SHANTO-MARIAM UNIVERSITY OF

CREATIVE TECHNOLOGY

Module Code
MGM - 4102

Assignment Topic
Product development (Polo Shirt)

Submitted To

Eng.Saleh Ahammad Lablu

Assistant Professor
Dept. of Apparel Manufacturing Management & Technology

Submitted by
Mohammad Raim Razzak ID-191057011

Md Sayem Khan ID-171051043

Taufikur Rahman ID- 173051032

Group: A, Semester: 11th, Batch: 31st

Dept.: AMMT
 Acknowledgement

we have taken efforts in this project. However, it would not have been
possible without the kind support and help of many individuals and our
Professor. I would like to extend my sincere thanks to all of them. I am
highly indebted to Eng.Saleh Ahammad Lablu for his guidance and
constant supervision as well as for providing necessary information
regarding the project & also for his support in completing the project. I
would like to express our gratitude towards our parent’s kind co-
operation and encouragement which help us in completion of this
project. I would like to express my special gratitude and thanks to
Eng.Saleh Ahammad Lablu for giving me such attention and time.
 Product development(Polo Shirt):

Introduction

Our product is POLO T-shirt. We see many types of T-shirt in the market. If any
one wants to buy a quality T-shirt he/she should have to spend a big amount of
money. But our product is different. The quality of our product is really good and
public need not to spend very big amount to buy it. it is export quality and has
various type of design.

As we said before that we want to do garment business. So we choose the one

product. That is polo T-shirt. Our product is normal polo T-shirt. . Our product will
have two different type of border under the Sleeve. The collar of the T-shirt will
have different color then all part.
A polo shirt, also known as a golf shirt and tennis shirt, is a form of shirt with a
collar, a placket with typically two or three buttons, and an optional pocket. It is
the most stylist and popular dress in apparel world. Polo shirt is mainly dress for
men but women also wear. Collar is the basic different between t-shirt and polo
shirt. Polo shirt has collar and t-shirt has not it. Polo shirt is produced abundantly
in Bangladeshi apparel industry. Manufacturing process of polo shirt is divided by
some steps. Step wise flow chart of polo shirt is given below
 Polo-Shirt (Rib Neck)

Pieces received from cutting section.

↓
Edge neatening of the moons (a part attached with back part which looks exactly
like a moon) by over lock sewing machine.
↓
Label attaching with the moon by plain sewing machine.
↓
Moon joining with the back part by plain sewing machine.
↓
Moon top stitching by flat lock sewing machine.
↓
Front part, back part, and moon matching according to number and size so that
avoiding shading problem.
↓
 Shoulder joining by over lock sewing machine.
↓
Shoulder top stitching by flat lock sewing machine.
↓
Rib sewing (for neck) as per size by plain sewing machine.
↓
Rib rounding by plain sewing machine.
↓
Neck joining with the body by over lock sewing machine.
↓
Placket interlining (fusible) with hand iron and marking on it by chalk as per size.
↓
Plackets (both left and right) joining with the front part as per exact position by
plain sewing machine.
↓
Placket top stitching by flat lock sewing machine.
↓
Scissoring of front part exactly at the middle keeping the two plackets in two sides.

↓
Nose tagging by plain sewing machine.
↓
Neck joining by over lock sewing machine.
↓
Neck top stitching by flat lock sewing machine.
↓
Placket top stitching by flat lock sewing machine.
↓
Button and box plate tagging by plain sewing machine.
↓
Placket box top stitching by plain sewing machine.
↓
Neck piping by plain sewing machine.
↓
Piping top stitching by flat lock sewing machine.
↓
Sleeve matching as per exact size and number.
↓
Sleeve joining (Left and Right) with the body by over lock sewing machine.
↓
 Arm hole top stitching by flat lock sewing machine.
↓
Sleeve tagging by plain sewing machine so as to facilitate easy positioning while
side seaming.
↓
Side seaming with label by over lock sewing machine.
↓
Length measuring as per demand and scissoring if necessary.
↓
Bottom hemming by flat lock (Zigzag stitch) sewing machine.
↓
Inspection and send it for ironing.

