SRF HOSIERY MANUFACTURING INDUSTRY

INTRODUCTION

We , SRF Hosiery Manufacturing Industry will be dealing with hosiery items specializing in

Knitted Garments, French Terry, Single Jersey, Fleece , Tri-blends, V Necks, Knitted Denim.

We have our own vertical integrated unit where we will be working with the top most brands of

Europe, USA, UK, Australia, Romania and hence forth to deliver the highest standards of quality

products to meet customer expectations.

Hosiery sector is one of the key components of the Pakistani clothing industry. The total hosiery

market is highly fragmented due to the presence of several brands and non-brand companies.

Some of the most popular hosiery brands are Puma, Nike, Adidas, Reebok, and Bata. Also, you

can find plenty of regional small hosiery companies here.

Generally, socks account for the maximum volume of the total hosiery market in Pakistan.

Typically, the hosiery caters to a wide range of items that all come in the knitted fabric. Some of

the most popular hosiery products are vests, briefs, nights shirts, pajamas, bathrobes, dressing

gowns, panty, leggings, jeggings, short pant, Capri, socks etc.

MISSION

“To deliver the highest standards of quality products to meet the needs of people that will

enrich their lives and engage effectively, responsibly and profitably in the global textile

industry"

VISION

“To constantly evolve and create quality products that add value to all our stakeholders

and strive towards inclusive growth”

• To create income as much as we can.

• To produce great quality pieces of clothing in minimal effort.

• To produce piece of clothing productively.

• To be the success of piece of clothing in the worldwide market.

• To work with each mammoth array purchasers gathering.

LOCATION

S.I.T.E Area

CAPACITY

750,000 garments per month.

WORK FORCE

3,000 people.

OTHER INFORMATION

• 1 Acre

• Starting from 14,000 PKR

• Latest machineries.

• Provide safety and hygiene

• Emergency exits

• Information charts

• Technician to repair the machines.

CERTIFICATIONS:

Certification occurs when an accredited independent body (an auditor) verifies that a supplier is

in conformance to the appropriate standard. Upon successful verification, the auditor typically

issues a certification statement.

Description: One of the most widely used quality management systems. Created by the largest

standards organization in the world, the International Organization for Standardization.

2. NAME: SA8000

Description: Designed to protect human rights in the workplace through social accountability.

Manufacturers demonstrate their compliance to purchasers with this certification, there isn’t

consumer-facing label. Ideal standard in apparel and textile manufacturing.

3. NAME: FAIR TRADE

Description: Created by the World Fair-trade Organisation (WFTO), this certifiable standard is

dedicated to providing farmers and workers in developing countries with increased wages and

working conditions.

UNITS OF SRF HOSIERY MANUFACTURING INDUSTRY

- Spinning

- Yarn dyeing

- Fabric dyeing

- Knitting

- Cutting

- Printing

SPINNING:

Twisting together of drawn-out strands of fibers to form yarn, and is a major part of the textile

industry. The yarn is then used to create textiles, which are then used to make clothing and many

other products. There are several industrial processes available to spin yarn, as well as hand-

spinning techniques where the fiber is drawn out, twisted, and wound onto a bobbin.

YARN DYEING:

Yarn dyeing is the special type of dyeing process. Yarns are dyed in package form or hank form
by yarn dyeing process. It is slightly difference from woven or knit dyeing. Dyed yarns are used

for making stripe knit or woven fabrics or solid dyed yarn fabric or in sweater manufacturing.

FABRIC DYEING:

Dyeing in textiles is a process that permanently transfers color to a textile material using a

substance called a dye. It's a very old process.

KNITTING :

Knitting is a method by which yarn is manipulated to create a textile or fabric, often used in

many types of garments. Knitting creates multiple loops of yarn, called stitches, in a line or tube.

Knitting has multiple active stitches on the needle at one time

CUTTING:

Cutting is the major operation of the cutting room, when the spread fabric is cut into garment

components. Of all the operations in the cutting room this is the most decisive, because once the

fabric has been cut, very little can be done to rectify serious mistakes.

PRINTING:

Textile printing is the process of applying colour to fabric in definite patterns or designs. In

properly printed fabrics the colour is bonded with the fibre, so as to resist washing and friction.

Textile printing is related to dyeing but in dyeing properly the whole fabric is uniformly covered

with one colour, whereas in printing one or more colours are applied to it in certain parts only,

and in sharply defined patterns.

In printing, wooden blocks, stencils, engraved plates, rollers, or silkscreens can be used to place

colours on the fabric. Colourants used in printing contain dyes thickened to prevent the colour

from spreading by capillary attraction beyond the limits of the pattern or design.

DEPARTMENT INFORMATION:

BUYING:

Buying is all about getting the right product for the customer. Buyers focus should be on meeting

customer’s needs through sourcing and taking product forward, negotiating cost prices,
predicting and forecasting what the customer would like to wear next. With all this developing a

strong relationship with our suppliers is a great focus. Buying works closely with Merchandising

to plan the season and react to current trading.

MERCHANDISING:

Merchandising is all about getting the right product, in the right place at the right time.

