aknowledgement
Industry Internship is a platform where we learn how to apply our curriculum knowl-
edge in more practical way and take our creativity to a higher level.
I am highly obliged to Gokaldas Exports Ltd for giving me this opportunity. I would like to express my warm gratitude to Ms. Vishaka Agarwal for guiding me the entire time and all the informative feedback that I received. I would also like to express my warm gratitude to Ms. Sheila Chandy, Mr. Amit Kumar for their continuous support, and encouragement and valuable guidance throughout the internship period. They gave me an opportunity to learn and explore more in the field of design. It was a pleasure working with all my colleagues and I appreciate the help and the time they spent getting my work done. I would also like to thank Ms. Kathelene (HR Department) for giving me the opportunity to work with Gokaldas Exports Ltd.
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content 1. INTRODUCTION 2. COMPANY PROFILE 3. BACKGROUND 4. MANUFACTURING FACILITIES 5. INFRASTRUCTURE 6. DEPARTMENTS 7. PRODUCT RANGE 8. CLIENTS 9. HUMAN RESOURCE -EMPLOYEE WELFARE -FACILITIES -SOCIAL INITIATIVE 10. WORK FLOW -DESIGN DEPARTMENT -MERCHANDISING DEPARTMENT -CAD DEPARTMENT -R&D DEPARTMENT -EMBROIDERY DEPARTMENT -PRINTING DEPARTMENT -INDIGO BLUE -FINISHING AND PACKAGING 11. THEMES OF A/W 15 12. FOREVER 21 EMBROIDERY COLLECTION 13. EMBROIDERY FOR A/W 15 14. SEQUINS WORK FOR A/W 15 15. VISUAL MERCANDIZING 16. CONCLUSION
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introduction This report is based on the internship work done at Design unit of Gokaldas Export Ltd in Bangalore
during the period of 2nd June 2014 to 25th July 2014 as a part of course curriculum of National Institute of Fashion Technology, Bachelor Degree of Textile Designing. The main objective of the internship was to gain in-depth knowledge of the working of the industry in terms of organization structure, product range, materials and manufacturing processes, costing, design management, quality control, marketing and distribution and corporate social responsibility. Small scale project in a particular unit was also part of the internship brief. As a student of Textile Design, the 14 weeks long export house internship helps in gaining an insight and hands on experience of the real deal happening in a garment manufacturing unit. It helps in linking our academics learning with the real work that happens in these export houses.
company profile
vision “To be a globally reputed apparel manufacturer, evoking distinctive recognition for Product, Performance, Processes and People.”
mission “Achieve profitable growth through Innovation, Quality, Consistency and Commitment.”
Gokaldas Exports Limited was a family owned business founded by the late Jhamandas H. Hinduja in 1979. Gokaldas Exports Limited is one of leading exporter of apparel in India having worldwide presence with established manufacturing, marketing and research capabilities. They have more than 40 factories spread across Bangalore, Chennai, Mysore, Tumkur, Hyderabad and Madanappalle manufacturing 2.5 million garments per month with advanced equipment. The factories include various ancillary units which manufacture the input material such as labels, tags, elastics, cords and woven tapes. These factories also have in-house facilities for value added services like poly fill quilting, embroidery, printing & specialized washes. The Company is engaged in the business of design, manufacture, and sale of a wide range of garments for men, women, and children and caters to the needs of several leading international fashion brands and retailers. The principal source of revenue for the Company is from export of garments and related products. 10
background The Company started as a business that manufactured silk scarves and stoles and later changed
its business model to manufacture shirts in a 1,000 square feet rented space with 40 leg machines. The company’s target was export markets- primarily The US and Europe and began to expand through partnership arrangements. Incorporated on 1979, GE rapidly rose to become India’s largest manufacturer/exporter by 1981 and has retained that position to date. New technology was introduced as the company went forward. Huge industrial washing machines churned denim garments to give them the look of the hour stonewashed, acid washed, bleached while other garments were manually spray painted, sand blasted or laser engraved. Massive multi head embroidery machines emblazoned shirts and jackets with appliqués, badges, and embroidery. They also have centralized laundry, in-house units manufacturing poly wadding, and quilting. By end of 2004 Gokaldas had 43 factories with 258 production lines scattered in and around the southern Indian city of Bangalore. It had more than 35,000 workers, which was nearly double the no. it employed in 1999-2000, and its total sales had increased at an annual compounded growth rate of 19.67% over this period. The company was valued at approximately $215 million and exported nearly 90 percent of its production. Our product strengths - outerwear, bottoms, sportswear, formal suits, trousers, skirts, and denim wear - across all genders.
