Report On Poppys Knitwear Limited FINAL1.
Report On Poppys Knitwear Limited FINAL1.
Report On Poppys Knitwear Limited FINAL1.
Table of Contents
EXECUTIVE SUMMARY...........................................................................................................................2
INTRODUCTION.....................................................................................................................................3
COMPANY’S PROFILE.............................................................................................................................3
SISTER CONCERNS OF POPPYS...............................................................................................................4
MERCHANDISING DEPARTMENT...........................................................................................................4
POPPYS COMPACT KNIT........................................................................................................................6
POPPYS TAPES: MANUFACTURING OF TAPES........................................................................................6
FABRIC SECTION:...................................................................................................................................7
POPPYS PACKS:......................................................................................................................................8
LILY LABELS - LABEL MANUFACTURING.................................................................................................8
POPPYS ART: THE DYEING UNIT OF POPPYS KNITWEAR LIMITED..........................................................9
POPPYS EMBROIDERY UNIT.................................................................................................................10
POPPYS PRINTING................................................................................................................................10
POPPYS LAB.........................................................................................................................................10
PRODUCTION UNIT OF POPPYS KNITWEAR PVT LIMITED....................................................................11
DOCUMENTATION PROCESS IN POPPYS..............................................................................................12
MARKETING ENVIRONMENTS..............................................................................................................14
CONCLUSION.......................................................................................................................................18
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REPORT ON STRATEGIC ANALYSIS OF POPPYS KNITWEAR PVT LIMITED
EXECUTIVE SUMMARY:
Poppys Knitwear Pvt Limited is a knitwear manufacturing company which exports
garments to countries which are poles apart. The company was started by Mr. A.
Sakthivel in the year 1973 and is a large enterprise now with more than 2500
employees. The company is making a turnover of about $70 million per year. This
descriptive report about Poppys Knitwear Pvt Limited and their sister concerns
describe who they are? What are they doing? And how are they doing it?
The management and the manufacturing process in all the sister concerns of Poppys
are explained in detail and analysis is performed on it. A strategic analysis for the
company is done to scrutinize the internal environment and the external environment
which will be helpful for marketing purpose in the future. The summary of internal
and the external environment of the company are given as conclusion for the report
which is the SWOT analysis.
TERMS OF REFERENCE:
This is the report written by Mr. Karthikeyan Kumar. B.E, MBA during the internship
training period in Poppys Knitwear Pvt Limited, Tirupur. This report is only for the
internal use for Poppys Knitwear Pvt Limited and this is written for the purpose of
personal assessment of the author which is the part of training.
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REPORT ON STRATEGIC ANALYSIS OF POPPYS KNITWEAR PVT LIMITED
INTRODUCTION:
Some men see things as they are and say, “Why?” I dream of things that never were
and say, “Why not?” - George Bernard Shaw. Every entrepreneur has a history
beyond their innovation and imagination. Tomorrow is the most important thing in
life. It’s perfect when it arrives and puts itself in our hands. The following is the report
on strategic analysis of Poppys Knitwear Pvt Limited. Their analysis is done on the
basis of their management and the manufacturing process in all the units of Poppys.
The report includes the operations taking place in all the sister concerns of Poppys.
The analysis like Pest, Swot, and Porter’s Five Forces are done for the company and
a conclusion is given according to the analyses.
COMPANY’S PROFILE:
POPPYS KNITWEAR PVT LIMITED, We Design Dreams for the Future is the tag
line of the company. The company was started by Mr. A. Sakthivel in the year 1973
in Tirupur. Company’s annual turnover is about $70 million. Mr. A. Sivakumar the
Managing Director’s efforts have been vital to the development of the company as
one of the best administered companies in Tirupur.
Poppys Knitwear Pvt Ltd has opened up global markets for its products. It exports to
over 50 countries worldwide and is a trusted supplier to global brands like Hanes,
Ralph Lauren, Harley Davidson, Caterpillar, M & M, Domino’s Pizza etc. Poppys also
has an enviable product range that includes knitted and woven wear for men, women
and children.
Poppys Knitwear Pvt Ltd makes such world class products possible by integrating
cutting edge technology, infrastructure and global best practices in design,
manufacture and quality control. The knitwear division is ably supported by equally
well equipped and world class labelling, tapes and packaging units.
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REPORT ON STRATEGIC ANALYSIS OF POPPYS KNITWEAR PVT LIMITED
– Poppys Tapes
– Lily Labels
– Poppys Plastics
– Poppys Packs
– Edelweiss
– Poppys Art
There are many departments in the company which are explained hierarchically.
