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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
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Internship report by kamran

Aug 19, 2014

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Engineering

Kamran Khattak

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Page 1: Internship report by kamran

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

Page 2: Internship report by kamran

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. From HR 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 Mehmood sandhu & Mr. Saqib Shahzad for 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

Textile experience. !

Page 3: Internship report by kamran

MISSION STATEMENTAt 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.

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TextilesNishat 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:

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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

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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.

DEPARTMENT LIST FLOW CHART

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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

MARKETING/ MERCHANDIZING

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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.

Qualities of Merchandiser

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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

Pre production follow up

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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 %)

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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.

FABRIC PRECUREMENTS DEPARTMENT

FLOW OF PROCEDURES INVOLVED IN

M.M.C.

( PRECUREMENTS)

MERCHANDISER RAISES DEMAND

APPROVAL FROM MERCHANDISER

BULK ORDERING

SAMPLES FROM SOURCES/ VENDORS

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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.

CONCEPT OF MATERIAL MANAGEMENT AND CONTROL

IN-HOUSE

If Not OK

SENT BACK TO VENDOR

If OK

QUALITY CHECK

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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

Poly-bags

Stickers

Tape

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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

• Approaches to Development

• Fabric-driven: select fabrics, create silhouette

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• 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

Process flow chart of Sampling Dept

Sample request & Tech pack received from Merchant (Merchandising Dept.)

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Develop Patterns

Costing / CAD Marker

Develop fit/Proto sample

Pre production sample

Size set sample

Sealer sample (final)

PRODUCTION PLANNING AND

CONTROL

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INTRODUCTIONProduction 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 MANAGEMENTProduction 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.

TYPES OF PRODUCTION SYSTEM

INPUTS CONVERSION PROCESS OUTPUTS

CONTROL

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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.

MANUFACTURING PROCESS

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The nature of the process of production required by these three different types of production

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 the following 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

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.

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(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 in capacity 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

1. Production Planning

PRODUCTION PLANNING AND CONTROL

PRODUCTION PLANNING PRODUCTION CONTROL

Planning

Routing

Scheduling

Loading

Dispatching

Following Up

Inspection

Corrective

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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 are also 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 which can easily be

handled by plant and equipment without interference. Its not independent decision as it takes

into account following factors.

(1) Physical plant facilities of the type required to process the material being scheduled.

(2) Personnel who possess the desired skills and experience to operate the equipment and

perform the type of work involved.

(3) Necessary materials and purchased parts.

Master Schedule: Scheduling usually starts with preparation of master schedule which is

weekly or monthly break-down of the production requirement for each product for a definite

time period, by having this as a running record of total production requirements the

entrepreneur is in better position to shift the production from one product to another as per

the changed production requirements.

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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 as it brings out efficiency in the operations and reduces

cost price. The organization four types of schedules to have a close scrutiny of all stages

namely an enquiry schedule, a production schedule, a shop schedule and an arrears

schedule out of above four, a shop schedule is the most important most suited 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 in advance of operations,

establishing the extract route of each individual item part or assembly, setting, starting and

finishing for each important item, assembly or the finishing production and releasing the

necessary orders as well as initiating the necessary follow-up to have the smooth function of

the organization. The production control is of complicated nature in small industries. The

production planning and control department can function at its best in small scale unit only

when the work manager, the purchase manager, the personnel manager and the financial

controller assist in planning production activities. The production controller directly reports

to the works manager but in small scale unit, all the three functions namely material control,

control starts with dispatching and ends up with corrective actions.

GATE OFFICE

Work and Procedure

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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

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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

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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. Over lock 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

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50cm

50cm

5CM

60CM

60CM

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

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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

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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,

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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.

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Operation Description Machine TypeSmall Parts1 Coin Pocket Hemmig D.N.L.S2 Coin pocket attachment on facing D.N/S.N3 Facing attachement on pocketing Cover stitch4 Pocket bag closing Safety5 Top stitch on Pocket Bag S.N.L.S6 Back pocket hemming D.N.L.S7 Over lock left & right fly Over Lock8 Make Left & right fly S.N.L.S9 Attach Zipper to right fly S.N.L.S10 Make loops Flat Lock

Front11 Fly attachment with front panel S.N.L.S12 J-Stitch on fly D.N.L.S13 Fly top Stitch/Edge Stitch S.N.L.S14 Fron Rise/Crotch Stitch 2N-Feedo15 Front Pocket attachment with Front Panel S.N.L.S16 Top stitch on front pocket opening D.N.L.S17 Secure Stitch S.N.L.S

Back18 Safety Stitch on Yoke & Back Panel Safety19 Top Stitch on yoke 3N-Feedo20 Safety Stitch on Back rise Safety21 Top Stitch on Back Rise 3N-Feedo22 Back Pocket attachment D.N.L.S

Assembly-123 Safety on Inseam Safety24 Top Stitch on Inseam 3N-Feedo25 Safety on Side seam Safety26 Top Stitch on Side seam 2N-Feedo27 Waist Band attachment Waist Band m/c

Assembly-228 Waist Band closing S.N.L.S29 Loop Attach Bartack m/c30 Bartack on fly, back pockets & S.S Bartack m/c31 Button Hole Eye-let m/c32 Bottom Hemming S.N.L,S

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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

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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,

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

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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.)

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Relaxed Single Cycle (R.S.C) = Av. Single C.T + Allowances (m/c Allowance, Contingencies Allowances, Material Handling Allowance etc.)

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

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7. Fabric fault

8. Stain marks

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)

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Bleach wash (light color)

Super bleach( very light color)

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.

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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.

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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.

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8. Metal Detection:

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.

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Shipping Department

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 “

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Certificate of origin issued by the chamber of commerce & industry

Bill of lading ( sea shipment ) & Airway bill ( air shipment )

THE END