GARMENT INDUSTRY

INTRODUCTION:
GARMENT INDUSTRY HISTRY:

As early as 1860 the manufacture of ready-to-wear clothing became one of Cleveland's leading
industries. The garment industry probably reached its peak during the 1920s, when Cleveland ranked close
to New York as one of the country's leading centers for garment production. During the Depression and
continuing after World War II, the garment industry in Cleveland declined. Scores of plants moved out of
the area, were sold, or closed their doors. Local factors certainly played their part, but the rise of the ready-
to-wear industry in Cleveland, as well as its decline, paralleled the growth and decline of the industry
nationwide. Thus the story of the garment industry in Cleveland is a local or regional variant of a much
broader phenomenon.

In the early 19th century clothing was still handmade, produced for the family by women in the
household or custom-made for the more well-to-do by tailors and seamstresses. The first production of
ready-to-wear garments was stimulated by the needs of sailors, slaves, and miners. Although still hand-
produced, this early ready-to-wear industry laid the foundations for the vast expansion and mechanization of
the industry.

The ready-to-wear industry grew enormously from the 1860s to the 1880s for a variety of reasons.
Increasing mechanization was one factor. In addition, systems for sizing men's and boys' clothing were
highly developed, based on millions of measurements obtained by the U.S. Army during the Civil War.
Eventually, accurate sizing for women's clothing was also developed.
ORGANISATIONAL CHART
GOKILA GARMENTS:

Gokilaa garments, an illustrious manufacturer and exporter of knitted and woven apparels have
cropped up from a very small startup in 1997. With the consistency in quality and workmanship, we have
come long way up here and achieved a very strong hand in the European and Middle East Market. There
was a parallel road of this growth from our customers as well. Our foremost employees, Partners and Buyers
take a huge share in this success.

WHO WE ARE:

We started up in 1997, with a vision of unanimously interlacing the comfort life style with our
casual clothing. Since then, we bettered ourselves gradually and delved into a vast experience in the field.
With futuristic technologies in the house, we owe the competence in delivering qualified products which
made us to stretch our product portfolio to any design in knits and woven. Furthermore, our prowess in
garment making brought us a limelight of recognition from the Government of India to become an Export
House. We assure our quality outfits are made and delivered with absolute care and perfection.

CERTIFIED WITH:
INFRASTRUCTURE:

Based in Tiruppur, an Export hub of India, Our factory has a very safe and convenient work
atmosphere assured to all our employees and partners. With the ability of producing of 250000 garments in a
month, we in parallel line, keep ourselves abide to compliances and audit regulations. 500 machinists are in
the operations to ensure the best garments been produced along with the couple of state of the art printing
and embroidery machines. Any design can be done here with absolute perfection

Machinery list Unit 1 Unit 2 Unit 3

Production 230 85 45

Finishing 13 05 03

Special 07 04 03
machines
Printing

Machine 1 M and R fully Automated chest printing(16 colors 20 palette)

Machine 2 M and R fully Automated chest printing (12 colors 14 palette)
Embroidery
Machine 2 Tajima computerized machine 12 colors 40 heads

STYLE CIASS AND FABRICS:

We make T-shirts, Polo shirts, Ladies Tops, Cardigans, Sweatshirts, Jumpers, Pyjamas, Shorts,
Cropped Pants, Leggings, Underwears, Socks, Slippers and Bags. Our Fabric range encompasses Jerseys,
Rib, Fleece, French and American Terry on Cotton and Polycotton. Any design on Viscose, Polyester, and
Modal, Slub, Lycra Slub, Insect Slub and Cotton fabrics can be done with perfection
 COMPANY PROFILE:

 Kids wear
 Men’s wear
 Women swear
 Sportswear
 Nightwear
 Knitted Accessories

 Contact Us

 Managing Directors
Rtn. M. SHANMUGAM + Rtn. N. GOPALAN
+91 9894648844 +91 9894648855
gopalan@gokilaa.com

 Managing Partner
S.RAVI
+91 8220448844
ravi@gokilaa.com

GOKILAA GAARMENTS
GOVERNMENT RECOGNISED EXPORT HOUSE

OLD NO:3/306/S.F.NO:302/2A1 (new)

