INDUSTRY INTERNSHIP REPORT

BATCH: 2015-2017

WORKING IN AN EXPORT HOUSE

INDUSTRY SPONSOR: PARAGON APPARELS PVT.

LTD

FAISAL NUMAN
Batch 2015-17
MASTER OF FASHION MANAGEMENT

Department of Fashion Management Studies

National Institute of Fashion Technology

WORKING IN AN EXPORT HOUSE

INDUSTRY
SPONSOR:
APPARELS PVT. LTD

INDUSTRY INTERNSHIP REPORT

Submitted in partial fulfillment of the Industry Internship of
Masters of Fashion Management Department
At National Institute of Fashion Technology, Rae Bareli .

Student name: Mr. Faisal Numan

Faculty guide: Mr. Amitava Chowdhury,
Associate Professor

PARAGON

DECLARATION
I, FAISAL NUMAN hereby declare that the Internship Project Report
entitled
WORKING 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: Faisal
Numan
Batch: MFM
2051-17
Centre: Raebareli

Date: 29th August, 2016

Place:Raebareli

CERTIFICATE BY THE FACULTY MENTOR

REGARDING
COMPLETION OF WORK

This is to certify that Mr. FAISAL NUMAN of Masters of Fashion Management

Department at National Institute of Fashion Technology Rae Bareli, has been
evaluated for his Industry Internship Report titled WORKING IN AN EXPORT
HOUSE and have fulfilled the requirements set by the institute and the evaluation
jury. His work has been found satisfactory.

Mr. Amitava Chowdhury

Associate Professor &
Faculty Mentor

Mr. Amitava Chowdhury

Associate Professor &
Centre Coordinator

Copyright 2012 by National Institute of Fashion Technology.

All rights reserved. No part of this document may be reproduced, stored in a retrieval
system, or transmitted in any form or by any means, electronic, mechanical,

photocopying, recording and scanning or otherwise in any form without the written
permission of the copyright owners.
Design: Faisal Numan
Printed at Rae Bareli, U.P. India.

ACKNOWLEDGEMENT
A project report seems to be an individual effort is in fact a teamwork. Summer
internship at Paragon apparels ltd was just like an opportunity to shake hands with
the practical world of business.
I am indebted to all those individuals who helped me in gaining knowledge and
insight into various aspect of working of an export house. The source of learning
have been one too many and a complete list of individual reference would become
encyclopedic.
I want to express my deepest gratitude to my Industry Mentor Mr. Yogesh Behrani,
Merchandising Manager, Paragon Apparels, without whose help this summer
internship in Paragon Apparels would not have been possible.
I am grateful to Mr. Anil Negi, Chief Financial Officer, Paragon Apparels for
sharing his experience and knowledge.
I will be failing if I do not express my heartfelt gratitude to Mr. Aakash Jain (AVPMerchandising & Marketing), Amit Kumar (Senior Merchant) for their continuous
support and encouragement and valuable guidance in doing this project which would
be an unforgettable experience to me. My overriding debt continuous to be for Mr.
Rashid, Merchant, Mr. Shekhar, Merchant, Mr. Suresh Kumar Pandey, Head QC
for their support and help during the internship period.
Back at my institute I would like to express my sincere thanks to Mr. Amitava
Chowdhury, Associate Professor (My mentor and Course Coordinator, MFM )
for his exemplary guidance monitoring and constant encouragement throughout the
project
And a Special token of thanks to Mr.Pratap and Mr. Babloo for their constant help
and support.

TABLE OF CONTENTS
PREFACE 8
COMPANY PROFILE...........................................................................................9
ORGANIZATION STRUCTURE..10
WORK FLOW.14
PRODUCT DEVELOPMENT.. 15
COSTING........20
SAMPLING DEPARTMENT.21
TRIMS STORE24
RESEARCH & DEVELOPMENT.27
CAD DEPARTMENT.28
SPREADING DEPARTMENT..31
CUTTING DEPARTMENT32
TICKETING, FUSING, CHECKING, BUNDLING.33
PACKAGING DEPARTMENT.34
FINDINGS...44
SUGGESTION45
CONCLUSION46
BIBILOGRAPHY.47

COMPANY CERTIFICATE

PREFACE
This report is an account of hard work done and experience gained in the company
having a reputed stand in the international market and policy of keeping itself
updated with the changing times. This hard work is original in style and method & no
pains have been spared too make it as compact, perfect and reliable as possible.
The report mainly deals in the application of theoretical knowledge into a practical
experience.
This report attempts to present my experience in PARAGON APPARELS Ltd.
Indias premier export house. It gave us an opportunity to be a part of an esteemed
organization and get the first-hand knowledge of working of various departments
under various heads.
It covers the basic structure of an export house and working. It also includes various
formats that are used in firms to maintain the records. Overall, this report covers the
individual study of each department that a garment undergoes.
As such, this report is not sufficient to pen down what i have gained from this
training. So, it should not be compared with the experience that is learned by
working in an export house.

