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internship Report on Masood Textile

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         INTERNSHIP REPORT

                   ON

   MASOOD TEXTILE MILLS (Pvt) LTD.
        (Apparel Division Fsd.)

                   By
       Muhammad Shafiq Shahid
            S/O Rafiq Ahmad
              Roll No. 1622
      MBA (MKT. 2) Final Semester




  Department of Management Sciences,
Govt. College University Fasialabad.
                                          Masood Textile Mills Fsd.
                              TO BE THE WORLD BEST APPAREL COMPANY




  In the name of Allah,

  Most Benevolent, Ever - Merciful.

  All Praise be to Allah

  Lord of All worlds.

  Most beneficent, Ever- Merciful,

  King of the Day of Judgment,

  You alone we worship to you.

  Alone we turn for help.

  Guide us (O Allah) to the path that is straight,

  The path of those you have blessed,

  Not of those who have earned you anger,

  Nor those who have gone astray.




                          2



Prepared By: Muhammad Shafiq Shahid (MBA. Marketing)
  Department of Management sciences, GCUF. - 2 -
                                                                       Masood Textile Mills Fsd.
                                                      TO BE THE WORLD BEST APPAREL COMPANY




   All praises to Almighty Allah alone, the Most Merciful and the most compassionate and His Holy
Prophet “ Muhammad” (Peace be Upon Him) the most perfect and exalted one among and of ever
born on the surface of earth, who is forever touch of guidance and knowledge for the humanity.
   The work presented in this manuscript was accomplished under the guidance generous assistance,

constructive criticism and enlightened supervision of   Venerated Mr. Syed Urfi Hashmi.
His efforts towards the inculcation of spirit of constant work and the maintenance of professional integrity
besides other invaluable words of advise will always serve as beacon of light through out the course. I
take this humblest opportunity to my deepest sense of gratitude and thankfulness to him.
   “No one writes alone”. This internship report is not the result of individual effort. It is a result of
wonderful team- work.

   I am really thankful of Venerated    Mr. Nasir Zia who is Manager of human resource of
MTM Apparel Division arrange all the lecture of internship related to Apparel Division activities. I am also

really thankful of   Venerated Mr. Muhammad Imran                             who is Assistant Manager of

Human Resource of MTM Apparel Division arrange all the lecture of internship related to Apparel

Division and control the student attendance. I am really thankful to               Venerated Mr.
Muhammad Fiaz & Mr. Ahmad Faraz who is working in MTM provided all
information related to my Internship. I am really thankful to Mr. Hashim who is PPC officer
(Production, planning & control) of MTM Apparel Division (jameelabad) provided all information related to
production and PPC.
   I am thankful to all those who supported us and provide great help for completion of this task. I am

tried our level best to prepare this event with high level of accuracy but no one claim to perfect other than


                                                  3



                     Prepared By: Muhammad Shafiq Shahid (MBA. Marketing)
                       Department of Management sciences, GCUF. - 3 -
                                                       Masood Textile Mills Fsd.
                                           TO BE THE WORLD BEST APPAREL COMPANY
ALMIGHTY ALLAH.




         Dedication


                  To my Teachers,

                             The motivation for all that we do.

                  To my Friends,

                        Who share their knowledge and experience with me in

                        learning process.

                  To my parents,

                              Who always prayed for our success and

                  their love and affection have always been a source

                  of inspiration for us.




                                       4



             Prepared By: Muhammad Shafiq Shahid (MBA. Marketing)
               Department of Management sciences, GCUF. - 4 -
                                                      Masood Textile Mills Fsd.
                                           TO BE THE WORLD BEST APPAREL COMPANY
Table Of Contents

          Title                                 Page #
          Company Information                   6
          Key Personnel’s                       7
          History                               9
          Vision & Mission Statement            10
          Organization’s values                 11
          Quality policy                        12
          About Company                         13
          Corporate Objectives                  15
          Employees                             16
          Structure                             17
          Departments                           18
          Vertical Operations                   19
          Apparel Division                      20
          Back Track System                     21
          Rewards                               22
          Marketing Departments                 23
          Situation Analysis                    28
          PPC Department                        31
          Stores                                33
          Flow Of Garments                      34
          Quality Control Department            45
          IT Department                         47
          HR Department                         48
          Finance Department                    52

          Suggestions                           53




                                       5



            Prepared By: Muhammad Shafiq Shahid (MBA. Marketing)
              Department of Management sciences, GCUF. - 5 -
                                                        Masood Textile Mills Fsd.
                                            TO BE THE WORLD BEST APPAREL COMPANY
Company Information:

             Key personnel


                 Chief Executive                    Ch. Shahid Nazir

                 Director Finance                   Muhammad Farooq

                 General Manager (Marketing)        Tayyab Masood

                 General Manager                    Amer H. Khan

                 General Manager (Operation G1)     Kamal Anjum

                 General Manager (Operation G2)     Atta-ullah




Key personnel:

                                        6



             Prepared By: Muhammad Shafiq Shahid (MBA. Marketing)
               Department of Management sciences, GCUF. - 6 -
                                          Masood Textile Mills Fsd.
                              TO BE THE WORLD BEST APPAREL COMPANY
 Finance Manager                       Muhammad Binyamin