Kuppandampalayam, veerapandi, (po)

Palladam road, trippur-641605

Phone: 0421-2266000to2266030

Fax: 0421-2217709

www.gokilaa.com
PATTEN MAKER:
 Readymade Denim Garment Manufacturers near me
 Children Corduroy Trouser Wholesalers near me
 Children Ethnic Wear Exporters near me
 Seeka Children Ethnic Wear Manufacturers near me
 Children Readymade Garment Exporters near me
 Embroidery Accessory Retailers near me
 PVC Elastic Manufacturers near me
 Silk Wholesalers Retailers near me
 Safety Mask Exporter near me
 Elastic Fender Dealers near me
 Fiber Mannequin Wholesalers near me
 Sports Legging Distributors near me
1. PRODUCTION:

Meaning of Production:
Since the primary purpose of economic activity is to produce utility for individuals, we count as
production during a time period all activity which either creates utility during the period or which increases
ability of the society to create utility in the future. Business firms are important components (units) of the
economic system.

Products

 MEN’S WEAR
 KID’S WEAR
 LADIES WEAR

We proudly supply to
METERIAL:

Textile fibers refer to filaments or threads which are woven, knitted, matted or bound to be used to
make fabrics for different purposes. To put it in perspective, Fabric is made from yarns and yarn is made
from fibers.

Textile fibers are generally classified as natural textile fibers and man-made fibers. As man advanced in
textile technology he has discovered a variety of man-made as well as natural fibers which have been a boon
to designers looking for different characteristics in the textiles they use to design their creations with.
INVENTORY:
Management of inventory is not an easy task; you need to be careful when you work with inventory
management. Textile and garments industry is huge in terms of volume of production as the demand for
clothes is increasing day by day. In an apparel industry, you may have to keep inventory in different forms.
It can be of raw materials or finished goods. Because of the extra burden of improper inventory planning
every year apparel industry incurring a huge cost which ultimately decreasing the profitability of that
company.
List of Inventories in Textile and Garments Industry:
1. Raw Materials (Yarn, Dyes Chemicals, Packing Materials, Trims, and Accessories, etc.)
2. Semi Processed Materials (Gray Fabric)
3. Finished Goods (Garments Products)

1. Receiving Fabrics

Garment factories receive fabric from overseas textile manufacturers in large bolts with
cardboard or plastic Center tubes or in piles or bags. The fabric typically arrives in steel commercial
shipping containers and is unloaded with a forklift. Garment factories often have a warehouse or
dedicated area to store fabric between arrival and manufacturing

2. Fabric Relaxing

“Relaxing” refers to the process that allows the material to relax and contract prior to being
manufactured. This step is necessary because the material is continually under tension throughout the
various stages of the textile manufacturing process, including weaving, dyeing, and other finishing
processes. The relaxing process allows fabrics to shrink so that further shrinkage during customer use is
minimized.

3. Laying

 Lay large pieces first and then fit in the smaller ones
 It is very economical in laying the pattern and cutting. Even a small amount of material saved in
a single layer will help to bring about a large saving of money as hundred’s of layers of fabric
will be laid and cut simultaneously.

4. Marking
 This can be a manual or a computerized technique

 The marker planner uses full-size patterns and arranges them in an economical manner on
marker paper.
  This is a specially printed paper having symbols on it which enable the marker planner to
visually control the positioning of components according to specified grain lines.
 Markers produced on paper are fixed to fabric with pins, staples or on an adhesive paper which
is heat sealed to the top layer of the fabric.

5. Cutting

 A first planning consideration is whether the totals arrived at in the cutting room are the same
as those required to maintain full production in the sewing room and subsequently the planned
delivery schedule
 Assuming all components of fabric, design, and trims are acceptable and correctly planned and
cut, the next stage is to extend the cutting room programme to the sewing room.
 All cutting operations are carried out by straight knife cutting machines.

