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INTRODUCTION
1.1 INTRODUCTION:
India Textile Industry is one of the leading textile industries in the world.
Though was predominantly unorganized industry even a few years back, but the
scenario started changing after the economic liberalization of Indian economy in
1991. The opening up of economy gave the much-needed thrust to the Indian
textile industry, which has now successfully become one of the largest in the
world. India textile industry largely depends upon the textile manufacturing and
export. It also plays a major role in the economy of the country. India earns about
27% of its total foreign exchange through textile exports. Further, the textile
industry of India also contributes nearly 14% of the total industrial production of
the country. It also contributes around 3% to the GDP of the country. India textile
industry is also the largest in the country in terms of employment generation. It not
only generates jobs in its own industry, but also opens up scopes for the other
ancillary sectors. India textile industry currently generates employment to more
than 35 million people. It is also estimated that, the industry will generate 12
million new jobs by the year 2010. There were 2,500 textile weaving factories and
4,135 textile finishing factories in all of India. According to AT Kearney's 'Retail
Apparel Index', India was ranked as the fourth most promising market for apparel
retailers in 2009.
India is first in global jute production and shares 63% of the global textile and
garment market. India is second in global textile manufacturing and also second in
silk and cotton production. 100% FDI is allowed via automatic route in textile
sector. Reiter, Trutzschler, Soktas, Zambia, Bilsar, Monti, CMT, E-land,
Nisshinbo, Marks & Spencer, Zara, Promod, Benetton, and Levi's are some of the
foreign textile companies invested or working in India.
India textile industry largely depends upon the textile manufacturing and export. It
also plays a major role in the economy of the country. India earns about 27% of its
total foreign exchange through textile exports. Further, the textile industry of India
also contributes.
The time allotted for conducting the organizational study was only 28 days. It
is not enough for understanding about the organizational in detail. Employees were
busy in their work so they could not give more information. The study is limited to
my experience and knowledge.
The internship program I have faced a lot of problems to complete the report.
In fact, it is faugh to get into all the department for gather information for me since
every department have their own confidential strategy and process of working.
Chapter-1 Introduction
This chapter include introduction, objectives of the inplant training, objectives of
the study, scope of the study, limitation of the study, importance’s of the
organizational study and methodology of the study.
HISTORY
The archaeological surveys and studies have found that the people of Hardpan
civilization knew weaving and the spinning of cotton four thousand years ago.
Reference to weaving and spinning materials is found in the Vedic Literature.
There was textile trade in India during the early centuries. A block printed and
resist-dyed fabrics, whose origin is from Gujarat is found in tombs of Foster,
Egypt. This proves that Indian export of cotton textiles to the Egypt or the
Nile Civilization in medieval times were to a large extent. Large quantity of
north Indian silk were traded through the silk route in China [5] to the western
countries. The Indian silk were often exchanged with the western countries
for their spices in the barter system. During the late 17th and 18th century
there were large export of the Indian cotton to the western countries to meet
the need of the European industries during industrial revolution.
Various Categories: Indian textile industry can be divided into
several segments, some of which can be listed as below:
• Cotton Textiles
• Silk Textiles
• Woolen Textiles
• Readymade Garments
• Hand-crafted Textiles
• Jute and Coir
COTTON TEXTILES:
In the early years, the cotton textile industry was concentrated in the
cotton growing belt of Maharashtra and Gujarat. Availability of raw materials,
market, transport, labor, moist climate and other factors contributed to
localization. In the early twentieth century, this industry played a huge role in
Bombay's economy but soon declined after independence. While spinning
continues to be centralized in Maharashtra, Gujarat and Tamil Nadu, weaving
is highly decentralized. As of 30 September 2013, there are 1962 cotton textile
mills in India, of which about 80% are in the private sector and the rest in the
public and cooperative sector. Apart from these, there are several thousand
small factories with four to ten looms.
India exports yarn to Japan, United States, United Kingdom, Russia, France,
and Nepal, Singapore, Sri Lanka and other countries. India has the second-
largest installed capacity of spindles in the world, with 43.13 million spindles
(30 March 2011) after China. Although India has a large share in world trade
of cotton yarn, its trade in garments is only 4% of the world's total. This is due
to the incompetency of local spinning and weaving mills to process yarn.
