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Naveena textile Report
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INTERNSHIP REPORT
NAVEENA TEXTILE (PVT) LIMITED
1. K.M off Bhoptian Chowk, Raiwind Road Lahore.
Telephone: (92-42) 5320062-66
Fax: (92-42)-5320067-68
ADVISOR:
MADAM SADAF RAUF
(Lecturer) Management Sciences
Presented By:
SHOUKAT ALI
MBA-FA04-75
COMSATS Institute of Information Technology
M.A.Jinnah Campus, Defence Road off Raiwind Road, Lahore
Dedications
I dedicate this report to my loving parents whose prays, affection and support are always a source of encouragement for me to reach at this destination and a humble icon for others in future. My parent and teachers who give me real eyes that help me to leads myself and others in the dark and cruel world.
Acknowledgment
At first I am thankful to Almighty ALLAH and the Holy Prophet (P.B.U.H), their blessings have been with me in all good and bad times. Then I am grateful for the
thorough support by my advisor MADAM SADAF RAUF and also Mr. NAEEM (Asst.Manager Admin), WAQAR AHMED (Merchandiser), for providing related information on which this project is based. They were the constant source of inspiration and encouragement that helped in completion of my internship.
Executive Summary
This report consists of my six weeks internship at NAVEENA exports (Pvt) Ltd. This organization is situated in Lahore. The organization started its business from Karachi since 1967.
The salient features of this report are NAVEENA’S organizational background, its vision, corporate values and goals of the company. This report focuses its business operations including major suppliers of the company, its overall marketing strategies, Management Information Systems, its dynamic Human Resource, Purchase Merchandising and import & export strategies in special. This report also enhances the organization’s challenges in perspective to its domestic and international competitors. The organization’s BCG matrix, marketing strategy, competitive strategy and thus the analysis of all these operations is really a fascinating experience of mine. Finally, this report is a nutshell comprises of my practical learning, recommendations and suggestions.
.
Company Background
Group NAVEENA is a progressive name in the textile industry established in 1967 has become one of the largest manufacturer and exporter of textile in USA and Europe.
When started it’s operations, it was a small dying and embroidery unit in Karachi. Today NAVEENA exports comprises of three independent units, it offer distinctive branded garments, producing six million pieces annually with special emphasis on fashion apparel, NAVEENA apparel, is a broad spectrum of source houses internationally.
Bond of Trust
It‘s bond of trust is consistent upon this remarkable notion given below:
“We are proud to have some of the most reputable name worldwide. This has been achieved over time through the approach of work fast and work smart.
The bond of trust has been developed because of our ability to fulfill our commitments to deliver the right product at the right time. Check and balances are placed from the initial stages to eliminate any possibility of error.
Vision of Company
The company undertakes to apply the vision in letter and spirit under the following guiding principles:
1. In time action
2. Clear understanding of customer’s instructions.
3. Clear communication with vendors
4. Clear instructions for production
5. Strict compliance with quality control system.
6. Total devotion maintains first class quality standard.
7. Absolute efforts for in time shipments
8. Career development opportunities for employees
MISSION STATEMENT
NAVEENA’s Mission statement, statement focused on its major commitments i.e.
Ø We make clothes that fit well, look good and most importantly feel great when you wear them.
Ø We are committed to become number one supplier of causal clothing around the globe.
It’s Corporate Values
Ø Team work
Ø Integrity
Ø Excellence
Ø Commitment to buyer.
Ø Maintenance of consistent standard
It’s GOALS
Ø Continuous improvement.
Ø Customer’s satisfaction.
Ø Quality of product and system.
Organizational chart
CEO/OWNER
Director
GM
Merchandising
Manager
Finance Manager
Production Manager
Export Manager
Quality
Manager
INTRODUCTION TO DIFFERENT DEPARTMENTS AT NAVEENA
Merchandising
Flow of Information
Buyers Merchandiser PPC
· Material Planning
· Time & Action Plans
· Production Plans
Production Department
o Yarn store
o Knitting
o Dyeing
o Cutting
o Stitching
o Packing & Finishing
o Purchases
o Stores
Merchandising
PURPOSE OF
MERCHANDISING AT NAVEENA
Merchandising is a global process through which products are produced, sourced, and sold all over the world. Merchandisers must have leadership for the value chain (developing, distributing, and selling products) in a global market.
Merchandisers need to see "the whole process" from product innovation through consumer satisfaction. This requires logical thought processes such as problem solving, decision-making, and resource management. It is a critical need for merchandisers at NAVEENA, which has strong business background, yet it also stays focused on fashion or other products that undergo continuous change in the consumer-driven market.
Here, the merchandising department is mainly divided into accounts buyers. This shows that there is individual or a team of merchandising, who takes care of a specific buyer or account.
Merchandising serves the following purposes at NAVEENA:
Gateway:
It acts as a bridge between buyer and the company for communication.
Marketing:
Merchandiser has to market his company in order to increase his customers and generate more and more revenue.
Costing:
Merchandise makes a cost sheet to see if the product is feasible or not in terms of cost and revenue. Merchandiser has to calculate the cost of products including all wastes and accessories to tell the final cost of the product to his customers.
Negotiation:
Merchandiser must have a negotiating power on the price to convince his buyers on specific price to lessen the chances of loss.
Sampling:
Merchandiser must send the sample to his buyers for confirmation and satisfaction. At this stage, Sampling is also done to avoid loss.
Information Management:
As merchandiser has direct contact with his buyers so the buyers have to give information about their product’s requirements and if there is any problem the merchandiser has to inform his buyers in return.
Implementation:
It is the responsibility of merchandiser to prepare the product according to the requirement of buyer.
Production Follow Up:
Merchandiser must be aware of the quality, packaging and on time delivery.
Process of Merchandising
The following process describes how merchandising carries out its responsibilities at NAVEENA:
§ Initial Inquiry
§ Initial Research & Development
§ Costing
§ Cost Sheet Approval
§ Order Booking Status Management
§ Sampling Process
§ Information Handling & Forwarding
§ Buyer Performance Review
Initial Inquiry:
An initial inquiry may be a simple fax describing briefly the target price *FOB and product or it may be detailed package from a buyer describing in detail.
Initial Research & Development
Initial Research & Development or preliminary discussion is carried out with RESEARCH AND DEVELOPMENT to see if the company has the capability to produce the product in terms of man and machines.
Costing:
Merchandise makes a cost sheet to see if the product is feasible or not in terms of cost and revenue. For this purpose a cost sheet is prepared, keeping in view the styling and accessories to be used on the product.
Approval:
After the cost sheet is prepared it is presented to the CEO or any other approving authority for approval. The approval is mainly granted keeping the profit in view.
Merchandising process continues if a specific cost sheet is approved.
Order Booking Status:
Once an order is received it is mentioned in order booking status. OBS is extensively necessary to maintain the track of records, capacity optimization, and planning further through OBS strategic planning is also carried out. It helps in calculating cash in and out follow.
OBS is normally kept confidentially and it is only accessible to predefine personal.
Advantages of Establishing OBS(Order Booking Status)
Following are the advantages to establish the OBS.
Ø Makes order follow up easier
Ø Allow better planning
Ø Helps in contingency optimization
Ø Helps in contingency planning
Ø Improves time management
Ø Improves coordination
Ø Helps in financial forecasting
This document must be kept confidential as it contains very sensitive information access to be only allowed at a specific level, as per the policy of company.
Sampling:
It is the complete process through which sampling approvals are taken. It starts from a proto sample and ends at shipment sample depending on the buyer as different buyer have different sampling requirements. Samples may be paid or free depending on the category, quantity, contract with the manufacturer.
