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INDUSTRIAL ENGINEERING

•The industrial engineering approach integrates people into the design and development of systems, thus requiring an understanding of the physiological, psychological, and other characteristics that govern and affect the performance of individuals and groups in working environments

SO

Industrial Engineering applied specifically to the apparel industry.
We can say that Apparel Engineering is finding the best way to do something, the time required to do it, and the way to measure results.

Some Functions of Apparel Engineer

•Quotas and Piece Rate
•Costing
•Manpower Planning
•Machine Requirements
•Production Planning
•Plant Layout
•Production Flow System
•Machines and Attachments
•Pay Systems
•Operator Performance
•Production Control System
•Plant System, Maintenance etc

TYPES OF PRODUCTION SYSTEM

There are three type of production system use in apparel industry:

·         Make through production system

·         Modular production system

·         Assembly line production system

ü  Progressive bundle system (PBS)

ü  Unit production system (UPS)

Each system requires different types of:

· Management philosophy

· Material handling arrangement

· Floor layout

· Employee training

· Companies may combine the systems or use only one depending on their need.

Make through production system:

It is the traditional method of manufacture in which an operator makes right through one garment at a time. That is one operator will do all the stages of the sewing operations of one garment and after completing it he will go for the next garment. Some advantage and disadvantage is as following:

Advantages of make through production system:

ü  Quick throughput time

ü  Easier to supervise

ü  Reduce work in progress (WIP)

Disadvantage of make through production system:

ü  Low productivity

ü  High labor cost

ü  Highly experience operator require

ü  This process is only suitable for highly fashion garment and sample making.

Assembly line system:

This type of production system is designed for a sequential organization. Each operator is assigned only for one operation. Garment component are move from operator to operator.

PBS (Progressive bundle system):

Parts of various components after being cut in the cutting room are tied with in bundles and distributed out to the sewing section. Bundle ticket is attached to cut parts. One operator is expected to perform the same operation on all the pieces in the bundle. Some advantage and disadvantage of PBS is as following:

Advantages:

ü  Cheap labor cost

ü  Increase productivity

ü  Better utilization of specialized machine

ü  Very low variation in the sewing

ü  Less chance for loot mix-up, shade variation and size variation

ü  Bundle tracking is very easy

Disadvantage:

ü  Slow process

ü  Line balancing is difficult

ü  Increase in WIP that increase inventory cost

ü  System is not adaptable for short run production and frequent style change

ü  High level of management skill is require

ü  Improper planning causes labor turnover, poor quality and less production so highly accurate planning is require

ü  Individual operators that work in a PBS are dependent to other.

UPS:

Similar to a relay race, each production operator has a task and passes that garment on to the next person. Normally there is only one garment between operations. The unit of production is single garment and not bundles. The garment components are automatically transported from work station to work station according to pre-determined sequence. The work station are so constructed that the components are presented as close as possible to the operator’s left and in order to reduce the amount of movement required to grasp and position and component to be sewn. All the components for one garment are loaded into a carrier at a work station specially designed for this purpose. The carrier itself is divided into sections, with each section having a quick – release retaining clamp which prevents the components from falling out during movement through the system. When a batch of garments has been loaded into carriers they are fed past a mechanical or electronic device which records the number of the carrier and addresses it to its first destination.

Advantages:

ü  Improve productivity

ü  Improve load time

ü  Minimizes WIP

ü  Improve productivity and quality monitor

ü  Improve ergonomics (to provide ease to working staff)

ü  Keep the factory floor clean

ü  Labor cost reduce

Disadvantage:

ü  High initial cost required

ü  Special training require

ü  Down time is potential problem.

Modular production system

A group of people who working together to accomplish individual goals effectively and efficiently while simultaneously accomplishing goals of the team or organization or a team is a small number of people with complementary skills who are committed to common purpose, set of performance goals, and approach for which they hold themselves mutually accountable

· The line layout is U -shaped with garments progressing around the line.

· Each operator is cross trained on a different portion of line (i.e. continuous operation) depending on skills and operation complexity. Ideally all the operators are cross trained on all the operations.

· Thus operators work to predominantly predetermined adjacent tasks.

· Each operator is assigned at least one operation.