 IT Manager                            Shakeel Ahmed Shah

 Sen. Manager PPC                      Muhammed Imitiaz

 Manager of Accounts                   Zafar Iqbal

 Manager HRM                           Nasir Ali Zia

 Purchase Manager                      Mr. Muhammad Ismail

 Technical Manager                     Mr. Ashiq Shahzad

 Production Manager                    Mr. Muhammad Arif

 Production Manager                    Mr. Muhammad Naveed

 Merchandising Manager                 Mr. Tanveer A Khan

 Merchandising Manager                 Mr. Anwar lattif

 Merchandising Manager                 Mr. Shahzad Nadeem

 Merchandising Manager                 Mr. Mehmood Elahi

 Production Manager                    Mr. Adnan Ghaffar Piracha

 Production Manager                    Mr. Zahid Mehmood

 Cutting Manager                       Mr. Usman Massod

 Compliance Manager                    Mr. Nasir Mehmood

 Inventory Manager                     Mr. Rashid Mehmood




                          7



Prepared By: Muhammad Shafiq Shahid (MBA. Marketing)
  Department of Management sciences, GCUF. - 7 -
                                             Masood Textile Mills Fsd.
                                 TO BE THE WORLD BEST APPAREL COMPANY

Mills:

32_ km Sheikhupura road, Faisalabad

Apparel Division:
Sargodha Road Faisalabad, Pakistan

Head Office:

Universal House West Canal road Faisalabad

Lahore Office:

16/3A, Eden Homes, Main Gulberg, Lahore

Phone:

(92-41) 787931-34, 783890, 787391

Fax:

(92-41) 781361

Web Site:

WWW.Masoodtextile.com



                             8



   Prepared By: Muhammad Shafiq Shahid (MBA. Marketing)
     Department of Management sciences, GCUF. - 8 -
                                              Masood Textile Mills Fsd.
                                  TO BE THE WORLD BEST APPAREL COMPANY



History Of Masood Group:

     Kohistan Bus Services                 1973

     Masood Textile Mills

                     Spinning              1984

                     Garments              1995

     Industrial Co-Operative Bank          1994

     Rabia Trust Hospital                  1994

     KakaKhel Ghee Mills                   1994




                              9



    Prepared By: Muhammad Shafiq Shahid (MBA. Marketing)
      Department of Management sciences, GCUF. - 9 -
                                                 Masood Textile Mills Fsd.
                                      TO BE THE WORLD BEST APPAREL COMPANY




                              Vision


                To be the world’s Best Apparel Company.


                      Mission Statement


“We value quality in our products and in our relationships with customers and
      suppliers. We consider our employees our more critical resource.”




                                 10



        Prepared By: Muhammad Shafiq Shahid (MBA. Marketing)
         Department of Management sciences, GCUF. - 10 -
                                           Masood Textile Mills Fsd.
                                TO BE THE WORLD BEST APPAREL COMPANY




Organization’s Values:


                    Trust


                    Integrity


                    Respect




                           11



  Prepared By: Muhammad Shafiq Shahid (MBA. Marketing)
   Department of Management sciences, GCUF. - 11 -
                                            Masood Textile Mills Fsd.
                                 TO BE THE WORLD BEST APPAREL COMPANY



Quality Policy:



      Customer’s satisfaction



      Zero Defects



      TQM. (Total Quality Management)




                            12



   Prepared By: Muhammad Shafiq Shahid (MBA. Marketing)
    Department of Management sciences, GCUF. - 12 -
                                                                    Masood Textile Mills Fsd.
                                                       TO BE THE WORLD BEST APPAREL COMPANY
About Company:


        M       asood Textile Mills Limited was established in 1984 by Ch. Nazir Ahmad, which is
                located at 32 – km Sheikhupura Road Faisalabad. While Apparel division is located in
Faisalabad at Sargodha Road near Sangeet cinema, which is producing best quality garments. The
preference is given on the quality not quantity. That’s why company’s sale is increasing every year.
The company has shown distinguish achievements during many previous years. Masood Textile Mills
have own in-house


        Knitting
        Spinning
        Ginning
        Dyeing
        Processing
        Laundry
        Manufacturing facilities
    Masood Textile Mills has also proud of work with world best Labels like
        Saralee          (Polo Ralph Lauren, Champion, Hanes)
        JC Penney        (Stafford, Arizona, St. John’s Bay)
        War Naco         (Chaps Ralph Lauren, Calvin Klein)
        Indus            (Vantage, Champs, Tom Tailer)
        Tommy Hil Figer
        Vanity fair      Lee, Wrangler
        Perry Ellis
        Levi’s
        Dockers
        Integrity
        Duckhead

                                                  13



                      Prepared By: Muhammad Shafiq Shahid (MBA. Marketing)
                       Department of Management sciences, GCUF. - 13 -
                                                          Masood Textile Mills Fsd.
                                               TO BE THE WORLD BEST APPAREL COMPANY


      Most of the products are exported to US. UK. & Germany.
      Different departments of MTM are equipped with modern technology
imported from Switzer Land, Germany, England, and Japan to achieve the
required quality. Masood has research and development laboratory for spinning
process where cotton and yarn is tested and inspected according to international
standards.
      MTM has obtained ISO 9002 certificate, which proved its quality and
consistency, MTM has 20,000,000 ordinary shares of Rs. 10 each fully paid up in
cash. MTM has extention in his operations by adding new equipment and
machinery in near past.
    Automatic cone winding machines enhanced the production capacity of yarn
from 210 bags to 400 bags. To enhance the efficiency and quality some
investment is made in other machines. Which would be very beneficial for the
company in the upcoming trade challenging.




