Final industrial-attachment

Faculty of EngineeringDepartment of Textile Engineering

REPORT ONIndustrial Attachment

AtNur Group

Hortokitola, Attabah, Chandra, Kaliakoir, Gazipur

Prepared By-MD. ABU TALEB TARAQUE

Supervised ByDr. Md. Mahbubul Haque

Prof & Head, Dept. of Textile Engineering

This report is presented in partial fulfillment of the requirements for the degree of Bachelor of Science in Textile Engineering.

Advance in Apparel Manufacturing TechnologyDuration: From June 08, 2016 to August 08, 2016

DECLARATION

1 | P a g e© Daffodil International University

We hereby declare that, this industrial attachment has been done by us. We also declare that

neither this internship report nor any part of this internship report has been submitted elsewhere

for award of any degree.

Supervised By:

Dr. Md. Mahbubul Haque

Prof & Head, Dept. of Textile Engineering

Daffodil International University


LETTER OF APPROVAL

August 18, 2016

Dr. Md. Mahbubul Haque

Professor & Head

Dept. of Textile Engineering

Daffodil International University

Dhaka, Bangladesh.

Subject: Submission of internship report.

Dear Sir,

Here in my internship reports that fulfills partial requirements for Degree of B.Sc. in Textile

Engineering. It is very important for a student of Science and Information to undergo a

project/practical field of study.

I completed my internship report on “NUR GROUP”. In the report, I have tried to

accommodate your valuable comments & suggestions. In this concern, if you need any further

clarification, please email/call.

Thank you for your kind cooperation. Without your support, this internship report would not

have been completed. So I am submitting the final version of our internship report and requesting

your acceptance.


ACKNOWLEDGEMENT

At first I would like to express my heart-felt thanks to almighty ALLAH for his kind blessing to

complete of this internship report successfully.

I would like to thank my honorable course teacher & supervisor, Dr. Md. Mahbubul Haque,

Professor & Head, at Department of Textile Engineering, Daffodil International University for

his guidance, help and encouragement throughout the progress of the internship report. I am very

grateful for his kind advice and instructions.

I would like to thank Md. Abdul Mottaleb Hossain (G.M. Dyeing & Finishing) of NUR GROUP

and the Staffs who motivate me thoroughly and the other people, who have made a significant

contribution to make this report successful. Their guide lines, suggestions & inspiration helped

me a lot.


Table of Contents1.EXECUTIVE SUMMARY........................................................................................................1

2. INFORMATION ABOUT FACTORY....................................................................................2

2.1 Introduction............................................................................................................................2

2.2 Company profile:...................................................................................................................3

2.3 Site Direction for Nur Group:................................................................................................4

2.4 History of the factory:............................................................................................................4

2.5 General information about factory:........................................................................................5

2.8 Organogram of Garments Section:........................................................................................6

2.11 Clients:.................................................................................................................................7

2.12 Sister concerns.....................................................................................................................7

2.13 Philosophy, Vision, Values, Strategy and Sustainability.....................................................8

3.DESCRIPTION OF DIFFERENT SECTIONS.....................................................................09

3.1 KNITTING SECTION.........................................................................................................09

3.1.1 Layout of knitting section:..............................................................................................9

3.1.2 Oranogram of knitting section:......................................................................................10

3.1.3 Knitting machines:...................................................................................................10-13

3.1.4 Knitiing m/c specification:............................................................................................14

2.1.5 Types of fabric are produced in knitting section of Nur Group:...................................13

2.1.6 Knitting faults:...............................................................................................................14

3.1 SAMPLE SECTION............................................................................................................14

3.1.1 Layout of sample section:..............................................................................................14

3.1.2 Organogram of sample section:.....................................................................................15

3.1.3 Flowchart of sample department:..................................................................................16

3.1.4 Sample type:..................................................................................................................17

3.1.5 The details attached to the garment sample:.................................................................17

3..6 Sample swatch card (trims):............................................................................................18

3.2 CUTTING SECTION..........................................................................................................19

3.2.1 Layout:...........................................................................................................................19

3.2.2 Organogram:..................................................................................................................20


3.2.3 Flowchart of cutting section:.........................................................................................21

3.2.4 Fabric Cutting:...............................................................................................................22

3.2.5 Types of cutting machine use:.......................................................................................22

3.2.6 Fabric inspection:..........................................................................................................23

3.2.7 Fabric inspection report sheet:......................................................................................24

3.2.8 Shrinkage test:...............................................................................................................24

3.2.9 Destortion test:..............................................................................................................25

3.2.10 Shade band:.................................................................................................................25

3.2.11 Marker inspection:.......................................................................................................26

3.2.12 Table checking inspection:..........................................................................................26

3.2.13 Parts checking inspection: …………………………………………………………...27

3.2.14 Bundle inspection input: …………………………………………………………….27

3.3 SEWING SECTION............................................................................................................27

3.3.1 Layout:...........................................................................................................................27

3.3.2 Organogram :.................................................................................................................28

3.3.3 Process Flow Chart of Sewing section:.........................................................................29

3.3.4 Name of machines used in sewing section:...................................................................30

3.3.5 Different types of Stiches:.............................................................................................30

3.3.6 Machine Description:…………………………………………………………………31

3.3.7 Description of Different type of Sewing machines:.................................................32-35

3.3.8 Sewing Quality Planning……………………………………………………………..36

3.3.9 Sewing Quality checking points………………………………………………………36

3.3.10 Sewing line quality check list…………………………………………………………….37

3.3.11 Sewing table quality check list……………………………………………………….38

3.3.12 Different type of Sewing fault………………………………………………………..38

3.4 INDUSTRIAL ENGINEERING..........................................................................................39

3.4.2 Organogram :.................................................................................................................39

3.4.3 Process Flow Chart of industrial engineering:..............................................................40

3.4.4 Calculation Formula:.....................................................................................................41


3.4.5 Line Balancing:.............................................................................................................41

3.4.6 Productivity related analysis of work study…………………………………………..43

3.4.7 Capacity Study………………………………………………………………………..44

3.6 FINISHING..........................................................................................................................44

3.6.1 Layout:...........................................................................................................................44

3.6.2 Organogram of Quality:................................................................................................44

3.6.3 Process Flow Chart of Garments Finishing:..................................................................45

3.6.4 Objectives of Finishing:................................................................................................45

3.6.6 In finishing to be checked.............................................................................................46

3.6.7 Work in the Finishing Room:.......................................................................................46

3.6.8 Metal detection machine:..............................................................................................47

3.6.9 Materials used in garment finishing:.............................................................................48

3.6.10 The General Rules of Spot Removing:........................................................................49

3.6.11 Ironing:........................................................................................................................49

3.6.12 Garment Inspection:....................................................................................................50

3.6.13 Different type of folding:............................................................................................52

3.6.14 Assortment:.................................................................................................................52

3.6.15 Cartooning procedure:.................................................................................................53

