Seior report2

8/2/2019 Seior report2.

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Richa & Co.

AIM & OBJECTIVE OF PROJECT

Aim of this project is to have in-depth knowledge on production of a garment andsuccessfully understanding flow of production stage by stage. Understanding variousdefects that arise at every stage and rectifying the problem while keeping the quality of

garment intact. Maximum utilization of available resources with the aim of achieving

maximum profit.

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Richa & Co.

COMPANY PROFILE

Richa GlobalPlot No 239, Udyog Vihar, Gurgaon

U.P. India

1. INTRODUCTION

It is the one of the leading exporter based at Gurgaon, Established by Mr. Vijay Uppal inyear 1977.

2. MACHINERY CAPACITY

We have our unit with 250 machines and doing business with few of the prestigious

labels of USA & Europe.

Our staff supervisors and worker are well trained to make quality product as per ourcustomer specification

3. They produce kids wear, ladies T-shirts , caprices , skirt, jacket, vest, pajamas set in

various kind of fabric both woven and knits.

4. FABRIC STRENGTH

We have contractedFabric from south india ( ARUN FABRIC ), erode for our customer

order requirements. also they have very good contact with all reputed mills in India and

can procure any kind of fabric as per our customer requirement.

5 QUALITY CONTROL

They have quality control at factory to control the product quality.

6 SAILENT FEATURES

a. Well versed in the field of fabric and embroidery.

b. Committed to work

c. On time delivery of quality products.d. Production capacity according to buyers requirment

e. Timely delivery of product and services

Name of partners :- Mr. Vinay Uppal

Mr. Gaurav Uppal

Nature of business : Garment Manufacturing

Year of establishment :- 1977

Export Market :- USA

Total production capacity per month :- 25000 garments

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Richa & Co.

PRODUCT DETAIL

TECHNICAL SKETCH

MEASURMENT CHART

UNIT CM SAMP

LE

TOL PROGRESSIONS

DESCRIPTION 5A 6A 8A 10A 12A 14

A

16A +/- - +

A:MIDDLE FRONT

LENGTH

34.2

5

37 39.7

5

42.5 46.25 50 51.7

5

1 -2.75 3.75

B:1/2 CHEST FLAT 29 31 33 35 37.5 40 43 1 -2 2.5

E:SHOULDER

LENGTH

4.75 2.5 6.25 7 7.75 8.5 9.25 0.5 -0.75 0.75

F:1/2 SLEEVE

LENGTH

10.7

5

11.5 12.2

5

13 13.75 14.

5

15.2

5

1 -0.75 0.75

G:1/2 NECKLINE ALL

COLLAR

15.5 16 16.5 17 17.5 18 18.5 0.5 -0.5 0.5

G1:1/2 NECKLINE

STRETCHED

MINIMUM COLLAR

28 28 28.5 28.5 29 29 29.5 Minimum

measure

0 0

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Richa & Co.

L:1/2

BOTTOM(JACKET,DR

ESS,SKIRT,CLOTHES)

29 31 33 35 37.5 40 43 1 -2 2.5

M:MIDDLE BACK

LENGTH

38 41 44 47 51 55 57 1.5 -3 4

N:1/2BOTTOM

SLEEVE

8.6 9.4 10.2 11 11.8 12.

6

13.4 0.5 -0.8 0.8

P:SLEEVE LENGTH 9.5 10 10.5 11 11.5 12 12.5 1 -0.5 0.5

O:RIBBING HEIGHT 1 1 1 1 1 1 1 0.2 0 0

PO:T-

SHIRT,DEBARDOUR,

NECKLINE DEPTH

5.6 5.9 6.2 6.5 6.8 7.1 7.4 0.5 -0.3 0.3

P1:NECKLINE

UNDERSHIRT

SWIMMING BACKDEPTH

2 2 2 2 2 2 2 0.2 0 0

PO DETAILSGENERAL INSTRUCTION SHEET

REFRENCE

S

BUYER: Decathlon

QUANTITY: 177.200 pcs

FABRIC

SPI

24/1 Ne S/J 100% organic cotton 160 GSM

12-13 SNLS ,9-10 F/L

4

Date P.O NO. STYLE NO.

