TABLE OF CONTENTS

SL NO. CONTENTS PAGE NO.

PROJECT-I

1 Project Objective 6

2 Project Analysis 7

3 Visual Roadmap of project execution 8

4 Project Overview 9

5 Flowchart for the approach towards Project 10

6 Project Scheduling 11

7 Problem Background 12

8 Greige Fabric Working Methodology 13

9 Shrinkage data Analysis 14

10 Greige Fabric Analysis 15

11 Record keeping & Data generation 16

12 Results & Findings 29

13 Variation in Quantity 32

14 Final Outcome 33

15 Store Space Analysis & details 34

16 Background of problem 36

17 Actual space & capacity observations 39

18 Changes Proposed 44

19 Expected Outcome 48

20 Conclusion 51

APPAREL INTERNSHIP REPORT 2019 | MODELAMA EXPORTS

 PROJECT-II

21 Project Introduction 53

22 Approach Adoption to Methodology 54

23 Project Objective 56

24 Structural Flowchart 57

25 Background Research 58

26 Internal Capacity Planning 61

27 Brand study 62

28 Implementation Strategies 63

29 Competitor Analysis 64

30 What’s so different about ZABT 66

31 Expected outcome 69

32 Launch Details 72

APPAREL INTERNSHIP REPORT 2019 | MODELAMA EXPORTS

 PROJECT REPORT –I

Reducing Fabric wastage by evaluating Shrinkage

&
Streamlining the flow of goods & information

APPAREL INTERNSHIP REPORT 2019 | MODELAMA EXPORTS

 PROJECT OBJECTIVE

Target area of project : Fabric Store Department

Primary Objective of the Evaluation, up gradation, utilization and systemization of the

project: fabric store towards more cost effective steps.

-According to their shrinkage given &

received
Evaluation of greige - Wastage analysis
fabric - Supplier’s trend
- Cost analysis

-Vendor management
-New SOP’s
Up gradation of -More online work than manual work
Secondary Objective : internal working -Single destination & single information
system flow

-Modular space management technique to

be implemented
-Maximum accommodation of the
inventory with proper management to
minimise the lead days
Utilization of space - Proper mapping & planning of goods
&manpower inwards and out ward movements
- Manpower allocation and management to
get the best with minimum requirement

-Required proper indexing which will

allows the flexibility of planning the
capacity utilization in advance
Systemization -Establishing optimum inventory level
- Visibility board for clear indication of the
in-house stock
- Kanban library& visual tool
implementation for allocation &
identification of goods.

APPAREL INTERNSHIP REPORT 2019 | MODELAMA EXPORTS

 PROJECT ANALYSIS

-Tracking the fabric to fabric as well

as supplier to supplier shrinkage
variations
- Received and actual quantity
variations
Greige goods tracking: - Manage lead time to provide 100%
inspection
-New policy for fabric shrinkage
according to the supplier
-Present space
-present capacity
Analysing part : Actual space and capacity -present available space
observation: -area/ scope of expansion
- layout analysis & its potential laid
-Present manpower designated for the
fabric store
-Their present job task
-Profile assigned to each
Manpower status -manpower requirement
-Identifying the scope of utilization
-Find the positive as well as negative
Exploring present aspects of the present ERP system
information flow system - Certain work data entry
and its response - Report transparency ,authenticity
and its circulations
-Accessibility of goods record

APPAREL INTERNSHIP REPORT 2019 | MODELAMA EXPORTS

 VISUAL ROADMAP OF PROJECT EXECUTION

APPAREL INTERNSHIP REPORT 2019 | MODELAMA EXPORTS

 PROJECT OVERVIEW

PROJECT BRIEF
This project is all about evaluating Greige fabric and eliminating the wastage problem based
on shrinkage analysis. This project would even encompass streamlining the process flow
activities carried out in the fabric store department so that the inefficient time can be reduced.

PROJECT LOCALE

Fig 1.a Plot-105/106, Modelama Exports Ltd, Gurgaon, Haryana

SIGNIFICANCE OF THE PROJECT

Most of the factories in India still are not aware of how much shrinkage (%) occurs in which
fabric. These are only known to fabric mills where these fabric is been sent for processing. Due
to this sometimes the fabric mills take advantage and demand a large sum of money for
processing of fabric. This creates loss for the organisation in terms of money as well as fabric
wastage.

APPAREL INTERNSHIP REPORT 2019 | MODELAMA EXPORTS

 FLOWCHART FOR THE APPROACH TOWARDS PROJECT

• Problem & Waste Indentification

STEP 1

• Analysis of shrinkage data (based on fabric mills)

STEP 2

• Study on on-going process (Greige Fabric)

STEP 3

• Record keeping & data generation

STEP 4

• Result & Findings

STEP 5

• Final Outcome
STEP 6

APPAREL INTERNSHIP REPORT 2019 | MODELAMA EXPORTS

 PROJECT SCHEDULING

TASK DURATION
TASK DESCRIPTION START DATE END DATE
NO. (in days)

Detailed observation on markings done on

1 27th May, 19 8th June,19 12
Greige fabric

Analysis & manual records maintained on

2 10th June,19 6th July,19 24
processed fabric

3 Report generation based on study details 24th June,19 6th July,19 12

4 Results & Findings 8th July,19 10th July,19 3

Meetings & discussions with higher

5 10th July,19 13th July,19 4
management

Final outcome after decision - taking

6 15th July,19 20th July,19 6
procedure

APPAREL INTERNSHIP REPORT 2019 | MODELAMA EXPORTS

 BACKGROUND OF PROBLEM

 Fabric Wastage
 Shrinkage Variation (Given Vs. Received)
 Absence of tracking the flow of Greige & Processed fabric

FABRIC WASTAGE
After evaluating the Processed fabric, it was observed that no internal records were kept to
track the actual shrinkage of processed fabric. Modelama Exports rely on their fabric mill
suppliers report for shrinkage due to which absence of internal records created enormous
amount of fabric wastes.

SHRINKAGE VARIATION (GIVEN Vs. RECEIVED)

Since Modelama was totally dependent on their fabric mill suppliers, this problem always arise.
What percent shrinkage was demanded by these mills were provided to them and in return the
processed shrinkage result always varies fabric –fabric & mill-mill. Even a slight variation can
cost a large sum to the company.

ABSENCE OF TRACKING THE FLOW OF GREIGE & PROCESSED FABRIC

After observing the document flow structure of the fabric store, there was no effective tracking
method of griege fabric which provided the details regarding the number of rolls along with
their particular metres sent to the mills and was received after processing. As a result Modelama
was unable to maintain records whether all the griege fabric have been received or not.

APPAREL INTERNSHIP REPORT 2019 | MODELAMA EXPORTS

 Greige Fabric Working Methodology

Work on the existing norms for the process shrinkage given to the supplier according to the fabric type, along
with the 100cm marking

Comparing the greige fabric and processed fabric reports, which concluded that the process shrinkage we give
is more than the actual shrinkage we received

Plus the fabric we received is exact to the PO we have generated on the basis of our shrinkage norms , but the
actual fabric we should received is as per the actual shrinkage of the fabric

As per the supplier’s those fabrics has been consumed for the initial starting of the batch as the wastage fabric
but we also provide the extra wastage amount for that process

Prepare a new SOP’s for the greige as well as processed fabric inspection and for the testing. Also
development of new norms for the process shrinkage on the basis of the supplier as well as on the fabric type

Will also propose the technique of defect marking for certain meters and send for the processing to avoid
the statement of fabric defected wastages by the supplier

Greige fabric allocations as per the space and set targets & workflow of the greige fabric

Will achieve to save fabric as well as cost, plus will help to make process more systematic and transparent
which would help to identified the problem concerned areas

APPAREL INTERNSHIP REPORT 2019 | MODELAMA EXPORTS

 SHRINKAGE DATA ANALYSIS
(Based on Fabric Mills)