N.B: Stitch type at each and every point must be followed carefully. Some samples
(counter sample) are hung at the top of the line to facilitate easy production. The
line supervisor and line quality controller must keep keen supervision to ensure
desired quality.

Polo-Shirt (Collar & Cuff)

Pieces received from cutting section.

↓
Edge neatening of the moons (a part attached with back part which looks exactly
like a moon) by over lock sewing machine.
↓
Label attaching with the moon by plain sewing machine.
↓
Moon joining with the back part by plain sewing machine.
↓
Moon top stitching by flat lock sewing machine.
↓
Placket interlining (fusible) with hand iron and marking on it by chalk as per size.
↓
Plackets (both left and right) joining with the front part as per exact position by
plain sewing machine.
↓
Placket top stitching by flat lock sewing machine.
↓
 Plackets (both left and right) joining with the front part as per exact position by
plain sewing machine.
↓
Placket top stitching by flat lock sewing machine.
↓
Scissoring of front part exactly at the middle keeping the two plackets in two sides.

↓
Nose tagging by plain sewing machine.
↓
Front part, back part, and moon matching according to number and size so that
avoiding shading problem.
↓
Shoulder joining by over lock sewing machine.
↓
Shoulder top stitching by flat lock sewing machine.
↓
Collar joining with the body by over lock sewing machine.
↓
Collar top stitching by flat lock sewing machine.
↓
Cuff joining with the sleeve by over lock sewing machine.
↓
Cuff top stitching by flat lock sewing machine.
↓
Sleeve joining with the body by over lock sewing machine.
↓
Arm hole top stitching by flat lock sewing machine.
↓
Length measuring and scissoring if necessary.
↓
Bottom hemming by flat lock (Zigzag stitch) sewing machine.
↓
Sleeve tagging by plain sewing machine so as to facilitate easy positioning while
side seaming.
↓
Side seaming with label by over lock sewing machine and dividing at the bottom.
↓
Bottom division piping by plain sewing machine.
↓
 Piping folding and sewing by plain sewing machine.
↓
Cuff tagging by plain sewing machine.
↓
Button holing and attaching by respective machines.
↓
Bar taking.
↓
Inspection and send it for ironing.

N.B: Stitch type at each and every point must be followed carefully. Some samples
(counter sample) are hung at the top of the line to facilitate easy production. The
line supervisor and line quality controller must keep keen supervision to ensure
desired quality.
Causes of choice:

There is number of reasons to choice polo t- shirt as our product. Polo t- shirt is
that product that can be used by any aged people at any time. Its not only one
that product of garment which can be used by a specific age or group or gender of
people. It can be used by all. 2nd its is a profitable business. It doesn’t need that
much of investment but can earn a good profit. The costing price of not that much
of high. 3rd the raw material of the product is so much available.

Steps of selling:

We will take some steps to sell our product.

The first step is, we will sell our Product to local buying house. That will not give
us much profit but can sell a big quantity.

Then we can sell directly to the retailer. In that case we have to go directly to the
market. Then we have to convince the retailer that why he/she should by our
product. in that case we can earn a good profit. We can sell 1 t- shirt more then
62 taka, but quantity would be less. If we capture 10 or 15 shops that will buy our
product, our selling quantity would be huge.
If our business speared much and if we collect good amount from our business,
we will make our own showroom and brand. The 1st advantage of own showroom
is we can sell our product directly to the customers. And we can sell our product
in the rate of retailer. If the retailer sell 1 t- shirt in 100 taka, we can sell it 90 or
95 taka in our own showroom.

Market analysis:

In recent time, polo t- shirt has captured a big market of garment sector. This is
not formal so any one can were that at any time. The age of the people who by a
huge number of polo t- shirt mainly is 14-40. They r very much choosy to buying
that. They want various colors and design. And also want different type of shape
like full-slive or half-slive and also they want which is fit to their body. Most of
them want different colors of collar then the whole t- shirt body color.

The price is different in the basis of quality. One color t- shirts selling price is 60-
70 taka. If it is a high brand it will take more. The price of the different colors of
one t- shirt is more then 100 taka. This is the one, which has very good market
demand.

