Final Report to Company

8/8/2019 Final Report to Company

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PARAMOUNT SPINNING MILLS LIMITED

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Production planning and control

Deputy General Manager: Ali Nayaz Manager: Khalid ikram

Assistant manager:Akmalshahzad PPC Officer:RanaZahid

Job of the posts:

Deputy General Manager:

Take orders from marketing department Give order completion date to the Marketing department Guide manager about order Overall checking of the order processing

Manager:

Get order from Deputy General Manager Make per day plan of action Get reports from production departments through WIP department on daily basis

department are

o Cutting departmento Stitching departmento Dying and printing departmento Washing departmento Finishing departmento WIP department

Update the reportsAssistant Manager:

Coordinate with manager Collect reports from Manager and make final report and update it Send its report to all concern department


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All the office work related to documentation

PPC Officer:

Take standards of order requirement from marketing department and send relatedspecification to concern production departments

Get raw material fabric make a sample and send it for test and make report on thatsample for the meeting in which Quality department, Marketing department, Finance

department, PPC department and WIP department make minutes(Points) of that

meeting and send it to the above departments.

Linked Departments:

Commercial department:

Get order from Marketing department Arrange fabric from supplier according to the order requirement Deal outside from the company Sourcing department for PPC department

Material Management & Control department:

Get order from Marketing department Arrange Zip, buttons, thread from supplier according to the order requirement Deal outside from the company Sourcing department for PPC department

Note:

Marketing department deals with these departments and order them to get material

then send the report to PPC that the raw material will be in PPC store and asked about

the order completion date or you are able to handle this order know or not. Then DGM

meets with his team and check the availability of empty slot and machine, if availability

exist them DGM send report to marketing department to take the order and give them

a date and then finally marketing department take the order.


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Cutting department:

Direct link with PPC department Capacity of 6000 piece per day Send daily report to WIP department

Stitching department:

Direct link with PPC through WIP department Capacity of 6000 piece per day Send daily report to WIP department

Washing department:

Direct link with PPC through WIP department Capacity depend on washing type Send daily report to WIP department

Finishing department:

Direct link with PPC through WIP department Capacity depend on demand type Send daily report to PPC department

WIP department:

Feeding

Its a chain or link between department Direct link with PPC department Send report to PPC of overall moving order from store to warehouse.

Note:

Capacity of the production department can be vary according to demand by overtime.


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Some Main Points:

Order id:

In order ID two things are taken first one is short form of costumer name and

second one is order number. Lets take an example of FHI Garments Company

make short form of FHI Garments like FHG and if order is 15 then the code of

the order will be FH-15.

Extra percentage of the Material:

There is a percentage of extra raw materials for making order because there is

a chance of fault at any stage of production. This percentage varies according

to order importance normally average percentage is 3 to 5 percent. The

importance of the percentage depend upon two main factor

o

Complexity of processo Importance of costumer commitment

Exchange of reports:

Gulistan Group Of Company has its own server room so Email facility within

company is allow in all departments and department like marketing

department are allow to Email and contact outside the company to stay

connected to costumer.

Vehicle permission:

If outsourcing is required a form is execute for this purpose. Basically there

are three section on it. First is checked by head of department which contain

following data


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Daily modus operandi (routine): PPC

1. Receive daily report from WIP department of production section, name ofdepartment s of production section are

a. Cutting departmentb. Stitching departmentc. Washing departmentd. Finishing departmente. WIP department

2. Check and compare all individual reports with the combine report provided byWIP department, approved it and allow WIP department to send it to all

production department and also to finance department.

3. Contacting commercial and MM&C department if the shortage of the rawmaterial take place and send memo to then and one copy to marketing

department.

4. Planning for future work, orders and manage them, define overtime handleextra holidays and handle man power.

5. Send complete order to quality department and get report from them.6. Send report to related department about their work, faults and overall average.7. Get standards from marketing department and send specification to every

department about their work.

8. Check the sample get report on it from sampling department and arrangemeeting on every step of production with Quality department, Marketing

department and production department, make minutes of the meeting and send

it to all related department .


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Work In Process Control Department

Deputy General Manager: Ali NayazManager: This post is not in this department

Assistant manager:ArshadBhattiIncharge of receiving: Mohammad Nadeem

Incharge of feeding: Baber GillIncharge of issuing: Mohammad awais

Store supervisor:Liaqat Ali

Job of the posts:

Deputy General Manager:

Take orders from marketing department Give order completion date to the Marketing department Guide Assistant manager about order Overall checking of the order processing

Assistant Manager:

Get order from Deputy General Manager Coordinate with the manager of PPC department Get reports from Incharge receiving section and send it to PPC manager and DGM Update production departments

Incharge of receiving section:

Receive fabric from PPC department after cutting and move it to stitching, washing andfinishing department.

Collect reports from production department combine it and make WIP daily report and sendto PPC manager through Assistant manager WIP along with all individual reports of

production departments.


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Incharge of receiving section:

Receive standard from PPC officer and complete it by attaching sample on it and compare it Produce shortage report Issue material and control feeding reports

Incharge of feeding section:

Control no. of feeding area between different stitching department Generate daily report and send to incharge issuing section Handle troubleshoot at any step of production.

