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Under the Guidance of Presented by

Mrs Vasundhara ChaudharyAssociate Professor

Atul Dwivedi, Navneet Yadav andVinay Prajapati; M.F.TECH, SEM-III

National Institute of Fashion Technology, Gandhinagar

Presentation based on 3 Month Internship at

Modelama Exports Ltd.

19-09-2011

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COMPANY NAME MODELAMA EXPORTS PVT LTD

ADDRESS PLOT NO. 105/106, UDYOG VIHAR, PHASE-1GURGAON, HARYANA- 122015

HEAD OFFICE B-57 OKHLA INDL. AREA PHASE-1NEW DELHI- 110020 INDIA

TELEPHONE 0124-4008105FAX 0124-4008108E MAIL info@modelamaexports.comWEBSITE www.modelamaexports.comYEAR ESTD. 1979OWNER MR. LALIT GULATIDIRECTORS MR. SANJAY GULATI

MR. GAGAN GULATIMR. GAURAV GULATI

ANNUAL TURNOVER 60 MILLION (OF ALL FACTORIES)MARKET 100% EXPORTTOTAL COVERED AREA 4,00,000 SQ. FT.TOTAL WORKING FORCE 5500IN HOUSE/FABRICATION/BOTH BOTHPRODUCTION CAPACITY 8 MILLION/YEAR

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Company Profile

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Team Modelama

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Corporate Office

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VisionModelama 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.

MissionModelama 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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Vision/Mission

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APPAREL

HOME FURNISHING

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Product Range

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Organisation Structure

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Infrastructure

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HARYANA184, 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, IMTManesar, Gurgaon

529, Phase-I, Bahrhi, Dist. Sonipat

Plot No 1, Sector 8, Bawal, Dist. Rewari

DELHI

B-33, Okhla Industrial Area, Phase -1, New Delhi

CHENNAIPlot No - K 46/47/48/49, Appragel Park , Irun Gattukottai. Dist. Tairnatur

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Production Units

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BUYER PRODUCT DEVELOPER MERCHENT SAMPLING FABRIC

TESTINGMARKER PLANNINGSPREADINGCUTTING

BUNDILING AND

TICKETING

PRODUCTION WASHING FINISHING AND PRESSING PACKING DISPATCH

Work Flow

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Buyers

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.

Merchandising

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1. Chase for fabric/trims prior to PCD date.2. Size sets/PP/TOP samples-Monitoring and delivering.3. Coordinating buying agency QA Inspection.

Merchandiser’s Responsibility

Responsibility

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This department is not buyer specific and work for all the buyers that company caters to.

Product Development

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PROTO TYPE

SAMPLE MADE

FIT SAMPLE MADE

PP SAMPLE MADE

TOP SAMPLE MADE

SIZE SET SAMPLE

SHIPMENT SAMPLE

Sampling

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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

MARKER LAYERING

TICKETING

CUTTING MANUAL/AUTOMATIC

BUNDLING

CHECKING

FUSING

TRANSFER TO PRODUCTION

Spreading & Cutting

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Spreading

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Spreading FlowFABRIC 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

TRANSFERRED TO THE CUTTING TABLE

AIR FLOW IS GIVEN FROM BOTTOM

WHEN FINISHED, VACCUME IS TURNED OFF

MARKER IS SPREAD OVER IT AND PASTED BY TAPE

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Types of cutting devices:

1. 5 fusing machine2. 16 straight knife3. 6 edge cutters4. 2 computer aided machines5. 4 spreader 6. 1 round knife

Spreading Flow

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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 150 Kg

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Lectra Victor Automatic Cutter

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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Blade Size (inch) 5 6 7 8

Blade Size (cm) 12.7 15.2 17.7 20.3

Cutting Capacity (inch) 3 1/2 4 1/2 5 1/2 6 ½

Cutting Capacity (cm) 8.89 11.4 13.9 16.5

Stroke Size (inch) 1 1/8 1 1/8 1/4 1/4

Stroke Size (cm) 8.89 8.89 11.4 11.4

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Straight Knife Cutter

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Fusing Machine

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Fusing Machine Specification

