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PRIMEASIA UNIVERSITY

A mission with a vision


A report submitted on Industrial Training in Knit Concern Ltd to the Department
of Textile Engineering in partial fulfillment of the credit requirement for awarding
the Bachelor Degree in Textile Engineering by Primeasia University.
Supervisor
Dr.M.A.Sayeed
Associate professor
Department of Textile Engineering
Primeasia University
By
Md.KamalHossain
ID: 123-098-041

A REPORT ON INDUSTRIAL TRAINING IN KNIT CONCERN LTD.


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62, Water works Road, Godnail, Narayangonj-1400, Bangladesh.

TRAINING PROGRAM FOR THE DEPARTMENT OF TEXTILE ENGINEERING, PRIMEASIA


UNIVERSITY,
BANANI,DHAKA
FROM 01 August to 31 August 2016

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Acceptance

The project work Industrial Training on Garments Manufacturing in


Knit Concern Ltd. is prepared by using the relevant documents
related to the assigned topic written by Md.Kamal Hossain, ID:123-098041 students of Textile Engineering, Primeasia University has been
acknowledged as it is acceptable

(Supervisor)
M.A. Sayeed
Asst. Professor
Dept.of Textile Engineering
Primeasia University.
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ACKNOWLEDGEMENTS
At first my gratefulness goes to Almighty Allah to give me strength and ability to
complete the industrial training and this report. May your name be exalted,
honored and glorified .Industrial Attachment Courseis an academic function of the
Primeasia University. We are highly delighted to express our regards & gratitude to
our honorable teacher Professor M.A.Khaleq (Dean, School of engineering & Head
of Textile Engineering Department, Primeasia University) for providing us the
chance to complete our Industrial Attachment in Knit Concern Ltd. Special thanks
to our supervising teacher ProfessorDr.AssistantProfessor M.A. Sayeed (Department
of Textile Engineering) I am extremely indebted for his tremendous support and
guidance throughout my training period, without whose help it would not have
been possible to complete the training successfully. We also take the opportunity
to express our sincerest gratitude to the management, administration & personnel
of Knit Concern Ltd. for their kind assistance. Heartfelt thanks goes to Md.
Kamruzzaman khan (Zaman),Director Merchandising, Mr.Nasim Ahmed, GM
Garments, (Anamul Bahar Babu), DGM Garments ,Abdul Awal Shohel, Sr. Manager,
HRD, Admin & Compliance, Mr.Aziz, Manager, HRD, Engr. A. K. M Mohsin Ahmed,
General Manager, Knit Dyeing, Knit Concern Ltd. and Mr. Khalid Masud, CEO & GM,
Yarn dyeing, Knit Concern ltd. for their permission & excellent cooperation during
the period of our training. We would also like to thank Mr. Muhammad Asiful Alam
Asif(Dyeing Manager, Knit) & Mr. Zahid Arman (Dyeing Manager, Yarn) for their
sincere support. The generous support is greatly appreciated.I would also like to
thank Production Officers, Senior Production Officer and other officials of Knit
Concern Ltd. for helping me to complete industrial training successfully. My
gratitude also goes to all theem ployeesof Knit Concern Ltd. for their sincere cooperation, support and valuable advices. Above all, we would like to acknowledge
our deep debt to all teachers of our university & particularly of Wet Processing
Department for their kind inspiration & help, which remain as the backdrop of all
our efforts. Finally, we would like to acknowledge that we remain responsible for
the inadequacies & errors ,which doubt less remainin the following

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Tabel Content
1. Acknowledgement .

04

2. EXECUTIVE SUMMARY ... 07


2.1. Introduction...
2.2. History of the factory

08
09

2.3. GENERAL INFORMATION. 10


2.4. Organogram..
11
2.5. LAYOUT... 12
2.6. Major Buyers logo. 13
2.7. Mission and vision. 15

3.1.Knitting Section. 16
3.1.1. Organogram
3.1.2. Process flow chart..
3.1.3. Knitting...
3.1.4. Product Details
3.1.5. Knitting machine Detail.
3.1.6. Sequence of operation
3.1.7. Knitting Faults & Remedies..

17
18
19
19
20
21
21

3.2. Knit Dyeing Section.

29

3.2.1. Organogram
31
3.2.2. Layout..
32
3.2.3. Machine Details 33
3.2.4. Different Types of Dyeing Process & curve . 34

3.3.Dyeing Lab.. 39
3.3.1.Organogram.. 39
3.3.2.Layout 40
3.3.3. SEQUENCE OF OPERATION. 41
3.3.4.FLOW CHART OF RECIPE FORMULATIO
42
3.3.5.COTTON DYES IN DYEING
LAB.. 43

3.3.6. Physical section 44


Machine Details3.3.7. Different types of Test.. 45
3.3.8. Color Fastness to Washing:.. 45
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3.4. Knit Dye Finishing Section. 51


3.4.1. LAYOUT 52
3.4.2. Machine Details.. 53
3.4.3. Flow chart of finishing & Machine Function . 54
3.4.4. Machine Function 56
3.4.5. Finishing Faults and their Remedies .. 57

3.5.Garments Division .. 60
3.6.Sample Section 61
3.6.1.Organogram62
3.6.2. Layout.. 63
3.6.3. Sample Making Procedure .. 64
3.6.4. Types of Sample. 64

3.7. Cutting Section 67


3.7.1.Organogram....68
3.7.2. Layout... 69
3.7.3. Machine Details. 70
3.7.4. Cutting Process..... 76

3.8. Sewing Section.. 79


3.8.1.Organogram.80
3.8.2.Layout......81
3.8.3. Machine Details.. 82
3.8.4. Working Procedure of Sewing Department 85
3.8.5. Sewing Defects 87

3.9.FinishingSection .88
3.9.1.Organogram. 89
3.9.2. Layout.. 90
3.9.3. Finishing Process Flowchart.. 91

3.10. Industrial Engineering.92


3.10.1. Discuss 92

4. Compliance ....94
4.1. Definition. 94
4.2. List of Compliance Issues.. 94

5. Quality assurance System 96


6. Merchandising.. 101
6.1. Organgram ... 107

7. Maintenance.. 108
8. Utility Section... 111
9. Marketing Activities 117
10. Conclusion.. 120

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2. EXECUTIVE SUMMARY
The internationally recognized Buyers or clients are looking for those countries for
producing their apparel products where different types of mills have established as a one stop source for
the global apparel market, satisfy and meet customers expectation by developing and providing
products and services on time, which offer valuein terms of Quality, Price, Safety & Environmental
impact. And also assure complete compliance within ternational quality standards and /standards. In
Bangladesh, there are different types of Textile Industry those are producing high quality textile and
apparel product. Knit concern Ltd. is one of them. Knit concern Ltd. Garments Manufacturer &
Exporter, having all state of the artfacilities with annualturn over Tk.15,00,00,000 to 20,00,00,000.They
have Different types of Cutting, Sewing, and Finishing machines supplied by mostly Japan, Taiwan,
U.K, USA, Singapore, etc. which are very latest. It has high production rate finished garments are
produced perday. Theproduction is control ledby skill persons. All of the decision makers production
sectorin. Knit Concern Ltd. inottextiles graduates.Finishing is well branded They produce their product
for their buyer and client those are coming from international market like U.K, France, Germany,
Belgium, and U.S.A. They follow all the system for their machines maintenances production can no
thamper In this report, I have tried to give some information about Knit Concern Ltd. and I have
observed that Knit Concern Ltd. Produced high quality garment and fulfill the special requirements
from the different types of buyers by according different internationally recommended standard method.

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2.1 INTRODUCTION
The word textile originally applied only to woven fabrics, now generally
applied to fibres, yarns, or products made of fibres, yarns, or fabrics. The term
textile originates from the Latin verb texere, meaning toweave. It has,
however, come to include fabrics produced by other methods. Thus, threads,
cords, ropes, braids, lace, embroidery, nets, and fabrics made by weaving,
knitting, bonding, felting, or tufting are textiles. Some definition softheterm textile
would also include those products obtained by the paper making principle that
have many of the properties associated with conventional fabrics. In addition to
clothing and home furnishings, textiles are used for such industrial products as
filters to air conditioners, life rafts, convey or belts, tents, automobile tires,
swimming pools, safety helmets and mine ventilators
At KNIT CONCERN LTD., cutting-edge technologies merge seamlessly with human
ingenuity and deep seat recommitment to ensure excellence in every stage and
area of their activities. From fiber to fabric, KNIT CONCERN LTD is truly integrated
undertaking. The KNIT CONCERN LTD. has the capability to offer a complete
product range for the export textile markets. The goal of KNIT CONCERN LTD. is
to become the preferred partner for sourcing high quality fabrics and clothing
from Bangladesh With highly advanced technology and an emphasis on developing
local human resources. KNIT CONCERN LTD has the potential to make an important
contribution to the nation's growing readymade garments export sector.

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2.2. History Of The Factory


Knit Concern Limited home base is Narayangonj- a city with the largest river port of
Bangladesh. It launched its very humble journey in 1990 from a rented building at
Nayamati. That potential embryo, byvirtue of futuristic enterprising, dedication to
quality, commitment to excellence, a doption of state-ofthe-art technology, and
keen focus on customers' satisfaction, it could very rapidly metamor phoseinto
alarge corporate entity, in its most modern sense, just by 1998. Its production has
branched out into four full-fledged factories at three location- Godnail & Chasara
at Narayangonj and Mirpurin Dhaka. Knit Concern Limited at present has a daily
production capacity ofover 20 ton of knitted fabric, 30tons of dyed fabric and
60,000 pieces of garments. Knit Concern Limited became one of the few garments
in Bangladesh that implemented ISO 9001:2000 Quality Management System.The
government to Bangladesh also recognized its excellence by awarding the status of
a Commercially Importance Person(CIP) to its Chief Executive, Mr. Joynal Abedin
Mollah, the founder Managing Director of KCL,since 1995without break

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2.3. General Information of Factory


Name of the Company

Knit Concern Ltd.

