Modelama Exports - Apparel Manufacturing Internship Presentation by Vinay Prajapati, Atul & Navneet.

1. Under the Guidance of Presented by
Mrs Vasundhara Chaudhary Atul Dwivedi, Navneet Yadav and
Associate Professor Vinay Prajapati; M.F.TECH, SEM-III
National Institute of Fashion Technology, Gandhinagar
19-09-2011 1

2. COMPANY NAME MODELAMA EXPORTS PVT LTD
ADDRESS PLOT NO. 105/106, UDYOG VIHAR, PHASE-1
GURGAON, HARYANA- 122015
HEAD OFFICE B-57 OKHLA INDL. AREA PHASE-1
NEW DELHI- 110020 INDIA
TELEPHONE 0124-4008105
FAX 0124-4008108
E MAIL info@modelamaexports.com
WEBSITE www.modelamaexports.com
YEAR ESTD. 1979
OWNER MR. LALIT GULATI
DIRECTORS MR. SANJAY GULATI
MR. GAGAN GULATI
MR. GAURAV GULATI
ANNUAL TURNOVER 60 MILLION (OF ALL FACTORIES)
MARKET 100% EXPORT
TOTAL COVERED AREA 4,00,000 SQ. FT.
TOTAL WORKING FORCE 5500
IN HOUSE/FABRICATION/BOTH BOTH
PRODUCTION CAPACITY 8 MILLION/YEAR
19-09-2011 2

3. 19-09-2011 3

4. 19-09-2011 4

5. Vision
Modelama will guide its business activities maintaining a balance between ethical
values and corporate objectives. The company will strive to achieve its goals by
executing its strategic plans and caring for the profits of all the stake holders.
Mission
Modelama has a vision to establish itself as a multi-product and multi-services
business conglomerate. It is committed to expand the spheres of its business activities
into newer sectors in the years ahead. The company is confident of building the same
brand image in all areas of its operations that it has in garments and home furnishing
sectors
19-09-2011 5

6. 19-09-2011 6

7. 19-09-2011 7

8. 19-09-2011 8

9. HARYANA
184, Udyog Vihar, Phase-I, Gurgaon 105, Udyog Vihar, Phase-I, Gurgaon
106, Udyog Vihar, Phase-I, Gurgaon 200, Udyog Vihar, Phase 1,Gurgaon,
Mervyns 201, Udyog Vihar,Phase 1 204, Udyog Vihar,Phase 1, Gurgaon
660, Udyog Vihar, Phase-V, Gurgaon Plot No-5, IMT Manesar, Sector-4, Gurgaon
Plot No 7, IMT Manesar, Sector 5,IMTManesar, Plot No 18, IMT Manesar, Sector 5,IMTManesar,
Gurgaon Gurgaon
Plot No 89, IMT Manesar, Sector 8, IMT 529, Phase-I, Bahrhi, Dist. Sonipat
Manesar, Gurgaon
Plot No 1, Sector 8, Bawal, Dist. Rewari
CHENNAI
Plot No - K 46/47/48/49, Appragel Park , Irun
Gattukottai. Dist. Tairnatur
DELHI
B-33, Okhla Industrial Area, Phase -1, New Delhi
19-09-2011 9

10. PRODUCT
BUYER DEVELOPER MERCHENT SAMPLING FABRIC
BUNDILING MARKER
CUTTING SPREADING TESTING
AND TICKETING PLANNING
FINISHING AND
PRODUCTION WASHING PACKING DISPATCH
PRESSING
19-09-2011 10

11. 19-09-2011 11

12. A merchant is the person who acts as a link
between a buyer and vendor. He is the one who is
central or integral part of a garment industry.
19-09-2011 12

13. 1. Chase for fabric/trims prior to PCD date.
2. Size sets/PP/TOP samples-Monitoring and delivering.
3. Coordinating buying agency QA Inspection.
Responsibility
19-09-2011 13

