Final Poject Aama Garment

WOLKITE UNIVERSITY
COLLEGE OF ENGINEERING AND

TECHNOLGY
DEPARMENT OF GARMENT ENGINEERING

INTERNSHIP FINAL REPORT AND PROJECT
HOST COMPANY: ADAMA GARMENT INDUSTRY
PROJECT TITLE: QUALITY IMPROVING IN SWEING SECTION
PEREPARED BY: -KIBRU BELAYNEH…………………….519/09
-WONDESEN BEKELE………..................908/09
ACADAMIC ADVISOR: MR. JEMAL

ASSRES
[INTERNSHIP AT ADAMA GAREMENT
INDUSTRY] 2013E.C/2021G.C
COMPANY ADVISOR: MR. GIREMA. A
SUBMITTED DATE: 19/06/13E.C
DECLARATION
We are kibru Belayneh and Wondesen Bekele a 4th year students of Wolkite University taking
apparent ship at Adama garment industry for two month. We was working effectively on the
company and the company approved our existence with their certificate. We give our regards to
all peoples but after this anyone who like to use this paper have to mention the outer of this
project.
MR. JEMAL ASSRES __________________ _____________
Name of Academic Advisor Signature Date
MR. JEMAL ASSRES __________________ _____________
Department Head Signature Date
KIBRU BELAYNEH ___________________ 19/06/13 E.C
WONDESEN BEKELE ___________________ 19/06/13 E.C
Name of Students Signature Date
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ACKNOWLEDGMENT
Before the beginning of anything we would like to thank “GOD” and his mom for the endless
blessing. Next to that we need to give condolence thanks for who participate in this paper and
make the dream true, my university advisor MR.Jemal Assres and company advisor MR.Germa
we like to thanks our families for the best motivation, friends, the adama garment industry stuffs
specially in sewing room 2 production manager MR.Abedulab, folding ayelech thanks all for
your shearing everything what we have got. Finally all employee at adama garment industry.
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EXECUTIVE SUMMERY
Internship is a certified way to gain relevant knowledge, skill and experience while establishing
important connection in the field. This final internship report covers our two months stay in AGI.
This paper is a written report about the internship program. It is a clear fact that the knowledge
of garment engineering cannot be upgraded without practical experience in each field of the
subject matter.
Chapter one
This chapter consists of brief history of the company, the raw material and accessory Supplier,
raw material quality parameters, organizational structure and work flow of the section, main
product or service and main customers or the end users of its product.
Chapter two
Discuss about a project work which we have done on effective improving quality for adama
garment industry. The project contains project title, project statement, objective of the project,
methodology, identified problems and their solutions and conclusion and recommendations.
Chapter Three
Deal with, the overall benefit of internship practice, in terms of improving practical skills,
upgrading theoretical knowledge, interpersonal Communication skills, team playing, leadership
skills, work ethics and entrepreneurships.
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TABLE OF CONTENTS
DECLARATION..............................................................................................................................................ii
ACKNOWLEDGMENT...................................................................................................................................iii
EXECUTIVE SUMMERY................................................................................................................................iv
LIST OF FIGURE...........................................................................................................................................vii
LIST OF TABLE............................................................................................................................................viii
ACRONYMS AND ABBREVIATION................................................................................................................ix
CHAPTER ONE..............................................................................................................................................1
1. COMPANY PROFILE..................................................................................................................................1
1.1 BACKGROUND OF ADAMA GARMENT INDUSTRY..............................................................................1
1.2 VISION OF ADAMA GARMENT...........................................................................................................2
1.3 MISSION OF ADAMA GARMENT........................................................................................................2
1.4 OBJECTIVE OF THE INDUSTRY............................................................................................................3
1.5 CORE BUSINESS OF THE INDUSTRY....................................................................................................3
1.6 CORE VALUES OF THE COMPANY......................................................................................................3
1.7 DUTY OF THE INDUSTRY....................................................................................................................3
1.8 STRATEGIES OF THE COMPANY.........................................................................................................3
1.9 WORKERS IN ADAMA GARMENT INDUSTRY......................................................................................4
1.10 RAW MATERIAL USED IN AGI...........................................................................................................4
1.10.1 ACCESSORY USED IN ADAMA GARMENT..................................................................................5
1.11 ORGANIZATIONAL STRUCTURE OF ADANA GAREMENT FACTORY...................................................6
1.12 WORK PROCEDURE OF THE COMPANY............................................................................................7
1. 13 DEPARTMENT AND THEIR FUNCTION...........................................................................................10
1.15 MAIN PRODUCTS OF ADAMA GARMENT INDUSTRY......................................................................19
1.16 THE MAIN LOCAL AND FOREIGN CUSTOMER OF AGI.....................................................................20
1.17 VARIETIES OF PRODUCTS IN PICTURE............................................................................................21
CHAPTER TWO...........................................................................................................................................22
2. QUALITY IMPROVING IN SEWING SECTION...........................................................................................22
2.1 INTRODUCTION...............................................................................................................................22
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2.2 STATEMENT OF PROBLEM...............................................................................................................23

2.3 OBJECTIVES OF THE STUDY..............................................................................................................24
2.3.1 GENERAL OBJECTIVES...............................................................................................................24
2.3.2 SPECIFIC OBJECTIVES................................................................................................................24
2.4 SCOPE OF THE PROJECT...................................................................................................................24
2.5 SIGNIFICANCE OF THE PROJECT.......................................................................................................24
2. 6 LIMITATIONS OF THE STUDY...........................................................................................................25
2. 6.1 OVERCOMING OF THOSE LIMITATIONS...................................................................................25
2.7 LITERATURE REVIEW........................................................................................................................25
2.8 METHODOLOGY...............................................................................................................................28
2.8.1 DATA COLLECTION....................................................................................................................28
2.8.2 PRIMARY DATA.........................................................................................................................28
2.8.3 SECONDARY DATA....................................................................................................................31
2.9 DATA ANALYSIS................................................................................................................................33
2.9.1 DATA ANALYSES IN SEWING SECTION.......................................................................................33
2.9.3 RECORDING DATA IN SEWING SECTION...................................................................................35
2.9.4 SOLUTION FOR THE ABOVE PROBLEM......................................................................................38
2.10 RESULT AND DISSCUTION..............................................................................................................38
2.10.1 AFTER IMPLIMENTATION........................................................................................................40
2.12 CONCLUSION.................................................................................................................................44
2.13 RECOMMENDATION......................................................................................................................44
CHAPTER THREE........................................................................................................................................47
3. INTERSHIP EXPRIENCE...........................................................................................................................47
3.1 BENEFIT WE GAIN FROM THIS INTERNSHIP.....................................................................................47
3.1.1 PRACTICAL SKILLS.....................................................................................................................49
3.1.2 THEORETICAL SKILL...................................................................................................................50
3.1.3 COMMUNICATION SKILL...........................................................................................................50
3.2 CHALLENGES FACED FROM INTERNSHIP EXPERIENCE.....................................................................50
3.2.1 FACILITY PROBLEMS..................................................................................................................50
3.2.2 FINANCIAL PROBLEMS..............................................................................................................50
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LIST OF FIGURE
Figure 1 Company view..............................................................................................................................1
Figure 2 Spreading room...........................................................................................................................12
Figure 3 Cutting room...............................................................................................................................12
Figure 4 Sewing room...............................................................................................................................14
Figure 5 Garment factory..........................................................................................................................15
Figure 6 Heavy duty..................................................................................................................................16
Figure 7 Weaving section..........................................................................................................................16
Figure 8 Embroidery section.....................................................................................................................17
Figure 9 Printing section............................................................................................................................18
Figure 10 terming and quality check.........................................................................................................18
Figure 11 varieties of products in AGI......................................................................................................21
Figure 12 different types of defects...........................................................................................................30
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LIST OF TABLE
Table 1 Machine availability in cutting room............................................................................................13
Table 2 Machine availability in sewing room............................................................................................14
Table 3 Data analyses in sewing room......................................................................................................33
Table 4 Record data in sewing section......................................................................................................35
Table 5 Problem cause and solution..........................................................................................................38
Table 6 Record data after improving.........................................................................................................40
Table 7 Record data change in to time.......................................................................................................41
Table 8 Compere the data before and after................................................................................................43
viii
ACRONYMS AND ABBREVIATION

