Internship Report

MASOOD TEXTILE MILLS LIMITED FAISALABAD PAKISTAN

Apparel division, Faisalabad

Submitted By: Tabish Anwaar

Contact: +61412076336 Email: tabisha@hotmail.com

Submitted To: Mr. Qazi Mohammad Irfan

School of Business & Economics University of Management & Technology LAHORE Date of Submission: 1st February,2011.

Acknowledgement
The special thank goes to my helpful supervisor, Miss Humera. The supervision and support that she gave truly help the progression and smoothness of the internship program. The co-operation is much indeed appreciated. My grateful thanks also go to Mr. Imran (Manager Quality Control), Mr Saeed and his co-workers (Finance Department) and Mr. Nauman Khalid (HR Department) . A big contribution and hard worked from these people during the six week is very great indeed. All projects during the program would be nothing without the enthusiasm and imagination from these people. Besides, this internship program makes me realized the value of working together as a team and as a new experience in working environment, which challenges us every minute. Not forget, great appreciation go to the rest of MTMs staff that help me from time to time during the internship. The whole program really help me to motivate and understand the true value of working in groups and in an organization.

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Table of Contents
Organization (introduction)........................................................................................................................5 CEO MESSAGE.........................................................................................................................................................5 History Of Masood Group:.........................................................................................................................................7 Vision..........................................................................................................................................................................7 Mission Statement.......................................................................................................................................................7 Values..........................................................................................................................................................................8 Organizations Values:................................................................................................................................................8 Quality Policy:............................................................................................................................................................8 Awards .......................................................................................................................................................................9 Products/Services....................................................................................................................................14 Company Profile.......................................................................................................................................17 Major Departments...................................................................................................................................25 FINANCE DEPARTMENT.....................................................................................................................................26 STORE Department..................................................................................................................................................28 MARKETING DEPARTMENT ...............................................................................................................................30 Internal Analysis.......................................................................................................................................34 PPC DEPARTMENT ................................................................................................................................................36 PRODUCTION DEPARTMENT.............................................................................................................................38 QUALITY CONTROL DEPARTMENT.................................................................................................................44 QUALITY ASSURANCE DEPARTMENT............................................................................................................44 IT DEPARTMENT...................................................................................................................................................46 HR DEPARTMENT .................................................................................................................................................47 SUGGESTIONS.........................................................................................................................................50 REFERENCES...........................................................................................................................................51

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Executive Summary

This is a report on my internship at Masood Textile mills apparel division Faisalabad, from 20/07/2010 to 06/09/2010 (6 week), as part of my graduation requirements for the Bachelor In Business Administration (BBA-Honors) at University of Management And Technology, Lahore.

During the internship at MTM I have been assigned at all the major departments working in the mill for about one week at each department to gain the working pattern and style of each department. I observed that each department is limited to its own rules and regulations and is working collectively with other departments to achieve organization mission.

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Organization (introduction)
CEO MESSAGE
Welcome to MTM, Masood operates throughout the world with over 16,000 employees as part of our team. MTM Collection has a wide selection of quality garments including T-shirt, Polo shirt, Jogging suit, Henley shirt, Raglan shirt, Tank top , Bikini, Shorts, Pants and Sleepwear. Competent professional staff, a team of talented merchandisers, excellent supplies & support services, and state-of-the-art technology is the driving force behind MTM phenomenal growth in the past years. MTM has expanded its operations to include the Internet, and has taken advantage of the variety of international trade facilitated by the Web. Now MTM uses state-of-the-art client/server
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technology for its market information processes to coordinate its network of global buyers and agents around the world.

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History Of Masood Group:

Kohistan Bus Services Spinning Garments

1973 1984 1995 1994 1994 1994

Masood Textile Mills

Industrial Co-Operative Bank Rabia Trust Hospital KakaKhel Ghee Mills

Vision
To Be The worlds Best Apparel Company Our vision is of continual improvement and sustained growth, and of a family of workers. Who are given the best compensation benefits and working conditions in the region, in this respect, mTm continues to emphasize the need to invest in and develop its most precious resource - its human capital. mTm continues to provide training courses and self-enhancement opportunities for all our workers".

Mission Statement
We value quality in our products and in our relationships with customers and suppliers. We consider our employees our more critical resource.

