Industry Project
To Create Storage Space for the Unused Samples in Theme Exports Private Limited
Submitted by Shreya Tewari
In Partial Fulfilment of the Requirements for the Degree of B. A. (Honours) Fashion Business Management (2014 – 2018)
Submitted to Mrs. Shazia Amanat School of Creative Business
Submitted on 5th December 2017
Acknowledgement The success and the final outcome of this project required a lot of guidance and assistance from many people and I am extremely fortunate to have got this all along the completion of my project work. At this juncture, I feel deeply honoured in expressing my sincere gratitude to my mentor Mrs. Shazia Amanat for her guidance and constant supervision as well as providing me with the relevant information as and when required to help me complete the project on time. I am grateful to my industry mentor, Mrs. Nandani Singh (Managing Director, Theme Export Pvt. Ltd.) for her support, invaluably constructive criticism and direction throughout my internship. I would also like to thank my fellow colleagues for guiding me throughout my internship period and imparting as much knowledge as they could. Lastly, I thank all my family members and friends who have been constant source of support during the preparation of this project work.
Declaration I hereby declare that the project report entitled “To Create Storage Space for the Unused Samples in Theme Exports Private Limited” is a record of authentic project work carried out by me, under the guidance of my mentor Mrs. Shazia Amanat. Any material taken from any published source has been suitably referred and acknowledged at various places in the report. Shreya Tewari Fashion Business Management 2014 – 2018 December 5th, 2017
Executive Summary Embroidery is one of the oldest and most popular forms of surface ornamentation of fabrics and garments, and India is among the top suppliers of embroidered fabrics and garments worldwide. The demand for garments embellished with embroideries with sequins and crystals is quite strong in the international market, as also in India. However, while embroidery is used in a whole lot of products internationally, the market is still an unexplored one in India. As in 2012, the size of the Indian embroidery market was slated to be around Rs. 800-900 crore per annum. Theme Exports Private Limited is a business started by two friends who believed in the embroidery sector of India. The export house has been in the industry for two decades now and is a huge player of embroideries in the women and the kid’s wear sector. It is headed by Mrs. Nandani Singh (Managing Director) and they have big customers like Michael Kors, Chico’s, Club Monaco, Boscov etc. Sampling department is an important part of an export house in the apparels industry. It is important to understand that the main business of any garment export house starts with its sampling department and therefore, it is important to keep a record of all the samples that have been created in the past or about to be created. Hence, an export house must have a proper process or method that can be followed to eliminate the unorganised method of working and delay of services. A flow-chart has been suggested to follow in order to keep all the used and the unused samples available as and when required so that they do not come in the way of the merchandisers and do not affect the productivity of the export house. The flow-chart is laid down by a primary approach.
Table of Contents S.No. 1.1 1.2 1.3 1.4 2.1 2.2 2.3 2.4 2.5 3.1 3.2
5.1 5.2 5.3 5.4
7.1
7.2
Particulars Chapter 1: Introduction Rationale Objective of the Study Scope of the Study Limitation Chapter 2: Introduction to the Company About the Company Product Categories Major Customers Department Structure Corporate Social Responsibility Chapter 3: Company Analysis SWOT Analysis Critical Analysis Chapter 4: Day to Day Work (24) Chapter 5: Background Study Sampling Unit at a Garment Export House Storing/Warehouse Unit at a Garment Export House Importance of Storage at a Garment Export House Activities in a Storage Unit at a Garment Export House Chapter 6: Research Methods (37) Chapter 7: Analysis and Findings Analysing the Sampling Department at Theme Exports Private Limited Analysing the Storage Capacity of the Sampling Department at Theme Exports Private Limited Chapter 8: Recommendations (40) References (41)
Page No. 1 1 1 2 3 3 5 6 21 22 23
32 32 35 35
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Table of Images S.No.
Particulars
Page No.
1. 2. 3. 4. 5. 6. 7. 8. 9.
Ratna Singh and Nandani Singh Product Range at Theme Exports Techniques J. Crew Club Monaco Neck & Neck Michael Kors Showroom Design Cell Different types of testing apparatus at Theme Exports Merchandising Department Fabric Storage Area Cutting Sewing Embroidery Dry Cleaning Process of keeping a record of Unused Samples
3 3 4 5 5 6 6 7 8
10. 11. 12. 13. 14. 15. 16. 17.
9 10 13 14 15 16 17 39
Chapter 1: Introduction 1.1. Rationale Sampling is the first and the most important stage in a garment export house since it helps an export house to build a relationship with its buyers and receive orders for various collections created by the brands. However, at Theme Exports, various buyers get a huge number of different styles made but tend to choose only a few out of the lot. This results in the creation of a pile full of samples that aren’t used by the buyer and the export house as well. There is a need to understand that a lot of cost is incurred by an export house when a sample is created. When the buyers don’t take all the styles and leave behind a pile of samples they don’t require, it becomes difficult for the export house to store them and save them for the future. The rationale of the study is the situation and the mess in the sampling department because of the unused samples kept there with an uncertainty of whether they will be used later or not. Thus, there is a need to develop a method for keeping a record of the samples that were once created but never used again. This will help the export house in getting rid of the mess at the workplace and also, will help the merchandisers to reach an old sample as and when required.
1.2. Objective of the Study The objective of the study is to analyse the sampling unit of Theme Exports Private Limited in terms of keeping a record of all the samples made for various buyers and understanding the importance of storing the unused samples in a way that might help the export house in recovering those samples when required later. The main objectives of the study are: 1. To study the importance of a storage area in an export house. 2. To develop a suitable method to record and store the unused samples in Theme Exports.
1.3. Scope of the Study The study will include an assessment of the storing of samples at Theme Exports Private Limited. There will be a theoretical approach to the importance of a defined Standard Operation Procedure (SOP) for the proper recording of the unused samples in the sampling department. The study will provide a suggestive method for keeping a record of the samples left behind by the buyers so that they can be used later.
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1.4. Limitation The following limitations were faced while working on the present study which helped in achieving better results: 1. The merchandisers were unable to give an insight into the number of samples that were not taken by the buyers. 2. The lack of any manual or digital record of what all samples are kept unused in the department.
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Chapter 2: Introduction to Theme Exports Private Limited 2.1.
About the Company Theme Export is a Government recognized star rated export house established in 1997 in New Delhi, India by two friends Nandani Singh & Ratna Singh. What started as a small studio project with a vision to take Indian embroidery traditions to the world is now the go-to manufacturing cell for the crème de la crème of international design. (www.themeexport.com)
Ratna Singh and Nadani Singh; Source: www.themeexport.com
Bringing together the vast variety of techniques and traditions that the country has to offer, under one roof, their product range including apparel, accessories, jewelry and home furnishings working with clients all over the world in the US, UK, Italy, France, Spain, Turkey, UAE and India. (www.themeexport.com) The export house works on bringing in all the craftsmanship existing in the nation and combining it with the latest technology to deliver innovation in design and aesthetics, sophistication in production and a cost-effective working environment to create a place in the evolving global marketplace. (www.themeexport.com)
2.2.
