Apparelinternship 12577915272209 Phpapp02

APPAREL EXPORTS PVT. LTD.
, INTERNSHIPGURGAON
COMPANYCOMPANY
PROJECT I PROJECT II SWOT ANALYSIS
RICHA GLOBAL
Presented By:
Shivangi Srivastava
APPAREL INTERNSHIP AT RICHA GLOBAL EXPORTS PVT.LTD.,GURGAON
COMPANY PROFILE
Richa Group of Companies were COMPANYCOMPANY
PROJECT I PROJECT II SWOT ANALYSIS incorporated in 1977. Richa Group has over 22 fully integrated
manufacturing units in Delhi, Gurgaon,

Noida and Bangalore. Richa Global is one of the new facility
which was set up in Oct 2006 at Gurgaon.
COMPANY P PROFILE
COMPANYCOMPANY
roduct ange: All Types Of Knitted Garments
The product range covers T-Shirts Collar-Shirts Night Wear Skirts Overcoats Jerkins Jackets Sports wear
COMPANY E PROFILE
COMPANYCOMPANY
STEEMED
CUSTOMERS
GAP Tommy Hilfiger
WAL-MART
DKNY Calvin Klein Liz Claiborne
American Eagle
Armani Exchange IZOD NAUTICA
COMPANY PROFILE
COMPANYCOMPANY
Monthly Production: 2,60,000 Pcs. Workers Capacity: 1400 workers Factory Floor Space: 97,715 Sq. Feet In Five Floors Including Basement Total Production Area: 45,074 Sq.Feet (Cutting, Sewing, Washing & Finishing
ORGANISATIONAL STRUCTURE
DIRECTOR FACTORY MANAGER Mr.NAYAN WAGHELA
SENIOR MERCHANT Ms.VINNY
SENIOR MERCHANT Mr.VIPIN
SENIOR MERCHANT Ms.RIDHIMA
SENIOR MERCHANT Ms.MANPREET
SENIOR MERCHANT Ms.PHALGUNI
FINISHING MANAGER Mr RAJU
QUALITY MANAGER Mr.AMIT
PURCHASE MANAGER Mr.AJEET
ACCOUNTS MANAGER Mr.ASHOK GUPTA
WASHING & DYEING MANAGER Mr.RAKESH
MANAGER HR & COMPLIANCES
TECHNICAL MANAGER
Jr.Merchants -Ms.SAUMYA -Ms.DIVYA
Jr.Merchants -Mr.ASHISH Ms.ANUBHUTI
Jr.Merchants -Mr.TARANDEEP -Ms.POONAM -Ms.NEHA
Jr.Merchants -Mr.PANKAJ -Ms.SONIA Mr.DINESH
Jr.Merchants --Ms.SONIA -MrYASH
PRODUCTION CO-ORDINATOR Mr.DILIP SHARMA EXECUTIVE Mr.SUNEET CUTTING INCHARGE Mr.RAM BILAS
ASST. INDUSTRIAL ENGINEER Mr.ABHISHEK GOEL
FLOOR INCHARGE
PACKING INCHARGE Mr.KAMAL
SAMPLING MASTERS
MACHINE MAINTAINENCE INCHARGE Mr.SUNIL
LINE SUPERVISORS
ELECTRICAL TECHNICIAN
PROJECT 1
COMPANY PROJECT I PROJECT I PROJECT II SWOT ANALYSIS
WASTAGE: ESTIMATION AND

CONTROL MEASURES
Time allotted for project 2 weeks(30th June- 12th July)
WASTAGE CONTROL
PROJECT 1
OBJECTIVES
To define wastage and outline the challenges to control it To calculate wastage of each department through study of styles To identify the stages of wastage To find waste percentage and the cost lost in wastage through the costing sheet
WASTAGE CONTROL
To develop formats on wastage for each department and the costing sheet
PROJECT 1
DEFINITION
WHAT IS WASTAGE?
Waste is purchased raw material that is subsequently not sold as product.
Waste costs money. Reducing the
amount of waste the company

produces will increase profits and
WASTAGE CONTROL
help the company to remain
competitive.
PROJECT 1
STYLES
To evaluate the amount of

wastage happening at various stages and its reasons, study was conducted on 3 styles.
BUYER: DKNY STYLE NO. KP-28 GARMENT: HOODIE JACKET
BUYER: NAUTICA STYLE NO. 7K3502 GARMENT: POLO
WASTAGE CONTROL
BUYER: NAUTICA STYLE NO. 7K3501 GARMENT: POLO

