Apparel Internship Document PDF

APPAREL INDUSTRY INTERNSHIP
AT
AMBATTUR CLOTHING LIMITED

CHENNAI
SUBMITTED BY:
SHISHIR GUPTA
UDAY SHANKAR JHA
Bachelor of Fashion Technology
(Batch 2004 08)
DEPARTMENT OF FASHION TECHNOLOGY

NATIONAL INSTITUTE OF FASHION
TECHNOLOGY
HYDERABAD
INDUSTRY INTERNSHIP AT AMBATTUR CLOTHING LIMITED, CHENNAI
Page 1
CERTIFICATE
This is to certify that the following students of Fashion Technology Department

specializing in Apparel Production
Shishir Gupta
Uday Shankar Jha
had carried out Apparel Industry Internship at Ambattur Clothing Limited, Chennai
from 21st May 2007 to 13th July 2007.
Centre Coordinator
Page 2
ACKNOWLEDGEMENT
The quest for knowledge provokes man to undertake many journeys in life. Through
his pursuit, there are various people who extend their invaluable support to make it a
success we would like to extend our sincere gratitude to those people whose help and
guidance made our apparel internship at ACL possible.
First of all we would like to thank Mr. Indevar Pandey (Director NIFT, Hyderabad)
and Dr. P Krishna Mohan (Registrar NIFT, Hyderabad) for giving us an opportunity
to have first hand experience of the Apparel Industry. We sincerely thank our course
co-ordinator Mr.Sanjay Shrivastava and Mr Rajasekhar (RIC,NIFT,Hyd) who took
pains in arranging for the internship and ensuring its success .
We are extremely thankful to Mr. S.V.Srinivan (HRM), Mr. Amaan, Mr. Bala and
Mr. Sairam for their cordial warmth and support that they have extended.
We are extend our sincere and heartfelt gratitude to Mr.Radha Krishnan (factory
manager), Mr. Shiva Kumar (Production Executive), Mr. Vasu Devan and Mr.Ajay
for their continuous, encouraging and patient support. Without their practical advice
and valuable experience and expertise, we would never have completed this report.
Page 3
PREFACE
The Industry internship is a means to provide fresh college student a practical

knowledge about the industry work culture. The internship acted as a interface where
we experienced how the theoretical learning and input of three years of education in
NIFT can be applied to real life situations. This experience was indeed made
wonderful with the help and support given by people from Indias one of the best
manufacturing unit Ambattur Clothing Limited.
ACL is a place where best brands are manufactured with great care and customers are
looked upon as god. Gap, Banana Republic, J Jill, J Crew, Old Navy, Ann Taylor,
Espirit, Levis, Diesel are some of the brand names which would obviously require no
introduction. Working with such a big name was really an achievement.
The document describes the structural and functional working aspects of a Garment
manufacturing unit through our experience in Ambattur Clothing Limited.
Page 4
TABLE OF CONTENT
Sr. No.
TOPIC
Pg. No.
COMPANY PROFILE
1.1
INTRODUCTION
1.2
COMPANY FACT FILE
1.3
CAPACITY
1.5
LOCATION
1.4
PRODUCT RANGE
3-4
ORGANISATION CHART
2.1
CORE MANAGEMENT
2.2
PRODUCTION
H.R. AND WELFARE DEPARTMENT
3.1
ACL MISSION
3.2
WELFARE MEASURES
MARKETING AND MERCHANDISING DEPARTMENT
4.1
ORGANISATION HIERARCHY
4.2
PRODUCT DEVELOPMENT DEPARTMENT
10
4.2.1
A BRIEF DESCRIPTION OF DIFFERENT STAGES
11-23
PRE PRODUCTION DEPARTMENT
24
5.1
PATTERN DEPARTMENT
23
5.1.1
ORGANISATIONAL HIERARCHY
24-25
Page 5
5.1.2
FUNCTIONS
25
5.2
CAD DEPARTMENT
25
5.2.1
FUNCTIONS
25
5.2.2
PM AND GRADING DETAILS
25-26
5.3
SAMPLING DEPARTMENT
27
5.3.1
COMPONENTS OF THE SAMPLING DEPARTMENT
27
5.4
MARKER DEPARTMENT
27
5.4.1
FUNCTIONS
27
R & D DEPARTMNET
28
6.1
FUNCTIONS
28
6.2
COMMENTS FROM BUYER
28-29
MIS DEPARTMENT
30
7.1
BUSINESS MANAGEMENT CENTER
30-31
7.2
PRODUCTION MANAGEMENT CENTER
31-32
CENTRAL INDUSTRIAL ENGINEERING DEPARTMENT
33
8.1
OBJECTIVES OF CIED
33
8.2
FUNCTIONS OF CIED
33-34
EXPORT DEPARTMENT
35
9.1
PRE-SHIPMENT DOCUMENTATION
35
9.1.1
AEPC DOCUMENTATION
35
9.1.2
CUSTOM DOCUMENTATION
35-36
9.2
BUYING HOUSE DOCUMENTATION
36
9.3
BUYER DOCUMENTATION
36
9.4
LETTER OF CREDIT
37
10
MATERIAL MAINTAINENCE CENTER
38
10.1
FABRIC STORE
38-39
10.1.1
FABRIC QUALITY CHECKING
39-41
10.2
TRIMS STORE
41-42
Page 6
11
WASHING UNIT
43
11.1
WORK FLOW IN THE WASHING UNIT FOR BULK PRODUCTION
43-45
11.2
LAUNDRY MACHINERIES DETAIL
46
12
PRODUCTION UNIT: ACL SP 10/8
47
12.1
INTRODUCTION
47
12.2
FACT SHEET: ACL SP 10/8
47-48
12.3
ORGANISATIONAL CHART: SP 10/8
49
13
LAYOUTS
50
13.1
CUTTING DEPATMENT LAYOUT
50
13.2
SEWING DEPATMENT LAYOUT
51
13.3
FINISHING DEPATMENT LAYOUT
52
13.4
PACKAGING DEPATMENT LAYOUT
52
14
STORES
54
14.1
FABRIC STORE
54
14.1.1
A BRIEF DESCRIPTION OF THE PROCESS FLOW
54-55
14.2
TRIM STORE
56
14.2.1
56-57
15
CUTTING DEPARTMENT
58-60
15.1
61-64
15.2
M/C & TABLE DETAILS
65
15.2.1
TABLES
65
15.2.2
MACHINERY
65
15.2.3
MISCELLANEOUS
65
15.3
QUALITY CHECK IN CUTTING ROOM
66
15.3.1
S.O.P. FOR SPREADING AUDITOR
66
15.3.2
S.O.P. FOR CUTTING SUPERWISOR
67
15.3.3
S.O.P FOR FUSING MECHANIC
68
16
SEWING DEPARTMENT
69
Page 7
16.1
LINE SECTION
70-72
16.2
KAJA SECTION
73
16.2.1
73-74
16.3
QUALITY CHECKING IN SEWING ROOM
75-76
16.4
MACHINE ANE EQUIPMENT DETAIL
77
16.4.1
MACHINES
77
16.4.2
MISCELLANEOUS
77
17
FINISHING DEPARTMENT
78
17.1
78-81
17.2
MACHINE AND EQUIPMENT DETAIL
82
17.2.1
MACHINES
82
17.2.2
MISCELLANEOUS
82
18
PACKAGING DEPATMENT
83
18.1
83-84
18.2
EQUIPMENT DETAILS
84
18.3
POLY BAG, BARCODE, CARTON STICKERS DETAIL
85
19
QUALITY CONTROL DEPARTMENT
86
19.1
LIST OF THE DETAILS TO BE CHECKED
86-87
19.2
LIST OF THE DEFECT CHECKED
87
19.3
AUDIT FIOW CHART IN ACL
88
19.3.1
SAMPLE SELECTION TECHNIQUES
88
20
MAINTAINENCE DEPARTMENT
89
20.1
PREVENTIVE MAINTAINENCE PROCEDURE
89
20.1.1
MECHANICAL MAINTAINENCE
89
Page 8
20.1.2
ELECTRICAL MAINTAINENCE
89
20.2
BREAKDOWN MAINTAINENCE
90
20.2.1
MECHANICAL MAINTAINENCE
90
20.2.2
ELECTRICAL MAINTAINENCE
90
20.3
SPARES INVENTORY
90
20.4
ARRANGEMENT OF MACHINES & ATTACHMENTS
90
20.5
GENERAL MAINTAINENCE
91
20.6
WORKSHOP
91
21
PROJECT
92-97
22
CONCLUSION
98
APPENDIX
ANNXEURES
Page 9
1. COMPANY PROFILE
1.1 Introduction:
Ambattur Clothing Limited was incorporated in the year 1981 by Mr. Vijay
Mahtaney (VIJU), who is a first generation entrepreneur. The company was started
with a single factory with a work force of around 150 employees. In just 2 decades
the organization has become the fifth largest exporter of garments in India, with a
total workforce of over 15000 people employed in nine production facilities managed
by the company.
ACL has a very high reputation in the global market for its commitment to Quality
and delivering within the stipulated time equipped with the latest state of the art
technology. ACL specializes in the manufacture of Shirts, Trousers, Ladies wear,
Jackets etc. ACL clientele includes GAP, BANANA REPUBLIC, J JILL, J CREW,
OLD NAVY, ANN TAYLOR, ESPIRIT, LEVIS, DIESEL to name a few. COLOR
PLUS which has a very high reputation in the domestic market was a part of the
ACL group. CLOTHES ENCOUNTER is a retail division of ACL, which has got
its showrooms in 7 locations across India.
In a highly demanding industry like Apparel Exports, where competition from both
domestic and abroad is fierce, Human Resource and Infrastructure decides sustenance
and success of any key player. ACL has the positive edge in both the factors, which is
the prime and sole reason for its success.
Over the years, ACL has come to signify the best in the service and dependability for
many of its clients. This resulted as a great achievement for the organisation as last
year it has crossed an annual turn over of 140 Million US dollars. The organisation
has also been rated as Best client in India by IDBI bank.
Page 10
1.2 Company Fact File:
Name of the Company
Ambattur Clothing Limited
Head office
Establishment Year
86/ E2, Industrial Estate, Ambattur,

Chennai
1981
Managing Director
Mr. Vijay Mahtaney
Nature of Business
Export
Product Category
Product MiX
Main Export Market
USA, Europe, Canada, Middle East
No. of Workers
15000
Annual Turnover
140 Million US Dollars
1.3 Capacity:
Location
Capacity (2005-06)
Capacity (2006-07)
ACL, Chennai, India
8 Million pieces
9 Million Pieces.
ACL, Bahrain
3 Million Pieces.
3 Million Pieces.
Total
11 Million Pieces.
12 Million Pieces.
Page 11
1.4 Location:
Ambattur Group
Ambattur
Chennai, India
2000 Machines
Export Zone
Chennai, India
2 Production Facilities
500 Machines
ACIL
Bahrain
1 Production facility
600 Machines
1.5 Product Range:

Ambattur provides a wide variety of products. It manufactures bottoms from basic
chinos, to denim, to classic wool pants. The factories are well equipped to sew, wash
and pack the diversified range. Even in tops, it makes the basic shirts (mens &
ladies) going on to dress shirts and fitted garments in fabrics ranging from polyester,
linen & Voile.
Buyer wise product range distribution is described as follows:

Product
Buyers
Woolen pants
Banana Republic, Gap, Liz Claiborne, Tommy Hilfiger
Two Ply Twill Chinos
Banana Republic, Next, Esprit, Gap, Kohls, Eddie Bauer
Cotton / Lycra Stretch
Banana Republic, Ann Taylor, Liz Claiborne, Lauren
Polyester / Blends
Jones NY, Banana Republic, Levis, Ann Taylor.
Page 12
Cotton Shirts / Tops
Banana Republic, Arrow, Liz Claiborne, Eddie Bauer, Ann

Taylor.
Linen Shirts / Pants
Banana Republic, Liz Claiborne, Marks & Spencers, Gap
Woolen Jackets
Banana Republic, Gap
Jackets Moleskin/ Cotton
Banana Republic, Esprit.
Products range categorization on the basis of volume of manufacturing:
Product-mix
Others
5%
Tops
35%
Bottoms
60%
ACL product range can also be categorized product wise as follows:
Page 13
Product Range
Mens wear
Womens wear
Shirts
Top
Trousers
Skirts
Jackets
Pants
Shorts
Dresses
Jackets
Shorts
2. ORGANIZATIONAL CHART
2.1 Core Management:
Page 14
Mr. Vijay Mahtaney

