A Summer Internship Report

On

“MAPPING THE PROCESS FLOWCHART AND DOCUMENTATION IN AN EXPORT HOUSE”

At

ORCHID OVERSEAS PVT.LTD.Gurgaon, Haryana

By

Ajit Kumar Gupta

Batch – 2011-13

MASTER OF FASHION MANAGEMENT

Department of Fashion Management Studies

National Institute of Fashion TechnologyJodhpur

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DECLARATION

I, AJIT KUMAR GUPTA hereby declare that the Internship Project Report entitled

“MAPPING THE PROCESS FLOWCHART AND DOCUMENTATION IN AN

EXPORT HOUSE” submitted towards, partial fulfillment of the Degree of Master of

Fashion Management is my original work and no part of the project has been copied from any

other reports or any other work carried by someone else which has been submitted for any

other degree/award. However, any material taken from any other published source has been

suitably referred and acknowledged at various places.

Name: Ajit Kumar Gupta

Roll Number: 2011101

Batch: MFM – 2011-13 Centre: Jodhpur

Date: 23th August, 2012

Place: Jodhpur

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. FIRM’S CERTIFICATE

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CERTIFICATE BY THE FACULTY MENTOR REGARDING COMPLETION OF WORK

This is to certify that the Internship Project entitled “MAPPING THE PROCESS

FLOWCHART AND DOCUMENTATION IN AN EXPORT HOUSE” submitted

towards the partial fulfillment of the Degree of Master of Fashion Management by AJIT

KUMAR GUPTA is his original work under my guidance and the results are based on the

research done by him.

(_________________________)

Mr. VIKAS KUMAR Faculty Mentor

NIFT JODHPUR

Date: 23th Aug, 2012

Place: Jodhpur

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Acknowledgement

A project report seems to be an individual effort is in fact teamwork. Summer training at

Orchid Overseas Pvt. Ltd. was just like an opportunity to shake hand with the practical world

of business.

I am indebted to all those individuals who helped me in gaining knowledge & insight into

various aspects of mapping the process flowchart and documentation in an export house. The

source of learning have been one too many & a complete list of individual references would

become encyclopaedic.

I want to express my deepest gratitude to Mr. Rohit Kumar, Asst. Production Manager,

Orchid Overseas, without whose help this summer internship in orchid overseas would not

be possible.

I am grateful to Mr. Anurag Shukla, Factory manager, Orchid Overseas, for sharing his experience

& knowledge & without whose help the project would not have got any shape.

My deepest appreciation also extends to Mr. Vikas Kumar, Project guide, Faculty NIFT-

Jodhpur, who critically reviewed my project report & provided suggestions.

I would like to thank Mr. Jabber Singh, Director NIFT-Jodhpur, for his constant support

& encouragement.

Finally, I would express my gratitude towards Mr. Ankur Saxena, Faculty NIFT-Jodhpur

for facilitating my Summer Internship.

NAME: AJIT KUMAR GUPTAADDRESS: NIFT Campus,

Old Nagar Nigam Bldg, Sojati Gate, Jodhpur – 342001

Master of Fashion ManagementDate of submission: 23th August, 2012

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Table of Contents

Executive Summary .......................................................................................................6

Chapter 1

Introduction ....................................................................................................................7

Background of the problem task undertaken ...................................................................7

Project Objectives ............................................................................................................7

Rationale of the study .......................................................................................................8

Scope of the study ............................................................................................................8

Introduction of the company ............................................................................................9

Chapter 2

Methodology ...................................................................................................................17

Chapter 3

Objective of the project .................................................................................................19

What role the different department play for completion for the export order? ...............20

Close look of merchandising department..... ...................................................................41

What are the different documents prepared & used for the export? ...............................49

How important are these documents? ………………………………………………….

Organisational structure ………………………………………………………………..56

Bibliography ....................................................................................................................61

Annexure ..........................................................................................................................62

List of Illustrations

Figure 1: Layouts……………………………………....................................................12

Figure 2: Fabric Process Flow Chart ..............................................................................23

Figure 3: Garment Process Flow Chart ..........................................................................28

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EXECUTIVE SUMMARY

This project is aimed at understanding mapping the process flowchart and documentation in

an export house. It begins with the introduction of the company i.e. company profile. This

part includes introduction of the company, its plant location, capacity, the client base & some

export figures giving idea of Exports at Orchid Overseas Pvt. Ltd.

Chapter 2 discusses the Methodology used for the data collection. Exploratory research is

used for data collection as is best suited for this fulfilling the project objective.

Next objective discusses a view of different departments working in synchronization in order

to process an export order. The role of each department is discussed in context of mapping

the process flowchart and documentation in an export house & what contribution they make

towards it.

Next objective gives a brief idea on the merchandisers & what role they play. They are the

one who interacts with the clients & update the company with client’s requirement. They act

as a liaison between the company & the client.

In the final objective a brief summary of all the export documents used at the Orchid

Overseas for legalizing an export order is given. Further the documents regarding pre & post

shipment procedure are discussed.

In the end Annexure are attached as supporting documents.

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CHAPTER-1 Introduction

Background of the problem task undertaken

It is an opportunity to do the summer internship in Orchid Overseas Pvt. Ltd. which is a

manufacturer & exporter of Women’s Wear, Kids Wear &Men’s Wear garments. Project on

Export house is uncommon & that on an Apparel Export House is rare.

As we know, exporting is complex and challenging activity in today’s dynamic world

environment as it involves the performance of operations that determine existing and

potential demand in a market. Learning the step-by-step processes & procedures to be

followed in an export contract is a crucial activity in export procedure.

So, selecting a project on mapping the process flowchart and documentation in an export

house is an obvious & important decision.

Project Objectives

a) What role the different department play for completion of the export order?

b) Close look of merchandising department.

c) What are the different documents prepared & used for the export?

d) How important are these documents?

e) Organisational structure.

Rationale of the Study

Export in simple words means selling goods abroad or Export refers to outflow of goods

and services and inflow of foreign exchange. Each country has its own rules and

regulations regarding the foreign trade. For the fulfilment of all the rules and regulations of

different countries an exporting company has to maintain and fulfil different documentation

requirements. The documentation procedure depends on the type of goods, process of

manufacturing, type of industry and the country to which goods is to be exported. In

order to complete an order for garment, many activities like communication between

different departments, the process of outsourcing raw material, payment process, quality

control, packing and shipment of goods etc. are undertaken.

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Different departments work in synchronicity & various documents are prepared in the

process. Hence, a single mistake or lack of proper planning can lead to the rejection of

the whole order or increase the cost.

