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Cotton Web (Pvt) LTD

School of fine Arts and Architecture


GIFT University Gujranwala
Corporate Internship
Cotton Web (Pvt) LTD
Ferozpur road Lahore.

Reported to: Mr. Tayyab Naveed


Prepared by: Huma Riaz
10126012
Date: 6November.2013

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Cotton Web (Pvt) LTD

TABLE OF CONTENT
TOPIC

PAGE

o TITLE
o ACKNOWLEDGEMENT
o DEDICATION
o EXECUTIVE SUMMARY
o VISION
o MISSION STATEMENT
o QUALITY POLICY
o OVERVIEW ABOUT INDUSTRY
o COOPERATE AND SOCIAL RESPONSIBILITY
o MANAGEMENT
Competitors
International brands
o PRODUCT LINE
o COMPANY HAURAKI

1
5
6
7
8
9
10
11
12
13
16
17

o PROCESS FLOW
o DEPARTMENTS

18
19

Product development

20

Sales and merchandising

24

Industrial engineering

26
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MMC (material management control)

29

PPC (product planning control)

31

Fabric procurement

33

Fabric inspection and Quality lab

33

Quality control

40

Quality assurance

41

Store

42

Utility

45

ERP department

47

Sampling
Technical and Cutting

52

Stitching

56

Embroidery and printing

61

Special effect

62

Washing

63

Finishing

66

HR

71

Admin

71

Accounts

73

Export/finance

75

o SWOT ANALYSIS
o
o

CONCLUSION
SUGGESTIONS

77
79
80

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ACKNOWLEDGEMENT
First, I am thankful to ALLAH Almighty who gives me strength and courage.
Secondly, I am thankful to my parents who support me and their love motivate me that they give
permission to live on an unknown place, especially my mother how always being my moral support.

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Thanks to our respected sir tayyab Naveed who guide us and arrange this internship program for our
learning and for focus on practical working.
Thanks to respected Mr. Adil at cotton, web the HR manager always there to guide us, give knowledge,
and clear all the points that make any confusion. He manages things very well, and thankful to Mr.
Salman how help me to give data about Cotton web.

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DEDICATION

I dedicate this to my Beloved Parents for all their love & attention which has made it
possible for me to make it up to this point and as well as the Internship Advisor Mr.
tayyab Naveed, who courage me, the commitment and the awareness to follow the
best possible route, by his possible training.

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Cotton Web (Pvt) LTD

EXECUTIVE SUMMARY

Appeals, one of the basic needs of humankind, represent a major industry in the world. Link
directly to their customers. The success of any industry is on ability to produce variety of
products up to the customer demand, taste and related to new market trend
This report provides an over view about how cotton web is working with big well-known
international brands. Start with brief history three friends establish this company in 1998 from a
very small scale. There product Line is not so vast they work on ladies denim mostly which is
we must say that Cotton web asset.
An analysis and overview thing how a garment industry is works the overall product
procedures. I spend a good time with the company learn many things which is helpful for my
practical life.
Visit all of the departments one day for one department. I complete my internship in almost one
month.

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VISION
The company is working with vision to produce quality goods as per international standards.

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MISSION STATEMENT
Mission of Cotton web is not only provide quality products to customers

and explore new markets to promote/expand sales of the company


through good governance and foster a sound and dynamic team, so
as to achieve optimum prices of products of the company for
sustainable and equitable growth and prosperity of the company.

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QUALITY POLICY
"In order to exceed customer expectations in producing high quality garments, workers, at all
levels of our organization, are committed for continuous improvements and adoption of
advance technical resources. These efforts are in compliance with applicable social, ethical, &
environmental rules & regulations"

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Cotton Web (Pvt) LTD

OVERVIEW
Situated in Lahore, Pakistan, Cotton web (Pvt) Ltd was established in 1998 as an
entrepreneurial venture among three friends at a very small scale, Cotton Web has grown into
a multimillion $ company in a short span of time. Come at rank 19, Pakistan 25 th Fast growing
company. They have two units and collectively produce average 4, 000, 00 garments per
month.
Equipped with a blend of youth and experience team, Cotton Web is successfully supplying its
product to various leading brands and labels across the fashion world.
Their clients are mostly in Norway, Germany, England, Poland, France, Swaziland, Italy, Spain
etc.

From the very first day when company born persuasively and gradually moved into
Success stage and built foreign offices and did extension in plants capability and
capacity.

Currently, Cotton Web is managing 4, 000, 00 garments per month. They have art
machines, and great team with a mixture of young and experienced people continuously
working for betterment of organization.

Cotton Web has refined systems including ERP for IT support and human resources
combined together to achieve maximum from given resources, 2200 employees are
working where cotton web is meeting all parameters of compliances and satisfying labor
laws.

Cotton web has unique design cell where our customers make their seasonal
collections with the help of our design team. Product development team was devoted to
introduce new styles, washes, and product for customers for all seasons.

