A

PROJECT REPORT
ON
PRODUCTION PLANNING AND MANAGEMENT
AT
K.L KNITWEARS
SUBMITTED TO
PUNJAB UNIVERSITY
IN PARTIAL FULFILLMENT OF THE REQUIREMENT OF AWARD
FOR THE DEGREE OF THE
MASTER OF COMMERCE
SESSION 2022-23

SUBITTED TO SUBMITTED BY
PUNJAB UNIVERSITY CHETNA
UNIVERSITY ROLL No.
42561
MASTER TARA SINGH MEMORIAL COLLEGE FOR WOMEN
LUDHIANA

1
 Date:22July2023
TO WHOM IT MAY CONCERN
It is certified that Ms Chetna D/O of Harish Kumar of Master Tara
Singh Memorial College For Girls, Ludhiana has successfully completed
her training in K.L knitwear from 03-06-2023 to 18-07-2023.
During this period Ms. Chetna has worked on project “production
planning and Management” and has successfully completed the work
assigned to her. We wish her all the best for future endeavours.

For K.L knitwear

Auth. Signatory

2
 DECLARATION
I Chetna hereby declare that the Project Report entitle “Production planning and
Management” has been undertaken by me as a part of my studies in degree of M.COM. I
have complete this study under the guidance of Mrs. Praveen Mam of Management
department of MTSM College Ludhiana. The matter embodied in this project report has not
been submitted to any university or institute for the award of degree. This Project is my
original work and it has not been presented earlier in this manner. This information is purely
for Academic interest.
Chetna
M.Com 2nd Semester
Roll no.42561
Project Guide
[Mrs. Praveen Mam]

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 ACKNOWLEDGEMENT
I wish to express my gratitude to K.L Knitwear for giving me an opportunity to be a part of
their esteemed organisation and enhance my knowledge by granting permission to do
project under their guidance.
I am deeply indebted to my guide, Mr. Ajay Goyal, Proprietor, K.L knitwear, Ludhiana for his
valuable and enlightened guidance. He provided me with the opportunity to learn in the
organisation and spread his valuable time to help me.
I like to express my special Thanks of gratitude of my teacher Mrs. Praveen Mam as well as
our principle mam who gave me this golden opportunity To do this wonderful Project on
“Production planning and Management”. Which also help me in doing a lot of research and I
came to know about so many new things. I am really thankful to them.

CHETNA

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 TABLE OF CONTENTS

Content Page. No

DECLARATION iii

ACKNOWLEDGEMENT iv

TABLE OF CONTENTS V

LIST OF TABLES Vi

LIST OF FIGURES Vii

LIST OF APPENDICES Viii

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 TABLE OF CONTENTS

CHAPTER CONTENT Page No.

No.
1. INTRODUCTION 7-15
2. LITRATURE REVIEW 16-17
3. RESEARCH METHODOLOGY 18-21
3.1 Introduction
3.2 Sampling Procedures
3.3 Sources Of Data
3.3.1 Primary Data
3.3.2 Secondary Data
3.4 Data Collection
4. DATA ANALYSIS 22-60
5. FINDINGS & CONCLUSION 61-62
5.1 Summary and Conclusion
5.2 Suggestion
Annexure BIBLIOGRAPHY AND 63-64
REFRENCES

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 CHAPTER-1
INTRODUCTION

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INTRODUCTION
Manufacturing of T-shirts and Trousers are under the category of readymade Garment industry. Readymade
garment industry has occupied a unique place in the industrial scenario of our country by generating
substantial earnings and creating a lot of employment. Its contribution to industrial production,
employment are very significant. This provided by it is a source of livelihood for many of people. It also
provides maximum employment with minimum capital investment. Since this industry is highly labour-
intensive, it is ideally suited to Indian conditions. This project report is prepared for the manufacture of
Men’s and women t-shirts and trouser, kids carpi, cotton shirt etc. as they find wide acceptance in local and
Indian markets. Any person having the knowledge of cutting and stitching operations can easily set up such
establishments.

MARKET POTENTIAL
Readymade garments are the choice urban people. It is also gaining wider acceptance in semi-urban and
rural areas. The huge charges made by tailors and delay in delivery has made people to switch over to
readymade garments. Domestic market and export market, it has made spectacular progress in last decade.
This industry is becoming very vibrant and lot of foreign investment pouring in the industry because low
risk and higher earning nature of the industry. As this products are fashion oriented, entrepreneurs should
always keep in mind the changing fashion styles. Considering its advantages position, it is assumed that
there will be no constraints in marketing of readymade garments.

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COMPANY PROFILE

COMPANY NAME K.L KNITWEARS

ADDRESS 2040/9B, JAIN NAGAR, SHIVPURI,

LUDHIANA, 141008

TELEPHONE Ph:9465372986

E-MAIL Klknit551@gmail.com

YEAR ESTD. 2008

MARKET ALL OVER INDIA

OWNER MR.AJAY GOYAL

DIRECTOR MR.AJAY GOYAL

ANNUAL TURNOVER Rs.25 Lakh - 50 Lakh

TOTAL WORKING FORCE 21-50 people

MONTHLY PRODUCTION 8000 - 10000 pcs.

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 K.L KNITWEARS
High class hosiery Manufacturers

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ABOUT THE COMPANY
With a strong hold on varied market segments across the world K.L Knitwear’s are recognized as a reputed
garment manufacturing company. Registered in the year 2008, they have acquired immense design
expertise that helps us in meeting the diverse requirements of their Indian clients.
They are manufacturers, wholesalers and suppliers of exclusively designed & fabricated Men, women, kids
apparel Woven and Knits.
They have state-of-the art facilities comprising in-house computer embroidery facility, washing facilities and
a sophisticated array of machinery.
These facilities assist us in producing a quality assured range of garments for their valued clients.
Ever since its inception, K.L knitwear has never looked back. Growing with Strength as well as value it has
achieved the production capacity of 8000-10000 Pcs. Garments per Month.

K.L knitwear has gained immense expertise in Supplying & trading of high class hosiery goods, woollen
products, yarn etc. The supplier company is located in Ludhiana, Punjab and is the one of the leading seller
of listed products.

Product categories –Men’s wear (70%), girls wear- NB, infant, toddler, kids wear(30%).
Technical aspects
Process of Manufacture: The manufacturing process involves the following steps:
• Procurement of Fabrics – Predominantly woven fabrics-solid and printed voiles, cambric,
poplin, yarn dyed (mainly auto loomed and mill made), complete range of polyester fabrics, Viscose,
mill made twills, canvas. Dyed/bleached/printed cotton/synthetic fabrics as per demand are to be
produced from the open market.
The fabric will be inspected by laying on the inspection table against light before cutting so that
unevenness in colour/shade or any fault, if any visible in the fabric are eliminated.

• Cutting and Stitching: The inspected fabric is placed on the cutting table in layers and then the
different parts of the respective garments are demarked by a chalk as per different sizes. Cutting is
carried out by the cutting machine. Stitching is carried out for individual portion of the garment by
skilled workers with the help of over-lock, lock stitch machines etc.

• Rinsing, Checking, Pressing and Packing: All garments are charged into washing machine
containing mild detergent and washed for 4 hours in order to remove dirt and stains acquired
during the manufacturing process. After washing, the garments are hydro extracted to remove
excess water and after this, these garments are dried in tumbler dryer. Final checking is done before
pressing and packing on the checking table so that any fault in the piece are pressed by steam
presses to remove any wrinkle marks and packed in the carton boxes.

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 • Factory capacity – Initially, ten machines will be used for an average production of hundreds of
piece per day, with capacity utilisation of 60%. Then it will gradually increase to 90%. New markets
are to identified along with it, production can be enhanced.

• They operate 35 machines , Approx.8000-10000 pcs. Per month with in house computer embroidery
with sequin attachment(40 head)& complete laundry facilities (enzyme /
bleach/silicon/bio/softener wash/perc (petrol- free) machines for dry cleaning).They have complete
in house cut to pack facilities, including a highly capable product development and sampling
department.