Today’s world is the global village in which each country is trading with other countries in

the form of export or import. This field has a great scope because today each company

whether it is small or big wants to engage in foreign trade.

So, it is very important to study the mapping the process flowchart and documents in an

export house. Hence, selecting this project is a judicious decision.

Scope of the Study

The aim of this project report is to unfold stepwise all complexities involved in the export

business right from receiving an export order to final realization of export proceeds. It gives a

detail idea of how different departments in an Apparel export house work in synchronization

so that an export order is processed.

This project would be helpful to fulfil many loopholes of manufacturing, processing and

analysing the export order as well as documentation.

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Introduction of the Company

About Orchid Overseas Pvt. Ltd.

An exporter manufacturer based in the capital of India with plants based at both

Delhi and the outskirts with a turnover of USD 15 million.

Dynamic and young management team headed by Mr. Rajiv Bal who has an

experience of more than 26 years in the apparel trade.

Mr. Rohit Bal, India’s ace haute couture designer, who’s also the Design Director

with Orchid, initiated the change of focus from conventional manufacturing to

proactive design innovation and product development.

Selective about clientele, Orchid has focused on developing capabilities to cater to the

high end market.

One of the few exporters with extensive experience in servicing high fashion wears in

South Asia.

“The vision of the Company is to become a leading manufacturer and exporter of

apparel by continuously excelling in quality, service, and customer satisfaction using the

best technology, processes and people.”

Key Strengths

Well qualified trained and committed professionals with a shared vision.

Highly qualified Design team, Product development skills and a Design Studio

equipped with modern CAD systems.

High degree of adoption of advanced manufacturing technology IT systems. All

factories and offices are electronically linked to facilitate all time access to

information.

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Focus on quality

DETAILS OF ORCHID OVERSEAS PVT. LTD.

IEC Code number: 05588023396

AEPC Registration number: 01957

LOCATION OF THE PLANTS

The Company’s Plants are located at –

1. Garment manufacturing plant - Plot No.128, Phase-1, Gurgaon (India)

2. Garment manufacturing plant - Plot No.189, Phase-1, Gurgaon (India)

3. Garment manufacturing plant - Plot No. 61-D Phase-5, Gurgaon (India)

4. Washing & Finishing Department and Head Office – Plot No. 133, Phase-

1,Gurgaon(India)

All Locations are within 10 KM from New Delhi, and located within 1-2 km from each other.

Orchid Overseas Capacities

• No of Machines-740..

• Capacity-Approx.150000garments/month.

1) Has the ability and experience to design and execute ornamentation in fabric and garments

by hand/machine embroidery and printing.

2) Reliable and resourceful supply chain who have been partnering us for many years.

3) State of the art manufacturing facilities which are fully compliant.

4) Flexibility to handle smaller quantities at shorter lead time.

5) Rigorous internal quality systems have been the reason for the continuous patronage from

our customers.

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Orchid Overseas Customers

Orchid’s high profile customers are not only happy but also satisfied which has earned them

recognition and unflattering loyalty from prominent buyers worldwide.

• Esprit, Germany . Esprit, Australia

• Esprit, New Zealand . Esprit USA

• Esprit, Canada . Next, UK

• Choice Discount Store UK . ASDA, UK

• Tesco, UK . Paul Smith USA

• Paul Smith, UK . Paul Smith, Japan

• Okaidi, France . Monoprix, France

• Mexx . MarcAurel

• Mark’o’Polo . Ishwar SA, France

LAYOUTS

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Orchid Overseas Pvt. Ltd., Gurgaon unit is a huge organization and has various department,

located in a multi storey building. The building has four floors and a basement.

Different Departments are located on different floors. They are as follows:

Floor DepartmentsBasement The basement has the fabric store area, Trims & accessories store, fabric

inspection area, cutting and spreading area, ticketing and bundling

sections, IT department.

Ground Floor The ground floor has the Stitching department, Sampling area, & Quality

Department, Packing department, Pressing and Pantry.

First Floor The first floor has the Stitching department, Production department.

Second Floor The second floor has the Stitching department, & Quality Department.

Other departments like Industrial Engineering department, Computer aided design (CAD)

department, Documentation department & Computerized Embroidery department are located

at 128 & 133 Units. Works regarding that department are coordinated from 133 unit.

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Chapter-2

Methodology

Our primary objective of doing this project is to get the first-hand knowledge of functioning

of an export house. Since we are not comparing two different entities on the basis of their

financial results, rather we are learning the export procedure. Hence exploratory research

design is the need of the hour.

Further there are few reasons which made me to use Exploratory Qualitative research:

It is not always desirable or possible to use fully structured or formal methods to obtain

information from respondents.

People may be unable & unwilling to answer certain questions or unable to give truthful

answers.

People may be unable to provide accurate answer to question that tap their sub

consciousness.

Thus, project research methodology is as follows:

In Primary data, Qualitative research through In-Depth Interviews has been adopted.

For interviews non–structured open-ended questions were used.

In Secondary data, both internal & external research was done. For internal research

Ready to use documents available with the organization were used. For external research

Internet website & published books were consulted.

Limitations of the Methodology

1. Concern about the validity: the issue arises from the fact that qualitative research does

not rely on tests for reliability & credibility that are external to data collection & analysis.

2. Labour intensive data collection: it can be extremely time consuming. Data collection is

the labour intensive process the researcher immerses himself or herself to build an

understanding of the organization, through contact with the employees, exposure to the norms

& familiarity with their practices.

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3. Conclusion & interpretation of qualitative research: they are primarily communicated

in the form of case studies. The case study is written after an extensive process of data

collection through interviewing & participant observation.

4. Need for training in qualitative research: There is a need of training in qualitative

research methodology. Persons having low knowledge in this field don’t go for such

methodology.

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Chapter-3

Objective of the project

a) What role the different department play for completion of the export order?

b) Close look of merchandising department?

c) What are the different documents prepared & used for the export?

d) How important are these documents?

e) Organisational structure.

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DEPARTMENTS

MERCHANDISING DEPARTMENT

A merchandiser is an interface between the buyer and the supplier who has to ensure the

quality of production and timely delivery. Merchandising is a process through which products

are planned, developed, executed and presented to the buyers. It includes directing and

overseeing the development of product line from start to finish.

A merchandiser is always careful to order the correct volumes and set the correct process to

maximize the retailer’s profit. Outside of head office merchandisers also liaise with store

managers and external suppliers and manufacturers.

Opportunities for merchandisers with structured career paths exist within high street retailers,

supermarkets, mail order companies, internet businesses, export houses and some suppliers.

In the export house the whole process of sampling is monitored by a merchandiser.

Merchandiser takes care of everything from ordering the correct fabric, trims, approvals from

buyers etc.