Store Supervisor:

Issue raw material from main store and issue it to stitching department through incharge issuesection

Generate report for transactions

Linked department:

MM&C PPC Stitching department Washing department Finishing department

Internal section:

Fedding section Mini store


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Daily modus operandi (routine):WIP1. Receive daily report from production section, name of department s of

production section are

a. Stitching departmentb. Washing departmentc. Finishing department

2. Combine it and send combine report with individual report of everydepartment to PPC manager and DGM.

3. After check by PPC manager this report is send to all concern departments.4. Receive standard and complete it by attaching sample on it.5. Issue material from main store and count it in mini store and then issue it to

stitching department.

6. Generate shortage report.7.

Feeding the fabric in stitching

8. Send memo to MM&C department


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Order execution process: PPC & WIP

Marketing department take orders after asking DGM of PPC that can PPC have the

capacity of taking order and then take orders. The date given to the costumer is

decided by the DGM of PPC. After commitment from marketing department that raw

material will be in PPC store on this date then DGM have a meeting with his team of

PPC and they check that is there any free slot and are machines available then date is

finalized.

DGM send ok report to marketing department to get order. Marketing departmentsend standards of order to PPC department were PPC officer receive it. Standards are

also sending to commercial department and MM&C department for to buy raw

materials. PPC officer check the standard and pass it. Then give this standard to

incharge of issue section in WIP department were he check it and complete it by

attaching sample of raw material from MM&C department.

A sample is made by sampling department and PPC officer send it to washing and all

process and get result and arrange meeting to discuss the product changing nature.

Marketing department, Quality department, Production departments, PPC department

and Finance department attend this meeting, points are make and report of this

meeting is send to all related departments. After getting ok PPC officer send clearance

report to commercial, MM&C and WIP department.

Commercial and MM&C department contact to supplier to send the material and

incharge of issue section form WIP department complete the report and wait until the

PPC department give fabric to WIP after cutting(fabric is directly send to cutting

department there is no roll of WIP in this process) . When fabric is received from PPC

department feeding section of WIP department activate. Feeding section is place in

every step of stitching section. The purpose of feeding section is to pair the parts of

the order to avoid the fault of change in fabric material and color. Along with feeding

section there is a one section of quality from Quality department for the checking ofquality at every step of production from cutting to packing.

Now incharge of feeding department receive fabric and pair it and give it to stitching

department and send memo to incharge issue section in WIP who coordinate with

mini store supervisor and send report to main store for the material arranged by

MM&C department. Assistant store incharge check the status of the availability give

the available items to mini store supervisor of WIP department after counting and

give report to store incharge of the shortage which is then send to the MM&C

department from main store. Mini store supervisor report to incharge issue section of


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the shortage who send report to assistant manager of the WIP department and PPC

officer of shortage both send memo to MM&C department of shortage and one copy

to marketing department for follow-up.

After getting material from main store mini store supervisor issue it to stitchingdepartment. After stitching incharge of receiving section of WIP department collect it

counts it and send it for washing. After washing, incharge of receive section of WIP

department collect it counts it and send it for finishing department WIP works end

here. PPC department send order to quality department were quality is check and at

last order packing take place then packing section send report to PPC department and

send order to store and at the end PPC department send complete report to DGM of

PPC and marketing for shipment. PPC send report to every production department

about their work, faults and over all working. During all this process daily report is

produce by every department and collects by the WIP department and then combinesreport is generated by incharge of receiving section of WIP department then gives it to

assistant manager of WIP. Assistant manager send it to PPC manager and DGM. PPC

mangers check it and send it to all concern departments.


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Stitching Department

General Manager Production: Fawad Khan SeniorManager: Imtiyaz Ahmed

Deputy Manager: Daud Khan Assistant Manager 1: Ijaz Shah

Assistant Manager 2: Mohammed Saeed Line 1 Incharge: Sarfraz Ahmed Khan

Line 2 Incharge: Mohammad Iqbal Line 3 Incharge: Mohammad Imran

Line 4 Incharge: Mohammad Ali Coordinator: Mohammad Waris

Job of the posts:

General Manager Operation:

Head of Production department. Receive report on order taking and finalize the report Guide manager Overall checking of the Production department

Senior Manager:

Report to General Manager Operation Take plan from PPC Contact PPC and WIP department to give the fabric and accessories Make internal plan to get the target

Deputy Manager:

Coordinate with manager Collect reports from supervisor and make final report and update it Verify the reports send to PPC department and WIP department Check the status of the work Incharge of working line 1 and line 2


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Assistant Manager 1:

Coordinate with deputy manager Collect reports from line man and make final report and update it Verify the reports send to deputy manager Check the status of the work Incharge of working line 3 and line 4

Assistant Manager 2:

Coordinate with deputy manager Collect reports from line man and make final report and update it Verify the reports send to deputy manager Check the status of the work Incharge of working line small parts (line 5)

Line Man(1 and 2):

Coordinate with deputy manager Collect reports from supervisor and make final report and update it Verify the reports send to deputy manager

Check the status of the work

Line Man(3and 4):

Coordinate with assistant manager 1 Collect reports from supervisor and make final report and update it Verify the reports send to assistant manager 1 Check the status of the work

Line Man(5):

Coordinate with assistant manager 2 Collect reports from supervisor and make final report and update it Verify the reports send to assistant manager 2 Check the status of the work


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Program Coordinator:

Taking attendance Make gate pass for who apply for the jab in this section Leave or any kind of application submission Give program for over time before two hour of ending shift Guide cashier in monthly payment to workers Emails and send reports All paper work in office

Linked department:

MM&C ( for thread, zip and other accessories) PPC ( for reporting and plan of action) WIP (for fabric taking and give stitched garments)

Department Sections & Processes:

Basically there are number of step to make a stitched garment form raw fabric. The

department is divided in to 5 sections

Front section Back section Small section Assembly 1 Assembly 2


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Front section:

In this section front part of the pent is stitched or complete. WIP department

get fabric from cutting department and give cut piece of front part of pent to this section.

