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ACKNOWLEDGEMENT
I would like to express my gratitude to NATIONAL INSTITUTE OF FASHION TECHNOLOGY, KANNUR for giving this opportunity to do my internship session of learning, as well as my mentor Ms. Lalitha Lakshmi, Assistant professor, KD department – NIFT Kannur; who supported and guided me to do this project report on NORTH REPUBLIC, BANGALORE, which also helped me to do a lot of research Also, I would like to thank NORTH REPUBLIC, BANGALORE for supporting me and giving me this platform to learn more. My sincere thanks to my industrial mentor Mr. Mohan Varghese, Sourcing manager of North Republic. I thank all the department heads, operators and staffs for their co-operation and my special thanks to Mr. Raghunath, General Manager of North Republic. Finally I would like to thank my parents and friends who helped me a lot to complete the project report within the limited time frame.
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DECLARATION
I, the undersigned solemnly declare that the project report is based on my own work carried out during the course of our study under the supervision of my mentor Ms. Lalitha Lakshmi, Assistant Professor, NIFT Kannur and my industrial mentor Mr. Mohan Varghese, Sourcing manager of Updates clothing inc. I assert the statements made and conclusions drawn are an outcome of my research work. I further certify that the work contained in this report is original and has been done by me under the general supervision of my mentors. The work has not been submitted to any other institution for any other degree/diploma/certificate in this university writing the report.
RAGAPRIYA C.M BD/17/2445 KNITWEAR DESIGN DEPARTMENT
MENTOR
MS. LALITHA LAKSHMI ASSISTANT PROFESSOR KNITWEAR DESIGN DEPARTMENT NIFT, KANNUR
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TABLE OF CONTENTS
INDEX EXECUTIVE SUMMARY COMPANY PROFILE ABOUT THE COMPANY FACTORY LAYOUT ORGANISATION CHART WORK FLOW LIST OF MACHINERY FABRIC DEPARTMENT SAMPLNG DEPARTMENT MERCHANDISING DEPARTMENT CAD DEPARTMENT TRIMS STORE CUTTING DEPARTMENT SEWING DEPARTMENT QUALITY CONTROL DEPARTMENT FINISHING DEPARTMENT PACKAGING DEPARTMENT
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TITLE PAGE
The report is based on 8 weeks internship at Updates clothing inc, Bangalore, Karnataka
Prepared by RAGAPRIYA C.M, Semester 7, B.Des Knitwear design, National Institute of Fashion Technology, Kannur
The project will be under the guidance of Ms. Lalitha Lakshmi, Assistant Professor at KD department, National Institute of Fashion Technology
Date of submission on 26 December 2020
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AIM
The main aim of the industrial internship is to get quality training in the working atmosphere of the industry and to understand the process and functions done there.
OBJECTIVE
The objective of the internship is to get in-depth knowledge of the working of the industry in terms of organization structure, infrastructure, and corporate social responsibility and do small projects assigned by the industry The internship helps the students to get an overall understanding about the industry and the process happening there. It is a learning opportunity in which the intern can also use their skills and develop them by doing the projects assigned to them by the company.
EXECUTIVE SUMMARY
In the past two decades, the Indian textile industry in term of home textile, garments and accessories have witnessed a complete transformation in term of quality, market and product development as well as the expansion, looking from this perspective Updates Clothing inc, is a very good and important organization in its work. Internship at Updates Clothing inc has been a good exposure for the practical application of my learning. I gained knowledge about actual work culture of the company and how to deal with the people at a work place I did my internship at almost all departments but mainly in knitted tshirts at updates clothing inc.
DURATION
The duration of the internship was from 2nd November 2020 to 24th December 2020 a period of 8 weeks.
