Professional Documents
Culture Documents
Garments Manufacturing Technology by Saiful Azam
Garments Manufacturing Technology by Saiful Azam
By:
Md. Saiful Azam
Md. Abu Saleh
Khondokar Abu Nafiz
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l0.0l.Interlining. ........265
10.02. Typesorinte.linin;..................... ..265 -266
1, Sewn Interlining
2. Fusible Interlining
10.03. Condition of fusing.... ...266 -268
10.04. Types of fusible interlining. ......268 -270
1) Polythene coated interlining
2) Poly propylene coated interlining
3) Poly amide coated interlining
4) Polyester coated interlining.
5) PVC coated interlining
6) PVA coated interlining
7) Cellulose acetate coated interlining
10.05. Properties of fusible interlining. .270 -271
10.06. Types of fusing. ...271 -272
10.07. Defects of fusing.... ....272 -273
10.08. Different types of fusing machine .......273 -276
10.09. Quality control in fusing.. ........276 -278
10.10. Methods of resin coating.. .......278 -280
11.01. Garments Washing.....f .... .....281
11.02. Garments washing first started in Bangladesh........28l
11.03. Objects of Garments Washing. ..........281 -ZB2
I I .04. Effects of Garments Washing. .. .... .....282
1 1.05. Advantages of garments washing. ......282
11.06. Machines in a Garments washingfactory. .....283
11.07. Garments washing machine. ..,..283 -284
11.08. Types of Garments Washing. .............285 -294
I1.08.01. Normal Wash. ..........285 -287
I1.08.02. Soft Wash. ......287 -ZBB
I1.08.03. Pigment Wash. .......288
11.08.04. Bleach Wash... ........288 -290
11.08.05. Caustic Wash... .....290 -292
I I "08.06. Stone Wash .....292 - 293
1 I .08.07. Whitening Wash. ....293 - 294 ..
1 I .08.08. Acid Wash ....294
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12.01. Pressing. ....295
pressing
12.02. Objects of ........295 -296
pressing
12.03. Categories of ...296 - 297
& methods.
12.04. Pressing equipments ........297 -300
finishing.
i2.05. Garments ........300 - 301
12.06. Label. ......301
12.0T.lnternationalCare labelingcode.. .......301 -304
12.08. Types of necessary components of a shirt:.....304 - 306
I2.08.1. Types of pocket according to style..........304
12.08.2. Types of cuff according to style..............305
12.08.3. Types of collar according to styIe............305
12.08..1. Types of button according to hole...........306
i 2.08.5. T3,pes of button according to raw material.306
12.08.6. Button used.according to ligne number......306
13.01. Definition of euality. ...307
13.02. Quality Assurance &...... ........307
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needlework; tablet weaving; and lace-making. Construction
rnethods such as sewing, knitting, crochet, and tailoring, as
well as the tools and tecliniques employed (looms, sewing
needles, and pleating) and the objects made (carpets,
coverlets) all fall under the category oftextile arts.
1.01.2. Functions:
From early times, textiles have been used to cover the human
body and protect it from the elements; to send social cues to
other people; to store, secure, and protect possessions; and to
soften, insulate, and decorate living spaces and surfaces.
The persistence of ancient textile afts and functions,
and their eiaboration for decorative effect, can be seen in a
Jacobean era portrait of Henry Frederick, Prince of Wales by
Robert Peake the Elder (above). The prince's capotain hat is
rnade of felt using the most basic of textile techniques. His
clothing is made of woven cloth, richly embroidered in silk,
and liis stockings are knitted. He stands on an oriental rug of
wool which softens and w'arms the floor. and heavy curtains
both decorate the room and block cold drafts from the
window. Goldwork ernbroidery on the tablecloth and curtains
proclaim the status of the home's owner, in the same way that
the felted fur hat, sheer linen shirt trimmed with reticella lace,
and opulent embroidery on the prince's clothes proclaim his
social position.
1.01.3. Textiles as art:
Traditionally the term art rvas used to refer to any skill or
mastery, a concept which altered during the Romantic period
of the nineteenth century, when art came to be seen as "a
special faculty of the human mind to be classified with
religion and science". This distinction between craft and fine
art is applied to the textile arts as well, where the term fiber art
or textile aft is now used to describe textile-based decorative
objects which are not intended for practical use.