Type

100 % Export Oriented Composite


knitwear Industry

E-mail Address
URL

62,Water Works Road


Godnail,Narayangonj-1400
Bangladesh
02 7631086, 02 7645641
02-7641087
info@knitconcern.com
http://www.knitconcern.com

Person to be contact

Mr. Jahangir Alam (Managing Director)

Year of Establishment

1990

Business

100% export oriented knit fabrics


manufacture & readymade knit
garments
exporter

Products

Knit Fabrics & Knit Garments

Production capacity

Knitting: 35 tons/day
Dyeing & Finishing: 35 tons/day

Overall manpower

7000

Project Cost

1000 core Taka (Approximately).

Project Area
Legal Form of Company

approx. 82000 sq. ft.


Private Limited Company.

Factory Address
Contact No

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2.4.Organogram

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2.5.Layout

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2.6.Major Buyers logo

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2.7. Mission and vission:


In the global marketing, ever-changing fashion world, knit Concern 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. KCL 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, KCL
mainly aims to know their perception about themselves and translates those into
garments. Doing that, over the years, KCL designers have acquired an almost
telepathic understanding of the consumers needs. KCL has started manufacture
and export garments since late 1990. Its mission is to produce the latest design;
quality knit fabrics and apparels for international markets. KCL is one of the few
elite private sector business groups, which contributed wealth as well as welfare to
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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 efficacy and a keen
sensitivity to style, makes KCL an emerging brand destined to light up the horizon
of fashion. KCL has team of skilled and dedicated technocrats backed by adequate
number of modern USA and European machinery and equipments to match
international standard of all kinds of knitwear products.

3.1 Knitting Section

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3.1.1.Organogram

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3.1.2. Process flow chart


Process Flow Chart for Knitting:
Knitting is one kind of fabric manufacturing process in which fabric is produced
by inter looping among loops formed by single or several yarn feeding
simultaneously. Knitted fabrics produced with stitch formation.

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Circular Knitting m/c


Stitch is most important structural element of knitted fabrics .The stitch consists
of a head ,two legs ,two feet and upper& lower connection point.

Process Flow Chart for Knitting


Yarn in package form

Place the yarn package in the creel

Feeding the yarn

Set the m/c as per design & GSM

Knitting

Withdraw the roll fabric and weighting

Roll marking

Inspection

Numbering

3.1.3.Knitting
The process in which fabrics are produced by set of connected loops from a series
of yarns is called knitting.

Warp knitting
Weft knitting
When fabric is produced by this method in weft direction then its called weft
knitting & warp direction then its called warp knitting.

3.1.4. Product Details


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Raw Materials used in Knit Concern Group:


Type of yarn

Count

Cotton Yarn

20/1, 24/1, 30/1, 34/1,40/1

Polyester Yarn

75/D, 100/D,150/D

Grey Mellange (C-90% V-10%)

10/1,24/1,30/1,34/1,

PC (65%Polyester & 35% cotton)

10/1,30/1

Single Jersey M/C:


a)
b)
c)
d)

S/J Plain
Single lacost
Double lacost
Terry

Rib M/C:
A) 11 Rib fabric
B) 22 Rib fabric

3.1.5. Knitting machine Detail


Machine list of knitting section:
TYPE

BRAND

MC. QTY.

Single Jersey

Orizio. Italy

03

Single Jersey

Fukuhara, Japan

32

Single Jersey

Lisky, Taiwan

04

Single Jersey
Open/Slitting

Fukuhara, Japan

16

Single Jersey

Mayer & Cie ,German

10

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Open/Slitting
Single Jersey
Open/Slitting

Lisky, Taiwan

08

Rib / Interlock

Fukuhara, Japan

20

Interlock

Fukuhara, Japan

08

Interlock

Lisky, Taiwan

01

Rib

Well Knitting

01

Rib eyelet

Jinhar, Taiwan

01

Auto Striper (Four


Color) S/J

Fukuhara, Japan

04

Auto Striper (Four


Color) S/J

Fukuhara, Japan

01

Auto Striper (Four


Color)
Rib/Interlock

Fukuhara, Japan

02

Fleece 3 Thread

Fukuhara, Japan

04

Fleece 3 Thread

Lisky, Taiwan

06

Flat Knit Semi


Jacquard

Stoll, German

02

Flat Knit Semi


Jacquard

Shima Seiki

05

Flat Knit Semi


Jacquard

Matsuya Japan

12

Flat Knit Semi


Jacquard

Protti, Italy

02

Total

144 Nos

3.1.6. Sequence of operation


SEQUENCE OF OPERATION:

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Receive the requisition of fabric sample & quantity

Determine the fabric design, structure & other related parameters

According to these fabric knitting starts with respective m/cs

Inspection of grey fabric

Grey fabric sends to batching section

3.1.7. Knitting Faults & Remedies


a) Hole Mark

Causes:

Holes are the results of yarn breakage or yarn cracks.


During loop formation the yarn breaks in the rejoin of the needle hook.
If the yarn count is not correct on regarding structure, gauge, course and density.
Badly knot or splicing.
Yarn feeder badly set.

Remedies:
Yarn strength must be sufficient to withstand the stretch as well as uniform.
Use proper count of yarn.
Correctly set of yarn feeder.
Knot should be given properly.

b) Needle Mark
Causes:

When a needle breaks down then needle mark comes along the fabrics.
If a needle or needle hook is slightly bends then needle mark comes on the fabrics.

Remedies:

Needle should be straight as well as from broken latch.

c) Sinker Mark Causes:

When sinker corrode due to abrasion then some times can not hold a new loop as a result sinker
mark comes.

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If sinker head bend then sinker mark comes.

Remedies:

Sinker should be changed.

d) Star
Causes:
Yarn tension variation

during production.

Buckling of the needle latch.

Low G.S.M fabric production.


Remedies:

Maintain same Yarn tension during production.

Use good conditioned needles.


e) Drop Stitches

Causes:

Defective needle.
If yarn is not properly fed during loop formation i.e. not properly laid on to the needle hook.
Take-down mechanism too loose.
Insufficient yarn tension.
Badly set yarn feeder.

Remedies:

Needle should be straight & well.


Proper feeding of yarn during loop formation.
Correct take up of the fabric & correct fabric tension.
Yarn tension should be properly.

f) Oil stain
Causes:

When oil lick through the needle trick then it pass on the fabrics and make a line.

Remedies:

Ensure that oil does not pass on the fabrics.


Well maintenance as well as proper oiling.

g) Pin hole
Causes:

Due to break down or bend of the latch, pin hole may come in the fabric. Remedies:
Change the needle
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h) Fly dust:
Causes:

In knitting section too much lint is flying to and fro that are created from yarn due to low twist as well as
yarn friction. This lint may adhere or attaches to the fabric surface tightly during knit fabric production.

Remedies:

Blowing air for cleaning and different parts after a certain period of time.
By cleaning the floor continuously.
By using ducting system for cleaning too much lint in the floor.
Over all ensure that lint does not attach to the fabric.

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3.2.Knit Dyeing Section


Knit dyeing:
Knit dyeing is a technique of dyeing the knitted fabrics. The dyeing of knitted fabrics
occurs in the exhaust method or in batch-wise process. Knit dyeing process is near
similar to yarn dyeing process but there is some difference in quality measurement.
Generally all types of single jersey, double jersey and their derivatives are dyed by
different way. Flowchart of knit fabric dyeing describe shortly.

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3.2.1. Organogram

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3.2.2. Layout

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3.2.3. Machine Details


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Greece

Ath
ena
2

15
0k
g

01

Greece

Ath
ena
2

25
0k
g

01

Greece

Ath
ena
2

50
0k
g

01

Greece

Ath
ena
2

75
0k
g

02

Greece

Ath
ena
2

10
00
kg

01

Greece

Ath
ena
3

50
0k
g

01

Greece

Ath
ena
3

10
00
kg

01

Greece

Ath
ena
3

15
00
kg

01

Greece

Ath
ena
S

20
kg

02

Greece

Ath
ena
S

50
kg

02

Sclavos Machine

Greece

Ath
ena
3

25
0k
g

01

J&X

Chaina

HFHT

15
kg

01

J&X

Chaina

HFHT

25
kg

01

J&X

Chaina

HFHT

50
kg

01

HFHT

10
0k
g

01

15
kg

01

Sclavos Machine

Sclavos Machine

Sclavos Machine

Sclavos Machine

Sclavos Machine

Sclavos Machine

Sclavos Machine

Sclavos Machine

Sclavos Machine

Sclavos Machine

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J&X

Chaina

BNCS

Bangladesh

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3.2.4. Different Types of Dyeing Process & curve

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Dyeing Curve

Flow Chart For Dyeing:


Grey fabric receive from knitting section

Batching

Select m/c no

Fabric loading

Select production program

Pre treatment

Select recipe for dyeing

Recipe confirm by D.M / S.P.O

Dyeing

Post treatment
Unload

3.3.DyeingLab
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3.3.1.Organogram

3.3.2.Layout
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3.3.3.SEQUENCE OF OPERATION
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Defining the color as buyer wanted

Recipe formulation by spectrophotometer/

From previous history

Lab dip preparation

Send to buyer for approval

Send the recipe of approved sample to Dyeing section

Recipe formulation:
Buyer can give fabric sample or color code or pantone number. So at first the color is to identify if the
buyer gives color code or pantone number. It is easier to formulate recipe by spectrophotometer from
color code or pantone number because they are very specific. But if it is fabric sample then with the
help of spectrophotometer several numbers of recipes are to formulate.

