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An ISO 9001-2000 Unit

ORIENT AND CRAFT LTD FOUR STAR GOVT RECOGNIZED EXPORT HOUSE

SUMMER TRAINING REPORT


ON
FINANCIAL ANALYSIS OF PRODUCTION THROUGH MODREN
AND TRADITIONAL TECHNOLOGY IN ORIENT AND CRAFT
LIMITED AN **** EXPORT HOUSE.

(SUBMITTED IN PARTIAL FULFILLMENT FOR THE AWARD OF


MASTERS DEGREE IN BUSINESS ADMINISTRATION)
UNDER THE GUIDANCE OF:
MISS VIDHI
FINANCE MANAGER

SUBMITTED BY:
GEETIKA CHHABRA
MBA/05/54
2005-2007

N.C.COLLEGE OF ENGINEERING, ISRANA


(KURUKSHETRA UNIVERSITY, KURUKSHETRA)

ACKNOWLEDGEMENT

No big thing in the world is achieved without the help and blessing of our well
wishers. I feel obliged to express my grateful thanks to all those persons who
rendered me all possible help in completion of this project.
I thank Mr. B.M Chhabra (General Manager) for giving me the opportunity to
work in the Finance Dept, that is the field I wanted to work in and would like to
take up in the future as my career.
I am grateful to Mr. Vyas Pasricha (Chief Finance Manager), who extended his
whole-hearted and unreserved help to me throughout this project and enabled
me to give the project its present shape.
Words fail to express adequately, my feeling of deep gratitude, which I owe to
Miss. Vidhi ( Dy. Finance Manager) for his invaluable counsel, constant help and
continuous encouragement at all stages of this work.
The completion of the project could not have been completed without the grand
support of Ms. PUJA MANN H o D MBA Department
I would also like to extend my thanks to my supporting faculty of
N.C.C.E., ISRANA, KURUKSHETRA UNIVERSITY.
THANK YOU ALL!

PREFACE
Today every company is trying to make itself best in every aspect to lead in the
present competitive environment. For efficient output & results, satisfaction of
company employees is essential. For this purpose every company provides its
employees with various welfare schemes to innovate them. This is the best way
to meet the desired objectives through employees satisfaction.

ORIENT & CRAFT LIMITED has built its leadership by making itself as one of
the largest export house of ASIA. In the present scenario when it has become
difficult to survive in such a cut throat competition, OCL is able to not only survive
but to hold top position in Garment business. OCL produces multiple products
like JEANS SHIRT,SKIRTS ,TROUSER., KURTA,FOR MAJOR BRANDS LIKE
LEVIS ,REEBOK ,TOMMY HILFIGRE ETC.

This study is basically divided into following major parts. The first part of the
report includes the introduction of the study. The second part deals with company
profile, its objectives, financial objectives, obligations, vision & mission and social
responsibility. Third part contains description about modern and traditional

technology and fourth part deals with financial analysis. The last part deals with
conclusions, suggestions & limitations.

CONTENTS

1. EXECUTIVE SUMMARY

2. ABOUT THE COMPANY


2.1 Company Profile

2.2 Vision

12

2.3 Mission Statement

13

2.4 Objectives & Goals

15

2.5 Obligations

17

2.6 Safety Policy

18

2.7 Organizational Chart

19

2.8 Social responsibility

20

2.9 Awards achieve by company

22

3. OBJECTIVES OF THE STUDY

29

4. RESEARCH METHODOLOGY

31

5. TRADITIONAL TECHNOLOGY

41

6. MODERN TECHNOLOGY

44

7. FINANCIAL ANALYSIS BETWEEN MODERN

74

AND TRADITIONAL TECHNOLOGY.


8. LIMITATIONS

96

9. CONCLUSION

98

10. SUGGESTIONS

101

11. ANNEXURES

103

12. BIBLIOGRAPHY

105

EXECUTIVE SUMMARY
The project was undertaken to conduct a study on the financial benefits of
production of shirt through use modern technology and traditional technology and
deciding whether it is profitable to produce through use modern technology or
traditional technology by taking into consideration investment labour and other
important aspects.
The study is done in the production and finance department of Orient &
Craft Limited. It covers study of various modern technology machines including
CAD and other imported machines from USA & Japan. A brief study on 5S is also
covered in the project.
The project report includes:
Profile of the company: The profile of the company is included in short in the
report. OCL is the sole Indian presence in Fortunes prestigious listing of the
worlds100 largest companies. OCL has a vision to be the BENCHMARK FOR
GARMENT INDUSTRY.
The project also includes the various machines which are used in OCL
along with photographs and research undertaken on the upcoming trends.
Project gives brief information about its major buyers and the main products in
which company basically deals with. Few recommendations have also being
given in suggestions.

The procedure of the study was to first of all see the production procedure of
OCL using various modern technology machines and then to study the annual
report of OCL, to get a clear picture of the organization which would help to
conduct further study. Secondly, to collect information about man-hours required
to produce various products using different machines and there production
status. Then to find out from my project guide about the procedure of analysis
and collect the necessary information needed to conduct the study from OCL.
Thirdly, to go through a few books & magazine which helped me in preparing a
report. The study has been conducted with the help of the material and
information provided at OCL, through some books on technology and a few
websites.
Some limitations may be there in a study of this nature because some
confidential data may create problems for the company in future.

The Beginning
ORIENT AND CRAFT
ORIENT CRAFT IS THE LARGEST EXPORT HOUSE OF INDIA.THE MAIN
BUSSINESS IN WHICH COMPANY deals is manufacturing of ready made
garments, it exports in most of countries .
Orient Craft Ltd. Was a set up in 1978 and has been India's number one garment
manufacturer and exporter and is recipient of the 'Gold Trophy' give by Govt. of
India for highest global exports out of the country for the year 1997, 1998, 2000,
2001, 2002 and 2003.
The company is divided into three divisions:
Knits
Woven
HFD
(Home furnishing division)
It has 40 units all over the country. The company is situated at 25 different
locations in Delhi, Gurgaon, and Maneasar. Company has the most modern
manufacturing plants in the country with over 1, 40,000 sq. / feet of covered area
in one location. The company contains more then 150000 imported sewing
machines for its manufacturing operations in woven and knitting units.

The company has in-house lab testing for garments, fabrics & trims. Its labs are
well equipped to test for all parameters including Color-fasteners to light. Orient
Craft Lmtd. has several in-house latest computerized units, inHouse garment Dyei Units and Manual Sand- blasting and laser sand blasting
units.
The company has three 100% export oriented units thereby having the
advantage of importing all raw materials and trims, free of duty from any
part of the world.
The company also has a specialized home furnishing division, wherein all soft
furnishing products are manufactured and exported to some of the most
prominent brands.
The company has a production capacity of 50,000-dz. Woven and
90,000-dz knit garments every month from its one unit.
The major exports comprise
Dresses
Skirts
Knitted shirts/T-shirts
Mens shirts
Blouses
Jacket
Coordinates
Kids wear
Ropers
Outwear
Duvet cover and pillow cover
It comprise mostly to the US, the EU and Canada. The total FOB value of
exports was of the order of $152 million during 2004-2005.

The company has three 100% export oriented unit thereby having the advantage
of importing all raw materials, trims free of duty form any part of the world. The
Company has in-house lab testing for garments, fabrics and trims.
The labs are well equipped to test for all parameters including color fastness to
light. OCL also has several in-house latest computerized embroidery machines,
washing plants and dry cleaning units.
The company also has a specialized Home Furnishing division wherein all soft
furnishing products are manufactured and exported to some of the most
Prominent brands such as William Sanoma, Donna Karen, ELM Street and
Marks & Spencer.
The Company is rapidly growing year with use of new modern technology.
The complex is completely air-conditioned and dust proof. This is the single
largest multi-product manufacturing plant in the whole of India producing various
diverse products under one roof like, cut and sews knits, specialty denim, woven
sportswear, silk apparel and ladies formal suits and coordinates.
IN each of its unit worlds most modern and sophiscated technology
is used. Of the total area 420000sq feet has been occupied by the machines
which is used for manufacturing purpose.
Company is using more than 14000 imported sewing & fusing machines which
are used for weaving and knitting purposes in its various units.
For best results company has established its own research and development
centre and for the inspection of the clothes company has established its own
laboratories, in different units.
In the laboratories most sophisticated machines are used. In orient and craft
there is provision of modern computerized embroidery, dry cleaning and washing
plants.

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Of the total units its one unit is engaged in manufacturing of home


furnishing products, which is named as H.F.D...& it prepares finished goods for
branded firms for exporting.
Besides being compliance by the current standards, in an endeavor to go beyond
compliance we have adopted the village next door as one of the community
welfare programs under which we are helping the local community build a
primary school as well as a garment sewing and embroidery unit.

MAIN BUYERS
The company has developed strategic alliances with some of the worlds premier
fashion brands. The trust bestowed by these global giants over the years has led
us to the path of growth and prosperity both in revenue and stature.
The clientele includes names like
Nike

Banana Republic

Mustang Jeans

O'Neill

Mexx

Abercrombie & Fitch

Arnold Palmer

Champion

Pierre Cardin

Sears,Canada

Polo Sport

The Childrens Place

Mustang

Macys Merchandising Group

Greg Norman

Lebek

Joop Jeans

Oilily

Adidas

George Asda

Ralph Lauren

VF Asia

Tommy Hilfiger

Decathlon

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Reebok

Vetir

Mother care

M&S

Rueh

Diesel

Hollister

Sag Harbor

Oxbow

Izod

New Yorker

Replay

Paris Saint German

H&M

Old Navy

Tiffany

London Fog

Dewhirst

Gap

Spykar

Tom Tailor

The Metro Group

VISION
At Orient And Craft Ltd. CUSTOMER DELIGHT is top priority to be
achieved through timely shipment of quality product.
Orient and Craft team continuously strives for more value for money
through COST REDUCTION drive in the organization.
The challenges in the terms of targets to be met at all levels through
effective team work, continuous improvement &meaningful human
resource.

