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Industrial training report
- 1. 1 1.INTRODUCTION: Indian subcontinent isthe second manufacture of garments after china being the global leader in garment production. India is known for its high quality garment for men and most of the garment manufactures are in small and medium scale industry indian men’s clothing industry has been growing steadily over the past few years this has been possible owing to the indian male becoming more fashions conscious, and hence there is more consumption which has increased global demand of men’s garments by the rest of the world. Indian garment industry has an advantage as it produces and exports stylish garments for men at economical price due to cheap labour rates. Today the way of technological advancement and use of sophisticated machinery it has enable the manufacturers to achieve better quality and well designed garments. The contribution of the garment export industries to the exports and foreign exchange earnings has increased in leaps and bounds during the last decode. The demand for garments increasing the international market leading to a decreasing gap between the demand and supply. Since the beginning of the mankind humans have used some kind of garments for their body. The archaeologists and anthropologists say that the earlier clothing was made of leather, leaves or grass, draped or tried to the body, we in the modern times still drape, wrap or tie our cloths. The difference in that of different materials or fabrics we use to make our garments.
- 2. 2 2.HISTORY OF COMPANY: Fiberfashion is fast growing knitting garments manufacturer and export is splendidly steered by the combined vision effort and knowledge of its founders Mr.L.PRABHAKAR and Mr.G.BASKARA RAJA. The company was founded in the year 2004 and has vast experience in main activity namely knitting, processing and conversion to garments. The company is capable of supplying knitted garments to customer requirements competitive price. The company their success in the result of the companies to product quality, on time delivery and human resource. They ensure that product delivery is in line with customer’s requirement. The company core aim is to sustain quality in our production cycle. The company mean it by saying quality is not our aim but it our hanit. They cultivate the habit of being quality in all activities. They have their own internal auditing checkpoits for quality throughout the entire production cycle. Fabric inspection before & after processing Inline auditing End of line checking Pre final inspection Company have done orders in all product range for men,women and kids. Company have come across all of knitted fabrics process Company have a capacity to manufacture an average of 30000 basic styles garments or 15000 value added garments per month.
- 3. 3 TYPES OF MACHINERIESUSED: CUTTING MACHINES: Lay machine Band knife ( accurate cutting) SEWING MACHINE: Pegasus (over lock) Juki computers Air flat lock (pegasus) Cylinder bed flat 10ck(siruba) Siruba (over lock) Pegasus FIC CHECKING MACHINES: Strain remover machine Iron box + stteam box) YARN PURCHASE MILL: 1. SSM group of mill 2. SULOCHANA cotton spinning mill (p) ltd PROCESS/VALUE ADDED: Merceried Enzyme wash Crushing All over print Garments dyed Denim wash EMB/sequence High density print Cold pigment dyed Acid wash Foil/glitter print Digital/photo print Lava dyeing Ball wash Tie & dye Burnout print
- 4. 4 CUTTING PIECES RATE: Powertable + singer = pieces rate Checking = pieces rate/ shift TRACK PANT: CUTTING POWER TABLE SINGER CHECK IRONING & PACKING Rs.3 Rs.12 Rs.18 Rs.4 Rs.4.75 BASIC T – SHIRT: CUTTING POWER TABLE SINGER CHECK IRONING & PACKING Rs.2 Rs.8 Rs.3 Rs.3.75 Rs.4.25 COLLER T – SHIRT: CUTTING POWER TABLE SINGER CHECK IRONING & PACKING Rs. 4.5 Rs.9 Rs.21 Rs.4.5 Rs.4.75
- 5. 5 3.OBJECTIVES OF COMPANY: To increase the standared of living of the people. To satisfy buyer’s wants end needs. To be the No.1 company in Tirupur. Manufacture of the garments and there by making profit. To create an employment opportunity for the people. To improve productivity of the worker through trainning and development program.