BUSINESS DEALING IN:-

-Manufacturer of kids carpi in Ludhiana
-Cotton T-shirt and trouser manufacturer.
-Hosiery T-shirts manufacturers.
-Supplier of cotton shirts.

-Affordable rates of Polo t-shirts.

-Reasonable amount of men’s lowers.

About Product/Service & Process:-

K.L Knitwear are leading manufacturers of a wide range of track pants suits, sports wear, kids carpi,
readymade shirt, trouser, sports wear etc. They procure these garments from the trusted and renowned
vendors after stringent Market Analysis. Further, they offer these garments at reasonable price and
delivered these within promised time -framed.

Readymade shirts:-
Shirts are made from various materials such as Cotton, Teri-cotton, silk, linen etc. according to the market
demand. It is made in sizes 38’, 40’, 42’, 44’. Only fast moving sizes are made in initial stage. The raw
material is procured from Coimbatore, Bangalore, Karnataka, Gujarat where the rates is comparatively less.

Readymade Trouser and Sports wear:-

Nowadays Trousers and Sports wear are the most common dress of the men’s , women’s, kids. Various
types of latest materials are available. It range from cotton to artificial fabrics.
Materials are collected from Mumbai and Bangalore, where the latest fashion material at a cheap rate are
available.

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T-shirts:-
T-shirts are a favourite among individuals of all ages, body types and genders. Being comfortable, durable
and Functional, t-shirt are considered an ideal everyday clothing items. These are available in wide range of
colour, design and cuts, including the traditional crew neck, V-neck, tank top, scoop necks etc. Over the
year, T-shirt have undergone tremendous change when it comes to design and patterns.

T-shirts manufacturer in Shivpuri, are renowned for offering t-shirts made from different varieties of fabric
such as cotton, polyester and wool etc.

PROCESS
The Raw material is procured from the wholesale market of Karnataka, Tamil-nadu, Maharashtra and
Gujarat. After quality checking, with the help of designers, the cloth is cut and them move for stitching.
Parts are stitched and then finally stitch together to make the finished goods. After the final quality
verification, move for packing.

Design and product Development – They believe in investing in best talent in the market to get
something on the table for our principals and as our own initiative and hence, we have a full- fledged in-
house design, product development and sampling department. They assure you that you shall get fresh
ideas and bodies from us every season.

Quality Control & Standard

The internal quality control system ensure that Goods of highest quality shipped to their customers. The
quality of garments mainly depends on the quality of fabric used. Therefore, care must be taken while
purchasing fabrics to ensure good colourfastness properties, uniformity in shade etc. Generally garments
are made as per customer’s specification in respect of size, design and fashion.

PRODUCT RANGE:
They are one of the distinguished manufacturers and suppliers of sports range of men’s wear, ladies wear,
kid’s wear. Product includes:-
Sports Jackets.

Sports Shorts.
Sports T-shirts.
Track suit.
Track pants.

Sweatshirts.
The Company has it own active brand name CONSIDER.

13
The raw material required are:-
1. Clothes of different materials & lining cloths
2. Zips, Hooks
3. Thread
4. Buttons
5. Decoration material
6. Packing material

STRATEGY
The promoters has personal contact with many retail shops, where the product can be displayed and sold.
Being an experienced person, the products can be directly sold to the customers who are known to them.
Sale through social media is also planned. Online marketing is expected to grow in a fast pace as trend
among the youth is towards that line. For that attractive schemes like pay on delivery, return if you don’t
like etc. Plan to implement. The physical as well as digital marketing together, No doubt will boost the
marketing of the products. With the growth of sales, the expansion of the unit of more production will be
needed.

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FACTORY LAYOUT
Floor Department

Ground a) C.E.O office

b) Showroom
c) Director office
d) Merchandising
e) Stitching
f) Sampling
g) Quality
h) IT and Accounts
1st a) Fabric store
b) Trim store
c) Cutting Department
d) Human resource

2nd Finishing and Packing

3rd Washing

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 Chapter-2
REVIEW OF LITERATURE

16
REVIEW OF LITERATURE
• Schmitt, B. (1999) Brand experience is conceptualized as sensations, feelings, cognitions, and
behavioural responses evoked by brand-related stimuli that are part of a brand’s design and identity,
packaging, communications, and Environments. The authors distinguish several experience
dimensions and construct a brand experience scale that includes four dimensions: sensory,
affective, intellectual, and behavioural. In six studies, the authors show that the scale is reliable,
valid, and distinct from other brand measures, including brand evaluations, brand involvement,
brand attachment, customer delight, and brand personality. Moreover, brand experience affects
consumer satisfaction and loyalty directly and indirectly through brand personality associations.
• Verma (2001) in his article emphasized on the impact on the Indian textile and clothing industry
after quota elimination. It says that Indian textile and clothing exporters have to bring in necessary
changes in their methods of production, management style, capacities, marketing skills and
productivity level in order to remain competitive in international market. Also it put special
emphasis on the size of Indian textile units when compared to its counterpart in China.
• Meenakshi (2003) did a comprehensive study on the opportunities that would be provided by WTO
to Indian Textile industry. This paper gives a lot emphasis on new capacity installation to take the
benefits to the fullest extent in India has to be a true gainer in competition to other nations. Since
India’s own Consumption per capita is also on the rise with the rise of income and consumption
habits, the profit margins available to Indian textile and clothing producers will be more. But in
export market, the prices will be driven by international factors and profits will be under pressure.
So the exporters might have to go for strategy of partial exports and partial domestic sale.
• Uraiwan (2004) had worked extensively on the knitwear/ hosiery products development process to
understand the complexities underlying in it; because a well defined development process assist the
organization to determine its future direction, plan for rapid changes, create new product line with
profits and plan for technology adaptation and implementation. The goal of this research was to
propose an optimal product development process for a knitwear/hosiery company by examining the
process used by major US Sweater Company and comparing its process to established processes.
• Vivek (2004) in his article had said that JC Penny a leading retail chain of US looks India for sourcing
its garments in woven and hosiery. He is of opinion that India will be fulfilling its major need of
Hosiery and woven garments in cotton while China will be good for synthetic fabrics and its
garments.
• Chugan (2005) emphasized that Indian textile Industry has to change to be more competitive in the
long run. This paper emphasis that merely cost competence is not enough to maintain the lead
while Indian companied has to have a global competitive view.
• Singh and Kathuria (2006) in his article discussed in details the problems faced by Indian garment
exporters in post quota regime. The study focuses on the analysis of problems of garment exporters
located in Ludhiana and Delhi. It highlights the factors which are hindrance in the growth of
garment exports from the region and important determinants in increasing the exports share from
the region.
• Rajan saxena (2006) calls consumer mind as black box which is influenced by company controlled
stimulus like product, price, advertising ,sales promotion, Display and distribution, besides social
stimulus as word of mouth and reference group. He calls it an enigma or black box which responds
to the various stimuli resulting in either buying or not buying at all.

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 CHAPTER-3
RESEARCH METHODOLOGY

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OBJECTIVE
Objective of the study is to learn about the functioning of manufacturing unit and working of various
departments particularly production, merchandising and sampling, earning knowledge about different
departments of the organisation, their function and information flow during work.