Company emphasizes on:Deliver on-time, every time, anywhere in the world.

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Keep a sharp eye on product quality and put in all efforts to raise the
bar..... Constantly.
Comply flawlessly with all statutory regulations required by our customers
in any country.
Augment and maintain a logistics infrastructure that adheres to the highest
levels of efficiency that seamlessly blends with our customers' own supply
chain.
Ensure escalating productivity standards at the lowest operating cost, thus offering
our customers a product of the highest quality at the most competitive price. .

MISSION STATEMENT
To achieve international standards of excellence in all aspects of
production, manufacturing and exports of diversified products with focus
on customer delight through value of product and services, and cost
reduction
To maximize creation of wealth, value through satisfaction of the
employees.
To provide technology and services through sustained Research and
Development, Computer Aided Designing, Computer Aided Manufacturing.
To foster a culture of participation and innovation for employee growth and
manufacturing.
To cultivate high standards of business ethics and Total Quality
Management for a strong corporate identity

13

TEAM WORK

COMPANY EMPHASIS IN HARMONY: TEAM WORK


WE WONT BE ABLE TO HELP OURSELVES, UNTIL & UNLESS
WE HELP OTHERS : COMPANYS POLICY
COMPANY RUNS ON POLICY: We wont be able to bring happiness to our
lives unless we give happiness to others, we wont be able to progress, until we
support others in their progress.
ORIENT CRAFT TRIES TO MAKE THE COMPANYS ENVIRONMENT TO
MAKE PURE AND PROGREESIVE.
Company goals is to make a policy which aims at development of the employees
It tries to discharge its responsibilities in different parts, which best fulfill the
moral obligations and employees satisfaction.

14

In order to discharges its social responsibilities the companies has done various
works.
In cooperation with non profit organization to develop the urban areas
surrounded by Company.

OBJECTIVES
To maintain the first position in exporting the largest bulk of garments.
To earn a wealth through satisfaction of employees.
To create a strong research development base in the field of technology
To introduce new technologies, in work environment.
To provide best quality products through sustained quality control.
To minimize the wastage of material in manufacturing of garments ,through
the use of new technologies like, computer aided designing and computer
aided manufacturing

15

FINANCIAL OBJECTIVES
To ensure adequate return on the capital employed & maintains a
reasonable annual dividend on its equity capital.
To ensure maximum economy in expenditure
To develop long term corporate plans to provide for adequate growth of
the activities of the corporation.
To endeavor to reduce the cost of production of garment products by
means of systematic cost control measure.
To endeavor to complete all planned projects within the stipulated time &
cost estimates.
To provide high quality financial staff support for decision making control to
all levels of management-corporate divisional, unit and location to enable
the achievement of overall corporate objectives and goals.

16

To play a lead role in scanning the domestic and international financial


environment, the formulation and achievement of all the financial

GOALS
CUSTOMER SATISFACTION AT THE HEART OF MIND
QUALITY A WAY OF LIFE
SYNERGY THROUGH COLLABORATIVE TEAM WORK
AN URGE TO EXCEL , ALWAYS
WILLINGNESS TO LEARN AS AN ORGANIZATION
CONTINIOUS SKILL & KNOWLEDGE UPGRADATION
MANPOWER THE ESSENCE OF EPIS UNIVERSE

OBLIGATION

Towards Customers and dealers


To provide prompt, courteous & efficient service & quality products at fair &
reasonable prices.

Towards suppliers
To ensure prompt dealings with integrity, impartiality & courtesy & prompt
ancillary industries.

Towards employees

17

Develop their capability & advancement through appropriate training &


career planning.
Expeditious redressal of grievances.
Fair dealings with recognized representatives of employees in pursuance
of healthy trade union practice & sound personnel policies.

Towards communities
To attract foreign investment by exporting best quality product to buyers.
To improve the condition of employees, working in the company.
To discharge its responsibility towards society by doing fruitful works like
opening hospitals.

ORGANIZATIONAL CHART
O r ie n t C r a f t L t d .
P lo t N o . 1 4
P r o d u c t io n M g r .
P r o d u c tio n E x e .

P a c k in g I / C
T /C

F in is h in g I / C
C h e c k e rs

P /M

P e rs o n n e l M a n a g e r

Q A M anager

A s s t . P e r s o n n e l O ffic e r

Q A E x e c u t iv e s

P e r s o n n e l A s s is t a n t s

C o m p u te r O p e ra to r

S r. Q A
C h e c k e rs

18

SAFETY

POLICY

Aim of safety policy is to protect people material, machines from being


damaged.
GOAL-safely policy/security main purpose is to make companies environment
peaceful.
Work of security
To make safety related rules and law & to implement them.
To maintain discipline in company premises.
To protect employees & there belonging from theft.
To make gate pass for incoming & outgoing goods.

19

To solve grievances & dissatisfaction among employees.


To restrict the entry of unofficial persons.
To check gate pass of employees while leaving company during company
hours.
To keep check on vehicles going outside & coming inside the company.
To maintain & keep the safety devices at the right place.
To prohibit taking cigarettes, tobacco &any other harmful drugs in
company premises.
It is the responsibility of security in charge of each floor to maintain record
of incoming &outgoing material.
To maintain internal hotline.
To make & maintain the following records:To maintain record of returnable goods.
To maintain record of keys.
To maintain record of duty security guards.
To maintain record of security guards, working during night shifts.

SOCIAL RESPONSIBILTY
The company is part of a Global Alliance Program, which looks at creating
a favorable working environment among the employees for higher
productivity. Social issues and problems are addressed and resolved. This
ensures that equilibrium is maintained between their professional and
personal lives.
The company is has set up own dispensaries where free consultation and
medical treatment is provided for employees and their families. A fully
equipped ambulance is on call 24 hours of the day.

20

OCL has adopted one village in khandsa, they impart training to people
free of cost and look after there welfare.
Company is maintaining water tanks for water supply etc.
Company has opened hospitals and dispensaries for the well being of
people.
The company is part of a Global Alliance Program, which looks at creating
a favorable working environment among the employees for higher
productivity. Social issues and problems are addressed and resolved. This
ensures that equilibrium is maintained between their professional and
personal lives.

OUR WORK CULTURE


At OCL, chief objective is to nurture growth at all levels. OCL strive to attract,
enhance and retain the best global talent and to build a culture that drives
individual, organizational and business growth through talented, engaged and
committed employees. To achieve this company focus on learning, career
development, performance management, compensation and benefits.
The company

role is to ensure that OCL is a true 'learning habitat', which

grooms people and their talents giving them the skills they need to excel. Hence,
training of personnel at all levels of organization is an essential component to

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augment and update the knowledge base. The training programs are allpervasive and are structured to hone the specific skills of each employee.
Finally, OCL plays an essential role in shaping development processes that help
people advance their careers as far and as fast as they can.

An ISO 9001-2000 Unit


ORIENT AND CRAFT LTD FOUR STAR GOVT RECOGNIZED EXPORT HOUSE

ORIENT AND CRAFT LIMITED is wholly privately owned private limited company
registered under the companys act, 1956 and is managed by a board of
directors who are appointed by the chairman of the company Mr.Sudhir Dhingra.
Orient craft is a four star export house.

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AWARDS
The recognition gained by Orient and Craft Ltd is epitomized by each and every
single award bestowed on it the highest in Asia!
The company has the distinction of winning the top export awards, since 1980.

Year
1980-81
1981

Award
Outstanding Export Award for Cotton
Handloom Readymade garments
Award for Highest Global Exports.

Top Exporter Award


1981-82
Gold Trophy - for Highest Exports.

1982

Award for Highest Global Exports.

Awarded By Govt. And Other Indian


Institutions
THE HANDLOOM EXPORT
PROMOTION COUNCIL Madras
CLOTHING MANUFACTURERS
ASSOCIATION OF INDIA , Mumbai
APPAREL EXPORT PROMOTION
COUNCIL Ministry of Textiles,
Government of India, New Delhi
GARMENTS EXPORTERS
ASSOCIATION, New Delhi
APPAREL EXPORT PROMOTION
COUNCIL Ministry of Textiles,
Government of India, New Delhi
CLOTHING MANUFACTURERS

1983

Award for Second Highest Exports

ASSOCIATION OF INDIA - for Global


Exports., Mumbai
APPAREL EXPORT PROMOTION

1984

1985

Award for General Currency Area

Award for Global Exports and General


Currency Area

COUNCIL Ministry of Textiles,


Government of India, New Delhi
APPAREL EXPORT PROMOTION
COUNCIL Ministry of Textiles,
Government of India, New Delhi

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CLOTHING MANUFACTURERS
Award for Second Highest Exports
1986
Export Performance Award Global
Exports
Silver Trophy - for Global Exports
1988

ASSOCIATION OF INDIA - for Global


Exports. Mumbai
APPAREL EXPORT PROMOTION
COUNCIL Ministry of Textiles,
Government of India, New Delhi
THE CLOTHING MANUFACTURERS
ASSOCIATION OF INDIA, Mumbai
APPAREL EXPORT PROMOTION

Gold Trophy for outstanding export

COUNCIL, Ministry of Textiles - for

performance

Global Exports. Ministry of Textiles,


Government of India, New Delhi
APPAREL EXPORT PROMOTION

Silver Trophy - for Global Exports


1990-91
Silver Trophy - for Global Exports

1991

Award for Highest Global Exports

1992-93 Award for Top Performer

COUNCIL, Ministry of Textiles,


Government of India, New Delhi
CLOTHING MANUFACTURERS
ASSOCIATION OF INDIA , Mumbai
APPAREL EXPORT PROMOTION
COUNCIL, Ministry of Textiles,
Government of India, New Delhi
GOVERNMENT OF KARNATAKA -

Readymade Garments Exports


Gold Trophy for Highest Global Exports APPAREL EXPORT PROMOTION

1992

& Silver Trophy for Second Highest

COUNCIL Ministry of Textiles,

Exports of Woven Garments


Top Award for Apparel Exports.

