WOLEGAA

WOLKITE UNIVERSITY
COLLEGE OF ENGINEERING AND TECHINOLOGY

ADAMAGARMENT INDUSTRY INTERNET SHIP FINALE REPOR
DONE BY TEMESGEN DEREJE
IDNO 361/0
ADVISER: MUSTAFA ABAS
Date October-18/10/2016
ADAMA GARMENT INDUSTRY 2016
PREPARED BY TEMESGEN DEREJE ID NO 361/05 Page ii

DECLARETION
I am 4th year garment engineering student in Wolkite university college of engineering
and technology I declare that this project work is my own work and I have not used any
of others idea the origin is my mind. Thus to use this project work as reference it is
obligated to mention the author of this title and all rights reserved so I approved my
project by my signature
Mustafa Abas_______ _____________ ___________

Name of academic advisor Signature Date
Temesgen Dereje ______________ __________

Student done signature date
PREPARED BY TEMESGEN DEREJE ID NO 361/05 Page iii

Acknowledgement
First, I want to praise God for helping me in this report and in general for the knowledge
and strength he offered me in my life time. Special thanks to Wolkite University College
of Engineering and Technology all so, garment Engineering Department, for giving me
the chance to have an experience on the practical work and getting better skills with
theoretical knowledge.
It is also my pleasure to thanks production manager Ato Girma Atinawu as well as Ato
Taye Tafese forgiving me fully information And also his day to day supervision, sharing
his experience & advice in my future endeavour and I would like to say thank all the
workers of the company especial operator who have long experience w r Zenebwork
Sebsebe sharing her deep experience and all so I would say thanks my advisor
MUSTEFA ABAS he shows me the direction of my projectFinally, I would like to give
my heartfelt appreciation to my family and friends for their encouragement, tolerance and
endless support throughout my stay in the internship program.
PREPARED BY TEMESGEN DEREJE ID NO 361/05 Page iv

Executive summary
This final internship report covers my four months stay in Adama garment industry. From
March, 2016up to June, 2016It is a clear fact that the knowledge of garment engineering
cannot be upgraded without practical experience in each field of the subject matter. This
paper is a written report about the internship program. This report is about the
background of our hosting company including its history and major achievements, our
overall internship experience, tasks and the procedures we followed, the practical and
theoretical knowledge we gained including the challenges we faced while performing
those tasks.
The contents of the report have been divided into four chapters and the topics covered
include the company background, our overall internship experience, and the benefits we
gained from the program, our conclusions and recommendations for the company. To
help anyone reading this report better understands the discussed topics and ideas,
figurative illustrations and samples of works and different report formats which are
attached at the middle of the topics. Generally, this internship practice enlightened me
with different theoretical and practical know-how’s. Chapter one is about background of
my hoisting company. Here brief history of the company; its vision, Mission objective
core business organization structure main products of the company .suppliers, customers,
and utilities and other important information of the company are included. Chapter two
discusses about a my project work which I have done on minimization of time wastage
through layout change The project contains project title, project statement, objective of
the project, methodology, identified problems and their solutions and conclusion and
recommendations. Chapter three presents about my experience and my work tasks I
performed during the four-month internship program. There are points, which has been
facing when I am performing my work tasks what measures I have taken to those
problems and benefits I have gained from my internship program. The benefits are
explained briefly in this chapter. Chapter4 conclusion and recommendations that I
recommend to the intern ship experience and the references I used are written at the end
of this project report.
PREPARED BY TEMESGEN DEREJE ID NO 361/05 Page v

PREPARED BY TEMESGEN DEREJE ID NO 361/05 Page vi

CONTENTS
DECLARETION .................................................................................................................................. iii
ACKNOWLEDGEMENT ..................................................................................................................... iv
EXECUTIVE SUMMARY...................................................................................................................... v
CHAPTER ONE .................................................................................................................................. 3
1 BACK GROUND OFCOMPANY ....................................................................................................... 3
1.1 INTRODUCTION ......................................................................................................................... 3
1.1.1VISION OF ADAMA GARMENT ................................................................................................. 4
1.1.2MISSION................................................................................................................................... 4
1.1.3 OBJECTIVES ............................................................................................................................. 5
1.1.4 CORE BUSINESS ADAMA GARMENT ....................................................................................... 5
1.1.5 CORE VALUES OF THE COMPANY ........................................................................................... 5
1.2 ORGANIZATION STRUCTURE OF ADAMA ARMY FOUNDATION: ............................................... 8
1.3 PROCESS FLOW OF GARMENT PRODUCTION IN ADAMA ....................................................... 10
1.4 MACHINE AVAILABLE IN ADAMA GARMENT INDUSTRY ......................................................... 19
1.5 MAIN PRODUCTS IN ADAMA GARMENT INDUSTRY (AGI)....................................................... 22
1.6 PRODUCT VARIETY IN ADAMA GARMENT ............................................................................... 24
1.7 TIME STUDY ........................................................................................................................... 26
CHAPTERTWO............................................................................................................35
2.0 MINIMIZATION OF TIME WASTAGE BY LAYOUT CHANGE..................... 34
2 .1 ABSTRACT ........................................................................................................... 34
2.1.1 INTRODUCTION ............................................................................................... 34
2.1.2 GENERAL OBJECTIVE OF TITLE .................................................................. 34
2.1.3 SPECIFIC OBJECTIVE ...................................................................................... 34
2.1.4 STATEMENT OF PROBLEM ............................................................................ 34

2.1.5. METHODLOGY ................................................................................................ 36
2.1.6 CALCULATION ..................................................Error! Bookmark not defined.
2.1.7 RECOMMENDATION .......................................Error! Bookmark not defined.
2.1.8 CONCLUSIONS.................................................................................................. 42
3. BENEFITS FROM INTERNSHIP EXPEIENCE ............................................................. 44
3.1BENEFITS I GAINED FROM INTERNSHIPS .............................................................. 44
REFERENCES........................................................................................................45
PREPARED BY TEMESGEN DEREJE ID NO 361/05 Page 2