manufacturing facilities Gokaldas Exports’ manufacturing units are located at Bangalore. The units are well equipped with 48
manufacturing factories.These units have a production capacity of 2.5 million garments a month and the company exports the same. It also has a state-of-the-art laundry fully equipped with automatic machinery and a processing capacity of over 100,000 garments a day. The company’s Polyfill manufacturing plant has a production capacity of over 400,000 yards per month of polyfill per day ranging between 40-360gsm. GEL’s quilting unit has a processing capacity of over 500,000 yards per month a day. Its printing unit, installed with spider printing machines and printing tables, has a capacity to print upto 50,000 to 70,000 garments per day. Its embroidery unit installed with 42 multi-head embroidery machines produces appliquesm badges, simple and complex embroideries fulfilling a requirement a more than 50,000 pieces per day. The company’s label manufacturing units has production capacity of 1,00,000 labels a day. The knits manufacturing unit produces 500,000 pieces per month. Gokaldas Exports Ltd. also operates an in-house design facility that focuses on creating and developing new collection of garments according the seasons. The company also operates retail chain of garment under the brand name ‘The Wearhouse’. These outlets are located in Banglore, Chennai, Hyderabad and Coimbatore. The company has strategic alliances with various fashion giants namely Nike, Mexx, Mustang, Greg Norman, Reebok, Oxbow, Old Navy, Banana Republic, Levis, Dockers, Macy’s Merchandising Group, Diesel and Puma are amongst others. The company owns subsidiaries namely All Colour Garments, Deejay Trading, Glamourwear Apparels, Madhin Trading, Magenta Trading, Rafter Trading, Rajdin Apparels, Reflexion Trading, Rishikesh Apparels, Seven Hills Clothing, SNS Clothing, Vignesh Apparels and Robot Systems
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INFRASTRUCTURE The head office of Gokaldas Exports Ltd is at Mission Road, Bangalore where they have CEO’s Office, Marketing and Merchandising Department, Sourcing Department, Research & Development Department, Sampling Department, Planning Department, CAD Department, IT Department, Finance Department, HR Department and Design Department. Gokaldas manufactures more categories of garments by starting more number of successful factories in and around the state of Karnataka.
Hinduja Sports Wear I Hinduja Sports Wear II Carnival Clothing II & III
Hinduja Sports Wear II The Wearwel II Global Garments II
Carnival Clothing I New Generation Apparels-I Asiatic Exports Intex I Intex V JD Clothing Company International Clothing Company IV
Wearcraft Apparels Atlantic Apparels I The Unique Creations Chennai SEZ Division Gokaldas Exports R&D I Global Garments I Gokaldas Exports R&D II Gokaldas Exports R&D IV Venkateswara Clothing Company II Euro Clothing I The Intex II Wearcraft Apparels I & II Venkateswara Clothing Company Sri Krishna Industries Atlantic Apparels II Triangle Apparels VI Indigo Blues Balaji Finishing House I & II Euro Clothing Company II Triangle Apparels VI Triangle Apparels-I
Gokaldas Export R&D
International Clothing Company-II Hinduja Fashions Hinduja Processing & Finishing Unit Hinduja Sports Wear I Triangle Apparels I Triangle Apparels II Luckytex III Triangle Apparels III Dress Master Suits Global Garments III Atlantic Apparels-111 Carnival Clothing Co. Carnival clothing company-II
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WASHING DEPARTMENT
PRINTING DEPARTMENT
cad DEPARTMENT
STITCHING DEPARTMENT
HAND EMBROIDERY
EMBROIDERY DEPARTMENT
DEPARTMENTS These are some of the departments, Gokaldas exports ltd. is divided into; s+80$1 5(6285&( $'0,1,675$7,21 '(3$570(17 s'(6,*1 '(3$570(17 s6$03/,1* '(3$570(17 s&$' '(3$570(17 s)$%5,& 6725( s6285&,1* '(3$570(17 s75,06 $1' $&&(6625,(6 6725( s,1'8675,$/ (1*,1((5,1* '(3$570(17 s5(6($5&+ $1' '(9(/230(17 '(3$570(17 1. SEWING DEPARTMENT 2. FINISHING DEPARTMENT 3. CUTTING AND FUSING DEPARTMENT s(0%52,'(5< 35,17,1* 6&5((1 '(3$570(17 s48$/,7< '(3$570(17 s0$,17(1$1&( '(3$570(17 s$&&28176 $1' ),1$1&( '(3$570(17 s,1)250$7,21 7(&+12/2*< '(3$570(17 s75$,1,1* '(3$570(17
