bachelor project

TABLE OF CONTENT

Letter of transmittal Acknowledgement Introduction History of RMG industries of BD Company profile Working zone Product development life cycle Activities of product developer Development product

Learning through factory:

Marketing Department Store & Inventory Marker, Spreading & cutting CAD section Sewing Section Maintenance Garment Washing Finishing Section Quality Department Merchandising Department Commercial Department Utility Facility Compliance HRM Problems during project work Conclusion

Letter of Transmittal

Dear Sir

I am submitting the final project paper on product development by the reference of J.M Fabrics

LTD.

I have really learned a lot and have gained valuable experience and knowledge while collecting

information for the report. I will do my level best to prepare this report to the required standard.

It was certainly a great opportunity for us to work on this real life project to actualize my

theoretical knowledge of this course in the practical arena and some more which is out of this

course.

I hope that this project paper has been to your expectation, if you come across any question or

quarries regarding these cases, it will be my pleasure to clarify your questions.

Thank you

Kazi Tauhidul Alam

ID # 091-030-045

ACKNOWLEDGEMENTACKNOWLEDGEMENT

At first my gratefulness goes to Almighty Allah, Most Gracious, Most Merciful, the

Master of the Day of Judgment, the Cherisher and the Sustainer of the world for giving me

the strength and capability to complete my long industrial training. You have made my life

more bountiful. May your name be exalted, honored, and glorified.

I wish to take this excellent opportunity to thank a lot of people who have assisted

and inspired me in the completion of my industrial attachment:

At first I want to give my Special thanks to my Great Father and Mother who gives

me a chance to study in BUFT and their unforgettable love.

Md. Monirul Alam, Merchandising Manager, to whom I am extremely indebted

for his tremendous support and guidance throughout my training period and writing of this

report. Being working with him I have not only earned valuable knowledge but was also

inspired by his innovativeness which has helped enrich my experience to a greater extent. His

ideas and way of working was truly remarkable.

I would like to express my deep gratitude to Kazi Shamsur Rahman

Sr. Asst. Professor, Proctor of BUFT, for his detailed and constructive comments, and for

his fatherly nature support and continuous guidance throughout my long journey in BUFT.

Standing at the threshold of the end of my university life, I realize how BUFT has

molded me into the person I am today. Now I take a walk down the memory lane BUFT has

paved for me, I realize that I will cherish every single moment I have left behind in this

institution. It is amazing how, a place that had seemed so unknown the first day I walked into

it, has today become a home away from home. I shall forever remain indebted to the teachers

who have tried time and again to help me rectify myself into a better person. With all that this

institution has given me, I must admit that without BUFT. I would be incomplete. I express

my heartfelt gratitude and appreciation to all the teachers, administrators, the Vice

Chancellor, the Registrar and everybody who is a part of BUFT for giving me the best and

happiest days of my life.

I would like to thank my fellow friends and juniors who have shown greater interest

and provided helpful hands whenever I needed.

Last but not least, thanks goes to my precious family for their never-ending supports

and loves in every stages of my life which has motivated me to do such work.

INTRODUCTIONINTRODUCTION

For any technical education, practical experience has almost equal importance in association

with the theoretical knowledge. By means of practical knowledge it is possible for the students to

apply theoretical knowledge. The industrial training course is engineered in such a way that it

enhances understanding power, skill of the performer. It helps the students to be familiar with

technical matters, various stages of the production and modern machinery used in the production.

It also provides clear conception about management system, work study, efficiency, production

planning and control, cost analysis, inventory management, procurement, utilities, their operation

techniques and maintenances of machinery. It is true that the above mentioned matters cannot be

achieved successfully only with theoretical knowledge. This is why it should be accomplished

with practical knowledge in which it is based on. This makes the students familiar with industrial

environment which ultimately courage them, and makes self-confident as well.

I believe that three months long industrial training made me hard worker, innovative and

enthusiastic and very punctual. Now I realize that I shall be able to work in the industry adopting

the environment.

I tried my best to prepare this report in the partial fulfillment of the requirements of the degree of

Bachelor in Apparel Manufacturing & Technology. Despite my best effort to ensure the

accuracy, some mistakes or errors may still remain in the report. All types of suggestions for the

improvement of my future career from teachers and students would be taken with humble

courtesy.

HISTORY OF RMG SECTOR

The garments industry of Bangladesh represents one of the recent success stories of industrial development in a poor, developing country. Starting from scratch in the late 1970s, the industry is now Bangladesh's most important source of foreign exchange earnings. It currently exports about $5 billion worth of products each year; this is a little over three-fourths of our annual export earnings.

How did this industry take off? The answer to this question has important lessons for designing approaches to promote industrialization and private sector development. In particular, it would inform the debate on the relative efficacy of focusing on improvements in the overall policy environment vs. micro-level interventions, such as subsidized credit or business advisory services.

This note describes what happened in the early years of the industry. The story of the early growth of the garments industry in Bangladesh is a story of the diffusion of good practices, from foreign to local enterprises and then from one local enterprise to many others. It is also a story of how a few, but strategic, improvements in policy and institutions opened up opportunities even within a generally unconductive environment. One entrepreneur seized these opportunities after another, each learning from the success of those who had entered the arena earlier. Direct, subsidized support to individual firms from government had very little r ole in all this. The catalyst for the birth of the industry was the South Korean company, Daewoo, whose collaboration with the Bangladeshi enterprise, Desh Garments, led to the growth of the industry.The first ready-made garment factories in Bangladesh aimed at the export market were opened in the late 1970s by investors from other Asian countries whose exports had been restrained by quotas imposed by importing nations. By the mid-1980s, the ready-made garment industry had become a strong export earner. Garment exports brought receipts of only US$3 million in FY 1981, but by 1984 exports had risen to US$32 million, and the following year revenue soared to

US$116 million. For FY 1985 and FY 1986, ready-made garments were the second biggest foreign exchange earner for Bangladesh after jute.

The surge in Bangladeshi exports eventually caused a reaction among some industrial nations. Canada, the European Economic Community, and the United States expressed concern that inexpensive Bangladeshi garments were flooding their markets. In 1985, after a series of notices as called for by multilateral agreements, the United States--which was the destination of about 25 percent of Bangladesh's garment exports--began imposing quotas on Bangladeshi garments.

http://www.knitasia.com/Company-Home-JMFLJM Fabrics LTD is one of the new generation manufacturer and exporter of knitwear garments. Our product range includes almost all Inner & Outerwear in Knits. We started exporting from 2007 and since then, have expanded our business to various regions in North America (US, Canada etc), EU Countries (UK, Germany, Norway etc) and south Asian Countries.

Since day one, our motto is to establish ourselves as a reputable apparel manufacturer who is committed to customer's satisfaction, by producing high quality products, making on time shipment and delivering efficient & Quality services.

To achieve this we place great emphasis on giving special attention to each of our client to accurately determine their individual requirements. Our products and services are customized to meet the needs of each client.

We believe that successful management of any operation requires efficiency, administrative ability and dedication. We also believe that, for JM Fabrics, the ultimate test of success lies in attaining customer satisfaction.

Our Vision

JMFL commenced its operation in 2007 by setting up JM Fabrics Limited.

It achieved quick successes because of it's entrepreneurs long experience & involvement in this industry.

Anticipating the new requirements of apparel manufacturing like shorter lead time & flexibility in production, JMFL located itself in Gazipur, a port-adjacent Composite manufacturing hub of Bangladesh, along with installing sophisticated technology & machineries.

As a result, JMFL successfully has secured reputed retailers of UE and US in its clientele. JMFL takes a lot pride that it is serving most of its clients through a lasting & trusted relationship.

To turn over volume order, JMFL expanded its capacity continuously and now has reached around 27 thousand pieces per day in garments manufacturing and around 15 tons of fabrics per day. 2010 target is $ 15 Milion.

JMFL has awarded ISO 9001-2000 for its Quality Management System (QMS) certificate for the responsible composite manufacturing process.

Fabric Quality: We are OEKO-TEX Class I certified for kids and woman Products

J.M Fabric Back Ground

We are involved in indenting, manufacturing and exporting of various Textile and

Clothing products.

We employ over 8,500 people.

Our group’s annual manufacturing turnover is about Taka 13.50 Billion (US$ 180

Million).

One of the few vertical setups globally covering the full supply chain starting with US

Raw Cotton to the finished clothing including AOP, Body Prints, Embellishments,

Embroidery, etc

Capacity and Sales Summary

Company Capacity Annual Sale

Malek Spinning Mills Ltd. 35,000 KG/day US$ 50 million

Salek Textile Ltd. 40,000 KG/day US$ 40 million

Knit Asia Ltd. Fabric : 20 tons/dayRMG : 120,000 pcs/day

US$ 60 million

Rahim Textile Mills Ltd. 60,000 mtrs/day US$ 25 million

Titas Denim Ltd 10,000 mtrs/day US$ 20 million

JM Fabrics Ltd. Fabric : 6 Tons/dayRMG : 40,000 pcs/day

US$ 25 million

Total US$ 220 million

Malek Spinning Mills Limited (MSM)

100% Carded and Combed Yarn

Sources Contamination free raw cotton from U.S.A. only

Cotton USA Licensee

Annual Turnover (BDT)2007-08 2,349,807,000 2008-09 2,587,741,790 2009-10 3,439,506,873

Salek Textile Ltd. (STL) ( 40 Tons/Day Open End Yarn)

Started production in March 2009

Most modern automated Open-end yarn mill in the country

Chilled/ Air Conditioned for quality assurance and comfort

3,600 Oerlikon Schlafhorst AutoCoro Rotors

Cotton USA Licensee

Production : 40 tons of yarn/day

(Mainly for Denim Manufacturing)

Rahim Textile Mills Limited (RTM)--Dyeing -Finishing Mill

Established in early 1980s.

Pioneer All Over Print (AoP) facility in the country.

Equipped with two Stork RD-4 (8 & 12 color) rotary screen printing machines.

Produces reactive, discharge, pigment prints.

Facilities to print on knit and woven cotton, synthetics and blended fabrics.

Nominated printer for H&M, Marks & Spencer, Walmart, C&A, etc.

Going through expansion for new dyeing lines.

Knit Asia Ltd.---Composite Knitting, Dyeing, Finishing & Ready Made Garmenting

Year Production Turnover

2000 3,000 KG/DayRMG: 20,000 pcs/day

$ 1 Million

2010 18,000 KG/DayRMG: 100,000 pcs/day

$ 44.5 Million

2011 Fabric : 18,000 KG/DayRMG : 120,000 pcs/day

$ 60 Million

Customer Profile

Cotton Innovation

Moisture Management

Water Repellency

Stain Repellency

Color Retentions

Antimicrobial/ Anti Odor

Certifications & Compliances

Management

• All our units have core managers with expertise who have been chosen from amongst the

best in the country.

• All our mangers have technical qualifications and training required for the job which is

continually updated.