There are number of step in front section which are

1. Tracing:First the tic pocket (small pocket in jeans pent) is trace on front of the pocket

known as face of the pocket.

2. Ticket pocket making:Basically this is also a small part of the pent but if pocket is simple is made in

front section otherwise in small parts.

3. Ticket pocket attached:In this process ticket pocket is attached to front of the pocket on tracing area

with double needle stitch or depend on requirement.

4. Trimming:In this process the extra part of ticket attached to face of the pocket is trimmed

for accuracy.

5. Facing stitch:There are two types of facing stitch

Cover stitch:In this process simple stitch is used to attach pocket bag

with front.

Clean finish stitch:In this process first front is fold from sides and then

attached with pocket bag.

6. Pocket bag over lock:In this process pocket bag is lover lock from bottom side in inner side for the

safety.

7. Pocket bag top:In this process pocket bag is stitch from bottom side on outer side to hide over

lock and give a shape to pocket bag.

8. Hang:This is a basic process in which pocket is attached with panel simply with

double stitch on top or folding with double stitch.


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9. Patching:In this process stitch attach the pocket bag with panel from side to cover and

secure.

10.ZIP attached kachha:In this process zip is attach with a strip which is then attached to panel.

11.ZIP attached packa:In this process strip with zip is attach with right side panel.

12.Edge attached:In this process front strip in attach on left side panel to hide zip.

13.J stitch:In this process J type stitch with double needle is place on front strip with zip

second side. This process is for attaching ZIP on both panels of the pent.

14.Crouch:In this process area under zip is attached together to complete the front of the

pent. There are two ways to crouch

Folded:First fabric is fold fro edges and then attached.

Top:

Simple stitch is used to attach the both side.

15.Bar tack:In this process the extra stitch is used on edges of stitch is used to protect the

stitching edges.

NOTE:

After is all process front part is ready now this part is send to the matching area

of its own line.


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Small Part section:

In this section small part of the pent is stitched or complete. Basically this

section is extension or helping section for back section. WIP department get fabric from

cutting department and give cut piece of small part of pent to this section with standard and

sample. Process depends on demand but basic are discuss here. There are number of step in

small part section which are

1. Back pocket making:There are two ways

Over lock:

Pocket is over lock from sides and then presses it to give it a

shape.

Hamming:Pocket is fold from the sides and double stitch is apply and then

press it to give it a shape.

2. Mock stitch:Basically it is a double line curve stitch that shows a simple design on pocket

middle. Sometime costumer required embroidery then WIP department send

this cutting for embroidery then give it to this section only for hamming.

3. Yoke attached:Yoke is a piece which is attached between back panel and the belt of the pent.

Both yoke is attached with panels means left yoke with left panel and right

yoke with right panel.

4. Panel attached:Both panel left and right attached together and seet seem process is start in

which double needle stitch is apply to make a strong connection between both

panels.

NOTE:

After all this process this small part is send to pack section for further process.

This section is making small part of all the 4 lines.


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Back section:

In this section small part and back panel is receive from small part section.

There is little number of steps in back section which is

1. Tracing:Back pocket is trace on back panel to get complete accuracy.

2. Back pocket attached:Back pocket is attached on back panel on tracing area.

3. Bar tack:Extra stitching on the ends of stitching is applied to protect it from stitch

losing.

After all this back part is also send to matching area of its own line then front part of the same

code is paired with back part and then this bundle move to assembly 1.

Assembly 1 section:

In this section following steps are done

1. Folder or Inseem safety:Pent front panel is attached with back panel of the same code. Attachment can

be folder in which both panels are attached fold and then joined with double or

triple stitch or simply with inseem safety in which both panels are attached

with single stitch with over lock the ends.

2. Out seem safety:Outseem safety is same like inseem safety but this stitch is on outer section or

on sides of the pent.

3. Top stitch 7 inches:It is a stitch on pocket side starts from belt end and end after 7 inches.

4. Loop making:Loop is a part of the pent that hold the external belt with pent is part is made in

this section.


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5. Loop attached:There are two ways to attach the loop with pent

Insert:In this method loops are attached and stitches are inside of the

belt.

Onside:In this method stitches are also show on loop and attached on

the belt.

6. Waste belt attached:Then waste belt is attached with pent belt can be single piece or in pair.

After belt attachment pent send to assembly 2 after quality checking.

Assembly 2 section:


1. Extra belt cutting and end close:In this process extra belt of the pent is cut according to requirement and end

close stitch is apply to close the end.

2. Eye let:It is a process in which hole is make for the button and edges are stitched for

safety.

3. Bar tack:At the end bar tack stitch is apply on loops, side seem and on hang.

NOTE:


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There are two machines in the end of each line for small fault clearance

and if the fault is big then pent is send back to the person who create this

fault.

