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Internsship Reeport

On

M
Masood Textilee Mills
Sargoodha Rooad
Faiisalabad
d
Su
ubmitteed to: HR Deepartmeent
Sub
bmitted
d by: Usmann Sajid
BB
BA (H) Reg.:
R 2012-G
GCUF-002942
MT
TM Regg.: TE221586

Sub
bmissioon Datee: 13-08--2015

GC Universi
U ity Faisaalabad
 
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DEDICATED TO
My Worthy Parents and the  

Respected Teachers Who  

Always try to find ways  

And think to provide which 

 We do not know and do not have 

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Table of Content
Sr. No  Subject Page NO. 
1.   Acknowledgement  08 
2.   09 
Executive Summary
3.   Textile Industry of Pakistan 10 
4.   Introduction of Company 11 
5.   History 12 
6.   Distance from Major Cities 13 
7.   CEO’s Message/Experienced Professional 14 
Management
8.   Business Principle of Company 15 
9.   Quality Control System at Masood 16 
10. Vision /mission statement/values 17 
11. Customers of MTM 18 to19 
12. Product Mix/product line 20 to 23
13. Operations Division 24 to 26
14. Stages of Garment Manufacturing Process 27 to 37
15. Laboratory Tests in MTM 38 
16. Departments 39 

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I.   Merchandising Department 40 to 41

II.   Production, Planning and Control (PPC) 42 to 46
III.   R&D Department 47 
IV.   Industrial Engineering Department 48 
V.   Procurements Department 49 
VI.   Production Department 50 to 52
VII.   Store department 53 
VIII.   Finishing Department 54 to 56
IX.   I.T Department 57 
X.   Finance Department 58 to 59
XI.   HR Department 60 
XII.   Forwarding Department 61 to 64
XIII.   Shipment Department 65 
17. Promotional Activities of MTM 66 to67 
18. Corrective and Preventive Actions 68  
19. SWOT Analysis of MTM 69 to 70
20. PEST Analysis of MTM 71 to 72
21. Conclusion 73 
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Acknowledgement
All praises are for Allah Almighty that has bestowed upon human being
the crown of creation and has endowed him with knowledge and
wisdom. After Allah, is the Last Prophet Mohammed (SAW) who
brought for us revelation and unlimited knowledge and civilized the
barbarian human beings.
Although this report base only my name but numerous people were very
important to the development of this report but without the support of
them I could never successfully completed the internship as well as the
report.
I am highly thankful to the staff member of Masood Textile Mills
Limited. Who really cooperated with me and provided me their complete
guidance. My special thanks to marketing team 3.

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Executive Summary
I joined Masood Textile Mills Ltd as an Internee in marketing
merchandising department. The motive of joining the MTM was to have
an exposure of textile sector and potential to avail a sound and
promising career. I devoted our time to learn about MTM, which will be
beneficial to me if I join textile sector. In this 8 weeks internship
program I attended the lectures of key departments (Merchandising,
Stitching, PPC, IE, Forwarding, Testing labs, and mills etc.) of this
largest knitted garment manufacturers of Pakistan which are delivered
by experienced managers running these departments. After attending the
lectures I also visited these departments for acquiring practical
knowledge.
The object of this report that I have placed is to express what I observed
and the necessary measures that can help to capitalize the strengths to
overcome weakness and remove the threats.
Masood Textile is one of the largest knitted garment manufacturers of
Pakistan. The company is 100% export oriented. U.S.A. and Europe are
major markets of Masood Textile. It is a quality conscious company.
The company is ISO 9002 certified. Company’s mission statement is
“To be the world’s Best Apparel Company.” Company’s values are trust
integrity, respect.

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Textile Industry of Pakistan

In 1947, at the time of independence Pakistan Textile Industry was like a
feeble child with only three cotton mills, a small woolen spinning,
whereas weaving, hosiery and knitwear were features of cottage
industry. Now when we have entered into new millennium, Pakistan’s
Textile Industry has become a stalwart fellow, which has grown in all
sections. Now we are not only self-sufficient but are also exporting
surplus products. Today we have over 8.358 million installed spindles,
166,000 installed rotors 20,000 shuttle less looms, 200,000 power
looms, 8,000 terry towel looms, 7620 canvas looms, 157,000
woolen/worsted installed spindles, 15,000 woolen looms, 12,000
knitting machines, over 600 processing units and over 2500 garments
units. The textile sector in Pakistan has an overwhelming impact on the
economy, contributing 57% to the country’s exports. In today’s highly
competitive global environment

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Introduction of Company
Ch. Nazir Ahmed who was the founder established Masood Textile mills
limited in 1984 and now Ch. Shahid Nazir is the chief executive. The
Masood textile mill is established under the company ordinance 1984.
The company has latest equipment and machinery to serve globally. The
company has modern computerized networking system. All the
Accounting and finance relating work is carried out through computer.
The company has capability in fabric, ginning spinning, knitting laundry
and apparel manufacturing.
The company’s apparel division, which is producing high quality
garments, is situated at Sargodha Road, near Singeet Cinema,
Faisalabad. But its registered office has shifted to near to Jail road
Faisalabad.
The company implements the quality system and had awarded ISO 9002
certificate. The company maintains quality standard at all levels to
establish consistency and efficiency. The company is exporting its
products to U.S.A, Europe and china.
The company also have AATCC certified which ensure that all quality
standards are maintained.