3.3.4.FLOW CHART OF RECIPE FORMULATION:


Swatch
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Click recipe

Click on first match

Fabric type

Buyer name

Color name

Browse data

Browse

Click shade

Shade select

OK

Dye set

Dye select

3.3.5.COTTON DYES IN DYEING LAB


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1. Remazol Br Blue BB 133%


2. RemazolGld Yellow RGB
3. Remazol Navy RGB 150%
4. Remazol Orange RR
5. Remazol Red RR
6. RemazolTurquise Blue G133%
7. Remazol Yellow RR
8. Levafix Amber CA
9. Levafix Blue CA
10. Levafix Fast Red CA
11. Levafix Orange CA
12. Levafix Blue RR
13. Kimsoline Black K-BD 130%
14. Kimsoline Black B 150%
15. Kimsoline Red KLL
16. Kimsoline Red L-E
17. Kimsoline Red HF-6BN 150%
18. Kimsoline Red K-ED Conc.
19. Kimsoline Orange SHF-RR 150%
20. Kimsoline Blue L-E
21. Kimsoline Navy Blue K-d Conc.
22. Kimsoline Yellow KLL Kimsoline
Yellow HF-4GL 150% etc

Recommended Salt & Soda Concentration

Depth of shade
Upto- 0.1
0.1-0.5
0.5-1.0
1.0-2.0
2.0-3.0
3.0-4.0
4.0-5.0
Abobe 5.0

3.3.6.Physical section

Machine Details43 | P a g e

Glubar salt(g/l)
15
20
30.0
40.0
50.0
60.0
70.0
80.0

Soda ash(g/l)
5
6
8.0
10.0
15.0
15.0
20.0
5.0

44

Instrument

Makers Name

Code No.

Gyro Wash

James H.Heal

TTL/GW/001

Wascator

Electrolux

TTL/WC/002

Washing Machine

Siemens

TTL/TD/004

Tumble dryer-1

Whirlpool

TTL/TD/005

Balance-1

Ohaus

TTL/EB/006

Balance 2

Ohaus

TTL/EB/007

Balance-3

AND

TTL/EB/007

GSM Cutter

James.H.Heal

TTL/GSM/009

Crockmaster

James.H.Heal

TTL/CM/010

ICI Pilling Tester

James .H.Heal

TTL/PT/011

Pilling Measurement

James.H.Heal

TTL/PAV/012

Incubator

James H.Heal

TTL/INB/013

Steal Scale

Local

TTL/PHM/015

Ph Meter

Hanna

TTL/PHM/015

Light Box

Verivide

TTL/CL/016

Perspirometer

James H.Heal

TTL/PM/017

Conditioning Chamber

TTL/CC/018

Weight Box

TTL/WB/019

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3.3.7. Different types of Test

Dimensional Stability to Washing( Shrinkage)


Spirality/Twisting
Colorfastness To Water
Colorfastness to Washing
Colorfastness to Perspiration
Colorfastness to Rubbing
Colorfastness to Saliva
Colorfastness to Actual Laundering
Print Durability
Fabric Weight
Thread Count
Pilling Resistance
Ph test
Yarn Appearance
Yarn count

3.3.8. Color Fastness to Washing


Color fastness to washing means, A specimen of the textile, in contact with one or two specified
adjacent fabrics, is mechanically agitated under described conditions of time and temperature in a
soap solution, then rinsed and dried. The change in color of the specimen and the staining of the
adjacent fabric are assessed with the grey scales.

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In my personal experience, in case of fastness test color fastness to washing is the first and most
important requirements of buyers. There are a number of ISO test for color fastness to washing.

These are :

ISO 105 C06 A2S

ISO 105 C06 B2S

ISO 105 C06 C2S

Among them ISO 105 C06 is the first choice of maximum buyers.
Now I will discuss about those fastness test.

Multi fiber fabric

ISO 105 C06:


Instruments:
1. Rotawash / Gyrowash,
2. Stainless Still Ball,
3. Multi-fiber fabric,

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4. Grey scale,
5. Sewing machine,
6. Thermometer,
7. Color matching cabinet

Recipe:
Sodium Perborate..1 gm/litre
ECE Phosphate..4 gm/litre
Sample Preparation:
Sample Fabric.10 cm*4 cm
Multi fiber fabric10 cm*4 cm

Working Procedure:
Collecting the sample from bulk and then conditioning for 04.30 to 06 hours

Making a specimen of 04 cm*10 cm in size.

Sewing the specimen with multi-fibre fabric of same size at one corner.

Making the solution of 4gm/litre ECE detergent & 1 gm/litre sodium perborate, (If required SKFL use
0.15 gm/litre TAED).

Putting the specimen with multi-fibre fabric into the solution in Rotawash m/c Prog.: C2S Temp.:
60OC/ 40OC Time: 30 min Still ball: 25 pcs

Rinsing with hot water respectively.

Squeezing with cold water of the sample is done (Hand Wash).

Then drying is done at a temperature in the air not exceeding 60OC

The stitching is then broken out except on one of the shorter end.

Measuring the staining and color change by grey scale & make a test report.
For ISO 105 C06 A2S:
1. Total solution (changeable) 150 ml
2. Stainless Still Ball..10 (for hitting)
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3. Time40 min
4.

Temperature40 C Everything
is same.

For ISO 105 C06 B2S:


1. Total solution (changeable) 150 ml
2. Stainless Still Ball..25 (for hitting)
3. Time40 min
4.

Temperature50 C Everything is same.

For ISO 105 C06 C2S:


1. Total solution (changeable) 50 ml
2. Stainless Still Ball..25 (for hitting)
3. Time40 min
0

4. Temperature60 C

Physical Lab Testing Machine

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3.4.Knit Dye Finishing Section

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3.4.1. LAYOUT

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54

3.4.2. Machine Details


Type
Dewatering
/Squeezer

Dryer

Open Compactor
Open Compacto

TubeCompactor
Slitting m/c

Seuding m/c
Brushing m/c
Tumble dryer
Tumbledryer
Tumble dryer
Stenter

Hydro Extractor

Brand

Origin

MC QCT.

Switzerland

01Nos.

Santex,
Switzerland

Swit
zerl
and

01 Nos.

Santex,
Switzerland

Swit
zerl
and

01 Nos.

Santex

Lafer, Italy

Italy
Swit
zerl
and

Santex,
Switzerland
EL, Italy

03 Nos.

Italy

02 Nos.
Swit
zerl
and

Santex,
Switzerland

01 Nos.

02 Nos.

Arrtex, Taiwan

Taiwan

01 Nos.

J & X, China

Taiwan

01 Nos.
Cha
ina

Abatex,China

01 Nos.

Abatex, China

Taiwan

05 Nos.

Monforts,
Germany

Germany

03 Nos.

CHINA

China

02 Nos.

3.4.3. FLOWCHART OF FINISHING & MACHINE FUNCTION


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Flow chart for tube fabric finishing:

Tube fabric

Dewatering

Dryer

Compactor

Final Lab

D.Q.L

F.Q.L

Delivery to Garment

Flow chart for open fabric finishing:


Open fabric

Slitting

Stenter/Dryer (santex)

Compactors

Final Lab

D.Q.L

F.Q.L

Delivery to Garment

3.4.4. MACHINE FUNCTION


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Slitting:
Slitting is a process that is applied for cutting the tubular fabric through the intended break Wales line
on lengthwise direction prior to stenter processing.
Function of the Machine:

To slit the tube fabric by the knife for opening of the fabric and ready for stentering.

Used to remove excess water after pretreatment and dyeing.


Delivered fabric increase Free State.

Before squeezing balloon is formed with the help of compressed air passing by a nozzle or air sprayer.

It can control the diameter of fabric and GSM and shrinkage by over feeding mechanism.

Picture of slitting machine:

Dewatering / Sequestering Machine:


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Function:
Reduce water content.
Apply chemicals.
Apply over feed to give some compaction.
Open the fabric from the rope form.
Width wise stretch the fabric.
Plait the fabric.

Dryer:
Function
-

To dry the fabric.


To control the overfeed system.
To control the vibration which increase the G.S.M.

Stanter:
Function of Stenter:

GSM Control
Drying
Shrinkage control.
Heat setting.
Width control Finishing chemical application.
Moisture control

3.4.5. FINISHING FAULTS AND THEIR REMEDIES:


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3.5.Garments Division
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garment is a product which is manufactured by fabric for protecting human body and
decorated purpose.

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3.6.Sample Section

Production Sample

Definition
Sample is a product which represents a group of product or lot or batch, in order to assess their
quality, style or design or any other characteristic of the product. Based on the samples, the
buyer will give approval or comments for any alteration in design or style or quality. Samples will
reflect the quality and workmanship of the exporter or manufacturer. Samples are made to
make sure to get a desired style design or fit and good quality in the particular order.

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3.6.1.Organogram

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3.6.2. Layout

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3.6.3. Sample Making Procedure


SAMPLE MAKING PROCEDURE

Flow Chart of Sample Making


Garments Design or Sketch (Manually or Computerized)

Basic Block (Manually or Computerized)

Working Pattern (By Machine)

Sample Garments (Manually)

Problem of Production or Production Related Matter

Costing Send to Buyer

Approved Sample

Production Pattern (By Hand or Computer)

3.6.4. Types of Sample


The different types of samples sent to the buyer, in the order of dispatch process, are:

Develop Sample
Quotation Sample
Size Set Sample
Pre-production/Counter Sample/Ok/Tag Sample
Production Sample

Photo Sample
Color Sample

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Fashion Sample
Any Size type of Sample
Shipment Sample

Briefly Discuss

Development Sample: Which sample make by available fabric & accessories and send to buyer
to collect order from the buyer that is called development Sample.
Quotation Sample: Which sample make for the Buyers at least maximum 3 pieces of Sample.
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.

Pr-production sample (PP Sample):Pre-production 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.

Production sample: First production garment will be send buyer for buyer satisfaction
Photo Sample: These samples are to be made after getting the order sheets. These samples are
needed to check the measurements, style and fit. So they can be made in available similar fabrics
but in the actual measurements and specifications. Some buyers may need these samples if they
want to print the photos of garments on photo inlays, packing box, hang tag, etc. These samples
may be needed for local advertisement or buyers promotional occasions.

Color Sample: Color samples are which samples to create color variation on different types of
sample. To send Buyers to see that sample they are ordered.

Fashion Sample: Fashion samples are made to put on display in the retail showroom. Fashion
sample are displayed for assessing customer's feedback and according to customers response buyers
forecast demand of a particular style. Fashion samples are made with actual fabric and trims and
accessories.

