This document is posted to help you gain knowledge. Please leave a comment to let me know what you think about it! Share it to your friends and learn new things together.
Transcript
Industrial Training Report Sadma Fashion Wear Ltd.
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 2
Table of Content Page
1. Chapter One (Company Profile) 7-16
1.1. Company Profile at a glance
1.2. Office Staff:
1.3. Quality Policy
1.4. Welfare Facilities
1.5. Compliance
1.6. Recruitment policy
1.7. Different Departments
1.8. Present Buyers
1.9. Logo of Present Buyer
1.10. Certification
1.11. Production Capacity
1.12. Production Area
1.13. Location of Sadma Fashion Wear Ltd
1.14. Basic Layout of Whole Factory
1.15. Factory Building of Sadma
2. Chapter Two (Manpower Management System) 17-21
2.1. Manpower Management System
2.2. Management Medium
2.3. Shifting
2.4 Section Wise Manpower
2.5. Duties and Responsibilities of Different Post
2.6. Deputy General Manager (DGM) Production
2.7. Manager
2.8. Senior Production Officer
2.9. Production Officer
2.10. Shift In charge
3. Chapter Three (Production Planning & Control) 22-23
3.1. Basic Procedure of Production Planning & Control
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 3
4. Chapter Four (Raw-Materials) 24-28
4.1. Main Raw- Materials
4.2. Type of Raw-Materials
4.3. Chemical Use in Sadma Fashion Wear Ltd
4.4. Dyes use in Sadma Fashion wear Ltd.
4.5. Remark
5. Chapter Five (Working Sequence of Knitting Section) 29-33 5.1. Working Sequence of Knitting Section
5.2. Working Sequence of Batch Preparation
5.2. Working Sequence of Batch Preparation
5.4. Working Sequence of Finishing Section
5.5. Working Sequence of Garments Manufacturing Section
5.6. Production Parameter of Knitting
5.7. Production Parameter of Dyeing
5.8. Remark
6. Chapter Six (Knitting Section) 34-57 6.1. Layout Plan of Knitting Section 6.2. Fabric 6.3. Knitting Fabric 6.4. Classification of Knitting 6.5. Process Flow Chart of Knitting
6.6. Different Fabric Characteristics & End Uses
6.7. Machine List of Knitting Section in Sadma
6.8. Different Parts in Knitting Machine
6.9. Types of knitted Fabric Produce in Sadma
6.10. Design Development by Changing Different Cam Setting
6.11. Considerable Points to Produce Knitted Fabrics
6.12. Production Calculation
6.13. Production Parameter
6.14. Important Parameter & Their Effect in Fabric Production
6.15. Faults with their Causes and Remedies in Knitting
6.16. Quality Assurance System of Knitting
6.17. Fabric Inspection
6.18. Fabric Inspection Machine
6.19. Faults are detected By Inspection 6.20. Point Distribution for Different kinds of Fault
7. Chapter Seven (Batching) 58-61
7.1. Batching
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 4
7.2. Batch Process Follow-Up
7.3. General Instructions for the Final Inspection
7.4. Object of Batching
7.5. Types of Batching
7.6. Proper Batching Criteria
7.7. Machine in Batch Section
8. Chapter Eight (Color Measurement System) 62-72
8.12. Color Measurement of Standard Sample
8.12. Machine Specification in Section
9. Chapter Nine (Dyeing Section) 73-102
9.1. Layout of Dyeing Floor
9.2. Dyeing Machine Specification
9.3. Specification and Images of Dyeing & Finishing Machine
9.4. Operation Procedure
9.5. Dyeing Process Definition
9.6. Dyeing process of Cotton
9.7. Dyeing Process of CVC of PC
9.8. Process Sequence of Critical Shade (Turquoise Color)
9.9. Some Important Parameter for Dyeing
9.10. Common Dyeing Fault with their Remedies
10. Chapter Ten (Finishing Section) 103-111
10.1. Introduction of Finishing
10.2. Objective of Finishing
10.3. Different Finishing Machine in Sadma Fashion Wear Ltd.
10.4. Observation of Different Finishing Machine
10.5. Squeezer of De-Watering Machine
10.6. Dryer
10.7. Tube Compactor
10.8. Slitting Machine
10.9. Stenter Machine
10.10. Open Compactor
10.11. Fabric Inspection
10.12. Fault Point System
11. Chapter Eleven (Garments Section) 112-132
11.1. Garments
11.2. Garment Machinery & Equipment
11.3. Garments Manufacturing Process
11.4. Sewing Sequence of T- Shirt
Industrial Training Report Sadma Fashion Wear Ltd.
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 9
13. Bank: SOCIAL ISLAMI BANK LIMITED.
Foreign Exchange Branch,
Motijheel C/A, Dhaka, Bangladesh.
TEL: 9571254 FAX: 9571100
Factory A/C NO: 13300009963
Bank Swift No: SOIVBDDHFEX
14. Product Mix: Single jersey plain fabric, Pique, Single lacoste, 1x1 rib, 2x2 rib, Plain interlock
15. Main Product: T-shirt, Polo shirt and different types of Men‟s, Lady‟s & Kid‟s wear in varies
kinds of knit fabric.
16. Year End Turnover: 50Million USD
1.2. Office Staff:
A large team of Technical personnel are directly working, assisting the workers &
Coordinating pattern, cutting, sewing, quality & finishing-packing. About 200 people are working as a
Supervisor, Line chief, Floor in-charge, Section Manager.
1.3. Quality Policy
Sadma Fashion Wear Ltd. is totally committed to provide quality products that always meet
the needs and expectations of customers for reliability, safety, and economy and on time delivery of
shipments. To achieve this objective, Sadma Fashion Wear Ltd. provides all the necessary resources
to ensure a well-equipped and adequately trained, and experienced manpower to take proper
care of customer requirements. Sadma Fashion Wear Ltd. Emphasized that quality is the shared
responsibility of its entire staff. The company ensures that all personnel are familiar with, and work
to the company‟s work practices as well in conformity with the legal and other obligatory
requirements and are determined to comply with the requirements of Buyer‟s expectation e.g. code of
conduct, social compliance and continually improve its production and Quality Assurance
Department. To manufacture quality products and Customer satisfaction is the company‟s goal.
1.4. Welfare Facilities
Induction of workers welfare committee aimed at improving workers morale, job Satisfaction
& attendance.
Canteen facilities.
Subsidized lunch for staff.
Free snacks for workers.
Full time free of medical service provide by a professional doctor.
Provision for day care center for workers children, annual picnic.
Cultural function.
Each floor has sufficient number of washroom.
Each floor has sufficient lighting to facilitate production.
A large dining hall is in the factory including pure drinking water & well sitting arrangement.
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 10
Maternity leave & benefit for female workers are provided as per labor law.
1.5. Compliance
Factory are obeying and maintaining international and local law‟s, Human rights, Social
compliance, Labor law and other rules and instruction by related department of Government.
1.6. Recruitment policy
No child labor in this factory.
No gender discrimination in recruitment procedure.
There is no force labor.
1.7. Different Departments
Knitting
Dyeing
Finishing
Garments
Utility
Maintenance
Quality Assurance
Planning
Research & Development
Admin
HR & Compliance
1.8. Present Buyers
C & A(Germany)
Zellers (Canada)
George (U.K)
Sears (Canada)
Sainsbury (U.K)
Diplomat Fashion (U.S.A)
Matalan (U.K)
Artextyl (U.S.A / France)
S F G (Australia)
Xios (U.S.A)
Vayla (U.S.A)
Walmart (U.S.A)
Emporio Junior(Italy)
Pierre Cardin (Italy)
Carrefour Import Sas (France)
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 11
1.9. Logo of Present Buyer:
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 12
1.10. Certification
ISO 9001:2008, WRAP.
Member: Bangladesh Garments Manufactures & Exporters Association (BGMEA)
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 13
1.11. Production Capacity
Production Capacity Knitting: 12000 Kgs Per Day
Production Capacity Dyeing & Finishing: 8000 Kgs Per Day
Production Capacity Garments: 20000 Pcs. Per Day
Production lead time: 45-90 Days
1.12. Production Area
Knitting space: 5000 sq. feet
Dyeing space: 34000 sq. feet
Finishing Goods & Store: 5500 sq. feet
2nd Floor: 5500 sq. feet
3rd Floor: 6500 sq. feet
4th Floor: 6500 sq. feet
5th Floor: 6500 sq. feet 6th Floor: 6500 sq. feet
Other space: 2000 sq. feet
Total space: = 77000 sq. feet
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 14
1.13. Location of Sadma Fashion Wear Ltd
Figure: Location of Sadma Fashion Wear Ltd.
