Abdullah Ali Akbar Reja Internship Report

7/28/2019 Abdullah Ali Akbar Reja Internship Report

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Pearl Academy of Fashion

An Internship Report

On

International Knitwear and Apparels Ltd and ESSES Fashion

Ltd, BEXIMCO Group

By

Abdullah Ali Akbar Reja


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An Internship Report

On

International Knitwear and Apparels Ltd and ESSES Fashion

Ltd, BEXIMCO Group

By


Fashion Business Management, 6th

Semester


New Delhi, India

Submit to

Mr. Tarun Pandey

Faculty


New Delhi, India

Submission Date: 25April, 2012


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Acknowledgement

Through this project report I would like to thank numerous people whose consistent support

and guidance has been the standing pillar in architecture of this project. To begin with, my

sincere thanks to the management of PAF for giving this opportunity to experience and learnthe processes practiced in Apparel Industry.

For the completion of this document I would like to thank Tarun Pandey, for being my

mentor and my guide throughout the project and Shazia Amanat (Course Coordinator,department of Fashion Business Management, PAF).

I would like to express my sincere thanks to the Management and staff of International

Knitwear & Apparel Ltd (IKAL1) and ESSES Fashion Ltd, for their outstanding Support and

cooperation in my efforts to gain knowledge about the practical aspects of Apparel industries

during the Internship.

I am thankful to Shamim Al Mamun GM and Head of the factory, IKAL1, Md. Rafiqul

Hasan, Deputy Manager, Planning, IKAL1, and Mr. Sorder Mominul Hoq, GM and Head of

Factory, ESSES Fashion Ltd (EFL), Md. Sadequn Nabi, Factory Manager, EFL, Md.

Shahabul Alam Biswas, Sr. IE Officer, EFL, Mr. Syed Abu Zahid Hakkani, Sr. HR manager,

Beximco for the guidance and planning out the schedule for the internship.

I also would like to thanks to Mr. Samsu Doha and Shafiul Islam (Merchandiser), who help

me to learnt merchandising works done by factory merchandisers.

I would specially like to thank all the staff members and workers for helping me throughout

internship. Without their support, it would have been difficult job to successfully complete

the training.



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Declaration

I hereby declare that the work presented in the project report submitted to the Department ofFashion Business Management for the partial fulfillment of the requirement for the award of

Degree of BA Honors in Fashion Business Management is an authentic record of my

work carried out at International Knitwear & Apparel Ltd and ESSES Fashion Ltd , Member

of BEXIMCO Ltd.(Mother Company) for a period of 7 weeks from 23rd

January 2012 to 14th

March 2012 as per my curriculum requirement.

The matter embodied in this project report has not been submitted elsewhere by anybody for

the award of any degree.


FBM, 6th

SEM,

PAF, New Delhi.


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Index

SL# Subjects Pages

1 Acknowledgement 3

2 Declaration 4

3 Introduction 6

4 Company Profile 7

5 Company Product Profile 7

6 Company Working Process Flowchart 8

7 Company Analysis 10

8 Department-wise Working Procedures:

Merchandising Department

CAD Department

Factory Sampling Department

Factory Storage Department

Quality Control Department

Cutting Department:

Industrial Engineering (IE) Department:

Production Planning and Control (PPC)

Department:

Production Department:

Finishing and Packing Department

11

9 SWOT Analysis 19

10 Compliance Policies 20

11 Area of Work 22

12 Special Study 2313 Conclusion 27

14 References and Bibliography 28

15 Reflections 29

16 Glossary 31


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Introduction

As a part of my honors course I have got a chance to intern in International Knitwear and

Apparels Ltd 1 (IKAL1) and ESSES Fashion Ltd a member of BEXIMCO group, for 2

month. BEXIMCO is one of the leading groups of company for foreign earning ofBangladesh. BEXIMCO has pharmaceutical unit, ceramics, textile and apparel, real estate

and trading, energy, aviation and ICT & media. BEXIMCO has developed in-house design

capabilities with teams based in Bangladesh and Spain. BEXIMCO Yellow is one of the

famous Retail (Manufacturers own) brand in Bangladesh. As a member of BEXIMCO group

IKAL and ESSES is one of the most reputed knit garments manufacturing company.

As a requirement of my course, I have work in all departments according to my working

schedule in this factory. I have tried to learn all of working processes of all departments and

connection between one and other departments. In this two month I have seen and learnt

many things from this factory. All things I have learnt from this factory included in this

report. In this report I have included all the basic information about this company. This report

is made based on my works and leanings from this company. During the period of intern inthis organization I got the chance to analyze and apply class room learning to real life

application and contribute to formulation of overall organization strategy. From this study I

have learnt about the working environment of a garment factory, how managers are face

problems and manage problems, how they response to planning for future change. This study

helps me to coordinate my learnings to the practical work environment.


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Company Profile

International Knitwear & Apparel Ltd (IKAL1) and ESSES Fashion Ltd a member of

Beximco Group started its commercial production in November 2004. IKAL and ESSES are

export oriented knitwear manufacturing company, located at Beximco Industrial Park,Sarabo, Kashimpur, Gazipur. IKAL1 and ESSES Fashions Limited is managed by a group of

professionals including expatriates and aims at producing high quality knit garments through

an effective quality control system right from sourcing of fabric to end product.

IKAL1 and ESSES Fashions Limited produces high quality knit garments (tops & bottoms)

for prominent brands and retails in USA, Canada & Europe. They are working with reputed

brand American Eagle, Zara, River Island, H&M, Macys, Gap, Kohls, Arcadia, Baska,

Charter House etc.

