5.

PRODUCTION DEPARTMENT
The production department is responsible for converting inputs into outputs through the stages
of production processes. The Production Manager is responsible for making sure that raw
materials are provided and made into finished goods effectively. He or she must make sure that
work is carried out smoothly, and must supervise procedures for making work more efficient
and more enjoyable.
The company is well integrated with most modern machines for knitting, processing, fabric
finishing and sewing. It is capable of producing products with high quality. It includes several
processes.
KNITTING:
Knitting plays a key role in the manufacturing process. Knitting is the operation of producing
knitted fabric according to the design by the knitting machine. In the knitting process, multiple
loops of yarn are created, called stitches and formed in a line or tube.
The knitting operation creates multiple active stitches at one time in the knitting machine.
These stitches were done by the needle of the machine. The fabric consisting many consecutive
rows of intermeshing of loops. As the progress of one loop, the same time another is creating.
The knitting machines are from Mayer & Cie. Which produce a variety of flawless knits including
single jersey, double jersey, auto stripped, fabrics, lycra, jersey, and electronic jacquards. The
knitted cloth may be tubular i.e, round or open width. Interlock is a type of fabric in which the
thickness of the cloth will be greater.
DYEING:
The process of applying colour to fiber stock, yarn or fabric is called dyeing. There may or may
not be thorough penetration of the colorant into the fibers or yarns. Dyeing can be done at any
stage of manufacturing of textile fabric, yarn, fabric or a finished textile product including
garments and apparels. The property of colour fastness depends mainly on two factors,
1. Selection of proper dye according to the textile material.
2. Selection of the method for dyeing the fabric.

WASHING:
Normally we use the word ‘washing to mean cleaning. But in the case of garments, washing is
not limited to this function. For garments, washing is not only required for cleaning but also
required for improving fabric quality, increase the softness of fabric, reduce shrinkage, removing
dirt, and for creating colour effects. In other sense, washing is a technique used to remove
impurities dirt, dust, oil, etc. from the surface of garments, softness feeling of cloths. Outlook
fashion of the apparel, and increasing colourfastness.
Types of washing:
NORMAL WASHING- Normal washing is the simplest type of washing with lowest washing cost. By
this system starch materials present in the new garment is removed together with dirt, hence
after wash the garments feel soft during use. During normal wash on garments, washing effect
could be varied by altering washing temperature, washing time. Quantity of detergent used etc..
PIGMENT WASHING- Pigment washing process is similar to normal washing process. Apparels are
made from pigment dyed or pigment printed fabric. Then the apparels are subjected to pigment
washing. By this washing, fading effect is produced in the garments.
BLEACH WASH- There is a similarity between bleach and pigment washing. In both the cases,
partial colour fading effect is produced. In case of bleach washing, the fabrics of the Apparels
are normally dyed with direct or reactive dye,
STONE WASHING- It is done on the garments made from heavy fabrics like denim and jeans. It is a
very popular wash. Due to this type of washing, different types of irregular colour fading effect
is produced. Moreover, shrinkage also occurs in the apparels resulting correct size of the
garments.
ACID WASH- Apparels made from denim and heavy jeans fabric are normally considered for acid
wash.

COMPACTING:

Compacting process is used for controlling shrinkage of fabric, GSM control and make
compaction the fabric in length wise direction to provide over feed to the fabric while
processing in presence of steam and able to control the shrinkage. Compacting can be done
with both open width fabric and tubular fabric. Residual shrinkage of the fabrics can be brought
down to 3% to a maximum of 0. Compactors are of two types:
1. Open width compactors
2. Tube compactors
PATTERN MAKING AND CUTTING:
Pattern Making is a blueprint for the garment, on the basis of which the fabric is cut. It is the
technical drawing or drafting of a garment. Standard size charts, dress forms or figure are
measured, these measurements are then converted into 2D patterns and then garments are
made from them.
Cutting is one of the most important stage in the garment manufacturing process. The fabric is
first cut using the first pattern to make any garment. To make complete the garment, the fabric
is cut into several pats, then these cut parts are sent to the sewing department for stitching,
where the whole garment is made by adding these parts.