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 15
1.14. Basic Layout of Whole Factory
Figure: Basic Layout of Whole Factory.
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 16
1.15. Factory Building of Sadma
Figure: Factory Building of Sadma.
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 17
CHAPTER-TWO
Manpower Management
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 18
2.1. Manpower Management System
The Sadma Fashion Wear Ltd. committed to the best human workplace practices. Their goal is
to continuously improve human resource policies & procedures through education, training,
communication and employees improvement.
2.2. Management Medium
Intercom Telephone.
Fax.
E-mail.
Written letter & papers.
Oral.
2.3. Shifting
In Sadma Fashion Wear Ltd. the whole day production time is divided into 3 shifts. Per shift consists
of 8 hours.
Shift Duration
Shift A
6:00 am- 2:00 pm
Shift B
2:00pm – 10:00 pm
Shift C 10.00pm-6.00am
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 19
2.4 Section Wise Manpower
Department Manpower
Knitting
90
Dyeing & Finishing
300
Lab & QC
25
Garments
800
Power, Boiler ,Utility & Maintenance
15
Inventory
15
Administration
25
Security
30
Others 20
Total 1320
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 20
2.5. Duties and Responsibilities of Different Post
G.M in Dyeing and Finishing Section
Overall supervision of dyeing and finishing section.
Check the sensitive parameters of different machines for smooth dyeing.
Check the different log books and report to management.
Check the plan to control the best output.
To trained and motive the subordinates how to improve the quality production.
Control the Manager, Asst. Manager, Senior Production Officer, Production Officer, in-
charge, supervisor of dyeing and finishing section.
2.6. Deputy General Manager (DGM) Production
Overall supervision of dyeing and finishing section.
Check the sensitive parameters of different machines for smooth dyeing.
Check the different log books in different areas and report to management.
Check the plan to control the best output.
To trained and motive the subordinates how to improve the quality production.
Control the supervisor, operator, asst. operator and helper of dyeing machine.
Any other work as and when required.
2.7. Manager
To supervise the personal working under him
To plan the sequence of production
To arrange necessary raw materials for the production problems.
To find out the possible reasons which are responsible for less production.
To follow up the instruction of Managing Director and Executive Director as well.
2.8. Senior Production Officer
Overall supervision of dyeing and finishing section.
Batch preparation and pH check.
Dyes and chemicals requisition issue and check
Write loading/unloading time from machine.
Program making, sample checking color measurement.
Control the supervisor, operator, asst. operator and helper of dyeing machine.
Any other work as and when required.
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 21
2.9. Production Officer
To collect the necessary information and infrastructure from the previous shift for the
smooth running of the section.
To match production sample with target shade.
To match production sample lot sample matching next production.
To observed dyed fabric during finishing running and also after finishing process.
To identify disputed fabrics and report to PM/Gm for necessary action.
To discuss with PM about overall production if necessary.
To sign the store requisition and delivery challenge in the absence of PM
To execute the overall floor work.
To maintain loading/unloading paper.
2.10. Shift In charge:
To follow the workers movement.
Should discuss with the production Officer about what is happening.
To maintain the production sequence.
To check the sample at certain time interval.
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 22
CHAPTER-THREE
Production Planning and
Control
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 23
3.1. Basic Procedure of Production Planning & Control
A planned work brings success. Without planning nothing is complete within the required
time. So planning has its own importance which is intolerable. Planning gives a scheduled task and
control completes it successfully. But production planning and control is not an easy task. Its basic
working procedure is as follows-
A. Taking order form marketing division ,
B. Analyzing the orders
C. Planning for knitting the fabric
D. Planning for dyeing the fabric
E. Planning for finishing the fabric
It is only a basic procedure. It may change according to the type of order. Sometimes the order is
planned only for finishing the materials or only for dyeing the goods. Then some steps are
minimizing for planning.
A. Taking order from the marketing division
Marketing division supplied fabric orders to the planning and control division by a specific
format.
B. Analyzing the orders
After getting the fabric order, this section analyzes the orders according to buyers order
quantity, type of orders (i.e. type of fabric, color to be dyed etc.) delivery date etc. This section plans
for required quantity of fabric to be knitted, knitting balance, fabric to be dyed, dyeing balance RFD
(ready for delivery), RFD balance, delivery fabric & delivery balance.
C. Planning for knitting:
This section plans for knitting production. It selects m/c for knitting the fabric, no of m/c to be
used, type of yarn used, from which source of yarn will be collected, required GSM, width etc. It
also gives delivery date of knitted fabric.
D. Planning for dyeing of the fabric
Production planning for dyeing is called "Batch Plan". Batch plan is prepared according to
m/c capacity, no. of nozzle batch no, fabric construction, color, width, GSM and priority of delivery
etc. and written in a batch card.
E. Planning for finishing of the fabric
Finishing schedule is same as dyeing. After dyeing, materials go to the finishing section with
the batch plan. The fabric can be finished in the open line finish or tube line finish. Finishing line
will be selected according to the type of the fabric to be finished. Finishing data is written to the
batch card and is informed to the planning section. However this section always forces to all the
departments to finish all the work within the delivery time given by the buyers. Thus, it plays a very
important role in the success of the company.
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 24
Chapter-Four
Raw Material, Dyes & Chemical
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 25
4.1. Main Raw- Materials
Raw material is a unique substance in any production oriented textile industry. It plays a vital
role in continuous production and high quality fabric.
4.2. Type of Raw-Materials
A. Yarn
B. Fabric
C. Dye stuff
D. Chemical and auxiliaries.
A. Yarn
The raw material for knitting is the yarn. Different types of yarn of wide range of different
count are used. Both carded and combed yarns are used for knitting.
Generally used yarn and yarn count
Yarn Type Yarn Count
Cotton 24s, 26
s, 28
s, 30
s, 32
s, 34
s, 40
s.
CVC 24s, 26
s, 28
s, 30
s, 32
s.
Grey Melange 24s, 26
s, 28
s, 30
s, 32
s.
PC(65%Polyester & 35%Cotton) 24s, 26
s, 28
s, 30
s.
Spandex yarn 20D, 40D, 70D.
B. Sources
The required yarns are supply from
Cotton Yarn
Name of the spinning Mills Location
Gulshan Spinning Ltd. Gazipur
J K Spinning Gazipur
N Z Textile Rupgonj,Narayangonj.
Tamijuddin Textile mill Ltd. Konabari, Gazipur
Shajahan Spinning Mills Shreepur,Gazipur
R N Spinning Gazipur.
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 26
Badsha Spinning Gazipur
Hanif Spinning Gazipur
Shirin Spinning Ltd. Shreepur, Gazipur
Pakiza spinning Narshindi
Sqaure Spinning Valuka, Mymensingh
Lycra
Singapore
Korea
Indonesia
Japan
Fabric:
Single jersey
Single jersey with lycra
Polo pique
Single lacoste
Interlock
Interlock with lycra
Fleece
Rib
Rib with lycra
1×1Rib
2×1Rib
2×2Rib
Different types of Collar & Cuff
Twill tape
4.3. Chemical Use in Sadma Fashion Wear Ltd
Basic Chemical
Acetic Acid
Sulphuric Acid
Caustic Soda
Soda ash
Hydrogen peroxide
Formic Acid
Bleaching Agent
50%H2O2
Enzyme
Gold RSL
Biozyme
Rezyme
P200
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 27
Sequestering Agent
PS cone
HRO
E3R
Anti foaming Agent
ATS
UDF
Antimusol FFC
Leveling agent
CFTR
Ladi
L.Quest
Stabilizer
Info ST
Best
Salt Glubar salt Anti creasing Agent Best Ant
Detergent
Sirix 2UD
Info NGE
BGL
Peroxid Killer
Infozyme
Softener
4D
CSB
HD
Reducing Agent
Hydrose(Na2S2O4)
Fixing Agent
ECO
Polyfix AC
Optifix EC
Brightening Agent 4BK
BVB
Washing Agent
Best
Info RW
Innocol RD
Whitening Agent
Uvitex BAM
Uvitex BHV
Synowhite
4.4. Dyes use in Sadma Fashion wear Ltd.
SI.
