an organisation study at bombay rayon fashion ltd

An Organization Study At Bombay Rayon Fashions Ltd

INDIAN ACADEMY DEGREE COLLEGE, BANGALORE

INTRODUCTION:

The Internship program as part of the curriculum of Bangalore University for MFA students

plays a vital role to bridge the gap between the theories studied and the real business world. It

helps the students to get the real exposure in understanding the functioning of an organization.

The internship study helps to enrich the practical knowledge of the students on activities of the

organization, its functional departments, organizational structure, strengths, weakness,

opportunities, threats and the business performance in terms of growth and market share.

The present study was carried out at Bombay Rayon Fashion Limited industrial area

Doddaballapur Bangalore rural (district) to understand the overall organization.

The study started on a daily basis visit to the organization. Through the method of observation

and informal discussions the information are collected at primary level and the secondary sources

includes both published and unpublished sources. The factual information was mainly collected

from published annual reports of the company.

TITLE OF THE STUDY:

The Title of the study is “AN ORGANIZATIONAL STUDY AT BOMBAY

RAYON FASHIONS LIMITED”

OBJECTIVES:

To understand the practices of an organization by relating to managerial theory.

To study the Departmental strategies and their functioning of an organization.

To understand how the key business process are carried out in organization.

To study the procedures and programs of the company and study their effectiveness.

SCOPE:

The internship study mainly aims in risk involved in production process and export of textile

products. And the study was also carries on in other departments like H R Department,

Production Department, marketing Department, finance Department. From which the

applicability of theoretical knowledge to practical work was came to know.



LIMITATIONS OF THE STUDY:

Data fetching was difficult due to busy work schedule of the employees.

It was difficult for the officials to give detailed description about to their routine work.

Some of the facts and figures were kept strictly confidential by the management.

Most of the data was not kept in the branch, it was in head office.

Some of the employees were ignorant to give information.

Lack of co-ordination from certain departments due to their work load.



INDUSTRY PROFILE

HISTORY AND GROWTH OF THE TEXTILE INDUSTRY IN INDIA:

The Indian textile industry has a great legacy, which is perhaps unmatched in the history

of India’s industrial development. India’s textile industry evolved and developed at a very early

stage and its manufacturing technology was amongst the best. Prior to colonization, India’s

manually operated textile machines were among the best in the world, and served as a model

for production of the first textile machines in newly industrialized Britain and Germany. Indian

textiles were sought after for their finesse, quality and design. According to Chouta-Kuan, the

Chinese observer preference was given to the Indian weaving for its and delicacy’ Prestige

trade textiles such as Patola from Patna and Ahmedabad, coast were sought after by the

Malaysian royalty and wealthy traders of the Philippines. Textiles have historically formed an

important component of India’s exports. Marco Polo’s records show that Indian textiles used

to be exported to China and South-East Asia. Textiles have also comprised a significant portion

of the Portuguese trade with India.

The attractiveness of the fast dyed, multi-colored Indian prints on cotton (chintz) in

Europe led to the formation of the London East India Company in 1600, followed by Dutch

and French counterparts. By the late 1600s there was overwhelming demand for their

governments to ban the import of these cottons from India. The legacy of the Indian textile

industry stemmed from its wealth in natural resources silk, cotton and jute. The textile industry

stemmed from its wealth in natural resources silk, cotton and jute, the technology used was

superior and the skills of the weavers gave the finished product a most beautiful and ethnic

look. The Indian textile industry with such a great pedigree could have gone only on way from

here. But same did not happen.

GARMENT PRODUCTS EXPORTED FROM INDIA

India is known as a GROUP II country which exports simple, low value products with low to

medium price range like basic woven tops (Ladies blouses, Men’s shirts, T-shirts) and a small

quantity of trousers, skirts, jackets/coats, ladies dresses. Indian apparel is made mainly with

cotton fabric having different and small production of wool and blended garments.



GROWTH AND PROSPECTS OF THE INDUSTRY:

Information revolution promises to bring the world closer to cohesion. In the emerging

face of fast moving information, technological transfer is bound to take place at a higher speed.

As the International borders blur supply Chain Management and Information

Technology take a crucial role in Apparel manufacturing. Global partners in the clothing supply

chain are exchanging information electronically, thus the need for Indian Clothing Industry to

spruce up.

Upcoming technologies for mass customization such as three dimensional non contact

body measurement and digital printing ought to be discussed thoroughly and implemented fast.

This mass customization shall be successful for meeting unpredictable demand levels, for

luxury goods, uncertain customer wants and for heterogeneous demand. It is to be noted that

mass customization is different from mass production.

The future requires generation of real value service for the customers, comprehensive

study of multifaceted and multi-layered supply chain, and global integration of supply system

in a cost and time effective manner. Inventory planning, sales forecasting, manufacturing

strategy, distribution network and transportation management are some of the areas which need

improvement. The economic scene of US and its trade partners need to be eyed carefully if

India is to survive in the faster and throat cut competition of 21st century.

As well as the appreciation of the rupee against the dollar, India’s exports are being hit

by increasing competition from China. The effects of a weakening dollar are having less impact

however, on neighboring Pakistan, Bangladesh and Srilanka, which are emerging competitors

to the India in the international textile and garment market.

MAJOR PLAYERS IN THE INDUSTRY:

Raymond group of Companies.

Nitisun Fabs.

AS Internationals.

Gokaldas Companies.



CHALLENGES OF THE INDUSTRY:

The industry is back loaded with technological obsolescence and sub-scale of

operations.

Indian industry is had been plagued skilled labour problems.

Lack of modernization.

Cotton apparels constitute major part of India’s apparel exports, although cotton

appears to be out thing in current global markets.



HISTORY OF THE COMPANY

Bombay Rayon Fashion Limited (BRFL) was established by Mr.Janardhan Agrawal in 1986.

On 1990 The First fabric manufacturing facility of the group comes into existence at

Maharashtra for domestic fabrics. On 1998 BRFL starts exports of fabrics. In 2001 the

commencement of garmenting division of the group. The company got their present name,

Bombay Rayon Fashion Limited (BRFL) during the year 2003-2004. In March 2005 BRFL

amalgamated with two partnership firms that are B R Exports and Garden City Clothing and

also BRFL, company makes a successful IPO & is listed on all stock exchanges in India. In

2005/06 BRFL Group sets up 7 garments manufacturing facilities in Bangalore with 7000

machines. And on 2007 Commencement of the mega USD 250 million textiles & garment

project under a special MOU signed with the government of Maharashtra.

BRFL is setting up new manufacturing unit in Karnataka (Bangalore), Maharashtra

(Navi Mumbai). The company exports its products to the United States, United Kingdom and

rest of Europe. Bombay Rayon Fashion Limited (BRFL) has been allotted 20.16 acres of land

in the Apparel Park at Doddaballapur for setting up an integrated textile project of yarn dyeing,

weaving, process house and garment manufacturing. Based on the Techno-Economic

Feasibility Report prepared by Gherzi Eastern Limited, Mumbai, the total cost of the Integrated

Textile Project at Doddaballapur, Bangalore at the time of Initial Public Issue was estimated at

Rs.161.72Cr.The Company has expanded the scope of the aforesaid project in view of setting

up a new green field Garment facility for 7.8 million pieces pa at Bangalore. The total cost

after the new plans has increased to Rs. 246.72 Cr.

GROWTH OF THE COMPANY

The Indian textile industry is seldom held as a proxy for growth. But that is where

Bombay Rayon Fashions Limited (BRFL) is different from the rest. It believes that here lies

the opportunity. Because the Indian textile industry has such strengths. Bombay Rayon Fashion

Limited is one of the largest players in the Textile market. They are growing through several

ways. Through integration, through expansion, through acquisition. Every conceivable way

through which they can grow and create sustainable value for every stakeholder.



They are one of the most integrated companies, present across the value chain from

fabric to garments. They are adding capacities in every segment including yarn dyeing,

weaving, processing, garmenting and now in retail. They are also growing inorganically not

just to build size, but also for integration. They have acquired the garment business of three

companies, one distribution company in U.K and an Italian retail brand 'GURU', thus

integrating further into international retail. The BRFL is one of the few large scale, fully-

integrated textile companies in the country. From design to yarn dyeing to fabric manufacturing

to garment manufacturing to retail, they have a strong presence across the entire value chain.

1) INTEGRATED GROWTH:

A holistic approach to growth is what will differentiate those who create growth from

those who participate in it? All company prefers the former. We lead multiple ways to grow.

The vision is simple. To become a global leader in the fashion textiles and apparel industry as

an integrated player by focusing on design leadership, exemplary execution and superior

service. BRFL is one of the few large scales, fully-integrated textile companies in the country.

From design to yarn dyeing to fabric manufacturing to garment manufacturing to retail and

have a strong presence across the entire value chain and keep growing this. Being integrated,

they add value and margins since to capture everything internally. The customer stays longer,

buys more. Integration helps in reduce the time-to-market with shorter lead times for the client.

