Industrial Engineering in Apparel Manufacturing: A Case Study of Intimate Fashions (Pvt) L, Schemes and Mind Maps of Entrepreneurship

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NATIONAL INSTITUTE OF FASHION TECHNOLOGY,

CHENNAI

Submitted By:

VISHWAHAREESH RAJESWARAMOORTHY

(BFT/21/814)

A Report of Apparel Intenship

DECLARATION

I, Vishwahareesh Rajeswaramoorthy, hereby declare that the project titled

“Apparel Internship Report” at MAS Intimate Fashion Ltd., submitted to

the National Institute of Fashion Technology, Chennai, in fulfillment of the

requirements for the end-term jury of Semester VII, is my original research

work conducted under the guidance and supervision of Mr. Prabhakar,

Assistant Professor, Department of Fashion Technology, Chennai. I further

confirm that this project or any part of it has not been submitted in any form

for any other degree or diploma. All information obtained from other

sources has been duly acknowledged.

Vishwahareesh

S.No: CONTENT

COMPANY OVERVIEW

Company Profile CORPORATE VALUES AND OBJECTIVES Milestones Vision &Mission 2

BUSINESS DIVISIONS

An Integrated Business Model Subsidiaries Global Footprint 3 PRODUCTS 4 MAJOR BUYERS 5

PRODUCT RANGE

Product Profile 6 CORPORATE SOCIAL RESPONSIBILITY 7 DEPARTMENTS 8

MERCHANDISING DEPARTMENT

Role of the Department Objective of Merchandiser Functioning of the Department Costing Detailed Process Activities of Merchandising Section Costing Sheet Manufacturing Cost

S.No: CONTENT

FABRIC SOURCING DEPARTMENT

Process Flow 10 RAW MATERIAL WAREHOUSE 11

FABRIC AUDIT AND INSPECTION DEPARTMENT

Process Flow Chart for Bulk Purchase FOB (First of Bulk) Submission Process Flow Chart for Buyer Nominated Supplier Fabric Store and Fabric Audit Standard Operating Procedure (Fabric Receipt) Bulk Fabric Inspection Fabric Store after Inspection Bulk Fabric Testing Fabric Issue to Fabric Store Fabric Defects PRODUCTION PLANNING AND CONTROL 12

SPREADING & CUTTING DEPARTMENT

Spreading CAD Cutting

Introduction MAS holdings (pvt) ltd In 1987, Mahesh, Ajay, and Sharad Amalean pioneered lingerie manufacturing in South Asia, marking the genesis of MAS Holdings. What started as an unconventional venture has propelled MAS to the forefront of global lingerie manufacturing. MAS Holdings is the largest apparel manufacturing company in South Asia and a global leader in the apparel industry. Founded on principles of innovation, quality, and sustainability, MAS Holdings has expanded its operations worldwide, serving some of the most prestigious brands in the fashion industry. The company’s extensive network of subsidiaries each specializes in distinct areas of apparel production, ensuring comprehensive and high-quality services across the board. Together, these subsidiaries enable MAS Holdings to deliver a comprehensive range of apparel solutions, from design and development to manufacturing and marketing, ensuring the company remains at the forefront of the global apparel industry. SUBSIDIARIES: MAS Intimates (Pvt) Ltd MAS Active (Pvt) Ltd MAS Kreeda (Pvt) Ltd MAS Brands (Pvt) Ltd attune Consulting rizing Bodyline (Pvt) Ltd

1.COMPANY OVERVIEW

Bodyline (Pvt) Ltd Bodyline (Pvt) Ltd, established in 1992, represents a landmark achievement in Sri Lanka's export-oriented garment industry. The company was founded through a strategic partnership involving two of the world’s most renowned lingerie retail brands: Victoria’s Secret, the leading fashion lingerie brand in the US, and Triumph, a significant German lingerie brand with a broad presence across Europe and Asia. The local founding partner was MAS Holdings, which has since grown to become the largest apparel manufacturing company in South Asia. In its early years, Bodyline operated primarily as the manufacturing arm of its key brand partner, MAST Industries (the sourcing arm of Victoria’s Secret), focusing on fulfilling capacity requirements. Triumph International, the product development partner, provided crucial technical support, enhancing Bodyline’s capabilities. The essence of MAS Bodyline encapsulates the fusion of three titans in the apparel industry: Triumph International, MAST Industries and MAS Holdings. Today, Bodyline (Pvt) Ltd., based in Horana, Sri Lanka, has evolved into a world-class apparel manufacturer. The company engages in product design, development, execution, and marketing for global brands, including Victoria’s Secret, Nike, Triumph, Sloggi, VSX, Arena, and Odlo. Bodyline operates five plants, including overseas facilities, demonstrating its significant capacity and geographical reach: BPL 1 – Horana BPL 2 – Pimbura BPL 3 – Agalawaththa IFI – India

