TOPIC

Presentation on Production & Handling of Jeans

Group Members:- Roll No.:Avinash Sonawane 107 Mithun Jalui Sunny Singh Sandip Guneshwar Kundan Kamble Umesh Mehtre

(G.L) 82 89 95 108 111

Name of Industry
KHUSHI GARMENTS

INDEX
Introduction. History of Jeans. History of Khushi Garments. Material Handling. Process of Production. Process of Handling. Analysis. Bibliography. Acknowledgement.

Introduction

Today we are here to discuss with you how the production of jeans takes place. It used to be that we just walked into a shop and bought something without sparing a thought for where it came from, or who'd made it. The product we are talking about is found easily, in a glass showroom and mall with double doors and escalators, we will find it. And somewhere in the middle, under a huge sign saying Starting Price of Famous Brands for Rs.3,000 Just a pair of jeans, nestling among dozens of identical others. Blue stonewashed denim five-pocket jeans, straight leg, zip fly. We visited a manufacturing industry named Khushi Garments. In the industry, they showed us how manufacturing of jeans takes place but before going on that I want to share some basic knowledge of Jeans. Jeans are a world famous and mostly prefer by teenagers and young age people. Jeans are trousers made from a different cloth or fabric know as Denim. Denim is a name of that cloth which is used for making of jeans, this word Denim came from the

History of Jeans

Levi Strauss was a German-born American businessman who founded the first company to manufacture b l u e j e a n s . Some of the earliest blue jeans were made by Jacob Davis, Calvin Rogers, and Levi Strauss in 1873. Starting in the 1950s, jeans, originally designed for cowboys. Historic brands include Levis, Lee and Wrangler. Jeans come in various fits, including skinny, tapered, straight, boot cut and flare. Jeans are now a very popular form of casual dress around the world, and have been so for decades. They come in many style and colors; however, "blue jeans" are particularly identified with all cultures.

History of Khushi Garments

Khushi Garments was started around in year of 2002, now it is on its 10th year. They started their business in a place by rent and with only two employees or workers. They slowly and gradually expanded their business as well as process by establishing more machines to it and hiring more workers. Now the industry have its own place, better and more flexible then the rent one and almost 40 (male) workers are working in khushi Garments.

Raw Material Handling

Denim Rolls brought from Ahemdabaadh Supplier. 50-60 rolls of denim fabric are kept therein.. Separate room for storage of Denim rolls. They order rolls according to needs and factors likes expected future rise in price.

RAW AND AUXILIARY MATERIALS REQUIREMENT

Sr No. Description
A. Major Raw Material

Qty.

1.

Denim Cloths (60-70 Rolls)

375000m

B. Auxiliary Materials
Fabric for internal lining 1. 2. 3. 4. Thread Buttons Zip Fasteners Lumpsum Reqd. Lumpsum 2,52,000pcs

The Process of Productio n :-

Different Parts are Cut from Denim are as fallows :1.Front part (1pcs). 2.Back part (2pcs). 3.Waist belt (2pcs). 4.Belt loop (5-6pcs). 5.Fly piece (2pcs). 6.Large pocket (4pcs). 7.Small pocket (1pcs). 8.Pocketing fabric (2pcs). 9.Support fabric (2pcs).

Followings are the Machine mentioned in the above table:-

(1) Roll of Denim Fabric

The one roll of denim fabric is lifted or handled horizontally my something and then spread it in a particular length and makes a bunch of it. Then the design of different sizes and pockets are kept over it and cut it according to that size. It is cut as front side and back side. The many layers of fabric are cut into pieces for legs, pockets, waistband and accents. The pieces are bundled together by component, with up to 100 layers of cuts ready to go.. Their were different machines for cutting (small and big one) according to the bunch and design.

