Industrial attachment of divine group of industries limited (dgi).

1. Industrial attachment of divine group of industries limited (dgi). INDUSTRIAL TRAINING Course Code: Tex -4036 INDUSTRIAL ATTACHMENT OF Divine Group of Industries Limited (DGI).

2. Introduction The industrial attachment is the process, which builds understanding, skills and attitude of the performer, which improves his knowledge in boosting productivity and services. University education provides us vast theoretical knowledge as well as more practical attachment, in despite of all these industrial attachment helps us to be familiar with technical support of modern machinery, skillness about various processing stages. It also provides me sufficient practical knowledge about production management, work study, efficiency, industrial management, purchasing, utility and maintenance of machinery and their operation techniques etc. The above mentioned cannot be achieved successfully by means of theoretical knowledge only. This is why it should be accomplished with practical knowledge in which it is based on. Industrial attachment makes me reliable to be accustomed with the industrial atmosphere and improve courage and inspiration to take self-responsibility. Textile education can’t be completed without industrial training. Because this industrial training minimizes the gap between theoretical and practical knowledge and make us accustomed to industrial environment. I got an opportunity to complete two-month long industrial training at Divine Group Ltd. In the field of ever changing moderns fashion work Divine Group Ltd. considers it prime mission to every new test. Which & demand of customers from around the World & all strains human culture Divine Group of Industries Limited (DGI) acts on the basis premise that fashion is an exploration in to the images people seek to convey about themselves & the way they live. It has well planned & equipped Knit fabric dyeing-finishing and Garment units in addition to facilitate knitting and knitwear manufacturing. I have prepared this report as required in competition of my attachment course in regarding guideline given by the university authority which will lead to a strong guideline and milestone for my future carrier. Introduction The industrial attachment is the process, which builds understanding, skills and attitude of the performer, which improves his knowledge in boosting productivity and services. University education provides us vast theoretical knowledge as well as more practical attachment, in despite of all these industrial attachment helps us to be familiar with technical support of modern machinery, skillness about various processing stages. It also provides me sufficient practical knowledge about production management, work study, efficiency, industrial management, purchasing, utility and maintenance of machinery and their operation techniques etc. The above mentioned cannot be achieved successfully by means of theoretical knowledge only. This is why it should be accomplished with practical knowledge in which it is based on. Industrial attachment makes me reliable to be accustomed with the industrial atmosphere and improve courage and inspiration to take self-responsibility. Textile education can’t be completed without industrial training. Because this industrial training minimizes the gap between theoretical and practical knowledge and make us accustomed to industrial environment. I got an opportunity to complete two-month long industrial training at Divine Group Ltd. In the field of ever changing moderns fashion work Divine Group Ltd. considers it prime mission to every new test. Which & demand of customers from around the World & all strains human culture Divine Group of Industries Limited (DGI) acts on the basis premise that fashion is an exploration in to the images people seek to convey about themselves & the way they live. It has well planned & equipped Knit fabric dyeing-finishing and Garment units in addition to facilitate knitting and knitwear manufacturing. I have prepared this report as required in competition of my attachment course in regarding guideline given by the university authority which will lead to a strong guideline and milestone for my future carrier.

3. CHAPTER -01 COMPANY PROFILE AT A GLANCE Name of Company : Divine Textile Ltd. Address : Chandra, Kaliakoir, Gazipur, Bangladesh Phone : 06822-51229 Head Office : House No: 348, Road No: 26, New DHOS, Mohakhali, Dhaka – 1206, Bangladesh. Fax Number : + 88-02-9885032 CHAPTER -01 COMPANY PROFILE AT A GLANCE Name of Company : Divine Textile Ltd. Address : Chandra, Kaliakoir, Gazipur, Bangladesh Phone : 06822-51229 Head Office : House No: 348, Road No: 26, New DHOS, Mohakhali, Dhaka – 1206, Bangladesh. Fax Number : + 88-02-9885032

4. FACTORY INFORMATION Factory Type : 100% Export Oriented Knit Composite Industry. Year of Establishment : 1997 Investor : Mr. Hasanuzzaman Location : Chandra, Kaliakoir, Gazipur. Annual Turnover : Tk. 10, 00, 00,000 to 12, 00, 00,000 Certification & Awards : ISO 9001:2000 & WRAP Production Capacity : Knitting : 15.5 tons/day (Average) Dyeing : 15.5 ton/day (Average) Sewing : 100000 pcs/day (Average) Main Production : Basic T-Shirt, Tank top, Long Sleeve, T-Shirt, Polo Shirt, Shorts, Pajama, Set, Ladies ,Kids Knitwear & all kinds of knit garments & Knit fabrics. FACTORY INFORMATION Factory Type : 100% Export Oriented Knit Composite Industry. Year of Establishment : 1997 Investor : Mr. Hasanuzzaman Location : Chandra, Kaliakoir, Gazipur. Annual Turnover : Tk. 10, 00, 00,000 to 12, 00, 00,000 Certification & Awards : ISO 9001:2000 & WRAP Production Capacity : Knitting : 15.5 tons/day (Average) Dyeing : 15.5 ton/day (Average) Sewing : 100000 pcs/day (Average) Main Production : Basic T-Shirt, Tank top, Long Sleeve, T-Shirt, Polo Shirt, Shorts, Pajama, Set, Ladies ,Kids Knitwear & all kinds of knit garments & Knit fabrics.