Key personal attributes of a merchandiser:

Strong negotiation skills

Attention to detail

Excellent communication

Understanding of garment construction

Computer literacy with MS Office

Strong time management

A team player is required to work closely with the warehouse/ shipping and quality control

departments to ensure garments meet quality standards relating to style, colour, and size and

delivery schedules.

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FABRIC STORE

The Fabric store of Orchid Overseas Pvt. Ltd., Gurgaon, and all the necessary fabric is made

available when required. The main fabric store is in 128 unit. All the documentation and

formalities have been done by the 133 unit. When the fabric is sourced and brought to the

company, they are stored in the factory’s fabric storage area and it is the responsibility of

fabric stores department. From here, the fabric is taken for inspection and then stored in

specific locations from where it is issued for cutting. The fabric is stored lot-wise. Rolls of

fabric that are of similar shade are kept together.

Fabric Sourcing Department

The fabric sourcing department of Orchid Overseas Pvt. Ltd. is located in 133 unit of the

fabric is the responsibility of this department. The department is segregated buyer wise.

Some important point that is followed by fabric sourcing department:

Before placing an order, the sourcing department analyses all the vendors and selects

the best one.

Based on the lead times for procurement of fabrics, it is decided whether it is feasible

to complete the order on time or not.

According to PCD, 40% fabric should be in house.

The average lead time for fabric to be in house is 30 – 60 days.

Fabric Sourcing Region

Automatic and Power Looms fabric sourcing region is Salem, Tirupur(Jerscy Fabric)

Ludhiana (Jerscy Fabric), Vardaman(Woven Fabric),& Bobay Rayon(Woven Fabric)

Etc .

Mill Made fabric sourcing is from Arvind Mills & Vardhman.

For GEORGE : Nominated Source

After the fabric sourcing department places order for fabric, the production fabric is received

by the fabric stores. The fabric always receives in lots. When the goods come in, supplier

invoice is received. It has the following details:

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- PO number

- No of Lot

- Number of rolls, colour, length, width

The goods are then offloaded and stored in receiving location. The fabrics are then sent for

inspection after which they are stored in separate racks according to whether the fabric is

accepted or rejected. The rejected fabric is returned back to the supplier. The accepted fabric

is also stored in specific locations.

Workforce

2 staff members

3 checkers

4 helpers

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Process Flowchart of Fabric Store and Inspection Department

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Issue to cutting from location

when required and update in

system

If fabric is approved then document it in

system in correct location

Re-inspection for all re-processed

fabric as per above process

Rejected fabric returned to

supplier for re-process

If fabric is rejected then segregate &

keep in the rejected location

Issue to cutting from location

when required and update in

system

If fabric is approved then document it in

system in correct location

Make audit report with over all comments and send to the concerned

merchants

After getting approval on swatch, starts fabric inspection as per 4 point system

(100% inspection)

Send fabric swatch to merchant for shade/colour standard and hand feel

approval

Cut 1 meter fabric from each lot for lab test (shrinkage, colour fastness to crocking, count construction, GSM. etc)

Fabric moved to the inspection table

Fabric put on the receiving location and updates the system

Fabric uploaded from the container

Start receiving fabric in lots

Order the fabric

Approval of quality through Lap dip, Strike offs or Bit Loom

Buyer specifies fabric quality and specifications

TRIMS & ACCESSORY STORE

Trims & Accessory store of Orchid Overseas Pvt. Ltd. is not so huge but all the necessary

trims are made available when required from the 128 unit. The Trims & accessory store is

sometimes referred as Non-Fabric Store because it does not only store trims & accessories,

but also various requirements like stationary, machines, spare parts, grains, sugar, etc.

When need of items arises, it is communicated to the purchase department which places the

order and the goods are then received. Any of the accessories which fail to pass the quality

checking is returned to the supplier. Also in case excess trims & accessories are left over after

their requirement is fulfilled, they are disposed to suppliers or are sold at discounted prices.

Types of thread that are available are:

100 Tex

40 Tex

25 Tex

20 Tex

Types of Buttons available are:

Polyester Button

Plastic Button

Pearl Button

Polyester Pearl Button

Coconut Button

Snap Button

Metal Snap Button

Wooden Button

Metal Button and etc

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Workforce

3 staff members

2 helpers

Process Flowchart of the Trims & Accessory Store

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Taking out materials as mentioned on challans

checking quantity / Items as per challans and packing

Issue challans raised on request to order located unit /

Individual requirement

Request for dispatch comes from various sources

Production Merchant Production Unit Sampling Miscellaneous

Reject/Pass material located in designated place

Physical check of the quality and quantity preparation for

approval Send for approval to merchant and for lab test

Physical Movement of the material to QC from Gate

and System updating

Physical receipt/document check/gate entry

Material received from supplier

Requirement sent by the merchandiser is entered in

Microsoft dynamics & order is placed.

LABORATORY TESTING DEPARTMENT

Orchid Overseas do not have Testing Laboratory in any of its unit and testing is done by the

outer firm named SGS Ltd.

For Fabric Testing (FTP) & Garment Testing (GTP), fabric and garment are sent to

SGS.

For measuring GSM, color fastness, rubbing fastness, Dimensional Stability,

stretchability and testing others properties of fabrics are test by SGS.

INDUSTRIAL ENGINEERING DEPARTMENT

The Industrial Engineering department (IED) has a role to play in various stages of garment

production. IED is involved in different departments like sampling, cutting, sewing, finishing,

etc. Its responsibility is to monitor the performance of different departments through

techniques such as time studies, suggest methods of improvement (for example using a

specialized attachment), monitor production, suggest methods for improving productivity and

efficiency of different departments etc.

The main functions of the Industrial Engineering Department are:

Target setting

Line balancing

Type of machines & folders to be used in sewing is decided by IED to provide

maximum output in the minimum time.

Monitoring production & providing solutions

The formulae used in calculation are:

Productivity (per operator) = Output / No. of operators used

This department is located in 128 unit. All the information is shared through mailing or Tele

calling. Industrial Engineering Department also calculates SAM.

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CAD DEPARTMENT

This department is centralized for all the units at Orchid Overseas Pvt. Ltd., Gurgaon. There

are two sections of it in the 128 & 133 unit:

Embroidery Section : It makes the punch cards according to the design of

embroidery. This punch card is fed into a floppy which is inserted into the embroidery

machine for it to understand the design. It is located next to the embroidery

department.

Pattern Making Section : Making the patterns using specification sheets, they are

graded up to the required number of sizes up & down and making the marker.

The software used in the CAD department is NEST.

