PROPOSAL With Budget

PROPOSAL
A PROJECT REPORT TO UPGRADE TRANING CUM

PRODUCTION CENTER INTO MODEL TRANING CUM
PRODUCTION CENTER
INDEX
S.NO Content
1. Background
2. Reason behind creating a Model TPC
3. Purpose of model Training Cum Production
Centre
4. Factory layout
5. List of Department to be setup
6. SOP of Departments & it’s working Procedure
1. BACKGROUND
The textile industry in India is traditionally second largest employment generation industry after agriculture,
it is the only industry that has generated huge employment for both skilled and unskilled labour in textiles
industry. The textile industry continues to be the second largest employment generating sector in India and it
is the one of potential source of income generation for the rural youth is apparel.
Clothes/Garment is the one of basic need of human being. People may be rich or poor but everyone has need
of garment to protect and cover his/her body. It can be said that everyone use garment but brand and quality
will be varied only due to economic condition and buying capacity of client. Everyone wants to use quality
and brand but due to weak economic condition they don’t fulfil his/her desire.
If a brand establishes and quality product produce in Jharkhand and sale at reasonable price, everyone must
buy the product and use it. The population of Jharkhand is more than 3 crores and not a single unit of apparel
industry is available here. Jharkhand is rich due to its resources and known for steel industry like Bokaro and
Jamshedpur, coal area, mica production etc... Jharkhand people is always ready to adopt new fashion and
buying capacity of this state is also more.
2. Reason behind creating a Model TPC
Jharkhand people migrate to other state for the livelihood and most of them working as a labour in out of
state. The people of this state are laborious and honest about his/her work. The women of this state also
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PROPOSAL
migrate to other state and work there. All these people want to work in home state but due to lack of
opportunity in the state these people move to other state. But these labour forces always think that if any
opportunity will be provided in the home state they shall return and work at minimum salary also. Apparel
sector is one of the biggest employment sectors in the country after agriculture and clothes are one of the
basic needs of the human.
Looking into the scenario of apparel manufacturing 70-80% operators are women and most of them work
maximum 2-3 years as per factory expert. The retention rate is high with these women worker due to
different societal and personal home reason including marriage. Women’s have a deep interest & very
laborious in this sector if they get job in these sectors at their home state it will be more fruitful for them as
well as for the state. So, we have to give them exposer and job according to their capabilities and help them
to find job in their home town.
3. Objective of model Training Cum Production Centre

➢ Main objective to create a model TPC is to develop a pool of channel of defined working procedure,
monitoring channel & upliftment of other TPCs in the state supported by JSLPS.
➢ With the mandate of apparel manufacturing unit create all necessary departments in model TPC to
showcase the potential of TPC in apparel manufacturing market in the state and to emerge as a
bigger platform
➢ Looking into the metropolitan city’s status on apparel manufacturing, they are leading and capturing
all over the Indian and international market and its trend, all migrants’ workers are leaving their state
to generate livelihood over there but those cities are so expensive to live.
➢ Thus, capturing those market potential on apparel manufacturing sector, in model TPC is to be
formed which can be emerge as a bigger platform to provide livelihood for consistently longer
period of time which will uplift the status of rural women dignified way of living as well as for state
uplifting in apparel market to set an example in apparel market.
Model TPC of JSLPS

What is model TPC?
A model TPC defines as an organised and specific setup of each department for training and production
process which reflects a proper structured work flow in the centre. As incorporating these structure helps
in monitoring and evaluation of each department which coherently gives a positive outcome of an area to
grow in a bigger platform of an apparel sector. By forming model TPC it may be capable to take big
work order from recognised organisation which can add a good profit to become self-sustainable model.
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PROPOSAL
Hierarchy
HR Resources
Factory Administrative
HR Technology Infrustructure Marketing
Manager Staff
Marketing Production Finance Fabric & Trim

Upgradation Buyer
Manager Manager Manager Sourcing
Senior Cutting Sweing Room Finishing Quality Account Commercial

Merchandiser Manager Manager Manager Manager Manager Manager
Merchandiser Helpers Line Supervisior Supervisior Supervisior
Junior
Merchandiser
Flow chart of Departments in Model TPC:
Merchindising
Department
HR and
Sampling
Admin
Depatment
Department
Finance &
Fabric Store
Accounts
Department
Department
Trims and
Marketing Acessories
Department store
Department
I.E CAD
Department Department
Spreading &
Maintanance
Cutting
Department
Department
Finishing &
Sewing
Oacking
Department
Department
Fabric testing Washing

Department Department
Quality
Assurance
Department
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PROPOSAL
4. List of Department to be set up
Following are the departments involved in the production process from cutting to packing:
➢ Fabric Store and Inspection

➢ Accessories Store
➢ Cutting Department
• Spreading
• Cutting
• Fusing
• Ticketing
• Bundling
• Quality Section
➢ Sewing Department
• Audit and Dispatch Department
• Kaj button department
• Bar tack department
➢ Finishing & Packing Department

• Thread Trimming
• Pressing
• Stain Removal
• Initial Checking
• Alteration
• Measurement Check
• Tagging
• Folding
• Carton Packing
• Assortment
Associate Department:
➢ Merchandising Department
➢ Sampling Department
➢ Computer Aided Design Department
➢ Production Planning and Control Department
➢ Fabric Sourcing Department
➢ Purchase & Logistics Department
➢ Testing Laboratory Department
➢ Washing Department
➢ Industrial Engineering Department
➢ Maintenance Department
➢ Marketing Department
➢ Finance & Accounts Department
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PROPOSAL
➢ HR and Admin Department
➢ Electronic Data Processing (EDP)
5. Factory Layout
Ground
• Reception
• HR Office
• Conference Room
• Accounts Department
• Fabric Store
• Fabric Department
• Trim & Accessories Store
• Packing Area
• Washroom
• Cutting Area
First Floor
• Office Area
• CAD Room
• Pantry Area
• Production Department
• Washroom
• Machine Maintenance
Second Floor
• Washing Department
• Testing Department
• Cafeteria
➢ Estimated area 5000 square meter.

➢ Estimated cost to build 11,000,000
6. Capacity
Department Capacity
Cutting 11000pcs/day
Sewing 200000pcs/day
Finishing 8000pcs/day
Packing 10000pcs/day
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PROPOSAL
7. SOP of different departments and its working procedure
FABRIC SOURCING DEPARTMENT

The responsibility of this department is sourcing of the fabric for sampling as well as for bulk quantity.
The role of the fabric sourcing department is given below -
Working Procedure:
In case of Sampling:
For sampling merchandiser sends the fabric swatch to fabric purchase department. Firstly, Purchase guy
cross checks if the fabric is available in store or not. If not they he/she send request to local supplier for
developing the fabric for same quantity as per merchandiser’s advice. (E.g., 15-50 mtr). The fabric mill
gives the lead time and according to the lead time purchase team cross check and once it comes, purchase
personnel send it to merchant and merchant then do the needful. It is called FOB (First of Bulk).
In case of Bulk Quantity:
Step 1: Once order is confirmed, merchandiser sends the bill of material for bulk order to purchase
department and they also send the approved fabric sample which is to be used for upcoming style. The
fabric sourcing departments cross check each & everything. Then they send the fabric swatch to various
mill and request to develop the fabric. As per request fabric mill develop the fabric and send back to
factory with price quotation and lead time. After verifying everything purchase team ordered for bulk
quantity.
[In case of buyer’s nominated supplier, they don’t need to do it, because buyer will pay for the bulk
fabric.]
Step 2: Once the raw materials or the fabric is been sent by the supplier to the company and once, they
reach in-house the concerned person keeps the track of all the documents and material, he checks the
quantity of the material in-house and the material ordered and cross checks i.e., he checks the materials
against invoice/ DC / Packing list.
After confirmation he enters the details in the “SAP” (System Analysis Programme). Then they have to
do the bill entry and keep the record and maintain the document of whatever the slips received or
delivered.
Step 3: Then the entries are forwarded to the head office for the checking and payment.
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PROPOSAL
Fabric Process Flow chart for Sampling & Bulk
➢ Estimated material required and cost
Product Quantity Cost per piece Total cost

Computer 2 70,000*2 140,000
Landline 1 3,000 3,000
Printer 1 11,000 11,000
Total 4 154,000Rs
➢ Estimated Man power Required
Position Requirement Salary Total Salary per month

