AN INSTITUTIONAL TRAINING AT JUPITER KNITTING

COMPANY, TIRUPUR

Submitted in partial fulfillment of the requirement for the award of Degree of

MASTER OF COMMERCE

Submitted by
Ms. K.SATHYA
(Reg No.183AA0586)

Under the Guidance of

Dr. M.Akila, M.Com., M.Phil., Ph.D., SET

DEPARTMENT OF COMMERCE
A.V.P. COLLEGE OF ARTS AND SCIENCE
(Affiliated to Bharathiar University)
4, Chettipalayam, T.M.POONDI, Tirupur – 641 652
November 2019
DECLARATION

I Ms. K. SATHYA declare that the institutional training entitled “Institutional training
report on garment industry” is submitted to Bharathiar University Coimbatore in partial fulfillment of
the requirement for the award of the degree MASTER OF COMMERCE is a record of original work
done by me during the period of 2018 – 2020 at A.V.P. College of Arts and Science, Tirupur.

Place: K.SATHYA
Date: (183AA0586)
CERTIFICATE

This is to certify that “AN INSTITUTIONAL TRAINING AT JUPITER KNITTING

COMPANY" undergone by Ms. K.SATHYA (Reg No. 183AA0586) is a bonafide work done during May
– 2019. This report is submitted to the Bharathiar University, Coimbatore in partial fulfillment of the
requirement for the award of degree of Master of Commerce.

Place: Signature of the Guide

Date:

Head of the Department Viva voce examination

Date:

Guide:

Principal HOD
 WORK DIARY

DAY REPORT

DAY 1 VISITED THE JUPITER KNITTING COMPANY

DAY 2 INTRODUCTION ABOUT THE COMPANY AND ORGANISATION STRUCTURE

DAY 3 COLLECTED THE INFORMATION ABOUT THE COMPANY

DAY 4 INTRODUCTION ABOUT THE PRODUCTION PROCESSES

DAY 5 COLLECTING THE BUYERS DETAILS

DAY 6 STUDIED ABOUT THE TYPES OF PRODUCTS OF THE COMPANY

DAY 7 GENERAL INTRODUCTION ABOUT THE COMPANY’S DEPARTMENTS

DAY 8 VISITING THE PURCHASE DEPARTMENT

DAY 9 GATHERING INFORMATION ABOUT PURCHASE DEPARTMENT

DAY 10 VISITING THE PRODUCTION DEPARTMENT

DAY 11 INTRODUCTION ABOUT THE PRODUCTION PROCESS

DAY 12 BRIEFLY EXPLAIN THEIR PRE PRODUTION PROCESS

DAY 13 VISITING THE VARIOUS SECTION IN THE PRODUCTION DEPARTMENT

DAY 14 GATHERING INFORMATION ABOUT THE EQUIPMENTS USED IN

PRODUCTION PROCESS

DAY 15 STUDIED ABOUT THE POST PRODUCTION PROCESS

DAY 16 VISITING THE FINANCE DEPARTMENT AND STUDY ABOUT THE

FINANCIAL POLICY

DAY 17 VISITING THE HUMAN RESOURCE DEPARTMENT AND COLLECTING THE

INFORMATION

DAY 18 COLLECTING THE INFORMATION ABOUT THE ACCOUNTING DEPARTMENT

DAY 19 GATHERING INFORMATION ABOUT THE MAINTENANCE DEPARTMENT

DAY 20 VISITING THE EXPORT DEPARTMENT AND COLLECTING INFORMATION

ABOUT THE PROCEDURE OF EXPORT

DAY 21 AN OVERVIEW OF ALL THE WORK PERFORMED IN THE JUPITER KNITTING

COMPANY
 CONTENT

C.no CONTENT Pg.no

1 1.1 INTRODUCTION

1.2 HISTORY OF GARMENRTS IN INDIA

1.3 HISTORY OF TIRUPUR GARMENTS INDUSTRY

2 2.1 COMPANY PROFILE

2.2 OVER VIEW OF THE COMPANY

2.3 BUYERS DETAILS

3 3.1 FLOW CHART

3.2GARMENT PRODUCTION

3.3 PRE – PRODUCTION PROCESS

3.4 PRODUCTION PROCESS

3.5 POST PRODUCTION PROCESS

3.6 TYPES OF MACHINES USED AND ITS SPECIFICATION

4 4.1 VARIOUS DEPARTMENTS IN JUPITER KNITTING COMPANY 27

AND ITS FUNCTIONS

4.1.1 PURCHASE DEPARTMENT

4.1.2 FINANCE DEPARTMENT

4.1.3 HUMAN RESOURCE DEPARTMENT

4.1.4 ACCOUNTS DEPARTMENT

4.1.5EXPORT DEPARTMENT

5 5.1 FINDINGS & SUGGESTION 30

5.2 CONCLUSION 30
CHAPTER I
CHAPTER III
CHAPTER II
CHAPTER IV
CHAPTER V
1.1 INTRODUCTION

Textile Industry has been playing a pivotal role in Indian economy. Textile sector alone
presently provides for nearly 28% of the total organized manufacture sector’s employment in India. About
93 million people directly and indirectly are engaged in this industry. Indian Textile Industry enjoys
inherent comparative advantages because it is almost self-reliant from the stage of production of raw
materials to the delivery of finished products-from cotton growing, ginning, spinning, and weaving to
manufacturing of clothing items.

