Industrial attachment

DEPARTMENT OF TEXTILE ENGINEERING

Dhaka, Bangladesh

INDUSTRIAL TRAINING

Course Code: TE410

INDUSTRIAL ATTACHMENT

FASHION MEET LTD

PREPARED BY

Name: Md. Sabbir Alam

ID: 111-0355-007

Department: Textile Engineering

Email: [email protected]

Atish Dipankar University Science and Technology

Textile Engineering Department

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1.1 ACKNOWLEDGEMENT

Industrial Attachment Course is an academic function of the AtishDipankar University. Like all other years our teacher Prof. Dr. SM Mominul Haque, Chairmen of Department of Textile-Engineering, Gave us an opportunity to choose preferable mills for Industrial Attachment Course. I am a student of 5th batch choose the Fashion Meet Ltd. joyfully with the supervising teacher Mr. Asad Al Farabi.

During the attachment with The Fashion Meet Ltd I worked in all the departments related with the Garments Manufacturing Technology. I learned about quality control section, warehouse, store & Finishing. I owe a particular debt of gratitude to Md. Kamrul Hasan, Manager(Merchandising), Md.SorwarHossen,GM (Production & Head Of The Factory) in Fashion Meet Ltd. They gave always some of his valuable time regularly in helping me to achieve my intended goal. I also express our gratitude to all the executives of cutting, sewing, finishing, store & inventory control. Of course I wish to pay my special thanks to the persons guided me cared during this days- MD. Kamrul Hasan, Manager,(Marketing &merchandising Dep’t. of Fashion Meet Ltd). However, I have prepared my Industrial Project overcoming all the difficulties & also the shortage of time. Here I would like to present the report.

Md. Sabbir Alam

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Chapter-IProject Description

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TEXTRIMS GROUP100% Export oriented knit wear Manufacturer.

ADDRESS: FACTORY

Rashid Market, Gazirchat, Ashulia, Savar, Dhaka.

ADDRESS: HEAD OFFICE

Main Road,H-1012,2ndfloor,Mirpur DOHS, Dhaka.

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Preface

We would like to introduce ourselves and highlight our company’s role in the produce and supply of quality textile and apparel products to the world market from Bangladesh.

In today’s sourcing world no major player in apparel industry can ignore Bangladesh’s capability in offering quality and valued products.

FASHION MEET LTD has the capability to ensure quality services, timely deliveries, competitive price and adherence to customer’s quality standards.

In today’s world the key to success of any customer is to identify the country to source the right product at right price. This is where we will step in to cater your needs.

Our company maintains a constantly high standard of business conduct. ethics and social responsibility. We take pride in the efficiency of what we do and always employ the most effective and latest technology available.

We are committed to grow and improvements of all aspects of our operation and will continue to be the leader in our industry.

Product Range: We would like to draw kind attention of valued customers that, we are a ready-made garments exporter with well-established market outlets in Europe and USA. We are producing & supplying wide range of knitted garment and have earned a well-deserved reputation for quality, competitive price and prompt delivery.

Kids Wear:

Baby Suit, T-shirt, Polo Shirt, Shorts, Trousers, Night Wear, Diaper set, Baby rompers,

Sweat Shirt, Tops, Trouser, Formal & Casual Wear etc.

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Women’s Wear:

Swim Wear, Night Wear, Casual Wear, Party Wear, T-Shirts, Polo Shirts, Tank top , Trousers,

Designer Tops, lingerie, Shorts, Skirts, Capri, Formal Wear etc.

Men’s Wear:

T-Shirts, Polo Shirts, Boxer Shorts, Bermuda, Sports Wear, Night Wear, Trousers, Shorts, Jackets, Beach Wears, Under Garments, Lower, Party Wear, Casual Wear, Formal Wear etc.

Others following Items :

Embroidery, Printing, all sorts of Elastic, Tape, Drawstring, Draw Card, Poly Bags, Sewing Thread,

Gum tape, Hang Tag, Photo Card, etc.

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Our Management Net:

Mr. RamivMehedi Chowdhury Rossi (CEO)

Cell No : +880-1729 091191

E-mail :[email protected]

Mr. MasumuzzamanShohan (COO)

Cell No : +880-1784 890570


Mr. ZahirRayhan (Group Director )

Cell No : +880-1923332666


Md. Kamrul Hasan ( Head of Merchandising )

Cell No : +880-1717494211


Bank Details : The Farmers Bank LimitedGulshan Corporate Branch, 59-61 Gulshan South Avenue,

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mailto:[email protected]

mailto:[email protected]

Gulshan-01, Dhaka- 1212, Bangladesh.Tel : +88-02-9858066-70

Established Year : 2012

Floor Space: 65, 200SFT (Single Floor only)

Certification : BSCI.

Installed Export Capacity : US$ 18.00 million per year.

Projected Export (2015) : US$ 9.50 million (by Dec-2015)

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MACHINERY & EQUIPMENT.

SEWING MACHINE

SLNAME OF

THE MACHINE

MODEL BRAND ORIGIN QTY.

