APPAREL INTERNSHIP

AT
THE RAJLAKSHMI
COTTON MILLS





















































Presented by:
ZIAUL HODA
ARVIND KUMAR
Company Profile
The RAJLAKSHMI COTTON MILLS is a company based in the city of Kolkata in India.
The company produces and exports Organic textile products.

The countries to which it caters include The Netherlands, European countries, Japan,
South Korea, New Zealand and Australia.

Product Range: Ladies tops & shirts , kids tops and infants undergarments

Tops and Tees 60%
Skirts 20%
Other dresses 20%

Production Capacity:
Tees: 15000 pcs per month
Undergarments: 5000 pcs per month
Other dresses: 5000 pcs per month

Organisation Chart

Pattern Making I/C
Maintenance I/C
Managing Director

HR Manager GM Marketing

GM Operations Commercial Manager

Head Merchandiser

Marketing Manager

Production Manager
Merchandiser
(Knits)

Merchandiser
(Woven)

Stitching I/C Packaging I/C
Quality I/C
Finishing I/C
Sampling I/C
Cutting I/C
Sampling Department



Works for the preparation of the samples before the confirmation of order.

This department is responsible of developing all types of samples.

Department consisted of:
1 4- Single Needle Lock Stitch M/C
2- 3 Thread Overlock M/C
1- 5 Thread Overlock M/C
1- Flat Lock M/C
1- Double Needle Chain Stitch
1- Iron Table


Merchandising Department

The department was headed by the head merchandiser with a team of 4 merchandisers

The Merchandising department serves as a connecting link between production, design &
marketing department.

The main responsibilities and accountabilities of this team are during the sampling
programme were:-

Sourcing of fabrics and trims
Pre-production activities
Keep in touch with the buyers/buying house for any comments
Order for fabric and keep the status report
Find the fabric shortage(if any) so as to get the fabric on time
Label and trims requirement










Process flow in the Merchandising Department

Start of season
Sampling request send by the buyer along with techpk
Samples made & sent to the buyer
Modification & approval sent by the buyer
Costing sent by the company
Final order placed by the buyer
Development of Black Seal (Pre-production Sample)

Sent for final approval
Production starts after final approval
Salesman samples sent to the buyer
Store

The store area was divided into two sections one of which was for the fabric and the other for
trims and accessories.

The fabric stores included the racks containing fabrics as per the order.

Each rack had a swatch card which contained the details about the lot received including the
buyers name, weight/length of fabric, colour with samples attached on the swatch card.






Sewing Department

There were 11 sewing lines

Each line had 36 machines and inspection tables on either side of the line.

Total number of workforce:
Number of operators: 500
Number of helpers/distributors: 50
Number of supervisors: 11
Number of in-line checkers: 22


Before the production, a Time and Action plan was developed so that production is carried on
smoothly.





Work Flow in Sewing Department

Sent to finishing
Received cutting
Loading
Stitching
Fusing
To buffer area
In-line inspection
Finishing and Packaging Department

This department was responsible for some of the major operations like thread
trimming, mending/alteration, spot/stain removal, ironing, packaging of the garments
after the final inspection.

The department had a separate washing and spotting section

It had
20 iron- tables
6 tables for thread cutting
6 tables for spotting
Projects
Project: Control over needle breakage/damage so as to
reduce machine idle time

Objective: To study and analyze the probable reasons for the needle damage and controlling it

Reason for selection: Its one of the most important reasons for keeping the machine idle

Time Duration: 2 Weeks

Methodology:
We conducted a study for 5 consecutive days to find out the various reasons which
lead to the breakage of the needles .

Kept a record of all the needles that were broken during this period.

We provided the line supervisors with a format that contained the details about the
buyer, style number, time of the needle breakage, needle type, machine type and
name of the operator.

This was the format made by us to keep the records which we handed over to the Maintenance
Department.

S No. Buyer Time Style/job M/C type Needle type Operator Broken
needle
sample
Filled up format: Day 1
Observations
Total number of needle breakage : 73
DB X 1 - 28
DC X 1 - 17
UY 128 - 27
TQ X 1 - 1

Observed causes for needle breakage:
1. Needle is inserted incorrectly
2. Needle clamp screw is loose
3. Bent needle being used
4. Upper or lower threading is not correct
5. Upper thread tension is set too tight/high
6. Bobbin case not inserted correctly


Solution
Imparting knowledge of needle to the operators while their training module so that
the operators can change the needle themselves.