                                          14



                 Prepared By: Muhammad Shafiq Shahid (MBA. Marketing)
                  Department of Management sciences, GCUF. - 14 -
                                                      Masood Textile Mills Fsd.
                                           TO BE THE WORLD BEST APPAREL COMPANY



   Corporate Objectives:

 Maximization of wealth of shareholders.


 To increase the market share.


 To achieve the customer satisfaction.


 Making arrangements toward achieving total quality standards.


 To get growth through professional Management.


 To reduce the cost of production up to minimum level.


 To continue to improve past achievements.


 To lead the local manufacturers.




                                      15



             Prepared By: Muhammad Shafiq Shahid (MBA. Marketing)
              Department of Management sciences, GCUF. - 15 -
                                                            Masood Textile Mills Fsd.
                                                 TO BE THE WORLD BEST APPAREL COMPANY



Employees:

    Permanent Employees:


                     Mills          2200
                     Garments       4000
    Total employees                         6200


    Piece Rate Workers:
                     Mills           800
                     Garments       1600
                                            2400


    Grand Total:                            8600




                                            16



                   Prepared By: Muhammad Shafiq Shahid (MBA. Marketing)
                    Department of Management sciences, GCUF. - 16 -
                                                        Masood Textile Mills Fsd.
                                           TO BE THE WORLD BEST APPAREL COMPANY
Masood Structure

     Management:


              G - 1- 4        General Manager
                M-1           Senior Manager
                M-2           Manager
                M-3           Deputy Manager
                M-4           Assistant Manager
                M-5           Unit Manager / Senior Officer
                M-6           Management Trainee


    Non- Management:


                S–1           Supervisor
                S–2           Skilled Worker
                S–3           Semi Skilled Worker
                S–4           Unskilled Worker




                                      17



             Prepared By: Muhammad Shafiq Shahid (MBA. Marketing)
              Department of Management sciences, GCUF. - 17 -
                                                          Masood Textile Mills Fsd.
                                               TO BE THE WORLD BEST APPAREL COMPANY
Departments:


     Operations
                   Production
                   PPC
                   I.E.
                   Cutting
                   Quality Control
                   Commercial


     Services
                   HR & Admin
                   IT.
                   Compliance
                   Security
                   Purchases
                   Quality Assurance
     Marketing
                   Merchandising
                   Prod. Dev.
                   Forwarding
                   Procurement


     Finance
                   Accounts
                   Inventory


                                          18



                 Prepared By: Muhammad Shafiq Shahid (MBA. Marketing)
                  Department of Management sciences, GCUF. - 18 -
                                                          Masood Textile Mills Fsd.
                                             TO BE THE WORLD BEST APPAREL COMPANY



Vertical Operations:

                       Spinning
                       Knitting
                       Fabric dying             Mills
                       Processing
                       Laundry

                       Cutting
                       Stitching                Apparel Division
                       Finishing
                       Packing




                                        19



               Prepared By: Muhammad Shafiq Shahid (MBA. Marketing)
                Department of Management sciences, GCUF. - 19 -
                                                        Masood Textile Mills Fsd.
                                          TO BE THE WORLD BEST APPAREL COMPANY
Apparel Division:

            Established in 1995 to enter into value added field.


            Now it has 22 Production Units With 2200 Stitching Machines.


            Each and every operation has been linked with back track system.


            An independent Quality Assurance team exists to ensure the quality of the
     garments.


            Garments Production Procedure (Cutting, stitching, clipping, finishing &
     packing)


            Total production is 2.0 – 2.5 Million per Month of garments like Tops,
     bottoms, Inner and outerwear.


            In house embroidery facility having to tajima machines as well.


            95% of production is exported to US and 5% export to Europe.




                                     20



         Prepared By: Muhammad Shafiq Shahid (MBA. Marketing)
          Department of Management sciences, GCUF. - 20 -
                                                    Masood Textile Mills Fsd.
                                        TO BE THE WORLD BEST APPAREL COMPANY




Back Track System:



            Each Garment produced at Masood has a unique ID No.


            Latest Computerized Bar Code system ensures quality in every
            operation of production from cutting to Packing.


            Products at each operation carry Bar_ Code Stickers that bear all the
            details and history of the operations on that product. Hence if any
            problem occurs, one can trace back the root cause of problem to
            prevent its occurrence in future.