CURRENT DYEING PRICE LIST MODELAMA

Shrinkage for Shrinkage for

Quality Width Price white Dyed

White
with 5001 5001 Residual
S Mursarize 800 - to 800 - to After
No Quality G/Width C/Width / Singing Light Med Dark 5000 above 5000 above Iron

C/Voil /
1 Cambric 63" 52' 10.00 19.00 19.00 20.00 5%+L 5%+L 5%+L 5%+L 3%

2 Poplin 63" 52" 15.00 20.00 21.00 23.00 5%+L 5%+L 5%+L 5%+L 3%
60's Modal/
30's Rayon /
Rayon Moss -
Dobbies (flat
3 dyeing) 63" 52" 12.00 19.00 20.00 22.00 12%+L 12%+L 12%+L 12%+L 5%
30's Rayon
Moss /
Dobbies ( Soft
4 Flow) 63" 44- 50 " 12.00 19.00 20.00 22.00 15%+L 15%+L 15%+L 15%+L 5%

Rayon Crape (
5 Line Dry ) 63" 46" 12.00 19.00 20.00 22.00 18%+L 18%+L 18%+L 18%+L 5%

Actual
60's Cambric no. of
6 Schiffly 63" 48" 15.00 20.00 23.00 25.00 than 5%

Viscose GGT (
7 Flat finishing ) 63" 46" 12.00 19.00 20.00 22.00 22%+L 22%+L 22%+L 22%+L 5%

Viscose GGT (
boota dana
8 GGT ) 63" 46" 12.00 19.00 22.00 24.00 23%+L 23%+L 23%+L 23%+L 5%

9 Cotton Twill 63" 53' 20.00 25.00 28.00 30.00 5%+L 4%+L 4%+L 3%+L 5%

10 Relly 63" 53' 14.00 19.00 21.00 24.00 24%+L 24%+L 24%+L 24%+L 5%

11 kelly 63" 53' 14.00 19.00 21.00 24.00 21%+L 21%+L 21%+L 21%+L 5%

APPAREL INTERNSHIP REPORT 2019 | MODELAMA EXPORTS

 GREIGE FABRIC ANALYSIS

Before the initiation of this project, the records that were maintained was only the overall
number of Rolls sent to the fabric mills for processing along with their metres and was kept in
a record book known as “PACKING SLIP”.
After detailed examination, it was observed that the fabric store was unaware of how much
fabric was consumed by fabric mills in the name of shrinkage & wastage.
NEW-METHOD IMPLEMENTATION:
To overcome this problem, markings were done during the Greige fabric inspection stage so
that when the processed fabric will be received from the sent mills, proper inspection of
shrinkage & wastage can be calculated easily.
This new implemented method will make fabric store aware on how much shrinkage they are
actually receiving from the fabric mills and wastage can be calculated accordingly.
MARKINGS ON GREIGE FABRIC:
For shrinkage inspection:
 Markings of 1 metre at every 10 metre at both sides on selvedge.

For wastage calculations:

 Markings at every 40 metre on selvedge.

Details are mentioned on selvedge of Fabric Roll:

Roll No. Total metre of particular Count/Construction/Width Name of

fabric checker

FIG 1 b : Markings on Selvedge of Greige Fabric

APPAREL INTERNSHIP REPORT 2019 | MODELAMA EXPORTS

 FIG 1(a): Markings at Selvedge (Greige Fabric)
RECORD KEEPING & DATA GENERATION

Total 5 articles were analysed and records were maintained in excel sheet of Greige fabric and
Processed fabric.

ARTICLE 1: COTTON VOILE

FIG 1(c): Cotton Voile (Greige & Processed)

Article (Greige) : 100% Cotton Voile (70*90-92*104) Size/Width: 63 Inch

Article (Finished) : 100% Cotton Voile (70*90-104*104) Size/Width: 42 Inch
Colour : White Process Order No: 22197 Challan No : 32611
Style : Supplier :
W 1950L 11TP-WOMAN Buyer : RALPH Color Fabs Pvt. ltd.

Total Qty. Sent: 3023.90 Total Qty. Received : 2886 Total Qty. Left : 8
Wastage
Qty. Shrinkage (%)
(in mtr) Width (in Inch) (%)
Than Than Roll No. of
No. Qty. No. Sent Rec. Joints Greige Given Rec. Sent Rec

3 140 84
1 131.5 24 276.8 40.5 1 63 62 52 5 1 4
11 140.7 114
12 43 42.4
2 168 20 20.8 13.7 2 63 62 52 5 1 4
24 27 8.5
8 64.5 64
3 226 15 199.1 199.1 2 63 62 52 5 0,1 4,5
4 216 24 276.8 216 0 63 62 52 5 1 4
23 178.1 29.5
5 148 6 169 118.5 1 63 62 52.5 5 1 4
6 146 20 20.8 5.5 1 63 62 52 5 1 4

APPAREL INTERNSHIP REPORT 2019 | MODELAMA EXPORTS

 23 178.1 140.5
10 166.6 115.2
7 172 7 98.8 57 1 63 62 52 5 1 4
8 172 22 232.2 172 0 63 62 52 5 1 4
9 159.3 150.5
9 200 10 166.6 49.5 1 63 62 52.5 5 1 4
10 150 21 181.4 150 0 63 62 52 5 1 4
4 72.4 57
18 105 104.3
11 188 11 140.7 24.7 2 63 62 52 5 1 4
19 95.3 88
12 159 14 81.3 71 1 63 62 52 5 1 4
22 232.2 16
2 95.7 94
13 164 3 140 54 2 63 62 52 5 1 4
15 199.1 43
16 118.4 117
14 170 14 81.3 10 2 63 62 52 5 0,1 4,5
6 169 47.8
25 97.7 96.4
15 186 22 232.2 41.7 2 63 62 52.5 5 1 4
5 148.4 122.8
16 139.2 4 72.4 14.5 1 63 62 52 5 1 4
7 98.8 41.5
13 86.9 86
17 148 5 148.4 20.5 2 63 62 52 5 1 4
Total 2886

After the records were maintained in excel sheets, further observations were made:

Given shrinkage: 5% Actual shrinkage: 1%

Max. No. of Joints : 2 Min. No. of Joints : 0

Min. Than Qty. : 131.50 Max. Than Qty. : 226.0 Average Calculated : 178.75

Min. Roll Qty. Attach : 5.50 Max. Roll Qty. Attach : 216 Average Calculated : 110.75

APPAREL INTERNSHIP REPORT 2019 | MODELAMA EXPORTS

 After our observations, calculations were done to get the knowledge of fabric consumption by
these mills after processing.
STEPS FOR PERFORMING CALCULATIONS:
I. Records checking based on total amount of Rolls sent vs. Rolls received.
II. Shrinkage inspection based on markings (Given vs. Received).
III. Fabric-loss calculations on the basis of fabric with actual shrinkage received.

Article (Greige) : 100% Cotton Voile (70*90-92*104) Size/Width: 63 Inch

Article (Finished) : 100% Cotton Voile (70*90-104*104) Size/Width: 42 Inch
Colour : White Process Order No: 22197 Challan No. : 32611
Style : Supplier:
W 1950L 11TP-WOMAN Buyer : RALPH COLOR FABS PVT. LTD.
Total Qty. Left :
Total Qty. Sent: 3023.90 Total Qty. Received : 2886 8