MODEL HP-1000LW

POWER SUPPLY Three phase

RATED OUTPUT HEATER： 21.6kw

MOTOR： 705WFUSHING WIDTH 1,000mmMAX.BELTSPEED 12.7m/minMAX.PRESSURE 5kg/cm2

MAX.TEMPERATURE 198℃HEATING TIME 6.5～ 31sec.DIMENSIONS 4,327 X 1,606 X 1,255mm

WEIGHT (Approx)1,500kg

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PATTERN MAKING

GRADING

CUT ORDER PLANNING

DIGITIZING

STYLE/PATTERN DESCRIPTION

MARKER MAKING

PRINTING FOR CUTTING

Computer Aided Design

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ModarisThis software performs the following functions:

o Pattern makingo Pattern modificationo Pattern digitizingo Pattern grading

DiaminoThis 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.

OptiplanThis software is used when buyers send uneven ratios.

Main equipment used:• Pattern pieces• Digitizer• Software• Plotter

FLY PEN ALYS-30

CAD Software

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CAD Advantages1. 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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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

Sewing Department

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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 panels with patterns.

Bundling of cut panels is done.

Operation wise feeding of cut panel into the line.

Inline checkpoints.

Output of line.

Final checkpoints.

Auditing of checked pieces.

Working: Production Department

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LaundryTo restore this aesthetic value, they are subjected to cleansing process like washing.

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Normal Wash

Desize Wash

Enzyme Wash

Stone Wash

Softener

Bleach

Acid Wash

Monkey Wash

Sand Wash

Type of Washes

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Process Time

Desizing 30 min

Enzyme 30-60 min

Softener 20- 30 min

Process Time

Desizing 30 min

Enzyme 30-60 min

hypo chloride 30 min

Neutralization 30 min

Softener 20 min

Process Time

Desizing 20 min

Washing 30 min

Enzyme Wash

Softener WashNormal Wash

Process Time

Desizing 30 min

Enzyme 30-60 min

Stone 20 min

hypo chloride 30 min

Neutralization 30 min

Softener 20 min

Stone Wash

Washes

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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

Finishing

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GARMENT COMES FROM PRODUCTION

washing

THREAD CUTTING

INITIAL CHECKING

AND SPOTTING

ALTERATION REIRONING

FINAL CHECHING

PERSENTATION/FINAL IRONING

MEASUREMENT

SENT FOR PACKING

Process Flow: Finishing

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Finishing Machines No. of Machines

Vacuum Table 60

Up Steam Table 5

Stain Removing Gun 13

Stain Removing W/S 3

Form Finisher 2

Finishing Machine Details

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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.

Packaging

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Process Flow: Packaging

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1. All garments packed in individual poly bags.2. Poly bag sticker on poly bags, which may be printed by the factory3. 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 passed through

Packing Norms

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AQL Chart

No. of Cartons Sample Size Pass 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

AQL Parameters

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1. Incorrect quality2. Carton labeling error3. Incorrect Prepackaging4. Carton not as per specified size5. Use of wire of metallic strap

Shipment Rejection Reasons

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Visual Audit Standard

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Shipment Size Sample Size Gap AQL (2.5) LevelPass/Fail

Old Navy AQL (4.10) LevelPass/Fail

0-500 20 1/2 2/3

501-1200 32 3/2 3/4

1201-3200 50 3/4 5/6

3201-10000 80 5/6 7/8

10100-35000 125 7/8 10/11

35000 > 200 10/11 14/15

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IE/R&D

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Working of IE is as follows:

Calculating SMV Making Operation Bulletin Calculation of thread consumption Designing of work aid devices; Folders, Guide & Profiles Update SMV and finalize report Prepare work station layout Line setup Capacity check analysis and feedback Production study and increased efficiency

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Project

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MONITORING OF LOST TIME & OPERATOR PERFORMANCE

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Project Outcome

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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 You19-09-2011