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COMPANY PROFILE
COMPANY NAME
UPDATES CLOTHING INC
ADDRESS
NO;5 2ND CROSS, BEGUR ROAD, BOMMANAHALLI, BANGALORE, KARNATAKA, INDIA
BRAND NAME
NORTH REPUBLIC
TELEPHONE
08049596910
E-MAIL
[email protected]
WEBSITE
www.northrepublic.in
YEAR ESTD
2011
MANAGING PARTNERS
MR. JIJU MR. ASWIN NARAYAN
TOTAL WORKING FORCE
10% inc, 90% outside
MONTHLY PRODUCTION
100,000 pcs
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INDUSTRY BUILDING
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ABOUT THE COMPANY
BRAND: NORTH REPUBLIC
North Republic is not about stuffed suits or uncomfortable jackets. It is all about fine shirts and Tshirts. They believe that every moment is an occasion. They design real clothes for real people. They create casual shirts, tshirts and trousers to take you from the office to the dinner party on the same day- making you feel your best. Founded in 2011, Updates clothing inc. combines well-designed and elaborate garments for work wear and leisure. North Republic is the result of passion to create something really good at affordable prices. Head-quarters in Bengaluru. Updates clothing Inc. brings forth 100% cotton and linen and denim shirts and single jersey and pique round neck and polo tshirts. All their shirts are produced in Bangalore on their very own production lines. Tshirts’ final productions are done at Tirupur. For them, every details matters, great design matters, great style matters. The difference between ordinary and extra-ordinary is that little extra. They are suppliers of exclusively designed and fabricated men’s wear and kids’ (boy) They are provided in M, L, XL0, 2XL, 3XL sizes in men’s wear, 6-16 sizes in kids sizes (shirts) Denim, M, L, XL, 2XL, 3XL They have state of the art facilities in house computer embroidery, printing facility, washing facilities and a sophisticated array of machinery. These facilities assist them in producing a quality assured range of garments for their valued clients. Ever since its starting, Updates clothing inc. jas never looked back, growing with strength as well as value it has achieved the production capacity of 100,000 pcs garments per month.
Product categories – Men’s and Kids’
This company has another brand named Frettini. Frettini is controlled under Pan India department.
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Fabric – Predominantly woven cotton fabric, cotton + doby cotton + matty, cotton+oxford, cavalry twill fabric, popline, matty fabric, denim, corduroy velvet, satin and linen For knits – Single jersey for round neck tshirts, Pique for Polo tshirts and 2 x 2 rib for collar and sleeve cuff
Design and product development
They believe in best talent and creative talent in the market to get something on the table for their principles as their own initiative and hence they have a full-fledged in design, product development and sampling department, they assure you that you shall get fresh ideas and style from them every season.
QUALITY CONTROL
The factory is equipped with “STATE-OF-THE-ART” imported stitching and washing machines. The internal quality control system ensure that goods of high quality are shipped to their customers
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FACTORY LAYOUT
Floor
Ground
1st floor
2nd floor
Departments
a. Fabric store b. Dispatch Department (Ware house) a. b. c. d. e. f. g. h. i. j.
Director’s office Manager’s office Merchandising department Out sourcing agency (Pan India) Designing Department Finance and Accounts Department HR Department Quality Assurance Department Conference hall Rest room
a. b. c. d. e.
Sampling Department CAD Department Studio Production manager office Online Department
3 floor
a. Cutting Department b. Stitching Department
4th floor
a. Material Stores
rd
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UPDATES CLOTHING IN ORGANISATION CHART MANAGING DIRECTOR JIJU KP
MANAGING PARTNER
MANAGING PARTNER
SUBEESH
ASWIN NARAYAN
HR DEPT
FINANCE DEPT
HEMA RAO
JAYAKUMAR
ADMINISTRATION
SOURCING DEPT
GENERAL MANAGER
MOHAN VARGHESE
RAGHUNATH
QUALITY ASSURANCE DEPT
MERCHANDISING DEPT
PRODUCTION DEPT
PRASANNA
JUSTIN JOSH
SHAKTHI VELU FABRIC DEPT KUMAR
CUTTING DEPT RAJ KUMAR
STITCHING DEPT BAIJU WARE HOUSE DEPT Page | 14 MIDHUN
WORK FLOW
Research development
Fabric
Testing
Product developing
Sampling
Market planning
Merchandising
Cutting
Production / sampling
Washing
Other like printing and embroidery
Finishing
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LIST OF MACHINERY
1. Single needle stitching machine 2. Double needle stitching machine 3. Computerized bartack machine 4. Buttonhole machine 5. Computerized cross-stitch lock stitch buttoning machine 6. Waistband attachment machine 7. 5 thread over lock machine 8. Cutting machine 9. Feed of arm machine 10. Computerized embroidery machine 11. Thread winding machine 12. Flat lock machine 13. Four thread over lock machine 14. Automatic stickering machine 15. Snap attaching machine 16. Carton strapping automatic machine 17. Cutting machine 18. Thread sucking machine 19. Layer drilling machine 20. Flat lock with trimmer
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21. Fusing press 22. 200 kg capacity washer 23. 150 kg capacity washer 24. Drying tumbler 25. Heated vaccum table 26. Dry cleaning machine
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FABRIC DEPARTMENT
For a bulk production industry it is essential to maintain a well-organized and well equipped inventory system. The main responsibility of this department is to store all the raw material necessary to produce the garments. In updates clothing inc, fabric department is controlled by Kumar.
