INDUSTRIAL REPORT diploma project
INDUSTRIAL
REPORT
INTRODUCTION
The apparel industry is a broad based
international system of merchandising producing and financing. It involves
sourcing textile and finding from
international market merchandising
product lines manufacturing related products and marketing finished course to retailer
and ultimate consumers .
Over
the past 150 years the apparel business has evolved from custom fitting and
assembling of individual hand sewn garments to the merchandized automated and sometimes robotized mass production and distribution of ready to wear in the world market compared to any other product
lines apparel manufacturing reminds labor intensive because of variety of product calories the endless change in
materials and styling the difficulty in handling goods manual production and
operations are usually needed.
Advancement in technology has increased
functions and capabilities of flexible material and dealing with constantly
changing styles limit the degree of automation for many production operations
the apparel industry is major business structure spinning the globe.
In
an apparel industry firstly, fabrics inspectional storage, fabric inspection,
sampling, pattern making, spreading, cutting, numbering, sorting, bundling
,sewing, quality checking, finishing, packing. These are the several processes
done to produce the knitted garments. These all process is done according to
the buyer order. Garment and textile industry is 2nd most important industry in
the world. Garment manufacturing is an elaborating process like any other
industry in fact it’s even much more complicated since the entire production
depends only on human resources and on the machinery.
COMPANY
PORFILE
COMPANY NAME : SHAHI EXPORTS. PVT LTD
ADDRESS : STNO.156 KTADB
INDUSTRIAL AREA
NIDIGE SHIVAMOGGA577204
WEBSITE :
www. shahi.co.in
YEAR
ESTABLISHED : 1974
MANAGING
DIRECTO : Mr. HARISH AHUJA
ANNUAL
TURNOVER : 4000 cr
INTROUCTION
OF THE COMPANY
Shahi
export started in 1974 in Delhi. Bangalore operations began on 1st
July 1988 with 250 associates and 104 machines Expansion by 60 times by last 30
years. In Shahi 3 million piece of high quality woven and knits per month and catering to all segment
in apparel industry a whooping over 2 million square feet for woven / knits in
SHAHI the finest knit garments in India supported by world class sewing facilities as per international standards
VISION
BUSINESS VISION
“Be
the global best in bringing delight to human life by weaving dreams of fashion and feeling of comfort’’
ENVIRONMENTAL
VISION
“We are committed to spearhead
environment friendly business by preventing pollution and conserving natural
resource’’
BUYERS
1. UNIQLO
2. AEO [AMERICAN EAGLE OUT FITTERS]
3. C AND A
4. GAP
5. OLD NAVY
6. BUFFALO
7. JC PENNY
8. ARIZONA
9. TCHIBO
10. TCP
SHAHI
EXPORT PROVIDES VARIOUS FACILITIES FOR
THE EMPLOYEES LIKE:
It
provides wages to the employees accordion the minimum
wages standard sit by Government
of India also provides
facilities like providing funds bonus incentives for overtime work.
For taking care & providing basic
education for the children of employers they have separate play home for the children’s of the
employers within the industry
premises
As we are human beings we have health
problems by keeping this mind there is hospital facility for the employers
within the industry premises emergency exiting facility is been provided.
SHAHI
exports have been below the age of 18 years are allowed to working SHAHI
Exports They not only manufacture the garments but also they have the spinning
with & dyeing centers. Where the yarns are manufactured & dyed
according to the spec sheet.
Here first sampling is done & it is
accepted then according to the order mentioned in speed sheet the garments are
manufactured here both type of spearing technique are used i.e. speeding by
hand & supporting by latest automatic spreads & CAD/CAM cutting after
spreading and is done then the fabric is sent for sewing micro process
controlled sewing machine with under bed trimmer sewing machine are used at a
time various colors T shirts are cut and sewn.
After
sewing is completed it stains or spots an found then it is removed here by hand
spot gun next pressing nearby 2 to 3 times quality is been cheeked here because
the export oriented industry gives more preference to words the quality
awards/achievements of SHAHI exports Recently SHAHI exports was awarded by AEPC
for the following third highest exports on global basis 2005-2006 Second
highest group employment providers 2005-2006 highest exports in MMF garments
Women entrepreneur of 2005-2006.
