forbes campbell

8/3/2019 Forbes Campbell

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Forbes Campbell KnitwearBelgaum

COMPANY PROFILE

Name of the Company : Campbell Knitwear Ltd

Address of the company : Campbell Knitwear Ltd

Post Marihal, Bagalkot road

Dist Belgaum- 591167

Karnataka India.

Year of Establishment : 1995.

Nature of industry : Textile Industry.

Head office of the company : Mumbai.

Corporate office : Khatau House,

2nd floor, 410/411 MogulLane.

Mahim (west)

Mumbai-400016-India.

Website : www.campbellknitwear.com

Gogte College Of Commerce Page 1


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The company has spent US $ 8.00 million on this project and the investments in most

modern machinery and equipment with latest technology. The machines are imported

from Italy, Germany, Switzerland, USA, Japan and Sweden etc.

They have in-house training faculty fresh workmen are recruited so as to suit and

mould them in our working environment. It has a team of young and energetic workmen with

an average age of 24 years. Campbell do not recruit anyone below 18 years of age and

all the rights of the workmen are protected.

With such human technical infrastructure and corporate backing Forbes Campbell Knitwear

(Div of Forbes Gokak Ltd.), is committed to the world class product.

KEY INFORMATION

Products Polo shirts and T-shirts for men, women and children

Garment 2,40,000 garments per month.

Fabric Dyeing Capacity - 90 MT/Month

Month Fabric Knitting

Capacity- 90 MT/Month

Fabric Specification

Pique 165 gsm to 260 gsm Single Jersey 140 gsm to 220 gsm RIB

with and without Elastomer

Shrinkage Maximum 5 % TUMBLE DRIED

Order Size Minimum order of 5000 garment (Minimum 900 pcs per color)

Lead Time30 to 90 days depending on the order Size and requirement of

development.

Payment Terms Irrevocable confirmed L/C payable at sight.

Our Bankers

Standard Chartered Bank (Main Branch)

23-25 M.G. Road, Fort,

Mumbai-400001



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Process at Campbell

Receiving orders.

Order confirmation.

Issuing C.K.Ls order copy.

Order planning

Kitting

Cutting.

Sewing.

Productions follow up.



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CLIENTS OF THE COMPANY

Country. Buyers. Brand Names.

USA. 1. Mens wear group.

2. Vantage.

3. PGA Golf.

4. Andrew Sportswear.

Twin Hill Original.

Vantage.

PGA Golf.

Andrew Sport Destination.

Europe. 1. Esprit.

2. Smart Way.

3. Worthvaley.

4. Asics.

Esprit.

Smart way.

Pierre cardin.

Asics.

New Zealand. 1. Wales and makenly Pearl.

Mexico 1. Mexinde The One.

Oman 1. Oman textiles. Nasse.

Joman.

DOMESTIC BUYERS



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Buyers Brand name.Levies. 1. Dockers

2. Levies

Trents. Westside.

Shoppers Stop. Stop!

Killers. Killer

Reebok. Reebok.

Proline. 1. Proline.

2. Fila.

3. K-Swiss

Arvind brands. 1. Wrangler.

2. Newport.

3. Lee.

4. Flying Machine.

5. Arrow.

J C clothing. 1. M.T.V2. Mini phoss.



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NUMBER OF DEPARTMENTS

Yarn department.

Knitting section

Batch preparation department.

Dying department.

Sampling Department

Cutting department.

Embroidery Department.

Sewing preparation department.

Production/ Sewing department.

Packing department.

Stores department.



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YARN DEPARTMENT

This is the starting point of the production process where the main raw material, the yarn is

received that goes the metamorphosis of being converted into fully finished garments.

The location of the yarn godown is such that the yarns are directly unloaded from the

trucks, inside the godown without being damaged. They are stored in a well organized

manner and proper records are maintained.

