INDUSTRIAL TRAINING Course Code: Tex -4036

INDUSTRIAL ATTACHMENT OF

Divine Group of Industries Limited (DGI).

Introduction

The industrial attachment is the process, which builds understanding, skills and attitude of the

performer, which improves his knowledge in boosting productivity and services. University

education provides us vast theoretical knowledge as well as more practical attachment, in despite of

all these industrial attachment helps us to be familiar with technical support of modern machinery,

skillness about various processing stages.

It also provides me sufficient practical knowledge about production management, work

study, efficiency, industrial management, purchasing, utility and maintenance of machinery and their

operation techniques etc. The above mentioned cannot be achieved successfully by means of

theoretical knowledge only. This is why it should be accomplished with practical knowledge in

which it is based on. Industrial attachment makes me reliable to be accustomed with the industrial

atmosphere and improve courage and inspiration to take self-responsibility.

Textile education can’t be completed without industrial training. Because this industrial

training minimizes the gap between theoretical and practical knowledge and make us accustomed to

industrial environment. I got an opportunity to complete two-month long industrial training at Divine

Group Ltd. In the field of ever changing moderns fashion work Divine Group Ltd. considers it

prime mission to every new test. Which & demand of customers from around the World & all strains

human culture Divine Group of Industries Limited (DGI) acts on the basis premise that fashion is

an exploration in to the images people seek to convey about themselves & the way they live. It has

well planned & equipped Knit fabric dyeing-finishing and Garment units in addition to facilitate

knitting and knitwear manufacturing.

I have prepared this report as required in competition of my attachment course in regarding

guideline given by the university authority which will lead to a strong guideline and milestone for

my future carrier.

CHAPTER -01

COMPANY PROFILE

AT A GLANCE

Name of Company : Divine Textile Ltd.

Address : Chandra, Kaliakoir, Gazipur, Bangladesh

Phone : 06822-51229

Head Office : House No: 348, Road No: 26, New DHOS,

Mohakhali, Dhaka – 1206, Bangladesh.

Fax Number : + 88-02-9885032

FACTORY INFORMATION

Factory Type : 100% Export Oriented Knit Composite Industry.

Year of Establishment : 1997

Investor : Mr. Hasanuzzaman

Location : Chandra, Kaliakoir, Gazipur.

Annual Turnover : Tk. 10, 00, 00,000 to 12, 00, 00,000

Certification & Awards : ISO 9001:2000 & WRAP

Production Capacity : Knitting : 15.5 tons/day (Average)

Dyeing : 15.5 ton/day (Average)

Sewing : 100000 pcs/day (Average)

Main Production : Basic T-Shirt, Tank top, Long Sleeve, T-Shirt,

Polo Shirt, Shorts, Pajama, Set, Ladies ,Kids Knitwear & all

kinds of knit garments & Knit fabrics.

In the backdrop of a mercurial, ever-changing fashion world, Divine Group of Industries Ltd. considers its

prime mission to suit every new taste, whim and demand of customers from around the world and all strains

of human culture.

Divine Group acts on the basic premise that 'fashion’ is an exploration into the images people seek to convey

about themselves and the way they live.

So, in dealing with its target consumers, Divine Group mainly aims to know their perception about themselves

and translates those into Garments. Doing that, over the years, Divine Group designers have acquired an

almost telepathic understanding of the customers' needs.

Mr. Hasanuzzaman,

Managing Director

The Chief Executive of Divine Group of Industries Ltd.

Divine Group has started manufacture and export of garments since late 1997. Its mission is ti produce the

latest design; quality knit fabrics and apparels for international markets.

Divine Group is one of the few elite private sector business groups, which contributed wealth as well as

welfare to the struggling economy of Bangladesh.

As time is essential to space so is taste to its products. The secret is love-which, paired with meticulous

efficiency and a keen sensitivity to style, makes Divine Group an emerging brand destined to light up horizon

of fashion.

Divine Group has team of skilled and dedicated technocrats backed by adequate number of modern USA and

European machinery and equipment’s to match international standard of all kinds of knitwear products.

Within only a decade, Divine Group by hyper-growth has been transformed into a futuristic entrepreneurial

saga. Its production has branched out into eight full-fledged factories at four locations- Chandra, Kaliakoir in

Gazipur, Chowgasa in Jessore and Mirpur Dhaka.

Divine Group Chandra premise houses an ultra-modern Divine Textile Ltd, with forth story building as the

main one. Divine Textile Ltd Unit-2 a new 09-story building in the same premises.

Divine Fabric Ltd. a new 3rd story building is under construction at Chandra, Gazipur.

The Divine Textile Ltd. at Chandra, Housed in four floors of 24,000 square foot, employees of 750 staff with

a daily production capacity of 12,000 pieces of complete garments, while 2650 staff of Divine Textile Ltd.

unit -2 at the same premises produce around 50,000 pieces of garments a day.

Divine Group of Industries Ltd. has its own water pre-treatment plan and 24,500 cubic feet water reservoirs in

its Chandra, campus. The Chandra premises has its own power Generators plant where 2,200 kw power

generators guarantee smooth and uninterrupted power supply to its every operation.

Divine Group of Industries Ltd. has its own Wastage water treatment plan (ETP) and 24,500 cubic dyed water

has been treated in this campus and go through the outside.