No
Dye name Origin SI.
No
Dye name Origin
1 Hellocron Red
HXF(Dis
China 21 Fucozol Blue EBL China
2 Hellocron Blue HXF China 22 Fucozol Blue EXN China
3 Hellocron Navy HXF China 23 Fucozol Blue RSPL China
4 Hellocron Black HXF China 24 Fucozol T-Blue G China
5 Hellocron Yellow
Brown HXF
China 25 Fucozol N-Blue NBF China
6 Hellocron Yellow
6GSL
China 26 Fucozol N-Blue USB China
7 Hellocron Navy Blue
ECOR
China 27 Fucozol Black BG China
8 Hellocron Orange ERL China 28 Fucozol Orange D2R China
9 Hellocron Black ECOR China 29 Remazol Yellow RR Germany
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 28
10 Hellocron Blue BGE China 30 Remazol Red RR Germany
11 Hellocron Red FB China 31 Remazol Blue RR Germany
12 Fucozol Yellow 3RF China 32 Remazol Orange RR Germany
13 Fucozol Yellow L3R China 33 Remazol Yellow 3GL Germany
14 Fucozol Yellow UCF China 34 Remazol T-Blue G Germany
15 Fucozo Yellow UCX China 35 Remazol Blue RSPL Germany
16 Fucozol Red 3BF China 36 Reactive Yellow 3RE China
17 Fucozol Red L3B China 37 Reactive Red 3BE China
18 Fucozol Red UCX China 38 Reactive Yellow 4GL China
19 Fucozol Red USG China 39 Reactive Black B China
20 Fucozol Red USB China 40 Reactive Orange MCRL China
Note:
Disperse Dyes
Reactive Dyes
4.5. Remark:
As quality is the prime concern of the factory, qualitative raw material are always bought by the
management of factory. Besides there is enough space to keep this raw material in the factory.
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 29
CHAPTER-FIVE
Working Sequence of different
Section
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 30
5.1. Working Sequence of Knitting Section
Order sheet receiving from Merchandiser
Selecting of production parameters
Arranging of yarn
Testing of yarn
Arranging of selected machine
Making a pre-production sample
Starting of bulk production after approval
Checking of grey fabric
Delivery of grey fabric according to batch wise
5.2. Working Sequence of Batch Preparation
Process sequence of batch preparation receive batch card from grey fabric in-charge.
Make priority as per dyeing plan.
Take one specific batch card.
Read the batch card for own understanding.
Check the availability of fabric.
The required quantity of body fabric from ware house.
Take collar & cuff as per size keep the total weight.
Distribute the collar, cuff or rib in each rope equally ensure equal length.
Stitch the fabric.
Write down the weight against roll no. in the back side of the batch card.
Put signature and date.
5.2. Working Sequence of Batch Preparation
Batching
Pretreatment
Dyeing
Fabric sent to finishing section
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 31
5.4. Working Sequence of Finishing Section
Receive fabric from dyeing section
Tube or Open fabric
Squeezer
Slitter (Tube fabric)
Stenter
Compactor
Final inspection
Packing or Rolling
Fabric sent to delivery section
5.5. Working Sequence of Garments Manufacturing Section
Merchandiser receive order from buyer
Order confirmed
Knitting
Dyeing & Finishing
Cutting
Printing and Embroidery (If required)
Sewing
Finishing
Inspection
Packing
Shipment
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 32
5.6. Production Parameter of Knitting
Machine diameter.
Machine rpm.
No. of feeder or feeders in used.
Machine gauge.
Count of yarn.
Required time (m/c running time)
Machine running efficiency.
5.7. Production Parameter of Dyeing
pH level for different stage of Polyester fabric Dyeing
Name of Stage pH rate
Initial (Bath) 6.5-7.0
Scouring (Bath) 10.0-11.5
After Scouring (Bath) 8.5-9.0
Before addition of leveling chemical 6.0-6.5
After addition of leveling chemical 4.5-4.7
After addition of color (Bath) 4.2-4.5
During reduction cleaning (Bath) 10.5-11.5
Before softener (Bath) 6.3-6.8
After softener (Bath) 5.8-6.2
pH level for different stage of Cotton fabric Dyeing
Name of Stage pH rate
Initial bath 6.5-7.0
Scouring & Bleaching (Bath) 10.0-10.5
After Scouring & Bleaching 8.5-9.0
Before Enzyme (Bath) 4.5-4.7
After Enzyme (Bath) 5.5-6.0
Before addition of leveling chemical 6.5-7.0
After addition of leveling chemical 6.7-7.0
After addition of dyes 6.0-6.5
After addition of Salt 7.5-8.0
After addition of Soda 10.5-11.0
Hot wash (Bath) 8.5-8.7
Before softener (Bath) 7.2-7.8
After softener addition (Bath) 6.5-6.8
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 33
5.8. Remark
This data‟s are varied depending upon the grey GSM and finished GSM and also on the
diameter of the fabric all this parameters are suitable for grey GSM range 140 to 160 to get final
GSM 170 to 185 without lycra fabric. All this data‟s are practiced in mills which may very factory to
factory.
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 34
CHAPTER-6
KNITTING SECTION
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 35
6.1. Layout Plan of Knitting Section
A. Supervisor Desk
B. Inspection Machine
C. Wash Room
Figure: Layout Plan of Knitting Section
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 36
6.2. Fabric
Fabrics are manufactured assembly of fibers or yarn. Which have substantial surface areas in
relation to the thickness and sufficient strength to give the assembly inherent cohesion.
There are three types of fabric. They are-
Knitted fabric
Woven fabric
Non-woven fabric
6.3. Knitting Fabric
Knitting is the method of making fabric by transforming continuous strands of yarn into a
series of interloping loops, each row of such loops forms the one immediately preceding it.
6.4. Classification of Knitting
6.5. Process Flow Chart of Knitting
Yarn in cone form
↓
Feeding the yarn cone in the creel
↓
Feeding the yarn in the feeder via trip-tape positive feeding arrangement
↓
Tension devise
↓
Knitting
Warp Knitting
Weft Knitting
Flat Knitting
Circular Knitting
Knitting
Knitting
Double Jersey
Single Jersey
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 37
Knitting
↓
Withdraw the rolled fabric and weighting
↓
Inspection
↓
Numbering
6.6. Different Fabric Characteristics & End Uses
Characteristics of Single Jersey
Fairly elastic.
Face side and back side of fabric are different.
Front side is smooth and the back side is rough.
V-Shaped loops in the front, while semi-circular needle loops shown in the back.
Curl or roll of fabric occurs at the edges.
Wales are clearly visible on the face side of the fabric.
Extensibility in widthwise is approximately twice than length.
Unraveling of fabric occurs from either side is possible.
Thickness of fabric is approximately twice the diameter of yarn used.
There is only one series of knitted loop per courses in the fabric
End Use
T-shirt Underwear Dresses Stocking
Characteristics of Double Jersey
A broken stitch will cause laddering. Consume more quantity of yarn than a plain fabric. Does not curl at both ends. Good stretch ability in widthwise direction.
End Use
Cuffs Collars Sweaters Garments
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 38
Characteristics of Plain Interlock
Interlock the technical face of plain on both sides so the appearance of face and back
are same.
The Wales of each side re exactly apposite to each other and are locked together.
Widthwise and length elongations are approximately the same as single jersey .
The fabric does not curl at the edges .
The fabric can be unraveled from the knitted last.
Two yarn must be removed to unravel a complete repeat of knitted courses.
Fabric thickness is approximately twice than that of single jersey.