1SINGLE NEEDLE PLAIN (AUTO)

MO-6714D-BE6-44H JUKI JAPAN 140

2OVER LOCK

(AUTO)DDL-9000BMS-7-WB JUKI JAPAN 120

3FLAT LOCK ( FLAT BED)

MF7723-U10-B56 JUKI JAPAN 20

4FLAT LOCK

( SYLINDER BED AUTO)

MF7823-U10-B56/UT25/SC921C

JUKI JAPAN 30

5FLAT LOCK

( SYLINDER BED AUTO)

MF7823H12B56/UT25/MC35 JUKI JAPAN 14

6FLAT LOCK

(CUP SYLINDER)MF7223D/U10-B56 JUKI JAPAN 2

7BACK TAPE

( CHAIN STITCH)DLR-1502L

KANSAI SPECEIAL

JAPAN 16

8 TWO NEEDLES LH-3528ASFA JUKI JAPAN 6

9BUTTON HOLE

(AUTO)LBH-1790S/MC601KSS JUKI JAPAN 4

10 BUTTON STITCH LK-1903ASS-301/MC-596- JUKI JAPAN 4

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(AUTO) KSS

11BARTACKING

(AUTO)LK-1900ASS/MC596KSS JUKI JAPAN 4

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12 ZIGZAG (AUTO) 22908 JUKI JAPAN 2

13PLAIN MACHINE

VARTICALDLM-5200ND JUKI JAPAN 10

14 PICOTING EC-700MKANSAI

SPECEIALJAPAN 2

15KANSAI

SPECIAL(AUTO)DFB-1404PMD

KANSAI SPECEIAL

JAPAN 4

16 SNUP BUTTON GMC CHINA 10

TOTAL QTY OF SEWING MACHINES 388

OTHER MACHINE

SL NAME OF THE MACHINE MODEL/ORIGIN

QTY.

1 CUTTING MACHINE K.M KS.AU-V-8" 2

2 CUTTING MACHINE K.M KS.AU-V-10" 6

3 BAND KNIFE MACHINE PX-302-4W 1

4 PIPING CUTTER L-U922 6

5 LABEL CUTTING MACHINE CHINA 8

6 THREAD CLEANING MACHINE (SUCKER) CHINA 2

7 VACUUM IRONING TABLE (COOL SET BRAND)

CST-ST 40

8 STEAM IRON (RAMSONS BRAND) N/A 40

9 FUSING MACHINE HASIMA 1

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10 HEAT PRESS MACHINE CHINA 10

11 FABRIC INSPECTION MACHINE CHINA 1

12 LIGHT BOX ( VERIVIDE) CAC 60-5 1

13 COMPRRESSOR ( 60 HP) CHINA 1

14 WASHING MACHINE CHINA 1

15 METAL DETECTOR HASHIMAModel:HN-770G-

100

1

16 BOILER LOCAL MADE 2

17 GENERATOR (500 KVA) CUMMINS UK 1

FACTORY PICTURES

Factory Entrance Sewing Unit

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Sewing Floor (inside view) – 37000 sft in a single shed

Sewing floor

Sewing shed Doctor’s Room

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Needle detector machine at Finishing unit Carton storage at Finishing unit

Sample section Finishing unit

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Sewing unit view from west side

FACTORY COMPLIANCE

BSCI: DBID No. 347385

Accord Audit pending, tentatively by End December-2015.Thank

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TEXTRIMS EMBROIDERY SECTION

.

Established : 2005

Product Range: All kind of Embroidery

Floor Space: 8,000SFT

Production capacity: 4,726 Million Stitch /Month.

Total Employee: 256 (Officer & Staffs: 10,Workers :246).

Machinery & Equipment.

SL Description Quantity

01 Computerized 09 Color 15 Head Sequence Double Device Machine (China)

01

02 Computerized 09 Color 20 Head Sequence Single Device Machine (Japan)

01

03 Computerized 09 Color 20 Head Flat Machine (China) 05

04 Computerized 06 Color 20 Head Flat Machine (Japan) 04

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05 Computerized 09 Color 20 Head Flat Machine (Japan) 04

06 Computerized 09 Color 08 Head Flat Machine (Korea) 01

07 Leaser Cutting Double Head Machine C.M.A Brand (China) 01

08 Dice Cutting Machine (China) 01

09 Quality Controller Heat Machine (China) 10

10 Re-Made Machine (China) 02

11 Fusing Machine HA-SHINA (Japan) 01

12 Generator ( 550 KW) 01




Managerial Workforce

SL Designation Number of Post

01 Manager 01

02 Production Manager 02

03 Marketing officer 05

04 Delivery Man 02

Garments Embroidery Workforce.


01 Senior Supervisor 04

02 Designer 02

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03 Senior Operator 32

04 Junior Operator 96

05 Helper 64

06 Sample Man 02

07 Quality Controller 28

08 Q.C Inspector 16

09 Electrician 02

TEXTRIMS SCREEN PRINT SECTION

Established: 2005


Production capacity: 4,00,000 Pcs ~14,00,000 Pcs/Month.

Total Employee : 202 (Officer & Staffs: 09,Workers : 193 )

Printing Equipment

SL Description Capacity

01 Glass Table 75 fit X 11 (Production space) 825 fit

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02 Glass Table 80 fit X 08 (Production space) 640 fit

03 Glass Table 30 fit X 02 (Sample space) 60 fit

21 Tables. Total Space = 1525 fit.

Managerial Workforce.


01 Manager 01

02 Production Manager 01

03 Marketing officer 04

04 Delivery Man 03

Garments Printing Workforce.