COMPANY PROFILE
COMPANY NAME

Paragon Apparels PVT. LTD

B-59 Hosiery Complex, Phase 2,Noida,
Uttar Pradesh, 201305

ADDRESS

+91-0120 493 2200/04

TELEPHONE
info@paragonapparels.co.in
E-MAIL
WEBSITE

http://www.paragonapparels.co.in

YEAR ESTD.

1997

OWNER

MR. Roshan Baid

DIRECTORS

Mr.

Roshan

Baid(Chief

Managing

Director)
Mr. Rajiv Pande (President)
ANNUAL TURNOVER

USD 60 Million

MARKET

100% EXPORT

MACHINES

2000

ORGANIZATION STRUCTURE
Roshan Baid

CMD

President

Finance Head

Head of Operations
Vacant

Rajiv Pande

Anil Negi

HR & Compliance

Merchandising
Aakash Jain
GM

Uma Shankar Kaushik

AVP

MERCHANDISING

10

Rohit Aneja

Rajiv Pande

Director

President

IT

Merchandising
Fabric

Aakash
Vacant
Jain
Kapil Maheshwari
GM
Manager

Aakash Jain

Manish Valecha

& Marketing
MAVP-Merchandising
M
(M&S/Benetton/
Yogesh Behrani
Kshitiz Chandra
M
(Rel/ Lifestyle/ Schissor)

M
(Adidas / Rbk)

Pravin Kr.

FACTORY LAYOUT
1. BASEMENT
a. Fabric Testing Lab
b. Fabric Store
c. Accessories Store
d. Cutting/CAD/CAM

11

M
(Hummel/Splash/ Joy Storts)

2. GROUND FLOOR
a. Reception
b. Conference Room
c. Personal Department
d. Human Resource
e. Production Floor
f. Finishing Department
g. Packing
h. Quality control
3. FIRST FLOOR
a. Production floor
b. Finishing
c. Packing
4. SECOND FLOOR
a. Merchandising
b. Product development
c. R & D
d. Production plan & control
e. Sampling
f. Export documentation
g. EDP (Electronic Data Processing)
h. Accounts
i. Surplus fabric & accessory store

ABOUT THE COMPANY

Paragon Apparel Pvt Ltd (Paragon Apparel) commenced business operations in the
year 1997. Its registered office is located in New Delhi and head office in Noida. The
company is engaged in the business of manufacturing and export of readymade
garments.

12

Paragon Apparel is engaged in manufacturing sportswear including Polo Tee,

Sweatshirts, Tanks, Open front Shirts, Bottoms, Active Wear and Halters for mens,
ladies & kids. The company is amongst the key suppliers to sportswear brands
including; Adidas, Reebok, Puma, Hummel, SuperDry, Tata Trent, and Reliance
Retail among others. Paragon Apparel is also engaged in exporting its products
across USA, France, UK and other parts of Europe and APAC. Some of its
international customers include; Adidas International Trading BV, Reebok
International Ltd, Hummel International, Benetton Group SPA, VF Imagewear Inc.
and Jones Denim Group FG.
The company manufactures and supplies its products to the premium client base
Use of latest computer software like CAD, Intellocut Cutting Software to reduce the
fabric wastage, and efficient use of the thread.
The company operates four factories in Noida, Delhi with an installed capacity of
20,000 pcs/day. Paragon Apparel has ventured into a new project of knitting and
process house at UNA through its group entity Paragon Knits Ltd as a step of
backward integration.
Paragon Apparel is accredited with
ISO 14001:2004 and
OHSAS 18001:2007 certifications.

WORK FLOW

BUYER

13

PRODUCT DEVELOPER

MERCHANT

SAMPLING

FABRIC

TESTING

MARKER PLANNING

SPERADING

CUTTING

BUNDLING

RESEARCH& DEVELOPMENT

PRODUCTION

WASHING

FINISHING&PRESSING

PACKING

14

PRODUCT DEVELOPMENT

This department is not buyer specific and for all work the buyer that company caters
to. The major role of this department is to getting business for the company.
Foundation of all other department, it assists in covering their ideas into reality.
First interaction of the buyer is with PD department, but in some case PD is directly
done by the merchandising department, there is showroom for meeting as well as
presentation for new developing /line adopting to buyer, sample/mock developed are
for style and design purpose and measurement do not play measure role .if buyer
select any of the style then further development will be done by PD department,
once order is been locked further follow up and communicating regarding that style
will be the responsibility of the concerned merchandiser.