· Operatives work on standing workstations & WIP is less

· The first and last operations are uniquely assigned to the first and last operator r

Method improvement

There are two different area of sewing for improving method

Ø  Big method

Ø  Little method

Big method:

The method which require initial cost to implement. The method include work aids, table alteration, m/c attachment etc

Ø  Auto machine

ü  Profile stitching

Ø  Loading device

Ø  Stacking device

Ø  Faster machine

Ø  Thread cutter

Ø  Folder

ü  Inbuilt UBT(Under bit trimmer)

Ø  Work aid

ü  Bin

ü  Shelves

ü  Trays etc

Ø  Needle positioner

Ø  Construction change in garments

Ø  Combine separate operation into one

Little method:

Little method is technique which requires no initial cost. The method include how operator handle work how he/she control machine and dispose the garment

Ø   Basic

ü  Correct table height

ü  Correct chair height

ü  Correct operator positing at machine

ü  Both feet on treadle

Ø  Principle of motion economy

Ø  Specific of sewing job

ü  Things to change

§  Operator idle during machine operation time on automatic machine

§  Operator pit pat the garment and dispose

§  Operator pick up dispose and pick up again

ü  Things to encourage

§  Operator locate parts close to the needle

§  Operator fold anything that need folding while moving the machine

Calculation of SAM

SAM or Standard Allowed Minute is used to measure task or work content of a garment. This term is widely used by industrial engineers and production people in the garment manufacturing industry. For the estimation of cost of making a garment SAM value plays a very important role. In past scientists and apparel technicians did research on how much time to be allowed to do a job when one follows standard method during doing the job. According to the research study minute value has been defined for each movement needed to accomplish a job. Synthetic data is available for each movement.

General Sewing Data (GSD) has defined set of codes for motion data for SAM calculation. There are also other methods through which one can calculate SAM of a garment without using synthetic data or GSD. In this article both methods are explained in the following.

Method #1: Calculation of SAM Using Synthetic Data

Step 1: 

Select one operation for which you want to calculate SAM.
Step 2: 

Study the motions of that operation. Stand by side of an operator (experienced one) and see the operator how he is doing it. Note all movement used by the operator in doing one complete cycle of work. See carefully again and recheck your note if all movement/motion are captured and correct. (For example motions are like - pick up parts one hand or two hand, align part on table or machine foot, realign plies, etc.)

Step 3: List down all motion sequentially

 Refer the synthetic data for TMU (Time measuring unit) values. For synthetic data you can refer GSD (without license use of GSD code prohibited but for personal use and study one can refer GSD code and TMU values) or Sewing Performance Data table (SPD). Now you got TMU value for one operation (for example say it is 400 TMU). Convert total TMU into minutes (1 TMU=0.0006 minute). This is called as Basic Time in minutes. In this example it is 0.24 minutes.
Step 4:

 Standard allowed minutes (SAM) = (Basic minute + Bundle allowances + machine and personal allowances). Assume bundle allowances (10%) and machine and personal allowances (20%) to basic time. Now you got Standard Minute value (SMV) or SAM. SAM= (0.24+0.024+0.048) = 0.31 minutes.

Method #2: Calculation of SAM through Time Study

Step 1:

 Select one operation for which you want to calculate SAM.
Step 2:

 Take one stop watch. Stand by side of the operator. Capture cycle time for that operation. (cycle time – total time taken to do all works needed to complete one operation, i.e. time from pick up part of first piece to next pick up of the next piece). Do time study for consecutive five cycles. Discard if found abnormal time in any cycle. Calculate average of the 5 cycles. Time you got from time study is called cycle time. To convert this cycle time into basic time you have to multiply cycle time with operator performance rating.

ASCT is average single cycle time and can be calculated by following formula

Step 3: Performance efficiency

Now you have to rate the operator at what performance level he was doing the job seeing his movement and work speed. Suppose that operator performance rating is 80%. Suppose ASCT is 0.60 minutes so target single cycle time TSCT = (0.60 X 80%) = 0.48 minutes

TSCT is target single cycle time and can be calculated by

TSCT= ASCT*rating or efficiency

Step 4: Standard allowed minutes

SAM = TSCT * (1 + MDA% + PF %) + BHT.

MDA is machine delay allowance

PF is personal fatigue

BHT is bundle handling time (standard)

Suppose bundle allowances (10%) and machine and personal allowances (20%) to TSCT. Now you got Standard Minute value (SMV) or SAM. SAM= 0.624 minutes.

There are two schools of thoughts

·         One say’s SAM and SMV are same

·         Other say SAM and SMV are different

Straight Knife Cutting Machine

Straight Knife Cutting Machine:

It is the most useful cutting instrument in apparel cutting. In apparel industry, more than 99% cases this knife is used. This machine is called straight knife cutting machine because its cutter is straight in shape. It is used for both woven & knit fabric. In this machine different types of straight knife are used according to the different cutting objects. This machine provides good efficiency. 

