CONTENTS

INTRODUCTION TO GARMENTS INTRODUCTION TO THE COMPANY AS AN INTERNEE MY ROLE COMPANY PROFILE MISSION AND VISION OF THE CONCERN PRODUCT PROFILE ORGANIZATIONAL CHART OUTCOME OF THE INTERNSHIP CONCLUSION

INTRODUCTION TO GARMENTS

The word hosiery is probably derived from the French word, Bonneterie hoer. The term hosiery was known to the people only from the 16th century which means complete covering of the legs. The term hosiery includes machines knitted garments of all kinds of jersey, knickers, batting costumers, beach wear combinations, pants, gloves, waist coasts, sports, vests (Banians, Socks etc.) Hosiery export is a chief source of foreign exchange earnings; Indian export of hosiery products has undergone many ups and downs in the past. The government has made many efforts to boost export. Hosiery generally means knitted fabrics, knitting process involves in interloping of thread with the help of needles. The knitting industry has been concentrating on the production of only underwear garments. However with recent shift in clothing habit in India, knitted fabrics are becoming increasingly popular for outerwear garments. Garments are one of the basic necessities of life like shelter and food. It is used by every individual of the world. The trend of garments also changes according to the needs and fashion of the people. Garments industry is one of the leading sectors which earn high foreign exchange earnings to the country. Indian garments are very well known for its quality and its best prices. The knitwear garments of tirupur are popular worldwide. Textile manufactures of tirupur are producing different types of garments to cater to the needs of childrens, mens, women, and the like. Tirupur garments are exporter to many countries across the world, particularly to USA, UK and European Countries.

CHAPTER 1

INTRODUCTION TO THE INDUSTRY

The Indian garment industry is characterized with high level of uncertainties and high level of fast changing consumer preference, fashion change etc...Garment companies are facing threats due to change in environment and policies. The garment companies have to adopt different modes of marketing because the competition has increased in the hosiery fields. The first hosiery business in Tirupur was started at 1999.At that time machineries were mostly imported from foreign countries such as Japan, Germany, Newyork etc., At present, there are more than 2500 companies in TIRUPUR. They are giving employment opportunities for both skilled as well as un-skilled workers. About half of the population in Tirupur is working in garment industries. NO DOUBT, TIRUPUR IS REFERRED TO AS BANIAN CITY.

ABOUT THE ORGANISATION

KESARINANDAN KNIT FABS is a private limited company, which was established in the year 1995,with an initial investment of Rs.3 Lakhs with only 10 employees. At present the capital of the company is more than about Rs.40 lakhs.

This is a renowned manufacturer and exporter of quality knitted hosiery garments in SOUTH INDIA. The company manufactures basic inner-wears for all age group, both for MEN AND WOMEN and high fashioned casual wear for all ages right from just born babies.

The products are well accepted in the domestic market as well as international market for its premium quality. It has a well established domestic market with a strong agents-distributors-dealer network.

HISTORY
KKF KNIT FABS is one of the leading garment manufacturers in TIRUPUR. The Company was established in 1995.The main promoters of the group are Mr. Sajan Parmanandka and Mr. Purusottam Parmanandka. The limited product range manufactured were marketed within the state at initial stages and gradually, the group penetrated into all the regions of the country an has established its own brand image in the Indian market. KKF knitting company has been a fore runner in the Knitting industry since 1999.They manufacture and export qualities knitted garments. They have made a global impression by extending their frontiers to various continents. They are equipped with technical expertise through competent technology and robust machinery about 750 skilled men work in communication with state of art technology in an effort to bring the best products to its clients.. KKFS products include knitted garments for newborn, baby, kids, toddlers, women and men. T shirt, raglan T shirts, romper T shirts, cardigan T shirts, skirts, jumpsuit, shorts, pant, tops, booties, caps, scarfs form bulk of our exports

