Report on Industrial Attachment | SEPAL GROUP 1 INTRODUCTION As all Engineering subjects are practical oriented subject. Specially Textile Engineering is lame without sound practical knowledge. So practical implication is very essential for any textile person, engineer or students. It is said that textile industry is the heart of Bangladeshi economy. Industries are run by successful, skilled engineers. So it will not be wrong if it is said nowadays Textile Engineers are the main weapon for our economical Success. Industrial training as offered by the Bangladesh University of Textiles is very useful which gives the directions & ideas about the production, manufacturing, capacity, power etc. of a certain mill and with this ideas getting adopted a student can flourish his debut in the engineering field. We had been attached in Sepal Group for two months starting from 1st August to 30th September. There are four factories, one washing plant, and one buying house in Sepal Group. We successfully ended our training while gathered some useful things like mill management, production, quality assurance, maintenance, planning, machine operation, merchandising etc.
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Report on Industrial Attachment | SEPAL GROUP 1
INTRODUCTION
As all Engineering subjects are practical oriented subject. Specially Textile
Engineering is lame without sound practical knowledge. So practical implication is
very essential for any textile person, engineer or students. It is said that textile
industry is the heart of Bangladeshi economy. Industries are run by successful,
skilled engineers. So it will not be wrong if it is said nowadays Textile Engineers are
the main weapon for our economical Success.
Industrial training as offered by the Bangladesh University of Textiles is very useful
which gives the directions & ideas about the production, manufacturing, capacity,
power etc. of a certain mill and with this ideas getting adopted a student can
flourish his debut in the engineering field.
We had been attached in Sepal Group for two months starting from 1st August to
30th September. There are four factories, one washing plant, and one buying
house in Sepal Group. We successfully ended our training while gathered some
useful things like mill management, production, quality assurance, maintenance,
planning, machine operation, merchandising etc.
Report on Industrial Attachment | SEPAL GROUP 2
Chapter 1
Project Description
CONTENTS
Name Of The Company
Type Of The Company
Year Of Establishment
Product Mix Of The Company
Annual Production Capacity
Project Cost
History Of The Project Development
Different Departments Of The Company
Physical Infrastructure Of The Building
Remarks
Report on Industrial Attachment | SEPAL GROUP 3
INTRODUCTION
Sepal Group is one of the leading ventures in the garment industry operating from
Dhaka, Bangladesh. Being a 100% export oriented industry they have been
approved by the Board of investment of Bangladesh and have their own garment
manufacturing and washing units all under one roof. The commencement of
business was in 1986 and from the time of inception till now the group has grown
many folds as it has always maintained quality and punctuality. The group has
gainer name and fame since its inception and herded by a team of dedicated,
hardworking and efficient management and staff who are always on the lookout
for a challenge. They at Sepal make garments the same way that a painter
composes his art on canvas.
The group comprises of the six companies as listed below
1. Sepal garments ltd.
2. Orchid garments ltd.
3. Creative garments ltd.
4. Glory fashion wear ltd.
5. Sepal washing ltd.
6. Mastrade International Garments ltd.
We the students of Bangladesh University of Textiles have joined in Sepal Group
from 1st August to 30 September for our industrial attachment. We came here and
knew how this company is running & the management of this company. We also
learned how to make a garments production as well as merchandising of the
Raw materials and accessories are the major term of garment production. We can
say that this term is the heart of a garments industry. We have tried our label best
to collect all data about raw materials though it was not an easy task to do.
More over Sepal group maintain a good fame by using brand item and qualified
raw material. A number of people are always checking the quality of these items.
They also inspected them and keep documents by the time.
The store house is very much secured and only authorized person can enter that
room. We are thankful to our supervising teacher Mr. Julian for his help while
collecting these data.
We are also grateful to our respectful teacher Mr. Moshiur Rahman Khan for
giving important check routine and advice.
Report on Industrial Attachment | SEPAL GROUP 42
CHAPTER 5
Production Planning Sequences & Operations
CONTENTS
Production Parameters
Description of production process
Daily production report
Monthly average production
Production flow chart
Monthly efficiency
Remarks
Report on Industrial Attachment | SEPAL GROUP 43
INTRODUCTION
Production planning is the very first step to start a production. At first the
company gets an order from buyer and then they start the production planning.
Here in Sepal group production planning and production process is specified and
extra ordinary. In this chapter we have described all the procedure and the
necessary document related to run a production. We also included a sample and
all of its information. The ID no of the product is 00247619.
There is disclosed a system for fastening together different pieces of an article of
clothing so as to enable a customer to select a specific clothing style and design by
selection of different garment pieces. The fastening creates a garment seam
equivalent to a sewn seam yet provides non-permanent closures for garment
assemblage and thus allows a garment to be created specifically to the customer's
wish. There is also disclosed a system for producing garments from a plurality of
different garment pieces and a simplified design and production schedule.
A garment production process wherein garment parts are knitted in a continuous
length of knitted material with water soluble yarns being formed in the knit
construction between the garment parts. The length of material is moved along its
length and bathed with a heated aqueous solution to dissolve the water soluble
yarns and separate the garment parts. The separated garment parts are dried and
vibrated and passed to subsequent garment making stations. The temperature of
the bathing and drying steps and the vibration of the garment parts serve to heat
set the garment parts.
DESCRIPTION OF PRODUCTION PROCESS
Here we have described the whole production processes which are followed by
the Sepal Group after getting an order. We described the processes step by step
according to our limitation. We have also attached an order sheet, PID file, a
sample, production lay out plan and production flow chart and some other
documents to enrich our assignment.
Report on Industrial Attachment | SEPAL GROUP 44
STANDARD INSPECTION PACKET (SIP)
Sepal Group will have to maintain a SIP file for all orders at the factory. Factory
will have to make sure that all tests are timely done and approved. The following
information has to be in the SIP:
PID and any changes to order.
MTL Fabric Testing Reports.
MTL Pre Production Sample Testing Reports.
MTL TOP Sample Testing Reports.
Interlining Testing reports.
Invoices of all Trims / Fabric that have been ordered from the nominated
suppliers.
Factory Pre Final/Final inspection reports.
TCPS Final inspection reports.
Approved fabric swatches and Trim samples
Fit and Pre production approval comments
Pre-production meeting reports
FABRIC INSPECTION PROCEDURE
Sepal Group must maintain the following fabric inspection procedure:
10 % of all fabric shipments should be inspected prior to cutting.
Records should be maintained for every fabric invoice packing list and
inspection report.