Total No. Of Rolls Sent : 24 Total No. of Than Received : 17

Shrinkage Fabric received

Roll No. Sent Rec. Left Sent Rec 5% 1% Wastage

2 95.7 94 1.7 5.00% 1% 90.95 94.74 0.74
3 140 138 2 5.00% 1% 133 138.6 0.6
4 72.4 71.5 0.9 5.00% 1% 68.78 76.67 0.17
5 148.4 145.2 3.2 5.00% 1% 140.98 146.91 1.71
6 169 166.3 2.7 5.00% 1% 160.55 167.31 1.01
7 98.8 98.5 0.3 5.00% 1% 93.86 97.81 2.31
8 64.5 64 0.5 5.00% 1% 61.27 63.85 +0.15
9 159.3 150.5 8.8 5.00% 1% 151.33 157.7 7.2
10 166.6 164.7 1.9 5.00% 1% 158.27 164.93 0.23
11 140.7 139.7 1 5.00% 1% 133.66 139.29 +0.41
12 43 41.4 1.6 5.00% 1% 40.85 42.57 1.17
13 86.9 86 0.9 5.00% 1% 82.55 86.03 0.03
14 81.3 81 0.3 5.00% 1% 77.23 80.48 +0.52
15 199.1 196.5 2.6 5.00% 1% 189.14 187.1 0.6
16 118.4 117 1.4 5.00% 1% 112.48 117.21 0.21
17 52.5 NYR NYR 5.00% 1% 49.875 51.97 52.5
18 105 104.3 0.7 5.00% 1% 99.75 103.95 +0.35
19 95.3 88 7.3 5.00% 1% 90.53 94.34 6.34
20 20.8 19.2 1.6 5.00% 1% 19.7 20.59 1.39
21 181.4 150 31.4 5.00% 1% 172.33 179.58 29.58
22 232.2 229.8 2.4 5.00% 1% 220.59 229.8 0
23 178.1 170 8.1 5.00% 1% 169.19 176.31 6.31
24 276 267 9 5.00% 1% 262.2 273.24 6.24
25 97.7 96.4 1.3 5.00% 1% 92.81 96.72 0.32
TOTAL 3023 2879 2871.7 2987.7 118.66

APPAREL INTERNSHIP REPORT 2019 | MODELAMA EXPORTS

 ARTICLE 2: 100% VISCOSE

FIG 1(d): 100% Viscose (Greige & Processed)

Article (Greige) : 100% viscose (40-2/40X40-92X72) - Size/Width: 63 Inch

Article (Finished) : 100% viscose (40-2/40X40-104X72) -Size/Width: 42 Inch

Colour : Ecru, Mehroon, Black, Navy Process Order No: 22379

Style : 14.910.11.2371 Buyer : INC Supplier: Jain Cord Industries PVT. LTD.
Total Qty. Sent: 1809.1 metre Total Qty. Received : 1674.7 metre
Qty. (in metre) Width (in Inch) Shrinkage (%)
Than Than Roll No. of
Give
No. Qty. No. Sent Rec. Joints Greige Rec. Sent Rec.
n
7%,6
20 130.8 23 63" 62" 56.5" 12% %
11 80 1
8 65 57 63" 62" 56.5" 12% 7%
12 57 41 79.6 57 0 63" 62" 56" 12% 7%
46 119.5 103 63" 62" 56.5" 12% 6%
1 111 No roll number 1 63" 62" 7%
8 56.5" 12%
63" 62" 7%
41 79.6 11 63" 62" 56.5" 12% 7%
10 70 1
33 126.3 59 63" 62" 56.5" 12% 7%
10 59.5 47 63" 62" 56.5" 12% 7%
9 102 1
1 80.4 55 63" 62" 56.5" 12% 7%
No roll number 63" 62"
56.5" 12%
10 63" 62" 7%
8 138 2
24 85.4 80 63" 62" 56.5" 12%
11 79.8 48 63" 62" 56.5" 12%
19 120 91.6 63" 62" 56.5" 12% 7%
7 124 1
23 120.5 32.4 63" 62" 56.5" 12% 7%
1 80.4 17 63" 62" 56.5" 12% 7%
6 70 1
4 86.2 53 63" 62" 56.5" 12% 7%
23 120.5 80 63" 62" 56" 12% 7%
4 162 1
3 94.4 82 63" 62" 56" 12% 7%
22 84.5 71 63" 62" 56" 12% 7%
2 138 1
25 102.3 67 63" 62" 56" 12% 7%
3 132 20 130.8 96.5 1 63" 62" 56" 12% 7%

APPAREL INTERNSHIP REPORT 2019 | MODELAMA EXPORTS

 11 79.8 35.5 63" 62" 56" 12% 7%
25 102.3 29.5 63" 62" 56" 12% 7%
6 84.3 79.5 63" 62" 56" 12% 7%
5 165 3
7 30.2 28.3 63" 62" 56" 12% 7%
4 86.2 26.5 63" 62" 56" 12% 7%
5% &
2 65 56 89 65 0 63" 62" 55" 12%
4%
49 92.3 87.5 63" 62" 12%
4%/4.
1 180 57 45.3 43 2 63" 62" 55.5" 12%
5%
53 54.5 49.3 63" 62" 12%
4 51 48 85 51 0 63" 62" 55.5" 12% 5%
35 101.6 16 63" 62" 12%
3 104 1 55.5" 5%
52 128 88 63" 62" 12%
35 101.6 73.3 63" 62" 12%
48 85 21.4 63" 62" 12%
101.5 No roll 2 4%/4.
5 63" 62" 55.5" 12% 5%
numbe 7
r 63" 62" 12%
No roll 63" 62" 12%
numbe 7
63" 62" 12%
r
5%/4
6 100 56 89 12.5 2 63" 62" 55" 12% %
No roll 63" 62" 12%
numbe 80.5
r 63" 62" 12%
18 61 57.5 63" 62" 12% 4%/5
7 119 1 55"
34 71.7 61.5 63" 62" 12% %
1 88 51 107.5 88 0 63" 62" 55.5" 12% 4%
15 88.9 35.2 63" 62" 54.5"/55 12% 6%/7
2 109.5 1
55 100 73.3 63" 62" " 12% %
50 84.7 79.6 63" 62" 12% 5%/6
3 101.2 1 54.5"
55 100 21.5 63" 62" 12% %
5%/6
4 95.8 21 99.8 95.8 0 63" 62" 54.5" 12%
%
53.5"/54
5 67.2 42 68.7 67.2 0 63" 62" 12% 5%
"
6%/7
6 70 17 79.2 79.2 0 63" 62" 55" 12%
%
15 88.9 49.05 63" 62" 12% 4%/5
7 117.5 1 54.5"
54 72.2 67.75 63" 62" 12% %
4%/5
8 82 43 102.1 82 0 63" 62" 54.5" 12%
%
54"/54.5 4%/5
9 65.6 5 71 65.6 0 63" 62" 12%
" %
4%/6
10 102 9 107.2 102 0 63" 62" 54" 12% %
11 102 47 115 102 0 63" 62" 55" 12% 8%
12 52 40 59 52 0 63" 62" 54" 12% 5%
13 72 31 90.8 72 0 63" 62" 54" 12% 4%

APPAREL INTERNSHIP REPORT 2019 | MODELAMA EXPORTS

 29 58.6 50 63" 62" 12%
14 85 1 54" 5%
39 84.6 32 63" 62" 12%
12 60 51.5 63" 62" 12%
1 124 1 5%
32 116.7 72.5 63" 62" 55" 12%
63" 62" 12%
2 100 44 118.9 100 0 5%/6
63" 62" 55" 12% %
63" 62" 12%
3 16 105.4 77 63" 62" 55" 12%
63" 62" 12%
138.5 1
5%/6
63" 62" 12%
45 121.8 %
61.5 63" 62" 12%
4 95 14 115.3 95 0 63" 62" 55" 12% 5%
5 37.5 13 106.4 37.5 0 63" 62" 55" 12% 6%
16 105.4 20.7 63" 62" 12% 5%/6
6 136 55"
26 115.5 102 63" 62" 12% %
2
No roll No roll
10.5 63" 62" 12%
no no
7 86.4 28 99.4 86.4 0 63" 62" 55" 12% 5%
17 94.5 51.4 2 63" 62" 12%
5%6%
8 142 28 99.4 8.5 63" 62" 55" 12% 7%
38 87.6 81.5 63" 62" 12%
No roll No roll
9 40 40 0 63" 62" 55" 12% 6%
no no
10 82 37 90.2 82 0 63" 62" 55" 12% 5%
11 74.5 2 108 74.5 0 63" 62" 55" 12% 6%
12 32.5 17 94.5 32.5 0 63" 62" 55" 12% 6%
13 66 30 71.7 66 0 63" 62" 55" 12% 6%
14 61.5 13 106.4 61.5 0 63" 62" 55" 12% 5%
15 84 36 102.7 84 0 63" 62" 55" 12% 5%
Total 4654 4654

