Presentation based on 3 Month Internship at
Modelama Exports Ltd.
Under the Guidance of
Presented by
Mrs Vasundhara Chaudhary Associate Professor
Atul Dwivedi, Navneet Yadav and Vinay Prajapati; M.F.TECH, SEM-III
National Institute of Fashion Technology, Gandhinagar 19-09-2011
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Company Profile COMPANY NAME
MODELAMA EXPORTS PVT LTD
ADDRESS
TELEPHONE
PLOT NO. 105/106, UDYOG VIHAR, PHASE-1 GURGAON, HARYANA- 122015 B-57 OKHLA INDL. AREA PHASE-1 NEW DELHI- 110020 INDIA 0124-4008105
FAX
0124-4008108
E MAIL
[email protected]
WEBSITE
www.modelamaexports.com
YEAR ESTD.
1979
OWNER
MR. LALIT GULATI
DIRECTORS
ANNUAL TURNOVER
MR. SANJAY GULATI MR. GAGAN GULATI MR. GAURAV GULATI 60 MILLION (OF ALL FACTORIES)
MARKET
100% EXPORT
TOTAL COVERED AREA
4,00,000 SQ. FT.
TOTAL WORKING FORCE
5500
IN HOUSE/FABRICATION/BOTH
BOTH
PRODUCTION CAPACITY
8 MILLION/YEAR
HEAD OFFICE
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Team Modelama
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Corporate Office
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Vision/Mission Vision Modelama will guide its business activities maintaining a balance between ethical values and corporate objectives. The company will strive to achieve its goals by executing its strategic plans and caring for the profits of all the stake holders. Mission Modelama has a vision to establish itself as a multi-product and multi-services business conglomerate. It is committed to expand the spheres of its business activities into newer sectors in the years ahead. The company is confident of building the same brand image in all areas of its operations that it has in garments and home furnishing sectors
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Product Range APPAREL
HOME FURNISHING 19-09-2011
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Organisation Structure
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Infrastructure
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Production Units HARYANA 184, Udyog Vihar, Phase-I, Gurgaon
105, Udyog Vihar, Phase-I, Gurgaon
106, Udyog Vihar, Phase-I, Gurgaon
200, Udyog Vihar, Phase 1,Gurgaon,
Mervyns 201, Udyog Vihar,Phase 1
204, Udyog Vihar,Phase 1, Gurgaon
660, Udyog Vihar, Phase-V, Gurgaon
Plot No-5, IMT Manesar, Sector-4, Gurgaon
Plot No 7, IMT Manesar, Sector 5,IMTManesar, Gurgaon
Plot No 18, IMT Manesar, Sector 5,IMTManesar, Gurgaon
Plot No 89, IMT Manesar, Sector 8, IMT Manesar, Gurgaon
529, Phase-I, Bahrhi, Dist. Sonipat
Plot No 1, Sector 8, Bawal, Dist. Rewari
CHENNAI Plot No - K 46/47/48/49, Appragel Park , Irun Gattukottai. Dist. Tairnatur DELHI B-33, Okhla Industrial Area, Phase -1, New Delhi 19-09-2011
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Work Flow BUYER
PRODUCT DEVELOPE R
MERCHENT
SAMPLING
FABRIC
BUNDILING AND TICKETING
CUTTING
SPREADING
MARKER PLANNING
TESTING
PRODUCTI ON
WASHING
FINISHING AND PRESSING
PACKING
DISPATCH
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Buyers
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Merchandising
A merchant is the person who acts as a link between a buyer and vendor. He is the one who is central or integral part of a garment industry. 19-09-2011
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Merchandiser’s Responsibility 1. Chase for fabric/trims prior to PCD date. 2. Size sets/PP/TOP samples-Monitoring and delivering. 3. Coordinating buying agency QA Inspection.
Responsibility
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Product Development This department is not buyer specific and work for all the buyers that company caters to.
