This document provides an overview of the textile manufacturing process from spinning to processing at a textile company. It includes descriptions of the machinery and processes in various departments like spinning, knitting, dyeing, finishing and quality control. It also lists common fabric types, finishes, and faults observed during production. Key departments and their functions are outlined along with process flows, material types and testing procedures.

1. Textile Division
Knitting
Spinning Processing Cutting Embroidery
Auto
Placket
Printing
Trial Run
Shop
RG Div.
Beacon
Impex
MTM
Spinning
Division-2
Division-1
Laundry
Division-2
Division-1 Yarn Dye

2. Spinning Orientation

3. MTM Spinning Valued Customers
 Tommy Hilfiger
 Tom Tailor
 Messy Sports Wear
 Gander Mountain
 Philloper
 S-Oliver
 Forever 21
 VND
 Addidas
 Puma
 Wall Mart
 Jessy P

4. Mixing Department
Blow Room
Carding
Drawing
Combing
Simplex
Ring
Auto Cone
Production Flow Diagram

5. Machinery Setup
Department Machine Type Manufacturer No. of machines
Mixing
Auto Plucker 3
Step Cleaner 1
Blow Room Two lines 2
Card Crossrole 24
Drawing
Breaker Toyoda 5
Inter Toyoda/China 4
Finisher Rieter 5
Fancy Top 1
Lap Former Rieter 1
Comber Rieter 6
Simplex FL-16 Toyoda 6/120
Ring RY-4 Toyoda 30/480
Auto cone 6/60

6. Mixing Department
 Get mixing recipe from R&D Department
 Allocation of material as per given recipe
 Placement of Material in the form of sandwich on the floor
 Manual mixing on floor
 Feeding to Auto plucker to get homogeneous mixing
 Passage of material from step cleaner to remove impurities
 Placement of material lot wise
 Sampling to get approval from R&D Department
 If approved ready for production
 If rejected then remixing of material to get required results

7. Raw Materials
 Cotton ( Natural & Dyed)
 Viscose ( Natural & Dyed)
 Polyester ( Natural & Dyed)
 Modal ( Natural)

8. Blow Room
 Bale breaker by Trutzchler
 Axi flow by Trutzchler
 RN Beater by Trutzchler
 Multi mixer by Trutzchler
 RV Beater by Trutzchler
 Scutcher by Toyoda/China

9. Carding
 Lap Feeding
 Fibers opening
 Removal of trash
 Removal of lint
 Fibers straightening & alignment
 End product Sliver

10. Drawing
 Feeding of 8 slivers to increase mixing
 Sliver Drafting
 Alignment & straightening of fibers
 Reduce shade variation
 End product Sliver

11. Combing
 LAP Feeding
 Removal of noils
 Straightening & alignment of fibers
 Removal of trash
 End product sliver
 Suitable for fine counts

12. Simplex
 Sliver feeding
 Straightening & alignment
 Draft application to increase length
 Twisting to give strength
 End product roving

13. Ring
 Roving feeding
 Draft to get required yarn count
 Twisting to get required strength
 End product yarn

14. Yarn Testing Department
 IGP posting of yarn in system
 Yarn testing i.e. CV%, Count & strength
 10 Kg Trial fabric on knitting machine,
 Physical inspection of ecru fabric for yarn quality
 Trial fabric dyeing & inspection to check yarn faults after dyeing
 If results found ok, yarn will be online for production
 If yarn is rejected, informed to procurement department
 Same procedure follows for in-house yarn

15. Yarn Testing Process Flow
Yarn Received
for testing
Yarn Testing
• Count
• Strength
• Uster Testing
• Thick, Thin, Neps,
U%, CV 1M, CV3M,
CV10M, IPI
• Hairiness
• TPI
• Moisture
Yarn Test
Evaluation
Team Reject The
Yarn
Yarn Test
Decision
Reject
Fabric Testing
Sample Knitting
Sample Inspection
Sample Dying
Fabric Inspection
Report
Result Evaluation
• Dead Cotton
• Bareness
• Unevenness
• Thick, thin yarn
• Slub
• Contamination
• Fabric Blending Ratio
• Color Fastness to
washing/Crocking
• Shade Checking
• Color Brightness(For White)
Team reject the
yarn
Yarn Returned to
Party
Fabric Test
Decisions
Yarn Online for Bulk Production
Reject
OK

