Declaration

My name is Abiy Girma. I am a fourth year Garment engineering student and I

have undertaken my internship program in SHINT ETP. GARMENT PLC. for a period of
four months with the guidance of my academic advisor Mr. Makbeb and my plant advisor
Mr. Feteh.

My work is original and based on the internship report writing guideline given
by our university Garment Engineering Department.

Name: Abiy Girma

Signature:

University Advisor: Makbeb

Signature:
Acknowledgment

I would like
Executive Summary

Internship is a way for a student to gain knowledge or it would enable the

student to see and practice what he/she have learned before theoretically.
 Chapter One

Introduction to SHNITS ETP. GARMENT PLC.

Company Profile

SHNITS ETP. GARMENT PLC. is global leading apparel manufacturer in

functional and high technical garments industry. Headquarters is located in Seoul, Korea
there are 120 employees for sales, logistic, material sourcing, accounting and sample
making. 2016 estimate sales volume around 80 million dollars and also in Vietnam it has
around 5200 sewing workers and 75 sewing line 2016 estimate sales volume 3 million
dollars. They have around four offices. The Main office is in Korea at Seoul, USA at
Florida, Vietnam and Ethiopia. Address Bole Lemi Industry Park at bole sub-city, Woreda
11 Addis Ababa, Ethiopia. The distance from Addis Ababa airport to the factory is about
9.5 km. The factory size at Bole Lemi 1 is

 building size – 44,000 ㎡,

 land size - 75,000 ㎡

Bole Lemi 2:

 land size: 250,000 ㎡

The Primary Objective of the Factory

Shints ETP garment PLC set three goals for its operation:
 Company that gives hope for the employee.
 A company that give satisfaction for the buyers.
 A company contributes for development of Ethiopia.
Objectives:
 To achieve and receive a profit.
 To provide excellent quality and host dealing to its custome
 To improve number of employee to 9000.
 To improve all sheds in to 2 stores.
Vision
 Global blue-chip Company which grows constantly based on apparel
manufacturing business.
 Top ranking company in the world which has excellent production technology on
the high value of active sports products.
 Full service Garment manufacturer that offers its customer all the aspects of design
and production with the best available It is our policy to design and produce the
best products at the absolute best price to performance ratio on the market.
 We value all our employees as essential partners and provide them with fair
working conditions and compensation.
Mission
 We are committed to offering a wide selection of sports apparel and accessories to
ensure that our customers have the right products in all conditions.
 In addition, we support the education of our employees and their family by
contributing a portion of our corporate profits to their educational cost.
Values
 Quality and efficiency
 Punctuality/integrity
 Professionalism
 Working Procedure of The Company
Fabric store
Order CAD and Trims and
and
Reciving Sample accessories
Inspection
Room Making Room store
Room

Spreading and
Bundling/ Sewing Quallity
Cutting
Sorting Department Assurance
Department

Shooping
Packaging Ware House
Room

Organizational Structure

CEO

General Legal
Manager Director
Productio ACCT/H Trade/Sal Construct MD/MR
n R/GA e ion P
General Accounti Ware
PR Plan PR 1 PR 2 Trade Planning MD
afair ng/HR house
G.Manag PR Line G.Manag PR Line Audit HR Forwardi Purchasin
Planning QA/QC EMBD Planning h Accounting Storage Opr. 1
er 13 er 16 Mgm. Mgm. ng g
PR Distributi
Iron Printing Security Audit Recruting Tax Customs Welding MD
Supprt 1 on
PR Importin
Finishing Welding Odd jobs Dicipline Bank Engineer Opr. 2
Support 2 g
Attendanc Exportin
CAD Cutting Cleaning Cash Interpret
e g
Electricit
Legal Visa
y
Purchasin
Cafeteria Mechanic
g

Machines Available in The Company

In SHINTS ETP. Garment PLC. There are more than 50 variety of machineries
and all the machines are up to date which means that most of them are used under 2 years
which means that the performance of the machines is still in good condition.
 NO. Machine type Needle type No of No of machine
used thread available
1 Single needle lockstitch machine DB*1 1 1859

