Subject:- PRODUCTION AND MARKETING MANAGEMENT (PMM)

Submitted to :- Prof. RESHMA KUKREJA

INDEX :-

Introduction

History of Jeans

History of "Khushi Garment"

Raw Material Handling

Raw & Auxiliary Materials

The Process of Production

Hanlding Process

Analysis

Bibliography

Acknowledgement

Name of the Firm We Visited:KHUSHI GARMENTS

Roll No. 107 82 89 95 108 111

Names of Group Members:Avinash Sonawane (G.L) Mithun Jalui Sunny Singh Sandip Guneshwar Kundan kamble Umesh Mehtare

INTRODUCTION:It used to be that we just walked into a shop and bought something without sparing a thought for where it came from, or who'd made it. The product we are talking about is found easily, in a glass showroom and steel mall with double doors and escalators, we will find it. And somewhere in the middle, under a huge sign saying: "Famous Brands for Rs.3,000" Just a pair of jeans, nestling among dozens of identical others. Blue stonewashed denim five-pocket jeans, straight leg, zip fly. Lee Cooper LC10s, to give them their proper name. Today we are going to discuss you how the production of jeans takes place. We visited a manufacturing industry named Khushi Garments. In the industry, they showed us how manufacturing of jeans takes place but before going on that I want to share some basic knowledge of Jeans. Jeans are a world famous and mostly prefer by teenagers and young age people. Jeans are trousers made from a different cloth or fabric know as Denim. Denim is a name of the cloth which is used for making of jeans, this word Denim came from country France, de Nimes serge de Nimes

History of Jeans:-

Levi Strauss was a German-born American businessman who founded the first company to manufacture blue jeans. Some of the earliest blue jeans were made by Jacob Davis, Calvin Rogers, and Levi Strauss in 1873. Starting in the 1950s, jeans, originally designed for cowboys. Historic brands include Levis, Lee and Wrangler. Jeans come in various fits, including Skinny, tapered, straight, boot cut and flare. Jeans are now a very popular form of casual dress around the world, and have been so for decades. They come in many style and colors; however, "blue jeans" are particularly identified with all cultures.

History of Khushi Garments:-

Khushi Garments was started around in year of 2002, now the firm is on its 10th year. They started their firm in a place by rent and with only two employees or workers. They slowly and gradually expanded their firm as well as process by establishing more machines to it and hiring more workers. Now the firm have its own place and better and more flexible then the rent one and almost 40 workers are working in khushi Garments.

Raw Material Handling:-

The raw material which is needed in production of jeans are denim rolls. In Khushi Garments the denim rolls are purchased from a Ahemdabad supplier. The firm always order 50 - 60 rolls for kept therein for not delay in production process. They also have a separate room for storage of raw materials. And the rolls of denim were stored properly and in decent manner. They order rolls from suppliers according to their needs and other factors likes expected future rise in price.

Sr No.

Description

Qty.

A. Major Raw Material

1.
Denim Cloths (60-70 Rolls)

375000m

B. Auxiliary Materials
1. 2. 3. 4. Fabric for internal lining Thread Buttons Zip Fasteners Lumpsum Reqd. Lumpsum 2,52,000 pcs

RAW AND AUXILIARY MATERIALS REQUIREMENT AND COST :-

RAW AND AUXILIARY MATERIALS:The major raw material required for the preparation of jeans is cotton fabrics dyed and finished with different colors. The cotton fabric used for jeans preparation is usually hard blue cotton twill, also known as

denim cloth. This material can either be imported or locally produced and used for this purpose as long as it meets the required quality and specification. Auxiliary materials consist of thread, zip fasteners, button, labels and packing materials. The annual requirements of raw and auxiliary materials together with costs at full capacity production of jeans production industry is given in Table above.

The Process of Production:-

Different Parts are Cut from Denim are as fallows :1.Front part (1) 2.Back part (2) 3.Waist belt (2) 4.Belt loop (5-6)

5.Fly piece (2) 6.Large pocket (4) 7.Small pocket (1) 8.Pocketing fabric (2) 9.Support fabric (2 ) Machinery and Equipment Required by Jeans Manufacturing Industry: Sr. No.
1. 2. 3. 4. 5. 6. 7.

Description
Sewing Machine Electric knives fitted with Disc Lapping trolley Electric iron Dyeing Machine Spraying Machine Washing Machine

Qty.
22 10 8 20 9 2 1

Sewing Machine

electric iron

Lapping trolley

Dyeing Machine

Spraying Machine

Washing Machin

1) Roll of Denim Fabric:-

The one roll of denim fabric is lifted or handled horizontally my something and then spread it in a particular length and makes a bunch of it. Then the design of different sizes and pockets are kept over it and cut it according to that size. It is cut as front side and back side. The many layers of fabric are cut into pieces for legs, pockets, waistband and accents. The pieces are bundled together by component, with up to 100 layers of cuts ready to go.. Their were different machines for cutting (small and big one) according to the bunch and design.

2) Sewing and Finishing:-

The jeans head over to the sewing machines, where they're sewn by workers on incredibly fast industrial machines. According to Jeans Info, an average worker can piece together a whole pair of jeans in about 15 minutes. Firstly, the front side of jeans are sewed with yoke sheet (inside cloth of pockets)Of pockets by Hunda machine. Afterwards when the front side of jeans are sewed with front pockets then it is over locked with the back side. Then a five thed machine is over locking the bottom of jeans. The second last machine sew the top part of jeans i.e. belt. As the fabric of belt of jeans and on belt grips are too thick so for that the special machine with big needle sew belt grips on the belt of jeans. As a normal machine cant do it. And at last the button to jeans are stitched by another machine. Afterward, the stitched garments are washed in industrial machines and processed for color.

