INTERNSHIP REPORT

ON
MASOOD TEXTILE MILLS LIMITED

SUBMITTED BY:
MUJAHID KHALID

ROLL NO 619

SESSION 2007-2011

BS (HONS) COMMERCE

COLLEGE OF COMMERCE
GOVERNMENT COLLEGE UNIVERSITY FAISALABAD
 Dedication

WE DEDICATE THIS PROJECT TO OUR HOLY PROPHET HAZRAT MUHAMMAD

(PEACE BE UPON HIM).

WE ALSO DEDICATE THIS PROJECT TO OUR PARENTS AND TEACHERS

BY VIRTUE OF WHOSE PRAYERS,

WE HAVE BEEN ABLE TO REACH AT THIS POSITION

AND

WHOSE HANDS ARE ALWAYS

RAISED FOR PRAY, FOR OUR WELL BEING,

EVEN AT THIS MOMENT OF TIME.

THEN TO OUR RESPECTABLE TEACHERS

AND

TO THOSE WHO LOVE US

AND

TO WHOM WE LOVE.
 Acknowledgement

All praises to Almighty Allah alone, the Most Merciful and the most
compassionate and His Holy Prophet “ Muhammad” (Peace be Upon Him) the
most perfect and exalted one among and of ever born on the surface of earth, who
is forever touch of guidance and knowledge for the humanity.

The work presented in this manuscript was accomplished under the guidance
generous assistance, constructive criticism and enlightened supervision of
Venerated Mr. Shahid Naveed Finance Department of MTM Apparel Division-II.
His efforts towards the inculcation of spirit of constant work and the maintenance of
professional integrity besides other invaluable words of advice will always serve as
beacon of light through out the course. We take this humblest opportunity to my
deepest sense of gratitude and thankfulness to him.

“No one writes alone”. This internship report is not the result of individual effort. It
is a result of wonderful team- work.

We are really thankful of Venerated Mr. Muhammad Ishfaq who is Manager of

Finance Department of MTM Apparel Division-II give all the lectures related to
finance department and overall activities of other departments related to Finance
department and company. We are also really thankful to Venerated Mr.
Muhammad Aftab & Mr. Muhammad Anees who is Deputy Manager and
Assistant Manager respectively of Finance Department Apparel Division-II arrange
all the lecture and necessary information of internship related to Apparel Division
(Finance Department). We are also thankful to Venerated Mr. Muhammad Rashid
who is working in MTM as Accountant at Saeed Colony in Finance Section provided
all information related to my Internship.

We are thankful to all those who supported me and provide great help for

completion of this task. I am tried our level best to prepare this event with high level

of accuracy but no one claim to perfect other than ALMIGHTY ALLAH.

 EXECUTIVE SUMMARY

I joined Masood Textile Mills Ltd as an Internee. The motive of joining the MTM is to
have an exposure of textile sector and potential to avail a sound and promising career. I
devoted one and a half month to learn about MTM, which will be beneficial to me if I join
textile sector. I got Six weeks training to learn about the organizational culture, their
values and products. During training, I almost visited every department of MTM and
strive to learn ceiling.

The objective of this report that I have placed is to express what I did observed and
what are the necessary measures that can help to capitalize the strengths to overcome
weakness and remove the threats. It will be difficult for me to express the whole process
and procedures from technical point of views are needless to express.
 TABLE OF CONTENTS

INTRODUCTION 02

HISTORY 03

MISSION 03

VISION 03

STRATEGIC OBJECTIVE 03

HUMAN RESOURCE DEPARTMENT 04-06

MARKETING & MERCHANDISING 07-13

FINANCE DEPARTMENT 14-19

IT DEPARTMENT 20-22

PRODUCTION DEPARTMENT 23-25

PRODUCTION & PLANNING CONTROL DEPARTMENT 26-29

SUGGESTIONS 32
 EO MESSACE
C

Welcome to MTM, Masood operates throughout the world with over 16,000

employees as part of our team.

MTM Collection has a wide selection of quality garments including T-shirt, Polo

shirt, Jogging suit, Henley shirt, Raglan shirt, Tank top , Bikini, Shorts, Pants and

Sleepwear. Competent professional staff, a team of talented merchandisers,

excellent supplies & support services, and state-of-the-art technology is the

driving force behind MTM phenomenal growth in the past years.

MTM has expanded its operations to include the Internet, and has taken

advantage of the variety of international trade facilitated by the Web. Now MTM

uses state-of-the-art client/server technology for its market information processes

to coordinate its network of global buyers and agents around the world.
Introduction

Masood is a truly Vertically Integrated Textile Unit. It has in-house Yarn, Knitting, and Fabric
Dyeing, Processing, Apparel Manufacturing and Laundry facilities.

The Company has five SPUs and a highly qualified experienced mills manager heads each unit.
All Mills Managers in turn report to the General Manager. The objective to operate in this
manner is that there is a close co-ordination and link between all the divisions. Every unit
operates in the most efficient manner in-order to achieve competitive prices, timely delivery and
quality products.

We believe that prevention is better than cure. The sooner the problem is tracked, the better it is
in delivering the goods on time. During the process of stitching we have inline inspection and
final inspection processes. The garments are 100% inspected by highly experienced inspectors.

The ‘BACK TRACKING SYSTEM’ plays a vital role in developing sense of responsibility and
accountability in every person in making and inspecting the garments. The same thing is
emphasized in ISO-9002, so we are not only the ISO-9002 Certified holder but also the true
executors. The company has independent Quality Assurance Team that conducts inline audits
and final finished goods audits. The QA Manager ensures that before the goods leave the
factory, they comply with the customer’s AQL standard.
Brief History

Kohistan bus service was the first professional step in the life of Ch. Nazir Ahmad father of
Mr. Shahid Nazir in 1973. Afterwards dreamland Hotel, Sangeet Cinema, Aizad beverages were
established in 1978 and 1983 respectively. Mr. Zahid Nazir and Mr. Shahid Nazir helped his
father by the formation of an industrial co-operative bank along with the developments of Rabia
trust hospital. Kakakhel ghee mills and flying training schools were established in 1994.

Masood Textile mills were incorporated in 1984 with 4 spinning mills. It is a public limited
company with its registered office at Faisalabad and listed in all stock exchanges of Pakistan.

It is vertically integrated textile unit. It has its own spinning, knitting, processing and stitching
units. Initially it was engaged only in spinning. But in 1993 company changed its strategy in

Adding up most process and disposed off three spinning units. In 1995 company made its own
garments units with only 35 stitching machines but today it has about 1500 stitching machines
of different brands. All credit of this success goes to visionary personality of Mr. Shahid Nazir,
the Chief Executive of the company.

They strive to lead in creating, developing and manufacturing of knitted apparel products right
from basic to highly fashioned garments thus responding to emerging trends in the industry.
They translate conceptual ideas of our customers into reality and shape them through our
technical bent and professional acumen. The team here strongly believes that Customer
satisfaction is the essence of business today. MTM has the technology with expertise, products
with knowledge and most importantly the right mindset to achieve total customer satisfaction.
Vision

“To Be the World’s Best Apparel Company”

Our vision is of continual improvement and sustained growth, and of a family of workers. Who
are given the best compensation benefits and working conditions in the region, in this respect,
mTm continues to emphasize the need to invest in and develop its most precious resource - its
human capital. mTm continues to provide training courses and self-enhancement opportunities
for all our workers".

Mission Statement

“We value quality in our products and in our relationships with customers and suppliers. We
consider our employees our more critical resource.”