Target market:

Every aged people wear polo t- shirt. It can be wear by 10 years old kid and also
can by 50 years old, old people. But our main target market is 14- 40. In this age,
they buy their own. And they can spend much for a t- shirt is its good.

Segmentation of our product:

We have segmented our product in three different part.

1st we keep 10 –16 years old kid in one pattern. They always choose color full t-
shirt. So we have to thik differently for them. For that we have to make more
colorful t- shirt then them.

2nd we keep 17-35 years old people in another pattern. They r more depends on
style. They don’t like many color full t- shirts. Some of them don’t like the pocket
in the chest.

3rd we keep 36-48 years old people in the last pattern. This age people are more
depends on comfortable. So we have to produce more soft and thin t- shirt which
is much comfortable.

Competitor analysis:

We analysis and found two types competitor for us.

No 1 is local garments. There is number of local garments which is producing polo

t- shirt like us. Rehan garments, shitol garments, shotorupa garments etc are the
big industries which are producing big quantity of polo t- shirt in a day. And also
purchasing a huge quantity of t- shirt in market. There are also quite a few small
garments like us, which are producing the product.

No 2 are the brands. There are also number of brands in Bangladesh, which are
famous for polo t- shirt. Cats- eye, crocodile, diesel, wastes, moods etc are the
most famous brand. Though they are famous but people have to spend a big
amount to buy 1 t- shirt.

Product development:

After analyzing the computer and market we found that, we need to develop our
product a little bit. Most of the People want design, which is made by weive. We
also found a small group of people doesn’t like different colors collar then the
body. They want the same color which in the body. So we need to make our
product in the basis of this analysis. We have to make different types of design,
which is attractive. On the other hand we have to put the same colors collar.

SWOT analysis:

Strength: the strength of our product is its price. We are giving much lower price
then others. If any customer wants to buy a brand t- shirt he/she have to spend
700-1000. But as our production cost is low we can sell is in a lower price. If any
one wants to buy a local garments t- shirt he/she have to buy 150-200 tk. And
comparing them we also selling much lower then them in here also. We are giving
much better quality in terms of our price.

Weakness: the main weakness of our product is we are relatively new in market.
People needs time to depend on our product.

Opportunities: we have a big opportunity if we keep our promise to the

customers. That is lower price better quality. If we can attract the local customers
with our quality, we can earn a good profit from the local market. The best
opportunity we would like to have, that is exporting. There is lots of opportunities
for the country like Bangladesh to go internationally. If our quality is good, we can
easily attract the foreign buyers too. If we are success to do that we can earn a
huge amount then the local market.

Threats: the first threat that we have that is from our local competitor. If we want
to run in that race we have to compute very well then them. We have to depend
on our product quality to win it. In first we will face some difficulty to attack the
customer, this is the survival period that we must not fail.

Advertising:

As we are relatively new in market and we don’t have much investment, we will
do business to business advertising. Our buying house and the retailer shop will
do advertising for us. When our business spread we will give our product add on
television, radio, or on billboard.

Consumption Process:
Today we will know how to calculate polo shirt’s fabric consumption of an order.
We know fabric consumption is the most important factor to carry out any order
in apparel industry. Fabric consumption is requiring getting an idea over the cost
of the garments product. Since it depends on fabric prices, therefore, we should
focus on fabric consumption to get accurate and closure consumption of an order.
It will reduce fabric wastage which will be economically beneficial for us.
Garments merchandiser has to do fabric consumption frequently as it is a
common practice in this arena. Fabric wastage and loss can be reduced by
preparing accurate consumption. Accurate fabric consumption is relative to the
order profit margin. Today I will try to share the formula of fabric consumption of
a Knitted Polo Shirt. I think you will get benefit after reading this article.

A knitted polo shirt consists of the following parts. We should sort out the major
parts of a knitted polo shirt before going to consumption calculation.

1. Body parts (Body + Sleeve),

2. Collar,
3. Cuff,
4. Pocket,
5. Half-moon.

Half-moon and pocket are dependent upon the buyer requirements. If buyer added
these items in their spec sheet, then you have to count these parts.

Suppose,
Nike buyer has given an order of 20,000 pieces with the following specification.