End Use
T-shirt
Ladies dresses
Sweaters
Garments
Outerwear
6.7. Machine List of Knitting Section in Sadma
Serial
No Machine Type Brand Origin Quantity
Machine
Diameter
Machine
Gauge
No. of
Feeder
1 Single Jersey Lisky Taiwan 2 18” 24 54
2 Single Jersey Lisky Taiwan 3 20” 24 60
3 Single Jersey Lisky Taiwan 2 22” 24 78
4 Single Jersey Lisky Taiwan 3 24” 24 90
5 Single Jersey Lisky Taiwan 4 26” 24 84
6 Single Jersey Fukahama Taiwan 4 28” 24 108
7 Single Jersey Fukahama Taiwan 2 30” 18 80
8 Single Jersey Fukahama Taiwan 4 34” 24 90
9 Single Jersey Fukahama Taiwan 2 38” 24 120
10 Single Jersey Fukahama Taiwan 4 40” 24 102
11 Rib Young
Cheng Taiwan 2 20” 18/24 88
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 39
12 Rib/Interlock Lisky Taiwan 2 24” 18/24 64
13 Rib/Interlock Lisky Taiwan 2 28” 18/24 80
14 Rib/Interlock Lisky Taiwan 3 30” 18/24 114
15 Rib/Interlock Lisky Taiwan 3 34” 18/24 90
16 Rib/Interlock Lisky Taiwan 4 38” 18/24 120
17 Rib/Interlock Lisky Taiwan 2 40” 24 96
6.8. Different Parts in Knitting Machine
Figure: Circular Knitting machine
1. Creel
Creel is a part of a knitting machine where yarn package are store and ready to feed in the machine.
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 40
Figure: Creel
2. VDQ Pulley
It is a very important part of the machine. It is used to control the GSM by controlling the stitch
length.
Figure: VDQ Pulley
3. Belt & Pulley: It controls the rotation of the MPF wheel.
Figure: Pulley Belt
4. Tension Disk: It confronts the tension of the supply yarn.
Figure: Tension Disk
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 41
5. Inlet and Outlet Stop Motion:
It is an important part of the machine. It stops the machine instantly when a yarn is break.
Image: Inlet and Outlet Stop Motion
6. Yarn Guide: Its help the yarn to feed in the feeder.
Figure: Yarn Guide
7. MPF Wheel: Its control the speed of the MPF. Pulley belt gives motion to the wheel.
Figure: MPF Wheel
8. Feeder Ring: It is a ring where all feeders are pleased together.
Figure: Feeder Ring
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 42
9. Positive Feeder: Positive Feeder is help yarn to feed in to the machine.
Figure: Positive Feeder
10. Needle
The fundamental element of construction of knitted fabrics is the knitting needle, during yarn
feeding, the hook is opened to release the old loop and to receive the new loop which is then
enclosed in the hook. The new loop is then drawn by the hook through the old loop which slides over
the outside of the closed hook.
There are mainly three types of needle-
1. The bearded needle.
2. The latch needle.
3. The compound needle. According to the butt position Latch needles are four types-
1. One butt latch needle
2. Two butt latch needle
3. Three butt latch needle
4. Four butt latch needle
Figure: Needle
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 43
11. Needle Track: Where all Needles is placed together in a decent design.
Figure: Needle Track
12. Needle Detector: This part is detected the any type of faults of needles.
Figure: Needle Detector
13. Sinker
The sinker is the second knitting elements. It is a thin metal plate with an individual or a
collective action operation approximately at right from the hook side between adjacent needles.
Figure: Sinker
14. Sinker Ring: Sinker ring is a ring where all sinkers are pleased together.
Figure: Sinker Ring
15. Cam
Cams are the third primary knitting elements which cover the rotary machine drive into a
suitable reciprocating action for the needles and other elements. The cams are carefully profiled to
produce precisely timed movement and dwell periods. The drive transmitted and adapted via cam
followers, leavers, pivots and rocking shafts. One complete 360° revolution of the driver shaft is
equivalent to one knitting cycle. Two types of cam:
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 44
1. Engineering cams
2. Knitting cams
A. Knit cam
B. Tuck cam
C. Miss cam
Figure: Cam
16. Cam Box: Where the cams are set horizontally
.
Figure: Cam box
17. Cylinder: Needle track are situated hear.
Figure: Cylinder
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 45
18. Cylinder Balancer: It helps the cylinder to set in a proper alignment.
Figure: Cylinder
19. Lycra Attachment Device: Lycra is placed hear and feeding to the machine.
Figure: Lycra Attachment Device
20. Lycra Stop Motion: It is one kind of stop motion to stop the machine when the Lycra is
break.
Figure: Lycra Stop Motion
21. Uniwave Lubrication: The Uniwave lubricator provides uniform lubrication to needles,
cam tracks, lifters and other knitting machine components. The patented nozzle construction
separates the air-oil mixture into air and droplets of oil.
Figure: Uniwave Lubrication
22. Adjustable Fan: This part removes lint, hairy fiber from yarn and others. To clean the dust
by air flow.
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 46
Figure: Adjustable Fan
23. Expander:
To control the width of the knitted fabrics. No distortion of the knitting courses. Even take
down tension in the knitting machine. As a result, an even fabric structure is achieved over the entire
fabric width. The deformation of the knitted fabric goods can be reduced.
Figure: Expander
24. Air Gun Nozzle: To feed the yarn; sometimes it is used for cleaning purpose.
Figure: Air Gun nozzle
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 47
6.9. Types of knitted Fabric Produce in Sadma
6.10. Design Development by Changing Different Cam Setting
Fabric Cam design
Single Jersey K K K
Single pique K T
T K
Double pique K K T T
T T K K
Single Jersey
Single Jersey
Single Jersey (Lycra)
Single Jersey (Auto Stripe)
Pique
Single Pique
Double Pique
Pique (Auto Stripe)
Interlock
Interlock
Interlock (Cotton)
Interlock (PC)
Rib
1×1Rib
2×2Rib
2×1Rib
Fleece
Fleece
Terry Fleece
Lacoste
Single Lacoste
Double Lacoste
Lacoste (Auto Stripe)
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 48
Single lacost K K T K
T K K K
Double lacost K K K T T K
T T K K K K
Terry fleece K T K M
K M K M
K M K T
Fleece K K T K M
K K M K M
K K M K T
Rib Dial: K K
K K
Cylinder: K K
K K
Interlock Dial: K M
M K
Cylinder: K M
M K
Note: K= Knit cam, T= Tuck cam, M= Miss cam
6.11. Considerable Points to Produce Knitted Fabrics
When a buyer orders for fabric then they mention some points related to production and
quality. Before production of knitted fabric, these factors are needed to consider. Those are as
follows.
Type of Fabric or design of Fabric.
Finished G.S.M.
Yarn count
Types of yarn (combed or carded)
Industrial Training Report Sadma Fashion Wear Ltd.
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 112
CHAPTER-11
Garments Section
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 113
11.1. Garments
The garments production processing steps and techniques involved in the manufacturing for
the large scale of production in industrial basis for business purposes is called garments
manufacturing technology.
11.2. Garment Machinery & Equipment
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 114
11.3. Garments Manufacturing Process
This is the Basic Production Flow chart of a garment. In advance some of the process can be added
or removed.
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 115
11.4. Sewing Sequence of T- Shirt
Number matching front to back part
↓
Solder stitching (By Over lock m/c)
↓
Neck rib truck (By Plain m/c)
↓
Neck rib sewing (By Plain m/c)
↓
Neck rib join with body part
↓
Neck top sin
↓
Solder to solder back tip
↓
Size label sewing
↓
Solder to solder back sin
↓
Sleeve marking and number matching with body part
↓
Sleeve tuck with body part (Sleeve mark point & solder mark point)
↓
Sleeve joint with the body part
↓
Side sewing and care label joint
↓
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 116
Bottom hem tuck (At the end side)
↓
Bottom hem sewing
↓
Arm bottom hem joint
↓
Inspection
11.5. Sewing Sequence of a Polo Shirt
Lining joint with collar part by heat pressing
↓
Collar marking for open stitch
↓
Collar inside open stitch
↓
Collar marking
↓
Collar 1/4 top sin
↓
Collar cutting
↓
Band rolling
↓
Band joint with Collar
↓
Band top sin 1/6
↓
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 117
Placket lining
↓
Placket marking
↓
Placket rolling
↓
Placket joint
↓
Placket top sin 1/6
↓
Placket pattern top sin
↓
Placket pattern top sin 1/6
↓
Box sewing
↓
Pocket rolling
↓
Pocket iron
↓
Pocket marking
↓
Pocket joint with body
↓
Yoke joint with back part
↓
Yoke ¼ top sin
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 118
↓
Back & front part matching number
↓
Solder joint
↓
Solder top sin
↓
Collar and body number matching
↓
Collar joint with body part
↓
Collar top sin in joining point
↓
Sleeve marking
↓
Sleeve over lock
↓
Sleeve rolling
↓
Sleeve pair matching
↓
Sleeve and body matching
↓
Sleeve body tuck
↓
Sleeve joint with body part
↓
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 119
Sleeve marking for batch
↓
Sleeve batch joint (Left & Right side)
↓
Body marking for batch
↓
Batch joint with body part
↓
Label marking
↓
Label ironing
↓
Main label joint with back side
↓
Sleeve opening tuck
↓
Body hem sewing
↓
Care label sewing
↓
Side joint
↓
Band tuck
↓
Band tape joint
↓
Band top sin
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 120
↓
Sleeve chap tuck
↓
Inspection
11.6. Garments Accessories
Fabric is the basic material in garment manufacturing. Except fabric the other materials are
known as accessories. For garments making there are some accessories are commonly used.