Daily modus operandi(routine): Stitching

9. Receive daily report from each line and make a plan to get target output.10.After check by manager this report is send to GM production, PPC and WIP

departments.

11.Receive standard distribute it according to section wise.12.Deputy manager Coordination with manager13.Report to General Manager Operation14.Take plan from PPC15.Contact PPC and WIP department to give the fabric and accessories16.Make internal plan to get the target17.Taking attendance18.Give program for over time before two hour of ending shift19.Emails and send reports


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Washing Department

General Manager Production: Fawad Khan SeniorManager: Mohammad Zahid

Assistant Manager: Ashfaq Ahmed

Product development Manager: Fasial Shahbaz

Three shift incharge for Morning, Evening and Night

Job of the posts:



Senior Manager:

Report to General Manager Operation Take plan from GM Operation Make internal plan to get the target and implement it.

Assistant Manager:

Coordinate with Senior Manager Take target time from Senior Manager Check the status of the work Overall take care of washing

Product Development Manager :

Overall work on sample washing Report to Senior Manger


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Linked department:

MM&C ( for chemical like enzyme, softener and other accessories) PPC ( for reporting and plan of action) Sewing (for the garment taking) WIP (middleman between Washing, Sewing and Finishing) Finishing (for send the wash garments)


Basically there are number of step to wash garment to get required shade, color, style and

size. The department is divided in to 5 sections

Style section Washing section Drying section Shade checking section

Special effect:In this section required style is made on paint as required by the costumer.

Style can be

16.Fading:To fade the paint KMNO4 chemical is sprayed on the pants on the required

area and then send it for washing.

17.Crinkles:Basically it is a style found on thy panel on front and back. It is like wrinkles

on pant. For this purpose hardener chemical is spray on required section andthen wrinkles are made manually and clip with clipper and bake it in oven

with the temp of 70 to 80 degree centigrade and then after the wash.

NOTE:

There is much other style required by the costumer small changes are made in

this process and goal is achieved. Recipe of chemical is made with the help of

sample recipe which was applied on sample piece.


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Washing section:

In this section garment is wash. The purpose of the wash is to get required color, shade, size

and style. There are some elements uses in washing which are

5. Desizer:Desizor is used in washing to desize or shrink the garment according to

requirement.

6. Enzyme:Basically it is a bacteria whose eat the garment fabric and it is use to get grain

on the fabric or you can say that it is used to thinner the garment fabric.

7. Stone:It is basically a simple stone used in wash to help enzyme and bleach to do

their work as fast as possible.

8. Bleach:It is used for lighter the color of the fabric.

9. Bio-Polish:It is basically an acidic enzyme used to fade the required area where KMNO4

is spray.

10.Softener:It is basically used for soften the garment and remove the hardness

With the combination of all these steps there are different types of wash for the denim and

twill garments.


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For Denim washes are

4. RIN wash:This wash is combination of desizor and softener.

5. Enzyme wash:This wash is combination of enzyme and softener.

6. Bleach wash:This wash is combination of desizor, enzyme and bleach.

7. Hard or Dark stone wash:This wash is combination of desizor, Enzyme with stone and softener.

8. Middle stone wash:This wash is combination of desizor, Enzyme with stone, small amount of

bleach and softener.

9. Light stone wash:This wash is combination of desizor, Enzyme with stone, bleach and softener.

10.Bio-Polish wash:This wash is combination of polish, desizor, Enzyme with stone, bleach and

softener.

For Twill washes are

1. Garment wash:Only softener is used in this kind of wash.

2. Enzyme wash:This wash is combination of enzyme and softener.

3. Stone Enzyme wash:This wash is combination of enzyme with stone and softener.

4. Garment dying wash:This wash is combination of bleach, dying and softener.

After wash the garment is move to spinner to spin out the garment and then move to the dryer

to dry the garments and then move it to the shade checking if shade is not according to

requirement then garment is send back for the washing.


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Machine Uses in washing department:

In this department following machines are used

7. Oven:Any type of wrinkle style made on pent is backed in oven to make the wrinkle

permanent so the style remains after wash. This machine has time and

temperature control panel so easy to set time and temperature according to

requirement.

8. Barrel machine:Used for both denim and twill wash. This machine has two way water input

system for hot and cold water with time and temperature control meter.

9. Spinner machine:It is used after wash with fresh water to clean the garment with chemical

recipe with machine has also time control panel.

10.Dryer machine:Dryer is used to dry the garment because there is no time to dry the garment in

sun light this machine has time with temperature control panel.

11.Tonello machine:It is a window PLC operated machine which is used for twill garment wash

and especially for garment dying process known as Tint wash. The following

step is feed in the panel and machine do the entire task automatically. This is a

machine which can perform both washing and spinning. The steps are

Set the level of water Setting of rotation Set the work time Drain 1 (changing of water) Set the level of water Set the level of heat Setting of rotation after second filling Addition of chemicals (softener, bleach, enzyme etc) Set the work time Drain 2 (discard the second filling of water) Setting of spinning time. Opening of door


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Daily modus operandi (routine): Washing

20.Receive daily report from each section and make a plan to get target output.21.After check by manager this report is send to GM production, PPC and WIP

departments.

