Product knowledge and Detailed study of

customer portfolio. Current process flow and

improvement.
Fahad Farooqi
Designation: MTO Marketing
Submission Date: 16-07-2018
Contents
Abstract....................................................................................................................................................................4
Acknowledgement.......................................................................................................................................................5
Summary......................................................................................................................................................................6
Socks:........................................................................................................................................................................... 7
Types of socks.......................................................................................................................................................... 7
Knee High Socks...................................................................................................................................................7
Crew socks........................................................................................................................................................... 7
Quarter socks.......................................................................................................................................................7
Low cut.................................................................................................................................................................7
No Show...............................................................................................................................................................8
Cushioning in Socks......................................................................................................................................................8
Full cushioning.....................................................................................................................................................8
Half cushioned..................................................................................................................................................... 8
Classification of Socks..................................................................................................................................................9
Fabric Wise...............................................................................................................................................................9
Flat Knit................................................................................................................................................................9
Sandwich Terry.....................................................................................................................................................9
Normal Terry........................................................................................................................................................9
Selective Terry/ Heel and toe cushioning:............................................................................................................9
Reverse Terry:......................................................................................................................................................9
Feature wise socks:................................................................................................................................................10
Basic sock...........................................................................................................................................................10
Performance sock:............................................................................................................................................. 10
Fashion sock:......................................................................................................................................................10
Heel Types..................................................................................................................................................................11
Sock parts:................................................................................................................................................................. 12
Additional feature..................................................................................................................................................13
Toe linking..................................................................................................................................................................15
Simple linking / Rosso / Real / Rosso / Reciprocated:............................................................................................15
Fine Linking / Fine Rosso........................................................................................................................................15
Ultra fine Linking....................................................................................................................................................16
Thin Linking:...........................................................................................................................................................16
Hand Linking.......................................................................................................................................................... 16
Auto Linking / Classic Linking.................................................................................................................................16
Ingredients of socks:..................................................................................................................................................17
Types of Yarns............................................................................................................................................................18
Main Yarn...............................................................................................................................................................18
Plaiting Yarn:..........................................................................................................................................................20
Elastic Yarn:............................................................................................................................................................23
Pattern Yarn:..........................................................................................................................................................23
Tie Down Yarns:..................................................................................................................................................... 23
Linking Yarns:.........................................................................................................................................................23
Yarn Measuring System:............................................................................................................................................ 23
Indirect system (in case of spun yarn):...................................................................................................................23
Direct System (In case of filaments):......................................................................................................................24
Specs Measurement.................................................................................................................................................. 25
Machine details in Interloop:.....................................................................................................................................26
Machine details in VSF for sampling:.....................................................................................................................26
Basic Terminologies...................................................................................................................................................27
Machine Days.........................................................................................................................................................27
 Cycle Time..............................................................................................................................................................27
Courses.................................................................................................................................................................. 28
Identification of machine type:..............................................................................................................................28
Customer Portfolio and Value added portion:...........................................................................................................29
Adidas.................................................................................................................................................................... 30
Delta textile............................................................................................................................................................30
Dobotex................................................................................................................................................................. 30
H&M...................................................................................................................................................................... 31
Tesco......................................................................................................................................................................31
Primark, Penney’s.................................................................................................................................................. 31
Target.....................................................................................................................................................................32
Euro sox plus..........................................................................................................................................................32
Payless................................................................................................................................................................... 33
Amazon.................................................................................................................................................................. 34
Puket......................................................................................................................................................................34
Current Process Flow and Improvement of sample development.............................................................................35
Current Process flow of Product development:.....................................................................................................35
Flow diagram of product development:.....................................................................................................................36
PDS (Product Development System)..........................................................................................................................37
Improvements and Recommendations:.....................................................................................................................39
 Abstract

Interloop is amongst one of the world’s top manufacturers of socks. To be part of such firm you need to
be at your best and as a marketer, knowledge about product, customer portfolio, current process flow is
a key to become a successful professional. The report elaborates the knowledge about the product,
Product development system, product development department, the whole development process of
socks from receiving inquiry from customer to dispatch samples to customers.

All Pre-development activities like customer inquiries, CADs understanding, request punching process,
meeting with PD department and post development activities like sample receiving, evaluation and
study on product data sheet are observed. Quality is the very basic principle that drives the organization,
this is achieved by infusing strict quality control measures, checking and validation processes across the
entire functional mechanism. Furthermore, this report elaborates different quality measures to meet
the customer requirements.
 Acknowledgement

“And Whoever puts all his trust in Allah (Almighty) He will be Enough for him.”
(Al-Quran)

All praise to Allah Almighty, for making me able to become a part of Interloop Ltd.

