Description
The overall organization study report
Summer Internship Training At Remo Aapparels
Submitted by
Satheesh.J
Register No : 098001123089
Under the Guidance of
Mr. N. Ramu
In partial fulfillment of the requirements of Anna University – Coimbatore for the award of the degree of
MASTER OF BUSINESS ADMINISTRATION
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
This is a bonafide certified of practical record work done by Mr. Satheesh.J, Register No: 098001123089 for Remo Aapparels, Summer Internship Training of the Fourth Trimester of MASTER OF BUSINESS ADMINISTRATION during August - 2010.
Director/HOD
Submitted for the Practical Examination held on_____________
Faculty Guide
Internal Examiner
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 express my thanks to Mr. P. Rathinakumar, General Manager giving us an opportunity and Mr. A. Manthrachalam, Production Manager for his cooperation extended to me by providing necessary information & timely help for doing the project work. Words are inadequate to express my gratitude to the Remo Aapparels for giving me an opportunity to undergo the Internship program in their company and extend me full cooperation, enabling me to successfully complete this study report.
I acknowledge the immense help rendered by family and friends without whom the effort would not have been possible.
Chapter
TABLE OF CONTENT Content Introduction 1.1 1.2 1.3 1.4 1.5 About the training Apparel & garments Indian apparel and textile industry Textiles Committee About Tirupur
Page no
1
1 2 2 3 4 4 6 7 7 7 7 7 8 8 9 10 11 12 13 14 15 16 17 17 17 18 19
2
Company profile 2.1 2.2 2.3 2.4 2.5 2.6 2.7 About Remo Aapparels Culture Vision Strategy Quality Rest room facility Operation The company’s organization structure The company’s product profile
3
Organization structure 3.1
4
Product profile 4.1
5
Project taken process 5.1 5.2 Steps Sample measurement schedule
6
Finance Department 6.1 6.2 6.3 Introduction Functions Need and importance of finance
7
Merchandising department 7.1 Introduction
7.2 7.3 8
Functions Responsibilities
19 20 21 22 22 23 23 23 23 24 24 24 25 25 26 27 27 27 27 28 28 28 28 29 29 29 29 30 30
Production department 8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8 8.9 Definition Materials management and inventory control Material planning Inventory control Purchase management Stores management Stores inventory control Raw materials management Yarn dyeing
8.10 Knitting process 8.11 Basic principle of knitting 8.12 The manufacturing process 8.13 Styling 8.14 Cutting 8.15 Assembling the front and back 8.16 Assembling the sleeves 8.17 Stitching the hem 8.18 Adding pockets 8.19 Stitching the shoulder seams 8.20 Attaching the neckband 8.21 Finishing the neckline 8.22 Ironing 8.23 Label setting 8.24 Optional features 8.25 Finishing operations and checking 8.26 Quality Control
9
Human Resource department 9.1 9.2 9.3 9.4 9.5 9.6 9.7 9.8 9.9 Attendance Monitoring employees in/out time Monitoring employee over time list Leave report Control attrition Employee recruitment Training program HR plan month wise Provident fund and employees state insurance
31 32 32 32 32 32 32 33 33 33 33 34 34 35 35 35 36 36 36 36 37 38 39
9.10 Labor welfare 9.11 Motivation training 9.12 Solve employees issues 9.13 Analyse the employees status 9.14 Award distribution 9.15 Performance review 9.16 Salary preparation 9.17 Promotion and increment plan 9.18 Employees master data 9.19 Responsibility 9.20 Roles Personal learning Bibliography
CHAPTER – 1 INTRODUCTION
1.1 ABOUT THE TRAINING The overall objective of summer internship training is to provide an opportunity for gaining insight into the organization atmosphere and to understand the organizational climate and the expectation of the industries. 1.2 APPAREL & GARMENTS 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.