The world is fast moving towards natural products and as a result of this trend; demand for cotton
garment is increasing. The demand for hosiery garments is increasing at a fast pace because of the comfort
and soft feel of the product.

1.2 HISTOICAL BACKGROUND OF GARMENT INDUSTRY OF INDIA

India is the world’s second largest producer of textile and garments after China. It is the
world’s third largest producer of cotton after China. The fundamental strength of the industry flows from
its strong production base of wide range of fibers yarns from natural fibers like cotton, jute, silk and wool
to synthetic made fibers like polyester, viscose, nylon and acrylic. The growth pattern of the Indian textile
industry in the last decade has been considerable more than the previous decades, primarily on account of
liberalization of trade and economic policies initiated by the government in the 1990s.

Today the Indian Garment Industry is truly a global one with intense competition for capturing the
major consumption markets in America and Europe.

In India there were about 1200 garment making units during 1970. But, now the total number of
garment manufacturing units in 19 clusters in India is around 33371.

Garments industry has been broadly classified into three segments:

 Men
 Women
 Kids

1.3 TIRUPUR GARMENT INDUSTRY

Garment sector has been emerging as the fastest growing sector. Tirupur has been exporting
more than one hundred knitted garment product categories, mainly falling in cotton, semi-fashion, middle
price segment of casual wear, with the main product categories being T-shirts, men’s shirts, ladies blouses,
ladies dresses and skirts. Orders from USA have been mostly basic styles, in huge quantities like T-Shirts,

1
under garments, ladies wear, men’s wear, kids wear, sportswear, etc., whereas orders from Europe and
Japan have been but fashion oriented in which Tirupur exporters have excelled.

According to Tirupur Exporters Association, 55% of the exports from Tirupur has been sent to
Europe, 35 % to USA and the rest of 10 per cent to the Middle East (Egypt, Iran, Iraq, Turkey, Saudi
Arabia, Yemen, Syria, Israel etc.,) and oceanic countries (Island countries found in the Pacific ocean, New
Zealand, Australia, etc.,). Most of the leading international brands such as Nike, Cutter & Buck, Adidas,
GAP, Tommy Hilfiger, Katzenberg, Van Heusen, Fila, Arrow and leading retail chain stores such as C&A,
Wal-Mart, Target, Mother’s Care, H&M, have sourced garments regularly from Tirupur. It has also
supplied jerseys to players in the last Federation international World Cup Football tournament. . Tirupur
became the second town in India to start cotton knitwear units after Kolkata.

2
2.1 COMPANY PROFILE

 NAME OF THE COMPANY: JUPITER KNITTING COMPANY

 YEAR OF ESTABLISHMENT: 1957 (TIRUPUR).
 FOUNDER OF THE COMPANY: Mr. SUBRAMANIAM
 DIRECTOR OF THE COMPANY: Mr. KRISHNARAJ
 CERTIFICATION

ISO 9001: 2000

Jupiter has put into place a streamlined production program, transparent
operations , a collaborative product commerce approach a deep understand of
client needs ensure complete compliance to international quality management
system.

WRAP
Jupiter is a member of WRAP – the WORLD RESPONSIBLE APPAREL
PRODUCER, testifying to its dedication to the environment and
community. This has enabled the company to instantly establish a direct code
of acceptance with buyers throughout the world.

 SPECIALIZATION
 Woven - It covers men’s & boy’s shirts, Casuals men’s shirts, Formals, ladies & girls dress.
 Knits - The product range covers Polo T- shirts, crew neck-shirts, Jackets, sportswear, and sleep
wear, etc.

 SITUATED AT: Jupiter knitting company,

1-J-24 Jupiter Avenue,
Ammapalayam,
Tirupur 641652. India.
Email: krish@jupiter.india.com

 CORPORATE LOGO

3
2.2 AN OVER VIEW OF THE COMPANY

JUPITER KNITTING COMPANY, one of the famous names in the garment industry. The
company was established by Mr. Subramaniam when he was about 17. The rein of the company were
gradually handed over to his son Mr. krishnaraj, a business graduate, in the year 1988. His approach to a
very large extent was shaped by his father’s thinking. Applying that basic & reasoning to all levels within
organization and to those associated with it from the outside he ensured its growth.

 VISION
“Always no. 1 in the knitted garment business”

 QUALITY POLICY
“We Strive to Delight Customers through Lean Manufacturing Systems with
Respect for Human Values”

 QUALITY OBJECTIVES
Aim: To attain high score on customer delight index by understanding customer’s
Value expectations and striving to achieve the same.
 To achieve zero claims and reduction in customer complaints by 95%.
 To achieve on time delivery and reducing internal failures by 2%.
 To work towards continual improvement of processes and reduction
 in throughput time by 10% and waste reduction by 15%
 To become preferred employer by scoring high on Associate Delight Index.