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product range DENIM WEAR FORMAL SUITS CASUAL SHIRTS FORMAL SHIRTS CASUAL TROUSERS SPORTS WEAR KNITS OUTERWEAR JACKETS COATS, BARKAS, RAINWEAR LADIES’ BLOUSES, SHITS DRESSES EMBROIDERED GARMENTS TIE-DYE GARMENTS SLEEPWEAR CHILDREN’S WEAR
clients
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major countires AUSTRALIA CANADA EUROPE JAPAN 0(;,&2 MIDDLE EAST SOUTH AFRICA UNITED STATES
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human resource In today’s challenging business scenario the success of an organization is shaped by its people and cul-
ture. Keeping this philosophy in mind, they lay a strong emphasis on developing there people and building a cohesive and constructive work culture. Employees drive the business performance and they ensure that all of them are motivated and committed. Team work, trust, honoring commitments, challenging others and goal orientation are the behaviors that they demonstrate in the company. In addition to these, to keep pace with the fast changing environment, they foster a culture of embracing change on a continuous basis. employee welfare
Gokaldas strives to attract, enhance and retain the best talent and to build a culture that drives individual, organizational and business growth through talented, engaged and committed employees. To achieve this we focus on learning, career development, performance management, compensation and benefits. There role is to ensure that Gokaldas is a true ‘learning habitat’, which grooms people and their talents giving them the skills they need to excel. Hence, training of personnel at all levels of organization is an essential component to augment and update the knowledge base. Our training programs are all-pervasive and are structured to hone the specific skills of each employee. Finally, they play an essential role in shaping development processes that help people advance their careers as far and as fast as they can. -Self awareness programme for supervisors -Quality training in factories -Management leadership program -Training for tailors in association with ILFS
scholarships for employees children
training session groupp photo
health enabled retures project
facilities Gokaldas Exports has set up healthcare centers where free medical attention and treatment is available to all employees and their families. An ambulance is on call 24x7. Every factory has a creche for small children, who cannot be left at home by their mothers. Spacious canteens offer workers a comfortable and convivial lunchtime environment. social initiatives With an employee base of 30,000 we provide the livelihood for more than 100,000 people. It is our endeavour to contribute not just to this 100,000, but to the society beyond that. Our Human Resource team has events organized at regular intervals aimed at creating social awareness that has a direct impact on society. - Hepatitis-B Vaccination Programme - Blood Donation Camp - Summer Camp for Employees’ Children - Law awareness programme organised in the factories - Scholarships for Employees’ Children - HER (Health Enabled Returns) Project
quality training in factories
management leadership program
self awareness programme for surpervisors
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WORK FLOW design department HOD: Ms. Sheila Schandy Designer Manager: Mr. Amit Kumar Designers: Ms. Shanti, Ms. Saswata, Ms. Satya, Ms. Julie, Ms. Beenu, Ms. Evelyn, Mr. Shashank, Mr. Abhishek, Ms. Sapna, Ms. Ruma
The main challenges that are faced by Design Team is that they need to satisfy a wide range of customer in a very limited time. They need to also make sure that the prices are low, new sillhouetes are introduced, unique emblishments and need to be one step ahead. s ,QGHQW UHOHDVHG WR &$' 'HSDUWPHQW LQFOXGHV )ODW VNHWFKHV 0HDVXUHPHQW VKHHW DQG 'HWDLO VKHHW ZLWK fabric swatch s ,QGHQW UHOHDVHG WR 5 ' 'HSDUWPHQW LQFOXGHV )ODW VNHWFKHV 0HDVXUHPHQW VKHHW 'HWDLO VKHHW DQG 7ULP card (button, label, fabric swatch, thread) Fabrics, thread rolls.