1.3 INDIAN APPAREL AND TEXTILE INDUSTRY 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. 1.5 About Tirupur 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:
Knitting and/or stitching units Dyeing and/or bleaching units Printing units Embroidery units Other (Compacting, Rising, and Calendaring)
: : : : :
4500 750 300 100 200
CHAPTER - 2 COMPANY PROFILE
2.1 ABOUT REMO AAPPARELS REMO incorporated in 2001 consists of a team of committed and dedicated professionals in serving the domestic market. 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 The organizations commitment to client orientation is found in its vision-“To be the undisputed leader in the lifestyle industry delivering continued value growth for all stakeholders.” 2.4 STRATEGY 1. To consolidate and build current brands of Levis, Genesis, Lee copper, through various product categories. 2. To continue thrust on T-shirt through in-house manufacturing capabilities. 3. Innovations to sustain leadership in T-shirt. 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. ? Matching and continually improving the global management system standards ? Implementing cleaner production technology ? Committed and dedicated work force ? Close cooperation of suppliers ? Maintain legal and other requirements.
2.6 REST ROOM FACILITIES 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
Remo Aapparels organization structure
CHAPTER - 4
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.
full sleeve with collar
full sleeve without collar
Basic sleeve
Kids wear
CHAPETR - 5
PROJECT TAKEN PROCESS
5.1 Project taken process Steps ? First the manufacturer gets the measurement schedule from buyer. ? 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
Space for comments from buyer
Sample measurement schedule after prepared pattern
CHAPTER - 6
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”. 6.2 FUNCTIONS OF FINANCE DEPARTMENT ? ? ? ? ? ? ? ? ? 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
6.3 NEEDS AND IMPORTANCE OF FINANCE 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 ? Planning the product range with the buying team ? Liaising with buyers, store managers, distributors and suppliers ? Visiting manufacturers, stores and suppliers ? Setting budgets using figures and forecasts new range
CHAPTER - 8
PRODUCTION DEPARTMENT
8.1 DEFINITION The set of interrelated management activities which are involved in manufacturing certain products is called as production management. 8.2 MATERIALS MANAGEMENT AND INVENTORY CONTROL 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. The different function of materials management are materials planning, purchasing, receiving, stores, inventory control, scrap and surplus disposal. The integrated materials management will result in the following advantages: ? 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. ? Estimating the individual requirement of the parts ? Preparing materials budget ? Forecasting the levels of investment ? Scheduling the orders ? Monitoring the performance in the relation to production and sales. 8.4 INVENTORY CONTROL ? Fixing economic order quantity ? lead time analysis ? Setting safety stock and re-order level. 8.5 PURCHASE MANAGEMENT These tasks under purchasing are listed below ? Evaluating and rating suppliers ? Selection of suppliers ? Finalisation of terms of purchases ? Placement of purchase orders ? Follow up ? Approval of payments to suppliers 8.6 STORES MANAGEMENT The different tasks under stores are listed below: ? Physical control materials ? Preservation of stores ? Minimization of obsolescence and damage through handling ? Disposal and efficient handling
? Maintenance of stores records ? Proper location and stocking of materials ? Reconciling the materials with books figures. 8.7 INVENTORY CONTROL Inventory is essential to provide flexible in operating system. The inventory can be classified into raw materials inventory remove dependency between suppliers and plant. The work process inventories remove dependency between machines of a product line. The finished goods inventory removes dependency between plant and its customers/market. The main functions of inventory are summarized below: ? Smoothing out irregularities in supply. ? Minimizing the production cost. ? Allowing organisation to cope with perishable materials. 8.8 RAW MATERIALS 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. 8.9 YARN DYEING 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. After this process, the dyed yarn packages are packed 8.10 KNITTING PROCESS 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. 8.11 BASIC PRINCIPLE OF KNITTING 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. 8.12 THE MANUFACTURING PROCESS 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.