Fabric sourcing 1 38,000 38,000
Head
Fabric sourcing 2 25,000*2 50,000
assistant
Total 3 88,000Rs
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PROPOSAL
➢ FABRIC STORE
After receiving fabric, it goes to storage area for inspection. There are two areas for sorting the checked
and unchecked fabric. Unchecked fabrics are kept on pallet. Normally 4 ways pallet is used. From there it
is issued to fabric table.
Process flow chart

Fabric dispatched from supplier
↓
Fabric receiving
↓
Fabric checking
↓
Fabric checking by security guards
↓
Shade checking
↓
Send to the merchandiser for approval
↓
Quality checking for defects
↓
Fabric lot rejection
↓
Kept in store
Fabric Moving 4 9,000*4 36,000Rs

Trolley
Racks 15 10,000*15 1,50,000
Computer 1 70,000 70,000
Landline 1 3,000 3,000
Total 21 259,000Rs
➢ Estimated Man Power Required
Position Requirement Salary Salary per month
Fabric Department 1 40,000*1 40,000

Head
Fabric Store 1 15,000*1 15,000

Incharge
Stock Handle 1 15,000*1 15,000
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PROPOSAL
Helper 4 10,000*4 40,000
Total 7 110,000Rs
FABRIC INSPECTION
Quality Control of fabric: -
➢ Normally, 4-point system is used for fabric inspection.

➢ In This system is used in inspection of knitted & woven fabric.
➢ 100% fabric is inspected.
➢ Complete visual inspection is being done.
➢ Fabric inspection reports are at the discretion of the operator only.
➢ 40 defects per 100 sq. yards of fabric is an accepted roll, above that is rejected.
➢ In any kinds of defects, they use red arrow sticker for easy to understand and recognize.
4-point system:
SL. NO. SIZE OF DEFECTS ASSIGNED POINT
1 3 Inches or less 1
2 >3 inch to 6inch 2
3 >6 inch to 9inch 3
4 >9 inch 4
5 Holes (<1inch dimension) 2
6 Holes (>1inch dimension) 4
Process flow chart

Fabric received
↓
Manual fabric inspection
↓
GSM test
↓
Shrinkage test
↓
Shade check
↓
Confirmation of fabric quality
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PROPOSAL
WORKING PROCEDURE:
➢ Fabric comes in thane and roll also. Fabric rolls are checked in fabric inspection machine and
thane fabric is checked by manually.
➢ The fabric checker cuts the 25 x 25 cm swatch which goes to buyer for shade approval which then
moves for inspection.
➢ At first the width of fabric is taken, after that checking is carried out.
➢ The fabric defects are marked as per 4-point inspection system, defected area is marked by red
color and fabric inspection report is made based on defect’s size. Eventually the length is
measured.
➢ After the fabric is declared pass in fabric inspection report then a tag is attached to thane [Green=
ok, Yellow=careful, Red=rejected.]
➢ Then lot wise the fabric rolls are placed on the selective racks in a systematic manner.
➢ If the fabric doesn’t meet quality parameters, it is kept in the rejected fabric storage area to be sent
back to the supplier for reprocessing.
➢ For passed lots an accounts copy is made on the basis of which payments are made to the
supplier.
➢ When all fabric lots are checked, all fabric swatches (25 x25cm) are taken in a one place and then
they are grouped and sorted as per same class or shade. Then it is sent to merchandiser.
➢ The passed fabric is issued against the cut plans of a particular item to the production departments
which is then cut and sew.
➢ N.B: [In case of fabric roll, 10% roll is inspected, but in case of thane 100% inspection is carried
out.]
Fabric Moving 4 9,000*4 36,000Rs

Trolley
Racks 15 10,000*15 1,50,000
Computer 1 70,000 70,000
Landline 1 3,000 3,000
Fabric checking 4 30,000*4 1,20,000

table
Fabric inspection & 1 2,50,000 2,50,000
rolling machine
Table 2 10,000*2 20,000
Rolling Chair 2 8,000*2 16,000
Cabinet for file 1 15,000 15,000

segregation
Chair 4 4000*4 16,000
Total 35 696,000Rs
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PROPOSAL
Fabric Inspection 1 25,000*1 25,000

Head
Stock Inspector 4 15,000*4 60,000
Helper 2 10,000*2 20,000
Total 7 105,000Rs
TRIMS & ACCESSORIES STORE
The Trims Store is also a different body in the unit. All the trims are received in the Trim Store. After
receiving the supply of trims, all the contents are thoroughly checked and counted. After verification, a
trim card is made. The documentation is done. All the records are maintained, and further issuance is
done to the production floor. The accessories storage comprises of all kinds of trims purchased such as,
Buttons, Zippers, Threads, Laces, Labels and etc.
Process flow chart

Receive material
↓
Inventory
↓
Quality inspection in AQL
↓
Inspection Pass
↓
Received technical sheet
↓
System Update
↓
Issue/Release material to Production Floor
↓
Received approved trims
↓
Accessories received
↓
Inventory
↓
Decision
↓
Storage accessories
↓
Delivers
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PROPOSAL
WORKING PROCEDURE:
✓ Receive invoice and LR (Lab report)
✓ Check LR details with physical quantity.
✓ Check the trims with respect to invoice details.
✓ Cross check PO copy with reference to item number and material description with quantity.
✓ Send material for storage.
✓ Data entry into system.
Issue as and when required as per quantity required.
✓ Prepare stock maintaining sheet.

Accessories:
✓ In case of accessories mainly variety of laces are used for different styles.
✓ They are issued to the respective departments against the challan after their inspection and updating
in the system. The store in charge is responsible for keeping day –to- day track of the accessories
and ordering them whenever needed. The store keeper and the clerks are responsible for issuing the
required trims against a challan and maintaining the store.

Accessories Moving 2 9,000*2 18,000

Trolley
Racks 12 10,000*12 120,000
Accessories 1 11,000*2 22,000

checking table
Computer 1 70,000 70,000
Landline 1 3,000 3,000
Table 1 10,000 10,000
Rolling chair 1 8,000 8,000
Total 19 251,000Rs
Store Incharge 1 15,000*1 15,000
Stock Handle 1 15,000*1 15,000
Checker 4 12,000*4 48,000
Helper 2 10,000*2 20,000
Total 8 98,000Rs
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PROPOSAL
FABRIC TESTING LAB DEPARTMENT
An in-house testing lab for:
1. GSM
2. Count Construction
3. Shrinkage
4. Ph. test
5. Color Fastness to Washing
6. Color fastness to crocking (Rubbing)
For lab dips, strike offs and other approvals (FPT Report), fabrics are sent to testing laboratories like:
➢ INTERTEK
➢ SGS
GSM cutter 1 8,000 8,000
Count Construction 1 3,000 3,000
Crock meter 1 13,000 13,000
Perspirometer (Color 1 25,500 25,500

fastener)
Computer 1 70,000 70,000
Landline 1 3,000 3,000
Table 2 10,000*2 20,000
Total 8 142,500Rs
Lab Head 1 42,000*1 42,000
Lab assistant 1 22,000*1 22,000
Helper 1 10,000*1 20,000
Total 3 84,000
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PROPOSAL
COMPUTER AIDED DESIGN DEPARTMENT
OBJECTIVES:
➢ Pattern designing
➢ Grading
➢ Marker making
➢ Improve turnaround times
➢ Reduce material waste
➢ Reduce labour cost
➢ Save pattern for future use
Software Used: Lectra, Optitex, Gerber
Marker making: Markers are made keeping in mind the following factors:
✓ Mode of spreading
✓ Width of the fabric available
✓ Matching if required
✓ Shrinkage along warp and weft
✓ Size ratio required
The markers contain the following details:
✓ Size
✓ Shrinkage
✓ Total garment patterns
✓ Marker efficiency
✓ Fabric yield
✓ Marker length
✓ Average consumption per garment
MARKER MAKING BY CAD:

A Marker implies a large sheet of paper on which the edges of all pattern pieces are drawn. This is only
appropriate when cutting is done by manually controlled knife where a line must be provided for the
cutting operator to follow. Sometimes it is more appropriate to mark the pattern lines directly onto the
fabric under rather that onto paper.
Paper marker is used. It is normally stabilized on the top ply of the lay by stapling, so that an adhesive
backing on the paper may likely stick to surface of the fabric.
DEVELOPMENT CENTRE:
Lectra /Optitex:
1. Pattern Processing, Digitizing, PDS
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PROPOSAL
2. Marker Creation, Editors
3. Plotting & Cutting
▪ Digitizing Board
▪ Plotter
Process flow chart
Initial Tech-pack/ PDM receive From Merch Dept

