Production Department (Garments) of AKH Knitting & Dyeing LTD - 1

Production Department (Garments) at AKH Knitting & Dyeing Ltd.
INTRODUCTION OF THE INTERNSHIP PROGRAM

Now a days, real experience is a vital factor in a factor or work field. As a
result, after acquiring degree from schools, colleges and universities the
students are being frusted in the practical field because of want of practical
experience. This study in a part of my MBA final examination. After
completing the written and viva examinations the department assign me to
go through 8-9 weeks study on the topic Production Department
(Garments) of AKH Knitting & Dyeing Ltd.
During my internship in AKH Knitting & Dyeing Ltd. I worked with the
production department (Sample Section, Cutting Section, Sewing Section,
Finishing Section, Store Section, Quality Control Section). There I observe
the procedure of recording data, receiving order from buyers, making
document like mater L/C, Back to back L/C, production activating and how
they make there different type of product like T-Shirts, Polo Shirts, Ten
Top, etc. The raw material of the product comes mainly from Europe, Korea
and China.
In this report I tried to identify the various problem related to the operation
of AKH Knitting & Dyeing Ltd. I gave recommendations. To solve some
problems. My identifying problems and recommendations reflect the picture
of the AKH Knitting & Dyeing Ltd. the company can take necessary steps to
solve this problem.
Page # 1
OBJECTIVE OF THE INTERNSHIP PROGRAM

Every study has some specific objectives the main objective of the
internship program is to fulfill the academic requirement of MBA degree in
management as well as to gather practical. Knowledge about the
management activities of the company. This practical knowledge will help
us face challenges in our future business carrier. We have also some
objectives of study on AKH Knitting & Dyeing Ltd. The following are
common out significant of the internship program.
1. To know about the Garments industry sector of Bangladesh by
observing AKH Knitting & Dyeing Ltd.
2. To know abort there management process and its implementation.
3. To find out similarities between theoretical knowledge and practical
knowledge.
4. To know the managerial structure of the enterprise.
5. To know the organizational structure of various section.
6. To know about leadership of management.
7. To ascertain the production management.
8. To know the attitude of worker and executive of the industry.
9. To identify the various problem of management of the industry.
10.To evaluate the flow of recording process.
11.Finally to suggest some policy recommendation for the production of
the organization.
Page # 2
PROGRAMMING AND IMPLEMENTATION
The authority of AKH Knitting & Dyeing Ltd. has kindly accorded
permission for an internship program of 8-9 weeks for us. the company
formulated a program schedule for us to observe different section seand talk
to different high officials of AKH Knitting & Dyeing Ltd. According to the
schedule we worked and observed different section of the company. We also
take interview and had open discussion with high officials of the company.
The internship period in AKH Knitting & Dyeing Ltd. was very useful for us
because it gave us a clear idea about the production department.
Page # 3
IMPORTANT OF THE STUDY

To days world is very complex. To over difficulties and to confront the
challenge of modern age experience along with educational qualification is
absolutely necessary. Internship programme, the essential past of the MBA
degree in the university of Chittagong, Department of Management Studies
introduces a student to real world situation and help him to acquire first hand
experience. This programme is also helpful in entrepreneurship development
which is needed for a developing. Country like Bangladesh. So, the
internship programme for MBA degree is most importance.
There are so many importance of the study. The various importance of the
study are as follows:
1. To know about the service rending by the public VS private
organization.
2. To know the way of facing challenges in the regard.
3. To know the pattern of competition in the same kind.
4. To know the problems in the regard of better customers service.
5. It will be helpful to go through any comparative analysis on the said
topic.
Page # 4
METHODOLOGY OF THE STUDY

Generally, to say research method means, to collect the data used in research
work. The study was conducted at AKH Knitting & Dyeing Ltd. In Savar,
Dhaka, this Garment was selected purposively. We divided our informations
and datas into two parts. They are:
1. Primary data: At first we visiting the industry. We performed the
task of collecting primary data by personal meeting and traveling the
AKH Knitting & Dyeing Ltd, we composed a questionnaire with sixty
questions for the research work and sent to the proper authority of the
industry. For collecting primary data relevant to the questionnaire and
overview of the industry, open discussion was made with Mr. Tofazzal
Hossain, Quality Manager, R.M.A. Kareem, Senior Manager (Head of
Admin, HRD & Compliance), Md. Zahid Al Hasan, Deputy Manager
(Dyeing), Mohammad Mohoshiur Rahman, Production Manager.
2. Secondary Data: We collected some relevant report and paper of
various documents from AKH Knitting & Dyeing Ltd. in order to
gather secondary data secondary data were mainly used in our
research paper.
Page # 5
LIMITATION OF THE STUDY

I had to go AKH Knitting & Dyeing Ltd. for 8-9 weeks. I had an objective to
complete a detailed study in different section in AKH Knitting & Dyeing
Ltd. But it was not possible because of time constraint. It is the major
limitation of the study as because with this short period a study on
management in such as large enterprise cant be done.
Although the General Manager (Production) of AKH Knitting & Dyeing
Ltd. appreciated us and allowed to visit the enterprise and also made all
necessary arrangements to collect the data, some officials tried to give us
interview. Beside all the data used in this report are not primary and new
data. So the study suffers from the following limitations:
1. It was not possible to collect the all information to prepare the report
2. Due to short time we cannot prepare the report properly.
3. Data that are collected should have to use absolutely for academic
purpose.
4. Some of the selected samples refused to give data.
5. We do not know the present situation of the company.
6. Though the top management formulates the strategy of the industry,
which is very much confidential, the manager failed to supply the
relevant data in respect to our demand.
7. Despite the shortcoming we received a great help from the officials of
the company.
Page # 6
RATIONAL OF THE STUDY