Information Management & Forwarding:
All information received from the buyer is forwarded to the relevant department in the factory as to PPC package, checklist, accessories etc. information is provided which in terms is processed by the PPC and is forwarded to the relevant departments to start production.
Buyer & Country Dependence:
It is always better to establish an optimum buyer that dependence on the buyer be balanced so that just dependence on the buyer is also avoided and on the other hand dependence on too many buyer is also not recommended.
Updating of OBS:
OBS could Management Information Systemlead document in case it is not properly updated. Special checks need to be maintained for proper upgrading of the OBS ad if data on the OBS is incorrect capacity and management could be seriously affected.
COST SHEET
Style Number: 26898 Fabric: S/Jersey
Season: 1Q 2003 GSM: 225
Buyer: Target Gauge: 24
Division: Men’s
Consumption of yarn: 5.67Kgs/Dzn 12.50 Lbs/Dzn
Process Cost/Unit TTL Cost
Yarn 55 Rs/Lbs 687.5
Knitting 10 Rs/Kgs 56.70
Dyeing 65 Rs/Kgs 368.55
Cutting -
Embroidery 2.5 Rs/Pc 30
Flocking -
Printing 6 Rs/Dzn 6
Accessories 15 Rs/Pc 1440
Stitching 120 Rs/Dzn 120
Inland Freight 20 Rs/Kgs 113.40
2822.14647
Total Cost/Dzn
30
Over Head % Rs 846.6
Mat + OH + Cost Rs 3668.8
25
Profit % Rs 917.2
Mat + OH + Profit Rs 4586.0
58
Exchange Rate TTL USD 79.1
Rs/USD
Price per Piece USD/Pc 6.6
Package
Package is basically the collection of information given by the buyer regarding to specification, details and other related information about the specific product that has to be manufactured.
Components of a package:
Package consists of the following components:
1. Cover Sheet
2. Fabric Mill Sheet
3. Sketch Sheet
4. Accessories Detail
5. Size Specification Sheet
6. Packing Manual
7. Revision History
1. Cover Sheet:
It contains the general information about buyer, style #, garment, season, division.
2. Fabric Mill Sheet:
It contains the information about fabric for garment and it includes:
Division, style, season, type of Fabric, type of yarn, gauge, diameter, GSM, GSM before and after wash, dyeing, details, finishing details and shrinkage etc.
3. Sketch sheet:
It contains the information about front and back view. It also includes the stitching type i.e. (overlooks, main stitch, back stitch, folder, and flat lock).
4. Accessories Detail Sheet:
It contains the complete information about stitching threads, button material, button color, and button thread. It also includes the size of button (16, 18, 20 or
22 line.) and that either buttons contain two holes or four. Line is the unit of button.
Type of Stitching
Ø Over lock
Ø Lock stitch
Ø Flat lock
Ø Folder stitch
Labels:
It also includes the detail of label with its size specification. There are three kinds of labels;
Ø Main labels
Ø Size labels
Ø Care labels
Ø Tablet labels
Ø COO labels
And two main types of labels are as follow;
1. Woven Labels
2. Printed Labels
Accessories detail also contains detail about taps. There are three types of tapes.
1. Hearing Bone Tape
2. Plain Tape
3. Fusing Tape
Fusing tape further consists of two types;
1. Tear away
2. Non Tear away
Fuse able through glue while using iron.
Normal width of fusing roll is 40``.
Fusing Roll
Tear way is fusible while non-tear way is non fusible.
GMT Color
Color Code
Stitching Thread
10% cotton DTM
Embroidery Thread +
Code
Style #
Main Label Code
Main Label Source
Size Label
Code Source
Red 0020 RedStucco MD-1001
ML101 Futek SM-1 Futek
Green 0030 GreenRed MD 1181
ML 101 Futek SM-1 Futek
Yellow 0040 YellowWhite MD 10001
ML 101 Futek SM-1 Futek
5. Size Specification Sheet:
It contains the size of garments.
Description Small Medium LargeX
LargeXX
LargeTolerance
Chest 1” below arm hole
23 23.5 24 24.5 25 + 0.5
Heam Across Shoulder
23 23.5 24 24.5 25 + 0.5
Cuff Opening _ _ _ _ _ _
Arm Hole _ _ _ _ _ _
In SPEC sheet all values are taken in inches while tolerance means acceptable deviation. Buyer gives all sizes.
6. Packing Manual:
Packing manual contains the folding details of a garment, printing details, and material to be placed. It also includes hangtags detail, carton dimension details.
Packing Strategies:
There are four packing strategies;
1. Solid Color Solid Size
2. Solid Color Assorted Size
3. Assorted Color Solid Size
4. Assorted Color Assorted Size
Solid Color Solid Size:
According to this strategy all garments are of same size and color. e.g
Garments = 42
Color = Red , Size = Small
Solid Color Assorted Size:
According to this strategy color of all pieces is same while there is variation in size e.g.
Garments = 42
Color = red
Size = Small, Medium, and long with ratio 1:2:1.
Assorted Color, Solid Size:
In this strategy color of garments is different while size is same.
Garments = 42
Color = Red & Blue
Size = Medium
Assorted Color, Assorted Size:
Garments are of different colors and sizes.
Garments = 42
Color = Red & Blue
Size = small & Medium
7. Revision History:
It includes all the changes required by the buyer afterwards e.g. buttons changed 3 to 2 or change in thread.
Ti also includes the revision description, date, time and initiating authority.
POLY-BAG
1. Types:
There are three types of poly bags.
I. Individual Poly bag:
Individual poly bag contain 1 pc/bag.
II. Blister Poly bag:
Blister poly bag contain more than 1 pc/bag in a carton.
III. Master Poly bag:
It contains more than one piece/bag.
2. Dimension:
10``
9``
Flap 3``
Fold Size L W
W x L x F
9.5`` x 10.5`` x 3``
3. Material/Transport/GG:
Printing
Weight of Carton
Instructions
Logos
Address
Buyer’s individual idea
Carton tape
Carton stickers
Cartons
Solid Color Solid Size:
Garments = 42
Color = Red
Size = Small
Solid Color Assorted Size:
Garments = 42
Color = red
Size = Small, Medium, and long
Assorted Color, Solid Size:
Garments = 42
Color = Red & Blue
Size = Medium
Assorted Color, Assorted Size:
Garments = 42
Color = Red & Blue
Size = small & Medium
Information Required For Carton:
Following information is required for a carton.
Ø Hang tags
Ø Tag pins
Ø Plastic Clips/Jet clips
Ø UVM (Universal Vender Mark)
Ø VMT (Vender Mark Ticket)
Ø UPC (Universal Product Code Ticket)
These above accessories are used 1/pc and only tag pins are used 2/pc and jet clips are used 4/pc.
Types of Carton:
· Regular slotted
· Telescopic carton
Regular Carton
Telescopic Carton
1. Dimensions
Flap
Height
Width
Length
L x W x H
28 x 26 x 8
2. Carton Printing
Ø Addresses (From & To)
Ø Carton Contents (Size, Color)
Ø Symbols
Ø Weight of Carton (With garments weight)
Printing Types
Ø 2 Side printing
Ø 4 Side Printing
3. Carton Accessories
Ø Carton Sticker
Ø Carton Tape
Ø Carton Strapping
Sampling Management Process
Management is the process to do work on time, achieve target/goal on time while using
All resources (machine, personnel, Human Resource).
