KGI CLOTHING PRIVATE LIMITED

Entrepreneurship and sustainable business practices

ASSIGNMENT 02

Submitted by:
Kriti Singhal

Manvi Jain

Shubhangi Kumari

Simran Bahl

Vrinda Singh
 Table of content
S.No Content Page No.
 Acknowledgement

We would like to express our special thanks to our teacher, Mrs Malar Selvi to
give us this golden opportunity to do an industrial visit to KGI Clothing Private
Limited and thereby giving us the pleasure to present this project of
Entrepreneurship and Sustainable Business Practices. This project taught us
patience, the importance of teamwork and delegation of work. This would not
have been possible without the continuous guidance of you, ma’am.

DATE: 16/11/18 Kriti Singhal

Manvi Jain

Shubhangi Kumari

Simran bahl

Vrinda Singh

Masters of Fashion Management

NIFT Chennai
 INTRODUCTION
KGI Clothing is non-government, Chennai based company. It is a Leadership in
Energy and Environmental Design (LEED) rated, sustainable green factory, housing
close to 500 employees in a built-up area of 87,188.4 square feet, it is a state of
the art-facility. It is into garment manufacturing, supplying and exporting of
menswear, womenswear and kidswear, majorly manufacturing shirts and
kidswear using viscose, cotton, linen, polyester, lycra, blend of lycra and cotton. It
exports its products to the United States, and the United Kingdom, the major
buyers being PMS, IKKS and Lifestyle.

The company was established in 2016 at Sri city, Tada, Andhra Pradesh. Sri City is
a smartly planned integrated business city spread across 70 kilometres. It hosts a
number of small to medium scale industries such as engineering, electronics,
automotive, aerospace, apparel, renewable energy, biotech/pharma, sporting
equipment, toys, logistics and warehousing, IT/ITES/BPO, education & training
institutes and other Eco-friendly industries.

It is a private company and is classified as “company limited by shares”.

Company’s authorized capital stands at Rs. 200 lakhs and has 100% paid-up
capital which is Rs. 200 lakhs.
 WHY SRI CITY?
Companies make decisions with an eye to maximize profits. That includes taking
taxes into account. If there’s a tax credit available for developing, say a new anti-
biotic or opening a store in a particular district, some companies will choose that
option over a path that doesn’t lead to a credit. Tax law shapes big decisions, such
as which country to base operations in, as well as smaller decisions such as
whether to open a home office.

And this is what happened in the case of KGI Clothing, as the Andhra Government
was giving many subsidies to open up an industry in this area, thus they finalized
this as their location. Major location advantages offered by the Andhra
Government based on their survey conducted in april,2015 are as follows:

 The capital investment for the first two years is made interest free as a
subsidy by the government.
 25% reduction in the cost subject to innovative capital goods.
 Centralized water system by the Sri city, Special Economic Zone belt.
 Every month a meeting is conducted by the collector of Andhra Pradesh to
resolve the issues faced by the entrepreneurs in the Sri city.
 Leadership in Energy and Environmental
Design (LEED)

Leadership in Energy and Environmental Design (LEED) is one of the most

popular green building certification programs used worldwide. Developed
by the non-profit U.S. Green Building Council (USGBC) it includes a set of
rating systems for the design, construction, operation, and maintenance of
green buildings, homes, and neighborhoods that aims to help building
owners and operators be environmentally responsible and use resources
efficiently.
“The KGI garment factory is now globally recognized as a GOLD-LEED
certified building for its sustainable design”.
GREEN FACTORY requirements met by KGI Clothing

A basic requirement for a “green factory” is an energy-efficient and sustainable

production that balances environmental and business interests. This holistic
approach does not start with machinery but much further back down the line
with building planning. As a result, companies can achieve cost savings over the
long term while making an active contribution to environmental protection.

For new constructions or existing factory structures, a comprehensive energy

demand analysis can help to achieve the aim of creating a green factory where
production is efficient and ecological, and costs are optimized. Such an analysis
ranges from the building structure and the materials used and the amount of
power required for each unit of production. Based on the information collected,
appropriate optimization measures are defined for existing structures or
integrated as part of the planning for new buildings.

In addition to the ecological and economic benefits of a green factory, it can also
be very good for publicity. For instance, the internationally recognized LEED
certification (Leadership in Energy and Environmental Design) acknowledges
efforts to reduce energy consumption and documents these for customers and
shareholders to see.