FINDINGS
STYLES
STYLE KP28.
STYLE 7K3502.
STYLE 7K3501.
STAGES FABRIC
WASTAGE
WST % 6.40%
WASTAGE
WST % 3.20%
WASTAGE
WST % 8.50%
160KG
50KG
161KG
CUTTING
BUNDLING
1
28
0%
1.20%
0
0
0%
0%
37
77
0.83%
1.73%
WASHING / DYIENG
SEWING WASHING / DYEING PRINTING FINISHING TOTAL TOTAL LOSS IN WASTAGE 10 160 0.40% 6.40% 14.92% RS. 99,960. 13 0.52% 187 17 21 33 5.12% 0.49% 0.61% 0.96% 10.38% RS. 52,296. *Still in progress *Still in progress 14.26% RS. 76,041. 140 3.21%
WASTE PERCENTAGE AT VARIOUS STAGES
FINISHING
0.96% 6.40%
STYLE 7K3501 STYLE 7K3502 STYLE KP28
PRINTING 0 WASHING / DYEING

ST AGES
0.61% 0.40% 0.49% 3.21%
SEWING 0.52% 1.73% BUNDLING 0% 1.20% 0.83% CUTTING 0% 0%
5.12%
8.50% FABRIC 3.20% 6.40% 0.00% 1.00% 2.00% 3.00% 4.00% 5.00% 6.00% 7.00% 8.00% 9.00%
WASTE PERCENTAGE
WASTAGE STAGES
FABRIC SOURCED FROM OUTSIDE FABRIC ISSUED TO CUTTING PCS.CUT CUT PCS. ISSUED TO BUNDLING PCS. ISSUED TO PRINTING PCS. REC. FROM PRINTING PCS. ISSUED FROM BUNDLING TO SEWING PCS. FROM PROD. TO FINISHING PCS. ISSUED FROM FINISHINGTO WASHING/DYEING
PCS. REC. FROM WASHING/DYEING

PCS. ISSUED TO PRINTING PCS. REC. FROM PRINTING
PCS. ISSUED TO FINISHING

PCS. ISSUED TO PACKING
PROJECT 1
REASONS
Fabric store
Inspection of the incoming fabric is very important. The fabric which is sourced from outside into the fabric store should be inspected for the defects.
WASTAGE CONTROL
PROJECT 1
REASONS
Wastes in the Cutting Room

Wastes in the cutting room can come from several sources including marker utilization, cutting waste and roll
remnants.
WASTAGE CONTROL
PROJECT 1
Bundling Room
REASONS
The inspection is not 100%, some
defective pieces go undetected and reach the stage of production
WASTAGE CONTROL
PROJECT 1
Production floor
REASONS
The loaders load the lines with the
bundles which pass on in the line

according to the operation. The operator may find the piece defective at any stage and dispose it off there and then only.
WASTAGE CONTROL
PROJECT 1
REASONS
Dyeing and Washing:

The wastage happens when either the pieces are lost or misplaced during the transportation.
WASTAGE CONTROL
PROJECT 1
Printing / Embroidery:
REASONS
The printing on the garment
does not match the standard

while in case of embroidery, it may not be on the correct place
on the garment or the number of

threads used are less and
WASTAGE CONTROL
desired effect is not obtained.
PROJECT 1
REASONS
Finishing
Measurement / Fit defect Trims defect Pressing
WASTAGE CONTROL
PROJECT 1 M
CAUSES
AIN CAUSES OF WASTAGE IDENTIFIED ARE 1.Motion
2.Delay or waiting
3.Conveyance (moving things around) 4.Correction(defects) 5.Overprocessing 6.Inventory
WASTAGE CONTROL
7.Overproduction 8. Knowledge disconnection underutilization of resources
INFERENCES FROM QUESTIONNAIRE_
High
10 9 8 7 6 5 4 3 2 1
Delay or waiting Correction (defects) Knowledge disconnection or underutilization of resources Incorrect method of working Inventory Overprocessing Overproduction Poor quality check Human errors
Moderate
Low
PROJECT 1
WASTE REDUCTION METHODS
METHODS
Wastes in the Cutting Room
Care in movement of work-inprogress Quality Control
WASTAGE CONTROL
PROJECT 1
RECOMMENDATION 1
WASTE STREAM REDUCTION

PRACTICES FOR APPAREL MANUFACTURERS TO DEVELOP A COMPREHENSIVE WASTE MANAGEMENT SYSTEM
WASTAGE CONTROL
PROJECT 1
RECOMMENDATION 2

PRACTICES FOR APPAREL MANUFACTURERS
TECHNIQUES TO REDUCE INDUSTRY SPECIFIC WASTE
WASTAGE CONTROL
PROJECT 1
RECOMMENDATION 3