Fabric inspections should be done by using the 4 point system and on the
Rotary fabric inspection machine.
Fabric inspection cannot be done while spreading.
Fabric should be inspected for color accuracy as well as shading (side to
side, end to end, roll to roll and number of shade lots).
All rolls that are out of the color shading guidelines should be rejected.
Report on Industrial Attachment | SEPAL GROUP 45
All roles with color defects such as side-to-side shading, side-center-side
shading, and end-to-end shading will not be given points, but should be
rejected.
All fabric inspection forms should have the defects classified separately.
E.g.:- Stains, Weaving defects, Holes, Slubs, etc.
The Four Point system classifies defects as shown in Table 1:
Table 1: Four Point System
Size of defect Penalty
3 Inches or Less 1 Point
Over 3, But not over 6 Inches 2 Points
Over 6, But not over 9 Inches 3 Points
Over 9 Inches 4 Points
Note - A Maximum of four points can be charged to any one linear yard.
The length of defect should be used to determine the penalty points. Only major
defects are considered. (A major defect is any defect that, if found in a finished
garment, would classify that garment as a second.) No penalty points are recorded
or assigned for minor defects.
Major Defects for woven fabrics is classified as follows
a. Slubs
b. Hole
c. Missing Yarn
d. Conspicuous Yarn
e. Variation
f. End Cut
g. Soiled Yarn
h. Wrong Yarn.
Report on Industrial Attachment | SEPAL GROUP 46
Major Defects for Knit fabrics are classified as follows:
a. Mixed yarn
b. Yarn Variation
c. Runner
d. Needle line
e. Barre
f. Slub
g. Hole
h. Press off.
The inspection procedure listed below details the steps involved in performing the
piece goods inspection in the correct manner. These steps must be followed by
the Fabric Inspector/Auditor.
Review the packing list and determine how much total fabric to inspect and
then how much of each color. Determine how many rolls of each color to
inspect and then choose from the packing list and the physical rolls, which
rolls are to be inspected.
Count the rolls in the shipment to make sure they match the packing list
and then mark the rolls that are to be pulled for inspection.
Check the packing of the rolls in the shipment to make sure all the packing
and markings are correct.
Move all the rolls to be inspected to the inspection machine and load the
first roll on the machine. As the roll is put on the machine check to make
sure the inner packing is correct and proper. Also check to make sure the
roll is rolled on the tube squarely and that the tube does not stick out of
the end of the roll more then 1 inch on each end. Also make sure the first 3
meters of fabric is rolled properly, not creased or distorted, and that it is
clean from dirt and marks.
Cut off the first 6 inches and last 6 inches of fabric from each roll and mark
it with the roll number, whether it is from the head or tail of the roll, which
is the right and left side of the fabric and which side is the face side of the
fabric. These strips will then be used in the light box for reviewing end-to-
end, side-to-side and roll-to-roll shading. Use the head strip to check for
end-to-center shading during the inspection.
Report on Industrial Attachment | SEPAL GROUP 47
Inspect the fabric using the recommended form that is included in the
manual and mark the faults and their points. Run the inspection machine at
a speed that allows you to see the defects properly, yet keeps the fabric
moving in a steady and smooth manor. Make sure that you have the proper
and adequate light at the machine shining on the face of the fabric.
Check the length of the fabric on the roll and compare it to the ticket
yardage for the roll. Note this on the “Inspection Form.”
Check the width of the fabric at the beginning and end of the fabric as well
as at least once in the middle of the roll. Mark this on the “Inspection
Form.‟
Check for skewing, bias, and bowing, compare this to the standards and
note findings on “Inspection Form”.
When inspection is completed do calculations on the „Inspection Form” to
determine the point count for each roll and whether or not it passes or is a
“second roll.” Make sure all „second rolls” are separated.
Calculate the percentage of the average point count for the shipment per
square yard. This will determine if the shipment passes or fails.
ACCEPTANCE CRITERIA
Example
Total yards inspected : 700 yards
Width of the fabric : 1.6 yards
Total points found : 300 points
i.e. 700 X 1.6 = 1120 Square yards
300 x 100 / 1120 sq yards = 26.78 points
Result : Pass
Report on Industrial Attachment | SEPAL GROUP 48
ACCEPTANCE POINT COUNT
The max defective points accepted are 28 points per 100 Sq yards.
The max defective 1 point accepted is 14 points per 100 Sq yard.
SHRINKAGE REPORTS
For washed products the factory should see that shrinkage is checked for a
minimum of 10% rolls per color for every shipment.
A test run must be made before starting bulk to ensure shrinkage control
techniques and patterns. Test run is the most important check point to verify if the
technique and patterns are all correct.
Fabrics with a spandex mixture in its composition have to be handled very
carefully due to high shrinkage variance between rolls.
If the noticed shrinkage variation is more than the garment tolerance then it is
recommended that 100% rolls get checked for shrinkage and factory makes
groups and different patterns for different groups.
It is always recommended to make a average pattern by considering only ½ the
tolerance give to the spec. for example if the hip tolerance is 1” you should only
consider ½” while making patterns for different shrinkages. Factory will have to
study the tolerances given in the spec for Bottoms and tops and decide
accordingly on the different patterns required
Factory will have to maintain a file on shrinkage reports. All shrinkage tests need
to be done on a minimum 50 cm x 50 cm square marking – factories have to make
a square marking template.
Factory will also have to mention the wash recipe and time used to dry the
garment in the shrinkage report file. The wash recipe and time that is once set;
can not be changed for the full program.
Report on Industrial Attachment | SEPAL GROUP 49
PRE PRODUCTION SIZE SET PROCEDURES
The factory will check if the shrinkage allowance that is added to the
pattern is good enough to start the test run.
Size sets have to be made for all colors and for all different shrinkage
groups.
The Pre production pattern has to be used as a base and if the shrinkage of
the bulk fabric matches with the shrinkage of the pattern used for the pp
sample then the same pattern has to be graded and used for bulk.
Any adjustments that are required to make different patterns for different
colors and shrinkage groups have to be made to the base pattern.
All the stitching details and techniques that factory is planning to use in
bulk must be check for accuracy.
The factory Quality manager and Quality Auditor will have to check the size
set and make a spec report of before wash and after wash to verify that the
shrinkage allowances that were added in the pattern is ok or needs to be
adjusted.
The before wash spec evaluation of the size set has to match with the
before wash spec with zero tolerance. If the before wash spec does not
match, the inspector will have to analyze and see if the error is in the
pattern or if the operators took wrong seam allowances while making the
sample. Factory will have to remake samples if the before wash spec
doesn’t match.