3.7 STORE SECTION...............................................................................................................00

3.7.1 Layout:...........................................................................................................................53

3.7.2 Organogram:..................................................................................................................54

3.7.3 Process Flow Chart of Garments store..........................................................................55

3.7.4 Grey fabrics store:.........................................................................................................55

3.7.5 Finished goods:..............................................................................................................55

3.7.6 Accessories Store:.........................................................................................................55

3.7.7 Sewing thread:...............................................................................................................56

3.7.8 Button:...........................................................................................................................57

3.7.9 Interlining:.....................................................................................................................57

3.7.10 Trim card contain with:...............................................................................................58

3.7.11 Accessories Inspection:...............................................................................................58


3.7.12 Accessories are inspection 100% for some defects:....................................................59

3.7.13 Quality for Inventory/Storage:....................................................................................59

3.8 COMPLIANCE:...................................................................................................................60

3.8.1 Organogram:..................................................................................................................60

3.8.2 Different compliance issues which they are obeyed:....................................................61

3.8.3 Compliance item:..........................................................................................................62

4. IMPACT OF INTERNSHIP:.................................................................................................65

4.1 Sample Section:....................................................................................................................65

4.2 Cutting Section:....................................................................................................................65

4.3 Sewing Section:....................................................................................................................65

4.5 Washing section:..................................................................................................................65

4. 6 Finishing Section:...............................................................................................................66

4.7 Store Section:.......................................................................................................................67

4.8 Compliance:.........................................................................................................................67

4.9 Utility:..................................................................................................................................67

5. CONCLUSION:.......................................................................................................................68


1. EXECUTIVE SUMMARY

The Industrial Attachment is the most effective way for Textile Engineering student’s to

achieve the knowledge about the practical field of the Textile Manufacturing. It brings an

opportunity to all the learners to enrich their academic knowledge by practicing with the

experts of the practical field of textile.

It is my pleasure that I had an opportunity to complete my two month internship at Nur

Group, which is one of the most modern industries of the country.

Nur Group is one of the major garments manufacturing organization in Bangladesh. This

organization increasingly reducing its rejection and rework rate in-process and final garments

in order to ensure product quality and delivery time as per buyer requirement and increase

profitability. Nur Group will ensure sufficient training and suitable work to increase

productivity and skills of the employee. Now Nur Group has a 55,000 square feet area. Its

production capacity is around 2640000, number of machines 1100 and number of employees

at least 2000.

In this report I tried to cover a short profile of Nur Group and major customers of Nur Group

and their different activities.


2. INFORMATION ABOUT FACTORY

2.1 Introduction

By means of practical knowledge it is possible to apply the theoretical knowledge in the practical field. For any technical education practical experience is almost equally important in association with the theoretical knowledge.

The industrial attachment is the process which builds understanding skill and attitude of the performer, which improves his/her knowledge in boosting productivity and services. Academic education provides us vast theoretical knowledge as well as more practical attachment, despite all these industrial attachment help us to be familiar with the technical support of modern machinery, skill about various operation stages.

It also provides us sufficient practical knowledge about production management, Productivity evaluation, work study, efficiency, industrial management, production planning & control, production cost analysis, inventory management, purchasing, utility & maintenance of machinery and their operation techniques etc. The above mentioned cannot be achieved successfully by means of theoretical knowledge only. This is why it should be accomplished with practical knowledge in which it is based on industrial attachment makes us reliable to be accustomed with the industrial atmosphere & improve courage & inspiration to take self- responsibility.

We have prepared this attachment in Nur Group which is 100% export oriented garments industry. It has well planned, environment and over all section for making garments. The training minimizes the gap between theoretical and practical knowledge and makes us familiar with the industrial environment, we got an opportunity to complete 45 days long industrial training.


2.2 Company profile:

COMPANY NAME NUR GROUP

Factory Hortokitala, Chandra, Kaliakoir, Gazipur. Tel: + 06822-51951. Fax: +880258314663

Total floor area 55,000 sq. ft.

Listing status Private listed company.

Main Market Europe, USA, Canada, etc. Factory Equipment’s Different types of Sample, Cutting, Sewing, washing, Finishing and

Generator machines. Number of sewing m/c 1100

Number of worker 2000, Male : 900 Female : 1100

Company motto We believe in the power of industry to build a bright future for Bangladesh on the global stage.

Company mission We are passionate about achieving socio-economic growth and change through intelligent business practice.

Company vision The vision of Nur Group is to create an outstanding value for customers and other stakeholders. We are committed to produce world-class products through our hard labor which can satisfy our customers.

Product/Service: T-shirt, Polo shirt, Sweat shirt, Polar jacket, Denim trouser short, Twill trouser short, Shirts, sleep-wear, pyjamas set etc

Contact Person: Raihan Rafi Khan Anjan Manager Admin

E-mail [email protected] site www.nurgroupbd.com


2.3 Site Direction for NUR GROUP from Dhanmondi, Dhaka:

2.4 History of the factory:

NUR GROUP of companies began with the establishment of NUR KNITWEARS LIMITED AT SHIDDIRGONJ, ADAMJEE ROAD, AT NARAYANGONJ in the year 1995. Since then the group has expanded substantially to become one of the largest groups in the RMG sector in Bangladesh with 2, 000 Employees and an annual target turnover USD 15 million. The main focus of this carefully designed expansion with a future vision has added stability to their business obligations and win customer confidence in product quality, reliability and competent. The approach towards progress and growth is enormous in Nur group till date. Their groups management guideline principle customer above all, quality first is the invariable principle of the group the cause of group going in forever satisfying the requirement and expectation of the customer.


2.6 General information about factory:

NUR Group is one of Bangladesh’s largest industrial conglomerates, achieving highly respected status worldwide since its initial incorporation as a garments manufacture in 1995.

They are exporting all kind of high quality readymade garments like T-shirt, Polo shirt, Sweat shirt, Polar jacket, Denim trouser short, Twill trouser short, Shirts, sleep-wear, pajamas set etc. for Men, Ladies and kids from Bangladesh to Europe, Canada and America and all over the world Nur Knitwear Limited Established year 1995, Tillottama Fashions Limited Established year 2002, Sumaiya Fibres Ltd. Garments Established year 2002, Production Floor Area 55, 000 Sq. Feet. Production Capacity 200, 000 pc per Month Polo Shirts 450, 000 pc per Month Basic T-Shirts Tank Tops Production Line 15 Lines Products Polo Shirts, T-Shirts, Shorts, Pajamas etc. For Men’s, Ladies, Juniors Kids. Manpower 1300 Nur Wool wears Ltd. Sweater Established year 2003. They have also sweater factory Production Capacity 50, 000 pc per Month Basic Pullovers Cardigans Products Pullover, Cardigan, Tops etc. For Men’s, Ladies, Juniors and Kids. They have own Buying House with all necessary logistic and technological support and facilities. They are exporting all Ready-Made Garments item to over the world.