• Managers are all highly ethical and have a great culture of motivation and performance

driven management.

• Moral and ethical values of the top are passed on throughout the organization

• Our managers tend to have a long service tenure with us, as they are treated well and

highly empowered to be able to succeed in their respective field.

Workers

• Our 4000 J.M Fabric workers are our greatest asset.

• They are trained on a regular basis to increase their skill level and competency so they

can further excel and get promoted.

• There is a great sense of community and togetherness within the organizations.

• We have annual lunches, prayers and picnics for recreation and team building.

• Compared to the industry our worker turnover is low.

Projects Under Development

200,000 sft building for Bangladesh University of Health Sciences

A Nursing school with the Diabetic Hospital at Shafipur

ICU Unit for Shaheed Khalek Ibrahim Hospital at Wari

Large donations and management to the Liberation War Museum

Sponsored the Musical Sitar Division at Chayanote in Dhanmondi

Community and Charity III

Organizations Getting Regular

Financial Support

UCEP

IUB

SwanirbhorBangladesh

War Course Foundation

Anjuman Mohfidul Islam

Utshob

Special Olympics Bangladesh

Local Community Support (Factory Sites)

Established and running of Malek Chowdhury Memorial Girls’ High School at Shafipur

Donated land and developed local community graveyard at Shafipur

Generous Assistance for local mosques at Shafipur

Noi Solution / Design Asia:(Sister concern of New Asia Group):

A new generation complete New York based own group buying house. Country office is in

Bangladesh. Another Laiago Office in Hong Kong and all over the place.

My Working Jone:

My Department:

Working Department: Merchandising

Position: Merchandiser (Marketing)

Division: Top’s and Bottom

Measurement DatePoints XS S M L XL XXL Amended

chest 2.5cm down fm underarm 44 48 52 56 60 64

hem width - at hem edge 37 41 42 46 50 54

across shoulder seam to seam 38 40 42 44 46 48

length fm snp 66 68 70 72 74 76

sleeve length fm armhole seam 66 67 68 69 70 71

armhole straight - front 23 24 25 26 27 28

bicep at underarm 16 17 18 19 20 21

elbow at half underarm 15 15.5 16 16.5 17 17.5

cuff opening - at cuff edge 12 12.5 13 13.5 14 14.5

back neck width seam to seam 21 21.5 22 22.5 23 23.5

Neck trim depth at SNP 7 7 7 7 7 7

Front neck drop fil in to top button 16 16.5 17 17.5 18 18.5

back neck drop fil to bns 2 2 2 2 2 2

hem depth 5 5 5 5 5 5

cuff depth 5 5 5 5 5 5

across front 15cm down fm snp 36 38 40 42 44 46

across back 15cm down fm snp 37 39 41 43 45 47

shoulder angle 5 5 5 5 5 5

min neck stretch 33 33 33 33 33 33

Placket width 5 5 5 5 5 5

Pocket Opening 15 15 15 15 15 15

Elbow patch width 10 10 10 10 10 10

Elbow patch length 16 16 16 16 16 16

Elbow patch postion from cuff edge 23 23 23 23 23 23

ALL ABOVE MEASUREMENTS ARE IN CMS AND MEASURED FLAT

TOLERANCE: 0.5CMS BELOW 25.0CMS, 1.0CMS ABOVE 25.0CMS

SPEC SHEETThis design is the property of Visage Ltd

Designed on behalf of Visage group

STYLE: Norton CUSTOMER: Pennys

CODE: FABRIC:

DESCRIPTION: V neck Button thru cardigan BLOCK:

Sizes

DATE CREATED: 23.11.12 DATE AMENDED:

Exported Garments by me:

Merchandising Duties and Responsibilities:

i. Checking the submissions on regular basis.ii. Checking costing & consumption to get idea.

iii. Communicating with supplier.iv. Checking & monitoring the material, production & execution planning.v. Also checking the implementation of planning.

vi. Coordinate between QC team, supplier and forwarder to ship smoothly.vii. Attending final Inspection of the product with the inspection team.

viii. Contacting, communicating with new suppliers and following up both old & new contactsix. Contacting, communicating & Co-ordinate with different production level for follow up orders.x. Supervising the quality in the floor.

xi. Doing consumption, costing, & other regular work including booking of yarn, fabrics & all related accessories to concern department.

xii. Making production plan together with superior & planning department.xiii. Communicating with concern buyer & buying house about all related issue.xiv. Manufacturing merchandising.

Specialization:

i. I have very sound knowledge in all kind of garment items, also have idea on factory evolution & compliance issues.

ii. I’m quick learner, cool headed, honest & maintaining ethical practice on work.iii. Always believe in team working, good cooperation, helping minded.iv. Maintaining close relation with buyer, collogues, suppliers.v. Always flexible & ready to accept any new idea which can solve any problems.

vi. Believe in long time relationship.vii. Trustful & ready to take any risk to get the success.

viii. Having good track record for human resource development & management.ix. Customer focused.x. Having strong team leadership and coaching skills.

xi. Quick responder and good problem solver as well as trouble shooter.

xii. Highly foresighted, credible and consistent role model for team members.

xiii. Transparent, confident, positive communicator with a professional attitude.

xiv. Good Follow up skill on activities and projects through to the end.

xv. Believe in success & reward.

LEARNING THROUGH FACTORY VISITINGLEARNING THROUGH FACTORY VISITING

MARKETING DEPARTMENT:

Marketing department carries out three major functions which, according to the size and organizational structure of the company may be combined or may be separate entities within the department. These are-

Marketing:

This is the generic name for the activities involved in directing the flow of goods from producer to customer. This department main function are-

Prepared marketing calendar Product pricing. Order collection Promoting the company’s products and image. Price evaluation. Product planning. Customer findings.

STORE & INVENTORY

Inventory systems for raw materials:

The types of inventory carried in this Industry are as follows:

10% inventory system.

All types Accessories & fabrics before stored must be metal free.

Fabric storage: Supplied Grey fabrics are first subjected to the 4 point inspection system and

fabric allowance point is 20 per 100 yards. only those goods are stored here which are passed

from the quality control department. And defected fabric are back to the supplier.

The types of fabric defect are check in 4 point inspection system.

- Oil spot

- Missing yarn- Dye defect- Hole- Color yarn - Drop pick- Net- Knot- Broken yarn- Slub yarn & Color shading etc.

Accessories:

Before sending the goods to the final destiny packaging materials are necessary. These materials

are needed to be purchased or ordered earlier. Therefore, they should also be stored in suitable

condition. Accessories are purchased from local market .Accessories are subjected to the 100%

check.

Finished goods:

Finished goods are also necessary to be stored. The goods which are better in quality and can be

sent to the final destiny are stored first. Besides these, the goods which are bad in quality or

rejected from the quality control department stored for selling as wastage.

Name of some Accessories.

- Zipper - Button- Elastic- Level- D –Ring- Buckle/ Suspender slider.- Canvas Tap- Hook & Bar- Hanger size etc

MARKER, SPREADING & CUTTING

Production sequence of spreading and cutting

Received Finished Fabric

Inspection

Marker making with the aid of CAD

Received Pattern

from Sample

Spreading (Manual or Spreading m/c)

Cutting

Sorting and Numbering

Inspection

Pieces sent to Sewing

Production Flow Chart in the Cutting Room.

Fabric inspectionCut ratio

Markers Planning

Spreads

Production

Manual

Spreading Machine

Machine Cutting Die press Computer

Shade Marking

Cut inspection Preparation for Sewing Tickets

Bundles

Marker:

Marker is a thin paper which contains all the pattern pieces of a garment. It is made just before

cutting and its purpose is to minimize the wastages. The width of a marker is equal to the width

of the fabric and it should not be greater than the width of the fabric i.e. 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 it will obviously minimize

wastages.

Objects of marker making:

- To reduce cost;

- To improve the quality of the garments;

- To reduce the cutting time;

Marker Efficiency:

The ratio between the total areas of the pattern pieces to the total area of the maker paper is

technically termed as Marker Efficiency. It is expressed in percentage. If it is denoted by the

symbol ή then –

Marker Efficiency (ή) = (Total areas of the pattern pieces/Total area of the Marker paper) * 100

The factors which influence the Marker Efficiency–

- Manufacturers of the marker;

- Size of pattern pieces;

- Length of the marker;

- Pattern Engineering;

- Nature of the fabric;

- Method of marker making;

- Marker width;

- Kinds or design of garments.

Constraint of Marker making:

The hinders of marker making are –

Grain Line:

Grain line is a more effective constraint of marker making. Because of grain line sometimes it is

tough to place the pattern pieces on to the marker, even though it is possible the wastage become

higher.

Design of Garments:

Sometimes the designs and repeats of the fabric are regarded as constraints of marker making.

The patterns may miss the designs or may overlap the designs.

Nature of the Fabric:

Nature of the fabric may sometimes be regarded as a constraint of marker making. Nature of the

fabric includes symmetric and asymmetric.

Cutting Accuracy:

Accurate cutting may be one of the constraints of marker making.

Production Planning:

Production planning includes rate of production, types of garments, sizes of garments, etc.

Fabric wastages inside and outside of the marker:

INSIDE WASTAGE:

That wastage that is obtained from the inter-spaces of the pattern pieces in the marker paper. It

depends on the efficiency of the marker maker and on the size of the patterns as well.

OUTSIDE WASTAGE:

Besides the inside wastages, some fabric is wasted outside of the marker –

Ends of the ply losses:

Generally each ply of the fabric losses up to 4 cm at both sides (Two sides * 2 cm).

End of fabric losses:

The length of fabric may sometimes not cover the ply, it may finish its end at less than 5 yards

(cut piece). This piece of fabric goes through wastage and is called end of fabric losses.

Selvedge losses:

Generally selvedge losses are 2% to 3%.

Purchase losses:

Sometimes losses may arise from purchase. Wrong consumption calculation may cause huge

wastage.

Fabric cutting:

To cut out pattern pieces of garment components as per exact dimension of the patterns from a

fabric lay is called fabric cutting. It is totally different from general cutting in which exact

dimension is not taken into account. The term fabric cutting is only applicable for garments

manufacturing technology.

Requirements for fabric cutting:

The following points must be fulfilled in fabric cutting-

Precision of fabric cutting:

Fabric cutting should be done accurately as per exact dimension of the pattern pieces in the

marker. Accurate cutting depends on methods of

cutting and marker planning. If manual cutting method is used, then cutting accuracy depends on

sharpness of knife, skill ness of operator, and attentiveness of operator. Computer controlled

cutting and die cutting have their self cutting accuracy.