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Any Size type of Sample : Which sample make by actual fabric & accessories and send to local
laboratory (Buyer Nominated) to check fabric structure such as-GSM, Color fastness, Rubbing,
Shrinkage, printing,& embroidery, Wash.

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.

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3.7.Cutting Section

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3.7.1.Organogram

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3.7.2. Layout

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3.7.3. Machine Details


Its highly sophisticated cutting room solutions ensure precision and accuracy in cuttingminimizing wastage of fabricant man hours spent.

Machine Name
Digitizer

Ploter

Pattern Cutter

Brand

Origin
France
USA
China

QTY
01
01
01

Gerber

USA

01

Winda
IMA

CHINA
Italy

02
01

Gerber

Japan

01

Winda

China

01

Lectra
Gerber
Winda

Straight knife
cutting
M/C
Computerized
cutting
M/C
Fabric Spreader

05
03
06
Total

23

Description of Fabric which are available in Knit concern:

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73
2Yarn
Count
34/CB
20/CB
26/CB
34/CB

Guage
18
20
24
18

Gsm
180
190
165
180

40/CB

24

150-155

30/CB

24

185

34/CB

24

160

40/CB

24

150-155

30/CB
30/CB
24/CB
20/CB
40/CB
30/CB
20/CB
40/CB
34/CB

24
24
24
24
24
20
24
24
24

150-155
150
170
190
110-115
130-140
190
110
130-140

40/CB
30/CB
30/CB
20/CB

24
18
20
24

155
150
220
190

40/CB
30/CB

18
24

150-155
220

30/CB
30/CB

24
24

150-155
150

24/CB

24

170

34/CB
20/CB

24
20

130-140
190

40/CB
30/CB
26/CB

24
18
34

150-155
220
150-155

34/CB
34/CB
30/CB

24
18
20

180
180-190
300

34/CB
24
26/CB
73 | P a g e18

160
240

Fab/Type
1/1 Rib
S/J (open) Solid
Slub S/J (open) Solid
1/1 Rib
S/J lycra (open)
Solid
S/J lycra (open)
Solid
S/J lycra (open)
Solid
S/J lycra (open)
Solid
S/J lycra (open)
Solid
Slub/J Tube
S/J (open) Solid
S/J (open) Solid
S/J (open) Solid
S/J Tube
S/J (open) y/d Stripe
S/J Tube
S/J Tube
S/J lycra (open)
Solid
S/J (open) Solid
1/1 Rib Tube
S/J (open) Solid
S/J lycra (open)
Solid
1/1 Rib Tube
S/J lycra (open)
Solid
S/J Tube
S/J lycra (open)
Solid
S/J lycra (open)
Solid
S/J (open) Solid
S/J lycra (open)
Solid
1/1 Rib Tube
S/J (open) Solid
P.K lycra (open)
Solid
1/1 Rib Tube
F-Terry (open) Solid
S/J lycra (open)
Solid
2/2 Rib

M-Dia
38
46
42
38

R-Dia
34
46
84
34

F-Dia Remarks
37
48
85
35

34

68

71

30

66

67

34

66

67

32

66

66

30
42
32
46
26
48
46
46
48

28
41
66
46
47
45
87
41
45

31
43
68
47
47
45
88
48
46

36
32
38
34

71
60
34
67

72
60
34
68

32
38

66
34

69
36

30
42

28
41

31
43

32

66

68

46
34

42
67

44
68

32
38
34

66
34
68

69
36
69

28
38
30

66
34
67

70
33
70

30
38

63
25

68
26

G/wash

74

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3Yarn
Count

Guage

Gsm

34/CB

18

180

34/CB

24

40/CB

M-Dia

R-Dia

1/1 Rib Tube

40

36

130-140

S/J Tube

42

38

24

110-115

S/J Tube

38

34

34/CB

24

160

S/J lycra (open) Solid 34

66

34/CB

24

160

S/J lycra (open) Solid 34

66

20/CB

18

190

S/J Tube

46

46

24/CB

24

170

S/J (open) y/d Stripe

32

69

36/CB

18

180

1/1 Rib Tube

44

40

30/CB

24

150

S/J (open) y/d Stripe

44

88

34/CB

24

170

S/J lycra (open) Solid 30

59

40/CB

24

150-155

S/J lycra (open) Solid 36

71

20/CB

20

180

S/J (open) Solid

36

68

34/CB

24

130-140

S/J Tube

36

33

34/CB

24

170

S/J lycra (open) Solid 30

59

40/CB

24

155

S/J lycra (open) Solid 36

72

24/CB

24

220

P.K (open) Solid

34

43

18/CB

20

190

S/J (open) y/d Stripe

38

70

26/CB

24

150-160

S/J (open) Solid

32

65

34/CB

24

130-140

S/J (open) Solid

36

33

40/CB

24

150-160

S/J (open) Solid

32

35

34/CB

24

130-140

S/J (open) Solid

36

33

20/CB

20

180

S/J (open) Solid

38

74

34/CB

24

160

S/J lycra (open) Solid 34

66

34/CB

18

180-190

1/1 Rib Tube

38

34

40/CB

24

150-155

S/J lycra (open) Solid 34

71

130-140

S/J (open) Solid

45

34/CB75 | P 24
age

Fab/Type

48

F
D
i
a Remarks
3
7
4
2
3
6
6
8
7
0
4
7
7
0
4
0
9
0
6
2
7
5
6
8
3
4
6
1
7
3
4
4
7
0
6
7
3
6
3
7
3
6
7
4
6
7
3
6
7
1
4
6
8

75

76

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4Yarn
Count
34/CB
34/CB
34/CB

Guage
18
18
24

Gsm
180
180
130-140

40/CB

24

150-155

40/CB
34/CB

24
18

150-155
180-190

18/CB
20/CB

20
20

190
200

20/CB
34/CB
26/CB
30/CB
34/CB
26/CB
40/CB

20
24
18
18
18
24
24

190
130-140
240
210
190
150-160
155

34/CB
34/CB
20/CB

24
18
20

160
190
180

30/CB
40/CB
24/CB
20/CB

24
24
16
20

180
110-120
190
180

34/CB
40/CB

24
24

170
110-115

30/CB
40/CB

24
24

150
110-115

40/CB
30/CB

24
24

150-160
150

30/CB
26/CB

24
18

150
240

40/CB
24/CB

24
24

155
180

34/CB
40/CB

24
24

180
180

26/CB
26/CB

18
18

220
240

40/CB
77
| P a g e24
30/CB
18

110-115
200

Fab/Type
1/1 Rib Tube
1/1 Rib Tube
S/J Tube
S/J lycra (open)
Solid
S/J lycra (open)
Solid
1/1 Rib Tube
S/J (open) y/d
Stripe
S/J Tube
S/J lycra (open)
Solid
S/J Tube
2/2 Rib
1/1 Rib Tube
Slub/J Tube
S/J (open) Solid
S/J (open) Solid
S/J lycra (open)
Solid
1/1 Rib Tube
S/J (open) Solid
S/J lycra (open)
Solid
S/J Tube
Pointal Rib
S/J (open) Solid
S/J lycra (open)
Solid
Slub S/J Tube
S/J (open) y/d
Stripe
S/J Tube
S/J lycra (open)
Solid
Slub S/J Tube
S/J (open) y/d
Stripe
2/2 Rib
S/J lycra (open)
Solid
S/J (open) Solid
S/J lycra (open)
Solid
P.K lycra (open)
S/J (open) y/d
Stripe
2/2 Rib
S/J (open) y/d
Stripe
1/1 Rib Tube

M-Dia
42
44
36

R-Dia
38
40
33

F-Dia
40
40
35

32

66

69

36
38

71
34

73
35

38
30

90
32

90
32

46
48
38
34
38
38
36

87
45
25
32
34
76
72

88
45
25
32
36
79
74

34
38
34

66
34
67

71
36
68

30
40
30
34

62
36
31
62

62
39
34
63

30
42

57
40

62
43

30
40

55
39

58
45

32
42

66
43

70
43

30
38

55
25

57
26

36
32

71
66

72
67

36
30

72
67

72
68

33
38

63
25

64
26

32
42

58
40

58
40

Remarks

G/wash
P/wash

G/wash

78

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EYarn
Count
30/CB
40/CB
34/CB
34/CB
40/CB
34/CB

Guage
24
24
18
24
24
24

40/CB
24/CB
24/CB
26/CB
30/CB
20/CB
20/CB

24
24
24
24
24
20
20

30/CB

20

34/CB
30/CB
20/CB

24
24
20

40/CB

24

34/CB
34/CB

24
24

40/CB

24

34/CB
20/CB

24
20

34/CB
34/CB
40/CB
34/CB

18
24
24
24

40/CB
30/CB
26/CB

24
24
18

40/CB
34/CB
30/CB

24
24
24

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Gsm
150
110
180
160
155
170
110115
170
220
165
185
180
180
300
130140
150
180
150155
130140
170
150155
130140
180
180190
160
110
160
110115
150
165
110115
160
180

Fab/Type
s/j (open) Y/D strip
S/j tube
1/1 rib tube
s/j lycra (open solid)
s/j lycra (open solid)
s/j lycra (open solid)

M-Dia
44
46
44
34
36
30

R-Dia
89
41
40
66
71
59

F-Dia
91
49
41
71
75
61

Remarks

Slub S/J tube


S/J (open) solid
Pique tube solid
Slub S/J open
s/j lycra (open solid)
S/J (open) solid
S/J (open) solid
France Terry open
solid

30
34
34
30
30
34
34

34
68
43
63
66
62
66

39
69
45
64
66
63
67

G/wash

30

69

69

G/wash

S/J (open) solid


s/j (open) Y/D strip
S/J (open) solid

36
34
34

33
62
62

36
68
66

T-dry

s/j lycra (open solid) 34

68

71

S/J tube
S/J (open) solid

48
30

45
59

45
63

S/J (open) solid

34

68

69

S/J tube
S/J (open) solid

48
34

45
62

45
63

1/1 rib tube


s/j lycra Y/D strip
S/J tube
s/j lycra (open solid)

42
30
46
34

38
63
41
66

40
64
47
71

Slub S/J tube


s/j open Y/D strip
Slub S/J open solid

38
44
30

36
89
63

40
90
65

G/wash

Slub S/J tube


Slub S/J open solid
Slub S/J open solid

38
34
32

36
66
67

38
70
71

G/wash

T-dry

T-dry

G/wash

80

3.7.4. Cutting Process


CUTTING PROCESS
The Cutting section is running according to the following flow chart.
Finished fabric from Dyeing & Finishing
Fabric inspection
>Relaxation
>Test of GSM, Dia, Shed, Shrinkage, Twisting, Fastness etc.
>Test cutting
>Approval
>Marker making
>Fabric spreading
>Cutting
>Sorting (Sticker, Numbering)
>Bundling
>Cut panel checking
>Input section
>Send to sewing section

Fabric Inspection:

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When the fabrics are received from the dyeing and finishing section, it needs to be checked, because,
faulty fabrics can be supplied from dyeing and finishing. But the cutting section has to check it.
Otherwise the end products will be faulty.
For this, the fabric is being inspected by the quality inspector of the cutting section. They check the
fabric fully and find out the faults. Then mark it so that, these faulty portion of the fabric can be
rejected during spreading and cutting. Then the fabric is being stored for relaxation.