- 023 - out,of.384.
however, the great expansion of the ready-to-wear industry
coincided with and was partly the result of the tremendous
urbanization and the great wave of immigrants that came to
the U.S. in the last decades of the l9th century and early
decades of the 20th. Industrial cities such as Cleveland also
experienced rapid growth, and it was during this period that
Cleveland's ready-to-wear clothing industry blossomed. The
early entrepreneurs of the clothing industry in Cleveland rvere
often JEWS & JUDAISM of German or Austro-Hungarian
extraction. Their previous experience in retailing prepared
them for the transition to manufacturing and wholesaling
ready-to-wear clothing. One example was Kaufman Koch, a
clothing retailer whose firm eventually evolved into the
JOSEPH & FEISS CO., a leading manufacturer of men's
clothing. The company still exists in the early 1990s, although
it is no longer locally owned. The entry-level manufacturer
needed relatively little capital to launch a garment factory. H.
Black & Co., which would become a major Cleveland
manufacturer of women's suits and cloaks, started out as a
notions house. The Black family, Jews of Hungarian origin,
decided to produce ready-to-wear clothing based on European
patterns in their own home. Later, fabric was contracted out to
home sewers and then returned to the factory for final
assembly. This system of contracting was widely practiced at
this stage of the garment industry's development, but by the
close of the l9th century home work had been generally
superseded by factory production. Garment manufacturing
started in the FLATS, but in the early 20th century, it was
concentrated in what is now called the WAREHOUSE
DISTRICT, an area bounded by W. 6th and W. 9th streets and
Lakeside and Superior avenues. L. N. Gross Co., founded in
1900, was one such firm in the growing garment district,
specializing in the production of women's shirtwaists. Many
women wore suits, and the separate shirtwaist provided a
:.077.:,avt qf-i384-
in the men's garment factories, successfully waged organizing
campaigns (see AMALGAMATED CLOTHING AND
TEXTILE WORKERS UNION). Some owners acquiesced;
othcrs resisted or simply closed their doors. The process of
decline in Cleveland's garment industry began during the
1930s. During World War II, the industry was once again
geared fcrr war production. Factories produced uniforms, knit
scarves, and parachutes. LION KNITTING MILLS was
farnous for its production of the knitted Navy watch cap.
Following the war, a nunrber of garment manufacturers were
unable to adjust to new' market conditions and to new price
levels. But while some companies fell by the u,ay, new and
vigorous garment factories grew, especially in the 1950s.
Among them was Bobbie Brooks, founded by MAURICE
SALTZMANT, and the Dalton Co., organizedby Arthur Dery.
In fact, the Cleveland garment industry was still so large and
influential in the 1950s that Cleveland manufacturers were
able to convince the Phoenix Dye Works of Chicago to
relocate in Cleveland, where many of its customers were
located. Throughout the years other businesses ancillary to
garment manufacturing also flourished in Cleveland. The
garment industry is traditionally a low-paying industry. and
rising Iabor costs aggravated the industry's problems.
Although most of the large Cleveland manufacturers were
unionized, unionization itself did not necessarily mean that
one company had an unl-air advantage over another. The city's
garment unions, holever, generally sought and received wage
settlements above the national minimum. Labor costs were
considerably less in the South, and Cleveland manufacturers
as ,"vell as garment and textile rvorkers throughout the U.S.
faced groiving cor':rpetition from lower-paid workers in other
parts of itr're ivorld. Fcr example, knitwear and other textile
protiucts prodLrced in South Korea, Taiw-an. Hong Kong, or
Singapore r:ould be sold in ihe U.S. at substantially less than
GaLrrrrg*f4 - +
Talile 1: Hey rnaeroecouomic iudicators, 2001-1006
Qowce:AD$
Otherfextlel,,,,,''.
I 135.49
. . I ::i ij:.:! ; :::r i._.:: tr _r r: ar i. .
Others 688 81
Total E.qrorts 7,601,99
.035 . out.of.'384-
Back tacking:
Approximately lcm or small stitch backward at the beginning
and finishing of sewing and thus securing of the sewn end so
that the thread could not be loosed easily.
Backing:
Linen or a piece of other fabrics inserted inside the apparel at
certain places so that they could bear & sustain the external
pressure.
Balance:
Adjustment of different sections of apparel with the human
body in according with the weight, shape & appearance in
general& adjustment of front and backside length.
Basic block:
The pattern is made in accordance with the area of different
part of the human body & their flexes & folds without
allowance & style.
Bar tack:
Re-stitching over a very short length to give and increase the
area a high load bearing strength. (E.g. belt loops & pocket
corner are bar tacked)
Basting:
Prirnary & temporary stitching before final stitch with a view
to facilitating accurate placement is called basting. Basting
could be done either by hand or machine.