 CORPORATE VALUES
 Incorporate high quality into all products
 Integrity & Team Work
 Customer Driven
 Continual improvement & learning

 TOTAL EMPLOYEE SUMMARY

Jupiter Knitting Company in total a huge part of organization with a large number of employees.
This total division contains several sections like Design studio, various departments, production units,
Factories, Plants etc. so, overall there is 2500 employees for whole textile section where more than 500
work as Management staffs.

4
  TOTAL FACTORY AREA: 90500 Sq .ft

 ANNUAL TURNOVER: US$ 80 million

2.3 MAJOR BUYERS (COUNTRY WISE)

Country Company

UK - TESCO, DIMENSIONS, SAVILE ROW,

BHS, ROCHES, GRAHAM HUNTER, PRIMARK,
NEXT

FRANCE - CELIO, VETIR, FABRISTYL, CAMAIEU

(JULES), RIPCURL, GO SPORTS

SWEDEN - KAPPAHL

DENMARK- BEST SELLER

HOLLAND - DOMO

SPAIN - CORTEFIL (SPRINGFIELD)

GERMANY - BROADWAY

USA - MOTHERS WORK, MAY DEPT., SAKS,

NYNE, MEIJER, BOSCOV, JC PENNEY,
LEE, WALMART, SEARS, CARHARTT,
CATO, K-MART, AMERICAN EAGLE etc.

5
3.1 MANUFACTURING PROCESS OF GARMENTS INDUSTRY

There are various processes involved in the manufacturing of garments. The clothes we wear are
mostly made of textile fabrics. The textile fabrics are made of from yarns in weaving and knitting process.
Fabrics are converted into wearable garments through the garment manufacturing process in the garment
industry. At the time of garment making, functional trims and accessories are attached to the garment at
various stages.

The garments manufacturing processes are categorized as

1. Pre-Production processes,
2. Production processes
3. Post-production processes.

3.2 PRE-PRODUCTION PROCESS

The processes that are done prior to the start of bulk garment production are known as pre-
production process. From sample development, approvals, research and development work for orders,
testing of raw material to pre-production meeting are pre-production process. Pre-production processes are
very important for the efficient production.

A typical garment export business generally has following pre-production processes

 Pattern making,
 Meeting with buyer
 Garment sampling,
 Cost of garment
 Pre Production meeting

3.2.1. Pattern Making

From the design sketch and product specification sheet, garment patterns are made by a technical
person (also called as pattern master). To cut the fabric for making any kind of apparel product, you need a
template for different body parts. These paper templates are called as pattern.
The first pattern of a design is made at the time of prototype making. The patterns are modified and
corrected as the sample development progressed and patterns are graded during size set sample making.
The final patterns are approved after the Pre Production sample approval.
Now-a-days most of the designers and garment factories use Computer Aided Design (CAD)
systems for making the patterns. The CAD system has other advantage of maker making, instead of manual
marker making, marker paper are printed by a plotter. The markers are efficiently made by CAD system
and fabric utilization can be improved.

6
3.2.2. Meeting with buyers

In this stage, the designer of a manufacturing house shows their creations, latest designs to
buyers. On the other hand, if the buyer already had fixed design of a style and need few changes on it
related to fit, fabrics or trims they discuss those things with the merchandiser of the manufacturing unit. A
pre-production meeting is conducted at the factory by the merchandising team. In this meeting product
design, production schedule and responsibilities, buyer requirement in all aspect of product quality, and
production completion deadline are discussed.

3.2.3. Garment Sampling

Factories develop garment samples and take approvals on the sample from their buyers. Without
sample approval, factory is not allowed starting the bulk process. Factories need to develop various types
of sample at various stages of the sample development.
In the sampling stage factory learns the garment construction details and material requirement
for a given order. The sampling department is also work as research and development (R&D) section for
the factory. Sampling process helps production team start the bulk production without many issues.

3.2.4. Costing of Garment

Merchants prepare cost sheet with details cost break up such as raw material cost, manufacturing
cost, overheads and margin. Costing is very a critical stage. Because whether a company will get order or
not depends on their costing. If the garment cost is very high then the manufacturer may lose the order and
on the other hand, if the factory keeps their cost low, they will not earn profit from the order. Estimation of
the garment cost should be done on data based.

3.2.5. Pre-production meeting

Once pre-production (PP) sample is approved (also called sealer sample) and most of the trims are
sourced, merchants or production planning department conduct pre-production meeting with the production
team, quality team and sourcing team. All important comments, procedures to be followed, dos and don’ts
are discussed. Scheduling of PCD (planned cut date) and shipment date is announced to all teams.

7
3.3 PRODUCTION PROCESS

Garments manufacturing process involves Product Design, Fabric Selection and Inspection,
Patternmaking, Grading, Marking, Spreading, Cutting, Bundling, Sewing, Pressing or Folding, Finishing
and Detailing, Dyeing and Washing, QC etc.

There are many steps having in production process

 Choosing fiber
 Yarn
 Yarn dyeing
 Knitting
 Fabric development
 Bulk fabric sourcing
 Fabric quality inspection
 Production planning
 Cutting process
 Garments printing & embroidery
 Garment Stitching
 Garment washing

3.3.1 Choosing fiber

Fibers are often used in the manufacture of other materials the manufacturer use the buyer’s
requirement.
There are two types of fiber can select the manufacturer
 Natural fibers (ex: cotton, jute, hemp, silkworm, etc.)
 Manmade fibers (ex: synthetic, etc.)

