Indian Textile and Clothing

Training module for the middle level managers

based on the skill gap identification for Garment

Industry in Tiruppur

By

D.Malmarugan Associate Professor

SARDAR VALLABHBHAI PATEL INTERNATIONAL SCHOOL OF TEXTILES & MANAGEMENT

Autonomous Institute, Ministry of Textiles, Govt. of India. 1483, Avanashi Road, Peelamedu,Coimbatore 641 004.Tamilnadu.

Training module for the middle level managers based on the skill gap

identification for Garment Industry in Tiruppur

Executive Summary

The apparel exporters have an ambitious target of USD15 billion in exports by

year 2011-12, even though 2009-2010 exports at USD 10.64 billion were

slightly down by 2.64% over the previous year. Each USD 1 billion in exports

requires an input of 36 million man-hours of work and the attendant demand for

raw materials, accessories and logistics creates vibrancy in the entire

ecosystem. The value chain comprises of spinning, weaving, knitting and

garmenting. Also, it uses different materials such as cotton, jute, and wool, silk,

man-made and synthetic fibers.

The government should implement the Indo-EU Free Trade Agreement (FTA)

soon.FTA has the potential to boost India's textiles and clothing exports to the

European Union by over $3 billion. It will also create an additional 2.5 million

jobs in our economy. Currently, the apparel sector employs 6 million people

directly and 3 million indirectly. And 50 per cent of the work force is women.

With right policies, this sector can absorb another 5 million workers directly

within the next 3 years. The need of the hour is Skill development for

employees in the Tiruppur Garment cluster, to be competitive in the Global

level.

A study to identify Skill gaps among middle level managers of organizations in

The Tiruppur Garment cluster. Based on the findings training modules were

developed for a period of Twenty days in functional areas like Production,

Merchandising, Material Sourcing, Human resources and Finance and Costing.

Table of Contents

Sl.No Topic Page Number

1. 1. 1.1 Introduction 3

2. 1.2 Problems faced by the Indian Garment

Industry

4

3. 1.3 Government Intervention and need for

the study

4

4. 2.1 Production processes involved in

Garmenting

6

5. 2.2. Skill requirements and skill gaps 8

6. 2.2.1Nature of Skill Gap 9

7. 2.2.2Labour Laws and Skill Gap 9

8. 2.3 Existing Institutions 10

9. 2.3.1Garments 11

10. 2.3.2Measures to Improve the Institutions 11

11. 2.4 Current Training/Education

Infrastructure

19

12. 2.5 Emerging trends in skill requirements 20

13. 2.5.1 Research & Development 22

14. 2.5.2 Labour laws

22

15. 2.5.3. Regions which will drive human

resource requirements

23

16. 2.6 Projected Human Resource

Requirements in the Textile & Clothing

Sector

24

17. 2.6.1 Projected Size of the Textile and

Clothing Industry

24

18. 2.6.2 Projected human resource

requirement

24

19. 2.6.3 . Skill Pyramid for the T&C industry 25

20. 3 Methodology 27

21. 3.1 Instrument

28

22. 3.2 Sample

28

23. 3.3 Statistical tools of Analysis. 28

24. 4. Analysis and Discussion 30

25. 4.1 Descriptive Analysis 30

26. 4.2 Inferential Analysis using Test of Significance.

72

27. 5. Findings and Conclusion

139

28. 5.1 Production Functional area.

140

29. 5.2 Merchandising functional area

140

30. 5.3 Material Sourcing Functional Area

141

31. 5.4 Human resources Functional area

142

32. 5.5 Finance Functional area

142

33. 6. The Training Modules. 143

34. 6.1 .Merchandising Functional area 143

35. 6.2 Production Functional area

145

36. 6.3 Material Sourcing Functional area

151

37. 6.4 Human Resource Functional area.

157

38. ANNEXURE: Questionnaire

167

39. References 176

‘

Chapter 1

Introduction

1.1 Introduction:

Indian Textile and Clothing (T&C) industry is currently one of the largest and

most important industries in the Indian economy in terms of output, foreign

exchange earnings and employment. The industry contributes 4% to the

country’s GDP and 14% to the country’s industrial production. The textiles

industry accounts for around 14% of total exports from India. The apparel

exporters have an ambitious target of USD15 billion in exports by year 2011-

12, even though 2009-2010 exports at USD 10.64 billion were slightly down by

2.64% over the previous year. Each USD 1 billion in exports requires an input

of 36 million man-hours of work and the attendant demand for raw materials,

accessories and logistics creates vibrancy in the entire ecosystem. The value

chain comprises of spinning, weaving, knitting and garmenting. Also, it uses

different materials such as cotton, jute, and wool, silk, man-made and synthetic

fibers.

The clothing sector is the final stage of the textile value chain and the

maximum value addition takes place at this stage. Apparel and clothing

industry is fragmented and pre-dominantly in the small-scale sector excluding

tailoring units, there are around 13,000 units of which 12,000 are SSI units.

Most apparel manufacturers (80%) have small operations (with <20 sewing

machines) while 99% of them are proprietorship/partnership concerns. The

clothing industry is fragmented and pre-dominantly in the small-scale sector.

The reason for this could be attributed to the SSI reservation policy which was

in vogue till 2001 for woven apparels and up to March 2005 for knitwear. The

quota policy which prevailed during the quota regime also did not encourage

consolidation of the units. The apparel industry is concentrated primarily in 8

clusters, i.e., Tirupur, Ludhiana, Bangalore, National Capital Region or NCR

(Delhi/Noida/Gurgaon), Mumbai, Kolkata, Jaipur, and Indore. While Tirupur,

Ludhiana and Kolkata are major centres for knitwear; Bangalore, NCR,

Mumbai, Jaipur, and Indore are major centers for woven garments.

1.2 Problems faced by the Indian Garment Industry

The unprecedented rise in price of raw materials (cotton & yarn) over the past

few months and also general increase in all other costs due to hike in duty of

petroleum products has made Indian garments uncompetitive in the world

market. While our exports from India are falling, exports from low-cost

countries such as Bangladesh, Vietnam and Cambodia continue to rise. The

slowdown in the global economy has hit Indian garment exports. Exports to

Europe which was facing a debt crisis have fallen. The US market is still

fragile.

1.3 Government Intervention and need for the study

What’s needed now is the government's support to compete with other

countries. The government should support the sector in terms of higher duty

draw back rates to offset cost disadvantages. The government should

implement the Indo-EU Free Trade Agreement (FTA) soon.FTA has the

potential to boost India's textiles and clothing exports to the European Union by

over $3 billion. It will also create an additional 2.5 million jobs in our

economy. Currently, the apparel sector employs 6 million people directly and 3

million indirectly. And 50 per cent of the work force is women. With right

policies, this sector can absorb another 5 million workers directly within the

next 3 years. The need of the hour is Skill development for employees in the

Tiruppur Garment cluster, to be competitive in the Global level.

For the above said reasons a study on skill gap identification and Training

Requirements was necessary. Apex Cluster development Services , an

Organization involved in developmental activities in the Tiruppur Garment

Cluster handed over the assignment of identifying the Skill gaps among

supervisory level employees in the Tiruppur Garment cluster, to Sardar

Vallabhbhai Patel International School of Textiles and Management.(An

Autonomous institute under the ministry of Textiles, government of India).The

following report is the outcome of the efforts taken in Data collection, analysis

and Suggestions as Training modules in various functional areas for the Skill

gaps in Tiruppur garment Cluster. The report is arranges as chapters in

Literature Review, Methodology adopted, Data analysis, Findings and Training

modules in various functional areas.

Chapter 2

Literature review

2.1 Production processes involved in Garmenting

The various activities involved in garment manufacturing are .

� Cutting

The fabric is cut as per the defined pattern for different parts of the garment.

Markings are made on the spread fabric which is then cut/chopped in the

cutting machine. Wastage reduction is a key consideration during this step.

� Stitching

A number of stitch and seam types, and sewing machines are used for stitching

the garment.

Name of operations

1 Hem pocket

2 Crease pocket

3 Sew front placket

4 Folding right front edge

5 Sew pocket

6 Attach yoke to back

7 Join shoulder

8 Attach sleeve

9 Top stitch on sleeve

10 Side seam & in seam

11 Fuse collar &band interlining

12 Run stitch

13 Trim collar & band

14 Pressing

15 Top stitch & join

16 Trim upper collar

17 Top stitch collar band

18 Trim band & notch

19 Attach collar &label

20 Close collar

21 Hem cuff interlining

22 Run stitch cuff

23 Turn & press cuff

24 Top stitch cuff

25 Attach cuff

26 Close cuff

27 Bottom hem

28 Sew button hole

29 Sew button

Source: ATDC

Stitch classification is based on the structure of the stitch and method of

interlacing. Machine in each class may have the capability of producing several

different types of stitches depending on the machine structure and how it is set

and threaded.

A group of stitches with specific purpose is called seam, or in other words a

line of stitches.

Seams are categorized into 8 classes are designated according to the types and

minimum number of components within the seam.

Assembling

Assembling will be required for a unit which has a line system of

manufacturing where different components of the fabric are stitched separately

and have to be assembled to make the complete garment. Various accessories

like button are also added to the garment.

Finishing

Finishing involves the following operations:

Removal of excess thread, Washing Pressing/ Ironing and Folding.

2.2. Skill requirements and skill gaps In the age of cut throat competition among continuous upgradation of

machinery is must to remain competitive in a sector like textiles and clothing,

where export potentials are high. Along with modernization there occurs need

for skilled workers who can run the machinery efficiently and understand the

modern production processes. Thus skill requirement increases with the

technological upgradation. In the Indian scenario for want of availability of

skilled laborers in adequate quantity many firms in the industry are hesitant to

expand their scale of operations or enter into high end segments with cutting

edge technology.

Low level of skills of the workers has a bearing on income of both workers as

well as the firm. This works like a vicious circle. Low skilled employees in an

organization means an organization with low productivity, and low quality and

low value of output. It results in low competitiveness in the market leading to

low returns for the firm. Such situation not only leads to low investment in HR

and technology (obstruction in expansion and/or up-gradation of the existing

system), but also results in low wages and low morale of employees. Lack of

investment in HR and technology again means low skills/knowledge, which

completes one side of the loop of low-skill poverty vicious circle. Lack of

investment in HR and technology also results in creation of no or few

additional jobs. It means supply and demand of labour gets imbalanced in

favour of supply. Less demand and more supply puts pressure on wages.

Eventually, organizations remain in the vicious circle of low productivity, low

quality output and low value output .(Rehman and Ali, 2008)

2.2.1Nature of Skill Gap

Skill gap can be defined as the gap between required level of knowledge and

skill to do a particular activity and the existing level of knowledge and skill to

accomplish the work. Alternatively, it can also be identified by the gap in the

demand and supply of skilled workers at the existing wage rates in a unit. Skill

gap may be at varying levels in different sort of activities in a textiles unit.

Further, skill gap can be found at different hierarchical levels of an

organization, e.g. at operative level, supervisory level, middle management

level or senior management level. So remove the skill gap at various levels

different strategies should be adopted. In some sort of activities, skill gap can

be easily removed by a few days of training or on job training but in some other

tasks a formal and intensive training is required.

In addition, literate and educated workers are quicker to learn as compared to

illiterate and uneducated workers. So the former are easier to train as compared

to the latter.

2.2.2Labour Laws and Skill Gap

Persistent skill gap in the textiles and clothing sector is very closely linked with

the prevalent labor laws in the country. They can create a conductive

environment for skill enhancement or they may hinder the growth of labour

skills by hindering expansions during seasonal industries. It is therefore

important that labour laws should be framed in such a manner that it should not

hinder the growth and instead be used for the overall development of both

workers and industry.

2.3 Existing Institutions

Industrial Training Institutes (ITIs) established during the 1950s was the major

effort on the part of Government to impart skills in various vocational trades to

meet the skilled manpower requirements of the various industries of the

country. But they hardly provided core-competency training in textiles at

operator level unlike other engineering disciplines. Vocational training for

workers in the pre-or post-employment stages did not develop significantly in a

structured and regular fashion. The Indian textiles workforce was generally

developed within the industry where newly inducted unskilled workers

acquired their skills from skilled colleagues already engaged in the industry,

who passed on their expertise to such unskilled workers. As a result, they

inherited the basic expertise along with any flaws and faulty skills. Some of the

progressive composite mills did have special training programmes for

unskilled, semiskilled and skilled workers apart from on job training (Ministry

of Textiles, 2006).

Currently, out of the total 4971 ITIs 1243 ITIs offer training in textiles with a

yearly intake of 33372. They impart training in following trades-Bleaching,

Dying; Block printing; Cutting and tailoring; Dress making; Embroidery; Hand

weaving of niwar tape; Durries, Carpet, Knitting with hand operated machine;

Weaving of silk and woollen fabrics, etc.

2.3.1Garments

In the apparels segment most of the training imparted to workers is informal in

nature. An unskilled worker first works as a helper in different activities of a

garment making unit e.g. cutting, labeling, ironing, packaging, etc. Over a

period of time he becomes a skilled worker. A few units recruit worker trained

through ITI or other institutions. In Ludhiana knitting cluster, several apparel

units recruit teen aged boys and provide them on the job training in stitching. It

was found during the NCAER survey, 2008-09 that in certain clusters, a few

skilled workers impart training in stitching to new labourers on payment during

their leisure time at home. This is also an informal arrangement of training. In

select clusters, Government established a few Apparel Training & Design

Centres (currently total thirteen in number) to train and upgrade the skills of

workers in the garment sector. Recently, Infrastructure Leasing and Finance

Services (IL&FS) has launched a project called Skills for Employment in

Apparel Manufacturing (SEAM), a pilot effort to train and place rural below-

poverty-line youth in the apparel industry. But considering the massive skill

gap in the sector, the efforts are little to have major impact.

Generally, workers gain full expertise within 2-3 years. Scarcity of skilled

workers is felt more during peak season.

2.3.2Measures to Improve the Institutions

Currently, there is a massive gap between the availability of skilled manpower

and the requirements of the industry, particularly in the weaving, dying,

processing and garment segments. To bridge this gap requires massive

expansion and modernization of training institutes/polytechnics across the

country. They can be opened on a public -private partnership basis with

maximum industry-institute interface.

· The number of ITIs targeted specifically to the requirements of the textiles

sector need to be increased significantly to meet the shortage of operatives.

They may be persuaded to relate their courses and curriculum in textiles with

the inputs from the textiles industry to make them more relevant to modern

machineries and processes used in textiles industry.

· Post graduate courses are required to develop a specialized skilled labour pool

for the industry.

These are to be offered as part of engineering degree programmes in various

engineering colleges, IITs and NITs.

· The Textile Research Associations (TRAs) may be strengthened with one time

grant from the government to design and offer more short term structured

training programmes.

· The existing network of Apparel Training and Design Centres (ATDCs)

promoted by the Apparel Export Promotion Council may be expanded and

strengthened to meet the needs of the rapidly growing RMG sector.

· Knitting & knitwear service centers may be set up in the major knitting

centers of Tiurupur, Ludhiana, Delhi and Kolkata to cater to the support service

needs of the decentralized knitting and knitwear industry

· Emphasis should be laid on not only educating and skilling the workers but

also on a

continuous process of skilling, re-skilling, multi-skillin g and skill modulation.

· Capacities of powerloom service centres to conduct training programmes can

be expanded.

Simultaneously, new training centres may be established in smaller clusters

where presently there are no training centres for skill development of workers.