01 Senior Supervisor 04

02 Designer 01

03 Screen Man 62

04 Lear Man 35

05 Helper 30

06 Senior Sample Man 04

07 Line Quality Controller 20

08 Quality Controller 25

09 Q.C Inspector 10

10 Electrician 02

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SL Designation Quantity

01 Curing Machine Conveyer belt System 02

02 Curing Machine Hydraulic Press System Double Plate 14

03 Expose Camera 02

04 Flock Machine 05

05 Hand Dyer Boss 140

06 Expose Frame Wash Machine 10

07 Auto Frame Setting Machine 01

08 Manual Frame Setting Space 04





Our Facilities at a Glance.

Textile Print. Rubber Print. Metallic Print. Foil Print. Sugar Print (on any background). Discharge Print. Stone on any fabric. All over reactive Print. Pigment Print. High-density Print.

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Emboss Print. Special Printing on Denim, Nylon & Artificial Fabric. Heat Transfer Print. Reflective Print. Photo Print. Gel Print. Glitter Print. Flock Print. Puff Print. Crack Print.

Our Commitments.

Sample Support. Quality Flow up. Properly Delivery Flow up.

TEXTRIMS THREAD SECTION

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Established: 2007


Total Employee: 40 (Officer & Staffs: 6,Workers: 34)

Product Range : Sewing and Embroidery thread

Production capacity : 1, 70,000 cone ~2, 00, 000 Cone /Month.

1 Sewing Thread 2,00,000 Cone / Month

2 Embroidery Thread 2,00,000 Cone / month

3 Yarn Dyeing 5000 KG

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SL MACHINES NAME

ORIGIN CAPACITY Q’TY

1 Dyeing Machine China 160 lbs 01 pcs







8 Lab dip Machine China 01 pcs

9 Hydro China 50 lbs 01 pcs

10 Dryer China 01 pcs

11 Shade Light Box China 01 pcs

12 Railing Machine China 02 pcs

13 Hangs machine China 06 pcs

14 Coning Machine China 12 pcs

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TEXTRIMS ELASTIC SECTION

Established: 2007


Total Employee: 15 (Officer & Staffs: 1,Workers : 14)

Product Range :All type of Crochet Knitting Elastic

Production capacity : 2,00,000 Pcs ~4,00,000 Yds./Month.

1 300~1050 Denier 1 cm 4,00,000 Yds. / Month

2 300~1050 Denier 2.5 cm 2,00,000 Yds. / Month

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SL MACHINES NAME

BRAND ORIGIN HEAD Q’TY

1 Crochet Knitting

TCH-LB5000

Taiwan 4 pcs

2 Crochet Knitting

TSEB-803B3

Korea 2 pcs

3 Elastic Rolling M/C

2 pcs

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TEXTRIMS TAPE SECTION

Established : 2007

Floor Space : 800SFT

Total Employee : 7 (Officer & Staffs : 1, Workers : 6)

Product Range :All type of Twill tape / Herringbone tape

Production capacity : 2,00,000 Pcs ~4,00,000 Yds/Month.

1 1 cm ~ 4 cm 4,00,000 Yds / Month

2 5 cm ~ 8 cm 2,00,000 Yds / Month

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SL MACHINES NAME

BRAND ORIGIN HEAD Q’TY

1Twill Machine SEAHWA

LOOMKOREA 8 1 pcs

2Twill Machine SEAHWA

LOOMKOREA 4 1 pcs

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TEXTRIMS POLY SECTION

Established : 2007


Total Employee : 10 (Officer & Staffs : 1,Workers : 9)

Product Range :All type of Poly

Production capacity : 50,000 kg ~60,000 kg/Month.

1 PP Poly 30,000 kg / Month

2 LDP/ PE Poly 30,000 kg / Month

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SL MACHINES NAME

BRAND ORIGIN

HEAD

COLOR Q’TY

1 PP Poly Machine BD 1 pcs

2LDP/PE Poly

MachineBD 1 pcs

3 Poly Printing HJ-4001 Taiwan

4 color 1 pcs

4 Poly Side selling LY-800S Taiwan

1 pcs

5 Bottom selling EXK-32 Taiwan

1 pcs

6 BOPP Folding Devisor

China 1 pcs

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TEXTRIMS GUM TAPE SECTION

Established : 2007


Total Employee : 3 (Officer & Staffs:, Workers : 3)

ProductRange :All type of Gum Tape

Production capacity : 2,60,000 Roll ~15,60,000 Roll/Month.

1 6.5 cm Gum tape 2,60,000 Roll/ Month

2 1 cm Gum tape 15,60,000 Roll / Month

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SL MACHINES NAME ORIGIN Q’TY

1 Gum tape slating m/c Taiwan 1 pcs

2

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TEXTRIMS OFFSET PRINTING PRESS

Established : 2007


Total Employee : 10 (Officer & Staffs :1 ,Workers : 9)

Product Range :All type of Press Printing

Production capacity : 10,00,000 Roll ~15,00,000 pcs/Month.

1 Hang Tag 15,00,000 pcs/ Month

2 Photo Board 8,00,000 pcs / Month

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SL MACHINES NAME

BRAND ORIGIN COLOR Q’TY

1Offset Printer HEIDEL

BERGGerman Multi 01 pcs

2 Paper Cutting M/c China 01 pcs

3 Dye cutting China 01 pcs

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TEXTRIMS CARE LABEL SECTION

Established : 2007


Total Employee : 4 (Officer & Staffs :1 , Workers : 3)

Product Range :All type of Press Printing

Production capacity : 26,00,000 ~30,00,000 pcs/Month.