PRINTING:
Printing is a process of decorating textile fabrics by application of pigments, dyes, or other
related materials in the form of patterns. Textile printing is related to dyeing but in dyeing the
whole fabric is uniformly coloured with one colour, whereas in printing one or more colours are
applied to it in certain parts only and in sharply defined patterns.

TYPES OF PRINTING:
CHEST PRINTING – This type of printing is done either after cutting or after finished the full
garment. Techniques used for this type are
1. Pigment printing
2. Discharge printing
It can be done manually and automatically. When it is done manually only four colours are
available whereas automatically the colour ranges up to 10 colours.

ALLOVER PRINTING – All over printing is done only by manual method

POLYSTER PRINTING – Polyester printing is only done by digital method.
EMBROIDERY:
Embroidery is the process of embellishing the surface of textiles with decorative stitching using
colourful threads often made of cotton or silk. It gives elaborate shadings to fabric variety of
pigment, discharge, embossed, flock and foil prints.

SEWING:
Sewing is an important department in the garments manufacturing industry. All the parts of a
garment are joined here by making stitches with the help of a needle and thread.

SEWING MACHINES:

The most common types of sewing machines used are;

 SINGLE NEEDLE MACHINE – Single machine is the most commonly used Sewing
machine in the apparel industry, especially in woven garments.
 OVERLOCK MACHINE
 FLATLOCK MACHINE

6.QUALITY CONTROL DEPARTMENT:

CHECKING:
For the textile and apparel industry product quality is calculated in terms of quality and
standard of fibers, yarns, colour, designs of the final finished garment. Quality control in terms
of garments manufacturer, pre-sale and post sales service, delivery, pricing, etc. are essential for
garment manufacturing, trade or export.
Certain quality related problems are often seen in garment manufacturing like sewing, colour,
sizing or garment defects which can never be overlooked.

SOME OF THE DEFECTS:

 SEWING DEFECTS – Wrong stitching techniques, non-matching threads and missing
stitches, improper creasing of the garment, erroneous thread tension and raw edges are
some of the sewing defects which can affect the garment quality adversely.

 COLOUR DEFECTS – Variation of colour between the sample and final garment.

 Wrong colour combination and miss matching dyes should always be avoided.

 SIZING DEFECTS- Wrong gradation of sizes, difference in various parts of a garment

like sleeves of XL size of L size garment can deteriorate the garment beyond repair.
  OIL STAIN DEFECTS – Oil stain can be removed by oil stain remover. The stain is Due to
the leakage from machine.

IRONING AND PACKAGING:

Ironing is the most important finishing process in the readymade garment sector which is done
by subjecting a cloth to heat and pressure with or without steam to remove unwanted creases
and to impart a flat appearance to the garments. Pressing or ironing is also done to introduce
creases in the apparel.
Objectives of ironing are;
1. Removal of unwanted creases and crinkles,
2. Shaping,
3. To apply creases where necessary,
4. Under pressing,
5. Final pressing.
After doing the iron and final check, the garments go for the packaging section. In this section,
the garments will be sorted on the basis of design and size and and then packed in some poly
bags and finally in the big cartons with the labels and price tags. Then the whole production is
ready for the delivery to its buyers.
 CHAPTER IV
CONCLUSION

The industrial training in ASWATHI HOSIERIES PVT. LTD was a good opportunity for me to learn
about the various aspects of the departments practically. The day to day function of various
departments were carried perfectly and efficiently.
During the training period the staff of various departments inside the organisation helped me to
know the duties performed by them and as well as do’s and don’ts of all functions in the
organisation. The training also helped me in improving my planning skills, coordination with
team members and time management. Overall, this internship period was very useful for me.
The company Is known for its quality products and will maintain and succeed in all of its future
operations.