16. Yarn Faults
 Thick & thin places
 Neps
 Count variation
 Shade variation
 Yarn strength
 Contamination
 Holes in fabric
 Dead Fibers
 Uneven Dyeing

17. Lab Testing Equipment
 Wrapping Reel
 Lea Strength Tester
 Sliver/Roving Wrapping Drum
 Uster UT-3 & UT-5
 HVI (High Volume Instrument)

18. General Knitted Yarn Types
 Ecru yarn
 Mélange Yarn

19. Ecru Yarn
(Un Dyed Yarn)
 Carded Yarn
 Combed Yarn
 Combed compact Yarn
 Slub Yarn
 Siro Yarn
 Inject Slub
I. Base Cotton+ polyester Injection
II. Base Polyester + Cotton Injection
III. Mixed Blend Base & Injection

20. Mélange yarn
Mixture of Dyed & Un-dyed
 Cotton Mélange
 CVC Mélange
 PC Mélange
 Cotton mélange with colored Injection
 Cotton mélange with different colors injection
 Fancy Top (Mix mélange)

21. Flow Chart Of Quality Systems In Yarn Testing
Material Requisition
Random Sampling
Dying Lab Test
Finishing
Inspection
Complete Yarn Testing
Knitting
Dying/Bleaching
Requisition generated by Testing department
Random sample selection from yarn Lot
Count, Strength, u%, Thick & thin places, Neps, IPI
& TPI testing
4~5 Kg fabric knitting from sample yarn for physical
inspection
It is done to check yarn faults, penetration & contamination
issues.
Required finish applies to check further yarn specs
Dead Fibers, Contamination, Slub, Shade variation, Color
brightness, Un-evenness
Color Fastness, Blending Ratio

22. Order Handling Flow Chart
Marketing
New Development
Innovation
Bulk Production
Sampling
Recipe Calculation
Approval
MRP
Repeat Order
Bulk Production
Approval
Sampling
Internal R & D

23. Observations
 We have not seen any preventive maintenance schedules & record
 Lot of chances of mixing mélange traces with ecru material where
both materials are side by side. Observations have been made
mixing of traces of dyed fibers with ecru materials. Even during
spinning mélange contamination entangles with ecru yarn.
 House keeping need to improved

29. Knitting Orientation

30. Knitting
Division-2
Division-1
Production Coordination Coordination Production
Unit-1A Unit-1B Unit-6 Unit-7 Unit-9
Unit-2 Unit-3 Unit-4 Unit-5 Unit-8
Knit. R & D
46 knitting
Machines
47 Knitting
Machines
43 Knitting
machines
53 Knitting
machines
30 Knitting
machines
67 Knitting
machines
50 Knitting
machines
51 Knitting
Machines
188 Flat
Knitting
machines
50 knitting
machines
Maintenance

31. Knitted Fabric
Warp Knit Weft Knit
Flat Knit Circular Knit
Terry
Rib 1/1 Rib 2/1 Rib 2/2 Single Knit
Honey Comb
Double Locaste
Single Locaste
3 Thread
Waffle Flat back Rib Mesh
Rib Interlock Structured
2/2 Rib
2/1 Rib
1/1 Rib
Herring Bone Thermal
Double Knit
PQ Single Jersey
2 Thread

32. Knitting Process Flow
Marketing
MRP
Knitting CRP
Spinning Dyeing
Coordination
Prod./Maint.
WO generation
QC/QA
Yarn Store
•Yarn Requisition
from Production.
•Yarn Issuance to
production.
•Posting in system
•Preparation of
machine as per
given specs by
MRP.
•Production of req.
fabric as per given
target line.
•First piece
checking before
bulk production.
•In-line inspection
to ensure A-grade
production.
•Final inspection
for grading before
dispatch.

