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Internship report in garment Industry

Internship report in the garment Industry

TABLE OF CONTENTS

Chapter 1 Company Overview
Chapter 2 Objective
Chapter 3 Data Collection Method
Chapter 4 Main Flowchart of Garment Industry
Chapter 5 Overview of Different In the Company
5.1 WORKFLOW OF MERCHANDISER 
5.2 WORKFLOW OF SAMPLING 
5.3 WORKFLOW OF CAD
5.4 WORKFLOW OF CUTTING
5.5 OBJECTIVE
5.6 WORKFLOW OF STITCHING PIECES OF PIECES OF PIECES OF DENIMS / CHINOS 
5.7 COMMON SEWING PROBLEMS
5.8 DEFECTS IN COTTON AND DENIM JEANS
5.9 PARTS OF JEANS
5.10 WORKFLOW OF FINISHING
5.11 PROCESS FLOW OF PACKING
Chapter 6 Name of Brands
Chapter 7 Machines used in Company
Chapter 8 Conclusion 
Chapter 9 Summary


1. OVERVIEW OF THE COMPANY

  • Nisan ClothSmith is a garment manufacturing unit of bottoms located in Shahwadi near Narol, Ahmedabad.

  • Shivani Vaidya is the owner of Nisan ClothSmith.

  • The company was established on May 2018.

  • Nisan ClothSmith manufactures :

    ⮚ Cotton Chinos ⮚ Denim

  • Cotton chinos are originally made of 100% cotton.

  • Denim is a strong cotton fabric made using a twill weave, which creates a subtle diagonal

    ribbing pattern.

  • Here at Nisan ClothSmith,, the complete garment manufacturing starts from sampling to bulk

    dispatch of the garments to the respective brands.

  • The company manufactures bottoms only for categories like

    Men’s wear, women’s wear and kids'' wear. 


2. OBJECTIVE

  • The objective of the study is to learn about the functioning of garment houses and the working of various departments particularly.

  • Merchandising and sampling and cutting, earning knowledge about different departments of the company, their function and information flow during work. 


3. DATA COLLECTION METHOD

  • Personal discussion from various departments.
  • Close observation discussion work.
  • Internal data from various departments.
  • And secondary data was collected from the website of Nisan Clothsmith.


4. MAIN FLOWCHART OF THE GARMENT INDUSTRY

Garment manufacturing means sewing, cutting, making, processing, repairing, finishing, assembling, or otherwise preparing any garment or any article of wearing apparel or accessories designed or intended to be worn by any individual, including, but not limited to, clothing, hats, gloves, handbags, hosiery, ties, scarfs, and belts, for sale or resale by any person or any persons contracting to have those operations performed and other operations and practices in the apparel industry as may be identified in regulations of the Department of Industrial Relations consistent with the purposes of this part.

MERCHANDISING 

SAMPLING AND COST AND SPEC SHEET 

BUYER APPROVAL 

ORDER CONFIRMATION 

PATTERN-MAKING AND CAD MARKING 

CUTTING 

↓ 

STITCHING 

↓ 

WASHING 

FINISHING 

DISPATCH 

BUYER


5. OVERVIEW OF DIFFERENCES IN THE COMPANY 

5.1 WORKFLOW OF MERCHANDISER

  • Garment merchandiser is like a bridge between the buyer and industry.

  • He has to look after every job like buying the raw materials which are required to finish the product, making the garment, finishing the garment, preparing documentation, and finally shipping.

  • Actually, he is the main responsible person to make the product timely.

As its importance, this article has presented a vast discussion on the roles and responsibilities of a merchandiser.

THE TECH PACK COMES FROM THE BUYER 
INITIAL SAMPLING AND COSTING 
GET ORDER CONFIRMATION FROM BUYER 
ORDER REVIEWING AND PLANNING 
FABRICS AND TRIMS PURCHASE 
FIT / P.P. / GPT TESTING 
GETTING APPROVAL FROM BUYER 
INTERNAL JOB CARD AND CONDUCTING 
P.P. MEETINGS 
COORDINATING WITH DIFFERENT DEPARTMENTS 
SHIPMENT SAMPLE APPROVAL
INSPECTION 
DISPATCH 


THREAD CHOOSING CARD

THREAD CHOOSING CARD 



 5.2 HERE IS THE WORKFLOW OF SAMPLING

A sample is a prototype of a product to be manufactured in the future course of production.

It is also called mock-up of a product and is made to check the design effectiveness and fit of the garment.

Sampling is a set of the procedure followed to produce various sample styles.

It contains activities like making the pattern for proto type according to the measurement of the sample with the help of machinery and getting buyers approvals for sample produce.

In an export house, the sampling department plays vital role in the up-lifting of a unit.

This department directly coordinates with the merchandising dept. and production dept. sampling done to see how the product will look when produce in bulk and to check discrepancies in the pattern.