Values

Respect for the individual, integrity, speed, simplicity, self-assuredness, and a 100%
commitment. Our values are non-negotiable; they are never to be jettisoned.

For us, our values are our well-spring

➢ To provide market leadership and brand coverage

➢ To pursue technological innovation
➢ To partner with operators for their maximum productivity

To provide virtuous to our customers, employees, communities, and the environment

 uality Policy:
Q

➢ Customer’s satisfaction
➢ Zero Defects
➢ TQM. (Total Quality Management)

Awards and Certificates

 rowth History:
C

Largest Knitwear Exporting Company of the country for the Year 2005

Turn Over in Millions

mployment Cenerated
E

Employees in Number
 bout Company
A

asood Textile Mills Limited was established in 1984 by Ch. Nazir Ahmad,
M which is located at 32 – km Sheikhupura Road Faisalabad. While Apparel
division is located in Faisalabad at Sargodha Road near Sangeet cinema,
which is producing best quality garments. The preference is given on the quality not
quantity. That’s why company’s sale is increasing every year. The company has shown
distinguish achievements during many previous years. Masood Textile Mills have own
in-house

Knitting

Spinning

Ginning

Dyeing

Processing

Laundry

Manufacturing facilities

Masood Textile Mills has also proud of work with world best Labels like: -

Saralee (Polo Ralph Lauren, Champion, Hanes)

JC Penney (Stafford, Arizona, St. John’s Bay)

War Naco (Chaps Ralph Lauren, Calvin Klein)

Indus (Vantage, Champs, Tom Tailer)

Tommy Hil Figer

Fruit of the Loom
Vanity fair Lee, Wrangler
 Perry Ellis

Levi’s

Dockers

Integrity

Duckhead
Wal-Mart

Most of the products are exported to US. UK. & Germany.

Different departments of MTM are equipped with modern technology imported from
Switzer Land, Germany, England, and Japan to achieve the required quality. Masood
has research and development laboratory for spinning process where cotton and yarn is
tested and inspected according to international standards.

mTm has obtained ISO 9002 certificate, which proved its quality and consistency, mTm
has 20,000,000 ordinary shares of Rs. 10 each fully paid up in cash. mTm has
extension in his operations by adding new equipment and machinery in near past.
Automatic cone winding machines enhanced the production capacity of yarn from 210
bags to 400 bags. To enhance the efficiency and quality some investment is made in
other machines. This would be very beneficial for the company in the upcoming trade
challenges.
 orporate Objectives:
C

❖ Maximization wealth of shareholders.

❖ To increase the market share.
❖ To achieve the customer satisfaction.
❖ Making arrangements toward achieving total quality standards.
❖ To get growth through professional Management.
❖ To reduce the cost of production up to minimum level.
❖ To continue to improve past achievements.
❖ To lead the local manufacturers.

mployees:
E

Permanent Employees:

Mills 4800

Garments 6000

Total employees 10800

Piece Rate Workers:

Mills 500

Garments 4700

Total employees 5200

Grand Total: 16000

 Masood Structure

Management:

G - 1- 4 General Manager

M-1 Senior Manager

M-2 Manager

M-3 Deputy Manager

M-4 Assistant Manager

M-5 Unit Manager / Senior Officer

M-6 Management Trainee

Non- Management:

S–1 Supervisor

S–2 Skilled Worker

S–3 Semi Skilled Worker

S–4 Unskilled Worker

Products

MTM Spinning is capable of producing more than 35,000 lbs of Combed & Carded ring
spun yarn from 6/s to 40/s count. Spinning is equipped with state of the art machines from
Japan, UK and Switzerland.
MTM yarn is famous for its consistent quality because of stringent QC system and most
modern lab equipments.
Fabric

One of the largest Fabric facility in Pakistan having the capability to produce all kinds of knitted
fabrics in 100% cotton & blends.

Single knit Flat knit Strippers

• Single Jersey • Feed Striper

• Collar & Cuffs
• Pique • Auto Striper
• Flat Knit Panels
• Fleece • Engineered Striper

Double knit Textures Jacquards

• 1x1 Rib • Herring Bones

• Mini Jacquard
• Variegated Rib • Pique Jersey
• Thermals
• Interlock • Waffles
Garments

mTm is a leading apparel company in Pakistan having expertise & machinery capable of
transforming customer ideas into superior quality garments, which are taken as the most
famous brands in the world.

Loungewear Active wear Sleepwear

Sportswear Underwear Athletic

Loungewear

Top apparel companies present Masood’s loungewear as the most comfortable stuff and sell it
with the tag of Ralph Lauren, Calvin Klein and Tommy Hilfiger.

Raglans, Vees, Crews, Hooders, Pants, Shorts.

Active wear

One can find enough energy and more drive while wearing Masood’s active
wears.

Polo Shirt, Hanely Shirt, Knitted Dress, Shirt, Pullovers, Jackets.

Athletic

Our pro-cotton, blended and polar fabrics when stitched by our skilled
hands, become a rich source of ease, flexibility and vigor. Sporter, Power
line, Boxer, Brief Shorter Boxed, Adult Sporter boxed, Cool Linker boxed,
Cool brief boxed, Cool jocked boxed, Athletic Shirt, Hood sweat Shirt.
Sportswear

Sport was never so entertaining. Our yarn dyed Polo’s, fashioned crew necks
and pants have added more delight to the world of sports

Golf Shirt, Base Ball Shirt, Rugby Shirt, Sports Shirt, Tennis Shirt, Jogging
Suit, Sweat Shirt, Sweat pant, Cycling Shot, Tank Top.

Underwear

There is unique joy in wearing Masood’s underwears. Being the no.1 exporter of
underwear category in Pakistan, we have specialized in making superior quality
underwears through modern machine attachments and Innovative techniques.

Boxer Brief, Brief, Bikini Brief, Crew Tees, Thermal tops & Bottoms, Fashion,
Trunks, Lycra Shorts, Fashion Brief.
Sleepwear:

As the name shows, this type of dress used for sleeping purpose
and it has very much demand in the foreign markets especially in
Europe and America.

PJ Suits, Sleep Shirts, Sleeping, Gown, Shorts.

Our Customers

We proud on our customers because they trust on us.

Abercrombie & Fitch Chaps Calvin Klein Champion

Carhartt Dockers Fruit of the Loom Foot Locker

JCPenney Kohl's Levi's Nautica

Polo Russell Speedo Sears

Sara Lee Tom Tailor Tommy Hilfiger

Divisions

Masood is a truly Vertically Integrated Textile Unit. It has in-house Yarn, Knitting, and Fabric
Dyeing, processing, Apparel Manufacturing and Laundry facilities. The Company has five SBU's
and a highly qualified experienced mills manager heads each unit. All Mills Managers in turn
report to the General Manager. The objective to operate in this manner is that there is a close
co-ordination and link between all the divisions. Every unit operates in the most efficient manner
in-order to achieve competitive prices, timely delivery and quality products

Spinning

Masood Spinning is a well reputed and quality oriented spinning unit operating in Pakistan.
Systems and spinning techniques in operation provides useful learning to textile industry
specialists. We have a well maintained machinery setup starting from blow room to packing,
producing count range 10Ne - 40Ne. At Masood, currently we have capacity of 14400 spindles.
Spinning process involves flow of raw material through mixing, blow room, carding, drawing,
combing, simplex, ring and auto cone.