First and foremost, I would like to thank God Almighty for giving me the strength, knowledge,
ability and opportunity to undertake this project and to persevere and complete it
satisfactorily. Without his blessings, this achievement would not have been possible. I would
like to express my special gratitude to CEO Mr. Musadaq Zulqarnain and COO Mr. Navid Fazil
to take such an initiative for hunting talent and starting MTO program and giving us a
platform to express our capabilities.
I am also really grateful to all Marketing department, especially Mr. Muhammad Bilal General
Manager (Marketing), Mr. Muhammad Afzal (Deputy Manager Marketing), Mr. Abdul Khaliq
(Sr. officer) for guiding and supporting me throughout the endeavor of this report.
.
 Summary
This project is part of my training as an MTO Marketing of batch 2017-2018. In phase 1 my
objective was to know understanding product knowledge, customer development needs,
customer portfolio and current process flow and improvements in it. Internal Customer and
external customer understanding should be on one page to avoid any misunderstanding. I
should have complete product understanding which is sock, understanding on Product data
as what it is, how it is generated and how it is studied and where is it used, and
comprehensive understanding on product development process from customer query to
developing the product and dispatching the samples to customer and get their feedback and
fetch orders.
It gives you the basic understanding of the said objectives and will help you understand PD
and Marketing activities, customer portfolio and Current process flow and improvements in
it. This project will also give data and information regarding the equipment and machines
present in PD.
Socks:

Types of socks
Main types of sock are

Knee High Socks

The height of the sock is above knee that is why it is known as
knee high socks.

Crew socks
Crew socks are the socks which contain rib and its length is long. It is also
known as ribbed socks.

Quarter socks
This sock has a short rib almost quarter of the length of the rib as
compared to crew sock.

Low cut
High heel portion is less in low cut as compared to ankle sock.
No Show
The sock that is not visible after wearing the shoes.

Tube socks
It has no heel and is plain in shape like a tube that is why it is known as tube sock.
But it can be shaped if required with the help of the specially designed tube boards and then it is
known as boarded tube socks.

Cushioning in Socks
Full cushioning
Terry is made on complete foot

Half cushioned
In half cushioned only foot sole is covered by terry
Classification of Socks
Socks are classified on the following bases
· Fabric wise
· Special Feature wise

Fabric Wise

Flat Knit
It is simplest knitted construction that is achieved by
intermeshing of loops drawn to one side of the fabric. It’s
technical face and back side can be clearly distinguished.
Vertical wales are clearly visible on face side. It is a plain
structure having no outside or inside pulled loops. It has more
stretch in horizontal direction than vertical.

Sandwich Terry
Plaiting yarn is sandwiched between main yarns in the construction of
sandwich terry. It can only be seen when we stretch the socks. It is visible
in shape of shinny thread and is not on upper or inner side of the socks.
With addition to it, it has a soft, fine and smooth physical feel.

Normal Terry
In normal terry main yarn is partly covering with plaiting yarn and it can be easily
identified by plucking the yarn with the help of yarn pucker. Two yarns at the
same came out of the socks which are overlapped with each other. The physical
feel of the normal terry is not so fine and smooth as compared to sandwich terry.

Selective Terry/ Heel and toe cushioning:

Terry is made only on high pressure areas of sock i.e. heel and toe.
terry can be constructed on the desired portion of the
socks i.e. ankle, etc.

Reverse Terry:
The socks which contain loops on the outer side like
a towel is known as reverse terry.
Feature wise socks:

Basic sock
These are basic socks developed for everyday casual wear

Performance sock:
Performance socks contain technical yarns or finishes that add benefits to enhance performance
in sports activity. High tech fibers that wick away moisture, reinforced heel and toe, arch and
ankle support and anti-microbial to keep feet healthier are the key features of performance
socks. Interloop have lots of patent Performance socks.

Fashion sock:
It contains full range of embellishments textures, designs, patterns and seasonal fashion colors.

There are some more types of socks i.e.

Turn cuff:
They are made on double cylinder and its cuff are turn as a style or
fashion.

Tab socks:
It is kind of low cut socks but have tab for holding and
supporting purpose.
Heel Types
Socks are also classified on the bases of heel formation; the formation of heels are made by
using different needle techniques as by missing the needles to give different shape. The
required shapes are achieved by feeding the system accordingly. As heel’s pocket size is
increased towards outer side, production is going to be decreased because cycle time of
socks will increase. A line formed on heel helps to identify type of heel and is known as gore.

Real heel:
In case of real heel one by one half needles are disabled till its
gore works step by step.

Y-Heel:
In Y-heel ‘Y’ shape is formed. Stitch is picked and dropped
continuously and it gives a Y shape.

Pouch heel:
The heel is made on four feeds but during pouch heel one feed
is used.

Double Y:
It is similar to Y heel but another Y is added and is more comfortable.

Triple Y:
It is similar to Double Y heel but another Y is added and is more
comfortable.
Sock parts:
Some parts of socks are necessary to give it a
proper shape and further parts are also added to
achieve different features.
Welt: It is the most upper part of sock. A rib like
structure is made for the gripping of sock at leg
portion. Elastic yarn is used in this part. Different
types of constructions are used in welt e.g.1x1, 2x1,
3x1, 3x2 etc.