CLASSIFICATION

PRODUCT DEVELOPMENT

EXTERNAL
INTERNAL DESIGNING
DESIGNING

15

INTERNAL DESIGNING
Design development done in house. Product development is done on following
basis:

MOCK OR SAMPLE WILL BE PREPARED FOR

SELECTION

IF SELECTED IN THE MEETING SAMPLE WILL BE

MADE

COSTING AND NAGOTIATIONS

SALESMEN SAMPLE

GRADING

ORDER CONFIRMATION
PASSED BY MERCHANDISER THEN FOR PD

16

BUDGETING

EXTERNAL DESIGINING

LINE ADOPTION WITH BASIC DETAILS

SAMPLE WILL BE MADE (2 PCS)

APPROVAL /COMMENTS

BUYER SENT A TECH PACK

THEN AGAIN PROTO SAMPLE MADE(3PCS)

FIT SAMPLE MADE ((3PCS)

APPROVAL / COMMENTS

BUYER

WILL

SENT

FIT

SAMPLE

SPECIFICATION

SIZE SET ARE MADE

APPROVAL

REVISE FIT OR SELLER SAMPLE IS MADE

17

ORDER CONFORMATION

PROCESS FLOW OF MERCHANDISING

DEPARTMENT
TECH PACK COMES FROM BUYER

INITIAL SAMPLING AND COSTING

GET ORDER FROM THE BUYER

ORDER CONFORMATION

WITH BUYER

RE

SAMPLE

/PROTO

TYPE

APPROVAL
FIT
APPROVAL

18

SAMPLE

GPT
SAMPLE
SIZE

SET

SAMPLE

APPROVAL

PURCHASE ORDER

PO is an external document which is issued by buyer in the name of Paragon

Apparels Pvt.Ltd; it is an evidence as well as support of order confirmed in the favor
of company.

Po include the following information-

1.
2.
3.
4.
5.

19

Delivery date
FOB
Ship cancel date
Destination
Ship mode

6. Terms if sale
7. Currency
8. L/C
9. Quantity
10. Size break up / color break up

Paragon Apparels PVT.LTD USES WFX ERP SOFTWARE

In company employee work on WFX ERP software for making challan, purchase
order, indent etc. its very simple and useful software.

COSTING
The most important function of the merchandising department is to calculate the total
cost of garment. It is the job of merchandiser to estimating the initial cost correctly
and also negotiates the cost of production with buyer before he send his PO. The
costing should be such that it suits the buyer and also the export house. At the pre
production stage initial costing is done so as to get an idea of cost likely to be
incurred. After the buyer has placed this order and production sample is approved
then final costing is done. The final costing uses fabric average from CAD, cost of
fabric& trim etc.
A cost sheet includes:
1. Buyer name
2. Style
3. Garment

4. Quantity
5. Budget
6. Fabric description

Total cost fabric includes:

1.
2.
3.
4.
5.

Greige fabric cost

Cartage
Dyeing
Embroidery
Washing

6. Finishing
7. Shrinkage
8. Wastage
9. Total fabric consumption

Accessories cost include

1.
2.
3.
4.
5.

Main label
Wash care
Price ticket
Tags
Cartons

Cost of company:
1.
2.
3.
4.

20

Margin
Overheads
Quota
Shipping cost

6. Poly bags
7. Stitching threads
8. Embroidery threads

SAMPLING DEPARTMENT
A sample is a proto type of a product to be manufactured in future course of
production. It is also called mockup of a product and is made to check the design
effectiveness and fit of the garment. Sampling is a set of the procedure follow to
produce various sample style. It contains activities like making of the pattern for
proto type according to measurement of the sample with the help of machinery and
getting buyers approvals for sample produce.
In an export house, the sampling department play vital role in the up- lifting of a unit.
This department directly coordinates with the merchandising dept. and production
dept. sampling is done to see how the product will look when produce in bulk and to
check discrepancies in the pattern are.