Knitting

The knitting Division of Masood has latest knitting machines from Mayer & Cie, Terrot,
MI(Mayer) , Matsuya , Fukuhara & Vanguard. These machines are capable of making Jersey,
Pique, and Fleece, Interlock and Rib in addition to the mini Jacquard designs of Single Knit
Jersey. The gauges range from 20 to 28 for Single jersey Knit, 20 to 24 for Interlock and 14 to
18 for Rib machines. Most of the machines are equipped with Lycra attachment. Moreover, it
has 13 flat bed machines for welt collars and cuffs. 100% production is inspected and only 'A'
grade fabric is transferred to the subsequent operations.

Fabric Processing

The Fabric Processing Division of Masood Textiles has a capacity of dyeing 41,450 kgs per day.
It is equipped with Thies, T.S.I, SCHOLL, Gaston dyeing machines. It is capable of dyeing both
100% cotton and blended fabric. The machine size selection gives the flexibility in dyeing a lot
size ranging from 100 kgs to 1,000 kgs.
Apparel

Apparel division was established in 1995 to enter into value addition field. The company started
producing underwear briefs for Jockey U.K. Now it consists of 17 independent stitching units. An
M.B.A Manager is responsible for each unit from receiving of cut parts to packed garments.
After the cutting of fabric, it is sent for 100% cut parts inspection.

Infrastructure

To produce quality goods, and that too on time, you need a good production facility, capable of
taking on any challenge thrown at you. In this regard, mTm Exports possesses the best
infrastructure that has the ability and potential to give you quality products

Our manufacturing process has been vertically integrated to facilitate all

the processes involved in garment manufacturing under one roof. This
enables us to reduce the time spent in completing your orders.

All our machines are the latest available in the market, and whenever
required, mTm export has never shied away from purchasing the most
modern equipments. All our divisions are equipped with the latest
equipments to maintain the high quality standards that we have set for
ourselves.

Spinning

Masood has invested in growing and ginning of cotton. The company

would ask the growers to sow the most suitable cotton variety for
knitted products. With the help of ginning process, we procure the raw
cotton for the whole year. This helps us to provide the consistent quality
products for our customers through out the year. If the customers want
to lock the prices for a certain period, Masood can offer this service as we reserve the cotton for
the particular program.

Mixing

Blow Room

Carding

Draw Breaking

Draw Finishing

Simplex

Ring

Auto Cone

Conditioning

Packing

Export or Knitting
 Mixing

Maximum numbers of lots are mixed to get uniform results

and avoid Barre (patta). Raw cotton is procured from best
cotton growing areas. Sandwich mixing technique is used for
stocking, which is a conventional method. Its contamination
picking system is unique one contamination system. It is
designed and made by Masood's Engineers. It claims the
lowest level of contamination in yarn of Pakistani cotton.

74 bales are mixed daily, and then contamination is removed

manually from such bales, the object to mix a large quantity
of cotton is to mix all types of cotton and this policy provide
facilitation while keeping stability in the shade of color of tone of
color of fabric. It performs such duties.

• Opening of Cotton
• Mixing of Cotton
• Cleaning of Cotton
• Lap forming

Blow Room

We have a single line Toyoda OHara Hergeth Blow Room in

operation. All produced Laps made are weighed and those found
beyond quality controls limits at this stage are discarded. Removal
of waste at subsequent beaters improves cotton cleanliness.

Removing of Trash, 6.25% trash is successfully is removed here

Opening of cotton that its fibers have fair look individual preparation
of Laps.

Carding

Carding section has 24 carding machines of Cross Roll MK-4.

Best quality wire is used for cylinder, doffer, taker-in and flats.
Additional stationary flats are installed to reduce IPI Level. We
have a very good cleaning and suction system. Filter room is also
of Cross Roll. Our technical expertise and equipment allows
reducing higher percentage of fly and dropping to get good
results.
Drawing

Combined machinery setup of TOYODA and latest model of RIETER

is at function in our premises. In addition to photocells, in-house
designed and fabricated Electric Silver stop motion on Toyoda
Drawings is installed. Color silver picking system on Breaker
Drawings is introduced. A special team of color- silver picker work
round the clock. Rieter SB-2 and RSBD30C are installed with auto
leveler. Barco silver watch system is used for color contamination.
Wrapping is checked round the clock.

Combing

Lap formers of Toyoda Sk-4 and eight combers of Toyoda CM-10 are in
operation at Masood. Strict quality and maintenance checks are followed
at Top comb and cylinder for proven quality product.

Simplex

Six Toyoda Fl-16 type machines are currently in operation in Simplex

sector. Special type of Flyer on machines is installed to get even quality
roving.

Ring

Thirty RY-4 TOYODA Ring Frames work round the clock at ring section.
SKF PK-225 drafting system is attached on these Ring frames. LUWA Air
conditioning systems in Ring department maintain the required R.H and
temperature in the whole ring department to maintain low hairiness in
yarn. Cots, Apron and Steel rings of machinery is changed at proper time.

Auto Cone

We installed new 21 C Process Coner. We are producing yarn having low

level of contamination. It is a fully computerized system and helps to
determine departmental efficiency round the clock. Yarn hairiness is
controlled on 21 C Process Coner by its special balloon system.
Packing

Our packing department consists of Xorella machinery. With the help

of Xorella, we get superlative conditioning of yarn in very short period
of time. Enhanced conditioning of yarn increases the strength of yarn
and therefore, decreases the breakage of yarn during the knitting
process. This result in a product which is not only conditioned
exceptionally but additionally it helps to decrease the wastage as
well.

24 Auto Cones are packed in one bag

One bag of Auto Cones consists up on 100 kgs

Each Cone has a weight of 4.17 kgs

Round about 400 bags are to be transferred into one Container

In case of Combed yarn only one process added after Draw Finishing process and that is called,
Combing

Combing

Combing of the Drawed Yarn

Taking off of the small fibers

20% of the total fibers are taken off

result is finest and strengthened yarn

Capacity Related Issued

Daily Processing 110 Bales

Daily production 300 Bags

Production of Carded Yarn 280 Bags

Production of combed Yarn 080 Bags

Average Count 19.5/s

Count Capacity 10/s to 30/s

Yarn Quality

Twist per inch TPI

Imperfection Index IPI

Uniformity variation (# of fibers in diameter)

Nep Huge Variation

Thin Places

Thick Places

Slub

Hairiness

Short fibers on the surface of he yarn

Barays, shade variation, tone changes, immature yarn

Long thick

Long thin

Mixing
 Knitting

The process of fabrication through needles is called knitting. Knitting involves the preparation of
loops and interlacing/attaching them.

Before discussing further about knitting in MTM we should have to know about some important
terminologies being used in the knitting department,

Wales

Vertical lines of loops are called wales.

Courses

Horizontal lines of loops are called courses.

MPF
Through this system the yarn is fed to the knitting portion of the machine.

Dial

Dial is structure of metal in which needles move horizontally.

Cylinder

Cylinder is structure of metal in which needles move vertically.

Grooves
Th e se a re th e e n g ra ved a re a p a th s in cylin d e r/ d ia l in wh ich ne ed le s mo ve .

Types of knitting
Wa rp k ni tti ng:

A me t h o d of ma kin g a f ab ric b y n o rma l kn it t in g me a n s in wh ich th e loo p s ma de f ro m

e a ch wa rp t h re a d is f o rme d sub st a n t ia lly a lo n g t h e le n g t h of t he f a b ric. It is
ch a ra ct e rize d b y t h e f a ct t h at e a ch wa rp t h re a d is f e d mo re o r le ss in lin e wit h t h e
d ire ct io n in wh ich t h e f a b ric is p ro d u ced .