Infused edge:

During fabric cutting, the friction between the fabric and the blade produces temperature in the

blade; the temperature may be up to 3000C. If the fabric contains synthetic fibers, e.g. nylon,

polyester, acrylic or their blends, then fused edge may result in the fabric. As because most of

those fibers melt at around 2500C. Therefore, sticking of cut edge of fabric will increase the

fabric wastage Moreover, the fused edge after cooling will form hard bid, which will be problem

of irritation during use of garments

To avoid the problem of fused edge formation, the following steps

may be taken-

- Reduce the height of the lay;

- Reduce the cutting speed;

- Use anti-fusion paper in the lay at regular interval;

- Lubricate the knife during cutting.

Supporting of the lay:

Surface of the cutting table depends on methods of fabric cutting. The table surface should be

capable to support the lay as well as to ensure that all the plies are cut at a time during fabric

cutting.

Consistent cutting:

Whatever the cutting method is used for fabric lay cutting, it should be ensured that the shape of

the cut components from top to bottom lay are of exact size and shape, otherwise the garments

produced will be defective.

Methods of fabric cutting:

Fabric cutting methods are as follows-

Manual Method: Computerized Method

Scissor - Knife cutting Round knife - water jet Band knife - Laser cutting Straight knife - Plasma torch cutting Die cutting Nether, and Drill

MACHINE FOR CUTTING:

Cutting Section REF NO.

Equipments Types BRAND MODEL

1 BELT LOOP CUTTER KS-ACE C-1502 BELT LOOP CUTTER WA-1090-42-P

3COLLER POINT TRMMING/TURNING M/C

NGAI SHING+LOCAL NS-76+ 10Nos

4COLLER NOTCHER MACHINE NGAI SHING NS-95

5 BELCRO ROUND CUTTER CUTEX TBC-50R6 ELASTIC CUTTER CUTEX TBC-50P7 AUTO LEVEL CUTTER (HOT) CUTEX TBC-50SH

8TOTAL APPAREL SYSTEM (CUTTING) LECTRA 2000

9FABRIC INSPECTION MACHINE NAGI SHING NS-59

10 FUSING MACHINE HASHIMA HP-450 JS11 FUSING MACHINE HASHIMA HP-90LD12 FUSING MACHINE SUMMIT SR-40013 FUSING MACHINE HASHIMA HP-220 JS14 FUSING MACHINE HASHIMA HP-900LCS15 CLOTH CUTTING MACHINE KOON SING KS AU -V1016 CLOTH CUTTING MACHINE EASTMAN 62917 END CUTTER MACHINE EASTMAN EC-318 END CUTTER MACHINE TOYO TY-880LHA19 DRILL MACHINE EASTMAN CD-320 DRILL MACHINE BULLMER 336SLe63621 HOT NOTCHER BULLMER HVN822 NUMBERING MACHINE METO PA 72223 MASH CUTTING GLOVES WHITING

24AUTOMATIC FAB. SPREADER LECTRA PG II

25 BAND KNIFE MACHINE WASTEMA SGV-376GT

Straight knife:

It is the most common and extensively used fabric cutting machine in the garments

manufacturing Industries.

The machine has a base plate;

under base plate there are wheels to facilitate easy movement of the cutting machine during

fabric cutting on the cutting table. There is a big motor on the stand; the stand is connected to the

base plate. On the motor, there is a handle to move the cutting machine. The blade or knife is

situated inside of the stand. The knife has a knife guard. There is a grinding wheel near to the

knife which facilitates knife sharpening during fabric cutting. Two types of power are needed to

cut fabric in this machine. Electric power is used by the motor for the reciprocating movement of

the knife and manual power is needed to move the cutting machine and blade through the fabric

lay. Higher the size of the motor, higher the force of the blade and higher the depth of the fabric

lay could be cut.

The height of the blade may vary from 10 to 30 cm and stroke of blade may be 2.5 to 4.5 cm.

The cutting edge of the blade may be plain (for soft fabric), waved (for plastic), saw edge (for

canvas), and serrated (for hard fabric e.g. Denim).

For cutting different types of fabric, different speeds of blade may be set. There are modified

versions of straight knife also available. The modified version has a cantilever

SUMMURY WORKING PROCEDURE IN CUTTING SECTION

# FOLLOW PRODUCTION PLANNING

#COLLECT P.O. SHEET FROM MERCHANDISER

# SAMPLE COLLECT FROM SAMPLE SECTION WITH PATTERN AND GARMENTS

APRROVED.

# TRIM. ACCESSORIES & FABRIC ALL IN-HOUSE IN STORE OR NOT. IF OK

# LAY ODER SHEET/ DOCKET / RATIO SHEET FILLUP BY CUTTING SECTION

(FABRIC WIDTH. ITEM. COLOR. SIZE. STYLE. BUYER. P.O COUNTRY )

# LAY ODER SHEET FILLUP OK THEN SEND TO CAD SECTION FOR MARKER

MAKING

# MARKER MAKING OK

# FABRIC REQUSITION FROM CUTTING SECTION TO STORE FOR CUTTING

ACCORDING TO PLAN .

# FABRIC IS COMING INCUTTING TABLE AS PER MARKER AND CUTTING PLAN .

# FABRIC MATCH TO TRIM CARD BY MERCHANDISER APRROVED FABRIC WIDTH

& LENTH AS PER MARKER .

# ITS OK THEN LAYERING START MANUL & MACHINE ALL FABRIC . POCKTING

AND INTERLINING.

# AFTER LAY THEN SAPREAAD MARKER UPON ON THE FABRIC .

# MARKER CHECK BY PATTERN IN QUALITY PEOPLE .

#KEEP ALL DOCUMENT MAKE & STYLE . COLOR . AND SIZE WISE SEND REPORT

TOSTORE & SEWING LINE .

# BEFORE CUTTING CUTTER MAN ATTACH CLAMP. GUM TAP ON THE LAYER.

IF MARKER HAVE DRIL MARK THEN NEED TO DRIL .

# CUTTING START BY CUTTER MAN.

# THEN GROUP AND RATIO WISE STRICKE.

# AS PER LAY ORDER SHEET MAKE BUNDLE CHART AND SEND TO I.E. SECTION

FOR BUNDLE CARD PRINTING .

# AS PER BUNDLE CHART WISE NUMBERING .

# THEN PANEL CHECK.

# IF HAVE ANY FAULT NEED TO RECUT/ REPLACE CUT BUNLE ROUL AND SHAD

WISE THEN BUNDLE AND SEND TO LINE BY INPUT GIRL.

# IF HAVE ANY FUSING, EMBRODERY THAN SEND TO THIS SECTION.

Embroidery

In embroidery section there are two high speed (Barydan) m/c with a capacity of 22,000stitches

per hour 9colour.

The following things are to be checked before starting bulk

production.

** After completing 1st 20 piece embroidery thread tension & bobbin tension &

measurement should be check.

** Spare parts

** Pattern

** Measurement

** Embroidery quality

** Design & speed

** Machine accessories

** Embroidery thread &Bobbin thread.

CAD SECTIONCAD SECTION

PATTERN MAKKING

CUTTING M/CSEWING SECTIONSEWING SECTION

Sewing:

The process of joining of fabrics by the use of needle and sewing thread or by other techniques is

called sewing. The line of joining fabric is called seam. The arrangement of fabric ends at the

seam line called seam type.

SEWING FLOOR

Properties of seam:

Properties of seam are assessed on the following aspects-

Appearance:

After sewing, the sewn area is observed for any defects, if present which affects out look.

Normally it is expected that there will be no defective view of stitches, seam pucker, or unsightly

view.

Here The picture is a Denim pant & the stricture of the fabric is 3/1twill & buyer is m&s, style

no is 5814U.Sewingflow chart are

FRONT PART BACK PART

OPERATION

FRT. COIN PKT. (1X1) COIN PKT ROLLING (1X1)

F.PKT.FCNG. (UNDER)MARK ON FACING FOR COIN PKT ATT.

ATT. COIN PKT. BY 1/16 + 1/4 T/ST W/ DEC ST.FRT PKT FCNG 3 O/L (1X4)ATT FCNG TO FRT PKT 1X4

FRONT PKT BAGCLOSE FRT PKT BAG

TURN FRT PKT BAG1/4 TOP ST ON FRT PKT

S.FLYFRT RISE, S.FLY,D.FLY 3 O/L

D.FLYTACK & TURN D.FLY

BACK PKT.BACK PKT. ROLLING

IRON BK. PKT. FOR ATT.

FRONTATT PKT TO FRT

1/16 TOP ST ON FRT PKT OPEN1/4 TOP ST ON FRT PKT OPENREMOVE FRT PKT 2 STICKER

TACK TOP BTM FRT PKT OPENFLY 1/16 & ZIP ATTFLY TOP J ST BY PATTERN

DEC ST ON FLY BY PATTERNREMOVE COIN PKT STICKER

ATT D.FLY & TOP STFRT RISE 1/16 & 1/4 TOP STBTK ON FLY 3 NOS

LOOP MAKE LOOPS BY FOLDER

BK. YOKEATT. YOKE TO BK. BY F.O.A (FOLDER)CUT Thread YOKE & BK RISE THTEAD

BACKTOP STITCH BACK RISE BY F.O.A

MARK ON BK FOR PKT. ATT.ATT. PKT. TO BACK BY 1/161/4 T/ST ON BK PKT

BTK. ON BK PKT MOUTHMARK ON WAIST FOR GAP MARK + LOOP SELECT

W/BANDMARK W/B FOR ATTACH W/ SELECT

BUTTON HOLE ON W/BBUTTON ATT ON W/B

REMOVE YOKE & BK PKT STICKER

ASSEMBLESELECT FRT. & BK. W/GAP MARK

CLOSE SIDE SEAMS BY 5O/LATT. SIZE & CARE LABEL TO S/SEAM W POLY

T/ST. ON SIDE SEAM BY F.O.AMARK ON WAIST FOR LOOP ATT ( 2 MARK).ATTACH LOOP TO WAIST W/ CUT

MART FRT FOR FLY & COIN PKT GAP MARKREMOVE W/B STICKER

ATT. W/B TO WAIST BY K/S FOLDER (TOP & BTMOPEN K/S ST + REMOVE W /B STIKER

CUT W/B MOUTHCLOSE WAIST BAND MOUTH (L+ R)

TACK LOOP TOP & BTMREMOVE OTHER STICKERCLOSE INSEAM BY 5 O/L

BOTTOM HEM WITH THREAD CUTE/H ON W/B MOUTH

TURN BODY FOR QA CHECKBTK ON CROTCH POINT

BTK. ON LOOP TOP & BTM (10 NOS)

MACHINE SUMMURY OF SEWING SECTION 1st floor:

Sewing SectionREF NO.