3.3.2 Yarn

Yarn is a long continuous length of interlocked fibers, suitable for use in the production
of textiles, sewing, crocheting, knitting, weaving, and embroidery. Thread is a type of yarn intended for
sewing by hand or machine.

3.3.3 Yarn Dyeing

Dyeing is the process of adding color to textile products like fibers, yarns, and fabrics. There are
several methods of dyeing. Yarn dyeing is one of them. There are many forms of yarn dyeing. Common
forms are the package form and the hanks form. Cotton yarns are mostly dyed at package form, and acrylic
or wool yarn are dyed at hank form.

8
3.3.4 Knitting

Knitting is a process of using long needles to interlink or knot a series of loops made by one
continuous thread. Each loop or knot connects to another one, and when enough loops have been made, the
result is a flat piece of material called a textile. Most textiles are made either through knitting or a process
called weaving, in which vertical and horizontal threads are interlaced on equipment called a loom. Knitted
materials tend to be more elastic and have more give than woven materials, which tend to be tighter and
firmer.

It can be done by hand, or by a device called a knitting machine that uses many steel needles
mounted on a frame called a needle bar. The machine simply mechanizes the process of pulling threads
through loops to create stitches. Machines can be round or horizontal. They can be small or large circular
machines that take up an entire room.

3.3.5 Fabric Development

 Little about Fabrics: Textile fabrics are available in three main categories - knitted, woven and
non-woven fabrics. Fabrics are manufactured in textile mills, and power looms sectors. Later,
fabrics are finished as per the buyer’s (garment manufacturers) requirement. The factory only
needs to find the fabric(s) that is required for the style/design.

 Selection of fabric: There are thousands of fabric designs and fabric quality. Fabric selection is
done based on fabric quality required, like fabric color, fiber content, surface texture, hand feel,
physical and chemical properties. If the required fabric is already available in the market, factory
purchase those fabrics from the stock. For this factory need to explores various places for finding
the required fabrics. Otherwise, they work with the fabric supplier to develop the desired fabric
quality.

 Fabric development: The garment maker gives the fabric quality requirement to the fabric supplier
for developing a new fabric design. At the fabric development stage the negotiation of fabric price
is done with the fabric vendors. Lab dip and desk loom is developed at this stage prior to bulk fabric
ordering. Prior to bulk sourcing, fabric sample is tested to check whether the desired quality is
matched with the developed fabric or not. For yarn dyed stripes knits fabric knit-down is developed.

3.3.6 Bulk fabric Sourcing

 Fabric sourcing: How much fabric is required for each garment? What is the average fabric
consumption for bulk production? At this stage there are few calculations on fabric consumption
per garment. This work is done by pattern making department (CAD department). Based on the
fabric consumption, total fabric requirement is generated for an order and the same is sourced from

9
 the pre-approved fabric supplier. The fabrics are in-housed in the factory or in a central warehouse
of the company.

3.3.7 Fabric quality inspection

Whether the fabrics are purchased from the buyer nominated fabric suppliers or from the open
market, garment makers are not sure whether all the fabrics are without fault and defect free. So fabric
checking is a must have process. Fabric may be required to check 100% or can be checked randomly based
on fabric quality received. For an example, 4 Point System is used by the factories for fabric inspection and
fabric quality grading. Some fabric tests like fabric GSM (, fabric shrinkage and color bleeding in washing
are done by the factory. If the fabric shrinkage is more than the allowance, fabrics are pre- shrunk for bulk
cutting. Sometimes patterns are modified according the fabric shrinkage which gives correct measurement
in the garment after washing.

 Fabric sorting and shade banding It is a common fact that when fabrics are sourced in bulk, the
fabrics are processed in different lots (batches) depending on dyeing machine capacity. So, there are
chances of having shade variation of fabrics of same colors. To avoid shade variation in garments
shade band is prepared by the factory.

 Sourcing for trims and accessories Similar to fabric sourcing all required trims and accessories
are purchased. Trims and accessories are sourced in advanced to production start. Trims
requirement is calculated based on the trims consumption per garment.

 Quality checking of trims and accessories Quality of the trims are inspected and approved for
production. Trims like laces, twill tapes, button, zippers, and draw cords are tested for color
bleeding. Defective and damaged trims are separated and are not used in garments.

3.3.8 Production Planning

All the processes and activities are planned and scheduled in advance by the production
planner. Production planning team executes and controls the production activities. They keep track of the
actual process activities to ensure on-time order completion. A time and action calendar is prepared by
planning team for production scheduling and controlling. Mostly the T&A is made by a merchandiser.

3.3.9 Cutting Process

Fabric is the most costly item in garment manufacturing. About 60-70% cost of the garment is
incurred in fabrics. For this reason garment makers wisely utilize fabrics. Some of these fabric saving tips
in the cutting room surely help garment makers to save fabric as well as money.

10
 The bulk cutting is done by means of cutting machines. Different types of fabric cutting
machines are available for bulk cutting. Before the cutting of fabric, cut order plan is prepared and fabric is
taken from the fabric store according the requirement. Following steps are followed in the cutting section.

