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Forbes Campbell KnitwearBelgaum
COMPANY PROFILE
Name of the Company : Campbell Knitwear Ltd
Address of the company : Campbell Knitwear Ltd
Post Marihal, Bagalkot road
Dist Belgaum- 591167
Karnataka India.
Year of Establishment : 1995.
Nature of industry : Textile Industry.
Head office of the company : Mumbai.
Corporate office : Khatau House,
2nd floor, 410/411 MogulLane.
Mahim (west)
Mumbai-400016-India.
Website : www.campbellknitwear.com
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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 Polo shirts and T-shirts for men, women and children
Garment 2,40,000 garments per month.
Fabric Dyeing Capacity - 90 MT/Month
Month Fabric Knitting
Capacity- 90 MT/Month
Fabric Specification
Pique 165 gsm to 260 gsm Single Jersey 140 gsm to 220 gsm RIB
with and without Elastomer
Shrinkage Maximum 5 % TUMBLE DRIED
Order Size Minimum order of 5000 garment (Minimum 900 pcs per color)
Lead Time30 to 90 days depending on the order Size and requirement of
development.
Payment Terms Irrevocable confirmed L/C payable at sight.
Our Bankers
Standard Chartered Bank (Main Branch)
23-25 M.G. Road, Fort,
Mumbai-400001
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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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CLIENTS OF THE COMPANY
Country. Buyers. Brand Names.
USA. 1. Mens wear group.
2. Vantage.
3. PGA Golf.
4. Andrew Sportswear.
Twin Hill Original.
Vantage.
PGA Golf.
Andrew Sport Destination.
Europe. 1. Esprit.
2. Smart Way.
3. Worthvaley.
4. Asics.
Esprit.
Smart way.
Pierre cardin.
Asics.
New Zealand. 1. Wales and makenly Pearl.
Mexico 1. Mexinde The One.
Oman 1. Oman textiles. Nasse.
Joman.
DOMESTIC BUYERS
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Buyers Brand name.Levies. 1. Dockers
2. Levies
Trents. Westside.
Shoppers Stop. Stop!
Killers. Killer
Reebok. Reebok.
Proline. 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.V2. Mini phoss.
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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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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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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.
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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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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 thisdepartment
the fabric
takes its true
colors and the department consists of:
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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.
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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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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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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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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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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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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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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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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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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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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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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:
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Marketing
Finance HRDMaintenance
Production
KnittingDept DyeingDept
PackingDept
Sewing
Dept
Cutting
Dept
Chief executive officer
Vice president (marketing)
General Manager (production)
Factory manager (HRD Department)
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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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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
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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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