Product Profile

To harmonize fashion trends allover world in competitive market IKAL1 and ESSES has wellscore in its own range of design and styling product.

The company producing a wide range of knitted garments that includes- T-Shirts, Polo shirt,Sweat Shirts, sportswear, jackets, jogging suits, pajama, nightwear, and all kinds of inner and

outer knit-wear.

They ensure high quality product. To ensure quality they have quality check point in every

stage of critical operation in production line.


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Company Working Process Flowchart

If Fabric ok, Send to Cutting On the other

hand

Make Cut Order Planning: Marker

planning, Lay planning

Receipt of Order

Fit CycleTrim OrderingFabric OrderingPrepare Detailed

T&A

Fabric PO, Pi,

LCTrim PO,

PI

Pilot Yardage In-

houseBulk In-house

Inspection

shrinkage test

Bulk In-house

Inspection Test Report

All Departments

Advised of the

T&A

Fit Approval

Size set & Sealer

Sample Approval

Preproduction Meeting

Pilot Run Approval

Bulk Fabric Receipt by Factory Store from central Store or

Knitting

Fabric Checking by QC Department (4 point system)

Planning department make

Production T&A, Capacity

planning, line planning, loadingplanning,

Width Segregation

Manually Fabric Spreading

IE: Making M/C Layout & Fix theTarget


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Numbering & Bundling

Sewing Input

Cutting Manually

Quality Check Inline

Sewing Process

Sewing Output

Quality check in Finishing

(Randomize)

Ironing and Packaging

Final Inspection

Dispatch


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Company Analysis

Here analyzing this company I have seen that IKAL1 and ESSES is just working like anyother company of Bangladesh. A Special facility that IKAL1 has that is BEXIMCO has

knitting factory in own premises. And which is under same roof. International Knitwear

& Apparel Ltd is a horizontally setup factory, following Progressive Bundlingproduction (PBP) system for bulk production and Section production (SP) system for

sampling department.

1. Progressive Bundling production (PBP) system: There have several causes workingand following those system, i.e. here working all employees and workers are habituate

and experienced with this system only, because in Bangladesh approximate 98% factories

are working with this system. There has another main cause that our country labor cost. In

PBP system labors of all levels, i.e. unskilled, skilled, semi skilled labors are involved

where the operations are broken into small simple operation. Here the quantity of each

component is checked during the individual operation itself, so the quality is good. The

components are moved in bundles from one operation to next operation, so there is less

chance for confusion like, lot mix-up, shade variation, size variation, etc. this is also amain cause. Specialization and rhythm of operation increase productivity. As the WIP is

high in this system, this is stable system. Because of the buffer, the breakdown,

absenteeism, balancing of line, change of style can be easily managed. Bundle tracking is

possible, so identifying and solving the problems becomes easy. And they can also

effectively implement production control system and quality control system, viz. time

study, method study, operators training program and they can use material handling

equipment, such as centre table, chute, conveyor, trolley, bins, etc. and they can easily

move m/c in case change of operation.

2. Section production (SP) system: They are following SP system as because of makingsample they cant use bulk line. They have to make another line. In sample section the

QTY of product also too less on the other hand company have to submit their sample on

time thats why they think about batter and effective production system then make

through system and less costly. Where labor of all levels, i.e. semi skilled, skilled, trainee

can be used. Productivity is higher compared to make through system, because of the use

of special machine and all types of labor. This system is very efficient for producing a

variety of styles in reasonable quantities. Automation and specialization can be done.

Absenteeism and machine breakdown problems will not cause serious problems. The

labor cost is less compared with the individual system.


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Department-wise Working Procedures

This is an experience for me that seeing and learning each and every function and work done

in every department according to process flow. And I also learnt and understood all the

coordination between all departments in factory.

Merchandising Department

This is the most important department of the company. All of orders distribute to the factory

from this department. In BEXIMCO this department is run from the Head office. At the

beginning of the process flow Merchandising Department receipt orders. Here under a senior

merchandiser I have learnt:

1. Understanding Purchase order sheet, spec sheet, tech packs.2. Fabric, thread, trims and accessories calculation.3. Making of proper Time & Action Calendar (T&A) and Bill of material (BOM) or

Material Order sheet which is made for ordering materials. Here BOM is sent by the

buyer.

4. Here they have use Excel format for making of T&A and BOM.5. After making of T&A it advised to all departments.6. Committing all mistakes for calculating fabric consumption they generate pattern and

marker in CAD according to all size by the technical pack. First they calculate

consumption for 1 dozen.

7. Giving order to the Procurement Department through Purchase order. In one areaBEXIMCO have own knitting and weaving unit from where Procurement Department

collect fabrics.8. Learnt how to do follow up the running styles and the new styles to the responsible

department according to T&A.

9. In every document there has to be present two code number, i.e. DPI NO from DataTex software & BKL NO also a code from Data Tex software for knitting. Without

those number no document will accepted by any factory.

10.Learnt Sample development and approval process. Samples are made according tobuyer requirement. Here commonly proto, fit, size set, pre-production, shop sample,

bulk sample are made. Shop sample made sometime if buyer want, which is for

sowing in retail shop. Buyer can be asking for sample more than one time.

CAD Department:

CAD department has very important role in reducing extra uses of fabric and also it helps to

time consuming. From sampling to cutting they use Lectra CAD software.

1. CAD department has important role in booking fabric,2. Merchandisers collect information of fabric width required and weight of fabric from

this department and then they give booking order to the supplier.