↓
Create a New Pattern
↓
Calculate Fabrics Consumption by Electric mini marker in Yardage Yield (YY)
↓
Send Consumption to Buyer
↓
Consumption Approval
↓
Order Confirmation
↓
Receive E-Pattern, block and Fit Sample from a buyer
↓
Pattern Grading
↓
Submit Pattern to buyer
↓
Approve→ Reject→ Remake
↓
Marker Making for Sample
↓
Shrinkage and Sewing loss adjustment
↓
Sample making for bulk production
↓
Approve sample from Buying House
↓
Marker making for size set
↓
Marker printing
↓
Cut size set
↓
PP Meeting
↓
Pattern correction
↓
Marker printing by plotter
↓
Send Marker to cutting
↓
Marker Lay
↓
Bulk cutting
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PROPOSAL
Plotter 1 350,000 350,000
Computer 1 70,000*2 140,000
Landline 1 3,000 3,000
Rolling chair 2 8000*2 16,000
Table 2 10,000*2 20,000
Pattern cutting table 1 10,000 10,000
Total 8 539,000Rs
CAD Head 1 35,000*1 35,000
Pattern Master 2 28,000*2 56,000
Marker Master & 2 28,000*2 56,000

Grading Master
Helper 1 10,000 10,000
Total 6 157,000Rs
CUTTING DEPARTMENT
From fabric store rolls or thanes are shifted to cutting floor using the trolley. The rolls are temporarily
stored in a section on the cutting floor before the actual spreading and cutting to be done. All the
spreading and cutting is done manually.
The Cutting Floor comprises the following section:
✓ Temporary Fabric storage Area

✓ Spreading & Cutting Area
✓ Bundling and Ticketing Area
✓ Fusing Area
✓ Department for size set
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PROPOSAL
BASIC INFORMATION ABOUT CUTTING DEPARTMENT
✓ A sheet of paper is used to lay the plies of fabric upon which helps the movement of the lay while
cutting and also to protect the fabric from damage by any rough edges on the table.
✓ The usual spreading mode used for fabric is Face-One-Way-Nap-One-way according to the fabric
used or according to the buyer requirement.
✓ The spreading operators manually pull the fabric up to required ply length and then cut it using
end cutter.
✓ All the plies in the lay are laid similarly.
✓ Due to excess humidity and temperature, there is more relaxation allowances for worker which
decreases overall on standard time.
Straight knife machines are used for bulk cutting.
✓ Smaller parts such as pockets and waistband interlining are cut using bend knife machine.
✓ Size wise and color wise cutting of pieces is recorded.
✓ In case of any change, it is mentioned on the marker.
Process flow chart

Cutting plan based on shade band record
↓
Receive PO sheet, Tech pack and others detail
↓
Fabric received from a store as per requisition
↓
Relax fabric, if necessary, with record
↓
Make a Marker to Determine consumption
↓
Marker and pattern Crosses Check (ratio, grainline, jumping, etc.)
↓
Laying as per marker length (Spreading)
↓
Spreading quality control
↓
Random quality check on fabric fault & others
↓
A cutting (if necessary, hand scissoring done during check fabric) and band Knife cutting (small panel such
as single fly etc.)
↓
Cutting Quality control
↓
Randomly Panel check with hard pattern
↓
Panel check with CAD marker paper
↓
Layer numbering &bundling
↓
100% panel check
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PROPOSAL
↓
Replace defective parts shade wise
↓
Ready cutting parts to input.
↓
Supply to Fusing & Sewing as per approved requisition & ratio
Spreading costs
❖ Labour cost
❖ Fabric waste
❖ Splicing loss
❖ End loss
❖ Width loss
Fabric Moving 2 9,000*2 18,000

Trolley
Cutting moving 4 9,000*4 36,000
trolley
Racks 4 10,000*4 40,000
Fabric Cutting Table 4 15,000*4 60,000
Band Knife 1 90,000 90,000
Straight Knife 3 13,000*3 39,000
Piping cutting 1 75,000 75,000

machine
Landline 1 3,000 3,000
Total 20 361,000
Position Requirement Salary Total salary per month
Cutting Head Master 1 30,000*1 30,000
Cutting Master 5 20,000*5 100,000
Helper 4 10,000*4 40,000
Total 10 170,000Rs
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PROPOSAL
SEWING DEPARTMENT
Sewing department can be termed as the heart and soul of any garment manufacturing unit. This
department is responsible for the conversion of cut panels into actual garments.
➢ It has an immense sewing floor set up comprising production lines.

➢ When a new style comes; the various information like operation breakdown, sewing details,
critical operations etc. is done by I.E., department and put up on the board of In line & End line
checking. A sample of the garment is also put up in front of the sewing line for any type of
reference.
➢ In production floor A & B the “Progressive Bundle system” is followed and in floor C “Single
flow system” is followed.
➢ Line is set as per line layout plan.
➢ Operations are assigned to the operators according to their skill set. [E.g., Skill A, Skill B, Skill
C].
➢ Required SPI, thread tension and needle no. is set by supervisors and mechanic as per
requirement.
➢ Line in charge & supervisor give the direction to the operators about their respective jobs.
➢ In line checkers and Q.C‘s ensures that the quality coming out of each operation is as per the
quality specification.
➢ Industrial Engineer does the study of operators and their respective operations again. If any
change is needed in the layout and working method for maintaining the quality and production,
immediate action is taken.
➢ The production floor receives the details from I.E as below: -
▪ The style or the garment,
▪ Number of operators required,
▪ The batch for which the style has to be installed.

▪ Any extra kinds of machines that are to be used for the particular style.
▪ Target for each day
➢ Maintenance schedule is recorded by Maintenance in charge and slip is attached with the
machine.
➢ During the process of garment making there exists two types of checking, they are:
▪ In-process Checking.
▪ End line Checking
Process flow chart

Product analysis
↓
Set up a target for production
↓
Set up machine layout based on target
↓
Set up operator layout based on target
↓
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PROPOSAL
QC check of the product
↓
Line balancing
↓
Line setup
↓
Distribution of all the processes
↓
Cutting parts received section
↓
Cutting parts distribution to the operator and helper
↓
Complete parts making individually
↓
Online QC check
↓
Online quality audit
↓
Counting output and checking with the target
↓
Final quality check (for each Garment)
All the process sequence of the garments sewing department are discussed below:
S/L Process Job

01 Product analysis In which way, a product has to sew, it’s decided here.
02 Set up a target for production Have to set a target for production based on the shipping schedule.
Set up machine layout
03 based on target Have to prepare a machine setup layout based on daily target quantity.
Set up operator layout based on
04 target Prepare operator layout set up based on machine quantity.
Each garment must have to fulfil its right quality. So, product checking
05 QC check of the product must be needed by QC.
Line balancing is a tool used for production line to capacitate the flow
06 Line balancing line of production.
07 Line setup Line setup must be needed to achieve healthy production.
All the processes of sewing must be distributed to the right person to
08 Distribution of all the processes avoid the damage of garments.
Cutting parts received
09 section A section, which received the cutting parts from the cutting department.
Cutting parts distribution to the All the cutting parts should be distributed to the operator and helper after
10 operator and helper receiving those from the cutting department.
Complete parts making By joining all the parts, a complete garment has to make here
11 individually individually.
During the running of garments sewing, an online QC check must be
12 Online QC check needed to make fault free garments.
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PROPOSAL
An online quality audit must be needed here to show the buyer actual
fault free product making
13 Online quality audit process.
Comparing with the target quantity, all the output garments should be
Counting output and checking counted here to make sure
14 with the target achieving the target quantity.
In this section, all the output garments are checked finally by
Final quality check maintaining one by one method to provide fault free clothing into the
15 (for each Garment) finishing department.
SNL machine 300 50,000*300 15,000,000
Bar tack machine 4 131,000*4 524,000
Fusing machine 1 120,000 120,000
Over lock machine 4 40,000*4 160,000
Flat lock machine 4 55,000*4 220,000
Button hole machine 2 90,000*2 180,000
Button attaching 2 100,000*2 200,000

machine
Racks 2 10,000*2 20,000
Seating stool 320 1800*320 576,000
Garment checking 1 10,000 10,000

table
Landline 1 3,000 3,000
Total 641 17,004,000Rs
Supervisor 1 30,000*1 30,000
Line Supervisor 3 25,000*3 75,000
Stitching Master 316 20,000*316 6,320,000
Line quality checker 3 15,000*3 45,000
Helper 4 10,000*4 20,000
Total 327 802,000
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PROPOSAL
WASHING DEPARTMENT
Garment washing is normally done after garment stitching. According to the fashion trend and the customers'
demand, buyers ask for garment washing for specific product ranges. For the washing, apparel buyers
mention exactly what types of washing they need for the order.
For example, I worked with the buyer Tom Tailor and made t-shirts and polo shirts. They asked for garment
washing like – Vintage wash, Cloud wash, enzyme wash, softener wash or Acid wash. Each wash has
different types of appearance on the fabric surfaces. Wash types mainly depend on product types. For denim
product, a heavy enzyme wash is required where for the knitted T-shirt, light softener wash may be okay.
Importance of Garment Washing
The primary objects of garment washing include

