Professional Documents
Culture Documents
Submitted by:
ATIK FOYSAL RABBI
ID: 191-229-801
Rashidul Amin Shakil
ID: 191-254-801
Major: Apparel Manufacturing Engineering
Supervisor:
Dr. Sirajul Karim Choudhury
Professor & Dean FES
E-mail: skc@buft.edu.bd
BGMEA University of Fashion & Technology (BUFT)
This Internship Report Submitted in partial fulfillment of the requirement for the Degree of B.Sc.
in Textile Engineering in the Faculty of Textile Engineering of BGMEA University of Fashion &
Technology (BUFT).
March, 2023
i
Submitted by:
ATIK FOYSAL RABBI
ID: 191-229-801
Rashidul Amin Shakil
ID: 191-254-801
Major: Apparel Manufacturing Engineering
Submitted To:
Department of Textile Engineering
In partial fulfillment of the requirements for the degree of Bachelor of Science in Textile Engineering
Supervisor:
Dr. Sirajul Karim Choudhury
Professor & Dean FES
E-mail: skc@buft.edu.bd
BGMEA University of Fashion & Technology (BUFT)
…. March, 2023
Dr. Sirajul Karim Choudhury
Professor & Dean FES,
Department of Industrial Engineering,
BGMEA University of Fashion & Technology
Nishatnagar, Dhaka
Dear Sir,
We are extremely indebted for your tremendous support and guidance throughout our long journey at
"BGMEA University of Fashion & Technology" and internship period. Being working with you, we have
earned valuable knowledge and were inspired by your innovativeness, which helped enrich our experience
to a greater extent. An internship report on "HA-MEEM GROUP." is submitted to you for the partial
fulfillment of the Bachelor of Science in Textile Engineering Degree.
During our internship period, we have trained in all departments of HA-MEEM GROUP.; we made
sincere efforts to study related materials, observe operations performed in bonded warehouse, cutting,
sewing, garments washing, finishing & merchandising section which are the sources of collected data to
prepare the present report on Industrial training.
We have to make this report as comprehensive as possible within the time limit. But there may be some
mistakes due to various limitations. For this reason, we beg your sympathetic consideration. Finally, we
pray for your blessing for our successful engineering career.
Thank you,
Yours Faithfully,
Declaration
ATIK FOYSAL RABBI & Rashidul Amin Shakil, we are the Student of Bachelor of Science in
Textile Engineering, ID:191-229-801 & ID: 191-254-801 at the Department of Textile Engineering,
BGMEA University of Fashion & Technology (BUFT), do hereby declare that the internship report
on Industrial Attachment is a work done under the supervision of Dr. Sirajul Karim Choudhury,
Professor & Dean FES in BUFT. We also declare that this report is an original work and no part of this
report has been copied from elsewhere. Furthermore, this report has not been published or submitted for
being awarded any degree, diploma or recognition earlier.
……………………… ………………………
ATIK FOYSAL RABBI Rashidul Amin Shakil
B.Sc. in Textile Engineering B.Sc. in Textile Engineering
ID: 191-229-801 ID: 191-254-801
Department of Textile Engineering Department of Textile Engineering
BGMEA University of Fashion & Technology BGMEA University of Fashion & Technology
Board of Examiners
Name Signature
ACKNOWLEDGEMENT
The industrial training program is the pre-requisite for the graduation of B.Sc. Classroom discussion alone
cannot make a student perfect in handling the real business situation; therefore, it is an opportunity for the
students to gather more information about the professional work situation through this program. This
report has to be built for the university and organization requirement. This report is made based on the
reputed multinational company named “HA-MEEM GROUP”. The main purpose of the report becomes
very clear from the topic of the report. This Group is one of the leading groups among south Asian
Garments Industries. We had a great chance for our industrial training. This is a large factory with all the
facilities. Here the production process runs from developing different brand sample through production
to finished garments for export. In this age, Bangladesh is flourished with RMG sector where this division
has its immense contribution. The annual export income of garments sector is driven from Woven
garments. Ready Made Garments is 100% export oriented. RMG exports various garments product to
foreign country. The company makes Gents shirts, pants, chinos, cargo pants and others for U.S.A, U.K,
and European market. Basically, This Report is prepared on our industrial training, where our
concentration is in- Inventory management, cutting section, Increase Production, Efficiency, Bottle neck,
Quality of products, Washing, Finishing and Merchandising Practiced in RMG. This report also belongs
the whole activities of production department. An efficient Industrial Engineer should know all the
technical knowledge of all departments like development, develop productivity, work process
development time study, method study, line balancing, capacity study, m/c layout, motion study, worker
train up, skill development, etc. He has to coordinate with all these activities. we would like to extend
thanks to Honorable Founder chairman, Board of Trustees Mr. Muzaffar U. Siddique, (BUFT) not only
for this tremendous academic support, but also for giving us so many wonderful opportunities and logistics
supports to do this project. Special thanks go to our enthusiastic Prof. Dr. Eng. Ayub Nabi Khan, Vice
Chancellor (BUFT), who so generously inspired & contributed to do this type of project work. Special
thanks to my enthusiastic supervisor Dr. Sirajul Karim Choudhury, Professor & Dean FES (BUFT)
has been an amazing experience and we thank him wholeheartedly, not for his tremendous academic
support, but also for giving us so many wonderful opportunities. We would like to express our gratitude
to the management of HA-MEEM GROUP for giving us the opportunity to undergo Industrial Training
there. We also thankful to Engr. Imran Sarker, IE manager (Central), Mr. Abusur, Senior Merchandiser
at GAP. Finally, we want to show our gratitude to all the Management & Non-Management staffs who
helped us during the internship period & also had impact in completing our whole report. Our gratitude
also goes to all the employees of HA-MEEM GROUP. for their sincere cooperation, Support and
valuable advice which they have provided us during these two months of training.
Finally, we highly appreciate the support & understanding of my colleagues in the preparation of this
report.
EXECUTIVE SUMMARY
The industrial training program is the pre-requisite for the graduation of B.Sc. Classroom discussion
alone cannot make a student perfect in handling the real business situation; therefore, it is an
opportunity for the students to gather more information about the professional work situation through
this program. This report has to be built for the university and organization requirement. The topic of
this report is “Overview of Production Activities in Garments Industries in Bangladesh’. This report
is made based on the reputed multinational company named HA-MEEM GROUP. The main purpose
of the report becomes very clear from the topic of the report. This Group is one of the leading groups
among south Asian Garments Industries. It was a great chance for me to do my internship. This is a
large factory with all the facilities. Here the production process runs from developing different brand
sample through production to finished garments for export. In this age, Bangladesh is flourished with
RMG sector where this division has its immense contribution. The annual export income of garments
sector is driven from Woven garments. Ready Made Garments is 100% export oriented. RMG exports
various garments product to foreign country. The company makes Gents shirts, pants, chinos, cargo
pants and others for U.S.A, U.K, and European market. Basically, This Report is prepared on “The
production activities in RMG Industries” Where my concentration is in, Increase Production,
Efficiency, Bottle neck, Quality of products, and Practiced in RMG. This report also belongs the
whole activities of production department. An efficient Industrial Engineer should know all the
technical knowledge of all departments like development, develop productivity, work process
development time study, method study, line balancing, capacity study, m/c layout, motion study,
worker train up, skill development, etc. He has to coordinate with all these activities.
“Table of Contents”
Chapter 1: Introduction 10
1.1 Introduction 11
1.2 Objectives 12
3.1 Introduction 19
3.2 Consignment 19
4.1 Introduction 44
4.7 Numbering 53
4.10 Fusing 54
5.1 Introduction 57
5.2 Objective 58
7.1 Introduction 83
“List of Figures”
Name Page
Fig-2.1: Front View of Ha-Meem Group (CCL) 16
Fig-4.4: Numbering 53
Fig-6.1: Formulas of IE 78
Fig-7.1: PP Spray 86
Fig-7.3: Destroy 87
Fig-7.4: Tagging 88
Fig-7.5: Grinding 89
Fig-7.6: Whiskering 90
“List of Tables”
Name Page
Chapter: 01
Introduction
1.1 Introduction:
Industrial training or internship is an important part of a B.Sc. in Textile Engineering course. It provides
students with hands-on experience in the textile industry, which is essential for their professional growth
and development.
During the internship, students get the opportunity to work in real-world textile manufacturing
environments, which helps them understand the practical aspects of textile production. This experience is
crucial for students to develop their skills and knowledge, which will prepare them for a successful career
in the textile industry.
Internships also provide students with the opportunity to network with professionals in the textile industry,
which can be helpful when seeking employment after graduation. Additionally, internships can be a great
way for students to explore different areas of the textile industry and gain insight into their own career
interests.