We ft k ni tti n g:

A me t h o d of ma kin g a f a b ric b y n o rma l kn it t in g me a n s in wh ich t h e lo o p s ma d e b y

e a ch wef t t h rea d is f o rme d su b st an t ially a cro ss t h e wid t h o f t h e f a b ric. It is
ch a ra ct e rize d b y th e f a ct t ha t ea ch wef t t h re a d is f ed mo re o r le ss a t rig h t an g les t o
t h e d ire ct io n in wh ich t h e f a b ric is p ro d u ce d .

W ef t kn it t in g is f u rt h e r d ivid ed in t o t wo t yp e s

Do u b le kn it

S ing le kn it

Di ffe re nc e be twe e n s ing le a nd doub le k nit t ing :

Sin gle kn ittin g Do u b le kn ittin g

• T op of the machi ne i s open T op of the machi ne i s
cl osed
• Di al i s used No di al
• Si ngl e needl e Doubl e needl e
• Si nkers are used Si nkers are not used
To produce knitted fabric of supreme quality, it is impetrative that superior quality

raw material is procured at competitive prices. At Masood finest quality yarn in the market is
produced for our in house knitting.

Fleece Machines

We have dedicated a complete unit of machines for fleece fabrics with additional capability to produce
heavy single jersey fabric as well. A variety of fabric such as plain, cross, sueded, textured fleece can
be produced at our versatile facility. We have "Vanguard supreme" Machines to knit body size fleece
fabric and "Mayer & Cie" machines for open width fleece fabric. The vast variety of available Dia
Gauges has enabled us to produce all the widths thus reducing our costs in cutting.

Rib Machines

Another unit is dedicated for main Rib fabric while a few 8-locks machines are capable of
manufacturing mini thermal and waffle. Additionally, we also have machines for Neck size ribs that help
us producing consistent ribs for necks. All the rib machines are equipped with "LYCRA" attachment for
producing the best stretch recovery fabric. In addition, we are also using “Mayer & Cie” and "Terrot" to
knit high quality ribs with excellent recovery.

Single Jersey Machines

Single knit fabric is knitted on four track machines. These machines can produce fabric such
as single jersey, P.Q, mesh, drop needle jersey, bird eye jersey etc. Masood also has Lycra
attachment equipment for best fabric stretch recovery. A large number of " Mayer & CIE " and
"Vanguard" knitting machines are currently in production at Masood.
Available Dia Gauges given below:
Dia: 16'' 18'' 20'' 22'' 24'' 30''

Inter Lock Machines

Drop needle and feeder stripe fabric are mostly produced on our inter lock machines which have the
capability to produce rib fabrics in addition to Interlock fabrics.
Available Dia Gages given below:
Dia: 30''
Gauges: 20e - 24e.

Flat Knitting Machines

Considering the importance of fabric accessories such as Collars, Cuffs,

Waist band, Trims, we have invested in a vast number of Matsuya flat
knitting machines that are producing the trims for all our major
replenishment programs.

Fabric Inspection

Our knitting units are producing fabrics of excellent quality with

minimum defects. Additionally, an online 100 percent fabric
inspection system is in function to meet the international quality
parameters as required by most of our customers. “4–points quality system
“introduced by J.C PENNY (USA) is also being followed at our knitting
facility.

Processing

The Fabric Processing Division of Masood Textiles has a capacity of dyeing 41,450 kgs per day. It is
equipped with Thies, T.S.I, SCHOLL, Gaston dyeing machines. It is capable of dyeing both 100%
cotton and blended fabric. The machine size selection gives the flexibility in dyeing a lot size ranging
from 100 kgs to 1,000 kgs. The department has two Santex finishing lines from Switzerland, which
include hydro extractors, dryers and compactors. In order to maintain the quality of processed fabric,
Masood has the testing laboratory with latest equipment to check the fabric. It ensures that the fabric
quality is maintained and is according to the required parameters of our customers.

Dying

The treatment with a dye to obtain a persistent modifications in the color of fabric is known as the
dyeing process”.
Color

“It is the wave length of light that a thing omits”

in other words the property of thing which makes it visible

Types of color
The color may be primary or secondary.

➢ Primary colors
There are three primary colors

▪ Yellow
▪ Red
▪ Blue
➢ Secondary colors
There are three secondary colors

▪ Turquoise
▪ Blue R*
▪ Blue BRF
“R” represents “reddish”

Blends

To obtain different other colors we can mix above-mentioned colors in different proportion for
example: -

Black = yellow 3.5% + red 2.80% +blue 4.0 %

Green = yellow + blue

Orange =yellow + red

Navy = yellow + red + blue

Khaki = yellow + red + blue BRF

Royal = blue R + red + blue

Our in-house and very well-equipped Dyeing department with a production
capacity of around 41,450 Kg of dyeing / day allows us to fully meet our dyeing
requirements. We have dyeing machines for dyeing cotton fabric and a fully
computerized high temperature jet-dyeing machine to dye all kinds of synthetic
fabrics including polyester. A well equipped laboratory ensures all dyed fabric
is properly checked, as per buyer's requirements, for factors such as
shrinkage, color fastness, etc.

Finishing

De scrip t ive o f p ro ce sse s, ph ysica l o r ch e mica l, a p p lie d t o a su b st ra te t o

p ro d u ce a d e sire d ef f e ct .

Finishing department at Masood, comprises of automatic hydro-extractors for

the removal of moisture from dyed fabric, computerized tensionless dryers for
instant fabric drying, soft-setting and calendaring machines for systematic soft-
setting and rolling of fabric, fully computerized compaction machines for
complete shrinkage control, and panel wash machines and tumble dryers for
panel washing the fabric to give minimum shrinkage value. Again personal
attention ensures that all the fabric leaving the finishing department is properly
inspected and thoroughly checked for relevant factors before being forwarded
to the next stage of production.
Intro d uctio n to AP P AR EL Di visio n
Apparel division was established in 1989 to enter into Value addition field. The company
started producing underwear briefs for Jockey U.K. Now it consists of 17 independent stitching
units. An M.B.A Manager is responsible for each unit from receiving of cut parts to packed
garments. After the cutting of fabric, it is sent for 100% cut parts inspection. We believe that
prevention is better than cure. The sooner the problem is tracked, the better it is in delivering
the goods on time.
During the process of stitching we have inline inspection and final inspection processes. The
garments are 100% inspected by highly experienced inspectors. Our objective is to produce
with Zero Defects. The ‘BACK TRACKING SYSTEM’ plays a vital role in developing sense of
responsibility and accountability in every person in making and inspecting the garments. The
same thing is emphasized in ISO-9002, so we are not only the ISO-9002 Certified holder but
also the true executors.
The company has independent Quality Assurance Team that conducts inline audits and final
finished goods audits. The Q.A Manager ensures that before the goods leave the factory, they
comply with the customer’s AOL standard.
Established 1995 to enter into value added field.
Now it has 13 production units consisting 1300 skilled workers in all units with 2200 stitching
machines. Each and every operation has been linked with “Back Track System”
An independent quality assurance department exits to ensure the quality of the
garments.

Cutting

5 cutting units working under the supervision of skilled unit managers, these cutting units are well
equipped with latest machinery including Gerber Plotter, Spreader etc.