Leg: It is part between heel and welt that can be of

rib or plain structure.

Foot: It is lower part of sock between heel and toe.

Heel: It is the most pressured area of socks so different

yarns are used here for reinforcing. It has different types like real, pouch, Y and extended
Y.

Toe: The front part of sock that is opened during knitting and it is closed later on. It may be
anatomical for left and right is known as toe.

Clip: It is part of sock that is kept so that knitting can be done and is cut of later after
linking/toe-closing process the length of clip is 1.5 cm. Regenerated, a cheaper version of
yarn is used as clip yarn.

Rib: A rib like structure is made mostly on leg portion to give comfort and good gripping to
leg. Various constructions can be made as 1x1,2x1, 3x1, 3x2 etc. Rib can be of 2 types. The
construction can be every course and every other course.

· True rib: It can be made only on double cylinder machine. Its inner and outer side
has same construction.

· Mock rib: Mock rib is made on single cylinder machine. It is not actually rib but due
to its construction, it seems to be like rib. It is achieved by pulling elastic inside.
Welt closing step is necessary in this case.
Additional feature
Arch support
This feature is commonly added in sports sock to give the grip
to foot. Elastic is used in each courses of rib.

Ankle Support
It is made for ankle gripping and to avoid sock slippage.

Mesh
It is made to improve breathability of sock. In its formation, main yarn is missed at some
places to give mesh like structure. Mesh can be single feed or double feed. If a simple pique
mesh is required, then it can be made by using 2 feeds but a special mesh like honey comb
structure is made only by single feed. If mesh structure is small then 4 feeds can be used for
other parts but in case of big mesh structure, 4 feeds are not preferred to avoid change

Mesh

Ring Toe
An extra covering is made around toe to protect it from strong blisters.
Logo Window
It is made to prominent the logo and to give it a proper appearance.

Logo

Back Tab
Provide an additional tab of fabric on the back of the sock
that prevents the shoe from rubbing against the back of
heel and helps to protect against blisters in this friction
prone area.

Splicing
Splicing of nylon or polyester is made into pressure points of sock foot commonly to achieve
abrasion resistance, mostly at heel & toe.
Toe linking

Simple linking / Rosso / Real / Rosso / Reciprocated:

In this linking, coaster line appears as a single line.

Fine Linking / Fine Rosso

In fine linking, coaster line appears in the form of a 3 lines. In this linking the courses of rosso
are made up with nylon and an extra yarn is employed above and below the coaster line.
Ultra fine Linking
In ultrafine linking, 4-6 courses of linking are made with Lycra. 20/75/1 or 20/70/1 Lycra is
used.

Thin Linking:
In thin linking 4 to 5 pre linking courses are added with 30/2 yarn.

Hand Linking
This linking is done manually.

Auto Linking / Classic Linking

In classic linking, liking is done with the help of knitting machine.
Ingredients of socks:
Every product has basic ingredients involved in its final formation. Yarn plays the vital role in making
sock. A good knowledge about fibers and their properties is necessary for better understanding of
socks.
Socks are available in different type of fiber content & blends depending upon customer
requirements. Fiber content and knitting constructions are very important factors to enhance comfort
and performance of all type of socks.

Yarn used in Sources of Yarns Features

socks

Main Yarn Cotton/Nylon/Polyester/PC/Bamboo Shape of Sock

Yarn/Cotton Wool, Viscose

Plaiting Yarn Nylon/Polyester/Spandex/Poly-Covered For Strength and Stretch

Spandex/Nylon Covered Spandex

Motif Yarn Spun or Filaments ,Polyester, Nylon Used in making patterns

and logos

Elastic Yarn Nylon, Lycra and other covered yarns used Used in arch support and

at welt and rib for stretch

and grip
Types of Yarns
The basic raw material used in the construction of socks is Yarn. A continuous strand of twisted
threads of natural or synthetic material is called yarn. Socks is normally composed of following types
of yarn.

Main Yarn
Yarn used in the formatting of the main body of socks is called main yarn. It is visible in socks and used
in vertical direction. Following are the main yarns which are mostly used in the construction of socks.

Cotton
Cotton is natural fiber which is made up of 100% cotton fabrics.

Description Characteristics Counts Used

Combed and carded wastage make OE yarn. Cheaper.
Open End
Strength Poor. 6/1 to 16/1
Staple fibers have not even Length.
The yarn that is obtained without combing is called carded
yarn.
Carded yarn Less strength.
Less Expensive.
In this technique cotton is combed to remove the hairiness 6/1 to 24/1
of yarn. 12/2 to24/2
Combed yarn is Superior than carded yarn in Quality,
Combed Yarn Smoothness, fineness and evenness.

More Expensive.
Higher Strength.

