NATIONAL INSTITUTE OF FASHION TECHNOLOGY

PRESENTATION ON APPAREL INTERNSHIP IN

TEXPORT SYNDICATE (I) LIMITED, BENGALURU

By Mukul Kashyap M.Ftech IIIrd Sem. Nift Gandhinagar

Company profile
Estd. in 1978 with a secure foundation in garment production (knits & woven) Thirty Four years to the manufacturing of both knitted and woven apparel Incorporated in 1976 headquartered in Mumbai India.

16 fully equipped, modern, manufacturing factories based across Bangalore, Mumbai, Hyderabad, Tirpur. 5000 Japanese and German sewing machines

BRASS MANAGEMENT

RAJU GOENKA Chairman of the Board and Managing Director Finance

SUNIL GOENKA Director - Marketing

AMIT GOENKA Director - Planning & Production

AVINASH MISHRA Director &CEO

CORPORATE & PRODUCTION CENTERS

Mumbai HO (INDIA) Type: Corporate Office NEW YORK (USA) Key Apparel Resources Ltd.

Bangalore HO (INDIA) Type: Production Centre

Tirupur HO (INDIA) Type: Production Centre

CLIENTELE

CLIENTS
Walmart Mother Care Mar Max Izod Nostic Weca American Eagle Vetura V.V.M k.Mart Mighty Huricane Top Security

P.V.H

Hurley
George

PRODUCT MIX
Texport Syndicate over the years has become a major player in a number of clothing categories:MEN S WEAR - Basic Casual /Dress shirts, Fashion shirts, bottoms , Polos, T Shirts, Crew necks, Hoodies , Sweatshirts & Auto stripe polos WOMEN S WEAR - Casual blouses, skirts, Tunics, Rompers, Casual pants, Jeans ,sleepwear, kaftans, dresss, fashion tops as well as casual jackets, ladies tops, t -shirts, hoodies, polos, dresses, sleepwear. They also specialize in ornamentations, bead work, sequin work, embroidery, appliqus, and discharge prints.

Product

Tops, shorts, coats, T- shirts, skirts, shirts, Bermudas, Briefs, suits, children wear, pants, casual wear, Gowns, Jackets, Trousers, Jeans, and Boxers etc.

Department-wise process flow

Merchandising

Sampling

Production planning

Cutting Dept.

Fabric sub store

Fabric main / Trim store

Sewing Dept.

Finishing section

Quality control

Packing & Dispatch

Merchandising
In Texport, the merchandising can be divided in two parts: Marketing Merchandising Product Merchandising marketing merchandising Product development Costing Getting Purchase Orders It brings the order, develops the product, and does the costing. It has a direct access to the Buyer.

Product Merchandising

This is from sourcing to finishing that is from first sample to onwards, the product merchandising work starts and ends till the shipment

Sampling

The package file is received from the merchandiser and the copies of it are handed over to the sampling manager, CAD in charge, sampling technician and the sampling QA in charge. The pattern request is received from the merchandiser by the sampling manager for the following samples:

Request from main store Receiving sample fabric from main store Lab number is assigned Conditioning Shrinkage and test reports are prepared Reports are sent to merchandiser

Generate the factory planning

Generates pcd planning

Generates line planning

Continue

Decisions with units

I.E
The Industrial engineering department is primarily responsible for monitoring of the batches from the batch setting period,

throughout the production process until the

incentive earned by the operator and line.

Method Implementation in the batch. Issuing and maintaining gum sheets of each operator. Generating Daily production report and style-wise efficiency report.

Maintaining incentive report.

To conduct Time study of each operator at pre-fixed intervals. Create and update skill matrix of each operator & submit the same to personnel department. Assist in Factory planning.

Texport syndicate has a centralized main fabric store located at TS-IV. All fabric and interlining is received by the main fabric store and distributed further to various units according to required quantity. All the units have fabric sub stores locate in the unit itself The fabric main store consists of a fabric incharge, godown incharge, fabric checker, fabric QC, QA executive, stores assistant, computer operator, DTP operator and fabric assistants.