(2) Sewing and Finishing: The jeans head over to the sewing machines, where they're
sewn by workers on incredibly fast industrial machines. According to Jeans Info, an average worker can piece together a whole pair of jeans in about 15 minutes. Firstly, the front side of jeans are sewed with yoke sheet (inside cloth of pockets)Of pockets by Hunda machine. Afterwards when the front side of jeans are sewed with front pockets then it is over locked with the back side. Then a five thed machine is over locking the bottom of jeans. The second last machine sew the top part of jeans i.e. belt. As the fabric of belt of jeans and on belt grips are too thick so for that the special machine with big needle sew belt grips on the belt of jeans. As a normal machine cant do it. And at last the button to jeans are stitched by another machine. Afterward, the stitched garments are washed in industrial

Machinery and Equipment Required by Jeans Manufacturing Industry:Sr. Description No. 1. 2. 3. 4. 5. 6. 7. Sewing Machine Electric knives fitted with Disc Lapping trolley Electric iron Dyeing Machine Spraying Machine Washing Machine Qty . 22 10 8 20 9 2 1

(3)Dyeing And Washing:-

When jeans are brought to another place of industry. This can mean dyeing in rock stone washing as well as other embellishments. To list all the washings that we have been asked to do before would probably take a few weeks and several pages to list, so we'll just talk about the most well know washings first.

(i) Rinse (water) Wash:-

Speaks for itself mostly . Like in the good old days the jeans will be washed at about 50 degrees Celsius. High risk of color bleeding , so ideal to use for brightening up your old faded jeans by washing them together. Make certain to wash separate from other garments the first few times. Some Jeans brands will even not use sanforized fabric, so that you can shrink them to fit in a hot bath. This was (again) very popular back in the 80's.

(ii)Stone wash/Stone
liquid :

Still the most famous of all washings. The jeans are washed with oval or round pumice stones which should all have roughly the same format. The pumice stones are very light with a rough surface. Sometimes, when the final quality inspectors at the jeans factory forget to clean the pockets, you may even find some residue of these stones in the pockets of your new jeans. During the washing process these stones will scrap off a thin layer of the denim does showing some of the white threads from the part of the cloth where the indigo dyeing stuff was not able to penetrate. It also creates and effect called brilliance. You may also encounter words like deep stone or super stonewash, which are an indication of how long the jeans have been stonewashed.

(iii)Overdye:- An additional dying after the jeans have

been sewn. This ensures a very deep dark or black color and makes the sewing thread blend in with the jeans color.

(iv)Dirty Wash: - After stonewashing the jeans or

denim jackets, they will be dyed with special chemicals thus creating a look in which the jeans will appear to be dirty.

(v)Destroyed / Damaged / Used / Whiskers:-

There are several different techniques to make the jeans or denim jackets look old, worn and /or used. Most of these techniques involve actual sandblasting or abrading by some kind of power tool. Whiskers, which normally appear around the hip to crotch area of the pant, are usually made by using a grinder. Another popular way to make jeans appear damaged is to cut the edges at bottom, (back-) pockets, fly and knee area before the (stone)washing.

(vi) Spraypainting:

From the high-tech side there has been a renewed interest in the jeans and garment industry in general. A few of the very cool new inventions are: the jeans laser marker and the Jeans spray robot, as shown above. However, due to the relative high cost of these machines they are hard to find in these parts of asia. In that place there were six dyeing machine and 5 Hp Motor is used in every machines and 3 phase power is used. According to supervisor, every dyeing machines takes approximately 6 7 hour taken by each machine to dye. And 60 70 pieces of jeans are kept in dye machine at a time. They are using rock stones in liquid form and different colors, mostly Indigo blue dye is used. After dyeing the last step is washing of jeans. Their was one big machine used for washing of jeans.

(4) Handling Process:-

After all this the jeans are stored in a separate room. Where jeans are stored for sometime and then it will takes to their another place for dyeing of jeans which make it looks like brand new product. The storage facilities are good and the room is separated from the production process.

Analysis:

Firstly Denim roll is cut in different piece like size, pockets, designs and patterns. Then it moves towards sewing and over locking. Then it keeps for storage in separate room for shifting it to another process i.e. dyeing of jeans. The dyeing process takes 6-7 hours per machine and it dyes 60-70 piece at a time. Then it keeps for drying.

Bibliography:1)Khushi Garments 2)Internet: a) www.wikipedia.com. b) www.guardian.co.uk.