Forbes Campbell Knitwear Belgaum COMPANY PROFILE

Name of the Company Address of the company :

: Campbell Knitwear Ltd Campbell Knitwear Ltd Post Marihal, Bagalkot road Dist Belgaum- 591167 Karnataka India.

Year of Establishment Nature of industry Head office of the company Corporate office

: : : :

1995. Textile Industry. Mumbai. Khatau House, 2nd floor, 410/411 MogulLane. Mahim (west) Mumbai-400016-India.

Website

www.campbellknitwear.com

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Forbes Campbell Knitwear Belgaum

Forbes Campbell Knitwear (Div of Forbes Gokak Ltd.) is designed as down stream integration to add the value to yarn produced by Gokak Mills a division of Forbes Gokak Ltd., a member company of our parent group. Forbes Campbell Knitwear (Div of Forbes Gokak Ltd.), project is located 18 kms away from Belgaum city (North Karnataka) surrounded by lush green pollution free farms our plant is accessible by air, rail and road from Bombay and Bangalore. Goa is only 150 Kms away from our plant.

While establishing the plant emphasis was laid

on being eco friendly and azo effluents,

free. The plant has fully automatic water treatment plant for recycling the

captive power generation and water supplies. It uses dyestuff supplied by global firms like ICI Sandoz, Ciba and Atul etc. the waste water is released for afforestation, which they are developing with plantation over 250 acres of hilly land around factory.

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Forbes Campbell Knitwear Belgaum The company has spent US $ 8.00 million on this project and the investments in most modern machinery and equipment with latest technology. The machines are imported from Italy, Germany, Switzerland, USA, Japan and Sweden etc.

They have in-house training faculty fresh workmen are recruited so as to suit and mould them in our working environment. It has a team of young and energetic workmen with an average age of 24 years. Campbell do not recruit anyone below 18 years of age and all the rights of the workmen are protected. With such human technical infrastructure and corporate backing Forbes Campbell Knitwear (Div of Forbes Gokak Ltd.), is committed to the world class product. KEY INFORMATION Products Garment Fabric Dyeing Capacity Month Fabric Knitting Capacity Fabric Specification Shrinkage Order Size Lead Time Payment Terms Our Bankers Polo shirts and T-shirts for men, women and children 2,40,000 garments per month. - 90 MT/Month - 90 MT/Month Pique 165 gsm to 260 gsm Single Jersey 140 gsm to 220 gsm RIB with and without Elastomer Maximum 5 % TUMBLE DRIED Minimum order of 5000 garment (Minimum 900 pcs per color) 30 to 90 days depending on the order Size and requirement of development. Irrevocable confirmed L/C payable at sight. Standard Chartered Bank (Main Branch) 23-25 M.G. Road, Fort, Mumbai-400001

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Forbes Campbell Knitwear Belgaum

Process at Campbell

Receiving orders. Order confirmation. Issuing C.K.Ls order copy. Order planning Kitting Cutting. Sewing. Productions follow up.

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Forbes Campbell Knitwear Belgaum

CLIENTS OF THE COMPANY Country.

USA.

Buyers.
1. Mens wear group. 2. Vantage. 3. PGA Golf. 4. Andrew Sportswear.

Brand Names.
Twin Hill Original. Vantage. PGA Golf. Andrew Sport Destination. Esprit. Smart way. Pierre cardin. Asics.

Europe.

1. Esprit. 2. Smart Way. 3. Worthvaley. 4. Asics.

New Zealand.

1. Wales and makenly

Pearl.

Mexico Oman

1. Mexinde 1. Oman textiles.

The One. Nasse. Joman.

DOMESTIC BUYERS
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Forbes Campbell Knitwear Belgaum

Buyers
Levies. Trents. Shoppers Stop. Killers. Reebok. Proline.

Brand name.
1. Dockers 2. Levies Westside. Stop! Killer Reebok. 1. Proline. 2. Fila. 3. K-Swiss

Arvind brands.

1. Wrangler. 2. Newport. 3. Lee. 4. Flying Machine. 5. Arrow.

J C clothing.

1. M.T.V 2. Mini phoss.

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Forbes Campbell Knitwear Belgaum

NUMBER OF DEPARTMENTS

Yarn department. Knitting section Batch preparation department. Dying department. Sampling Department Cutting department. Embroidery Department. Sewing preparation department. Production/ Sewing department. Packing department. Stores department.