This helps the client introduce more fashion and earn better margins. And the client pays more

for this, adding to company’s margins, cash flow and ROCE too.

2) ORGANIC GROWTH:

Having become an integrated player, company becoming even stronger by adding significant

size and are growing organically by expanding the business in every possible area.

Company is using intellect to expand organically and adding capacities and size as more

customers prefer and the same customer buys more.

Company is expanding yarn dyeing capacity from1.4 million kg p.a. to 11.9 million kg

p.a. and expanding fabric manufacturing capacity from 55 million meters p.a. to 235 million

meters p.a. and expanding garment manufacturing capacity from 30 million pieces p.a. to 75

million pieces p.a. By aiming to become the lowest cost producer of fabrics in the world by

creating the best manufacturing facilities. New manufacturing units are being set up in

Maharashtra (for fabrics and garments) and in Bangalore, Karnataka (for garments). The

project in Maharashtra has already received approvals from the Ministry of Textiles under the

Scheme for Integrated Textile Parks (SITP) through SPVs.



3) INORGANIC GROWTH:

The world is our stage. We aspire to be an integral part of the global textiles space,

catering to customers in every part of the world. Our aim is inclusive, all-encompassing growth.

Not just organic, but inorganic as well. We are constantly exploring opportunities that offer us

a strategic advantage is it the client base, the expertise or the size. If we see an inorganic

opportunity that helps company to attain their vision faster, better, acquire it. Company did that

not once, but four times in the last one year.

BRFL VISION:

To be a Complete Fashion Apparel Company focused on Total Customer Orientation, attaining

a Position of Pride for stakeholders through creation of Congenial Business Environment,

offering Products and Services Par Excellence.

BRFL MISSION:

1. Most innovation – sought after Fashion Apparel and Fabrics Manufacturer.

2. Most dependable for shortest turnaround time.

3. Most reliable for quality, service and deliveries.

4. Most permanently bonded with customers, suppliers and other stakeholders.

5. Most valued employer.

6. Most looked up to for transparency, Government and social responsibility.

BRFL GOALS AND OBJECTIVES:

1. To improve the quality.

2. To maintaining good customer relation.

3. To providing employment for unemployment.

4. To expansion of the company throughout the world.



Designation Name of the person

Chairman Mr. Janardan Agarwal

Vice Chairman Mr. Aman Agarwal

Joint Vice Chairman Mr. Naseer Ahmed

Managing Director Mr. Prashant Agarwal

Executive Director- Finance Mr. A .R. Mundra

Executive Director- Corporate Mr. Uday Mogre

Director Mr. S. B. Agarwal

Director Dr. Pravin P. Shah

Nominee Exim Bank Mr. John Mathew

Company Secretary Ms. Prachi Deshpande

Auditors Registered Office

V. K. Beswal & Associates,(C A)

D-1st Floor, Oberoi Garden Estates,

Chandivali Farms Road, Chandivali.

Mumbai- 400 072.

The Company's shares are listed on:

LISTINGOF EQUITY SHARES

(Listing fees paid)

The National Stock Exchange of India Ltd.

("NSE") and The Bombay Stock Exchange

Limited ("BSE").

Bombay Rayon Fashions Ltd



Plant Address

KIADB, Apparel park,

Near Railway -Station,

Doddaballapur, Bangalore-561 203

THE FOUNDER SPEAKS:

At Bombay Rayon, it continues to lead the field by focusing on what

we know best. Creating exclusive top of the line garments, and suiting and shirting for those

who love the very concept of dressing up. From the shirting to the fabrics, and to the formal

wear and exclusive collections, when it comes to corporate performance and refreshing

lifestyle, Bombay Rayon has always been a leader.

Since 1986, Bombay Rayon has been the name India relies on for clothing that fits the active

Indian spirit. Bombay Rayon provides apparels that are inspired by the five basic elements that

make up the atmosphere and the garments do perform. Exclusive construction details and only

the finest fabrics ensure our patrons will be equipped to take on whatever challenge comes their

way. It has always wanted the customers to head out in the adventure of their lives in the brand

that has made living and lifestyle great for nearly two decades. Bombay Rayon.

It was still remember the time when the both son’s stepped onto the corridors of the

manufacturing unit. The overwhelming sense of achievement that was witnessed on their faces

then, continues to inspire her in walking to the extra mile. What began as a small business

enterprise in the mid-eighties is now a powerhouse textile giant catering to the needs of people

from across global parameters. Bombay Rayon has not only instilled in its employees a never



ending drive to reach out, but has also equipped their families with a sense of pride and

achievement; such that no other can parallel. This in essence is that their real accomplishment

and Bombay rayon shall always live up to the intrinsic demands and expectations of India and

the world.

Bombay Rayon’s product designs are all about being at ease in comfortable clothing

with effortless style so the clientele never have to worry about the wearing. At work or at your

leisure, with the Bombay Rayon tag, our patrons can never cease to enjoy the simple comfort

of just being it. That’s a promise, which over time has transformed into a cherished legacy and

a trusted assurance matched by none. Let me hereby reaffirm, “This distinction will always be

the hallmark of the brand that’s Bombay Rayon.”

It was in multi divisional textile company engaged in the manufacture of a Variety of

fabrics and garments with modern production facilities. That is grouped in manufacturing

fabrics and expanded the fabrics capacity and started catering to premium shirting segment.

Realizing the potential the group as intently moved towards the garment manufacturing mainly

to conserve the fabrics margins and take advantage of the higher margins offered by the

designer, fancy shirt segment.

Presently it is exporting 100% of their garments. However it supply fabrics to the

domestic garment exporters and it has positioned there selves as a multi-product, multi fiber

and multi market player ensuring that their target market is a diverse mix of the domestic fabrics

market, garment export trade and international market. The manufacturing facilities are spread

across four locations at Navi Mumbai, Silvassa, and Sonale in Thane district and Bangalore,

fully backed by the facilities for product development, design studio and efficient sampling

infrastructure to provide quality services to its customers in India and abroad. It currently

employed over 5000 people. Presently it has 250 weaving machines producing approximately

20 million meters of woven fabric. Per annum 2800 sewing machine with production capacity

of 8.4 million garments per annum.

BRFL Competitive Strengths:

Experience of their promoters

Flexibility in manufacture of garments

Designing capabilities



Lower turnaround time

Low labour cost

Economies of sale

High productivity

Quality assurance

Sampling capabilities

HIGHLIGHTS:

EXPERIENCE OF OUR PROMOTERS:

The promoters and it has adequate experience in the textile industry and it has

successfully implemented expansion project earlier. It has also adequate technical and

commercial staff to handle implementation of the proposed new expansion project.

FLEXIBILITY IN MANUFACTURE OF GARMENTS:

The company was in the business of manufacture of woven fabric and for the last fifteen

years it has been our main stay. It has been for the period of time developed expertise in the

manufacture of any customer desired variety involving complex design of woven fabrics of

superior quality.

DESIGNING CAPABILITIES:

Designing is a critical element of fabrics and garments both. Development of innovative

designs is one of our main strengths. It is also our USP (UNIQUE SELLING PROPOSITION).

It has into the high end products it has in house teams of experienced designers in weaving

garmenting and home textiles. It has installed software packages CAD/CAM systems for

generating designs on computers. At least 4-5 new designs are developed on a daily basis in

each of the divisions.

LOWER TURNAROUND TIME:

Garment manufacturing is highly fashion oriented. Fashion is time bound and delay in

meeting deadlines results in loss of businesses. Meeting customer deadlines on a consistent

basis is important for business. Our in house facilities of design studio, sampling of fabrics and

garments, weaving, and garmenting allows us to plan and deliver the order in shortest

turnaround time.



ECONOMIES OF SCALE:

The company‘s production capacity in each of the units or divisions can be considered

mid to large size. It allows us the advantage of economies of scale. Although the units are

spread over different locations, the raw material procurement and purchase functions are

centralized. And therefore it takes the advantages of bulk discounts.

HIGH PRODUCTIVITY:

High level of modernization, trained work force and managerial expertise results in

consistent high level productivity. It has established modern production facilities at each of the

plant and it has continuously on the lookout for new or updated technologies. The company is

in the investment of value adding equipment’s or attachments to the machines as resulted in

twin benefits of consistent high quality and improves productivity.

QUALITY ASSURANCE:

Each of the company’s products passes through stringent quality checks. The quality

assurance measures taken by the company include through checking of all raw material and

other inputs right down to finished goods to ensure quality, statistical methods to identify and

analysis areas of improvement, experienced man power for quality assurance activities,

creation of data base for future reference and analysis etc.

SAMPLING CAPABILITIES:

The company has all the facilities like desk looms, sample dyeing, sample printing,

washing and processing facilities to produce fabric samples per designs developed by the

design studio. In the initial stages of the order the design and sampling department continuously

interacts with the buyers till the fabric sample is approved. Sample Yardages are made for

making garments and it has dedicated fabric sampling unit, garment samples are made, remade,

design changes are incorporated till the customer finally approves the garment sample. This

entire process is very time consuming and can take 2 months dedicated in house facilities

enable it to compress this time substantially.