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Values
Respect for the individual, integrity, speed, simplicity, self-assuredness, and a 100% commitment. Our values are non-negotiable; they are never to be jettisoned. For us, our values are our well-spring

To provide market leadership and brand coverage To pursue technological innovation To partner with operators for their maximum productivity

To provide virtuous to our customers, employees, communities, and the environment

Organizations Values:
Trust Integrity Respect

Quality Policy:
Customers satisfaction Zero Defects TQM. (Total Quality Management)

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Awards
Faisalabad Chamber Of Commerce Posted on 21-Oct-09

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JCPenney Purchasing Partnership Award 2007

Posted on 05-June-08

JC Penney has awarded MTM Purchasing Partnership Award 2007. Fruit of the Loom (FTL) Posted on 01-April-08

FTL has awarded MTM. FTL Accuracy of Information and Compliance Supplier award Posted on 12-April-06 (2006)

FTL has awarded MTM "Accuracy of Information and Compliance Supplier Award ".

JCPenney Purchasing Partnership Posted on 12-April-06 Award (2004 , 2006)

JCPenney has awarded MTM "Purchasing Partnership Award". UBL - UBL Award Posted on 12-April-07
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UBL has awarded MTM WRAP - Worldwide Responsible Apparel Production.(2007) Posted on 12-April-07

MTM is certified by the WRAP Certification Board. Divisonal Quality Award 2005 Posted on 25-May-06

JCPenney has awarded MTM "Divisonal Quality Award".

WRAP - Worldwide Responsible Apparel Posted on 25-May-06 Production.(2004,2005,2006)

MTM is certified by the WRAP Certification Board. Quality Control Award 2005 Posted on 21-May-06

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Fruit of the Loom has awarded MTM"Quality Control Award 2005". Operational 2002 Excellence Award for Posted on 23-Jul-03

JCPenney has awarded MTM "Operational Excellence Award for 2002". Best Quality Award 2002 Posted on 30-Apr-03

JCPenney has awarded MTM "Best Quality Award for 2002" Certificate.

"Quality Certificate

Recognition

2001-2002" Posted on 30-Nov-02

Russell Corporation has awarded MTM "Global Quality Recognition 20012002"Certificate.

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"The Best Supplier of Region 2001Posted on 17-Jul-02 2002"

JCPenney Awards MTM"The best supplier of the region award 2001-2002". The ceremony was held in Singapore on 17th July 2002. Shahid Nazir (C.E.O.) received this award.

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Products/Services
Masood Textile Mills Limited was established in 1984 by Ch. Nazir Ahmad, which is located at 32 km Sheikhupura Road Faisalabad. While Apparel division is located in Faisalabad at Sargodha Road near Sangeet cinema, which is producing best quality garments. The preference is given on the quality not quantity. Thats why companys sale is increasing every year. The company has shown distinguish achievements during many previous years. Masood Textile Mills have own in-house Knitting Spinning Dyeing Processing Laundry Manufacturing facilities Masood Textile Mills has also proud of work with world best Labels like:

Saralee (Polo Ralph Lauren, Champion, Hanes) JC Penney (Stafford, Arizona, St. Johns Bay) War Naco (Chaps Ralph Lauren, Calvin Klein) Indus (Vantage, Champs, Tom Tailer) Tommy Hil Figer Fruit of the Loom Vanity fair (Lee, Wrangler) Perry Ellis Levis Dockers Integrity Duckhead Wal-Mart

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Most of the products are exported to US. UK. & Germany. Different departments of MTM are equipped with modern technology imported from Switzer Land, Germany, England, and Japan to achieve the required quality. Masood has research and development laboratory for spinning process where cotton and yarn is tested and inspected according to international standards. mTm has obtained ISO 9002 certificate, which proved its quality and consistency, mTm has 20,000,000 ordinary shares of Rs. 10 each fully paid up in cash. mTm has extension in his operations by adding new equipment and machinery in near past. Automatic cone winding machines enhanced the production capacity of yarn from 210 bags to 400 bags. To enhance the efficiency and quality some investment is made in other machines. This would be very beneficial for the company in the upcoming trade challenges.

MTM Spinning is capable of producing more than 35,000 lbs of Combed & Carded ring spun yarn from 6/s to 40/s count. Spinning is equipped with state of the art machines from Japan, UK and Switzerland. MTM yarn is famous for its consistent quality because of stringent QC system and most modern lab equipments.

One of the largest Fabric facility in Pakistan having the capability to produce all kinds of knitted fabrics in 100% cotton & blends.
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Single knit Single Jersey Pique Fleece Double knit 1x1 Rib Variegated Rib

Flat knit

Collar & Cuffs Flat Knit Panels

Strippers Feed Striper Auto Striper Engineered Striper Jacquards

Textures Herring Bones Pique Jersey

Mini Jacquard Thermals

Interlock

Waffles

mTm is a leading apparel company in Pakistan having expertise & machinery capable of transforming customer ideas into superior quality garments, which are taken as the most famous brands in the world.