 

Fig: Straight Knife Cutting Machine

Features of Straight Knife Cutting Machine: 

1. The main parts of this machine are straight knife, electric motor, handle, grinder, base plate, stand/ knife holder, lubricating unit, wheel etc.
2. Could be used to cut higher depth of fabric.
3. Knife height is 10 cm to 33 cm.
4. Knife stroke is 2.5 cm to 4.5 cm.
5. Motor r.p.m. is 3000 to 4000.
6. Auto grinder is used.
7. Auto lubricating unit works for this machine.
8. Different types of knife edge are used for cutting different objects. Such as, straight edge, wave edge, sew edge & serrated edge.
9. A Handle for the cutter to direct the Knife.
10. Knife guard is attached to the front of the knife.
11. Sharp & heavy corners can be cut.
12. Maximum 70% of knife height is used for fabric lay.
13. Wheels are under the base plate to move the machine smoothly.
14. Machine weight is around 12-15 kg.
15. Knife cut the fabric very fast due to high speed of motor. That increases the risk of fabric damage.

Advantages of Straight Knife Cutting Machine: 

1. A large number of fabric lays can be cut by the machine due to high length of knife & r.p.m. of the motor. So, productivity is high.
2. Automatic grinding.
3. Automatically lubrication.
4. Comparatively cheep.
5. Can be moved easily by wheel.
6. Suitable for straight line & curve line.
7. Can be cut high curve line than round knife.
8. Fabric can be cut from any angle.

Disadvantages of Straight Knife Cutting Machine: 

1. High speed of the machine causes high risk of damage.
2. Faulty knife could damage fabric layer.
3. Motor weight creates knife deflection which may be creates faulty pieces.
4. Risk is high for physical damage of operator.
5. Knife required to replace.

Round Knife Cutting Machine

Round Knife Cutting Machine:

This machine is called round knife cutting machine because its cutter is round but slightly octagonal in shape. This machine is small in size, flexible & used for small production. It is also a popular cutting machine. 

 

 

 

 

Fig: Round Knife Cutting Machine

Features of Round Knife Cutting Machine: 

1. It contains a round but slightly octagonal type knife with sharp edge.
2. The other main parts of this machine are base plate, electric motor, handle & knife guard.
3. Knife diameter varies from 6-20 cm.
4. Manual grinder is used.
5. Motor r.p.m. is 800-1600.It depends on machine.
6. A handle for the cutter to direct the knife.
7. Easy to handle & movement due to low weight.
8. Knife is lubricating manually.
9. Three types of knife edge can be used for cutting different objects. Such as, waved edge, toothed edge & circular edge.
10. A round knife rotating so that the leading edge cuts downwards into the fabric.
11. Flexible movement helps to cut non linear shape.
12. Base plate gives support for fabric.
13. Maximum 40% of the knife diameter can be used for fabric lay.

Advantage of Round Knife Cutting Machine: 

1. Suitable for cutting single ply as well as multilayer (say 20-30layers).
2. Easy to handle & operate.
3. Suitable for small scale cutting.
4. Suitable for gentle curve line cutting.
5. To cut the larger part of the garments.
6. With a same r.p.m. its efficiency is 10 times greater than the straight knife.

Disadvantage of Round Knife Cutting Machine:

1. Very low r.p.m. & knife height.
2. Manual grinder is used.
3. Low productivity since few number of lay can be cut.
4. Difficult to cut small components & high curve line.
5. Not suitable for large production.
6. Lubrication is manually done.

Uses/Application of Round Knife Cutting Machine: 
It’s useful for gentle curve line cutting, big parts cutting, cutting out fabric block from lay & small scale cutting. It’s normally use for small production. 

Band Knife Cutting Machine

Band Knife Cutting Machine:

Band knife cutting machine is an endless and looks like a loop. It is used for the cutting of fabric rolls without cardboard-inner tube. It is important instrument of cutting fabrics. This cutting machine works automatically according to the height of the relevant material. This machine is with special blower decreases resistance between fabrics and table,which enables the fabrics be moved easily and be cut precisely. And it could adjustable speed to fit different fabrics. Band knife cutting machines have been recognized around the world for many years for their high quality even when faced with difficult customer-related conditions and in applications with demanding materials. 

