 If he approves that garments are OK for shipment then arrangements for
shipment.
 Otherwise garments are re-screened or re-checked.
Shipping Department

40. Once the garment is ready from production, the next important step is to ship it out timely .This
is where the above mentioned dept. comes into action. The merchandising dept. gives there ex-
mill dates to shipping department and ensure that they receive the packed goods on time from
production. The shipping department than load the goods on the container to send to port.
They work out the best options with the shipping lines so shipment can reach there destination
in the minimum possible time.
The merchandising department gives the:
Sales contract
Packing list
To the shipping people and on the basis of this commercial invoice is made at the company
head office. The shipping dept. also follows the customer payments through there people in the
Head office. There are different payments terms settled with customers mainly it include:
Advance payment
L/C at sight
L/C at 30/60/90 days
Cash against Document (CAD)
The following sets of documents are usually required to release payment from bank:
Signed commercial invoice
Packing list showing net & gross weight
Original of certificate “GSP Form A “
Certificate of origin issued by the chamber of commerce & industry
Bill of lading ( sea shipment ) & Airway bill ( air shipment )

41. THE END