                                   21



          Prepared By: Muhammad Shafiq Shahid (MBA. Marketing)
           Department of Management sciences, GCUF. - 21 -
                                                          Masood Textile Mills Fsd.
                                               TO BE THE WORLD BEST APPAREL COMPANY



Rewards:


    The Logic


                 Profit sharing among all level of employees
                 Motivation and compensation
                 Competition for improvement
                 Productivity improvement
                 Extra earning
    Performance Rewards
    Unit of the Month
    Best cutting group
    Best in line Inspector
    Best final Inspector




                                          22



                 Prepared By: Muhammad Shafiq Shahid (MBA. Marketing)
                  Department of Management sciences, GCUF. - 22 -
                                                                 Masood Textile Mills Fsd.
                                                   TO BE THE WORLD BEST APPAREL COMPANY



Marketing Department:

            Marketing Department cannot be ignored in any organization. Because it is the heart
& soul of the organizations.
            MTM cannot ignore the pivotal importance of this department. The marketing
manager with the Chief Executive officer performed the marketing activities jointly. They not only
promote their department but also visit the foreign markets to search their new customers.


Marketing Manager performs the following activities,


                  Look overall problems of the departments and the problems faced by the
                     customers.
                  Devises all the marketing related policies.
                  Delights the customers by solving their problems.
                  Co-ordinates with the merchandising department.
                  Checks and observes all the activities of textile sectors especially keeping
                     focus on the competitors activities.




            The marketing department with the help of merchandising department makes it
    possible that the order place by the customers should be completed within specified time.
            MTM sell the product with the brand name of the customers.




                                              23



                  Prepared By: Muhammad Shafiq Shahid (MBA. Marketing)
                   Department of Management sciences, GCUF. - 23 -
                                                             Masood Textile Mills Fsd.
                                                TO BE THE WORLD BEST APPAREL COMPANY
Marketing Mix:
Product Mix.
        Products of Masood Textile Mills are cotton/ synthetic fiber yarn, knitted / dyed
fabrics and garments. MTM exports whole of its products to US, Germany and various other
country. Major portion of yarn are used in manufacturing process and surplus is exported.


        Fabric:
            It is divided into two types
                a) Gray- Fabric
                b) Other Fabric


        Garments:


                        Trousers
                        T-Shirts
                        Hooded Shirts
                        Sweat Shirt
                        Zip Shirt
                        Open Front Shirt
                        Dress Shirt
                        Under Garments
                        Shorts
                        Golf Shirts
                        Base ball Shirt
                     Tennis Shirt


                                           24



             Prepared By: Muhammad Shafiq Shahid (MBA. Marketing)
              Department of Management sciences, GCUF. - 24 -
                                                                   Masood Textile Mills Fsd.
                                                     TO BE THE WORLD BEST APPAREL COMPANY



Pricing:

            A little can be said about the pricing strategies of Masood textile Mills. Basically any
kind of strategy is composed of two variables.


    1. Fixed cost
    2. Variable cost


        MTM is adopting much kind of strategies; as for price setting is concern these are
    different, if the company export directly or in other case indirectly its products.
        As for as the direct export is concern the price is settled as follow


 Fixed cost+ Variable cost+ % of profit


In case, the company export indirectly the price will be settled as follow.


            Fixed cost+ Variable cost+ Middleman commission+ % of profit
    But usually MTM sets its products prices through negotiation with its buyers. And normally
MTM Charges very high prices due to its commitment with high quantity.




                                                25



                  Prepared By: Muhammad Shafiq Shahid (MBA. Marketing)
                   Department of Management sciences, GCUF. - 25 -
                                                                    Masood Textile Mills Fsd.
                                                      TO BE THE WORLD BEST APPAREL COMPANY
Physical Distribution:
             MTM exports its products through two different marketing channels.


Direct Marketing Channels:


             MTM directly contact with its customers through mail, telephone, and personal
contacts and sell its products directly to the ultimately buyers.


Indirect Marketing Channels:


             When it comes to indirect marketing channel, distribution is made through
intermediaries. MTM exports its products through many agents in some cases.
             MTM is using different channels of transportation for the distribution of its products
like, ships, trucks etc.


Countries of Export:


             MTM is making a good effort to increase the market share. Today company is
exporting its products to many countries like,
                  o USA.
                  o Hong Kong
                  o Japan
                  o Germany
                  o Malaysia
                  o Singapore
                  o Korea
                  o Thailand

                                                 26



                   Prepared By: Muhammad Shafiq Shahid (MBA. Marketing)
                    Department of Management sciences, GCUF. - 26 -
                                                                   Masood Textile Mills Fsd.
                                                      TO BE THE WORLD BEST APPAREL COMPANY



Promotional Activities:

                Major export of MTM is made through telle-mail services. Many contracts are settled
     through personal sitting. MTM do not waste any chance to promote its product. MTM
     participate in various exhibitions that take place under export promotion bureau in different
     areas of the worlds.
                MTM also take part in world trade show for promoting its products. It also sends
     many samples to its potential customer. Promotion is one of the four major important
     elements. The main promotion tools are advertising and other country business relationship.
     The MTM should advertise its products not only in the worlds trade magazine also in national
     industry magazine. The company has to decide how to set the promotion budget. The
     appropriate budget approach is to send the company can afford with respect to its funds and
     product.




