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Report: The Industrial Visit of a Garment

Manufacturing Unit at The Shirt Company

Submitted to: Submitted by:


Ms Garima Srivastava Bhavik Gandhi
FMS Dept. M/FMS/08/10

National Institute of Fashion Technology, Navi Mumbai


About the Visit:
Day – 23rd October, 2008
Place – The Shirt Company, Turbhe, Navi Mumbai
Subject Guide – Ms. Garima Srivastava
Duration – 2 hrs
Unit – Garment Manufacturing
Objective – To understand the practices in the garment manufacturing unit

The Shirt Company

 Established 2003
 Area 30,000 sq ft
 Output - 110,000 pieces per month

Mr. Shivanand Shetty founded The Shirt Company in 1984. In May 2005, the name was
changed to Shirt Company (I) Pvt Ltd.
The Shirt Company has six manufacturing units that employ thousands of employees
and produce 400,000 garments of various styles every month. He overlooks both design
and styling with extreme foresight and a sharp eye for detail, building up collections of
high fashion garments for each season and marketing them at various production units.
His enthusiasm and astute marketing skills are reflected in the growing number of
customers that TSC has developed over recent years.
Production Facility
TSC’s production facilities are vertically integrated to facilitate all processes involving
garment manufacture in-house. The company has invested in state-of-the-art machinery
for the flawless execution of processes like fabric cutting, fusing, finishing, washing and
packing. This means higher efficiency in productivity and markets, and lower costs of
production - a benefit that is passed on to the customers.
Clients
The Shirt Company has its clients including designer brands to merchandising firm to
popular and renowned brands like Esprit, Woolworths, Pepe Jeans, Barbie, Tom Taylor,
Metro, DKNY, Otto Vernard, Colby, Belk, Bad Boys, Tarrant, Zoo York etc.
Production Flow Chart:
Cutting Room:
The main functions at the cutting room were:
1. Planning – sampling, spreads, marking, production
2. Spreading
3. Cutting
4. Preparation for sewing – shade marking, tickets, bundling

Planning
The input of this functions are cut order plan which contains detailed instructions
regarding cutting markers to be planned and graded set of pattern can be cut out in
pattern paper or may exist in memory of a dedicated computer. The operation consists
of planning layout of pattern in most economical manner. Computerized system are
used and the marker planner works interactively with system to plan the markers, which
can then be used for manual cutting.
Spreading
Preparatory operation for cutting and consists of laying plies of cloth on top of the other
in a pre-determined direction and relationship between right and wrong shade.
Manual spreading is done at The Shirt Company.
Cutting
Spread fabric is cut into garments. The types of cutting machine used for cutting are:
 Round Knife – Very fast machine, excellent for cutting straight lines or graded curves.
Effective cutting height is 40% of blade diameter.
 Straight Knife – The work horse of most cutting rooms, the straight knife, if correctly
used is versatile and accurate enough for most purpose.
 Band Knife – Narrow blade of this machine allows the finest shapes to be cut very
accurately.

There was air floatation table which support the block of work on a fine air cushion,
enabling the cutter to maneuver the work during the cutting with minimum disturbance
to plies.
Preparation for Sewing
Position Marking – The operation marks component with guides for sewing and other
operations.
Shade Marking – Components cut from different shades of same color do not get mixed
up, for this a small sticker applied.
Bundle Preparation – Bundle of cut work preparation according to size, shape, color.
Stitching
The stitching process along with button holing and button stitching is performed in
progressive bundling system
Progressive bundling system – a system in which garment are gradually assembled as
the move through successive sub assembly and main assembly operation in bundle
form.

Make Set Pockets Store Cross back


Pocket Store/stock & Front

Prepare Make Store Make


front Backs collars

Store Set Stores


Collar
Finish Store Set
Sleeve
Store Make Stores
Sleeves

A button hole is a straight or shaped slit cut through the garment and then sewn round
its edges to prevent fraying and stretching. Button with 2 holes, 4 holes or staples can
be sewn on same machine by simple adjustment to button clamping and spacing
mechanism.
Printing
Printing was done on Graphic Printing m/c, Flat bed butterfly printing machine & Fabric
screen printing machine.
Embroidery
There were modern embroidery machines in order to have brand names, floral designs
and animations for Barbie. The machine were fully automatic and computerized.
Washing
The Shirt Company is equipped with state of the art laundry machines. There were
separated machine for white and dyed garments.
Pressing & Quality control
Pressing was done manually by skilled labors and they were also responsible for the
final checking for any defects and stains on the garment. They apply stickers at all the
places they find those defects and stains.
Folding, Packing & Tagging
Then the next process was folding along with tagging. Final packaging is done
according to the specification. Then finally the cartons were filled with specific number
of the units.

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