28-0-7-2008

DC0083 59374A


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Richa & Co.

STYLE

59374/ A

Girls S/Slv

tee

SHADE 5Y 6Y 8Y 10

Y

12

Y

14

Y

BALLETPINK(PINK

)

4100

6100

8150

8150

6100

4100

HYACINT

H(MAUVE)

23

00

63

00

12

30

0

12

30

0

63

00

23

00

MENTHOL

GREEN(GREEN)

26

50

26

50

26

50

26

50

26

50

26

50

BUBBLE

PNIK(CORAIL)

90

0

15

00

50

00

50

00

15

00

90

0

MILKYYELLOW(

YELLOW)

250

275

1000

1000

275

250

WHITE 60

00

91

50

15

000

15

000

91

50

60

00

BLACK(TR

UE

BLACK)

52

5

80

0

10

00

10

00

80

0

52

5

TOTAL CODE No

36700 PCS 450337211

41800 PCS 4503337213

15900 PCS 4503337532

14800 PCS 4503337531

3050 PCS 4503337533

60300 PCS 4503337212

4650 PCS 4503337534

TOTAL 177200LABEL

PLACEMEN

T AND

PROCEDUR

E

LABELS Embroidery

WASH

CARE

LABEL

Other labels

Heat transfers- inside and outside

As per approved sample

no As per

approvedsample

Barcode

labelsTraceabilityla

bels

Needle

thread

MATCHING TO BODY COLOR, spun

polyester thread.

Bobbin

thread

MATCHING TO BODY COLOR, polyester

filament thread.STYLE

NOTE

SEAM TYPE OF FINISH REQUIRED

TYPE OF

STITCH

Note: comet grey transfer for hyacinth, milky yellow & true black shade & drizzle heat

transfer for ballet pink, menthol green, bubble pink & white shade

SALES ORDER NO.: FINISHING INSTRUCTION SHEET

DESIGN THREAD COLOR PLACEMENT

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Richa & Co.

PRINT

DESIGN &

PLACEMENT

Heat transfer on back,panel & inside

Match with body Heat transfer placement asper approved sample

PRESSING TISSUE

PAPER/INSERTER

FOLD SIZE CLIP/PINS OTHERS

YES YES Pc to be roll fold for

packing

No

PACKING TYPE OF PACKING

PRE-

PACKING

DETAILS

SIZE SPECS PACKING METHOD

POLY BAG M. POLY BAG DETAILS OF PACKING IS GIVEN

ON A SEPARATE SHEET

TO BE CONFIRM

AFTER PILOT

FINAL

PACKING

DETAILS

FINAL CARTON SIZE PRINTING DETAILS

7 PLY, 6-X20X40

CARTON TAPE IS PRINTED- DP INDIA

SHIPPING MARK

LENTHWISE WIDTHWISENO. OF PCS/CARTON AS PER PREVIOUS ORDER

Given on packing detail

sheet

QUANTITY

VARIATION

Given on packing detail

sheet

MANUFACTURING SEQUENCE

6

FLOW CHART OF MFG. PROCESSES

COUNTER SAMPLE

MAKING

SHIPPING


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Richa & Co.

MANUFACTURING SEQUENCE OF GIRLS S/S T

7

COUNTER SAMPLE

APPROVAL

FABRIC & ACC. AVG.

CALCULATION

FABRIC &

ACC.PURCHASE

FABRIC LENTERING

& CHECKING

FABRIC ISSUE

COMPUTER / HAND

EMBROIDERY

FUSING

TICKETING

FINAL INSPECTION

PACKAGING

PACKING

FINISHING

WASHING /DRYCLEANING

SPOTTING

INHOUSE SEWING

CUTTING DOCKETISSUE

CUTTING

ACCESSORIES ISSUE

THREAD TRIMMING

BUNDLING

FABRIC ISSUE

CUTTING

MARKER PLANING

TESTING


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Richa & Co.

