SHANTO-MARIAM UNIVERSITY OF CREATIVE TECHNOLOGY

Internship on Ananto Garments Ltd.

Submitted to
Sharah Nafisa Kakoly
Associate Director (Human Resource)
Ananta Companies

Supervised by
Suresh Kumer Mondol Niloy
Executive Human Resource

Submitted by:

Zamir Hasan Nishan

University ID: 172055009
Intern ID : 389

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 ACKNOWLEDGEMENT

I would like to thank Almighty of Allah who made me able to complete this
internship report by utilizing my skills and knowledge. I am also thankful for
giving me the spirit of patience, consistency and courage during my internship.

I am acknowledging to my respectful Professor Dr. Masud Al Noor sir for his

kind co-operation and direction in my internship program.

Also express my deep gratefulness to Sharah Nafisa Kakoly Madam

Associate Director (Human Resource) Madam , Suresh Kumer Mondol Niloy

sir,(Excutive HR) of Ananta Garments Ltd. for their kind permission to allow
me for Internship.

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 TABLE OF CONTENT
INFORMATION ABOUT ANANTA GARMENTS:
 Basic information………………………………………………………………………
 Key information…………………………………………………………………………
 Available process
 Clients…………………………………………………………………………………….
 Organogram of AGL……………………………………………………………….04

DESCRIPTION OF THE ATTATCHMENT:

 Store section…………………………………………………………………………05-12
 Technical/Sample section………………………………………………………13-17
 Cutting section……………………………………………………………………….18-21
 Sewing section………………………………………………………………………..22-24
 Washing section……………………………………………………………………..25-32
 Finishing section………………………………………………………………………33-38
 Work study………………………………………………………………………………39-48
 Quality control Quality assurance & Quality management system...48-50
 Requirement for quality system………………………………………………….51-53
 Admin & Compliance…………………………………………………………………..53-54
 HR(Human resource)……………………………………………………………………54-55
 Welfare…………………………………………………………………………………………56-57
 CONCLUSION: …………………………………………………………………………………..58

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“ORGANOGRAM OF ANANTA GARMENTS LTD.”

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 DESCRIPTION OF THE ATTACHMENT

Store:
There are three types of store room in Ananta Garments ltd.

 Fabrics & accessories store.

 General store.
 Finished goods store.

Fabric & accessories store

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Fabric store:
Fabric store which maintained the fabric roll and its quality. There are some
employees with Worker whose are working on it first. They received the roll as
per purchase order. Then it Counted by order sheet and started inspection.
Main things of inspection try to find out the Fabric fault and its quality. There
are different types of fault Such as, stick mark, missing Yarn, thick yarn, Slub,
knot, spot, and hole. Faults are detected by follow the 4-point system and
strictly follow to hold the fabric quality keep the best.

Accessories store:
Fabric is the basic material in garment manufacturing. Except fabric of
garment, the materials are known as garment accessories. Which maintain the
accessories and it’s quality that’s called accessories store.

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Quality department flow chart for accessories/trims:

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Finished goods store
After finishing process the garments are ready for shipment, before shipment
the products are stored in a safety place which is known as finished goods
store. In the finished goods store the products which are ready for shipment
are placed with safety.

General store
In the general store all item which are necessary for factory & production are
stored. Such as air condition, m/c etc. All the equipment which are useful for
production. All the materials and equipments which are stored in a place is
called general store

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Quality Department Flow Chart For Fabric Store

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Inventory:
Inventory is the raw materials, work-in-process products and finished goods
that are considered to be portion of a business’ assets that are ready or will
be ready for sale. Inventory represents one of the most important assets of a
business because the turnover of inventory represents one of the primary
sources of revenue generation and subsequent earnings for the company’s
shareholders.

Fabric inspection:
There are so many facilities for inspection in every section of garments
industry. The aim of inspection is to reduce the time and cost by indentifying
the fault and defect in every steps of garment making.

To do success in inspection, the process can be run by maintaining following

“inspection loop”:
 Inspection.
 Identification the defect or fault.
 Knock the appropriate person.
 Identify the reason of defect or fault.
 Remove the defect or fault.

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In Ananta Garments Ltd. “fabrics are inspected by Four-Point System.
Four-Point System: In this method points are found defect points are found
out of 100 yards of inspection. The fabric must be rejected if the defected
point are >40.

Defect length for warp way and weft way

Up to 3” ------------------------------------------------ 1
More than 3”-6” 2
More than 6”-9” 3
Above 9” 4
Defect area for holes and openings
1’’or 1’’ 2
Above 1’’ 4

Fabric quality inspection:

The quality of a final garment depends on the quality of a fabric when it is
received as a roll. Inspect at least 10% of the total rolls of the shipment.
Selection of rolls; select at least one roll of each color. If more than one roll
must be selected, then choose the additional roles in proportion to the total
number of roles per color received. This way, they can avoid fabric related
quality problems before it is put into production.

Fabric fault:
 Burl Mark

 Drawbacks

 Dropped Pick

 Smash

 Jerk-in

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  ™Knots

 Mixed End (Yarn)

 Mixed Filling

 Open Reed

 Slub

 End out

 Holes:

 Stop Mark:

 Thin Place:

 Soiled Filling or End

Shrinkage Test:
On the other side from each roll 50cm cut as width wise and making blanket
and then it goes to washing section to measuring its shrinkage.