There exist some large factories, but most of the production is fragmented in
small units, which cater to the local market. This mismatch is a major
drawback for the industry. As a result, many of the spinners export yarn while
apparel and garment manufacturers have to import fabric.
The power supply is erratic and machinery is outdated and needs to be
upgraded. Other problems include low output of labor and stiff competition
with the synthetic fiber industry.
JUTE TEXTILES:
India is the largest producer of raw jute and jute goods and the second largest
exporter after Bangladesh. There were about 80 jute mills in India in 2010-11,
most of which are located in West Bengal, mainly along the banks of the
Hooghly River, in a narrow belt (98 km long and 3 km wide). Factors
responsible for their location in the Hooghly basin are: inexpensive water
transport, good network of railways, roadways and waterways to facilitate
movement of raw material to mills, abundant water supply, and cheap labor
from neighboring states.
Silk is produced by several insects; but, generally, only the silk of moth cater
pillars as been used for textile manufacturing. There has been some research
into other types of silk, which differ at the molecular level.
Silk is mainly produced by the larvae of insects undergoing complete
metamorphosis, but some insects, such as webspinners and raspy crickets,
produced silk through their lives. Silk production also occurs in hymenopter,
silverfish, mayflies, thrips, leafhoppers, beetles, lacewings, fleas, flies, and
midges. Other types of arthropods produced silk, most notably various
arachnids, such as spiers.
Woolen Textiles:-
Wool is the textile fiber obtained from sheep and other animals, including
cashmere and mohair from goats, quiet from muskoxen, from hide and fur
clothing from bison, angora from rabbits, and other types of wool from
camelids; additionally,the highland and the mangalica breeds of cattle and
swine respectively, possess woolly coats, wool consist of protein together with
percentage lipids. In this regard it is chemically quite distinct from more
dominant textile, cotton, which is mainly cellulose.
Readymade garments:
PRODUCTION
India is the second largest producer of fiber in the world and the
major fiber produced is cotton. Other fibers produced in India include silk,
jute, wool, and man-made fibers. 60% of the Indian textile Industry is cotton
based. The strong domestic demand and the revival of the Economic markets
by 2009 has led to huge growth of the Indian textile industry. In December
2010, the domestic cotton price was up by 50% as compared to the December
2009 prices. The causes behind high cotton price are due to the floods in
Pakistan and China. India projected a high production of textile (325 lakh
bales for 2010 -11). There has been increase in India's share of global textile
trading to seven percent in five years. The rising prices are the major concern
of the domestic producers of the country.
The Woolen Sector: India is the 7th largest producer of the wool in the
world. India also produces 1.8% of the world's total wool.
The Jute Sector: The jute or the golden fiber in India is mainly produced in
the Eastern states of India like Assam and West Bengal. India is the largest
producer of jute in the world.
The Sericulture and Silk Sector: India is the 2nd largest producer of silk in
the world. India produces 18% of the world's total silk. Mulberry, Eri, Tasar,
and Mega are the main types of silk produced in the country. It is a labor-
intensive sector.
Production process :
Sampling
MARKET SIZE:-
Davangere
Number of employee 25
email
Zkgarments123@gmail.com
2.1 INTRODUCTION :
ZK Garment’s in Davangere brings raw material from Surat and Belgaum and
from Tamil Nadu they buy raw cotton, Dopen, Viscous, silk and Wool etc. and its
varies in. And also in stitching branded shirts from various company of readymade
and wear brand in the Davangere city today. It has a wide range of apparel design
for all segments including corporate, formal and casual dressing.
In the mid 2015-2016 the textile industry faced another major crisis. With the
power loom churning out vast quantities of inexpensive fabric, many large
composite mills lost their markets, and were on the verge of closure. Yet that
period saw Z K Garments at its highest level of profitability. There could be no
better time, concluded the management, for a rethink on strategy. The Z K
Garments management coined a new word for it new strategy-Reno vision. It
simply meant a new way of looking at issues, of seeing more than the obvious
and that became the corporate philosophy.
RAW MATERIAL
Raw material like cotton threads are being purchased in bulk and this is being used
as the main ingredient for production process at ZK GARMENT.
Cotton threads are fed to the machinery where it uses them to get in to the
shape of the long rolls of woolen cloth and stitching of shirts by dealing clothes,
Branded and reputed company Textile materials. The firm has taken the order from
the various clients and stitch the shirt and delivery as per their requirements in a
stipulated time.