3) Handling Process:-

After all this the jeans are stored in a separate room. Where jeans are stored for sometime and then it will takes to their another place for dyeing of jeans which make it looks like brand new product. The storage facilities are good and the room is separated from the production process.

4) Dyeing And Washing:-

When jeans are brought to another place of industry. This can mean dyeing in rock stone washing as well as other embellishments. To list all the washings that we have been asked to do before would probably take a few weeks and several pages to list, so we'll just talk about the most well know washings first.

1) Rinse (water) Wash:-

Speaks for itself mostly . Like in the good old days the jeans will be washed at about 50 degrees Celsius. High risk of color bleeding , so ideal to use for brightening up your old faded jeans by washing them together. Make certain to wash separate from other garments the first few times. Some Jeans brands will even not use sanforized fabric, so that you can shrink them to fit in a hot bath. This was (again) very popular back in the 80's.

2)Stone wash/Stone liquid :-

Still the most famous of all washings. The jeans are washed with oval or round pumice stones which should all have roughly the same format. The pumice stones are very light with a rough surface. Sometimes, when the final quality inspectors at the jeans factory forget to clean the pockets, you may even find some residue of these stones in the pockets of your new jeans. During the washing process these stones will scrap off a thin layer of the denim does showing some of the white threads from the part of the cloth where the indigo dyeing stuff was not able to penetrate. It also creates and effect called brilliance. You may also encounter words like deep stone or super stonewash, which are an indication of how long the jeans have been stonewashed. Ergo: The longer the wash, the lighter the jeans. For over thirty years, manufacturers of jeans and denim fabrics have used enzymes, stones, and pumice to create a "stonewashed" look. Essentially the goal has been to "age" the fabric so that it looks worn and feels much softer. For many years the process involved washing-out the sizing, and then washing the denim in large commercial/industrial machines with either enzymes or stones, or both. The result was a finish which through abrasion and chemistry made a new product look old, worn, and comfortable.

Unfortunately with traditional "stonewashing", large, expensive laundry machines are abused by the same process which works on fabric, and basic denim can be abraded too much. During the last ten years, alternatives to real stones (volcanic pumice) have been tested by all the major jean manufacturers. The goal has been to reduce the amount of maintenance required when using stones, and to achieve a softer finish. After years of testing, many are using various grades of pertile. Perlite has been found to perform many of the same properties as stones. It produces a much softer, pliable finish, and it reduces substantially the wear on the machines. Perlite also gives a worn, finished look throughout the fabric and not just on the upper surfaces. In some cases it also has allowed a reduction in the use of enzymes which chemically attact the fibers and ultimately result in fabrics that wear-out very quickly. Currently many grades of perlite are being used ranging in size from the largest horticultural grade to the finest grades (see either Finishing with Perlite) or Standard Gradations of Horticultural Perlite----Fine, Medium, and Coarse). Some manufacturers also use a very, very fine filtration grade similar in size and appearance to DE (ground, and milled diatomaceous earth). The exact gradations of perlite used and the special enzymes chosen are considered proprietary process information by all the large finishing companies. And yet more and more stonewashing is being done every day with basic perlite both in this country and many others.

3)Overdye:- An additional dying after the jeans have been sewn. This ensures a
very deep dark or black color and makes the sewing thread blend in with the jeans color.

4)Dirty Wash: After stonewashing the jeans or denim jackets, they will be dyed
with special chemicals thus creating a look in which the jeans will appear to be dirty.

5)Destroyed / Damaged / Used / Whiskers:

There are several different techniques to make the jeans or denim jackets look old, worn and /or used. Most of these techniques involve actual sandblasting or abrading by some kind of power tool. Whiskers, which normally appear around the hip to crotch area of the pant, are usually made by using a grinder. Another popular way to make jeans appear damaged is to cut the edges at bottom, (back-) pockets, fly and knee area before the (stone)washing.

6) Spraypainting:-

From the high-tech side there has been a renewed interest in the jeans and garment industry in general. A few of the very cool new inventions are: the jeans laser marker and the Jeans spray robot, as shown below. However, due to the relative high cost of these machines they are hard to find in these parts of asia. In that place there were six dyeing machine and 5 Hp Motor is used in every machines and 3 phase power is used. According to supervisor, every dyeing machines takes approximately 6 7 hour taken by each machine to dye. And 60 70 pieces of jeans are kept in dye machine at a time. They are using rock stones in liquid form and different colors, mostly Indigo blue dye is used. After dyeing the last step is washing of jeans. Their was one big machine used for washing of jeans.

Analysis:1) Firstly Denim roll is cut in different piece like size, pockets, designs and patterns. 2) Then it moves towards sewing and over locking.

3) Then it keeps for storage in separate room for shifting it to another process i.e. dyeing of jeans. 4) The dyeing process takes 6-7 hours per machine and it dyes 60-70 piece at a time.

5) Then it keeps for drying.

Bibliography:1)Khushi Garments 2)Internet:a) www.wikipedia.com b) www.guardian.co.uk