PRODUCTION PLANNING

Fabric in house 25-09-08

Layering 1-10-08

8

FUSING

TICKETING

BUNDLING

INHOUSE SEWING

WASHING /

DRYCLEANING

FINISHING

PACKING

FINAL INSPECTION

SHIPPING


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Richa & Co.

Layer length 8.25 mtr

No of layers 100Relaxation time 5 hour

No of table allotted to the style 2

Production / day 3200

Stitching Start 3-10-08

SAM for stitching one garment 8.56 minute

No of M/C per line 21

Production / line /day 780 Pcs.Line allotted to style 4

Production of 4 lines 3120

Day required to finish 177200 Pcs 56s

Finishing and Packing

Finishing and packing done simultaneously with production

Shipment Date 22-12-2008

FABRIC DEPARTMENT

9

FABRIC LENTERING

OVER VIEWCHECKING

INSPECTION


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Richa & Co.

Fabric sourced from the mill comes directly to the fabric department. Then the fabric is

checked in there. Overview checking includes color wise checking of all the rolls

FABRIC PACKAGES

Fabric from the mill comes in following form

Bundle

Roll

Fabric packing depends on the lot size. Longer length woven fabric comes in the roll form

and small length fabric comes in the folded form. Knitted fabric comes in the folded form

FABRIC ARRANGEMENT

Fabric packages arrange on

Racks

Wooden palate

It is very necessary to arrange the fabric in the proper form and manner it makes the work

and process easier and convenientThe fabric is arranged in the racks and wooden palate according to following -

Types of fabric (woven or knitted)

Weave wise

Quality wise

Color wise

Style wises

FABRIC PARTICULARS

Fabric Type: - KnittedWeave - Single Jersey

Fabric Dial Gauge - 30/ 24

Count - 24/1 NeGSM - 160

WPI - 24

CPI

M/C AND EQUIPMENT DETAILS10

ARRANGE IN THE

RACKS

ISSUE FOR

CUTTING


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Richa & Co.

S NO M/C DESCRIPTION QUANTITY

1 Mapping machine(inspection M/c) 4

2 Weighting Balance 1

3 Spotting gun 4

FABRIC QUALITY INSPECTION

The quality of a final garment depends on the quality of a fabric when it is received as aroll. Even the most outstanding manufacturing methods cannot compensate for defective

materials.

Fabric inspection is the important part of the fabric department, it is necessary to inspect

the fabric to check the defects in the fabric that where are the defects in the fabric. Duringthe inspection the defect removed and mended by the checker, whether the defect t is

acceptable or unacceptable is determined during the inspection with the help of someparameters and standards. Normally, we inspect all of the rolls we receive and evaluatethem based on a four-point system. This way, we can avoid fabric related quality problems

before it is put into production

Defect Classification (Four- Point System):

Size Defect Penalty .3 inches or less 1 Point

Over 3 inches, but less than 6 2 Points

Over 6 inches, but less than 9 3 Points

Over 9 inches 4 Points

Acceptance Criteria and Calculation:

40 points per 100 yards is the acceptable defect rate

# of Points per 100 yds = # of penalty points x 100 Yds inspected

INSPECTION PROCEDURE

Put the rolls on the inspection machine or other viewing device

1. Inspect for visual defects with the light on at a speed slow enough to find thedefects. (The fabric must be checked at a slow rate in order to effectively find

flaws). Sometimes you may have to turn the light off to see how a flaw will affect

the appearance of a garment

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Richa & Co.

2. Stop the inspection process every 50 yards and use the strip to check for any

shading problems. Also make sure to check the end of the role

3. Check that the roll contains the correct yardage as stated by the piece goodssource.

4. Check for skewed, biased, and bowed fabric

5. Mark any defects to the side with colored tape so that they can be easily found andnoted

6. Record any defects

7. Cut off a 6 inch piece across the width off the end of the roll. Mark the right and

left side of the strip.