Fabric Relaxation:
When the fabric comes from the dyeing and finishing, the fabric remains a slightly hot. In dryer,
Stenter and compactor heat is applied on fabric. So moisture is removed from the fabric and it is not
in actual condition. But if we keep the fabric in normal temperature and pressure for a certain time,
the fabric absorbs moisture from the atmosphere and regains its original nature. This process is
called fabric relaxation.

Relaxation Period:
Fabric relaxation is performed for a certain period. This time is varied from fabric to fabric. But the
minimum time of relaxation is twelve (12) hours. This time also may vary according to the buyers
recommendation. After fabric relaxation, different tests are performed for maintaining the proper
quality.

Different Tests:
Different tests are being performed here to ensure the buyer recommended quality. Among the tests,
the important test matters are GSM, Dia, shed, shrinkage, twisting, fastness etc. These tests are
done to be sure about that the fabric quality is fare enough for maintaining garments quality.

Test Cutting & Approval:


After testing the fabric, if it is seemed that, the fabric quality is ok, and then test cutting is done. Here a
little amount of fabric is cut and sewed in sewing section. Then the garments are compared with the
approved sample. Sewing allowance and other measurements are also observed.
If everything is ok, then the approval is given and the fabric is ready for bulk production.

Spreading or Laying:
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Spreading means the smooth laying out of the fabric in superimposed layers of specific length. At Knit
Concern Ltd. spreading is carried out by the manually and mechanically both. Fabrics are laid directly
from the roll on the table. The operation begins by the laying of first fabric lay on a brown sheet
previously laid on the cutting table. This total operation is done manually by hand. The length of the
lay depends upon the quality of the fabric and length of the marker as specified by the CAD. The
height of the lay depends on the quality and thickness of the fabric and also on the condition of the
table and cutting table. After required length of fabric is laid on the table it is cut by a knife attached
with the table. The smoothness of the lay is kept by pressing the fabric with the help of a rod.

Cutting
Cutting is the operation by which fabric lay is cut with accuracy and properly to be used as different
parts of garments. The company provides straight knife and bend knife for cutting. Fabric lay are cut
rendering the outline of the parts drawn on the marker by the straight knife. Bend knifes are used to cut
more sharp corner parts like collars and cuff. Sometime hand scissors are used for cutting when some
parts are missing or lack in quality.

Numbering
After cutting the cut pieces are shorted out size and shade wise. All the components of the same size
are brought together. And they are numbered with Tokai machine or Numbering machine. This
numbering process is an important factor. As it prevents the garments parts form mix up. The sorted
pieces are now ticketed. Ticketing is the process of marking the cut components for shade matching
precision and sequence identification.

Quality Inspection & Replacement:


The numbered and ticketed parts are then passed to the quality inspection area. Here the parts are
inspected by the quality inspectors, under required conditions. Every cut parts are inspected and the
rejected ones are replaced by new fresh one. If it is possible to repair them they are repaired by hand
scissors.

Bundling:

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83

The checked components of one styles and in one size are now clubbed and bundled using ties. The size
of bundle depends upon the requirement of the production plant. Each bundle contains pieces of the
same style and same size only.

3.8.Sewing Section
SEWING:
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.

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3.8.1.Organogram

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3.8.2.Layout
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86

3.8.3. Machine Details


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87

MACHINE DETAILS:
Sewing
Descriptions
PLAIN MACHINE
OVERLOCK 4 THREAD
FLAT LOCK
KANSAI SPECIAL
BARTEK MACHINE
BUTTON HOLE
BUTTON STITCH
PICOTING
RIB CUTTER
TWO NEEDLE
SNAP BUTTON
Feed Of the Arm
Fusing machine

Origin
Japan
Japan
Japan
China
Japan
Japan
Japan
Japan
Japan
Japan
Japan
Japan
Japan

Quantity
360 PCS
368 PCS
220 PCS
7 PCS
14 PCS
17 PCS
14 PCS
10 PCS
8 PCS
8 PCS
24 PCS
4 PCS
3 pcs

Smoking

Japan

2pcs

ZigZag

Japan

1pcs

Two Needle back Tape M/c

Japan

6pcs

Chain Stitch

Japan

5pcs

Vertical Trimmer

Japan

20pcs

Operation of Sewing M/C

87 | P a g e

88

Plain sewing m/c:


R
R
R
R
R
R
R
R
R
R
R

Plackets join.
Upper placket close.
Lower placket close.
Placket 1/16 top stitch.
Placket box stitch.
Collars make.
Collar band top stitch.
Collar band make.
Collars join.
Collar top stitch with label.
Collar band join.

Tape attach at side slit.


Side slit top stitch.

Zippers join.

Zipper top stitch.

Patch label attach.

Hanger loop attach.

Pockets join.

SLV in & out side tack.

Neck in & out side tack.

Neck V tack.

Figure: Plain sewing M/C

Nose tack
1. Over lock sewing m/c:

Shoulder joins with tape.

SLV ribs attach.

SLV joins.

SLV lengths 1st side join.


Over lock sewing m/c

SLV lengths 2nd side join.

SLV joins.

Side seam.

Side seam with care label.

Side seam with placket edge over lock.


Neck rib joins.

Figure-

Elastic attach at waist belt.

g) Flat lock sewing m/c:

SLV hem.

lock sewing m/c

SLV contrast hem.


Bottom hem.

Bottom contrast hem.


Leg hem.

Hood mouth hem.

Back neck binds.

Armhole binds.

88 | P a g e

Figure- Flat

89

Armhole top stitch


Shoulder top stitch.
Wais belt top stitch

89 | P a g e

90

3.8.4. Working Procedure of Sewing Department

WORKING PROCEDURE OF SEWING DEPARTMENT

Working Procedure of sewing Department:

Sewing is an operation by which the fabric cut panels are joined together by
thread and gets the shape of a garment. Main responsibility of this department is
to stitch fabric together in a standard way that it meets the needs of a buyer as a
garment. As mentioned earlier this garment industry contains 32 sewing lines.
These production lines are equipped with sound sewing machines. All the lines are
functional and executing the function of sewing. Each line`s general structure is
more or less like bellow

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This procedure may differ with the change of product style & buyer requirement.
However for a particular style the working procedure of sewing is given bellow.

At first the production dept. receives some documents. They are:

The
style or the garment

Number of operators required of the batch for which the style has to be installed.

90 | P a g e

91

Any extra kinds of m/c s that are to be used for the particular style, target for each

day.

Breakup of the production quantity.

Input from cutting & store

After receiving all these details they send a request for the cut parts from the
cutting & sorting section & the request is sent to the accessory stores for all the
accessories that are required for the particular style then they start the production
for the new style.

Starting of layout

Before starting the proper production the production floor does a process of batch
setting for the floor which is training the operators for the new style that has to be
produced bulk, this teaching session will go on for about 3-4 days maximum.
After this batch setting process the production for the next day starts with a
smaller commitment i.e. may be for 50 pieces for the entire day then the
production gradually increases from 50100-150 & so on, this will make the
operators team slowly & precisely about the processes that has to be carried out
for the particular style.

In process quality control Sewing:

During the swing In process quality control is done by the line QCs through
7 pieces inspection system. For critical operations 100% process inspection are
carried out.

The following parameters are also checked in sewing process

a) Machine check.

b) Tension.

c) Stitch per Inch (SPI) checks

d) Needle check.

e) Cleanness.
91 | P a g e

92

Once the cut parts are received from the cutting & store section then the parts are
prepared & assembled according to the line that is planned. After the assembling
of the parts is done then there will be a line checking where the shade matching
the measurements are checked sent.

3.8.5. SEWING DEFECTS

1. Skipped Stitch: Missing in loop formation and speed variation in feed dog is the
main
cause of these defects.
2. Staggered Stitch: This type of defect occurs for thin needle. If needle size and
thread count are not matched and needle displaced then this defect also appear.
3. Unbalanced Stitch: This type of defect appears due to un-uniform thread
tension.
4.
Variable Stitch: If feed dog is not in right track then this type of defect occurs.
5. Open Stitch: This type of defects occur due to blunt needle and poor strength of
sewing
thread.

6. Needle mark: Needle is the main elements of sewing. When wrong stitching
arises then this defect arises.

92 | P a g e

93

Section

93 | P a g e

3.9.Finishing

94

3.9.1.Organogram

94 | P a g e

95

3.9.2. Layout

95 | P a g e

96

3.9.3. Finishing Process Flowchart

96 | P a g e

97

3.10. Industrial Engineering


97 | P a g e

98

Functions of Production Planning and Control (PPC) Department in


Apparel Manufacturing:

Production planning and Control department is one of the


important department for the apparel manufacturing company. In the
context of the apparel manufacturing primary roles of the Production
Planning and Control (PPC) department has been listed below. Each
functions has been explained briefly just overview about the task. To
know details about the task read related articles.