• To remove starch that applied during fabric manufacturing.
• To soften the garment hand, feel and improve bulkiness
• To remove dirt, spots, oil stains that accumulate to the garment at the garment manufacturing
processes.
• To remove chemicals used during the printing process and embroidery process
As mentioned above, sometimes you wash garments to meet customer requirement.
• Washed clothes can be worn directly after purchasing
• To give a faded look or any other colour-tinted look to the garment.
• To stabilise garment shrinkage and dimensional instability
• To improve bulkiness and soft hand feel.
Process flow chart
Garments receive from the sewing department

↓
Garments sent to the dry process (If there’s any dry process)
↓
Hand scrapping
↓
Whiskering
↓
Tacking
↓
Garments sent to the wet process
↓
Garments loading into the washing machine
↓
Washing (Maintaining wash reference)
↓
Extracting
↓
Drying
↓
Garments sent to the dry process (If there’s needed any more dry process)
Page 22
PROPOSAL
↓
P.P spray (If the process needed)
↓
P.P sprayed garments sent to the wet process
↓
P.P sprayed garments loading into the washing machine
↓
Washing (Completing rest of the wet process)
↓
Extracting
↓
Drying
↓
Garments sent to the dry process (If there’s needed any more dry process)
↓
3D (If needed)
↓
Curing
↓
Quality check (Q.C)
↓
Send to the finishing department.
All the above garments washing processes are discussed in the below table:
SL No. Process Procedure
Garments receive from the

01 sewing department At first, garments should be received from the sewing department.
Garments sent to the dry All the garments are sent to the dry process department if the buyer
02 process approved wash reference garment containing dry process.
Here hand scrapping is done by the following buyer approved wash

03 Hand scrapping reference garment.
Whisker process is completed here by following buyer approved wash

04 Whiskering reference garment.
If buyer approved wash reference garment contains tacking effect,

then tacking process should be done here by following approved
05 Tacking garment.
Garments sent to the wet After completing all the required dry processes, garments are sent to
06 process the wet process department.
Garments loading into the Here the garments are loaded into the washing machine for a required
07 washing machine wash.
By following buyer approved wash reference, garments are washed

08 Washing here using the required chemicals.
Page 23
PROPOSAL
When the garments wash will complete, then these are unloaded from
09 Extracting the washing machine and extracted by using a hydro extractor.
All the garments are dried here by using a gas or steam dryer which is
10 Drying dependent on the shade.
After drying, all the garments are sent to the dry process for
Garments sent completing P.P process if the buyer approved wash reference garment
11 to the dry process contains this process.
Here P.P spray should be done using the required chemical by

12 P.P spray following buyer-approved wash reference.
After completing P.P spray, garments are sent to the wet process for
P.P sprayed garments sent completing the rest of the wet processes such as P.P neutral, Tinting,
13 to the wet process and Softening.
P.P sprayed garments

loading into the washing
14 machine Here P.P sprayed garments are loaded into the washing machine.
P.P neutral, Tinting, and softening is done here by following buyer

15 Washing approved wash reference garment.
When all the machine wash is completed then garments are unloaded
16 Extracting from the machine and extracted by using a hydro extractor.
Here, the garments are dried by using a gas or steam dryer which
17 Drying totally depends on the required shade.
If the buyer approved wash reference garment contains 3D process,

Garments sent to the dry then these garments should be sent again to the dry process for
18 process completing 3D.
Here the 3D process is completed by the following buyer approved

19 3D wash reference garment.
Applying the 3D process, the garments are cured here by using the
20 Curing woven machine.
After completing all above, the processes, washed garments are

21 Quality check (Q.C) checked here by following buyer-approved wash reference garments.
Send to the finishing Finally, all the clothing is sent to the finishing department for the next
22 department required processes.
Page 24
PROPOSAL
Fabric Moving 2 9,000*2 18,000

Trolley
Tumble dryer 1 115,000 115,000
Boiler 1 50,000 50,000
Side loading 1 130,000 130,000

washing machine
Hydro extract 1 115,000 115,000
machine
Spotting Gun 2 3,500*2 7,000
Computer 1 70,000 70,000
Landline 1 3,000 3,000
Total 10 508,000Rs
Washing Head 1 35,000*1 35,000
Washing Assistant 3 25,000*3 75,000
Helper 1 10,000*1 10,000
Total 4 120,000Rs
QUALITY CONTROL FOLLOWED IN FINISHING DEPARTMENT
Each quality checker is provided stickers for marking defects, thread clippers etc. Each checker is instructed
to check the garments thoroughly, mark the defects with arrow stickers and also to cut the uncut threads if
found. Checker puts his allotted number on each of the garment piece passed by him. Each checker is
monitored for their performance. Every time a defective piece is found at a later stage it is traced back to the
checker who passed it or sent for stitching alteration or spotting. This checker is then shown his mistake and
taught the correct method so that this is not repeated again.
There are two types of production records that are maintained for these quality checkers. They are:
a) Hourly production record
b) Daily production record
Responsibilities of quality department
Page 25
PROPOSAL
• To impart quality in the product.
• To ensure that the product has achieved the quality parameters of buyers.
• To restrict the defects entering into the final product.
• Main function of quality department is to carry out inspection.
• Inspection can be defined as the visual examination or review of raw materials, partially finished
components of the garments and completely finished garments in relation to some standards,
specifications, or requirements, as well as measuring the garments to check if they meet the required
measurements.
Principle of inspection (inspection loop)
Inspection
Correction of Detection of
defects defects
Feedback of
Determination
these defects to
of causes of
appropriate
Defects
personnel
IDENTIFICATION OF DEFECT
o Major Defect: A defect that, if conspicuous on the finished product, would cause the item to be
second.
o Minor Defect: A defect that would not cause the product to be termed as a second either because of
severity or location.
o Second: A ‘Second’ is a garment with a conspicuous defect that affects the saleability or
serviceability of the item.
Process flow chart

Fabrics and Trims in-house
↓
Fabrics and Trims inspection
↓
QC file /Trim card receive
↓
Size set cutting
↓
Size set sample making
↓
PP Meeting
↓
Pattern correction/adjustment
↓
Pilot run cutting (If need)
↓
Page 26
PROPOSAL
Pattern correction (If need)
↓
Pilot run approval
↓
Start Bulk cutting approval
↓
Fabric relaxation
↓
Spreading
↓
Spreading Quality control
↓
Receive marker from CAD
↓
Marker checking and report
↓
Pattern collection
↓
Pattern checking (Measurement and Grain line)
↓
Cutting process
↓
Cutting Quality control→ (Cutting defects)
↓
Cut Panel inspection
↓
Sewing Quality control
↓
Front part Inspection
↓
Back Part Inspection
↓
Assembly Inspection
↓
Output Quality Inspection
↓
Garments measurement
↓
Quality Audit
↓
Sending goods for washing
↓
Washing process
↓
Shade segregation
↓
Shade inspection
↓
Finishing
↓
Trimming
↓
Trimming QC check
Page 27
PROPOSAL
↓
Buttoning
↓
Buttoning QC check
↓
Button pull test
↓
Ironing
↓
Garments Inspection
↓
Get up inspection
↓
AQL Quality Audit
↓
Attach Hangtag, sticker and others ticketing
↓
Quality Checking sticker and ticketing
↓
Folding
↓
Garments Pass through needle detector machine
↓
Packing/Cartooning
↓
Final Inspection Request to buyer
↓
Making Packing List
↓
Submit Packing List to buyer
↓
Final Quality Inspection
↓
Pass-fail →Recheck→ Re-audit
↓
Finished Goods warehouse
↓
Shipment
Final Inspection:
o Open seams
o Skipped stitches
o Cracked stitches
o Stitches/inch
o Uneven seams
o Crooked, puckered, curled, pleated seams
o Needle and feed cuts
o Unclipped threads and long ends
o Raw edge
o Snaps, fasteners, buttons
Page 28
PROPOSAL
o Labels
o Elastic
o Measurements
o Mends or repairs
o Stripe
o Hems
o Trim
o Broken needle
o Distortion
Garment Moving 2 9,000*2 18,000