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Cotton Web (Pvt) LTD

COOPERATE AND SOCIAL RESPONSIBILITY

In pursuance to fulfill the social responsibility Cotton web is compliant with ISO 9001:2008, ISO
14001:2004, and OEKO TEX. Cotton Web is committed to establish and maintain a CSR
System to ensure compliance with legal, ethical, and social obligations towards employees,
customers and society.

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MANAGEMENT

Cotton Web follows the motto of team effort. Efforts are focused on objectivity and positive
attitude.
Owing to the nature of our product and varying requirements of the fashion, a comprehensive
management information network designed, by employing a specialized system.
Cotton Web provides range of services to their clients starting from initial design concepts &
ideas up to final ready to wear garment at their doorstep.

MAJOR COMPOTATORS:

Asgard 9

Crescent bahuman

Nishat appeals.

US Appeals

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Cotton Web (Pvt) LTD

INTERNATIONAL BRANDS:
Cotton web is working internationally with suppliers worldwide. The very well knows brands
with which they are working. Cotton web did not have their own brand but they made products
to following brands on order.

Mango

Rifle

Gemo

Conbipel

Mirza fashion

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Tesco

Mustang

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PRODUCT LINE

They mostly deal with women wear denim and twill almost 80%

The remaining 20% is for:

Means

Children wear

Sometimes according to order, they made jackets also.

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COMPANY HIERARCHY

Organization Chart:

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Directors

General
Manager
(Marketing)

General
Manager
(Production)

Managers
(of every
production
department +
services)

Deputy General
Manager

Manager

PROCESS FLOW:

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technical

fabric
inspection

Spreading
numbering
bundling
WIP
embiodery/pri
nting
sweing
Q.C
washing
finishing
packing
shipment

DEPARTMENTS
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Product development
Sales and merchandising
Industrial engineering
PPC (product planning control)
MMC(material management control)
Fabric procurement
Fabric inspection and Quality lab
Quality control
Quality assurance
store
ERP department
Sampling
Cutting
Stitching
Embroidery and printing
Special effect
Washing
Finishing
Admin
HR/admin
Utility
Accounts
Export/finance

PRODUCT DEVELOPMENT

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Hierarchy

Business
Developmen
t Manager
Product
Developmen
t Manager
Senior
Assistant
Manager

Designer

Office Boy

Number of workers:
Approximately six persons.

WORKING:
In PD Planning about new mode and designs,
Ladies denim working is 80% and 20% is mens, childrens and other
categories.

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They forecast about the trends, colors, styles


Draws the pattern, and coral draw sheet in which there are specifications.
The customer gives a layout of teck-pack.
MS excel sheet is used for material flow within the organization codes are
given to different pieces

OBJECTIVE:
After this according to customer demand, we check the availability of specific design, color with
style etc, according to customer demand.

SKETCH SHEET
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EXAMPLE # 1:

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EXAMPLE #2

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MERCHANDIZING:

Hierarchy
General
Manager
(vacant)
Deputy
General
Manager

Manager

SAM
(two in each
wing)
AM
(two in each
wing)

Office Boy

Number of workers:
There are approximately 30 employees

Working:
There basic work is merchandising, marketing, sampling, pricing, and tagging.
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Deeply understand the customer order and specifications


.
Different between merchandizing and marketing
Merchandising is the direct sealing to the consumer conducted in an immediate, often
face-to-face manner, in-house consulting and sample making.
The goal of merchandising is to compel the consumer to buy the product.
Marketing Merchandising is a subset of marketing. Marketing has several other areas that do
not overlap with merchandising. For instance, marketing also enables how to distribute the
product and how best to package the item. Gathering data is another marketing field, from
issuing surveys to holding consumer focus groups.

Make sample of the specification of customer and make it approval.


Sampling pattern, sampling cutting, sampling stitching all is different from
bulk.
We understand about costing sheet, fabric consumption, trims, accessories
and embroidery quality and type.
ERP system work is to flow information about new fabric receiving to all
depts. as well as in merchandizing.
Shipment process check is also come under the merchandiser people.
Maximum 400,000 are made monthly in production house.
OBJECTIVE:
Calculation lead-time and delivery terms and response to customer are the responsibility of the
merchandiser.
Costing: This unit deals with the skills and knowledge required to cost the new and existing
styles of garments while considering the cost of raw material, labor, services, and a reasonable
profit margin.
In short, merchandiser play roll in every dept progress.
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INDUSTRIAL ENGINEERING

Hierarchy
IE
Manager
Senior
assistant
Manager
Assistant
Manager
Industrial
Engineer
Office

Boy

Number of workers:
Approximately 25 employee's work

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Working:
Process flow

I.E

preproduction

I.E
production

risk analysis

cost

SAM

SAM FORMULA: (standard allowed min)


SAM=basic min (1+Mechine delay%+personal fatigue) +bundle handle time
Formulas for calculation:

Basic min =average single cycle time*rating%

Single cycle time = time (pick - pick)


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ASCT= sum of all value / no. of values


Rating: >100% fast

<100% slow
Basic min = ASCT* rating%
Efficiency:
= output/input

OBJECTIVE:
Plan evolution about SAM calculation
Planning and development programs are run for the employees to increase
the SAM and efficiency
Layout design of work
Price rate working in which we calculate the place according to SAM.
LAYOUTS
Work flow and risk analysis

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MATERIAL MANAGEMENT CONTROL

Hierarchy
Manager

Senior
assistant
manager

Assistant
manager

MTO

Number of workers:
There are approximately 80 employees working under this dept.
WORKING:
Material is not constant
Material is not constant except the fabric all accessories.
QC checks quality of material, first in initial stage then during the process, if
defects are found then forward to merchandiser.
Direct material and indirect come under this
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direct we select those which are directly related to our product work labor
Different items was checked and placed to the fabric by different people. He only
does the specific operation e.g. tag, zipper etc
In direct is related e.g. electricity, salaries, and add overhead expenses.
They are mostly constant and controlled and check by MMC dept.

PRODUCTION PLANNING CONTROL (PPC)


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Hierarchy
Manager

Deputy Manager

SAM

AM

Supervisor (WIP)

Working:
A production planning and control (PPC) system is concerned with planning and controlling all
aspects of manufacturing, including materials, scheduling machines and people, and
coordinating suppliers and customers. A PPC system's design is not a one-off undertaking; it
should be adaptive to respond to changes in the competitive area, customer requirements,
strategy, supply chain, and other possible problems
The working of production planning and control system should match the needs of the firm. In
designing the PPC system, we have to keep in mind:

Objectives of production planning:


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1.

Effective utilization of resources.

2.

Steady flow of production.

3.

Estimate the resources.

4.

Ensures optimum inventory.

5.

Co-ordinates activities of departments.

6.

Minimize wastage of raw materials.

7.

Improves the labor productivity.

8.

Helps to capture the market.

9.

Provides a better work environment.

10.

Facilitates quality improvement.

11.

Results in consumer satisfaction.

12.

Reduces the production costs.

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Cotton Web (Pvt) LTD

FABRIC PROCUREMENT

Working:
Product which are using have PD range 8-12 ounces
o Womens 8.0 ounces
o Childrens 8.5 to 9.5 ounces
o Youngster 10 to 15.5 ounces
o Older 13 ounces.
Fabric range depends upon customer demand or availability.
First, the manufacture make sample garment for customer and for organization all
the points and discussions are take place on that garment then it is approved from
customer and the fabric procurement process for bulk.
Price detail calculated and send to the mercendiser
Printing is done during fabric stage
Shrinkage and fabric elongation is calculated at the very first stag
Cotton have moisture absorbency 8.5
Polyester have 0.1 to 0.5
OBJECTIVE:
Cotton web is using nearby sourcing

FABRIC INSPECTION

Working
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In fabric inspection is working:


Shade variation 1-3 fault give 1point
o 3-6 fault give 2 points
o 6-9 fault 3points

o 9-12 fault 4points


For fabric inspection, they cut one 50/50 swatch and mark the fabric before
shrinkage and after check the result.
They cut swatches from each roll to check the fabric characteristics.
After washing one labor mark the roll no. shrinkage ,shade matching before after
and with customer demand then length of the fabric and specification on it then
give that to QC dept

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The inspection rules explain by this picture

Then in inspection dept, test with the fabric half hour weather dye have faint
with moisture simply with distilled water
All the processes will be done with distilled water having 4-5 pH
They test on both alkaline (Di sodium hydrogen phosphate 2.5 g/L and L-histidiumhydrochloride monohydrate 0.5 and sodium chloride 5g/L) and acidic soln. (sodium

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hydrogen phosphate 2.2g/L, L-histidium-hydrochloride, monohydrate 0.5g/L, sodium


chloride 5g/L) color fastness test.
Then the fabric come under Rota wash machine for color fastness test washing with
detergent(ECE detergent 4gm/L and sodium per borate tetra hydrate 1g/L) on 40C
for 30min
Rubbing test for color fastness10cicles in 10 sec in dry and wet both in is according to
ISO standard.
pH test after wash 1gm fabric 5ml water
o 7-8 rpm then I will be neutral
Second American method is used before wash
o 4gm 100ml water for 10 min on full boiling temperature cool down then and check the
pH
Nickel test
Absorbency test with simple distilled water.
o If absorb quickly have good absorbency.
Data color machine in which check color photo spectrum.

Some of the test which cotton web is taking outside is SDS, tear tensile, seam seepage
formaldehyde test etc.