The Machine used is:

Plotter

Scanner

COMPUTERIZED EMBORIDERY DEPARTMENT

This department is centralized for all the units at Orchid Overseas Pvt. Ltd., Gurgaon. The

process involved is:

Pieces to be embroidered are first cut and ticketed in the and then they go for

embroidery in 128 unit.

The design is punched into a floppy by the CAD department which is the loaded on

the computerized embroidery machine.

For different types of patterns and different sizes of cut pieces, different sizes of

frames are set.

Insertion of Sequence CD or thread setting is done.

Running of Machine and then thread cutting is done.

Finally, bundling, quality audit and sent back to 128 unit.

Thread used in embroidery may be of Polyester, sometimes rayon, and spun polyester.

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Frames are used for holding the garment from all sides firmly so as to prevent the fabric from

going down with the needle or accumulating into folds. They are of different sizes and

shapes. They may be:

Circular

Rectangular

Embroidery is analysed during sampling stage for the production friendliness & possible

sources off error. Changes are advised to production to make the production process error

free.

GARMENT MANUFACTURING FLOWCHART

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Packing

Finishing (includes washing, Spotting, thread cutting, Kaj button, etc

Stitching

Cutting of Fabric

Production Starts

File pass from merchandising department to Production department

Order Shipping

Audit

Packing

Finishing (includes washing, Spotting, thread cutting, Kaj button, etc

Stitching

Cutting of Fabric

Production Starts

File pass from merchandising department to Production department

CUTTING DEPARTMENT

The cutting floor of Orchid Overseas Pvt. Ltd. has acquired a good amount of space. It is

located in the basement of the factory and includes the following department:

Fabric Store

Trim Store

I.E Department

And also includes

Spreading and Re Cutting Area

Bundling and Ticketing Area

The cutting department of Orchid Overseas Pvt. Ltd, 128 unit is not practicing the today’s

technology. Automated spreading facilities are not available here which leads to take a huge

amount of time in spreading the layers.

Machine Details:

Straight Knife

Scissor

Fusing Machine (2nd Floor)

Sticker Gun

No Round Knife was available.

Workforce

1 Cutting Manager

1 Cutting in charge

3 Cutting Master

3 Cutting Operator

2 Fusing In charge

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3 Ticketing Operator

2 Bundling Operator

10 Helpers

Total Workforce: 25

Process Flowchart

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Cutting of fabric

File receive from Production Department and new pattern from CAD (shrinkage considered)

Correction, if required by

Cutting Master

Re-cutting, if required

Washing, if required and re-numbering after

washing Issue to Stitching Department

Bundling

Quality Check

Send for either Embroidery or smocking or fusing, if required

Ticketing

Pattern set and Marking

Layering of Fabric

Fabric Issue from Fabric Store

STITCHING DEPARTMENT

Stitching department is the most important department of any garment manufacturing unit.

This department is responsible for the conversion of cut panels into actual garments. Orchid

Overseas Pvt. Ltd. has 3 floors dedicated to the stitching department comprising of 12 lines

having 30-45 machines each.

When a new style comes over; the various information like operation breakdown, sewing

details, critical operations etc. is put up on the display board. A sample of the garment is also

put up in front of the sewing line for any type of reference.

Line is set as per line layout plan.

Operations are assigned to the operators according to their skill set.

Line in charge & supervisor give the direction to the operators about their respective

jobs.

In line checkers and QC’s ensure that the quality coming out of each operation is as

per the quality specification.

Machinery Details

Single Needle

Double Needle

Overlock Machine

Bartack Machine

Flat bed Machine

Feed off machine: used for Hoisery

Bartack Machine

Button attaching

Button Hole Machine

Snap Button Machine

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Most of the machines are of Juki & Goldstar.

Needles of sizes 6, 9, 11, 14, 16, 18, 21 are used.

Workforce

3 Floor Manager

8 Supervisor

12 Line Incharge

450 Operator

15 Helper

12 Inline Checker

25 Final Checker

3 Mechanic

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Workflow of Stitching Department

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Alterations done

Not OK

Pcs counted & dispatched to washing

OK

Pcs dispatched to sewing checking table after counting & documenting

no. of pcs

Alterations done

Not OKOK

Alterations done

Not OK

Final checkpoints placed at the end of line

Inline checkpoints places at critical operations

Received cutting from the Cutting Department along with style file and patterns

OK

Stitching Starts

Bundles are allotted to the respective individuals

Line is set as per the plan

WASHING DEPARTMENT

Washing Department of Orchid Overseas Pvt. Ltd., Gurgaon is located at the second floor of

the 133 unit and is capable of imparting different finishes such as acid wash, softener wash,

enzyme wash, stone wash, bleaching and caustic wash.

A hand written challan is issued to the washing department by the stitching department while

sending the pieces for washing. The washing department issues a challan upon returning the

goods after washing.

The capacity of washing department is 750 kg/day.

Type of Washing

Softener Was

Enzyme Wash

Stone Wash: This wash uses volcanic rock or pumice stones added during the

washing of products to act as an abradant.

Acid Wash: Acid wash is done in a large rotating wooden cylinder coated with

solution of HYPO, Zinc and Calcium. It is not used anymore.

Bata Wash

Importance of Washing

The Washing is done to test:

Shrinkage

Color Fastness

Unwanted Material

Softener Wash is used to check hand feel is checked whether garment wash are

similar to the garment buyer has sent

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Some Chemicals used in Washing Department are:

Amile: Remove Black stain

Acetone: Removes Ink, Ball pen mark

Ammonia: In neutralizing, it is used as a base

Solvent: for removing oil turmeric and black stain.

KB-300: Liquid soap used to remove stain.

Hydrofluoric Acid: Removal of stai

KAJ BUTTON

After washing, the garment goes to Kaj Button area, where button holes and buttons are

attached. Area is located in the stitching department

Machinery Details:

Button Attach Machine

Snap Button Machine

FINISHING DEPARTMENT

The Finishing department of Orchid Overseas Pvt. Ltd., Gurgaon is located at the basement

& ground floor of the unit 133 along with Packing and Dispatch Department. The various

jobs done in the finishing department are:

Thread Cutting

Spotting

Initial Checking

Pressing

Tagging

Measurement Checking

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Final Checking

Equipment’s used in the finishing department are:

Thread Cutter

Steam Iron, Flat bed

Sewing Machine

Thread Clipper

Measuring Tape

Spotting Guns

Clippers

Tagging Gun

Stickers

Chemicals

Workforce:

1 Floor Manager

2 Supervisors

70 Operators

15 Helpers

8 Inline and Final Checker

PACKING DEPARTMENT

The Packing department of 128 & 133 unit is located at ground floor near finishing

department. Shipments for all the units in Orchid Overseas are planned and controlled from

the 133 unit (office).