NUR GROUP

Located in Hortokitala, Attabah, Chandra, Kaliakoir, Gazipur.

Total floor area 55,000 sq. ft.

Capacity 35000 dz per month (shirt, pant, shorts).

Number of production line 18.


2.8 Organogram of Garments Section:

Executive Director

General Manager

Factory manager

Administration manager

Production manager

Cutting manager

Quality manager

Shift in-charge

Floor in-charge

Supervisor

Line chief

Operator & helper


2.11 Clients:

2.12 Sister concerns:i. RAIYAN KNIT COMPOSITE LIMITED.

ii. TILLOTTAMA FASHION’S LIMITED.iii. RAIYAN TERRY TOWEL & DYEING LTD.

2.13 Philosophy, Vision, Values, Strategy and Sustainability:


Philosophy:

We believe in the power of industry to build a bright future for Bangladesh on the global stage.

We believe in the responsibility of our industry to our customers, our people, our surrounding communities and our environment.

We are dedicated to sustainability, accountability and excellence in everything we do.

We are passionate about achieving socio-economic growth and change through intelligent business practice.

Vision:

The vision of Nur Group is to create an outstanding value for customers and other stakeholders. We are committed to produce world-class products through our hard labor which can satisfy our customers.

Values:

We believe in the power of industry to build a bright future for Bangladesh on global stage.

We believe in the responsibility of our industry to our customers, our people, our surrounding communities and our environment. We are dedicated to sustainability, accountability and excellence in everything we do.

We are passionate about achieving socio economic growth and change through intelligent business practice.

Strategy:

Growth through business expansion and acquisition.

Diversification with a focus on professionalism and enhanced management system.

Improved cost-efficiency ratios through intelligent use of manpower and new technologies.

Steadfast improvement and development of our quality product portfolio.

Working in genuine partnership with customers to ensure their total satisfaction.

Enhancing the reputation of Bangladesh’s apparel manufacture industry worldwide.

Sustainability:

We are dedicated as a group to the vital role of sustainability in securing a bright commercial, social and environment future. We address through:

Our people: Building their capacity through professional development and education.


Innovation and technology: Investing in the latest computer aided manufacturing technology.

Quality : Insisting on stringent standards of quality control.

Service: Delivering the highest standards of client care, ensure accountability across supply chain.

Environment : Implementing a 3 years plan to reduce gas water consumption and effluent waste.

3. DESCRIPTION OF DIFFERENT SECTIONS

3.1 KNITTING Section

Knitting is a method by which yarn is manipulated to create a textile or fabric. Knitting creates multiple loops of yarn, called stitches, in a line or tube. Knitting has multiple active stitches on the needle at one time. Knitted fabric consists of a number of consecutive rows of interlocking loops. As each row progresses, a newly created loop is pulled through one or more loops from the prior row, placed on the gaining needle, and the loops from the prior row are then pulled off the other needle.

3.1.1.1 Layout of Knitting Section:

3.1.1. Organogram of Knitting


Knitting Manager ↓

Knitting Assistance Manager ↓

Knitting Master ↓

Production Master ↓

Production Officer ↓

Knitting Incharge ↓

Knitting Supervisor ↓

Knitting Technician ↓

Knitting Operator ↓

Knitting Helper ↓

Knitting Cleaner

3.1.2 Knitting Machine:

There are 2 types of knitting m/c in Nur Group

a. Full circular knitting m/cb. Semicircular knitting m/c

No. of circular knitting m/c: 21

Basic parts of knitting m/c-

i. NEEDLEii. SINKER

iii. CAM

Important knitting parameters-


i. M/c gaugeii. M/c diameter

iii. V.D.Q. pulleyiv. Needle gauge.

Production parameter:

i. Machine diameterii. Machine r.p.m.

iii. No. of feedersiv. Machine gaugev. Yarn count

vi. Machine running timevii. Machine running efficiency

Common hand tools used in knitting:

i. Tension meterii. Salary range

iii. Dallyiv. G.S.M. pulleyv. Gauge Patti

vi. Wheelvii. Nose plus

viii. Lock keyix. Screw driver.

Picture of Knitting Machines:

Knitting m/c Specification:


M/c no. M/c type Dia×Gauge Feeder no. M/c brand Origin1 S/jersey 30×28 90 QUANZHO

U HENGYI. China

2 S/jersey 30×28 90 QUANZHOU HENGYI.

China

3 S/jersey 30×28 90 QUANZHOU HENGYI.

China

4 Interlock 34×24 82 Top Knit Korea5 Interlock 34×28 82 Top Knit Korea6 Interlock 34×28 82 Top Knit Korea7 S/jersey 30×28 96 Terrot Japan8 Rib/Interlock 32×24 68 Mayer&Cie Germany9 Interlock 32×24 68 JIUNN

LONGTaiwan

10 Fleece/S/jersey

30×24 96 JIUNN LONG

Taiwan

11 Fleece/S/jersey

30×24 96 JIUNN LONG

Taiwan

12 Fleece/S/jersey

30×24/28 90 JIUNN LONG

Taiwan

13 Terry 34×24/28 108 Lisky Taiwan14 Terry 30×20/24 96 Lisky Taiwan15 Terry 30×20/24 96 Lisky Taiwan16 S/jersey 38×24 123 Mayer&Cie Germany17 Fleece/S/

jersey30×20/24 96 PAI LUNG Taiwan

18 S/jersey 36×24 114 PAI LUNG Taiwan19 Rib 34×18 72 PAI LUNG Taiwan20 Rib/Interlock 34×18/24 72 PAI LUNG Taiwan21 Rib 30×18 62 PAI LUNG Taiwan

Other machine in knitting section:

I. Grey inspection m/cII. Electric balance for fabric weight

III. Electric balance for GSM checkIV. Compressor


Fig: Fabric inspection machine & Balance.

3.1.3 Types of fabric are produced in knitting section of Nur Group:

S/Jersey Fabric-i. S/jerseyii. 2 thread fleeceiii. 3 thread fleeceiv. S/lacostev. D/lacostevi. S/piquevii. D/piqueviii. E/stripe

D/Jersey Fabric-i. Plain interlockii. Interlock (design)iii. Rib (in various formation)iv. Mesh (pin mesh)

Considerable points of knitted fabric:

i. Design/type of fabricii. Finished G.S.M.iii. Yarn countiv. Type of yarnv. Diameter of fabricvi. Stitch length & color depth


3.1.4 Knitting faults:

There are 2 reasons for knitting fault-i. M/c faultii. Yarn fault

Faults found in knitting section-a. Contaminationb. Flyc. Needle mark d. Needle breakagee. Holef. Star markg. Lycra outh. Pattai. Slubj. Wheel freek. Count mistakel. Lot mistakem. Se

3.1 SAMPLE SECTION

Garment samples are inevitably important and are developed tested before starting the bulk production. It means making a sample of the garment /fabric which requires to be sold. Sampling is one of the main process in Garment Industry and it has a vital role in attracting buyers. Because the buyers generally places the order after they are satisfied with the quality of the sample.