5. In the backdrop of a mercurial, ever-changing fashion world, Divine Group of Industries Ltd. considers its prime mission to suit every new taste, whim and demand of customers from around the world and all strains of human culture. Divine Group acts on the basic premise that 'fashion’ is an exploration into the images people seek to convey about themselves and the way they live. So, in dealing with its target consumers, Divine Group mainly aims to know their perception about themselves and translates those into Garments. Doing that, over the years, Divine Group designers have acquired an almost telepathic understanding of the customers' needs. In the backdrop of a mercurial, ever-changing fashion world, Divine Group of Industries Ltd. considers its prime mission to suit every new taste, whim and demand of customers from around the world and all strains of human culture. Divine Group acts on the basic premise that 'fashion’ is an exploration into the images people seek to convey about themselves and the way they live. So, in dealing with its target consumers, Divine Group mainly aims to know their perception about themselves and translates those into Garments. Doing that, over the years, Divine Group designers have acquired an almost telepathic understanding of the customers' needs.

6. Mr. Hasanuzzaman, Managing Director The Chief Executive of Divine Group of Industries Ltd. Divine Group has started manufacture and export of garments since late 1997. Its mission is ti produce the latest design; quality knit fabrics and apparels for international markets. Divine Group is one of the few elite private sector business groups, which contributed wealth as well as welfare to the struggling economy of Bangladesh. As time is essential to space so is taste to its products. The secret is love-which, paired with meticulous efficiency and a keen sensitivity to style, makes Divine Group an emerging brand destined to light up horizon of fashion. Divine Group has team of skilled and dedicated technocrats backed by adequate number of modern USA and European machinery and equipment’s to match international standard of all kinds of knitwear products. Mr. Hasanuzzaman, Managing Director The Chief Executive of Divine Group of Industries Ltd. Divine Group has started manufacture and export of garments since late 1997. Its mission is ti produce the latest design; quality knit fabrics and apparels for international markets. Divine Group is one of the few elite private sector business groups, which contributed wealth as well as welfare to the struggling economy of Bangladesh. As time is essential to space so is taste to its products. The secret is love-which, paired with meticulous efficiency and a keen sensitivity to style, makes Divine Group an emerging brand destined to light up horizon of fashion. Divine Group has team of skilled and dedicated technocrats backed by adequate number of modern USA and European machinery and equipment’s to match international standard of all kinds of knitwear products.

7. Within only a decade, Divine Group by hyper-growth has been transformed into a futuristic entrepreneurial saga. Its production has branched out into eight full-fledged factories at four locations- Chandra, Kaliakoir in Gazipur, Chowgasa in Jessore and Mirpur Dhaka. Divine Group Chandra premise houses an ultra-modern Divine Textile Ltd, with forth story building as the main one. Divine Textile Ltd Unit-2 a new 09-story building in the same premises. Divine Fabric Ltd. a new 3rd story building is under construction at Chandra, Gazipur. The Divine Textile Ltd. at Chandra, Housed in four floors of 24,000 square foot, employees of 750 staff with a daily production capacity of 12,000 pieces of complete garments, while 2650 staff of Divine Textile Ltd. unit -2 at the same premises produce around 50,000 pieces of garments a day. Divine Group of Industries Ltd. has its own water pre-treatment plan and 24,500 cubic feet water reservoirs in its Chandra, campus. The Chandra premises has its own power Generators plant where 2,200 kw power generators guarantee smooth and uninterrupted power supply to its every operation. Divine Group of Industries Ltd. has its own Wastage water treatment plan (ETP) and 24,500 cubic dyed water has been treated in this campus and go through the outside. Divine Group home base is Gazipur - a city furnished with the largest garments factory of Bangladesh. It had been a center of Textiles and garments in this region ever since the middle ages - a time when it was world famous for its ethereal muslin - and has continued in that tradition as the happening place for Knitwear. A busy area, availability of skilled artisans, and a range of other facilities and possibilities render it the ideal ground for Divine Group. Since its inception, Divine Group has never stopped growing - in quality, quantity, capacity and everything in between. Its production has branched out into nine fledged factories at four locations - Chandra in Gazipur, Chowgasa in Jessore, Mirpur in Dhaka and near EPZ in Savar. Divine Group at present has a daily production Within only a decade, Divine Group by hyper-growth has been transformed into a futuristic entrepreneurial saga. Its production has branched out into eight full-fledged factories at four locations- Chandra, Kaliakoir in Gazipur, Chowgasa in Jessore and Mirpur Dhaka. Divine Group Chandra premise houses an ultra-modern Divine Textile Ltd, with forth story building as the main one. Divine Textile Ltd Unit-2 a new 09-story building in the same premises. Divine Fabric Ltd. a new 3rd story building is under construction at Chandra, Gazipur. The Divine Textile Ltd. at Chandra, Housed in four floors of 24,000 square foot, employees of 750 staff with a daily production capacity of 12,000 pieces of complete garments, while 2650 staff of Divine Textile Ltd. unit -2 at the same premises produce around 50,000 pieces of garments a day. Divine Group of Industries Ltd. has its own water pre-treatment plan and 24,500 cubic feet water reservoirs in its Chandra, campus. The Chandra premises has its own power Generators plant where 2,200 kw power generators guarantee smooth and uninterrupted power supply to its every operation. Divine Group of Industries Ltd. has its own Wastage water treatment plan (ETP) and 24,500 cubic dyed water has been treated in this campus and go through the outside. Divine Group home base is Gazipur - a city furnished with the largest garments factory of Bangladesh. It had been a center of Textiles and garments in this region ever since the middle ages - a time when it was world famous for its ethereal muslin - and has continued in that tradition as the happening place for Knitwear. A busy area, availability of skilled artisans, and a range of other facilities and possibilities render it the ideal ground for Divine Group. Since its inception, Divine Group has never stopped growing - in quality, quantity, capacity and everything in between. Its production has branched out into nine fledged factories at four locations - Chandra in Gazipur, Chowgasa in Jessore, Mirpur in Dhaka and near EPZ in Savar. Divine Group at present has a daily production