Garments Accessories:
Thread
Interlining
Lining
Button (Snap button, Plastic button, Metal button etc.)
Label (Main Label, Size Label, Care Label)
Motif (Leather, Plastic, Metal)
Pocketing fabric
Velcro
Elastic
Cord
Ribbon
Toggles
Zipper
Rivet
Collar bone
Finishing Accessories
Hang tag
Price tag
Plastic / Poly bag
Tissue paper
Carton
Scotch tape
PP belt
Tag pin
Plastic clip
Sticker
Butterfly
Collar insert
Back board
Neck insert
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 121
11.7. Description of Process Sequences
1. Garments design, Sketch and Measurement sheet Garments design, sketch and measurement
sheet is given by the buyer to the sellers. Buyers make a design of required garments with
sketch having all the required accessories and trimmings. They also provide a measurement sheet
of different sizes. All these including name as merchandising details sheet. After getting these
requirements pattern master makes a pattern for sample making of different sizes. In these there are
also manufacturing details with the help of all required accessories and trimmings.
2. Pattern: The individual part of a garment which is shaped by a hard paper like drawing sheet is
called pattern. It is classified into 2 types as follows-
Working pattern: The pattern which is used to make sample garment is called working or
master pattern.
Production pattern: The pattern which is used for bulk production is called production pattern.
Pattern grading: After developing pattern, pattern master decreases or increases master pattern
stepwise, it is called pattern grading. Like this-
S ↔M↔L↔XL
Before making a sample pattern making according to sketch and measurement or directly from
sample is very important. The construction of pattern is done by two methods like-
a. Manual construction of pattern
b. Computer aided construction of pattern
In Sadma Fashion Wear, they use manual methods of construction of pattern. During manual or
computer aided construction of pattern the pattern draft is developed by calculation based on the
following instructions-
a. Actual body size
b. Size charts or sample
c. Grading increment
d. Easy allowances
On pattern the following instructions must be marked-
Name of the pattern
Style
Size
Grain direction
CFL & CBL
Seam allowances
Balance mark
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 122
The following tools and equipment are used for pattern construction-
Working surface
Paper
Pencils
Eraser
Marker pen
French curves
Compass
Set square
Scissors
Measuring tape
Rubber, scale, scotch tape etc.
3. Sample Garment
The patterns are used to cut the fabric. Then the garment components in fabric form are
used to sew the garment. Sample garment manufacturing is to be done by very efficient and
technically sound person.
To make sample garment for buyer approval.
To make pattern sets for bulk production when needed.
4. Production pattern
The patterns of the approved sample garment are used for making production pattern.
During production pattern making, sometimes patterns design may be modified if buyer or
authority suggests any minor modification.
5. Grading
Normally for large scale of production of any style needs different sizes to produce from asset of particular size of patterns, the patterns of different sizes are produced by using grade rule which is called grading.
6. Marker Making
Marker is defined as a large thin paper which contents all required patterns pieces of
different sizes for a particular style of apparels.
Marker is made by following steps-
Pattern are placed onto a large thin sheet
Then marked by pen around the pattern
First place big part & small part are placed at the end position
Finally found a marker
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 123
Marker is made of fulfill the following objects-
To get similarities among the apparel To save times To minimized fabric wastage To reduce cost
Marker is made by two methods as follows-
1. Manual method
2. Computerized method
Depending on making of marker it has the following types as follows-
One way marker
Two way marker
Interactive marker
Auto marker
Paper marker
Fabric marker
Whole garment marker
Single size marker
Multi size marker
During marker making the following points should be checked-
a. Pattern direction b. Pattern alignment c. Parts missing d. Mismatched checks or stripes e. Overlapping f. Marker too width than fabric. g. Poor line marking. h. Double line marking. i. Pattern to pattern distance. j. Notches and drills marks are omitted
7. Fabric spreading
Fabric spreading means the smooth laying out of fabric with respect to marker length and width which is specified. When spreading is done the following basic requirements maintained-
- Alignment of plies
- Correct or uniform ply tension
- Smooth surface of fabric
- Static electricity is not formed during spreading
- Fusion free for synthetic fabric
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 124
- Matching of stripe or check
- Distortion free of plies
There are two methods used for spreading-
1. Manual method
2. Mechanical method
In Sadma they use manual method of spreading. Problems may occur during spreading-
- Misalignment of plies
- Mismatching checks or stripes
- Wrong direction of plies
- Incorrect tension of plies
- Fabric relaxation
- Narrow width fabric
- Shaded fabrics
8. Fabric Cutting
On the spread fabric the marker is placed carefully and accurately and pined with the
fabric to avoid unwanted movement or displacement of the marker paper. Normally straight
knife cutting machine is used to cut the garment component as per exact dimension of
each patterns, care must be taken to avoid cutting defects.
During cutting of fabric the following flow chart is followed-
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 125
9. Sewing /Assembling
Sewing is defined as an operation by an operator through a m/c named sewing m/c which
used sewing thread to sew the fabric by forming stitch in the way of interloping, interlacing of sewing
thread. To sew a fabric by sewing m/c needle along with sewing thread is used. So to sew a
fabric needle, sewing thread are important elements.
12.5. Sewing Problems
There are various types of sewing problems found in sewing floor. Among these problems
the following are the main -
1. Problem of formation: It has four types as follows -
1. Supplied stitch
Causes:
Loop size of needle is small Bent needle Tension variation of looper and needle thread.
2. Staggered stitch (Stitch line is not parallel with seam line)
Causes:
Bent needle Wrong needle point Improper needle adjust
3. Unbalanced stitch (If bobbin thread does not work, it produces hole & forms this stitch)
Causes:
Incorrect tension of sewing thread Incorrect passage of thread through guide Insufficient lubrication
4. Frequent thread breakage
Causes:
Improper unwinding
Higher thread tension
Excess heating
Lower quality thread
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 126
2. Seam pucker: It is caused for five purposes as follows-
a. Unequal stitch on fabric due to limitation of feed m/c b. Fabric dimensional stability due to unequal shrinkage of one ply then other for washing
c. Extension of sewing thread due to tension
d. Sewing thread shrinkage after washing or ironing
e. Compact fabric with high EPI, PPI is caused seam puckering during sewing.
3. Fabric damage at the seam line: It is visible after washing and wear which is mainly caused for
needle bending or improper selection of needle size. This is two types of fabric damage with
needle as follows-
Mechanical damage (m/c speed high)
Needle heating damage (300-350°C)
11.8. Finishing
Finishing Flow-chart-
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 127
11.9. Final Inspection
For complete garment that is not in bundle form, it is recommended that statistical inspection done
based on AQL .The defects may be identified in finished garments:
1. Broken ends
2. Broken picks
3. Reed marks
4. Broken pattern
5. Thick and thin place
6. Rough surface cloth
7. Iron stain
8. Holes in the cloth
9. Shading
10 Shuttle marks
11.10. Garments Merchandising
“Merchandising” is known to the persons specially involved in garments trade. The term
merchandising has been derived from merchandise. Merchandise means goods that are bought and
sold. The term “Merchandising” may be defined as: Person who merchandises the goods,
specifically for export purpose. Garments merchandising means buying raw materials and accessories,
producing garments, maintaining required quality level and exporting the garments within schedule
time. From the above definitions, we can say that a person involved in garments merchandising needs
a wide range of knowledge and skill to perform his job successfully. The job itself is Technical and
general as well.
1. Quality of a merchandiser
The qualities must be needed of a merchandiser are as following:
Good English speaking & writing skill.
Must have computer knowledge like- MS Word, MS Excel, Internet & E-
mail etc.
Proper knowledge on mathematics.
Sound working capacity always be prepared for any kind of working pressure.
