TEXPORT SYNDICATE

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TEXPORT SYNDICATE : 

TEXPORT SYNDICATE Internship At By Romel Chakma (AMIT) Nift Bangalore

Company profile : 

Company profile established in 1978 Twenty nine years to the manufacturing of both knitted and woven apparel 5000 Japanese and German sewing machines Employing more than 6000 skilled managers and craftspeople throughout its numerous offices and manufacturing facilities in India and internationally represented in North America by Key Apparel in New York

Directors : 

Directors Mr. Raju Goenka Mr. Sunil Goenka Mr. Amit Goenka

CORPORATE OFFICE : 

CORPORATE OFFICE TEXPORT SYNDICATE, Plot no. 6, C.E.P.Z, Central road, M.I.D.C, Andheri Eas Mumbai – 400093 Bangalore Mumbai Tirupur Manufacturing unit

Product : 

Product Tops, shorts, coats, T- shirts, skirts, shirts, Bermudas, Briefs, suits, children wear, pants, casual wear, Gowns, Jackets, Trousers, Jeans, and Boxers etc.

CLIENTS : 

CLIENTS American Eagle Vetura V.V.M k.Mart Mighty Huricane Top Security Hurley George Walmart Mother Care Mar Max Izod Nostic Weca P.V.H

Department-wise process flow : 

Department-wise process flow Merchandising Sampling department Testing lab   Production planning department     Fabric main store   Fabric sub store   Cutting Department   Ticketing,fusing & bundling

continue : 

continue Sewing department Washing Finishing section   Quality control   Packing shipment

Merchandising : 

Merchandising In Texport, the merchandising can be divided in two parts: Marketing Merchandising Product Merchandising marketing merchandising Product development Costing Getting Purchase Orders It brings the order, develops the product, and does the costing. It has a direct access to the Buyer.

Product Merchandising : 

Product Merchandising This is from sourcing to finishing that is from first sample to onwards, the product merchandising work starts and ends till the shipment

Sampling : 

Sampling The package file is received from the merchandiser and the copies of it are handed over to the sampling manager, CAD in charge, sampling technician and the sampling QA in charge. The pattern request is received from the merchandiser by the sampling manager for the following samples: Fit sample PP sample Size set sample Sealer sample

Cad : 

Cad investronica Astor Tanya

Process chart : 

Process chart

In house test method : 

In house test method Count Construction Shrinkage Colorfastness to Washing Rubbing crocking GSM

Production planning department : 

Production planning department Receives the booking order Generate the factory planning Generates pcd planning Generates line planning

Continue…… : 

Continue…… Generates finishing line Generates hourly production reports Decisions with units

I.E : 

I.E The Industrial engineering department is primarily responsible for monitoring of the batches from the batch setting period, throughout the production process until the incentive earned by the operator and line.

Functions : 

Functions

Fabric main store : 

Fabric main store Texport syndicate has a centralized main fabric store located at TS-IV. All fabric and interlining is received by the main fabric store and distributed further to various units according to required quantity. All the units have fabric sub stores locate in the unit itself The fabric main store consists of a fabric incharge, godown incharge, fabric checker, fabric QC, QA executive, stores assistant, computer operator, DTP operator and fabric assistants.

Physical Testing & Inspection: : 

Physical Testing & Inspection: Fabric is inspected by using a 4 point system. It is a projection of total defects based on the total number of defects found during inspection of a sample as a basis for acceptance/rejection criteria. In this point inspection system penalty points are assigned base on the standard fault. For every type of fault colored stickers are put, to identify serious defects in the subsequent process.

Four point Inspection systems : 

Four point Inspection systems Fault Size Point Assigned Sticker color 0 to 3 inches 1 Yellow 3 to 6 inches 2 Green 6 to 9 inches 3 Blue 9 & above 4 Red

Common Fabric Defects Found Are: : 

Common Fabric Defects Found Are: Weaving Defects:-Missing picks, end out, mixed filling, mixed ends, dropped pick, slubs, yarn distortion, pattern fault, stop marks, holes, etc. Dyeing/printing/finishing Defects:-Bowing, Color Bleeding, Puckering, stains, Skewed or biased, Selvedge variation, scrimp etc.