14. This department is not buyer specific and work for all the buyers that company
caters to.
19-09-2011 14

15. PROTO
TOP
TYPE SIZE SET
SAMPLE
SAMPLE SAMPLE
MADE
MADE
FIT PP SHIPMENT
SAMPLE SAMPLE
MADE MADE SAMPLE
19-09-2011 15

16. 19-09-2011 16

17. 19-09-2011 17

18. 19-09-2011 18

19. 19-09-2011 19

20. SPREADING
MARKER LAYERING
CUTTING MANUAL/AUTOMATIC
TICKETING
FUSING
CHECKING
BUNDLING
TRANSFER TO PRODUCTION
19-09-2011 20

21. 19-09-2011 21

22. FABRIC IS LOADED ON SPREADING MACHINE
PERFORATRED PAPER IS SPREAD ON SPREADING TABLE
VACCUME IS TURN -ON IN THE SPREADING TABLE
AUTOMATIC/MANUAL SPREADING IS DONE
PROPER TENTION IS MAINTAINED WHILE
WHEN FINISHED, VACCUME IS TURNED OFF
MARKER IS SPREAD OVER IT AND PASTED BY TAPE
AIR FLOW IS GIVEN FROM BOTTOM
TRANSFERRED TO THE CUTTING TABLE
19-09-2011 22

23. Types of cutting devices:
1. 5 fusing machine
2. 16 straight knife
3. 6 edge cutters
4. 2 computer aided machines
5. 4 spreader
6. 1 round knife
19-09-2011 23

24. Parameters Value
Speed 100 m/min
Thickness can lay 30- 40 cm
Working width 2.5 meter
Length 20 meter
Suction Tables
Roll Weight 150 Kg
19-09-2011 24

25. Parameters Value
Speed 100 km/hr
Thickness can cut 6-7 cm
Cutting width 2.54 mtr
Cutting Length 3.5 mtr
Suction 4 kg/cm2
19-09-2011 25

26. Blade Size (inch) 5 6 7 8
Blade Size (cm) 12.7 15.2 17.7 20.3
Cutting Capacity (inch) 3 1/2 4 1/2 5 1/2 6½
Cutting Capacity (cm) 8.89 11.4 13.9 16.5
Stroke Size (inch) 1 1/8 1 1/8 1/4 1/4
Stroke Size (cm) 8.89 8.89 11.4 11.4
19-09-2011 26

27. 19-09-2011 27

28. MODEL HP-1000LW
POWER SUPPLY Three phase
HEATER：21.6kw
RATED OUTPUT
MOTOR：705W
FUSHING WIDTH 1,000mm
MAX.BELTSPEED 12.7m/min
MAX.PRESSURE 5kg/cm2
MAX.TEMPERATURE 198℃
HEATING TIME 6.5～31sec.
DIMENSIONS 4,327 X 1,606 X 1,255mm
WEIGHT (Approx)1,500kg
19-09-2011 28

29. PATTERN MAKING
DIGITIZING
STYLE/PATTERN DESCRIPTION
GRADING
CUT ORDER PLANNING
MARKER MAKING
PRINTING FOR CUTTING
19-09-2011 29

30. Modaris Main equipment used:
This software performs the following functions: •Pattern pieces
o Pattern making •Digitizer
o Pattern modification •Software
o Pattern digitizing •Plotter
o Pattern grading  FLY PEN
 ALYS-30
Diamino
This software is used for marker making. It can be manual or automatic.
Efficiency of marker as decided as per the garment in this seam allowances
are also added.
Optiplan
This software is used when buyers send uneven ratios.
19-09-2011 30

31. 1. Significant reduction in lead times.
2. Reduction in labour costs for generating new styles & modifying existing
ones.
3. Achieving significant reductions in fabric utilization.
4. Block’s images stored in computer.
5. Grading technique replaced by expert system. So that grading is now in
the form of tables and auto matched.
6. Percentage wasted; computed and displayed for each layout.
7. Fabric pattern constraints incorporate in the program.
8. Cutters replaced by CAD/CAM.
9. Wages reduced.
19-09-2011 31

32. 19-09-2011 32

33. Production floor follows Bundle system. Following are steps to start a production line:
Study the production file.
Study operation bulletin and set line accordingly.
Manpower – tailors and helpers.
Load and feeding lines.
Arrange buffer or work-in-progress.
Manufacturing.
Make daily production and to achieve targets accordingly.
Understand bottlenecks stage of production
19-09-2011 33

