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Faculty of EngineeringDepartment of Textile Engineering
REPORT ONIndustrial Attachment
AtNur Group
Hortokitola, Attabah, Chandra, Kaliakoir, Gazipur
Prepared By-MD. ABU TALEB TARAQUE
Supervised ByDr. Md. Mahbubul Haque
Prof & Head, Dept. of Textile Engineering
This report is presented in partial fulfillment of the requirements for the degree of Bachelor of Science in Textile Engineering.
Advance in Apparel Manufacturing TechnologyDuration: From June 08, 2016 to August 08, 2016
By means of practical knowledge it is possible to apply the theoretical knowledge in the practical field. For any technical education practical experience is almost equally important in association with the theoretical knowledge.
The industrial attachment is the process which builds understanding skill and attitude of the performer, which improves his/her knowledge in boosting productivity and services. Academic education provides us vast theoretical knowledge as well as more practical attachment, despite all these industrial attachment help us to be familiar with the technical support of modern machinery, skill about various operation stages.
It also provides us sufficient practical knowledge about production management, Productivity evaluation, work study, efficiency, industrial management, production planning & control, production cost analysis, inventory management, purchasing, utility & maintenance of machinery and their operation techniques etc. The above mentioned cannot be achieved successfully by means of theoretical knowledge only. This is why it should be accomplished with practical knowledge in which it is based on industrial attachment makes us reliable to be accustomed with the industrial atmosphere & improve courage & inspiration to take self- responsibility.
We have prepared this attachment in Nur Group which is 100% export oriented garments industry. It has well planned, environment and over all section for making garments. The training minimizes the gap between theoretical and practical knowledge and makes us familiar with the industrial environment, we got an opportunity to complete 45 days long industrial training.
Main Market Europe, USA, Canada, etc. Factory Equipment’s Different types of Sample, Cutting, Sewing, washing, Finishing and
Generator machines. Number of sewing m/c 1100
Number of worker 2000, Male : 900 Female : 1100
Company motto We believe in the power of industry to build a bright future for Bangladesh on the global stage.
Company mission We are passionate about achieving socio-economic growth and change through intelligent business practice.
Company vision The vision of Nur Group is to create an outstanding value for customers and other stakeholders. We are committed to produce world-class products through our hard labor which can satisfy our customers.
Product/Service: T-shirt, Polo shirt, Sweat shirt, Polar jacket, Denim trouser short, Twill trouser short, Shirts, sleep-wear, pyjamas set etc
2.3 Site Direction for NUR GROUP from Dhanmondi, Dhaka:
2.4 History of the factory:
NUR GROUP of companies began with the establishment of NUR KNITWEARS LIMITED AT SHIDDIRGONJ, ADAMJEE ROAD, AT NARAYANGONJ in the year 1995. Since then the group has expanded substantially to become one of the largest groups in the RMG sector in Bangladesh with 2, 000 Employees and an annual target turnover USD 15 million. The main focus of this carefully designed expansion with a future vision has added stability to their business obligations and win customer confidence in product quality, reliability and competent. The approach towards progress and growth is enormous in Nur group till date. Their groups management guideline principle customer above all, quality first is the invariable principle of the group the cause of group going in forever satisfying the requirement and expectation of the customer.
NUR Group is one of Bangladesh’s largest industrial conglomerates, achieving highly respected status worldwide since its initial incorporation as a garments manufacture in 1995.
They are exporting all kind of high quality readymade garments like T-shirt, Polo shirt, Sweat shirt, Polar jacket, Denim trouser short, Twill trouser short, Shirts, sleep-wear, pajamas set etc. for Men, Ladies and kids from Bangladesh to Europe, Canada and America and all over the world Nur Knitwear Limited Established year 1995, Tillottama Fashions Limited Established year 2002, Sumaiya Fibres Ltd. Garments Established year 2002, Production Floor Area 55, 000 Sq. Feet. Production Capacity 200, 000 pc per Month Polo Shirts 450, 000 pc per Month Basic T-Shirts Tank Tops Production Line 15 Lines Products Polo Shirts, T-Shirts, Shorts, Pajamas etc. For Men’s, Ladies, Juniors Kids. Manpower 1300 Nur Wool wears Ltd. Sweater Established year 2003. They have also sweater factory Production Capacity 50, 000 pc per Month Basic Pullovers Cardigans Products Pullover, Cardigan, Tops etc. For Men’s, Ladies, Juniors and Kids. They have own Buying House with all necessary logistic and technological support and facilities. They are exporting all Ready-Made Garments item to over the world.