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Company Profile
Key Personals
Chief Executive Officer:
Directors:

Ch. Shahid Nazir

Mr. Naseer Ahmed Shah Mr. Matloob Hussain Mr. Muhammad Arshad Mr. Muhammad Ali Sohail Mr. Fazal Ahmed Mr. Muhammad Nawaz Tishna

Management: Finance Manager IT Manager Finance Manager Sen. Manager PPC Manager HRM Purchase Manager Technical Manager Muhammad Binyamin Imran Waheed Babar Muhammad Ishfaq Muhammed Imitiaz Nasir Ali Zia Mr. Muhammad Ismail Mr. Ashiq Shahzad
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Manager of Accounts Zafar Iqbal

Production Manager Production Manager

Mr. Muhammad Arif Mr. Muhammad Naveed Mr. Tanveer A Khan Mr. Anwar lattif Mr. Shahzad Nadeem Mr. Mehmood Elahi

Merchandising Manager Merchandising Manager Merchandising Manager Merchandising Manager Production Manager Production Manager Cutting Manager

Mr. Adnan Ghaffar Mr. Zahid Mehmood Mr. Usman Massod

Compliance Manager Mr. Nasir Mehmood

Growth History:
Largest Knitwear Exporting Company of the country for the Year 2005 Turn Over in Millions

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Employment Generated
Employees in Number
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Corporate Objectives:
Maximizing the wealth of shareholders To increase the market share. To achieve the customer satisfaction. Making arrangements toward achieving total quality standards. To get growth through professional Management. To reduce the cost of production up to minimum level. To continue to improve past achievements. To lead the local manufacturers.

Employees:
Permanent Employees: Mills 4800
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Garments Total employees

6000 10800

Piece Rate Workers: Mills 500 Garments Total employees Grand Total:

4700 5200 16000

Masood Structure
Management:
G - 1- 4 M-1 M-2 M-3 M-4 M-5 M-6 General Manager Senior Manager Manager Deputy Manager Assistant Manager Unit Manager / Senior Officer Officer

Non- Management:
S1 S2 S3 S4 Assistant Officer / Supervisor Skilled Worker Semi Skilled Worker Unskilled Worker

BACK TRACK SYSTEM

Masood Textile Mills is the only textile mill in Pakistan with latest computerized Barcode System that assures quality in every operation of production from spinning to packing. Products of each department carry bar coded stickers, which bear all the details and history of the operations of that product. Hence

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if any problem is reported, one can trace back the root of the problem and enable to prevent occurrence of the same in future.

VERTICALLY INTEGRATED OPERATIONS

Besides, MTM is one of the few fully vertical textile mills in Pakistan having inhouse Yarn, Knitting, Fabric dyeing, Processing, Laundry and Apparel Manufacturing facilities. The vertically integrated operations help us in achieving shorter lead times and greater flexibility to cater to the customers demand.

CUSTOMER PROFILE
MTM is proud to work with the worlds best labels. This exposure to the brand labels has been a continuous learning experience for the entire team. Currently, 85% of production is exported to the U.S. while rest 15% to Europe.

STITCHING DIVERSITY
With over 1,749 stitching machines, MTM is producing about 120,000 dozens per month of fashion garments like Polo, Rugby and Henley shirts along with basic garments like Crew Neck Tee, Sweat shirt, Boxer shorts and Bikinis. MTM has in-house Embroidery facility equipped with Tajima machines.

EXPERIENCED PROFESSIONAL MANAGEMENT

The MTM Team comprises a balanced blend of experienced professionals including over 200 MBAs, Textile Engineers and Industrial Engineers. Continuous training and development keeps them abreast with modern technical and management tools. MTM is WRAP certified and ISO 9002 certified as well.

AGGRESSIVE R&D FACILITY

A very aggressive and creative R&D department is always busy in exploring innovative product development enabling MTM to be ahead of many in the
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field. Our keen, extensive and aggressive Merchandising team comprising experienced and trained MBAs functions with the core objective of rendering ultimate customer satisfaction through product development and smooth execution of orders. They are capable and keen to meet an average 3~4 days lead time for proto samples.

