BASICS OF PRODUCTION SYSTEMS Title: To Study The Pre-Production And Production Systems In Apparel Industry In nahar By: Shreya Bahl And Ridhi Kapoor

Objectives To study various production processes involved in an apparel manufacturing organization. Develop an intellect for clothing manufacture technology with regard to fabric cutting. To study the layouts of the fabric, cutting and sewing department and propose the layouts for to utilize the floor space efficiently.

Conclusions Learning of different steps in production related to the pre production and sewing processes. Ample knowledge about managing production for maximum output how to manage the industries how the work floor and the labour were being under used and how they can be put to best use to get maximum output. The project on the whole helped us learn in a practical way how work is done in a garment producing unit and how efficiently can we process the work.

Suggestions Changes required in fabric storage area: Division of storage area into-ready to cut area, surplus fabric area, dead stock area Well maintained fabric under check area. Well maintained components storage area. Change in off loading technique- equal length of bed required to the loading bay. Prevents miss happening and saves manpower. Proper medical chest required. Workers should be should be provided with metal glove while using straight knife. Prevents cut.

Marker making and Grading Project work Fabric received Fabric stored Fabric checking Marker making and Grading Cutting Sewing Primary checking Stain removal Mending

Fabric receiving Received from sister concern-DHANDHARI through truck.

Offloading-manual-movement through trolleys and bins. Rolls carried through trolleys and entered in register after weighing them, entry as per challan, ticket attached to the roll, carrying roll#, date, DIA, GSM. ROLL.NO G.S.M DIA WEIGHT DATE

FABRIC STORAGE- in racks, after weighing, white-out of the poly bag, colored- covered, trims and collars stored seperately. No inspection of fabric, testing for GSM, DIA. 3 Fabric cards maintained:- One stored with the department. One sent to buyer. One to supervisor for approval

Marker making and grading Markers made through CAD GRADING- CAD system used.

Spreading It is done manually. Continuous ply laying is the method generally used.

Cutting Department Hand sheers and vertical straight knife used Plaid fabrics- cut as one ply, require careful cutting Plain fabric- cut as many plies through vertical straight knifes.

For cutting stripers cutting pasted on the patterns for matching garment parts. Fabric board hanged in the cutting room containing all combos which are being cut.

Bundles made and sent to sewing department.

Sewing department Issue to sewing through computers. Straight line system followed.

LAYOUT FOR SEWING DEPARTMENT

First sent to moon patch attachment. Making and attachment of sleeve tape. Offline operation is followed

First attached to the front, then sent to fusing. Then stitched Then bundles are then issued to sewing hall. 2 people employed for each operation. STEP 1: Placket making-fusing and attachment. First attached to the front, then sent to fusing. Then stitched

It is done after making the placket to give a better finish. STEP 2: Placket box making It is done after making the placket to give a better finish.

STEP3: Shoulder attachment with overlock machine. STEP4: Collar making

STEP5: Side slit making with SNLS machine. STEP6:Hamming with folding machine

STEP7: Button hole and button stitch First marking with white Button holes made pencil and marking card. With button hole machine.

Button stitch Marking with mark card and white pencil on placket. Marking on placket for Buttons attached with Buttons. Placket divided button stitch machine. in 6 halves.

Step7: Primary checking Manually, removal of threads and checking for skips in knit or any other kind of holes or cuts or any default in sewing.

With guns, using benzene solution STEP8: Stain removal With guns, using benzene solution STEP9: Mending Manually with needle

Layout for fabric storage

Actual layout

Proposed layout

Layout for cutting room

Actual layout

Proposed layout

Thank you