Since most of the cost of a garments manufacturing unit in Bangladesh lies
in the coast of the fabric, any means where by the fabrics can be produced
and processed locally will be the most obvious route to increasing value
addition. There is a desperate need through out the industry for good quality
knit fabrics. A part from the potential to increase value addition there are
more practical reasons as to why every effort should be made to make
available local fabrics of the current quality. The following are some
ornaments, which explain the necessity of using locally produced and
processed knit fabrics knit in the knit garments manufacturing units in the
country.
Turnover of stock can be increased due to the reduce lead-time
resulting in an improved financial performance.
Interest on out standing L/C is eliminated or reduced to the same
end result i.e. increased profit.
The cost and time delay of shipment is drastically reduced, again
being reflected as a reduction in out lay on the past of the
garments manufacturing planning production is facilitated and
there are less of problems caused by fabrics not arriving on time.
Page # 7
COMPANY PROFILE
AKH KNITTING & DYEING LTD. AT A GLANCE
Name
Date of Establishment
Location
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Market served
Chairman
Managing Director
No. of total employees
No. of total machines
Total factory building area
Major products
Export to
Quality standards
Nature of business
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Targeted Turnover
Estimated growth rate
Board of Directors
Pattern of Leadership
Nature of Ownership
Nature of employee
Working environment
Trade Union
Performance grade
Business growth
Social welfare
Nature of payment
Experience of management
Policy
Boss-sub-ordinate relationship
Future prospect
Bank Dealings
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AKH Knitting & Dyeing Ltd.

May 02, 2004
Head Office : 24/1,Ring Road ,Shamoli,
Mohammadpur,Dhaka-1207.
Tel: 8155637-39, 9121277, 9112789
Fax:880-2-8155640-41
Web: www. akhfashions.com
Factory: 92, Phulbaria , Tetuljhora, Savar,
Dhaka, Bangladesh.
Phone: 8129898, 8127881
Fax: 8126215-230
Garments
Md. Delowar Hossain
Md. Shamsul Alam
2700
650
1million sq.ft working space
T-shirts, Polo shirts, Ten -top
France, Europe & U.S.A
Internationally approved
100% export oriented garments
(manufacturing) group of companies.
Last year 18 million dollar
20%
Family members
Mostly autocratic
Private Ltd. Co.
Skilled , Semi-skilled, Unskilled
Good
Absent
Good
Gradually
Present
Cash
Good
Defensive
Fairly good
Bright
Uttra Bank, Islami Bank, National Bank
Page # 8
Group of Business:
AKH Fashions Ltd.

AKH Stitch Art Ltd.
AKH Knit wear Ltd.
AKH Kargo service
AKH Knitting & Dyeing Ltd.
AKH Packaging & Accessories Ltd.
AKH Shirts Ltd.
Angshuk Ltd.
Creative shirts Ltd.
Sabah Trade International Ltd.
Angel Enterprise Ltd.
Mission of the Company:

To expand present client base and seeking new client , who presently not working
in Bangladesh.
Manpower position of AKH Knitting & Dyeing Ltd.
No. of employees on the floor
No. of employees in other plants(washing , quality,
embroidery etc)
No. of employees in maintained department
No. of employees in store section
No. of administrative staff
2090
550
50
60
50
Page # 9
ORGANOGRAM OF FACTORY OPERATION

Managing Director
Executive Director
General
Manager
DGM
Dyeing
Admin
HRD
Admi
Engg.
Dept
Comp
liance
CPC
Utility
Knittin
g
Dyeing
Batch
Sample
Section
Laboratory
Dyeing
QC
Finishin
g
Sample
QC
Store
DGM
Garments
Electr
ical
Maint
enan
Cut
ting
Mech
anical
Maint
enan
Sew
ing
Plannin
g
Central
QC
Fini
shin
g
Store
Accoun
ts
Page # 10
BUSINESS POLICY DESIGN AT AKH KNITTING & DYEING LTD.

The AKH Knitting & Dyeing Ltd. of companies maintains a defensive
policy in their marketing strategy . From the company profile I find that
AKH Knitting & Dyeing Ltd. Where I have completed my MBA internship
program also follows or maintains a defensive policy in their marketing
strategy.
A defensive marketing policy means to hold the current market shares of the
company by applying various marketing strategy.
In defensive policy AKH Knitting & Dyeing Ltd. makes the following
assumption about their imported countries.
1) Imported countries share the same perceptions of each brands product
attributes.
2) Imported countries differ in their preferences for various product
characteristics.
3) Imported countries very in the number of brands they know and will
consider.
4) Imported countries choices are affected by product features , prices,
distribution , advertising and promotion.
Page # 11
PRODUCTION PROCESS OF AKH KNITTING & DYEING LTD.

The production system of an organization is that part which produces the
organizations products.
Production is involved with the selection , organization and control of
resources to produce desired product or service.
Production is an international act of producing something in an organized
manner. In a manufacturing organization, Production is the fabrication of
physical object through the use of men , materials and equipments.
Production is defined as the step-by-step conversion of one form of material
into another form through chemical or mechanical process to create or
enhance utility of the product to the user.
DETERMINE THE STANDARD AND QUALITY CONTROL

Production department determine the standard according to the demand of
buyers. They take steps to keep the standard from collecting the raw
materials to every stage of production level. Thats way the quality
of AKH Knitting & Dyeing Ltd. products is equivalent to
international standard. The company follows the random selection
method. Sampling method and supervision method for controlling
the standard and quality.
Page # 12
STRUCTURE OF PRODUCTION DEPARTMENT