APPAREL INTERNSHIP REPORT 2019 | MODELAMA EXPORTS

 AFTER CALCULATIONS:

Article (Greige) : 100% viscose (40-2/40X40-92X72) - Size/Width: 63 Inch

Article (Finished) : 100% viscose (40-2/40X40-104X72) -Size/Width: 42 Inch
Colour : Ecru,Mehroon,BlackNavy Process Order No: 22379
Style : 14.910.11.2371 Buyer : INC Total no. of thans received = 15
Total no. of rolls sent =58 Supplier : Jain Cord Industries PVT. LTD.
Metres as per 6%
ROLL NO. SENT RECVD 12% Shrinkage FABRIC LOSS
1 80.4 72 70.752 75.576 3.576
2 108 74.5 95.04 101.52 27.02
3 94.4 82 83.072 88.736 6.736
4 86.2 79.5 75.856 81.028 1.52
5 71 65.6 62.48 66.74 1.4
6 84.3 79.5 74.184 79.242 0.25
7 30.2 28.3 26.576 28.388 0.08
8 65 57 57.2 61.1 4.1
9 107.2 102 94.336 100.768 1.23
10 50 47 44 47 0
11 79.8 83.5 70.224 75.012 8.488
12 60 51.5 52.8 56.4 4.9
13 106.4 99 93.632 100.016 1.016
14 115.3 95 101.464 108.382 13.38
15 88.9 84.25 78.232 83.566 0.684
16 105.4 97.7 92.752 99.076 1.376
17 79.2 79.2 69.696 74.448 4.752
18 61 57.5 53.68 57.34 0.16
19 120 91.6 105.6 112.8 21.2
20 130.8 119.5 115.104 122.952 3.45
21 99.8 95.8 87.824 93.812 1.98
22 84.5 71 74.36 79.43 8.43
23 120.5 112.4 106.04 113.27 0.87
24 85.4 80 75.152 80.276 0.276
25 102.3 96.5 90.024 96.162 0.338
26 115.5 102 101.64 108.57 6.57
27 94.5 83.9 83.16 88.83 4.93
28 99.4 94.9 87.472 93.436 1.46
29 58.6 50 51.568 55.084 0.084
30 71.7 66 63.096 67.398 1.39
31 90.8 72 79.904 85.352 13.35
32 116.7 72.5 102.696 109.698 37.19

APPAREL INTERNSHIP REPORT 2019 | MODELAMA EXPORTS

 33 126.3 59 111.144 118.722 59.72
34 71.7 61.5 63.096 67.398 5.89
35 101.6 89.3 89.408 95.504 6.204
36 102.7 84 90.376 96.538 12.538
37 90.2 82 79.376 84.788 2.788
38 87.6 81.5 77.088 82.344 0.844
39 84.6 32 74.448 79.524 47.524
40 59 52 51.92 55.46 3.46
41 79.6 68 70.048 74.824 6.824
42 68.7 67.2 60.456 64.578 2.622
43 102.1 82 89.848 95.974 13.974
44 118.9 100 104.632 111.766 11.766
45 121.8 61.5 107.184 114.492 52.92
46 119.5 103 105.16 112.33 9.33
47 111.5 102 98.12 104.81 2.81
48 85 72.4 74.8 79.9 7.5
49 92.3 87.5 81.224 86.762 0.74
50 84.7 79.6 74.536 79.618 0.018
51 107.5 88 94.6 101.05 13.05
52 128.1 88 112.728 120.414 32.414
53 54.5 49.3 47.96 51.23 1.93
54 72.2 67.75 63.536 67.868 0.11
55 100.1 94.8 88.088 94.094 0.706
56 89 77.5 78.32 83.66 6.16
57 45.3 43 39.864 42.582 0.418
58 121 0 106.48 113.74 113.74
TOTAL 598.196

NOT YET RECEIVED

> 10 MTR

APPAREL INTERNSHIP REPORT 2019 | MODELAMA EXPORTS

 ARTICLE 3:
100% VISCOSE KELEY CREPE(S-Z)

Article (Greige) : 100% Viscose (S-Z) Keley Crepe Size/Width: 63Inch

Article (Finished) : 100% Viscose (S-Z) Keley Crepe Size/Width: 47Inch
Print : Disty Print Process Order No: 125489

Style : 560227 Buyer : NEXT Supplier : TEX SHADOW PVT. LTD.

Total Qty. Sent: 3062.3772 Total Qty. Received : 2358.0305
Qty. (in mtr) Width (in Inch) Shrinkage (%) Wasta
Than Than Roll No. of Greig Give ge
No. Qty. No. Sent Rec. Joints e n Rec. Sent Rec. (%)
32 330 43
1 80 33 301 36 1 63 63 50.5 20 16,17 3,4
38 366 60.5
39 341 16.2
2 123 43 459.5 46 2 63 63 50.5 20 15,18 3,5
34 483 46.6
3 91 43 459.5 44.4 1 63 63 50.5 20 16,18 2,4
4 74 37 565 75 0 63 63 50.5 20 15 5
5 81 34 483 81 0 63 63 50.5 20 16 4
32 330 24.75
6 46.5 34 483 20.25 1 63 63 50.5 20 16 4
7 58 32 330 58 0 63 63 50.5 20 15 5
8 80 33 306 80 0 63 63 50.5 20 17 3
9 71 57 394 71 0 63 63 50.5 20 15 5
10 64 39 341 64 0 63 63 50.5 20 17 3
34 483 23.25
11 67 43 459.5 45.5 1 63 63 50.5 20 15,18 2,5
37 565 47.5
12 98 43 459.5 50.25 1 63 63 50.5 20 16 4
13 73 34 483 73 0 63 63 50.5 20 16 4
14 91 43 459.5 27.25 3 63 63 50.5 20 14,15,16 4,5,6

APPAREL INTERNSHIP REPORT 2019 | MODELAMA EXPORTS

 No roll
number 13.75
No roll
number 4.75
43 459.5 45.25
30 255 44
15 113 39 341 68 1 63 63 50.5 20 15,16 4,5
30 255 28.3
33 301 16.3
39 341 45.5
16 114 33 301 22.5 3 63 63 50.5 20 13,15,17 3,5,7
32 330 33.6
17 76 33 301 41.1 1 63 63 50.5 20 16 4
30 255 41
18 85.5 39 341 46.3 1 63 63 50.5 20 15,17 3,5
19 61 32 330 61 0 63 63 50.5 20 14 6
30 255 46.3
20 93 32 330 46.7 1 63 63 50.5 20 15 5
34 483 37.5
21 65 37 565 28.6 1 63 63 50.5 20 13,14 6,7
84 34 483 31
43 459.5 47.9
No
Roll
22 No 6 2 63 63 50.5 20 14,18 2,6
23 55 34 483 53.2 0 63 63 50.5 20 15,18 2,5
81 37 565 34
24 43 459.5 47 1 63 63 50.5 20 14,15 5,6
79 32 330 21
33 301 40
25 38 366 18 2 63 63 50.5 20 15 5
91 30 255 46.6
26 38 366 44.4 1 63 63 50.5 20 17 3
88 37 565 42
27 47 339 46.8 1 63 63 50.5 20 16,17 3,4
28 68.5 34 483 68.5 0 63 63 50.5 20 16 4
29 62 38 366 62 0 63 63 50.5 20 18 2
78 39 341 34.4
30 57 394 43.6 1 63 63 50.5 20 16 4
64 37 63
31 63 63 50.5 20 15 5

APPAREL INTERNSHIP REPORT 2019 | MODELAMA EXPORTS

 No
Roll
10 No 8.25
No
Roll
32 No 2.4 1 63 63 50.5 20 No Mark
2465.5 2463.95

AFTER CALCULATIONS:

Max. No. of Joints : 3 Min. No. of Joints : 0

Max. Than Qty. : 123

Min. Than Qty. : 10 Average Calculated : 77.04
Max. Roll Qty. Attach
Min. Roll Qty. Attach : 255 : 565 Average Calculated : 383.35

Roll Qty. (in mtr.)

