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Internship Report on Garments Merchandising
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Aasif Arafat
, Managing Director at Network Marketing

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Published on Jan 18, 2015

Internship Report On MERCHANDISING IN GARMENTS INDUSTRY. Hope it will be help

for everyone. Thank

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Internship Report on Garments Merchandising

1. 1. TABLE OF CONTENTS Contents Acknowledgment Executive Summary Of Orbid Apparels

Introduction Objectives Methodology Scopes Limitations Part- 01 Organization Part Brief History
of Orbid Apparels Ltd Garments Merchandising Garments Trims/Accessories Activities of
Merchandising Department Kinds of Garments Industry Part-02 Main Report Part Name Of the
Buyers Of Orbid Apparels Ltd Fabric Supplier Of Orbid Apparels Ltd Trims Supplier Of Orbid
 Apparels Ltd Store Of Orbid Apparels Ltd Job Responsibility Of Merchandiser Essential Duties
And Responsibilities Thread,
2. 2. Interlining, Label, Buttons, Zippers, Elastic Services Of Merchandising Team To Buyers
Execution Process Of Export Order Sampling Facilities Quality Assurance Quality Control And
Inspection Procedures Sourcing Services Factory Evaluation Capet Audit Part-03 QUALITY Quality
Procedure Quality Depends On Some Factors Quality In Sewing Types Of Quality Checkers
Quality In Washing Checklist For Auditing Carton Cost Of Failure Remarks Quality Control
Definition Of Quality
3. 3. Dimension of Quality The Great Value Of Quality Controlling Quality In-line Inspection Section
Supervisor Finial Audit Quality Procedures Quality Drills Points To be Checked: Cutting Section
Spreading Cutting Others Sewing Section Finishing Section Fabric Inspection Grading System 4
Points Types Of Reporting Format
4. 4. Garments Defect Classification Of Defect Possible Garment Defects: Fabric Cleanliness
Pressing Stitching Button Hole Button Sewing waistband Belt Loops Hem Pockets Zippers Fly
area Labels Final Inspection Of Garments AQL Garment Checking Quality Planning 5 “S System 5
“S System Activities 5 “S System Steps Documentation For Export:
5. 5. Consular Invoice Commercial Invoice Certification Of origin Shipping marks Marks Of Origin
Compulsory Marks Of Origin Corrective Marks Of Origin Making method Loading the Goods
aboard Ship Truck Transportation Types of Tariffs Export Transportation and Shipment
Alternative Shipping Methods Import Quotas Exchange Controls Trading Blocks Part-04
Conclusion Reference ACKNOWLEDGEMENT A warm felicitation goes for me to acknowledge the
people, who hold the desirability for encouraging, praising, assisting as well as believing me on
the tasks of Merchandising activities what I have worked through my internship period. First of
all I would like to take the opportunity to thank Courses Coordinator of National Institute of
Fashion Technology & my internship supervisor for providing me guidelines, help in assisting my
report. He was constantly
6. 6. supporting me with his inspiring personality. I will always be always thankful for his
extraordinary reinforcement. I would like to take the opportunity to thank Mr. Abu Soud, Senior
Merchandiser, Orbid Apparels Ltd for being my on-site supervisor & providing me time to time
information, suggestion as well as procedures to work with my topic. I also want to thank Mr.
Yousof Ali, Merchandiser of Orbid Apparels Ltd for being so cooperative in my work. Finally I will
show my gratitude to all the Management & Non-Management Staffs who have helped me
during the internship period and the entire persons who somehow have impact on me in
completing my whole report. Executive Summary Readymade Garments Industry is the leading
foreign currency earning sectors of Bangladesh. Now-a-days Bangladesh financial sector is very
much dependent upon this sector. The annual export income of garments sector is driven from
two sources one is woven garments and others is knit wear. Readymade Garments is a 100%
export oriented garments. Readymade
7. 7. garments exports various garments product in foreign market. The company makes shirts,
ladies dress, shorts, trousers, and others for U.S.A, U.K, European countries They use high tech
machineries to produce a quality garments product. They also add new machineries to increase
their production line. They have a mission and the vision is profit maximization. The
merchandising philosophy of readymade garments is to keep good relation with their buyers.
The garments Industry maintains a good relationship with every buyer. Hard working and
commitment maintenance is their main strategy. They always try to satisfy their buyers. In this
perspective the merchandiser always try to do their merchandising activities in due time. The
merchandiser of this company is not very much skilled person. More over him has no assistant.
For this reason Sometimes the company face problem. So, here readymade garments can recruit
 high skilled people with giving high salary. The Readymade garments should improve their
product quality, packing system, internal environment, and other merchandising activities to
satisfy their foreign buyers. This report is prepared on “Merchandising activities and buyer
satisfaction of readymade garments. The OCP report helps the reader to know about the
merchandising activities, practiced in Readymade garments And the buyer satisfaction level
towards the merchandiser Introduction RMG (Ready Made Garment) is very important and
helpful for our Bangladesh. Bangladesh has emerged as a key player in RMG (Ready Made
Garment) sector since 1978. Textiles and clothing account for about 85% of total export earnings
of Bangladesh. Out of which, 75% comes from the apparel sector which covers the major
products of knit and woven shirts, blouses, trousers, skirts, shorts, jackets, sweaters, sports
wears and many more casual and fashion items. The sector currently employs approximately
1.5+ million workers, mostly females from underprivileged social classes. I have completed this
report on the basis of all the
8. 8. department of RMG sector such as Merchandising Department, Commercial Department,
Production Department, Supply Chain Department, Human Resource Department, Compliance
Department, MIS Department, and relevant organization like BGMEA, BKMEA, Export Promotion
Buru, Yarn suppliers, Chittagong Port, Insurance Company, Shipping Company. So by completing
this report I get overall idea about RMG sector, so its carry more value than any books. I
preferred this attachment in Orbid Apparels Ltd, which is a 100% export oriented composite knit
industry. For continuing the study of internship in the Orbid Apparels Ltd, almost worked all the
sections of this company and tried to find out the activities, planning and many other things as
well. In context, I have discussed about these things deliberately to let you know about.
Objectives: Objective means the purpose of this report. The objectives of this report are as
follows: Its documents for future. • To know detail about RMG sector. • Information gathers
about commercial. • Getting idea about shipping procedure. • Concept develops about spinning,
knitting • • Comparison between class room learning and practical learning. • Knowledge gather
about RMG sector related other organization. • To achieve new idea about knit garments
manufacturing process. • To know about the management and technical process of apparel
industry. • To know the management Procedure in Garments Industry. • To mark a comment
over the whole Internship Report. • To mark out the important part of Internship Report. • To
focus on the valuable part of Internship Report. • To have skill labor for quality product. • To
study the present market composition for the Bangladeshi garment product about Market
diversification.
9. 9. • To analyze the recent labor unrest in the garment industry of Bangladesh. • Opportunity of
behavioral theory practice in our garments sector. • Regularly behavioral theory practice in
garments industry. • Identifying the trade agreements that might affect the export growth. • To
do a merchandising practice in the factory. • Identify the additional services that the existing
companies are going to avail. • To relate the use of groupware and collaborative systems with
future trends in managers' roles and responsibilities. • To identify merchandising and total
production system. • To find the current scenario of backward supply chain status of Orbid
Apparels Ltd. • To find the ways of improving the backward linkage of the supply chain for Orbid
Apparels Ltd. Methodology: Methodology defines how we go through all the processes of
research and how I have proceeded on. Here includes the steps of conducting the report and
the explanation of the sources of data. • Factory • Different organization. • Books • Discussion •
Internet • Class lecture • Library • Annual report • To collect information what I am seeing in
practical in My Internship Program. • To collect information what I did in practical what was
done by me for my practical knowledge. • To make a comment over the project we have to
understand the whole project.
10. 10. Scopes: Scope means how many uses for completing this report space. The scopes are given
bellow- Factory Buying House Discussion Internet Some of our senior brothers can
help me. • I can collect information various books and relevant paper what related with
apparel industry. Limitations: Limitation refers the obstacles I have to face for completing this
report and what I could not cover for this limitation. Time constraint Merchandiser doesn’t
have enough time to give the information elaborately. Short time visit in different work
stations Lack of organizing chain of command Lack of instruction book, and any change.
They are following traditional business. I may have to suffer for lack of supply chain
management. No other garment’s data has been compared with Bextex s data. There might
be some‟ discrepancies with other factories supply chain scenario‟ Due to high employee
turnover rate and lack of good reporting practices in the factory, problems with collecting data
have been faced.
11. 11. PART - 01 ORGANISATION PROFILE CONTACTS Head Office House No #14(Ground Floor)
Road No #09, Sector # 09, Uttara Dhaka-1230, Bangladesh Phone/Fax: 088 02 8931015 E-mail:
orbid@orbidapparels.com Factory Address Plot # 186, Madha GazirChat, Ashulia EPZ Road,
Saver, Dhaka(2nd & 3rd Floor) Phone/Fax: 088 02 7790778 E-mail: Soud.orbid@gmail.com
Knitting Factory Address Katgora Bazar, Zirabo, Savar, Dhaka Dying Factory Address BEQ Fabrics
Ltd. Allianace Group. Vajon Textile. Sadma Fashion Ltd. Print Factory Plot # 10, Lane # 8, Block-A
Banarashi Palli, Section-10, Mirpur-1216, Dhaka, Bangladesh Factory Area: 5,000 Sqf for Knitting
Ground Floor 5,000 sqf for Fabrics Store & Cutting First Floor 5,000 sqf for Sewing 2nd Floor
5,000 sqf for office & Finishing
12. 12. 3rd Floor 5,000 sqf for Sewing, samples & Store Knitting Section : Total 13 nos. circular
knitting machine (Korea) Gauge-24 "Dia-16" Qty-1 no-S/J & Pique Guage-24 "Dia-17" Qty-1 no-
S/J & Pique Gauge-24 "Dia-18" Qty-1 no-S/J & Pique Gauge-24 "Dia-19" Qty-1 no-S/J & Pique
Gauge-24 "Dia-22" Qty-1 no-S/J & Pique Gauge-24 "Dia-24" Qty-1 no-S/J & Pique Gauge-24 "Dia-
26" Qty-1 no-S/J & Pique Gauge-24 "Dia-30" Qty-1 no-S/J & Pique Guage-24 "Dia-30" Qty-1 no-
Rib & Int Gauge-24 "Dia-36" Qty-1 no-Rib & Int Guage-18 "Dia-36" Qty-1 no-Rib & Int Guage-20
"Dia-30" qty-1 no-Terry Fleece Guage-20 "Dia-36" Qty-1 no-Terry Fleece Cutting, Sewing &
Finishing Section Cutting Section: Cutting mc -04 no(Km Japan) Cutting Table -04 nos(28' Ft.)