Managing Director
Production Units
Operational Functions
Support Functions
Ms.Ambika/ Mr.Bopanna
Mr.Behram K
Director - Production
Director
Merchandising/
VP - Merchandising
Mr.T Rajendran
Head Human
Resources
Administration
Mr.Darius K
Head R&D
CAD/CAM/Sampling
Quality Assurance
Mr.T Subramaniam
Finance & Accounts
MIS, Projects & IT
Mr.Vinayak T
Head - MMC
Mr.V Paranthaman
Head - Commercial
Page 15
2.2 Production:
Mr. Behram K
Director
Mr. Manohar K
Babu Genreral
Manager
Mr. .Ganapathy S
General Manager
Mr. Gopinath
General
Manager
Mr. Krishnan, FM
Mr. Sekar/Mr.
Mani, PM
SP 53
Mr. Anandraj, FM
Mr. Raja, PM
69 B
Mr .Dave, FM
Mr. Shaji, PM
B 12
Mr. Narasimhan,
FM
Mr. Balakrishna,
PM
B 13, B 15
MEPZ Division
Mr. Anand, FM
Mr. Prince, PM
( B 9)
Mr. Rajendran PM
(B 10)
Mr. Pawan /
Mr. Sudhakar,
FM
Mr. Srikanth, FM
Mr. Gopalan, PM
D 26
Mr.Radhakrishnan
, FM
Mr.Shankar, PM
SP 10/8
Page 16
3. HUMAN RESOURCE AND WELFARE DEPARTMENT
ACLs human resource policy stems from the underlying belief that human resource
is one of its greatest assets. These assets appropriately motivated developed and
above all professionally managed will be source for the advancement of ACLs
corporate plans. Corporate personal policy strives to secure job satisfaction for all its
employees. It is ACLs vision is to be the MOST PREFERRED EMPLOYER in
garment industry and the means employee towards this end includes:
Ensuring value driven management
Highly contemporary HR practices
Focus on candidates short term and long term plans
Flexibility towards horizontal and vertical movement within the organization
3.1 ACLs Mission
To evolve a corporate work culture supportive of every individuals pursuit of

dreams, equality of human dignity, ownership of organizational effectiveness
and open communication for collaborative and cohesive team work
To constantly foster strong customer orientation, highly accountable role

holding and total performance alignment across the organization
To incorporate the most effective and progressive training and development

policy which strives to meet the rising demands of the organization, wherein
every employee in the organization will undergo a minimum training on
technical and behavioural areas in a given calendar year
To constantly foster a congenial working environment which motivates every

employee in the organization to facilitate maximum output
To align with the changing Business Demands and Goals and accordingly
institutionalize the key performance areas of the functional departments and
every individual.
Page 17
Employee Welfare is a continuous process and Department emphasizes on

developing suitable welfare measures, which are on par with the best industrial
practices.
3.2 Welfare Measures Provided To Employees:
Medical facility: The organization has its medical centre located in SP-24,
which has an in house medical practitioner, with renowned specialist visiting
regularly. The service is totally subsidized and the employees have to pay a
very nominal amount for registration. The centre also provides medicines at
very nominal rates.
Crche facility: The organization also offers crche facility to the employees
children in the age group between 1-6 yrs of age. Certified and well trained
personnel in childcare manage this facility. The centre also provides periodic
health checkups for the children.
Library facility: The organization has a corporate tie-up with British council
library for taking care of the library needs of the employees and the
organization. Every employee is eligible to avail this service and borrow
books, periodicals, magazines, videos for a period of 2 weeks.
Transportation facility: The organizations provide transportation facility

where ever it is feasible. The HR department makes all the necessary
arrangements.
Company functions: Employees are called upon to participate in the any of

the companys functions, either conducted in the premises or outside the
premises on various occasions, including physical activities conducted
regularly.
Page 18
4. MARKETING AND MERCHANDISING DEPARTMENT

The company has exclusive teams of merchandisers for each buyer like GAP, Diesel,
Eddie Bauer, Levis, Banana Republic and J- Jill respectively. The major functions of
the department can be summarized as follows:
Identification of selling avenues and Buyers
Maintaining buyers faith and promises.
Promotion or marketing the brand to the right audience at the right time.
Coordinates different departments to achieve production within lead time.
4.1 Organizational hierarchy of the Department:
BMC HEAD
(MANAGER)
MERCHANDIS
ER
(PRODUCT
DEVELOPME
NT)
Jr.
MERCHANDISER
(P D)
Sr.
MERCHANDIS
ER
(PRODUCTIO
N)
Sr.
MERCHANDIS
MERCHANDIS MERCHANDIS
ER
ER
ER
(PRODUCTIO
(SOURCING) (SOURCING)
N)
Jr.
Jr.
MERCHANDISER MERCHANDISER
(TOPS)
(TOPS)
(P D)
(P D)
(BOTTOMS)
(BOTTOMS)
Page 19
4.2 Product Development Department

Product development department comes under marketing. The company has inhouse design studio to anticipate and react to market trends and buyers orders.
The product development department takes care for the steps of conversion of design
from paper to garment with actual fabric.
Design
on
paper
Garment
with actual
fabric
Garment design
Proto
Printing &
development
Wash trials
Adoptio
n
Franchise
Critical fit
Production
Diagram showing the sampling stages from design to bulk production of the garment
Page 20
Page 21
4.2.1 A brief description of different stages:

Proto/ Early Book sample: It is the first sample from paper to fabric. In this the
main points which are looked into are Pattern, fit, drape, fall of the garment.
Substitute trims can be used. Then it is sent to buyer for approval. Fit comments are
sent by buyer. Measurements should be within the tolerances.
Wash trials: It is done after the fit is finalized for proto. It is the same style which
can be done on different fabric. Finalize type of wash for fabric. Sleeve modes, leg
panels, shirt mocks etc are made to test for wash trials.
Developments: Initially it is done in the form of sketches on the piece of the sample.
It is done in order to check the capacity of vendor. It is submitted to buyer for getting
the feedback on the sample.
Adoption sample: It is very important stage of production of styles in different fabric
of different colour. It should contain actual aesthetic appeal. It has actual trims and
approved wash standards. It is representative of Ambattur to the buyer. Final order
placement by the buyer is done only after the acceptance of adoption sample.
Critical fit: After the proto fit buyer would give comments, which would be
incorporated in adoption stage. In adoption stage presentation is covered, in critical
fit all specifications should be within tolerance to assess the fit of the garment. It is
sent to the buyer for confirmed order; all specifications are followed in this.
Franchise: Marketing team of buyer sends all styles of the sample to the different
retail units to predict the market response. Here, the aesthetics of the garments is
important to them than measurement.
Page 22
Buyer Tracker
GSS
BOM
Pattern
CIED
DD
S
A
M
Research &
Development
Pattern request
Sample request
Marker request
Research & Development

Comments
Wash request
(If applicable)
Costing
Sample
Basic procedure in Product development
Tracker: It is the excel chart from the buyer which mentions styles allocated to
different vendors. It is a comprehensive chart which is circulated among all SVD
offices (Supplier Vendor Development office), indicating entire status of adoption
sample for a particular season. It has all the details of the styles to be made with like
fabric, colour and the wash.
Garment specification sheet: It is made by the designers and sent to SVDs.
Designers provide details such as sewing, construction details, which are required to
make the garment diagrammatic introduction. It includes buyer block / pattern to be
followed for shapes and the measurement/ specifications of all the parts of a finished
garment. As soon as GSS is received, it is checked if any extra information is needed
Page 23
or not. For any extra information the CSP (customer supplied product) will be
circulated to CIED (central industrial engineering department) and R&D (research n
development).
BOM (Bill of materials): It contains the details of shell fabric, labels, buttons,
interlinings, threads, prints, embroidery, wash specifications, packaging details etc.
Trims ordering should have following details:
Supplier name
Buyer ref no.
Trim description label, button, colour, size, quantity
Buyer Bloch: It is the soft copy of the pattern which is necessary for pattern making
on paper.
Pattern request: After GSS, BOM and Buyer Bloch, pattern request is issued for the
preparation of computerized or manual pattern. Communication with this department
is only through marker request form.
These are the following detail in the pattern request form:
Version of pattern
Size
Fabric type
Enclosed GSS, BOM, Sample and Pinned sample
R & D comments: When the pattern is ready, the pattern department will send
merchandising department comments. They will also give costing comment which
can be done on style without affecting design and style. These comments to be
enclosed with sample request.
Sample request: As soon as fabric and trims are required sample request is issued,
which contains following details:
Style no
Page 24
Pattern version to be used
Main fabric details with swatch
Labels detail
Button detail
Other detail like zip, tape, lace
Colour, size wise quantity of samples required
Wash details
Special instructions
Enclose the copy of GSS, BOM and R&D comments.
Once sample request is given the following sequence is followed:
Store has to handover the fabric and trims required for a sample request
Pattern cutting: Here the cutting of fabric as per the pattern takes place
Embroidery and printing(if applicable)
Lining issual
Buttons, Hooks, Contrast thread required issued
Washing(if applicable)
Finishing: After washing samples will be checked for quality, ironed and
packed
After samples reaches merchandiser (Product development team) it is needed to cross

check the samples with GSS and BOM and fill the details of the sample on its label
and tag. Now sample is ready to be dispatched to the buyer.
Wash request: After sample is stitched it has to be sent for washing. It is sent with
an enclosed wash request form to instruct the washing department with the wash
required on sample.
Costing: Before sample is dispatched it is needed to give costing for the same. The
costing of the sample is done in each stage of the sample like proto adoption etc.
Page 25
The following points are considered while costing:
Fabric consumption and price
Trims consumption and price
Wash price
Printing and embroidery price
SAM given by CIED
Marker request: After receiving the details about the fabric for a particular style
merchandising department has to determine the consumption of a fabric which is
given by CAD/CAM (Marker department).
The Marker request should contain the following details:
Style no.
Pattern to be used for marker
Cuttable width of the fabric
Repeat size of the fabric with swatch
Placement of fabric
Matching standard for stripe and plaid(checked) fabric
Add information such as NAP up down fabric, one way or two way fabric
Based on above details, marker department will give the consumption (wastage is
added with this and called yield yardage) of the fabric for that particular style.
Matching standard:
For stripes and plaid fabrics, Banana republic has some
matching strategy at various parts of a garment to give nice appearance while

wearing. Those standards have big impact on yield yardage. It is always better to give
a swatch to avoid confusion.
To finalize the costing of sample following factors are taken in consideration:
Page 26
Fabric factor- Fabric consumption * Fabric price + Wastage (Varies from 5%10%)
Contrast fabric factor- Contrast fabric consumption * Fabric price + Wastage
Trims factor-Trims consumption * Price + Wastage
Printing and embroidery prices
Washing
Cutting and manufacturing charges(CM)
Flow Chart for Production
Page 27
Bulk GSS, BOM &

ACT
CPS
Fabric booking
Trims ordering
Proto
AD sample
No
Rev M
Yes
No
Approval
Approval
Yes
GPT sample
Yellow tag
Green tag
Size Set sample
PCD
Trim card approval,
Thread approval,
shade band approval
Interlining report, FTP, GCR
PP meeting
Shipment sample
Wash sample
Final Inspection
Shipment
Page 28
Top sample
PRODUCTION
After adoption is over, buyer will start placing order through ACT (All channel
trackers). It is an excel format which has the details about confirmed styles, orders
quantity and delivery etc. after that final GSS and BOM is sent by the buyer. Then
the costing is done again and it is very tight to BOM. The costing is done in CPS
format which should be very tight & competitive. The Product Development
department has to hand over the samples to the concerned production merchants to
carry over.
Confirmed Program Sheet: After receiving the bulk GSS and BOM, the costing for
bulk is done and same is sent in a format called CPS to the buyer. This includes all
the details about product like fabric details with price, delivery details and mode and
Time & Action (T&A) plan of that style.
Quantity Indication: Once orders are confirmed, indication of the new order to
management, import & export department to plan for production & spacing is given.
For that we have to give details like style no, colour ways, SAM, order quantity per
colour way, delivery date, and mode of delivery.
Time & Action Plan: This is the plan through which merchandisers commit the exit
dates of various samples such as (Proto, Revised M, yellow tag, green tag,
advertisement sample & shipment sample) to buyer to meet the delivery required by
them. Buyer will give the delivery as IN-DC date. So, we have to work backward &
give the dates for sample exit. From the given details we can have the idea to give
dates & will change time to time for different cases:-
Page 29
Ex-country: - 35 days back from In-DC.
Ex-factory:-6 days for sea-shipment and 2 days for air shipment.
PCD (package date):- 35 days from Ex-factory for a regular cut n sew
program and 45 days for an O/D (over dye) program.
Yellow tag exit date: - 12vdays before PCD.
Revised M exit date:-20 days before yellow tag ED(exit date)
Proto Exit date:-20 days before revised M ED.
PP meeting: - 10 days after PCD.
TOP exit date:- 2 weeks before shipment
Order Registration: For order registration Software called Business Management