• Continuous Flow of Production - One of the primary objectives of production planning and
control is the continuous flow of production through the production facility. Production planning
and control will attempt to achieve a smooth and continuous production process by eliminating
bottlenecks and waste from your facility, which allows you to take your production to the next level
in terms of productivity.
• Planned Requirements – The production planning component of production planning and
control is essential to ensure that your production facility has what it needs, in the right amount, at
the right time. Having a production plan ensures that you have enough material, machines, tools,
equipment, and manpower to perform the work.
• Increased Productivity – Increased productivity is another substantial objective within
production planning and control. Production planning and control ultimately aims to increase
productivity through efficiency enhancement while also being economical. Increased productivity is
successfully achieved through optimizing the use of existing production resources and labour
resources while eliminating wastage/spoilage of materials.
• Customer Satisfaction – All companies want to increase customer satisfaction. This is because
demand is driven by customers and happy customers means more business in the future. Having
defective products and having delays in shipment days will only be harmful to the company.
Production planning and control focuses primarily on ensuring that the manufacturing process
successfully completes orders on time and reducing lead times. This ensures that customer orders
are fulfilled on time and within a short time frame and will improve customer satisfaction with your
company.

DATA COLLECTION METHOD

I collected this by following method:-

• Personal interview from various departments.

• Close observation during work.
• Internal data from various departments.
• And secondary data was collected from the websites of K.L Knitwear .

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COMPANY HIRERCHY

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DIFFERENT DEPARTMENTS IN THE COMPANY

• Marketing and Merchandising

• Sampling
• CAD
• Fabric Sourcing
• Fabric Store
• Purchase
• Trim and accessories Store
• Accounts
• Human Resource Management
• Production Planning and Control (PPC)
• Production
• Maintenance

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 CHAPTER-4
DATA COLLECTION AND ANALYSIS

22
 WORK FLOW
BUYER

PRODUCT DEVELOPER

MERCHANT

SAMPLING

TESTING

MARKER PLANNING

SPREADING

CUTTING

BUILDING

RESEARCH & DEVELOPMENT

PRODUCTION

WASHING & FINISHING

PRESSING & PACKING

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 LIST OF MECHINERY/EQUIPMENTS REQUIREMENTS

Sr. Value (₹ in
Particulars Qty. Rate (₹)
No. Lacs)

Plan & Machinery /

equipment’s

a) Main Machinery

Single needle machines +

i. 20 75,000 15.00
Accessories

ii. Fabric Cutting table + Machine 1 1,00,000 1.00

iii. Over lock machines 2 75,000 1.50

Double Needle machine +

iv. 2 75,000 1.50
Accessories

v Zigzag stitching machine 2 75,000 1.50

Button hole & stitching

vi. 1 2,50,000 2.50
machines

Washing machine -
vii 2 1,00,000 2.00
commercial

b) Ancillary machinery

i. Lab Equipment’s 1 2,00,000 2.00

ii. Steam Iron, Blower etc. 1 1,00,000 1.00

iii. Trolleys & material handling 1 1,00,000 1.00

sub-total Plant & Machinery 29.00

Furniture / Electrical
installations

a) Computer and printer 2 50,000 1.00

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 b) Office Tables, Chairs 1 1,00,000 1.00

Inspection, packing & storing

c) 3 25,000 0.75
tables

d) Storage Racks 25 8,000 2.00

sub total -

Other Assets 4.75

a) Rent Deposits 2 1,25,000 2.50

b) Delivery Van 1 7,50,000 7.50

sub-total Other Assets 10.00

Total 43.75

Single Needle and Double Needle stitching machines are available from following suppliers. They have offices
across several cities in India. There may also be other local machinery manufacturers offering alternate
machines of various makes and models.

Names and addresses of Machinery Supplier

• IIGM Private Limited Springdale No. 51, Residency Road, 3rd cross, Bangalore 560025, www.iigm.in
• Juki India Private Ltd, 1090/I, Ground Floor, 18th Cross, Sector III, HSR Layout, Bangalore 560102,
www.jukiindia.com
• Brother International (India) Pvt. Ltd, Unit No.408, 215, Atrium B-Wing, 4th floor, Opp. Sangam
Cinema, Andheri Kurla Road, Andheri (East), Mumbai 400093, www.brother.in
• M/s Paras Special Machine Co., Madhopur Kucha No. 7,
Rohan Road, Ludhiana.
• M/s Mehala Machines India Limited, C62, Okhla Industrial Area, Phase-1, New Delhi-110020.
• M/s Vijay Sewing (P) Ltd., 17-D, Everest House, 46-C, Chowringhee Road, Kolkata.
• M/s Industrial Machines Pvt. Ltd., 1/23 B, Asaf Ali Road, New Delhi-110002.
• JUKI Machinery (India) Pvt. Ltd., A-215/B, Okhla Industrial Area, Phase-1, New Delhi.
• M/s B. B. Corporation, 123-B, Dada Nagar, Kanpur.

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Name & Addresses of Raw Material Suppliers:
• M/s Vardhaman Threads, Mahavir Spinning Mills Ltd., Chandigarh Road, Ludhiana-141001.
• Dhown Hosiery mill, E-372, Focal Point Phase 6, Dhandari Kalan, Ludhiana, Punjab 141014
• Ocean K, Lane 3, Rahon Road, Naginder Nagar, Vardhaman Nagar, Ghelewal, Ludhiana, Meharban,
Punjab 141007
• Local Market, Ludhiana.

PRODUCT DEVELOPMENT
In Conventional industry like textiles and apparel industry the product development can be broadly
classified into four categories:-

• The first and most common is to develop fabrics or apparels based on a sample supplied by the
customers.
• The products designed by fashion designers or professionals using their own imagination and
predicted market trends.
• Replacement products using newly developed raw materials which give better performance or
lower the cost of production.
• The fourth one is development of products using latest raw materials, technology and knowledge,
which market has not seen earlier.
In the context of garments export business normally product development is handled by the design
department. But where is no design team, merchants are responsible for whole production development
process. In export houses sampling department is considered as production development department.

PRODUCT DEVELOPMENT

INTERNAL DESIGNING EXTERNAL DESIGNING

OWN INSPIRATIO
DESIGN LINE NAL TECH PACK

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PRODUCT IMPROVEMENT
Product improvement is aimed at bringing about significant changes with the purpose of getting new
clients, retaining existing users, and recapturing lost customers. In fact, there are two ways of improving
products: adding fresh features and upgrading existing ones.
New specs and updates make a current product more advanced. Such a solution enhances the value
proposition and expands the target audience base. Plus, it drives value for existing customers, diminishes
current rate, and contributes to building brand loyalty.

PROPER
SCHEDULING,
STRATEGIC
PLANNING &
SUPERVISORY

TRAINING & TECHNOLOGICAL

RESEARCH UPGRADATION
PRODUCT
IMPROVEMENT

EFFECTIVE UTILISATION
PROPER WASTE
OF MANPOWER,
MANAGEMENT
MACHINE, MATERIAL &
SPACE

PRODUCT LIFE CYCLE

Product life cycle is the entire process through which a clothing items is introduced in the market till it
leaves the market. In theory, there are 4 stages of products life: Introduction, Growth, Maturity, Decline.
Depending on the preference of majority, Some products remain in a prolonged maturity state, while some
quickly go extinct, and some eventually return and revolve after many years.

The life of a fashion item is visualized as a bell shaped curve, where it starts in the Introduction stage,
gradually goes up in the growth stage, reaches it maximum popularity and profi in the maturity stage, then
demand decreases and it falls into the decline stage.

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 PRODUCT LIFE CYCLE STAGES

INTRODUCTION: Introduction stage is the beginning of the product Life cycle of clothes when a new
item is launched in a market. In this stage, the item requires lots of marketing efforts and dedicated
approaches to disclose it, like advertisements, fashion shows, magazine, PR events, etc. The primary goal is
to promptly educate and attract customers.

GROWTH: With the rising appeal of a product, more and more people are accepting the fashion trend. As
a result of fashion recognition, companies will produce more to meet demand. Sales will begin to climb
significantly, and more competitors starting to notice the opportunity.

MATURITY: In this phase, the product has reached its peak of popularity. When the public interest
decreases, the item’s price and sales volume go down, meaning profit margin are thinner. Competition for
this item also becomes more intense and there’s no room for new entries, indicating that the market has
reached saturation.