Merchandisers plan the season and trade the department to deliver profit. They work along with

Buying to achieve required results and solve business problems. Merchandisers concentrate on

effectively managing the supply chain and maximizing sales potential whilst minimizing risk.

PRODUCT DEVELOPMENT:

Technologists work with Buying and Merchandising to make sure that the product is of the best

possible quality. The product development team manage suppliers and visit their factories

worldwide, to help them deliver the right quality product. In addition, Technologists steer

practices to optimize value added to the business, reduce costs and consider advances in product

capability.

QUALITY ASSURANCE:

Quality assurance (QA) is any systematic process of determining whether a product or service

meets specified requirements.

QA establishes and maintains set requirements for developing or manufacturing reliable

products. A quality assurance system is meant to increase customer confidence and a company's

credibility, while also improving work processes and efficiency, and it enables a company to

better compete with others.

MARKETING:

Marketing tells our customer about our brand aswell as the product. The Positions available in

the markets are challenging and fast paced and typically involve planning and carrying out all

marketing and promotional activity for the brand thus marketing plays as important role to make
people aware of the brand and the product in simple words it would help in promoting the brand.

HUMAN RESOURCES:

The Human Resources and Training teams play an essential role in developing key ideas,

understanding the customers, developing initiatives and strategies to help drive individual, team

and group performance. They work with the managers in both Head Office and Retail to provide

guidance and advice to support the business objectives with respect to the customers.

APPAREL & GARMENT TESTING:

the quality of our product’s materials, our workmanship, would be checked and tested using a

number of quality control checks and tests which are described below.

1. Color shading

2. Colorfastness check (Rub test)

3. Size fitting test

4. Adhesive check (logos, printings, markings fastness)

5. Fabric weight test (for knitted garments)

6. Fasteners fatigue and zip quality test

7. Waterproof test

8. Down feather leakage testing

9. Seam slippage test (for woven garments)

10. Care labeling

11. Barcode scanning test

12. Burn test (for 100% cotton garment)

13. Mold contamination prevention

14. Metal contamination prevention

15. Ventilation test

JOB REQUIREMENTS:
QUALIFICATIONS AND TRAINING REQUIRED:

Production-based jobs, such as sewing or clothing pressing, may require only a high school

diploma or GED. Graduates will need a relevant degree such as clothing and textiles technology

or materials and polymer sciences. A postgraduate textiles/clothing qualification can be helpful

for graduates from other relevant disciplines.While the workforce may not require formal

education, but professional training should be experienced by the applicant related to the field.

KEY SKILLS FOR AUTHENTIC APPARELS:

• Creativity

• Precision

• good knowledge and understanding of fabric and materials

• understanding of technicalities

• Interpersonal skills

• The ability to work well in teams

CAREER PROSPECTS AND SALARY INFORMATION’S:

Graduates of design program will be prepared to work in a variety of positions, including

designer, colorist, stylist or fabric engineer. They can be employed by apparel manufacturers,

home furnishing companies and product developers.

QUALITY POLICY:

Each employee is charged with the responsibility and authority to produce product to defined

specifications and customer requirements.

Through the application of the Key Ideas of the Quality Policy (i.e. Quality Product, Customer

Satisfaction and Continual Improvement) it is expected that each employee understands and

meets our customer’s expectations.

The Quality Policy has been communicated to all employees via meetings and a variety of

handouts and postings. Continuous evaluation during internal audits ensures the implementation

and maintenance of the Quality Policy as well as the employees understanding of how they help
contribute to the achievement of the Quality Objectives

Annually, the Top Management Team will define goals and objectives that will be utilized to

measure the suitability and effectiveness of the Quality Management System

All requirements of the ISO 9001 Standards have to be addressed.

CAREER PROSPECTS AND SALARY INFORMATION’S:

Alumni of a formal plan program will be set up to work in an assortment of positions, including

fashioner, colorist, beautician or texture engineer. They can be utilized by attire makers, home

outfitting organizations and item engineers.

Generally, the machinery requirement varies depending on the specific raw materials you use

and what product you want to produce. As an example, if you procure printed clothes, then you

don’t need to have the dying arrangements. Here, we have provided some basic machinery

requirement list.

PROCURING MACHINERY

• Cutting machine (Power Operated)

• Overlock machine (3 thread) with motor and stand (1/2 HP)

• Folding machine with stand and motor (1/2HP motor)

• Rib Cutting machine with stand and motor (1/2 HP motor)

• Sewing machine with a motor stand (1/2 HP)

• Scissors, measuring instruments, checking table and miscellaneous items

• Garment washing machine

• Hydro-extractor

• Dryer Tumbler

• Washing room trolleys

• Steam press portable

• Packing machinery

PROCURING THE RAW MATERIALS

basic items are:

• Dyed/bleached knitted cotton cloth in different count

• Top elastic

• leg elastic

• Zips, buttons

• Different sewing threads

• Labels and polythene bags for individual packing

• Cartoon box for bulk packaging

• Detergent for washing and other miscellaneous items

QUALITY TRAINING:

The purpose of the training program is to train operators to attain high speed and production

together with good quality work. Good quality comes from the consistent use of correct methods

The steps to be taken to achieve good quality are as follows:

1. INITIAL INSTRUCTION

Point out the key points of method and quality to the trainee and be sure that she understands

them.