Trolley
Checking Table 4 10,000*4 40,000
Landline 1 3,000 3,000
Total 7 61,000Rs
Quality Head 1 35,000*1 35,000
Quality checker 15 25,000*15 375,000
Helper 2 10,000*2 20,000
Total 18 430,000Rs
AQL (Acceptable Quality Level)

• The AQL is the maximum percent defective that, for the purpose of sampling inspection can be
considered satisfactory as a process average.
• The AQL is a designated value of percent defective that the customer indicates will be accepted most
of the time by the acceptance sampling procedures to be used.
FINISHING DEPARTMENT
Finishing is the last stage of garment production where garment gets its final look. In this department each
garment undergoes different finishing processes.
The aim of this department is to give optimum quality to the garments before they are sent for packing.
The finishing floor includes the following activities.
Page 29
PROPOSAL
✓ Thread Cutting
✓ Initial Checking
✓ Removing Stain
✓ Ironing
✓ Measurement checking
✓ Folding & Tagging
✓ Packing Garment
Process flow chart

Finishing input (style, color & size wise)
↓
Initial quality check
↓
Spot Removing
↓
Ironing/Pressing
↓
Inspection
↓
Hangtag
↓
Get up change
↓
Folding
↓
Poly
↓
Bar code (buyer wise sticker)
↓
Metal check
↓
Cartooning/ Packaging to box
↓
Inspection of ready to ship goods
↓
Dispatch shipment
All the processes of Finishing have discussed in the below table:
Processes Procedure
1. Finishing Input Here, sewn garments are received for finishing the garments.
Page 30
PROPOSAL
Sewn garments are checked here by the quality controller. If found

2. Initial quality check major sewing problems then garments sent again to the sewing section
for rectification.
Sometimes garments contain various types of spots which removes here

3. Spot removing
carefully.
It’s one of the important processes in garment finishing. Here garments

4. Ironing or pressing
are ironed by following the measurement chart of those garments
After completing ironing or finishing, garments are inspected again here

5. Inspection by the quality controller to confirm the correct measurement of the
apparel.
6. Hangtag attaching In this section, the hangtag has to attach to the garments.
7. Folding After completing all the above processes, garments are folded here.
Garments are poly-bagged here to keep the garments dust, dirt, and
8. Poly
other impurities free. send the garments safely to the buyer
In this section, garments should be passed through a metal detector

9. Metal check
machine to identify metal lies in the garments.
Finally, all the garments should pack to send the garments safely to the
10. Packaging or cartooning
buyer.
It’s time to check the final inspection and then go for the dispatch
11. Inspection & Shipment
shipment.
Page 31
PROPOSAL
Trolley
Table 4 10,000*4 40,000
Steam Iron 5 80,000*5 400,000
Thread Cutter 15 18*15 270
Seam opener 15 15*15 225
Landline 1 3,000 3,000
Seating Stool 10 1,800*10 18,000
Total 47 497,495
Position Requirement Salary Total Salary per

Month
Finishing Head 1 22,000*1 22,000
Garment Finisher 10 10,000*10 100,000
Iron Man 6 12,000*6 72,000
Helper 2 10,000*2 20,000
Total 19 214,000Rs
PACKING DEPARTMENT
It is the method of preparing products for proper transportation. In packing department, packing is done
according to buyer’s specification.
TYPE OF PACKAGES:
a) Plastic container
b) Carton
• Presentation checking and cartoon packing It is very important to check the packed garments for
presentation. Checkers check the packed garments for the following things:
o Poly bags are as per specification.
o Tags and price stickers are as per specification.
o Packing is secured or not if specified.
o Poly bags should not be soiled and torn.
o Hangers are there or not if specified.
o Garment has been folded as per specification etc.
Packing can be done by following two manners:
Ratio Packing: Garments are packed according to size ratio as per buyer’s packing list.
Page 32
PROPOSAL
Solid Packing: Here garments are packed one shade and one cartoon.
PACKING FACTORS: Packaging always depends on these factors:
➢ Breakage
➢ Weight
➢ Moisture
Different Types of Packing Ideas:
Page 33
PROPOSAL
Process flow chart
Received garments from the finished section
↓
Hang tagging
↓
Folding with inserting back board, tissue
↓
Poly Bagging
↓
Cartooning
↓
Applied adhesive tape on the pack
↓
Bar-coding
↓
Packing complete

Trolley
Cartoon moving 4 10,000*4 40,000
trolley
Tagging machine 5 1,000*5 5,000
Computer 1 70,000 70,000
Landline 1 3,000 3,000
Table 1 10,000 10,000
Rolling Chair 1 8,000 8,000
Total 15 172,000Rs
Packing Head 1 34,000*1 34,000
Packers 15 12,000*15 180,000
Helper 2 10,000*2 20,000
Total 18 234,000Rs
Page 34
PROPOSAL
INDUSTRIAL ENGINEERING DEPARTMENT
Industrial engineering department is considered the backbone of any garment factory. It plays a vital role
in production of the garment. It involves all other production departments and is responsible for
monitoring performance of the same. It gives technical solutions to the problems faced during the garment
production. It is responsible for improving productivity and efficiency of different departments. It is a
systematic approach for:
➢ Design
➢ Development
➢ Installation
➢ Implementation and Maintenance of the integrated system of Man, Material and

Machine/Equipment
The industrial engineering department works for their optimum utilization for the higher productivity of
the organization with ultimate goal of earning better profit. The tech pack made by the IED for a
particular order consists of the following details of a particular order,
➢ Batch layout
➢ Operation bulletin
➢ Operation process chart
➢ Critical point analysis Cutting instructions
Page 35
PROPOSAL
Process flow chart
Negotiation with garments merchandiser
↓
Garments analysis
↓
Make P.P meeting if all the required fabrics, trimmings, and accessories are in-housed
↓
Production target
↓
Set machine layout
↓
Line setting
↓
Line balancing
↓
Continuous production meeting
↓
Collecting production data
↓
Preparing production report
↓
Production report analysis
↓
Report submitted to the factory manager
All the above processes are discussed in the below table:
SL No. Process Procedure
It is the very first work of an industrial engineer. Here, he should

Negotiation with garments vastly discuss with garments merchandiser about the in-coming
01 merchandiser garments product.
Confirmed garments product is clearly analysed here by an

industrial engineer. It helps to complete the rest of the processes
02 Garments analysis very easily.
Here, P.P meetings should be organized if all the required fabrics,

trimmings, and accessories are housed and take all the precautions
03 Make P.P meeting for the up-coming garments production.
Production target should set here according to factory capacity. It

04 Production target helps to respect the shipment date.
Machine layout is set here according to the total processes needed

05 Set machine layout to complete a garment item.
In this process, the actual line setting should be done to utilize the
garment workers properly. If it takes more time in line setting
06 Line setting then garments production will be decreased.
Page 36
PROPOSAL
To minimize the number of work stations, cycle time, line
balancing is done here. It’s a very important process to achieve
07 Line balancing the desired production target.
Production meetings should be done here at regular intervals. If

Continuous production any problem will arise during garments production, should take
08 meeting necessary actions to solve that.
Production data should be collected here for preparing the

09 Collecting production data production report.
Here, the total garments production report has prepared to

10 Preparing production report analysis about the whole production.
The clothing production report is analysed here from different