Therefore, industrial training or internship is a mandatory requirement for all textile students to fulfill
their Bachelor Degree, and it plays a critical role in their professional development and success.
So, we have accomplished 8 weeks long industrial training in Ha-Meem Group (Tongi Zone), Nishat
Nagar, Tongi, Gazipur-1711, Bangladesh. Which is 100% export-oriented apparel industry. It helps
us to acquire knowledge about garments production in practical environment. During this period, we
have been able to gather knowledge about Store, Quality Control & Inspection, Cutting, Sewing, IE,
Finishing, Embroidery, Printing Packaging, and Merchandising and other related section as well as
duties and responsibilities of a garment’s factory. We have noted down all the necessary information
part wise most beneficial outcome from the industrial training.
1.2 Objective:
• Practical Experience: The primary objective of industrial training is to provide us with practical
experience in a real-world textile manufacturing environment. It allows students to apply their
theoretical knowledge to practical situations, gain hands-on experience with textile machinery,
and understand the technical aspects of textile production.
• Skill Development: Industrial training provides students with the opportunity to develop their
technical, analytical, and problem-solving skills. They learn to work independently and as part of
a team, communicate effectively with colleagues and supervisors, and manage their time and
resources efficiently.
• Exposure to New Technology: Textile industry is constantly evolving, and new technologies are
being introduced. Industrial training allows students to stay up-to-date with the latest trends in the
textile industry and learn how to operate the latest machinery and equipment.
• Professional Network: Industrial training provides an opportunity for students to meet and network
with professionals in the textile industry. This helps them to develop contacts, gain industry
insights and advice, and explore potential job opportunities after graduation.
Overall, the objectives of textile industrial training or internship are to enhance students' academic
knowledge, technical skills, and professional development. It provides a platform for students to apply
their theoretical knowledge to practical situations, develop their professional network, and prepare for a
successful career in the textile industry.
Chapter: 02
Company profile
Ha-Meem Group, a Bangladeshi clothing manufacturer, is leading supplier of readymade garments and
denim fabric in the world. We are one of the top clothing companies in Bangladesh. The company
produces some of the most fashionable denim fabrics and garment products and owns one of the most
comprehensive and resourceful manufacturing facilities in Bangladesh.
Ha-Meem Group has earned name and fame both at home and abroad as one of the top clothing companies
in Bangladesh. The continuous growth of this group is moving forward hand on hand with the
industrialization of the home country Bangladesh. Moreover, we as a Bangladeshi clothing manufacturer
have been contributing immensely in the financial growth of the nation.
Ha-Meem Group, one of the top clothing companies in Bangladesh exporting to USA and Europe for a
long time. Because of our successful history with the world leading customers and buyers, we are the
most valued and well reputed Bangladeshi clothing manufacturer.
Company produces 7 million pieces of woven garments per month with the assortment of infant to adult
in men and women. Today Ha-Meem Group employs around 50,000 workers and the company is equipped
with 26 garments factories, a unique Denim mill, Sweater factory, Embroidery and Printing factory,
Carton factory, Poly bag industry, Label factory, Jute mill, Chemical formulation plant, Tea Gardens,
Transport company, News Channel and a national daily newspaper. Its overseas office in Hong and China
gives fastest support in procurement of fabric and accessories. Own C&F office in every Bangladeshi port
gives privilege of quick clearing and forwarding support.
Company Profile
Chapter: 03
Bonded Warehouse
3.1 Introduction:
Bonded Warehousing means the facility provided to export oriented industries for importing
inputs/raw materials and packaging materials without paying any duty or taxes. When goods are
stored in a non-bonded warehouse, an importer must pay taxes on goods received and ensure they
are fully inspected immediately.
3.2 Consignment:
Consignment is the total roll of one chalan, like 100 roll comes in one chalan so this is one
consignment. Color variation could have but consignment is one.
In the time of Inventory consignment number is given to see roll number and color for do not
miss during inspection.
When fabric is coming there are a term use in warehouse is pre alert forfabric whom will
receive fabric from chalan is always alert for fabric.
When fabric is come one buyer nominated person receive the chalan and check it physically and
there is lock number in chalan and the person check the lock number and cut it. And then roader
came and unload materials andtake it to quarantine area.
MAT Cutting for test: 1 yds fabric cut from each roll of consignment and create blanket (six
blanket are created from each roll) for shrinkage, shade matching and GSM checking. After
create blanket those are going for wash after wash test are done by inspection department.
• Blanket procedure:
• Step 1: Blanket should be made with 100 % rolls.
• Step 2: Length and width s / b 25 cm and fabric naps s / b one way.
• Step 3: 100 % rolls serial maintain for cut pcs as like spreading with numbering.Step 4 8 " x 8 "
by pattern wise mark and fabric should be cut.
• Step 5: Blanket sewing or over lock point s / b even and one way.
• Step 6: All blanket should be wash as per buyer wash requirement
• Step 7: blanket shade s / b check with approval lab dip and counter in the light box (minimum two
people)
• Step 8: Group wise shade band swatch making
• Step 9: Color continuity control card making.
• Step 10: Shade band summery and report making & submit to related department.
We need to know how much a fabric is liable to shrink for a number of reasons. Firstly,
manufacturers need to know that the fabric or garments they are producing are of excellent quality.
There’s brand reputation to think of. And also, the wasted materials and energy involved in
having to remake things because fabric has shrunk at a late stage in garment production.
Secondly, if a fabric shrinks after it has been cut or sewn, the finished garment will be misshapen.
Seams might end up puckered. And the hang of a garment will be affected.
Lastly, manufacturers need to provide care labels telling consumers how to look after their
garment. Without a fabric shrinkage test, the information on these labels will not be accurate
step 1: shrinkage should be 100 % for cotton and denim / spandex fabric.
step 2: shrinkage fabric should be length 50 cm and width 50 cm.
step 3: writing style name, order no roll no, yards, on shrinkage fabric.
step 4: four side surrounding mark should be 50 cm by fabric marker.
step 5: out line should be over lock, at 3 side, 1 side s / b open.
step 6: wash should be based on customer requirement.
step 7: after wash length / width wise measurement check.
step 8: formula: after wash - before wash x 100 / before wash=Ans
step 9: make report and send the copy to related department.
step 10: pattern adjust on according to shrinkage group wise.
Fabric shade variance is the variation of shade in one roll of fabric orseparate pieces of fabric
that were intended to match.
6 blankets are
making 2 set wash
1 set before wash
1 set shade
1 set for GSM
1 set for future requirement
The shade achieved is to be checked several times while in process & at finished state to ensure
the customers demand under a recommended light source. Generally, the shade is checked at the
following stage, after washing.
In washing buyer standard shade are given by merchandiser they wash blanket by amount of
chemical. After wash they mark A B C D by shade variation. After that when blanket is in shade
checking room then they check by various light source and match it. Then shade variation
Generally, if there is a variation in the tension of the fabric during knitting or weaving, then after
dyeing, some changes in the shape of the fabric or it is dimensional deformation, in which
skewness is seen between the fabric. This problem of cloth is called twisting.
3.4.6.2 GSM:
GSM stands for grams per square meter, which refers to the weight of a fabric.
Apparatus required
2. Weighing Balance.
Method:
2. Weight all test swatches accurately and calculate the average weight of swatches.
3. Multiply the average weight of swatches by 100 to calculate the GSM of the sample
fabric. (Normally, the area of round GSM cutter is 1/100 square meters.)
4-point system:
Determining 4 points in 1 yard of fabric is called 4-point system.
• Location
• Buyer
• Style
• PO
• Roll quantity
• YDS quantity
• Consignment
• Item name
• Remarks
3.7.1 Trims:
The raw materials used in sewing room other than fabric are called Trims. On the other hand,
materials are directly attached to the fabric to make a garment are called trims. Like: Threads,
buttons, lining, Interlining, zippers, labels, care labels, etc.(Interlining is used as shape
forming/preserving materials.)
• Labels
• Buttons
• Zippers
• Padding
• Interlining
• Down
• Elastic
• Thread
• Twill Tape
• Stopper
• String/Draw Cord
• Piping Cord
• Emblem
• Logo Print
• Swivel Hook
• Eyelet/ Grommet
• Collar Stay
• Cord Bell
• Buckle
• Rivet
• Weaving Belt
• Hook and Eye
• Velcro Tape
• Seam Sealing tape
• Shoulder pad
• Cable (steel ware)
• Adjuster
• Recco
• Elastic Threads
• Shoulder Tag
3.8 Accessories:
The materials, which are used to make a garment attractive for sale and packing, other than
fabrics and trims, are called Accessories.