22.Receive standard distribute it according to section wise.23.Report to General Manager Operation24.Take estimated time from GM Operation25.Make internal plan to get the target26.Taking attendance27.Emails and send reports


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Finishing Department

General Manager Production: Fawad Khan Manager: Mohammad Ramzan

Assistant Manager: Anwar-ul-Haq Shift Incharge: Bashir Mohammad

Trim/buttoning Incharge: Mr. Mudassar Carding Supervisor: Tahir Mehmood

Measurement Supervisor: Mohammad Harron Dispatch Incharge: Aslam Masee

Job of the posts:

Manager:

Report to General Manager Operation Take plan from GM Operation

Make internal plan to get the target and implement it.

Assistant Manager:

Coordinate with Senior Manager Take target time from Senior Manager Check the status of the work Overall take care of washing

Shift Incharge:

Report to Assistant Manager Take plan from Assistant Manager Responsible for the work of his shift Guide supervisor to achieve the target


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Linked department:

MM&C ( for thread, zip and other accessories) PPC ( for reporting and plan of action) WIP (for washed garment taking and dispatch it) Marketing Department (send report of finish the order)


Basically there are number of step to dispatch the complete garment form washed garments.

The department is divided in to 5 sections

Trimming/Buttoning section Press section Checking section Measurement section Carding section Dispatch section

Trimming/ buttoning section:

In this section washed garment is revieved from washing department

through WIP department. Here two type of process are performed

Trimming:

In this process all the extra thread is trimmed and pent is send to checking

table for inspection. Trimming is for

o Extra loop (inside/ outside)o Extra thread (inside/ outside)o Checking


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Buttoning:

In this section following steps are done and then send to the checking table for

final approval

o Shank button ( Top button on pent for eyelet)o Reverts ( For the safety of corner stitches)o Lather label ( Attached or patch on back side)o Size or Care label ( Extra label required by costumer)

Press section:

In this section pent is press according to the given table in which required

shrinkage and after wash shrinkage is given if pent is more than its size then it go back to

washing and if there is over shrinkage pent then this fault is cover by pressing and machine

used for this purpose is known as MACPI. In this section press is checked in following

manner

o Inseam presso Out seam presso Front and Back press

After press garment is send to the Checking area.

Checking Area:

In this section final check is take place of pent in which finishing is check.

Because it is a final checking area so it is important to check the garment carefully so there

are three type of checker for this checking

Checker ( Initial checker for inspection) Final Checker ( Final checker for inspection) Super Checker ( End checker for the garment inspection)

First two belong to finishing department last one belong to Quality department

Measurement section:

In this section full measurement of the pent is checked like waist, length, thy,

Inseam, Out seam and after this it is send to the Carding area


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Carding section:


Attachment of Tags Disclaimer Tags Waist band Tags Price Tickets Pocket Flasher

Dispatch section:

In this section after carding pent are separate on two basis

Shade wise ( For packing same shade in same pack) Size wise ( For packing required size in order)

Packing is further divided in two parts (depend on customer demand)

Per piece poly bag Jumbo poly bag

Carton of packed pent is divided in two ways

Assorted carton:Is this carton type customer defined the different size ofsame order for example 4 pants of 34 size, 10 pants of

32 size etc.

Solid carton:In this type costumer required same size in single carton

for example all pieces of 32 sizes.

Number of pants in each carton is depend on customer demand if costumer asked for

fixed packing them he define the number of pant in each carton and if he asked for weight

based then he will give the required weight like 90 kg or 180 pound then carton is made withtotal weight of 90 kg or 180 pound number of pants are not defined in this type. After carton

is made following tags are apply on carton

Size wise back up Carton mark/ number Shipment mark (based on customer) Carton sticker Bar codes


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Daily modus operandi (routine): Finishing

28.Receive daily report from each section and make a plan to get target output.29.After check by manager this report is send to GM production, PPC and WIP

departments.

30.Receive standard distribute it according to section wise.31.Assitant manager Coordination with manager32.Report to General Manager Operation33.Take plan from GM operation and required date of dispatching from PPC34.Contact PPC and WIP department to give accessories35.Make internal plan to get the target36.Taking attendance37.

Give program for over time before two hour of ending shift

38.Emails and send reports


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Quality Department

GM Production: Fawad Khan Manager: Mohammad Salman

Fabric Q.Incharge: Javed Iqbal Cutting Q.Incharge: Mohammad Shahid

Sewing Q.Incharge: Ibrahim Doger Washing Q.Incharge: Mohammad Hafeez

Finishing Q.incharge:

Job of the posts:

Manager:

Report to General Manager Operation Take plan from GM Operation

Make internal plan to get the target and implement it. Make it possible to complete the order quantity with quality. Check the report and the sample of the order and pass it

Incharge:

Report to Manager Take plan from Manager Responsible for the quality work of his department Guide quality supervisor to achieve the target Check all the order and match with sample Create daily report of departmental progress Surprise checking of working lines Randomly check of any piece in any section


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Linked department:

MM&C ( for thread, zip and other accessories quality checking) Fabric store ( for check the quality of the fabric) PPC ( for reporting and plan of action) Marketing Department (get the sample of the order) Cutting Department ( for the checking the quality of work ) Sewing Department ( for the checking the quality of work ) Washing Department ( for the checking the quality of work ) Finishing Department ( for the checking the quality of work )


Basically quality department is almost present in all production departments. From fabric

import to garments export there is quality section in every production department. The

purpose of this department is to control and manage quality of the order with quantity of theorder. There are basically six section of this department which is distributed in production

section which

Quality department for fabric inspection (FID) Quality department for cutting department Quality department for sewing department Quality department for washing department Quality department for finishing department

Quality department for MM&C department

Quality department for fabric inspection:

This is the section of quality department which exist in fabric store. The

purpose of this section is to check the fabric at initial stage so the is no b-pare pant because of

fabric fault. Fault may be of any kind to find out fault number of processes are apply to the

fabric describe as under


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end. Three of half meter and left three of one meter. One full width with 12 inches

length piece is also cutted from every roll.