3.2 Layout of sample section


3.1.2 Organogram of sample section:

15© Daffodil International University

General Manager

Sr. Executive

Shift in charge

Floor in charge

Supervisor

Operator

3.1.3 Flow chart of sample department:

Sketch/design

(It is given by buyer for make sample and products are made according to that style of designed)

Basic block

(Without any allowance)

Working pattern

(To make of garment according to design)

Sample making

(Sample is made by sample man)

Basic manufacturing difference

(Critical path is identify)

Approved sample

(Sample approved by buyer)

Costing

(To estimate the making charge, trimming, fabric required and profit)


Design or Sketch: It is nothing but one kind of engineering art including all measurement of particular style.

Basic Block: It is an individual component of garments without any design or style.

Working Pattern: To make pattern for a particular style with net dimension. .

Problem of Production or Production Related Matter:Production related problems should be eliminated in this step.

Approved Sample:The sample which is approved by buyer is called approved sample.

Send to Buyer: When all process is done, then the garments are sent to buyer.

Production Pattern: To make pattern for a particular style with net dimension along with allowance.

3.1.4 Sample type:

I. Development sampleII. Salesman Sample

III. Photo SampleIV. Approval SampleV. Size set Sample

VI. Mock up SampleVII. Pre-production Sample

VIII. Production SampleIX. Shipping Sample

3.1.5 The Details Attached to the Garment Sample:

After the confirmation of order, each sample sent to the buyer has the following details attached to it, with the help of a tag. It contains the details pertaining to both, what the buyer has demanded and what supplement fabric/trim etc. they have used (if applicable).


i. Ref no. ii. Color

iii. Fabric iv. Composition v. Description

vi. Quantity vii. Style no/ Size

viii. Store

There may be a separate sampling department in a company. But as the merchandiser is the person who is interacting with the buyers regarding samples and other requirements, this sampling department will work under the supervision of merchandising department. Also as the samples are to be made according to the buyers’ price ranges and quality levels, merchandiser has to advise sampling department suitably.

3.1.7 Sample swatch card (Trims):

Fig: Swatch of sample


3.2 CUTTING SECTION

3.2.1 Layout:


3.2.2 Organogram:


General Manager

Manager

Shift in charge

Floor in charge

Supervisor

Operator

Helper

3.2.3 Flowchart of cutting section:

Pattern received from pattern department

↓

Cutting ratio received from merchandiser

↓

Marker making

↓

Fabric received from the store

↓

Fabric Checking

↓

Fabric Spreading

↓

Marker placing on to the lay

↓

Cutting the fabric

↓

Numbering

↓

Checking

↓

Sorting and Bundling

↓

Send to the sewing department


3.2.4 Fabric Cutting:

Cutting is the major operation of the cutting room, when the spread fabric is cut into garment

components. Of all the operations in the cutting room this is the most decisive, because once

the fabric has been cut, very little can be done to rectify serious mistakes. Cutting can be

done manually using powered knives or by computer-controlled system.

Factors affect the cutting process for fabrics are as follows:

Nature of fabric (grain line shade, twill etc.)

Thickness of fabric.

Design characteristics of finished garment.

Machines and tables used.

3.2.5 Types of cutting machine use:

There have three types of cutting machine

Straight knife cutting m/c

Round knife cutting m/c

Band knife cutting m/c

But mostly straight knife cutting m/c is used.

Fig: Straight knife cutting m/c


http://textilelearner.blogspot.com/2012/02/process-sequence-of-cutting-section.html

3.2.6 Fabric inspection:

For fabric inspection 4-point system is used in Nur Groups.

4-point system

The 4-point system, also called the American Apparel Manufacturers Association (AAMA)

point-grading system for determining fabric quality, is widely used by producers of apparel

fabrics and by the department of defense in United States and is endorsed by the AAMA as

well as ASQC (American Society for Quality Control).The system in which the penalty point

of a defect is maximum 40 is called 4-point system of quality control.

4 Points System:

In this method, defected points are found out in 100 square yds. of fabric by inspection. The fabric must be rejected if the defected points are greater than 40.

Defects length for warp way and weft way Points

Up to 3 inch 1

3” – 6 “ 2

6” – 9” 3

Above 9” 4

Defects area for holes and openings Points

1 “ or less than 1” 2

Above 1 “ 4


3.2.7 Fabric inspection report sheet:

Fig: Fabric inspection report sheet.

3.2.8 Shrinkage Test:

Shrinkage is the process in which a fabric becomes smaller than its original size, usually through the process of laundry. Cotton fabric suffers from two main disadvantages of shrinking and creasing during subsequent washing.

There are two types of shrinkage occurs during washing

1) Length wise 2) Width wise

Cause: Due to high tension during preparation of fabric which result in excess stretch in yarn. This type of shrinkage is known as London shrinkage. Due to swelling of fibers for fiber structure.


Shrinkage is determined as;

Shrinkage % = (length of fabric before wash)-(length of fabric after wash))/ (length of fabric after wash) *100

Fig: Shrinkage test report

3.2.9 Distortion test:

Distortion test is the one of the important test to check the fabric to find, is there any bias, twisting in the fabric which are take place during weaving process. If fabric contain bias more than 3%. During sewing leg twisting and bad shape will come on garment. It’s totally unacceptable. So before cutting we have to ensure about twisting and bias through the distortion test.

3.2.10 Shade band:

Shade band is an important factor before cutting fabric. When fabric is stored in inventory

then sample is collected from every roll than a blanket is made from every single pieces.

After making blanket it is washed and then shade is checked under shade box and categorized

shade. According to this report the fabric is placed on cutting table.


3.2.11 Marker inspection:In marker inspection it is seen every parts of marker is right or wrong on marker paper.

Fig: Marker inspection report

3.2.12 Table checking inspection:

Received the bundle issue at first table Q.A personnel check bundle ticket / confirm the style

and fabric surface. Cutting Q.A personnel check only paper indicates cut panel. If get any

information from layer (Yellow tag & others) check cut panel before issue to production line

and findings defect panel take out from bundle for replacement and maintain cut panel

inspection report / summary report and log book.

Fig: Table checking inspection


3.2.13 Parts checking inspection:In this stage every parts is checked if there is any variation on measurement. If there any fault is found than it is solve.

3.2.15 Bundle inspection input:At last of cutting every bundle of cutting fabric is checked if there is less of any parts.