Fabrics Checking Table -02 no(Local) Piping/Tape cut mc -02 nos(Adea) Sewing Section: Plain
Machine -100 nos(Siruba) Over Lock -74 nos(Siruba) Flat Lock -46 nos(Siruba) Rib Cut Machine -
02 no (Yamate) Buttons Hole -02 no (Yamata) Button Stitch -02 no (Taking) Feed of the Arm -02
no (Siruba) Snap Button -03 nos Total: -233 nos
13. 13. Finishing Section: Thread sucking Mc -01 no(Local) Washing Machine -01 no(Samsung)
Steam Boiler (El) -01 no(Local) Steam Boiler (Gas) -01 no(Local) Vacuum Iron Table -13 nos(Local)
P.P.Bailing Machine 01 no Iron -13 nos(Silver) Generator -02 no(Japan) Employees For Office 25
people(No child labor) For Sample 23 people(No child labor) For Cutting 42 people(No child
labor) For Sewing 460 people(No child labor) For Finishing 65 people(No child labor) For Knitting
25 people(No child labor) Total: 640 people ALL TYPE OF KNIT ITEMS T-SHIRT POLO SHIRT TANK
TOP SWEAT SHIRT PAJAMA LADIS & GIRLS DRESS JOGGING SUITE ALL TYPE OF FLEECE ITEMS
Production Capacity: T-SHIRT: 300000 pcs/ month POLO SHIRT: 100000 pcs/ month Others:
30,000 pcs/ month (As per Styles)
14. 14. Our Associate Factories : 1. Orbid Fashion(Garments Printing Factory) 2. Orbid(BD)
International (Accessories) General: 1. We are able to make garments using any sorts of fabrics
as desired by you such as single jersey, interlock, pique, terry, fleece, rib, mini pique as well as
different composition of fabrics in different constructions like 88% polyester, 12% lycra, 50%
cotton, 50% Modal, 100% Pima cotton, 95% Viscose, 5% Elasthan, 100% polyester, 50%
 polyester, 50% coolmax, 90% Supplex, 10% Lycra etc. 2. We are able to control the shrinkage for
single jersey in 3-4%, interlock 4-5%, rib 5-7%, all polyester within 3%. 3. We are able to deliver
the goods 60 days after received the L/C GARMENTS MERCHANDISING Orbid Apparels Ltd 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. The term “merchandiser” may be defined as the person who
merchandises the goods. Garments merchandising means buying raw materials & accessories,
producing required garments, maintaining required quality level and exporting the garments
within time frame. According to Mr. Yousof Ali, Marketing can do everything but he can’t do
anything directly is called merchandiser. From the above definition we can assume that a person
involved in garments merchandising need a wide range of knowledge & skill to perform his job
successfully a merchandiser should possess the following basic knowledge and skill. Are:- a)
Good command of English and adequate knowledge of technical terms for accurate and efficient
communication. b) Good knowledge of yarn, fabric, and dyeing, printing, finishing, dyes color
fastness garments production, etc.
15. 15. c) Clear conception of usual potential quality problems in the garments manufacturing. d)
Good knowledge of the raw materials inception systems & garments inspection systems. When
an export order is given to a merchandiser, he has to schedule the following main function to
execute the export order perfectly in time. Are:- I. Fabric requirement calculations, 2.
Accessories requirement calculations (-Thread, Button, Interlining 1abet Poly bag, Main label,
Woven label, Fit label, Cartoon etc.) 3. Source of Fabrics 4. Sources of trims. 5. Possible date of
arrival of fabrics & trims in the garments factory 6. Costing. 7. Garments production planning. 8.
Pre shipment inspection schedule. 9. Shipment documents. 10. Have to make proper & Action
plan 1. GARMENTS Trims: 2. Garments trims means all items used in the garment except the
basic is called garments trims. There are hundreds of items used to manufacture the garments
which are used as trims. i. A list of few important trims is mentioned here. a. Sewing thread k.
Hanger b. Interlining I. Guru tape c. Label m. Scotch Paper d. Button n. Tissue Paper e. Zipper o.
Plastic: clip f. Lining n. Tag pin g. Shoulder Fad q. Collar insert h. Elastic r: Collar bone i. River s.
Back Board j. Poly-bag t. Neck Board . 3. Quality of trims as well as proper selection of trims is
very important; otherwise the garments may be rejected returned by the customers. 4.
Activities of Merchandising Department of Orbid Apparels Ltd: 5. Activities of Merchandising
Department are as follows: 6. Communication with Buyers
16. 16. a. Procure Order & Order confirmation b. Costing 7. Consumption a. Price Quoting b. Sample
Control & Approval c. Potential Sourcing of Materials & Approval Fabric, Trims & Accessories d.
Lab dipping & Approval e. Purchasing of Materials f. Testing g. Factory Scheduling / Planning h.
Order Follow up: all steps of production & Quality i. Ensure On Time Delivery j. Liaison with the
customer during Design, Sourcing, Production & Shipping k. Conduct coordination Meeting with
other departments / Pre production meeting l. Attend Buyer’s meeting m. Ensure Customer
Satisfaction n. Product Development etc. There are three types of garment industry in RMG
sector: • Woven Garment Industry: The industry manufacturing garments and using woven
fabric. Ex: Shirt, Trouser, Blouse & so on. • Knit Garment Industry (cut & sews): The Industry
producing garments and using knitted fabric. Ex: T-shirt, Polo shirt, Tank top etc. • Fully Fashion
Garment Industry: The Industry producing knitted garments and using yarn as main materials
instead of fabric - Ex: Sweater, Pullover, Cardigan etc. Various Departments / Sections of Orbid
Apparels Ltd are as follows: 1. STORE 2. SAMPLE 3. PATTERN 4. CAD/CAM/DESIGN 5. CUTTING 6.
SEWING 7. FINISHING & PACKING 8. MERCHANDISING / MARKETING 9. QUALITY CONTROL /
ASSURANCE 10. WORKSTUDY 11. Industrial Engineering 12. COMMERCIAL 13. ACCOUNTS 14.
PERSONNEL
17. 17. 15. PURCHASE / PROCUREMENT 16. MAINTENANCE 17. HRD PART- 02 Name of the Buyers of
Orbid Apparels Ltd: ALDI (Germany & UK) SDV (Portugal) EWS (Germany & Austria)
GINKANA (Germany) MOULY (Italy) ROY WATSON (UK) NORWEST (UK) RAGADI S. L
(Spain) MGB METRO GROUP (Germany) DITO FASHION (Denmark) SARA CONFEZIONI SRA
(Italy) REWE ZENT RAN AG (Germany) DIETER RENNER (Germany) WAYSNAR FAR EAST
(Hongking) INSTYLE (Italy) SOMERBOND(UK) BBA BEYMEN BOGA ZICI(Turkey) SGP
(France) KOOTENAY (Canada) Fabric Suppliers of Orbid Apparels Ltd: 1. CALIK 2. JEMIEI TEX
3. MOU FUNG 4. NIEN HSING 5. SHANDONG
18. 18. 6. SHANGHAI SHELYEN 7. SUNTEX 8. TAKSANG 9. ANLE RIVER 10. ZABIR ZUBAYE Trims
Suppliers Orbid Apparels Ltd: 1. A& E 2. BRILLIANT LABEL 3. COATS 4. PAXER/ A VERYDENSISON
5. SHORE TO SHORE 6. SML 7. TOPSON 8. WANFORD 9. YK BTN/RVT 10. YKK JOB RESPONSIBILITY
FOR A GARMENTS MERCHANDISER: The ideal candidate plays nicely with others and has a
proven track record of success leading a team of graphic artists, an understanding of screen-
print and with merchandising. Specific responsibilities include managing daily operations
including providing supervision to employees as well as managing vendors, departmental
communications, stylistic direction and managing associated budgets. ESSENTIAL DUTIES AND
RESPONSIBILITIES: • Develops and maintains a clearly defined strategy in support of company’s
mission, vision and objectives. • Works closely with key individuals and teams to integrate
strategic opportunities into the prioritized workflow. Ensure cross-organizational support and
extraordinary results for customers and partners. • Responsible for day-to-day operations
including managing employees, vendors, communications, stylistic direction and associated
budgets. This position will also provide support to customer service, Sunrise marketing, and
product development. • Carries out supervisory responsibilities in accordance with the
organization’s policies and applicable laws. • Manages and directs all pre-launch sampling and
distribution of samples to sales & customers. • Work with sales teams and design staff to
provide cost estimates. •Coordinates all aspects of tradeshow. •Develops business internally by
participating in Merchandising Team. 1. SEEWING THREAD: There are various types sewing
threads, which are used in the garments manufacturing industries. 100% Cotton. 100%
Polyester, Nylon, Viscose, Mono Filament, Multi Filament, Textured, and Core spun thread
especially finished thread etc.