2 Two needle lockstitch dp*5 2 543

3 Over lock Dc*27 3-5 128

4 Chain lock stitch TV*7 4-5 94

5 Zigzag machine Dp*5 2 45

6 Button attach DP*17 2 25

7 Button hole Dp*5 2 28

8 Bar tack Dp*5 2 26

9 Cover stitch machine UY*128 3&5 26

10 Feed of arm uY*128 4-5 20

There are also special machineries in the company which improve quality of
work and also simplify the work to be done. These machines are:
 Seam sealing
 Welding
 Auto CAM cutting
 Embroidery
 Printing
 Quilting
All those special machines above have their own special purpose and also their
own trained operators to yield the out most best result by them.
Product Variety of The Company
There are many and different types of products which are produced with in the
company from orders by different customers. Let’s see these different products:
 Motor cycle clothing
 Outdoor sport wear
 Gore-Tex garment
 Work wear /safety cloth
  Sean sealed water proof garment
 Soft shell and wind breaker jacket
 Down/padded out wear
 Casual active outwear
 Gloves/sport accessories
 Tent/outdoor
Work Flow Process

Ware House

Cad Design

Cutting
Embrodery/
Printing/ Welding
Sewing

Quality Control

Finishing/ Packing

World Wide Customers

SHINTS ETP. Garment PLC. has different customers throughout the world.
These customers have got their own product type, with different design, with different
fabric and accessories, and different specifications on sewing, finishing and packing. The
following figure shows the Logo, or Brand marks of the customers.
  In USA: Aerostich, Sherpa, Klim, Polaris, Costco Kirkland, TUMI Outerwear
 In Asia: Black Yak, le coq sportive, New Balance, WILD ROSE, Toray
 In Europe: Jack Wolfskin, Schoffel, La Sportive, Salewa, GRIFONE, Trangoworld,
KTM, Alpine star, Dinesen, REV'IT, Geox
Company Department Details
Warehouse
Store is a place where raw materials, accessories, work aids, finished goods and
machineries are placed or stored up to the changed to the product. The well-designed
material storage is very important in that it ensures the smooth flow of material in working
area. Store is the place where items may be accumulated or materials, stocks and supplies
where kept. The SHINTS ETP. garment PLC. Store there are raw materials where they
kept to transfer in to other departments. The SHINTS ETP. garment PLC. Company is in
further expansion so the warehouse is used for store purpose.
Type of Equipments Found Stored in Warehouse
Trims Fasteners
Button, Zippers, Snaps, Loops, D-rings Decorative Trims
Linear Trims, Elastic Tapes, embroidery, edges, ruffles, Braids, ribbons
Others-belts, pockets Velcro, Lighter

Ladder Packaging Materials

Pattern making tools Tag pun
Labels Weight balance
Office tools Washing materials
Shelf’s (pallets) Store room tools and computers
Computer Aided Design Department

CAD is the contraction which stands for Computer Aided Design. This term
means different things to different people involved in designing, manufacturing and
mechanical engineering. CAD or Computer Aided Design has brought a revolution in the
Textile industry, especially in apparel industry. The time consuming and cumbersome
process of textile designing has been made easier by CAD. Now thoughtful and innovative
designs are available to the textile designers and textile manufacturers at the click of a
mouse.
 Flow Process

Modernizing of all Aligning all size

Taking the image
Receiving of pattern parts by the pattern parts in the
of pattern in CPU
pattern parts software marker by the
by digitizer
(Modernizer) software (Daimio)

Bringing out the

Taking approval Completing the
marker through
from CAM section marker
plotter

Sample and design department

This department develops patterns for the required order received samples that
the customer brings. The designer makes the sample based on the customer order
specification sheet. After the customer approved the design sample the designer generates
the production pattern according to the specification made before. In shint ETP Garment
PLC and garment design and sample room have one longest white table for manual pattern
marker making.
 Flow Process

Order receiving with the

specification

Level of the required

sample pattern

Receive the required

fabric type from the store
for the sample
Prepare a sample for
customer specification
based
Send the sample prepared
for the approval to the
customer
Sample approved sample not approved
Coasting by sales
department

Finally prepare
production pattern
Cutting Department
Cutting is one the most important department for ultimate of the productivity
and quality of the finished garment and it is the main and essential supplier of sewing room.
The department head create a suitable and appropriate cut order plan to finish the required
order based on the order specification accordingly the marker will be developed and
prepare for effective utilization of cutting the fabric. This quality control section is very
important before garments cutting. The fabric is roughly checked from dyeing section and
then those are sending to garments factory for producing complete garments. Usually very
small amount of fault comes from dyeing. Small hole and pin hole are the main fault get in
cutting quality check. But a single pin hole in single part of garment could be the cause of
rejection of garments and it is a major defect.

