INDUSTRIAL TRAINING REPORT

FROM 3rd APRIL 2021 TO 3rd JUNE 2021

Fayzul Islam
ID: 171-111-0-145

DEPARTMENT OF APPAREL MANUFACTURING & TECHNOLOGY

BGMEA UNIVERSITY OF FASHION & TECHNOLOGY DHAKA, BANGLADESH

April 6, 2021

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 INDUSTRIAL TRAINING REPORT
FROM 3rd APRIL 2021 TO 3rd JUNE 2021

Fayzul Islam
ID: 171-111-0-145

An Industrial Tanning Report

Submitted to
A. T. M. Mohibullah
Assistant Professor
Department of Apparel Manufacturing & Technology
BGMEA University of Fashion & Technology
in Partial Fulfillment of the Requirements for the Degree of
Bachelor of Science in Apparel Manufacturing & Technology

DEPARTMENT OF APPAREL MANUFACTURING & TECHNOLOGY

BGMEA UNIVERSITY OF FASHION & TECHNOLOGY DHAKA, BANGLADESH

April 6, 2021

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 CERTIFICATE OF APPROVAL
The Industrial Training Report with SWOT analysis submitted by Fayzul Islam, ID: 171-111-0-145 has
been accepted as satisfactory in partial fulfillment of the requirement for the degree of Bachelor of Science in
Apparel Manufacturing & Technology in the Department of Apparel Manufacturing & Technology,
BGMEA University of Fashion and Technology Dhaka, Bangladesh on April 6, 2021.

BOARD OF EXAMINERS

A. T. M. Mohibullah Supervisor
Assistant Professor
Department of Apparel Manufacturing & Technology
BGMEA University of Fashion & Technology

Examiner Name: ……………. Examiner

Designation………………….
Department of Apparel Manufacturing & Technology
BGMEA University of Fashion & Technology

Examiner Name: ……………. Examiner

Designation………………….
Department of Apparel Manufacturing and Technology
BGMEA University of Fashion &Technology

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 LETTER OF TRANSMITTAL

Date: 06.04.2021

A. T. M. Mohibullah
Assistant Professor
Department of Apparel Manufacturing & Technology (AMT)
BGMEA University of Fashion & Technology (BUFT)

Subject: Submission of Industrial Training Report.

Dear Sir,

I, Fayzul Islam (ID:171-111-0-145)the student of Apparel Manufacturing &Technology (AMT) Department

with great attribution, I would like to state I have successfully completed my internship at Basic Shirts Ltd
and completed my industrial training report.

I, therefore, hope that you would be kind enough for accepting and evaluating my industrial training report
and oblige thereby.

Sincerely Yours,

-------------------------

Name: Fayzul Islam

ID: 171-111-0-145
Batch: 171
Section: AMT-3
Cell: +8801619999091
E-mail:fayzulnoman@gmail.com
Bachelor of Science in Apparel Manufacturing & Technology
Department of Apparel Manufacturing & Technology
BGMEA University of Fashion and Technology, Dhaka, Bangladesh

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 STUDENT’S DECLARATION

It is hereby declared that the Industrial Training report with SWOT analysis is a work done under
the supervision of A. T. M. Mohibullah, Assistant Professor, Department of AMT.I also declare that
this report is an original work and no part of this report has been copied from elsewhere. Furthermore,
this report has not been published or submitted for being awarded any degree, diploma or recognition
earlier.

---------------------------
Fayzul Islam
ID: 171-111-0-145

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 ACKNOWLEDGEMENTS
At first gratefulness goes to Almighty to give me the strength and ability to complete the industrial internship
and this industrial report. This report has made me experienced and honored. A number of people have made
significant contributions to the preparation of this report. Their insights, advice and suggestions helped me a
lot.
I would like to extend thanks to Honorable Founder Chairman, Board of Trustees Mr. Muzaffar U.
Siddique, BUFT, for not only for his tremendous academic support, but also for giving me/us so many
wonderful opportunities and logistic supports to do this report.
Special thank goes to our enthusiastic Prof. S.M. Mahfujur Rahman, Vice Chancellor, BUFT & Prof.
Engr. Ayub Nabi Khan, Pro Vice Chancellor, BUFT. who so generously inspired & contributed to do this
type of report work.

Special thanks go to my enthusiastic supervisor, A.T.M. Mohibullah, Assistant Professor, Department of

AMT, BGMEA University of Fashion &Technology has been an amazing experience and I thank him
wholeheartedly, not only for his tremendous academic support, but also for giving me so many wonderful
opportunities. Similar, profound gratitude goes to HOD, who has been a truly dedicated mentor.

I would like to extend thanks to all of persons, who contributed to the work presented in this project.
Especially I have to mention the name of Industrial Personnel Mr. Tapos, Manager, Merchandising &
Mohammad Asifur Rahman, Merchandiser of Basic Shirts Ltd.