Merchandising department in the company is considered to be an essential one as
the first point of entry of orders from the buyers is via merchandisers.
MERCHANDISING DEPARTMENT:
Merchandising is considered to be the back bone process of a company where the
merchandiser of the company will be directly in contact with the buyer. This is a very
big process where the aim of it is to get the order from the prior buyer and despatch
to shipment within the deadline.
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REPORT ON STRATEGIC ANALYSIS OF POPPYS KNITWEAR PVT LIMITED
o Fabric Approval
o Fit Sample
o Lab Color Approvals.
The next process is the LC (Letter of Credit) from the buyer. LC contains each
and every detail of the garment and its type which is required by the buyer.
This is more like a conformation where the merchandiser could start planning
with the route map to initiate the process.
The next process is the purchase of bulk yarn.
Then following is the Knitting process.
Dyeing is the next process after knitting.
Finally the fabric finishing.
Attachments of accessories according to the requirement of buyer.
Packing and Documentation
Despatch to Shipment within the lead time.
Characteristics of a Merchandiser:
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REPORT ON STRATEGIC ANALYSIS OF POPPYS KNITWEAR PVT LIMITED
The raw material which is the “Yarn” comes into the company for which it
should be converted into its equivalent fabric.
The yarn is then fed into the machines.
Then the program is fed into the machine as given by the manager in the
fabric section.
Then the managers in the knitting unit feed the program in the circular
knitting machines to manufacture the fabric.
The GSM measurements for the fabric are set carefully as it describes the
nature of the fabric.
The time management is maintained by the manager and it varies according
to nature of the yarn (20’s, 40’s, and 60’s).
The quality control manager keeps an eye on the roll of fabric as soon as it
is out of the machine.
If any flaw detected in the fabric, it is rectified by the employee and
corrected to prevent further blemishes.
After the quality control and inspection the fabric is ready to despatch.
The different brands of machines in Poppys are Vignoni, Unitex, Orizo, and Smart.
All these machines are Italian made ones.
There are two types of tapes namely elastic and non elastic. The elastic tapes are
widely used and it is done by knitting and weaving. There are even designs and
names of brands woven on the elastic tapes by using the jacquard yarn on it. The
management process is more or like same as the knitting. They use the chroched
knitting elastic machine for this process. The tapes are usually measured in Deniers.
FABRIC SECTION:
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REPORT ON STRATEGIC ANALYSIS OF POPPYS KNITWEAR PVT LIMITED
The manager in the fabric section (roll room maintenance) has direct contact with the
merchandisers. The manager in the fabric section will receive the order form from
the merchandiser with all the specifications in it. After that the manager will do a
program for knitting and forward it to the knitting section which is discussed above.
Then the yarn moves to knitting section and comes out as a fabric back to the fabric
section (roll room). Then the manager in the fabric section fixes the program for
dyeing and sends it to the dyeing section. After prior inspections the fabric
manufactured is despatched.
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REPORT ON STRATEGIC ANALYSIS OF POPPYS KNITWEAR PVT LIMITED
POPPYS PACKS:
Poppys packs is the company who manufacture carton boxes in which the finished
garment goods are despatched to the shipment. These boxes are manufactured in
various thickness and quality as required by the buyer and mentioned in the LC. The
process starts by the purchase of paper rolls from various paper mills. The first
process is called corrugation which is the making of flutes in the paper. The rolls of
paper are let into the machines and after the process certain lines are made on the
paper which comes out as the cardboard. Then the board is pasted with papers on
either side with the starch powder mixed with water. The quality of the board
depends upon the thickness as the number of cardboards and papers are pasted
together (3’s, 5’s, 7’s, 9’s). Then all the boards are sent to pressing. After pressing,
the boards are pushed for greasing where the size is properly cut and an impression
is made in the length and breadth wise which is used to make the fold. Then the
same process is repeated in another machine for making the impression for fold
height wise. The final process is slotting where the cuts are made on the board
which is helpful during the packing. After all these process if any printing required on
the board is done before the despatch.
The buyers give the design for their brand name and their logo along with the order.
The labels are generally done with the polyester yarn in the weaving machine. Lilly
Labels use the Mucad software for designing the labels. The design given by the
buyer is first scanned and then edited accordingly. Then the design is fed in the
floppy and with the polyester yarn in the jacquard weaving machine the labels are
manufactured. After that the cutting and folding is done. The laser cutting is also
done for designer labels where generally cartoons or any object is required on the
labels. Printing is also done in the same unit which are required for the labels. It is
done in the different material which is generally imported. The ink for the printing is
also imported. Then finally after all the process the labels are ready to despatch.
