INDUSTRIAL TRAINING REPORT

A report submitted to Gobi Arts and Science College (Autonomous)

Gobichettipalayam, affiliated to Bharathiar University, Coimbatore in partial
fulfilment of the requirement for award of the degree of

BACHELOR OF COMMERCE

REGISTER NUMBER : 12-CO-056

NAME OF THE STUDENT : T. SUKUMAR

NAME OF THE GUIDE : Thiru. S. MOHANRAJ, M.Com., (CA), M.Phil.,

PLACE OF TRAINING : M/s. K.M. KNITWEAR PRIVATE LIMITED

PERIOD OF TRAINING : 14.11.2014 to 25.11.2014

P.G. & RESEARCH DEPARTMENT OF COMMERCE

GOBI ARTS & SCIENCE COLLEGE
(AN AUTONOMOUS INSTITUTION RE-ACCREDITED BY NAAC WITH
‘A’ GRADE)
GOBICHETTIPALAYAM – 638 453
FEBRUARY - 2015
 INDUSTRIAL TRAINING REPORT
EVALUATION

Signature of the Supervisor

Signature of Head of the Department

Remark
 ACKNOWLEDGEMENT

I express my sincere thanks to Thiru. S. Mohanraj, M.Com.(C.A.).,. M.Phil.,

facultry advisor to me, Assistant Professor, Department of Commerce for his valuable
guidance during the period of my Institutional Training.

I wish to express my grateful thanks to Dr. A. Selvaraj, M.Com., M.B.A.,

M.Phil., P.G.D.C.A., Ph.D., Head of Commerce Department for having given me this
opportunity to pursue this training.

I express my heartfelt thanks to our principal Dr. R. Sellappan, M.B.A.,

M.Com., M.Phil., D.L.L., Ph.D., and faculty members of Commerce for having given
me this wonderful opportunity to undergo this Institutional Training.

I am very thankful to the Management of Gobi Arts & Science College,

Gobichettipalayam for having given me this opportunity to pursue this training.

Also, I extend my sincere thanks to M/s. K.M. KNITWEAR PRIVATE

LIMITED for providing the opportunity and guidance to do this training in their
concern.
 I express my thanks to all Staff members of the Department of Commerce for
their kind co-operation.

CONTENTS

CHAPTER I

INTRODUCTION

CHAPTER II

TRAINING

CHAPTER III

CONCLUSION
 Introduction

M/s. K.M. Knitwear was founded by Mr. K. Muthusamy, the Chairman of the
Company as a partnership firm consist his family members as its partners in 1997 to
manufacture knitwear garments for the Indian Market. Right from inception, the policy
of the company has been to provide total customer satisfaction by offering quality of
knitwear in time.
From 2000, it has started to export its garments to Foreign countries like USA,
Germany, China, Japan, etc.,

COMPANY PROFILE:

M/s. KM Knitwear is vertically integrated ISO 9001-SA 8000 company and

certified by OEKO-TEX by ARPANSA (Australian Radiation and Nuclear Safety
Agency) as compliant with standard AS/NZS 4399:1996 clothing (Evaluation and
Classification) with UPF 50+rating. It is also a Government Recognized Export House.

M/s. KM Knitwear’s core strength of planned infrastructure is reinforced by 750

employees who form the backbone of the company. Departments are headed by
qualified and experienced managers assisted by executives who undergo continuous
training and attending development workshops are exposed to the new developments in
the industry.

M/s. KM Knitwear is located at 14-D, F Lakshmi Nagar, First Street, City

Garden, Tirupur 641 602, Tamil Nadu and its share capital is Rs.5 crores as on date.
 ORGANISATION STRUCTURE
ADMINISTRATORS

MANAGING DIRECTOR

GENERAL MANAGER

Purchase Production Accounts Marketing Quality Control

Manager Manager Manager Manager Manager

Supervisors Accounts Marketing Technical

Assistants Executives Assistants

Employees

The Organisation Chart is formed in such a way as of “Chain of Command”

which enables the executive to have direct authority over his subordinate.
VARIOUS DEPARTMENTS:

The various departments which are functioning in M/s. KM Knitwear are as

follows:

PURCHASE DEPARTMENT

The Purchase Department is an important department in the company. It is been

setup in such a way for smooth functioning of production process without any
interruption by providing necessary materials for production. The Management lays
down the purchase policy and purchase department, purchase the materials according to
the policy to achieve the desired goal.