3.10.1. Discuss

According to the International Labor Organization (ILO) Hand Book, it is a term used

to embrace the techniques of method study and work measurement, which are employed to
ensure the best possible use of human and material resources in carrying out a specified
activity. It is an essential part for the mass production industries. Turag Garments and
Hosiery Mills Ltd. understands the need of work study and has set up an independent
department of work study. In some other industries this dept. is called IE or Industrial
Engineering.

Function of the Department:

Work study department has to work with many other departments as this department
gives the entire idea of the garment construction the thread & trims consumption criteria.
And also provides layout for sewing, finishing etc.

Detail activities of work study:

Style details collect

SMV make

Lay out make

M/C arrange

After production planning meeting

First week production plan

Line feeding

Work aid arrange

Method study (Innovation) take video


Time study

Line capacity find out


98 | P a g e

99

Bottle neck operation find out

Individual follow up bottle neck operation try to increase production


Capacity efficiency wish target setting try to achievement housing daily

Loss time record.

Important Terms in Work Measurement:

Standard performance Optimum rate of output achieved by a qualified worker as an


average per working day/shift, due allowance being made for the necessary time required

for rest.
Qualified worker One who has the necessary physical attributes, intelligence and
education, and has acquired the necessary skill and knowledge to carry out the work in
handto the satisfactory standards of safety, quantity and quality.
Work cycle The sequence of elements which are required to perform a job or yield a
unit
of production.

(Observed) Worker Rating The assessment of a workers rate of working relative


to the observers concept of rate corresponding to the standard pace.

Rating factor It is the multiplying unit to the standard rating which gives the
observed rating. For e.g., if the observed rating is 100, rating factor is 1; if observed
rating is 90, the rating factor is 0.9 and so on.

Basic (Normal) time It is defined as the time taken by a qualified worker to do a


piece of work at the standard rate of performance.

Relaxation allowance The additional time that is allowed to a worker for a


specified work over and above the basic time, counted as a percentage of basic time and
taken into account several factors depending upon the job.

Work content It consists of work plus allowances for rest, personal needs, and any
allowance for additional work.
other
Standard time The total time in which a job should be completed at standard

performance.

Standard time = Basic time + (Basic time x Allowance)

99 | P a g e

100

standard time is increased appropriately by a factor representing a bonus and / or policy.

Allowed time A time allowed for payment purposes to the factory worker where the

Standard minutes A standard minute (SM) expresses a unit of work in terms of the 100
BS scale. Standard performance is recognized as being 60 SMs an hour. It is different from
standard time, in that the latter includes ineffective and occupied time.

4.1. DEFINITION

4.Compliance

Compliance means conformity of certain standard. Knit Concern Ltd. Maintain a


moderate working condition for their employees. Though it is well established project, there
is some lacking of proper compliance issues.

4.2. LIST OF COMPLIANCE ISSUES

Here is the list of compliance in which some points are maintained fully and
some are partially.

Compliance for holiday

Leave with wages

Time
care

Health
register

Accident
register

Working
register

Equal
remuneration

National
festival holiday

Overtime
register

Labor
welfare

Sexual
harassment policy

Child
labor abolition policy

Anti-discrimination
policy

Working
hour policy

Environment
policy

Security
policy

Buyers
code of conduct

Canteen
100 | P a g e

101

Health and safety committee

Health:

Drinking
water at least 4.5L/day/employee

Cup
availability

Drinking
water supply

Water
available in canteen

Drinking
water vassal
at once
in a week
signs inclean
Bangla
and English
locate min. 20 feet away from work place

1
2
3
4

Fire Safety:

Toilet:

Sufficient
fire extinguisher and active

Access area without hindrance

Fire
signs in both language

Fire certainly personal photo


Emergency exit

Separate
toilet for woman & men
Aseat with proper privacy and lock facility

Urinal
accommodation
Effective water sewage system

Safety Guard:

Metal glows on good conditio


Rubber mats and ironers
First aid box one
Ironers wearing sleepers
First trained employees
Doctor
Medicine
Medicine issuing register

Others:

Room temperature
Lighting facilities

101 | P a g e

102

5.Quality assurance System


Quality Control:

The Quality assurance Department is assigned to maintain


consistently uniform quality of the material in process and various stages of
its manufacturing. Landmark Fabrics Ltd is more about concern about
quality. In this factory quality assurance is more preferred than quality
control, but both are in advancement.

Objects of Quality Control

Research.
Selection of raw materials.
Process control.
Process development.
Product testing.
Specification test

Garments Quality:

Garments quality means the garments are reasonably satisfactory


that means no problem with seam , appearance , performance, filling
,acceptable accessories.Two ways to measure the quality of garments
By testing
By inspection

Inspection:

Inspection means to test fabrics, button, sewing, thread, zipper,


measurement of garments according to desirable standard or specification
of garments . In garments manufacturing industry, there is a arrangement
of inspection in each garments section. The main object of inspection is to
rectify the faults in primary step as early as inspection such that reduction
of time
and economic.

Three stages of inspection in garments industries

1. Raw material inspection.


102 | P a g e

103

2. In-process inspection
3. Final inspection.
4. Raw material inspection:

4-point system

In this system fabric faults are identify with defects points in the scale
of 4 i.e. maximum defect point is 4. According to this system , if the total
defect parts per 100 yards of fabric are 40 or more, the fabric will be
rejected. But it may be changed according to buyers requirements. Now the
pointing system is shown below

Points of fault

Point /
Length

40p/100m

4060p/100m

6080p/100m

More than
80p/100m

Class
A
B
C
Reject

than

Fault size
0-3
3-6
6- 9
More
9
Any hole

103 | P a g e

Point
1 Point
2 Point
3 Point

4 Point
4 Point

104

Types of fabrics fault:

Slub (Major)

Knot (Major)

Missing yarn (Major)

Spot (Major)

Contamination (Major)

Weaving Fault

Thick yarn (4 point)

Stop mark

Dyeing stain

Hole (4 point)

Crease & stick mark

Jerk in
Oil Spot (4 point)

Quality control of sewing thread:

Sewing thread is an important raw materials for ready made


garments. Due to below quality sewing thread the quality of sewing
decreases and thread breakage occurs frequently. So the following
features of sewing thread should be inspected and tested before
purchasing

5. Thread
construction:

Thread count
Thread ply
Number of twists
Thread balance
Thread tenacity
Thread elongation

6. Sewability
R

In-process inspection:

Imperfections
Finish
Thread color
Package density
Winding
Yardage

Inspection
Inspection
Inspection
Inspection
Inspection

in
in
in
in
in

marker making section


fabric spreading section
fabric cutting section
fabric sewing section
pressing & finishing section

Varies defects in sewing section:

Sewing defect:
o

Needle damage
o

Skipped stitch
o

Thread breakage
o

Seam pucker
104 | P a g e

105

Wrong stitch density


Uneven stitch
Staggered stitch
Improper formed stitch
Oil spot

Seaming defect:

Wrong seam line


Twisting
Wrong matching of checks
Not matching of seam
Using of wrong stitch type
Mismatching of sewing thread shade with fabric

Assembly defect:

If finished components are not of proper size shape


If garments is of wrong size & shade
Any components attach at wrong place with out proper alignment
Wrong placement of interlining
Too light or too loose or too creased garments
Shade variation within the cloth of garments

Final inspection:

The aim of final inspection is to inspect garments from customers


point of view. The final inspection is carried out by the buyer of his
representative. Here the following points are checked

Size of garments

From fitting

Faults of apparel at first sight

Over all get-up

There is no hard and fast rule regarding this inspection. The buyer
chooses any garment for inspection at his will. But generally one garment
is inspected
out of 13. the result of inspection may be 3 different types
Garments are accepted
Garments are rejected
Garments are sent for re-audit

105 | P a g e

Quality control in sewing section


Front joint

Make Section

Collar closing

One robbing QC check

Output table checking

106

Input
section (Quality Checking):

Label measurement
Label placement
Shoulder point
Back yoke attachment
Back part
Box plate
Pocket

Make Section:

V-V measurement
Band overall
Band width
Collar point
Top stitch
Band rolling
Cuff overall measurement
Cuff rolling
Top stitch

Collar Closing:

Quality Control Finishing Section:

Size label
V-V measurement
Collar to collar band joint
Band down stitch
Shoulder joint accuracy
Sleeve length

Get up checking
Collar closing
Side seam
Sleeve placket attach
Cuff attach
Bottom hem
Back yoke
Every parts of a body

Records:

Records of
material
Records of
Records of
Records of
Records of
Records of

106 | P a g e

check list for inspection of accessories and packing


swatch cards of approved accessories
production swatch
daily QC report
cutting problem report
inspection report during sewing

6. Merchandising

107

Garment merchandising

Merchandising is one of the most important parts for garments trade. Without merchandising
this trade never be fulfilled. Merchandiser deals or handles all the things from buyer to
production. He is the center for all the tasks. After getting an order, merchandiser calculates
all the things, what he needs to complete this order & make a nice plan by which he can do the
shipment in time with buyers requirement. In factory level, merchandiser makes all the orders
for accessories need for an order like; fabric need, sewing thread, button, washing if
necessary, carton, polybag, shipment arrangement etc. Actually merchandiser makes looks on
the whole progress. Normally, the production people are always try to do work in delay, thus
many trouble can come for the shipment. But, merchandiser always makes a good follow-up
to work in time with right quantity & right quality. In the other hand, merchandiser deals with
the buyers about order approval & comments. At last, we can say that, merchandising is the
heart of garments trade. Without this garments trade is valueless. The Merchandizing is
known to the persons specially involved in garments trade. The term merchandising has been
derived from the merchandise. Merchandise means goods that are brought & sold. Garments
merchandising means buying raw materials & accessories, producing garments, maintaining
required quality level and exporting the garments within schedule time. From the above
definitions, we can say that a person involved in garments merchandising needs a wide range
of knowledge & skill to perform his job successfully.

