SFA::Indian Fashion Academy 4 Garment Manufacturing Technology Merchandising Institute Tirupur

One Year Post Diploma in Merchandising and Management

Semester 1
Diploma in Fabric Management :

1. Fibre Science

Fibres - Textile Fibres - Properties - staple length - history - relevance of fibres to merchandisers.
Types - Natural - sub classification - various fibres - properties - cotton varieties - genetically modified cotton - organic cotton.
Manmade - sub classification - various fibres - properties.
Yarn - spun yarn - filament yarn - spinning - various types - spun yarn making - combing - warp vs weft - hosiery vs warp - combed vs carded - filament yarn making - special yarns making - coloured yarns.
Yarn - types - ply - cable - thread - special yarns - sewing thread - number systems - direct - indirect - various numbers - numerical calculations.
Blending - aesthetics - functions - profitability - fibre identification tests - burn test - solubility test - microscopic test - other methods - texturisation - mercerisation - singeing - latest in fibres, yarns and spinning.

2. Fabric Making

Fabric making - introduction - characteristic of fabrics - classification - weaving - knitting - non-wovens. Weaving - principles - basic loom operations - preparatory processes - warping - sizing.
Types of looms - handloom - power loom - shuttle loom - shuttle less loom - projectile - rapier - jet - circular - tappet system - drop box - circular box - dobby - jacquard - leno - terry.
Designing - principles - plain - twill - satin - honeycomb - waffle - mock leno - lace - cords - crepe - huck - extra warp - extra weft - double warp face - double weft face - double cloths - leno - piles - weft - warp - velvet - plush - pique - 3 & 4 yarn systems -Figure design - dobby - jacquards - designing - card cutting - automated looms.
Sheets & pillowcases - blankets - terry towels - table cloths - mats - floor, bar - hand towels - kitchen towels - aprons - mittens - napkins - carpet and rugs - fabrics - sizes.
Clothing standards - yarn calculations - other textile calculations.
Glossary of fabrics.

3. Fabric Making II

Knitting - principles - open loop, closed loop - stretchability - knitting vs weaving - warp knitting vs weft knitting - Classification of machinery - principle of knitting machines - circular(weft), flat(warp) - others.
Weft knitted structures : Flat fabrics - circular fabrics - single jersey - rib - interlock - purl - semi fashioned - fully fashioned.
Warp knit structures : Tricot - Raschel - crochet - Milanese - simplex - carpet pile - other structures - braids - laces.
Loop length - let off - shrinkage - spirality - tightness factor - GSM control - practical calculations - fabric faults.
Basic designing - air tex - pique - honeycomb - mini waffle - popcorn - fleece - drop needle - flat back ribs - waffles - other designs - stripes - intarsia - plating - jacquards - mechanisms - electronic jacquard.
Non wovens : introduction - definition - raw materials - binders - manufacturing processes - finishing - characteristics - applications.

4. Textile Processing

Processing - introduction - classification - history - effects of colour - designs - dyes classification - properties - conditions - colouring process - lot segregation.
Processing machinery - fibre dyeing machinery - yarn dyeing machinery - woven fabric dyeing machinery.
Stretch / knit fabric dyeing machinery - continuous dyeing - garment dyeing - handling of tubular fabric and stretch fabrics.
Dyeing - flow diagrams - dye selection - dyeing of blends - dyeing faults - introduction to effluent treatment - fastness - colour matching.
Preparatory processes - bleaching - mercerising - singeing - scouring - sizing - desizing - degumming. Finishing processes - stiffening - weighting - glazing - embossing - moireing - raising - sanding - shearing - crepe and crinkle effect - shape retentive finishes - wrinkle resistant finishes - aesthetic and functional finishes.
Printing - introduction - dyes used - ingredients -styles - direct - discharge - resist - methods - contact - screen - transfer - computer - special printing methods - printing faults - fastness - colour matching.

5. Fabric Planning and Quality

Fabric planning - loom widths - open width fabrics - effect of selvedges - planning by length - planning by weight - process wastage - wastage and productivity - conversion of pounds and kilos - conversion of metres and yards
Tubular fabric - consideration of width (machines) - limitations - planning by length - planning by weight - on fold - process wastage and edges - side-to-side problems - handling.
Effect of designs - horizontal, vertical designs - effect on length - effect on width - effect on tubular fabrics - fabric planning from patterns - effect of shrinkage on width - effect of GSM while planning by weight - practical considerations in designed fabric planning - effect of shrinkage, GSM.
Fabric inspection - 4 point system - 10 point system - 10 points per 100 metres systems - other systems - consideration on acceptable mistakes - testing - fibre length - fineness - maturity - strength - trash content - testing of yarn - numbers - twist - strength - evenness - quality of fabric - fabric strength - abrasion resistance - handle - permeability - air, water.
Production planning - widths - piece lengths - time schedules - process methods & machinery selection - effect of total qty in width selection - tubular to open and vice versa
Fabric care - care labeling

6. Accounts & Finance Management

Accounting principles - definitions - rules - records - cash, purchase, sales and returns book - debit and credit note - journals - double entry system - ledger - balancing - trial balance - suspense account - bank reconciliation.
Final accounts - financial statements - expenditure - capital, revenue - receipts - trading accounts - closing inventories - gross profit - profit and loss account - adjustments and other entries - balance sheet - limitations of financial statement - valuation of inventories.
Financial statement analysis - types - comparative statements - trend analysis - common size statements - limitations - ratio analysis - funds flow, cash flow statements.
Financial management - maximisation - financial decisions - financial planning - long term, short term - fixed capital, working capital - capitalisation - fair, over, under - capital structure - various theories - cost of capital - leverages.
Sources of finance - shares, debentures, bonds, securities, loans - SEBI - working capital - excess, inadequate - management of cash - receivables - inventory - dividend - bonus - rights issue - depreciation
Cash flows - capital budgeting - pay back - various methods - capital expenditure control - social cost benefit - business forecasting - projects appraisal - network analysis