AGI----------------------------Adama garment industry
HDF---------------------------Heavy duty factory
GM----------------------------General Manager
PM-----------------------------Production manager
CAD--------------------------Computer aided design
CAM-------------------------Computer aided manufacturing
HR---------------------------Human resource
SMV------------------------Standard mine value
PPC-------------------------production planning and control
NOW-----------------------Nap one way
NUD------------------------Nap up and down
NEW------------------------Nap either way
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CHAPTER ONE
1. COMPANY PROFILE
1.1 BACKGROUND OF ADAMA GARMENT INDUSTRY
Figure 1 Company view

Adama Garment Industry was established in 1980 E.C. from the capital city of Addis Ababa 105
KM. western region of Adama town. The factory was established by gating the support from
Korea Republic about 500,000(us dollar) this money used to buy different kind of machine.
At the establishment Adama garment industry was known by the people by Nazareth canvas
sewing factory. This factory occupies 113,500m2. This company follows from 1980-1998 E.C.
under the commission of defense and engineering industry, from 1990-1994 E.C. under metal
and agency also from 1995 up to now under metal and Engineering Corporation. Under the name
of metal and engineering and Adama garment industry (AGI).
This industry covers 85% of the demand of clothes and related military product and 15% of
commercial product. Currently it’s the only industry that supplies UN tent to all peace keeping
force of deployed by UN. Adama garment industry is made all military clothes regarding with all
quarter master items provide to national army’s and foreign national army’s and also made
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commercial products to governmental and non-governmental offices, companies, industries and

organizations.
The factory has Office, design room, military uniform sewing room, heavy duty room, parachute
room, embroidery room, weaving section and cafeteria, parking all are the most known sections.
In Adama Garment Industry there are totally 5-manifacturing unit. These are
 Heavy duty
 Parachute and drug chute
 Garment manufacturing
 Shoes and gloves manufacturing
 Calvin and furnishing manufacturing
But from those units’ shoes and gloves manufacturing is placed at Northern part of Ethiopia at
Adowa town.
1.2 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 center 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.
1.3 MISSION OF ADAMA GARMENT

Creating national industrial technology network 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 centers. 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
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work. Create collaboration with different organizations and introduce new technological
Achievements to the country. Obtain hard currency by selling different garment products to the
market.
1.4 OBJECTIVE OF THE INDUSTRY

Develop technologies Objective that satisfy armed force garments and military requirements at
the desire time and place perform engineering activities that support industrial development and
specifically the garment industry.
1.5 CORE BUSINESS OF THE INDUSTRY

Manufacturing of commercial products, military uniform, gown (for many purpose), sleeping
bags, waist belt, covers (for many vehicle), raincoats, parachutes, shoes, gloves, smart clothing
for chairs of cars, trains, air plane and automobiles dashboard covers and etc…
1.6 CORE VALUES OF THE COMPANY

The factories 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 plan

 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 our development
 Team work is our culture
 Increasing productivity is our target
 Improvement is the growth for our development
Honesty, industriousness, good work habit and open mindedness are the best features of our
work.
1.7 DUTY OF THE INDUSTRY

The factory has legal organization and they have their own duties such as: - Produce and sell
Canvas, leather and twill products. Produce different types of civil clothes. Produces and sell
canvas products. Buy raw materials from local and foreign markets. Be Profitable and to be a
3
Produce military uniforms clothes and title showing signs (defense, police and federal marimya
bet signs) Sources of income for military defense.
1.8 STRATEGIES OF THE COMPANY

The factory has different prospective such as work core values, work philosophy, systematic core
values, organizational work culture and have the following core values: -
 The first target in our industry is to satisfy our customer

 Everything we work is by our plain.
 Corruption is the main challenge for our development
 Team work our culture
 Our workers are the main resources for the industry
 Improvement is the growth for our development
 Honesty, industriousness good work habit and open mindedness are the best features of
our work.
1.9 WORKERS 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 113, 500sq.mts.
1.10 RAW MATERIAL USED IN AGI

 100%cotton fabric
 PC (polyester cotton blend) fabric
 Polyester blend fabric
 Teheran 6000 fabric
 Canvas
 Accessories
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 Leather
 Thread
FABRIC SUPPLIERS FOR ADAMA GARMENT INDUSTRY
 Alameda T.S.C
 Awash T.S.C
 SygenDema factory
 Aica Addis factory
 M lead limited company
 Amaga L.C
 Indonesia
 India
ACCESSORIE SUPPLIERS FOR ADAMA GARMENT INDUSTRY
 Gafat armament industry

 Cotebe metal factory
 Hiberet manufacturing industry
 Merkato market
CANVAS SUPPLIERS FOR ADAMA GARMENT INDUSTRY
 Almeda T.S.C
 Double S business group
 Hambone general trading
 WS business group
LEATHER SUPPLIERS FOR ADAMA GARMENT INDUSTRY
 Mojo leather factory

 Coleba leather factory
 Ethio leather industry
THREAD SUPPLIERS FOR ADAMA GARMENT INDUSTRY
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 Ethio thread factory

 Ember thread factory
 Salina trading
1.10.1 ACCESSORY USED IN ADAMA GARMENT

 Two holes &three holes' metals……………………………. End clip
 End clip pool bag Hook spring……………………………. snap button
 Canvas olive………………………………………………. polyester thread
1.11 ORGANIZATIONAL STRUCTURE OF ADANA GAREMENT FACTORY

Army Foundation
General manger
Audit Design and development
Rule and regulation Inspection and quality
Security and safety Supply and store
HR Finance Operation Material Marketing

administration administration management and sale
development
Engineering Vice operation

team manger
Heavy duty Parachute and drug

shut factory Garment factory Coven and decorative
factory
factory
Industrial engineering (PPC)

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Cutting section Sewing section Finishing Weaving Embroidery
Supervisor Supervisor Supervisor Supervisor Supervisor
Team leader Team leader Team leader Team leader

