AN INTERNSHIP REPORT ON AMA SYNTEX LIMITED

BY
KHAIRUL ISLAM BASHER
ID: 191051001, Group: A
Batch: 35

AN INTERNSHIP REPORT SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENTS

FOR THE DEGREE OF
BA(Hons) IN APPAREL MANUFACTURING MANAGEMENT &TECHNOLOGY

UNDER THE FACLTY OF DESIGN & TECHNOLOGY

I ACCEPT THIS INTERTNSBHIP REPORT AS CONFORMING TO THE REQUIRED STANDARDS:

………………………………………………………………………………………………..
FARJANA MITA

ADDITIONAL HEAD AND INTERNSHIP SUPERVISOR

DEPARTMENT OF APPAREL MANUFACTURING MANAGEMENT & TECHNOLOGY

DATED THIS 10TH DAY OF May, 2023, IN AMMT CAMPUS, SMUCT, AND DHAKA, BANGLADESH
 AN INTERNSHIP REPORT ON AMA SYNTEX LIMITED
BY
KHAIRUL ISLAM BASHER
ID: 191051001, Group: A
Batch: 35

AN INTERNSHIP REPORT SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENTS

FOR THE DEGREE OF
BA(Hons) IN APPAREL MANUFACTURING MANAGEMENT &TECHNOLOGY

UNDER THE FACLTY OF DESIGN & TECHNOLOGY

I ACCEPT THIS INTERTNSBHIP REPORT AS CONFORMING TO THE REQUIRED STANDARDS:

………………………………………………………………………………………………..
FARJANA MITA

ADDITIONAL HEAD AND INTERNSHIP SUPERVISOR

DEPARTMENT OF APPAREL MANUFACTURING MANAGEMENT & TECHNOLOGY

DATED THIS 10TH DAY OF May, 2023, IN AMMT CAMPUS, SMUCT, AND DHAKA, BANGLADESH
 INTERNSHIP DECLARATION CERTIFICATE

I, KHAIRUL ISLAM BASHER

ID: 191051001

I affirm that this Internship report, submitted in partial fulfillment of the requirements for the award of BA
(Hons) in Apparel Manufacturing Management & Technology under the Faculty of Design & Technology,
Shanto-Mariam University of Creative Technology, Dhaka, Bangladesh is unreservedly mine unless
otherwise referenced or acknowledged. The document has not been submitted for qualifications or other
purposes at any other institution. There is no information in the report beyond the assigned industry.

I will responsible for any kind of claim of this industrial training report.

......................................................
KHAIRUL ISLAM BASHER
Department Of AMMT
10th May 2023

3|Page
 ACKNOWLEDGEMENT
At first i would like to remember the Almighty Allah to give us the successfully the internship program. I
am grateful to the following people and acknowledge that without their valuable contributions, this thesis
would not have been successfully finished.

Farjana Mita, my supervisor, who has not only guided me through the work process but also has provided
her own valuable critiques. She has challenged me on several occasions as an approach to stimulate me
too efficiently implements my exposure on this report.
I am very thankful to the management of Ama Syntex Limited for giving me the opportunity completed
my internship. My sincere gratitude and cordial thanks to Engr. Md Arifur Rahaman, Deputy General
Manager, who assisted me a lot by giving an opportunity for eye opening in this particular sector and
extended an all-out support in all respect for writing this report in the most comprehensive manner within
the specified time frame. MD Sirajul Islam, Senior Merchandiser, Ama Syntex Limited for their kind I
completed my Internship.
Above all, I shall remain ever grateful to many of my friends and other well-wisher that extended
their helping hands to me during my study work.

Khairul Islam Basher.

4|Page
 ABSTRACT

This Report is prepared as per requirement of the internship phases of BA Honors in AMMT of Shanto
Mariam University of creative Technology. The study is based on overall industrial working activities in
Ama Syntex LTD. The main objective of the report is to find out Process which followed by “Ama Syntex
Ltd.” in their overall department activities. This report starts with a general introduction of RMG sector
and “Ama Syntex ltd.” as well as its mission Vision and Product detail. Then this report proceeds onto
the company overview of Ama Syntex Limited.

Industrial training is an important phase of a student life. A well planned, properly executed and evaluated
industrial training helps a lot in developing a professional attitude. It develop an awareness of industrial
approach to problem solving, based on a broad understanding of process and mode of operation of
organization. The aim and motivation of this industrial training is to receive discipline, skills, teamwork
and technical knowledge through a proper training environment, which will help me, as a student in the
field of Information Technology, to develop a responsiveness of the self-disciplinary nature of problems
in information and communication technology.

From this document I am able to learn about dying process procedure, finishing procedure, and lap dip
process. I am able to learn about the garment production process, ironing, folding of the garments,
packaging process. I am able to learn about the quality, quality control process. I am able to learn how
to control quality in every step in making a complete garment. I am able to learn fabric consumption,
carton measurement etc. I am also known about the Merchandising Department. How is it works and
which working Process they follow in the industry, and why it is necessary for a factory.

Through this Industrial Training I am able to gather practical knowledge which will help us in our future
life and which will be helpful my future career. I think this Industrial Training is a constant part for my
academic stage and without this Industrial training my academic study would be incomplete.

5|Page
 TABLE OF CONTENTS

ABBREVIATIONS AND ACRONYMS ............................................................................................ 03

ABSTRACT …………………………………………………………... 05
Chapter 1: Introduction ……………………………………………………………………………09
1.1 ORIGIN OF THE REPORT ………………………..………………………….…10
1.2 Objectives of Internship …………………………………………………..……..10
1.3 Methodology ………. …………………………………………………………….12
1.4 Scope ……………………………………………………………………………..12
Chapter 2: Company Profile ……………………………………………………………………………14
2.1 List of Machinery for Garments ……………………………………………...16
2.2 The Organogram of the administration is as follows ...............................……17
2.3 CLIENTS ……………..…………………………………………………………….17
2.4 Location of all departments …………………………………………………….18
Chapter 3: Merchandising Department ……………………………………………………………...19
3.1. Process Flow Chart of Apparel or Garments Merchandising……………….. 20
3.2. First email to buyer for business development ………………………………..21
3.3. Feed –back from buyer in response to first email …….………………………22
3.4. Fabric Consumption Calculation ………………………….…………………….22
3.5. Consumption Sheet preparation ………………………………..………………23
3.6. Cost Calculation System ………………………………………………………23
Chapter Four: Supply Chain Management ………………………………………………………….30
4.1. Supply Chain Management (SCM) ……………………………………….…….31
4.2. Diagram for Supply Chain Management ………………………………………31
4.3. Supply Chain Management Process …………………………………………...32
4.4. Responsibility for supply chain management ………………………………… 32
4.5. Penalty for shipment delays/ Failure. …………………………….…………….32
4.6. Store Ware house ……………………………………………….………………..33
4.7. Work flow process: …………………………………………..……………………33
Chapter Five: Commercial Department …………………………………………………………….35
4.1. Document Against Acceptance (D/A)…………………………………………. 36
4.2. Documents Against Payment (D/P) ……………………………………………36
4.3. Open Account…………………………………………………………………… 36
4.4. Letter of Credit (L/C) …………………………………………………………….36
4.5. Types of credit……………………………………………………………………36
Chapter Six: Production Department ……………………………………………………………..39
6.1 Sample …………………………………………………………………………… 40
6.2 Different Type of Sample ……………………………………………………… 40
6.3 Sample Procedure ………………………………………………………………41
6.4. Dyeing ……………………………………………………………………………42
6.5. Printing…………………………………………………………………………… 44
6.6. Cutting …………………………………………………………………………….45
6.7. Sewing…………………………………………………………………………… 47
6.8. Finishing …………………………………………………………………………..49
Chapter Seven: Human Resource Department ………………………………………………51
7.1. Human Resource Management ……………………………………………... 52
7.2. Culture Of HRD …………………………………………………………………..52
7.3. Kye Principle Standards ………………………………………………………...53
7.4. HRD Activities ……………………………………………………………………53
BANGLADESH TEXTILE MILLS ASSOCIATION ……………………………………………….54
Bangladesh Knitwear Manufacturers & Exporters Association ……………………………. 56
FINDINGS ……………………………………………………………………………………….……..57
CONCLUSIONS ……………………………………………………………………………………….57
REFERENCE ………………………………………………………………………………………….58
APPENDICES ………………………………………………………………………………………...58
Chapter 1
Introduction
 CHAPTER: 1

Introduction

Bangladesh, the southern Asian country has a population of approximately 164 million people. The
economy of Bangladesh is significantly dependent on agriculture. But it’s great news for the country that,
Garments sector (RMG) sector of Bangladesh has raised as the biggest earner of foreign currency. This
sector creates about 4.2 million employment opportunities and contributes significantly to the GDP.
Readymade garments (RMG) of Bangladesh is powered by young, urbanizing, workers, where most of
them are women.