Stitching

With over 1,749 stitching machines, manned with the most skilled and expert operators, Masood is
capable of producing about 120,000 dozens per month versatile garments ranging from basic to high
fashion, men’s, women’s and kids with maximum flexibility in size and color assortments. The Quality
control and Quality Assurance departments are in place to make sure the company’s objective of zero
defect. Computerized Bar coding and Back Track systems provide Masood 100% predictability and
tracking performance.
Stitching Units Quantity
pparel
A 1168

pparel III
A 188

pparel IV
A 289

pparel II Warehouse
A 227

Falcon 341

Falcon-2 161

Leopard 155

Lion 220

Panther 286

Zain Godown 1

Total Machines 3036

 Departments

Departments can be distinguished into three categories

Operations, Services & Finance

1. Operations

• Production Planning & Control

• Industrial Engineering
• Cutting
• Production
• Quality Control

2. Services

• Human Resource
• Information Technology
• Merchandising
• DTS (Direct-to-store)
• Purchase
• Quality Assurance
• Product Development
• Compliance Department
• Administration

3. Finance

• Inventory
• Accounts
PRODUCTION PLANNING & CONTROL

PPC stands for product planning and control. As its name indicates its function i.e., to plan a purchase
order and control thereof. All activities of PPC department revolve around purchase order. The
customer demands different standards of GSM (grams per square meter), shrinkage and fastness of
color. Because this purchase order is placed before MTM Garments division, so this PO is then
communicated to the Mills PPC. The Garments division demands specific width & shade from Fabric
division for that specific purchase order. There are three sections in PPC department.

• Planning
• Costing
• Control
• Yarn

Department Hierarchy

PPC (senior manager)

Senior deputy manager

Deputy Manager

Assistant manager

Senior officer

PPC officer

Working of PPC

Buyer sheet or product package received by merchandiser that ppk includes

• color and size breakdown

• what is the GSM required
• what are the finishing parameter
• garment wash or not wash
• size specs parameter

Color and size breakdown

is important it means that how many pieces are required .If color and size are not available. Cutting
cannot and consumption will not be accurate.

GSM requirement

GSM is given by the customer it is gram per square meter .if GSM is more less pieces are made. If the
GSM is less many pieces will be made.
Factory finishing standards

Factory finishing standards like torching, bowing, skewing, ph value, shrinkage, color fastness.

Garment wash or not garment wash

How many washes the customer are requires when the garment is wash their GSM and shade problem

Size specs parameter

Length size, color size arm holes, shoulders length etc

Margins are always kept so that after washing it comes to the actual specs

If the garment is not to be washed there is no need to keep the margin.

Costing steps

Costing

Time lines

To plan the accessories

Fabric planning

Unit planning

In costing you have to see each and everything

• Type of fabric
• Gram mage of the fabric
• Finishing standards
• Yarn quality
• Knitting charges
• Recipe cost

The cost details are given to the merchandiser and he communicates with the customer. if the price is
acceptable then the order is given
Then PPC has to plan that order it will take into consideration three things

• Material planning
• Machine availability
• Unit planning
Material planning

Material planning includes the fabric plan and the pattern availability details about the
accessories etc.

Machine availability

Then PPC has to see that machines are sufficient to run the purchase order.

Unit planning

The purchase order will be run in which unit so we have the production capability so we have skilled
labor to perform the task.

Fabric order plan

Fabric order plan is made for the mills to arrange the fabric. They will generate the yarn demand. It
consist of details that how much fabric is required of one color. It also includes the washing
programmes whether t he fabric will be washed or not

It also includes

• Knit reference
• Lab reference
• Composition

Time lines

It is the specific time period. It is different for different orders.

After the purchase order the time is allocated to each department, this allocation is on the days
according to the targets.

Monitoring of running orders

In monitoring PPC monitor all the tasks of different department.

Accessories planning, Just like fabric demand plan accessories demand plan is made. Os plan the
accessories color and size break down should be clear.
PPC File

• Color and size break down

• Time lines
• Cutting programme
• Stitching detail
• Packing programme
• Accessories sheet
• Fabric order sheet

Color and size break down means that how many pieces are large, enter a large medium should be cut
from one color. Then time lines are set for every process and for

every department. According to the specks the cutting should be done. How the fabric is stitched. How
the garment will be packed.

• Solid packing
• Assorted packing
• Catalog packing

What are the accessories that will be used like zips, buttons, labels etc?

PPC follows all the tasks whether it is going according to the standards required by the customers.

PPC file is send to each and every department.

Production Planning & Control

Cutting & Induction

Requisition process

PPC (Production planning control) department sends the requisition to

the store.

Production planning officer sees which PO (Purchase order)is at which

priority. If the shipping date is closed, It makes call to the mill to
average the fabric. When the fabric is shown at the gate pass all the
information are stored in the system.

Apparel management system is updated accordingly.

Combos detail

If the shirts is of different colors. Sleeves are of different pattern or color. If the fabric is in one color
then we say the combo is not complete. FMS (Fabric management system) This system is used in the
mill. Fabric styles

Tubular fabric

Tubular fabric is 13 inches in width. Their is no stitching is requires on sides

Open width fabric

Its width is 72 -75 inches

In fabric cutting 9 persons in a team

In which 5 are skilled person, 3 are layman, & 1 is helper

Job Card system

CPO (Cutting process officer) prepares job card following details are in the job card.

Customer #, PO, Garment description, etc

Pattern Code

In which pattern the fabric is going to be cutted. Pattern code is given by G.G.T.

Lab List

GSM (Grams per square meter) is a measurement used to measure fabric. You see the GSM of the
fabric and plan.

Process Card

Process card is the identity of the bundle. Style # color date Size Bundle # Lot No. Now PPC does the
planning how much fabric is used. Till the shipment is done. Fabric is checked. It checks the final fabric
only quality wise.

Compensation notes

If 100 kg fabric is required for 50 pieces, but were able to make 40 pieces, they will ask for
compensation from the mill. The person come from mill examines & signed and fabric is issue.

Role of G.G.T. in cutting

Input sheet comes to the sample room. They make the hard pattern then the hard pattern reaches GGT
and they are responsible for making the computerized copy.

Trim

Any thing accept cloth like color tap etc

Accessories

Like Zip, buttons

Shrinkage

Shrinkage varies according to clothes like Single jersey 2 inches flees 1” Jersey & PIQUE have the
same. First the fabric is tumbled. After washing the fabric is shrinks & after tumbling shining is removed.
Inspection

Ply 2 ply: is used to check the color variation

Swatch is taken from every roll to check the continuity

Bundling

There are 99 pieces are in one bundle. It depends on the fabric if the fabric is flees the bundle may
contains of 25 to 30 pieces.

If there is slant in the fabric you will use the manual sample. If the lines of the fabric are straight you will
put the sample straight. If the lines are filled you will put the sample in a titled way.

In bundling everything is packed front back sides sleeves. This is packed in Polly bags and send to the
barcode. Then it goes to stitching

Ply 2 ply shade variation is called stickering.

Bar Code

Job order is completed by CPO then its gain to bar code officer for the bar code

Problem & Solution

If the problem are solved in the cutting then the can be minimized.

Shade difference

Either the fabric reprocessed or sometimes at can be removed by washing

Width Problem

If you want the width of the fabric to be 70 after knitting and if you get 75.This problem solved by GGT

If the width in the fabric is increase the weight is also increases

G.S.M. Excess problem

If you want the G.S.M to be 250 and you received a fabric of 280 GSM, if the weight decrease and less
pieces are made. Then the compensation is made.
Contamination

It is the fault of knitting

Cutting Management

5 cutting units working under the supervision of skilled unit managers, these cutting units are well
equipped with latest machinery including Gerber Plotter, Spreader etc.

Cutting

Requisition for fabric

Job Card

GGT planning

Cut fabric according to plan

Bundling

Induction
 Bar code & label generation

Allocation of bundles

Stitching

Cutting Planning Officer (CPO)

CPO is the representative of PPC department.