34. Shrinkage production pattern is issued to production floor from CAD department.
Ready patterns are made as per the requirement of production room.
Cutting receives from cutting department.
Cross checking of cut panels with patterns.
Bundling of cut panels is done.
Operation wise feeding of cut panel into the line.
Inline checkpoints.
Output of line.
Final checkpoints.
Auditing of checked pieces.
19-09-2011 34

35. To restore this aesthetic value, they are subjected to cleansing process like washing.
19-09-2011 35

36. Normal Wash
Desize Wash
Enzyme Wash
Stone Wash
Softener
Bleach
Acid Wash
Monkey Wash
Sand Wash
19-09-2011 36

37. Normal Wash Softener Wash
Process Time Process Time
Desizing 30 min Desizing 20 min
Enzyme 30-60 min Washing 30 min
Softener 20- 30 min
Stone Wash
Enzyme Wash
Process Time
Process Time Desizing 30 min
Desizing 30 min Enzyme 30-60 min
Enzyme 30-60 min Stone 20 min
hypo chloride 30 min hypo chloride 30 min
Neutralization 30 min Neutralization 30 min
Softener 20 min Softener 20 min
19-09-2011 37

38. After assembly, the garments now come for finishing- a key stage of garment
manufacturing process. Finishing is done to prepare the final garment according to
the quality standards of the buyer before packing it for shipment
19-09-2011 38

39. GARMENT SENT FOR
COMES FROM PACKING
PRODUCTION
washing ALTERATION REIRONING MEASUREMENT
INITIAL
PERSENTATION
THREAD CHECKING FINAL
/FINAL
CUTTING AND CHECHING
IRONING
SPOTTING
19-09-2011 39

40. Finishing Machines No. of Machines
Vacuum Table 60
Up Steam Table 5
Stain Removing Gun 13
Stain Removing W/S 3
Form Finisher 2
19-09-2011 40

41. Packing is the last stage where the finished garments are primed, organized,
geared up for the shipment to the buyer, the entire process from the way a
garment will be folded to the final labelling of the cartons is dictated by the
buyer’s specifications.
19-09-2011 41

42. 19-09-2011 42

43. 1. All garments packed in individual poly bags.
2. Poly bag sticker on poly bags, which may be printed by the factory
3. Order must be completed (packed, ready for shipment) prior to bulk
orders.
4. Order must be inspected and audited by the factory 100%.
5. Order must be of first quality, no repair or ungraded garments should be
in license shipments.
6. Order must be shipped 100% complete otherwise notified.
7. The packed goods are now ready to be passed through
19-09-2011 43

44. AQL Chart
No. of Cartons Sample Size Pass Fail
5-15 3 0 1
16-50 8 0 1
51-150 20 0 1
151-500 50 1 2
501-1200 80 1 2
1200-up 125 2 3
19-09-2011 44

45. 1. Incorrect quality
2. Carton labeling error
3. Incorrect Prepackaging
4. Carton not as per specified size
5. Use of wire of metallic strap
19-09-2011 45

46. Shipment Size Sample Size Gap AQL (2.5) Old Navy AQL
Level (4.10) Level
Pass/Fail Pass/Fail
0-500 20 1/2 2/3
501-1200 32 3/2 3/4
1201-3200 50 3/4 5/6
3201-10000 80 5/6 7/8
10100-35000 125 7/8 10/11
35000 > 200 10/11 14/15
19-09-2011 46

47. Working of IE is as follows:
 Calculating SMV
 Making Operation Bulletin
 Calculation of thread consumption
 Designing of work aid devices; Folders, Guide & Profiles
 Update SMV and finalize report
 Prepare work station layout
 Line setup
 Capacity check analysis and feedback
 Production study and increased efficiency
19-09-2011 47

48. MONITORING OF LOST TIME & OPERATOR PERFORMANCE
19-09-2011 48

49. During the project we observed that initially most of the times were going waste in
extra other activities like drinking water etc.
It was observed the operators were not flexible to work in the new line setup that’s
why their performance was not up to the mark.
With the Help of this project the IE department of the Modelama exports put some
pressure on the operator not to waste the time on other activities and increased the
average performance of Operator from 23.9 to 26%.
19-09-2011 49

50. 19-09-2011 50