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