6. Embroidery and Screen Printing

Embroidery and screen printing are two processes that occur only if directly specified by the
customer; therefore, these processes are commonly subcontracted to off-site facilities. Embroidery is
performed using automated equipment, often with many machines concurrently embroidering the
same pattern on multiple garments. Each production line may include between 10 and 20 embroidery
stations. Customers may request embroidery to put logos or other embellishments on garments.

 The central process in the manufacture of clothing is the joining together of components.
 Stitching is done as per the specification is given by the buyer.
 High power single needle or computerized sewing machines are used to complete the sewing
operation. Fusing machines for fusing collar components, button, and buttonhole, sewing
machines for sewing button and buttonholes are specifically employed.

7. Checking

 Establishing a standard as a criterion for measuring quality achievement.

 Production results can be measured and compared to the planned quality standard.
 Corrective measures to be carried out if there are any deviations in the plans.
8. Spot Cleaning and Laundry

In addition to identifying manufacturing defects, employees tasked with performing quality

assurance are also looking for cosmetic flaws, stains, or other spots on the garment that may have
occurred during the cutting and sewing processes. Spots are often marked with a sticker and taken to
a spot-cleaning area where the garment is cleaned using steam, hot water, or chemical stain
removers.

9. Fusing and Pressing

Fusing and pressing are two processes which have the greatest influence on the finished look
of a garment. Fusing creates the foundation and pressing put the final seal of quality on the garment.

After a garment is fully sewn and assembled, it is transferred to the ironing section of the
facility for final pressing. Each ironing station consists of an iron and an ironing platform. The irons
are similar looking to residential models but have steam supplied by an on-site boiler..

10.Packaging and Shipping

In the last steps of making a product retail-ready, garments are folded, tagged, sized,
and packaged according to customer specifications. Also, garments may be placed in protective
plastic bags, either manually or using an automated system, to ensure that the material stays clean
and pressed during shipping. Lastly, garments are placed in cardboard boxes and shipped to client
distribution centers to eventually be sold in retail stores.
 Process Flow Chart of Merchandising:

Receive product package form buyer

↓
Sample development
↓
Price negotiation
↓
Order confirmation and receive order sheet.
↓
Sourcing acceptable quality goods right time
↓
Material collection and receive it in factory
↓
Check and listing
↓
Swatch card making and approval
↓
Pre production meeting
↓
Daily collect daily production report and daily quality report
↓
Arrange final inspection
↓
Shipment
services of value with other

1. Concepts of Knit Garments Merchandising

2. Career in Merchandising: Factory vs Buying House
3. Role of Merchandiser in Apparel Industry
4. Study on Merchandiser and Merchandising in Apparel Industry
5. Process Flow Chart of Apparel Merchandising
6. Introduction of Merchandiser/Merchandising
7. How to Become A Successful Apparel Merchandiser
Purchase Department in a Garment Company:

The purchasing department in a garment company is similar to the sourcing department but the main
difference is that the sourcing department works for sourcing the fabrics alone while the purchasing
department works for sourcing the accessories and trims.

Quality control department:

Quality means customer needs is to be satisfied but maintaining an adequate standard of quality also
costs effort. There are a number of factors on which quality fitness of garment industry is based such as -
performance, reliability, durability, visual and perceived quality of the garment. Quality needs to be defined
in terms of a particular framework of cost produce work of good quality.
Process flow chart of quality section:

Working procedure of quality control department in apparel industry:

Fabric Inspection and QC Procedures: Incoming fabrics are inspected at JC Penney’s

recommended 4 Point system. 100% fabric is inspected by fabric QC’s. Each fault is given points keeping in
view the nature and intensity of the faults. 40 Points are allowed in 100 inspected yards. If number of
faults/points exceeded than 40 per 100 yard, the fabric roll is rejected. Lab test reports are also taken from
fabric suppliers and verified through internal and third party labs randomly.
Accessories Inspection:

Access ories at the time of receipt in store are randomly inspected by QC’s/concerned persons at least
up to 10% of the received quantity.

Cut Parts Inspection: 100% cut parts are inspected before input to sewing. The rejected components are
replaced from remnants or removed. Cut parts are also inspected 100% before sending and after receipt from
printing and/or embroidery.

