BY :-

ANUJ KUMAR
M.FTECH
(A.P.)
 Arvind Ltd. - A flagship company of a
diversified $550 million Lalbhai group
founded in 1908
 Lalbhai Group Businesses are:
› Textiles & Clothing's (Core Business)
 Manufacturing ( Arvind Ltd., Lifestyle Fabrics & Apparels)
Retail (Megamart Retails)
› Financial Services (Anagram Sec. Ltd.)
› Engineering (Anup Engg. Ltd.)
› Chemicals & Dyes (Atul Ltd., Anil Starch Products Ltd.)
› Telecom & Electronics (Arvind Telecom)
 DENIM SHIRTINGS SHIRTS KNITS KNITS

Production
1987 1999-00 2000-01 1999-00 1999-00
commenced

Yarn & Yarn &

Products Garment Fabric Garment
fabric fabric

4.8 M 7200 tons

Capacity 120 mmpa. 30 mmpa shirts 12.0 M pcs
pa

Amber,
Plant location Naroda Santej Bangalore Santej Vadsar &
EmBee

GAP, GAP, M&S, M&S,

Major end GAP, BR, M&S Tommy, Hanes,
Levi’s, Hanes,
user brands Lee, JC M&S, Wal- Reebok, Reebok,
Penney Mart Indian Adidas
Retailer
KNITS BUSINESS
DIVISION
Santej Road, Near Khatrej, Taluka Kalol,
Dist Gandhinagar Gujarat – 382721. India
Tel: +91-2764-281100/22
Fax: +91-2764-281060
Contact Person : Praney Mehta
e-mail : praney.mehta@arvind.in

Life Style Apparels -

Knitwear
 Sportswear,
 Graphic Tees,
 Casual Tees,
 Cut & Sew Tees,
 Golf Polo shirts,
 Lounge Wear
 Casual Polo shirts,
 Rugby shirts,
 Joggers ... & many
more.
 MERCHANDISER MERCHANDISER
BUYER
Trims and accessories are decided queries for date of fabric
availability
Briefing sheet
specifies color, trims, After approval material order form
is prepared Forwarded to sewing floor
sewing trims, buttons,
to get dispatch date
embroidery etc.
KNP is released

BUYER
MERCHANDISING SAMPLING
DEPT Confirms date
Contract seal prepared which
Development specifies exact construction of the Order is placed
(3 – 4 weeks) product

MERCHANDISER
MERCHANDISER
yarn requisition is
BUYER Garment Order processing form raised
Review & order Fabric technical hanger along At the same time the
placement with fabric swatch sent to buyer trims order is also
for approval placed
Receive sample Receive
Verify material / Request trims
request and materials from
requisition from store
material marketing

Internal audit
In case of
rejection from
Forward sample
Receive patterns Prepares samples marketing
to marketing
Remake
sample from first
step

Receives buyers If sample

feedback with approved Hand over
comments from proceed, else approved sample
marketing repeat process
TYPES OF SAMPLES
◘ PROTO SAMPLE
First sample meant for look, actual fabric & trims not
required, could be revised as per buyers requirement
◘ FIT SAMPLE (BASE SIZE)
For exact construction & measurement, can be alternate
fabric, one sample of each color in medium size
◘ SIZE SET SAMPLE
Critical stage, decides order confirmation, two samples each
in color and size, one for buyer and one for department
◘ PRE PRODUCTION SAMPLE (PPS) / CONTRACT SEAL /
GOLD SEAL
meant for internal assessment,, 2-3 set in all color & sizes are
sent to buyer
◘ RACK SAMPLE
a random sample taken from the production line
PLANNING AND IMPROVEMENT CONTROL

Developing line plans Buyer specific floor merchants

Operation breakdown
GSD study Sends GOPF to all departments
Set target for each line
Communicate daily KNP progress
Daily feeding plan forwarded to sewing with buyer’s merchant
floor
Responsible for timely shipment
Device methods for improving
productivity
TYPES OF GOODS INFRASTRUCTURE

Open width fabric on card board rolls Total floor area = 17.53 m x 22.86m
= 400.73m²
Tubular fabric in cutled form
Total number of racks 48 - 49

Capacity = 15 – 17 tones
Fabric
issued
Daily usage = 6 – 7tones
FABRIC
STORE Package type
Rolls (open) = 20 – 25 kg
Fabric
received Rectangular shape (tubular) = approx. 35 kg
 AUTOMATIC SPREADING MANUAL SPREADING
(2 -3 PERSONS AT EACH TABLE) (CONTRACTUAL BASED)

SPREADING OF SRIPES
SPREADING OF SOLIDS
SOME TIMES OF SOLID

PROCESS PROCESS

Loading
Spread
of roll on Opening block
perforated
to the of roll cutting
paper
M/C

Insert
stripes to
Spreading Match
locate Spreading of blocks stripes
roll
change
 STRAIGHT KNIFE
GERBER (AUTO CUTTER)
(MANUAL CUTTING)

PROCESS PROCESS

Spread
Moving lay polythene Pattern
to Gerber sheet placement Marking with
table over the on block chalk
lay

pieces
pieces Run the sorted out Cutting
sorted out loaded according to using
according to marker plan the different straight
the different in the M/C rolls knife
rolls
 FUSIN
HEAT TRANSFER
G
Check specs
Moon patch Cut the rolls as per width mentioned in KNP sheet &
and
pieces quantity required for shift by using roll cutting machine
selecting
received
appropriate
from cutting
sticker

Load the fusing roll on machine stand

Temporary
attachment Placement
using hand using
iron template Place the cut on the on the machine bed

