Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
At
Remo Aapparels
Submitted by
Satheesh.J
Register No : 098001123089
Mr. N. Ramu
SCHOOL OF MANAGEMENT
SRI KRISHNA COLLEGE OF ENGINEERING AND TECHNOLOGY,
COIMBATORE
August 2010
Sri Krishna College of Engineering and
Technology Coimbatore.
School of Management
BONAFIDE CERTIFICATE
Director/HOD
Place: Coimbatore,
Date:
ACKNOWLEDGEMENT
I express my deepest sense of gratitude to the God Almighty for the abundant blessing to
do the study with great attitude.
I am also obliged and indebted to Mr. A. Ramanathan, Director and Dr. R. Krishna
Kumar, H.O.D, School of Management, SKCET, Coimbatore for the valuable suggestions and
encouragement in completing this study successfully.
I owe my reverential gratitude to my faculty guide Mr. N. Ramu, Lecturer for his
valuable suggesting and constructive criticisms rendered at each stage of the Summer Internship
Program. Under his guidance I have been available to conduct the study and complete it
successfully.
I acknowledge the immense help rendered by family and friends without whom the effort
would not have been possible.
TABLE OF CONTENT
Chapter Content Page no
1 Introduction 1
The Global Textile Industry, particularly the Apparel Industry has seen remarkable
changes in the past few years. The Garment Manufacturing Industry and the Garment Companies
in developed countries are now always on a lookout for cheap source of garment production. The
days are gone when textile garment industry was concentrated in the consumption hubs of US,
EU and other developed countries of the world. The clothing wholesale supply is increasing
worldwide in all the sectors of the industry, whether it is men’s clothing, women’s clothing, kids
wear or infant wear. The elimination of global export quotas has led to a shift towards low cost
countries having strong and established Clothing Industry especially the Asian countries.
India is the second most preferred country after China for textile and apparel sourcing. Its
Apparel industry is likely to achieve an export target of US$ 25 billion by 2010-11. The rise of
exports in India is due to several factors like vast sources of raw materials, low labor costs,
entrepreneurship and design skills of Indian traders, changes in the policies to open up Indian
economy to the outside world etc.
The Apparel Clothing & Garments Companies Directory lists the Manufacturers and
wholesale supplier companies dealing in various sectors of clothing such as men’s clothing,
women’s clothing, kids clothing, infant wear, sportswear etc. With the Industry going global, the
Manufacturers and Suppliers do not have to limit themselves within any boundary. The
Companies from varied countries join hands in order to meet the ever expanding demands of the
consumers worldwide. In such a situation, a vast resource of Apparel and Garment Industry
becomes indispensable.
The cotton is a traded commodity on the stock exchange. Most cotton in the world comes
from USA or Uzbekistan. It has to be bought on world stock exchange trade prices based on
quality and availability. Therefore it is beneficial that the buyer state that they would require say
xxx amount per month per year. Then buyer and seller can plan ahead. As we can see trial orders
then become a problem as manufacturer can’t lock in a futures buy on the cotton or chemicals or
even production line space.
The textile and apparels sector in India is a diverse and heterogeneous industry, which
covers a wide variety of products from hi-tech synthetic and wool fibers to yarns to fabrics to
apparels, cotton fibers to yarns to fabrics to home textiles to high fashion apparels (knitted and
woven). This diversity of end products corresponds to a multitude of industrial processes,
enterprises or market structures.
The Indian textile and apparels industry is in a stronger position now than it was in the
last six decades. The industry, which was growing at 3-4 percent during the last six decades, has
now accelerated to an annual growth rate of 9-10 percent. There is a sense of optimism in the
industry and textile and apparels sector has now become a sunrise sector.
The catalysts, which have placed the industry on this trajectory of exponential growth,
are a flexible domestic economy, a substantial increase in cotton production, the favorable policy
environment provided by the Government, and the expiration of the Multi Fiber Agreement
(MFA) on 31 December, 2004 and implementation of Agreement on Textiles and Clothing
(ATC).
1.4 Textiles Committee (Ministry of Textiles, Government of India)
The Parliament in its 14th year of the Republic enacted the Textiles Committee Act, 1963.