· The reorient and modernize of the industry may require major adjustments in

human resource development policies so that skilled workers displaced during

the adjustment process may be reabsorbed into productive employment. For

this purpose, there is need to develop and install a meaningful mechanism that

can utilize skilled weavers displaced from the hand-loom sector to productive

employment in the power-loom and mill sectors. These skilled hand-loom

weavers are major assets to the industry, but only if they can be utilized in the

production of the sophisticated products that are in demand for domestic and

export markets in hand looms or even in power looms and mills sector.

· Need to reforms the rigid labour laws.

· Industry associations like CITI (Confederation of Indian Textiles Industry)

and other smaller associations should play a pivotal role in coordinating with

training institutions and industry for the fulfilment of the training needs of

various sectors of textiles industry and help in laying foundation for

development of such institutes.

The following table contains the Functional area wise Skills Required and Skill

gaps in various levels.

Function Level Skills Required Skill Gaps

Knowledge of various types

of fabrics (type of material,

count/picks, Dye

requirements, etc).


Purchase of fabric defects such as

Manager breakage of threads, missing

threads, stains, patches and

shade variation, etc.

Awareness of the latest price

trends in the fabric market.

Negotiation and

communication skills for

negotiating with the fabric

manufacturers.

Ability to calculate the

amount of requisite quality

Procurement

fabric required based on the

order size and likely

wastage.

Purchase


associate/

of fabric defects and other

executive

quality parameters.

Liaison with the fabric

manufacturers and fabric

In-depth knowledge of the

various types of fabric and

quality parameters. Negotiation and

communication skills.

Insufficient knowledge of

various types of fabric

defects and other quality

parameters.

Function Level Skills Required

processors.

Understanding of various

production activities as the

merchandiser is interface

between the buyer and the

Senior company

Merchandiser Soft skills like negotiation

and communication skills.

These skills assume more

significance for export

oriented units.

Knowledge of foreign

languages such as French

Merchandising for better co-ordination with

the buyer.

Ability to handle multiple

accounts/customers.

Thorough understanding of

costing.

Understanding of buyer

requirements of design and

quality.

Junior Reviewing materials used for

Merchandiser/ garment manufacturing

Merchandising Understanding of various

executive production activities as the

person is responsible for

Skill Gaps

Lack of soft skills for

interacting with buyers in

the international market.

Knowledge of foreign

languages is limited to

English – this might prove to

be an issue with India

becoming a sourcing hub for

garments and knitwear

Understanding of various

factors affecting costing.

Inadequate understanding of

various production

activities. The person

employed picks up the

requisite skills with


execution of the order. experience.

Ability to work closely with Inadequate understanding of

other functions like design, quality requirements.

production etc.

Time management skills to

handle multiple orders at the

same time.

Basic computer skills.

Design and develop Inadequate understanding of

garments according to buyer buyer requirements which

requirements. leads to number of iterations

Ability to modify existing before the sample is

Design Designer designs to suit the current accepted.

trends in the market. Insufficient knowledge of

Keep abreast with the latest latest fashion trends in the

fashion trends in the key international markets –

markets - the designer should changes in design between

be aware of the colours, ‘seasons’. It is required that

contours which are in vogue. the designer be able to

Knowledge of Styling, forecast trends by being

Elements of Design, Basics networked with foreign

of Costing, Fabric Study, designers in major markets.

Pattern Making and Draping. The same is applicable to

Indian markets as well.

Production Knowledge of pattern Inadequate knowledge of

Manager making speciality fabrics

Ability to undertake Lack of adequate scientific

inspection, production knowledge of line

planning and control balancing, work study, and

Function Level Skills Required

Man-management skills. Production

In-depth knowledge of

production process and

inspection methods

Line Knowledge of different type

Supervisor/ of fabrics as well as

Floor understanding of stitching

supervisor processes.

Ability to guide the sewing

machine operators.

Man-management skills to

manage the shop floor. The

Supervisor should be able to

motivate the workers in the

challenging work

atmosphere as the demand is

seasonal and order driven.

Good machine control -

knowledge of threading of

sewing machine, stitching on

different shapes, seaming

garment components

together in various fabrics to

Operator specified quality and quality

Skill Gaps

Quality Control (this is

because a large number of

managers have been

elevated by experience

rather than by formal

training).

Insufficient knowledge of

various types of sewing

machines (refer table listed

earlier) – ability work in a

cross-functional manner

across sewing machines

Inadequate soft skills to

manage the shop floor

personnel.

Lack of proper knowledge of

sewing machine operations,

and different types of seams

and stitches

Ability to work across

different machines is

missing

20


standard Ability to stitch the complete

Knowledge of machine garment is missing ( In case maintenance procedures of units which do not follow

Knowledge of Pattern line system of production)

Making, Grading and

Draping.

Knowledge of CAD for

Pattern Development

Ability to sew complete

garment.

Quality requirements are all

the more important for Knowledge of international

companies focussing on quality standards is a

international markets. Even significant gap.

Quality control small quality issues can lead

Quality executive to cancellation of order.

Understanding of the

customer requirements by

interacting with the

merchandiser.

Knowledge of international

standards is desirable.

Knowledge of in line and

final quality testing

procedures - ability to

understand and prevent

defects like size variations,

loose threads, stains etc.

21

2.4 Current Training/Education Infrastructure

Human Resource and Skill Requirements in the Textile Industry

The current training infrastructure is inadequate on both number of people

trained and also the quality of training being imparted. Also, very few of the

training initiatives are targeted at the shop floor level. The newly inducted

workers learn through informal training and learning from the experience of the

existing work force.

Training Infrastructure of Textile Sector

Training Institute Number of centres/units

Textiles Research Associations (TRAs) 8

Powerloom Service Centres (PSCs) 44

Indian Institutes of Handloom Technology (IIHT) 4

Weaver’s Service Centres (WSC) 24

Industrial Training Institutes (ITI) offering courses related to Textiles 1,243

Home Science Colleges offering Textiles & Clothing Courses 24

Apparel Training & Design Centres (ATDCs) 52

Institute of Apparel Management 1

National Institute of Fashion Technology 12*

Sardar Vallabhbai Patel Institute of Textiles Management

Source: Report of the Committee to assess the requirement of human resource

in the Textile sector, Ministry of Textiles, ATDC, NIFT

*Does not include one international centre

22

Training in these Industrial Training Institutes (ITIs) is mainly imparted in the

following trades:

(1) Bleaching

(2) Dyeing

(3) Block printing

(4) Cutting and tailoring

(5) Dress making

(6) Embroidery

(7) Hand weaving of niwar tape

(8) Durries

(9) Carpet

(10) Knitting with hand operated machine

(11) Weaving of silk and woollen fabrics, etc.

The availability of trained manpower is a key issue for the garmenting sector.

The ATDC, ITIs and NIFT annually train up to 50,000 workers. A few private

sector players also provide training specific to the garmenting sector. A large

portion of the requirement of human resource at the operator level is met by on

the job training. Hence training at the operator level is a key gap. Acute

shortage of skilled man power leads to poaching and acts as a detriment to

spending on in house training initiatives.

2.5 Emerging trends in skill requirements

Emerging trends in human resource requirements

Technology

23

� The changes in technology would significantly affect the profile of people

involved. As mentioned earlier, the share of shuttle-less looms in the Indian

textiles industry is only 2-3% as against a world average of 16.9%, thereby

indicating a low degree of modernization in the Indian weaving industry.

Although the Indian spinning sector is relatively more modernised, around60%

of installed spindles are more than 10 years old and open-end (OE) rotors

account for only 1% of total installed spindles. In the apparel sector, India has

much lower investment in special purpose machines, which perform specific

functions and add value to the product. Very few export establishments have

invested in cutting machines or finishing machines. The low level of technology

and government incentives like TUFS would drive modernization in the

industry where as the high power costs would be a detriment.

� The technological upgradation would necessitate the human resource to be

trained in modern machinery and also greater in house spending on training.

The shortage of labour and increasing wage rate would further induce greater

automation which will lead to higher productivity. For instance, the operating

hours per quintal of yarn have decreased from 77 to 25 on account of

modernization and would continue to fall. Also, the numbers of people involved

in post spinning operations have come down on account of automatic cone

winding machines.

� The modern machinery would require skilled maintenance people who have

the requisite knowledge of the same. Proper maintenance would be crucial as

machine down time and costly spare parts would significantly affect the

performance of the industry.

Quality Processes There would be increasing focus and adoption of quality and

environment related processes, such as:

� ISO 9001:2008

24

� ISO 14001.

2.5.1 Research & Development

� The textile industry does not have R&D as a focus area. The industry would

have to invest more in both process and product R&D to maintain product and

cost competitiveness. This requires industry-academia collaborations as well as

individual R&D efforts by the companies.

2.5.2 Labour laws

� More flexible labour regulations will positively affect the industry. Currently,

T&C industry comes under the purview of Contract Labour Act, 1970 which

prohibits contract labour for the work that is perennial in nature. The exporters

find it difficult to manage the seasonal and order based volatility in demand on

account of this. Change in the current regulations can lead to opening up of

more employment opportunities. Also, the current regulations prohibit women

from being employed in night shifts. Relaxation of the same with adequate

safeguards can lead to more participation of women and also help in addressing

the skill shortage in the industry.

Human resource related

� Modernisation of technology would necessitate more technical skills for

operators in the production and maintenance functions across the value chain of

the textile industry. The sector also needs multi-tasking/multi skilling at the

operator level. The human resource at the higher levels as well as in other

functions like procurement would need to possess the knowledge of various

types of machines and also keep abreast with the changes in technology.

� The garmenting sector would be the key driver of the employment in the

textile sector. Majority large portion of the human resource requirement will be

for operators who have the adequate knowledge of sewing machine operations

25

and different types of seams and stitches. Although, the industry will continue

to have predominantly line system of operations, designer and high end fashion

exports would necessitate “make through” system of operations which would

require the operators to have the ability to stitch the complete garment. The

availability of merchandising and designing skills would be crucial for

increasing share in export markets and tapping the potential in new markets.

2.5.3. Regions which will drive human resource requirements

The major centres in India where this employment generation would take place

are Tamil Nadu, West Bengal, Karnataka, Maharashtra, and Gujarat. The state

of Tamil Nadu will account for around 30% of the employment in the textile

sector.

The poor performance of the industry in the recent past has resulted in the

sector not attracting new investments. The cluster development activities of

various organisations have not found takers and hence new clusters do not

appear likely at this point of time. However, Andhra Pradesh is a likely future

destination for new investments, especially in the garmenting sector with the

establishment of Apparel Parks. The government initiatives of providing power

at a cost of 2 Rs per unit will be a key factor in attracting investments in

spinning sector. Also, the state has surplus cotton and would result in lower

logistics cost. Availability of raw materials and low power costs will also attract

investments in the downstream activities like fabric manufacturing, processing

and garmenting.

The scheme of integrated textile parks and various SEZs would also affect the

regions availability of labour. States like Uttranchal necessitate that most of the

labour force in the units operating in SEZ should be local.

26

The states of UP, Bihar and Orissa etc would be key catchment areas to meet

the labour requirements.

Already the spinning sector in Tamil Nadu is seeing more and more influx of

labour from these states as the current wage rates in the states are very high.

Environmental concerns would affect the processing sector. The effluent

treatment requirements might see units shifting to coastal areas as marine

discharge requirements are less stringent.

2.6 Projected Human Resource Requirements in the Textile & Clothing

Sector

In this section, we shall review the projected human resource requirement in the

Textile and Clothing sector based on the projection of industry size.

2.6.1 Projected Size of the Textile and Clothing Industry

It is estimated that the PFCE on clothing will grow at a CAGR of 7.5% between

2008 and 2024. Based on projected growth of GDP and exports, we expect that

the exports of textiles will grow at a rate of 11% to 11.5%. Thus, the overall

T&C sector will grow at a CAGR of 9.5% to a size of Rs. 6,730 billion. Out of

this, the share of exports is expected to increase from just under 50% currently

to about 60% in 2022.

4 Our overall approach to macro-economic modeling and forecasting is

explained in a separate annexure

2.6.2 Projected human resource requirement

While analysing the human resource requirement, we have categorised the

overall T&C sector as follows:

1. The Mainstream T&C sector – comprising of Spinning, Fabric

Manufacturing, Fabric Processing,

and Garmenting.

27

2. Other related industries such as:

a. Handloom

b. Woolen

c. Sericulture

d. Handicrafts

e. Jute.

While we expect the human resource requirement in the Mainstream T&C

sector to be closely related to market driven T&C industry growth, the human

resource requirement in areas such as handloom and handicrafts would have to

be supplemented by initiatives from the Government and Industry. The addition

of human resource into these other sectors would be at a much lower rate as

compared to the Mainstream sectors due to need for significant support for

earnings, scope for enhanced technology intervention and automation as

compared to current levels, the need to add value, and attractiveness of the

sector among the human resource supply.

Keeping in mind the above factors and the growth of the industry, we have

projected the human resource requirement for the T&C sector. It is expected

that the overall employment in the sector would increase from about 33 to 35

million currently to about 60 to 62 million by 2022. This would translate to an

incremental human resource requirement of about 25 million persons. Of this

the Mainstream T&C sector

has the potential to employ about 17 million persons incrementally till 2022.

2.6.3 . Skill Pyramid for the T&C industry

Given that the industry would required a varied profile of skill sets, the

following figure presents an overview of the profile of skill requirements as

28

derived from human resource requirements across different sectors of the T&C

industry.

The skill pyramid, in summary, captures where the T&C industry stands

relatively in terms of skills (a function of activity, educational requirements,

and amount of ‘preparatory’ time required to inculcate aspecific skill) as

compared to all other industries.

As can be observed, the lower portion of the pyramid, ‘Skill Level 1’, has the

highest incremental requirement of human resources. It requires persons who

are minimally educated, yet can handle simple and/or repetitive tasks (persons

employed in activities such as basic machine operations, knitting, cutting, and

stitching/sewing, etc.). Such skills can also be obtained in lesser time duration

as compared

to engineering or ITI courses. As many as over 15 million persons are required

across skill levels 1 and 2 outlined above.

29

Chapter 3

Methodology

The methodology to be adopted is as provided by the funding agency Apex

Cluster Development Services Pvt. Ltd and fine tuned by frequent interactions

with the team at Tiruppur led by the Cluster Development Manager

Sl. No.

TITLE OF SERVICES DESCRIPTION No. of Man-Days

1. Preparatory Study

For undertaking study in the cluster about its functions and to understand the skill requirements and to identify the existing gap in the Middle Management Level.

6

2. Drafting of Questionnaire 2

3. Sample Survey 20

4.

Revising and finalizing the Questionnaire based on Sample Survey

To be designed for interviewing 200 Middle Level Managers working in the cluster for Understanding the gap in the knowledge level of Middle Managers in their relevant functional areas.

Also this survey to be used to understand the most convenient time, etc., so as to make the program more participative.

2

5. Survey

At-least 200 Middle Level Managers have to be covered for making the study through MSMEs in the Cluster.

200

6. Monitoring

The whole process is to be closely monitored and documented by right resource persons so as to attain the desired result in developing the

200

30

cluster and addressing the gap.

7. Compilation and analysis

The data acquired to be compiled properly and analysed to identify the skill gaps in the cluster.

10

8.

Preparation of training modules and course materials.

Developing Training modules in relevant functional areas.

20

9. Coordinating activities

All the administration and coordination of survey to be covered under this.