CLIENTS FOR BRFL:

Federated store –USA

(Macys & Bloomingdales)

VF (WRANGLER) – USA

Liz Claiborne –USA



DKNY –USA

ECKO –USA

MARK ECKO –USA

Guess –Italy

Roberto Cavalli -Italy

Tom tailor – Germany

Otto’s Germany & Switzerland

C &A Chain of stores – Germany

Kiabi stores – France

WR Replay –Italy

BHS – UK

Burtons – UK

Top man – UK

Kickers –UK

Next –UK

GEORGE – UK

CONTACT DETAILS:

BOMBAY HEAD OFFICE

-Mr. Aman Agarwal

Vice Chairmen -Mr. Prashant Agarwal

Managing Director -Mr. Nazim Khan.

MILESTONE:

Established in 1986, BRFL is on the verge of completing 25 glorious years in the industry.

The journey of the organization has been dynamic.

1986: Mr.Janardhan Agarwal established the Bombay Rayon Group.

1990: Maharashtra gets its first fabric manufacturing facility.

1998: Bombay Rayon Group commences export of fabrics.



2000: Launch of Garment division.

2005: Bombay Rayon Group business is consolidated into BRFL.

2005: The Company makes a successful IPO with a listing on all the stock exchange in

India.

2005: BRFL acquires DPJ clothing UK, supplying to high street retailers in UK.

2005: Set up of 7 garment manufacturing facilities in Bangalore with around 7000

machines.

2007: BRFL acquire “Leela Scottish Lace”, one of the Largest garment manufacturing

unit set up in India, making BRFL one of the largest apparel group in India.

2007: BRFL acquire “LNJ Apparel” a 1000 machine specialized bottoms plant.

2007: BRFL marks the commencement of the mega USD 250 million Textiles and

Garment Project under a special MOU signed with the government of Maharashtra.

2007: BRFL establishes a fully integrated textile mill in Doddaballapur, Bangalore with

a capacity to process 1 lakh meters per day.

2008: BRFL acquires the iconic brand “GURU”.

2009: BRFL is sanctioned the project under the scheme for Integrated Textile Park

(SITP) by the Government of India.

2010: BRFL establishes the world’s largest fabric processing capacity of 5 lakh meters

per day at Tarapore.

2010: BRFL acquire STI India Ltd, a world class producer of 100% cotton yarn.

BOARD OF DIRECTORS:



MR. J D AGARWAL (CHAIRMAN)

The key person behind the establishment and growth of the Bombay Rayon Group is Mr. JD

Agrawal. He founded the company in 1986 and as Chairman; he has led the company to greater

height of success with a strategic approach. He has brought innovations in his business. Be it

the establishment of the Bombay Rayon brand of fabric in the local retail market or a unique

trend of bi-annual presentation of the company’s collections to the trade. Under his guidance,

the company has gained international recognition.

MR.AMAN AGRAWAL-EXECUTIVE (VICE CHAIRMAN)

With over 15 years of experience in the Textile Industry, Mr.Aman Agrawal has strategically

directed the business to newer heights. He has always encouraged innovation like newer

approach to projects, implementation of new technologies and IT system integrations. His

challenging and competitive approach has led to top class manufacturing facilities in weaving,

fabric processing, garments and value addition and today with the versatility of producing multi

fiber textile products regardless of value and volume constraints. His inspiring leadership has

brought competitive costs and consistent quality of our products.

MR. NASEER AHMED- JOINT(VICE CHAIRMAN)

A sitting member of the legislative council of the state of Karnataka, Mr. Naseer Ahmed

has been a minister of state for small-scale industries in Karnataka (1990 - 1992). He holds a

Bachelors Degree in Commerce from Kolar Gold Fields 1st Grade College. After completing

his studies he entered into politics and held various positions in the Congress Party. He has

promoted four companies in the textile sector and his group has successfully established a niche

in the export market by supplying to top international brands.

MR. UDAY MOGRE EXECUTIVE DIRECTOR (CORPORATE)

Mr. Uday Mogre has over 25 years of experience with organizations like Advani

Oerlikon Limited, Universal Luggage as General Manager (Finance), Reliance Industries

Limited (VP Finance) and Texmaco group of companies (Jakarta, Indonesia as Senior VP &

CFO). He was involved in project financing and implementation of SAP. In the initial stage of

his career he worked as Scientific Officer with Heavy Water Project Tuticorian. Department

ofAtomic Energy. He holds a Bachelors Degree in Technology (Chemical Engineering) from

Laxminarayan Institute of Technology, Nagpur and a Post Graduate Diploma in Management

from IIM Ahmadabad.



MR. A R MUNDRA - EXECUTIVE DIRECTOR (FINANCE)

With over 25 years of experience in finance, commercial and managerial related

matters, Mr. A R Mundra core strength lies in fund procurement, internal controls,

organizational systems and strategic planning. He has worked with organizations like Bhansali

Engineering Polymers Limited (President), Welspun group of companies (Senior VP-Finance,

CS and Chief Executive Commercial). In the initial years, he worked with Indian Rayon and

Industries Limited, Birla group of companies and Gujarat Ambuja Cement Limited in various

capacities. He is currently an associate member of the Institute of Chartered Accountants of

India and the Institute of Company Secretaries of India. He is also a member of the International

Institute of Business Management, London. He was awarded ‘Samaj Shri’ for excellence in

management by Indian Institute of Management Executives, Mumbai in 1994.

DR. PRAVIN P. SHAH-INDEPENDENT DIRECTOR

Dr. Pravin P. Shah has over 34 years of professional experience in the areas of financial

consultancy, corporate structuring, restructuring, management consultancy, taxation,

valuation, property matters, accounting, auditing, company law and FEMA matters etc. He is

on the board of many companies including J. M. Morgan Stanley Private Limited, Adani

Exports Limited, Bhansali Engineering Polymers Limited etc. Since 1980, he is a partner of

Pravin P. Shah, a firm of chartered accountants undertaking specialized services mainly in the

areas of public issues, private funding, foreign collaborations, business reorganizations,

valuation, tax planning etc. He is a fellow member of Institute of Chartered Accountants of

India and Institute of Cost and Works Accountants of India.

DR. B.S. BHESANIA- INDEPENDENT DIRECTOR

Dr. B.S. Bhesania is a Senior Partner in M/s Mulla & Mulla & Craigie Blunt & Caroe,

with specialization in areas in shipping laws, corporate laws, property laws, etc. He practices

as an Advocate at the Mumbai High Court and Supreme Court of India and serves as Solicitor

at the Mumbai High Court, Supreme Court of England & Wales and Supreme Court of Hong

Kong. He was appointed on the Board of Directors of BRFL in May 1983.

MR. S.B AGRAWAL - INDEPENDENT DIRECTOR

Mr. S.B. Agrawal has over 39 years of professional experience as President of J. C.

Mills (Birla Group), President and CEO of Rajasthan Spinning Mills (Bhilwara Group),

Business Head for global textile companies in Aditya Birla Group. He is presently heading the

textile group in the Indo-American Chamber, Mumbai and Textile Promotion Group of



Federation of India Chambers of Commerce and Industries. He is a member of the Institute of

Chartered Accountants of India.

MR. M.M. AGRAWAL

Mr. M.M Agrawal has over 35 year experience in banking, financial services. He has

retired from Axis Bank as Dy. Managing Director and at present he is the Advisor.

MR. MUKUL SARKAR

Mr. Mukul Sarkar is the General Manager of Export Import Bank of India and has over

13 years exprience in banking, structured financing.

MR. SURESH VISHWASRAO-DIRECTOR

With over 40 years of professional experience, he is a retired Banking Officer. He has

wide experience with Banking Regulations, Foreign Exchange Management Act, Loan

Syndication, Capital market activities, etc.

QUALITY POLICIES

Improve customer satisfaction through delivery and service.

Improve quality by reducing rejection.

Improve quality by reducing reworks.

Larger employers must establish a safety committee. Smaller employers have the choice of

either establishing a safety committee or holding safety meetings with a management

representative present.

NATURE OF BUSINESS MODEL:

It has multi product, multi fiber and multi market company operating in the manufacture of

woven and garment. It presence in the total value addition chain in textiles is indicated below:

MANUFACTURE OF WOVEN FABRIC:

The company was into the manufacture of woven fabric for almost two decades. It

manufacture woven fabric of different varieties using cotton, manmade fibers and there blends.

It has 152 weaving machines spread at 3 location at village sonale in thane district, Navi



Mumbai in silvassa. All the fabric for manufacture of woven fabric use modern technology

using imported projectile based seltzer, rapier based so met positive rapier based Dornier and

Belt based Picanol weaving machines.

The company has total fabric manufacturing capacity is about 10 million meters per

annum. It also out sources fabric from the unorganized sector to meet our requirement of the

customer. It supplies fabrics to both domestic and overseas markets.

GARMENT MANUFACTURING:

The company has started the garment manufacturing division in September 2003 and

in a short span of time it has grown substantially in this business. One main feature of the

garment business is that it are into high end fashion products as compared to commodity

garment.