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3. All the sample is develop from this department.4. CAD dept make the marker for maximum utilization of fabric.5. They make pattern in two ways, totally generating new pattern or from hard pattern

given by buyer scan with digitizing board which automatically convert pattern into

computer file format and then it open it in the CAD software.

6.

In CAD dept only for solid fabric marker is made, and for check fabric they makemarker manually.

7. Much more time given to the CAD, it will gives more efficiency. But usually 2 to 5minute is given. Because after 5 min it will give most of the time same efficiency.

8. In CAD here has two formats AAMA and ASTM. Those are uses as universal formatof CAD. Where in any CAD those two formats are supported.

Factory Sampling Department

All the samples required by buyer are made from this department. Everything I learnt from

this department:

1. After making of pattern by CAD dept in sample dept make the sample.2. In this factory they following sectional production system, there has one line planed

for sampling department.

3. Here all the workers are multi skilled operator work under 1 sample in charge.4. Operation breakdown information is collect from this department, which help IE

department to plan for production line and machine.

5. Samples are made: Proto, Fit, Size set, Pre production, Ad sample and Top of theproduction or bulk sample.

6. Those samples are varied on buyer.7. In this factory another sample ware made which is called shipment sample. This is

kept by factory. In-case any problem can happen after shipment or for repeating ofsame style.

Factory Storage Department

1. After collecting all materials Procurement board sent them to the Central store. Thenfactory store collect those materials from Central store.

2. All the records of materials in and out are kept in this dept. This dept also keptfinished packing storage information.

3. Material quality inspection also done in this dept. Where also count quantity.4. For keeping data they have Datatex format and excel format.5. In store they do not allow more then 5% allowance. If there come any extra they kept

it as left over.

6. For keeping trims and accessories systematically they use Bin card system.7. In store department they create Different types of Challan sheet, i.e. Returnable

Challan, which is issued by factory for sending goods out of the factory for washing,

printing or compacting.


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Quality Control Department (receipt fabric inspection section)

All the things I have learnt from this department:

1. This is one of the most important departments of factory. Until unless assurance ofanything from this department nothing will go for production or even for shipment.

2. Work of this department is start from as soon as the fabric and materials are received.3. After getting fabric there has possibilities to get some different common problems in

fabric, those are: hole in fabric, different spots on fabric, shading problems, crease

mark, weaving problems, stain, bowing, needle line problem etc.

4. They use 4 point quality checking system to check the quality of fabric, where theygive point according to those problems, i.e.

Problems up to 1 to 3 inches 1 point

3-6 inches 2 point

6-9 inches 3 point

Above 9 4 points

For hole problem they always gives 4 point.5. Below 20 point fabric might accepted for production by production meeting but above

20 point it is rejected.

6. Because of they cut fabric manually they also use rejected fabric, throwing affectedareas out and using non affected areas of fabric. Most of the time rejected fabric is use

for sample making.

7. Every day QC dept has to report on how much fabric and complete garments arerejected.

Cutting Department:

After checking by QC fabric goes to cutting dept. from this dept I have learnt:

1. In cutting dept pattern and markers are made,2. Cutting manager gives cut order plan to the CAD dept according to size ratio and

color wise size break up. Then CAD dept make marker according to the cut order

plan. According to the size and color ratio cutting team prepare one marker or

multiple markers.

3. Planning of cut order is the most important job of cutting department. Because markerlength and number of lay to be cut are planned in this stage. It shows the complete

way to cut the fabric. And it also consumes time by a proper cut order planning.

4. Cut order planning is planning for in how many lays will spread for cut the wholequantity of product.

5. Fabric requirement for an order is calculated according to the average consumption ofthe fabric from the marker. In case of multiple color order, color wise requirement is

made. Fabric department issue fabric to cutting against the fabric requirement

(generally requisition slip is used).


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6. For laying fabric it is an important job for cutting manager to know about that fabric.Because knit fabrics are much problematic to handle then woven fabric. Thats why

fabric relaxation has been done in this dept.

7. Lay is cut following the marked lines on the top of the lay. Cutting is done usingstraight knife or other cutting means. In cutting process garment component are

separated. On the basis of pattern shape different cutting method/ machine areselected.

8. Separated garment components are numbered to ensure that in stitching allcomponents from same layer are stitched together. It is important to avoid shade

variation in a garment. Between the cutting and sewing processes cut components

may be passed through other processes like printing and embroidery. There is

maximum chance of mixing of the components. If there is layer number in each

component then at the time of stitching only correct components will be stitched

together.

9. After numbering all the cutting parts of same shade and size are bundle by tiedtogether. Each bundle is marked with bundle number, style name, size number and

quantity of pieces in that bundle. At this stage cutting are ready to send to production

line for stitching.

10.Every day they have to report on daily cutting report, daily fabric utilizing repot, dailyfabric output report etc.

Industrial Engineering (IE) Department:

After cutting of fabric, it goes to production. IE department work starts from when factory get

the order of new style. Merchandiser gives spec sheet and tech-pack to the factory. According

to tech pack sample dept make sample and IE dept took his all the necessary data from them.From IE department I have learnt:

1. To improve performance of factory IE department do lot of things. There is number oftools and techniques which are used in by industrial engineers to establish an effective

production system in the company. Without having such tools earlier production

managers and line supervisors faced difficulty in measuring work content, garment

costing, and production planning correctly, even it was difficult to finalize orders.

2. In IE department works are done:a) Time study (cycle timing)b) Motion analysis of the operationsc) Preparation of operation bulletind) SAM calculatione) M/C layout and work station layoutf) Line set up and line balancingg) Production estimation of a lineh) Work samplingi) Method study


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j) Performance ratingk) Calculating M/C requirement.