Function of a merchandiser

When an export order is placed to a merchandiser, He or she has to schedule the

following main functions to execute the order perfectly on time:


Fabric requirement calculations

Accessories requirement calculation (e.g. thread, button, label, polybag, carton etc.)

Sourcing of yarn & fabrics & accessories.


Possible date of arrival of fabrics & accessories in the garments factory
Costing
Garments production planning with the help of production DGM.
Pre shipment inspection schedule
Shipping documents.

All the main functions, mentioned above are important but the procurement of the

fabric & accessories are most important as there are many technical parameters involved
inspecification in this area. In most collection of fabric for the garments is to collect in time
is a major problem. To procure a fabric we should clearly specify the technical specimen of
the fabric during placing a fabric supply order, the following list of points should be
considered in preparation of the contract before placing a fabric purchase order.

107 | P a g e

108

Types of Merchandiser:

Junior Merchandiser

Senior Merchandiser

Activities of a merchandiser in a factory

Sample development
Price negotiation
Order confirmation
L/C opening
Opening summery
Sourcing
Material collection
Production planning
Production monitoring
Quality assurance
Arrange shipment
Collect inventory report from store
Swatch making ,sample making & getting approval from buyer
Place order to different production unit
Collect Daily Production Report &Daily Quality Report
If any shortage in store, arrange locally.
Arrange final inspection.

Qualities of a merchandiser:

Good knowledge about fiber, yarn, fabric, dyeing, printing, finishing, dyes, color

fastness, garments production, etc.

Clear conception of the usual potential quality problems in the garments

manufacturing.

108 | P a g e

109

Good knowledge of the usual raw materials inspection systems & garments inspection

system

Knowledge of the quota system used in each of the production countries, duty rates,

custom regulation, shipping and banking documentation etc.

Right consumption knowledge of various goods

Costing knowledge of raw materials

Order getting ability

Sincere & responsible

Hard worker

Negotiation with buyers:

The most critical work is the procurement of garment export order. Normally garment

export order is found from the potential garment importers called garment buyer. Anybody
wants to collect garments export order, should be able to convince the buyer. When the buyer
is convinced about garment production, garments quality, garments costing and shipment
ability of a garments exporter, he or she can think about issuing garments export
order.Without clear confidence among buyer & exporter from both sides, may be a risky
business deal. If a garment exporter can continuously deal with only three or four buyer with
buyers satisfaction, it will be sufficient enough to run garment production & garment export
business smoothly round the year.A successful negotiation outcome does not generally occur
through luck, but by following a clear process. The process reflects the different levels of
knowledge of the subject of negotiation, various parties and the way they communicate at
various stages in the negotiation. The following is an outline of steps essential to effective
negotiation :

Costing

Costing is another important work of a merchandiser. A merchandiser has to calculate

the consumption of the buyers product and calculate the costing. In Opex costing is
calculated by their own software.

Consumption:

109 | P a g e

110

Fabric consumption calculation for basic shirts, Z = X + Y

Body part, X = (A+ 3) x (B+ 3) x2 Sq. Inch

Sleeve Part, Y = (C+ 2) x (2D+ 2) x2 Sq. Inch

Where,

A = Shirt length

B = Chest width

C = Sleeve length

D = Width of the arm hole.

Fabric consumption calculation for


Basic Trousers, P = (H+4 ) + (J+2) x 4

Where,

P = Total fabric required for trouser.

H = Height of the trouser

J = Width (Crouch length )

Consumption calculation for knitted fabric in kg per dozen (T-shirt) =


Body Length + Sleeve Length + Sewing Alowance X(Chest Width + 4
c. m)

10000000*GSM*12

Example of fabric consumption calculation

Product: Trouser

Height of the trouser = 40

Width = 13

Fabric Width = 60

110 | P a g e

111

Wastage = 5%

Fabric consumption for trouser P = (H + 4) x (J+2) x 4

c) (40+4) x (13+2) x 4 sq. inch

d) 2640 sq. inch

Fabric Length
for single
trouser =
2640/60 inch.
=44 inch.
=44/36 yds.

1.2 + (1.2 x 5%) yds

1.28 yds.

Apart these there are so many responsibilities of a merchandiser. At the end a

merchandiser takes all the responsibilities to hand over the final garments to the buyer.

111 | P a g e

Process flow chart of Merchandising

Receive product design

Price negotiation

Order confirmation and receive order sheet

Sample development

Sourcing

Material collection and receive it in factory

Sample making and approval

Pre-production meeting

Weekly production report

Arrange final inspection

Shipment

6.1. Organgram

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Maintenance

7.

Maintenance of Machine:

Maintenance of machinery is very essential mechanical effort for


achieving smooth running of different machines. Maintenance is a process
by which equipment is looked after in such a way that trouble free.
Services and increased machine life can be ensured and specific product
quality required by the customers is sustained. On time maintenance
increase m/c lifetime & ensures trouble free services.

In
Knit Concern Group two types of maintenance
1. Break Down Maintenance

2. Routine maintenance

Routine
Maintenance

Mechanical
Maintenanc
e

Electrical
Maintenance

Maintenance

Break Down
Maintenance

Mechanical
Maintenanc
e

Electrical
Maintenance

Break Down Maintenance:

Break down maintenance is done instantly when problem arises in


machine. In this case, repairs are made after the equipment is out of
order and it cannot perform its normal functions.

Routine Maintenance:

After a particular little the machines are cleaned & reordered, that is
routine or schedule maintenance. PPC does it once in a month. Schedule
maintenance varies, time in time & also depends on situation according to
types of machines, because maintenance is directly related to production.
Most of the time, all the screws, nuts, bolts & levers are checked,
lubrication is also done. Workers inform about the problem areas of the
machines. Depending on their information, maintenance is done.
Maintainers analyses the machine records & take steps according to
requirements.

Maintenance procedure:

1. Here standard system is to service a machine once per 15 days. But it


is
month.
done once per
2. Some machine needed to oil in oil tank. In that case. A pump once
per two month
changes oil.

Machine
that have rotary hook are oiled once per week.

3. At first the service system of machine is written on the machine


log card with
machines remarks & next schedule.
4. To confirm the document is also registered on a register in
each floor.
5. Trouble form is also filled-up in each floor.

Oiling & servicing:

Machine Name

1. Single needle/ plain m/c

2.over lock

3. F/L m/c

4. kansi

5.Feed of the arm

Oil
change/month

7 days

Service/ month

6. button whole

General M/C problem:

The
following problem to be changed

Gap stitch
Tension
Needle defective
Oil spot
SPI (up date change)
Set change
Measurement change
Parts change
Thread change
Fabric change

Maintenance Tools & Equipments

Tools / Equipment

Combination tools / spanner


Socket ratchet set

Slide range

Monkey pliers
Pipe threat cutting tool

Bearing puller

Pipe range
Pipe cutting tools
Hole punch

Divider
Easy opener
External threat die
Heavy scissor
Oil can
Drill machine and drill bit

Grease gun
Grinding m/c

Function

Tightening & loosening of nuts


& bolts.

Tightening of nuts & bolts.

Tightening & loosening of nuts


& bolts.

Tightening & loosening of nuts


& bolts

To cut the threat in pipe.

To assist the opening of bearing


from shaft

Tightening & loosening of pipe


joint

For pipe cutting.

Punching the hole.

For circle marking on metal &


wood

To open the broken head bolt.

For external threat cutting.

Cutting of gasket & steel sheet.

Oiling of moving parts

For drilling.

For greasing of moving parts of


m/c.

For grinding & cutting of mild

Welding m/c
Spirit leveler
File
Hammer
Circlip tools
Hacksaw blade
Handsaw

steel.

For welding & cutting

For perfect leveling.

For smoothing the surface

For scaling & right angling.

Circlip opening & closing

For metal cutting.

For wood cutting.

Remarks

Maintenance of m/cs are very essential to prolong the m/c life and
good maintenance is important consideration. It is necessary to check that
all routine maintenance is being done regularly and properly otherwise
efficiency of each department will be reduced.

Section

8. Utility

Major Utilities Used In KCL Dyeing Are:

Water

Electricity
Steam

Compressed
Air

Effluent treatment plant

WATER

The major concern for any kind of wet process industry is


Water because it is the quality of water which determines the
quality of dyeing. Water quality generally vary in different
areas, also depends on the level or height of water level
beneath the ground. In Narayangonj water level is around 130140 ft but Knit Concern dyeing water is lifted from about 600 ft
deep by submergible pumps.

There are three pump units available here

1. Knit Dyeing 3 pumps


2. Yarn Dyeing 2 pumps
Printing 2 pumps

Knit dyeing Yarn dyeing -

Hardness

<70

<50

8-9

pH

Quality of water required for Dyeing:

Iron content
0.02 ppm

0.02 ppm

<500 5-7
TDS

<500

Quality of Water found in the raw water here total Hardness 250-300 ppm

Water Treatment Plant:

Three Water Treatment Plants in Knit concern.

Plant 1&2 : KCL Knit dyeing Capacity 250000 lit/hr

Plant
3:
KCL Yarn dyeing Capacity 150000 lit/hr

In plant 1&2:
Treated water Reserve tank capacity 960000

Raw water tank capacity 288222 lit & 660000 lit


Plant Description: Demineralization by Resin treatment

lit

Three vessels system


Vessel 1 Multi-Grade Filter (MGF) For Iron Removal
Vessel 2 Activated Carbon Filter (ACF) For TDS removal
Vessel 3 Softener Filter (SF -Resin) For Hardness removal

PH
6.

6.

distribution system:

By booster pump treated water is supplied to the


dyeing m/c pipe line, where, 4 kg pressure is always kept
constant by automatic controlling of booster pumps. Total 3
sets of booster pumps each contain 6 pumps.

Water is drawn by the m/c by centrifugal pumps.