• Polybag
• Elastic bag
• Mini Polybag
• Master Carton
• Inner Carton
• Size Clip
• P.P. Band
• Tag Pin
• Brass Pin
• Collar Stand
• Safety Pin
• Gum Tape
• Arrow Sticker
• Scotch Tape
• Barcode
• Defect Indicator
• Tissue Paper
• Backboard
• Neck Board
• Butterfly
• Numbering Stickers
• Hanger
• Size Stickers
• Carton Pad
• Both Side Tape
• Plastic Staple
• Iron Seal
• Clip
• Ball chain
• Size Tag
• Carton Sticker
• Safety Sticker
• Plastic Clip
Received Inventory at
Accessories Unload quarantine
(Trims) from area
suppliers
Inspection by
aql for all
Ready to issue Racking countable or 10%
non-countable
Inspection:
Follow the Buyer standard and check items. For metal item use metal detector m/c, then moisture
check.
3 days maximum time for inspection.
For inspecting trims and accessories following standard procedure will be followed:
• Trims and Accessories Quality Control (QC) will check trims after in housed by using
AQL065 of every lot.
• If this particular lot fails as per AQL, QC will check 50 rims of whole lot.
• If QC finds more defective Trims from out of 50 % check, QC will check 100 % Trims
(whole lot).
• After completing the check, QC will claim supplier via merchandising.
• A claim must be done within 7 days after in - jpisom factory.
1. Print Mistake: Any problem showing for incorrect printing, Example or bleeding.
2. Color Problem: Used different color / shade not match with approved trims color.
3. Code Mistake: Barcode or any types of code mistake
4. Fitness Problem: Not found as per ordered length and width.
5. Print Spot: Any spot only for printing.
6. Measurement Problem: Any types of measurement do not match with an approved swatch.
7. Size Mistake: When everything okay but mentioned size not correct.
8. Gum nil: If there needed gum but not found in the inspection.
9. Running Color: Different types of color in trims when one color is approved.
10. RO Mistake: When everything is okay but mentioned PO number not correct.
11. Style Mistake: When everything is okay but mentioned style not correct.
12. Letter Mistake: Used capital letter instead of small or small letter instead of ca
13. Spot: Any type of spot is to be considered as a defect.
14. Broken: Trims and accessories broken is a critical defect.
15. Logo Mistake: Any problem in logo design and color.
• Location
• Quantity
• Buyer
• Style
• PO
• UOM
• Consignment
• Item name
• Remarks
A bonded warehouse can be an excellent solution for storing textile trims and accessories.
These specialized warehouses are designed to provide secure, climate-controlled storage
for a wide range of goods, including textiles and related materials. By using a bonded
warehouse, textile manufacturers and suppliers can reduce their overhead costs and
streamline their supply chain management. Bonded warehouses also offer a range of
additional benefits, such as streamlined customs clearance and access to a range of value-
added services, including repackaging, labeling, and sorting. In the case of textile trims
and accessories, bonded warehouses can provide a secure and well-organized storage
solution that protects these important materials from damage, loss, or theft. With proper
inventory management and tracking, manufacturers and suppliers can ensure that they
always have access to the materials they need to produce high-quality textile products.
Overall, the use of a bonded warehouse for textile trims and accessories can help textile
businesses to manage their inventory more effectively, reduce their costs, and enhance
their overall supply chain efficiency. As such, it is an important consideration for any
business involved in the textile industry.
Chapter: 04
Cutting Section
4.1 Introduction:
The cutting department is responsible for cutting fabrics for the garment orders and feeding
the sewing department with cuttings. The cutting department's capacity is planned based on
the daily feeding requirement of the sewing lines.
The cutting department gets a cut order plan from the production manager. According to the
cut plan, the cutting in-charge generates a fabric requirement sheet or requisition slip to the
fabric store to issue fabrics.
The fabric receiving process from the fabric store may be done on the same day of the cutting
or one day before the cutting schedule.
Fabrics relaxation means relaxing fabrics from its roll-type tie. Relaxation is very important
to get fabric's own shape, garments measurements depend on proper fabrics behavior.
Relaxation is must necessary for stretch fabrics. The objective of fabric relaxation is to keep
fabric's dimensional stability after cutting.
Marker making is the process of determining a most efficient layout of pattern pieces for a
style, fabric and distribution of sizes.
1. To ensure the markers are made to a size ratio that gives the required quality
and quantity per order by reducing the wastage of fabrics.
2. To ensure no garment part is missed in the marker and the marker is of
comparable length and width of the fabric being laid.
3. To check notch or drill mark
4. Fabric width must be higher than marker width
5. Fabric length must be higher than marker length
6. Matching of green line
7. Check pattern size and dimension
8. Matching of check and stripe taking into consideration
3 Ensure the correct sizes have been drawn onto the marker No allowance
as per the size ratio
4 Ensure all the garment parts have been drawn onto the No allowance
marker
5 Ensure the patterns are facing the correct direction in case No allowance
of marker making modes.
6 Ensure the patterns have been placed onto the marker in Stripes and Checks 80% & Solid
such a manner as to achieve the highest fabric utilization. color 95%
7 Ensure the marker is of the correct widths, comparable to Zero to half inch
the fabric so that the fabric is not wasted. If the marker is
too small or too wide then incomplete garment parts are
cut.
10 Ensure all notches and drill holes have been drawn on the No allowance
marker.
Fabric spreading:
Spreading is the process of unwinding large rolls of fabric onto long, wide tables and laying
them in superimposed plies of specified length. The number of lays depends upon the number
of garments desired and the fabric thickness.
1. Alignment of plies in both length and width direction- length and width of fabric must
be at least equal to marker length and width.
2. Elimination of fabric defects/flaws- any faults identified on the incoming fabrics will be
tagged and will be avoided.
3. Correct ply direction (especially for asymmetrically printed fabrics)- all faces up, all
faces down, face to face etc.
4. Correct ply tension- ply tension must be uniform and as much less as possible.
5. Avoidance of distortion in the spread during cutting- polythene sheets are used under the
bottom ply to resist friction of the bottom ply with the base plate of the knife.
6. Fabrics must be flat and free from any crinkle & crease- these cause defect in garments
due to variation in dimension.
Automatic spreading machine with unique design cradle feed, with manual operation through
“twist and go”
handle, and automatic operation with interactive digital control, for straight and reverse rolls.
Spreading
planning with steps. It’s provided with “tension free” spreading control for all Woven fabric.
The manual spreading process is suitable for small-scale production. Manual spreading may be
used for all kind of fabrics, including those with complex structures and intricate patterns. In
large-scale production, manual cutting is often used for working with intricately patterned and
high-cut pile fabrics. When compared to automated spreading, the cost of technical equipment
in manual spreading is low, but the productivity is poor. The fabric spreading process is carried
out by one/two workers at each side of the spreading table who move the fabric ply to the
beginning of a spread. The spreading process is repeated until the desired number of fabric
plies are laid down
4.6 Cutting:
To cut out pattern pieces of garment component as per exact dimension of the pattern from a
fabric lay is
• Powerful marker-making using Diamino with digital transfer to the cutting room
• Precise edge alignment with Brio spreader
• No buffer between parts
High productivity
Up to 98% uptime
The main role of a cutting department is to cut garment components from fabric rolls or fabric
than as per style specifications and send cut components to sewing department in bundles. A
cutting department of a garment manufacturing unit includes following sub-processes.
Cutting inspection:
To maintain the cutting quality, standard cutting components are checked randomly by quality
checkers. If defective components are found, they replace those defective parts.
4.7 Numbering:
Fig-4.4: Numbering
In this stage sticker is attached with all part of cutting part for shade matching. The sticker
number maintains cutting number, size number, serial number.
Layers are sorted size-wise and color-wise. Each ply is numbered using stickers. Bundles are
kept on inventory tables, before these are sent to undergo the next process Each ply is numbered
using stickers. Bundles are kept on inventory tables, before these are sent to undergo the next
process.
4.10 Fusing:
Fusing process is one kinds of alternative method of fabric joining which is vastly used to
attach the interlining. At present, apparel manufacturing cannot be imagined without fusing
process.
Reissued size for collar in/collar top, and band in/top = 25 min
Reissued for body = 9 min
Total 27000 cut pcs of 1/2 sleeve shirt numbering time = 230 min with allowance
collar in/top, band in/top, Nonwoven interlining =6000 pcs
Chapter: 05
Sewing section
5.1 Introduction:
A sewing machine is a machine which is used to sew fabric and materials together with
thread. Sewing machines were invented duringthe first industrial revolution to decrease the
amount of manual sewing work performed in clothing companies. The sewing machine
is the most important element in the garments industry. It minimizes laborious task. By
using sewing machine, we can get more standard quality garments within a short time.