Centre (in house development) is used. All the details about all the orders from
sampling to the shipment and all the data/ status required can be immediately seen
from it.
Fabric Booking: It includes arranging material required for the production. The
fabric required for the particular order is ordered based on yield yardage received
from CAD/CAM. Since Ambattur Clothing Ltd. (banana republic dept) is dealing
with nominated supplier, SVD will give the indication (in form of fabric cutter/ fabric
order confirmation) FOC about the fabric quantity to the mills which should be cross
checked and confirmed to the mill by the department and then have to follow up,
cross check some of the internal procedures like Material Required Chart (MRC),
Raw Material Order (RMO), Performa Invoice (PI) from the mills and purchase order
(PO). While ordering the fabric for bulk, the quantity and delivery of tailoring /
sample yardages (for making the samples) are also specified.
Trims Ordering: Trims like interlining, labels, tags, buttons, price tags and packing
materials to the concerned purchase department through MRCs (Material
requirement charts). The MRCs are raised by PPC (production & planning coordination) and merchandisers have to overview the internal procedures like PI
(purchase invoices) from suppliers and POs (purchase orders).
Page 30
BOM & GSS Classification: As soon as the department receives the BOM and GSS,
it has to be studied carefully and asked about the classification within 48 hrs.
Shrinkage Sample: When washed fabric shrinks, it needs to be measured and
examined properly to maintain the specification that buyer wants for the wash
programs. Normally the shrinkage is checked in both warp and weft direction of the
fabric which will be added in the pattern so that it meets/hits the specifications
required by the buyer. It is very important to study the shrinkage on different roles of
the fabric as it will differ from roll to roll or takka to takka. Normally one shrinkage
study sample is made before doing any sample valid for specification/fit to avoid the
last time rejection due to measurement problems and this is totally for internal
purpose.
Proto Sample: After getting the classification for GSS & BOM merchandisers
arrange the samples to be sent to the buyer. First stage sample of production in base
size which is only meant for fit, specification and fabric. In this sample Trims are not
actual. Buyer will review the sample and give their approval or comments on fit.
Revised M Sample: If buyer is giving his comments to a proto, another sample in
the same base size incorporating all the comments is made and sent for approval
which is known as Revised M sample. Again buyer will review the sample and give
their approval which will be called as Revised M. Again buyer will review the
sample and give their approval or comments.
Wash Sample: In tailoring yardage, sample in base size (normally in 4 pieces) is
made with actual wash required for wash approval. The same will be sent to SVD,
Delhi and then approved and then forwarded to the buyer. The approved wash should
be maintained till the end of the order.
Garment Package Test (GPT) Sample: This is exclusively done for Banana
republic as the buyer has set some standards for their products in all the aspects.
Page 31
Banana republic has nominated some laboratories like ITS Mumbai and BY/MTL
Bangalore. So before starting production the garments to be tested and passed for its
qualities like fabric, trims and stitching quality from those laboratories. Here they
will test the sample for fabric weight, fabric content, flammability of fabric, tear
strength, tensile strength, pilling resistance, rain test, belt loop test, pocket attaching
strength, button attachment strength, snapping/unsnapping strength and various
colour fastness tests. To ensure the quality of the product the department has to make
and send the sample as per the labs requirement (4 pieces in dark colour way + 3
pieces in other colours -all in basic sizes).
Yellow Tag or Sealer Sample: Once proto/ Revised M is approved by buyer, the
department has to make a sample same as the Revised M with actual fabric and trims
to get it sealed by SVD Chennai. That is meant for all actual trims, specifications and
washes and to be followed by factory for production.
Green Tag Sample: There are times when all the trims required to make the yellow
tag sample are not received. In that case the department makes the yellow tag with
substitute trims and get SVD sample in any colour with actual trims and wash. This is
basically done to reduce the production delay.
Advertising Sample: In the meanwhile the department has to send the advertisement
samples (12 pieces) as instructed by the buyer for their catalogue/Marketing team. It
is for presentation purpose so it contains actual trims and fabric.
Size Set: All samples made till this stage After PCD (Production commencement
date- Date on which factory starts working on an order) are made in the base size
only. Therefore, before starting the production factory under goes pilot run that is
doing a trial production and making garments in all sizes. And one piece from each
size will be sent to SVD office to set the approval. The department should get the
approval for size set by pre-production meeting.
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Pre Production Meeting: After pilot run and before starting the production the PP
meeting is been conducted at SVD offices to discuss the critical points of the
particular order.
Top of Production (TOP) Sample: As soon as the production starts TOP samples in
base size (4 pieces) are sent to SVD offices and then to buyer to show them the
production product quality. If no comment is received within 48hrs then the
production will continue.
Shipment Sample: Samples from bulk are sent to SVD covering all sizes to
represent the shipment. It will contain the actual trims and packaging material and
exact wash.
Package File: Normally factory will be located away from headquarters so in turn to
avoid wastage of time in asking the classifications from merchants and to avoid
making mistakes. It will have to give all the details regarding the particular order for
which there is a checklist which were generated from the past experience. All the
details should be put in the package file.
PRODUCTION PACKAGE FILE CHECKLISTS:
1. Approved Yellow Tag(Sealer)/Pre production sample

2. Full size set pattern and version written on index ( If the style carries
embroidery or print the layout has to be passed on to the size set patterns
while sending to the factory with grading).
3. Index
4. R & D package comment
5. Final updated buyer BOM with CSP date
6. Update internal BOM(ACL)
7. Final GSS with CSP date
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8. All fit comments and buyer approvals highlights for constructions

9. Sealer comments and R&D reply for sealer comment
10. Trim cards approved by buyer merchant BMC containing:
a. Thread trim card with all thread qualities, colours, shade approvals
and placement
b. Label trim card with all labels required for all constructions
c. Layout for reference
d. Buttons, snaps, tapes, elastic, zippers etc
e. Price tickets, match books, stickers, hang tag etc.
f. If there are many trims missing from the above mentioned details of
the trims are given
(i) Fabric swatch card (Approved by buyer merchant)
g. Fabric swatches (shell, pocketing, lining, binding, contrast etc). In all
colours with selvedge and right side and nap direction marked on it
(where fabric is plaid or striped then centre front line to be marked).
h. Approved shade bands for fabrics, if not available attach the option
sent for approval.
i. Interlining swatches
(i)
Work order
11. POs (work order) with CSP date

(i) Reports
12. Fabric package test report for all fabric qualifies (for small quantity where it
is not required, attach the waiver)
13. GPT report
14. Interlining test report
15. General conformance report for styles having snaps, hook with mocks
16. Thread advisory report
17. Fabric shrinkage report
APPROVALS
Wash approval/band
Digitals for folding instructions of a garment approved from buyer
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Pressing standard
Labels and packing trim placement approval with digitals
Print/Embroidery/Swatch with approval for placement, color, artwork

appearance and technique
Matching standard and mini marker for stripes and plaid fabrics
Zipper grading
Any other style specific issues
Internal BOM: It is a system generated BOM in BMC which has all the details
about the particular order like fabric detail, trim detail, order style, PO and the status
of the raw material etc. Shortly it has the complete up to date status of that particular
order. This is circulated to the factory, stores (SP-76) by PPC at time of production
for the follow up.
Trim Card: This is swatch card which has the swatch or samples of all fabric and
trims such as labels, buttons, zipper, thread, interlining; tape etc. a set of swatch card
has to be sent to the SVD offices before starting the production and get their
approval. Same will be sent to factories along with the package file for their
reference and to avoid confusion.
Thread Advisory Report: Some fabrics are sent to the thread supplier and the
quality of the thread which is to be used for that fabric is taken. Based on that PDD
have to match the thread for fabric and get approval from buyer. The approved
thread panel should be kept in the package file.
Shade Band: Since the yarns for bulk will be dyed more than once, the scope for
different shades of colour is more. As soon as the company receives the fabric, fabric
stores will segregate the shade, inform the quantity per shade, and then send the band
(collection of different shade swatches) to buyer and get the approval.
Interlining Report: To check the operating temperature and pressure of the
interlining to a particular fabric and to choose the correct interlining supplier and get
Page 35
their suggestions/advice for the interlining which should be included in the package
file.
List of forms used at different stages:
Sample request form
Wash request form
Pattern request form
Marker request form
Short Quantity: After package file is handed over to the factory, factory will start
pilot run, size set samples, TOP samples and shipment samples. At the time of
production or end of the production, factory will inform us the short quality to the
actual required quality, the same to be informed and get approved from buyer
beforehand.
Final Inspection: Once the goods are ready, QA from SVD will come and inspect
the goods. Once it is approved, the goods can be moved from the factory premises to
the buyer nominated forwarder and then the goods will be shipped to the buyer.
Shipment Advice: Once the goods are shipped, the details about the shipment like
invoice, delivery challan, Bill of shipping or Air fare & vessel / flight details etc to
the buyer is taken care by Export department. They are also taking care of payment
related activities.
5. PRE PRODUCTION DEPARTMENT

The pre production department is the assemblage of four different departments which
work in coordination. A brief description of the different component is given below:
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5.1 Pattern Department

It is headed by Mr. Chandrasekhar, Mr. Gopal Kumar and Mr. Ganesh Kumar who
handles different buyers such as GAP, Diesel, Eddie Bauer, Levis, Banana Republic
and J Jill.
5.1.1 Organizational hierarchy of the Pattern making & CAD Department:
Technical head
Senior pattern maker
Junior pattern maker
Assistant pattern maker
The basic procedure followed in the department for a new order can be summarized
as follows:
New patterns are made
Buyer amendments are incorporated
Shrinkages are added
Grading is done
These patterns are used in sampling and sent to the buyer for approval, and
also sent to factories for production
Pattern tracking system prevails with version numbers for every amendment.
5.1.2 Functions
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The senior pattern makers work on styles like jackets, outerwear, shirts,
trousers, dresses etc.
The junior pattern makers help out in adding shrinkage to existing patterns,
grading and amendments
The pattern assistants trim the tracing received from the buyer and make
templates
Consumption of lace, webbing tapes draw-cord etc are also given by this
department
All factory amendments are also done by the pattern department
5.2 CAD Department

This department is affiliated to the pattern department. The entire computer aided
patterns, amendments, shrinkage and markers are done in this department.
5.2.1 Functions
The senior CAD technicians work on the new patterns, amendments,

shrinkage and grading.
The junior CAD technicians work on digitizing the patterns, tracings,

duplications etc.
5.2.2 Pattern making and Grading details:
Time taken to make a new pattern : 4 hours(Manual), 6 hours (computerized)
Time taken in grading: 8 hours (Manual), 6 hours (computerized)
Total time taken by marker department to give final pattern : 2days
Software used by CAD department : GGT (Gerber Garment Technology)
Type of marker planning: Mixed marker
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Working flowchart of the Pattern making & CAD Department
Merchant gives pattern request form
Pattern version-A is made and given to the merchandisers
Merchant gives changes as per buyer
Pattern version-B is made (if required)
Cross checking
Costing (to book the order) and sampling patterns
Adding shrinkage factor
Checking
R
e
j
e
c
t
i
o
n
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Quality Audit
.
5.3 Sampling Department

This department is headed by Mrs. Prasanna kumari. T. This department is equipped
with state of art machineries. This department is self sufficient with a stores, cutting
section, button, and button hole section, finishing, home laundry and embroidery.
This department is segregated buyer wise and each unit is self sufficient with a
sampling supervisor and a quality person who understands the quality standards for
their particular buyers.
5.3.1 Components of the Sampling department:
Stores- The stores in sampling keeps account of all the sampling fabric and
trims issued to them. They issue the same to cutting as per the sampling
requests.
Cutting section- This department is equipped with personnel who cut fabrics,
pocket interlinings.
Sewing section
Button and button hole section
Finishing/pressing/checking section
5.4 Marker Department

This department works on markers done at costing, amendment and final stages to
derive on the fabric consumption of a garment. All factory lay markers and centrally
issued from marker and CAD department, markers are taken at costing and fit stage
5.4.1 Function
The senior marker will maintain the centralized record from sampling, pattern
and markers
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They will file all Patterns by buyer wise and the pattern request form also
Marker maker they mainly concentrated on costing, they have responsibility

to check out the consumption level.
6. RESEARCH AND DEVELOPMENT DEPARTMENT
The research and development department has different roles in case of different
buyers. However the basic functions of research & development department can be
summarized as
6.1 Function
Review the Tech pack for producing a fusibile trims details.
Reviewing a fit for the samples.
Giving an alternative option for some difficult operation.
Giving a fit comment properly to the production people.
Updating the tech pack regularly.
Giving guidance for factory production.
6.2 Comments from Buyer
Fit comment it special for fit of the garment.
Construction comment.
Specification comment.
Trims details.
After getting the GSS and BOM from buyer this will send to three department
Research and development department and CIED department and patter making
department.
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In research and development they will make costing for each and every
process.
They will check the capacity of machines and ability of the workers of factory
for a particular style.
Whether the design and trims of the garment
is feasible or not .if the
style is feasible how can will do it in a effective manner .
From sampling development to the end of the production
R&D department
have a responsible in each and every step.
While production if the factory people have any doubt in the operation
R&D department will come and clear the doubt regarding the production and
productivity
If there any technical problem
R&D department will analysis the problem
and find a proper solution for that problem.
While sending the sample to the buyer we have to attach the comment from
R&D department.
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7. MIS DEPARTMENT
The company uses centralised information system which is developed by the core IT
team of the company. The company has two tier integrated information system to
track the over all production with the management, planning, Sourcing and inventory
facilities. All the production and the support facilities are interconnected by optical
fibre on LAN network.
The information system can be divided in two parts i.e.
1. BMC (Business Management Centre ) and
2. Production Management System
7.1 Business Management Centre