Roll No. Sent Rec. Left Wastage (%) Shrinkage (%)

30 255 206.2 48.8 19.14% 15%/16%
32 330 290.05 39.95 12.11% 15%/16%
33 301 239.9 61.1 20.30% 15%/16%
34 483 437.3 45.7 9.46% 15%/16%
37 565 291 274 48.50% 15%/16%
38 366 184.9 181.1 49.48% 15%/16%
39 341 274.4 66.6 19.53% 15%/16%
43 459.5 353.55 105.95 23.06% 15%/16%
47 339 46.8 292.2 86.19% 15%/16%
57 394 114.6 279.4 70.91% 15%/16%

Color Codes

< 5 Mtr. & > 20 Mtr.

>20 Mtr.
Not yet Received

APPAREL INTERNSHIP REPORT 2019 | MODELAMA EXPORTS

 ARTICLE 4: COTTON SHEETING

Article (Greige) : 100% COTTON-SHEETING (30 X 30- 68 X 68) Size/Width: 63 Inch

Article (Finished) : 100% Cotton SHEETING (30 X30 - 80 X 68) Size/Width: 42 Inch
Colour : TANK Process Order No: 22379

Style : MEPL26877(100082722) Buyer : INC Supplier : Jain Cord Industries PVT. LTD.
Total Qty. Sent: 1809.1 mtr. Total Qty. Received : 1674.7 mtr.
Than Than Roll Qty. (in mtr) No. of Width (in Inch) Shrinkage (%)
No. Qty. No. Sent Rec. Joints Greige Given Rec. Sent Rec.
14 103.3 15.6 63 62 51 5% (+)2%
1 111.8 14 103.3 83.5 2 63 62 50.5 5% (+)2%
7 101 4.1 63 62 51 5% (+)6%
2 74 9 73 74 0 63 62 50.5 5% (+)4%
3 152 8 151 149 0 63 62 51 5% (+)7%
5 56 54.4 63 62 51 5% (+)6%
4 111.5 1
16 62.8 54 63 62 51 5% (+)6%
5 103.5 15 102.8 103.5 0 63 62 51 5% (+)4.5%
6 101 7 101 101 0 63 62 51 5% (+)6.5%
7 156.2 1 153.5 156.2 0 63 62.5 50.5 5% (+)5%
12 102 14 63 62 50.5 5% (+)3.5%
8 115.5 1
17 102.4 101.2 63 62 (+)4%
9 60 12 102 60 0 63 62 50.5 5% (+)4%
10 100.5 18 102.7 103.5 0 63 62 50.5 5% (+)4.5%
96 23.6 63 62 51 5% (+)5%
11 90 1
96 65.3 63 62 50.5 5% (+)3%
12 102 2 102 102 0 63 62.5 51 5% (+)6.5%
10 88.3 91.2 63 62 50.5 5% (+)6%
13 197.2 1
11 101.5 106 63 62 5% (+)6%
14 103 13 101.2 103 0 63 62 50.5 5% (+)6%
15 103.5 4 101.6 103.5 0 63 62 51 5% (+)5.5%
16 97.8 3 103 95 0 63 62 51 5% (+)6%

APPAREL INTERNSHIP REPORT 2019 | MODELAMA EXPORTS

 Max. No. of Joints : 2 Min. No. of Joints : 0
Min. Than Qty. : 60 Max. Than Qty. : 197.2 Average Calculated : 111.2

Min. Roll Qty. Attach : 4 Max. Roll Qty. Attach : 156.2 Average Calculated : 80.2

AFTER CALCULATIONS:

Article (Greige) : 100% COTTON-SHEETING (30 X 30- 68 X 68) Size/Width: 63 Inch

Article (Finished) : 100% Cotton SHEETING (30 X30 - 80 X 68) Size/Width: 42 Inch
Colour : TANK Process Order No: 22379

Supplier: Jain Cord Industries PVT.

Style : MEPL26877(100082722) Buyer : INC LTD.
Total no.of rolls sent =18 Total no.of thans received = 16
ROLL NO. SENT RECVD 5% shrinkage 6% stretch FABRIC LOSS
1 153.5 156.2 145.825 162.71 6.51
2 102 102 96.9 108.12 6.12
3 103 95 97.85 109.18 14.18
4 101.6 103.5 96.52 107.696 4.1
5 56 54.4 53.2 59.36 4.96
6 101 0 95.95 107.06 107.06
7 101 105.1 95.95 107.06 1.96
8 151 149 143.45 160.06 11.06
9 73 74 69.35 77.38 3.38
10 88.3 91.2 83.885 93.598 2.4
11 101.5 106 96.425 107.59 1.6
12 102 74 96.9 108.12 34.12
13 101.2 103 96.14 107.272 4.3
14 103.3 99.1 98.135 109.498 10.4
15 102.8 103.5 97.66 108.968 5.5
16 62.8 54 59.66 66.568 12.6
17 102.4 101.2 97.28 108.544 7.3
18 102.7 103.5 97.565 108.862 5.4
TOTAL 1809.1 1674.7 242.9

COLOUR CODES
> 15 mtr.
Not yet recvd.

APPAREL INTERNSHIP REPORT 2019 | MODELAMA EXPORTS

 RESULTS & FINDINGS

COST ANALYSIS

Article Griege Rate Processed Total CGST SGST Freight Total

Name fabric / Rate/ Fabric (2.5% (2.5% of charge cost
consumption Mtr. Mtr. cost of total total
(In mtr.) fabric fabric
cost) cost)

QUANTITY RECEIVED BEFORE PROCESSING

3023.9 60 - 1,81,434 4,535.5 4,535.5 1,013.1 1,92,518.8

EXPECTED QUANTITY TO BE RECEIVED AFTER PROCESSING

COTTON
VOILE 3004.66 60 10 2,10,326.2 5,258.15 5,258.15 1,031.1 2,21,855.5

Style No.
W 1950L
11TP- ACTUAL QUANTITY RECEIVED AFTER PROCESSING
WOMAN

2886 60 10 2,02,020 5,050.5 5,050.5 1,031.1 2,13,134.1

TOTAL LOSS

Expected quantity of fabric received – Actual quantity of fabric received

2,21,885.51-2,13,134.1

= 8,751.41

APPAREL INTERNSHIP REPORT 2019 | MODELAMA EXPORTS

 Article Griege Rate Processed Total CGST SGST Freight Total
Name fabric / Rate/ Fabric (2.5% (2.5% of charge cost
consumption Mtr. Mtr. cost of total total
(In mtr.) fabric fabric
cost) cost)

QUANTITY RECEIVED BEFORE PROCESSING

5,289 64 - 3,38,496 8,462.4 8,462.4 1,200 3,56,620.8

EXPECTED QUANTITY TO BE RECEIVED AFTER PROCESSING

4,072.53 64 42 4,31,688.18 10,792.2 10,792.2 1,200 4,54,472.5

DISTY
PRINT

ACTUAL QUANTITY RECEIVED AFTER PROCESSING

3783.15 64 42 401013.9 10025.3 10025.34 1200 422264.59

TOTAL LOSS

Expected quantity of fabric received – Actual quantity of fabric received

4,54,472.58– 4,22,264.59

= 32,207.99

APPAREL INTERNSHIP REPORT 2019 | MODELAMA EXPORTS

 Article Griege Rate Processed Total CGST SGST Freight Total
Name fabric / Rate/ Fabric (2.5% (2.5% of charge cost
consumption Mtr. Mtr. cost of total total
(In mtr.) fabric fabric
cost) cost)