Bespoke: {a
The apparel made for the specified individual after taking his
body measurement.
Bust point/Body rvidth/Chest:
Most conspicuous place of the chest is bust point (bunny).
Bodkin:
A srnall device used for rnaking holes in the fabric.
Box pleat:
A special shape is given to cloth by folding it to make the
cloth along or expandable that is flexible.
C.F. Line:
The straight line bottom to up vertically along the middle
point of the body front of the shirt or jacket.
Channel:
A narrow and long passage is made with multi fold cloth
inside the apparel, which is called channel ordinarily such
channel is made to place cord or something like that inside it.
--..037.- ogt,of,i384-
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Closing:
It is operation carried out by whiclr the side seam of the
apparel is attached or lining is attached to the fore part.
Collar:
It is part of apparel, which stays spread around the neck.
Collar stand:
It is aparl of the collar, which stands vertical along the neck.
Crutch/Crotch:
The place or area along which the inside two legs joins
together.
Color bleeding:
It is the pigment or dye or color of a cloth that is parlly gone
into the water if such colored cloth is soaked in water or
solvent or suck color or pigment dye come our from one place
to another and is stuck place near by suck characteristics is
color bleeding.
Crease:
Any kind of folding in cloths.
Crocking:
The act of taking out color from the dry & wet cloth by
rubbing or scouring.
Back rise:
It is the measurc from crotch intersection point, along centre
back seam following curve up to waistband top edge (Unless
otherwise specified).
Back length (H.P.S.):
It is the measure from high point of shoulder down to bottom
edge of garment.
Back length (C.B.N.):
It is the measure from centre back neck seam or edge down to
bottom edge of garment.
038 -out,of,.,364:
=
Backing:
An extra warp or filling, or both, woven or knitted into the
back of a fabric to give it support or additional weight is called
backing.
Basic block:
Assimilating of diagram of net dimension on papers each and
individual part without any allowance which is called pattern
and this is called basic block.
Bounded ryare house facilities:
This facility allows for export oriented factories to import
their raw materials and store it.
C&F':
Clearing related with importer and forwarding related with
exporter. If the price of the goods is mentioned in invoice
including transport cost then it is called C & F.
C.I.F.:
If the price of the goods is mentioned in invoice including
transport cost and insurance cost then it is called C.I.F.
Chest/bust:
Garment closed measure straight across front of garment at
lowest point of armholes or at specified level. (For pleated
back, measure with pleats closed.)
Counter sample:
The sample which is followed by the approved sample is
called counter sample.
Category:
Category is a number which indicates what type of fabric is
used for making the particular garment and it also indicates
the type of this garment.
Generally, it is of three digits:
First digit indicates fabric type (such as cotton, polyester).
.039.-out.of =384"
Last two digits indicates type of the garments (such as shirt,
pant).
Dart:
It is used for tightness of garments. It is made by stitching the
fabric sewing the fabric. It is used for removing wedge from
the garments surface.
Darning:
Repairing holes and damages in cloth by the interlacing of
darning yarn, by hand or sometimes by sewing machines.
In the other words, using a darning stitch to sew a pattern into
lace mesh or textile ground, as in enrbroidery or crewel work.
Double faced:
Cloth with both end similar & also both sides could a laced as
face side either way.
Drape:
The state or quality of haw a hung end of a cloth comes of
when such cloth is hung from either end. The texture quality
of the fabric, staple kind and also the finishing determine the
draping quality of cloth in question.
Donkey:
It is special type of dressing board with the help of which
pressing could be done without creasing the cloth of the
apparel in places.
Drop loop:
The technique of placing belt loop a little below from the
upper end of the waistband of the trouser (normally l-2cm).
Drop loop stops the possibility of belt moving above the waist
band.
Durable press:
It is a particular kind of finishing treatment by which it is
possible to give specific sharp size and crease to the cloth or
- 042 :-out,of:384-
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Handle:
It is a characteristic of fabrics that is perceived by touching,
squeezing or rubbing them.
Hood width:
With front edge even, measure across the middle of hood from
front to back.
Hood height:
With hood folded in half and front edges together, measure
from neck seam at high point of shoulder up to top seam or
fold.
Hip:
At a specified level down from waist seam and gatment
closed, measure straight across garment, from one edge to the
other.
Invoice:
After sending the garments goods to the importer country, the
documents mentioning the price is sent to the buyer for
collecting is called invoice.
Interlining:
Interlining is one kind of accessories which is used between
two layers of fabric in garments to support, re-enforce and
control areas of garments and to retain actual shape. It rnay be
applied on base fabric by sewing and bonding.