3.3 SEWING SECTION

3.3.1 Layout:


3.3.2 Organogram:


General Manager

Manager

Shift in charge

Floor in charge

Supervisor

Operator

Helper

3.3.3 Flowchart of sewing section:

Input from cutting

Initial Inspection part by part

Stitching with Process Wise

Table Quality Check

Size Wise Garments Count

Sewing Output

Sewing:

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

Elements of sewing

I. Sewing Thread,II. Needle &

III. Sewing Machine


3.3.4 Name of machine used in sewing section:

I. Single needle lock stitch Machine

II. Double needle lock stitch Machine

III. Single needle chain stitch Machine

IV. Double needle chain stitch Machine

V. Multi needle chain stitch Machine

VI. 3&5 thread Over lock Machine

VII. Bar tack Machine

VIII. Button hole Machine

IX. Button attaching Machine

X. Snap button attaching Machine

XI. Velcro Machine

XII. Feed of the arm Machine

XIII. Fusing Machine

3.3.5 Different types of stitches:

The two main stitches that sewing machines make of which the others are derivatives are lockstitch and chain stitch.

Back tack

Backstitch - a sturdy hand stitch for seams and decoration

Basting stitch (or tacking) - for reinforcement

Blanket stitch

Blind stitch (or hem stitch) - a type of slip stitch used for inconspicuous hems

Buttonhole stitch

Chain stitch - hand or machine stitch for seams or decoration

Cross-stitch - usually used for decoration, but may also be used for seams

Lockstitch - machine stitch, also called straight stitch

Overhand stitch

Over lock

Pad stitch


Padding stitch

Running stitch - a hand stitch for seams and gathering

Sail makers stitch

Slip stitch - a hand stitch for fastening two pieces of fabric together from the right side without the thread showing

Stretch stitch

Tent stitch

Topstitch

Whipstitch (or over sewing or overcast stitch) - for protecting edges

Zigzag stitch

3.3.6 Machine Description:

NO. Name of Machine Quantity

01 Plain m/c 42602 Plain m/c computer 5903 Vertical m/c 2604 Two needle lock stitch 9605 Two needle chain stitch 5806 One needle chain stitch 507 Over lock 6 thread 9708 Over lock 5 thread 4609 Over lock 4 thread 810 Over lock 3 thread 1711 Kansai m/c 3112 Loop m/c 613 Bar tack m/c 4914 Button hole m/c 2915 Button stitch computer 2716 Eyelet hole computer 617 Flat lock m/c 618 Feed of the arm 3N 5719 Feed of the arm 2N 2020 Snap button m/c 2921 Zig zag m/c 322 Pocket passing 823 Thread sucking 524 Snap button air 5

Total 1120


3.3.7 Description of Different Type Sewing Machines:

Plain m/c:

Component:

One needle

Two tensioners

Three guide

One hook

Two thread

One bobbin case Fig: Plain m/c

One magnate guide

Application:

Bottom hemming

Belt top seem stitch

Belt joint stitch

Loop tack stitch

Pocket joint stitch

Zipper joint

Flap top stitch

Flap joint

Fly top stitch

Flap 1/4 stitch

Front rise stitch

Back rise stitch


Over lock m/c:

Component:

5 thread

4 tensioner

2 knifes (up / down)

2 needle for 5 threads

1 needle for 3 threads

3 looper for 5 threads

2 looper for 3 threads Fig: over lock m/c

Applications:

Over lock stitch

Bar tack m/c:

Applications:

To created bar tack stitches in garments.

Loop attach

Fly make

Pocket side

Front side

Back pocketing

Zipper lay Fig: Bar tack m/c

In seem


Flat lock

Component:

4 tensioner

3 thread

Contain a holder

2 needle

Applications:

Zigzag stitch

Knit hemming

Loop making

Chain stitch m/c:

Component:

2 needle

2 lopper

4 thread

4 tensioner (back 2/front 2)

Applications:

Back rise stitch

Back yoke stitch

Top sin ¼ stitch

Feed off the Arm m/c:

Component:

2 needle

2 Lopper

4 thread (Lopper 2/needle 2)

Contains T & Magnate guide

3 tensioner Fig: Feed of the Arm


Applications:

Back rise stitch

Inseam stitch

Back yoke top sin

Eye late Button holing m/c:

Component:

3 thread or 4 thread

1 needle

Contains bobbin case

2 lopper

Contains a hammer

Applications:

To make eye late hole in garments.

Button Attach m/c:

Component:

2 thread

1 needle

Contains shoulder, shoulder Cap bobbin catching

Applications:

To attach button in garments

Snap Button Attach m/c:

Components:

Not use any types of thread & needle.

It has button attach stage.

Snap stage has two parts.


Applications:

To attach snap button in garments.

To attach sub button in garments.

III.3.8 Sewing quality planning:

Fig: sewing quality planning

3.3.9 Sewing Quality checking points

Skip/Drop/Broken stitch

Raw edge

Size mistake

Uneven hem

Uneven cuff36

© Daffodil International University

Uneven neck

Uneven shoulder

Uneven placket

Uneven pocket

Twisting

Without care label

Open tack

Sleeve up-down

Stripe up- down

Open seam

Four point up-down

Shading etc

3.3.10 Sewing Line quality Check List:

Buyer Approved Sample & Measurement Sheet Check.

Sample Wise Input Check.

Buyer Approved Trims Card Check.

Buyer Approved Sample Wise Style Check.

All Machine Thread Tension Check.

Style Wise Print & Embroidery Placement Check.

All Process Measurement Check.

All Machine Oil Spot Check.

All Process S.P.I Check as Per Buyer Requirement.

Input Time Shading, Bundle Mistake & Size Mistake Check.

Buyer Approved Wise Contrast Color Check.

As per Buyer Requirement Wise Styling Check.

All Machine Stitch Tension Balance Properly.


3.3.11 Sewing Table Quality Check List:

Style Wise Garments Check.

All Process Measurement Check..

Front Part, Back Part, Sleeve & Thread Shading Check.

S.P.I Check for All Process.

Print/Embroidery Placement Check.

Main Label, Care Label, Size Label &Care Symbol Check.

Size Mistake Check.

All Process Alter Check.

Any Fabric Fault /Rejection Check.

3.3.12 Different type of sewing fault:

Skip/ Drop stitch

Uneven stitch

Over stitch

Joint stitch

Raw edge

Tension loose

Broken stitch

Puckering

Open stitch

Oil spot

Shading

Incorrect stitch per inch

Pleat


Needle cut

Wrong Thread

Wrong size/ care label

Slanted

Wrong button placement

Run off stitch

Etc

3.4 INDUSTRIAL ENGINEERING

3.4.2 Organogram of IE Section:


Manager

Asst. manager

Senior IE officer

IE officer

Asst. Officer

Management Trainee

3.4.3 Process Flow Chart of Industrial Engineering (IE):

Industrial Engineer

↓

Negotiation with Merchandiser

↓

If in-house accessories & fabric then do the preproduction meeting

↓

Planning

↓

Line balancing

↓

Go for production based on planning

↓

Production continuous meeting

↓

To achieved production as planning

↓

Production continuing (follow up)

↓

Shipment/Delivery


3.4.4 Calculation formula:

SL Formula1 S.M.V. = Basic Time + Allowance

2 Observed Time * Observe RatingBasic Time = ---------------------------------------------------

Standard Rating3 (No. of Manpower *60)

Line Target = -------------------------------------S.M.V.