Raw material cotton is purchased from states like Tamil Nadu, Maharastra,
Andra Pradesh, Kerala and Karnataka. Samples are tested to know the strength of
the cotton and maturity of the cotton. Samples are collected from different supplier and
send for testing. Once the testing is completed, Purchase Manager places the purchase
order.

SPINNING DEPARTMENT
Spinning is nothing but the process of producing yarn. Yarns are mainly
classified into two types.
1. Carded Yarn
2. Combed Yarn
And yarns are also classified according to the count.
Count:
Count is defined as the number of 840 yards present in one pound. It is
indirectly proportional to the thickness of the yarn.

MIXING DEPARTMENT
The cultivated cottons are differentiated according to the staple length of fibres
(i.e.) Micronaire Value. Micronaire Value is defined as the maturity of fibres.
According to the count, the required type of cotton is selected by the spinning master. In
Mixing Department, various types of cottons are mixed with the help of pre-mixer.

Objectives of Mixing Department:

(i) To reduce the production cost
(ii) To maximize the quality of yarns
(iii) To maximize the profit

Yarn:
Yarns are classified into three types namely
(i) Warp Yarn
(ii) Weft Yarn
(iii) Hosiery Yarn

Warp Yarn
In a fabric, the vertical length of yarns is called warp yarn. This type of yarn is
produced with high twist and high count strength product.

Weft Yarn
In a fabric, the horizontal length of yarns is called weft yarns. This type of yarn
is produced with low twist and low count strength product.
Hosiery Yarn
The hosiery yarns are more elastic in nature. These are produced only for the
garment field (i.e) knitted goods.

Blow Room:
In this process, sequence of machinery line is used for gradual opening and
cleaning of cotton. Then, the cotton is converted into lap form.

Mixing Bale Opener

Step Cleaner

Mono Cylinder

Condensor

Hopper Feeder

Three Bladed Beaters

Krichner Beater

Lap Forming Unit

 As the cotton passed on these machineries, the cotton gets opened and cleaned.
The beaters are used for opening and cleaning the material. According to the fiber
strength and maturity, beating points are given to the cotton. The opened cottons are
formed into lap form i.e. cotton sheet form.

Carding

It is also known as “Heart of Spinning”. In this section, the lap form of cotton
is feed into a machine for removing the dust and then it is converted into silver form
(i.e.) thick untwisted fibers.

Silver Lap Machine:

For the convenience of combing process, this process is adopted. 18 silvers are
combined together and given some draft (draft is nothing but stretching of fibers). After
the material is stretched, it is formulated as spools.

Ribbon Lap Machine:

It is also adopted for the convenience of combing process. Using this machine,
6 silver leap spools are converted into one spool.

Comber:
Combed yarns are high quality yarn due to the absence of short fibers. In this
process 17% of short fibers are removed. The short fibers creates protrude in the yarn.
(i.e.) unevenness created by the short fibers. These types of short fibers are called as
noils.
The percentage of removal of short fibers is fixed according to the type of cotton
variety. If the short fibers are more in the cotton, the percentage of noils will be
extracted highly which would affect the quality.
Advantages of combing process:
(i) This process improves the yarn quality
(ii) It reduces the yarn unevenness
(iii) It gives more strength when compared to the carded yarns
(iv) It gives the maximum count to the cotton

Drawings:
Drawings is the process of parallelizing the fibre towards its original position. In
this process, 8 combed silvers are converted into one silver. It gives the fibre evenness.
Simplex Speed Frame:
In this process the silver is converted into Roving Form. (i.e.) thick yarn forms.
The fibres are passed into 4/4 drafting system. The vollers are rotated at different
speeds. Due to the speed variation, the silver is converted into roving form. Small
amount of twist per inch is introduced in this process.