NUR GROUP
Located in Hortokitala, Attabah, Chandra, Kaliakoir, Gazipur.
Total floor area 55,000 sq. ft.
Capacity 35000 dz per month (shirt, pant, shorts).
We believe in the power of industry to build a bright future for Bangladesh on the global stage.
We believe in the responsibility of our industry to our customers, our people, our surrounding communities and our environment.
We are dedicated to sustainability, accountability and excellence in everything we do.
We are passionate about achieving socio-economic growth and change through intelligent business practice.
Vision:
The vision of Nur Group is to create an outstanding value for customers and other stakeholders. We are committed to produce world-class products through our hard labor which can satisfy our customers.
Values:
We believe in the power of industry to build a bright future for Bangladesh on global stage.
We believe in the responsibility of our industry to our customers, our people, our surrounding communities and our environment. We are dedicated to sustainability, accountability and excellence in everything we do.
We are passionate about achieving socio economic growth and change through intelligent business practice.
Strategy:
Growth through business expansion and acquisition.
Diversification with a focus on professionalism and enhanced management system.
Improved cost-efficiency ratios through intelligent use of manpower and new technologies.
Steadfast improvement and development of our quality product portfolio.
Working in genuine partnership with customers to ensure their total satisfaction.
Enhancing the reputation of Bangladesh’s apparel manufacture industry worldwide.
Sustainability:
We are dedicated as a group to the vital role of sustainability in securing a bright commercial, social and environment future. We address through:
Our people: Building their capacity through professional development and education.
Innovation and technology: Investing in the latest computer aided manufacturing technology.
Quality : Insisting on stringent standards of quality control.
Service: Delivering the highest standards of client care, ensure accountability across supply chain.
Environment : Implementing a 3 years plan to reduce gas water consumption and effluent waste.
3. DESCRIPTION OF DIFFERENT SECTIONS
3.1 KNITTING Section
Knitting is a method by which yarn is manipulated to create a textile or fabric. Knitting creates multiple loops of yarn, called stitches, in a line or tube. Knitting has multiple active stitches on the needle at one time. Knitted fabric consists of a number of consecutive rows of interlocking loops. As each row progresses, a newly created loop is pulled through one or more loops from the prior row, placed on the gaining needle, and the loops from the prior row are then pulled off the other needle.
There are 2 reasons for knitting fault-i. M/c faultii. Yarn fault
Faults found in knitting section-a. Contaminationb. Flyc. Needle mark d. Needle breakagee. Holef. Star markg. Lycra outh. Pattai. Slubj. Wheel freek. Count mistakel. Lot mistakem. Se
3.1 SAMPLE SECTION
Garment samples are inevitably important and are developed tested before starting the bulk production. It means making a sample of the garment /fabric which requires to be sold. Sampling is one of the main process in Garment Industry and it has a vital role in attracting buyers. Because the buyers generally places the order after they are satisfied with the quality of the sample.
Design or Sketch: It is nothing but one kind of engineering art including all measurement of particular style.
Basic Block: It is an individual component of garments without any design or style.
Working Pattern: To make pattern for a particular style with net dimension. .
Problem of Production or Production Related Matter:Production related problems should be eliminated in this step.
Approved Sample:The sample which is approved by buyer is called approved sample.
Send to Buyer: When all process is done, then the garments are sent to buyer.
Production Pattern: To make pattern for a particular style with net dimension along with allowance.
3.1.4 Sample type:
I. Development sampleII. Salesman Sample
III. Photo SampleIV. Approval SampleV. Size set Sample
VI. Mock up SampleVII. Pre-production Sample
VIII. Production SampleIX. Shipping Sample
3.1.5 The Details Attached to the Garment Sample:
After the confirmation of order, each sample sent to 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).
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.
For fabric inspection 4-point system is used in Nur Groups.
4-point system
The 4-point system, also called the American Apparel Manufacturers Association (AAMA)
point-grading system for determining fabric quality, is widely used by producers of apparel
fabrics and by the department of defense in United States and is endorsed by the AAMA as
well as ASQC (American Society for Quality Control).The system in which the penalty point
of a defect is maximum 40 is called 4-point system of quality control.
4 Points System:
In this method, defected points are found out in 100 square yds. of fabric by inspection. The fabric must be rejected if the defected points are greater than 40.
Shrinkage is the process in which a fabric becomes smaller than its original size, usually through the process of laundry. Cotton fabric suffers from two main disadvantages of shrinking and creasing during subsequent washing.