SOCIAL & ENVIRONMENTAL RESPONSIBILITIES

MTM, as a corporate citizen, recognizes and believes in fulfilling its responsibility towards the society and the environment. An effluent treatment plant is in the phase of completion. The compliance standards of international community are fully implemented and ensured at all times.

Apparel Division:
Established in 1995 to enter into value added field. Now it has 26 Production Units with 2500 Stitching Machines. Each and every operation has been linked with back track system. An independent Quality Assurance team exists to ensure the quality of the garments. Garments Production Procedure (Cutting, stitching, clipping, finishing & packing) Total production is 2.5 3.0 Million per Month of garments like Tops, bottoms, Inner and outerwear. In house embroidery facility having to Tajima machines as well. 95% of production is exported to US and 5% export to Europe.

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Back Track System:

Each Garment produced at Masood has a unique ID No. Latest Computerized Bar Code system ensures quality in every operation of production from cutting to Packing. Products at each operation carry Bar_ Code Stickers that bear all the details and history of the operations on that product. Hence if any problem occurs, one can trace back the root cause of problem to prevent its occurrence in future.

Vertical Operations:
Spinning Knitting Fabric dying Processing Cutting Laundry Stitching Finishing Packing

Apparel Division

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Major Departments
Operations
o o o o o o Production PPC I.E. Cutting Quality Control Commercial

Services
o o o o o o HR & Admin IT. Compliance Security Purchases Quality Assurance

Marketing
o o o o Merchandising Prod. Dev. Forwarding Procurement

Finance
o Accounts o Inventory

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FINANCE DEPARTMENT
The Finance Department at Apparel Division is mainly dealing with Daily & Final Accounts, Inventory and Cash of the Firm not with allocating or investing spare funds of the firm as such finance means.

MAIN WORKING:
According to working of the Finance Department, it is divided into two teams. There are four Divisions under Apparel Division,

Apparel I Apparel III

TEAM 1

Apparel II Apparel IV

TEAM 2

Other sites are controlled from Main Garment, on each site there is one person allocated to handle all the matters on site related to Finance Department and they are reporting to their immediate in charge at Main Garment. The persons at Main Garment are reportable to Head Office for their working on data received from different sites.

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WORKING AT SITE:
The different types of Duties are performed by an accountant at sites are given below: Verify the Monthly Stock Taking Reports Checking Over time Detail sheet & Payment sheets Checking Security staff Over Time Checking of New Appointment, Missing Days, Reinstate, Arrears Bills Checking of Daily Wages Bills Checking of Final Dues Checking Leave Encashment Checking Contract Wages sheets (Twice in a Month) Checking Incentive Payment sheets (Twice in a Month) Checking of Extra Payment sheets All kind of Gate passes Receive Reconcile Maintain & send to Head Office. Verification of Vouchers on Daily Basis & Prepare Expense Detail Summary Prepare & Verify the Utility Bills (Electric, Telephone, Sui Gas) Verify the Monthly Vouchers of Contract Vehicle, Photocopier, Subsidiaries Verify the Fuel & Maintenance Bills, Mobile Bills. Prepare the Assets Detail Time to Time. Prepare the Over Head Detail & Salary Comparison. Maintain of All kind of Record in Files for Audit. Checking of Final Settlements. Verification of GRNs Note: Any Other Assignment as per Department Requirement

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Cash Department
Cash department is also under the Finance Department and take cash from Head Office on demand as per sheets of different payments are reached after signing of the Director Operations. Like as, Contractual Payments Sheets (Twice in a Month) Salary Sheets Daily Wages Sheets Over Time Attendance Reward

STORE Department
The Inventory or Store Department is also under the Finance Department. There are different types of stores given below: - Main Store (General Items) Accessories Store Fabric Stores Shipment Store Leftover & Rejection Store The detail of important stores are given below: -

Fabric Store

Accessories Store

Shipping Store

Apparel Division (Stores) Fabric Store:

PO wise fabric comes from the mills for Garments, according to the purchase order. Fabrics issued towards cutting depart on behalf of requisition.

Accessories Store:
Accessories store provided the following things on the requirement of different department like as, Thread, Labels, buttons, etc

Shipping Store:
After completing the Garments for the export purpose is sent to the shipping store.
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Leftover & Rejection Store: All the waste and rejected pieces are sent to this store. mTm has strong inventory management system (IMS). IMS is divided in to two sections: i) General: All the things not directly related to the production but are necessary or supporting to the production. i.e. Mobiles, computers, stationary, Air Conditioners, Electric Generators, Furniture and Fixture etc. ii) Accessories: All the things that are related to the production and are directly used in producing the finished products are kept in accessories division i.e. Buttons, stitching thread, inlay cards, labels, poly bags etc.