Cutting department : 

Cutting department Receive package file Receive total order quantity Divide total quantity into lays Issue lay slip to the spreader Lay brown sheet, set length and put two to three plies Get Q.C. approval for length, width, and continue spreading once approved Give lay slip and lay report to cutter

Continue…. : 

Continue…. Marking (manual cutting) or lay plotter marker (auto cutting) Cutting Maintain the record of the lays cut in minusing register Sorting Bundling and numbering Part banking and issue to sewing

Sewing department : 

Sewing department Report maintained by Sewing Department Daily production report Purchase order sheet Folders send by IED for every P.O. Manpower report Hourly production report Monthly labor report Batch order completion Batch planning file Cutting loading book Time and motion study

Quality Check : 

Quality Check Inline quality check End-line quality check

Inline : 

Inline Inline inspection is done after every critical operation. This are---- Collar end Sleeve and cuff end Front end Collar attaching Side seam (feed of arm) End line End of the line inspection is done after the last operation.

Inspection : 

Inspection The evaluation process consists of the following steps applied to each characteristic 1. Interpretation of the specification 2. Measurement of the quality of the characteristic 3. Comparing 1 with 2 4. Judging conformance 5. Processing of conforming items 6. Disposition of nonconforming items 7. Recording of data obtained

Purpose of inspection : 

Purpose of inspection The purpose of inspection and test is to determine the conformance of the product or service to the standard or specific requirements and to disposition the product or service based on the results of the evaluation This determination involves three main decisions Conformance decision: To judge whether the product conforms to specification Fitness-for-use decision: To decide whether nonconforming product is fit for use Communication decision: To decide what to communicate to outsiders and insiders

Washing : 

Washing Location: Texport Syndicate Unit 3  Infrastructure: Tumble drier (60 kg) (Ramsons) : 6 Cooler machine (25 kg) (Ramsons) : 1 Dry Cleaner (25 kg) (Suprema) : 1 Industrial Washing Machine (180 kg) (Ramsons) : 6 Hydro Extractors (25 kg) (Ramsons) : 2 Sample washing machine (20 kg) (Ramsons) : 1

Work force: : 

Work force: Washing head 1 Supervisor 1 Machine operators 2 Helpers 4 Total 8

Process chart : 

Process chart Receive garments from finishing department Check garments in accordance to the quantity mentioned in D.C. Store garments in before wash racks Buyer approved wash standard received from merchandiser Carry out 1st bulk wash Identify the faults and make changes to the recipe

Continue….. : 

Continue….. Bulk wash ranges send to buyer with comments Comments received from buyer Bulk washing is carried out Hydroexractor Tumble dry

Continue……. : 

Continue……. Garments are inspected as per A.Q.L 2.5 Grinding if required for the style Garments send to finishing for packing

Finishing section : 

Finishing section Ironing  Final Checking  Presentation checking  Measurement checking  Tagging  Poly bag packing  Middle checking  Carton packing Counter checking  Button mark & sew  Batch Receiving  Kaja and bartack  Send for washing  After wash checking Trimming

Packing : 

Packing This is a part of finishing section, but maintained differently and inside a cabin –like-structure. Here all the final processes of packing the garments for the dispatch is done. The processes followed inside are: 1.jocker tag attachment 2.price ticket attachment 3.garment folding 4.poly bag packing 5.Carton packing

Shipment : 

Shipment A quantity of good that are shipped together as a part of same cargo. Once the production is done than the garments are packed in accordance to the buyer specifications.the packed garments are then needed to go for shipment . This is done by the following wasys 1.truck/lorries 2.train 4.ship 4.by air

Slide 38: 

Implementation of statistical process control in sewing floor project

Slide 39: 

Identify the defects of the past data To calculate defects rates Institute p chart Classify the defects objectives

Slide 40: 

Hourly production defect analysis and correction reports P chart Materials

Slide 41: 

Batch-3,5 and 6. Based on End line inspection report UCL and LCL based on that day data for analysis Formulation of p chart

Slide 42: 

pi = number of non conforming units ni = sample size Formulae

conclusion : 

conclusion Concluding this internship at TEXPORT SYNDICATE is not an easy task .we had a great learning experience here during this grilling eight weeks. Before this internship I was with theoretical inputs only but really had no idea how thing change when they are implemented in real industry scenario This internship was voluminously added upto our knowledge and mede us more aware of various problems faced in the industry and ways to tackle with them. We would like to mention that being in TEXPORT SYNDICATE for the past two months and doing internship with guys from different colleges and different centers of NIFT was a good experience and shall be treasured forever.

Slide 45: 

THANK YOU

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