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SUBMITTED TO : MS.V.PRIYADARSHINI
SUBMITTED BY : ASINE AMON
SYMPHONY SATPATHY
ACKNOWLEDGEMENT
This project consumed huge amount of work, research and dedication. Still,
implementation would not have been possible if we did not have a support of many
individuals and organizations. Therefore we would like to extend our sincere
gratitude to all of them.
First of all we are thankful to our faculty,ms.V.Priyadarshini for her logistical support
and for providing necessary guidance concerning projects implementation.
We are also grateful to seniors for provision of expertise, and technical support in the
understanding and acqiring the base information. Without their superior knowledge
and experience, the Project would like in quality of outcomes, and thus their support
has been essential.
Nevertheless, we express our gratitude toward our families and colleagues for their
kind co-operation and encouragement which help us in completion of this project.
INTRODUCTION
QUALITY ASSURANCE:
All those planned or systematic actions, necessary to provide adequate confidence
that, a product or service will satisfy given requirements for quality.
Quality assurance refers to the assurance to customers that the product, parts,
components, tools etc. contain specified characteristics and is fit for the intended
use.
The assurance of quality is not the responsibility of a senior person or a department
only. Only the inspection department or its personnel cannot be held responsible for
assurance of quality. It is the responsibility of everybody connected with the
production, directly or indirectly and each and every department.
ROLE OF QAD:
QAD in an organization, works on improving the quality produced and monitor
systems of functioning. The main role of this department is to ensure no quality
issues are compromised with-in production. The department usually consists of a
quality/merchandise manager, fabric checker and a mechanic.
Productivity
Quality
COMPANY PROFILE
Orient craft limited was established in 1978 and is one of the largest Export House in
India having a turnover of around 725 crores. It is dealing with US and European
buyers and is having 21 manufacturing units in and around Delhi. It is one of the
largest manufacturers of womens, mens and childrens woven (including denims)
and knit garments in India.
Orient Craft was setup by Mr. Sudhir Dhingra (Founder and Chief Managing Director)
in 1972 with 4 employees. Having employee strength of 25000 workers it is one of
the major companies in the garment sector of India.
Major Customers
Orient Craft stands true to the image of being 'the name behind names.
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Department of Fashion Technology, Semester - V
MERCHANDISING DEPARTMENT
Merchandising Department is the most important department of an export house.
The merchandisers relate and negotiate within and outside the company i.e., with the
other departments and buyers/suppliers respectively.
Activities of a merchandiser
Sampling
Fabric sourcing
Accessories sourcing
Gather Test reports
Production targets and its achievements
Quality Check
Report maintenance
Forwarding
List of orders pasted on the left hand inside cover of the file.
Tech pack.
CAD marker-costing and factory costing.
Trim pro forma invoices from the supplier.
Confirmation of the trims
Commercial invoices (C.I.)
Confirmation of the CI from the store
Order chart from the buyer
P.O. copies from the buyers
Fabric order confirmations with approved fabrics swatches
Time and action calendar.
Hard copy of all incoming and outgoing crucial and important mails that may
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Department of Fashion Technology, Semester - V
SAMPLING DEPARTMENT
Here the work of a garment manufacturing unit is done on a small scale or it is a mini
production floor. All the functions ranging from cutting to finishing are being done.
Sampling is done to get approval from the buyer based on the samples made and for
the product development team. The sampling section followed the make through
system for production of garments.
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Revising the specification of the buyer.
Minimizing operations and consumption.
Innovation of new methods for completion of operations more efficiently.
Grading section
Requisition of material
Acquisition of Material
Issue of Material
Acquisition of Material
After delivery first fabric is checked at the gate physically. If there are any
discrepancies in any of the details then needed steps are taken for the same. Else, a
request is sent to the fabric store and the material is delivered there.
Entry is done in the designated register, and then fabric goes through various
inspections. Fabric rolls are checked according to the four point system.
Issuing of Material
TRIM STORE
The trims store is another store where the trims such as thread, zipper, buttons, and
labels etc. are stored and issued as per requirements.
Process Flow of the Trim Store
Documents Used
Style file
Cutting register
Fabric Challan file
Fabric Relaxation register
Cutting Inspection file
Lot Information file
Sober register
End Bits register
Part Change register
Cutting Quality Defect Report file
Cutting Issue register
Blade and Scissors Record register
FUSING
Process Flow Chart Fusing
SEWING DEPARTMENT
Sewing Department is the backbone of the industry. Here the garment takes its final
shape. Better the sewing process, better the quality and profits. The basic aim is to
produce more and better garments in less time. The garments are made as per the
specifications of the buyer. The application of technology to clothing manufacture is
concerned with the achievement of satisfactorily sewn seams or less defects.
2.8.1 Work Process of Sewing Department
A report is prepared by the In Line checkers and On Line QC for style quality
progress. Industrial Engineer does the operations study again, if any change needs
to be incorporated in the layout and working method for quality and production
purpose, immediate action is taken. When the output is complete, it is checked by
final checkers again to ensure the product quality.
45 machines
4 tables
1 line in charge
3 supervisors
10 helpers
2 inline checkers
1 line QC
Stitching defects
Stains
Finishing Defect
Holes/ Cut/ Fabric defects
Every checker sticks their allotted number the garment passed by them. Every time a
defective piece is found at a later stage it is traced back to the checker who passed
it. The checker is then shown the mistake so that it is not repeated again. They
checkers are given regular on-the-job training.
4.
5.
6.
7.
Seam Ironing
Alterations
Final Ironing
Final Checking
In this section the overall look of the garment is checked. For stain removal at this
stage, every table is provided with a stain removal gun and a thread clipper to cut the
uncut threads. All the defective pieces are sent for alteration.
8. Tagging and Packing
9. Presentation Checking and Carton Packing
Again checking is done and if the lot passes, then the consignment is send for
shipment along with a packing list which comprises of
Style no.
P.O. no.
Size ratio and mix
Color
Gross weight
Net weight
Dimensions
Labels
Air or Ship shipment
Sewing
In sewing, a 100 % inspection is done inline as well as end of line.
Dry Processing
If garment have any dry processing operation on them then garment is taken from
the sewing floor they are checked by the quality checkers.
Washing
Quality check ensures the quality of goods coming to washing. After washing the
shades are matched according to the shade band and if the shade is not matching or
not lying in the range then it is rejected.
Finishing
This section has most number of QC points starting from the middle checking where
the garment is checked from inside and outside, then final check where the quality is
checked by looking at the top side of the garment. Then garment goes to
Final Audit
Final Audit is done internally by quality auditor and externally by buyer's QC. They
use SQC as their tool as check few pieces so as to get the idea of the lot.
MAINTENANCE DEPARTMENT
Maintenance department maintains all the machines in the unit. As the machine
breakdown is quite unpredictable it is very crucial to the industry. They try to amend
the problem as soon as possible. They look after the machinery and the
attachments/work aid requirements in conjunction with the industrial engineering
department. They order jigs and other attachments to the supplier and regularly take
a feedback from the operators so the best option can be ordered for machines that
are not have desired attachments.
Oil change
Motor and Control box clean by air pressure
All moving parts checking/replacement
Gear and bearing proper checking/ replacement
WASHING DEPARTMENT
Garment Processing Process Flow Chart