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History

Kohistan Bus Service 1973

Masood Textile Mills 1984
Spinning 1994
Garments 1995
Industrial Co-operative Bank 1994
Rabia Trust Hospital 1994
Kakakhel Ghee Mills 1994

Head Office: Jail Road Faisalabad

Mills: 32-K.M Sheikupura Road, Faisalabad

Apparel Division: Main Sargodha Road Faisalabad

Web Site: www.masoodtextile.com

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Distance from Major Cities

Lahore 134 km
Islamabad 372 km
Peshawar 519 km
Quetta 1096 km
Karachi 1181 km

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CEO’s Message
Welcome to the Masood Textile Mills Ltd. It operates throughout the
world with over 21,000 employees as part of our team.

It’s Collection has a wide selection of quality garments including T-

shirt, Polo shirt, Jogging suit, Henley shirt, Raglan shirt, Tank top,
Bikini, Shorts, Pants and Sleepwear. Competent professional staff, a
team of talented merchandisers, excellent supplies & support services,
and state-of-the-art technology is the driving force behind Masood’s
phenomenal growth in the past years. Masood has expanded its
operations to include the Internet, and has taken advantage of the variety
of international trade facilitated by the Web. Now Masood uses state-of-
the-art client/server technology for its market information processes to
coordinate its network of global buyers and agents around the world.

Experienced Professional Management

The MTM Team comprises a balanced blend of experienced
professionals including over 200 MBA’s, Textile Engineers and
Industrial Engineers. Continuous training and development keeps them
abreast with modern technical and management tools. MTM is WRAP
certified and ISO 9002 certified as well.

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Business Principle of Company

Corporate Objectives:
• To maximize the wealth of shareholders, increase market share and
achieve customer satisfaction. Making arrangements towards
achieving total quality standards,
• To get growth through professional management
• To reduce the cost of production up to minimum level
• To control the atmosphere by installation of latest machinery
• To continue to improve / surpass past achievement
• To lead the local manufacturers, attain a good word of mouth and
to make company image stronger in the international market

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Quality Control System at MTM

There are quality checks at every stage of manufacturing starting from
Raw Cotton, Yarn Fabric, Processing, Cutting, Stitching and Packing.
Before the fabric is cut, it is checked whether it conforms to the
customer’s standards of shrinkage, finished g/cm 2 etc. After each lot of
fabric is cut, 100% cut parts inspection is conducted to ensure that only
good quality pieces move to the stitching units.
During the process of sewing, each and every process is inspected by in
line inspectors. The inspectors make sure that only good parts move to
the next stage. An individual tracking number is sewn inside each
garment. After trimming and pressing of the garments, highly
experienced final inspectors inspect each garment
The Quality assurance team monitors the performance of every
individual inspector b picking up the inspected garments and checking
the quality of these garments.
To ensure that the garments are packed as per the requirements of our
valued customers, we can even track & check, which ease the garments,
has been packed in. With the help of this, we plan to achieve the Zero
Defect Level.

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Vision Statement
• A leading producer of textile products by producing the highest
quality of products and services to its customers.
• To strive for excellence through commitment, integrity, honesty
and team work.
• Highly ethical company and be repeated corporate citizen to
continue playing due role in the social and environmental sectors
of the company.
• To develop and extremely motivated and professional trained work
force, which would drive growth through innovation and
renovation.
• Sustained growth in earning in real terms.
Mission Statement
Our mission is to be a dynamic, profitable and growth oriented company
by providing good return on investment to its shareholders and investors,
quality products to its customers, a secured and friendly environment
place of work to its employees and to project Pakistan’s image in the
international market.

Organizations Values
• Trust
• Integrity
• Respect

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Customers of MTM

Abercrombie Fruit of the

Adidas Champion
& Fitch Loom

Calvin
Aeropostale Asiam Champs
Klein

Foot
Chaps Dockers Guess
Locker

Tommy
Haness Hollister Walmart
Hilfiger

Izod JCpeney Jockey Kohls

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Lee Levis Li & Fung Macys

Nautica NFL Polo Puma

Reebok Sears StJohnsBay Stafford

Under
Artisans Tom Tailor V&D
Armour

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Product Mix/Product Line

Products of Masood Textile Mills are cotton/ synthetic fiber yarn,
knitted / dyed fabrics and garments. MTM exports whole of its products
to US, Europe and various other country. Major portion of yarn are used
in manufacturing process and surplus is exported.
Masood Textile Mills produced different high quality export oriented
products to the international market. These are as under.
• Yarn
• Knitted Fabric
• Garments
(1) Yarn:
Masood Textile Mills Limited produces high quality yarn according to
the demand of the market. 50% yarn is exported rest of the yarn is used
is in Masood Textile Mills.
(2) Knitted Fabric:
One of the largest Fabric facility in Pakistan having the capability to
produce all kinds of knitted fabrics in 100% cotton & blends.

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Garments:
MTM is a leading apparel company in Pakistan having expertise &
machinery capable of transforming customer ideas into superior quality

Single knit Flat knit Strippers

• Feed Striper
• Single Jersey • Collar & Cuffs • Auto Striper
• Pique • Flat Knit Panels • Engineered
• Fleece Striper
Double knit Textures Jacquards

• 1x1 Rib • Herring Bones

• Mini Jacquard
• Variegated Rib • Pique Jersey
• Thermals
• Interlock • Waffles
garments, which are taken as the most famous brands in the world.
These includes the
• Loungewear
• Sportswear
• Active wear
• Sleepwear
• Athletic
• Underwear

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Types of Fabric
A material made from fibers or threads by spinning, weavings, knitting,
processing…etc as any cloth. There are different types of fabrics.