The Committee is under the administrative control of the Ministry of Textiles, Government of
India. Its main objective is to ensure the quality of textiles and textile machinery both for internal
consumption and export purposes. As corollary objectives, the Textiles Committee has been
entrusted with the following functions, under Section 4 of the Act:
To undertake, assist and encourage, scientific, technological and economic research.
To establish standard specifications for textiles, textile machinery and the packing
materials.
To establish laboratories for the testing of textiles and textile machinery.
To provide training in the technique s of quality control.
To provide for the inspection and examination of textiles and textile machinery.
To promote export of textiles.
To collect statistics and
To advise the Central Government on all matters relating to textiles and textile machinery.
Tirupur is a textile center of Western Tamil Nadu, located 50 km. covering a population of
around seven hundred thousand. Predominantly an export niche, the town gains its significance
for its updated technology and the quality of its macroeconomic environment. Buyers are from 35
countries frequently air-dash Tirupur. Some 90 percent of India’s total knitwear exports originate
from here. The Indian Export Import Policy of 2002-2007 includes a special tribute to Tirupur and
calls it a “Town of Export Excellence.”
The first banyan factory in Tirupur was started in 1925. With the advent of electricity in
1931 more knitting and weaving factories came into existence. Initially, all the knitting machines
were imported from Germany, Japan and New York. By 1942, there were 34 hosiery factories in
all. By 1968 this increased to 250 and today sophisticated machines are being imported from
Germany, Japan, Italy, U.S.A., Korea, Taiwan and many other countries. As documented by the
Tirupur Exporters Association, the composition of the knitwear industry in Tirupur today is
broadly classified as:
Mr. Rathinakumar, a young and energetic management graduate was the founder and the
Managing director of this firm handles day-to-day operations with the active cooperation of
dedicated young team of professionals
Their products are eco-friendly, using AZO free dyes confirm to stringent quality norms,
reasonably priced with timely delivery assured. They combine skills and technology to
effectively showcase the traditional as well as the modern, keeping in mind the needs of the fast
changing market.
2.2 CULTURE
Remo fosters an extremely open culture where the emphasis is on people and the focus
performance with client orientation.
2.3 VISION
2.4 STRATEGY
1. To consolidate and build current brands of Levis, Genesis, Lee copper, through various
product categories.
2.5 QUALITY
They always strive to maintain the highest quality standards and fashionable design,
enabling us to offer to our clients a wide range of standards and mixed colors.
Ethics, Integrity, quality of product and service, make us a valuable business partner.
The rest rooms are provided to the staff, which is suddenly affected by illness, and a hall
is provided for the staff to relax after lunch.
2.7 OPERATION
The company has a separate main office, production, stock, checking and packing units.
In office only all the order receiving and other processes relating decision making will take place
and directions are given for carrying the production process.
The production units are equipped with different machines that are needed to carry out
the production activities and the packing will also done in another place in the production unit.
The company is engaged in the manufacture and export of woven and knitted home
textile made ups, fabrics and furnishing fabrics of natural and synthetic materials to the
customers and processing of natural and synthetic yarn.
Manufacture involves various stages of core activities like purchasing of raw materials,
dyeing, weaving, cutting, stitching, embroidery, checking, packing, etc., and processing of
processed yarn involves various stages like purchasing of dyes & chemicals, bleaching & dyeing,
extraction, drying, etc.
CHAPTER - 3
ORGANIZATION STRUCTURE
3.1 ORGANIZATION STRUCTURE
PRODUCT PROFILE
4.1 PRODUCT PROFILE
They specialize in mill made and power loom yarn-dyed, yarn fabric and printed fabrics
ranging from exclusive 100% cotton and whole range of other qualities of woven fabrics. They
manufacture high quality men’s and kid’s t-shirt.
Second, the buyer can send all t-shirt size measurements for their requirement.
Third manufacturer made the pattern depending upon the requirement and send to buyer.
The sample is requested from the manufacturer so that the buyer can see the look and the
feel of the garment.
This way of assessing if the manufacturer real as they have no problem in sending
samples.
A counter sample is then checks and sent to the manufacturer. Like everything buyer pay
for quality.