Apparently the two most important factors behind the success of the RMG industry in Bangladesh are

1. The availability of chip labor and

2. The GAAT/WTO controlled international textile and apparel trading system through the operation of
the multi fiber Arrangement (MFA).

In the RMG sector of Bangladesh, there are more than 5000 garment factories (private statistics) at the
current time, employing more than 12 lack laborers, where 85% of the labor force is women. But,
according to BGMEA the number of garment factories in Bangladesh around 4000. Now, the RMG
industry is the countries largest export earner with a value of over $24.49bn of exports in the last financial
year. It’s great news for us that Bangladesh is clearly ahead of other South Asian suppliers in terms of
the capacity of the ready-made garments industry.

Though, there are various types of garments are manufactured in Bangladesh, but all the ready-made
garments are classified into two broad categories, where one is woven products and another one is
knitted products. Woven products include Shirts, Pants, and Trousers. On the other hand, the knitted
product includes T-Shirts, Polo Shirts, Undergarments, Socks, Stockings, and Sweaters. Woven
garments still dominate the export earnings of the country. From the BGMEA website, it’s seen that Day
by day knitted items production is increasing at a considerable rate and now about 40% export earnings
have been achieved from knitted products.

9|Page
1.1 ORIGIN OF THE REPORT

This report has been prepared as the partial fulfillment of BA program in Shanto-Mariam University of
Creative Technology. To complete the BA program successfully each participants required to undergo
internship program in the organization for three months to learn practical knowledge RMG sector
activities. 'To accomplish the aforesaid requirement, I am assigned as an intern in Ama Syntex Limited
for 3months starting from December, 2022. The topic of my internship report is

Farjana Mita, Assistant Professor And Internship Supervisor Department Of Apparel Manufacturing
Management And Technology, have given me the permission to do the report on this topic.

1.2 Objectives of Internship

To enhance our University learning experience through involvement in industrial and commercial field,
thus enabling to relate theoretical concepts with practical situations;

To develop our ability to evaluate issues and situations critically and propose well considered options and
solutions;

• To develop and enhance my professional awareness and communication skills;

• To know detail about RMG sector.
• Information gathers about commercial.
• Getting idea about shipping procedure.
• Knowledge gather about RMG sector related other organization
• To achieve new idea about knit garments manufacturing process.
• To know about the management and technical process of apparel industry.
• To know the management Procedure in Garments Industry.
• To analyze the recent labor unrest in the garment industry of Bangladesh.
• Opportunity of behavioral theory practice in our garments sector.
• Regularly behavioral theory practice in garments industry.
• Identifying the trade agreements that might affect the export growth.

10 | P a g e
1.3 Methodology

I am preparing this project by visiting a Knit factory and doing class in university and reading book and
collecting data from internet. I m collecting maximum information from my class and when I am work in
the factory. In my class I learn about merchandising process and learn what is their job and in factory I
practically seen what I learn in class, and some information I collect from internet & by reading books. To
object, at first have divided my work plan into two sections

a) Primary research

b) Secondary research

a) Primary research: In this research process I included my all types of outdoor works trips, data
collection, data processing, marketing promotion and applying documents and other search and working
process.

• Factory visiting: Factory visiting is important for my project. Where the merchandising is
working.
• Documentation and photograph: Collecting all information must be stored in computer for
future research. Besides all photograph is very important for this project.
• Interview: To communicate with any specialized person interviews are very important. To take
important it so very important to know the person. It’s very important to prepare the question
before the interview.
• Questionnaires: To research the price and market demand directly from the market and target
customer it is one of the way.
• Data Collection: It is very important to collect the data. From different types of books, journals
and other sources. I have collected my data.
• Data processing: After collecting all necessary information and data I will compare all these
information and arrange according to my work and research plan.
• Market analysis: According to the collection of the information and work plan, I will analysis the
demand and price with help of different survey and questionnaires to the target customer.

b) Secondary research: In secondary research I have included all my documents which I have got from
different books and websites.

11 | P a g e
1.4 Scope

Scope means how many uses for completing this report space. The scopes are given bellow:

• Factory
• Discussion
• Internet
• Some of our senior brothers can help us.
• I can collect information various books and relevant paper what related with apparel industry.

1.5 Limitations:

Limitation refers the obstacles I have to face for completing this report and what I could not cover for this
limitation.

• Time constraint
• Merchandiser doesn’t have enough time to give the information elaborately.
• Short time visit in different work stations
• Lack of organizing chain of command
• Lack of instruction book, and any change. They are following traditional business.
• I may have to suffer for lack of supply chain management.
• Due to high employee turnover rate and lack of good reporting practices in the factory, problems
with collecting data have been faced.

12 | P a g e
 Chapter 2
Company Profile
 Chapter 2

Company Profile

Ama Syntex Ltd.

100% Export oriented Garment Manufacturer and Dyeing, Finishing Knit Textile Mills for open width &
tubular knit fabrics.

Company Address: Plot 936-939, Vill.-Jarun (South), P.O. Kasimpur, P.S. Joydebpur,

Dist. Gazipur, Bangladesh.

14 | P a g e
Company Name : AMA SYNTEX LTD.

Head Office : Blue Ribbon (2nd Floor)

House- 25, Road-7/D, Sector- 9, Uttara Model Town, Dhaka- 1230.

Phone : 880 2 7914248, +8801926676501, 01972166623

Fax : 880 2 48952938

Year of Establishment : 2007

No of employees : 1500 Persons including staff.

Fire Code : Meets all fire code regulations.

Ownership : Private Limited.

Product Range:

• Fabric Various kinds of knit fabrics.

• Tubular & open-end finishing.
• All over print, All kind of Pigment, Discharge,
• Floroscent, Burnout,Foil, Glitter etc.

Garment products : Basic T-Shirt, Polo Shirt, Jackets, Ladies Night Wears, Ladies Dresses & all
kinds of knit items.