8. capacity of over 20 tons of knitted fabric, 25 tons of dyed fabric, 30 tons of finished fabric, 10 tons of yarn dyeing and 60,000 pieces of complete Garments per day. In the way of becoming a massive success story, Divine Group became one of the few garment houses in Bangladesh that implemented Oeko-Tex mark certificate. The Government of Bangladesh, too, recognized its excellence by awarding the status of a Commercially Important Person ( CIP ) to its chief executive, Mr. Hasanuzzaman, the founding Managing Director of Divine Group, since 1997 without any break. Management Meeting After successful operation in Divine Textile Limited, the owner had decided to start a fully information & technology based along with the social accountability and quality controlled modern capacity of over 20 tons of knitted fabric, 25 tons of dyed fabric, 30 tons of finished fabric, 10 tons of yarn dyeing and 60,000 pieces of complete Garments per day. In the way of becoming a massive success story, Divine Group became one of the few garment houses in Bangladesh that implemented Oeko-Tex mark certificate. The Government of Bangladesh, too, recognized its excellence by awarding the status of a Commercially Important Person ( CIP ) to its chief executive, Mr. Hasanuzzaman, the founding Managing Director of Divine Group, since 1997 without any break. Management Meeting After successful operation in Divine Textile Limited, the owner had decided to start a fully information & technology based along with the social accountability and quality controlled modern

9. readymade composite knit garments industry in large scale. In this connection Mr. Salim Reza had decided in a resolution to start a company in Chandra, Kaliakoir, Gazipur in the year 1997 to manufacture knitwear garments for the international market. Right from inception the policy of the company has been to provide total customer satisfaction by offering quality knitwear in time. To meet the commitments of quality and prompt delivery, Divine Textile Limited Decided to integrate the manufacturing process in a planned manner. Over the years the entire process has been integrated by importing sophisticated machinery from world-renowned manufacturers. Working on new concepts in styling & content of the knitwear is a continuous activity in Divine Textile Limited with an objective to up the quality and the value of merchandise. In 1997, the year in which International business was started; Divine Textile Limited concentrated all its strengths and resources in developing a wide range of knitwear for the international market. The mission and vision of Divine Textile Ltd. is to manufacture and deliver high quality readymade garments (RMG) to its customers. The core objective is to attain and enhance customer satisfaction by providing on time delivery of desired quality readymade garments and also to increase efficiency of workforce. To attain these objectives, the management of Esquire Knit Composite Ltd. has decided to adopt the following- 1. To increase awareness regarding customers requirements throughout the organization. 2. By providing training to develop efficiency of the employee. 3. To collect customer’s feedback regularly to know about their conception about their company and to take timely appropriate action. 4. To reduce the percentage of wastage / rejection minimum by 2% per annum’s implement and monitor ISO 9001:2000 quality management system within the organization. readymade composite knit garments industry in large scale. In this connection Mr. Salim Reza had decided in a resolution to start a company in Chandra, Kaliakoir, Gazipur in the year 1997 to manufacture knitwear garments for the international market. Right from inception the policy of the company has been to provide total customer satisfaction by offering quality knitwear in time. To meet the commitments of quality and prompt delivery, Divine Textile Limited Decided to integrate the manufacturing process in a planned manner. Over the years the entire process has been integrated by importing sophisticated machinery from world-renowned manufacturers. Working on new concepts in styling & content of the knitwear is a continuous activity in Divine Textile Limited with an objective to up the quality and the value of merchandise. In 1997, the year in which International business was started; Divine Textile Limited concentrated all its strengths and resources in developing a wide range of knitwear for the international market. The mission and vision of Divine Textile Ltd. is to manufacture and deliver high quality readymade garments (RMG) to its customers. The core objective is to attain and enhance customer satisfaction by providing on time delivery of desired quality readymade garments and also to increase efficiency of workforce. To attain these objectives, the management of Esquire Knit Composite Ltd. has decided to adopt the following- 1. To increase awareness regarding customers requirements throughout the organization. 2. By providing training to develop efficiency of the employee. 3. To collect customer’s feedback regularly to know about their conception about their company and to take timely appropriate action. 4. To reduce the percentage of wastage / rejection minimum by 2% per annum’s implement and monitor ISO 9001:2000 quality management system within the organization.