CAD Department
R&D Department
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frame placement on machine
beads and sequins rack
process of sequins work
machine embroidery
hand embroidery
process of bead work
process of sequins work
Embroidery Design Manager: Mr. Shrinivas Embroidery Punching: Mr. Krishna Murti Hand Embroidery: Mr. Ashok Machine Embroidery: Bablu Master Machine Handler: Mr. Baseya
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checking layers for sceen making
printing process
after removal of screen
screen
screen
placement in frame
placement on fabric
placement of frame
printing
The in-house printing unit is equipped with 12 printing machines and 9 printing tables,, with a capacity to print up to 500,000 pieces per month. Smooth co-ordination between the production and the printing units is the hallmark of Gokaldas Export’s order execution process.
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washing machines
tie up for techniques
sun dry process
washing machines
after wash
sampling using sand paper
stone wash
display room
spray booth
washing process Indigo Blue is one of the factories at Gokaldas that deals with mainly Denim and conduct various different kinds of washes with different techniques. DRY process Different types of dry process are done PDLQO\ E\ KDQG VXFK DV s :KLVNHULQJ s +DQG VDQGLQJ s 6DQGEODVWLQJ s 7DFNLQJ s 5HVLQ s *ULQGLQJ s 0LONLQJ s 33 3WDPLXP 3HUPDQJDQDWH
wet process
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merchandizing
In this department, the buyers sent there demand for particular garment and then the merchandizer cre-
ates a sample and send back to the buyer with costing details. If it gets approved the design is sent of mass production. The merchandizers work is also to calculate the costing of the garments made in design depart ment and send to the buyer (if demanded). &RVWLQJ LQFOXGHV )DEULF FRVW SDWWHUQ &$' HPEURLGHU\ QXPEHU RI VWLWFKHV ODERXU FRVW DQG SURILW
merchadizing
quality assurance Gokaldas Exports implements Lean Production processes across all manufacturing units ot meet hte goal of “Getting the right things to the right place at the right time, the first time, while minimizing wast and being open to changes.” This holistic approach eliminates waste, minimises inventory and maximises throughout creating a cluture of continous improvement. The company’s Kaizen teams ensure that stringent standards and design specifications are exactly replicated through every stop of the manufacturing process. The industrial Engineering Team, comprising personnel trained in garment manufactuing technology, analyses each style before it goes on to the production line, examinging every requirement from sewing to packing. Here, the Quality Control department steps in. Pre-production meeting are carried out with each factory before any new style is located on the lines, detailing every aspect of the process and making certain that Lean Production systems are in place. Post- production, the garment goes through several on-line, prefinal inspectoons that adhere to customer quality standards.