Tasks of CPO

• Requisition for the issuance of fabric

• Issuance of job card
• Update status of cutting

Garment Gerber Technology (GGT)

There are 2 main functions of GGT

1. Fabric planning for PPC (especially width with the help of pattern method )

2. Pattern making for cutting for optimal fabric consumption.

Induction

It plays the role as a junction; store the cut fabric for the issuance to units. It does (performs) audit and
collects bar code & labels.
Store

Store

Main store Fabric store

Receiving of Fabric

Accessories General from mills

Procurement Purchase
Production department

Management hierarchy

Senior production manager Unit production

Production manager Manager

Assistant production manager Management trainee

Work order plan

Whenever a new purchase order start planning sheet is prepared. In that sheet unit wise no of
purchase order .their daily target are mentioned.

Stitching

With over 1,749 stitching machines, manned with the most skilled and expert operators, Masood is
capable of producing about 120,000 dozens per month versatile garments ranging from basic to high
fashion, men’s, women’s and kids with maximum flexibility in size and color assortments. The Quality
control and Quality Assurance departments are in place to make sure the company’s objective of zero
defect. Computerized Bar coding and Back Track systems provide Masood 100% predictability and
tracking performance

Stitching flow

Production department receives samples from the

merchandising department the production department
finalize the flow by keeping that sample in mind. The
task is to improve productivity and to have the maximum
output

Production supervisor job responsibilities

➢ Setting of flow
➢ Arrangements of machines
➢ Checking of induction
➢ Arranging number of operators according to flow
➢ To meet the targets
In line supervisor job

To maintain quality and help in line inspector

In line inspectors

To check the garment is stitching quality operation wise.

Production flow

➢ Induction
➢ Stitching
➢ Enter
➢ Clipping
➢ Pressing
➢ Finishing
➢ Packing
➢ Shipment

Quality control

During stitching process quality control persons check the quality according to customer requirement.

Kinds of fabrics

Single jersey: Waffle Mini Thermal Terry

Single Jersey Brushed Terry

Heavy Jersey French Terry

Double Jersey Baby Terry

Lycra Jersey PiquelPK

Striper Jersey Pique Locast

Sueded Jersey Pop-Corn Pique

Bird Eye Jersey Honey Combed Pique

Printed Jersey Mesh Pique

Interlock Fleece

Simple Interlock Simple Fleece

Sueded Interlock Lycra Fleece

Kinds of garments

Polo shirt Faig Sleeve

Crew neck V neck

Ringer Neck Hood shirt

V Insert Hanley shirt

Boxer Bikini

Full Zipper Rugby shirt

Quarter Zipper Pant

High Neck Short

Mock Neck Mid-rise

Sleeve-less Boxer Brief

Tank Top

Reglons

Kinds of needles

No. 9 to 14

From cutting department the pieces goes to the production department for stitching. The pieces are
stitched than it goes in the enter. From here the stitched fabric goes to clipping to remove the extra
threads. Then the garment goes for finishing.

Finishing flows

• Pressing
• Final inspection
• Super inspection
• Specs

Finishing faults

Stain (oil, dust)

Alter (skipping, stitch broken)

Rafu (small holes)

In final inspection stain, alter and rafu faults are removed. If there is a major faults are send to
reprocessing.

Packing procedure

After finishing the garment goes in packing, ID labels Stickers are pasted

Garments are folded packed in ploy bags. After that packed in master poly bags.

Different types of packing

➢ Assorted packing
➢ Solid packing
➢ Catalog packing

Assorted packing

Color is same but different sizes ratio are packed together

Or

Size is same but different sizes ratio are packed together

Solid packing

Same color and same size

Solid by color (Color remains same)

Solid by Size (Size remains same)

Catalog packing

Different sizes and different color, say according to the requirements of the buyer, each bundle will
have its own specification and packing details.

Shipment move to store

ASN (advance security note)

Security sticker

Bar code sticker

Production problem

➢ Pieces are rejected

➢ Pieces are short
In both the cases short fall are sanded to PPC department.

Embroidery machines

Latest Tajima embroidery machines, fully automated, 6 color

40 heads provide Masood the flexibility and capability to
cater to the customer requirements.

Direct-to-Store

Imports comprise an increasing share of retailer sales. The job of getting goods from overseas
origins to the store shelf is fraught with challenges, particularly for seasonal or time-sensitive
products. One way to simplify international supply chain management is through direct-to-store
distribution.

This practice can benefit many importers by moving goods directly from the port to final
destination much more rapidly, reliably and often cost effectively.

Benefit of DTS

• Reduce distribution centre costs

• Manage peak season volumes
• Increase speed to market
• Overcome delays
• Increase shipment visibility

Hurdels to Overcome

In discussions with shippers about direct-to-store distribution, we have found that not all
shipping managers are ready to make the shift away from the traditional distribution mode.
While cultural hurdles are often difficult to overcome, we see no major technical issues that
stand in the way of the effective use of direct-to-store distribution by most shippers. In our view,
the only way to remove uncertainty about any potential issues associated with this distribution
model is to conduct a test.

ales istory
ctual s ro ecte d rd erin
orecast e t e eds s ct ual r ders
n and n vent ory s r ders
ales s rders

e e l y ales er orm anc e

ollar alue ales er orma nce n alysis
eman d tud y ve
nts llocatio n

Masood abric apacit y la n

ewin a pacit y lan
PerpetuaI DTS CycIe urn rou nd a ys

ee l y rder o nitorin rac in

n transit ch ed ule o nitorin
onit orin
hippin arrier er orma nce
ill ate

C
Coon
ncce
eppkku
uaall F
Fllo
oww

D eman d
P Ian n in g P ro d u ct io n S t o ck S h ip p ed D eIiv ered
F o reca st in g
Masood’s Strength on DTS Model

E-IMS

■ A web based IT tool

■ Real time data visibility
■ Decision support system

Management Team

■ Dedicated team of business analysts

■ Demand forecasting Tools
■ Leadership to production/planning

US Based Co-ordination Team

■ Weekly meetings with customer’s forecast dept.

■ Presence in SKU’s audits
■ Intelligence about future demand trends

MTM also provide services in direct to store operations;

 Inter Loop

Amtex

Chenab Fibers use their software for DTS operations. Now management of MTM decieded that
DTS Department will be separate company with the name of Becon Ampex.

Compliance Department

ISO AND TQM

ISO department provides a management system at Masood, which is free of non-conformance. The
department has training system that creates awareness of Total Quality Management System (TQM).
All the departments and people at all levels are involved in this program. Masood has a team of
qualified and certified auditors who would check, improve and ensure the consistency in the system.

Masood has documented a quality manual that states the quality management system of the
organization. Management establishes a documented quality plan setting out the specific quality
practice, resources required and the sequence of activities relevant to particular product.

We are proud being WRAP (Worldwide Responsible Apparel Production) certified. The certification
ensures that sewn products are produced under lawful, humane and ethical conditions.

