A COMPLETE STUDY ON PRODUCTION PROCESS FROM CUTTING TO FINISHING

CELEBRITY FASHIONS LTD The company is engaged in the business of designing, manufacturing and selling of mens garments and they set up in the year 1988 as a small 50 machine factory and 72 people venture in Chennai. The company cater to the demand of leading international brands and also to the domestic market through their own brand Indian Terrain. They have over the last two decades grown to 8 factories (4283machines), housed over 300,000 sq. ft. employing over 5000 employees.

Production process

Pre production meeting Size set Production start up meeting Pilot run Bulk production

Pre- production meeting

During this meeting they discuss with all department members regarding the style quantity, quality, critical path, and availability of informations, technical aspects, raw materials, manpower, in-house details, plan and time frame.

A. FABRIC Type of fabric. Interlining details ( woven /non-woven) Fusible details (fusible or non fusible) Fabric inspection report Shrinkage report Types of fabric used for the style

B. CUTTING Fabric consumption details Fusing standard Mini marker No of parts for the style details Approved shade cards for the required colour in the tech pack Patterns availability

C. TRIMS Special trims Approved tech card for the required colours in the tech pack

D.PRODUCTION Construction details Cut of date for size set Lay out and the no of machines required for the style Number of batches required for the style Start-up and end date.

E. FINISHING Washing standards required for the style Type of washing

F. PRESSING Pressing details Type of folding required for the style

G. PACKING Instruction for packing Type of packing to be followed. Contras dimension Carton dimension.

H. QUALITY CONTROL Sample comments Measurement spec sheet Any special care

GENERAL Availability of Sample Style bulletin & layout Shade (washed/unwashed)

SIZE SET Size set consist of the following operations Cutting (they cut only 5-6 pieces) Assembling Washing size set approval

Production Start up meeting

Conducted with following members 1. Factory manager 2. Production manager 3. Quality assurance manager 4. Quality controller 5. Cutting quality controller 6. Industrial engineer 7. Store in charge 8. Cutting in charge 9. Mechanics

In this meeting they discuss about time frame, critical operation, remarks, (pilot and bulk) quantity.

Cutting Process
After PSU Spreading Marking Ready cutting Lay Cutting (straight knife) Labelling Folding Relay Checking Bundling Assembling

SPREADING

Spreading table length 14 meters and width 70 inches. Total no of workers 6 each table 3.

MARKING

LAY CUTTING

LABELLING

FOLDING

RELAYING

BAND KNIFE

BUNDLING

Assembling
This unit consist of 7 lines . Each line have 1 supervisor 1 quality controller and 43 operators Factory target is 2300 per day Machines used SNLS, SNEC, KANSAI, FOA, BTN HOLE, BTN. They use straight lay out for assembling.

MACHINE`

COLLAR/FLAP

MACHINE

SNLS

T.S HEM NB

PROFILE COLLAR

SNEC

SNEC

PROFILE COLLAR

NOTCH & INVERT COLLAR

TURNING M/C

SNEC

ATTACH NB TO COLLAR

T.S COLLAR

SNLS

SNLS

E.S NECKBAND JOINT

ATTACH NB TO COLLAR

SNEC

IRON TABLE

BUFFER

TRIM NB MARGIN

SNEC

MACHINE

FRONT

MACHINE

SNLS

MAKE PITCH STITCH ON BTN PLKT

HEM BTN PLKT

TABLE

KANSAI

MAKE BH PLKT

MAKE BH PLKT

KANSAI

IRON TABLE

PRESS PKT SHAPE

HEM PKT OPEN

SNLS

SNLS

ATTACH PKT TO FNT

MARK FOR PKT ATTACH

TABLE

TABLE

CHECK POINT

ATTACH PKT TO FNT

SNLS

MACHINE

BACK

MACHINE

IRON TABLE

ATT LBL

ATT LBL

SNLS

IRON TABLE

PRESS BACK YOKE

ATT BACK YOKE

DNLS

DNLS

ATT BACK YOKE

FRONT & BACK SETTING

TABLE

SNLS

JOIN SHOULDER/INVERT

T.S JOINT SHOULDER

SNLS

SNLS

ATTACH COLLAR

CLOSE COLLAR

SNLS

SNLS

ATTACH COLLAR

SLEEVE SETTING

TABLE

SNLS

ATTACH SLEEVE

ATTACH SLEEVE

SNLS

MACHINE

ASSEMBLY

MACHINE

SNLS

T.S ARM HOLE

T.S ARM HOLE

SNLS

FOA

CLOSE SLEEVE & SIDE BODY

ATTACH W/C LABEL

SNLS

TABLE

CHECK POINT

SLV HEM PCS SETTING

TABLE

SNLS

T.S HEM BOTTOM

JOINT SLV HEM PCS SIDES

SNLS

SNLS

ATT LBL TO BTN PLKT

T.S HEM BOTTOM

SNLS

SNLS

ATT HEM PCS TO SLV END

ATT HEM PCS TO SLV END

SNLS

DNLS

CLOSE SLV HEM PCS

CLOSE SLV HEM PCS

DNLS

SNLS

SEW BUTTON HOLE

MARK FOR BH

TABLE

BTN

ATTACH BTN

SEW BUTTON HOLE

BH

After Receiving assembled garments from lines

Finishing

Trimming and checking Final inspection Measurement checking

1. FABRIC 1. Shade variation 2. MACHINE 1. Broken stitch 2. Skip stitches 3. Uneven SPI 4. Puckering 5. Loose tension 6. Insecure BTN/SNAP

3. SKILL

1. High-Low 2. Uneven 3. Raw edge 4, Needle holes 5. Pleats 6. Missing operation 7. Run off stitch 8. Pressing 4. CLEANLINESS 1. Dirt mark 2. Oil stains 3. Stickers 4. Uncut threads

FPY MEETING

The no of pieces get approved with out any rework in all aspects like measurement and specification. First passing yield meeting will be conducted daily at 12:45. with the following members checking in charge, industrial engineer, line supervisors, quality controllers, quality manager, mechanic.
Line no style Checke d Qty Skip Broken Raw edge Run off Today FPY Vag FPY Position

sno

Checking in-charge will give the defects detail and the FPY %. Here the members discuss about the cause of defects and what are all the measures should be taken to reduce the repeated mistakes. This meeting will help to increase the FPY% eventually

Pressing Presentation Labelling Packing Preparation of carton barcodes Carton packing and sealing

Quality Assurance
1.
2. 3.

Inter Pre final Final

AQL CHART MIL STD

LOT SIZE

S/S

1.5
A/R

2.5
A/R

4.0
A/R

6.5
A/R

0-90
91-150 151-280 281-500 501-1200 `1201-3200

13
20 32 50 80 125

0/1
0/1 2/3 5/6

1/2
1/2 2/3 3/4 5/6 7/8

1/2
2/3 3/4 5/6 7/8 10/11

2/3
3/4 5/6 7/8 10/11 14/15

3201-10,000
10001-35000 35001-UP

200
315 500

7/8
10/11 14/15

10/11
14/15 21/22

14/15
21/22 21/22

21/22
21/22 2/122

Final Inspection
Acceptance Quality levels are given from 1.5- 6.5 for various quantity with their sample size. In final inspection they check all the aspects like carton size and weight, packing, garments measurements, SPI, constructions, tags, fabric & trims, lining, interlining, colour combo, zipper, buttons, labels, threads, hang tag, price tag etc. According to the buyer requirement level inspection will be done. Once the finished garments get approve then it will send for loading, otherwise it will be rejected.

THANK YOU