Final heat
transferring Sticker Align the fusing of fabric feed to conveyer
using removed
HASHIMA HP
Trim the fused of fabric using tied scissors in exit the
rear end
 There are 3 BARUDAN LTD. Embroidery machines
2 machines with 20 heads &
1 machine with 12 head

marking as
Receive per
Receipt
instructio placement
of cut
n sheet given
panels
and instruction
and trims
pattern sheet

load the Floppy Load framing

machine with transfer to with
framed embroidery canvas/fusing
panels to machine

Carry out Thread/canvas

embroidery /fusing cutting
operations checking
 For single color
Efficiency is about 90%
And max. no of pieces they can print is 5000

Positive is on polyester
prepared mesh (frame) positive is
the screen is
referring photo emulsion mounted on the
dryed
spec coating is done, screen
sheet turns to screen

in the machine assembly goes to

itself after printing photo camera
there light washing as for device machine
attached with
emulsion which removing wet area where assembly
printing machine
tends to dry the (black area) gets exposing of
printing light

the printed panel after passing from test

goes to check as then online the panels are arranged
for placement of inspection with bundles and sent
print and print to embroidery or sewing
quality sections
AMBER PLANT 7 lines capacity approx 4500 garments / day
VADSAR PLANT 11 lines ( 9 PBS& 2 UPS ) capacity approx. 12000 garments /
day

PROCESS FLOW IN PROCESS FLOW IN

SEWING FINISHING

After inline inspection

Receipt of sewing plan from PPC

ironing
Sewing operations

Supervision and application of Final inspection

correct methods in sewing
folding
Inline inspection

Packing in polybag
Final inspection
Sent to audit
 Line out Lot making audit

Special finish
tagging folding Dispatch
(if any)

Dead man fold Final checking polybagging External audit

Check for
Button
pressing metal storage
attaching
contamination

Pre press Alteration Carton making

Online audit
checking (if any) and packing
 AQL LEVEL OF BUYERS
Online audit
MARKS & SPENCER : 2.5
OUTER BANK : 2
Final internal audit ADIDAS & REEBOK : 1.5

External audit

AUDITING
PROCESS

failed passed
AUDIT

Final
Online audit
inspection
TWO CONCEPT PRODUCTION FACILITIES
• VADSAR - Designed for producing Casual wear / Cut & Sew Tee's &
Polo's

• AMBAR- Designed Specifically for producing Premium High End

Golf-wear and Sportswear
OBSERVATION
 METHODOLOGY
 Following steps in lay planning

 Study on different formats used in the lay

planning

 Taken an random example of lot wise cut

program

 Observing the manual way of filling formats

 Problems can arise due to not properly filling the

formats
 Generating Fabric Requisition
 Generating Cut Program
 Generating Cut Numbers
 Issuing Cut Program and Fabric
Requisition
 Generating and Issuing Lay Information
Slip
It consists of
the total
amount of
fabric that is
needed for a
particular
Lot wise Cut
Program.
The various
rolls that are
issued to fulfill
the fabric
required are
listed according
to their weights.
The roll no. of
the fabric rolls
is used to
identify the
rolls for a
particular lot
no.
It consists of the K&P, style and lot numbers.
It includes the fabric consumption per garment and the various size ratios
The cut no. generation program is generated by the
system and it clearly states the number of plies and
marker length of each lay.
This has to be filled by the worker who is laying a particular cut
no.
It includes the roll no, roll width, roll weight and the no. of plies that were
spread from a particular roll for 1 cut no.
This sheet helps us to keep a record of all the rolls were used
for all the cut programs.
A random lot wise cut program was selected and all the
required formats of that program were checked to see if
the total fabric that is issued was actually used or not and
whether the entries done in the formats against the
system laid down in the manual were correct or not.
A total of 31 fabric rolls were issued in the
fabric requisition sheet
A total of 31 fabric rolls were issued in the
fabric requisition sheet
While the lay information slips showed :
While the lay information slips showed :
While the lay information slips showed :
While the lay information slips showed :
 While the lay information slips showed :

That only 24 fabric rolls were actually used

Only 24 rolls were used compared
to the 31 rolls that were actually
issued. Therefore 7 rolls were
missing…….
When the total fabric consumption for the garment pieces actually cut was
calculated, it matched with the total fabric actually issued.
This leads to the conclusion that the workers
have spread more than 1 fabric roll together and
have done entry of only 1 roll. Therefore the rolls
do not have any record in the lay information slip
and hence seem to be missing.
Due to this mistake of entering information
of only 1 roll in place of 2 or more in the lay
information sheet, there can be problem of
shade variation in the cut parts if there is
roll to roll shade variation. Since the bundle
card is made on the basis of the lay
information slip, now 1 bundle will contain
cut parts of more than 1 roll. Hence shade
variation in the cut parts and hence more
rejections.
Due to this mistake, there will be
problem if an external auditor comes
and checks as this shows that the
system entries are not properly being
followed.
The same roll was entered in the lay information
slip for 2 different lays which is not possible.
Taking attention to the CUT NO. 43, there are ROLL NO ‘14’ & ROLL NO
‘9’ with other roll no.
Then in CUT NO. 45 (I), here once again there is ROLL NO ‘14’
Also in CUT NO. 45 (II), here also again there is ROLL NO ‘9’

Means,

The same roll was entered in the lay information slip for 2 different lays
which is not possible.
Overall there was due to the carelessness of the workers. There is
shade variation in the cut parts hence more rejections, which is not good
in the companies point of view.
 Provided the SOP to every worker & machine,

 Making aware to the workers about importance of quality,

 Unskilled or untrained workers should not be placed as an operator

in case of absenteeism,

 Supervisor must Check the formats time to time and must keep the
record,

 There should be random inspection audits to check formats filling,

 Indiscipline should be handled with stricter action,

 All mobile phones should be banned on the work floor.

THANK YOU