Sampling is the complete process through which sampling approvals are taken. It starts from a proto sample and ends at shipment sample depending on the buyer as different buyer have different sampling requirements. Samples may be paid or free depending on the category, quantity, contract with the manufacturer.
Sampling programmers can be a cost effective, tangible and highly visible method of launching new product, boosting sales or re-educating lapsed users.
Sampling programs provide a conduit for consumers to experience product trials. Product samplings and mailings increase brand awareness and result in additional sales.
Sampling should be complete on time with resources;
Ø Initiate Sampling Process
Ø Sampling Budget (To Control Cost)
Ø Time & Action Plan of Sampling
SAMPLING PROCESS
Proto Type Sample:
This is the first sample given to the buyer. The sample is prepared according to requirement of buyer and this is the rough sample. The range of sample is about 1-2 to vary according to the requirement of buyer.
Comments on Proto Type:
Buyer gives his comments on sample and also recommends the changes in sample.
Counter Proto Sample:
This sample is based on the comments received from the buyer. For this sample, 2-3 pieces are required.
Salesman Sample:
Buyer sends the samples in market by salesman to get market feedback from customers it is done on 250-500 pieces or may exceed depending on season and customer. Buyer has to sell these garments to check and view.
Samples
Market
Feedback
Buyer’s Design
Buyer’s Merchandisers
Manufacturer’s Merchandiser
Comments on Salesman Sample:
Feedback on ample from customer is send to merchandiser/ manufacturer.
Pre-Production Sample (PPS):
Manufacturer prepares it. All changes are confirmed on it. 2-3 pieces are required in pre-production sample.
Approval of PPS:
It is the stage where a sample may be approved or rejected.
If accepted go ahead to next step and if rejected then there will be the process of revision of previous steps. PPC department is also involved at this stage. Once PPC is involved, no change in styling is acceptable.
Size Set Sample:
2-3 sets of different size are sending to PPC (planning production and control). Manufacturer keeps one sample himself and one sends to buyer for cutting
approval. Its purpose is that buyer will make no change in cutting details. If he makes some changes, he himself will be responsible for any loss/ damage.
Fit Sample:
No change in stitching is acceptable at this stage. 2-3 garments are used in fit sampling.
Photo Shoot Sample:
Now the sample is ready fort shipment. Buyer picks some pieces randomly to test its gauge, GSM, shrinkage. If all these are according to the requirement of buyer then shipment is said to be ok. 15-20 pieces are picked up as a sample to test.
Shipment Sample:
This stage is the completion of total order. And the garments are sending to shipment.
SAMPLING BUDGET
It consists of the following data.
Sampling budget
Knitting plan
Dyeing Plan
Accessories Sheet
Cutting& Stitching Plan
1. Sampling Budget:
It contains the general information about;
Buyer: Target Fabric: Mesh
Season: 3Q 2003 Pieces: 500
Style #: 295 Division: Men’s
GMT: S/S Polo with 1x1 Rib DTM body at neck.
2. Knitting Plan:
Knitting plan is used for the description of material to be knit.
Description Yarn F. Width 36’’F. Width
26’’
Mesh 20 S Carded 200
Rib 20 S Carded 9’’
Total Width 209’’
Total # of Pieces = 500
Mesh for 1 Shirt = 400g
Mesh for 500 Shirts = 500 x 400 g
= 200,000 g
1000
= 2 Kgs
Total # of Pieces = 500
Rib for 1 Shirt = 18g
Rib for 500 Shirts = 500 x 18 g
= 9,000 g
1000
= 9 Kgs
Yarn Requirement:
20 S Carded = 209 = 5
45.36
Dyeing Plan:
Color C. Code Mesh Kgs Rib Kgs
Red -250 x 400/1000 = 100
250 x 18/1000 = 4.5
Navy -250 x 400/1000 = 100
250 x 18/1000 = 4.5
Accessories Sheet:
Description Factor TTL Material
Stitching Thread Red 200m250x200/2286 = 22
Stitching Thread Navy -250x200/4500 = 12
Main Label 1 1x500 = 500
Side Label 1 1x500 = 500
Label 1 1x500 = 500
Core Label 1 1x500 = 500
Twill Tape 1m 1x500 = 500
Poly bag 1 1x500 = 500
Tissues 2 2x500 = 1000
Cartons (24/Pieces/Carton)
500/24 21 cartons
Prepare By: ________ Checked By: _________ Received By: ________
Stitching Thread:
Small Cone = 2286m
Large Cone = 4500m
1m = 39.37’’
Cutting & Stitching Plan:
Color C. Code S M L XL TTL
Red - 100 100 50 250
Navy - 100 100 25 25 250
Total 100 200 125 75 500
Time & Action Plan:
Pieces = 500
Packing = 200Pcws/DAy
Stitching = 150Pieces/DAy
Cutting = 1day
Dyeing = 2 days
Knitting = 3 days
Yarn Package = 1 week
Yarn Req. Knitting Dyeing Cutting Stitching PackingFactory Date
S.D E.D S.D E.D S.D E.D S.D E.D S.D E.D S.D E.D
28Jul
5Aug
9Aug
12Aug
15Aug
17Aug
20Aug
21Aug
20Aug
24Aug
23Aug
27Aug
7 Sep.
Prepare By: ________ Checked By: _________ Received By: ________
METHODS OF BREAKDOWN
Following are the methods of breakdown.
1) Purchase Order
2) Production Summary
a. Ratio
b. Percentage
c. Direct given by buyer
RATIO METHOD
Color C. CodeS
1
M
2
L
1TTL
Red - 1/4x1000=250 2/4x1000=500 1/4x1000=250 1000
Green - 1/4x2000=500 2/4x2000=1000 1/4x2000=500 2000
Htr Grey - 1/4x3000=750 2/4x3000=1500 1/4x3000=750 3000
PERCENTAGE METHOD
Color C. Code S (30%)(M
20%)(L 50%) TTL
Red - 300 200 500 1000
Green - 600 400 1000 2000
Htr Grey - 900 600 1500 3000
DIRECT METHOD
In direct method the buyer gives all values.
Color C. Code S (30%)(M
20%)(L 50%) TTL
Red - 1000 2000 3000 6000
Green - 5000 9000
Htr Grey - 6500 6000
FABRIC
CONSUMPTION CALCULATION
Following methods are used to calculate the fabric consumption.
Step 1:
Identify components of a garment.
Step 2:
Take finish width available from R & D.
Step 3:
Layout patterns + optimizes wastages.
Step 4:
Calculate length of layout.
Step 5:
Apply formula.
39.37 x 39.37 = 1550 yarn/pc/layout
L x W x 2 x GSM = ____________ = ___________
1550 No. of Pieces/day grams/Pc
While 2 = No. Of Layers of Fabric
Circular Knit consists of 2 Layers
Open width consists of 1 Layer
Step 6:
Add wastage.
Step 7:
Calculate / make plans.
Basic Terms:
Ø Open Pattern
Ø Close Pattern
Ø One Garment
Ø Components
Calculations:
Rib = 26’’
Fabric = 30’’
30 x 60 x 2 x 200 = 464.5
1550 2
= 233g/Pc
Neck Calculation:
Neck = 3’’ x 26’’ x 220 x 2 = 23 = 7.3g/Pc
1550 3
Cuff Calculation:
Cuff = 3.5 x 26 x 220 x 2 = 25.832 = 12.9g/pc
1550 2
Fabric = 233
Neck = 8
Cuff = 13
Total 254
Including small wastages254 x 12 x 2.2046 = 6.72lbs/Dzn
1000
TYPES OF WASTAGES
Cutting:
It includes;
Excess planning
Small wastage 5 % included in layout
Large wastage 3 %
Dyeing:
It includes;
Dyeing wastage 6-9% normally for fleece
Finishing wastage
Knitting:
It includes;
Knit 2-2.5% wastage that is left over yarn wastage
Yarn Dyeing:
It includes
5-7% Yarn dyeing wastage
WASTAGE
ADDITION METHOD
There are two methods used for waste addition.