COMPETITORS
1. MAYURA APPARALS.
2. ANUGRA GARMENTS
3. BANJARA GARMENTS
4. HPC GARMENTS
5. NANDI APPARALS
6. MAGNUR GARMENTS
7. VMS FABRICS
8. RK APPARALS
9. JAIHANUMAN GARMENTS
QUALITY POLICY:
Functions:
Four types of women's clothing which end above the knees: (clockwise from
top) minidress, miniskirt, shorts and romper, all worn by the same model.
The most obvious function of clothing is to protect the wearer from the elements.
In hot weather, clothing provides protection from sunburn or wind damage. In the
cold it offers thermal insulation. Shelter can reduce the functional need for
clothing. For example, coats, hats, gloves and other outer layers are normally
removed when entering a warm place. Similarly, clothing has seasonal and
regional aspects, so that thinner materials and fewer layers of clothing are
generally worn in warmer regions and seasons than in colder ones.
Clothing performs a range of social and cultural functions, such as individual,
occupational and gender differentiation, and social status.[5] In many societies,
norms about clothing reflect standards of modesty, religion, gender, and social
status. Clothing may also function as adornment and an expression of personal
taste or style.
Clothing protects against many things that might injure or irritate the uncovered
human body, including rain, snow, wind, and other weather, as well as from the
sun. Garments that are too sheer, thin, small or tight offer less protection.
Appropriate clothes can also reduce risk during activities such as work or sport.
Some clothing protects from specific hazards, such as insects, noxious chemicals,
weather, weapons, and contact with abrasive substances.
2. Waste :
DEPARTMENT ANALYSIS
INTRODUCTION :
Garment technology is a broad based subject because it combines a number
of individual technologies, with each making a specialized contribution to the
production of garment. The apparel industry is very diverse in nature and along
with textile industries, it forms a complex combination of performing
heterogeneous functions of transforming fiber into yarn and then to fabric. It is one
of the oldest and largest industry providing ample employment opportunities and it
exemplifies the growth in global manufacturing. This industry is very versatile in
nature and offers the world with a choice of garments ranging from mass market to
high end fashion. This industry follows a combination of functional and line type
of organization. Garment manufacturing process includes number of processes
from order receiving to dispatching shipment of the finished garments. Apparel
manufacturing flow chart helps understand a garment manufacturing method that
how the raw materials are converted into the wearable garments. The main task for
a garment manufacturer is to produce shell structures out of flat fabrics to match
the shape of human body. The overall flowchart of the garment manufacturing
process is illustrated in figure-1.
1 Production department
Production may be defined a process concerned with the conversion of inputs
(Raw materials, machinery, manpower and other factors of production.) with the
help of creation process.
Here in the government industry production me and the ratio between the input
of the fabric and the output of the ferment.
The production departments takes care from finding the source to
manufacturing garments and subsequently packing the garments. In between
various activates are taken places, which are detailed mentions in this project.
The product is of utmost to any organization without which any managerial
activity is impossible. So Z K Garments The production department acts as a core
center of the whole organization.
OBJECTIVES:
To follow up the daily production schedule as per plan
To cover up any deviation from the standard.
To coordinate and maintain close relationship with all other key
department.
To upgrade technical efficiency of the production.
FABRIC DEPARTMENT:
FABRIC INSPECTION :
A) INSPECTION METHOD:
• MANUAL INSPECTION:
Table in this method the fabric is drawn to the from the fabric roll manually
under the tube.
Light table where fabric is inspected according to the system of inspection.
• USING FSBRIC INSPECTION MACHINE
In this method the fabric are drawn to the table from the fabric roll using
servo motor under the tube light, where fabric is inspected according to the
system of inspection.
B) SYSTEM OF INSPECTION :
• 4 POINT SYSTEM
• 10 POINT SYSTEM
SHADE SEGREGATION
INSPCTION BY POINT
INTERDEPARTMENT DELIVERY
CUTTING DEPARTMENT :
CUTTING
Cutting is a process of separation of pattern pieces from the lays of fabric
with the help of cutting marker. The marker is spread over the top ply of the
lay.