PRACTICES FOR APPAREL
MANUFACTURERS
TO HANDLE SPECIFIC
OPERATIONAL WASTES
WASTAGE CONTROL
PROJECT 1
MEASURES
TO CONTROL COST LOST IN

WASTAGE Finish In Time Minimum Changes in Original Design Least Make Break/ Rework
WASTAGE CONTROL
Keep Check on Labour and

Material Costs
PROJECT 1
MEASURES
Avoid Rework due To bad Quality

Optimise Usage of Material Enhance Labour Productivity through Skills Training Efficient Management Information Systems for Timely Decision
WASTAGE CONTROL
Making
INFERENCES FROM QUESTIONNAIRE

10 Finish in time Least make break/rework Keep check on labour and material costs Avoid rework due to bad quality Enhance Labour Productivity through Skills Training Efficient Management Information Systems for Timely Decision Making 9 8 7 6 Optimise Usage of Material Moderate 5 Avoid Lumpsum Contracts Minimum Changes in Original Design 4 3 2 Low 1 High
PROJECT 2
COMPANY PROJECT I PROJECT II PROJECTII SWOT ANALYSIS
To
Identify the critical quality checkpoints in the industry in

Fabric Store Accessory Store Spreading and Cutting Department Sewing Department Finishing Department
QUALITY CONTROL
PROJECT 2
OBJECTIVE
To analyze the existing quality systems,

trends available in the system and study its utilization for corrective action.
Propose
measures to improvise the quality system. study the existing quality control norms and procedure in various departments o make the quality monitoring process more efficient and reliable
To
QUALITY T CONTROL
PROJECT 2
Time allotted for project
METHODOLOGY
2 weeks(30th June- 12th July)
Step 1 Study of the system Step 2 Review of existing quality system Step 3 - Analysis of quality checkpoints
followed by Buying House
Step 4 Analysis of checkpoints in the

industry (through flowcharts)
QUALITY CONTROL
Step 5 Identifying the problem areas Step 6 Suggesting ways to improve

production
PROJECT 2
INFERENCES
FROM QUESTIONNAIRE_:
Most
of the rejections are followed by their own QC personnel and QC Head followed by inspection agencies and buying houses.
The
QUALITY CONTROL
approximate amount of money spent as a result of poor quality ranged from 5%-7% of sales.
PROJECT 2
INFERENCES
COMPANY
REASONS FOR REJECTS IN PERCENTAGE

Fab ric shad e variat io ns and o t her f ab ric d ef ect s
10% 10%
Wo rkmanship
Pro cessing
10%
50%
Po o r rub b ing Qualit y
20%
PROJECT I PROJECT II PROJECTII SWOT ANALYSIS
Cut t ing d ef ect s, d amag es d uring manuf act uring ( w ro ng b ut t o ning , et c)
CAUSES OF "BULK OF HARM"
Wrong Pat t ern 10% 20% Sewing Defect s
QUALITY CONTROL
30%
Fabric problems Improper washing and dy eing
40%
Fabric arrives from textile industry
IN-HOUSE QUALITY
INSPECTION
COMPANY
Fabric issued for embroidery
Inspection for Fabric Defects by checkers
Fabric issued to cutting department
Spreading Under constant supervision by Quality Controllers Cutting Under constant supervision by Quality Controllers Bundling
PROJECT I
Bundles issued for printing
Cutting Audit Bundles issued to sewing department
PROJECT II PROJECTII
Bundles issued to sewing lines
SWOT ANALYSIS
In-line inspection at critical pts(100% or according to criticality of style
QUALITY CONTROL
End-Line Inspection NOTE: QUALITY CHECKERS
Washing
B/A, B/H, B/T
QCs X
IN-HOUSE QUALITY
INSPECTION
Finishing
Thread Cutting
General Checking
Measurement Checking On Iron tables
Thread Cutting
General Checking
Final Checking
Re-Final Checking
Measurement Checking
Balancing
QUALITY CONTROL
Needle Checking (needle detection)
Packing (Buying House inspection) NOTE: QUALITY CHECKERS Dispatch to Buyer
QCs
PROJECT 2
INFERENCES
COMPANY PROJECT I
50%
STAGES AT WHICH QUALITY PROBLEMS ARE FACED