The raw materials are purchased by the manager according to the requirements and
then the entire process is managed. All the process in the garment industry starts
with sampling which includes this also. After the samples getting the conformation
the bulk manufacturing is done.
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REPORT ON STRATEGIC ANALYSIS OF POPPYS KNITWEAR PVT LIMITED
Poppys Art is located in Karaipudur. The process of dyeing the fabric with the
required color is done here. The following reflects the entire process from the knitted
fabric coming inside the company until the despatch of the dyed fabric.
Dyeing is nothing but conversion of a grey fabric to a coloured fabric. Dyeing process
consists of many stages in which that fabric undergoes. Essential elements to make
the color for the fabric are the dye and the chemicals which brings the color for
dyeing in that fabric.
To discuss about the process, the merchandiser will give the sample cloth for color
identification or the standard name of the color to the manager in the dyeing unit. A
sample is made and it should be approved by the buyer. After the approval, the
entire fabric is dyed which contains the series of process. The chemicals and the dye
are mixed in the required proportion and then after obtaining the color, the process
starts. Initially the fabric is reversed after it comes from the fabric section in SIDCO.
This reversing is done to avoid faults in the fabric.
There are two types of dyeing machines in the unit. One is a Pune make another one
is the Taiwan make. The mixture of chemical and the dye is filled in the tank of the
dyeing machines and then the cloth is inserted with the ends tied. Immediately the
dyeing process starts and after the completion, dyed fabric is collected. The dyed
fabric is then sent to balloon padding. This process is nothing but like squeezing the
fabric so that the water is dried. Finally the fabric is sent to drying. This is done in a
machine which generates steam and then dried completely. After this the fabric is
again reversed to the normal position. The final process is compacting which is
generally known as the sequential arrest. This is done to control the expansion of the
fabric and then finally folded. The dyed fabric is then ready for despatch.
The management of this process mainly falls in the color creation and dyeing it with
the time management. Certain political issues had affected the dyeing industry and it
has been a great disaster to many companies in Tirupur. The company had
undergone the regulations of the government and doing the dyeing process in a
good standard.
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REPORT ON STRATEGIC ANALYSIS OF POPPYS KNITWEAR PVT LIMITED
After dyeing and all the process, the fabric comes to production unit. The fabric is cut
according to the required dimensions and if required it is sent to embroidery. The
fabric comes to this unit if the embroidery is been asked by the buyer on the
garment. The particular part of the garment is cut and it is sent for the embroidering.
Embroidering is done with the 2 play yarn or the double yarn. This is generally used
for making badges. The yarn is purchased separately and fed into the embroidery
machines for embroidering. There are brands of machines available namely Damei
and Barudan. The cutting for labels is done in the same unit by laser. This makes the
work easier as it is done by software called Wilcom and APS-Eltos. The labels which
should be attached on the garment are cut using this laser machine. After completing
the embroidery process the garments are inspected then and there and despatched.
POPPYS PRINTING:
Poppys has got its own printing unit where this is also just like adding an accessory
to the garment. Same like embroidery, printing is also done if asked by the buyer.
The fabric for printing first undergoes a process called curing. This is done in order to
make the print stagnant on the fabric. The design for printing is first printed on the
film. Then the nylon cloth is bolted on the frame with the help of vacuum machines.
After that the printed film along with the frame is kept on a machine so that the print
comes on the frame. After that the frame is kept on the machine and with the
suitable coloured ink the printing is done manually. There are also automatic
machines for printing available in Poppys printing unit in Karaipudur. After printing,
certain garments undergo a process called fusing in which the print is pressed with
the steam for making the print heavy. Then the finished garment is also sent for
curing if required.
POPPYS LAB:
Poppys has got a lab where the testing of garments is done for knowing the various
characteristics of the garment. They are
Shrinkage
GSM
Spirality
Color fastness against washing, water, perspiration, rubbing.
These processes are done in order to test the fabric’s quality and control. The
garment after manufacturing will pass all the tests in the lab and get approved to be
manufactured in bulk.
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REPORT ON STRATEGIC ANALYSIS OF POPPYS KNITWEAR PVT LIMITED
After the process of knitting, dyeing, compacting, etc the fabric comes to the
production unit. Lots of processes takes place in this unit like cutting, sewing,
accessories attachments, packing and despatching. Each and every process is
explained hierarchically.