Semester 2
Diploma in Garment Merchandising :

1. Garment Production

Cutting : Marker planning - requirements - efficiency - marker making - spreading - types - lays - lay types - cutting - methods - objectives.
Sewing : Seams - types - stitches - classes - types - feed mechanisms - sewing needles - sewing threads - fibres - construction - finish - sizing - packages - costs - properties and seam performances - sewing problems - basic sewing machines - work aids - special machines
Components and trims : labels, motifs - linings - interlining - wadding - lace - braid and elastic - fasteners - zip fasteners - buttons - shoulder pads - seam binding and tape - embroidery - appliques - insets - printing.
Alternative methods of joining : Fusing - welding - adhesives - moulding. Pressing - categories - means - equipments - methods - pleats - permanent press.
Material sourcing - role of sourcing decisions - selecting fabrics - aesthetics - performance - fabric quality - sourcing issues - global sourcing - priorities and processes.
Use of forms - mannequins - body measurements - garment names - pattern making principles - seven and a half head theory.

2. Management Concepts

Introduction - various approaches - functions of managers - various theories - environment.
Planning - nature - purpose - steps - types - objectives - setting objectives - strategies - policies - decision making - alternatives.
Organizing - nature - purpose - levels - division - span - departmentation - line of authority - line and staff concepts - delegation of authority - decentralisation - effective organisation.
Staffing - defining - systems approach - factors affecting - staff selection - job design - skills and characteristics - selection process - techniques - instruments - orientation - performance appraisal - development of managers.
Leading - human factors in managing - behavioural models - objectives - motivation - various theories - job enrichment - leadership - definition - ingredients - behaviour - styles - communication - effective communications.
Controlling - control process - control points - standards - control as feedback - control techniques - budget - non-budgetary controls - network analysis - MIS - audit systems.

3. Cost & Production Mgmt

Costs - concept - analysis - classifications - fixed, variable, semi variable - marginal costing - PV ratio - cost volume profit analysis - break even point - analysis - margin of safety - differential cost - determination - essential features - standard costing - variance analysis.
Budget - meaning - nature - budgetary control - objectives - characteristics - requisites -essentials - organisation - budgeting vs forecasting - budget classifications - types
Responsibility accounting - meaning - definition - fundamental aspects - responsibility centres - transfer prices - job costing - batch costing - transfer costing -nature - suitability - objectives - costing procedures.
Production / operations management - strategies for profit - operations capacity - location planning - layout planning - project management
Scheduling - systems planning - aggregate planning of - production - services - operations - inventory control - material requirement planning
Raw material planning - process planning - cut planning - line balancing - line planning - estimation of costs - daily plans for man, machine, materials and money - follow ups - quantity - feedbacks - revision of planning - exception reports

4 Quality in Garmenting

Quality - concept - consumer perspective - buyer perspective - some common mistakes - quality management - definitions - quality assurance - total quality management
Quality department - Quality Manager - Quality controller - Quality inspectors/Line QCs - checkers - characters - functions - responsibilities.
Pre production - quality of - raw materials - accessories - approvals.
Mid production - cutting quality - use of patterns as quality parameter - stitch quality - measurements - puckering - fabric handling - packing quality - delay as quality parameter - shortage as quality parameter - zones in garments - critical, major, minor faults - rejection of a garment - quality reports.
Final inspection - submission - inspection procedure - 100% inspection - percentage inspection - statistical quality inspection - AQL standards - one level - two level - multi level AQL inspections - recheck - effects of quality - care labelling - quality costs - health hazards - banned substances.
Total quality management - elements - tools - quality standards.

5 Productivity

Productivity - introduction - measuring methods - causes for productivity loss - productivity in USA - EU - global comparisons.
Material storage - organising storage - efficient transportation - effective lifting operations - work station design - placement of materials, tools and controls - work posture - garment designing - use of guides, jigs and fixtures.
Machine check - safety - maintenance - training operatives - cleaning environment - lighting - glare - backgrounds - light sources - shadows.
Premises - insulation of environment - air flow - pant layout - work organisation - elimination of extra tasks - monotony - buffers in production line - WIP control - flexible jobs - autonomy - progress control system.
Bench marking - case studies - strategy for productivity improvement - work and motion study - simple productive techniques - line balancing - line, batch, bundle systems - training - operatives, supervisors managers - productivity measurement systems.
Worker involvement - welfare facilities - worker benefits - worker support - worker involvement - production planning, scheduling and control - incentive schemes - information systems and productivity.

6 Merchandising

Merchandising - definitions - merchandising in EU, USA - supplying nations.
International buying office - structure - buyers - merchandisers - technologists - fashion designers - making units - stores - functions - interrelations.
Visual merchandising - visual presentation - store designs - lighting - background - space - sinages - props - mannequins and forms - window display - sample presentations - presentation - self and stationery.
Buyer related functions - international marketing - environment - market entry modes -buyers requirements - sample submissions - types of samples - target prices - retaining an account.
Production related function - production planning - steps in planning - order distribution - follow up - factory evaluation - coordinating with quality department - specification and approvals - reasons for approvals.
Logistics - export documentation principles - insurances - ECGC - shipping logistics - containers - freight calculations - freight forwarders - shipping marks - INCOTERMS.