I. Progressive/ Step By Step Method
II. Direct Method
Calculation for Yarn Consumption:
Length = 60’’
Width = 25’’
No. Of Pieces = 2
GSM = 220
60 x 25 x 2 x 220 = 425.80g
1550
425.80 = 212.90g/pieces
2
Calculation for Rib:
Length = 5’’
Width = 30’’
GSM = 250
5 x 30 x 2 x 250 = 48.50g
1550
48.50 = 12.10g/pc
4
Wastages:
= 5.95 x 1.05 x 1.03 x 1.06 x 1.02
= 6.95Lbs/Dzn
RESEARCH AND DEVELOPMENT
Ø Research and development or RESEARCH AND DEVELOPMENT is related with product development.
Ø Concerned Merchandiser forwards the Fabrication Info to the Product Library and will get the exact match.
Ø If there is required match, Documentation and Planning is done, Merch is developed and PD Plan is made by the PD center.
Ø If there is no exact match, Technical evaluation (Pricing), Documentation and Planning is carried out. RESEARCH AND DEVELOPMENT starts working here. After that PD Plan is made by the PD center.
RESPONSIBILITIES OF THE RESEARCH AND DEVELOPMENT MANAGER
Ø She decides the fabric styling, finishing Routes. He submits the fabric in the Lab.
Ø He compiles the results.
Ø He sends the results to the buyer.
Ø If OK for the results, Data is inserted into the computer for making the file. If result is not OK, we refinish the fabric.
Ø RESEARCH AND DEVELOPMENT sends the developed samples to the P.I. Lab, for the quick wash and sees the results after the 3 washes and required GSM is produced. After the quick wash, 20-30 g (weight) of the fabric is reduced just because of chemicals and detergents. Maximum sample weight is 10 Kg but is according to the merchandiser’s requirement. Yarn Count, Single Knit/Double Knit, Width and GSM is calculated and observed in RESEARCH AND DEVELOPMENT.
PRODUCT DEVELOPMENT PLAN
Ø It issues the work order, tells about the style, design, counts, gauges, fabric finishing routes and fabric dyes.
Ø PD plan is send to the three departments; RESEARCH AND DEVELOPMENT, SAMPLING, Sewing and ACCOUNT.
Ø One copy remains with the Merchandiser.
Ø One copy remains with the PD- Officer.
QUALITY PLAN
Ø Quality Product Requisition (QPR) is made in RESEARCH AND DEVELOPMENT.
Ø Within three days Quality Plan is issued from RESEARCH AND DEVELOPMENT.
Ø Quality planning includes the “Consumption Sheet or Pattern Efficiency” that is 85% required..
Ø Quality Planning also includes the “Garments to Kg concept”, that shows that how much garments can be abstracted from the 1 Kg of fabric.
Ø An independent and vertically integrated product development and research center is one of its own kinds. It is a 35000 sq ft facility, largest in Asia, designed to achieve the following
Fulfilling Designer’s Dreams
§ A facility where an idea can be accurately converted in to product in quickest turnover rate.
§ Continuously developing and innovating new and exciting fabrics, garments and finishes in line with ever changing trends in knitwear world.
§ Ensuring reproducibility and predictability of new products for production.
Meeting Merchandizing Requirement
§ Delivery of all types of samples with speed, accuracy, quality and competitive pricing.
§ Prototype samples in 3-4 days in actual fabric and color.
§ Sales man samples in 2-4 weeks at actual production parameters
MANAGEMENT INFORMATION SYSTEM Department
MANAGEMENT INFORMATION SYSTEM department more than 100 hardware computers in factory. He is responsible the maintenance and hardware related problem. Look after of these computers.
Only available recourses are planned.
Software’s:
The software’s that are being used in NAVEENA Textiles are:
Ø Inventory management
Ø Fixed assets system
Ø Salary system software
Ø Piece rate related software
Ø Engineering system
Ø Attendance system
Security:
Login is provided to every user and password is provided, he can change according to his convenience. In all organization we provide three types of login.
1. Home directory
2. Department share
3. Care drive
Home Directory:
Home directory the user can build folders, files. He is only responsible for compiling and security for this data.
Departmental share:
The departments can share data with each other.
Care drive:
In care drive the departments can read only. Write facility is not provided because security purpose.
Future plan:
In future plan they will implement the E Commerce for update the status of the garments. They also plan to implement ERP step by step. They are using SQL because this provides more security and cheaper than database.
HUMAN RESOURCE DEPARTMENT
Human resource department is responsible for
Ø Recruiting
Ø Training
Ø Compensation
Ø Performance appraisal
Ø Firing
Recruiting
In NAVEENA for management hiring three interviews are conducted if they are experienced. If they fresh graduate then first written test is done after this initial interview, and then final interview is conducted. This process is done for management trainees.
For workers and officer level the head of department hire. His criteria will accord job requirements.
Training
On the job training is mostly provided. But sometimes for management we conduct seminars; in LUMS some lectures are scheduled. Some mangers they visit to foreign countries for getting training.
Compensation
For management trainees they provide Rs.12000 and other according to job requirement and skills of the employee. They also compensate according market going situation.
For workers they are providing minimum Rs. 3000 according to government rolls. For officers the G.M decide how much salary will be provided. This depends on the nature of the job and skills, experience of the employees.
Firing the employees
If any employee is not doing his job very well then the Head of the department fire the concern employee.
PRODUCTION PLANNING AND CONTROL
Production Planning and Control (PPC) is the nervous system of the organization and its basic task is to receive information from the merchandiser and link it to the production. It involves the Pre-Production Analysis to ensure quality and reproducibility.
PPC has two further branches
A) Material Resource Planning
B) Production Planning and Monitoring
MATERIAL RESOURCE PLANNING
Material Resource Planning is done for the material procurement, like sundries, yarn and fabric. It is basically done to analyze that how much is needed, what is needed, when is needed, what is the cost of the material and how to acquire the resources.
PRODUCTION PLANNING
It includes the planning like the Sewing Plan (we can also call it as the Master Plan). Back Ward Production Planning is done and this Production Time Line involves when’s and what’s of the production. Date Wise Plans are made from work order to delivery.
MONITORING
It is the different entity. Monitoring is done for the whole production process and in this we check out the planning implementation. If the planning is failed, re-planning is done for that. Off- the- track and On-the- track planning is also done by the PPC.
DOCUMENTS RECEPTION IN PPC
Two types of the documents are received by the in the PPC from RESEARCH AND DEVELOPMENT and Cutting.
RESEARCH AND DEVELOPMENT
PPC receive Quality Plan from the RESEARCH AND DEVELOPMENT. In this Quality Plan specification, quality, width, weight, dyes, gauges and counts are mentioned.
Cutting
PPC receive Fabric Consumption Patterns from the Cutting department and plans that how much fabric must be used.
DOCUMENTS GENERATION IN PPC
Store Plan
Store Plan can also be called as Accessories Plan. It involves all the documentation about the sundries being used in the production of the order. It also involves the information about Threads, Buttons, Sewing and Labels. Store Plan is basically a Quantity Plan.
Dyeing Plan
It is related with the Dyeing of the fabric that how much fabric is required for an order, and then it is converted in to the Acro fabric. It plans for how much dyes and chemicals are required. For the procurement of the materials, PPC goes for the purchase department.