FABRIC DEFECTS

WEAVING AND KNITTING DEFECT

Slubs

Holes

missing yarns

yarn variation

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Richa & Co.

soiled yarns

wrong yarn

DYEING DEFECTS

Dye spot

Machine stop

Color out

Color smear

Shading

Shade off, tone change

Shade uneven

Whiteness in shade, oxidation type patch

Color patch, ring formation air bubble

Shade dullness

CUTTING

13

Spreading

Fabric Issue

Cut Order Plane

Instruction Sheet


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Richa & Co.

M/C AND EQUIPMENT DETAILS


1 Cutting Table 4

2 Straight Knife 4

14

Marker

Cutting

Fusing

Ticketing

Bundling

StitchingDepartment

Spreading &Marker Checking

Cutting Checking


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Richa & Co.

3 Round Knife 2

4 Band Knife 1

5 Continuous Fusing Machine 2

6 Vertical Fusing Machine 2

7 Ticketing 2

MARKER MAKING

There are some important factors which are considered while making the marker to

minimize the waste and to gate the pattern according to buyers sample or instruction.

Instruction Sheet

Cutting is done according to pattern whether it is on grain, cross grain or bias all the

instruction or pattern (garment) given by the buyer. According to that garment

Merchandiser forwards the cutting instructions to cutting department, cutting department

prepares the cutting instruction sheet and forward to marker planning department andmarker prepared according to that report.there are following instruction in the cutting

instruction sheet.

1. FABRIC WIDTH(30DIA)

2. PATTERN CUTTING

On Grain

Cross Granin

Bias

CUT ORDER PLANThe cut order plan prepares to proceeds the primary production process. There are some

parameters according which cut order plan prepares which are following as

marker planning

table length

cutting machine capacity

No. Of layers - 100

Layer length - 10.52 mtRelaxation time - 5hr

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Richa & Co.

Cutting - Cutting done by three size wise, cut together to increase the marker efficiency,the sizes which cut to gather are following as

FABRIC ISSUE

The cutting department gets the fabric issued from the fabric department according to cutorder plan and the layering parameters.

FABRIC ISSUE CHALLAN

Sales Order No. :

Run Date :Time :

STYLE Fabric Description:

S. NO. FABRIC ISSUE

LINE

ROLL

NO.

ACTUAL

FINAL

WIDTH

ROLL

QUANTITY

IN MTR.CODE COLOR SIZE

Line Total ......

Cutting Dept.( Receiving qty:_______) Store Dept. ( Issued

qty:_____)

LAYERING

After the inspection of the fabric, it goes to the cutting department. Then they do the

layering of the fabric in accordance with the inspection report.

CUTTING

Cutting done by the straight knife cutting m/c, where the band knife also used for smooth

and even cutting of critical parts.

BUNDLING AND TICKETING

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Richa & Co.

Bundle ticket system (B.T.S) is a tool to measure individual operators performance andefficiency. The operator in the sewing line works on a bundle and pastes a ticket office

operation on every bundle change. The supervisor takes an hourly score of that operator by

counting the number of tickets in that hour. The ticket has got the name of the operation,

S.M.V, bundle number, style number (F8914).B.T.S can help the in line and end line examiner to find the operators producing defects by

tracing the bundle number on his ticket.

Method:-

All the operators working in the sewing line in a bundle system pastes their ticket on a

bundle change. At the in line and the end line the defect producing operator can be traced

out on the basis of the bundle ticket for that bundle. So the auditor and the examiner can

easily find out the operator and suggest corrective action.

STITCHING

17

Bundle Distribution


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Richa & Co.

In sewing department the process can be done by using one of these line depending uponthe size of order and skills required to do a job

1. Body line : This means one person is manufacturing whole garment. Skill required

b the operator is more. This is mostly used for sampling of a product.2. Assembly line: this means one operation one machine. Chances of stoppage are

less. Skills required is less.