50%
PROJECT II PROJECTII SWOT ANALYSIS
35% 40% 30% 20% 10% 8% 7%
QUALITY CONTROL
0%
M A N UF A C T UR IN G F IN ISH IN G A N D P A C KA GIN G C UT T IN G F A B R IC IN C OM IN G A N D ST OR A GE
PROJECT 2 R
INFERENCES
COMPANY
NO. OF GARMENTS WITH MARKINGS TO BE REMOVED BY SPOTTING
100 90 80 70 60 50 40 30 20 10
79 67 82
easons for which the quality is not given stress are:
Lack of presence of good markers in the cutting department

NO. OF GARM ENTS OUT OF 100
95 89 72 64 89 83 67
PROJECT I PROJECT II PROJECTII SWOT ANALYSIS
NO. OF GARM ENTS WI TH M ARKI NGS TO BE REM OVED BY SPOTTI NG
7/ 1/ 20 07
7/ 2/ 20 07
7/ 3/ 20 07
7/ 4/ 20 07
7/ 5/ 20 07
7/ 6/ 20 07
7/ 7/ 20 07
7/ 8/ 20 07
6/ 30 / 20 07
7/ 9/ 20 07
7/ 10 / 20 07
7/ 11 / 20 07
QUALITY CONTROL
DAT E
7/ 12 / 20 07
PROJECT 2
INFERENCES
Lack of proper formats for tracking the defects in accessory and fabric department Improper fabric inspection Improper ply alignment and varying ply tension COMPANY PROJECT I PROJECT II PROJECTII SWOT ANALYSIS
QUALITY CONTROL
PROJECT 2
INFERENCES
Shorter lead time and large orders COMPANY PROJECT I PROJECT II PROJECTII SWOT ANALYSIS
The number of alterations in the pieces is high.

LINE NO. 1 2 3 4 5 AVG :1st week 30THJUNE-5THJULY 13.22% 10.85% 16.26% 10.46% 8.19% 11.26% 14.40% 24.81% 7.43% AVG :2nd week 6TH JULY-12THJULY 10.71% 9.17% 9.72% 9.14% 7.37% 7.88% 17.89% 14.75% 21.99% TOTAL AVG 11.97% 10.01% 12.99% 9.80% 7.78% 9.57% 16.15% 19.78% 14.71%
QUALITY CONTROL
6 7 8 9
PROJECT 2
INFERENCES
There is no proper system for repair control. A lot of time is spent in material handling Piling up of huge WIP in the lines
WIP AS ON 5TH JULY, 2007
8000 7000 6000 5000 4000 3000 2000 1000 0

452 809 1111 616 2400 2502 2500
7680
WIP AS ON 5TH JULY, 2007
7K3000
7K3000
7K3000
7K3000
7K3000
9
QUALITY CONTROL
CK#007(39000)
MG37U07
10
7K3000
PROJECT 2
INFERENCES
Lack of proper thread cutting machines
THREAD CUTTING OBSERVATION STYLE NO 7590

400 350 300 250 200 150 100 50 0
356
NO. OF THREADS
326
212 139 105 56 5 21 67 19 63 18 28 29
bot t om neck underarm sleeve hem placket side seam label
upt o 3mm
3mm t o 1cm SIZE OF THREAD
above 1cm
QUALITY CONTROL
PROJECT 2
RECOMMENDATION I
Proper Training
Supervisors Operators Quality checkers
QUALITY CONTROL
PROJECT 2
RECOMMENDATION II
To keep a check on repairs

Designate a special person (helper) as a repair person and a special rack at each examination point (in-line and final examination)
Examiner must mark the faults
Put the complete faulty bundle in the repair rack
Collection of the faulty bundles in the repair rack and record them on the repair list
Give the bundle to the appropriate operator
QUALITY CONTROL
Bundle should be returned back to the QC within 1 hour of its collection by the repair person
PROJECT 2
RECOMMENDATION III
Random inspection by
Use of Random Number Table
Roaming QC
Use of Red and Yellow Card System Use of Uncleared Operators Recording
format_
QUALITY CONTROL
PROJECT 2
RECOMMENDATION IV
Use of formats
Use of formats for tracking of defects in accessory (accessory audit report) and washing department(after and before wash report) for proper tracking of defects
QUALITY CONTROL
STRENGTHS
COMPANY PROJECT I PROJECT II SWOT SWOT ANALYSIS ANALYSIS In-House Facility Good Working Relationship Capacity expansion
SWOT ANALYSIS
WEAKNESSES
Due to shorter lead times, the quality is not upto the mark. COMPANY PROJECT I PROJECT II SWOT SWOT ANALYSIS ANALYSIS Competition from other domestic knit industries.
No T&A charts
Data is stored in files instead of computers in many departments
SWOT ANALYSIS
Absence of production Planning Department
OPPORTUNITIES
COMPANY PROJECT I PROJECT II SWOT SWOT ANALYSIS ANALYSIS
Export income from garments made from knit fabrics increased by 64%
Quotas are gone now for 31 months, and India has the opportunity to derive the maximum gains as a garment exporter. Consolidation of global retail industry.
SWOT ANALYSIS
THREATS
COMPANY PROJECT I PROJECT II SWOT SWOT ANALYSIS ANALYSIS
Richa Global Exports Pvt. Ltd. will have to gear up to global standards and expectations of quality, delivery schedules and still remains sharply cost competitive.
Indian Export house faces competition from Bangladesh, Indonesia, etc. as they are the lowest cost supplier in almost all categories
SWOT ANALYSIS
Thank You