Spinning (or) Ring Frame

In yarn converting process, it is the final stage. The roving yarns are the feed
material for the spinning department. These Roving yarns are passed into 3/3 drafting
system. Due to the speed variation between the rollers, the roving yarn is converted into
yarn. High twist is introduced in this process. Different twist gives different counts.

Cone Winding
The produced Cotton yarns are packaged into cop. Its maximum capacity will
be around 80 gms. It is difficult to transport bulk yarns so, to avoid this factor the
spinning cops are winded into cone winding. Its maximum capacity is 1.250 kgs. and
knots and neps are removed in this process. Finally, the yarn is send to the garment
field.

FABRICATION UNIT
In the process of fabrication, yarn is knitted into woven cloth using machines.
The knitting process starts with the proper scheduling of the process.
Types of Fabrication
1. Warp fabrication
2. Weft fabrication (or) circular knitting

1. Warp Fabrication
In this Fabrication, yarn is knitted into plain cloths and is self explanatory where
the loop formation is done in horizontal way. The machineries used for this process are
manufactured in Ludhiana of Punjab. Mostly these machines are made in Germany
named as Meyar & Cie Terrott.

2. Weft Fabrication (or) Circular Knitting

In this fabrication, yarn is knitted into inner garments like

(i) Vests
(ii) Briefs
(iii) Panties
The knitting is done in circular form

Types of Fabricating Machines

(i) Ordinary Machines
(ii) Imported Machines
1. Power and Man Power Requires
20 HP line is needed for 25 fabric machines. Five Foremens look after 20
fabrication machines. One operator can operate 3 machines at a time whose duties are
 To check the defects in the cloths
 To cut and remove the role when it is completed
 To change the empty cones
 To lubricate the machines
 The cost of needle used in the ordinary fabrication machines is Rs.800/- each and is
manufactured in Maharastra.

2. Imported Machines
Various designs of complex nature can be created using this machine. The main
component of this machine is imported from German and the body of the machine is
built by Lakshmi Machine Works (LMW) and supplied to the user industries with a
brand name called Lakshmi Tarot. The efficiency of these machines is high in
producing quality fabrics.

3360 needles are fitted in these machines. The cost of a needle is Rs.50/- and all
spares including needles are imported from German. One operator for each machine and
foremen for four machines are needed for running.

The price of one machine is Rs.1,24,00,000/-. In Tirupur one third of the price of
the machine is borne by the user industries and balance by Tamil Nadu Investment
Corporation (TIIC) on Loan basis.

The horizontal stripes and vertical strips can be made usin this machine. Each
machine consists of an individual motor and if the shape of yarn increases, the machine
will be automatically stopped and the defect will be indicated by light.

Yarn Processing

The first step in processing the yarn is subject to setting the desired shads. Since,
the yarn will be in form of carrion, which might seem to look like a kaki color. If the
shades are not as per specifications, it is dyed further. At a time a dyeing tube dyes a
single yarn. One bag of yarn can be dyed in one hour by a single dyeing tube. However
this is not necessary for this industry process because, the dyeing in this industry is
carried out after the fabrication only. This is so because each and every colour has its
own weighed prosperity which will not fit to the GSM (Grams per Square Meter) after
fabricating the yarn into cloth form, so it will not be upto the satisfactory level of export
order.
DYING

After fabrication the fabric is subjected to either bleaching (or) dyeing.

Stages of Bleaching:

1.The fabrics are washed by keeping it 6 hours in hot bleaching process.

2. Next the cloth is kept in the Sulphuric acid for half an hour.
3. Then ordinary water washing is done by keeping it in ordinaty water for
30 minutes.
4. Next fabric is mixed in winch tank and kept in it for 2 hours.
5. Again ordinary water wash is done of half an hour.
6. Then Dehydration process is done. Lastly the fabric is either shade dried
tumble dried.
In some cases, the manufacturer will prefer outside vendors for dyeing the
fabric.