Types of Fabric:
• Jersey
• Pique
• Inter Lock
• Rib
• Waffle
• Min Thermal
• Fleece

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Operations Division
MTM is one of the few fully vertical textile mills in Pakistan having in-
house Yarn, Knitting, Fabric dyeing, Processing, Laundry and Apparel
Manufacturing facilities. The vertically integrated operations help us in
achieving shorter lead times and greater flexibility to cater to the
customers’ demand.

Spinning
Knitting
Fabric dyeing Mills
Finishing
Laundry
Cutting

Stitching
Finishing Apparel Division
Packing

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Spinning:
Spinning Division of Masood Textiles is capable of producing 60,000
lbs. of Ring spun yarn every day (based on 20/s count). The division,
equipped with most modern machinery from Japan, England and
Switzerland, produces a vast range of yarn counts from 10/s to 40/s. To
ensure consistent quality, spinning laboratory has been equipped with
latest and most modern testing equipment. 50% of yarn production is
exported to Hong Kong, Japan, Korea, Malaysia and Thailand. The rest
of capacity is used for in-house production of fabric, converted
subsequently into apparel.

Knitting:
Knitting Department machines capable of making Jersey, Pique,
Fleece, Interlock and Rib in addition to the mini jacquard designs of
single knit jersey. The gauge ranges from 9 to 28 for single knit, 18 to
24 for Interlock and 15 for Rib machines. Most of the machines are
equipped with Lycra attachment. Masood has added striper machines
for producing feed, auto and engineered stripe jersey.
Moreover, it has flat bed machines for collar and armband making.
100% production is inspected and only ‘A’ grade fabric is transferred
to the subsequent operations. Masood has a daily knitting capacity of
95,000 kg.

Dyeing, Processing & Laundry:

The Processing Department has an installed capacity of dyeing 120
Tons per day. Equipped with These dyeing machines from Germany,
it is capable of dyeing both 100 % cotton and Poly-cotton blended
fabrics. The machine size selection provides flexibility in dye lot size
ranging from 200 Kg to 2,200 Kg.

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The department has Santex finishing lines from Switzerland including

hydro extractors, dryers and compactors for tubular as well as open
width fabrics. Moreover state of the art Lamperti sueding equipment
with Nylon Brushing Technology makes Masood capable of
producing immaculate and delicate knit fabrics. German Technology
Munfort Stanter and Corino slitting machines are the latest additions
to processing department.
A separate testing Laboratory with latest equipment is in place
to ensure that the processed fabric quality is maintained to meet
the required parameters of our buyers.
Laundry division is capable of doing garment dyeing and
garment washing including pigment dyeing, tie & dye ,soda
wash, enzyme wash, stone wash etc. contributing a good part
towards value chain.

Stitching:
With over 5,600 stitching machines, manned with the most skilled and
expert operators, Masood is capable of producing about 7.5 million
pieces per month versatile garments ranging from basic to high fashion,
men’s, women’s and kids with maximum flexibility in size and color
assortments. The Quality control and Quality Assurance departments
are in place to make sure the company’s objective of zero defects.
Computerized Bar coding and Back Track systems provide Masood
100% predictability and tracking performance.

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Stages of Garment Manufacturing Process

Gining

Spinning

Fabrication

Dyeing

Fabric Finishing

Cutting

Printing and EMB

Sewing

Finishing

Packing

Audit

Shipment

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Ginning
It is a process in which cotton lint and other contaminations in the cotton
are eliminated. Purified cotton is compacted to bales for commercial use.
Spinning
It is combination of all processes which are involved in conversion of
fiber into yarn. In textile when we say spinning then we mean to say
about the final process in the transformation of fiber into yarn.
• Mixing: Mixing of different lots of cotton.
• Blowing: Input is mixed cotton & output is “Lap”, like a sheet of
paper rolled over a steel rod.
• Carding: Input for carding is lap which is obtained from blowing
section & output is “Sliver”, like rope.
• Drawing: Drawing is a process in which different slivers are
combined together to produce single sliver. Normally 8 slivers are
fed behind one drawing machine and get an end product in form of
single sliver.
• Combing: If fine yarn is required then this process is added.
• Simplex: Simplex is almost the finishing stage of the spinning. In
the Simplex process, sliver is fed and “Roving” is manufactured.
Finished sliver is drafted and very low twist forms roving.
• Ring: In this section roving from simplex section is turned into
fine & sophisticated yarn of different counts.
• Auto Cone: The primary objective of this process is to assemble a
packaged form suitable for subsequent procedures such as weaving
and knitting.

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Yarn Count:
Count is the fineness of yarn. Number of hanks per pound is called count
(one hank is equal to 840 yards). We may say that if one pound cotton
makes one hank count will be 1. If same weight of cotton makes 10
hanks then count will be 10 and if it makes 20 hanks then count will be
20. Count can be measured by given formula,
“Count = length in hanks/Weight in pound”.
Single yarn having 20 count can be written as 20/1, if 20/2 it means 20
double, if 20/3, 20/4, 20/5 it means count 20 is three ply, four ply, or
five ply etc.
Count always irreversibly proportion to diameter. If count is fine e.g. 20
or 22 yarn will be fine and thin. If count is coarser e.g. 12 or 10 then
yarn will be thick. The woven or knitted fabric with higher count will be
fine and smooth but it may not be durable.
Different Counts of Yarn:
10 Single 22 Single 32 Single
12 Single 24 Single 36 Single
16 Single 26 Single 40 Single
20 single 30 single 50 single
Counts from 10 single to 16 single are coarser, from 20 single to 30
single are medium and from 32 single to 50 single and upwards are fine.

Twist Direction of Yarn:

• S-Twist ( Clock Wise)
The yarn used in weaving and knitting is mostly S-Twist, and rarely
Produce Z-Twist yarns for knitted fabric.
• Z-Twist ( Anti Clockwise)
Z-Twist yarn mostly use for thread making and sewing purpose.