The existing garment manufacturing facilities are in two units and are based at

BANGALORE. The existing facilities have capacity of 5000 pieces of garment manufacturing

per day. One more units of garment manufacturing are expected to be commissioned by

September 05, which will increase our capacity 10000 pieces per day.

After implementation of the expansion project it has an additional 22000 pieces of

garment manufacturing capacity per day. Presently, it focus in garment manufacturing is on

designer men’s shirts. However, it has already started diversification into ladies tops, kid’s

weaver and bottoms for both men &women. After implementation of the expansion project, it

intends to take up the production of bottoms to top opportunities in that area.

Fibers(Natural/

Manmade)

X

Yarn(Spinning

& Textures)

X

Weaving

Processing-

Yarn &fabrics

xx

Garments/Home

Textiles



BRIEF DESCRIPTION OFDIFFERENT STEPS INVOLVED IN

GARMENT MANUFACTURING IS AS FOLLOWS.

PROCUREMENT OF FABRIC:

Based on the order and design, the fabric and appropriate fabric source are identified

and the quantity required is assessed based on the consumption of fabric per garment,. It has a

team of skilled professionals who makes this assessment. It source majority of the fabric

required from our fabrics weaving plants at village sonale in Thane district, Navi Mumbai and

silvassa.

FABRIC CHECKING:

Besides fabric, the accessories are also thoroughly checked for defects and damages.

FABRIC CUTTING AND GARMENT STITCHING:

The fabric is laid on the cutting table and then plotted with the help of CAD /CAM

machinery as per the specific patterns. This is a system for consumption planning and ensures

optimum usage of fabric keeping the cutting wastage at the minimum level. After plotting the

fabric is cut with the help of cutting machines. Different parts of shirt are then stickered for

identification of size and shade. This process is known as sorting of fabric. The sorted fabric is

then bundled and sent for fusing of the three main parts namely collars and plackets. Then

collars and cuffs are attached to the main body completing the first stage.

FINAL CHECKING OF GARMENTS:

The company has subject to 100% of the garments that it manufactures to stringent

quality control measures. To ensure that every piece manufactured is as per specification and

the required quality standards, responsible for ensuring that all finished goods are free from

defects and stitched as per measurement. This team compares the final product with the

measurement chart and style chart given by the design department. Any variance beyond

acceptable limits is rejected.



MANUFACTURE OF MADE UPS:

Very recently it has ventured into the value added segment of home textiles i.e. Bed

sheets, fitted sheets, pillow covers, Quilt covers, Duvet covers etc. mainly for direct exports.

The size of global trade in this segment is expected to be over US 12 billion. The market for

home textile products as been growing at a rapid pace over the last few years. With the removal

of quota restriction the segment offers great opportunity for growth.

MARKETING AND SELLING STRATEGY:

It has positioned their company in a reasonably strong position in the business segment

in which it operate due to our quality, consistency, pricing and delivery schedules our customer

profile for fabrics include leading garment exporters in India. Leading garment makers in the

overseas markets, domestic garment manufacturers, domestic wholesalers and traders and

retailers. In addition, it has developed a strong network of marketing agents who sells fabrics

to various small sized unit and traders there by ensuring greater penetration of markets. As far

as garment customers go, top labels in garments in the European and US markets are on our

customer list.

THEIR DISTRIBUTION CHANNELS:

They use the following distribution channels for marketing our products.

Products/Market Segments Distribution Channel

Fabrics-Domestic sale BRFL-Marketing agents/Wholesalers/Garment

manufacturers/Retailers

Fabrics-Exports BRFL-Oversea Garment Manufacture / Exporters/

International Buying house.

Garments-Exports BRFL-Buying house international brands / Retailers .



DOMESTIC SALE OF FABRIC:

The local retail market is well developed and it has been catering to this market for

almost 2 decades. It has a network of over 10 agents and 70 distributors catering to network of

more than 2000 retailers spread across India. Presently in the domestic retail division, it has a

turnover of around Rs 200 lacks per month, which it plans to increase to Rs. 300 lacks per

month.

DOMESTIC SALE OF FABRIC TO READYMADE GARMENT

MANUFACTURER EXPORTERS:

This is the fastest growing market segment. With our range of fabrics, the buyers of

these garment exporters specify and approve fabrics made by BOMBAY RAYON. Thus it is

custom made product for these garment exporters. These are bulk and repeat orders.

DOMESTIC SALE OF FABRICS TO READYMADE GARMENT

MANUFACTURERS OPERATING IN DOMESTIC MARKET:

This is another fast growing segment mainly caters to domestic garment industry. Many

Indian and international brands have set shop to grab this ever growing market with the

popularity of readymade garment going up, the Indian customer have almost stopped buying

fabrics from retails shops and getting the garment stitched from tailors.

EXPORT OF FABRICS:

It has been established fabric exporters to various markets. Suiting fabrics exported to

Europe and shirting to Middle East country. It has no concentrating and developing export of

shirting fabrics territories too.

EXPORT OF GARMENT:

The strategy for exports of garments is to focus on medium to high class garment as per

unit price realization is maximum in high value garments segment. It has been able to attract

well know names in overseas fashion garments industry, due to ability to offer garments based

on seasonal fashions trends and colour choices. It has expertise in design of fabrics as per



customer specification, garment designs and garment samples meeting the stringent quality

required have made a preferred garment supplier to discerning from Europe and USA. It enjoys

a steady market for their products in this segment and has established significant brand

goodwill among overseas buyers for our garments. In addition to above it has now focusing on

significant reduction in turnaround time.

EXPORT OF MADE UPS/HOME TEXTILES:

The company is believed that in the post- WTO era, home textiles will be a driving

force of Indian textile exports. With the closure of home textile plants in the US and shift in

international buying patterns towards Aspic Pacific Region, there is expected to be

considerable demand for home textiles out of Asian countries.

PRODUCT PROFILE

FABRIC:

Every thread woven at Bombay Rayon Fashions Limited is a part of an incredible range

of fabrics that BRFL has to offer. Each fabric has one inherent quality - Comfort. Their promise

to manufacture the finest fabrics inspires us to put in that extra effort to create magic. It

showcases an enormous range of fabrics and size offerings available in various colors to suit

every occasion and every budget. It has in-house multi fiber capabilities to produce pure fabrics

and their motto is "Contemporary clothing for the new gen!" their fabrics offer an extensive

range of men’s styling. It was the leading Indian fabric manufacturers and suppliers in the

Domestic markets as well as International Fashion Export Industry.



APPAREL:

Comfortable, durable and stylish are the inherent qualities of the range of apparels

available. Admiration is guaranteed with BRFL apparels. Apparels from Bombay Rayon

Fashions Limited are a creative exploration of the same comfort brought in by our fabrics.

Whether you need a uniform for your team, a gift or program item, it offer just the right look

and feel for a corporate or a casual event. Tailored with fine detailing to create a style that suits

you, it spend a lot of time and effort in bringing innovations in our apparels. The corporate

collection is designed with easily complementing colors and styles that any combination you

pick would match. And the best part is that are priced ‘right’. Check our new collection for the

finest apparels with a comfortable fabric at just the right price. A must-have for your wardrobe.

RETAIL:

Guru, a renowned apparel brand in Italy has been a subsidiary of BRFL since 2008.

Guru has stores in 18 countries around the World, including Italy, Spain, France, Germany,

Holland, Belgium, Luxemburg, Greece, England, Portugal, the Middle East, Turkey, Russia,

Ukraine, Austria, Switzerland, the Canary Islands, Scandinavia, China and India.



TRIMS:

With an initial goal to maintain quality and consistency in button manufacturing, BRFL has set

up an in-house state of the art button manufacturing unit; the Trims Division is today the largest

and most sophisticated Button Industry in India. It has huge collection of polyester buttons of

the highest quality. This includes buttons for shirts, coats, outer wear, trousers and fancy

buttons. Their buttons are pre dyed and free from banned elements like Azo, Lead, Cadmium,

and Phthalate and meet the Oekotex-100 Class 1 standard.

YARN:

In 2010 Bombay Rayon Fashions Ltd. completed its vertical integration in the textile

industry with the acquisition of a yarn manufacturing company of great repute, STI India Ltd,

thus making BRFL one of the privileged few to have the capability of producing everything

from yarn to garment. Yarn division is well known for Production of world class cotton yarn



and knitted grey fabric, quality consciousness, fair business practices, modernization,

environmental consciousness, social awareness, ultra modern plant equipped with

sophisticated high-tech machinery and high caliber personnel & a great work culture Strengths

and features of our yarn and knitted products are procurement of high quality cotton fiber for

4-6 months in advance, every bale of Cotton fiber is tested for Length, Micronaire, and Rd

(Reflective Index) value for making homogeneous and uniform mixing to avoid shade variation

and barre effect in fabric. It has controlled yarn contamination by implementing systematic and

controlled raw material sourcing, manual contamination sorting with scientific method, eight

VISION SHIELD machines with POLY PROPYLENE identification system in blow room

lines and Electronic yarn clearers with foreign fiber, contamination cleaning facility (eg. 'Siro'

clearer or 'Quantum' Clearer). It has Tandem cards (Double Carding) machine, which gives

good quality of super carded and super combed yarn with very low tolerable objectionable

classmate faults, which in turn gives more consistent and better fabric appearance. All yarn is

'Xorella' saturated steam conditioned for ensuring even moisture level at every layer of the yarn

which gives better results during knitting and weaving. Samples from all lots of yarn are tested,

knitted and dyed to ensure consistent and right quality before shipment to customers. The yarn

products are 100 % Cotton Combed Yarn,100 % Organic Yarn,100% Organic Yarn under fair

trade and 100% cotton yarn under fair trade.