EXTRA PLANNING
3-5% extra planning is done for the losses. There are some visible losses and some invisible losses. Visible losses occur from cutting to shipment. Invisible losses are being made in Dyeing process and Finishing Process. Any extra
planning requires extra cost. So for the additional planning and additional cost, PPC managers have to go for the Chief Executive.
The Production Planning and Control is the nervous system of our organization and undoubtedly it is our key success factor. The nucleus of NAVEENA and Sarah’s remarkable success has been its impeccable system. PPC conducts detailed pre-production analysis to ensure quality and reproducibility.
PURCHASE DEPARTMENT
Every aspect of organization for the manufacturing of the product like sundries, stationary, parts of machineries that can be available locally, chemicals and dyes etc. have to be purchase locally from the local markets. These are usually the general items, involve local purchasefor the purchase of machines machinery that is not available in the local market, import department involves in such purchases. This whole import department is concerned with the high involvement machinery. They whole purchase department is do not work the work order or purchase order. Things are purchased according the buyer demand. No buying is done without the order. As such no inventory level is maintained for such goods as these goods are utilized immediately and plan is made for the minimum for the week. Three most important documents are used in the purchase department.
Store Plan Store plan comes from the Store and purchase Requisition; It comes from the warehouse. Buyer provides purchase Order and according to this the store department make plan. It is made for one supplier only at one time only. Demand of the supplier is mentioned in the purchase order. These documents are used all over department.
MPR: Material Procurement Recognition
Every department issues this then the purchase department is responsible for procurement.
MRP: Material Requirement and Planning
This document is used within factory for issuing the material.
EXPORT DEPARTMENT
EXPORT PROCEDURE
Purchase order is received from buyer through the merchandizing department. A fax message is send to buying house/buyer for opening L/C. Expected Audit date/time received and go-head is taken from concerned unit (manager) to carry shipment. Arrangements are made for the transportation to move the consignment by the road/train/air as per plan.
Funds arrangement for the transportation and custom clearance charges.
Shipment moves for the Karachi through the following ways. Eg. Truck, Train, and Air. Rates are as per shipment volume.
Cargo lifting advice is fixed to custom clearing agent/ Forwarder/ Transportation. Forwarder / clearing agent make arrangements for the custom clearance and booking of the space at earliest vessel. Following documents are required for the custom clearance. Detail is given following;
INVOICE
In Invoice following criteria is required.
Ø Consignee and Applicant Addresses
Ø Garment Description
Ø Garment Price and Total Invoice value
Ø Net and Gross Weight of Garments
Ø PO (purchase order) no.
Ø Freight Terms; FOB/ C&F/ CIF/ Ex-Work Pakistan.
Ø From # & Date
Ø L/C. #(letter of credit)
PACKING LIST
There are following details in the packing list required as per buyer’s instruction or mentioned in L/C.
§ Consignee and applicant addresses
§ Product description
§ Garment Style and color
§ Net and Gross weight of Garments
§ No. Of Pieces in the Carton and Carton Dimension also other necessary information, which gives help for the custom clearance.
Export-FORM
E-FORM is issued and attested by the concerned bank.
VALUATION FORM
It is for the custom purpose to inform the value of the consignment to the State Bank of Pakistan.
BILL OF ENTRY
Applicable only in case of the imported material used in the manufacturing of the garments for the export purposes.
SHIPPING BILL
The forwarder prepares shipping bill. After the sub Management Information Systems ion of the custom docs, by the forwarder, custom authorities check the docs. And examine the shipment accordingly. They write the report on the backside of the shipping bill and allow the shipment for the export from the Pakistan. All these docs are then returned to the export department.
QUOTA PROCEDURE
Ø Arrangement of the quota for the exporting the above goods or the garments as per category.
Ø Quota purchase from the open market/ EPB (export promotion bureau)
VISA PROCESS
After receiving the Docs from the forwarder, Export Department prepares the Visa docs, which are required for the export of garment to the following countries; USA, CANADA, EUROPEAN countries.
The set of Visa with required docs is presented to P.H.M.A. for the issuing/ entering of the Passbook and the given serial numbers.
After this P.H.M.A. pass the Visa to the E.B.P. for the Visa issuance. Then after the checking of the docs Visa is signed and stamped by the Director of the E.P.B (textile section). All original docs are returned to the export department.
NEGOTIATION / COLLECTION
After the completion of the Visa process, we submit the docs in the Bank for the negotiation/ collection. The docs are prepared according to the L/C. or the buyer requirement.
DOCUMENTS FOR THE BUYER
Export department also prepare documents for the buyer for the custom clearance of the shipment at the destination.
PAYMENT PROCEDURE
After the negotiation/ collection procedure of the docs, bank dispatches the same to L/C opening bank, to realize the payment. Foreign bank is bound to realize the same within the 10 to 15 days. After realization of the payment, our bank is bound to issue the PRC within the working days.
REBATE CLAIM
After receiving the PRC, export department claims the duty draw back (rebate) from the customhouse in Karachi or Lahore.
COMMERCIAL INVOIVCE
In the commercial invoice all the details are mentioned required under conditions of L/C for the custom clearance and other necessary purposes.
PACKING LIST
It consists of color, weight, product code/other, coding numbers, no. of cartons, carton dimension, and carton packing.
BILL OF LADING/ AIRWAY
This is according to the L/C terms and conditions.
SHIPPING CERTIFICATE
In this certificate the shipping line intimates that the vessel /flight is not affected buy on Indian or the Israeli Flag vessel.
BENEFICIARY’S CERTIFICATE
It is according to per buyer requirement.
§ INVOICE: It is custom attached and details of the imported material are also given, that is used in the manufacturing of the garment.
§ SHIPPING BILL: It is provided by the clearing agent and attested by the custom authorities.
§ BILL OF LADING: in it all the required information is provided which is needed for the custom clearance.
§ BILL OF ENTRY: We need detailed information like Description, Foreign Exchange Rate, Insurance, H.S Code, Weight, Custom and sales tax duties and etc.
Business Operation
Management:
The management team of NAVEENA comprises of dedicated and highly motivated individuals, laying much emphasis on teamwork and interdependency, which brings synergetic results.
They bring with them, experience in the knitwear industry and diverse educational backgrounds, both local and international.
NAVEENA has tried to develop a company culture where quality is given the top priority, innovation is encouraged, system are followed and fool proof inspection procedures at every stage of production and carried out.
Quality Standers:
Continuity in quality is an integral part of this organization. there is team of professionals who head this department .their work starts from yarn till the end product .strict quality control measures are implemented from the beginning and at all subsequent levels to maintain standards .
Quality Emphasis:
The organization has already achieved ISO 9002 certification and has acquired various quality certificates and awards.
Laboratory Testing:
The organization have a comprehensive lab to check dye lots .its the organizational routine to check fabric for shrinkage, lot to lot shade continuity, color fastness to corking etc.
Among other equipment the most noted are the data colors, spectra flash, tumbler and washing.
Major Clients:
The organization is working with leading multinational companies and believes in developing long term, sustainable relationships rather then “one time” commercial contract. Organizational buyers are recognized and respected names in the international apparel industry, including the followings,
Factory Facility
Factory area KHI 12000sq.yards covered area 175000sq .FT
Factory area LHR 5375sq. yards covered area 150000sq FT
No. Of employees-KHI 2500
No. Of employees LHR 1500
Gov’t departments involve with organization:
There are many departments, which are involved in term of Govt intervention in the textile industry, which are followings,
CBR
Ministry of labor and manpower
Ministry of excise and taxation
Custom department
Quality standards assurance organization
State bank of Pakistan
Structure and design of organization:
Structure of the organization is flat and functional. And it is to some extend is a mechanistic organization. But it is due to its mass production .The organization along with its functional structures has horizontal linkage which is most necessary thing in garment industry because of high quality consciousness.