OBJECTIVE:
They help to check the quality of fabric

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Rubbing test

GSM calculation

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QUALITY CHECK

Hierarchy
Quality Manager

Deputy Manager

Senior assistant manager


Incharge
(in each production deptt)
Supervisors

Quality Checkers

Working:
There are a number of factors on which quality fitness of garment industry is based such as performance, reliability, durability, visual and perceived quality of the garment. Quality needs to
be defined in terms of a particular framework of cost
Cotton web have two processes for quality check

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QUALITY CONTROL:

The systems required for programming and coordinating the efforts of the various groups in an
organization to maintain the requisite quality". As such, Quality Control seems as the agent of
Quality Assurance or Total Quality Control.
In industry, quality control is in right from the initial stage of sourcing raw materials to the stage
of final finished garment. For industry product, quality calculated in terms of quality and
standard of fibers, yarns, fabric construction, color fastness, surface designs, and the final
finished garment products.
Sample sizing check daily 30,000 meter checked as per sample size
Pre production shade and shrinkage check from every roll 1-meter fabric cut to
50/50 1-meter measurement mark before washing and then check that how

much shrinkage takes place in length and width.


Shade a, b, c, d marked by QC then give approval or rejection.
After relaxing the fabric for 24hour it come to next future processing.
3sizes take for production check run
QC check the risk analysis, shade, shrinkage etc

QC has check run in every processing dept after processing and before e.g. sampling, cutting,
stitching, washing, finishing, bundling etc.
Quality control and standards are one of the most important aspects in the industry.
Total Quality Control: To ensure that required quality of product is achieved. This
ensures customer satisfaction.
OBJECTIVES:
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To maximize the production of goods within the specified tolerances correctly the
first time.

To achieve a satisfactory design of the fabric, choice in design, styles, coolers,


suitability of components and fitness of product for the market.

QUALITY ASSURANCE:

In developing products and services, quality assurance is any systematic process of


checking to see whether a product or service being developed is meeting specified
requirements. Cotton web have a separate department devoted to quality assurance. A
quality assurance system is said to increase customer confidence and a company's
credibility, to improve work processes and efficiency, and to enable a company to better
compete with others.
QA set the standards and QC implement on those standards.
When garment is ready in it is assured by quality assurance dept. if any defect is
found then go back to related process again
If a product is rejected it effect the lead-time as well as efficiency of the garment.
After the fabric pass through cutting it is checked by quality assurance if more
than standard given faults found it will be rechecked by specific person again
Sewing equal quantity of auditing take place e.g. 50 pieces sample size 8 pieces
random select for checking
o If 5,000 pieces 200 sample sizes select randomly 7 major 7minor defects
are allowed.
Washing when checked by QC, it would be checked by quality assurance same
an EQUAL rule is applied on washing.

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Finishing have 2 checks pre quality check:


o Trimming, thread, button etc
o Check percentage of all processes
o 100% inspection of every garment passes through metal detector.
o Final check audit:
o According to customer need audit by 5KPI

STORES

There are 4 stores we visit all of them all stores have same function to control
inventory and check which fabric is present, come and the measurement of that
fabric is what?
This all information is then uploaded to ERP and all the dept share this
information
There are 4 stores
o before sewing,
o after sewing,
o pre pare wash store,
o Fabric re sewing.
Store flow chart: (same for every dept)
Receipt
Checking
Decision
GRN
Entry in register
Storage
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SIR

OBJECTIVE:
Is to store the inventory in warehouse

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UTILITY:

Hierarchy
director
DCM
maneger utility
dipty manager utility
assistant manager
executive
senior officer
officer

WORKING:
They provide service to production machine availability.
Boilers, steamers, electronic all machine provided to industry.
Three types of maintains
o Preventing maintains
o Corrective maintains

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o Pro active maintains


They have different suppliers
Eng section:
Boiler:
o
o
o
o

1 boiler eng
Operator 4
Assistant 4
Loader 12

Electrical:
o
o
o
o

Eng
Senior Supervisor
Supervisor
Technicians

Mechanical
o
o
o
o

Senior supervisor
Supervisor
Technicians
Assistant

Electronic:
o Senior supervisor
o Supervisor

o Technicians

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Sewing machine maintains is not utility work

ERP (enterprise resource planning)


SOFTWARE

Working:
enterprise resource planning software in which all the information about how much
fabric is in invert and how much we need by which dept which we need and which we
does not it all are managed within the organization by ERP software. It is actually
information flow within the originations.
Enterprise software solution for the apparel industry is to facilitate manufacturers to
streamline their business and integrate information across departments and locations.
Having the maximum number of variables in orders, items, events to be tracked, and
much more, their management is the key to success. ERP system addresses these with
ease and helps garment manufacturers accurately track their orders status, change
design instantly to work orders, handle small-scale batch runs and rapid re-orders, trace
the product in its route, apply quality checks at every junction and then dispatch it to the
customers.

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o First when the fabric enter into the gate the information is given to ERP manger
they set up all information and then generate a code for each lord and then it will
share to every dept.
o If any person enter incorrect code the ERP manger make this information to
related person to make it correct.