33. Knitting Faults
 Knit Hole
 Press Off
 Needle Line
 Single Kunda
 Double Kunda
 Yarn Fly
 Missing Yarn
 Feeder Tight
 Lycra Tuck
 Lycra Short
 Fluff Knit
 Sinker Line
 Oil spot
 Oil Line
 Lycra Tight
 Miss Pattern
 Machine tension
 Stitch length variation
 Pulling Thread
 Polyester out
 Drop stitch
 Knots
 Winder streaks
 Needle shade

34. Yarn Faults in Knitting
 Thick Yarn
 Thin Yarn
 Smoke Yarn
 Mix Yarn
 Bare Yarn
 Double Yarn
 Dead Cotton
 Jute
 Hair
 PP
 Slub
 Count Variation

35. Q.C Inspection Flow
FAIL
Inspection sheet forwarded to IT
Roll Stacking in Racks
Inspection on 4 Point System
Alternate Roll selection
Bar Coding
Shade Checking
Roll Scanning
QC Feed back provided to
Production
Rework Issue
Inspection after Re-work
B-Grade
System Feeding
Verification
Pass
System Feeding
Rejected
Verification
System Feeding
Clearance Performa
Summery for store rcving
Issuance to waste store

36. Knitting Findings
 More than 50% knitting capacity found idle, reason may be
I. Wrong capacity calculation by CRP,
II. We have not seen IE involvement in Knitting,
III. Poor Production Planning By MRP,
IV. Marketing Department is not fulfilling capacity.
 R&D Department need re-structuring by allocating proper
resources, issues observed are as under,
I. Delay in sampling,
II. Machine Efficiency/Production loss,

37. Knitting Findings
 We have not seen proper implementation of in-line inspections,
 4 Point system is not implemented in true sense,
 Fault identification tag is not implemented,
 Pre-production sample approval exists but at the same time
production is in process. Bulk production should start after sample
approval.

38. Processing Orientation

39. Processing Machines set up
Division-1 Division-2 Yarn Dyeing
Dyeing Finishing Finishing
Dyeing
Machines in
operations 20
with 50000
kg/day
capacity
Machines in
operations 18
with 50000
kg/day
capacity
Slitting
machines 06
Stenter 08
Dryer
machines 02
Compactor 04
Dryer 06
Stenter 03
Stretching
machines 05
Slitting
machines 03
Compactor 10
Fiber Dyeing:
9~10 Ton/day
Yarn dyeing:
7~8 Ton/day
Sewing thread:
2~2.5 Ton/day

40. Store/Preparatory Deptt.
 Fabric receives from knitting to ecru fabric store in processing,
 MRP sends requirement to CRP,
 CRP creates work order which circulates in Bleaching, Dyeing &
fabric store,
 Lap dip approval from Lab,
 Process route from R & D,
 Store prepares ecru fabric lot size as per advice of CRP,
 Fabric issues to preparatory department for unwinding & roll to roll
attachment,
 Fabric issues to bleaching & dyeing as per loading plan by CRP,

41. Lot making Criteria
 Machine Capacity,
 Fabric GSM,
 Fabric weight in Kgs,
 Yarn Source,
 Shade in which fabric to be dyed,

42. Division-1
Yarn Dyed fabric
Ecru Fabric
Store
Fleece
Lot making
Washing
Bleaching
Dyeing
Slitting/Drying
Raising
Finishing
Inspection
Packing
Lycra Fab.
Store
Lot making
Slitting/Laping
Heat set
Washing
Bleaching
Dyeing
Drying
Finishing
Inspection
Packing
Other Fab.
Store
Lot making
Washing
Bleaching
Dyeing
Slitting
Drying
Finishing
Inspection
Packing
Store
Lot making
Washing
Slitting
Finishing
Inspection
Packing

43. Division -2
Tubular
Dyeing
Compaction
Dyeing
Normal Finish
Bleaching
Squeezing
Bleaching
Slitting
Washing
Dyeing
Washing
Bleaching
For fleece
Washing
For special
finish
For normal
finish
Open Width
Washing
Washing
For normal
Finish
Drying
Slitting
Slitting
Packing
Inspection
Drying
Normal Finish
Stretching
Dyeing
Bleaching
For special
finish
Packing
Inspection
Compaction
Bleaching
Stretching
Drying
Special Finish
Drying
Compaction
Inspection
Packing
Dyeing
Special Finish Finishing
Drying
Compaction
Inspection
Packing
Raising
Compaction
Inspection
Packing