- 6. 6 4.COMPANY PROFILE COMPANY NAME: FIBER FASHION PROPRIETOR NAME : Mr.L.PRABHAKAR ADDRESS : No.454/1, PALLADAM ROAD THENNAMPALAYAM (Near IOC petrol bunk), TIRUPUR PIN CODE : 641604 CONTACT : 00 91 421-4324885 FAX : 00 91 421-2217374 MAIL : [email protected] YEAR OF ESTABLISHMENT : 2004 MANUFACTURING ITEMS : T-shirt, Track pant BANK : 132, MANGALAM ROAD TIRUPUR-641604 PHONE : 00-99-421-2200563 FAX : 00-99-421-2245762 TIN : 33872427135 CST : 1159734 IE CODE : 3214005740
- 7. 7 5.ORGANISATION CHART: MANAGING DIRECTORS GENARALMANAGER PURCHASE DEPARTMENT PRODUCTION DEPARTMENT SALES DEPARTMENT QUALITY CONTOL DEPARTMENT STORE DEPARTMENT ACCOUNTS DEPARTMENT PURCHASE MANAGER PRODUCTION MANAGER SALES MANAGER MANAGER STORE KEEPER ACCOUNTANT PURCHASE OFFICER SUPERVISOR ASSISTANT WORKERS WORKERS CASHIER ASSISTANTS WORKERS WORKERS STAFF ASSISTANT WORKERS
- 8. 8 6.OBJECTIVES OF TRAINING: To study the organisation structure To have a practical knowledge about in garments function To know the various functions of the department To know the working environment of organisation as a whole To know the function of organisation towards their goal
- 9. 9 7.FUNCTIONS OF VARIOUSDEPARTMENTS: The functioning of various departments in FIBER FASHION are 1. Purchase department 2. Production department 3. Stores department 4. Quality contol department 5. Sales department 6. Accounts department
- 10. 10 7.1 PURCHASE DEPARTMENT: Thepurchase department was maintained by the purchase manage. All the purchasing bills invoice are maintained by this manager. They maintain separate account for their purchase. FLOW OF CONTROL Purchase manager Purchase officer In purchase department the main aim is to get quality raw materials. The basic raw materials purchased in every company is the yarn. According to the customer the order of fabric they are purchasing. The raw materials(fabric) are purchased in weight basis. Therefore small untill will buy the raw materials from this dealer. They will also arrange the purchase of needles to trims requirement for the garment. Assistant officer Workers
- 11. 11 RECORDS MAINTAINED BYPURCHASE DEPARTMENT: Basic sample collection list Offer sample test result note Purchase confirmation register Confirmation order
- 12. 12 7.2 PRODUCTION DEPARTMENT: Productionis a very impartant and highly technical area in an organisation, which can be divided into several units. Production mean “convertion of raw material as fabric into finished goods as garments”. The major function of this department is managed by the production manager. This department in backbone of the organisation. In this industry production department is a largest department. According to buyer’s requirement, the present market survey and marketing department, details are collected regarding the pattern, measurement and way to produce a garment from a fabricated cloth. The work should be completed and delivered within the required time. In this production department, I visited fabric section, cutting section, sewing section, stitching section, checking section, ironing section and final packing section MANUFACTURING ITEMS PER DAY: Track pant – per day 600 pieces Basic t – shirt – per day 800 to 900 pieces Collar t- shirt – per day 600 pieces MANUFACTURING STYLES: Men’s crew Neck Ladies – T- shirt Kids t- shirt Jackets Men’s V Neck Leggings Rompers Hoodiles Track pant Pyjamas Pull over Shorts Sweat shirts Night wear Track top Baby suit
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- 14. 14 FABRIC SECTION: The fabricsection receives fabric from the head office. The purchase of fabric section was managed by purchase manager and the details are maintained in head office. The fabric details are entered in the checking register. The purchasing fabrics are: Jerseys French Auto stripers Griddle Ribs Fleece Jacquards Space dyed Air Tex Single/double PQ waffle Neppy melange Interlock velour slub Poly & viscose blends FABRIC PROCESS: In fabric section they relax the fabric for 24 hours relax is normal relaxation. The maximum time of relaxation is 48 hours. The time is varied according to their cloth nature. They maintain two things shade approvals. The controller gives the report after fabric is tested.If the test is acceptable by the lab, it will ready for cutting section, otherwise it will send to reprocess.
- 15. 15 CUTTING SECTION: Cutting departmentis responsible for cutting fabrics and feeding the sewing section with cutting. The cutting section capacity is planned based on the daily feeding requirement of the sewing lines. The cutting is set up with the cutting department head, cutters, spreaders, quality checker and helpers for storing, part numbering and bundling/shorting. The cutting supervisor receives the tested fabric from fabric section. Also obtain pattern board from pattern master, and then do further process. Sample cut piece in all size would be made and after getting the approval by the production in-charge, arrange for bulk cutting.
- 16. 16 SEWING SECTION: After receivingthe garments components from cutting section, all the garments parts are joined and sewn as sequentially. Obviously all the components are sewn respects on buyer requirement. Sewing section is the most important departments of a garment manufacturing industry. Sewing machines of different types are arranged as a vertical line to assemble the garments. Sequence of types of sewing machine arrangement depends on sequence of assembling operation.
- 17. 17 STITCHING SECTION: After thecloth stitching is done using machines like singer, over lock, flat lock. According to style of the garment, model is submitted. Stitching of a garment will then take place. The stitching supervisor (or) co-ordinator receives the cutting pieces, order copy specification sheet, the approval, accessories and stitching plan from respective department leads for converting into stitched pieces. THREE TYPES OF MACHINES ARE USE OF IN STITCHING: Singer Over lock Flat lock The stitching unit is equipped with latest sewing machines easily adoptable to accommodate and execute the exact requirements as per the customers styling needs
- 18. 18 CHECKING SECTOIN: The checkingsection is most important section in the production department. If any careless made in this section the customer satisfaction of this organisation will reduced. The supervisor receives the stitched garments for online. Piece to piece checking with they regard to measurement accessories, fabric stains, holes and other if any. The checking supervisor receives stitched pieces along with order copy specification sheet and the approved accessories from the respective department heads. Also verifies the delivery challah with the actual quality received. Each and every piece stitched garments will be checked with regard to fabric weight, stain, holes, piece weight accessories position, loose thread parts positioning depends upon the requirements.