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Fabrication
Generally there are two types of fabric.
1. Woven Fabric
2. Knitted Fabric

• Weaving is defined as the process of making fabric by interlacing

yarns.
• Knitting It is a process of making fabric by interloping one or
more yarns, instead of two sets of yarns crossing each other in
weaving. Tubular machines are used for knitting. Machine gauge
and setting will be different for the different fabric types.
Types of Knitting Machines

Circular Knitting Flat Knitting

Types of Knitted Fabric:

There are basic two types of knitted fabric.
1. Warp Knit Fabrics:
I. Single Knit Fabrics
II. Double Knit Fabrics

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2. Weft Knit Fabrics:

I. Single Knit Fabrics:
• Single jersey
• Fleece
• Pique
• Honey Comb Pique
• Locast Pique
• Bird Eye pique
II. Double Knit Fabrics:
• Interlock
• Rib
• Flat-back rib
• Waffle / thermal etc.
*The knitted stitches that occur in vertical columns are called Wales,
and those in horizontal rows are called courses.

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Types of Stripes in Garments:

• Feed Stripes: Those have a small repeat of the stripe design,
which generally fits within 1.9 inches.
• Auto Stripe: Those have larger repeats of the stripes i.e. more than
1.9 inches.
• Engineered Stripe: A design of the stripes which is not repeated
in the garment. The size of the repeat depends on the size of the
garment. Where one repeat ends in the fabric during knitting, the
next garment starts.

Feed stripe Auto stripe Engineered stripe

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Dyeing
It is the process of coloring the fabric according to the required color and
shades through different processes in different stages such as,
• Singeing: The process by which loose, hairy projecting fibers are
removed.
• De-sizing: By this process gummy and size materials are removed.
• Scouring: This process is performed for removing impurities of
the textile materials.
• Bleaching: This process removes the natural color of the material.
• Mercerization: It is an additional treatment. It increases the
strength and luster of the material.
Types of Dyes:
• Direct Dyes
• Reactive Dyes
• Disperse Dyes
• Sulphur Dyes
• Vat Dyes

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Fabric Finishing
In this process, fabric is treated with some mechanical or chemical
process before or after dyeing or printing to give the fabric a
fancy/novelty touch to make it more durable, flexible, soft and good in
appearance & handling.
Cutting: is the process of converting fabric into sew-able cut parts. It
consists of following processes
Getting the Fabric: Issue from fabric store.
Spreading: Manually or through computerized spreading machine.
Pattern Marking: Manually or through computerized GGT pattern
making.
Cutting: Hand cutters or with modern automatic cutters.
Bundling: All cut part according to roll or lot

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Printing and its Types

Screen Print:
A process, where ink is mechanically applied to a surface with the use of
a screen
Pigment Print:
These penetrate the fabric more and create a much softer feel. Also
useful for larger area prints where texture is important
Flock Print:
This process involves printing of glue on the fabric first, applying the
fiber flock on the gel printed by keeping the fabric on special table
(electro statically charged).
Discharge Print:
Used to print lighter colors onto dark background fabrics, they work by
removing the dye already present in the garment.
Foil Print:
This printing method is based on the use of metallic foil paper of
aluminum or copper one.
Puff Print:
An additive to Plastic sole inks which raises the print off the garment,
creating a 3D feel.
Heat Transfer Print:
Heat transfer printing is a method of transferring a desired pattern via
heat onto a substrate.

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Embroidery
Embroidery is an art form that uses close or overlapping stitches to form
intricate, three-dimensional, surface designs to embellish piece goods,
trims or garments. Embroidery is a flat trim that adds interest and
differentiation to a product.
Embroidered designs may be applied directly to piece goods, garment
components, finished garments, or as individual emblems that are an
add-on type of trim.
Direct Embroidery: Direct embroidery becomes an integral part of
garment structure as stitching cannot be removed without damaging
piece goods. Garment components such as pockets, shirt fronts and
collars may be embroidered with designs or logos prior to assembly to
facilitate handling and manipulation of materials.
Emblems: Emblems are individual embroidered designs with finished
edges. They are mass-produced trims known as embroidered patches,
appliqués, insignia, or badges frequently used on outerwear.
Compared with direct embroidery, emblem designs are often larger,
more complex and use more stitches, colors and thread.
Embroidery too Thick:
Where the embroidery is too thick and Can be caused by too high of a
stitch density or not using the correct backing for the application.
Bunching at Corners:
Where the corners of shapes are not sharp and crisp
but are unshed up or distorted. Usually caused by too
much thread in the corners due to poor digitizing.

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Fabric Grin Through or Gapping

Where the fabric is seen through the embroidery
design either in the middle of the pattern or on the
edge.
Sewing is the process of converting fabric cut parts
into garment with the help of different machines
according to the specified seam classes and stitch
types or the process in which conversion of two
dimensional fabrics into three dimensional fabrics is
called sewing.
Finishing in this process stitched garments are
inspected for further purification of defects occurred in
the sewing process.
Packing is the stage in which finished garments (after
finishing) are packed according to the buyer’s
requirement using different packing accessories and
different quantities in the carton.
Internal Audit-External (Buyer’s) is the stage of
random inspection of the finished packed goods ready
for shipment either by internal Q.A (pre-final or final)
or by the buyer’s auditors or third party inspector in
case of any ambiguity.
Shipment Move if OK Otherwise Re-Screen If the
shipment is ok then it is moved. Otherwise it will be
100% rechecked to meet the required quality standard.