Training is needed for knowing primary knowledge about
merchandising.
Proper knowledge about garments production
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 128
Proper knowledge about Commerce & Banking. Proper knowledge about Shipping line &
Airline.
2. Duties & Responsibilities of a Merchandiser
Dealing with the buyer & convincing the buyer is the main duty of a marketing officer or
merchandiser. A merchandiser also has some other duties. The main duties & responsibilities of a
merchandiser are given bellow-
To prepare cost sheet by dealing with the buyer.
To take different steps by discussing with the high officials & merchandisers.
To maintain a regular & good relationship between commercial officers &
merchandisers.
To maintain communication with the buyers and buying houses.
Communicate with better knowledge of the products.
3. Scope of a Merchandiser
Merchandisers are the key player for generating business for any manufacturing
plants/company.
Merchandisers are responsible for making good profit for the company. Whatever the
nature of business, they are always keen to increase the profit margin for the company.
To maintain a good relationship between all the departments and to get the best output rom
each department is also important and merchandisers play a vital role in getting good
output from each department.
Communication skill is important to maintain an effective communication between all
concerned parties. Corresponding with buyer/agent for all related work i.e. sample
approval, testing, packaging, shipping.
To act as a link between different departments of company for order processing, upplying,
payment collection and other export related documents.
4. Costing/Pricing
Costing is the principal task of any merchandisers.
Methods of Pricing:
1. Calculate the fixed and variable costs associated with the product.
2. Also the cost elements below need to consider during costing.
Pricing for Fibers & Yarns
Pricing for fabric manufacturing
Pricing for garment manufacturing
Cost of accessories Commercial cost
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 129
Break-even point Consumption of fabric and accessories with wastage percentage. Total cost analysis (how much does it cost to provide merchandise to end customer)
11.11. Images of Garments Section
Figure: Sewing Floor
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 130
Figure: Fabric Cutting
Figure: Folding room
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 131
Figure: Ironing Unit
Figure: Packing room
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 132
Figure: Inspection Floor
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 133
CHAPTER-12
QUALITY CONTROL
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 134
12.1. Quality Control
Quality control cares with the analysis of check knowledge and its application to
manage of the textile method, raw materials, intermediate product and final product. It is
involved not solely with quality level and price of maintaining this quality level however
conjointly involved with the presentation of tangible values to live quality and changes in
quality. so as to manage quality one should realize the consumers‟ expectations.
12.2. Process Flow Chart of Final Inspection
At first check the shade as per vendee commonplace with dimensional stability from research
lab.
↓
Secondly check dia / width fabric weight
↓
Thirdly check fabric surface or appearance as per buyer standard.
↓
The every roll with every meter check (as per four (04) point system)
↓
Make a report.
↓
Send to the buyer
↓
If OK then ready for delivery.
↓
If not OK then identify the fault.
↓
If it's knitting fault then inform the knitting department by job card and mail, & requested
the material for replacement.
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 135
↓
If it's coloring fault, then offer job card to coloring department correction. And if isn't utilize
ready then reject the material & inform the coloring department to switch the rejected
amount
12.3. Objects of Quality Control
Selection of raw materials
Specification test
Product testing.
To ensure the product desired quality.
To fulfill requirements for quality.
Process control and development
To control and different techniques will be required by different conditions.
Quality assurance and so on.
To evaluate accurately of the end product.
To research and development
Quality assurance and so on.
12.4. List of Equipments
Computer
Sample Dyeing M/C
Electrical Balance
Light box
Washing M/ C
Shrinkage & Spirality measurement instrument
Electric Heater
PH meter
GSM Cuter
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 136
12.5 Quality Management System
Quality assurance procedure may be provided by the following two major parts-
On Line Test:
Grey Fabric Inspection with 4 point system
Diameter and Width control
Fabric GSM control
Shade Check;
Bias and Bowing;
Stripe.
Visual appearance (Enzyme performance).
Off Line Test:
Off line quality are divided into two groups-
Physical Tests and
Chemical Tests.
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 137
12.6. Textile Testing for Knit Fabric
Color Fastness Test
1. Color fastness to washing-ISO105C06, AATCC.
2. Color fastness to actual-ISO6330, BSEN/ISO26336.
3. Color fastness to rubbing/crocking-ISO105X12, AATCC8.
4. Color fastness to perspiration-ISO105E04,AATCC15
5. Color fastness to water-ISO105E01,AATCC
6. Color fastness to sea water-ISO 105 E02
7. Color fastness to light-ISO105E02
8. Color fastness to saliva & perspiration-DIN 53160
9. Color fastness to saliva-Chinese standard G3/T18886:2002
Shrinkage & related Test
a. Dimensional stability to washing-ISO6330, BSEN ISO 26330.
b. Spirality/skewness-AATCC179, ASTMD 3882.
Fabric / Garments Performance Test
a. Pilling resistance, ICI BOX-ISO 12945-1, BS5811.
b. Abrasion resistance (Martindale method)-ISO 12947-1/2/3/4, ASTM D4966.
c. Pilling resistance (Martindale method)-ISO 12945-2, ASTMD4970.
d. Elongation & modulus-ASTM D4964.
e. Stretch ability of narrow fabric-BS 4952(LINE CONTACT)
f. Stretch & recovery-ASTM D2594.
g. Spandex/lycra slippage(flex test)- Martindale method 15.
Analytical Test
pH value-AATCC81, ISO B071.
Construction Analysis
a. Fabric weight-ASTM D3776, ISO 3801.
b. Stitch density-ASTM D3775, ISO 7211/2.
c. Fabric width- ASTM D3774.
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 138
Fabric / Garments Strength Test
a. Tensile strength-ASTM D5034, 5035, 4964, BS/EN ISO 4952.
b. Tearing strength-ASTM D1424.
c. Bursting strength-ASTM D3786, ISO 13938-1.
d. Seam performance-ASTM D1683, ISO 13935-1 & 2.
Yarn Test
a. Twist-ASTM D1423.
b. Yarn appearance-ASTM D2255.
c. Yarn count-ASTM D1059.
d. Tensile strength (single strand)-ASTM D2256.
e. Tensile strength (skein form)-ASTM D1578.
Other Test
General appearance - AATCC143.
12.7. Quality Control Flow Chart
Yarn receiving
↓
Sample Knitting
↓
Batching
↓
Dyeing (Check shade & Faults)
↓
Dewatering
↓
Drying (Check diameter, Pretreatment, Shrinkage Spirality and GSM)
↓
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 139
Compacting
↓
Final inspection
↓
If sample OK go for bulk production
12.8. Quality Assurance
Quality assurance is outlined as all those doable planned and systematic actions necessary
to produce adequate confidence than a product or service can satisfy given necessities for
quality. The standard Assurance Department is allotted to take care of systematically uniform
quality of the fabric in method and numerous stages of its manufacturing.
Quality Assurance at Different Stage
Assures the quality of the products of dyeing section in the following three steps:
In laboratory
In dyeing section &
In finishing section
Procedures are described below
In laboratory:
Fastness & other tests of the fabric or yarn are done here.
Swatch card from buyer according to their requirement
recipe prediction for sample dyeing
sample dyeing until matching with swatch card
In dyeing section:
During dyeing, samples are taken until accurate shade matching. The
interval may be 30-40 minutes.
According to the buyer‟s sample, sample dyeing is done in sample dyeing
machine in dyeing shed & again matched with the approved sample.
After dyeing sample is collected after softening matching is done.
Last of all, sample is collected after fixation & matched.
If result is OK, then bulk production.
Then allowed the fabrics to be finished.
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 140
In finishing section
By employing a series of finishing machines correct breadth, softness
& look square measure maintained in keeping with needs.
Then sampling is finished for many times to check GSM, Shrinkage
& fastness properties.
Finally cloth is inspected & ready for delivery.
List of equipments:
In the quality assurance department used equipments are as followed-
a. Lab. Dyeing Machine
b. Electronics Balance
c. Rota Wash
d. Iron
e. Crock Meter
f. Spectrophotometer with software (Data Color)
g. PH meter
Fabric Inspection:
The examination of fabric could be a procedure by that the defects of material area unit known
and fabric is classed per degree or intensity of defects. Material |the material examination is
completed for each grey and finished fabric.
Grey Fabric Inspection:
Grey fabric inspection is performed according to 4-point system.
Finished Fabric Inspection:
4 point numbering system is followed for finished fabric inspection.