STORAGE

Rack system of storage is followed i.e. packages are stored in two areas:
1. Check fabric
2. Unchecked fabric

They are further segregated on the basic of style no. and lot wise. The fabric rolls are
put in rack manual way. Such systematic maintenance of the store makes it easy to
make the fabric whenever needed in future.
ORDER PROCESSING AND FABRIC IN-HOUSE:
The merchant receives the purchase order from the buyer. On the basis of this
purchase order, the fabric source prepares a requisition for fabric as per the demand
of the buyer and raises it to the fabric vendors in the market. The best deal and the

21

vendor are finalized and the order is placed. The factory may send the yarn from the
store to the fabricator for fabric production, buy greige for dyeing or directly order
processed fabric to the vendors. Once the fabrics development receives the approval
for the fabric, the vendor send it from of lot within the specified the time period and
the fabric is made in house in the fabric store. About 5% extra goods are supplied by
the vendor. The fabric via transport trucks comes in various packages like rolls, book
fold etc. each consignment comes in with an invoice having details like quantity,
color, GSM, and weight. The goods are weighted and other detailed are reconfirmed
before they store.

TESTING LAB
Garment are made from fabric with help of sewing thread and no. of accessories like
button, lace, ribbons etc. are sewn on them. All these things used to construct a
garment have uncertain characteristics i.e. how they behave in condition like
washing, sunlight, heat etc. when used by the customer. Any undesirable change in
fabric, thread or trims would detract the aesthetic value of the garment and decrease
its utility before time. Thus it became necessary to check or test characteristics of
this entire component under conditions to which they are susceptible to charge or get
damaged. Fabric and trims are tested for their quality, durability color fastness,
dimensional stability and physical known how. Goods are produced from the
suppliers only when lab test results confirm that they comply with the standard or
requirement of the buyer.
The buyers are also specific about the method that has to be followed. AATCC and
ASTM are two American standards that are used in the lab. AATCC (American
association of textile chemists and colorists) are given primarily for all color fastness
and dimensional stability. ASTM (American slandered for testing materials) covers all
the physical tests.
ISO (international standard organization) is a European standard, which covers the
color fastness tests and the dimensional stability tests.
Paragon Apparels Pvt. Ltd has its own in-house fabric testing laboratory equipped
with all sophisticated instrument as per AATCC and ISO standard where tests on

22

fabric, garment and trims are conducted. There are separate dry, wet and chemical
testing areas in lab along with a dark room for color matching.

BASIC WORK FLOW

TESTING lab receives the fabric to be tested along with test request from either from
fabric sourcing department or the fabric (or garment form quality assurance/
merchandising department). This from contains all the details like buyer name, style,
sample description and vendor. A swatch of fabric to be tested is passed on the form
and tests to be conducted are specified. Depending on the no. and type of tests to
be carried, fabric yardages are sent to be lab (almost mtr to 2 mtr).
Testing is done on the behest of buyer and it is the buyer who specifies the test to be
conducted. Fabric sourcing department coordinates the communication and testing
activities. Each buyer has its standard acceptance levels in testing. He may require
testing to be done at a specified testing laboratory or one nominated by the buyer
itself.
Once the fabric is received for testing, it is allowed to be relaxed, condition and
acclimatizes to the standard temperature and humidity maintained in the laboratory
for at least 2-4 hrs. a variety of test are conducted on the condition sample but some
of tests like that of washing, crocking, rubbing, dimensional stability, count, fabric
construction, GSM, content etc. are necessarily

TRIMS STORE
Trims store as the name suggests is a department, which acts as a storehouse for
accessories. It is the place where all the accessories required in an export house,
are stored. Right from sewing thread, needles to packaging material mike poly bags
and taps etc. all are stored in the accessories store.

23

The merchandiser as per buyer specifications order the purchase dept. to buy the
accessories that are used in a particular style of that buyer. Merchandiser prepares a
swatch card containing all the accessories and their quantity in a cycle. These
accessories used in the swatch card are as per the quality and color mentioned and
approve by the buyer. The purchase dept. with help of swatch card prepared by the
merchandiser purchase the required quantity of accessories. The accessories are
purchased 10 15% extra then the required, as the wastage in case of accessories
is more. The receiving dept. then receives these accessories from the vendor and
then checking and testing of these accessories are done. They are checked quality
and color. The accessories like buttons are tested with help of button snap tester.
After all accessories are checked and tested as per the buyers specification then an
accessories approval card is prepared.
After the accessories are received they are stored in the accessory store. The
accessories are stored in different racks. The accessories of a single buyer are
stored in one rack but the different accessories are stored separately from each
other in the same rack. The accessories store also houses the stationary required in
export house.
Now, whenever the production starts the accessories required in production are
issued to the production dept. through an internal channel. A stock register is used
for maintaining records. Thus an accessory store function as a store house for
accessories where all accessories are assembled and kept and also issued to
sampling and production dept. for the garment manufacture.