Sewing Inline Inspection:

During stitching operations, the inspections are done on JC Penney’s recommended 7-0 System.
Inline QC inspects 7 pieces randomly for each machine operator twice a day. If he finds any fault among
these 7 inspected pcs, the Sewing operator has to inspect the whole bundle himself and offer inspection
again to Inline QC. If the inspection is fault free, then this sewing operator will undergo follow up inspection
of 03 Consecutive bundles. If 03 Follow up Inspections are ok, the Inline QC moves to next machine
operator.

Sewing End Line Inspection:

100 % garments are checked on sewing related faults after sewing completion. Both in and out sides
of the garments are inspected.
Use of Auto Trimmer & Thread Sucking Machines: We are using Auto Trimmers for clipping to
avoid un-necessary clipping cuts during this process. We are also using thread sucker machines to ensure
that packed garments are free from loose threads.
Final QC Inspection:

Garments are checked 100% on quality after pressing for fabrication, finishing, appearance, sewing,
shading, labeling etc. to make sure that quality garments are packed into cartons.
Measurement Specs Control

Before packing, garments are 100% checked on measurements for key measuring points.
Internal Q.C Lab & Third Party Testing:

Fabrics and garments are randomly tested at internal QC lab on fabrics’ basic performance
features like fabric weight, shrinkage, torqueing, color fastness, PH Value etc. In addition to this, garments
are sent to third party labs (SGS, ITS, BV) for independent testing to make sure that the outgoing goods are
meeting customer’s required quality standards.
2. MENUFACTRING DEPARTMENT

Introduction:

Production Merchandising is a function of multiple activities performed by a person which are either parallel
or inter connected. Some of them are interdependent and others are independent of each other.
Merchandising involves planning and execution of the export order with the right place, at the right time, in
the right quantities, at the right price.

1. Product development:

Product development is the business policy of the organization which includes the development
of the new designs and styles within the organization. Whenever buyer visits to the organization,
presentation of new color, prints, embroidery patterns and desk loom developments is done by
production merchandiser.

2. Sampling:

Sampling is one of the main processes in Garment manufacturing and it plays vital role in
attracting buyers and confirming the order, as the buyers generally places the order once satisfied with the
quality and responsiveness of the sampling. Sampling is the most crucial and most important stage of
fashion merchandising. Sampling department makes samples on the basis of the specification and
requirement by the buyer.

3. Costing:
 Trims
 CMT
 Value added services: printing, embroidery, washing, applique
 Testing
 Transportation and logistics cost
 Profit of the manufacturing organization
 Currency exchange rate
 The role of merchandiser does not end only after calculating the cost, but after quoting the cost
merchandiser need to negotiate with buyer on cost of the garment.

4. Planning (Time and action calendar):

Production merchandising is an interdependent activity. Successful merchandising is outcome

of effective preparation and follows up of time and action calendar by all departments. Time and Action
Calendar or TNA, a most important jargon used in fashion merchandising, it is an effective way of
coordination and following up of important milestones in preproduction processes to ensure timely
delivery within stipulated delivery date.

5. Communication:

Communication is a most important aspect of any export order process. Merchandiser must be
able to communicate with buyer and with internal departments effectively to process the export order
effectively. There are several modes of communication like telephone, email, actual meetings, fax etc.
merchandiser must aware of etiquettes to use these modes of communication.

6. Coordination:

Coordination is the major aspect of fashion merchandising, one need to coordinate with all the
departments within the organization and outside the organization in order to run the export order
successfully. Production merchandiser needs to coordinate with buyer as buyer also takes the follow up
from merchandiser. Merchandiser provides the formats to the buyer like production status report,
packing list, TNA etc.

7. Sourcing:

As soon as the fabric is in the stores, then only the sourcing of the threads start because the
colour of the thread must match the buyer’s requirements. Sourcing department along with
apparel merchandiser plays the vital role to execute and shipment of export order successfully.
2. MARKETING DEPARTMENT:

 A marketing department promotes your business and drives sales of its products or services. It
provides the necessary research to identify your target customers and other audiences. Depending on
the company's hierarchical organization, a marketing director, manager or vice president
of marketing might be at the helm.
 It serves as the face of your company, coordinating and producing all materials representing the
business. It is the Marketing Department's job to reach out to prospects, customers, investors and/or
the community, while creating an overarching image that represents your company in a positive
light.
 In the fashion and textile industry marketing roles are involved in selling and promoting products to
retailers, brands, or suppliers.