Government of India, New Delhi


GOVERNMENT OF KARNATAKA
CLOTHING MANUFACTURERS

Award for Highest Global Exports


1993-94
Highest Export Award - Woven
Garments and for Global Exports
1994-95 Award for Highest Exports Global
Exports

ASSOCIATION OF INDIA, Mumbai


APPAREL EXPORT PROMOTION
COUNCIL Ministry of Textiles,
Government of India, New Delhi
CLOTHING MANUFACTURERS
ASSOCIATION OF INDIA, Mumbai

24

Award for Highest Exports - to quota


countries and non-quota items to quota

CLOTHING MANUFACTURERS

ASSOCIATION OF INDIA, Mumbai


countries
Best Manufacturer Export Award - Gold GOVERNMENT OF KARNATAKA
APPAREL EXPORT PROMOTION
Highest Export Award - Woven
1994
COUNCIL Ministry of Textiles,
Garments
Government of India, New Delhi
CLOTHING MANUFACTURERS
Gold Trophy for Highest Global Exports
ASSOCIATION OF INDIA, Mumbai
Gold Trophy for Exports to Non-quota
1995-96
CLOTHING MANUFACTURERS
countries and Non-quota items to
ASSOCIATION OF INDIA, Mumbai
Quota countries
Best Manufacturer Export Award - Gold GOVERNMENT OF KARNATAKA
Award for Highest Exports to NonCLOTHING MANUFACTURERS
Quota Countries & Award for Second
ASSOCIATION OF INDIA, Mumbai
Largest Exporter in Global Exports
Award for Highest Exports in Global
CLOTHING MANUFACTURERS
Exports and Award for Highest Exports
1996-97
ASSOCIATION OF INDIA, Mumbai
to Non-quota Countries
Silver Trophy for Second Highest

1996

Exports in Global Exports & Gold

CLOTHING MANUFACTURERS

Trophy for Highest Exports to Non-

ASSOCIATION OF INDIA, Mumbai

Quota Countries
Award for Second Highest Exports in

APPAREL EXPORT PROMOTION

Global Exports & Award for Highest

COUNCIL Ministry of Textiles,

Exports in Woven Garments Exports Government of India, New Delhi


Top Exports Award - Global Exports & APPAREL EXPORT PROMOTION
Gold Trophy for Exports to Non-Quota COUNCIL Ministry of Textiles,
Markets

1997

Highest Exports Award

Government of India, New Delhi


CLOTHING MANUFACTURERS

ASSOCIATION OF INDIA, Mumbai


1998-99 Award for Highest Exports - for Group CONFEDERATION OF INDIAN
Turnover

APPAREL EXPORTERS, Mumbai

25

Highest Exporter Award for Woven

CONFEDERATION OF INDIAN

Garments

APPAREL EXPORTERS, Mumbai


CLOTHING MANUFACTURERS

Highest Exporter Award

1998

Silver Trophy for Largest Exports in


Woven Garments
Gold Trophy for highest exports for

19992000

Award for Second Largest Exports in


Woven Garments
2000
Silver Trophy for Highest Exports in
Global Exports
Award for Top Exporter

2001-02

Government of India, New Delhi


CLOTHING MANUFACTURERS

ASSOCIATION OF INDIA, Mumbai


APPAREL EXPORT PROMOTION

Quota
COUNCIL
Exports & Award for Highest Exports to Ministry of Textiles, Government of
Non-Quota Countries

2000-01

COUNCIL Ministry of Textiles,

Global Exports
ASSOCIATION OF INDIA, Mumbai
Award for Highest Export Performance
FEDERATION OF INDIAN
Readymade Garments Government of
EXPORTERS ASSOCIATIONS,
India. (FIEO)
Award for Highest Exports to NonCLOTHING MANUFACTURERS
Quota Countries
Award for Second Highest in Non-

1999

ASSOCIATION OF INDIA, Mumbai


APPAREL EXPORT PROMOTION

India, New Delhi


APPAREL EXPORT PROMOTION
COUNCIL Ministry of Textiles,
Government of India, New Delhi
APPAREL EXPORT PROMOTION
COUNCIL Ministry of Textiles,
Government of India, New Delhi
COCHIN EXPORT PROMOTION

Certificate of merit for Outstanding

COUNCIL Govt. of India, Cochin


THE CLOTHING MANUFACTURERS

Export Performance
Award for highest Exporter in Non-

ASSOCIATION OF INDIA, Mumbai


CONFEDERATION OF INDIAN

Quota Markets
Award for Highest Exporter in Non-

APPAREL EXPORTERS, Mumbai


CONFEDERATION OF INDIAN

Quota Market
Silver Trophy for Second Largest

APPAREL EXPORTERS, Mumbai


CLOTHING MANUFACTURERS

Global Exports

ASSOCIATION OF INDIA, Mumbai

26

Highest Exports Award for Non-Quota CLOTHING MANUFACTURERS


Countries
Award for Top Exporter
Export Award 2002
2002

2002-03

& Silver Trophy for Global Exports


ASSOCIATION OF INDIA, Mumbai
Highest Award for Exports - Non-Quota CONFEDERATION OF INDIAN
Exports
APPAREL EXPORTERS, Mumbai
Highest Exports Award for Non-Quota CONFEDERATION OF INDIAN
Market

1996-

Best Export Award - Gold (4 years

2000

continuous award)

2004

COUNCIL Govt. of India, Cochin


Federation of Karnataka Chamber of

Commerce and Industries, Bangalore


Highest Award for Non-Quota Exports CLOTHING MANUFACTURERS

Best Performance Award

2004

ASSOCIATION OF INDIA, Mumbai


COCHIN EXPORT PROMOTION

Highest Exports Award for Non-Quota


Market

APPAREL EXPORTERS, Mumbai


COUNCIL OF INTERNATIONAL
AWARDS
GOVERNMENT OF KARNATAKA
CONFEDERATION OF INDIAN
APPAREL EXPORTERS, Mumbai (Fifth

Exporter of the year - Golden Scale

International Fashion awards)


Clothing Manufacturers Association of

Trophy

India

27

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OBJECTIVES OF THE STUDY


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Specific Objectives
Study is conducted mainly to find out cost involved in production of skirt
through modern technology and traditional technology.

General Objectives
To get an overview of working of export house.
To study the Structure of the organization.
To find any discrepancy and making suggestions.
To understand the various benefits of modern technology.
To understand various operations involved in production of ready made
garments.
To understand the working of CAD ( Computer aided designing)
To study production procedure through modern technology.
To study production procedure through traditional technology.
To interpret the results thereof and to reach at some conclusion.
To study the overall Objectives and Obligations of the company.

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RESARCH METHODOLOGY

Research methodology refers to the tools and methods used for obtaining
information for the purpose of the subject study. Research Methodology is a way
systematically solves the research problem. It may be understood as a science of
studying how research is done systematically. Research refers to search for
knowledge. Research can also be defined as a scientific and systematic search
for pertinent information on a specific topic. Research is an art of scientific
investigation.

OBJECTIVES OF RESEARCH:
RESEARCH:
The study has been conducted in the Orient & Craft Limited (Finance &
production Department), Gurgaon. It covers the preparation of financial analysis
of production of skirt through modern technology and traditional technology. The
study is mainly done to find out the cost that is involved in production through
modern technology and traditional technology and then deciding which one is
better for carrying on a production. Information has been obtained from
respective production floors managers and effort has been made to cover major
costs involved in production of skirts.

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RESEARCH METHODOLOGY PROCEDURE:


1. DEFINING RESEARCH PROBLEM.
2. REVIEWING THE LITERATURE.
3. FORMULATING HYPOTHESIS.
4. RESEARCH DESIGNING.
5. SAMPLE DESIGNING.
6. DATA COLLECTION.
7. ANALYSING DATA.
8. INTERPRETING AND REPORTING.
1. DEFINING RESEARCH PROBLEM: There are two types of research
problems, that are those which relates to state of nature and those which
relate to relationship between variables. Our research is the former one and
the problem in precise way is FINANCIAL ANALYSIS OF MODREN AND
TRADITIONAL TECHNOLOGY
2. REVIEWING THE LITERATURE: The extensive literature study is
undertaken from the journals, newspapers and from officers concerned.
3. FORMULATION OF HYPOTHESIS: Hypothesis is a tentative assumption
made in order to draw out and test its logical and empirical consequences.
The study is related only to modern technology used in OCL LTD

33

4. RESEARCH DESIGN: Research design is a conceptual structure within


which research is conducted. A Research design is the arrangement of
conditions for collection and analysis of data in a manner that aims to
combine relevance to the research purpose with economy in procedures.
This study has been conducted in head office of OCL LTD. The required
information is taken from the officers related to the banking section and is
DESCRIPTIVE in nature.
5. SAMPLE DESIGN: Sample is a part of population, which represent the
whole population. From various types of sample design Judgment
Sampling was opted. Judgments or opinions of some experts form the
basis of research. These samples are expected to be better as they are
based on experience.
6. DATA COLLECTION:
METHODS OF DATA COLLECTION:
The study requires both the Primary as well as Secondary data for the
completion of the project.
PRIMARY DATA: Primary data has been collected by interviewing certain
executives who were chosen on the basis of their in depth knowledge and
work experience in the company.
SECONDARY DATA: The second source of data collection is the
secondary data, which is collected from the past-recorded files, annual
reports of the company and also from some other financial statements.
The monthly magazines on garment industry are also one of the most
important sources of data collection.