ORDER CONFIRMATION FROM THE BUYER 

PROTOTYPE SAMPLE MADE 

PP SAMPLE MADE 

TOP SAMPLE 

SIZE SET MADE 

BULK PROCEED

SHIPMENT SAMPLE


Sampling department
Sampling department

5.3 WORKFLOW OF CAD

  • Computer-Aided Design (CAD) becomes an essential tool for pattern-making and related jobs in the garment industry.
  • In the apparel industry CAD Software is used for pattern making, Grading of patterns, marker making digitizing manual patterns.
  • CAD system involves any type of design activities used to develop analyses or modify any engineering or garment design.
  • TUKA cad is an innovative apparel pattern-making software that is perfect for manufacturers and designers of any size.
  • Operating under Microsoft Windows, TUKA cad allows the user to accurately builds patterns, grade rules and markers for single styles or entire lines.
  • It is the advanced pattern-making, grading and marker-making system that will streamline your production process and reduce operating expenses.
  • Including all of its measurements, spec sheets are used by designers to communicate design concepts to manufacturers.

5.3.1 FLOWCHART:

CONSTRUCTION OF SAMPLE SPEC SHEET FOR BUYER

SEND TO BUYER FOR APPROVAL 

IF APPROVED BY THE BUYER THEN RECEIVE BULK ORDER 

BULK ORDER SEND TO SHRINKAGE MEASUREMENT 

SEND FOR CAD PREPARATION 

PATTERN DEVELOPMENT 

CHANGE OF SHRINKAGE FABRIC TO PERCENTAGE (ENTER B/W AND A/W VALUE TO FIND

PERCENTAGE INCREASE /DECREASE) 

CREATING OF MARKERS ACCORDING TO ORDER / RATIO 

CUTTING


5.4 WORKFLOW OF CUTTING

  • Cutting means separating out different garment processes from the lay of fabric with the help of cutting templates and devices.

  • It is done to get the required shape indifferent no. or as a whole to make a complete product.

  • The first stage in the manufacture of a garment is the cutting of material into the necessary pattern shapes.

  • These patterns are joined to form a garment when a large amount of garment style has to be cut, a layer is created, which consists of many piles of fabric spread one above the other.

  • Now all the pattern pieces for all sizes are from this layer.

  • The main objective of the cutting dept. is the cutting of garment parts accurately and economically and in sufficient value to keep the sewing room supplied with work.

  • The department of any garment industry, where several layers of fabric are cut together by the pattern for the production of the garment, is called the cutting department.

  • Cutting is a technique where the operator moves a material (workpiece) such as metal and the tool about each other to shape the workpiece into the desired form through shaving, drilling, etc.

  • The cutting department is responsible for cutting and feeding the sewing department with cutting.

  • Layers of fabric are cut together by the pattern for the production of the garment.

  • We here at NISAN CLOTH SMITH LLP studied cutting jeans as only here denim and cotton fabrics are used.

Also learned different aspects like

  1. FRONT POCKET

  2. BACK POCKET

  3. THE ELASTIC CUT FOR TOP AND BOTTOM(for chinos)

  • ●  The elastic cut was done for joggers only.

  • ●  The size of the pocket is the same as the size of the jeans.

  • ●  The samples of three beams are taken and stitched together and roll numbers are also given respectively.

  • ●  Then these samples are sent to the finishing department.

  • ●  The fabric is cut by a steel cord belt-cutting shear instrument.

  • ●  At last the numbering is done in this cutting section.

  • ●  Bundling is also done i.e. assembling the stacked and cut pieces are re-assembling them in production lots grouped by garment units.

  • ●  The machines used in the cutting department:-

    1. Straight knife cloth cut machine:-

  • ●  The automatic knife-sharpening system ensures the finest cutting quality, and its safety mechanisms keep users protected from harm during the cutting process.

  • ●  Straight-knife cloth-cutting machine working best on light- to medium-weight materials like all kinds of leather, cotton, silk, and chemical fibre fabrics.

  • STRAIGHT KNIFE CLOTH CUT MACHINE

    1. STRAIGHT KNIFE CLOTH CUT MACHINE 


  • 2. Electric rotary cutter machine

  •  3. Semi-automatic cloth-cutting machine 

  • 4. Round knife machine:- Round-knife machines vary in diameter and rotary speed of the blade. Vertical and band blades come in circular, waved, or sawtooth perimeters. Vertical blade edges may be straight, waved, notched, serrated, or striated; band blades may be straight, waved, or saw-toothed. Straight-edge blades including the circular perimeter of rotary blades are used generally; the others are special-purpose blades. 