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finishing
After the garments have been sewn, they go through a finishing process. During this step, the garments are inspected for quality, individually trimmed of excess backing material and excess threads, then foldedand packaged ready for shipping to the end user. Customers have the option of polybagging which takesplace in this step. Polybagging involves individually folding each garment and placing in into a plastic bagpreserving it from stains and dust. Todays garments require a lot of different finishes. Our facilities can helpwith details such as distressing, appliques, grinding and paint spots. Heat Transfer our facilities can help create custom heat transfer prints or use pre-made foil and process colordesigns that will produce more vibrant photo prints on garments than process (CMYK) coloroffers.Stones & BeadsStones and beads make an interesting embellishment on almost any garment. We can help withheat transfer or studded applications for versatility in any situation. We can apply rhinestones,glitter, caviar beads, nail heads, square beads and stick beads to garments.Get a quote on your job today!
finishing process
export packaging
Export packaging is also often referred to as transport packaging, which is one of three main types of packaging that are likely to be needed for exported goods. Transport or export packaging is the outermost layer of packaging and is designed to protect your goods during transit. Examples include wooden crates, metal drums and plastic shrink- wrapping. See the page in this guide on your export packaging options. Outer packaging is an intermediate layer of packaging, which often also serves a retail- promotion purpose. An example would be a box containing multiple units that doubles as a retail display fixture and can be placed directly on a shop shelf, as is common with many convenience foods. Sales packaging is the immediate layer of packaging around your goods - the packaging that remains when the goods reach their end-user. Sales packaging often also serves a marketing purpose by containing prominent branding images and information. These three types of packaging work like Russian dolls - each layer of packaging is complete on its own terms, but contained within a further layer of outer packaging. This guide is concerned primarily with export or transport packaging, but it makes sense to consider all your packaging choices together at the outset.
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Work division in design department
themes of A/w 15
Gokaldas Export Ltd. work on there own themes using inspiration from WGSN and Stylesight. After they decide the themes, they create a theme board with details such as inspiration pictures, keywords, trending colors of the season, fabric direction, other detailing with differnt techniques and styling direction that would help the designers to work in more specific direction with the knowledge of the trends of the season.
mood board
cLIENT board
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embroidery developments art work
design 1 mock up
inspiration
design 2
art work
mock up
garment placement
inspiration
design 3 art work
garment placement
mock up
design 4 art work
mock up garment placement
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design 5 art work
mock up
garment placement
design 6
art work mock up
garment placement
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design 7 art work mock up
garment placement
inspiration
design 8
mock up
inspiration
garment placement
art work
design 9
art work
mock up
garment placement
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EMBROIDERY FOR A/W15 design 1 mock up
art work
inspiration
mock up
design 2
inspiration
art work
design 3
art work
mock up
inspiration
design 4
art work inspiration
mock up 46
design 5
art work
mock up
design 6 mock up art work
inspiration
design 7 inspiration mock up
art work
design 8
art work
mock up
inspiration 48
design 9 art work
inspiration mock up
design 10
art work
inspiration
design 11 inspiration
art work
mock up
design 12 art work
mock up
inspiration
50
design 13 mock up
art work
design 14 art work
mock up
inspiration
design 15 art work
inspiration
mock up
design 16 inspiration
art work
mock up 52
design 17 inspiration art work
mock up
design 18 art work
mock up
inspiration
design 20 art work
inspiration
mock up
design 21 art work
inspiration
mock up
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SEQUINS WORK FOR A/W15 design 1
mock up
inspiration
design 2
inspiration
mock up
design 3
inspiration
mock up
design 4
mock up
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design 5
mock up
inspiration
design 6
mock up
inspiration
design 7
inspiration mock up
design 8
inspiration
mock up 58
visual merchandizing
The ready garments made as GE collection are dislayed in this studio where they are distributed according to the trend, theme and the buyers requirement. Buyers come and select the garments and then mass production of those selected garments takes place.
CONCLUSION Gokaldas Export Limited has been a great experiance overall as it give me a great opportunity to learn and explore more in designing. Apart from the work done in the design department, each day spent helped me to gain more knowledge on discovering of new things. Interaction with professionals with differnt talent helped me gain a lot of knowledge and helped me understand more about how work is done in export house and how it is differnt from the work done in retail. The knowledge that i have gained her would definitely help me further in my lifetime.
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reference - www.gokaldasexports.com (23.7.2014/ SP
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- economictimes.indiatimes.com SP
- www.forever21.com (23.7.2014/ SP