Finally, thanks to Humayun Kabir (Managing Director)Basic Shirts Ltd.

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 EXECUTIVE SUMMARY

Basic Shirts Ltd, established in 2001, is situated in Dhaka, Bangladesh. With a total sewing workforce of
2400, Basic is formidable player in garment making in the region In order to support improved working
conditions for its staff, The board of Basic Shirts has invested in a brands new, state of the art manufacturing
facility in Gazipur Dhaka. Known as Basic ‘Tower, this newly built, 6 storey, single oceupaney facility
brings with it the latest new thinking and practices. taking Basic Shirts forward in all aspects of improved
product quality, consistency and variety,as well as becoming the company of choice for local working
people.
Resting in the Bay of Bengal and forming the bridge between South and East Asia, Bangladesh is one of the
most populous countries in the world, with a rich tradition of garment manufacturing. Over three quarters of
Bangladesh's industry is apparel manufacture, making it the second largest exporter of clothing in the world.
Firmly considered to be one of the “Next Eleven” economic success stories of the current century,
Bangladesh's improving economic status brings with it welcome changes in approach to garment
manufacturing. Improving conditions, minimum wages and worker welfare standards, have prompted huge
investment in the manufacturing infrastructure. With this investment has come an initiative amongst the best
companies in Bangladesh, to drive forward with efficient production plants, new thinking on productivity and
machinery and workforce-focussed initiatives, to ensure that competitiveness in the region goes hand in hand
with social progress. Basic Shirts, we are committed to supporting growth in Bangladesh as a region and in
the social and economic changes that are gathering pace.

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 TABLE OF CONTENTS

Sl. Contents Page No.

Certificate of Approval iii
Letter of Transmittal iv
Student Declaration v
Acknowledgement vi
Executive Summary vii
Table of Contents viii
List of figures xiii
   
   
     
CHAPTER-1 1
1.1 Introduction 1
CHAPTER -2: INFORMATION ABOUT THE FACTORY 2
2.1 Management 2
2.2 Location 3
2.3 Mission 4
2.4 Vission 4
2.5 Compliance 4
2.6 ISO & Certification 5
2.7 Fire Safety and Building Code 6
2.8 Organogram of Basic Shirts Limited 6
2.9 Present Buyer of Basic Shirts Limited 6
2.10. Countries of Exports & Imports 7
2.11 Company Objectives 7
CHAPTER-3: Production Department Analysis 10
3.1 STORE & INVENTORY 10
3.1.1 Layout 10
3.1.2 Organogram 11
3.1.3 Store flow chart 11
3.1.4 Function of store section inventory 12
3.1.5 Scope of inventory control 12
3.1.6 Inventory store system for accessories 12
3.1.7 Raw Materials Ware House 13