30

3.1 Instrument Questionnaire was prepared based on Literature review and discussion with

experts in this field and was finalized by the taem at Apex Cluster Tiruppur

office.The questions are relevant and important to measure the skill gaps in the

Tiruppur Garment Clsuter

3.2 Sample Sample of 200 middle level Managers working in the cluster in various

functional areas for Understanding the gap in the knowledge level of Middle

Managers in their relevant functional areas was chosen. The sample is a large

sample so generalization of findings is possible.

3.3 Statistical tools of Analysis.

Data was analyzed using statistical techniques like percentage and Chi-square

Analysis

31

Chapter 4 Analysis and Discussion

The data was analyzed using Percentage analysis and chi-square analysis. 4.1 Descriptive Analysis: Percentage Analysis was used for Descriptive analysis

32

Table: 1 Departments of the respondents Department

Frequency Percent Valid Percent

Cumulative Percent

1.Merchandising 48 24.0 24.0 24.0

2.Production 44 22.0 22.0 46.0

3. Human Resources

36 18.0 18.0 64.0

4.Finance &costing

33 16.5 16.5 80.5

5. Fabric sourcing 39 19.5 19.5 100.0

Total 200 100.0 100.0

The above table provides the department wise breakup of the respondents.24%

of the respondents belong to Merchandising Department. Production personnel

were 22% while Human resource executives made up 18% of the respondents.

About a fifth were from Fabric sourcing and 16.5 % belong to finance and

Costing.

34

Table: 2 Qualification of Respondents. Qualification


Cumulative Percent

1.Matriculation (sslc)

3 1.5 1.5 1.5

2.higher secondary(plus two)

19 9.5 9.5 11.0

3.Diploma in textiles tech

8 4.0 4.0 15.0

4.other diploma 21 10.5 10.5 25.5

5.Graduate in fashion design

21 10.5 10.5 36.0

6.P.G. in textile 3 1.5 1.5 37.5

7.other graduates 119 59.5 59.5 97.0

8.Textile engg. graduate

6 3.0 3.0 100.0

Valid

Total 200 100.0 100.0

Graduate degree holders from streams other than Textiles make up about 60%

of the respondents. A tenth are Higher secondary passed and Diploma in

streams other than Textile are another one tenth and Graduates degree holders

in Fashion Design make up one tenth of the respondents. Engineers in Textiles

are just 3%while Postgraduates in Textiles are a mere one and a half percent.

Diploma holders in Textiles are 4% and Matriculation passed are just 1.5%.

35

Table:3 Experience of respondents. experience


Cumulative Percent

1. less than 5 years

87 43.5 43.5 43.5

2. 5-10 years 81 40.5 40.5 84.0

3. 10-15 years 22 11.0 11.0 95.0

4. 15-20 years 9 4.5 4.5 99.5

5. >20 years 1 .5 .5 100.0

Valid

Total 200 100.0 100.0

36

A vast Majority of the respondents are having Experience of less than 10 years

and half of them are having experience less than 5 years. A tenth are having

experience between 10-15 years and only about 5% are having experience

between 15-20 years.

Table 4: Human Relation skills

hrskills


Cumulative Percent

1.yes 186 93.0 93.0 93.0

2. no 14 7.0 7.0 100.0

Valid

Total 200 100.0 100.0

A vast Majority are confident of possessing Human relationship skills.

37

Table 5 Sufficient knowledge to perform Tasks

sufficientknowledge


Cumulative Percent

1. yes 195 97.5 97.5 97.5

2. no 5 2.5 2.5 100.0

Valid

Total 200 100.0 100.0

Almost everybody are confident of possessing sufficient Knowledge to perform

Their Tasks

38

Table 6: Updated Technical Knowledge

uptodatetechknowledge


Cumulative Percent

1. yes 177 88.5 88.5 88.5

2. no 23 11.5 11.5 100.0

Valid

Total 200 100.0 100.0

Except for a tenth of the respondents , others are confident of having Updated

Technical Knowledge in their respective Domains.

39

Table:7 Convenient Timings for Training Convenient timings


Cumulative Percent

1. Sunday 161 80.5 80.5 80.5

2. Saturday &Sunday

6 3.0 3.0 83.5

3. weekdays 7 3.5 3.5 87.0

4. no time 26 13.0 13.0 100.0

Valid

Total 200 100.0 100.0

A vast Majority prefer the weekends especially Sundays for the Training

Programs, as they are occupied with their work on weekdays. A bit more than a

tenth are unable to find time for Training.

40

Table 8Production: Production Planning

Production planning


Cumulative Percent

1.yes 52 26.0 81.2 81.2

2. no 12 6.0 18.8 100.0

Valid

Total 64 32.0 100.0

Missing System 136 68.0

Total 200 100.0

About a fifth of the respondents are not conversant with Production Planning

techniques.

41

Ta

ble 9: Production: Budgeting and costing Budgeting and costing


Cumulative Percent

1.yes 23 11.5 35.9 35.9

2. no 41 20.5 64.1 100.0

Valid

Total 64 32.0 100.0 Missing System 136 68.0 Total 200 100.0

Two thirds are not conversant with Budgetting and Costing methods in

Production

42

Table 10 :Production:Machinery Planning

mcplanning


Cumulative Percent

1.yes 19 9.5 29.7 29.7

2.no 45 22.5 70.3 100.0

Valid


Two thirds are not conversant with Machinery Planning methods in Production

43

Table 11: Production: Layout

playout


Cumulative Percent

1.yes 18 9.0 28.1 28.1

2.no 46 23.0 71.9 100.0

Valid


Two thirds are not conversant with Prodcution Layout Planning methods .

44

Table 12 Production: Standard Alerted minute

psam


Cumulative Percent

1.yes 42 21.0 65.6 65.6

2. no 22 11.0 34.4 100.0

Valid


One third of the respondents are not conversant with Stadard Alert minute.

45

Table 13: Production:Quality control and newly developed Fabrics.

pqcnewdevfabrics


Cumulative Percent

1.yes 45 22.5 70.3 70.3

2.no 19 9.5 29.7 100.0

Valid


About 30% are not aware of Quality control techniques and Newly Developed

Fabrics.

46

Table 14: Production: Statistical Quality control and Operations Research

psqcandor


Cumulative Percent

1.yes 39 19.5 60.9 60.9

2.no 25 12.5 39.1 100.0

Valid


About 40% of the respondents are not familiar with Statistical Quality control

and Operations Research techniques.

47

Table 15:Production:Lighting, ergonoimics and Industrial engineering plightingergoie


Cumulative Percent

1.yes 38 19.0 59.4 59.4

2.no 26 13.0 40.6 100.0

Valid


Four tenths of the respondents are not familiar in Lighting impact, ergonomics

and other industrial engineering aspects.

48

Table 16:Production:Lean Maufacturing

pleanmfrg


Cumulative Percent

1.yes 26 13.0 40.6 40.6

2.no 38 19.0 59.4 100.0

Valid


Sixtenths of the respondents are not familiar with Lean Manufacturing

techniques.

49

Table 17: Merchandising: Prospecting and Vendor evaluation mvendor


Cumulative Percent

1.yes 32 16.0 68.1 68.1

2.no 15 7.5 31.9 100.0

Valid


50

About 32% of the respondents are not familiar with Prospecting and Vendor

Evaluation

Table 18: Merchandising: Sample Development

msampledev


Cumulative Percent

1.yes 45 22.5 95.7 95.7

2.no 2 1.0 4.3 100.0

Valid


Most of the respondents are aware of Sample and Product Development

techniques.

51

Table 19:Merchandising:Printing , Dyeing and Washing

mprintdyewash


Cumulative Percent

1.yes 42 21.0 89.4 89.4

2.no 5 2.5 10.6 100.0

Valid


52

Printing Dyeing and Washing methods are known to nine tenths of the

respondents.

Table20 : Merchandising: Sketch studying and Garment Construction methods

msketchgarmentconst


Cumulative Percent

1.yes 40 20.0 85.1 85.1

2.no 7 3.5 14.9 100.0

Valid


53

Sketch studying and Garment Construction methods are known to 85%

of the respondents.

Table 21: Merchandising: Department wise costing details

mdeptcosttech


Cumulative Percent

1.yes 37 18.5 78.7 78.7

2.no 10 5.0 21.3 100.0

Valid


54

Department wise costing details are known to about eight tenths of the

respondents.

55

Table 22: Merchandising: Communication, Interpersonal skills

mcommun


Cumulative Percent

1.yes 43 21.5 91.5 91.5

2.no 4 2.0 8.5 100.0

Valid


Nine tenths of the respondents are familiar with Communication, Interpersonal

skills

56

Table 23:Merchandisng: Fabric consumption details mfabricconsump


Cumulative Percent

1.yes 43 21.5 91.5 91.5

2. no 4 2.0 8.5 100.0

Valid

Total 47 23.5 100.0

Missing System 153 76.5

Total 200 100.0

Fabric consumption details are known to nineteenths of the respondents.

57

Table 24: Material Sourcing: Fabrics, Geographical availability and Price

msfabavasilprice


Cumulative Percent

1.yes 38 19.0 92.7 92.7

2.no 3 1.5 7.3 100.0

Valid


Most of the respondents know specification of Fabrics, Geographical availability and Price

58

Table 25: Material Sourcing: Trims and Accessories-quality parameters

mstrims


Cumulative Percent

1.yes 37 18.5 90.2 90.2

2.no 4 2.0 9.8 100.0

Valid


Nine tenths of the respondents are aware of Trims and Accessories-quality

parameters

59

Table 26: Material Sourcing: Interacting with merchandiser for requisition

msinteractionmerch


Cumulative Percent

1.yes 35 17.5 85.4 85.4

2.no 6 3.0 14.6 100.0

Valid


85 % of the respondents are good in interacting with merchandiser for

requisition.

60

Table 27: Materials Sourcing: Negotiating and communication skills

msnegotiatecomm


Cumulative Percent

1.yes 38 19.0 92.7 92.7

2.no 3 1.5 7.3 100.0

Valid


61

Most of the respondents are familiar with Negotiating and communication

skills.

Table 28: Materials Sourcing -Incoming quality inspection, Lot to lot variation of incoming materials

msincomqc


Cumulative Percent

Valid 1.yes 41 20.5 100.0 100.0Missing System 159 79.5 Total 200 100.0

Everybody are familiar with incoming quality inspection, Lot to lot variation of incoming materials

62

Table 29: Human Resources: Prospecting and selecting employees hrprospectnselection


Cumulative Percent


All of the respondents were familiar with Prospecting and selecting employees

for various

positions

63

Table 30: Human Resources: Various Laws of Industrial Relations hrlawsnir


Cumulative Percent

1.yes 40 20.0 97.6 97.6

2.no 1 .5 2.4 100.0

Valid


Almost everybody are aware of Various Laws of Industrial Relations.

64

Table31: Human Resources: various Welfare measures hrwelfare


Cumulative Percent

1.yes 39 19.5 95.1 95.1

2.no 2 1.0 4.9 100.0

Valid


Most of the respondents are aware of the various welfare measure of

employees.

‘

65

Table 32: procedures of Rewarding employees for Better performance hrrewardemp


Cumulative Percent


Everybody are aware of the procedures of Rewarding employees for Better

performance

66

Table 33: Human Resources: measuring performance of Employees hrperfmeasure


Cumulative Percent

1.yes 40 20.0 97.6 97.6

2.no 1 .5 2.4 100.0

Valid


Almost ever respondent was conversant with methods of measuring

performance of Employees

67

Table 34: Human Resources: Training and Development of Employees hrtraingndevp


Cumulative Percent

1.yes 40 20.0 97.6 97.6

2.no 1 .5 2.4 100.0

Valid


Almost ever respondent was conversant with methods of measuring

performance of Employees

68

Table 35: Finance: Book Keeping Practice finbookkeep


Cumulative Percent

yes 34 17.0 89.5 89.5

no 4 2.0 10.5 100.0

Valid


Book Keeping Practice are known to nine tenths of the respondents.

69

Table 36: Finance: Computerized accounting method fincomputer


Cumulative Percent

yes 36 18.0 94.7 94.7

no 2 1.0 5.3 100.0

Valid


Computerized accounting methods are familiar to almost every respondent.

70

Table 37: Finanace: Working capital Management Practices finwc


Cumulative Percent

yes 34 17.0 89.5 89.5

no 4 2.0 10.5 100.0

Valid


Working capital Management Practices are known to nine tenths of

respondents.

71

.

Table 38: cash Management fincashmanage


Cumulative Percent

yes 35 17.5 92.1 92.1

no 3 1.5 7.9 100.0

Valid


Most of the respondents are aware of cash Management Practices

72

Table 39: Banking Procedures

finbanking


Cumulative Percent

yes 32 16.0 84.2 84.2

no 6 3.0 15.8 100.0

Valid


More than eight tenths of the respondents are aware of banking Procedures

73

Table 40: Taxation Procedures fintax


Cumulative Percent

yes 36 18.0 94.7 94.7

no 2 1.0 5.3 100.0

Valid


Almost everybody are familiar with Taxation Procedures.

74

4.2 Inferential Analysis using Test of Significance. Chisquare analysis was adopted to test the significant relationship between Dependent variable and Independent variable such as qualification, experience etc.

Table 41:Significance of relationship between sufficient

knowledge and experience

Crosstab

Count

experience

less than 5 years 5-10 years

10-15 years

15-20 years >20 years Total

yes 86 79 20 9 1 195sufficientknowledge no 1 2 2 0 0 5Total 87 81 22 9 1 200

Chi-Square Tests

Value df

Asymp. Sig. (2-sided)

Pearson Chi-Square 4.829a 4 .305Likelihood Ratio 3.683 4 .451Linear-by-Linear Association

1.247 1 .264

N of Valid Cases 200

a. 6 cells (60.0%) have expected count less than 5. The minimum expected count is .03.

There is no significant relationship between the Experience and knowledge

sufficient to discharge their responsibilities in the area of function and the

Experience level of the respondents.

75

Table 42: Significance of relationship between sufficient

knowledge and Qualification

Qualification

sslc

higher secondary

dip tex tech

other

dip

gra fashion design

pg in textile

other

gra textileengg

graduate Total

yes 2 17 8 20 20 3

119

6 195sufficientknowledge

no 1 2 0 1 1 0 0 0 5Total

3 19 8 21 21 3 119

6

Chi-Square Tests

Value df



13.041 1 .000



There is significant relationship between the Experience and knowledge sufficient to discharge their responsibilities in the area of function and the Qualification level of the respondents

76

Table 43: Significance of relationship between up to date technical

knowledge and Experience

Crosstab

Count

experience


10-15 years


yes 79 73 18 7 0 177uptodatetechknowledge no 8 8 4 2 1 23Total 87 81 22 9 1 200

Chi-Square Tests

Value df



4.401 1 .036


4 cells (40.0%) have expected count less than 5. The minimum expected count is .12.