CORPORATE VALUES

1. Innovation and Excellence: Pioneering Solutions: IFL is committed to being at the forefront of innovation in the intimate apparel industry. The company invests in cutting-edge technologies and continuously explores new methods to enhance product quality and production efficiency. Commitment to Quality: Quality is a cornerstone of IFL’s operations. The company implements rigorous quality control measures to ensure that every product meets or exceeds industry standards, providing customers with superior garments. 2. Sustainability and Responsibility: Eco-Friendly Practices: IFL prioritizes sustainability by adopting environmentally friendly manufacturing processes. The company actively seeks to reduce its carbon footprint and promotes the use of sustainable materials. Ethical Operations: Ethical business practices are integral to IFL’s culture. The company upholds fair labor standards, ensures transparency in its operations, and is committed to responsible sourcing and production. 3. Customer Focus: Client Satisfaction: Understanding and fulfilling the unique needs of each client is paramount. IFL strives to deliver high levels of customer satisfaction through consistent quality and service excellence. Customization and Flexibility: IFL offers tailored solutions that cater to the specific requirements of its clients, demonstrating flexibility and responsiveness to diverse market demands. 4. Employee Development: Skill Enhancement: IFL is dedicated to the continuous professional development of its employees. The company provides ongoing training and development opportunities, fostering a culture of growth and excellence. Inclusive Work Environment: IFL promotes diversity and inclusivity within its workforce, ensuring that all employees are valued and supported in a safe and empowering work environment. 5. Community Engagement: Social Responsibility: IFL actively participates in community development initiatives aimed at improving education, healthcare, and overall quality of life in the regions where it operates. Positive Impact: The company is committed to making a positive social impact, contributing to the well-being and prosperity of the communities it engages with.

CORPORATE OBJECTIVES

1. Market Leadership: Expand Global Footprint: IFL aims to strengthen its market presence internationally, expanding into new regions and increasing its client base to become a leading global provider of intimate apparel. Brand Reputation: The company focuses on building and maintaining a strong brand reputation for quality, reliability, and innovation, solidifying its position as a trusted partner in the industry. 2. Innovation and R&D: Invest in Research: IFL is committed to investing in research and development to drive innovation in product design and manufacturing processes. Adopt Advanced Technologies: The company aims to integrate the latest technologies into its operations to enhance production efficiency, reduce costs, and improve product quality. 3. Sustainability and Environmental Stewardship: Reduce Carbon Footprint: IFL is dedicated to implementing environmentally sustainable practices across its operations, aiming to significantly reduce its carbon emissions and overall environmental impact. Promote Eco-Friendly Products: The company plans to increase the use of sustainable and eco-friendly materials in its product lines, offering consumers environmentally conscious options. 4. Employee Welfare and Development: Foster Employee Growth: IFL is committed to providing continuous learning opportunities for its employees, supporting their career growth and development within the company. Promote Workplace Well-Being: The company aims to create a healthy, positive work environment that fosters well-being, job satisfaction, and productivity. 5. Community and Social Impact: Support Community Initiatives: IFL actively engages in and supports community development projects, contributing to the betterment of society through various initiatives. Promote Social Responsibility: The company encourages socially responsible practices and strives to ensure that its operations have a positive impact on the communities it serves.

7. Certification and Compliance 2017: The company achieved key certifications for quality management and environmental sustainability, including ISO 9001 and ISO 14001. These certifications underscored Intimate Fashions’ commitment to high standards in manufacturing and environmental responsibility.
8. Product Innovation and Market Growth 2021-2022: Intimate Fashions launched several new product lines and innovations in lingerie and intimate wear. These products included advanced fabric technologies and new design aesthetics, further enhancing the company’s market presence.
9. Plant Transfer and Expansion 2023: One of the IFI plants was transferred to MAS Parana, a strategic move to optimize production capabilities and align with MAS Holdings' broader strategic goals. This transfer allowed Intimate Fashions to streamline operations and focus on core competencies.
10. Future Goals 2024 and Beyond: Intimate Fashions aims to continue its growth trajectory by focusing on sustainable practices, expanding its product portfolio, and leveraging new technologies to meet evolving consumer demands and market trends. These milestones highlight the growth and achievements of Intimate Fashions (Pvt) Ltd, demonstrating its commitment to innovation, quality, and sustainability in the global apparel industry.

At MAS Holdings, being changemakers is ingrained in their DNA. They are committed to transforming the way apparel manufacturing operates, driven by a vision to reimagine a future that extends beyond their own lifetimes. Their dedication to sustainability is not just a value but a crucial element of their growth strategy. This commitment is concretized through their Plan For Change. Overview of the Plan For Change The Plan For Change represents MAS Holdings' strategic approach to fostering sustainable change across various dimensions of their business. This plan is designed to inspire and implement significant improvements in how they interact with their customers, employees, communities, and the environment. Vision Intimate Fashions (Pvt) Ltd envisions a future where the company clothes the world with possibility. The aim is for the people and partners of Intimate Fashions to realize their dreams, with sustainability intricately woven into the fabric of the industry. Mission People: Intimate Fashions (Pvt) Ltd aims to inspire its people to change the world for good. By fostering a culture of innovation and ethical practices, the company empowers its workforce to make a positive impact on the global stage.

Products: The mission is to innovate products that are human-centered and sustainable. Intimate Fashions (Pvt) Ltd is committed to designing and producing apparel that meets the highest standards of quality, comfort, and environmental responsibility.