Streaming:

The fabric is then put to streaming to have area surfing. This controls the
shrinkage to a certain extent. The speed of the steam machine is 0 to 110 points. The is
connected to a boiler from where the water at a temperature of 50 degrees Celsius to 5 to
25 Kgs of rolled cloth and steamed in this machine. The price of a steam machine is about
2.5 to 3 lakhs. An operator maintains the steaming unit and he is supported by a helper.

Compactin

Then, the rolls are feed into the compacting machines to control the shrinkage
in full (i.e., 100%). The cost of the compacting machine is about Rs. 4,00,000. This
machinery is named as Tube - Tex Tirrato.
PRINTING
This process involves printing of various designs to fabric as per the requirements.

Types of Printing

Rotary Printing

This is done by a high speed machine. The dyes and colors are used printing.
The designs frames are fitted in the roller. The colors of required shade are fed to the
frame from a tank through a rubber tube. The output is 1 mt/2 sec. The cost of the
machine is about 1 crore. The machine is attached to a dryer and boiler.

Ordinary Printing

In this type completely manual printing is done without using machine the fabric
is spread over long printing is done using frames.

Machine Printing
It is used for chest printing only. The machine is imported from Australia. The
cost is about 50 lakhs. The brand name is MHM. The machine is fully automatic and
computerized and operated by two persons. This machine functions in pneumatic
system. The required colours are feed in to machine from a tank through a tube and the
output is 300 pieces per hour.

Curing

In this printing, waxes are removed. It is done by heating the fabric by curing
machine. All types of cloths are cured in this machine. The cloths are fed into the
machine by conveyor belt. This machine is imported by Australia. It is manufactured
by MHM Company, Australia and the cost of the machine is Rs.25,00,000. One helper
and one operator are needed to operate this machine.

GARMENT UNIT
Process of Garment:

Measuring

Cutting

Manual Stitching

Machine Stitching

Embroidery

Fixing Accessories

Trimming

Packing

Measuring
Measuring is the first step of garment filed. Mainly the measuring is varied
according to the buyers. It is classified into two types.
1. European Measurement
2. American Measurement
Cutting

As per the buyer’s requirement the design is cutted on a card board. Then the
rolls are checked thoroughly and damages if any are marked on the cloth. After that, the
pieces are cutted to the required size with the help of the card board designs. In this
process, the damaged portions are also cutted and removed.

Stitching

After cutting the pieces, they are sent for stitching to the stitching unit. The
following machines are used in stitching.
1. Flat Lock
2. Over Lock
3. Singer Lock
Embroidery

Embroidery is the process of making designs on the fabric. It gives more

attraction to the fabric. The designs to be given for fabric (letters or any designs) are
decided by the company. The machines are classified into three types.
1. Ordinary Machine
2. Computerized Embroidery
3. Digital Embroidery

Trimming

Trimming in the sense means removal of extra thread (or) yarns on the fabric
while stitching, embroidering the extra threads or presents on the surface of fabric.
These are removed in this process.
 And also, due to the machinery parts the fabric may get oily and waxes. These
will reduce the quality of the fabric. So, these are removed with the help of soap oil and
caustic soda.

Fabric Accessories

Additional products that are included with the fabric are known as accessories.
Common accessories used in the garmenting are
1. Wash care Instruction Label
2. Fibre Composition Label
3. Style Number Label
4. Brand Label
5. Tag
6. Brand Tag
7. Hanger
8. Neck Tap Structure

Checking

In the process of checking, damages in the stitching and oil strain are located in
every piece. The oil scratch is removed using spray gun filled with CTC oil. The
damaged pieces are separated from the lot.

Ironing

Ironing is the process of removing shrinkage on the fabric. Mostly, steam

ironing is used in all garments where the shrinkage is removed in the high steam
pressure. After ironing, the fabric goes to packing department.

Packing

Packing plays an important role in garments and also in garment industry

particularly exporters give more and minute attention to the packing of product.
Product Packing:
a. Single Piece Packing
b. Multi Piece Packing

QUALITY CONTROL DEPARTMENT

Process

Quality Control Manager

Inspector

Supervisor

Inspection of Foreman

Quality Control Department perform inspection, testing and analysis to conclude

whether the quality of each product is as per laid quality standard or not.