44. Type of Finishes
a
Finishes
Normal Finish
Compaction
Raising
Peaching
Chemical Finish
Mechanical Finish
Silicon Finish
Raisin Finish
Water
Repellant
Anti Microbial Wicking Finish
•Acid: 0.11
•Polyavin:
1.75%
•RH-685B:
1.75%
•ECO: 6.3
g/litre
•Magnesium
Chloride: 1.2
g/litre
•Dimensional
stability & color
bonding
•Acid: 0.11 %
•Polyavin
PEN:.823 %
•MA6ASIL MT:
1%
•RH-6858-2:
1.65%
•Used for
softness & good
hand feel
•Citric Acid:
0.44%
•Bio GuardX-19:
8%
•Rucoguard:
2.5%
•Used to remove
water
penetration
•Citric
Acid:.44%
•Polyavin PEN:
.825%
•Rucofin SIQ:
.4%
•Rucobal AGP:
.1%
Used to protect
fabric from
becteria

45. Color Lab process flow
 Customer colors request for Lab Dip as per given protocols,
I. Customer's swatch,
II. Pantone number,
III. Electronic file Qtx,
 Recipe calculation with the help of Spectro Photo meter,
 Recipe feeding to color dispenser & liquor preparation,
 Sample dyeing in IR dyeing machine,
 Dyes fixation,
 Soaping & washing,
 Shade matching in dark room with customer swatch,
 Preparation of lab dips in 4~6 closest options,
 Approval from customer & assigning code,

46. Color Lab parameters
For Cotton
 Reactive dyes,
 Temperature range 60ċ
 Time required 60 Min.
For Polyester
 Disperse Dyes,
 Temperature Range 135 ċ
 Time Required 45 Min
 PH 4.5~5.5
 For Light colors Soda Ash,
 For Dark colors Caustic Soda,

47. Testing Lab Process flow
 Sample collection from Production,
 Sample Testing as per customer's protocols,
 If testing is OK then go head for bulk production,
 If rejected, immediately inform to production for corrective action,

48. Testing Lab Tests range
 Color fastness to water,
 Color fastness to perspiration,
 Color fastness to light,
 Pilling test,
 PH test,
 Crocking test (Dry & Wet),
 Absorbency test,
 Button Pulling test,
 Bursting strength test,
 Tensile & seam strength test,
 Elastic Recovery test,
 Wicking test,

49. Yarn Dyeing Department
Fiber dyeing Yarn dyeing
Sewing thread dyeing
Nylon dyeing
Cotton Polyester Viscose
Polyester
Cotton
Polyester
PC
Bleaching
Temp. 135 Ċ
Time. 30 min
Detergent, Optical
brightener
Dyeing
Disperse dyes,
Acetic Acid,
Temp. 135 Ċ
Time. 30 min
First Polyester
dyeing then
cotton dyeing
Bleaching
Temp. 100Ċ
Time. 30 min.
H2O2, NaOH,
Stabilizer
Dyeing
Temp. 60 Ċ
Time. 30~60 min
Reactive dyes
Salt, Soda
Bleaching
Temp. 100Ċ
Time. 30 min.
H2O2, NaOH,
Stabilizer
Dyeing
Temp. 60 Ċ
Time. 30~60 min
Reactive dyes
Salt, Soda
Bleaching
Temp. 100Ċ
Time. 30 min.
H2O2, NaOH,
Stabilizer
Dyeing
Temp. 60 Ċ
Time. 30~60 min
Reactive dyes
Salt, Soda
Bleaching
Temp. 135 Ċ
Time. 30 min
Detergent, Optical
brightener
Dyeing
Disperse dyes,
Acetic Acid,
Temp. 135 Ċ
Time. 30 min

50. Fiber Dyeing Process
 Material requisition to store,
 Material receiving from store,
 Bale opening,
 Cake making,
 Feeding to dyeing machine,
 Bleaching
 Dyeing,
 Hydro extraction,
 Fiber opening & drying,
 Bale packing,
 Dispatch,

51. Yarn /Sewing thread process
 Material requisition to store,
 Material receiving,
 Soft winding,
 Loading in machine,
 Hot wash,
 Bleaching/ semi bleaching,
 Dyeing,
 Hydro extraction,
 Drying,
 Hard winding,
 Packing.
 Dispatch,