19. 19. Amount all of them spun polyester thread is used in most cases. It is vary strong and have
well colorfast. It can stand all kinds of rough washing such as stone wash, acid wash with its
color unaffected. 100% Cotton threads should not be used unless you are making the garments
for garment-day, because the cotton threads are expensive and easy to break down. Sewing
threads are available in various types of package forms. Spool, Cap, Cone, Vicone, Small vicone,
Container, Cacoon, Per-wound bobbin etc. Among the mentioned packages in most cases
sewing threads are used in cone form. Within a cone length of sewing thread varies from 1000
to 500 meters. 2. INTER LINING: The fabric which is used between two plies of garments basic
fabric with an intention to make certain parts attractive, strong & retain those shapes for long
times called interlining. Interlinings are of two types, non-fusible and fusible interlining. At
present days non-fusible interlinings are not used commonly. Types of fusible interlinings are
available & price varies considerably. Polyethylene coated interlining — Water wash
Polyethylene coated interlining — Water wash Polyethylene coated interlining — Dry wash PVC
coated interlining — All types of wash, costly. PVA coated interlining –Mild water wash Care
should also be taken during selection of interlining otherwise there may be a great problem. (a)
Shrinkage of interlining should be less than the fabric shrinkage (b) Color of interlining should
not affect the color of garments in the fused area. 3. LABEL: Label is a common accessory, which
 is to use in each garments. Within each garment no of label to be used more than one because
there are various types of label to be used for various information. In the garment label you will
get some information. Main label — name of company Size label — Garments size Price label
Tag — Cost of garments Composition label-fiber composition (Sometimes size in included) Care
label-Ironing & washing code, dying come (Instruction of garments care) There sometimes also
some components used outside/face side of the garment to increase the beauty or fashion of
the garments is called motif. A sometimes motif bears the symbol, trademark etc. Labels are
available with various types, Qualities, & prices. Printer labels arc cheaper while labels
manufactured in jacquard type label loom is expensive. 4. BUTTONS: It is also common
accessories used in the garments. It ‘may work as functional part as well as decorative item,
Buttons are made from Nylon Polyester, Wood Bone, Purl, Metal etc. it may have two or four
holes with shank. Attaching of button in the garments is very important, usually it is attached by
the button attach machine. If lock stitch type button attaching machine. It looks stitch type
button a size also varies. To express the button size the term line” is used. 1 line ÷ O.638mm •
Melamine button • Sandwich button • Shank button • Plastic button
20. 20. • Horn button 5. ZIPPERS: In the pant, trouser and jacket is a common component Metal or
plastic-Teethes are used on narrow tapes of polyester or Nylons & those two series of teethes
locked by a slider. Sometimes two sliders are used within a single zipper. Usually zippers do not
shrink after wash but increase of garments, which may shrink a wash then the sipper area, may
look wavy. 6 ELASTIC: Elastics are available in many sizes, shapes, stretched. The force required
to stretch the & elastic also various depending on types of Elastic used. The elastic used in the
bottom waistband of a jacket, vest or pull over shirt etc yeas should consider using the elastic
with more tractability. For pants shorts, skirts (all buttons) the elastic should be of medium
stretch ability. Elastic suppliers usually sell elastics by gross (one gross means 144 yards) unit,
but if you measure one gross length you may get 140 yds. In most cases. Elastic are supplied in
roll form in production if you want to cut it into 20” length you should do it after relaxation of
the elastic at east far. MERCHANDISING Our merchandising team is committed to complete
customer satisfaction. Our merchandising department consists of highly qualified team of
merchandisers whose prime aim is to provide full satisfaction to our customer starting from the
fabric procurement stage to shipment and reporting the status of the order to the buyers
regularly. The services our merchandising team provides to our clients are: Systematic follow-up
on each stage of production and execution of order on time. .Monitoring new trends in fabric,
fashion and design. Locating new reliable sources to meet the requirements of the customer
with regard to fashion and design. Introducing new sample to buyers to enable them to expand
their business. Educate the customer about the characteristics of variety of fabrics, dyes, dyeing
and printing process, and their positive and negative points and caution the buyers about the
pitfalls involved. Liaison between the customer and our factories and follow-up. Guiding the
supplier in preparation of the range to meet the customer's requirements with regard to fashion
and design and negotiation. In addition, we at Decent Printing and Design keep our buyers
updated at every stage of their orders. Due to this, we prepare daily production report from the
manufacturers unit. This report keeps the buyer updated about their order at every stage of the
production process.
21. 21. Execution Process for a Garment Export Order in a Factory (In Brief) 1) Order enquiry from
buyer to factory: Merchandiser sits with Production Manager for ship date planning. Enquiry on
price (some times the target price is also given) Enquiry on ship date i.e. whether it can be
shipped in due date? 2) Approval of order from buyer, as par the costing given by the
merchandiser: Merchandiser makes Time and action Plan contain the details of the action be
taken as per fixed date, in order to execute the shipment on the due date as committed to
 buyer). 3) Buyer Bank given Master L/C to the Factory: Master L/C is the contract given to bank,
which covers the total value of the export order.) Commercial dept. deals with the follow-up of
L/C matter. 4) B/B L/C is given to the suppliers of accessories and fabric etc: Commercial
department deals with the open up of B/B, L/C Merchandiser deals with the follow-up of the
materials on time. 5) Fit sample sent to buyer for the fit approval: Merchandiser co-ordinates
with sampling section, for the fit sample, and get it approved from the buyer for fit and
measurement. 6) Pre-production sample submitted to buyer with original accessories and fabric:
P.P sample to be made from the production line. PP. sample approval from buyer means
Merchandiser takes approval on style, original fabric & original accessories. 7) Fabric and trims
to be in housed on due time as per time and action plan: Inventory to be monitored by
merchandiser so that there s no problem in quality or shortage of quantity in fabric and
accessories. If thaw is anything wrong prompt action to be taken by merchandiser. 8) Pilot
production to be started as per time and action plan: Or Initial production mean consists of 100
to 200 Pcs. Production managers and quality team should check very carefully about. The style
& quality of the garment. The measurement needs to follow as per buyers spec sheet. 9) On line
inspection by buyers QC certifies the quality of the garment: Buyer QC gives suggestion where
the quality defects are and how to improve on that. 10) Bulk production to be started as per the
time and action plan: Buyers Q.C monitor on the production and quality of garments. Production
manager and supervisor need to be very careful to meet. The production deadline or production
target, to meet the ship date on time.)
22. 22. 11) In the mean time commercial section prepares the shipping documents: Contact with
shipping line for the booking of vessels. (For sea shipment). 12) Final inspection as per time and
action plan: Buyer’s QC. Do random inspection during final inspection. Only if buyer’s QC
certifies the quality is satisfactory then only we can. Ship out the goods. 13) Goods are made ex-
factory: Goods send to seaport (sea shipment). Goods send to airport (air shipment) 14) Goods
handed over to the shipping line: NOTE: NOW IN ANY CASE WE FAIL TO SHIP THE GOODS ON
TIME AS PER THE DATE GIVEN ON MASTER L/C, BUYER WILL CANCEL THE GOODS OR WILL ASK
FOR AIR FREIGHT I.e. F THE ORDER WAS IN SEA SHIPMENT. (Airfreight may come nearly 4 to 5
times of a sea freight cost.) SAMPLING FACILITIES Besides nearly 1,000 sorts of fabric samples,
we have in house sampling department with modern machines and equipped with state of the
art technologies for the development of samples for our customers. Our sample makers have
over 10 years experience in sample development. Our sample makers have developed the
expertise of producing excellent quality of sample as per the need and requirements of the
customer. We encourage our potential buyers to ask us for samples so that they can have an
idea of the product and its workmanship. We can provide our potential customers with samples
of our own designs from our collection. In addition, we are very much willing to do the
development of our clients' own designs and fabrics. Our philosophy is to provide superior
customer services to our valued clients in order to satisfy their needs a step further than the
market. Quality Assurance At Decent Printing and Design, we are committed to quality
requirements of the highest standard. We do not sacrifice on quality. We make sure quality is
adhered to throughout our operation from sampling to
23. 23. final shipment. We take extra efforts in ensuring the suppliers comply with strict quality
control. Quality Assurance is an inherent part of our services and we ensure that our customers
do not face any problem at any stage. Quality Control and Inspection Procedures We normally
follow AQL Level 4.0 inspection method, but on special case we follow any inspection method
our customers require. Our 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 - Knitted & Flannel
Inspection - Measurement Spec checking - Accessories Inspection testing - Accessories Color
Matching checking - Daily Cutting checking - Fabric Inspection - Lab dip testing - Washing Fabric
testing
24. 24. SOURCING SERVICES Proper sourcing is the key to success in Textile/garments business.
Keeping this in mind, besides our own factories, Decent Printing and Design sources products
from reliable vendors with a careful assessment of price and quality. We have built up an
extensive sourcing network of dedicated Manufacturers and Exporters from all around China. In
addition, we have reliable sources of raw material such as fabric, trim & accessories from many
countries/area such as Korea, Taiwan, and Pakistan at very competitive prices. Sourcing is our
core strength, which distinguishes us from the rest of the market. We offer a complete sourcing
package from design to delivery. Our sourcing department ensures great measures to evaluate
the most suitable manufacturer and supplier for our client's requirements. FACTORY
EVALUATION At Decent Printing and Design, we take an extra step to source the most
appropriate vendor for our customers. Before selection we thoroughly evaluate Factory on the
basis of the following assessment: . Factory design . Financial performance . Factory equipment
& machinery . Factory productivity . Quota export performance . Prevalent working procedures .
Factory past performance . Technical competency . Factory personnel competency . Factory
reputation . Level of professionalism In addition, we have formulated a Factory Evaluation Form,
which is filled out for every factory and then based on the physical, and financial assessment
includes creation of a rating grade to the factory. This rating grade can determine the quantity
of Garments it can manufacture for "Decent Printing and Design" as well as whether it has
adequate production capacity. These services can be further extended in locally reliable fabric
sources, dyers and printers, which ultimately promote quality of merchandise. This is an
important process as no factory should be over booked, which causes delays in delivery and
impacts production quality negatively. Factory assessments are an ongoing process. Decent
Printing and Design is constantly investing time and effort in finding new factories, which can
meet the requirements of client in terms of fashion and price. Shipping/Documentation Being a
supply chain service provider, we have the knowledge and expertise to provide total logistic and
transportation solutions to our customers. Our qualified personnel work in close association
with leading freight forwarders, air and shipping lines at various locations. In addition, we can
provide you specific value added services by pre advising all shipments on a regular basis with
tentative arrival dates CTPAT Audit Documents need to be checked during factory evaluation •
Written security policies.