CHAPTER ONE
1 BACK GROUND OFCOMPANY

1.1 Introduction
Adama garment industry is found east Ethiopia that was established in 1980E.C and It is
located about 105km away from Addis Ababa on the centre of Adama to Wangi Town
and occupies 113,500sq.mts. the administrational history of the Industry from 1980 E .C
up to now is as follows; from 1980-1989E.c under the commission of Defences and
engineering industry, from 1990-1994 E .C under the metal agency, from 1995-2001E.c
under metal and Engineering Corporation under the title name of “metal and engineering
CorporationAdama Garment Industry from 2002E.c up to now under army foundation
and The title name of” army foundation Adama Garment Industry. This industry has four
branches of factory namely, heavy duty, Garment Sewing Section, Parachute and drag
hut section and small parts sewing section. To produce 85% of military
Related products and 15% commercial products. But the parachute and drag hut section is
not functional at the time being due to the scarcity of raw materials. This factory is the
only industry that supplies tents to united nation to all peacekeeping force of Africa
deployed by united nation.

1.1.1 VISION OF ADAMA GARMENT
The vision of Adama garment industry is to see the industry as leading a model garment
industry and to be competitive on east African market. which plays important in garment
industry sector and garment engineering skill centre creating national industrial
technology to be competent on the given field and sell products in the reasonable price
and quality to domestic and international customer obtain good feedback by selling
different product to the market, conducting research and development work, create
collaboration with different organization and introduce new and technological
achievement to the country.
1.1.2 MISSION
Creating national industrial technology net work is competent on the given field and sell
products in reasonable price and quality to the domestic and East African market To see
the industry as leading model which plays important role in Garment Industry Sector and
Garment Engineering skill centres. Creating national industry technology to be competent
on the given field and sell Products in reasonable price and quality to domestic and
international customers. Obtain hard currency by selling different products to the market
Conducting researches and development work. Create collaboration with different

organizations and introduce new technologicalAchievements to the country. Obtain hard

currency by selling different garment products to the market. Creating international and
national partnership with different organizations and facilitate transfer to the
1.1.3 OBJECTIVES
Develop technologies that satisfy armed force garment and military requirement at the
desire time and place perform engineering activities that support garment industries.
1.1.4 CORE BUSINESS ADAMA GARMENT
Manufacturing and selling military garment products and giving service for our militar
1.1.5 CORE VALUES OF THE COMPANY

The factory have different prospective such as work core values , work philosophy ,
systematic core values , Organizational work culture and have the following core values:
Everything we work is by our plain. Our workers are the main resources for the industry
The first target in our industry is to satisfy our customer corruption is the main challenge
for development Team work is our culture Improvement is the growth for our
development Honesty, industriousness good work habit and open mindedness are the best
features of our work.
LOCAL CUSTOMER OF ADAMA GARMENT:

Adama garment industries are many customers why because of its produce for all
Ethiopian military army and have foreign country
 Oromia police
 Southern Ethiopia Police College
 Dire Dawa police commotions
 Arm foundation
 Federal police
 Wangi sugar factory
 Matahar sugar factor
 Federal police
 Military collages

 Military defense logistic
 Military Defense Foundation
 Sebeta Garment engineering
 Dijon aviation industry
 Beshoftu automotive industry
 Power engineering industry
 Adama agriculture machinery production industry
ADAMA FOREIGN CUSTOMERS
 Somalia
 Djibouti
 Sudan
WORKER IN ADAMA GARMENT INDUSTRY
The total worker in Adama garment s has 1000 workers among this
Sewing room + cutting room + finishing room+ supporters =750
Office worker=211
Nursing=4
Gourd=10
Cafeteria worker=25
Area of the company
ROW MATERIAL USED IN AGI
 100%cotton fabric
 PC (polyester cotton blend) fabric
 Polyester blend fabric
 Teheran 6000 fabric

ACCESSORY USED IN ADAMA GARMENT
 Eyelet with washer thread

 Two holes &three holes metals End clip
 Buckle hook spring
 End clip pool bag
 Hook spring snap button
 Canvas olive polyester thread
 Zipper blue pen
 Button

1.2 ORGANIZATION STRUCTURE OF ADAMA ARMY FOUNDATION:
General manger
Assistance
Assistance
manger
manger Commerce
Production department
Department
Administration& finance
Design development department
research
Cutting room Administration division Sale &market Purchase

research research Research research
Human resource
Sewing department
management
research Quality
research
Line supervisor
supervi
Finishing &packing
sor
research Clinic service
research
Guard

ORIGANAZETION CHART
NO NAME Responsibility of organization

1 General manger controls the overall activities of the company
2 Production Managing the production
manager
3 Commerce
Department
4 Sale& market Control goals and study cost/price of product and promotion of
products.
5 Purchase
6 Administration controls and supply payment custom clearance/cost analysis
&finance
department
7 Human resource Identify the amount of worker and employing
management
8 Line supervisor Transfer of product from operatory to operatory
9 Cutting cutting & spreading fabric according to necessary & supervisor
&spreading all activity in this room
department
supervisor
10 Administration
division
11 Finishing Checking the product according to the size and colure
&packing
supervisor
12 Quality supervisor Kipping the quality of products
13 Clinic service Giving service for worker
14 Gourde Kipping security

1.3 PROCESS FLOW OF GARMENT PRODUCTION IN ADAMA
Order received Design/sketchi Sample making

ng
Spreading Marker making Production
section pattern
Sewing section On line inspection

Cutting&
bundling
Final Ironing Trimming

inspection
Packing Dispatch
GARMENT PRODUCTION
Store room: Store is a place where raw materials, accessories, work aids, finished goods
and machineries are placed
Design: is knighting sketch of one product at ways to need and all so sketching is normal
either computer or manual sketch of a give products. Function of sketching: the function
of sketching is to give full information about the products or representing of one object.
In Adama garment industry sketching are by manual on hared paper sketcher by
Yearusewake Beru
Pattern making: is a basis for analyzing, interpreting and realizing the designer ideas or
sketches in the actual garment product .Values of pattern making are to get strictly
measurement, minimize of fabric wastage and for fit and balance of the body. So in
Adama garment pattern making are according to customary order by manual ways on the
hared paper by designer hade ato beniyam kebede.