Production process flow chart
8.13 Styling 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 The T-shirt sections are cut to the dimensions of the patterns. The pieces consist of a tubed body, or separate front and back sections, sleeves, perhaps pockets, and trim. 8.15 Assembling the front and back 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. 8.16 Assembling the sleeves The edges of sleeves are generally finished before they are fitted into the garment, since it is easier to edge the fabric while it is flat. An automated system moves the sleeves to the stitching head by conveyor. The edge may be finished by folding it over, forming the edge and stitching, or by applying a band. The band may be attached as a superimposed seam or folded over the edge as binding. 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. 8.18 Adding pockets 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. 8.19 Stitching the shoulder seams 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. 8.20 Attaching the neckband 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. 8.21 Finishing the neckline Necklines with superimposed seams may be taped, so that the shirt is stronger and more comfortable. Tape may be extended across the back and over the shoulder seams to reinforce this area as well and to flatten the seam. The seam is then cover stitched or top stitched. 8.22 Ironing
Singular machine
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.
8.23 Label setting
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. 8.24 Optional features Some T-shirts will have trim or screen prints added for decorative purposes. Special Tshirts 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. 8.26 Quality Control Most of the operations in manufacturing clothing are regulated by federal and international 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. The basic components of products qualities are listed below: ? Careful consideration of products design specification. ? Adequate inspection procedures for manufacturing or assembled products ? Acceptance procedures for purchased raw materials and parts and control practices to maintain quality levels in in-process stage. ? Commitment from top management, lower level of management and supervisors towards quality. ? Formulations for quality assurance procedures which are necessary to integrate and coordinate all these functions.
CHAPTER - 9
HUMAN RESOURCE DEPARTMENT
9.1 ATTENDANCE ? Maintain daily attendance chart ? List out the absentees and find out the reason. ? Counseling will give to the absentees after return to work. 9.2 MONITORING EMPLOYEES IN/OUT TIME ? Monitoring employees from their Production Chart. ? Find out their skill evaluation from their supervisors and by direct Observation ? Training should be given to the needed employee. 9.3 MONITORING EMPLOYEE OVER TIME LIST ? Evaluate their skill at the period of overtime and distribute the overtime incentive. 9.4 LEAVE REPORT ? Maintain the leave letter form. ? 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. 9.5 CONTROL ATTRITION ? Reduce absenteeism. ? Shorten the leave duration. ? Interaction and Counseling. 9.6 EMPLOYEE RECRUITMENT ? Introduction about the work, and the Department they are recruit. ? Counseling give when they joining on work.
? Introduce them in their work spot. ? Make them to realize the training period and motivate them to get proper training. ? Give guidance and counseling if necessary. ? Care should be given to the recruits by HR. ? Lengthen the training period of recruits if necessary. 9.7 TRAINING PROGRAMME ? Find out the low skill level employees from their production chart and from their supervisors. ? On-the-job training for low skill employee. 9.8 HR PLAN MONTH WISE ? Weekly HR review meeting. ? Work review. ? Discuss with overall observation. 9.9 PROVIDENT FUND AND EMPLOYEES STATE INSURANCE ? Reduction of 12% for P.F and 1.75% for ESI from employee salary. 9.10 LABOR WELFARE ? Transportation ? Canteen ? Dining hall ? ESI, PF, Insurance and loan facilities ? Incentive
? Counseling ? Rest room ? Fire and safety ? Toilet facility ? Ventilation ? Free accommodation ? Free medical facility ? First-aid ? Drinking water facility 9.11 MOTIVATION TRAINING ? Team work ? Interpersonal development ? Self production ? Behavioral change
? Self efficacy training
9.12 SOLVE EMPLOYEES ISSUES ? Find out the problem of the employees by observation, their friends, and co-workers and from their supervisors. ? Give proper guidance and Counseling ? Interact with them ? Analyse their problem