10. . West East North South POND Main Gate of the Divine Textile 1 2 3 6 7 8 12 4 5 9 10 Gate Main Gate of Divine Fabrics Bridge 3 5 6 4 2 4 11 13 13 1 1 14

11. . 1. Security office 2. Gas Pump 3. Knitting section Unit – I & Air Compressor Room (1st Floor) + Garment section (2rd -4th Floor) 4. Color Store (1st Floor) + Medical Care (2nd Floor) + Quarter (3rd Floor) 5. Chemical Store 6. Fabric dyeing (Unit – I ) & Tube finishing section + Boiler Room 7. Dyeing Lab + Open Finishing Section 8. Fabric Dyeing Unit – II +Boiler Room 9. Generator 10. Yarn & Hanger Store 11. WTP Plant 12. Dyes & Chemical Store (Under Ground) + Kniting & Fabric Inspection Section & Air Compressor Room (1st Floor) + Garment Section (2nd – 6th Floor) + Garment Printing Section + Office Room, Merchandising Section, HR Department (8th Floor) 13. ETP Plant 14. Under Constructed Building Divine Fabrics 1. Under Constructed Building 2. Garment Section (Which Construction is also running) 3. Grey Fabric Store + Printing Section + Knitting Section ( 2nd Floor) 4. ETP & WTP Plant 5. Fabric Dyeing & Open Finishing Section & Dyes, Chemical Store (1st Floor) + Dyeing & QC Lab (2nd Floor) 6. Yarn Dyeing + Yarn Dyeing Lab + Dyes & Chemical Store + Generator

12. . CHAPTER -02 MAN POWER MANAGEMENT Knitting section AGM PM Store In charge Knitting Master Supervisor Fitter man Operator Fitter man Operator

13. . Dyeing & Finishing Section GM DGM PM SPO Batch Incharge Finishing Incharge Lab Incharge PO APO Supervisor Sr. Operator Operator Astt. Operator Sewing man Helper Turning m/c Operator Helper Sewing man Squeeze Operator Dryer Operator Compactor Operator Helper Lab Technician Q.C. Technician

14. . Divine Group can produce wide range of products and they deals with some renowned buyers from Europe and USA market some of those are with whom they worked and those whom they are still working. Main buyers name of the company are given below- Target Australia Carrefour Lindex Charles Vogele Calvin Klien TCHIBO H & M ( Hennes & Mauritz) Department Manpower Knitting 300 Dyeing & Finishing, Lab & QC Yarn Fabric 309 405 Garments 3325 Power, Boiler, Utility & Maintenance 173 Inventory 15 Administration 54 Security 135 Others 590 Total 5306

15. . Duty time / shift change For knitting & dyeing The industry has three (3) shifts for the workers. Shift duration of every shift is eight (8) hours. SHIFT FROM TO A 6.00 AM 2.00 PM B 2.00 PM 10.00 PM C 10.00 PM 6.00 AM For garments section: SHIFT FROM TO DURATION OVERTIMR One shift 8.00 AM 5.00 AM 8 hours 2.00 hours

16. . Different section: A) Knitting section  Knitting  Inspection B) Dyeing section  Batch section  Dye house  Dyeing lab  Quality control  finishing C) Garments section  Merchandising  Industrial Engineering  Sample section  Cutting section  Sewing section  Finishing section D) Maintenance section  Electrical  mechanical E) Store section F) Administration section G) Compliance section H) Security section I) Marketing section J) Human resource & Development section Communication system:  Intercom telephone  Fax  Mobile phone  E-mail  Written letters  Oral Different section

17. . Receiving measurement chart from merchandiser ↓ Checking measurement chart ↓ Making pattern paper ↓ Checking the pattern paper ↓ Send to merchandiser for buyer approval CHAPTER -03 CAD SECTION Pattern section In this section normally pattern is modify. After receiving an order buyer send the measurement chart to merchandisers .Merchandisers send the measurement chart to pattern section. Pattern master made the pattern according measurement chart. if buyer sends the pattern paper that time pattern master modify that pattern paper Flow chart of pattern section:

18. . Types of pattern made in Pattern Section Sample pattern: When sewing allowance is added & sample make following the pattern is called Sample pattern. Production Pattern: These are used for bulk production just after grading all of different sizes. Finished pattern: These are used in sewing section. Contents of pattern paper:  Style No  Grain Line  Name of parts  Size of Garment Marker Section Marker is a thin paper which contains all the pattern pieces of garments.it is made just

19. . Receive pattern ↓ Taking the image of pattern in CPU by digitizer Or making pattern ↓ Modernizing of all pattern part by the software ↓ Pattern grading by software ↓ Aligning all sizes of pattern in the marker by the software ↓ Completing the marking ↓ Taking approval from cam section ↓ Print marker id delivered to cutting section Before cutting and its purpose is to minimize the wastage. The width of marker is equal to the width of the fabric and should not be greater then the width of the marker is kept less than or equal to the width of the fabric. The pattern pieces should be placed very carefully in such a way that will obviously minimize wastage. Marker section included in CAD SECTION- Following equipment’s are consists in CAD Section- Name of Equipment’s No. of Items Win da pattern cutter 01 Win da Plotter(Accu Plot) 01 Win da Digitizing Board 01 Sequence of Cad for garments:

20. . Method of marker making in garments: Marker can be made either in – 1. Manual method 2. Computerized method. a. Digitizing system b. Scanning system Computerized marker making method is of two (2) types. They are - 1. Automatic Marker Making. 2. Interactive Method. Interactive Method is used in Crossline Knit Fabrics Ltd. It is a common process, here the marker planner plan markers by interacting directly with the system through a computer screen. All the pattern pieces are displayed in the miniature form at the top of the screen. They are dragged & dropped in the marker area. After placing of all pattern pieces, it is possible to see the data like marker efficiency, marker length, and marker width etc. information just below the parallel lines. After completion of marker making, it is saved in the computer memory & it is possible to take the printout of the marker any time. Efficiency Measure: Total placed area x 100% Formula: Total marker efficiency% = Length x Diameter Efficiency (usually get) For Tank top - 75% For trouser - 78% or t shirt - 85% For polo shirt - 85% N.B.: If a garment consist smaller parts then there efficiency is higher than the larger parts of a garment.

