BGMEA University of Fashion & Technology
Department of Textile Engineering
Submitted by
Md. Fahmidul Hossain
172-003-0-155
Submitted to
Mr. Abdur Rouf
Assistant Professor & Head, Dept. of KMT
Nafis Abir
Lecturer, Dept. of TE
Mr. Faisal Ahmed
Lecturer, Dept. of TE
Internship Presentation on
“Azim Group”
Global Fashion Garments Ltd
and
Global Outerwear Ltd
List of Content
• Introduction
• Store Department
• Planning and Control Department
• Merchandising Department
• Sample Department
• Cutting Department
• Sewing Department
• Industrial Engineering
• HR Compliance & Environment Department
• Conclusion
Introduction
Azim Group is a 100% export oriented denim industry. They have been
involved in this sector since its inception in Bangladesh in the early
1980s. The Founder, Mohammad Fazlul Azim, brought Azim
Group into existence in 1975.
Company Profile
•Name of the factory: Global Fashion Garments Ltd & Global Outerwear Ltd.
•Type: 100% Export Oriented Denims Industry
•Fully Vertical Setup: Sewing, Washing and Finishing.
•Year of Establishment: 1975
•Production Capacity-
•Sewing: 35000 pcs per month
•Washing: 30000 pcs per mot
•Total Manpower: 4200
•Location: 89, Berulia Road, Tati, Savar
Clients of Azim Group
Store Department
Fabric Store Flow Chart
Fabric Received as Per Lot
Inventory
Any shortage/damaged packing are
Physical Counting found that will be informed to
concerned merchandiser
Quarantine Area
Fabric Inspection
4 Point System
Lot Pass Lot Fail
Fig: Fabric Store Flow Chart
Fabric Inspection
Both way in warp and weft the length of the defect in
fabrics
Distribution of points
Defects up to 3” inches 1
Defects from 3” to 6” inches 2
Defects from 6” to 9” inches 3
Defects of more than 9” inches 4
* For every hole mark * 4
Table : Fabric Inspection as per Industry
𝑇𝑜𝑡𝑎𝑙 𝑑𝑒𝑓𝑒𝑐𝑡 𝑝𝑜𝑖𝑛𝑡 36
4 𝑝𝑜𝑖𝑛𝑡 𝑆𝑦𝑠𝑡𝑒𝑚= 𝑥 𝑥 100
𝐹𝑎𝑏𝑟𝑖𝑐 𝑙𝑒𝑛𝑔𝑡h 𝐹𝑎𝑏𝑟𝑖𝑐 𝑤𝑖𝑑𝑡h
Name of some Fabric defects:
1. Missing Yarn
2. Slub
3. Thick Yarn
4. Knot
5. Hole
6. Spot
7. Foreign Yarn
8. Oil Spot
9. Stop Mark
Rules of lot fail & roll fail:
* If the defect point of the total lot is more than 20 points it is then considered as a lot fail.
* If the defect point of a roll is more than 28 points it is then considered as roll fail.
Fig: Inspection table & few defects
Accessories Store Flow Chart
Trims & Accessories
received as per lot
Inventory
Physical counting
Quarantine Area
Accessories inspection as per If fail inform
AQL level and uncountable Lot Fail concerned
items 10% from sample merchandiser
Accessories inspection as
per AQL level and
uncountable items 10%
from sample
For every order 1 QC swatch Metal materials to be All attaching components
will be made to conduct all checked by metal detector should be sent to pull test
lab test
Inspection Pass
Prepare 1 QC report and
send to marketing section
If it is approved from the
merchandiser then prepare
trims card files for production
& Quality reference
Store all trims & accessories
in the warehouse
Fig: Accessories Store Flow Chart
Defects of Accessories
The defects of Accessories are classified into three defect classes –
Major defects
Minor defects
Critical defects
Major defects:
Care label wrong
Label print wrong
Main label lettering
Main label cut
Zipper tape wrong color
Button wrong color
Minor defects:
Care label spot
Main label spot
Zipper length short
Zipper spot
Elastic spot
Leather patch spot
Button spot
Critical defects:
Care label letter missing
Care label cut off letter
Elastic weaving
Broken button
Broken rivet
Different Types of Accessories
Care Label Size Label Main Label
Fig: Labels
Hang Tag Price Tag Size Tag
Fig: Tags
Fig :Buttons
Rivet Shangk Button
Snap Button Plastic Button
Fig: Store Trim Card
Accessories Lab Test
After all accessories are QC checked, few samples are sent to the lab for some testing.