Orders are placed with Gokak Mills, it spins the required yarn in 15 to 20 days and

sends them to Campbell knitwear limited, 70% of the yarn is brought from the Gokak Mills

and other 30% is filled by Arihanta spinningMill (Vardhaman), Amarjyoti Spinning Mill

Tripur and mahaveer Spinning Mill and so on.

Types of yarn

Grey yarn.

Dyed yarn.

Melanged yarn.

Polyester cotton yarns.

Lycra threads.

Viscose rayon.

Filament yarn.



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KNITTING DEPARTMENT

This department is the second step of production where the yarn starts taking a form into a

knitted fabric. The temperature maintained normally is between 22 to 26 degree celcius,

the machines are set before starting the knitting process. The knitting process goes on for 24

hours a day comprising of 3 shifts when the operators change.

In knitting

department they have circular knitting machines out of which 12 are single jersey machines

and 1 is double jersey machine. The machine diameter is selected as per the buyers order,

which means lower diameter for kids garment and higher diameter for larger size. The

machine stops production automatically when 25 kgs are produced. Roller take down

mechanism is used.

For cuffs and collars they use flat knitting machine, which can knit four yarns at a

time or more, there are 5 flat knitting machines in the company. The company uses

programmed floppies for various ribs. Due to the software present inside the machine, rib

designing can be done in the machine itself. The maximum collar length that can be achieved

in this machine is 50 cms.



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HUMIDIFICATION

The humidification plant is located besides the knitting department to maintain the ideal

temperature and pressure for knitting. The temperature maintained normally is between 22

to 26. The relative humidity maintained is 65%.

During knitting, a lot of fly and fluff is generated inside the knitting department which

obstructs the knitting process and thereby results in a number of defects in the fabric knitted.

In order to avoid any such problems, the air inside the department needs to be replaced by

fresh air from outside. The humidification plant which supplies fresh air at the right

temperature and humidity, thus helping to maintain the quality of the fabric knitted and the

working environment inside the department carry on this task of replacement of air.

.



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Batch Preparatory Department

This department helps the company in taking its foremost step towards maintaining

global quality. Once the fabric is knitted it is brought in the form of rolls to this adjoining

department and sent to dyeing department in form of Batches.

The fabric is unrolled inspect5ed for defects, reversed and batches are made along

with required tapes collars, cuffs and are sent to the dyeing department to be dyed in the

same shades. The batches are marked, labeled before sending to the Dyeing Department.



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Though the fabric-unrolling machine has the capacity of unrolling 600 kgs of fabric

per day but based on the order it unrolls approximately only 200 kgs.

Dyeing Department

In thisdepartment

the fabric

takes its true

colors and the department consists of:



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Dye Lab

Dye Kitchen

Dye Section

Dye Lab:

The company has fully fledged lab in their dying house, equipped with all required

equipments to test the dyes and chemicals as well as finished fabrics.

The laboratory supports the dying department of the company based on the order

placed by the buyer the dyes are prepared for the shade required. For the testing of dyes

various tests like dry rub and wet rub are done on the swatch sample, all tests are carried out

according to ISO standards.

The swatch samples are sent to the buyer who then gets it tested by dyeing testing

agencies like SGS India etc. In case the tests of the dye lab and the buyers testing agency

match, the approval for bulk dyeing is given.

Dye Kitchen:

The dye kitchen is located above the dye lab and which can be broadly divided into

three sections:

Chemical sectionfor storing the chemicals used for making the dyes

Dye preparation sectionwhere bulk dye is prepared.



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Dozing sectionwhich consists of dozing tanks for each Dyeing machine. The

speed and proportion of dye which is sent to the dying machines is controlled by these

dozing tanks.

Dyeing Section

The

Dyeing

Section

consists

of 5 soft-flow jet dyeing machine, the capacity of two being 400 kgs each, two being of 200

kgs each and one of 50 kgs. The 50 kgs capacity machine is used for sample dyeing and the

rest four are used for bulk dyeing. Also, one garment dyeing machine is used as and when

fully finished garments need to be dyed.



