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I would like to thank and acknowledge the contributions of my mentors Miss. Alinda Mohanty and the design team of Duke Fashions Ltd. Without whose constant guidance and support, I would not have been able to accomplish the given task. Their valuable suggestions helped me to develop an insight about the areas which led to the accomplishment of my graduation project. I would like to convey my gratitude to my Course Coordinator, Mr. Navaid Mehtab, the staff at DUKE fashions and the KD department itself who have made all the needed facilities available and made the task a worthwhile learning experience.

ACKNOWLEDGEMENT

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Duke is synonym with the international quality T-shirts and in fact the harbinger of T-shirt culture in the country. After making a modest beginning in the early 1970’s Duke has been a great success story in the Indian apparel market today.

“Duke was adjudged as India’s number 1 selling T-shirt brand” – ORGMARG

The duke group is one of the largest manufacturers of knitted fabrics and garments. Apart from the well established domestic market it is into exports also.

As Duke’s owner SHRI. Komal Jain states

“It is the power of dreams. Dreams are what drive us. Ever since our inception in 1966 we have continued to deliver innovative knitwear and fabric that have made key style statements.”

INTRODUCTION

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» Chairman mr.Komal Kumar Jain

» DireCtor mr. Kuntal Jain

» Design heaD mr. Kuntal Jain (temporarily) » merChanDising heaD mr. munish Jain

» aDevertising heaD mr. gagan Jain

» Quality Control mr. thomas valley

» proDuCtion heaD mr. mahinDer singh Joshi

» marKeting heaD mr. BalKar singh

» Knitting Department mr.ritesh Jain

» emBroiDery seCtion mr. ashisih Jain

» FaBriC inspeCtion mr. pappu

» Cutting hall mr. y.p. BhimsBhau

» unit heaD mr. om praKash

» sample room mr. ishwar giri

» sample heaD mr. arun Kumar

» aCCount Department mr. Bharat Bhushan

DUKE HIERARCHY

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The chairman of Rs. 150 crore Duke Group is soft spoken and self effacing and doesn’t have any affectations of some self made tycoons. HE started as in trader in Ludhiana in 1960’s with an investment of Rs. 50,000. Thus the journey of Duke Group began 42 years ago, with chairman Sh. Komal Kumar Jain. The steps were firm and full of dreams.

The Family is originally from Ambala, Punjab. In 1962, at the age of 15, he completed his high school and went to Ludhiana to get his training in the hosiery business form relatives who had a factory there. In 1966 after the death of his father the family moved to Ludhiana. With a small investment of Rs. 50,000 he opened a small shop and started as DK Knitwear’s at Dal Bazaar in Ludhiana. Initially the group was only into mufflers, but after three years we got into the business of manufacturing as well.

ABOUT THE GROUP

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CORPORATE TRACK RECORD

The Duke saga commenced about four decades ago, in Ludhiana, the fashion hub of Punjab.

Today Duke embraces a complete vertically integrated garment manufacturing plant, with knitting, dying, processing, finishing, mercerizing, compacting, embroidery and printing under one roof. Production facilities are in India.

Duke Fashions (India) Limited pioneered the T-shirt culture, and gradually established several new trends in knitting garments and fabric research. In 1998, Thermal wears were introduced for the first time in India, under the brand name “Neva”, by Mr. Nirmal Jain, Younger brother of the founder. Two other group constituents – Venus Garments (India) Limited and Venus cotsyn (India) Limited, Glaze Garments (India) Limited, is headed by Mr. Anil Jain, the youngest of the brothers.

Today Mr. Kuntal Jain, son of the founder, is steering the flagship brand in the new millennium. Thanks to his dynamic Programs, Duke is acknowledged today as the undisputed leader, with a turnover Rs. 65 crores.

Stringent quality control mechanisms punctuate the entire operations and make certain that the final products enjoy true value for money status and first choice of customer in India and abroad as well.

The Company strives to be a good corporate Citizen, with several path-breaking eco-friendly initiatives to minimize pollution, e.g. waste water treatments, use of nature and eco-friendly materials such as dyes and chemicals, and recycling of polyester yarns. The goal, simply stated, is to ensure a “green, unpolluted environment”.

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Duke is evolving, growing and diversifying to attain new heights.

The key expression is cutting edge technologies and relentless quality checks by a Quality Assurance Team to achieve impeccable synergy. Our in house knitting, dying, mercerizing, finishing, compacting, garment printing, embroidery and manufacturing facilities feature state-of-the-art machineries and equipment supplied by world class Juki, Pegasus, Yamato, Brother, Barudan, Stefab, Ramsons and others. The embroidery section is fully computerized.