There are different parts of a sewing machine, where one part is relatedto other parts.
5.2 Objective:
The objective of a study on garments sewing machine can vary depending on the specific
focus of the study. However, some common objectives of such a study may include:
• Identifying the factors that affect sewing machine performance: This objective
involves identifying the factors that can impact the performance of sewing
machines, including operator skill, maintenance, and the type of fabric being sewn.
• Assessing the impact of sewing machine technology on the garment industry: This
objective involves evaluating the impact of advancements in sewing machine
technology on the garment industry, including increased automation and the use
of computer-controlled machines.
• Understanding the types of sewing machines used in the garment industry: This
objective involves identifying the different types of sewing machines used in the
garment industry and understanding their specific features, functions, and
applications.
Overall, the sewing floor plays a crucial role in the garment manufacturing process. The
quality, efficiency, and productivity of the sewing floor directly impact the quality
Learning
curve
Single needle lockstitch is a type of industrial sewing machine that is commonly used in
the garment industry for sewing fabrics such as cotton, silk, and synthetic materials. Here
are the typical specifications of a single needle lockstitch machine:
Some single needle lockstitch machines come with additional features, such as built-in
LED lights, automatic thread trimming, automatic backstitch, and programmable settings.
The specifications of a single needle lockstitch machine may vary depending on the
manufacturer and model
Double needle lockstitch machines, also known as twin needle machines, are a type of
industrial sewing machine commonly used in the garment industry for sewing a variety
of fabrics such as knits, woven, and synthetic materials. Here are the typical specifications
of a double needle lockstitch machine
Needle carries needle thread and helps in penetration and helps in sewing,
Motor rpm controls the speed of the machine. The rpm is controlled by the tightening or losing the
belt over machine and motor pulley.
• Spm: 6000
• No of needle: 2/3
• No of thread: 4/6
Application: For making garments of jeans fabric, used in long seam of trousers, frequently used
for joining lace, used for joining braid and elastic in the garments.
• Brand: JUKI
• Origin: JAPAN
• Model no: ZOJE ZJ-B9500-13-PD3-02 SET
• Function: 2-needle / 4-thread overlock (safety stitch) machine (stitch type 514) for light
and medium materials. Serial equipped with automatic functions: thread trimmer with
suction for fabric leftovers, pneumatic foot lifter, needle positioning. Equipped with
energy-saving LED lamp for lighting of working field.
Overlock equipped with two sensors responsible for raising the presser foot at the
beginning of sewing and for automatic thread cutting. This significantly speeds up the work
with the machine.
• Spm: 6500
• No of needle: 1/2/3
• No of thread: 2/3 to 6
• Application: Used in Woven, knit; all types of garments.
Function: The operator sets the machine to the desired buttonhole size and type (such as keyhole
or rounded). The fabric is placed under the presser foot and the machine is activated. The machine
sews a series of stitches that create the buttonhole, including a bartack (a tight zigzag stitch that
secures the buttonhole) at the beginning and end. The operator then cuts the fabric between the
bartacks, creating the opening for the button. Based on the principle of lock stitch or chain stitch.
Chain stitched -good appearance and less durability. It provides purl effect and is preferred for
jackets, light-weight materials etc.
Application: Buttonholes are the essential finishing touch on blouses, jackets and any other
project that utilizes buttons for closure, they are normally stitched when the garment is finished.
VI.BE MAC's bartack machines are also designed to be durable and reliable, with a solid
construction that can withstand heavy use. The machines can create a range of bartack patterns,
including rectangular and keyhole bartacks, and they can be customized to meet the specific needs
of the user.
Overall, VI.BE MAC's bartack machines are a popular choice for industrial sewing applications
that require strong and durable bartacks. The machines are designed to be easy to use, with
advanced features that increase productivity and efficiency
VI.BE MAC's J-stitch machine is a type of industrial sewing machine that is designed to create J-
stitch patterns. J-stitch is a decorative stitch that is often used in garment manufacturing and other
sewing applications, and it features a unique zigzag pattern that resembles the letter "J". J-stitch
can be used for a variety of applications, such as attaching pockets, reinforcing seams, and adding
decorative accents.
VI.BE MAC's J-stitch machine features a number of advanced features that make it easy to create
precise and consistent J-stitch patterns. Some of the key features of VI.BE MAC's J-stitch machine
include:
• High-speed operation for increased productivity
• Programmable settings for customized stitching patterns
• Automatic thread trimming for faster operation
• Adjustable presser foot pressure for improved fabric control
• Touchscreen controls for easy operation
• LED lighting for improved visibility
• Servo motors for improved energy efficiency
VI.BE MAC's J-stitch machine is also designed to be durable and reliable, with a solid construction
that can withstand heavy use. The machine can create a range of J-stitch patterns, including
different stitch lengths and densities, and it can be customized to meet the specific needs of the
user.
Overall, VI.BE MAC's J-stitch machine is a popular choice for industrial sewing applications that
require precise and consistent J-stitch patterns. The machine is designed to be easy to use, with
advanced features that increase productivity and efficiency
VI.BE MAC is a brand of industrial sewing machines and one of their products is the pocket
setter machine. The VI.BE MAC pocket setter sewing machine is designed specifically for
setting pockets on garments in a fast and efficient manner.
The machine is equipped with features such as automatic fabric feed, adjustable stitch length
and width, and a high-speed sewing capability to increase productivity. It has a compact and
ergonomic design for ease of use and maneuverability, making it ideal for use in small and
medium-sized production facilities.
The specifications of the VI.BE MAC pocket setter sewing machine may vary depending on
the specific model, but here are some typical specifications:
Note that these specifications are provided as a general guideline and may differ based on
the specific model of VI.BE MAC pocket setter sewing machine. It's always recommended
to refer to the manufacturer's specifications for accurate and up-to-date information.
Revise by 12-10-2022
Buyer: JC PENNY
Prepared date 11-09-2022
Style:141321
Article: pull on cargo short OPERATION BULLETIN Order qty 24209
Prepared by
Check by
Revise by 12-10-2022
Prepared date 11-09-2022
Order qty 24209
OPN NO. section operation name M/C S.M.V TGT/HR Op Efficiency op TGT/H TGT/DAY
Learning
curve
Chapter: 06
Industrial Engineering
I.E: In garment industry, I.E is the branch Department that is related with the optimization
of the complex system or process. It is a department that has a function, responsibility to
measure, analyze and solve problems given in terms of efficiency, productivity, health, work,
discipline in order to spur growth and health corporate.
6.1.1 Task:
We have visited a number of lines for collecting some data about the operator. Such as-
• Operator’s running operation.
• Machine his/her ID No & Name.
• Finding out his/her running working line.
• It he/she is absent from the line. then the reason behind it.
• Training
• Wastage control
• Cost analysis
The Garments IE (Industrial Engineering) department is a crucial department in the apparel manufacturing
industry. The IE department is responsible for optimizing the manufacturing processes and improving the
efficiency and productivity of the production lines.
The primary responsibilities of the Garments IE department include:
1. Time study: The IE department conducts time studies to determine the standard time required to
complete a specific task. This helps in setting up production targets, measuring operator
performance, and identifying bottlenecks in the production line.
2. Method study: The IE department analyzes the manufacturing processes to identify opportunities
for improvement. This may involve reorganizing the production line, modifying the work
methods, or introducing new equipment to improve efficiency.
3. Workstation design: The IE department designs and sets up workstations for operators to work in
a safe and comfortable environment, which can help to reduce operator fatigue and injuries.
4. Production planning: The IE department plays a critical role in production planning. They create
production schedules, determine the required workforce, and allocate production resources such
as machinery, raw materials, and labor to meet the production targets.
5. Quality control: The IE department also plays a vital role in ensuring the quality of the final
product. They design and implement quality control procedures, train operators on quality
standards, and conduct quality inspections to ensure the product meets the required quality
standards.
Overall, the Garments IE department plays a crucial role in ensuring the smooth and efficient operation
of the manufacturing process in the apparel industry.
SL
Process Procedure
No.
Negotiation It is the very first work of an industrial engineer. Here, he
1 with should vastly discuss with garments merchandiser aboutthe
garments in-coming garments product.
merchandi
ser
Confirmed garments product is clearly analyzed here by
2 Garments industrial engineer. It helps to complete rest of the
analysis processes very easily.
Here, P.P meeting should be organized if all the required
Make P.P fabrics, trimmings and accessories are in housed and takeall
3 meeting the pre-cautions for the up-coming garments
production.