Good for a few washes then it’s out of shape, stitching broken and faded color.
Again manufacturer always ask for buyer’s to see the stitching weight and general
quality.
With this in hand manufacturer can work out if buyer can meet the target prices.
5.2 Sample
FINANCE DEPARTMENT
6.1 INTRODUCTION
In present modern oriented economy everyday needs finance to carry on its operation and
to cover its targets. Finance plays an important role in a company’s life. It is rightly said that
“finance is the life blood of an enterprise”.
Financial planning
Formulation of financial policy
Working capital management
Negotiation with banks and finance institutions
Analysis of financial position
Analysis of day to day management of funds.
Preparing of profit and loss a/c and balance sheet.
Dealing with sales tax matter
Effective development of fund
Through finance is an essential requirement for all trading and commercial activities, it is
all the more so in the case of foreign trade transactions because of their size and complexity.
Buyer and seller in foreign trade separated by long geographical distances, this creates the
problem of transportation of goods from one country to another further, because goods remains
in transit for long periods, there is considerable risk of loss due to damage or destruction. Also
communication between concerned parties became difficult particularly because of language
problem.
All this needs of an exporter are varied to being with. If he is a manufacturer himself he
needs credits so as to be able to produce goals for export. And if he is a trader he needs credit to
buy goods for the purpose of export.
Then, as the goods are consigned he needs credit during the interval, which is often quite
long between the shipment of goods and realization of proceeds from the foreign buyers.
CHAPTER - 7
MERCHANDISING DEPARTMENT
7.1 INTRODUCTION
The function of the merchandising department begins with the sourcing for the new order
or the repeat order, and continues till the shipment deadline has met. Merchandisers act as
mediators between the manufacturer and the buyers. They know what buyers want and what the
company is able to and willing to deliver. They are responsible for timely execution of the
orders.
7.2 FUNCTIONS
The main function of the merchandising department is a follow up process. They carry
out pre-production planning with the help of the production manager so that the order
gets completed in a smooth and organized manner on time.
The merchandisers keep track of all the departments' progress with their orders. They
maintain a copy of the documents from all the departments, which show the status of the
orders in those departments.
The merchandisers discuss the details of the tech pack with the QC's and pattern masters
and negotiate with the buyer if there are any changes to be done.
They get the samples made under their supervision.
The job of costing the garments is with the senior merchandiser and it has to be approved
by the divisional merchandising head.
Placing orders for sampling fabrics and trims is also merchandiser's responsibility after
getting the approval for the same.
At Orient Craft the merchandisers have to maintain various documentation for their own
as well as for the reference of quality and production purpose. At the time of production
they have to do a file handover along with a sealer sample that is approved by the quality
head of the company. This file contains all the details of the garment from fabric entrance
used to the washing specification. A copy of this file is handed over to the production
manager and another copy is given to the Quality control concerned.
Various documents, files that merchandisers maintain are fabric files; trim files style
master files, format files, art works files etc.
7.3 RESPONSIBILITIES
Forecasting sales
PRODUCTION DEPARTMENT
8.1 DEFINITION
The main activity of production system is to convert the raw material s into useful
products by value addition process.
The material which are required for the production purposes are normally produced and
stored in raw material warehouse and then shifted to manufacturing plant. Otherwise, the raw
material is to be purchased in advance and stocked in stores mainly to smoother then production
process.
Better accountability
Better co-ordination
Better performance
Adaptability to computerised systems.
The components of the integrated materials management can be classified into the following
modules
Materials control
Inventory control
Purchase management
Stores management
8.3 MATERIAL PLANNING
Sales forecasting and aggregated planning are the basic inputs for material planning.
The different tasks under planning are listed below.
The majority of T-shirts are made of 100% cotton, polyester, or a cotton/polyester blend.
Environmentally conscious manufacturers may use organically grown cotton and natural dyes.
Stretchable T-shirts are made of knit fabrics, especially jerseys, rib knits, and interlock rib knits,
which consist of two ribbed fabrics that are joined together. Jerseys are most frequently used
since they are versatile, comfortable, and relatively inexpensive.