They give training also of outlook and excel sheet software.


BENEFITS OF ERP IN INDUSTRY:
Following are the benefits:
Supplier benefit

Information in time
about material to be
provided.

Management benefit

Cost
improvement
savings.
customer

savings,
in
Good

Employee benefit

Satisfaction in working
and achieving goals
with good teamwork.

Customer benefit

Good services.
Good
quality
cheaper price

at

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Relationships.

SAMPLING

STITCHING:
When a order come to merchandiser he plan the system for which it work then give all
specification and teckpack to sampling dept . It is different from bulk production it sampling the
2 or 3 garment are made for customer approval and when customer approve the sample and
adding up then it come into bulk production.
Sampling first cutting and then we see the stitching as it is not bulk production so
wastage and lead-time doesnot matter too much in it.
First digital pattern make then the fabric is cut according to it and come under the
stitching process
In stitching one piece is stitch by one person in r own working after stitching they go to
washing

WASHING:
In washing process, nee
o
o
o
o

Sample no.
Specification teck pack
Wash type
Dry process
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o Viscose
o Scarping
o
o
o
o

Washing techniques.
De sizing enzyme washing if customer demand
Blending
Neutralization.

Washing techniques:
Dark wash
Dry wash
De size
Rips spray
Neutralize
These processes needed 8 hours. Simple wash need 1 hour.
Before 1st wash Viscose and scraping done
Before second wash destroy done then spray of KMnO4 soln. then neutralizing agent used
are leva kon max (special wash for changing tone)
Sodium Meta bi sulphite use for making (slightly blue tone)
o TWC used as de seizer
o Enzymes effect
Cellulose wash or stone wash as required temp 45C
Neutralize enzymes NH gold used.

They have lead time of one day for fashionable garment in which more process are needed

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o Viscose effect boards, which have viscose effect, are use and sand paper for rubbing
to give effects to jean
o Scraping as customer required where he need it .the jeans is lifted to a balloon and
o
o
o
o
o

give effects.
Mostly the effect is on knee area back pocket area
After that, KMnO4 soln. applied to make effect visible after washing.
Destroy effect as according to customer requirement.
Tagging effect in which faint special effect is given to garment by wrinkle it.
Crinkle effect crinkle the fabric and clip it during washing.

After the processes is QC check that the effects is given according to customer or not after
check it passing to washing dept
OBJECTIVE:
To produce a sample product to approve order from customer

TECHNICAL AND CUTTING


DEPARTMENT
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Hierarchy
Manager
Senior assistant
manager
Assistance
maneger
Shift Supervisor
Operator
Assistant Optr.
Framer
Helper

NUMBER OF WORKERS:
Cutting of total cotton web is 200 employees.
WORKING:
TECHNICAL DEPARTMENT:
It is related to bulk to cutting dept. when sample is approved from the customer it will
come under technical department where they made again the pattern of sample for bulk
of produnction now.

The fabric is the cut 1 meter from bulk production, check the shrinkage in length
and width then these measurements are written to the fabric the person give this
report to the technical dept to add up the all ounces in pattern maker.
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Width has greater shrinkage as compare to length. Then they + or it from pattern.

GET work on the sample again and made pattern design for bulk of production
where they are keep in mind all specification and wastage should too low
.maximum fabric utilization in pattern making is 75 to 80% in cotton web.
After that technical department made computerize pattern for bulk by making the
wastage kept in mind because its bulk production

CUTTING:

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Then after pattern making it will come under the cutting process
These dept. deals with the skills and knowledge required to cut the fabrics according to
required pattern made according to customer demand design to produce the orders.
There are 2 units of cotton web and both have cutting process of same capacity.
All the plan order are same as in unit 1 same capacity and efficiency but I notices is unit
2 have less workers but more organize work as compare to unit 1.
Moreover, the process flow is in se
Total 70 labor direct labor is 40.
PERFORMANCE STEPS:
Quality checks to ensure that fabric is of the required quality standards before it
is cut.
Mark off the table to establish the length of the lay ensuring that actual yields are

better than or equal to minimum markers estimated.


Lay out fabric without applying excessive tensions.
Ensure that each roll is separated so that the garment panels are not shaded
Mark top layer of the lay using hard patterns or markers
Cut the lay carefully and accurately using chain gloves to ensure safety.
Separate cut panels and bundling in required quantities while ensuring that

panels are of the same shade


Mark panels to ensure that garments are assembled with same shade panels
Maintain record of fabric issued for cutting

Maintain record of lay details and of pieces cut by size


Maintain records of bundles and quantities transferred to sewing
Report production on daily basis to production planning and control(PPC)
Fabric shades separated accurately with in bundles.
After cutting and tagging of the shade and bundling come to QC and after QC quality
assurance.
TO DONE:
mark table accurately
use cutting knife without applying under pressure and without distorting the lay
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optimize use of fabric resulting into less waste.


Operate pattern-enabled cutter.
Maintain records.