Shrinkage% = (After wash – Before wash) ÷ before wash) ×100.

After washing how much fabric shrinkage from its previous size that is
measuring because when they got shrinkage result then they informed about
fabric shrinking measurement.

Material item lab test:

Main label, size label, care label, price tag, thread, elastic, zipper, button,
leather patch all this materials are check with approved trim card & shade
check with light box. Brand name check , quality check. If have any metal item
should be checked nickel from every packet/bundle 03 pcs and keep visual
record. Check ferrous by metal detector machine & keep all this record for 6
month.

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 CAD & Sample section
CAD: CAD or Computer Aided Design has brought a revolution in apparel
industry. The time consuming of designing has been made easier by CAD.
Here, mainly pattern and marker is created by computer which ensure
accuracy of the pattern and marker which ensure defect less cutting and
defect less garments.

Software used in factory:

 Pattern design
system and
garment grading
system
 Garment marker
system
 Garment file
format converter

Machine used in pattern and CAD section:

 Pattern
cutter
 Plotter

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Working procedure of CAD section:
In CAD section at first the pattern put on the digitizer to take clear image of
the pattern
part inside
the CPU.
After
making all
required
size pattern
using the
software
pattern parts are aligned in the mini marker. Then it is sent to CPU of CPM
section for approval & checking the length & width of marker and pattern
parts alignment. After getting approval from CAD section then printer is used
to print out the whole real marker then this marker as well as mini marker are
provided to the CAD section for cutting the fabric.

Sample section:
Garment sample section is very
important department in apparel
manufacturing process. Garment
sample are developed tested
before starting the bulk
production, because the buyers
generally place the order after they are satisfied with the quality of the
sample. The sample decide the ability of an exporter.

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Working process of sample room in garment industry:
Receive tech pack: Sample section 1st receives tack pack from merchandiser so
that they can take initiative to make sample.

Pattern make: Sample section inform pattern or CAD section to make required
pattern or grading pattern for sample development.

Sample make: After make pattern or manually cut fabrics for sample making,
sample is make according to buyer’s requirements.

Approval gain : Make sample sends to buyer for approval, if not gain approval,
sample section has to re-make sample based on corrective comments.

Types of sample make:

Different types of sample make according to different buyer. It’s depend on
buyer demands. Different types sample name are given below:

 Proto sample
 Fit sample
 Sales man sample
 Size-set sample
 Pre-production sample
 Top of production sample
 Shipment sample
 Counter sample
Proto sample: It is made to communicate the design of a style or a line
or to present garment structured according to tech pack.

Fit sample: Fit sample is being tasted on live model or dress form to
verify garments fit and fall.

Sales man sample: It is made to put on display in the retail showroom. It

is displayed for customers feedback and buyer’s forecast demand of a
particular style.

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Size-set sample: The purpose of the sample is to check the fit of the
garment of different size.

Pre-production sample: Buyer wants pre-production sample to be made

in actual production line before bulk production.

Top of production sample: Buyer ask this sample to check whether

factory is following PP sample or not.

Shipment sample: When style is being finished and packed for shipment
2-3 finished with all packing details are sent to the buyer to give
knowledge what is being sent to the buyer through shipment.

Counter sample: Generally, all type of sample sent to buyers, taken

same copy at the factory for future reference id called counter sample.

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 Cutting:
Cutting department is one of
the most essential sections
for garments manufacturing in
the apparel industry. The
fabric cutting is started after
completing the fabric
spreading. In cutting section,
fabrics are cut according to
the pattern. Perfect fabric
cutting depends on the
method of cutting and marker
planning. For making quality
garments they have to follow
a working procedure of
cutting department to
continue their work.

Flow chart of cutting section:

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Function of cutting department with process:
Received the fabric from dyeing finishing: When merchandiser confirm
about the work order sheet, then cutting section received the required
fabric from the dyeing section.

Received the cutting ratio from merchandiser: Merchandiser sends a

cutting ratio for every style of garment to do this job smoothly.

Make the cutting quantity plan: Cutting manager should make the

perfect cutting quantity plan.

Lay planning: Before fabric spreading, cutting manager and in-charge

make a plan about fabric lay.

Marker making: To finish the accurate cutting process, marker making

must be needed for each style of garment. 

Make marker ratio: In this stage marker maker prepare a marker ratio to
complete this cutting process. 

Decide the quantity of fabric spreading: Before spreading, cutting in

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charge take the decision, how many fabrics spreading are required? 

Fix the number of lay per cutting: They also fixed the number of lies
which are appropriate for each cutting. 

Take the fabric from

store: For cut the
every style of
garment, cutting in
charge receive the
fabric from store. 

Check the
fabric: Cutting
supervisor inspect
the fabric faults like,
fabric holes, color
shading, and any
other defects on fabric. 

Fabric spreading: In this stage, fabrics are spread on cutting table

according to correct lay height and ply tension. 

Marker setting on lay: When fabric spreading completely done, then the

different size and styles of marker set on the top layer of the fabric lay. 