The fabric enters the production unit with all the dimensions of it for identification.
The diameter of the fabric is watched intensely as this variation can lead to exertion.
The roll of fabric is weighed again and cross checked. After that the fabrics are
arranged in proper racks which are generally alphabets for identification. They are
arranged with their dimensions and denoted with the buyer’s name. Then the fabric
is inspected using the four point system and if any flaw detected a sticker is placed
on it so that it can be rectified by the cutting employees. Generally, for every order
10 % of the fabric is inspected. There is a point grading system for calculating the
number of flaws in the roll of fabric which is generally measured in Kilograms. For
each and every 100 sqm, 30 points of flaw is allowed. As the fabric is measured in
Kilograms the points are also mentioned in kilograms and then converted for sqm.
The shade verification and the GSM verification are also done. There is also a dark
room available for testing. Then the fabric passes to the cutting section
The cutting process is done with laser cutting machines and also manually. It
depends on the type of the fabric which decides how it should be cut. There are two
brands of machines for cutting namely Lectra and Gerber. First a machine is used for
laying the fabric on the table and the diameter is checked. The flaws are also noted
here. After laying the fabric on the table, the design is fed into the machines using
cad and the fabric is cut using laser. This is a less time consuming process which
can cut the fabric in required dimensions. For certain fabrics which are stripped
cannot be cut using the laser machines as the lines should be matched accordingly.
After cutting each and every part of the garment is bundled. Then the bundles are
stored. There is an inspection team. Then the fabric is stickered as it can be
identified easily. Certain portion of the garment should be stiff and it undergoes a
process called fusing. This is nothing but the certain piece of cloth is kept along with
the foam and allowed to pass through a machine. After that the fabric passes on to
the sewing section.
In the sewing section there are lines of machines where the cut fabric passes the line
and come out as the finished garment. The floor is divided into lines where each and
every line consists of series of machines. The cut fabric passes the series of
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REPORT ON STRATEGIC ANALYSIS OF POPPYS KNITWEAR PVT LIMITED
machines and comes out as the finished garment. The stitched garment is again
inspected. If any embroidery is required on the garment that particular portion alone
is send for the process and received. The garment is passed to the AQL audit
section. After stitching the garment is send for ironing and packing.
The garment is then ironed according to the requirement of the buyer. The garment
is wrapped in the polybag and then stored. According to the requirement of the buyer
the garment in the polybag is packed in the carton boxes. All the essential
information about the garment is mentioned in the label of the carton boxes. The
garment is then despatched to shipment.
This is a man power and a time consuming process. The unit is well maintained and
managed with all requirements. All the process should be watched keenly as a single
flaw could lead to a great disaster.
For each and every export and import done in a company, it should be done with
proper documentations. The documentation department is responsible for any good
imported or exported. Likewise the documentation process done in Poppys is
observed and the following report reflects the process. This department works as an
intermediate between the buyers as well as the suppliers and get the work done for
the merchandisers of the company.
There are various types of essential documents required for imports and exports.
The documentation department of the company becomes active whenever there is a
shipment, airway towards or outwards the company. In the purchase order given by
the buyer, it would be specified that certain accessories for the garment should be
bought from the particular supplier only. Henceforth the merchandiser will inform the
documentation team so that they would take the responsibility on their shoulders to
import the goods from the particular country.
DDP- Delivered duty paid and many. These are the most commonly used
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REPORT ON STRATEGIC ANALYSIS OF POPPYS KNITWEAR PVT LIMITED
The important documents which are required during the import are
Invoice
Packing List
Sea – Bill of lading or Air- Airway bill
Bill of entry
Technical write up
And it also depends upon the country as the norms and regulation varies for each
and every country. All the documents are important for export also but the bill of
lading is replaced by bill of shipment. Rest others are common for both.
There are 3 types of agents who can be involved during the shipment.
1. Liner
2. Freight forwarders
The liners can be of two types namely the vessel operator and NVOCC (Non Vessel
Operator Container Carrier).
The freight forwarders act as an intermediate between the supplier and the liner.
They are like agents where there are lot of benefits while going through the freight
forwarders.
There is another agent called C&F, who act on behalf of the supplier and the buyer
to declare the purpose of shipment and the product details. They are also
responsible for collection of duties.
The rules and norms vary for each and every country and it should be
observed carefully.