52. Nylon yarn dyeing process
 Store requisition,
 Receiving from store,
 Muff making,
 Loading in machine,
 Semi bleach,
 Disperse dyeing,
 Hydro extraction,
 Cone making,
 Dispatch,

53. Laundry Section

54. Laundry store
Receiving ( IGP) Issuance ( OGP) Issuance to laundry Receiving from laundry
In-house activities
Outside activities

55. Laundry Process
Washing
Dyeing

56. Garment Dyeing
Pigment Dyeing
White Seam Dyeing Dischargeable Dyeing
Reactive Dyeing
Reactive white seam
Dyeing
Cold pigment Dyeing
Double Dyeing
Pure pigment Dyeing
Blended Dyeing
Sulphure Dyeing
Spec. Reactive
Dyeing
Direct Dyeing

57. Garment Washing
Vintage wash
Pigment stone
dyeing
Burn out
Slush dyeing
Spray category
Acid wash
Random socks
wash
Random rag
wash
Sand wash
Stone wash
Coating
application
Color addition
Color discharge
Bio polish
Carbon finish
Graphite finish
Soda wash
White pigment
bath wash
Enzyme wash
Rubbing enzyme

58. Laundry store Process flow
 Receiving of retrieve copy of OGP from Apparel Div.,
 Garments receiving against OGP in store,
 Physical quantity verification against OGP,
 IGP posting in system,
 Lot making on below parameters,
I. Machine capacity,
II. Order size,
 Bar code generation which contains information,
I. Material specs,
II. Process route,
III. Process time line,
IV. Process type,

59. 1
 Issuance to Laundry for processing,
 Receiving from Laundry after processing,
 Quantity verification after QC go head,
 Ready for dispatch,
 OGP generation,
 Dispatch to apparel Div.,

60. Current issues facing store
 Actual quantity variation from Apparel Div.,
 Wrong color/wrong PO,
 Different colors mixing in same poly bag,
 Lot mixing issues during laundry operations,

61. Laundry Commercial Activity
 Vacant capacity estimation,
 Market search for commercial orders,
 Commercial rates negotiation with Parties,
 Commercial Order taking,
 PO feeding which contains information,
I. Commercial rates,
II. Process route,
III. Lead time
IV. Order quantity,
 Production planning & execution,
 Quality inspection & dispatch,

62. Suggestions

63. Zero rework Policy
 Need more focus on preventive measures along with corrective
measures.
I. To reduce rework,
II. To improve efficiency,
III. To improve quality,
IV. To save money,
 Continuous training & development of operators, Supervisors &
Managers.
 Incentives for operators who produce good quality with out any
rework,
 Link performance of Supervisors & managers with promotions &
reward system,

64. Team alignment with Company Vision
 As per our observation, majority of Supervisors & Managers is
staggrent & playing in a self created circle.
 Training & Development of Supervisors & Managers,
 Performance reward system should be there,
 One goal one team policy,
 Continuous coaching for team alignment,
 Floating a concept of MTM Family,
 +Ve competition within departments for productivity & Quality,

65. Lean Manufacturing
 To much travelling from spinning to Sewing which causes,
 Heavy transportation charges,
 Increases lead time,
 Effects material quality,
 Increases work force,
 Increases lead time for issue handling,

66. Product Development

67. MARKETING
PD
CUSTOMER
PPC
Analysis
Plotting
Customer
Approval
Checking
Sewing
Cutting
Product development Process flow

68. Trial run shop

69. Process Flow
Trial run plan from order management system
E-Pattern, PPC file, Approved sample garment & PPK from Merchandiser
Analysis of approved pattern, sample & provided data
Adjustment sewing margins in pattern & nesting verification
Pattern plotting & sample Cutting
Final go ahead for cutting via mail
Trial evaluation by apparel QC
Specs measurement after wash
Sewing/Pressing & measurement of garment before wash
Cut parts measurement & documentation

70. Cutting go ahead meeting
Participants include:
• Cutting Production & QC heads,
• GGT representative,
• Pilot run shop representative,
• Planning representative,
• IE representative,
• Process improvement representative,
• Embellishment representative,
Meeting Agenda:
• Sample garment study,
• Hard patterns, mini markers,
• Trial run instructions page & garment route,
• Laying, cutting method & bundling decision,