GARMENT QUALITY
INSPECTION
INTRODUCTION:
Garments
are assembling of different elements such as, fabric, sewing thread, buttons,
trims etc. The quality of garments depends on proper inspection of every step
of garment production. For maintaining the required quality levels needs to check
every step of garment production. This procedure is known as garment
inspection.
Garment
inspection is very important for quality maintenance of garment. These
inspections are followed from beginning of garment assembling process till the
end of it. But garment quality inspection is a kind of process at the end is
called as final inspection.
Garment
inspection is the one of the important process, because a customer needs
quality products. So every industries are inspects the end products are ready
garment to fulfill the customer needs and to satisfying their demands for
quality.
As
followed by, even SHAHI Exports private limited also checks in ready garment
and if any defects were found in the garment, that particular garment is sent
back to the sewing section. Then after correction of the defects again it is
send to the end section for inspection.
In
garment industry, there are three stages of quality inspection and are
1. Row
material inspection
2. In
process inspection
3. Final
inspection
In
each stage of inspection the attention is paid to get a complete garment with
best quality and less defects at the end. Garment inspection is done at the
final stage. Garment inspection is inspection system which is carried on a
complete garment. Before this stage. So
final inspection is very important from customers point of view. size of
garment, fitting, and other defects is inspected during inspection.
Finishing department in garment
section:
Checking done prior to pressing of the garment at finishing room is
known as initial finishing. Garments are again checked and passed for tagging
and packing.
After garments are packed up to
certain quantity, quality control team, to audit of packed garments. This
process is carried out to ensure that before handing shipment to buyer quality
check.
If
the completed work is being checked at each process and defective pieces are
corrected before handing to the next process that at the end of production
there is very little chance to have a defective at final checking stage.
Process flow chart of
4point quality inspection system has given in the following :
Conformation of garment quality
Confirmation of trimmings and
accessories
Measurement inspection
Garment in side inspection
Garment outside inspection
Final inspection
Packing
For example, garment quality inspection of
men’s dress shirt:
At
color both should be in same length, strips, plaids, checks should batch.
Checking
the metal type component into the garment or with its accessories, like button,
zippers etc.. is called metal check.
Metal
checking
Button
and button holes, pockets, hems, yoke, and shoulder, side seam, cuff also
checked in ready garment and the measurement should be under the tolerance
standards given according to the spec sheet.
EMBROIDERY SECTION
INTRODUCTION:
SHAHI
is an organization where it entirely works on a single ERP system it unifies
all the department working.
The
atomization level in the SHAHI industry is among the best in garment industry.
The
technological advantages with SHAHI are that makes unique with improved
business.
EMBROIDERY SECTION :
-Embroidery machine generally have
one or more machine formats specific to their brands .However, same formation
such as DST TAJIMAS and MELCOS example CND and BURADNS.
- Computer embroidery machine as the
name itself says it words as per the feedback of the computers.
- There are 18 machines in SHAHI
industry where each machine carries 9 needles [to totally 62 needles in 18
machines]
-Beautiful designs will be created
by given piece of fabric at a time all machines works together in function of
second.
-
The length and width of the design will be set before.
- The design will be set before.
-
If defects or problem occurs during process then they are light displays
as it denoted the errors.
-The as defects/error will be correct
and continued with further steps.
PROCESS.
- The embroidery designs were create.
-Getting
the design and color approval.
-
Creating a sample for approval embroidery design.
-Sending
sample to the approval.
-Checking
quality, color, and pattern, of embroidered sample.
-If changing need, they are change
accordingly.
-Again
sent for approval.
-After
the final approval sent to the computerized section for format designing.
-Format
creating.
-Software
updating to machine.
-Starting
the process of production.
DESIGNING
FILES
Digitized
embroidery design file can be either purchased or created with industries
specific embroidery digitizing software.Software files Formats are created in
two categories.
1.
SOURCE FORMATS
Are specific to software and to create the
design for there, the digitizer keeps the original file the purpose of editing.
2. MACHINE FORMATE
Are
specification to particular brands of embroider machine, and is not easily
editing or scaled and ensures the optimum stitch quality.
MACHINES
Modern embroidery machine are computer
control and specifically engineered for embroidery industry.