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Sampling
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PROTO TYPE SAMPLE MADE
TOP SAMPL E MADE
SIZE SET SAMPL E
FIT SAMPL E MADE
PP SAMPL E MADE
SHIPME NT SAMPLE
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Machine Details in Sampling Department
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Process Flow of Fabric Store
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Inspection
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Defect Categorisation
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Spreading & Cutting SPREADING
MARKER LAYERING
CUTTING MANUAL/AUTOMATIC
TICKETING
FUSING
CHECKING
BUNDLING
TRANSFER TO PRODUCTION 19-09-2011
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Spreading
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Spreading Flow FABRIC IS LOADED ON SPREADING MACHINE
PERFORATRED PAPER IS SPREAD ON SPREADING TABLE VACCUME IS TURN -ON IN THE SPREADING TABLE
AUTOMATIC/MANUAL SPREADING IS DONE
PROPER TENTION IS MAINTAINED WHILE
WHEN FINISHED, VACCUME IS TURNED OFF MARKER IS SPREAD OVER IT AND PASTED BY TAPE
AIR FLOW IS GIVEN FROM BOTTOM
TRANSFERRED TO THE CUTTING TABLE
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Spreading Flow Types of cutting devices: 1. 2. 3. 4. 5. 6.
5 fusing machine 16 straight knife 6 edge cutters 2 computer aided machines 4 spreader 1 round knife
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Lectra Automatic Spreader Parameters
Value
Speed
100 m/min
Thickness can lay
30- 40 cm
Working width
2.5 meter
Length
20 meter
Suction Tables Roll Weight
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150 Kg
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Lectra Victor Automatic Cutter
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Parameters
Value
Speed
100 km/hr
Thickness can cut
6-7 cm
Cutting width
2.54 mtr
Cutting Length
3.5 mtr
Suction
4 kg/cm2
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Straight Knife Cutter Blade Size (inch)
5
6
7
8
Blade Size (cm)
12.7
15.2
17.7
20.3
Cutting Capacity 3 1/2 (inch) Cutting Capacity 8.89 (cm) Stroke Size (inch) 1 1/8
4 1/2
5 1/2
6½
11.4
13.9
16.5
Stroke Size (cm)
8.89
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8.89
1 1/8
1/4 11.4
1/4 11.4
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Fusing Machine
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Fusing Machine Specification MODEL POWER SUPPLY RATED OUTPUT FUSHING WIDTH MAX.BELTSPEED MAX.PRESSURE MAX.TEMPERATURE HEATING TIME DIMENSIONS WEIGHT
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HP-1000LW Three phase HEATER : 21.6kw MOTOR : 705W 1,000mm 12.7m/min 5kg/cm2 198℃ 6.5 ~ 31sec. 4,327 X 1,606 X 1,255mm (Approx)1,500kg
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Computer Aided Design PATTERN MAKING DIGITIZING STYLE/PATTERN DESCRIPTION GRADING CUT ORDER PLANNING MARKER MAKING PRINTING FOR CUTTING
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CAD Software Modaris This software performs the following functions: o Pattern making o Pattern modification o Pattern digitizing o Pattern grading
Main equipment used: • Pattern pieces • Digitizer • Software • Plotter FLY PEN ALYS-30
Diamino This software is used for marker making. It can be manual or automatic. Efficiency of marker as decided as per the garment in this seam allowances are also added. Optiplan This software is used when buyers send uneven ratios. 19-09-2011
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CAD Advantages 1. Significant reduction in lead times. 2. Reduction in labour costs for generating new styles & modifying existing ones. 3. Achieving significant reductions in fabric utilization. 4. Block’s images stored in computer. 5. Grading technique replaced by expert system. So that grading is now in the form of tables and auto matched. 6. Percentage wasted; computed and displayed for each layout. 7. Fabric pattern constraints incorporate in the program. 8. Cutters replaced by CAD/CAM. 9. Wages reduced.