The Factory Quality manager will then write all the comments on one of the
sample and make it a production reference sample which will be hung on
the production floor.
The factory Quality manager and Quality auditor will have to make sure
that all patterns and templates are signed by the pattern master.
Shrinkage percentage has to be mentioned on all patterns for review.
Report on Industrial Attachment | SEPAL GROUP 50
PRE-PRODUCTION MEETING PROCEDURE
Required Attendees
1. Buyers Representatives (if required)
2. Production Director
3. Finishing Manager and Supervisors
4. Factory Quality Manager
5. Factory Quality Auditor
6. Factory Production Managers
7. Factory Pattern Master
8. Line supervisors
9. Store-in-charge
10. Maintenance-in-charge
OBJECTIVES OF PRE PRODUCTION MEETING
Review PID package and all information pertaining to the production
program.
Review all the machine and folder requirements to make sure that
factory is fully equipped to handle style.
Review an approved sample and all the specification will be
discussed and confirmed with everyone present in the meeting.
Review all critical process and measurement with allowances and
tolerance. It must be made sure that everyone present understands
and works accordingly.
Trims card test results for Fabric, Zipper, Button and Interlining etc.
will be shown and presented for understanding.
Review on the time and action plan to perform the order timely.
Plan all shipment and FRI inspection dates.
Review the preproduction sample with the factory production
sample.
Ensure all approvals are in place.
Factory will have to make an additional spec for all the
measurements that are not mentioned in the PID.
Report on Industrial Attachment | SEPAL GROUP 51
Factory will have to make a before wash spec for in line Quality
inspectors to measure and see that garments that come off line are
as per required. This will also be a check point to see if operators in
line are following proper seam allowances.
Review all the marking templates and techniques.
Factory advise on methods of construction, tolerances, production
lay out and techniques as applicable to the product.
Verification of all product test reports. MTL fabric, MTL Pre
Production.
Verification of all care instruction approvals
Review of the Floor ready spec.
Review all Fit and Pre production comments – so that all points are
clearly understood and taken care off.
Check the spec of any garment based on the how to measure
manual to make sure that the factory uses the correct measuring
method.
All concerned will be advised to co-operate for achieving smooth
execution of the production process as per the assigned target.
OTHER RESPONSIBILITIES
To make sure all technical issues that are production related are cleared
and understood.
To make sure all that is discussed and agreed on during the meeting is
followed in production.
To ensure that a test run performed prior to bulk production.
To ensure that a production sample is hung in the production floor with all
the comments and placements written.
To ensure that factory is maintaining the schedule and all that was
discussed is been followed. In case some changes need to be made,
approval was be taken from the Buyer first.
To ensure that all junior production staff are clear on the method of
measuring the garment.
Report on Industrial Attachment | SEPAL GROUP 52
PRODUCTION TEST RUN
OBJECTIVE OF TEST RUN
The test run is the most important check point in the full production
process.
The information gathered from the test run will verify that the techniques,
patterns, machinery and the systems are all ready for bulk production.
Factory can also make the necessary adjustments for issues that are found
in the test run so that they. can be avoided in the bulk production
The test run is a replica of bulk so every process and procedure should be
exactly as planned for bulk.
The test run will also give factory the final before wash spec that will be
used by all quality auditors.
TEST RUN PROCEDURE
Factory has to plan a cut of minimum 30 layers. It is very important that
factory takes every layer from different rolls.
The numbering has to be done from 1 to 30, Numbers have to be written or
labeled on the garment so that it can be identified after wash. This will help
in checking the shrinkage variations.
The cutting marker that factory will use for the test run has to be exactly
the same as what they will use in bulk production.
Garments have to be then produced in line using the same techniques as
bulk.
4 size sets will be then measured for before wash and the same garments
will be then checked after wash. Garments have to be numbered with a
water proof pen so as to check them against their respective before wash
measurements.
The size sets have to be specked after wash and after pressing.
The needle work, stitching techniques, sewing quality has to be scrutinized
and documented.
Garments will have to be then ironed and packed the same way as bulk
requirements.
Report on Industrial Attachment | SEPAL GROUP 53
OTHER RESPONSIBILITIES:
To follow the procedures as discussed in the Pre-Production meeting
To check the spec on 4 size sets before and after wash.
To check the spec on the size sets after pressing.
To finalize the before wash spec.
To approve the final pattern for bulk by adding the correct shrinkage.
To make a report on the packed pieces.
To make sure that all the issues noticed during production are corrected
and taken care of.
To finalize the method or procedure to make the product.
CUTTING PROCEDURE
All cutting machine operators must use metal hands gloves while cutting to
avoid cut injury on the finger.
All cutting department employees must use dust mask while cutting to
avoid breathing in cutting dust.
Before starting the size set cutting process, all reports and tests should be
completed on the fabric to be cut. The size set cutting process should be
based on the findings from these reports:
1. Fabric Inspection Report
2. Shrinkage Report
3. Blanket Report
4. Shade Band Report
To confirm the shading the fabric should be joined side to side, side to
middle and front to end and compared for color variation, if all is ok then
size set cutting process should proceed
Before and after wash swatch boards must be made for all approved fabric
swatches with all kinds of parts (body fabric, pocketing, binding, inside
w/band etc. These must be matched under buyer approved light box before
wash & after wash.
Report on Industrial Attachment | SEPAL GROUP 54
All lay/cuts must be inspected prior to cutting. The following points that will
need to be checked:
1. Marker Length
2. Marker Placement
3. Counts
4. Tension
5. Leaning
6. Ends
7. Splice
8. Fabric Flaws
Total defects found and action taken towards the defects will need to be
noted
After cutting the parts, they need to be checked with hard pattern to see if
there is any variation between the pattern and cut parts.
Nested pattern has to be kept ready before the pilot run cutting.
Cutting layer should be selected from one dye lot however if mixed dye lot
needs to be used then paper lay must be placed with correct identification
information between each dye lot.
Cutting table needs to be always clean. If there is any damage on the
tables, they need to be repaired immediately.
After cutting is complete parts numbering needs be 100 percent accurate
for all the cutting parts to avoid size and shading problem on the sewing
floor.
All cuts must be inspected prior to issue in the line. All cut parts (Top /
Middle and Bottom) must be inspected from each layer and recorded. This
record includes the name of the component inspected. Variation found
(Actual compared with paper pattern) and the action taken towards the
defects.
NEEDLE PROCEDURE
A) All the broken needle must be deposited before new needle issue to the
worker.