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Types of Packing:

Assorted Size/Solid Color

Assorted Color/Assorted Size

Single N: Buyer will specify how much quantity in a carton.

Loose Packing: Bulk Packing

Multi N: Packing depends on Vendor

Multi Y: If only 1 garment packed in a carton.

Folding Types:

Flat Packing

Half fold

Normal Folding

Roll Packing

o Loose

o Normal

o Tight

Collar Turning folding

Crush folding

Bundling folding

Key Points

Packing is done country wise

Maximum weight of each carton allowed is 15 kg.

Garment are packed lot wise as mentioned by the buyer in PO

Each country have different code

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Carton comes from a nominated source from the buyer.

Sticker should be stick to the carton which contains the details style number, color

code, country code, fabric description etc

Records maintained by packing department are:

Records of number of pieces received from finishing department along with their style

number, ratio etc.

Records of pieces shipped along with date, quantity, ratio, mode of shipment, style no,

PO etc.

Delivery schedules

There are various stickers or information that are put on the cartons. It consists of buyer’s

logo, carton no. style no. customer code, measurement of the carton, size ratio chart, weight

etc.

Every country has a different type of sticker. Thus stickers are put on the cartons depending

on to which country the order is going

Dispatch

It is responsible for all the in-coming and out-going material, to and from the company. It has

the basic work of receiving and issuing.

Some of the records maintained by this department on the on line system are:

Dispatch receipt

Dispatch issue

Checklist

Finishing pending

Records

Packing department handover the goods to documentation department, this is located in

Faridabad unit.

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Workforce

1 Assistant

1 Supervisors

15 Operators

5 Helpers

DOCUMENTATION DEPARTMENT

Documentation department of Orchid Overseas Pvt. Ltd., Gurgaon is centralized for all the

units is located in 133 unit. The entire data relating to this department is stored and backed up

in a computer system through EDI system. This department arranges document for shipping

the order on the date of shipment.

This department helps in custom clearance from the custom office following the rules made

by ministries of commerce and finance respectively.

Documents required for the shipment export

Shipping Bill

Custom Clearance

Certificate of Origin of Goods

Invoice duly signed

Test certificate of goods

Purchase Order

Letter of Credit

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QUALITY DEPARTMENT

Quality is of utmost importance and finishing is the stage where the whole of quality is being

taken into consideration. Here all the measurements are taken into account, the neatness as

well the fall of the garment is being checked, and if any sequins are being attached they have

to be carefully handled. Quality checked is AQL base. There are three types of audit:

Measurement Audit: Measurement is checked.

Visual Audit: Aesthetic look of the garment is checked.

Packing Audit: Audit by the buyer.

As Orchid makes apparel for the kids, there are two most important prospects of quality

which needs to be undertaken:

Every garment is passed through needle detection machine.

If there is a snap button, then they must conduct a Snap Button Test which should

meet the limit of 6.0.

Quality department takes care of quality during garment manufacturing, the

flowchart is given below:

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Audit by buyer

Packing

Final Checking (overall look of the garment, Measurement etc)

Initial Checking (thread checking, Stain, overall stitch check etc)

Finishing

Pre checking (100% check)

Final Checking

Inline Checking

Garment Stitching

MERCHANDISING DEPARTMENT (Close Look)

As we have already discussed earlier, a merchandiser is an interface between the buyer and

the supplier who has to ensure the quality of production and timely delivery. The function of

the merchandising department begins with the sourcing for the new order or the repeat order

and continues till the shipment deadline has met. Merchandisers act as mediators between the

export house and the buying house. They know what buyers want and what the company is

able to and willing to deliver. They are responsible for timely execution of the orders.

Role of the Department

To look for the appropriate market

To get the samples made according to the buyer’s specification

To estimate and quote the cost of the garment to the buyer and negotiate with them

Getting orders

Constant interaction with the buyer for the approval

To get the fabric and trims in-house for bulk production

Co-ordinating with the PPC and production

Activities of a Merchandiser

Merchandising activities include:

To get order & Order confirmation :

Buyer directly communicates with the merchandiser in order to place the order. Fixed buyers

are allotted to merchandisers and the communication is between the buyer and that particular

merchant. After the approval of the development samples, the order is confirmed by the

buyer. Merchandiser receives the PO sheet. Then he fixes up the PCD and delivery date with

the buyer.

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Process Flowchart

Costing :

Costing of the garment in bulk is calculated on the basis of quality of material and their

requirement in the garment. It is one of the most important activities of the merchandiser. To

arrive at a perfect price to be quoted to the buyer, following points are taken into

consideration:

Calculation of consumption of fabric (yields per yard) and threads to produce one

garment

Calculation of cost of fabric per garment

Calculation of cost of trims and threads

Cut-make cost

Poly bag cost

Cost of carton box

Calculation of Average

For Buyer: Average is found by Pattern Master only for Costing Purpose.

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PO Received (i.e. order approved)

Confirm Delivery

Confirm Costing

Range Planning

Development Sample

Presentation from buyer/for buyer

For Company: Average is found out by cutting department for production

purpose to determine how much fabric is used in production in making an

garment and difference between both average is net profit.

Sampling:

Merchandiser is involved in coordinating with the sampling department. Based on the mutual

agreement between the merchant and the buyer, sampling department is involved in making

samples. In every step of samples, buyer sends back comments along with the tech pack.

Sampling is the product development stage. This department makes samples on the basis of

specifications and requirements sent by the buyer.

Types of Sample

1. Buying/Development Sample: It is the reflection of the first techpack or design sheet

received from the buyer. The sample is sent to the buyer for the design approval.

Proto sample is made in the base size. Styling is important. The comments and second

tech pack is sent back referring changes in the sample

2. Fit sample: The comments are received regarding the shape, size and fullness. The

sample is checked for fit on body forms. It is made in exact fabric, though print

maybe different, since the drape and fit are to be checked.

3. Second fit sample: It is similar to the first fit sample made with a few changes

according to comments received from the buyer. Again a third or fourth fit sample

may be required to be made. After approval of fit sample, order is confirmed along

with all the specifications.

4. Pre-production/sealer sample: This sample is known as the bible of production. It is

done for the base size of any one colour and actual fabric and actual trims are used. If

this sample is approved and the buyer attached some tag to this sample to ensure the

approval.

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Buyer Tag

GEORGE Green Tag

NEXT Yellow Tag

5. GPT sample: These samples are made for garment testing for seam-slippage, tearing

strength, button pulling etc.

6. TOP (top of production) sample: It is the best sample from first of bulk production.

Sometimes TOP sample is also called shipment sample.