 Knowledge and job skills for a Marketing manager:

These job skills and knowledge’s are very essential who are interested to consider a career as
a marketing manager.

 An analytical and creative mind

 The ability to priorities
 Excellent communication and presentation skills
 Good literacy, numeracy and IT skills
 Strong people management skills
Sales turnover:

Annual turnover is defined as the total sales revenue of a factory in a year (financial year).
By selling garments or exporting garments the total revenue earned by a garment factory during a financial
year is its Annual turnover for that financial year.
To get factory's annual sales turnover total up all the sales the company made in the financial year.
If sales value does not exist with accounts department then you can follow following steps to get
your annual turnover.
 Collects all PO shipped during a time period from merchants or shipping department.
 Check PO wise quantity shipped and FOB and calculate PO wise revenue earned by the company
 Total up sales revenue of all PO.
 Thus you get annual turnover of your factory.
Competitors:

As a small-business owner, it's probably hard for you to wrap your head around the idea of a billion-
dollar industry. But just in case you want to try: The U.S. clothing market is the biggest in the world, with
consumers ringing up about $292 billion on store-based purchases alone, according to Statist. Another
statistic is likely to resonate with you even further: Clothing industry analysis shows that the average
consumer buys about 60 percent more clothing than he did 15 years ago.

Is this because clothing is trendier? More affordable than ever? Or those retailers are finessing their
ability to engender brand loyalty? Most likely, it involves a little bit of all three factors, which portends good
things for your small business, whether you're a clothing designer or retailer. But since competition in the
fashion industry often results in a contest of survival of the fittest, it's smart to size up four competitive
challenges just as carefully as a customer will size up your offerings.

Market share
3.FINANCE DEPARTMENT:

The finance department is responsible for managing all the financial administrative affairs of the
company and has a very important influence on many of the policy and commercial decisions taken
by management. The financing of a company’s operations require precise timely planning and control in
order to ensure that adequate funds and credits are available when needed.

The finance department is responsible for managing all the financial administrative affairs of the
company and has a very important influence on many of the policy and commercial decisions taken
by management. The financing of a company’s operations require precise timely planning and control in
order to ensure that adequate funds and credits are available when needed.

Apart from the money to pay suppliers, salaries, expenses, etc funds have to be on hand to finance
stocks of raw materials and finished goods. In periods when trading is difficult and revenues are down,
provision has to be made to cover such periods.
Some important functions performed by this department are:

1. Providing management information

2. Budgeting
3. Garment costing
4. Administration.
1. Management Information:
In the world of business, success or failure is ultimately measured by money and therefore it is
essential that the financial pulse of the company is under continual measurement. This department is
directly responsible for providing the management with up-to-date information on the current and
future financial status. Some typical reports prepared for management are: balance sheets,
stock levels and values, production costs, operating statements for different departments, cost rejects,
returns etc.
2. Budgeting:
The object of budgeting is to plan and control the company’s activities so as to maximize
profitability, and the starting point for all budgeting is the sales budget. This is usually drawn up
before the beginning of each financial year or season considering the sales to be established and new
 customers, general economic trends at home and abroad, manufacturing capacity and availability of
finance. Other budgets considered are: labour costs, material costs, overheads, and departmental
budgets.
3. Garment Costing:
It is the ‘identity card’ of the garment and contains all the information required for the pre-
production and production stages making garments. The costing sheet shows the detailed costs for:

 Material,
 Labor,
 Fixed and variable overheads,
 Other expenses.
The information for garment costing comes from various sources: sample section, cutting room,
break down time values and costs involved in cutting, sewing and finishing, costs of trims and
materials, overhead costs from finance department.

4. Administration:
All the departments in a clothing industry require administrative support for their operations
to ensure orderly and systematic functioning.