 Fabric spreading First the fabric rolls are opened and spread on a cutting table layer by layer.
This process is done by hand or by using an automatic spreading machine. The length of the layer
is decided based on the marker size and marker length. Multiple numbers of fabric layers are
spread on the table and all the fabric layers are cut together. Depending on the fabric thickness
number of plies in a lay is decided. Normally the height of the lay is kept according to the cutting
machine blade height.

 Marker making For manual marker making, cutter use paper pattern for marking and use chalk to
mark outlines of the patterns. After marking the outlines on the lay, patterns are removed and the
cutter follows the outline to cut the garment parts.

 Component numbering on the marker Normally in a marker more than one garment are
cut and garment may be of different sizes. To avoid mixing of different garment sizes during
bundling and sorting, the size is marked on the top layer after manual marking. For automatic
cutting or paper printed marker, this marking is not required, as all patterns are already come with
style and size marking.

 Lay Cutting After marker making, the lay is cut by using a cutting machine. For a single ply and a
small number of plies, hand scissors are used.

 Ply numbering Ply numbering is done to all the garment components. This process is included to
avoid color variation in the garment components of a same garment. In single piece production
system bundle numbering is not required. A hand machine is used for numbering the cut plies.

 Sorting and bundling Cut components are sorted by size, color, and bundle size. Then bundling is
done and stored in the cutting room. A ticket (bundle tag) is attached to the bundle to identify the
component and style details.

 Dispatch cuttings to stitching section Cut bundle are sent to stitching section as per the need of
sewing floor and loaded to the line. Some factories prefer to send the whole lay to stitching section
and bundling of the layer are done on the production line.

 Quality checking in cutting section In the cutting section, quality of the cut components
like notches, pattern shape, components measurement, and major fabric defects (hole in fabric, cut
mark etc.) are checked. Parts measurement is taken from top, middle and bottom plies and
compared with the actual patterns, and shapes etc.
11
3.3.10 Garment Printing and Embroidery

Printing and embroidery processes are value added but an optional process. Printing on the
garment is done at either fabric stage or after cutting of garment components. For small set up, this is not
necessary to set-up facility for printing and embroidery process. If required, printing and embroidery
process are outsourced.

3.3.11 Garment Stitching

After cutting and printing process (optional process), cut components are sent to sewing
department. Operators stitch and assemble garment components one by one and make the complete
garment. At the time of sewing garments are checked by quality checkers. Stitched garments are dispatched
to finishing or washing department if washing is required.
The garment stitching process involved following sub-processes.

 Part preparation
 Marking
 Folding and pressing
 Stitching/assembling
 Quality checking

In the sewing section, operators are also provided various sewing supplies like stitching threads,
sewing machine needle, trims, operation specific guides and attachments.

 Parts preparation Before assembling the garment, individual garment parts are prepared in the
preparatory section. For an example, in shirt manufacturing, shirt collars, sleeve cuffs and sleeves
are prepared in the preparatory section and later loaded in the shirt assembling section. Preparatory
section is introduced in the line to improve line balancing. Be noted preparatory section is not
required for products like t-shirt, boxer, leggings.

 Marking part In a garment, some part requires marking to attach one garment component to
another precisely. Marking is normally done by using chalk or magic pencil by using a template or
laser ray.
Like in formal shirt for button holing and button attachment, front plackets are marked
manually to define the correct location of the button positioning. The marking process helps
operator deciding where the job needs to be done accurately.

 Part folding and pressing Depending on the requirement an operator may need to fold the
component and press it by means of a template. Like, chest pocket is folded and pressed prior to
attaching the pocket on the chest.

12
  Assembly section The garment components are assembled by the operators step by step in a
sequence of product construction. To sew garments different types of sewing machines are used.

 Quality inspection on the floor On the sewing floor, stitching quality is checked by the checkers.
Normally the semi-stitched garments are checked to detect the stitching faults. The checker
suggests a solution to the operator who is responsible for making the defects. Inline quality
inspection, roaming inspection and end-of line quality checking is done in the sewing floor.

 Production line set-up The stitching floor requires maximum number of manpower in a garment
production units including sewing machine operators, helpers, pressman, alteration tailor, feeder,
data collection, work-study officer, quality checker and line supervisors.
In mass garment production, the production line layout and line setting is done prior to
loading every new product (style). The industrial engineers prepare the operations bulletin and line
layout. In the operation bulletin, they estimate manpower requirement and machine requirement to
produce the target quantity. Learn more about industrial engineer in the apparel manufacturing from
my blog.

 Production reporting Production data capturing and reporting is integral part of the garment
manufacturing. Production and quality related data are collected to track the production and
monitoring the production. Various kind of production reports are made and analyzed by a factory.
Garment manufacturers prepare report on key performance indicators (KPI) of the various
production departments.

3.3.12 Garment Washing

Washing is done to remove dirt and dust from the garments. Washing process involves
additional cost, so this process is done only if buyer asks for washing of their orders. More than just
cleaning of garments, washing is also done to give washed look to the finished garment with different types
of finishes.