The commercial machines have combination of
sewing embroidery with hooping and framing system. Are of fabric under the
needle and the embroidery needle itself mover automatically.
Designs
create according to the per-programmed digital embroidery pattern.
-In
SHAHI export there are 8 multi needles embroidery each machine have 9 needles
and all works at a time to produce beautiful embroideries.
-The
brother pe770 computerized embroidery machine comes with preloaded designs and
compatible memory stick with super easy bobbin winder system.
GARMENT
WASHING
Washing is one of the important process in
every garment industry because in this process we are giving extra softness to
the particular garment and to check that particular garments color fastness.
And also remove the dust and impurities of the garment .
Steps of Garment
Washing
Send to the finishing department
1. Garment
receive from sewing department:
At first garments should be
received from the sewing department to
washing department.
2. Garments
sent to the dry process:
All the garments are set to the dry
process department if the buyer approved wash reference garment containing dry
process.
3.Hand Scrapping: Here hand scrapping is done by following
buyer approved wash reference garment most widely used process for creating the
blasting effect. It is usual done by mounting the garments on rubber balloons.
2.Tacking:
If buyer approved wash reference
garment contains tacking effect then tacking process should be done here by
following approved garment.
3. Garments
sent to the wet process:
After completing all the required dry
process garments are sent to the wet process department.
4. Garments
loading into the washing machine: Here the garments are loaded into washing
machine for required wash.
5. Washing:
By following buyer approved wash
reference garment are washed here using required chemicals solvent for garment
colors and quality maintain.
6. Extracting:
When the garments wash will complete
then these are unloaded from the washing machine and extracted by using hydro
extractor.
7. Drying:
All the garments are dried here by using
gas or steam dryer which is dependent on the shade.
8. Garment
sent to dry process:
After drying all the garments are sent
to the dry process for completing process if the buyer approved wash reference
garment contain this process.
9. Curing:
Applying 3D process the garments are cured
here by using woven machine.
12. Quality
Check:
After completing all above the processes
washed garments are checked here by following buyer approved wash.
14. Sent to the
finishing department:
Finally all the garments are sent to
finishing department for the next required processes.
FINISHING
PROCESS
In
the apparel industry, finishing room is the last step of garment manufacturing
Garment
finishing consists of a series of finishing operation performed in the garment
to improve its aesthetic and functional properties.
The
term garment finishing is a buzzword for the process in denim industry.
Shirt,
trousers, and jackets and even to all other type of clothing.
Various
chemicals are used for value addition and also the functionality to the
garment.
RECEIVED
SEWN GARMENT FOR SEWING ROOM
After
making complete stitched garment by sewing section the garment are passed in
the department for ironing, folding, poly packing, cartooning to get attractive
appearance.
INITIAL
QUALITY CHECK
Here
stitched garments are initially checked by quality control, if they found any
repairable or washable defects then the garments need repair work in finishing
section. But if found major sewing defects, fabric faults then again garment is
send to the sewing department for correction.
WASHING
If
there are any faults like oil marks, stains, other dust and spots. Then the
garment needs garment washing must be needed. Some of the spots can be removed
by spots remover and dust and stains can be removed by machine wash.
THREAD SUCKING
Loose
threads on garments needs to be removed and can be done through threading
sucking machine. High vacuum makes this possible and the loose threads in the
garment can be sucked out. Threads
can be sucked by two methods
1
manual thread sucking
2
machine thread sucking
PRESSING
/ IRONING
Pressing
is a very essential finishing process in garment industry, by pressing unwanted
creases and wrinkles can be removed from the garment and as well as appearance
of garment become well. The garment may be different in types, especially
different in designs and garment materials.
As
a result it needs different type of pressing for different types of garment and
needs different types pressing machine.
The
method of pressing are;
1.
Ironing
2.
Steam press
3.
Steam air finisher
4.
Steam tunnel
INSPECTION
This is the important section where the
product has to inspect and solve the defects of the garment,
Various
type of faults are check here; such as
Ø Proper
inspection of the garment including measurement, spots, dirt, and also
impurities.
Ø Shade
variation check.
Ø Smooth
and unfold in the pocket.
Ø In secured or broken chain or button.