Report on Industrial Attachment | SEPAL GROUP 55
B) A written record must be maintained line wise what type of needle is
broken and who is depositing.
C) Broken parts must be found out from the machine area or garments. If
necessary hand needle detector or magnet might be used.
D) The broken needle with its part must be paste and preserved separately
in a needle log register.
E) All kids’ garments after preparation must be checked thoroughly in a
Needle Detector Machine for any unseen needle. If the parts are not
located in the garments/parts, it must be rejected and kept in a
quarantine box.
F) PM and compliance personnel should check the needle daily. So that
there is no anomaly in preserving the broken needle.
PRODUCTION PROCEDURE
All operators must use dust mask while operating the sewing machine.
Needle guards have to be fixed & needs to be checked before starting the
work.
Cutter, Scissors & Point pin have to attached to the machine with a
drawstring
Approved daily goal, swatch card and garment sample must be posted
before starting a new input or style.
S.P.I. needs to be checked everyday before starting the work.
Parts numbering must be matched and followed 100% during all relevant
processes.
Bundling system needs to be followed 100% cutting wise to avoid size
mistake and shading.
The Machine Mechanics must check all sewing machines before the start of
work for problems and record their finding in the inline machine
adjustment log.
All machine issues found must be fixed before starting work.
The operators have to check the needle point everyday by following the
needle points check procedure.
All mechanics, operators, supervisors and line chiefs must check to see if
the machine thread handling systems are clean and correct.
Report on Industrial Attachment | SEPAL GROUP 56
Before starting the production every operator has to clean their machine.
While sewing all operators must keep the stitch quality as per the buyers
requirement.
All factory PM, Line Chiefs, Supervisors and QA inspectors must maintain
production and quality goals discussed during PP meeting.
All operators must follow parts attaching mark and pay particular attention
to all difficult processes like pocket, flap, waist band & loop attachment as
per buyer requirement.
All production employees must maintain and follow the correct bundle
serial and numbering systems to avoid size mistake.
If any parts are rejected during sewing process, the particular part must be
replaced by selecting another piece from the same fabric roll to avoid any
kind of shading.
All mechanics must adjust the machine to control and minimize oil marks.
All employees must maintain cleanliness to control stains and dirty spots on
garments
No garments or parts can be kept on the floor and must be kept in the
assigned place.
SAMPLE LAYOUT
Actually, Sepal Group maintains all quality products in the world. Here, we have
described a layout for cargo short pant. The number of machines and other things
needed described on below-
Production target per hour 90pcs
PID# 222217
BELTED WALKING SHORT PANT
Machine name Type Number
1. Front rise O/L 3TH O/L 1
2.Front pocket piping P/M 1
Report on Industrial Attachment | SEPAL GROUP 57
3. Front pocket same +
tuck
P/M 2
4. White pocketing 5
thread
O/L 1
5. Zipper Joint P/M 1
6. S/Fly body attach +
D/Fly tuck
P/M 1
7. J/stitch P/M 1
8.R/part+D/Fly Joint P/M 1
9. Front rise Joint 1/32 +
top stitch ¼
P/M 2
10. Back rise 5th O/L 1
11. Back rise +side pocket
ruling
D/N 1
12. Back rise taken + top
stitch
P/M 3
13. White pocketing Joint P/M 1
14. Fashung 3 thread O/L 1
15. Bone Joint + Bone
make
P/M 3
16. White pocketing Joint P/M 2
17. Bone top stitch P/M 3
18. White pocketing top
stitch
P/M 3
19. Side Joint 5th O/L 1
20. side top stitch D/N 1
Report on Industrial Attachment | SEPAL GROUP 58
21. Side pocket making P/M 4
22. Side pocket Joint P/M 2
23. Belt tuck P/M 1
24. Pippen P/M 1
25. Belt make P/M 2
26. Belt Joint C/S 2
27. Label Joint P/M 1
28. Mouth close P/M 1
29.Belt loop stitch D/N 4
30.Inseam 5 thread O/L 1
31.Loop make & top
stitch
D/N 1
32.Loop joint & tuck P/M 4
33.Hem P/M 2
34.Bartake stitch B/M 1
35.Button hole stitch Button hole m/c 1
36.Button attaching Button attaching m/c 1
TOTAL 59
REQUIRED NO. OF M/C
M/C types No. of M/C
Plain Machine 42
Double Needle Machine 7
Report on Industrial Attachment | SEPAL GROUP 59
Chain stitch Machine 2
Over Lock Machine 6
Zigzag stitch m/c 2
Others 2
OPERATION SEQUENCE OF BOOT-CUT CHINO PANT
Back Part:
1. Back part marking at knee position.
2. Marking at bon-pocket position by means of hard pattern.
3. Fold and stitching at both side .
4. Pocketing fabric and back part joining.
5. Stitching at facing.
6. Back rise overlock ( 2 back parts joined).
7. Back rise top stitch.
8. Bon pocket top stitch (1st one)
9. Bon decoration stitch (2nd one)
10. Bon facing join (fusing side).
11. Bon top stitch (pocketing fabric is folded first, then stitched)
12. Facing join.
13. Stitching at three sides to make pocket.
14. Back pocket tuck
15. back part completed.
16. Inspection
Front Part:
1. Front part marking at knee position.
2. Front rise overlock.
3. Double fly.
4. Front part + zipper joined.
5. Marking and stitching at fly piece.
6. Double fly join (zipper’s face side).
7. Thigh part top stitch.
Report on Industrial Attachment | SEPAL GROUP 60
8. Bon marking.
9. Another pocketing fabric joining.
10. Joining front bon.
11. Bon hole is made/cut manually.
12. Ironing.
13. Bon pocket top stitch.
14. Decoration stitch.
15. Pocketing fabric joining by stitching.
16. Coin pocket stitching at 3 sides.
17. Pocket facing attaching with pocketing fabric.
18. 2nd facing attaching with pocketing fabric.
19. Marking at pocketing fabric.
20. Front pocket joining.
21. Front pocket top stitch.
22. Joining with marked line.
23. Pocket making by tucking.
24. Stitching at lower part.
25. Front part completed.
26. Inspection.
Assembly (joining front & back part) :
1. Matching the serial number of front & back part.
2. In-seam making (overlock).
3. Top stitch by Feed of the Arm m/c.
4. Hemming formed by ironing.
5. Side overlock at one side.
6. Side overlock at the other side.
7. Inspection of in-seam & side seam.
Fusing at waist band joining :
1. Fusing for belt are joined.
2. Piping joining with fusing fabric.
3. Take another blue color fabric , folding with help of folder and then
stitching.