Defects found in the final inspection
Double yarn
Dead cotton
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 141
Uneven shade
Oil spot
Machine Stoppage mark
Neps
Crease mark
Listing
Line mark
Pick missing
Fly yarn contamination
Bowing
12.9. Some Test procedure are Given Below
GSM Test:
GSM is that the most significant issue. there's a GSM Cutter. The Sample is cut then weighted
within the balance. The reading is then (in gm) from the balance, increased by one hundred, to
urge price of GSM.
Finished fabric diameter:
In Knit, coloring finishing, finished diameter is incredibly necessary issue. It ought to be
unbroken because the purchaser necessities. merely a activity tape measures it. Finished diameter
is controlled at compacting m/c.
Color Fastness to Rubbing:
Rubbing fastness is that the resistance to color fading of colored textile, once rubbing against a
rough surface.
Process:
The test specimen size 15cm x 15cm are taken
Then place on the cork meter.
(5cmx5cm) Cotton, desized, bleased but without finished fabric is attached to the
cork meter finger.
Rubbing 10 minutes at 10 second.
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 142
Rubbings are test in two conditions.
Dry condition and
Wet condition
Here gray scales are used and grade the fabric rubbing fastness according to the
gray scale.
Color fastness to wash
The resistance to color loss of any dyed or printed material during wash.
Chemical:
ECE Detergent 4gm/l
Sodium per-borate 1gm/l
Time 30 mine
Temperature 60◦C
Steel balls 25
Solution of chemical 150 ml (From 1 litter ECE or Sodium per borate)
Required materials
a. Sample size 40 x 10 cm
b. Multi-fiber at 40 x 10 cm
c. Sodium Per-borate (Na2BO3.H2O2-1g/L)-1g/L
d. ECE detergent (WOB)-4g/L
e. Normal cold water
f. Distilled water
Required instrument:
Rota wash
Scissor
Stitch machine
Process:
The cut sample sized 4cmx10cm.
Attach the multi-fiber with the sample.
Sample immersed in 150ml solution of ECE or Sodium per-borate and put into
the Rota wash m/c for 30 mine at 60◦C
After that dry on oven.
Here gray scale is used to measurement.
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 143
Changing After wash and before wash the sample.
Staining Color bled from sample to multi-fiber
Water hardness test:
Water
↓ →
Buffer solution
↓ →
Indicators
↓ →
Titration with EDTA solution.
↓
The titration is done until the violate color are reached.
Hardness cause
The presence of Calcium salt and Magnesium salt, that means bi-carbonate, sulphate and
chloride is causes of water hardness.
Types of water hardness
Temporary hardness (Presence of Chlorides or sulphate of Calcium and
Magnesium)
Permanent hardness (Presence of bi- carbonate of Calcium and Magnesium)
5gm
5 drop
1 drop
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 144
Color fastness to light
Purpose
Light fastness is the test design to evaluate the laundering fastness test of dyeing, Pigment which
re to be made in comparison of result obtained on many test pieces treated under light.
Method: ISO
Apparatus:
a. Light fastness tester & blue scale
b. Scale
c. Scissor
d. Hard paper
e. 4cm X 2cm
Process:
Cut the sample specimen into (4X2) cm
Stay the sample into the sun test m/c for 20 hour.
Finally measure the color change with blue wool scale.
Expectable value (5-8)
Result:
The take a look at results of light-weight fastness take a look at is resembling the category of
normal half-dozen.So we will say that the color fastness of unreal material is aver.
Standard Rating
8 Fast
7 Fast
6 Average
5 Average
4 Average
3 Average
2 Not fast
1 Not fast
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 145
Shrinkage test:
M/C Name: Washing m/c
Temperature 40 ◦C
Time (37-40) minutes
Water amount 20 litters
Chemical:
ECE Detergent 20,40,50gm/l (According to the buyer requirement)
Sodium per-borate 5.10gm/l
Process:
At first wash the fabric sample in washing m/c with require chemical at 40◦C on (37-
40) mine.
After that dry the fabric in oven in required temperature.
Before washing the fabric are marked with tame plate or measuring tape.
After washing find out the length, chest, salvage or spirality change.
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 146
Example:
Before After
Length 73 69.5 (73-69.5) =3.5=4.79%
Chest 48 46.5 (48-46.5) =1.5=3.12%
PH Test:
Procedure:
Take 2gm sample fabrics and cut into small pieces.
Then put it conical flax with 100cc water (M: L -1:50).
Then shake it 15 min, then place it in a shaker m/c for 1 hour.
Then check PH
by PH meter
Color fastness to perspiration-ISO105E04, AATCC15
Perspiration test are two types. As follows-
1. acidic
2. alkali
Acidic:
Solution:
sodium chloride -5gm/l
sodium dihydrozen phosphate dehydrate-2.2 gm/l
L-hesdin monohydrade chloride-0.5 gm/l
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 147
Alkali:
Solution:
sodium chloride -5gm/l
sodium hydrozen phosphate-5 gm/l
L-hesdine -0.5 gm/l
Procedure:
Specimen size: 4×10 cm+ Multifibre
Time: 4 hours
Temp: 37±1
At first the specimen is wet in 1st solution and then put it and again wet in 2 solution
Then it place to the woven. Dry according to the procedure.
Scale: standard scale.
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 148
CHAPTER-13
MAINTANENCES
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 149
13.1. Maintenance
Maintenance could be a method by that instrumentation is taken care of in such the way
that bothers free. Service and accrued machine life will be ensured and specific product quality
needed by the shoppers is sustained. On time maintenance increase m/c period of time &
ensures bother free services. Maintenance of machineries is extremely vital for any sort of
industries and it's should for a knit composite plant. All machines and machine components of
knitting, coloring and clothes are maintained with extreme care. As a result of production quality
and amount, each depends on the upkeep with regularity.
13.2. Objective of Maintenance
To ensure specified accuracy to product & time schedule of delivery to customer.
To keep the factory plants, equipments, machines. Tools in an optimum working
condition.
To keep the machine down time to minimum thus to have control over the production
program.
To modify the machine settings to meet the need for the production.
To keep the production cycle within the stipulated range.
13.3. Types of Maintenance
Maintenance
Preventive Maintenance Break Down
Maintenance
Mechanical
Maintenance
Electrical
Maintenance
Mechanical
Maintenance
Electrical
Maintenance
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 150
Description:
Preventive Maintenance:
Preventive maintenance is a predetermined routine actively to ensure on time inspection / checking
of facilities to uncover conditions that may lead to production break downs or harmful description.
Normally in case of dyeing m/c maintenance after 30 days complete checking of different important
parts are done.
Break down maintenance:
In this case, repairs are made after the equipment is out of order and it can‟t perform its normal
functions.
13.4. Maintenance Tools & Equipments
Mechanical Electrical
Pliers
Inside Calipers
Outside Calipers
Digital Millimeter
Heating Shoulder
Hammer
Plies
Gauge
Allen Key Set
Steel Roll
Vermeer Calipers
Lather M/C
Drill M/C
Welding M/C
Spanner Set
Measuring Tape
Crew Driver
Voltmeter
Contact Cleaner
Ammeter
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 151
13.5. Maintenance Procedure
Normally preventive maintenance is done here. During maintenance procedure following points should
be checked.
Machine: Dyeing Machine
Maintenance: Mechanical
Check all bearings, seals, gaskets.
Check the main pump oil level.
Check all mechanical seal flush pipes.
Discharge the water from air filter.
Check all m/c flange & platform bolts.
Grease RCR rotary joints every 2 weekly
Check the adjustment of catch basket mechanism and plaited system.
Clean & check the control panel.
Machine: Squeezer Machine
Maintenance: Mechanical
Grease squeezer bearings.
Grease all the bearings.
Check oil level of pneumatic oilers.
Check oil level of gearboxes.
Check magnetic spreader adjustment.
Machine: Compactor
Maintenance: Mechanical
Check Grease if necessary
Pressure springs of chain tensioner.
Nuts of width adjustment spindles for wear.
Check all spindle bearings for free running.
Free running of guide rollers, deflection rollers & contact rollers.
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 152
Perform visual inspection: -
Gear box oil level
Belts, pulleys
Machine: Stenter
Maintenance: Mechanical
Crease all bearing with stuburg NBU-12, energrease 1002
Complete cleaning of the machine
Check all belt and belt tension
Check all door sills
Check gear box of platting and its oil.