Working of Store: The working at store consists of following three divisions: i) Counting: When mTm purchase anything from the market the buyer often delivered it to one of the two main stores i.e. Apperal-II and Creasent. After checking of security the Inword Gate Pass (IGP) is prepared and is forwarded to the counting section and then to the quality section if the purchased material is imported, if the purchased material is local than it is forward to the counting section 1st and then to the quality sections. mTm has a contract with Riaz & Co. for counting purpose. So the team of Riaz & Co is available for counting at their main stores. They check the IGP and verify the quantity of that good physically either general or accessory. After checking the quantity of that good they forward that thing to the quality section who make sure that the good is up to the quality standard of order. Quality: Quality section is responsible for the quality of the goods purchased. If the good relates to general division than the person who has ordered it verify the quality of that good and if the good relate to accessory division mTm has its own quality assurance team who check the quality of that good very carefully. If the quality of the good is not found up to the mark than the good is rejected.
ii)
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If the quality of the good is up to the mark than it is forward to the store for stocking. Store: Store is responsible for stocking the goods and accessories and issue the demand if made by any person or any other store of different divisions of mTm. It is a complete system to stock and manage all the accessories. After receiving the GRN from the quality or quantity section the staff of store verifies quantity of that good once again physically. If the quantity of the accessory found complete they stock it in specific rack and record it. When the demand is made by that particular accessory they can easily find that particular accessory by tracing the rack no from the system.
iii)

MARKETING DEPARTMENT
Marketing Department cannot be ignored in any organization. Because it is the heart & soul of the organizations. MTM cannot ignore the pivotal importance of this department. The marketing manager with the Chief Executive officer performed the marketing activities jointly. They not only promote their department but also visit the foreign markets to search their new customers.

Activities of Marketing Manager: Look overall problems of the departments and the problems faced by the customers. Devises all the marketing related policies. Delights the customers by solving their problems. Co-ordinates with the merchandising department. Checks and observes all the activities of textile sectors especially keeping focus on the competitors activities.

The marketing department with the help of merchandising department makes it possible that the order place by the customers should be completed within specified time. MTM sell the product with the brand name of the customers.
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Marketing Mix:
Product Mix: Products of Masood Textile Mills are yarn, fabrics, loungewear, activewear, sleep wear, athletic, sportswear, underwear. MTM exports whole of its products to US, Germany and various other countries. Major portion of yarn are used in manufacturing process and surplus is exported. Fabric: It is divided into two types a) Gray- Fabric b) Other Fabric

Garments:

Trousers T-Shirts Hooded Shirts Sweat Shirt Zip Shirt Open Front Shirt Dress Shirt Under Garments Shorts Golf Shirts Base ball Shirt Tennis Shirt

Pricing:
A little can be said about the pricing strategies of Masood Textile Mills. Basically any kind of strategy is composed of two variables. 1. Fixed cost 2. Variable cost MTM is adopting much kind of strategies; as for price setting is concern these are different, if the company export directly or in other case indirectly its products. As for as the direct export is concern the price is settled as follow
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Fixed cost+ Variable cost+ % of profit In case, the company export indirectly the price will be settled as follow. Fixed cost+ Variable cost+ Middleman commission+ % of profit But usually MTM sets its products prices through negotiation with its buyers. And normally MTM Charges very high prices due to its commitment with high quantity.

Physical Distribution:
MTM exports its products through two different marketing channels. a) Direct Marketing Channels: MTM directly contact with its customers through mail, telephone, and personal contacts and sell its products directly to the ultimately buyers. b) Indirect Marketing Channels: When it comes to indirect marketing channel, distribution is made through intermediaries. MTM exports its products through many agents in some cases. MTM is using different channels of transportation for the distribution of its products like, ships, trucks etc. Countries of Export: MTM is making a good effort to increase the market share. Today company is exporting its products to many countries like, o USA. o Hong Kong o Japan o Germany o Malaysia o Singapore o Korea o Thailand

Promotional Activities:
Major export of mTm is made through tele-mail services. Many contracts are settled through personal sitting. mTm do not waste any chance to promote its

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product. mTm participate in various exhibitions that take place under export promotion bureau in different areas of the worlds. mTm also take part in world trade show for promoting its products. It also sends many samples to its potential customers. Promotion is one of the four major important elements. The main promotion tools are advertising and other country business relationship. The MTM should advertise its products not only in the worlds trade magazine also in national industry magazine. The company has to decide how to set the promotion budget. The appropriate budget approach is to send the company can afford with respect to its funds and product.