Production target should set here according to factory
4 Production capacity. It helps to respect the shipment date.
target
Fig-6.1: Formulas of IE
In the sewing section of a garment manufacturing process, a bottleneck can occur when the production
process slows down due to a particular task taking longer to complete than the others. This bottleneck can
have a negative impact on the overall efficiency of the manufacturing process, resulting in longer lead
times and reduced productivity.
One of the most effective solutions to resolve the bottleneck in the sewing section is to identify the cause
of the problem. There are several factors that can cause a bottleneck in the sewing section, including
inefficient workstations, poor production planning, and inadequate worker training.
Once the cause of the bottleneck is identified, the following solutions can be implemented to improve the
efficiency of the sewing section:
Workstation Layout: The workstation layout can be improved by rearranging the machines, adjusting
their heights, and providing the necessary tools and materials to reduce worker movement and increase
productivity.
Production Planning: An efficient production planning system can be implemented to ensure that the
right amount of fabric, thread, and other materials are available to the workers at the right time. This can
help prevent bottlenecks caused by material shortages or delays.
Worker Training: Proper training of workers on the use of machines, sewing techniques, and the
importance of meeting production targets can increase their efficiency and reduce the chances of mistakes
and rework.
Automation: Introducing automation in the sewing section, such as the use of computerized sewing
machines, can increase the speed and accuracy of the sewing process and help reduce bottlenecks.
By implementing these solutions, manufacturers can improve the efficiency of the sewing section and
reduce the chances of bottlenecks, resulting in improved productivity and faster lead times
A bottleneck in a sewing floor refers to a point in the production process where the flow of work is
restricted, causing delays and inefficiencies. To solve this problem, the following steps can be taken:
Identify the bottleneck: The first step is to identify the bottleneck in the sewing floor. This can be done
by analyzing the production process and identifying the step where work piles up or slows down.
Analyze the cause: Once the bottleneck is identified, the next step is to analyze the cause. The cause may
be due to a lack of resources, inefficient processes, or equipment breakdowns.
Improve the bottleneck area: To improve the bottleneck area, various measures can be taken. For
instance, if the bottleneck is caused by a lack of resources, then additional staff or equipment can be added.
If the bottleneck is caused by inefficient processes, then the process can be optimized to reduce the cycle
time.
Implement quality control measures: Quality control measures can be implemented to ensure that
defects are minimized, reducing rework and minimizing delays caused by fixing errors.
Continuous improvement: The last step is to implement a continuous improvement program that
continually monitors and improves the production process to prevent bottlenecks from reoccurring.
In summary, identifying the bottleneck, analyzing the cause, improving the bottleneck area, implementing
quality control measures, and implementing a continuous improvement program can help to solve
bottleneck problems in a sewing floor.
Chapter: 07
Garments Washing
7.1 Introduction:
The technology which is used to modify the appearance, outlook, comfort ability & fashion of the
garments is called garment washing. By the washing technique, faded/old look or tinted effect is created.
1. Washing process of garment is done to create wash look appearance. After washing the garments
create a new look.
2. By the washing technique, faded/old look, color or tinted affect is
created in the garments.
3. The important function of washing is to make the garments soft.
4. To attraction the customers/Buyer by different types of Fashionables
washing and market developments
5. Any dirt, spot or germ if added in the garment’s during manufacturing is
also removed due to washing.
• Whiskering
• Hand Scrapping
• P.P Spray
• P.P Sponging
• 3D or crinkle.
• 2D or crinkle
• Grinding
• Destroy
• Resin spray
• Heat pressing
Fig-7.1: PP Spray
This process is used to remove/fade the color from specific area of the garments with an abrasive
paper.The faded effect is nicely visible after wash.
➢ Working Procedure:
a. Specify the area
b. Put the garments into dummy
c. Scrapping with emery paper
d. Quality checking
7.6.3 Destroy:
This process is done by pen grinding machine which destroy only the warp yarns of the fabrics or
garments. The destroy look on the garments is best viewed after washing.
➢ Working Procedure:
a. Marking the area
Fig-7.3: Destroy
7.6.4 Tagging:
Tagging or tacking is the process which is done at unwashed condition of garments. After wash
we will get it effect. Maximum time we will do it at edge area by folding the garments. Sometimes this
process damages the garments by creating hole.
➢ Materials Needed:
a. Tag gun
b. Tag pin
c. Chalk
d. Hand gloves
➢ Procedure:
a. the garments
b. Fold the garments as per standard
c. Then tag the garments
d. Quality check
Fig-7.4: Tagging
7.6.5 Grinding:
This process is done at edges area of garments. If the garments require two-time wash in that case grinding
is done after first wash to avoid the damages of garments.
➢ Materials Needed:
a. Grinding machine
b. Hand gloves for safety.
➢ Working Procedure:
a. Run the machine
b. Touching the edge of garments according to standard.
c. Quality Check.
Fig-7.5: Grinding
7.6.6 Whiskering:
Whiskering is the most common dry process for denim garments. This is done by making a pattern and
put the garments then remove color from pattern area. After wash we can see the pattern mark. It is one
kind of design on the garments.
➢ Whiskering are two types depends on process:
a) Manual Whiskering
b) Laser Whiskering
a) Manual Whiskering
This whiskering is done by manual way with the help of a pattern. On denim garments we have done it
by abrasive paper.
➢ Material needed for manual whisker
a) Pattern
b) Abrasive paper
c) Marking chalk
➢ Procedure:
I. Put the whisker pattern into the garments
II. Then rub the pattern area according to standard intensity by abrasive paper
III. Quality check
Fig-7.6: Whiskering
b) Laser Whiskering
This whiskering is done by laser machine. Here, garments specific area are burned by imposing laser
with high intensity. After wash the burned indigo color will be removed and whisker effect will be
visible.
➢ Procedure:
a. Making the design by photoshop/illustrator
b. Put the garments on the machine surface
c. Set the intensity of burn
d. Burn the garments
e. Quality check
➢ Required Equipment’s:
a. Laser Machine
b. Leather hand gloves and goggles for safety.
This process is done by crinkle machine or by manual clipping of a specific area and the effect is more
visible at front and back knee area. In this process, two-dimensional effect is produced.
➢ Material needed for crinkle:
a. Crinkle machine
b. Resin
c. Clip
d. White fabric
➢ Process flow:
a. Applying Resin
b. Garment Placement on machine
c. Squeeze the garments
d. Keep it up to retention time (Curing)
e. Quality Check.
➢ Procedure:
a. Apply resin
b. Placement into dummy
c. Make 3D crinkle as per standard
d. Pre-cure the garments at 90 degree C
e. Taken out the garments from machine
f. Put into curing oven for full cure
g. Quality check
Here, pp is used as the main chemical and the final effect on the garments will be visible after
neutralization process.
➢ Material needed
a. PP solution
b. Phosphoric acid
c. Sponge
d. Dummy
e. Hanger
f. Hand gloves for safety.
➢ Working Procedure:
a. Put the garments into the dummy
b. Rubbing PP solution by sponge
c. Dry the garments by hanging
d. Neutralization
e. Quality Check.
This process in done for coating on the garments. When garments need to be very smooth and hard then
this process is applied. It is done by spraying resin on the full garments then put into oven for
curing the garments. After curing, surface coating become visible on the garments.
➢ Materials needed
1. Spray gun
2. Resin
3. Catalyst
➢ Procedure:
I. Put the garments into dummy
II. Spray resin
III. Curing in oven
IV. Check the quality
Heat pressing is used to get permanents pleats of garments. First, we spray resin on specific area of
garments then pressing by heat press then we will get a permanent pleated.
➢ Equipment’s:
I. Resin
II. Heat press machine
➢ Procedure:
I. Keep the garments on the pressing machine
II. Apply resin on the required area
Normal wash is the simplest type of wash with lowest washing cost. Normal wash consists of washing
garments in hot water with adequate detergent and softener, rinsing in plain water and drying in tumble
dryer. Some soda ash is added to lend the garment a prominent washed look. Water temperature and the
proportion of components of the wash are adjusted as per requirement of the wash and types of fabrics.
The softener makes the fiber soft and tumble-drying makes the fabric fluffier.
The purposes of this wash are
I. To remove dust, oil spot and other impurities.
Load the garments in the machine. A Batch of 100 kg cotton garments in the normal wash process is
described below-
Recipe:
In this wash enzyme is used to create desired effect. They work basically on the surface of the fabric.
Enzyme may be neutral or acidic according to the requirement of shade. The main benefits of using
enzyme is that it is biodegradable and hence eco-friendly.