? Discuss their problem with superiors and find out the solution 9.13 ANALYSE THE EMPLOYEES STATUS ? Find out the total number of employees in each department ? Find out the needed workers in each department ? Recruitment and placement of employees department wise ? Prepare the new employee list department wise and month wise ? Prepare the left employee list department wise and month wise 9.14 AWARD DISTRIBUTION ? Individual performance ? Attendance ? Work efficiency and effectiveness ? Interpersonal relationship ? Co-ordination with workers 9.15 PERFORMANCE REVIEW ? Individual performance ? Attendance ? Work efficiency and effectiveness ? Interpersonal relationship ? Co-ordination with workers ? Rating scale evaluation
9.16 SALARY PREPERATION ? Attendance details ? Overtime details ? Incentive details ? Loan details ? Other reduction details 9.17 PROMOTION AND INCREMENT PLAN ? Recruitment ? Selection ? Training ? Work efficiency and effectiveness ? Monitoring ? Performance appraisal ? Promotion ? Increment 9.18 EMPLOYEES MASTER DATA ? Employees personal details, salary structure and benefits
? Target
9.19 RESPONSIBILITY ? To be prepare the attendance details ? To be prepare the overtime details
? To be prepare the incentive details ? Maintain the loan details ? Maintain the other details
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 Cleaner Production is an attractive approach to tackle environmental problems associated with industrial production and poor material efficiency. The cleaner production approach was successfully implemented in the textile sector. It shows that significant financial saving and environmental improvements can be made by relatively low-cost and straight forward interventions. This improves the quality of products and minimizes the cost of production, enabling the branch to compete in the global market. Moreover, Cleaner Production also improves the company’s public image by highlighting the steps it has taken to protect the environment. The main purpose of this study it to give an overview on the main processes involved in the textile manufacturing. For each process and extensive material and energy balance is provided as well as the impact of each in both environmental and human health terms. It also presents literature that will help on carrying out the cleaner production review especially in the identification of the company performance and in comparing this performance with industry averages.
BIBLIOGRAPHY ? ? ? ? ? ? ? ? S N Chary Productions and Operations Management Tata McGraw- Hill Publishing Muhelemann, Oakland, Loakyer, Sudhir, kalyani, Production and Operations
Management, Pearson,2009 I M Pandey Financial Management Ninth Edition Vikas Publishing House,2006 Willam, Ferell, Marketing, Cengage Learning, 2009 Gary Dessler Human Resource Management Pearson Education 2009 Biswajeet Pattanayak Human Resource Management Prentice Hall of India,2009 http://en.wikipedia.org/wiki/Knitting_yarn http://en.wikipedia.org/wiki/Human_resource_management
doc_928333033.pdf
The overall organization study report
Summer Internship Training At Remo Aapparels
Submitted by
Satheesh.J
Register No : 098001123089
Under the Guidance of
Mr. N. Ramu
In partial fulfillment of the requirements of Anna University – Coimbatore for the award of the degree of
MASTER OF BUSINESS ADMINISTRATION
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
This is a bonafide certified of practical record work done by Mr. Satheesh.J, Register No: 098001123089 for Remo Aapparels, Summer Internship Training of the Fourth Trimester of MASTER OF BUSINESS ADMINISTRATION during August - 2010.
Director/HOD
Submitted for the Practical Examination held on_____________
Faculty Guide
Internal Examiner
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 express my thanks to Mr. P. Rathinakumar, General Manager giving us an opportunity and Mr. A. Manthrachalam, Production Manager for his cooperation extended to me by providing necessary information & timely help for doing the project work. Words are inadequate to express my gratitude to the Remo Aapparels for giving me an opportunity to undergo the Internship program in their company and extend me full cooperation, enabling me to successfully complete this study report.
I acknowledge the immense help rendered by family and friends without whom the effort would not have been possible.