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Situation Analysis

Internal Analysis

External Analysis

Opportunities Weaknesses Strength

Internal

S W O T

External

Situation Analysis:
Mangers of MTM always review the mission and goals then they can do the internal and external environment analysis to identify elements that influence the organization performance. To determine such elements SWOT analysis is conducted. SWOT analysis is the method that helps manager identifies the organizational strength, weaknesses, opportunities and threats.

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Internal Analysis:
Strengths: Modern Textile Machinery & equipment Acquisition of ISO 9002 certificate Proven Management Product Innovation abilities Good competitive Skills Complete Back Track facility Equipped with WRAP certification

Weaknesses: Centralized Managerial Decision Making High Cost of Production Small International Market Share High Reproduction Cost High Wastage Cost

External Analysis:
Opportunities: Threats: Entry of new textile competitors Rising cost of production Adverse Govt. policies Easy access of buyers in the world market Political stability Economy is not up to market Difficult upcoming challenges of free trades.
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Entering new markets Addition of new product line Faster market growth Acquiring the benefit of free trade

PPC DEPARTMENT
It is obvious from the name of the department that this department is meant for production, planning & controlling of production towards the right direction in and effective and efficient manner in given period. PPC department has been subdivided into three divisions, Planning Control Yarn The actual customer of mTm mills division is the mTm apparel division. The whole process in mTm mills is initiated with the placement of PO from Apparel to Mills division. The PO is first placed in PPC department from where it is fed in the FMS (Fabric Management System). Now this PO is available to all concerned department in Mills. Here is the flow of PO in Mills.

PO Dye

PPC

R&D Finishing

Knitting Dispatching

PPC is involved at each level of PO in Mills. The three divisions of PPC work as follows;

Planning:
This division plans the whole Po with order specifications, work schedule, time line for knitting, dyeing (Lot Making), finishing and up till dispatching of fabric to customer (Apparel Division).

Control:
This division actually looks after the PO time line execution for in time production and dispatching to customer. Many people name this division as Peechay Peechay Challo (PPC) due to its involvement in PO.

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Yarn:
This division makes the availability of yarn in time before knitting gets started. The procedure followed for yarn procurement is as follows,

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PRODUCTION DEPARTMENT
Production Department (Flow of Garments)
Fabric Cutting Induction Stitching Finishing Packing

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Fabric:
A material made from fibers or threads by spinning, weavings, knitting, processingetc as any cloth. There are different types of fabrics.

Types of Fabric:
1) Jersey Single Jersey Heavy Jersey Bird eye Jersey Striper Jersey Lycra Jersey Sueded Jersey Printed Jersey 2) 3) 4) 5) 6)

Pique Pique Locast POP Corn Pique Honey Combed Pique Mesh Pique Inter Lock Simple interlock Sueded interlock Rib Rib 1*1 Rib 2*2 Rib 11*1 Rib 15*1 Fleece Fleece Sueded Fleece Terry Brushed Terry French Terry Baby Terry

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Cutting:
PPC department (Production, planning and control) issues requisition to cutting department. Cutting department receive requisition and issues fabric in the store. Fabric come to the cutting department and issued any group (lines 1,2,3 and 4) Cutting auditor check ply to ply shade and cut out continuity and make mock up for approval shade of ply to ply and trims approval of shade group person receive job card and issue of marker to GGT department (Garber Garments Technology), and spread the lay of fabric. Fabric cutting auditor check marker species and spread the marker and shape of lay and group members shape of lay in the bundle and bundles record in the job card and lot is issue to 100% inspection auditor lot is inspection 100% and all ok pieces, issued to induction and reject pieces separate to the bundles.

Induction:
After cutting department fabric comes in induction department. Where pcs are arranged in sizes, colors etc, Po (Purchase Order) wise. etc. Induction department is the responsible of the quantities, maintain, balance of receiving from the cutting department. Others responsibly of the induction department is issues the particular quantities to stitching department for furthers operations.