                                                 27



                     Prepared By: Muhammad Shafiq Shahid (MBA. Marketing)
                      Department of Management sciences, GCUF. - 27 -
                                                          Masood Textile Mills Fsd.
                                               TO BE THE WORLD BEST APPAREL COMPANY




                                            Situation Analysis




           Internal Analysis                                                External Analysis




Strength                       Weaknesses                          Opportunities          Threats




      Internal                        S                       W


      External
                                      O                        T




                                          28



              Prepared By: Muhammad Shafiq Shahid (MBA. Marketing)
               Department of Management sciences, GCUF. - 28 -
                                                                 Masood Textile Mills Fsd.
                                                   TO BE THE WORLD BEST APPAREL COMPANY
Situation Analysis:

              Mangers of MTM always review the mission and goals then they can do the internal
     and external environment analysis to identify elements that influence the organization
     performance. To determine such elements SWOT analysis is conducted. SWOT analysis is
     the method that helps manager identifies the organizational strength, weaknesses,
     opportunities and threats.


Internal Analysis:
 Strengths:


                  Modern Textile Machinery & equipment
                  Acquisition of ISO 9002 certificate
                  Proven Management
                  Product Innovation abilities
                  Good competitive Skills
                  Complete Back Track facility
                  Equipped with WRAP certification


Weaknesses:
                  Centralized Managerial Decision Making
                  High Cost of Production
                  Small International Market Share
                  High Reproduction Cost
                  High Wastage Cost
                                              29



                  Prepared By: Muhammad Shafiq Shahid (MBA. Marketing)
                   Department of Management sciences, GCUF. - 29 -
                                                            Masood Textile Mills Fsd.
                                                 TO BE THE WORLD BEST APPAREL COMPANY



External Analysis:


Opportunities:


            Entering new markets
            Addition of new product line
            Faster market growth
            Acquiring the benefit of free trade


Threats:


            Entry of new textile competitors
            Rising cost of production
            Adverse Govt. policies
            Easy access of buyers in the world market
            Political stability
            Economy is not up to market
            Difficult upcoming challenges of free trades




                                            30



                   Prepared By: Muhammad Shafiq Shahid (MBA. Marketing)
                    Department of Management sciences, GCUF. - 30 -
                                                                   Masood Textile Mills Fsd.
                                                      TO BE THE WORLD BEST APPAREL COMPANY




PPC Department In MTM:

                                  It is obvious from the name of the department that this

department is meant for production, planning & controlling of production towards the

right direction in and effective and efficient manner in given period.

       PPC department has been subdivided into three divisions,
    Planning
    Control
    Yarn
                        The actual customer of MTM mills division is the MTM apparel division. The
   whole process in MTM mills is initiated with the placement of PO from Apparel to Mills division.
   The PO is first placed in PPC department from where it is fed in the FMS (Fabric Management
   System). Now this PO is available to all concerned department in Mills.
   Here is the flow of PO in Mills.



        PO                     PPC                     R&D                   Knitting


                       Dye                    Finishing                      Dispatching


   PPC is involved at each level of PO in Mills. The three divisions of PPC work as follows;




                                                 31



                     Prepared By: Muhammad Shafiq Shahid (MBA. Marketing)
                      Department of Management sciences, GCUF. - 31 -
                                                               Masood Textile Mills Fsd.
                                                TO BE THE WORLD BEST APPAREL COMPANY
    Planning:



    T
           his division plans the whole Po with order specifications, work schedule, time line
           for knitting, dyeing (Lot Making), finishing and up till dispatching of fabric to
           customer(Apparel Division).


    Control:

        This division actually looks after the PO time line execution for in time production
        and dispatching to customer. Many people name this division as Peeshay Peeshay
        Challo (PPC) due to its involvement in PO.

    Yarn:

    This division makes the availability of yarn in time before knitting gets started.    The

procedure followed for yarn procurement is as follows,


PO                 PO Feeding in FMS (PPC)                          Approval Sheet(R&D)

                                       Yarn Demand

 Generation including the yarn count, quality and quantity (PPC)


 Forwarded to Head Office                         Feed back with time & vendor

 Feed back Fed

     In FMS (PPC)  Receiving of Yarn (Store)  Testing of Yarn (Q. C.) 

 Received in Store  Allocation to Po’s on priority Bases (PPC)  Availability of Yarn in

 POs

                                           32



             Prepared By: Muhammad Shafiq Shahid (MBA. Marketing)
              Department of Management sciences, GCUF. - 32 -
                                                                     Masood Textile Mills Fsd.
                                                        TO BE THE WORLD BEST APPAREL COMPANY




                                    Apparel division (Stores)




                                Fabric              Accessories             Shipping
                                Store                  Store                 Store

Fabric Store:
                  PO wise fabric comes from the mills for Garments, according to the purchase order.
Fabrics issued towards cutting depart on behalf of requisition.

Accessories Store:
          Accessories store provided the following things on the requirement of different department
like as
Needles
Threads
Stationary
Labels …………etc

Shipping Store:
          After completing the Garments for the export purpose is collecting from production
department.