3.2 FABRIC INSPECTION SECTION 13

3.2.1 Fabric Inspection 13
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3.2.2 Talisman Fabric inspection procedure 13
3.2.3 Criteria of penalty points based on defects and defect length 14
3.2.4 Shrinkage & GSM Test 15
3.2.5 GSM Test 15
3.2.6 Skew Test 15
3.2.7 Bowing Test 15
3.2.8 Shade Segregation (Blanket) 15
3.2.9 Shade Separation 16
3.3 SAMPLE & CAD 17
3.3.1 Divided Part of the section 17
3.3.2 Sample section 17
3.3.3 Organogram 18
3.3.4 Flow chart of sample section 19
3.3.5 Flow chart Pattern section 20
3.3.6 Marker Section 20
3.3.7 Flow chart of Marker making 21
3.3.8 Process of Marker making 21
3.3.9 CAD Section 22
3.4 CUTTING SECTION 22
3.4.1 Cutting 22
3.4.2 Layout 23
3.4.3 Organogram 24
3.4.4 Flow Chart of Cutting Section 25
3.4.5 Function 26
3.4.6 Equipment of Cutting 26
3.4.7 Method of fabric cutting 26
3.4.8 Description of cutting machine 26
3.5 SEWING SECTION 28
3.5.1 Sewing 28
3.5.2 Organogram 28
3.5.3 Process Sequence of Sewing Section 29
3.5.4 Name of the machines used in sewing section 30
3.5.5 Activities of sewing section 31
3.5.6 Equipment & Machine Details 32
3.5.7 Different types of Needle used in different Sewing M/c 35
3.5.8 Some defects of sewing operation 35
3.6 WASHING DEPERTMENT 36
3.6.1 Organogram 36
3.6.2 Layout 36
3.6.3 Washing process Flow chart 37
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3.6.4 Machine type 38
3.6.5 Dryer machine: There two types of dryer machine. 38
3.6.6 Types of Washing 38
3.6.7 Chemical used in washing plant 39
3.6.8 Name of some lab test equipment 39
3.7 FINISHING DEPERTMENT 40
3.7.1 Finishing Section Layout 40
3.7.2 Organogram 40
3.7.3 Objective of finishing 40
3.7.4 Process Flow Chart of Garment Finishing 41
3.7.5 Description of finishing machine 41
3.7.6 Chemical Used to Remove Spot 42
3.7.7 Packing 43
3.7.8 Carton 43
3.7.9 Dispatch 43
3.8 INDUSTRIAL ENGINEERING 43
3.8.1 Organogram 44
3.8.2 Layout 44
3.8.3 Process breakdowns 45
3.8.4 Target fixing 45
3.8.5 Line Balancing 45
3.8.6 Training new operators 45
3.8.7 Calculating Incentives 45
3.8.8 Equations used in IE department 45
3.8.9 Work Study Officer & IE Responsibilities 46
3.9 QUALITY CONTROL DEPERTMENT 47
3.9.1 Quality 47
3.9.2 Quality Control 47
3.9.3 Organogram 48
3.9.4 Importance of Quality Control 48
3.9.5 Objectives of Quality Control 48
3.9.6 Classification of Quality Control 49
3.9.7 Quality Control Section 50
3.9.8 Definition of AQL 50
3.9.9 Standard AQL sheet 51
3.9.10 Checking points for quality inspection 51
3.9.11 Initial works at Q/C table 53
3.9.12 Check List at Q/C Table 53
3.10. MERCHANDISING DEPARTMENT 53
3.10.1 Organogram 53
3.10.2 What is Merchandising 54
3.10.3 Merchandiser 54
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3.10.4 Responsibilities of merchandisers 54
3.10.5 Qualities of a merchandiser 55
3.10.6 Process Flow chart of Merchandising 56
3.10.7 Require documents for Shipment 56
3.10.8 Chronological Process of Merchandising 57
3.10.9 Consumption & Costing 62
3.11 COMPLIANCE DEPERTMENT 63
3.11.1 Organogram 63
3.11.2 Compliance issues maintained by Talisman Ltd 64
3.11.3 Code of conduct maintained by Talisman Ltd 66
CHAPTER-4: IMPACT OF INTERNSHIP 67
4.1 Store and Inventory 67
4.2 Fabric Inspection Section 67
4.3 Quality Control Section 67
4.4 Sample and CAD Section 68
4.5 Cutting Section 68
4.6 Sewing Section 68
4.7 Finishing Section 68
4.8 Washing Section 69
4.9 Industrial Engineering Department 69
4.10. Merchandising 69
4.11 Compliance 69
4.12 SWOT Analysis of merchandising department 70
4.13 RECOMMENDATION 72
CHAPTER-5: 73
5.1 CONCLUSION 73
REFERENCES 74

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 LIST OF FIGURES

Figures Name Page No.

Fig 2.1: Talisman 1st floor layout plan 4
Fig2.2: Google map location of (Talisman ltd.) 4
Fig:3.1.1 Store Layout& Inventory 10
Fig 3.2.2: Fabric inspection machine 14
Fig: Cutting section Layout 23
Fig: Plain sewing machine 32
Fig: Flat lock machine 32
Fig: Over lock machine 32
Fig: Bar tack machine 33
Fig: Button holing machine 33
Fig: Button attaching machine 33
Fig: Feed of the arm 34
Fig: Blind Stitch 34
Fig: Snap button attaching machine 34
Fig: Vertical lock stitch 35
Fig: Industrial washing machine layout 36
Fig: Industrial washing machine. 38
Fig: Finishing section Layout 40
Fig:Standard AQL chart 51

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Chapter One: Introduction
Bangladesh, the southern Asian country has a population of approximately 164 million people. The economy
of Bangladesh is significantly dependent on agriculture. But it’s great news for the country that, garments
sector (RMG) sector of Bangladesh has raised as the biggest earner of foreign currency. This sector creates
about 4.2 million employment opportunities and contributes significantly to the GDP. Readymade garments
(RMG) of Bangladesh is powered by young, urbanizing, workers, where most of them are women.

Internship has made this opportunity. Because we have learned theoretical knowledge last three years but due
to lack of proper industrial knowledge on my course, we would not been said a complete engineer. Industrial
attachment did work for us. We have taken part in this industrial attachment in Basic Shirts Ltd. is one of the
renowned 100% export- oriented industry in Bangladesh. The factory is concern with the production in
Woven garments. Due to the change in current scenario, the textile sector is facing a great challenge here.