11 Production report analysis points of view.
Report submitted to the Finally, the garments production report has to submit to the
12 factory manager factory manager.
Function
The IED department has to work with many other departments as this department gives the entire idea of
the garment construction and the thread and trims consumption criteria, operator’s skill level
categorization and other related aspects. Hence, they play a vital role in determining the cost of producing
a single piece of the garment and cost of the factory for that particular style of garment. The different
departments with which the IED works are as follows:
Planning Department: The IED department helps the planning department to know the time required for
the production of that particular style of the garment by calculating the SAM value for it and they also
help in finding the capacity of the factory based on which the planning department takes a decision if they
have to proceed with order or not.
➢ Merchandising Department: The IED calculates the SAM value for the garment, calculates the
productivity of the given style for the initial costing and also calculates the accessories
consumption by the style and gives all these details to the merchandising department for the
costing purpose and it also gives the merchants suggestions regarding the reduction of the cost
of manufacturing the garment by modifying any of the steps and the method of doing it.
➢ Research and Development Team: The IED people using the General Sewing Data (GSD)
prepare the style bulletin which includes the different types of seams and stitches that has to be
done for the garment and it also includes the length of the seams and the types of stitches that has
to be carried out at different places of the garment as per the buyers’ specifications and approval.
➢ Human Resource Department: IED department will analyse and estimate the manpower and their
skill level which is required for the production of the garment.
Page 37
PROPOSAL
Computer 2 70,000*2 140,000
Landline 1 3,000 3,000
Table 1 10,000 10,000
Rolling Chair 2 8,000*2 16,000
Total 6 169,000Rs
I.E Head 1 38,000*1 38,000
I.E Assistant 2 22,000*2 44,000
Work Study Officer 1 16,000*1 16,000
Total 4 98,000Rs
MAINTENANCE DEPARTMENT
Maintenance department is consisting of electrician and machine mechanic. Maintenance department

doing their job for a particular style at the time of size set sample and pilot run sample. What types of
machines, folders and guides required to complete the operation is planned so that in bulk production it
runs smoothly. If a complicated style required extra folder and guides then they arrange for it. Also, the
department is responsible for following aspects:
SAMPLING DEPARTMENT:
Sampling department is the most important department of the organization. It is the department that
develops the samples thus enabling the Product Development. Sampling is the best way to place an order.
Though it is a difficult and time taking process but it will help the exporter to get the order from the
buyer. The samples decide the ability of an exporter. The buyers will assess the exporter and his
organization only by the samples. If the samples are of good quality and with reasonable price naturally
the buyers will be forced to place the order, so it is essential that the samples should be innovative and
with optimum quality.
Sampling was self-sufficient as it has its own stitching, washing, trimming, spotting, ironing and checking
or inspection etc. dedicated for the construction of samples only.
Page 38
PROPOSAL
REQUIREMENT OF SAMPLING
The purpose of sampling is not only to get bulk order but also it gives some additional benefits to the
exporters. By doing sampling the exporter can estimate.
✓ The yarn consumption for developing the fabric

✓ A clear idea on costing
✓ Manufacturing difficulties
✓ Optimizing the processing parameters for mass production, this helps to avoid all kinds of bottle
necks.
TYPES OF SAMPLES
PRODUCT DEVELOPMENT TEAM
➢ Development sample- Based on tech pack submitted by buyer or on the design developed in-
house.
➢ Proto sample – It is a development sample. It is the reflection of the first tech pack received from
the buyer. The sample is sent to the buyer for the design approval. Proto can be made with
different fabric but quality of fabric should be same as per buyer instruction. Proto sample is
made in the base size. Styling is important. The comments and second tech pack are sent back
referring changes in the sample.
➢ Salesman Sample (SMS) - After sending proto, if buyer approves, SMS sample is sent to buyer. It
should be the actual fabric, trims and measurements.
If SMS sample approved then its handover to the production team in the merchandising
department.
PRODUCTION TEAM
➢ Fit sample- Different buyers have different fits, based on which samples are requested in each fit.
➢ Red Seal sample (RSS)- It is First fit sample made after SMS sample. It has 3 stages, RSS, 2nd
RSS, 3RD RSS. In RSS: two sample are made one for the buyer and one for the merchant
department counter; in this sample FOB fabric is used for making samples according to the buyer
comment after SMS sample. After RSS sample sent to the buyer for is fit approval then buyer
comments on it whether they want 2nd RSS or GSS sample.
➢ Gold Seal Sample (GSS) - It is second sample made after RSS sample. It has 3 stages, GSS, 2nd
GSS, 3rd GSS. In GSS: three samples are made one for buyer and another two for merchant
department counter; in this sample bulk fabric is used for making samples according to the buyer
comment after RSS sample. After GSS sample sent to the buyer for is fit approval then buyer
comments on it whether they want 2nd GSS or Reference sample either it approved for production.
➢ Reference Sample- It is third sample made after GSS sample. In reference sample: three samples
are made one for buyer and another two for merchant department counter; in this sample bulk
fabric is used for making samples according to the buyer comment after GSS sample. After
reference sample buyer approved for production then if buyer want photoshoot for catalogue.
Then photoshoot sample made by merchant department and do the photoshoot of the sample and
sent it to the buyer.
➢ Garment Assessment Test (GAA Test) - It is a sample which is made for garment test. In GAA
Test: three samples are made for testing; in this sample we use actual fabric of bulk, bulk trim,
bulk thread is mandatory to use for making sample. GAA testing for D.S Washing, Appearance
Page 39
PROPOSAL
assessment test in 2 sample, if garment has print then 1 sample is used for print durability test and
if garment has embroidery, then the sample is used for quality and color fastness test.
➢ Shipment Sample- When production is approved the buyer want shipment sample for approval in
actual bulk fabric, bulk trim, bulk thread. Buyer assures that production garment is right or not.
PROCESS FLOW OF SAMPLING:
Start
Style Sheet/ Tech pack
Merchandiser order for the

Fabrics & Trims
Merchandiser send program to

Pattern Master
Pattern Master send the Pattern

to CAD for grading & Plotting
CAD Dept. sends Fabric

consumption to Maerchandiser
Embroidery if any
Merchandiser sends cutting

program to Cutting Master
cutting
Page 40
PROPOSAL
Stiching
Bar tack
Button Attach,
Holding/Riveting
Thread cutting
Washing
Pressing
Measurment
checking
Alteration if any
Final Checking
Packing
End
Page 41
PROPOSAL
SECTION IN SAMPLING DEPARTMENT:
✓ Pattern Making
✓ CAD Dept.
✓ Cutting section
✓ Sewing Section
✓ Embroidery/Printing Section
✓ Finishing Section
✓ Washing Dept.
✓ Ironing Section
✓ QC & Checking Section
MERCHANDISING
Merchandising is the root of apparel industry. Merchandising is a process through which products are
planned, developed, executed and presented to the buyer. It includes directing and overseeing the
development of product line from start to finish.
According to American Marketing Association, merchandising encompasses “planning involved in

marketing the right merchandise or service at the right place, at the right time, in the right quantities, and at
the right price”
MERCHANDISER’S KEY RESPONSIBILITY IS AS FOLLOWS:

• Product Development
• Production
• Market and product Analysis
• Selling the concept
• Booking orders
• Confirming Deliveries
• Designing and Sampling
• Preparing Bill of Material
• Costing
• Raw Material
• Production Follow Ups
• Payments Follows
• Internal & external communication,
• Sampling
• Accessories & trims
Page 42
PROPOSAL
• Preparing internal order sheets
• Preparing time & action calendar
• Preparing purchase orders
• Advising and assisting production,
• Advising quality department about quality level
• Mediating production and quality departments
• Giving shipping instructions and following shipping,
• Following up the shipment
IN MERCHANDISING DEPARTMENT THERE ARE TWO TEAMS:

1. PRODUCT DEVELOPMENT (PD)
2. PRODUCTION
PRODUCT DEVELOPMENT:
In this we made sample using Tech Pack. It is a very first stage of introduction of new style. In this process
we convert 2D design in tech pack we convert into 3D design in garment with the all technical and aesthetic
approach kept in mind.
PD Samples:
1. Proto Sample – 2pcs.
2. SMS Sample – 6pcs.
PRODUCTION:
It takes handover of style file from PD merchandiser. Its starts after receiving of Purchase Order (PO). They
prepare schedule for production activities. Follow up with production team and with factories because a
factory has multiple production units. Their responsibility ends after shipment is dispatched to buyer.
Production Samples:
1. RSS Samples – 2pcs.
2. GSS Samples – 3pcs.
3. Reference Samples – 3pcs.
4. GAA Test Samples – 3pcs.
5. Photoshoot Sample – 2pcs,
6. Shipment Sample – 4pcs.
PRODUCT MARKETING & MERCHANDISING TEAM