DGM
Production
Knit P. Chief
Manager
Unit-1
Manager
Unit-3
Asstt. of
PM
Line Chief
Dyeing
P. Chief
Dyeing
Garment P. Chief
Manager
Unit-2
In charge
Manager
Unit-10
Manager
Unit-8
Manager
Unit-9
Manager
Unit -11
Manager
Unit-12
P.Sr.
Supervisor
Supervisor
Jr.
Supervisor
In charge
Cutting
Production
Executive
P.Jr.
Executive
Quality
Control
Operator
Page # 13
PRODUCTION PROCESS
Store Receipt and Inventory is stock
Sample Making
Approval Sample for Buyer
Pattern Making
Making approved
Speeding on cutting machine
Setting of marking on the Speeding
Cutting
Bounding for Avoiding Shed
Supply to sewing machine
Thread cutting
Quality Control
Finishing
Ironing
Folding
Polly
Bag
Blister
Bag
Inner
Carton
Master
Carton
Ready for Final Inspection of the Buyer

Shipment
ACTIVITIES OF PRODUCTION DEPARTMENT

Page # 14
PP.
Band
(A) Sample Section:

Sample section is starting section for production. Briefly discussion of
sample section of AKH Knitting Dyeing Ltd. are below:
# Structure / Level of sample section
Sample Section
Pattern Unit
Pattern Manager
Quality Unit
Quality Controller
Sample Unit
Sewing In-charge
Pattern Master
Sewing supervisor
Asst. Pattern Master
Sample man
Pattern Supervisor
# Functions of sample section of AKH Knitting & Dyeing Ltd.:

1) Order collection: Patter master collect the order from the
merchandiser.
2) Sample preparation: Sample is prepared according to sketch.
3) Collection of original sample by checking quality controller
4) Sample Sending: The prepared sample is send to the buyer.
5) Checking: Buyer check the sample
6) Approve & make order: Finally buyers approve the sample and
make order
# History of sample section of AKH Knitting & Dyeing Ltd.
Page # 15
1) Number of sample machines: 20

2) Number of total worker of sample section: 39
3) Number of floor: 1
4) Daily normal sample produce : 150 pieces
5) Daily critical sample produce : 60 pieces
6) Weekly holiday: 1 day
# Problems of Sample Section:
1) In adequate fabric: In adequate fabric according to buyers order in this
company.
2) Lack of logistics: Just time cannot supply needed equipment
3) Absence of good director: In this company absence of good direction
person.
4) Pressure of authority: All time authority create pressure to the sample
section
5) Lack of good relationship among sample man, pattern man &
employer
6) Break of machine
7) Accessories problems
8) Inadequate of machines
# How to remove the problems:
1) Supply sufficient fabrics
2) Maintaining logistic system
3) Making good relation between top level to low level
4) Collecting necessary accessories
5) Established proper machine
(B) Cutting Section:
Page # 16
This job of cutting section is to send cloth to the sewing section after cutting
the cloth according to the prescribed size and maintaining its color. After
making sample cutting function is started.
# Structure of the cutting section:
Cutting Section
Mgt. Unit
Cutting Manager
Quality Control Unit
Quality Controller
Operation Unit
Layman
Cutting in charge
Sticker man
Asst. Cutting Incharge
Bundle man
Cutting supervisors
Checker man
Marker man
Print counter
Cutter man
Print sender
Page # 17
# Functions of Cutting Section:

1) Lay man: Making lay with fabrics on the table for cutting.
2) Scissors man: Using Scissors machine for cutting
3) Marker man: Drawing/ marking on the fabrics according to buyer
order for cutting
4) Cutter man: Handling cutting machine for fabrics cutting
5) Sticker man: to perform adding sticker with cutting fabrics
6) Bundle man: Making bundle with cutting fabrics
7) Panel checker man: To panel check with bundling fabrics
8) Re-cutting man: If mistaken of cutting then needed re-cutting for
production
9) Collar opining man: to making collar for polo shirt.
10)
Line workers input supply man: To perform cutting fabrics
supply from cutting section to sewing section

# Material used in cutting section:
1) Cutting table
2) Marking paper
3) Pattern paper
4) Mark sheets
5) Cloth cutter machine
6) Scissors
7) Clip/clump
8) Scale
9) Measure tape
Page # 18
# History of cutting section of AKH Knitting Dyeing Ltd.

1) Number of cutting table: 9
2) Number of floor : 2
3) Number of total cutting worker : 218
4) Amount of daily cutting : 9 tons or 35000 bodies
5) Number of cutter machine : 8
6) Number of gloves : 9
7) Weekly holiday : 1 day
8) Number of lay man: 60
9) Number of Scissor man: 12
10) Number of marker man : 6
11) Number of cutting man: 8
12) Number of sticker man : 40
13) Number of bundle man : 14
14) Number of panel checker man : 18
15) Number of re-cutting man : 4
16) Number of line worker input supply man: 8
o Cutting section always 5% fabrics are more cutting because
fabrics are wastage for various processing.
o Dying department supply 8% lessees fabrics because fabrics are
losses by dyeing processing this loss is called process loss.
o Production department daily demand 10 ten fabrics but. Dyeing
& knitting department supplies 7 ton. Because this company
can not produce deficit 3 tons as a result deficit 3 tons hired
from another company.
o Cutting section depend on dyeing department. If dyeing
department supply more fabrics then cutting section cutting
more bodies other wise vice versa.
Page # 19
# Formula of fabrics consumptions:

If Dia with 40 inches and Dia length 5 YDS + 12 inches. Then fabrics
consumption is.
36x5 + 12x40x180 G.S.M. 1550 1000 x 12 pieces 6 x 2 + 5%
But some have restrictions
If dia have open then 2 is not multiplied and if dia have tube then 2 is
multiplied.
# Problem faced of Cutting Sections:
1)
Difference between required dia & delivery dia. If required dia is