Divine Group home base is Gazipur - a city furnished with the largest garments factory of Bangladesh. It had

been a center of Textiles and garments in this region ever since the middle ages - a time when it was world

famous for its ethereal muslin - and has continued in that tradition as the happening place for Knitwear. A

busy area, availability of skilled artisans, and a range of other facilities and possibilities render it the ideal

ground for Divine Group.

Since its inception, Divine Group has never stopped growing - in quality, quantity, capacity and everything in

between. Its production has branched out into nine fledged factories at four locations - Chandra in Gazipur,

Chowgasa in Jessore, Mirpur in Dhaka and near EPZ in Savar. Divine Group at present has a daily production

capacity of over 20 tons of knitted fabric, 25 tons of dyed fabric, 30 tons of finished fabric, 10 tons of yarn

dyeing and 60,000 pieces of complete Garments per day.

In the way of becoming a massive success story, Divine Group became one of the few garment houses in

Bangladesh that implemented Oeko-Tex mark certificate. The Government of Bangladesh, too, recognized its

excellence by awarding the status of a Commercially Important Person ( CIP ) to its chief executive, Mr.

Hasanuzzaman, the founding Managing Director of Divine Group, since 1997 without any break.

Management Meeting

After successful operation in Divine Textile Limited, the owner had decided to start a fully

information & technology based along with the social accountability and quality controlled modern

readymade composite knit garments industry in large scale. In this connection Mr. Salim Reza had

decided in a resolution to start a company in Chandra, Kaliakoir, Gazipur in the year 1997 to

manufacture knitwear garments for the international market. Right from inception the policy of the

company has been to provide total customer satisfaction by offering quality knitwear in time. To

meet the commitments of quality and prompt delivery, Divine Textile Limited Decided to integrate

the manufacturing process in a planned manner. Over the years the entire process has been integrated

by importing sophisticated machinery from world-renowned manufacturers.

Working on new concepts in styling & content of the knitwear is a continuous activity in Divine

Textile Limited with an objective to up the quality and the value of merchandise. In 1997, the year in

which International business was started; Divine Textile Limited concentrated all its strengths and

resources in developing a wide range of knitwear for the international market.

The mission and vision of Divine Textile Ltd. is to manufacture and deliver high quality readymade

garments (RMG) to its customers. The core objective is to attain and enhance customer satisfaction

by providing on time delivery of desired quality readymade garments and also to increase efficiency

of workforce.

To attain these objectives, the management of Esquire Knit Composite Ltd. has decided to adopt the

following-

1. To increase awareness regarding customers requirements throughout the organization.

2. By providing training to develop efficiency of the employee.

3. To collect customer’s feedback regularly to know about their conception about their company

and to take timely appropriate action.

4. To reduce the percentage of wastage / rejection minimum by 2% per annum’s implement and

monitor ISO 9001:2000 quality management system within the organization.

West East

North

South

POND

Main Gate of the Divine Textile

1

2

3

6

7

8

12

4

5

9

10

Gate

Main

G

ate

of

Div

ine F

ab

ric

s

Bridge

3

5

6

4

2

4

11

13 13

1

1

14

1. Security office

2. Gas Pump

3. Knitting section Unit – I & Air Compressor Room (1st Floor) + Garment section (2

rd -4

th Floor)

4. Color Store (1st Floor) + Medical Care (2

nd Floor) + Quarter (3

rd Floor)

5. Chemical Store

6. Fabric dyeing (Unit – I ) & Tube finishing section + Boiler Room

7. Dyeing Lab + Open Finishing Section

8. Fabric Dyeing Unit – II +Boiler Room

9. Generator

10. Yarn & Hanger Store

11. WTP Plant

12. Dyes & Chemical Store (Under Ground) + Kniting & Fabric Inspection Section & Air

Compressor Room (1st Floor) + Garment Section (2

nd – 6

th Floor) + Garment Printing Section +

Office Room, Merchandising Section, HR Department (8th Floor)

13. ETP Plant

14. Under Constructed Building

Divine Fabrics

1. Under Constructed Building

2. Garment Section (Which Construction is also running)

3. Grey Fabric Store + Printing Section + Knitting Section ( 2nd

Floor)

4. ETP & WTP Plant

5. Fabric Dyeing & Open Finishing Section & Dyes, Chemical Store (1st Floor) + Dyeing & QC Lab (2

nd

Floor)

6. Yarn Dyeing + Yarn Dyeing Lab + Dyes & Chemical Store + Generator

CHAPTER -02

MAN POWER MANAGEMENT

Knitting section

AGM

PM

Store In charge Knitting Master Supervisor

Fitter man

Operator

Fitter man

Operator

Dyeing & Finishing Section

GM

DGM

PM

SPO Batch Incharge Finishing

Incharge

Lab Incharge

PO

APO

Supervisor

Sr. Operator

Operator

Astt. Operator

Sewing man

Helper

Turning m/c

Operator

Helper

Sewing man

Squeeze

Operator

Dryer Operator

Compactor

Operator

Helper

Lab Technician

Q.C. Technician

Divine Group can produce wide range of products and they deals with some renowned buyers from

Europe and USA market some of those are with whom they worked and those whom they are still

working. Main buyers name of the company are given below-

Target Australia

Carrefour

Lindex

Charles Vogele

Calvin Klien

TCHIBO

H & M ( Hennes & Mauritz)

Department Manpower

Knitting 300

Dyeing & Finishing, Lab & QC Yarn Fabric

309 405

Garments 3325

Power, Boiler, Utility & Maintenance 173

Inventory 15

Administration 54

Security 135

Others 590

Total 5306

Duty time / shift change

For knitting & dyeing

The industry has three (3) shifts for the workers. Shift duration of every shift is eight (8) hours.