7. Salesman sample & Ad Sample: It is made for the buyer to find out the opinion of

the store owners whether the style would sell in the market or not, and the demand of

that product.

Stages of Sampling For Product Development

Buyers sending his tech pack, defining the requirements. Pinned Sample might also be

received.

Patterns are developed by the masters with necessary amendments in the pinned

sample.

Fit samples are developed.

By the time fit sample develop fabric color, thread runs, embroidery mocks, lace

mock etc are sent for approval.

The necessary tests are done on the fabrics and trims.

First fit after QA review and buying house QA review is sent to the buyer.

If it gets approved well and good else 2nd and 3rd fits are made.

Once the sample gets approved the Market adopt sample and the GPT samples are

developed.

Also 3pcs cutting is sent to the production unit for checking production feasibility.

After the three pieces report, comes sealers and size sets are developed.

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By the time we reach the sealers level the bulk fabric is sources, trims are sources, and

all these receive approvals. The garment test report is passed and other test reports are

passed.

The costing gets finalized.

Before the PPM occurs the complete working on the garment is done all the tests

should be passed.

Workforce of Sampling Department

1 Pattern Master

1 Tailor Master

12 Operators

Workflow of Sampling Department

4 5 | P a g ePacking

Ironing

Finishing

Kaj Button

Measurement Checking

Washing

Stitching

Cutting

Patterns are made as per PO

Sample Requisition sent by Merchandiser along with Fabric & Trims

Preparing the time and action plan :

This is prepared by the merchant stating that all the different activities associated with the

order should be complete by the stipulated dates. It is like making sub goals to accomplish

the ultimate goal which is shipping of the order on the pre- decided date.

1. Preparing the bill of material: This enlists all the different materials required for

making the garment.

2. Execution: Merchandising department communicates with the buyer QA during the

production. He gets the approval of the quality or any changes in the garment.

3. Shipment of goods: According to delivery date the goods are shipped on time.

Documentation department is informed about the delivery date, the quantity etc. In

case of any delay, goods are sent through air on the company’s co

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Workflow of Merchandising Department

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Order Shipping

Regular Tracking and Update Buyer

Getting the pattern made as per PO

TOP Sample

Production begins

Ad Sample, Salesman Sample

GPT Sample

PP Sample

2nd fit Sample

1st fit Sample

Fabric Process Test (FPT)

Fabric/Trims Inhouse

Fabric/Trims Follow up

Trims Order

Trims Approval

Fabric Order

Fabric Approval (Lab dip, Fabric Swatch)

Send TNA Plan

Sample Approval Process

Techpack & PO Received (i.e. order approved)

Confirm Delivery

Confirm Costing

Range Planning

Development Sample

Presentation from buyer/for buyer

Sample Send to buyer for approval

Packing

Ironing

Finishing

Kaj Button

Measurement Checking

Washing

Stitching

Cutting

Sample Requisition sent by Merchandiser along with Fabric,

Trims & Pattern

So the Role of a Merchandiser in an Export House is:

To create market

Understanding buyers’ requirements

Develop new quality / design as per market feedback.

Prepare samples according to sketches of styles.

Create different ranges as per different current buyers as well as the targeted buyers.

Sourcing of materials, fabrics

Select the range

Creating the Sample

Ensuring timely delivery of samples.

Managing the tailors and masters

Making the paper pattern.

Quality checking of material

Prepare T & A Plan

Taking buyers approvals

Negotiation with buyer

Procuring the orders

Cross check samples at the pilot run, inline and midline and keep a track of day-to-

day production output based on the status given by the factory as well as the stationed

QCs

WIP on daily basis

Active involvement in all the company’s activities.

Coordination between production and production planning department

Dispatching the shipment

After shipment dispatching merchandiser is also responsible for buyer claims, profit and

subsequent orders. If buyer has any problem in quality of the product then it is the

responsibility of the merchandiser to resolve the problem with the buyer.

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Export Documents

An export trade transaction distinguishes itself from a domestic trade transaction in more than

one way. One of the most significant variations between the two arises on account of the

much more intensive documentation work. The documents mentioned in the pre & post

shipment procedure are discussed below:

1. Invoice:

It is prepared by an exporter & sent to the importer for necessary acceptance. When the buyer

is ready to purchase the goods, he will request for an invoice. Invoices are of 3 types:

a. Commercial invoice: It is a document issued by the seller of goods to the buyer

raising his claim for the value of goods described therein, it indicates description of

goods, quantity, value agreed per unit & total value to be paid. Normally, the invoice

is prepared first, & several other documents are then prepared by deriving information

from the invoice.

b. Consular invoice: It is certification by a consul or Government official covering an

international shipment of goods. It ensures that exporter’s trade papers are in order &

the goods being shipped do not violate any law or trade restrictions.

c. Customs invoice: It is an invoice made on specified format for the Custom officials

to determine the value etc. as prescribed by the authorities of the importing country.

2. Packing list:

It shows the details of goods contained in each parcel / shipment. Considerably more detailed

and informative than a standard domestic packing list, it itemizes the material in each

individual package and indicates the type of package, such as a box, crate, drum or carton.

Both commercial stationers and freight forwarders carry packing list forms.

3. Certificate of Inspection:

It is a type of document describing the condition of goods and confirming that they have been

inspected. It is required by some purchasers and countries in order to attest to the

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specifications of the goods shipped. This is usually performed by a third party and often

obtained from independent testing organizations.

4. Certificate of Origin:

Importers in several countries require a certificate of origin without which clearance to

import is refused. The certificate of origin states that the goods exported are originally

manufactured in the country whose name is mentioned in the certificate. Certificate of origin

is required when:

The goods produced in a particular country are subject to’ preferential tariff rates in the

foreign market at the time importation.

The goods produced in a particular country are banned for import in the foreign market.

5. GSP:

It is Generalized System of Preference. It certifies that the goods being exported have

originated/ been manufactured in a particular country. It is mainly useful for taking advantage

of preferential duty concession, if available. It is applicable in countries forming European

Union.

6. IEC Certificate:

It is an Import-Export Code Certificate issued by DGFT, Ministry of Commerce,

Government of India. It is a 10 digit code number. No exports or imports will be effected

without the IEC code. It is mandatory for every exporter.

7. Wearing Apparel Sheet:

It is like a check list which gives the detail regarding the content & design of the garment

packed.

8. Bill of Lading:

The bill of lading is a document issued by the shipping company or its agent acknowledging

the receipt of goods on board the vessel, and undertaking to deliver the goods in the like order

and condition as received, to the consignee or his order, provided the freight and other

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charges as specified in the bill have been duly paid. It is also a document of title to the goods

and as such, is freely transferable by endorsement and delivery.