Following are the core standards that we strictly follow through out our production process.
Compliance with Laws and Workplace Regulations

Prohibition of Forced Labor

Prohibition of Child Labor

Prohibition of Harassment or Abuse

Compensation and Benefits

Hours of Work

Prohibition of Discrimination

Health and Safety

Freedom of Association and Collective Bargaining

Environment

Customs Compliances
Security
Quality control System at masood

There are quality checks at every stage of manufacturing starting from Raw Cotton, Yarn, Fabric,
Processing, Cutting, Stitching and Packing. Before the fabric is cut, it is checked whether it conforms to
the customer’s standards of shrinkage, finished g/cm2 etc. After each lot of fabric is cut, 100% cut parts
inspection is conducted to ensure that only good quality pieces move to the stitching units.
During the process of sewing, each and every process is inspected by inline inspectors. The inspectors
make sure that only good parts move to the next stage. An individual tracking number is sewn inside
each garment. After trimming and pressing of the garments, highly experienced final inspectors inspect
each garment. The Quality assurance team monitors the performance of every individual inspector by
picking up the inspected garments and checking the quality of these garments.
To ensure that the garments are packed as per the requirements of our valued customers, we can even
track & check, which case the garment, has been packed in. With the help of this, we plan to achieve
the Zero Defect Level. Quality assurance department check the quality after packing and check
randomly and try to maintain

the standard of garments according to customer requirement .this department gives report to direct
CEO of the factory.

Types of Quality:

AQL (Acceptable Quality Level)

OQL (Over All Quality Level)

Quality Control

GM Operations

Div. Manager Div. Manager

Dy. Quality Manager

AQM AQM

QCO QCO QCO

Supervisor

Ass. Supervisor QC Auditor

QC Inspector

(Inline Inspector)
Quality Assurance

CEO

Manager QA

D.M.Q.A D.M.Q.A

AM AM

Internal Audit Final Good

QA Officer QA Officer
Acceptable Quality Level

AQL mean a standard of Rejection and acceptance defined by the mutual concentration of buyer and
seller, where they mutually decides size of the sample and standard for rejection and acceptance

Overall Quality Level

OQL is a standard where garments are audited on their total rating, also called average quality rating,
after the AQL, when over percentage of rejection is checked it should also comply with the standards
already defined or decided in agreements.
 H R M Department

HR D ep t
HR

HRM

Recr itment

N L

Career lan
To develop the professionals in MTM to achieve organizational vision, considering the concept.

Career Plan for Management Trainees ant Trainee Engineers.

Management Levels

The Top Level Management is consisted of following hierarchy;

Chief Executive Officer

General Manager

The Middle Level Management is consisted of following hierarchy;

Manager

Deputy Manager

Assistant Manager

Senior Officer

Officer

The Lower Level Management is consisted of the following hierarchy mainly;

Super visor

Foreman

Operator

Helpers

Management Level

Management Trainee M6

Senior Office M5

Assistant Manager M4

Deputy Manager M3

Manager M2

Senior Manager M1

Non Management Level

 Unskilled Worker S4

Semi-skilled Worker S3

Skilled Worker S2

Supervisor S1

T&D

“Future-oriented training, focusing on the personal growth of the employee”

Importance of T&D in MTM

Types of training in MTM

Training Schedules

Procedure of T&D in MTM

T&D Policy of MTM

Off Job Training

On job Training

College Visits

Internships

Seminars, Lectures, functions etc.

Performance Management

Confirmation Evaluation

Bi-Annual Evaluation

Annual Evaluation

Increment

Promotion / Demotion

Transfers

Rewards
 Performance Reward System PRS

Unit of the Month

Best Final Inspector

Best Inline Inspector

Best Cutting Inspector

Promotions

Overtimes

Compensations and Benefits

Leaves

Sick Leaves 8

Casual Leaves 10

Encashment Leaves 14

32

EOBI (Employee old age benefits & Insurance)

Death Grants

Marriage Grants

Scholarships

Group Insurance

Health Insurance

DISPLINARY ACTIONS

Complaint

Explanation

Inquiry

Action

(Dismissal / Termination / Fine/ Warning)

EMPLOYEE RELATIONSHIP
 • Laws and Workplace Regulations
• Forced Labor
• Prohibition of Child Labor
• Prohibition of Harassment or Abuse
• Compensation and Benefits
• Hours of Work
• Prohibition of Discrimination
• Health and Safety
• Freedom of Association
• Working Environment
• Customs Compliance
• Security

Time Keeping

Card Scanning

Attendance System

Other Responsibilities

Grievance Handling

Charge Sheet

MACHINE SHOP DEPARTMENT

Machine Shop plays a vital role in any apparel firm growth, as it Looks after all the Machine related
tasks/issues and works out to make possible the provision of all required machines/spares for the
required operations.

Responsibilities of Mlc shop Department

Perform the preventive maintenance of machines according to scheduled plan.

To keep the proper record of machines within units & machine shop.
To arrange all the necessary attachments/accessories according to the style.
To hire & train the Mechanics & to assign their duty in different production units.
To perform the daily/routine maintenance with in the production units.
To maintain all necessary maintenance records about machines.

General maintenance Shop

This section is responsible for general overhaul, preventive maintenance & to install necessary
attachments according to the requirement

Electronics section
This section is responsible for

Maintenance of heat transfer machines.

To encounter all electronics disorders in special computerized machines.
Maintenance of cropping machines.

In Masood Textile Mills machine shop department comes under the Supervision of Industrial Engineering
department. I.E is performing to well maintain the following functions

Maintenance Formats

Daily Machines’ monitoring format.

Daily Auto-trimming devices monitoring sheet.
Daily Monitoring of Clipping Machines.
Daily Monitoring of Heat Transfer Machines.
Preventive maintenance formats.

Inventory Management System

At Masood Textile Inventory has been managed with the help of specially designed database named
IMS. This system helps to manage inventories both for general items & Accessories.

Machine spares comes under the general items.

IMS contains number of trigger reports to assist in managing the inventory a few of which are as follows.

Pricing

• Product Costing at three stages

– -Initial
– -Order Budgeting
– -Actual
• To Prepare the Production Standards (Masood vs. Market)
• Comparison of Order Budgeting vs. Actual Cost Sheets
• SAM Based Capacity Utilization Report
• Calculation of $Cost Per Minute ($SMV)
• Man To Machine Ratio Analysis

To Prepare the Production Standards (Masood vs. Market)

• Updated Currency Exchange Rates

• Yarn Rates
• Knitting Rates
• Dyeing Rates
• Finishing Rates
• Washing Rates
 • Embellishment Rates
• Cutting Rates

Comparison of Order Budgeting vs. Actual Cost Sheets

• What we Planned and what are the Actual Results

• Handling all customer inquiries and Pleasing client by fulfilling his cost models and other
cost breakdown to make sure that our prices are trustworthy

SAM Based Capacity Utilization Report

• How Many Machines are running in each Particular Unit

• Available Minutes on the basis of Machines
• Utilized Minutes
• Calculation of Efficiency (Available vs. Utilized Minutes)

Calculation of SMV (Standard Minutes Value)

• FOH (Factory Over Heads) for a particular Period

• Available Minutes of That Particular Period
• Calculation of SMV (Standard Minutes Value)
Man To Machine Ratio Analysis (Employees l Machines)

• Operators
• Productions Units
• Production Supporting
• Services
• Marketing

Placement
Masood textile has good opportunity of globalization.Masood sell its products to its customer in USA,
UAE, Dubai, UK and Canada. So placement of its products as its customer demands.

Promotion

For promotional activities they do direct marketing and personal selling .The top level management is
responsible for this. Through occasion and exhibition they promote their products in USA, UAE. UK and
canada.

IT Department

One key of success of the MTM is its strong IT department. Totally operations in MTM is computerized. It
is cost effective and time saving. Its ‘BACK TRACKING SYSTEM’ is its best competitive advantage. The
‘BACK TRACKING SYSTEM’ plays a vital role in developing sense of responsibility and accountability in
every person in making and inspecting the garments. The same thing is emphasized in ISO-9002, so we
are not only the ISO-9002 Certified holder but also the true executors.
Software engineers help all departments to maintain their data in daily work. They develop software
named e-IMS for their customers to check their orders on line.