21. . Fabric wastage: 1. Inside wastage 2. Outside wastage  Ends of fabric losses: Sometimes some allowance needed to keep during fabric spreading. Usually 2” each side, total 4” each ply wastage occurs  Selvedge losses: Each fabric has two selvedges. 2-3% wastage occurs  Purchase losses: For wrong consumption purchase losses occurs.

22. . CHAPTER -4 SAMPLE SECTION Sampling in garment exports and its importance: Sampling of garments is given great emphasis. It determines the approval of future orders from buyers and fetches business for a garment manufacturing or export company. Sampling is one of key elements of the pre-production processes in a garment industry. Before a manufacturer produces bulk orders, a prior sampling of styles is done to get approvals and jumpstart the fabrication of garments. Samples of garments work as a bridge between buyers and the producers. Machineries of sample section: Name of machine No. of machine Overclock sewing machine 09 Flat lock sewing machine 04 Lock stitch machine 10 Button hole sewing machine 01 Button attaching sewing machine 01 Safe guard machine 01 Process sequence of sample section:

23. . Buying office reference merchandiser ↓ Merchandiser to pattern section ↓ Pattern making ↓ Sample fabric cutting ↓ Sample sewing ↓ Quality inspection ↓ Ironing ↓ Final quality inspection & measurement ↓ Folding & packing ↓ Send to buyer ↓ Buyer approval / buyer rejection ↓ Production pattern The details attached to the garment sample: After the confirmation of order, each sample sent to buyer has the following details attached to it , with the help of a tag . it contains the details pertaining to both, what the buyer has demanded and what supplement fabric/trim etc. they have used (if applicable)  Ref no.  Color  Fabric  Composition  Garments size  Style no Description of different types of samples:

24. . FIT Sample/Develop: Once proto sample is approved, FIT is being made with actual measurement. Modification on the pattern is done to get desired fit of the garment. FIT is one of the most important factor to be considered during sample development. FIT sample is being tested on live model or Dress form for to verify garment fit and fall. Size set Sample: The purpose of the size set is to check fit of the garment in different sizes. In this stage factory develops samples in multiple sizes. Generally, buyers ask size set sample in jump sizes, like S, L, and XXL. Buyer check size set sample and give feedback to factory if anything need to be corrected. Pre-production Sample (PP sample): All the above samples are made in sampling department. Buyer wants pre-production sample (PP sample) to be made in actual production line, so that operators know what they are going to make. This sample is made with actual fabric, trims and accessories and made by sewing line tailors. PP sample must be approved by buyer or buying house merchants (technical persons) prior to proceeding actual production. Top of Production Sample (TOP sample): Once production is online, few pieces is taken out in the middle of the production. Production pieces are sent to buyer as TOP sample. All buyers do not ask for TOP sample. Purpose is to cross- check whether factory is following PP sample specification or not. Shipment Sample: When style is being finished and packed for shipment, 2-3 finished and packed pieces with all packing details are kept for future reference. Shipment sample is kept by factory merchants and buyers merchant. The approved shipment is sent directly to warehouse and merchants at the buyer do not get garment out of the shipment. That is why they keep shipment sample for future reference.

25. . CHAPTER -5 CUTTING SECTION Cutting section is the most important and risky section in garment industry. For a little mistake full order may be cancelled. With the false measurement a big portion of garment may employed. With very care this section is handled. Cutting section composed of following section-  CAD section  Fabric inspection  Spreading & cutting section  Cutting pieces inspection section Following machines are available in cutting section Machine name No. of Machine Cutting Table 11 Fabric Inspection machine 01 Straight knife cutting machine 07

26. . Lining machine 01 Hand Scissors Numbering Machine Process sequence of cutting section Store ↓ Fabric Fault Checking ↓ Relaxation ↓ Shade Checking ↓ Prepare the fabric in the fabric spreading m/c ↓ Spreading ↓ Marker attachment ↓ Cutting ↓ Numbering ↓ Bundling ↓ Panel Check (QC) ↓ Fault OK ↓ Replace Cut ↓ Solid Not Solid ↓ Print / Embroidery ↓

27. . Checking & Counting (QC) ↓ Sewing Specification of Machine: Fabric Inspection Machine: Cutting machine: Straight knife cutting machine: Machine Name K.M. Company Cloth Cutting Machine Model : KM KS-AUV Origin : Japan Producer : K.M. Cutting Machine Co Type : Heavy Duty Industrial Cloth Cutting M/C self-Sharpening. Dimension : 8" W x 11" L x 24" H Knife size : 4 to 14 inches Speed :3000-3600 rpm No. of Machine :07