Production capacity: Fabric: 15 Tons (24 hours)

Garment products : 8 hours

Item Per Day Per Month

Basis T-Shirt 10,000 2,60,000

Polo Shirt 3,000 78,000

Knitted Trouser 5,000 1,30,000

Production line: 16 Nos Total 18,000 pcs 4,68,000 pcs

Lead Time : Garment products: 65-90 days

15 | P a g e
2.1 List of Machinery for Garments

Name Of Machine Machine Nos

Plain Machine 300

Flat Lock Machine 70

Flat Lock Cylinder Bed Machine 70

Two Needle Machine 20

Kansai Special Machine 20

Four Thread Over Lock Machine 120

Five Thread Over Lock Machine 08

Computerized Bartack Machine 06

Button Hole Machine 06

Button Stitch Machine 06

Rib Cutter Machine 08

Snap Cutter Machine 08

Vacuum Table 26

Needle Director 01

Fabric Cutting Machine 06

Thread Sucker Machine 04

Cutting Table 04

Total 682 Nos

16 | P a g e
2.2 The Organogram of the administration is as follows:

Organ gram of Administration Organ gram of Operation

Chairman Senior manager

Managing director Assistant manager

Executive director Production officer

General Manager Shift in charge

Deputy General Manager Supervisor

Assistant general manager Senior operator

Production manager Operator

Assistant operator

Helper

2.3 CLIENTS:

❖ Gemo ❖ Ardene
❖ Home Plus ❖ Bench
❖ Medicine ❖ Aox
❖ Sebastiano ❖ Sultan
❖ Samsung ❖ France Collection
❖ Front Line ❖ Dark & Cover
❖ Teddy Smith ❖ Whispering Smith

17 | P a g e
2.4 Location of all departments:

There are so many departments are available in the company:

1. Ground floor:
➢ Procurement Room
➢ Store room
➢ Dyeing section
➢ Knitting section
➢ Yarn Room
➢ Buyer inspection

2. 1st floor:

➢ Chairmen Room
➢ Director room
➢ Executive Director room
➢ HR department
➢ Admin department
➢ Production department
➢ Accounts department
➢ IT department
➢ Machine maintenance section

3. 2nd floor:
➢ Compliance
➢ Cutting section
➢ Sewing section
➢ Sample section
➢ Work study department
➢ Welfare department
➢ Finishing section
➢ Quality inspection section

4. 3 & 4 Floor
➢ Sewing section
➢ Finishing section
➢ Quality inspection section

18 | P a g e
 Chapter 3
Merchandising Department
 MERCHANDISING DEPARTMENT

Merchandising
Merchandising is a business on marketing activities responsible for ensuring a products description both
quality and quantity. Merchandising means total responsibility of a Merchandiser. A man who collects
order from customer sourcing raw materials production on time with quality and maintains lead time.
Garments merchandising means buying raw materials & accessories, producing garments, maintaining
required quality level and exporting the garments within scheduled time. Most importance things for a
Merchandiser is:

• Communication.
• Planning
• Production Follow Up
• The responsibility of a smart Merchandiser in handling order at four stages:
• Sourcing for future orders/Buyers
• New Order
• Confirmed Order
• Running Order

Apparel merchandiser:
An apparel merchandiser, also known as a fashion merchandiser, is the person who conceives and
implements merchandising displays in retail environments focused on the sales of clothing and
accessories. She may dress mannequins, create fashion-focused scenes in store windows and design
promotional graphics for in-store promotions. This position normally involves much more than
merchandising. An apparel merchandiser is often the pulse of the retail environment, the person
depended upon to predict fashion trends and incorporate her vision into the store’s inventory. A large part
of her job is to keep her educated on the latest fashion fads and styles around the world and make sure
her store is the first to carry cutting-edge clothing and accessories. When new inventory is being chosen,
the apparel merchandiser is commonly consulted. She provides input on ordering fabrics, colors, sizes
and styles based on her analysis of what is in vogue, coupled with style trends in local demographics.
Every time the season changes, she is relied upon to have the latest information on what is fashionable
and what will bring in the highest revenues. Departments of merchandising

• SD- sells & distribution

• MM- material management
• PP- Production processing

19 | P a g e
3.1. Process Flow Chart of Apparel or Garments Merchandising:

Order received from the Buyer with details

Sample Development

Price negotiation with the Buyer

Confirmation of order and receive the order sheet

Make buyer requirement sample (Fit, Proto, etc) for approval

Make requisition for bulk fabric

Make requisition for accessories

Swatch board making and approval

Raw material collection and also receive it in factory

Check and also listing

Make P.P (pre-production Sample) with all actual

Pre-production meeting

Start bulk production

Collect daily production and quality report

20 | P a g e
 Make online inspection by strong quality team

Sample sent to third party testing center

Make final inspection for bulk production

Shipment

Send all documents to the Buyer

Receive payment from Bank

3.2. First email to buyer for business development

F.K. Company

MATT, Texas, U.K.

Sub: Requesting For Business development.

Sir,

We are pleased to introduce that garment merchandising is the well reputed & specific name in Apparel
industry in Bangladesh since last one decade. Our company deals with many world fames buyers in the
world like Wal-Mart, H&M , Kmart etc. We are pleased attach brief company profile and list of product
along with photograph for your understanding and knowledge about our company.It will be highly
appreciated. If let me know your feedback, so that we sent some sample to your judgment of quality and
If we get the business then you also get the business for a long time.So we are anxiously waiting for your
feedback.

Thanking you,

Md. RAZA

senior Merchandiser.

Dhaka, Bangladesh

21 | P a g e
3.3. Feed –back from buyer in response to first email

XYZ

Ama Syntex limited

Sub: Feed –back from buyer in response to first email

Dear sir,

I am pleased about your company, so I want to make a business with you. So you should send some
original sample include with FOB price.

Best regards,

ABC Group

This is happened in case of choosing buyer by UNION TEX itself but mostly the buyer choose the supplier
and in that case they send a product pack first and then supplier send the product according to their
requirement.

3.4. Fabric Consumption Calculation

The quantity of fabric which is required to produce a garment is called consumption. How much fabric is
required to produce a garment, we can determine it through marker planning and mathematical system.
We can calculate and determine the consumption of fabric by the following two systems:

Marker Planning System

In the system mentioned here studying the range of size, following six pcs of six sizes can be sorted out
from size range. As in XS, S, M, L, XL, XXL Besides these we can choose three pcs of three size or
twelve pcs of twelve sizes for our convenience. It depends on our intelligence and the size range;
thereafter paper pattern can be made by grading to the above garments as per measurement sheet.
Having made the paper pattern it should have to lay each parts of the paper pattern on a marker paper
of similar fabric width. After marking the paper pattern if we measure marker paper to length wise, we will
find an aggregate consumption of six pcs of garment. If the aggregate is divided by six, we will find a
consumption of one pc garment. As such we will find a consumption of one dozen garments from the
above system calculations.

22 | P a g e
Mathematical System
Whatever is the fabric consumption of a garment or whatever quantity of fabric is required to produce a
garment is measured by mathematical system। Mathematical system is a system of rough estimation.
Consumption of a sample garment or consumption as per measurement sheet is calculated
mathematically by measuring the area of length and width of each parts of each pcs of garment.

3.5. Consumption Sheet preparation

For Garment business fabric consumption is very much important and also essential. When Garments
get order inquiry from Buyer then fabric consumption is very much needed to make cost sheet and when
order is confirm then fabric consumption need for give a booking to supplier for fabric. In time of costing
if Merchandiser make a less consumption of fabric then actual need as a result factory has to pay the
money for fabric so the percentages of profit is less and sometime factory has to pay from their own
pocket. The less consumption of fabric very much responsible dos a loss of factory. As like this if
consumption of fabric is more than need then also factory has to face a great loss. Also buyer loses their
attraction or wish of giving the order. For a correct consumption of garments, merchandisers should have
knowledge about the making of Garments. They have to know how to sewing each and every part of
garments and how much extra fabric has to attach with the main measurement foe seam allowance.

Merchandiser has to keep a calculation for Garments sleeve hem, bottom hem, inner facing etc for extra
fabric when they make consumption. Merchandiser also has to keep in head about the Shrinkage
problem, so extra allowance is essential when factory make a pattern.

Fabric Consumption is to made according to as per Garments size ratio for per dozen. Sometimes fabrics
have to cut In bays, so for that extra fabric is needed.

3.6. Cost Calculation System

During the fixation of price following notes are to be followed carefully:

Cost of fabric Cost of accessories /Doz. garments.

C. M (Cost of manufacturing)/Doz. Garments

Cost of transportation from factory to sea port or airport.

Clearing & forwarding cost

Overhead Cost. Commission/Profit.

23 | P a g e
3.7. Cost sheet & consumption sheet preparation.