I have done my internship on Masco group which is a 100% Export Oriented Woven factory.They started
their journey in 2001 now Basic Tower's 100,000 unit per month non-iron shirt capacity is the result of the
latest automated technological investment. Full taping, followed by an impressive sequence of men’s and
ladies side, armhole and placket presses, sets up the garments, for final ironing and presentation processing.
2.1 Management:
1) Chairman : Mr. Nurul Islam

2) Managing Director : Humayun Kabir

Type of Business –Export oriented garment manufacturer.

Ownership-Private Limited Company.

Principal Exportable Product:

Shirts ,Ladies Blouses ,Boy's Shirts

Production capacity: 80000(Yearly in dozen)

Number of Man power : 2400

Export Percentage: 100% export.

 2.2 Location:

Address & contact Information:

Head Office: Basic Tower, Mujkhan

Harbaid,Gazipur Sadar, Gazipur-1710
Factory: Basic Tower, Mujkhan Harbaid,Gazipur
Sadar, Gazipur-1710

Phone No: 04478333301-7

Fax :+88-02-9011415

Website: http://basicshirtsltd.com

Figure 1: Side Location

2.3 Mission:
Providing the Quality Products and services through environmentally & friendly technology along with the
satisfaction of the customers and the interests of related partners. We implement a high productive
technology through efficient and capable human resources to implement our dreams. We will again build a
beautiful and healthier world by going beyond the expectations of the Customers.

2.4 Vission:
Commitment, Integrity, Passion, Seamlessness, Quality Products & Modern Services as per demand of the
Customers.

Values:
Respect the Customers Feelings. Achieved goals as celebrities and owner/workers celebrated success. No wastes are
acceptable. We never complacent. We enjoy our responsibilities & believe in Social & Environmental Awareness.

2.5 Compliance
The factory is full compliance with ILO and Bangladesh Labor Law. Their company policy is as
follows:

 No child labors.
 No forced labor.
 Transport facilities for worker.
 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. We are
giving a top priority on prevention of fire and eventual evacuation.
 Compensation cases department.
 The development of compliance programmer.
 Environmental developer.
 Smoking free zone.
 2.6 ISO and Certification
ISO 900

ISO 9002 is an industry standard created by the International Organization for Standardization.

Its long title is "Model for quality assurance in production, installation and servicing."

2.7Fire Safety and Building Code

Stair cases                     : 2 Six feet wide spacious stair cases with one emergency evacuation

Wash room & toilet      : 2: 25 Persons (Men & Women Individual)

“Exit” signs                   : Exit signs are marked clearly for emergency evacuation

Medical facility             : One M.B.B.S doctor caters to the health needs of the workers

Emergency Medical     : Trained team of staff & workers to take initiatives in case of emergencies

First Aid                        : Adequate First Aid Boxes/Kits are placed at different places

Emergency Tele No.     : Lists containing emergency Telephone numbers such as Fire brigade, Hospitals & Police
Stations hanged for emergency needs

Fire Extinguisher         : Fire extinguishers are placed in a very balanced manner

Fire Drill                       : Weekly fire drills are initiated

Emergency Light          : Emergency lights are there to use in case of power failure

2.8 ORGANOGRAM of Basic Shirts limited

2.9 Present Buyer of Basic Shirts Limited

BUYERS DETAILS

SHIRTS BY
SHIRTS:
(Turkey)
ZARA

MATALAN

INDITEX

LEFTIES

LA REDOUTE
& CELLO

SLATER,
BROOK
TAVERNER &
DUNNES
JOHN LEWIS,
D&G &
WINTER
BOTTOM,
T.J.MAX
KARIBAN
 LONDON FOG

ENGELBERT
STRAUSS

Countries of Exports & Imports:

Exports:
U.S.A
UK
GERMANY
SPAIN
FRANCE
ITALY
CANADA

IMPORTS:
CHINA
HONGKONG
KOREA

2.11 Company objectives:

Basic Shirts Ltd has always offered quality products and serviced the industry to enhance the productivity a
and efficiency of the factories.
  Expand business activities.
 Produced more standardize quality products.
 Ensure higher productivity of the production and more responsible to customers’ needs and satisfaction.
 Participating in economic growth through earning foreign currency by exporting its products.
 Generating higher employment taking newer internship.
 Establishing strong brand image through aggressive marketing and promotional campaign.
 To became the market leader.
 To contribute more in country’s Export business.
 To achieve more productivity through sustainable lean production.

Production Department Analysis

During the internship period at Basic Shirts limited I visited all the production section. Got a very strong
understanding about the factory and production process. Now analyzing the data and equipment’s of the industry.

IE Department
Industrial engineering is a profession in which a knowledge of mathematical and natural sciences
gained by study, experience and practice is applied with judgment to develop the ways to utilize
economically the materials and other natural resources and focus of nature for the benefit of mankind.
American Institute of Industrial Engineers (AIIE) defines Industrial Engineering as follows:
“Industrial Engineering is concerned with the design, improvement and installation of integrated system of
men, materials and equipment. It draws upon specialized knowledge and skills in the mathematical, physical
sciences together with the principles and methods of engineering analysis and design to specify, predict and
evaluate the results to be obtained from such systems”.

