Report on Industrial Attachment | SEPAL GROUP 1
INTRODUCTION
As all Engineering subjects are practical oriented subject. Specially Textile
Engineering is lame without sound practical knowledge. So practical implication is
very essential for any textile person, engineer or students. It is said that textile
industry is the heart of Bangladeshi economy. Industries are run by successful,
skilled engineers. So it will not be wrong if it is said nowadays Textile Engineers are
the main weapon for our economical Success.
Industrial training as offered by the Bangladesh University of Textiles is very useful
which gives the directions & ideas about the production, manufacturing, capacity,
power etc. of a certain mill and with this ideas getting adopted a student can
flourish his debut in the engineering field.
We had been attached in Sepal Group for two months starting from 1st August to
30th September. There are four factories, one washing plant, and one buying
house in Sepal Group. We successfully ended our training while gathered some
useful things like mill management, production, quality assurance, maintenance,
planning, machine operation, merchandising etc.
Report on Industrial Attachment | SEPAL GROUP 2
Chapter 1
Project Description
CONTENTS
Name Of The Company
Type Of The Company
Year Of Establishment
Product Mix Of The Company
Annual Production Capacity
Project Cost
History Of The Project Development
Different Departments Of The Company
Physical Infrastructure Of The Building
Remarks
Report on Industrial Attachment | SEPAL GROUP 3
INTRODUCTION
Sepal Group is one of the leading ventures in the garment industry operating from
Dhaka, Bangladesh. Being a 100% export oriented industry they have been
approved by the Board of investment of Bangladesh and have their own garment
manufacturing and washing units all under one roof. The commencement of
business was in 1986 and from the time of inception till now the group has grown
many folds as it has always maintained quality and punctuality. The group has
gainer name and fame since its inception and herded by a team of dedicated,
hardworking and efficient management and staff who are always on the lookout
for a challenge. They at Sepal make garments the same way that a painter
composes his art on canvas.
The group comprises of the six companies as listed below
1. Sepal garments ltd.
2. Orchid garments ltd.
3. Creative garments ltd.
4. Glory fashion wear ltd.
5. Sepal washing ltd.
6. Mastrade International Garments ltd.
We the students of Bangladesh University of Textiles have joined in Sepal Group
from 1st August to 30 September for our industrial attachment. We came here and
knew how this company is running & the management of this company. We also
learned how to make a garments production as well as merchandising of the
garments.
Report on Industrial Attachment | SEPAL GROUP 4
ADDRESS
Head Office
Sepal Group
247/248, Tejgaon Industrial Area,
Dhaka, Bangladesh
Tel: 88-02_8827707, 9885341, Fax: 88-02-8823026
E-Mail: [email protected]
Associate Office
Apexfair Holdings Ltd.
Flat# 3, Building# 1, 1st Floor,
Ataur Park, Sion – Trombay Road,
Chember, Mumbai – 40071, India
Tel: 91-22-5567255, 5510852, Fax: 91-22-5563549
E-Mail: [email protected]
NO. OF FACTORIES : Five
1. Sepal Garments Ltd.
2. Orchid Garments Ltd.
3. Creative Garments Ltd.
4. Glory Fashion Wear Ltd.
5. Sepal Washing Ltd.
PRODUCT MIX
Mainly woven garments. Major items are
Trouser
Pant
Shirt
Bermuda
Skirt
Shorts etc.
Report on Industrial Attachment | SEPAL GROUP 5
PRODUCTION CAPICITY
1) SEPAL GARMENTS Cutting capacity : 6000 pcs /day
Sewing capacity : 4000 pcs/ day
Laundry capacity : 30000 pcs /day
Production line : 5
2) ORCHID GARMENTS Cutting capacity : 6000 pcs/day
Sewing capacity : 4000 pcs /day
Laundry capacity : 30000 pcs/ day
Production line : 5
3) GLORY FASHION WEAR Cutting capacity : 4800 pcs /day
Sewing capacity : 3200 pcs /day
Laundry capacity : 30000 pcs/day
Production line : 5
4) CREATIVE GARMENTS Cutting capacity : 6000 pcs day
Sewing capacity : 4000 pcs day
Laundry capacity : 30000 pcs
Production line : 5
5) SEPAL WASHING UNIT
Wet processing (Based on 60-minute stonewash / day) 15000 pcs
Garment dying (based on medium shade in direct process type) 7500 pcs
Dry processing (based on standard specialty) 5500 pcs
ANNUAL PRODUCTION CAPACITY
As a group, Sepal group export approximately 45000 dozens of various garments every
month and these range from newborns, infants, ladies & men’s wear such as Ladies
Dresses, Vests, Jackets, Shortfalls, Overalls, Jumpers, Shirts, Pants, Shorts & Skirts. Annual
production capacity is approximately 540000 dozens.
Report on Industrial Attachment | SEPAL GROUP 6
DIFFERENT DEPARTMENTS
Whole sepal group building has different department. Every department is well
decorated and perfectly maintained by the management of the company. We
have visited every department of this building during our training period. Here we
gave name some of the department.
Merchandising department.
Sewing department.
Cutting department.
Sampling department.
Buying house department.
Custom & security department.
Welfare department.
Child care department.
Medical & maternity department.
Fire department.
Building maintenance department.
Electricity & generator controlling department.
Store
Canteen
Training center
Recreation club etc.
HISTORY OF THE PROJECT DEVELOPMENT
Sepal group is one of the leading ventures in the garments industry operating
from Dhaka, Bangladesh. Being a 100% export oriented industry we are approved
by the board of investment of Bangladesh and having their own garment
manufacturing and washing unit all under one roof. The commencement of
business was in 1986 and from the time of inception till now the group has grown
many folds as it has always maintained quality and punctuality.
In 1986, the year of establishment of sepal groups the picture was not alike as
present. At first sepal garments was started with some simple plain sewing
machines and with a few operator and one supervisor .In that time garments
Report on Industrial Attachment | SEPAL GROUP 7
factory was not familiar in this city. So many difficulties were appeared.
Nevertheless, this factory survived against all odds and has achieved impressive
success. Day by day it has increased its profit and extended. More five factory also
established, which are seems to results of success along the way of achievement
since 25 years for sepal group. Now it has own huge factory building in tejgaon
industrial area. Though the founder of this company is TIPU MUNSHI, now it is as
ltd company.
PHYSICAL INFRASTRUCTURE
It is thirteen-storied building. It also attached with another five-storied building
which is an additional to factory building.
1) Sepal garments floor measurement is 30,500 square feet & total floor
measurement of the company office is 5000 square feet.
2) Orchid garments floor measurement is 30,500 square feet.
3) Glory fashion wear floor measurement is 19,800 square feet & total floor
measurement of the company office is 5000 square feet.
4) Creative garments floor measurement is 30,500 square feet.
5) Sepal washing total floor measurement of the factory is 11,000 square feet &
total floor measurement of the company office 1000 square feet. It has three lifts
one is used for cargo and another two is used as a passenger lift.
The company of the cargo lift is 2000 kilogram and the passenger lift is 800
kilograms. There are three stare inside the building and another one is outside of
the building.
FLOOR BY FLOOR DESCRIPTION OF THE BUILDING
- Twelve floor :Training center, CNF office.
- Eleventh floor : Reception clubs, directors’ rest room.
- Tenth floor : Apex square (buying house), sample section -1.
- Ninth floor : Sample section -2.
- Eighth floor : Canteen, kitchen, M/C storage room, office.
- Seventh floor : Sewing floor (creative), office.
Report on Industrial Attachment | SEPAL GROUP 8
- Sixth floor : finishing and store section of creative garments ltd.
Medical care section.
- Fifth floor : Merchandising section, sewing and cutting section of
sepal garments ltd.
- Fourth floor : Finishing section of sepal garments ltd. Cutting and
store section of orchid garments ltd.
- Third floor : Sewing section of orchid garments ltd. Administration
office.
- Second floor : Director’s office, finishing section of orchid garments
ltd. Child care section, store.
- First floor : Sepal washing unit, boiler, generator, store,
reception.
- Basement : Parking, ETP.
ADDITIONAL BUILDING : Glory fashion wear ltd.
SEPAL Group at a glance
Company name SEPAL GROUP
Type & business of the company A 100% export oriented woven &
washed garments manufacturer and
exporter
Factory location 247/248, Tejgaon Industrial Area, Dhaka,
Bangladesh
Year of Establishment 1986
Number of employee Around 5000
Factory Floor Space 1,22,300 sq. ft.
Factory equipments Different types of sewing, inspection,
finishing and washing machine and
generator, boiler effluent treatment
plant.
Main production Mainly woven garments including
trousers, pants, dresses, Bermudas,
skirts, shorts, jackets, vests, jumper etc.
Production Capacity Approximately 45000 dozen of various
Report on Industrial Attachment | SEPAL GROUP 9
garments every month
Main market USA, Canada , China etc
Key personnel Mr. Deepak V. Bhojwani
Chairman
Mr. Tipu Munsi
Managing director
Mr. Anil. D. Rao
G.M Operations
Mailing Address Sepal Group
247/248, Tejgaon Industrial Area,
Dhaka, Bangladesh
Phone Number 88-02-9898259,9898475
Fax Number 88-02-8826072
Website www.sepalgroupbd.com
DIFFERENT SECTION OF SEPAL GROUP
Report on Industrial Attachment | SEPAL GROUP 10
REMARKS
It is the introduction of our project. We will stay here about two month and
gradually we will know every part and every section of this building as well as
sepal group. Here every portion of this sepal group building is very much secure,
neat and clean as well. Every person in sepal group must have company’s ID card.
And everybody should bear it during working hour. We also got ID card from
company. We were surprised to see that our attendances are kept by modern
punching machine.
Sepal group is one of the leading export oriented garments manufacturer in our
country. It is also developing its knit and dyeing factory. Overall we want to say
Sepal Garments and all other four garments factories of sepal group is technology
base modern garments.
Report on Industrial Attachment | SEPAL GROUP 11
Chapter 2
Man Power Management
CONTENTS
Organ gram
Man-power Administration
Production
Management system
Shift change system
Responsibilities of Production Officer
Job description
Remarks
Report on Industrial Attachment | SEPAL GROUP 12
INTRODUCTION
Management
Management controls, in the broadest sense, include the plan of organization,
methods and procedures adopted by management to ensure that its goals are
met. Management controls include processes for planning, organizing, directing,
and controlling program operations. A subset of management controls are the
internal controls used to assure that there is prevention or timely detection of
unauthorized acquisition, use, or disposition of the entity's assets.
Methodology of management system
The art and science of management have developed and changed over the years ,
and so too have definitions of management. Some early theorists viewed
management simply as the ability to work through others. But contemporary
managers work with many resources and tools, so this definition of management
must be broadened beyond the human aspects. Today, management can be
defined as the process of achieving organizational goals through planning,
organizing, leading, and controlling the human, physical, financial, and information
resources of the organization in an effective and efficient manner.
By this definition, management is a distinct process, a set of ongoing, coordinated
activities that managers engage in as they pursue the organization's goals.
Therefore, a manager is someone who actively participates in the management
process through the four functions of planning, organizing, leading, and
controlling the resources of the organization. Managers in various organizations
are confronted by different challenges and call on different resources, elements
such as raw materials, people, information, and money that the organization
needs to produce goods or services.
Depending on their situation and on their resources, managers stress one or
another of the four management functions to accomplish their goals. For example,
the chairmen and CEOs of different companies want to focus on leading and
motivating to build their business. Naturally, all of these executives, and the
managers at every level in every organization, shift their focus from one
management function to another as conditions dictate.
Report on Industrial Attachment | SEPAL GROUP 13
Management of Sepal group
Management system of sepal group is very much modern one. And the
management of this company is very strong as well as friendly to all. It has
improved managing power to make all employee hard working and dedicated.
Organ gram
Report on Industrial Attachment | SEPAL GROUP 14
TOP MANAGEMENT
Mr. Deepak V. Bhojwani
Chairman
Mr. Tipu Munshi
Managing Director
Mr. Mobarak Ali Sikder
Executive Director
Mr. Anil D. Rao
G.M Operations
CONTACT INFORMATION
Head Office Sepal Group
247/248, Tejgaon Industrial Area,
Dhaka, Bangladesh
Tel: 88-02_8827707, 9885341, Fax: 88-02-8823026
E-Mail: [email protected]
Associate Office
Apexfair Holdings Ltd. Flat# 3, Building# 1, 1st Floor,
Ataur Park, Sion – Trombay Road,
Chember, Mumbai – 40071, India
Tel: 91-22-5567255, 5510852, Fax: 91-22-5563549
E-Mail: [email protected]
Report on Industrial Attachment | SEPAL GROUP 15
SAPAL MERCHANDISING DIVISION
KEY PERSONNEL TO CONTACT FOR SEPAL MERCHANDISING DIVISION
Name Phone E-mail
Anil D. Rao 9885941 [email protected]
Aftab A. Sayed 9885341 [email protected]
T. Hossain Ejaz 9898005-12 [email protected]
Monzurul Haque 9898005-124 [email protected]
PRODUCTION
As a group, Sepal group export approximately 45000 dozens of various garments
every month and these range from newborns, infants, ladies & men’s wear such as
Ladies Dresses, Vests, Jackets, Shortfalls, Overalls, Jumpers, Shirts, Pants, Shorts &
Skirts.
MANAGEMENT SYSTEM
Sepal Group comprises of the six companies as below-
1. Sepal Garments Ltd.
2. Orchid Garments Ltd.
3. Mastrade International Garments Ltd.
4. Creative Garments Ltd.
5. Glory Fashion wear Ltd.
6. Sepal Washing Unit
So the management system of this company is a little bit critical. There are four
garments factory and one washing factory in that thirteen storied building, where
we worked. Two sampling section is for that four garments factory and four
Report on Industrial Attachment | SEPAL GROUP 16
cutting section, four storing section for accessories. Management system of
Washing Unit is a little bit different, which will be discussed in another part.
The management system of all four garment factory are almost same. There are
four production managers for four factories. They supervise all activities related
production. All staffs related to production are accountable to production
manager directly. In the factory, ten to twelve operator works under a supervisor,
a few supervisor works under a line chief. All line chief of all production lines
directly accountable to production manager. Besides them, there are also some
QA manager, inline inspectors, mechanic and many other persons of different
positions are related and responsible to the production.
Here employee information of Sepal Garments Ltd. is given to describe the
management system of that factory.
EMPLOYEE INFORMATIONS OF SEPAL GARMENTS LTD.