Tools and equipment used in marking and cutting


marking techniques using tools and equipment according to requirements and slope
possible allowances in different components of the garments
possible matching sizes to minimize consumptions
fabric acceptance qualities and parameters
Maintaining records accurately and on specified formats.

OBJECTIVE:
Cut according to customer specifications

STITCHING
Hierarchy

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Manager
Senior assistance
manager
Assistant
manager
Senior
Supervisor
Supervisor
Assistant
Supervisor

Operators &
helpers

Number of workers:
Stitching 1+2+3= 700 employees
WORKING:
Stitching works in 3 floors in unit 1.
First floor only small parts are to be stitched.
All safety devices (needle/eye guard, finger guard, and belt cover) in place
.
First operation is of back pocket then front pocket coin pocket, pocket bag.
o Two lines for fashionable pieces
o Two lines for back pocket
o three machines for fly
Two small lines capacity 23, 00 pieces and 1 big line capacity 4,000 is working on first
floor.
A safety stitch is in inside pocket lining.
Label attach inside of the pocket as per customer requirement.
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INSTRUCTIONS:
Adjust bobbin and thread tensions
Operate the sewing machine to sew the garment parts
Perform minor machine maintenance i.e. oiling, needle replacement
Document work done accurately and as required
Machines kept in operational form
Regular maintenance has been done and recorded properly
Machines adjusted for particular job requirements
Garments stitched correctly in line with the specific standards
Then it comes in bundle form to second floor (back section) U shape the process flow.
First line then assembly 1 assembly 2
26-27 pieces one bundle
York folds by arm machine.
Safety ends by fedo machine.
Bundle matching and place separately.
Over lock and safety, stitches to back panel.
Then back panel pocket tracing
Attachment of pockets
All the machines are working auto in which servo motor speed variety. In auto machine
there is cutter that cut the thread after stitching.
Auto machine is controlled machine even you can fixed the thread length.
o 7 labor 1 supervisor
(Front section)
Lining attach
Tacking
Zip and fly attach
Shape to crotch

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2 panels of front attach through


Crotch stitch
Barteck
Extra piece cutting in fly
Paring of the shade front back panels
The QC check
Inseam(safety stitch)
Fedo arm machine a safety stitch at the end of seam
Hip stitch
Belt match
Extra belt cut
Chain opening for proper stitching
Close process then of belt
QC check after waist belt because it is a critical operation and chances of more
rejection
Turn up the fabric
Bottom hemming
Loop attaching
Button holes
Then final QC check audit of 10 bundles.
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Third floor
Machine detail:
In stitching 265 machines in which two looper, machines, 2 needle, 1 cutter or
trimmer, waist belt 8 thread machine
Workers 322
Eight multi task workers.

In unit 2 same processes is done and capacity is also the same


All section front, back, pocket, fashion, embroidery, lining, pre process store all are at 1
floor.
Same production capacity.
33 lack SAM min
This is calculated by
Target=direct labor*shift time/SAM
Utilization=SAM*target/D.L*shift time
On floor cut and order wise working .flag are place on each trolley.
L shape the process flow is moving.
Machine detail:
No. of machines working 247
40 change over machines.
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Total no. of machines 288


Fashion garments machines 16

Line 5 and line 6-7 then assembly 1 and 2 the QC and QA


Direct labor 352
Line 5 174 machines
Line 6-7 178 machines
Front 24 machines
Assembly 1 (23) machines
Assembly 2 (27) machines
Four operators in pocket trac
8 labor 1 supervisor
Small parts 38 machines (11 manual 6 auto10 multi skill worker)

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EMBROIDERY AND PRINTING


WORKING:
Embroidery:
Machine, which is used in embroidery, is fully auto tagena embroidery machine. It Is a
Japanese machine
o 3 machines are use for embroidery
1 machine at a time stitches 20 pieces of same stitch and embroidery at a time, and has
capacity of 500 stitches in 1min time
First, the pattern is made in software wilcom software then it gives command to
machine to work.
Daily production minimum 16,000 parts min 3,000 stitches.
Nine needles and at a time nine different threads will use. If a Single thread breakage
occurs, it will stop the whole machine. When one cut complete, the machine will stop.
Using CUT and in house embroidery at this place and if order is more it will outsource.
After the embroidery process complete the QC audit check occur of 10%
Some main points are
o Max speed is 1000 rpm
o 35 direct labor working
o 2 framers, 1 assistant, 1 helper, 1 supervisor, 1 master, 1 design maker
o 2 shifts
o Sequences stitches are not available it will outsource.
o Threads which are used 60/40
o Polyester threads are also use in small ratio.
Printing:
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One table
40 rounds
Only screen printing

Design from outsource or from customer


Then it placed on screen in dark house
Pants used for printing.
Fuji film paints
o Before washing this process take place
o After printing it will be fix by wet machine .standard temperature is 180C for
40 to 35 seconds for lining
Belt machine time is 1 min.