GROWTH CHART OF BOMBAY RAYON FASHION LTD(2015-2016)

BRFL COMPETITORS:

Arrow Textiles Ltd.

Gokak Textiles Ltd.



First Winner Industries Ltd.

Gokaldas Company.



ORGANISATIONAL STRUCTURE AND DEPARTMENTAL

FUNCTIONS:

VICE PRESIDENT

GENERAL MANAGER

HUMAN RESOURCE

MANAGER

WORK MANAGER

PRODUCTION

MANAGER

MARKETING

MANAGER

ACCOUNTS

MANAGER

HR

ASSISTANT

SUPERVISORS MARKETING

EXECUTIVE

ACCOUNT ASSISTANT

HELPERS HELPERS HELPERS HELPERS



FUNCTIONAL DEPARTMENTS OF BOMBAY RAYON FASHIONS

LIMITED:

BRFL is a manufacturing concern of moderately large size. We can see here functions

wise department. It facilitates effective utilization of manpower and resources and it is a simple,

economical and reasonable organization pattern.

FUNCTIONAL DEPARTMENTS OF BRFL

1. HUMAN RESOURCE DEPARTMENT

2. PLANNING DEPARTMENT

3. PRODUCTION DEPARTMENT

4. STORE DEPARTMENT

5. MARKETING DEPARTMENT

6. PURCHASE DEPARTMENT

7. FINANCE DEPARTMENT

8. QUALITY ASSURANCE (QA) AND TOTAL QUALITY MANAGEMENT (TQM).



3.1 HUMAN RESOURCE DEPARTMENT

Introduction:

Human Resource Department is a vital important of organization. It concerns to people

and employees. It has motivation to the employees for achieving organizational objectives.

Management is considered as on art of getting thing done through others with a view to

achieve the common objectives of the organizations, but these objectives can be achieved if

the organization is managed efficiently. The management of the organization is considered to

be efficient of it is able to co-ordinates the several of production is such way that they contribute

their maximum towards the realization organization.

Objectives:

Objectives are pre-determined goals to which individual or group activity in an

organization is directed. The objectives are:-

To attain organization objectives by winning and maintaining the whole hearted co-

operation from all employees in the organization.

To ensure that the organization gets the right type of employees, in the right quantity at

the right time and at right place.

To motivate the employees to contribute their maximum to the organizational goals.

To optimize the utilization of the manpower resources of the enterprise.

To maintain high moral among the workers.

Future human resource planning.

To take the welfare care of the labours.

Creating the employment opportunity to the society.

Functions:

Assessing and recruiting staff based on the needs specified by the department.

Selecting the required candidates as per the requirement by following pre- determined

procedures.

Enlarging the jobs of the employees if necessary.



Hierarchy of human resource department:

WORKING HOURS:

The working hour for all employees are fixed in accordance with the factory act 1948

and the working hours will starts with same timings for all the workers in the company. There

is no shift system in this company, but it undergoes O.T., when the customer requirement is

very urgent.

TIME SCHEDULE FOR WORK:

For all workers, staffs and executive: 9.00 am to 5.30 pm

Lunch Hour: A Floor- 12.30 pm to 1.00 pm

B Floor- 01.00 pm to 1.30 pm

C Floor- 01.30 pm to 2.00 pm

For staffs executives and staff- 2.00pm to 2.30 pm.

ALTERNATIVE WORK:

All employees wherever thus are employed will have to do instead of their usual jobs

any alternative work, whenever there is insufficient or no work in their respective departments

or in ties of exigencies when assured to do so by the supervisors or employments of employees,

however not be affected refusal to obey. These will be constructed as misconduct as these

standing orders

Human Resource Department

Senior personnel officer

Personnel officer

Personnel Assistant

Complaint officer

Welfare officer



ATTENDANCE:

The starting and closing of work and for breaks there will be a siren bell.

When the workers enter into their work, if they takes a break and finishes their work on

that time they should punch their card.

The attendance register shall be entered from the punch card, and employees failed to

record or get marked on the card is liable to be treated as absent.

Every employee shall be at place or work at the time fixed for them.

TERMS AND CONDITIONS FOR EMPLOYEES:

This terms and conditions are displayed in the notice board it should also be known by

employees.

The employment age should be 18-above.

Working hours-8 hours, (8-45 am to 5-15 pm).if there is an O.T,-2 hours.

Leave is given at weekends to the required employee, if it is unforeseen circumstances;

half day of Sunday has to be work.

Salary & Wages:7th day of every month

Salary break up

O.T. wages (double rate as per hour worked)

ESI-4.75% from employer & 1.75% from employee’s basic salary, D.A.H.R.A.

Provident fund is 12%

Leaves & Holidays: 14 days per year leave, if employees worked all working days this

is calculated from Jan-Dec.

Health & Safety:

Safe and hygienic environment.

There is ESI facility.

If there illness or Injury at working time company taking responsible of medical.

There is a first Air Kits in the company.

Fire Safety: Training is given for some selected persons in company.

Ambulance Room: There is a medical facility with Doctor and nurse.

Freedom of Expression:

There is a suggestion Box.



Health & Safety committee, welfare committee.

Canteen committee.

RECRUITMENT:

Recruitment is done by HR Manager, to select employees accoutring to

requirement. Recruitment is taken place through newspaper, Internet, consultancy &

through employees reference.

SELECTION:

For workers:

Company select the workers according to the requirement. Workers should have to

bring age proof like S.S.L.C marks card or Ration card for address proof. Here both

experience and un-experience persons are to be selected. For experienced persons work

will be allotted according to their skills.

For Executive Staff:

The selection process is done in head office. When the personas selected, then they

will send them to the training department in UNIT VII.

Selection process flow chart for staffs and executive staff

Selection of Resume

Interview

Short listing

Interview

Final selection

Job



Employees are classified as:

Permanent

Probationers

Temporary

Casual

Fixed term Employee

On the job Trainee.

TRAINING:

Training is given to the new workers for 40 days, if the worker trained up well, then

they will be placed for batches. If they are not got prepared well then they will be send back

to the training still to get through in particular work.

PROMOTION:

For employees: promotion is given to the workers according to their performance, skill and

experience.

TOTAL NO. OF STAFF AS ON AUGUST 2015:

WORKERS AS ON AUGUST 2015:

Executive Staffs 60

Non-Executive staffs 1130

Total no. of Staffs 1190

Male Workers 664

Female Workers 526

Total no. of Workers 1190



Human Resource Planning :

All the departments in the BRFL are according to the requirement of workforce submit

a requisition letter asking for recruiting employees to the corporate human resource

management department. This department analysis the actual need of the employee’s and then

plans how many employees should be called for interview. In case they have excess of

employees then measures are taken to reduce the number of employees.

Orientation & Placement

Here basically whenever a new employee is selected in the company, the supervisor of that

particular division introduces the new employee to the staff and assigns work to the employee.

The supervisors not only assigns work to the employee but also inform him about the

procedures to be followed by him to report to his immediate supervisor, his duties-

responsibilities, his rights and his limitations in the organization.

Employee Remuneration:

The remuneration for the employee is fixed earlier and all the employees have to abide

to it. This payment increases as their period of service rendered to the federation increases, that

is pay of an employee depends on the number of years he serves the federation

Promotion and Transfer:

In BRFL the employee can be promoted only if there exists a vacant post or if anyone retires

or leaves the organization. Few times employees are promoted on basis of transfers that is if

they have an excess of workforce and they need to send that person to a different unit. They

usually transfer that employee to another unit by giving a promotion.



3.2 PLANNING DEPARTMENT

Planning department is the main department of the company, where the planning of all the

production is done in planning department.

FLOW CHART OF PLANNING DEPARTMENT

When the company gets the order from the buyers, here is three process of planning department:

1. Size set

2. Pilot run

3. Bulk stock

1. Size Set:

The buyers is ask for a sample piece, which is done by the company, if the sample piece

is accepted by the buyers, then the order is placed for a quantity of a garment it normally

specified a quantity of each size and colours, the sizes will be a follows, S, M, XL, XXL.

2. Pilot Run:

After the sample is accepted by the buyers, Pilot run will be done. Pilot run means

some quantity of production will be done within the total quantity.

