Magnum Clothing Private Limited, Industrial Report

Magnum Clothing Private Limited, Industrial Report

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  N.SARANYA 16BFT1006 APPARAEL MACHINERIES ANDEQUIPMENTS IV REPORT MAGNUM CLOTHING PVT LTD A Brief about the Industry: Magnum Industries pvt ltd, located in Oragadam is a sewing unit which exports garments to UK’s leading clothing shops. They sew high quality fabric whose cost starts at minimum 2.5k.It is a
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  woven unit wherequill weave fabric is used. This unit produces about 2500 pieces per day. Source of Raw Material: Head office Fabric: Woven Unit. Buyers: Next, Matlam, Marks and Spencers Materials: Cotton, polyester, Lurex No.Of.Employees: 650 Steps of Manufacturing a Garment:  Fabric Relaxation  Laying  Cutting  Bundling  Ticketing
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   Fusing  Sewing Reinforcements  Bar tacking  Assembling  Inspecting  Packaging  Exporting Fabric Relaxation: After collecting the raw materials from the merchandiser, we are not in a state to lay the fabric directly. It has to get along with the atmosphere of the industry either by absorption or desorption of moisture. For this process the fabric is laid for a minimum of 10hrs. This process is known as fabric relaxation. For woven fabric the relaxation period is 10 to 12hrs and for knitted fabric it is 12hrs. Laying: After relaxation, now the fabric is in ready to lay state. From the HO the fabric comes in a long single material of definite measurement. This single piece of fabric is known as ply. Each ply is laid one above the other. This forms a lay. Laying is done to prepare the fabric for easy and quick cutting. It is the thickness of the fabric that decides how many plys are laid at a stretch. If the fabric is super thin then it is goes up to 70ply which is the utmost count. After laying the fabric, they are held together by clips which prevent slipping of ply.
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  Cutting: Cutting department isthe heart of the industry. Cutting is done here by straight knife machine and band neck machine. The main thing used here is the ‘Mini Marker’. The Mini-marker is like the guide on how to cut the ply. It has in it the number of component to be cut, the cut pieces, the measurement of each piece, number of lay etc. It is like the compressed copy of the marker that is laid on the ply as a template on how it should be cut. The mini marker is prepared by CAD operator. In bigger manufacturing units there is no need for these marker kind of stuffs as the entire cutting is done by the use of Herber which is an automated cutting machine programmed with all the cutting measurements. For cutting straight parts we use straight knife machine and for collar, pleats or round cut parts we use band neck knife. While using these cutting instruments using protection is very much important and is insisted. Band Neck Knife
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  Fusing: In order tomaintain the fabric stiffness and keep it erect we add a layer of interlining material. The interlining material is made especially for this purpose. This layer is used mainly in collar, cuff and pleat area. The interlining layer is placed on the reverse side of the fabric and is left inside the fusing machine where they both stick together due to excessive heat. As same as ironing process. The color of the fusing material is selected in regard with the color of the fabric material. This color and the fusing temperature is selected according to the buyer requirements. Bundling: Straight Knife Machine FUSING MACHINE
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  After all theseprocesses the resultant garment pieces are grouped together depending on their cut shape as sleeve or front patch etc. This is known as bundling. Bundling is done to segregate each partition of the garment and also for easy passing to next section. Ticketing: Ticketing is the process of adding temporary stickers for easy identification. The sticker consists of serial number given to each BUNDLING SECTION
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  garment. They followthe principle that all parts of the particular garment will have the same serial number based on which pieces with same serial number are grouped together to form the entire garment. This process is undertaken to get exact shade matching throughout the entire garment. OB: OB stands for Operation Bulletin. Before moving on to the sewing section, the manager is provided with the OB by the head office. The OB contains the steps and the Standard allocated value which is the time allotted for each operation to progress in the sewing operation. In this industry there are 5 rows among which 1 row are for preparation and other 4 rows are for sewing.
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  Before dyeing dummybuttons are stitched which are later replaced by the required buttons to avoid button damage and breakage. Sewing: Sometimes RFD threads are used for sewing or at times the thread with the final garment color is used. All parts from the previous sections are brought here for assembly. They start the procedure at sleeve tapping. After which tagging, blind hemming, top stitch etc. are done. Care must be taken to join parts of the same serial number. Reinforcements are used at some parts mainly like below button points. Bar tacking is done to avoid open edges. For these automatic bars tacking machines a computer program is applied which is called as e-pharm. This e-pharm is a computer programming language which defines the shape and size of the bar tack stitch. After this pocket placement is done. Assembling Section: Here collar and sleeve attaching is done. Over lock machine is used mostly. By here 95% of the garment is done. Balance is the finishing things like dying, placements of buttons, adding the name tag, ironing etc. Sometimes even non-washing clothes are
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  requested by thebuyer. As per the shade it is segregated and bundled. After this section the garment manufacturing process is mostly over. Now the garment is sent for ironing and checked for any chance of presence of metal components such as needle broken parts or any such kinds. After even more quality checks the garment is sent for packing and is exported either abroad or for other domestic or international markets.