Test types:
Nickel Test
Main Label, Care Label Test
Detergent Test
Nickel Test:
In this test a solution of Ammonia & Dimethy glyoxium is used. A cotton bud is lightly dipped in this
solution and then it is rubbed against the surface of a sangk button, rivet or a zipper to see if the tip of cotton
bud turns in pink color. If it turns pink then the lot is considered as lot fait and if it dose not change then the
lot is ok.
Main Label, Care Label Test:
In this test 5 pcs of main label and care label are put into a washing machine with
unwashed garment or a A4 size unwashed fabric sample to see the after-wash effect. If the
effects found after washing are: Color bleeding, Crease mark and damaged writing then
they are rejected.
Detergent Test:
In this test an unwashed garment is put into the washing machine and after adding
detergent the machine is run for an hour. The main purpose of this test is to see if the
metallic or label materials loss any color gets any rough edge if so then they are rejected.
Planning and Control Department
Procedure of Production Planning and Control
1. In advance preparing the production budget.
2. Design the facility layout.
3. Specify the types of machines and equipment.
4. Appropriate production requirements of the raw materials, labour, and machinery.
5. Drawing the appropriate schedule of the production.
6. Confirming the shortage or any excess of the end product.
7. Future plans are drawn for any sudden surge in the demand for the product.
8. The rate and scale of production is setup.
Three Important Stages of Production Planning and Control
The three essential stages of Production Planning and Control are:
Planning stage
Action stage
Monitoring stage
Merchandising Department
Merchandiser is the interface between Buyer & Exporter. He is responsible from
order analysis to shipment.
Knowledge and Skill Requirement for an Apparel Merchandiser
• He should have clear concept about all the garments shipping terms.
• He should have sound knowledge about banking and commercial matters.
• He should have strong sourcing network of raw materials.
• He should be self-motivated and a hard worker.
• He must have ability to maintain commitment.
Responsibilities of a Garment Merchandiser
To arrange all the materials needed for the garments to manufacture and export
To monitor collection of raw materials as per time schedule
To monitor the quantity and quality of the collected raw materials
To select garment factory if needed
To monitor garment production progress as per time schedule
To monitor desired/imposed quality level of the produced garment
Sample Department
Activities of Sample Room
1. To make the proper sample by following the buyer’s instructions.
2. To understand the requirements of the buyer.
3. To fulfill the requirements of the buyer.
4. To confirm the measurement and fabric requirements.
6. To make perfection in the pattern and marker.
7. To make perfection in fabric consumption.
8. To utilizes the skill operation with a skilled operator during garment sewing.
9. To get understanding completely to the operators and management as well about
the upcoming garment production of that order.
10. To combine the overall performance of a garment export order.
Types of Samples made in Sample section
1. Virtual Proto Sample
2. Proto Sample
3. Size Set Sample
4. Seles Man Sample.
5. P.P Sample.
6. Counter Sample.
7. Color Sample.
Sample Department
Sample Department Flow Chart
Check Pattern
Teck Pack Input in
Technical if Making & Cutting
Receive Sewing Line
any Confusion Mini Marker
Assembly
Send to Wash BRTK/Hole QC Pass Send to QC
Complete
After Wash Final Check by
Iron Table Send to Buyer
Check by QC QC
Fig: Automatic Marker Printing Machin Fig: Automatic Pattern Cutting Machine
Machines used in sample section
1. Single Needle Plain Stitch/Lock Stitch
2. Double Needle Lock Stitch
3. Three Needle Flat Lock
4. Double Needle Chain Stitch
5. Double Needle Over Lock With 5 Thread
6. Blind Stitch
7. Zig Zac
8. Bartack
9. Button Hole
10. Button Attaching
11. Eyelet Hole
12. Straight Knife Cutting Machine
Cutting Department
Productin Pattern Marker Fabric Fabric Marker
order sheet recive Making receive sprading placing
Input to
Checking Numbering Bundling Sorting Cutting
sewing
Fig: Cutting Flow Chart
Basic Information
Lay spreading length
For 100% cotton fabric 16 yds
For cotton spandex fabric 14 yds
For small cutting 14 yds
Lay hight
For 100% cotton fabric 4 inch
(some times 3.5 inch)