SPECIAL EFFECTS
The following special effects are using
Visor (sand paper use)
Scraping
Tagging (wrinkles)
Distress (with grinding machine)
Destroy

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Pinky effect then washe

WASHING:

Hierarchy
Garment dry
process/Garment wet
process/PD Manager
Deputy Manager
GDP Senior assistant
manager

GWP Senior assistant


manager

Senior Supervisor

GWP Assistant
manager

Supervisor

Process Engineer

Assistant Supervisor

Senior Supervisor
Supervisor
Assist. Supervisor

NO. OF WORKERS:
There are approx 159 employees in GDP and 115 in GWP
WORKING:
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This unit deals with addition of value using washing techniques on the garment and to
condition it for finishing. Performance Criteria
Stone wash on the garment
Use enzymes and softeners
Over dyeing of the garment
Normal wash of the garment

Check shrinkage of the fabric


Handle chemicals carefully
Observe OSH measure while undertaking wash and dye

INSTRUCTIONS:
The washed cloth matched the sample requirements
Provided hand feel
Shrinkage of the fabric has been make sure that it is within the permissible allowance
operate the machines safely
use suitable chemical for washing and dyeing
use enzymes, detergents and softeners as per requirement
adjust processing time and temperature as per requirement

AFTER WASHING:
neutralizing techniques of the garment after process
safe boiler operations
drying equipment types, its uses and operations
Range: This unit covers the washing of the garments using different methods to
achieve desired results. Environmental regulations regarding use of detergents
may be care taken. This unit does deal with the finishing of the garments.

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After washing

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FINISHING:
Hierarchy
Manager
SAM
Process
Engineer
Seinor
Supervis
or
Supervis
or
Assistant
Supervis
or

NUMBER OF WORKERS:
There is approx 500 number of employees

WORKING:
Same process as in unit 2

Loop cutting manual 6 workers


Label stitching 5 workers
Button rivet placement 8 labor(one contractor on them)
Thread cut trimming 30 machines
Thread sucking 1 machine

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Ironing 10 workers
Then checking start 100% quality check(code to every fault and goes to re check)16
labor
Then checking 16 labor
Machines for repairing
After alteration check 16 workers
Final check 3 persons
1 insurance labor check
Measurement check
Accessories attachment
Tag gun
Hand tag attach
Verification of paper accessories
Packing according to customer
Packing list
Shift to warehouse
Pre quality check is after receiving garment from washing,

Extra working 14 people


Loop section cutting 7 persons
Label section(cover with poly bag) 7 persons
Trimming 30 auto trimmer

Manual clipping 15
8 checker of teley
13 machines button rivets
2 sucker machines 3 worker 1 is helper
Gun machine to catch small threads
16 iron machine to set the fabric.

UNIT 2:

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Makeup area:
In this,100% checking take place
24 checkers in one-hour 50 pieces.
Code to every operation fault and take back to operation.
o Piece damage, rejection, Barteck, missing, skip stitch, stain check and b-2
The operation separate for this fault and then give it for re operation.
2 verifier of faults
Then super check
PDI pre delivery inspection.
Quality control check e.g. 20 out of 100 pieces
Extra working table for fashionable garments.
Measurement checks to be accurate.
Paper accessories attachment.(9 workers)
Needle detector

Sizing
Size wise tagging
Price tag.
Paper tag
Paper accessories verification.
Folding as per requirement of customer
Shade wise packing
Poly bag sealing
Verification sticker on pieces that of same size
Verification of carton sticker.

Ready for shipment

Performance Criteria of finishing:

Clip threads and other projections


Attach hang tags and labels
Fold the garment
Use pins and clips if necessary
Pack the garments in polythene bags
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Final audit:
The garment finally checked
The garment has been pressed, folded and packed in polythene bags or any
other suitable type of packing

Product description and price tags have been attached

customer requirements and technical package agreed with the clients


different packing materials and special design of packing
occupational safety and health measures specially while handling chemicals
and/or using electrical appliances
OBJECTIVE:
This unit deals with presenting the garment to the customer in an attractive manner and
as required. This unit does not deal with packing of the garments.
o Check the garments to ensure that it is symmetrical and saleable
o Describe that there are no open seams
o Ensure that there are no raw edges visible
o Demonstrate that there are no skipped and/or broken stitches
o Demonstrate that the garment is free from fabric faults
o Demonstrate that the garment is stain free
o Demonstrate that fabric quality in terms of weight, colorfastness and shrinkage
are as required
o Demonstrate that garment colors and trim colors are wash passed
o Demonstrate that garment specs are within tolerances of the customer
requirement.

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MANAGEMENT:

HRM:
Hiring:

Minimum education is F.A


Aptitude test
Technical skill test
Panel interview

Training:

The person training which skill is weak the person is train by that in house
training and outdoor trainings
Excel training, software training
5monh is the training time
4 month performance check
Then the person is hiring permanently.