34

7. ANALYSIS AND INTERPRETATION OF DATA: After doing operations likeCoding, Editing & Tabulation, the data is analyzed by making various
graphs, which are depicted in the last of this project report. : RESEARCH
METHODOLOGY FOR FASHION TRENDS 2007

RESEARCH METHODOLOGY FOR FASHION


TRENDS2007
Fashion Forecast
The Summer of 2007 will see strong feelings being evoked by colours. There are
smart, elegant colours, alongside the expressive femininity of bright pinks,
orange and yellow. There is a new freshness in hues of blue along with white
which is continued by greens. There is a major trend for decoration and
embellishment. The clean look is out. Bold prints, embroideries. appliqu works,
decorative bindings, smocking, crochet cotton laces, bows and last but not the
least, fancy accessories also evoke strong feelings.

Colour Trends
The colours for the coming summer and spring
are going to be Bright and in some cases Bold.
The colours would range from Sensual Accent

35

of - Hot Pink, Fuchsia, Coral Orange, and


Yellow, Green and Mint.

Style Trends
This Summer all most all the styles will be based on comfort and basic cuts.
Comfort means a simple straight cut in comfortable fabrics with stretching effect
and tangibility. For a teenage girl comfort means tight fitted shirt in a stretchable
fabric with any kind of tangibility and maybe still baggy pants or an ankle length
skirt with detachable pockets. There is a revival of the eighties, the lust for
decoration and the logo-mania. Trimmings in ribbon, ruffles. Skirts will also have
ruffles, embroidery, asymmetry (hanky hems) and fringe. You will find Crochet on
trims, as open weave sweaters -- even swimwear or accessories. Can be

feminine or femme fatale.

Fabric Trends

36

Fabrics for this season will be seersucker cotton


and stretch Bardot checks, yarn dyed, Madras
checks, stripes.
Small to medium Floral Prints, Embroidery
Anglais,

big

of all types -

all over

flowing prints. Dot prints

polka, unsystematic etc.

The fabrics will have a soft feel to them.


Softwash,

silicon

fabrics will be in

wash and enzyme washed

demand

Viscose georgette, cotton satin, cotton poplin


and

60's cambric.

Category Wise
1. Babies (Age 0 to 3)
Colours are evocative of poetry, softness and
gaiety, and fabrics boast freshness and
smoothness. Pure whites, sandy beiges, pearly
greys and the colours of the clouds,

blues.

Styles are functional and practical with a


contemporary

poetic touch. Little wrapover

sweaters, knotted jackets, comfy Safari-style


outfits, burnous, smooth hardwearing dungarees
etc.

37

Fabrics are lightweight cottons in crumpled,


crushed, washed styles, little candy stripes. The
romantic look comes to the fore with embroidered,
smocked, stylishly finished clothes. Brushed,
woven

cottons, delicate flowers and small checks

for prints.

2. Kids (Age 3 to 8)
Colors are rich and fabrics natural or synthetic,
exploiting

technical innovations to the full with

coatings

and elasticity. Colours are mauve, beige,

yellow,

dusky

pink, fondant

blue

and

natural green.

38

Styles - Clothes play on the mixed theme with


tight-fit

trousers, fitted blouson jackets, fastening

details, A-line

dresses, and wrap over mini-skirts

etc. Fabrics go techno with

coatings, glossy

effects and stretch fits. Smooth knit or

woven

fabrics such as cotton and viscose are used the


most; linen is teamed with poplins, twills, canvas,
lightweight jerseys and interlocks.

3. Pre Teens (Age 8 to 12)


Colours are varied: dark colours and neutrals
combined with intense shades.

Shapes draw inspiration from biker wear,


American

college style, from the club scene,

the baggy

look, designer fashion.

For girls - combat style skirts and multi-pocket


skirts,

embroidery and beading, braiding and

ribbons, zips,

drawstrings,

stoppers,

protective extras
For boys -track pants in woven fabrics are all
the

range.

39

Fabrics showcase
performance
spinnaker,

all

the

techno, high-

fabrics for boys, coated canvas,


padded microfarad,

polyamide woven cotton,

viscose,

openwork jersey and

mesh etc.

4. Ladies
The mood is erotic and cheerful and focuses on
beauty, romanticism and new elegance. While
shapes are simple, the dresses themselves have
movement and flow. Sheaths are slimming at anklelength or longer, in wispy, light fabrics.
Dresses-While sleeveless dresses and halter-like
tops are still

stylish, but the new look which is

coming in is of the V-

shaped necklines and short

or elbow-length sleeves.
Jackets tend to be either really long or really short,
and

many of them have soft, feminine details

like rounded

collars, three-quarter length sleeves

or nipped-in waists. The

cropped trouser, too, is

back, but this time it isn't skin tight,

and it's being

worn with short, relaxed jackets.

40

Skirts are either very long or very short. Kneelength skirts are

either straight or slightly flared.

The long skirts are more

slimming and have a slit

down the leg.


Strong feelings are evoked by colours. There are
smart, elegant colours, alongside the expressive
femininity of bright

pinks, orange and yellow.

There is a new freshness in hues of blue along with


white which is continued by greens.

41

TRADITIONAL TECHNOLOGY
Traditional technology as the name shows the style of working since long time.
The traditional technology in manufacturing clothes is used since long time.
This technology is commonly used by small scale investors.

TRADITIONAL TECHNOLOGY ACTS AS A FIRST STEP IN EVOLUTION OF


GARMENT INDUSTRY AND MODERN TECHNOLOGY.

MANUFACTURING OF GARMENTS IN ORIENT


AND
CRAFT THROUGH TRADITIONAL TECHNOLOGY
42

CUTTING:The cutting is done through ordinary scissors. The piece to be stitched is marked
through chalk & is put on table &cutting is done manually by hands.

STICHING;The stitching is done through the UMBERELLA MACHINE& Simple sewing


machines which are operated manually by hand or by foot. If one has to stitch a
shirt, then all operations undergone under it can be operated, through this
machine like cuffs, collars, back, front pocket& finally attaching all parts to make
a shirt.

INTERLOCK

43

For interlock, a machine name INTERLOCK MACHINE is used. Interlocking is


used to support the stitching of the cloth, so that threads cant be trimmed out.

EMBROIDERY
Firstly design is drawn over trace paper. The trace paper is needled. This design,
then again traced over cloth with help of blue ink called neel. Then cloth is
tightened up with wooden frames called ADDA. Then on it finally embroidery is
done manually with help of needles.

44

MODERN

TECHNOLOGY
45

Ready-made garments account for approximately 45% of India's total textile


exports. They represent value added and less import sub sector. India's thrust
into ready made garment production started in the early 80s in the wake of the
liberalization, received a big impetus during economic reforms in the early 90's
and during the last two decades, has moved to the Tenth position, in the World's
export of ready made garments.
Ready made garments are Indias leading export products and achieved rapid
growth in the late 1980s and the first half of the 1990s. However, Indias share of
world ready made garments exports has not risen since 1994. The immediate
cause is apparently the slowdown in the import growth of Indias major markets,
namely, the United States and the EU.
The export of ready made garments, which was to the tune of 253.6 million
pieces, valued at US$ 826.5 million during January-February 2002 has increase
in quantitative terms to 306.1 million pieces, valued The role of this sector is
poised for radical changes in view of the changes in the international trading
environment.
As the International borders of trade are vanishing, Supply Chain Management
and Information Technology are taking up a crucial role in Apparel manufacturing.
Global partners in the clothing supply chain are exchanging information
electronically, thus the need for Indian Clothing Industry to spruce up. . The 3C's
of Commitment, Co-ordination and Co-operation need to be applied at all levels
by the industry to be able to maintain its presence in the global market. Global
partners in the clothing supply chain are exchanging information electronically,
thus the need for Indian Clothing Industry to spruce up. Hence, the Indian
Readymade Garment Industry is adopting modern technology:

46

MODERN TECHNOLOGY USED BY ORIENT AND CRAFT TAKE CARE OF


KEY AREAS:
Technological up gradation
Joint Ventures
Enhancement of Productivity
Quality Consciousness
Strengthening of the raw material base
Product Diversification
Increase in exports and innovative marketing strategies
Financing arrangements
Maximizing employment opportunities
Integrated Human resource Development

Global Ready Made Garments exports have experienced extraordinarily high


rates of growth, along with the continual entry of new suppliers.
Global export of textiles and ready-made garment (RMG) exceeds US $ 300
billion per year, well over one-third of which is accounted for by developing
countries.
Several developing countries such as India, Thailand, Bangladesh, Indonesia,
Sri Lanka, Pakistan, East European countries and Turkey are all becoming
sizeable producers of ready garments.

47

Orient & Craft Specializes in Manufacture of


Outerwear, Blazers and Pants (Formal and Casuals), Shorts,
Shirts,
Blouses,
DENIM WEAR, Active and Sports Wear.
An ISO 9001:2000 Certified Company
A full fledged in-house design team
Creating and developing exciting collections each season.
In House Facilities
A state-of-the-art Laundry fully equipped with automatic machinery and a
processing capacity of over 100,000 garments a day.
Polyfill manufacturing
Plant with a production capacity of over 30,000 meters of polyfill per day ranging
between 40-360gsm .
Highly sophisticated quilting unit equipped with computerized quilting machines
processing over 30.000 meters a day.
Printing unit

48

Installed with spider printing machines and printing tables having a capacity to
print up to 375,000 pieces per month.
Embroidery unit
Installed with 42 multi-head embroidery machines producing appliquesm badges,
simple and complex embroideries fulfilling a requirement a more than 50,000
pieces per day.
Label manufacturing unit
Capacity of over 1, 00,000 labels a day.
Elastic manufacturing unit - capacity of over 50,000 meters a day.