Running a business successfully requires a lot of financial planning and effective financial management.
A cost sheet can be a way of being aware of all the costs incurred by us on different things while running
a factory or facility. From the knowledge of costs, we can easily think of cost cutting ideas for companies
and institutions. So, you must have some idea as to why do we prepare a cost sheet now. The job cost
sheet format is standard and we are expected to follow it. Let us see how one goes about preparing a
cost sheet in the next section.

3.8. Preparing a Cost Sheet Calculation of Materials consumed

The aim of preparing a cost sheet is to show the various types of costs incurred by the factory in the
course of its operations. The cost sheet consists of particulars and amount columns. In the particular
columns, you show the different kinds of expenses of the company. Calculating the materials consumed
is the first step in preparing the cost sheet. The materials consumed is calculated by adding the purchased
raw material cost and carriage inward to the opening stock of raw materials and then subtracting the
closing stock of raw materials from this total.

Materials Consumed = (Opening stock of raw materials + purchase of raw material + carriage inward) -
(closing stock of raw material).

Calculation of Prime Cost

Prime cost is calculated by adding direct wages and direct expenses to the materials consumed total.
Direct wages are the wages given to workers in the factory and direct expenses are the expenses incurred
while making the finished goods.

Prime Cost = Materials consumed + direct wages + direct expenses.

Calculation of Factory cost

The next step in the cost sheet preparation is the calculation of factory cost. The factory cost is calculated
by adding the factory overheads to the prime cost. The factory overheads are the expenses related to
the factory and are in no way related to administration and marketing expenses. These factory overheads
can include lighting costs, salaries for workers, machinery cost, rent for factory, insurance for factory,
power costs, fuel cost etc. Overhead is actually the sum total of indirect material, indirect wages and
indirect expenses.

Factory Cost = Prime cost + sum of all factory overheads.

24 | P a g e
Calculation of Cost of Production
The cost of production can be calculated by adding the office and administration overheads to the factory
cost. Now, the office and administration overheads are the salaries of managers, director's fees, office
light expenses, stationery expenses, building maintenance expenses etc.

Cost of Production = Factory cost + office and administration overheads.

Once this cost of production is calculated, you need to add the opening stock of finished goods and then
subtract the closing stock of finished goods before we calculate the cost of sales.

Calculation of Cost of Sales or Total Cost

The total cost can be calculated by adding the selling and distribution overheads to the cost of production.
These selling and distribution overheads are mainly the expenses on promotion and marketing related
activities. These can include postage expenses, transportation expenses, advertising expenses,
marketing expenses and carriage outward.

Total Cost = Cost of production + selling and distribution overheads.

Calculation of Total Sales

The total sales can be calculated by adding the total cost and the net profit of the firm. This is the last
part of the cost sheet.

Total Sales = Total cost + net profit.

This explanation on how to prepare a cost sheet gave us knowledge of all items of cost sheets and how
they are used to calculate the total cost. Only monetary aspects are considered in the preparation of cost
sheets. So try preparing the same yourself and test your accounting knowledge and skills. Good luck!
There are three methods for fixation of export prices which are as follows:

• FOB
• C&F
• CIF
• FOB

FOB means ‘free on board’. exporter does not bear the cost of freight of ship or air. In this case, the
exporter quotes the price by adding the fabric cost, accessories cost, cost of manufacture, overhead cost,
his commission, C&F commission & cost of transportation from factory to port. It is buyer (importer) who
himself bears the freight of ship or air.

25 | P a g e
C&F
C& F means Cost of Freight, FOB (Cost) +Freight.
In the case ship or air freight is carried by the exporter while quoting price, the exporter quotes price a bit
higher than FOB. The whole responsibility including the sending of goods to the selected port of the
importer is shouldered by the exporter ship or air. Freight may vary from place to place and shippers to
shippers.

CIF
C I F means Cost, insurance & Freight. In this case in addition to the bearing of freight the Cost of
insurance is also borne by the exporter. The exporter, while quoting CIF price, quotes much higher than
C & F value. C & F + Insurance

The following example will clarify how to fix price of a particular commodity: Let us quote a price of one
dozen long sleeve shirts.

3.8. Sampling

The samples decide the ability of an exporter. The buyer will access the exporter and his organization
only by the samples. If the samples are of good quality and with reasonable price naturally the buyers
will be forced to place the order. So it is essential that the samples should be innovative and with optimum
quality. The purpose of sampling is not only to get bulk orders and also give some additional benefits to
the exporters. By doing sampling the exporter can estimate the yarn consumption for developing the
fabric, a clear idea on costing more ever the manufacturing difficulties. Besides by doing sampling only
the exporter can optimize the processing parameters for mass production, which helps to avoid all kind
of bottlenecks. All these works are carried out by the sampling department, which us led by a sampling
in charge.

26 | P a g e
The Details Attached to the Garment Sample
After the confirmation of order, each sample sent t 0 the buyer has the following details attached to it,
with the help of a tag. It contains the details pertaining to both, what the buyer has demanded and what
supplement fabric/trim etc they have used (if applicable).

• Ref no.
• Color
• Fabric
• Composition
• Description
• Quantity
• Style n0/ Size
• Store

There may be a separate sampling department in a company. But as the merchandiser is the person who
is interacting with the buyers regarding samples and other requirements, this sampling department will
work under the supervision of merchandising department. Also as the samples are to be made according
to the buyers’ price ranges and quality levels, merchandiser has to advise sampling department suitably.

Persons involved in Sampling

We have to send many samples to buyers. They are

• Salesmen samples or promotional samples

• Proto samples or fit samples
• Counter samples or reference samples or approval samples
• Wash test samples
• Photo samples
• Fashion show samples
• Pre-production samples
• Production samples
• Shipment samples

27 | P a g e
Procedure of Order:
Style No. stroke No. price all in excel sheet, break-down of total qty confirmation

Fabric booking (MM portion)

Arrange PP meeting (by IE)

Proceed to bulk

Proceed for size set

Bulk cutting

Printing/ Embroidery

Sewing

Rack sample (shipment)

Contract sample

Shipmen

28 | P a g e
3.9 Documentary Letter Of Credit In Apparel Industry (Import/Export Documentation)

Documentary letter of credit is such kinds of commercial letter which a bank issue on behalf of foreign
seller (exporter) according to the direction of the (importers) purchasers. The documents shown under
are known as export documents from the importer’s side. These are

3.9.1. Bill of lading:

A bill lading is a document of title to goods entitling the holder to receive the goods as beneficiary or
endorsee and it is with the help of this document on receipt from the exporter that the importer takes
possession of the goods from the carrying vessel at the port of destination.

3.9.2. Airway bill / Railway receipt:

When goods to be transported are small in bulk or requiring speedy delivery or those are perishable in
nature on the deal is in between the neighboring countries then mode of transports other than shipping
may be resorted to far the carriage of the goods Airways bill / Railway receipt take place of Bill of lading
depending on the nature of the carrier.

3.9.3. Commercial invoice:

It is the seller’s bill for the merchandise. It contains a description of goods, the price per unit at a particular
location, total value of the goods, packing specifications, terms of sale, letter of credit, bill of lading number
etc. There is no standard form far a commercial invoice. Each exporter designs his own commercial
invoice form. The invoice is made out by the seller under his signature in the name of the buyer and must
be submitted in a set of at least 3 copies. Its main purpose is to check whether the appropriate goods
have been shipped and also that their unit price, total value, marking on the package etc. are consistent
with those given in other documents.

3.9.4. Insurance policy:

In the international trade insurance policy is a must to cover the risk of loss on consignments while they
are on seas, roads, airways. The insurance is the responsibility of the buyers (consignee) under FAS,
FOB and C&F contracts and of the seller (consignor) under CIF contract. The policy must be of the type
as specified in the relative contract / credit. The policy would be for the value of CIF price plus 10 (ten)
percent to cover the expenses and that is required to be obtained in the same currency as that of the
credit and dated not later than the date of shipment with claims* being payable at the destination. It must
be properly stamped. Like a bill lading it must be negotiable and be endorsed where it is payable to order.