3. Different equation or formulas are use in this department to increase production.Those are Basic time, SMV, Efficiency, Target calculation, Allowance calculation,

Thread consumption etc.

4.

All the report they made: 1. Daily production report (product wise), 2. Dailyproduction report (per line wise), 3. Daily production report (all line wise), 4.

Daily production report (shift wise), 5. Daily target and achievement report, 6.

Loss summary report, 7. Daily sewing size wise report, 8. Production evaluation

report, 9. Daily efficiency report line wise, 10. Daily efficiency report day wise,

11. Daily efficiency report factory wise.

5. I have also learnt about different production system, viz; Progressive Bundling,sectional production system, Unit Production System, Modular system etc. and

also learnt why they follow Progressive Bundling system for production.

Production Planning and Control (PPC) Department:

Production planning and Control department is one of the important department for the

apparel manufacturing company. Whatever I have from this area is listed below:

1. This department prepare time and action calendar (job schedule) for each order fromorder receiving to shipment. The job schedule contains list of tasks to be processed for

the styles. Against each tasks planner mentions when to start a task and what is dead

line for that task. Name of responsible person (department) for the job is being listed.

For example, scheduling planned cut date (PCD), line loading date etc.

2. Preparation of Material requirement sheet according to sample product and buyerspecification sheet. Consumption of material (fabric, thread, button, and twill tape) is

calculated and estimated costs of each material are also made in this department.

3. In this department planner plan for which style to be loaded to the production line andhow much quantity to be loaded.

4. Planning department plays a major role during order booking. They suggest howmuch order should accept according to production capacity. Allocating of total

capacity or deciding how much capacity to be used for an order out of total factory

capacity. Regularly updating factories current capacity (production capacity).

5. They prepare detailed line planning with daily production target for the productionline. Most cases line planning is made after discussing with production team and

Industrial engineers.

6. Estimating quantity and costs of production are also plan by this department.7. Whatever plan is made is executed by PPC department. PPC department keeps close

look whether everything is progressing according the plan. Chasing other department

heads on daily basis to keep plan on track. They update order wise completed tasks on

the Time & action Calendar. When they found something is going to be late they

expedite and create an alarm about the delay.

8. All the report of WIP is made every month from this department. They also madedaily target and achievement report, daily production (overall), daily line-wise


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production, date-wise monthly production report, production/datatex variation report,

style closing report etc.

Production Department:

After cutting, cut panel goes to sewing for final production. I have learnt from this area:

1. Once pre-production (PP) sample is approved (also called sealer sample) and most ofthe trims are sourced, merchants or production planning department conduct pre-

production meeting with production team, quality team and sourcing team. All

important comments, procedures to be followed, dos and donts are discussed.

Scheduling of PCD (planned cut date) and shipment date is announced to all teams.

2. Estimate costs of production are also define by this department. This helps to costingfor new style.

3. This department has that importance where they have to check whether the rawmaterials that is being used for production is up to the set industry standards.

4. I have learnt to estimate garment production formulas from this department which is:Daily production = Total man minutes available in a day/SAM * Average Line

efficiency

(Total available man-minutes =Total no. of operators X Working hours in a day X 60)

5. I have learnt factors that hamper production, i.e. M/C break down, imbalance line(WIP control), Continuous feeding to the line, Quality problems, Individual

operator performance level, Operator absenteeism etc.

6. They also keep the measurement of all labor productivity. This called workerproductivity report.

Quality Control Department (Finishing section)

Quality is a big issue to cancel an order. Maintaining 100% quality is also challenging job.

From QC department I have learnt:

1. In each and every steps there has to be check quality, viz, fabric quality check, trimquality check, cutting quality checks, stitching quality, finishing and washing quality

check, safety measure for Kids Garments etc.

2. I have learnt about garment wash care label symbol.3. I have learnt how check a finished garment, i.e. Inspection of garment is done on a

clock wise direction.

a) First, check appearance by holding the garment at shoulder points. Examine frontand back of the garment.

b) Lay the garment flat on the audit table. Check for garment details.c) Open and check center front opening.d) Inspect inside and outside of the collar and Neck. Inspect inside shoulder seamse) Fold garment forward at shoulder and check back neck.f) Check tension of neck seam. Stretch out to full extent.g) Inspect left shoulder seam. Inspect left armhole seam.


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h) Fold left sleeve across front of the garment. Inspect left back armhole. Check forshading.

i) Inspect left sleeve cuff outside and inside. Check tension of left cuff seam. Stretchout to full extent.

j) Inspect left underarm. Inspect left side seam.k) Check tension of left underarm seam. Check tension of left side seam.l) Inspect bottom outside and inside, front and back.m)Check tension of bottom hem. Stretch out bottom to full extent.n) Inspect right side seam. Inspect right under arm.o) Check tension of right side seam. Check tension of right underarm seamp) Inspect right sleeve cuff outside and inside. Check tension of right sleeve cuff.

Stretch out to full extent.

q) Fold right sleeve across the front of the garment. Inspect right back armhole.Check for shading.

r) Inspect right armhole seam. Inspect right shoulder seam.s) Turn garment over. Lay garment flat on the audit table. Examine style details and

examine uncheck seam on back.

t) Turn garment inside out. Lay garment flat on audit table. Inspect for obviousdefects. Examine unchecked seams on inside.

4. For trims are normally they check Shade matching, Shrinkage, Color bleeding, Widthand thickness, Strength, Number and size, Fiber content, Text content/font/language

in labels and tags etc.