30 inches and delivery dia is 29 inches then 1 inches is company
financial loss.
2)
Involving needle whole, dia mark, criss mark of required fabrics
3)
Absence of pure fabrics as a result fabrics is re-cutting
4)
Difference between pique fabrics & collars shed as a result

fabrics are redyeing
5)
Lack of rib matching, as a result single gerse is redyeing.
6)
Absence of fabrics relaxedness, as a result fabrics are may be

positive or negative for production.
# How to remove the problems:

1) Matching between required dia & delivery dia.
2) Remove needle hole, Dia Mark, criss mark of required fabrics
3) Supply of pure fabrics
4) Reduce difference pique fabrics & collar shed
5) Maintaining rib matching
6) Established of fabrics relaxedness
Page # 20
(C) Sewing Section:

The job of sewing section its to sew as per buyers instruction and send the
goods to the finishing section.
# Structure of Sewing Section:
Sewing Section
Mgt. Unit
Quality control unit
Production Manager
Assst. Production
Manager
Sewing In-charge
Quality in-charge
Quality controller
Operation unit
Operator
Helper
Quality Inspector
Line chief
Supervisor
# Functions of Sewing Section:

There are mainly four function of sewing section
1) Front parts function
2) Back part function
3) Assembling
4) Output
Page # 21
1) Front part functions

o
o
o
o
o
o
o
Mark
Pear tack
Tacking
Pocket joining
Pocket rolling
Pocket over lack
Pocket tack
o
o
o
o
o
o
o
topsin
Simple fly join
Zipper join
Double fly join
Zipper topsin
Front rise tack
Front rise topsin
o
o
o
o
o
o
o
Level join
Pocket over lock
Pocket topsin
Bone topsin
Back rise over lock
Back rise topsin
Pocketing tack
2) Back part function

o
o
o
o
o
o
o
Back part mark

Back part pear tack
Back tacking
Back tack topsin
Pocketing tack
Bone join
Bone topsin
3) Assembling Function
o Front back number
o Side topsin
adjust
o Side over lock
o Imseam over loop
4) Assembling Function
o Loop join
o Belt join
# Name of the Sewing Machines:
o
o
o
o
o
o
Basic machines
Double needle
Over lock
Barteck
Kansai special
Button Hole
o Loop tack
o Hem (Bottom)
o
o
o
o
o
o
Pocket welting
Hemming
Flat lock
Feed of the arms
Top stitch
Velero attach
Page # 22
o Eyelet Button hole

o Button stitch
o Blind stitch
# Machines needed for various productions:

o For polo-shirts machines needed 35
o For T-shirt machines needed 25
o For Ten-top machines needed 20
o For Knitting trousers machines needed 25
o For woven trousers machines needed 30.
# History of sewing section of AKH Knitting & Dyeing Ltd.
1) Number of sewing machines : 600
2) Number of sewing floor : 3
3) Number of total sewing worker : 1300
4) Daily produce of sewing section : 3500 pieces
5) Number of total sewing line : 19
6) Number of hourly input : 2500 pieces
7) Number of hourly output : 2000 pieces
8) Number of production manager : 1
9) Number of assistant production manager : 1
10) Number of sewing in-charge : 4
11) Number of line chief : 17
12) Number of super visor : 34
13) Number of operator : 591
14) Number of helper : 522
15) Number of quality in-charge : 4
16) Number of quality controller : 16
17) Number of quality inspector : 108
# Problem faced of sewing section of AKH Knitting & Dyeing Ltd.
Page # 23
1) Altering problems: Altering problems means becoming uneven, skip

stitch, top stitch, undown or gathering of fabrics
2) Level mistake: It is the main problems of sewing section. Buyer order
level is XL but supply M or S size
3) Fabrics problems: Do not maintaining buyer order fabrics
4) Reduce overtime with minor causes: Sometime worker does not
maintain companys regulation as a result authority reduces worker
overtime.
5) Lower wages rate
6) Thread problem: Sometimes cutting section supply threading fabrics.
7) Break of machines
8) Absence of good relationship between management unit & operation
unit
9) Size problems
10) Lack of skilled worker
# How to remove sewing problem of AKH Knitting & Dyeing Ltd.
1) Removing altering problem
2) Removing level mistake
3) Removing fabrics problem
4) Maintaining good between employer and employee
5) Established proper wage rate
6) Removing threat problem
7) Recruiting skill worker
(D) Finishing Section:
Finishing section is responsible to folding and packing the readymade
garments prepared in sewing section and get them ready for export.
# Structure of Finishing Sections:

Page # 24
Finishing Section
Management Unit
Quality control unit
Finishing Manager
Asst. Quality
manager
Assst. Finishing Manager
Quality in-charge
Operation Unit
Iron man
Folding man
Finishing In-charge
Quality controller
Poly man
Finishing supervisor
Quality inspector
Assort man
Supervisor
Iron
supervis
Poly/foldin
g
supervisor
Packing man
Packing
superviso
r
Sucking
superviso
r
Helper
Page # 25
# Functions of Finishing Section:

There are various functions involved in finishing section There are :
1) Sucker
2) Quality inside checking
3) Final check
4) Button
5) Ironing
6) Measurement
7) Quality get up check
8) Poly packing
9) Inspection
10) Shipment
Page # 26
# New Finishing layout and manpower requirement of AKH Knitting &

Dyeing Ltd.
Designation
1) Finishing Manager
2)
Assistant
Finishing
Manager
3) Finishing in-charge
4) Finishing supervisor
5) Quality control in-charge
6) Finishing Quality Control
7) Auditor
8) Computer operator
9) Reporter
10) Peon
11) Iron man
12) Quality inspector
13) Hand taq man
14) Folding man
15) Poly man
16) Get-up man
17) Spot man
18) Assort man
19) Loader
20) Helps
21) Helper
22) Helper
23) Helper
24) Helper
25) Helper
26) Quality Helper
27) Operator & Helper
28) Finishing receiver