Purpose:
Desizing
↓
Enzyme Wash
↓
Softening
↓
Hydroextracting
↓
Drying
↓
Delivery
Recipe:
1st Step: (Desizing)
Desizing is an important stage of all textile processing in which' size material ' is removed from the fabric
or garment before the pre-treatment process is completed, which is necessary before garment wash or
other textile processes. Here, we add desizing agent and detergent for cleaning and removing size material.
• Machine Running.
Here all garments are dried by using the gas dryer or steam dryer.
To give the garments more unique appearance and softer hand, abrasive stones were introduced to the
wash bath. Pumice or volcanic stone are widely used in this purpose. The stones not only abrade the fabric
but also gradually abrade the inside of the rotary drum.
Desizing
↓
Stone Wash
↓
Neutralization of chlorine
↓
Neutralization
↓
softening
↓
Hydroextracting
↓
Drying
↓
Delivery
Recipe:
Stone wash means washing garments with special stones so that garments achieve a very strong washed
effect. To get a faded look on the garment surface, white stones are used with enzymes during washing.
During washing, the fabric comes in contact with stones and the color fades by the rubbing action.
Recipe:
5. Temperature………………………………………………….. 60°c.
6. Time (Depend upon the shade) ………………… 12 to 15 mts.
7. Drop the liquor.
8. Rinse twice, each 3 minutes.
• Hydroextraction the garment to remove excess water from the washed garments.
1. Load 40 kg garments
2. Set temperature ……………. 75°c to 85°c.
3. Time ……………………. 35 to 40 mts.
4. Time ………………… 10 minutes in cold dry.
It is done on the garments from heavy fabrics like denim and jeans. fading effect are irregularly produced
by fumic stone. Acid wash on denim jeans has become popular owing to its significant contrasts and
attractive appearance in color.
Purposes of Acid Wash on Denim Jeans:
• To get regular fading effect on jeans.
• To increase softness of the denim or jeans.
• “Wash look” appearance is developed.
↓
Wash for cleaning
↓
whitening
↓
softening
↓
Hydroextracting
↓
Drying
↓
Delivery
Recipe:
1st Step: (Desizing)
▪ Lot size: 60 kg batch of denim trouser
▪ M:L 1:10
▪ Add desizing agent 1g/L
▪ Add detergent 1g/L
▪ Temperature: Supply steam to raise temperature 60°c.
▪ Time 20 minutes
2nd Step: (Hot wash)
▪ M:L 1:10
▪ Temperature 60
▪ Time 50 minutes
▪ Drop the liquor
▪ Pre treat the pumic stone with: water potassium per manganate and phosphoric acid for 15
minutes
▪ Load the pretreated stones
▪ Start m/c
▪ Time 7-10 minutes
3rd Step: (wash for cleaning)
▪ Water add @M:L = 1: 8
▪ Add detergent
▪ Temperature:40-50 c.
▪ Time: 10 minutes.
Bleach wash is the process which is done by using strong oxidative bleaching agent. In bleach wash,
bleach chemical is used in water while washing in a tumble washer. Strict washing time is a requirement
with such a wash, otherwise the garment may be overbleached and the color cannot be reversed. Bleach
wash refers to light blue shades of denim. most widely used chemicals are sodium hypo-chlorite, calcium
hypo-chlorite, hydrogen per oxide and potassium permangate.
↓
Drying
↓
Delivery
Recipe:
First Step: Pre-treatment/Desizing
▪ Batch size………………….. 60 kg Denim Long Pant
▪ Add water @ L: R = 1: 9………….. 540 liters.
▪ Start the machine.
▪ Temperature……………….. 60°C
▪ Add Desizing agent @ 0.6 gm / liter ………… 324 gm.
▪ Add Detergent / Antistain @ 1 gm / liter….. 540 gm.
▪ Time………………………….. 15 to 25 mts.
▪ Drop the liquor.
Second Step: Hot Wash
▪ Add water @ L: R = 1: 9………….. 540 liters.
▪ Temperature………………………………… 60°C.
▪ Time…………………………………………… 5 mts.
This wash is done to create an uneven effect like acid wash which is simply known as cloudy effect.
During processing, small pieces of towel are used with bleaching solution which create the actual effect
following by neutralization process.
Desizing
↓
Rinse-Wash
↓
Bleach
↓
Rinse-Wash
↓
Neutral
↓
Rinse-Wash
↓
Hydro Extract
↓
Hot Dryer
↓
Send to destroy and PP spray
↓
Rinse-Wash
↓
Towel Bleach
↓
Rinse-Wash
↓
Neutral
↓
Rinse-Wash
↓
Tint
↓
Rinse-Wash
↓
Softener
↓
Hot Dryer
↓
Cold Dryer
Recipe:
Desizing: For desizing 150-liter water and 50 gm desizing agent are needed. It is done for 20 minutes at
60 ºC.
Rinse-Wash: 400-liter water is needed. It is done for 3 minutes at a cool temperature for 2 times.
Rinse-Wash: 400-liter water is needed. It is done for 3 minutes at a cool temperature for 2 times.
Neutral: 100-liter water and 200 gm hypo are used. It is done for 5 minutes at 450 ºC temperature.
Rinse Wash: 400-liter water is needed. It is done for 3 minutes at a cool temperature for 2 times.
Rinse-Wash: 400-liter water is needed. It is done for 3 minutes at a cool temperature for 2 times.
Towel bleach: For towel bleaching, 2 kg towel and 3 kg sodium hypochlorite are used. The machine
should be in dry condition. Check time is 10-20 minutes.
Rinse-Wash: 400-liter water is needed. It is done for 3 minutes at a cool temperature for 2 times.
Neutral: 150-liter water and 200 gm Meta bi Sulfite are used. It is done for 5 minutes at 500 ºC
temperature.
Rinse-Wash: 400-liter water is needed. It is done for 3 minutes at a cool temperature for 2 times.
Tint: 100-liter water, 1 gm Brown GTL, 200 ml Yellow RL and 200 gm salt are used. It is done for 5
minutes at 450 ºC temperature.
Rinse-Wash: 400-liter water is needed. It is done for 3 minutes at a cool temperature for 2 times.
Softener: 400-liter water and 200 gm Mesoft-CVS Flakes (Cationic) are used. It is done for 5 minutes
at cool temperature.
Quality check
Finishing
Delivery
Silicon wash is an important and common wash in garment washing. It is done to make fabrics softer.
Silicon wash generally is done on all type of fabrics i.e., Twill, Denim, Canvas, Knit, Corduroy. This
wash gives elastic handle, durable softness of garments. Silicon softener is used in the washing machine.
Desizing
↓
softening
↓
Hydroextracting
↓
Drying
↓
Delivery
Actually, it is not machine, it is a dummy. This machine contains one balloon, stand and some pneumatic
signals. Garments are put on dummy, then take air pressure and process is done.
A. Front Loading
B. Top loading/Belly machine
7.9.5 Dryer:
The machine which is used for drying the garments after wash is called dryer. Dryer are basically two
types based on heating process; namely- Gas dryer and Steam dryer. In the gas dryer garments are dried
within short time compare to steam dryer.
Chapter: 08
Finishing Section
8.1 Introduction:
Finishing Department room is the last step of apparel industry. After making complete stitched garments
by sewing section then passed in finishing department for ironing, folding, ploy packing, cartooning to
get this way attractive movement. For this way finishing work complete & ready for due particulars work.
➢ Thread Cutter
➢ Iron
➢ Metal detector
Clean
Measurement check
Final check
Metal pass
Divided by size
Folding
SQ check
Poly pack
Make carton
Carton close
Moved to warehouse
Sort: This step involves separating necessary and unnecessary items. In garment finishing, this means
sorting through equipment, tools, and supplies to identify what is essential and what is not. Unnecessary
items should be removed to reduce clutter and improve workflow.
Set in Order: After sorting, the next step is to organize the necessary items. In garment finishing, this
could involve creating a designated space for each type of tool, arranging them in a logical order, and
labeling storage containers to make it easy to find what is needed.
Shine: The third step involves cleaning and maintaining the work area to ensure it is free of dirt and
debris. In garment finishing, this could involve sweeping the floors, wiping down work surfaces, and
regularly cleaning equipment to prevent buildup of fabric fibers and other materials.
Standardize: This step involves creating standard procedures and guidelines for completing tasks. In
garment finishing, this could involve creating standardized work instructions for each task, ensuring that
all workers follow the same procedures, and using visual aids such as diagrams and pictures to help
workers understand the procedures.
Sustain: The final step involves maintaining the improvements made in the previous steps over the long
term. In garment finishing, this could involve regularly auditing the work area to ensure that it remains
organized and clean, providing ongoing training to workers to ensure they follow the standardized
procedures, and continuously looking for ways to improve the processes to make them more efficient.