Fig: Round Knife Cutting Machine

Features of Band Knife Cutting Machine::

1. It comprises a series of three or more pulleys,which provide the continuous rotating motion of the knife .
2. An endless knife is used here.
3. Knife is usually narrower than on a straight knife.
4. A large size of table is used to support the fabric & for cutting.
5. Air blower blows the air to minimize the weight of fabric.
6. Balls in air blower help to move the fabric in different direction.
7. Automatic grinder is used.
8. In this method machine is stationary but fabric is movable.
9. High speed r.p.m. motor is used.
10. Required a large space for it.
11. This is like a saw mill cutter.
12. Knife life time depends on fabric type & uses of machine.

Advantages of Band Knife Cutting Machine: 

1. Suitable for any types of line.
2. Very large productivity for limited product
3. Such as collars, cuff, placket etc.
4. Automatic grinder grind the knife instantly
5. Air blower helps to reduce the fabric weight which increases smooth movement of fabric.
6. Possible to cut 90⁰ angle of the lay.
7. Intensity of accident is low.

Disadvantages of Band Knife Cutting Machine:

1. Not suitable for large component due to the length of the table.
2. Work load is high as machine is stationary & fabric is movable.
3. Running cost is higher.
4. Required fix space.
5. Not possible to cut fabric directly. 

Process Sequence in Cutting Room

Cutting section is one of the most important section for manufacturing garments in Garments Factory.There is a process or sequence which is strictly followed in the cutting section of a garment manufacturing industry.

Process Sequence in Cutting Room: 

Marker Making
↓
Fabric Spreading
↓
Placing Marker Paper on to the Lay
↓
Fabric Cutting
↓
Numbering
↓
100% checking & Parts Replacing if needed.
↓
Shorting & Bundling
↓
Sewing/Assembling

Operation of Cutting During Garments Manufacturing are given below in details: 

Marker Making:
The measuring department determines the fabric yardage needed for each style and size of garment. Computer software helps the technicians create the optimum fabric layout to suggest so fabric can be used efficiently. Markers, made in accordance to the patterns are attached to the fabric with the help of adhesive stripping or staples. Markers are laid in such a way so that minimum possible fabric gets wasted during cutting operation. After marking the garment manufacturer will get the idea of how much fabric he has to order in advance for the construction of garments. Therefore careful execution is important in this step.Computer marking is done on speciallized softwares. In computerized marking there is no need of large paper sheets for calculating the yardage, in fact, mathematical calculations are made instead to know how much fabric is required.

Fabric Spreading:
With the help of spreading machines, fabric is stacked on one another in reaches or lays that may go over 100 ft (30.5 m) long and hundreds of plies (fabric pieces) thick.

Cutting:
The fabric is then cut with the help of cloth cutting machines suitable for the type of the cloth. These can be band cutters having similar work method like that of band saws; cutters having rotary blades; machines having reciprocal blades which saw up and down; die clickers similar to die or punch press; or computerized machines that use either blades or laser beams to cut the fabric in desired shapes.

Sorting/Bundling:
The sorter sorts the patterns according to size and design and makes bundles of them. This step requires much precision because making bundles of mismatched patterns can create severe problems. On each bundle there are specifications of the style size and the marker too is attached with it.

Sewing/Assembling:
The sorted bundles of fabrics are now ready to be stitched. Large garment manufacturers have their own sewing units other use to give the fabrics on contract to other contractors. Stitching in-house is preferable because one can maintain quality control during the processing. On the other hand if contractors are hired keeping eye on quality is difficult unless the contactor is one who precisely controls the process.

There are what is called sewing stations for sewing different parts of the cut pieces. In this workplace, there are many operators who perform a single operation. One operator may make only straight seams, while another may make sleeve insets. Yet another two operators can sew the waist seams, and make buttonholes. Various industrial sewing machines too have different types of stitches that they can make. These machines also have different configuration of the frame. Some machines work sequentially and feed their finished step directly into the next machine, while the gang machines have multiple machines performing the same operation supervised by a single operator. All these factors decide what parts of a garment can be sewn at that station. Finally, the sewn parts of the garment, such as sleeves or pant legs, are assembled together to give the final form to the clothing.

process Sequence of Garments Manufacturing

The clothing creation running actions and methods included in the developing outfits for the huge of creation in company time frame for company reasons is known as outfits developing technologies. On industrial basis there are certain areas or sequence through which garments are manufactured.