29) Helper
Name of process
Total need
person
1
1
Remarks
5
Production supervising
14
3
Quality control
5
Quality audit
1
Computers operating
1
Finishing
/Production 1
reporting
Inspection room
1
STUFF TOTAL 33
Ironing
55
Inspection
75
Hand tag
12
Folding
30
Poly
20
Folding get up
6
Sport removing
14
Packing
44
Loading
4
Thread sucking
24
After Iron garments count
6
Color & sizing
4
Shade segregation
4
Scotch tape & sticker
17
Folding & poly counting
7
Q.C. pass garments count
3
Repairing
13
WORKER TOTAL 337
Finishing total
370
Garments
reactive
& 6
counting
Garments received
14
RECEIVER TOTAL 20
TOTAL 390
Page # 27
# Spot Removing Unit:

Spot removing unit is an important unit of finishing section. These unit
remove spot fabrics. Sometimes fabrics are becoming oil sported, thread
sported. Daly 3000 pieces remove sported. These unit remove spot using by
following chemical:
o Hydro
o Wash
o Dryer
o Color machine
o AC dryer
# Problem of Finishing Section:
1) Difference between required order & finishing production
2) Accessories problem
3) Management measurement
4) Oil mark problem
5) Shading problems
6) Neck shape uneven
7) Worker problems
8) Shipment problem
# How to remove the finishing problem
1) Maintaining required order production
2) Supply of proper accessories for production
3) Maintaining accurate measurement
4) Remove oil mark problems
5) Removing shading problems
6) Making even neck shape
7) Established appropriate shipment
Page # 28
Above four section are directly related to the garment production. If any
section closed then production closed. Four section maintaining logistic for
production, such as:
Sample
Section
Cutting
Section
Sewing
Section
Finishing
Section
Garments
Production
Also another two section are directly & indirectly involved for production.
These are:
1) Store section, and
2) Quality control section
1) Store Section: Store section supply various instruments/ equipment to the
sample, cutting, sewing & finishing section for production.
# Structure of Store Sections:
Store Section
Store Manager
Store Officer
Asst. Store Officer
Issue man
Checking
Helper
Comparatively AKH Store section is wealthy section than other company.

AKH has lot of instrument storing for production. Store section just in time
supply various instrument as a result production is increased.
Page # 29
(2) Quality Control Section:

Quality control section an important section of production. This section
checking quality of sample section, cutting section, sewing section and
finishing sections.
# Structure of Quality Control Section:
Quality Control Section
Quality manager
Quality Asst. Manager
Quality In-charge
Quality controller
Quality inspector
# History of Quality Control Section of AKH Knitting & Dyeing Ltd.

1)
2)
3)
4)
5)
6)
7)
8)
Total number of quality control worker: 219

Area of quality control function
Daily quality checking: Per hours 60 pieces
Number of quality manager : 1
Number of assistant quality manager : 0
Number of quality in-charge : 12
Number of quality controller : 26
Number of quality inspector : 180
Page # 30
RAW MATERIAL USED IN PRODUCTION

Thread, button, cloth, fabrics, poly bag, hanger etc. are the raw materials that
used in production. The sources of these accessories are imported from
Hong Kong, Taiwn, Indonesia and China. But some raw materials are
collected from their own units.
WARE HOUSING OF THE RAW MATERIALS IS HELD AT
BANDED WAREHOUSE OF THE FACTORY
1. Inventory of the raw materials
2. Fabric inspection
3. Fabric cutting for sampling
4. Pattern marketing
5. Fabric spreading and cutting
6. Bundle making, numbering of bundles
7. Searing, line inspection, threat cutting, timing, quality control.
8. Finishing, packing, final inspection by buyers authorized bodies. If
approved then shipment.
PROBLEMS FACED DURING THE COLLECTION OF RAW
MATERIALS
1. Sometimes suppliers especially of over sear who are almost controlled
by the buyers agents, sometimes can not supply the raw materials in
times and lastly supply after frequent amendment of our back to back
betters of credit opened favoring them.
2. Due late supply of raw materials, sometimes, we are supposed to
comply shipment schedule on incurring huge to loss applying over
time works by the workers.
Page # 31
3. It is some times happened that due late supply of raw materials, we

are unable to ship out I/M/G in full written the target of shipment date.
In case the shipment validity is not extended, our problem knows no
bound. In such case, we have no other alternative but to face the
customs problems of duty, taxes for the raw materials or R/M/G on
account of stock lot.
4. The political crises, like, hartal is said to be one of the serious
problems in running garments industry is particular.
5. The port strike and increasing export charges both with Chittagong
port authority and the freight forwarders, we are facing tremendous
hard hip is the trade.
HOW TO REMOVE THE PROBLEMS
To get the solution, the problem as faced under above item, has to taken in to
account our government is taking no vital role to secure the interest of terms
of the suppliers of raw materials, buying houses and the buyers as a whole.
The government or its constituencies, have no headache for better interest of
the manufacturing and exporters, they have only headache to the them is
collecting custom taxes.
1. To awake the willingness of suppliers that means they have to
business attitude.
2. Port authority should take steps for the shipment of raw materials in
due time.
3. To reduce the red tapism in government sector.
4. Political stability is essential.
5. Honest and experienced suppliers should be selected for supplying
raw materials.
6. Speed money should be avoided.
Page # 32
MACHINERY IMPORTED COUNTRY