The time varies for importing a product from one country to another.
If any problem occurs in shipment delay, then it should be done by air which
again increases the cost.
The terms should be properly fixed as each and every term has got different
function.
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REPORT ON STRATEGIC ANALYSIS OF POPPYS KNITWEAR PVT LIMITED
MARKETING ENVIRONMENTS:
Micro Environment
Macro Environment
Actors who are close to the company that affects its ability to serve its customers
come under the Micro Environment. The actors of the Micro Environment are
The Company
Suppliers
Marketing Intermediaries
Customers
Competitors
Public
The company:
Poppys Knitwear Pvt Limited is a large enterprise and there are more than 2500
employees in the entire group. Every concern that is mentioned above has
managers who are responsible for their firms. The company experiences insufficient
labours which is been a common problem in Tirupur now. The employees in the
company should take responsibilities as this is more like a team work and if anything
goes wrong at one stage the entire process could be a fiasco.
Suppliers:
The sister concerns of Poppys are the major suppliers of the company. For certain
orders the buyers want Poppys to get the accessories from the particular suppliers
only. So a delay in delivery of good from the supplier may also affect the
manufacturing of garment in the company. Even the transport agents are the
suppliers for the company.
Marketing Intermediaries:
There are no such intermediaries for the company for marketing purpose.
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REPORT ON STRATEGIC ANALYSIS OF POPPYS KNITWEAR PVT LIMITED
Customers:
The customers of the company are:
Hanes
Harley Davidson
M&M
Caterpillar
Next
Gap
C&A
Carter’s
M&S
Michael Morgan
Competitors:
The competition in the garment industry is high. There are many players in the
industry who are even the market leaders. The major competitors for the company
are Eastman Exports, KPR Mills Limited, etc
Political
Economic
Social
Technological
PEST analysis can be used for marketing and business development assessment
and decision-making, and the PEST template encourages proactive thinking, rather
than relying on habitual or instinctive reactions.
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REPORT ON STRATEGIC ANALYSIS OF POPPYS KNITWEAR PVT LIMITED
POLITICAL:
ECONOMICAL:
With the abolition of quota system in January, 2005 and the imposition of a 10% cap
on Chinese textile exports till 2008, the Indian textile exports are under a mega-
bonanza altogether. As per data available from the Indian Govt., textile exports to
U.S.A leaped up by 26 per cent and those to European countries increased by 18
per cent, since 2005. China’s export growth in the last quarter of 2005-06 stood at
nine per cent, while that of India went up to 13 per cent. However, there continues to
be a sharp difference in value terms between exports from China and India. China
clocked $120 billion in export of textiles and clothing in 2005, while India earned a
mere $17 billion that year.
Tirupur that accounts for 90% of India’s cotton knitwear export has gained the most
in the milieu of the post-quota textile boom. Its export earnings shot up from Rs.4726
crores in 2004 to an estimated Rs. 8000 crores in 2006, nearly a 70% growth in two
years. The bustling business of knitwear exports crossed Rs.9600 crores between
January and December 2006.
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REPORT ON STRATEGIC ANALYSIS OF POPPYS KNITWEAR PVT LIMITED
REFERENCE: The New Developments in Tirupur, Produced by FWF, with inputs from Mr.
Angelis, Advocate, Mr. Prithiviraj, CARE, Mr. Narayanasamy of LRC – SAVE and E. Rajarethinam,
GCT. October 2006.
SOCIAL:
There must be ethical issues during exports and imports as two different
countries are involved in the transaction.
Consumers of the company are the people who are in businesses. So b2b
marketing is required.
Buying access and trends might change according to the recession in each
and every country.
Any law introduced by the government might affect the social factor of the
country.
TECHNOLOGICAL:
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REPORT ON STRATEGIC ANALYSIS OF POPPYS KNITWEAR PVT LIMITED
CONCLUSION:
The management and the manufacturing process in the Poppys Knitwear Pvt Limited
are explained. The internal and the external analysis for the company are done and
the summary of it is given as SWOT analysis in the conclusion. The company has
got a good profile with all the necessary infrastructures and capabilities to do better.
SWOT ANALYSIS:
Swot analysis would give a brief explanation about the business, the ability of the
business to perform and its drawbacks as well.
STRENGTHS:
WEAKNESS:
OPPORTUNITIES:
THREATS:
Anyone can copy the design of the product and manufacture once the design
is out.
There are threats for new entrants i.e. the small players in the industry who
are ready to do job orders for big companies.
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