13
3.4 POST PRODUCTION PROCESS

All the clothing articles are finished prior to sending to customers. Even a tailoring shop does
finishing of tailored shirt and pants. Here is a brief list of garment finishing processes

 Thread trimming
 Removing sticker and loose threads
 Initial garment checking
 Garment pressing
 Final garment checking
 Garment folding and packing
 Internal Audit
 Finished and ready product

3.4.1 Thread trimming

In case garments contain uncut threads – left by stitching operator during stitching, threads are
cut at this stage. Uncut threads can be trimmed by manual trimmer or a thread trimming machine.

3.4.2 Removing sticker and loose threads

I have mentioned above that in cutting department, all the garment components are labeled by
paper stickers. Those stickers are removed manually by a team of workers.

3.4.3 Initial garment checking

This checkpoint is placed prior to ironing the garments. Visual inspection and measurement
checking is done in the initial checking. Finishing checkers check for loose and uncut threads, ply
numbering stickers, garment construction, garment labeling, workmanship and measurement after
washing / non- wash.
Checkers also check for stitching defects in seams, fabric defects in the garment and any other kind
of defects those need to be repaired. So, at this stage checkers segregate the defective garments and
defective garment are sent to the repair section.
All stitching defects are sent to a repair tailors. Defect like stains and hard stains, defective garment
are given to stain removers. Small jobs like thread trimming and removing of stickers are done by the
checker.

3.4.4 Garment pressing

The garment pieces are pressed by an iron. Normally steam iron is used for processing cotton
garments. In this process, creases and wrinkles in unfinished garments are removed, and give a fresh look

14
to the apparel products. Different types of pressing equipment are available for garment pressing.
Depending on the product and production volume, the right pressing equipment is used.

3.4.5 Final garment checking

The pressed garments are rechecked for measurement and visuals inspection. Shade variation,
correct labeling of size and content labels are check in this stage. Any defective garment detected at this
stage is sent back for repairing.

3.4.6 Garment folding and packing

 Folding The finished garments are then folded in a specific dimension. Folding can be done by
using a template too. The price tags, hang hags and any other kind of tags are attached to
garment after folding. The garment folding types varied depending on the article and buyers
requirement. Sometimes the whole garment is packed in a hanger without folding.

 Packing The folded garment is packed into a poly bag to keep it fresh till it reached to the retail
showroom. Different types of packing accessories are used to keep the garment in a desired
shape. Some products are packed into paperboard cartons directly without packing it into a poly
bag.

 Carton packing For the transport of the finished garment are packed into bigger cartons.

3.4.7 Internal Audit

The packed garments are then inspected for quality assurance of the outgoing finished products.
This process is followed for internal quality audit and to ensure that no defective garments are packed into
the cartons.

3.4.8 Finished and ready product

Finally the garments are ready for the shipment and ready for the end consumers.

15
Jupiter knitting company products

16
 3.5 Garment manufacturing process flow chart (major processes)

Order receiving

Sampling
Planning
-FIT sample Material sourcing
-man power
-material -Size set sample
-machine
Fabric & Trim in house
PP sample approval

Material FAIL
PP meeting
inspection

Cutting PASS

Printing / Embroidery

Stitching

FAIL
Checking Repair / Alternative
Garments

17
 PASS

Washing

Finishing

Checking FAIL Repair / Alternative

Garments

PASS
Packing

FAIL Shipment
Audit

PASS

Shipment Dispatch

18
3. 6 TYPES OF MACHINES USED & THEIR SPECIFICATIONS
 BAND KNIFE MACHINES
LF-BK-00850
MODEL EC-700
220V, 50/60 HZ, 1PH, 3AMP
KNIFE SIZE 3500 mm.

 END CUTTER
MODE EC-3
LF –EC-00900
220 V, 50HZ, 1 PH, 0.5AMP
EASTMAN M/C CO.
NEW YORK, US

19
 STRAIGHT KNIFE

Motors
110v, 1ph:
Weight
34 lbs. (15.4kg)
Horsepower
.65hp
Blade Size
(Inches): 5"
(cm): 12.7cm
Cutting Capacity
(Inches):3.5"
(cm):8.89cm
Stroke Size
(Inches):1.125"
(cm): 2.86cm

20
  SINGLE NEEDLE LOCK STITCH

Specifications

Bed dimensions:
 Length: 18 3/4" (477 mm) Width: 7" (178 mm) Space to right of needle: 10 5/16" (262 mm)
 Outside diameter of machine pulley: 2 61/64” (75 mm) effective diameter for V-belt
 Regular machine: Singer® clutch motor high speed 1/2 H.P.
 Under bed thread trimmer (U.T.T): Singer® AC servo motor/EC (N.P.) motor
 Including the operation panel C-30
 Needle bar Stroke: For 200A: 1 3/16 " (30 mm) For 300A: 1 3/18" (35 mm)
 Clearance under presser foot: By hand 7/32 " (5.5 mm) By knee 1/2" (13 mm)

 DOUBLE NEEDLE LOCKSTITCH

21
Specifications

 Max sewing speed -3000rpm

 Max. stitch length-5mm
 Needle bar stroke-33.4mm
 Needle-DPX5 #14.
 Bed size-517mm*478mm
 Weight of machine-43kgs
 Power required- single phase 100,420V,200.
 Three phase 200,240V/650VA.
 With automatic UBT.