Team leader
1.12 WORK PROCEDURE OF THE COMPANY
Design &
Order Sample
development Material
receiving making Inspection sourcing
Sewing Numbering
& ticketing Cutting Marker
Spreading
making
Inspection Inspection
Final Matching
Inspection Trimming Inspection ironing & packing
Some of the process in details: -
A, Order taking: this process is done by the customer (owner of the order) and company
manager treaty or dell which is either by phone, email, Posta or/and face to face communication.
After they meet or discuss about the order, they make decision about the product delivery time,
shipment (to foreign country or inside the country), sourcing material (from local market or
foreign markets) and etc…
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B, Design and development: in this section they make design for specific order according to the
given specification or re-engineering (deconstructing the garment and taking measurements) and
patterns are made in this section and also grade the patterns in the given order of sizes.
Function of sketching: the function of sketching is to give full information about the products or
representing of one object.
In Adama garment industry orders comes in two forms: Customers may send specification sheet,
the develop pattern based on the specification sheet.
C, Store room: Store is a place where raw materials, accessories, work aids, finished goods and
machineries are placed.
Sourcing materials: all materials required for production purpose of specific order is received
from main store and may temporarily store in the satellite store of the section where it is to be
produced, the section head is responsible to retrieve these material from the satellite store for
production in controller manner.
D, Sampling operation: in this operation class they make samples for reduces errors and body
fitted garments or products in the order they take different sizes like S, M, L, XL and XXL etc…
Sampling 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 Products in the order they take different sizes Sample making also cover
by cutting room.
E, Marker making operation: this is the pre-production section by which all component parts
making up the product are trace on the required rolled fabric.
The operation is done by using pattern in the sizes of the parts in tracing section. 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 because 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.
8
F, spreading operation: in this section the fabric is spread on the spreading table and make sure
that the edge of the fabric correctly matched.
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
is spread of knave by manual.
G, cutting operation: cutting is the next operation after spreading and it is making each
component parts ready for sewing operation. This is done by machines such as straight (to cut
large component) and band knife (to cut small pieces or component) and also by using other
machineries. After cutting operation is completed each component parts are coded and numbered
to avoid parts mixing.
Garment cutting room manufacturing process
Design Get pattern Get marker Check marker quality
Check cut panel Numbering Cutting Spreading fabric
Bundling Check if embroidery/ fussing Input into sewing.
H, Sewing and in-process ironing: sewing is the main operation of the section that assembles
each component parts which is prepared by the cutting operation in the desired shape and sizes.
Sewing operation includes: stitching, ironing, quality inspection and etc…Other operation such
as accessory attachment is also included under this process step.
There is long table between machines, which serves the material flow from one operator to
another.
Once the operator finishes his/her operations to the next operator in the table and this process
continues to the end, the work in progress (WIP) movement carried by hand manually.
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.
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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.
I, trimming operation: trimming operation used to remove extra sewing threads which enhance
the quality of the product.
J, Final ironing operation: is under taken to increase the attractiveness of the product, this
might be the final operation made to the product.
K, Inspection: the final garments from last operation are fully checked and corrected
immediately for any defect.
L, Matching and packing: this is the last operation of the section and involved in matching
products according to the similarities and/ or as required. After matching is completed the
products will be packed as specified in the requirements.
1. 13 DEPARTMENT AND THEIR FUNCTION
DESIGN AND DEVELOPMENT ROOM
In this section which makes design, pattern and also grade patterns according to the order
receiving from customer. But each factory has their own design and sampling department. All
the designs of the styles are made by customer demand order based on specification.
The samples of the garments are made depend on design type. In each factories sampling
department are depending on the type of products and order. The sample maker to developed &
(pattern and grading) are done by manually which is absence of CAD or other IT systems for
producing of sample.
The materials which are used in the designs and development room are: sewing machine, rubber,
pencils, rulers, measurement rape, scissors, pens, French curve, hip curve, mechanical pencils
and sharpener, straight pin holder (pin cushion), hangers hook or ringers (which hold the patterns
of one style or one garment component), tracing wheels, awl (which used to indicate the ending
of darts, pockets, trim and button hole placements), hard paper (A3) and so on.
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Design and development head has duties and responsibilities to checks:
 Grain line accuracy

 Size measurements missing parts
SAMPLE MAKING SECTION
The requirement of sample making before mass production is: -

 For time study
 For operation break down
 Give correction of fitness
 Modify and develop the pattern industry sample making are done in pattern room.
MARKER MAKING ROOM
After they completed the sample making process the next step is marker making. The area which
is covered by marker making room is 3.5m and 10.5m length (3.5*10.5 m^2). Inside in the
marker making room there are many and different types of patterns of styles or the garments
which are held by hanger placed in the wall.
The marker making table is 1.5m width, 9m length and 0.78m height from the ground. The
operators are work this marker making process by standing position which is high fatigue to the
operators (this means the marker making process are done by 100% in manually), the marker is
done on the fabric and they have only one marker making table.
When we see their marker efficiency it is really we appreciates and it is very good because they
are highly experienced, among from the workers which they are work in this marker making
section. We ask some of the workers which they are work in this garment factory at least for
minimum of 6 up to 18 years in tracing pattern. This goes to work in high efficiency. But there is
lack of knowledge about marker making type like: block or sectioned marker (contain all pattern
pieces for one style in one or two size), continuous marker (contain all pattern pieces for all
sizes), and splicing marker (which used when a roll change is made and short length of fabric).
SPREADING ROOM
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In this garment factory there is no individual spreading room but they have their own position or
place and the spreading and cutting process are made in one table. They have only one
spreading/cutting table. The spreading table has 12m length, 2m width and 0.87m height from
the ground. The rolls are manually spread on the spreading table, the work forces on spreading
sections are the following: -
 one spreader,
 Six plies tension controller
 Two edge aligner
 One quality checkers and one end cuter which is totally 11 workers in spreading process.
The maximum numbers of plies are 99 and another one is the marker is made it which is totally
100 plies in one lay they spread.
The duty and responsibility of quality checkers in spreading sections is seeing and control the
following things: -
 Count the number of plies

 Ply alignment
 Width of fabric
 Plies tensions
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Figure 2 Spreading room
CUTTING ROOM
In cutting section there are three band knife machine, two straight knife machines, and two close
drill machine, Once the rolls of fabrics are spread and which are checked by quality checkers and
seeing all the quality requirements they done the next process is cutting, first they start from
cutting large component by using straight knife machine and then goes to separate small and
large components, the small components are cut by band knife machines.
Figure 3 Cutting room

Machine availability in cutting room
Table 1 Machine availability in cutting room
Machine available in Machine name Quantity Machine code

cutting room s/no
1 Straight knife 2
2 Band knife 2
3 Driller machine 1
4 Scissor 3
5 Numbering machine 2
Total machine in 10
cutting room
SEWING ROOM
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This section is covered around 85% of the garment factory which includes marker making room,
supervision room, and inspection place, roll fabric place, spreading/cutting place, tasting and
bundling place, packing and finishing place and also warehouse (area which finished products
are placed).
Most of the sewing machines are single needle lock stitch ,some are double needle, button hole
machine, over lock machine, MS machine double needle with binder, interlock machine, button
attach, bar tucker, double needle over lock machine, cuff iron and collar iron.
In this section there is satellite store which used to keep needles (for different machine), sewing
thread, buttons, zippers, accessories, trims and etc. Which used to reduce the distance, the time,
unnecessary movement to pick materials from the main store which is far from the garment
factory.
Operations done in sewing section are stitching, ironing; quality inspection and etc…Other
operations such as accessory attachment are also included under his process. In each sewing line
there is one supervisor.
Duty of the supervisors are cheek fault seam, puckering seam, open seam, pleated seam, skipped
stitch, and missed stitch, loose thread, security of back stitch and so on.
Figure 4 Sewing room

Machine Available in Sewing Section
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Table 2 Machine availability in sewing room
s/no Machine type Brand name Quantity

1 Jack single needle JK-8700 24
2 Zoje single needle ZJ 9701R-D3/PF 43
3 Double needle spelt parser foot ZJ 8750-5 1
zoje
4 JUKI Single needle LH-3128 15
5 Typical single needle GC5550 14
6 Zoje single needle ZJ 9701R 4
7 Zoje single needle ZJ 5300R-02B 3
8 Zoje single needle 120401005 2
9 Zoje Zigzag zJ457B 4
10 Punch pocket prepration LH-896N 2
11 Double needle juki LH_3128 9
12 Cuff Irons STP/15 1
13 Collar Iron STc/T 1
14 Zoje cap attach ZJ9610 2
15 KANSAL placket attach FBX1104P 2
16 Over lock(pagasus) LS2-o1 2
17 Inter lock GEMSY GEM_757FXH 2
18 Over lock GEMSY GEM-737-F 2
19 Over Lock(pagasus) L52-o1 2
20 Siruba inter lock 516m2-55 7
21 Waist band Zoje ZJ1508PR 1
22 Hailet machine Juki MAX-03 1
23 Button Hole Juki LBH-1790-5 5
24 Button Attach Juki LK-1903AN-SS 4
25 Bar tacking Juki LK-1903AN-ss 8
26 Air Compressor 270 L ABAC 1
27 MACPI steam iron - 12
DIFFERENT SECTION OF ADAMA GARMENT INDUSTRY

1) Garment Factory
This unit is the second factory after heavy duty in the company. In this factory different kind of
products are produced. Some of them are; ranger for solider and officer, jam per overall, shirt,
trousers, ties, gown and etc.
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Figure 5 Garment factory

2) Heavy duty
Heavy duty it’s the oldest of all in the company. Heavy duty from the name we understand that
heavy material that directly related to solider or military purpose is manufacture here. Some of
the products produced in this unit are: vest, bullet proofing, jacket, gun holder, bullet bag, holster
and different tent.
Figure 6 Heavy duty

3) Weaving Section
In this section the main product is military belt. One spinning machine was there that used to
change the thread in to the cone form, it’s used to facilitate the weaving section. Six weaving
machines where settle one into the other.
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There are two new machines that produce belt using nylon thread. The other two machines
producing using nylon cotton blend (NC) thread but the rest two machines were not working.
Figure 7 Weaving section