PLANNING INCHARGE

P.A. (C FLOOR) P.A. (B FLOOR) P.A. (A FLOOR)



For example: there will be the 20,000 order in that, the company will release only 3000

productions to know the allotment of manpower, machine, time, materials and how the output

is coming and if there is any alteration/correction has to be done in that, it will be done.

3. Bulk Stock:

The completion of Pilot run, if any correction/alteration is found it will be done in

Pilot run. Then the company will be release the bulk production for cutting, stitching and

finishing.

The production of the company is checked by the daily process. To see that to

complete the target which is given by the buyers, to complete that target the planning

department also have their own date. For that, the planning in-charge will have an eye on the

production in hourly, daily checking process. Here in the BRFL having 3 floors, for each floor

there is a planning assistant to give proper information.

3.3 PRODUCTION DEPARTMENT

Garments are shaped and formed in three ways. Materials formed to a form fabric pieces

cut to shape and assembled by bonding and pieces cut to shape and sew. The first two methods

are used to a limited degree. Sewing garment pieces together with thread formed into stitches

and seams is the most used method at this time.

Fabric goes through 3 major processes before becoming a garment they are:

1. Cutting

2. Sewing

3. Finishing

This company has maintaining 3 production Batches in a single roof that is A, B, and C each

sections. The batch chart for the company as shown below:-



Batch Chart of Production Department

A Batch B Batch C Batch

Production Department

Cutting

Stitching

Finishing

Cutting Cutting

Stitching Stitching

Finishing Finishing



PROCESS FLOW CHART OF PRODUCTION DEPARMENT

FABRIC INSPECTION

CUTTING LINE AUDIT

SEWING INLINE PART

CHECKING

CUTTING LINE PART

CHECKING

BUNDLE INSPECTION

SEWING INLINE AUDIT

SEWING END LINE PART

CHECKING

CHECKERS AUDIT

FINISHING COMPLETE

GARMENT

CHECKERS AUDIT

PRESENTATION CHECKING

PRESENTATION CHECKERS

AUDIT

PACKING AUDIT

MEASURING AUDIT

PRE SHIPMENT AUDIT



FABRIC SECTION:

In the fabric section the fabrics are received from main go down in roll form or in a

taka form. This section has got its own standard operation procedure, according to which the

process follows. The Fabric bale is checked by a fabric checker using 4.2 systems. Checkers

has to fill the ‘Piece goods quality control inspection report according to the inspection. Each

department has an ‘Hourly production Board’ which helps in recording the production rate for

IE people.



SOP (STANDARD OPERATION PROCEDURE) OF FABRIC SECTION:

Fabric bale check is done by fabric checker using 4.2 systems.

Total acceptable point given is 30 point for a length of 100 meters, if it is exceeds 30

points for a length of 100 meters, and the whole taka will be rejected.

Fabrics are separated according to the shades by using shade bands.

Checked fabrics are stored according to width wise and shade wise and it will stack

accordingly.

Shrinkage test is done for the received fabric on random basis.

Pies good quality control inspection report has to be maintained.

Segregated parts of the fabric have to be snickered accordingly so that the defects parts

can be identified and can be avoided and replaced.

100% inspection is carried out for all the fabrics received in the fabrics received by the

factory.

Final inspection report and fabric completion report (FCR) has to be maintained.

The defects of fabric as follows:

Hole

Knot

Stain

Flooding marks

Forge in yarn

Pick sang

Miss line

Broken filament

GRADING:

Grading of a pattern is a science. This subject can be under taken after having learnt the drafting

of pattern requires knowledge of human proportions. Accuracy of the diagram is the most

essential thing in factories. Grading of pattern is adopted in factories and in wholesale of

garment manufacturers to obtain different sized patterns.

Grading of a paper patterns means, obtaining pattern for different actual calculations

involved in establishing those patterns. But the shape and curve of the pattern is maintained



proportionally. Before grading a medium sized pattern must be cut accurately. Grading of a

pattern is generally applicable in regular figures. When the measurements are proportionally

increased or decreased according smaller to larger sizes.

DIGITIZING PATTERNS:

Most of the companies using CAD & CAM system for pattern cutting they cut their

pattern for a design manually. Therefore to grade the pattern on the system of perimeter of the

pattern has to be fed into computers by digitizing the contour.

However the grade points and the grade rule number can be input at the same time.

Pattern is placed on the digitizer and the pattern profile is entered into computer by use of a

cursor. The centre of the cross hairs of the cursor is placed on points on points to be recorded.

These points are grade points and other point defines the curves or corners. When a cursor

button is pressed, signals are sent to the computers which are then translated into numerical

record of the information for the piece. The cursor has number of button which allows the

appropriate grade rule numbers to be “Typed” into the system on the relevant points as the

pattern profile is digitized.

MARKER PLANNING:

The industry was always paid great attention to marker planning, because when the

cutting room cut the fabric means it spend around half of the companies turn over. In this

section supervisor allot the work to vary operators to develop the marker planning. The entire

component patterns are should be correctly placed on the marker plan with regards to the grain

line direction indicated on the gap paid adjust the small component pattern. If it is satisfied,

paid the marker efficiency then making on the cloth with using by marker chalk.

MAIN REQUIREMENT OF MARKER PLAN:

The nature of the fabric and result in the finished garment.

The requirement of quality in cutting.

The requirement of production planning.

The design characteristics of the finished garment.

Symmetry or asymmetry (one way or either way).

Pattern alignment in relation to the grain of the fabric.



Fabric requirement.

All the detail of cutting.

Production planning requirement.

The CAD planner sheet is given to the operator and accordingly the paper patterns are

placed on the lay as per the CAD planning sheet. When the entire marker is placed over the

brown sheet then it is given to the cutting section to placed over the fabric and cut according

to the pattern done in the brown sheet.

EMBROIDERY SECTION:

In embroidery section, embroidery is done by according to the customer order. The most

intricate embroideries can be executed by world class latest computerized machines, because

whatever the design is given by customer first it will feed into the computer, and then the

employees adjust all embroidery machines and the fabric where the machine required to do a

embroidery, after adjusting everything employee will give ok to the computer. Then the

embroidery machines start its work.



SEWING SECTION:

The objectives of sewing are the construction of seas, which combine the required

standards of appearance and performance with an appropriate level of economy in production.

Assuming that the fabric is sew able and suitable for garment, the achievements, at an

economical level of the various requirement of appearance and performance of seams, both

initially and during use, is the result of the selection of five factors during manufacturing.

The seam and stitch type.

The Sewing machine feeding mechanism which moves the fabric, the needle and

enables a succession of stitches to be formed.

The needle which inserts the thread into the fabric.

The thread which forms the stitch which either holds the fabric together neatens it or

decorates it.

A seam is a joint consisting of a sequence of stitches uniting two or more pieces of material

and is used for assembling parts in the production of sewn items.



SEWING MACHINE FEEDING MECHANISM:

To achieve the objectives of good appearance and performance in seams, correct and

even stitch length is essential, along with fabric joins which are either smooth and unobtrusive

or evenly eased or gathered, according to the requirement of fit and style. In the construction

of seams and the perforation of stitches that holds them together, these requirements are

achieved by means of a mechanism that feeds the fabric past the needle. There are various

types of feeding mechanism that can be used for different requirement of seaming.

Industrial sewing machines are classified according to their intended use and the means

of forming stitches. A stitch can be defined as “One unit of conformation resulting from one

or more strands or loops of thread inters looping, intra looping or passing through material”.

MACHINES USER FOR SEWING SECTION:

Buttoning machine

Kansai machine

Pat lock machine

Shad stitch machine

Chine stitch machine

Welt pocket machine

Three needle machine

Embroidery machine

SEAM DEFECTS:

Incorrect or uneven width of seam which is due to mishandling of components by the

operator.

Irregular or incorrect shape of sewing line in case of top stitches due to incorrect

handling or badly shape guide.

Insecure back stitches are generally taking place due to skip stitching.



ASSEMBLY DEFECTS:

During stitching, parts or panels are assembled together.

Finishing components should be attached in correct shape and size.

Parts components which get damaged in previous operation should repair before assembly.

Interlining incorrectly positioned, twisted, pleated should be avoided.

Lining too full or too light showing below the garment should be avoided.

MODES OF STITCHING DEFECTS:

Raw edge seam

Main label cross

Label pip out

Run off stitch

Uneven width

Loose stitch

Uneven SPI(STITCHES PER INCH)

Skip stitch(d/n)

Miss alignment

Down stitch

Piping stitch

Parallel stitches

Peep out(inside panel visible)

Size label cross

Over back tack

Stay stir visible open seam



MEASURE INSPECTIONS:

After the garments come out of the sewing line, random inspection should be done for

measurements. Three pieces from each size and from sewing line is checked for confirmation

to the measurement specifications. Few critical measurements are taken. If two or three pieces

are exceeding the tolerance then three more pieces of that size should be measured. If it is not

a sewing problem but problem with the patterns then the appropriate authority is informed and

necessary steps taken to rectify the problem.