Stepwise garments manufacturing sequence on industrial basis is given below:

Design / Sketch

↓

Pattern Design

↓

Sample Making

↓

Production Pattern

↓

Grading

↓

Marker Making

↓

Spreading

↓

Cutting

↓

Sorting/Bundling

↓

Sewing/Assembling

↓

Inspection

↓

Pressing/ Finishing

↓

Final Inspection

↓

Packing

↓

Despatch

Sequence of Garments Manufacturing are given below in details: 

1. Design/ Sketch: 

In the garment manufacturing the first step is designing the sketch for the dresses that have to be prepared. For this purpose the designer first draw several rough sketches in the sketch book. The designer does not go for details at this moment but he rather let his creativity flow on the paper and he draws many sketches. Later these sketches are analyzed by a panel of designers. They finally select few out of them. These few sketches are rendered in detail separately or in the form of a single collection. The designer also draws working drawings along with the sketch. Working drawings are flat drawing of the sketch and it help pattern maker in understanding the patterns involved in the construction.

2. Pattern Design: 

Hard paper copy of each component of the garment of exact dimension of each component is called pattern. The patterns also include seam allowance, trimming allowance, dirts, and pleats, ease allowance, any special design etc affairs. Pattern design could also be done manually or with the help of computer.

3. Sample Making: 

The first patterns are sent to the sewing unit for assembling them into garment. This is usually stitched on calico or muslin which is an inferior quality of fabric and it reduces cost. This sample is constructed to analyze the pattern fit and design too. After the sample garment is stitched it is reviewed by a panel of designers, pattern makers and sewing specialists. If any changes have to be made they are made at this time.

4. Production Pattern: 
The pattern design is now taken for creating the production patterns. The production pattern is one which will be used for huge production of garments. The pattern maker makes the patterns on standard pattern making paper. These papers are made-up of various grades. The most important component, the tissue paper pattern, is made from the lightest and thinnest paper commercially available (it is not made at the pattern companies). It is called 7.5 lb (3.4 kg) basis paper, meaning that a ream of it (500 sheets) only weighs 7.5 lb (3.4 kg).

Garment patterns can be constructed by two means: manual method, CAD/CAM method. Today many companies have developed CAD/CAM because of the ease of designing patterns, fluency and precision involved which cannot be guaranteed with the manual method. Investing once into the CAD/CAM unit is worth in itself. Many buyers around the world prefer manufacturers who are using CAD/CAM methods. The production patterns created in CAD/CAM can be stored easily and they can be modified at any point of time.

A garment sewing pattern or garment fabric & patterns draft is developed by calculating, taking account of the following measurements: -

1. Direct Sample.
2. Specification Sheet/ Measurement Chart.
3. Actual body size measurements.
4. Ease Allowances.
5. Sewing Allowance.

These allowances are different for different type of fabrics and patterns.

5. Grading: 

The purpose of grading is to create patterns in different standard sizes. Grading a pattern is really scaling a pattern up or down in order to adjust it for multiple sizes. Pattern sizes can be large, medium and small or else there are standard patterns of size 10, 12, 14, 16 and so on for different figure and statures sizes. This is generally how we get S M L XL XXL sizing. Pattern grading by manual method is a cumbersome task because the grader has to alter the pattern on each and every point from armhole, to neckline, sleeve cap and wrist etc. by using CAD it is much easier and faster.

6. Marker Making: 

All the pattern pieces for all the required sizes are arranged n the paper in such a way so that maximum number of garments could be produced with minimum fabric wastag4e. Markers are made for 6, 12, 18, 24 etc. pieces. Marker is also useful to estimate fabric consumption calculations.

7. Spreading: 

It is the process of arranging fabrics on the spreading table as per length and width of the marker in stack form. Normally height of the lay/fabric is limited upto maximum six inches high. But 4 inch to 5 inch height of the lay is safe.

8. Fabric Cutting:

 On the fabric lay/spread the marker paper is placed carefully and accurately, and pinned with the fabric to avoid unwanted movement or displacement of the marker paper. Normally straight knife cutting machine is used to cut out the garment component as per exact dimension of each patterns in stack form, care must be taken to avoid cutting defects.

9. Sorting/ Bundling: 

After cutting the entire fabric lay, all the garments components in stack form is shorted out as per size and color. To avoid mistake in sorting, it is better to use code number on each pattern.

10. Sewing or Assembling:

 It is the most important department/ section of a garment manufacturing industry. Sewing machines of different types are arranged as a vertical line to assemble the garments. Sequence of types of sewing machine arrangement depends on sequence of assembling operations. Number of sewing machine per line varies from 20 nos to 60 nos depending on the style of the ga4rmnet to be produce. Production pr line pr hour also varies from 100 to 150 pieces depending on specific circumstances. Number of sewing machine arrangement per line may be upto 60 depending on design and out put quantity of garment.