That’s why a thoroughly checking is done before cutting. Here Fabrics are being
checked before going to relaxation section of cutting. Required number of table is
preserved for fault checking. Fabric fault like hole, yarn miss, dart etc.… are being
checked. Normally 10% fabric is checked. There are two popular fabric fault checking
system is exist. Ten-point system and four-point system. Usually four-point system is very
much popular for knitted fabric and ten-point system is popular for woven fabric.

Flow Process

MARKER/ PATERN CUT RATIO

FABRIC RECIVED
RECIVED RECIVED

CAD/PATERN FABRIC RELAXIATON

MAKING IF NEEDED
SPREADING (FABRIC
LAYRING)

MARKER MAKING

PART NUMBEING

RE-CUTTING IF
CUTTING THE LAY DEFECTIVE

SORTING AND
BUINDING

Printing Department

For printing purpose mostly, the company uses screen printing method. 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 are then dried to set the ink. This process may have varying levels of automation or
may largely be completed at manually operated stations. Like embroidery, 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.

Flow Process

Applied chemical auto Placed design

Mesh fabric tight sol and potassium
dichromate on the mesh paper under the
with frame
& dried 8 min in air mesh

Light passes Remove the

through the design colored TXR from
paper & mesh the design area by Cleaning
fabric for 3-4 min water spraying

Drying

Embroidery

Embroidery has been used on textile products for thousands of years. It is a way
of adding interest and emphasizing details. Although many people still embroider by hand,
machine embroidery has overtaken it in popularity. Most domestic machines have a range
of decorative stitches, with some computerized machines offering the opportunity to design
your own. Computerized machines also offer the opportunity to embellish textile products
with motifs and logos.
 Flow Process

Art work from

buyer
Input to ES-
65(Software)
Design analysis

Send to buyer
Recommendation &
correction
Prepare sample

Send to buyer
If approved start
mass production

Sewing Section

Sewing room is one of the main and critical departments of changing a cutted
fabric piece in to 3 dimensional garments which needs to be fit and balance the required
person (customer). In these room the operators receive a cut bundle fabric through the
lines supervisors and repeatedly sew the required product and the end of the lines there is
a quality assurance is performed to ensure that the produced garment will reworked or
mended at a designated room.
Supervisors
Each line has 1 leader, 1 sub-leader and 1 technician whom are responsible for
a line they assigned to initiate operators, control the line and solve line problems and to
facilitate the overall production and productivity of the line to meet the planed daily
production and to produce beyond the plan or over produce for incentive if possible. They
have to hold workers compliance as much as possible and if it is beyond them they report
to their boss (Total Leader). There is a dispatching table for all lines and the supervisors
receive the cut piece for their own line and where the part is missed or below cut they
communicate with cutting room.

Material Handling
Mostly the material handling method they use for transporting cut pieces is by
hand carry method which means that there are operators appointed for carrying the cut
pieces from the cutting department and delivering them to the sewing lines. In bulk and
large pieces cases they use rectangular carts and they travel a long path way by using the
company gates to travel from the cutting department to the sewing.

Quality Control

Quality control is done through line checkers and end line checkers. There is
only 1line checkers per a line whom spine around the line to check and control the quality
of each part produced. Checking is done randomly with in an interval they check the
product if there is a mistake they give an order to be rework at the station before moving
to the next operation in order to prevent damage at the source.
 End line checkers are responsible to inspect the final garment for approval.
There are 2 end line checkers per a line they have to report amount of rework and its reason
per day and per production. Problems that are not detect by the line checkers will be
detected here and will be send back to the station where the problem happens this is done
by the supervisors. In addition to these if the problem happens at most they will order to
take action at the station weather to show the operator or to change the operator from the
station. When there is misunderstanding between supervisor and end line checkers the
production manager and the quality department will decide on the matter. The garment that
is quality approved by end line checkers it will be pass to packaging.

Finishing section

This department task is where ready sewn, trimmed and quality checked
garment from the sewing line are going to be iron, press, tagged, fold, packed and
cartooning. Final auditing is random checking by internal quality controller to ensure that
only quality goods are being packed after these processes the garment are ready to shipment
or dispatch. Good packaging makes the garment sellable and presentable on the costumer
or market and also important informational are transfer from manufacturer to users.