Stitching:
In this department, stitch the garments in the different operations like as Operations: EMB / Pockets Placket Collar/ Collar Closing / Labels Shoulder (Left) Arm Hole (Left) Sleeve Hem (Left) Side Seam (Left) Side vent (Left) Care Label Placement Bottom Hem Side vent (right) Side Seam (right) Sleeve Hem (right)
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Arm Hole (right) Shoulder (right)

Machines available for stitching Department. Basically two types of machines are used 1. Over Lock 2. Flat Lock

Over Lock

Single Needle 2 Threads

Single Needle 3 Threads

Double Needle 4 Threads

Double Needle Puller

Elastic Attach Bikini

Flat Lock

Cylinder Bed 5 Threads

Mini Cylinder 5 Threads

Flat Seaming 5&6 Threads

Feedo

Flat Bed

4 Needles 6 Threads

Body Hem 5 Thread s

Flat Bed Puller Attach Elastic Attach

Multi Needles (6T, 4N) Manual

Feed of the Arm (inseam + Flat seam)

Tap Attach Cutter

Auto Trimmer

Lock Stitch
Single Needle 2 Threads
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Others
41

Needle

Zig - Zag

Bartake

Button Hole

2 Threads

Button Attach

Lock Stitch

Others

Single Needle 2 Threads

Double Needle 4 Threads

Zig - Zag 2 Threads

Bartake

Button Hole

Button Attach

Finishing:
The process of making the garment ready for shipment Or Inspection of Garment / Final Enhancing Details Fabric Faults: There are two types 1. Yarn faults 2. Machine faults Other Faults: Here are some o o o o o o o o o o

faults that occur due to both above-mentioned categories. Oil spots Heavy yarn Lint hole Thin yarn Tuck stitch Knot Hole Drop Run Down Broken Needle Tape Down / Tape off of Wheel Winding Hole Caused by Broken Needle

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Packing:
Packing is the process by which garments dispatched for the shipment on the requirement of buyers. Types of packing: There are two major types 1. Solid packing 2. Assorted packing Solid packing: In which packing, organization used the same size and colors of garments in one poly bag. Assorted packing: In which packing, organization not used the same size and colors of garments in one poly bag. Packing instruction: Packing instruction is provided from the buyer requirement. The following instructions are below o Colors o Size o Fold size o Insert board o Upc sticker o Pcs/pack o Poly bag o Master poly bags o Pcs/carton o Size sticker o Baler bag sticker o Carton sticker o Magic tape solo tape

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QUALITY CONTROL DEPARTMENT

Quality may be defined as the set and required parameters by the customers. It is quite difficult task to fulfill the customer requirements. To assure this thing MTM has two departments; A. Quality control departments B. Quality assurance departments QUALITY CONTROL DEPARTMENTS This is the department, which can be said as an agent from mTm side, which checks the required parameters and recommends solution at each level of process. It has two sections, i) Grey section: Which checks the fabrics for faults, attaches bar cods and clearance. ii) Inline section: Which checks the finished and dyed fabric for faults according to 20 point system?

QUALITY ASSURANCE DEPARTMENT

This department can be said as agent from customer side, which audits the QC checked fabric and give positive or negative opinion whether the fabric is according to customer requirements or not. This department does not suggest any thing.

Responsibilities of Quality Assurance Department

1. Indulge and Monitoring Quality System The QA department is required to induce the QC department implement standard quality system required by buyers to improve and maintain very good OQL.

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The implemented quality system should monitor on a daily basis .So that the system runs with out any failure. Under no circumstances the systems should be changed or stopped. The quality system should be very strong so that nothing could penetrate through and result in failure of audit or re-screening. 2. Training and Evaluating Quality Staff. It is the responsibility of the senior staff to train all the QA staff to achieve skilled levels within a short frame of time The QA department to coordination with the production department and QC department should train the QC team to achieve skilled levels. A training program should be designed which will enable to execute simple and proper training to enhance skill levels of QC and QA staff up to standards. The QA department will evaluate all the inline and final quality inspectors on their performance. The evaluation will be based on the overall quality level less than 4% for any merit are reward system.

3. Training and Evaluating Quality Staff QA will performance audits at cutting stage to assure the cut products to confirm required quality standards. The inline QA supervisor or QA auditor will perform random audits to assurance stitching quality of products. The objective will be to inspect and identify the problems and give Corrective action to the root cause of the problem, with a view of preventing re-occurrence of the problems. The final QA officers and concentrating more on the presentation of the final product. The final auditors will conduct finished goods before packing with the same objectives and concentrating more on the presentation of final product.

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The final auditors will also conduct packing audit to insure the quality, ratio, color, cartooning, packing accuracy, presentation, and packing accessories.

LAB IN PROCESSING:
To assist both of these departments, there is a lab in mTm. The different kinds of test are applied according to the requirements of QC or QA in the lab.