Finishing and Packing Department

The finishing department is the department which comes after all the departments and it plays

an equally important role in the final appearance of the garment. This department includes

majorly of the following steps,

1. This involves the removal of the extra threads from the garment at the stitched areas.2. The inspection carried out here is according to the Acceptable Quality Level (AQL)

2.5 system and sometimes it depends on the buyer also i.e., if the buyer emphasizes

for a 100% inspection then the company has to do as specified.

3. This happens when a garment is difficult to inspect in the crushes manner as it comesfrom the washing department hence, they do a partial pressing for the garments and

then inspect it and trim it and then send it to the complete pressing process.

4. The pressing is done after the garment has been completely inspected and thegarments are pressed on the basis of how they will be folded during packing.

5. Once the garments are been done with the inspection and complete pressing then theyare sent for tagging the labels and the labels include the size labels, price tags and

miscellaneous labels if any required by the buyer. Once the tagging is done the

garments are folded according to the buyers specification and also they are either

folded plainly or sometimes they are folded after they are put to the hangers as per the

buyers specifications again.


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6. The packing material, PCB details, number of size ratios that are supposed to be putin are all suggested by the buyer and the packing is done according to these

specifications.

7. The packing is always done in the carton boxes and there are several criteria for thepacking of the garments they are as follows, there are generally two kinds of packing

the garment: The garment is individually packed/wrapped in the poly bag whose design will be

specified by the buyer i.e., either with the hanger attached or plain poly bag

packing and then the entire garments (as per the packing criteria) is arranged in

the carton box.

The other method is that the garments are just folded and arranged in the cartonboxes without putting them in the poly bag.

8. The packing criteria followed in each carton box as already mentioned is done indifferent ways which is as follows:

In this method of packing, the carton box will include garments of single colorand same size. For example, 20 shirts of a similar color say navy blue and the sizesay S will be put in one carton box.

In this method the carton box includes garments of same color but of differentsizes according to the ratio. For example, (S: M: L: XL = 5: 7: 7: 5.)

In this method the carton box includes garments of different color but of same sizeor garments with different color and different sizes in a particular ratio form.

After the packing is done the garments are kept in the go-down/stores until the buyer sends

the buyer QC for the inspection purpose before delivering them and once the QC arrive he

will check them according to the 2.5 AQL level and then see if the garments has to be

accepted or rejected.


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SWOT Analysis

Strength

Have in house spinning, knitting,dyeing, printing and embroidery unit

Working with reputed buyers withhuge order quantity

Have ability to catch buyers. Have good connection with

customers.

Have good infrastructure Spare manufacturing capacity. Minimal diversion of mind from

work.

Weakness

Less implementation of industrialengineering.

Less implementation of IT. Lack in employee motivation. Problem in coordination among

employee and other units.

No direct marketing to the end-users. High management turnover High wastage of materials.

Opportunity

Could develop more market in otherunits.

Have ability to new specialistapplication.

Have ability to use IE moreefficiently.

Profit margins will be good.

Support core business economies. Could seek better supplier deals.

Threat

Vulnerable to reactive attack by majorcompetitors.

Management turnover will increasedif not control

Changing fashion trends may shiftconsumer interest in our product

range

Company may not be able to fullyutilize their own resources.

Foreign exchange rate variation mayimpact costs.

SWOT Analysis

By the above statements, I have analyzed that the company is improving day by day

having unique brands protected by sole supply agreements, successful relationship

marketing and innovative sales techniques. Company has potential to improve their

working culture, and making it more systematize through developing IT, reducing

management turnover, making all weakness to strength and solving all threats. After thenthey need to adopt and utilize their all opportunities properly to become more beneficial

company.


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Compliance Policies

This is mandatory for all RMG factories to follow compliance policies strictly. All the

factories have to follow Bangladesh Labor Law 2006. The company I have worked is a

compliance oriented company. There are some of the policies that they are following-:

1. Appointment and Condition of Employment, Act 2006, Chapter II:Under this Act Company have to ensure several things to their all employee, those are:

Appointment Letter And Id Card, Service Book, Un-Available Leave, Stoppage Of Work,

Closure Of Establishment, Benefit Of Death, Retrenchment, Discharge From Service,

Misconduct & Punishment-Dismissal Of Service, Procedure Of Punishment, Special

Provision With Regard To Fine, Termination Of Employment By Otherwise Then By

Dismissal, Termination Of Employment By Employee, Grievance Procedure.

2. Employment of Young Person, Act 2006, Chapter III:This act is undertaken because of prohibition of employment of children and adolescent.

Under 18 years old every human are think as child according to this act.

3. Maternity Welfare Facilities, Act 2006, Chapter IV:This is one of the most important laws for every company. Because of misuse of this lawcan create huge destruction of a factory. Main objects of this Act are, Employment of

women workers prohibited during certain period, Right to and liability for payment of

maternity benefit, Procedure regarding payment of maternity benefit, Amount of

maternity benefit, Payment of maternity benefit in case of a womens death, Restriction

on termination of employment of women in certain case.

4. Health and Hygiene, Act 2006, Chapter V:Every factory should be clean, should have Ventilation system, Dust and fume should not

be there, there should have way of disposal of wastes and effluents, artificial

humidification. According to this law there also have to follow avoid Overcrowding,

proper lighting, Healthy Drinking Water, Latrines and urinals, Dust bean and Spittoon.