Polyester Cotton (PC)

Description Characteristics Counts Used

PC is comprises of It has more shine as compared to 100 % cotton. 10/1 to 24/1
blend of cotton and
polyester.
 Spun Polyester
Description Characteristics Counts Used

It is the yarn which is spun in the It gives ultra-stretch, easier to put 10/1,14/1
same way as cotton is spun but it on, and more comfortable to wear 16/1,20/1
consists of 100% Filaments. sock.

Acrylic

Description Counts Used

It is synthetic/ manmade fiber which is alternative to 18/1, 28/2, 32/2 (due to less strength doubled the
wool. It has very low heat resistance. yarn to improve strength).

Wool
Wool is the soft, curly hair of sheep that is spun into yarn. Wool is warm, sturdy & durable. It has a
crisp, resilient hand and excellent insulating properties, even when wet.

Mélange Yarn
It is the mixture of two colored staple fibers which form single yarn strings. It may be 100% dyed
cotton or blend of dyed polyester/cotton. In mélange yarns white and color yarns are blended
before spinning process. Mélanges are mostly carded.

Grey Grey Grey Grey

H4 light 24
 Marl yarn
When two yarns of different colors are twisted together it is
called Marl Yarn. Marled yarns are formed by twisting
together plies of different colors. In marl separate process
are run and mixed at end of the process to make marl yarn.
In marl yarn the white thread is available.
Cool Max

Description Characteristics Composition Counts

It is the registered trade Exceptional Moisture

mark of INVISTA. Transport 50% CTN 50% Cool Max
Mostly used in extreme Evaporation Properties 10/1 to
sports product category 20/1
socks to maximize the Extra Soft & Comfort 100% Cool Max
Superior Breathability
performance.
Durable & Easy to Care
70% CTN 30% Cool Max

Plaiting Yarn:
The horizontal yarn lines which are seen under the main yarn by stretching the sock, is called
Plaiting yarn. The basic purpose of using this yarn is to impart some stretch in socks.

Polyester

Description Characteristics Denier Used

Polyester is a man-made fiber that Polyester has high strength.
is abrasion resistant has excellent Wrinkle resistant.
wash-ability. It is really heat- Low absorbency which allow 75/36/1
settable & dye-able. fiber to dry quickly. It is 75/48/1
measured by denier. 150/48/1
300/48/1

Nylon

Description Characteristics Denier Used

Nylon intended to be a synthetic Nylon has the ability to be very
fiber. This fiber is famous for its lustrous, semi lustrous or dull. 70/24/1
strength, abrasion resistance, Excellent abrasion resistance 70/24/2
dimensional stability, soft hand, Highly resilient (Nylon fabrics 70/24/4
elasticity and easy washing are Heat-set)
characteristics.
Spandex
Spandex is a generic term denoting a man-made elastomeric fiber used in place of a rubber.
It can stretch to more than five times its relaxed strength and recover. It provides better size
ranges, improved fit and better comfort. Spandex in knitting is used after covering. Nylon
covered Spandex is used in expensive products while Polyester covered is used in cheaper
products.

· Air Covering:
Elastomeric yarns (Spandex) has a property that they can be stretched. To control the stretch to a pre
specified limit, they are covered with either polyester or nylon so that they don’t exceed that limit.
The process of covering the elastomeric yarn is called covering.

· Double covering (spandex is passed in material then that fiber is again wounded on
spandex)

Knotting:
Knotting is the process of tying the covering yarn with elastomeric yarn so that they remain
firmly connected with each other i.e. knotting holds Spandex.
Nylon covered Spandex

Description Denier Percentages Used

Spandex Nylon Spandex Nylon

20 70/1 6% 94%
Nylon covered Spandex
11% 89%
20 70/2 4% 96%
6% 94%

Polyester covered Spandex

Description Denier Percentages Used

Spandex Polyester Spandex Polyester

20 75/1 6% 94%
Polyester covered Spandex
9% 91%
20 150/1 4% 96%
6% 94%

· Nylon is used in to achieve softness

· For rich grip POLY CVD Rubber is used mostly with ratio of 40:60 where 40% is rubber
· Nylon Price is greater than polyester.
· Covered Yarns are not used in Motifs.
Elastic Yarn:
Elastic yarn is used to increase the griping properties of socks at specified areas such as arch,
welt, rib, and ankle.

Denier Yarn Composition

Nylon CVD Spandex 140.70/24/1 19% Spandex

81% Nylon

Pattern Yarn:
Pattern or motif yarn is used for any type of designing or formation of motif in the socks.
Normally one type of yarn is used at one time but in some cases different yarns can be used
in one motif i.e. Nike uses two different yarns for its motif.
Nylon 70/1, 70/2, 70/4

Polyester 75,150, 300, 450 Denier

Tie Down Yarns:

Tie down yarn used to join the welt and Rib portion of the sock. In Interloop only 70/2 Nylon
yarn is used for tie down.