4. Fusing fabric with piping and belt fabric.
5. Top seam applied.
Report on Industrial Attachment | SEPAL GROUP 61
6. Marking for pocket.
7. Marking at both sides to equal pocket.
8. Belt joining.
9. Pocket joining.
10. Label joining.
11. Mouth tongue joining.
12. Cutting at mouth tongue.
13. Inspection.
14. Ironing at belt.
15. False stitch applied to prevent slipping.
16. Top stitch for belt.
17. Opening false stitch.
18. Inspection
19. Marking for loop.
20. 1st loop attaching at lower position.
21. Folding top loop stitch.
22. Bottom hem made.
23. Final inspection.
24. Bar tack stitching.
25. Bar tack stitching at belt.
26. Bar tack stitching at pocket.
27. Back pocket hole and front pocket hole made.
28. Inspection.
Production rate : 110 pieces / hour.
PACKING PROCEDURE / POLICY
1) To check and confirm the carton size, dimension, volume and printed
stickers as per buyer requirement.
2) To check the cartons weight and quality before putting poly packed
garments into the cartons.
3) To check poly size, quality & weight and printed information before packing.
4) To confirm the pressing quality and folding before putting inside the poly.
5) To confirm the assortment ratio and pieces.
6) Stack the cartons size wise in the carton area separately.
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PRE FINAL AUDIT PROCEDURE (FINISHING)
Pre final audit will be done by the factory QA when 10%, 50%, 70% goods are packed. The audit procedure has to be just like the daily pre-final audit done by the factory packing department QC. 1. The cartons that will be pulled for inspection have to be taken from the total
cartons packed at that time.
2. The QA report will have to be shown to the Buyer’s GQC when they come for their regular audits.
3. If goods fail the QA audit, then factory will have to re-check and after all issues are corrected the goods will be offered to the Buyer for their regular audit.
4. The factory QA will select the cartons that are packed at random based on the square root of the total. (The audit will be done as per AQL 2.5).
WASHING PROCEDURES IN WASHING UNIT
Factory QA Manager will receive approved wash standard from
merchandisers for hand feel, shade and grinding.
Factory QA Manager will ask for wash recipe from the washing plant.
Factory QA Manager will provide approved wash standard to the washing
plant.
Factory QA Manager will provide approved wash standard to the
production / QA file.
Factory QA Manager will provide approved wash standard to the wash
quality auditor / checker.
QA Manager will check pre-wash spec against each & every dye lot prior to
sending for washing. All pre-wash garments should be stored in a particular
place.
All subcontract inventory control reports must be maintained in a register.
All washed garments must be stored in a particular place.
All washed garments spec must be checked and verified for hand feel,
shade and grinding against each and every dye lot prior to sending for bulk
thread trimming.
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All wash damaged garments must be stored in a particular area by
maintaining proper a record.
DAILY PRODUCTION REPORT:
Daily production capacity of Creative garments ltd.
Cutting capacity = 6000 pc
Sewing capacity = 4000 pc
Laundry capacity = 30000 pc
Production line = 5
Production capacity of a line per hour: Per hour a production line can produce 80-
100 pc of garments. Thus per hour creative garment ltd. can produce up to five
hundreds pc garment. In this factory there are eight working hour in a day. Hence
the total production of a day is 3200 to 4000 pc. Sometimes more working hour is
needed which are considered as over time to maintain the production rate in
time.
Note: Here we also added some daily production report.
MONTHLY AVERAGE PRODUCTION
Monthly production of this factory is about 87500 pc.
MONTHLY EFFICIENCY
Daily optimum production = 4000 pc
Daily actual production = 3200 pc
Daily efficiency = 3200/4000*100%
= 80%
Monthly optimum production = 100000 pc
Monthly actual production = 87500 pc
Monthly efficiency = 87500/100000*100%
= 87%
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REMARKS
Garment production is a very complex work to do because of it needs a huge
number of machineries and large man power system as well. To maintain
production rate with in shipment time is very important and it is difficult as well.
We worked hard to know the whole procedure of a production process. We have
collected all the documents are needed to run a production. Some of them we
have attached. We have tried our best to collect them. We are grateful to our
supervising teacher Mr. Julian for his help while collecting these data.
We are also grateful to our respectful teacher Mr. Moshiur Rahman Khan for
giving important check routine and advice.
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Chapter 6
Inspection and audit
CONTENTS
Quality Audit
Audit Procedure
DUPRO Audit
Final Inspection
Remarks
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INTRODUCTION
Quality audits are performed to verify conformance to standards through review
of objective evidence. A system of quality audits may verify the effectiveness of a
quality management system. This is part of certifications such as ISO 9001. Quality
audits are essential to verify the existence of objective evidence showing
conformance to required processes, to assess how successfully processes have
been implemented, for judging the effectiveness of achieving any defined target
levels, providing evidence concerning reduction and elimination of problem areas
and are a hands-on management tool for achieving continual improvement in an
organization.
To benefit the organization, quality auditing should not only report non-
conformances and corrective actions but also highlight areas of good practice and
provide evidence of conformance. In this way, other departments may share
information and amend their working practices as a result, also enhancing
continual improvement.
COMPARING FIRST PRODUCTION UNIT TO THE CLIENT’S APPROVED
SAMPLE
The QC department along with the production team must follow the
procedures mentioned below while comparing first production unit to the
clients approved sample:
The QA manager / Line QC will randomly select and pull the first produced
garments from the output table and summon all the relevant production
employees along with PM to the inspection room for a meeting
The approved client sample has to be compared with the first produced
units by the QA manager
The first units should be checked and verified according to clients
specifications
Accurate measurements should be taken
Trim attachment and positions should also be checked and noted
Construction with all critical processes should also be checked and
If any non conformity is found, these are identified per Buyers Defect
Classification List and shown to the production personnel for rectification
The defects should be discussed and their causes identified and explained
to the production personnel
A corrective action plan should be formulated to avoid the same issues
again
All points should be documented and acknowledged by all present
Records must be retained for future reference.
OPERATOR WISE IN-PROCESS AUDIT PROCEDURE
In line quality inspectors have to check every operator at-least twice a day
especially for critical sewing work. The Quality inspectors will pick a bundle that is
complete and pull out 7 pieces at random. If they find any defect then the
inspection fails. The inspector records the details which will include the operator
name, operation, number of pieces inspected, number of defect found, the DPCI
number and action taken towards the defects. Steps to be followed in case of a
failed bundle inspection:
All the pieces of the rejected bundle have to be checked for defects by the
operator and fixed before they proceed with the next bundle. At this stage
the inspector will have to attach a red ticket to the bundle and also attach a
red flag to identify the machine and operator for possible quality problems.