1. 100% cotton single jersey Knitted fabric for body parts (Body + Sleeve),
Half-moon and Pocket. Where fabric GSM is 160gm.
2. 1 × 1 Rib fabric for collar and Cuff. Where the fabric GSM is 220gm.
3. Item: Basic men’s s/slv Polo shirt
Merchandiser should find out accurate consumption before yarn and fabric
booking. Buyer will provide a size measurement chart. Now he has to find out
consumption based on the middle size of that measurement chart. We can select L
size to get the consumption.

Polo shirt consumption and cost sheet usually prepare based on dozen. Formula
will be same whether it is one piece or one dozen. There is two formula exists to
prepare a basic Polo shirt consumption. European buyer always prefers CM to do
measurement but USA buyer prefers inch to do measurement of garments product.
You should know both formulas to become an expert merchandiser. Let’s find first
formula to prepare basic Polo shirt consumption.

Now, we will find out the fabric consumption for the above order.
1. Fabric consumption for Body parts (Body +Sleeve):
Here, we will follow the following formula (per dozen),

So, fabric’s consumption for Body parts (Body +Sleeve) is 3.46 kg per dozen.

= 0.1161kg per dozen.

So, fabric’s consumption for Collar is 0.1161kg per dozen.

3. Fabric’s consumption for Cuff:
Here, we will follow the following formula (per dozen),

= 0.0712kg per dozen.

So, fabric’s consumption for Cuff is 0.0712kg per dozen.

4. Fabric’s consumption for Pocket:

Here, we will follow the following formula (per dozen),

= 0.0411kg per dozen.

So, fabric’s consumption for Pocket is 0.0411kg per dozen.

5. Fabric’s consumption for Half-moon:

Here, we will follow the following formula (per dozen),
= 0.0633kg per dozen.

So, Fabric’s consumption for Half- moon is 0.0633kg per dozen.

Now, total amount of single jersey cotton fabric needed for this order is (per
dozen),

= [{Body parts Fabric consumption (Body +Sleeve) + Pocket Fabric consumption

+ Half- moon Fabric’s consumption} + wastage (10%)]

= {(3.46+ 0.0411+ 0.0633) kg + 10%}

= 3.56kg + 10%
= 3.91kg per dozen

So, for 20,000pcs (1666.66 dozen) polo shirts, cotton single jersey fabric needed
(3.91 × 1666.66) = 6516.64kg

And,
Total amount of (1 × 1) Rib fabric needed for this order is (per dozen),
= {(Collar Fabric consumption + Cuff Fabric consumption) + wastage (10%)}
= {(0.1161 + 0.0712) kg + 10%}
= (0.1873kg + 10%)
= 0.2060kg per dozen.

So, for 20,000pcs (1666.66 dozen) polo shirts, (1 × 1) Rib fabric needed (0.2060 ×
1666.66) = 343.33kg.

Costing Process:
Costing is very important for a productive factory. Without proper costing all
production curriculums will go vain. Because a factory cannot reach to its goal
without achieving good profit and good profit is not possible without skillful
costing.
Method of Garments Costing for Polo Shirt:

At the starting of garments costing for knitted polo shirt, a knit garments
merchandiser should be known about the following matters:

1. Yarn Price ,
2. Knitting and Washing Cost,
3. Dyeing Cost,
4. Printing cost,
5. Embroidery Cost,
6. Cost of Making (CM),
7. Accessories Cost,
8. Commercial Cost,
9. Others Cost.
10. Total working hours per day.

Now by applying following formula, a garment merchandiser can easily calculate

the actual cost of garments making.

Cost of making (CM) per pcs,

Now one example is enough to remove all the confusions from the above
discussion.

Example:

Suppose,
H.N apparels has received an order of basic T-Shirt item.

Where,
H.N apparels total expenditure per month-30,00,000 taka
Total number of machines in the factory-100
Total number of machines required to complete an item-25
Targeted production per hour from the existing layout-180
Total working day per month-26
Total working hours per day-08
Now calculate the costs of making (CM) of the mentioned item.