There are two types of shrinkage occurs during washing
1) Length wise 2) Width wise
Cause: Due to high tension during preparation of fabric which result in excess stretch in yarn. This type of shrinkage is known as London shrinkage. Due to swelling of fibers for fiber structure.
Shrinkage % = (length of fabric before wash)-(length of fabric after wash))/ (length of fabric after wash) *100
Fig: Shrinkage test report
3.2.9 Distortion test:
Distortion test is the one of the important test to check the fabric to find, is there any bias, twisting in the fabric which are take place during weaving process. If fabric contain bias more than 3%. During sewing leg twisting and bad shape will come on garment. It’s totally unacceptable. So before cutting we have to ensure about twisting and bias through the distortion test.
3.2.10 Shade band:
Shade band is an important factor before cutting fabric. When fabric is stored in inventory
then sample is collected from every roll than a blanket is made from every single pieces.
After making blanket it is washed and then shade is checked under shade box and categorized
shade. According to this report the fabric is placed on cutting table.
3.2.13 Parts checking inspection:In this stage every parts is checked if there is any variation on measurement. If there any fault is found than it is solve.
3.2.15 Bundle inspection input:At last of cutting every bundle of cutting fabric is checked if there is less of any parts.
iv. Special properties required for particular uses like waterproofing flame-proofing etc.
v. Covering of the faults in the original cloth.
vi. Increasing the weight of the cloth.
3.6.6 In finishing to be checked
Iron or press Folding Tagging Packing Measurement checking Pre-final inspection
Quality assurance Procedure:
The decision plans and action that is necessary to provide adequate confidence that a product or service will satisfy given requirements for particular quality.
Body Inspection:
All rolls are kept in front of the inspection M/c. The fabric are spread over white inspection board which ensures high transparency and even light reflection. Then the inspection machine fabrics and are inspected at a standard speed against light. For any major or minor faults are recorded in inspection report to classify the fabric based on four points system.
Collar &cuff inspection:
Collar &cuff are inspected visually under the light box. For any major or minor faults in collar /cuff like having wrong ply, hole, needle line, slubs, first round problem etc are counted and recorded. Quality inspector will check 100% of receive fabric for quality. He will identify any defect, hole or stain in the fabric and make calculation.
3.6.7 Work in the Finishing Room:
Eliminate micro-dust and residual thread from the garment;
Press/iron garments as specified by buyer or as per requirements;
Fold the garments as required by customer;
Fix necessary tickets (Price tickets) or tags (hang tags),etc to the garments at this stage;
Insert garments into poly bags;
Divide garments as per size and color (assortment);
1. The longer a stain remains, the tougher it is to remove.
2. Always treat a stain before laundering.
3. Blot gently — never rub; and don't ever blot with hot water.
3.6.11 Stain Removal:
Ironing:
Ironing is the use of a heated tool (aniron) to remove wrinkles from fabric. The heating is commonly done to a temperature of 180–220 °Celsius, depending on the fabric. Ironing works by loosening the bonds between the long-chain polymer molecules in the fibers of the material. While the molecules are hot, the fibers are straightened by the weight of the iron, and they hold their new shape as they cool. Some fabrics, such as cotton, require the addition of water to loosen the intermolecular bonds.
Inspection Procedure of Garments are Described Below:
Confirmation of Quantity:
First step of garment inspection start with confirmation of Quantity with the vendors packing list by counting all Pecs of each box. If Qty is not matching to the packing list and written in the box then this discrepancy is informed to the vendor.
Confirmation of Accessories:
Next step is the confirmation of accessories, here we confirm brand tags, demerit tags, Price tags, or other tags, wash care labels, woven labels, or other labels and accessories as required by the buyer.
Size Specification inspection:
After confirmation of accessories all pieces are checked as per size specification based on the instruction sheet which is given by the buyer side. If any measurement problem is noticed then we check the original sample and inform the buyer same time.
In Side Inspection:
At this stage garment is checked from reverse side to ensure that there is no fabric defect, poor stitching, and stains etc. in the garment.
At this stage garment is checked from outside to ensure that there is no color variation, weaving defect, fabric defect, printing defect, holes, poor stitching, bad smell , dying defect and stains etc in the garment.
Final Inspection:
Final Inspection stage is the most important part of inspection process, here garment is rechecked to confirm that inspection is done properly without missing any checking step if any defect is noticed we put it into rejection bin or send it for repay.