3. Miscellaneous line: this is a mixture of both

Company follows the assembly line production system for our style :

M/C AND EQUIPMENT DETAILSS. No. M/C DESCRIPTION QUANTITY

1 Single needle lock 140

2 Over lock 80

3 Flat lock 9

4 Chain stitch 75 Button hole 3

6 Button Attach 3

7 Zig -Zag Lock Stitch 2

8 Bar-tuck 2

9 Embroidery 1

10 Needle Detector 1

11 Thread Trimmer M/c 1Total 298

INTERNAL WORK ORDER SHEET

MODEL NAME :

FABRIC : Woven check shirt 100

% COTTON

P.O.# F8014

COMBO : LIGHT

BLUE / WHITE,

TAMOTO RED /

WHITE

P.O.QNTY : 25000

ITEM : QUARTER SLEEVE SHIRT

18

Stitching Inline inspection

End Line Inspection

Washing

Internal WorkOrder


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Richa & Co.

FABRIC HAS FACE REFER

SWATCH ATTACHED

WOVEN SHIRT GSM 109

SIZES Misi s, m, l, xl mama

1x, 2x, 3x , 4xQTY

BREAK OF ATTACHED

P.O.BREAK UP Single Delivery

TRIMS TYPE &

PLACEMENT

FINISHING DETAILS

MAIN LABEL Attached 100%COTTONGARMENT WASH

STEAM IRON

WASHING DETAILS

SOFTENER WASH

PACKING DETAILSSINGLE PC POLYPACKED

CARTON POLYPACKED

AND STRAPPEDREQUIRED INNER CTNS

ONLY FOR IDE,INL& INO

FOR LOT WISE

PACKING.REQUIRED ID

BARCODES FORIDEORDERS.PLAIN

TRANSPARENT TAPE ON CARTONFOR SEALING.

CARTON MAKING

P.O. # :

MODEL NAME : EIKO JRS

MODEL NO: 076079

COMBO: BLUE LIGHT/KHAKI

PELICAN/WHITE

SIZE:QUANTITY:

CARTON NO:

NT WT & GR WT:MEASURMENT: CMS

GR WT SHOULD NOT EXCEED

20KGS

FOLDING DETAILS

TO BE FLAT PACKED IN SELF SEAL

POLY BAG.

SIZE LABEL Attached

FACTORY CODE LABEL Attached

TAB LABEL

WASH CARE LABEL Attached

MAIN BUTTON No

PRINT/PLCMNT No

MAIN O/L THERAD

O/L THREAD Two ply.

TAB LABEL THREADTISSUE PAPER Put tissue Paper on

folding

LUGGAGE LOOP No

HAND TAG No

EAN CODE STICKER No

STITCH PER INCH 9-12

POLYBAG 1Pc/poly bag

MASTER POLYBAG

INNER CARTON STICKER No

INNER CARTON No

OUTER CARTON 7 ply 24x16x16

OPERATION FLOW CHART

YOKE

COLLAR BAND ATTACHMENT

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Richa & Co.

SLEEVE & SLEEVE SLIT ATTACHMENT

POCKET FLAP ATTACHMENT

COLLAR ATTACHMENT

COLLAR FINISH

SLEEVE ATTACHMENT

SIDE SEAM

CUFF ATTACHMENT

DARTS

FRONT PANEL

LOADING

INPUT

NO OF M/C REQUIRED / OPERATION

PROCESS NAME ACTUAL NO M/C

ALLOTTED

BOTTOM HEM 1

SHOULDER ATTACH 1

NECK RIB ATTACH 1

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Richa & Co.

NECK TAPE ATTACH 1

NECK RIB FLATE 1

NECK TAPE FINISHING 1

LABEL MAKING 1

LABEL ATTACH 1

SLEEVE ATTACH 1

ARM HOLE FLAT 1

SIDE ATTACH 1

SLIT MAKING 1

SLIT DOWN 1

SLEEVE HEM 1

TOTAL 1

DEFINITION OF CRITICAL, MAJOR AND MINOR DEFECTS

Critical Defects:

A Defect that means that the product fails to meet mandatory regulations And/or

affects the safety of the customer.