There are many forms of yarn dyeing. Common forms are the at package form and the at
hanks form. Cotton yarns are mostly dyed at package form, and acrylic or wool yarn are dyed at
hank form. In the continuous filament industry, polyester or polyamide yarns are always dyed at
package form, while viscose rayon yarns are partly dyed at hank form because of technology.
The common dyeing process of cotton yarn with reactive dyes at package form is as follows:
1. The raw yarn is wound on a spring tube to achieve a package suitable for dye penetration.
2. These softened packages are loaded on a dyeing carrier's spindle one on another.
3. The packages are pressed up to a desired height to achieve suitable density of packing.
4. The carrier is loaded on the dyeing machine and the yarn is dyed.
5. After dyeing, the packages are unloaded from the carrier into a trolley.
6. The packages are hydro extracted to remove the maximum amount of water.
7. The packages are then dried to achieve the final dyed package.
It is a known fact that the main material for fabric construction is yarn. Knitting is the
second most frequently used method, after weaving, that turns yarns or threads into fabrics. It is
a versatile technique that can make fabrics having various properties such as wrinkle-resistance,
stretch ability, better fit, particularly demanded due to the rising popularity of sportswear and
casual wears.
A knitted fabric may be made with a single yarn which is formed into
interlocking loops with the help of hooked needles. According to the purpose of
the fabric, the loops may be loosely or closely constructed. Crocheted fabric is
the simplest example of knitting where a chain of loops is constructed from a
single thread with the help of a hook. As the loops are interlocked in a knitted
fabric, it can stretch in any direction even when a low-grade yarn having little
elasticity is used.
Making T-shirts is a fairly simple and largely automated process. Specially designed
machines integrate cutting, assembling, and stitching for the most efficient operations. The most
commonly used seams for T-shirts are narrow, superimposed seams, which are usually made by
placing one piece of fabric onto another and lining up the seam edges. These seams are
frequently stitched with an over edge stitch, which requires one needle thread from above and
two looped threads from below. This particular seam and stitch combination results in a flexible
finished seam.
Another type of seam that may be used for T-shirts are bound seams, in which a narrow
piece of fabric is folded around a seam, as at the neckline. These seams may be stitched together
using a lockstitch, chain stitch, or over edge stitch. Depending on the style of the T-shirt, the
order in which the garment is assembled may vary slightly.
The T-shirt style is designed and the dimensions are transferred to patterns. Adjustments
are made for size differences and stylistic preferences.
8.14 Cutting
For fabric that is not tubed, the separate pieces for the
front and back sections must be stitched together at the sides.
They are joined at the seam lines to form a simple, narrow,
superimposed seam and stitched together using an over edge
stitch. Care must be taken to avoid a needle cutting the yarn of
the fabric, which can lead to tears in the garment.
If the T-shirt body is tubular, the sleeve material is first sewn together, and then set into
the garment. Alternatively, if the T-shirt is "cut and sewn," the seamed sleeve is set into place.
Later during the final stage of sewing the shirt, the sleeve and side seams are sewn in one action.
8.17 Stitching the hem
The garment hem is commonly sewn with an over edge stitch, resulting in a flexible hem.
The tension of the stitch should be loose enough to allow stretching the garment without tearing
the fabric. Alternative hem styles include a combination of edge finishing stitches.
Pockets may be sewn onto T-shirts intended for casual wear. Higher quality T-shirts will
insert an interlining into the pocket so that it maintains its shape. The interlining is inserted into
the pocket as it is sewn onto the T-shirt front. Pockets may be attached to the garment with
automated setters, so the operator only has to arrange the fabric pieces, and the mechanical setter
positions the pocket and stitches the seam.
Generally, shoulder seams require a simple superimposed seam. Higher quality T-shirt
manufacturers may reinforce seams with tape or elastic. Depending on the style of the T-shirt,
the seams at the shoulder may be completed before or after the neckband is attached. For
instance, if a tubular neckband is to be applied, the shoulder seams must first be closed.