 5 THREAD OVERLOCK

Specifications

 Brand: Juki
 Application: For light-weight materials
 Feed Dog: 4-Row
 Feed System: Bottom-Feed
 Max. Sewing Speed: 7000 rpm/spm
 Max. Stitch length: 1.5~4mm
 Needle Bar Stroke: 24.5mm
 Needle System (at time of delivery): DC X 27
 Lubrication: Automatic
 Lubricating Oil: Juki New Defrix Oil #2(Equivalent to ISO VG32)
 Lift of Presser Foot by Hand: 7 mm
 Number of Threads: 2/3/4/5 Threads

22
 BUTTON STITCHING MACHINE

Specifications

 Max. Sewing speed- 1500 spm.

 Number of stitches-8, 16 and 32.
 Applicable buttons- round shaped, flat (2 holed, 4 holed), shank/snap/metal.
 Needle bar stroke-48.6 mm
 Needle size -TQ x 7 #18 ~#20TQ x 1 # 14~#18.
 Button clamp lifting height / system- >9mm/Automatic System.

 BUTTON HOLE SEWING MACHINES

Specifications

 Max. Sewing Speed -3,000 spm

 Number of Stitches -83~225 (by gear change method).
 Max lift of work clamp-12 mm (15/32”)
 Needle bar stroke -34.6 mm
 Length of bottom holes -6.4-38.0 mm
 Needle Size -DP x 5 # 11~ 16

23
 FUSING MACHINE

Specifications: - Continues fusing machine

AE-300
MODEL
SINGLE PHASE
POWER SUPPLY
HEATER 3 KW

MOTOR 0.40 KW

CURRENT 17 A

TEMPERATURE 200’ C

PRESSURE 1 KG/CM2

BELT SPEED 8.7 M/MIN

FUSING WIDTH 300 MM

24
  PRESSING

NO. OF DIMENSIONS(L*W WEIGHT

MODEL POWER
MOTORS *H) INCHES KG.

NX-2429 1 .75 HP, 1 PH/3PH 50*30*36 80

25
4.1 VARIOUS DEPARTMENTS IN JUPITER KNITTING COMPANY AND ITS
FUNCTIONS
There are many departments having in Jupiter knitting Company

 Purchase department
 Finance department
 Human Resource department
 Accounting department
 Maintenance department
 Export department

4.1.1 PURCHASE DEPARTMENT

The primary objective of purchase department is to obtain the right materials, in the right quality,
at right time and price. As purchasing department and raw materials stores are operational departments,
they are responsible to the operations manager, and in management of finished goods.

 Functions of Purchase department

 Identifying requirements for goods, materials and services.

 Identifying reliable suppliers.
 Price negotiations.
 Comparison of delivery terms.
 Establishing order quantities.
 Writing requests for bids and awarding supply contracts.
 Coordinating delivery with the warehouse against storage capacities.
 Product testing and quality control.
 Managing budgets and payments.

4.1.2 FINANCE DEPARTMENT

This is the major department of the company. It prepares different kinds of financial reports and
gives information to management for decision making purpose.

Finance department prepares the Income Statement, Balance Sheet, Trial Balance,
Cash Flow, Production report for the whole month, stock taking report, and yield comparison report etc.
these all reports are useful for the management to make production plan, financing decision and other
important matters. The head of this department is Finance Manager.

26
 Functions of Finance department

 They are prepare monthly and half yearly reports

 They have kept the record of inventory and stock
 They are maintain a liquid position
 To have maintain adequate cash to run the operations of business
 To reconcile the bank statements
 To make payments to the suppliers
 To deal with sale tax and income tax departments
 Preparation of bank payment and bank receipt vouchers
 Prepare profit and loss accounts and Balance sheet
 Keep record for the payments of salaries

4.1.3 HUMAN RESOURCE DEPARTMENT

Human resources strategies play a key role in the development of textile enterprises, both in
day-to-day activities and long-term objectives. HR is responsible for enhancing the capacity of the sales
department in negotiation and contract management, motivating staff through benefits programs and
creating conditions that facilitate technological advancement.

 Workers welfare
Labor welfare entails all those activities of employer which are directed towards providing the
employees with certain facilities and services in addition to wages or salaries.

 To provide better life and health to the workers

 To make the workers happy and satisfied
 To relieve workers from industrial fatigue and to improve intellectual, cultural and material
conditions of living of the workers.
 Functions of Human Resource department

 They provide better physical and mental health to workers and thus promote a healthy work
environment
 Facilities like housing schemes, medical benefits, and education and recreation facilities for
workers’ families help in raising their standards of living. This makes workers to pay more
attention towards work and thus increases their productivity.
 Employers get stable labor force by providing welfare facilities. Workers take active interest in
their jobs and work with a feeling of involvement and participation.
 Employee welfare measures increase the productivity of organization and promote healthy
industrial relations thereby maintaining industrial peace.
 The social evils prevalent among the labors such as substance abuse, etc are reduced to a greater
extent by the welfare policies.