Check all pin bars & clean
Check chain and give oil if required .Clean exhaust blower & duct
All chamber blowers check and clean
Chamber nozzle cleaning
Check gas pressure, adjust if required
Machine: Boiler
Maintenance: Mechanical
Check and clean fluff & dart at all machine.
Feed pump servicing.Main boiler servicing.
Cheek all temperature & pressure gauge meter.
Cheek gas strainer.
Clean gauge glass &change if required.
Clean feed tank.
Clean fire tube.
Clean all safety valves.
Check all steam valves.
Check all gas regulators.
13.6. Remarks:
Maintenance of machine is incredibly essential to prolong the m/c life and smart
maintenance is very important thought. During this business maintenance program is completed
by professional maintenance team. So, only a few times production is stopped attributable to m/c
downside.
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 153
CHAPTER-14
UTILITIES & ETP PLANT
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 154
14.1. Available Utility Facilities
Sadma Fashion Wear Ltd. is a large project. So, it requires adequate utility services. In
Sadma Fashion Wear Ltd. the following utility services are available.
1. Electricity
2. Gas
3. Water
4. Steam
5. Compressed air
Electricity:
It is not possible to continue the assembly while not electricity. A frequent provide of electricity
is extremely a lot of essential to make sure sleek production. In Sadma Fashion Wear Ltd. the
complete demanded electricity is generated by Own Generator.
Starting Procedure (Generator):
Total power is then distributed as per requirements of different section of Sadma Fashion Wear
Ltd.
Generator Room should be Clean
Cooling Tower water reserve tank shold
filled
Oil Circulation pump run for 10 min
Start the Engine 5 Min without any load
Close the main circuit breaker and
connect the load.
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 155
Gas:
The gas is supplied to Gas Generator, Boiler.
The source of gas is TITAS Gas Ltd.
Water:
Continuous supply of water for Sadma Fashion Wear Ltd. is ensured by Water pump. The deep
well water is subjected to Water Treatment Plant (WTP) to make sure the water quality
parameter suitable for Textile Wet Processing.
Environmental Standards:
All the solid waste and effluent generated by the factory are treated and disposed off in an
environmentally safe manner. Our textile complex has its own water treatment facility or
Effluent Treatment Plant (ETP). The Environmental Protection Agency (EPA) of Bangladesh
certifies the compliance.
Sadma Fashion Wear Ltd. commitment:
Improve work environment and work safety.
To continuously improve our waste management facilities.
Meet relative environmental safely standards.
Continual waste reduction, recycle and reuse.
14.2. Effluent Treatment Plant
ETP means Effluent Treatment Plant. It can be defined as a plant where the effluent is
treated. Now a day ETP is mandatory for industries which produced huge amount of waste water
(such as wet processing industries in Textiles).By basic studies on ETP, we learn how to control
textile waste water pollution, how waste water is treated in order to save our environment.
14.3. Classification of ETP
ETP can be classified as follows
a. Physicochemical
b. Biological – i) Conventional
ii) Membrane Bio-Reactor (MBR)
c. Physicochemical followed by biological (Bio-chemical)
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 156
The ETP of Sadma Fashion Wear Ltd. is used Physicochemical followed by biological (Bio-
chemical). The ETP of Sadma Fashion Wear Ltd. is described below:
Amount of using chemicals:
1) Polyelectrolyte 2kg/1000L
2) Lime (50-100) kg/1000L
3) FeSO4 50 kg/10000
4) DAP +Urea (8+2) kg/1000
14.4. Using Chemicals in Sadma Fashion Wear Ltd.
1) H2SO4/HCl :
Function:
Neutralize the waste water controlling the PH. It is auto dispensed in the neutralization tank.
2) Polyelectrolyte:
Function:
Make chemical particles bigger in size
3) Sodium Hypochlorite (NaHCl)
Function:
It is used to kill the harmful bacteria. It is used in the biological oxidation tank.
4) De-colorant:
Function: It is used for removing color of waste water.
5) FeSO4:
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 157
Function:
Used for coagulation and sludge separation from waste water.
6) Lime
Function:
To change the color of waste water.
7) Urea:
Function:
Using food of bacteria.
8) Di-ammonium phosphate:
Function:
Using food of bacteria.
14.5. Product Quality Checked
a. Biological Oxygen Demand (BOD)
b. Chemical Oxygen Demand (COD)
c. Total suspended solids
d. Total dissolved solids
e. Color
f. PH etc.
After treatment the waste water the permissible limit of various parameters of waste water is
understood as discharge limit .It is a suitable worth that is normal for all mills and factories.
Parameters Discharge limits
BOD(20 C0.mg/L) 150 mg/L
COD(mg/L) 100 mg/L
TSS(mg/L) 2100 mg/L
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 158
Discharge customary for textiles liquid waste water in step with the National Effluent Quality
Standards (NEQS) guided by DOE (Department of Environment)
TDS(mg/L) 10 mg/L
Oil & Grease(mg/l) 6.5-9
Waste water flow 100 L/Kg of fabric processing
Parameters Discharge limits
BOD(20 C0.mg/L) 150 mg/L
COD(mg/L) 100 mg/L
TSS(mg/L) 2100 mg/L
TDS(mg/L) 10 mg/L
Oil & Grease(mg/l ) 605-9
Waste water flow 100 L/Kg of fabric processing
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 159
14.6. Overall view of ETP Plant
Figure: Overall view Of Sadma’s ETP
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 160
Figure: Overall view Of Sadma’s ETP
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 161
14.8. Remark
Waste water from processing industries e g. Dyeing , Printing , Finishing and washing
causes great harmful effect on our environmental, As a result agricultural land loses its fertility,
natural water becomes polluted aquatic life is destructive and crops are damage.
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 162
CHAPTER-15
MARKETING
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 163
15.1. Marketing Activities
Marketing is one of the important part of every industry. Sadma Fashion Wear Ltd. used
to visit in to new market area searching the buyers of unique interests and value knit items.
Always attempts to satisfy the buyer‟s requirements conforming superior quality honoring their
creativity.
15.2. Buyer’s Compliance
All the buyer of Sadma Fashion Wear ltd. strictly follows the Labor and Labor welfare
rules of Bangladesh Government. If the factory does not maintain the rules and requirement of
Bangladesh Government Labor welfare then they do not accept the product.
15.3. Global Partners
Brands Origin Flag Logo
JHK
Spain
Orchestra
France
Okaidi France
Kaporal France
New Yorker Germany
Lidl
Germany
Dupareil
Spain
Payper
Italy
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 164
Plaza Italia
Italy
Preca Brummel
Italy
LPP
Poland
Conclusion
Industrial training is an essential part for textile education because it minimizes the gap
between theoretical and practical knowledge. Undoubtedly, this industrial training taught us lot
about textile technology, production processes, textile machineries, industrial management and
made us comfortable to industrial life. Besides it gave us the first opportunity to work in
industry. Industrial Training program send us to the expected destiny of practical life. The
completion of six week industrial Training at Sadma Fashion Wear Ltd. we have got the
impression that the factory is one of modern knit dyeing projects in Bangladesh. Though it was
established only few years ago, it has earned very good reputation for its best performance over
any other knit dyeing project. It was really a productive practical learning and methodological
knowledge successfully in the textile industry and the economy of our country.
During my industrial training I had tried to my best to done my duty. My supervision officer
conjointly glad to Maine & supply co-operation in each steps. it's utterly a brand new expertise in
my life, which can be terribly effective in my service life. Throughout my coaching period I
spotted that sensible expertise is effective for service life.
Limitations of the Report:
It is unimaginable to carry the complete issue of a textile trade in such atiny low frame as this
report. So, strive our arduous to summarize all the data that we tend to area unit provided.
Industrial Training Report Sadma Fashion Wear Ltd.
BUBT 165
Because of secrecy act, the information of cost accounting and selling activities
haven't been equipped.
We didn't get enough oversight kind the accountable persons of various section as a result
of their busy schedule. thus there might some limitation of information of various section
during this report.
We had a really restricted time. In spite of temperament to review in additional details it
had been unimaginable to try and do thus.
Some of the points in several chapters don't seem to be embrace as these weren't offered.
References:
To write this report I take some help from different source. To developed this attachment I
collect data from internet, different journal, and book. Which photo I attach here that‟s I collect