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Laboratory Tests in MTM: -

Certain lab tests are used in MTM for the checking of fabric quality.
These are following: -

• Shrinkage Test
• G.S.M. Tests
• Width Stretch Test.
• PH scale Test
• Crooking Test.
• Bleeding Test
• Scorching Test
• Hot Wet Press Test
• Cotton Polyester Test
Qualified fabric specialists in a lab do these tests

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Departments
Departmentalization is the arrangement of Individuals job activities into
groups and these groups are combined to from larger department and
units to form the total organization
The Departmentalization in Masood Textile is very clear. These
departments are Human resources marketing finance production export,
purchasing, administration and quality assurance.
Except quality assurance all department are under the supervision.

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Merchandising Department
Customer Merchandiser Factory
Merchandising performs the following functions
• Market Analysis
• Data Analysis
• Procurement
• Visual Presentations
• Feed Back
• Product Planning
• Pricing
• Distribution
Market analysis includes anticipation of future trends in the market
regarding economic, life style, fashion and competitors. Currently MTM
anticipates the future competitors like China and India in result of WTO
policies and now successful competing the china in quality and price.
Analyzing all the available data for improvement and anticipation,
Merchandiser also search about the accessories purchase and to
negotiate. Product planning concerns about sampling and regarding
research and development.
The merchandiser starts his work with new inquires, new inquires are
the customers first knock at MTM. The merchandisers increase the sale
of products through personal selling, seminars and physically stall
presentation in worldwide cloth fairs and exhibitions. But currently due
to high quality of MTM and customers trust on MTM quality MTM only
relying on personal selling or old customer relations.
When new inquires comes in the merchandising department starts
working on it on the bases of customer demand required in the inquiry.
Merchandising department prepares samples.
 

40 
 
  
 

Confirmation of PO and Follow Up

After the conformation of PO the merchandiser sends it to PPC and production
department for performing their functions. The last function of merchandiser is
follow up of the PO from sample to shipment and communicates with the
customer.

41 
 
  
 

Production, Planning and Control (PPC)

Merchandising Production

PPC
PPC works as a bridge between merchandising and production. It stands
Production planning and Control. In this department the works starts
when new inquire converted into purchasing order. The merchandiser
sends to PPC department which starts work on it.
Functions of PPC:
• Optimization of Resources (Man, Machine, Material)

• Costing Research and Development(R&D)

• Purchase Order Receiving

• Capacity

• Time Line (Time, Action)

• Fabric Accessories (Stitching and Packing)

• Fabric Demand Plan (Lead Time)

• Accessories Demand Plan

42 
 
  
 

PPC Costing:
This is the most important responsibilities of PPC department .It is
responsible for accurate costing of production. The price of the single
accessory can’t be ignored .On the basis of cost, given by PPC
merchandiser negotiates with the customer. This is crucial point in
getting the purchase order (PO) the main things that are taken into
account during costing and pricing of product are as follows

• Fabric Cost (Yarn Dying and Knitting)

• Stitching Cost
• Packing and Accessory Cost
• Overhead Financial Charges
• Margin and Rejection
• Freight on Board

PPC Profile:
A PPC profile is prepared which contains all the specifications that has
been demanded by customer and distributed to all the concerned
departments in which whole execution of order is done. Following
points are included in this profile.

• Purchase Order
• Buyer Name
• Description
• Quality
• Color and Size Breakdown
• Time Line
• Size Chart and Cutting Design
• Packing Program

43 
 
  
 

PPC department have two types of planning regarding production

1) Martial Planning
2) Unit Planning or Time Line & Machine Planning
Martial Planning:
Martial planning includes,
• Fabric Planning
• Accessories Planning
Fabric Planning:
Each purchasing order has its own demand about fabric. Each
purchasing order has its own product package. Project package means
every purchasing order has a different (GSM) gram per square meter.
There is a slight margin in GSM, which is allowed by the customer due
to shrinkage effect, it is up to 5%. Fabric planning also includes that
what type of cotton requires for producing this fabric.
In fabric planning color and size brake down has another important
functions, when purchasing order receives it has its own requirement of
color and size. The department has check weather this type of dying
facility has available in MTM mills or it requires some out sourcing.
Then PPC department informs the mills what size sheet is more efficient
for this purchasing order. What type and gage size is required for this
fabric? Weather this size of sheet length is suitable for this order or not.
PPC also plans for marker making (most precise size for different parts
cut from lay sheet). Department plans the size of sheet which has
minimum wastages during cutting

44 
 
  
 

There are two types of wastages from sheet.

• Big Wastage
• Small Wastage
85% output are required from the sheet. The fashion body part has less
efficiency as compare to simple wear. PPC department also concern a
different sizes of a shirt e.g. large, small, extra, large, and medium.
How many quantities of each size required by the customer and how
much sheets size is more efficient for each size.
PPC transforms all these information to mills for fabric.
Accessories Planning:
• Stitching
• Packaging
Stitching accessories planning includes thread, buttons, labels, or
anything extra is customer’s wants to attach with the shirt. Some time
customer’s gives some instruction cards attach with the shirt.
In packaging accessories all the martial includes which will used in
packaging e.g. Rappers, paper packaging.
PPC plans about accessories are forward to procurement department.
Which have responsible to purchase these accessories. Sometimes
customer sends these accessories or some part of accessories to MTM.
It may possible that customer may indicate or bond MTM management
to purchase these accessories from specific buying house. if customers
not suggests then procurement department. Purchase it from open
market.