WORK FLOW OF ACCESSORIES STORE

24

ACCESSORIES/ TRIM ORDERING AND THEIR APPROVAL

Thread ordering and approval:

For ordering thread, merchandiser has to match the color standard or
approved lab dip or initial bulk fabric with the shade card of the supplier
company, if not matched then lab dip for thread will be done.
Thread approval is taken through thread runs. Thread run means running of
different thread option matching with the color standard or approval lab dip or
initial bulk fabric used for production.

Button ordering and approval:

For ordering button, its line, color, finish and quality should be matched with
color standard or approval lab dip or initial bulk fabric.

25

Hanger and sizes ordering and approval:

These are ordered according to the buyers sizes.

Poly bag and carton ordering and approval:

Poly bag are ordering according to length, width and height of the garment
and carton are ordered as mentioned in PO and DCPO.

Labels ordering and approval:

As labels are different type, so it should be ordering according to buyer
requirement only wash care label is ordered after G.P.T.

Zipper ordering and approval:

For ordering zipper, its teeth width, tapes quality and color and important
elements should be matched with quality and color standard or initial bulk
fabric.

Other accessory ordering and approval

Other accessory like fusing, twill tape shoulder pads, price tickets and hang
tags ordering as other are done.

RESEARCH & DEVELOPMENT

R&D and IE are two separate departments working for the same aim i.e. increasing
the production of a company with minimizing the cost.
Various tasks performed are:

To check that product is production feasible or not before sending final

approval to buyer.
Line balancing
Calculating thread consumption
Time study
Creating operating breakdown
Find out SMV
No. of machine
Helper required
Sketching layout for production

26

To find out the efficiency of the individual operator and line

Calculating daily efficiency of the unit
Co-ordination with PPC for improving the efficiency
Fix the target production
Decide the type of the machine and work aids attachment requirement for

particular operation
Machine breakdown
To monitor hourly production
Hourly line tracking status

CAD DEPARTMENT
CAD stands for computer aided design. It is done of the most important department
of export house. This department acts as a service department for merchandising,
sampling and cutting department. The working of these three departments is highly
depends upon CAD department. Without CAD it is very difficult for these
departments to move ahead.
CAD system involves any type of design activities which use of to develop analyses
or modify any engineering or garment design.
Basic Software which is used for computer aided designing in Paragon Apparel Pvt.
Ltd is as follows:
1. Modaris
2. Diamino
3. Optiplan

1. Modaris
This software performs the following functions:
Pattern making
Pattern modification
Pattern digitizing
Pattern grading
With the help of this software we can export and import pattern to another place in
soft copy.
2. Diamino

27

This software is used for marker making. It can be manual or automatic. Efficiency of
marker as decided as per the garment in this seam allowances are also added.
Function per formed by this software are as follows:

All markers with minimum wastage.

Solution of problems created due to center selvedge, length variation
and side selvedge with best efficiency.

3. Optiplan
This software is used when buyer send uneven ratio. Functions performed by
Optiplan are:
Main equipment used in CAD

Pattern pieces
Digitizer

MARKER MAKING

A marker is a diagram of precise arrangement of pattern pieces for size of specific

style that are to be cut from a single spread.
Marker making is a process of developing a diagram which is superimposed on the
top of a ground of superimposed piles as a guide for cutting these plies.
It determines the most efficient layout of pattern pieces for a specific style fabric and
distribution sizes.
Cut order planning determines:

How many markers are needed?

How many of each size should be in each marker and the number of plies that
will be cut from each marker?

WAYS TO MAKE MARKER MOST EFFICIENT

28

PATTERN ENGINEERING
An examination of the seam location to ensure the possible placement of
pattern in marker

HEM ALTERATION ALLOWANCES

Means dividing a large panel awkwardly shaped pattern into two pieces to
better accommodation in the marker.

THE SELECTION OF FABRIC WIDTH

The best width depends among other factor on the cost of various fabric
width/ square meter, the typical number of size in a marker, the potential
pattern engineering changes at various width and the marker efficiency
achieve.