DECLINE: While companies makes effort to extend the product life in the market, an eventual decline is
unavoidable. In this stage, the appeal and demand for the product decrease, causing sales and profit to
plummet. The item losses it’s market share and competitors are progressively being stuck with outmoded
inventory. Eventually, the product retries from the market, and people’s attention shifts to the latest trend.

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 PRODUCTION CONTROLS:
Importance of Control Function:
The function of production control is to :
•Provide for the production of parts, assemblies and products of required quality and quantity at the
required time.
•Co-ordinate, monitor & feed back to manufacturing management, the results of the production activities,
analysing and interpreting their significance and taking correction action if necessary.

•Provide for optimum utilization of all resources.

•Achieve the broad objectives of low cost production and reliable customer service.

Benefits of Production Control:

1.Improvement in profits through:
•Maintenance of a balanced inventory of material, parts. (WIP) Work in process and finished goods.
•Balanced and stabilized production.
•Maximum utilization of equipment, tooling, labour (manpower) and manufacturing and storage space.
•Minimum investment in inventory.

•Reduction in direct costs.

•Reduction set up costs
•Reduction scrap and rework costs
•Reduction in inventory costs

2. Competitive advantages:
•Reliable delivery to customers

•Shortened delivery schedules to customers–Production costs and greater pricing flexibility.

•Orderly planning marketing of new or improved products.

Elements of Production Controls:

•Control of planning: Assure receipt of latest forecast data from sales and production, bill of materials
data from product engineering and routing information from process engineering.

•Controls of materials: Controls of inventory and providing foe issue of material to the shop and
movement of materials within the shop.

•Control of tooling: Check on the availability of tooling and provide foe issue of tools to departments from
tool cribs.

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•Control of manufacturing capacity : Determine the availability of equipment and labour capacities
and issue realistic production schedules and provide means of recording completed production.

•Control of activities: Release order and information at assigned times.

•Controls of information: Distribute timely information and report showing deviations from plan so that
correction action can be taken and provide data on production performance measurement for future
planning.
The production Control system consists of a group of procedural elements that operates as a whole to fulfil
the four functions listed under importance of control functions.

The elements of production control systems are:

•Means of setting the system in motion such as production orders.
•Methods to determine lead-time for production.

•Methods to control and monitor production operations including means to:

•Determine what and where work to be done
•Determine when work is to be done
• Issue orders to production shops and ensure that work is completed.

MAKE OR BUY ANALYSIS

The capacity of the firm to produce finished products depends on at what stage the firm beings the
manufacturing process if it starts with basic raw materials, the total output will be much less than if many of
the parts and components are purchased form vendors. The form is faced with a decision of whether to make
or buy each part or subassembly. Make or buy decisions are basically questions of specialization and vertical
integration. Each and every subassembly has a detailed design drawing specifying the materials and piece
parts required to make the subassembly or the raw material required to make the piece part. The process
planning engineer has to make an important decision of “Make or Buy” after studying the detailed drawing
of assemblies, parts and components. Many components, subassemblies, and piece parts can be either
bought, subcontracted or producing – house.

Consideration in Make or Buy Decision :

In the economic consideration based on cost of manufacture versus cost or buying the item, the least cost
alternative is selected. Economic analysis of make or buy analysis is based on Break-even-analysis or
Economic Batch Quantity or Economic Order Quantity Concepts. There are some non economic consideration
such as :
a) Availability of supply or alternative sources of supply for components and sub-units.
b) Control of trade secrets and design secrete.
c) Quality and reliability consideration.
d) Research and development facilities available in-house.
e) Delivery schedules to be met.

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f) Reliability of supply of outside suppliers.
g) Lead time required for procurement.
h) Availability of manufacturing capacity (in-house).

i) Employee references.

When to Make:
Some of the reasons that may lead a firm to make a product or components in-house instead of purchasing
it are:
a) Lower cost because the firm doesn’t have to pay for the vendor’s overhead or profit.
b) Assurance of availability because the firm doesn’t have to depend on vendors.

c) Better control on quality.

d) Availability of appropriate equipment and expertise.

When to Buy :
a) When the part can be bought from the vendors at lower cost, higher quality and faster delivery times
than would be possible if the firm made them in-house.
b) When the firm uses only a few numbers of a particular item and special equipment’s are needed to
produce it in-house, then the firm will look for an outside vendor.
c) When an outside vendor can sell an item at a lower cost than the purchasing firm would have to spend
to produce it.
d) When the vendors hold patents on the required item.
e) When opportunity cost of producing are much higher than that of buying.

f) When the vendors are able to meet the requirements of the purchasing firm in terms quality, quantity,
price and delivery period.

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MERCHANDISING DEPARTMENT
Merchandising is the specialized management functions with in the fashion industry. It is the business that
moves the world fashion from designers showroom to retail sales floor and into the hands of customers. It
is the internal planning that take place within a retail organisation in order to ensure adequate amount of
merchandise are on hands to be sold at prices that the customer are willing to pay to profitable operation.

Following are the responsibilities of merchandiser which gives importance to them:-

1.Internal and external communication.
2. Sampling

3. Lab dips
4. Accessories and Trims
5. Preparing internal order sheets
6. Preparing purchase order

7. Advising and assisting production

8. Advising Quality department about quality levels
9. Mediating Production and quality departments
10. Giving shipping instructions and following shipping

11. Helping documentation department

12. Taking responsibility of inspection and following shipping

PROCESS FLOW MERCHANDISING DEPARTMENT

TECH PACK FROM BUYER

INITIAL SAMPLING AND COSTING

GET ORDER FROM THE BUYER

ORDER CONFIRMATION

BUDGETING

INTERNAL EXTERNAL
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PURCHASE ORDER
Purchase order is an external document which is issued by buyer in the name of K.L knitwear; it is an evidence
as well as support of order confirmed in favour of company.

Purchase order includes the following information:-

• Delivery Date.
• FOB.
• Ship Cancel date.
• Destination.
• Ship Mode.
• Terms if Sale.
• Currency.
• L/C.
• Quantity.
• Size break up / Colour break up.

K.L KNITWEAR USE WFX ERP SOFTWARE —

In company employee work on WFX ERP software for making challan, purchase order, indent etc. It’s very
simple and useful software.
K.L knitwear hosiery merchandising may be defined as all the planning & activities involved right from the
buyer communication & order receiving till the execution or shipment of the order by fulfilling the
following factors (six rights):-

Right Merchandise:

Retailers must fill their shelves with the merchandise that customer wants .
Right place:
The location of the merchandise is of prime importance since it decides the accessibility. Much
merchandise is seasonal in nature and must be on the hand when it is most needed.

Right Time:
Much merchandise is seasonal in nature and must be on hand when it is most needed.

Right Quality:
A profitable balance between volume of sales and amount of inventory is the desired goal.

33
Right price:
Merchandiser must arrive at a price that is high enough to give the store profit and yet low enough to meet
the competition and the customer expectations.

Right promotion:
Right Balance between investment and the appeal created for the customers. The successful execution of
any garment order depends on the work performance of a merchandiser. Merchandiser is a person who
plans and coordinates all the activities right from the order procuring and till the shipment order. A
merchandiser should have the comprehensive knowledge of his work procedures and responsibilities so
that he could perform his job efficiently and effectively.

In the apparel manufacturing industry, a merchandiser has to perform the following functions:-

Communication:
It is one of the foremost functions of merchandiser because the merchandiser has to communicate with
different levels of people in his day to day activities.

Planning & Programming:

A merchandiser has to check the order requirement, planning for the given order, programming for various
activities, proper allocation of work to the assistants.

Follow ups:
It includes sending of samples at various stages of order, buyer and buyer house for sample and other
approvals.

Decision making:
A merchandiser has to make several decisions during the order processing like giving approvals like fabrics,
colour, design, accessories, and packing, selection of suppliers and vendors, selection of buyers, sometimes
time extensions for order shipment.