Sample making: is ways of giving fully information for customer or express of one
product to customary. The need of this sample making is way of gating fed back on
customer, so in Adama garment industry sample making are done in pattern room.
Fig sample room
Marker making: is the process of determining the most efficient layout of pattern pieces
for specified style, fabric, and distribution of sizes (requires time, skill and concentration)
Marker making is one of the carefully doing in garment why b/c of when one fabric
wrong marker done its obtunds great problem (its product in mass) so marker making
need deep skilled. And in Adama marker making system is nap one way (NOW).its use
for space consumption
Spreading: before spreading the raw material came from store rooms Spreading is the
process of rolling out layer after layer of cloth, smoothly without wrinkles in Adama
heavy duty we seen that, a worker are spread of knave by manual. in this section the
spreading table area 1.8*13m2 and number of layer are depend on the worker (spreader)
may be 80 layer same time 60 layer and the most of time depend on type of fabric either
woven or knitted the spreading ways are worker out stand aligning side to side in terms of
speed and minimize of wastage all so give the good products. What we advice to heavy
duty section is that, spreading and cutting head please try to put as such place which has
knowledge about spreading and cutting

Fig 1 1 Spreading table

Cutting: is a process of cutting fabric into necessary pattern shapes. Is the first stage of
garment manufacturing. Under this, the cutter depends on the marker and time for
straight cutting is straight cutting machine. Garment production starts with the cutting
process. In this process, fabric is being cut into components (shapes or patterns of
different garment parts). In mass production, multiple layers of fabrics are laid on a table
and large number of garments is being cut at a time. The laid fabric stack is called as lay
in Adama garment industry cutting system is manual and amount of worker is eight
among two is spreader and the left are kipping the side of fabrics the machine availability
in cutting room generally in Adama garment around 10 machine and the of head cutting
&spreading is Ato Getu
Process sequence in cutting room
Offloading (cleaning table) Marker making Spreading fabric with required
sizes
Placing marker paper on the table Ironing plot paper by using flat iron Fabric cut
Checking size part Sorting and bundling

Fig Straight knife Fig band knife
Fig drillings machine

Sewing section
This is the largest section of the floor which covers about 65% of the total floor. From the
total area of sewing section 80% is occupied by sewing machines lines and the other 20%
occupied by other machines and free space the one sewing line but the machines are
arranged in four lines including special machines are found. Sewing is one of the
measure areas of garments so; sewing is the process of construction of one garment and
Sewing is heart of garment. In Adama garment industry there is 750sewing machine in
heavy duty among this 300single needle 250 in garment sewing section the left are 200
are in parachute drug store and they have four line each line have40 operators the
manufacturing system heave duty are progressive bundle system that means production
system are sequentially (it may goes us one operators to another operators) capacity
operator per day a and each line produce all sewing line dominated by Mr. Lemma
Fig 1 3 sewing room
Finishing section: - The first work is trimming the thread from the finished products and
goes to inspection table to inspect those inspected threads and if the problem is occurring
they work again. After inspection neck pressing operations and buttoning then passes
through ironing and inserting butterfly on neck band and back and poly packaging by
inserting labels and those packaged in the carton and transported temporary store. There
are 12 ironing machines in this section and these machines responsible for its work
during inline process and after production.

Trimming: this operation removes extra and unnecessary protruded threads from the
finished or unfinished production.
Inspection: the final garments or finished products checked for quality and to see
whether production made according to order and all errors corrected here.
Final Ironing: this is used to straighten the finished products and to increase
attractiveness of the finished product and to provide desired shape for the finished
products.
Match and Packing: The last operation section pack items using plastic bag branded
with company name, labels and other desired information manager that take order..
Dispatching: it’s simple ready for exports/ to customer
Storeroom: In this store, there are available different types of woven and knitted fabric.
In addition, found non-woven material and other accessories. In Adama garment raw
material is set in storeroom and production system are pull system.
Embroidery machine
There are three embroidery machine .two of them has18 head machine and one has 15
head machine. Embroidery and screen-printing are two processes that occur only if
directly specified by the customer; therefore, these processes are commonly sub
contracted to off-site facilities. Embroidery is performed using automated equipment,
often with many machines concurrently embroidering the same pattern on multiple
garments. Each production line may include between 15 and 18 embroidery stations or
head at a time. Customers may request embroidery to put logos or other embellishments
on garments.
Printing
Screen-printing is the process of applying paint-based graphics to fabric using Presses
and textile dryers. Specifically, screen-printing involves sweeping a rubber blade across a
porous Screen, transferring ink through a stencil and onto the fabric. The screen-printed
pieces of fabric then dried to set the ink. This process may have varying levels of;screen-
printing is wholly determined by the customer and may be requested to put logos or other
graphics on garments or to print brand and size information in place of affixing tags