The fabrics which are used as interlining are made from
cotton, nylon, polyester, rvool and viscose. Sometimes
finishing is necessary to improve its properties i.e. shrink
resist finish, crease resist finish.
Inseam length:
Along inside seam of leg, measure from crotch seam down to
bottom edge of leg opening. Rib/elastic bands included in this
measurement.
- 044 = out'of=384-
Pleat:
It is used to increase the fullness of the garments. It is
generally made by folding the fabric.
Darl & Pleat both are used in the back part of the Men's shirt
usually.
Quota:
il
Fig: Dart (squeezcd|
It is an agreement
Fig: Pleat (expandcO
- 046,.- out,of,384-
Ooeration Job Method
04. After getting all the Manual
Sample Making specs the sample is
made and sent to the
buyers for approval to
rectifu the faults.
05. The critical path is Manual
Basic identified i.e. the
Manufacturing problems during the
Difference several onerations.
06. After rectifo the faults, Manual
Approved sample is again sent to
Sample buyers. If it is ok, then
it is called approved
samole.
07. . Fabric required Manual
Costing , Making charge
. Trimmings
. Profits
08. Production Add allowance with net Manual /
Pattern dimension. Computerized
09. It is done according to Manual/
Gradins different size. Computerized
10. IVlarker is a thin paper Manual i
Marker which contains all the Cornputerized
Making components of all sizes
of a oarticular stvle.
11. Fabric Fabric is spreaded in a Manual/
Snreadins lay form. Computerized
12. To cut fabric according Manual /
Cutting to the dimension by Computerized
special type of cutter.
: 48:.o-ut of -384-
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3. Sewing section: Sewing.
4. Finishing section: Ironing/packing
Except those there are two more sections as follows:
a) Embroideringsection
b) Washing section: Store washing, Enzyme washing.
2.07. Difference between Tailoring & Garments
industries:
Tailorins Garments industries.
Tailoring is for a small Garments industries are for
grouD ofoeoole. mass oeoole.
A garment is made for a Garments are made for many
oarticular Derson. oeoole at a time.
Body measurement of a Standard body
particular person is taken measurements chart is taken
into an account. into a account.
No grading is done. Grading is done for a
parlicular size.
Garment can be made by Many machines are needed
one or more numbers of here for production of a
machines. sarment.
Initial set up cost is low. Initial set up cost is hish.
Single plyllay of fabric is Multiple plies of fabric are
used durins cuttins. used durine cuttins.
Fabric wastase is hish. Fabric wastase is less.
Risk of loss is least. Risk of loss is hish.
No need of pattern. Pattern is a must.
It takes more time to make It takes comparatively less
garments. time.
2.08. Category:
This is a unit of classification system for industrial products.
According to the STANDARD INDUSTRIAL
CLASSIFICATION, this is used for gathering statistics on
1051,::.ou.t-of -384.
inii"c.s
2.09.3. U.S.A non-o uota Catesories
Catesorv Descriotion
239 Children sarments.
JJJ Suit Wpe coat. MB.
345 \_ Sweater
349 Bodv supoort sarments.
350 Dressins sown- Duster.
352 Underwear.
359 Other sarments.
360 Pillow cases.
361 Seat.
363 Towelwith pile.
369 Twisted ouilt & travel russ.
631 Synthetic ash sloves & Satin.
650 Dress sown. Robe.
659 Other sarments.
835 Coat made by mixed of silk & vegetable
ash W&G.
836 Dresses.
840 Ladies shirt & blouse.
842 Skirts.
84s Sweater, Vase.
8s9 Other sarments.