25. 25. • Records of all movement of raw materials/ components in & out to & from storage. •
Movement record register of all packed/ finished cartons & partially filled cartons from the
packing area to the separate packed goods storage. • Movement record register of all packed
goods/ cartons in and out from the packed goods storage • Movement record/register for
dangerous goods/chemicals from storage. • Enclosures (doors, windows, gates, fences ,etc )
 checklist / checking record by security guards per shift. • Empty truck checking records. • Duty
roster of security Guards of last 3 months. • Visitors log book / records. • Log book /records for
incoming/outgoing goods with both weight & quantity details. • Report / record of shortages &
overages in incoming & outgoing goods/accessories. • In the event of staff turnover, are there
procedures & documents to control the return of keys or security access code changes? •
Previous job verification record of employees before hiring. & Security training program &
record. PART - 03 QUALITY Introduction: In manufacturing, quality is the concept of making
products fit for a purpose and with the fewest defects. Many different techniques and concepts
have been tried to minimize defects in products. Quality Assurance: "The establishment and
maintenance of ALL activities and functions concerned with the attainment of requisite quality"
Quality Control: "The systems required for programming and co-coordinating the efforts of the
various groups in an organization to maintain the requisite quality" As such Quality Control is
seen as the agent of Quality Assurance or Total Quality Control Specifications: Quality Control
requires the establishment of adequate specifications with proper tolerances
26. 26. Objective: To maximize the production of goods within the specified tolerances correctly the
first time. By considering such information it can be decided what requires to be monitored.
Monitoring the process is the essence of quality control 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.
27. 27. 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 Sewing: Maximum quality
controlling is in sewing lines as maximum defects occurred during sewing. Some common
defects are- 1) Thread tension 2) Broken stitch 3) Raw edge 4) Wrong back tack 5) Puckering 6)
Open seam 7) Skip stitch 8) Joint stitch 9) Fabric defects 10) Shading 11) Stains 12) Un-even
shape 13) Down stitches 14) Up-down 15) Center out 16) Gap difference 17) Poor ironing 18)
Holes and damages 19) Slanted 20) Missing Bar tack 21) Marking mistake etc. There are 3 types
of quality checkers in sewing line. They are- a) End Post QC: Check for defects after some
specific operations. They make two kinds of report. One is “Sewing Quality Inspection Report”
and another is “Repair Report”. b) Final QC: They inspect the whole garment after sewing
complete. They also use the same report as End Post QC. Additionally they also do
“Measurement Chart Fit Audit” c) Roving QC: They audit an operator randomly using “Random
Number Table” and collect any 7 pieces of garment (JC Penney 7 piece System) from him and
 check for defects. If he doesn’t find any defects than whole lot get pass. If he finds any one
major defect in any garment than he declares the whole lot fail and hang a “Red card” near the
Un-cleared operator
28. 28. Also there is some Technician who concerned for better quality. AQL department in sewing
lines, audit the garments with specific AQL rating system and pass the garments only if they
satisfied the Buyer accepted DHU level for passing. Quality in Washing: Shading is the main
quality problem in washing. There is a quality checker who matches the garments with approval
shade after each wash. 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
29. 29. Remarks: 1) Better quality makes the production rate better and also satisfied customer or
buyer. If quality is poor then we need much time to repair the altars, which decrease the overall
production rate. 2) Roving auditor using red card for poor quality of an operator. He also can use
a green card for better quality of an operator, which will inspire him and others for better
quality. Quality control According to my sub objective quality is a fact to survive in a post MFA
situation for competitive market. The factory Lenny Fashion Ltd. is also concern about it, and
they show interest about better techniques of quality and its controlling system. I have just
going to introduce it and presenting some core activities those will be very much helpful to
increase the product quality and its assurance system. I have also mention here the new 5s
system that will help to decrease the cost. Definition of Quality- Quality has been with us since
the dawn of civilization; however science, after second world war it has been used more as a
competitive weapon or competitive advantage. In order to understand this we can have a
looked at Japan. In the first few years after the Second World War Japan was rebuilding from
the war, many business executives through training in quality, which conducted by dr. deeming
at Japan. These executives took the quality messes to heart and we can see the resold today,
which are taken obvious to mention. Some other countries such as South Korea, Taiwan and
Singapore in Asia /pacific followed this model and became very successful in the world arena.
Quality is a complex concept. No single definition addressee the entire dimension, areas of
impact and concerns related to quality. The term itself is used in many ways for many reasons,
each use reflect a different perspective based on philosophy, economics consumers behavior,
production each. Definition may focus a holistic perspective, the impact of quality on the
organization income, the changing market place, the nature of a product or service, the way a
product or service conform to specifications or the ability of a product or service to meet
customers’ needs. And satisfy their demands. Companies and their employees need to
understand how quality affects organizations. Eight dimensions of quality 1. Performance 2.
 Features 3. Reliability 4. Conformance 5. Durability 6. Serviceability 7. Aesthetics 8. Perceived
quality The great value of Quality Many talk about the importance of quality in soft goods but
not everybody recognize how important it really is. In most cases one employee that produces
bad quality can greatly affect sales for a company. A study in the U.S. showed that an average
individual will probably spend about $70,000 through his life buying from one brand that he is
comfortable with .Most sales are repeat sales so you can potentially lose about $70,000 of
business if this customer suddenly becomes unsatisfied. In the production floor it is
30. 30. sometime hard to imagine that one skipped stitch can cause customer dissatisfaction please
recognize that, if something is not as specified, it is defective. Defects are a waste! Let's see
what happens to defective garments in the factory: If a defective unit is found you have two
possibilities: That it can be repaired, that it can’t. 'Seconds' are sold at a loss by the factory.
Units to be repaired are also an extra cost because extra costs are incurred in 1) Handling the
unit before repair, 2) Extra labor and materials in repairing and 3) Extra handling to get it back
with the first goods. The time consumed on repairing defective goods can always be used to
produce first class goods. In all cases defective units are costs for the factory. "Do it right the
first time" is the key to success. To ensure quality we need to do a number of things: 1.
Recognize who the customer is 2. Build processes that anticipate and prevent defects 3. Make a
plan to achieve the desired quality level 4. Set up ways to measure our progress 5. Work as a
team to achieve the goal Receive Sewing Finishing A good plan requires: 1. A clearly defined
objective 2. Goals or expected results 3. The activities needed to achieve the desired results 4.
Defined roles and responsibilities for the activities 5. Dates for the begin and completion of each
activity 6. An analysis of potential problems Measurements are a vital part of any quality
improvement program. Anything that is not measure does not improve. We need to establish
these standard measures and measure the progress periodically Teamwork is also an essential
element for the success of the program. Remember, "Not ONE of us is better than ALL of us".
The whole effort needs to have a direction that a team leader will provide. The Executive's Job
Related to Quality There are two separate areas of dealing with quality that an Executive
becomes involved in: Cutting Inspect
31. 31. 1. Handling repairs Getting repairs corrected and work back into the production flow. 2.
Preventing repairs Working with operators to prevent repairs (correct at the source). • Which
one is the most important? • Which one is the most effective way to control quality? • Which
one should be the Executive's primary aim? • Which one takes up the majority of your time?
Answer honestly. To Control Quality 1. Have the proper approach toward operators • Approach
operator with defective garment • Ask operator kindly to stop her work and pay you attention •
Explain defect found and ask if she understands why garment is defective • Make sure operator
understands why it is defective • Try to find out why the defect was created or why it was not
detected at the workstation • Restate the company's commitment to quality • Ask operator to
inspect the current bundle for more defective parts and then repair all parts that are out of
tolerance including the one found by the inspector. This Should be done immediately Stay and
observe sewing method Make sure method is being followed 2. Train operators to sew with
good quality from the beginning 3. Know quality specifications and tolerances Be sure you
understand what constitutes good and poor quality. 4. Be consistent in your decisions toward
quality. 5. Comment on both good and bad qualify. We all have a tendency to be silent during
good times and vocal during the bad. 6. Be sure to check each operator's work daily. The
amount of defects found should govern the amount of inspections performed. Vary inspection
times and inspection sequence. Check into middle of bur-die. Do not always look at only the top
garments. 7. Use a checklist - do not rely on memory of specs. 8. Do not rely on inspectors to tell
you the quality level of your operators. 9. Never give the impression that you think work is OK
 but inspector will not pass it. If you do have this problem, resolve it with plant manager away
from operators. Quality Control Procedures Summary In-Line inspection: During the production
of garments the operator's finished work is audited in an in-line inspection. A quality inspector
move's from one operator to another at random inspecting a predetermined number of parts
from a finished bundle. In-process inspector
32. 32. If the in-line inspector finds a defect n a part he is inspecting he should: 1. Take defective
part/parts out of the bundle 2. Take part to the operator's immediate supervisor 3. Give the part
to the supervisor to examine while inspector explains the defect found. 4. Decide with the
supervisor whether it is actually a defective part send if defective the supervisor should return
the part to the operator. 5. Go back to the operator and mark the bundle as rejected with a red
card or cloth and fill in the appropriate paperwork for the inspection and mark the workstation
with the quality banner to signal that follow/-up bundles have not been cleared. 6. Continue to
the next operator selected randomly from the list of operators and perform the inspection
based on the approved sampling plan. 7. If an operator has a bundle rejected then all bundles
coming from that operator are going to be checked by the quality inspector until three
consecutive bundles are free of defects. At this point the red quality banner will be removed.
Follow-up bundles are inspected in the same fashion (audit not 100% inspection) 8. The quality
banner helps the inspector remember to inspect the follow-up bundles from that operator and
also helps the supervisor identify what operators are having quality problems. 9. Make sure that
the element of surprise exists when doing an inspection. Inspections should always be
performed at random and should never follow patterns. Following a predetermined path in the
line can hint operators you are going to inspect their work next. Inspect operators at random.