It is the data entry software package used by the Merchandizing and marketing
Department. Each employee of the department has a separate user Id by which they
can access the system. The range of access is pre- defined so that no one can interfere
outside their Domain. The Package function details are pictorially shown below in
the screen shots of the package interface:
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Screen shorts showing different menu options of BMC

In this merchandiser can click on any of the menu option in the interface according to
the need. E.g. if he clicks on the Order Registration again following interface will
Come with all the order registration details along with the list of people who are
responsible for the job and can do data entry. For all other users it is read only
facility.
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7.2. Production Management System: It is also a data entry software

package used to record information at production facilities. This Package function
details are pictorially shown below in the screen shots of the package interface:
Screen shorts showing Login Screen

Page 45
Screen shorts showing different menu options of PMS
8.
CENTRAL INDUSTRIAL ENGINEERING DEPARTMENT

Page 46
Industrial Engineering department acts as the bridge between the corporate office and
the production floor. It helps marketing people in understanding the complexity of
the product for accurate negotiation of manufacturing cost with buyer against the
production cost involved for the product based upon the factory efficiency.
8.1 Objectives of Central Industrial Engineering Department
Establish standard method for the operation.
Establish standard work content for a garment.
Reduce the work content there by reducing the manufacturing cost.
Increase utilization of available resource like man, machine and work

space.
Making production system more effective.
8.2 Function of Central Industrial Engineering Department
Analyzing the work content of a garment at pre-proto stage for CMS

(Cutting and Manufacturing Charges) with option to negotiate for CMS
After order confirmation the evaluation garment is reanalyzed for better &
economical methods to reduces the negotiated CMS in order to stay in
safe margin
At production stage the factorys achievements are being closely

monitored and recorded, there by creating the awareness of factory status
and requirement to improve its standard and in benchmarking its
achievements.
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Role of Central Industrial Engineering Department
Buyer
Merchandizing
R&D
Planning
CIED
Factory
Sampling
HRD
MIS
Accounts/
Finance
Page 48
9. EXPORT DEPARTMENT
Export department receives delivery schedule from marketing department and
confirm the product category, quantity, delivery date and destination of orders with
the concerned merchandiser. The following documents are been prepared.
9.1 Pre Shipment Documentation

9.1.1 AEPC (Apparel Export Promotion Council) Documentation
(a) Preparation of following documents and submitting the same to AEPC
Commercial invoice
Shipping bill
Visa format
AEPC annexure
(b) Ensure that the above documents submitted not later than two days before
shipment
(c) Follow up with AEPC and receive following documents
Endorsed shipping bill
Visa with necessary entries
(d) Ensure that the above documents submitted not later than two days before
shipment
9.1.2 Custom documentation
(a) Selection of C & F (Carriage & Freight) agent
(b) Coordinate with C & F agent and decide on shipping line
(c) Preparation of following documents and the same shall be handed over to the C &
F agent days before the planned shipment:
Customers invoice
GRI
Packing slip
Shopping bill
Page 49
Order copy
(d) Follow up with the C & F agent and ensures that the above documents are
submitted to the customs days before the shipment.
(e) Coordinate with C & F agent and receive the following document from him
Bill of lading/ airway bill
Freight cargo receipt
GRI duplicate
9.2 Buying House Documentation

Preparation of following documents and sends the same to buying house not later
than days before shipment
(a) Invoice
(b) Packing list
(c) Visa copy
(d) Bill of lading/ airway bill
(e) Single country declaration
(d) QC report
Follow up with buying house and receive inspection certificate not later than days
before inspection.
9.3 Buyer Documentation

Preparation of following documents and forward to buyer
(a) Commercial invoice
(b) Packing list (colour wise and size wise quantity)
(c) Inspection certificate
(d) Bill of lading/ airway bill
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(e) Any other declaration required by buyer (e.g. Certificate of origin, single country
declaration)
(d) Ensuring the above document reach buyer in time and receiving feed back
(e) Providing any other information required by the buyer.
9.4 Letter Of Credit (LC)

After issuing PO buyer will approach to their bank to open LC and accordingly buyer
bank will issue LC and same will be send to manufacture bank. Then the
manufacturers bank will hand it over to the manufacturer.
Then the manufacturer will go through the LC and if all the terms and conditions are
correct manufacturer will ask their bank to send message to the buyers bank as LC is
accepted.
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10. MATERIAL MAINTENANCE CENTRE

ACL has a centralized fabric and trims store known as Material Maintenance centre
(MMC), situated at SP-76, Industrial Estate, Ambattur. It is one of the most specious
facilities in the company. Its function starts from receiving the fabric and trims, their
inspection, checking the shade variation and shrinkage percentage roll length
verification till the fabric and trim issue to the respective production unit.
Department receives the purchase order of the fabric and trims, purchased by the
purchase department. Goods entered at the gate are checked physically as per the
Purchase Order. It has two separate departments for receiving the fabrics and trims
respectively. The basic work flow in the MMC can be described as follows:
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Fabric / Trims Receiving
Fabric / Trims checking
Fabric / Trims test report
Fabric / Trims issue
10.1 Fabric store:

After verification with concerned merchant, Pre GIN (Goods Inward Notes) is raised
against the supply invoice. Material is received in forms of bales. Each bale carries
100-200 fabric rolls. Now bales are opened and all the data is entered in the computer
and based upon Pre Gin a particular bar code no is assigned to each roll which is
called GIN. Rolls are stored width wise and colour wise in racks.
Total rolls are checked any if there is any shortage, information is sent to Purchase
department.
The MMC has in-house fabric testing laboratory, which is equipped with high
precision and state of art machinery. Lab makes the FIR (First information report of
the fabric received). With in three days of receiving of fabric, lab has to perform all
the tests and has to submit the report to the head. After all the tests, report is made
and sent to merchant whether to accept it or to reject it. After his remarks, swatches
are made and sent to the reputed labs for same tests. After passing from them the
fabric is distributed to the production factories. List of the tests performed by the
MMC lab are as follows:
TEST
Count Determination
Construction
EQUIPMENT
Beasley meter
Pick glass
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Washing fastness
Perspiration fastness
Crocking
Pilling test
Tearing strength
Flammability
pH
Colour matching
Laundromat
Perspirometer
Crocking meter
Pilling tester
Tearing strength tester
Flame Burner
pH meter
Visual Matching
10.1.1 Fabric quality checking: The universally accepted 4-point inspection system
is used to check the fabrics. After receiving the fabric half a meter, full width fabric is
cut. Fabric swatch is cut from this piece for shade identification and to find roll wise
shrinkage. Roll no is marked on each swatch for identification. The fabric is scanned
for all the defects. All the detail of defects with the Non Conformance Report is made
and is issued to concerned merchandiser for the approval. A minimum 10% checking
is done of each received lot.
Checking process: the checking process constitute following steps which are as
follows:
Fabric is being checked as per standard fabric swatch approved by the

merchandiser.
Fabric rolls are checked both in the flat table as well as machine so that the
faults, which could not get detected in the flat table, can be detected on the
machine and vice-versa.
Fabrics are being checked for selvedge to selvedge and centre to selvedge
shade variation.
Defective
samples
are
sent
to
concerned
merchandiser
for
approval/disapproval.
Preparation of Non Conformance Report, which highlights all the defects and
characteristics of the fabric, is issued to the concerned merchandiser. He
decides whether to accept or to reject the fabric roll.
Fabrics are inspected and all defects are marked with stickers for
identification.
Checked are classified as sounds, seconds or rejected.
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Shade identification: The unit has a separate section for fabric shade
identification. Where fabrics are segregated into different shades. It is done by
experts based on their experience.
Shrinkage checking: A square piece of fabric (45 X 45 cm.) is taken for

shrinkage checking. Over locking is done on all four sides to avoid edge
fraying. Four points are marked using a template to check both warp wise and
weft wise shrinkage. After washing in desired conditions the specimen is
taken back to checking section and distance between the two points is noted
by a shrinkage scale.
Width checking- Width of the roll is checked with the help of specimen cut
from the roll and record is maintained.
Note:
Before sending bulk fabric, supplier has to send a pilot yardage of same fabric
to us where the defects and quality of the fabric is analyzed. If this pilot
yardage is meeting the buyers standard, only then bulk order is given to the
supplier, otherwise report is sent to concern merchandiser to sort out the issue.
List of few fabric defects generally found:

S.No.
defects
Page 55
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
weaving defect
broken warp
oil stains
slubs
warp line
crease marks
stopping marks
knots
holes
broken weft
weft line
10.2 Trims store:

After receiving trims the department raises the Goods Inward Note (GIN) against the
Purchase order of each item. Makes the swatch card with all necessary information
like - PO No, GIN no, buyer, supplier and style. It is sent to the concerned merchant
for approval. After verification Quality checking department checks the quality of
trims received as follows:
Checks 2% of received quantity, if it is ok, trims are sent to issue department

to issue it to production units.
Otherwise checks 5%. In this 5%, if rejection is less than 2%, forward it to
issue department.
Again if checking fails it Checks 10%. In this if rejection is more than 2%,
NCR (Non Conformance Report) is made and sent to concerned merchant.
Note:
A report at each stage is sent to the concerned merchant for

approval/rejection.
For rejected trims, debit note is made and sent to accounts department
mentioning P.O no, quantity, rate, amount.
Thread consumption: Department also finds out the thread consumption. After
finding out thread consumption it is confirmed with the concerned factory.
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Factory finds out the consumption at its side. Comparison of both is done and
approval is given to the minimum.
11. WASHING UNIT

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The Company has recognized the importance of having state of the art wet processing
facility to backup its world class production facility. To achieve this goal, the
company has brought experts from other countries to develop washes and to manage
the laundry. This is also complemented with Capital investment in buying world class
washing equipments.
The company has centralized washing unit to fulfil its all washing and wet processing
needs, located at D-16, Industrial Estate, Ambattur.
In general the quality of the laundry is related to many factors such as:
Quality of the equipment used: washer, dryer etc
Quality of the chemical used: all imported from Europe
The follow up and proper execution of the laundry procedure with well
trained workers and staff, the quality of finished goods get enhanced.
11.1 Work flow in the washing unit for the bulk production
Goods Reception : All the goods after receiving are 100% checked for quality and
entered to the laundry production control systems into the daily washing status
sheet using this system we are able to know and control how many garments are
received, washed, issued and in progress for wet process as well as dry process.
Unwashed Quality Audit: Goods received into laundry for wash are checked before
wash for any quality issue such as fabric defects, sewing quality, uncut sewing thread
etc. 100% check need to be done for 1 st bulk including 32 pieces, and 10% for normal
production. Only when the goods are perfect it will be cleared for wash. If any
defects are found, it will be registered into the Pre-wash quality check reports
sheets, and the defective garments are kept aside. The Pre-wash audit form is then
signed by the quality assurance manager from the laundry and forwarded to
manufacturing manager and QC manager along with the defective goods for their
inspection. We wait for the comment from the sewing plant whether we can proceed
with wash or return the goods for the repair work. After getting approval from the
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manufacturing plant, the pre-wash quality check report form get signed by FM and
QM and returned back to laundry than the goods are proceed for wash.
First bulk wash: No garment is allowed for washing without the approved wash
standards and the shade bands for the same style, after receiving all this, the wash
recipe is taken from the technical laundry department. The production and quality
control work sheet and recipe worksheet is created by the laundry systems in charge,
attached to the goods and handed over to the washing supervisor for the wash. Only
for the first bulk wash, the work sheet printed is green in colour for auditors
identification. On the first bulk, it is 100% quality check up for shade, hand, feel etc.
Bulk wash: Few garments representing the shade range from the first bulk will be
forwarded to the merchandiser for approval before laundry proceeds into further
wash. For any other issue not related to washing, they will inform the factory
accordingly for future care.
Merchandiser will sign the first bulk wash garment and will be accordingly to the
laundry for containing the bulk wash. The final production and quality control
worksheet, repair worksheet and chemical registration slip will be created into
systems for the balance bulk production.
Post wash quality: After drying, the goods are subjected to quality check at the
laundry by QC team. The goods are checked for the shade, hand feel, defects etc. the
% of the total garments check is starting from 20% for the basic wash ( rinse wash,
soft wash) up 100% for stone wash, dyeing and denim. The goods, which are not
satisfying the shade, hand feel, are sent back for re-wash, the number of the rewash
garment is mentioned in the final QC report as correctable pieces, for the goods
satisfying the approved standard and shade are packed and sent to manufacturing
plant.
After that the travelling work sheet will be finalized and saved into laundry quality
systems computer.
Rinses and softener wash 20% check
Enzyme wash, enzyme stone, denim and dye 100% check
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In general for the major defect as shade, holes, streaks etc. They stop washing until
the problem get resolved by looking again through the washing recipe and doing
trails in sampling before proceeding for bulk.
Quality Department: The data from travelling work sheets are saved into the
systems that automatically generate the final QC report for daily production.
The laundry QC supervisor will analyze the final quality report of each order and
update the laundry on the quality issue and get it signed from QC manager and FM
for further action if it needs to be taken.
This final report allowed the production people to control better what they are
producing and stop the problem in the earlier stage. By this method the % of reject
due to washing are minimized.
Chemical Stocks: By using the chemical requisition slip, the quantity of all
chemicals has been saved through laundry systems, and automatically they will be
able to check and control their chemicals stocks daily.
List of washes given in the unit:
S.No.
WASH
S.No.
WASH
1
Enzyme wash
22
Soda wash
2
Enzyme wash-mild
23
Soap wash
3
Enzyme wash-heavy
24
Water wash
4
Bio wash
25
Crinkle wash
5
Band wash
26
Distress wash
6
Detergent wash
27
Colour fixing wash
7
Stone wash
28
Mud wash
8
Bio polish
29
Paper effect wash
9
Anti pilling bio wash
30
Caustic wash
10
Softner wash
31
Leather finishing wash
11
Denim wash
32
Rubber finishing wash
12
Denimax wash
33
Desize wash
13
Dip wash
34
Starch wash
14
Silicon wash
35
Ice wash
15
Ball wash
36
Feather finish wash
16
Silicon ball wash
37
Silky wash
17
Rubber ball wash
38
Carbonised enzyme wash
18
Optical brightness wash
39
Zinc vodka wash
19
Vintage wash
40
Acid wash
AT AMBATTUR CLOTHING LIMITED, CHENNAI
20INDUSTRY INTERNSHIP
Tea stain
wash
41
Stone enzyme washPage 60
21
Bleach wash
11.2 Laundry Machineries Details:

Machine Type
Bulk Wash
Tenello
Ramson
Ramson
M/C Capacity
Machine Type
sample Wash
Ramson
Ramson
Ramson
Ramson
Tonello
M/C Capacity
Machine Type
Dryer Capacity
Ramson
100 kg
400 kg
200 kg
150 kg
35 kg
20 kg
5 kg
3 kg
17 kg
Wash Capacity of
Goods
120 kg
60 kg
60 kg
No of M/C
Wash Capacity of
Goods
15 kg
10 kg
3 kg
2 kg
10 kg
No of M/C
Wash Capacity of
Goods
60 kg
No of Dryer
4
2
4
4
3
2
1
1
24
Note:
In general garments are dried between 55 to 60 degree centigrade and for the
delicate fabric the temperature followed would be 50 degree centigrade.
Page 61
12. PRODUCTION UNIT: ACL SP 10/8

12.1 Introduction:
The second stage of our internship includes the study of manufacturing processes in
the Production unit. We had been allotted to carry out our study and project in the SP
10/8.
The Unit is located on the third main road in the Ambattur industrial Estate at a
distance of 2.5 Kilometres from the Head office. It was earlier known as Southern
Garments taken over by ACL in April, 2000. The unit is a bottoms manufacturing
Facility with the production capacity of average 2000 pieces per day.
12.2 Fact Sheet - Ambattur Clothing Limited - SP - 10/8
Total Area & Dept - Wise Area Of Facility

DEPARTMENT
AREA ( SQ FT )
CUTTING
7268.19
PRODUCTION
11698.66
FINISHING
5550.83
COMPRESSOR & BOILER ROOM
748.52
GENERATOR ROOM
769.97
LADIES TOILET
734.37
GENTS TOILET
174.94
CANTEEN
2152.95
TOTAL AREA ( INCLUDING UNUSED )

APPROX
HEIGHT OF THE COMPOUND WALL ( in feet )
29098.43
7.5
Page 62
Dept - Wise , Sex Wise Employee Strenght Of Facility

WORKERS
MEN
WOMEN
0
0
10
16
4
28
14
4
2
20
3
0
5
4
4
0
27
202
3
2
3
1
1
21
DEPARMENT
ADMINISTRATION
CHECKING
CUTTING
IRONING
KAJA BUTTON
MAINTENANCE
PACKING
PRODUCTION
SEWING
STAIN - REMOVING
STORES
TRIMMING
TOTAL
76
298
STAFF
MEN
4
1
3
0
0
5
4
1
9
0
2
0
WOMEN
2
0
2
0
1
0
0
0
1
0
0
0
29
TOTAL STRENGHT OF THE FACTORY
409
Amenities Provided In The Facility

TOTAL NO OF FIRE EXITS
11
TOTAL NO OF FIRE EXTINGUISHERS
53
INDUSTRIAL TYPE EMERGENCY LIGHTS
13
FIRE ALARM POINTS
13
FIRST AID BOXES ( FULLY LOADED )

TOILETS (MEN)
TOILET (WOMEN)
CANTEEN CAPACITY
MEDICAL CENTRE
6
6
20
150
CENTRALIZED AND PROVIDED AT SP-24
DAY CARE CENTRE
CENTRALIZED AND PROVIDED AT SP-24
Committees
No. OF MEMBERS
FREQUENCY OF MEETING
GRIEVANCE COMMITTEE
13
BI-MONTHLY
CANTEEN COMMITTEE
15
BI-MONTHLY
SAFETY COMMITTEE
14
BI-MONTHLY
Page 63
12.3 Organizational Chart- SP 10/8
Mr. Mohan K
Babu
General
Manager
Mr.
Radhakrishnan
Factory
Manager
Mr. Christopher
Franklin
Quality
Manager
Mr. Shankar
Production
Manager
Mr. Wilson
Store
Incharge
Mr. Mohan
Cutting
Incharge
Sewing Line
Incharge
(3)
Supervisor
( 4 per line)
Mr.
Ramakrshna
Finishing
Incharge
Mr. Babu
Ironing
Incharge
Mr. Miller
Packaging
Incharge
Mr. Sigamani
Button and
Button hole
Mr.
Vasudevan
Defect
Analyser
Quality
Controller /
Checkers
(5)
Page 64
13. LAYOUTS
13.1 Cutting Department Layout:
Page 65
13.2 Sewing Department Layout
Page 66
13.3 Finishing Department Layout
Page 67
13.4 Packaging Department Layout
Page 68
14. STORES
The unit has in-house store for the fabric and trims issued from the MMC which
stores the goods for the production period. The store is divided into two sections:
1.
Fabric store
2. Trims store
14.1 Fabric Store:

Process flow:
Fabric received from MMC
Fabric storage
Fabric issue to cutting
14.1.1 A brief description of the process flow:

Fabric receiving: Fabric required for the production is issued from the MMC in the
roll form. The factory maintains Goods receiving note (GRN) for the every issue. The
GRN contains following information:
Buyer no:
Page 69
Style no:
Colour:
Width:
Date
Factory
Delivery
Length(in
challan no.
metres)
Grand Total
Total no of
Rolls
Fabric storage: The fabrics received are first shade wise segregated and placed on
the storage racks. However, final segregation is done according to the shade as well
as the shrinkage percentage. The fabric rolls contains specification stickers which
contains following information:
BARCODE
PO No.( purchase order number)
Code
Bale/DC
Po Width
Weight
Supplier code No.
Fabric Description
Count
Takka No.
Lf No.(Ledger folio no.)

Colour
Qty/Mtr
Actual width
Less:0.5:
Batch
Construction
Buyer code
The shade and shrinkage family name is manually written over each roll after
receiving the shrinkage report from MMC.
Fabric issue to the cutting Department: Now according to the time and action plan
(in which cutting date is mentioned), the fabric is issued to the cutting department
and log book is maintained in the cutting department which contains following
information:
Style No. :
Buyer Name :
Fabric Colour :
Fabric :
Garment Description:
Order quantity :
Fit of the Garment:
Fusing to be used :
FABRIC
SAMPLE
Page 70
Warp shrinkage (%):
Weft shrinkage (%):
14.2 Trims Store:

Process Flow:
Trims received from MMC
Trims storage
Trims release for the sewing

Trims receiving: According to the style and order quantity trims and accessories are
issued from the MMC and received to the production unit. Here also, Goods
receiving note is maintained, which contain following details:
D.C. receiving date
D. C. No
Style No
Items
Nos.
Trims storage: According to the type and quantity trims and accessories are kept in
the designated racks placed in the store. The list of different types of trims and
accessories are given below:
Labels:
Main label (contains brand name and trademark)
Tab label (contains detail about company)
Care content label (contains content of the fabric)
Size label (size of the garment)
Wash care label (wash care instructions)
Vendor ID label (contains name of the vendor)
Buttons
Page 71
Zippers
Locker loop
BTW tape
Trims release: A trim card is made for each and every order containing all the
qualitative and quantitative trims specifications needed for that order. Exact
samples for each item are also attached on the card for identification. It also
includes the information about the buyer, style, ACL style, GMT (garment),
Quantity. The accessories are matched with the samples and then issued to the
sewing department.
Page 72
15. CUTTING DEPARTMENT

The department receives marker plan from the E2 unit which consist of following
information:
Marker length
Marker width
Buyer name
Version
Sizes
Marker efficiency
According to the marker plan spreading is planned and a Lay Slip is maintained in
the following format:
Format no
Version
Lot no
Book no
Style no
Name of buyer
Counted by
Name of cutter
QC name & checked by
H.O.D
Item code
Fabric width
Lay length
Colour
No of layers
Sizes
Lay starting time
Lay finishing time
Shade
Lay starting and lay finishing time helps the supervisor in monitoring the hourly
target for the spreading:
Target
40 plies/hr (approx.)
Spreader also maintains the spreading particulars in Lay Info slip as following:
Date
Cut no -
18/5/07
Lay length
5.23 mts
Lay width
51
Page 73
Sizes Colour Roll no

Black 5404
XS, S, M, L
Quantity
61
Shade Takka no
A
No of plies
11
Balance Lay sequence

3.70
1
Process flow in Cutting Department:
Roll segregation
Roll opening
Fabric inspection
Fabric relaxation
Page 74
Spreading
Lay relaxation
Cutting
Ticketing and
bundling of cut parts
Fusing
Page 75
Cut part inspection
Approved bundle
Cutting storage
Disapproved bundle
Bit end storage
Page 76
Damage cutting and

replacement
Cutting storage
15.1 A brief description of the process flow in Cutting Department:

Roll segregation: The fabrics issued for the production are first numbered. Pre wash
and after wash samples are taken from each roll and they are categorized in the three
families that are A, B and C. The categorization is based on the number of factors
like colour, shade, shrinkage. But the major factors considered here are shrinkage
percentage (max. 2.5%*1.0%) and shade variation.
Fabric opening and inspection: At this stage the fabric rolls are put on the clamp
placed on the inspection table and the rolls are opened in the opposite direction so
that the fabric can slide down easily and simultaneously the inspection is also carried
Page 77
out and the fabric is being kept in relaxed / loose form on fabric relaxation trolley for
2-5 hours.
Spreading and relaxation: In this process, first a brown paper is spread over the
table which is fixed on the table by the cellotape. After that the fabric is laid flat over
the table so that the uniformity in the fabric can be obtained while cutting. For this
purpose, generally wooden scales are used to remove the wrinkles and crimps. Lay
weights (iron blocks) are also used for keeping the correct fabric alignment. The
spreading table used are made up of wooden base with plywood surface mounted on
the
steel
stand.
The
dimensions
of
the
table
are
11m*1.5m*1m
(length*breadth*height).The ply cutting or the lay cutting for the spreading purpose
is done by the rotary cutter. Generally 75-125 lays are put in one spread and average
height of the lay is 3.75 inches. The lays are kept for the period of 5-12 hours for the
proper relaxation. However, the relaxation time depends on the nature of the fabric,
temperature and relative humidity at the work. In spreading, the lay length and fabric
consumption calculation are done on the basis of CAD marker.
Cutting: The CAD marker needed for the cutting comes from the E2 / E3 units, are
actually size set samples markers. These markers are further manually modified by
the cutting master as per the modification needed for the bulk production. Now, are
placed over the spreaded lay and cutting is carried out with the help of straight knife.
Band knifes are also used for cutting smaller and complicated parts while Drill
markers are used for making holes for the marking purposes.
Fusing: The fabric cut parts which require fusing before the stitching are sent to the
fusing section. It has two fusing machines. The temperature of fusing machine is set
according to
The type of thermal shrinkage of the shell fabric
The type of interlining used
The type of fusible resin (polyethylene, polypropylene, polyester etc)
The type of fusing whether it is double, reverse or sandwich fusing.
Page 78
The section also maintains the Daily Fusing and Bonding Strength Report in the
following format:
Buyer style-BR-514519
Temp
Sample
F Noon
A Noon
Pressure
Date-31/05/07
Time
Bonding strength
Sec
11
11
GMS
800
800
C
Kg/sq cm
125
1.5
125
1.5
Factory ACL-SP 10/8
Length in inches
Before
4
4
After
4
4
Width in inches
Change
Before
3
3
Interlining-P*313
F Noon Sample
After
3
3
A Noon Sample
The fusing equipment must provide control over three major factors as instructed by
R&D Department:
Time
Temperature
Pressure
Machine setting is also checked after every two hours and recorded in Fusing Report:
Date
31/05/07
8:30
125C
10:30
125C
12:30
125C
3:00
125C
5:00
125C
Signature
Any other
Signature
CE
Fusing defects are also checked and record is maintained as