Employee Position Number Employee
QA Manager 2
Inline Inspectors 60
Final QA Inspectors 20
Mechanics 6
Cutting Operators 3
Cutting Supervisors 3
Sewing Supervisors 20
Sewing Operators 340
Sewing Helper/finish.hel. 160
Finishing 60
Packing 25
Pressman 17
staff 34
Male 260
Female 490
Total Staff 750
Report on Industrial Attachment | SEPAL GROUP 17
EMPLOYEE INFORMATIONS OF ORCHID GARMENTS LTD
Employee Position Number Employee
QA Manager 2
Inline Inspectors 65
Final QA Inspectors 20
Mechanics 6
Cutting Operators 3
Cutting Supervisors 3
Sewing Supervisors 24
Sewing Operators 355
Sewing Helper/finish.hel. 160
Finishing 60
Packing 28
Pressman 20
staff 34
Male 220
Female 520
Total Staff 778
EMPLOYEE INFORMATIONS OF ORCHID GARMENTS LTD
Employee Position Number Employee
QA Manager 2
Inline Inspectors 50
Final QA Inspectors 17
Mechanics 5
Cutting Operators 3
Cutting Supervisors 3
Sewing Supervisors 15
Sewing Operators 290
Sewing Helper/finish.hel. 142
Finishing 50
Report on Industrial Attachment | SEPAL GROUP 18
Packing 22
Pressman 15
staff 31
Male 227
Female 423
Total Staff 650
EMPLOYEE INFORMATIONS OF CREATIVE GARMENTS LTD
Employee Position Number Employee
QA Manager 2
Inline Inspectors 60
Final QA Inspectors 20
Mechanics 6
Cutting Operators 3
Cutting Supervisors 3
Sewing Supervisors 25
Sewing Operators 360
Sewing Helper/finish.hel. 170
Finishing 60
Packing 30
Pressman 20
staff 40
Male 274
Female 521
Total Staff 795
The management system of these four factories is same. The management system
of the company is different. The director supervises all the activities and the
decision maker. In this company there are more directors for different section. At
present the managing director of this company is Tipu Munshi. Two more director
are Tania Munshi and Patric E.A.
Report on Industrial Attachment | SEPAL GROUP 19
The management system of whole production activities is directed by production
director of the Sepal Group Ltd. At present Mr. Anwarul Islam is the production
director of Sepal Group. Production director supervises the activities of production
managers, electric managers, finishing mangers and cutting managers.
Quality manager supervises all the activities of quality inspectors and officers.
Moreover the whole quality section is separate section which is directed by quality
chief. The fire department and medical care and training center is directed by own
department manager.
MANAGEMENT TEAM
Managing Director : Mr. Tipu Munshi
Director : Tania Munshi
Petric E.A
Production Director : Mr. Anwarul Islam
Production Manager : 1. Anisur Rahman(Sepal)
2. Shah Alom (Orchid)
3. Alomgir Hossain(Glory)
4. Ala Uddin(Creative)
Production Coordinator : Ariful Islam
Manager (sample section) : Nasir Uddin
Cutting master : Mathus
Quality Chief : Shiva
Technical Compliance Officer : Jullian Hawladar
William
CTPAT Officer : Kazi Shahidul Islam
Store in Charge : 1. Sofikul Alom(Sepal)
2. Mubarok Hossain (Orchid)
3. Sri Bimol(Glory)
4. Anisur Rahman(Creative)
Administration Head : Ershadul Alom
Welfare Manager : Taposhi Rabeya
Report on Industrial Attachment | SEPAL GROUP 20
IT Officer : Forhad Akbar
Custom in charge Officer : Rajib Sarkar
Training center Head : Lili Gomaje
Fire Department Head : Shahin Alom
SHIFT CHANGE
The shift of work of this factory is one shifted for all four garments factories. But
the washing unit is three shifted factory. Every shift is of eight hours. Normally the
shift begins at 8:00 am and ends at 5:00 pm for staffs. In the middle of working
hour there is a break of an hour for lunch. The weekly off day of the factory is
Sunday.
RESPONSIBILITIES OF PRODUCTION OFFICER
To assist Production Executive on departmental related operation matters.
To lead a group of leader(s)/Assistant leader(s), production floor
assistant(s) and/or production assistant(s) to achieve production schedule
and meet customers’ requirements.
Co-ordinate and interact with relevant groups to ensure quality and
productivity targets are met.
Monitor, update daily production progress and report to Production
Executive if the production target is affected by machine problems or if
reschedule is required.
Responsible for production work order creation (if any), updating of
manufacturing output into weekly report and ERP system and prepare
monthly manufacturing closing.
Train and lead subordinates on upgrading their jobs knowledge.
Involved and guide/assist the team in any improvement assignment/project
related to the department operation and comply any additional
responsibilities when assigned by the company.
Reports to the Production Manager Operations.
Report on Industrial Attachment | SEPAL GROUP 21
Monitor and control shift wise production, plant utilization, waste
generation etc, implement correct work methods and maintain all records
related to production.
Responsible for systematic planning and execution of production programs.
Adequate control over process in order to achieve quality of products,
better waste management and to reduce the occurrence of defective yarn.
Monitor shift wise production, utilization etc and take corrective action for
any shortfall.
Maintain all the procedure of his department and shall incorporate
amendments as and when required in the procedure.
Liaise with maintenance department for evaluating the performance of the
machinery and to take corrective actions.
Responsible for monitoring the performance of manpower under him and
identification of training needs.
Co-ordinate with other department heads such as Engineering,
Commercial, marketing and HR so as to achieve the objectives of the
company.
REMARKS
The management system of Sepal Group Ltd. is very smooth and strong as well as
friendly to all staffs. The management acts as power behind all of its achievement.
All of its Managers, Officers, Staffs are very responsible about their duty. Overall
the relationship among the staffs and employee is very fine and discipline is
noticeable as well.
Report on Industrial Attachment | SEPAL GROUP 22
CHAPTER 3
Machine Description
Contents
No. of M/C
Brand name
Main specification
Machine lay out plan
List of Machinery
Remarks
Report on Industrial Attachment | SEPAL GROUP 23
INTRODUCTION
Sepal group is an extra-vigorous project which has a huge reputation for the
garment industry. It has four garments and one washing unit which contain
various types of machines and technology. Here are production machines, sample
machines , dryers, extractors , sand blast machines, dryers, transports equipments
etc. all the description are given below-
NUMBER OF MACHINES
In the sepal Group they have four Garments. No. 01-Creative, no.02- Sepal, no.03-
Glory and the last one is Orchid. All the garments use same machines for their
products . So, we are giving number of machine for all the garments including
Sepal. The things are showing below:
Name Creative Sepal Glory Orchid
1. Plain Machine 208 208 215 208
2. Over lock
Machine
36 35 35 35
3. Feed of the
arm
12 10 10 10
4. Two needle
Machine
30 30 30 30
5. Button hole
Machine
6 4 7 4
6. Button stitch
Machine
6 6 5 6
7. Bar take
Machine
8 11 11 11
8. Snap button
Machine(power)
6 25 8 25
9. Snap
button(power)
2 21 4 21
Report on Industrial Attachment | SEPAL GROUP 24
10. Kansai
special (pmd)
6 6 5 6
11. Flat
lock(kansai)
1 2 1 2
12. Blind stitch
Machine
1 1 1 1
13. cloth cutting
Machine
3 5 5 5
14. Pocket 2 2 2 2
15. Flat lock
(Pegasus)
1 6 2 6
16. Eyelet/B/H
Reece
3 4 4 4
17. Collar
training
5 5 4 5
18. Threat
sucker
1 1 1 1
19. Fusing
Machine
1 1 1 1
20. cloth
winding
inspection
Machine
1 1 1 1
21. Core
winding
Machine
1 1 1 1
22. Velcro
attaching
2 2 1 2
23. Metal
detector
Machine
1 1 1 1
24. Vacuum iron
Machine
10 12 10 12
25. Marker
computer
pattern machine
1 1 1 1
Report on Industrial Attachment | SEPAL GROUP 25
26. End cutter
Machine
1 2 2 2
27. Label
Machine
6 2 5 2
28. Chain stitch
T/N
10 0 0 0
Total 371 405 373 405
All together : 371+405+373+405= 1554
Washing Plant
Washing Machine : 11 (Golden Resources, Hong Kong), 500 lbs Each.
Sample machines : 3 (Golden Resource, Hong Kong) 110 lbs each.
Dryers : 15 (7 steam + 8 Gas)
Extractors : 3 (golden resource, Hong Kong)
Sand Blast m/cs : 6 (six)
Generators : 2 (1 diesel 930 KVA + 1 Diesel 400 KVA)
Boiler : 1 (2.4 tones)
Transports : 3 (three)
Employees : 153
MACHINE BRAND NAME
In Sepal Group we are using various kind of Machine. Such as, Kansai, Plain
Machine, Eyelet etc. We are giving such types of brand names which are
mentioned on below:
Number Brand Company Country
1. Kansai Brother Japan
2. Plain m/c Brother Japan
3. plain automatic machine Sun star China
4. Eyelet Brother Japan
5. computerized Eyelet M/C Brother Japan
6. Chain stitch M/c Typical China
Report on Industrial Attachment | SEPAL GROUP 26
7. Button hole Brother China
8. Over lock(5 threat) Juki Japan
9. Over lock (4 threat) Juki Japan
10. Feed of the arm Brother Japan
11. Vertical machine Brother Japan
12. Flat lock Pegasus Japan
13. Button stitch Brother China
14. Fusing machine Hashima Japan
15. Straight Knife Blue streak-II USA
16. Lay cutting machine Eastman USA
17. Light box - -
All the machines we are specified here are using various types of products. all the
machines are very important for the better production according to the buyer
requirement.
MACHINE SPECIFICATION
Here, we have described about the specification of the machine. Description of
the machine given below-
Name Model No. Speed
Control
Needle
No.
Needle
Size
1. Kansai (Brother,
Japan.)
DFB1411PXF PULLY UOX113 11-22
2. Plain machine
(manually, Brother,
Japan.)
H7200A40B - DBX1 9-18
3. Plain auto(sun star,
China.)
KM250B-75 - DBX1 9-18
4. Eyelet (Brother,
Japan.)
RH-9820-01 - EBX7 14-18
5. Eyelet
(computerized,
RH-9820-02 - DOX558 14-20
Report on Industrial Attachment | SEPAL GROUP 27
Brother, Japan.)
6. Button Hole
(Brothers, China,)
HE806A-2 - - -
7. Over lock (5 threat,
Juki, Japan.)
MO-67165 - DCX1 9-20
8.Over lock(4 threat,
Juki, Japan
mo-67145 - dcx1 9-20
9. Feed of the arm
(inside seam, Brother,
Japan.)
DA-9820-8 Three
stitches-, 6
threads.
UYX128 11-20
10. Vertical machine
(cutting and swing,
Brother, Japan.)
EI77B-3 - - -
11. Flat lock(Belt loop,
Pegasus, Japan)
W500 5 threads,
three
needles
- -
12. Button stitch
(Brothers, China.)
BE-438D - - -
13.Auto Marker - - - -
Report on Industrial Attachment | SEPAL GROUP 28
SOME MACHINES USED IN SEPAL GARMENTS
Report on Industrial Attachment | SEPAL GROUP 29
REMARKS
We have described all the machines specifications, their brand names, a lay out of
a short pant and now we can realize how many machines would be required for a
garment and what would be their arrangement. Though it always varies for
different design or type of garments, it depends on the basic stitch type. We have
collected quite a few lay out plan for different garments and special design.
Sepal group consists of number of factories so that it is difficult to collect all the
specification and other information about all machineries. We have tried our best
to collect them. We are grateful to our supervising teacher Mr. Julian for his help
while collecting these data.
Report on Industrial Attachment | SEPAL GROUP 30
CHAPTER 4
Raw Materials
CONTENTS
Raw materials types
Raw materials Price
Raw materials Source
Annual Requirement
Remarks
Report on Industrial Attachment | SEPAL GROUP 31
INTRODUCTION
Raw material means the accessories, fabrics and the other trimmings which all are
needed to produce a garment. In another word all the material are needed to
produce a garment item or apparel except the machineries and man power could
be considered as raw material. These raw materials play a vital role during
production. If any kind of defect or disassembly is present then the product quality
will be hampered. Beside this raw material must be used in garments factory for
ornamentation of the product as well as they provides necessary information.
Raw materials used tell a lot about the product and its impact on the potential
buyer. As for e.g.: A company who supplies organic food or recycled,
environmentally-safe products or services would send wrong signals to buyers if
the hang tag or swing ticket was made of aluminum or plastic. Thereby, lays the
careful selection of raw material for making tags and swing tickets.
Raw material can be classified in two types:
1. Fabrics
2. Trimming or accessories
Fabric
This is the main raw material of a garment. Except this ready made garments can
not be thought. Different types of fabric can be used for different garment. It can
be varied by color, design, construction etc. Moreover in a particular garment
different fabric can be used to produce different parts. Mainly woven fabrics are
used for shirt, trouser, pant etc. Basically denim fabrics are used to produce pant
& jackets. Knit fabrics are used for knitted goods like T-shirt, polo shirt etc.
Sepal group is one of the leading garments in Bangladesh which manufactures a
huge quantity of woven garments. Basically they import their required fabric
according to buyer recommendation. The most of fabrics are imported from
Shanghai & Hong Kong.
Realty Textile of Shanghai is one of favorable industry from which most of fabrics
are imported for Sepal Group. Some fabrics are also imported from U.S.A. The
pocketing fabric are not imported these are collected from local market.
Report on Industrial Attachment | SEPAL GROUP 32
Trimmings
All the materials except fabric required to make a garments are known as
trimmings or accessories. For example: sewing thread, button, zipper, label etc.
And there are many other trimming are used in garment factory such as Badge,
Bag and box, Belt, Button, Bra-strap, Card, Cord and piping, Fastener, Fashion
jewelry, Film, Glasses strap, Key chain, Lanyard, Label, Patch, Packaging paper,
Seal, Stickers, Tag, Tape, Transfer, Trims, Zipper pull and miscellaneous.
Here we have given some information about different trimming used in this
factory with their source from where they are collected. Later we will give the
description of most important trimmings item.
No Name of item Description Source
1. Thread Polyester, linen, polyester coated,
single ply, multiple ply of different
Tex.
Local Market.
e.g. Twice, Coarse
etc.