5. The procedures covered are;

 Preparing orders to supplies,

 Checking goods inwards,
 Timing and methods for stock taking,
 Imports and exports,
 Obtaining credits for returned goods and materials,
 Issuing credits for customer returns,
 Negotiating and issuing tenders for major projects,
 Purchase of office furniture and equipment etc.
A clothing business has ‘up-front’ departments such as design, marketing and production and the fact
that they function smoothly is the result of good administrative support.
 The financial account of the balance of payments saw a net capital outflow of EUR 2.9bn in the
third quarter of 2017 (up EUR 0.5bn over the same period in 2016). Broken down by account, the net capital
outflow was recorded in the account of other and portfolio investment, international reserves edged up and
only the account of direct investment saw a net capital inflow
4.HUMAN RESOURCES DEPARTMENT:

Human resources is used to describe both the people who work for a company or organization and
the department responsible for managing resources related to employees. The term human resources was
first coined in the 1960s when the value of labor relations began to garner attention and when notions such
as motivation, organizational behavior, and selection assessments began to take shape.

Human resource management is therefore focused on a number of major areas, including:

 Recruiting and staffing

 Compensation and benefits
 Training and learning
 Labor and employee relations
 Organization development

Due to the many areas of human resource management, it is typical for professionals in this field to possess
specific expertise in one or more areas. Just a few of the related career titles for HR professionals include:

 Training development specialist

 HR manager
 Benefits specialist
 Human resource generalist
 Employment services manager
 Compensation and job analysis specialist
 Training and development manager
 Recruiter
 Benefits counselor
 Personnel analysis

Past Future

Work 9 to 5 Work anytime

Work in an office Work anywhere and from anywhere

Use company equipment Use your own modern gadgets and

requirements
 Focused on inputs Focused on outputs

Climb the corporate ladder Create your own ladder for career

Pre-defined work Customized work

Hoards information Shares information

No voice Can become a leader

Focused on knowledge Focused on adaptive learning

Purpose of Human resource management:

The purpose of the Human resource management is to make the job and deal with the job holder
(employee). So as to perform a job in an organization, one needs to be identified. In order to identify right
person for a particular job, notification should be issued which contains job description (duties and
responsibilities) and specifications ( academic qualifications and physical qualifications). So as to verify the
correctness of the candidates invited, they should be tested by the suitable selection methods for picking-up
right person. Subsequently selected candidates should be provided with the proper training for performing
his duties & responsibilities mentioned in the notification. Later, assessment of employees' performance
should be done to know whether employees are performing to the desired standards set by the management.

Responsibilities of the Human resource manager:

 To develop a thorough knowledge of corporate culture, plans and policies.
 To act as an internal change agent and consultant.
 To initiate change and act as an expert and facilitator.
 To actively involve himself in company’s strategy formulation.
 To keep communication lines open between the HRD function and individuals and groups both
within and outside the organization.
 To identify and evolve HRD strategies in consonance with overall business strategy.
 To facilitate the development of various organizational teams and their working relationship with
other teams and individuals.
 To try and relate people and work so that the organization objectives are achieved effectively and
efficiently.
 To diagnose problems and to determine appropriate solution particularly in the human resources
areas.
 To provide co-ordination and support services for the delivery of HRD programmers and services.
PLANNING:
Planning is the first and basic function of the management and everything depends upon planning as
it is a process of thinking about things before they happen and to make preparations in-advance to deal with
them. Poor planning results in failure and effects overall system. Therefore HR Mangers should be aware of
when is right time to do things, when things should be done and when things should not be done in order to
achieve goals and objectives of the organization.
SUGGESTION:
 The PROKINTS company has providing all the facility to the worker.
 But, want to increase the salary some more high because compare to another
organization here the salary is low so they want to improve the salary .The salaries
want to give according to their performance.
 Organization want to provide transportation facility to the workers then only they feel
happy and their morning tension will be reduced.
CONCLUSION:
 It’s very useful to me.
 Because, I learn about how to maintain organizational as good way.
 The all the deportments heads are giving the clear explanation about company
maintenance.
 In the training as to give me the more ideas about company management.