Process flow in table
SNO Operatio Job method Name of

n super
father
1 Design/sk It is given by Manual/Computerized Bin yam
etcher buyers to
manufacturers co
nge sketches
including
measurements of
particular styles
2 Basic Basic block is an Manual/computerized

block individual Bin yam
component of
garments without
any style of
design (without
Allowance, Style,
Design)
3 Working When a pattern is Manual/Compu W
pattern made for a terized r.
particular style A
with net ri
dimension se
regarding the
basic block along
with allowance
then it is called
working pattern.
Sample To make a Manual Bi
garment sample, this will n

be approved by ya
buyer. After m
making a sample,
it is sent to buyer
for approval to
rectify the faults
5 Approve After rectify the Manual

sample faults, sample is
again sent to
buyers. If it is ok
then , then it is
called approved
sample
6 Productio Making Manual
n pattern allowance with
net dimension for
bulk production
7 Grading If the buyer Manual/comput
requires different erized
sizes, so should
be grade as S, M,
L, XL, XXL
8 Marker Marker is a Manual/comput Getu
making thin paper erized
which
contains all
the
component
s for
different
sizes for a

particular
style of
garments
9 Fabric To spread the Manual/comput Getu
spreading fabrics on table erized
properly for
cutting
1 Cutting To cut fabric Manual/comput Getu
0 according to erized
marker
dimension
1 Sorting& Sort out the Manual Getu
1 bundling fabric according
to size and for
each size make in
individual
bundles
1 Sewing To assemble a Manual Lammi
2 full garments
1 Ironing & After sewing we Manual Kabso
3 finishing will geta
complete
garment which is
treated with
steam ironing &
also several
finishing
processes are
done for example
extra loose thread
cutting
1 Inspection Should be Manual Yomeyu
4 approved as

initial sample
15 Packing Treated by Manual Ebisa
Polyethylene bag
16 Cartooning After packing, it Manual Senaa
should be placed
In cartooning for
export
17 Dispatching Ready for export Manual Gada
1.4 MACHINE AVAILABLE IN ADAMA GARMENT INDUSTRY
No REG-code Machine name Modal No Quantity

1 1703-01 Single needle mistubush LU2-400 117
2 1703-108 Single needle typical GC5550 3
3 1703-127 Cloth drill(ETWA) PR157 2
4 - Cloth drill(bast man) BS-201 3
5 - cloth cutting machine Escort 8
6 1703-08 Grommets machine electrical - 3
7 - Grommets machine manual - 1
8 1703-38 Selling machine packing machine ARSH-500 2
9 1703-09 Brather single needle DB2-B755 30
10 1703-124 Juki double needle LUH-521 16
11 1703-116 Sun star single needle KM-560 22
12 - ZOJE single needle ZJ0302CX 11
13 - ZoJE single needle ZJ9701_5_D3-PF 5
14 1703-03 Brother bartacker LK3-434-T48 6
15 - JUKI bartacker LK-1900A-HS 6
16 1703-41 Pegasus over lock LS2-01 3
17 1703-07 Snap fasting machine AMP-20/NP 3
18 1703-34 Portable bag clothier - 2
19 1703 Single zigzag 4
20 1703 Seal packing LS2-10 2

21 1703 Mis ZOIJE LK4-03 5

22 1703 ZOIE zigzag TM4-032 7
23 Total machine 261
MACHINE AVAILABILITY IN Parachute & Drag hut factory

S no rig cod Machine name model Quantity
1 1703-17 Band knife Dbk -D 1
2 Single needle mist bush LU2-400 1
3 >>>>>> >>>> 1
4 Sing needle sun star kM-560 1
5 Single needle typical GC5550 1
6 Single needle typical 1
7 Single needle brother DB2-B755 28
8 Jack single needle KJK8700 3
9 ZoJE zigzag ZJ457B 7
10 Gems’ over Locke ZJ22905-sR 1
11 Double needle ZoJE GEM757f-XH 5
12 Waste band ZOJE Zj8750-5 1
13 Single needle spelt parser foot Zj8750-5 2
ZOJE
14 MS-ZOJE ZJ 928-PL 3
15 Electrical steam BOILER ALBA Dol-2 1
16 Electrical steam BOILER ALBA Dol-2 1
with ROTO 500L
17 Form finishing m/c(ALBA) CO3 1
18 Trouser topper horizontal ALBA CO1 1
19 Gemmy button attach Gem 1108 1
20 Brother button attach Lk3-B438-2 1
21 Portable NP-7A 1
22 JUKI double needle LH-3128 1
23 ZOJE ZJ9610 2
24 Pegasus over Locke L52-01 1

24 Juki button hole LBH-781 1

Total machine
MACHINE AVAILABILITY IN GARMENT SECTION

S no Re cod Machine name model Quantity
1 1703-55 single needle JK-8700 44
2 1703-34 ZJ970IRD3/PE 47
3 1703-44 Single needle juki DDL-8300N 8
4 1703-43 Typical single needle GC555O 21

5 1703-23 ZoJE single needle ZJJ970RSD3/PE 5
6 1703-54 Dabble needle juki LH-3128 3

7 MS JUKI MS-261 9
8 MS GEMSY GEM431 5
9 Weating m/c (JUKI) LH-895 4
10 Cuff iron Step/15 1
11 Collar iron Stc/T 1

12 Over lock garead(GSMSY) GEM500-01 1
13 Over lock (Pegasus) LS2-01 4
14 Inter lock Gemsy GEM-757F-XH 2

15 Over lock Gemsy GEM-737-F 1
16 SIRUBA ENTERLOCK 516M2-55 2
17 Button attach brother LK-3B438-2 1

18 Button attach GEMSY GEM11-08 3
19 enter lock Gemsy GEM-757EXH 3

20 Bar tucker brother LK3-B4-30 2

21 Button hole GEMSY GEM11888 1
22 Button hole juki 1
23 Bar tucker juki LK1850 1
24 Waste band ZoJE LBH-781 2
25 Higelat M/C Juki MAX-03 1

26 bag Clothier DHEAYDUTY 1
27 button attach juki LK-1903AN-SS 5
28 Bar tacking juki LK-1900A-HS 5
29 Band knife DBK-D 8

30 Cloth cutting KS-AUV 2
31 Cloth drilling 2
32 Seating packing m/c ELMA6013/P 1
33 Bag clothe DA-HEAU 1
DUTY
34 Gromate m/c 1
35 Over Locke Gemsy GEM-500-01 1
36 Stem iron(vm) 2
Finishing machine fusing machine