AS AN INTERNEE - MY ROLE
As an internee I acquired detailed knowledge about the various sub process carried out in the production section. The major units under production section are as follows: KNITTING UNIT DYEING/BLEACHING UNIT COMPACTING UNIT PRINTING UNIT CUTTING UNIT

EMBROIDERY UNIT STITCHING UNIT CHECKING UNIT IRONING UNIT PACKING UNIT

KNITTING UNIT

The knitting plays the back bone for the knitted garments production or manufacturing. The knitting process is the conversion of yarn into cloth. It is also referred to as FABRICATION. It is the foremost stage in the production process. The company has both both local as well as imported knitting machines. Most updated High Speed Knitting Unit imported machines produce high quality fabrics including single and double jersey, jacquards, auto/engineered stripes, yarn dyed, interlocks and pique and fleece.

FABRIC RANGE:

Single/Double jersey Drop needle Feeder stripes Mini/full jacquard Waffle Interlock Loop knit Pique Yarn dyed auto stripes Single/Double rib Airtex Mesh Air mercerized Terry

Fleece Cotton, Polyester mix

DETAILS OF KNITTING MACHINES: IMPORTED KNITTING MACHINES

* MAYER & CIE * TERROT * NO.OF MACHINES IN KNITTING UNIT ARE: 55

BLEACHING/DYEING UNIT
This is the second stage in production process. The cloth is decided to be bleached or dyed at this stage. After knitting, the fabrics is decided whether to bleach the fabric or to dye the fabric.

DYEING UNIT

The fabric comes as grey color from knitting (the yarns original color).THE PROCESS OF ADDING COLOUR TO THE FABRIC IS KNOWN AS DYEING.

DYEING MACHINES:

Imported Bleaching, Mercerizing, Jet Dyeing Yarn or Fabric is dyed into vibrant colors. Superior mercerizing and technology driven finishing provides superior products of global standard.

DYEING CAPACITY-3000 KGS PER DAY

BLEACHING UNIT

To turn the grey color fabric into white color, the bleaching process is done. The company has both soft flow machines and winch machines. The process time for the bleaching is 5 hrs and for dyeing is for light shades around 8 hrs and for dark shades around 12 hrs. The rates for the dyeing and bleaching depend upon the shades and the chemicals used and the machines used whether winch or soft flow machines.

BLEACHING CAPACITY-3000 KGS PER DAY The laboratory test done in the dyeing lab for ensuring the quality is as follows: SHADE CONFIRMATION RUBBING FASTNESS WASHING FASTNESS FINISHING CONFIRMATION SUCH AS STONE

WASH, DENIM FINISH, AND SILICON WASH.

COMPACTING UNIT

After dyeing the fabric is dried and compacted in the compacting machine. Basically, the knitted garments has more elongation and strechability, which is a dis-advantage in this field. Although GSM is adjusted and textures are adjusted properly in the imported machines, when we go for wetting process such as bleaching, dyeing or when we use it regularly and wash it for the next time, we may find some disorder in shape of the garment either it may expand or congest in widthwise or lengthwise, to avoid this compacting is done.

COMPACTING MACHINES:
Computerized Continuous Finishing Compacting, Hydro Extraction, and Shrink Dyeing ensure shrinkage is limited to a 5% level.

CUTTING UNIT
After the fabric is compacted, it is brought to the cutting unit, where cutting is done both manually and through cutting machines. The fabric is been cut according to the pattern of that particular garment or product.

EMBROIDERY UNIT

The embroidery is the value addition process or decoration done on the garments. The threads such as nylon, polyester are used for designing. The motif or the foam is used for stitches. The first process is the punching or the design drawing in the computer and the incorporating in the floppy discs and feeding the design in the embroidery machine.

EMBROIDERY MACHINES:
TAJIMA WITH 12 HEADERS & 12 COLOURS. Computerized Embroidery Machines modular 60 heads machinery affords complete flexibility in colors and designs. The company in addition to its knitting and dyeing plants, it owns quality checking section, ironing section, etc., It also provides Design Resources which are customer specific dependant on customer's unique needs.