4) Parachute and Drag chute
This is also the newest factory than the rest of the company factories. This factory did not start
production still now this because of there is no ordered. Currently, they produce small quantity
of products that support for garment unit through producing quantity items.
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.
This machine is used to stretch the nylon fabric and the area is 120*120cm 2. It uses pneumatic
lifter to hold the spreading table to move. Also, there are 10 hand holders in one way. So, totally
40 holders are there to stretch the fabric.
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Figure 8 Embroidery section

PRINTING MACHINE
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
Figure 9 Printing section
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FINSHING ROOM
In this section some activity is done to improving of the garment quality such as Ironing,
Togging, Quality checking, Stain removing, Packing, Button attaching Bar taking, Rivet attach
and Trimming.
Figure 10 terming and quality check

MAINTENANCE IN AGI
Machine breakdown is one of the major problems that can affect the productivity of the industry.
During the field study it was observed that there is un planned and unsatisfactory recording of
maintenance system .operators have high waiting time for mechanics due to their machine
breakdown during production on addition to this the maintenance head and mechanics were
interview about type and program of maintenance system used in Adama garment industry and
the attention of top management to this issue .accordingly the machine are maintained after
breakdown or after machine stop during operation that means breakdown maintenance is used in
this industry the overall maintenance is performed ones a year.
Failures accord frequently at the most in opportune times and severely disrupt production there is
no scheduled or preventive maintenance program.
19
Generally, the control and monitor mechanism of the maintenance system of the industry is very
poor there is also forward that the management attention to this problem is very poor and the
skill and knowledge of the maintenance worker is limited.
1.15 MAIN PRODUCTS OF ADAMA GARMENT INDUSTRY

Product is the outcome of a production process supplied to the public at large .it should to the
society in the required amount quantity and time as well as at reasonable price. At the Garment
company produces woven (plain, twill) that they store in the form of gray fabrics before sending
to garment department.
The Adama garment department can produce the following products as listed bellow
 Trousers
 Shirt
 cap
 Gown/over coat
 Field jacket
 Bed cover/sheet
 Rain coat
 Police coat
 Sleeping bag
1.16 THE MAIN LOCAL AND FOREIGN CUSTOMER OF AGI

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
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 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
 Metal fabrication industry
 Homicho ammunition industry
ADAMA FOREIGN CUSTOMERS
 Somalia
 Djibouti
 Sudan
 Rwanda
1.17 VARIETIES OF PRODUCTS IN PICTURE
Back pack Canteen cover
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Sleeping bag Products of Embroidery and engraving
Figure 11 varieties of products in AGI
CHAPTER TWO
2. QUALITY IMPROVING IN SEWING SECTION
2.1 INTRODUCTION
Quality: - is the key to any company’s success which is meeting or exceeding customer
expectations all the time and helps firms increase sales and reduce costs. It is the ability of a
product/service to satisfy stated or implied needs. It can also mean that meeting or exceeding
22
customer expectations all the time by which degree of excellence a product or service provide. It
is brought about by strict and consistent commitment to certain standards that achieve uniformity
of a product in order to satisfy specific customer or user requirements. If a garment company
finds a defect in one of their cloths and makes a product recall, customer reliability and therefore
production will decrease because trust will be lost in the cloths quality.
In our present economic world of demand and supply, price and quality are the key factors,
which determine the success of any business. All the Company’s actions are directed towards
producing a quality product for the target market, satisfying the target market, and meeting the
company’s business. Products that meet the level of quality are assumed to produce greater profit
and income for the company.
Definition of Product Quality Before we proceed to understand, “what is product quality?” First,
let's focus on the definition of quality. It is not easy to define the word Quality since it is
perceived differently by the different set of individuals. If experts are asked to define quality,
they may give varied responses depending on their individual preferences. These may be similar
to following listed phrases.
According to experts, the word quality can be defined either as;
 Fitness for use or purpose.

 To do a right thing at first time.
 To do a right thing at the right-time.
 Find and know what consumer wants?
 Features that meet consumer needs and give customer satisfaction.
 Freedom from deficiencies or defects.
 Conformance to standards.
 Value or worthiness for money.
Benefits of qualities are: -

 In order to get a good fitting for the wearer.
 To be came competitiveness with others and to get high profit.
 To get acceptance whether in the local or global market.
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 To being satisfied whether in our profit or fitting.

In Adama garment industry there also so many problems that affecting the quality of the
products which decreases the profit of the company focused on industry on the sewing
department.
SEWING DEFECT CATEGORIZATION

Sewing defect can be divided in to two that are major or minor defect but based on their source
they are categorized in to three: that are fabric defect, workmanship defect and placement defect.
Generally, the sewing defects are categorized in three (3) that are:
A. Fabric defect
Fabric hole, miss of yarn and color variation
B. Workmanship defect
Open stitch, broken stitch, skipping stitch, puckering, uneven stitch and loss stitch
C. Placement defect
Dust and oil stain
2.2 STATEMENT OF PROBLEM

To achieve its goal, the company must produce quality full product with minimum faults as
possible. There is high rework, high defect, poor quality and they are not achieving the delivery
date in production section, due to this problem the customers are not satisfy by the product
quality. The major problems on the quality of the product in the factory are occurrence of Low
number of quality check person. Absence of highest skilled man power on the quality checking
of the product. The occurrence of defects on the piece during sewing operation. The occurrence
of less skilled of operator and operator carelessness. Incorrect threading and deselect of machines
on each operator. These cause of problems are creating different defects on the garment. Depend
on material, method, man power, machinery.
2.3 OBJECTIVES OF THE STUDY

2.3.1 GENERAL OBJECTIVES
To increase quality of product in ADAMA Garment Industry and Reducing defect in sewing
section.
24
2.3.2 SPECIFIC OBJECTIVES

 To investigate the root cause of sewing section.
 To investigate the problems that affects the productivity of the sewing machine.
 Investigate the rework problem that affect the production.
 To identify the defect and determine the area of defect happen.
 Operator motivation.
 Operator training.
 To minimize defects on the sewing operation.
 To reduce the cost of rework.
 For maximization of the final product.
 To produce quality product.
 To improve the quality of products that to satisfies the customers.
2.4 SCOPE OF THE PROJECT

This project has been done on Adama Garment Industry specifically in sewing room on quality
improving. To improve customer satisfaction, we should have to know right quality of products
while producing high value of product strategy by preparing correct use of resources at right time
for reducing of defect and reworks on each sewing line when it occurs.
2.5 SIGNIFICANCE OF THE PROJECT

The main target of a factory is to be cost-effective; being profitable is through many methods.
Some are;
 increasing speed of operators

 Increase ability to improve the degree of sewing in order to solve the formation of defects
 Increasing customer maintenance and decrease the amount of defects to be the most
competitive with other company.
 To develop work experience.
 To skilled the operator.
 To increase profit.
 Increasing quality.
 Customer satisfaction and Produce Quality products.
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2. 6 LIMITATIONS OF THE STUDY

Lack of computer and internet access to write and search important information for our project.
Time and cost are limited to study this project and also lack of experience. Lack of full
information and there is no written full information document concerning this problem in the
company. The disses of corona (covid 19) it limited us to fully communicate with in workers
because of the firing the transition of the virus.
2. 6.1 OVERCOMING OF THOSE LIMITATIONS

Asking different operators and supervisors to overcome the problems.
Using our own money to uses computer in internet cafe for connection.
2.7 LITERATURE REVIEW