The knitting division is fully equipped to make single jersey, double jersey, auto stripes for ribs, fleece, velour, feeder stripes, terry and computer jacquards in diverse gauges, Our fabric choice ranges from 100% cotton to techno-blends with polyester, acrylic, linen, polymix, lyocell, viscose, modal spandex, nylon, rayon etc.

The design studio of the company is well laced with expert professionals and latest software. At the beginning of each season, our design team carries out extensive research-based forecasting to ensure that we stay at the pinnacle of contemporary fashion.

DUKE - CUTTING EDGE SYNERGY

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Creation of a unique corporate management system and culture is enabling DUKE to develop into a conglomerate that becomes a role model of worldwide respect and trust. Founder of the group, Komal Kumar Jain, and his son Kuntal Jain, have embraced and taken forward the principles of total Quality Management which translates to doing “whatever it takes!” to guarantee 100% customer delight. The Group corporate philosophy is based on the following principles:• Credibility, integrity and honesty• Straightforward business dealings• Work as a worship• Spirit of Social Service and human respect The business of fashion is dreaming and styling the future. Business strategy, vision & innovation are the principal pillars on which our forward-thinking corporate policy is founded. After all, no company can afford to stand still. We work ceaselessly to develop new directions in apparel production and export, thus ensuring that all our constituent companies shall continue to have a strong voice in the international apparel and textile forums of today and tomorrow.

PHILOSOPHY

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Every design that DUKE create, every contact that DUKE accept, DUKE execute it with the strictest regulation. No impractical designs, no cutting corners, no compromising on quality for our valued customers and vendors.Customer satisfaction begins at our drawing board. Every design is created with the need of customers foremost in our mind – DUKE considers how they will fit our designs around their lifestyle.

The Duke group produces for men, women, and children:

* T-shirts * Jackets * Sweaters * Track – suits * Sweatshirts * Shirts * Trousers * Denims * Lounge Wears * Lowers * Bermudas * Thermal Wears * Innerwear * Accessories

THE PORTFOLIO

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The Duke group’s strategic approach is entirely brand centric and strategically defined to reach divergent markets in India and around the World, especially in Nepal, Sri Lanka, Canada and U.S.A. with the help of extensive advertising and promotional campaigns. Our seasonal product catalogues are successful in positioning our brand at the top echelons of quality and value for money.

A strong market network of over 2500 multi-brand outlets and over 70 exclusive stores across major cities in India is succeeding in bolstering the profit curve of the entire product range. Our own sales team monitors this massive network to:

Make it easy for the network to build positive relationships and increase sales.Understand market segments and changing demands.Communicate feedback to the Group headquarters.We are the only national brand with international standards. Our well-rounded and multi-leveled marketing approach incorporates a wide assortment of image management and customer interactive programs.

STARTERGIC APPROACH

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» Duke fashions (India) Limited has received the most coveted ISO 9001-2000 certificate from DNV, the largest certification body in India. » ORG_MARG, the largest market intelligence service in Asia, has

proclaimed Duke T-shirts as the number one selling T-shirts brand in India. » Mr. Komal Kumar Jain, founder, was awarded the prestigious Udyog

Patra Award by the Institute of Trade & Industrial Development for his contributions towards economic growth. » DFU publications have felicitated Duke with the “Inside Fashion” award,

or excellence in retail. » Safety award from Director of factories and Punjab industrial safety

council Chandigarh. » TID Quality Excellence Award for manufacture of T-shirts & Ready-made

Garments from Shri. S. Vaghela (Hon’ble Minister of Textiles, Govt. of India)

AWARDS AND ACCOLADES

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DUKE COMPANY WORKFLOW

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COMPANY WORKFLOW

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» Knitting

» FaBriC store

» sampling

» marKeting

» aDvertising

» Designing

» proDuCtion anD planning Control

» Quality Control

» emBroiDery

» reCieve anD DispatCh

» purChase

» loose store

VARIOUS DEPARTMENTS

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Knitting DepartmentMachines used for circular knitting are:Top Knit KEMYONG: o Interlock, single jersey, pique o 38”, 28 gauge and 90 feeder setup.Jumberica Spain (sinker) o Sinker, single pique, doubles pique and miss knit. o Solid color designs o 30”, 28 gauge and 72 feeder setup.Well knit By KAFO group o Single jersey, single pique and double pique. o 36”, 144 feeders 20 gauge.Jumberca Guamtex SL o 30”, 24 gauge and 48 feeder. o High speed 24 rpm. o Make striper in 6 colors Tarrot o 30”, 24 feeder and 24 gauge o Interlock pique and ponteFakuhara o 30”, 24 gauge and 48 feeder. o Max 4 color jacquard o Single jersey , single pique, intarsia, stripers, jacquards.Orizio o Used to make auto striper fabric in 4 colors o Single jersey, interlock, fleece and pique o 30”, 24 gauge and 48 feederMayer and Cie o Used to make auto striper fabric in 4 colors o 30’, 24 gauge, 44 feeders. o Stripers, single jersey, interlock, pique, jacquard max 4 colors.

