Company Profile: Campbell Knitwear Limited
Company Profile: Campbell Knitwear Limited
Company Profile: Campbell Knitwear Limited
COMPANY PROFILE
Introduction
Campbell Knitwear Ltd. is the latest investment of Forbes Gokak Ltd., a
diversified company of the Tata Group, which is the largest business conglomerate in India
with combined turnover of US $10.00 Billion per year.
Campbell Knitwear 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.
Campbell Knitwear 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 free. We
have fully automatic water treatment plant for recycling the effluents, captive
power generation and water supplies. We use dyestuff supplied by global firms like ICI
Sandoz, Ciba and Atul etc. the waste water is released for afforestation, which we are
developing with plantation over 250 acres of hilly land around factory.
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.
We have in-house training faculty fresh workmen are recruited so as to suit and mould
them in our working environment. We have a team of young and energetic workmen with an
average age of 24 years. We 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 Campbell Knitwear Ltd, is
committed to the world-class product.
KEY INFORMATION
Products Polo shirts and T-shirts for men, women and children
Pique 165 gsm to 260 gsm Single Jersey 140 gsm to 220
Fabric Specification
gsm RIB with and without Elastomer
OUR CLIENTS
DOMESTIC BUYERS
Dockers
Levies (India)
Levies
Allen Solly
Ruggers
Newport
Lee
Arrow
Flying Machine
Ruggers
Mini Phoos
Proline Proline
K-Swiss
Fila
Trents Westside
Killer Killer
Reebok Reebok
Copley Copley
Aureus Aureus
Intimo Intimo
Ivy Crew
Capital Mercury Bill Blass
Robert Stock
B.T.C. Kirkland
Today's Men
Huntigton
Alexander Julian
Jackpot
Esprit
S.Olive
Gilbert
Wothvaley Pierre
Asics Asics
Joman
CONTACT US
Corporate Office:
Khatau House , Second Floor , 410/411 Mogul lane , Mahim (West)
Mumbai-400 016 , India
Tel : 0091-22-4442663
Fax : 0091-22-4442675
Marketing Office:
Plant:
INFRASTRUCTURE
MISSION
We the people of the Forbes Gokak and associate companies, are dedicated to providing
quality products and services in diverse fields of textiles, consumer durables,paints and
pigments, cutting tools, business machines, molded plastics, shipping,, multi-modal
transport, travel, freight forwarding communications, property development, exports
and in related areas, to our customers, in a fair and efficient manner and at a reasonable cost
to both sides.
Our reputation, has been established on the basis of Integrity and Quality, extending over 200
years is our proud heritage which we strive always zealously to preserve. We continue to
endeavor to reach the Best International Standards in Quality and Service in each of our
enterprises.
VISION
Profitability: To achieve a mini return on investment of 10% over and above the
inflation rate. (Return on investment as measured in terms of profit before tax on the
capital employed)
Growth: To achieve a group turn over of times the turn over of 1995-96 by year
2005-06 the capital i.e. to reach a level in excess of Rs45,000 millions per annum.
Customers loyalty: To ensure that customers become and remain our Loyal Friends
and our most effective spokesmen and advertisement.
PRESENT MARKETS
CANADA GERMANY
CHILE FRANCE
NEWZELAND ITALY
DUBAI BELGIUM
ARROW K-MART
GAP DECATHLON
TODAY’S MAN
MIGROS
ORGANISATIONAL CHART
VICE PRESIDENT
Mr. F. K. Shah
GENERAL MANAGER
Mr.A.B.N. Patel
FACTORY MANAGER
Mr.R.S. Patil
Departmental Study
1. PRODUCTION
This unit consist of various departments
A. Yarn department
B. Knitting
D. Dyeing department
E. Sampling department
F. Cutting department
G. Embroidery section
I. Production/sewing department
J. Packing department
K. Stores department
Yarn Inspection
Procurement
Knitting
Batch Folding
Preparation
Dyeing
Inspection
Stores
Pattern
Making
Cutting
Packing &
Sewing
Dispatch
Preparatory
Sewing
A. 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.
B. 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 Celsius,
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 buyer’s
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.