Equipments Types BRAND MODEL

1 SINGLE NEEDLE JUKI DDL-85002 SINGLE NEEDLE (UBT) JUKI DDL-8700-73 SINGLE NEEDLE (UBT) JUKI DDL- 5700N74 SINGLE NEEDLE (NDL FEED UBT) JUKI DLM-5410N-75 SINGLE NEEDLE (EDGE CUTTER) JUKI DLM - 5200ND

6SINGLE NEEDLE(Bottom Hem)(UBT) JUKI DLN-6390-7

7 SINGLE NEEDLE BROTHERDB2-B735-6(White)

8 SINGLE NEEDLE BROTHER DB2-B101-59 SINGLE NEEDLE BROTHER DB2-B736-310 SINGLE NEEDLE (NEEDLE FEED) BROTHER DB2-B721-311 SINGLE NEEDLE (UBT) BROTHER DB2-B737-415 II12 SINGLE NEEDLE (UBT) BROTHER DB2-B737-413 III13 SINGLE NEEDLE (UBT) BROTHER SL-B737-405 III14 SINGLE NEEDLE (UBT) BROTHER S7200A-40515 SINGLE NEEDLE (EDGE CUTTER) BROTHER DB2-B777-3A

16SINGLE NEEDLE (TOP & BTM FEED) BROTHER B773-003

17 SINGLE NEEDLE (ZIGZAG) JUKI LZ-391N18 SINGLE NEEDLE (ZIGZAG) BROTHER ZE-855A19 SINGLE NEEDLE (UBT) DURKOPP 271-140442 20 DOUBLE NEEDLE JUKI LH-312821 D/NEEDLE (SPLIT BAR. UBT.) JUKI LH-3168-722 D/NEEDLE (SPLIT BAR. UBT.) JUKI LH-3588-723 D/NEEDLE (SPLIT BAR) JUKI LH-316824 DOUBLE NEEDLE (Fix) BROTHER LT2-B842-5 H25 D/NEEDLE (SPLIT BAR) BROTHER LT2-B845-3 M26 D/NEEDLE (SPLIT BAR) BROTHER LT2-B845-5 H27 DOUBLE NEEDLE (Larg Hook) BROTHER LT2-B872-5 H 28 AUTO WELT POCKET BROTHER BAS 620029 AUTO WELT POCKET JUKI APW 19530 DOUBLE NEEDLE CHAIN STITCH BROTHER DF962031 DOUBLE NEEDLE CHAIN STITCH JUKI MS 380 32 FEED OFF THE ARM JUKI MS 119033 FEED OFF THE ARM JUKI MS 1261

34 FEED OFF THE ARMJUKI UNION SPECIAL 35800

35 OVER LOCK (5 THREAD) JUKI MO-3316-FF636 OVER LOCK (5 THREAD) JUKI MO-361637 OVER LOCK (5 THREAD) JUKI MO-6916SFH660H38 OVER LOCK (4 THREAD) JUKI MO-6914-S39 OVER LOCK (4 THREAD) YAMATO AZ8125G40 OVER LOCK (6 THREAD) YAMATO AZ8500G41 OVER LOCK (5 THREAD) PEGASUS M 632-3842 OVER LOCK (3 THREAD) PEGASUS M 652-01-4 43 BUTTON HOLE JUKI LBH-78144 EYE LET BUTTON HOLE REECE 10445 EYE LET BUTTON HOLE REECE 10146 EYE LET BUTTON HOLE REECE S- 21147 EYE LET BUTTON HOLE JUKI MEB 320048 COMPUTER CNTRL BARTACK JUKI LK-1900-ASS

LK-1900-AWS/

SL MACHINE NAME BRAND MODEL TOTAL

01. ZIG-ZAG STITCHING M/C PROTEX 02 Sets

02. SADDLE STITCH M/C JUKI SS-3888 05 Sets

03. BLIND STITCH M/C TREASURE BS -101 02 Sets

04. PIN HOLE M/C STAGER SZ25 01 Set

05. FRONT PLACKET FUSING M/C

NGAISHING NS-8233 02Sets

06. SLEEVE PLACKET FORMING

NGAISHING NS-2410 04Sets

07. METAL DETECTOR LOCK/CINTEX MET-30 03 Sets

08. CAD SYSTEM INVESTRONICA 14 Sets

09. FUSING M/C

NGAI

SHING

NS-893401

Set

HASHIMAHPM – 600

B/LCS09

Sets

FIBLON HM – 450 01 Set

FIBLON FA-700DS 01 Set

KEUMSUNG KFP – 177- 8 01 Set10. ARM HOLE FUSING M/C NGAISHING NS-8230/335 07 Sets

1

1SIDE SEAM FUSING M/C NGAISHING NS-8232 04

Sets

1

2.PIN TUCK M/C(25 NEEDLE) MURATA WX-008 01

Set

1

3.PIN TUCK M/C(12 NEEDLE) RENOUN MT-12 02

Sets

1

4.

BUTTON TESTING SOLUTION

SAFGUARD 01

Set

1

5.NEEDLE SEARCH M/C HASHIMA HN-25 06

Sets

1

6.ELECTRONIC B/H M/C BROTHER HE-800A 27

Sets

TOTAL SPECIAL MACHINES= 94Sets

SL#

MACHINE NAME BRAND MODELBDL

BGL

TTL TOTAL

01. SINGLE NEEDLE LOCK STITCH M/C

JUKI DDL-227 08 10 18

638Sets

JUKI DDL-5530 62 34 96JUKI DLN-5410 01 03 04JUKI DDL-8300 25 86 111JUKI DDL-8700 08 10 18JUKI DLM-5200N 04 04 08

BROTHER DB2-B735-6 80 61 141BROTHER DB2-B737- 05 11 16BROTHER SL-737 16 39 55BROTHER DD-777 04 04BROTHER DD7100+710A 02 06 08BROTHER S-7200 28 02 30BROTHER SL-1010 07 62 69BROTHER SL-2110 06 06BROTHER S-6200 06 12 18CELSTAR BSL-5580 01 01

SUNSTAR 01 04 05JACK JK-5550 15 07 22

TYPICAL GC-6150H 01 07 08

02SINGLE NEEDLE CHAIN

STITCH M/CJUKI MH-481 02 06 08 08

Sets

03.TWO NEEDLE LOCK STITCH M/C

JUKI LH-3528S 02 04 06

35Sets

JUKI LH-3128 01 02 03BROTHER LT2-B842-3 05 08 13BROTHER T-8420A 03 08 11TYPICAL GC-6842H 01 01 02

04. OVER LOCK M/C

JUKI MO-2316

63Sets

JUKI MO-2416 02 04 06JUKI MO-3616 06 02 08JUKI MO-3716 01 01JUKI MO-6716 08 15 23

PEGASUS MO-732 04 09 13PEGASUS MX-3216 01 05 06TYPICAL GN-2000A 05 05

05. TWO NEEDLE CHAINSTITCH M/C

JUKI HM-380 04 07 11 11Sets

06 PIN TUCK (25 NEEDLE) MURATA WX-008 01 0103

Sets07 PIN TUCK (12 NEEDLE) RENOUN MT-12 01 01 02

08.MULTINEEDLE CHAINSTITCH M/C

KANSAI DFB-1404 06 13 1919

Sets

09.FEED OFF THE ARM

JUKI MS-1190/1190M 10 20 3031

Sets

BROTHER DA-9280DDALIAN KG-43001 01 01

10. BUTTON HOLE M/CBROTHER LH4-B814-2 10 20 30

49Sets

BROTHER HE-800A 06 11 17JUKI LBH-781 02 02

11 BUTTON SEWING M/C

JUKI LK-1903A 04 07 11

43Sets

BROTHER LK3-B438E 03 07 10BROTHER BE-438B 04 03 07BROTHER BE-438C 03 05 08BROTHER BE-438D 01 06 07

12.BAR TACK M/C

BROTHER JUKI

KE-430/LK-1900

03 06 09 09Sets

13 PIN HOLE M/C STAGER SZ-25N 01 01 01 Set14

ZIG-ZAG STITCHING M/C PROTEX 01 01 02 02Sets

15SADDLE STITCH M/C JUKI SS-3888 02 03 05 05

Sets

16BLIND STITCH M/C TREASURE BS –101 02 02 02

Sets

17 COLLAR BOTTOM CUTTING M/C

KGP-586 02 04 06 06Sets

18COLLAR FORMING M/C KGP-535 02 04 06 06

Sets

19 STRAIGHT KNIFE CUTTING M/C

KM / EASTMAN

KS-AUV/629X 06 11 17 17Sets

20BAND KNIFE CUTTING M/C DAC SUNG DS3050 01 03 04 04

Sets

21CLOTH DRILL M/C KM 01 02 03 03

Sets

22DIE CUTTING M/C 01 01 02 02

Sets

23 FUSING M/C

HASHIMA HPM – 600 B 01 01 02

08Sets

HASHIMA HP-600LCS 02 02FIBLON HM – 450 01 01FIBLON FA-700DS 01 01

NGAISHING NS-8934 01 0124

FUSING M/CKEUMSUN

GKGP – 177- 8 01 01 01

Set

25SIDE SEAM FUSING M/C

NGAISHING

NS-8232 02 02 04 04Sets

26FRONT PLACKET FUSING M/C

NGAISHING

NS-8233 == == == ==Sets

27ARM HOLE FUSING M/C

NGAISHING

NS-8230/335 03 04 07 07Sets

28 SLEEVE PLACKET FORMING M/C

NGAISHING

NS-2410 01 01 02 02Sets

29NECK PRESS M/C FIBLON HBP-09 01 02 03 03

Sets

30FABRIC INSPECTION M/C TSSM 01 01 02 02

Sets

31METAL DETECTOR M/C LOCK == 01 01 01

Set

32 HAND HELD NEEDLE DETECTOR

HASHIMA HN-25 01 02 03 03Sets

33THREAD SUCKER M/C

TSSM/LOCAL

01 02 03 03Sets

34GENERATOR CUMMINS 01 01 02 02

Sets

35SNAP BUTTON M/C ZUSUN CB-818 05 08 13 13

Sets

36END CUTTER M/C KM KC-02 01 02 03 03

Sets

37COMPRESSER 01 05 06 06

Sets

38AUTO. STRAPPING M/C UZU 01 03 04 04

Sets

39HEAT SEAL M/C 01 02 03 03

Sets

40CONE WINDER 02 05 07 07

Sets

41COLLAR TURNING M/C 02 04 06 06

Sets

42INTERLINING CUTTING M/C == 01 01 01

Set

43SPOT WELDING M/C == 01 01 01

Set

44BOILER 01 02 03 03

Sets

45BUTTON TESTING SOLUTION

SAFGUARD

01 01 01Set

46INTER LOCK FLAT BED SIRUBA 01 01 01

Set

47PF-PULLAR 03 06 09 09

Sets

48RIBBON CUTTING M/C LOCAL 01 02 03 03

Sets

49LIGHT BOX VERIVAID 01 01 01

Set

50GSM TESTING M/C 01 01 01

Set

51NUMBERING M/C 04 06 10 10

Sets

TOTAL M/C =421 643 1064

1065

Sets

Sewing Section m/c

SNL m/c Band :- JUKI Model : DDL-87007

DNL Angular m/c Band :- JUKI Model :

Sewing Section

Lopper Thread Brand Model

DOUBLE NEEDLE CHAIN STITCH JUKI MS 380

Edge CutterSINGLE NEEDLE (EDGE CUTTER) BROTHER DB2-B777-3A

ARM

Page

60

FEED OFF THE ARM JUKI MS 1190

COMPUTER CNTRL BARTACK JUKI LK-1900-HS

Brand ModelCOM. CNTRL BELCRO ATTATCH JUKI AMS-215D

Brand Model KANSAI SPECIAL KANSAI SPECIAL KS-1411

MAINTENANCEMAINTENANCE

Maintenance:

The act which is done to keep the factory-plants, equipment, machine tools etc. in an optimum

working condition, minimize the break down of machines to improve productivity of existing

machine tools and avoid sinking of additional capacity and to prolong the useful life of the

factory plant & machinery is called maintenance.

Types of maintenance:

Break down or Overhaul Maintenance

Schedule Maintenance

Preventive Maintenance

Planed Maintenance

In FACTORY Maintenance schedule is as follows-

Daily

Weakly

M1

M2

M3(Where, ‘M’ means ‘Month’)

M6

Yearly

F (Every for night check)

Daily:

Mainly inspection of bad sound of pump or motor and m/c parts, excessive heat generation on

motor.

Weakly:

Check pump housing oil, check all bearings, values, and check all electrical & electronic

appliances.

M1:

Check the door mechanism, check oil level of the circuit, replace air filter element.

M2:

Change the tube, oil & clean the oil pan& check values.

M3:

Check up & test at intervals the efficiency of-

- Electrical contract;

- Power transmission;

- Rectifier bridge;

- All electrical components in general.

-

M6:

Disassemble & clean & maintenance of m/c properly.

Yearly:

Open & check motor & varnish its coil.

Routine Maintenance schedule in Factory:

Maintenance procedure:

Normally preventive maintenance is done here. During maintenance procedure following points

should be checked:

GARMENT WASHINGGARMENT WASHING

Garments Washing:

S/L Items need to be checked & serviced

1. Grease the winch bearing

2. Complete cleaning the machine

3. Cleaning the drains valves, replace scales if required

4. Check air supply filters, regulators and auto drain seals

5. Clean filters element and blow out

6. Gearings of unloading rollers bearings

7. Checking of oil level and bolts of unloading roller gearbox

8. Checking of unloading roller coupling and packing

9. Checking and cleaning of main level indicator

10. Check the oil level of pump bearing and refill if required

11. Check the function of heat and cool modulating valves, Check all

belts & belt tension.

It is a new technology by which outlook, size, comfort ability & fashion etc properties are changed of a Garment are called Garments Washing. The technology was first developed in 1988. Before this washing was done in Hong Kong, Singapore & some other country .

Objective of Garments Washing :

## To Develop Softness in Garments.

## To introduce Fading effect.

## To create new fashion.

## To satisfy the customer.

## To remove dirty thing from the Garments.

## To remove starch or size material.

There is Different type of Garments washing In our country:

## Normal Wash.

## Pigment Wash.

## Bleach Wash.

## Caustic Wash.

## Acid Wash.

## Enzyme wash.

## Enzyme Wash With Stone.

## Stone Wash.

## Supper White Wash.

## Wash and Over Dyeing.

Production sequence of Washing

Garments receive from

sewing

↓

Scraping ↓

Tearing ↓

Whickering ↓

P.P spray ↓

Curing/Tearing

↓Washing

↓Drying Hot + cold

↓Checking

↓ Disposes

Special affect on Garments can be obtained by the following process as a Dry Process.

## Scraping ## Tearing## Whickering ## P.P. spray## Curing ## Tagging## Grinding ## Sanding Blasting etc.

WASHING MACHINE

3 1 2

Washing Machine SMARTEX 225

Washing Machine SMARTEX 340

Washing Machine NGAI SHING 2250

MACHINE SUMMURY OF WASH SECTION:

MACHINE SUMMARY

REF NO.

TYPE OF MACHINE MACHINE BRAND

1 Washing Machine SMARTEX 225

2 Washing Machine SMARTEX 340

3 Washing Machine AVANTEC 340

4 Washing Machine NGAI SHING 2250

5Washing Machine Sample

RAMSONS


NGAI SHING 2211


SUNLEGUE-SLW-100(S)


SUNLEGUE-SLW-250(S)

9 Hydro Extractor NGAI SHING

10 Hydro Extractor Sample RAMSON

11 Drying Machine NGAI SHING 2330

12 Drying Machine TRANSRERON

13 Drying Machine AVANREC

14 Drying Machine Sample RAMSON

15 Ironing Table RAMSON

16 Hot Pressing Machine RAMSON

17 Trouser Finisher MACPI

18 Trouser Finisher NGAI SHING

19 Jacket Dummy VE-CO

20 Scraping Motor

21 Teg Machine SPA 80

22 Cmpressor INGARSOL RAND

23 Cmpressor ATLAS COPCO

24 Sand Blasting MEC SHOT BLASTING+TM-JM.

25 Spray Gun

26 Spray Baloons

27 Grinding Machine

28 Crock Master Testing

29 Light Box VERIVIDE

30 Light Box MECHBATH

31 Lab Dip Machine ROACHRS

32 Oven AVANTEC

33 Oven RAMSON SUPER CARE

34 Photo Spectrometre DATA COLOR

35 Teg Machine DENISION

36 Steam Iron

37weighting Indicator. A&D

38 Vertical Dummy Concorde

39 Genarator (320KW) Vibro Power


SMARTEX 20KG

41 Scrunch MC GFK

42 TECA GFK

43 Popping Machin GFK

44FMG(Fabric Grinding M/C)

GFK

FINISHING SECTIONFINISHING SECTION

FINISHING LAYOUT

1. Button Section

2. Thread Cut

3. Preliminary check/ Quality Check

4. Thread sucking

5. Iron

6. Alter the garments

7. Measurement Check

8. Final Check

9. Iron

10. Get up Check

11. Shade segregation

12. Poly

*** Remove spot***

Spot name & Use remove chemical

# Oil spot - A.D Max

# Shying spot - G.R.O

# Ink spot etc . - B.T.S

Others chemical

Thinner, H.P, NASHA, etc.

Trims:

Trims cover all the items used in the garment except the basic fabric. There are hundreds of

items used to manufacture the garments. Proper selection of trims and its quality are very

important for styling; otherwise the garment may be rejected or returned by the customers.

Following is a part of list that covers some names of the items:

ZIPPER/FASTENER:

Teeth : Nylon, Vislon, Metal

Color : Tape color, Teeth color

Size : #3, #5, #8, etc.

Length : As per requirement 18 cm, 72 cm

End : Close End (C/E), Open End (O/E)

Slider : One way, Reversible.

SEWING THREAD:

- Shade, color fastness, etc.

- Tensile strength, Elasticity, Shrinkage, Moisture Regain, Abrasion Resistance,

etc.

- 30s, 60s, 20/2, 40/9 Ne, etc.

LABELS:

- Main label

- Size label

- Care label

- Content

- Price

- Patch, etc.

BUTTON:

- Horn and

- Metal buttons are very common in use.

ELASTIC:

- Cotton

- Polyester, etc.

EYELET:

- Antique

- Matching, etc.

VELCRO:

- Hook and Pile

STRING/CORD:

- Cotton

- Polyester, etc.

TAGS:

- Price tags

- Hang tags, etc.

POLYBAG:

Strength, Chemical mixture, Thickness (micron/mm; 1mm = 1000 micron).

BLISTER BAG:

- 0.05 mm in thickness;

- Loaded capacity is higher than poly bag.

CARTON:

- 3 ply

- 5 ply

- Size (L, W, and H).

STICKER:

-Hook and Pile.

PLASTIC CLIP:

TAGPIN:

SCOTCH TAPE:

HANGER:

GUM TAPE:

ETC.

Snap Button Attach M/C (Numatic)

Snap Button Attach M/C (Electric)

Assessment:

Color change:

The original and tested dyed samples are placed side by side, oriented in the same direction

along with the color change grey scale and compare the contrast between the treated dyed sample

and the same untreated sample with the appropriate pair of color change grey scale. If there is no

color change, then its ratting will be 5.

Color staining:

Again, compare the contrast between the untreated white fabric and the stained white with the

appropriate pair of grey white samples of the grey scale for staining.

PH Check’s

Purpose:

To fulfill the buyer requirement. To keep the PH of the fabric as per standard.

Method:

ISO-3071

Apparatus:

Beaker, Stirrer, Conical flask,

Procedure:

- Take 3 pieces of 2 gm sample;

- Take 100ml of distilled water (PH-5.5 to 7.5) in three conical flasks;

- Put the 2 gm treated sample in each conical flask;

- Shake them for 1 hr in normal temperature;

- Finally measure the PH by averaging them.

(Standard PH range for colored fabric 6 to 8 and Standard PH range for white fabric 5 to 8)

QC DEPARTMENTQC DEPARTMENT

Quality is unusually slippery and difficult to come to grip with and therefore someone has said,

"Quality is something I know when I see it". To some, quality defined is like 'love' explained.

Once the concept of quality is understood fundamentally it stops being slippery

and become something, which you can hold by the all.

The main function of the Quality Control Department is not to control quality but to provide a service which allows other people to make good clothes. Their main concern must be to do this at the minimum cost, balancing the expense of the department against die savings it makes possible in terms of reduced repairs and rejects. One aspect of this is to define the quality level of the plant and of the workplaces in-it.

Function:

Q.C in store

Q.C in PDS.

Q.C in cutting

Q.C in embroidery.

Q.C in printing

Q.C in sewing line

Q.C in down section

Q.C in finishing section

Q.C for pre-shipment

ORGANIZATION OF QUALITY DEPARTMENT

Director

Q C Manager

Quality Controller

Cutting Sewing Finishing

Fabric Inspection

Cutting Inspection

Before Iron Quality Inspection

After Iron Quality Inspection

GET-UP Inspection Quality Inspection

Final Table Quality Inspection Shell / Linen Quality Inspection In Process Quality Inspection

QUALITY CONTROL DEPARTMENT & THERE FUNCTIONS ARE-

INSPECTION

Upon receipt of the fabrics, the fabric inspector at the factory shall be responsible for making arrangements to inspect for visual and technical defects present in the fabric rolls. If passed on unnoticed, fabric defects cause-increased problems in successive manufacturing stages. This section explains the steps necessary to conduct an effective piece goods inspection.Steps:

Select at least 10% of the fabric rolls randomly in the case of woven and 20% of the fabric rolls randomly in the case of knits.

Determine the yardage of the fabric to inspect. Verify that there is enough light for clear vision.

Run the roll at a sufficient speed to identity the defects, approximately 25-30 yds/min.

FABRIC WIDTH CHECKING

The fabric lots that are received by the factory for checking should be according to their widths. This is very important since garment consumption varies from width to width. In all cases, fabric width less than the minimum specified should be considered as a defect.The following example illustrates the significance of fabric width checking. (i.e. the importance of separating rolls having varying widths).

A Factory orders 22,000 Yds. of fabric to make 10,000 garments tolerances to compensate for defective and rejected garments), and receives theShipment as,

45" 17,000 Yds44" The estimated fabric consumption for making a garment of that particular Style and size range is:

For 45" fabric width 2.1 Yds

For 44" fabric width 2.2 Yds

If the fabric rolls are separated according to width and made, the factory should be able to cut,

17,000/2.1 = 8,095

5,000/2.2 = 2,272

= 10,367 garments

Whereas, if the fabric rolls are not separated according to widthwise, it is only possible to cut 10,000 garments.

Systems for grading fabric

Defects or Penalty points are based on the length of the defect. Several options for assigning points to defects exist Longer defects are assigned more points because their existence presents more significant problems in terms of fabric usage, The following section describes 4-point system of grading knitted and woven fabrics. Attention should be focused to see that well-trained fabric inspectors are assigned the job. Inspection should be carried out using a fabric inspection machine that moves the fabric lengthwise across the viewing surface from the beginning to the end of the roll. Fabric inspectors shall use the systems described below for grading fabrics (woven and knitted) to ensure proper fabric quality.

POINT SYSTEM OF GRADING FABRICS

This system was published in 1959 by the National Association of Shirt, Pajama, and Sportswear Manufacturers. This system assigns penalty points based on four categories of defects and each category of defect is assigned a penalty point. Faults are recorded according to the size and frequency, regardless of cause and type.

Size of Defect (Inches) Assigned Points

3 inches or less 1

Over 3 inches but not over 6 inches 2

Over 6 inches but not over 9 inches 3

Over 9 inches 4

Normally this system is to be used in the inspection of knitted fabrics although it is also applicable to woven. Fabric inspection is usually based on fabric width of 64-66 inches (for knitted fabrics). Generally, one linear yard of fabric should not be assigned more than 4 points. After noting the points. Points /100 Sq. Yd is calculated using the following formula:

Potato/100 Sq. Yd Total points x 3600

Fabric width in Inches x Total yards inspected

If the Points / 100 Sq. Yd is below 25 points, the fabric is considered as First Quality, otherwise it is considered as Second Quality.

Entire shipment should be 100% inspected if the point level exceeds 25 points per 100 square yard.

CHECK NOTES FOR FACTORY QUALITY INSPECTOR

Spreading :

Verity that the correct type of fabric is being spread and that it agrees with the marker width.

Check whether the fabrics are uniformly spread out without any creases, leaning, edging, folding and uneven tension.

On face-up spreads, check that nap of fabric is in same direction. If shade of fabric varies from one roll to another, separation paper is to be placed between

rolls. A discussion should be held with the production representative to resolve how to handle the shading lots.

Perform length and width verification.

Marking:

See that the markers are not creased, damaged, or have overlapped parts. All parts of marker are clearly marked. Width of marker fits fabric width. Check for the correct grain direction of the patterns. Cutting: Check whether the top and bottom ply are comparable. No notches and drill holes are missing. Extra care to be taken while cutting fabrics made with blended fiber contents (synthetics)

in order to prevent slippage and ragged cutting.

Maintain a record of any defects found while performing these functions. It is Quality Assurance's responsibility to stop production at any stage of cutting where any major defect or problem is found that has not been corrected or approved- Discussion should be held with the Schwab Quality Inspector to resolve any issue before proceeding further.

IN-LINE INSPECTION

To identify quality issues, and defects at each stage of the production process and to take appropriate corrective actions. An effective in-time inspection and subsequent corrective action program great greatly improves the quality of the final product. Remember, Quality cannot be inspected into the garments; it has to be built into the garments.

STANDARD IN-LINE INSPECTION GUIDELINES

Listed in the following paragraph are the Schwab Company's "Standard ln-Line Inspection Guidelines" for sewing/stitching process that all our vendors must use to manufacture the Company's products. See the appendix to this manual to gain a clear understanding of different kinds of stitches.

SEWING / STITCHING

During in-line inspection of sewing. Quality Inspectors shall observe the following at key points throughout the manufacturing sequence according to the given specification:

- Quality of seam including the seam types, seam puckering, seam grinning, seam allowance and seam tolerances.

- Quality of stitching, including stitch type, stitch tension, stitch uniformity, skipped stitches and stitches per inch.Quality Control In Stitching:In order to avoid waste and garments getting rejected at a tater stage, In-One quality Inspection is performed The fast few pieces of production as components / parts or as garments will be inspected by the production department and the quality department for all the discrepancies. All the defects shall be noted and highlighted. After that, the Quality team consisting of Quality checkers. Quality controllers, and the Quality Manager, shall do random checking and 100% checking wherever appropriate. Stitching Quality can be improved by using the following techniques:

Checking, Recording and analyzing observations of defects. Guiding each individual operator. Training programs. Developing Quality consciousness at all levels.

COMPREHENSIVE FINAL INSPECTION

PURPOSE

The purpose of the final inspection is to visually inspect garments at random in order to verify their general conformity and appearance with technical specifications and approved samples received. This should be carried out when the production of the total quantity of an order or partial delivery is completed-A sample tot has to be selected fine the order axed a percentage of the garments should be inspected, this percentage being stipulated by the S. Schwab Company's Quality Assurance Department

REQUIREMENTS OF A FACTORY FOR FINAL AUDITIN

Shipments axe to be 90% packed for Schwab QA to perform final Audit Note: Factories are responsible to have 100% inspection done on the whole shipment.

All boxes must be dosed, labeled, organized by style, size, color, quantity and Purchase Order.

Most prepare and give a copy of the packing list to the quality inspector before the final audit begins.

Approved Trim card.

Current construction specification file.

Current measurement specification sheet

Functions of Quality Manger

The function of Quality Control managers are as follows:

Is to ensure good products and to stop bad work living the factory and reaching the customer.

Reduce the amount of-bad work being made.

Savings the cost of the repairs and rejects but also speeds delivery.

He helps people to make garments correctly the fist time.

Planning:

Definition of required quality characteristics and quality level.

Establishment of revised quality control procedures.

Evaluation of sampling levels and selection of examination Points.

Calculation of appropriate manning levels.

Prevention:

Specifications with tolerances:

Fabric and trimmings to specification.

Correct methods and good training.

Inspection:

Properly selected and trained examiners

Standard examination procedures, with suitable equipment.

Rapid feedback of information, checked against results.

Monitoring:

Checking the efficiency of the examination.

Seeking out trouble spots.

Comparing defect-rations with budgets.

Comparing the costs of prevention with those of poor work.

He is reportable to Higher Authority so that he can work independently to reduce loss of the company. He gives clearance for export.

Functions of Quality Controller:

They ensure quality control at the floor level.

The functions of Quality controller are as follows.

Ensure quality productivity in the production floor.

Ensures proper shedding.

Certify correct market.

Certify correct cutting.

Certify numbering process.

Certify correct placement.

Ensures correct measurement.

Ensure quality requirements as per buyers need.

Ensure correct allowances.

Ensure SPI (Stitch per inch)

Specify needles and the accessories.

Ensures right materials.

Specify proper cutting making ironing, folding, packing.

Allocation of line Quality control Inspection.

The quality controllers ensures for the very beginning to the ends of the process. He should be a technical person in the field of Quality department.

MERCHANDISING DEPARTMENTMERCHANDISING DEPARTMENT

Merchandising Department

Second major elements of marketing & is involved with physical movement of merchandise from the factory warehouse to retailers shops or central store. Apart from merchandising section of the marketing department is also responsible or :

The warehousing of finished products. Allocating customers orders. Packing the order’s when necessary. Delivered the products to customers Inventory control. Ensure that garments are delivered to buyer/ customer as per there requirements. Consumption calculation Costing and pricing.

Finance department

The finance department is responsible for managing all the financial and administrative affairs of the company. Finance department main function are-

Providing mgt. informationBudgeting

Accounts:

Maintain record all kind of earning and expenditure of the company including salary and wages.

COMMERCIAL DEPARTMENTCOMMERCIAL DEPARTMENT

Payment by L/C D/P & D/A :

Business transactions usually begin with a purchase order placed by a buyer with a seller. It is very easy to understand, the order, represented by a piece of paper written by the buyer, or a fax received from the buyer, is not something very reliable and secure. Although the order should be treated as an agreement binding both parties, the buyer and the seller, it is not a guarantee or an instrument for the seller to use to obtain payment for the merchandise shipped. For this reason, the "L/C" comes into the picture.

The full name of "L/C" is IRREVOCABLE LETTER OF CREDIT" which means once it is issued by the bank for the buyer and received and accepted by the beneficiary (the seller), it cannot be cancelled or withdrawn by the buyer or the opening bank, unless with the consent of the beneficiary. In short, once the buyer opens the L/C from his bank to cover the goods he has purchased, he will have to pay for the goods when the seller ships the goods exactly as per the terms stipulated in the L/C. Therefore, as far as the seller is concerned, the sooner he has the L/C on hand, the safer he is. L/Cs can be opened in many ways, but in essence, it is a promise the buyer's bank makes to the supplier, to pay him when he does certain things with evidence to pay him when he does certain things with evidence to prove. the L/C opening bank wants the supplier to do are called "terms". Therefore, when the supplier receives an L/C, he must read the terms carefully to make sure he is capable of fulfilling them all exactly as they are written. If some terms are beyond his ability to fulfill, he must point them out to the buyer and explain why he cannot comply with those terms, and request the buyer to amend them by means of an official amendment through the bank. Following are some different ways L/Cs are commonly written:

SIGHT L/C:

It means when the shipper ships the goods covered by the L/C, and resents the documents to the bank for negotiation, the bank (the negotiating bank) will credit the proceeds to the shipper's account immediately after checking and finding the documents in order.

When the documents are sent by the negotiating bank to the L/C opening bank, the L/C opening bank will effect payment to the negotiating bank also immediately. Such L/Cs usually says "AT SIGHT" which means "pay when the bank sees the documents".

USANCE L/C:

It means L/C with time allowed for the opening bank to make payment of a foreign bill of exchange. Or, put it in another way, payment from the L/C opening bank to the negotiating bank will only be made after a period of time as stipulated in the L/C. The length can be worked out between the buyer and the supplier; something's 60 days or 120 days. Sometimes when you (or your supplier) receive a usance L/C of, for instance, 90 days sight, you may think you have to wait 90 days after shipping goods to receive. payment, or if you wish to receive payment at once, you will have to pay interest to your bank.

However, this is not always the case. Something's, the L/C may say "at 90 days sight with interest to be borne by the L/C OPENER. If it does say this you virtually can use it like a sight L/C. After you have presented the documents to your bank, your bank should pay you in full at once after checking them and finding them in order. However, the negotiating bank would have to wait 90 days for the L/C opening bank to pay. Therefore, as far as you are concerned, you can receive payment as if it is a sight L/C. If the usance L/C does not say "Interest is to be borne by the L/C opener", then either you will have to wait till the maturity of the 90 days or whatever the time span is as specified in the L/C, to receive payment, or you may request your bank to pay you at once and charge you for the interest. Your bank usually should accept your request.

Revolving L/C :

It means that the beneficiary can draw money from such L/C up to the amount specified by means of documents, and after drawing, the amount drawn will automatically be replenished and is available for another drawing ......... and another drawing, and so on. However, in order to limit the size of loss which might be caused by fraudulent activities by the beneficiary, it is advisable for the opening bank to specify a time interval between each drawing based on the actual need of the beneficiary. Revolving L/Cs are good for the buyer and the supplier to cover purchases made regularly as on L/C can be used many times saving a lot of paper work as well as L/C opening charges and receiving charges at both ends. However, the L/C opening bank usually would not open a revolving L/C for the buyer unless he has much bigger credit line than the size of the L/C he would like the bank to open for him.

Stand – by L/C:

This is normally used by the opener, party

a. to assist the beneficiary, party

b. or for party

c. to guarantee party

d. For certain reasons. The following example will illustrate the function more clearly :

D/P TERM :

D/P (Documents against payment) means that after shipment, the shipper should present his documents to his bank to forward to his bank's correspondent bank in the city where his customer is, with instructions for them to notify his customer to pay and take possession of the documents to clear the goods. In other words, without paying for the goods, his customer cannot take possession of the goods. D/P Term will provide the following advantages to the buyer and the supplier:

a. The buyer dose not has to have a credit line with the bank to open an L/C to the supplier to cover his purchases in advance. He only has to have the money ready to pay for the goods when the shipment arrives.

b. The supplier would not have to worry that his customer may take the goods without paying him because without paying the bank to pay him, the bank would not release the documents. However, D/P term cannot save the supplier in the following case : After the supplier ships the goods and sends the documents to the bank for his customer to pay and to take possession of the documents, his customer at this time, still may change his mind to renounce the goods by ignoring the bank's notification, or simply inform the bank that he is no longer interested in the goods. Under the circumstances, the bank will notify the supplier's bank accordingly and ask for his bank's decision the documents. There is nothing the supplier's bank or its correspondent bank can do to force the customer to pay. In this case, he may ask his bank to call bank the documents. Although the supplier has not lost the goods, he owns the goods in an overseas country creating demurrage charges everyday. To resolve the situation, the supplier will have to resell the goods to another customer.

D/A TERM :

D/A (Documents against Acceptance) term as a payment method is far more risky than D/P term to the supplier. D/P term usually come with a time before a certain date, and not after a certain date so as to give a time limit for this matter to end. When such L/C is received by (b), (b) will surrender it to his bank with the invoice or receipt prepared as required by the L/C for a loan of $ 10,000.00 or any amount less than $ 10,000.00 against it, or will get a credit line from the bank for his business activities. He should be able to achieve this by means of this stand – by L/C In short, the spirit of a stand – by L/C is to transfer some financial strength from one company to another.

DOCUMENTATION

When we refer to documentation in the process of export, we usually refer to the process of documents which the shipper uses to collect money for the goods shipped. Therefore, this is the finale of the transaction and an important step. Depending on how the payment term is set up between you and your buyer, we should prepare the documents accordingly. However, no matter it is L/C payment or DP/DA or open account, you must prepare your documents to satisfy the following parties :

a. The buyer's bank who has open the L/C to you if it is L/C payment, otherwise you will have delay in receiving the proceeds of the goods you have shipped.

b. The customs, otherwise you will have delay in clearing the goods through customs.

COMMERCIAL INVOICE: This is the document that you use to collect money from your buyer. Therefore, it must contain the correct unit price with the indication of FOB the shipping port, or CIF or CNF at the shipping port, then it is simple and easy. The following example will satisfy the bank and customs:

Style No

1234

Quantity

1, 000dz

Description

Men's

100% Cotton Woven shirt

Unit price FOB BANGLADESH

US$ 80.00

Total FOB Amount

US $80,000.00

Based on the above, the customs will Impose duty on US$ 80,000.00 When you show the above CIF breakdown on the invoice, the customs will impose duty on the FOB value. However, please note you have to be truthful about the sea freight amount and insurance premium. You must get them from the Bill of Lading, where the freight amount prepaid is shown, and the insurance premium from the insurance company. You cannot inflate these figures to save duty. Otherwise, you may create delays or even bigger trouble for your buyer. The second import things in the preparation of your invoice is that you must provide a full description of the merchandise so that the customs officer can determine what duty rate he should use. The following is a chart

you can use as a guide to form a full description of the garment : To form a full description of the merchandise to be used on the invoice, you should go from (1) to (7) below and select one answer from the column on the right : (1) For what sex is this garment ?

(a) Men's (b) Boys' (c) Ladies' (d) Girls' (2) What is the fiber content ?

(a) 100% cotton (b) 60% cotton, 40% polyester (c) 100% polyester (55% ramie, 45% cotton. Or whatever it is if not listed here. (3) How is the fabric made ? (a) Woven (b) Knitted

5. If it is a shirt/ blouse ) how is the font constructed (a) Full open front (b) Half open front. 6. If it is a shirt/ blouse with full open front, which side is on top. (a) Left over right (b) Right over left.

7. What about the sleeves ? (a) Long sleeves (b) Short sleeves (c) Sleeveless. When you go from (1) to (7) and pick your answers from the column on the right side, you will have a description of the merchandise enough for the customs to judge if the quota provided by the visa is correct or not and what duty rate it falls under without having to open up cartons to see the merchandise to determine. Please note, if the item is a knitted shirt or a sweater, in addition to the description formed in the above manner you still have to make a statement in the invoice about how many stitches to a centimeter horizontally and vertically as elaborated in chapter 7 under "HOW TO DIFFERENTIATE SWEATERS FROM KNIT SHIRTS FOR U.S. QUOTA APPLICATION" If the description you have formed from the chart above is different from the one on the L/C you should use the description on the L/C followed by the new description you have formed in parentheses See example below :

See example below :

Style No

1234

Quantity

1, 000dz

Description

Men's

100% Cotton flannel shirt /

Unit price

FOB BANGLADESH

US$ 80.00

Total FOB

Amount

US$80,000.00

Description for customs :

Men's 100% Cotton woven-shirt,

Long selves, full open front, left front over right front

This way you will satisfy the bank in terms of the L/C, and the customs as far as the identification of the merchandise is concerned. The above description will help the customs identify the item for proper quota and duty. However, in order for the customs to determine the quota and duty, they also need the following information to be included in your commercial invoice : breakdown of materials by weight with related information for customs :

Nature of fabric :100% cotton woven piece

Tariff no. (tsus no) : 6205.20.20.65.

Quota category : 340

Duty

Please refer to chapter 20 for more information like the above. Anyway, your buyer or his agent should provide you with this information. : 20.9 %

(2) PACKING LIST : There is no hard and fast rule as to how exactly it should be prepared. You can use your own format. As long as you can show the following, it will be acceptable :

(a) The content of each of the cartons shipped, including the color and size assortment.

(b) The measurements and gross weight of each carton. Please note, some garments are subject to duty by percentage of the FOB value only, but some garments are subject to duty by percentage of the FOB value and weight (How much per kilo). Therefore, on your packing list you must indicate the gross weight, net weight and net weight clearly (See full detail on "weight list" later.

WEIGHT LIST : Sometimes the buyer may ask for this on the L/C. If he dose, then you should prepare it and submit it to the bank as one of the documents required for L/C negotiation. If your buyer doses not ask for it, then you should You can handle the weight information as follows:

(a) If the L/C says such weight information is needed on the invoice, you follow the L/C and put such information on the invoice, and repeat it on the packing list.

(b) If the L/C does not specify the need of weight information on the invoice, you may omit it on the invoice, but put it on the packing list. If the L/C requires a weight list, then you put the weight information on the weight list and repeat it on the packing list, but you may omit it on the invoice. Weight information should truly be put on the packing list where it belongs. That is says it should be on the invoice, you follow the L/C too. If the L/C requires a weight list, you follow it also. The weight information in question should consist of:

Gross weight:

Gross weight means the weight of the goods including all packing materials. You should provide weight per carton and the total weight of the shipment which should be the same as, or similar to that on the Bill of lading.

Net weight:

Net weight means gross weight less only the export carton and inner boxes if used. Net weight will include the packing materials used for the individual piece of merchandise, for example, the individual poly bag, cardboard and paper hangtag etc. Net weight:

Net weight means the weight of the merchandise excluding all packing materials. In order words, it is the weight of the garment without hangtag, price ticket or even a piece of pin.

You should provide this information for each dz, each carton and for the whole shipment. Based on this information provided, weight duty, if any, will be paid. If the L/C requires you to provide Gross weight and Net weight, you should know, it is Gross weight and Net weight needed, and you provide Gross weight and Net weight, but call it Net weight on the document.

Net weight is needed for duty purpose; Net weight is of no practical purpose – it is for reference only.

BILL OF LADING :

If the shipment is to be mead by boat, B/L (Bill of lading) is usually used. In preparation of the B/L the most important thing is the use of the correct consignee and notifies party.

should use the exact wording as stated on the L/C opened by your buyer so that you will not have any discrepancy against the L/C. In regard to the other aspect of the B/L, you can just follow the format as provided by the shipping line However, sometimes the buyers' L/C may require you to do the following for their convenience:

a) They want you to send one original B/L to their customs broker directly by courier service, and submit the balance 2 original B/C.

b) They also want you to consign the shipment to them (use their company name as the consignee) instead of the shipment to their bank.

AIR WAYBILL :

Air waybill is used for air shipment; with similar function of B/L on boat shipment. However, there is some important difference between Air waybill and Bill of Lading. Please note the following to guard you accordingly. On boat shipments, the buyer needs at least one original B/L to take possession of the goods. However, on air – shipments, the buyer does not need the original Air waybill, or even a copy of the Air waybill to take possession of the goods. If the shipment is consigned to the buyer, the buyer can legally claim the goods from the airline. In fact, the airline will notify the buyer to claim the goods. As long as the buyer can identify himself as the consignee, he is allowed to take the goods from the airline. Therefore, when we make shipments by air, unless we have received payment up front, we should not consign the goods to the buyer. We should always consign the goods to the bank making the bank the legal owner of the goods. The bank will only pass the title to your buyer when your buyer pays the bank

for the goods. When the bank passes the title to your buyer, it is responsible to pay you. If by mistake, you have consigned the goods to your buyer, it is at his mercy to pay you.

UTILITY FACILITYUTILITY FACILITY

Effluent Treatment Plant:

Waste water from wet processing industries e.g. Dyeing, Printing, Finishing, and Washing

causes great harmful effect on our environment. As a result agricultural land loses its fertility,

natural water becomes polluted, aquatic life is destructed and crops are damages. Effluent

Treatment Plant is a plant by which waste water is treated in order to make the waste water

environmental friendly. This Group has a biological ETP, which is described below:

Standard Value of Effluent which is given by-

USEAPA (United States Environment Protection Agency)

IWRA (International Water Resource Association)

GOB (Government Of Bangladesh)

Table: Standard values of Effluent

Tank Parameter Unit Standard value

Clarifier

(Treated

Effluent)

Phosphate,PO4 5 to 15

PH 6 to 8

Color APHA 220 to 250

BOD PPM 29 to 60

COD PPM 250 to 300

Ammonia, NH3 PPM 5 to 10

Nitrate, (NO3)- PPM 10 to 15

Nitrate, (NO2)- PPM Less than 1

Sulphate, (SO4)2- PPM 1000

Chlorine,Cl2 PPM 1

Chloride, Cl- PPM 500 to 600

Total Suspended Dissolve

Solid

PPM 60 to 80

Total Dissolve Solid PPM 2100

Process Flow Chart of Biological Effluent Treatment Plant:

Fabric Dyeing

Pumping and Screening

Homogenizing TankAcid

Dosing

Filter Press

Distribution Tank

Biological Oxidation Tank

Sludge Return Tank

Sedimentation Tank

Sludge ThickenerPolyelectroly

te Dosing

De-colorantDosing

Dry Sludge

Dispose to Land Filling

AntifoamDosing

BUYER’S COMPLIANCEBUYER’S COMPLIANCE

All the buyers of J.M FABRICS LTD. BD ltd strictly follow the Labor & Labor Well Fair rules

of Bangladesh Government. Their company policies are as follows –

- No child labor;

- No forced labor;

- Transport facilities for employees;

- Hours of work;

- Voluntary over time;

- Intervals for rest;

- Weekly holidays;

- Annual leave;

- Festival holidays and leaves with bonus;

- Maternity protection;

- Workers; welfare committee;

- Mineral drinking water;

- Sanitary facilities;

- First aid box;

- Canteen services;

- Health care activities for the workers and employ company doctor;

- Fire extinguisher on each and every floor and conduct fire drill at least 12 times a

year. We are giving a top priority on protection of fire and eventual evacuation;

- Other safety departments (no discrimination);

- Compensation cases department;

- The Development of compliance program;

- Environmental development;

- Smoking free zone

If the factory does not maintain the rules and requirement of Bangladesh Government Labor

Well Fair, then they do not accept the products.

WORKING ENVIRONMENT:

Management is fully aware of the importance of healthy and suitable working environment and is taking all necessary steps to provide mist appropriate suitable working environment to our people for better working relations efficient production and to achieve the desired quality from company force. Following are the areas being gives to priority to ensure the provision of conducive working environment.

a. Health and Hygiene

b. Cleanliness

c. Disposal of waste and Effluents

d. Ventilation and temperature

e. Dust and fumes

f. Lighting

g. Drinking water

h. Latrines and urinals

i. Spittoons

j. Fencing of moving parts of machine.

k. Eye protection

l. Day care centre

m. Canteen facility to provide the hygienic food.

n. Private lockers for personal belonging.

Human Resource Management:

Having consideration to have latest technology skills development is an immediate concern

to the management of the J.M FABRICS LTD. LTD.

At present necessary procedures has been defined documented and being implemented under

the direct supervision of foreign expert for the following.

a. Employment criteria and policies

b. Hiring and staffing policy and procedure.

c. Orientation/Induction procedure.

d. Procedure for probationary employment

e. procedure for service award

f. Procedure for incident reporting

g. Rules and code of conduct

h. Development of leadership skill

i. Compensation administration procedure

j. Policies and procedure for salary and salary structure.

k. Polices and procedure for work schedule and tine away.

l. Working hours.

m. Policies and procedure for absentees.

EMPLOYEES Benefit

#►Efficiency Bonus#►Performance Bonus#►Yearly Performance Bonus#►Two Festival Bonus#►Free Lunch#►Clean and Hygienic work Environment#►Locker for Every Employee#►Purified Drinking water (WTP)

Health and Safety

#►In house Clinic with six beds#►First Aid Boxes#►Free Personal Protective Equipments#►Clean, Hygienic and Modern Toilet and Wash Facilities#►Fire Exit, Fire Hydrant, Fire Extinguisher, Automatic Fire Control Panel with smoke detection facilities #►Bus-bar Electric System

SAFETY CONDITION

Garments industry is playing a pioneer role in a industrial fire of the country. Its a severe threat to the and property of any organization as well as to the country. Injury, death and financial loss result from the fire. The country has to suffer loss of thousands of millions of taka each and every year for fire all over the country.

In garments industry most of the fire accidents take place due to electrical short circuit results

from defective electrical wiring design and system ,inadequate fire protection and safety system,

lack of awareness of the worker and management.

Appropriate fire protection and safety system, effective training and awareness of the worker,

skilled & technically sound electrical and last of all good management practices and commitment

can reduce the possibility of fire substantially.

I have just given one example of safety condition now I am giving the activities, which are

followed-

1. Safety condition: All machines & equipments should be set very carefully. Use the machine

guard.

2. Construction work: Factory should be developed according to the approved plan.

3. Goods keeping: All goods should be kept systematically in the store so that anybody can walk

without any risk. There should be 3 to 4 distance from rack to rack.

4. Work on running machine: Only the person can do the work that is experienced in the

particular operation. Worker should follow below instruction.

4.a. In the cutting section cutting man cant cut the fabric without wearing the stainless steals

gloves.

4.b. Must have to use the mask in the time of sewing.

4.c. In the time of using the boiler must have to check the meter & also have to maintain the

others instruction of the boiler.

5. Equipment & plant: In the cutting machine there should be sufficient electricity & wearing

should be good. No machines should be set in the factory, which are health hazards.

6. Fire protection: There should be lot of fire protection equipment according to the instruction

of fire service & civil defense. These should be set up according to their instruction.

6.a. Extinguisher is placed in different floors at highly visible place with easy & unobstructed

access. Carbon di oxide extinguisher is placed at the adjacent area of the electrical boxes for

electrical fire. Location of the extinguisher is marked by clearly visible.

6.b. Fire protection & exit layout of floor is posted at highly visible area of respective floor.

6.c. Exit doors are side hinged & unobstructed to open and always kept on open. All emergency exit doors are able to be opened form the direction of exit travel without the use of a key or any especial knowledge or effort.

6.d. Floor should have the fire alarm.

7. Heavy Weight: No person can carry more than twenty kgs

.

8. Audio system: Factory should have the audio system so that any emergency announcement

could be given in the audio system.

These are the policy this factory is applying for the safety condition. So we can say that it is a well-organized factory.

FACILITIES OF STUFF & HEALTH SERVICES

1.Cleanliness: Whenever darts & refuges are accumulated, these are swept by the cleaner at

once, from the floor and passages. The floor is cleaned at least once in every week by washing

and housekeeping of whole workroom is done once in the month, using detergent and disinfected

where necessary. Record of cleanliness is maintained in a register , as prescribe in the local law.

2. Lime washing and painting : The interior walls ,ceilings ,passages and staircases of the

factory is clean ,dirt free and painted. Floor is clean & painted with Epoxy.

3. Wastages and Effluents: There are small disposal of fabrics cut pieces and loose threads that

usually accommodated in the factory and once in a month it is disposed off through local vendor.

They crashed all cut pieces into cotton for various domestic uses, which is environment friendly.

There is nothing effluent in factory floor. Effluents of latrines usually drained to underground

safety tank. Waste water from drains has been constructed maintain sufficient slope so that

nothing can be accumulated on the floor and there is no bad smell.

4. Ventilation & temperature: The factory floor is equipped with sufficient number of ceiling

fans. South and east side of the floor surrounded by the wider window which provide proper

ventilation and circulation of fresh air. Natural fresh air from the south sweeped over the whole

floor and keep the temperature reasonably comfortable for workers.

5. Lighting: Glass fitted water windows are available which provide enough natural light as

south side is being obstructed. Glass at windows is kept clean on both the outer and inner side. In

addition to the natural lights the factory floor is lightened with tube sets having reflector with

that to intensify the lighting, which is sufficient and suitable for work place and passages all over

the work place and passages. Level of illumination is more than 600 lax in the working area.

6.Drinking water: There is sufficient volume of natural pure drinking water preserved in jars

kept at convenient place on the floor and marked DRINKING WATER in English and Bangla.

The water jars usually washed with normal water, hot water, detergent etc and record of wash is

maintained. After wash refilling is done with fresh water and purified with Water Purification

Tablets and recorded.

7. Latrines & Urinals: There are total 19 toilets available for male and female workers. The

toilet floor and wall is tiled and having hygienically proven sanitary system. Each toilet is

provided with supply water line also equipped with cistern flashing system to wash dawn the pan

and commode. Toilets are being cleaned once everyday with different type of liquid cleaner.

Sufficient lighting systems are available inside the toilet. Toilets are fitted with industrial exhaust

fans to accelerate the flow of fresh air. Human disposal drained out to under ground safety tank.

This safety tank has been constructed according to design of local public health department

polices.

8. Spittoons: There are sufficient numbers of spittoons kept at every entrance of the factory.

These are filled with dry & clean sand and covered with a layer of bleaching powder on the top.

9.Medical facilities: Company has their own Doctor to serve the employee of the factory.

10. Company has the children care center also.

PROBLEMS DURING PROJECT WORKPROBLEMS DURING PROJECT WORK

In behind of every gain there should have some restriction and that’s why we are assign to project work to overcome that problem, to do so have learn a great points are as follows from which we have learn.

1. Managements always wants to hide some information mostly on merchandising activities like price and costing on which we are very much in need. It may be to maintain their competitive advantage with local factory.

2. Compliance people were not interested to cooperation. Their perception is that we may forward their lacking to BGMEA as we are from BUFT.

3. Differentiation of technical terminology in between production personnel and me.

4. Sometimes they are confused about our course in BUFT is it training or Hons. Course so personnel try to underestimate.

5. It was too difficult that to get right person in different department from whom I could take information and guide line.

6. On top of everything I must say it was hard tusk to find documents which we should include in internship project file as we were we are assign to include.

CONCLUSIONCONCLUSION

Industrial attachment in J.M FABRICS LTD. LTD. was a concluding part of the B.Sc in Apparel Manufacturing & Technology course. During the training period, the whole days were segmented and schedule to a systematic routine.

Through this project I’ve achieved different experience with the theoretical knowledge. This will help me in every sphere of my career. Again I’m specially giving thank to our respected teacher Kazi Shamsur Rahman Sr. Asst. Professor, Proctor of BUFT and under the supervision Md. Monirul Alam to make me able to have this huge experience.

bachelor project

Documents

proctor of buft

real life project

memory lane buft

university life

valuable knowledge

final project paper

project work conclusion

theoretical knowledge