Fabric cutting: Finally fabric cutting is done here. 

Numbering: When the cutting process is finish then numbered the every

style of fabric parts to avoid the mixing.

Cutting quality check: In this stage check the all cutting fabrics quality. 

Storing & Bundling: Fabric cutting parts are storing and bundling here
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according to color, size and style. 

Bundles are sending to sewing section for bulk production: 

Finally all bundles are sending to the sewing section for completing bulk
production.

Fabric spreading process in cutting section:

Spreading is the process during which fabric is cut into pieces of a

specific length which are then placed on top of each other to form
several plies. The length of a ply is determined by the shape, size and the
number of the components which are to be cut from it. The number of
plies in a spread depends on the number of articles ordered and the

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technological and technical limitations of the fabric spreading
and cutting processes. 

Manual Spreading Process: 

The manual spreading process is suitable for small scale production.
Manual spreading may be used for all kind of fabrics, including those
with complex structures and intricate patterns. In large scale production,
manual cutting is often used for working with intricately patterned
fabrics. The cost of technical equipment is low compared with
automated spreading, but the productivity is poor.

The fixing of a marker on the top of a spread: 

A marker printed on a paper is placed on the top of a prepared spread.
Clamps are placed around the edges of the spread to hold it in position.
If the marker is printed on the paper with glue on its reverse side, it is
lightly fixed to the top ply of the spread by using a special large base
iron.

Sewing Section:

In the apparel
industry or clothing
industry, sewing
section is the main
department for
garments
manufacturing. When
all the garments are
complete to cut in the
cutting section, all of
these cutting parts are
sending to sewing
department for making
garment. In this section
different cutting parts

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are joining together with the help of different types of sewing machine,
threads and needle. To complete the perfect garment easily and timely
Floor in-charge always maintains a working procedure. Working
procedure is also called as process flow chart of sewing department in
the garments industry.

Flow chart of sewing section:

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Name of the sewing machine which are used in
sewing section:
 Plain m/c

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  Over lock m/ ™Zigzag m/c
 Flat lock m/c
 Bar tack m/c
 Kansai m/c
 Button Holing m/c
 Chain stitch m/c
 Button attach m/c
 Vertical m/c
 Snap Button attach
 Two needle m/c
 Bar tack sewing m/c
 Blind stitch sewing machine
 Button attaching machine
 Button hole m/c
 Button hole sewing m/c
 Chain stitch sewing machine
 Feed of the arm
 Lock stitch m/c
 Over lock m/c
 Zigzag lock stitch sewing machine

Washing:

Types of garments washing:

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 The different types/methods of washing are mentioned below:
Primarily garments washing are two types.
▪ Dry process/Mechanical process
▪ Wet process/Chemical process

Types of Dry process/Mechanical process in Paradise Washing Plant

Ltd..
 Whisker
 Hands scraping
 Over all wrinkles
 Permanent wrinkle
 Broken and tagging
 Grinding and destroy
 PP spray and PP sponging etc.
 Resin(3D)

Types of Wet process/Chemical process in Paradise Washing Plant

Ltd..
 Normal wash/ garment wash/rinse wash.
 Enzyme wash.
 Stone Enzyme wash.
 Bleach wash.
 Tinting (Tie) & Over Dyeing (Dip Dyeing).
 Soft wash.

Types of machine which are used Ananta Jeanswear Ltd..

 Sample washing machine ™Hydro extractor machine.
 Dryer machine.

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  Boiler. ™Grinding machine ™Tagging machine.
 Steam chamber for crinkle. ™E.T.P (Effluent treatment plant) ™Spray gun
and dummy
Dry process:
Whisker:

Whiskers are one of the most

important designs of a used look
garment. The idea of whiskers is
taken from the worn out lines
and impression patterns
generated by natural wearing on
hips and front thigh area. On old
jeans, a number of patterns can be finding consequential to fabric, body
shape of user or sitting posture. It is also known as Cat's Whisker .
Hand scraping:

To create the impression or visibility of pocketing fabric of any inside

materials visibility to the face side of the jeans pants with the help of emery
paper is called hand scraping. Emery paper comes in different number
generally starts from 40 till 600 and above, higher the number finer the emery
paper, lower the coarseness of the paper. In garment industry from 220, 320
& 400 number papers are most popular & widely used.

Wrinkle

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The process is kind of resin finishing process. In this process of applying resin
on textile material, resin form cross-linking inside the amorphous region and
block the free hydroxyl (OH) group and preventing hydrogen bond formation
thus improve wrinkle free finishing. Mainly it is applied on twill fabric, single
jersey and denim fabric.
Tagging:

Tagging is doing on garment for fashion and value-added fashion wear.

 Tagging is doing by tagging machine.
 Tagging is also by needle and manually.
 After wash upper portion of garment occur crease mark and
inside of tagging occurs dark shade.

Tacking & Grinding

Tacking: is a process which is being done by swift tag machine with the help
of plastic or nylon tag pins in rigid form of garment to get very heavy contrast
on waistband, bottom hems, back pocket & front pocket corners etc.. After
completing wash cycle, it must be removed from garment before making
softening.
Grinding: is being done on pocket edges & bottom hems edges by running
against abrasion surface or stone to achieve worn out effect. Many different
make of machines & pen grinding tools are available in the market which runs
with pneumatic system.