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Production Floor
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Sewing Department Production floor follows Bundle system. Following are steps to start a production line: Study the production file. Study operation bulletin and set line accordingly. Manpower – tailors and helpers. Load and feeding lines. Arrange buffer or work-in-progress. Manufacturing. Make daily production and to achieve targets accordingly. Understand bottlenecks stage of production
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Working: Production Department Shrinkage production pattern is issued to production floor from CAD department. Ready patterns are made as per the requirement of production room. Cutting receives from cutting department. Cross checking of cut s with patterns. Bundling of cut s is done. Operation wise feeding of cut into the line. Inline checkpoints. Output of line. Final checkpoints. Auditing of checked pieces. 19-09-2011
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Laundry To restore this aesthetic value, they are subjected to cleansing process like washing.
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Type of Washes Normal Wash Desize Wash Enzyme Wash Stone Wash Softener Bleach Acid Wash Monkey Wash Sand Wash
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Washes Normal Wash
Softener Wash
Process
Time
Process
Time
Desizing
30 min
Desizing
20 min
Enzyme
30-60 min
Washing
30 min
Softener
20- 30 min
Enzyme Wash
Stone Wash Process
Time
Process
Time
Desizing
30 min
Desizing
30 min
Enzyme
30-60 min
Enzyme
30-60 min
Stone
20 min
hypo chloride
30 min
hypo chloride
30 min
Neutralization
30 min
Neutralization
30 min
Softener
20 min
Softener
20 min
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Finishing After assembly, the garments now come for finishing- a key stage of garment manufacturing process. Finishing is done to prepare the final garment according to the quality standards of the buyer before packing it for shipment
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Process Flow: Finishing GARMENT COMES FROM PRODUCTI ON
SENT FOR PACKING
washing
ALTERATION
REIRONIN G
MEASUREMEN T
THREA D CUTTIN G
INITIAL CHECKING AND SPOTTING
FINAL CHECHING
PERSENTATI ON/FINAL IRONING
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Finishing Machine Details Finishing Machines
No. of Machines
Vacuum Table
60
Up Steam Table
5
Stain Removing Gun
13
Stain Removing W/S
3
Form Finisher
2
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Packaging Packing is the last stage where the finished garments are primed, organized, geared up for the shipment to the buyer, the entire process from the way a garment will be folded to the final labelling of the cartons is dictated by the buyer’s specifications.
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Process Flow: Packaging
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Packing Norms 1. All garments packed in individual poly bags. 2. Poly bag sticker on poly bags, which may be printed by the factory 3. Order must be completed (packed, ready for shipment) prior to bulk orders. 4. Order must be inspected and audited by the factory 100%. 5. Order must be of first quality, no repair or ungraded garments should be in license shipments. 6. Order must be shipped 100% complete otherwise notified. 7. The packed goods are now ready to be ed through
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AQL Parameters AQL Chart No. of Cartons
Sample Size
Fail
5-15
3
0
1
16-50
8
0
1
51-150
20
0
1
151-500
50
1
2
501-1200
80
1
2
1200-up
125
2
3
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Shipment Rejection Reasons 1. 2. 3. 4. 5.
Incorrect quality Carton labeling error Incorrect Prepackaging Carton not as per specified size Use of wire of metallic strap
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Visual Audit Standard Shipment Size
Sample Size
Gap AQL (2.5) Level /Fail
Old Navy AQL (4.10) Level /Fail
0-500
20
1/2
2/3
501-1200
32
3/2
3/4
1201-3200
50
3/4
5/6
320110000
80
5/6
7/8
1010035000
125
7/8
10/11
35000 >
200
10/11
14/15
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IE/R&D Working of IE is as follows:
Calculating SMV Making Operation Bulletin Calculation of thread consumption Deg of work aid devices; Folders, Guide & Profiles Update SMV and finalize report Prepare work station layout Line setup Capacity check analysis and Production study and increased efficiency
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Project MONITORING OF LOST TIME & OPERATOR PERFORMANCE
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Project Outcome During the project we observed that initially most of the times were going waste in extra other activities like drinking water etc. It was observed the operators were not flexible to work in the new line setup that’s why their performance was not up to the mark. With the Help of this project the IE department of the Modelama exports put some pressure on the operator not to waste the time on other activities and increased the average performance of Operator from 23.9 to 26%.
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Thank You 19-09-2011
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