Function of IE Department

1.Selection of processes and assembling methods.

2.Selection and design of tools and equipment.
3.Design of facilities including plant location, layout of building, machine and equipment.
4.Design and improvement of planning and control system for production, inventory, quality and plant maintenance
and distribution systems.
5.Development of time standards, costing and performance standards.
6.Installation of wage incentive schemes.
7.Design and installation of value engineering and analysis system.
8.Operation research including mathematical and statistical analysis.
9.Performance evaluation.
10.Supplier selection and evaluation.
Job areas of Industrial Engineering
There is number of tools and techniques which are used in by industrial engineers to establish an
effective production system in the company. Without having such tools earlier production managers
and line supervisors faced difficulty in measuring work content, garment costing,
and production planning correctly, even it was difficult to finalize orders.

Knowledge about various sewing production systems

 Knowledge of all types of Sewing machine necessary for the company

 Time study (Cycle timing)

 Motion analysis of the operations

 Operation break down

 Preparation of OB (Operation bulletin)

 SAM Calculation

 M/C Layout and Work station layout

 Line Set up Production estimation of a line

 Work Sampling

 Method Study (Seeing Movements of an operation)

 WIP Control

 Line Balancing

 Capacity study
ORGANOGRAM of IE Department

Manager

Asst. Manager

Senior IE Officer

IE Officer

Asst. IE Officer

Management Trainee
Industrial Engineering Tools

 Lean Manufacturing
 5S
 JIT (Just in Time).
 Kanban.

 KAIZEN

Lean Manufacturing

Lean Manufacturing, also called Lean Production, is a set of tools and methodologies that aims for the
continuous elimination of all waste in the production process. The main benefits of this are lower
production costs, increased output and shorter production lead times. More specifically, some of the goals include:

Defects and wastage-Reduce defects and unnecessary physical wastage, including excess use of
raw material inputs, preventable defects, and costs associated with reprocessing defective items,
and unnecessary product characteristics which are not required by customers.
Cycle Times-Reduce manufacturing lead times and production cycle times by reducing waiting times
between processing stages, as well as process preparation times and product/model conversion times.

Inventory levels-Minimize inventory levels at all stages of production, particularly works

in-progress between production stages. Lower inventories also mean lower working capital requirements.
Labor productivity -Improve labor productivity, both by reducing the idle time of workers and
ensuring that when workers are working, they are using their effort as productively as possible
(including not doing unnecessary tasks or unnecessary motions).
Utilization of equipment and space-Use equipment and manufacturing space more efficiently
by eliminating bottlenecks and maximizing the rate of production though existing equipment, while
minimizing machine downtime.

Flexibility -Have the ability to produce a more flexible range of products with minimum changeover
costs andchangeover time.

Output –Insofar as reduced cycle times, increased labor productivity and elimination of bottlenecks
and machine downtime can be achieved, companies can generally significantly increased output from
their existing facilities.

Most of these benefits lead to lower unit production costs –for example, more effective use of
equipment and space leads to lower depreciation costs per unit produced, more effective use o
f labor results in lower labor costs per unit produced and lower defects lead to lower cost of goods sold.

5S

5Srepresents 5 disciplines for maintaining a visual workplace (visual controls and information systems).
These are foundational to Kaizen (continuous improvement) and a manufacturing strategy
based "Lean Manufacturing" (waste removing) concepts. 5S is one of the activities that will
help ensure our company’s survival.

1. Sort-All unneeded tools, parts and supplies are removed from the area

2. Set in Order-A place for everything and everything is in its place

3. Shine-The area is cleaned as the work is performed

 4. Standardize-Cleaning and identification methods are consistently applied

5. Sustain-5S is a habit and is continually improved

JIT (Just In Time)

 JIT philosophy means getting the right quantity of goods at the right place and the right time.

 JIT exceeds the concept of inventory reduction.

 JIT is an all-encompassing philosophy found on eliminating waste.

 Waste is anything that does not add value.

A broad JIT view is one that encompasses the entire organization.

Objective of JIT

 Produce only the products the customer wants.

 Produce products only at the rate that the customer wants them.

 Produce with perfect quality.

 Produce with minimum lead time.

 Produce products with only those features the customer wants.

 Produce with no waste of labor, material or equipment --every movement must have a purpose

so that there is zero idle inventory.

 Produce with methods that allow for the development of people.