TYPES OF FABRIC USING IN NORTH REPUBLIC
Cotton (pure)
Cotton + Doby
Cotton + Oxford
Cotton + Matty
Cavalry twill
Poplin
Matty Fabric
Filafil Fabric
Denim
Corduroy
Velvet
Chambray
Satin
Linen
RFD Fabric
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For knits
Single Jersey
Pique
Rib
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SAMPLING DEPARTMENT
A sample is a prototype of a product to be manufactured in the future course of production. It is also called mock-up of a product and it is made to check the design effectiveness and fit of the garment. Sampling is the set of the procedure follow to produce various sample style. It contains activities like making of the pattern for prototype according to the measurement of the sample with the help of machinery and getting buyers approvals for sample produce.
STEPS OF SAMPLING
DEVELOPMENT / PROTO SAMPLE
MASTER SAMPLE
SALES SAMPLE
Production manager controls sampling departments. Pattern master (Pandu Venga Nayak), cutting assistant (Nanda Gopan) Highly skilled, skilled, unskilled employees are in a sampling section. Pattern master create a proper pattern (based on a style) and cut the fabric using this pattern, creating a new sample style. Designers are approved in this master sample the, the pattern master creates the SS sample.
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MERCHANDISING DEPARTMENT
Merchandising is the department which mediates marketing and production departments. It is the method, practices, and operations used to promote and sustain certain categories of commercial activity. Merchandising means to arranging all the required raw materials and to make the goods ready. Responsible person of merchandising is called merchandiser. Actually a merchandiser is responsible for almost everything from order analysis to shipment and finally payment realization. He has to take after every job like buying the raw materials, which is required to finish the product, making the garment, finishing the garment, preparing the documentation and finally shipping.
Following are the responsibilities of merchandiser which gives importance to them, 1. Internal and external communication 2. Sampling 3. Lab dips 4. Accessories and trims 5. Preparing internal order sheets 6. Preparing purchasing orders 7. Advising and assisting production 8. Advising quality department about quality level 9. Mediating production and quality department 10. Giving shipping instructions and following shipping 11. Helping documentation department
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PROCESS FLOW OF MERCHANDISING DEPARTMENT
TECH PACK MADE BY DESIGNER
INITIAL SAMPLING AND COSTING
ORDER CONFORMATION
BUDGETING
TRIM DETAILS
RE-SAMPLE/PROTOTYPE APPROVAL
FABRIC DETAILS
DEVELOPMENT SAMPLE
LOIT APPROVAL
PP SAMPLE
SS SAMPLE
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Update Clothing Inc. Company has a merchandising department. Justin Josh is the merchandising manager. Ms. Nisha is a senior merchandiser. Merchandisers usually create job work cards. A job card is a detailed description of work that is performed for a work order. You use the job card application to create and manage job cards. When you create a job card, you specify planning and scheduling information that can be used by the task cards and work order tracking applications. Job card is completely included all details of fabric based on serial number. In this company’s job card including all processing details, for eg. Brand name, Fabric type, Shrinkage, Trim fabric, Body fabric consumption, Decorative, SPI, Packaging type, Size, Job type, Sample add date, Thread, Job workers, Fab issued date, Delivery date, Fabric received date, Fabric page no., Emby/print, Fab color, Fab type, Main label, Pocket label, Side seam label, etc. Company purchase fabric, then Ms. Anjali (sample section) take the fabric and give it to designers (Akhil Xavier, Akhil V, Jonish, Aneesh, Madhu) Designers create designing patterns and give these details to Anjali and create a detailed tech pack. Tech pack is an informative sheet that designers create to communicate with a manufacturer all the necessary components needed to construct a product. Usually designers will include measurements, materials, color, trims, hardware, grading, labels, tags etc. After tech creating the tech pack, the fabric will be sent to sampling department. The pattern master creates pattern and then makes the master sample. The master sample is then checked by the designers and then approved by Jiju sir (managing partner). After the master sample is approved, they create the sales sample. Jiju sir approves this sample after the merchandiser creates the job cards.
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PURCHASE ORDER
Purchase Order is an external document, which is issued by the company (Update clothing inc) Purchase Order includes the following information;
1. Delivery date 2. FOB 3. Ship cancel date 4. Destination 5. Ship mode 6. Terms if sale 7. Currency 8. L/C 9. Quantity 10. Size break up / Color break up
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CAD DEPARTMENT
Computer Aided Design (CAD) becomes an essential tool for pattern making and related job in garment industry. In a company CAD software is used for pattern making, grading of pattern, marker and digitalizing manual patterns. In this company, CAD section is controlled by Santhosh.