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 22º to
26º. 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
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.
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.
D. Dyeing Department
In this department the fabric takes its true colors and the department consists of:
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 buyer’s 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 section—for storing the chemicals used for making the dyes
Dozing section—which 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.
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
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.
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.
E. Sampling Department
The sampling department makes the garment according to the buyer’s 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 buyer’s needs.
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.
F. 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.
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.
G. Embroidery Section:
Cost- 14 lacks
900m/tube- 63 L
Supplier:
Yashawantpur Bangalore-560022
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.
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 buyer’s 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.
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.
In this department, the various garment parts are assembled, top stitched and various
finishing touches are given as per the buyer’s requirement. It is adjacent to sewing
preparatory department and Packing Department.
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.
J. 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 buyer’s requirement.
A small slip is placed in each carton containing information regarding the following.
Serial Number
Order Number
Date
Color Number
Size Ratio
Reference Number
Purchase Order Number
Style Number
Size
Quantity
Carton Number
Country of Origin
K. 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
Department. The third copy is sent to the purchasing department. It is on their approval that
the payment is made.
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
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
2 MARKETING DEPARTMENT
-To make strategies by understanding the ups and downs in the market.
-To understand the requirement of the buyer and try to satisfy their needs and wants.
-To prepare Samples for the buyer as per their Specifications (Buyer specifications).
-To make purchase order which gives the details of the garment regarding measurements,
packing, tagging, stitching and dispatch or delivery.
3 MERCHANDISING DEPARTMENT
This is the main office of the company and even the Vice President’s as well as the General
Manager’s offices are located inside this office.
Functions:
This department handles an important task as there work starts after marketing work
is over.
Merchandisers are the co-ordinates between the buyer and production team.
They arrange to send the samples to the buyer at the time of final order.
They have to monitor the progress of order availability of fabric accessories etc.
If any changes specified by the buyer during production of buyer’s order, they have
to inform to the concerned development have to document it.
They keep the buyer informed about the status of the order.
To ensure timely delivery of order.
4 PURCHASE DEPARTMENT
To plans and assign the work flow for each department till it is dispatched.
Fixing of assembly lines based on the quantity and styles.
To getting the flow of orders smoothly.
To inspect the procedure of production.
Production Planning is done both at Macro and Micro level and it starts at the end of
every month –
- Macro Level: At macro level a budget is prepared for the next month, where
after looking at what orders we have and pending orders with us, we plan for
what to produce for the whole month. Then we calculate the utilization and
cost and profitability of it. So as to get a rough estimation. Then planning for
each party is done separately and a budgetary control system plan is made for
them, which help us to understand the profitability of individual, as the
material required by him right from yarn to packing.
- Micro Level: Micro level looking at the order of different sizes and quantity
and after analyzing the sample which we have send to the buyer gives us a fair
idea that how much material is required for its manufacturing.
It is also taken into consideration that how much time the lot takes under production.
6 MAINTENANCE DEPARTMENT
7 ACCOUNTS DEPARTMENT
FINDINGS
The orders for the year have shown the excess stock of 0.5421% of the total quantity
ordered and consumed.
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.
Usually the excess stock can be found in the big orders than the small orders.
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 2 are in
Bogar ways and Neheru Nagar).
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 restricted to some extinct to avoid wastage of raw
material
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 yarn should be ordered according to the orders only and not on the forecast of
orders.
CONCLUSION
As a basis of my findings through the observation it was realized that the wastage was more
than the standard waste As explained in the suggestion part, I have arrived at the conclusion
that procurement of the yarn should be by crosschecking the available inventory of yarn at
the stores before ordering yarn to avoid excess of material . As a practice where company is
ordering extra yarn, should be reviewed by past performance of the similar orders and reduce
the extra quantity ordered.
BIBLIOGRAPHY
Brochures