Solution:

Cost of making (CM) per pcs,

= 20.03 taka per pcs

= (20.03 × 12) taka per dozen
= 240.38 taka per dozen
= 240.38/78 (in dollar) {1dollar-78taka (running)}
= $3.08 per dozen

Example of garment costing calculation:

The calculation of garment costing is given by assuming the following dimensions
for polo neck T-shirt, 

So, the costs of making (CM) per dozen basic T-Shirt is $3.08

 No. of pieces = 4000,

 Salary of the operator =6240 tk/month=80$/month,
 No. of working days = 26,
 Line efficiency considered= 50%,
 Sewing SAM= 15 min.,
 Cutting SAM= 7 min. 1$ =78 taka
 Chest = 60 cm,
  Length (HSP to waist) = 75 cm,
 Sleeve length = 25 cm
 Fabric used is 2/60s 100% cotton S/J fabric.
 GSM is 180

Solution
The fabric consumption can be calculated as

= [{(B.L +S.L + 4-10 cm) ×( ½ chest+ 2-4 cm) ×2}×GSM ] / 10000000

= [{(75+25 + 4) ×( 60+ 2) ×2}×180 ] / 10000000
= 0.232 + Wastage 10% [if consider 10% wastage]
= 0.255 kg/dozen

CMT (cost of making with trimming) charges may be calculated as follows

Labour cost per minute = (Monthly salary of an operators/Total minutes available

in the month

= 6240/ (26×8×60)
= 0.5 tk.

Sewing cost = (SAM of the garment * Minute cost of the labour) / Line eff%

= 15*0.5 / 50%
= 15 tk.

Cutting cost = (SAM of cutting * Minute cost of the labour) / cutting efficiency
(%)

= 7*0.5 / 50%
= 7 tk.

Now trimming cost is considered as 3 tk. but it depends how number of operators
are there for trimming .

CMT = sewing cost + cutting cost + trimming

= 15+ 7+ 3
= 25 tk.

Production Process:
An accurate estimation of garment production can provide the surety of garments
shipment in timely. But there are some key factors which affect the estimation of
garments production. As a result, sometimes it’s not possible to respect the
shipment date.

Factors Affecting Estimation of Garments Production:

The main five key factors which affect the estimation of garments production are-

1. Standard allowed minutes,

2. Number of operators- working in a line,
3. Production line running time in a day,
4. Average line efficiency,
5. Total break time

All the above key factors are discussed in the below:

1. Standard allowed minutes:

Standard allowed minutes or SAM of garments means how much time will require
to make one complete garment. Standard allowed minutes or SAM has a great
importance in estimating garment production. Here, if time required more, then
production will take more times and vice-versa. It is the main key factor among
five key factors which affect on the estimation of garment production.

2. Number of operators- working in a line:

It is the second important one that affects on the estimation of garment production,
if higher number of worker will work in a working line, then production of an
order also takes less time to complete and vice-versa.

3. Production line running time in a day:

It is another key point which affects on the estimation of garments production. If
production line will run more time than its schedule time, then the production of an
order also takes less time to complete and vice-versa.
4. Average line efficiency:
Average line efficiency is totally related with machine break down, imbalance line,
continuous feeding to the line, quality problems, level of individual operator
performance and absence of operator. If these types of problem have to face during
garment production, then automatically reduce the average line efficiency of any
production and vice-versa.

During calculation of garments production, we have to follow a formula, that

is-

Per day production (pc),

Here, total man-minutes mean number of operators working in a day including

total break time for Launch, Tea and Others.

Or,

Total man-minutes = [Total Number of operator’s × {(Working hour in a day ×

60minutes) – Total break time}]

Now, we can write equation (1) in the following way-

Per day production (Pc),

So, it is the main formula for estimation/calculation of garment production.

Now, one example is enough to understand the estimation of garment production

and that is in the below:

Example:

Let,
For a polo shirt garment,
  Standard allowed minutes (SAM) is-25 minutes,
 Number of operators in a working line is-20
 Number of hours running-production line work in a day- 8hrs
 Average line efficiency – 60%
 Total break time including Launch, Tea and Others- 60 minutes

So, calculate the estimation of polo shirt garment production.

Solution:
Now, applying the above information in equation (2), we have-

Per day production (pc),

= 336 × 60%
= 201pcs

So, Estimation of polo shirt garment production per day is 201pcs.