STEAM BOILER

Steam:

Steam is an important utility for dyeing section. Steam


produced by the boiler Supply water is simply treated in the
boiler section by the two softener tank Then water reserves to
the feed water tank & this feed water tank warms the water
Then water passes to the boiler which produces steam & that
steam
supplies to the factory . Main parts of the boiler :

Gas
Chamber
Blower
-Gauge
glass

Safety valve

Burner

No
of boiler
Type of
boiler
Brand
Capacity
Fuel
Steam
Consu
mptio
n
Steam
Bo
ile
r

:
03

: Horizontal, Fire tube boiler :LOOSE


INTERNATIONAL
(Germany) : 10 ton/hr

: natural gas,Diesel.

: 2300 kg/hr for 1200-1500 products. :


7-8 bar

: 3-4 bar

: 180-190C :
300C

: For antiscalant,Tandex SD 15
Tandex
BWS Tandex BWT

For Wash, Sulphuric acid+Para


sulphates+Caustic+Nelbross+Nalco Feed water
Quality
: pH 7-8

TDS 430-530
Hardness
- <2 ppm

Power Consumption : 40

ELECTRICITY/GENERATOR

Total

Generator: 4
Types : Diesel Generator CAT (USA) capacity 1710 KW

Gas Generator WAVKESHA Capacity 1100 KW (2) & 900 KW

Total Requirement 2-2.5 MW/day (3500-4000 kAmp current)

Total
Output of Three Gas generators 2100-2500 kw
Pressure
required for Gas generators 222 kpa for 1100 kw & 145 kpa for

900 kw.
Line Pressure 13 to max 145 kpa

Comressed Air/Compressor

Natural gas is drawn by pipe through the filter above the


compressor & the air is compressed. In such a case the air
becomes slightly hot. Hence cold water is drawn to reduce the
temperature of compressed air. Thus the cold water becomes
121

slightly hot & goes through outlet pipe to the overhead


reservoir. Then the water falls slowly through a compressed air
along with some vapors are transferred to the reservoir where
the vapours
are condensed & outlets drop by drop.

The moist compressed air is transferred to the dryer& a


slight warm compressed air is delivered to require sections of
KCL.

Source :
Natural Air
M/CName:
Compressor

Brand:BOGG
E (Germany)
CECATTO (ITALY)
No
of m/c : 04

Capacity :
27,0001/hr, 1800 1/hr.
Unloading pressure :
7.2bar

Loading pressure : 5.6 bar

Chemical Used: Grease, Oil AMERIL

Effluent

Treatment Plant

Type Of Plant Biological


Approximate Area 20 katha
Set up completed by Italian Technology

Project Description:

Tank/Unit

1
.
Screen Brush

2
.
Lifting Pump Unit

3
.
Storage & Homogenizing Tank

4
.

Function

Big particle & materials remover.

Automatic flow lifter with levelsensored pumps.

mixing by air circulation reduce


temperature

convert dissolved particles into


suspension

storing for 24 hrs

pH 11-12

Nutralization tank

to nutralize the alkalinity by dozing


sulphuric acid (98%)
122

5
.

6
.

Distributor tank

Passes & store the nutralized


effluent water.

Sludge return

7
.

8
.

different types of micro-organisms


are cultured.

Suspendation of effluents Destroy


toxic chemicals

Separate organic, inorganic &


synthesized

particles.

Dye particles are eaten by microorganisms

pH 7-8.5

Sedimentation feeding tank

Decolration of existing color


particles & feed to

sedimentation curve.

Biological & Oxidation Tank

Sedimentation curve

9. Sludge return pump slump

10. Sludge thickener

pH 7-9

Three section
-separator

-clarifier

-scrapping bridge

Sludge is thikened & resedue


passed into

distributor tank.

Sludge condensed & made cake.

Chemical used in different Section:

Ant

ifoam
Biological tank

De

Sedimentation

colorant
feeding tank.

Nut

rient Salt

(Urea
& TSP)
Biological Tank

Polyel Sludge

ectrolyte Thikener

Sulphu Nutralization

ric acid tank

Na(
Biological tank

123

OCl) Function of different chemicals:

98% H2S04
-Neutralize the water by controlling pH

-It is auto dispensed in the neutralization tank.

Polyelectrolyte -Used for sedimentation/sludge coagulation


- It is used auto/manually in sludge thickener tank.

Decolorant
-Used for removing color.
-It is used auto/manually in sludge thickener tank.

Anti-foaming agent -Used for reducing/controlling foam.


-It is used auto/manually in the oxidation tank.

Sodium hypochlorite -It is used to killing harmful bacteria/insect.

-It is used in the Biological Oxidation tank.

Nutrients
-when bacteria become weak it is added to a certain
quantity

-It is added in the oxidation tank.

Activities

9. Marketing

124

Marketing :

Marketing plays a vital role in the field of


displaying/showing the good criteria of the products to the
buyer & to communicate with the buyer .there about 30
people in the marketing section of the industry.

Marketing Strategy:

Marketing strategy is a very important factors to sale the products to


the buyers If the marketing strategy Is not so developed it will be very hard
to reach the goal In case of garments marketing the dealings with the buyer
is a very important factor. Mainly senior marketing officers, merchandisers &
higher officials deal with the buyer there are some fixed buyers of the
125

industry. The buyers give their orders continuously all over the year. The
Marketing officers & by both side understanding the rate & the order
quantity are fixed. Duties & Responsibilities Of Marketing Officer: Dealing
with the buyer & convince the buyer is the main duty of the marketing
officer. A marketing officer has some also other duties The main duties &
responsibilities
of a marketing officer are given below :

To prepare cost sheet by dealing with buyer.

To
take different steps by discussing with the high officials &

merchandisers .

To
maintain a regular & good relationship between commercial officers

& Merchandisers

To
maintain a regular communication with the buyers & buying

houses .

Communicate with the new buyers .

Display the better criteria of the products .

Actually the responsibilities & duties of marketing officer begins from


getting order of buyer & ends after receiving goods by the buyer So he
should be always smart energetic & sincere.

IMPORTING COUNTRIES:

KNIT CONCERN LTD. is a 100% export oriented industry.


All the goods produce in this industry are exported to various
country
.

Europe Countries like UK France Germany etc.


U.S.A.

Japan

Product Label:

Product label differs from fabric to fabric. The product


labels are prepared according to the quality & the buyer
requirements .

Local Market:

KNIT CONCERN LTD is a 100% export oriented industry. All the


goods produced in this industry are exported into various foreign
countries . So, goods are not supplied into local market.

Marketing Strategy:

Marketing strategy is a very important factors to sale the


products to the buyer. If the marketing strategy is not so developed , it
will be very hard to reach the goal . In case of garments marketing the
dealings with the buyer is a very important factor . In KNIT CONCERN
LTD. mainly senior marketing officers, merchandiser & higher officials
126

deal with the buyer . There are some fixed buyers of the industry. The
buyers give their orders continuously all over the year . The marketing
officers & the merchandisers communicate with the buying houses to
collect the orders. By both side understanding the rate & the order
quantity are fixed.

BUYER:

KCL is 100 % export oriented industry. All the goods produced in this
industry are exported into various foreign countries. Name of the main
buyers
of this mill are given below:

H&M


OKAIIDI

CAMAIEU

CARREFOUR

JULES

DECATHLON

SPRIT

QUICK SILVER

BIZBEE

KNIT LINE

S.OLIVER

AMS INTERNATIONAL

RIPCURL

BETTER BARCLAY

REMARKS:

KCL has a well learned marketing & merchandising team. They always
communicate with the buyers KCL has some fixed buyers The marketing
section also looks for the quality & quantity of buyers .

10. Conclusion

127

We have completed our industrial attachment successfully by the


grace of Almightyn Allah. Industrial attachment will give us our expected
destiny of practical life .By the completion of two months of Industrial
attachment at KNIT CONCERN LIMITED, we have got the impression that the
factory is one of the most modern export oriented knit composite in
Bangladesh. Though it was established only a few years ago ,it has earned "
very good reputations " for its best performance over many other export
oriented textile mills . Mill is settled with utility to give all convenient
supports to the productions for twentyfour hours . KCL has its own water
pre-treatment plant & 26,300 cubic feet water reservoirs in its Godnail
campus .The Godnail premises has its own power generation plant where
1,900 kw power generators guarantee smooth & uninterrupted power

128

supply to its every operation . However there are some points to be


mentioned :

During the transportation of the fabric on the dyeing floor & also
during the loading of the machine, fabrics are soiled by the contact with
floor. This makes the fabric/part of the fabric dirty. It may require more
scouring/bleaching agent or may create stain making it faulty.

OUR APOLOGY :

The management of KCL were very helpful &our respective seniors


gave us time
whenever they got .

Due to secrecy act, all the data on costing & marketing activities has
not been supplied
& hence this report excludes these chapters.
Some of the points in different chapter are not described as these were
not available.
The whole process is not possible to bind in such a small frame as
this report, hence
our effort spent on summarizing them.
But it must be said that KCL is a best place to get the practical
knowledge about the dyeing as they have a lot of production of all
quality.

AT THE END :

We are enough fortunate that we have got an opportunity of having a


training in this mill .During the training period we have received cooperation & association from the authority full & found all man , machines &
materials on appreciable working condition. All staffs & officers were very
sincere & devoted to their duties to achieve their goal . Special Thanks to
those whom we are so grateful - -
1. Md. Kamruzzaman khan (Zaman), Director Merchandising,
2. Mr.Nasim Ahmed, GM Garments,
3. (Anamul Bahar Babu), DGM Garments,
4. Abdul
Awal Shohel, Sr. Manager, HRD, Admin & Compliance,
5. Mr. Aziz,
Manager, HRD,

6. Engr.Shimul ( P.O. Knit dyeing)


7. Engr.
Sonod (P.O Knit finishing)
8. Engr. Mahabub (P.O Knit dyeing)
9. Engr. Antu (P.O Knit dyeing)
10. Engr. Nahid (P.O Knit dyeing)
13. Engr. Shoibal (P.O Yarn Dyeing)
14. All other personnel who helped us lot to learn so many things.

129

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