29 | P a g e
3.9.5 Certificate of origin:

This is a certificate issued by a recognized authority in exporting country certifying the country of origin
of the goods. It is usually by the Chambers of commerce. Sometimes, it is certified by local consul or
Trade Representative of the importing country as per terms of the credit.

3.9.6 Packing list:

The exporter must prepare an accurate packing list showing item by item, the contents of the consignment
to enable the receiver of the shipment to check the contents of the goods, number and marks of the
package, quality, per package net weight, gross weight, measurement etc.

3.9.7. Bill of Entry:

A bill of entry is a document which contains the particulars of the imported goods as well as the amount
of customs duty payable.

The exporter submits the following papers/documents to the Negotiating bank:

• Bill of exchange /Draft.

• Bill of lading.
• Airway bill / Railway receipt.
• Commercial invoice.
• Insurance policy.
• Certificate of origin.
• Packing list.
• Weight & measurement list.
• Other etc.

30 | P a g e
 Chapter Four
Supply Chain Management.
 Supply Chain Management

4.1. Supply Chain Management (SCM)

In commerce, Supply Chain Management is the management of the flow of goods and services. It
involves the movement and storage of raw materials, work-in progress inventories and finished goods
from point of origin to point of consumption. Interconnected or interlinked networks, channels and nodes
of the business, combine need the provision of supply chain management. However, this is the bookish
definition of supply chain management, but the SCM of Ama Syntex Ltd can be divided into three major
parts:

1. Information Flow: This flow both upstream and downstream (both sides).

2. Materials & Goods flow: This flow from suppliers to the manufacturer and then to distributor /consumer

(Left to right).

3. Fund Flow: This Flow downstream to upstream ( Right to left)

Although supply chain management has stayed for ages, most companies have only nowadays given
attention to them as a value-add to their operations. In SCM, the availability chain manager coordinates
the logistics of all aspects of the availability chain which consists of five parts:

❖ The plan or strategy

❖ The source (of raw materials or services)
❖ Manufacturing (focused on productivity and efficiency)
❖ Delivery and logistics
❖ The return system (for defective or unwanted products)

4.2. Diagram for Supply Chain Management

Supply chain management: Supply chain management is the management of flow or raw goods and
services from the suppliers to the manufacturers, which it is process, to deliver finished goods /services
to the distributors and consumers.

Goods Distributers/
Consumers
Supplier Manufacturer

Services Distributers/
Consumers

31 | P a g e
4.3. Supply Chain Management Process:

Supply Chain may be a progression by which unprocessed materials like accessories makeover from
Supplier to Garment Industries within the bartering of order and payment. The general elements of the
supply chain process are:(Based on the Bangladesh Garment Industry)

❖ Raw materials
❖ Embroidery/Printing/Washing
❖ Accessory & Trim
❖ Finished goods
❖ Shipping
❖ Retailer/buyer
❖ Customers/Outlets

4.4. Responsibility for supply chain management

Marketing: Negotiates with the buyer and gets firm order:

❖ Merchandising: Make estimates of material and arranges procurement. Monitors all activities
from order to shipment.
❖ Storage: Temporary storage of raw material and good inspection.
❖ Production: Cutting, Printing, embroidery, sewing, and washing.
❖ Finishing and Packing: Thread cutting, Buttoning, pressing, packing.
❖ Quality Control: Total Quality Control Throughout the Process
❖ Inspection: Inspection by buyer and acceptance.
❖ Shipment: By store Department using a Covered van up to port then.

4.5. Penalty for shipment delays/ Failures:

• For delay production, air shipment may be required. This is very expensive.
• A Financial Penalty may also be imposed .It amounts to a large sum of money.
• The Order may be cancelled .Huge loss to the company
• A Short quantity is also liable to the penalty

32 | P a g e
4.6. Store Ware house

A warehouse, also known as a go down in Indian English, is a commercial building for storage of goods.
Warehouses are used by manufacturers, importers, exporters, wholesalers, transport businesses,
customs, etc. They are usually large plain buildings in industrial areas of cities and towns. They usually
have loading docks to load and unload goods from trucks. Sometimes warehouses load and unload
goods directly from railways, airports, or seaports. They often have cranes and forklifts for moving goods,
which are usually placed on ISO standard pallets loaded into pallet racks.

4.7. Work flow process:

Item received by supplier

Quality cheek is carried out

After quality checking item are sending to ware house or store

Store gives them racks location, card/bin card

Located the item and be appropriated places

After physical inventory to located the places where it is applicable

At the same time inventory documentation carried output in location number in the Software

Physical issued by required people

Receiver receive the physical material and signature receive Colum

Again update in soft ware

33 | P a g e
4.8. Recommendation

Ama Syntex Limited Chain Management is the beneficial ones for generating the order to the shipment
(start to end) appropriately as per the factory and the buyer’s obligation. Apparel buyers around the
sphere insist product as they want it when they want it, and the best possible price so that the supply
chain can do a lot to this concern in reality. Supply chain management different in garments factories to
other factories.

• The inventory management system of the garments industry is moderately effective.

• So the inventory management system should be improved.
• Success Depends on Teamwork at all levels.
• Strong Monitoring is required by ERP Software.
• Monitoring, scheduling, and controlling support should be improved. Communication and
feedback should be more frequent.
• CPM is a useful tool for identifying Bottlenecks.

4.9. Literature Analysis

To compare with the actual data I have studied on few things so that I can give few effective
recommendations in this report.

• Benchmarking is a tool, which is used to measure the organization’s value against the best
industry practices. It promotes superior performance by providing an organized framework
through which an
• organization can learn how to do the best things.
• Total Quality Management (TQM) is a systematic way of ensuring zero defect in production. If
TQM is applied in all the steps of the production, the ultimate finished products will have zero
defects
• Quality certification is the procedure adopted by organizations to letthe customers and the
stakeholders know about the system being followed. It is used as a mode of quality assurance.
International organization for standardization (ISO) has several certifications for quality
assurance. Having certification adds value to an organization.+
• Economic order quantity is that order quantity which minimizes the total variable cost of
managing the inventory. It reduces the stock holding time and helps to run the production more
efficiently by holding sufficient amount of raw materials for a specific period of time

34 | P a g e
 Chapter Five
Commercial Department
 Commercial Department

4.1. Document Against Acceptance (D/A)

The buyer is allowed to make payment for the goods on credit, as agreed between him and the seller.
Payment for the merchandise is commonly 60 or 90 days after acceptance of documents. The buyer
gains the advantage of not having to pay for the goods for a period of time after accepting the documents.
The supplier bears some risk because he will not receive payment until a specified period after the
documents and titles to the merchandise have been accepted.

4.2. Documents Against Payment (D/P)

The supplier agrees to release any documents referring to the transfer of title for the merchandise upon
payment. Since the goods are produced and shipped before the supplier tenders the required documents
for payment, there is some risk to the supplier for demurrage charges if the buyer does not accept the
documents and title to the goods.

4.3. Open Account

This method of payment does not involve the services of a bank, but is based upon an agreement
between the supplier and the buyer. The buyer has no legal obligation to pay the supplier and payment
is normally made directly to the supplier. The supplier bears some risks as the goods and documents are
usually delivered to the buyer before payment is made.

4.4. Letter of Credit (L/C)

A letter of credit (also known as documentary credit) is a document issued by a bank on behalf of an
applicant (the buyer) undertaking to make payment to a beneficiary (the seller) up to a stated amount of
money, within a prescribed time limit and against stipulated documents.

There are usually two banks involved in a letter of credit operation. The issuing bank is the bank of the
buyer and issues the credit; the advising bank, usually located in the seller's country, is the bank through
which the advising bank sends the credit to the beneficiary.