SPREADING:
Spreading is a layering fabric piles to form a lay of specified length it
may consists of a single ply or multiple piles. The height of a lay or spreads
id limited and depends on fabric characteristics, size of the order to be cut,
cutting method and the vertical capacity of the spreader.
METHODS OF SPREADING
• Manual
• Spreading
• Automatic spreading machine
SORTING
Sorting is a process of all parts garment cutting in the table and check
presence all parts referring approved sample.
BUNDLING:
Bundling is done as per cut components and as per batch requirement as per
purchase order and style number and cut number.
IMPORTANT FACTORS:
• Number of piles should not exceed more than 70 lays while spreading.
• Cut plan should make against the taper report.
• One way cutting is recommended.
• Z K Garments using the number sticker at top side of the fabric since
it may leave gum residue after wash.
• Z K Garments the writing by chalks and white pencil on the cut
panels.
SWEING DEPERTMNENT :
Most major important and dominant process in garment is sewing,
the objective of sewing are constructing of seems which combines the
required standards of awing means achievement of strength, elasticity,
security of comfort and the maintenance of specialize fabric the garment is
processed from one operation to another to obtain a finished product.
This is process of assembling the cut panels; the method of
production follows I this section is line production the process R and D
department specifies the number of machines required for the complete
process of sewing. Sewing process consists of ironing and sewing in the line
production. The line production system is arranged in such a manner that in
such start from stitching of first part till the last part the fabric moves
towards the operator for a particular stitching is in a straight line direction,
hence it is called line production.
This is how the stitching process is done in sewing department after
each 10 operation, there is one in line checking point to assure the quality in
stitching in case of any mistake in stitching, is corrected by replacing the
stitching fabric to particular operator who has made the mistake. There is an
line checking points which checks the complete stitching points play a vital
role in getting perfectly stitched garments.
TECHNOLOGY USED :
AUTOMATION :
The level of automation use in Export Industries pvt is semi automation.
The material handling equipment are lifts and helper.
COMPUTER AIDED DESING (CAD)
The CAD is the research software. The CAD is used for pattern making for fabric’s
and garments, cutting the designs for the fabric. The package used is “TREACH” .
MARKETING DEPARTMENT :
MARKETING DEPARTMENT FLOWCHART :
MARKETING MANAGER
ASSIST ASSIST
MANAGER MANAGER
EXCUTIVE
EXCUTIVE
The main function of this department is to get orders from the buyers. The
marketing department in charge for getting orders, price fixing. Keep regular
communication with customer, sending quotation to the customer, and other
function relating to the marketing the products. A part from the regular
correspondence with existing customer, the companies focus on developing market
both domestic and international like institution and corporate orders.
OBJECTIVES :
The marketing objectives are set by text port Industries pvt To increase the
profits of the company through cost of reduction increasing market share, creating
new customer base at the same maintaining the existing customer loyalty the
following are the objective of the marketing department vide.
• Setting up of marketing goals and objective
• Developing the market plan
• Organizing the marketing function
• Controlling the market program
PROCESS;
Enquiry
Garment spec tech pack
Quotation
Negotiation
Order finalization
Documentation
Money realization
This department prepare the sample for buyer as per the requirements given
by the merchandiser. If news style comes, they have to prepare four sample;
PRODUCT DEVELOPMENT:
AREA MANAGER
o PACKAGING:
o PAYMENT PERIOD
The payment period varies upon the value of transaction, it is
usually 30 to 45 days period in normal transaction.
o PROMOTIOM
According to Philip kotler sales promotion consists of diverse
collection of incentive tools mostly short term designed to stimulate
quicker and or greater purchase of particular products and or services by
consumer or trade. Company should communicate with their present and
potential customer.
o PROMOTION
o INTERDEPARTMENTAL COMMUNICATION
• Weekly review meeting with design & concerned business unit.
• Review with CEO president on process & targets.
• Result:
HUMAN RESOURCE DEPARTMENT
HRD
HR MANAGER
COMPLENCE WELFARE
OFFICERS OFFICERS
HR EXCUTIVES
HR ASSISTENT
HR ASSISTENT
D.E.O
The visions manager HR is “a business driven compassionate HR function
which is the foundation that synergizes vision there by creating a performances
given culture that facilitates the maximization potential”.