1) Monofilament Sewing Thread Used

2) Infestation of live Insect

4) Needle detected

5) Any sharp point on accessory of Garment6) No country of origin/fiber composition

Major Defects:

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Richa & Co.

A Defect which will result in product failure, reduce the ability of the product to be

used, or cause the product not to be saleable.

Minor Defects:

A Defect not likely to reduce the utility of the product, but is likely to reduce the

salability of the product on the discrepancy from the agreed acceptable limit.

SEWING DEFECT

1 Types of Defects

1. Open Seam2. Raw Edges

3. Puckering,

4. Bowing at Bottom Hem.5. Heat Seal. Label Cross

6. Heat Seal Peel off.

7. Joint Stitch Uneven.

8. Bottom Wavy Stitch9. Loose Stitch

10. Needle Hole.

11. Skip Stitch.12. Broken Stitch.

13. Loose Thread.

14. Bar-Tack Uneven.15. Cut Damage.

16. Oil Stain.

17. Handling Stain.18. Wrong Joker Label

19. Wrong Joker Label Attach.20. Uneven Stitch Length.

21. Bottom Hem Width Uneven22. Shade Variation in sewing thread

23. Bar-Tack Missing

24. Binding Joint Uneven At Armhole25. Neck shape out

WASHING

22

Detergent

ash n

Drying

Softner Wash

l con ash


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Richa & Co.

M/C AND EQUIPMENT DETAILS


1 Washing M/C 5

2 Drier M/C 6

3 Dry Cleaning M/C 2

After stitching garment Process in the washing Department to remove the stains dirtand oil marks. there are some factors which affect the washing process of any garment.

The chemical and washing time of garment is depending on type of fabric. The

chemical composition of washing agent depends on the fabric and the dye used on thefabric.

Washed fabric put for drying in the drying M/c. the temperature and time taken to

drying depend up on the fabric. Synthetic fabric requires less time and temperature as

compare to natural fabrics.The drying process takes 1 hour to completely dry thegarment After drying garment transfer to finishing department

FINISHING

23

Thread Triming

Initial Checking

MendingGun Spotting

PressingPacking

Department

Finishing

Department


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Richa & Co.

The various process involving finishing of the garments are

Thread Trimming

It isthe primary operation of finishing process in which hanging threads are trimmedmanually

Stain Removal

In these process the stains are removed by spotting gun or chemical depend on type of stain

Steam Ironing

It is the last operation of finishing department in which garments are pressed by steam iron

PACKING

24

Final Checking

Checking

Folding

Poly BagPacking

Price Tag


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Richa & Co.

Label Attachment: - Brand Label Attach with neck label through Kimble Attachment

M/C. Which has a title of FASHION BUG.

Folding: - According to buyers specification

Poly Bag Packing: - one poly bag / garment

Carton Packing: - Accordin to the size.

Carton Labeling:-, Size, color, Quantity, Barcode

PACKING DEFECT

1. Barcode Sticker Missing.

2. Defective Barcode Sticker

3. Defective Print At Size Ring

4. Hanger Position Wrong

5. Improper Folding Pieces

6. Print Missing At Size Ring

7. Organic Sticker Position Wrong

8. Size Sticker Missing

9. Wrong Barcode Sticker

25

Carton Packing

Carton Labeling


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Richa & Co.

10. Wrong Size Ring

11. Wrong Size Sticker

12. Less Pieces In Carton

13. More Pieces In Carton

14. Wrong Size Pieces In Carton

15. Dirty Packing Material.

TESTING

The object of testing is to improve the product quality, testing takes place at different

stages of in the manufacturing process. Mainly there are two stages where the testing is

necessary.

Fabric testing

1. Physical test

GSM Reed/Pick

Strength

Pilling

2. Processing Test

Shade

Washing fastness

Rubbing fastness26


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Richa & Co.

Garment testing

Seam strength

Button Strength

The samples tested in house and out house depending on test. They have some physical

and processing tests. They send the samples to the testing labs for lab dips washing fatness.