Different types of packing are done in finishing section. Following is the most used packing types –
8.6 Cartooning:
After packing, cartooning is done according to apparel size and color.
Carton packing vary according to Buyer’s requirement. Carton pack may be-
• 12pcs/Carton
• 24pcs/Carton
• 36pcs/pack
Chapter: 09
Merchandising &HR
9.1 Introduction:
Merchandising is an important function in the textile industry, and it involves coordinating the
production and sales of textile products. The primary objective of textile merchandising is to
maximize profitability by ensuring that the right products are produced at the right time and at the
right cost. Some of the key responsibilities of a textile merchandiser include:
1. Product Development: Merchandisers work closely with designers and product
development teams to create new textile products that meet customer requirements. They
provide input on product design, costing, and pricing, and ensure that products are
developed according to customer specifications.
2. Costing and Pricing: Merchandisers are responsible for ensuring that textile products are
produced at the right cost and are priced competitively in the market. They work closely
with production teams to determine the cost of raw materials, labor, and other expenses,
and then determine the appropriate pricing for the product.
4. Sales and Marketing: Merchandisers work closely with sales and marketing teams to
promote textile products to customers. They provide input on product positioning,
advertising, and promotions, and work to build strong relationships with customers to
promote repeat business.
5. Quality Control: Merchandisers are responsible for ensuring that the quality of textile
products meets the required standards. They work closely with quality control teams to
monitor the production process, identify any defects or issues, and take corrective action
to ensure that products meet customer expectations.
Overall, the role of a textile merchandiser is critical to the success of textile products in the market.
They play a key role in coordinating the production and sales of textile products, ensuring that they
are produced and sold profitably and meet customer expectations.
↓
Sample sent to third party testing center
↓
Make final inspection for bulk production
↓
Shipment
↓
Send all documents to the Buyer
↓
Receive payment from Bank
SL Subject Job
No.
01 Order received from the The very first work of a merchandiser is to collect order from the
Buyer with details buyer with the detail’s information (Art work, technical sheet).
03 Price negotiation with the In the meantime, Price should be negotiated with the Buyer.
Buyer
04 Confirmation of order and Here price have to fix and collect order sheet from the Buyer.
receive the order sheet
05 Make Buyer requirement Should be prepared proto or fit sample for Buyer’s approval.
sample (Fit, Proto etc.) for
approval
06 Make requisition for bulk In the meantime, make fabric requisition for bulk production.
fabric
07 Make requisition for Make a requisition for the required accessories of that order.
accessories
08 Swatch board making and Should prepare swatch board of required accessories for the
approval Buyer’s approval.
09 Raw material collection All the requisite raw materials have to collect and receive in
and also receive it in factory at right time.
factory
10 Check and also listing Check all the in-hosed material with requisite sheet.
11 Make P.P (pre-production By following Buyer’s instruction make a P.P sample with all
Sample) with all actual actual.
12 Pre-production meeting Before going into the production, have to arrange pre-production
meeting for smooth production.
13 Start bulk production Finally, you have to go into bulk production.
14 Collect daily production Regular production and quality report should be collected here in
and quality report regular basis.
15 Make online inspection by During bulk production, have to make online inspection by strong
strong quality team quality team.
16 Sample sent to third party For making a strong approval about the quality of the product,
testing center have to send sample in third party testing center.
17 Make final inspection for After completing bulk production, make a final inspection for the
bulk production order.
18 Shipment After making final inspection of the product, all the garments
should send to the Buyer.
19 Send all documents to the All the documents about the order should send to the buyer after
Buyer sending the full order quantity for receiving payment.
20 Receive payment from Finally receive the payment from the Bank.
Bank
to producing clothing, footwear, or fashion accessories, we will typically use what is called a Time
& Action Calendar to monitor the projects progress. The calendar is also sometimes referenced as
a TNA or T&A calendar. This is essentially a detailed to-do list that covers all the various steps of
the production process. The goal is to create a fairly accurate method to evaluate and maintain the
status of a project and the length of time it would realistically take to complete the project.
When creating an apparel manufacturing time & action calendar, it should include the date the
order is received all the way to the time that the product will be delivered at its final destination.
This would include manufacturing schedules, transit dates for freight, approval times, etc.
From the time the order is received to order completion a large number of tasks of various duration
and requirement of resources are involved. The process is complicated because the tasks do not
always follow one directly after the other in an orderly manner. Some process can’t begin until
another process completes. Other processes are completely fine running at the same time as others.
There are many moving parts during the order production process that must be considered. A very
detailed plan with well-defined responsibilities is must for each order to be successful and meet its
delivery schedule. The business of clothes manufacturing is not often a business that is a “One
Man Show”. It is team work both internally within one’s own company and team work between
various suppliers. It is critical that all members of the supply chain are informed of the program’s
status. Moreover, all tasks have to be accomplished with in a given time frame to ship out the
garments on time.
Production managers prepare a plan in a spreadsheet (typically an excel file) listing down key
processes in one column and planned date of action for each process is noted in another column.
The file should include ever step in the process and the production manager should receive advice
from various suppliers to properly complete the document. For example, the label manufacturer
will need to advice the number of days it will take them to produce the labels and the number of
days transit to reach the cut & sew facility. The hanger, zipper, and button manufacturer would
need to do the same. The production manager collects all the data and inputs the dates onto the
calendar. In addition to the components, they also determine the amount of time needed for
sewing, swatch approvals, factory inspections, transit times, etc.
Once TNA calendar is created, it should be shared with other people and companies that are
involved with the project. It is important that each supplier in the chain meets his or her deadlines
or it will have a negative effect on other aspects of the project. For example, the fabric mill cannot
begin production of fabric until approval swatches are sent to the buyers, reviewed, and approved.
What happens if the mill schedules 3 days for approvals, but the buyer declines the swatch? The
mill will need to make new swatches and re-send for approval. This will take far more than three
days. If the production of fabric starts later than originally planned, that means that the cutting &
sewing of fabric will begin later than originally anticipated. This will push the entire project back
and potentially result in a late delivery to the buyer. It is important to plan in extra days for the
unexpected.
In addition to creating a T&A Calendar, it is important to “maintain” the file. If one date pushes
back, it should be added to the calendar so that the entire list gets updated to new dates.
The TNA schedule processes are executed on daily basis so that all companies evolved know
whether an order is on track or becoming delayed
In the apparel manufacturing industry, the TNA is a perfect technique for tracking and following
up of important milestones during the pre-production processes and production process to ensure
timely delivery within an assigned delivery date requirement.
The chart consists of time frames listed for every action planned (major ones) and these actions
need to be achieved on time according to the chart. The purpose of TNA is to cross check at
frequent intervals, whether the planning is being executed properly and on time. TNA is especially
useful when a buyer requests to know the current status of execution of an order.
Buyer will not accept any delay in the garments delivery and if the garments cannot be shipped
out on time, then there will be good possibility that buyer may cancel the order or may ask for air
shipment or Buyer may ask for discount. To avoid all such adverse situation merchandiser, need
to do proper planning to execute any order.
TNA is most important activity for timely shipment. If any merchandiser is able to follow the TNA
properly then it will be not a big challenge to ship the garments on schedules for any production
unit is summery of sampling, sourcing and production activities and their sub activities.
Merchandiser generally makes the TNA on the basis of lead time mentioned by buyer, shipment
date negotiation, order quantity, production capacity. The milestones and key/critical activities
dates are mentioned by buyer while other in-house activities need to manage by merchandiser by
keeping many things in mind. With the help of TNA merchandisers can ensures satisfaction of
each and every step with constant follow ups and in shortest cycle time possible. Rapidly changing
trends of the fashion industry is making merchandising activities more complicated and so TNA.
Merchandiser has to prepare good and flexible TNA by keeping all facts and facets in mind. If
used effectively, a good TNA can help factory to meet production and shipment deadlines, increase
inventory turns, improve customer service, and enhance profits.
ORDER CONFIRMATION
➢ After reviewing the factory's capacity status, quoting the delivery dates
to the client, and checking all the details in the order sheet once received
from the buyer.
➢ Any difference in the order sheet should be communicated to the buyer.
2 ➢ Passing the accurate order sheet to all departments involved, such as
planning, manufacturing, and commercial
SAMPLING
➢ Coordinating all fabric + trims that are required for sampling purposes.
Updating production development team reg. diverse sample
requirements of buyer at various stages (sales man, fit, size set, pp
sample, etc.)
➢ For sampling, coordinate print, embroidery, and wash.
➢ Before releasing samples to customers, all technical aspects of the
samples are checked.
3 ➢ Before releasing samples to customers, we inspect them for all visual
elements.