The corrected bundle has to be then rechecked by the line supervisor to
make sure all defects are fixed before the operator is allowed to proceed
with the next bundle.
The very next bundle of that operation will have to be also inspected for
defects. If no defects are found the operator can then proceed with the
third bundle. If the bundle gets rejected then the operator will have to
recheck all pieces and alter all the defects. The corrected bundle will have
to be re-inspected by the line supervisor to make sure all defects are fixed
before the operator can proceed with the next bundle.
The third bundle will also be audited and if passed then the flag will be
taken of and the operator can proceed with the operation. If this bundle
gets rejected then the operator will be stopped from resuming production
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and sent for re-training. The factory manager will have to be notified and
he will have to sign on the quality form related to that quality operator. The
factory manager will have to approve the return of the operator after the
training is complete.
Note: The Factory manager and the Production team have to analyze all defects
that are found at the red flag area. The machinery and tools used by the operator
will also have to be checked for improper setting and defects. If the problem is
with the machinery and tools then necessary action has to be taken to correct the
issue.
PROCESS END TABLE DEFECT TALLY AUDIT PROCEDURE
A defect tally must be maintained for every line. It is very important that the
managers analyze the defects and makes sure that the total defects found per
operation decrease as the days pass by. The defect tally must have the following
information:
a) Operation type
b) Defect type
c) Hourly tally DPCI number
d) Day’s total defects
e) Previous day’s total
f) Corrective action taken
Before wash spec on critical positions has to be checked on 100% garments with a
template that is fixed on the checking table. The defected garments have to be
recorded on an hourly basis. The production team has to analyses all defected
garment for spec to see if operators take in the proper seam allowance while
stitching. Tolerance of not more than ¼” has to be given to spec before wash
garments.
All reports have to be signed and analyzed by the quality auditors, line supervisors
and the production manager. Defects that do not show any improvements and
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appear on a daily basis will have to be checked 100 % in line in front of the sewing
machines that produces that particular operation.
Offline DUPRO audit and before-wash spec check procedure
The audit must be done on the out put from each sewing line as per AQL 2.5 for
workmanship and AQL 4 for Fit. The quality inspector must base the sampling plan
based on the days out put per line. The process will be similar as the DUPRO
inspection and form used will be Form # 6. All defects will be identified by DPCI
number and a defect trend will be analyzed with the factory production team.
Before wash spec has to be checked every day and attached to every audit report.
Four pieces per size is the minimum one should check. Factory will have to wash
the pieces that were measured and re check if they are ok to spec after wash and
after ironing. Tolerance of not more than ¼” has to be given to the before wash
spec and only at some of the spec points. If the before wash spec fails then the
immediate conclusion has to be that the operators are either taking a wrong seam
allowance or cutting extra at the marrow stitch . Early detection of this problem
will help in solving spec issues.
Inline DUPRO Audit Procedure
Factory QA will have to do a DUPRO audit when the factory has completed 10%,
30%, 50% and 90% of production. The factory QA will select pieces from all the
lines at random. The Factory QA will also use Form Ref # 6 to do his inspection.
The specifications that will be checked during these audits have to cover all sizes
and a minimum of 4 pieces per size. The Factory QA will also have to get all pieces
measured, washed and then rechecked both before and after ironing. All
measurements have to be checked in details during this audit. All defects will be
identified by DPCI number and defect trends will be analyzed with the factory
production team. The process for DUPRO Audit is as follows:
The Inspector has to first decide on the sample selection based on the
factory’s daily output.
The pieces have to be selected at random from all lines.
Only garments that have passed the output check will be selected for the
audit.
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AQL 1.5 STD has to be used to evaluate whether goods passed or failed for
workmanship and AQL 4.
Defects have to be identified by using DPCI number and a defects trend will
have to be made while analyzing the report.
Defect classification code will have to be used for specifying every defect.
Every defect in the garment will be recorded on the report but only one
garment will be counted for major and minor defect evaluation.
A defect trend will be made and analyzed with the factory production team.
The inspector has to make sure that all defects that are found are attended
to inline so that the root cause of the problem is solved immediately.
The pre-wash specs have to be checked on 4 pieces per size – the garments
have to be measured to the specs with a tolerance of ¼ inches. If the
measurements are out of tolerance, the production team will have to see
that all operations are re-checked to verify if the operators are taking
excess seam allowance (excess seam allowances and cutting at the narrow
seams will cause the spec on the garments to differ from the before wash
specs).
DUPRO Audit Procedures before Pre-Final Audit
Factory QA will have to do a DUPRO audit. When the factory has completed
10% - 30% and 50% goods are packed. The audit procedures have to be
same as the pre-final audit done by the factory QA and they are as follows:
The cartons that will be pulled for the inspection have to be taken from the
total cartons packed at that time.
All the information gathered during inspection will have to be kept in a
DUPRO report.
The report will have to shown to the Buyer’s GQC when they come for their
regular audits.
If goods fail the audit then factory will have to re-check and offer the
factory QA for re-audit after all issues have been fixed.
The factory QA should only select cartons that are packed at random based
on the square root of the total. (The audit will be done as per AQL 2.5)
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Final Table Checker Defect Tally Procedure
The final checkers will have to maintain a defect tally list – Form Ref # 7 for
analyzing the defects and to make sure the specific defects found on the finished
product are controlled and proper action is taken. The defects have to be totaled
on a daily basis and proper steps have to be taken by the factory managers to
make sure that all issue are controlled in the process. NOTE – Factories have to
make a defect trend history style wise to keep in records and records have to be
analyzed often with the factory manager so that factory can make improvements
in systems and procedures to get better in future orders.
Table Specs Check Procedure
Factory has to make a template and fix it on the table for checkers to check the
critical specs on 100% garments. Defected garments for spec have to be recorded
on an hourly basis.
Daily Pre-final Audit Procedure
Pre final audits have to be done on a daily basis using form Ref# 8. Goods that fail
the audit have to be rechecked the following day. All inspections have to be done
based on AQL 2.5 for workmanship. The cartons that will be pulled by the
inspectors have to be signed and pulled at random to get a proper statistics on the
goods. The Square root method will be used to select the quantity of cartons that
need to be pulled for every inspection. All inspection reports should have a
measurement spec report done based of AQL 4. The factory has to see that a
minimum of 4 pieces per size per color is taken for a spec audit.