11. Inspection: 

Each and every garment after sewing passes through the inspection table/ point, where the garments are thoroughly and carefully checked to detect/find any defect if present in the garment. The defects may be for example variation of measurement, sewing defect, fabric defects, spots etc. if the defect is possible to overcome, then the garment is sent to the respective person for correction. If the defect is not correctionable, then the garment is separated as wastage.

12. Pressing/ Finishing: 

After passing through the inspection table, each garment is normally ironed/ pressed to remove unwanted crease and to improve the smoothness, so that the garments looks nice to the customer. Folding of the garment is also done here for poly packing of the garments as per required dimension.

13. Final Inspection:

 It is the last stage of inspection f the manufactured garments on behalf of the garment manufacturing organization, to detect any defective garments before packing.

14. Packing: 

 After final inspection, the garments are poly-packed, dozen-wise, color wise, size ratio wise, bundled and packed in the cartoon. The cartoon is marked with important information in printed form which is seen from outside the cartoon easily. 

15. Despatch: 

The cartoons of the manufactured garments are delivered or placed in the despatch department or finished product godown, from where the garments lot is delivered for shipment.

Different Sections Garment manufacturing industry

Here are all of the sections of a garment industry have been described briefly. 

1. Sample section
2. Cutting section
3. Sewing section
4. Finishing section

1. Sample Section :
It is the first section of garment manufacturing process. This section is used in apparel industry for-

a) To make sample garment for approval.
b) To make pattern sets for bulk production when needed.

2. Cutting Section : 
It is the second section of apparel manufacturing. In this section the following works are completed-

a) Marker Making
b) Fabric Spreading
c) Fabric Cutting

3. Sewing Section : 
Garment’s cut parts are assembled here.

4. Finishing Section : 
It is the last step of garment making. All of the finishing processes are done here. Let yourself know what kinds of work are to be carried out in this segment-

a) Pressing/ Ironing
b) Packing
c) Cartooning &
d) Arranging final inspection and shipment. 

Process Flow Chart of Merchandising and its function

Merchandising

Merchandising is the department which mediates marketing and production departments.It is the methods, practices, and operations used to promote and sustain certain categories of commercial activity.It includes directing and overseeing the development of product line from start to finish. Marketing and merchandising department: A team of merchandisers and marketers work together under a profit controls head. Merchandisers handle the foreign buyers. The teams are made according to the buyers being handled.

Merchandiser
The person who is related in merchandising is called merchandiser. The merchandiser coordinates with the design team to effectively present the product or product line. He or she develops colors and specifications, and performs market research to determine the most effective ways to sell and promote the product. This person needs strong communication and negotiation skills and visual and analytical abilities. He or she also needs to be a creative and innovative thinker.

Types of Merchandising:

Two type of merchandising done in garment exports

1. Marketing merchandising.
2. Product merchandising.

Marketing Merchandising:
Main function of marketing merchandising is

1. Product Development
2. Costing

Ordering Marketing merchandising is to bring orders costly products development and it has direct contact with the buyer. 

Product Merchandising:
Product merchandising is done in the unit. This includes all the responsibilities from sourcing to finishing i.e. first sample onwards, the products merchandising work start and ends till shipment.

A Merchandisers key responsibility is as follows:

• Product Development
• Market and product Analysis
• Selling the concept
• Booking orders
• Confirming Deliveries
• Designing and Sampling
• Costing
• Raw Material
• Flow Monitoring
• Production Follow Ups
• Payments Follows
• Internal & external communication,
• Sampling
• Lab dips
• Accessories & trims
• Preparing internal order sheets
• Preparing purchase orders
• Advising and assisting production,
• Advising quality department about quality level
• Mediating production and quality departments
• Giving shipping instructions and following shipping,
• Helping documentation department
• Taking responsibility for inspections and
• Following up the shipment. 

Structure and Functioning of Merchandising

 

Process Flow Chart of Merchandising: 

Receive product package form buyer 
↓ 
Sample development 
↓ 
Price negotiation 
↓ 
Order confirmation and receive order sheet. 
↓ 
Sourcing low good quality right time 
↓ 
Material collection and receive it in factory 
↓ 
Check and listing 
↓ 
Swart card making and approval 
↓ 
Pre production meeting 
↓ 
Daily collect daily production report and daily quality report 
↓ 
Arrange final inspection 
↓ 
Shipment