There are hosts of opinions as to how to define quality. Traditionally producers think about
quality as a determinant of producer, more specifically determinant of engineers and marketing
professionals. But the new concept of quality differs here. It defines quality as a determinant of
customer, more specifically level of customer satisfaction determines level of quality. Broadly
speaking, customers want to see a result from the product or service what they pay for.
(Crosby, 1979) defines quality as, “Quality is conformance to requirements or specification”.
(Juan, 1974) defines quality as, “Quality is fitness for use”.
Quality is a system of means to economically produce goods or services which satisfy customers'
requirements. (Japanese Industrial Standards Committee, 1981)
Quality refers to the amounts of the unpriced attributes contained in each unit of the priced
attribute. (Loffler, 1982)
"Quality is the customer's opinion." Quality means best for certain conditions... the actual use
and the selling price. (Feigenbaum, 1983)
Quality means that the organization's culture is defined by and supports the constant attainment
of customer satisfaction through an integrated system of tools, techniques, and training. (Siskin
& Kiser, 1993)
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"Quality is variability." (walter A.Shewart) who contributes SPC theory for Quality management
and He is called grandfather of total quality management (TQM)
“Jordan’s Quality Handbook,” 5th Edition. Saied, definition of product quality can be stated as
follows: “Product quality means to incorporate features that have a capacity to meet consumer
needs (wants) and gives customer satisfaction by improving products (goods) and making them
free from any deficiencies or defects.”
Product quality mainly depends on important factors like:
a. The type of raw materials used for making a product.
b. How well are various production-technologies implemented?
c. Skill and experience of manpower that is involved in the production process.
d. Availability of production-related overheads like power and water supply transport, etc.
The five main aspects of product quality are depicted and listed below:
1. Quality of design: The product must be designed as per the consumers' needs and high-quality
standards.
2. Quality conformance: The finished products must conform (match) to the product design
specifications.
3. Reliability: The products must be reliable or dependable. They must not easily breakdown or
become non-functional. They must also not require frequent repairs. They must remain
operational for a satisfactory longer-time to be called as a reliable one.
4. Safety: The finished product must be safe for use and/or handling. It must not harm consumers
in any way.
5. Proper storage: The product must be packed and stored properly. Its quality must be
maintained until its expiry date. Company must focus on product quality, before, during and after
production: In order to improve competitiveness of a garment industry and build better
reputation amongst consumers and competitors it is important to maintain level of quality of the
27
garments. Quality refers to the degree to which a product meets customers’ perceptions on a
variety of characteristics of the delivered products.
Quality is meeting the "stated" and "implied" needs of the customer. It is by Quality a customer
can be satisfied, delighted and be retained for mutual benefit.
Dr. Joseph Juran coined a short definition of quality as; “Product's fitness for use.
Juran's definition of quality is quite simple and popular one. However, it doesn't directly convey
an in-depth meaning of quality needed by managers who are faced to decide on selecting a right
course of action.
As early as the 1950s, Japanese companies began to see the benefits of Emphasizing quality
throughout their organizations and enlisted the Help of an American, W. Edwards Deming, who
is credited with giving Japanese companies a massive head start in the quality movement. His
Methods include statistical process control (SPC) and problem-solving Techniques that were
very effective in gaining the necessary moment-tum to change the mentality of organizations
needing to produce high-quality products and services. Deming believed that 85 percent of all
quality problems were the fault of management. In order to improve, management had to Take
the lead and put in place the necessary resources and systems. According to Deming, there were
two different concepts of Process improvement that quality systems needed to address:
Common (systematic) causes of error and Special causes of error.
Systematic causes are shared by numerous personnel, machines, or Products; and special causes
are associated with individual employees or equipment. Systematic causes of error include poor
Product/service design, materials not suited for their use, improper Bills of lading, and poor
physical conditions. Special causes of error Include lack of training or skill, a poor lot of
incoming materials, or Equipment out of order.
Moreover, the notion of quality has been defined in different ways by various authors. So mainly
quality is customer satisfaction.
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2.8 METHODOLOGY
Methodology is the systematic theoretical analysis of the method applied to a field of study. It
comprises the theoretical analysis of the body of methods and principles associate with a branch
of knowledge. Typically, it encompasses concept such as paradigm theoretical model, phase,
quantitative or qualitative techniques.
2.8.1 DATA COLLECTION

It is the process of measuring, gathering, assembling the raw data up on which the statistical
investigation is to be based. Is the main statistical investigation method and be performed
through two main methods.
During the duration of internship primary and secondary data are used.
Data collection
Primary data collection Secondary data collection
Interview Observation Questioner Text book Internet Preexist data
2.8.2 PRIMARY DATA

Primary data are collected from: -
 By oral interview of the operator.

 By day to day activity observing of the work.
 By asking of persons about the quality of some daily final product.
Interview
The design of the interviews questions was based on the project objectives Interview was the
major instrument we used in order to collect some information.
We used in order to collect some information form: -
 Line operator
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 Line supervisor
 quality checker
 quality mangers
 production manager
 Company Administration and Top manager.
First we prepared necessary questions that can answer our objectives appropriately and asked
some workers/operators that we have chosen randomly.
Question: Why rework is occurring?
Line supervisor: the operator are less skill.
Question: Why defect is occurring in this line?
Line supervisor: machine problem, operator carelessness
Question: Why operator carelessness happen?
Line supervisor: less motivation, the operator because of less payment.
Question: What kind of inspection method dose the company use, how to identify defect?
Quality checker: off line inspection method only, when defect happen it will turn to the
operators.
Question: methods of quality work such as trimming, maintenance, inspection process?
Quality manager: actually inspection method is off line inspection. When the machine is stop
when become to maintain.
Observation
In this project direct observation is used as a means to assess the techniques used in
documentation and production process.
The following are the observed data.
1. Specify the defect of garment
30
Figure 12 different types of defects
2. Categorize type of defects

 Open seam
 Miss stitch
 Uncut thread
 Color variation
 Uneven stitch
 Broken stitch
31
 Seam Puckering
 Absence of top stitching
 Skipping stitch
 Loose stitch
 Float
 Hole
 Oil and stain
3. Study the root Couse
4. Counting the inspected garment
2.8.3 SECONDARY DATA

Secondary data are gathered from some record documented materials from the company
Secondary data collections are: -
1. Internet access.
2. Company profile.
3. Text books.
QUALITY CONTROL
Main function of quality department is to carry out inspection.

Inspection can be defined as the visual examination or review of raw materials, partially finished
components of the garments and completely finished garments in relation to some standards,
specifications, or requirements, as well as measuring the garments to check if they meet the
required measurements.
In sewing area there are two-line inspection Inline and off line inspection.
1. Inline inspection: is before garment making random inspection inside sewing area.
Inline inspection during the production of garments the operator’s finished work is audited in an
inline inspection. A quality inspector moves from one operator to another at random inspecting a
pre-determined number of parts from a finished bundle.
2. off line inspection: - is 100% inspection after garment production out of sewing area. It is
consisting from end line quality controller in sewing area and finishing quality controller area. In
32
this section different operator checking or inspection different garment to avoid any kind of
defect.
In this section the quality checker must be check the garment product and trimming and re check
the garment by visually.
BASIC QUALITY CONTROL PROCEDURE IN SEWING LINE

a. 100% inline parts checking the operations which are difficult to re-process after
assembling is checked 100% to avoid damages and waste of time.
b. Inline inspection during the production of garments the operator’s finished work is
audited in an inline inspection. A quality inspector moves from one operator to another at
random inspecting a pre-determined number of parts from a finished bundle.
c. 100% end-line inspection at the end of a line or section there should be a checker to
inspect all the parts before they leave the section. The inspections should be effective in
identifying all defects in a garment. The checkers should have their forms filled correctly.
A good source of information to determine the quality performance of the section is the
point of 100% inspection.
d. Pre-final audit a pre-final audit should be performed on packed items on a daily basis to
ensure that the good packed items are meeting the quality standards. Any problem seen
can be arrested at the early stage. If pre-final audits are done properly, the final audit of
the buyer should also be carried out without any issues.
FACTORS AFFECTING THE GARMENT PRODUCTION PROCESS ON QUALITY
CONTROL
In producing garment many factors affect quality of the product produced.
A, Operators
Human resources is a key element that determines the quality control process is labor that has
commitment, dedication, responsibility, and loyalty are high that greatly affect the quality of the
product.
B, Machine
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Machine is a support tool enables the creation of a wide variety of product in form, amount and
speed of the process of completion of work. The machine can help reduce the number of
defective products caused by the negligence of labor during the production process.
C, Time
The time factor in determining whether or not the product is very influential. When the time is
little or processing is the slipshod production process so that defect generated a lot of chance.
2.9 DATA ANALYSIS