PRINTING UNIT

Printing is a process of making and pasting pictures or figures in the fabric. Before printing, the fabric is sent to the cutting unit and it is cut and then the printing on the fabric is done. The printing is the process of pouring the printing paste in the screen and pulling and penetrates in the screen. The required design is first drawn in the art sheet with the marker and kept in the dark room and the UV-Light is passed then a weight is placed on the top and the design is transferred to the blank screen and it is fitted to the printing machine. Their print house comprises of two divisions, rotary printing and chest printing. The rotary printing division is capable of printing 10 colors simultaneously in pigment, reactive and discharge printing. They also have a well equipped facility for chest and table printer.

THE TYPES OF PRINTING TECHNIQUES ARE: I. II. III. TABLE SCREEN PRINTING CIRCULAR CHEST PRINTING ROTARY PRINTING MACHINE ETC. PRINTING CAPACITY -3000 KGS PER DAY

PRINTING MACHINES:
Printing unit has diverse printing options including screen printing, rubberized printing, reactive, discharge, puff, light sensitive and special effects printing. We specialize in Reactive, Discharge and plastic prints using imported dyes and chemicals totally azo free.

STITCHING UNIT

The production is the process of completing the fabric into a garment. The cutting is done both manual and by cutting machine. The cutting machine is of capacity 3000 pcs. Also after cutting, embroidery and printing can be done and the fabric is sent to the stitching unit, where the garment attains its finishing stage. The sewing operations are done through machines like, siruba over lock tape cutting machine siruba flat lock.

TOTAL NO.OF MACHINES IN STITCHING UNIT: 250 PEGASUS KANSAI SPECIAL SIRUBA YAMOTO JUKI

CHECKING UNIT

After the garment is being stitched in the stitching unit, the garment is taken for checking, in the checking unit. If any alterations or mistakes are found, they are to be rectified before they are sent to the packing section. In such cases the garment is again taken to the stitching department.

IRONING UNIT

After checking is over, the garment is ironed and taken to the packing unit for safe packing.

PACKING UNIT
The finished garments must be well packed not only to give good appearance but also to ensure safety to the garment. The packing

materials used by the company to pack its garments are mainly cartoon boxes. They purchase those cartoon boxes from outside manufacturers and use them for packaging. The size of those boxes varies according to the size of that garment being packed. Safe packing is done at the packing unit. All production facilities available at DSP come under the strict supervision of the Quality Assurance Department. An elaborate system to control and monitor all orders is done through an Order Management System, which tracks the status of each order in production.

QUALITY CONTROL
Centralized quality control system is maintained with strict supervision in order to maintain good quality

QUALITY POLICY:

At KKF, quality is the driving force behind each of their operations. They believe, A GOOD PRODUCT SPEAKS MORE ABOUT THE MANUFACTURER THAN ANYTHING ELSE and hence they take all possible efforts to give their customers the best! Every process is lined with meticulous quality control and supervised with precision, right from purchase up to delivery. This groups are committed to work towards enhancing their customers satisfaction by consistently producing quality knit garments and delivering them on time to achieve this they, Implement the internationally accepted quality management Establish methods to determine the changing needs of the market With their vast experience in knit garment manufacturing, they system. and customers. establish methods for continually improving the effectiveness of the process. They establish a close working relationship with all their suppliers, guide and monitor them to supply quality goods.

CHAPTER 2 COMPANY PROFILE

NAME OF THE ORGANISATION : PRIYA KNIT FABS

NATURE OF BUSINESS HOSEIRY GARMENTS. REGD.OFFICE ADDRESS ROAD,

MANUFACTURERS OF KNITTED

S.F.NO.360/B2, DHARAPURAM TIRUPUR-641 608

PHONE NO DIRECTORS

: :

0421 2262555 MR.MOHAN MR.KUMAR

MISSION AND VISION OF THE CONCERN

l The main objective of the organization is to manufacture their products and that are to be accepted in the domestic market as well as international market for its premium quality. l l They aiming at making a global impression by extending their The organization is producing product with good quality in order frontiers to various continents. to satisfy their customers.