FABRIC MATCHING
Engineer pattern pieces according to fabric prints, stripes or plaids, fabric print can be transferred to marker making for perfect matching. All transactions are checked by Production manager.
MARKER MAKING
A marker is a diagram of precise arrangement of pattern pieces for size of specific style that are to be cut from a single spread. Marker making is a process of developing a diagram which is super imposed on the top of a grounded of superimposed piles as a guide for cutting these piles. It determines the most efficient layout of pattern pieces for a specific style fabric and distribution sizes.
Cut order planning determines
How many makers are needed?
How many of each size should be in each maker and the number of piles that will be cut from each marker?
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WORK FLOW OF SPREAD AND CUTTING
SPREADING
LAYERING
CUTTING MANUAL/AUTOMATIC
TICKETING
FUSING
CHECKING
BUNDLING
TRANSFER TO PRODUCTION
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TRIM STORE
Trim store as the name suggests is a department which acts as a store house for accessories. It is the place where all the accessories required in a store right from the sewing thread, needles to packaging materials mike poly bags and taps etc. All are stored in the accessories that are used in a particular style of that buyer. Merchandiser prepares a swatch card containing all the accessories and their quantity inn a cycle. These accessories used in the swatch card are as per the quality and color mentioned and approve by the buyer.
In the trim store items
Buttons
Snaps
Canvas
Micro dot
Zippers
Tapes
Labels (main label, side seam label, size label, pocket label, wash care label, twill tape, loop label, additional label, bottom label, patch label, leather patch, embossing label, logo heat transparent, fit tag, fabric tag, disclaimer tag, photo canvas, metal ids)
Packing items (m-clip (back, centre), side clip, Back supporter (4/5 types), tissue paper, safety pin, inside collar paper, placket, traveller (outer collar), butterfly poly bag, ratio bag, master poly carton box, swatch card, size sticker, MRPC plain tag, gum tape, company tag etc.
In updates clothing inc, trims store is controlled by Mr. Viveesh
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CUTTING DEPARTMENT
Cutting means to separate out different garment pieces from the lay of fabric with the help of cutting template and devices. It is done to get required shape in different no, or as a whole to make a complete product. The first stage in the manufacture of garment is the cutting of the material in to the necessary pattern shapes. These patterns are joined to form a garment when large amount of garment style has to be cut, a lay is created which consist of many piles of fabric spread one above the other. Now all the pattern pieces for all sizes are from this lay. The main objective of the cutting department is the cutting of the garment parts accurately and economically and in sufficient value to keep the sewing room supplied with work.
BASIC WORK FLOW
Cutting department receive the order for cutting a garment style from the production manager. Cutting order is an authorization by the production manager to cut a given amount of styles from the spreads. It comes in form of a package file that comes in the following details. 1. Sampling average (base fabric consumption only) and other trims averages. 2. Measurement sheet 3. Design work sheet of the garment 4. Purchase order 5. Fabric requisition sheet 6. CAD mini maker 7. Marker planning length of lay etc. size ratio and colors in which the patterns are to be cut.
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CUTTING SUB DEPARTMENT
1. Layering and spreading 2. Cutting 3. Bundling and ticketing 4. Fusing area 5. QA Department
TICKETING
Once the pattern pieces are cut by the cutting machine, they are then ticketing. Cut components are group together as per their sizes and taken to the checking table. Here the cut components are inspected for any error. It is very important to take pieces cut from two differently bolts of fabric are not mixed up. This is because within lot there bold variation in color shade.
FUSING
Fusing is also carried out in the cutting room itself. The parts to be fused are separated from the bundle. The fusing material (like interlining) is cut according to size of the component to be fused. The component along with the cut fusing materials are kept between to paper sheets and packs is passed through the fusing machine by means of temperature and pressure fusing takes place at particular speed and for a particular time. The pack comes out at the other end on conveyors and the pieces are removed and re bundled.
PARAMETRES AFFECTING THE FUSING PROCESS
Pressure Temperature Time
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CHECKING
The ticked panels are now sending to the checking are for inspection of every individual pieces for any objectionable faults. Panels having faults like wrong grain line, inappropriate size, incorrect shape and any fabric defects like holes, cut, shade variation etc. that are not within the acceptable quality parameters, are removed from the cut lay. A cutting component checking report is filled for the total quantity cut, checked and approvals. The rejected pieces are sent back and equal number of trash panel are separately cut, replaced in the set and ticket with the same no as the rejected once other mend able fault are marked with an alteration sticker and passed on. These will be spotted out during garment finishing or washing.