Sourcing & Purchasing:

A merchandiser may have to do sourcing and purchasing for raw materials and accessories, suppliers and
vendors, new designs, new buyers.

Controlling:
This is the crucial activities for any merchandiser. A merchandiser has to make sure that all the activities are
carried out as per the planning and even if there is any deviation, he/she should make the alternatives
measures.

Coordination:
Merchandiser has to coordinate in such way to reduce the uncertainties and difficulties and if there is a
problem arises, the merchandiser has to support and lend helping hand in order to complete the task

34
successfully in the given period. Both the controlling and coordinating activities complement each other
and the merchandiser has to adopt the both accordingly.

Negotiation:
It is the activity of convincing, compromising and cooperation which would benefit the both parties
involved in the negotiation.

Costing:
It is the process of estimating the expenditure of a given product and subsequent price. It is an another
crucial function because mostly order confirmation is depend on its price offered to the buyers. The
merchandiser should know the current price and rates of various products and processes to do the
accurate costing.

Meeting:
There are two types of meeting the merchandiser has to be involved. First type, a merchandiser has to
conduct the meeting with the concern department in charges to discussed about the proceeding and the
status of running order. In second type, a merchandiser has to attend the meeting with the supervisor or
the buyers or the business people in giving reporting or participation or discussion.

Forecasting:
Forecasting is the activity of predicting the future happenings or problems. A merchandiser has to predict
the future uncertainty in the current order or industry so that alternative actions and corrective measures
can be taken in the advance. This also includes giving suggestion or ideas about technologies or new
products or latest industrial trends.

35
QUALITY CONTROL DEPARTMENT
K.L knitwear processes the goods order in the factory. While Raw material is converted into garments, there
are possibility to make errors, like making defective Garment components and defective garment. Making
defective garment is a cost to the company. So to make sure garments are made as per customer
requirement and whatever raw material are sourced must meet the factory standard, factory establish
quality control department.
Functions of the quality control department can be vary widely. But most common functions of quality
control department are as follows:-

Quality inspection of internal processes and outsourced work

Inspection of Raw Material: Checking of Raw Material to ensure there is no defective or abnormal
goods.

Testing of Raw Material: Quality Control Department doesn’t conduct testing of raw material but they
sent sample to testing lab for testing physical and chemical test. Once factory received test report, quality
control team get assurance weather raw material to accept or not.

Inspection of Sample: Visual inspection and measurement checking is done prior to sending sample to
respective buyers.

Cutting Room Inspection: Quality department is also inspects work done by cutting room. Like, layering
of fabrics on cutting table, cut layer inspection, cut component inspection, bundle inspection etc.

Preparatory Work Inspection: In high fashion garment, lot preparatory work are outsourced like
Printing, Machine Embroidery, bead work, special decoration on garments etc. Before feeding the
outsourced goods, quality department checks and approve for further process (sewing process).

Sewing process: In sewing there are multiple checking process is practiced by experts like inline
inspection, end of line inspection, stitching quality audit etc.

Finishing process: Finally quality personnel checks finished and packed goods and do auditing prior to
handover shipment to external inspector.

Quality System Development

To make quality product throughout the garment manufacturing process, factories need to develop quality
system. Quality control Development is responsible for setting quality system for the factory.

Quality Awareness
They are also responsible to bring quality awareness among the workers and all employees.

36
SAMPLING DEPARTMENT
A Sample is a proto type of a product to be manufactured in future course of production. It is also called
mock up of a product and is made to check the design effectiveness and fit of the garment. Sampling is a
set of the procedure follow to produce various sample style. It contains activities like making of the pattern
for proto type according to measurement of the sample with the help of machinery and getting buyers
approvals for sample produce.
In an manufacturing house, the sampling department play vital role in the up- lifting of unit. This
department directly coordinates with the merchandising dept. and production dept. sampling is done to
see how the product will look when produce in bulk and to check discrepancies in the pattern are.

PROTOTYPE SAMPLE MADE

FIT SAMPLE MADE

PP SAMPLE MADE

TOP SAMPLE

SIZE SET MADE

SHIPMENT SAMPLE MADE

37
FABRIC SOURCING DEPARTMENT
SOURCING DEALS with getting information about material form different Sources then selecting the best
material which suits over budget and buyer’s Specification.
Fabric sourcing means souring the right kind of fabric which fulfils the specification. Fabric sourcing
department is quite important as more than 90%ofgarment is fabric and approximately 70% cost of
garment is due to the fabric cost.
Selecting the right quality of the fabric as per the buyer’s specification other Wise it may lead to
cancellation or rejection of the whole order given by the buyer. The fabric sourcing department gets the
fabric sample from the vendor. These samples are tested before sending to buyer for approval. After the
buyer approves the sample, the fabric is order for bulk production.

TYPE OF FABRIC
Fabrics are the basic material for clothing. Basically knit fabrics are three types, those are-
1.Weft knitted fabrics
2.Warp knitted fabrics
3.Single jersey fabric

All the above three types have discussed below:

1. Weft knitted fabrics: Weft knitted fabrics are characterized by a series of horizontal loops formed by
horizontally running threads and binds with a previously formed series of loops of the same thread. This
type of fabric is mostly used in knit clothing manufacturing.

Weft knitted fabrics

2. Warp knitted fabrics:

In the case of weft knitted fabrics, structural threads of the fabric are run along with the length of the
fabric which is approximately parallel with the fabric selvage. Here, one horizontal row of loops or course is
made from many threads, and in this way warp, knitted fabric is formed. This type of fabric is not widely
used in knit garments as weft knitted fabrics.

38
 Warp Knitted Fabrics.

3.Single jersey fabric :

Cotton jersey knit fabrics are made both of 100% cotton or cotton blend. They are soft, strong, and opaque.
Such knit fabrics are less droppable than; silk or viscose jerseys, however, they provide more structure to a
garment. Cotton is a breathable material. Cotton jersey fabric used to make undergarments, t-shirts,
cardigans, turtle necks, and children wear as well as coats and dresses .

Single jersey fabric

Steps Followed for fabric purchasing:

1.Market trends enquiry
2.Vendor Folders in- house swatches

3.Display to buyer
4.After approval from the buyer swatch is send for the sampling ( 5- 10 meter of fabric)

39
FABRIC STORE:-Fabric storehouse actual are where the fabric for production is receive or dispatched for
processing. Beside storage the fabric store department is also responsible for the inspection of good
receives by it .

STORAGE
Rack system of storage is followed i.e. packages are stored in two areas:
1.Check fabric

2.Unchecked fabric
They are further segregated on the basic of style number and lot wise. The fabric rolls are put in rack
manual way. Such systematic maintenance of the store makes it easy to make the fabric whenever needed
in future.

ORDER PROCESSING AND FABRIC IN-HOUSE:

The merchant receives the purchase order from the buyer. On the basis of this purchase order, the fabric
source prepares a requisition for fabric as per the demand of the buyer and raises it to the fabric vendors in
the market. The best deal and the vendor are finalized and the order is placed. The factory may send the
yarn from the store to the fabricator for fabric production, buy goods for dyeing or directly order processed
fabric to the vendors. Once the fabrics development receives the approval for the fabric, the vendor send it
from of lot within the specified the time period and the fabric is made in house in the fabric store. About
5% extra goods are supplied by the vendor.