SHIFT FROM TO

A 6.00 AM 2.00 PM

B 2.00 PM 10.00 PM

C 10.00 PM 6.00 AM

For garments section:

SHIFT FROM TO DURATION OVERTIMR

One shift 8.00 AM 5.00 AM 8 hours 2.00 hours

Different section:

A) Knitting section

Knitting

Inspection

B) Dyeing section

Batch section

Dye house

Dyeing lab

Quality control

finishing

C) Garments section

Merchandising

Industrial Engineering

Sample section

Cutting section

Sewing section

Finishing section

D) Maintenance section

Electrical

mechanical

E) Store section

F) Administration section

G) Compliance section

H) Security section

I) Marketing section

J) Human resource & Development section

Communication system:

Intercom telephone

Fax

Mobile phone

E-mail

Written letters

Oral

Dif

fere

nt

sect

ion

Receiving measurement chart from merchandiser

↓

Checking measurement chart

↓

Making pattern paper

↓

Checking the pattern paper

↓

Send to merchandiser for buyer approval

CHAPTER -03

CAD SECTION

Pattern section

In this section normally pattern is modify. After receiving an order buyer send the measurement

chart to merchandisers .Merchandisers send the measurement chart to pattern section. Pattern

master made the pattern according measurement chart. if buyer sends the pattern paper that time

pattern master modify that pattern paper

Flow chart of pattern section:

Types of pattern made in Pattern Section

Sample pattern: When sewing allowance is added & sample make following the pattern is called Sample pattern.

Production Pattern: These are used for bulk production just after grading all of different sizes. Finished pattern: These are used in sewing section.

Contents of pattern paper: Style No

Grain Line

Name of parts

Size of Garment

Marker Section Marker is a thin paper which contains all the pattern pieces of garments.it is made just

Receive pattern ↓

Taking the image of pattern in CPU by digitizer Or making pattern

↓

Modernizing of all pattern part by the software ↓

Pattern grading by software ↓

Aligning all sizes of pattern in the marker by the software ↓

Completing the marking ↓

Taking approval from cam section ↓

Print marker id delivered to cutting section

Before cutting and its purpose is to minimize the wastage. The width of marker is equal to the width of the fabric and should not be greater then the width of the marker is kept less than or equal to the width of the fabric. The pattern pieces should be placed very carefully in such a way that will obviously minimize wastage. Marker section included in CAD SECTION- Following equipment’s are consists in CAD Section-

Name of Equipment’s No. of Items

Win da pattern cutter 01

Win da Plotter(Accu Plot) 01

Win da Digitizing Board 01

Sequence of Cad for garments:

Method of marker making in garments:

Marker can be made either in –

1. Manual method

2. Computerized method.

a. Digitizing system

b. Scanning system

Computerized marker making method is of two (2) types. They are -

1. Automatic Marker Making.

2. Interactive Method.

Interactive Method is used in Crossline Knit Fabrics Ltd. It is a common process, here the marker

planner plan markers by interacting directly with the system through a computer screen. All the

pattern pieces are displayed in the miniature form at the top of the screen. They are dragged &

dropped in the marker area. After placing of all pattern pieces, it is possible to see the data like

marker efficiency, marker length, and marker width etc. information just below the parallel lines.

After completion of marker making, it is saved in the computer memory & it is possible to take the

printout of the marker any time.

Efficiency Measure:

Total placed area x 100%

Formula: Total marker efficiency% = Length x Diameter

Efficiency (usually get)

For Tank top - 75%

For trouser - 78%

or t shirt - 85%

For polo shirt - 85%

N.B.: If a garment consist smaller parts then there efficiency is higher than the larger parts of a

garment.

Fabric wastage:

1. Inside wastage

2. Outside wastage

Ends of fabric losses: Sometimes some allowance needed to keep during fabric

spreading. Usually 2” each side, total 4” each ply wastage occurs

Selvedge losses: Each fabric has two selvedges. 2-3% wastage occurs

Purchase losses: For wrong consumption purchase losses occurs.

CHAPTER -4

SAMPLE SECTION

Sampling in garment exports and its importance:

Sampling of garments is given great emphasis. It determines the approval of future orders from buyers and fetches business for a garment manufacturing or export company. Sampling is one of key elements of the pre-production processes in a garment industry. Before a manufacturer produces bulk orders, a prior sampling of styles is done to get approvals and jumpstart the fabrication of garments. Samples of garments work as a bridge between buyers and the producers.