9. Airway Bill:

An airway bill, also called an air consignment note, is a receipt issued by an airline for the

carriage of goods. As each shipping company has its own bill of lading, so each airline has its

own airway bill. Airway Bill or Air Consignment Note is not treated as a document of title

and is not issued in negotiable form.

10. Mate’s Receipt:

Mate's receipt is a receipt issued by the Commanding Officer of the ship when the cargo is

loaded on the ship. The mate's receipt is a prima facie evidence that goods are loaded in the

vessel. The mate's receipt is first handed over to the Port Trust Authorities. After making

payment of all port dues, the exporter or his agent collects the mate's receipt from the Port

Trust Authorities. The mate's receipt is freely transferable. It must be handed over to the

shipping company in order to get the bill of lading. Bill of lading is prepared on the basis of

the mate's receipt.

11. Shipping Bill:

Shipping bill is the main customs document, required by the customs authorities for granting

permission for the shipment of goods. The cargo is moved inside the dock area only after the

shipping bill is duly stamped, i.e. certified by the customs. Shipping bill is normally prepared

in five copies:

Customs copy.

Drawback copy.

Export promotion copy.

Port trust copy.

Exporter's copy.

12. Letter of Credit:

This method of payment has become the most popular form in recent times; it is more

secured as company to other methods of payment (other than advance payment).

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A letter of credit can be defined as “an undertaking by importer’s bank stating that payment

will be made to the exporter if the required documents are presented to the bank within the

variety of the L/C”.

Contents of a Letter Of Credit

A letter of credit is an important instrument in realizing the payment against exports. So,

needless to mention that the letter of credit when established by the importer must contain all

necessary details which should take care of the interest of Importer as well as Exporter. Let

us see shat a letter of credit should contain in the interest of the exporter. This is only an

illustrative list.

Name and address of the bank establishing the letter of credit

letter of credit number and date

The letter of credit is irrevocable

Date of expiry and place of expiry

Value of the credit

Product details to be shipped

Port of loading and discharge

Mode of transport

Final date of shipment

Details of goods to be exported like description of the product, quantity, unit rate,

terms of shipment like CIF, FOB etc.

Type of packing

Documents to be submitted to the bank upon shipment

Tolerance level for both quantity and value

If L/C is restricted for negotiation

Reimbursement clause

Terms of Shipments – Incoterms

The INCOTERMS (International Commercial Terms) is a universally recognized set of

definition of international trade terms, such as FOB, CFR & CIF, developed by the

International Chamber of Commerce (ICC) in Paris, France. It defines the trade contract

responsibilities and liabilities between buyer and seller. It is invaluable and a cost-saving

tool. The exporter and the importer need not undergo a lengthy negotiation about the

conditions of each transaction. Once they have agreed on a commercial terms like FOB, they

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can sell and buy at FOB without discussing who will be responsible for the freight, cargo

insurance and other costs and risks.

The purpose of Incoterms is to provide a set of international rules for the interpretation of the

most commonly used trade terms in foreign trade. Thus, the uncertainties of different

interpretations of such terms in different countries can be avoided or at least reduced to a

considerable degree. The scope of Incoterms is limited to matters relating to the rights and

obligations of the parties to the contract of sale with respect to the delivery of goods.

Incoterms deal with the number of identified obligations imposed on the parties and the

distribution of risk between the parties.

More Clarification on Incoterms

EXW (At the named place)

Ex Works: Ex means from. Works means factory, mill or warehouse, which are the seller’s

premises. EXW applies to goods available only at the seller’s premises. Buyer is responsible

for loading the goods on truck or container at the seller’s premises and for the subsequent

costs and risks. In practice, it is not uncommon that the seller loads the goods on truck or

container at the seller’s premises without charging loading fee. The term EXW is commonly

used between the manufacturer (seller) and export-trader (buyer), and the export-trader resells

on other trade terms to the foreign buyers. Some manufacturers may use the term Ex Factory,

which means the same as Ex Works.

FCA (At the named point of departure)

Free Carrier: The delivery of goods on truck, rail car or container at the specified point

(depot) of departure, which is usually the sellers premises, or a named railroad station or a

named cargo terminal or into the custody of the carrier, at seller’s expense. The point (depot)

at origin may or may not be a customs clearance centre. Buyer is responsible for the main

carriage/freight, cargo insurance and other costs and risks.

In the air shipment, technically speaking, goods placed in the custody of an air carrier are

considered as delivery on board the plane. In practice, many importers and exporters still use

the term FOB in the air shipment.

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FAS (At the named port of origin)

Free Alongside Ship: Goods are placed in the dock shed or at the side of the ship, on the dock

or lighter, within reach of its loading equipment so that they can be loaded aboard the ship, at

seller’s expense. Buyer is responsible for the loading fee, main carriage/freight, cargo

insurance, and other costs and risks In the export quotation, indicate the port of

origin(loading)after the acronym FAS, for example FAS New York and FAS Bremen. The

FAS term is popular in the break-bulk shipments and with the importing countries using their

own vessels.

FOB (At the named port of origin)

Free on Board: The delivery of goods on the board the vessel at the named port of origin

(Loading) at seller’s expense. Buyer is responsible for the main carriage/freight, cargo

insurance and other costs and risks. In the export quotation, indicate the port of origin

(loading) after the acronym FOB, for example FOB Vancouver and FOB Shanghai.

Under the rules of the INCOTERMS 1990, the term FOB is used for ocean freight only.

However, in practice, many importers and exporters still use the term FOB in the air freight.

In North America, the term FOB has other applications. Many buyers and sellers in Canada

and the USA dealing on the open account and consignment basis are accustomed to using the

shipping terms FOB Origin and FOB destination.

FOB Origin means the buyer is responsible for the freight and other costs and risks. FOB

Destination means the seller is responsible for the freight and other costs and risks until the

goods are delivered to the buyer’s premises which may include the import custom clearance

and payment of import customs duties and taxes at the buyer’s country, depending on the

agreement between the buyer and seller. In international trade, avoid using the shipping terms

FOB Origin and FOB Destination, which are not part of the INCOTERMS (International

Commercial Terms).

CFR (At the named port of destination)

Cost and Freight: The delivery of goods to the named port of destination (discharge) at the

seller’s expenses. Buyer is responsible for the cargo insurance and other costs and risks. The

term CFR was formerly written as C&F. Many importers and exporters worldwide still use

the term C&F.

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CIF (At named port of destination)

Cost, Insurance and Freight: The cargo insurance and delivery of goods to the named port of

destination (discharge) at the seller’s expense. Buyer is responsible for the import customs

clearance and other costs and risks.