There is significant relationship between the up to date technical knowledge and the Experience level of the respondents

77

Table 44: Significance of relationship between up to date technical

knowledge and Qualification

Crosstab

Count

Qualification

sslc

higher

secondar

y

dip tex tech

other dip

gra fashion

design

pg in textil

e other gra

textileengg gradu

ate

Total

yes

2 15 7 17 16 3 111 6 177uptodatetechknowledge

no 1 4 1 4 5 0 8 0 23Total 3 19 8 21 21 3 119 6 200

Chi-Square Tests

Value df



7.912 1 .005



There is no significant relationship between the up to date technical knowledge and the Qualification level of the respondents

78

Table 45: Significance of relationship between Familiarity with Production

Planning Techniques and Experience

Crosstab

Count

experience


10-15 years

15-20 years Total

yes 28 16 6 2 52pproductionplanning no 7 5 0 0 12Total 35 21 6 2 64

Chi-Square Tests

Value df



.881 1 .348

N of Valid Cases 64


There is no Significant relationship between Familiarity with Production

Planning Techniques and Experience of the respondent

79

Table 46: Significance of relationship between Familiarity with Production

Planning Techniques and Qualification

Crosstab

Count

Qualification

sslc

higher second

ary

dip tex tech

other dip

gra fashion design

other gra

Textileengg

graduate Total

yes 1 8 6 11 9 15 2 52pproductionplanning no 0 2 0 2 3 4 1 12Total 1 10 6 13 12 19 3 64

Chi-Square Tests

Value df



.731 1 .393

N of Valid Cases 64


There is no Significant relationship between Familiarity with Production

Planning Techniques and Experience of the respondent

80

Table 47: Significance of relationship between Familiarity with budgeting and

costing Techniques and Experience

Crosstab

Count

experience


10-15 years

15-20 years Total

yes 13 7 1 2 23pbudgettingandcosting no 22 14 5 0 41Total 35 21 6 2 64

Chi-Square Tests

Value df



.106 1 .745

N of Valid Cases 64


There is no Significant relationship between Familiarity with budgeting and

costing Techniques and Experience of the respondent

81

Table 48: Significance of relationship between Familiarity with budgeting and

costing Techniques and Qualification Crosstab

Count

Qualification

sslc

higher

secondar

y

dip tex tech

other dip

gra fashion

desig

n other gra

Textile engg

graduate

Total

yes

0 3 1 1 6 10 2 23pbudgettingandcosting

no 1 7 5 12 6 9 1 41Total 1 10 6 13 12 19 3 64

Chi-Square Tests

Value df



5.882 1 .015

N of Valid Cases 64


There is Significant relationship between Familiarity with budgeting and

costing Techniques and Qualification of the respondent( at 0.1 significance

level)

82

Table 49: Significance of relationship between Familiarity with machinery

planning Techniques and experience

Crosstab

Count

experience


10-15 years

15-20 years Total

yes 10 5 3 1 19pmcplanning no 25 16 3 1 45Total 35 21 6 2 64

Chi-Square Tests

Value df



.705 1 .401

N of Valid Cases 64


There is no Significant relationship between Familiarity with machinery

planning Techniques and experience of the respondent.

83

Table 50: Significance of relationship between Familiarity with machinery

planning Techniques and Qualification

Crosstab Count

Qualification

sslc

higher

secondar

y dip tex techother dip

gra fashion design

other gra

Textileengg

graduate

Total

yes

0 0 1 3 5 9 1 19pmcplanning

no 1 10 5 10 7 10 2 45Total 1 10 6 13 12 19 3 64

Chi-Square Tests

Value df



7.404 1 .007

N of Valid Cases 64


There is no Significant relationship between Familiarity with machinery

planning Techniques and Qualification of the respondent

84

Table 51: Significance of relationship between Familiarity with Layout and

Experience

Crosstab

Count

experience


10-15 years

15-20 years Total

yes 8 7 2 1 18playout

no 27 14 4 1 46Total 35 21 6 2 64

Chi-Square Tests

Value df



1.140 1 .286

N of Valid Cases 64


There is no Significant relationship between Familiarity with Layout and

Experience of the respondents.

85

Table 52: Significance of relationship between Familiarity with Layout and

Qualification

Crosstab Count

Qualification

sslc

higher

secondary

dip tex tech

other dip

gra fashion

design other gra

Textile Engg

graduat

e Total

yes 0 2 1 3 4 7 1 18playout

no 1 8 5 10 8 12 2 46Total 1 10 6 13 12 19 3 64

Chi-Square Tests

Value df



1.756 1 .185

N of Valid Cases 64


There is no Significant relationship between Familiarity with Layout and

Qualification of the respondent.

86

Table 53: Significance of relationship between Familiarity with SAM

techniques and Experience

Crosstab

Count

experience


10-15 years

15-20 years Total

yes 24 13 4 1 42psam

no 11 8 2 1 22Total 35 21 6 2 64

Chi-Square Tests

Value df


Pearson Chi-Square .483a 3 .923Likelihood Ratio .472 3 .925Linear-by-Linear Association

.283 1 .595

N of Valid Cases 64


There is no Significant relationship between Familiarity with SAM techniques and Experience of the respondent

87

Table 54: Significance of relationship between Familiarity with SAM

techniques and Experience

Qualification

sslc

higher second

ary

dip tex tech

other dip

gra fashion design other gra

Textile Engg

graduate Total

yes 1 5 6 10 9 10 1 42psam

no 0 5 0 3 3 9 2 22Total 1 10 6 13 12 19 3 64

Chi-Square Tests

Value df



1.835 1 .176

N of Valid Cases 64


There is no Significant relationship between Familiarity with SAM techniques

and Qualification of the respondent.

88

Table 55: Significanof of relationship between Familiarity with newly

developed fabrics and Experience Crosstab

Count

experience


10-15 years

15-20 years Total

yes 22 19 3 1 45pqcnewdevfabrics no 13 2 3 1 19Total 35 21 6 2 64

Chi-Square Tests

Value df



.040 1 .841

N of Valid Cases 64


There is Significant relationship between Familiarity with newly developed

fabrics and Experience of the respondent (at 0.1 significance level)

89

Table 56: Significance of relationship between Familiarity with newly

developed fabrics and Qualification

Qualification

sslc

higher

secondary

dip tex tech

Other dip

gra fashion design

other gra

Textileengg

graduate Total

yes 0 6 4 10 9 14 2 45pqcnewdevfabrics no 1 4 2 3 3 5 1 19Total 1 10 6 13 12 19 3 64

Chi-Square Tests

Value df



.802 1 .371

N of Valid Cases 64


There is no Significant relationship between Familiarity with newly developed

fabrics and Qualification of the respondent

90

Table 57: Significance of relationship between Familiarity with Statistical

Quality Control and Operations Research and Experience

Crosstab

Count

experience


10-15 years

15-20 years Total

yes 18 17 3 1 39psqcandor

no 17 4 3 1 25Total 35 21 6 2 64

Chi-Square Tests

Value df



.526 1 .468

N of Valid Cases 64


There is no Significant relationship between Familiarity with Statistical Quality

Control and Operations Research and Experience of the respondent

91

Table 58: Significance of relationship between Familiarity with Statistical

Quality Control and Operations Research and Qualification

Qualification

sslc

higher second

ary dip tex

tech other dip

gra fashion design

other gra

textileengg gradu

ate Total

yes

0 6 5 11 6 9 2 39psqcandor

no 1 4 1 2 6 10 1 25Total 1 10 6 13 12 19 3 64

Chi-Square Tests

Value df



1.003 1 .317

N of Valid Cases 64


There is no Significant relationship between Familiarity with Statistical Quality

Control and Operations Research and Qualification of the respondents.

92

Table 59: Significance of relationship between Familiarity with Lighting

impact, ergonomics and other industrial engineering aspects and Experience

Crosstab

Count

experience


10-15 years

15-20 years Total

yes 19 15 3 1 38plightingergoie no 16 6 3 1 26Total 35 21 6 2 64

Chi-Square Tests

Value df



.074 1 .786

N of Valid Cases 64


There is no Significant relationship between Familiarity with Lighting impact,

ergonomics and other industrial engineering aspects and Experience of the

respondent.

93

Table 60: Significance of t relationship between Familiarity with Lighting

impact, ergonomics and other industrial engineering aspects and Qualification

Qualification

sslc

higher second

ary dip tex

tech other dip


textileengg

graduate Total

yes

0 4 4 7 7 13 3 38plightingergoie

no 1 6 2 6 5 6 0 26Total 1 10 6 13 12 19 3 64

Chi-Square Tests

Value df



3.830 1 .050

N of Valid Cases 64


There is no Significant relationship between Familiarity with Lighting impact, ergonomics and other industrial engineering aspects and Qualification of the respondent.

94

Table 61: Significance of relationship between Familiarity with Lean

Manufacturing techniques and Experience

Crosstab

Count

experience


10-15 years

15-20 years Total

yes 14 7 4 1 26pleanmfrg

no 21 14 2 1 38Total 35 21 6 2 64

Chi-Square Tests

Value df



.484 1 .487

N of Valid Cases 64


There is no Significant relationship between Familiarity with Lean

Manufacturing techniques and Experience of the respondent.

95

Table 62: Significance of relationship between Familiarity with Lean

Manufacturing techniques and Qualification

Qualification

sslc

higher

secondar

y dip tex

tech other dip

gra fashion design

other gra

textileengg

graduate Total

yes 0 4 3 8 6 4 1 26pleanmfrg

no 1 6 3 5 6 15 2 38Total 1 10 6 13 12 19 3 64

Chi-Square Tests

Value df



1.716 1 .190

N of Valid Cases 64


There is no Significant relationship between Familiarity with Lean

Manufacturing techniques and Qualification of the respondent

96

Table 63 Significance of relationship between Familiarity with Prospecting,

Vendor Evaluation techniques and Experience

Crosstab

Count

experience


10-15 years

15-20 years Total

yes 18 6 5 3 32mvendor

no 10 1 3 1 15Total 28 7 8 4 47

Chi-Square Tests

Value df



.126 1 .723

N of Valid Cases 47

a. 5 cells (62.5%) have expected count less than 5. The minimum expected count is 1.28.

There is no Significant relationship between Familiarity with Prospecting,

Vendor Evaluation techniques and Experience of the respondent.

97

Table 64 Significance of relationship between Familiarity with Prospecting,

Vendor Evaluation techniques and Qualification

Qualification

higher

secondar

y other dip

gra fashio

n design

pg in textile

other gra

textileengg

graduate Total

yes 0 5 6 1 17 3 32 mvendor

yes 1 3 3 1 7 0 15 Total 1 8 9 2 24 3 47

Chi-Square Tests

Value df



1.934 1 .164

N of Valid Cases 47


There is no Significant relationship between Familiarity with Prospecting,

Vendor Evaluation techniques and Qualification of the respondent.

98

Table 65 Significance of relationship between Familiarity with Sample and

Product Development techniques and experience

Crosstab

Count

experience


10-15 years

15-20 years Total

yes 27 6 8 4 45msampledev

no 1 1 0 0 2Total 28 7 8 4 47

Chi-Square Tests

Value df



.118 1 .732

N of Valid Cases 47


There is no Significant relationship between Familiarity with Sample and Product Development techniques and experience of the respondent.

99

Table 66 Significance of relationship between Familiarity with Sample and

Product Development techniques and experience

Qualification

higher secondary

other dip

gra fashion design

pg in textile

other gra

Textile engg

graduate Total

yes

1 7 8 2 24 3 45 msampledev

no

0 1 1 0 0 0 2

Total 1 8 9 2 24 3 47

Chi-Square Tests

Value df



2.392 1 .122

N of Valid Cases 47


There is no Significant relationship between Familiarity with Sample and

Product Development techniques and Qualification of the respondent.

100

Table 67 Significance of relationship between Familiarity with Printing

Dyeing and Washing methods and experience

Crosstab

Count

experience


10-15 years

15-20 years Total

yes 25 6 7 4 42mprintdyewash no 3 1 1 0 5Total 28 7 8 4 47

Chi-Square Tests

Value df


Pearson Chi-Square .603a 3 .896Likelihood Ratio 1.017 3 .797Linear-by-Linear Association

.110 1 .740

N of Valid Cases 47


There is no Significant relationship between Familiarity with Printing Dyeing

and Washing methods and experience of the respondent.

101

Table 68 Significance of relationship between Familiarity with Printing Dyeing

and Washing methods and Qualification

Qualification

higher second

ary other dip

gra fashion design

pg in textile other gra

textileengg graduate Total

yes

1 7 8 2 21 3 42mprintdyewash

no 0 1 1 0 3 0 5Total 1 8 9 2 24 3 47

Chi-Square Tests

Value df



.001 1 .972

N of Valid Cases 47


There is no Significant relationship between Familiarity with Printing Dyeing

and Washing methods and Qualification of the respondent

102

Table 69 Significance of relationship between Familiarity with sketch studying

and Garment Construction methods and Experience

Crosstab

Count

experience


10-15 years

15-20 years Total

yes 25 6 7 2 40msketchgarmentconst no 3 1 1 2 7Total 28 7 8 4 47

Chi-Square Tests

Value df



2.263 1 .132

N of Valid Cases 47


There is no Significant relationship between Familiarity with sketch studying and Garment Construction methods and Experience of the respondent.

103

Table 70 Significance of relationship between Familiarity with sketch

studying and Garment Construction methods and Qualification

Qualification

higher second

ary other dip

gra fashion design


textileengg

graduate Total

yes

0 5 8 1 23 3 40msketchgarmentconst

no 1 3 1 1 1 0 7Total 1 8 9 2 24 3 47

Chi-Square Tests

Value df



8.554 1 .003

N of Valid Cases 47


There is Significant relationship between Familiarity with sketch studying and

Garment Construction methods and Qualification of the respondent.

104

Table 71 Significance of relationship between Familiarity with department

wise costing details and Experience Crosstab

Count

experience


10-15 years

15-20 years Total

yes 20 6 8 3 37mdeptcosttech no 8 1 0 1 10Total 28 7 8 4 47

Chi-Square Tests

Value df



1.419 1 .234

N of Valid Cases 47


There is no Significant relationship between Familiarity with department wise costing details and Experience of the respondent.

105

Table 72 Significance of relationship between Familiarity with department

wise costing details and Qualification

Qualification

higher secondary

other dip

gra fashion design

pg in textil

e other gra

textileengg

graduate Total

yes 1 6 5 2 21 2 37 mdeptcosttech no 0 2 4 0 3 1 10 Total 1 8 9 2 24 3 47

Chi-Square Tests

Value df



.649 1 .421

N of Valid Cases 47


There is no Significant relationship between Familiarity with department wise

costing details and Qualification of the respondent.

106

Table 73 Significance of relationship between Familiarity with

Communication, Interpersonal skills and Experience

Crosstab

Count

experience


10-15 years

15-20 years Total

yes 25 7 7 4 43mcommun

no 3 0 1 0 4Total 28 7 8 4 47

Chi-Square Tests

Value df



.246 1 .620

N of Valid Cases 47


There is no Significant relationship between Familiarity with Communication,

Interpersonal skills and Experince.of the respondent.

107


Communication, Interpersonal skills and Qualification

Qualification

higher second

ary other dip

gra fashio

n design

pg in textil

e other gra


yes

1 8 6 1 24 3 43 mcommun

no 0 0 3 1 0 0 4 Total 1 8 9 2 24 3 47

Chi-Square Tests

Value df



1.287 1 .257

N of Valid Cases 47


There is Significant relationship between Familiarity with Communication,

Interpersonal skills and Qualification of the respondent.

108

Table 75 Significance of relationship between Familiarity with Fabrics,

Consumption Details and Experience

Crosstab

Count

experience


10-15 years

15-20 years Total

yes 26 6 8 3 43mfabricconsump no 2 1 0 1 4Total 28 7 8 4 47

Chi-Square Tests

Value df



.268 1 .605

N of Valid Cases 47


There is no Significant relationship between Familiarity with Fabrics, Consumtion details and Experience of the respondent.

109

Table 76 Significance of relationship between Familiarity with Fabric

Consumption Details and Qualification

Qualification

highe

r secondary

other dip

gra fashion design


textileeng

g graduate

Total

yes 1 7 8 2 22 3 43mfabricconsump no 0 1 1 0 2 0 4Total 1 8 9 2 24 3 47

Chi-Square Tests

Value df



.159 1 .690

N of Valid Cases 47


There is no Significant relationship between Familiarity with Fabric

Consumption Details and Qualification of the respondent.