Machineries of sample section:

Name of machine No. of machine

Overclock sewing machine 09

Flat lock sewing machine 04

Lock stitch machine 10

Button hole sewing machine 01

Button attaching sewing machine 01

Safe guard machine 01

Process sequence of sample section:

Buying office reference merchandiser

↓

Merchandiser to pattern section

↓

Pattern making

↓

Sample fabric cutting

↓

Sample sewing

↓

Quality inspection

↓

Ironing

↓

Final quality inspection & measurement

↓

Folding & packing

↓

Send to buyer

↓

Buyer approval / buyer rejection

↓

Production pattern

The details attached to the garment sample:

After the confirmation of order, each sample sent to buyer has the following details attached to it ,

with the help of a tag . it contains the details pertaining to both, what the buyer has demanded and

what supplement fabric/trim etc. they have used (if applicable)

Ref no.

Color

Fabric

Composition

Garments size

Style no

Description of different types of samples:

FIT Sample/Develop:

Once proto sample is approved, FIT is being made with actual measurement. Modification on the

pattern is done to get desired fit of the garment. FIT is one of the most important factor to be

considered during sample development. FIT sample is being tested on live model or Dress form for

to verify garment fit and fall.

Size set Sample:

The purpose of the size set is to check fit of the garment in different sizes. In this stage factory

develops samples in multiple sizes. Generally, buyers ask size set sample in jump sizes, like S, L, and

XXL. Buyer check size set sample and give feedback to factory if anything need to be corrected.

Pre-production Sample (PP sample):

All the above samples are made in sampling department. Buyer wants pre-production sample (PP

sample) to be made in actual production line, so that operators know what they are going to make.

This sample is made with actual fabric, trims and accessories and made by sewing line tailors. PP

sample must be approved by buyer or buying house merchants (technical persons) prior to

proceeding actual production.

Top of Production Sample (TOP sample):

Once production is online, few pieces is taken out in the middle of the production. Production

pieces are sent to buyer as TOP sample. All buyers do not ask for TOP sample. Purpose is to cross-

check whether factory is following PP sample specification or not.

Shipment Sample:

When style is being finished and packed for shipment, 2-3 finished and packed pieces with all

packing details are kept for future reference. Shipment sample is kept by factory merchants and

buyers merchant. The approved shipment is sent directly to warehouse and merchants at the buyer

do not get garment out of the shipment. That is why they keep shipment sample for future

reference.

CHAPTER -5

CUTTING SECTION

Cutting section is the most important and risky section in garment industry. For a little mistake full

order may be cancelled. With the false measurement a big portion of garment may employed. With

very care this section is handled.

Cutting section composed of following section-

CAD section

Fabric inspection

Spreading & cutting section

Cutting pieces inspection section

Following machines are available in cutting section

Machine name No. of Machine

Cutting Table 11

Fabric Inspection machine 01

Straight knife cutting machine 07

Lining machine 01

Hand Scissors Numbering Machine

Process sequence of cutting section

Store ↓

Fabric Fault Checking ↓

Relaxation ↓

Shade Checking ↓

Prepare the fabric in the fabric spreading m/c ↓

Spreading ↓

Marker attachment ↓

Cutting ↓

Numbering ↓

Bundling ↓

Panel Check (QC) ↓

Fault

OK ↓

Replace Cut ↓

Solid

Not Solid

↓ Print / Embroidery

↓

Checking & Counting (QC) ↓

Sewing

Specification of Machine:

Fabric Inspection Machine:

Cutting machine:

Straight knife cutting machine:

Machine Name K.M. Company Cloth Cutting Machine

Model : KM KS-AUV

Origin : Japan

Producer : K.M. Cutting Machine Co

Type : Heavy Duty Industrial Cloth Cutting M/C self-Sharpening.

Dimension : 8" W x 11" L x 24" H

Knife size : 4 to 14 inches

Speed :3000-3600 rpm

No. of Machine :07

Quality inspection of fabric before feeding:

Shade Crease mark

Fabric width Needle mark

GSM Slub

Oil spot Hole

Dirty spot Yarn contamination

Quality inspection of fabric during spreading:

Shade Slub

Fabric width Hole

Oil spot Yarn contamination

Dirty spot No. of ply

Crease mark Marker length

Needle mark Style no

Quality inspection of cutting pieces:

Following faults are checked-

Oil spot Hole

Dirty spot Yarn contamination

Crease mark Measurement

Needle shade

slub

After inspection same no of sticker are matched fold& bundle:

Numbering

In this stage stickers attached with all part of cutting part for shade matching. The sticker number

maintains cutting number, size number, serial number.

Prepared bundle card

Prepared bundle card according to fabric lay report this card maintain

Program no

Cutting no

Roll no

Size no

Plies

CHAPTER -6

SEWING SECTION

After receive the garments components from cutting section, all the garments parts are joined and

sewn as sequentially. Obviously all the components are sewn respects on buyer requirement.

Sewing section is the most important department of a garment manufacturing industry. Sewing

machines of different types are arranged as a vertical line to assemble the garments. Sequence of

types of sewing machine arrangement depends on sequence of assembling operations.

Sewing:

Sewing is a craft that involves stitching fabrics together either with a needle and thread by hand or

with a machine. This is the main assembly stage of the production process, where sewers stitch

fabric pieces together, and a garment is assembled.

Basic Components of Sewing:

Needle

Feed Dog

Pressure Foot

Throat Plate

Sewing Thread

Fabric

Process sequence of sewing section:

Cutting fabric load in sewing section

↓ Layout of machine according to style & design of garments

↓ Inspection of cutting pieces

↓ Feed into line

↓ Sewing according to design & style of garments

↓ Quality inspection during sewing in mid line

↓ Quality inspection after sewing

↓ Excess thread cutting

↓ Remove dirt’s or other faults which can rectify

↓ Quality audit

↓ Send to finishing section

Machineries of sewing section:

Sl. No.