Product Categories The idea is to “create something beautiful, one piece at a time”. Their product range includes: 1. Apparels - From casual to party wear. 2. Fashion accessories - from bags, belts and scarves to precious, semi-precious and costume jewellery. 3. Hard goods 4. Home furnishings.
Product Range at Theme Exports; Source: www.themeexport.com
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Each product is a labor of love, produced with the finest stitching and craftsmanship, and keen attention to the finesse of execution. With over 20,000 products and precious embroidery swatches, the design archive has been collected painstakingly over the last 18 years, with hidden treasures and inspirations in every corner. (www.themexport.com) Other than a wide range of products, Theme Export also has a huge range of embroidery techniques which it is famous for in the global market. They take inspiration from myriad cultural tones, moods and needlework techniques, indigenous to each region of India and take them one step further through a process of innovation and fusion, giving birth to the unique design signature. (www.themexport.com)
AARI
Bandhani
Bead and Sequin Embriodery
Block Printing
Chikan
Crochet
Embriodery on Leather
French Knots
Bead and Sequin Embriodery
Knitting
Schiffly
Soutache: Dori, Ribbon & Gota
Techniques; Source: www.themeexport.com
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2.3.
Major Customers Theme Export works with a wide range of customers from all over the world. It believes in collaborating with the brands and the buyers who work honestly and tend to deliver the best to the world. The export house works with the following brands: 1. J. Crew
J. Crew; Source: www.jcrew.com
J. Crew was started in 1983 when it first started selling its catalogues. It opened its first flagship store in New York’s South Street Seaport, six years later. The brand is now known by its retail outlets worldwide.
J. Crew launched its first factory in 1988. The styles offered by the factory are known for their exclusive designs including cool colors, bold prints and casual classics. The brand also partners with many other leading brands from different categories like Jack Purcell, Timex, Thomas Mason and Red Wing etc. (www.jcrew.com) 2. Club Monaco
Club Monaco; Source: www.clubmonaco.com
Club Monaco is an international retail brand that designs and creates modern yet timeless clothing and accessories for women and men. Since its first store opened in Toronto in 1985, Club Monaco has been recognized by fashion influencers for it’s thoughtfully deddesigned, purposeful collections featuring relevant, wearable pieces, fine fabrics and exceptional fits. Headquartered in New York City’s Chelsea Gallery district, Club Monaco can be found worldwide with stores in the United States, London, Sweden, Canada, Hong Kong, Seoul, Beijing, and Macau. (www.clubmonaco.com)
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3. Neck & Neck
Neck & Neck; Source: www.neckandneck.com
Neck & Neck is a leading Spanish brand in children´s clothing with more than 200 exclusive stores located in 15 countries. Family oriented values inspire their decisions and way of working as well as their collection´s designs, and without doubt exemplify the philosophy that has guided them ever since the brand’s birth in Marbella. With a clear and strong international focus since the company´s creation, NECK & NECK has been working hard since 1993 to offer their creations worldwide. (www.neckandneckusa.com) 4. Michael Kors Michael Kors is a world-renowned, award-winning designer of luxury accessories and ready-to-wear. His namesake company, established in 1981, currently produces a range of products under his signature Michael Kors Collection and Michael Kors labels. These products include accessories, footwear, watches, jewellery, men’s and women’s ready-towear, eyewear and a full line of fragrance products. Michael Kors stores are operated either directly or through licensing partners in some of the most prestigious cities in the world including New York, Beverly Hills, Chicago, London, Milan, Paris, Munich, Istanbul, Dubai, Seoul, Tokyo, Hong Kong, Shanghai and Rio de Janeiro. (www.michaelkors.com) Michael Kors; Source: www.michaelkors.com
2.4.
Department Structure Garment export houses like Theme Exports, take orders from buyers or buying agencies and process the order in a factory to produce finished products. To process an order, from sourcing of raw materials to cutting to stitching to packing to dispatching goods to buyers, materials are passed through many hands (Garment Export House). To make garments ready to ship with desired quality and on time delivery, garment manufacturers need to establish various departments based on the activities. Each department performs number of activities. There is no fix number of activities and activities of department depend on the organization size and major processes involved in export order processing (Sarkar, P., 2013). An Export house performs the following functions: 6
Marketing Merchandising Sourcing Sampling Production Quality Control Industrial Safety Product Safety Documentation Logistics Finance
At Theme Exports, work and responsibilities related to the above functions are allocated to the following departments to manage process and sub-processes smoothly: 1. Showroom and Meeting Room
Showroom displaying the latest collection manufactured by the export house; Source: Author
It is where all the meetings with the buyers and decisions on orders take place. The room is set up by the merchandisers and it showcases the following:
Collection of the newly developed range for the current season, along with the details Collection of past production successes in order to gain the trust of any new buyers Collection of fabric swatches, swatches with value addition and swatches with different washes, along with the required details.
The showroom identifies with the company’s essence and is set up with the utmost care since it’s the only contact point with the buyers or potential buyers. Hence, while setting up a showroom for business, products are displayed according to the requirement of the buyer. Also, each and every detail is 7
discussed with the buyer like the minimum required time etc., before processing any order. For the meetings with the buyers, all senior merchandisers are present along with the technical team (for any suggestions or explanations), the design team (for any changes) and merchandisers from the suppliers’ company. 2. Design Cell Design and innovation are the USP of Theme Exports, making the design studio an eminent part of the company. The export house has a team of expert designers, merchandisers and engineers across various divisions who ensure that it manufactures highly sophisticated, uniquely designed pieces for the customers. The large team of designers includes graphic designers who with the help of CAD (Computer Aided Design) focus on designing customized embroidery layouts and lace patterns which are developed in the in-house facilities. A designer working on the intricacies of a design; Source: www.themeexport.com
The division focuses on providing services such as market intelligence & trend forecasting both to fabrics & end line products. In addition, they also work on creating mood boards as well as developing products from direction provided by the customers. Along with getting the designs ready for the buyers, they also focus on information about the product lines so as to provide the buyers with the best possible presentation. 3. CAD Department Computer Aided Design system or CAD involves any kind of design activities which use of computer to develop, analyse or modify any engineering or garment design. It prepares the marker using the patterns prepared by the sampling department. A marker is a diagram of precise arrangement of pattern pieces for a specific style fabric and distribution sizes. It determines the most efficient layout of pattern pieces, hence avoiding wastage as much as possible. 4. Sampling Department Sampling is the making of a sample according to the buyer’s specification or the tech pack of the buyer just to check or analyse the style, look, fit etc. of the garment. Sampling is the basic step of any style before reaching the bulk production. 8
Sampling Department is a restricted area used for making samples of collections and for fitting. The focus of this department is on product development. It is a beehive of continuous product development aimed at creating lines and collections as per “the look” of a specific customer of general collections following the international fashion trends. At Theme Exports, there were various operations under sampling like pattern making, sewing, embroidery, bucket dyeing, finishing etc. 5. In-house Testing Lab
Different types of testing apparatus available at Theme Exports Pvt. Ltd.; Source: Author
The fabric samples are sent to the laboratory for Fabric Package Test (FPT) with a list of tests that are to be carried out as per the buyers’ specification. Below are some of the tests conducted by the laboratory: Tearing Strength Tester is used to determine the resistance of fabric against wearing and tearing. Tensile Strength Tester is used to give the resistance against normal loading. Crocking Fastness Test is used to find out the resistance of colour against rubbing. Digital Pilling Tester is used to predict the pilling behavior of the fabric or the garment after its use. Launderometer /Wash Meter is used to test the number of washings before the color fades from the fabric. PH Meter Hot Air Oven is used to check the fabric for flammability.