QUANTITY RECEIVED BEFORE PROCESSING

5062 80 - 423124 10578 10578 1,200 445480.2

EXPECTED QUANTITY TO BE RECEIVED AFTER PROCESSING

100% 4654 80 50 605280 15132 15132 1,200 636744

VISCOSE

Style No.
14.910.11.2

371 ACTUAL QUANTITY RECEIVED AFTER PROCESSING

4375.4 80 50 568802 14220 14220 1200 598442.1

TOTAL LOSS

Expected quantity of fabric received – Actual quantity of fabric received

6,36,744.0 – 5,98,442.1

= 38,301.9

APPAREL INTERNSHIP REPORT 2019 | MODELAMA EXPORTS

 COTTON VOILE
300
250
200
METER

150
Sent
100
Rec.
50
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

140
VISCOSE
120
100
80
SENT
60
RECVD
40
20
0
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 51 53 55 57

600
500
KELEY KREPE
400
300 SENT

200 RECEIVED

100
0
1 2 3 4 5 6 7 8 9 10

180
160
140
COTTON SHEETING
120
100
Series1
80
Series2
60
40
20
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

APPAREL INTERNSHIP REPORT 2019 | MODELAMA EXPORTS

 VARIATION IN QUANTITY

700000

600000

500000

400000

Expected quantity
300000 Actual quantity

200000

100000

0
100% C.VOILE (S-Z) KELEY
VISCOSE CREPE

Fig: 1.e Line graph depicting variation in quantities of 3 styles

APPAREL INTERNSHIP REPORT 2019 | MODELAMA EXPORTS

 FINAL OUTCOME

After several meetings amongst higher management, they came to a conclusion to provide
limited amount of fabric for processing to fabric mills. Implementation of this project in
MODELAMA EXPORTS mainly aims to reduce the fabric wastage as much as possible which
will ultimately reduce the large sum of money associated with it. It will streamline the process
by avoiding the loss for the organization.

NEW DYEING PROCESSING LIST

(As per discussed with the mills after meeting)

NEW DYEING PRICE LIST MODELAMA 9TH JULY 2019.

Shrinkage for Shrinkage for
Quality Width Price white Dyed
White
with 5001 5001 Residual
S Mursarize 800 - to 800 - to After
No Quality G/Width C/Width / Singing Light Med Dark 5000 above 5000 above Iron
C/Voil /
1 Cambric 63" 52' 9.00 13.00 15.00 18.00 3%+L 2%+L 4%+L 3%+L 3%

2 Poplin 63" 52" 11.00 15.00 17.00 20.00 3%+L 2%+L 4%+L 3%+L 3%
60's Modal/
30's Rayon /
Rayon Moss
- Dobbies
3 (flat dyeing) 63" 52" 12.00 16.00 18.00 20.00 10%+L 9%+L 10%+L 9%+L 4%
30's Rayon
Moss /
Dobbies (
4 Soft Flow) 63" 44- 50 " 12.00 16.00 18.00 20.00 13%+L 12%+L 13%+L 12%+L 4%
Rayon
Crape ( Line
5 Dry ) 63" 46" 12.00 16.00 19.00 21.00 18%+L 16%+L 18%+L 16%+L 4%
60's Actual
Cambric 18- 22- no. of
6 Schiffly 63" 48" 11.25 15.00 20 25 than 5%
Viscose GGT
( Flat
7 finishing ) 63" 46" 11.25 16.25 17.50 18.75 17%+L 16%+L 17%+L 16%+L 4%
Viscose GGT
( boota
8 dana GGT ) 63" 46" 11.25 16.25 17.50 18.75 23%+L 22%+L 23%+L 22%+L 4%

9 Cotton Twill 63" 53' 18.00 22.00 26.00 30.00 4%+L 3% 5%+L 4%+L 4%

10 Relly 63" 53' 16.00 19.00 21.00 23.00 23%+L 22%+L 23%+L 22%+L 4%

11 kelly 63" 53' 16.00 19.00 21.00 23.00 20%+L 19%+L 20%+L 19%+L 4%

APPAREL INTERNSHIP REPORT 2019 | MODELAMA EXPORTS

 STORE SPACE ANALYSIS & DETAILS

Descriptions Measurement Symbolization

Longest length 224 foot(approx)

Main surface area
General width 28 foot(approx)

Longest width 112 foot (approx)

General length 28 foot (approx)

Elevated floor Length 112 foot (approx)

(Mezzanine)
Width 16 foot (approx)

No of cubes 8
Base Cubes
(Mezzanine) Each cube Length 18 foot (approx)

Each cube Width 8 foot (approx)

Each cube Height 6 foot (approx)

Goods in-house Length 28 foot (approx) Goods In house

room
Breadth 28 foot (approx)

Number of cubes 149

Racks
Cube length 6 foot (approx) [2 foot
partition]

Cube width 4 foot (approx)

Cube height 4 foot (approx)

Non value added Racks area 576 sq ft

space
Surface area 564 sq ft

Space for excess Number of Cubes 30

fabric storage
Length 6 foot (approx)

Width 4 foot (approx)

APPAREL INTERNSHIP REPORT 2019 | MODELAMA EXPORTS

 No of inspection table 7

Inspection table Length 32,18,14,8 foot (approx)

[inside = 4foot partition]

Width 4,6,4,4 foot (approx)

Height 3 foot (approx)[inside=

2Ft]
No of machine greige 2

4 point Machine Length 14 foot (approx)

Width 10 foot (approx)

No of M/C normal 3

Length 6 foot (approx)

Width 6 foot (approx)

No of Trolley 12
Trolley
Length 6 foot (approx)

Width 3 foot (approx)

No of PVC 120
PVC pallets
Length 4 foot (approx)

Width 4 foot (approx)

Maximum height 6.36 foot (approx)

Floor per day average 969500 mtrs to

1030900mtrs
Per rack meters Roll= 5000 to 5500 mtrs
Capacity Than = 2000 to 4000 mtrs
Per rack’s no of rolls 50 - 55

Per PVC no of rolls 35 - 40

Per PVC capacity Roll = 2000 to 7000 mtrs

Than = 2500 to 4500 mtrs
Avg/day cutting 20161 – 24038 mtrs
requirement

APPAREL INTERNSHIP REPORT 2019 | MODELAMA EXPORTS

 Existing layout Study:

APPAREL INTERNSHIP REPORT 2019 | MODELAMA EXPORTS

 CALCULATIONS REGARDING PLAN

PLANS CALCULATIONS

As per previous layout 64 X 5000 mtrs (max avg) = 3,20,000

at place of cube +3,20,000
partition 6,40,000 mtrs capacity approx

As per plan 1 if we 63 X 5000 mtrs (max avg) = 3,15,000

remove the cube +3,00,000
partition 6,15,000 mtrs capacity approx
32 X 2 = 64 sq foot free space available

As per plan 2 if we 90 X 5000 mtrs (max avg) = 4,50,000

remove the cube +1,05,000
partition 5,55,000 mtrs capacity approx
6 foot free space available on both side of the racks

APPAREL INTERNSHIP REPORT 2019 | MODELAMA EXPORTS

 BACKGROUND OF PROBLEM

1. Time line is not fixed for receiving as well as issuing fabric to the cutting which at times
leads misbalancing of the inventory management.

2. Due to delay in meeting the PCD dates unable to conduct 100% inspection of the local
supplier fabrics.

3. There is not a uniform way of sending as well as receiving of greige fabric lots due to
which we cannot make any conclusion at the initial stage, have to wait for full fabric to
received mean while the fabrics are issued to the cutting.

4. No single point of access of good’s information and people have to go through multiple
places for the same info.

5. There is no record system of the testing as well as inspection report, it still works on
the old manual method which eventually last from 3 to 5 months.

6. There is lots of manual & registered work which needs to be replaced with the system.

APPAREL INTERNSHIP REPORT 2019 | MODELAMA EXPORTS 38

 ACTUAL SPACE AND CAPACITY OBSERVATION

Present Space

Greige fabric capacity Floor space Length = 84 foot approx

Width = 28 foot approx

No. Of racks 8

Rack capacity 3,24,000 mtrs. to 4,05,000 mtrs.