5.4.1 FLOWCHART OF CUTTING DEPARTMENT

CUTTING WIDTHWISE SWATCHES FROM THE BEAM FOR SHRINKAGE OF ALL ROLL

MEASUREMENT OF WIDTH IN INCHES EXCLUDING SELVEDGE 

CUTTING WIDTHWISE SWATCHES FROM THE BEAM FOR SHRINKAGE OF ALL ROLL

MEASUREMENT OF WIDTH IN INCHES

EXCLUDING SELVEDGE 

MARKING OF PIECE (50*50) 

BLANKET ACCORDING TO BALE NUMBER FOR SHADE GROUPING

SEQUENCE CHECKING 

OVERLOCKING EDGES (SELVEDGE) OF MARKED PIECE 

W ASHING 

THE MARKED PIECE IS HANDED OVER TO THE MASTER FOR MEASUREMENT OF SHRINKAGE %

(FROM JOB CARD) 

MARKER PLANNING 

NUMBERING OF CUT PARTS 

POCKET CUTTING 

FUSING 

SIZE BUNDLING 

DISPATCH FOR STITCHING 

IMAGES OF MACHINE USED IN CUTTING DEPARTMENT

IMAGES OF MACHINES USED IN THE CUTTING DEPARTMENT 


Cutting department

CUTTING DEPARTMENT 


FABRIC CUTTING WIDTHWISE

FABRIC CUTTING WIDTHWISE 


CUTTING OF DIFFERENT PARTS

CUTTING OF DIFFERENT PARTS 



5.5 OBJECTIVE

  • To maintain the quality of the cut components.

  • To cut the raw material in the required shape and quality.

  • Availability of cut components on time


5.6 WORKFLOW OF STITCHING PIECES OF PIECES OF TYPES OF PIECES OF DENIMS / COTTON CHINOS

Sewing is an important department in the garments manufacturing industry. All the parts of a garment are joined here by making stitches with the help of a needle and thread. Where the sewing process flow chart helps to make a complete garment easily. By maintaining the sewing process flow chart, an order can be completed in a timely.

A stitch is a single turn to the loop of thread or yarn.

Stitches are a fundamental element of sewing knitting embroidery crochet and needle placements whether by machine or hand

It is a process whereby a fabric is fashioned into a finished product using different sewing techniques.

Stitching or sewing is done after the cut pieces are banded according to size colour and quantities determent by the sewing room.

Garments are sewn in an assembly line. To deliver quality with quantity the ratio between and service is known as productivity reciprocally related to each other.

Treads (spun polyester) like 50TEX for the bottom and trousers and for denim - 25TEX for the top and 50TEX for bottoms are used.


5.6.1 FLOWCHART OF STITCHING CHINOS/JEANS:

FRONT MAKING

BACK MACKING 

ASSEMBLY OF BELT FINISH WITH LABEL 

BOTTOM HEM 

BARTEK 

FINAL CHECKING 

STICKER REMOVING 

20 PIECE BUNDLING 

TOTAL PIECE 

W ASHING 

 

5.7 COMMON SEWING PROBLEMS:

  • Needle Thread Breakage
  • Bobbin / Looper Thread Breakage 
  • Thread Fusing
  • Skipped Stitches
  • Imbalanced / Variable Stitching 
  • Staggered Stitching
  • Variable Stitch Density

Sewing problem
Sewing problem


5.8 DEFECTS IN COTTON AND DENIM JEANS

  • Broken Stitches

  • Disappearing Stitches in Stretch Denim

  • Holes

  • Different shades within the same garment

  • Dropped stitched

  • Open seam

  • Pulled / loose yarn

  • Stain

  • Unfinished buttonhole

  • Zipper too short

Defects in fabric

5.9. THERE ARE MANY PARTS IN JEANS LIKE

  • Waistband

  • Belt loop

  • Button fly

  • Watch pocket

  • Front pocket

  • Back pocket

  • Jeans rivets

  • Crotch point

  • Back yoke

  • Side seam

  • Back rise

  • Inseam

  • Zipper (metal zipper)


5.10. MACHINES USED IN THE STITCHING PROCESS ARE:
SINGLE NEEDLE MACHINE

BARTECK MACHINE

BARTECK MACHINE 


BARTECK MACHINE
BARTECK MACHINE 

FLAT LOCK MACHINE

FLAT LOCK MACHINE 


FEED OF THE ARM

FEED OF THE ARM 


DOUBLE-NEEDL machine
DOUBLE NEEDLE MACHINE

DOUBLE NEEDLE MACHINE 


BELT MACHINE

BELT MACHINE 



5.11. MINIMIZING BROKEN STITCHES DUE TO NEEDLE CUTTING

  • Use a higher-performance Perma Core or D-Core thread.
  • ●  Use a larger diameter thread on operations where the thread is being cut.

  • ●  Make sure the proper stitch balance is being used. On a chain stitch seam on denim, you normally would like to maintain a 60%/40% relationship of Needle thread to looper thread in the Seam.