In the export quotation, indicate the port of destination (discharge) after the acronym CIF, for

example CIF Pusan and CIF Singapore. Under the rules of the INCOTERMS 1990, the term

CIFI is used for ocean freight only. However, in practice, many importers and exporters still

use the term CIF in the air freight.

CPT (At the named place of destination)

Carriage Paid To: The delivery of goods to the named port of destination (discharge) at the

seller’s expenses. Buyer assumes the cargo insurance, import custom clearance, payment of

custom duties and taxes, and other costs and risks. In the export quotation, indicate the port of

destination (discharge) after the acronym CPT, for example CPT Los Angeles and CPT

Osaka.

CIP (At the named place of destination)

Carriage and Insurance Paid To: The delivery of goods and the cargo insurance to the named

place of destination (discharge) at seller’s expense. Buyer assumes the importer customs

clearance, payment of customs duties and taxes, and other costs and risks.

DAF (At the names point at frontier)

Delivered at Frontier: The delivery of goods at the specified point at the frontier on seller’s

expense. Buyer is responsible for the import custom clearance, payment of custom duties and

taxes, and other costs and risks.

DES (At named port of destination)

Delivered Ex Ship: The delivery of goods on board the vessel at the named port of destination

(discharge) at sellers expense. Buyer assumes the unloading free, import customs clearance,

payment of customs duties and taxes, cargo insurance, and other costs and risks.

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DEQ (At the named port of destination)

Delivered Ex Quay: The delivery of goods to the Quay (the port) at the destination on the

buyers expense. Seller is responsible for the importer customs clearance, payment of customs

duties and taxes, at the buyers end. Buyer assumes the cargo insurance and other costs and

risks.

DDU (At the named point of destination)

Delivered Duty Unpaid: The delivery of goods and the cargo insurance to the final point of

destination, which are often the project site or buyers premises at sellers expense. Buyer

assumes the import customs clearance, payment of customs duties and taxes. The seller may

opt not to insure the goods at his/her own risks.

DDP (At the named point of destination)

Delivered Duty Paid: The seller is responsible for most of the expenses which include the

cargo insurance, import custom clearance, and payment of custom duties, and taxes at the

buyers end, and the delivery of goods to the final point of destination, which is often the

project site or buyers premise. The seller may opt not to insure the goods at his/her own risk.

“E”-term, “F”-term, “C”-term & “D”-term: Incoterms 2000, like its immediate predecessor,

groups the term in four categories denoted by the first letter in the three-letter abbreviation.

Under the “E”-TERM (EXW), the seller only makes the goods available to the buyer

at the seller’s own premises. It is the only one of that category.

Under the “F”-TERM (FCA, FAS, &FOB), the seller is called upon to deliver the

goods to a carrier appointed by the buyer.

Under the “C”-TERM (CFR, CIF, CPT, & CIP), the seller has to contract for carriage,

but without assuming the risk of loss or damage to the goods or additional cost due to

events occurring after shipment or discharge.

Under the “D”-TERM (DAF, DEQ, DES, DDU & DDP), the seller has to bear all

costs and risks needed to bring the goods to the place of destination.

All terms list the seller’s and buyer’s obligations. The respective obligations of both parties

have been grouped under up to 10 headings where each heading on the seller’s side “mirrors”

the equivalent position of the buyer. Examples are Delivery, Transfer of risks, and Division

of costs. This layout helps the user to compare the party’s respective obligations under each

Incoterms.

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ORGANIZATIONAL STRUCTURE

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RAJIV BAL(MD)

CAN.NAIR (SM)

R.S.MISHRA(M

A)

LALIT (Q.A.M)

S.GANESH (CEO)

ROHIT SINGHAL

(GM)

PAWAN(HR)

SURENDER(P&A.O)

SARVADA

(A.O)

VIJAY (QA)

KUNADEL.LAL(AO

)

PRADEEP(SE)

MAHESH(AS)

RAMESH(F.M)

SUPRIYA(M.M)

WASHIF (S.M)

MANOJ(AS)

ISHA(DESGENER)

BHUPESH(AO)

TRIPTI(DESIGNER

)I

ATUL(SUPERWIS

ER)

ABHIJIT(A.F.I)

RAJVINDER(S.M)

PRONAV(QA)

GULAB(CASHIER)

GOPAL(AO)

RAJINDER(P&A.

O)

FINDINGS

1. The organization is well organized and systematic.

2. The merchandiser is the connection or the key player between all the departments.

3. Every department has their key roles well defined, and the supervisors who keep track

of who is working on what in the department.

4. Cutting head, stitching head, finishing supervisors and other heads are the main

people with whom a merchandiser deals.

5. The cutting process of samples is coordinated with cutting department.

6. There exists a supervisor over every group of 14 tailors and a supervisor over all the 2

stitching lines.

7. The finishing process of samples is coordinated with finishing department and there a

worker is fixed who works for sampling as well as production department.

8. The fabric and garment testing are done by SGS, an external testing laboratory.

9. Embroidery work, pattern making by CAD, research and development are done by

133 Unit.

CONCLUSION

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1. The merchandiser keeps the business running. They communicate with the buyer,

buying house and even with all the departments so as to get the work done as per the

deadlines.

2. It is always an advantage to know about different fabrics used, the kinds of trims used

for every buyer still there is fabric testing department and trims departments which

have complete details about them.

3. There are merchandiser’s team which includes Senior Merchant and Asst. Merchant

and Trainee Merchant which makes the work more systematically and organized.

4. A Merchandiser should have some knowledge about production whether it could be

cutting, stitching, washing or finishing, maintain good relation with them, updated to

latest designs and trends in market.

SUGGESTIONS

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1. Even after being an automated export house major work was done manually. The

Prosuite system was employed still the receiving and other acknowledgements were

taken manually which requires a lot of man power. This can be avoided and a lot of

cost can be saved.

2. Work flow & material flow is not standardized.

3. Quality checking & alteration making is not satisfactory.

4. Housekeeping can be improved a lot.

5. More care should be provided in operator safety

Bibliography

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REFERENCES

Webshttp://orchid overseas.com (Accessed 18st July, 2012)

Fibre2fashion.com, “the fascinating world of small people” an overview of the Indian Kidswear Market.

Reference book

Paul, Justin & Aserkar, Rajiv, Export Import Management, 2nd Edition, Oxford University Press, 2008, Chapter – 2, pp. 17-29.

Annexure 1

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Annexure 2

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Annexure 3

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Annexure 4

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Annexure 5

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Annexure 6

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Annexure 7

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Annexure 8

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Annexure 9

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Annexure 10

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Annexure 11

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Annexure 12

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