IT DEPARTMENT
mTm is at almost pure Dot Com positions and we can say that IT has been so much flourished in mTm that it will be difficult to survive for mTm without IT at this time. Near about all the departments have been computerized in mTm. IT department has developed ocracle base system for performing different tasks according to the requirement of any department. Each and every computer is the part of the intranet of the mTm. Any employee can share the information from any site or location of mTm. If computer of any employee get defected he/she call to the IT department and IT after asking the IP of that particular computer take access and they repair it sitting many miles away. There is no need to take the computer physically to the IT department. IT has the complete access of any system in the network of mTm. The staff of IT is also responsible for monitoring the computers of employees so that they can be checked either they are working or not or doing any disallowed task at their computers. IT department is also responsible for scanning the barcodes of the workers according to which system automatically makes their wages sheet and overtime sheets. In this way no worker can claim more salary than he / she deserve. Moreover IT department has developed many oracle based system. The system developed by the IT department includes HRMS GMS FMS VMS AMS IMS Human Resource Management System Gate Management System Fabric Management System Vehicle Management System Apparel Management System Inventory Management System
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FAMS OTMS WMS EMS OPD ACS

Financial Accounting Management System Overtime Management System Waste and Leftover Management System Employee Management System Organizational Planning and Development Apparel Accounting System

Now IT department is developing software named ERP (Enterprise Resource Planning) And they are planning now for the following systems at the urgent bases, JMS JOB BANK AIS Job Management System For online Job Application Accounting Information System

HR DEPARTMENT
HR Department in mTm is involved in different types of human Resources development activities.

Activities of HR Department: Here are the activities of HR department in mTm, i. Recruitment ii. Training and Development iii. Compensation iv. Performance Appraisal v. Employee Welfare vi. Rewards and Punishments vii.Retiring and termination Benefits

Recruitment
HR department in mTm regarding recruitment is almost online up to the middle level management and has the following procedure; Approved strength in each department Invitation of vacant or new positions Applications
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Scrutinizing of Applications Test including intelligence and aptitude tests Interviews in panel form

Training and Development

The training and development process in mTm is very strong and has following steps Indoor Training Apprentices Trainee supervisors Trainee operators Trainee Engineers Management Trainees Trainee Officers Outdoor Training Training in Institutions Meetings and interviews

Compensation: mTm has set up for workers as Market Rates Overtime Incentives Vehicles Accommodation

Rewards and Punishment: mTm gives in terms of rewards Appreciation

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 Cash Prizes Promotions In mTm for the control purpose there are also punishments Disciplinary Actions Show Cause Notice Suspension Termination Charge Sheet Fines

Performance Appraisals: Promotions in mTm have very fair methodology. Personality and job related traits are evaluated at regular basis. Best performance results in good rewards in mTm.

Employee Welfare: There are many employee benefits policies being followed in mTm. Some of them are follows, Health Insurance Social Security 5% of profit Accommodation Transportation Canteen and Mess Leave Encashment

Retiring and Termination

Gratuity and provident fund is being maintained for the retiring personals in mTm.

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SUGGESTIONS
The mTm is losing its benefits in lower raw material prices, while energy cost and credit cost have increased considerably. There is a need to check the trend of further increases both by policy, support by the Government and it self. The major challenges are to enhance the competitiveness of the mill, which have been created on account of internal weaknesses to improve quality productivity and production efficiency to be desired levels. The suggestions that particularly relate to the mTm are as followings; Allocating a specific budget should enhance the promotional activities of mTm. The company should control the financial charges especially commission to the agents should be controlled. The cost of production of company should be controlled. The utilizing the plant capacity in full can reduce fixed cost. The sale of company should increase by searching new markets. New product lines in fashion design and style should be launched. Political stability consistent Government policy and Government that remains for its tenure. Lowering of energy costs to allow the industry to become more competitive. To create an environment that attracts and supports foreign investments including joint venture.

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REFERENCES
o o o o o o o Mr. Shahid Naveed (DGM Finance Apparel Division-II) Mr. Ishfaq Ahmed (Sr. Manager Finance Apparel Division-II) Mr. Muhammad Aftab (Deputy Manager Finance Apparel Division-II) Mr. Muhammad Anees (Assistant Manager Finance Apparel Division-II) Mr. Muhammad Rashid (Accountant Finance at Saeed Colony in Finance Section) Mr. Muhammad Tariq (Accountant, Finance Apparel Division-II) Mr. Muhammad Aasif (Accountant, Finance Apparel Division-II)

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