Linking Yarns:

Linking yarn is used to close the toe of socks. In Interloop only 30/2 Nylon yarn is used as linking
yarn.

Yarn Measuring System:

· Indirect System (In case of Spun Yarn)
· Direct system (In case of Filament)

Indirect system (in case of spun yarn):

There are mainly two methods of measuring yarn count in case of spun yarn i.e.
· English Numbering system (Ne)
· Metric Numbering system (Nm)

English Numbering system (NE)

 Yarn count = No of hanks in one pound = No. of hanks/1
pound 1 cotton Hank: 840 yards
So, for example, if we say that the yarn count is 20/1, it means that one pound of yarn is
covering a length of (840*20 = 16800) yards.
As the number of hanks in one pound increases, the yarn count increases which depicts that
the yarn is becoming finer i.e. 20/1 is finer as compared to 16/1 because 20/1 cover a greater
length keeping the weight constant i.e. 1 pound.
Yarn length is increased via techniques of “drafting” and “twisting

Metric Numbering system (NM)

The method of measuring is almost similar to Ne but the units of measurement are different
i.e.
instead of hanks, kilometers are used and instead of pounds, kilograms are used.
So, in this case, if we say that yarn count is 20/1, it means that one kg of yarn is covering a
length of 20 kilometers.
If the yarn count increases, the yarn becomes finer as it was in the case of Ne.

Direct System (In case of filaments):

Denier System:
In case of filament like Polyester and Nylon, Denier system is used. Denier is measured by
measuring the weight of 9000 meters’ length of filament, for example, if weight of 9000
meters of filament is 75 grams then it is said to be 75 denier i.e.
75g/9000m = 75 Denier, similarly 150 g/9000m means 150 Denier. It is opposite to spun
yarn as the counts increases it becomes coarser instead of finer.
Tex System:
Tex is another system which is used to measure the yarn count in case of filaments, but the
only difference is that in this case we measure the weight of length i.e. 1000 meters.
Identifying yarn in sample data
140 70/24/1 DN DCV R/W
Color: Raw White

Denier
Double Covering
Denier for Nylon
No of Ply/Layers

Denier of Spandex
No of Filament
Specs Measurement

A Leg Length ( Back of heel)

B Foot Length ( Back of heel)
C Rib Length
D Welt Width
D1 Leg Width
E Foot Width
E1 Arch Support
F Welt Length
G Ankle Support
Machine details in Interloop:

MACHINES AVAILABLE IN INTERLOOP

HD-01 1,289
HD-02 1,628
HD-03 1,084
HD-04 500
ILB--(108/144N 4" SC FL54J / L454 JS / G54J / G544GL) 121
STORE/NON OPERATIONAL 149
VSF 86
R&I CENTER 9
TECHNICAL TRAINING CENTER 3
GRAND TOTAL 4,869

Machine details in VSF for sampling:

VSF Numbers of Machine

84N 3.5" SC (LONATI L-474 J) 1
84N 4" SC (FL 54) 1
84N 4.5'' DC (SILVER) 2
84N 5'' SC (ANGE) 1
96N 3.5" SC (GL 725) 3
96N 3.5" DC (DC 88X) 1
108N 4" SC (G 54J) 7
108N 4" SC (GL 544) 1
120N 4" SC (FL 54) 3
132N 4" SC (G 54J) 2
132N 4" SC CL (GK 544F) 2
132N 4" SC NID (STAR) 2
132N 4" SC NID (STAR D40) 1
132N 4'' DC (BRAVO) 1
144N 3.5" SC (GL 725) 6
144N 3.5" SC (GL 716) 3
144N 4'' SC (GL 544) 13
144N 4'' SC (GL 516 D) 2
144N 4" SC (GL 525) 6
144N 4'' SC CL (GK 516 DF) 4
168N 3.75" SC (GL 616S) 3
 168N 3.75" SC (GL 625S) 11
168N 3.75" SC (L462) 1
168N 3.75" SC CL (SANGIACOMO) HI TECH 1
168N 3.75" SC CL (GL 616 DF3) 3
168N 4" DC D/H (SILVER) 2
288N 4" SC (LB41TV) 3
TOTAL 86

Basic Terminologies
Gauge
Gauge is number of needles in a cylinder, it varies with models. In Interloop finer gauge starts
from 144N in which gauge value is 11.46.
Gauge= No of needles/circumference of machine
 COM= Diameter x π (π=3.14)
e.g. No. of needles=144
144/12.56= 11.46

Machine Days
Machine days is known as total number of days taken to any knitting production running.
Machine days is an important factor in costing of the product as the machine days are
reduced, the cost of making a sock is reduced. To find machine days following formula is used
Machine Days= Total No. of Dozens/Production per day

Example, 1000 dozens/30.6 dozens= 32.67 days

Hence, it takes 32.67 days to knit 1000 dozens if production per day is 30.6 dozens