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Light Box is used for the color assessment for textiles and clothing. It assesses any color changes and matches the swatches under different light sources such as sunlight, daylight, fluorescent, etc. An instrument is used to measure the weight of a fabric in GSM i.e. weight expressed in grams per square meter. Button Pull Test Perspiration Test
6. Merchandising Department A merchandiser is the interface between the buyer and the supplier who has to ensure the quality of production and timely delivery. A merchandiser directs and oversees the Merchandising Department at Theme Export; Source: Author
development of product line from start to finish. The role of the merchandisers is to look for the appropriate market, to get the samples made according to buyers’ satisfaction, the estimate and quote the cost of the garment to the buyer and negotiate with them, to get orders, to be in constant interaction with the buyer for the approval, to get the fabric and trims in-house for the bulk production and to coordinate with PPC and production. Also, a member of the merchandising department works closely with the workhouse/shipping and quality control department to ensure that all the garments meet the quality standards related to style, colour and size. Levels of merchandisers for a company depend on the volumes of business. More the number of product categories, wider are the merchandising unit. 7. Quality Assurance Department For Theme Exports, quality is of utmost importance. Here, attention to detail is the name of the game, from neatness to the fall of the fabric. People here are involved in the product development process, ensuring that product standards are defined and achievable. In order to ensure high quality, the export house maintains some sort of quality assurance or quality control plan and procedure. Quality control is AQL (Acceptance Quality Level) based, which is a sample
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based product inspection system where minimum defective goods are acceptable in an order as per the guidelines provided by the buyer. The quality floor performs the following functions: Inspection of Raw Material Checking of raw materials to ensure there is no defective or abnormal material. Testing of Samples Theme Exports sends its sample to testing lab for testing physical and chemical test. Once the factory receives the test report, the quality control team gets assurance of whether to accept the raw material or not. Inspection of Sample Visual inspection and measurement checking is done, prior to sending sample to respective buyers. Cutting Room Inspection It inspects the work done by the cutting room like layering of fabrics on the cutting table, cut layer inspection, cut component inspection, bundle inspection etc. Preparatory Work Inspection A lot of preparatory work is outsourced like printing, etc. Before feeding the outsourced goods, quality department checks and approves for further process (sewing process). Sewing Process In sewing there are multiple checking processes that are practiced by the exporters like inline inspection, end of line inspection, stitching quality audit etc. Finishing Process Finally quality personnel checks finished and packed goods and do auditing prior to handover shipment to external inspector. Quality System Development Quality Control Department is responsible for setting quality system for the factory. Quality Awareness Development They are also responsible to bring quality awareness among the workers and all employees.
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8. Department for Research and Development (R&D) This department is responsible for the following: Analysing products, whether they are production feasible or not, before sending final approval to the buyer. Risk analysis and viability of the orders the company receives. Advice on ways to execute the order. 9. Department for Production, Planning and Control (PPC) This department controls the planning and gives the guidelines from everything related to fabric to shipment. The main aim of PPC is to create deadlines for each process and to coordinate with various departments. The PPC department formulates the construction feasibility and cost analysis of the style of the garment based on the report from the department of R&D. They also prepare a monthly capacity budget for each production unit. The PPC department takes care of the following in the export house: Optimum utilization of production capacity. Production scheduling and allocation of orders. Resource planning for man, machine and raw materials. Ensuring quality. 10. Industrial Engineering Department The I.E. department of the export house is involved with different departments performing the following functions: Designing of plants and their components. Monitoring the performance of different departments through techniques such as time studies and suggesting methods of improvement in productivity and efficiency. Introducing and maintaining new mechanical and electrical systems. Designing various production processes. Planning of production and machinery to improve plant efficiency. Monitoring the thread consumption. Dealing with line balancing, i.e. setting up or rearranging a production line and deploying whatever machines and operators are available so as to achieve the optimum level of output.
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11. Fabric Storage Unit
Fabric Storage Area at Theme Exports Pvt. Ltd.; Source: www.themeexport.com
When the fabric is sourced and brought to the export house, they are stored in the factory’s fabric storage area, under the responsibility of Fabrics Storage department. This department keeps a record of the movement of fabrics into the export house and within the export house. The structure and size of the fabric storage unit is as per the size of the export of house. Fabrics used are procured from noted textile mills in the country & overseas. Before placing an order, the merchandisers analyze all the vendors and then select the most suitable one based on the quality and the lead time on procurement for the fabric. Or, they source fabric from the supplier nominated by the buyer. From here, the fabric is taken for inspection and then stored in specific locations from where it is issued for cutting. Every inch of the fabric is checked for uniformity in color, printing & finishing. There are various racks to stack fabric. At Theme Exports, rolls of fabric are kept together on the basis of a particular buyer. 12. Trims and Accessories Store It is a huge store house for all the accessories required by the export house, both for sampling and for the bulk production. It includes rivets, buttons, labels, wash care, fusing, zipper, threads (from Euro brand), velcro, packing material, general stationary items, pattern paper rolls, cutting blades, trimmer, needles, beads, lace and many more items. The merchandisers as per buyer’s specifications order in all the accessories that are used in a particular style for that buyer. Once the accessories are received from the vendors, they are sent in for checking and testing for quality and colour. They are then issued to the sampling and production departments when the production starts.
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13. Cutting Department Cutting is the very first process in garment manufacturing. It is done according to the master patterns with 100% accuracy.
Patterns are sent to the cutting room for laying fabrics according to the patterns; Source: www.themeexport.com
Functions of the Cutting Department Spreading Layering Cutting Manual/Autom atic Ticketing Fusing Checking Bundling Transfer to Production 
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Spreading and Layering It is a process of smooth layering of fabrics in superimposed layers of specified length. It can be done manually or through a spreading apparatus. Cutting It is done to get the raw materials in required shape and quantity, accurately and economically and in sufficient value to keep the sewing room supplied with work. It can be done manually by skilful labour or automatically using instruments like powered scissors or round, straight or band knife.
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Ticketing Here, cut components are grouped together as per their sizes and taken to the checking table for any errors. Fusing The parts to be fused are separated from the bundle. The fusing material is cut according to the size of the components to be fused. Both the component and the cut fusing material are then passed through the fusing machine. Checking The ticketed panels are sent to the checking area for inspection of every individual piece for any objectionable faults. Panels having faults like wrong grain line, inappropriate size, incorrect shape and any fabric defects like holes, cuts, shade variation, etc. that are not within the acceptable quality parameters are removed from the cut lay. Bundling The checked components are arranged into bundles which contain pieces of same style and same size. The cutting department issues the amount required by the production department as and when asked for.