10. Make sure that only the defined number of units is inspected. No more, no less. 11. The
units inspected should always be taken randomly from the bundle to ensure that the sample
taken is representative from the bundle. Taking samples only from the top of the bundle is not
correct and can give skewed results. Section supervisor: If a quality inspector approaches the
supervisor with a defective unit he or she should: 1. Greet the inspector do not ignore him/her.
Inspect the part according to the quality specifications 2. If it is defective let the inspector know
you understand it is a defective part and you are going to address the part with the operator. 3.
As soon as possible take the part to the operator and approach the situation appropriately: •
Approach operator with defective garment • Ask operator kindly to stop her work and pay you
attention • Explain defect found and ask if she understands why garment is defective • Make
sure operator understands why it is defective • Try to find out why the defect was created or
why it was not detected at the workstation • Restate the company's commitment to quality •
Ask operator to inspect the current bundle for more defective parts and then repair all parts
that are out of tolerance including the one found by the inspector. This should be done
immediately, • Stay and observe sewing method • Make sure method is being followed If
necessary review the operator's card with the operator to see if this was an isolated occasion or
if it is a recurring problem. Try to motivate the operator to continue working with good quality.
33. 33. The supervisor leaves the operator repairing the defects the supervisor should return after
some time to make sure all work has been inspected and the defects repaired. Before the
bundles continue to the next operation the supervisor should be sure that there are no defects
in them. All bundles coming from that operator are going to be checked by the quality inspector
until three consecutive bundles are free of defects. If there are defects in the bundles following
a rejection, you could say the supervisor is no; doing a good job of ensuring quality in that
operation. 100% inspection: At the end of a section there will be an inspection made to all parts
exiting the section. The inspections should be effective in identifying all defects in a garment. To
ensure all seams and quality characteristics are inspected in a short period of time a defined
 inspection method should be followed. The inspection operators should have their forms filled
out correctly. A good source of information to determine the quality performance of the section
is the point of 100% inspection. The section supervisor should check the quality level at the
point of 100% inspection periodically. From the 100% inspection forms the supervisor should
analyze what are the operators /operations with the highest defect frequency. For these
operators/operations the supervisor should identify the type of defects found most often, the
cause (machine/method), and the frequency at which the type of defects happen. With this
information the supervisor should address the problems, correct the possible causes and make
plans to prevent them. The inspection form is totaled 4 times a day so a supervisor can actually
see the results of what he or she has done to stop defects, Final Audit: A final audit should be
performed on packed items. When the boxes are ready to be shipped a certain number of units
should be inspected. Using the MIL-STD-105D determine how many garments need to be
inspected. Randomly select a number of boxes from the lot that contain the determined amount
of units to be inspected. For example, if there are 75 boxes of 10 garments each and I need to
inspect 80 units I would open one box and inspect 5 garments, another box and inspect 7
garments, another and inspect all 10 garments, and so on until I have inspected a total of 80
garments. After entering all the information in-to the Final Audit form, the final inspector should
determine if the lot was accepted or not. Any rejected lots should be addressed promptly to
minimize the chance of having a late order. Quality procedures in the Cutting Area During the
cutting process the factory should ensure quality by having a Spreading Inspection, a Cutting
Inspection, and a Final Audit. During Spreading the following is checked-.
34. 34. 1. The side of the spread should be aligned +/- 1/8 2. The base marker should be aligned
parallel to the length of the table 3. The splice points should be identified on the base marker
before spreading 4. All splices should be marked with paper that is at least longer than the
overlapped fabric 5. The overlap of fabric at a splice point should exceed at least 2" on either
side of the parts in the splice 6. The fabric laid should extend 1-1.5" outside of the marker 7. The
fabric laid should never be less than the marker's width. The fabric width should be at least
inches wider than the marker. 8. The spread fabric should be relaxed, not stretched, and
wrinkle-free before cutting. 9. No defective fabric should be laid unless there has been an
official authorization. During Cutting the following is checked'. 1. The marker lines should be
followed. You can go out of the line by 1/8" max but never cut into the part. In other words, you
should always be able to see the marker lines. 2. All notches should be located correctly with a
depth of %" +/- 1/16" 3. The markers should be attached to the stack of parts with approved
stapes or pins 4. When cutting care should be taken not to shift the stack of parts to a since or
to cut with the blade at an angle. In bundling and shade marking care should be taken to ensure
that this numbering is correct. In other words, no skipped numbers. The bundled parts should
be grouped correctly: 3b fronts with 3b backs with 3b yokes, and so on. For the final audit
process, the quality inspector will determine how many bundles to check from every size
according to the MIL-STD-105D. Each of these bundles will undergo the following inspection- 1.
All parts from the same shade number should not have shade differences. 2. All parts have the
proper shape according to the marker 3. All parts must have all notches in the correct location
and with the appropriate depth. The contact that a supervisor and the operator have during the
Quality Drill is very valuable. During this time the commitment of everyone to guarantee a job
well done is strengthened. At this time the operator should be encouraged to learn what the
requirements for his operator are and he is complimented if he knows them wholeheartedly and
works to achieve them every lime. This exercise should be performed on standard time and at
least once a day. If you are having quality problems with an operator you should increase the
frequency of the exercise even to one exercise an hour. It is necessary that the trainer and the
 supervisor explain the importance of the Quality Drill to the operators stressing that its; sole
purpose is to help them improve their quality. The initial resistance by the
35. 35. operators is normal, but as soon as positive results from exercise are seen, the operators
'A/ill takes the initiative to do the exercise themselves. Quality Drills: The production supervisor
is responsible of the operator's work so it is of almost importance that he or she has control
over the quality level at which the operators produce. To prevent repairs and to ensure good
quality there is a useful tool called "Quality Drill". It is very effective in making operators quality
conscious. During this exercise you confirm to the operator the commitment to good quality
that the company has made and motivate him/her to produce with quality. The procedure is the
following: 1. Ask the operator to stop what he is doing and stand up. 2. Give the masking tape to
mark defects 3. Ask the operator to inspect, based on the Quality Specification, the bundle in
which he is working on, the bundle he has already finished, and the bundle he is going to work
on next. This way the operator has the chance to see if the work he is doing is of good quality
and also make sure that the work he is receiving from the previous operation is not defective. 4.
Ask the operator to mark any part that is out of tolerance with the tape 5. Ask the operator to
do it while standing up and when he or she is finished he should signal the supervisor that he is
ready to have the results evaluated. 6. The supervisor makes sure that the instructions have
been understood and then leaves to continue with the regular activities. 7. When the operator
has signaled that he is finished, the supervisor returns 8. The supervisor then proceeds to
inspect at random a number of parts of any bundle. If he is to find a defective part he should
separate it and ask the operator why the part was not identified. If there are no defective parts
found by the supervisor he turns to the operator and asks the operator to show him the
defective parts he found. 9. If the operator has found no defects then the supervisor should
select a part and ask the operator to explain why this part is of acceptable quality. The operator
should be able to explain why based on the points described in the quality specification. 10. If
defective parts have been identified then the operator should explain v/why they are defective
based on the points described in the quality specification. 11. If the supervisor notices that the
operator is not very clear of what the requirements for his operation are or how to find out if
these requirements have been met or not, then the quality specification sheet should be
reviewed point by point. 12. If the supervisor notices that the operator "overlooks" the defects
then the supervisor should review with him the importance of doing a job properly every time.
Section wise quality control: To ensure the quality of the product, quality control personnel have
to control quality in different section / department in clothing, which are directly or indirectly
involve with production.
36. 36. Controlling areas are as follows: Store: • Inventory • Fabrics and other material inspection •
Material testing • Cleanliness • Swatch board making • Reporting Sample: Quality control
personnel must check sample before sending it to the buyer. Important points to be checked:
Whether the samples are as per buyers specifications or not, such as style description, sketch
measurement sheet, photograph etc. and workmanship has to be checked with reference
sample or related documents provided by the buyer. Report to be submitted to the
merchandiser as well as to the superior. Cutting section: Pattern marker: pattern and marker
must be checked by the quality control personnel check points are s follows; • Measurement, •
Gradation, • Allowances, • Pattern parts missing, • Mixed parts, • Pattern shape, • Direction of
pattern in the marker, • Pattern alignment with respect to the grain line, • Poor line marking, •
Marker too wide than fabric width, • Notches and drills marks omitted, • Mismatch checks and
strips, • Overlapping, • Too thick line or double line marking, • Invisible line marking, • Marker
incorrectly positioned on the lay, Spreading: During spreading following should be checked: •
Fabric relaxation, • Incorrect tension of plies, • Wrong direction of plies, • Unacceptable
 damages found, • Mismatching of checks and strips, • Narrow fabric, • Shaded fabric, •
Misalignment of plies. Cutting:
37. 37. During cutting the following points should be checked: • Inaccurate cutting, • Notches –
misplaced, too deep, angled, omitted or wrong type • Drills –marks –wrong drill, omitted
angled, • Knife cut- garment parts damaged by careless use of knife, • Frayed edges scorched or
feud edges caused by faulty knife. • Slits opened inaccurately or omitted. • • Others: • Bundling
with bundle card, • Numbering, • Cut panel checking, • Wrong size in the bundle, • Fused parts
checking, • Cleanness, • Proper raking/ storing. • Proper issuing, • prefer test cutting than bulk
cutting, • Reporting. Sewing section: Quality control system for sewing section: There are some
systems are in practice in the sewing floor are as follows: • Traditional system • JC penny system
• Traffic light system • SPC. In line checking criteria: During construction of garments the
processes / components must be checked in the line as follows: • As per pre- production
meeting some critical process to be checked in the sewing line. (Randomly or 100%) • Each and
every process must be checked. • Auditing / monitoring. • Cleanliness (in the line and work
place) • Reporting. End line checking criteria: After completion of the garment in the sewing line
,it has to be checked further at the end of the line. • Inspector will check all process of a
garment. Sample may be picked randomly or 100%. • Reporting. Other: • Transportation
section-to-section or stat ion. • Proper machine
38. 38. • Maintenance • Proper attachment each. • Cleanness (floor/ line / work place) Points to be
considered: Points to be considered during controlling quality in the sewing line are as follows: •
In line inspection should be performed at the work station. • Inspector ratio in the line depends
on the system being implemented in the line. • As per JC penny system, one inspector for 30
operations. All operations are audited minimum twice a day, where operator are minimum
skilled. • As per pre production meeting inspector will be provided considering the controlling
system. • Number of inspectors in the line depends on number, of operation of the style being
produce and number of machine in the line. • Defect and measurement both should be checked
in the line. • 1/4 inch, masking tape or arrow sticker to be used to indicate the defects. •
Number of pieces, to be inspected a) randomly) 100% ,c) 7 sample per bundle( up to 180 units
per bundle) as per JC penny . N the inspector should check complete bundle/ complete process.