The goal of ecological production entails identifying sources of inefficiency and

optimizing them while reducing costs. The need for action is thus rooted in a
comprehensive analysis that ranges from the building structure to an examination
of individual sub-processes.
KGI Clothing has met with the following requirements in order to obtain the LEED
certificate:

 Responsible construction for waste management and sustainable sourcing

of materials, they have waste disposal unit with proper segregation of
wastes into five different categories viz; plastic, paper, wet waste, clothes,
glass.
 35% open area out of which 25% is dedicated to the green cover and
plantations, adding beautiful aesthetics to the surrounding.
 Indoor and outdoor water control,
Indoor: Low flowing fixtures, saving 20% more water than conventional
taps
Outdoor: Rain Water harvesting system
 Fire Management System :
 A water hydrant installed after every 15 meters
 Underground Sump Room:
A pump room to facilitate the fire extinguishing water hydrants
with a capacity of 2 lakh meters consisting of a pump pressure
regulator which regulates 3 pumps viz;
a) Electric main pump - taking upto 3 to 5 kgs of pressure
b) Jockey pump - taking 5 to 7 kgs of pressure
c) Diesel engine pumps - Automatic pump which supplies
water if the electricity supply goes off.
 Occupational health measures for on duty requirements, having emergency
contact numbers and first aid boxes installed.
 Innovation in operations and regional priority.
 Use of natural light and air conditioning.
 Green transportation:
Land protection and access to public transportation and green vehicles, in
addition they provide car pooling facility, electrical vehicle charging station
and alternative transport facility.
 WORKFORCE

KGI currently provides employment to around 200 workers out of which 98% are
women employees; as it encourages women empowerment.

Workers are categorized into three levels based on their skills.

Category Skill Percentage Salary

A Highly skilled 20-30% 9000-9500 pm

B Medium skilled 30-40% 8000-9000 pm

C Low skilled 20-30% 7000-8000 pm

Facilities provided to the workers include:

 Creche – As majority of the employees are women, therefore they provide

an inhouse crèche for their children to play, study and watch television.
 Mobility – 17 to 18 vans are provided by the company for the easy
commute of its employees.
 Training – Twenty one days of stitching workshop to help them to update
to new techniques and manufacturing processes.
 Locker room and mess – A locker room is made for the workers to keep
their belongings and a mess for them to have their meals.

Attendance bonus is kept as an incentive wherein 450-500 Rs. Per month is

rewarded for maintaining full attendance.
WAYS IN WHICH KGI CLOTHING CONTRIBUTES TO
SUSTAINABILITY
Infrastructure:
Detailing of the roof and walls:
 “Skylights” are created to bring in ample sunlight for keeping the space
cool and comfortable for the factory workers. The smart use
of skylights eliminates the usage of electricity for lighting during the day
time completely, as it provided 100% natural day lighting. The combined
effect from the ventilation and skylight interventions alone results in
an energy savings of 48%*. Sixty locations for skylight maintain the “lux”
levels as per required standards making this a completely naturally day-lit
building.

 The “air change” is configured to be 5 times per hour. “S” type Louvered
ventilators are also installed on East and West side of the multipurpose hall
factory.

 Ventilation and room temperature is maintained through a hybrid system

combining thirty turbo vents that are installed on the roof.They offer
energy savings and low up front cost.

 “Double-sided insulation”, a two-layered structure using glass wool inside

the panels which reduce the temperature by 5-6 degrees. The top layer of
which is made of a special fibre sheet to defuse sunlight evenly having small
prism-shaped structures.

 “High volume low speed (HVLS) fan” saving around 1000 watts. Its rotating
speed is 65 rounds per minute saving more power than the conventional
fans. In addition industrial exhaust fans are installed for facilitating
ventilation.
  “Earth sand wall” - The Rammed Earth, a technique of construction using
natural materials derives its origin from ancient times. Today, it has been
revived as a sustainable building material. It’s superior thermal mass
ensures appropriate temperature control inside the building. This
temperature stability makes it comfortable for the workers even during
extreme weather conditions. The wall provides sound insulation which
makes it easier for the factory workers to concentrate on their work. Such
muting of external noise can be beneficial for those requiring a quiet
interior environment. Another advantage of rammed earth walls is that
they’re maintenance comes at a low cost. It proves worthy as an
investment as they stand in good stead for at least 10 to 20 years. Also, the
walls don’t need finishing and this saves time and money.

In addition to all this, these structures are fire proof and provide substantial
bracing to buildings. They can be artistically and creatively worked on using
elements such as patterns, reliefs, shaped windows and feature stones.

Fittings and Fixtures:

 “special low flowing fixtures” are plumbing fixtures that use significantly
less water than conventional fixtures.Allowing 20% less water usage than
normal taps.

 Light Emitting Diode (LED) lights are energy efficient and last longer.
 OPERATION UNITS

CUTTING
Fabric Cutting in Garment Manufacturing. Cutting is the process which cut out the
pattern pieces from specified fabric for making garments.Using the markers made
from graded patterns and in accordance with the issue plan, fabrics are cut to
prepare garment assembly. The main purpose of cutting section involves cutting
of garment panels precisely, consistent with the pattern shape and size as well as
economically and in a necessary volume to keep the sewing department supplied
with work. The process flow in the cutting department is given below.

Process flow chart in cutting section in KGI garment industry:

Marker making
↓
Fabric spreading
↓
Placing marker paper on the lay
↓
100% inspection of parts and replacement of parts if needed
↓
Numbering
↓
Fabric cutting
↓
Sorting and bundling
↓
Input to sewing department
The four main operations or processes involved in the cutting section in apparel
industry are:

 Marker planning
 Fabric spreading
 Fabric cutting
 Preparation for the assembling process

Lay planning and marker making processes:

When all the necessary data about the textile materials delivered to the cutting
room have been obtained, lay planning and marker making processes may be
further work processes in the cutting room. Several factors that influence
productivity and work efficiency in the cutting room are taken into account in
performing the lay planning process. The most important of these are:

 The number of articles ordered for each size of a style;

 The optimum use of the fabric to minimise any fabric wastage;
 The technological limits of the spreading and cutting processes;
 The optimum use of time and labour.