2. TRAINEE PRACTICE

When the trainee first practices an exercise, the instructor should watch her methods very closely

and correct any incorrect methods immediately. The trainee should not be timed or be permitted

to start timing until she is doing the exercise correctly. Even after starting her timing, the

instructor should keep a close watch on her methods and quality.

3. QUALITY CHECKING

Whenever the instructor finds any faulty work, or whenever defects are found by other inspectors

or operators, the instructor should:

Tell the trainee not just what she is doing wrong, but what she must do to perform the work

correctly.

4. METHODS CHECKING

The best way for an instructor to ensure good quality is by watching the trainee while he is

working, by inspecting some of his work and by correcting any faults immediately. It is much

easier and more effective to correct a fault when it happens, than to try to change the method

after he has turned out a quantity of bad work. In order to become skilled at this part of training,

the instructor should take every opportunity to stand and watch each trainee at work, in order to

detect and stop any defects in method, immediately.

QUALITY INSPECTION AND CONTROL IN SRF INDUSTRY:

The various Steps of Garments manufacturing where in-process inspection and quality control

are done are mentioned below-

• In Sample making section

• In- Marker making section

• Inspection in fabric spreading section

• Inspection in fabric cutting section

• Inspection in fabric sewn section

• Inspection in pressing & Finishing section

• Quality Control in Sample Section:

• Maintaining buyer Specification standard

• Checking the sample and its different issues

• Measurements checking

• Fabric color, gsm, Fastness etc properties required checking

• Spi and other parameter checking

• To check notch or drill mark

• Fabric width must be higher than marker width

• Fabric length must be higher than marker length

• Matching of green line

• Check pattern size and dimension

• Matching of check and stripe taking into consideration

• Considering garments production plan

• Cutting table length consideration

• Pattern direction consideration

• Quality Control in Fabric Spreading:

• Fabric spreading according to correct alignment with marker length and width

• Maintain requirements of spreading

• Matching of check and stripe

• Lay contains correct number of fabric ply

• Correct Ply direction

• To control the fabric splicing

• Tension control

• Quality Control in Fabric Cutting:

• The dimension of the pattern and the cut piece should be same and accurate

• Cut edge should be smooth and clean

• Notch should be cut finely

• Drill hole should made at proper place

• No yarn fraying should occur at cut edge

• Avoid blade deflection

• Maintain cutting angle

• Quality Control in Sewing Section:

• Input material checking

• Cut panel and accessories checking

• Machine is in well condition

• Thread count check

• Special work like embroidery, printing panel check

• Needle size checking

• Stitching fault should be checked

• Garments measurement check

• Seam fault check

• Size mistake check

• Mismatching matching of trimming

• Shade variation within the cloth

• Wrong placement of interlining

• Creased or wrinkle appearance control

• Quality Control in Finishing Section:

• Proper inspection of the garments including measurement, spot, dirt, impurities

• Water spot

• Shading variation check

• Smooth and unfold in pocket

• In secured or broken chain or button

• Wrong fold

• Proper shape in garments

• Properly dried in after pressing

• Get up checking

• Collar closing

• Side seam

• Sleeve placket attach

• Cuff attach

• Bottom hem

• Back yoke

• Every parts of a body

• Quality Control of Sewing Thread:

• A slender, strong strand or cord, especially one designed for sewing or other

needlework. Most threads are made by plying and twisting yarns. A wide variety of

thread types are in use today, e.g., spun cotton and spun polyester, core-spun cotton

with a polyester filament core, polyester or nylon filaments (often bonded), and mono

filament threads.

QUALITY PARAMETERS OF KNITTED FABRICS:

Following are some quality parameters of knitted fabric.

• Strength and extensibility.

• Course density.

• Wales density.

• Lop length.

• Elasticity.

• Deformation.

• Grams per square meter (G.S.M)

• Yarn count.

• Design.
MEASURES OF QUALITY ASSURANCE:

QUALITY CONTROL:

A quality control and inspection services for different customers from all over the world. Using

international standards such as ISO 2859, our Quality Controllers (QC) method consists to check

different control points:

CONFORMITY:

The QC checks the conformity of the product (design, colors, raw material…) with the Pre-

Production Sample (PPS) and other technical files.

QUALITY:

Our QC checks for defects (fabric defects, colors defects, accessories and label defects,

manufacturing defects) and classifies them accordingly.

MEASUREMENT:

Following the measurement chart, our QC checks the measures for each size of the product.

PACKAGING:

Our QC checks the quantity of cartons, size of cartons, their weight, shipping marks, etc.

QUALITY COST:

Preventing, detecting and dealing with defects cause costs that are called quality costs or costs of

quality.

FUTURE EXPECTATIONS

In the coming years, Authentic Apparels are expected to become the Pakistan’s largest hosiery

wear exporters.