PRODUCTION SYSTEM
MODERN TECHMOLOGY IS USED AS:
Computerized fabric Spreading Machines
Computer Aided Cutting Machines
Fusing machines
Steam Sealing Machines
Power Operated Sewing Machines
Smocking Machines
Pocket Welt Machines
Sleeve Attaching Machines
Auto Surging Machines
Eton Unit Production Systems
Switch Track Systems

49

The

factories have their own inbuilt stores for fabric and accessories which

enables them to handle all necessary details required to complete one particular
order at a time. The production facilities are totally integrated to facilitate all the
process involved in garment manufacturing in-house, be it fabric cutting, fusing,
finishing or packing.
The production facilities are fully equipped with sophisticated computerized
spreading machines. These machines ensure that fabrics are spread evenly by
way of length and width. By doing so, maximum usage of complete fabric width is
ensured, thereby optimizing consumption, minimizing wastage and saving of
time.
The workforce consisting of designers, experts, skilled and unskilled laborers is
the mainstay for our continued success. 50,000 highly skilled and experienced
people work, measuring up, each day, to growing and changing international
fashion trends.

50

QUALITY
Monitoring Quality is an obsession at ORIENT AND CRAFT Exports. We have
adopted a Total Quality management System (TQM) program, Kaizen. Kaizen
bestows greater responsibility on individuals within the labour force, thereby
ensuring greater quality and productivity. Through the unprecedented
involvement in every step of the manufacturing process, we have raised the bar
for quality standards.
It is an ISO 9001:2000 company. Standards and design specifications are
replicated with fanatical care.
The team comprising of personnel trained in 'garment manufacturing technology'
maintains a strict vigil on the quality. They inspect each style before it goes on to
the production line, examining every requirement from sewing to packing. An
operation breakdown and machine specification list is prepared for each style.
Here, in-house quality control department steps in. A detailed pre-production
meeting is carried out with each factory before the new style is located on the
lines.
Post-production, the garment goes through several on-line, pre-final inspections
are made. This ensures that the product manufactured by us is world class.

51

TECHNOLOGY
As technology has become a dominant force of the new era, keeping pace with
the changing technologies has become imperative. At Orient and Craft Exports,
endeavor to take various technological initiatives that will help in increasing the
productivity and reducing the overhead costs.
IT integration is an essential constituent that puts us in a different league. The
automated manufacturing system through E.R.P enables efficient production
management. This allows us to track and monitor production at all our
manufacturing facilities at every stage, so that any changes or bottlenecks can
be detected and quickly resolved.
The factories are streamlined for mass production with production lines that allow
our group the flexibility to execute small or large orders with speed. The company
is EDI compliant with most of our buyers and have invested in a customized IT
package. Annually, company spends a substantial amount on technology
upgrades, cutting-edge IT solutions relevant to our business and addition of
production capacities.

52

IN HOUSE FACILITIES
The designing capabilities span dimensions beyond technology and
infrastructure. It is innovation that is embedded at all the levels within the work
process.
The company has a full-fledged in-house design team that comprises of
seasoned designers who create the designs on fabric. These designs are then
specifically woven on handlooms, power looms and in our weaving mills.
The designers also use their creativity and present exciting and innovative
collections of garments each season. The company adapts and creative team of
designers is cornerstone of the success.
European designers are invited each season, bringing with them the knowledge
and expertise required for researching and choosing new fabrics and style trends
that are in vogue. This exercise results in the creation of exclusive collections
each season.
To create works of art, we are setting up a design studio exclusively for our key
customers. For buyers who bring their own designs, there are state of the art
sampling facilities: 400 machines, including sleeve setting, pocket welting and
auto-jig machines that will enable them to complete their entire styling during

53

their stay in Bangalore.

LAUNDRY
In-house capabilities include special services like laundry services. The laundry
division is fully equipped with automatic machinery and has a processing
capacity of 1, 00,000 garments a day.
The laundries are well equipped to handle all kinds of washes like bleach wash,
stone wash, chemical sand wash, acid wash, pigment wash, caustic wash, indigo
wash, softener wash and enzyme crack wash, and various desired effects on
fabrics like denim etc. They also possess sandblasting and laser designing
machines that help in integrating the entire laundry processing.
The staff is trained on continual basis by technicians and experts from Europe
and Hong Kong. These experts impart and share their knowledge and expertise
with our technicians.
EMBROIDERY
The needle work embellished on different fabrics brings out the elegance and
style of a garment. In the past few years, there has been great emphasis on the

54

use of embroidery on both ethnic and western garments.


To cater to the specific demands of our clients, we have in
Stalled 42 multi-head Tajima embroidery machines. Appliqus, badges, simple
and complex embroideries are produced on these machines fulfilling a
requirement of more than 50,000 piece a day.

ACCESSORIES
Various accessories such as woven and bungee cords, stoppers, labels, tags,
cartons and other packing materials are all manufactured at the company owned
facilities.
The label manufacturing unit can handle a minimum of 100,000 labels per day.
The unit is installed with automatic jacquard looms imported from Europe. It is
fully aided by a well-equipped designing center that encourages and facilitates
innovations.
The company is also equipped with an elastic manufacturing plant with a
production capacity of 50,000 yards per day. We import technical expertise from
England to keep abreast of the changing technologies.
The bungee cord unit has been set up with technological know how and
expertise from Hong Kong. This unit has the capacity of manufacturing 40,000
yards of cord per day.
PRINTING

55

The dedicated unit for carton manufacturing is well equipped to design pin-less
(metal free) cartons. The unit has the capacity to manufacture 5,000 cartons per
day.
Quality, productivity and sound production planning facilitate the smooth coordination

between

the

production

and

the

printing

units.

The in-house printing unit is equipped with 13 TAS spider printing machines and
9 printing tables. specially import technical know-how from Srilanka to upgrade
our technology.

printing unit has the production capacity of 375,000 pieces per

month.

MODERN TECHNOLOGY - MACHINERY USED IN


ORIENT AND CRAFT FOR

PRODUCTION

OF

DIFFERENT READY GARMENTS

STRAIGHT KNIFE USED FOR CUTTING OF FABRICS

56

Ergonomic and easy to use, light straight knife, equipped with automatic knife
grinding device and lubrication system. This model is available for cutting
materials such as cotton, woolens, linen, silk, chemical fiber, leathers etc. It has
features such as steady run, low noise, flexible and convenient operation,
powerful cutting ability. Rating power 550W, 2.800 rpm, and voltage 230V.
Weight 15kg.

PRODUCT FEATURES

Special steel ensures a sharp cutting edge for perfect cuts and guarantees
a long blade life.
Quality welds achieved by using the world's best machines.
Blade machined to avoid wobbling.
100% Quality assurance because all blades are test run at the factory
before dispatch.

57

Back edge of the blade is rounded to avoid damage to the jaw plates and
back guides.
Blade surface polished to ensure a smooth run & less resistance while
cutting.

SINGLE NEEDLE MACHINE

LOCK STICHING

58

FEATURES.
The machine runs at higher sewing speeds than any other lockstitch
machine intended for heavy materials anywhere in the world, reaching, up
to 4,000rpm for stitch length of less than 5mm and 3,500rpm for stitch
length of up to 7mm. The result is dramatically increased productivity.
By adopting the locus best suited to the sewing of leather and heavy
materials
By adopting the locus best suited to the sewing of leather and heavy
materials, the machine smoothly feeds heavy materials without stitch
gathering even on multi-layered portions. The machine also uses a
fluorocarbon resin presser foot that offers sharp-curve sewing capability to
prevent from scratch on the material.Heavy multi-layered portions of the
material with no stitch gathering or thread breakage.
The machine has an attachment mounting seat. This makes it easier to
replace attachments and increases the durability of the machine bed.
Furthermore, the machine is equipped with a feed eccentric pin. This

59

enables easy adjustment of the feed dog inclination and feed timing
(phase), thereby offering improved maintainability.
The machine head was remodeled to achieve an optimally balanced and
highly rigid machine head frame. With its reduced vibration and noise and
easy operation of the feed lever at the time of reverse stitching, the
machine

promises

to

make

sewing

work

more

comfortable.

The wider distance from the machine arm to the needle on the front of the
machine head, smoothened design of the machine head, larger needle
bar stroke (35 mm), and higher lift of the presser foot (13 mm) enable
easy handling of heavy material. In addition, the machine is equipped with
a hand wheel that is larger than normal for easy turning.
The stitch length can be adjusted to a maximum of 7mm (both in normal
feed and reverse feed directions). The highly reliable and durable feed
mechanism ensures accurate and consistent stitch length with no errors in
the case of long stitching pitches.

60

Automatic Serging Machine

The ASN Series machine has been provided with the capability of sewing lightweight materials, and a low-tension sewing feature to enable sewing according to
the material to be sewn, as well as achieving consistent high-quality seams free
from slip-off seams at curved parts of the material.
FEATURES
The machine offers high-speed performance with its maximum sewing speed
of 8,000rpm. With this feature, the machine makes the most out of its original
capabilities as a serging machine to help dramatically increase productivity.
The machine is fully equipped with mechanisms developed through a full
consideration for seam quality. The machine, therefore, supports any type of
material.
The machine can be adjusted externally according to the material to be sewn.

61

A ball control method has been introduced to the cloth control device. This
device demonstrates advantageous features in the sewing of small parts and
sharp curves of the material. In addition, the ball control base can be easily
removed/installed to offer improved maintainability.

The machine comes with upper and lower needle bar bushings in a sealed
structure

to

offer

enhanced

durability

and

reliability.