Partnerships: Building strong partnerships is key to achieving ambitious and profitable growth. Intimate Fashions (Pvt) Ltd strives to excel by working collaboratively with partners, ensuring mutual success and sustainability in all ventures.

Future Impact The Plan For Change is not merely a set of goals but a comprehensive strategy to embed sustainability into every aspect of their business. It reflects their commitment to creating a better future through actionable and impactful measures. As they progress, their collective efforts will contribute to a more sustainable and equitable world, ensuring that the benefits of their changes extend beyond their immediate reach.

VISION AND MISSION

MAS Holdings operates through several specialized business divisions, each focused on different aspects of the apparel industry. These divisions collectively contribute to the company’s broad capabilities and global reach.\

1. MAS Intimates Focus: Production of lingerie and intimate wear. Key Brands: Victoria’s Secret, Triumph, and other leading international lingerie brands. Capabilities: Includes design, development, and manufacturing of high-quality intimate apparel. 2. MAS Active Focus: Production of activewear and performance apparel. Key Clients: Leading sportswear brands. Capabilities: Specializes in creating technologically advanced and high-performance activewear, including sports bras, yoga wear, and athletic garments. 3. MAS Kreeda Focus: Sports apparel and performance wear. Key Offerings: High-performance sports bras, compression garments, and other sports-related apparel. Capabilities: Known for integrating advanced textile technologies and designs that enhance athletic performance. 4. MAS Brands Focus: Development and marketing of consumer-facing brands. Key Brands: Various in-house and licensed brands. Capabilities: Engages in creating and managing brands that appeal directly to consumers, ensuring a strong market presence. 5. attune Consulting Focus: Technology solutions and consulting services. Key Services: Provides expertise in enterprise management systems, technology integration, and process optimization. Capabilities: Helps improve efficiency and effectiveness in apparel production and business operations.

SUBSIDIARIES

6. Bodyline (Pvt) Ltd Focus: High-quality lingerie and intimate wear production. Key Clients: Victoria’s Secret, Nike, Triumph, and other global brands. Capabilities: Includes multiple production facilities in Sri Lanka and India, offering comprehensive design, development, and manufacturing services. GLOBAL FOOTPRINT

Product Range in Intimate Fashion The intimate fashion industry offers a diverse array of products designed to cater to various needs, preferences, and styles. Below is an overview of the key product categories commonly found within the intimate fashion sector: Lingerie Lingerie is a cornerstone of intimate fashion, encompassing a variety of styles and designs meant for everyday wear as well as special occasions. Bras: Ranges include push-up bras, plunge bras, balconette bras, sports bras, and bralettes, catering to different levels of support and fashion preferences. Panties: Options include briefs, thongs, boyshorts, high-waisted panties, and hipsters, offering a mix of comfort and style. Bodysuits: Combining a top and panties in one piece, bodysuits can be functional or fashionable, often used for layering or as a statement piece. Camisoles and Chemises: Lightweight and often lace-trimmed, these are designed for comfort and allure, suitable for sleepwear or layering. Shapewear Shapewear is designed to enhance the body’s natural shape, offering support and a smooth silhouette under clothing. Waist Cinchers and Corsets: Target the waist and abdomen to create a defined silhouette. Bodysuits and Control Slips: Provide overall shaping for the torso, often incorporating bra and panty elements. Thigh Shapers and Control Panties: Focus on the lower body, offering support and shaping for the hips, thighs, and buttocks. Activewear Activewear in intimate fashion includes pieces designed for physical activity, providing support, flexibility, and comfort. Sports Bras: Designed to offer varying levels of support, from low-impact to high- impact activities. Leggings and Yoga Pants: Made from stretchable, breathable fabrics suitable for exercise and leisure. Tank Tops and Crop Tops: Provide comfortable upper-body coverage, often with built-in support or layering options.

PRODUCT RANGE

Swimwear Swimwear in intimate fashion covers a range of styles suitable for different body types and activities. Bikinis: Two-piece sets offering various styles of tops (halter, triangle, bandeau) and bottoms (briefs, thongs, high-waisted). One-Piece Swimsuits: Provide full-body coverage with various cuts and designs to flatter different body shapes. Cover-Ups: Lightweight garments like sarongs, tunics, and dresses designed to be worn over swimwear. Tees Tees in intimate fashion offer a comfortable and stylish option for casual wear, lounging, or layering. Basic Tees: Simple, versatile designs made from soft fabrics like cotton or modal, ideal for everyday wear. Graphic Tees: Feature various prints, patterns, or slogans, adding a touch of personality and fun to the wardrobe. Fitted Tees: Tailored to hug the body, offering a more polished look suitable for layering or wearing alone. Oversized Tees: Provide a relaxed fit, often used for lounging or casual outings. Conclusion The product range in intimate fashion is extensive and diverse, offering something for every need and preference. From lingerie and sleepwear to shapewear, activewear, maternity wear, swimwear, tees, and accessories, each category is designed to provide comfort, support, and style. This variety ensures that customers can find the perfect items for any occasion, enhancing their wardrobe and personal comfort.