1 Printed Care Label 30,00,000 pcs/ Month

2

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SL MACHINES NAME ORIGIN COLOR Q’TY

1 Care Label Printer China 5 color 01 pcs

First Aids Box:

First aids box is provided each floor by “The Fashion Meet Ltd.”. The First aid boxes are contained the following items:

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Nix. Surgical gauze. Or-Saline. Paracitamol Antiseptic cleaner (Savlon). Roller bandages Cotton. Surgical scissors. Tourniquet. Adhesive tape (plasters). Antibacterial ointment sterile (Savlon cream).

Fire Protection:

The Fashion Meet Ltd. has own Fire section and firefighting equipment. Each floor wall is contained firefighting equipment and wall post, which create awareness about fire and use of firefighting equipment. Also the company arrange training

program on fire protection.

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Duties & Responsibilities of Different Post

Managing Director:

To deal with the buyer and merchandiser. To set up price for the product. To plan apply and control all administrative functions. To follow up the instruction of managing director and chairman. To supervise the personal working under him To plan the sequence of production

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To arrange necessary raw materials for the production problems. To find out the possible reasons which are responsible for less production? To follow up the instruction of Managing Director and Executive Director as

well.

Deputy General Manager (DGM) (production):

Overall supervision of dyeing and finishing section. Check the sensitive parameters of different machines for smooth dyeing. Check the different log books in different areas and report to management. Check the plan to control the best output To trained and motive the subordinates how to improve the quality

production. Control the supervisor, operator, asst. operator and helper of dyeing

machine. Any other work as and when required.

Senior Production Officer:

Overall supervision of dyeing and finishing section. Batch preparation and pH check. Dyes and chemicals requisition issue and check. Write loading/unloading time from machine. Program making, sample checking color measurement.

Production officer:

To collect the necessary information and infrastructure from the previous shift for the

To match production sample with target shade. To match production sample lot sample matching next production.

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To observed dyed fabric during finishing running and also after finishing process.

To identify disputed fabrics and report to PM/Gm for necessary action. To discuss with PM about overall production if necessary. To sign the store requisition and delivery challenge in the absence of PM To execute the overall floor work. To maintain loading/unloading paper. Smooth running of the section.

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Chapter-02Garments Section

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The garment production processing steps and techniques involved in the manufacturing garments for the large scale of production in industrial basis for business purposes is called garments manufacturing technology.

Garments Manufacturing Process Flow ChartDesign / Sketch

Pattern Design

Sample Making

Production Pattern

Grading

Marker Making

Spreading

Cutting

Sorting/Bundling

Sewing/Assembling

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Inspection

Pressing/ Finishing

Final Inspection

Packing

Sample Development Process in Garments:

Measurement Chart Remake

Design Sketch Received Comment

Pattern Making

Garment Sample Making

Send To the Buyer

If not Ok If Ok

Approved Sample

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Measurement Chart:

Measurement Chart is known as technical chart. A measurement chart is a detailed description of garments. It is also merchandising detailed sheet. By this sheet at first the sample of the garment is prepared then after approved the sample the bulk order is produced. In a product package the information for a garment can be achieve:

Style no. of garments.

Item no. of garments

Design of garments.

Measurement list of garments.

Colour of the garments.

Size of the garments.

Packing information of the garments.

Folding instruction of the garments.

Types of sewing thread used in different garments.

Types of stitch used in the garments

Types of trimmings & accessories used for the garments.

Exact place of attaching the accessories.

Instruction of care label.

Types of fabric used.

Consumption & Construction of the garments.

Types of Sample:

1. Fit Sample: The sample which is made by following only the measurement chart. Then the sample we gate is called fit sample.

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2. Photo type Sample: Actual fabric and the accessories used to make this fabrics then it is send to the buyer. It is only one size Like “M”.3. Size Set Sample: When all size of sample are included in a set those sample is called is size set sample.

4. Production Sample: During production some of the sample garments collecting from the production line then send to the buyer these are called production sample.5. Shipping Sample: After final inspection, when shipment the goods to the buyer destination some sample should be send to buyer air advanced this sample are called shipment sample.6. Approved Sample: The sample which is approved by buyer.

Some Information of Sample Section

Manpower:

Technician : 01 Pattern Master : 01 Quality Controller : 02 Cutting Man : 01 Skilled Operator : 08 Cleaner : 02

Equipment:

4 Needle Flat Lock : 02 set 3Needle Flat Lock : 02 set 4Needle Over Lock : 02 set Plain Machine : 04 set Elastic Attaching Machine : 01 set Button Attaching Machine : 01 set Cutting Table : 01 set

Fabric Spreading:

Spreading means the smooth laying of fabric in specific length and lay according to the buyer requirement. The cutting marker paper is laid in the top of the fabric layer. Generally number of the lay depends on the thickness of the fabric and the height of the fabric. There are different

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types of spreading method. But in Bangladesh the Straight method of spreading is used. In Straight method, every ply is placed according to the marker length.

Fig: Fabric Spreading

Marker Making:

Marker is a thin paper where all parts of a Style drown by placing pattern by pencil and then it placed upon a lay and cut along the drawing line is called marker. The process of making a marker is called marker making. There are many types of method are use for marker but Hypoid Composite Knit used only manual method.

Point to be checked during marker making:

Mismatched checked or stripe. Over Lapping. Parts missing. Pattern direction. Pattern alignment. Marker too wide then fabric.