4 Line Output * S.M.VEfficiency = --------------------------------------------- *100

(Manpower*Working Hour)*605 Line Output

Performance = ------------------------------- * 100 Line Target

3.4.5 Line balancing:

Line balancing is the allocation of sewing machine according to style and design of garment.

It depends of that what type of garment we have to produce.

The objective of line balancing:

Line balancing is a main part of a mass production. These kinds of systems, regardless of

being different in details, are workstations in a sequence. Row material is included in the line

at the beginning or in the middle. Parts included in the system transfers from one workstation

through the other and at the end leaves the system as a completed product. Transfer lines uses

manpower very little when compared to assembly lines. The certain properties of Transfer

lines are transfer and process of a product automatically through a line.


Objectives that should be gained balancing an assembly line are as follows;

Regular material flow;

Maximum usage of man power and machine capacity;

Minimum process times;

Minimizing slack times;

Minimizing workstations;

Maximum outputs at the desired timed;

Agreed quality maintenance of the garments;

Reduce production costs.

Importance of Line Balancing:

The importance of line balancing could be summarized as follows –

Good line balancing increases the rate of production;

This is the pre-condition for smooth production;

Line balancing helps to compare the required machinery with the existing one and make a balance;

It also helps in the determination of labor requirement;

Good balancing reduces production time;

Profit of a factory can be ensured by proper line balancing;

Proper line balancing ensures optimum production at the agreed quality;

It reduces faults in the finished products;

Line balancing helps to know about new machines required for new styles;

It becomes easier to distribute particular job to each operator;

It becomes possible to deliver goods at right time at the agreed quality for least costs.


Steps in line balancing:

Now-a-days, Standard Minute Value (SMV) is used as a tool for the line balancing,

production control and the estimation of efficiency. In a similar way, the time taken to do a

job for making garments like shirt/trouser/blouse/dresses could depend upon a number of

factors like –

The length of the shirt/trouser/blouse/dress;

The number of stitches per inch;

The presentation of item;

The pricing of garments.

3.4.6 Productivity related analysis of Work Study:

a. Operation analysis: – Research and analysis for timing and method for any

operation.

b. Process analysis: – Analysis for flow of work of any new product according

to the space layout, machinery available and material flow

c. Motion study: – Research of every part of body movement of operator while

executing any particular operation so that useless activity may be removed and

better efficient time of any operation.

d. Time study: – Research for actual time for executing any particular operation

or process.

e. Modern equipment and technology adaptation: – Research for latest

technology for executing an operation in better cost effective and quality

competitiveness.

f. Synchronization: – Research for distribution of equal time of work to every

operator involved for better production line balancing and smooth flow of

work.

g. Layout: – Most effective arrangement of plant, machinery, equipment and

material for minimization of handling and distribution time for higher output.


3.4.7 Capacity study:

Fig: Capacity study sheet

3.6 FINISHING SECTION

3.6.1 Layout:

3.6.2 Organogram of Quality:


3.6.3 Process Flow Chart of Garments Finishing:

Sewn garments received in finishing section

↓

Initial quality check

↓

Spot removing if there’s any spot

↓

Ironing or pressing

↓

Inspection

↓

Hang tag attaching

↓

Folding

↓

Poly bag

↓

Metal check

↓

Packaging or cartooning

3.6.4 Objectives of Finishing:

i. Improving the appearance, luster, whiteness etc.

ii. Improving the feel, this depends on the handle of the material& its softness,

suppleness, fullness etc.

iii. Wearing qualities, non- soiling, anticrease, antishrink comfort etc.45

© Daffodil International University

iv. Special properties required for particular uses like waterproofing flame-proofing etc.

v. Covering of the faults in the original cloth.

vi. Increasing the weight of the cloth.

3.6.6 In finishing to be checked

Iron or press Folding Tagging Packing Measurement checking Pre-final inspection

Quality assurance Procedure:

The decision plans and action that is necessary to provide adequate confidence that a product or service will satisfy given requirements for particular quality.

Body Inspection:

All rolls are kept in front of the inspection M/c. The fabric are spread over white inspection board which ensures high transparency and even light reflection. Then the inspection machine fabrics and are inspected at a standard speed against light. For any major or minor faults are recorded in inspection report to classify the fabric based on four points system.

Collar &cuff inspection:

Collar &cuff are inspected visually under the light box. For any major or minor faults in collar /cuff like having wrong ply, hole, needle line, slubs, first round problem etc are counted and recorded. Quality inspector will check 100% of receive fabric for quality. He will identify any defect, hole or stain in the fabric and make calculation.

3.6.7 Work in the Finishing Room:

Eliminate micro-dust and residual thread from the garment;

Press/iron garments as specified by buyer or as per requirements;

Fold the garments as required by customer;

Fix necessary tickets (Price tickets) or tags (hang tags),etc to the garments at this stage;

Insert garments into poly bags;

Divide garments as per size and color (assortment);


Machine Description of finishing section.

Finishing capacity: 1000 pcs/hrs. (Approximately)

3.6.8 Metal detection machine:

Fig: Metal detector

Fig: Metal detector machine report.


Machine Number

Heat Iron 6

Steam iron 9

Metal detector 2

Neck press 2

Thread sucker 3

Thread sucker machine:

Fig: Thread sucker m/c

3.6.9 Materials used in garment finishing:1. Neck board2. Back board3. Collar stand4. Butterfly5. Tie placket support6. Danishing loop7. Fit label8. M-clip9. T-clip10. Metal clip11. Cuff link12. Droop loop13. Cable tie14. Boa tie15. Full board16. Hand tag17. Tag pin18. Tissue paper19. Al pin20. Ball pin21. Elastic clip22. Hanger23. Poly bag24. Size sticker25. Gun tap26. Inner box27. Muster cartoon box28. Pp belt29. Blister, Etc.


3.6.10 The General Rules of Spot Removing:

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

2. Always treat a stain before laundering.

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

3.6.11 Stain Removal:

Ironing:

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

3.6.12 Garment Inspection:


STAIN TYPE USED CHEMICAL (COMMERCIAL NAME)

Oil stain Spot lifterGeneral stain ThinnerTurmeric stain MRSInk stain MRGlue stain(Polymer based ) Heat gunRust stain MarksvillePrint mark Printvill

Do not iron

Cool iron (110°)

Medium iron (150°)

Hot iron (200°)

http://en.wikipedia.org/wiki/Iron_(appliance)

Flow Chart of Garment Inspection

Confirmation of Quantity ↓

Confirmation of accessories ↓

Size specification inspection ↓

In side Inspection ↓

Outside Inspection ↓

Final Inspection ↓

Packing

Inspection Procedure of Garments are Described Below:

Confirmation of Quantity:

First step of garment inspection start with confirmation of Quantity with the vendors packing list by counting all Pecs of each box. If Qty is not matching to the packing list and written in the box then this discrepancy is informed to the vendor.