Fabric inspection:

Fabric inspection on machine:

To inspect the fabric on machine, four point system (American) is used in this

respect. The method is if the fault is in between 0 to 3 inches then give it one

point if the fault is in between 4 to 6 inches then the points are two if between

7 to 9 then three and if 10 inches to one meter then 4 points. At the end all

points are added and then multiply with 100 x 100 and then divide by total

length and at last dive the answer with the smallest width of the fabric if theanswer is more than 15 points the fabric is b-two if less than 15 than fabric is

in A condition. If fabric got points more than 20 then the fabric is rejected

piece.

Fabric inspection for shade and shrinkage:

To inspect the fabric for shade and shrinkage following steps are done

1. Half meter piece is cutted from fabric of all rolls of same order.2. Make a 25 x 25 inches square on it by garment marker.3. Kg tube is made of the mark fabric4. Send it for wash and then get its results and make a report on shrinkage

and shade changing behavior of the fabric

Fabric inspection for skew (twist checking):

To inspect the fabric for skew checking following steps are done

1. Get the piece of 4 x 6 inches from the fabic of all the rolls of sameorder.

2. Sewing it and then wash it3. Get the result and make a report that how much the twist is present in

this fabric.

Fabric inspection for center to side shade:

To inspect the fabric for center to side shade following steps are done

1. Get the piece of full width and 12 inches length.2. Cut it in to 4 equal pieces3. Sewing side part in middle with central part on side4. Send it for wash and then get its results and make a report on shrinkage

and shade changing behavior of the fabric


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Fabric inspection for Gram Square Meter:

To inspect the fabric for gram square meter first we get the piece and cut it inrequired size and weight it in ounces and then convert it in grams. Normally

the weight of denim is in between 8 to 14 ounces and 14 is a good quality and

for twill the value starts from 4 to 9 and 9 is the good quality for twill fabric.

Quality department for cutting inspection:

In cutting department quality department have different task to do which are

Check the fabric layer that layer is according to shade report. Marker is first check by the quality department and then apply on the

fabric

Do line to line checking on cutting but this checking is randomlynearly 10% if fault is miner

Check the number on the cutting and marker randomly Fault caught by cutting department checker wait for the quality

department and asked for approval or rejection

Quality department for sewing inspection:

In sewing department quality department have following task

Receive the cutting report with cutting from cutting Check the feed to sewing department Piece to piece checking on the final checking table Randomly in line checking

Quality department for washing inspection:

In sewing department quality department have following task

Receive the garment report with garment from sewing department


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Check the feed to washing department Piece to piece checking on the final checking table

o Shade wiseo Fashion wise

Randomly in line checking Rejection send back to the washing for rewash

Quality department for finishing inspection:

In finishing department quality department have following task

Receive the washing report with garment from washing department Check the feed to finishing department Piece to piece checking on the final checking table Randomly in line checking

Quality department for MM&C inspection:

In MM&C department quality department have following task

Receive the report with sample from marketing department Check the quality of the before wash and after wash accessories


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Industrial Engineering

General Manager: Fawad Khan DeputyManager: Asif Muzaffar

Job of the posts:



Manager:

Making daily and monthly production efficiency reports Make style bulletins at costing stage Check feasibility of new styles and suggest and monitor garment feasibility at

sampling stage

Training of new time study supervisors Time and motion study of new operations to suggest piece rate Production rating by capacity study Layout setting and making production flow according to new styles Any other assignment given by seniors

Linked Departments

Marketing department (reporting about export import) Finishing department (reporting for the status of order) PPC department (report of order dispatch)


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Department Purpose and Procedures

Industrial engineering is most important in every business especially in production line. Let

start discuss from where it start

Frederick Taylor and Scientific Management

In 1911, Frederick Winslow Taylor published his work, The Principles of Scientific

Management, in which he described how the application of the scientific method to the

management of workers greatly could improve productivity. Scientific management methods

called for optimizing the way that tasks were performed and simplifying the jobs enough so

that workers could be trained to perform their specialized sequence of motions in the one

"best" way.

Prior to scientific management, work was performed by skilled craftsmen who had learned

their jobs in lengthy apprenticeships. They made their own decisions about how their job was

to be performed. Scientific management took away much of this autonomy and convertedskilled crafts into a series of simplified jobs that could be performed by unskilled workers

who easily could be trained for the tasks.

Industrial Engineering is the combination of Engineering plus Business Administration. In

this modern age, Industrial Engineering is the main tool of success that helps boost up

production with quality assurance. Industrial Engineering is about making the best use of

available resources ( man, money, machine, material & methods) to:

a) Increase the productivity

b) Improve the quality

c) Lower the costd) Assure safety of Personal & machines.

e) Create and maintain good working criteria to improve efficiency.