28. . Quality inspection of fabric before feeding:  Shade  Crease mark  Fabric width  Needle mark  GSM  Slub  Oil spot  Hole  Dirty spot  Yarn contamination Quality inspection of fabric during spreading:  Shade  Slub  Fabric width  Hole  Oil spot  Yarn contamination  Dirty spot  No. of ply  Crease mark  Marker length  Needle mark  Style no Quality inspection of cutting pieces: Following faults are checked-  Oil spot  Hole  Dirty spot  Yarn contamination  Crease mark  Measurement  Needle  shade  slub  After inspection same no of sticker are matched fold& bundle: Numbering In this stage stickers attached with all part of cutting part for shade matching. The sticker number maintains cutting number, size number, serial number. Prepared bundle card Prepared bundle card according to fabric lay report this card maintain

29. .  Program no  Cutting no  Roll no  Size no  Plies

30. . CHAPTER -6 SEWING SECTION After receive the garments components from cutting section, all the garments parts are joined and sewn as sequentially. Obviously all the components are sewn respects on buyer requirement. Sewing section is the most important department of a garment manufacturing industry. Sewing machines of different types are arranged as a vertical line to assemble the garments. Sequence of types of sewing machine arrangement depends on sequence of assembling operations. Sewing: Sewing is a craft that involves stitching fabrics together either with a needle and thread by hand or with a machine. This is the main assembly stage of the production process, where sewers stitch fabric pieces together, and a garment is assembled. Basic Components of Sewing:  Needle  Feed Dog  Pressure Foot  Throat Plate  Sewing Thread  Fabric

31. . Process sequence of sewing section: Cutting fabric load in sewing section ↓ Layout of machine according to style & design of garments ↓ Inspection of cutting pieces ↓ Feed into line ↓ Sewing according to design & style of garments ↓ Quality inspection during sewing in mid line ↓ Quality inspection after sewing ↓ Excess thread cutting ↓ Remove dirt’s or other faults which can rectify ↓ Quality audit ↓ Send to finishing section Machineries of sewing section: Sl. No. Name of the M/C Brand Name Model Origin No. of M/C Unit 1 PLAIN M/C BROTHER SL-2110-403 Japan 128 Set 2 PLAIN M/C BROTHER S-6200-403 Japan 162 Set 3 PLAIN M/C JUKI DDL-8700-7 Japan 63 Set

32. . 4 PLAIN M/C JUKI DDL-9000B-MS Japan 60 Set 5 OVER LOCK M/C PAGASUS (M.N) Series Japan 208 Set 6 OVER LOCK M/C PAGASUS M-800 Japan 110 Set 7 OVER LOCK M/C TYPICAL GN-2000-5H 22 Set 8 FLAT LOCK M/C PAGASUS W-200 JAPAN 20 Set 9 FLAT LOCK M/C PAGASUS w-500 Japan 50 Set 10 FLAT LOCK M/C PAGASUS W-1500 JAPAN 50 Set 11 FLAT CYLINDER BED M/C PAGASUS W-600 JAPAN 59 Set 12 FLAT SMALLCYLINDER BED M/C PAGASUS W-200 JAPAN 2 Set 13 SINGLE NEEDLE VERTICAL M/C JUKI JAPAN 20 Set 14 BUTTON HOLE JUKI Japan 18 Set 15 BUTTON STITCH JUKI Japan 18 Set 16 P. M.D KANSAI KANSAI JAPAN 6 Set 17 ZIG ZAG M/C BROTHER JAPAN 2 Set 18 BAR TACK M/C BROTHER JAPAN 9 Set 19 TWO NEEDLE M/C BROTHER JAPAN 11 Set 20 RIB CUTTING M/C DINO Japan 9 Set 21 Cloth Cutting M/C JAPAN 14 Set 22 THREAD CUTTER M/C JAPAN 20 Set 23 GRINDING M/C JAPAN 3 Set 24 SNAP BUTTON JUKI JAPAN 13 Set 25 PICOTING M/C P×302-4W JAPAN 7 Set Sewing Machine: There are different types of sewing machine used for different types of sewing application. Most widely used & common machine are-  Plain m/c  Flat lock m/c  Over lock m/c  Button holing m/c  Button attaching m/c  Feed of the arm m/c

33. . Sewing Machine Description: Plain machine: Properties:  One needle  Two needle  Three guide  One hook  Two thread  One bobbin casa  One magnate guide Application:  Bottom hemming  Belt top seem stitch  Pocket joint stitch  Jipper joint  Flap make  Flap top stitch  Loop tack stitch  Belt joint stitch Over lock machine: Properties:  5 thread  4 tensioner  2 knifes(up/down)  2 needle for 5 thread  1 needle for 3 thread  3 lopper for thread  2 lopper for 3 thread Applications: Over lock Machine Plain machine

34. . O  Over lock stitch Flat lock machine: Properties:  4 tensioner  3 thread  Contain a holder  2 needle Applications:  Zigzag stitch  Knit hemming  Loop making Feed of the arm machine: Properties:  2 needle  2 looper  4 thread (lopper2 / needle 2)  Contain T & magnate guide  3 tensioner Application:  Back rise stitch  Inseam stitch  Back yoke top sin Flat lock machine. Feed of the arm