KANBAN

KANBAN, a technique for work and inventory release, is a major component of Just in Time
and Lean Manufacturing philosophy. It was originally developed at Toyota in the 1950s as a way
of managing material flow on the assembly line. Over the past three decades the Kanban process,
a highly efficient and effective factory production system, has developed into an optimum
manufacturing environment leading to global competitiveness. Kanban stands for Kan-card,
Ban-signal. The essence of the Kanban concept is that a supplier, the warehouse ormanufacturing
should only deliver components as and when they are needed, so that there is no excess Inventory.
Within this system, workstations located along production lines only produce/deliver desired components
when they receive a card and an empty container, indicating that more parts will be needed in production.
In case of line interruptions, each workstation will only produce enough components to fill the
container and then stop. In addition, Kanban limits the amount of inventory in the process
by acting as an authorization to produce more Inventory. Since Kanban is a chain process in which
orders flow from one process to another, the production or delivery of components are pulled to
the production line, in contrast to the traditional forecast oriented method where parts arepushed to the line.

Advantages of Kanban Processing

Provides a simple and understandable process. Provides quick and precise information.
There are low costs associated with the transfer of information. Provides quick response to changes.
There is a strict limit of over-capacity in processes. Avoids overproduction. Minimizes waste.
Full control can be maintained. Delegate’s responsibility to line workers.
KAIZEN

Kaizen is a Japanese word means, simply, Continuous Improvement.

Kai = to take a part
Zen = to make good
Together these words mean to take something apart in order to make it better.

HOW DOES KAIZEN WORK

 Ten basic principles for Improvement in the view of KAIZEN:

 Throw out all of your fixed ideas about how to do things.

 Think of how the new method will work-not how it won’t.

 Don’t accept excuses. Totally deny the status quo.

 Don’t seek perfection. A 50-percent implementation rate is fine as long as it’s done on the spot.

 Correct mistakes the moment they’re found.

 Don’t spend a lot of money on improvement.

 Problems give you a chance to use your brain.

 Ask “why” at least five times until you find the ultimate cause.

 Ten people’s ideas are better than one person’s.

 Improvement knows no limit.

PURPOSE OF KAIZEN
Kaizen activities focus on every operation and process in order to add value and eliminate waste.
Process: is the sequence of operations needed to design and make a product.
Operation: is one activity performed by a single machine or person on that product.

TARGET OF KAIZEN

Products (Quantity, Rejects etc.)

Equipment (Changeover, Utilization, Breakdown)
Human (Communication, Awareness, Stillness)
Processes (Waiting Time, Bottleneck, Line Balancing, VCS)
System (QC, Specification, Infection)

Cutting Section
Cutting is the Heart of a RMG industry, it is where the garments parts are being prepared. The fabric
is cut with cutting machine according to pattern and marker. The efficiency of cutting depend on
marker efficiency, labor efficiency, marker allowance, machine performance.

Floor Plan in Cutting Room

Process Flow of Cutting Room

 Marker and
Pattern Marker

Fabric Spreading

Fabric Cutting
Re-Cutting

Checking Cutting

Fusing Stickering

Sorting and Bundling Printing and embroidery

Stitching

Machinery in Cutting Room

 Machine Name Brand Number

Fabric Relaxation machine Winda (Auto edge alignment

machine)
Spreading machine Morgan fox 50

Fabric Cutting machine Blue Streak II

Responsibility of Cutting In charge

 Check the mini marker and ensure marker efficiency according to marker ratio & Assortment, actual fabric

dia, GSM.

 To know the daily target set by the IE department.

 Receiving the fabric according to order, size and quantity.

 Giving instruction of cutting according to requirement.

 Check if the marker is ready according cutting schedule.

 Make preparation for cutting.

 Strictly maintain safety procedure in cutting room.

 Checking if the efficiency is up to the mark.

 Checking and inspecting the cut pieces.

 Checking the fabric for QC inspection.

 Identifying the damage pieces and removing them aside.

 Assorting all the pieces and bundling them according to size and order.

 Sending the bundles to the sewing floor or Printing section for printing.

Sewing Floor Analysis

Sewing is the main production procedure of RMG industry. Without a good sewing floor with good line
layout, efficient worker and good machinery a company cannot success in achieving the required production
goal of a company.

