Project
Index
Certificate
Acknowledgement
Abstract
Company profile
Swot analysis
Table of contents -
Objective – how to reduce lead time
Sub objective- to study major and minor problems regarding 5 styles from all the aspects
Scope of the project -
Literature review-
Methodology
Project / Findings-
Case study of 5 styles- through secondary data
Comparative analysis
Suggestions and recommendations –
Bibliography
ACKNOWLEDGEMENT
We extend our gratitude to the top management of Radnik exports for accepting us as
internee in their manufacturing unit. At this juncture we want to place our sincere thanks to
Mr. MANIK MANNA, managing director, Mr. AMIT MEHENDIRATTA, Mr.
SUBHASISH DAS.
We would like to extend our sincere thanks to Mr. PRADEEP, Mr.SACHIN, Mr.
VIJENDRA, Mr. VIKRANT, Mrs. NEERA and Mr. RAJESH, Merchandising department
who helped us to completing this project work.
We are greatly indebted to Mr. Amit, coordinator, merchandising department for their
valuable, timely help and for the support given by them through this period and shaping this
internship into the best form.
Last but not the least we thank our faculty members (pearl academy of fashion), our parents
and our dear friends who have been a source of inspiration and guidance in the process of
learning.
SURUCHIKA
RITU JAIN
COMPANY PROFILE
An Overview:-
address RADNIK EXPORTS, UDYOG VIHAR , PHASE
-2,Gurgaon (HR)
Year Established 1975
Type of Company Private Held
Owners/ Directors Mr. manik mahna
Mr. nikunj kapoor
Mr. aksay kapoor
Mr. vinod kapoor
Mrs. mahna
Annual turnover Rs 175 cr (approx)
No of people employed 6000 approximately
Production Capacity 1,20,000 per month (woven)
Total Capacity
Capacity utilization
Major export market UK
BUYERS:-
COUNTRY BUYERS
USA Tommy Hilfiger.
Sweden H&M, Lindex, Indiska, Jc, Sister, Lexington,
Ahlens, Gudrun Sjoden.
UK M & S, Mama & Papa’s, Evans, Asda,
Debenhams, River Island, Walls, Miss
Selfridge, Dorothy Perkins, Bhs, Sainsberry
Spain Cortefil, El-corte Inglise,| Inditex
Others Mexx, Promod, Kiabi, Cubus, Esprit, C&A,
Vetir, Seppala, Folks Gym.
Radnik Exports which has been ranked 34th by APPREL ONLINE MAGAZINE, has nine
production factories, covering a total area of 5, 00,000 sq. feet, with a capacity to handle 6,
00,000 garments per month.
INFRASTRUCTURE:-
Nine production units located in Noida, gurgeon, Okhla.
Over 200 machines including straight knife machine, band knife machine, bottom
hem
Wet and dry processing unit comprising perc based dry cleaning machines, brushing
machines offering a wide range of finishes from light softner washes to heavy
enzymatic washes.
Cutting department is equipped with the CAD system from LECTRA offering the
most efficient method of pattern designing, pattern grading, marker length planning
and cut plan.
PRODUCT MIX:-
Radnik exports use a wide array of fabrics to create distinct style for its buyers. They mostly
use cotton silk, cotton voile, cambric, polyester, satin, and georgette. Its area of specailzation
includes:
Kids wear
Women’s wear
Men’s wear
ACHIEVEMENTS:-
ISO 9001: 2000 Certification by BVQI
Awarded by AEPC for Outstanding Performance in Rupee Trade Area & global
export
Certificate of State Awards for Outstanding Export Performance
Its Factories are compliant under International Code of Conduct Laws
It’s also certified by Price Water House Coopers, CSCC (USA), Interlek Testing
Services, SGS, H&M, Lindex & The Acardia group,TUV - SUD
Radnik has been awarded an, “NSIC-CRISIL rating of CRISIL SE2A”
for high performance capability and high financial strength.
1ST STYLE –
Style no – 1715
Buyer – Debenhams kids wear
Buying agent – impulse
Order qty – 2000 pcs
Ship mode – sea (flat pack with hanger)
Order confirmation date – 07/04/09
Ship date – 03/08/09
Fabric description –
Poly satin print 40’’
Poly satin solid 40’’
Cotton voile lining – 92 x 104
Problems which occurred during this order
Colour bleeding problem between green & pink color
Fish tail sequence problem
Price ticket got changed
Velvet bow & binding got removed
Lining average was increased that’s why fabric was ordered again
Sequence rows at bottom were wavy.
5 threads over lock was missing from side seam at shell and lining.
An uneven gap between sequence rows at bottom was observed.
Baby over lock was very poor.
Size set got rejected.
Lining length was said to be decreased – 1 cm shorter from the shell fabric
Comment on fit.
Sequence work said to be done with machine lock stitch machine not by hand work
White patches also came on the print.
Major problems –
(a) Fabric lot problem - The approved sample was made by table / screen printing. And that
approved strike off had thin boundary. So 1300 mts fabric was ordered at two times in which
rotary printing was done but that strike off was not coming in the right way. So these 2 lots
of 1300 mts fabric got rejected. Finally the fabric was ordered on the third time but still it
was not matching up to the level. Then the settlement was done and buyer accepted this
fabric with the settlement of 3 % discount (CPR).
(b) Sequence problem - Sequence strength was poor. So core spun thread was suggested to
reduce this problem by the buyer. So the merchant decided to use 2 core spun thread
instead of 1 thread as a precaution.
Fish tail problem was occurring again and again. So these people were unable 2
eliminate this problem. But they tried to reduce this fish tail problem which was
accepted by the buyer.