2. Pocketing Fabric Simple plain fabric of different
color. but basically white color is
mostly used.
Local Market.
3. Interlining Fusible interlining white color
natural. For denim temp is 149.
Local Market.
e.g. Vilene
4. Lining Extra fabric or wedding are used
mainly in jacket.
Local Market.
5. Button Sew-On Button, garment Button,
Metal button :
Material: Brass Size: 9-25mm
Color: Paint-plating Customer's
designs, colors and logos
Jeans button:
Size: 17mm Materials: Brass and
stainless steel Cap with diamond
and be painted Customer's logo
Snap Button:
Mould: 831#, 201#, 633#, 655#,
203#, 833# Sizes: 10mm, 11.5mm,
12.5mm, 14mm, 15mm, 17mm
Local Market &
Imported
Brand items must
be imported.
Report on Industrial Attachment | SEPAL GROUP 33
etc. Colors: Various materials:
Brass.
Polyester / Resin / Plastic Button:
Polyester Button/Resin
Button/Plastic Button/Nylon
Button Materials: Polyester In a
Variety of Designs and Fashion
style.
Coat Button:
Material: Polyester Shape: Many
shapes, round, square, triangle,
rectangle, abnormity Color: Chalk
and DTM.
Metal Button: materials: Brass,
zinc alloy and others Shape:
Round, rectangle, oval, other
shapes Design: Different pattern,
with logo Color: Enamel colors,
anti brass, nickel, black nickel,
gold imitation.
Fabric Cover Button :
Fabric covered button 1. Style:
Round, square, heart shape,
eyelet holes, plastic shank, metal
wire shank 2. Size: 12L, 14L, 16L,
18L, 20L, 22L, 24L, 28L, 30L, 32L,
36L, 40L, 44L, 60L etc.
6. Zipper nylon zipper, metal zipper, plastic
zipper, aluminum zipper Metal /
Brass Zipper, Nylon Zipper
Imported
7. Poly Bag Used for covering the garments.
And its size and color depends on
product type and design.
Local Market
8. Label Size label, Main label, Care code
label, price label, composition
label etc.
Local Market &
Imported
Brand items must
Report on Industrial Attachment | SEPAL GROUP 34
Barcode Label, Ticket, Waist Card
for Clothing (SLYK0032):
Equipped with most advanced
barcode machine, apply to
different specs of barcode label,
hangtag, price ticket, sticker and
washable label Supports both
separate and continuous printing.
Metal Label / Charm / Plate for
Garment, Bags:
Features: Product name: Lloyd
label/metal label 1) materials:
Alloy with gold electroplating or
chrome electroplating. 2) Various
shapes, sizes and designs available
3) Buyers’ logos and designs.
Metal: Features: Product name:
Lloyd label/metal label 1)
material: Alloy with gold
electroplating or chrome
electroplating. 2) Various shapes,
sizes and designs available 3)
Buyers’ logos and designs. Paper
Label (DY0086):Item: Hangtag 1)
Materials: 1mm cardboard 2)
Surface Disposal: Glossy or matte
lamination, spot UV, varnish are
available 3) Printing: 4 color
printing or Pantone color printing
4) With metal clip.
Woven Labels: Woven labels are
the most common and
economical way of identifying
your garments or products.
Polyester Label Tape, Garment
be imported.
Report on Industrial Attachment | SEPAL GROUP 35
Label, Band Label. Yuma ribbon
and bows company can supply
good quality woven edge label for
garment and home textile. Woven
Labels (LJ060): Material: Printing
label or woven label Application:
Textile clothes attached at the
inside the back of shirt. For
marking. Paper Label
(HEDY004):Name paper label
Material paper Size 4.5*3.0CM
(material PVC Size customize)
9. Hand Tag Plastic, paper, woven, printed
hand tag etc. mainly contain
product and company’s brand
name.
Features: 1) Size of paper hang
tag: According to clients'
specifications 2) Materials of
paper hang tag: Ivory card paper,
white paper board, glossy art
paper 3) Function: Labels, tags,
name cards,
Local market
10. Match Box To matching size and bundle
number.
Local market
11. Sticker Hologram Sticker : Hologram
Sticker, 1. Item: Hologram Sticker
2. Material: sticker 3. Size,
Printing, Design according to
customer's requirements. Label:
label, tag, sticker tag, logo, paper
sticker 1) Safe and non-toxic, no
harm, no radiation 2) Material
PVC, PET, paper, self-adhesive
sticker 3) Different materials,
designs and sizes available
Local market
Report on Industrial Attachment | SEPAL GROUP 36
12. Tag Pin Pin: Tag gun, Tag pin, loop pin,
hook pin, cable tie, twin tag pin
Standard tag gun and fine tag gun.
Pin available size from 15mm to
75mm to 125mm. Material Nylon
and PP. Multi-colors.
Pin: Tag pin The tag needle is for
tagging and labeling use For
standard tag gun Available in
various length.
Pins: Tag Pin 1) Used for hanging
various kinds of merchandise
brands 2) Sizes: 8 - 225mm (PP
regular); 10 - 75mm (micro pin)
3)Material: PP and Nylon Packing:
5000pcs/box, 20box/ctn.
Local market
13. Button sticker Transparent or may be colored. Local market
14. Button poly Simple colored poly. Local market
15. Hanger wooden hangers, metal hangers,
Aluminum hangers, Laminated
wooden hangers, plastic hangers
and etc.
Local market
16. Hanger Sizer According to products size and
buyer Recommendation different
color is used.
Local market
17. Poly sticker Hologram Sticker: Hologram
Sticker, 1. Item: Hologram Sticker
2. Material: sticker 3. Size,
Printing, Design according to
customer's requirements
Local market
18. Packaging paper Transpired or colored paper of
plastic.
Local market
19. Bra-strap Bra Strap (DS-FW-
004):Commodity name: Bra
Local Market &
Imported
Report on Industrial Attachment | SEPAL GROUP 37
Strap(DS-FW-004) Material:
Cuprum, Rhinestone, nickel-free
electroplating Color: Silver
Specification: Main chain 32cm,
subsidiary chain 17cm without
length of buckle Strap:
Compositions: 100% copper,
rhinestone, nickel-free
electroplating Specifications:
Various styles are available and
customized designs are accepted
Colors: Silver, gold, black, bronze.
Commodity name: Fabric bra
strap(FS-FW-Y016) Material:
Spandex belt Color: Yellow
(Different color as per your
requirement) Specification:
Length 40cm, extended 60cm
Brand items must
be imported.
20. Buckle, hook &
loop
Loop: Hook and loop Material:
100% nylon, or nylon mixed with
polyester. Width: 16mm, 20mm,
25mm, 38mm, 50mm, 100mm,
125mm, 150mm Colors: 300 kinds
of colors Used for garments,
Hook and Loop (HL1003): Hook
and loop Several quality grade &
type to reach customers' various
requirement. 1. Normal Hook &
loop 2. Adhesive hook & loop 3.
Back to back hook & loop
Local Market &
Imported
Brand items must
be imported.
21. Seal Company seal: Rubber, metal seal
etc.
Local Market
22. Card PVC Card (Plastic Card): Material:
PVC or paper Size: 86mmx54mm
or other size as required.
Local Market
Report on Industrial Attachment | SEPAL GROUP 38
Thickness: 0.3mm; 0.5mm;
0.76mm or others. Printing: Full
color, encoding.
23. Cord and piping Used in waist band wedding and t-
shirt. Mainly soft knitted fabric.
Local Market
24. Tape TPU Tape, Mobil on Tape (NCB-
2):1)Product name: TPU TAPE
2)color: Transparent, semi-
transparent, black, bluish etc.
3)width: 3mm-16mm(or to
requirement) 4)thickness:
0.08mm-0.30mm(or to
requirement)
Local Market
25. Zipper puller PVC Zipper Puller: Material: Soft
pvc or silicon Standard: Can pass
EN71, Cadmium and non
phthalate test With one-sided or
double-sided logo About OEM
Sample. Alloy Zipper Puller (FZY-Z-
078): Zipper puller Material: Alloy
customer zed color & design.
Leather Zipper Puller: Brass
Zipper, Aluminum Zipper, Nylon
Zipper, Polyester Zipper, Plastic
Zipper, Rhinestone Zipper
Local Market &
Imported
Brand items must
be imported.
26. Belt
27. Key chain Key Chain: Watermarks indicate
the serial NO. And size of each
hangtag
Local Market
28. Hanger bag PVC Hanger Bag (YX12):Material:
0.12mm PVC Size:
23.5cm(L)*18cm(W) Daily Output:
10000pcs/day Package:
50pcs/bag, 1000pcs/ctn MOQ:
1000pcs Printing: Silk printing or
offset printing
Local Market
Report on Industrial Attachment | SEPAL GROUP 39
29. Cuff Links,
Button
Cuff Links, Button:
Introducing yourself to your
clients, this is the best way,
putting your own Logo in a little
gift, common but everybody
needs. 1) Material: brass 2)
Golden and satin finish 3
Local Market
ANNUAL REQUIREMENT
Thread : 60000 tons approximately. Basically depends on order.
Fabrics : 500000 tons approximately. Basically depends on order.
Others : Depends on order.
Report on Industrial Attachment | SEPAL GROUP 40
Some Trimmings
Report on Industrial Attachment | SEPAL GROUP 41
REMARKS
Raw materials and accessories are the major term of garment production. We can
say that this term is the heart of a garments industry. We have tried our label best
to collect all data about raw materials though it was not an easy task to do.
More over Sepal group maintain a good fame by using brand item and qualified
raw material. A number of people are always checking the quality of these items.
They also inspected them and keep documents by the time.
The store house is very much secured and only authorized person can enter that
room. We are thankful to our supervising teacher Mr. Julian for his help while
collecting these data.
We are also grateful to our respectful teacher Mr. Moshiur Rahman Khan for
giving important check routine and advice.
Report on Industrial Attachment | SEPAL GROUP 42
CHAPTER 5
Production Planning Sequences & Operations
CONTENTS
Production Parameters
Description of production process
Daily production report
Monthly average production
Production flow chart
Monthly efficiency
Remarks
Report on Industrial Attachment | SEPAL GROUP 43
INTRODUCTION
Production planning is the very first step to start a production. At first the
company gets an order from buyer and then they start the production planning.
Here in Sepal group production planning and production process is specified and
extra ordinary. In this chapter we have described all the procedure and the
necessary document related to run a production. We also included a sample and
all of its information. The ID no of the product is 00247619.
There is disclosed a system for fastening together different pieces of an article of
clothing so as to enable a customer to select a specific clothing style and design by
selection of different garment pieces. The fastening creates a garment seam
equivalent to a sewn seam yet provides non-permanent closures for garment
assemblage and thus allows a garment to be created specifically to the customer's
wish. There is also disclosed a system for producing garments from a plurality of
different garment pieces and a simplified design and production schedule.
A garment production process wherein garment parts are knitted in a continuous
length of knitted material with water soluble yarns being formed in the knit
construction between the garment parts. The length of material is moved along its
length and bathed with a heated aqueous solution to dissolve the water soluble
yarns and separate the garment parts. The separated garment parts are dried and
vibrated and passed to subsequent garment making stations. The temperature of
the bathing and drying steps and the vibration of the garment parts serve to heat
set the garment parts.
DESCRIPTION OF PRODUCTION PROCESS
Here we have described the whole production processes which are followed by
the Sepal Group after getting an order. We described the processes step by step
according to our limitation. We have also attached an order sheet, PID file, a
sample, production lay out plan and production flow chart and some other
documents to enrich our assignment.
Report on Industrial Attachment | SEPAL GROUP 44
STANDARD INSPECTION PACKET (SIP)
Sepal Group will have to maintain a SIP file for all orders at the factory. Factory
will have to make sure that all tests are timely done and approved. The following
information has to be in the SIP:
PID and any changes to order.
MTL Fabric Testing Reports.
MTL Pre Production Sample Testing Reports.
MTL TOP Sample Testing Reports.
Interlining Testing reports.
Invoices of all Trims / Fabric that have been ordered from the nominated
suppliers.
Factory Pre Final/Final inspection reports.
TCPS Final inspection reports.
Approved fabric swatches and Trim samples
Fit and Pre production approval comments
Pre-production meeting reports
FABRIC INSPECTION PROCEDURE
Sepal Group must maintain the following fabric inspection procedure:
10 % of all fabric shipments should be inspected prior to cutting.
Records should be maintained for every fabric invoice packing list and
inspection report.
Fabric inspections should be done by using the 4 point system and on the
Rotary fabric inspection machine.
Fabric inspection cannot be done while spreading.
Fabric should be inspected for color accuracy as well as shading (side to
side, end to end, roll to roll and number of shade lots).
All rolls that are out of the color shading guidelines should be rejected.
Report on Industrial Attachment | SEPAL GROUP 45
All roles with color defects such as side-to-side shading, side-center-side
shading, and end-to-end shading will not be given points, but should be
rejected.
All fabric inspection forms should have the defects classified separately.
E.g.:- Stains, Weaving defects, Holes, Slubs, etc.
The Four Point system classifies defects as shown in Table 1:
Table 1: Four Point System
Size of defect Penalty
3 Inches or Less 1 Point
Over 3, But not over 6 Inches 2 Points
Over 6, But not over 9 Inches 3 Points
Over 9 Inches 4 Points
Note - A Maximum of four points can be charged to any one linear yard.
The length of defect should be used to determine the penalty points. Only major
defects are considered. (A major defect is any defect that, if found in a finished
garment, would classify that garment as a second.) No penalty points are recorded
or assigned for minor defects.
Major Defects for woven fabrics is classified as follows
a. Slubs
b. Hole
c. Missing Yarn
d. Conspicuous Yarn
e. Variation
f. End Cut
g. Soiled Yarn
h. Wrong Yarn.
Report on Industrial Attachment | SEPAL GROUP 46
Major Defects for Knit fabrics are classified as follows:
a. Mixed yarn
b. Yarn Variation
c. Runner
d. Needle line
e. Barre
f. Slub
g. Hole
h. Press off.
The inspection procedure listed below details the steps involved in performing the
piece goods inspection in the correct manner. These steps must be followed by
the Fabric Inspector/Auditor.
Review the packing list and determine how much total fabric to inspect and
then how much of each color. Determine how many rolls of each color to
inspect and then choose from the packing list and the physical rolls, which
rolls are to be inspected.
Count the rolls in the shipment to make sure they match the packing list
and then mark the rolls that are to be pulled for inspection.