Name of the M/C Brand Name

Model Origin No. of M/C Unit

1 PLAIN M/C BROTHER SL-2110-403 Japan 128 Set

2 PLAIN M/C BROTHER S-6200-403 Japan 162 Set

3 PLAIN M/C JUKI DDL-8700-7 Japan 63 Set

4 PLAIN M/C JUKI DDL-9000B-MS Japan 60 Set

5 OVER LOCK M/C PAGASUS (M.N) Series Japan 208 Set

6 OVER LOCK M/C PAGASUS M-800 Japan 110 Set

7 OVER LOCK M/C TYPICAL GN-2000-5H 22 Set

8 FLAT LOCK M/C PAGASUS W-200 JAPAN 20 Set

9 FLAT LOCK M/C PAGASUS w-500 Japan 50 Set

10 FLAT LOCK M/C PAGASUS W-1500 JAPAN 50 Set

11 FLAT CYLINDER BED M/C PAGASUS W-600 JAPAN 59 Set

12 FLAT SMALLCYLINDER BED M/C PAGASUS W-200 JAPAN 2 Set

13 SINGLE NEEDLE VERTICAL M/C JUKI JAPAN 20 Set

14 BUTTON HOLE JUKI Japan 18 Set

15 BUTTON STITCH JUKI Japan 18 Set

16 P. M.D KANSAI KANSAI JAPAN 6 Set

17 ZIG ZAG M/C BROTHER JAPAN 2 Set

18 BAR TACK M/C BROTHER JAPAN 9 Set

19 TWO NEEDLE M/C BROTHER JAPAN 11 Set

20 RIB CUTTING M/C DINO Japan 9 Set

21 Cloth Cutting M/C JAPAN 14 Set

22 THREAD CUTTER M/C JAPAN 20 Set

23 GRINDING M/C JAPAN 3 Set

24 SNAP BUTTON JUKI JAPAN 13 Set

25 PICOTING M/C P×302-4W JAPAN 7 Set

Sewing Machine:

There are different types of sewing machine used for different types of sewing application. Most

widely used & common machine are-

Plain m/c

Flat lock m/c

Over lock m/c

Button holing m/c

Button attaching m/c

Feed of the arm m/c

Sewing Machine Description:

Plain machine:

Properties:

One needle

Two needle

Three guide

One hook

Two thread

One bobbin casa

One magnate guide

Application:

Bottom hemming

Belt top seem stitch

Pocket joint stitch

Jipper joint

Flap make

Flap top stitch

Loop tack stitch

Belt joint stitch

Over lock machine: Properties:

5 thread

4 tensioner

2 knifes(up/down)

2 needle for 5 thread

1 needle for 3 thread

3 lopper for thread

2 lopper for 3 thread

Applications:

Over lock Machine

Plain machine

O

Over lock stitch

Flat lock machine: Properties:

4 tensioner

3 thread

Contain a holder

2 needle

Applications:

Zigzag stitch

Knit hemming

Loop making

Feed of the arm machine:

Properties:

2 needle

2 looper

4 thread (lopper2 / needle 2)

Contain T & magnate guide

3 tensioner

Application:

Back rise stitch

Inseam stitch

Back yoke top sin

Flat lock machine.

Feed of the arm

Kansai Machine

Kansai Machine:

Properties:

2 needle

4 thread

8 tensioner

21 lopper point(used two lopper

Depends on distance of stitches)

Application:

Back yoke stitch

Back belt stitch

Button holing m/c Properties

2 thread

1 needle

2 tensioner

Contains bobbin case, hook& knife

Applications:

To attached button in garment

Button attaching m/c

Application:

To attach button in garments

Button attaching m/c

Button holing m/c

Sewing thread:

Sewing threads are special kinds of yarns that are engineered and designed to pass through a

sewing machine rapidly. They form efficient stitches without breaking or becoming distorted during

the useful life of the product. The basic function of a thread is to deliver aesthetics and

performance in stitches and seams.

Factors affecting performance

Thread used in garments must be durable enough to withstand the abrasion and needle heat that

occur while sewing, garment finishing, stretching and recovery during wear.

Thread performance in garments can be evaluated from its-

Seam strength

Abrasion resistance

Elasticity

Chemical resistance

Flammability

Colour fastness

Types of sewing thread:

Cotton

Polyester

Silk

linen

Seam:

The line where two or more pieces of fabric are joined by application of a series of stitches or stitch

types with a defined geometry to one or several thickness of fabric material is defined as seam.

Properties of seam:

strength

Elasticity

Durability

Security

Appearance

Accessories used in sewing:

20/2 Sewing thread

Plastic /coconut button

Snap button

Woven label

Hang tag/price tag

Zipper

Barcode + size label

Name label

Size label

Lock pin

Poly sticker

Benny

Twill tape

Drawstring

Satin tape(hanger loop)

Lace

Lurex thread

Reflective tape

Elastic

Alarm sticker

Main label

Velcut

Sewing problem:

1) Problems of stitch formation:

Slipped stitch

Staggered stitch

Unbalanced stitch

Needle thread breakage

Frequent thread breakage

2) Problems of pucker:

Unequal stretch

Fabric dimensional instability

Extension in sewing thread

Sewing thread shrinkage

Fabric construction

Mismatched pattern

3) Seam wise fabric damage:

Mechanical damage

Needle heating damage

CHAPTER -7

QUALITY CONTROL & FINISHING SECTION

Finishing section:

The final section to make the product attractive and salable condition & achieved the quality of

garments. It is very important section for garments factory.