Packaging In the last steps of making a product retail-ready, garments are

folded, tagged, sized, and packaged according to customer specifications. Also, garments
may be placed in protective plastic bags, either manually or using an automated system,
but in these company the process is done by manually to ensure that the material stays
clean and pressed during shipping. Lastly, garments are placed in cardboard boxes and
shipped to client distribution centers to eventually be sold in retail stores. Most garments
are packed in plastic bags, either at the end of production or when they enter the finished
goods store.
 Chapter Two

Project Title: SNLS Machine Laser Line Sewing Guide

Introduction

Background of study

This project is done in SHIN ETP. GARMENT PLC. in order to achieve

improvement in operator training, product quality, simplification of work, reduce work in
progress, reduce manufacturing cost, facilitate proper utilization of resources and so on. As
it’s known the above stated factors are major factors in garment industries and they can
determine whether if a company is profitable or not and also its survival.

To implement this project the company should be willing to let go of pervious

ways and methods that I used to use to perform different tasks. This means that making
changes starting from training methodologies of the sewing machine operators up to ways
and steps of operations in the sewing lines.

Statement of Problem

In SHIN ETP. GARMENT PLC. before production starts in the sewing lines
there is an operation called drawing. This operation requires 4 operators per line and they
would be drawing stitch lines for the sewing machine operators as which they would use it
as sewing guides. This operation is time taking and also carelessness is mostly spotted on
this operation because it’s very tiering and the operators would have to stand all day to
perform this task. This has resulted in poor quality in the manufacturing process which
resulted in poor quality clothes.

Objectives

 Improve productivity in sewing lines

 Improve training methods of sewing operators

Specific objectives

 Improve productivity
  Reduce WIP
 Reduce cost
 Improve quality
 Simplify work
 Avoid returns and reworks

Scope of Study

This study is done in SHINT ETP. GARENT PLC. at shade ‘D’ and in machine
training section and also sewing line ‘H’ which is also in shade ‘D’. It’s done mainly to
improve productivity and simplify work while increasing quality.

Limitation

While doing this project there were some limitations. Those are:

 Shortage of working materials

 Unwillingness of the company personals
 Misunderstanding of high officials especially foreign employees

Significance of the project

If all the principles of the project are applied correctly in the company, the
following results would be obtained for the industry, end users, and workers;

For the Industry:

 Reduce operation cost

 Avoid unnecessary costs
 Improve productivity, quality and human resource

For the End users:

 Receive a satisfactory product

 Would have full trust on the company
 Enable them to have a good market value and name
For the workers:

 Would improve their skill

 Upgrade their capacity and performance
 Be subjected to a new technological advancement
 Work would me more simpler and less stressful

Literature Review

Brothers Dream Waver XE is the first machine to implement this project/.

PROJECT METHODOLOGY

In order to find out where this project might come in helpful different
information is collected by using two methods of collections. After data collection the
collected data is assessed and analyzed then came to result and conclusion.

Project
Methodology

Data Collection

Primary Data Secondary Data

Reference
Interview Observation Internet
Document

Data Analysis

Result and Conclusion

 Primary Data Collection Method

Interview

By personally approaching sewing operators, team leaders, technicians,

production manager team, quality inspectors and asking them different questions that might
aid in the doing of this project.

Observation

Direct observation is used as a means to study and assess the existing production
method to collect some essential data. This means I tried to observe the whole production
process starting from the start up to the end.

Secondary Data Collection Method

From the internet

Though there was not enough information I needed on the internet I got
different hints in how to do my project and methods of implementation.

Data Analysis

From the data I was able to collect it shows that even though the company has
a three-phase quality inspection method because of the lack of skill of operators,
uncomfortable working condition and also carelessness the quality of the product which is
being produced is low and also there is a problem of achieving daily targets and there is a
high loss of operation time these reasons are causing the company more cost and
dissatisfied customers.

So, from the above problems stated it clearly shows that there is a big gap in
the production methodology used specially in the sewing section. So, I tried to identify the
time taking and also what makes it hard for the sewing operators to produce a good quality
product. I spotted the first operation which was called drawing. Drawing is done by 4
operators which means they are given a cut out pattern piece out of a hard carboard and a
tailor’s chalk. They draw a stitch line or the seam allowance border of each component by
the pattern piece provided for them.
 After they complete the drawing phase the components are distributed to the
sewing operators and they have to be able to align those lines and stitch exactly on top of
that line. And this operation is hard because of their level of skill they have. Almost all of
the sewing operators that work in that company have no background information about
how to even stitch a straight line on top a piece of fabric. So, this makes it hard for them to
concentrate and straight on the line which is drawn for them.