For crew neck shirts, the neck edge should be slightly shorter in circumference than the
outer edge where it is attached to the garment. Thus, the neckband must be stretched just the
right amount to prevent bulging. Tubular neckbands are applied manually. The bands are folded,
wrong sides together, stretched slightly, and aligned with the neckline. The superimposed seam
is stitched with an over edge stitch.
Bound seams are finished with a cover stitch and are easy to achieve. Bound seams may
be used on a variety of neckline styles. The process entails feeding ribbed fabric through
machines which fold the fabric and apply tension to it.
Some neckbands on lower-priced shirts are attached separately to the front and back
necklines of the garment. Thus when the shoulder seams are stitched, seams are visible on the
neckband.
V-necks require the extra step of either lapping or mitering the neckband. In the former
process, one side is folded over the other. A mitered seam is more complex, requiring an
operator to overlap the band accurately and stitch the band at center front. An easier method for a
V-neck look is to attach the band to the neckline and then sew a tuck to form a V.
Singular machine
8.22 Ironing
Ironing is to remove wrinkles from fabric. Ironing works by loosening the ties between
the long chains of molecules that exist in polymer fiber materials. With the heat and the weight
of the ironing plate, the fibers are stretched and the fabric maintains its new shape when cool.
One or more labels are usually attached at the back of the neckline. Labels provide
information about the manufacturer, size, fabric content, and washing instructions.
Some T-shirts will have trim or screen prints added for decorative purposes. Special T-
shirts for infants have larger openings at the head. The shoulder seams are left open near the
neck, and buttons or other fasteners are attached.
8.25 Finishing operations and checking
T-shirts are inspected for flaws in the fabric, stitching, and thread. High-quality T-shirts
may be pressed through steam tunnels before they are packaged. Packaging depends on the type
of T-shirt and the intended distribution outlet. For underwear, the shirts are folded and packaged
in pre-printed bags, usually of clear plastic, that list information about the product. Shirts may be
boarded, or folded around a piece of cardboard, so that they maintain their shape during shipping
and on the shelf. Finally, they are placed into boxes by the dozen or half-dozen.
Most of the operations in manufacturing clothing are regulated by federal and inter-
national guidelines. Manufacturers may also set guidelines for the company. There are standards
that apply specifically to the T-shirt industry, which include proper sizing, and fit, appropriate
needles and seams, types of stitches, and the number of stitches per inch. Stitches must be loose
enough to allow the garment to stretch without breaking the seam. Hems must be flat and wide
enough to prevent curling. T-shirts must also be inspected for proper application of neck-lines,
which should rest flat against the body. The neckline should also recover properly after being
slightly stretched.
Find out their skill evaluation from their supervisors and by direct Observation
Evaluate their skill at the period of overtime and distribute the overtime incentive.
Make the workers to get Permission for Leave and give intimation by phone call.
Make the workers to follow the procedure to get the signature on form.
Reduce absenteeism.
Shorten the leave duration.
Interaction and Counseling.
Introduction about the work, and the Department they are recruit.
Make them to realize the training period and motivate them to get proper training.
Find out the low skill level employees from their production chart and from their
supervisors.
Work review.
Reduction of 12% for P.F and 1.75% for ESI from employee salary.
Transportation
Canteen
Dining hall
Incentive
Counseling
Rest room
Toilet facility
Ventilation
Free accommodation
First-aid
Team work
Interpersonal development
Self production
Behavioral change
Find out the problem of the employees by observation, their friends, and co-workers and
from their supervisors.
Prepare the new employee list department wise and month wise
Prepare the left employee list department wise and month wise
Individual performance
Attendance
Interpersonal relationship
Individual performance
Attendance
Interpersonal relationship
Attendance details
Overtime details
Incentive details
Loan details
Recruitment
Selection
Training
Monitoring
Performance appraisal
Promotion
Increment
Target
9.19 RESPONSIBILITY
9.20 Roles
List of new employee every month
List of left employee every month
Absenteeism report prepare month wise/department wise
H.R Plan will be prepare monthly wise
Labor recruitment in various places
New employees skill mapping /provide the correct job
New employee full training to be given /monitoring 15 days report prepare
Employee promotion and increment plan
Meeting organize
Bus spare details prepare
To be maintain the employees master data’s
11 PERSONAL LEARNING