To organize an efficient work process in a cutting room, two or more garment

sizes are typically combined in every marker, the number of fabric plies (or layers)
in every spread and the number of spreads needed for the markers required are
determined.

In accordance with the customer’s specification, markers for all ordered pieces,
sizes and quantities required are created. Taking into account fabric quality, type
of pattern (e.g. striped, check etc.) and style, the pattern pieces are placed in the
marker in the right position and as close to each other as possible to obtain the
most efficient use of the fabric. Nowadays marker making is often automated.
Special nesting software allows creation of a marker on a computer screen and
makes the work process quicker and easier by allowing the user to reconfigure
the arrangement of pattern pieces to get the best arrangement of the marker.
Markers can be also created automatically using the right software.
Fabric Spreading Process:
Spreading is a process during which fabric is cut in pieces of certain length and the
pieces placed one above another in many plies. The length of the cut fabric ply is
determined by the shape, size and number of the components to be cut from it.
Spreading also involves placing layers (or plies) of fabric on top of one another.
The number of plies in a spread is dependent on the number of articles required
and the technical limits of the fabric spreading and cutting processes. Spreading
process may be either manual or automated. We have also published article
on fabric spreading in apparel industry.

Fabric Cutting Process:

Cutting is the process of separating a spread into garment components as a
replica of pattern pieces on a marker. It also involves transferring marks and
notches from the marker to garment components to facilitate sewing.
FUSING
Fusing Machine at KGI: Fusing Machines are used to fuse a fusible material to a
base fabric through a process of heat, pressure and time. Fusing is done in the
garments wherever stiffness is required like the collar and the cuff areas.
STITCHING
Sewing section is the most important department of a garment manufacturing
industry. Sewing machines of different types are arranged as a vertical line to
assemble the garments. Sequence of types of sewing machine arrangement
depends on sequence of assembling operations. After receiving the garments
components from cutting section, all the garments parts are joined and sewn as
sequentially.

Machine used in the sewing section:

1. Single Needle Lock Stitch machine

2. Double needle Lock stitch machine

The machines used in KGI Clothing are computerized ‘BROTHER’ machines

imported from Japan, that work on Servo engine facilitating less energy
consumption.

The stiching process at KGI is done by using the assembly line method where in
they have a manually operated hanger system.

At the first loading point the collar operation is performed which is followed by
stiching the shoulders and the side seams. Then the pocket and hem operation is
performed one by one.

After the complete stiching of the garment the piece is passed through a check
point clearing which it is sent for the button and gauge operation.
STEP 1 STEP 2

STEP 3 STEP 4
CONVEYER BELT
WASHING AND DRYCLEANING
Once the garment is stitched it is packed and sent for washing. Washing operation
is outsourced by the industry along with other operations like embroidery, dying
and printing.

IRONING AND FINISHING

Pressing or ironing is the most important finishing process in
readymade garments 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.

After receiving the washed garments, a final Quality Check is done and then they
are sent for packaging.
PACKAGING
Garment packaging is the process of wrapping, compressing, filling or creating of
goods for the purpose of protection and their appropriate handling. This is the
final process in the production of garments, which prepares the finished
merchandise for delivery to the customer.

Packaging has two major functions:

 Distribution
 Merchandising

The main purpose of distribution packaging is packaging the garment in a way

that it allows the garment manufacturers to transport the garment at a minimum
cost and in the shortest time to the retailer or purchaser, without deteriorating
the quality of the product. The merchandising function deals with showcasing the
garment product in a way that it stimulates consumer desire for purchasing the
particular product.

Requirements of Garment Packing:

The plastic bags are most commonly used for garment packing either at the
completion of production or when they arrive at the finished goods stores.
Apparel such as shirts and underwear is usually bagged and boxed immediately
after final inspection and enters the stores in prepacked form. Other hanging
garments like jackets, dresses and skirts are usually bagged when they enter the
stores. A carton package made of quite strong corrugated material is normally
preferred while transporting the boxed or hanging garments in bulk form. The
packed garment boxes are sealed by contact adhesive paper tape or bound with a
plastic tape.
 Flowchart of Garment Packaging:

Received garments from the finished section

↓
Hang tagging

↓
Folding with inserting back board, tissue

↓
Poly Bagging

↓
Cartooning

↓
Applied adhesive tape on the pack

↓
Bar-coding

↓
Packing complete

The garment is folded neatly and kept in place with a special garment clip.
FINISHING
 REFERENCE

http://shilpaarchitects.com/Shilpa_Portfolio/kgi-garment-factory/
http://textilelearner.blogspot.com/2017/07/sewing-section-garment-
industry.html
https://www.iigm.in/Industries/Apparel/Cutting-Fusing/Fusing-
Machines/Br