Industrial Engineer applies engineering methods and production plans to produce more

efficient & effective human machine systems. Industrial Engineer makes production lines

more efficient, analyze people, objects flow through system and design work stations that

reduce employees fatigue and accidents. Industrial Engineer coordinates the systems &

processes multifaceted operations to ensure the most efficient flow at an optimum cost.


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The techniques used in carrying out productivity improvement programmers are mostly for

collecting information and increase the effectiveness of work. The methods used fall into two

groups

The technical approach (engineering technique and economic analysis) The human approach (behavior method)

Since most of the techniques are well describe in the literature of the industrial engineering

three well known techniques are as under

Work study:

Work study is a combination of groups of techniques, methods, study and work measurement

which are used to examine peoples work and indicates the factor which effect efficiency.

Work study is normally used in an attempt to increase output from a given quantity of

resouses with little or no further capital investment. This is achieved by systematically

analyzing existing operation process and work methods.

The basic procedure ok work study is as under

Select the job or process to be studied Record from direct observation everything that happen in order to obtain data for

analysis

Examine in turn, the purpose of of the activity, the place it is performed, thesequences in which the element is performed, the person who is doing this

Develop the most economic method, taking into account all the circumstancesmeasure the amount of the work involved in this method used and calculates a

standard time for doing

Define the new method and the related time Install the new method and time as agreed standard practice Maintain the new standard practice by proper control procedures


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Method study:

Method study is also called mention study, method analysis or method engineering is the

systematic recording and critical examination of existing and perposed ways of doing work in

order to develop and apply easier more effective methods and to reduce cost. It is used in

improving processes and procedures, plant layout, design of plant and equipment to reduce

human factor and fatigue, use of material, machine and man power and develop better

physical and working environment. The basic stage of method study is complex technique

that combines several simple tools. The commonly used method study tools are

Analysis of films Emotion photography (memory and motion a way of using film to analysis to film to

analyze)

Micro motion analysis Question technique (general and specific questions which help to indicate purpose,

place, sequence, person, means )

Work measurement:

Work measurement establishes the tome to qualified worker needs to carry out a specified job

at a define level of performance. Whereas method study helps us to eliminate unnecessary

movement help in investigating, reducing and subsequently eliminates in effectives time

during which work is not be performed.

Work measurement also used to set of standard times for carry out work. Thus work

measurement help to

Compare the efficiency of alternative methods Determine the number of machines one can operate or monitor Provide information and using set time standards on which the planning and

scheduling of production can be base

Set standard for the machine use and labor performance


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Provide information on which tender selling prices and delivery promises can bebased

Work measurement provide the basis information necessary for designing, planning,organizing and controlling the work especially in industries where the time element is

important.


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MM&C Department

GM Production: Fawad Khan Manager: Mohammad Suleman

Assistant Manager (M): Safqat Mehmood Assistant Manager (M): Syed Ahsan Raza

Control Incharge (C): Mohammad

Job of the posts:



Manager:

Report to General Manager Operation Take OC (order conformation) from Marketing department. Contact Supplier if there is any kind of problem take place Check on assistant manager and their work

Assistant Manager (M):

Coordinate with manager Receive bill of material from marketing department Generate purchase order and send it to supplier, marketing department, account

department, control assistant Incharge

Receive daily feedback from MM&C control incharge Approved accessories send by the supplier


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Department working criteria:

After getting order conformation, marketing department merchandiser send full details in

specification report and sample of small accessories on trim card with order conformation

letter. After getting these all things assistant manager do number of jobs

Check to the list of the supplier of the related accessory Short list them on company criteria Send them sample and detail to them Negotiate with them on price and quality After negotiation assistant manager generate purchase order (PO) and send it to

o Suppliero Accounts departmento Control inchargeo Main store

Purchase letter is with accessories details and sample. So supplier get following things from

MM&C department

Purchase order Accessories sample and details Time of delivery

The control incharge receive order with delivery challen with same purchase order number.

Some time supplier send the copy of purchase order with delivery challen. Control incharge

count the number of packets and asked item per packets and send a report to main storethrough their software WIZMAN and in which daily report of receiving is generated on daily

basis which is then send to the MM&C assistant manager. Control incharge from MM&C

department take receiving on the register manually and give accessories to them. After

receiving of accessories main store count it if the accessories are short then they send report

to MM&C department. If the shortage is on small level then supplier sends it free of cost

(FOC) otherwise depend on their deal,


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Daily modus operandi (routine): MM&C

39.Update daily receiving report from control incharge40.Contact supplier for delivery41.Handle small problems in accessories42.Generate over all progress report43.Receive daily report from control incharge to get planned target output.44.After check by manager this PO is send to store, control incharge accounts and

PPC departments.

45.Report to General Manager Operation46.Take order conformation (OC) from Marketing department47.Take accessories details and sample on trim card from Marketing department48.