➢ Checking each sample's quantity needed.
➢ Checking the reach sample's required paper work.
➢ Follow up on the buyer's remarks on each sample.
BULK FARBIC
BULK TRIM
➢ Preparing a pricing sheet/check list for individual trims required for a
style, as well as chasing down the buyer's trim specifics.
➢ Obtaining consent from the buyer for the required trims.
➢ Provide individual trim bookings to the permitted source.
➢ Obtaining the P/I from the most reliable source ensures on-time
delivery.
➢ Monitoring the status of B/B L/C or TT payments.
5 ➢ All trimmings should be sourced from the most commercially possible
supplier.
➢ Maintain contact with suppliers to ensure timely delivery.
➢ Liaise with the retailer to verify that all trimmings are RCVD in the
appropriate amount and quality.
ESTABLISHMENT
➢ Obtaining the suitable artwork from the buyer for all print/embroidery
projects. Developing the design in the most efficient manner feasible.
➢ Provide capacity reservations for the printing/embroidery plant ahead of
time.
➢ submitting a print/embroidery strike off for approval by the buyer
6 ➢ Providing the print/embroidery facility with an approved copy of the
strike off.
➢ Negotiating with subcontractors on price.
➢ To ensure a smooth production flow, keep track of the panels delivered
and received dates.
➢ For general difficulties, communicate with the provider.
MEETING
Unit Cost: Unit cost mean cost of single garments. It can be FOB, Cnf or C.I.F.
Goods Description: Description about goods which can be long or shortin Top orBottom
wear.
There are two types of source Ha-meem Group uses for recruitment:
• Internal source.
• External source.
We try to discuss all relative sources which are used for recruitment in Ha-meem Group.
The purpose of job posting is to encourage employees to seek promotion and transfers the
help the HR department fill internal opening and meet employee's personal objectives. Not all
jobs’ openings are posted. Besides entry level positions, senior management and top stuff
positions may be filled by merit or with external recruiting. Job posting is most common for
lower-level clerical, technical and supervisory positions.
needs and other commitments are the common reason. Some might gladly stay if they could
rearrange their hours of work or their responsibilities Instead, they quit when a transfer to a
part-time job may retain their valuable skill and training. Even if part-time work is not a
solution, a temporary leave of absence may satisfy the employee and some future recruiting
need of the employer.
9.19.3 Advertising:
Want ads describe the job and the benefits, identify the employer, and tell those who are
interested how to apply. They are most familiar form of employment advertising for highly
specialist requites, ads may be placed in professional journal or out of town newspaper in
areas with high concentration of the desired skills
Development is a related process. It covers not only those activities, which improve job
performance, but also those, which bring growth of the personality; help individuals to the
progress towards maturity and actualization of their potential capacities so that they become
not only good employees but also better men and women. In organizational terms, it is
intended to equip person to earn promotion and hold greater responsibility.
Chapter: 10
SWOT in Ha-meem
10.1 Introduction:
Chapter: 10
Strengths:
Diversified Business Portfolio: HA-MEEM group has a diversified business portfolio which
includes textiles, renewable energy, power, and real estate. This helps the group to spread the
risks associated with any one particular business.
Modern Production Facilities: The group has modern production facilities with state-of-the-
art machinery and equipment, which enable them to produce high-quality products and
maintain a competitive edge in the market.
Strong Financial Position: HA-MEEM group has a strong financial position with a high level
of liquidity and low debt-to-equity ratio. This provides the group with the necessary financial
resources to invest in new projects and expand its existing businesses.
Strong Brand Image: HA-MEEM group has a strong brand image, which has been built over
several years of delivering high-quality products and services to its customers.
Weaknesses:
Dependence on the Textile Industry: HA-MEEM group is heavily dependent on the textile
industry, which makes up a significant portion of its revenue. Any downturn in the textile
industry could negatively impact the group's financial performance.
Limited Geographic Presence: HA-MEEM group has a limited geographic presence, with
most of its operations concentrated in Bangladesh. This limits the group's ability to tap into
new markets and diversify its revenue streams.
Opportunities:
Growth in Renewable Energy: With the increasing focus on renewable energy sources, HA-
MEEM group can capitalize on the growth opportunities in this sector by investing in
renewable energy projects.
Expansion into New Markets: HA-MEEM group can expand its operations into new
markets, both domestically and internationally, to tap into new growth opportunities and
diversify its revenue streams.
Threats:
Competition: HA-MEEM group faces intense competition in all of its business segments,
which could impact its market share and profitability.
Chapter: 11
11.1 Introduction:
HA-MEEM Group has a strong commitment to corporate social responsibility (CSR) and
has implemented various initiatives to ensure sustainability, social responsibility, and
ethical practices. Some of the CSR practices in HA-MEEM group include:
Safe and Ethical Workplace: The group has implemented various measures to ensure the
safety and well-being of its employees, such as providing training on safety and health,
ensuring fair labor practices, and implementing ethical workplace practices.
Community Development: The group has implemented various initiatives to support the
development of local communities. This includes supporting education, healthcare, and
providing employment opportunities.
Philanthropic Initiatives: HA-MEEM group has also been involved in various philanthropic
initiatives to support various social causes, such as disaster relief, poverty alleviation, and
supporting disadvantaged communities.
Ethical Business Practices: The group has implemented ethical business practices and has
a zero-tolerance policy towards corruption, bribery, and other unethical practices.
Chapter: 12
Conclusion
12. Conclusion:
The textile industry is a complex and diverse industry that involves many different processes,
technologies, and materials. Interns gain valuable knowledge and experience in the industry
by being exposed to these various elements and by working in different departments of a
textile company. Interns play an important role in the industry, as they are able to contribute
fresh perspectives and ideas, and they can also learn from the experienced professionals
around them. The textile industry faces many challenges, including issues related to
sustainability, supply chain management, and quality control. Through our work and research,
interns can help identify and address some of these challenges. The textile industry is
constantly evolving, and it is important for textile companies to stay up-to-date with the latest
trends, technologies, and market demands. Interns can help companies stay ahead of the curve
by providing insights and recommendations based on their research and observations.
Internships are valuable learning experiences that can help prepare students for future careers
in the textile industry. Through this internship, I can develop important skills, such as
communication, problem-solving, and teamwork, which will serve them well in any industry
or career path they pursue.
In conclusion I can say that this internship report is really essential for every student to get
idea about textile industry. By completing this report, I have got overall idea of RMG sector
and these may be helpful to know about the technical and management knowledge of garments
industry also these sector related organizations. This is a huge sector and yet to discover the
whole.
I want to thank my department Head for giving me great opportunity of learning. This
Internship program will help me in the further challenges of life. I try my best to make this
project enriched with lots of apparel related documents. Ha-Meem Group is really a good
experience for me because every person of there so much helpful and give me the proper
methods of practical learning. So, at last, there is a hope of eradicating all the obstacles and
become the leader of garment industries in near future.
The RMG sector earns the majority of Bangladesh's foreign currency. As a result, it is self-
evident that the development of this industry would bring our country good fortune, and as
Textile Engineering graduates, we must devote our earnest efforts to the future advancement
of RMG and associated industries. It is one of the main RMG producers, and it provided us
with the opportunity to participate in two months of industrial training, which was highly
valuable to us. Because no knowledge, particularly in the field of Textile Engineering, can be
fully realized without hands-on experience. It provides us with a fantastic opportunity to blend
our theoretical and practical expertise. Modern manufacturing equipment, worker welfare, and
good management are the keys to a company's success, all of which are carefully maintained
at the HA-MEEM Group (CCL). We genuinely believe that this experience will provide us
with the confidence we need to put our skills to work in this field.
Chapter: 13
Reference
I. Primary Data: We are working practically two months in “Ha-Meem group” to obtain
all the information that requires preparing this report.
II. Secondary Source: Different published materials, internet, library works.
1. http://en.wikipedia.org/wiki/Bangladeshi_RMG_Sector
2. http://www.bgmea.com bd /c hart/total_product_export#.VX8S4fmqqko
3. http://www.scribd.com/doc/55039857/6/LITERATURE-REVIEW
4. http://textilecalculationblogspot.com/2014/11/fabric-consumption-formula-for-pant-html
5. http://www.slideshare.net/PriyambadaKhushboo/apparel-manufacturing process?related=1
6. http://www.iiste.org/Journals/index.php/IKM/article/viewFile/6679/6822
7. Introduction to apparel merchandising, Engr. A.J.S.M. Khaled
8. Apparel Merchandising, Jermy A.Rosenau, David L.Wilson, and book
9.https://apparelbrif,wordpress.com/merchandising-term/apparel-garment-consumption-
costingt-shirtspants/