Plant and Equipment:
The organization’s most of the plant and equipment is procured internationally, configured to generate optimal production at all stages and to ensure high quality.
In term of knitting
Type Model Gauge Diameter No.
Auto striper (terrot) s4f-248 18 30 5
Auto striper (terrot) s4f-248 20 30 2
Auto striper (fuquhara) s4f-248 18 30 2Auto striper (fuquhara) s4f-248 20 30 1
Mini jacquard (terrot) s3p4f-148 18 20 1
Feed stripe (Mayer & cie) 1mv4 11 20 30 1
Feed stripe (Mayer & cie) 1mv4 11 20/24 30 1
Feed stripe (Mayer & cie) 1ml-bf 20 30 1
Eight lock double knit t130-9621 18 30 2
RIB (pai-lung) t130-9621 16 34 1
Flatbed machines:
Make Origin Gauge length Number
Matsuya Japan 14 80cm 16
Matsuya Japan 14 56 05
Dying
Yarn dyeing:
Description make capacity number
fong’s yarn dyeing H.K 30kg 1
Atyc yarn dyeing H.K 90kg 1
fong’s yarn dyeing H.K 200kg 1
fong’s yarn dyeing H.K 300kg 3
fong’s yarn dyeing H.K 750kg 1
atyc yarn dyeung H.K 850kg 1
fong’s yarn dryer H.K 300kg 1
these machinbes are wiuth a capacity of four batches.
Fabric dyeing:
fong’s 2t soft flow H.K 300Kg 1
Fong 3t soft flow H.K 500-600kg 2
Atyc –ht 4t soft flow SPAIN 900kg 1
Atyc –ht soft flow SPAIN 165kg 1
Winding machines:
SSM cone winder Switzerland 2000kg 4
Re-winder local 9000kg 6
Garment washing:
Suit lick washing machine H.K 4000/day 2
Finishing:
hyadro extractor local 60kg 1
Hydro extractor Taiwan 60kg 1
Tumbler (askmer) H.K 30kg 8
Tumbler (sutlick) H.K 30kg 2
tumbler (askmer) H.K 30kg 8
Tumbler china 60kg 1
Dryer (sanatax) Switzerland 5 ton/day 1
Stenator Italy 15ton/day 1
Fabric slitter local 500kg 1
Squeezer Switzerland 6000kg 1
Corino (slitting machine) Italy 12000kg 1
Monforts (6chamber stenter Italy 15000kg 1
With graving system)
Gravimeter system raising machine china 3000kg 1
Cutting /Embroidery:
Electric cutting machine KM (Japan) 12 heads 5
Embroidery machine tajima 6needles 1
Band knife nagi shing 1
Stitching
480 –sewing machines comprising along with 5 uni8ts having capacity of 22000 dozen garments /month.
Auxiliary equipment:
The organization has an in house repair, maintenance and development facility classified under electrical and mechanical department. Currently the following equipments are installed on the pre-Management Information Systems.
Equipment Made Specification Number
Boiler England 5.50ton/hr 1
Generator USA 375KVA 1
Generator USA 300KVA 1
Compressor Japan 1580lbs 4
The organization has a strong capacity of production, which also works as competitive advantages in term of technology. The brands which the organization is currently using all are of well named in industry. Which also work for attracting the buyers towards organization, and helpful for obtaining order and fulfilling it on time.
NAVEENA Dying
The dyeing process starts from the sample swatches that are sent by the Buyer.
Lab Functions:
Samples are prepared according to the needs of the buyer and the process is called lab dipping. After the buyer then the dyeing approves the samples people follow the production plan provided by the PPC.
Dyeing Process:
There are two types of dyeing
1. Yarn Dyeing
2. Fabric Dyeing
There are two Methods
1. Hi-Temperature dyeing
2. Atmospheric Dyeing.
Machinery:
In Yarn dyeing all machines are of Hi-Temperature. The capacities of the machines are as following.
1. Machine 1 is 800kg
2. Machine 2 is 90 kg
3. Machine 3 is 30 kg
4. Machine 4 is 200kg
5. Machine 5+6+7 is 300kg each
6. 8th in line is only drier of 800kg.
In fabric dyeing three machines are hi-temperature and rest is atmospheric. The capacity of the machines is as following.
1. Machine 1 is 700 kg
2. Machine 2 is 150 kg
3. Machine 3+4 is 550 kg
4. Machine 5 is 350 kg
5. Machine 6 is 50 kg and is named as winch machine.
6. Machine 7 is 20 kg and is also winch machine.
After the dyeing fabric is transferred to finishing.
Reasons for dyeing:
For attractive purpose
For uniformity
Shade variation controlling
Color gives:
More comfort
More satisfaction
Process flow:
Singeing
To remove protruding fibers
De –Sizing
To remove the size for uniform dyeing (over dry)
Scouring
To remove added and natural impurities
Detergents
To remove soil and keep it suspended in
Water. So they don’t penetrate again in the fabric.
Bleaching
Removing of color
Changing absorbency
Mercerization
Length of fiber
Fineness of fiber
Types of dyes:
Reactive dyes make covalent bond Disperse dyes make a penetration
Vat dyes make a trapping
Sulphur dyes -
Direct dyes make a overlapping
Component of dyeing:
Temperature
Salt
Machines
Factor effect the cost:
q Labor
q Raw materi
al
q Machinery
q Maintenance
q Electricity
q Transportation
q Dyes
q Chemical
q Gas
General requirements by buyers
· Strong color bonding
· No bleeding & staining
· After twenty washes no change in color
· No absorption affect on garment after twenty washes
Recommendations for cost control in dyeing house:
1. Compare the cost with competitors
2. Before selecting the product consider followings;
q Price
q Quality
q Availability
q Performance
q Packing
q Storage
q Concentration
q Final cost
q Compatibility
q Environmental factors
Required expertise:
Electric and electronic work
Mechanical work
Machine / work knowledge
Responsibility:
Maintenance Manager / Knitting Manager
Benefits:
a. Less stoppage
b. More production
c. High quality
NAVEENA Knitting
There are two kinds of knitting:
· Flat knitting
· Circular knitting.
These both categories of knitting are being performed at NAVEENA 2 facility. Let’s take a brief over view how it is done.
Flat Knitting:
The purpose of flat knitting is to prepare collars and coughs. They are given the fabric by circular knitting department and after that the technician at the flat knitting machine feeds the designs according to the demand of the buyer. They are given a complete production plan by the PPC department, which they need to follow to get the desired result.
Machinery:
For the purpose of flat knitting NAVEENA 2 facility flat knitting department is equipped with 21 automatic flat knitting machines. Three operator’s one helper and a master manage them. The capacity of each machine is 250 sets in 24 hours, and according to the statement of machine operators they are easily achieving the maximum capacity on regular basis. All the machines are 14 gauge machines, which mean every machine can have 14 needles per inch. The more the gauge better will be the quality. Common error is that of needle break, which spoils the whole fabric if not detected at once. Setting the needles in the machine according to the requirement is an art and the master has to be the master in this art to get the desired result and to avoid error.
Maintenance:
There is a separate maintenance department present but there is no concept of preventive maintenance, only break down maintenance is done which costs the organization much more than the preventive maintenance.