71. Snap back test
 From first lot of bulk cutting random selection of cut part components
of garment & sending to trial run shop for Snap back test,
 Measurement of cut parts in trial run shop,
 Re-trial done,
 After getting snap back results, co-relation with trial reports,
 In case of any abnormality, discussion with production & QC heads.
Revision in patterns after mutual understanding,

72. Observation
 PD & Trial run shop are not synchronized with each other
regarding,
I. Product making,
II. Seam allowances,
III. Shrinkage,
 Manual pattern tracing & cutting in PD department, although
Accumark software & plotter available there which causes,
I. Wastage of time,
II. Accuracy issue,
 Grading checked manually by master in trial run shop although
software is available there,
 Seam allowance standards of different machines are not
available in PD & Trial run shop,

73. 1
 No authentic method to add shrinkage in patterns in trial run shop &
PD,
 No soft data back up procedures available in PD & trial run shop,
 Rejected samples data is not available in trial run shop to calculate
rejection % age & root causes,
 Risk assessment form available but not properly utilized,
 No yield data available to compare consumptions on PD & bulk
stages,
 Product & Data revision history is not properly maintained,
 In cutting go ahead meeting no representative of PD,

74. Suggestions

75. Product
Development
Sampling
Technical
Services
Sample Dev. Wet Process Dev. Garment Package
Mnfg. Spec
Trim Card
Control Matrixes
Wash Recipe
Wet Process
Routing
Step Targets
Constructional
queries
Pattern Analysis
Garment Yields
Proposed Lay-out for Product Development
Design Cell
Develop MTM
Own Development

76. PROPOSED PRODUCT DEVELOPMENT - ROLE
SAMPLING:
• To cater Reactive development being received from customer.
• To maintain product record of every customer in terms of digitized pattern, sample Evaluation / callout sheet,
Measurement record along with reference garment
• Assign product tracking identification in form of product ID label.
• To deliver sample to Merchant completed in all respects with above mentioned package and Sample delivery card.
TECHNICAL SERVICES:
• Working as a technical hub for every product with Merchandizing, Production planning, Production Floor.
• Direct liaison with customers technical teams for clarifying product related queries.
• Liaison with Production planning, QA and Production floors for technical backup of product.
DESIGN CELL:
• Design new products according to existing customers trends as well as by catering new trends in market season
wise.
• Develop mood boards by understanding in house bulk capabilities to present our products to customers.
• Execute these development through sampling and present to existing customers, new customers, Exhibitions, &
fairs.

77. MARKETING PD
CUSTOMER
BULK
Technical Communication
Communication
/Inputs
Order Execution
CUSTOMER
Dispatch /
Communication
Proposed Process flow for Product Development

78. MARKETING PD TECH SERVE
CUSTOMER
SEWING
FIN/PACK
CAD / CUT
QA
PRODUCT RELATED
COMMUNICATION &
TECHNICAL SERVICES
PPC
Proposed PD Tech. Service Process flow

79. MANUFACTURING SPECIFICATIONS
• MNFG. SPECS is one of principal document that should be generated to make
services to production teams. Manufacturing Specifications document, basically has
each answer of “how a product needs to make and execute”?.
• This document contains standardized formation (product to product as well as brand
to brand) and categorized in 4 sections i.e. Product Brief, Fabric & Wash Detail, Trim
detail and Thread detail.
• PD should get info about a product from marketing and Manufacturing Specification
should be generated/released by PD for conveying the methodology of product
making and execution to production teams i.e. CAD/GGT, PPC, SEWING, GWP,
FINISHING & PACKING, QUALITY.

80. TRIMS DIGITAL LIBRARY
• Trims Digital library is a data base about accessories information with their digitals.
This Library will contain the information like Customer, Accessory Item, Accessory
Code & Digital of each Item/accessory.
• Trim Library should be maintained purposely to have data base of each accessory as
digital record. When and where ever any accessory or it’s code misplaced, this data
base will help in finding the info of that item either via item’s code or item’s physical
sample.
• This Data Base should be maintained customer wise and PD will update by posting a
digital shot of trim along with info while making trim cards.