Cycle Time
It is the time take by machine to knit a whole sock. To find cycle time you need total
production per day as firsthand information.
Example, production per day= 30.6 dozens
3060/30.6= 100s
Hence 100 is the cycle time with given information
Calculation of production per day through cycle time
Example,
Cycle time= 100 seconds
Machine efficiency 85%
1 Day= 24 Hour
1 Hour= 60 minutes
1 Hour= 3600 seconds
24 Hour= 86400 seconds
Working:
86,400 x (85%) = 73440
73440/cycle time= 73440/100= 734.4 units
734.4/2= 367.2 Pairs
367.2/12= 30.6 dozens
Hence, the production per day is 30.6 dozen

Courses
It is a single horizontal round of a sock around the machine cylinder to make a sock.
How to speed up knitting
Normally for a solid generic sock the quickest way to make a sock is increasing feeds of the machine.
Example, GL544 x 4 feed x 4” Diameter cylinder will knit a sock quicker rather than using 2 feeds.
This cannot be applied to all kinds of socks as there are constraints of designs, material and type of
sock.
To increase quality
As the number of needles will increase and diameter of cylinder decreases, the quality of sock will
improve as this will reduce difference between needles and hence the finer gauge will work and
result into a finer quality sock.
Composition
No. of ingredients used at the same time in a sock is known as composition. Example, 74% cotton, 24
% Nylon, 2% elastic used in a sock. This is known as composition of a sock.

Identification of machine type:

Example,
Model Diameter Main Feeds Color Feeds
GL 624 6 2 4
GL 615 6 1 5
GL 716 7 1 6
GL 725 7 2 5
Note: Diameter 6= 3.75” cylinder, if machine shows Diameter 5= 4” cylinder, similarly Diameter 7= 3.5”
Cylinder.
Customer Portfolio and Value added portion:
Customers
ILP
Adidas
Brand & Fashion
Camano
C&A
CEC + MKL
Delta Textile (EEC)
Dobotex
Friends Textile
H&M Sweden
Hope Hosiery (Directly by ILP 2010)
Kaufland
Nike - FOB
Nike - ILNA( INTERLOOP NORTH AMERICA) A/C
UK/Ireland
Tesco
Dunne’s Stores
Penney Ireland
Primark Ireland
Russia
Sports Master Russia
ILNA
Family Dollar
JCP
PAYLESS
McGregor
Target Sourcing USA
ESP
Euro sox Plus B.V
JAPAN
Takeda Legwear Japan
 Adidas
Total Business: 1.5 million dozen

Adidas has four brands under the Adidas group out of which Adidas & Reebok are stars; Both of
these individual brands have a strong market share but at the same time the competition in this
sports and fitness segment is very high. Other brands like Puma, Nike also fight for a large share
of the market. Rockport & Taylor made is question mark – This is because their market share is
low but at the same time there is a good potential for these brands. But when this potential will
actually benefit the company in a large way is yet to be seen.
Value added products: 2 percent of total business are value added products business with
Interloop and Have more potential to buy value added products.
Constraints: Lead time

Delta textile

Total Business: 0.35 million dozen business with Interloop

Value added products: It’s sub brand CK has all fashion articles, can go for new value added
products. Have much potential to buy more value added products.
Constraints: Lead time

Dobotex

The Dobotex has four brands under its company

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\* MERGEFORMATINET

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Total Business: 7 million dozen

Value added products: It’s sub brand Levi’s and Tommy Hilfiger continuously purchase 360
printing articles, Embroidery articles, they also purchase special yarn articles, have more
potential to increase the sales of value added products.
Constraints: Lead time

H&M

H & M is a Swedish multinational clothing-retail company known for its fast-fashion clothing for
men, women, teenagers and children. H&M and its associated companies operate in 62
countries with over 4,500 stores and as of 2015 employed around 132,000 people. It is the
second-largest global clothing retailer. The company has a significant on-line presence, with on-
line shopping available in 33 countries
H&M group has 9sub brands under its head but we are mainly serving H& M .it has 4328 stores
all over the world,69 stores market,47 online markets
Total Business: 8 million dozen business with Interloop
Value added products: H&M buying 4 % value added products of its total business with
Interloop
Constraints: Price challenge, capability limitations, resource group limitations.

Tesco

Tesco has shops in seven countries across Asia and Europe and is the market leader of groceries
in the UK (where it has a market share of around (28.4%), Ireland, Hungary and Thailand. Tesco
is one of the largest food retailers in the world, operating around 2,318 stores. As well as
operating in the UK, it has stores in the rest of Europe and Asia. It also provides online services
through its subsidiary, Tesco.com. The UK is the company’s largest market operating under four
banners: Extra, Superstore, Metro and Express.

Total Business: 1 million dozen business with Interloop

Value added products: 26% of total business is dedicated to value added products, mostly no
show articles. More innovation in fashion articles can be encouraged.
Constraints: Lead time, cading process is very slow.

