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NATIONAL INSTITUE OF FASHION TECHNOLOGY

NEW DELHI

KALAMKARI EXPORTS PVT LTD

INTERNSHIP REPORT
FOR THE MONTH OF JUNE
UNDER THE GUIDANCE OF
MR. MD ASLAM , SR. MERCHANDISER

SUBMITTED BY DEEPANSHU SHARMA

MFM SEMESTER 3

INTRODUCTION

RITIKA PVT LTD. (KALAMKARI)

KALAMKARI EXPORTS

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THE COMPANY
Ritika Pvt. Ltd. is a managed fashion garment manufacturer and exporter based at Gurgaon (Haryana) near New
Delhi. India. They started business in 1976 with a clear concept of innovating on traditional Textile weaves, prints
and embroideries, and have moved on from there to the area of Hi-Fashion. All alone our endeavour has been to
make products of honest quality standards based on the best design inputs.
Their products make their presence felt the world over. The focus is on innovation in design quality in production
and punctuality in delivery
The Company is a recipient of several awards for excellence Export Performance and Quality. They have an
annual turnover of USD 10 million and are seeking to build further on a solid foundation by constant efforts to
further improve their product.
The Management
Mr. S. C. Kumar who founded the company is currently the President supported by Mrs. Ritu Kumar, also a
Director Of the company and in charge Of alt design and development. Mrs. Ritu Kumars one of the best-known
textile designers and runs the Ritu Kumar' chain of boutiques numbering 15, around the country. Mr M. Midha, a
certified accountant who started his career in finance is another Director, in-charge Of operations. He has been
With the company since 1980.
All team members are professionally qualified and thoroughly experienced. Their strength lies in flexibility and a
willingness to learn from the Industry every day.
The work force is literate, technically skilled & capable of producing quality garments.
Product Range
Men: Shirt, Casual shirts, Boxers, Sleepwear
Women: Shirts, Blouses, Skirts, Sleepwear Dresses, Trousers, Jumpsuits, jackets, Co-ordinates
Specialities: Development of print designs. Embroideries, Appliques, Sequin & Bead work and other value added
embellishments.
Factory and Production Highlights
Operational work space Of 84,000 sq. ft.
Machinery : About Sewing Machines and 150 misc Machines
Make : Juki, Brothers, Kansai, Siruba, Ramsons, Sunstar, Hasma, Pegasus.
Production Capacity :
Woven : Equivalent to 100000 woven blouses and tops per month.
Knits : Equivalent to 25.000 knitted tops, T-shirts per month.
Production facilities are extremely well planned with segregated areas for

Design Development
Sample Development
Production Planning
Greige Fabric Store
Processed fabric & Accessories Store
Quality assurance
Cutting
Sewing
Equipped Laboratory
Washing & dry-cleaning
Finishing
Packing/Shipping
Human resource & Compliance
Showroom

Ritikas main client base

Soft Surroundings
DVF
Aritzia
True worth
Zendaya
American eagle outfitter
American rag
Rene derhy
Full beauty
Cabana life
Lucky brand

Organizational Design with respect to the Departmentalization.

LAYOUT AT RITIKA PVT LTD. EXPORTS:BASEMENT: FABRIC DEPARTMENT
TRIM DEPARTMENT
SAMPLING
CUTTING
TESTING LAB
QUALITY DEPARTMENT
FINAL PACKAGING.
ADMIN DEPARTMENT
GROUND FLOOR : PRODUCTION FLOOR Production lines
Production managers room
Finishing & packaging
FIRST FLOOR : PRODUCTION FLOOR
FINISHING & PACKAGING
SECOND FLOOR : MERCHANDING DEPARTMENT
HR DEPARTMENT
WASHING
CONFERENCE ROOM
SHOWROOM

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FABRIC & TRIM DEPARTMENT

STAGES OF FABRIC CHECKING

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SAMPLING DEPARTMENT
(CAD , PATTERN MAKING, CUTTING , SEWING, FINISHING&PACKAGING)
The sampling department takes cares of manufacturing of all the samples involved in order
processing from development sample to TOP samples.
SAMPLING SECTION

SAMPLING

SAMPLING
INCHARGE

PATTERN
MASTER

No. of employees in sampling

Sampling Incharge 1
Pattern master
- 2
Cutting master
- 2
QA
-2
Tailor- 14
Pressing men
-5
Types of sample
1. Development sample
2. Fit sample
3. Pre production sample
4. Size set
5. TOP(Top of production)

CUTTING
MASTER

SEWING
LINE

FINISHING &
PACKAGING

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CAD

SAMPLING ROOM

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(Sampling stitching line)

Sampling pattern making and QA tables.