Sewing floor Layout

Sewing Machines at Basic Shirts Limited

SL/N NAME OF THE MACHINERY'S BRAND QTY
01 Single Needle Lock Stitch with Wrinkle Free Components JUKI 72
02 Single Needle Feed Lock Stitch JUKI 05
 03 Single Needle Vertical Trimmer Knife JUKI 10
04 Single Needle Chain Stitch Button Sewing with Knot Tying JUKI 08
05 Single Needle Lock Stitch JUKI 106
06 Single Needle Lock Stitch Bar-taking SUNSTAR 02
07 Single Needle Lock Stitch with Auto Thread Trimmer JUKI 18
08 2 Needle, Needle Feed-Lock Stitch JUKI 08
09 2 Needle Chain Stitch JUKI 12
10 2 Needle Feed-off-the Arm Chain Stitch JUKI 13
11 4 Needle Chain Stitch (Kansai Special) MORIMOTO 07
12 5 Thread Over Lock JUKI 24
13 Lock Stitch Button Hole JUKI 14
14 Lock Stitch Button Sewing JUKI 12
15 Straight Knife Cloth Cutting (10") EASTMAN 03
16 Straight Knife Cloth Cutting (8") OSHIMA 04
17 Electric Steam Boiler NAOMOTO 06
18 Auto Twin Steam Iron NAOMOTO 22
19 Vacuum Table for Ironing NAOMOTO 20
20 Pneumatic Shirts Folding Table NAGASHING 04
21 Auto Carton Strapping Machine TOYO 02
22 Needle Detector Conveyor Type PANDORA 01
23 Needle Detector Top Table Type HASHIMA 01
24 Verified Colour Assessment Cabinet PANDORA 01
25 Fabric Inspection Machine NAGASHING 01
26 Auto Shirt Arm Hole Press NAGASHING 02
27 Auto Sleeve Side Seam Press NAGASHING 06
28 Neck Press Machine FIBLON 02
29 Collar Contour Trimming NAGASHING 02
30 Cuff Pressing NAGASHING 06
31 Collar Turning NAGASHING 01
32 Rotary Pressing with Left/Right Placket NAGASHING 02
33 Vacuum Pump NAOMOTO 03
34 Band Knife EASTMAN 03
35 Top Center Fusing Press (Conveyor Type) RELIANT 02

QUALITY MANAGEMENT SYSTEM

Quality Assurance
Quality control is practiced right from the initial stage of sourcing raw materials to the stage of final finished
garment. For textile and apparel industry product quality is calculated in terms of quality and standard of
fibers, yarns, fabric construction, color fastness, surface designs and the final finished garment products.
However quality expectations for export are related to the type of customer segments and the retail outlets.

Here it follows:

1. Understanding the customers' quality requirements

2. Organizing & training quality control department
3. Ensuring proper flow of quality requirements to the QC department
4. Ensuring proper flow of quality requirements to the Production Department.
5. Establishing quality plans, parameters, inspection systems, frequency, sampling techniques,
etc.
6. Inspection, testing, measurements as per plan
7. Record deviations
8. Feed back to Production Department.

Objects of Quality Control:

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

 
Quality control and inspection procedure includes the following functions:

Our Quality Assurance department checks all the fabric/Accessories to ensure that quality/color etc
conforms to the order / style.
Our Quality Assurance and merchandising team goes to factory location to evaluate pre-production
(size set) sample, patterns, etc to approve for trial production.

 Quality Assurance team evaluates trial production and then finally approves for bulk production.

As bulk production starts, our Quality Assurance team goes for inline inspection. This inline inspection during
production is performed on daily basis.

At the middle stage of production if (standard of quality) result is acceptable / good then we go for pre-final
inspection. Here we check the case pack, carton quality, shipping mark, assortment, presentation etc.
 If the pre-final result is acceptable then we go for final inspection & if it passes, we approve for the final
shipment.
To ensure quality of the highest standard, we inspect at every stage of the production process.
The following Quality & Inspection steps are being currently employed in sourcing and manufacturing:

                      - Accessories Inspection

                      - Measurement Spec checking
                      - Accessories Inspection testing
                      - Accessories Color Matching checking
                      - Daily Cutting checking
                      - Fabric Inspection
                      - Lab dip testing
                      - Washing Fabric testing

Total Quality of a garment depends on the following factors-

1)      Quality of Fabrics
2)      Quality of Accessories
3)      Quality of Cutting
4)      Quality of Machines
5)      Quality of Sewing
6)      Quality of Washing
7)      Quality of Finishing

In each stage there are quality controlling with quality checkers or controllers. Quality manager is
responsible for total quality of a product. Quality controlling in different stages described bellow-
Quality of Fabric: There are some fabric inspectors, who check the fabric defects with fabric inspection
machine. And follow “American 4 Point System” for better quality.
Quality of Accessories: Trim inspection bay at main store inspects the trims and accessories for
quantity and quality.
Quality in Cutting: In cutting section there are 3 types of quality checkers. They are
\
a)Marker checking QC: Marker checking QC checks the marker used for cutting for any type of
mistake or defect. He checks for the following things-

i) Style, size, color and type of marker

ii) Any drawing defects on marker
iii)Any overlapping of parts
iv)All parts present on marker
v)Ratio of marker is correct
vi)Check with hard pattern provided by technical manager if needed.

b). Table or Lay QC: Table QC checks for lay defect and correct procedure for lay. He checks
for the following things-

i)  Marker length and lay length and proper allowance (1/2”+1/2”=1”) for lay length.
ii)  Any fabric defect
iii) Pile of fabric is correct
iv) Tension of fabric
v)  Salvage of fabric is outside the marker.
vi)Fabric nap is correct.

c). Bundle checking QC: S/He checks for total parts are present in a bundle. S/He checks the
bundle with JC Penney 3 piece system. In this system he collects 3 pieces from the bundle and
checks them for any fabric defect, size and shape and proper cutting.