• The inspector must select the units at random basis from a bundle/ from the complete units. •
The inspector must inspect exactly the number of units called for the sampling plan. No more no
less or as per the system. • The inspector must rove the s/ line as per the instruction of the
superior. • If more than one inspector rotates them so that the same inspector does not inspect
the same operator too long. • If the inspector finds a defective unit, corrective action should be
taken. • To ensure that the problem has been corrected the inspector re- audit the corrected
bundle inspecting 7 units at random from the entire bundle/ or re- check the corrected unit or
as per the system. • The concern production supervisor should rectify defective units with the
same operator. • For product that is not in bundle from, it is recommended that a statistical
inspection based on AQL. Finishing section: This final section to make the product saleable
condition and the finishing processes should be controlled to achieve the quality target. For
wash garments 100% check is required after receiving the garment from the washing plant.
Defective garments should be rectified and reject pcs. Should sort out. Checking: • Iron / press •
Folding • Tagging /sticking • Packing Audit: Audit can be performed in the sewing floor as well as
in the finishing section or whatever required. Mini- Qc: It is a new concept, yet to be
implemented in Bangladesh but its very effective quality control activity to achieve the quality
target. Introduction to Fabric Inspection:
39. 39. Fabric inspection is one of the most important quality control activities in clothing industry.
This involves the inspection of-the fabric in order to quantify the patent defects found in fabrics.
 During this process other details could be collected without, any additional cost and these
details can be used to minimize waste. After fabric is received, it should be inspected to
determine its acceptability from a quality viewpoint. Otherwise, extra cost in garment
manufacturing may be incurred due to either the loss of the material or time, to say nothing of
customer returns and dissatisfaction due to poor quality. In many small companies the same
personnel do spreading and cutting and fabric is inspected as it. Is being spread on a table for
cutting. Regardless of what practice is followed, the important point is that the fabric should be
inspected before cutting, the defects marked and the patterns cut. Around the defects so as not
to include them in the finished garment. The main raw materials Used in the manufacture of
garments are fabric. About 60% or more of the value of a garment can be attributed to fabric. In
order Lo maximize profit; the fabric should be used efficiently. Fabric inspection is usually done
on fabric inspection machines. These machines are designed so that rolls of fabric can be
mounted top behind the inspection machine and the fabric will run over the inspection table
under adequate light, re-rolled as they leave the table. Defects in a fabric can be seen readily
with these machines, as the inspector has a very good view o!' the fabric. These inspection
machines are either power-driven or the inspector pulls the fabric over the inspection table. The
defects are located, marked and recorded on inspection findings or reporting format. Such
machines are also equipped lo accurately measure the length of each roll of fabric as well as
monitor the width of the fabric. Objective of Fabric Inspection: The objective of fabric inspection
is to ascertain whether the fabric received is of the expected Quality standard or not. The main
objective is, detection of fabric defects and non-conformances early as possible, So that the
time and money are riot wasted in the manufacturing process. The ultimate goal of any quality
control activity in clothing industry is to satisfy the customer. Importance of Fabric Inspection:
As we know that fabric are the main and costly raw materials of a garment. So it is very
important to use fabric efficiently and control wastage of fabric. On the other hand fabric
defects are the maximum defects of garments, for which many-unexpected problem may occur
in a clothing industry. Such as-short shipment, discount, low price etc. To avoid all above
problems and to take preventive measures fabric inspection is very important for a clothing
industry. It is also important for the following aspects: • Improved product quality, • Minimize
waste, • Reduce the cost • Avoid short shipment • Increase productivity. Grading Systems:
There arc-different types of standard grading systems in practice. A system is agreed or selected
by mutual acceptance between supplier and buyer.
40. 40. Some of the available grading systems are given below: • 4 point system • 10 point system •
Graniteville '78' system • 6 point system • Dallas systems 4 Point System: Penalty points are
assigned according to size of defects. Warp and Weft Directions Length of the defect penalty
points Up to 3" 1 3"-6" 2 6"-9" 3 more than 9" 4 Maximum penalty points per yd. are 4. Defects
within 1/2 of selvedge disregarded. The system is recommended for use where smaller -defects
are critical and for fabric of wider widths and also this is very suitable for sample inspection.
Types of Reporting Format: (1) (Sheet 1) Normal inspection - the type of sheets usually used in
inspecting fabric. (2) (Sheet 2) Special sheet to show distribution of defects within the roll. (3)
(Sheet 3) Special sheet to show location of defect within each yard. • Defects such as colors
variation, skew ness, and bowing are not considered in awarding penalty points. The expected
fabric quality should be specified and agreed with the Supplier at the time of negotiation. By
inspecting the fabric, the quality can be improved, but it could be used to minimize waste.
Garment defect: Product variation is a normal result of the manufacturing process. It is
impossible in make each garment exactly the same. In order 10 establish acceptable levels of
variation; Tolerances should lie slated as a pan of product specifications. Defect: Variations that
exceed tolerances or do not meet specifications arc called detect. Garment Defect can be
 defined as below: Any irregularities or deficiencies in the fabric Materials used, in (cutting,
Construction Assembling Knitting, linking , pressing or in the Finishing of a garment that
adversely affects its appearance, serviceability or sale ability or do not meet the specifications
and exceed the tolerances is
41. 41. garment defect. Classification of Defects: Generally, three main categories of defects are
classified for the garment standards as per defects guide. '1 lie categories of defects are as
follows: • Critical Defect • Major Defect • Minor Defect Critical Defect: A defect that is likely to
result in hazardous or unsafe conditions for an individual in consuming or using the product, or
that is contravenes any mandatory regulations. Major Defect: A defect that is likely to result in
failure, reducing the usability or serviceability of the product. Any obvious appearance of defect
will affect the sale ability of the product. Most of the cases garments are rejected. Minor Defect:
A defect that does not reduces the consumption or sale of the product is nevertheless a
workmanship error beyond the quality standards. It is recommended, at the manufacturer level
that defects may be at the borderline between Major and Minor should classified as Major, for
the sake of emphasis in activating corrective action. Factors to be considered for classification of
defects: • Location of defect • Size of the defect • How visible the defects from 18" distance. •
End use of the product POSSIBLE GARMENT DEFECTS: Materials/fabric: 1. Hole or surface Haw
that could develop into hole. 2. Slues that is easily distinguishable 3. Distinctive shading 4. Dye
spots misprints, or out-of-register prints. 5. Cut, tears or visible surface repairs 6. Bow or skew
exceeding 1.5 percent. 7. Plaids, checks, or horizontal stripes dial are conspicuously out of match
at center front or back of a product. Cleanliness: 1. Soil, Spots, stains or Dust 2. Attached thread
clusters Pressing:
42. 42. 1. Burn or scorch marks 2. Glaring shine marks 3. Press marks from camps 4. Absence of
pressing when specified 5. Products packaged moist after steam pressing 6. Improper pressing 7.
Seams not lined up when specified for center leg crease 8. Loops twisted after pressing 9.
Pressed-increases uneven Seams and Stitching: 1. Twisted, roped, or puckered scams 2. Open or
broken stitches 3. Raw edges when covered edges are specified 4. Scams not back stitched or
bar tacked when specified 5. Irregular or uneven top stitching 6. Scam grin-through 7. Any part
of product caught in scam or stitches 8. Any exposed drill holes 9. Length of legs off by more
than 3/8 in. 10. Stitch count not conforming to specs 11. Stitch or scam type not conforming to
slices 12. Label is not correctly attached 13. Sewn on design attached at incorrect place and
sewn not according to specs 14. Double needle stitch on crotch seam; t not specified 15. Use of
monofilament thread, other than where specified BUTTON HOLE: 1. Size within specs 2. Ragged
edges 3. Uncut buttonhole 4. Out of 'alignment or improper spacing 5. Stitch depth too narrow
or wide Button/Button Sewing: 1. Button not securely attached 2. Butler-missing 3. Broken or
damaged button 4. Out of alignment or improper spacing 5. Button not to specs 6. Lack of
support materials on fragile fabric 7. Buttons that crack, chip, discolor, rust, bleed, melt or
otherwise cause consumer dissatisfaction when care label is followed
43. 43. Waistband: 1. Uneven in width 2. Excessive fullness, puckering or twisting 3. Closure
misaligned 4. Belt loops are crooked Belt Loops: 1. Not fully secure 2. Extend above waistband 3.
Missing tacks 4. Color shade not to specs 5. Thread shade not to specs 6. Raw edges showing
Front and back: 1. Uneven at bottom hem 2. under facing showing 3. Pockets conspicuously
uneven 4. Darts uneven in length 5. Darts poorly shaped 6. Spot shirring not even right and left
sides Hems: 1. Twisted, roped, puckered, pleated, or excessively visible from exterior 2. Uneven
in width 3. Uneven length of product unless specified Pockets: 1. Not uniform in size and shape
2. Misaligned horizontally or vertically 3. Crooked 4. Missing bar tack, back tack or rivet where
specified 5. Bar tack or rivet not as specified 6. Sewn-in pleats or puckers Zippers: 1. Any
malfunction in operation 2. Tape does not match color specs 3. Wavy /Zipper 4. Exposed /zipper
 that detracts from product's appearance 5. Irregular or uneven stitching 6. Crooked or uneven
placket 7. Bar tack missing or incorrectly located at bottom or base of zipper
44. 44. Gripper: 1. Misaligned 2. Missing or incorrect 3. Defective in operation Fly area: 1. Width is
not uniform 2. Bottom stop not securely clinched 3. Top of zipper not caught in band 4. Either
side of fly extends past other side by excessive amount Labels: 1. Labels are not correct 2.