Confirmation of Accessories:

Next step is the confirmation of accessories, here we confirm brand tags, demerit tags, Price tags, or other tags, wash care labels, woven labels, or other labels and accessories as required by the buyer.

Size Specification inspection:

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

In Side Inspection:

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


Out Side Inspection:

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

Final Inspection:

Final Inspection stage is the most important part of inspection process, here garment is rechecked to confirm that inspection is done properly without missing any checking step if any defect is noticed we put it into rejection bin or send it for repay.

Packing:

All “Grade-A” goods are put back into poly bags as per the original packaging and then they are send for needle inspection

Pressing or Folding:

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

Pack inspection

Fig: Packed inspection report


3.6.13 Different type of folding:

Standard folding

Semi standard folding

Flat folding:

Roll folding

Hang folding

Half folding

Eco folding

Twill folding

Packaging:

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

3.6.14 Assortment:

Buyers generally place order of garments in certain assortment of color and sizes. The production of such colors and sizes is called assortment. Another order with an assortment of 1:2:2:1 is shown below:

Color/size S M L XL Quantity

Red 1000 2000 2000 1000 = 6000

Yellow 1000 2000 2000 1000 = 6000

Olive 1000 2000 2000 1000 = 6000

Violet 1000 2000 2000 1000 = 6000

Total= 24000


3.6.15 Cartooning procedure:

There are 4 types of cartooning assortment:

1) Solid size and solid color (the order comprises one size & one color)

2) Solid size & assorted color (the order comprises one size & different colors)

3) Assortment sizes & assorted color (the order has only one color but different sizes)

4) Assorted sizes & assorted color (different sizes & different colors in the order)

Cartoon type:

Master carton (Almost cubic)

Coffin carton (Length > 2*width)

Inner carton (Small & insert able into other carton )

Etc.

Dispatch:

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

3.7 STORE SECTIONFor a bulk production industry it is essential to maintain a well-organized & well equipped inventory system. The main responsibility of this department is to store all the raw material necessary to produce garments. This department is sub divided into three sections.

3.7.1 Layout:


3.7.2 Organogram:


General Manager

Manager

Asst. manager

Sr. Executive

Jr. Executive

Store Asst.

Loader

3.7.3 Process Flow Chart of Garments store

3.7.4 Grey fabrics store:All the grey fabrics are stored in the fabric store, near the batch section. Different types of fabrics are listed in the sheet according to the fabric types, quantity & consumer‘s requirements. Fabrics GSM, shrinkage, diameter & other properties are also taken into consideration. The bathes are prepared by taking the required fabrics from the grey store.

3.7.5 Finished goods:Nur Group supplies its finished garments to its finished goods store. So, finished garments are stored for short time in the finish store. All the delivered fabrics are noted on the note according to the Lot no., quantity, size, buyer‘s name, colors, & considering other parameters.

3.7.6 Accessories Store:According to Buyer and style number, store keeper arranged their rack for inventory. When an order is confirm they communicate with merchandiser / suppler and confirm inventory. Store keepers receive all accessories by counting.

If everything is ok then they give satisfactory comments and if found any kind of problem they mention in challan sheet. After receive all accessories they give entry in computer & keep arrange in rack for easily searching. Trim card make for different style & buyer wise for smooth work.


Raw material receive

Material receive report

Store in main go-down by bin card

Running go-down

Production floor

Hanger sizer: Identify the size of the garment by hanger

Label: Labels are the most important trimmings by which customer easily, know about the product. Here two types of label are available:

Main label: It contains the name of buyer and country. Ex. Wal-Mart, USA etc

Sub label:

Size label: It contains the size of the garment

Care label: It contains care construction. Different types of care label are given below.

Washing code

Bleaching code

Ironing code

Dry cleaning code

Drying code

Cost label: It contains the cost of garments.

Composition: It contains fiber composition of the fabric. Ex 65% cotton, 35%polyester.

3.7.7 Sewing thread:

Different types of sewing treads are available in store room. Such as

60/3 (100% polyester)

50/3 (core spun yarn)

40/3 (100% polyester)

20/3 (100% cotton) etc


3.7.8 Button: Many types of button are available in store room. Some examples of button are given below.

Horn button

Purl button

Shank button

Snap button

Coconut button

Chalk button

Amount determination of button:

There are two systems of determination the amount of amount. These are given below.

1G.G =12GRS

Each cartoon contain 750 gross

1 gross =144 pcs

750 gross =144×750=108000 pcs

3.7.9 Interlining:

Types of interlining are available in store room are given below.

Dot fuse.

Paper fuse.

T.C interlining.

Woven fabric fuse.

Non fuse etc.


Packing section:

Various types of packing accessories are available in store room such as polybag, packing board, tissue paper, hanger, scotch tape, gum tape, carton etc.

3.7.10 Trim card contain with:

-Main, size & care label.

-Back neck tape.

-Button.

-PSP paper.

-Tag pin.

-Master carton.

-Poly stiker.

-Carton stiker.

-Poly bag.

-Logo gum tape.

-Heat transfer.-Interlining.

-Woven twill fabric.

-Country flag sticker.

-Hang tag.

-Mobilon tape.

-Security label

3.7.11 Accessories Inspection:

At first 10% accessories are inspected by QC inspector. If the defectives amounts cross over 1% then the accessories will fail. In the situation according to suggestion of QA & QC manager these accessories send to the merchandiser and buyer representatives finally to work according to their decision.


3.7.12 Accessories are inspection 100% for some defects:such as-

Missing of composition

Size mistake

Barcode mistake

Style mistake in the hang tag

Metal item inspection such as magnet test. Nickel test, Rust test, ferrous test etc.

3.7.13 Quality for Inventory/Storage:

Fabrics or other Raw Materials and Accessories should be safe from the following:

Soiling,

Mechanical damage,

Environmental damage due to temp. & R.H% which may cause dimensional changes,

Fungal Attack,

Fadding due to light exposure,

Damage during Handling.


3.8 COMPLIANCE:

3.8.1 Organogram:

Compliance:

Compliance means comply something i.e. yield to the wishes another. The main aim of compliance is to ensuring the all labor rights and facilities according to buyer code of conduct.

3.8.2 Different compliance issues which they are obeyed:

Personnel policies

Attendance and leave register card Recruitment policy Leave and holiday policy Their weekly working hour not more than 66 hours including overtime in a week They have the approved manpower list.


Head of Compliance

Sr. Compliance officer

Compliance officer

Sr. Social welfare officer

Social welfare officer

Health & hygiene:

First aid ensures. Medicine registers. Maternity and pregnancy register. Pure drinking water. Towel for hand dry.