Statistical Quality Control is that the statistical techniques are employed to

control quality (or) to solve quality control problems. It makes inspection more reliable

and at the same time less costly. It controls the quality level of the outgoing products,

which are very essential one in the alloys of manufacturing industries. The quality

control Manager usually heads the quality control department.

Inspection
 An item or component or product is required to be in a standard form anticipated

by the management. The act of checking whether a component actually does so or not is

called inspection.

Inspection Officer:

The inspection officer’s duty is to control and co-ordinate the various activities of

the quality contorl department. At every stage of the production, supervisors do

inspection and they report to quality control department head (the Manager) the defects

to be rectified and removed. The superviosr also make note even a minute defect in

case of alloys, but, this is more perfect since the machineries are introduced in the

manufacturing process. If they fail to do this, then the consumer will return the whole

order. The supervisor should take immediate action on the defect on the product. So,

the quality can be maintained in case of international export business.

Supervisor is the one who act as an assistant to the inspector (or) inspection officer

in all cases irrespectiove of the siltuation plrevailing in the organization. But in all these

cases they are directed by top level authorities like inspectors and managers of the

quality control department. At the same manner, they are also empowered to direct

their sub-ordinates who are working at the foremen level.

Foreman Inspection:

There are number of people working in the various process of production who are

also responsible to maintain the quality of the product which came as a finished product

after the processing is being completed. Thus, it strongly implies that “ Quality

Control” is noly a part but involves with the whole part of the production organization.
MARKETING DEPARTMENT

In general sense, marketing is the process to sell the goods and services through

creating the four utilities like.

Place

Promotion

Price

Policy

Marketing Managsr:

Marketing Manager is the top level authority in the marketing department and his

lower level subordinates are

(i) International Export Manager

(ii) Local Marketing Manager

(iii) Marketing Research Manager

MARKETING DEPARTMENT

Marketing
International Domestic Research
Manager Manager Manager

Product
Export Local Dispatch Research
Manager Manager Manager

Logistic Local Marketing

Manager Manager Research
Main aim of the Marketing Department:

(a) The ultimate aim of the marketing department is to encourage the

production unit through achieving NIL stocks at the year end.

(b) To boost the sales throughout the national and international marketing

sections

(c) To motivate all kinds of consumer irrespective of his class and social

affairs

(d) To increase the profit ratio of the concern

(f) To create a mutual interlink between the producer and final consumer in

solving the problem of gap in communication

In this firm, Marketing Department has wide scope and functions. These

activities are controlled and co-ordinate by the Marketing Managers who are the

head of the department.

Phases of Export Procedures:

Offer and Receipt of Confirmation of Order

Production and Clearance of the Product for exports

Shipment and Documentations

Negotiation of documents and realization of export

Obtaining various export incentives

 The proposal submitted by an exporter (be in the form of a letter, quotation etc.,)

is referred to as the ‘Offer” . The offer when accepted by the Foreign buyer becomes an

order. The order made by the exporter is usually in the form of a “Performa Invoice”.

PERSONNEL DEPARTMENT

Personnel Manager heads this department. As he knows well that, “the success

or failure of an organization depends not on materials, machines and other factors but on

the efficiency of the personnel to put in their best efforts for an efficient performance of

their job” he has to co-ordinate all the human resources and direct their efforts towards

success of the concern.

It is also to be noted that the materials, machines and even offices themselves can

be replaced and any risks involved can be insured against but, a good loyal team of

workers cannot be replaced so easily.

To achieve the basic objective of an organization, efficient and effective use of

people at work is essential. Personnel Management is the management of people at

work. Personnel management is a function of the general management with the

objective of ensuring that every employee makes his fullest contribution to the

achievement of the objectives of business.