WORK FLOW OF SPREADING AND CUTTING

SPREADING

LAYERING

CUTTIN G MANUAL/ AUTOMATIC

TICKETING

FUSING

CHECKING

BUNDLING

29

TRANSFER TO PRODUCTION

SPREADING DEPARTMENT
Spreading is the process of smooth layering of fabrics in superimposed layers of
specified length. After fabric is received it is issued to spreading department for
further processing. Spreading is done with the type of fabric, print of fabric and
marker issued by CAD dept.
PROCESS FLOW OF SPREADING:
FABRIC IS LOADED ON SPREADING MACHINE

PERFORATRED PAPER IS SPREAD ON SPREADING

TABLE

VACCUME IS TURN ON IN THE SPERADING TABLE

AUTOMATIC / MANUAL SPREADING IS DONE

MARKER IS SPREAD OVER IT AND PASTED BY TAPE

AIR FLOW IS GIVEN FROM BOTTOM

TRANSFERRED TO THE CUTTING TABLE

30

CUTTING DEPARTMENT

Cutting means to separate out different garment process from the lay of fabric with
the help of cutting template and devices. It is done to get required shape in different
no. or as a whole to make a complete product. The first stage in the manufacture if
garment is the cutting of material into the necessary pattern shapes. These patterns
are joined to form a garment when large amount of garment style has to be cut, a lay
is created, which consist of many piles of fabric spread one above the other. Now all
the pattern pieces for all sizes are from this lay. The main objective of the cutting
dept. is the cutting of garment parts accurately and economically and in sufficient
value to keep the sewing room supplied with work.

BASIC WORK FLOW

Cutting department receives the order for cutting a garment style from the production
manager. Cutting order is an authorization by the production manager to cut a given
amount of styles, from the spreads. It comes in from of a package file that carries the
following details:

1. Sampling average, weight of garment (base fabric consumption only) and

2.
3.
4.
5.
6.
7.

other trims averages.

Measurement sheet
Design worksheet of the garment
Purchase order
Fabric requisition sheet
CAD mini marker
Marker planning length of lay etc. size ratio and colors in which the
patterns are to be cut.

31

CUTTING SUB DEPARTMENT

1.
2.
3.
4.
5.

Layering and spreading

Cutting
Bundling and ticketing
Fusing area
QA department

TICKETING
Once the pattern pieces are cut by the cutting machine, they are then ticketed. Cut
components are group together as per their sizes and taken to the checking table.
Here the cut components are inspected for any error. It is very important to take care
that pieces cut from two different bolts of fabric are not mixed up. This is because
within lot there bolt to bolt variation in color shade.

FUSING
Fusing is also carried out in the cutting room itself. The parts to be fused are
separated from the bundle. The fusing material (like interlining) is cut according to
size of the component to be fused. The component along with the cut fusing material
are kept between to paper sheets and the pack is passed through the fusing
machine by means of temperature and pressure fusing takes place at particular
speed and for a particular time. The pack comes out at the other end on conveyors
and the pieces are removed and re-bundled.

CHECKING
32

The ticked panels are now sending to the checking are for inspection of every
individual pieces for any objectionable faults. Panels having faults like wrong grain
line, in appropriate size, incorrect shape and any fabric defects likes holes, cut ,
shade, variation etc. That are not within the acceptable quality parameters, are
removed from the cut lay. A cutting component checking report is filled for the total
quantity cut, checked and approvals. The rejected pieces are sent back and equal no
of trash panel are separately cut, replaced in the set and ticketed with the same no.
as the rejected once. Other mend able faults are marked with an alteration sticker
and passed on. These will be spotted out during garment finishing or washing .

BUNDLING
The checked components of one style and in one size are now clubbed and bundled
using tie. The size of bundle depends upon the requirements of the production plant.
Each bundle will contain pieces of same style and same size only. These pieces are
stored in racks made beneath the cutting table. The cutting department issues the
amount required by the production dept. as and when ask for. The cut component
may be issued in installment or all at once as the needs of the production dept.
against the job order.

PACKAGING
Packing is the LAST STAGE WHERE THE FINISHED GARMENT 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 labeling of the cartons is dictated by
buyers specifications. These instructions are standardized for a particular type of
garment and sent to the merchandiser in from of a packing manual. The
merchandiser forwards it to the packing in charge along with a top of production
sample i.e. packed with dimension approved by the buyer. This is kept as a visual
reference for the packers.

SEWING DEPARTMENT

33

The basic aim of an export house is to deliver value satisfaction of the customer at
the profit level.

Production is an act of producing i.e. quantity obtained by multiplying two quantities

to gather by making use available resources.

To deliver quality with the quantity the ratio between input resources or material &
output good and service is known as productivity are reciprocally related to each
other. Therefore an increase in production leads to fall in the cost per unit & rise in
profit.