5. Safety, Act 2006, Chapter VI:Safety is one of the basic needs for every human being. To ensure proper safety accordingto this act steps should be under taken, Safety of building and machinery, Precaution in

case of fire, Fencing of machinery, Work on or near machinery in motion, Striking gear

and devices for cutting off power, Self acting machines, Casing of new machinery,

Cranes and other lifting machinery, Hoists and lifts, Revolving machinery, Pressure plate,

Floors, Stairs and means of access, Pits-.sumps, opening in floors etc., Excessive weights,

Protection of eyes, Powers to require specifications of defective parts or tests of stability,

Precaution against dangerous fumes, Explosive or inflammable dust, gas .etc

6. Welfare Measures, Act 2006, Chapter VIII:According to this act company ensure First aid appliances, Maintenance of Safety, Record

Book, Washing facilities, Canteens, Shelters etc., Rooms for Children, Medical care,

Compulsory Group Insurance.

7. Working Hours and Leave, Act 2006, Chapter IX:As like other and according to law company ensure Daily 8 hours as working hour, 1 hour

Interval for rest or meal, Weekly hours, 1 day Weekly holiday, Compensatory weekly

holiday, Spread over, extra fee for Night shift, Restriction on cumulative hours of workon a vehicle, Extra allowance for work overtime, Limitation of hours of work for

women, Restriction on double employment, Notice of periods of work for adults and

preparation thereof, Special age limit for road transport service worker, Hours of work to

correspond with notice and register, Closure of shops etc., Casual leave, Sick leave,


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pg. 21

Annual leave with wages, Festival holiday, Calculation of wages and payment during

leave or holiday period.

8. Wages and its Payment, Act 2006, Chapter X(Revised 2009):If wages not given properly, it can be a big issue for damage a company. This act is

updated from 2006 act to 2009, where minimum wages define for a trainee worker is

BDT 3000 TK, where it was BDT 1662 TK according to 2006 law. Company has to bepaid in between first week of the month.Wages to be paid in current coin or currency

notes, there also define some possibilities for Deduction of wages, which may be made

from wages, Deductions for absence from duty, Deductions for damage or loss,

Deductions for services rendered, Deductions for recovery of loans or advances, Other

deductions from wages, Payment of undisguised wages in cases of death of workers,

Claims arising out of deductions from wages or delay in payment of wages, Court fees in

proceeding under section, Single application in respect of a clad of workers whose wages

have not been paid or wages deducted, Appeal, Conditional attachment of property of

employer or other person responsible for payment of wages, Power to recover from

employer in certain cases.


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Department Sty

Merchandising Polo shirt

Fig: Ameri

Polo style# 67

Cutting Polo shirt

IE T shirt

Production Tank top

Quality Polo shirt

Area of Work

le Work Done Proble

can Eagle

22.

Create T&A

Create BOMCreate spec sheet

Generate tech

pack

Shade band

production

Make cut orderplanning under

cutting manager

Lay wasproperly so

some cut

smaller then

Placed under IE

officer

Line wa

properly b

operation

found

Placed under

Production officer

Due to p

shortage

armhole pip

stop,

As a resulhappened a

achieve full

Under Quality

Manager

At sleeve a

tension see

why it req

altering.

pg. 22

s Faced

found in pre-

ample

not spreadafter cutting

panel seem

pattern

balanced

t at critical

bottle neck

iping fabric

neck and

ing operation

bottle necknd target not

y

rmhole stitch

s low, thats

ired sending


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pg. 23

Special Study

Style 1- Polo Shirt

Buyer:

Its buyer was Charter House and its merchant was Intra Max.

Department:

Industrial Engineering

Responsibility Undertaken:

I had been placed in a line which was making mens polo shirt. Responsibilities are to finding

out and solving all the bottle neck from the line which hampering production running

smoothly.

Problem Identified:

All the problems I found:

1. After piping at collar joint and making of button placket box, in line quality checktaking much time to checking. Thats why in checking garment parts are created

gathering. And also IE persons are not taking SMV for in line QC. That problem arise

because of QC get a bundle and after checking all garment then he leave hole bundle

to next operator.

2. Some time workers are set idle, chat with other worker. It also happened sometimeworker go to toilet and take much more time than normal.

3. One helper was absence that is why in matching front and back part after T/S Moonware using one Helper. Where this is much load for her. And there not replacing any

other helper for absent worker.

4. In matching sleeve to front operator taking 0.5 minute where he can complete onecycle at 0.26 minute. It also seems at closing side seam with care label attaching

where worker is taking above 1 minute to complete one cycle where he can complete

it in 0.86 minute.

5. In final quality check QC found that in some M size garment care label was attachedof large size. Those garments are sent to line for altering.

Action Plan and Implementation:

To solve those problems I have taken following steps:

1. I have make operation breakdown for this style. And observe all the operations.2. Then I take time, motion and method study of all operation and calculate SMV.3. For getting accurate SMV I have taken time for 10 times each operation.4. Then I calculate line capacity of the line, this style was running.5. For in line QC delay problem I suggested them after getting one bundle, and open it

QC should check one garment and then should send this to next operator, again check

another and then send to the next. Because after checking one bundle QC retie it and


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pg. 24

then send to the next, and next operator had to reopen bundle where operator take

extra time.

6. For altering I have suggested them to utilize pilot section where there are multi skilledoperators who have no any sampling work.

7. To reduce SMV of matching sleeve to front and closing side seam with care labelattaching I have cross check motion of those operators and studied time carefully and

then discuses with IE officer and then resolve their motion and reduce SMV.8. I also discus to the production manager about operators idle sitting and late in toilet

problem. Then PM discuses this matter with line super to be careful.

9. In floor internal hot air evacuation system should be modify because in floor it alwaysstay hot. Thats why many workers are fell problem.