Marketing merchandising is done in the unit. This includes all the responsibilities from sourcing to finishing
i.e., first sample onwards, the products merchandising work start and ends till shipment.
MICRO PROCESS FLOW OF MERCHANDISING DEPARTMENT
Page 43
PROPOSAL
Steps:
1. In the first stage buyer sends style sheet, specs or sketch of any garment pieces and asks for proto sample
with costing. Sometimes they send Tech pack with required specs and measurements.
[N.B.: In this process, buyer wants to see that factory is capable or not to make the style.]
2. The merchandiser gets the available fabric with same quality as per Tech pack and at the same time they
send a programme to pattern making and sampling department for that style.
3. During the proto preparing time, the merchandiser gets the approval of all things like fabric, trims, label,
costing etc. and either buyer gives the approval or gives the vendor’s name.
[From the CAD dept. the average fabric consumption is calculated and from GSD the SMV of the style is
calculated-On this basis costing is done.]
4. After sampling done, merchant sends proto sample with cost-sheet. If buyer approves the proto, he asks
for SMS sample.
[In this stage, merchandiser sends SMS sample with costing]
5. After SMS sample approval, the fit approval process is carried on in this time all the negotiation (Sample
fit, costing etc.) is happened. After fit approval merchandiser sends pre-production sample and according to
this sample production should be carried.
[During fit approval, merchandiser gets the approval of bulk fabric and trims from buyer.]
SENT FOR PRODUCTION PROCESS
6. When SMS Sample is approved, then Purchase order is sent by buyer; merchandising team co-ordinate
with production team. Before starting the production, it is necessary that everything i.e., fabric, trims should
be in house and this time merchant gives the lead time to buyer.
7. During production merchant gives the status update to buyer according TNA calendar and follow up the
shipment.
8. After shipment done, payment follow up.
Costing:
1. Material cost - cost of fiber, yarn
2. Fabric, trims and accessories
3. Making and trim cost [CMT cost]
4. Fabric consumption calculation
5. Costing of a garment
Objectives of Garment Costing:
▪ Ascertain cost per unit of different products manufactured.
▪ Provide a correct analysis of cost both by process and operations.
Page 44
PROPOSAL
▪ Disclose sources of wastages.
▪ Act as a guide to price fixation of products manufactured.
▪ Ascertain the profitability of each products manufactured.
▪ Exercise effective control of stocks of raw materials at various stages.
▪ Implementation of cost control system.
▪ Guide management in the formulation and implementation of incentive bonus plans.
▪ Help in preparation of budgets.
▪ Help in implementation of budgetary control.
ELEMENTS OF COSTING
Materials
Labor
Other expenses
Final cost of the fabric depends on
Cost of the fabric = Cost of grey fabric + dyeing charges + finishing charges + shrinkage + wastage
Cost of Making
The cost of making is based on the total cost per hour multiplied by the number of hours it takes to make the
style and divided by the number of units produced if the making is done by a contractor. The contractor
adds profit on to this amount.
• CMT charges are calculated as: Total available capacity per month (in minute) = 26
working days*8 hours/day*60=12,480 minutes
• Labor cost per minute = (Monthly salary of an operators/Total minutes available in

the month) at 100% efficiency
• Sewing cost = (SAM [Standard Allowed Minute] of the garment * Minute cost of the
labor)/Line efficiency (%)
• Cutting cost = (SAM of cutting * Minute cost of the labor)/cutting efficiency (%)
Page 45
PROPOSAL
• Production cost of garment (CMT) = sewing cost + cutting cost + trimming cost.
Page 46
INTERNSHIP REPORT 2021
FABRIC APPROVAL STAGE
FOR PRINT FABRIC FOR SOLID COLOR FOR YARN DYED & STRIPE
FABRIC
Art work Color standards (Buyer sends a Art work
(Buyer sends an art work sheet color standard according (Buyer sends an art work sheet
where Print design and color to which fabric is where Print design and color
code (CIS) are mentioned.) ordered.) code (CIS) are mentioned.)
Strike Off
(After sending the fabric as per LAB DIP Strike off or Desk look with Yarn
art work, buyer sends comment Skin
(In this stage merchant sends
sheet and tells to resubmit after (After sending the fabric as per
many shades of fabric of same
correction.) art work, buyer sends comment
color to buyer: Like op.1, op.2
sheet and ask for the resubmit
etc.)
after correction)
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FOB [First on Bulk]

(In this stage fabric mill sends
FOB [First on Bulk] (In this Strike Off the FOB fabric as per color
stage fabric mill sends the FOB (After sending the fabric as per depth & shades which needs
fabric as per color depth which shades, buyer sends comment to be send to
needs to be send to buyer for sheet and tells to resubmit after buyer for approval.)
approval.) correction)
Bulk
(After getting approval, bulk is FOB [First on Bulk] (In this
ordered.) stage, as per buyer a comment, Bulk
the fabric is developed and sends (After getting approval, bulk is
again to buyer for bulk approval.) ordered.)
Bulk
(After getting approval, bulk is
ordered.)
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DOCUMENTATIO IN MERCHANDISING DEPARTMENT
Details of the file prepared by the merchant:
Buyer: Name of the buyer.

Style Specification: contains a brief description of the style.
Style #: As mentioned by the buyer.
Merchant: Name of the merchant handling the style.
Content of Production file:

1. COVER PAGE
2. CHECK LIST
3. PO
4. PPM SHEET
5. CAD AVERAGE
6. FIT COMMENTS
7. WASHING RECEIPE CARD
8. FABRIC INSPECTION REPORT
9. FABRIC LOTS
10. JOB CARD
11. TRIM SHEET
12. LABELS
13. TESTING
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PROCESS FLOW OF MERCHANDISING DEPARTMENT:
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TOP SAMPLE SENT

TO BUYER
Production in bulk
Follow up with
production
departments
Offer garments to
buyer
Follow up on the
payments of goods
STOP
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Tagging Gun 2 1,000*2 2,000
Table 5 10,000*5 50,000
Rolling Chair 10 8,000*10 80,000
Computer 5 70,000*5 450,000
Landline 1 3,000 3,000
Printer 1 13,000 13,000
Total 18 598,000Rs
Head Merchant 1 48,000*1 48,000
Merchant 6 25,000*6 150,000
Production 2 28,000*2 56,000

Incharge
Helper 3 10,000*3 30,000
Total 12 284,000Rs
Marketing department
The marketing department in a garment company is responsible for marketing products made by the
factory, finding new customers and bringing more and more orders for the company. A marketing
department is headed by the marketing manager and supported marketing team.
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• They meet with prospects and existing buyers. They show their latest product development
(designs) to the buyer. They are given responsibility for business development for the
company.
• This department showcases factory’s ability for developing new designs, factory compliance,
and quality policy and quality performance.
• Most common marketplace for manufacturers is international apparel shows and exhibitions,
where buyers and sellers meet to find each other. In the exhibition, buyers pick their
interesting design and place order if their target price is met.
• In this internet age, garment factories build websites for marketing purpose and increase their
visibility to potential customers. Small factories post their product in online yellow pages and
do content marketing to reach a bigger market. Social Media like Facebook, LinkedIn and
Twitter are used as marketing tools.
• More than just developing new clients, retaining the existing customer is also important. To
retain your existing customers, you need to satisfy your customers by shipping quality
products and timely delivery and providing quality services. The main mantra to retain
customers and making them marketer for you is to deliver more than you are paid for. Deliver
more than commitment and customer expectation.
Marketing Head 1 38,000*1 38,000
Marking assistant 2 28,000*2 56,000
Sale representative 1 20,000*1 20,000
Total 4 114,000Rs
Supporting departments and their activities

Departments if a garment factory those are no directly involved in garment production but support
garment production team to perform their work smoothly. Necessary supporting departments are
Accounting, EDP, Shipping and documentation, Human resource and Administration.
Accounts department activities

• Accounting department prepare payroll for employees, give payments to workers and write
checks for staffs. They manage accounts of the company.
• Maintain records of supplier payment and follow up with buyers for pending payment. This
department is involved in all kind payment and cash management.
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Human Resource and Administration
• This department is concern about the social issue of the employee. They look after recruiting
and employee welfare.
• This department maintains employee attendance and absent records.
• Handle labour issues
• Factory compliance and social compliance
• New employee orientation
• HR Qualification – MBA in Human Resource Management
• Experience – 5-6 years
• Salary – 50,000 – 60,000Rs
Electronic Data Processing (EDP)