Physical Testing & Inspection:

Fabric is inspected by using a 4 point system. It is a projection of total defects based on the total number of defects found during inspection of a sample as a basis for acceptance/rejection criteria. In this point inspection system penalty points are assigned base on the standard fault. For every type of fault colored

stickers are put, to identify serious defects in the

subsequent process.

Four point Inspection systems

Fault Size color 0 to 3 inches 3 to 6 inches 6 to 9 inches 9 & above Point Assigned 1 2 3 4 Sticker Yellow Green Blue Red

Common Fabric Defects Found Are:

Weaving Defects:-Missing picks, end out, mixed filling, mixed ends, dropped pick, slubs, yarn distortion, pattern fault, stop marks, holes, etc.

Dyeing/printing/finishing Defects:-Bowing, Color Bleeding, Puckering, stains, Skewed or biased, Selvedge variation, scrimp etc.

Cutting department

Receive package file Receive total order quantity Divide total quantity into lays Issue lay slip to the spreader Lay brown sheet, set length and put two to three plies Get Q.C. approval for length, width, and continue spreading once approved Give lay slip and lay report to cutter

Continue.

Marking (manual cutting) or lay plotter marker (auto cutting) Cutting Maintain the record of the lays cut in minusing register Sorting Bundling and numbering Part banking and issue to sewing

Sewing department
Report maintained by Sewing Department

Daily production report Purchase order sheet Folders send by IED for every P.O. Manpower report Hourly production report Monthly labor report Batch order completion Batch planning file Cutting loading book Time and motion study

Quality Check

Inline quality check End-line quality check

Inline

Inline inspection is done after every critical operation.

This are---

Collar end Sleeve and cuff end

Front end
Collar attaching Side seam (feed of arm)

End line

End of the line inspection is done after the last

operation.

Inspection
The evaluation process consists of the following steps applied to each characteristic 1. Interpretation of the specification 2. Measurement of the quality of the characteristic 3. Comparing 1 with 2 4. Judging conformance 5. Processing of conforming items 6. Disposition of nonconforming items 7. Recording of data obtained

Purpose of inspection
The purpose of inspection and test is to determine the conformance of the product or service to the standard or specific requirements and to disposition the product or service based on the results of the evaluation This determination involves three main decisions Conformance decision: To judge whether the product conforms to specification Fitness-for-use decision: To decide whether nonconforming product is fit for use Communication decision: To decide what to communicate to outsiders and insiders

Washing
Location:

Texport Syndicate Unit 2

Infrastructure:

Tumble drier (60 kg) (Ramsons) : 6 Cooler machine (25 kg) (Ramsons) : 1 Dry Cleaner (25 kg) (Suprema) : 1 Industrial Washing Machine (180 kg) (Ramsons) : 6 Hydro Extractors (25 kg) (Ramsons) : 2 Sample washing machine (20 kg) (Ramsons) : 1

Work force:
Washing head Supervisor Machine operators Helpers Total 1 1 2 4 8

Process chart
Receive garments from finishing department

Check garments in accordance to the quantity mentioned in

D.C. Store garments in before wash racks Buyer approved wash standard received from merchandiser Carry out 1st bulk wash

Continue..
Bulk wash ranges send to buyer with comments Comments received from buyer Bulk washing is carried out Hydroexractor

Tumble dry

Continue.

Garments are inspected as per A.Q.L 2.5

Grinding if required for the style

Garments send to finishing for packing

Finishing section

Counter checking Button mark & sew Batch Receiving Kaja and bartack Send for washing

Ironing
Final Checking Presentation checking Measurement checking Tagging Poly bag packing Middle checking

After wash checking

Trimming

Carton packing

Packing
This is a part of finishing section, but maintained differently and inside a cabin like-structure. Here all the final processes of packing the garments for the dispatch is done. The processes followed inside are: 1.jocker tag attachment 2.price ticket attachment 3.garment folding 4.poly bag packing 5.Carton packing

Shipment
A quantity of good that are shipped together as a part of same cargo. Once the production is done than the garments are packed in accordance to the buyer specifications.the packed garments are then needed to go for shipment . This is done by the following wasys 1.truck/lorries 2.train 4.ship 4.by air