14. Sewing Department It is the most important department of any garment manufacturing unit which is responsible for the conversion of cut panels into actual garments. Brand labels and size labels are also attached in sewing. When a new style comes over, information like operation breakdown, sewing details, critical operations, etc. is put up on the display board. A sample of the garment is also put up in front of the sewing line for any type of reference.
A worker sewing on a garment of the latest trend; Source: www.themeexport.com
Theme Exports Pvt. Ltd. follows the Assemble Line Production System in which a garment is stitched by a number of workers. Therefore, one part is stitched by one worker and then passed on to the next worker. Hence, operations are assigned to the operators according to their skill set. Line-in-charge or the supervisor gives directions to the operators about their respective jobs and Inline checkers or QC’s ensure that the quality coming out of each operation is as per the quality specification. 15
Modern machinery from recognized brands such as High Lead, Juki etc. is used to sew garments. A mix of simple lock stitching machine, over lock machine, flat bed machine, button attaching, button hole and snap button machine, machines for piping, shearing, cuffs and collar are present in the export house. 15. Embroidery Unit Different export houses use different methods of embroidery for their garments, i.e. Hand or Machine or Computerised embroidery. This also depends on the requirement of the buyer. Theme Exports uses both hand and machine embroidery for their clients. A series of embroidery techniques are possible on machines.
Embroidery of intricate designs into the fabric by hand; Source: www.themeexport.com
16. Printing Unit Export houses are equipped with printing apparatus like printing machines and tables with the capacity of printing garments. A lot of times, printing is outsourced and if it’s in-house, they do a lot of panel printing on garments. 17. Washing Unit Garments pass through various handling processes, which may render them dirty and stained, thereby reducing their aesthetic appeal. To restore this aesthetic value, they are subjected to cleansing processes like washing and dry cleaning. Garments are sent for washing by the production department as per the buyer’s requirement. Washing is done for several reasons: Control uneven shrinkage Lighten colour shade Even out colour shade variations Remove printing smell Execute a dyeing program 16
Theme Exports Pvt. Ltd. uses a Tumble Dryer for washing which evaporates out all of the left over water from the garments making them completely dry. The garments go through different types of washing like: Normal wash Garment wash Enzyme wash Stone wash Softener Bleach Acid wash Monkey wash Emery balls wash Silicon balls wash Sand wash 18. Dry Cleaning Unit This process makes use of a PERC machine. The solvent used in this machine for stain removal is Perchloroethane. Every garment is not subjected to this treatment. Only those garments which have stubborn impurities like oil and rust, under this process. Mostly light or white coloured garments that are more vulnerable to staining are dry-cleaned. This PERC treatment gives whiteness as well as shiny appearance to the garment.
Left: Stain removal process; Right: Textile spot cleaning gun; Source: Author
A number of other chemicals like softener, optical brightening agent, hard stain (Zn) remover, anti-wrinkle agents, hard water stain remover, etc. are also added. 19. Finishing Department After assembly, the garments are sent for finishing - a key stage of garment manufacturing process. It is done to prepare the final garment according to the
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quality standards of the buyer before packing it for shipment. Stitched garments need to be finished and nicely folded and packed to display on retail shops. Various jobs are done in this department such as thread cutting, checking and spotting, alteration, re-ironing, final quality and measurement check, tagging, folding as per buyer’s specification, etc. Some of the instruments used for these functions are thread cutter, steam iron, flat bed, thread clipper, spotting guns, stickers, etc. Garments are checked again at this stage to dismiss errors like missing of labels, fabric flaw defect, holes, stains, poor construction, sizing problem, poorly trimmed garment threads, broken or skipped stitches, open seams, etc. 20. Packing Department Packing is the last stage where the final garments are primed, organized and geared up for the shipment to the buyer. The entire process from the way a garment will be folded to the final labelling of the cartons is dictated by the specifications provided by the buyer. Buyers demand this so as to achieve consistency in the packages and to also provide a visual value to the product at retail label within their vendor base. These instructions are standardized for a particular type of garment and sent to the merchandiser in the form of a packing manual. The merchandiser forwards it to the packing in-charge along with a sample, i.e. packed with the packing dimensions approved by the buyer. This is kept as a visual reference for the packers. As the garments are received from the finishing department, they are first sent to the packing table for counting. This is done to maintain a record of how much goods have been received by the department and how much have been packed. Packing is done in two stages: 1. Poly bag packing, which involves tacking and folding. 2. Carton packing, where cartons come from a nominated source by the buyer. Also, stickers are stuck to the cartons which contain details like buyer’s logo, measurement of the carton, style number, colour code, country code, fabric description, size ratio chart, weight, etc. 21. Shipment Department The shipment department of the export house takes care of all the shipments. It looks after the following: 1. Delivery Schedules The department holds the responsibility of handling all the delivery schedules as and when promised by the export house. 2. Dispatch The department looks after the in-coming and out-going of materials in the export house. The following details are recorded: Dispatch receipt Dispatch issue 18
Checklist Finishing pending Records 3. Pre-shipping The department prepares two invoices i.e. commercial invoice and custom invoice. The commercial invoice is prepared for the buyer and the custom invoice is prepared for the authorities of both the countries before the shipment of goods. 4. Post-Shipment After the shipment of the goods, the exporter sends all the documents to the buyer’s bank for the payment. As the buyer’s bank will receive the documents, it will confirm with the buyer for the release of payment. 22. Documentation Department The documentation department of Theme Exports is centralised for all the units. The entire data related to all the departments is stored with a backup in the computer system through an EDI system. The department holds the following documents: Shipping Bill Custom Clearance Certificate of Origin of Goods Duly-signed Invoice Test Certificate of Goods Purchase Order Letter of Credit 23. HR and Administration Department This department is responsible for the human resource management, hiring employees, establishing HR policies as per Government rules and regulations and taking care of legal issues. The export houses have a formalized selection, evaluation, and payroll processes for its employees. The function of this department consists of tracking innumerable data points on each employee, from personal histories, data, skills, capabilities, experiences to making payroll records. They work in close co-ordination with documentation to ensure all documents are correct. They also keep the Government policies notification up to date. The HR department is divided into two sections for the better control of manpower, i.e. Corporate HR and Factory HR. There is an HR head leading a group of people. The hierarchy of HR is much more detailed for the factory because of large number of workers. 24. Accounts Department Like any other company, accounting department in the export house is responsible for preparing employees payroll, distribution of salary and wages, 19
managing company accounts, etc. They help in ensuring that all the payments are correct and on time for all the suppliers. This department also ensures that the company receives payments for sampling/sale sampling. They maintain the salary records with close co-ordination with the HR department. 25. Vendor Social Compliance As a corporate citizen and a business entity that is evolving through continual improvement in ethical business, employee welfare and adherence to local and international laws has been certified SA – 8000, by Bureau Veritas Quality International (BVQI). The certification is widely accepted in the Europe & the US as a sign of a corporate body that has definite ethical business practice. It not only ensures better work environment, equal pay, grievance handling mechanism, definite disciplinary procedure, mechanism to check and address sexual harassment and healthy employee-management relationship at the premise of manufacturing that is certified but also takes care of the supply chain, and ensure that starting from raw material supplier, accessory supplier to shipment of final product, ethical business is practiced. This is ensured in the form of Supplier Compliance. The following are the standards:
Child labour Forced labour Health and safety Freedom of association Discrimination Disciplinary practices Working hours Remuneration Management system
26. Cafeteria Cafeteria in an export house is very similar to a lunchroom or dining hall where food is served from counters or dispensed from vending machines or where food brought from home may be eaten. It is a great place to promote social interaction among employees at a time when social interaction is appropriate. Through cafeteria, employees can be served with healthy food options which in turn can improve their productivity.