  • ●  Use needles with the correct needlepoint.

  • ●  Change the needles at regular intervals on operations where the Needle Cuts are occurring frequently.


5.12. WORKFLOW OF GARMENT FINISHING

  • After assembly, the garments now come for finishing – a key stage of the garment manufacturing process.

  • Finishing is done to prepare the final garment according to the quality standards of the buyer before packing it for shipment.

INVERT 
THREAD TRIMMING 
RIVET BUTTON (FIBER BUTTON) 
P U PATCH ATTACH 
PRESSING 
FINAL CHECKING 
TAGGING 
BARCODING ↓POLY PACK 
SIZE DISTRIBUTION (ACCORDING TO RATIO)
CARTON BOX 
STRAPPING 
WRAPPING 
DISPATCH


5.13 PROCESS FLOW OF PACKING

  • Packing is the LAST STAGE WHERE THE FINISHED garments ARE PRIMED, Organized, and geared up for shipment to the buyer, the entire process from the way a garment will be folded to the final labelling of the cartons is dictated by the buyer’s specifications.

  • These instructions are standardized for a particular type of garment and sent to the merchandiser in form of a packing manual.

  • The merchandiser forwards it to the packer in charge along with a top-of-production sample i.e. Packed with dimensions approved by the buyer.

  • This is kept as a visual reference for the packers.



5.13.1 FLOWCHART OF PACKING:

GARMENT IS CHECKED
IT’S THEN FOLDED 
1 OR 2 ARE PACKED TOGETHER 
ALL PIECES ARE KEPT IN CARTONS
DETAILS ARE POSTED ON THE CARTON 
CARTON IS SEALED
LOADED INTO TRUCKS 
SENT FOR SHIPMENT 


6. Name of brands

  • WRONG

  • JOY

  • JOHN LOUIS

  • MANCHESTER

  • RIO

  • PANTALOONS

  • FAME FOREVER

  • CELIO

  • LIVER POOL

  • GLOBUS

  • GINGER

  • EYE WALK


7. MACHINES USED IN NISAN CLOTHSMITH

  • SINGLE NEEDLE MACHINE (JUKI) LOCK STITCH (DP-5) | DB*1

  • DOUBLE-NEEDLE MACHINE (JUKI) LOCK STITCH (DP-5) | DB*

  • 5 THREAD OVERLOCK MACHINE (JUKI)
    OR FEED OF THE ARM (DOUBLE NEEDLE) (DC-2718)

  • BELT MACHINE (KANSAI) (CHAIN STITCH) (TU*5)

  • BARTEK MACHINE (JUKI) (DP-1718)

  • FLAT LOCK MACHINE (KANSAI) (CHAIN STITCH) (UY*128)(DP-5)

  • EYE GAJ MACHINE (JUKI) (LOCK STITCH) (DP-5)

  • EYELET MACHINE (JUKI) (LOCK STITCH) (DO-558) (18)

  • FUSING MACHINE (HASINA)

  • RIVET MACHINE (ARTI)

  • STRAIGHT KNIFE CLOTH CUT MACHINE

  • ELECTRONIC ROTARY CUTTER MACHINE

  • SEMI-AUTOMATIC CLOTH-CUTTING MACHINE

  • ROUND KNIFE MACHINE



CONCLUSION

OVERALL ANALYSIS OF THE INTERNSHIP

  • ✔ During this internship period I got a lot of knowledge and communication skills with strangers.

  • ✔  I learnt many new things about weaving as well as business.

  • ✔  Working as an intern may allow me to meet a potential mentor naturally and establish

    a relationship that helps guide my career path.

  • ✔  The supervisors and mentors I met during my internship can be valuable references for me as I pursue a full-time job.

  • ✔  The more positive and hardworking I am, the more likely managers are willing to recommend me for open positions.

  • ✔  References generated from an internship can be valuable in my job searches because those managers will have known me personally and seen how I contributed to the company.

  • ✔  The transition from college to full-time employment can fill me with excitement, anxiety, hope and ambition all at once.

  • ✔  An internship is a good way to fill some transition time with the work I hope to do long-term.

  • ✔  It can eliminate some pressure of quickly finding a permanent job and help me to apply the skills and knowledge I have been studying to a practical situation. 

 

SUMMARY

  • ✔  So finally, I thanks my mentor SHIVANI VAIYA, all staff at the company, the respected HOD sir, and my teachers for giving me a good opportunity to do an internship.

  • ✔  This project was quite a learning experience for me at each and every step.

  • ✔  I got knowledge as well as learned communication skills.

  • ✔  I learnt many new things about garmenting.

  • ✔  I got to experience a job nature.

  • ✔  I learn how to work in a group and it develop my nature.

  • ✔  This way I got overall broad knowledge and develop skills of communication. 

 

 

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