Date
Setting
FN
AN
No
bubbling
F N AN
No colour
change
FN
AN
Bonding
strength
FN
AN
FN
AN
31/05/0
7
Page 79
Change
-
Ticketing and Bundling: After that the cut parts are allotted with ticket number and
stickers are used for this purpose, which consist whole description about the part and
now the bundling is done. The cut parts of similar types are put in one bundle.
However, the number of cut pieces in a bundle varies with the production runs and
the sizes. The stickering operators are issued with the list of numbers, which has to be
stuck on the cut parts. Each operator has the following info to stick the tickets issued
by the department. Example:
Lot no
Destination
Style No.
Colour
Lilly rose
Size
XS
S
M
L
Version
Cut no
Lay length
Takka no
4962(D)83, 3930(E)85
4962(D)309, 3930(E)311
4962(D)227, 3930(E)229
4962(D)83, 3930(E)85
Date
Time
Page No.
Bundle no
7192450
7192454
7192458
7192462
Pcs
20
20
20
20
FPLY
83
309
227
83
TPLY
102
328
246
102
Operators adjust their ticketing gun according to the numbers issued to them and
three different stickers are put on the every cut piece. The placement of label/sticker
on the cut pieces is pre decided in the pre production meeting.
Sticker Details:
324702
ZB500267 * 3/2/
USA/ SHADOW
Style number
Destination / Colour
8208344 31/30
[71-73] 3
5 - Fly
[Ply No.] No. of pieces
ZBJO33742 (B)
Takka No. ( Shade)
Lot No. * Cut No. / Size serial /
Bundle No. Size / Inseam
Parts name
Page 80
Cut part inspection: The cut parts are inspected as per the damages and the ticket
number and if any discrepancies are found they are sent to bit end storage section
other wise bundle is approved and sent to the sewing department by the trolleys. For
confirming proper cut quality 100% panel checking is done as well as from each cut
block top, middle and bottom panel are matched against original pattern as well as
each other for the exact and even measurements.
Bit end storage: Here end bit of the fabric which is in production run are kept and if
any damage part in the bundle is found then according to the shade again parts are
cut and damaged parts are replaced in the bundle. Thus, again the same ticket number
is allotted to that particular cut piece and sent to the sewing departments.
Page 81
15.2 Machinery and Table details in the Cutting department:

15.2.1 Tables:
Tables
Spreading table
Inspection table
Cutting table
Damage cutting
Ticketing
Bundling
No.
5
2
2
1
1
1
No. of worker/table
2
4
3
5
3
7
15.2.2 Machinery:
Machine
Straight knife
Band knife
Drill marker
Rotary cutter
Fusing machine
Rod Clamp
Stickering machine
No.
2
2
2
1
1
2
2
1
5
Operators/machine
1
1
1
1
3
3
2
2
1
Make/ Model
Eastman machine Co.
Blue Streak BS2
KM bk-700
Eastman machine Co. CD3
Ngai Shing NS-71
Hashima
Kannegiesser
Local
BlitzTextile Mod.2234
No.
5
10
5
10
10
10
Make
Local
Local
Orient/Usha
Elite
Gec Alsthom
Local
15.2.3 Miscellaneous:
Items
Racks
Trolleys
Fans/Table
Tube light/Table
Exhaust fan
Lay weights
Page 82
15.3 Quality Checking In Cutting Room

15.3.1 Spreading operator procedures for Spreading auditor:
S.NO.
1
WHAT
Narrow
goods
WHY
To ensure that all
the plies extend
beyond the
marker line.
count
Leaning
edge
Marker
Marker
placement
To ensure correct
quality of the lay
as well as to
ensure that plies
extend to the
table marking
line at both
sides/ends.
To ensure that
one edge of the
lay is square to
the table.
To make sure that
marker is not
over torn, over
lapped, creased,
damaged or
altered
To ensure that all
cut part are
complete
Tension
To ensure that
spread is not
slack or tight,
very much
important for
knits and stretch
fabrics.
HOW
Visual
inspection by
checking far
edge of the lay
with marker line
By counting
plies at both
ends of the lay.
WHO
Quality
controller
WHEN
At random during
laying and after
the completion of
lay before cut.
Quality
controller
After spread is
finished and
before the cut.
Visual
inspection
Quality
controller
Visual
inspection and
check against
original patterns
Quality
controller/
supervisor
At random during
the laying and
after completion
of lay before cut.
After marker is
put on lay and
before cut.
Marker should
be placed
parallel to
selvedge of the
lay i.e. visual
inspection
Visual
inspection
Quality
controller/
Cutter
After marker is
put on lay and
before cut
Quality
controller/
spreader
At random during
laying
Page 83
15.3.2
Standard
operation
procedures
for
cutting
supervisor:
S.No.
1
WHAT
Check actual
temperature
Check actual
time
Visual check
Bond
strength test
Durability
wash
Mocks of
fusing parts
(interlining
placement)
Fusing
specification
WHY
To check against
RnD
specification for
conformity
To check against
RnD
specification for
conformity
To ensure no
discolouration,
no adhesive, no
bubbling coming
out shell
To ensure
durability of
bonding
To check bond
strength and
variation in
shrinkage
As a ready
reference for parts
that are to be
fused
As a ready
reference
HOW
Thermal stripe/
digital meter
WHO
Quality
controller
WHEN
Once in 2
hours
Stop Watch
Quality
controller
Morning and
evening
Visual
Quality
controller
Once in 2
hours
Spring balance/
manual
Quality
controller
Morning and
Afternoon as
per the
buyers
specification
Once in a day
Quality
controller
Visual display
Cutting
supervisor
During entire
run of the
style
By interlining test
report or approved
fusing specification
Cutting
supervisor
During entire
run of the
style
Page 84
15.3.3
Standard
operation
procedures
for
fusing
HOW
Stripe/
digital meter
WHO
Mechanic
/ Quality
controller
WHEN
Morning
and after
noon
Stop Watch
Mechanic
/ Quality
controller
Morning
and after
noon
Control
knobs
Mechanic
/ Quality
controller
Morning
and after
noon
As per the
manufacture
rs manual
guidelines
mechanic
As
stipulated
by the
manufactur
er
mechanic:
S.No.
1
WHAT
Temperature
Time
Pressure
Machine
cleaning
WHY
To set the fusing
machine as per the
RnD or approved
specification
To set the fusing
machine as per the
RnD or approved
specification
To set the fusing
machine as per the
RnD or approved
specification
Daily maintenance
Page 85
16. SEWING DEPARTMENT

The sewing department consists of the actual work floor in the production unit. The cut
parts are received from the cutting department and data is recorded in the following
format:
Style:
Date:
Country:
Time:
S. no.
1.
2.
Cut no
3
3
Prepared by
Marker
3
4
Colour Size
Black M
Black L
Issued by
From bundle
7192827
7192837
To bundle
7192836
7192846
Received by
F Ply
277
180
T Ply
476
379
Cutting supervisor
After receiving the cut parts they are again counted by the receiver to counter check. The
setting and process flow of the sewing department changes with every order. Before the
execution of the order, the operation breakdown of the garment is done and operation
bulletin is made. The operation bulletin acts as the tool for the line balancing and helps in
production target achievement. According to this breakdown the sewing line is set so that
the through put time can be reduced for the smooth production flow. The production
bulletin prepared for the sewing comes from the CIED department.
All sewing operators are provided with a production slips (time sheet) in which bundle
stickers are stuck as soon as bundle operation gets completed. The work slips are counted
after every two hours to prepare the manual production report as well as the barcode are
Page 86
scanned and hourly production status is fed into the production management system. It
helps to check the efficiency of each operator at regular intervals. At the end of the day
total production report is made.
There are five checkpoints in each line to check the quality. If any problem occurs the
production manager and executives gets into immediate action and rectification is done for
producing any quality garment.
The sewing department is divided into four parts:

1. Line A
2. Line B
3. Line C and
4. Kaja Section
16.1 Line Section:

Lines A, B, and C are general sewing line which execute all the main sewing operations.
The workflow of the section has been described below with the help of ANN TAYLOR
ladies bottom order which was running during our tenure.
The garment style has been divided into nine groups and further subdivided into detailed
production procedures. The Operation breakdown for the style is as follows:
1.FLY
Make Flybox
Turn Flybox
Press Flybox
Serge Fly & Flybox
Topstitch Flybox
Tack Flybox O/L Threads
2.WAIST BAND
Make Top Waistband Face
Attach Top Waistband Middle Waistband
Join Waistband Panels (3 Pc)
Dummy Stitch Waistband
Press Waistband
Attach Inner Waistband To Outer Waistband
Mark Waistband
Make Waistband
Page 87
Turn Waistband Face

Attach Tunnel Patch to Waistband
Make Lable
Attach Lable To Back
3.SIDE POCKET
Serge Pocket Facing
Serge Front Pocket Bag
4.BACK FLAP
Make Flap
Turn Flap (Rectangular)
Topstitch Flap
Ready Cut Flap
Attach Tab to Flap
5.FRONT
Serge Front Rise
Attach And Topstitch Fly
Attach Zipper To Fly
Attach Flybox To Zipper
Topstitch Front With Flybox And Zipper
Attach Facing Scoop Pocket to Front
Turn And Press Front Pocket
Topstitch Front Pocket Mouth
Attach Pocket To fornt
Stay Stitch Front Pocket At Side And Waist
Sew J-Stitch
Sew Front Rise
6.BACK
Mark Back For Welt Pocket And Dart
Sew Darts
Press Back Dart
Topstitch Dart All round
Serge Pocket Facing
Make Welt Pocket
Page 88
Turn Welt
Press Welt
Tack Welt
Topstitch Down Welt
Topstitch Top Welt
Serge Welt Pocket Bag
Pattern Stitch On Welt Pocket Bag
Attach Back Pocket Flap To Back
Topstitch Back Pocket Flap
7.SUB ASSEMBLY
Match Front With Back
Sew Side Seam
Topstitch Side Seam
Sew Inseam
Sew Back Rise
Topstitch Back Rise
Topstitch Back Rise
Attach Label at Side
8.ASSEMBLY
Mark Body For Loops & Waistband
Match Waistband With Body
Attach Waistband To Body
Close Waistband Face
Topstitch Waistband All around
Hem Bottom
9.FINISHING
Attach Button to Waistband
Keyhole Waistband
Attach Button To Back
Keyhole Flap
Bartack Crotch & Fly
Bartack Front Pocket
Bartack Welt Pocket
Attach Snap To Waistband (Female)
Page 89
Attach Snap Button (Male)
16.2 Kaja Section:

Process Flow:
Kaja Marking
Kaja Making
Button Marking
Button attach
Button shank wrapping
Button and Kaja checking
Sticker removing
Page 90

Kaja Marking and Making:
This Section receives the sewn garments. Initially
templates and pins are used to mark the kaja position. Now kaja are made the marked
position by the specialised machine.
Button Marking and Attaching: Similarly with the help of button attaching machine
buttons are attached at the marked positions.
Button Shank wrapping: Now the button shank is wrapped by the button shank
wrapping machine to provide strength and tight hold to the buttons on the fabric surface.
Button and Kaja checking: There is a separate inspection table for the kaja section where
proper button and kaja placement and alignment are checked. If any discrepancies found
they are again sent back for correction.
Sticker Removing: Now finally stickers are removed from the garments and they are
further sent to the washing or the finishing department.
Page 91
16.3 Quality Checking In Sewing Room

Each production step is followed by a quality checking point. The quality parameters that
are taken into consideration at each quality check points for bottoms are described as
follows:
Quality Checking Scope for Front:
1. SPI: 7 for top stitch and SPI: 10-12 for attaching.
2. Front pocket opening should be both ways (horizontal and vertical)
3. J- stitch width 1 3/8 and J- stitch should be per pattern shape with 1/4 DNLS
4. Front rise attaching should be on curve and avoid puckering.
5. Front pocket top stitch should be even and avoid puckering.
6. Front top stitch and front pocket opening should be 5/16 DNLS.
7. Front pocket shape should be as per the pattern and both ways identical, avoid high
and low.
8. Down fly shape should be as per the pattern.
9. Front pocket opening should be 1/8 loose.
10. Front pocket bag seam piping should be even all around.
Quality Checking Scope For Back:
1. SPI: 7 for top stitch.
2. Back pocket dart DNTS distance should be 5/16
3. Flap should be centred to welt with 5/16 DNTS.
Page 92
4. Back welt pocket should be balanced both sides.