The organization is seeking various orders from various buyers

from different countries to extend their name all over the world.

PRODUCT PROFILE
l l The organization is of the top most manufacturer and exporter of The company manufactures basic inner-wears for all age groups,

quality knitted hosiery garments in SOUTH INDIA. both for men and women and high fashioned casual wear for all ages right from just born babies.
l

KKFS products include knitted garments for newborn, baby,

kids, toddlers, women and men.

T shirt, raglan T shirts, romper T shirts, cardigan T shirts, skirts,

bodies, jumpsuit, shorts, pant, tops, booties, caps, scarf form bulk of our exports

3. ORGANIZATIONAL CHART
I. Yarn

Fabricated Cloth Bleaching or Dyeing

Steam Calendaring

Production Unit

Cutting Section

Embroidery or Printing

Stitching Section

Checking Section

Ironing

Packing Section

Sales

DEPARTMENTS:
PURCHASE DEPARTMENT STORES DEPARTMENT PRODUCTION DEPARTMENT KNITTING UNIT DYEING UNIT BLEACHING UNIT

COMPACTING UNIT PRINTING UNIT CUTTING UNIT EMBROIDERY UNIT STITCHING UNIT CHECKING UNIT IRONING UNIT PACKING UNIT

l PURCHASE DEPARMENT
BASIC MATERIALS:
YARN is the primary and the important factor that determines the further and the related sub-sequence process. the selection of yarn is very important .the yarn is first purchased from the standard mills of the required count and if required as specified finishes and special process done to the yarn during spinning such as electronic yarn, combed yarn, carded single yarn or buying the yarn and further process as yarn dyeing. Generally, the yarn used in hosiery field is from 10s40s count yarn.

The basic materials that are purchased for production are yarn, stitching threads, needles, packing materials. The quest for perfection and quality starts right from the raw material stage and continues to the finished product. The entire production is managed in-house, to ensure that all specifications and quality requirements are met promptly and accurately.

STORES DEPARTMENT:
The yarn purchased for production, and the finished products, that are ready for sale, are kept in store house called GODOWNS.

METHOD OF STORING:
The yarn and the finished products are warehoused separately. The packing materials such as carton boxes are also stored here. The store house is located within the company itself.

DUTIES OF STORE-KEEPER:
Take good care of goods in store house

Maintain the records properly, regarding the goods stored Strictly follow the rules and regulations in the ware house. Eg:

NO SMOKING

PRECAUTIONERY MEASURES:
RISKS ARE UNAVOIDABLE IN EVERY SITUATION. If something unexpected takes place and as a result of that, there is some damage caused to the goods ware-housed in the storage unit, that brings loss to the company. To avoid such critical situations, the company has insured its assets, not only the raw materials and finished goods, but also the companys machineries, vehicles etc

PRODUCTS MANUFACTURED:

The companys products include babies & childrens wears, Tshirt, trousers, night wears, kids wears, casuals, inner wears, sports and beach wears etc..

PRODUCT RANGE:
- 100% COTTON KNITTED HOSIERIES. Jogging suits Pyjama sets T-shirts Night wears Polo shirts Leggings Pique shirts Pull overs Boxer shorts Shorts

Jackets Childrens wear Skirts

PRODUCTION DEPARTMENT:
The production department is based on the following units and its process.

KNITTING UNIT DYEING/BLEACHING UNIT COMPACTING UNIT PRINTING UNIT CUTTING UNIT

EMBROIDERY UNIT STITCHING UNIT CHECKING UNIT IRONING UNIT PACKING UNIT

MARKETING DEPARTMENT
Marketing is a process in which the seller finds a buyer to his products .The company has two types of market

EXPORT DOMESTIC MARKET Australia Holland Austria Canada Denmark France Germany Sweden U.K

The companys overseas market includes

Hongkong Hungary Italy Norway Saudi Arabia Switzerland U.S.A

DOMESTIC MARKET
The company has a very good local market throughout the country. They have agents and authorized dealers for their products all over the country state wise.