4.5.1. Types of credit:

There are three common types of credit: revocable, irrevocable, and irrevocable and confirmed
Revocable credit: this type of credit can be amended or cancelled by the applicant without any prior
warning or Irrevocable credit: this type of credit can be amended or cancelled only with the agreement of
all parties concerned. It also represents a definite undertaking by the issuing bank to pay provided that

36 | P a g e
the stipulated documents are presented and that the terms and conditions of the credit are complied with.
Irrevocable and confirmed credit: this type of credit involves the undertaking of the advising bank in
addition to that of the issuing bank; it means that the issuing bank requests a second bank to add its own
confirmation to the credit so that the confirming bank is responsible to make payment if the issuing bank
fails to pay the beneficiary.

A letter of credit should usually stipulate a requirement for the following documents:

❖ bill of lading
❖ copy of the certificate of origin
❖ commercial invoice
❖ export license
❖ packing list

4.6. Commercial Invoice

A commercial invoice is a business document which records the sale of goods or services between two

parties, and by which the seller informs the buyer of the amount to be paid for the goods. Usually, the

original and four copies are stipulated in the L/C.

A commercial invoice normally includes the following information:

Date and authorized signature

The correct name and address of both buyer and seller (or the name of the consignee if the goods are
not consigned to buyer)

A detailed description of the merchandise purchased strictly corresponding with the description given in
the letter of credit, along with quantity, unit price, and total price, all deductions and additional charges
included in the price

Weight of the goods, number of packages, any identifying shipping marks, any import license number,
contract number or any other details requested and stipulated in the L/C

➢ Terms of delivery and payment (FOB, CIF, C&F)

➢ The name of the issuing bank and the letter of credit number
➢ The port of entry for which the merchandise is destined
➢ The type of currency and rate of exchange
➢ Bill Of Lading (BIL)

37 | P a g e
It is a major document if the goods are dispatched by sea. The document represents:
A formal receipt for the goods, The evidence of the contract of carriage of the goods between the shipper
of the goods and the shipping company, The document of title to the goods

A bill of lading may include the following details:

➢ A description of the goods in general terms not inconsistent with that in the letter of credit
➢ Identifying marks and numbers, if any
➢ The name of the carrying vessel
➢ Evidence that the goods have been loaded on board
➢ The ports of shipment and discharge
➢ The names of shipper, consignee (if not made out "to order"), and name and address of the
"notifies" party if any
➢ Whether freight has been paid in advance or is payable at destination
➢ The number of original bills of lading issued
➢ The date of issue
➢ The departure date of carrying vessel or aircraft

4.7. Combined Transport Bill of Lading

A bill of lading covering carriage by a combination of transport movements where the carrier issuing the
bill undertakes responsibility for the goods from a point or place of receipt to a point or place named in
the bill of lading. This document is also commonly called a "container bill of lading" as it is issued by
container companies and their agents.

4.7.1. Master Airway bill

A receipt or air consignment note issued by an airline or their authorized agents evidencing the dispatch
of merchandise by air freight. Usually three originals are made: one for the consignee, one for the
shipper/supplier, and one retained by the issuing carrier.

38 | P a g e
 Chapter Six
Production Department
 Production Department

6.1 Sample:
A sample is a subset of a population. Typically, the population is very large, making a census or a
complete enumeration of all the values in the population impractical or impossible. The sample represents
a subset of manageable size. Samples are collected and statistics are calculated from the samples so
that one can make inferences or extrapolations from the sample to the population. This process of
collecting information from a sample is referred to as sampling.

The best way to avoid a biased or unrepresentative sample is to select a random sample, also known as
a probability sample. A random sample is defined as a sample where the probability that any individual
member from the population being selected as part of the sample is exactly the same as any other
individual member of the population. Several types of random samples are simple random samples,
systematic samples, stratified random samples, and cluster random samples.

6.2 Different Type of Sample

❖ Development Sample
❖ Advertisement Sample
❖ Fit Sample
❖ Pre-production Sample
❖ size set sample
❖ Lab test Sample
❖ Seal Sample
❖ Counter Sample
❖ Production Sample
❖ shipment Sample

Development Sample: Which sample make by available fabric & accessories and send to buyer to
collect order from the buyer that is called development sample.

Fabric Consumption: According to size pack & ratio the requirement of fabric for 1dz garments that is
called Fabric Consumption.

Fit sample: Medium or large size have to send buyer for checking fits of dummy that is called fit sample

40 | P a g e
Pre-production sample (PP Sample): which sample make by actual fabric & accessories and send to
buyer for final approval to start production.

Lab test: Which sample make by actual fabric & accessories and send to local laboratory (Buyer
Nominated) to check fabric structure such as-GSM, Color fastness, Rubbing, Shrinkage, printing,&
embroidery.

Size set sample: send to local buying house all size sample made by according to order, style & color&
get them approved from buying house

Counter sample: To reserved with pattern for future order from buyer that is called counter sample
Production sample: First production garment will be send buyer for buyer satisfaction.

Shipment sample: according to the buyer requirement like accessories, ploy bag, tag etc is been made
and kept ready to ship the before dispatched.

6.3 Responsibility of sample room:

1. Mail corresponding

2. Deals with byre

3. All goods should be as per buyer requirement

4. Analysis all comment of buyer.

5. Revising sample.

6.4 Sample Procedure:

Sourcing the fabric and accessories for making the garment

Cutting (for sample only)

Embellishment

Sewing

Iron

41 | P a g e
 Quality controller

Pre check from

Buyer QC

Forwarding collects from the merchandiser

Sending sample to the buyer

Dyeing Section

6.5.1 Dyeing

Dyeing is the process in order to dye textile production like fibers, yarns, fabrics. Dyeing is normally done
in a special solution containing dyes and particular chemical material. After dyeing, dye molecules have
uncut Chemical bond with fiber molecules. The temperature and time controlling are two key factors in
dyeing. There are mainly two classes of dye, natural and man-made.

Dyeing is a method which imparts beauty to the textile by applying various colors and their shades on to
a fabric. Dyeing can be done at any stage of the manufacturing of textile- fiber, yarn, fabric or a finished
textile product including garments and apparels. The property of color fastness depends upon two factors-
selection of proper dye according to the textile material to be dyed and selection of the method for dyeing
the fiber, yarn or fabric.

6.5.2 Forms of dyeing

Dyeing can be done in various forms

(1) Fiber → to make mélange / spl. Color effect in the fabric

(2) Yarn → to make stripe effect.

(3) Fabric → Solid effect.

(4) Its → to make ethane faded or used look effect.

42 | P a g e
Deferent Dyeing M/C

(1) Fiber → Conical point loose stick dying

(2) Yarn → Cone/Package dyeing for cotton

➢ Hark dyeing m/c for terylic

➢ High pressure dying m/c for synthetic yarn.

(3) Fabric dyeing → Knit fabric → Winch. (Tubular form)

Woven fabric→ Jigger (open width form)

(4) Grts & Footwear → Rotary drum for hose → Socks → over head paddle dyeing m/c.

6.5.3 Classification of dyestuff

On the basis of application dyestuff can be classified in following way.

(1) Direct (2) Reactive (3) Sulphar (4) Vat (5) Vat (5)Azoic (6) Mordant

(7) Acid (8) Basic (9) Dispense

6.5.4 Dyestuff for different fiber dyeing on

(1) Cotton → Reactive dye, Direct dye, sulpher dye, vat, azoic.

(2) Viscose → Reactive & Direct.

(3) Polyester → Disperse dyes.

(4) Nylon → Acid dyes.

(5) Modal → Reactive & direct dyes.

(6) Acrylic → Basic dye.

(7) Wool → Acid dye.

43 | P a g e
 Printing Section

6.6.1. Printing
Printing is the process of applying color to fabric in definite patterns or designs. In properly printed fabrics
the color is bonded with the fiber, so as to resist washing and friction. Textile printing is related to dyeing
but, whereas in dyeing proper the whole fabric is uniformly covered with one color, in printing one or more
colors are applied to it in certain parts only, and in sharply defined patterns.