5. Back pocket DNTS should be 5/16 even all around and as per the pattern shape.
6. Button hole should be centred to the flap.
7. Back welt pocket smiling not allowed
8. Back pocket bag seam piping should be even all around.
9. Avoid pocket high low both ways (horizontal and vertical).
10. Flap tab should be centred to the flap.
Quality checking scope for side attachment:

2. Side seam DNTS width should be 5/16 even in both the panels.
3. Side seam over lock quality should be neat and clean with SPI: 10
4. Edge stitch should be on the right side of the wearer.
5. Avoid loose and skip stitches at the double needle top stitch.
6. avoid puckering at inseam over lock and SPI should be 14
7. Back rise DNTS should be and avoid puckering and loose stitches.
8. Front rise should be single needle edge stitch.
Quality Checking Scope For Waist Band Attachment:
2. Waist band joint and side seam should match.
3. Waist band attaching seam margin should be even.
4. Avoid puckering while waist band attaching.
5. Waist band high low is not allowed.
6. Waist band centre front should be straight.
7. Crotch joint should match.
8. Main label should centre to the waist band at centre back.
9. Back pocket and lip high low should be avoided.
10. Face closing should be straight and avoid run off stitches.
Quality checking scope for end of the line:
Page 93
2. Waist band height 1 even all over.

3. Waist band finishing should be proper , avoid puckering and roping.
4. Waist band high low not allowed.
5. Waist band roping inside not allowed.
6. Waist band top stitch should be even avoid joint stitches.
7. Waist band should be straight at centre front between hem height double fold
while roping and puckering should be avoided.
8. Waist band lip should be even all around.
9. Eye let placement should be as per the sample
16.4 Machine and Equipment details in sewing department:

16.4.1 Machines:
Machine
SNLS (without UBT)
SNLS (with UBT)
3- Thread overlock
4- Thread overlock
5- Thread overlock
Welt pocket maker
SNLS Edge cutter
Chain stitch
Double needle lock stitch
Snap attaching
Feed of arm
Bartack
Keyhole (kaza)
Button attach
Button hole
Button shank wrapping
No.
18
2
120
20
4
3
15
2
18
10
2
40
4
2
7
2
2
3
1
1
Make
JUKI
Brother
JUKI
Brother
JUKI
JUKI
JUKI
Beiser
JUKI
JUKI
Brother
JUKI
Ngai Shing
JUKI
Brother
Brother
JUKI
JUKI
Brother
Ascolite
No. of operator/ machine

1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Items
Checking tables
No.
18
Make
Local
Page 94
Hangers
Fans
Tube light
Exhaust fan
Chairs
9
90
312
7
270
Local
Orient/Usha
Elite
Gec Alsthom
Local
17. FINISHING DEPARTMENT

The machine setting and work flow of the finishing department also changes with the
order and style. The process flow described below is according to the ANN TAYLOR
ladies bottom order.
Process Flow:
Washed Garment received
Draw cord
Trimming
Inside Checking
Stitching repair
Stain removal
Page 95
Thread suckering
Bulk ironing
2nd Garment checking
Security label attaching
Tag attaching
Final stain removing
Belt tieing
Final ironing and folding
Page 96
Draw cord tacking
Measurement Checking
Security label attaching
Tag attaching
Final stain removing
Belt tieing
Final ironing & folding
17.1 A brief description of the process flow in Finishing Department:

Washed Garment Receiving: The unit do not have the in-house washing department so
the garments are sent to the central washing unit at D-16. Generally, it takes one day for
the washing and washed garments are received after one day.
Page 97
Draw Cord: This step is for this style only as per the design requirement.
Trimming: After this the garments are sent to the trimming table, where extra thread is
trimmed from the garment and a trimming report is also maintained as follows:
S. No
Name of
Operator
9:15 10:15
11:15
...
5:00
1.
2.
3.
4.
5.
22
22
22
10
22
20
13.
22
242
10
235
477
20
240
2190
Total
Grand total
Inside Checking: After receiving the garments, inside checking is done to check out
defects like broken stitches, skip stitches and uncut threads etc. After checking the
garment each checker has to stick a sticker at each garment, inspected by her. Each sticker
has a particular number assigned to that checker to track out which garment is being
inspected by which checker. A set format is given to each checker to maintain the record
of defects at various areas like A/H, cuffs etc. It also helps to find out the total garments
inspected by the checker and percentage defectives found.
Stitch Repairing: In case of any sewing defect the respective garments are sent back to
sewing line to repair it immediately. However, finishing department has its own tailors to
repair the minor faults. To rectify defects, checker puts the clip at the defective garments
after tying the defective area with the help of thread. Each clip has a particular no assigned
to each checker. After repairing the garments are sent back to the respective checker to
recheck
Stain Removing: As each garment suffers multiple handling right from receiving the
fabric to the finishing, it leads to stain marks on the garments. So, the garments are sent to
stain removal section to remove the stains from the garments. These stains are removed by
stain removal guns in which white petrol is used to remove the stains. Sometime they also
Page 98
use stain removing sprays. Here, also each operator sticks the particular sticker assigned to
her to track out the garment handled by her.
Thread suckering: Now the garments are exposed to the thread sucker machine where
the left over cut threads are sucked from the garments.
Bulk ironing: The department has fourteen pressing work stations, where the garments
are passed for the pressing.
2nd checking: Now the garments are sent to 2nd checking to find out fabric defects, shade
variation, shape distortion (bottom shape, cuff and placket shape etc.), minor stitching
defects etc. After checking the garment each checker has to stick a sticker at each garment,
inspected by her. Each sticker has a particular number assigned to that checker to track out
which garment is being inspected by which checker.
At the 1st checking stage, major concern is stitching defects and extra threads only.
Draw cord tacking: This step is also style specific as per the design of this garment only.
Measurement Checking: The garments are now sent to the measurement checking table
where all critical measurements are taken and matched according to the specifications and
tolerance.
Security Label attaching: This is also a buyer specified attachment as in this style RFID
security labels are attached.
Tag attaching: Here price tags and wash care labels along with the extra buttons are
attached with the garment.
Final Stain removing: Again stain removing is done by the sprayer before final packing.
Belt tieing: This is also specific to this style only as per the buyer specification.
Final folding and packing: It is the final step in which garment is folded as per the
packing instructions and packed in the poly bags.
Page 99
All garments are passed to needle detection machine to meet the safety compliance
of the buyer before the packing. But it is done for a few buyers only.
17.2 Machine and Equipment details in finishing department:

17.2.1 Machines:
Machine
Needle detector
Pressing work station
Thread sucker
No.
1
14
1
Operators/machine
2
1
1
Make/ Model
HASIMA/ HN740 G
Ramsons Veil
Ramsons
Items
Checking tables
Storage bin
Fans
Tube light
No.
55
3
48
143
Make
Local
Ramsons
Orient/Usha
Elite
Page 100
18. PACKAGING DEPARTMENT

Process Flow:
Receive finished garment
Shade checking
Placing shade sticker
Garment alignment check
Packet concealing
Barcode scanning
Size sorting
Packing in carton
Sent to store
Page 101
18.1.1 A brief description of the process flow in Packaging Department:

The finished garments kept in the polyethylene bag are sent to the packaging Department,
where firstly shade checking is done in order to the matching the shade written on the
polyethylene bag with the actual garment pieces. Shade checking is done on a ordinary
wooden table with tube light mounted on the top by the stand and the inspection area is
enclosed from three side by thermocol sheets. After that packets are sent to another table,
where an operator puts shade sticker on the approved packets and another worker conceal
the packet after checking the proper alignment of the garment inside the packet. Now, the
barcode scanning of the packed garment pieces is done and all data are fed into the
computer. Scanned pieces are stacked and separated on the basis of sizes and shades on
the other table, where garment polybags are kept in the cardboard cartons and cartons are
concealed by the adhesive tape. Only 10 pieces of garments are kept in one carton. These
cartons are again sent to the stores by the trolleys and one trolley has the capacity of 18
cartons. The carton dimensions and specifications are given by buyer. Generally two
dimensions are used i.e. for bottoms 37*30*18 cm3 and for shirts 66 *39* 22.5 cm3.
18.2 Equipment Details in packaging Department:

Items
Tables
Barcode reader
Weighing machine
Fans
Tube
Exhaust fans
Trolleys
No.
3
1
1
6
12
6
5
Model/Make
Local
ARGOX
F6AP/ ATCO
Usha
Philips
Usha
Local
Page 102
18.3 Polybag, Barcode, Carton Sticker Details

Descriptions printed on the Polybags:
Example:
DEPT
STYLE
COLOUR
SIZE
P.O.
SHADE GROUP
#69
#208993
#7440
#6P
#971875
B
Barcode details fed in the Computer per carton:

Example:
CTN NO.
389
389
389
389
389
389
389
389
389
SHADE
A
A
A
A
A
A
A
A
A
COLOUR
SEA- SIDES
SEA- SIDES
SEA- SIDES
SEA- SIDES
SEA- SIDES
SEA- SIDES
SEA- SIDES
SEA- SIDES
SEA- SIDES
SIZE
OOP
OP
2P
4P
6P
8P
10P
12P
14P
ACT PCS
1
1
1
1
1
1
1
1
1
SCAN PCS
1
1
1
1
1
1
1
1
1
Sticker details on the carton:

Example:
P.O.(Purchase order number)#
DEPT
STYLE
COLOUR
SHADE LOT
SIZE
QTY
PACK SKU
DIM
GROSS WEIGHT
NET WEIGHT
PACK RATIO
972130
59 - MISSY
203860
1295
A
10 pcs.
81230815
37*30*18 cms
4.450 Kgs.
3.700 Kgs.
OOP/1 OP/2 2P/3 4P/2 6P/2 8P/2 10P/2 12P/1
14P/1 TTL/14
Page 103
19. QUALITY CONTROL DEPARTMENT

To ensure the right quality of the product is one of the important objectives of the
company.
Therefore, Quality control is applied at every stage of the garment i.e.
spreading, cutting, sewing, washing, finishing and packaging..

There is 100% inline inspection and end line inspection for the garments. Hourly reports
are made for the checking and follow up of the repairs.
Statistical process control technologists are employed to improve on the quality standards.
In ACL Statistical process control starts from laying and cutting. An Statistical process
control checker fills up the spread quality report and control quality report, there reports
indicates any defects or imperfections in tension of lay, pattern sizes, width variation etc.
In sewing Four Statistical process control checkers carry out Statistical process control
checking at 4 critical points, also the factory quality control team go on taking rounds of
line. The merchandiser, buyer, quality checker and R&D people come for inspection too.
AQL (Accepted Quality level) is set as per the buyer recommendations.
The number of inline checkers and end line checkers are as follows:Inline checkers: 3
End line checkers: 2
19.1 List of the details to be checked in Cutting Department:
SL. NO
Version
Style No
Fabric
Cut No
Lay Length
No. Piles
Table Marking
Marker Placing
Ends
Marrow Goods
Page 104
Leaning
Tension
Counts
Marker
Total Defects
Sign QC
Cutting Super
19.2 List of the defects checked during the inline and end line checking,
and the quality audits:
fabric defects
colour shading
broken stitches
skip stitches
uneven SPI
loose stitches
insecure button/snap
high low
raw edge
needle holes
unwanted pleats
missing operation
run off stitch
incorrect labels
stains/dirt marks
stickers
uncut thread
out tolerance
Page 105
19.3 Audit Flow Chart in Ambattur Clothing Limited
Before Wash Audit
After Wash Audit
Before Packaging Audit
External Audit by R&D

Department
19.3.1 Sample Selection Techniques at different stages of the Quality Audit:

Type of Audit
before finishing
Before wash/ after
finishing
After wash
No of
samples
7
Total no of the samples
Rejection level
Total production one

hour
500
500
2 minor/ 1 major
defect
2 minor/ 1 major
defect
2 minor/ 1 major
defect
NOTE:
After external audit is done buyer representative is invited for the audit. The AQL
depends on the buyer. E.g. the AQL for Levis is 2.5 whereas for J-JILL it is zero
(0).
All the quality inspection sheets are in the annexure.
Page 106
20. MAINTAINENCE DAPARTMENT