Solutions –
Style no - 1715 PLANNED ACTUAL DEVIATION REASONS SUGGESTIONS
DATE DATE DAYS
Proto sample
1st fit sub 23 April
1st fit comments 29 April
2nd fit sub 5 may
2nd fit comments 13 may
Fit seal by date 13 may
PP / green seal sub 10 June
PP seal by date 17 June
Trims sub date 15 June
Trims seal date 17 June
lab dip/ strike off/ 15 April
desk loom sub
Lab dip/ strike 20 April
off /desk loom
comments
2nd lab dip/ strike 24 April
off/ desk loom sub
2nd lab dip/ strike 29 April
off/ desk loom
comments
Lab dip / strike 29 April
off/ desk loom seal
date
Fabric booking 8
April(Greige
)
Emb / print sub
Emb/ print
approval dt
Trims booking 17 April
Grading submit 16 may
Grading approved 14 may
Size set submit 27 may
Size set approval / 29 may
comments
Gold seal submit 30 June
Gold seal approval 8 July
Trims in house 30 may
Initial bulk fabric
sub
Initial bulk fabric
approval
Bulk fabric in 5 June
house
FPT sub 10 June
GPT sub 25 June
Fabric inspection 10 June
PILOT 26 June
Bulk cut date 27 June
Emb start date 6 July
Recut date Na
Production start 29 June
date
Washing start date 16 July
Emb completion 20 July
date
Finishing / 17 July
packaging start
Initial inspection 10 July
Mid inspection 16 July
Production end 18 July
date
Washing end date 22 July
Finishing / 23 July
packaging end
Internal inspection 23 July
Final inspection 24 July
Ex factory 27 July
2nd style –
Style No. – ECT 018
Buyer – Marks & Spencer
Shipment Mode – AIR (By hanging)
Fabric – Yarn dyed stripe
Color – Blue / Grey
Quantity – 18,434 pcs
Problems of the style–
Excess of fabric at the base of the bib that is not laying flat.
Over lock is running over the braid.
The braid on which the bobbles are attached must be hidden.
.Side seams were untidy.
Sample when fitted on the dummy, was falling to the back.
Bobble lace was unravelling.
Seam slippage problem – Acceptable till 4.5 kg after wash.
Weaving defects noticed in the fabric.
Lace bobble trim coming away from the seam as it is not attached correctly.
Major problems-
1. Braid problem –
1.1 Style no ECT018 has a braid lace on the front and this braid lace was creating a lot of problems
from initial approval till production. Problems which occurred during the selection-
Unravelling of Bobble lace.
Weaving defects, breakage of bobbles in the lace.
Poor strength
Higher stiffness
1.2 As the lace was having so many problems in the manufacturing, so the wastage ratio got
increased that’s why they increased the average of the lace.
2. Fabric problem-
On the other side, seam slippage problem and weaving defects problem were also
occurring in the fabric. That’s why fabric average also got increased.
Corrective measures taken by the merchants –
The merchants asked for some changes to be done by the supplier. The changes are-
The bobbles should be locked tightly.
The thread used to make the bobbles was changed from single ply to double ply.
The chemicals used in washing proved too harsh for the bobbles and they tended to unravel.
So, the chemicals used for washing were changed.
For reducing fabric problem, mending was done.
Actual problem and solutions –
Style no – ECT PLANNED ACTUAL DEVIATION REASONS SUGGESTIONS
018 DATE DATE DAYS
Proto sample
1st fit sub
1st fit comments
2nd fit sub
2nd fit comments
Fit seal by date
PP / green seal sub
PP seal by date
Trims sub date
Trims seal date
Bit loom sub 17 may
Bit loom
comments
2nd lab dip/ strike
off/ desk loom sub
2nd lab dip/ strike
off/ desk loom
comments
Bit loom seal date 20 may
Fabric booking 7 may
Emb / print sub
Emb/ print
approval dt
Trims booking 20 may
Grading submit
Grading approved
Size set submit
Size set approval /
comments
Gold seal submit
Gold seal approval
Trims in house
Initial bulk fabric
sub
Initial bulk fabric
approval
Bulk fabric in
house
FPT sub
GPT sub
Fabric inspection
PILOT
Bulk cut date
Emb start date
Recut date
Production start
date
Washing start date
Emb completion
date
Finishing /
packaging start
Initial inspection
Mid inspection
Production end
date
Washing end date
Finishing /
packaging end
Internal inspection
Final inspection
Ex factory
STYLE NO - 3
Style no – PLANNED ACTUAL DEVIATION REASONS SUGGESTIONS
DATE DATE DAYS
Proto sample
1st fit sub
1st fit comments
2nd fit sub
2nd fit comments
Fit seal by date
PP / green seal sub
PP seal by date
Trims sub date
Trims seal date
lab dip/ strike off/
desk loom sub
Lab dip/ strike
off /desk loom
comments
2nd lab dip/ strike
off/ desk loom sub
2nd lab dip/ strike
off/ desk loom
comments
Lab dip / strike off/
desk loom seal date
Fabric booking
Emb / print sub
Emb/ print
approval dt
Trims booking
Grading submit
Grading approved
Size set submit
Size set approval /
comments
Gold seal submit
Gold seal approval
Trims in house
Initial bulk fabric
sub
Initial bulk fabric
approval
Bulk fabric in
house
FPT sub
GPT sub
Fabric inspection
PILOT
Bulk cut date
Emb start date
Recut date
Production start
date
Washing start date
Emb completion
date
Finishing /
packaging start
Initial inspection
Mid inspection
Production end
date
Washing end date
Finishing /
packaging end
Internal inspection
Final inspection
Ex factory