81. EMBELLISHMENT LOG
• Embellishment Log is a data base about coding system of embroidery artworks. This
code should be assigned to each embroidery design that has to run within MTM either
just for development purpose or bulk production.
• Embroidery Coding System reflects exactly that what customer/supplier defines a
code to their products/accessory for making easy access to their products.
Embellishment Log should be designed with the same purpose. Embellishment Log
will support in arranging the embroidery artworks as well as will define the criteria i.e.
development, approved, rejected, cancelled etc..
• PD will make the services by sharing Embroidery Code with production team for
proceeding bulk production with correct and approved design.

82. Auto Placket

83. MARKETING
PD TECH SERVE
CUSTOMER
PPC
Placket
attachment
Bundling
Fusing
attachment
Bundling
Tape cutting
Auto Placket
Auto Placket Process Flow

84. QC check points in Auto placket
• Order checking,
• Tape Dimensions checking,
• Fusing Dimensions checking,
• Placket measurement checking,
• Placket placement checking,
• Sewing quality checking,
• 10~20% Final inspection,

85. Auto placket department machines set-up
• Tape cutting machine 01
• Fusing machines 09
• Auto Placket machines 26

86. Printing

87. MARKETING
CUSTOMER
PPC
Printing Dep Printing
Color mixing
Exposing
Designing
Curing
Printing Process Flow

88. Printing Section
Garment Printing
Fabric Printing
Digital Printing
Screen Printing
Digital Printing

89. Embroidery

90. MARKETING
CUSTOMER
PPC
Embroidery
Deptt.
Designing
Embroidery
Framing
Threading
Embroidery Section Process flow
Bundling

91. Embroidery Section machines set-up
• Machine Type TAJIMA
• No of machines 02
• Color options 06
• Heads 20

92. Cutting

93. MARKETING
CUSTOMER
PPC
Cutting
department
QA
Pre-Cutting
meeting
Marker Laying
Cutting
Bundling
Cutting Department Process flow

94. PP Meeting
Meeting may include the below points,
• Customer & garment style,
• Cut panels & specs required,
• Tolerance levels in specs measurements,
• Accessories required in PO,
• GGT marker instructions & requirements as per QC & GGT
consensus,
• Maximum & minimum lay length & height based on fabric type,
• Special laying instructions by QC, Cutting & Bundling,
• Analysis on the basis previously closed PO of same style &
suggestions to avoid mistakes of past history,

95. Pre-laying check points
• Approved mock check with shade bands, continuity & identification of
FID reports,
• Verification of fabric categories (Green, Yellow & Blue) & segregation
of rolls category wise,
• If blue category is more than 35% portion of the lot then separate job
card will be generated for separate induction & 100% CPI,
• Checking planned job card against given lot to verify lot color, fabric
construction & width,
• Marker go ahead after feeding data in system,
• Ensure fabric relaxation time minimum 24 hours before laying,

96. Fabric laying procedure & check points
• Analysis of marker from GGT department & checking points,
I. Pattern code verification,
II. Size direction,
III. Verification of complete components placed in marker,
• Fabric laying as per segregated category & to maintain data on laying
report,
• Lay length, height & splice checking as per agreed standards,
• Points to be checked during laying,
I. Roll to roll shade variation,
II. Lay tension,
III. Lay length,
IV. Alignment of fabric edges,
• Waste collection & adding in report,

97. Cake inspection
• Random cake inspection by QC (Top, Middle & Bottom) Shaping issues,
• Checking of notch marking, miss cut & get it right by the shaper,
• Mark hold if any cake is rejected,
• If cake is OK, move it to trolley,
• Re-inspection of reworked cake & marking it pass on inspection report,

98. Final inspection of bundles
• Bundling team put category wise bundling detail on report for procss card
generation,
• QC picks 20% random samples from given lot & Applies OQL 1.5
• QC checks following point during audit,
I. Garment specs& shapes,
II. Bundle size & no of pieces,
III. Shade variation in components of same garment,
IV. Trims shade & size checking,
• If results of given lot are according to OQL 105, then it will be considered
pass otherwise fail,
• Ok & rejected lots are mentioned on audit report,
• In case of embellishment, cut parts are checked 100%