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Destroyed Denim :
One of the most popular distressing effects currently, ‘Destruction’ is an art
which make denim look
unique & used. To make
destruction pen type of stone
tools being used in mid of
wash process to apply on
desired area. It can also be
achieved by cutting it thru
knife the warp yarns & keep
the weft yarn as is to show
white thread. Holes also can
be made by cutting weft &
warp yarn.

Potassium Permanganate Sponging/ Brushing:

PP Spray is being done on denim garments to achieve local abraded area to

appear whiter than back ground indigo color shade. This can be applied by
sponges dipped in to PP Solution & rubbed on
desired area followed by neutralization in wet
process. This process can be done in rigid after
doing hand scrape or in the middle of the wash.
Doing after enzyme or bleach cycle will give more
natural & white effect that doing in rigid. There
are many additives can be added in order to
achieve desired intensity and look.

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Wet process:
Flow chart of wet wash process:

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Process description:
DE sizing Process:
DE size is the first process on garment washing.

Object of enzyme wash:

To remove size material from the garments.

To remove the starch present on the garments.
To improve the anti-pilling properties.

Enzyme wash: Enzyme wash is done on the garments made from heavy
fabrics like jeans and denim. Cellulose enzyme is used for this types of wash.
These cellulose Enzyme hydrolyses the projecting hairy cotton of the garment
fabric surface and also removes color.

Object of enzyme wash:

 To remove size material from the garments.
 To achieve the buyer reference sample /washing standard.
 Enzyme attack as chemically not mechanically for this reason low
damage.
 Enzyme improves anti-pilling properties.
Types of enzyme: mainly two types of enzyme.
 powder enzyme
 liquid enzyme

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Stone enzyme wash:

Object of stone enzyme wash:

To create or produce irregular fading or old looking affect on garment.
Especially developed the “bio-polishing “affect of cotton/denim.
To remove dust, dirt, spot, impurities from the garment.
For soft feeling to wear the garment.
To achieve the buyer washing standard.

Bleach wash: Bleach wash the fabric are garment normally dyed with
direct dye or reactive dye and these are washed with bleaching agent which
reduce color.

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Object of bleach wash:
To produce fading affect or old looking affect on garment.
To remove size material from, starch from the garment. ™For soft hand
felling to wear the garment ™To achieve the buyer washing standard

Cleaning process:
Object of cleaning process:
To remove dirt, dust, impurities etc. from the garment.
To increase brightness of garment.

Softener process:
Object of softener:
To increase softness of the garment. As if the consumer wears directly.
To achieve the buyer washing standard.

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 Finishing:

In a garment industry finishing section involves with garment washing,

checking, final inspection, pressing, packing, etc. Proper finishing
process can be improved quality of garments and make on time order
shipment. Garments shipment is very much dependable on Garments
finishing section. Finishing section add value to the product which
attracts customers by the presenting activities of the product according
to buyer’s requirements.

 Basic Finishing sequence are given below:

 Shade matching
 Size cutting/ writing
 Pocket cleaning
 Top side thread cutting
 Inside thread cutting
 Pocket bag iron
 Thread sucking

 Inside alter check

 Top side alter check
 Draw cord attaching
 Draw cord middle bar tack
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  Button check
 Iron
 Measurement check
 2nd altering check
 Alter
 Thread re-sucking
 Spot check
 Lot check
 Metal detecting
 Folding ( Flat folding, Standard Folding, Hanger folding ,Rolling)
 cartooning.

Machine and equipment used in finishing section:

 Thread sucker machine

 Thread Cutter
 Hand tag Gun
 Lifter
 Iron
 Metal detector
 Textile cleaning Gun etc.

Work procedure of finishing section in apparel industry:

Finishing Input (color, size & style wise): In this stage, body come from sewing
section by way of per color, style or size to finishing section as a input. 

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thread cutting

Thread Sucking: Here finishing input is brought in touch of thread sucking

machine to remove loose thread from the body. 

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pocket cleaning:

Initial Iron: In this stage, garments are being ironed and close all the button of
the garments for helping further step easier. 

Quality Check: Here body is inspected by a quality inspection to check if there

any swing, washing, or any other faults exist in the garments. If found, the
garments are send to the repair section or defective garments are declared as
reject. Here 100% quality check is done. 

Sends body to get Up change: In this stage, an inspector ensure the garments
get up is okay or not. 

Body inspection: An inspection randomly inspection some number of garments

to ensure measurement is correct or not, quality checking has been done
properly or not, initial ironing as per requirements or not.

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 Iron: Here, garments are ironed properly for folding as per buyer’s
requirements.

Folding: After the ironing of the garments, the garments are being folded in
the way buyer direction. 

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Accessories Attachment: Here, accessories like hang tag, security tag, collar
stand, butter fly etc. are attached before poly the garments. 

Poly: In this stage garments are being poly to protect the garments from dust
as well as to ensure the garments be safe in the cartoon. 

Cartooning: According to the packing list, after being poly the garments,

garments are being cartooned for shipment. 