2.9.1 DATA ANALYSES IN SEWING SECTION
There are some common defects which occur frequently during manufacturing the garments. We
got some common defects by using check sheet.
Table 3 Data analyses in sewing room
Date Seam Broken Miss Open Color Uneven Total Inspected Accepted
record pucker stitch stich stitch variatio stitch defect
date ing n
6/5/13 8 7 6 5 3 6 35 490 455

7/5/13 8 5 6 7 2 7 35 500 465
8/5/13 6 7 6 5 3 6 33 545 512

12/5/13 8 7 8 6 1 7 37 465 428
13/5/13 2 6 9 6 4 8 35 540 505
14/5/13 7 6 8 9 1 6 37 524 487
15/5/13 8 6 9 6 3 6 38 565 527

17/5/13 8 7 2 8 2 7 34 490 456
18/5/13 6 5 7 6 3 7 34 600 566

19/5/13 7 5 6 6 2 7 33 520 487
20/5/13 5 6 7 5 1 8 32 620 588

21/5/13 7 6 6 9 4 7 39 625 586
34
22/5/13 7 5 8 6 3 7 36 650 614

24/5/13 6 7 6 4 3 8 34 552 518
25/5/13 7 6 7 8 1 7 36 511 475

26/5/13 8 6 5 6 3 7 35 540 505
27/5/13 7 9 6 7 2 6 37 570 533

28/5/13 5 7 8 6 4 5 35 532 497
29/5/13 9 6 6 8 2 6 37 492 455

1/6/13 6 7 5 7 3 8 36 490 454
2/6/13 7 6 6 6 2 7 34 500 466

TOTAL 142 132 137 136 52 143 742 11321 10579
 Defect (%)= Number of defective piece = 742/11321*100 = 6.55%

Total inspected piece
6.55% this amount of percent defective pieces is rework.
 Average of defective piece in one day= Total sum of defect= 742/21 = 35.3
Total number of days

= 35.3 piece of garment per day
 Defect per day= 35.3 piece/day
 Defect Per week = 35.3piece*6=211.8 piece/weak
 Defect per month =211.8piece*4 =847.2 piece/month
 Defect per year = 847.2piece*12=10166.4 piece/year
In the above table show 35.3 defects are reworks per day this affect production time and
profitability of the company.
The following data indicate the present of defect
 %seam puckering=142*100 =1.25%
11321
35
 %broken stitch =132*100 =1.16%
11321
 %miss stitch= 137*100 =1.21%
11321
 %open stitch =136*100 =1.2%
11321
 %color variation =52*100 =0.45%
11321
 %uneven stitch =143*100 =0.89%
11321
types of defect in %
seam puckering
1.26 1.25
broken stitch
miss stitch
0.45
open stitch
1.16
color variation
1.2
uneven stitch
1.21
The above graph shows defects of seam puckering and uneven stitch are more problems in the
sewing section. To minimize these problem, use inline inspection system.
2.9.3 RECORDING DATA IN SEWING SECTION

Table 4 Record data in sewing section
Date record Production Rework Time taken reworking

garment/day (minute)
36
date
6/5/13 490 35 31.5
7/5/13 500 35 30.5
8/5/13 545 33 29.5
12/5/13 465 37 33.4
13/5/13 540 35 30.5
14/5/13 524 37 33.4
15/5/13 565 38 33.5
17/5/13 490 34 31.4
18/5/13 600 34 31.4
19/5/13 520 33 30.5
20/5/13 620 32 29.5
21/5/13 625 39 35.1
22/5/13 650 36 34.5
24/5/13 552 34 31.5
25/5/13 511 36 34.5
26/5/13 540 35 33.4
27/5/13 570 37 34.5
28/5/13 532 35 32.2
29/5/13 492 37 33.5
1/6/13 490 36 34.4
2/6/13 500 34 30.5
37
TOTAL 11321 742 679.2
AVERAGE 539 35.3 32.34
The above data shows Company produces maximum production is 539 over all pieces per day
but 35.3 pieces are reworked.
 Defective piece reworked/day=Total sum of time taken to reworking = 679.2 =32.34

Total Number of day 21
= 32.34 minute/day
 One piece takes 40 minute to produce
One piece=40minute
X=32.34 minute
X=32.34= 0.8piece
40
When 0.8 piece/day rework
When we calculate in week,
One week=6 working day
0.8piece*6=4.8 piece per week
To change in to month,
One month =4 weeks
4.8piece*4=19.2 piece per month
Rework piece in year
Rework in month*12
19.2piece*12=230.4 piece per year
 When Cost of one piece=500ETB
One piece=500birr
0.8piece= X
X =400ETB per day
0.8piece change in to money 400ETB/day
 To calculate in week,
Working day=6day/week
38
400birr*6 = 2400 ETB/week

 Change in to month
One month=4 weeks
2400birr*4 =9600ETB/month
 When to calculate in to year
One year=12 month
9600birr*12= 115200ETB/year
Then after this problem we modified of defect minimization is improve productivity of the
company .so if the company used the above defect elimination method to get 115200ETB per
year it not uses the above defect elimination method to lose this profit.
2.9.4 SOLUTION FOR THE ABOVE PROBLEM

 Increase the operator motivation and Appreciate by different methods.
 Give training on types of sewing technique.
 Give training when the operator is multi skilled.
 Give training on different type of sewing machine.
 Increase the line supervisor and quality checker.
 Give training on swing machine how can control the speed and on swing needle type and
how to better use of needle size.
 Eliminate the operator carelessness.
 How can to handle different type of sewing machine.
 Give training on small maintenance like changing different sewing machine needle.
2.10 RESULT AND DISSCUTION

 To make company free from defect
 To reduce the amount of rework
 Reduce the cost of rework
 To minimize defects on sewing operation
 To improve quality of products that satisfies the customer
 When the company competent with other
39
Problem, cause and solution table

Table 5 Problem cause and solution
Problems Cause of problem Remedy /solution

Seam puckering This problem arises due to uneven Proper tension of the of lower
stretching on to plies of fabric and upper thread bobbin
Improper thread tension.
Wrong sewing thread selection.
Open seam This happens due to improper handling Proper setting of timing needle
of the parts of the garment and lopper or Hook
Improper setting and timing between Proper handling of the parts of
needle and loopier garments
Miss-stitch Unnecessary movement of materials of Eliminating unnecessary

equipment’s by workers movements by the workers
Un cut It appears due to improper trimming or Garment finishing should be
finishing checked properly
Holes Holes can from fabric or it could be Better inspection of fabric and
caused by the production side, either by cut pieces
improper trimming or broken needle
punctuating the fabric
Broken stitch It appears due to improper machine Proper machine usage

usage Proper trimming
color variation It arises due to improper cutting, After cutting the garment parts
with in different bundling and numbering must be kept in proper bundle
part with numbering
No fitting of absence of notches Make notches
component parts
Low degree of Less knowledge of sewing Taking good training of sewing
suability
How to Improving quality in swing section
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We gave training to operators, line supervisor and quality checker.
Operators, to understand the different kind of defect like seam puckering, open stitch, uneven
stitch and other. And how to solve this kind of defect. And also by which method to eliminate the
defect. The operator multi skill they work different part of the component. To train simple
maintenance when needle breakage how to correct this kind of problem.
Line supervisor, how to control defect in the process. When how to inspect quality in line and
off line inspection method use. And to reduce the operator carelessness by using sheet list check
the defect happen which area and correct properly.
Quality checker, the quality of product properly check out. How to identify the defect out.
Operator motivation, motivation is one way of improving quality because the operator are work
motivate when the working condition is good. And focuses on their work.
2.10.1 AFTER IMPLIMENTATION

Table 6 Record data after improving
Date Seam Broken Miss Open Color Uneven Total Inspected Accepted
record pucke stitch stich stitch variatio stitch defect
date ring n
3/6/13 4 3 3 2 _ 2 14 480 466
4/6/13 3 2 2 3 1 3 14 510 496
5/6/13 2 3 2 2 1 2 12 525 513
6/6/13 3 2 3 3 _ 2 13 485 472