There is also an auditor and AQL section at cutting for better quality controlling.

Quality in Finishing:
For better quality there are several quality posts in finishing. First step is Process wise inside checking,
then Process wise out side checking and last step is final quality Checking. And there are also
two audits in finishing.

They are-

1) Hourly Audit (Internal): They audit randomly any 7 pieces in each hour from a line. If they find any
major defect in any 1 piece than audit goes to fail and whole garments in that line have to check
again. Otherwise audit pass and garments goes to carton packing.

2)Carton Audit (External): They audit any 3 cartons from each line. They check for external matters
like Tag, size, ratio, color etc. If find any major defects in any piece of any carton, the audit fail and
all carton have to check and pack again.

 Note: After passing the external audit garments are ready for shipment.

Checklist for Auditing Carton:

The followings, we have to check while auditing a carton.

1)      Barcode/Shipping mark
2)      Assortment
3)      Size label
4)      Match box
5)      Sticker
6)      Shade
7)      Ratio
8)      Also for size, presentation of garments, looseness or tightness, folding, dimension etc.

Cost of Failure:

The main costs of failure due to poor quality are-

 1)      Losses due to faulty and spoilt work
2)      Examiners records
3)      Reprocessing 
a. Additional materials
b. Extra labor
c. Disruption of production
 5) Administrative Costs 
a.       Reaching agreement with customers
b.      Replacing defectives or complaint adjustments

Remarks:
1) Better quality makes the production rate better and also satisfied customer or buyer. If quality is poor
2) then we need much time to repair the altars, which decrease the overall production rate.
3) Roving auditor using red card for poor quality of an operator. He also can use a green card for better
4) quality of an operator, which will inspire him and others for better quality. 

Merchandising
RMG sector of Bangladesh is gaining ground in the world market at breakneck speed, but still not
flourished at the fullest extent. Although the resources are available abundant with a powerful
foundation of fabric and spanning sector to support. The key factors behind this are low technological
development, lower output, cut throat competition, high raw material cost, inadequate infrastructure
, traditional productivity, unfavorable regularity policies, and globalization in fact. However, there a
fair list of the producers, suppliers, and exporters that are fully acknowledge with regularity policies and
formalities, international marketing policies and procedures. The only concern is in executing their
productivity initiatives, and meeting with order deadlines. Garments merchandising means the work
to buy raw material and accessories to produce garments (Merchandise) against a particular work order
of garment and have to export these under the same work order within time schedule, maintaining required
quality level of buyer. The Merchandising is the important activities, term and section of a garment
that is not possible to run and deliver successfully. The term “merchandising” is well known to the
persons specially involved in garments trade. The term merchandising has been derived from the term
merchandise. Merchandise means good that are bought & sold.
Merchandising
Merchandisingis a business on marketing activities responsible for ensuring a products description
both quality and quantity. Merchandising means total responsibility of a Merchandiser.
Merchandiser Duty of merchandiser describes himself like this-

A man who collects order from customer sourcing raw materials production on time with quality
and maintains lead time.
Garments merchandising means buying raw materials & accessories, producing garments, maintaining required
quality level and exporting the garments within scheduled

If anybody has to be designated as Merchandiser then the word itself demands some qualities
from that individual, now let us see what all are the hidden meanings there in the word „‟MERCHANDISER¨.

 M- Should have good Managerial capacity.

  E- Efficient in both English written and spoken.
 R- Having high sense of Responsibility.
 C- Always keep commitment.
 H- Leads honest life.
 A- Attitude should always be positive in resolving any problem.
 N- Never does any argue with buyers and seniors.
 D- Fully devoted to his service.
 Always well informed about his all orders.
 S- Sincere in office and daily works.
 E- Enthusiastic in nature.
 R- Regular in e-mail correspondence.

Most importance things for a Merchandiser is:

 Communication.
 Planning
 Production Follow Up

The responsibilities of a smart Merchandiser are handling order at four stages.

 Sourcing for future orders/Buyers

 New Order
 Confirmed Order
 Running Order

Business Development procedure of Merchandising:

Buyer Selection
 Know about the nature of
buyer

First E-mail to buyer

Collect audit pass report

from buyer

Offer to buyer for visiting

the factory

Company arrange a meeting

with buyer for business

Sampling Stage

Price Negotiation

Price Conforms and Order

place from buyer

Things to be considered in first Sample: