Gp Report-midsem Final

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IMPROVING HIT RATE AND ON TIME DELIVERY OF SAMPLES AND DEVELOPING A SYSTEM TO MEASURE THE PERFORMANCE OF SAMPLE DEVELOPMENT

Under guidance ofMr. Abdul Salam Sait

Prepared byAnoop singh (08) AP VIII 08-12

Table of contentList of tables 1.1 Introduction 1.2 Statement of study 1.3 Objectives 2. Literature review 3. Methodology 3.1 Timeline 3.2 DMAIC Approach 4. PHASE-I: Define 4.1 Definition of Hit rate 4.2 Critical to Quality (CTQ) trees 4.3 SIPOC Bibliography 3 4 5 5 6 15 16 17 18 18 19 23 24

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List of figuresFigure 1. workflow of sampling.............................................................................11 Figure 2 Timeline..................................................................................................17 Figure 3 DMAIC approach to project methedology................................................18 Figure 4 CTQ tree1...............................................................................................20 Figure 5. CTQ tree for hit rate of samples.............................................................21 Figure 6 CTQ tree for factory's capability..............................................................22 Figure 7 TQ tree for meeting buyer's requirement................................................22 Figure 8 CTQ tree for rawmaterial.........................................................................23 Figure 9 CTQ for construction...............................................................................24 Figure 10 CTQ tree for value addition...................................................................24 Figure 11 CTQ tree for quality...............................................................................25 Figure 12 SPIOC diagram......................................................................................26

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1.Introduction:In recent decades, fashion retailers, such as Benetton, H&M, Topshop, and Zara have revolutionized the fashion industry by following what has become known as the fast fashion strategy, in which retailers respond to shifts in the market within just a few weeks, versus an industry average of six months. Specically, fast fashion is a concept developed in Europe to serve markets for teenage and young adult women who desire trendy, short-cycle, and relatively inexpensive clothing, and who are willing to buy from small retail shops and boutiques. Fast fashion chains have grown quicker than the industry as a whole and have seized market share from traditional rivals, since they aim to obtain fabrics, to manufacture samples, and to start shipping products with far shorter lead times than those of the traditional production calendar. (Nagurney & Yu, 2010) With rapid turnaround time the order of the day, it is essential that every link in the supply chain be tightened to the maximum possible. The sample development process in manufacturing takes typically around 50% of the total lead time, which could be minimized in order to reduce lead time of complete manufacturing. Though there is no existing method to measure the efficiency or performance of a factory in sample making and hence improvement in the process could not be controlled for long time. The Hit rate of a sample refers to success of a sample. A successful sample is one which went on-time and was approved first time. However it does not necessarily mean that a successful sample may fetch an order. Since a buyer comparatively evaluates samples from a number of manufacturers, a successful sample may not fetch an order for reasons beyond the manufacturers control. However manufacturers can minimize the risk of their sample being rejected by controlling the factors which are in their control, by streamlining the sampling process and making sure the standard practise is being followed, the manufacturer can make sure that their samples are of utmost quality, are not delayed and meet the requirements of the buyer. This project aims at determining the factors to minimize rejection of samples which are under the manufacturers control.

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1.2 Statement of study To improve hit rate of samples by maximizing on time delivery and first time approval of samples. To develop a system to measure the performance of the sample development process.

1.3 Objectives Analyzing the current sample development procedures. Identifying buyers method of measuring. Identifying reasons for samples not getting approved first time and eliminating the reasons. Exploring problems leading to late sample deliveries and developing new methods to increase on time delivery of samples. To find the performance indicators for the sample development procedures and based on that develop a performance measurement system.

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2.LITERATURE REVIEW

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Review of literature:2.1 Sampling in fashion industryThe process in which social, economic and environmental needs are identified and becomes fashion concepts which are developed into product samples as the trial types. Innovation and creativity are necessary for any business to move forward and take advantage of prevailing market conditions. The increasing use of computer aided design and manufacturing has helped all types of apparel businesses to speed up the process of sample development and to do this more cost effectively. Big may be better in manufacturing but the garment industry is dominated by numerous small to medium sized businesses and sample development is vital to the survival and success of textile business whatever its size or type of production. Larger organizations may have departments devoted to the research and development of products or sampling departments who are constantly producing new samples and ranges. Sampling is the phase of development of fashion assessing the capacity and capability of any manufacturing unit for bulk production of the same. Sampling also intend to ensure the aesthetic appeal or concept or theme that was expected in garment is achieved or not, also helps to incorporate any design or style changes if required to achieve accurate trend forecasted by trend analysts. Sample development is one of the main processes in Garment Industry and it has a vital role in attracting buyers. Because the buyers generally places the order after they are satisfied with the quality of the samples. The samples decide the ability of an exporter. The buyer will access the exporter and his organisation only by the samples. If the samples are of good quality and with reasonable price naturally the buyers will be forced to place the order. So it is essential that the samples should be innovative and with optimum quality. The purpose of sampling is not only to get bulk orders and also give some additional benefits to the exporters. By doing sampling the exporter can estimate the yarn consumption for developing the fabric, a clear idea on costing more ever the manufacturing difficulties. Besides by doing sampling only the exporter can optimize the processing parameters for mass production, which helps to avoid all kind of bottlenecks. All these works are carried out by the sampling department, which us led by a sampling in charge. Hit Rate is number of sales realized as a percentage of the number of sales calls (visits) or enquiries received.

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The Details Attached to the Garment Sample After the confirmation of order, each sample sent to the buyer has the following details attached to it, with the help of a tag. It contains the details pertaining to both, what the buyer has demanded and what supplement fabric/trim etc they have used (if applicable).

Ref no. Color Fabric Composition Description Quantity Style no. Size

The merchandiser is the person who is interacting with the buyers regarding samples and other requirements, this sampling department will work under the supervision of merchandising department. Also as the samples are to be made according to the buyers price ranges and quality levels, merchandiser has to advise sampling department suitably. (Sampling in apparels manufacturing)

2.2 IMPORTANCE OF SAMPLING

Sampling is the best way to place an order. Though it is a difficult and time ending process it will help the exporter to get the order from the buyer. The purpose of sampling is not only to get bulk order and also it gives some additional benefits to the exporters. By doing sampling the exporter can estimate the yarn consumption for developing the fabric, a clear idea on costing and manufacturing difficulties. Besides by doing sampling the exporter can optimize the processing parameters for mass production, which helps to avoid all kinds of bottle necks. The samples, decide the ability of an exporter. The buyers will assess the exporter and his organization only by the samples .If the samples are of good quality and with reasonable price naturally the buyers will be forced to place the order, So it is essential that the samples should be innovative and with optimum quality.8|Page

2.3 PERSONS INVOLVED IN SAMPLING Development team Designers/Sample developers, Customers/Clients, Textile technologists Garment technologists Packing & Dispatch, Sourcing &Purchasing, Costing & Finance, Sales & Marketing, Production team, Planning Control &,Testing Quality control

2.4 TYPES OF SAMPLES

Salesmen samples or promotional samples Proto samples fit samples Counter samples or reference samples or approval samples Wash test samples Photo samples9|Page

Fashion show samples Pre-production samples Top of production samples Shipment samples

2.5 SAMPLING PROCESS The process of sample department varies from context to context, and the development process covers a wide range of diverse products from new fibers, fiber blends, new yarns, fabric structures ,finishes and surface effec