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Unit Planning or Time Line & Machine Planning

It includes the capacity and no of machine required for a specific
purchasing order. For the specific purchasing order PPC cooperates
with industrial engineering departments. For example, for a purchasing
order of polo shirt, PPC send the sample of shirt to trial room where the
expert stitches stitch this shirt and finds out how much time require for
each stitch. In trial room there are different levels of stitches performing
this activity so that it’s near to reality.
According to this time line for specific stitch PPC plans how many no of
machines and stitches required for this shirt and for each specific
operations like collar stitch, collar attach, button attach how many
machines are required to speedy flow in production.

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R&D Department
A very aggressive and creative R&D department is always busy in
exploring innovative product development enabling MTM to be ahead of
many in the field. Our keen extensive and aggressive merchandising
team, comprising experienced and trained MBA’s functions with the
core objective of rendering ultimate customer satisfaction through
product development and smooth execution of orders. They are capable
and keen to meet an average 3~4 days lead time for proto samples

47 
 
  
 

Industrial Engineering Department

Industrial engineering is that branch of engineering, which deals with the
productivity increases the using all the available resources. These
resources are following.

• Men
• Materials
• Money
• Machine
• Methods
• Systems
• Land/Space

Industrial engineering provides us a systematic (step by step) organized

way of increasing productivity using simple techniques.

Productivity:
It is defined as the ratio of output and input i.e.
Productivity = Output / Input

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Procurements Department
It is the acquisition of goods and services at the best possible cost of
ownership in the right quantity at the right time in the right place for the
direct benefits of the organization.

Functions of procurement department:

• Receive PPC Sheet From Store
• Take Acquisition
• Price Negotiation
• Order Place
• Shipment of Goods
• Time Line
• Follow Up Tools
• IGP&GRN
• Accessories
• 10-Payments of purchased goods

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Production Department
We believe that prevention is better than cure. During the process of
stitching we have inline inspection and final inspection processes. The
garments are 100% inspected by highly experienced inspectors. Our
objective is to produce with Zero Defects.
The ‘BACK TRACKING SYSTEM’ plays a vital role in developing
sense of responsibility and accountability in every person in making and
inspecting the garments. The same thing is emphasized in ISO-9002, so
we are not only the ISO-9002 Certified holder but also the true
executors. The company has independent Quality Assurance Team that
conducts inline audits and final finished goods audits. The QA. Manager
ensures that before the goods leave the factory, they comply with the
customer’s AQL standard.
Followings are the stepwise operations, which are followed by the
production department

• In the first step when a new P>O is going to be produced then

production planning and control department forward a ppc file to
the production department.
• In second step industrial engineering department calculates the
standard allowed minutes for a particular function such as collar
attachments.
• After the above two steps production department will design the
flow of garment.
• Then fabric will cut in the cutting department
• After cutting induction will b moved to the allotted units.
• Stitching of the garments will be done in the units.
• Clipping is done after stitching .pressing
• Final Inspection
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• Super final Inspection

• Packing
• Internal audit
• External audit
• Ex-factories
Production Department (Stitch to Pack):
The basic objective of stitching department is to stitch the best quality
garments in efficient manner according to the specifications of the
customers.

1. Process Flow Stitching: -

Stitching unit takes its lot from induction department and start stitching
process. The workers in this department are on contractual basis. Every
stitching unit has a separate brand for stitch.
Chain flow technique is used in stitching units. Every worker performs a
single function on all pieces and forwards it to next worker for further
function. Until the piece is complete.
After stitching the clipping function is done on the garments. All extra
threads are removed in this function. After it the garments are pressed.
Steam is used for this purpose.
After pressing the garments are forward for audit. In stitching unit
following machines are used for garments making.

• Flat Lock Machine.

• Over Lock Machine
• Lock Stick Machine
• 2 NCS Machine.
• Zigzag Machine.
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• Bar Taking Machine.

• B/Sewing Machine
• Snap Machine.
• Tajima Embroidery Machine.

2. Packing Process:-
After stitching the garments are forward for packing. Chain flow is used
for packing one person checks the product, other attaches stickers, then
putting in Polly bags and then shifting to cartons. Every person who
done any operation on the garment take a barcode slip. And last slip is
attached with the garments. This bar code is feed in a computer program.
And can be use for back tracking if necessary. Then these cartons are
shifted to shipment store for further proceedings.

• Role of Inline Quality Control: -

Inline quality control is strictly applied. Inline inspectors check the
stitching, plucking, pressing, accessories, sizes and packing specification
of the garments. If there is any variation they immediately follow it and
try to cover it.
The main responsibility of inline quality control is to ensure quality at
every cost. They have to check every single piece after stitching.

3. Balance of Responsibilities b/w Production &

Quality Control:
The responsibility of production department is to produce every piece
according to specifications of customer and in the given time. They
work together for achieving their objectives

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Stores Department
• Main Store
• Fabric Store (Stock Pledge)
• Shipment Store
Main Store:
There are two types of things, which come under main Store.

General:
Stationary, Machine Parts, Maintenance etc

Structure of Inventory Stores Department

Inventory Manager

Fabric Store Manager Shipment Store Manager Main Store Manager

Store In charge Store In charge Store In charge

(II) Accessories:
Buttons, Thread, Zips, Labels, and Needles etc

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Finishing Department

Main finishing checks:

1. Stain
2. Darning
3. Re Stitch

In finishing department different activities are performed. This is very

important department because from here the garments are dispatch to
shipment. After sewing the garment goes to clipping department, where
extra thread from fabric cuts. After clipping the garment has checked to
find out the stain and spots. The garment which has stains sends for
removing stain to separate table where different chemicals are using for
removing the stains. There is 100% checking of measurement of the
garment by final inspectors, which is also another check on the quality
of the garment. Here some under quality garment are sends to operators
for alteration and the garments that not even alter are rejected. There is a
separate sheet for rejected garment. Finishing in charge randomly checks
the garment. Finally the ok garment sends to packing table, where whole
garment is checked 100% before packing. Then garments are packed
into rappers and rappers packed in paper packaging and sends to
shipment department.