In printing, wooden blocks, stencils, engraved plates, rollers, or silk-screens are used to place colors on
the fabric. Colorants used in printing contain dyes thickened to prevent the color from spreading by
capillary attraction beyond the limits of the pattern or design.

Traditional textile printing techniques may be broadly categorized into four styles:

➢ Direct printing, in which colorants containing dyes, thickeners, and the mordents or substances
necessary for fixing the color on the cloth are printed in the desired pattern.
➢ The printing of a mordant in the desired pattern prior to dyeing cloth; the color adheres only
where the mordant was printed.
➢ Resist dyeing, in which a wax or other substance is printed onto fabric which is subsequently
dyed. The waxed areas do not accept the dye, leaving uncolored patterns against a colored
ground.
➢ Discharge printing, in which a bleaching agent is printed onto previously dyed fabrics to remove
some or all of the color.

Resist and discharge techniques were particularly fashionable in the 19th century, as were combination
techniques in which indigo resist was used to create blue backgrounds prior to block-printing of other
colors. Most modern industrialized printing uses direct printing techniques.

6.6.2 Methods of printing

❖ Hand block printing

❖ Parroting printing
❖ Engraved copperplate printing
❖ Roller printing, cylinder printing, or machine printing
❖ Stencil printing
❖ Screen-printing
❖ Digital textile printing

44 | P a g e
 Cutting Section

6.7.1 Cutting method

A method and apparatus for cutting pieces of fabrics of uniform thickness and for stacking these pieces.
The method generally includes arranging and maintaining a length of unrolled fabric on a cutting table
which comprises a revolving cylinder which rotates so that the length of fabric is positioned to face a
cutting instrument. The fabric is cut out according to one or more predetermined patterns when the
cylinder stops rotating. Displacement of the cutting instrument over the circumference of a cylinder follows
the generators of the cylinder during its motion. After the fabric is cut, the cylinder rotates to deposit the
cutout pieces onto a fixed or mobile receiving/stacking table which is positioned under the cylinder. During
such deposition, a new length of fabric is simultaneously arranged on the cylinder preparatory to being
cut. Alternately, a conveyor belt can be used in lieu of the cylinder.

6.7.2 Capacity of Divine garments

Spreading capacity

Basic – 32,000Kgs – 7.5Kgs/Dz

➢ Critical – 20,000Kgs - 3Kg/Dz

➢ Cutting capacity (average): - 10,000Kgs-12,000Kgs

Cutting capacity (highest): - 14,000Kgs-15,000Kgs

Cutting M/C

Garber cutter – 1 (USA)

Spreader – 4 (RPM – 75m)

Straight Knife – 17-18 (RPM – 3300)

Bend Knife – 1

Spreading M/C

M/C Name – Garber – 3 (USA)

Autex – 1 (SPAIN

45 | P a g e
6.7.3. Work procedure of cutting department:

Fabric receive

Shade checking

Count checking

Spreading/ lay checking

Marker checking & Marker set up

Cutting

Cutting inspection

Sticker attaching

Final inspection print & embroidery

Bundling problem

In case Re-cut counting

Input rack

Sewing line

46 | P a g e
6.7.4. Marker

Multiple layers of fabric upon which a pattern or guide is placed for production-line cutting. In the process
of fabric spreading, the variance of fabric yardage between fabric rolls may lead to a difference in fabric
loss during spreading. As there are numerous combinations the arrangement of the fabric roll sequences
for each cutting lay, it is difficult to construct a roll planning to minimize the fabric wastage during
spreading in apparel manufacturing.

Maker length should be 10yds- 12 yds.

Sewing Section

6.8.1. Sewing:
Sewing is the craft of fastening or attaching objects using stitches made with a needle and thread. Sewing
is one of the oldest of the textile arts, arising in the Paleolithic Era. Before the discovery of spinning yarn
or weaving fabric, archaeologists believe Stone Age people across Europe and Asia sewed fur and skin
clothing using bone, antler or ivory needles and "thread" made of various animal body parts including
sinew, catgut, and veins. Although usually associated with clothing and household linens, sewing is used
in a variety of crafts and industries, including shoemaking, upholstery, sail making, bookbinding and the
manufacturing of some kinds of sporting goods. Sewing is the fundamental process underlying a variety
of textile arts and crafts, including embroidery, tapestry, quilting, appliqué and patchwork.

For thousands of years, all sewing was done by hand. The invention of the sewing machine in the 19th
century and the rise of computerization in the later 20th century led to mass production of sewn objects,
but hand sewing is still practiced around the world. Fine hand sewing is characteristic of high-quality
tailoring, couture fashion, and custom dressmaking, and is pursued by both textile artists and hobbyists
as a means of creative expression.

6.8.2. Types of stitches:

➢ Chain stitch, made with one thread

➢ Lockstitch, made with two threads in any of these geometries:
➢ Straight stitch
➢ Zigzag stitch (including Blind stitch)
➢ Stretch stitch
➢ Over lock, made with one to four threads
➢ Cover stitch, made with two or four threads

47 | P a g e
 ➢ backstitch - a sturdy hand stitch for seams and decoration
➢ blind stitch (or hemstitch) - a type of slip stitch used for inconspicuous hems
➢ buttonhole stitch
➢ chain stitch - hand or machine stitch for seams or decoration
➢ cross-stitch - usually used for decoration, but may also be used for seams
➢ catch stitch (also 'flat' & 'blind' -catch stitch)
➢ cross-stitch tack
➢ Embroidery stitch
➢ hemming stitch
➢ overcast stitch
➢ running stitch - a hand stitch for seams and gathering

6.8.3. Sequence of printing

Pigment flow preparation

Printing

Drying

Curing

48 | P a g e
 Finishing Section

6.9.1. Finishing

In textile manufacturing, finishing refers to any process performed on yarn or fabric after weaving to
improve the look, performance, or "hand" (feel) of the finished textile or clothing. Some finishing
techniques, such as falling, have been in use with hand-weaving for centuries; others, such as pole
bagging, are byproducts of the Industrial Revolution. System adopted in the Finishing Floor,

➢ After cleaning the thread all garments are being sent to iron-man directly.
➢ In the iron table we are drawing size wise graded patterns of the body and the garments are
being ironed conforming to the respective sizes.
➢ After ironing all garments are checked by QC and only OK garments are sent for 100%
measurement and reject garments are segregated and taken away from the finishing floor.
➢ After doing 100% measurement of all bodies only the OK garments are sent for folding and
packing.
➢ We have appointed one QC to do the hourly checking of all garments and prepare a report in
this regard and put up to AGM of the floor for his review.
➢ At the end of the day another QC person is doing the day-final and making a report in this respect
and keeping record. If the garments are found with problem in the day-final then all the garments
are being opened and re-checked
➢ After complete finishing of any order we are doing the Pre-Final from the point of view of Buyer
and making a complete report in his regard maintaining record also. If the result will be found OK
only then we will be offering Final Inspection.
➢ Once the garments pass the Pre-Final inspection then all the garments are kept under constant
surveillance.

6.9.2. Packing list:

This is a document that indicates the contents of each individual carton/ package in the container. The
packing list includes the cubic measurement of the cartons/package, the weight, the number of
cartons/packages, the breakdown of the goods by size/color/quantity. This document is prepared by the
seller or the ship-owner, and the buyer can specify which information should be included.

49 | P a g e
6.9.3. Finishing flow chart

Finishing flow chart

Finishing input size wise, style wise

Iron

Inspection

Buyer wise price ticket sewing ticket

Folding

Polly

Barcode attach

Metal check

Packing

Buyer final inspection

Shipmen

50 | P a g e
 Chapter Seven
Human Resource Department
 Human Resource Department

7.1. Human Resource Management

The role of human resource management in Ama Syntex Limited at counter stage. Managers are aware
that HRM is a function that must play a vital role in the success of organization. It is an active participant
in charting the strategic course an organization must take place to remain competitive, productive and
efficient. Its focal point is people, people are the life blood of the organization. The uniqueness of HRM
lies in its emphases on the people in work setting and its concerns for the well living and comfort of the
human resources in an organization. The HRM function is much more integrated and strategically
involved. HRM and every other functions must work together to achieve the level of organization.
Effectiveness required competing locally and internationally.