8/6/13 _ 2 3 2 2 3 12 510 498
9/6/13 4 2 4 3 _ 2 15 515 500
10/6/13 4 3 2 2 2 3 16 525 509
11/6/13 3 2 _ 3 1 3 12 470 458
12/6/13 2 3 3 2 _ 4 14 540 526
41
13/6/13 3 2 3 2 1 2 13 500 487
TOTAL 28 24 25 24 8 26 135 5060 4925
 Defect (%)= Number of defective piece = 135/5060*100 = 2.66%

Total inspected piece
2.66% this amount of percent defective pieces is rework.
 Average of defective piece in one day= Total sum of defect= 135/10 = 13.5
Total number of days

= 13.5 piece of garment per day
 Defect per day= 13.5 piece/day
 Defect Per week = 13.5piece*6=81 piece/weak
 Defect per month =81piece*4 =324 piece/month
 Defect per year = 324piece*12=3888 piece/year
Table 7 Record data change in to time
Date record Production Rework Time taken reworking

garment/day (minute)
date
3/6/13 480 14 10.5
4/6/13 510 14 10.4
5/6/13 525 12 9.5
6/6/13 485 13 11.3
8/6/13 510 12 9.5
9/6/13 515 15 11.4
10/6/13 525 16 10.5
11/6/13 470 12 8.4
12/6/13 540 14 11.4
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13/6/13 500 13 9.5
TOTAL 5060 135 102.4
AVERAGE 506 13.5 10.24
The above data shows Company produces maximum production is 506 over all pieces per day
but 13.5 pieces are reworked.
 Defective piece reworked/day=Total sum of time taken to reworking

Total Number of day
=102.4 = 10.24 minute/day
10
 Time taken by rework 10.24 minute per day.
 One piece takes 40 minute to produce
One piece=40minute
X=10.24 minute
X=10.24= 0.256piece
40
When 0.256 piece/day rework
When we calculate in week,
One week=6 working day
0.256piece*6=1.536 piece per week
To change in to month,
One month =4 weeks
1.536piece*4=6.144 piece per month
Rework piece in year
Rework in month*12
6.144piece*12=73.728 piece per year
 When Cost of one piece=500birr
One piece=500birr
0.256piece= X
X =128ETB per day
43
0.256piece change in to money 128birr/day

 To calculate in week,
Working day=6day/week
128birr*6 = 768ETB/week
 Change in to month
One month=4 weeks
768birr*4 =3072ETB/month
 When to calculate in to year
One year=12 month
3072birr*12= 36864ETB/year
COMPERE THE DATA BEFORE AND AFTER IMPROVE
Company profit =before improve per year cost - after improve per year cost
Company profit=115200ETB - 36864ETB=78336ETB/year
Then after this implantation the company to save 78336ETB per year
Table 8 Compere the data before and after
Date Before After Difference

Defect /day 35.3 13.5 21.8
Defect /week 211.8 81 130.8
Defect /month 847.2 324 523.2
Defect /year 10166.4 3888 6278.4
Defect (%) = 6.55% - 2.66%=3.89%
When by using implementation method the percentage of defect is reduced by 3.89%
44
defect before and after improve

12000
10166.4
10000
8000
6000
3888
4000
2000
847.2
35.3 13.5 211.8 81 324
0
defect/day defect/week defect/month defect/year
before Column1
2.12 CONCLUSION
Generally, Adama garment industrial. is one Ethiopian garment industry and it produce different
variety products like over all, military uniform, sleeping bag, back pack and other military wears.
The company produce their product only for local market but try to produce their product for
export through the world market for the next.
High quality of product increases the company which leads the company to be more profitable
and competent with other. The final goal of any garment production is to meet customer
expectations, to be able to exist in the industry.
The company gains the following advantages: - Increase quality of the production and Good
relationship between the customers and the company.
When we are producing a quality production, we will not have re process which means there is
no additional cost.
This intern ship program is very important and skill building for the students. So this kind of
intern ship program continued for the future in all universities, governmental and other
organizations. Because it gives more knowledge for the intern ship students like practical skill,
45
problem solve system, Work ethics, equipment utilization, idea sharing with different operator
and Work experience for future.
Generally, the road to business growth is; Clear Vision, Customer Satisfaction, Leadership,
Focus on Quality, Process Orientation, and Continuous Improvement.
2.13 RECOMMENDATION
The company should be full fill the following point in order to competitive.
 They should be overcome on the testing of raw materials before they receive and start
their production process.
 They should be testing of raw material by using inspection method 4point and 10point
system.
 Check the material or fabric cutting department to know material defects.
 They should introduce CAD and CAM manufacturing system.
 Cutting according to quality color and shading of the fabric.
 After fabric cut in the shape components do quality checks cut and size of components
that were previously in the drawn pattern.
 Check combined sewing supplies and apparel accessories
 Check combination of components that have passed the selection into semi-finished
garments.
 To check sewing quality and measurements.
 Check product after trimming.
 Check product after ironing clothes with steam iron.
 Supervising total finishing works such as adding finishing trims, ironing and folding.
 To check the quality of garments according to buyers a lieder sheet and sample.
 Check product after entering poly bag and packing.
 They should be allocated quality control personal in production department.
 The company should be full fill the training center, because it is the back bone of once
company for producing good quality production.
 They should represented/assign qualified, experienced and skill full maintenance person.
 They should be trained multi skilled operator.
 The management company give attention to working condition(Ergonomics)
46
 To minimize absenteeism employees in each department of company

 Separate the operators based on their skills.
 The company should be produced products based on the customer order and follow
market study.
 The finished items store should have been air conditioned room and should have washing
machine.
 Keeps knowledge on every kind of operations.
 Having good knowledge on machines.
 Keeps communication with merchandiser and buyer’s quality control
 Makes lay-out arrangement of machines of garments
 If each sewing operator performed their work in different ways.
 Motivating of the operators starting in design to finishing section.
 Motivate the operator by giving additional incentive/ bonus.
 Use ventilator in production areas
 Purchase fabric testing material
 Make preventive maintenance
 Develop ergonomics and develop work condition suitable
Garment production control process is usually done by way of a check on all departments to
minimize defects in production.
The most difficult thing in manufacturing is producing right quality for all the time still it is
important to work on improving product quality to satisfy customers, to control production cost
and to save energy.
Improving product quality is generally not difficult, but requires deliberate and ongoing
attentions and it requires the commitment of every individual with in the Manufacturing
Company.
If the above solutions of points are satisfied there are good working conditions in the factory. So
the company gains the following advantages of; Increase productivity of the factory, Increase
quality of the production and Good relationship between the customers and the company when
we are producing quality product we will not have reprocess which means there is no additional
cost.
47
During our stay at AGI we see all the operators are doing their work carelessly, they don’t use
working time properly, they don’t motivate to do their work, at each day many operators are
absent, working conditions are not really comfortable for workers, there is less management
skill, and also other reasons are the cause of low productivity and less aware of AGI. So such
type of problems really eliminated if the company use this study practically. There for, we
strongly recommend the company to use the study in practical to increase productivity, improve
quality and to be one of the competent company in the world.
CHAPTER THREE
3. INTERSHIP EXPRIENCE
3.1 BENEFIT WE GAIN FROM THIS INTERNSHIP

Our internship gave us the opportunity to apply our theoretical knowledge learned with the class
room to real-world activity. It also gives us an in-depth analysis of what it really likes to work
within our field of study and it benefited in that we were able to see all the different areas and we
were given a chance to create new relationships with both organization and staffs.
Internship has helped us to gain experience in our field of study. So, we thought some real life
experience would help us to solidify our future.
48
This internship made us to have a strong willing to work and how we do with work place rule
and regulation. With a strong willing to work ethic we are always committed to the work and
will stay until the task is complete.
Some of the benefit we gain from internship: -
 Practical skill
 Upgrade theoretical knowledge by practical practicing
 Industry problem solving skill
 Interpersonal communication skill
 Work ethics and industrial psychology
 Team work skill
 Entrepreneurship skill
 Leadership skill
PRACTICALL SKILL
During the time of internship, we develop operation break down, SAM and quality control. From
now we know how the order is going from the design to the shipment.
UPGRADE THERORTICALL KNOWLEDGE
When we are in the class and when we have completed this internship program we have checked
that those we have learned in theory are real and are found in the practical world. It gives us an
opportunity to apply the fundamentals learned in the classroom to real world issues.
INDUSTERY PROBLEM SOLVING SKILL