Vacuum table = 6 flat bade fusing = 6
Up stem table = 5 flat count fusing =4
Stem removing = 4
Drum continuous =_

1.5 MAIN PRODUCTS IN ADAMA GARMENT INDUSTRY (AGI)

In Adama factory, there are four Maine sections productions:
1. Some of its in Heavy duty section:

 Gloves
 Bag
 Canvas
 Suspender Engraving products
 Sleeping bags
 Suspenders; waist belts
 Canvas covers for different vehicles.
 Different size tents
 Different canvas and lather made safety produce
2. Garment sewing section:

 Military uniform, Shirts
 Covers for many vehicles
 Trousers
 Caps
 Ties
 Field jacket
 Gown
 Textile Weaving section in weaving there textile products like Welt belts
differentsizeSuspender all so different size like 30, 35, 50&100
3 Embroidery section: In this section different type of defines rank insignia,
federal police insignia and different name tagging is done. In this room, 3
embroidery machines are there. From those the smallest is used to make
sample rank of insignia. The rest 2 machines have 12 head, 10 needles used to
produce in quantity also there is in grooving machine that used to print name
in the steel, and different sewing machines is arranged in a line.

Fig. Embroider
4 Parachute section
Adama garment are not do parachute resettle because of lack of raw material &order
from customers so it some products like
 Over all
 Gowon
 Ethiopia commercial bank
1.6 PRODUCT VARIETY IN ADAMA GARMENT


1.7 TIME STUDY

SNO Operation SAM NB(0.60/65%=0.92)
breakdown
Op1 Op2 Op3 Op4 Total Total Hour Total
SAM SAM ly Work
(100 (65% qty er
%) )
1 Dart formation 0.65 0.63 0.61 0.51 0.60 0.92 65 0.46
on side pocket
2 Sewing edge 0.30 0.28 0.26 0.24 0.27 0.416 144 0.21
cover on side
pocket
3 Sewing short 0.58 0.56 0.54 0.52 0.55 0.85 71 0.42
stripe on top of
side body
4 Sewing edge 0.95 0.94 0.92 0.91 0.93 1.43 42 0.72
cover on

pocket flap
5 Attaching side 0.20 0.18 0.16 0.14 0.17 0.26 229 0.13
pocket flap
6 Attaching side 0.68 0.65 0.64 0.63 0.65 1.00 60 0.50
pocket
7 Attaching two
overlapped 0.44 0.45 0.43 0.36 0.42 0.65 93 0.32
stripes &
another single
stripe
@another side
exactly below
side pocket
8 Attaching
another 4- 0.45 0.44 0.42 0.41 0.43 0.66 91 0.33
stripes @
bottom most
part of side
body
FRONT BODY
9 Attaching 2-
belts side by 0.77 0.76 0.75 0.72 0.75 1.15 52 0.58
side & 1-belt
on back side
10 Attaching 1-
belt on 0.58 0.56 0.54 0.52 0.55 0.85 71
preceding step
11 Selvedge
formation on 0.49 0.48 0.47 0.48 0.48 0.74 81
front large

internal pocket
12 Sewing back
side & large 0.53 0.52 0.52 0.51 0.52 0.80 75 0.40
internal pocket
INITIAL ASSEMBLY
13 Sewing/attachi
ng front body 0.81 0.82 0.79 0.78 0.80 1.23 49 0.62
& side body
together
14 Top stitching 0.69 0.68 0.68 0.67 0.68 1.05 57 0.53
BACK BODY
15 Sewing
/forming/perip 0.26 0.25 0.25 0.24 0.25 0.38 156 0.19
heral edges by
in-folding
larger flap
16 Turning out
and top 0.39 0.36 0.37 0.36 0.37 0.57 105 0.29
stitching 0
peripheral
edges
17 Final top
stitching of 0.69 0.69 0.68 0.66 0.68 1.05 57 0.53
side edges
18 Sewing edge
cover on larger 1.14 1.12 1.11 1.11 1.12 1.72 35 0.86
flap
19 Suspender
preparation: 1.65 1.55 1.45 1.35 1.50 2.31 26 1.16
spearing

20 Suspender
preparation 2.35 2.34 2.32 2.31 2.33 3.58 17 1.80
sponge
attachment
operation
21 Insertion of
buckle 3-hole 1.05 1.03 1.03 1.01 1.03 1.58 38 0.80
manually to
suspender
22 Sewing/attachi
ng suspender 1.20 1.19 1.17 1.16 1.18 1.82 33 0.91
to larger flap
(2items-on
unit product )
23 secondary
sewing 1.23 1.25 1.24 1.20 1.23 1.89 32 0.95
fixation by x-
formation on
the above step
24 preparation of 1.20 1.19 1.17 1.16 1.18 1.82 33 0.91
back-body
25 Side-hemming
of back 0.97 0.95 0.94 0.94 0.95 1.46 41 0.73
internal pocket
(normal twill
fabric)
26 central
attachment of 0.35 0.36 0.35 0.34 0.35 0.54 111 0.27
two items of
the product on

step-23)
27 Attaching back
internal 0.95 0.94 0.92 0.91 0.93 1.43 42 0.72
pocket(24)
with back
body(22)
28 Attaching
larger flap 0.77 0.76 0.75 0.72 0.75 1.15 52 0.58
with back
body by single
line sewing
29 Attaching
larger flap 1.10 1.09 1.07 1.06 1.08 1.66 36 0.83
with back
body-only @
one-side
30 Attaching
larger flap 0.53 0.52 0.51 0.52 0.52 0.80 75 0.40
with back
body- @
remaining –
side
FINAL ASSEMBLY
31 Attaching
front & back 0.90 0.88 0.87 0.87 0.88 1.35 44 0.68
sides together
32 Turn out &
removal of un 0.88 0.86 0.84 0.82 0.85 1.31 46 0.66
fixed sewing
threads/trimmi