Following areas are consists in section-

Sub-store

Thread sucking Area

Spot removing Area

Ironing Area

Reject garments Area

Get up checking area

Measurement checking area

Final inspection area

Final quality inspection area

Folding & packing area

Cartooning area

Following machine consists:

Machine name No. of machine

Ironing machine 46

Vacuum table 46

Thread sucking machine 02

Metal detector machine 01

Tag Gun

Spray gun

Rivet machine

Iron machine

Garments receiving from sewing/washing section

↓

Thread sucking

↓

Inspection

↓

Ironing

↓

Final inspection

↓

Get up check

↓

Measurement check

↓

Final quality check

↓

Folding & Packing

↓

Metal detecting

↓

Cartooning

↓

Buying QC inspection

↓

Shipment

Iron machine:

Vacuum ironing table:

Flow chart of finishing process:

Vacuum Table

Accessories & Trimmings

Accessories list of finishing Section- Hang tag

Price tag/sticker

Poly bag-

Piece polybag printed

Piece polybag non printed

Duo pack polybag

Hanger polybag

Blister polybag

Hanger

Size sticker

Poly sticker

Tag pin

Carton

Carton sticker

Scotch tap

Gum tap

Barcode sticker

Security label/sticker

Composition sticker

Garments photo card

Buyer information sticker etc.

Garments packing:- Packing must do on approval packing method.

Single garments pack

Set garments pack

Double set pack

Assort color garments pack

Single color garments pack etc.

Following information consists on packing (buyer demand)-

Buyer name

Size chart

Garments photo

Buyer office name .address, helps &

complains address etc.

Price chart

Composition , color name

Barcode

Security sticker

Care label sticker

Carton packing- packing does on approval cartooning method.

No of garments with size & color wise depends on buyer demand

Carton size depend on buyer demand

Following information consists on carton (buyer demand)-

Buyer name

Size set chart

Garments photo, name. color

Order number,

Style number

Carton number

Quantity of garments

Carton size

Carton gross weight & net weight

Port name where loaded & unloaded

Spot Removing

Spots Chemical name

Greases & oil stain Spot lighter

Print spot & wet spot Oxyclean plus & colorox-2

Dirt’s & others Dryel-2 &Solvex-2

CHAPTER -8

STORE & INVENTORY SECTION

Fabric inventory:

Various types of fabrics are storage. The flow sequence of fabric inventory below:-

Received the fabric

Pre inspection

Physical inventory

Make the swatch card

Prepare blanket shade

Fabric is separated & stored according to lot no.

Accessories inventory:

The flow sequence of accessories inventory below:-

Import receive

Physical inventory

Swatch making

Record the entry

Swatch approval from buyer

Supply to sub store according to demand

Issue to bulk production

Following Accessories are inventoried

Hanger

Label

Main label

Care label

Size label

Price label

Sewing thread

Button

Interlining

Do sting tape

Twill tape

Elastic etc.

CHAPTER -9

EFFLUENT TREATMENT PLANT (ETP)

Effluent treatment plant is essential to purify the waste water which is come from different types of

manufacturing industry like textile , dyes and chemical manufacturing industry ,pharmaceutical etc.

different environment saving organization are trying to protect the environment from the harmful

effect of the effluent. Different waste water has different characteristics which pollute the water.

Process flow chart of effluent treatment with effluent treatment plant:

Following is the basic structure of effluent treatment plant-

Effluent from different manufacturing industry

↓

Primary filtration

↓

Cooling and mixing

↓

Neutralization (by acid or alkali)

↓

Chemical co-agulation

↓

Settling and separation of sludge

↓

Pressure filtration

↓

Discharge

Now I like to give a short description about the sequence of operation in ETP:

Primary filtration:

It is the first stage of effluent treatment plant, where effluent is come from weaving, dying, printing, or finishing unit. Here primary filtration is performed to remove solid waste particles.

Cooling and mixing:

In this stage, different types of effluent are mixed and cool down by the help of motor which ran a fan.

Neutralization tank:

After cooling and mixing; effluent is transferred to neutralization tank by the help of pump. Here

acid or alkali is mixed to neutralize the effluent. A pH meter is placed in the neutralization tank

Co-agulant bath:

After neutralization of effluent; effluent is transferred to a co-agulant bath. Here co-agulant is

added with the effluent.

Setting tank:

In here; effluent separates from the water and it found in the lower level of the tank. Effluent is like

as sludge.

Pressure filter:

Here, filtration is done under pressure. A certain amount of pressure is created here.

Carbon filtration: It is an optional filter process.

Discharge to drain:

After completion of all the process, the effluent becomes purify and it becomes safe to drain to the

environment. When treated water is drain to the environment it is checked by the different testing

lab. Different standard is maintained during discharge of the treated effluent.

CHAPTER -10

MAINTENANCE SECTION

Maintenance is a process by which equipment is looked after in such a way that trouble free.