40
PROCESS FLOW OF FABRIC STORE

FABRIC DISPATCH FROM MILL

FABRIC DESPATCH FROM MILL

FABRIC RECEIVING
FABRIC DESPATCH FROM MILL

GRIEGE FABRIC SOLID/YARN

FABRIC DESPATCH FROM MILL DYED/PRINTED

SEND IT FOR PROCESSING

FABRIC DESPATCH FROM MILL

BACK TO INHOUSE AFTER DYING OR PRINTING

FABRIC DESPATCH FROM MILL

100% CHECKING (4 POINT SYSTEM)

FABRIC DESPATCH FROM MILL

METRE CHECKING BY SECURITY GUARD

FABRIC DESPATCH FROM MILL

LOT MAKING AND SEND IT TO MERCHANDISING

FABRIC DESPATCH FROM MILL

QUALITY CHECKING FOR DEFECTS

FABRIC DESPATCH FROM MILL

KEEP IN STORE
FABRIC DESPATCH FROM MILL

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FABRIC INSPECTION
The fabric being the main contribution to development of our final product i.e. the garment, it is very
important to control its quality indicated by the no. of faults and various present in it. Identification of
these objectionable variations and faults right at the initial stage to reduce the production time. So once
the fabric is in- house it is immediately sent on a pilot and trolley assembly to inspection.

4 POINT SYSTEM: 4 Point system for fabric inspection is widely used in apparel industry for fabric quality
inspection.
1.Fabric inspection method or preparation.
2.Criteria of giving penalty points based on defects and defect length.

3.Calculation method of total penalty points for total defects found in a fabric roll.
4.A Check sheet or format for recording data.
5.Knowledge of different types of defects (how a defect looks and its appearance).

Criteria for giving penalty points

The penalty evaluation points have been given for different length of fabric defect and dimension of holes.

SIZE OF DEFECT PENALTY POINTS

Length of defects in fabric (either length or width)

Defects up to 3 inches 1

Defects > 3inches < 6 inches 2

Defects> 6 inches < 9 inches 3

Defects > 9 inches Holes and openings (largest dimensions) 4

1 inch or less 2

Over 1 inch 4

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FORMULA TO CALCULATED TOTAL POINT PER YARD
In 4 point system fabric quality is evaluated by unit points /100 sq.yds.

Points/100sq.yds = Total points in roll *3937

Fabric length in MTR * fabric width in inch

TRIMS STORE
Trims store as the name suggests is a department, which acts as a storehouse for accessories. It is the
place where all the accessories required in a firm, are stored. Right from sewing thread, needles to
packaging material like polybags and taps etc. all are stored in the accessories store.
The merchandiser as per buyer specifications order the purchase dept. to buy the accessories that are used
in a particular style of that buyer. Merchandiser prepares swatch card containing all the accessories and
their quantity in a cycle. These accessories used in the swatch card are as per the quality and colour
mentioned and approve by the buyer. The purchase dept. with help of swatch card prepared by the
merchandiser purchase the required quantity of accessories. The accessories are purchased 10 – 15% extra
then the required, as the wastage in case of accessorises more. The receiving dept. then receives these
accessories from the vendor and then checking and testing of these accessories are done. They are checked
quality and colour. The accessories like buttons are tested with help of button snap tester.
After all accessories are checked and tested as per the buyer’s specification then an Accessories approval
card is prepared.
After the accessories are received they are stored in the accessory store. The accessories are stored in
different racks. The accessories of a single buyer are stored in one rack but the different accessories are
stored separately from each other in the same rack. The accessories store also houses the stationary
required in Firm.
Now, whenever the production starts the accessories required in production are issued to the production
dept. through an internal channel. A stock register is used for maintaining records. Thus an accessory store
function as a store house for accessories where all accessories are assembled and kept and also issued to
sampling and production dept. for the garment manufacture.

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List of trims used in apparel manufacturing:
1.Sewing Thread. 6.lace
2.Button. 7.Braid
3.Zipper 8.Elastic
4.Lining. 9.All types of label

5.Interlining. 10.Hook & Loop

CAD DEPARTMENT
Computer Aided Design (CAD) becomes an essential tool for pattern making and related jobs in garment
industry. In apparel industry CAD Software is used for pattern making, Grading of pattern, marker making
and digitizing manual patterns.
CAD system involves any type of design activities which use of to develop analyses or modify any
engineering or garment design.
TUKA CAD Software which is used for computer aided designing in K.L knitwear.
TUKA CAD is an innovative apparel pattern making software that is perfect for manufacturers and designers
of any size. Operating under Microsoft Windows, TUKA CAD allows the user to accurately builds patterns,
grade rules and markers for single styles or entire lines. It is the advanced pattern making, grading and
marker making system that will streamline your production process and reduce operating expenses.
Fabric Matching Engineer pattern pieces according to fabric prints, stripes, or plaids. Fabric print can be
transferred to Marker Making for perfect matching. TUKA CAD even accommodates the flaws in warp
control.

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GRADING
Build block libraries with “master grading.” Changes made to base pattern are Automatically reflected in
entire size range eliminating need to recalculate grade rules. Easily insert size in between current sizes and
the system will automatically divide the grading in half.

MARKER MAKING
• A marker is a diagram of precise arrangement of pattern pieces for size of specific style that are to
be cut from a single spread.
• Marker making is a process of developing a diagram which is superimposed on the top of a ground
of superimposed piles as a guide for cutting these plies.
• It determines the most efficient layout of pattern pieces for a specific style fabric and distribution
sizes.

Cut order planning determines:

• How many markers are needed?
• How many of each size should be in each marker and the number of plies that will be cut from each
marker?

WAYS TO MAKE MARKER MOST EFFICIENT

–PATTERN ENGINEERING
An examination of the seam location to ensure the possible placement of pattern in marker.

–HEM ALTERATION ALLOWANCES

Means dividing a large panel awkwardly shaped pattern into two pieces to better accommodation in the
marker.

–THE SELECTION OF FABRIC WIDTH

The best width depends among other factor on the cost of various fabric width/ square meter, the typical
number of size in a marker, the potential pattern engineering changes at various width and the marker
efficiency achieve.

45
WORK FLOW OF SPREADING AND CUTTING

SPREADING

LAYERING

CUTTING MANUAL / AUTOMATIC

TICKETING

FUSING

CHECKING

BUILDING

TRANSFER TO PRODUCTION

46
SPREADING DEPARTMENT
Spreading is the process of smooth layering of fabrics in superimposed layers of specified length. After
fabric is received it is issued to spreading department for further processing. Spreading is done with the
type of fabric, print of fabric and marker issued by CAD dept.

PROCESS FLOW OF SPRADING

FABRIC IS LOADED ON SPREADING MACHINE

PERFORATRED PAPER IS SPREAD ON SPREADING TABLE

VACCUME IS TURN ON IN THE SPERADING TABLE PAPER IS

SPREAD ON SPREADING TABLE
AUTOMATIC / MANUAL SPREADING IS DONE
IDONEPERFORATRED PAPER IS SPREAD ON
SPREADING TABLE
PROPER TENTION IS MAINTAINED PROPER TENTION IS
MAINTAINED

WHILEWHEN FINISHED, VACCUME IS TUREND OFFIS MAINTAINED

MA MARKER IS SPREAD OVER IT AND PASTED BY TAPE

AIR FLOW IS GIVEN FROM BOTTOM

47
CUTTING DEPARTMENT
Cutting means to separate out different garment process from the lay of fabric with the help of cutting
template and devices. It is done to get required shape indifferent no. or as a whole to make a complete
product. The first stage in the manufacture if garment is the cutting of material into the necessary pattern
shapes. These patterns are joined to form a garment when large amount of garment style has to be cut, a
lay is created, which consist of many piles of fabric spread one above the other. Now all the pattern pieces
for all sizes are from this lay. The main objective of the cutting dept. is the cutting of garment parts
accurately and economically and in sufficient value to keep the sewing room supplied with work.

Objective:
• To maintain the quality of the cut components.
• To cut the raw material in required shape and quality.
• Availability of cut components on time.

BASIC WORK FLOW

Cutting department receives the order for cutting a garment style from the production manager. Cutting
order is an authorization by the production manager to cut a given amount of styles, from the spreads. It
comes in from of a package file that carries the following details:-

1. Sampling Average, weight of garment (base fabric consumption only) and trim averages.
2. Measurement Sheet.
3. Design worksheet of garments.
4. Purchase order.
5. Fabric requisition sheet.
6. CAD mini maker.
7. Marker planning length of lay etc. Size ratio and colours in which the patterns are to be cut.