ng/
33 Preparation of
nylon tying 0.79 0.78 0.77 0.74 0.77 1.18 51 0.59
rope
34 Nylon
interline(Gebe 0.78 0.77 0.77 0.76 0.77 1.18 51 0.59
r) side
hemming by
inserting a
nylon tying
rope
35 Sewing both
ends of nylon 0.44 0.43 0.43 0.42 0.43 0.66 91 0.33
interline &
form
annular/circula
r/ Geber
36 Top-stitching 0.52 0.50 0.50 0.48 0.50 0.77 78 0.39
37 Sewing
prepared
annular Geber 0.98 0.96 0.94 0.92 0.95 1.46 41 0.73
in accordance
to fit the
overall mouth
area of heaver-
sack
38 Stripe head 0.49 0.48 0.46 0.45 0.47 0.72 83 0.36
preparation
39 head punching 0.12 0.11 0.09 0.08 0.10 0.15 390 0.08
40 Eye-let 0.36 0.35 0.35 0.34 0.35 0.54 111 0.27

insertion to
head
41 Sewing head
& longer stripe 0.49 0.48 0.47 0.48 0.48 0.74 81 0.37
@larger flap
of main body
42 Sewing an
edge cover on 1.23 1.25 1.24 1.20 1.23 1.89 32 0.95
over all area
of product
43 Trimming 1.45 1.43 1.41 1.39 1.42 2.18 27 1.10
44 Visual quality
inspection-1 0.88 0.86 0.84 0.82 0.85 1.31 46 0.66
45 Attachment of 2.30 2.25 2.15 2.10 2.20 3.43 17 1.72

end-clips
46 Punching/hole
forming/side 0.20 0.18 0.16 0.14 0.17 0.26 229 0.13
pocket &
pocket flap
47 Snap button
insertion to 0.26 0.25 0.25 0.24 0.25 0.38 156 0.19
side pocket&
its flap
48 Final visual
quality 1.00 0.99 0.97 0.96 0.98 1.51 40 0.76
inspection
49 Arrange,
checking, 1.30 1.29 1.27 1.26 1.28 1.97 30 0.99

folding and
inserting in a
poly bag
50 Packing 0.15 0.13 0.12 0.12 0.13 0.20 300 0.10
51 Counting
/numbering/a 0.49 0.47 0.46 0.46 0.47 0.72 83 0.36
mount to be
dispatched
52 Final 2.65 2.64 2.62 2.61 2.63 4.05 15 2.03
shipment/dispa
tching/
Total 41.4 63.75 4112 31.20
4 .97
Table-10 time study for heaver sack
# Heaver- sack
Order Qty 100,000
Work Hrs/Day 8
Performance: 65%
Total Direct Workers 32
Table-11
1. Daily Target (Qty/Day)------------------------241
2. STD.TIME---------------------------------------63.75
3. HOURLY QTY----------------------------------4112.75
4. Total Worker--------------------------------------31.20
Planed Sewing Days------------------------------415.0

CHAPTER TWO
PROJECT TITLE
2.0 MINIMIZATION OF TIME WASTAGE BY LAYOUT CHANGE
2 .1 Abstract
This project is done on minimization of time wastage through layout change inadama
garment industry especial in heavy duet section normal after this project done when use
company in this layout gate many profit like time minimized, reduce movements and
other interims of cost the Layout is any analysis of light, heating and ventilator need and
the toilet facilities and rest room a convenient term used to describe the space and
arrangement of facilities and condition provided for worker.
2.1.1 Introduction
Layout is the way in which machinery, equipment material are arranged in working area
determined the layout in that i.e. when plant or even an office starts operating even if the
layout was well thought out are-examination of the utilization of space is obtained layout
is all so party of design that deals the arrangement of visual element in garment the value
of layout is smooth flow from one products to others and to get effective products this
proved for easy and safe movement of production when see time wastage is causing
same one to spend time doing something that is unnecessary or does not produce any
benefit all so time wastage is useless or profitless activity on productivity time and
money are the same what
There are two type of objective: those are
2.1.2 General objective of title

Minimization of time wastage by changing layout between stores to cutting section
2.1.3 Specific objective

 Reduce internal movement from storeroom to cutting section using layout change.
 Minimize space between machines to machine
 Approaches the toilet service to production room
2.1.4 Statement of problem

 Long transportation
 Operator idle time
 Far distance of facilities toilet, water service
 Unnecessary time wastage
Litratechure review
A facility layout is an integration of the physical arrangement of departments,
workstations, machines, equipments, materials, common areas etc, within an existing or
proposed industry. Most plant layouts are designed properly for the initial condition soft
the business. However, these layouts provide many bottlenecks during growth period.
Hence as long as capacity grows, it has to adapt the internal and external changes for
which a re-layout is necessary The reasons for a re-layout are due to changes in
production volume, changes in process and technology and changes in the product
Are common tools in optimization? Limitations of those heuristic methods are time
consuming and cannot get the feel
www.iaeme.com
Significant of project
o To increase profitability
o To minimize transportation
o To improve suitable work
Beneficial of my project
o Save time
o Proper use of layout
o Doing of Edraw soft ware
Company benefit
Increase productive
Increase profit of company
save time and distance

.
.
2.1.5. METHODLOGY
This project focused on the minimization of time wastages in Adama garment industry so
there is two type of methodology:
1. Primary
Through observation Primary data collection Primary data collection methods
Through observation method:- I identify that there is a problem time wastage by
observing simply and moving in department to department. There is also no proper time
use and there is some problem such as long travel of from cutting room to store room
which means there are no good layouts so it affects our production, and profit of one
company.
Through interview method:- in this method I ask some questions by moving to ask
some workers production manager and some operators who have long experience told
me that the layout of heavy duty same problem so interims of this I stand to change same
department and to try to change facility service near to production room to minimize
time
2. Secondary data collection
 From text book (work study)
 From handout
 From internet service and company documents