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2.5.
Corporate Social Responsibility Theme Export believes in strengthening the women all around the nation by making them contribute in the process of making the world a better and a safe place for the women all around the world. Two passionate women started a journey with a vision of changing the world and thus, their CSR is all about creating a workplace that is largely owned and run by women. And in order to create a better workplace for the women, the export house believes in extending its support to make the workplace more comfortable, conducive and safe through facilities such as their in-house crèche, transportation services to drop female staff at their homes at night, assistance during pregnancy and maternity leaves etc. (www.themexport.com)
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Chapter 3: Company Analysis 3.1. SWOT Analysis A SWOT is an analytical tool used to measure the overall environment of a company. SWOT Analysis consists of two factors that affect a company – internal and external factors. Internal Factors 1. Strengths Strengths describe the positive attributes, tangible and intangible, internal to an organization. They are within the company’s control. 2. Weaknesses Weaknesses are internal, negative attributes of one’s business that detract from the value they offer or place them at a competitive disadvantage. These areas are the ones that need to be enhanced in order to compete with one’s best competitor. External Factors 1. Opportunities Opportunities are external attractive factors that represent reasons one’s business is likely to prosper. 2. Threats Threats include external negative factors beyond the company’s control that could place their strategy, or the business itself, at risk. The company has no control over these, but they may benefit by having contingency plans to address them if they should occur. (www.economictimes.com) Given below is the SWOT analysis of Theme Exports Private Limited: Strengths The export house has an experience of more than 20 years in women’s wear and kids’ wear. It is an established export house that offers the best embroideries in the country. The employees working in the company are loyal and share a good rapport with their superiors. Weaknesses There is a lack of storage areas for various samples and production pieces which makes the working environment a bit messy.
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There is a lack of proper quality control over products, resulting in inefficient products.
Opportunities As the market of kids wear is emerging at its full pace, the company can look into expanding its base and taking in newer customers/buyers. Since the company has a rich experience in the domestic market of embroidery, it could rise immensely with modified policies and stronger implementation. Threats With the ever-emerging export business of India, slow growth can be damaging for the company as companies with better facilities and products are sprouting at a fast pace.
3.2. Critical Analysis Theme Exports has a vast experience in various types of embroideries across varying price segments in both domestic and international markets. The group has an experience of more than two decades in the domestic women’s wear and kids wear market with the experience ranging from manufacturing to exports. It has excelled in developing a global market for the embroideries originated in India. The export house’s strong relationship with international retailers and brands dates back several decades.
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Chapter 4: Day to Day Work At any given garment manufacturing unit, the process of manufacturing can be divided into three stages.
Process of Garment Manufacturing
Pre-production Process
Production Process
Post-production Process
The cycle starts with the pre-production processes related to a particular style, goes on to its bulk production in the factory and ends with the post-production processes involved. The processes involved in the cycle of production of each style is the same, with the only different processes to be involved are that of different value additions. (Since I witnessed only the Pre-Production and Post Production processes of a style, the Production processes will not be included in the discussion). The pre-production and the production processes followed at Theme Exports, for any given style are explained below.
Pre-production Process The pre-production process is followed prior to the bulk production of garments in an export house. The process starts with meetings with the buyers and ends at the production of a sample for the bulk production. It is a stage that determines what is to be manufactured, how it is to be manufactured and what guidelines are to be followed while manufacturing the style. It is as follows: 1. Meeting with the Buyers The first stage in the garment manufacturing process is meeting with the potential/existing buyers. The designers of the export house showcase their collection and designs to the buyers in the meeting/show room. The buyers then decide the designs according to their requirements. If the buyer already has a design then changes are made according to the fit, fabrics or trims. This is the stage at which all the inspiration that the designers have been working on over the past few months is put to use in terms of feasibility for the mass production.
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2. Creation and Receipt of Tech Packs Based on the discussions held at the meeting with the buyers, the designs of the garments that are feasible to go into bulk production are worked upon by the design department of Theme Exports or of the buyer. If the design belongs to Theme Exports, their design department creates a tech pack for that particular style and forwards it to the buyer for assessment. On the other hand, if the design belongs to the buyer, their design team sends the tech pack to Theme Exports to notify them about their requirements. Every tech pack goes through stages of improvements and changes until both parties are satisfied. The tech packs include Design sheet, to depict the look of the style. Specification sheet, to depict the seams, attachments to the garment or anything specific about the style. Measurement sheet, which is helpful while making patterns. Bill of Materials (BOM), to determine the quality of the raw materials that go into creating the garment and the source of procuring the raw materials. 3. Pattern Making Based on the tech pack of the style, the design department at Theme Exports work on the patterns required to manufacture the samples for that particular style. 4. Procurement and Inspection of Raw Materials The raw materials for the first sample are procured at this stage and are tested for its quality, as promised by the vendor. The tests are either done in the inhouse testing labs or are outsourced. The physical and chemical properties of the fabric and trims are checked. 5. Development of Proto Sample This is the first milestone in the process of garment manufacturing. Proto sample is the proto type of a new design created by the designers. This is made to communicate the design of a style or a line or to present garment structure. In proto samples, fit is not considered. It is made using the raw materials ordered by the export house to create the best possible version of the design. 6. Approval of Proto Sample by the Buyer After sending the proto sample to the buyer for assessment, the merchandising team at the buyer’s end comment upon the sample and suggest simple yet required changes, if any. If the sample is not approved, Theme Exports re-create the sample with suggested changes and re-send it to the buyer. If the sample 25
gets approved, Theme Exports move on to the next stage in pre-production process. When the proto sample gets approved, three major decisions are handled at this stage: Cost negotiation and closure (cost sheets are created with overheads and manufacturing costs added to it) Delivery closure Building up the Time & Action calendar according to the ex-factory date defined by the buyer Also, the tech packs are sent to the Industrial Engineering (IE) department to calculate the Standard Allotted Minutes (SAM) & Standard Minute Value (SMV) for the style and also to the planning department to plan the production according to availability, efficiency and capacity of the workforce and the factory. 7. Creation of Purchase Order After the design has been approved by the buyer, costs have been negotiated; delivery dates have been confirmed; shipping terms, payment terms and mode of payment has been settled and quantity of the style has been finalised, a Purchase Order is issued by the buyer to Theme Exports as the first official document indicating the order confirmation. 8. Development of Fit Sample Fit sample is made with actual measurements of the basic size provided by the buyer. Modifications on the pattern are done to get the desired fit of the garment. It is tested either on a live model or standard-sized mannequin to verify garment fit and fall. For the fit sample, the only requirement is the correct quality of the fabric, since different fabrics have different falls. This sample goes to the technician of the buyer’s end. Also, at this stage, the merchandising department at Theme Exports books around 60% – 80% of the greige fabric required for the style. 9. Approval of Fit Sample by the Buyer The fit sample can get approved at the 1st stage or can go up to 3rd stage, until the buyer approves of the fit of the style. Also, at this stage, the quality of the raw materials is approved by the buyer. For this, Theme Exports sends Lab Dips (for solid fabrics), Bit Looms (for yarn-dyed fabrics), Strike –offs (for printed fabrics) and Knit Downs (for knitted fabrics). Later on, the rest of the fabric is booked by the export house.