Packing:
All “Grade-A” goods are put back into poly bags as per the original packaging and then they are send for needle inspection
Pressing or Folding:
Although pressing remains largely a manual task, new automated process exists that apply force and steam to garments placed over a body form.
After final inspection, the garments are poly-packed, dozen-wise, color wise, size ratio wise, bundled and packed in the cartoon. The cartoon is marked with important information in printed form which is seen from outside the cartoon easily.
3.6.14 Assortment:
Buyers generally place order of garments in certain assortment of color and sizes. The production of such colors and sizes is called assortment. Another order with an assortment of 1:2:2:1 is shown below:
1) Solid size and solid color (the order comprises one size & one color)
2) Solid size & assorted color (the order comprises one size & different colors)
3) Assortment sizes & assorted color (the order has only one color but different sizes)
4) Assorted sizes & assorted color (different sizes & different colors in the order)
Cartoon type:
Master carton (Almost cubic)
Coffin carton (Length > 2*width)
Inner carton (Small & insert able into other carton )
Etc.
Dispatch:
The cartoons of the manufactured garments are delivered or placed in the dispatch department or finished product Go down, from where the garments lot is delivered for shipment.
3.7 STORE SECTIONFor a bulk production industry it is essential to maintain a well-organized & well equipped inventory system. The main responsibility of this department is to store all the raw material necessary to produce garments. This department is sub divided into three sections.
3.7.4 Grey fabrics store:All the grey fabrics are stored in the fabric store, near the batch section. Different types of fabrics are listed in the sheet according to the fabric types, quantity & consumer‘s requirements. Fabrics GSM, shrinkage, diameter & other properties are also taken into consideration. The bathes are prepared by taking the required fabrics from the grey store.
3.7.5 Finished goods:Nur Group supplies its finished garments to its finished goods store. So, finished garments are stored for short time in the finish store. All the delivered fabrics are noted on the note according to the Lot no., quantity, size, buyer‘s name, colors, & considering other parameters.
3.7.6 Accessories Store:According to Buyer and style number, store keeper arranged their rack for inventory. When an order is confirm they communicate with merchandiser / suppler and confirm inventory. Store keepers receive all accessories by counting.
If everything is ok then they give satisfactory comments and if found any kind of problem they mention in challan sheet. After receive all accessories they give entry in computer & keep arrange in rack for easily searching. Trim card make for different style & buyer wise for smooth work.
Various types of packing accessories are available in store room such as polybag, packing board, tissue paper, hanger, scotch tape, gum tape, carton etc.
3.7.10 Trim card contain with:
-Main, size & care label.
-Back neck tape.
-Button.
-PSP paper.
-Tag pin.
-Master carton.
-Poly stiker.
-Carton stiker.
-Poly bag.
-Logo gum tape.
-Heat transfer.-Interlining.
-Woven twill fabric.
-Country flag sticker.
-Hang tag.
-Mobilon tape.
-Security label
3.7.11 Accessories Inspection:
At first 10% accessories are inspected by QC inspector. If the defectives amounts cross over 1% then the accessories will fail. In the situation according to suggestion of QA & QC manager these accessories send to the merchandiser and buyer representatives finally to work according to their decision.
Compliance means comply something i.e. yield to the wishes another. The main aim of compliance is to ensuring the all labor rights and facilities according to buyer code of conduct.
3.8.2 Different compliance issues which they are obeyed:
Personnel policies
Attendance and leave register card Recruitment policy Leave and holiday policy Their weekly working hour not more than 66 hours including overtime in a week They have the approved manpower list.
First aid ensures. Medicine registers. Maternity and pregnancy register. Pure drinking water. Towel for hand dry.
Safety:
Safety committee Firefighting committee Rescue committee Broken needle register Needle detector Fire alarm & switch Evacuation plan Rubber mats to every iron man.
Welfare:
Welfare committee Day care center Canteen facility
Salary and wages:
Fix wages in considering minimum wages which is declared by the government. Salary and wages given before 7th day of month.
Physical security:
They have separate cargo entrance area (receiving and unloading) from the front side. They do not keep any partially filled/ completed cartons on the floor at the end of any
working day. They keep it to finished goods store.
They arrange security training program on regular basis for all employee of the factory.
3.8.3 Compliance item:
Some example of compliances item are given below: First aid box Water paper Toilet Wash basin Complain box Evacuation plan Exhaust fan Emergency exit/light/ light set Smoke detector Fire extinguisher Hose cabinet Manila rope Gas musk