To let them know at least which is the needle type that fits his machine and identify it.

Provision of needles to the line supervisor so that no time is wasted waiting for the
person to come and change the needle.

Scheduled maintenance of all the smaller parts like screws, needle guard etc.

Regular maintenance of records for the breaking needles by the Maintenance
Department.


Analysis
Chart depicting needle breakage in the company



Reason Number
1.Needle is inserted incorrectly
2.Needle clamp screw is loose
3.Bent needle being used
4.Upper or lower threading is not correct
5.Upper thread tension is set too tight/high
6.Bobbin case not inserted correctly
Reason no.
Q
u
a
n
t
i
t
y

No. of needle breakage was : 73
Reason
DB X 1 DC X 1 UY X 128 TQ X 1 TOTAL
Needle is inserted incorrectly

5 2 2 0 9
Needle clamp screw is loose

7 5 8 0 20
Bent needle being used

4 2 6 1 13
Upper or lower threading is not correct

3 4 6 0 13
Upper thread tension is set too tight/high

3 3 5 0 11
Bobbin case not inserted correctly

6 0 0 0 6
TOTAL 28 16 27 1
EXERCISE METHODOLOGY

Chart depicting needle breakage in the company post suggestion


Reason no.
Q
u
a
n
t
i
t
y

Reason Number
1.Needle is inserted incorrectly
2.Needle clamp screw is loose
3.Bent needle being used
4.Upper or lower threading is not correct
5.Upper thread tension is set too tight/high
6.Bobbin case not inserted correctly
No of needle breakage was reduced to : 36

Reason DB X 1 DC X 1 UY X 128 TQ X 1 TOTAL
Needle is inserted incorrectly

2 0 1 0 3
Needle clamp screw is loose

6 2 1 0 9
Bent needle being used

2 2 4 1 9
Upper or lower threading is not correct

2 3 2 0 7
Upper thread tension is set too tight/high

1 3 3 0 7
Bobbin case not inserted correctly

2 1 0 0 3
TOTAL 15 11 11 1
Project: Operating Training Module
Objective:
Giving knowledge of the basic stitching processes to the
workers.

Methodology:
Developing stitching templates which include paper exercises
as well as fabric exercises.

Developing a format to rate the workers efficiency on a
regular basis.





STEP 1
Duration: 1 Day

Theory:

1. General idea of other departments in the factory.
2. Different types of Sewing Machines
3. Sewing Machine and its parts.
4. Threading sequence for different types of Sewing Machines
(S/N,O/L,D/N,F/L)

STEP 2
Duration: 3 Days
Practical

1. Treadle movement, Treadle Control PART-I

a. Running the machine at high Speed
b. Running the machine at low Speed
c. Running the machine at very low speed,
d. Needle up & Needle down.
e. Full speed & stop at stop points.
f. Roughing exercises.

2. Different kinds of Stitches.
3. Different kinds of Fabric, and its general use.
4. Different kinds of Needles, Threads and their use.
5. Stitches per Inch (SPI) & Stitches per Cms (SPC) and adjustments.

STEP 3
Duration: 7 Days

Practical
Paper Exercises (Single ply) with threaded machine.
1. Straight line (single ply)
2. Square (single ply)
3. Triangle (single ply)
4. Curve. (Single ply)
5. Circle or oval shape (single ply)
6. Zigzag Exercises.

STEP 4
Duration: 7 Days

Practical
Fabric Exercises (Double ply) with threaded machine.
1. Straight line (Double ply)
2. Square (Double ply)
3. Triangle (Double ply)
4. Curve. (Double ply)
5. Circle or oval shape (Double ply)
6. Zigzag Exercises.

Single Needle Lock Stitch Course Over Lock Course
Exercise Paper Sew
PS
Machine Ex.
SNMC
Fabric Ex.
SNFB
Machine
OLMC
Fabric Ex.
OLFB
S.No Total
Days
Operator Name 1 2 3 4 5 6 1 2 3 4 5 1 2 3 4 5 6 7/8 9 1 2 3 1 2 3 4 5 6

















Thank You..