The department is run by two senior mechanics and three helpers who ensure the smooth
running of the production. The responsibilities of maintenance department can be divided
as follows:
1) Preventive maintenance
2) Break down maintenance
3) Spares inventory
4) Arrangement of machines, folders and attachments
5) General maintenance
6) Work shop
20.1 Preventive Maintenance Procedure

Daily check schedule of mechanics (during working hours) includes:
20.1.1 Mechanical maintenance: on daily basis
Needle point sharpness, bent
Oil leakage
SPI
Seam quality
Thread path
Attachment positions / alignment
20.1.2 Electrical maintenance:
One electrician takes care of all the sewing floor and checks all the live lines for
insulation.
Weekly inspection and cleaning of all the electrical lines of any foreign materials
Page 107
and rectifying loose connections
Cleaning of panel boards on a fortnightly basis
20.2 Breakdown Maintenance

20.2.1 Mechanical maintenance:
Each line is attended by a mechanic who will take care of breakdown maintenance in that
line and his functions can be summarized as follows:
Reports to chief mechanic who looks after all the lines.
Maintains a breakdown log book where the machine down time is noted.
Machines with major problems are sent to the workshop.
Line mechanic also maintenance a log book for broken and blunt needles.
20.2.2 Electrical maintenance:

An electrician is also deputed to take care of electrical maintenance on the sewing floors
Any major problems are reported to head of breakdown maintenances.
20.3 Spares Inventory

It includes:
Following buyer compliance
Maintaining needle log book
Broken needle is affixed completely ( including the broken part ) in the prescribed
format
If the broken part cannot be traced, the garment around that particular area will be
passed through needle detector
Blunt and bent needles are collected in a sealed box and audited by the concerned
buyer the QC every so often.
Needle detector is calibrated twice a day with the gauges and readings are
Page 108
documented.
20.4 Arrangement of Machines, Folders, and Attachments
The machines, attachments and folders requirement list for new style is given by
the production manager at pre production meeting
The requirement list is reconciled with the stores stock and items that are not
available indented giving the full specification of the purchase department
All the materials that are received from supplier are checked 100% for quality and
specification by the store keeper. The material stock is updated in the spares
registers with all the relevant details.
20.5 General Maintenance

It includes following:
Cleaning the machines completely from stand to machine head
Cleaning of oil ( taking the foreign materials from the oil reservoir)
All machines are provided with eye guard and finger guard
The band knife and cloth cutting machines operators are given metal gloves to
avoid accidents
All power points are provided with earthing to avoid accidents.
20.6 Workshop
Workshop involves the repair and fabrication of the damaged machine and machine parts.
Folders and attachments are as per the requirements of sewing line. Some of the
attachments fabricated here are also sent to other units of the company.
Page 109
21. PROJECT
AIM: Cutting and Sewing Department Process Analysis for increasing productivity in the
SP 10/8 unit.
DURATION: 7 days
METHODOLOGY APPLIED: Analysis of test reports and working procedures to find
out the deviation from the standard operating procedures.
INSPECTION AREA GIVEN BY THE FACTORY MANAGER:
In Cutting Department:
Shrinkage and shade sorting
Fabric relaxation
Cut Quality
Damage Cutting
Production time
In Sewing Department:
Pre production operation
In line Problems
DATA COLLECTION AND ANALYSIS:

In cutting Department:
Shrinkage and shade sorting: The test report sent by the MMC is followed and
proper roll segregation is done. Therefore there is not any problem.
Page 110
Fabric relaxation: recommended fabric and lay relaxation time is given so problem
regarding uneven lay length and stretching is not found. Lay checking is also
carried out and the bowing is corrected by making notches as well as pulling the
fabric in opposite direction.
Cut Quality: lay height is set according to the buyer specification as well as the
nature of the fabric. For confirming proper cut quality 100% panel checking is
done as well as from each cut block top, middle and bottom panel are matched
against original pattern as well as each other for the exact and even measurements.
So, there is no problem regarding the cut Quality.
Damage Cutting: End bit of the fabric which is in production run are kept in store
and if any damage part in the bundle is found then according to the shade again
parts are cut and damaged parts are replaced in the bundle. Thus, again the same
ticket number is allotted to the cut pieces and sent to the sewing departments.
Production time: There is no time lag has been found in the cutting room. All
orders are cut before or on the scheduled time.
Suggestions:
The marker efficiency is generally 70% so there is no measures have been taken to
utilize waste fabric in constructive way. Those can be used for the operators
training as well as for their stitch practices.
Whenever new blade is fed in the straight knife frayed edges and wavy marks are
seen on the lay sides. This should not be ignored.
The capacity of the cutting room is under utilization, it can take approx. 5% more
orders.
Page 111
In Sewing Department:
1. Pre production operation:
Production manager, executive and supervisor make the operation breakdown

according to the CIED recommendation as well as the convenience and comfort of
operators. This is done 3 days before the production in the pre production meeting.
Operators and tailors are assigned for the each and every operation in one day
advance.
List of the machineries and folders required for the production are given to the
maintenance department three to seven days in advance.
Capacity of the operator: at the time when any critical operation or bottleneck is
found in the line, then by time study operators capacity for an hour is calculated
by production manager/ executive.
Production executive / supervisor also analyses the way of stitching and operators
feedback may suggest some new innovative ideas for doing that operation.
Therefore nothing objectionable found in the preproduction operations.

2. Inline Problems:
Absenteeism: Through out the period of our internship we observed it as a one of the
major problem in order to increase productivity. This leads to major line imbalancement
and every day undesirable time and production is lost due to this. Therefore some time it is
Page 112
difficult to overcome the start up losses. However, a full function line can produce up to
850 pieces per day but it is rarely achieved. It also causes non uniformity in the stitches as
different people have different way of stitching. Due to absence of a skilled tailor, stitch
quality also deteriorates as well as that place has to fill with two semi skilled operators.
Absenteeis
Workers
Date
m%
present
7-Jun-07
8-Jun-07
9-Jun-07
11-Jun-07
12-Jun-07
13-Jun-07
14-Jun-07
15-Jun-07
16-Jun-07
18-Jun-07
19-Jun-07
20-Jun-07
21-Jun-07
22-Jun-07
23-Jun-07
25-Jun-07
26-Jun-07
27-Jun-07
28-Jun-07
29-Jun-07
30-Jun-07
2-Jul-07
3-Jul-07
4-Jul-07
12.94118
10.58824
7.058824
16.47059
12.94118
10.58824
11.76471
11.76471
11.76471
11.76471
11.76471
11.76471
11.76471
11.76471
11.76471
11.76471
11.76471
8.235294
8.235294
8.235294
8.235294
8.235294
8.235294
10.58824
74
76
79
71
74
76
75
75
75
75
75
75
75
75
75
75
75
78
78
78
78
78
78
76
The absenteeism percentage in Line A is given below for the reference.
Page 113
Graphical Representation of Absenteeism percentage in Line A
Page 114
18
16
14
12
10
8
6
4
2
0
7- 8- 9- 10- 11- 12- 13- 14- 15- 16- 17- 18- 19- 20- 21- 22- 23- 24- 25- 26- 27- 28- 29- 30- 1- 2- 3- 4Jun-Jun-Jun-Jun-Jun-Jun-Jun-Jun-Jun-Jun-Jun-Jun-Jun-Jun-Jun-Jun-Jun-Jun-Jun-Jun-Jun-Jun-Jun-Jun- Jul- Jul- Jul- Jul07 07 07 07 07 07 07 07 07 07 07 07 07 07 07 07 07 07 07 07 07 07 07 07 07 07 07 07
There is very less technical knowledge about the machine and stitches to the
workers.
There is not proper IE support to the production managers and the executives in the
unit.
Suggestions:
Absenteeism is major problem. Existing incentive scheme of Rs.600 for 100%

attendance is not enough to handle this problem So, the incentive scheme should
be in such a way that it should attract majority and should be achievable for them.
Recommended Incentive Scheme

Page 115
Leave per Month

No Leave
1 day
2 days
3 days
More than 3 days
Incentive
Rs. 600 + Medical Facility
Medical facility
No Medical Facility
There should be one hour training programme for the new operators after every 15
days.
There should be monthly general meeting between high authority and the operators
so that there problems can be seen from the grass root level.
New operator should spend every day first five minutes on the practice stitches and
these should be submitted as an assignment of the training programme.
There should be easy access to the IE tools and services for the production
managers and supervisors, so that their time can be effectively and efficiently
utilised.
Page 116
22. CONCLUSION
The industrial internship in the Ambattur Clothing Limited has exposed us to the different
and vivid facets of the garment field. Apart from the theoretical and practical knowledge
the internship has given us the opportunity to use our knowledge and skill in solving the
problems on the production work floor. The practical experience imparted by the
internship has helped us to visualize and analyse the ground level details in order to
understand the complexity of any problem. At the one end industrial experience had
conveyed the importance of professional and corporate approach towards the work and life
mean while at the other it helped us to understand the importance of emotional quotient in
increasing the productivity. It helped us to realize the importance and need of team work
in order to achieve success.The two months stay at Chennai has also given us the
opportunity to interact with the people of different culture, language and background.
Altogether it was a wonderful experience and memory to be treasured life long.
Page 117

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APPAREL INDUSTRY INTERNSHIP

AMBATTUR CLOTHING LIMITED

DEPARTMENT OF FASHION TECHNOLOGY

This is to certify that the following students of Fashion Technology Department

INDUSTRY INTERNSHIP AT AMBATTUR CLOTHING LIMITED, CHENNAI

INDUSTRY INTERNSHIP AT AMBATTUR CLOTHING LIMITED, CHENNAI

The Industry internship is a means to provide fresh college student a practical

INDUSTRY INTERNSHIP AT AMBATTUR CLOTHING LIMITED, CHENNAI

COMPANY FACT FILE

H.R. AND WELFARE DEPARTMENT

MARKETING AND MERCHANDISING DEPARTMENT

PRODUCT DEVELOPMENT DEPARTMENT

A BRIEF DESCRIPTION OF DIFFERENT STAGES

PRE PRODUCTION DEPARTMENT

INDUSTRY INTERNSHIP AT AMBATTUR CLOTHING LIMITED, CHENNAI

PM AND GRADING DETAILS

COMPONENTS OF THE SAMPLING DEPARTMENT

COMMENTS FROM BUYER

BUSINESS MANAGEMENT CENTER

PRODUCTION MANAGEMENT CENTER

CENTRAL INDUSTRIAL ENGINEERING DEPARTMENT

BUYING HOUSE DOCUMENTATION

MATERIAL MAINTAINENCE CENTER

FABRIC QUALITY CHECKING

INDUSTRY INTERNSHIP AT AMBATTUR CLOTHING LIMITED, CHENNAI

WORK FLOW IN THE WASHING UNIT FOR BULK PRODUCTION

LAUNDRY MACHINERIES DETAIL

PRODUCTION UNIT: ACL SP 10/8

FACT SHEET: ACL SP 10/8

ORGANISATIONAL CHART: SP 10/8

CUTTING DEPATMENT LAYOUT

SEWING DEPATMENT LAYOUT

FINISHING DEPATMENT LAYOUT

PACKAGING DEPATMENT LAYOUT

A BRIEF DESCRIPTION OF THE PROCESS FLOW

A BRIEF DESCRIPTION OF THE PROCESS FLOW

A BRIEF DESCRIPTION OF THE PROCESS FLOW

M/C & TABLE DETAILS

QUALITY CHECK IN CUTTING ROOM

S.O.P. FOR SPREADING AUDITOR

S.O.P. FOR CUTTING SUPERWISOR

S.O.P FOR FUSING MECHANIC

INDUSTRY INTERNSHIP AT AMBATTUR CLOTHING LIMITED, CHENNAI

A BRIEF DESCRIPTION OF THE PROCESS FLOW

QUALITY CHECKING IN SEWING ROOM

MACHINE ANE EQUIPMENT DETAIL

A BRIEF DESCRIPTION OF THE PROCESS FLOW

MACHINE AND EQUIPMENT DETAIL

A BRIEF DESCRIPTION OF THE PROCESS FLOW

POLY BAG, BARCODE, CARTON STICKERS DETAIL

QUALITY CONTROL DEPARTMENT

LIST OF THE DETAILS TO BE CHECKED

LIST OF THE DEFECT CHECKED

AUDIT FIOW CHART IN ACL

SAMPLE SELECTION TECHNIQUES

PREVENTIVE MAINTAINENCE PROCEDURE

INDUSTRY INTERNSHIP AT AMBATTUR CLOTHING LIMITED, CHENNAI

ARRANGEMENT OF MACHINES & ATTACHMENTS

INDUSTRY INTERNSHIP AT AMBATTUR CLOTHING LIMITED, CHENNAI

INDUSTRY INTERNSHIP AT AMBATTUR CLOTHING LIMITED, CHENNAI

1.2 Company Fact File:

Name of the Company

Ambattur Clothing Limited