apparel internship

1. REPORT ON APPAREL INTERNSHIP AT
ORIENT CRAFT LIMITED
( 9K UNIT)
SUBMITTED BY:
RIDDHI MALVIYA
(B.F.TECH VII)
UNDER THE
GUIDANCE OF:
ASST. PROFESSOR
ANKUR SAXENA
25th May- 28th August

2. COMPANY PROFILE
• 1997
Year
established
• Mr. Sudhir Dhingra
Owners/
Directors
• FOB US$ 225 Million for 2014-15
Annual
Turnover
• 8000 in-house
No. of people
employed

3. MERCHANDISING

4. PRODUCTION PLANNING AND CONTROL
1. Order clarity meeting
with marketing team
2. Receive the order
3. Plan to check if there is
available capacity in
sewing to achieve the
delivery date required
4. Plan to check the
available capacity in non-
sewing areas (cut,
embroidery; print, wash
and pack)
5. Plan to check sufficient
lead time to order and
receive fabric, trims,
approve sample, carry
out lab tests
6. Confirm delivery date
to customer and reserve
capacity
7. Plan Cut Date (PCD)
follow-up
8. Communicate plan to
sampling, cutting, sewing
and finishing
9. Monitor progress
against plan and doing
the follow-up

5. FABRIC SOURCING AND AUDIT
Entry in
excel
Shade segregation

6. TRIM STORE
ISSUE DEPARTMENT
CENTRAL PLANNING
QUANTITY & QUALITY CHECK
TRIM APPROVAL CARD
DATA ENTRY IN EXCEL SHEET
RECEIVING GOODS AT STORES
GOODS RECEIVED AT GATE

7. CENTRAL INDUSTRIAL ENGINEERING DEPARTMENT
(IED)
Product Analysis
(optimum method of
construction )
Product Costing Production Planning
(line plan)
Performance
Development
(SAM)
Method Engineering
(man and material
movement methods)
Operator Training

8. SAMPLING

11. CUTTING

14. SEWING

16. WASHING DEPARTMENT

17. FINISHING & PACKING
Tagging

18. TESTING LABORATORY

19. •Decreasing
alterations
in the
sewing
room
PROJECT

20. OBJECTIVES
•To estimate the alteration percentage to
get a quantitative prospective of
problems
•To detect the major defects and its causes
•To improve the quality standard from the
current status
•To increase the profits which is the major
area of concern for any organization

21. TRAIN OPERATORS TO THE NEW WAY OF WORKING
Sustaining is as important as implementing
SUGGEST POSSIBLE MEASURES TO REDUCE DEFECTS
After analysing the cost effectiveness
IDENTIFY THE MAJOR CAUSES OF DEFECTS
Discussing with line managers, using own knowledge
DETECT THE SEWING LINES HAVING MAXIMUM ALTERATION
Comparing data from inspection table

22. 0
200
400
600
800
1000
1200
1400
1600
1800
2000
Line 1( Day 5) Line 2 ( Day 2) Line 3 ( Day 3) Line 4 ( Day 6) Line 5 ( Day 7)
Total garments
produced
Number of
alterations

24. •Woven’s Sewing room
•Line 2
Location
•558015
Style
number
•Banana RepublicBuyer
•10000 pieces
Order
quantity

25. THE PROBLEM
Uneven
placket
width
Problem of
puckering,
roping

27. •8-10 minutes per garment
( opening stitch, stitching
again with increased
focus and time)
Time
required
for
alteration
•2 workers
•Salary = 6000*2 = 12000
Number of
workers
involved in
alteration

28. THE SOLUTION:
Anti puckering kit
Contains
needle
plates and
feed dogs.
Has a
transparent
glass guide.
Training
provided to
the
operator on
how to use
the guide
and needle
plate
Cost of anti
puckering
kit: Rs 180
per kit (
including
delivery
and basic
training)

31. 0
100
200
300
400
500
600
Day 1 Day 2 Day 3 Day 17
Total garments produced
Number of alterations

33. •Woven’s Sewing room
•Line 3
Location
•289221
Style
number
•Banana RepublicBuyer
•5000 pieces
Order
quantity

35. THE PROBLEM
Roping and
puckering
at the
bottom hem
Causing
unevenness

37. THE SOLUTION
Add a ‘stay-
stitch’ at the
hem before
doing the
final
hemming
Add one
operator to
the line and
train him to
do the stay
stitch
Reason for
reluctance:
adding an
extra step?!

38. CURRENT SAM OF
GARMENT : 28 MINUTES
ALTERATION % = 160/230 =
69% !
Thus, adding the alteration
time, the final time comes
out to be 28+8 = 36 minutes
Number of operators in line
= 49 operators + 2 for
alterations
Time taken for STAY
STITCH= 1 minute 49
seconds
Thus, final SAM = 29
minutes 49 seconds
No extra operator
required because one
operator from alteration
can be replaced here.

40. 0
50
100
150
200
250
300
Day 3 Day 4 Day 11
Total garments produced
Number of alterations

42. New correct method to sew main label for clean finish
from front & back : Nordstorm

43. Traditional method of attaching main label

44. In traditional method back side is not very neat after attaching main label and
may result in alteration if tried to finish.
Not neat from back

45. Correct method to sew label for clean finish
• Step 1
Keep needle thread up with
hand before starting the
operation.
Note: Auto trimming function of sewing
m/c need to be disable for label
attaching.

46. • Step 2
Start the operation and end
with keeping the needle
thread up.

47. • Step 3
Same on other side of the
label with keeping the
needle thread up.

48. After attaching label
Front side Back side

49. • Step 4
Finish the label by trimming
the extra threads visible on
front & back

50. Final view of label after finishing which is very neat from front
and back.
Front. Back.

51. Comparison
Traditional method Correct method
Back view Back view
Not neat Neat & clean
Not neat Neat & clean

52. SPECIALIZATION: MERCHANDISING

53. THANK YOU