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APPAREL EXPORTS PVT. LTD.

manufacturing units in Delhi, Gurgaon,

which was set up in Oct 2006 at Gurgaon.

APPAREL INTERNSHIP AT RICHA GLOBAL EXPORTS PVT.LTD.,GURGAON

roduct ange: All Types Of Knitted Garments

APPAREL INTERNSHIP AT RICHA GLOBAL EXPORTS PVT.LTD.,GURGAON

GAP Tommy Hilfiger

APPAREL INTERNSHIP AT RICHA GLOBAL EXPORTS PVT.LTD.,GURGAON

APPAREL INTERNSHIP AT RICHA GLOBAL EXPORTS PVT.LTD.,GURGAON

SENIOR MERCHANT Ms.VINNY

SENIOR MERCHANT Mr.VIPIN

SENIOR MERCHANT Ms.RIDHIMA

SENIOR MERCHANT Ms.MANPREET

SENIOR MERCHANT Ms.PHALGUNI

FINISHING MANAGER Mr RAJU

QUALITY MANAGER Mr.AMIT

PURCHASE MANAGER Mr.AJEET

ACCOUNTS MANAGER Mr.ASHOK GUPTA

WASHING & DYEING MANAGER Mr.RAKESH

MANAGER HR & COMPLIANCES

Jr.Merchants -Ms.SAUMYA -Ms.DIVYA

Jr.Merchants -Mr.ASHISH Ms.ANUBHUTI

Jr.Merchants -Mr.TARANDEEP -Ms.POONAM -Ms.NEHA

Jr.Merchants -Mr.PANKAJ -Ms.SONIA Mr.DINESH

Jr.Merchants --Ms.SONIA -MrYASH

ASST. INDUSTRIAL ENGINEER Mr.ABHISHEK GOEL

PACKING INCHARGE Mr.KAMAL

MACHINE MAINTAINENCE INCHARGE Mr.SUNIL

WASTAGE: ESTIMATION AND

Time allotted for project 2 weeks(30th June- 12th July)

Waste is purchased raw material that is subsequently not sold as product.

Waste costs money. Reducing the

amount of waste the company

help the company to remain

APPAREL INTERNSHIP AT RICHA GLOBAL EXPORTS PVT.LTD.,GURGAON

To evaluate the amount of

BUYER: DKNY STYLE NO. KP-28 GARMENT: HOODIE JACKET

BUYER: NAUTICA STYLE NO. 7K3502 GARMENT: POLO

BUYER: NAUTICA STYLE NO. 7K3501 GARMENT: POLO

WASTE PERCENTAGE AT VARIOUS STAGES

STYLE 7K3501 STYLE 7K3502 STYLE KP28

PRINTING 0 WASHING / DYEING

0.61% 0.40% 0.49% 3.21%

SEWING 0.52% 1.73% BUNDLING 0% 1.20% 0.83% CUTTING 0% 0%

PCS. REC. FROM WASHING/DYEING

PCS. ISSUED TO FINISHING

Wastes in the Cutting Room

defective pieces go undetected and reach the stage of production

bundles which pass on in the line

Dyeing and Washing:

does not match the standard

on the garment or the number of

desired effect is not obtained.

APPAREL INTERNSHIP AT RICHA GLOBAL EXPORTS PVT.LTD.,GURGAON

AIN CAUSES OF WASTAGE IDENTIFIED ARE 1.Motion

7.Overproduction 8. Knowledge disconnection underutilization of resources

APPAREL INTERNSHIP AT RICHA GLOBAL EXPORTS PVT.LTD.,GURGAON

INFERENCES FROM QUESTIONNAIRE_

Care in movement of work-inprogress Quality Control

WASTE STREAM REDUCTION

WASTE STREAM REDUCTION

TECHNIQUES TO REDUCE INDUSTRY SPECIFIC WASTE