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Fig: Marker Making

Factor related to marker efficiency:

1. Marker planner: Marker depends on experience, honesty, sincerity, trial and technical knowledge. Higher the number of marker is the possibility of higher efficiency.2. Size of garments: Higher the number of pattern size is the possibility of higher efficiency.3. Marker length: Higher the marker length higher the efficiency. It can also help to increase the production capacity of cutting room.4. Fabric characteristics: Systematical fabrics are those which are similar to all direction. Marker efficiency is good in this type of fabrics.5. Marker width: The more the fabric width is easier to plan or make marker which will increase the efficiency.

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Cutting Section

Flow chart of cutting section

Fabric Checking

Fabric relaxation

Fabric spreading

Marker making

Cutting

Numbering by Sticker

Bundling

Deliver to the sewing section

Some Information of Cutting Section:

Manpower:

Cutting Manager : 01 Quality Controller : 04 Cutting Supervisor : 01 Marker Man : 01 Cutting Man : 02 Input Man : 02 Cutting Assistance : 20

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Equipment:

Cutting Table : 02Cutting Machine 12” : 04 Bend Knife : 01 Numbering Machine : 01 Cutting machine (Straight Knife):

Brand Name : MACK. Country of Origin : Japan Company : K. M. Cloth Cutting Machine CO. Ltd. Volt : 220 V. Model : KS-AU. Quantity : 05 pcs.

Feature of Straight Knife:

Possible to cut pattern pieces decertify from the fabric lay. Could be used to cut for higher depth of fabric. High Cutting speed. Sharp and heavy comers can be cut. Blade could be sharpened by attached grinding facilities. Blade could be sharpened by attached grinding facilities. Blade height 10 to 33 cm. Blade stroke 2.5cm to 4.5cm.

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Fig: Fabric Cutting

Sorting/ Bundling:

The sorter sorts the patterns according to size and design and makes bundles of them. This step requires much precision because making bundles of mismatched patterns can create severe problems. On each bundle there are specifications of the style size and the marker too is attached with it.

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Fig: Numbering Machine

Sewing Section

The sorted bundles of fabrics are now ready to be stitched. Large garment manufacturers have their own sewing units other use to give the fabrics on contract to other contractors. Stitching in-house is preferable because one can maintain quality control during the processing. On the other hand if contractors are hired keeping eye on quality is difficult unless the contactor is one who precisely controls the process.

There are what is called sewing stations for sewing different parts of the cut pieces. In this workplace, there are many operators who perform a single operation. One operator may make only straight seams, while another may make sleeve insets. Yet another two operators can sew the waist seams, and make buttonholes. Various industrial sewing machines too have different types of stitches that they can make. These machines also have different configuration of the frame. Some machines work sequentially and feed their finished step directly into the next machine, while the gang machines have multiple machines performing the same operation supervised by a single operator. All these factors decide what parts of a garment can be sewn at that station. Finally, the sewn parts of the garment, such as sleeves or pant legs,are assembled together to give the final form to the clothing.

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Flow chart of sewing section

Received bundle of different parts from cutting section

Open the bundle

Through it to the sewing

Sewing the garments

Finished the sewing

In line inspection

Send garments to the finishing section

Some Information of Sewing Section

Manpower:

General Manager : 01 Production Manager : 01 Assist. Production Manager : 01 Line Chief : 05 Supervisor : 10 Operator : 110 Operator Assistance : 115 Iron Man : 15 Store In-charge : 01 Store Assistance : 03

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Plain Machine : 95 set 4 Thread Over Lock : 56 se 3Needle Flat Lock : 42 set 4Needle Flat Lock : 03 set Auto controlled 1 Needle Lock stitch : 02 set Elastic Attaching Machine : 03 set Button Attaching Machine : 02 set Button Hole machine : 02 set Back Top Machine : 03 set Bar Tack Machine : 02 set 2 Thread Over Edge for Butt and Sewing : 02 set Knasai Special : 07 set Dino Automatic Rib Cutter : 02 set Thread Sucking Machine : 01 set Oshima Needle Detector : 01 set Oshima Needle Inspection : 01 set Heat Transfer Label Attaching Machine : 03 set Snap Button Attaching Machine : 03 set Viet Steam Iron : 15 set

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Fig: Sewing Section

Some Machine Pictures Used in Sewing Section

Fig: Zig-Zag Machine Fig: Overlock Machine

Fig: Flat-bed, Top and Bottom Cover stitch M/c Fig: 2 needle chain stitch machine

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Fig: 1 needle chain stitch Fig: Button sewing m/c

Fig: 1 needle lock stitch Fig: Button Holing

Fig: Bar Tacking machine Fig: 2 needle Lock stitch

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Fig: Snap Button Machine

Machine Details in Sewing Unit

Machine Brand Name Country of Origin

Sets Total Quantity

Plain MachineSiruba Japan 20

95Juki Japan 62Sunsir Japan 13

Over lock Machine

Siruba Japan 756Juki Japan 44

Yamata Japan 5

Flat Lock cylinder bed

Siruba Japan 4

20Juki Japan 13

Sunsir Japan 3

Flat Lock Flat bed

Siruba Japan 4

25Jiki Japan 14

Yamata Japan 3Gemsey Japan 4

Back Tap Siruba Japan 3 3

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Machine

Kansai Special Kansai Japan 7 7

Button Attaching Machine

Siruba Japan 12

Jiki Japan 1

Button Hole Machine

Jiki Japan 2 2

Snap Button Attaching Machine

GMC China 3 3

Rib Cutter machine

DINO Taiwan 2 2

Bar Tack Machine

Jiki Japan 2 2

Needle Detector Machine

Oshima Taiwan 1 1

Fabric Inspection Machine

Oshima Taiwan 1 1

Heat Transfer Label Attaching

Machine3 3

Definition of Needle:

Needle is used to sew the fabric. An appropriate sewing thread is feed into the needleto sew the fabric by needle. Needle make a hole in the fabric without any damage and make a needle thread loop and pass this loop through the loop of lopper thread to make bond to each other.