Located in correct location 3. Insecurely attached
45. 45. DEFECTS ZONE A ZONE B Materials * Hole, (tear, cut, fabric run, dropped stitch MAJOR
MAJOR * Permanent crease M AJOR MAJOR * Permanent stain MAJOR MAJOR * Washable stain
MAJOR MINOR * Loose threads MAJOR PER SEVERITY * Frayed edges MAJOR PER SEVERITY
Seam and Stitching * Open Seams MAJOR MAJOR * Under stitching (Less stitches per inch PER
SEVERITY MINOR than Spec) PER SEVERITY MINOR * Overlap stitching PER SEVERITY PER SEN
TRITV * Double stitching Shade and color * Off Shade MAJOR MAJOR * Mismatched color
MAJOR MAJOR Label * Missing MAJOR MAJOR * Misplaced MAJOR MAJOR * Incomplete MAJOR
MAJOR * WRONG Label MAJOR MAJOR * Insecurely attached MAJOR MAJOR - * Pocket * Not in
specified location by more than 1/4 MAJOR MAJOR * Not in specified location by less than 1/4
MINOR MINOR * Sewn in crooked PER SEVERITY PERSEVERI IV * Size and shade not as specified
MAJOR MAJOR Pressing * Over pressed MAJOR PERSEVERI IV * Distorted MAJOR PER SEVERI IV
* Wrinkles MAJOR PER SEVERI IV * Buttons * Missing functional buttons MAJOR MAJOR *
Missing decorative buttons MAJOR MINOR * Misaligned buttons MAJOR MINOR * Functional
button Insecurely sewn MAJOR MAJOR * Decorative button Insecurely sewn MAJOR MAJOR *
Size, type or color not as specified MAJOR MAJOR * Damaged buttons MAJOR MAJOR BUTTON
HOLES MAJOR * Missing functional button holes MAJOR MAJOR * Missing decorative button
holes MAJOR MINOR * Extra button holes MAJOR MAJOR * Misaligned button holes MAJOR PER
SEVERITY * Broken or skipped stitches in button MAJOR MAJOR holes Embroidery * Missing
embroidery MAJOR MAJOR * Misplaced embroidery MAJOR MAJOR
46. 46. Final inspection of garments: Before shipment the final evaluation of any garments lot is
called final inspection to final audit. Final inspection consists of inspecting finished garments
from the buyer’s point of view and the final inspection occurs after garments are packed in box.
If it is done after garments are packed, then proper size and style markings on the boxes can
also checked. In any case there should be a list of points to be checked in a garments including
of a finished garments. The purpose of final inspection is conduct by the buyer’s representative.
Most of the time the senior quality control personnel the buying house or from the industry are
performed the final inspection. Sometimes the buyer engages third party inspection team.
Purposes of final inspection: • Buyers can understand about the quality standard of the
merchandise being purchased. • Last opportunity to know the quality status of the garments lot
for both buyer and supplier. • It is an important part of quality control in garment industry. • It
is an obvious condition from buyer end to conduct the final inspection. Sequence of final
inspection of garments: • Top perform a reasonable we have to maintain a sequence of
different steps of the inspection are as follows: • Packing list verify / compare with p.o. sheet:
Before start the final inspection we have to check the final status of the lot with p.o. sheet and
packing list. Are as follows: • Quantity • Color • Size • Packing etc. 1. Inspection preparation : To
get accurate result with must have well preparation for final inspections are as follows: Required
facilities are: 1) Sufficient space 2) Sufficient light 3) Inspection table 4) Clean, noise free
environment 5) Sufficient helping hand etc. Required tools and equipments: 6) Packing list 7)
Measuring tape 8) Arrow sticker 9) Marker pen 10) Highlight pen 11) Weight scale 12) Purchase
order sheet 13) Quality specification sheet 14) Reference sample 15) Pick glass 16) Approved
swatches 17) Finding and reporting format etc.
47. 47. 18) Metal detector Carton checking: There are some important points to be checked
during inspection check points are: 19) Quantity or carton 20) Quality of carton: a) Ply of carton
b) Size of carton c) Strength of carton d) Color of carton etc. 21) Shipping marks a) Main mark b)
Side mark c) Merchandise description 22) Strapping/trapping Carton selection: From the total
number of number of carton, we have to select sample carton and garment sample will be
picked from those carton. The methods of carton selection and point’s table considered are as
follows: o Methods of carton selections o Points to be considered Packing and packing check:
Now we have to open carton from those selected carton and check the packing methods used
for the lot and the packing used whether it is as per specification. Check points are as follows:
23) Packing check: a) Position of garment inside the carton b) Inner carton c) Protector d) Poly
bag e) Assortment f) Quality of garment Packing check: a) Packing materials must be checked
with approved sample. b) How it is used of attaching. • Sample selection: For sample selection
sampling plan should be followed and important points to be considered and few related terms
to be discussed are as follows: 1) Sample: A sample consists of one or more units of a product
drawn from a lot, the units of the sample being selected at random without regard to their
quality. The number of units of a product in the sample is the sample size. Lot or batch: The
term lot or batch shall mean “inspection lot “ or inspection batch that is a collection of units of a
product from which a sample is to be drawn and inspected to determine conformance with the
acceptability criteria.
48. 48. Lot or batch size: The lot or batch is the number of units of a product in a lot or batch. AQL
(acceptable quality level): The AQL is the maximum percent defective that, for the purpose of
sampling inspection, can be considered satisfactory as a product average. Sampling plan:
Sampling plan depends on types of inspection to be performed such as a) 100% check b) Spot
checking c) Arbitrary sampling 24) Points to be considered: a) Color b) Size c) Style Garments
checking: Selected sample must be checked 100% check points are as follows: 1. Appearance 2.
Materials conformance 3. Conformity of style 4. Color shade 5. Logos 6. Workmanship 7.
Finishing 8. Cleanness 9. Damages 10. Weight 11. Fitness 12. Record of defects non-
conformances: 13. Measurement checking 14. Defective sample draw for reference 15. Carton
fill up 16. Sticker and signature 17. Reporting. Quality Assurance: Quality Assurance is something
that everyone in the factory dose all the time. Everyone includes such as managers, designers,
pattern makers, marker makers, cutlers, pressers, packers, machinists, and supervisors. All of
those people must know what standards are necessary, must be able to detect defects and must
know what to do to correct and prevent it happening again. The Japanese have been extremely
successful in applying the idea to Japanese industry. Quality Assurance is about assisting people
to achieve desired standards helping them to do their job! Qualify control is as much an aspect
of Quality Assurance as it is about checking whether things are going well or not, identifying the
cause of a problem and applying the correct remedy. Actually Quality Assurance and Quality
control are two sides of one coin, they cannot be separated. It does make it easier though if we
talk as if they were separate. "Quality Assurance is a state of mind, a way of approaching the
organization of production to achieve Quality" Quality control is a process, a set of activities
designed and regulate the effectiveness of
49. 49. production to achieve Quality" Both of these ideas involve everyone in the company,
managing director to casual worker, design to warehouse Definition of Quality Assurance as per
BSI: All activities and functions concerned with the attainment of quality. Quality Assurance and
management: • Quality planning • Quality advice and expertise • Management of the quality
system • Training of personnel • Analysis of customer complaints, warranty claims and product
liability A quality management system based on the fact that all functions share responsibility
for quality, provides an effective method of acquiring and maintaining the desired performance
 standards. The quality department should not assume the direct responsibility for quality but
should support advice and audit the work of the other functions; in much the same way as a
financial auditor performs his duty without assuming responsibility for the profitability of the
company. The responsibility for actual control of quality during the operation of the
transformation process, whether that is the production of artifacts, delivery of a service or the
passing of information internally, rests squarely on the shoulders of the operators of the
process.; this means that staff carrying out the work must be given the tools to enable the
requirements to be met. The control of quality involves the quality of input materials, methods,
equipment, processes and the appropriate instructions designed for the purpose of preventing
failure. To enable the responsibility to be met, organizations must use every device practicable
to prevent, detect and correct errors that occur. This implies that, to achieve the control of
quality, the variables which may affect quality and which can result from the actions of human
beings, the nature of materials, and the performance of equipment, must all be controlled. In
Quality Assurance system, Quality to be builds including reliability into a product during its
development stage. Development stage starts from the planning of the new'- product. Once
properly install all these, will have well executed process control method and if necessary,
inspection to be performed as well. In other words, will have a perfect product, which never had
any kind of defect during manufacturing QUALITY PLANNING: • Quality Policy • Quality Manual
50. 50. QUALITY POLICY: Establish priorities relative to Materials Processes Training Product
Development Customer Service etc 5 s concept: It is a Japanese method of crating high
quality, a highly productive and safe working environment What is 5s? It is a systematic 5-step
method of organizing a work place. Objectives of 5 s: 1. To reduce wastage of labor and effort 2.
To reduce wastage of item 3. To reduce wastage of money 4. To reduce accidents 5. To reduce
stress 6. To improve customer service 5s standards for It stands for systematic steps of the
process. In Japanese al the steps being with the letter‘s’ 1. Seiri 2. Seiton 3. Seiso 4. Seiketsu 5.
Shitsuke 5s activities in garment factory: The book on 5s techniques for improved working
environment in beagle explain in detail about the concept and implementation of 5s in general.