Check the packing of the rolls in the shipment to make sure all the packing
and markings are correct.
Move all the rolls to be inspected to the inspection machine and load the
first roll on the machine. As the roll is put on the machine check to make
sure the inner packing is correct and proper. Also check to make sure the
roll is rolled on the tube squarely and that the tube does not stick out of
the end of the roll more then 1 inch on each end. Also make sure the first 3
meters of fabric is rolled properly, not creased or distorted, and that it is
clean from dirt and marks.
Cut off the first 6 inches and last 6 inches of fabric from each roll and mark
it with the roll number, whether it is from the head or tail of the roll, which
is the right and left side of the fabric and which side is the face side of the
fabric. These strips will then be used in the light box for reviewing end-to-
end, side-to-side and roll-to-roll shading. Use the head strip to check for
end-to-center shading during the inspection.
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Inspect the fabric using the recommended form that is included in the
manual and mark the faults and their points. Run the inspection machine at
a speed that allows you to see the defects properly, yet keeps the fabric
moving in a steady and smooth manor. Make sure that you have the proper
and adequate light at the machine shining on the face of the fabric.
Check the length of the fabric on the roll and compare it to the ticket
yardage for the roll. Note this on the “Inspection Form.”
Check the width of the fabric at the beginning and end of the fabric as well
as at least once in the middle of the roll. Mark this on the “Inspection
Form.‟
Check for skewing, bias, and bowing, compare this to the standards and
note findings on “Inspection Form”.
When inspection is completed do calculations on the „Inspection Form” to
determine the point count for each roll and whether or not it passes or is a
“second roll.” Make sure all „second rolls” are separated.
Calculate the percentage of the average point count for the shipment per
square yard. This will determine if the shipment passes or fails.
ACCEPTANCE CRITERIA
Example
Total yards inspected : 700 yards
Width of the fabric : 1.6 yards
Total points found : 300 points
i.e. 700 X 1.6 = 1120 Square yards
300 x 100 / 1120 sq yards = 26.78 points
Result : Pass
Report on Industrial Attachment | SEPAL GROUP 48
ACCEPTANCE POINT COUNT
The max defective points accepted are 28 points per 100 Sq yards.
The max defective 1 point accepted is 14 points per 100 Sq yard.
SHRINKAGE REPORTS
For washed products the factory should see that shrinkage is checked for a
minimum of 10% rolls per color for every shipment.
A test run must be made before starting bulk to ensure shrinkage control
techniques and patterns. Test run is the most important check point to verify if the
technique and patterns are all correct.
Fabrics with a spandex mixture in its composition have to be handled very
carefully due to high shrinkage variance between rolls.
If the noticed shrinkage variation is more than the garment tolerance then it is
recommended that 100% rolls get checked for shrinkage and factory makes
groups and different patterns for different groups.
It is always recommended to make a average pattern by considering only ½ the
tolerance give to the spec. for example if the hip tolerance is 1” you should only
consider ½” while making patterns for different shrinkages. Factory will have to
study the tolerances given in the spec for Bottoms and tops and decide
accordingly on the different patterns required
Factory will have to maintain a file on shrinkage reports. All shrinkage tests need
to be done on a minimum 50 cm x 50 cm square marking – factories have to make
a square marking template.
Factory will also have to mention the wash recipe and time used to dry the
garment in the shrinkage report file. The wash recipe and time that is once set;
can not be changed for the full program.
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PRE PRODUCTION SIZE SET PROCEDURES
The factory will check if the shrinkage allowance that is added to the
pattern is good enough to start the test run.
Size sets have to be made for all colors and for all different shrinkage
groups.
The Pre production pattern has to be used as a base and if the shrinkage of
the bulk fabric matches with the shrinkage of the pattern used for the pp
sample then the same pattern has to be graded and used for bulk.
Any adjustments that are required to make different patterns for different
colors and shrinkage groups have to be made to the base pattern.
All the stitching details and techniques that factory is planning to use in
bulk must be check for accuracy.
The factory Quality manager and Quality Auditor will have to check the size
set and make a spec report of before wash and after wash to verify that the
shrinkage allowances that were added in the pattern is ok or needs to be
adjusted.
The before wash spec evaluation of the size set has to match with the
before wash spec with zero tolerance. If the before wash spec does not
match, the inspector will have to analyze and see if the error is in the
pattern or if the operators took wrong seam allowances while making the
sample. Factory will have to remake samples if the before wash spec
doesn’t match.
The Factory Quality manager will then write all the comments on one of the
sample and make it a production reference sample which will be hung on
the production floor.
The factory Quality manager and Quality auditor will have to make sure
that all patterns and templates are signed by the pattern master.
Shrinkage percentage has to be mentioned on all patterns for review.
Report on Industrial Attachment | SEPAL GROUP 50
PRE-PRODUCTION MEETING PROCEDURE
Required Attendees
1. Buyers Representatives (if required)
2. Production Director
3. Finishing Manager and Supervisors
4. Factory Quality Manager
5. Factory Quality Auditor
6. Factory Production Managers
7. Factory Pattern Master
8. Line supervisors
9. Store-in-charge
10. Maintenance-in-charge
OBJECTIVES OF PRE PRODUCTION MEETING
Review PID package and all information pertaining to the production
program.
Review all the machine and folder requirements to make sure that
factory is fully equipped to handle style.
Review an approved sample and all the specification will be
discussed and confirmed with everyone present in the meeting.
Review all critical process and measurement with allowances and
tolerance. It must be made sure that everyone present understands
and works accordingly.
Trims card test results for Fabric, Zipper, Button and Interlining etc.
will be shown and presented for understanding.
Review on the time and action plan to perform the order timely.
Plan all shipment and FRI inspection dates.
Review the preproduction sample with the factory production
sample.
Ensure all approvals are in place.
Factory will have to make an additional spec for all the
measurements that are not mentioned in the PID.
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Factory will have to make a before wash spec for in line Quality
inspectors to measure and see that garments that come off line are
as per required. This will also be a check point to see if operators in
line are following proper seam allowances.
Review all the marking templates and techniques.
Factory advise on methods of construction, tolerances, production
lay out and techniques as applicable to the product.
Verification of all product test reports. MTL fabric, MTL Pre
Production.
Verification of all care instruction approvals
Review of the Floor ready spec.
Review all Fit and Pre production comments – so that all points are
clearly understood and taken care off.
Check the spec of any garment based on the how to measure
manual to make sure that the factory uses the correct measuring
method.
All concerned will be advised to co-operate for achieving smooth
execution of the production process as per the assigned target.
OTHER RESPONSIBILITIES
To make sure all technical issues that are production related are cleared
and understood.
To make sure all that is discussed and agreed on during the meeting is
followed in production.
To ensure that a test run performed prior to bulk production.
To ensure that a production sample is hung in the production floor with all
the comments and placements written.
To ensure that factory is maintaining the schedule and all that was
discussed is been followed. In case some changes need to be made,
approval was be taken from the Buyer first.
To ensure that all junior production staff are clear on the method of
measuring the garment.
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PRODUCTION TEST RUN
OBJECTIVE OF TEST RUN
The test run is the most important check point in the full production
process.
The information gathered from the test run will verify that the techniques,
patterns, machinery and the systems are all ready for bulk production.
Factory can also make the necessary adjustments for issues that are found
in the test run so that they. can be avoided in the bulk production
The test run is a replica of bulk so every process and procedure should be
exactly as planned for bulk.
The test run will also give factory the final before wash spec that will be
used by all quality auditors.
TEST RUN PROCEDURE
Factory has to plan a cut of minimum 30 layers. It is very important that
factory takes every layer from different rolls.
The numbering has to be done from 1 to 30, Numbers have to be written or
labeled on the garment so that it can be identified after wash. This will help
in checking the shrinkage variations.
The cutting marker that factory will use for the test run has to be exactly
the same as what they will use in bulk production.
Garments have to be then produced in line using the same techniques as
bulk.
4 size sets will be then measured for before wash and the same garments
will be then checked after wash. Garments have to be numbered with a
water proof pen so as to check them against their respective before wash
measurements.
The size sets have to be specked after wash and after pressing.
The needle work, stitching techniques, sewing quality has to be scrutinized
and documented.
Garments will have to be then ironed and packed the same way as bulk
requirements.
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OTHER RESPONSIBILITIES:
To follow the procedures as discussed in the Pre-Production meeting
To check the spec on 4 size sets before and after wash.
To check the spec on the size sets after pressing.
To finalize the before wash spec.
To approve the final pattern for bulk by adding the correct shrinkage.
To make a report on the packed pieces.
To make sure that all the issues noticed during production are corrected
and taken care of.
To finalize the method or procedure to make the product.
CUTTING PROCEDURE
All cutting machine operators must use metal hands gloves while cutting to
avoid cut injury on the finger.
All cutting department employees must use dust mask while cutting to
avoid breathing in cutting dust.
Before starting the size set cutting process, all reports and tests should be
completed on the fabric to be cut. The size set cutting process should be
based on the findings from these reports:
1. Fabric Inspection Report
2. Shrinkage Report
3. Blanket Report
4. Shade Band Report
To confirm the shading the fabric should be joined side to side, side to
middle and front to end and compared for color variation, if all is ok then
size set cutting process should proceed
Before and after wash swatch boards must be made for all approved fabric
swatches with all kinds of parts (body fabric, pocketing, binding, inside
w/band etc. These must be matched under buyer approved light box before
wash & after wash.
Report on Industrial Attachment | SEPAL GROUP 54
All lay/cuts must be inspected prior to cutting. The following points that will
need to be checked:
1. Marker Length
2. Marker Placement
3. Counts
4. Tension
5. Leaning
6. Ends
7. Splice
8. Fabric Flaws
Total defects found and action taken towards the defects will need to be
noted
After cutting the parts, they need to be checked with hard pattern to see if
there is any variation between the pattern and cut parts.
Nested pattern has to be kept ready before the pilot run cutting.
Cutting layer should be selected from one dye lot however if mixed dye lot
needs to be used then paper lay must be placed with correct identification
information between each dye lot.
Cutting table needs to be always clean. If there is any damage on the
tables, they need to be repaired immediately.
After cutting is complete parts numbering needs be 100 percent accurate
for all the cutting parts to avoid size and shading problem on the sewing
floor.
All cuts must be inspected prior to issue in the line. All cut parts (Top /
Middle and Bottom) must be inspected from each layer and recorded. This
record includes the name of the component inspected. Variation found
(Actual compared with paper pattern) and the action taken towards the
defects.
NEEDLE PROCEDURE
A) All the broken needle must be deposited before new needle issue to the
worker.
Report on Industrial Attachment | SEPAL GROUP 55
B) A written record must be maintained line wise what type of needle is
broken and who is depositing.
C) Broken parts must be found out from the machine area or garments. If
necessary hand needle detector or magnet might be used.
D) The broken needle with its part must be paste and preserved separately
in a needle log register.
E) All kids’ garments after preparation must be checked thoroughly in a
Needle Detector Machine for any unseen needle. If the parts are not
located in the garments/parts, it must be rejected and kept in a
quarantine box.
F) PM and compliance personnel should check the needle daily. So that
there is no anomaly in preserving the broken needle.
PRODUCTION PROCEDURE
All operators must use dust mask while operating the sewing machine.
Needle guards have to be fixed & needs to be checked before starting the
work.
Cutter, Scissors & Point pin have to attached to the machine with a
drawstring
Approved daily goal, swatch card and garment sample must be posted
before starting a new input or style.
S.P.I. needs to be checked everyday before starting the work.
Parts numbering must be matched and followed 100% during all relevant
processes.
Bundling system needs to be followed 100% cutting wise to avoid size
mistake and shading.
The Machine Mechanics must check all sewing machines before the start of
work for problems and record their finding in the inline machine
adjustment log.
All machine issues found must be fixed before starting work.
The operators have to check the needle point everyday by following the
needle points check procedure.
All mechanics, operators, supervisors and line chiefs must check to see if
the machine thread handling systems are clean and correct.
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Before starting the production every operator has to clean their machine.
While sewing all operators must keep the stitch quality as per the buyers
requirement.
All factory PM, Line Chiefs, Supervisors and QA inspectors must maintain
production and quality goals discussed during PP meeting.
All operators must follow parts attaching mark and pay particular attention
to all difficult processes like pocket, flap, waist band & loop attachment as
per buyer requirement.
All production employees must maintain and follow the correct bundle
serial and numbering systems to avoid size mistake.
If any parts are rejected during sewing process, the particular part must be
replaced by selecting another piece from the same fabric roll to avoid any
kind of shading.
All mechanics must adjust the machine to control and minimize oil marks.
All employees must maintain cleanliness to control stains and dirty spots on
garments
No garments or parts can be kept on the floor and must be kept in the
assigned place.
SAMPLE LAYOUT
Actually, Sepal Group maintains all quality products in the world. Here, we have
described a layout for cargo short pant. The number of machines and other things
needed described on below-
Production target per hour 90pcs
PID# 222217
BELTED WALKING SHORT PANT
Machine name Type Number
1. Front rise O/L 3TH O/L 1
2.Front pocket piping P/M 1
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3. Front pocket same +
tuck
P/M 2
4. White pocketing 5
thread
O/L 1
5. Zipper Joint P/M 1
6. S/Fly body attach +
D/Fly tuck
P/M 1
7. J/stitch P/M 1
8.R/part+D/Fly Joint P/M 1
9. Front rise Joint 1/32 +
top stitch ¼
P/M 2
10. Back rise 5th O/L 1
11. Back rise +side pocket
ruling
D/N 1
12. Back rise taken + top
stitch
P/M 3
13. White pocketing Joint P/M 1
14. Fashung 3 thread O/L 1
15. Bone Joint + Bone
make
P/M 3
16. White pocketing Joint P/M 2
17. Bone top stitch P/M 3
18. White pocketing top
stitch
P/M 3
19. Side Joint 5th O/L 1
20. side top stitch D/N 1
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21. Side pocket making P/M 4
22. Side pocket Joint P/M 2
23. Belt tuck P/M 1
24. Pippen P/M 1
25. Belt make P/M 2
26. Belt Joint C/S 2
27. Label Joint P/M 1
28. Mouth close P/M 1
29.Belt loop stitch D/N 4
30.Inseam 5 thread O/L 1
31.Loop make & top
stitch
D/N 1
32.Loop joint & tuck P/M 4
33.Hem P/M 2
34.Bartake stitch B/M 1
35.Button hole stitch Button hole m/c 1
36.Button attaching Button attaching m/c 1
TOTAL 59
REQUIRED NO. OF M/C
M/C types No. of M/C
Plain Machine 42
Double Needle Machine 7
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Chain stitch Machine 2
Over Lock Machine 6
Zigzag stitch m/c 2
Others 2
OPERATION SEQUENCE OF BOOT-CUT CHINO PANT
Back Part:
1. Back part marking at knee position.
2. Marking at bon-pocket position by means of hard pattern.
3. Fold and stitching at both side .
4. Pocketing fabric and back part joining.
5. Stitching at facing.
6. Back rise overlock ( 2 back parts joined).
7. Back rise top stitch.
8. Bon pocket top stitch (1st one)
9. Bon decoration stitch (2nd one)
10. Bon facing join (fusing side).
11. Bon top stitch (pocketing fabric is folded first, then stitched)
12. Facing join.
13. Stitching at three sides to make pocket.
14. Back pocket tuck
15. back part completed.