For cotton spandex fabric 3 to
3.5 inch
Fabric relaxation time period
For 100% cotton 12 hrs
For cotton spandex 24 hrs Fig: Cutting Table
For any other fabric 24-48 hrs
Straight Knife Cutting Machine
Machine Specifications:
Brand Name: Km
Origin: Made in Japan
RPM: 3400
Blade Size: 10 inch
Power: 110V/220V,
Weight: 32lbs/ 14.5 Kg
Cutting Machine
Fig: Fabric Cutting
Fig: Fabric Numbering
Fig: Cut Piece Pattern Check
Sewing Department
Input Ok garments Inside Check
Back &
Waist belt Topside
Front part
QC Check
QC
Defect
garments Assembly
Hourly Audit
repair & section
send to table
Recheck Ok garments Send to wash
Fig: Sewing Flow Chart
Different Sewing machines used in this section
Plain Stitch Machine Component:
Origin: Japan
Assembly: China
Brand: JUKI
One needle
Two tensioners
Three guides
One hook
Two thread
One bobbin case
Fig: Plain Stitch Sewing Machine
Over lock Machine Component:
Origin: China
Brand: ZUSUN
5 thread
tensioner
knifes (up / down)
needle for 5 thread
1 needle for 3 thread
lopper for 5 thread
2 lopper for 3 thread
Fig: Over Lock Machine (3 Thread)
Bar Tack Machine Components:
Origin: Japan
Assembly: China
Brand: JUKI
3 thread
tensioner
knifes (up / down)
needle for 1 thread
2 lopper for 3 thread
Fig: Bar Tack Machine
Bar Tack Machine Components:
Origin: Japan
Assembly: China
Brand: JUKI
3 thread
tensioner
knifes (up / down)
needle for 1 thread
2 lopper for 3 thread
Fig: Feed of the Arm Machine
Industrial Engineering Department
Duties and Responsibilities of the Industrial Engineering
• Layout preparation for every style.
• Monitoring weekly performance report of individuals and conduct meeting to
improve their performance.
• Updating the SAM Database based on method improvement.
• Hire skilled sewing operators.
• Make planes and training seasons for developing operator skill.
Some Important Formula & Example for IE
1. Target calculation
2. Efficiency Calculation
3. Capacity Calculation
4. Theoretical Manpower Calculation
5. Line Machine Productivity
Finishing & packing Department
Wash
garments Shade check Tread cutting QC check Ironing
receive
Measurement Leather patch Button
Lot audit Get up check
check attaching attaching
Metal Packing
Pull test
detector section
Button pulls test is used to determine the pulling strength of any
type of button and snaps used in garments.
Fig: pulls testing machine
Model: Conveyor Type Needle Detector
Type: HN-880C
Detecting System: Magnetic Induction
Metal Detect: Fe 0.8 mm to Fe 1.5 mm (Fe =
Ferrous)
Detecting Width: 600 mm
Detection Hight: 120 mm to 140 mm
(But the industry standard is 70 mm to 80 mm)
Belt speed: 15~ 40 m/min
(But for the industry 15 m/min is standard)
Fig: Ferrous Card Holder Fig: Ferrous Card
HR Compliance & Environment Department
Sections of HR Department
The HR departments have 4 sections
Administration
Compliance
Health & safety
Environment
Compliance
Strict compliance is observed in the case of female workers in terms of any
harassment.
Gender equality is also mention in the factory.
Child labor never allowed or employed.
The Industry strictly follows no policy of discrimination appointment of workers.
Working hours follow as ILO convention.
Health & Safety
Always safety first
No damage to the property
No damage to the workplace and environment
No damage to the human body
3 Reasons for accidents to occur:
Lack of knowledge
Ignorance
Over confidence
Wet
Fire Type Powder Foam CO2 Water
Chemical
Solids
Class A
(e.g. Wood, Plastic, Paper)
✓ ✓ ✘ ✓ ✘
Flammable Liquids
Class B
(e.g. Solvents, Paint, Fuels)
✓ ✓ ✓ ✘ ✘
Gases
Class C
(e.g. Butane, Propane, LPG)
✓ ✘ ✘ ✘ ✘
Metals
Class D
(e.g. Lithium, Magnesium)
✓ ✘ ✘ ✘ ✘
Equipment
Electrical (e.g. Computers, printers, ✓ ✘ ✓ ✘ ✓
TVs)
Table: Types of fire & fire extinguishers
Conclusion
With in the time span of four year B.Sc. Engineering education industrial internship
gives us the one time life time opportunity to wideness, experience and learn the
practical working process of a textile industry. It provides us the chance to marge four
years of technological theory knowledge with practical life knowledge giving us a
complete understanding of RMG sector.
Global Fashion Garments Ltd & Global Outerwear Ltd of Azim group granted me the
opportunity to experience the practical side. Under its watchful eyes and caring wings I
learned and experienced so many new things that the books failed to deliver.
I am forever thankful and hole heartedly pray for this growing industry to reach their
desired destination.