In necessary machineries of AKH Knitting & Dyeing Ltd. were imported
from Japan and Korea. And the brand name of machinery is JUKI
from Japan. JUKI is a brand name, which proved the quality and
loyalty of AKH Knitting & Dyeing Ltd.
PROBLEM FACED DURING IMPORT THE MACHINERY
The problem faced during import the machinery are as follows:
1. Suzerainty of middlemen.
2. High cost of machineries.
3. Imported machineries do not return back if it is defected.
4. High Tax on imported machineries.
5. Shipment procedure is slow at port.
6. Political inutility creates problem.
HOW TO REMOVE THAT PROBLEMS
1. By avoiding middlemen
2. Reduce the tax on imported raw materials.
3. Government can take steps against the go slow policy at port.
4. Reduce the complexity to import raw materials.
5. Political stability is essential.
Page # 33
JOB DESCRIPTION OF THE MANAGERS

General Manger (Production)
General Manager of production has to look after the task of production plan,
production system, quality control, material handling equipment layout,
production research, formulating production budget and etc. He is
responsible for the over all performance of the factory for production.
Manager (Accounts)
Manager of Accounts has to maintain all kind of transactions. He deals with
salary statement and prepares various account related books. He is
responsible for the over all performance of accounts department.
Manager (Commercial)
Manager of commercial is mainly concerned with the import and export
activities he has maintain constant touch with the out side world for
information at also maintain close relationship with the factory. He is
responsible for over all performance of commercial department.
Manager (Personnel)
At present this is no personnel manger in AKH Knitting & Dyeing Ltd.. But
personnel executive is responsible for over all performance of the personnel
manager. She has to maintain all kind of personnel management activities of
personnel department.
Manager (Public Relation)
Manager of Public Relation is mainly concern with the legal matter, labor
matter, advertisement, donation, companies safety and security. He links the
organization with the external and internal environment. He is responsible
for over all performance of public Relation department.
Page # 34
DUTIES AND RESPONSIBILITIES OF OFFICERS AND

EMPLOYEES OF THE FACTORY
Operator:
Operator operates a particular machine in a particular process at a time
efficiently. Line chief gives inputs to workers (operates) and also takes
outputs after processing or transforming. Line leader checks the expectable
output of quality.
Line Chief
Line Chiefs are fully responsible for their respective line. The daily activities
of line Chiefs are as follows:
They take necessary inputs from cutting section and supply it to lines
for sewing.
They make the workers understand respective sewing process in
respective line.
They give target unit to each workers for sewing in their respective
line.
They make the workers attention in sewgin to get target output from
each workers.
They supervises work properly and observe avoidance in work
For any machinery problem they complain to factory incharge and
listen all kinds of workers problem.
They always keep a relation with floor in-charge and general manager
of production.
Page # 35
Supervisor
Supervisor is fully responsible for production line. The activity of supervisor
summarized below:
She supervisors the workers doing work properly.
She is fully responsible for all sewing process and quality of every
line.
She handover per hour production to finishing sector to take step
rectify correction for any fault.
If finishing section claims about any problem supervisor tries to
remove it.
She complaints to Floor Incharge for any machinery fault.
She tries her best to maximum utilizes of worker.
She always keeps a link with floor incharge and general manager of
production.
Production Executive (Floor incharge)
Floor incharge is responsible for sewing to finishing section of production.
He looks after supervisors line leaders and workers activities. For any
problem in production process he contacts general manger of production and
takes decision. He also takes part in implementation of management
decision. The main function of floor incharge are summarized below:
In the morning he looks after attendance of line.
Design the plant lay-out according to order and style.
Requisition for materials and machines before starting production.
Target fixed up.
Page # 36
Input distribution in different lines.

He observes and controls supervisor, line leaders and the workers.
Fulfillment of hourly production.
He complaints to Maintenance department for any machinery
disturbance.
He tries his best to maximum utilities of man and machine.
He takes action for any kinds of complaints from supervisor worker
and line leader.
The requisition to management for maintain shipment date, any extra
work etc.
He is responsible for overall production performance of activities in
the floor area.
Cutting Master
Cutting Master is responsible to determine the ratio, size and color of the
cloth of confirm the pattern of the garments as per buyers instruction. He is
also responsible to determined amount of fabric to make required number of
garments.
Quality Inspector
The functions of the quality inspector are to see weather sewing and
measurement and of different part of the garments are done as per
specification, each activity of the machine in line is performed according to
style etc.
Page # 37
RECOMMENDATION
Bangladeshs ready-made garments industry has been said to be an
impressive story about how a private sector could successfully lead the
nation to a major export oriented country. And AKH Knitting & Dyeing Ltd.
is one of the renowned apparel in this country. It has played a vital role for
the development of socio-economic condition of the country.
It would be wonderful if the infrastructure facilities, including power
generation, port, roads and communications. Could be improved. As a
result, AKH Knitting & Dyeing Ltd. can perform more appropriately
and successfully.
Government should give concern on the various obstacles that are
barriers of garments development.
New machines are coming in the country with modern technology. So,
trained people can only survive in these competitive sectors. Thats
why; training is needed to help operators become more efficient. And
efficient workers can make effective production condition.
For the development of garments industries, banks and other financial
institute should be more open and come forward to help the
entrepreneurs who want to do something for the country and the
economy.
Page # 38
CONCLUSION
Ready-made garment is one of the golden gooses of our country. The role of
this sector in our socio-economic development cans hardly be over
emphasized. The lions share of our foreign exchange earning comes from
this sector, it is also the largest employer of women folk in the private sector.
AKH Knitting & Dyeing Ltd. is a private limited company. It is registered of
a joint stock company. Bangladesh owns its 100% share. It has a positive
contribution to the economy of Bangladesh. They are the largest export
oriented garments manufacturing company in Bangladesh. They believe in
quality and time and highly emphasized in maintaining a concerted harmony
in its working process and its environment.
AKH Knitting & Dyeing Ltd. limited is an ISO certified company. This is
one of the great opportunities in the readymade garments sector. Easily
foreign customer can feel interested to our ready-made garments sector.
The sincere effort has been duly recognized and AKH Knitting & Dyeing
Ltd. has thus been the proud recipient of many international awards and the
National Export trophy.
Lastly, I hope day-by-day development of the countrys one of the largest
garment based private organization.
Page # 39
BIBLIOGRAPHY
1. The Ready-made Garment Industry of Bangladesh: Mr. Hafiz G.A.
Siddiqi, The University Press Limited, First Published 2004, Page No.
68-228.
2. Hand Book of BGMEA, Volume 1&2
3. Personally Conduct with Officials of AKH Knitting & Dyeing Ltd.
4. Richard B. Chase Nichobs J.Aquiblano, Production and Operation
Management, Richard D. Irwin.Inc., 3rd Edition, U.S.A., 1981, P.
146, 278, 396, 512
5. James B. Dilworth, Production and operations Management,
Mc.Graw-Hill Co., New-York, 5th Edition, 1993, P. 142, 254, 300,
460, 520
6. Internet:
(a) www.bgmea.com
(b) www.akhfashions.com
Page # 40
APPENDIX
1) Front Sketch About Polo-Shirt
2) Daily Cutting Report
3) Daily Line Wise Production Report
4) Daily Style Wise Production Report
5) Finishing Production Report
6) Purchase Order
7) Daily Total Production Report
8) Description about long sleeves polo shirt
Page # 41
INTERNSHIP
REPORT
ON
PRODUCTION DEPARTMENT
(GARMENTS)
OF
AKH KNITTING & DYEING LTD.
SUBMITTED TO:
SUBMITTED BY:
DR. MD. ABU TAHER