Final inspection: In this stage, buyer’s represent inspect the garments based
on AQL label to ensure the garments are as per spec sheet or not, 

Shipment: Garments inspection is passed, the garments are ready for

shipment. 

List of major defects found in finishing section: 

 Brand: care or size label missing

 Shading
 Wrong color
 Hole in fabric Damage
 Conspicuous repair
 Poor construction
 Conspicuous soilage (inside or outside)
 Conspicuous abrasion marks from wash process
 High/ low pockets
 Buttons, snap defect
 Button hole raveling, incomplete not cut properly/ miss aligned
 Sizing problem
 Poorly trimmed garments threads
 Broken stitches
 Skipped stitches
 Open seam

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 Work study:

Activities of work study in textile and apparel industry are done by industrial
engineering department. Actually work study is used for measuring work.
Industrial engineering department is responsible for work study in the garment
industry. Work study is the most important tool for controlling production and
improving productivity. It is a new concept in textile and apparel industry. We
can define work study in the following way.

Work study is the investigation of the work done in an organization by

means of a consistent system in order to attain the best utilization of men,
machines and materials at a period of time. 

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Purpose of work study: 
In general, the purposes or objectives of work study are:

 Establish the most economical way of doing the work.

 Establish the time required for a job at a defined level of performance.
 Increase productivity and profitability.
 Increase job security.
 Make work easier.
 Establish fair tasks for everyone.
 Check achievements against standards.
 Install the work method as standard practice.

Responsibilities of work study department:

 Line setting

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  Line balancing
 Previous day target basis meeting
 Target sheet make
 Operation breakdown
 Paper layout
 M/c layout
 Preparing non balancing graph within 3 days
 After solving the bottle neck operations, prepare balancing graph within
5 days.
 Process to process production follow up as per target.
 New operator grading.
 Production study
 SMV, Target, Efficiency, Capacity, Cost of manufacturing Calculation.

Work study technique:

Work study is a generic term can notes both
 Method study
 Work measurement
Method study connected with the way in which work is done.
Work measurement deals with establishing a time standard.

Motion study: Motion study is a technique of analyzing the body motions

employed in doing a task in order to eliminate or ineffective movements and
facilitates effective movement.

Method study: Systematic recording and critical examination of existing and

proposed way of doing work as means of developing and applying easier and
more effective method and thereby reducing cost.

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Work measurement:
Work measurement refer to the estimation of standard time, that is the time
allowed for completing one piece of job using the given method. The
fundamental purpose of work measurement is to set time standard for a job.

Techniques of work measurement:

There are four basic technique for measuring work and setting standards.
They are:
Historical experience
Time study
Predetermined time standards
Work sampling

Time study: Time study is a systematic technique which measure and

estimate time of pre-forming any task.

Standard time:
Standard time is the time required for an average operator, fully qualified an
trained, and working at standard pace, to perform the operation. Standard
time is equal to the normal time plus the allowances.

Standard time = Normal time + Allowance

= Normal time + (Normal time × Allowances)
= NT (1 + Allowances)

In garments production world, the terms SMV or SAM used frequently.

 SMV stands for Standard Minute Value.
 SAM for standard allocated minute or Standard Allowed Minute.

SMV calculation :

SMV calculation of a basic t shirt from a time study sheet of garments

industry. Following formulas are use:

Normal time = (Average observed time)× (Performance rating factor)

SMV = Basic time + (Allowance × Basic time)

= Basic time × (1 + Allowance)

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Allowance are assumed for this calculation is 20%

Standard pitch time = Basic pitch time

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Page 45 of 60
Bottleneck :

Bottleneck is a constraint in a system or operation where the departments,

facilities, machines or resources work at their full capacity and therefore,
cannot handle any additional demand placed on it. We can also denote
bottleneck as, the lowest output point in production line is called bottleneck. It
is also called critical resource as it limits the throughput of associated
resources. Throughput simply means the rate of output or the amount of
material processed within a given time.
Identification of bottleneck: 
A bottleneck in the garment manufacturing process can be difficult to identify
in a complex system. The bottleneck can be found by looking at each sequence
of the process individually and measuring the production level at each step. If a
particular sequence has a low production level then it is the source of the
bottleneck. It should be noted that there can be multiple bottlenecks within a
complex system. 
Reduce bottleneck in Ananta Garments Limited LTD: 
A bottleneck can be solved by increasing the process capacity or adjusting the
production level in the sequence where the bottleneck is happening. This
might be achieved by: 

 Installing more efficient equipment

 Increasing labors and shifts
 Arranging pre-production meeting in time
 Allocation the task as per standard produced value equally
 Maintain sequence of task accordingly
 Reducing excess task from overloaded operator / find capacity where
else
 Reducing ineffective time / task by production study
 Minimizing non-value adding activities like transport, rework,
waiting, testing and inspecting.
 Redesigning the product for better manufacturability
 Layout making before input in line
 Customizing activities so as to increase flexibility
 Select right operator for right task
 Keeping the supply available in time
 Should not forward the reject products
 Supply should be forwarded after checking
 Should not be forwarded inconsistency process

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  Should not be forwarded quality fault product
 Reducing lead time
 Reducing costs
 By improving method.
 By improving workers performance.
 By reducing sewing burst.