Primark, Penney’s

Primark opened its first store in Dublin in 1969 under the name Penney’s and today operates in
over 350 stores in eleven countries across Europe and America.

Total Business: 7 million dozen business with Interloop

Value added products: 20% of total business is dedicated to value added products business with
Interloop. More innovation in fashion articles can be encouraged. Transit time is a big hurdle for
changing fashions. Turkey and Portugal takes this lead.

Target
Target is an upscale discount retailer that provide high-quality. On-trend merchandise at
attractive prices in clean, spacious and guest friendly stores. The first Target store opened in
1962 in the Minneapolis suburb of Roseville, Minn., with a focus on convenient shopping at
competitive discount prices. Today, Target remains committed to providing a one-stop shopping
experience for guests by delivering differentiated merchandise and outstanding value with its
Expect More. Pay Less® brand promise. Target currently is the second largest general
merchandise retailer in America, with Target.com consistently being ranked as one of the most-
visited retail Web sites. Target has 1834 stores in United States and 39 distribution center and
has global location in India
Total Business: 25 million dollars’ business with Interloop
Value added products: 4% of total business is dedicated to value added products business with
Interloop

Constraints: Price.

Euro sox plus

The founders of Euro Sox Plus (ESP) have lifetime experience within the socks industry and in
Feb. 2009, they established Euro Sox Plus B. V. Through its various Divisions, Euro Sox Plus offers
comprehensive and state of the art service to clients throughout Europe and the UK. Interloop
has a business alliance with Euro Sox Plus which extends various services to Interloop and its
clients as per requirement.
The Sales & Marketing Division at ESP serves multiple Retailers in Europe including Lidl,
Footlocker, Norma, etc. Besides Sales & Marketing, it also provides detailed market intelligence
and up to date information on the rapidly changing marketplace. With its experienced
multilingual Sales Team and Customer Service Department, ESP affords Interloop a strategic
presence in Europe.
Euro Sox Plus - Technologies Division utilizes the latest cutting edge technologies in fibers,
chemical applications and machine developments to create unique and innovative socks designs
and functions that give customers a truly competitive edge. It also works closely with Interloop’s
Research & Innovation dept.
Euro Sox Plus - Head Office and Distribution Centre in Holten, Netherlands, offers European and
UK Customers fully integrated logistics, warehousing and distribution services. This is to ensure
that buffer stock is always available to both manage and optimize customer inventory levels
while maintaining a "Never Out of Stock" position.
The entire ESP organization comprises of an experienced multilingual team, proficient in
conducting business in all areas and all at levels.
Total Business: 0.9 million dozen business with Interloop
Value added products: 80% of total business is dedicated to value added products business with
Interloop. More innovation in fashion articles can be encouraged. Transit time is a big hurdle for
changing fashions.
Constraints: Lead time.
 Payless

Payless Shoe Source Inc. is an American discount footwear retailer headquartered in Topeka,
Kansas. Established in 1956 by cousins Louis and Shaol Pozez, Payless is a privately held company
owned by Blum Capital, and Golden Gate Capital. In 1961, it became a public company as the
Volume Shoe Corporation which merged with The May Department Stores Company in 1979. In
the 1980s, Payless was widely known in the U.S. for its Pro Wings line of discount sneakers,
which often had Velcro straps instead of laces. In 1996, Payless Shoe Source became an
independent publicly held company. In 2004, Payless Shoe Source announced it would exit the
Parade chain and would close 100 Payless Shoe outlets. On August 17, 2007, the company
acquired the Stride Rite Corporation and changed its name to Collective Brands, Inc. The
company had a total revenue for 2011 of US$ 3.4 billion.

It was announced on May 1, 2012 that the company would be purchased by Wolverine World
Wide, Blum Capital, and Golden Gate Capital for US$1.32 billion. On December 13, 2016 it was
reported that all Payless shoe stores were to be closed in Australia with the loss of 730 jobs. On
July 14, 2014 Authentic Brands Group acquired some assets from Payless Shoe Source’s division
Collective Licensing International, LLC, which included brands such as Air walk, Hind sports
clothing, Vision Street Wear, and Above the Rim. In April 2017, Payless Shoe source filed for
Chapter 11 Bankruptcy and announced the closing of 400 stores in the United States.
Total Business: 4.5 million dollars’ business with Interloop
Value added products: 2% of total business is dedicated to value added products business with
Interloop. More innovation in fashion articles can be encouraged. Transit time is a big hurdle for
changing fashions.
Constraints: Lead time, Limited Business

Amazon

Amazon.com, Inc. doing business as Amazon is an American electronic commerce and cloud
computing company based in Seattle, Washington that was founded by Jeff Bezos on July 5,
1994. The tech giant is the largest Internet retailer in the world as measured by revenue and
market capitalization, and second largest after Alibaba Group in terms of total sales
Total Business: 3.11 million dozen business with Interloop
Value added products: New customer with lot of potential.
Constraints: Lead time, Price

Puket

In the 1980s, a brand showed up in the market destined to surprise everyone.