110


Geographical availability and Price and Experience

Crosstab

Count

experience


10-15 years


yes 18 14 2 3 1 38msfabavasilprice no 0 3 0 0 0 3Total 18 17 2 3 1 41

Chi-Square Tests

Value df



.095 1 .758

N of Valid Cases 41


There is no Significant relationship between Familiarity with Fabrics,

Geographical availability and Price and Experience of the respondent.

111


Geographical availability and Price and Qualification

Qualification

sslc

higher seconda

ry

dip tex tech other dip

gra fashion design

pg in textile

other gra

textileengg

graduate Total

yes 2 5 1 3 6 1 19 1 38msfabavasilprice no 0 2 1 0 0 0 0 0 3Total 2 7 2 3 6 1 19 1 41

Chi-Square Tests

Value df



5.361 1 .021

N of Valid Cases 41


There is Significant relationship between Familiarity with Fabrics,

Geographical availability and Price and Qualification of the respondent.(at 0,1

significance level_

112

Table 79 Significance of relationship between Familiarity with Trims and

Accessories-quality parameters and Experience

Crosstab

Count

experience


10-15 years


yes 17 14 2 3 1 37mstrims

no 1 3 0 0 0 4Total 18 17 2 3 1 41

Chi-Square Tests

Value df



.028 1 .867

N of Valid Cases 41


There is no Significant relationship between Familiarity with Trims and

Accessories-quality parameters and Experience of the respondent.

113

Table 80 Significance of relationship between Familiarity with Trims and

Accessories-quality parameters and Qualification

Qualification

sslc

higher secondary

dip tex tech

other dip

gra fashion design


textileengg

graduate

Total

yes 2 6 2 2 5 1 18 1 37mstrims

no 0 1 0 1 1 0 1 0 4Total 2 7 2 3 6 1 19 1 41

Chi-Square Tests

Value df



.388 1 .534

N of Valid Cases 41


There is no Significant relationship between Familiarity with Trims and Accessories-quality parameters and Qualification of th erespondnet.

114

Table 81 Significance of relationship between Familiarity with interacting

with merchandiser and Experience

Chi-Square Tests

Value df



.000 1 .991

N of Valid Cases 41


Ther is no Significant relationship between Familiarity with interacting with merchandiser and Experience of the respondent.

Crosstab Count

experience


10-15 years


yes 17 12 2 3 1 35msinteractionmerch no 1 5 0 0 0 6Total 18 17 2 3 1 41

115

Table 82 Significance of relationship between Familiarity with interacting

with merchandiser and Qualification

Qualification

sslc

higher

secondar

y

dip tex tech

other dip

gra fashion design

pg in texti

le other gra

textileengg

graduate Total

yes

2 4 1 3 6 1 17 1 35msinteractionmerch

no 0 3 1 0 0 0 2 0 6Total 2 7 2 3 6 1 19 1 41

Chi-Square Tests

Value df



2.536 1 .111

N of Valid Cases 41


There is no Significant relationship between Familiarity with interacting with merchandiser and Qualification of the respondent.

116

Table 83 Significance of relationship between Familiarity with Negotiating

and communication skills and Experience

Chi-Square Tests

Value df



.086 1 .769

N of Valid Cases 41


There si no Significant relationship between Familiarity with Negotiating and

communication skills and Experience of the respondent

Crosstab Count

experience


10-15 years


yes 17 15 2 3 1 38msnegotiatecomm no 1 2 0 0 0 3Total 18 17 2 3 1 41

117

Table 84 Significance of relationship between Familiarity with Negotiating

and communication skills and Qualification

Qualification

sslc

higher secondary

dip tex tech

other dip

gra fashio

n design

pg in textil

e other gra

textileengg

graduate

Total

yes

2 5 2 3 5 1 19 1 38msnegotiatecomm

no 0 2 0 0 1 0 0 0 3Total 2 7 2 3 6 1 19 1 41

Chi-Square Tests

Value df



3.121 1 .077

N of Valid Cases 41


There is no Significant relationship between Familiarity with Negotiating and communication skills and Qualification of the respondent.

118

Table 85 Significance of relationship between Familiarity with incoming

quality inspection, Lot to lot variation of incoming materials and Experience Crosstab

Count

experience


10-15 years


msincomqc yes 18 17 2 3 1 41Total 18 17 2 3 1 41

. No statistics are computed because this dependent variable is a constant

Table 86 Significance of relationship between Familiarity with incoming

quality inspection, Lot to lot variation of incoming materials and Qualification

Crosstab Count

Qualification

sslc

higher second

ary dip tex

tech other dip

gra fashion design

pg in

textile other gra

Textileengg

graduate Total

msincomqc yes 2 7 2 3 6 1 19 1 41Total 2 7 2 3 6 1 19 1 41

No statistics are computed because this dependent variable is a constant

119

Table 87 Significance of relationship between Familiarity with Prospecting

and selecting employees and Experience


Table 88 Significance of relationship between Familiarity with Prospecting

and selecting employees and Qualification

Qualification

higher second

ary other dip

gra fashion design

other gra

Textile

engg gradu

ate Total

hrprospectnselection

yes 1 1 2 35 2 41

Total 1 1 2 35 2 41


Table 89 Significance of relationship between Familiarity with various Laws of

Industrial Relations and Experience

Crosstab Count

experience


10-15 years

15-20 years Total

hrprospectnselection

yes 14 21 4 2 41

Total 14 21 4 2 41

120

Crosstab

Count

experience


10-15 years

15-20 years Total

yes 13 21 4 2 40hrlawsnir

no 1 0 0 0 1Total 14 21 4 2 41

Chi-Square Tests

Value df



1.189 1 .275

N of Valid Cases 41


There is no Significant relationship between Familiarity with various Laws of

Industrial Relations and Experience of the Respondent.

121

Table 90 Significance of relationship between Familiarity with various Laws

of Industrial Relations and Qualification

Crosstab

Count

Qualification

higher secondary other dip



yes 1 1 2 34 2 40hrlawsnir

no 0 0 0 1 0 1Total 1 1 2 35 2 41

Chi-Square Tests

Value df



.059 1 .809

N of Valid Cases 41


There is no Significant relationship between Familiarity with various Laws of

Industrial Relations and Qualification of the respondent.

122

Table 91 Significance of relationship between Familiarity with various

Welfare measures and Experience

Crosstab

Count

experience


10-15 years

15-20 years Total

yes 13 20 4 2 39hrwelfare

no 1 1 0 0 2Total 14 21 4 2 41

Chi-Square Tests

Value df



.419 1 .518

N of Valid Cases 41


There is no Significant relationship between Familiarity with various Welfare measures and Experience of the respondent.

123

Table 92 Significance of relationship between Familiarity with various

Welfare measures and Qualification

Crosstab

Count

Qualification




yes 1 1 2 33 2 39hrwelfare

no 0 0 0 2 0 2Total 1 1 2 35 2 41

Chi-Square Tests

Value df



.120 1 .729

N of Valid Cases 41


There is no Significant relationship between Familiarity with various Welfare measures and Qualification of the respondent

124

Table 93 Significance of relationship between Familiarity with procedures of

Rewarding employees for Better performance and Experince

Crosstab Count

experience


10-15 years

15-20 years Total

hrrewardemp

yes 14 21 4 2 41

Total 14 21 4 2 41


Table 94 Significance of relationship between Familiarity with procedures of

Rewarding employees for Better performance and Qualification

Crosstab

Count

Qualification




hrrewardemp

yes 1 1 2 35 2 41

Total 1 1 2 35 2 41


125

Table 95 Significance of relationship between Familiarity with measuring

performance of Employees and Experience

Crosstab

Count

experience


10-15 years

15-20 years Total

yes 13 21 4 2 40hrperfmeasure no 1 0 0 0 1Total 14 21 4 2 41

Chi-Square Tests

Value df



1.189 1 .275

N of Valid Cases 41


There is no Significant relationship between Familiarity with measuring

performance of Employees and Experience of the respondent.

126

Table 96 Significance of relationship between Familiarity with measuring

performance of Employees and Qualification Crosstab

Count

Qualification




yes 1 1 2 34 2 40hrperfmeasure no 0 0 0 1 0 1Total 1 1 2 35 2 41

Chi-Square Tests

Value df



.059 1 .809

N of Valid Cases 41


There is no Significant relationship between Familiarity with measuring performance of Employees and Qualification of the respondent.

127

Table 97 Significance of relationship between Familiarity with Training and

Development of Employees and Qualification Crosstab

Count

experience


10-15 years

15-20 years Total

yes 14 20 4 2 40hrtraingndevp no 0 1 0 0 1Total 14 21 4 2 41

Chi-Square Tests

Value df



.035 1 .852

N of Valid Cases 41


There is no Significant relationship between Familiarity with Training and

Development of Employees and experience of the respondent.

128

Table 98 Significance of relationship between Familiarity with Training and

Development of Employees and Qualification

Crosstab

Count

Qualification




yes 1 1 2 34 2 40hrtraingndevp no 0 0 0 1 0 1Total 1 1 2 35 2 41

Chi-Square Tests

Value df



.059 1 .809

N of Valid Cases 41


There sis no Significant relationship between Familiarity with Training and Development of Employees and Qualification of the respondent.

129

Table 99 Significance of relationship between Familiarity with Book Keeping

Practice and Experience

Crosstab

Count

experience


10-15 years

15-20 years Total

yes 9 19 5 1 34finbookkeep no 1 1 1 1 4Total 10 20 6 2 38

Chi-Square Tests

Value df



1.723 1 .189

N of Valid Cases 38


There is no Significant relationship between Familiarity with Book Keeping Practice and Experience of the respondent.

130

Table 100 Significance of relationship between Familiarity with Book Keeping

Practice and Qualification

Crosstab

Count

Qualification




yes 1 1 1 30 1 34finbookkeep no 0 0 0 4 0 4Total 1 1 1 34 1 38

Chi-Square Tests

Value df



.252 1 .616

N of Valid Cases 38


There is no Significant relationship between Familiarity with Book Keeping

Practice and Qualification of the respondent.

131


Computerised accounting method and experience

Crosstab

Count

experience


10-15 years

15-20 years Total

yes 8 20 6 2 36fincomputer no 2 0 0 0 2Total 10 20 6 2 38

Chi-Square Tests

Value df



3.255 1 .071

N of Valid Cases 38


There is no Significant relationship between Familiarity with Computerised

accounting method and experience of the respondent.

132


Computerized accounting method and Qualification

Crosstab Count

Qualification




yes 1 1 1 32 1 36fincomputer no 0 0 0 2 0 2Total 1 1 1 34 1 38

Chi-Square Tests

Value df



.119 1 .730

N of Valid Cases 38


There is no Significant relationship between Familiarity with Computerized

accounting method and Qualification of the respondent.

133

Table 103 Significance of relationship between Familiarity with working

capital Management Practices and Experience

Crosstab

Count

experience


10-15 years

15-20 years Total

yes 9 18 6 1 34finwc

no 1 2 0 1 4Total 10 20 6 2 38

Chi-Square Tests

Value df



.431 1 .512

N of Valid Cases 38


There is no Significant relationship between Familiarity with working capital

Management Practices and Experience of the respondent.

134

Table 104 Significance of relationship between Familiarity with working

capital Management Practices and Qualification

Crosstab

Count

Qualification




yes 1 1 1 30 1 34finwc

no 0 0 0 4 0 4Total 1 1 1 34 1 38

Chi-Square Tests

Value df



.252 1 .616

N of Valid Cases 38


There is no Significant relationship between Familiarity with working capital

Management Practices and Qualification of the respondent.

135

Table 105 Significant relationship between Familiarity with cash

Management Practices and Experience

Crosstab

Count

experience


10-15 years

15-20 years Total

yes 9 19 6 1 35fincashmanage no 1 1 0 1 3Total 10 20 6 2 38

Chi-Square Tests

Value df



.558 1 .455

N of Valid Cases 38


There is no Significant relationship between Familiarity with cash Management

Practices and Experience of the respondent.

136

Table 106 Significance of relationship between Familiarity with cash

Management Practices and Qualification

Crosstab Count

Qualification




yes 1 1 1 31 1 35fincashmanage no 0 0 0 3 0 3Total 1 1 1 34 1 38

Chi-Square Tests

Value df



.183 1 .669

N of Valid Cases 38


There is no Significant relationship between Familiarity with cash Management Practices and Qualification of the respondent.

137

Table 107 Significance of relationship between Familiarity with banking

Procedures and Experience

Crosstab

Count

experience


10-15 years

15-20 years Total

yes 9 15 6 2 32finbanking no 1 5 0 0 6Total 10 20 6 2 38

Chi-Square Tests

Value df



.305 1 .581

N of Valid Cases 38


There is no Significant relationship between Familiarity with banking

Procedures and Experience of the respondent.

138

Table 108 Significant relationship between Familiarity with banking


Crosstab Count

Qualification




yes 1 1 1 28 1 32finbanking no 0 0 0 6 0 6Total 1 1 1 34 1 38

Chi-Square Tests

Value df



.401 1 .527

N of Valid Cases 38


There is no Significant relationship between Familiarity with banking

Procedures and Qualification

139

Table 109 Significant relationship between Familiarity with various taxation


Crosstab

Count

experience


10-15 years

15-20 years Total

yes 9 20 5 2 36fintax

no 1 0 1 0 2Total 10 20 6 2 38

Chi-Square Tests

Value df



.000 1 1.000

N of Valid Cases 38


There is no Significant relationship between Familiarity with various taxation Procedures and Experience of the respondent.

140

Table 110 Significant relationship between Familiarity with various taxation

Procedures and Qualification

Crosstab

Count

Qualification




yes 1 1 1 32 1 36fintax

no 0 0 0 2 0 2Total 1 1 1 34 1 38

Chi-Square Tests

Value df



.119 1 .730

N of Valid Cases 38


There is no Significant relationship between Familiarity with various taxation

Procedures and Qualification of the respondent.

141

Chapter 5 Findings and Conclusion

Based the Analysis of data, the following conclusions are arrived at. 24% of the respondents belong to Merchandising Department. Production

personnel were 22% while Human resource executives made up 18% of the

respondents. About a fifth were from Fabric sourcing and 16.5 % belong to

finance and Costing

Graduate degree holders from streams other than Textiles make up about 60%

of the respondents. A tenth are Higher secondary passed and Diploma in

streams other than Textile are another one tenth and Graduates degree holders

in Fashion Design make up one tenth of the respondents. Engineers in Textiles

are just 3%while Postgraduates in Textiles are a mere one and a half percent.

Diploma holders in Textiles are 4% and Matriculation passed are just 1.5%.

A vast Majority of the respondents are having Experience of less than 10 years

and half of them are having experience less than 5 years. A tenth are having

experience between 10-15 years and only about 5% are having experience

between 15-20 years.

A vast Majority are confident of possessing Human relationship skills

Almost everybody are confident of possessing sufficient Knowledge to perform

their Tasks.

142

Based on Chisquare analysis, there is significant relationship between

The perception that their experience and knowledge is sufficient to discharge

their responsibilities of their area of function and the experience of the

respondent at 0.05 statistical significance level.

Except for a tenth of the respondents , others are confident of having Updated

Technical Knowledge in their respective Domains


their perception of their technical knowledge being uptpdate and the Experience

of the respondent. This statistically significant at the 0.05 significance level.