Planning:
Planning is an act of prediction, the accuracy of which varies enormously
depending upon the kind of objective, kind of circumstance, the skill of
planner and his techniques and chance.
Planning is necessary because resources are limited. Production planning
activities originate at the aggregate level and consider decisions relevant to
a specific planning horizon.

There are three types of production planning:

o Project planning
o Lot or batch planning
o Progressive of continuous planning

Project planning:
Before starting every project its planning is done. Project planning is a very
important task and should be taken up with great care. Project planning
consists of the following important steps:

o Market survey
o Project capacity
o Selection of site
o Plant layout
o Material requirement
o Operation planning
o Machine loading
o Sub-contract consideration
o Equipment requirement
o Organizational layout and staff requirement
o Material handling
o Budgeting
o Cost of calculation
o Procurement of finance

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Capacity planning:
Capacity: Capacity is the maximum rate of output for a process.

o Production capacity is depend on as well as affected by facilities,

equipment, processing, method, labor and supplies.
o If facility is too large, portions of it sit idle and add cost to existing
system.
o If facility is too small, customer and perhaps entire markets are
lost.

Production planning, sequence & operations:

 Production parameters
 Description of production process
 Daily production report
 Monthly average production
 Production flow chart
 Monthly efficiency
 Remarks

Production planning: Production planning is a suitable & clear study and

pre-arranging the technique involve to a long series of operation for achieving
best possible time by using man, machine, materials present in industry.

Production engineering:The engineering approach which is used

applied in every stage of production process of a product is known as
production engineering.

Production engineering includes:

 Ensure smooth production

 Involves with maintenance management
 It is applied on every stages of production

Pre-production meeting (PPM):

When clothing factory confirm a new order, general manager arrange a
meeting in the elementary stage of the production that’s called pre-production
meeting (PPM). It is also known as PP meeting in apparel industry. In this PP

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meeting some important persons from the buyer and suppliers side are
attained to take valuable decision. This pre production meeting is most
essential to increase the defect free production in the apparel industry. They
are discussing different production related matters that are directly involved
in garment production. After approve the PP sample generally PP meeting
should organize on an average 2 weeks. If this is not happened then the Buying
agent and supplier negotiate and fixed their possible date.

PP meeting places and Persons to be present for this meeting: 

PP meeting commonly occupied in apparel factory or in buying house &
some time in both places. PPM processes not totally different from one place
to another. Small differences can be seen these are in below: 

PP meeting in apparel factory: 

To bring out all the info about production process PP meeting is most
essential for supplier’s factory. Because only buyer’s official documents,
requirements, specifications, and sample comment may not be enough to
understand everything properly. Whereas, maximum production related
peoples are less educated therefore, buyers are always concern about that
and take every single steps to get high quality & defects free garment. If
suppliers factory is not follow the buyer’s requirements then customer might
ask for discount or cancellation. 

Matter of the discussion in PP meeting: 

 Production schedule.
 Pattern review.
 Size set sample review.
 Inventory of raw materials.
 Testing detail about fabric
 Cutting detail
 Accessories inventory.
 Sewing and stitching info
 Line layout design.
 Machine layout
 Operator per line & name
 Skilled operator in each machine
 Q.C. application

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  Finalizing & selection skilled operators
 Q.C. selection, names & card number etc
 Wet processing review
 Print special attachment review.
 Finishing & Packing process.
 Others

QC & QA:

Sewing QA (Quality Assurance System):

 Daily style wise styling ensure with report
 Daily styling compare with another line & keep report
 Daily line wise inline inspection with counseling the defects
garments related concern person & keep report
 Style wise measurement before wash & after wash
 Weekly fill-up sop checklist
 Record monthly styling mistake summery
 According to initial and pilot report follow up further production and
make status initial, pilot run, top, p/s status
 Daily sewing line QA defects percent send by viber

Finishing QA (Quality Assurance System):

 Style wise styling ensure with report
 Daily style basis inline and pre-final inspection with moisture check
and keep report.
 Monthly record style po wise inline pre-final pass fail, and packing
mistake record
 Daily style wise inline and pre-final passed fail report maintain and
send by mail.

QC(Quality Control):In the apparel industry quality control is

practiced right from the initial stage of sourcing raw materials to the stage of
final finished garment. Quality control in garment industry is very complex
and lengthy task. There are several stages to control quality in garment

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manufacturing. They are given below: 

 Pre-production quality control

 Quality control during production
 Final inspection
 Quality control to developing a sampling plan
 Post-production quality evaluation

Pre-production Inspection:
The following parameters & defects are checked prior to cutting.
 Shade Matching
 Fabric Construction
 GSM (grams per square meter)
 Softness
 Shrinkage
 Matching of Rib, Collars & Cuffs
 Fabric Holes
 Vertical & Horizontal Stripes
 missing loops, sinker lines, etc.
 Bowing
 Skewing
 Yarn defects such as thick & thin places
 Dirt's & Stains

During Production Inspection:

 Verify cutting patterns
 Cutting shapes
 Fabric defects
 Other specific parameters as required by the buyer Rib, Collars & Cuffs
matching
 Stitching defects
 Sewing threads matching
 Dirt`s & Stains
 Measurements
 Labels
 Trims & Accessories