Learning Outcome of Working in This Area:

From this area I have learnt:

1. In IE department need more technical person who can find out problems from line.They should be more active in line from starting to end of the production of a style.They should always look for all the problems even a small problem which can effect

production. They should always be aware of line balancing mistakes. IE person

should keep SMV for the entire department from cutting to finishing. So that in future

when problem will arise they can take immediate steps to solve this problem.

2. All the technical operational problems can detect from the sampling department andcan solve from there.

3. From this area I have learnt about many problems which always seem in factory andsolving those technicalities before starting bulk production and during production.

4. There has to be regular monitoring of the lines so as to check whether the line isperforming efficiently or not.

5. Absents of worker is a common problem in all garment factories which need to betaken seriously by proper system or rolls implementing.


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pg. 25

Style 2- Polo Shirt

Buyer: American eagle, style# 6722.

Department: Planning

Responsibility Undertaken: Afterbalancingline I have placed under Planning Manager for

controlling WIP of this style and Finding out all problems hampering WIP and planning to

solve those problems.

Problem Identified: There several problems ware found, which effecting WIP. Those are:

1. First problem ware found is Fabric delay from the factory. Because of during dyingsome chemical ware finished.

2. After receipt of fabric, 1380 kg fabric ware sent to cut where 4155 pcs bundle cameout and 4113 bundle ware sent to cutting and ware balanced 42 bundles.

3. In sewing 3533 ware sewed and 580 pcs ware left. And 3533 ware send to thefinishing.4. In finishing 3440 were finished and 93 pcs ware leftover because of rejection.

Action Plan and Implementation:

After gating all left over data I have start my action plan for WIP control, those are:

1. At first I have find out why and where those leftover has occur. I found that aftercutting 4155 pcs ware sent to the washing. In washing 4113 pcs ware washed properly

but 42 pcs ware not washed properly. So I have made a report and gave remark for

why this leftover happen how much leftover happened.

2. Then I made another report for sewing WIP, where 580 pcs ware leftover. Because ofline ware not balanced properly thats why where 65% efficiency target was given to

the line, there this much efficiency ware not come out. For that reason I have talk toIE manager and line in charge to re-arrange that line. Then I have re-calculated SMV,

and re-studied motion and methods. Then for solution some operation ware exchange

from hare and there, few extra m/c and helper ware added to overcome this problem.

3. After finishing of 3440 there found 93 pcs ware rejected because of 21 psc warefound shade band, hole found in 18 garment, 26 stitch problems, spot found in 28

garments.

4. Then I have plan for those garments which are rejected because of spot those are sentto spot fixing unit, 26 garments ware sent to altering section to remove those broken,

hidden, skip, and tension less stitch and re-stitch those part.

5. For 18 garments in which, hole problem found ware totally rejected those are nolonger use.

6. 21 psc garments which found shade band will negotiate with buyer QC. Which willthey accept those will be pack or which are not accepted by buyer QC those will not

pack.

Learning Outcome of Working in This Area:

From this area I have learnt:

1. WIP report is made for entire month of all styles are running.


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pg. 26

2. In factory planning department has to make this report.3. I have learnt about many problems which create troubles to run WIP smoothly and

their solutions. Those are fabric and accessories delay, cutting delay, printing and

embroidery delay, power failure during production, m/c break down, line not balance,

repairing, rejection problem etc.

4. I have learnt how much hamper production because of delay of sourcing rawmaterials. Normally factory planner discuss with supplier about lead time for sourcinggoods prior to making the final production scheduling. But suppliers fail to send good

on time due to too many uncertainties. Sourcing delays also consumed extra time and

make it difficult to start in-house processes on time.

5. Sometime to complete production harry as per urgency, not having much time onhand, managers push everything on fast pace. That time they give much importance

on quantity forgetting quality which is also create problems in WIP control.

6. There has some way to reduce WIP from bottleneck operation; at first save timethrough method improvement, because as much time as can save through method

improvisation from bottleneck operation there has chance to get better production that

will in turn reduce WIP level, some time also reduce bottleneck by sharing operation

one to another operators, adding additional manpower or machine is a common seen

to reduce bottleneck. Improving workstation layout is much technical and helpful wayto reduce WIP from bottleneck. Better operator allocation, work for extra time, using

of time saving tricks are also helps to reduce WIP from bottleneck


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pg. 27

Conclusion

From my experience of two month in this organization I have learnt many things. The most

important is that practical professional life is very hectic, competitive and tough. The best

thing, which I am able to find out, is that the stronger the culture of the organization betterwill be the productivity. In Readymade Garments (RMG) sector the thing of limitless

importance is how well the organizational personnel communicate with each other. There is

no room for personal grudges or aversion because each and every one depends on each other

if any one screw up the whole organization suffers.

As an Intern-Student I had the opportunity to visit all of the departments and sections of this

company. This experience will be my valuable asset for my future career path. In the class

rooms I have been thought everything that is needed for the apparel manufacturing. With the

acquired knowledge when I sent for the internship program in a manufacturing company I

had the opportunities to justify acquired knowledge and also gain some practical experience

on the subject.

I have included my entire learning outcome from this study for two month in an apparel

manufacturing company in this report. After doing internship and making this report I ammuch more confident than before. Now I can confidently take responsibilities and can face

problems happens in factories. Those knowledge, I have gather in this two month has

immense importance for me to start my career as an eminent merchandiser.


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pg. 28

References

American Eagle Polo. (2012) Style# 6722, PO#67304. [Photo]. In: International Knitwear &

Apparels Ltd.