Ø Wrong
fold.
Ø Proper
shade in garment.
Ø Properly
dried, after pressing.
ATTACH
PRICE TAGS AND ACCESSORIES
After
above process, different types of tags and accessories are attached with the
garment as per the buyer’s comments.
Accessories
are used for finishing and packing purpose.
Some
of the important accessories are as follows;
1.
Barcode
A
barcode is an optical machine readable representation of data relating to the
object to which it is attached.
2 .Hang tag
It
shows the brand name, style number and other information of the garment. It is
regarded as the finishing accessories.
3
.Price tag
Price
tag is also known as UPC [Unit Price code] in the apparel industry. It is paper
made tag which normally mentions price and bar code.
Barcode
stickers may be attached separately on it.
METAL
DETECTION
In
the apparel industry metal detecting device are utilized to detect needles that
may have been accidentally lodged in finished garments.
Exporting
garments embedded with needles or other unwanted metal articles could results
in the legal action towards the manufacturing company along with bad publicity
and heavy financial losses. Thus, garment companies prefer to invest in metal
detecting devices that thoroughly scan garment for needle or metal
contamination.
FOLDING
Garments are folded according to buyer’s
direction in a standard area. There are 4 types of garment folding.
Ø Stand
up.
Ø Semi
stand up.
Ø Flat
back.
Ø Hanger pack.
PACKING
After
folding, garments are ready for packing. The size of the polythene is vary
according to the size of garment ratio.
PROCESS OF GARMENT
PACKAGING
GARMENT PACKAGING
Packing
means wrapping, compressing or creating of goods for the purpose of material
protection and their convenient handling. It is an important part of production
which has to receive a lot of attention to the people. It is concerned with
designing and producing of appropriate packages for a product.
Packing
of the particular garment is one of the most important parts in garment
industry as we have seen already in [shahi exports] packing of the product has
been done in the stage of the garment is ready to wear also ready to ship.
Packing
can be described as a co-ordinate system of preparing goods for the transport,
warehousing, logistics, sales and ends.
After folding, garments are packing the of the polythene packet is permanent
FLOW CHART OF GARMENT PACKAGING
Packing complete
TYPES OF PACKING
Single piece packing
Blister packing
Single piece packing: single
garment is packed into the poly bags or into a cardboard box
Blister packing: In blister
packing more than one garment are packed into a poly bag in a size and color
ratio
What are the things and stuffs used
while packing?
·
X-clip
·
M-clip
·
Collar
·
Traveller
·
Butterfly
·
Back support
·
Foam
·
Main tag, bar code,
polybag
·
Cartons
·
Loop locks
·
Kimble
DISPATCHING
Dispatching
is a procedure for assigning employer (workers) or vehicle to customer Industries that dispatch include
service like airline dispatch and shipping.
Dispatching
manager:-
Dispatching manager is a responsible for
managing the dispatches as well as the production of goods of the field
personal. He/she is also responsible for
reviving and training the dispatchers.
Dispatching:-
After the whole order is packed the
shipping process follows. The address
label get printed on the demo transfer printer along with the data about the
order number shipping rate number. At distribution warehouses garment are checked
for quality and then divided in to groups account to style seam and color and put into stock storage area
where they may be hanging and racks or stocked on shelves. Garment are folded into shipping boxes
and marked with the mean transformation specified by the
retailer lodge manufactured are using robotic
automated warehousing equipment to speed packing. Manufacturing after use bar coded 128 or 2D carton.
Which may be scanned at the retail distribution
centre to the content without opening the box. The boxes are labeled with address and then
move by travelled or conveyer but to be loaded on the delivery truck and sent
to the retailer.
Finished
goods dispatch:-
Send delivery note
to factory purchase department
Goods
manufactured processed
Centre
clearance
Packing marking or labeling
Dispatching of goods to the part
SHIPPING
PROCESS
Shipping is a system process of model which cover
planning and execution of receipts, shipments, nomination and for ship truck.
It can handle world scale calculations and training
of vessels and inventers at multiple terminals and berths. This operational
model include all internal and externals movements.
Proper practice of shipping procedures can reduce
that cost to ensure sustainable growth of the company.