SHIFT TIMINGS:

Shifts In Time Out Time

General Shift (A) 7.00 a.m. 3.30 p.m.
Half Night Shift (B) 3.30 p.m. 12.00 a.m.
Full Night Shift (C) 12.00 a.m. 7.00 a.m.
Public Relation Officer:

The PRO is the one who takes care of the external affairs of the industry. He will

involve in all activities in and around the public (i.e.) the consumers and all other

institutional. He is the one, who possess the following functions and duties.

Duties and Responsibility of the PRO:

 He grants the permission to the outside institutions to make training consultations

with them

 He is the one to select the “right candidates to the right job” in accordance with their

qualifications

 He should maintain a cordial relation with his subordinates and public

 He should select and promote a right candidate to the right position in the

organization

 Responsibility and authority of each supervisor should be clearly defined in writing

 Responsibility should always be coupled with corresponding authority

LABOUR MANAGEMENT SECTION

Aims:

 To co-ordinate the workers together for the mutual benefits

 To interact as a middle person between both the side of the organization (i.e.)

between management and the labour force.

 To increase the job satisfaction within the workers

 To increase the productivity of the organization

 To provide the welfare, safety, measures to all categories of workers

 To give the training for the selected employees in the technical and non-technical in

accordance to the situation that prevails inside the organization

 Time Management of the Production Schedule

Safety Officer

The company has provided many safety measures to their labours. The company

has appointed a safety officer for mentioning the safeness of the labours. The memebrs

and employees are bound to them. He must ensure the following:

 The work place is having enough lighting facility and properly ventilated with fan

and ventilation.

 Air cooler and air conditioner are placed at hot working place

 Heavy works are not given to lady staff.

 Workers employees are entitled to wear shirts and tie their hairs, etc.

Welfare Officer:

The Company provides number of welfare facilities for workers to promote the

relationship with employees. The company appointed welfare officer to look after and

control the measures. Medical expenses, rest room, advance, bonus are some of the

welfare measures provided by the company.

Some of the main welfare facilities that are provided by this firm are:

 Canteen facility as per the prices prevailing in Industrial act

 Rest Room to both employees also lunch hall

 Company gives quarters to employees who are out to the sight of production

 The company provides transportation facilities through the van and bus
 Concession food facility in canteen is also provided in this firm

 The above said factor and aim of the welfare section are controlled and activagted by

the welfare officer the head of the department as per the factories act, 1946 in a very

strict manner.

Wages and salary administration

The wage is the remuneration that to the daily workers and foreman working in

the various unit of production. And the salary is the remuneration that provided to the

higher level authority and officer which also include the various departments for a period

of one month.

Bonus

The bonus means “Especially extra dividend of Wages” to the employee than

that of his normal wage or salary (or) gratuity to workman beyond their wages. The

employee’s bonus is controlled by the payment of bonus act, 1965. The company gives

bonus on different period of the year.

Under this several bonus system, the different percentages of bonus are paid.

Generally the bonus ratio was 14% to 15% in this concern. The three month salaries are

paid to employee as bonus. The man power is challenging. It is effectively controlled in

this concern, he personnel manager in this organization have more knowledge and

experience in the same field.

ACCOUNTS DEPARTMENT

An Accounts Manager is in-charge of the Accounts Department. The accounts in

this concern are computerized which reduces the work load of accounts department.
 Depreciation for all machineries are calculated on the written down value method

except for electrical machineries which are to be depreciated on straight line method of

depreciation.

Various Records maintained by the concern are:

 Credit and debit voucher

 Journal voucher

 Cash book

 Purchase and Sales journal

 General Journal and Ledger

 Debtors Ledger

 Stock register, etc.

CONCLUSION

Industrial training in M/s. KM KNITWEAR PRIVATE LIMITED helped me to

know about the actual working of a company. The same helped me to gain practical

knowledge within a short span of ten days.

This training has provided me broad knowledge about the company’s activities,

structure of organization, method of administration, how production activities are carried

on and procedures regarding export.

As a student, this training was very helpful for me to know the difference

between theoretical and practical knowledge.

EVALUATION
CERTIFICATE
ACKNOWLEDGEMENT
CONTENTS
CHAPTER I
CHAPTER II
chapter iii
conclusion