Chapter
TABLE OF CONTENT Content Introduction 1.1 1.2 1.3 1.4 1.5 About the training Apparel & garments Indian apparel and textile industry Textiles Committee About Tirupur
Page no
1
1 2 2 3 4 4 6 7 7 7 7 7 8 8 9 10 11 12 13 14 15 16 17 17 17 18 19
2
Company profile 2.1 2.2 2.3 2.4 2.5 2.6 2.7 About Remo Aapparels Culture Vision Strategy Quality Rest room facility Operation The company’s organization structure The company’s product profile
3
Organization structure 3.1
4
Product profile 4.1
5
Project taken process 5.1 5.2 Steps Sample measurement schedule
6
Finance Department 6.1 6.2 6.3 Introduction Functions Need and importance of finance
7
Merchandising department 7.1 Introduction
7.2 7.3 8
Functions Responsibilities
19 20 21 22 22 23 23 23 23 24 24 24 25 25 26 27 27 27 27 28 28 28 28 29 29 29 29 30 30
Production department 8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8 8.9 Definition Materials management and inventory control Material planning Inventory control Purchase management Stores management Stores inventory control Raw materials management Yarn dyeing
8.10 Knitting process 8.11 Basic principle of knitting 8.12 The manufacturing process 8.13 Styling 8.14 Cutting 8.15 Assembling the front and back 8.16 Assembling the sleeves 8.17 Stitching the hem 8.18 Adding pockets 8.19 Stitching the shoulder seams 8.20 Attaching the neckband 8.21 Finishing the neckline 8.22 Ironing 8.23 Label setting 8.24 Optional features 8.25 Finishing operations and checking 8.26 Quality Control
9
Human Resource department 9.1 9.2 9.3 9.4 9.5 9.6 9.7 9.8 9.9 Attendance Monitoring employees in/out time Monitoring employee over time list Leave report Control attrition Employee recruitment Training program HR plan month wise Provident fund and employees state insurance
31 32 32 32 32 32 32 33 33 33 33 34 34 35 35 35 36 36 36 36 37 38 39
9.10 Labor welfare 9.11 Motivation training 9.12 Solve employees issues 9.13 Analyse the employees status 9.14 Award distribution 9.15 Performance review 9.16 Salary preparation 9.17 Promotion and increment plan 9.18 Employees master data 9.19 Responsibility 9.20 Roles Personal learning Bibliography
CHAPTER – 1 INTRODUCTION
1.1 ABOUT THE TRAINING The overall objective of summer internship training is to provide an opportunity for gaining insight into the organization atmosphere and to understand the organizational climate and the expectation of the industries. 1.2 APPAREL & GARMENTS 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.
1.3 INDIAN APPAREL AND TEXTILE INDUSTRY 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. 1.5 About Tirupur 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:
Knitting and/or stitching units Dyeing and/or bleaching units Printing units Embroidery units Other (Compacting, Rising, and Calendaring)
: : : : :
4500 750 300 100 200
CHAPTER - 2 COMPANY PROFILE
2.1 ABOUT REMO AAPPARELS REMO incorporated in 2001 consists of a team of committed and dedicated professionals in serving the domestic market. 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 The organizations commitment to client orientation is found in its vision-“To be the undisputed leader in the lifestyle industry delivering continued value growth for all stakeholders.” 2.4 STRATEGY 1. To consolidate and build current brands of Levis, Genesis, Lee copper, through various product categories. 2. To continue thrust on T-shirt through in-house manufacturing capabilities. 3. Innovations to sustain leadership in T-shirt. 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. ? Matching and continually improving the global management system standards ? Implementing cleaner production technology ? Committed and dedicated work force ? Close cooperation of suppliers ? Maintain legal and other requirements.
2.6 REST ROOM FACILITIES 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
Remo Aapparels organization structure
CHAPTER - 4
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.