Name of Some Needle

Machine NameNeedle used for Machine

Wise Needle Size

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Plain Machine DB 7,9,11,14,18,21

Over lock Machine DC 7,9,11,14

Flat Lock Machine UY 128 7,9,11,14,16

Button Hole Machine DP×5 7,11,14,16

Button Attaching Machine

TQ or DP×14 9,11,14

Kansai Special UO×1 9,11,14

Some information of needle:

Company Name : Organ Origin : Japan Price : 10-25 Tk. (Per Needle). Company Name : Grosebeker. Origin : Japan. Price : 10-20 Tk. (Per Needle).

Broken Needle Policy:

All needles must be security stored. Only authorized staff may distribute new needle. New needle only distribute upon exchange of a full broken needle. .When a needle

breaks, search the whole area to locate all parts. All needle parts to be attached or recorded on the needle control sheet. If any parts of the broken needle cannot be found, the surrounding work must be removed

and metal detected to locate the missing fragments. If all parts cannot be found then these work pieces or bundles must be destroyed.

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Records of all incidents must be kept and available for auditing. Retain record sheet for 12 months.

Time Study for the Women’s T-shirt in Fashion Meets Ltd.:Join Parts Name No. of Machine Production Per hour

Tape joining 1 200

Back piping (Neck) 1 250

Shoulder joining (One side) 1 250

Shoulder tuck 1 300

Neck piping 1 200

Neck Tuck 1 300

Shoulder Joining (Other side) 1 200

V-Tuck 1 300

Chap tuck 1 200

Sleeve joining 2 100

Label joining 3 250

Side joining 3 240

Sleeve hem 2 240

Bottom hem 1 200

Tuck stitch 2 300

Garments Finishing

Finishing:

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Finishing is a series of processing operations applied to a textile material to improve its appearance, handle and functional properties.

Process Flow Chart of Garment Finishing:

Finishing input (style, colour& size wise) ↓

Initial quality check ↓

Spot Removing↓

Ironing/Pressing ↓

Inspection ↓

Hang tag ↓

Get up change ↓

Folding ↓

Poly ↓

Bar code (buyer wise sticker) ↓

Metal check ↓

Cartooning/Packaging↓

DispatchObject of Finishing:

To enhance the suitability of the fabric for end use. To improve appearance and sale appeal for comport and utility. To give desirable

qualities to the fabric like-

1. Luster 2. Drape3. Dimensional stability 4. Crease recovery5. Softness6. Soil repellence

Working Flow in the Finishing Room:

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As mentioned earlier, workflow in the Finishing Department is shown here for reference: Eliminate micro-dust and residual thread from the garment; Press/iron garments as specified by buyer or as per requirements; Fold the garments as required by customer; Fix necessary tickets (Price tickets) or tags (hang tags),etc to the garments at this stage; Insert garments into poly bags; Divide garments as per size and color (assortment); Package garments inside the cartons.

Characteristics of Well Finished Garments:

Good fitting is achieved by doing the work with care, patience and practice. A well-fitted garment feels comfortable, adjusts naturally to the activities of the wearer, is becoming in line and amount of ease and consistent with current fashions. Initial Production Check:This is carried out when the production of the total quantity of an order or partial delivery is completed. A sample lot will be selected from the order and a percentage of the garments will be inspected, this percentage usually being stipulated by the buyer. The AQL sampling inspection may be applied or another inspection system designed by the buyer.

The General Rules of Spot Removing:

1. The longer a stain remains, the tougher it is to remove.

2. Always treat a stain before laundering.

3. Blot gently — never rub; and don't ever blot with hot water.

Lipstick Stain Removing:

Blot with a baby wipe or a washcloth moistened with rubbing alcohol.

Blood Stain Removing:

If it's fresh, blot repeatedly with cold water, an ice cube, or club soda; if it's dried, use a 3 percent hydrogen-peroxide solution.

Oil Stain Removing:

Cover with talc or baby powder immediately and allow it to sit at least a half hour. Then brush it off, apply a stain remover (such as Spray n' Wash), and wash in the hottest water the fabric can stand.

Ink Stain Removing:

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On cotton, apply rubbing alcohol to the spot, then wash. On polyester, spray liberally with hair spray and pat with a clean, dry cloth. Then wash.

Red wine Stain Removing:

Douse with salt, dunk in cold water, blot until the stain disappears, and wash as soon as possible. If you're at dinner and unable to strip down, soak the spot with club soda and get home to your washing machine ASAP.

Ironing:

Ironing is the use of a heated tool (an iron) to remove wrinkles from fabric. The heating is commonly done to a temperature of 180–220 °Celsius, depending on the fabric. Ironing works by loosening the bonds between the long-chain polymer molecules in the fibers of the material. While the molecules are hot, the fibers are straightened by the weight of the iron, and they hold their new shape as they cool. Some fabrics, such as cotton, require the addition of water to loosen the intermolecular bonds.