Quality Parameters:
The quality checkers inspect the flat knitted fabric on the basis of Wales and courses. They check whether the whales and courses per inch meet buyer requirement or not. Wastage of 2 % is allowed.
Circular Knitting:
They again get their line of action from the PPC department. The purpose of the circular knitting is to convert yarn into fabric.
Machinery:
There are total 15 machines 9 of them are computerized and called auto machines. These machines are capable of making maximum stripes on a fabric while using four colors at a time. The auto machines are mostly used for the preparation of fabric of dark colors and having stripes or repeat. The remaining six machines are called feeder machines. They cannot make a stripe more than 2.5 inches on a fabric. Mostly they are used for simple fabrics of white and light colors. Each machine is capable of producing 150 kg per day. A total of 192 cones of yarn can be added to a single machine of four different colors, 48 cones belong to each color. One person handles each auto machine and two feeder machines are under one person. There is a supervisor and a master present to keep check on the things. The machinery is not capable of producing French terry and fleece fabric. Any order of these two fabrics is outsourced. All the machines have flexible gauge facility, which is set according to the buyer requirement.
Quality Parameters:
After the fabric is prepared it is checked by the quality personnel on a machine called clatter machine, using the 4 point system. This machine enables the quality personnel to detect various defects in the garment, after detecting the error they mark it and send for appropriate corrections. The errors, which cannot be removed, are then cut off in a way that their effect should not be on the finished garment.
Finishing:
The finishing can be termed as the process for drying the fabric. First of all the fabric is transferred to hydro machine which squeezes the water out of fabric. Then the fabric whose rate of shrinkage is more is sent for tumbling which is the traditional approach for drying and the other fabrics are transferred to tenter fesaro + compactor machine, where fabric is straightened. The machine is hi-tech and fully computerized. Then the fabric is transferred to slitting and squeezing machine. After that comes in the stenter machine having six chambers. After that the fabric goes through the erasing machine which smoothens the fabric mostly fleece is erased. Now fabric is ready and is transferred to NAVEENA 1. All the machines are of hi-technology and produce great results. A dryer is in the
process of being set up and will soon be functional increasing the efficiency of the finishing section.
Quality Parameters:
The quality personnel check the quality after the erasing and the main concentration is upon the variation of shades. If the fabric shade varies then it is sent back for re dyeing. The sophisticated fabric in whom there are more chances of shade variation it is even checked during the dyeing process by the quality personnel.
Cone WINDING:
It is of two types:
Ø Soft winding
Ø Re winding
Soft winding:
The yarn when firstly come is hard .the cone winding department re wind it to make it soften. Then it become easy to dye and the dye quality become higher.
Re winding:
After dyeing of the yarn it is re winded and is transferred from spring wind to the paper wind.
The biggest draw back is that there are no control checks what so ever in the cone-winding department. If any thing Management Information Systems the eye of supervisor then any error can easily go through
Major Suppliers
Din spinning
Sapphire
Ejaz spinning
Azgard9
Dewan Mills
Nishat Mills
Hussain Mills
Factors Affecting on Organization in Term of External Environment
There are factors which are currently affecting the organization and are as follow:
Gov’t policies
As the policy of Gov’t changes it directly effects organization because there are many factors, which entice the organization with Gov’t
· Tax policy
· Rebate
· Quota
· Industrial policy of Gov’t in term of garments manufacturer.
· Subsidies from Gov’t.
· Labor policy
Brands
Side out
High sierra
Antigua
Cherokee
Amc –stores
Aeropostale
Phat farm
Roots
Hard rock café
Hollister
Brake water Perry Ellis
Wal-Mart
The company devotes considerable time and effort to consolidate its present relationships and develop new ones, agin, with the goal of establishing relationships, which are long term and diversify the company client base.
Suppliers of organization:
The company also has the list of compatible suppliers and includes them in term of stakeholders and used to facilitate them with the maximum beneficial way to develop long-term relationship with them. The supplier side is although most critical aspect of the organization in term of quality and quantity because of the large-scale production in NAVEENA.
Organizational Culture
NAVEENA consider its employees to be its biggest assets. Adequate facilities exist and are constantly upgraded to improve the social environment.
The organization has following statement for their social culture
“We strictly, under all cost, forbid child labor and forced labor”
Competition
There is a big competition between industry .in term of taking orders and the main aspect is price of manufacturing garments. There is less innovation and differentiation in products.
So, because the commodity is same and due to witch there is cost factors which is very high and directly effect organization.
Domestic competition
· Masood textile
· Ammar textile
· Leisure textiles
· Irfan textile
· Shah –kam textile
· Angora textile
· Combined fabrics
· Comfort textiles
· Mian sons
These are all major competitors of the organizations, and all are Lahore based.
International Competition
The overseas competition is now –a –days very less but it will become very high after the remove of ATC .the organization has to develop its self from now to be in market in future. Because in that huge dynamic e4nvironment there will be more dimensions in organization to meet with uncertainty.
It can be come from:
· Singapore
· Bahrain (because the USA made a contract with UAE)
· China
· Bangladesh
· Thai-land
· Honk –Kong
· Malaysia
Technology:
Technology is also a key sector in term of external environment for garments industry. Because the technology is also working as a substitute for man power with more efficiency. The industrialist has a solid point that it also saved cost i9n term of
· Error reduction
· Les labor cost
In order to compete internationally the organization must have to depend on new and advanced technology. Although the technology, which NAVEENA is using not very low but there is no end in business.
Structure and design of organization:
The structure of organization is functional with horizontal linkage.
The organization has mechanistic design and which is working on the basis of efficiency, which means more production, maximum out put from least input.
SWOT ANALYSIS OF NAVEENA
During my internship I observe some strengths, weaknesses, opportunities and threats for Naveena are given below.
STRENGHTS
Ø Big buyers from market
Ø Well known strong suppliers
Ø Strong departmental structure
Ø MANAGEMENT INFORMATION SYSTEM department
Ø Quality Provider
WEAKNESSES
Ø Not a big player in market
Ø Low integration between departments
Ø Too much decentralized the departments.
Ø No RESEARCH AND DEVELOPMENT
Ø No marketing research
OPPORTUNITIES
Ø In WTO(World Trade Organization) implement quota will free this will be opportunity for especially NAVEENA because he can produce much more.
Ø Many brands we can start like sports garments.
Ø Expansion of business
Ø Diversification In term of open trade
Ø Capture local market
THREATS
Ø New entries in the market like small level unit after WTO implementing.
Ø China and India is big threat when quota will free
Ø Differentiation
Ø Switching of buyers
Ø No Isolation
Ø Persistent quality
Ø Low price from other countries
BCG MATRIX FOR NAVEENA
Boston Consulting Group Matrix (BCG MATRIX)
The BCG matrix measure market attractiveness by market growth rate and it assesses the firm ability to compete by, its relative market share. The BCG matrix assumes the causal relationship between market share and profitability.
Stars
Questionmark
Cash cows
Dogs
There is a huge slum in garments industry, after the incident of 9/11. This is directly and indirectly affecting the whole market. But NAVEENA is the organization working quite well, even in this situation and earning from international market. That’s the sign due to which I analyze that the NAVEENA is a cash cow in term of BCG matrix.
Competitive Strategy
Ø In garment washing different effects is provided to customer.
Ø Value added products are provided.
Ø Pull and push strategy is adopted
Ø Performance is better.
Marketing Strategy
§ The product improvement will be marketing strategy.
§ Product innovation
§ We make reasonable price against market.
§ Outlook of garment is very smart and excellent. This is accepted in the market.