The production department is spread in two floors, ground floor and first floor is for
jacket, blazer and basic garment. Both floors have common cutting dept. so all the
sizes of bundles are received from there only.

Production floor follows assembly line system. Following are steps to start a
production line.

To study the production file.

To study operation bulletin and set line accordingly.
Manpower operators, checkers, quality controller and helper.
Load and feeding line.
To arrange buffer or work in progress.
Manufacturing.
To make daily production and to achieve target accordingly.
To understand bottlenecks stage of production.

Working steps of production department:

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Shrinkage production pattern is issued to production floor from CAD dept.

Ready pattern are made as per the requirement of production room.

Cutting received from cutting dept.

Cross checking of cut panels with patterns.
Bundling of cut panels is done.
Operation wise feeding of cut angels into the line.
Inline checkpoint
Output of line
Final checkpoints.
Auditing of checked pieces.

Some important production points:

Ratio between worker and machinery

Bottleneck area to be considered
In most of machine, guide is there
They are using cartons to moving bundles
They generate report for broken needle
Complete assembly is divided in 6 parts, in end of every part there was a
record sheet, which show early target input, actual input, target output and
actual output, according to this can find out bottleneck area.

PRODUCTION CAN BE CARRIED OUT IN ONE WAY

1. ASSEMBLY LINE PRODUCTION SYSTEM:
In this production system a garment is being by no. of workers, therefore one
part is stitched by one worker and then passed on to other, due to which line
gets setup. In the end assembly of the parts is done, in modern industries
conveyor belts are used as a medium of transportation of garment part from
one worker to another. This system is very commonly used in industry as it
reduces the manufacturing cost increase the production.

WASHING

Garments pass through various handling processes, which may render them dirty
and stain, thereby reducing their aesthetic appeal. To restore this aesthetic value,
they are subjected to cleansing process like washing and dry cleaning. Garments are

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sent for washing by the production department as per the buyers requirement.
Normally the fabrics are not asked to go for wash by the buyer. Whether the fabric
department may internally sent it a number of other reasons.
1. To control uneven shrinkage
2. To remove bowing
3. To lighten colour shade
4. To improve hand
5. To even out colour shade variations
6. To remove printing smell
7. To execute a dyeing program

TYPE OF WASHING

1.
2.
3.
4.

Normal washes
Garment wash
Enzymes wash
Stone wash

5. Acid wash
6. Monkey wash
7. Emery balls wash
8. Silicon ball wash

METHOD OF DRYING
The choice for the method of dying depends upon the dimensional stability of the
fabric as predicted by the fabric sourcing dept. accordingly there can follow methods:

Tumble drying refer to the drying in a machine called tumbler.

Drip drying refers to drying the garment by directly hanging them after
washing i.e. without hydro. For this kind of drying the load is removing from
the washer just before the water begins to drain for the final spin cycle. The

garments are removing soaking and drip dried.

Line drying here, the garments after washing undergo for hydro and then
hang for drying.

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Flat drying refer to drying the garment by laying it flat on a surface. It is

usually carried out for highly unstable fabric material.

WASHING MACHINERY

Horizontal washing machine this machine is being used for washing

garments and fabric rolls. Normal wash, hard wash, enzyme wash, softener

wash, bleaching for dye, stripping are done in this machine.

Front loading washing machine this machine is used foe washing only. All
type of like normal wash, hard wash, enzyme wash can be done in this too.

Fabric lots are not washed in this machine.

Hydro the garment are wrung in these machine to remove excess water
after washing. The garments are spun in drums which rotate at high speed

squeezing the water out of them. This process takes about 3 min.
Tumble dryer this machine evaporates out all the left over water from the
garment making them completely dry. Tumbling is carried out for about half an
hour depending upon the fabric quality and temperature about 60c which
subsequently drops 35-40 c as the steam is exhausted.

FINISHING

After assembly, the garments now come for finishing a key stage of garment
manufacturing process. Finishing is done to prepare the final garment according
to the quality standards of the buyer before packing it for shipment.

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PROCESS FLOW OF FINISHING

GARMENT COMES FROM

PRODUCTION

WASHING

THREAD CUTTING

INTIAL CHECKING AND SPOTTING

ALTERATION

REIRONING

FINAL CHECKING

PRESENTATION/FINAL IRONING

MEASUREMENT

SENT FOR PACKING

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BASIC WORK FLOW

WASHING according to the buyers demand or as per the buyer specifies

recipes and the method to be employed.