In any organization the human resource are more important. Even though the
garments industries are machines oriented. The adequate skilled are more
important factor for the growing the company. The personal manager is
responsible for this department. He is mediate between the management and the
workers. He has to settle the issue in case any disputes arise. He looks after the
welfare of the employee, the company is having small canteen for the workers. In
case of overtime work the food is provided in the company itself at free of cost.
OBJECTIVE OF HUMAN RESOUYRCES MANAGEMENT
To employee the organization reach its goals
• To employee the skill and abilities of the work force efficiently
• To provide the organization with well trained well motivated
employee.
• To increase to the fullest the employees job satisfaction and self
actualization.
• To develop and maintained quality of work life.
• To communicate HR policies to all employees.
• To maintain good industrial relation.
• Maintain good relationship between the employer and employees .
• Select right types and number of employees
• Compensation, wages and salary administration.
• To be ethically and socially responsive to the needs of the society
• To comply with all government and statutory bodies.
RESPONSIBILITIES:
o SELECTION:
• The selection process includes:
• Conducting personnel interview.
• Aptitude test.
• Personnel interview
• Parent’s opinion
• References
o TRAINING:
Training is conducted for the period of 40-60 day’s company will
provide training for production department test is conducted for selection
and put their job based on their skill.
FOR STAFF:
RECRUITMENT:
The recruitment for staff takes place through :placement agency websites
monster. Times com. Shine com
o SELECTION
• The selection process include:
• Conducting personnel interview.
• Aptitude tests.
• Personnel interview.
• Reference.
• Training
o TRAINING:
• Training is given in following:
• Regulating job training.
• Communication training
• Area training
FINANCE DEPARTMENT:
OBJECTIVES:
To protect the financial interest of the company
It helps in achieving the business result (profitability)
Monitoring the funds, collection and payments
Lessening with the banks and financial institution
Controlling the in-flow and out-flow of cash
Financial planning and mobilization of cash
To see that company does not suffer from want of finance
To exercise the cost control and cost reduction of techniques
Working capital:
It refers to the follow of ready funds necessary for the working of the
organization. Apart from investment in fixed asset every enterprise has to
arrange for adequate funds for meeting day-to-day expenditure to keep it a
going concern
Inventory:
Revenue recognition:
For domestic sales, sales are recognized at the point of dispatch of finished goods,
for export sales are recognized the date bill of lading.
Sales return are accounted as reduction from current year sales irrespective of the
year in which sales accrued.
Gratuity and leave encashment are accounted on the basis of actuarial valuation.
Fixed Assets:
Depreciation:
This will be started after making adequate provision for doubtful balances.
Internal audit:
The area’s in which internal audit are covered are :
Purchase transaction
Store
Sales transaction.
Cash.
Bank.
Journal.
Payroll
CHAPTER -4
MCKINSY’S 7S FRAMEWORK AND SWOT ANALYSES
3.1 INTRODUCTION
A model of organization effectiveness that postulates that there are seven
internal factors of an organization that to be aligned and reinforced on order for it
to be successful. The 7S model was developed ad McKinsey & co. consulting firm
in the early 1980s by consultants tom peters and Robert Waterman.
The model is most often used as an organization analysis tool to assess and
monitor changes in the internal situation of an organization.
The model is based on the theory that, for an organization to perform well,
these seven element’s need to be aligned and mutually reinforcing. So, the model
can be used to help identify what needs to be realigned to improve performance, or
to maintain alignment (and performance) during other type of change.
Whatever the type of change – re structuring, new processes, organizational
merger, new system, change of leadership, and so on-the model can be used to
understand how the organizational elements or interrelated, and so ensure that the
wider impact of changes made in one area is taken into consideration.
The 7S Model specifies seven factors that or classified in to “ hard” and
“soft” elements are fuzzier, more intangible and are influenced by corporate
culture
1. STURUCTURE
The line of reporting, task allocation, and coordination and supervision levels is
structure. A small hierarchy is needed, which encompasses self-directed work
teams, daily interdepartmental stand up meeting to be held daily, the design of an
organization structure is a critical task of the top arrangement of any organization,
it refers to organizational arrangement and relationship, it prescribes formal
relationship among various position and activities, arrangement about reporting
relationship. How an organizational member is to communicate with other
members, what role he is to perform and procedures exist to guide the various
activities performed by members or all part of organizational structure.