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Final Inspection:
 Wrong Quantity
 Missing labels & tags
 Wrong Size & Color assortment
 Wrong Folding
 Wrong Shade
 Uneven dyeing
 Holes
 Knitting stripes
 Thick & Thin places
 Dirt & Stains
 Oil stains
 Crease Marks
 Open seam
 Puckering
 Needle holes & marks
 Unbalanced sleeve edge
 Unbalanced placket
 Insecure shoulder stitch
 Bottom hem bowing
 Uneven neck shape
 Cross labels
 Broken & Missing stitch
 Insecure buttons
 Untrimmed threads & fabrics
 Poor Ironing
 Double stitch
 Shade variation within the garment parts
 Shade variation between the garments

RQS (Requirement for quality system):

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Summary of minimum requirements (MR) of H&M for supplier
Step 1 (Minimum requirement-1):
 Is all color matching done in a light box with grey non-shiny walls and
possibility of total darkness?
 Are 2 persons checking together in all 3 lights, evaluating against
standard throughout the whole production?
 Does the light box contains H&M shop light TL83, Daylight D65, A-light
and UV light specified in color?
 Are the tubes used in pairs and 4 lights bulbs 40W for Alight for good
light level or is lux value min 1500 lux?
 Is the fabric check acc to fabric inspection guideline 4-point system or
similar (by 2 persons max-2 hours without break w. records kept)?
 Does the supplier visually inspect a minimum of 10% of the bulk fabric,
1000 m, representing all colors and dye lots?
 For other materials, does the supplier have an efficient method of
material inspection report ? all colors with records kept?
 Are all goods stored good air circulation/controlled humidity , off the
floor/away firewalls, covered when need/not stacked too high?
 Does babies and children's garments suppliers/ factories have a safe
button and accessories testing machine?
 Are all accessories like buttons, rivets, etc. tested for 90N fastness every
4th hour during production?
 Are tested garments permanently mark on front date, time signature
machine no and kept separately from bulk production in locked
container available for H&M staff and destroyed after 6 months?
 Are all goods stored w good air circulation/ controlled humidity, off the
floor/away from walls, covered when needed/ not stacked too high?
 Is H&M broken nidi and sharp objects policy or similar followed?
 Are all buttons sewn with lockstitch machine?
 Is needle detection made according to guideline for needle and sharp
object control?
 Is needle detector 9 point calibrated minimum 3 times a day?
 After detection, are the products held separate in a “metal free zone” in
the packing area?
 Are rejected goods kept in a locked box ?
 Are all finished goods stored country wise on pallets with good air
circulation and away from the walls?

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 Minimum Requirement -2 for H&M
 Do the independent QC team work totally independent from the
production team & report directly to the top management.
 Does the H&M sample responsible make sample control & create a
sample report incl. comments reg. all unclear points, sent w. sample to
PO?
 Are duplicate counter sample available in all production units &
departments, marked with o/n seal no/ comments/ date?
 Are colors/ shades controlled by color continuity records w. shades/
families of shades sorted and marked into planned country, after
checking dye lot to dye lot, within a dye lot 7 within a roll.
 Garments washed/ fused product: Are shrinkage tests of bulk fabric
yarn, all colors & lots, done prior to cutting/ knitting w. records kept?
 Garments washed/ fused products: Are cutting/ knitting pattern adjusted
w. correct shrinkage all. If needed several diff, prior to cutting/ knitting?
 Do the supplier perform nickel test acc. To H&M instructions?
 Is supplier conducting pre production meeting, style by style, with all
persons involved before & during the production attending?
 Does supplier have a process control system as described in RQS or
similar/ also for other parts e.g. embroidery, linking etc?
 Are all goods dry & clean when packed?
 Is factory ware-hoses dry & with good ventilation?
 Is insects net used in finishing area/ packing area/ metal free zone and
to close / cover doors & windows?
 Are goods kept, and eating done in designated areas only and factories
including; washrooms, kitchen and lunched room kept clean & dry.
 Are goods kept off the floor during production?

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  Does supplier follow AQL/ sampling plan acc. Random from finishing in
all size, colors and countries acc. To size break down/ records kept

Admin
Working Area Of Admin:

  Daily attendance report by attendance machine.

  Weekly attendance report by attendance machine.
  Monthly attendance report by attendance machine
  ID card prepare.
  Operators personal file prepare.
  Daily machine inventory.
  Daily man power report.
  Daily HR history position.
  Leave-taking procedure follow up.
  Leave letter issue.
  Leave report.
  Regain report.
  Attendance bonus report.
  Over time check report.
  Old id card repaired.
  Attendance missing report.