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Forbes Campbell Knitwear Belgaum

YARN DEPARTMENT

This is the starting point of the production process where the main raw material, the yarn is received that goes the metamorphosis of being converted into fully finished garments. The location of the yarn godown is such that the yarns are directly unloaded from the trucks, inside the godown without being damaged. They are stored in a well organized manner and proper records are maintained. Orders are placed with Gokak Mills, it spins the required yarn in 15 to 20 days and sends them to Campbell knitwear limited, 70% of the yarn is brought from the Gokak Mills and other 30% is filled by Arihanta spinningMill (Vardhaman), Amarjyoti Spinning Mill Tripur and mahaveer Spinning Mill and so on.

Types of yarn
Grey yarn. Dyed yarn. Melanged yarn. Polyester cotton yarns. Lycra threads. Viscose rayon. Filament yarn.

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Forbes Campbell Knitwear Belgaum

KNITTING DEPARTMENT

This department is the second step of production where the yarn starts taking a form into a knitted fabric. The temperature maintained normally is between 22 to 26 degree celcius, the machines are set before starting the knitting process. The knitting process goes on for 24 hours a day comprising of 3 shifts when the operators change.

In knitting

department they have circular knitting machines out of which 12 are single jersey machines and 1 is double jersey machine. The machine diameter is selected as per the buyers order, which means lower diameter for kids garment and higher diameter for larger size. The machine stops production automatically when 25 kgs are produced. Roller take down mechanism is used. For cuffs and collars they use flat knitting machine, which can knit four yarns at a time or more, there are 5 flat knitting machines in the company. The company uses programmed floppies for various ribs. Due to the software present inside the machine, rib designing can be done in the machine itself. The maximum collar length that can be achieved in this machine is 50 cms. Gogte College Of Commerce Page 9

Forbes Campbell Knitwear Belgaum

HUMIDIFICATION
The humidification plant is located besides the knitting department to maintain the ideal temperature and pressure for knitting. The temperature maintained normally is between 22 to 26. The relative humidity maintained is 65%. During knitting, a lot of fly and fluff is generated inside the knitting department which obstructs the knitting process and thereby results in a number of defects in the fabric knitted. In order to avoid any such problems, the air inside the department needs to be replaced by fresh air from outside. The humidification plant which supplies fresh air at the right temperature and humidity, thus helping to maintain the quality of the fabric knitted and the working environment inside the department carry on this task of replacement of air.

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Batch Preparatory Department

This department helps the company in taking its foremost step towards maintaining global quality. Once the fabric is knitted it is brought in the form of rolls to this adjoining department and sent to dyeing department in form of Batches.

The fabric is unrolled inspect5ed for defects, reversed and batches are made along with required tapes collars, cuffs and are sent to the dyeing department to be dyed in the same shades. The batches are marked, labeled before sending to the Dyeing Department.

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Forbes Campbell Knitwear Belgaum

Though the fabric-unrolling machine has the capacity of unrolling 600 kgs of fabric per day but based on the order it unrolls approximately only 200 kgs.

Dyeing Department

In this department the fabric takes its true colors and the department consists of:

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Forbes Campbell Knitwear Belgaum Dye Lab Dye Kitchen Dye Section

Dye Lab:

The company has fully fledged lab in their dying house, equipped with all required equipments to test the dyes and chemicals as well as finished fabrics. The laboratory supports the dying department of the company based on the order placed by the buyer the dyes are prepared for the shade required. For the testing of dyes various tests like dry rub and wet rub are done on the swatch sample, all tests are carried out according to ISO standards. The swatch samples are sent to the buyer who then gets it tested by dyeing testing agencies like SGS India etc. In case the tests of the dye lab and the buyers testing agency match, the approval for bulk dyeing is given.

Dye Kitchen:

The dye kitchen is located above the dye lab and which can be broadly divided into three sections: Chemical sectionfor storing the chemicals used for making the dyes Dye preparation sectionwhere bulk dye is prepared. Gogte College Of Commerce Page 13

Forbes Campbell Knitwear Belgaum Dozing sectionwhich consists of dozing tanks for each Dyeing machine. The speed and proportion of dye which is sent to the dying machines is controlled by these dozing tanks.

Dyeing Section

The Dyeing Section consists of 5 soft-flow jet dyeing machine, the capacity of two being 400 kgs each, two being of 200 kgs each and one of 50 kgs. The 50 kgs capacity machine is used for sample dyeing and the rest four are used for bulk dyeing. Also, one garment dyeing machine is used as and when fully finished garments need to be dyed.