Thread trimming pieces received from the washing department or from the
assembly line now come for thread trimming where trails of thread are cut off

from the seams, buttons etc. manually with the help of trimming scissor.
Spotting during the assembly, the garment may acquire stain and other
objectionable marks which must be removed. This is done either in washing
department or they are locally sported off. Objectionable stains like that of
chalk are spotted by means of spotting guns containing mild solvent. Harder
and stubborn stain (like that of tobacco, rust, dye, kerosene etc.) are sent to
the spotting room where they are cleansed under the spotting machine in a
protective environment. If the spots still dont go then they are sent for perc or

dry cleaning.
General checking now the garment comes for general checking relating to
overall stitching. Here, first the general visual appearance is studied which
includes shape of the garments; balancing of the parts; color variations etc.
then any seaming defects are recognized for example unmade seams,
missed stitches etc. as per requirement the checked pieces are send for
mending to assemble line. The production manager gives a top sample to

checkers as a visual aid.

Final thread cutting minute thread like those of labels, bar tack etc. are
trimmed off to give the neat look. Thread loosely sticking to the garments is
also shed off, both in and out by jerking the garment before it goes for

pressing.
Pressing pressing in general is shaping the assemble material with
pressure, with/ without heat and moisture, for further processing. In case of
knits, this is important but not as significant as in the case of woven because
of their property of excellent recovery and fit.

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Measurement and final checking this is the final and most stringent done
for garment measurement, appearance, labels, trim etc to study the final look
and shape the final look and shape of the product produced. Measurements
are done according to the specification sheets and recording are made for any
variations in the measurement chart. This gives an overall idea about the
quality of the garment being produced.

PACKAGING
Packing is the LAST STAGE WHERE THE FINISHED GARMENT 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 labeling of the cartons is dictated by
buyers specifications. These instructions are standardized for a particular type of
garment and sent to the merchandiser in from of a packing manual. The
merchandiser forwards it to the packing in charge along with a top of production
sample i.e. packed with dimension approved by the buyer. This is kept as a visual
reference for the packers.

PROCESS FLOW OF PACKING

GARMENT

COMES

FROM

INSPECTION

IT IS THEN FOLDED

1 OR 2 ARE PACKED TOGETHER

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ALL PIECES PUT IN TO CARTONS

DETAILS ARE PASTED ON CARTONS

CARTON IS SEALED

LODED INTO TRUCKS

SENT FOR SHIPMENT

ANNEXURE

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FINDINGS

A. The organization is well organized and systematic.

B. The merchandiser is the connection or the key player between all the
departments.
C. Every department has their key roles well defined, and the supervisors who
keep track of who is working on what in the department.
D. Cutting head, stitching head, finishing supervisors and other heads are the
main people with whom a merchandiser deals.
E. The cutting process of samples is coordinated with cutting department.
F. There exists a supervisor over every group of 14 tailors and a supervisor over
all the 2 stitching lines.
G. 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.
H. Embroidery work, pattern making by CAD, research and development are
done by B-59 Unit
I. Surplus fabric is stored in the A-49 unit
J. Surplus fabric is distributed to retailers for a fair sum of amount.

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SUGGESTIONS

a) Marketing Department should work more on the in house Brand ALCIS to

create more awareness about the product and in turn increasing the sales of
the merchandise.
b) They should work more effectively on the lean Management.
c) Work flow and material flow should be standardized.
d) Quality checking and alteration is not very satisfactory, they need to work on
it.
e) More care should be provided in operators safety.

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CONCLUSION
In review this internship has been an excellent and rewarding experience. I have
been able to meet and network with so many people that I am sure will be able to
help me with opportunities in the future.
One main thing that I have learned through this internship is time
management skills as well as self-motivation. When I first started I did not think that
I was going to be able to make myself sit in an office for eight hours a day, six days a
week. Once I realized what I had to do I organized my day and work so that I was
not overlapping or wasting my hours. I learned that I needed to be organized and
have questions ready for when it was the correct time to get feedback. From this
internship and time management I had to learn how to motivate myself through being
in the office for so many hours. I enjoy this line of work, I will continue to work hard in
my position and hope to continue to learn about the Garment export industry and
meet new people. This was an excellent experience and I hope that other interns
got as much out of it as I did.

I had the opportunity to learn about a great company. The workers are truly
passionate about the project and they passed on that passion to me.
A huge thanks to HR. Department and all the Staff of the Paragon Apparels.

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BIBILOGRAHY

a)
b)
c)
d)
e)

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http://www.Paragonapparels.co.in
http://www.textiletoday.com.bd/
http://www.fibre2fashion.com/
http://garmentsproduction.blogspot.in/
textilelearner.blogspot.com