- 19. 19 IRONING SECTION: Ironing isthe process of increasing the aesthetic quality of the garments. For ironing, steam ironing and vacuum tables are used. We must control the temperature spreading of garments, effective dispersion of steam measurement etc… IRONING PROCEDURE: The checked garments iron without any wrinkles before packing. In this section the steaming machines are used to supply heat. The steam is supplied to the iron box by the way of steam line (steam pipe) Remove the crease mark Remove the shrinkage Increase the aefchetic quality
- 20. 20 PACKING SECTION: Packing isthe final section of production department. when packing the garments poly pack, carton box are used. Garments should be packed according to the buyer requirement. The carton box contain the following details - Buyer name - Order number - Carton number - Garments style number - Garment colour - Size - Net weight - Gross weight Size of the garments: - S – small - M – medium - L – large - XL – extra large The stores department is located near at production department. The stores department is used for storing the raw materials, and spare particles. The store department details are maintained by store keeper. All the materials which are stored in this department was arranged by the workers. The store keeper is fully in-charged for the materials inside the store. In this store stationary materials also kept for purpose of usage in all department
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- 22. 22 7.3 QUALITY CONTROLDEPARTMENT: Quality is of prime importance in any aspect of business. Customers demand and expect value for money as procedures of apparel there must be a constant to procedure work of goods quality. The system required for programing and co-ordinating the effort of the various group in an organisation to maintain the quality. As such quality control is seen as the agent of quality assurance or total quality control establish acceptable working tolerance in to all values on the specification. Establish fault rate recording system. Improve technical understanding of the product including.
- 23. 23 7.4 SALES DEPARTMENTS: Thesales manager is responsible for selling a company’s products to computers, working with the team of sales representatives. And he is responsible to get order from international markets. Sales manager may also be responsible for recruiting sales representatives, settings sales target and monitoring achievement and client feedback. They also analyse sales data to uncover any trends and identify new information. Sales manager sometimes have to deal with major customers on a personal basis. They attend meetings, conference and trade fairs on behalf of the client. Sales manager spend most of the time in office environment but may travel frequently to meet clients and attend trade shows. STRUCTURE OF SALES DEPARTMENT: Executive manager Assistant manage In export sales merchandisers are appointed when the buyers and sellers enter into contract. Through agents or merchandiser the company exports the garments to foreign companies. EXPORTS COUNTRIES: The company mainly exports to FRANCE and USA. The other export countries are Canada, UK, Italy, Japan. Workers
- 24. 24 7.5 ACCOUNTS DEPARTMENTS: Theaccounts department under the administrative manager maintains the accounts of the company. Maintaining accounts is an important function in every of trading, without proper accounting they cannot know their position or financial level and stock levels. BOOK MAINTAINED: PURCHASE BOOK: The purchase book is the separate book to enter the purchase made with the outsides. The main role of purchase made in the company is purchase of raw materials. The amounts of articles purchased are entered in their respective column and the book is prepared monthly, the entries will be made according to the product wise. SALES BOOK: Sales book is the main book to be maintained with the following details: Sales are recorded in the basic of data, Bill number are to be note down in the records, Amount of the articles which are sold, will be entered in it. If the firm allows any discount to their customers to improve their relations it should be entered in separate columns of the book. CASH BOOK: All the cash transaction are passed through this cash book. This cash book was maintained by the cashier. The cash transaction are posted in the cash book. It has two columns namely cash and bank column. PURCHASE LEDGER: The purchase officer enters purchase vouchers and bills received are recorded in the purchase journal. The book is also called “ Bought note”. The purchase officer enters purchase vouchers and materials inwards into the computer. SALES LEDGER: The purpose of this book is to record sales of goods. Sales bills are prepared in sales office and entered in the computer. Cash sales are entered separately.
- 25. 25 CREDITOR’S LEDGER: The balanceoutstanding by the supplier is recorded. This part of the ledger enables the trade to calculate rapidly the balance due to each creditor. DEBTOR’S LEDGER: In this ledger the accounts of all our customer’s to whom goods have been sold on credit are recorded. This ledger is also known as “ sold ledger/customer ledger”. STOCK LEDGER: Materials inwards and outwards are posted to various material accounts. Work-in progress and finished goods are valued and recorded in separate system in the section. PROFIT AND LOSS ACCOUNT: The profit and loss account of the year prepared by accountant audited by the auditor, the audit report submitted to management to know the accurate profit and loss of the company. BALANCE SHEET: The balance sheet contains the assets and liablity. It helps the partner to know about the company’s financial position. It helps in indicating whether the firm has sufficient assets and liabilities.
- 26. 26 8.CONCLUSION: During the periodof my training in FIBER FASHION, I have studied the lot of fuctional aspects of the various departments like production, purchase, sales, accounts departments etc. From this training I have also trained with the flow and delegation of authorities from the top level management to middle level and lower level of management. The industrial training has provided a valuable knowledge on various function of different departments. This course enables me to have a correct view of the various practical as and difficulties of the various theoretical formalities are immensely benefits the training program.
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