A vast Majority prefer the weekends especially Sundays for the Training

Programs, as they are occupied with their work on weekdays. A bit more than a

tenth are unable to find time for Training. 5.1 Production Functional area. Based on Percentage analysis, the respondents are familiar in varying degrees

with Standard Alerted Minute (SAM), quality controlling techniques as well as

newly developed fabrics, Lighting impact, ergonomics and other industrial

engineering aspects, Statistical Quality Control and Operations Research and

production planning

The respondents are not so familiar with budgeting and costing,machinery

planning and layout and Lean manufacturing.

143

Based on Chisquare analysis, there is significant relationship between quality

controlling techniques as well as newly developed fabrics and experience of the

respondent.And there is significant relationship between budgeting and costing

methods in Production and Qualification of the respondent. Both are

statistically significant at the 0.1 significance level.

5.2 Merchandising functional area Based on Percentage analysis, the respondents are familiar in varying degrees

with Prospecting, Vendor Evaluation, Sample and Product Development

techniques, Printing Dyeing and Washing methods sketch studying and

Garment Construction methods, department wise costing details,

Communication, Interpersonal skills and fabric consumption details

Based on Chisquare analysis, there is significant relationship between sketch

studying and Garment Construction methods in merchandising and the

qualification of the respondent. And there is significant relationship between

Communication, Interpersonal skills and the Qualification of the respondent.

Both are statistically significant at the 0.05 significance level.

5.3 Material Sourcing Functional Area Based on Percentage analysis, the respondents are familiar in varying

degrees with specification of Fabrics, Geographical availability and Price,

Trims and Accessories-quality parameters, interacting with merchandiser for

requisition Negotiating and communication skills incoming quality inspection

and Lot to lot variation of incoming materials


144

specification of Fabrics, Geographical availability and Price and Qualification

of the respondent. This is statistically significant at the 0.05 significance level.

5.4 Human resources Functional area Based on Percentage analysis, the respondents are familiar in varying degrees

with Prospecting and selecting employees for various

positions ,various Laws of Industrial Relation,s various Welfare

measures ,the procedures of Rewarding employees for Better performance,

measuring performance of Employees and Training and Development of

Employees.

5.5 Finance Functional area Based on Percentage analysis, the respondents are familiar in varying degrees

with Book Keeping Practice, Computerised accounting method, working capital

Management Practices,cash Management ,banking Procedures and various

taxation Procedures

Since the Qualification of most of the respondents are not commensurate with

the Jobs, Training in various functional areas are required,. The Training

modules for 20 days in various functional areas was developed based on the

analysis of data.

145

Chapter 6 The Training Modules.

The Training modules were developed based on the analysis of data and the Conclusions drawn. 6.1 .Merchandising Functional area MODULE 1 – Apparel Industry Structure – an Introduction

DAY 1 – An overview of industry structure including all the key stake holders. DAY 2 – An Understanding of product life cycle and seasons in apparel industry. DAY 3 – An understanding of various target segments – designer label to discount stores. MODULE 2 – Decoding the Process and Role of Merchandiser DAY 4 – An understanding of trends forecasts, research and development, competitive shopping, international fairs. DAY 5 – Design and Prototype development and initial costing. DAY 6 – – Role and interface of Merchandiser at production - Pre-production – Production

– Post Production

– interface with different stake holders

MODULE 3 – Planning and Execution in a multi style environment within limited time and resources. DAY7 – understanding of various lead times – fabric, processing, transit, production. DAY 8 – Critical Path Management – application of fundamentals in applied apparel merchandising. DAY 9 – Tools for order tracking, control and monitoring. DAY 10 – Risk management and risk response planning. DAY 11 – Change management and control in apparel merchandising MODULE 4 – Basic technical knowledge and Retail merchandising DAY 12 – understanding of design basics – styles, silhouettes, basic sketches. DAY 13 –Technical knowledge for merchandisers -understanding of basic stitch types

146

– basics of fit evaluation and pattern correction – identification of patterns, methods of measurements etc . DAY14 – Basics of Quality

– AQL, Just in time,

– TQM, Process reengineering, Kaizen, Benchmarking, fishbone, Pareto charts etc.

– Basic defects – fabric and garment – Fabric testing & evaluation MODULE 5 – Sourcing skills DAY 15 – evaluation of supplier sources and negotiation. - using micro and macro perspective – Negotiation strategy and tactics. DAY16 – Sourcing fundamentals – - Key factors in sourcing decisions. - Comparative analysis of various sourcing destinations. DAY 17&18 – Costing / Pricing – micro and macro perspective DAY 19 – View from the Buyer’s side – landed costs, retail margins, customer returns, claims etc. MODULE 6 – Smart Merchandising skills

DAY 20 – Basics of filing, record keeping, paperwork, approvals and samples, and professional templates and SOPs for effective merchandising.

147

6.2 Production Functional area

Time Title Resource Person

DAY I

9.00-10.00 AM Registration 10.00-11.00 AM Inauguration Chief Guest: 11.15-12.15 AM Textiles & Apparel – Introduction to current scenario,

International and national perspective. – Market dynamics.

12.15 -1.15 PM Apparel Production Technologies – Introduction to tech. used across the globe and advantages and disadvantages. – Technology Management

1.15-2.15 PM Lunch 2.15-3.15 PM Product development: Steps from prototype to production

model – Importance of pre-production activities – Product data management:

3.15-4.15 PM Understanding and interpretation of specification sheet 4.15-4.30 PM Tea 4.30-5.30 PM Determination of machine requirements

DAY II

9.30-10.30 AM Basic Pattern Making: Measurement taking – Size chart and meaning of sizes – Definition of various garment parts and positions – Drafting: Basic principles used to draft standard size block patterns

10.30-11.30 AM Drafting of sleeve and collar & Computer grading 11.30 – 11.45 AM Tea 11.45-12.45 PM Computerized production pattern making – Hardware, software

and system programming to produce a sample production pattern – Computer aided manipulation of pattern pieces to create individual styles

12.45 -1.15 PM spreading and cutting – Types and functions – Spreading and cutting machines – Developments in spreading and cutting including computer aided machines

1.15-2.15 PM Lunch 2.15-3.15 PM Sewing machinery Classification - Concept of sewing

machinery functions

3.15-4.15 PM Stitch and Seam Classification 4.15-4.30 PM Tea 4.30-5.30 PM Sewing needle and sewing thread specification, thread

consumption

DAY III Industrial Visit – Most Modern Apparel Industry

148

DAY IV

9.30-10.30 AM Planning a logical garment construction sequence 10.30-11.30 AM Construction techniques of garment closures: Application of

zippers – fly, kissing, lap; Button and buttonholes, hooks and eye snaps, Velcro

11.30 – 11.45 AM Tea 11.45-12.45 PM Sewing problems and their remedies 12.45 -1.15 PM Classification and tabulation of data, construction of frequency

diagram and its applications- Quality– Measure of dispersion,

1.15-2.15 PM Lunch 2.15-3.15 PM Mean and standard deviation, co-efficient of variation- Quality

control charts for variables and attributes –

3.15-4.15 PM Acceptance sampling – AQL – Test of Significance 4.15-4.30 PM Tea 4.30-5.30 PM Quality Assurance – ISO 9000 Quality System

DAY V

9.30-10.30 AM Concept and application of fibre quality parameters of natural (Length, strength, fineness, maturity, moisture and trash) and man-made fibres ( Length, strength, fineness and crimp) – Fibre quality index and its relation with yarn strength and evenness

10.30-11.30 AM Quality parameters of spun(Count and Strength and its CV %, , Evenness, imperfection, hairiness, Classimat faults) and filament yarns (Count and Strength and its CV % , evenness) – Yarn testing concept application

11.30 – 11.45 AM Tea 11.45-12.45 PM Quality parameters of woven and knitted fabrics – Principle

and concept of Physical testing of fabrics – Fabric handle – Fabric Inspection – Fabric defects – Fabric grading system

12.45 -1.15 PM 1.15-2.15 PM Lunch 2.15-3.15 PM Garment quality parameters – 3.15-4.15 PM Quality control in pattern making, cutting and stitching –

Quality of trims and accessories

4.15-4.30 PM Tea 4.30-5.30 PM Quality control in garment finishing – Defects in garments

DAY VI Industrial Visit – Exposure to modern Testing

DAY VII

9.30-10.30 AM Job order Costing and its application in Garment industry. Marginal Costing technique for decision making

10.30-11.30 AM Costing in Knitting and Garments– Elements of cost 11.30 – 11.45 AM Tea 11.45-12.45 PM Calculation of garment weight of different sizes, Dia

determination, Setting the knitting program, Dyeing program

12.45 -1.15 PM Consumption of fabric per garment- Estimating of cost of process loss in Compacting, Bleaching, Raising, Shearing ,

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Printing and Dyeing 1.15-2.15 PM Lunch 2.15-3.15 PM

3.15-4.15 PM

Estimating the Knitting rates- Calculation of CMT charges. Cost sheet with Profit margins and foreign quotes.

4.15-4.30 PM Tea 4.30-5.30 PM New concepts in costing – Activity based costing – Target

costing – Cost restructuring issues and Cost Reduction Measures in the textile industry

DAY VIII

9.30-10.30 AM Preparatory processes of woven fabrics – Singeing – Desizing – Scouring – Bleaching – Mercerizing – Heat setting – Other preparatory processes – Process flow charts – Machineries.

10.30-11.30 AM Classification of dyes – Theory of dyeing – Banned dyes and chemicals – Water quality – Water analysis – Waste water treatment.

11.30 – 11.45 AM Tea 11.45-12.45 PM Dyeing of cotton – Dyeing of polyester – Dyeing of blends –

Wool and Silk dyeing

12.45 -1.15 PM Yarn dyeing 1.15-2.15 PM Lunch 2.15-3.15 PM Woven fabric dyeing 3.15-4.15 PM Knit fabric dyeing 4.15-4.30 PM Tea 4.30-5.30 PM Garment dyeing – Washing – Stone washing, acid washing,

enzyme washing, bio polishing, bleaching, laser fading and ozone fading - laundering equipment and procedures – garment processing machinery.

DAY IX Industrial Visit – Exposure to Dyeing and Finishing

DAY X

9.30-10.30 AM Finishing of woven fabrics – Finishing of knitted fabrics – Tubular and open-width finishing.

10.30-11.30 AM Softener finish – Anti-shrink finish – Resin finish – Water proof finish – Fire retardant finish – Anti-bacterial finish.

11.30 – 11.45 AM Tea 11.45-12.45 PM Modern developments in chemical processing 12.45 -1.15 PM State and modernization of textile chemical processing

industry

1.15-2.15 PM Lunch 2.15-3.15 PM Finishing: Optical brightening, stiffening, softening, crease

resistant and crease retentive finish, anti-static finish, anti-bacterial finish,

3.15-4.15 PM water proofing, flame proofing, soil release finish, mildew and moth proofing – Stain removal, care labels.

4.15-4.30 PM Tea 4.30-5.30 PM Mechanical finishing : raising, sueding, other surface effects.

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DAY XI

9.30-10.30 AM Product evaluation and profiling. 10.30-11.30 AM Production System - Products and Services – POM functions –

Operation Strategies

11.30 – 11.45 AM Tea 11.45-12.45 PM Competitive priorities of textile industry 12.45 -1.15 PM Productivity – Productivity Improvement 1.15-2.15 PM Lunch 2.15-3.15 PM Demand Forecasting – Delphi method – Moving Averages –

Exponential Smoothing –Simple Regression and Correlation analysis

3.15-4.15 PM Production Planning and Control in textile industry – Aggregate planning – Master production schedule –

4.15-4.30 PM Tea 4.30-5.30 PM Material requirement planning – Bill of material – Capacity

requirement planning – Introduction to ERP

DAY XII Practical Training in Garment CAD

DAY XIII

9.30-10.30 AM Inventory Management – Types of Inventory – Cost of Inventory – Fixed Order Quantity Systems – Fixed Order Period Systems

10.30-11.30 AM Economic Order Quantity – Other Inventory models – ABC in Inventory classification – JIT in manufacturing – Kanban.

11.30 – 11.45 AM Tea 11.45-12.45 PM Manufacturing operations scheduling – Work centers – Work

centre scheduling –

12.45 -1.15 PM Sequencing – Priority Rules and Techniques – Shop floor Control –

1.15-2.15 PM Lunch 2.15-3.15 PM Facility layout – Process layout – Product layout 3.15-4.15 PM Line Balancing – Cellular layout 4.15-4.30 PM Tea 4.30-5.30 PM Job Design – Considerations in Job design – Work method

analysis – Work Measurement – Time study – Work sampling – Work loads in textile manufacturing

DAY XIV Practical Training in ERP Software

DAY XV

9.30-10.30 AM Determination and Description of Material Quality-Receiving and Incoming Quality Inspection , Acceptance Sampling Plans, Vendor process capability; Cost reduction Techniques-Standardisation, Simplification and Variety Reduction; Value Analysis and Engineering

10.30-11.30 AM Make or Buy Decision, Purchasing Research , Sources of Supply, Price Determination and Negotiation, Vendor Rating, Selection and Development,

11.30 – 11.45 AM Tea

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11.45-12.45 PM Legal aspects of Purchasing ;Public purchasing and Tendering ;

12.45 -1.15 PM International Purchasing- Procedures and Documentation;.

1.15-2.15 PM Lunch 2.15-3.15 PM Purchasing of Capital equipment-Appraisal Methods,

evaluating Supplier’s Efficiency

3.15-4.15 PM Stores Layout, Classification and Codification; Material Logistics- Warehousing Management, Material Handling : Cases from Textile and Apparel Industry

4.15-4.30 PM Tea 4.30-5.30 PM Traffic and Transportation, Disposal of Scrap, Surplus

and Obsolete materials; Inventory control of spare parts, Materials Information System.

DAY XVI Out Door activity based learning - Ooty Soft Skills and Management games

DAY XVII

9.30-10.30 AM Introduction to energy management – need for energy conservation – Demand side management – Energy Consumption of textile machinery – Specific Energy Consumption (UKG)

10.30-11.30 AM Cost of energy vs. sales value of textile products 11.30 – 11.45 AM Tea 11.45-12.45 PM Energy Conservation in textile industry – Energy

conservation in lighting, compressors and boilers – Energy Audit in a textile mill

12.45 -1.15 PM Captive generation and different types of fuels – Non conventional energy Sources – Co-generation

1.15-2.15 PM Lunch 2.15-3.15 PM Types of effluents produced by textile industry – Effluent

treatment processes

3.15-4.15 PM Recent developments like Reverse Osmosis – Concept of zero discharge

4.15-4.30 PM Tea 4.30-5.30 PM Water quality and test methods – Quality requirement of

process water and drinking water – Water Pollution –

DAY XVIII

9.30-10.30 AM Effluent standards of pollution control boards – Solid water management

10.30-11.30 AM Environment pollution and Industrialization – Environment impact assessment and environment management systems –

11.30 – 11.45 AM Tea 11.45-12.45 PM Air Pollution – Air pollution control and equipments in

industry – Air quality monitoring

12.45 -1.15 PM Noise pollution 1.15-2.15 PM Lunch 2.15-3.15 PM Introduction to Business Communication – Meaning and

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significance – Types – Barriers – 3.15-4.15 PM Principles of effective communication Style of business

writing

4.15-4.30 PM Tea 4.30-5.30 PM Business letters, routine, bad news, sales, collection and

application – Memorandum

DAY XIX

9.30-10.30 AM Individual; Presentation on Business topics relevant to Textiles and Apparel-Video Feedback.