7.2. Culture Of HRD

HR manager have responsibility under HRD to make OCTAPACE culture climate in the organization.

➢ O-Openness
➢ C-Confrontation
➢ T- Trust
➢ A-Autonomy
➢ P- Proactive ness
➢ Authenticity
➢ Collaboration
➢ E- Experimentation

Management is a crucial element in a business, and the HR department does just that. The human
resource (HR) department is defined as a department that manages the most vital and valuable resource
of a company: the employees. It does this by managing the employees from their search, screening,
firing, recruiting, and training. The HR department also administers employee-benefit programs. It is an
essential component of a business because it protects the company's image, success, and interest by
laying off workers, firing, and applying disciplinary actions after violations.

52 | P a g e
7.3. Kye Principle Standards Of Ama Syntex Limited:

➢ No Forced Labor — Employment is freely chosen

➢ Freedom of Association and the Right to Collective Bargaining
➢ Safe and Healthy Working Conditions
➢ No Child Labor
➢ Fair Wages and Benefits
➢ Lawful Working Hours
➢ No Discrimination is Practiced
➢ Employment Security
➢ Respectful Treatment of Employees

7.4. HRD Activities

Research conducted by The Conference Board, a member-driven economic think tank, found six key,
people-related activities that HR must effectively do to add value to a company. They are:

• Managing and using people effectively

• Tying performance appraisal and compensation to competencies
• Developing competencies that enhance individual and organizational performance
• Increasing the innovation, creativity, and flexibility necessary to enhance competitiveness
• Applying new approaches to work process design, succession planning, career development,
and inter-organizational mobility
• Managing the implementation and integration of technology through improved staffing, training,
and communication with employees

53 | P a g e
 BANGLADESH TEXTILE MILLS ASSOCIATION

Bangladesh Textile Mills association (BTMA)

Unique Trade Centre
(Level-8), 8 Panthapath, Karwan Bazar
Dhaka-1215, Bangladesh
Phone- 880-9143461, 880-9130969, 880-8112361
Fax -9125338
Email- btmasg@gmail.com , btma2@yahoo.com , btma3@hotmail.com
Web- www.btmadhaka.co
Bangladesh Textile Mills association (BTMA)
is the national trade organization of Primary
Textile Industry i.e. Yarn Manufacturing,
Fabric Manufacturing and Dyeing-Printing
Finishing mills of the country under private
sector. BTMA is registered in 1983, among
others the following are the main objectives:
1. To promote and protect the trade, commerce and manufacturers of Bangladesh in general and of the
textile related trade in particular.

2. To collect and circulate statistics and to collect, classify and circulate information relating to the trade,
commerce and manufactures of its members.

3. To take all steps which may be necessary for promoting, supporting or opposing legislative and other
measures affecting the trade, commerce or manufactures of its members.

4. To make representations to the appropriate authorities on any matter connected with the trade,
commerce and manufactures of its members.

5. To advance and promote commercial and technical education connected with the trade and commerce
of its members.

6. To undertake special inquiries and initiate or support any action for securing the redress of legitimate
grievances connected with the trade or commerce of its members.

54 | P a g e
7. To engage in such activities for imports, exports of raw materials, spares and finished products for the
collective benefit of the members of the Association.

8. To organize such factories and workshops for selling or display centers centrally which may be of
common benefit for sections which might not be possible or feasible for individual members.

The Association is run by a BOARD OF DIRECTORS of 27 members, headed by one President and 3
Vice-Presidents, who are elected through ballot/votes as per provisions of the Trade Organization
Ordinance, 1961 and Rules made there under by the Government of Bangladesh. The tenure of the
Board of Directors is 2 years. The Association has a separate Secretariat to look after all Administrative
activities and is headed by the Secretary General. He is assisted by a numbers of officers in the discharge
of his duties.

Currently the number of member ship of BTMA is 1266 under:

1. Yarn Manufacturing = 361

2. Fabric Manufacturer = 682

3. Dyeing-Printing-Finishing = 223

Over 4.00 billion EURO has been invested in these mills and about 4.00 million people are currently
employed. BTMA fulfills:

❖ 100 % of the domestic fabric and yarn requirement.

❖ 50% of the cotton oven fabric requirement of export oriented garments sub-sector.
❖ Over 95% of the yarn and fabric requirement of export oriented Knitwear sub-sector

55 | P a g e
 Bangladesh Knitwear Manufacturers & Exporters Association

BKMEA Head Office

233/1 Bangabandhu Road
Press Club Building (1st Floor)
Narayanganj-1400, Bangladesh
hone 880-2-7640535, 7641295
7641857
Fax 880-2-7630609
E-mail info@bkmea.com
Bangladesh Knitwear Manufacturers & Exporters Association (BKMEA) was formed in 1996 by the all out
efforts of few knitwear manufacturers. Soon after the formation it undertook activities to look after the
interest of the knitwear sector of the country. Today it is an association of about 1700 knitwear
manufacturers

BKMEA is run by a 27-member Board of Directors led by the President. The Board of Directors is elected
for a 2-year period. To run the association efficiently, different committees are also working. BKMEA Was
Formed To Address The Following Agenda:

➢ Protect the Interest of the Sector

➢ Promotion & Development of the Market
➢ Promotion & Development of the Sector
➢ Capacity Building of the Sector
➢ Social Compliance Status Enhancement
➢ Basic Rights Education and Awareness Raising
➢ BKMEA's Services to the Member Units
➢ Product & Market Promotion
➢ Social Compliance
➢ Research & Development
➢ Productivity Improvement
➢ One stop service point regarding UD/UP
➢ Other necessary services at the shortest possible time

56 | P a g e
FINDINGS

Nowadays the factor is that, most of the merchandisers are not come from this educational track. The
technical or sample room sections also face the same problem. Most of the pattern masters are not highly
educated for that reason they are not able to make appropriate sample. For that’s why Buyer face many
kinds of problem and sometimes they cancel the order. In our country most of the Garments workers are
not educated so they go through the wrong way to make the garments.

CONCLUSIONS

Although Bangladesh is not developed in industry, it has been enriched in Garment industries in the
recent past years. In the field of Industrialization garment industry is a promising step. It has given the
opportunity of employment to millions of unemployed, especially innumerable uneducated women of the
country. It is making significant contribution in the field of our export income. History of our cloth Industry:
Today Garment industry is controlled by the transfer of production. The globalization of garment
production started earlier and has expanded more than that of any other factory. The companies have
transferred their blue-collar production activities from high-wage areas to low-cost manufacturing regions
in industrializing countries. The enhancement of communication system and networking has played a key
role in this development.

57 | P a g e
REFERENCE:

1. M.A. Razzaque Garment & Textile Merchandising ;2nd Edition; Gronthonir Publishers;56

2.Engr. A.J.S.M.Khaled Work study & Productivity Improvement 1st Edition:Books Fair Publishers;77

3.Professor J E Mcintyre Textile Terms and Definition 10TH Edition, Rupok Publishers.

4.M.A. Kashem Garments & Technology 9th Editon, Gronthonir Publishers.

5. Engr. A.J.S.M. Khaled Quality Management in Apparel Industry 2nd Editon, Gronthonir Publishers.

7.Tazammol hossain Garments Merchandising 3rd Editon, Galaxy Publishers.

8. Prof. Khalikujjaman Banking and Insurance; 10th Editon, Diganta Publishers.

APPENDICES

Without practice of every process in this report it is not possible to run apparel industry. For that reason
to run apparel industry have to know every procedure perfectly. At last I can say that “my internship
report” is helps to gather related knowledge about apparel industry

58 | P a g e