FRI (Final Random Inspection) Procedures
The final inspection will be done by the factory QA based on the form Ref # 9. The
audit will be done only when 80% - 100% of the cartons are packed. The final
inspections will be based on AQL 2.5 for workmanship and AQL 4 for spec (fit
audit). The number of cartons to be selected will be based on the square root
system. The QA will have to check the spec on a minimum of 4 pieces per size.
Goods that fail the audit will have to be rechecked and corrected before offering
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the buyer to perform their final inspection. The inspector should make sure that
he has the following before the starting of the audit:
Buyer’s Standard Inspection Package
Red tag Sample
Inspection Forms.
AQL Chart.
Wash /shade band approved samples.
Packing List.
MTL/CTL test passing reports.
Note: Shipment will not be released with out the required passing test reports.
The audit can be started when 80% goods are packed provided the balance
20% gets packed while the inspection is in process. The balance 20% then
has to be inspected at the end of the audit.
The inspector has to then decide on the sample size for the workmanship
audit based on the shipment quantity as per the AQL 2.5
(MIL-150E Single Sampling plan Level 2.)
The quantity of cartons that need to be pulled will be based on the square
root rule.
The Fit evaluation has to be done based on AQL 4 (MIL – 150 E Single
Sampling plan level 2). At least 4 pieces per size need to be measured.
The cartons have to be stacked properly in rows of equal height and should
be easily accessible. The carton quantity has to be verified first based on
the packing list.
The cartons that are selected for the audit have to be signed by the auditor
and accompanied to the inspection room.
The size and color ratio, shading in carton size and printing and paper trims
have to be compared with approved samples and the placement has to be
checked as per floor ready specs. Packing and folding instructions also have
to be verified as per the floor ready specs.
All finished pieces have to be stacked size-wise. Inspectors have to then
check for care instruction, size on all labels and hangtags.
Inspectors will pick two pieces at a time and pair the waist together to
check if it matches. This will ensure a 100% check on all size label mistakes.
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Garments have to be checked inside out. Zippers and buttons have to be
checked for functionality
FABRIC & TRIMS INSPECTION AND STORAGE PROCEDURE
The approved swatch card has to be collected from the merchandising
department and kept in the store.
All trims must have bin cards affixed on top of the rack where they are
stored and they must be stored color and size wise.
10 % percent of all trims must be checked and findings noted in a trims
report. Only 1 percent defect is a acceptable rate. The trims report has to
be affixed on the bin card.
Any one of Hang Tags may be checked from each bundle using a bar code
machine and a printed copy must be retained.
All trims have to be checked using a UL3000 light source.
All rejected trims must be kept in the reject room and disposed of following
the buyers recommended disposal process
All excess trims must be accounted for and stored in a secure place and a
record must be kept for reference until further notice from the buyer.
Fabrics have to be kept on pallets.
The bin card must be attached to fabric rolls dye lot wise
Shrinkage and Fabric Inspection Report should be on the bin card.
All fabrics must be issued shade-wise for cutting.
All rejected fabric must be placed in the reject room and disposed per
buyers disposal process
All access fabric must be accounted for and stored in a secure place.
Records must be retained for reference until further notice from buyer.
Note: Please see the fabric inspection procedure for fabric inspection process.
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Target Defect classification list
Fabric
Defect Code Description Classification
F001 Holes where the yarn is cut, broken ends, drop stitch that runs major F002 Vertical or horizontal lines permanently knit or finished into fabric (i.e. needle lines, compactor creases, barre, light/heavy ends). Visible at arms length major F003 Soil, oil spots with contrast visible at arm's length, adversely affecting appearance major F004 Not cut on grain line as specified affecting appearance or shrinkage major F005 Significant snags and/or slubs distinguishable when viewed at arm's length, adversely affecting appearance major F006 Knitted in, off color fly visible at arm's length major F007 Misweaves, mispicks (wovens) major F008 Washing/Dyeing Defects (streaks, uneven dyeing) major F009 Shaded parts/thread and/or visible components, adversely affecting appearance major F010 Printing defects: Wrong, missing or incomplete coverage of color, misregistered, over 1/16" major F011 Poor hand feel of product - not as specified major F012 Knit/Woven structure not to standard minor F013 Product (including all items in selling unit) not visually matching Archroma standard or approved shadeband major F014 Conspicuous pilling; not to agreed upon standard major F015 Mismatched stripe/plaid: side seam 1/8”-1/4” minor F016 Skewed, bowed or biased fabric, solid or stripe over 1/2" side to side for softlines; over 3% side to side for soft home major F017 Conspicuous repair (this covers knits and wovens) major F018 Mismatched stripe/plaid: side seam over 1/4”, pocket over 1/8”
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Components and Trim
Defect Code Description Classification
C001 Unapproved components or trim added or substituted affecting performance (Bias cut binding vs. warp cut; incorrect interlining etc.) major C002 Any specified trim or component missing, damaged, or not operational as intended. (Snaps won't snap, zipper won't zip or slider won't lock, fusible not bonded as per manufacturers instructions) major C004 Rivet, snap, clasp, grommet, or any closure device which is defective, damaged, incorrectly placed or attached which is likely to cause damage to wearer or property major C005 Buttons omitted, broken, damaged, defective or inverted; buttons that do not confirm to specification; misaligned or improperly spaced buttons major C006 Fusible interfacing must be compatible to garment without bubble or pucker; in a lined garment, the liner must not extend below hem or the shell major C007 Zippers: any malfunction; tape shade that does not closely match color specified; tape stitched too loose or tight resulting in excessive bulge on tape or placket when closed; exposed zippers that detract from appearance of garment; exposed edges of zipper tapes that would scratch or irritate wearer's skin; zipper not placed high enough in placket causing gap to top edge; aluminum zippers should not be used; zipper size and length should be appropriate to garment end use or as specified major C008 Hook and Eyes: Omitted or sewn in wrong places; hook and eyes misaligned when fastened causing bulge or twist as the point of closure; all metal parts must be rustproof, washable, dry cleanable, and attached securely; size appropriate to location and specification major C009 Belt color not as specified; width of belt out of specification in excess of 1/4"; eyelets out of alignment in excess of 1/4"; number of eyelets not as specified; end of belt not shaped according to spec; irregular belt width in excess of 1/4"; top stitching of belt is uneven or crooked; belt loop size not appropriate to belt width, missing or insecure loops; belt length must be appropriate to garment size; middle eyelet is not standard fit; any metal parts rusted or oxidized major
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CHAPTER 7
QUALITY ASSUARANCE SYSTEM
Contents
Quality assurance system
Procedure
List of machineries
Quality report
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INTRODUCTION
Quality assurance system
Introduction: Now a day’s quality makes a product perfect. In textile sector quality
is very necessary in every step of textile processing assurance of quality level is
important. In garments industry keeps a good quality all time.