Compliance:
Compliance means agreement with Apparel Compliance. Most of the apparel
industry used Compliance of ILO. Bangladeshi apparel industry used
Compliance of ILO & Apparel Compliance. Some contents of compliance with
ILO and Bangladesh Labor Laws are given below. …

 No child labor.
 No forced labor.
 Transport facilities for worker.
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  Hours of work.
 Voluntary over time.
 Intervals for rest.
 Weekly holidays.
 Annual leave.
 Festival holidays & leaves with bonus.
 Maternity protection.
 Worker’s welfare committee.
 Mineral drinking water.
 Sanitary facilities.
 First aid box.
 Canteen services.
 Day care center.
 Health care activities for the worker & employ company doctor.
 Fire extinguisher each & every floor & conduct fire drill at least 12 times
a year.
 Other safety department (no discrimination).
 Compensation cases department.
 The development of compliance programmer.
 Environmental developer.
 Smoking free zone.
 Disciplinary Practices/ Harassment.
 Freedom of association and right to collective bargaining.
 Welfare facilities.

Human Resource Management (HRM) in Ananta

Garments Ltd:

Human resource management (HRM) in garment industry has been defined

as the function in garment factory that facilitates the most effective
utilization of human resource to achieve the objectives of both the garment
factory and the employee. HRM is known by different names – Personal
management, personal administration, man power management.
The successful functioning of apparel industry is determined by the factors like
men, material, money and market. Among all these factors, manpower
assumes greater significance. So we can say that, there is no doubt that the
“personnel” as the principal resource of a labor-intensive garment industry
plays a crucial role in any productivity improvement and development. Every
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success of origination is depending on efficient and effective man power.
Further, this argument is supported by the facts that labor compromises about
20% of the cost price of a garment. Therefore, the way people are directed,
motivated, or utilized will be decided on whether the organization will be
prosperous and survive or fail. Hence, people are the key element for
competitive advantage and the most significant resources of any organization.
Function of human resource management in garment industry are given
below:

Activities of Human resource management in Ananta group:

 Recruitment
 Interview
 Salary fixation
 Allowances
 Posting/probation/confirmation
 Increment
 Promotion
 Transfer
 Training
 Discipline
 Elimination of job
 Working hour and leave
 Award
 Bonus
 Public relation
 CSR
 Financial grant and fund generation
 HRM database
 Mobile allocation
 Dormitory service
 Transport service
 Service charges
 Internship

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 Welfare:
Role & Responsibility of Welfare Officer under Factory Act Rules
 
To encourage provision of amenities such as canteens, shelters for rest,
creches, adequate latrine facilities, drinking water, sickness and benevolent
scheme payments, pension and superannuation funds, gratuity payments,
granting of loans and legal advice to workers;

To help the factory management in regulating the grant of leave with wages
and explain to the provisions relating to leave with wages and other leave
privileges and to guide the workers in the matter of submission of application
for grant of leave for regulating authorised absence;
 
To advise on provision of welfare facilities, such as housing facilities,
foodstuffs, social and recreational facilities, sanitation, advice on individual
personnel problems and education of children;
 
To bring to the notice of the factory management the grievances of workers,
individual as well as collective, with a view of securing their expeditious
redress and to act as a liaison officer between the management and labour;
 
To establish contacts and hold consultations with a view to maintaining
harmonious relations between the factory management and workers;
 
To study and understand the point of view of labour in order to help the
factory management to shape and formulate labour policies and to interpret
these policies to the workers in a language they can understand;
 
To watch industrial relations with a view of using his influence in the event of
a dispute between the factory management and workers and to help to bring
about a settlement by persuasive effort;
 
To advise on fulfilment by the management and the concerned departments of
the factory of obligations, or otherwise, concerning regulation of working
hours, maternity benefit, medical care, compensation for injuries and sickness
and other welfare and social benefit measures
 
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To promote relations between the concerned departments of the factory and
workers which will bring about productive efficiency as well as amelioration
in the working conditions and to help workers to adjust and adapt themselves
to these working environments;
 
To encourage the formation of Works and Joint Production Committees,
Cooperative Societies and Welfare Committee, and to supervise their work;
 
To advise the factory management on questions relating to training of new
starters, apprentices, workers on transfer and promotion, instructors and
supervisors, supervision and control of notice board and information bulletins
to further education of workers and to encourage their attendance at technical
institutes; and
 
To suggest measures which will serve to raise the standard of living of workers
and in general promote their well- being.
 
Welfare Officers not to deal with disciplinary cases or appear on behalf of the
management against workers. - No Welfare Officer shall deal with any
disciplinary cases against workers or appear before a conciliation officer in a
court or tribunal on behalf of the factory management against a worker or
workers.

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 Conclusion:
Ananta has now established in the world as a manufacturer of reputed fabric
and capable of Producing value added products and executing difficult orders
at very short lead time. The Planning, organizing, controlling, designing,
creativity, the technical skill and above all the Quality conscious have
cemented the base of this leading textile industry. With highly advanced
Technology and an emphasis on developing local human resources, its seems
to be Clear that Ananta group of textile has the potential to make an
important contribution to the Nation growing readymade, garments export
sector and makes an example for others.

We have found ourselves fortunate to have our industrial training at Ananta. It

has a huge Production capacity with a very efficient production team. Ananta.
Has very well, well Equipped and modern Machineries and producing a wide
range Product. During our training Period we have noticed that Ananta is very
concern about their quality and they rarely Have any quality complain. The
management of Ananta is very organized, pre-active and Co-operative.

At the end of the day we realized that industrial training makes our
knowledge’s application Practically and make us confident to face any problem
of our job sector.

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