full sleeve with collar
full sleeve without collar
Basic sleeve
Kids wear
CHAPETR - 5
PROJECT TAKEN PROCESS
5.1 Project taken process Steps ? First the manufacturer gets the measurement schedule from buyer. ? 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
Space for comments from buyer
Sample measurement schedule after prepared pattern
CHAPTER - 6
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”. 6.2 FUNCTIONS OF FINANCE DEPARTMENT ? ? ? ? ? ? ? ? ? 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
6.3 NEEDS AND IMPORTANCE OF FINANCE 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 ? Planning the product range with the buying team ? Liaising with buyers, store managers, distributors and suppliers ? Visiting manufacturers, stores and suppliers ? Setting budgets using figures and forecasts new range
CHAPTER - 8
PRODUCTION DEPARTMENT
8.1 DEFINITION The set of interrelated management activities which are involved in manufacturing certain products is called as production management. 8.2 MATERIALS MANAGEMENT AND INVENTORY CONTROL 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. The different function of materials management are materials planning, purchasing, receiving, stores, inventory control, scrap and surplus disposal. The integrated materials management will result in the following advantages: ? 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. ? Estimating the individual requirement of the parts ? Preparing materials budget ? Forecasting the levels of investment ? Scheduling the orders ? Monitoring the performance in the relation to production and sales. 8.4 INVENTORY CONTROL ? Fixing economic order quantity ? lead time analysis ? Setting safety stock and re-order level. 8.5 PURCHASE MANAGEMENT These tasks under purchasing are listed below ? Evaluating and rating suppliers ? Selection of suppliers ? Finalisation of terms of purchases ? Placement of purchase orders ? Follow up ? Approval of payments to suppliers 8.6 STORES MANAGEMENT The different tasks under stores are listed below: ? Physical control materials ? Preservation of stores ? Minimization of obsolescence and damage through handling ? Disposal and efficient handling
? Maintenance of stores records ? Proper location and stocking of materials ? Reconciling the materials with books figures. 8.7 INVENTORY CONTROL Inventory is essential to provide flexible in operating system. The inventory can be classified into raw materials inventory remove dependency between suppliers and plant. The work process inventories remove dependency between machines of a product line. The finished goods inventory removes dependency between plant and its customers/market. The main functions of inventory are summarized below: ? Smoothing out irregularities in supply. ? Minimizing the production cost. ? Allowing organisation to cope with perishable materials. 8.8 RAW MATERIALS 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. 8.9 YARN DYEING 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. After this process, the dyed yarn packages are packed 8.10 KNITTING PROCESS 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. 8.11 BASIC PRINCIPLE OF KNITTING 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. 8.12 THE MANUFACTURING PROCESS 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.
Production process flow chart
8.13 Styling 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 The T-shirt sections are cut to the dimensions of the patterns. The pieces consist of a tubed body, or separate front and back sections, sleeves, perhaps pockets, and trim. 8.15 Assembling the front and back 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. 8.16 Assembling the sleeves The edges of sleeves are generally finished before they are fitted into the garment, since it is easier to edge the fabric while it is flat. An automated system moves the sleeves to the stitching head by conveyor. The edge may be finished by folding it over, forming the edge and stitching, or by applying a band. The band may be attached as a superimposed seam or folded over the edge as binding. 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. 8.18 Adding pockets 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. 8.19 Stitching the shoulder seams 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. 8.20 Attaching the neckband 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. 8.21 Finishing the neckline Necklines with superimposed seams may be taped, so that the shirt is stronger and more comfortable. Tape may be extended across the back and over the shoulder seams to reinforce this area as well and to flatten the seam. The seam is then cover stitched or top stitched. 8.22 Ironing
Singular machine
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.
8.23 Label setting
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. 8.24 Optional features Some T-shirts will have trim or screen prints added for decorative purposes. Special Tshirts 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. 8.26 Quality Control Most of the operations in manufacturing clothing are regulated by federal and international 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. The basic components of products qualities are listed below: ? Careful consideration of products design specification. ? Adequate inspection procedures for manufacturing or assembled products ? Acceptance procedures for purchased raw materials and parts and control practices to maintain quality levels in in-process stage. ? Commitment from top management, lower level of management and supervisors towards quality. ? Formulations for quality assurance procedures which are necessary to integrate and coordinate all these functions.
CHAPTER - 9
HUMAN RESOURCE DEPARTMENT
9.1 ATTENDANCE ? Maintain daily attendance chart ? List out the absentees and find out the reason. ? Counseling will give to the absentees after return to work. 9.2 MONITORING EMPLOYEES IN/OUT TIME ? Monitoring employees from their Production Chart. ? Find out their skill evaluation from their supervisors and by direct Observation ? Training should be given to the needed employee. 9.3 MONITORING EMPLOYEE OVER TIME LIST ? Evaluate their skill at the period of overtime and distribute the overtime incentive. 9.4 LEAVE REPORT ? Maintain the leave letter form. ? 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. 9.5 CONTROL ATTRITION ? Reduce absenteeism. ? Shorten the leave duration. ? Interaction and Counseling. 9.6 EMPLOYEE RECRUITMENT ? Introduction about the work, and the Department they are recruit. ? Counseling give when they joining on work.