35. . Kansai Machine Kansai Machine: Properties:  2 needle  4 thread  8 tensioner  21 lopper point(used two lopper Depends on distance of stitches) Application:  Back yoke stitch  Back belt stitch Button holing m/c Properties  2 thread  1 needle  2 tensioner  Contains bobbin case, hook& knife Applications:  To attached button in garment Button attaching m/c Application:  To attach button in garments Button attaching m/c Button holing m/c

36. . Sewing thread: Sewing threads are special kinds of yarns that are engineered and designed to pass through a sewing machine rapidly. They form efficient stitches without breaking or becoming distorted during the useful life of the product. The basic function of a thread is to deliver aesthetics and performance in stitches and seams. Factors affecting performance Thread used in garments must be durable enough to withstand the abrasion and needle heat that occur while sewing, garment finishing, stretching and recovery during wear. Thread performance in garments can be evaluated from its-  Seam strength  Abrasion resistance  Elasticity  Chemical resistance  Flammability  Colour fastness Types of sewing thread:  Cotton  Polyester  Silk  linen Seam: The line where two or more pieces of fabric are joined by application of a series of stitches or stitch types with a defined geometry to one or several thickness of fabric material is defined as seam. Properties of seam:  strength  Elasticity  Durability  Security  Appearance

37. . Accessories used in sewing:  20/2 Sewing thread  Plastic /coconut button  Snap button  Woven label  Hang tag/price tag  Zipper  Barcode + size label  Name label  Size label  Lock pin  Poly sticker  Benny  Twill tape  Drawstring  Satin tape(hanger loop)  Lace  Lurex thread  Reflective tape  Elastic  Alarm sticker  Main label  Velcut Sewing problem: 1) Problems of stitch formation:  Slipped stitch  Staggered stitch  Unbalanced stitch  Needle thread breakage  Frequent thread breakage 2) Problems of pucker:  Unequal stretch  Fabric dimensional instability  Extension in sewing thread  Sewing thread shrinkage  Fabric construction  Mismatched pattern 3) Seam wise fabric damage:  Mechanical damage  Needle heating damage

38. . CHAPTER -7 QUALITY CONTROL & FINISHING SECTION Finishing section: The final section to make the product attractive and salable condition & achieved the quality of garments. It is very important section for garments factory. Following areas are consists in section-  Sub-store  Thread sucking Area  Spot removing Area  Ironing Area  Reject garments Area  Get up checking area  Measurement checking area  Final inspection area  Final quality inspection area  Folding & packing area  Cartooning area Following machine consists: Machine name No. of machine Ironing machine 46 Vacuum table 46 Thread sucking machine 02 Metal detector machine 01  Tag Gun  Spray gun  Rivet machine

39. . Iron machine Garments receiving from sewing/washing section ↓ Thread sucking ↓ Inspection ↓ Ironing ↓ Final inspection ↓ Get up check ↓ Measurement check ↓ Final quality check ↓ Folding & Packing ↓ Metal detecting ↓ Cartooning ↓ Buying QC inspection ↓ Shipment Iron machine: Vacuum ironing table: Flow chart of finishing process: Vacuum Table

40. . Accessories & Trimmings Accessories list of finishing Section-  Hang tag  Price tag/sticker  Poly bag-  Piece polybag printed  Piece polybag non printed  Duo pack polybag  Hanger polybag  Blister polybag  Hanger  Size sticker  Poly sticker  Tag pin  Carton  Carton sticker  Scotch tap  Gum tap  Barcode sticker  Security label/sticker  Composition sticker  Garments photo card  Buyer information sticker etc. Garments packing:- Packing must do on approval packing method.  Single garments pack  Set garments pack  Double set pack  Assort color garments pack  Single color garments pack etc.

41. . Following information consists on packing (buyer demand)-  Buyer name  Size chart  Garments photo  Buyer office name .address, helps & complains address etc.  Price chart  Composition , color name  Barcode  Security sticker  Care label sticker Carton packing- packing does on approval cartooning method.  No of garments with size & color wise depends on buyer demand  Carton size depend on buyer demand Following information consists on carton (buyer demand)-  Buyer name  Size set chart  Garments photo, name. color  Order number,  Style number  Carton number  Quantity of garments  Carton size  Carton gross weight & net weight  Port name where loaded & unloaded Spot Removing Spots Chemical name Greases & oil stain Spot lighter Print spot & wet spot Oxyclean plus & colorox-2 Dirt’s & others Dryel-2 &Solvex-2

42. . CHAPTER -8 STORE & INVENTORY SECTION Fabric inventory: Various types of fabrics are storage. The flow sequence of fabric inventory below:-  Received the fabric  Pre inspection  Physical inventory  Make the swatch card  Prepare blanket shade  Fabric is separated & stored according to lot no. Accessories inventory: The flow sequence of accessories inventory below:-  Import receive  Physical inventory  Swatch making  Record the entry  Swatch approval from buyer  Supply to sub store according to demand  Issue to bulk production Following Accessories are inventoried  Hanger  Label  Main label  Care label  Size label  Price label  Sewing thread  Button  Interlining