CUTTING AVERAGE
The cutting department duties are not limited to mere cutting of fabric. It is responsible for keeping control
over the consumption of fabric per garment piece cut this consumption is more specifically defined in
terms of cutting average. During marker planning, the CAD rules sends theoretical consumption of fabric as
per it is marker, which is calculated as follows:

Cutting average = Area of one piece in the marker (cm square)*GSM of the fabric
10000

Cutting average is used to determine the cost of raw material that is fabric for each garment. Hence it is
very important that it is maintained airing the bulk cutting also. The cutting manager finds out his actual

48
cutting averages before the bulk cutting and tries to keep it close as possible to average predicted by the
CAD.

CUTTING SUB DEPARTMENT

▪ Layering and Spreading.
▪ Cutting.
▪ Bundling and Ticketing.
▪ Fusing Area.
▪ QA department.

TICKETING
Once the pattern pieces are cut by the cutting machine, they are then ticketed. Cut components are group
together as per their sizes and taken to the checking table. Here the cut components are inspected for any
error. It is very important to take care that pieces cut from two different bolts of fabric are not mixed up.
This is because within lot there bolt to bolt variation in colour shade.

FUSING
Fusing is also carried out in the cutting room itself. The parts to be fused are separated from the bundle.
The fusing material (like interlining) is cut according to size of the component to be fused. The component
along with the cut fusing material are kept between to paper sheets and the pack is passed through the
fusing machine by means of temperature and pressure fusing takes place at particular speed and for a
particular time. The pack comes out at the other end on conveyors and the pieces are removed and re-
bundled.

Parameters affecting the fusing process:-

➢ Pressure – Pressure applied to the fabric should be adequate so that even contact between the
interlining and cloth takes place and uniform heat is supplied to the adhesive. Pressure should be
adequate for the correct penetration of resin among the fibres of fabric.
➢ Temperature – It is another important parameter. It depends upon the type of resin used in fusing
process. It should be high enough to change the dry thermoplastic resin into a molten state so that
it can flow properly between the fabrics. If temperature is low it gives proper low of resin and if is
high it gives to much flow of resin and the resin will come out.
➢ Time – Time should also be adequate along with temperature and pressure. It should be long
enough so that melting and penetration of resin among the fibres of fabric can takes place.

49
CHECKING
The ticked panels are now sending to the checking are for inspection of every individual pieces for any
objectionable faults. Panels having faults like wrong grain line, in appropriate size, incorrect shape and any
fabric defects likes holes, cut , shade, variation etc. That are not within the acceptable quality parameters,
are removed from the cut lay. A cutting component checking report is filled for the total quantity cut,
checked and approvals. The rejected pieces are sent back and equal no of trash panel are separately cut,
replaced in the set and ticketed with the same no. as the rejected once. Other mend able faults are marked
with an alteration sticker and passed on. These will be spotted out during garment finishing or washing.

BUNDLING
The checked components of one style and in one size are now clubbed and bundled using tie. The size of
bundle depends upon the requirements of the production plant. Each bundle will contain pieces of same
style and same size only. These pieces are stored in racks made beneath the cutting table. The cutting
department issues the amount required by the production dept. as and when ask for. The cut component
may be issued in instalment or all at once as the needs of the production dept. against the job order.

SEWING DEPARTMENT
The basic aim of each firm house is to deliver value satisfaction of the customer at the profit level.

Production is an act of producing i.e. quantity obtained by multiplying two quantities to gather by making
use available resources.
To deliver quality with the quantity the ratio between input resources or material &output good and
service is known as productivity are reciprocally related to each other. Therefore an increase in production
leads to fall in the cost per unit & rise in profit.
The production department is spread in two floors, ground floor and first floor is for jacket, blazer and basic
garment. Both floors have common cutting dept. so all the sizes of bundles are received from there only.

Production floor follows assembly line system. Following are steps to start a production
line:-
1. To study the production file.
2. To study operation bulletin and set line accordingly.
3. Manpower – Operators, checkers, quality controller and helper.
4. Load and feeding line.
5. To arrange buffer or work-in-Progress.
6. Manufacturing.
7. To make daily production and to achieve target accordingly.
8. To understand bottlenecks stage of production.

50
Working steps of production department.
• Shrinkage production pattern is issued to production floor from CAD dept.
• Ready pattern are made as per the requirement of production room.
• Cutting received from cutting dept.
• Cross checking of cut panels with patterns.
• Bundling of cut panels is done.
• Operation wise feeding of cut angels into the line.
• Inline checkpoint.
• Output of line.
• Final checkpoints.
• Auditing of checked pieces.

Some important production points:-

• Ratio between worker and machinery.
• Bottleneck area to be considered.
• In most of machine, guide is there.
• They are using cartons to moving bundles.
• They generate report for broken needle.
• Complete assembly is divided in 6 parts, in end of every part there was are cord sheet, which show
early target input, actual input, target output and actual output, according to this can find out
bottleneck area.

PRODUCTION CAN BE CARRIED OUT IN ONE WAY

In this production system a garment is being by no. of workers, therefore one part is stitched by one worker
and then passed on to other, due to which line gets setup. In the end assembly of parts is done, in modern
industries conveyer belts are used as a medium of transportation of garment part from one worker to
another. This system is very commonly used in industry as it reduce the manufacturing cost increase the
production.

51
WASHING DEPARTMENT
Garments pass through various handling processes, which may render them dirty and stain, thereby
reducing their aesthetic appeal. To restore this aesthetic value, they are subjected to cleansing process like
washing and dry cleaning. Garments Are sent for washing by the production department as per the buyer’s
requirement. Normally the fabrics are not asked to go for wash by the buyer. Whether the fabric
department may internally sent it a number of other reasons.
1.To Control uneven shrinkage
2.To remove bowing
3.To lighten colour shade

4.To improve hand

5.To even out colour shade variations
6.To remove printing smell
7.To execute a dyeing program

WASHING FACILITIES:-
ENZYME,
STONE WASHING,
OVERDYEING ETC…

FINISHING DEPARTMENT
After assembly, the garments now come for finishing – A key stage of garment manufacturing process.
Finishing is done to prepare the final garment according to the quality standards of the buyer before
packing it for shipment.

Machine and Equipment Used in Finishing Department:-

• Thread sucker machine
• Thread Cutter
• Hand tag Gun
• Lifter
• Iron
• Metal detector
• Textile cleaning Gun etc.

52
PROCESS FLOW OF FINISHING

Garments comes from production

Washing

Thread Cutting

Initial Checking and Spotting

Alteration

Reironing

Final checking

Presentation/Final Ironing

Measurement

Sent for Packing

53
BASIC WORK FLOW

• WASHING, PERC – According to the buyer’s demand or as per the buyer Specifies recipes and the
method to be employed. The pieces are count and sent with the asg or PERC program.
• Thread trimming – Pieces received from the washing department or from the assembly line now
come for thread trimming where trails of thread are cut off from the seams, buttons etc. manually
with the help of trimming scissor.
• Spotting – During The assembly, the garment may acquire stain and other objectionable marks
which must be removed. This is done either in washing. Department or they are locally ‘sported off’.
Objectionable stains like that of Chalk are spotted by means of spotting guns containing mild
solvent. Harder and stubborn stain(like that of tobacco, rust, dye, kerosene etc.) are sent to the
spotting room where they are cleansed under the spotting machine in a Protective environment. If
the spots still don’t go then they are sent for perc or dry cleaning.
• General checking – Now the garment comes for general checking relating to overall stitching.
Here, first the general visual appearance is studied which includes shape of the garments; balancing
of the parts; colour variations etc. then any seaming defects are recognized for example unmade
seams, missed stitches etc. as per requirement the checked pieces are send for mending to
assemble line. The production manager gives a top sample to checkers as a visual aid.
• Final thread cutting – Minute thread like those of labels, bar tack etc. are trimmed off to give
the neat look. Thread loosely sticking to the garments is also shed off, both in and out by jerking the
garment before it goes for pressing.
• Pressing – Pressing in general is shaping the assemble material with pressure, with/ without heat
and moisture, for further processing. In case of knits, this is important but not as significant as in
the case of woven because of their property of excellent recovery and fit.