Fig heavy dut
2.1.6 Actual Data
The distance between store rooms to cutting is 68m

Capacity track 3 roller so to bring three roller at the same time store to cutting room time
taken is 6mint for produce of 1120 pieces of haversack the roller required are nine roller
so
The maximum lay of haversack is 40 lay
One plies have 28 pieces
If one lay =28 pieces
40 Lay x

40*28 pieces =1120 pieces

X =1120 pieces and to spread those pieces, 9 roller are required so per days two
ice spreads so 18 roller are need for par days The capacity of track 3 roller at
time then time taken at one cycle is 6mint in distance 136m at one cycle
# In terms of time
One cycle =6minit
3cycle x
3cycl *6minit/1cycl =18 minutes
HINT:3 cycles express that to spread 40 layer of canvas in roller
Nine roller canvas consume 18 mint then eighty roller canvas are 36 mint transportation
per days when see in menthe and year
If one days = 36mint time consume
In 26days ?
22day*36 mint/1day =936mintp/month then in year 12*936mint
In terms of distance
The distance store room to cutting room is 136min one cycle
If 1 cycle = 136m
6cycle ?
136m*6cycle/1cycle =816m per days movements
HINT 6cycle is represent a cycle to cute 18 roller of canvas P/days (2*spread)
So time consume of 18 roller is 36mint or 816m per days all activity are unnecessary
transportation come due to bad layout so it ‘s difficult on the product as well as on time
and in terms of cost this bad layout is affects all in above explained
DATA ANALAYSIS

The transportation from store room to cutting room is reduced by 28m so inone cycle
56m that means the distance from store to cutting is in meter 28 ( in 6 cycle) is 156m
are reduced of transportation the new layout 40m in one cycle 80m so that in par days
80m*6cycle
Total transportation =distance before layout –distance after layout in per day
Total=816m-480m
=336m is reduced of transportations so that
OR in calculation method
In one cycle = 56m reduced
6 cycles ?
56m* 6 cycle
=336m is reduced
In terms of minutes after layout change

If one cycle = 3mint

6cycle ?
6cycle*2mint
=18mint p/days so that the actual time is 36mint regard to this 18mint p/day save
If In menthe and year we save that
One day = 18mint save
26day ?
18mint*26 day/1 day
=432 mint save p/month and in years 6336mint saved p/year
BEFORE LAYOUT TIME USED IN PRODUCT
I take the standard summation of suspender is 12mint by 10 machine and the actual time
is 36mint
Then: product loose
If One suspender =12mint
? 36mint
1 suspender *36mint/12mint
=3suspenderp/ day lose in 36 mint intermes of transportation
In terms of month 26 working days so that
If one days = 3suspender are loosed
26 day ?
=78suspender are lose p/month and all so in year936suspender are loosed p/year
In cost ways if one suspender are 100birr par day how much of adama garments due to
long transportation 1sus = 100birr
3suspender ?
100birr*3sus/1suspender =300 birr lose p/day in month
One month have 26 working days so
1day = 300birr
26day ?
26day*300 birr =7800 birr lose p/month in year
AFTER LAYOUT MODIFAY TIME USED IN PRODUCT

The SUM of suspender is 12minutes so in terms of new lay out 18mints P/day are saved
when in month or 26 working days so we save 624mints p/month
One suspender = 12mint
? 18 mint
18mint*1suspender/12mint =1.5 suspender is saved p/ days and 39 suspender are saved
p/month
For year: One year is 12month so
1menthe = 39suspender
12menthe ?
12menthe *39sus/1menthe = 468 suspender are saved p/year
COST SAVED
When see in terms of cost how much birr are saved the company
One suspender = 100 birr
1.5 suspenders ?
1.5*100birr=150 birr saved p/day so
When in month (26) day

One day =150birr
26 day x
X =3900 birr are saved p/month When in year
One year have 12 month so
1month =3900birr
12month ?
12month*3900birr/1month =46800birr are saved per year of one com
 Challenges during internship

 Lack of computer and Internet access to write and search important information.
 Lack of fully data about the company
 Problem communication with employees

 Lack of CAD/EDROWU software
2.1.7 Recommendation
I recommended that the company should be use new layout that can be able to eliminate
bad layout because of that are exists a long transportation. When company use by new
layout it should gate from this layout: Increase productive of company By improving
good work station and layout Time wastage is eliminated Long transportations is all so
highly reduce and company use good material handling equipments to minimize time
wastage I recommended adama factory use modern equipments like material handling
,spreading table, cutting machine and CAD system in generally to facilitate the jobs.
To Eliminated unnecessary movements. Company must Approaching departments to
departments.

2.1.8 Conclusion
I conclude that Good layout is very important to improve productivity In addition, to
plays A great role on the one factory profits, increase production reduce fatigue and
transportation, before improving new layout the transportation from department to
departments are 68m But after my new layout transportation exists 40m and intermes
of time transportation in per/ day time finished 36mint after new layout 24mints.All so
minimize toilet service 150m reduced to 75m and when see in cost ways the company has
save 300birr p/day and per menthe are and so company use this new layout such benefits
Generally, I conclude good layout is very importance for one garment factory in different
aspects and reduction of non-productive time. The subject of plant layout not only covers
the initial layout of machines and other facilities but encompasses improvements in the
methods of production

CHAPTER THREE
3. BENEFITS FROM INTERNSHIP EXPEIENCE
Beneficial
First of all when I was in the internship I really happy, and I believe that after the
internship program I have gate skill, I will developed knowledge and valuable work
experience Internship helps me to get experience in my field of study. It also gives me an
in depth analysis of what it really like to work best field of study. And practical skill,
solving of problem in garment industry all so leader ship and process flow of production
and all so I gate deep knowledge on the plant layout how to solve the when there is bad
layout exist and the all so gate benefit from my projects like minimization of time
through layout change company gate many profit in terms increase productive.
Practical skill
The four month internship program benefited me to have practical skill. Like sewing of
any product that are work in adama garment industry’s it also ways of quality chalking to
packing by machine how to packed one products and I get skill to cute the product by
band knife machines
Problem solving skill in garment

Completing this internship program makes me to identify the garment problems and then
how to solve them if happened.