TYPES OF CUSTOMERS:
As the company manufactures different types of products like tshirts, casuals, night wears etc for all ages, right from just born babies, the customers are both man and women and different ages .The companys product has gained importance in the market, due to its wide range of products and different types of customers.

DEALERSHIPS:
There are various authorized dealers for the company's product, all over the country. They are both wholesalers as well as retailers. The companys dealers construct showrooms in order to display its product and that has attracted the people the most and has induced them to purchase the same.

The company has more number of dealers within the state as well as in other states. Particularly, the company has quite a more number of dealers for is well-known products in TAMILNADU .In

Tirupur, there are about 6 manufacturing units for the garments products.

Some of the other states, in which they have dealers for its products, are, Karnataka Kerala Gujarat Andhra Pradesh Maharashtra New Delhi Calcutta

MODE OF ADVERTISEMENT:
Media advertising is an effective medium of promoting the business activities through Advertising. The Company also advertises its product range in newspapers, channels etc

CREDIT PERIOD:
The credit period provided by the company to its customers differs according to the total number of orders that have been placed, quantity of products ordered and the types of customers.

FINANCE DEPARTMENT
Finance is the life blood of every business organization. To arise the right finance at the right time of need, every organization should maintain a separate department for finance. It is not only meant for arising the companys fund but also for recording and analyzing every transaction taking place within the organization. It also has a separate department for finance. They record purchase bills for raw materials, processing bills etc. Each bills and receipts are checked and verified by the finance department. E.g.: Dyeing, chemical bills are checked and passed to the accounts department.

The company follows the internal audit system .All the bills are internally audited by the internal auditor of the company and he verifies the bills and looks after the finance department.

HR DEPARTMENT
In all the organization, another important factor to be considered is the welfare of the workers in that particular company or organization. In this company there are about 250 workers, working for the company in a single unit alone. There are 5 units for the company. Totally on the whole, there are about 1500 workers, working for the company. Hence, it becomes necessary to take good care of the

employees by motivationg, promoting and appreciating them and taking steps to solve their problems, both official and personal. The worker must be provided with a good working conditions and machineries, so as to work more and contribute to the companys income and profit.

PUBLIC WELFARE PROGRAMMES:

The company jointly with some service oriented organization conducts medical camps, by which the public are benefited. They provide free medical camps and check up, free medicines and performing operations and surgery at free of cost.

RECRIUTMENT:
Another important work of the HR department is to recruit people at times of need and place in the jobs.

SELECTION:
Advertisements are made for the recruitment through the mass media to the specified post box no. The applicants for the different posts in the company are interviewed and selected by the HR department.

TRAINING:
The selected applicants will be placed under two months training programs called the probatory period

PERFORMANCE APPRAISALS:

The performance of each individual worker and staff are been noted by the concerned departmental manager and they report to the centralized HR department.

GREIVANCE HANDLING:
For all the problems of the workers whether it may be within the workers or between the workers and the management, the concerned department manager is wholly responsible for it and he takes good care and solves the conflict without any harm to both the sides.

 PRIYA KNIT FABS GALLERY

CHAPTER 4 OUTCOME OF THE INTERNSHIP

The internship period helped me to gain abundant knowledge about the organizations objectives, processes, way of handling the situations, workers welfare, etc. During my internship I acquired various details regarding the organization as follows:

Nearly 30%workers is a women worker. The organization purchase goods in advance and that is The management is not demoting the employees even the

very useful for production. orders are less.

The organization has joint ventures with some foreign

buyers in getting various orders and to export the goods to various parts of the world. Their main buyers are from countries like Italy, France, Germany and Canada.

CONCLUSION

The training which I had undergone in

KKF KNIT FABS

,Tirupur ,has helped me in knowing the production process of the company, the way of managing workers, importance of managerial powers, decisions etc