BUNDLING
The checked components of one style and in one size are now clubbed and bundled using tie. The size of bundle depends upon the requirements of the production plant. Each bundle will contain pieces of same style and same size only. These pieces are stored in racks made beneath the cutting table. The cutting department issues the amount required by the production department as and when ask for. The cut component may be issued in instalment or all at once ass the needs of the production department against the job order.
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SEWING DEPARTMENT
The basic aim of an export house is to deliver value satisfaction of the customer at the profit level. Production is an act of producing ie. quantity obtained by multiplying two quantities to gather by making use available resources. To deliver quality with the quantity the ratio between input resources or material and out good and service is known as productivity are reciprocally related to each other. Therefore an increase in production leads to fall in the cost per unit and rise in profit. The production department is spread in 3rd floor. This floor is for production of shirts. All sizes are sewing in this department (M, L, XL, 2XL, 3XL) and kids’ shirts (6-16) The production of knitted tshirts are in Tirupur.
WORKING STEPS OF PRODUCTION DEPARTMENT
Shrinkage production pattern is issued to production floor from CAD department.
Ready pattern are made as per the requirement of production room.
Cutting received from cutting department.
Cross checking of cut panels with patterns.
Bundling of cut panels is done.
Operation wise feeding of cut angles into the line.
Inline check point.
Outline of line.
Final check point.
Auditing of checked pieces.
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PRODUCTION CAN BE CARRIED OUT IN ONE WAY
1. Assembly line production system:In this production system, a garment is being by no: of workers, therefore one part is stitched by one worker and then passed on other, due to which line gets set up. In the end assembly of the parts is done, in modern industries. Conveyor belts are used as a medium of transportation of garment part from one worker to another. This system is very commonly used in industry as it reduces the manufacturing cost increase the production.
WASHING DEPARTMENT
Garments pass through various handling process, which may render them dirty and stain, thereby reducing their aesthetic appeal. To restore this aesthetic value, they are subjected to cleansing process like washing and dry-cleaning, garments are sent for washing by the production department as per the buyer’s requirement. Normally the fabrics are not asked to go for wash by the buyer whether the fabric department may internally send it a number of other reasons.
To control uneven shrinkage
To remove bowing
To lighten color shade
To improve hand
To even out color shade variation
To remove printing smell
To execute a dyeing program
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WASHING FACILITIES
Enzyme
Stone washing
Overdyeing etc
Silicon washing
Silicon
Silicon softener washing
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QUALITY CONTROL DEPARTMENT
Quality control means, a process by which entities review the quality of all factors involved in production, ISO 9000 defines, quality control as a part of quality management focused on fulfilling quality requirements. In this company (updates clothing inc.) has a quality control manager, Prasanna. In a quality control department, they have quality assurance members. In this is company, they are 1. Sunil 2. Vasanth 3. Guru 4. Sainath
Quality inspection of internal processes and out sourced work 1. Inspection of raw material 2. Testing of raw material 3. Inspection of sample 4. Cutting inspection 5. Preparatory work inspection 6. Sewing process 7. Washing 8. Final inspection
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FINISHING DEPARTMENT
After assembly, the garments how 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.
PROCESS FLOW OF FINISHING
GARMENT COMES FROM PRODUCTION
WASHING
THREAD CUTTING
INITIAL CHECKING AND SPOTTING
ALTERATION
RE-IRONING
FINAL CHECKING
PRESENTATION/FINAL IRONING
MEASUREMENT
SENT FOR PACKING
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BASIC WORK FLOW
Washing perc
Thread trimming
Spotting
General checking
Final thread cutting
Pressing
Measurement and final checking PCM is the finishing department in this company
PACKAGING DEPARTMENT
Packaging is the last stage where the finishing garment 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 buyers specifications. These instructions are standardized for a particular type of garment and sent to the merchandiser in form of a packing manual. The merchandiser forward it to the packing in charging along with a top of a production sample. Ie, packed with dimension approved by the buyer. This kept as a visual reference for the packers.
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PROCESS FLOW OF PACKING
Garment comes from inspection
It is then faded
3 are packed together
All pieces put into cartons
Details are pasted on cartons
Carton is sealed
Loaded into trucks
Sent for shipment
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ONLINE WEBSITE
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PROJECT BRIEF
To create men’s polo T-shirt design collection tech packs for Autumn/winter 2021
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CONCLUSION
The industry internship was successfully completed in one of the popular upcoming men’s wear brand. I had a very good working experience at North Republic. The project was done both online and offline and is completed within a period of 8 weeks. During the time period, I did a research about the company, learned about the design development and made detailed tech packs. The tech packs were of men’s wear polo T-shirts. I consider it as an excellent opportunity to enhance and apply my skills and learn and experience the industrial process.
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