Fig: Ironing Section

Basic Ironing Symbols:

Do not iron

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Cool iron (110°)

Medium iron (150°)

Hot iron (200°)

Fig: Final InspectionIroning and Pressing Equipment:In the garment industry, equipment for handling fabrics with damp heat to iron surfaces, fold edges, iron out seams, shape flat parts, and raise the pile during the manufacture of clothing. Ironing and pressing equipment shapes the semi finished garment by bringing the fabric fibers into a highly elastic state and then deforming and setting them. This is done by the simultaneous action of moisture, heat, and pressure on the fabric. Inspection Procedure of Garments are Described Below:Confirmation of Quantity: First step of garment inspection start with confirmation of Quantity with the vendors packing list by counting all Pecs of each box. If Qty is not matching to the packing list and written in the box then this discrepancy is informed to the vendor.

Size Spec inspection: After confirmation of accessories all pcs are checked as per size spec based on the instruction sheet which is given by the buyer side. If any measurement problem is noticed then we check the original sample and inform the buyer same time.

In Side Inspection: At this stage garment is checked from reverse side to ensure that there is no fabric defect, poor stitching, and stains etc in the garment.

Out Side Inspection: At this stage garment is checked from outside to ensure that there is no color variation, weaving defect, fabric defect, printing defect, holes, poor stitching, bad smell , dying defect and stains etc in the garments. Final Inspection:

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Final Inspection stage is the most important part of inspection process, here garment is rechecked to confirm that inspection is done properly without missing any checking step if any defect is noticed we put it into rejection bin or send it for repay.Hang Tag:A tag attached to a garment or other piece of merchandise that includes information about the manufacturer or designer, the fabric or material used, the model number, care instructions, and sometimes the price.

Fig: Barcode Printed Hang Tags, Price Tickets, Multicolour Preprinted Tags

Pressing or Folding:

Although pressing remains largely a manual task, new automated process exists that apply force and steam to garments placed over a body form.

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Fig: Folding

Packaging:

After final inspection, the garments are poly-packed, dozen-wise, color wise, size ratio wise, bundled and packed in the cartoon. The cartoon is marked with important information in printed form which is seen from outside the cartoon easily.

Fig: Garments Packaging

Dispatch:The cartoons of the manufactured garments are delivered or placed in the dispatch department or finished product Go down from where the garments lot is delivered for shipment

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Chapter-03Quality assurance system

Quality assurance procedure: Inspection room and sewing line should be clean and tidy. Fabric Inspection report. Table stores easy identification Inspected and non Inspected fabric. Trim Inspection report 0.65% A,Q.I 10% total trims up to 30% in case of tan our in

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10%. Trims stores easy identification Inspected and non Inspected fabric. Color contents card. Each and every batch with collar and rib fabric. Fusing check report. Panel check report. Fabric relaxation report each and every batch import or local. Broken needle register. Process wise inspection system . Complete line file with list. Complete trims card. P.P sample to hangs in the relevant line. Size set checks records. P.P melting records. In the inspection report one for each 3000 pcs. SPC system and records. In line measurement report as per Temamaneal. First packing inspection within first 50to 1000pcs. Pre final inspection . Final inspection records. Original measurement checks records packing section style wise 100” garments.BEFORE STARTING PRODUCTION Fabric inventory. Fabric blanket individual style. 5 yds fabric to office. Accessories inventory. Trim card checking. Single poly measurement confirmed. Pre-production size set. All twill fabric/ cotton types washed before going to inline / elastics. Details pp meeting with factory/discuss possibility of problem critical area.DURING CUTTING Fabric checked based on 4 point system. Has factory out goods correctly as per latest order sheet. Fabric numbering method suitable and correct. Has factory cut shade wise( check the cutting record). Blanket shade as same per buyer approved shade.DURING IN LINE Compare pp samples comments with first output. Compare all trims against approval. Finish pattern are correct measurement. Fusing quality / color is appropriate with the fabric. Any bubbling after fusing / after wash. Is correct thread is used in bobbin and top thread. Number of stitch per cm as per buyer given requirement. Correct size needle used in each operation. Is all type of marking in line can be removed after sewing / washing.

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Measurement checked / before wash / after wash. If non denim garments are they going to washing plant. Blister poly / carton measurement.List of equipment: Abrasion and pilling tester. Seam slippage. Perspirometer. Wrinkle recovery tester. Light fastness tester. Air permeability tester. Crease recovery tester. Pressely strength tester. Spectra photo meter. Wrap block. Crock meter. Digital fibro graph. Aquraneps and length. Rape meter. Flame meter. Color matching cabinet. Launder meter.Quality standard:The standard quality level maintain is 2.5.Acceptance quality level 2.5 normal levelDeliverySizeInspectionQuantityMajor faults Minor faultsAccept Reject Accept Reject51-90 20 1 2 1 291-150 20 1 2 2 3151-280 32 2 3 3 4281-500 50 3 4 4 5501-1200 80 5 6 7 81201-3200 125 7 3 10 113201-10000 200 10 11 14 15

10001-35000 315 14 15 21 2235000-50000 500 21 22 21 22Quality report:SL.no Description of defects Minor Major01 Rivers open at front pocket 0502 Rivers missing at front pocket 0103 Broken stitch at front pocket(Bag side) 0204 Care label size missing at in side 01

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05 Over lock mark front at top side 0206 Standard at waist band 01TOTAL 04 09Remarks :Quality control department is checked all part of the fabric. It is understood that theinspection were carried out at random.