54 
 
  
 

All the information regarding shipment and garment attached through

the label.

Label Accessories
Labels:
Main Label
Size Label
Care Label

GMT Specification of Garments:

• Straight Shoulder
• Across Shoulder
• Sleeve Opening
• Sleeve Inseam
• Sleeve Length
• Sleeve Length From HPS
• Sleeve Hem Height
• Upper Arm
• Across Chest
• Chest
• Side Seam
• Bottom
• Neck Back Drop
• Arm Hole Straight
• Arm Hole Curve
• Neck Front Drop
• Sleeve Length From CBN
• Shoulder Slope

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• Waist
• Collar Bed Width
• Placket Opening
• Placket Length
• Waist Band Width
• Side Seam Excluding Waist Band
• Side Seam Including Waist Band
• Leg Opening
• Leg Hem Height
• Fly Opening
• Crotch Seam
• Thigh
• Hip

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I.T Department
I.T department of MTM is very well established. It reduced the paper
work system. All the work is done on computer. Data is transmitted
from one apparel to another and to the mills is through the wide area
networking. (WAN) In wide area networking s routers is used which
replicate the data and send it to the apparel. And they also have an
ability to update the whole data in main server. There are three servers in
overall Masood, one is online server, and other is stand by and third is
replication server. Whole the process of manufacturing can be tracked
from computer in MTM. Our customers can also check the status of their
ordered product by only using net. MTM is at almost pure Dot Com
positions and we can say that IT has been so much flourished in TM that
it will be difficult to survive for MTM without IT at this time.
The system developed by the I.T department includes
HRMS Human Resource Management System
AMS Apparel Management System
GMS Gate Management System
IMS Inventory Management System
FMS Fabric Management System

Back Track System:

MTM has latest computerized Barcode System in every operation of
production from spinning to packing. Products of each department carry
bar coded stickers, which contain details and history of the product.
Hence if any problem is reported, one can trace back the root of the
problem and enable to prevent occurrence of the same in future.

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Finance Department
Finance is art of science of managing money and managing the
financial resources.
Masood Textile Mills have a joint finance/ accounts department. As the
complexity and size of the organizations, the finance department of
MTM totally computerized to record the transactions, instead of
recording manually. The finance department of the MTM apparel
division is connected with the LAN. Thus the MTM is keeping the
clerical cast s low to increase the efficiency of processing transact
Finance department has major hold in Masood Textile mills. This
department plays an important role in any project investment, product
analysis and its budgeting. This department also performs investment
decisions and asset management decision functions. How the working
capital managed. How debt is used in asset management.
How and when the liabilities are to be paid. What are the achievements
of the organization by implementing decisions? Past financial decisions
are reviewed and imposed with new trends and requirements.
The function performed by the finance department is to collect and raise
funds with the varying demands of MTM Funds are created through
loans or by issuing share of the organization. This department also
makes financial analysis; cash flow and profit and loss account finance
department is headed by director finance manager is marked.
Under there personal, many sub-ordinates are worker like account
officers and assistant account officers.
The main objective of finance department of MTM is to manage finance
in such a way that maximum output is taken by minimum input.

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MTM’s financial administration is very strict in giving information.

Company rules are very strict for it. Following are the main functions of
finance department.

Functions of Finance:
• Preparation of Financial Statement
• Internal Control
• Conduct of Audit
• Comparison
• Order Wise Profit and Loss Account and their Analysis
• Checking of Wages and Salary
• Procurement Bills
• Purchase Bills
• GRN
• I.T Bills
• Machine Bills
• Dyeing
• Allowances
• Overtime
• EOBI
• Gratuity
• Marriage and Death
• Extra Payment
• Local Sale

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HR Department
HR department in MTM is involved in different types of human resource
development and human resource development activities. Here are the
activities of HR department in MTM;

• Recruitment
• Training and Development
• Compensation
• Performance Appraisals
• Employee welfare
• Rewards and Punishments
• Retiring and Termination Benefits
Objectives of HR Department:
• To help the organization to reach its goals.
• To increase employee’s job satisfaction and motivation.
• To employ the skills and abilities of the workforce efficiently.
• To develop and maintain a quality of working.
• To communicate and implement HR policies.

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Forwarding Department
Organize the safe and efficient movement of goods through different
mode of transportation .We use the most effective and economical
methods of transport for goods that might be the services of shipping
lines, airlines or road and rail freight operators. The forwarding
department play very important role for shipment of garment to various
countries with using of many documentation. They use container to
transfer of garments like 20ft, 40ft and 40 ft HC. They use the following
formulas to calculate the CBM.
L * W * H/ 61023 * No. of cartons
For Air
L * W * H/ 366 * No. of cartons
L=length
W=width
H=height

Functions of Forwarding:
• Research and planning of appropriate route for shipment
• Obtaining, checking and preparing documentation to meet customs
and insurance requirements.
• Arranging air transport for urgent basis.
• Working closely with customer and third parties to insure smooth
operations to deadlines.
• Maintaining current knowledge of relevant legislation, political
situation and other factors that could be affected.
• Transmitting data by internet and tracing of shipment
61 
 
  
 

Mode of Transportation:
• Road Transportation
• Rail Transportation
• Air Transportation
• Sea Transportation
Forwarding Documents:
Bill of Lading :
A document that establishes terms of a contract between a shipper and
transportation company.
The following heads include;