? Introduce them in their work spot. ? Make them to realize the training period and motivate them to get proper training. ? Give guidance and counseling if necessary. ? Care should be given to the recruits by HR. ? Lengthen the training period of recruits if necessary. 9.7 TRAINING PROGRAMME ? Find out the low skill level employees from their production chart and from their supervisors. ? On-the-job training for low skill employee. 9.8 HR PLAN MONTH WISE ? Weekly HR review meeting. ? Work review. ? Discuss with overall observation. 9.9 PROVIDENT FUND AND EMPLOYEES STATE INSURANCE ? Reduction of 12% for P.F and 1.75% for ESI from employee salary. 9.10 LABOR WELFARE ? Transportation ? Canteen ? Dining hall ? ESI, PF, Insurance and loan facilities ? Incentive
? Counseling ? Rest room ? Fire and safety ? Toilet facility ? Ventilation ? Free accommodation ? Free medical facility ? First-aid ? Drinking water facility 9.11 MOTIVATION TRAINING ? Team work ? Interpersonal development ? Self production ? Behavioral change
? Self efficacy training
9.12 SOLVE EMPLOYEES ISSUES ? Find out the problem of the employees by observation, their friends, and co-workers and from their supervisors. ? Give proper guidance and Counseling ? Interact with them ? Analyse their problem
? Discuss their problem with superiors and find out the solution 9.13 ANALYSE THE EMPLOYEES STATUS ? Find out the total number of employees in each department ? Find out the needed workers in each department ? Recruitment and placement of employees department wise ? Prepare the new employee list department wise and month wise ? Prepare the left employee list department wise and month wise 9.14 AWARD DISTRIBUTION ? Individual performance ? Attendance ? Work efficiency and effectiveness ? Interpersonal relationship ? Co-ordination with workers 9.15 PERFORMANCE REVIEW ? Individual performance ? Attendance ? Work efficiency and effectiveness ? Interpersonal relationship ? Co-ordination with workers ? Rating scale evaluation
9.16 SALARY PREPERATION ? Attendance details ? Overtime details ? Incentive details ? Loan details ? Other reduction details 9.17 PROMOTION AND INCREMENT PLAN ? Recruitment ? Selection ? Training ? Work efficiency and effectiveness ? Monitoring ? Performance appraisal ? Promotion ? Increment 9.18 EMPLOYEES MASTER DATA ? Employees personal details, salary structure and benefits
? Target
9.19 RESPONSIBILITY ? To be prepare the attendance details ? To be prepare the overtime details
? To be prepare the incentive details ? Maintain the loan details ? Maintain the other details
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 Cleaner Production is an attractive approach to tackle environmental problems associated with industrial production and poor material efficiency. The cleaner production approach was successfully implemented in the textile sector. It shows that significant financial saving and environmental improvements can be made by relatively low-cost and straight forward interventions. This improves the quality of products and minimizes the cost of production, enabling the branch to compete in the global market. Moreover, Cleaner Production also improves the company’s public image by highlighting the steps it has taken to protect the environment. The main purpose of this study it to give an overview on the main processes involved in the textile manufacturing. For each process and extensive material and energy balance is provided as well as the impact of each in both environmental and human health terms. It also presents literature that will help on carrying out the cleaner production review especially in the identification of the company performance and in comparing this performance with industry averages.
BIBLIOGRAPHY ? ? ? ? ? ? ? ? S N Chary Productions and Operations Management Tata McGraw- Hill Publishing Muhelemann, Oakland, Loakyer, Sudhir, kalyani, Production and Operations
Management, Pearson,2009 I M Pandey Financial Management Ninth Edition Vikas Publishing House,2006 Willam, Ferell, Marketing, Cengage Learning, 2009 Gary Dessler Human Resource Management Pearson Education 2009 Biswajeet Pattanayak Human Resource Management Prentice Hall of India,2009 http://en.wikipedia.org/wiki/Knitting_yarn http://en.wikipedia.org/wiki/Human_resource_management
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