The above testing parameters given by the buyers or there are some Testing standards

according to which testing does by the exporter

QUALITY CONTROL

27

Sewing Quality control Flow Chart

Feeding Point

1 Bundle feed into the

Sewing Line

Assembl wise sewin

Inline Examiner Sheet 1

Checks all the o erations

Inline Examiner Sheet 2

Checks all the o erations rom the

Inline Inspection SheetAuditor

OK

Defects corrected byconcerned operator

N

NOT

OK

Defects corrected by

concerned operator

N

NOTOK

OK


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Richa & Co.

STATISTICAL QUALITY CONTROL

FORMATS:-

1. Inline Examiner Sheet2. Inline Inspection Sheet

3. End Line Examiner Sheet

4. Short Control Interval Sheet

1. Inline Examiner Sheet

Concept

The Inline Examiner in the sewing line checks the operations for faults andidentifies the in line defects of the concerned operator. The position of in line

28

Pressing

Pressing of all sewn garment according to the

OK

N

NOTOK

N

NOT

OK

Rechecking

Defects corrected by line

supervisior

N

NOT

OK

Dispatch

Final dispatch of all the

packed goods

Carton Packing

Packing of all the goods

Final AuditFinal audit of all the packed

OK

Filter Point Audit

Checking the audit of all the garments

OK

End line Examiner Sheet 2

Checks all the operations from the sewn garmentCalculates no of repairs and total defects


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Richa & Co.

examination workstation in the sewing line is decided on the basis of particular style,

types of operation and critical operation.

Remedies

The Inline Examiner in the sewing line examines every operation till the first checkpoint and records the faults and the concerned operation for that particular operation.

He identifies the types of faults and informs the concerned auditor, supervisor andquality manager. There may be two inline examiner work station in sewing line.

2. Inline Inspection Sheet

Concept

The inline auditor of sewing line inspects 7 pieces out of 20 pieces of a bundle ever

hour of every operator in the sewing line. The faults on the operation and the operator

are identified and are given back for corrective action. The main idea is to prevent

faults from going towards the end line.

Remedies

The inline auditor records the name of every of every operator on the sewing line

and checks 7 pieces out of 20 pieces every hour. He identifies the different faults, the

poorest performer in the line and critical operation in the sewing line. The corrective

action in being taken on the basis of auditor report.

3. End Line Examiner Sheet

Concept

The end line examiner checks all the pieces at the end of the sewing line and

records the repairs and rejects of the sewing line. The repair and reject rate of thesewing line is calculated upon the observations recorded by the examiner

Remedies:-

The end line examiner keeps an hourly record of all the observations of the faults

found at the end of the line. He also identifies the particular operation and the operatorproducing faults on an hourly basis. He can also guide the line auditor to bestringent on those operations. At the end line we can know the repair rate and the total

defects produced.

4. Short Control Interval Sheet

Concept:

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Richa & Co.

The short control interval sheet is a tool for quality manager that gives precise and

accurate information about sewing line in terms of quality index and over allperformance of the line in that period. The quality manager can also keep a check an

the performance of the line auditor and end line examiner. They have a green light and

red light system.

Remedies

The Quality manager uses the short control interval sheet and calculates the repair

rate, rejects rate, final inspectors accuracy and quality index. Once the number of audit

done in that period are known, he suggest the corrective action for that line.

FINAL INSPECTION

In the final inspection the inspection head looks that if thers any stain left on the garmentor any stiching problem upcoming in the woven shirt. And then these garments goes for

pressing which is done manually by hand iron press of ramsons viet. And then they go for

packing and then garments finally are dispatched.

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Richa & Co.

CONCLUSION

By this project, we have gone through the process of manufacturing of

the garment. We have learnt how the garment passes through each

operations and how the quality is controlled. We have the variousdefects which arose at every stage and the solutions to overcome these

defects.

It proved to be very beneficial for us in terms of learning the practical

know-how of the industry.

Documents

Seior report2