43. .  Do sting tape  Twill tape  Elastic etc. CHAPTER -9 EFFLUENT TREATMENT PLANT (ETP) Effluent treatment plant is essential to purify the waste water which is come from different types of manufacturing industry like textile , dyes and chemical manufacturing industry ,pharmaceutical etc. different environment saving organization are trying to protect the environment from the harmful effect of the effluent. Different waste water has different characteristics which pollute the water. Process flow chart of effluent treatment with effluent treatment plant: Following is the basic structure of effluent treatment plant- Effluent from different manufacturing industry ↓ Primary filtration ↓ Cooling and mixing ↓ Neutralization (by acid or alkali) ↓ Chemical co-agulation ↓ Settling and separation of sludge ↓ Pressure filtration ↓ Discharge Now I like to give a short description about the sequence of operation in ETP:

44. . Primary filtration: It is the first stage of effluent treatment plant, where effluent is come from weaving, dying, printing, or finishing unit. Here primary filtration is performed to remove solid waste particles. Cooling and mixing: In this stage, different types of effluent are mixed and cool down by the help of motor which ran a fan. Neutralization tank: After cooling and mixing; effluent is transferred to neutralization tank by the help of pump. Here acid or alkali is mixed to neutralize the effluent. A pH meter is placed in the neutralization tank Co-agulant bath: After neutralization of effluent; effluent is transferred to a co-agulant bath. Here co-agulant is added with the effluent. Setting tank: In here; effluent separates from the water and it found in the lower level of the tank. Effluent is like as sludge. Pressure filter: Here, filtration is done under pressure. A certain amount of pressure is created here. Carbon filtration: It is an optional filter process. Discharge to drain: After completion of all the process, the effluent becomes purify and it becomes safe to drain to the environment. When treated water is drain to the environment it is checked by the different testing lab. Different standard is maintained during discharge of the treated effluent.

45. . CHAPTER -10 MAINTENANCE SECTION Maintenance is a process by which equipment is looked after in such a way that trouble free. Service and increased machine life can be ensured and specific quality by the customers is sustained. Types of maintenance: Preventive maintenance: Preventive maintenance is a predetermined routine to ensure on time inspection/checking of facilities to uncover condition that may load to production break downs or harmful depreciation. Corrective maintenance / break down maintenance: Maintenance Preventive Maintenance Mechanical Maintenance Electrical Maintenance Corrective Maintenance Mechanical Maintenance Electrical Maintenance

46. . In this case, repairs are made after the equipment is out of order it cannot perform its normal function. Maintenance procedure:  Here standard system is to service a machine once per month.  Log card used for every machines.  Service types, replace materials etc. were written on log card.  Data, time also written on log card. Name of different maintenance equipment’s or tools:  Screw driver  Hand socket wrench set  Phil  Pliers  Slide calipers  Hand drill machine  Stand drill machine  Hammer  Mobile gun  Grinder  Welding machine  Some electric equipment’s  Table vice  Hand vice etc.

47. . CHAPTER -11 COMPLIANCE ISSUE Compliance: Compliance means comply something i.e. yield to the wishes another. The main aim of compliance is to ensuring the all labor rights and facilities according to buyer code of conduct. Different compliance issues which they are obeyed-  Admin & HR dept.  Personnel policies  Recruitment police  Leave and holiday policy  Attendance and leave register card  Their weekly working hour not more than 60 hour including overtime in a week  They have the approved manpower list  Health and hygiene  First aid ensures  Medicine registers  Maternity and pregnancy register  Pure drinking water  Towel for hand dry  Safety  Safety committee  Firefighting committee  Rescue committee  Broken needle register  Needle detector  Fire alarm & switch  Evacuation plan  Rubber mates to every iron man

48. .  Welfare  Welfare committee  Day care center  Canteen facility  Salary and wages  Fix wages in considering minimum wages which is declared by the government.  Salary and wages given before 7th day of month.  Physical security  They have separate cargo entrance area (receiving and unloading ) from the front side  They do not keep any partially filled / completed cartons on the floor at the end of any working day. they keep it to finished goods store  Education and tanning program  They arrange security tanning program on regular basis for all employee of the factory

49. . Compliance item: Some example of compliances item are given below-  First aid box  Water box  Toilet  Wash basin  Complain box  Evacuation plan  Emergency exit/light/light set  Smoke detector  Fire extinguisher  Hose cabinet  Manila rope  Gas musk CHAPTER -12 GARMENTS MERCHANDISING Garments merchandising is the process which starts from buyer developing to order conformation & then execute the order with quality as buyer demand and delivery the order with in time. It is also known as garments whole selling business with foreigners.

50. . Types of Merchandising: Two type of merchandising done in garment exports 1. Marketing merchandising. 2. Product merchandising. Marketing Merchandising Main function of marketing merchandising is 1. Product Development 2. Costing Ordering Marketing merchandising is to bring orders costly products development and it has direct contact with the buyer. Product Merchandising Product merchandising is done in the unit. This includes all the responsibilities from sourcing to finishing i.e. first sample onwards, the products merchandising work start and ends till shipment. Duties & Responsibly A Merchandiser To produce or collect a garments export order or export L/C.  To estimate time schedule for the export of those garments as per L/C.  To arrange all the materials needed for the garments to manufacture and export.  To monitor collection of raw materials as per time schedules.  To monitor garments production progress as per time schedules.  To monitors imposed quality level of the produced garments.  To monitor garments packing instructions.  To monitor banking and shipment arrangements as per time schedule.  To maintain continuous liaison with the buyer or his/her representative if needed.  To maintain continuous liaison with his/her controlling authorities.  To follow up payment collection against garments export as per schedule.  And finally, to earn profit through garment export execution.