Completing this internship program makes us to identify the industrial problems and then how to
solve them if happened.
Our internship gave the opportunity to apply some industrial problem solving skill learned with
in the classroom to real world activity within the industry. It gives us an in-depth analysis of the
industrial problems really and how to solve them.
INTERPERSONAL COMUNICATION SKILL
We have developed our personal communication skill at the end of our internship program. We
developed both oral and communication skill. We got an experience on how to approach to
49
people who works in the company. We also developed how to communicate with people in the
factory using written communication method.
Generally, it helps us;
 To be good listener and speaker
 Be polite
 Attack ideas no other people
 Think legally
 Avoid faulty generalization
 Avoid confusing
 Respect others
WORK ETHICS AND INDUSTERY PSYCOLOGY
The internship made us to avoid personal issues on work time and to keep our positive attitude.
We also develop the following things after our internship program
 Build motivation and work ethics
 Punctuality and accountability to a given task
 Transparency in working once duty
 Respecting and friendship building with co-workers.
Internship enables us to act as advisers, professionals, provide recommendations for how to
resolve conflicts, increase worker productivity, and improve employee morale, among other
things.
TEAM PLAYING SKILL
Since internship is done in group it needs cooperation of individuals in the crew. When work is
done in group, different ideas will be raised at the beginning and through discussion that idea
will come to one conventional idea. For this to happen one must have good team playing skill
and tolerance. Moreover, we have learned how to convince someone with opposite idea and how
to accept ideas that are supported with convincing evidences.
Doing internship, we enable us to develop our team playing skill. It enables us working with our
colleagues who have substantial experience within the garment factory. We develop our
understanding on our contribution to the company as a member the group on the entire objective
to be succeeded.
50
ENTREPRENUR SHIP SKILL

Entrepreneurs are a people who are able to develop new business and affect the overall condition
of the global economy.
When we are in Adama garment industry we see a lot of business opportunity that can be open to
the others we choose to be the person who involving such a kind of business, and we will be
milliner in the next working time.
LEADERSHIP SKILL
Someone needs a high level commitment and ability to lead the workers of the company. The
organization’s internship supervisor is the one who is in charge of controlling each and every
worker and work flow in the crew. Even if the organization’s internship supervisor is above all
of us there are some responsibilities given for each individual.
What we understand that, if someone is expected to be effective in the leader ship position, then
the following traits must be achieved.
 Good decision making ability
 Administration skill
 Being confident on things done
 Good speaking and convincing ability
3.1.1 PRACTICAL SKILLS

 Pattern and development skill
 Production controlling skill
 Team playing skill
 Problem solving skill
 Line supervisor skill
 Embroidery section
 Cutting room
 Sewing room
 Packing
 Dispatching
 Quality room
 Maintenance
51
 New machine setting skill
3.1.2 THEORETICAL SKILL

 Human resource
 Marketing
 Planning and following up
 Work ethics and industry psychology
3.1.3 COMMUNICATION SKILL

 Improving interpersonal communication skills
 Interview with the skilled and experienced operators
 Annual celebration of the company introduces us with employees
 Knowing the value chain in the garment sector
3.2 CHALLENGES FACED FROM INTERNSHIP EXPERIENCE

3.2.1 FACILITY PROBLEMS
The company has no different facilities like computer rooms, internet access and library. Due to
this we are challenged to write our report and project because there are no any reference books
available in the company and it requires economy to use internet access from outside of the
company .so we are challenged to complete our project at the right time.
3.2.2 FINANCIAL PROBLEMS

When we write this project shortage of economy was another big challenge faced us to refer
different books, to write, to copy and print our project.
REFERENCE
[1] Company profile
[2] Garment manufacturing process textbook
[3] WOLKITE University garment engineering lecturing slides
[4] http://www.asq.org, The History of Quality – Overview
[5] http://www.dti.gov,uk/quality/evolution, The Evolution of quality,
52
[6] Mehta, Pradeep V. and Bhardwaj, Satish K., 1992, New Delhi, Managing Quality in the
Apparel Industry, National Institute of Fashion Technology
[7] Joseph M. Juan and A.Blanton Godfrey, 1999, USA, Juan’s Quality Handbook,
McGraw-Hill
[8] Mehta P V, “Quality Management: An Overview”, in ‘Testing and Quality Management’,
Vol. 1, Ed. V K Kothari, IAFL Publication, New Delhi, 1999.
[9] Onlineclothingstudy.com.
53

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WOLKITE UNIVERSITY

COLLEGE OF ENGINEERING AND

DEPARMENT OF GARMENT ENGINEERING

HOST COMPANY: ADAMA GARMENT INDUSTRY

PROJECT TITLE: QUALITY IMPROVING IN SWEING SECTION

PEREPARED BY: -KIBRU BELAYNEH…………………….519/09

ACADAMIC ADVISOR: MR. JEMAL

COMPANY ADVISOR: MR. GIREMA. A

SUBMITTED DATE: 19/06/13E.C

MR. JEMAL ASSRES __________________ _____________

Name of Academic Advisor Signature Date

MR. JEMAL ASSRES __________________ _____________

Department Head Signature Date

KIBRU BELAYNEH ___________________ 19/06/13 E.C

WONDESEN BEKELE ___________________ 19/06/13 E.C

Name of Students Signature Date

2.2 STATEMENT OF PROBLEM...............................................................................................................23

ACRONYMS AND ABBREVIATION

1.1 BACKGROUND OF ADAMA GARMENT INDUSTRY

Figure 1 Company view

commercial products to governmental and non-governmental offices, companies, industries and

1.2 VISION OF ADAMA GARMENT

1.3 MISSION OF ADAMA GARMENT

1.4 OBJECTIVE OF THE INDUSTRY

1.5 CORE BUSINESS OF THE INDUSTRY

1.6 CORE VALUES OF THE COMPANY

 Everything we work is by our plan

1.7 DUTY OF THE INDUSTRY

1.8 STRATEGIES OF THE COMPANY

 The first target in our industry is to satisfy our customer

1.9 WORKERS IN ADAMA GARMENT INDUSTRY

1.10 RAW MATERIAL USED IN AGI

FABRIC SUPPLIERS FOR ADAMA GARMENT INDUSTRY

ACCESSORIE SUPPLIERS FOR ADAMA GARMENT INDUSTRY

 Gafat armament industry

CANVAS SUPPLIERS FOR ADAMA GARMENT INDUSTRY

LEATHER SUPPLIERS FOR ADAMA GARMENT INDUSTRY

 Mojo leather factory

THREAD SUPPLIERS FOR ADAMA GARMENT INDUSTRY

 Ethio thread factory

1.10.1 ACCESSORY USED IN ADAMA GARMENT

1.11 ORGANIZATIONAL STRUCTURE OF ADANA GAREMENT FACTORY

Audit Design and development

Rule and regulation Inspection and quality

Security and safety Supply and store

HR Finance Operation Material Marketing

Engineering Vice operation

Heavy duty Parachute and drug

Industrial engineering (PPC)

Cutting section Sewing section Finishing Weaving Embroidery

Supervisor Supervisor Supervisor Supervisor Supervisor

Team leader Team leader Team leader Team leader

Some of the process in details: -

Garment cutting room manufacturing process

Design Get pattern Get marker Check marker quality

Check cut panel Numbering Cutting Spreading fabric

Bundling Check if embroidery/ fussing Input into sewing.

1. 13 DEPARTMENT AND THEIR FUNCTION

DESIGN AND DEVELOPMENT ROOM

Design and development head has duties and responsibilities to checks:

 Grain line accuracy

SAMPLE MAKING SECTION

The requirement of sample making before mass production is: -

MARKER MAKING ROOM

MR. JEMAL ASSRES ______ _

MR. JEMAL ASSRES ______ _