§ Targeting the young people and using price strategy to satisfy them.
Marketing Analysis
The structure of organization is quite well but the design is not. Because the coming trends are moving very fast. And in the end of this year the environment that is now-a-days stable will become dynamic. Then there will be need of
Differentiation
Added features Effectiveness
Quick response to changes
More flexibility
More complexity
Competitive edges not one but more then that.
It’s a big process, which can’t be achieved in day’s .It take lot of time to enhance theses capabilities in organization. Either to sit a side and looking on trend‘s changing the organization has to do a lot.
Practical learning
ECRU YARN STORE AND CONE WINDING
. At first I get the information about Ecru Yarn Store that how after the order of buyer a company bye the ecru yarn and store it according to W/O. After that I got the information about Cone Winding that how it works and what are the functions of cone winding.
YARN DYING / LAB AND CIRCULER KNITTING AND FLAT KNITTING
I learn about the yarn dying that how an ecru yarn dyed and after dying process how it preserves. Then I attached with the process of circular knitting and flat knitting and learn about these two processes and its importance.
ECRU FABRIC STORE / LAT MAKING AND FABRIC DYING/ PI LAB
I learn about the process of maintaining ecru fabric store and lat making. After this knows about the process of fabric dying and then there was a difficult and main process of approval and rejection of fabric in PI lab. NAVEENA following the international standards of approving and rejecting the dyed fabric.
DYING FINISHING AND DYED FABRIC STORE
Today I learn about the process of finishing the dyed fabric and how the fabric get ready for the next process and after this after all quality checks the fabric is ready to next process and for this it preserve or store in dyed fabric store.
PPC DEPARTMENT (PLANING PRODUCTION AND CONTROLLING)
.It is one of the major department of any textile Industry without having god professional it can not work so knowledge about PPC is very much useful.
PRODUCTION SHEET
Production sheet is given from buyer and buyer tell his requirements actually all the specs is given in this sheet, so according to this sheet we develop the required garment for approval and also we analyze the cost as well.
RESEARCH AND DEVELOPMENT (RESEARCH AND DEVELOPMENT)
In RESEARCH AND DEVELOPMENT we analyze and finalize the root of fabric that how it will complete and in finishing how it approaches the buyer requirements, actually we get all the lengths and get the information of cost as well and other things about the roots.
CONSUMPTION
After getting the all the lengths of garments we know about the consumption and it is known by the defined formula of body and sleeve. we get the sum of body and sleeve and get the consumption of garments.
ASSESRIES
In this we plan about how much accessories will be used in garment and also wastage factor will be added in it.
COSTING
In this process we added all the consumptions and compare it with the buyer rate if it is less than the buyer rate then it will be accepted otherwise not.
CONTROLLING
We the plan is accepted than according to due date every day PPC check that how much process is completed and how much time remaining will take. So process is checked at every stage.
Merchandising Department
I join the merchandising department and get the whole information and briefing about the merchandising department and its functions that are done under merchandising.
I learn about the basic functions of merchandising that how after the order of a buyer it works and what are the basic function like reading of spec sheet and other information about the specs.
PROTO SAMPLE AND COSTING
I learn that how to make a proto sample and how define the costing of that proto sample. After making a proto sample and costing merchandising department send the sample for approval.
FIT SAMPLE
After getting the information merchant made a fit sample and sends it to the buyer for the final approval. It is a core process and I today I learn about this process.
SALE SAMPLE
I learn about the process of sale sample the how this process is occur and one thing that is learning in it that the price of sale sample is doubled than the other garments. It is not the requirement of all the buyers but few buyers get the sale sample.
CONFIRMATION OF ORDER
I learn about that what happen after confirmation of order, after confirmation of order merchant demand to buyer to give accessories detail so that he can start the production.
SCHEDULE ABOUT TESTING
I learn that how get the schedule of testing the garments. Actually it is necessary to know about the schedule because after confirmation the order it is 1st requirement that have to fulfill first and after this bulk production is started.
SIZE SET AND PRODUCTION
Today I known that what is the importance of size set before stating the bulk production. Merchant made all sizes and gets the confirmation of all sizes from buyer then starts the next step.
These days I spent with the merchandiser that how he works when order is confirmed and how the whole process is completed. Actually it was a practical learning and no documentation was involved in these days
Issues and Suggestions
Suggestions and recommendations for knitting and dyeing
Ø There should be a preventive maintenance scheduled program.
Ø Effective maintenance is also important to get maximum utilization of machinery.
Ø In flat knitting department the quality inspection machine is not working. That should be repaired.
Ø Keeping high quality is not only the responsibility of quality department, but it should be embedded in each employees mind. Every employee should take it as personal responsibility.
Ø There is only one hydro machine in dyeing; it must be two .So the lot loaded on trolleys doesn’t have to wait for long time.
Ø There should be clearly written standard about the demand of buyers’ requirements about the production.
Ø Quality measures should be clearly defined, written and hang on the departmental walls.
Ø Raw material should be properly stored, because they’re hazardous if stored in knitting department.
Ø Common error of fluff, which is only due to the non-cleanliness of the production floor. And due to which a lot of quality problems are occurring which increase both the time and cost.
Issues and Suggestions, regarding production, planning and control:
The biggest draw back in the time and action plans of PPC in NAVEENA is that there is no contingency planning in advance it is a general rule that while planning production some cushion is given for activities such as machine break down or any other extraneous variables that can take place. The problem is addresses only when it occurs. There should be planning in advance for that in order to minimize the effects of a problem that has occurred.
Issues and Suggestions, regarding time and action plan:
The most common issue is of coordination Management Information System takes that lead to enormous losses at the end of the day. According to PPC personnel due to some Management Information System takes by merchants in
providing production summary they end up making garment, which was not required at all. In order to avoid this kind of scenarios the merchants need to be absolutely sure what is required and the PPC personnel should clear any ambiguities before going for production and should recheck with the merchant the basic requirements.
Although there is a co-ordination manager present but still personal interest of all the departments is required in order to make the coordination free of any doubts. There should be clear lines of communication established between the departments. Every concerned person should know what is going on and what was required so that controlling should not only limit to the PPC department. From Knitting to Finishing every responsible person should have a clear idea what he needs his team to do.
Limitations:
Buyer due to the fact that the merchant cannot forward the purchase order gives Some times the co-ordination gap to PPC, as it is a secret. Only production summary is prepared and is given to PPC so if merchant makes a Management Information System take in interpreting the PO there is no way PPC can come to know about if there are any ambiguities in the production summary? Sometimes the merchant delays in forwarding information as it arrives to him resulting in delay to initiate the production process.
Conclusion
Form my experience of six weeks in this organization I have learnt many things. The most important is that practical professional life is very hectic, competitive and tough. The best thing, which I am able to find out, is that the stronger the culture of the organization better will be the productivity.
In textile sector the thing of immense importance is how well the organizational personnel communicate with each other. There is no room for personal grudges because each and every one depends on each other if any one screw up the whole organization suffers.
BIBLIOGRAPHY
· Company profile I got the information regarding vision statement, core values.
· SWOT information gets from Senior Managers.
· HRD information get form HR Officer.
· Export related data gather from Export Manager.
· Import related data gets from Import manager.
· Merchandising related data from merchandising manager.
· Process related data collect from different departmental heads.
GLOSSARY
GSM: Stands for Gram Square per meter.
MMC: Stands for material Management and Control
MPR: This means Material Procurement Requisition
MIR: This stand for Material Issue Requisition
GPR: This means Gate Pass Requisition
GRN: Stands for Goods Received Notes