Measurement and final checking – This is the final and most stringent done for garment
measurement, appearance, labels, trim etc. to study the final look and shape the final look and shape of
the product produced. Measurements are done according to the specification sheets and recording are
made for any variations in the measurement chart. This gives an overall idea about the quality of the
garment being produced.

54
PACKAGING DEPARTMENT
Packing is the LAST STAGE WHERE THE FINISHED GARMENT AREPRIMED, Organized, geared up for the
shipment to the buyer, the entire process from the way a garment will be folded to the final labelling of the
cartons is
Dictated by buyer’s specifications. These instructions are standardized for a

Particular type of garment and sent to the merchandiser in from of a packing manual. The merchandiser
forwards it to the packing in charge along with a top of production sample i.e. packed with dimension
approved by the buyer. This is kept as a visual reference for the packers.

OBJECTIVE OF GARMENTS PACKING

• To provide physical protection.
• To give barrier protection.
• To attract customers to products.
• To carry the goods easily.
• To transport goods in suitable way.
• To control the quality of goods.
• To inform about goods property.
• To reduce risk in shipment process.

55
PROCESS FLOW OF PACKING

Garments Comes from Inspection

It Is Then Folded

1 or 2 Are Packed Together

All Pieces Put Into Cartons

Details Are Pasted On Cartons

Cartons IS Sealed

Loaded Into Trucks

Sent For Shipment

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SHIPMENT / SALESMAN SAMPLES:
➢ Inform Head of Quality Control for Shipment Sample.
➢ Obtain 2 sets of shipment samples from the Quality Control Department of all sizes covering all
colours or as specified by the buyer. One or two pieces to be provided to concerned Merchandiser &
all remaining to Manager Administration. In case where buyer requires shipment samples receive
one complete set from Quality Control.
➢ Shipment samples should be available to the merchandisers the next day of FRI.
➢ Upon receipt of samples, conduct a thorough check & match these against buyer specifications.
➢ Thoroughly check the getup, styling, stitching, fabric quality, fabric construction/GSM, hand feel,
washing standard, finishing, & accessories.
➢ Prepare Shipment sample format sheet.
➢ Head of department will give the final approval.
➢ Ensure that buyer receives the samples as per their precise requirement.
➢ Forward one set of shipment samples to administration department.
➢ Keep remaining samples in the department for future use & maintain a register.
➢ Update Order Checklist, format enclosed.
➢ Update the excel sheet accordingly, format enclosed

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SWOT ANALYSIS
STRENGTH :
• Market – (i)Strong presence in domestic market. (ii)Developing trust and relationship in the long
run.
• Technology – (i) Availability of customised machines.
(ii) Availability of high speed machines.
• Input Availability – (i) Raw material and allied items available in sufficient quantity since source is
located in Ludhiana.
• Skills – (i) Workers are skilled and working very hard.
(ii) skilled labours are trained from reputed institutes.

WEAKNESS:
• Markets – (i) Losing ground in international market because of the infrastructure problem.
(ii) Price competition in the market.
• Middleman/traders enjoying the most of the profits in the value chain technology – (i) Traditional
method of Production.
(ii) low level of technological development.
(iii) Manufacturing defects and rejection.
(iv) Problems with Quality and productivity.
• Input Availability – Most of the raw material is procured outside Ludhiana like from Gujarat,
Bangalore.
(ii) High duties.
(iii) Hardly and changes in design, technology process and marketing.
• Skills – (i) No skill upgradation technology training for the workers in hosiery unit.
(ii) scarcity of skilled labourers.
• Business Environment – (i) Business environment is changing.
(ii) Buyers requirements on the higher side and small scale industry sector has to invest more.
(iii) Competitions going to increase between entrepreneurs.
(iv) Innovative capacity.

OPPORTUNITY:
• Market –(i) Quality and productivity is the rule of the game.
(ii) Enterprises can join hand together for international marketing, brand building and participation in
trade fair.

• Technology – (i) Creation of technological awareness among the entrepreneurs.

(ii) Advent of latest technology with the intervention of various departments/firms.

• Input availability – (i) Competition is going to make availability of input cheaper and sufficient.
• Innovation Capabilities – (i) Exposure visits, participation in Exhibition may make the entrepreneur
technicians more innovative and problem solving.
• Demonstration effect skills – (i) Increased awareness is likely to improve the skill base of the worker.
• Business Environment – (i) Changing business environment can provide opportunity for enterprising
firms.
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THREATS:

• Markets – (i) Competition is going to increase.

(ii) Imports is going to increase in the coming years since local suppliers is not able to supply in time
and time constraints from outside.
• Technology – (i) low level of technological development.
(ii) Technology can impose a major threat unless it is changes/ modernized.
(iii) Technology is an ever changing process.
• Quality of Raw material – (i) innovation capabilities: Innovation is required in every face of business
operation.
(ii) skills: skill base of the workers need upgradation to adopt latest technology.
(iii) Business Environment: The changing business environment is always a problem for the less
enterprising firms.

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 CHAPTER-5
FINDING, SOLUTION AND CONCLUSION

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FINDINGS, SUGGESSIONS AND CONCLUSION

Findings:

• Presence in making region: With 16 years experience in making from the region.
• Value Addition: They add value to your product and it’s development with our pre-existent and
longstanding relationship through the complete supply chain
• Strong technical Know-how: They have a good understanding of all the technical aspects of the
manufacturing of a product (garments and others) including cutting and sewing operations.
• Quality Assurance: They are competent in assuring that the manufacturer is following the right
process during the product development and production stage
• Smooth Administration processes: The service departments including finance, accounts and
logistics ensure smooth administration of all financial and logistics processes.
• Social and technical compliance: Quality products manufactured clean and hygiene
environment and in accordance with all applicable legislation of the state / country of manufacture
regarding industry minimum standards.

Suggestion:
• The various departments should be supplied with more specialized work force so that efficiency can
be increased.
• The company should consider exporting its products by collaborate with foreign companies in
technology and marketing in order to keep up with the competition.
• The pricing policy and marketing strategies must be reviewed.
• The top management should monitor the productivity of its employees. If the level of productivity is
higher than
expected level the employees should be rewarded. This will enable him to perform in future and it
will also motivate his colleagues.
• The company senior should guide their subordinates at times of difficulty. The senior should
encourage the sub ordinates to do what feel is best for the organisation. Tis will help to develop
effective communication between various levels of management and employees in the organization.
• The company should have some sports or recreational facilities for its employees.

Conclusion:
To conclude the study it may be express the given suggested measures will help the K.L KNITWEAR to
improve the overall performance of the company.

• Each team has resources dedicated to Design, Product Development, Fabric, merchandising, Order
and Production Management, technical and Quality assurance.
• These teams have the expertise and resources to fulfil customer requirements and are structured to
work exactly as per the needs of the customer.
• They add value to the product and it’s development with our pre-existent and longstanding
relationship through the complete supply chain.
• They are one of the leading garment manufacturers in India.

61
BIBLIOGRAPHY AND REFERENCES

62
REFERENCES
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63
BIBLIOGRAPHY
1. MARKETING MANAGEMENT- Philip Kotler Millennium Edition.
2. HUMAN RESOURCE MANAGEMENT- K Aswathappa
3. ORGANISATION BEHAVIOUR- K Aswathappa
4. WEBSITES www.k.lknitwear.com

www.fibre2fashion.com
www.textiletoday.com
www.google.com

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