At first pursuing a goal that might have seemed everything but innovative, PUKET opened doors
to offer Brazilians that which was perhaps the dullest of products: socks! However, as soon as
the machines began turning out the first products it was clear there was something different
about those pieces.

Different from everything else on the market, PUKET socks carried with them much more than
foot comfort. They had bright colors, unusual prints, and a youthful, joyful vibe. People soon
realized that when they brought home PUKET, they were also bringing the joy and laidback feel
that came with the product and let themselves be carried away by our brand’s vibe.

The PUKET recipe became a hit! It did not take long for that factory to grow and soon turn into a
leading sock manufacturer in Brazil, boasting one of the most modern, efficient industrial
complexes across the country. PUKET had won over the feet and hearts of millions of Brazilians.
Total number of stores: 100+
Total Business: 20 thousand dozen business with Interloop
Value added products: continuous developments in value added products but not any order yet.
Constraints: Price.

Current Process Flow and Improvement of sample development

Current Process flow of Product development:

1. Sample request received from customer (CAD, Physical sample, idea).

2. Reading and understanding briefly each and every aspect of socks for socks making and
machine limitation point of view. if any confusion we do clear before proceeding further.
3. Request punch in system after meeting with PD team, the purpose of this meeting to
provide all information to PD team if any information is missing or PD need any clarity we
talk with customer for change or option B. in addition, we request punch in system same
day in which we receive request from customer we requested 6 pairs and 8 pairs
sometime according to requirement.
4. We demand T&A plan from PD and ensure need by date and customer due date to meet
customer desired date.
5. We update Log in system (online and local system both).
6. We do follow-ups frequently if there is any delay we take customer in confidence
regarding delay due to any reason (material shortage, machine capacity, imported yarn).
7. When we receive sample we do exact costing for meeting customer target price.
Normally Customer have 3 to 4 rounds of sampling. In 1 st we do sampling with close
match colors available with PD just to ensure designs and product look and for meeting
with customer, In 2nd phase we do sampling with exact colors and designs, in 3 rd phase if
Customer Suggest any changes in colors, designs, patterns or measurement and
sometime combination of these combinations. Sometime these changes may have
extended to 4th phase as well to meet desired look and customer expectations.
8. Prepare parcel of 4 pair of each request and send it Customer and remaining 2 or 3
samples we keep with our self for merchandising and waste all other. We save reference
sample with us in separate.
9. Transit time is 3 days so we keep in mind that parcel should be delivered before due
date.
10. We update PID in system. It’s basically related to measurement. We take pictures of
socks while testing measurement on NAHM board.
Flow diagram of product development:
PDS (Product Development System)
It is internal online system working for sampling. First step is fill sample request form with all the
details after finalizing it with PD through a meeting, the detail may include Brand, Resource group,
color, style, recipe and any other. Then sample request form is submitted through sample request
submit form. PD accepts the request and starts working provides T&A plan and dispatched the
physical sample also dispatches data on system. Marketer receives the data on system which is used
in costing and other matters. When everything Is clear and up to the mark the samples are dispatched
to the customer.

Product Development
System Sample Request

Sample Request Form Sample Request

Submission
 Sample Request Report Sample Receiving Form

Sample Data Finalization Sample Feedback Form

Product data has detailed information of all raw material and processes used to make the
product. By studying data sheet, it can be easily judged that which type of product is this
actually. It has complete information of yarns, their colors and counts. It also helps to find out
material composition percentage.
 Improvements and Recommendations:
Current process flow is running smoothly but chances of betterment are always there in every
system. According to my point of view we should educate our both customers, external
customer and PD department regarding changes that we can make to speed up process, cycle
time of sample delivery, meet target price and quality. customer should be vigilant regarding
CADs, written data and pictorial data in CADs should be same rather than proceeding
development as per previous development experience base and if we do so we should
communicate our understanding with customers.
Customer should have ILP color/shades book which we already have with us to send new
developments rather than adding new colors. In this way we do not need to develop color
recipe and color approvals, many customers normally have 3 to 4 rounds of sampling, we can
cut 1 or 2 round by developing samples first round with close match and 2 round after dropping
packs we proceed 2nd round with all exact requirements. By following we may save time for
sample delivery. secondly PD most of the time develop more samples than our requirement
and we waste all other pairs after saving reference pairs for future. Mostly fashion article
developed with expensive yarn, if restrict PD to send us only required samples this may save
our cost, minimize waste and will save time of our resource group too for other programs.
Thirdly we should develop samples as per customer portfolio, volume, buying behavior buying
patterns and should develop samples by considering target price rather than making samples
and then calculate price. for example, if customer is price conscious or willing to pay less than
we should offer them less expensive product. Fourthly customer should communicate forecast
of colors, yarns, special yarns for upcoming season so that we buy specials yarns e.g. (Lurex) for
sample development. In this way we may save time

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