PROFESSOR & CHAIRMAN
MD. NAJMUL ALAM

M.B.A. (MAJOR IN HRM)
CLASS ROLL 14642
EXAM. ROLL
COORDINATOR OF INTERNSHIP PROGRAM
DEPT. OF MANAGEMENT STUDIES

2004/08
UNIVERSITY OF CHITTAGONG
REG. NO 2487
DEPT. OF MANAGEMENT
STUDIES
Page # 42
UNIVERSITY OF
CHITTAGONG.
DATE OF SUBMISSION: SEPTEMBER 26, 2007.
LETTER OF SUBMISSION
To
Dr. Md. Abu Taher
Professor & Chairman
Coordinator of Internship Program
Department of Management Studies
University of Chittagong.
Subject: Submission of Internship Report.
Dear Sir,
I have completed the internship program as a course requirement of M.B.A.
Program and now I am greatly impressed by the submission of internship
report on Production Department (Garments) of AKH Knitting & Dyeing
Ltd. the duration of the internship program was 8-9 weeks. I have visited
the factories of AKH Knitting & Dyeing Ltd. and gained a first hand
knowledge about activities of production.
I am very goal to you because you assigned me to do the report. In the report
I have used primary and secondary information. I have collected information
from direct interviews of top-level management and low-level officials.
I hope that my report will meet your standard and oblige thereby.
Thanking you
Yours faithfully
Page # 43
Md. Najmul Alam

Class Roll: 14642
Exam Roll 2004/08
Reg. NO 2487
Page # 44
PREFACE
Our knowledge is limited in the textbooks. Only the theoretical knowledge is
not enough to build up our academic carrier. So, it is important for us to
gather practical knowledge along with theoretical knowledge placing this
important issue in the front after. Completing the M.B.A. written and viva
examination our department has taken the step of giving s the practical
know-how.
Here it is noted that, we have got the opportunity of acquiring the practical
know how is our previous year also. But it is a matter of great delight that to
over come the above situation and to ensure the theoretical education system
applicable. Every year Management Studies Department of University of
Chittagong give facility to the student of M.B.A. final year to Internship
Program.
So, what ever it is, dividing the students under a several groups with a
supervisor teacher the department decided to implement the internship
program. As per the rule my coordinator assign me to go through any
organization.
In order to fulfill these objectives my coordinator have been attached to
AKH Knitting & Dyeing Ltd. For period of 8-9 weeks under the
supervision of one of the teacher and also a program coordinator. As my
program coordinator Dr. Abu Taher, Professor as supervisor Dr. Sheikh
Ashraf Ali, Professor, Department of Management Studies, University of
Chittagong helped me a lot while preparing this report. The report has
prepared by collecting information, analyzing the information, observing the
working situation and discussing with the respective managers of AKH
Knitting & Dyeing Ltd.
Page # 45
ACKNOWLEDGEMENT
At first I am grateful to all mighty of Allah. To complete the internship
program successfully from the beginning I am really obligated to my
coordinator and best wishers. I would like to mention the name of my chief
coordinator of internship program. Dr. Md. Abu Taher, Chairman &
Professor and group supervisor, Dr. Sheikh Ashraf Ali, Professor,
Department of Management Studies, for his frankly behavior, suggestions
and guidelines to complete the internship program and preparing the report. I
like would like specially thanks to Md. Shahjahan Pathan, General Manager
(Production), AKH Knitting & Dyeing Ltd., who give us remission to
complete internship program. The report on Production Department
(Garment) of AKH Knitting & Dyeing Ltd. is and out come of an internship
program of 8-9 weeks time starting 22nd July 07 to 22nd September07.
During the above mention period I visit AKH Knitting & Dyeing Ltd. of
Production department (Sample Section, Cutting Section, Sewing Section,
Finishing Section, Store Section, Quality Control Section) and collected the
necessary data and information to write a report.
Then a would like to thanks, Mr. Tofazzal Hossain, Quality Manager,
R.M.A. Kareem, Senior Manager (Head of Admin, HRD & Compliance),
Md. Zahid Al Hasan, Deputy Manager (Dyeing), Mohammad Mohoshiur
Rahman, Production Manager.
I could not get the relevant data of my topic with out their kind consideration
and approval. I am grateful to them because of their recognition to conduct
the internship program in AKH Knitting & Dyeing Ltd. who supply me the
various relevant data and soon.
Md. Najmul Alam
Class Roll: 14642
Exam Roll 2004/08
Reg. NO 2487
Page # 46
EXECUTIVE SUMMARY
In export oriented Ready made garments industries, AKH Knitting &
Dyeing Ltd. is probably topping the list in Bangladesh. It is a symbol of
progress and advancement in the arena of garment export trade. Combined
efforts of its workers staff members and owners are the forces behind its
unique position of achievements to day.
Believes in quality and time and highly emphasizes in maintaining a
concerted harmony in its environment. We have seen a democratic
environment of AKH Knitting & Dyeing Ltd. We have got a general idea
about the management practices of AKH Knitting & Dyeing Ltd. while we
have visited the factory.
AKH Knitting & Dyeing Ltd. has always tried to direct the business in the
perspective of favorable national economy. Its related diversification was
strategically geared towards this. Indeed corporation such as AKH Knitting
& Dyeing Ltd. plays a recognizable role, and the integrated work of such
corporations and bodies like BGMEA and other associations can pave the
path towards enhanced national situation.
The globalization has dawned with newer challenges for the countrys
readymade garment sector. We welcome the globalization with a vow to face
those. On this occasion, we renew our firm commitment to our mission to
earn multiple success for the sector will continue even bolder.
It seems to me that the above all industry in situation is in a static position
which means the industry is in maturity stage of life cycle.
Page # 47
TABLE OF CONTENTS
Sl. No.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
Title of Contents
Page. No.
Introduction of the internship program
1
Objective of the internship program
2
Programming & implementation
3
Important of the study
4
Methodology of the study
5
Limitation of the study
6
Rational of the study
7
Company profile
8-9
Organogram of factory operation
10
Policy design
11
Production process & determine the standard and
12
quality control
Structure of production department
13
Production process
14
Activities of production department
15-30
Raw material used in production
31-32
Machinery imported country
33
Job description of the manager
34
Duties & responsibilities of officers & employees
35-37
of the factory
Recommendation
38
Conclusion
39
Bibliography
40
Appendix
Page # 48