In addition, the machine is provided as standard with a cartridge-type oil filter


and cooling fan to further improve reliability.
The ASN-697 is provided as standard with a cloth control device, curl
blower, in-curve and out-curve detecting sensor, cloth feed table air blower, as
well as other helpful mechanisms. When the machine sews crotches or joins
the seat seams of slacks, the in-curve and out-curve detecting sensor detects
sharp in-curves and out-curves to automatically control the sewing speed.
Automatic shirring is also possible at desired sections of the material by
programming sewing data. The machine adopts an air-driven feed
mechanism for feeding materials while preventing the material from slipping
off the needle entry point.

62

DOUBLE NEEDLE MACHINE


Sleeve Setting Machine with Multiprogramming Device

FEATURES
The JUKI's unique right-and-left independent drive system of the top feed
belt, right and left feed amounts can be adjusted separately. This prevents the
material from slipping out of position, thereby sewing sleeves with a
consistent seam allowance.
By introducing the belt feed, the machine reduces scratches to the material
made by the feed.
Data can be saved and transferred by means of Smart Media. As a result,
sewing machines in a factory or in subcontracted factories are able to sew
sleeves using the same data.

63

The operating screen gives a graphic display of an armhole. The operator


can, therefore, easily confirm the portion to be sewn and enter/edit data.

Computer-controlled, Eyelet Buttonholing


Machine
with Trimmer for Needle and Lopper
Thread with Gimp

FEATURES
Needle and lopper thread tensions can be digitally established on the
operation panel according to sewing conditions. Data can be registered on
a pattern-by-pattern basis to easily reproduce the same sewing conditions.
The machine also ensures the consistent production of high-quality
seams.
Threading work can be more easily.

64

Since fewer parts need to be threaded, the machine can be threaded


more quickly and easily than conventional buttonholing machines.
Vertically driven cloth cutting knife controlled by a stepping motor.
The knife is controlled by a stepping motor. This enables easy adjustment
of the knife pressure on the operation panel to suit the material to be used,
thereby preventing irregular cutting.
Data on knife pressure can be registered on pattern-by-pattern basis to
establish

the

best-suited

knife

pressure

according

to

sewing

specifications. Adequate knife pressure improves durability of cloth-cutting


knife and knife guard.
Selection between the cut-before knife and cut-after knife can be made on
the operation panel.
The stepping-motor-controlled cloth-cutting knife is free from the troubles
likely to affect air-driven knives, including dull cutting and the breakage of
parts such as the knife-driving arm. In addition, a large-capacity
compressor is no longer required since the machine uses less
compressed air.

65

Computer-controlled, High-speed,
Bartacking Machine

FEATURES
The world's highest sewing speed of 3,000rpm!

66

The proven computer-controlled bartacking machine has been


dramatically evolved to be an easier-to-use machine.
In addition to the high-speed sewing performance, the machine's starting,
stopping, thread-trimming and automatic presser lifting speeds have been
increased to significantly shorten total cycle time (reduced approximately
30% compared to our predecessor model: For 42-stitch large bartacks).
The machine comes with a newly developed needle thread grasping
mechanism. The mechanism prevents thread from slipping off from the
needle eyelet at the beginning of sewing, from tangling on the wrong side
of the material and also being stained during sewing.

The thread trimming mechanism has been further improved to shorten the
length of thread remaining on the wrong side of the material after thread
trimming.
With its 30mm (length) by 40mm (width) sewing area, the machine can sew
many different shapes of bartacks.
Since the machine is provided with an active tension mechanism, it is able to
set a needle thread tension that matches various sewing conditions (such as
thread, material and sewing speed) on the operation panel, store the data in
memory and reproduce it.

67

The needle thread tension can be separated according to stitching type or


portion of a seam, such as the beginning part of the seam, base stitched part,
zigzag stitched part and end of the seam (fastening stitch)

Over lock / Safety Stitch Machine

68

The

world's

first

dry-head

over

lock

machine!

JUKI's technology for developing machines that require no oiling has created an
over

lock

machine

with

maximum

sewing

speed

of

6,000rpm.

This over lock machine is capable of responding to the need for both high-grade
and high-quality sewing performance.
FEATURES
The needle bar, feed and looper mechanisms require no oiling. This
means they do not splash oil, thereby leaving no oil stains on the sewing
material, and thus contributing to upgraded quality.
The driving section of the machine, except for the needle bar, feed and
looper mechanisms is installed in a forced oiling block. This block is
completely sealed to prevent the leakage of oil.
Stain-removing work or re-sewing work resulting from oil stains is
eliminated.
The machine does not need periodical oiling or used-oil disposal, which
markedly improves maintainability.
The machine incorporates various mechanisms as standard, such as a
differential-feed micro-adjustment mechanism and an external adjustment
mechanism for adjusting the feed dog inclination as well as increasing the
differential-feed ratio, which can be easily adjusted to finish seams that
perfectly match the material to be used.

69

Comfortable operation is all but guaranteed, by a wider area around the


needle entry, the adoption as standard of a micro-lifter feature that offers
improved responsiveness to materials and provides the operator with
upgraded operability, and by the reduction of operating noise and
vibration, which has been achieved by designing an optimally balanced
machine.

Coverstitch Machine

70

FEATURE
The optimized thread take-up mechanism and top covering thread path
route contribute to an increased stability of top covering stitches. In addition,
the machine is capable of performing sewing with a low tension applied to
the thread to offer improved responsiveness to the sewing thread.
The machine is provided as standard with a great diversity of features, such
as a differential-feed adjustment mechanism with a micro-adjustment
mechanism, a feed dog inclination adjustment mechanism, a micro-lifter and
a needle bar stroke conversion
Mechanism. The machine can therefore be quickly adjusted to respond to
various materials and processes, thus increasing the applicable types of
sewing products.
The differential-feed amount can be easily adjusted to the best suited value
for the material to be used. Since the front and rear feed dogs are
synchronized, the differential- feed ratio is constant, requiring no additional
adjustment, even when the stitch length is changed.of the feed dog
inclination can be carried out from outside with ease. The feed dog
inclination adjustment mechanism works effectively to secure the material
being sewn in place with increased reliability and thereby preventing uneven
material feed and puckering.
The well-balanced design of the machine achieves low-vibration and lownoise

operation

even

under

the

high-speed

mode.

This enables the operator to concentrate on sewing work in a more


comfortable environment.

71

COMPUTER AIDED DESIGNING

CAD stands for Computer Aided Design. CAD is the use of a range of computer
based tools that help architects, engineers, and designers in design activities.
CAD is sometimes translated as computer assisted, or computer aided drafting.
All these terms are synonymous for CAD. CAD is used to develop and design
products which can be used by consumers or in other products. CAD is also
used in the design of machines and tools. Modern capabilities of CAD systems

72

include

modeling,

design,

data

exchange,

packaging

and

more.

Today, most CAD computer workstations are Windows based. CAD is


essentially an automated system for the design, drafting, and display of
graphically oriented information. Computer Aided Design, CAD is often used in
architecture for the design and development of plans for buildings. Computer
Aided Design, CAD is also used in engineering, to create drawings for modeling.
CAD is also used in the electronic field for design automation. Furthermore, CAD
is used in the manufacturing process for layouts.
This open source, digitizing software converts an image file showing a graph or
map, into numbers. The image file can come from a scanner, digital camera or
screenshot. The numbers can be read on the screen, and written or copied to a
spreadsheet.
This open source, digitizing software converts an image file showing a graph or
map, into numbers. The image file can come from a scanner, digital camera or
screenshot. The numbers can be read on the screen, and written or copied to a
spreadsheet.

73

Plotter
A plotter is a vector graphics printing device that connects to a computer.
Plotters print their output by moving a pen across the surface of a piece of paper.
This means that plotters are restricted to line art, rather than raster graphics as
with other printers. They can draw complex line art, including text, but do so very
slowly because of the mechanical movement of the pens. (Plotters are incapable
of creating a solid region of colour; but can hatch an area by drawing a number of
close, regular lines.)
Plotters are used primarily in technical drawing and CAD applications, where
they have the advantage of working on very large paper sizes while maintaining
high resolution. Another use has been found by replacing the pen with a cutter,
and in this form plotters can be found in many garment and sign shops.

ERP - ENTERPRISE RESOURCE PLANNING


IN
Orient & craft
ERP is often a confusing terminology but to put it in simple terms: ERP is an
acronym

meaning

Enterprise

Resource

Planning.

It

is

software

package/solution most often used within the manufacturing environment. ERP is


a business tool that management uses to operate the business day-in and day-

74

out. It is usually comprised of several modules such as a financial module, a


distribution module, or a production module. Each of these modules shares
information that is housed within the database structures on which the ERP
system was coded. ERP helps to break down barriers between departments
within a company. For example, many times the sales department may be selling
25%more product than the production department can produce. By utilizing an
ERP system, the sales department, production department, operations
management, shipping, financial department, purchasing department all have
access to the up-to-date information that is needed to operate smoothly within
any manufacturing environment.
In ERP solution there is only one database that is used by all departments, such
as Sales, Production, Finance and Accounting, Maintenance and Engineering,
Purchasing, etc. ERP applications contain several modules such as production,
finance and accounting, sales and distribution modules, etc. Those modules are
totally integrated and need only one database (to ensure no duplicate data).
Each module consists of the best business practice that can be implemented for
that companys industry, for example a manufacturing company. ERP software
should only require some customization to fit the requirements of the business
process.
One main difference between non-packaged software and ERP is the number of
databases. When you develop a program for each department with a unique
database, then you must integrate each database. In this situation, you must
maintain several databases.
In one sentence, ERP is a combination of business management practice and
technology, where Information Technology integrates with your companys core
business process to enable the achievement of specific business objectives.

75

Enterprise resource planning software, or ERP, doesnt live up to its acronym.


Forget about planning-it doesnt do much of that and forget about resource, a
throwaway term. But remember the enterprise part. This is ERPs true ambition. It
attempts to integrate all departments and functions across a company onto a
single computer system that can serve all those different departments particular
needs.