(Sampling cutting table

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CUTTING DEPARTMENT

(PROCESS PLOW OF CUTTING DEPARTMENT)

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Types of machines used for cutting

Straight knife cutter

(Eastman blue streal-II)

CUTTING TABLE

PRODUCTION FLOOR

Band knife cutting machine

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TESTING LAB

(Light box test to detect color

variation)

(shrinkage test using the above scale)

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MEASURING GSM

GSM PUNCHING

CROCKMETER
(Used to check the color fastness
of the fabric)

WEIGHING MACHINE

Button snap pull tester

(Used to determine the pull button strength)

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SEQUINS(ADDA)

The In-house Adda work is only done for sampling , bulk work is outsourced from their
embroidery vendor (Shyam embroidery gurgaon , Krishna embroidery noida)
WASHING

Types of machine in washing unit:Washing machine - Simple washing machine used for washing the garment/fabric.
Hydro machine - This type of machine is used for extracting excess water from the garments
Tumbler(Fabcare) This type of machine is used for drying purpose.

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FINISHING (PRODUCTION FLOOR)

THREAD CUTTING

GLOBE CHECKING

PRESSING

CHECKING LINE

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SPOTTING
Spotting - Spotting is a process of removing stains from the garment which occurs while
manufacturing it , this is done by a spot gun.
How it works - Solventis applied with pressure on the affected area.

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PACKAGING DEPARTMENT

Needle detector machine

Standards to be followed

Needle detector machine Once a garment is finished and sent for packaging in the packaging
department before packing the garment they pass the garment through a metal detector so as to
check whether any needle/metal is left in the garment by mistake.

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MERCHANDISING DEPARTMENT

The job of the merchant is to make sure that the sample developed is such that it fulfils as many
requirements of the buyer as possible, and is production feasible too. Plus, the team needs to
arrange for the material required while making the samples, and communicate to the workers
what exactly the buyers want. The team acts as a mediator between the buyer (who requests the
sample) and the workers(who make the samples)
COSTING

One of the most important activities for the merchant is to negotiate for the production cost
before the buyer sends his purchase order. During the pre-development stage an initial costing
occurs to get an idea of the garment cost likely to be incurred per piece. These costs include
general raw material cost, washing cost, manufacturing cost, washing cost, markup cost etc.
Once the production sample is approved and grading is done a final costing is made by CAD by
using accurate fabric averages, cost of trims etc
A garment costing includes:
Materials cost:
Fabric
Trims
CMT: CMT includes the cost of:Cutting
Sewing
Re-cutting
Packing costs
(tags, labels, hangers, pins, bags, cartons, kimble etc.)
Overheads:
Administrative expenses
Financing and interest
Returns and allowances
Sampling cost
Trade discounts
Taxes
Markdowns
Shortages

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COST SHEET FOR #28774(HIGHLAND FLANNEL SHIRT)

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PROCEDURE
Order inquiry

Collect all the details of the order, which has designed, by the buyer i.e. Tech Pack

Check the ability to meet the buyers requirements (Shipment Dates and Quantities)

Machinery allocation

Check with the Industrial engineering and maintenance department the availability of machinery for the
style. Get a report of Style Machine Mix up from I.E. Dept
Pricing
If the order requirements can be fulfilled pricing will be done by considering SMV, Fabric
consumption, Accessory consumption, Profit margin, Production cost and any other special
requirement (Washing, Embroidery, Printing etc.) If Minute cost of the factory is available pricing
can be done fast and accurate.

Order confirmation

If the price and the delivery agreed Order will be confirmed. Instruct buyer to open the Export Letter
Of Credit.

Order details
Request all the details of the fabric types, Colors, Accessory details, Quantities, Etc., and Time
and Action (T&A) calendar has to be prepared to execute the order on time.