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Production Department (Garments) at AKH Knitting & Dyeing Ltd.

INTRODUCTION OF THE INTERNSHIP PROGRAM

Production Department (Garments) at AKH Knitting & Dyeing Ltd.

OBJECTIVE OF THE INTERNSHIP PROGRAM

Production Department (Garments) at AKH Knitting & Dyeing Ltd.

PROGRAMMING AND IMPLEMENTATION

Production Department (Garments) at AKH Knitting & Dyeing Ltd.

IMPORTANT OF THE STUDY

Production Department (Garments) at AKH Knitting & Dyeing Ltd.

METHODOLOGY OF THE STUDY

Production Department (Garments) at AKH Knitting & Dyeing Ltd.

LIMITATION OF THE STUDY

Production Department (Garments) at AKH Knitting & Dyeing Ltd.

RATIONAL OF THE STUDY

Production Department (Garments) at AKH Knitting & Dyeing Ltd.

AKH Knitting & Dyeing Ltd.

Production Department (Garments) at AKH Knitting & Dyeing Ltd.

AKH Fashions Ltd.

Mission of the Company:

Production Department (Garments) at AKH Knitting & Dyeing Ltd.

ORGANOGRAM OF FACTORY OPERATION

Production Department (Garments) at AKH Knitting & Dyeing Ltd.

BUSINESS POLICY DESIGN AT AKH KNITTING & DYEING LTD.

Production Department (Garments) at AKH Knitting & Dyeing Ltd.

PRODUCTION PROCESS OF AKH KNITTING & DYEING LTD.

DETERMINE THE STANDARD AND QUALITY CONTROL

Production Department (Garments) at AKH Knitting & Dyeing Ltd.

STRUCTURE OF PRODUCTION DEPARTMENT

Production Department (Garments) at AKH Knitting & Dyeing Ltd.

Ready for Final Inspection of the Buyer

ACTIVITIES OF PRODUCTION DEPARTMENT

Production Department (Garments) at AKH Knitting & Dyeing Ltd.

(A) Sample Section:

Asst. Pattern Master

# Functions of sample section of AKH Knitting & Dyeing Ltd.:

Production Department (Garments) at AKH Knitting & Dyeing Ltd.

1) Number of sample machines: 20

Production Department (Garments) at AKH Knitting & Dyeing Ltd.

Quality Control Unit

Asst. Cutting Incharge

Production Department (Garments) at AKH Knitting & Dyeing Ltd.

# Functions of Cutting Section:

Line workers input supply man: To perform cutting fabrics

supply from cutting section to sewing section

Production Department (Garments) at AKH Knitting & Dyeing Ltd.

# History of cutting section of AKH Knitting Dyeing Ltd.

Production Department (Garments) at AKH Knitting & Dyeing Ltd.

# Formula of fabrics consumptions:

Difference between required dia & delivery dia. If required dia is

Involving needle whole, dia mark, criss mark of required fabrics

Absence of pure fabrics as a result fabrics is re-cutting

Difference between pique fabrics & collars shed as a result

Lack of rib matching, as a result single gerse is redyeing.

Absence of fabrics relaxedness, as a result fabrics are may be

# How to remove the problems:

Production Department (Garments) at AKH Knitting & Dyeing Ltd.

(C) Sewing Section:

Quality control unit

# Functions of Sewing Section:

Production Department (Garments) at AKH Knitting & Dyeing Ltd.

1) Front part functions

2) Back part function

Back part mark