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PRESENTATION ON APPAREL INTERNSHIP IN
TEXPORT SYNDICATE (I) LIMITED,BENGALURU
NATIONAL INSTITUTE OF FASHION TECHNOLOGY
By Mukul KashyapM.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
5000 Japanese and German sewing machines
Employing more than 11,000+ skilled workers300 + Admin & QASS. Staff throughout its numerous offices and manufacturing facilities in India and internationally
Incorporated in 1976 headquartered in Mumbai India.
16 fully equipped, modern, manufacturing factories based across Bangalore, Mumbai, Hyderabad, Tirpur.
BRASS MANAGEMENT
RAJU GOENKAChairman of the Board and Managing Director Finance
AVINASH MISHRA
Director &CEO
AMIT GOENKADirector - Planning &
Production
SUNIL GOENKADirector - Marketing
CORPORATE & PRODUCTION CENTERS
NEW YORK (USA)Key Apparel Resources
Ltd.
Tirupur HO (INDIA)Type: Production Centre
Bangalore HO (INDIA)
Type: Production Centre
Mumbai HO (INDIA) Type: Corporate Office
CLIENTELE
CLIENTS
American Eagle
Vetura
V.V.M
k.Mart
Mighty Huricane
Top Security
Hurley
George
Walmart Mother Care
Mar Max
Izod
Nostic
Weca
P.V.H
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 , Polo’s,
T Shirts, Crew necks, Hoodies , Sweatshirts & Auto stripe polos
WOMEN ‘S WEAR - Casual blouses, skirts, Tunic’s, Rompers, Casual pants,
Jeans ,sleepwear, kaftans’, dress’s, fashion tops as well as casual jacket’s,
ladies tops, t -shirts, hoodies, polo’s, dresses, sleepwear.
They also specialize in ornamentations, bead work, sequin work,
embroidery, appliqués, 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
Cutting Dept.
Sewing Dept.Finishing section
Fabric sub store
Sampling
Packing & Dispatch
Quality control
Fabric main / Trim store
Production planning
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:
I. Fit sampleII. PP sampleIII. Size set sampleIV. Sealer sample
Process chart
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
Production planning department
Receives the booking order
Generate the factory planning
Generates pcd planning
Generates line planning
Continue……
Generates finishing line
Generates hourly production reports
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.
FunctionsMethod 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.
Fabric main store
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 systemsFault Size Point Assigned
Sticker color
0 to 3 inches 1 Yellow
3 to 6 inches 2 Green
6 to 9 inches 3 Blue
9 & above 4 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 1Supervisor 1Machine operators 2Helpers 4Total 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
Identify the faults and make changes to the recipe
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
Ironing
Final Checking
Presentation
checking
Measurement
checking
Tagging
Poly bag packing
Middle checking
Carton packing
Counter checking
Button mark & sew
Batch Receiving
Kaja and bartack
Send for washing
After wash checking
Trimming
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
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