Dead stock capacity Floor space Length = 26 foot approx

Width = 12 foot approx
No. Of racks 3
Rack capacity 84,000 mtrs. 1,05,000 mtrs
Finished processed fabric Floor space Length = 84 foot approx.
capacity
Width = 28 foot approx.

No. Of racks 7

Rack capacity 3,42,000 mtrs. to 4,20,000 mtrs.

Complete processed fabric Floor space Length = 84 foot approx.

capacity
Width = 28 foot approx.

No. Of racks 7

Rack capacity 3,36,000 mtrs. to 4,20,000 mtrs.

Total capacity Only racks 11,07,000 mtrs to 13,71,000 mtrs.

120 PVC 3,00,000 mtrs to 4,80,000 mtrs.

Total 14,07,000 mtrs. To 18,51,000 mtrs

APPAREL INTERNSHIP REPORT 2019 | MODELAMA EXPORTS 38

 PICTURE
GALLARY

APPAREL INTERNSHIP REPORT 2019 | MODELAMA EXPORTS 39

 REQUIREMENTS:

Greige Fabric Inwards Average quantity received per 2,51,803 mtrs. (95,000 to
month 4,80,796)

Average fabric inspected per day Approx 9000 mtrs.

Average fabric inspected per month Approx 234000 mtrs

Processed fabrics (from Average goods send for processing / 3,36,000 mtrs (2 lakh – 3.5 lakh
Greige to emb.) month mtrs)

Average goods inward from 2,56,414 mtrs (50,000 – 2.8 lakh

processing / month mtrs)

Average fabrics received per month 5,94,459.69 mtrs (3lakh to 13

lakh mtrs)

Dead stock Total dead stock in fabric store Approx 3 lakh mtrs

Average dead stock generated per 12,000 mtrs to 15,000 mtrs

month

Average dead stock cleared per No monthly clearance system

month

Rejected fabric stock Average quantity rejected per 4000 mtrs to 10,000 mtrs approx
month

Inspection Average fabric inspected / day 15,944 mtrs (10000 to 16000

mtrs)

Fabric counting Average fabrics that can be counted 14500 mtrs

/ month

Wool relaxation Average fabric relaxed per day 1500 to 2000 mtrs

Fabric issued to cutting Average fabric issued to cutting per 20161 – 24038 mtrs
day

APPAREL INTERNSHIP REPORT 2019 | MODELAMA EXPORTS 40

 PICTURE
GALLARY

APPAREL INTERNSHIP REPORT 2019 | MODELAMA EXPORTS 41

APPAREL INTERNSHIP REPORT 2019 | MODELAMA EXPORTS 42
 NEW PROPOSED LAYOUT:

APPAREL INTERNSHIP REPORT 2019 | MODELAMA EXPORTS 43

 CHANGES PROPOSED

1. Removal of Mezzanine Floor:

Advantages:
 Additional space utilization by using the higher unused area.
 Floor wise storage.
 Modular, sealable and mobile.
 Can be used as hiding place of goods in case of some audit.
 Easily accessible as the operators can easily climb the higher floor using stairs
and storage is of floor category.
Disadvantage:
 It reduced the vision clarity from one end to other.
 It was converted to dumping ground which made it very difficult to access
deeper parts of mezzanine. Moreover it created a very unkempt look to the
outsiders.
 It took up huge amount of space.
 Created area block, unable to utilize the full space.
 Resulted in movement restriction of fabric.
 There is no proper separation in mezzanine floor as the storage is done in the
form of floor wise. Allocation & segregation of the fabrics cannot be
appropriately done. Thus resulted in unorganized storage.
 It was difficult to carry heavy rolls to upper floors of the mezzanine. Thus,
mezzanine was not fully utilized.
 Mezzanines are supported by posts, but these take up significant ground floor
space and are often creates busy traffic areas

2. Change in the orientation of inspection table:

By changing the orientation in the inspection table, we would be able to generate a lot
of space for the fabric movement. Moreover, with the new orientation, two tables can
be placed side by side, thus further creating space for easy movement.

APPAREL INTERNSHIP REPORT 2019 | MODELAMA EXPORTS 44

 Removal of Mezzanine Floor:

APPAREL INTERNSHIP REPORT 2019 | MODELAMA EXPORTS 45

 3. Change in position of Greige fabric inspection machine:
There are currently two greige fabric inspection machine in the company. It is
proposed to place both the machine together near the exit/entry gate of the fabric
store. This would enable in space generation and easy flow of greige fabric for
processing and storage.

4. Change in position of processed fabric inspection machine:

There are two processed fabric inspection machine in the company. It was proposed
that the machines should be placed near the racks that stored the inspected and those
fabrics which needed to be inspected. This would result in smooth flow of inspected
fabrics in the store.

5. Installment of new racks in the store:

More racks were proposed to be installed in replacement of mezzanine floor.
Moreover racks could be installed in the cutting section to store the fabrics that were
ready to be cut. Also racks could be installed in the spaces that were created by the
repositioning of inspection tables and greige fabric inspection machine.

6. Addition of new pallets:

New pallets could be introduced for storing the fabrics that is to be issued to the
cutting department or the fabric is to be inspected or the fabric is heavy and all the
lower racks are full. Pallets can be of different sizes so that fabric of different quantity
can be adjusted accordingly.

7. Shifting of dead stocks:

The quality of all the dead stocks present in the fabric store was evaluated and those
with good quality and who were in good condition were sent to the production floor
where the samples for the new brand of the company were being produced. Those
fabrics which were not in good condition were sold in the local market at the average
cost of Rs 50 per kg.
Thus, the removal of dead stocks created a large amount of space that was being
wasted before.

8. Segregation of fabrics on the racks:

The fabrics were proposed to be segregated in the following way:-
 Daily fabric inward
 Greige fabric stock
 Greige fabric inspection
 Greige fabric ready for processing

APPAREL INTERNSHIP REPORT 2019 | MODELAMA EXPORTS 46

  GRN approved fabric
 Processed fabric for embroidery inspection
 Processed fabric ready for issue
 Finished fabric inspection
 Finished fabric stock
 Nominated fabric inspection
 Nominated fabric stock
 Rejection
 Dead stock ( 4 months)
 Fabric ready to issue
 Sampling
 Fabric head ends and counting
The above segregation of fabrics in the racks would create an organized look in
the fabric store, thus removing any unused space.

APPAREL INTERNSHIP REPORT 2019 | MODELAMA EXPORTS 47

 EXPECTED OUTCOME

AN EFFICIENT FABRIC STORE IN GARMENT INDUSTRY

Working of an efficient fabric store:

1) Space Management:

 Demarked area for freshly arrived fabric: As soon as the fabric is unloaded, all the
fabric rolls should be counted, against the invoice received from the supplier.
 Proper Indexing of the stored fabric rolls: It may vary according to the fabric type,
order specifications etc. After the fabric is inspected, the indexing of the fabric should
be done and its exact location along with the order specifications should be noted. This
eases the process of locating the fabric in the fabric store.

2) Time Management: Easier to locate the rolls in the store without much difficulty and in
considerably less time. Segregation of fabric lots as per inspected, passed or rejected.

3) Capacity Escalation: The factory should better analyse their current capacity and their
ability to increase their capacity. A clear visibility of the in-house stock the factory has.

4) Information Management: With the visibility of in-hand inventory, the fabric store can
easily coordinate with the other departments that consume fabric.

5) Efficient Fabric Inspection Process: Reduce the amount of time spent in finding the rolls
to be inspected, it also allows for easy prioritization of the rolls for inspection, on the basis of
order requirements.