Garment factories use many electronics items such as computers, printer, Barcode systems etc.
Computers are used for daily activities like mailing, making reports and accounting software, EPRs
etc. An EDP department is necessary for troubleshooting of the computers and software.
The major activities of this department are

• Purchasing electronic items
• Breakdown maintenance of computers and other hardware
• Supporting internet and mailing activities
• Protecting the company’s server from outside bugs and viruses
• Database maintenance
• Report generating
Supporting Departments Staff Required:
Personnel Requirement Salary Total salary per month

HR 1 55,000*1 55,000
Accountant 1 30,000*1 30,000
EDP 1 25,000*1 25,000
Peon/Watchman 2 8,000*2 16,000
Electrician 1 10,000*1 10,000
Pantry Staff 2 8,000*2 16,000
Total 8 146,000Rs
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Estimated material required:
Material Quantity Cost per piece Total Cost
Compute/ Laptop 3 70,000*3 210,000
Photo copier 1 80,000 80,000
Printers 2 16,500*2 33,000
Set up a showroom for displaying 400,000-500,000

your designs, you need racks and
hangers and dress forms. The
dress form is all needed in the
sampling room and finishing
section for checking the fitting of
the garments
Total 6 823,000Rs
➢ Total Estimated of Material Cost:
Departments Cost
Estimated cost to build a factory 11,000,000
Fabric Sourcing Department 154,000
Fabric Store 259,000
Fabric Inspection 696,000
Trim & Accessories Store 251,000
Fabric Testing Lab Department 142,500
CAD Department 539,000
Cutting Department 361,000
Sewing Department 17,004,000
Washing Department 508,000
Quality Control Department 61,000
Finishing department 497,495
Packing Department 172,000
I.E Department 169,000
Sampling & Merchandising Department 598,000
Supporting Department 823,000
Total 33,234,995Rs
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➢ Overall salary of Department & Man Power Required:

Estimated Salary of Department & Man Power
Fabric sourcing Department
Position Requirement Salary Total Salary per month
Fabric sourcing Head 1 38,000 38,000
Fabric sourcing assistant 2 25,000 50,000
FABRIC STORE
Fabric Department Head 1 40,000 40,000
Fabric Store Incharge 1 15,000 15,000
Stock Handle 1 15,000 15,000
Helper 4 10,000 40,000
FABRIC INSPECTION
Fabric Inspection Head 1 25,000 25,000
Stock Inspector 4 15,000 60,000
Helper 1 10,000 10,000
TRIMS & ACCESSORIES STORE

Store Incharge 1 15,000 15,000
Stock Handle 1 15,000 15,000
Checker 4 12,000 48,000
Helper 2 10,000 20,000
FABRIC TESTING LAB DEPARTMENT

Lab Head 1 42,000 42,000
Lab assistant 1 22,000 22,000
Helper 1 10,000 10,000
COMPUTER AIDED DESIGN DEPARTMENT

CAD Head 1 35,000 35,000
Pattern Master 2 28,000 56,000
Marker Master & Grading
Master 2 28,000 56,000
Helper 1 10,000 10,000
CUTTING DEPARTMENT
Cutting Head Master 1 30,000 30,000
Cutting Master 5 20,000 1,00,000
Helper 4 10,000 40,000
SEWING DEPARTMENT
Supervisor 1 30,000 30,000
Line Supervisor 3 25,000 75,000
Stitching Master 316 20,000 63,20,000
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Line quality checker 3 15,000 45,000

Helper 4 10,000 40,000
WASHING DEPARTMENT
Washing Head 1 35,000 35,000
Washing Assistant 3 25,000 75,000
Helper 1 10,000 10,000
QUALITY CONTROL
Quality Head 1 35,000 35,000
Quality checker 15 25,000 3,75,000
Helper 2 10,000 20,000
FINISHING DEPARTMENT
Finishing Head 1 22,000 22,000
Garment Finisher 10 10,000 1,00,000
Iron Man 6 12,000 72,000
Helper 2 10,000 20,000
PACKING DEPARTMENT
Packing Head 1 34,000 34,000
Packers 15 12,000 1,80,000
Helper 2 10,000 20,000
INDUSTRIAL ENGINEERING DEPARTMENT

I.E Head 1 38,000 38,000
I.E Assistant 2 22,000 44,000
Work Study Officer 1 16,000 16,000
SAMPLING & MERCHANDISING DEPARTMENT

Head Merchant 1 48,000 48,000
Merchant 6 25,000 1,50,000
Production Incharge 2 28,000 56,000
Helper 3 10,000 30,000
MARKETING DEPARTMENT
Marketing Head 1 38,000 38,000
Marking assistant 2 28,000 56,000
Sale representative 1 20,000 20,000
SUPPORTING DEPARTMENRS
HR 1 55,000 55,000
Accountant 1 30,000 30,000
EDP 1 25,000 25,000
Peon/Watchman 2 8,000 16,000
Electrician 1 10,000 10,000
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Pantry Staff 2 8,000 16,000
TOTAL 448 89,48,000
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PROPOSAL With Budget

Uploaded by

PROPOSAL With Budget

Uploaded by

PROPOSAL

A PROJECT REPORT TO UPGRADE TRANING CUM

2. Reason behind creating a Model TPC

3. Objective of model Training Cum Production Centre

Model TPC of JSLPS

Marketing Production Finance Fabric & Trim

Senior Cutting Sweing Room Finishing Quality Account Commercial

Merchandiser Helpers Line Supervisior Supervisior Supervisior

Flow chart of Departments in Model TPC:

Fabric testing Washing

➢ Fabric Store and Inspection

➢ Finishing & Packing Department

➢ Estimated area 5000 square meter.

FABRIC SOURCING DEPARTMENT

In case of Bulk Quantity:

➢ Estimated material required and cost

Product Quantity Cost per piece Total cost

Position Requirement Salary Total Salary per month

Process flow chart

➢ Estimated material required and cost

Product Quantity Cost per piece Total cost

Fabric Moving 4 9,000*4 36,000Rs

Computer 1 70,000 70,000

Landline 1 3,000 3,000

➢ Estimated Man Power Required

Position Requirement Salary Salary per month

Fabric Department 1 40,000*1 40,000

Fabric Store 1 15,000*1 15,000

Stock Handle 1 15,000*1 15,000

➢ Normally, 4-point system is used for fabric inspection.

Process flow chart

➢ Estimated material required and cost

Product Quantity Cost per piece Total cost

Fabric Moving 4 9,000*4 36,000Rs

Computer 1 70,000 70,000

Landline 1 3,000 3,000

Fabric checking 4 30,000*4 1,20,000

Rolling Chair 2 8,000*2 16,000

Cabinet for file 1 15,000 15,000

➢ Estimated Man Power Required

Position Requirement Salary Salary per month

Fabric Inspection 1 25,000*1 25,000

Stock Inspector 4 15,000*4 60,000

Helper 2 10,000*2 20,000

TRIMS & ACCESSORIES STORE

Process flow chart

✓ Prepare stock maintaining sheet.

➢ Estimated material required and cost

Accessories Moving 2 9,000*2 18,000

Accessories 1 11,000*2 22,000

Landline 1 3,000 3,000

Table 1 10,000 10,000

Rolling chair 1 8,000 8,000

➢ Estimated Man Power Required

Position Requirement Salary Salary per month

Store Incharge 1 15,000*1 15,000

Stock Handle 1 15,000*1 15,000

Checker 4 12,000*4 48,000

Helper 2 10,000*2 20,000

An in-house testing lab for:

➢ Estimated material required and cost

Product Quantity Cost per piece Total cost

GSM cutter 1 8,000 8,000

Count Construction 1 3,000 3,000

Crock meter 1 13,000 13,000

Perspirometer (Color 1 25,500 25,500

Landline 1 3,000 3,000

Table 2 10,000*2 20,000

➢ Estimated Man Power Required

Position Requirement Salary Salary per month

Lab Head 1 42,000*1 42,000

Lab assistant 1 22,000*1 22,000

Helper 1 10,000*1 20,000

The markers contain the following details:

MARKER MAKING BY CAD:

1. Pattern Processing, Digitizing, PDS