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10. Development of Size Set Sample The main purpose of the size set sample is to check the factory's capability to make the sample in all sizes. It also depicts the placement of embroidery or prints whose dimensions change with the changing size. 1-2 samples (or quantity specified by buyer) of each size are sent to the buyer for assessment. 11. Approval of Size Set Sample The buyer sends in comments about the size set sample sent by Theme Exports. Once approved, the factory moves ahead with the next process. 12. Fabric Package Testing (FPT) At the fabric stage, the fabric procured from the vendors is tested for its approval for mass production. It is a mandatory test and the lab can be nominated by the buyer. Some of the basic tests that are conducted on each and every fabric are as follows: Yarn Count Construction Grams per Square Meter (GSM) Fibre Composition Tensile Strength Tear Strength Colourfastness to washing (at 40 degrees) Colourfastness to rubbing Colourfastness to perspiration. Colourfastness to water Shrinkage A buyer can ask for additional tests as per their requirement. If all requested test results don’t meet or exceed buyer specified requirement, then the fabric is not approved for further processes. In this case, the fabric is sent for re-processing. 13. Development of Pre Production Sample PP sample is considered to be a contract between the buyer and the factory. It has to be made in original fabric and trims with washing, embroidery and printing matching to the actual standards. It is the first sample to be made in actual production line by the sewing line tailors, so that the operators know what they are going to make. PP Sample is the standard for production and bulk production garments should be identical to PP sample. The factory can start the production of bulk garment only after the approval of pre-production sample.
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14. Approval of Pre Production Sample The buyer’s team follow up the receiving of pre-production sample with comments and any last suggestive changes. Once the sample is approved, the order file is transferred to the production department who then follow up with the order and provide with a Planned Cut Date (PCD).
Production Process at Theme Exports 1. Creation of CAD Marker A Computer Aided Design Marker is a thin paper/digital sheet which contains all the components for different sizes for a particular style of garments. Patterns are made according to the measurement specifications given by the product development team of Theme Exports and grading is done for all the sizes. The purpose of marker planning is to determine the most efficient combination of sizes and shades for each order and to produce the best fabric yield and equipment utilization. One cutting order may require several markers to achieve optimum efficiency (Textile Learner). At Theme Exports, it is made through Opitex software before cutting the fabric. 2. Fabric Spreading Once the fabric is approved after the inspection, it is spread down as a preparation for cutting. A pile of fabric is laid on a table in a predetermined direction and relationship between the right and wrong side of the fabric. (Kiron, M.I., 2013). Theme Exports follows the method of manual spreading in which the operators work back from the end, aligning the edges and ensuring that there is no tension and that there are no wrinkles while spreading the fabric. 3. Fabric Cutting Once the fabric is laid down, it is cut according to the marker made on CAD. Cutting can be done manually or through machines. Theme Exports follows the method of manual cutting through scissors and use machines such as straight knife for automated cutting. 4. Ticketing/Bundling After cutting the fabric, all the components cut are labelled and then combined in bundles according to the parts and sizes which they are cut for. Tickets carry details such as style number, size, ply number, bundle number and issued date. Bundle ticket consists of order number, bundle number, quantity, style number, size and section.
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5. Quality Check The quality check department checks whether all the cut components are available and qualify according to the standards set by the buyer, before stitching starts. 6. Sewing/Assembling of Components The most important step of the process is the assembly of all the parts and components of the garment. All the components are sewn together in an assembly line wherein each tailor is allotted different operations depending upon the number of operations involved in the making of the garment. A tailor completes his operation and passes on the stitched part to the next tailor for the next operation. This makes the working efficient and thus, lesser time is needed to make one garment. Hence, this is the stage where the bulk production starts for an individual style. 7. In-line Inspection The quality assurance department checks the ongoing production of a garment in between the line to assure that the ongoing processes are at par with the required standards. 8. End-line Inspection The inspectors check the garment once it has passed through the assembly line and has been sewn into the required garment. 9. Top of Production Sample The top of production sample is sent to the buyer as soon initial pieces are come out of the sewing line. In TOP sample, the buyer tries to evaluate the actual manufacturing of the style. Their purpose is to cross-check whether factory is following PP sample’s specification or not. 10. Finishing After the garment is stitched, a department looks after the finishing of the garment which trims all the unwanted threads from the garments to make it look good. 11. Ironing The garment is ironed once it is finished to make it look better and presentable. 12. Quality Check The final garments are checked before shipping it to the buyer.
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According to the processes explained above, following is the work I learnt at Theme Exports.
Work done in the following weeks
Week 1
Week 2
Week 4
Week 5
Week 6
1. Observed all the processes followed in the export house in different departments. 2. Observed the working of the employees as per their departments. 3. Learnt the working of a merchandiser in the sampling department. 1. Learnt how to understand the various instructions and comments given by the buyers. 2. Completed the task of getting a fabric washed and cut for a sample. 3. Created manual programs for new samples to be made for a brand. 1. Collected various fabrics and trims from the fabric and trims store as per the buyer’s comments. 2. Made trim cards as per the requirements of different buyers. 3. Observed how a fabric is sent for dyeing. 1. Learnt about the various pantones and how a lab dip is created. 2. Got lab dips approved by the buyer. 3. Learnt how to communicate with a buyer. 4. Created programs for various styles for proto. 1. Attended a meeting with a buyer for approvals and new developments. 2. Created requirements for various fabrics and trims as per the requirements of the 30
3. 4.
5.
1. 2. Week 7 3. 1. 2. Week 8
3.
4. 1. 2. Week 9
3. 4.
1.
Week 10
2. 3.
Week 11 Week 12
1. 1.
buyer. Sourced a few fabrics to get an approval of the buyer. Managed different styles in the absence of the merchandiser. Collected notes and comments from the buyer for the new developments. Learnt how to procure raw material. Learnt how to collect and send couriers to various buyers. Learnt how to create swatch cards for buyer’s approvals. Sent couriers to a buyer for fabric approval. Understood the process of getting embroidery done. Understood the different between different types of embroideries. Observed the working of the finance department. Observed how a challan is prepared for couriers. Gave fabrics for dyeing and washing. Prepared several sample orders for new styles. Communicated with the buyer to take an approval for a few styles. Attended a meeting with the buyer and learnt how a showroom is set up as per the buyer. Learnt how fabric is ordered for bulk production. Observed the method pf preparing a purchase order. Learnt the transportation process during shipment. Observed the process of QC inspection.