Administration Department

Administration department is responsible of all activities in the MTM specially:

Security

House Keeping

Transport

Major Departments

HR, Production, IE, Merchandising, Finance. QC, QA. IT

SWOT Analyses of MTM

Internal factors

Strength

• Quality products
• Skilled labor
• Using modern and latest technology
• Back track system
• Wrap certified
• Highly educated management
• Vertically integrated system
• Using apparel management system
• ISO certified
• Strong Security System (Hidden Cameras)
• Own Power Generation Plant
Weaknesses

• Having low production capacity

• Having low space
• Provide less benefits to employees
• High turn over
• Communication gap between different departments
• High production cost
• De-motivated employees
External factors

Opportunity

• Exploring new markets

• Capturing European countries
• Can expand their operations and finding new market segments
• Using their own label
• Opening their outlets throughout the world
• Globalization
 • End the quota system, now they expand the business
• Full potential of entertaining the local market
• Established its own Brand name
Threats

• Competition increase in that particular region.

• Depend only a few customers
• Low price offer other competitors just like china & India
• Politically instability in Pakistan
• Change government policies that are not in favor of textile industry
• Buyer needs and demands change

SWOT Matrix

O T

Mtm has enough strength Mtm manufacturing

to capitalize on
opportunities. They have
skilled labor and quality
products to capture new
markets.
quality products and
having modern and latest
technology by using
these mtm easily face
the threats of competition
and globalization

Mtm can remove their As competitation

weakness. By using
advanced technologies
and also mtm reduce their
cost.
increase, so masood
must remove their
weakness of high
production cost , and low
production facility

S W
 FUNCTIONS OF MARKETING DEPARTMENT
Marketing Strategy

Marketing Department cannot be ignored in any organization. Because, it is heart and soul
for organization.

Market Penetration

The major marketing strategy is market penetration strategy of MTM they are diversifying into a
same group of related products which is also called concentration strategy. MTM is also busy in
searching new customers and to show its state of art products to world by placing its stalls in the
different textile exhibitions, arranged worldwide.

MTM have a very strong merchandising department which is part of the Marketing department working
with highly professional team work. MTM focuses on Quality with timely delivery of goods and the
pricing decisions are based on the negotiation with the buyers.

Marketing Manager performs the following activities,

□ Look overall problems of the departments and the problems faced by the
customers.
□ Devises all the marketing related policies.
□ Delights the customers by solving their problems.
□ Co-ordinates with the merchandising department.
□ Checks and observes all the activities of textile sectors especially keeping
focus on the competitor’s activities.

The marketing department with the help of merchandising department makes it possible
that the order place by the customers should be completed within specified time.

MTM sell the product with the brand name of the customers.

Major Competitors of the Organization

The major competitors of Masood Textile Mills Limited are as

1. Chenab Fabrics Limited

 2. Amtex Limited
3. Arzoor Textile Mills Limited
4. Sapphire Textile Mills Limited
5. Crescent Textile Mills Limited
6. Ammar Textile Limited

These are the local competitors at the textile city but we face in international market our
competitors are the CHINA, INDIA, Sri Lanka and BANGLADASH in these countries labor is so
much cheaper available, so they sell their product in the international market cheaper as
compare to Pakistan.

But the Pakistani products the fines quality of cotton this kind of the cotton not available in other
countries, so in this way the Pakistan stands in the international market with their products

SHORT FALLS/ WEAKNESSES

Increased employee turnover

All organization are facing problem of high turnover of employees especially it becomes critical
when key personnel left the organization. Mtm is having high turnover due to employees
working on daily wages and their turnover is directly proportional to production. There is 5%
turnover of daily wagers and 2.5% at management level in masood textile mills.

Centralized management system

Management structure is centerlized which creates problem in the production.

To be fulfilled on the required time then, acquiring approval for more contractual employees
becomes difficult due to centralized management.

High cost of production

High cost of production is basically due to more FOH cost which is increased and intense
competition in the foreign market especially India, china where cost of production is low makes
great problem for MTM.

Low production capacity

Globalization impact has created great opportunities for the companies to avail its full benefits.
Now there are more big players in the market so, MTM has to enhance its production capacity
to cater.

De-motivated staff

De motivation among employees is become serious problem for MTM. Main reason for de
motivation is low salaries, longer duty hours, low growth opportunities.

Less promotional activities

MTM is working on promotional activities to enhance its market share. But, actually the
promotional activities especially outdoor promotion is not consider as effect tool of advertising.

Non-corporative culture

MTM culture has to be improved, where every employee consider to be and remain part of this
organization. There are some biases which creates obstacles in the way of achieving
corporative culture which shows it is not only profit oriented organization but people oriented
organization.

Insufficient benefits for the employees

MTM is quite good packages to the management but on the employees level, there is need to
increase salary, incentives, monthly bonuses on production, and medical facilities to be
improved.

Stereotype machinery for processing

Processing is vital part of production department. There are machines which are becoming
obsolete and working on past day’s style of processing. It is required to get new technology from
abroad to enhance production.

Communicational gap among different departments

Communication is very much important in the growth of organization. The communicational gap
creates lots of problems such as de motivation, layoffs, production delays, low growth.
Communication gap has to be reduced to achieve higher growth and profit.
Reduce employee turnover

MTM is facing problem of high turnover of employees. Mtm is having high turnover due to
employees working on daily wages and their turnover is directly proportional to production.
There is 5% turnover of daily wagers and 2.5% at management level in masood textile mills.
Employees turnover can be reduced by providing and increasing more salaries and fringe
benefits.

Centralized management system

MTM management structure is centralized. Now, MTM has to adopt more decentralized
management approach by increasing responsibilities of lower staff.

Cost of production

Cost of production is basically due to more FOH cost. High cost of production can be cater by
purchasing cheaper raw material, productivity enhancement methods like shift wise working of
employees.

High production capacity

MTM has to enhance its production capacity to cater world market. There should be more
knitting, processing machines to be imported.

Motivation of Employees

Motivation of employees can be achieved by providing more incentives and fringe benefits.
There is also recognition technique of motivation to be incorporated in the organization.

Promotional activities

MTM promotional activities have to be enhanced. Promotional activities should use outdoor
promotion as effective tool of advertising.

Corporative culture
MTM has to follow and adopt corporative culture which shows it is not only profit oriented
organization but people oriented organization.

Machinery for processing

MTM production depends upon high Processing machinery. Now it is required to get new
technology from abroad to enhance production to cater world market in efficient manner.

Coordination among Departments

Coordination and communication is needed in the growth of organization. The communicational

gap creates lots of problems such as de motivation, layoffs, production delays, low growth.
Communication gap has to be reduced and coordination among department is required which is
done in by HR department of MTM, to achieve higher growth and profit.
CONCLUSIONS & RECOMENDATIONS

Masood textile mills is the best knit wear in the world. In a short span of time, the company has
established a good image in the international market.

Although there is a tough competition in the international market, but Masood textile mills is
continuously going on its way to prosperity .the main customers of Masood are, JC PENNY,
SARA LEE.

They have established a good image in the mind of its customers. This is all due the company’s
high quality products. Company quality assurance department is so well establish that some
times the customers request the quality inspector to visit some other company s where their
other products are being manufactured, so the quality of that company can be checked.

China, India, Bangladesh are the major countries, which have direct competition with Pakistan.
Due to quota system the company has accepted only limited orders. The main advantage to the
company is of its mills unit. The company has manufactured the fabric itself, so the cost of the
production of the company is much reduced. Raw material like fabric and ribs are produce by
itself.