The Brother Dream Weaver XE sewing machines latest feature is a laser line
sewing guide. This machine is the only one and the first one to have this feature and it’s
applicable for domestic use only which costs $6999. So, this was what sparked the idea of
constructing a laser line sewing guide work aid.

Design Preparation

For the designing part I have majorly selected attaching the work aid on the face
pate because there would not be any machine part blocking it and also would be
comfortable to attach, adjust and use it easily.

Equipments Used To Build The Prototype

 Cross Line Laser Guide

 Circular metal tube
 Adjustable Hinge
 9V Dry cell battery
 Size 6 nuts and bolts
Cost of The Prototype Equipments

No. Equipment Name Cost in Birr Quantity Total cost

1 Line Laser Generator 8 Birr / piece 1 8 Birr
2 Circular Metal Tube 70 Birr / 3 meters 0.75 metes 17.50 Birr
3 Adjustable Hinge 10 Birr 1 10 Birr
4 9v Dry Cell Battery 75 Birr 1 75 Birr
5 Size 6 nuts and bolts 50 cents / piece 3 1.50 Birr

Actual Assembly

1-First cut the Circular Metal Tube to the desirable height/ length.

2-Weld the adjustable hinge to the top of the circular metal tube.

3-Attach the laser line generator to the tip of the adjustable hinge.

4-Attach the 9v dry cell battery with the circular metal and also the wire of the laser
generator providing it power.

5-Attach the finished work aid to the faceplate of the sewing machine.

Result and Conclusion

For generating the desirable result what I did is attach the prototype and first
try it out for myself and then secondly try it out and take results by making a sewing
operator use it and assess the difference.
 Step 1- Attaching it and trying it out

Step 2 – Get it tried out by a sewing machine operator.

Sample name: Netsanet

Work: SNLS sewing machine operator

Stitches done without using the work aid:

 Stitches done by using the work aid:

All of the stitches constructed are of ½ inch allowance. On the first picture
which means the stitches which are constructed without using the work aid the picture
clearly demonstrates that for an operator it’s hard to stitch lines of the same gap over and
over again straightly. This means these reasons are the ones that makes product quality
poor. And when we come to the second photos these pictures show improvement in the
stitch quality and also even by simple observations the stitch gaps are more better that the
first one. To get the ½ inch gap we used the throat plate measurement gauges in which their
first purpose is to facilitate seam allowance.

In my conclusion its far easier to use and implement this technology because
we can benefit a lot of things from it. When I say this, I mean that we can save and improve:

 Reduce operation cost

 Improve product quality
 Make work easy and more efficient
 Eliminate rework
 Eliminate unnecessary fatigue of sewing operators
 Eliminate the cost which was use to be subjected for drawing operation
 o Cost if tailors chalk
o Pattern carboard
o Drawer operators
 Reduce production time

CHAPTER –THREE

BENEFITS FROM INTERNSHIP EXPEIENCE

Internship experience

When I am to do an internship, I believe by doing an internship I can learn new skill,

develop my professional interest, and valuable work experience. my first task was finding
an organization which has some applications which are related with my studydepartment

Benefits I gained from internships

Internship helps me to get experience in my field of study. I was not sure what I wanted to
do when I graduated. So I thought some real life experience would help me solidify my
future endeavor. The benefit of internship which I acquired during my internship includes
the following.

• Practical skill

• Upgrade theoretical knowledge industrial problem solve

• Industrial problem

• Team playing skill

• Leader ship skill

• Work ethics issue and

• Entrepreneurship skill

• Inter personal communication skill

Practical skill

Able to make practical skill like make pattern making, sewing and other activities

Theoretical knowledge

After I have completed my internship program I am able to upgrade my theoretical

knowledge.

Garment problem solving skill

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

My internship gave the opportunity to apply some garment problem solving skill learned
with in the classroom to real world

Team playing skill

Doing internship me enables me to develop my team playing skill. It enables me working

with my colleagues who have substantial experience within the garment factory

Leadership skill

Doing an Internship made me to build my confidence and knowledge on leadership skill

i.e. I am able work with my colleague and prior goal of the company and become effective
without creating any disagreement with my colleagues.

Work ethics issues and industrial psychology

An internship made me to have a strong willing to work. With a strong willing to work
ethic I am always committed to the work and will stay until the task is complete.

The internship made me to avoid personal issues on work time and to keep my positive
attitude and I remember that I have smaller tasks to handle prior to my large, more
important ones.

I also develop the following things after my internship program Build motivation and work
ethics Punctuality and accountability to a given task Transparency in working once duty.