16. Inspection
Front Part:
1. Front part marking at knee position.
2. Front rise overlock.
3. Double fly.
4. Front part + zipper joined.
5. Marking and stitching at fly piece.
6. Double fly join (zipper’s face side).
7. Thigh part top stitch.
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8. Bon marking.
9. Another pocketing fabric joining.
10. Joining front bon.
11. Bon hole is made/cut manually.
12. Ironing.
13. Bon pocket top stitch.
14. Decoration stitch.
15. Pocketing fabric joining by stitching.
16. Coin pocket stitching at 3 sides.
17. Pocket facing attaching with pocketing fabric.
18. 2nd facing attaching with pocketing fabric.
19. Marking at pocketing fabric.
20. Front pocket joining.
21. Front pocket top stitch.
22. Joining with marked line.
23. Pocket making by tucking.
24. Stitching at lower part.
25. Front part completed.
26. Inspection.
Assembly (joining front & back part) :
1. Matching the serial number of front & back part.
2. In-seam making (overlock).
3. Top stitch by Feed of the Arm m/c.
4. Hemming formed by ironing.
5. Side overlock at one side.
6. Side overlock at the other side.
7. Inspection of in-seam & side seam.
Fusing at waist band joining :
1. Fusing for belt are joined.
2. Piping joining with fusing fabric.
3. Take another blue color fabric , folding with help of folder and then
stitching.
4. Fusing fabric with piping and belt fabric.
5. Top seam applied.
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6. Marking for pocket.
7. Marking at both sides to equal pocket.
8. Belt joining.
9. Pocket joining.
10. Label joining.
11. Mouth tongue joining.
12. Cutting at mouth tongue.
13. Inspection.
14. Ironing at belt.
15. False stitch applied to prevent slipping.
16. Top stitch for belt.
17. Opening false stitch.
18. Inspection
19. Marking for loop.
20. 1st loop attaching at lower position.
21. Folding top loop stitch.
22. Bottom hem made.
23. Final inspection.
24. Bar tack stitching.
25. Bar tack stitching at belt.
26. Bar tack stitching at pocket.
27. Back pocket hole and front pocket hole made.
28. Inspection.
Production rate : 110 pieces / hour.
PACKING PROCEDURE / POLICY
1) To check and confirm the carton size, dimension, volume and printed
stickers as per buyer requirement.
2) To check the cartons weight and quality before putting poly packed
garments into the cartons.
3) To check poly size, quality & weight and printed information before packing.
4) To confirm the pressing quality and folding before putting inside the poly.
5) To confirm the assortment ratio and pieces.
6) Stack the cartons size wise in the carton area separately.
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PRE FINAL AUDIT PROCEDURE (FINISHING)
Pre final audit will be done by the factory QA when 10%, 50%, 70% goods are packed. The audit procedure has to be just like the daily pre-final audit done by the factory packing department QC. 1. The cartons that will be pulled for inspection have to be taken from the total
cartons packed at that time.
2. The QA report will have to be shown to the Buyer’s GQC when they come for their regular audits.
3. If goods fail the QA audit, then factory will have to re-check and after all issues are corrected the goods will be offered to the Buyer for their regular audit.
4. The factory QA will select the cartons that are packed at random based on the square root of the total. (The audit will be done as per AQL 2.5).
WASHING PROCEDURES IN WASHING UNIT
Factory QA Manager will receive approved wash standard from
merchandisers for hand feel, shade and grinding.
Factory QA Manager will ask for wash recipe from the washing plant.
Factory QA Manager will provide approved wash standard to the washing
plant.
Factory QA Manager will provide approved wash standard to the
production / QA file.
Factory QA Manager will provide approved wash standard to the wash
quality auditor / checker.
QA Manager will check pre-wash spec against each & every dye lot prior to
sending for washing. All pre-wash garments should be stored in a particular
place.
All subcontract inventory control reports must be maintained in a register.
All washed garments must be stored in a particular place.
All washed garments spec must be checked and verified for hand feel,
shade and grinding against each and every dye lot prior to sending for bulk
thread trimming.
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All wash damaged garments must be stored in a particular area by
maintaining proper a record.
DAILY PRODUCTION REPORT:
Daily production capacity of Creative garments ltd.
Cutting capacity = 6000 pc
Sewing capacity = 4000 pc
Laundry capacity = 30000 pc
Production line = 5
Production capacity of a line per hour: Per hour a production line can produce 80-
100 pc of garments. Thus per hour creative garment ltd. can produce up to five
hundreds pc garment. In this factory there are eight working hour in a day. Hence
the total production of a day is 3200 to 4000 pc. Sometimes more working hour is
needed which are considered as over time to maintain the production rate in
time.
Note: Here we also added some daily production report.
MONTHLY AVERAGE PRODUCTION
Monthly production of this factory is about 87500 pc.
MONTHLY EFFICIENCY
Daily optimum production = 4000 pc
Daily actual production = 3200 pc
Daily efficiency = 3200/4000*100%
= 80%
Monthly optimum production = 100000 pc
Monthly actual production = 87500 pc
Monthly efficiency = 87500/100000*100%
= 87%
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REMARKS
Garment production is a very complex work to do because of it needs a huge
number of machineries and large man power system as well. To maintain
production rate with in shipment time is very important and it is difficult as well.
We worked hard to know the whole procedure of a production process. We have
collected all the documents are needed to run a production. Some of them we
have attached. We have tried our best to collect them. We are grateful to our
supervising teacher Mr. Julian for his help while collecting these data.
We are also grateful to our respectful teacher Mr. Moshiur Rahman Khan for
giving important check routine and advice.
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Chapter 6
Inspection and audit
CONTENTS
Quality Audit
Audit Procedure
DUPRO Audit
Final Inspection
Remarks
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INTRODUCTION
Quality audits are performed to verify conformance to standards through review
of objective evidence. A system of quality audits may verify the effectiveness of a
quality management system. This is part of certifications such as ISO 9001. Quality
audits are essential to verify the existence of objective evidence showing
conformance to required processes, to assess how successfully processes have
been implemented, for judging the effectiveness of achieving any defined target
levels, providing evidence concerning reduction and elimination of problem areas
and are a hands-on management tool for achieving continual improvement in an
organization.
To benefit the organization, quality auditing should not only report non-
conformances and corrective actions but also highlight areas of good practice and
provide evidence of conformance. In this way, other departments may share
information and amend their working practices as a result, also enhancing
continual improvement.
COMPARING FIRST PRODUCTION UNIT TO THE CLIENT’S APPROVED
SAMPLE
The QC department along with the production team must follow the
procedures mentioned below while comparing first production unit to the
clients approved sample:
The QA manager / Line QC will randomly select and pull the first produced
garments from the output table and summon all the relevant production
employees along with PM to the inspection room for a meeting
The approved client sample has to be compared with the first produced
units by the QA manager
The first units should be checked and verified according to clients
specifications
Accurate measurements should be taken
Trim attachment and positions should also be checked and noted
Construction with all critical processes should also be checked and
compared
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If any non conformity is found, these are identified per Buyers Defect
Classification List and shown to the production personnel for rectification
The defects should be discussed and their causes identified and explained
to the production personnel
A corrective action plan should be formulated to avoid the same issues
again
All points should be documented and acknowledged by all present
Records must be retained for future reference.
OPERATOR WISE IN-PROCESS AUDIT PROCEDURE
In line quality inspectors have to check every operator at-least twice a day
especially for critical sewing work. The Quality inspectors will pick a bundle that is
complete and pull out 7 pieces at random. If they find any defect then the
inspection fails. The inspector records the details which will include the operator
name, operation, number of pieces inspected, number of defect found, the DPCI
number and action taken towards the defects. Steps to be followed in case of a
failed bundle inspection:
All the pieces of the rejected bundle have to be checked for defects by the
operator and fixed before they proceed with the next bundle. At this stage
the inspector will have to attach a red ticket to the bundle and also attach a
red flag to identify the machine and operator for possible quality problems.
The corrected bundle has to be then rechecked by the line supervisor to
make sure all defects are fixed before the operator is allowed to proceed
with the next bundle.
The very next bundle of that operation will have to be also inspected for
defects. If no defects are found the operator can then proceed with the
third bundle. If the bundle gets rejected then the operator will have to
recheck all pieces and alter all the defects. The corrected bundle will have
to be re-inspected by the line supervisor to make sure all defects are fixed
before the operator can proceed with the next bundle.
The third bundle will also be audited and if passed then the flag will be
taken of and the operator can proceed with the operation. If this bundle
gets rejected then the operator will be stopped from resuming production
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and sent for re-training. The factory manager will have to be notified and
he will have to sign on the quality form related to that quality operator. The
factory manager will have to approve the return of the operator after the
training is complete.
Note: The Factory manager and the Production team have to analyze all defects
that are found at the red flag area. The machinery and tools used by the operator
will also have to be checked for improper setting and defects. If the problem is
with the machinery and tools then necessary action has to be taken to correct the
issue.
PROCESS END TABLE DEFECT TALLY AUDIT PROCEDURE
A defect tally must be maintained for every line. It is very important that the
managers analyze the defects and makes sure that the total defects found per
operation decrease as the days pass by. The defect tally must have the following
information:
a) Operation type
b) Defect type
c) Hourly tally DPCI number
d) Day’s total defects
e) Previous day’s total
f) Corrective action taken
Before wash spec on critical positions has to be checked on 100% garments with a
template that is fixed on the checking table. The defected garments have to be
recorded on an hourly basis. The production team has to analyses all defected
garment for spec to see if operators take in the proper seam allowance while
stitching. Tolerance of not more than ¼” has to be given to spec before wash
garments.
All reports have to be signed and analyzed by the quality auditors, line supervisors
and the production manager. Defects that do not show any improvements and
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appear on a daily basis will have to be checked 100 % in line in front of the sewing
machines that produces that particular operation.
Offline DUPRO audit and before-wash spec check procedure
The audit must be done on the out put from each sewing line as per AQL 2.5 for
workmanship and AQL 4 for Fit. The quality inspector must base the sampling plan
based on the days out put per line. The process will be similar as the DUPRO
inspection and form used will be Form # 6. All defects will be identified by DPCI
number and a defect trend will be analyzed with the factory production team.
Before wash spec has to be checked every day and attached to every audit report.
Four pieces per size is the minimum one should check. Factory will have to wash
the pieces that were measured and re check if they are ok to spec after wash and
after ironing. Tolerance of not more than ¼” has to be given to the before wash
spec and only at some of the spec points. If the before wash spec fails then the
immediate conclusion has to be that the operators are either taking a wrong seam
allowance or cutting extra at the marrow stitch . Early detection of this problem
will help in solving spec issues.
Inline DUPRO Audit Procedure
Factory QA will have to do a DUPRO audit when the factory has completed 10%,
30%, 50% and 90% of production. The factory QA will select pieces from all the
lines at random. The Factory QA will also use Form Ref # 6 to do his inspection.
The specifications that will be checked during these audits have to cover all sizes
and a minimum of 4 pieces per size. The Factory QA will also have to get all pieces
measured, washed and then rechecked both before and after ironing. All
measurements have to be checked in details during this audit. All defects will be
identified by DPCI number and defect trends will be analyzed with the factory
production team. The process for DUPRO Audit is as follows:
The Inspector has to first decide on the sample selection based on the
factory’s daily output.
The pieces have to be selected at random from all lines.
Only garments that have passed the output check will be selected for the
audit.
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AQL 1.5 STD has to be used to evaluate whether goods passed or failed for
workmanship and AQL 4.
Defects have to be identified by using DPCI number and a defects trend will
have to be made while analyzing the report.
Defect classification code will have to be used for specifying every defect.
Every defect in the garment will be recorded on the report but only one
garment will be counted for major and minor defect evaluation.
A defect trend will be made and analyzed with the factory production team.
The inspector has to make sure that all defects that are found are attended
to inline so that the root cause of the problem is solved immediately.
The pre-wash specs have to be checked on 4 pieces per size – the garments
have to be measured to the specs with a tolerance of ¼ inches. If the
measurements are out of tolerance, the production team will have to see
that all operations are re-checked to verify if the operators are taking
excess seam allowance (excess seam allowances and cutting at the narrow
seams will cause the spec on the garments to differ from the before wash
specs).
DUPRO Audit Procedures before Pre-Final Audit
Factory QA will have to do a DUPRO audit. When the factory has completed
10% - 30% and 50% goods are packed. The audit procedures have to be
same as the pre-final audit done by the factory QA and they are as follows:
The cartons that will be pulled for the inspection have to be taken from the
total cartons packed at that time.
All the information gathered during inspection will have to be kept in a
DUPRO report.
The report will have to shown to the Buyer’s GQC when they come for their
regular audits.
If goods fail the audit then factory will have to re-check and offer the
factory QA for re-audit after all issues have been fixed.
The factory QA should only select cartons that are packed at random based
on the square root of the total. (The audit will be done as per AQL 2.5)
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Final Table Checker Defect Tally Procedure
The final checkers will have to maintain a defect tally list – Form Ref # 7 for
analyzing the defects and to make sure the specific defects found on the finished
product are controlled and proper action is taken. The defects have to be totaled
on a daily basis and proper steps have to be taken by the factory managers to
make sure that all issue are controlled in the process. NOTE – Factories have to
make a defect trend history style wise to keep in records and records have to be
analyzed often with the factory manager so that factory can make improvements
in systems and procedures to get better in future orders.
Table Specs Check Procedure
Factory has to make a template and fix it on the table for checkers to check the
critical specs on 100% garments. Defected garments for spec have to be recorded
on an hourly basis.
Daily Pre-final Audit Procedure
Pre final audits have to be done on a daily basis using form Ref# 8. Goods that fail
the audit have to be rechecked the following day. All inspections have to be done
based on AQL 2.5 for workmanship. The cartons that will be pulled by the
inspectors have to be signed and pulled at random to get a proper statistics on the
goods. The Square root method will be used to select the quantity of cartons that
need to be pulled for every inspection. All inspection reports should have a
measurement spec report done based of AQL 4. The factory has to see that a
minimum of 4 pieces per size per color is taken for a spec audit.
FRI (Final Random Inspection) Procedures
The final inspection will be done by the factory QA based on the form Ref # 9. The
audit will be done only when 80% - 100% of the cartons are packed. The final
inspections will be based on AQL 2.5 for workmanship and AQL 4 for spec (fit
audit). The number of cartons to be selected will be based on the square root
system. The QA will have to check the spec on a minimum of 4 pieces per size.
Goods that fail the audit will have to be rechecked and corrected before offering
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the buyer to perform their final inspection. The inspector should make sure that
he has the following before the starting of the audit:
Buyer’s Standard Inspection Package
Red tag Sample
Inspection Forms.
AQL Chart.
Wash /shade band approved samples.
Packing List.
MTL/CTL test passing reports.
Note: Shipment will not be released with out the required passing test reports.
The audit can be started when 80% goods are packed provided the balance
20% gets packed while the inspection is in process. The balance 20% then
has to be inspected at the end of the audit.
The inspector has to then decide on the sample size for the workmanship
audit based on the shipment quantity as per the AQL 2.5
(MIL-150E Single Sampling plan Level 2.)
The quantity of cartons that need to be pulled will be based on the square
root rule.
The Fit evaluation has to be done based on AQL 4 (MIL – 150 E Single
Sampling plan level 2). At least 4 pieces per size need to be measured.
The cartons have to be stacked properly in rows of equal height and should
be easily accessible. The carton quantity has to be verified first based on
the packing list.
The cartons that are selected for the audit have to be signed by the auditor
and accompanied to the inspection room.
The size and color ratio, shading in carton size and printing and paper trims
have to be compared with approved samples and the placement has to be
checked as per floor ready specs. Packing and folding instructions also have
to be verified as per the floor ready specs.
All finished pieces have to be stacked size-wise. Inspectors have to then
check for care instruction, size on all labels and hangtags.
Inspectors will pick two pieces at a time and pair the waist together to
check if it matches. This will ensure a 100% check on all size label mistakes.
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Garments have to be checked inside out. Zippers and buttons have to be
checked for functionality
FABRIC & TRIMS INSPECTION AND STORAGE PROCEDURE
The approved swatch card has to be collected from the merchandising
department and kept in the store.
All trims must have bin cards affixed on top of the rack where they are
stored and they must be stored color and size wise.
10 % percent of all trims must be checked and findings noted in a trims
report. Only 1 percent defect is a acceptable rate. The trims report has to
be affixed on the bin card.
Any one of Hang Tags may be checked from each bundle using a bar code
machine and a printed copy must be retained.
All trims have to be checked using a UL3000 light source.
All rejected trims must be kept in the reject room and disposed of following
the buyers recommended disposal process
All excess trims must be accounted for and stored in a secure place and a
record must be kept for reference until further notice from the buyer.
Fabrics have to be kept on pallets.
The bin card must be attached to fabric rolls dye lot wise
Shrinkage and Fabric Inspection Report should be on the bin card.
All fabrics must be issued shade-wise for cutting.
All rejected fabric must be placed in the reject room and disposed per
buyers disposal process
All access fabric must be accounted for and stored in a secure place.
Records must be retained for reference until further notice from buyer.
Note: Please see the fabric inspection procedure for fabric inspection process.
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Target Defect classification list
Fabric
Defect Code Description Classification
F001 Holes where the yarn is cut, broken ends, drop stitch that runs major F002 Vertical or horizontal lines permanently knit or finished into fabric (i.e. needle lines, compactor creases, barre, light/heavy ends). Visible at arms length major F003 Soil, oil spots with contrast visible at arm's length, adversely affecting appearance major F004 Not cut on grain line as specified affecting appearance or shrinkage major F005 Significant snags and/or slubs distinguishable when viewed at arm's length, adversely affecting appearance major F006 Knitted in, off color fly visible at arm's length major F007 Misweaves, mispicks (wovens) major F008 Washing/Dyeing Defects (streaks, uneven dyeing) major F009 Shaded parts/thread and/or visible components, adversely affecting appearance major F010 Printing defects: Wrong, missing or incomplete coverage of color, misregistered, over 1/16" major F011 Poor hand feel of product - not as specified major F012 Knit/Woven structure not to standard minor F013 Product (including all items in selling unit) not visually matching Archroma standard or approved shadeband major F014 Conspicuous pilling; not to agreed upon standard major F015 Mismatched stripe/plaid: side seam 1/8”-1/4” minor F016 Skewed, bowed or biased fabric, solid or stripe over 1/2" side to side for softlines; over 3% side to side for soft home major F017 Conspicuous repair (this covers knits and wovens) major F018 Mismatched stripe/plaid: side seam over 1/4”, pocket over 1/8”
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Components and Trim
Defect Code Description Classification
C001 Unapproved components or trim added or substituted affecting performance (Bias cut binding vs. warp cut; incorrect interlining etc.) major C002 Any specified trim or component missing, damaged, or not operational as intended. (Snaps won't snap, zipper won't zip or slider won't lock, fusible not bonded as per manufacturers instructions) major C004 Rivet, snap, clasp, grommet, or any closure device which is defective, damaged, incorrectly placed or attached which is likely to cause damage to wearer or property major C005 Buttons omitted, broken, damaged, defective or inverted; buttons that do not confirm to specification; misaligned or improperly spaced buttons major C006 Fusible interfacing must be compatible to garment without bubble or pucker; in a lined garment, the liner must not extend below hem or the shell major C007 Zippers: any malfunction; tape shade that does not closely match color specified; tape stitched too loose or tight resulting in excessive bulge on tape or placket when closed; exposed zippers that detract from appearance of garment; exposed edges of zipper tapes that would scratch or irritate wearer's skin; zipper not placed high enough in placket causing gap to top edge; aluminum zippers should not be used; zipper size and length should be appropriate to garment end use or as specified major C008 Hook and Eyes: Omitted or sewn in wrong places; hook and eyes misaligned when fastened causing bulge or twist as the point of closure; all metal parts must be rustproof, washable, dry cleanable, and attached securely; size appropriate to location and specification major C009 Belt color not as specified; width of belt out of specification in excess of 1/4"; eyelets out of alignment in excess of 1/4"; number of eyelets not as specified; end of belt not shaped according to spec; irregular belt width in excess of 1/4"; top stitching of belt is uneven or crooked; belt loop size not appropriate to belt width, missing or insecure loops; belt length must be appropriate to garment size; middle eyelet is not standard fit; any metal parts rusted or oxidized major
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CHAPTER 7
QUALITY ASSUARANCE SYSTEM
Contents
Quality assurance system
Procedure
List of machineries
Quality report
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INTRODUCTION
Quality assurance system
Introduction: Now a day’s quality makes a product perfect. In textile sector quality
is very necessary in every step of textile processing assurance of quality level is
important. In garments industry keeps a good quality all time.
Quality of garment means a garment free from all kind of defects such as oil spot,
uneven sewing, Raw edge, frying, defect frees accessories etc. Measurement of
quality is done in industry in two ways. One is testing and another is inspection. In
SEPAL GROUP inspection is mainly done. Testing procedure is done by APPEXFAIR
BUYING HOUSE.
Quality assurance procedure
To assure a good quality it is very vast job .Spreading, cutting, sewing, finishing in
every where producer has to maintain and check the garments quality.
FEBRIC TESTING
At first the quality of fabric should be checked. If there found any kind of defect
such as hole, knot, spot etc upper than limit then fabric is rejected. Here use 4
point system to detect fabric quality.
By 4 point system we find the number of defective points of 1oo yds fabric. It is
done by the use of fabric spreading machine. it has a chart. According to this chart
with mathematical calculation we find fabric defects.
firstly fabric is spreading on machine surface and then the defect is counting per
100 yds of a roll. the chart is given below
THE LENGTH OF DEFECT IN WARP AND
WEFT DIRECTION
POINT
Beyond 3 inch 1
3 inch-6 inch 2
6 inch-9 inch 3
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Above 9 inch 4
FOR HOLE & OPENING
1 inch or low 2
Getter than 1 inch 4
After detect fault need of calculation. the theory is given bellow:
points/100yds=total defect pt/total fabric length in yds*100-1*36 inch/width of
fabric
The limitation of defective point is done by buyer will.
BLANKET: to detect shade of color this experiment is done. Shade testing is also
done by the use of LIGHT BOX machine. Here 6 types of ray is used to differentiate
shade as buyers rule.
DURING SPREADING
The rules are given below:
1. Check that the marker is placed on the spread with the edge parallel to
selvedge to the placed goods variety that all cut peaces will be
completed.
2. We check all shedding unless ply marked
3. Check for table marks as the table is marked allows no minus tolerance
for the splices .
4. We have to ensure no marker is creased damage.
5. After compilation of spread we check the splices to see that both plies
extend past the marked splice lie between 0.5 inch to 1 inch.
6. After complete we check the fur edge of the spread to see that all plies
are extended beyond marker line.
7. Then we check the tension and count.
8. At last we keep marking the roll which is necessary when reject part is
replaced.
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DURING CUTTING
The process is given below:
1. We check the miscut
2. We check the top middle & bottom ply compare those to a hard pattern
comparison with a hard patterns best tolerance +0.5 inch to -0.5 inch.
3. we check the notch location by placing the pattern over the top ply
tolerance +1/8 to – 1/8 inch.
4. To compare the marker to pattern paper to ensure .
DURING SEWING
It’s very crucial time for quality control. There is lot of inspection done in this
section. Before sewing need fusing. Here we check bonding strength. Then it’s
come to sew Inline 7 pcs inspection is the most important inspection. It is invented
by a USA buyer MR.JESSYPENY. Here we take 7 pcs garments from bundle of 20
pcs and then check and alter the defective parts.
Needle point check up is done daily by one kind of hand shocks. To have uniform
tension we daily check machine.
Daily goal report is one kind of audit or calculation to reach the goal with quality.
We always check the stitch condition. Specially backrise, outseam, inseam, front
fly, etc. We make a report to see that. This is called SPI(stitch per inch) report.
ALTERATION REPORT is one kind of table inspection. It is expressed as time
duration.
Defect tally is another kind of quality assurance procedure. Here we must check
back part, front part, waist band, side seam etc.
DURING FINISHING:
There are different lay out for different garment .Finishing layout also depend on
buyer. Quality assurance system in finishing is given below
a. Remove or cut extra thread
b. Inside check
c. Thread from garments surface is being slashed with the help of
slashing machine.
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d. Inside ironing
e. Final inside quality check
f. Outside qualities check.
g. Top side ironing.
h. Measurement.
i. Final quality check.
j. Thread & lint cleaning area(if required)
If we get any spot we send it to spot removing lab. By the help of spot removing
gun or chemical treatment we remove the spot. At last we make a bundle called
blister.
In case of shirt or trouser we check button strength by button pulling test. Those
are all the procedure of quality assurance system.
LIST OF MACHINARIES
1. Atom hydraulic cutting press Secom platting machine
2. Thread slashed machine.
3. Needle detector machine
4. Spot remover gun.
5. Button pull test machine.
6. Fabric shrinkage test machine
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IMAGES OF SOME QUALITY CONTROL EQUIPMENTS
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SEPAL GARMENTS LTD QC SYSTEMQC SYSTEM FLOW CHART
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PICTURES SOME DEFECTS
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CHAPTER 8
Maintenance
Contents
Manpower set up
Procedure
Tools
Oiling
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INTRODUCTION
Maintenance of machinery
Maintenance of machineries is very important in Garments industry. Because m/c
is subjected deterioration due to their use. If that remains unchanged then
everything will be standstill. So m/c is checked by routine. In SEPAL GROUP
machineries are checked on the routine.
Manpower set up
In SEPAL GROUP it has 4-5 line men who are set for machine control. They work
under a mechanical in charge. There are one mechanic and one electrician.
MAINTANANCE PROCEDURE
The procedure of SEPAL GROUP is given below:
1. Every machine must have two types record.
#Preventive Maintenance Record
#Daily Check List
2. Preventive maintenance records card should be hanged on the machine.
3. Everyday mechanic has to check the machine through the daily check list’
4. If found any problem in the machine, the operator must hang a red flag to the &
to the
Machine & mechanic must fix the problem.
5. The in charge must maintain the machinery per the manufacturer guideline
following all safety
& health condition.
6. The mechanic must ensure that the all necessaries equipments of machine
work of correct
Setting and has to adjust any equipment if required.
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7. If any fault found the responsible person must put down the machine in
breakdown status.
8. After repairing the machine should check for safety run.
9. All records must be updated with the necessary information
PREVENTIVE MAINTENANCE PROCEDURE FOR PRESSING
1. Service all the pressing machine monthly to keep the pressing machine un-
interrupted.
2. Steam lines and pressure should be proper.
3. The next servicing / maintenance date should be mentioned.
4. Pressing table should also be checked and charge the cloths on the table.
5. Vacuum pressure should be controlled and adjusted.
6. Preventive maintenance card should be hanged beside the machine.
TOOLS
The tools which are used to maintain machinery are
1. nut
2. screwdriver
3. hammer etc
OILING
It is one kind of maintenance. Oiling is done regularly on machine.
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SAMPLE CHARTS FOR MAINTENENCE
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CHAPTER 9
Utility Services
Contents
Utility facilities available
Capacity & other technical details
Source of utility
Cost of different utilities
Remarks
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INTRODUCTION
Utility means service that will provide different facilities or advantage for the
factory or mandatory one. In the every factory utilities service is not available and
production capacity also depends on that service. The utilities service of sepal
Group is available and they don’t have any lack of gas, generator system and other
Facilities.
We have seen all the utility section of Sepal Group and tried our best to collect the
necessary document and information. Though it is a huge building the control
management is very good.
MAIN UTILITIES FACILITY
Boiler
Generator
Water pumps
Electricity control room
Fire defense facility
ETP
BOILER
The m/c which generates steam and supply to the all necessary activities to the
factory is termed as boiler.