                                                   33



                       Prepared By: Muhammad Shafiq Shahid (MBA. Marketing)
                        Department of Management sciences, GCUF. - 33 -
                                          Masood Textile Mills Fsd.
                              TO BE THE WORLD BEST APPAREL COMPANY




Production Department (Flow of Garments)


                                  Fabric
                                    
                                  Cutting
                                    
                                  Induction
                                    
                                  Stitching
                                    
                                  Finishing
                                    
                                  Packing




                         34



Prepared By: Muhammad Shafiq Shahid (MBA. Marketing)
 Department of Management sciences, GCUF. - 34 -
                                                                  Masood Textile Mills Fsd.
                                                       TO BE THE WORLD BEST APPAREL COMPANY


   Fabric:

           A material made from fibers or threads by spinning, weavings, knitting, processing…etc

   as any cloth. There are different types of fabrics.

 Types of Fabric:

   1) Jersey

               Single Jersey
               Heavy Jersey:
               Bird eye Jersey:
               Striper Jersey:
               Lycra Jersey:
               Sueded Jersey:
               Printed Jersey:

2) Pique

               Pique Locast
               POP – Corn Pique
               Honey Combed Pique
               Mesh Pique



3) Inter Lock

           Simple interlock
          Sueded interlock




                                                  35



                     Prepared By: Muhammad Shafiq Shahid (MBA. Marketing)
                      Department of Management sciences, GCUF. - 35 -
                                                             Masood Textile Mills Fsd.
                                                  TO BE THE WORLD BEST APPAREL COMPANY
4) Rib

         Rib 1*1
         Rib 2*2
         Rib 11*1
         Rib 15*1




5) Waffle



6) Min Thermal


7) Fleece

         Fleece
         Sueded Fleece
8) Terry

      Brushed Terry
      French Terry
      Baby Terry




                                             36



                    Prepared By: Muhammad Shafiq Shahid (MBA. Marketing)
                     Department of Management sciences, GCUF. - 36 -
                                                                       Masood Textile Mills Fsd.
                                                         TO BE THE WORLD BEST APPAREL COMPANY




Cutting:

         PPC department (Production, planning and control) issues requisition to cutting department.
Cutting department receive requisition and issues fabric in the store. Fabric come to the cutting
department and issued any group (lines 1,2,3 and 4) Cutting auditor check ply to ply shade and cut
out continuity and make mock up for approval shade of ply to ply and trims approval of shade group
person receive job card and issue of marker to GGT department (Garber Garments Technology), and
spread the lay of fabric. Fabric cutting auditor check marker species and spread the marker and
shape of lay and group members shape of lay in the bundle and bundles record in the job card and
lot is issue to 100% inspection auditor lot is inspection 100% and all ok pcs, issued to induction and
reject pcs separate to the bundles.


Induction:

         After cutting department fabric comes in induction department. Where pcs are arrangement
in sizes, colors,
Po (Purchase Order) wise…. etc. Induction department is the responsible of the quantities, maintain,
balance of receiving from the cutting department. Others responsibly of the induction department is
issues the particular quantities to stitching department for furthers operations.


Stitching:

         In this department, stitch the garments in the different operations like as




                                                    37



                       Prepared By: Muhammad Shafiq Shahid (MBA. Marketing)
                        Department of Management sciences, GCUF. - 37 -
                                                             Masood Textile Mills Fsd.
                                                  TO BE THE WORLD BEST APPAREL COMPANY


Operations:



      EMB / Pockets
      Placket
      Collar/ Collar Closing / Labels
      Shoulder (Left)
      Arm Hole (Left)
      Sleeve Hem (Left)
      Side Seam (Left)
      Side vent (Left)
      Care Label Placement
      Bottom Hem
      Side vent (right)
      Side Seam (right)
      Sleeve Hem (right)
      Arm Hole (right)
      Shoulder (right)


Machines available for stitching Department.
      Basically two types of machines are used
          1. Over Lock
          2. Flat Lock




                                             38



                   Prepared By: Muhammad Shafiq Shahid (MBA. Marketing)
                    Department of Management sciences, GCUF. - 38 -
                                                                      Masood Textile Mills Fsd.
                                                         TO BE THE WORLD BEST APPAREL COMPANY




                                                    Over Lock



                Single Needle    Single Needle   Double Needle        Double Needle          Elastic Attach
                  2 Threads        3 Threads       4 Threads             Puller                  Bikini




                                                         Flat Lock



     Cylinder Bed      Mini Cylinder   Flat Seaming          Feedo       Flat Bed          4 Needles     Body Hem
      5 Threads         5 Threads      5 & 6 Threads                                       6 Threads     5 Threads



                                                                          Flat Bed       Multi Needles
     Puller Attach                                                     Elastic Attach      (6T, 4N)       Manual




     Feed of the Arm (inseam + Flat seam)                               Tap Attach                  Auto Trimmer
                                                                          Cutter



                     Lock Stitch                                                          Others



                                                                     Bartake            Button Hole Button Attach
Single Needle      Double Needle        Zig - Zag
  2 Threads          4 Threads          2 Threads

                                                    39



                        Prepared By: Muhammad Shafiq Shahid (MBA. Marketing)
                         Department of Management sciences, GCUF. - 39 -
                                                                Masood Textile Mills Fsd.
                                                   TO BE THE WORLD BEST APPAREL COMPANY
Finishing:

              The process of making the garment ready for shipment

                                      Or

              Inspection of Garment / Final Enhancing Details

Fabric Faults:

               There are two types
  1. Yarn faults
  2. Machine faults
 Here are some faults that occur due to both above-mentioned categories.
          o Oil spots
          o Heavy yarn
          o Lint hole
          o Thin yarn
          o Tuck stitch
          o Knot Hole
          o Drop
          o Run Down Broken Needle
          o Tape Down / Tape off of Wheel
          o Winding Hole Caused by Broken Needle




                                              40



                   Prepared By: Muhammad Shafiq Shahid (MBA. Marketing)
                    Department of Management sciences, GCUF. - 40 -
                                                                      Masood Textile Mills Fsd.
                                                        TO BE THE WORLD BEST APPAREL COMPANY
 Packing:
 Packing is the process by which garments dispatched for the shipment on the requirement of
buyers.
Types of packing:
                  There are two major types
   1. Solid packing
   2. Assorted packing
Solid packing:
          In which packing, organization used the same size and colors of garments in one poly bag.
Assorted packing:
          In which packing, organization not used the same size and colors of garments in one poly
bag.
Packing instruction:
          Packing instruction is provided from the buyer requirement. The following instructions are
below
   o Colors
   o Size
   o Fold size
   o Insert board
   o Upc sticker
   o Pcs/pack
   o Poly bag
   o Master poly bags
   o Pcs/carton
   o Size sticker
   o Baler bag sticker
   o Carton sticker
   o Magic tape solo tape
                                                   41



                       Prepared By: Muhammad Shafiq Shahid (MBA. Marketing)
                        Department of Management sciences, GCUF. - 41 -
                                                                       Masood Textile Mills Fsd.
                                                            TO BE THE WORLD BEST APPAREL COMPANY



       Quality control department:


                   Quality may be defined as the set and required parameters by the customers. It is
          quit difficult task to fulfill the customer requirements.
       To assure this thing MTM has two departments;
       A. Quality control departments
       B. Quality assurance departments
Quality control departments
          This is the department, which can be said as an agent from MTM side, which checks the
required parameters and recommends solution at each level of process. It has two sections, Grey
section, which checks the fabrics for faults,
attaches bar cods and clearance no; Inline section which checks the finished and dyed fabric for
faults according to 20 point system.
Quality assurance department
          This department can be said as agent from customer side, which audits the QC checked
fabric and give positive or negative opinion whether the fabric is according to customer requirements
or not. This department does not suggest any thing.
Responsibilities of Quality Assurance Department
  1.      Indulge and Monitoring Quality System

  (a)          The QA dept is required to induce the QC dept implement standard quality
  system required by buyers to improve and maintain very good OQL.

  (b)            The implemented quality system should monitor on a daily basis .So that the system
  runs with out any failure. Under no circumstances the systems should be changed or stopped.

  (c)             The quality system should be very strong so that nothing could penetrate through
  and result in failure of audit or re-screening.


                                                       42



                        Prepared By: Muhammad Shafiq Shahid (MBA. Marketing)
                         Department of Management sciences, GCUF. - 42 -
                                                                        Masood Textile Mills Fsd.
                                                         TO BE THE WORLD BEST APPAREL COMPANY
2.    Training and Evaluating Quality Staff.

(a)              It is the responsibility of the senior staff to train all the QA staff to achieve skilled
levels within a short frame of time

(b)           The QA dept to coordination with the production dept and QC dept should train the
QC team to achieve skilled levels.

(c)              A training program should be designed which will enable to execute simple and
proper training to enhance skill levels of QC and QA staff up to standards.

(d)              The QA dept will evaluate all the inline and final quality inspectors on their
performance.

(e)            The evaluation will be based on the overall quality level less than 4% for any merit
are reward system.

3.    Training and Evaluating Quality Staff
(a)              QA will performance audits at cutting stage to assure the cut products to confirm
required quality standards.

(b)               The inline QA supervisor or QA auditor will perform random audits to assurance
stitching quality of products. The objective will be to inspect and identify the problems and give
Corrective action to the root cause of the problem, with a view of preventing re-occurrence of the
problems.

(c)              The final QA officers and concentrating more on the presentation of the final
product.

(d)             The final auditors will conduct finished goods before packing with the same
objectives and concentrating more on the presentation of final product.

(e)            The final auditors will also conduct packing audit to insure the quality, ratio, color,
cartooning, packing accuracy, presentation, and packing accessories.


LAB IN PROCESSING:

              To assist both of these depts. There is a lab in MTM. The different kinds of test are
applied according to the requirements of QC or QA.