10.30-11.30 AM Group Discussions. Seminars aimed at improving presentation skills.

11.30 – 11.45 AM Tea 11.45-12.45 PM 12.45 -1.15 PM

Individual feedback on Scope for improvement to be provided by Faculty and internal assessment components awarded on presentation skills

1.15-2.15 PM Lunch 2.15-3.15 PM Principles of non-verbal communication and their application

to clothing styles and body language -

3.15-4.15 PM Speeches, introduction, thanks, occasional and thematic - Dialoged communication - Interviews, selection, appraisal, discipline

4.15-4.30 PM Tea 4.30-5.30 PM Group communication - Structured and unstructured.

DAY XX

9.30-10.30 AM Internal and External Communication of an organization - Components of organizational communication.

10.30-11.30 AM Report writing - Structure of reports - Presentation skills - Effective use of audio-visual media .Cases from Textiles and Apparel

11.30 – 11.45 AM Tea 11.45-12.45 PM Conducting Meetings – Procedure – Preparing agenda -

Minutes of meetings – resolutions

12.45 -1.15 PM Conducting seminars and conferences – Procedures of regulating group discussions.

1.15-2.15 PM Lunch 2.15-3.15 PM 3.15-4.15 PM

Small test / Feedback / Other Discussions 4.15-4.30 PM Tea 4.30-5.30 PM Closing Ceremony Chief Guest

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6.3 Material Sourcing Functional area


DAY I

9.00-10.00 AM Registration 10.00-11.00 AM Inauguration Chief Guest: 11.15-12.15 AM Textiles & Apparel – Introduction to current scenario,

International and national perspective. – Market dynamics.

12.15 -1.15 PM Textile Material Uniqueness and its properties 1.15-2.15 PM Lunch 2.15-3.15 PM Understanding and interpretation of specification sheet 3.15-4.15 PM Availability in the International Arena 4.15-4.30 PM Tea 4.30-5.30 PM Niche products and accessories

DAY II

9.30-10.30 AM 10.30-11.30 AM

Cotton material – Fibre to End product – Availability and Value addition.

11.30 – 11.45 AM Tea 11.45-12.45 PM Silk – Fibre to End product – Availability and Value

addition.

12.45 -1.15 PM Wool – Fibre to End product – Availability and Value addition.

1.15-2.15 PM Lunch 2.15-3.15 PM 3.15-4.15 PM

Other Natural fibres (Coir, Pineapple, bamboo etc)

4.15-4.30 PM Tea 4.30-5.30 PM Interaction on commodity trading

DAY III Industrial Visit – Fibre markets

DAY IV

9.30-10.30 AM 10.30-11.30 AM

Manmade fibres - Fibre to End product – Availability and Value addition

11.30 – 11.45 AM Tea 11.45-12.45 PM 12.45 -1.15 PM

Other manmade Fibres (mineral etc) Fibre to End product – Availability and Value addition

1.15-2.15 PM Lunch 2.15-3.15 PM Mean and standard deviation, co-efficient of variation- Quality

control charts for variables and attributes –

3.15-4.15 PM Acceptance sampling – AQL – Test of Significance 4.15-4.30 PM Tea 4.30-5.30 PM Quality Assurance – ISO 9000 Quality System

DAY V

154

9.30-10.30 AM Concept and application of fibre quality parameters of natural (Length, strength, fineness, maturity, moisture and trash) and man-made fibres ( Length, strength, fineness and crimp) – Fibre quality index and its relation with yarn strength and evenness

10.30-11.30 AM Quality parameters of spun(Count and Strength and its CV %, , Evenness, imperfection, hairiness, Classimat faults) and filament yarns (Count and Strength and its CV % , evenness) – Yarn testing concept application

11.30 – 11.45 AM Tea 11.45-12.45 PM Quality parameters of woven and knitted fabrics – Principle

and concept of Physical testing of fabrics – Fabric handle – Fabric Inspection – Fabric defects – Fabric grading system

12.45 -1.15 PM 1.15-2.15 PM Lunch 2.15-3.15 PM Garment quality parameters – 3.15-4.15 PM Quality control in pattern making, cutting and stitching –

Quality of trims and accessories

4.15-4.30 PM Tea 4.30-5.30 PM Quality control in garment finishing – Defects in garments

DAY VI Industrial Visit – Exposure to modern Testing

DAY VII

9.30-10.30 AM Job order Costing and its application in Garment industry. Marginal Costing technique for decision making

10.30-11.30 AM Costing in Knitting and Garments– Elements of cost 11.30 – 11.45 AM Tea 11.45-12.45 PM Calculation of garment weight of different sizes, Dia

determination, Setting the knitting program, Dyeing program

12.45 -1.15 PM Consumption of fabric per garment- Estimating of cost of process loss in Compacting, Bleaching, Raising, Shearing , Printing and Dyeing

1.15-2.15 PM Lunch 2.15-3.15 PM

3.15-4.15 PM

Estimating the Knitting rates- Calculation of CMT charges. Cost sheet with Profit margins and foreign quotes.

4.15-4.30 PM Tea 4.30-5.30 PM New concepts in costing – Activity based costing – Target

costing – Cost restructuring issues and Cost Reduction Measures in the textile industry

DAY VIII

9.30-10.30 AM Preparatory processes of woven fabrics – Singeing – Desizing – Scouring – Bleaching – Mercerizing – Heat setting – Other preparatory processes – Process flow charts – Machineries.

10.30-11.30 AM Classification of dyes – Theory of dyeing – Banned dyes and chemicals – Water quality – Water analysis – Waste water treatment.

155

11.30 – 11.45 AM Tea 11.45-12.45 PM Dyeing of cotton – Dyeing of polyester – Dyeing of blends –

Wool and Silk dyeing

12.45 -1.15 PM Yarn dyeing 1.15-2.15 PM Lunch 2.15-3.15 PM Woven fabric dyeing 3.15-4.15 PM Knit fabric dyeing 4.15-4.30 PM Tea 4.30-5.30 PM Garment dyeing – Washing – Stone washing, acid washing,

enzyme washing, bio polishing, bleaching, laser fading and ozone fading - laundering equipment and procedures – garment processing machinery.

DAY IX Industrial Visit – Exposure to Dyeing and Finishing

DAY X

9.30-10.30 AM Finishing of woven fabrics – Finishing of knitted fabrics – Tubular and open-width finishing.

10.30-11.30 AM Softener finish – Anti-shrink finish – Resin finish – Water proof finish – Fire retardant finish – Anti-bacterial finish.

11.30 – 11.45 AM Tea 11.45-12.45 PM Modern developments in chemical processing 12.45 -1.15 PM State and modernization of textile chemical processing

industry

1.15-2.15 PM Lunch 2.15-3.15 PM Finishing: Optical brightening, stiffening, softening, crease

resistant and crease retentive finish, anti-static finish, anti-bacterial finish,

3.15-4.15 PM water proofing, flame proofing, soil release finish, mildew and moth proofing – Stain removal, care labels.

4.15-4.30 PM Tea 4.30-5.30 PM Mechanical finishing : raising, sueding, other surface effects.

DAY XI

9.30-10.30 AM Product evaluation and profiling. 10.30-11.30 AM Production System - Products and Services – POM functions –

Operation Strategies

11.30 – 11.45 AM Tea 11.45-12.45 PM Competitive priorities of textile industry 12.45 -1.15 PM Productivity – Productivity Improvement 1.15-2.15 PM Lunch 2.15-3.15 PM Demand Forecasting – Delphi method – Moving Averages –

Exponential Smoothing –Simple Regression and Correlation analysis

3.15-4.15 PM Production Planning and Control in textile industry – Aggregate planning – Master production schedule –

4.15-4.30 PM Tea 4.30-5.30 PM Material requirement planning – Bill of material – Capacity

requirement planning – Introduction to ERP

DAY XII Practical Training in Garment CAD

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DAY XIII

9.30-10.30 AM Inventory Management – Types of Inventory – Cost of Inventory – Fixed Order Quantity Systems – Fixed Order Period Systems

10.30-11.30 AM Economic Order Quantity – Other Inventory models – ABC in Inventory classification – JIT in manufacturing – Kanban.

11.30 – 11.45 AM Tea 11.45-12.45 PM Manufacturing operations scheduling – Work centers – Work

centre scheduling –

12.45 -1.15 PM Sequencing – Priority Rules and Techniques – Shop floor Control –

1.15-2.15 PM Lunch 2.15-3.15 PM Facility layout – Process layout – Product layout 3.15-4.15 PM Line Balancing – Cellular layout 4.15-4.30 PM Tea 4.30-5.30 PM Job Design – Considerations in Job design – Work method

analysis – Work Measurement – Time study – Work sampling – Work loads in textile manufacturing

DAY XIV Practical Training in ERP Software

DAY XV

9.30-10.30 AM Determination and Description of Material Quality-Receiving and Incoming Quality Inspection , Acceptance Sampling Plans, Vendor process capability; Cost reduction Techniques-Standardisation, Simplification and Variety Reduction; Value Analysis and Engineering

10.30-11.30 AM Make or Buy Decision, Purchasing Research , Sources of Supply, Price Determination and Negotiation, Vendor Rating, Selection and Development,

11.30 – 11.45 AM Tea 11.45-12.45 PM Legal aspects of Purchasing ;Public purchasing and

Tendering ;

12.45 -1.15 PM International Purchasing- Procedures and Documentation; 1.15-2.15 PM Lunch 2.15-3.15 PM Purchasing of Capital equipment-Appraisal Methods,

evaluating Supplier’s Efficiency

3.15-4.15 PM Stores Layout, Classification and Codification; Material Logistics- Warehousing Management, Material Handling : Cases from Textile and Apparel Industry

4.15-4.30 PM Tea 4.30-5.30 PM Traffic and Transportation, Disposal of Scrap, Surplus

and Obsolete materials; Inventory control of spare parts, Materials Information System.

DAY XVI Out Door activity based learning - Ooty Soft Skills and Management games

DAY XVII

9.30-10.30 AM Introduction to energy management – need for energy

157

conservation – Demand side management – Energy Consumption of textile machinery – Specific Energy Consumption (UKG)

10.30-11.30 AM Cost of energy vs. sales value of textile products 11.30 – 11.45 AM Tea 11.45-12.45 PM Energy Conservation in textile industry – Energy

conservation in lighting, compressors and boilers – Energy Audit in a textile mill

12.45 -1.15 PM Captive generation and different types of fuels – Non conventional energy Sources – Co-generation

1.15-2.15 PM Lunch 2.15-3.15 PM Types of effluents produced by textile industry – Effluent

treatment processes

3.15-4.15 PM Recent developments like Reverse Osmosis – Concept of zero discharge

4.15-4.30 PM Tea 4.30-5.30 PM Water quality and test methods – Quality requirement of

process water and drinking water – Water Pollution –

DAY XVIII

9.30-10.30 AM Effluent standards of pollution control boards – Solid water management

10.30-11.30 AM Environment pollution and Industrialization – Environment impact assessment and environment management systems –

11.30 – 11.45 AM Tea 11.45-12.45 PM Air Pollution – Air pollution control and equipments in

industry – Air quality monitoring

12.45 -1.15 PM Noise pollution 1.15-2.15 PM Lunch 2.15-3.15 PM Introduction to Business Communication – Meaning and

significance – Types – Barriers –

3.15-4.15 PM Principles of effective communication Style of business writing

4.15-4.30 PM Tea 4.30-5.30 PM Business letters, routine, bad news, sales, collection and

application – Memorandum

DAY XIX

9.30-10.30 AM Individual; Presentation on Business topics relevant to Textiles and Apparel-Video Feedback.

10.30-11.30 AM Group Discussions. Seminars aimed at improving presentation skills.

11.30 – 11.45 AM Tea 11.45-12.45 PM 12.45 -1.15 PM

Individual feedback on Scope for improvement to be provided by Faculty and internal assessment components awarded on presentation skills

1.15-2.15 PM Lunch 2.15-3.15 PM Principles of non-verbal communication and their application

to clothing styles and body language -

158

3.15-4.15 PM Speeches, introduction, thanks, occasional and thematic - Dialoged communication - Interviews, selection, appraisal, discipline

4.15-4.30 PM Tea 4.30-5.30 PM Group communication - Structured and unstructured.

DAY XX

9.30-10.30 AM Internal and External Communication of an organization - Components of organizational communication.

10.30-11.30 AM Report writing - Structure of reports - Presentation skills - Effective use of audio-visual media .Cases from Textiles and Apparel

11.30 – 11.45 AM Tea 11.45-12.45 PM Conducting Meetings – Procedure – Preparing agenda -

Minutes of meetings – resolutions

12.45 -1.15 PM Conducting seminars and conferences – Procedures of regulating group discussions.

1.15-2.15 PM Lunch 2.15-3.15 PM 3.15-4.15 PM

Small test / Feedback / Other Discussions 4.15-4.30 PM Tea 4.30-5.30 PM Closing Ceremony Chief Guest

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6.4 Human Resource Functional area. \

The Training Module for Human resource Function

1. Prospecting and Selecting Employees for various positions: HRM – Introduction

Business Environment and HR Trends in HR

(i) Environmental Scanning

Forecasting the demand for employees Analyzing the current supply of Employees Decisions for Human Resource Planning

(ii) Human Resource Information System

(iii) Job Analysis: Writing Job Descriptions Job Specifications Job Design

(iv) Sources of Recruitment: Internal and External sources

Alternatives for Recruitment Cost Benefit Analysis on Recruiting

(v) Selection Process: Screening and Tests Interviews Cost Benefit Analysis on Selection

2. Laws related to Industrial Relation:

(i)The Factories Act (ii) Employee’s State Insurance Act (iii) Workmen’s Compensation Act (iv) Industrial Disputes Act (v)Employees Provident Fund and Miscellaneous Act (vi) Minimum Wages Act

3. Welfare Measures

(i)Statutory (ii) Non Statutory welfare measures

4. Training and Development

160

(i)Training Need Analysis (ii)Developing the Training Module (iii) Training Calendar (iv) On the job Training and Off the Job Training (v) Training Techniques (vi) Management Development Programmes (vii) Coaching (viii) Mentoring

5. Performance Management:

(i) Need for Performance Appraisal (ii) Techniques (iii) Performance Counselling (iv)Performance Interviews.

6. Compensation Management:

(i)Factors influencing the Compensation (ii) Pay Decisions – (iii).Pay structures – (iv) Direct and Indirect Compensation –

(v) Incentives : Financial and Non financial Days Titles 1 HRM – Introduction

Business Environment and HR Trends in HR

2 Environmental Scanning Forecasting the demand for employees

3 Analyzing the current supply of Employees Decisions for Human Resource Planning

4 Human Resource Information System

Job Analysis: Writing Job Descriptions Job Specifications Job Design

5 Sources of Recruitment: Internal and External sources

Alternatives for Recruitment

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Cost Benefit Analysis on Recruiting

6. Selection Process:

Screening and Tests Interviews

Cost Benefit Analysis on Selection 7. The Factories Act

8. Employee’s State Insurance Act 9. Workmen’s Compensation Act

10. Industrial Disputes Act

11. Employees Provident Fund and Miscellaneous Act

12. Minimum Wages Act 13. Statutory and

Non Statutory welfare measures

14. Training Need Analysis Developing the Training Module Training Calendar

15 On the job Training and Off the Job Training Training Techniques Management Development Programmes Coaching Mentoring

16 Need for Performance Appraisal Techniques

17 Performance Counselling Performance Interviews

18 Factors influencing the Compensation Pay Decisions Pay structures

19. Direct and Indirect Compensation Incentives : Financial and Non financial

20 Case Discussion

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6.5 Finance functional area


DAY I 9.00 – 10.00 AM Registration 10.00 – 11.00 AM Inauguration Chief Guest11.15 – 12.15 AM Financial Management-Introduction, Overview and

Current practices

12.15 – 1.15 PM Introduction to Book Keeping and Accounting– meaning and importance –Distinction between the Book Keeping and Accounting

1.15 – 2.15 PM Lunch 2.15 – 3.15 PM Detailed discussion on various aspects of accounting -

the Account - Debit and Credit – rules for debit and credit.