2.STRATEGY:
The top level plan top creates competitive advantage. Focus on the
firm's core competencies and deploying lean manufacturing principles throughout
the firm, targeting and eliminating waste.
Strategy is a unified course of action to achieve the goal.
Gluck defined the strategy as, Unified, Comprehensive and Integrated plan
designed to ensure that the basic objectives of the organization are achieved.
4. SHARED VALUES:
All members of the organization share some common fundamental
ideas or guiding concepts Around which the business in built. This may be to
make money or to achieve excellence in a Particular
• Customer centric
• Respect for individual &trust in relationships in the company
• Accountability
• Build the team work
• Integrity
• Motivate to employee and excellence
• Protect the environment
• Take responsibility on corporate social responsibility
• Value for the time
• Total quality
• Cost Consciousness
• Care for employee
5. STYLE
A leadership style refers to a leader’s characteristics behavior’s when
directing motivating, guiding and managing group of people.
6. STAFF:
The staff will specify the process by which employees are recruited,
deployed and developed. The procedure involving in recruiting the employees and
place of recruitment. The job and responsibility have to be assigned according to
their skills and experience. The ZK Garment consists of 2 departments.
Administration, Production, Quality, tool room, heat treatment, maintenance,
dispatch and packing.
7. SKILLS:
The skill and competencies of the employees. Develop new team
skills, problem solving, waste elevation and process analysis skills, empowerment
to make decision, the ability to run and close out kaizens.
Following the different types of skills being worked on very regularly as per the
priority:
Technical skill – Manufacturing raw wool to woolen cloth
Managerial skill – At ZK manager’s duty is to make sure that all the
employees are working at their maximum productivity
Clerical skill- Maintenance of accounts to a great extend use this skill.
Using the 7S model, the change agent’s task is to start with the end in mind.
SWOT ANALYSIS
4.1 STRENGTHS OF ZK GARMENT
.Huge woollen textile production capacity as in our city
.Efficient multi-fiber raw material manufacturing capacity
.Large pool of skilled and cheap work force
.Entrepreneurial skill
. Large domestic market
CHAPTER-5
FINDING, SUGGESTION AND CONCLUSATION
CONTENTS:
5.1 FINDING
5.2 SUGGESTION
5.3 CONCLUSION
SUMMARY OF FIDINGS :
SUGGESTION AND CONCLUSION :
A just as there problems employees there are individual who are committed and
motivated but who often got unnoticed, recognized, rewarded, particularly in large
organization, files move, work goes on, activities and functions continuous to takes
Place in organization because of such employees.
FINDING :
There is no training and development to the workers.
Poor welfare facilities to the workers.
The co-ordination between management and workers is good,
The Z K garments ltd produce good quality cloth because of that consumer
is satisfied with the product.
Large demand from European countries.
Lack of communication skill at employees.
Lack of new learning facilities for employees.
SUGGESTION :
CONCLUSION :
Z K GARMENT ltd have comes a long way, for renovation & modernization
of work.
Seems to be a part of their vision, Z K ltd and its promotion have long
standings relationship with banks like SBI, IDBI is the 15 years these
institutions have extended substantial’s support to the various expansion
and modernization.
Z K garment ltd has earned a lot of goodwill in the textile industry a quality
of clothes is assurance to ensure good quality products for its customer. HR
&A department is ensuring for good compensation policies for the workers
and employees if the company . marketing departments is stimulating and
to get more revenues.
The development of the textile industry went backwards . statin from the
downstream consumer end products of fabric, knitwear, to the upstream
subsectors like spinning printing, finishing and man made fiber
manufacturing.
The industry developed rapidly with the fast growth in garments export.
LEARING EXPERENCE
In this training period I really learnt many aspects and gain lot of experience in
knowing many things of the production process how raw material undergoes many
stage and finally becomes the finished product and work performance done in each
department.
The concepts which I have read in the books how one organization carry on its
business activities, by undergoing organization study I gained the practical
working knowledge and how the theoretical concepts are practically applied in an
organization.
So finally I conclude that the organization study has given me wide exposure to
real working environment. Training has helped me to get the real picture of
company’s operation. I ‘m sure that this study will help me a lot in entering my
profession field and also contribution to my career development.
Bibliography
2, websites
www.wikipedia.org
www.foam industry.com