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Chapter- 04Utility Services

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Utility facilities available:Fashion Meet Ltd is located Rashid Market, Gazirchat, Ashulia where utilityfacilities available.Capacity: 500mwSource of Utility:Electricity supply from PDB, water supply own dip machine and gas supply from Titas.

Remarks: It has good utility service

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Chapter- 05Store & Inventory Control

Inventory controlInventory in a wider sense is define as any idle resource of an enterprise in order to meetexpects of demand or distribution. It is commonly used to keep hold inventory of variouskind to act as a cushion between and demand.Types of Inventory

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Inventory are of the following 06 categories:Ind1. Production inventories:Items which are used to process final product e.g. raw material andother component.2. In processes inventories:Semi finish product at various sage of production.3. Finished goods inventories:Complete product ready for dispatch.4. Maintenance repair and operation inventories:Items those do not from a part of final product are used in productionprocess like spare parts.5. Miscellaneous inventories:Scrap, surplus and obsolete item which are not to be disposed off.6. Fluctuation inventories:These are maintain to safeguard fluctuation in customer demand for theproduct or availability of material.Objective/ Advantage of inventories controlImprovement of customer friction:This is achieved through maintenance of better balance among the quantities of finished itemon one hand and customer service to the other.Reduction in manufacturing cost:Manufacturing cost can be reduce by-I. By better utilization of labor ,supervision and facilities by eliminate idle time due toraw material shortage.II. By making economical manufacturing runs in place of small lots. Constantrescheduling and set up changes which are needed to component for unbalanceinventories.III. By minimizing machine down time caused by unavailability of spare parts.IV. By reducing purchase material cost by measuring requirement.V. By keeping safe an impotent asset against theft, preventive waste ,insurable damageor unauthorized use.Improve the effectiveness of key personnel:By taking care and minimize uncertainties like uncertainties in demand from customers anduncertainties in producing the material in time.Symptoms of poor inventory management:I. Periodic server backII. Continuously growing inventory quantities while the order backlog remainingconstant or increasing.III. High rate of customer turn over and order cancellation.IV. Uneven production with frequent layoffs and rehiring.V. Frequent used for uneconomical production to meet sales requirement.VI. Excessive machine down time because of material shortage.VII. Periodic lack of adequate storage space.Different inventory costs:I. Cost of orderingII. Inventory carrying costs

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III. Costs of shortage.Cost of ordering:Cost of ordering is the amount of money expended in getting an item an inventory.To evaluate this cost we have to identify the total annual cost associate with running apurchase department. If the total number order place during the year divides this cost ,the cost per order, can be obtained.So,Cost per order=Total cost in running purchase/Total no. of order during the year.The cost of placing order can estimate by considering various cost as below-Salary and wages of personnel of purchase departmentTelephone , postage power and stationary costRent / depreciation of machines and equipment building.Inventory carrying costs:This cost is carried in maintaining the stories in a firm and can be broken down in to twocategories:a. Cost of storage space –light , rent, maintenanceb. Cost of holding stock-pilferage, spoilage, deterioration, protectionc. Other cost:Stacking , packing, issuing, recording, keeping etc.Cost that depend on the value of inventory:I. Cost of capital, interest ,lostII. Cost of insuranceIII. Cost of obsolescenceI. Internal: Overtime and special administrative efforta. The second case is lost sale case.In this case we loss customers good will and also profit.Economic order quantity:The size of an order that minimize the total inventory cost is known as Economicorder quantity.Lead time:In case of procuring materials some the length of time ,which is spent to get suppliersand parts in store after they are ordered for is called lead time.The delivery date of plant orders are calculated by considering this lead time with thedate of which they are required .Any change in this lead time will change release dateof plant orders and this change will cause the total reschedules

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Chapter- 06Cost analysis

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Costing of T- shirtFabric Type :Single jerseyG.S.M :180Yarn count :24/1Measurement of Garments:Body length : 54 cmChest length : 43 cmSleeve length : 15 cmFabric Consumption = {(Body length + sleeve length + allowance) *(Chest length + 3)} * 2/10,000 * G.S.M / 1000 * 12 * 10 % (+)= {( 54 + 15 + 10 ) * ( 43 + 3 )} * 2 / 10,000 * 180 / 1000 * 12 * 10% (+)=1.72 kg=1.72* 0.18= 1.90 kg / doz.CostingFabrics cost : 17.10Cost of making : 4.5Print cost : 3.5Lab cost : 0.20Accessories cost : 2.5Washing cost : 1Total = $ 28.80 / Doz.= $ 2.40 / pcs

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Chapter- 06Conclusion

The Ready-Made Garments (RMG) industry occupies a unique position in the Bangladesh economy. It is the largest exporting industry in Bangladesh, which experienced phenomenal growth during the last 25 years. By taking advantage of an insulated market under the provision of Multi Fiber Agreement (MFA) of GATT, it attained a high profile in terms of foreign exchange earnings, exports, industrialization and contribution to GDP within a short span of time. The industry plays a key role in employment generation and in the provision of income to the poor. To remain competitive in the post-MFA phase, Bangladesh needs to remove all the structural impediments in the transportation facilities, telecommunication network, and power

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supply, management of seaport, utility services and in the law and order situation. The government and the RMG sector would have to jointly work together to maintain competitiveness in the global RMG market. Given the remarkable entrepreneurialinitiatives and the dedication of its workforce, Bangladesh can look forward to advancing its share of the global RMG market.

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Industrial attachment

Education

Transcript of Industrial attachment