76

77

FINANCIAL ANALYSIS
A BRIEF COMPARISON OF PRODUCTION THROUGH MODREN TECHNOLOGY &
TRADITIONAL TECHNOLOGY.
Following analysis is undertaken by considering some most important aspect of
producing skirts and in the following analysis cost for producing 200 skirts in
one line utilizing 400 meters of fabric has been considered.

STEP 1: CUTTING
MODERN TECHNOLOGY
MACHINERY

STRAIGHT KNIFE MACHINE (2),

USED

CHALKS

LABOUR

2 professional masters

TIME

2 hrs

PRODUCTION

200mts per hr

CAPITAL UTILIZED

RS 100000

DEPRICIATION

50,000per machine@ 10% per year


Rs10,000 per year
Rs834 per month
Rs 28 pr day

ELECTRICITY

200

78

TRADITIONAL TECHNOLOGY
MACHINERY
USED

SCISSORS (8), RULLER,


CHALKS, TABLE

LABOUR

8 masters

TIME

10 hrs

PRODUCTION

40 mts per hr

CAPITAL UTILIZED

5000

DEPRICIATION

Negligible

ELECTRICITY

Nil

79

FUSING
MODERN TECHNOLOGY
MACHINERY

FUSING MACHINE (4),

LABOUR

5 professional tailors

TIME

6 hours

PRODUCTION

34 pieces per hour

CAPITAL UTILIZED

RS 200000

DEPRICIATION

50,000per machine@ 10% yearly


RS20,000 pr yr
RS1667 per month .
RS55 per day

ELECTRICITY

RS350 Per Day

TRADITIONAL TECHNOLOGY
MACHINERY

JUKI MACHINE (8), RULLER,

USED

CHALK

LABOUR

9 tailors

TIME

9 hours

PRODUCTION

21 pieces per hour

CAPITAL UTILIZED

RS 40000

DEPRICIATION

RS5000 per machine@10%


yearly
RS2000 per year

80

RS167 per month.


RS11.11 per day

ELECTRICITY

RS50 per Day

STEP 2: PRODUCTION
(1) CREASING FRONT POCKET AND FLAP
MODERN TECHNOLOGY
MACHINERY

SNLS AND IRON TABLE (2),

USED

TEMPLATES (2)

LABOUR

TIME

3 hours

PRODUCTION UNIT

67 PIECES/HR

CAPITAL UTILIZED

RS105000

DEPRICIATION

RS50,000 per mach 10%yearly


RS20,000 per year
RS1667 per month.
RS55 per day

ELECTRICITY

RS200Per Day

TRADITIONAL TECHNOLOGY
MACHINERY

ORDINARY PRESS (4),

USED
LABOUR

81

TIME

5 hours

PRODUCTION UNIT

40 pieces per hour

CAPITAL UTILIZED

4000

DEPRICIATION

NEGLIGIBLE

ELECTRICITY

40 Per Day

(2)

ATTACHING AND SEWING &POCKET

MOUTH
MODERN TECHNOLOGY
MACHINERY

SINGLE NEEDLE MACHINE (3),

US ED

SWING GUIDE (3)

LABOUR

3 tailors

TIME

4 hours

PRODUCTION UNIT

50 pieces per hour

CAPITAL UTILIZED

RS600000

DEPRICIATION

RS 2,00,000per mach@ 10% yearly


RS 60,000 pr yr
RS 5000 pr month
RS 167 pr day

ELECTRICITY

RS 500 Per Day

TRADITIONAL TECHNOLOGY
MACHINERY

ORDINARY UMBERALLA

US ED

SEWING MACHINE. (8)

LABOUR

8 tailors

TIME

9 hrs

82

PRODUCTION UNIT

22 pieces per hour

CAPITAL UTILIZED

RS 40000

DEPRICIATION

RS 5000 per mach@10% yearly


RS 4000/Yr
RS 334per month
RS 5.5 pr day

ELECTRICITY

Nil

3.Top stich front pocket flap


MODERN TECHNOLOGY
MACHINERY

SNLS (4)

US ED
LABOUR

4 tailors

TIME

6 hours

PRODUCTION UNIT

34 pieces per hour

CAPITAL UTILIZED

RS 200000

DEPRICIATION

RS 50,000per mach@ 10% yearly


RS 20,000 per year
RS 1667 per month
RS 55 pr day

ELECTRICITY

RS240

TRADITIONAL TECHNOLOGY
MACHINERY

ORDINARY UMBRELLA(8)

US ED
LABOUR

8 tailors

TIME

9 hours

PRODUCTION UNIT

21 pieces per hour

83

CAPITAL UTILIZED

RS 40000

DEPRICIATION

RS 5000 per
mach@10%yearly
RS 4000 per year
RS 334per month
RS 11.11 per day

ELECTRICITY

RS.45

ZIPPER FLY
MODERN TECHNOLOGY
MACHINERY

DOUBLE NEEDLE MACHINE (4 )

US ED

SWING GUIDE (4)

LABOUR

4 tailors

TIME

4 hrs

PRODUCTION UNIT

50 pieces pr hr

CAPITAL UTILIZED

RS 400000

DEPRICIATION

RS 1,00,000per mach@ 10% yearly


RS 40,000 pr yr
RS 3334 pr month
RS 111 pr day

ELECTRICITY

RS 350Per Day

TRADITIONAL TECHNOLOGY
MACHINERY

ORDINARY UMBERALLA (10)

US ED

SEWING MACH. (10)

LABOUR

10 tailors

TIME

9 hours

PRODUCTION UNIT

22 pieces per hour

84

CAPITAL UTILIZED

RS 60000

DEPRICIATION

RS 6000 per machine@10% yearly


RS 6000 per year
RS 500per month
RS 17 per day

ELECTRICITY

nil

Attaching and sewing back


MODERN TECHNOLOGY
MACHINERY

SINGLE NEEDLE MACHINE (3)

US ED
LABOUR

3 tailors

TIME

7 hours

PRODUCTION UNIT

29 pieces per hour

CAPITAL UTILIZED

RS 150000

DEPRICIATION

RS 50,000per mach@ 10% yearly


RS 15000 per year
RS 1250 per month
RS 41.66 per day

ELECTRICITY

RS 160 per day

TRADITIONAL TECHNOLOGY
MACHINERY

ORDINARY UMBERALLA (6)

US ED
LABOUR

6 tailors

85

TIME

10 hrs

PRODUCTION UNIT

20 pieces per hr

CAPITAL UTILIZED

30000

DEPRICIATION

5000 per mach@10% yearly


3000 PER YEAR
250per month
8.33 Per day

ELECTRICITY

nil

Joining waist band and waist loop


MODERN TECHNOLOGY
MACHINERY

SINGLE NEEDLE MACHINE (4),

US ED

PICK STICH MACHINE (4)

LABOUR

4 tailors

TIME

4 hours

PRODUCTION UNIT

50 pieces pr hr

CAPITAL UTILIZED

200000

DEPRICIATION

50,000per mach@ 10% yearly


20000 pr yr
1667pr month
55.55 pr day

ELECTRICITY

120 per Day

TRADITIONAL TECHNOLOGY
MACHINERY

ORDINARY UMBERALLA (6)

US ED

86

LABOUR

6 tailors

TIME

10 hrs

PRODUCTION UNIT

20 pieces per hr

CAPITAL UTILIZED

30000

DEPRICIATION

5000 per mach@10% yearly


3000 PER YEAR
250per month
8.33 Per day

ELECTRICITY

nil

Final assembly :attaching and sewing all


parts of skirt
MODERN TECHNOLOGY
MACHINERY

SINGLE NEEDLE MACHINE (4)

US ED

DOUBLE NEEDLE MACHINE (4)

LABOUR

8 tailors

TIME

6 hours

PRODUCTION UNIT

34 pieces pr hr

CAPITAL UTILIZED

500000

DEPRICIATION

50,000per mach@ 10% yearly


750,00per mach@ 10% yearly
50000 PER YEAR
4167pr month
139 pr day

ELECTRICITY

400 per Day

TRADITIONAL TECHNOLOGY

87

MACHINERY

ORDINARY UMBERALLA (12)

US ED
LABOUR

15 tailors

TIME

10 hrs

PRODUCTION UNIT

20 pieces per hr

CAPITAL UTILIZED

60000

DEPRICIATION

5000 per mach@10% yearly


5000 PER YEAR
500 PER month
16.67 Per day

ELECTRICITY

nil

Bartacking
MODERN TECHNOLOGY
MACHINERY

SINGLE NEEDLE MACHINE (4),

US ED
LABOUR

4 tailors

TIME

7 hours

PRODUCTION UNIT

29 pieces pr hr

CAPITAL UTILIZED

200000

DEPRICIATION

50,000per mach@ 10% yearly


20000 Per year
1667pr month
56 per day

ELECTRICITY

200 per Day

TRADITIONAL TECHNOLOGY

88

MACHINERY

ORDINARY UMBERALLA (8)

US ED
LABOUR

8 tailors

TIME

10 hrs

PRODUCTION UNIT

20 pieces per hr

CAPITAL UTILIZED

40000

DEPRICIATION

5000 per mach@10% yearly


4000 Per year
334 Per month
11 Per day

ELECTRICITY

nil

Attaching snap button with waste band


MODERN TECHNOLOGY
MACHINERY

BUTTO TACKING MACHINE (3),

US ED
LABOUR

3 tailors

TIME

5 hours

PRODUCTION UNIT

40 pieces per hour

CAPITAL UTILIZED

2,25,000

DEPRICIATION

75,000per mach@ 10% yearly


22,500PER YEAR
1875 per month
625 per day

ELECTRICITY

400 per Day

89

TRADITIONAL TECHNOLOGY
MACHINERY

RIPET BASE HAMMERS(10)