                                                    43



                     Prepared By: Muhammad Shafiq Shahid (MBA. Marketing)
                      Department of Management sciences, GCUF. - 43 -
                                                               Masood Textile Mills Fsd.
                                                 TO BE THE WORLD BEST APPAREL COMPANY


IT Department At MTM Mills:
    Tm is at almost pure Dot Com positions and we can say that IT has been so much
M   flourished in TM that it will be difficult to survive for MTM without IT at this time. Most
    of the departments have been computerized except Finance Department.
           The system developed by the IT department includes


   HRMS             Human Resource Management System
   GMS              Gate Management System
   FMS              Fabric Management System


And they are planning now for the following systems at the urgent bases,


   JMS              Job Management System
   JOB BANK         For online Job Application
   AIS              Accounting Information System




                                            44



                Prepared By: Muhammad Shafiq Shahid (MBA. Marketing)
                 Department of Management sciences, GCUF. - 44 -
                                                                      Masood Textile Mills Fsd.
                                                          TO BE THE WORLD BEST APPAREL COMPANY
HR Department:

                HR Department in MTM is involved in different type of human Resources
development activities.
          Here are the activities of HR department in MTM,
          i.    Recruitment
         ii.    Training and Development
         iii.   Compensation
         iv.    Performance Appraisal
         v.     Employee Welfare
         vi.    Rewards and Punishments
        vii.    Retiring and termination Benefits


       Recruitment


                          HR dept in MTM regarding recruitment is almost online up to the middle
   level management and has the following procedure;
                         Approved strength in each department
                         Invitation of vacant or new positions Applications
                         Scrutinizing of Applications
                         Test including intelligence and aptitude tests
                         Interviews in panel form




                                                     45



                     Prepared By: Muhammad Shafiq Shahid (MBA. Marketing)
                      Department of Management sciences, GCUF. - 45 -
                                                            Masood Textile Mills Fsd.
                                                TO BE THE WORLD BEST APPAREL COMPANY
     Training and Development


           The training and development process in MTM is very strong and has following set
up
 Indoor Training


        Apprentices
        Trainee supervisors
        Trainee operators
        Trainee Engineers
        Management Trainees
        Trainee Officers


 Outdoor Training


        Training in Institutions
        Meetings and interviews


        Compensation
                    MTM has set up for workers as
                    Market Rates
                    Overtime
                    Incentives
                    Vehicles
                    Accommodation




                                           46



                Prepared By: Muhammad Shafiq Shahid (MBA. Marketing)
                 Department of Management sciences, GCUF. - 46 -
                                                      Masood Textile Mills Fsd.
                                           TO BE THE WORLD BEST APPAREL COMPANY
    Rewards and Punishment
               MTM gives in terms of rewards
              Appreciation
              Cash Prizes
              Promotions
In MTM for the control purpose there are also punishments
              Disciplinary Actions
              Show Cause Notice
              Suspension
              Termination
              Charge Sheet
              Fines




                                      47



            Prepared By: Muhammad Shafiq Shahid (MBA. Marketing)
             Department of Management sciences, GCUF. - 47 -
                                                   Masood Textile Mills Fsd.
                                        TO BE THE WORLD BEST APPAREL COMPANY


   Performance Appraisals
                            Promotions in MTM have very fair methodology.
Personality and job related traits are evaluated at regular basis. Best
performance results in good rewards in MTM.
   Employee Welfare
   There are many employee benefits policies being followed in MTM.
Some of them are follows,
            Health Insurance
            Social Security
            5% of profit
            Accommodation
            Transportation
            Canteen and Mess
            Leave Encashment
   Retiring and Termination
Gratuity and provident fund is being maintained for the retiring personals in
MTM.




                                   48



          Prepared By: Muhammad Shafiq Shahid (MBA. Marketing)
           Department of Management sciences, GCUF. - 48 -
                                                        Masood Textile Mills Fsd.
                                             TO BE THE WORLD BEST APPAREL COMPANY


   Finance Department:

                                        In our opinion there is a stock and

   inventory controlling dept at apparel division of MTM, which is named as

   finance department or we can say that it is only a part of accounts

   department.

    Besides, above-mentioned reports following documents are also

   mentioned,

                        Vouchers

                        Bill for daily expenses

                        Payment to employees

                        Collection and deposit of cash from head office




Suggestions:
                                        49



               Prepared By: Muhammad Shafiq Shahid (MBA. Marketing)
                Department of Management sciences, GCUF. - 49 -
                                                           Masood Textile Mills Fsd.
                                                TO BE THE WORLD BEST APPAREL COMPANY
              The MTM is losing its benefits in lower raw material prices, while
energy cost and credit cost have increased considerably. There is a need to check
the trend of further increases both by policy, support by the Government and it self.
The major challenges are to enhance the competitiveness of the mill, which have
been created on account of internal weaknesses to improve quality productivity
and production efficiency to be desired levels.


    `    The suggestions that particularly relate to the MTM are as
followings;


            Allocating a specific budget should enhance the promotional
              activities of MTM.
            The company should control the financial charges especially
              commission to the agents should be controlled.
            The cost of production of company should be controlled. The
              utilizing the plant capacity in full can reduce fixed cost.
            The sale of company should increase by searching new markets.
            New product lines in fashion design and style should be launched.
            Political stability consistent government policy and government that
              remains for its tenure.
            Lowering of energy costs to allow the industry to become more
              competitive.
            To create an environment which attracts and supports foreign
              investments including joint venture.




                                           50



                  Prepared By: Muhammad Shafiq Shahid (MBA. Marketing)
                   Department of Management sciences, GCUF. - 50 -
                                         Masood Textile Mills Fsd.
                              TO BE THE WORLD BEST APPAREL COMPANY




                         51



Prepared By: Muhammad Shafiq Shahid (MBA. Marketing)
 Department of Management sciences, GCUF. - 51 -

				
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