Receive bill of material from marketing department

49.Generate purchase order and send it to supplier, marketing department,account department, control assistant Incharge

50.Receive daily feedback from MM&C control incharge51.Approved accessories send by the supplier


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HR Department

GM HR & Admin: Major(R) Munir Ahmend Awan Deputy Manager: Mian Bashir Ahmed

Assistant Manager : Ibrahim Sabir Executive Officer: Mohammad Mobeen

Job of the posts:


Head of HR & Admin department. Receive report on employee problem, employee recruitment and finalize the report Guide deputy manager Overall checking of the HR & Admin department

Deputy Manager:

Report to General Manager HR & Admin Control issue of the employee like leaves, attendance, pay problem, facility payment Control the issue of recruitment of new employee Check the issue like office problem Check on assistant manager and their work

Assistant Manager:

Coordinate with deputy manager

All the paper work of the office Generation of the notices and work order letter Control time office Control the issue of recruitment of new employee and contact them Make file of daily documents which is send to GM on daily bases Handle security issues Arrange conservation between worker and deputy manager HR Control the issue of EOBI and SSC issue


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Handle the salary issue

Department working criteria:HR department do number of jobs which are defined below

Hiring process Attendance issues Leave and holidays issues Compensation issue Company letter generation Salary issue Loan issue Employee old age benefits issue Social Security Card Worker problem issues Control labor union issues

Hiring Process:

First of all we discuss the hiring process of the company because paramount stitching unit is

divided into two parts production and offices so there are two ways of recruitment of the

employees. First we talk about officers recruitment for these purpose numbers of steps arehere

First add in news paper Collection of CVs Short listing of CVs Interview call and Interview Rating of interview


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Final selection the candidates Appointment letter

Above criteria is for offices employee but when we talk about the worker recruitment there

is no add in newspaper basically worker recruitment reference method is used for this

purpose any employee refer them and the procedure starts

Call the with the reference of company employee Check the skill and take a trail Appointment of the worker

E_ From:

When the hiring process end no matter for officer or worker E_form (employment form) is

generated in which all the details are maintain with the following documents

Copy of national identity card Three photograph of the employee Joining letter Experience letter (if any) Copy of education documents (must for officers and optional for workers)

Attendance issue:

Copy of the joining letter is send to time office for attendance where hand scan is taken for

the daily attendance of the employee by the hand scan machine.

Probation Time:

Probation time is only for the officer employee worker starts their job instantly and observed

by the incharge but for officer employee knows as MT management trainee there is

probation period starts. Normally it may vary from 3 month to 9 month but this depend on

company management CEC (central executive committee) decision to increase it to 1 year


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and decrease it to zero. An induction plan is made for the MT which helps him/her to visit

nominated department within probation time and submit report on these department within

time of probation. This report become the base on which is decided to end the probation time

or increase it. During probation time, if company is not satisfied with employee workingcompany can fire him/her without any advance notice.

Hand Books:

When probation time ends and MT become permanent employee hand book is provided to

him/her to understand company rules and relation and help them to understand different

situation.

Leave Criteria:

According to company rule and regulation there are 1.5 leaves per month so there are 18

leaves in one year which is divided in two portions.

Casual leaves = 10 leaves Sick leaves = 8 leaves

Second kind of leave is annual leaves which are from 14 to 15 days. Third kind of leave is

maternity holidays for women 45 days before and 45 days after. Fourth one is CPL.

CPL (Compensatory leaves):

If someone work in off days then he will CPL. According to rule and regulation

person should use this CPL in three days but due to work load and order availability,

company allow the person to avail it at any time.

Compensation:

When the employee get the job compensation is decided by the management (CEC) like

Car of 800cc, 1000cc,1300c and more Mobile and charges of mobile calls


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Amount of petrol 200 liter, less or moreThis depend on CEC to give them all of this compensation or some or more of them

Fire or Resignation (permanent staff):

When the employee is fired or he/she want to resign clearance form is generated on which

employee need to take sign from different department like

Human recourse Head of department Canteen Store Security Time Office Cashier

Employee must give notice one month before. Company cut the salary of month as per

company defined rules. If employee spend more than one year them company give him/her

one month salary so this salary equalize the deduction of the salary, if employee more the 2

years then the formula is

Net Salary = salary*number of year - one month salary deduction

Company Letter:

There are two types of company letter

Warning letter Appreciation letter


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Warning letter:

During job if the employee is not taking interest in work and do not give its required

output them he/she got warning letter to improve its work.

Appreciation letter:

If employee show good interest in work and give more than required than he got

appreciation letter which also save in its file which help him in promotion.

EOBI (employee old age benefits Institute):

When employee joins the company generates EOBI (employee old age benefits institute)file

which pay pension to employee when he is more than 60 years. For EOBI company pay 300rupee and 60 rupee is paid from the employee pay.

SSC (Social Security Card):

Basically it is a medical card for the employee. Employee is eligible for this card when

his/her pay is more than 10000 rupees this card is also facilitate wife, children and parents of

the employee. Company pay all the expenses for SSC.

Salary:

Minimum salary of the worker is according to government rule which is 6000 rupee and for

the managerial level on upper level then worker pay is decided by CEC. The net salary is

calculated by following formula

First hand scan is calculated by machine Leaves and CPL added manually Then formula

Gross salary = (salary/days of the month)*no. of working days Then different kind of charges are minus from the gross salary like

o Income Taxo EOBI chargeso Breakage (if any)o Absents charges (if any)o Loan


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After minus these charges net salary is send to the accounts department If salary is more then 15000/= then pay is transfer to employee account and if salary is

less than 15000/= then employee take it by hand.

Worker Problem Solutions:

HR also handle the problem of labor unions and make budgets for ramazam, overtime food

and their transport.

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Final Report to Company

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