Following points are especially applicable to garment industry. Seiri: Classify all items around
you; make it separate what is wanted from what is not wanted. Reduce clutter. Cut off threads,
excess of pieces of materials, broken tools etc. Seiton: Storage areas should be located along the
operating order Back making process Front making process Sleeve making process Collar making
process2 3 4 5 8 7 6 1
51. 51. 1. shelf for front cut materials 2. shelf for back cut material 3. shelf for sleeve cut materials
4. shelf for collar cut materials 5. shelf for front, back, in process part 6. shelf for sleeve in
process part 7. shelf for collar in process part 8. shelf for finished product Seiso: Each operator
(who operates a sewing machine) 1. To be provided screwdriver, brush, dust cloth and pieces of
cloth to be used for sewing test. 2. To clear dust, with the brush, of the slits on the feed dog and
near surface of the throat plate. 3. To clean up the inner surface of the shuttle body with the
brush and the dust cloth. 4. To check the amount of oil pan and then remove dust and thread
waste from the oil plan. 5. To check the needle tip. 6. To remove thread waste from the area
around motor and v- belt. 7. To inspect the relation between the needle entry and the presser
foot. 8. To carry out the sewing test to adjust the thread tension. 9. To wipe and clean the whole
body of the sewing machine and the top of table, using the dust cloth. 10. To clean up the floor
around the sewing machine. In addition, the supervisor should make a study of cleaning tools to
introduce better ones that provide upgraded efficiency. Seiketsu: 1. Contains in containers have
to be visually observed from outside. 2. The supervisor attaches a label to containers to allow
anybody to know what is contained inside. 3. Control limits have to be given on controls chart.
4. The supervisor introduces the color control method. 5. The supervisor standardizes the
 control method. Shitsuke: 1. The supervisor to check repeatedly whether operators fully
understand direction. 2. The supervisor to provide the operators with the reason why the rules
have to be followed. This will encourage the operators to observe the rules. Developing
comfortable atmosphere in which the operators frankly give suggestion among one another
essential.
52. 52. 5s ACTIVITY STEPS 5-S steps points to be aimed 1 Seiri • Things placed on the work batch of
each operator. • Needle thread, bobbin • The space under the lay-up table 2 Seiton • Use of
shelves • Thread, needle, presser foot and attachment • Specification, patterns 3 Seiso •
Workshop, mess hall, locker room • Before the start of operation of sewing machine and after
the end of work • Lighting, fixture, air conditioner 4 Seiketsu • Laying down of rules for tidying,
orderly placement and preparation of duty roster • Dress • Preventive maintenance 5 Shitsuki •
Report, contact, consulting, compliments • Notice of absence, late –coming and early leave. •
Change of ones assigned work and support to others work
53. 53. Documentation for Export Which the goods are being sent, these documents will include
some or all of the following: consular invoice, commercial invoice, certificate of origin, bill of
lading, packing list, health certificate, import license, and insurance certificate. In general, their
purpose is to provide the foreign Customs authority with a complete, detailed description of the
goods so that the correct import duty can be levied. Sometimes they are required for the
administration of exchange control regulations or import quotas and depending on the product,
to safeguard public and animal health and prevent the spread of plant diseases. Statistical
information about a country's imports is also based on these documents. Failure to complete
the forms properly may lead to a fine and/or unnecessary delay in clearing the goods through
foreign Customs. If the information given is found false, heavier fines may be imposed and/or
the goods confiscated. The preparation of such documentation is one of the tasks of an export
firm's or of a shipping agent, known as a freight forwarder, whose services may be employed for
a fee. In addition to the documents required by the foreign country, the exporter must also
provide an export declaration. Consular Invoice This is a form, usually obtainable only from the
Consulate of the importing country, on which the exporter or its agent must enter a detailed
description of the goods being shipped. Certain countries require such a form. On the consular
invoice, there is space not only for the name of the goods but also for any marks carried, the
number of the items, their weight, the value and origin of the goods and a declaration that the
information given is correct. There must be no erasures or "strike-over" in typing, pen-and-ink
changes, or additions. In some countries, the goods must be described in terms of the customs
tariff of the importing country and the tariff number of the items given. Most countries
requiring consular invoice also insist that the document be "legalized" that is, have its accuracy
sworn to by the exporter or its agent at the consulate of the importing country. Commercial
Invoice Commercial Invoice is the export firm's invoice, addressed to the foreign importer
describing the goods shipped and the total price that it must pay. However, some countries
require the commercial invoice to be prepared on their own forms. Such forms are sometimes
called customs invoices. Countries that require a consular invoice also require a commercial
invoice as additional proof of the details of the export shipment. Countries that do not require a
consular invoice, uses the commercial invoice as the document upon which the import duty is
based. The exporter may also sometimes be asked, when providing an export quotation for the
foreign buyer, to supply a pro forma commercial invoice. This document shows the foreign
buyer what the commercial invoice will look like if the foreign buyer places the order. The
exchange authorities in the foreign country sometimes require it before an import license is
issued.
54. 54. Certificate of Origin Certificate of Origin is a document, which indicates the country in which
the goods were produced, is required whenever preferential duties are claimed. Sometime,
consular legalization of the document is necessary. Also, certification of the document by a
Chamber of commerce is required. Shipping Marks The purpose of these marks is to identify
your goods from those of other shippers. They should be made boldly, with waterproof and salt-
proof ink, so that they can always be easily read. They should be in black, with red or orange for
dangerous cargo. The marks should be in both English and the language of the country of
destination. The final destination point should be made to stand out so that the package can be
easily identified with the corresponding shipping documents and easily located for customs
clearance and delivery. To discourage theft, “blind marks” can be used that do not reveal the
contents of the package. Product descriptions or trademarks should not be shown. The shipping
marks must be exactly the same as those shown on the commercial invoice, bill of lading, etc.
Some countries indicate exactly the shipping marks to be used. Such specifications include the
size of lettering, their position on the containers, the method of applying the marks (brush or
stencil), and the types of weights and measures to be used. Some countries such as India require
that the import permit number be marked on the packing case. In the case of cautions for
handling, exporters are encouraged to use universally recognized cautionary marks such as a
wineglass on the commercial invoice and bill of lading, etc. for "fragile", as well as words. All
cautionary marks, international handling symbols, destination should be very distinct, on three
surfaces of each crate. Marks of Origin The exporter, as well as marking the container, must
ensure that the goods being shipped abroad have the required marks of origin. Compulsory
Marks of Origin Many countries require that all imported goods, and the packages in which they
come, be marked in a conspicuous place with the name of the country of origin. Exceptions are
usually made for goods that cannot be marked, those that cannot be marked without injury, and
those that can only be marked at prohibitive cost. Corrective Marks of Origin Other countries
require that a mark of origin be placed on imported goods, if its absence would create a false
impression about the origin of such goods. This can occur if the goods show the place of
manufacture with the same name as that of place from the importing country (Toronto, Japan,
compared with Toronto, Canada). Or when the label contains only the name of the importer or
import agent, rather than that of the foreign manufacturer. Marking Methods Each country has
regulations governing the manner in which imported goods should be marked, including the size
of the letters. Some countries require, in addition to the name of the country of origin, the
words "Made in" or" Produced in". Sometimes, the language of the importing country must be
used. As well as being legible and conspicuous, the mark should be non-erasable. Labeling for
Export The exporter must also comply with any labeling requirements for its product in the
importing country. These often exist for prepared goods, beverages, and pharmaceutical and
toilet preparations. Usually, the
55. 55. label must show the manufacturer's name and address, a list of the ingredients, the weight
or volume of the contents, and other relevant information. Often, the required descriptions
must be in the language and weights and measures system of the importing country. In some
countries, certain products must be registered with the appropriate government department
and the registration number shown on the label. Delivery to the Dockside One way is to use the
service of a freight forwarder The shipping company's representative checks the number of
items, their condition, shipping marks, weight, and perhaps size, and then issues a "dock
receipt". The exporter keeps this dock receipt until the goods are loaded aboard the ship. After
this has been done, the shipping company issues an ocean bill of lading to replace the dock
receipt. Another way to deliver goods to the ship is by rail. Small shipments are delivered to the
local railway freight depots where they are consolidated with other shipments for the same
 port. Large shipments go by carload lots and are usually loaded at the exporter's premises. At
the port, the shipping line has usually leased or has been assigned a shed in which all the box
cars containing goods for the particular ship are unloaded. The railways assume the
responsibility for unloading the boxcars, and checking and placing the goods in the warehouse
ready for loading abroad ship. The cost involved is included in the railway freight rate. Loading
the Goods aboard Ship: When the exporter's goods have been unloaded at the dockside, it is the
shipping company's responsibility to ensure that they are properly loaded aboard the correct
ship. Usually, a stevedoring firm does this on behalf of the shipping company and the cost
involved is already included in the freight rate paid by the exporter. With the goods safely
loaded aboard the ship, the shipping agent issues a "clean" ocean bill of lading to the exporter
so long as no shortages or damaged crates, boxes, etc. have been discovered. If damage had
been noted, the exporter can still obtain a clean bill of lading by signing a letter of indemnity
that absolves the shipping line of any responsibility for the damage should insurance claim be
made. The bill of lading, in the required number of copies, is evidence of ownership and is
negotiable - it is the key document that is surrendered to the foreign importer upon payment
for the goods or acceptance of a time draft as specified in a letter of credit. Truck Transportation
Truck transportation between Malaysia, Singapore and Thailand is quite convenient as it permits
warehouse-to-warehouse transportation and reduces the handling involved in transshipment.
However, it is more expensive than by freight train for heavy shipments. Most exporters, if
trucking suits their need, prefer to use commercial trucking companies to transport their goods.
Rail Transportation There are three types of railway freight rates: 1. LCL ("less than carload lot")
this is the most expensive rate and applies to small shipments based on a minimum charge for
100 lb. 2. CL ("carload" rate) this is the cheapest rate and applies to shipments 30,000 pounds or
more. 3. "Pool-car rate" - this is an intermediate rate and involves the combining of shipments
from different shippers. Rail transportation is most suitable for his shipment if: 1. The goods are
heavy. 2. The distance to be traveled not economical by truck.

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