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Chapter 5: Background Study 5.1. Sampling Unit at a Garment Export House Sampling is the first and the most important stage at a garment export house. It is the key element of the pre-production process and it determines whether the buyer will give an order for the bulk production or not. A sampling team works on creating samples for various styles offered by the buyers. The process includes minute details like the correct colors, prints, composition of fabrics, threads, embroideries, buttons, trims etc. Thus, a sampling unit at a garment export house works as a bridge between the buyers and the manufacturers. (www.fibre2fashion.com) Sampling is the making of a sample according to the buyer’s specification or the tech pack of the buyer just to check or analyse the style, look, fit etc. of the garment. It is the basic step of any style before reaching the bulk production. A sampling unit is a restricted area used for making samples of collections. The main focus of this department is on product development. It is a beehive of continuous product development aimed at creating lines and collections as per “the look� of a specific customer of general collections following the international fashion trends. At Theme Exports, there were various operations under sampling like pattern making, sewing, embroidery, bucket dyeing, finishing etc.
5.2. Storing/Warehouse Unit at a Garment Export House Storage is an important marketing function, which involves holding and preserving goods from the time they are produced until they are needed for consumption. 1. The storage of goods, therefore, from the time of production to the time of consumption, ensures a continuous flow of goods in the market. 2. Storage protects the quality of perishable and semi-perishable products from deterioration; 3. Some of the goods e.g., woollen garments, have a seasonal demand. To cope with this demand, production on a continuous basis and storage become necessary; 4. It helps in the stabilization of prices by adjusting demand and supply; 5. Storage is necessary for some period for performance of other marketing functions. 6. Storage provides employment and income through price advantages. (www.agritech.tnau.ac.in) Warehousing Warehouses are scientific storage structures especially constructed for the protection of the quantity and quality of stored products. 32
Importance 1.
Scientific storage The product is protected against quantitative and qualitative losses by the use of such methods of preservation as are necessary.
2.
Financing Warehouses meet the financial needs of the person who stores the product. Nationalized banks advance credit on the security of the warehouse receipt issued for the stored products to the extent of 75 to 80% of their value.
3.
Price Stabilization Warehouses help in price stabilization of agricultural commodities by checking the tendency to making post-harvest sales among the farmers.
4.
Market Intelligence Warehouses also offer the facility of market information to persons who hold their produce in them. (www.agritech.tnau.ac.in)
Working of Warehouses 1.
Acts: - The warehouses (CWC and SWCs) work under the respective Warehousing Acts passed by the Central or State Govt.
2.
Eligibility: - Any person may store notified commodities in a warehouse on agreeing to pay the specified charges.
3.
Warehouse Receipt (Warrant): - This is receipt/warrant issued by the warehouse manager/owner to the person storing his produce with them. This receipt mentions the name and location of the warehouse, the date of issue, a description of the commodities, including the grade, weight and approximate value of the produce based on the present prices.
4.
Use of Chemicals: - The produce accepted at the warehouse is preserved scientifically and protected against rodents, insects and pests and other infestations. Periodical dusting and fumigation are done at the cost of the warehouse in order to preserve the goods.
5.
Financing - The warehouse receipt serves as a collateral security for the purpose of getting credit.
6.
Delivery of produce: - The warehouse receipt has to be surrendered to the warehouse owner before the withdrawal of the goods. The holder may take delivery of a part of the total produce stored after paying the storage charges. (www.agritech.tnau.ac.in)
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Types of warehouse 1.
On the basis of Ownership a. Private warehouses: These are owned by individuals, large business houses or wholesalers for the storage of their own stocks. They also store the products of others. b. Public warehouses: These are the warehouses, which are owned by the govt. and are meant for the storage of goods. c. Bonded warehouses: These warehouses are specially constructed at a seaport or an airport and accept imported goods for storage till the payment of customs by the importer of goods. These warehouses are licensed by the govt. for this purpose. The goods stored in this warehouse are bonded goods. Following services are rendered by bonded warehouses: The importer of goods is saved from the botheration of paying customs duty all at one time because he can take delivery of the goods in parts. The operation necessary for the maintenance of the quality of goods spraying and dusting, are done regularly.
2.
On the basis of Type of Commodities Stored a. General Warehouses: These are ordinary warehouses used for storage of most of foodgrains, fertilizers, etc. b. Special Commodity Warehouses: These are warehouses, which are specially constructed for the storage of specific commodities like cotton, tobacco, wool and petroleum products. c. Refrigerated Warehouses: These are warehouses in which temperature is maintained as per requirements and are meant for such perishable commodities as vegetables, fruits, fish, eggs and meat. (www.agritech.tnau.ac.in)
Warehousing in India Central warehousing corporation (CWC) This corporation was established as a statutory body in New Delhi on 2nd March 1957. The Central Warehousing Corporation provides safe and reliable storage facilities for about 120 agricultural and industrial commodities. Functions
To acquire and build warehouses at suitable places in India. To run warehouses for the storage of agricultural produce, seeds, fertilizers and notified commodities for individuals, co-operatives and other institutions, To act as an agent of the govt. for the purchase, sale, storage and distribution of the above commodities. To arrange facilities for the transport of above commodities. 34
To subscribe to the share capital of state Warehousing corporations and To carry out such other functions as may be prescribed under the Act.
The Central Warehousing Corporation is running air-conditioned godowns at Calcutta, Bombay and Delhi, and provides cold storage facilities at Hyderabad. Special storage facilities have been provided by the Central Warehousing Corporation for the preservation of hygroscopic and fragile commodities. The corporation has also evolved techniques for the storage of spices, coffee, seeds and other commodities. (www.agritech.tnau.ac.in)
State Warehousing Corporations (SWCs) Separate warehousing corporations were also set up in different States of the Indian Union. The areas of operation of the State Warehousing Corporations are centres of district importance. The total share capital of the State Warehousing Corporations is contributed equally by the concerned State Govt. and the Central Warehousing Corporation. (www.agritech.tnau.ac.in) Food Corporation of India (FCI) Apart from CWC and SWCs, the Food Corporation of India has also created storage facilities. The Food Corporation of India is the single largest agency which has a capacity of 26.62 million tonnes. (www.agritech.tnau.ac.in)
5.3. Importance of Storage at a Garment Export House A storing area is an important place in a garment export house. For an export oriented and bulk production garment industry, it is essential to maintain a wellorganized & well equipped inventory system (Raaz, N., 2017). According to Towheed, A. (2013) a store room is important for the following reasons: 1. It helps the industry to run smoothly as all the material and the products required are in place. 2. It helps in delivering the products as and when required. 3. Increases the productivity of the export house. 4. Ensures the quality of the product.
5.4. Activities in a Storage Unit at a Garment Export House A storage unit in a garment export consists of a lot of activities that are essential to follow in order to maintain an organised record of all the products that are used and unused. Thus, the following activities take place in a storage unit: 1. 2. 3. 4. 5.
Inventory planning. Planning of the store. Issue materials to the concerned department as and when required. Issue samples to testing labs as and when required. Ensure safety and security of the store. 35
6. 7.