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The fabric is then passed through the WET SPREADER machine to remove all the

ridge marks. The capacity of this machine is 400 kgs per 1.5 hour, temperature required is

140 degree Celsius. This results in shrinkage ranging between 1cm to 2cm, then fabric

compacting is done on the compacting machine. This is done to remove shrinkage and set

the required GSM of the circular fabric. The fabric is then finally dried by passing it through

the RUCKH Drying machine of capacity 1500 kgs / 8 hours.

Sampling Department

The sampling department makes the garment according to the buyers requirements

in order to get them approved. Once the sample as approved, the bulk production starts.

The placement of the order depends upon the approval of samples sent by this

department to the Buyer. There are four kinds of samples.

Proto sample

Size set sample

Pre-production sample

Salesman sample

Proto Sample:

They have the main style and fitting features of the garment which are changeable

according to buyers needs.



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Size Set Sample:

These are prepared after the approval of proto sample and consists of all sizes, small,Medium and Large. This sample is important for measurements and fittings.

Pre-Production Sample:

This sample is the exact clone of the garment the factory is supposed to produce in

bulk. Three pre-production samples are produced, two being sent to the buyer and

one is kept with the company itself.

Salesman sample:

Around 30 to 40 pieces of garments are made and are hung in the shops.

When the pre-production sample is approved, bulk production is started. In case of

new orders, Pilot run is done within the sampling department and accordingly the

production process is changed. The company separately charges for the samples it

makes for the buyer.



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Various batches of fabric are sent to the cutting department along with the cuffs,

collars and trims. Records are maintained in each department and are crosschecked.

The cutting department has a capacity of 15000 pieces per day and is equipped with

an automatic Dye and Punch Bierrebi cutting Machine. This machine is used to cut the

fabric of various dia, acceptable by the machine. The machine cuts 1200 pieces per hour.

Band knife is used to cut the collars, cuffs and sleeves. Ten layers can be cut at a

time on a bank knife. Collars, plackets and pockets are cut along with the fusing.

Embroidery Section

M/C MODEL DC-6, 18 Heads, TAJIMA

M/C is of 18 headed / head 6 needles.

Rings Size Used are 7-24 Rings

Cost- 14 lacks

Threads used are 2 ply embroidery Silk thread

100% Viscose filament rayon

900m/tube- 63 L

One Box Contains 10 tubes



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Supplier:

Regd. Natesh implex private Ltd.

Yashawantpur Bangalore-560022

CKL has done more then 300 Designs.

M/C are fully computerized. The designs are fed into floppy and these floppies are stored

properly. When repeat order comes they have style no and CKL-No. According to which

they sort out and do the embroidery.



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Sewing Preparatory Department

This department lies in between the cutting department and the sewing department.

As the name suggests, it prepares the panels to be stitched and made into garments in the

sewing department.

In this department, the plackets are marked and stitched in the front panel and the

moon-patch with labels as per the buyers requirement in the back panels. Cuffs are also

attached to sleeves and various other functions are done according to the style of the

garment.

There are supervisors who keep a track off what the workers are doing check whether

the position of labels and pockets are proper and guide the operators accordingly. The

department also has a machine for printing with Heat-pressing which is used to print logos or

company name on the required panels.



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A yellow card is hanged at each machine which shows how many pieces the operator

has been able to produce in a day and whether he has been able to meet the targets. The

garment parts are transferred from one operator to the other in crates.

Production / Sewing Department

In

this

department, the various garment parts are assembled, top stitched and various finishing

touches are given as per the buyers requirement. It is adjacent to sewing preparatory

department and Packing Department.



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Based on the orders placed by the buyer, line setting is done in the production

department. There are six lines in this department and each line is given a target of number

of pieces which they should produce. At the beginning of each line, loading is done. The

department is equipped with switch track handling system and single line assembly system is

followed.