FINISHING SECTION:

FLOW CHART OF FINISHING DEPARTMENT

BUTTON HOLE& BUTTONING

BAR TACK

TRIMMING

MIDDLE CHECKING

DUSTING

IRONING

FINAL CHECKING

CHECKING FOR ITS

MEASURMENT

IRONING

PRESENTATION

PACKING



LAUNDARY SECTION:

The following process is there in laundry section,

Sand blasting

Grinding

Softener wash

Acid wash

Stone wash etc.

REQUIREMENT FOR PRODUCTION DEPARTMENT MANPOWER:

For pressing of garment man power is required that is skilled and unskilled. Proper

number of man should be provided processing. For operating a machine employees should

know the basic i.e.,

How to operate a machine.

Employees should know the chemicals and in what ratio has to input for a certain load of

the garment.

In process time factor is very important. worker should know the process timings.

Employees should know the standard tone, colour of any garments requirements.

Unskilled labors are employed to give helping hands to the skilled labours.

MACHINERY:

Machinery ordered should be as per garments requirements.

Machinery should be well maintained and well covered to avoid any kinds of accidents.

Inner basket should be as per garment requirements.

Safety measures should be well followed.

Boiler should be well maintained and operated by a certified operator. If it is a wood fired

boiler extra precaution to be taken by the boiler operator and the maintainer.

If the company is installing boiler they should install two boilers, because it will help

smooth operation and give good result when one boiler is shut down the second can be used

as a standby



POWER:

Power play is a very important role in processing unit. If power is not there machines

cannot start. Power backup is also important because processing has timings and if timings are

not maintained we will get consistence in processing. Generator is used as a power back up

source. There is three generator is used for power back up.

TRANSPORTATION:

Transportation system should be very smooth to enable garment to move to the required

units after processing and before processing.

CHEMICALS:

Chemical is the second important requirement for processing a garment, chemicals are

of different types for processing a garment requirement are only for basic chemicals.

Softener

Enzyme

Bleach

Water softener

Acidic acid

Detergents

Wetting agent

Lubricating agent

Anti-back stain agent

BLEACHING:

This chemical is used in Denim and Grey fabrics.

In denim it gives different shade.

In grey it turns grey fibre to cream white.

ANTI-BACK STAINING AGENT:

Anti-back staining agent is used on fabrics which loose colour in water, its property is to

protect fabric, natural looks.



WATER SOFTENER:

This chemical is used all over in the process. It reduces water impurities and provides

soft water for processing.

ACIDIC ACID:

This chemical is used to reduce the PH of water as you know that water all over used

is not same and not from government channels whereby PH of water is reduced to 50 to 150

GPH. In process water plays very important role. If water is soft and the PH value is maintained

we can get consistence in processing of the garment.

DETERGENTS:

Detergents are using for minute marks, which can be washing easily.

DE-SIZING AGENTS:

De-sizing agents are used for removing dye starch, impurities in the fabrics, to support

de-sizing in the process. There are other chemicals which has been widely used are,

Wetting agent

Lubricating agent

Anti-back stain agent.

This supporting chemicals helps the fabric to soften, give viscosity to the fiber penetration

of other chemical used is easy.

PACKING:

Packing impressing making section and gives finishing touch up and plays a vital role.

Packing is done according to the buyer’s instruction. And it is done by pre-packing, which

means size wise packing.



Types of Packing are:

Hanger Packing

Dead Folding Packing

Stand Packing

Flat Packing

3.4 STORE DEPARTMENT

Store is the main department of an establishment. Main inventory controlled in store to run aim

of the production effectively and efficiently.

Here store as per their function into,

1. RAW MATERIAL STORE: After getting approval of the sample from customer fabric

purchasing is done in bilk quantity as per order waw material (fabric) is inspected at

incoming stage before supplied to cutting.



2. INDIRECT MATERIAL STORE (TRIMS STORE): Include all mateial except fabric

such as thread, button, label, machine spare parts etc., material is issued only after

verification of materail slip with H.O.D. signature. Store position of each and every

material is matinained upto economic level so tht product is suffered.

Objectives of store department:

To store the fabric needs for producing garments.

To ensure tht quantity of fabric supplied is recting with the wauntity of fabric ordered.

To ispect the quantity of the fabric based on the needs of particular buyers.

To store farics in such a way that, there should not any kind of mingling & mimatch.

To store accessory properly and maintian Data.

3.5 MARKETING DEPARTMENT

Marketing starts with the determination of consumer wants and ends with the

satisfaction of those wants. It is the central activity of the business, which always focuses on

understanding the needs of the consumer. It stimulates the demand for a federation product.

FUNCTIONS OF MARKETING DEPARTMENT:

Marketing Mix : it is the policy adopted by the manufactures to get success in the field

of marketing

Product Policy: It includes both the turns of development & improvement produced and

existing products. This all totally done by BRFL both marketing & R & D department.

Distribution Policy: The manufactured product of BRFL is supplier to the factory depots.

There are various depots in various states & stored there.

Sales & Promotion: the drawback is poor advertising & sales promotion.

Packing: Uses different materials for different products, card board boxes synthetic

covers.



MARKETING STRATEGY OF BRFL:

The main strategy of marketing department is sale maximization. They use to prepare

sales budget. In anticipating sale budget different depots they choose. In different depots they

find out which product is moving very frequently and more demanded in the market. According

to this data the experience persons are preparing sales budget. In sales process 2 sales process

are involved one is primary sale and secondary sale.

The Nature of Distribution Channels

The BRFL uses third parties or intermediaries to bring their products to market. They

try to build a "distribution channel" which can be defined as all the organisations through which

a product must pass between its points of production and consumption”. Why does a business

give the job of selling its products to intermediaries? After all, using intermediaries’ means

giving up some control over how products are sold and who they are sold to. The answer lies

in efficiency of distribution costs. Intermediaries are specialists in selling. They have the

contacts, experience and scale of operation which means that greater sales can be achieved than

if the producing business tried running a sales operation itself.

Functions of a Distribution Channel:

The main function of BRFL distribution channel is to provide a link between production

and consumption. Organisations that form any particular distribution channel perform many

key functions:

Information.

Gathering and distributing market research and intelligence - important for marketing

planning.

Promotion.

Developing and spreading communications about offers.

Contact.

Finding and communicating with prospective buyers.

Matching.

Adjusting the offer to fit a buyer's needs, including grading, assembling and packaging.

Negotiation reaching agreement on price and other terms of the offer.

Physical distribution Transporting and storing goods.

Financing.



Acquiring and using funds to cover the costs of the distribution channel.

Risk taking.

Assuming some commercial risks by operating the channel (e.g. holding stock)

3.6 PURCHASE DEPARTMENT

Purchase department is also called as “Integrated Materials Management”. It mainly

contains buying of raw materials, inventory planning, and store keeping and material planning.

Objectives:

The main objective of BRFL is to reduce purchase cost by proper evaluation of vendor

(Supplier) by buying the right material at the right time for the cost with the right supply

schedule adherence.

Minimize inventory-carrying cost.

To reduce ordering cost.

Cost reductions checking for economies to profits in buying.

Reduce material handling cost.

To utilize the input to the most optimum level.

3.7 FINANCE DEPARTMENT

Finance is an area of financial decision harmonizing undivided motive and co-operative goods.

It covers not only financial planning, but also optimum use of funds as well the financial

control. The basic function performed are the day to day fund management, besides these the

book of accounts. The decision regarding acquiring plant & machinery or any other capital

expenditure is made on the basis of payback period or intercalates of return or net present value

method this being a co-operative organization the ultimate decision lies in the head of the board

of directors.



Finance is regarded as the life blood of the business enterprise efficient financial management

is very important to any organization lacks of this paralysis the activities of the firm. Hence,

it is essential to have a sound financial system organized in an organization or financial system

of an organization. BRFL has a sound financial department and well trained and experienced

employees to carry out the financial activities. Here very small beg activities are carried out

with at most care.

OBJECTIVES OF FINANCIAL DEPARTMENT AT BRFL:

To ensure that accounting records of various divisions are properly maintained.

To ensure that sales realization are properly accounted and remained the marketing section

from time to time over debtors portion in order to enable them to collect the dues.

The account section objectives are also to see that regular payments of milk bill due are

made to milk producers on priority.

To see that the payments creditors are made within stipulated time.

Account section has to provide management timely information about the financial position

of the union and guide them as to viability of the proposals that come in the course of

business activity.

The other objective of finance section is to keep the management/board appraised of

monthly trading and P&L figures.

To include timely submission of financial statement to auditors and ensure smooth audit is

conducted and give audit reports to management.

FUNCTIONS OF FINANCIAL DEPARTMENT AT BRFL

Preparation of annual budget.

Maintains of sales ledger.

Cash Book.

General ledger.