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Forbes Campbell Knitwear Belgaum There are five people working for all the dyeing machines in each shift, there are 3 shifts, the work being continued for all the 24 hours.

Dyeing Process
1. Scouring 2. Bleaching 3. Dyeing The whole dyeing process including scouring and bleaching takes around 11 hours.

Finishing Department

The finishing department is adjacent to the dyeing department and is equipped with all modern machinery. The fabric, which are dyed are passed on to this department.

Once dyeing is done, the fabric is squeezed to extract the water. For this there are two machines HYDRO EXTRACTOR of 100 kgs capacity and WEISS SQUEEZING machine of 200 kgs capacity are used. Gogte College Of Commerce Page 15

Forbes Campbell Knitwear Belgaum

The fabric is then passed through the WET SPREADER machine to remove all the ridge marks. The capacity of this machine is 400 kgs per 1.5 hour, temperature required is 140 degree Celsius. This results in shrinkage ranging between 1cm to 2cm, then fabric compacting is done on the compacting machine. This is done to remove shrinkage and set the required GSM of the circular fabric. The fabric is then finally dried by passing it through the RUCKH Drying machine of capacity 1500 kgs / 8 hours.

Sampling Department
The sampling department makes the garment according to the buyers requirements in order to get them approved. Once the sample as approved, the bulk production starts. The placement of the order depends upon the approval of samples sent by this department to the Buyer. There are four kinds of samples. Proto sample Size set sample Pre-production sample Salesman sample

Proto Sample:
They have the main style and fitting features of the garment which are changeable according to buyers needs.

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Forbes Campbell Knitwear Belgaum

Size Set Sample:

These are prepared after the approval of proto sample and consists of all sizes, small, Medium and Large. This sample is important for measurements and fittings.

Pre-Production Sample:
This sample is the exact clone of the garment the factory is supposed to produce in bulk. Three pre-production samples are produced, two being sent to the buyer and one is kept with the company itself.

Salesman sample:
Around 30 to 40 pieces of garments are made and are hung in the shops. When the pre-production sample is approved, bulk production is started. In case of new orders, Pilot run is done within the sampling department and accordingly the production process is changed. The company separately charges for the samples it makes for the buyer.

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Forbes Campbell Knitwear Belgaum

Cutting Department

The cutting

department is situated in between the warehouse and the sewing preparatory department, so the fabric is easily brought from the warehouse, gets cut and moves to the sewing preparatory.

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Forbes Campbell Knitwear Belgaum Various batches of fabric are sent to the cutting department along with the cuffs, collars and trims. Records are maintained in each department and are crosschecked. The cutting department has a capacity of 15000 pieces per day and is equipped with an automatic Dye and Punch Bierrebi cutting Machine. This machine is used to cut the fabric of various dia, acceptable by the machine. The machine cuts 1200 pieces per hour. Band knife is used to cut the collars, cuffs and sleeves. Ten layers can be cut at a time on a bank knife. Collars, plackets and pockets are cut along with the fusing.

Embroidery Section

M/C MODEL DC-6, 18 Heads, TAJIMA M/C is of 18 headed / head 6 needles. Rings Size Used are 7-24 Rings Cost- 14 lacks Threads used are 2 ply embroidery Silk thread 100% Viscose filament rayon 900m/tube- 63 L One Box Contains 10 tubes

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Forbes Campbell Knitwear Belgaum

Supplier:
Regd. Natesh implex private Ltd. Yashawantpur Bangalore-560022 CKL has done more then 300 Designs. M/C are fully computerized. The designs are fed into floppy and these floppies are stored properly. When repeat order comes they have style no and CKL-No. According to which they sort out and do the embroidery.

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Forbes Campbell Knitwear Belgaum

Sewing Preparatory Department

This department lies in between the cutting department and the sewing department. As the name suggests, it prepares the panels to be stitched and made into garments in the sewing department. In this department, the plackets are marked and stitched in the front panel and the moon-patch with labels as per the buyers requirement in the back panels. Cuffs are also attached to sleeves and various other functions are done according to the style of the garment. There are supervisors who keep a track off what the workers are doing check whether the position of labels and pockets are proper and guide the operators accordingly. The department also has a machine for printing with Heat-pressing which is used to print logos or company name on the required panels.

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Forbes Campbell Knitwear Belgaum A yellow card is hanged at each machine which shows how many pieces the operator has been able to produce in a day and whether he has been able to meet the targets. The garment parts are transferred from one operator to the other in crates.