Service and increased machine life can be ensured and specific quality by the customers is

sustained.

Types of maintenance:

Preventive maintenance:

Preventive maintenance is a predetermined routine to ensure on time inspection/checking of

facilities to uncover condition that may load to production break downs or harmful depreciation.

Corrective maintenance / break down maintenance:

Maintenance

Preventive Maintenance

Mechanical Maintenance

Electrical Maintenance

Corrective Maintenance

Mechanical Maintenance

Electrical Maintenance

In this case, repairs are made after the equipment is out of order it cannot perform its normal

function.

Maintenance procedure:

Here standard system is to service a machine once per month.

Log card used for every machines.

Service types, replace materials etc. were written on log card.

Data, time also written on log card.

Name of different maintenance equipment’s or tools:

Screw driver

Hand socket wrench set

Phil

Pliers

Slide calipers

Hand drill machine

Stand drill machine

Hammer

Mobile gun

Grinder

Welding machine

Some electric equipment’s

Table vice

Hand vice etc.

CHAPTER -11

COMPLIANCE ISSUE

Compliance:

Compliance means comply something i.e. yield to the wishes another. The main aim of compliance

is to ensuring the all labor rights and facilities according to buyer code of conduct.

Different compliance issues which they are obeyed-

Admin & HR dept.

Personnel policies

Recruitment police

Leave and holiday policy

Attendance and leave register card

Their weekly working hour not more than 60 hour including overtime in a week

They have the approved manpower list

Health and hygiene

First aid ensures

Medicine registers

Maternity and pregnancy register

Pure drinking water

Towel for hand dry

Safety

Safety committee

Firefighting committee

Rescue committee

Broken needle register

Needle detector

Fire alarm & switch

Evacuation plan

Rubber mates to every iron man

Welfare

Welfare committee

Day care center

Canteen facility

Salary and wages

Fix wages in considering minimum wages which is declared by the government.

Salary and wages given before 7th day of month.

Physical security

They have separate cargo entrance area (receiving and unloading ) from the front

side

They do not keep any partially filled / completed cartons on the floor at the end of

any working day. they keep it to finished goods store

Education and tanning program

They arrange security tanning program on regular basis for all employee of the

factory

Compliance item:

Some example of compliances item are given below-

First aid box

Water box

Toilet

Wash basin

Complain box

Evacuation plan

Emergency exit/light/light set

Smoke detector

Fire extinguisher

Hose cabinet

Manila rope

Gas musk

CHAPTER -12

GARMENTS MERCHANDISING

Garments merchandising is the process which starts from buyer developing to order conformation

& then execute the order with quality as buyer demand and delivery the order with in time. It is

also known as garments whole selling business with foreigners.

Types of Merchandising: Two type of merchandising done in garment exports

1. Marketing merchandising. 2. Product merchandising.

Marketing Merchandising

Main function of marketing merchandising is

1. Product Development 2. Costing

Ordering Marketing merchandising is to bring orders costly products development and it has direct contact with the buyer.

Product Merchandising Product merchandising is done in the unit. This includes all the responsibilities from sourcing to

finishing i.e. first sample onwards, the products merchandising work start and ends till shipment.

Duties & Responsibly A Merchandiser

To produce or collect a garments export order or export L/C.

To estimate time schedule for the export of those garments as per L/C. To arrange all the materials needed for the garments to manufacture and export. To monitor collection of raw materials as per time schedules. To monitor garments production progress as per time schedules. To monitors imposed quality level of the produced garments. To monitor garments packing instructions. To monitor banking and shipment arrangements as per time schedule. To maintain continuous liaison with the buyer or his/her representative if needed.

To maintain continuous liaison with his/her controlling authorities.

To follow up payment collection against garments export as per schedule.

And finally, to earn profit through garment export execution.

Responsibilities of a Merchandiser:

A merchandiser is responsible for the following tasks but not limited to these only.

Marketing

Costing and price quoting

Sample development and control whole sampling process

Fabric and accessories sourcing and tracking

Factory production scheduling and production tracking

Arranging final inspection

Shipping plan and booking

Customer liaison etc.

Process Flow Chart of Merchandising:

Receive product package form buyer

↓

Sample development

↓

Price negotiation

↓

Order confirmation and receive order sheet.

↓

Sourcing low good quality right time

↓

Material collection and receive it in factory

↓

Check and listing

↓

Swart card making and approval

↓

Pre production meeting

↓

Daily collect daily production report and daily quality report

↓

Arrange final inspection

↓

Shipment

↓

Received art work and size spec for development of the sample

↓

Making development sample

↓

Consumption (from CAD) & costing

↓

Meeting with buyer for price & order confirmation and LC received

↓

Lab-dip approval

↓

Making different types of sample (as per buyer requirement) for approval

↓

Making pre-production (pp) sample with all actual

↓

Yarn booking

↓

Bulk fabric order

↓

Accessories order

↓

After approval of pp sample arrange pp meeting

↓

Start bulk production

↓

Arrange an inline inspection

↓

Send a test sample to 3rd party testing center

↓

After completion of bulk production arrange final inspection

↓

Arrange all commercial papers for shipment

↓

Shipment

Oder types:

FOB

This is the export term of delivery and price quotation. The sellers send the goods for export and delivery them on boat. The risk is passed from seller to buyer when the goods are loaded in the ship at the port departure. The buyer pays the freight charges. The seller does not include the freight charge with his costing

FOA

This is the export term of delivery and price quotation. The sellers send the goods for export and delivery them to the air carrier. The risk is passed from seller to buyer when the goods are loaded in the air carrier at the port departure. The buyer pays the freight charges. The seller does not include the freight charge with his costing

Generally other types are:

C&F(Cost & freight)order

CIF(cost, insurance & freight ) order

CIFC(cost, insurance, freight& commission)

Order

CMT(cost of making with trimining) order

CM(cost of making) order

TT(telephonic transfer) order

Subcontract order

Exchange order

CMC(cutting, making& carton) order

Work done by Merchandiser:

Sourcing

Pricing(CM,C&F.CIF,FOB)

Order follow up and inspection

Ensuring on time shipment.

CHAPTER -13

INDUSTRIAL ENGINEERING

The main function of this department is to re-engineering the garment fro, the sampling stage so that would be production friendly for the production as well as helps to increase the productivity through machine layout, time, & motion study.

Duties & activities of Industrial engineering Department:

Style detail collect

SMV make

Layout make

Machine arrange

Attend pp. meeting

Make first week production plan

Work aid arrange

To follow up the production process

Work process development

Line target

Time study

Capacity study

Efficiency control

Worker interview

Line feeding

Line capacity find out

Bottle neck operation find out

Monitoring the production achievement hourly

Solve production related problem

Motivate the worker

Incentive arrange

Method study Standard method

Work flow

Quality specification

Attachment/placement of operator or helper

Time study SMV calculation

Standard time determination operation wise

Actual working time determination

Loss time determination

Capacity study Time determination operation wise

Actual & loss time determination

Efficiency determination

Work measurement

Standard time

Hourly target

Hourly production

Line target given process:

Generally two methods for line target

1. Theoretical method- theoretical SMV calculation and then given target, first this method

following for line target.

2. Practical method- it is the second and best method.in this method first line capacity find out

and then analyze. Then given target

Line capacity determination process

Input & output check

Find out the time required for each process

Find out the average SMV for making garments

Then find out the line capacity

If one garment needed 15 process to complete where average time required 0.30 minutes with

fatigue allowance , then line capacity will be =(60/0.30)pcs=200pcs

Problem identification & solution:

If the production target not achieved that time following steps taken-

1. Check the inputs

2. Check the line in process where may contains m/c problem operator or helper problem

3. If machine problem-

Check the m/c condition

If parts problem replace the parts

If machine not work properly then replace the machine

4. If helper needed then properly then attach the helper

5. If operator problem then discuss with operator and solve. If operator even not gives better

result, then replace the operator

Production duration determination process:

First prepare the production plan(SMV, no. machines & operator, production hour & day)

Select the line number, total no. of line

Calculate the time required to complete the production

CONCLUSION

There is large difference between the theatrical knowledge and practical experience. This is truer in

case of the study of textile technology industrial attachment or industrial training is an essential

part for textile education because it minimizes the gap between theoretical and practical

knowledge. This industrial training increases our through a lot about textile technology. It also helps

us to know a lot about industrial production process, machineries and industrial management and

make us suitable for industrial life.

From my experience of six weeks 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 better will be the productivity.

Divine textile ltd. It’s a wonder and well decorated and clean industry. The all section of this

industry is very nice and all machines are in good operating condition. A lot of order comes to the

industry from buyer & buying house. The production rate is very good. Overall the working

condition is very nice of the industry.

I have completed my industrial attachment from Divine textile ltd. During my two month long

industrial training at Divine textile ltd. I got the impression that this factory is the modern export

oriented composite knit garments of our country. This factory does not compromise in case of

quality. So they have established quality control of each product. Besides they also use the good

quality yarn, dyes and chemical in their production process. It has very well educated and

technically experienced manpower to get rid of any defect in production process.

Achievements:

In the industrial training I have learnt various things in more practically but prime

achievements are-

Being familiar with all departments.

Being familiar with process sequence of sewing and garments making.

Gathering vast knowledge on garments making, cutting, and sewing.

Detecting & minimizing the garments fault from technical point of view.

Knowing how the order is received & go to bulk production.

Learning on textile machineries & equipment’s.

Controlling & operation of industrial management

Some suggestions:

There are some suggestions from us with in our limitation knowledge:

Knitting production needs to increase as well as technical persons need to be employed

there & needs increase machineries

More skilled labor should be used in a project and the overall efficiency will increase

Should increasing understanding between the top level personal and floor level person

Dyeing floor space should be needed increase

Due to pressure of higher production sometimes machine operators do not maintain

accurate time according to the actual process so that less quality product is produced and

may reject. So our suggestion is to increase machine and reduce the pressure on the

operator

In knitting section every workers should use mask to make protect them from fly.

Otherwise the exhaust air should be more effective.

The person at the top level of a department must take good care of the trainees & he should

provide all kind support to them.

Limitation of this report:

Because of secrecy act, the data on costing and marketing activities have not been supplied.

Due to lack of time it was not possible to collect more data.

Some points in different chapters are not including as there were not available.

It is not possible to hold the whole thing of a textile industry in such a small frame a report.

So, try hard to summarize all the information that provided.