3.15 – 4.15 PM The books of accounts - The Journal – The Ledger – The Trial Balance

4.15 – 4.30 PM Tea Break 4.30 – 5.30 PM The adjusting and closing process: Need for adjusting

entries – Types of adjusting entries – closing entries

DAY II 9.30 – 10.30 AM Ruling and Balancing account – Summary of the

accounting process – Subsidiary books – Internal controls.

10.30 – 11.30 AM Significant book keeping ideas- discussion with practical examples followed in the industry.

11.30 – 11.45 AM Tea Break 11.45 – 12.45 PM Introduction to Computerised accounting methods 12.45 – 1.15 PM computers and accounting – need for computerized

accounting methods

1.15 – 2.15 PM Lunch 2.15 – 3.15 PM maintaining accounting data base systems- role of

computers in accounting

3.15 – 4.15 PM manual accounting – its relationship to computerized accounting - advantages of computerized accounting methods over manual accounting

4.15 – 4.30 PM Tea Break 4.30 – 5.30 PM software packages for accounting – significance of

accounting softwares

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DAY III Practical training on TALLY 1. Company Creation and Alteration 2. Creating and Displaying Ledger 3. Voucher Creation 4. Voucher Alteration and Deletion 5. Inventory Information – Stock Summary

DAY IV Practical training on TALLY 6. Inventory Information – Godown Creation and alteration 7. Final Accounts 8. Bank Reconciliation Statement 9. Accounting and Inventory Information’s 10. Bill wise Statements.

DAY V Industrial visit to Textile companies – practical exposure to other Accounting Softwares

DAY VI 9.30 – 10.30 AM Working Capital Management –Introduction –

Concept – Need for working capital – Types of Working capital

10.30 – 11.30 AM Techniques for assessing the working capital requirements

11.30 – 11.45 AM Tea Break 11.45 – 12.45 PM sources of finance for working capital – Bank credit-

Appraisal of working capital by banks – Commercial paper

12.45 – 1.15 PM RBI guidelines on lending for working capital 1.15 – 2.15 PM Lunch 2.15 – 3.15 PM Approaches for determining the working capital

financing mix

3.15 – 4.15 PM Issues in managing the Optimum level of Working Capital

4.15 – 4.30 PM Tea Break 4.30 – 5.30 PM Practical problems of managing working capital –

Examples or case study from the industry

DAY VII 9.30 – 10.30 AM Receivables management- Introduciton- importance-

objectives – cost of credit extension – benefits

164

10.30 – 11.30 AM credit policies – Credit terms, Collection policies 11.30 – 11.45 AM Tea Break 11.45 – 12.45 PM Issues in Receivables Management 12.45 – 1.15 PM Inventory Management – Introduciton- importance-objectives

classification and coding – cost of holding inventory- inventory models – inventory valuation

1.15 – 2.15 PM LUNCH

2.15 – 3.15 PM Inventory - classification and coding – cost of holding inventory- inventory models – inventory valuation

3.15 – 4.15 PM Issues in Inventory Management 4.15 – 4.30 PM TEA 4.30 – 5.30 PM Practical problems in receivables and inventory management –

examples from the industry DAY VIII Industrial Visit – How industries Manage their Working Capital DAY IX 9.30 – 10.30 AM Cash Management- Introduction – importance Motives for

holding cash

10.30 – 11.30 AM Objectives of cash management 11.30 – 11.45 AM Tea Break 11.45 – 12.45 PM - Basic problems in managing cash – Controlling the level of cash

– controlling the inflows of cash- 12.45 – 1.15 PM controlling the outflows of cash- optimum investment of surplus

cash. 1.15 – 2.15 PM Lunch 2.15 – 3.15 PM Cash Management models for determining the optimum level of

cash balance - Baumol model- Miller –Orr model 3.15 – 4.15 PM Practical issues in cash management 4.15 – 4.30 PM Tea Break 4.30 – 5.30 PM Practical problems of managing cash – Examples or case study

from the industry DAY X 9.30 – 10.30 AM Overview of Banking Services - Definition of banker and

customer – Relationships between banker and customer - Opening of account – special types of customer

10.30 – 11.30 AM Types of deposit – Bank Pass book-Banking regulation Act 1949

166

11.30 – 11.45 AM Tea Break 11.45 – 12.45 PM RBI credit control Measure 12.45 – 1.15 PM Managerial functions in banks- Bank deposits

accounts- Loans and Advances;

1.15 – 2.15 PM Lunch 2.15 – 3.15 PM Lending practices; Types of advances 3.15 – 4.15 PM Principles of sound bank lending; 4.15 – 4.30 PM Tea Break 4.30 – 5.30 PM preparation of reports; credit plans; planning

customers; limits of credit; security

DAY XI 9.30 – 10.30 AM Negotiable Instruments - Meaning, Types, Cheque,

Bills of Exchange and Promissory Notes, Features of Negotiable Instruments -Crossing and Endorsement.

10.30 – 11.30 AM Management of finance: Bank accounts; Records; Reports;

11.30 – 11.45 AM Tea Break 11.45 – 12.45 PM Statement of advances 12.45 – 1.15 PM Evaluation of loan applications; 1.15 – 2.15 PM Lunch 2.15 – 3.15 PM profit and loss account; balance sheet and statutory

reports regarding cash revenue

3.15 – 4.15 PM Practical issues in banking – examples from the industry

4.15 – 4.30 PM Tea Break 4.30 – 5.30 PM Practical issues in negotiable instruments– examples

from the industry

DAY XII 9.30 – 10.30 AM Investment Management – introduction- Nature of

bank investment; Liquidity and profitability;

10.30 – 11.30 AM preparation of cheques; Book debts; Securities - government and commercial.

11.30 – 11.45 AM Tea Break 11.45 – 12.45 PM Bill of lading; 12.45 – 1.15 PM Other Banking Services- Foreign Exchange

Management

1.15 – 2.15 PM Lunch

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2.15 – 3.15 PM Letter of credit. 3.15 – 4.15 PM Purchase and discounting bill 4.15 – 4.30 PM Tea Break 4.30 – 5.30 PM Traveling cheque, credit card, Teller system DAY XIII 9.30 – 10.30 AM New Modes of Financing 10.30 – 11.30 AM – Leasing as Source of Finance – Forms of leasing 11.30 – 11.45 AM Tea Break 11.45 – 12.45 PM Leasing- Current practices with examples from the

industry

12.45 – 1.15 PM Venture Capital –Dimension Functions – Venture Capital in India.

1.15 – 2.15 PM Lunch 2.15 – 3.15 PM venture capital - Current practices with examples

from the industry

3.15 – 4.15 PM Factoring and Forfaiting – Types – Modus Operandi of Factoring – Factoring as Source of Finance Factoring

4.15 – 4.30 PM Tea Break 4.30 – 5.30 PM Factoring - Current practices with examples from the

industry

DAY XIV 9.30 – 10.30 AM Securitisation of assets – Mechanics of Securitisation-

Utility of Securitisation

10.30 – 11.30 AM Securitisation in India – Current practices 11.30 – 11.45 AM Tea Break 11.45 – 12.45 PM Banks as Financial Intermediaries. 12.45 – 1.15 PM Role of Commercial Banks Financing/Term lending 1.15 – 2.15 PM Role of IDBI, IFCI, LIC, GIC, UTI 2.15 – 3.15 PM Banks as Mutual Fund and Investment Companies. 3.15 – 4.15 PM Role of banks as issue managers 4.15 – 4.30 PM Tea Break 4.30 – 5.30 PM Role of banks in corporate restructuring DAY XV 9.30 – 10.30 AM Taxation – Introduction & Overview 10.30 – 11.30 AM Income Tax Act – Definition of Income – Assessment

year – Previous Year.

11.30 – 11.45 AM Tea Break 11.45 – 12.45 PM Assessee – Scope of Income – Charge of Tax –

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Residential Status – Exempted Income. 12.45 – 1.15 PM Heads of Income: Income from Salaries – Income

from House Property -Profit and Gains of Business or Profession

1.15 – 2.15 PM Lunch 2.15 – 3.15 PM Income from Other Sources. 3.15 – 4.15 PM Capital Gains –Introduction and Overview 4.15 – 4.30 PM Tea Break 4.30 – 5.30 PM Deductions from Gross Total Income – with

illustrations

DAY XVI 9.30 – 10.30 AM Set off and Carry forward of losses 10.30 – 11.30 AM Aggregation of Income 11.30 – 11.45 AM Tea Break 11.45 – 12.45 PM Computation of Tax liability 12.45 – 1.15 PM Assessment of Individuals 1.15 – 2.15 PM Lunch 2.15 – 3.15 PM 3.15 – 4.15 PM

Practical problems in taxation

4.15 – 4.30 PM Tea Break 4.30 – 5.30 PM Illustrations from the industry DAY XVII 9.30 – 10.30 AM Special features of Indirect Taxes - Contribution to

government revenues - Taxation under the constitution - Advantages and Disadvantages of Indirect Taxes.

10.30 – 11.30 AM Corporate Tax- Introduction and Overview 11.30 – 11.45 AM Tea Break 11.45 – 12.45 PM Excise- Introduction and Overview 12.45 – 1.15 PM Levy and collection of Excise duty - Kinds of Excise

Duty - Basic conditions for liability to Excise

1.15 – 2.15 PM Lunch 2.15 – 3.15 PM Concept of Goods- Excisability and Intermediate

Products- Packing, Labelling and branding of goods- Valuation of excisable goods -

3.15 – 4.15 PM Registration in Central Excise -Procedure for Registration -Automatic or Deemed Registration.

4.15 – 4.30 PM Tea Break 4.30 – 5.30 PM Customs – Introduction and Overview

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DAY XVIII Out bound training – soft skills and personality development

DAY XIX 9.30 – 10.30 AM VAT: Terms and Definitions and Overview

10.30 – 11.30 AM VAT System in Tamilnadu – Registration of Dealers – Input and Output Tax – Exempted Sales and Zero Rated Sales – Penalties – Filing of Return

11.30 – 11.45 AM Tea Break 11.45 – 12.45 PM VAT as applicable to textile units 12.45 – 1.15 PM Main features of the Service Tax 1.15 – 2.15 PM Lunch 2.15 – 3.15 PM Customs Duty - Different Types of Customs Import

Duties

3.15 – 4.15 PM Abatement of duty in Damaged or Deteriorated Goods - Remission on duty on lost, destroyed or abandoned goods

4.15 – 4.30 PM Tea Break 4.30 – 5.30 PM Customs Tariff Act 1985 - Customs Duty Drawback. DAY XX 9.30 – 10.30 AM Central Sales Tax Act 1956 – Overview-Objectives of

the CST

10.30 – 11.30 AM Levy and Collection of CST – Sales and Deemed Sales - Subsequent sales

11.30 – 11.45 AM Tea Break 11.45 – 12.45 PM Practical examples – from the industry 12.45 – 1.15 PM Registration - Compulsory Registration - Voluntary

Registration- Security from dealer-registration procedure.

1.15 – 2.15 PM Lunch 2.15 – 3.15 PM 3.15 – 4.15 PM

Feedback and Other Discussions

4.15 – 4.30 PM Tea Break 4.30 – 5.30 PM Valedictory Chief Guest

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ANNEXURE: Questionnaire

QUESTIONNAIRE FOR UNDERSTANDING THE GAP IN THE KNOWLEDGE LEVEL OF MANAGERS IN THEIR FUNCTIONAL AREAS

WORKING IN THE GARMENT INDUSTRY AT TIRUPUR

Section – A (Common to all)

1. Name:

2. Designation:

3. Address:

4. Phone no/Mobile no:

5. Qualification/s:

6. Experience (starting with present experience)

Organisation Area of responsibility Experience

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7. What is your present functional responsibility? (If you are not assigned with any responsibility related to specific functional area, please mention NIL. You can also add other functional areas, if you are doing anything other than the area mentioned here)

Functional Area Responsibility

Production

Merchandising

Production Planning and

Sourcing of Materials

Human Resources

Finance and Costing

Any other(Please specify)

8. Do you posses HR management skills to manage labours and other

members in the supply chain? Yes No

9. Do you feel the present area of experience and knowledge is sufficient to discharge your responsibilities of your area of function?

Yes No

10. Is your technical knowledge upto date? Yes No

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11. If you wish to update your skills, what will be your convenient timings?

Section B (For Functional area -Production)

1. Are you thorough with A. production planning, B.budgeting and costing,

C.machinery planning and D. layout

2. Do you know Standard Alerted Minute (SAM)?

3. Are you well versed in quality controlling techniques as well as newly developed fabrics?

4. Are you familiar in Lighting impact, ergonomics and other industrial engineering aspects?

5. Are you aware of Statistical Quality Control and Operations Research?

6. Do you know about Lean Manufacturing?

(SECTION C-For Functional area -Merchandising) 1. Are you aware of Propecting, Vendor Evaluation? 2. Are you familiar with Sample and Product Development techniques?

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3. Are you familiar with Printing Dyeing and Washing methods? 4. Are you familiar with sketch studying and Garment Construction methods? 5. Are you familiar with department wise costing details? 6.How good are you in Communication, Interpersonal skills?

7. How familiar are you with fabric consumption details?

(SECTION D-For Functional area –Materials Sourcing)

1. How familiar are you with specification of Fabrics, Geographical availability and Price?

2. How familiar are you with Trims and Accessories-quality parameters? 3. Are you good in interacting with merchandiser for requisition/ 4. How familiar are you in Negotiating and communication skills?

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5.How familiar are you with incoming quality inspection, Lot to lot variation of incoming materials/

(SECTION E_For Functional area –Human Resources) 1. How familiar are you with Prospecting and selecting employees for various positions? 2. How familiar are you with the various Laws of Industrial Relations? 3.How familiar are you with the various Welfare measures ? 4. How familiar are you with the procedures of Rewarding employees for Better performance? 5. How familiar are you in measuring performance of Employees? 6.How familiar are you with Training and Development of Employees?

(SECTION F-For Functional area –Finance)

1. How familiar are you with Book Keeping Practice? 2. Do you follow a Computerised accounting method?

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3. How familiar are you with working capital Management Practices?

4. How familiar are you with cash Management? 5. How familiar are you with banking Procedures? 6.How familiar are you with various taxation Procedures?

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References

1. Apparel Export Promotion Council (AEPC), various issues, Handbook of

export statistics, Ministry of Textiles, Government of India, New Delhi

2. Ministry of Textiles (2006), Report of the Committee to Assess the Requirement of Human Resources in the Textiles sector-Vision 2010

3. Rehman, Atiq ur and Ghulam Ali (2008). A Study of the Skills Gap along the Cotton Value Chain:Garments Segment.

Retrieved from http://www.icac.org/tis/regional_networks/documents/asian/papers/ali.pdf

4. National Skill Development Corporation(NSDC),Human Resource and

requirements in the textile sector (2022)

Indian Textile and Clothing

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