Update records of the incoming and the outgoing of the material and samples. Manage the inventory according to their categories. (Towheed, A., 2013)
The above mentioned activities explain the importance of a storing unit in a garment export house. In short, a storage unit helps in maintaining an organised record of all the material and the inventory available in the export house. This further helps in assuring that all the important material and inventory is safe and is available for use when required.
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Chapter 6: Research Methods Research is the process of gathering, recording and analyzing critical and relevant facts about any problem in any branch of human activity. It refers to a critical search into the study and investigation of the problem, with a proposed course of action, a hypothesis or a theory. In brief, the research process consists of five steps: 1. Defining the problem and research objectives. 2. Developing the research plan. 3. Collecting the information. 4. Analyzing the information. 5. Presenting the findings. (Assignment Point)
To study the importance of storage area in the sampling department in a garment export house.
To develop a suitable method to record and store the unused samples in Theme Exports.
Exploratory
Exploratory
-
-
Observation
Observation
Online books and journals
Online books and journals
Sample Size
N/A
N/A
Sample Area
N/A
N/A
Qualitative
Qualitative
Research Objectives
Research Design Data Collection Method Primary Data Secondary Data
Research Analysis
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Chapter 7: Analysis and Findings 7.1. Analysing the Sampling Department at Theme Exports Private Limited The sampling department at Theme Exports consists of two sampling teams that work for different buyers. The teams are not big and thus, there are 5 merchandisers in each of the teams. Unlike, the sampling departments at other export houses, this department is organised and the merchandisers always keep a record of all the important samples and material used by them. The following observations have been made on the basis of what was witnessed. The observations are purely first-hand. 1. 2. 3. 4. 5. 6. 7.
There is a small communication gap between the sampling department and the various other departments at the export house. The department has its own set of assigned work and is completely organised in terms of the duties assigned to the team members. There is a problem of delivery of samples on time. However, the department does not delay the deliveries for more than 3-4 days. A healthy working environment exists in the sampling department and also among the team members. The department is a bit messy in terms of cleanliness as there is no specific storage area for the samples that are created once. The merchandisers do not update the time and action calendar regularly. There is no set Standard Operating Procedures (SOP) that are followed by the sampling department or any other department at Theme Exports Private Limited.
7.2. Analysing the Storing Capacity of the Sampling Department at Theme Exports Private Limited According to the observations formed about the sampling department at Theme Exports, it can be concluded that there is a need to create a storage unit for the samples that are created by the merchandisers for various buyers in different seasons. There is less storage space in the sampling department and therefore, it is difficult for the merchandisers to keep the used and the unused set of samples at their workplace with the other fabrics and material that have to be used late for other styles. In addition, this makes it difficult for the merchandisers to work in an unorganised place.
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A sampling department should only consist of the work desks of the merchandisers and the fabrics and the material that have to be used in the current styles and season. In the sampling department at Theme Exports, the unused samples are hanged on hangers and are put on a stand that is kept near the tables of the merchandisers. This helps the merchandisers to reach the samples easily. However, this makes the place messy and unorganised. Also, at times, it is difficult to look for a sample that was created 2 years ago as these samples are not put in any organised manner.
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Chapter 8: Recommendations In order to get rid of the problem existing in the sampling department that is a need to create a storing unit for the samples that are unused at Theme Exports Private Limited, the solution is to follow a system that helps the export house to reach the unused samples as and when required. There is a need to follow a proper working flow which will help the sampling department in understanding which samples can be used later and which ones can be destroyed so that they can get rid of the unorganized setting in the department. Thus, the following flow chart is the solution to the problem existing at Theme Exports Private Limited.: Create a record of all the samples created in a particular season.
Dispose off a particular sample if it is not being used for a period of 3 years.
Keep a count of the number of samples that are taken by the buyer.
Keep a record of these samples as and when they are used.
Keep a count of the number of samples that are not taken by the buyer.
Put all the unused samples in a separate sample storing unit according to the seasons they were created in.
Process of keeping a record of the unused samples; Source: Author
The above flow chart will help the export house in reaching their unused samples as and when required. This will also create a space in the sampling department which can be used for keeping all the fabric and the material that is required in the sampling process.
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References 1. THEME EXPORTS. 2015. Our Story [online]. Theme Exports Private Limited. [viewed 5th October 2017]. Available from: http://themeexport.com/our-story.html 2. THEME EXPORTS. 2015. Our Product [online]. Theme Exports Private Limited. [viewed 5th October 2017]. Available from: http://themeexport.com/productrange.html 3. THEME EXPORTS. 2015. Technique [online]. Theme Exports Private Limited. [viewed 5th October 2017]. Available from: http://themeexport.com/technique.html 4. J.CREW. 2017. About Us [online]. J. Crew. [viewed 12th November 2017]. Available from: https://www.jcrew.com/help/about_jcrew.jsp?sidecar=true 5. ECONOMIC TIMES. 2017. Definition of SWOT Analysis [online]. Economic Times. [viewed 12th November 2017]. Available from: https://economictimes.indiatimes.com/definition/swot-analysis 6. MICHAEL KORS. 2017. About Us [online]. Michael Kors. [viewed 10th November 2017]. Available from: https://www.michaelkors.com/info/about-us/s11400074 7. NECK&NECK. 2017. Who We Are [online]. Neck & Neck. [viewed 10th November 2017]. Available from: http://www.neckandneckusa.com/who-we-are 8. CLUB MONACO. 2017. Who We Are [online]. Club Monaco. [viewed 9th November 2017]. Available from: http://clubmonaco.borderfree.com/category/index.jsp?categoryId=12724227&ab=f ooter_aboutcm 9. SARKAR, P. 2011. Pre-production Process in Garment Industry [online]. Online Clothing Study. [viewed 27th October 2017]. Available from: http://www.onlineclothingstudy.com/2011/06/pre-production-processes-ingarment.html 10. FIBRE2FASHION. 2017. Sampling in Garment Exports and Its Importance [online]. Fibre 2 Fashion. [viewed 28th October 2017]. Available from: http://www.fibre2fashion.com/industry-article/6969/sampling-in-garment-exportsand-its-importance 11. AGRITECH. 2015. Storage and Warehousing [online]. Agricultural Marketing & AgriBusiness. [viewed 22nd November 2017]. Available from: http://agritech.tnau.ac.in/agricultural_marketing/agrimark_storage%20and%20ware %20housing.html 12. ASSIGNMENTPOINT. Report on Merchandising Process of Garments Sector [online]. Assignment Point. [viewed 20th November 2017]. Available from: http://www.assignmentpoint.com/science/textile/report-onmerchandising-processof-garments-sector-2.html. 13. RAAZ, N. 2017. Working Flow Chart of Store Department in Garment Industry [online]. Textile Flowchart. [viewed 28th November 2017]. Available from: http://www.textileflowchart.com/2015/11/working-flow-chart-of-storedepartment.html 41
14. TOWHEED, A. 2013. Assignment on Garment Manufacturing – Store Room Management [online]. Scribd. [viewed 27th November 2017]. Available from: https://www.scribd.com/doc/134452674/Assignment-on-Garment-ManufacturingStore-Room-Management
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