6) Use of 7s:

 SORT: Daily needed items, weekly needed items, and monthly needed items are
defined and kept separate.
 SET IN ORDER: All items, section, and area (In exist) are clearly identified by a label
and everything is well organized.
 SHINING: All items/place of workplace Floors, walls, stairs, ceilings, pipework
Racks, cabinets, shelves, Machines, equipment, tools, Stored items, materials, products
and lighting everything is kept clean.
 STANDARDIZE: Visualization by Information displays, related SOPs, signs, colour
coding and other markings are established everywhere in the fabric store.
 SUSTAIN: This is a way of life rather than just a routine.
 SAFETY & SECURITY: Workplace is safe for all employees and staffs working in
the fabric store.

7) An efficient fabric store must follow Maintenance Schedule

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 DAILY/WEEKLY MAINTENANCE MODULE

Monitor storage conditions.

If cycle counting, conduct physical inventory and update stock keeping records.

Clean receiving, storage, packing, and shipping areas.

Clean bins, shelves, and cupboards, if needed.

Ensure adequate ventilation and cooling.

Check the store roof for leaks, especially during the rainy season and during or after a storm.

Ensure that products are stacked correctly (the lower cartons shouldn’t be crushed).

Update stock records and maintain files.

Separate expired stocks and move to secure (quarantine) area.

Update back-up file for computerized inventory control records.

Monitor stock levels, stock quantities, and safety stocks.

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 MONTHLY MAINTENANCE MODULE

Check for signs of rodents, insects, or roof leaks.

Use established procedures to dispose of expired or damaged products.

Inspect the storage structure for damage, including the walls, floors, roof, windows, and doors.

Store products using correct procedures; rearrange commodities to facilitate the first-to-expire, first-
out (FEFO) policy.

Visually inspect fire extinguishers to ensure that pressures are maintained and extinguishers are
ready for use.

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 CONCLUSION

The fabric store is often an ignored part in garment factories when it comes to improvement
projects and efforts. But small store organization and space utilization projects can bring in a
lot of difference in the factory’s bottom line.

Knowing the location, status, value, and lead-times of inventory is essential to making the most
effective business decisions. The up gradation of fabric store will reduce the chance of error as
it will eliminate the paper-based system. Keeping this in mind the benefits of organized fabric
store will not only make industry profitable but also increase market share.

At last the more efficient & organised a fabric store is, the better will be the store management.

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 PROJECT REPORT –II

Launch of a Retail Brand

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 LAUNCH OF A RETAIL BRAND (Implemented)
“An initiative towards sustainability”

TM

“The unusual style in usual way”

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 APPROACH ADOPTION TO METODOLOGY

Fig 2.a Process Flowchart

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 INITIAL IDEA

Enormous amount of leftover fabric is generated every month in Modelama Exports and is
dumped in the Plot No-5/7/18/89, IMT Manesar, Sector-4,5,8, Gurgaon units. The initial idea
begin with this concept to utilise the left-over fabric and start a new retail brand keeping
sustainability in mind.

METHODOLOGY ADOPTED

This project is the mixture of theoretical as well as practical knowledge. Also it contains ideas
and information imparted by the guide. The secondary data required for the project was
collected from various websites and books of reputed authors.
The project started with sorting all the raw data and arranging them in perfect order. To add
value to the project and to understand the practicality of retailing business, we have visited
various stores who are the best ones in retailing business.
Further, to understand the consumers better, a field survey was also conducted to find out the
tastes and preferences, purchasing habits, expectations of the consumers etc. Analysis of this
primary data has been done to actually understand the survey in a better way.

Background Analysis
 Study on Left-over fabric generation
Understanding the environment
 Collecting facts & figures based on it
 Is there a sizeable market?
 What are we going to sell?
Understanding the brand  How are they suited to this area?
 What design collections we will be
making?
 Story and concept behind the brand
 Principle ethics that will revolve around Identify competition
 What did customers like about them?
Identify the right customer  How and where we can give better
offering to our customers?
 Segmentation  Can we do it differently?
 Identifiable
 Profitable

Set up a customer centric store

Exit the competition

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 OBJECTIVE

PRIMARY OBJECTIVE
I. To utilise left-over fabric.
II. To understand the concept of retailing.

SECONDARY OBJECTIVE
I. To identify the activities associated with
retailing
II. To understand the operational structures
associated with retail organizations
III. Understanding consumer behaviour in retailing
IV. To understand the nature of merchandise
budgeting and unit planning
.

LITERATURE REVIEW

Retailing consists of all activities involved in selling goods and services to consumers for their
personal, family or household use. The retail sector in India is highly fragmented with
organized retail contributing to only 2% of total retail sales.
Today, in India we see a rise in the purchasing power and growth of a middle class which
follows the western lifestyle. Hence, conditions are conducive for the rapid growth of organized
retail in India.
Organized retail is growing rapidly and we see the emergence of large organized retail chains
like Shoppers’ Stop, Life Style and Westside. We also find retail malls mushrooming all over
the country. The opportunities in retail industry in India will increase since Indian retailing is
on the threshold of a major change. However, with the rapid growth in organized retail and
increased emphasis of manufacturers on understanding sales at the retail level, the study of
retailing has become increasingly relevant.

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 STRUCTURAL FLOWCHART FOR THE APPROACH TOWARDS
PROJECT

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 BACKGROUND RESEARCH

STOCK FABRIC ANALYSIS BASED ON FACTS & FIGURES

VENUE: MODELAMA EXPORTS, Plot -105/106 Udyog Vihar, Phase-I, Gurgaon

MONTHS COVERED: NOVEMBER’18-MAY’19

SOURCE REFERRED: ERP Software (WFX), Manual Register maintained by Fabric store department

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 FABRIC ABOVE 100 Mtr.

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 FABRIC BETWEEN 50-100 Mtr.

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 INTERNAL CAPACITY PLANNING TO ACHIEVE TARGET

Fig 2.b Capacity Planning to achieve target

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 BRAND STUDY

Fig 2.c Brand Development Process

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 IMPLEMENTATION STRATEGIES

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 COMPETITOR ANALYSIS

A practical field survey was done to get a deeper knowledge of how our competitors cater the
target customers.
Our objective was:

 Ascertain the competitor’s positioning and value proposition in the market and in
consumer perception
 Understand the assortment breadth/depth in terms of the major items, styles, colours,
sizes and brands stocked
 Determining the Price points of different Categories
 Determining the Promotion Mix used by the Competitors
 To find out the human resource allocation plan with a view to understand remuneration
and incentives

Limitations / Constraints while doing this field survey for our project:
 The issues considered confidential by the store authorities were not revealed because
of which we could not gain access to several data and information which we considered
vital for the betterment of the project.
 The Project does not delve into financial aspects of retailing such as ROI, Inventory
turns, Return per Square feet. It focuses clearly on marketing and merchandising
elements only.

METHODOLOGY ADOPTED

Defining the Industry-Scope & Nature of industry

Determining the competitors

Determining the customer preferences

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 DATA COLLECTION & ANALYSIS

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 WHAT’S SO DIFFERENT ABOUT US

We are not only utilising the fabric but our main focus is to satisfy customer with our unique
approach that we will offer to them.

The garment will be presented with different styles which our customer can club and will be
guided accordingly. We have done a customer survey (internal) to get a proper knowledge of
Indian skin tone and the body shape. With the help of this survey the garments that we make
will be suitable for the Indian market.

Some of our research work is presented below:

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 EXPECTED OUTCOME

One room has been allotted to begin with the production process.
Till now we have:
MANPOWER MACHINES
5 Sewing operators , 1 Cutter man 5 SNLS, 1 O/L, 1 CUTTING TABLE
:

CUTTER MAN

SEWING OPERATOR

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 OUR DESIGN COLLECTION FOR ZABT:

STYLE GARMENT SKETCH GARMENT

NO.

I NOT YET MADE

NOT YET MADE

II

NOT YET MADE

III

IV

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 NOT YET MADE
V

NOT YET MADE

VI

VII NOT YET MADE

VIII NOT YET MADE

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 LAUNCH DETAILS

STORE LOCATION:
The place which has been selected for our brand ZABT is at EDM Mall, Gaziabad.

SATELLITE VIEW:

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