Object of boiler
1. To produce steam according the requirement.
2. To supply steam and boil water.
3. It mainly supply steam to the washing m/c and ironing m/c.
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No. of boiler
There is only one boiler in the sepal group.
Capacity of the boiler:
Capacity - 2400kg.
Steam hour delivery – 2400kg.
It is run by gas or electricity.
Company
The company name : KAMINS.
Origin : U.K
Different chemical used for boiler running
The entire chemical collected from the local market.
Management system of boiler:
1. One supervisor officer.
2. One boiler in charge and two electricians are working in the area.
Chemical name amount use
Doggy chemical (soluble) 250gm/8hr to lessen water hardness
Auto scaling (NaOH) 1200gm/day -
NaCl 25kg/48hr To remove carbonate.
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GENERATOR
The m/c which converts the mechanical power to electronic power is generator.
Object of generator
To generate electricity by using fuel such as oil, gas etc.
No. of generator
There are two generators in this group.
Company of those generators
1) KAMINS – U.K
2) CATER PILER – U.K.
Capacity, load and fuel required to the generator
Capacity
1. 930 KVA
2. 500 KVA
Load
1. 600 A
2. 510 A
Fuel
Generators are run by diesel in Sepal Group.
1. 90 L per hour
2. 35 L per hour
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MANAGEMENT SYSTEM OF THOSE GENERATORS
Supervisor officer: E.M Francis Gomege.
Electrician: 3 people.
Operator: 2person/shift.
ETP
ETP means effluent treatment plant all the effluent or wastage /usage water reach
to the ETP plant and there the chemical water is treated by various chemical and
than supply to drain by removing wasteful / hazardous chemical from water. it is
suited at below the ground floor.
PROCESSING OF WATER TREATMENT IN ETP:
At first water come from the washing, dying and other machineries reaches to the
collection tank and then treated water tank. In the treated water tank, there is a
net which hinders to reach powder from chemical to go to the equalization tank.
From the equalization tank the water are collected to the mixing tank. in the
mixing tank ,there is wheel driven by motor. The wheel helps to isolate chemical
and water. then all the wastage and chemical which are harmful for environment
is collected from the mixing tank and there those are neutralized that are not
harmful for environment but the water from mixing tank are reached to the
foliation tank and there poly electrolyte and a lam are mixed that remove the
harmful chemical from water and then goes to sludge tank and the filter press
tank. After all the process the water is dispatched to the environment from the
fresh water tank.
CHEMICAL USED IN ETP PLANT
Chemical name amount Source
Poly electrolyte 1 kg/day China
Alum 18 kg/day China
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COST OF THOSE CHEMICAL
Poly electrolyte: 380 taka/kg.
Alum: 36 taka/kg.
MANAGEMENT SYSTEM OF ETP
One supervisor: Mr. Pannu.
Operator: 3 people.
And other technicians and helper are about 5 person.
TOTAL COST FOR ETP PLANT SET UP
Approximately the cost of ETP plant set up is 1 core 60 lack taka.
PUMP
The m/c which collects water from source is called pump. There are three pumps
in the base ground of this factory.
Capacity of the pump
1.) 85 H.P
2.) 40 H.P
3.) 20 H.P
Management system for those pumps
Six operators are working for those pumps.2 people / shift.
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ELECTRICITY
Electricity is not available all the time. So they use gas and generator. The
electricity bill of sepal group is about 14 lack /month.
REMARKS
Those all the utilities are mandatory for a factory. To run a factory these utilities
play an important role. Moreover productivity of a factory is depending on it very
much. We have observed the total utility service is available here. It was not a
easy work to do but since the staffs were very helpful so it became easier to us to
collect information.
The ETP section is situated at the basement floor and we have collected a lay out
plan of this which was attached with the assignment file. We are thankful to our
supervising teacher Mr. Julian for his help while collecting these data.
We are also grateful to our respectful teacher Mr. Moshiur Rahman Khan for
giving important check routine and advice.
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CHAPTER 10
Store & Inventory Control
CONTENTS
Inventory system of raw material
Different inventory cost
Spares
Finished Goods
Others
Remarks
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INTRODUCTION
There are four garment in the sepal group they are sepal, orchid, creative and
glory. The entire floor is same area. But in one floor there are different section
such as store, cutting swing, washing and finishing section. All the section is
involved with different working.
AREA AND OBJECTIVE OF THE STORE ROOM
We know that there are four factories in sepal group. Their store room is also in
the individual floor and all the store room is same. Now we are describing about
one store room. The area of store room of sepal is 500sq foot.
The main objects of store room are following
I. To keep the material imported from foreign or local market.
II. To install the accessories from local or foreign market.
III. To remain different spare parts of different machine.
IV. To hang swatch board / term board on the wall.
V. To maintain a fixed relative humidity e.g. 76
THE TEST AND PROCESS OF STORE ROOM
Mainly the fabric is imported as lot and in one lot there are 100 or 120 yards of
fabric. When fabric is needed in the letting see lion then taken from the store
room.
TESTING SYSTEM OF STORE ROOM
There are different testing and inspection system in the store room.
1. 4 point system
2. 7 pious inspection system
3. 10 inspection system and
4. Other different inspection system such as shrinkage, strength,
elasticity and the evenness of the fabric.
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There is also a machine in the store room which name is fabric spreading and
quality checking m/c. By this m/c the length, width and shade of the fabric are
checked.
MANAGEMENT SYSTEM OF THE STORE ROOM
In every store room there is well arranged management system. In each store
room there are
1. one supervisor officer and
2. twelve workers
3. one stone in charge
4. two guards
THE WORK OF THE STUFF
The supervisor officer receives all the fabric and accessories from the local or
foreign market according to production director officer and supply the fabric and
accessories to the other section according to requirement. The store in charge
handles the worker to manage the test and other inspection. The workers look
after the store room.
INVENTORY CONTROL
Inventory in a widen sense is defined as any idle resource of in enterprise in order
to meet expects of demand or distribution. It is commonly used to indicate
materials, raw materials, finished, packing and stocked products. It is basically
necessary to keep hold inventory of various kinds to act as a cushion bet supply
and demand. It is almost necessary to maintain same inventory for the smooth
functioning of an organization.
CAUSES OF MAINTAINING INVENTORY CONTROL
1. It takes time to complete one operation and more products from
one store to another
2. To run manufacturing operation economically.
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3. To take care of uncertainties like uncertainties in demands from
customers and uncertainties in producing the materials in time.
4. To reduce the critical cost and to take advantage of discounts and
transportation.
FUNCTION OF INVENTORY CONTROL
1. To develop policies, plans and standard to achieve inventory control
objectives.
2. to build up a logical and workable plan for doing job satisfactorily
3. to provide necessary physical facilities
4. to develop methods that will bring desire result economically
5. To maintain overall control by checking result and adopting
corrective actions.
TYPES OF INVENTORIES
Inventions is following 5 categories
Production invention: It means which to inter the final products e.g. raw
materials.
In process inventories: Semi finished products at various stage of production.
Finished goods inventories: Compel products ready for dispatch.
Maintenance repair and operating: Though those are not form a part of final
product they are used in production process like spare parts.
Miscellaneous inventories: They are spare and obsolete item which are not to be
disposed off.
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OBJECTIVES OF INVENTORY CONTROL
Financial objectives
Here the goal is to keep inventory cost within limit of funds available and the
position of its working capital.
Property protection objectives:
a) To safe an important asset against theft, waste and measurable
damage.
b) To make certain that the value of this asset is correct stated in the
company s book.
Operating objectives
To obtain the best overall balance bet products and inventory caring cost on one
hand and customer service to others.
Advantage of inventory control
A well planed and property administered system of inventory control will bring
rise to the following benefits.
a. Improvement of customer’s frictions: This is achieved through maintenance
of better balance among the quantities of finished items on hands.
b. Improvement of labor and community relations.
c. Increase in the effectiveness of key personnel’s:
d. Reduction in manufacturing cost:
e. Strengthens financial position: This is achieved by onward inventory
controls.
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Different inventory cost
The important step in the inventory analysis is the identification. The following
classes of cost are usually involved in inventory control / decision.
1. Cost of ordering
2. Inventory costing cost
3. Colt of shortage
Now they are described below.
Cost of ordering:
Out of many other costs the order cost of inventory is the most difficult cost to
measure precisely. Placing of order is just one of the many other activities of
purchasing. So it is difficult to isolate and identify the cost of the cost of ordering
and measure them precisely.
There are two types of cost of ordering:
A. fixed
B. variable
Cost per order= Total cost in running purchasing dept/Total no. of order during
the year.
Inventory caring cost:
Inventory caring cost is also known as holding cost.
a. Cost that depends on quality of inventory: This cost includes.
1. Cost of storage space – light, rent maintenance etc.
2. Cost of hold stock e.g.: Pilferage spoils age, deterioration and protection.
b. Cost that depends on the value of inventory:
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1. Cost of capital, inter of cost.
2. Cost of insurance.
Cost of shortage:
When a demand arises and the item needed is not in stock then it is the
Cost of shortage of stock out of cost.
In the back order case there are two types of costs.
External Internal
-Loss of good will -over time
-Loss of future sales. - Special ad minis dative efforts
Spares:
Basically spares are the machine parts that are kept in the store room from the
different sewing and after m/c and made the reusable.
Now different spares are followings:
1. folder
2. guide 1/4 CR
3. guide 1/4 CL
4. guide 1/16CR
5. guide 1/16 CL
6. guide 3/16 CR
7. guide zipper
8. guide hanger
9. guide hamming
10. guide plain feet
11. guide gathering
12. guide CT
13. guide magnet
14. guide vertical
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15. guide thread
16. guide hook
17. guide piping
18. p/m bobbin
19. p/m needle plate
20. p/m rotary hook
21. p/m back stitch
22. p/m feed dog
23. p/m 60’’poly
24. p/m magnet screw
25. p/m thread stand
26. p/m tension spring
27. p/m needle bar cap
28. p/m pressure nut
29. p/m guide CR
30. o/l knife set
31. o/l upper holder set
32. o/l upper lopper
33. o/l lower lopper
34. o/l lower knife
Finished goods:
The term finished goods means the products that are ready for export. In the
sepal garment different types of garment are made for export such us.
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CHAPTER 11
Marketing Activities
Contents
Marketing service
Marketing plane & strategy
Consumer of the product
Product level
Package size & local level market
Importing countries
Man power
Duties & responsibilities of marketing officer
Remarks
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INTRODUCTION
Marketing is an integrated communications-based process through which
individuals and communities are informed or persuaded that existing and newly-
identified needs and wants may be satisfied by the products and services of
others.
Marketing is used to create the customer, to keep the customer and to satisfy the
customer. With the customer as the focus of its activities, it can be concluded that
Marketing is one of the premier components of Business Management - the other
being Operations (or Production).
The term marketing concept pertains to the fundamental premise of modern
marketing. This concept proposes that in order to satisfy its organizational
objectives, an organization should anticipate the needs and wants of consumers
and satisfy these more effectively than competitors
MAIN BUYER
MARKETING SERVICE
Marketing is a social and managerial process by which individuals and groups
obtain what they need and want through creating and exchanging value with each
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others. Actually, the process by which companies create value for customers and
build strong customer relationship in order to capture value from customers in
return.
In Sepal group, Marketing is a special branch of the garments sector. We have
mentioned earlier that Sepal group consists of four garments factory under one
roof so they have a strong marketing department. They need a lot of raw
materials to purchase as well as they need to convince buyers to sell their
product. So the marketing department should be strong and skillful as well. In
Sepal group some raw materials are collected from local market and rest are
imported from abroad. It is easy to say that buying them from this country or
abroad is not a easy work to do. That is why here marketing accumulation is
broadly opened. We have observed the account office and the marketing
department and collected some invoice. We were also introduced with some
marketing officer. They helped us by giving us information and documents.
MARKETING PROCESS
The marketing concept of building an organization around the profitable
satisfaction of customer needs has helped firms to achieve success in high-growth,
moderately competitive markets. However, to be successful in markets in which
economic growth has leveled and in which there exist many competitors who
follow the marketing concept, a well-developed marketing strategy is required.
Such a strategy considers a portfolio of products and takes into account the
anticipated moves of competitors in the market.
For marketers planning is an essential task that must be continually undertaken.
As we will see, shifting market conditions, including changing customer needs and
competitive threats, almost always insure that what worked in the past will not
work in the future, thus requiring revisions in how a product is marketed.
Marketing planning is also important since it is often a prerequisite for obtaining
funding whether one is a marketer in a large corporation seeking additional
money for his or her department or is part of a small startup company looking for
initial funding.
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To aid in our understanding of planning we introduce a key concept in marketing:
the Product Life Cycle. We will see the Product Life Cycle offers valuable insight
and guidance for marketing decisions. In this tutorial we also discuss different
types of marketing strategy that can be followed to meet marketing objectives.
Additionally, we look at how innovative products are adopted within a market and
how this impacts marketing planning.
We can describe the objectives also in following steps:
For creating value for customers and building customer relationship.
Understand the marketplace and customers needs and wants.
Construct a customer driven marketing strategy.
Design a marketing program that delivers supplier value.
Build profitable relationship and create customer delight.
Capture value from customer in return.
In our word we can say simply at first a marketing officer has to understand
customers need wants and demands. In Sepal group the needs are identified at
the states of left deprivation. Then the wants are calculated by the form needs
take as shaped by buyer and individual personality. The demand is however wants
that are backed by buying power.
MARKETING STRATEGY
There is a sequence of marketing strategies like following
Undifferentiated (mass) marketing
Differentiated (segmented) marketing
Concentrated marketing
Micro marketing (local or individual marketing )
In Sepal Group they have much extra ordinary marketing strategy. We were trying
to understand that clearly but could not understand thoroughly. We have
described below what we have understand.
They have segmented the marketing field in five ways:
On the basis of benefit
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On the basis of behaviors
On the basis of occasion
On the basis of user status
On the basis of loyalty status
CONSUMER OF THE PRODUCT
Marketing occurs when people decide to satisfy needs and wants through
exchange relationship. Exchange is the act of obtaining a desired object from
someone by offering something in return.
As we have mentioned earlier that Sepal Group is a 100% export oriented garment
company so the consumers and the customers are the foreigner normally.
America and Canada is the main consumer of the product. Moreover Germany,
Hong Kong, Thailand, France, South Africa, Norway, Switzerland etc. are the main
consumer of the product.