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ppC DepartmentPPC means PRODUCTION PLANNING and CONTROL. But nowadays it is being recognized by PPP, which means PRODUCTION PLANNING and PRECUREMENT.

It is of two types, i.e., IN HOUSE and OUT HOUSE.

In house Out houseCosting (after duplicate pieces) Design in house

Fabric order to knitting department CostingAfter recieveing the fabrics accordingly

production order is preparedAfter finalizing the fabric production order

is made

Issued fabric to production unit Dispatch after quality

In this process the quality manager is sent to the place where production is being

carried out

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DUKE DESIGNING PROCESS OVERVIEW

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DESIGN PROCEDURE

1. Proposal – (marketing heads)2. (4 proposal in a year – summer, Pre-Summer, winter + summer)3. Market Survey4. Planning of color, accessory to be used and prints.5. Preparation of color shades and accessory card.6. Color shade is then given to Knitting Department and the accessory card to the Purchase Department.7. Lap dips are collected of the required color shade and the sample of accessory are collected.8. Then approval of Lap Dips and sample of accessory is done.9. Order to Knitting and Purchase Department. 10. Preparation of Proto Sample.11. Preparation of Specification Sheet.12. Approval of Specification Sheet and the approval are done by – Marketing Head, M.D., Merchandising Head, Design Head, QC Head, Wastage Controller.13. ART NO. are attached to the Proto Sample.14. Duplicate pieces for booking with comments (20 pieces).15. 18 pieces for booking.16. 1 piece for sample room.17. 1 piece for Merchandising Department (PPC).

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In DUKE the production is divided into 4 SETS, A set is basically a range plan made by the marketing department according to the rising sales and demand in certain styles and trends.

a. Set I – Full sleeves (big one in quantity) more than 130 or so garment are designed)b. Set II (smaller only 35 are designed and fed into the design into the design gallery)- Half sleevesc. Set III (Big in nature as more than 150 garments are designed for in-house production)- FULL SLEEVES d. Set IV comparatively smaller than set 3, 80 or so garments.

The proposal contains the detail of the various styles and variety in the sampling pieces which would be sent to the buyer for orders. Also some of the production is outsourced so the plan for the outsourcing is also included in the proposal.The proposal of the SET is approved by the Chairman, the MD and the Production head. Once the Proposal is approved it is sent to the designing department.

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In the first SET Looking at the market trend new shades and colors are decided by the design team, then the new colors of pantone chips are given to the fabric dyers, which are further given to the laboratory to give them Lab dips which are in form of yarn or fabric, thus the color of yarn is sourced or else the fabric is dyed later. The Lab dips are in the process are approved by both the manufacturer and the design team. The approved colors are then used throughout the year with few new outsourced shades added with each set.

The actual work starts when the proposal is given by the marketing department which comprises of a collection of garments. The fabric and the designs is designed on Corel, by taking as an inspiration from current fashion trends and the market surveys.

For certain samples like Jacquard and stripers, the designing dept. sends the design sample to the knitting department through a sample order form. In the sample order form various aspects of sample like quality, repeat design, GSM are specified. All these are checked by the Knitting Dept. and decided if they can be achieved or not. The necessary changes are then approved by the HOD and a small batch of fabric around 10 KG is knitted for the sampling process.

First initial sample is made by design team, and then the sample coordinator makes a specification sheet report, and gets the sample approved by the HOD’s i.e. production head, design head, marketing head, managing director,a and finally by the chairman. Before sending the garment for approval the sample is sent to the PPC (Production and Planning dept. for calculating the estimated wastage.

Once the sample is approved by all the HOD’s its again sent to PPC for assigning a article no. And calculate the costing of the garment. If the garment is going above the required costing its rejected. So after the Final approval by the PPC dept. 20 more same sample’s are created, 1 piece for the sample room, 1 for the PPC department and 18 samples to be sent to buyers and distributors for orders.

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SPECIFICATION SHEET COST SHEET