Safety:

Safety committee Firefighting committee Rescue committee Broken needle register Needle detector Fire alarm & switch Evacuation plan Rubber mats to every iron man.

Welfare:

Welfare committee Day care center Canteen facility

Salary and wages:

Fix wages in considering minimum wages which is declared by the government. Salary and wages given before 7th day of month.

Physical security:

They have separate cargo entrance area (receiving and unloading) from the front side. They do not keep any partially filled/ completed cartons on the floor at the end of any

working day. They keep it to finished goods store.


Education and training program:

They arrange security training program on regular basis for all employee of the factory.

3.8.3 Compliance item:

Some example of compliances item are given below: First aid box Water paper Toilet Wash basin Complain box Evacuation plan Exhaust fan Emergency exit/light/ light set Smoke detector Fire extinguisher Hose cabinet Manila rope Gas musk

3.9 UTILITY:

3.9.1 Organogram:


Head of utility

Mechanical

Electrical

Civil

Nur Group is a large project. So, it requires adequate utility services. In Nur Group the following utility services are available.

Electricity

Gas

Water

Steam

Compressed air

3.9.2 Electricity:It is not possible to continue the assembly while not electricity. A frequent provide of

electricity is extremely a lot of essential to make sure sleek production. In Liz Apparels Ltd.

the complete demanded electricity is generated by Own Generator.

3.9.3 Gas:The gas is supplied to Gas Generator, Boiler.

The source of gas is TITAS Gas Ltd.

3.9.4 Water:Continuous supply of water for Liz Apparels ltd. is ensured by Water pump. The deep well

water is subjected to Water Treatment Plant (WTP) to make sure the water quality parameter

suitable for Textile Wet Processing.

3.9.5 Description of Generator:Description of m/c no.of m/c Capacity

Generated Power:

Prime power generation , Cruascar Gas Generator Model: FGLD 480 Origin: Spain

1Unit 636kW

Stand by: Diesel Generator, puma, Origin: England

1Unit 140 kW

A. Sub station 1000kVA

Total connected load 1776 kW


Air Compressor:

Kaeser Screw Compressor, Model: AS44, 30 kW,4M3

/MIN. each

2 Units 8M3 /MIN

Omgersp:-Rand Reciprocating Compressor, Model: SSR ML-5057.5kW

CAPACITY of air disharge

1Unit 8M3 /MIN

Ingersol- Rand Reciprocating Compressor, Model: 3000.22 kW

2 Units 4.40 M3 /MIN

SWAN Reciprocating Compressor, Model: C4080, 10 kW

1 M3 /MIN

Total air discharge capacity 21.4M3 /MIN

3.9.6 Description of Water pump:Description of WATER pump

no.of m/c Capacity

Centrifugal pump for water supply to washing others Section

1 100m3/h

20HP Pedrollo pump each pump , 1, 000L/min flow rate

4Unit 4,000 L/min

10HP Pedrollo pump each pump , 600L/min flow rate

1Unit 600 L/min

5.5HP Pedrollo pump each pump , 350L/min flow rate

1Unit 350 L/min

Spare pump motor Pedrollo 20HP

1Unit 1,000 L/min

Boiler:

Ciever Brooks Boiler 10 tons /hr

1 set


4. IMPACT OF INTERNSHIP:

4.1 Sample Section:

1. Understood why sample section is called a mini-industry.

2. Observed how skilled workers work in sample section.

3. Learned the process of preparing a pattern for an individual size & design.

4.2 Cutting Section:

1. Learned about different type of cutting machines (i.e. Straight knife cutting, Band knife

cutting machine etc.)

2. Learned the process of fabric spreading.

3. Observed the process of fabric cutting according to the marker.

4. Understood different process of fabric lay.

5. Realized the use and importance of metal gloves for fabric cutting process through

different cutting machines.

6. Observed the panel check process for different type of fabric of different style and design.

7. Understood how numbering and bundling is done.

8.Understood different inspection like parts check, marker report, parts replacement.

4.3 Sewing Section:1. Learned about different parts of a shirt (i.e. Upper front, Lower front, Back part, Facing,

Collar, Sleeve etc.).

2. Observed different sewing or joining process of different body parts of a shirt.

3. Learned about different type of machines used in a sewing floor (i.e. Single or double

needle lock stitch machine , Multi needle chain stitch machine, Over lock machine, Feed of

the arm machine etc.).


4. Observed the ironing and fusing process for different body parts (i.e. Collar, Placket,

Facing Interlining etc.).

5. Learned about Standard Minute Value (SMV) of different sewing process.

6. Learned the process of determining operator’s efficiency in an individual process for a

shirt.

7. Cleared the conception about production of a sewing floor ( line by line and total floor).

8. Observed and realized the importance of final inspection at the end of every sewing line.

9. Got experienced in making production study of an operator for an individual process for a

definite time interval.

10. Also got experienced in making capacity graph of a sewing line of a definite style and

design.

11. Realized the importance of Dept. of IE in raising the efficiency of production in a sewing

floor.

4.4 Industrial engineering:

1.We learn about line balancing.

2. we also learn smv calculation

3.How can increase productivity by applying IE process

4. 6 Finishing Section:1. Observed various type of finishing process after sewing and washing.

2. Observed different type of machines used in finishing section (i.e. Neck press machine,

Metal detector machine etc.).

3. Learned about various type of accessories used to attach to the garment (i.e. Security

alarm, Hang tag, Price tag, Barcode label etc.).

4. Cleared the conception about different packing type (i.e. Master pack, Blister pack, Coffin

pack etc.) and packing ratio.


5. Finally realized why finishing section is unavoidable in garments industry for making the

garment attractive and decorative for selling purpose.

4.7 Store Section:

1. Understood the necessity & process of inventory.

2. Realized the role of PI (Pro-forma Invoice).

3. Had cleared the conception about fabric inspection method.

4. Learned how to examine AQL in a fabric lot.

5. Learned the procedure of receiving materials & dispatching goods outside of the factory.

4.8 Compliance:

1.Different compliance issue that ensure for worker.

2.Saftey working environment for worker.

4.9 Utility:1.We can learn different type of generator and compressor.

2.Their cost .


5. CONCLUSION:

For every person who is fresher in the field of textile, industrial training works like learning

route. This course given me the opportunity to move liberally in every section of the industry

to learn the industrial work & follow the process sequence practically. From my two months

observation of the industry along with research & development section specially, I can say

that in the woven sector this industry has very strong possibility because the industry is

running with all modern machineries & very knowledgeable persons are working all the time

with their maximum effort. I just think the capacity of the industry should developed with the

amount of order the industry is being taking. In the production floor the commanding power

of the officers, compliance, administration rules everything is appealing. I hope that this

industrial training will help me a lot to work in the future period wherever I want to develop

my career. Finally wishing the best prospect of both the industry & myself.