Stores & Importers of Sepal Group:
Stores-U.S.A market: Importers- U.S.A market:
THE GAP * KIDS INTERNATIONALS
J.C PENNY * WORLD WIDE APPARELS
WALMART * RADIX APPARELS
K-MART * S.J TRADING
CHADWICKS OF BOSTON * FRANK & JANE LLC
TARGET * MILLENIUM CLOTHING
SEARS and many more.
PRODUCT LEVEL
Market consists of buyers and buyers can differ in one or more ways. They may
differ in theirs wants, resources, location, buying attitudes and buying practices.
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Sepal group divides large heterogeneous market into smaller segment that can be
reached more
Efficiently and effectively with products and services that match their unique
needs. In Sepal group, there are three levels of product
1. Core benefit product
2. Actual product
3. Argumentum product
PACKAGE SIZE
Packaging refers to the development of a container and a graphic design for a
product. Packaging can make a product easier to use safer and more versatile.
Packaging can make an affect on consumers’ altitude toward a product, which in
turn affect their purchase decisions.
In Sepal group packaging serves a number of purposes. It protects the product and
maintains its functional form. All the products in here are packaging with the
recommendation of buyers. So that here present package who consider the
promotional role of packaging using verbal and non verbal symbols which contains
the product content, features, uses, advantages and hazards etc.
LEVEL LOCAL MARKET
We know that all the finished goods are prepared in here for exporting in the
foreign countries. For that leveling local market is not sufficiently necessary in
Sepal group.
IMPORTING COUNTRIES
The main importing countries of Sepal group are America and Canada. They bring
their most raw material, accessories and other trimmings from there. Besides this
the maximum machines have been bought from China, Japan and Hong Kong.
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Some are also been bought from Korea and Malaysia. The sewing machines in
here are imported from Japan and China from Brothers companies. In washing
unit boiler has been imported from China. There two generators in Sepal group
which are imported from U.K.
MANPOWER
The whole marketing department of Sepal Group works under the supervision of
merchandising department. A number of marketing officer are worked under the
G.M of the company. There worked in different section. As it’s an export oriented
garment factory the merchandisers are always busy to get an order from abroad.
Sometimes they do some sub contacted order. Most of marketing officer are
doing the purchasing job in here. They buy the accessories and trimmings from
here. There is also a custom department here for doing the activities related to
shipment such as loading and unloading. They keep contact and make reasonable
bargaining with the transport company.
DUTY AND RESPONSIBILITIES OF A MARKETING OFFICER
A marketing officer directs firm's overall marketing and strategic planning
programs, and corporate communications. Facilitate client development through
marketing and client services programs.
1. Design, implement, and facilitate annual marketing plan for the firm.
Support and facilitate development and implementation of section
business/marketing plans.
2. Plan and administer the firm's Marketing Operations budget; support
development of regional marketing budgets.
3. Oversee the Charitable Contributions Foundation.
4. Organize and implement client relations including:
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· client satisfaction surveys
· client development activities
· client skills training
· special events
5. Supervise firm's RFP protocol process including soliciting RFPs from
desirable prospective clients and writing proposals for new business;
participate in planning and presentation sessions, when assigned.
6. Oversee business development activities including:
· efforts through Business Development Coordinator
· assisting attorneys in strategic planning for client presentations, beauty
· contests, etc.
· offer coaching for prospective client meetings, presentations, etc.
· work with regional offices on designing and implementing prospecting and
client contact systems.
7. Oversee corporate communications activities through Communications
Coordinator including:
· external communications and systems
· internal communications and systems
· public relations efforts
· external vendors and consultants
8. Develop and administer marketing database which includes client and prospect
information, mailing list applications, access to financial reports, etc.
9. Assist with and support firm's involvement in various legal networks including
coordinating business development and marketing activities via these
relationships.
10. Design and plan quarterly marketing training seminars for attorneys.
11. Oversee firm's electronic marketing efforts including supervision of Web site
design and maintenance.
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12. Supervise Marketing Assistant, Client Services Administrator, Communications
Manager, Practice Development Manager and Regional Marketing Manager(s).
Make staffing and hiring decisions within marketing department
REMARKS
In this sense, a firm's marketing department is often seen as of prime importance
within the functional level of an organization. Information from an organization's
marketing department would be used to guide the actions of other department's
within the firm. As an example, a marketing department could ascertain (via
marketing research) that consumers desired a new type of product, or a new
usage for an existing product. With this in mind, the marketing department would
inform the R&D department to create a prototype of a product/service based on
consumers' new desires.
The production department would then start to manufacture the product, while
the marketing department would focus on the promotion, distribution, pricing,
etc. of the product. Additionally, a firm's finance department would be consulted,
with respect to securing appropriate funding for the development, production and
promotion of the product.
Inter-departmental conflicts may occur, should a firm adhere to the marketing
orientation. Production may oppose the installation, support and servicing of new
capital stock, which may be needed to manufacture a new product. Finance may
oppose the required capital expenditure, since it could undermine a healthy cash
flow for the organization.
In Sepal Group all this criteria are maintained so they have good marketing
department. Every person of this department works as a team member that helps
to reach the goal of the company.
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CHAPTER 12
Washing Plant
Content
Washing
Dry Wash
Wet Wash
Wahing Machines
Washing procedure
Remarks
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INTRODUCTION
Denim washing
Denim washing is the aesthetic finish given to the denim fabric to enhance the
appeal and to provide strength.
Dry denim, as opposed to washed denim, is a denim fabric that is not washed
after being dyed during its production.
Much of the appeal of dry denim lies in the fact that with time the fabric will fade
in a manner similar to that which artificially distressed denim attempts to
replicate. With dry denim, however, such fading is affected by the body of the
person who wears the jeans and the activities of their daily life. This creates what
many feel to be a more natural, unique look than pre-distressed denim.
Types of denim washes
1. Mechanical washes
- Stone wash
- Micro sanding
2. Chemical washes
- Denim bleaching
- Enzyme wash
- Acid wash
Again, denim washes are of 2 types depending on the presence of water or not:
1. Wet wash
-Normal wash
-Pigment wash
-Caustic wash
-Silicon wash
-Super white wash
-Enzyme wash
-Bleach wash
-Stone wash
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2. Dry wash
-Sand Blasting
-PP spray
-Grinding
-Whiskering
-Tagging
-Hand scraping
DIFFERENT TYPE WASH EFFECT
ADDRESSES
Sepal Washing Plant
247/248, Tejgaon Industrial Area,
Dhaka, Bangladesh
Tel: 88-02-9898248, 9898005-117
Fax: 88-02-8823026
e-Mail: [email protected]
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FLOOR MEASUREMENT
Total floor measurement of the factory is
11,000 sq.ft
Total floor measurement of the company’s
office is 1,000 sq.ft
MACHINE DESCRIPTION
Production Machines : 11 (Eleven) (Golden Resources, hong Kong) 550 Lbs
Each.
Sample Machines : 3 (Three). (Golden Resources, hong Kong). 110 Lbs
Each.
Dryers : 15 (Fifteen) ( 7 Steam + 8 Gas)
Extractors : 3 (Three). (Golden Resources, Hong Kong).
Sand Blast Machines : 6 (Six) .
Generators : 2 (Two) (1 Diesel 930 KVA + 1 Diesel 400 KVA)
Boiler : 1 (One) 2.40 Tones.
Transports : 3 (Three)
PRODUCTION CAPACITY
Wet processing (Based on 60-minute stonewash / day) 15000 pcs
Garment dying (based on medium shade in direct process type) 7500 pcs
Dry processing (based on standard specialty) 5500 pcs
MAN POWER MANAGEMENT
Employees : 153 (One Hundred & Fifty-three)
Employee Position Number Employee
Dry Process Manager 1
Dry Process Operator 28
Dry Process Supervisors 2
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Wet Process Manager 1
Wet Process Operator 14
Wet Process Supervisor 6
Dying Supervisor 2
Dye Lab Technicians 1
Dye Manager/Master 1
Development Operation Supervisors 2
Q.A./Process Control Operators 5
Staff 3
Other Workers 87
Major Items
Trouser, Pant, Dress, Bermuda, Skirt, Vest, Jacket, Blazer, Shorts, Overall,
Shortfall etc.
Working Roster
Number of shifts in operation 3 (Three)
Number of Hours (per shift) 8 (Eight)
Work Schedule- days per week 6 (Six)
Washing Procedures in Washing Unit
Factory QA Manager will receive approved wash standard from
merchandisers for hand feel, shade and grinding.
Factory QA Manager will ask for wash recipe from the washing plant.
Factory QA Manager will provide approved wash standard to the washing
plant.
Factory QA Manager will provide approved wash standard to the
production / QA file.
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Factory QA Manager will provide approved wash standard to the wash
quality auditor / checker.
QA Manager will check pre-wash spec against each & every dye lot prior to
sending for washing.
All pre-wash garments should be stored in a particular place.
All subcontract inventory control reports must be maintained in a register.
All washed garments must be stored in a particular place.
All washed garments spec must be checked and verified for hand feel,
shade and grinding against each and every dye lot prior to sending for bulk
thread trimming.
All wash damaged garments must be stored in a particular area by
maintaining proper a record.
CHEMIMICAL USED IN WASHING PLANT
Name of chemical Origin Price (approximate)
Soda Ash Forester 32tk /kg
Caustic Soda Forester
Detergent Local market
Anti stain ECHOCHAME(India)
Enzyme 10 L Forester 25kg/gallon 410tk
Acetic acid Local market
Phosphoric acid Local market
Hypo Local market
Ozone softener GDS (India)
Pocket clear GDS (India) & Forester 140 tk/kg
Global salt Local market
Jet Powder Local market
Brightener Local market
Meta ACE chemical 38 tk/kg
Hydrogen per oxide Local market
Texanish-SF ECHOCHAME(India)
Silicon C-150 ECOSIL WS-150 (India) 40kg/gallon 410tk
Rotto SL GDS (India) 40kg/gallon 410tk
Enzyme 50L GDS (India) 40kg/gallon 410tk
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Enzyme 20L GDS (India) 40kg/gallon 410tk
Enzyme BIO GDS (India) 40kg/gallon 410tk
Polish GDS (India) 40kg/gallon 410tk
Yellow Tenon GDS (India) 40kg/gallon 410tk
Wetting agent Local market
LAY OUT OF WASHING PLANT
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WASHING PROCESS OF SAMPLE WASHING
LIQUID ENZYME WASH (WITH STONE)
Sample : 2 pieces of legs of denim pant.
Step 1 : Desizing
Recipe:
Water : 100 L
Desizing agent (desizing enzyme) : 50 gm
Anti-back staining agent : 20 gm
Temperature : 600C
Time : 15 min.
Process:
1. Put sample inside washing m/c.
2. Add water
3. Run the machine.
4. Add Desizing agent.
5. Add Anti-back staining agent.
6. Run m/c for 15 minutes with 60 .C temperature.
7. Rinse twice with 150 L water.
8. Stop m/c.
Step 2 : Enzyme wash
Recipe:
Pumice stone : 2 kg
Water : 60 L
Enzyme (enzyme-200) : 50 gm
Anti-back staining agent : 20 gm
Acetic Acid : 20 gm
Temperature : 450C
Time : 30 min.
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Process:
1. Add pumice stone.
2. Add water
3. Run the machine.
4. Add enzyme.
5. Add Anti-back staining agent.
6. Add acetic Acid.
7. Run m/c for 30 minutes with 450C temperature.
8. Rinse twice with 150 L water.
9. Stop m/c.
Step 3 : Neutralizing Step
Recipe:
Water : 100 L
Soda Ash : 20 gm
Temperature : 45 .C
Time : 3 min.
Process:
1. Add water
2. Run the machine.
3. Run m/c for 3 minutes with 450C temperature.
4. Rinse twice with 150 L water.
5. Stop m/c.
Step 4 : Hydro-extracting
Load sample in Hydro-extractor and run the m/c for 60 seconds.
Step 5 : Drying
Load sample in Gas Dryer and run the m/c for 30 to 40 minutes at 70 to 80 .C
temperature.
Step 6 : Quality Checking.
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Washing recipe and process sequence of Denim trouser. (enzyme + bleach wash)
Batch size: 90 pcs( 85 kg)
Step one: Desizing
caustic-500 g
Wetting agent-300 ml
Temperature -40 c
Time- 15 min
Water level-900L
Wash
Step two: Enzyme wash
Enzyme SL-500 ml
Pocket clear-200 ml
Acetic acid-300 ml
Temperature – 45 c
Time -60 min
Water level-700L
Wash
Step three: Neutral Wash
Soda ash- 200g
DP-7 -100ml
Temperature- 45 c
Time -60 min
Water level-700L
Wash
Step four: Bleach wash
Bleach – KCL-5kg
Bleach DANA-600g
Soda Ash- 200g
Temperature- 60c
Time -15min
Water level-700L
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Wash
Step Five: Neutral Wash
Hydrogen per oxide-1L
Soda ash- 200g
DP-7-100ml
Caustic -100g
BT Red-100ml
Temperature- 50c
Time -15min
Water level-700L
Wash
Step six: Dyeing
Color –GTL -400g
Color Red BWS- .20% owf
Temperature- 40c
Time -2 min
Water level-400L
Wash
Step seven: softener
B. Red- 10g
Softener 3g
Acetic acid 100ml
Temperature- 40 c
Time -6min
Water level-500L
Wash
Step eight : Hydro Extractor
Step nine : Dryer
Step ten : Quality check.
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MACHINERIES OF WASHING UNIT
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CONCLUSION
The course industrial training gives us first opportunity to work into mills during
our four year course in textile technology. We are very much fortune that we get
the chance to do our industrial attachment sepal group of garments.
Sepal group is one of the leading ventures in the garments industry operating
from Dhaka, Bangladesh. Being a 100% export oriented industry we are approved
by the board of investment of Bangladesh and having their own garment
manufacturing and washing unit all under one roof. The commencement of
business was in 1986 and from the time of inception till now the group has grown
many folds as it has always maintained quality and punctuality.
In 1986, the year of establishment of sepal groups the picture was not alike as
present. At first sepal garments was started with some simple plain sewing
machines and with a few operator and one supervisor .In that time garments
factory was not familiar in this city.
Sepal group is one of the leading export oriented garments manufacturer in our
country. It is also developing its knit and dyeing factory. Overall we want to say
Sepal Garments and all other four garments factories of sepal group is technology
base modern garments.
We wish that the company will continue our national economy more effectively
and this practical knowledge we have achieved during this training period will be
helpful for us in our future life.