There are 130 various machines installed in the sewing department. There production

capacity per day is 10000 to 12000 pieces.

Packing Department

The packing department is adjacent to the sewing department and has an adjacent

warehouse from where the cartons can be loaded onto the trucks when the lot is to be sent.

In this department the final packing is done. The shirts packed in poly bags from the

lines are sent to the department. It is here that they are packed into cartons. There are in all

14 workers in the department who are called as per requirement.

When packed pieces of garments are sent to this department from the line, an order

slip is also sent along with it. The worker at the receiving counter tallies the number in the

slip with the number of garments received. The garments are the packed in cartons in lots of

6 or 10 pieces as per the buyers requirement.

A small slip is placed in each carton containing information regarding the following.

Serial Number

Order Number

Date

Color Number



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Size Ratio

A sicker is also pasted on the cartons containing the following information.

Reference Number Purchase Order Number

Style Number

Size

Quantity

Carton Number

Country of Origin

Stores Department

It is adjacent to the production and packing department. The stores department has

racks in which buttons, labels, threads and various accessories of various orders are kept.

The racks are labeled and the accessories belonging to the particular buyer are kept in there

respective racks. It also stores the stationery to be used by the various departments.

When an order is placed, garment accessories are ordered by the company for bulk

production which is then sent to different departments according to the targets and

requirements of the day.

Labels, which are required by the sewing preparatory department, are sent to that

department when the lineman brings the slip with the signature of their supervisor.

When this department receives goods, goods Inward Invoice is prepared in which the

party name from whom the samples are bought is maintained and sample is attached to it.

One copy is kept with the Stores Department, another copy is sent to the Merchandising



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Department. The third copy is sent to the purchasing department. It is on their approval that

the payment is made.

FABRIC DEFECTS KEPT IN MIND WHEN INSPECTION IS DONE

Fabric Faults:

1. Color Combination

2. Thick Yarn

3. Thin Yarn

4. Barr effect

Knitting Faults:

1. Loop Drop

2. Sinker Line

3. Knitting Hole

4. Needle Line



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Dyeing Faults:

1. Mud Stains

2. Streak Marks

3. Tie Knots

4. Dye Stains

Other Faults:

1. Yellow Marks

2. End of roll

3. Oil stains

Organizational Chart:


Marketing

Finance HRDMaintenance

Production

KnittingDept DyeingDept

PackingDept

Sewing

Dept

Cutting

Dept

Chief executive officer

Vice president (marketing)

General Manager (production)

Factory manager (HRD Department)


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FINDINGS

The orders for the year have shown the excess stock of 0.5421% of the total quantity

ordered and consumed.

The major portion of the excess are

o Sewing thread

o Buttons

o Dyeing chemicals

The order has an excess because the pieces projected to be produced are more than

ordered because of the wastage in the production process.



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Usually the excess stock can be found in the big orders than the small orders.

They have known for their quality.

For Balanced pieces, they got two options.

They will ask the ordered customer to buy the extra pieces also (Customers will

accepts the extra pieces if they satisfied with the quality and product)

Other wise they have their own outlets where they market their products and sell

to retail customers (One in just side of the Campbell plant and another in Bogar

ves).

RECOMMENDATIONS

& SUGGESTIONS

As we have seen the above reasons for the Balance occurrence in stocks, the probable

suggestions would be

The excess ordering should be restricrted to around 0.2%.

It can be achievable by having effective control over the all departments. (because

already they have well organized departments, Experienced workers in their

particular fields)

The available stock has to be checked before ordering for materials



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The yarn should be ordered according to the orders only and not on the forecast of

orders.

BIBLIOGRAPHY

Forbes Campbell Company Profile

Forbes Campbell Company Website

Forbes Campbell Company Register

Brochures

Textile Industry Associations



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forbes campbell

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