ESSES Fashion Ltd. (2012). Company Profile. [Online] Available at:

http://www.essessfashions.com/Access date: 4/4/12.

People's Republic of Bangladesh, Ministry of Labor and Employment. (2006). The

Bangladesh Labour Act, 2006. Dhaka: Bangladesh Ministry of Labor and Employment.

Bibliography

Company profile I got the information regarding product profile, buyers, and core values.

SWOT information gets from Senior Managers.

HRD information get form HR Officer.

Export related data gather from Export Manager.

Import related data gets from Import manager.

Merchandising related data from merchandising manager.

Process related data collect from different departmental heads.


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pg. 29

Reflections

First day I went to the BEXIMCO industrial park, Sarabo, Kasipur that was great. That is a

beautiful place where everything, i.e. spinning, weaving, knitting, dyeing, washing, printing,

and garment factories are setup horizontally in one premises.

When I reached at their head office I seen one storied building fully covered with glass and

surrounded by beautiful garden with different flowers.

After starting my internship in IKAL1 & ESSES it was little difficult for me to understanding

their working process and environment at initial days. But after getting guidance from Mrs.

Shazia Amanat, Mr. Tarun Pandey, Md. Rafiqul Hasan, and Md. Shahabul Alam Biswas I

made a working schedule and start working department wise.

First day I just visit all the departments and seen the process flow of factory and all the

machine are using in production floor.

As an intern I got the chance to visit all departments, but as not I am doing job there I do not

get the chance to work like an employee. But however I start my work and observed workingprocess of all departments one by one.

At first I have start my work from CAD department. From where I have learnt about Lactra

CAD software, pattern and marker making with software, about plotter and digitizing board.

After CAD department I shift to the sampling department where I learnt all the samples are

made by the sampling department. Here I have seen the sectional production system, where

multi skilled operators are working.

After sampling I shift to storage department where I learnt the system of collecting and

storing fabric and accessories in store. I have also learnt the process of output of materials

from this department.

After store I have learnt many things from quality department. All the things I have learnt

from this department are about quality maintaining of product as well as company reputation.

4 point quality checking system I was learnt at my class room but when I work under QC

manager with this system practically I have seen many things become clear about this quality

checking system.

When I gone to the cutting department and work under cutting manager I got the practical

knowledge about cut order planning, lay planning.

Then I have shifted to the IE department, an important department in which I have interested.

In this department I have work under senior IE officer. Working in this department I have

learnt about different sewing machines, stitch classes, different sewing operation to make agarment. Then I have worked with an IE person in a line where production of ladies tank top

was going on. I have placed there to apply my class room knowledge to finding out problems

happening in line, viz. WIP. To finding out problems I have applied time study and motion

study on line; I also solve the problem with IE officer through line balancing.

I balancing that line I was little scare because it was my first time practical work in factory

and changing some operation here and there production was little slow but after half an hour


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pg. 30

workers habituated with this changes line production efficiency increased 3% where it was

64% before.

From this work of motion and method study I have learnt one most important thing that if

you push worker to do something in your way you will not get proper efficiency and also

there seems any problems latter worker will say that you told him to do this way. In this case

every IE person have to discuss with the line super and worker who going to do this work.Worker knows about that operation batter, that, in which way this work is much easier as well

as much efficient for production.

After then I have shifted to the planning department where I found the biggest draw back in

the time and action plans of PPC in IKAL is that there is no contingency planning in advance

it is a general rule that while planning production some cushion is given for activities such as

machine break down or any other extraneous variables that can take place. The problem is

addresses only when it occurs. There should be planning in advance for that in order to

minimize the effects of a problem that has occurred.

According to PPC personnel due to some Management Information System takes by

merchants in providing production summary they end up making garment, which was not

required at all. In order to avoid this kind of scenarios the merchants need to be absolutely

sure what is required and the PPC personnel should clear any ambiguities before going for

production and should recheck with the merchant the basic requirements.

Although there is a co-ordination manager present but still personal interest of all the

departments is required in order to make the coordination free of any doubts. There should be

clear lines of communication established between the departments. Every concerned person

should know what is going on and what was required so that controlling should not only limit

to the PPC department. From Knitting to Finishing every responsible person should have a

clear idea what he needs his team to do.

Buyer due to the fact that the merchant cannot forward the purchase order gives Some times

the co-ordination gap to PPC, as it is a secret. Only production summary is prepared and isgiven to PPC so if merchant makes a Management Information System take in interpreting

the PO there is no way PPC can come to know about if there are any ambiguities in the

production summary. Sometimes the merchant delays in forwarding information as it arrives

to him resulting in delay to initiate the production process.

One of my most interesting departments is merchandising department. In department I have

seen how difficult is managing everything or every site, i.e. managing all of processes

between buyer, suppliers, and manufacturers. One most important thing I have learnt from

this department is never left you work for latter. Complete you work just right that time when

it comes to your hand. Because when I start work in this department under a senior

merchandiser he shown me a time and action calendar. Then I have realized if I want to

shipment product on time I always have to remember my time schedule.


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Glossary

AQL: Acceptable Quality Level

BEXIMCO: Bangladesh Export Import Company

CAD: Computer Aided Design

Dept: Department

ERP: Enterprise resource planningIE: Industrial Engineering

IKAL: International Knitwear and Apparel Limited

PO: Purchase order sheet

PPC: Production Planning and Control

QC: Quality Control

SMV: Standard Minute Value

Spec sheet: Specification sheet

T&A: Time and Action Calendar

Tech Pack: Technical Package

Abdullah Ali Akbar Reja Internship Report

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Transcript of Abdullah Ali Akbar Reja Internship Report