Production / Sewing Department

In this

department, the various garment parts are assembled, top stitched and various finishing touches are given as per the buyers requirement. It is adjacent to sewing preparatory department and Packing Department.

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Forbes Campbell Knitwear Belgaum Based on the orders placed by the buyer, line setting is done in the production department. There are six lines in this department and each line is given a target of number of pieces which they should produce. At the beginning of each line, loading is done. The department is equipped with switch track handling system and single line assembly system is followed. There are 130 various machines installed in the sewing department. There production capacity per day is 10000 to 12000 pieces.

Packing Department
The packing department is adjacent to the sewing department and has an adjacent warehouse from where the cartons can be loaded onto the trucks when the lot is to be sent. In this department the final packing is done. The shirts packed in poly bags from the lines are sent to the department. It is here that they are packed into cartons. There are in all 14 workers in the department who are called as per requirement. When packed pieces of garments are sent to this department from the line, an order slip is also sent along with it. The worker at the receiving counter tallies the number in the slip with the number of garments received. The garments are the packed in cartons in lots of 6 or 10 pieces as per the buyers requirement. A small slip is placed in each carton containing information regarding the following. Serial Number Order Number Date Color Number

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Forbes Campbell Knitwear Belgaum Size Ratio

A sicker is also pasted on the cartons containing the following information. Reference Number Purchase Order Number Style Number Size Quantity Carton Number Country of Origin

Stores Department

It is adjacent to the production and packing department. The stores department has racks in which buttons, labels, threads and various accessories of various orders are kept. The racks are labeled and the accessories belonging to the particular buyer are kept in there respective racks. It also stores the stationery to be used by the various departments. When an order is placed, garment accessories are ordered by the company for bulk production which is then sent to different departments according to the targets and requirements of the day. Labels, which are required by the sewing preparatory department, are sent to that department when the lineman brings the slip with the signature of their supervisor. When this department receives goods, goods Inward Invoice is prepared in which the party name from whom the samples are bought is maintained and sample is attached to it. One copy is kept with the Stores Department, another copy is sent to the Merchandising

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Forbes Campbell Knitwear Belgaum Department. The third copy is sent to the purchasing department. It is on their approval that the payment is made.

FABRIC DEFECTS KEPT IN MIND WHEN INSPECTION IS DONE

Fabric Faults: 1. Color Combination 2. Thick Yarn 3. Thin Yarn 4. Barr effect Knitting Faults: 1. Loop Drop 2. Sinker Line 3. Knitting Hole 4. Needle Line

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Forbes Campbell Knitwear Belgaum Dyeing Faults: 1. Mud Stains 2. Streak Marks 3. Tie Knots 4. Dye Stains

Other Faults: 1. Yellow Marks 2. End of roll 3. Oil stains

Organizational Chart: Chief executive officer

Vice president (marketing)

General Manager (production)

Factory manager (HRD Department)

Marketi Finance ng
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HRD

Mainte nance

Produc tion
Cutting Dept

Knitting Dept

Dyeing Dept

Sewing Dept

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Packing Dept

Forbes Campbell Knitwear Belgaum

FINDINGS

The orders for the year have shown the excess stock of 0.5421% of the total quantity ordered and consumed. The major portion of the excess are o Sewing thread o Buttons o Dyeing chemicals The order has an excess because the pieces projected to be produced are more than ordered because of the wastage in the production process.

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Forbes Campbell Knitwear Belgaum Usually the excess stock can be found in the big orders than the small orders. They have known for their quality. For Balanced pieces, they got two options. They will ask the ordered customer to buy the extra pieces also (Customers will accepts the extra pieces if they satisfied with the quality and product) Other wise they have their own outlets where they market their products and sell to retail customers (One in just side of the Campbell plant and another in Bogar ves).

RECOMMENDATIONS & SUGGESTIONS

As we have seen the above reasons for the Balance occurrence in stocks, the probable suggestions would be The excess ordering should be restricrted to around 0.2%. It can be achievable by having effective control over the all departments. (because already they have well organized departments, Experienced workers in their particular fields) The available stock has to be checked before ordering for materials Gogte College Of Commerce Page 28

Forbes Campbell Knitwear Belgaum

The yarn should be ordered according to the orders only and not on the forecast of orders.

BIBLIOGRAPHY

Forbes Campbell Company Profile Forbes Campbell Company Website Forbes Campbell Company Register Brochures Textile Industry Associations

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