MAJOR SHAREHOLDERS:

LARGEST TEN SHAREHOLDERS OF THE COMPANY:

NAME OF SHAREHOLDERS NUMBER OF SHARES

Janardhan Agrawal 75,99,422

Prashant Agrawal 61,62,994

Scott Garment Private Limited 40,00,000

Vinita Agrawal 38,15,980

Aman Agrawal 33,38,404

Reynold shirting Private limited 30,00,000

BSMA Limited 46,32,920

Goldman Sachs Investments (Mauritius) 12,03,224

HDFC Trustee Company Ltd. 10,53,568



Financial Detail of BRFL Company:

Particulars 2014-2015 2013-2014 2012-2013

Financial Information

Total Income 27,497.70 22,783.27 16,304.26

Earnings Before Depreciation 7,464.00 5,643.55 4,031.79

Profit Before Tax 3,076.40 2,824.78 2,415.70

Profit After Tax 2,065.10 2,267.00 1,759.19

Earnings Per Share (In Rupee) 15.50 19.06 18.90

Financial Position

Equity share capital 1346.00 1279.00 1119.00

Reserves and Surplus 27978.60 24512.37 17974.17

Net Worth 29817.70 26651.52 19295.82

Gross Block 42435.00 31698.06 20914.37

Net Block 37248.30 28681.78 19259.21

Investments 1684.10 2227.22 4394.81

Key Ratio

EBIDTA Margin 27.29% 25.03% 24.97%

Debt Equity Ratio 1.08 1.17 1.29



3.8 QUALITY ASSURANCE (QA) AND

TOTAL QUQLITY MANAGEMENT (TQM)

Successful quality management requirement requires an orientation towards quality

that permeates the entire organization. Many psychological and emotional as well physical

and mechanical factors contribute to the production of high-quality goods. Top executives

must establish quality management as an ongoing part of the organization and provides an

equipment, supplies and personnel and budget its existence. Continual improvement in quality

comes only with the commitment of managers and employees to consistent, high-quality

performance in all aspects of the business.

Firms that have adopted this total concept of quality often use the terms. Quality

Assurance (QA) or Total Quality Management (TQM). The term QA is used throughout this

discussion. Under a QA system, evaluation of conformance to standards involves performance

of all the company’s divisions as well as the products and services that are produced by the

firm. It is recognized that production of quality products and services that are produced by the

firm. It is recognized that production of quality products depends on the quality consciousness

of the entire organization including merchandising, marketing, finance, operations and

production. Employee involvement throughout the firm is normally a part of a QA strategy.

Employees receive training on how to identify causes of product defects and how to resolve

the problem so defects do not continue to occur. Quality control (QC), a more limited form of

quality management, is the process of assuring that product is made according to the standards.

QC activities tend to the focus directly on the production process rather than on quality as a

responsibility of the entire firm.

INDUSTRIAL ENGINEERING DEPT (IED)

The engineering approach applied to all factors including the human factor, involved

in the minimum money and to get production and distribution products and services to use

more benefit. IED controls the following aspects:



MAN POWER

OPTIMISE

MONEY

MATERIAL MACHINERY



THE BASIC WORKING PROCESS OF IED:

TARGET

LAYOUT

ALLOCATION OF MEN &

M/CPOWER

OPERATOR GRADING

OPERATOR BULLETING

THREAD CONSUMPTION

FOLLOW UP

SYSTEM IMPROVEMENT

OPERATORS SKILL

IMPROVEMENT

FACTORY EFFICIENCY WITH

COSTING



TARGET:

The target is given by the planning department to the IED. The target is the production

has to be done within the mention period.

LAYOUT:

Layout/making sketch of operation is done to allotment of critical operations, man

power, machines, material, and quality and production analysis to fix the proper operator.

Operation simplification like avoiding double work by making it has a single work.

Eg: Folders and workers will be used to folding of cuff, colour, etc., in a proper size and it will

be easy to fold and it makes the wok faster and saves the time and damages.

Analysing the critical points like.

Line balancing

Employee transfer between operations

Assigning of off stand task

Over time planning

Rejecting defective product.

Allocation/planning of man power and machine:

After the layout the IED will be properly allocate the men, machine, materials,

electricity supply and time for the quality production.

OPERATOR GRADING:

After the allocation grading will be done, operators grading placing the right person for

a right job, by knowing their skills.



SWOT ANALYSIS

SWOT analysis is a framework for identifying and analyzing the internal and external factors

that can have an impact on the viability of a project, product, place or person. A SWOT analysis

is a structured planning method used to evaluate the strengths, weakness, opportunities and

threats involved in a project or in a business venture. A SWOT analysis can be carried out for

a product, place, industry or person. It involves specifying the objective of the business venture

or project and identifying the internal and external factors that are favorable and unfavorable

to achieve that objective. Some authors credit SWOT to Albert Humphrey, who led a

convection at the standard Research Institute in the 1960s and 1970s using data from fortune

500 companies. However, Humphrey himself does not claim the creation of SWOT, and the

origins remain obscure. The degree to which the internal environment of the firm matches with

the external environment is expressed by the concept of strategic fit.

STRENGTHS:

BRFL is giving great importance on quality and environment responsibility.

The Experience of BRFL promoters is remarkable.

The Flexibility in manufacture of garments as to accommodate timely delivery.

The BRFL Designing capabilities are present in house.

BRFL having Lower turnaround time.

It has Low labour cost.

The Economies of scale.

The BRFL company provides Quality assurance

It Sampling capabilities.



WEAKNESSES:

Unstable market share.

Relatively lower volume of production leading to higher cost of production.

Under utilization of asset structure.

Lack of skilled labour at rural area.

OPPORTUNITIES:

In carrying out there duties and responsibilities, Board Member and Senior

Management Personnel should consider the following;

Appropriating corporate business opportunities for the company that is discovered

through the use of company property or information or their position as Board

Member.

Using company property or information, or it should focus to create market.

Exploring number of advertising strategies to create awareness and to increase

sales.

A Board Member or Senior Management Personnel who wish to avail of such corporate

opportunity should disclose the same to the Board of Directors. If the Board of Directors

determines that the company does not have an actual or expected interest in such opportunity,

then only the Board Member or Senior Management Personnel may avail of it, provided that

the Board Member or Management Personnel have not wrongfully utilized the company's

resource in order to acquire such opportunity.

Company can grab the market with small period as it is all ready established.

Huge market potential in domestic.

Continuous increase in demand.

Develop local skills based through increased training.

The product of BRFL range to cater different need of customer so it can utilize this

opportunity against competitor’s threat.



THREATS:

The threat of Industrial unrest in terms of labour strikes.

Change in customer demand due to change in taste and preference.

Availability of skilled labours locally is not there.

Unexpected price fluctuation and the variation in currency exchange.

Heavy Competitions in the local markets.



5.1 FINDINGS

The information I have identified in working system of all the departments like, HRD,

Planning Department, Finance Department, Production Department, IED and store Department

with in a limited time given by the college and also the company the findings is as mentioned

bellow.

BRFL is highly employment oriented organization.

The majority of decision making will be done by top management only according to

the customer/buyer instruction.

80% of work force is women oriented only.

To avoid absenteeism the company is providing extra bonus.

BRFL provides job for skilled people, and also provides the training for new employees.

BRFL is maintaining the quality management for each and every step of the production

that is why they are leading in the market but still they have to maintain better quality

to come first place.

Optimum utilization of resources is in satisfactory level.

Less focused on promotional activities.

The company has simple work flow structure.



5.2 SUGGESTIONS

The BRFL should computerize and use advanced technology in stores, purchases and

total quality management departments.

The better co-ordination is the better quality, so BRFL should give more attention to

have a better coordination among different department and also with the workers of the

company because they are the main assets of the company.

BRFL should maintain all the record in a systematic manner, which can be used for

further study.

Improve the system for spare parts and services needed on regular basis, Improve the

level of maintenance.

Infrastructure should be utilized at maximum optimum level in order to avoid wastage

of materials.

The company should update its technology so that it can beat the competitors price and

also produce higher quality products.

Machines must be replaced in order to reduce cost of production.



5.3 CONCLUSIONS

Since the past 9 years, because of the financial crunch in the South East Asian countries,

the market particularly in the textiles has crash down. There was no parity between

cotton and yarn prices

Technological innovation and operational changes are important to bring about

transformation in the production practices.

In the context of a co-operative setup, where resources are limited and stakeholders are

many, appropriate operational changes need to be implemented along with

technological innovations to bring about awareness and benefits to all levels

management.

The company has been able to achieve the participation of workers at every level of the

organization that is from the shop floor level to the company level.

Each worker in the company is aware of the goals of the organization and they have

been able to match it with their own personal goals which encourage them to deliver

the best.

It has already shown its impact in various aspects such as increased productivity and

quality, better involvement and commitment, better decision making, better industrial

relation and so on in various organizations.

Executive leadership and six areas of specialization are required in order to operate

garments, marketing, merchandising, production, operations, finance and quick

response.

These functions must be performed, regardless of size of the firm or product line, in

order to carry out the manufacturing process and meet the needs of the target market.

Co-operation among these functional areas of specialization is the key to success for an

apparel manufacturing firms.

Information technology and computer to communication is key factors. It is one most

popular textile industry in India.

an organisation study at bombay rayon fashion ltd

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