PROCESS
OF SHIPPING:
1.Packing,
labeling, documentation and insurance requirement.
2. Packed correctly so that it arrives in good condition.
3. Labeled correctly to ensure that the goods are
handled properly and arrive on time at right time place.
4. Insured against damage, loss and delay.
CONCLUSION
1)
BLOW ROOM:-
Blow
room is the starting of the spinning operation. In blow room cleaning of fibers
takes place .In order like opening, cleaning dust removing,
blending etc..
After
the removal of dust particles in the fiber then the fiber evenly fed to the
carding.
Carding
is a mechanical process that disentangles, cleans and intermixes fibers to produce a continuous web
or sliver suitable for subsequent proc
DRAWING
MACHINE:-
Drawing is the
operation by which slivers are blended, doubled and levelled. In drawing
slivers are elongated when passing through group of pair rollers, each pair is
moving faster than previous one this permits combing, drawing and elongating of
several slivers to make strong and uniform.
2)
SIMPLEX MACHINE:-
Simplex
machine for spinning process of textile technology transform the drown slivers
in to roving process.
The
main function of simplex machine is the attenuation of drown slivers and insert
small amount of twist to give required strength twisted roving.
3)ROVING
PROCESS:-
In roving process a
long narrow bundle of fibre, yarn type. These yarn types are taken out by
machine and slightly twisted to form lengths suitable for spinning.
Roving’s are
produced during the process of making raw cotton, or other fibres. Their main
use is as fibre prepared for spinning, but they may also be used for specialised
kinds of knitting or other textile arts.
4) WINDING
MACHINE:-
Auto cone winding
machine is also a type of winding machine and this machine can control the yarn
with a yarn guide. In this machine the auto cones are kept at the cone holder
contact with the drum. If is a winding method used in industries.
3)
DYING PROCESS:-
Dying process of
adding colour to textile products like fibres, yarns and fabrics .Dying is
normally done in a special solution containing dyes and particular chemical
material in shahi export package dyeing process is done its a type of dying
yarns by package. It is an nature technology that is one of the most commonly
used methods of yarn dying.
THE
THREE TYPES OF KNITTING PROCESS
1. CIRCULAR OR TUBULAR KNITTING MACHINE:-
2.FLAT KNITTING MACHINE:-
Flat knitting is a method for producing
knitted fabrics in which the work is turned
Periodically that is the fabric is
worked with alternating sides facing the knitter.
3. SMART KNITTING MACHINE:-
Smart knitting machine is a knitting
machine which is used in industry for better
Production. In smart knitting machine
ten or more colors are used at a time to it.
After
the knitting process inspection of that knitted fabric. Inspection is done for
quality checking and also for identifying the defects in the knitted process.
In
apparel industry CAD software is used for pattern making. CAD is known as
computer aided design and drafting. It used as computer technology for the
process of design and design documentation. It also a time saving process.
Next
process is fabrics spreading, fabrics spreading are a method where piles of
fabric are spread a specific length and width wise according to the garment
marker measurement. After spreading making will be done by the help of paper
pattern. Next process is cutting process.
Cutting
deportment is the most essential section of garment manufacturing in the
apparel industry. The fabric cutting is started after completing the fabric
spreading. In this section the fabric are cut
according to the patterns. After these cutting process sewing sections.
The
sewing section is the main deportment for garment manufacturing. When all the
garments are complete to cut in the cutting section, all of these cutting parts
are sending to sewing deportment for making garments. In this section deferent
cutting parts are joining together with the help of different types of sewing
machine.
The
next process is garment quality inspection process. In garment quality
inspection the quality of garments depends on proper inspection of every steps
of garments, for maintaining the required quality level needs to check every
steps of garment production. This procedure is known as garment inspection.
The
next process is embroidery. Embroidery machines generally have one or more
machine format and specific to their brand. Computerized embroidery machines as
the name itself says it works as per the feedback of the computers. There are
18 machine in Shahi industry where each machine and carries 9 needles.
The
next process is finishing process. In the garment industry the finishing
process is the last steps of a series of finishing operations performed in the
garment to improve. Its aesthetics and function and properties.
In a garment production unit finished garment
are folded and packed in individual play bags later packed garments are placed
into carton boxes.
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