Technical sheet

Prepare the total requirement of Fabric and Accessory consumptions, copies of order

details and send to production department, Sample department, Finance department, Stores,
Quality department and purchasing department.

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Order processing
For ex. #28774 (HIGHLAND FLANNEL SHIRT)

NEW DEVELOPMENT
FIT TECH PACK
IF REJECTED

2nd FIT

Ist FIT

BUYERS
COMMENT/COSTING CLOSE

PURCHASE ORDER
LDR CLOSE
FABRIC & TRIM QUALITY CLOSE
APPROVAL&
TESTING GPT/FPT
PRE PRODUCTION
SAMPLE
BUYERS COMMENTS

IF REJECTED
CORRECTION

SIZE
SET

REPORT SENT TO BUYER

TOP OF
PRODUCTION
FINAL INSPECTION

SHIPMENT

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Documentation (ORDER PROCESSING) FOR SOFT SURROUNDINGS

PURCHASE ORDER RECEIVED AFTER COMPLETION OF DEVELOPMENT PROGRAM

(Purchase order is released by the buyer to place the order , the PO is issued after the new development program)

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Ist fit asked by the buyer (once the PO is released)

Ist fit is asked by the buyer to check the fitting of the garment on live model , fabric/trim color may vary but the
quality of the fabric/trim must be same as asked.
Once the buyer approves the 1st fit they asks for PP sample and before that the buyer asks for LDR(lab dip request) to
check the color variation of the lot of fabric which the factory has order, fabric quality/color approval , trim
color/quality approval.
Once the factory gets the approval for the above they start working on the PP(Pre-production sample).

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COMMENTS FROM BUYER ON THE 1st FIT (APPROVED)

Pre-production samples program initiated from here.

PRE-PRODUCTION SAMPLESBuyer wants pre-production sample (PP sample) to be made in actual colors. This sample is made with
actual fabric, trims and accessories. PP sample must be approved by buyer or buying house merchants
(technical persons) prior to proceed for actual production. The final approved sample from the PP
sample once sealed by the sampling team becomes the sealer sample.

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(FABRIC SWATCH SENT TO BUYER FOR FABRIC COLOR , QUALITY &PATTERN APPROVAL)

Before initiating the pre-production samples the factory sends swatch cards to the buyer for fabric , trim, label
approvals.

FABRIC SWATCH CARD FOR INTIAL BULK APPROVAL

Once the PP samples are approved by the buyer, the factory send swatches of fabric from their In house fabric for bulk
approval.

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LOT APPROVED BY THE BUYER (FABRIC TYPE- VELVET)

LABEL SAMPLES SENT TO BUYER FOR BULK APPROVAL

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The above style also consists of flock print on the back of the shirt so before going for bulk print , the factory send a
strike off (print sample) to the buyer. Once they get the approval then they proceed with bulk ordering.
Printing at kalamkari is outsourced from Krishna prints, gurgaon.

PP SAMPLE

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PP SAMPLE IS APPROVED BY THE BUYER (SIZE SET PROGRAM INITIATED)

SIZE SET
Once the buyer approves the PP sample he asks for size set report basically the purpose of the size set is to check fit of
the garment in different sizes. In this stage factory develops samples in multiple sizes. The sizes of the size set asked by the
buyer varies from buyer to buyer .Buyer check size set sample and give feedback to factory if anything need to be
corrected.
A team from the buying house visits the factory to check the size set and its report is sent to the buyer.
TOP PURCHASE ORDER
All the above samples (proto , fit , pp) are sent to the buyer free of cost but TOP samples are chargeable so the buyer
releases a purchase order for TOP samples.

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Top of Production Sample (TOP sample): Once production is online, few pieces is taken
out in the middle of the production. Production pieces are sent to buyer as TOP sample.
All buyers does not asked for TOP sample. Purpose is to cross-check whether factory is
following PP sample specification or not.
FINAL INSPECTION When the shipment is ready and packed , team from the buying
house inspects the shipment by taking 2-3 random samples.

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STYLES COVERED#29627- ANNALISE TOP

#2AA95- DENIM SHIRT
#29355- BEADED FEATHER TOP