• Shipper Name
• Consignee
• Notify Party
• Export Reference Numbers
• Agent’s Name
• Vessel Number
• Port of Discharge
• Place of Delivery
• Final Destination
• Description of Goods

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Air Way Bill:

An air way bill is a documentary proof of the contract of carriage
between the shipper and the carrier.
It includes the following heads

• Supplier Name
• Consignee
• Form Export Number
• Invoice Number
• Notify Party
• Airport of Discharge
• Airport of Receipt
• Airport of Loading
• Description of Goods
• Gross /Net Weight
• L.C Number

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Commercial Invoice:
The commercial invoice made by the forwarding department. Which go
to the buyer of products.
It includes the following heads

• Invoice Number
• Shipper Name
• Consignee Name
• Notify Party
• Agents Name
• Export Registration Number
• Payments Terms
• Discretion of Goods

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Shipment Department
The shipment department has following procedure
Receiving of packs Racking

Information to quality assurance department

Quality assurance audit Pink slip if rejected

Green slip if ok

Scans and shipped

The hole can be rejected on the basis of this quality audit

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Promotional Activities of MTM

Major export of MTM is made through E-Mail services. Many contracts
are settled through personal sitting. MTM do not waste any chance to
promote its product. MTM participates in various exhibitions that take
place under export promotion bureau in different areas of the worlds.
MTM also takes part in world trade shows for promoting its products. It
also sends many samples to its potential customer.
Promotion is one of the four major important elements. The main
promotion tools are advertising and other country business relationship.
MTM should advertise its products not only in the world trade
magazines but also in national industry magazine. The company has to
decide how to set the promotion budget. The appropriate budget
approach is to send the company can afford with respect to its funds and
product.

Physical Distribution:
MTM exports its products through two different marketing channels.

Direct Marketing Channels:

MTM directly contact with its customers through mail, telephone, and
personal contacts and sell its products directly to the ultimately buyers.

Indirect Marketing Channels:

When it comes to indirect marketing channel, distribution is made
through intermediaries. MTM exports its products through many agents
in some cases. MTM is using different channels of transportation for the
distribution of its products like, ships, airship etc.

66 
 
  
 

Countries of Export:
MTM is making a good effort to increase the market share. Today
company is exporting its products to many countries like,

• USA.
• Europe

67 
 
  
 

Corrective and Preventive Actions

The corrective and preventive actions are very strong in Masood. Strong
preventive actions are designed to ensure the quality and avoid any kind
of fault. But if anything goes wrong then relevant person immediately
takes corrective action.
1: Preventive Actions:
• Fabric Audit
• Cutting Audit
• Inline Audit
• Measurement Audit
• Finishing Audit
• Final Good Audit

2: Corrective Actions:
• Warnings
• Demotions

68 
 
  
 

SWOT Analysis of MTM

STRENGTHS  WEAKNESSES

1. ISO 9002 Certification. 1. Increased employee turnover 

2. WRAP Certified 2. Centralized management system 

3. Vertically integrated. 3. High cost of production. 

4. High quality products.
5. Excellent market image in the local
and international market.
6. Highly qualified management.
7. Adequate financial resources.
8. Competitive advantage.
9. Adopting information technology.
10. Recruitment on merit.
11. Loyal customers.
4. Low production capacity. 
5. De‐motivated Staff. 
6. Non‐Corporative culture. 
7. Insufficient benefits for the 
employees.  
8. Stereotype machinery for 
processing. 
9. Communicational gap among 
different departments. 

12. Skilled Labor.

13. Broad and motivational vision.

14. Back Track System

69 
 
  
 

OPPORTUNITIES  THREATS 

 
1. Can expand its division such as  1. Entry of new competitors just like 
entering in weaving sector also. 
China & India. 
2. Can introduce its own label in 
domestic as well in international  2. Buyer need and demand changes.
market  3. Political instability. 
3. Can capture new market segment.  4. Changing geopolitical situation. 
4. Full potential of entertaining the 
5. Change of government policies. 
local market. 
6. Low price offered by competitor 
5. Can reduce the cost by proper 
utilization of resources.  7. Globalization. 
6. End of quota restrictions by the   
end of year 2004. 
7. Can hire well‐educated and   
experienced staff. 
 

70 
 
  
 

PEST Analysis of MTM

• Political Instability:
The political situation of Pakistan is not satisfactory. Due to the rapid
change in the Government every government sets its own new trade
policies.

Govt. should apply sustainable policies for the beneficial of the

exporters as well as the investors.

• Economic Situation:
The economic condition of Pakistan can also affect the foreign investors
increasing inflation rate make the cost of production high and thus
reduce the profit margin of the investor.

• Social Situation:
The change in the lifestyle of the people affects the growing demand of
the MTM products. The change in the lifestyle and needs in different
demographics also affect the demand of the customers.

Due to all these changes MTM is performing excellent for the excellence
organization as well as for the customer.

• Technological Factor:
Technological advancement in all the sectors of the country has changed
the entire socio-economic environment. Especially in the textile sector
there is a lot of technological development.

71 
 
  
 

MTM Excellent computerized machines and devices are installed in the

MTM \has made extension in its present setup by installation of well
advanced technology imported from Japan China and France.

72 
 
  
 

Conclusion
 

Masood Textile Mills Limited is one of the leading groups in

Pakistan. The system, the management style, the policies &
decentralized decision making environment is really remarkable. In
this era of technology, the “Information” is the key to success in
the business. This means that the successful businessman will be
who will have the right information at the right time. This
comment leads to the conclusion that the Information Sharing
Process should really be improved.
 

   

73