US ED
LABOUR

10

TIME

5 hrs

PRODUCTION UNIT

40 pieces per hr

CAPITAL UTILIZED

500

DEPRICIATION

Negligible

ELECTRICITY

nil

Spoting
MODERN TECHNOLOGY
MACHINERY

DUROKOP AIR COMPRESSORS (1)

US ED
LABOUR

TIME

4 hours

PRODUCTION UNIT

50 pieces pr hr

CAPITAL UTILIZED

500000

DEPRICIATION

5,00,000per mach@ 10% yearly


50000 PER YEAR
4167pr month
139 pr day

ELECTRICITY

500 per Day

90

TRADITIONAL TECHNOLOGY
MACHINERY

SPRAY BOTTLES

US ED
LABOUR

15

TIME

10 hrs

PRODUCTION UNIT

20 pieces per hr

CAPITAL UTILIZED

500

DEPRICIATION

Negligible

ELECTRICITY

nil

Thread cutting
MODERN TECHNOLOGY
MACHINERY

JUKI THREAD CUTTERS (1)

US ED
LABOUR

TIME

8 hours

PRODUCTION UNIT

25 pieces pr hr

CAPITAL UTILIZED

200000

DEPRICIATION

2,00,000per mach@ 10% yearly


20000 PER YEAR
1667pr month

91

56 pr day
ELECTRICITY

350 Per day

TRADITIONAL TECHNOLOGY
MACHINERY

ORDINARY SCISSORS (10)

US ED
LABOUR

10

TIME

10 hrs

PRODUCTION UNIT

20 pieces per hr

CAPITAL UTILIZED

700

DEPRICIATION

70 per Scissor@10% yearly


70 per year
6 per month
0.2 Per day

ELECTRICITY

nil

Ironing
MODERN TECHNOLOGY
MACHINERY

JUKI IRON STATUES (2)

US ED
LABOUR

TIME

8 hours

PRODUCTION UNIT

25 pieces pr hr

CAPITAL UTILIZED

200000

DEPRICIATION

1,00,000per mach@ 10% yearly

92

20000 PER YEAR


1667pr month
56 pr day
ELECTRICITY

600 Per

TRADITIONAL TECHNOLOGY
MACHINERY

ORDINARY PRESS (10)

US ED
LABOUR

10

TIME

10 hrs

PRODUCTION UNIT

20 pieces per hr

CAPITAL UTILIZED

10000

DEPRICIATION

1000 per mach@10% yearly


100 PER YEAR
RS9 PER month
RS 0.3 Per day

ELECTRICITY

RS800

Tagging and packing


MODERN TECHNOLOGY
MACHINERY

DUROKOP TAGGING MACHINE (2),

US ED
LABOUR

TIME

4 hours

PRODUCTION UNIT

50 pieces pr hr

CAPITAL UTILIZED

50000

DEPRICIATION

25,000per mach@ 10% yearly


2500 PER YEAR

93

209 pr month
7 pr day
ELECTRICITY

200 Per day

TRADITIONAL TECHNOLOGY
MACHINERY

ORDINARY UMBERALLA (5)

US ED
LABOUR

TIME

9 hrs

PRODUCTION UNIT

23 pieces per hr

CAPITAL UTILIZED

25000

DEPRICIATION

5000 per mach@10% yearly


2500 PER YEAR
209 PER month
7 Per day

ELECTRICITY

nil

Profit and loss account for individual operations for producing 200 skirts.
Cutting
Expenses
Labour Man

RUPEES
Modern Technology
72

Traditional Technology
1440

28
200
300

Nil
Nil
1440

Hour
s
Depreciation
Electricity
Total

94

FUSING
Expenses
Labour Man Hours
Depreciation
Electricity
Total

RUPEES
Modern Technology
216
55
350
621

CREASING FRONT POCKET FLAPS


Expenses
Labour Man Hours
Depreciation
Electricity
Total

Modern Technology
108
55
200
363

ATTACHING AND SEWING POCKET


Expenses
Labour Man Hours
Depreciation
Electricity
Total

Modern Technology
108
167
500
775

TOP STICH FRONT POCKET FLAP


Expenses
Labour Man Hours
Depreciation
Electricity
Total
Zipper fly

Modern Technology
288
55
240
583

Traditional Technology
1458
11.11
50
1519.11
RUPEES
Traditional Technology
540
Nil
40
580
RUPEES
Traditional Technology
540
5.5
Nil
545.5
RUPEES
Traditional Technology
1296
11.11
45
1352.11
RUPEES

95

Expenses
Labour Man Hours
Depreciation
Electricity
Total

Modern Technology
216
111
350
677

Attaching and sewing back


Expenses
Labour Man Hours
Depreciation
Electricity
Total

Modern Technology
216
41.66
160
417.66

Traditional Technology
1620
17
Nil
1637

RUPEES
Traditional Technology
1620
8.33
Nil
1628.33

Join waist band and waist loop


RUPEES
Expenses
Labour Man Hours
Depreciation
Electricity
Total

Modern Technology
108
55.55
120
283.55

Traditional Technology
1440
8.33
Nil
1448.33

Final assembly :attaching and sewing all parts of skirt

Expenses
Labour Man Hours
Depreciation
Electricity
Total

Modern Technology
144
139
400
683

Traditional Technology
2700
17
Nil
2717

96

Bartacking

Expenses
Labour Man Hours
Depreciation
Electricity
Total

RUPEES
Modern Technology
216
56
200
472

Attaching snap button with waste band

Expenses
Labour Man Hours
Depreciation
Electricity
Total

Modern Technology
108
62
400
570

Spotting

Expenses
Labour Man Hours
Depreciation
Electricity
Total

RUPEES

Traditional Technology
500
Nil
Nil
500
RUPEES

Modern Technology
144
139
500
783

Thread cutting
Expenses
Labour Man Hours
Depreciation
Electricity
Total

Traditional Technology
1620
11
Nil
1631

Traditional Technology
2700
Nil
Nil
2700

RUPEES
Modern Technology
144
56
350
550

Traditional Technology
1620
Nil
Nil
1620

97

Ironing

Expenses
Labour Man Hours
Depreciation
Electricity
Total

RUPEES

Modern Technology
144
56
600
800

Tagging & packing

Expenses
Labour Man Hours
Depreciation
Electricity
Total

Modern Technology
144
7
200
351

Traditional Technology
1800
nil
800
2600

RUPEES

Traditional Technology
1620
7
Nil
1627

Combine profit and loss a/c for modern & traditional technology
Expenses
Labour Man Hours
Depreciation
Electricity
Total

Modern Technology
2376
1082
4770
8228

Traditional Technology
22518
105
935
23558

Conclusion
If company produces 200 skirts in 1 day through 1 line using modern
technology then cost incurred will be rupees 8228 approximately.

98

If company produces 200 skirts through 1 line in 1 day using traditional


technology then cost incurred will be rupees 23558 approximately.
Total saving will be of rupess 15330 per 200 skirts through one line per
day.
So in production of order of 10000 skirts in ten days total savings will be as
follows.
10000/200 = 50
50*15330= 766500RS
So saving of RS 766500 will be made in 5days if company utilizes all of its 10 line
in one floor for the production of 10000 skirts.

99

LIMITATIONS
100

Time limitation, as the duration of the project is only 6 weeks.


Company was having 40 units so it was not possible to get information
from all the factories.
It was difficult understand certain things because they were technical in
nature.
Responses, which come, are very slow.
The study doesnt covers human resource OCL.

101

102

CONCLUSION

OCL has been doing business from the past 34 years. During the years it has
made itself a largest export house of ASIA and it had gathered a lot of valuable
expertise and learned the trick of the trade the tougher way.
After undergoing an in depth study of the report, one can easily recognized that
OCL is manufacturer of ready made garment house which manufactures mainly
for the biggest brands of world.. OCL ensures that each of its buyers is provided
with the best services and ultimately all customers are satisfied.
After going through the report one can easily analyze that modern technology
used by OCL is cost saving. If company has got big order then it should carry on
production through use of modern technology as it will be time and cost saving
but if production order is small it should carry on production using traditional
process as it would be cheaper and depreciation on modern machinery will be
very high.
Undoubtedly, it is because of this incredible expertise an synchronize functioning
that OCL has a monopoly in manufacturing of ready made garments, but still
certain improvements are yet to take place.

Conclusion
If company produces 200 skirts in 1 day through 1 line using modern technology
then cost incurred will be rupees 8228 approximately.

103

If company produces 200 skirts

through 1 line in 1 day using

traditional

technology then cost incurred will be rupees 23558 approximately.


Total saving will be of rupess 15330 per 200 skirts through one line per day.
So in production of order of 10000 skirts in ten days total savings will be as
follows.
10000/200 = 50
50*15330= 766500RS
So saving of RS 766500 will be made in 5days if company utilizes all of its 10 line
in one floor for the production of 10000 skirts.

104

105

SUGGESTIONS
Regarding manufacturing
Instead of carrying on business in 40 Factories Company can can reduce the
number and increase the size of factory as it will help in following
More control
Less human resource problem
Cost saving
Quality service and performance
Increase in business
Regarding human resource
As human resource is the biggest asset, company should give more care to solve
the grievances of employees which can lead to lock ups.
Regarding maintenance of imported machines
As imported machines costs high amt. so proper care can increase the life .of
machineries. Separate maintenance department should be opened.
Miscellaneous
Compliance should be attended by production managers as ordinary
employee could do blunder mistakes which can lead to rejection of orders.

106

Security should be tightening up at sampling section as loose of samples


could be loose of business...
.

107

ANNEXURE

OPERATION BULLETIN

EMPLOYEE HANDBOOK

108

109

BIBLIOGRAPHY
JOURNALS
Material provided at OCL
www.google.com
Magazines

110

111