My internship gave the opportunity to apply some garment problem solving skill learned
with in the class room to real world activity within the industry. It gives me an in-depth
analysis of the industrial problems really and how to solve the
Leadership skill
Doing an Internship made me to build my confidence and knowledge on leadership skill
i.e. I am able work with my colleague and prior goal of the company and become
effective without creating any disagreement with my colleagues.
Team playing skill
Doing internship me enables me to develop my team playing skill. It enables me working

with my colleagues who have substantial experience within the garment factory. I
develop my understanding on my contribution to the company as a member the group on
the entire objective to be succeeded.
Interpersonal communication skill

I also understand that employees who work together well and are happy in their jobs can
significantly strengthen a business or organization. At the end of my internship program I
am able to identify how employee behaviors and attitudes can be improved through
hiring practices, training programs, and feedback and management systems psychologists
also help organizations transition among periods of change and development I have
developed my personal communication skill at the end of my internship program.
I developed both oral and communication skill. I got an experience on how to approach to
people who works in the company. I also developed how to communicate with people in
the factory using written communication method.


REFERENCE
Adama garment factory document

Hand out
Work study
www.w goggle.com

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WOLKITE UNIVERSITY

COLLEGE OF ENGINEERING AND TECHINOLOGY

DONE BY TEMESGEN DEREJE

ADVISER: MUSTAFA ABAS

PREPARED BY TEMESGEN DEREJE ID NO 361/05 Page ii

Mustafa Abas_______ _____________ ___________

Temesgen Dereje ______________ __________

PREPARED BY TEMESGEN DEREJE ID NO 361/05 Page iii

PREPARED BY TEMESGEN DEREJE ID NO 361/05 Page iv

PREPARED BY TEMESGEN DEREJE ID NO 361/05 Page v

PREPARED BY TEMESGEN DEREJE ID NO 361/05 Page vi

CHAPTER ONE .................................................................................................................................. 3

1 BACK GROUND OFCOMPANY ....................................................................................................... 3

1.1 INTRODUCTION ......................................................................................................................... 3

1.1.1VISION OF ADAMA GARMENT ................................................................................................. 4

1.1.3 OBJECTIVES ............................................................................................................................. 5

1.1.4 CORE BUSINESS ADAMA GARMENT ....................................................................................... 5

1.1.5 CORE VALUES OF THE COMPANY ........................................................................................... 5

1.2 ORGANIZATION STRUCTURE OF ADAMA ARMY FOUNDATION: ............................................... 8

1.3 PROCESS FLOW OF GARMENT PRODUCTION IN ADAMA ....................................................... 10

1.4 MACHINE AVAILABLE IN ADAMA GARMENT INDUSTRY ......................................................... 19

1.5 MAIN PRODUCTS IN ADAMA GARMENT INDUSTRY (AGI)....................................................... 22

1.6 PRODUCT VARIETY IN ADAMA GARMENT ............................................................................... 24

1.7 TIME STUDY ........................................................................................................................... 26

2.0 MINIMIZATION OF TIME WASTAGE BY LAYOUT CHANGE..................... 34

2.1.1 INTRODUCTION ............................................................................................... 34

2.1.2 GENERAL OBJECTIVE OF TITLE .................................................................. 34

2.1.3 SPECIFIC OBJECTIVE ...................................................................................... 34

2.1.4 STATEMENT OF PROBLEM ............................................................................ 34

2.1.5. METHODLOGY ................................................................................................ 36

2.1.6 CALCULATION ..................................................Error! Bookmark not defined.

2.1.7 RECOMMENDATION .......................................Error! Bookmark not defined.

3. BENEFITS FROM INTERNSHIP EXPEIENCE ............................................................. 44

3.1BENEFITS I GAINED FROM INTERNSHIPS .............................................................. 44

PREPARED BY TEMESGEN DEREJE ID NO 361/05 Page 2

1 BACK GROUND OFCOMPANY

PREPARED BY TEMESGEN DEREJE ID NO 361/05 Page 3

1.1.1 VISION OF ADAMA GARMENT

PREPARED BY TEMESGEN DEREJE ID NO 361/05 Page 4

organizations and introduce new technologicalAchievements to the country. Obtain hard

1.1.5 CORE VALUES OF THE COMPANY

LOCAL CUSTOMER OF ADAMA GARMENT:

PREPARED BY TEMESGEN DEREJE ID NO 361/05 Page 5

 Military defense logistic

 Military Defense Foundation

 Sebeta Garment engineering

 Dijon aviation industry

 Beshoftu automotive industry

 Power engineering industry

 Adama agriculture machinery production industry

ADAMA FOREIGN CUSTOMERS

PREPARED BY TEMESGEN DEREJE ID NO 361/05 Page 6

ACCESSORY USED IN ADAMA GARMENT

 Eyelet with washer thread

PREPARED BY TEMESGEN DEREJE ID NO 361/05 Page 7

1.2 ORGANIZATION STRUCTURE OF ADAMA ARMY FOUNDATION:

Cutting room Administration division Sale &market Purchase

PREPARED BY TEMESGEN DEREJE ID NO 361/05 Page 8

NO NAME Responsibility of organization

PREPARED BY TEMESGEN DEREJE ID NO 361/05 Page 9

1.3 PROCESS FLOW OF GARMENT PRODUCTION IN ADAMA

Order received Design/sketchi Sample making

Spreading Marker making Production

Sewing section On line inspection

Mustafa Abas_ _ _____

Temesgen Dereje ____