27
 Some of employee welfare Laws in India

 Factories Act, 1948

 Maternity Benefit Act,1961 (with latest amendments)
 Employee State Insurance Act, [ESI] 1948
 Employees' Provident Fund Scheme, 1952.
 Payment of Bonus Act, 1965

4.1.4 ACCOUNT DEPARTMENT

JUPITER Knitting Company has separate account department under the control of Chief
Accountant who is responsible for the financial affairs of the organization and to keep control on all
inflows and outflows of cash and funds.

 Accounts Department Structure

• Chief Accountant.
• Accountant.
• Assistant Accountant.
• Computer Operator.

 Functions Accounts department

The major functions of accounts department are as under

 Maintaining the record of the account receivable.
 Record of payments by bank.
 Record of payments by cash.
 Maintaining the record of raw material purchased.
 Maintaining the record of sale of Yarn, waste etc
 Record of store purchases.
 Record of insurance.
 Record of the expenses i.e., manufacturing and marketing.
 Record of wages and salaries.
 Preparation of financial statements.

28
 4.1.5 MAINTENANCE DEPARTMENT

Maintenance Department is one of the most important parts of the factory. The maintenance
department is mainly responsible to look after the machines and other production equipment in proper
working condition and take corrective action against any environmental pollution.

 Functions of Maintenance department

 Care of the fittings
 Adjusting settings
 Oil changing
 Graph maintenance
 Outward/inward reports
 Needle weekly reports.
 Machine configuration chart
 History card
 Needle log cards.

4.1.6 EXPORT DEPARTMENT

Export means the exchange of goods or products from inside country to any foreign country with
any currency equal to the value of product or goods. There is the demand of Jupiter knitting company
finished products all over the world. They try to meet the demands of the world. They also try to compete
with Quality and on time delivery in any environment according to its respondents. Jupiter Knitting
Company export its products in the following countries; UK, France, Sweden, United States of America,
Denmark, Spain, Germany, Holland. They export the T-shirt, Jackets and Sportswear to the above
mentioned countries.

 Functions of Export department

The following are the main functions, which an export department performs
 To build good relationship with the buyers.
 Co-ordination with the buyers and the production department.
 Getting orders from the buyers and try to fulfill them in time.
 Improve the quality of the product with the interaction of buyer and the production department.
 Prepare and arrange the documents of export.
 Prepare the documents for the taxation and excise purpose.

29
 Export documents contain the following things

Exporting of any commodity in the foreign market was very complex and risky in the past. But
now the export documentation provides the security from different risks. When the goods are exported, a
number of documents are to be prepared.

 Contract
 Bill of Exchange
 Invoice
 Packing list
 Bill of lading
 Copy of Letter of Credit
 Transportation documents

1. Bill of Lading

Bill of Lading is the important document in export. This document includes the shipper/exporter
address, Consignee (to the order of bank), port of loading, also port of discharge or place of delivery,
container , detail of product, origin of country , purpose of export and gross weight etc.

2. Copy of Letter of Credit

Letter of Credit defined as in simple words “THE TRUST OF PERSON ON OTHER PERSON”
The copy of “Latter of Credit” is the most important in the document of Export. Letter of Credit is the
guarantee for Exporter from Importer through bank. Importer opens the Letter of Credit in the bank and
pays negotiable amount for this service provided by the bank. The Importer pays the negotiable amount to
bank between 2% to 4%. He also gives the sum of money to Broker which is also negotiable. They deal
with any party through bank. The importer opens the L/C by giving the terms and conditions which are
suitable for him/her. Now the Exporter sends some amendments to Importer through bank. Amendment is
the change from Exporter in the terms and conditions showed by the Importer. Some time the Importer
accepts the terms and conditions according to the Exporter. In Jupiter Knitting Company all the work of
Import and Export is properly done. They have well established department separate from other sections.

30
5.1 FINDINGS & SUGGESTION

FINDINGS

The few findings on the institutional training at Jupiter knitting company includes,
 The firm concentrates mainly to produce quality goods and pays less attention in marketing them.
 It also provides employment opportunities to women at home through trimming garments and
garments embroidering
 The company provide job rotation for the employees in all department, so the employee know all
other activities
 They use in modern equipment to produce product
 The quality control as well inception in the garment department should be parallel.
 The value that customer is the only who come first. The fulfillment of the demand of customer is
their basic motive.
 The operators in the sampling department are very experienced and highly skilled. They are
explained the construction of any new sample by the pattern master and the supervisor.
 The maximum time is spent in the procurement and approval of trims and fabric.
 Any delay at any stage can delay the entire order.
 The company have sufficient production capacity
 Competitors are not that much strong like Jupiter knitting garments
 Distribution of power should be well managed and transparency among the workers and
the management should be followed.

SUGGESTION

Jupiter knitting garments already have a good brand name in the industry. So I do not have much to
recommend. Some suggestions are
 They should be careful about timely delivery of the sample.
 They can import some necessary modern and automated equipment.
 They can require some designers to make sample designs by themselves.
 Training facilities should be introduced specially for the new employees.

5.2 CONCLUSION
Jupiter knitting Garments already established a brand name in Garments industry. Now they have
lots of foreign customers and demand for their Garments is increasing day by day. Jupiter group is
providing washing, printing, embroidery facilities and sometimes accessories for Jupiter knitting garments
which make production much easier. So if it can maintain its quality and standard it can have a huge
business potential.

31