899 Table linen knitted or crossed.
2.09.4. E.E.C Ca Descri tron:
UT
Category Descrintion
2 Cotton fabrics
J Disk fabrics
4 T- shirt
J Jersey, Pullover
6 Trouser
7 Blouse
.- 055:.out af.:384-
340 I 640 1,954,654 2,091,148
341 1,619,254 1,732,602
342 / 642 280,1 56 299.767
347 I 348 1,457,327 I,559,340
3s1 / 65r 444.964 476.092
634 325,000 347,750
635 2t0,562 225.301
638 i 638 1.096.s68 1,173,328
614 679,027 725.489
64s / 646 2s7.517 275,543
647 / 648 916,559 980.718
847 463.485 49s.929
2.09.7. Canada - Bangladesh Bi- Lateral Quota
ement: 1992-93:
Asreementz
Label ( Accordins to oiece)
CatesorY 1992 1993
0l (49) t.402.552 887.213
02 G6\ 807"450 2t2.731
03 A (37) I .l 84,561 1,026,728
03 A (37\ 323.t84
04 B2\ 189,372 929.682
0s (3e) 1,310,769 1,718,733
05A 390.565
06 (42\ 1.607.872 1.605.782
06 A (42\ 1,071,914
06 B @2\ 535.957
07l08A 3.693.000
07l08B 333.938
08c 5,408,333
14 180.s64
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2.10. New Rules of Origin and Fake GSP certificate:
2.10.1. New Challenge for Bangladesh Garment Industry
GSP (Generalized System of Preferences) is a unilateral
preferential trade arrangement, which is governed by a set of
rules different from those applicable in regular trade. The rules
are based on the rationale to promote industrialization of the
developing countries through a reduced or zero-duty access to
the developed importing countries. The rules of Origin for
GSP, thus, tend to be tougher than that of regular trade. Unless
the required value addition is done, an export item will not be
considered eligible under GSP. It can still be exported, but a
regular tariff will be imposed, for LDCs (Least Developed
Country) quota will not be there and GATT (General
Agreement on Tariffs and Trade) rules of origin will be
applied.
EU (European Union) proposed new rules of origin criteria
requiring products from LDCs to have 30o/o local value to get
riuty-free access to EU market. The new rules of origin are
supposed to come into effect in the beginning of 2009.
Local textile and knitwear sectors fear that the
proposed single-stage rules of origin criteria would put their
industries In danger of losing market to advanced textile
manufacturing countries. They have urged the European
Commission to raise local value addition threshold to 45o/o to
help Bangladesh's dressmakers benefit from the revised GSP.
Bangladesh Textile Mills association (BTMA) leaders opined
that the proposed rules of origin would discourage investments
of textile entrepreneurs in local backward linkage industries,
and suppliers from China, India and Pakistan would grab local
of fabrics and yarns for export-oriented garment
market
industries.
The two-stage rules of origin effective frorn 1997 provide that
to get duty-free access under EU's GSPs, LDC exporters
require significant local value additions (80% for Bangladesh)
- 062,-.out.,of -381-
deal", said Anwar-ul Alam Chowdhury Parvez, president of
Bangladesh Garments Manufacturers and Expofters
Association.
"We've exported a small quantity, but it's a giant leap
for the industry. It is projected that India's ready-made
garments market would top 100 billion dollars by 2012. Our
target is to get a slice of this huge market," he added.
Bangladesh, which has a two-billion dollar trade gap
with India, last year, exported more than nine billion dollars of
textiles, mainly to the United States and the European Union.
The country's textile export market is growing rapidly,
spurred by a week Bangladeshi currency and a sharp increase
in production costs in China & Vietnam, its main globai rivals.
The improvement in trade relations comes against a backdrop
of sometimes tense relations between the Neighbours.
India helped Bangladesh win independence from
Pakistan in 1971. br.:t ties in recent years have often been
soured by border Skirrnishes for w'hi,:h both sides blame the
crther.
India officials rerularly ilcuuse Bangladesh of
harbouring militants figlitlng New Delhi's rule in India's far-
flung northeast.
Dhaka denies the charge and says New Delhi allows
Bangladeshi criminals to take refuge on its soil.
-.out of -384-
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Garments Pottern
3.01. Pattern:
An ornamental design or decorative element in a fabric.
Pattern may be produced either by the construction of the
fabric or by applying designs, by other means. For example,
printing, embossing, or embroidery.
On the other words, it is a hard paper which is made by
following all the specifications of each and individual
components.
3.02. Pattern making Tools:
To work efficiently, the patternmaker must have the proper
tools and supplies. To communicate effectively in the
workroom and to minimize errors due to misunderstanding,
the patternmaker should know and understand tenninology.
This chapter introduces tools, supplies and definitions of terms
used in industry.
The professional patternmaker arrives on the job with all tools
required for patternmaking. Each tool should be marked with
an identity symbol and transported in a carrying case. Tools
may be purchased from apparels supply houses. art stores,
department stores, and yardage stores. Specialized tools, such
as a rabbit punch used to punch pattern holes for hanger
hooks, are generally supplied by the manufacturer. The
following tools are used as the patternmaking tools:
a. Straight pins:
o Dress maker silk # l7 for draping and fittings.
b. Straight pin Holder:
. Pincushion, or magnetic holder for wrist, table
, ..0-66,.,9, 91 of 13!Q-