Compensations and benefits:

Max 2 hour overtime


Performance bonus
Absences bonus (in which if a person is not absent for 15 day they will get a
incentive of 1500 give to the worker)
Bus facility and charge of Rs500
Accommodation is also given reduction from salary

Eid bonuses

ADMIN:
Admin is a different dept, which manage
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Security supervisor:
Under his 21 guards
Housekeeping:
31 sweepers
Safety fire (every month check the cylinders)
Waste shed (through contractor dispose it off)
Nursery 2 workers
Painter 1 for maintained
Transportation:
14 buses on rent per month 12 lack rent (70 % company is baring the rent)
Toyota 1
Bolan 1
Attendance:
Salary sheet is enters the account of every person in the software by time data system
when they enter and
Then salary sheet is made at the end of month absentee is cut from it.
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Salaries calculation under admin then to accounts

Contract, piece rate, daily, salary base everyone have different salary
packages
Allowed holidays 34 total leaves. 14 annual, 8 casual, 12 sick
The international tour visa booking hotel and stay arrange by company is also
under the responsibility of admin
Gas, utility, fuel, telephone bill under admin hold.

ACCOUNTS:
This unit deals with the skills and knowledge involved in the management of accounts
like budget preparation, ledger account, payroll, balance sheet, and invoices for a
company.
Finalize budget and incorporate expected expenditures in quarterly and annual
financial plans
Maintain book keeping of different transactions
Prepare payroll according to the attendance sheet and do adjustment i.e. lone
deduction, bonus payment, compensation etc.
Use ledger to produce balance sheet and profit and loss statement
Prepare and issue invoices according to the dictates of financial instruments are
used.

OBJECTIVE:
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Budget prepared, approved, published and disseminated to all concerned


Copies of the filled out vouchers documented and account audit from reliable
auditor has been done and recorded.
Payroll sheets prepared and signed by employees.
Monthly balance sheet and profit & loss statement prepared and documented
Copies of invoices issued and received documented.

Ability to:
convince the importance of preparing and managing budgets and help them in

capacity building for budget preparation


maintain double entry accounting systems
prepare payrolls
perform accounting calculations to prepare profit and loss statement
Check conformances to budget code formalities while issuing and receiving
invoices.

This competency deals with the skill and knowledge of overall management of accounts
which includes budgeting, payroll, ledgers, profit & loss statement of a garment
manufacturing company

EXPORT AND FINANCE:


Hierarchy

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department head
depty export/finance
senior assistant manager
assistant manager
senior assistant
officer

WORKING:
This unit deals with the skills and knowledge required for the management of financial
resources of the company
Manage relationships with financial institutions and government regulatory bodies
Follow financial rules relating to the release of funds for different activities based

on the supply of correct budget codes


Release funds to projects of strategic importance as set by the management
Calculate rates of returns on investment
Calculate return on assets
Calculate returns on borrowings (if any)
Financial statements have been updated on a regular basis for generating
reports to companys own management and for regulatory bodies.

Rates of return for key indicators have been calculated


Books of accounts have properly been maintained
Classified financial reports shared with financial institutions

Ability to

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use budget codes as a basis for the release of funds, i.e. for on-going projects
and projects of strategic importance
apply financial rules to organizational policies and objectives
develop agreements with financial institutions for managing finances /funds for
projects essential for realizing companys strategic goals from other financial
institution

SWOT ANALYSIS

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STRENGTH:
Company good image
The company is ISO 9001:2008, ISO 14001:2004 and OEKO TEX
Many peoples are working here the very first day when the company start and
they are highly professionals and skillful.
They also have laboratory for testing the quality of fabric.

WEAKNESS:
There is no specific brand of the industry, they are working only order base
The staff is not much cooperative.
OPPORTUNITIES:
They are working with big brands like Mango, Mustang, Gemo, Tesco etc.
Working mostly on women denim.

THREATS:
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Giving order on time


Offer new and latest fashionable styles to the customer while taking orders.

CONCLUSION:

As it is a well, know international company so the working environment and


policies are up to international standard with international big brands. I enjoyed a

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Cotton Web (Pvt) LTD

lot working with them. We learn a lot about the organization how people are
working within an organization the challenges they face and how they are
managing it, we learn a lot about that.
We study in theory we understand the thing but when we see the practical
working organization we learn and understand a lot, most of the concepts are
now clear in my mind about how merchandiser work and how an order take plan
what customer demand is. They employee fresh graduates and treat their staff
really well.
There is I think minor things, which the industry has to change, but overall it is
working really wel

SUGGESTION:

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The first suggestion is no dough they share most of the knowledge with us but
we are internees I think according to time every staff have to manage to give us
time in better way.
Stitching dept needs attention because its the basic dept. and the staff and the
process is not managing .some of the workers are free n the time is wasting it will
be made attention
There will be a brand for the industry so that it would be reachable for every
customer.

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