Quality of garment means a garment free from all kind of defects such as oil spot,
uneven sewing, Raw edge, frying, defect frees accessories etc. Measurement of
quality is done in industry in two ways. One is testing and another is inspection. In
SEPAL GROUP inspection is mainly done. Testing procedure is done by APPEXFAIR
BUYING HOUSE.
Quality assurance procedure
To assure a good quality it is very vast job .Spreading, cutting, sewing, finishing in
every where producer has to maintain and check the garments quality.
FEBRIC TESTING
At first the quality of fabric should be checked. If there found any kind of defect
such as hole, knot, spot etc upper than limit then fabric is rejected. Here use 4
point system to detect fabric quality.
By 4 point system we find the number of defective points of 1oo yds fabric. It is
done by the use of fabric spreading machine. it has a chart. According to this chart
with mathematical calculation we find fabric defects.
firstly fabric is spreading on machine surface and then the defect is counting per
100 yds of a roll. the chart is given below
THE LENGTH OF DEFECT IN WARP AND
WEFT DIRECTION
POINT
Beyond 3 inch 1
3 inch-6 inch 2
6 inch-9 inch 3
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Above 9 inch 4
FOR HOLE & OPENING
1 inch or low 2
Getter than 1 inch 4
After detect fault need of calculation. the theory is given bellow:
points/100yds=total defect pt/total fabric length in yds*100-1*36 inch/width of
fabric
The limitation of defective point is done by buyer will.
BLANKET: to detect shade of color this experiment is done. Shade testing is also
done by the use of LIGHT BOX machine. Here 6 types of ray is used to differentiate
shade as buyers rule.
DURING SPREADING
The rules are given below:
1. Check that the marker is placed on the spread with the edge parallel to
selvedge to the placed goods variety that all cut peaces will be
completed.
2. We check all shedding unless ply marked
3. Check for table marks as the table is marked allows no minus tolerance
for the splices .
4. We have to ensure no marker is creased damage.
5. After compilation of spread we check the splices to see that both plies
extend past the marked splice lie between 0.5 inch to 1 inch.
6. After complete we check the fur edge of the spread to see that all plies
are extended beyond marker line.
7. Then we check the tension and count.
8. At last we keep marking the roll which is necessary when reject part is
replaced.
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DURING CUTTING
The process is given below:
1. We check the miscut
2. We check the top middle & bottom ply compare those to a hard pattern
comparison with a hard patterns best tolerance +0.5 inch to -0.5 inch.
3. we check the notch location by placing the pattern over the top ply
tolerance +1/8 to – 1/8 inch.
4. To compare the marker to pattern paper to ensure .
DURING SEWING
It’s very crucial time for quality control. There is lot of inspection done in this
section. Before sewing need fusing. Here we check bonding strength. Then it’s
come to sew Inline 7 pcs inspection is the most important inspection. It is invented
by a USA buyer MR.JESSYPENY. Here we take 7 pcs garments from bundle of 20
pcs and then check and alter the defective parts.
Needle point check up is done daily by one kind of hand shocks. To have uniform
tension we daily check machine.
Daily goal report is one kind of audit or calculation to reach the goal with quality.
We always check the stitch condition. Specially backrise, outseam, inseam, front
fly, etc. We make a report to see that. This is called SPI(stitch per inch) report.
ALTERATION REPORT is one kind of table inspection. It is expressed as time
duration.
Defect tally is another kind of quality assurance procedure. Here we must check
back part, front part, waist band, side seam etc.
DURING FINISHING:
There are different lay out for different garment .Finishing layout also depend on
buyer. Quality assurance system in finishing is given below
a. Remove or cut extra thread
b. Inside check
c. Thread from garments surface is being slashed with the help of
slashing machine.
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d. Inside ironing
e. Final inside quality check
f. Outside qualities check.
g. Top side ironing.
h. Measurement.
i. Final quality check.
j. Thread & lint cleaning area(if required)
If we get any spot we send it to spot removing lab. By the help of spot removing
gun or chemical treatment we remove the spot. At last we make a bundle called
blister.
In case of shirt or trouser we check button strength by button pulling test. Those
are all the procedure of quality assurance system.
LIST OF MACHINARIES
1. Atom hydraulic cutting press Secom platting machine
2. Thread slashed machine.
3. Needle detector machine
4. Spot remover gun.
5. Button pull test machine.
6. Fabric shrinkage test machine
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IMAGES OF SOME QUALITY CONTROL EQUIPMENTS
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SEPAL GARMENTS LTD QC SYSTEMQC SYSTEM FLOW CHART
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PICTURES SOME DEFECTS
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CHAPTER 8
Maintenance
Contents
Manpower set up
Procedure
Tools
Oiling
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INTRODUCTION
Maintenance of machinery
Maintenance of machineries is very important in Garments industry. Because m/c
is subjected deterioration due to their use. If that remains unchanged then
everything will be standstill. So m/c is checked by routine. In SEPAL GROUP
machineries are checked on the routine.
Manpower set up
In SEPAL GROUP it has 4-5 line men who are set for machine control. They work
under a mechanical in charge. There are one mechanic and one electrician.
MAINTANANCE PROCEDURE
The procedure of SEPAL GROUP is given below:
1. Every machine must have two types record.
#Preventive Maintenance Record
#Daily Check List
2. Preventive maintenance records card should be hanged on the machine.
3. Everyday mechanic has to check the machine through the daily check list’
4. If found any problem in the machine, the operator must hang a red flag to the &
to the
Machine & mechanic must fix the problem.
5. The in charge must maintain the machinery per the manufacturer guideline
following all safety
& health condition.
6. The mechanic must ensure that the all necessaries equipments of machine
work of correct
Setting and has to adjust any equipment if required.
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7. If any fault found the responsible person must put down the machine in
breakdown status.
8. After repairing the machine should check for safety run.
9. All records must be updated with the necessary information
PREVENTIVE MAINTENANCE PROCEDURE FOR PRESSING
1. Service all the pressing machine monthly to keep the pressing machine un-
interrupted.
2. Steam lines and pressure should be proper.
3. The next servicing / maintenance date should be mentioned.
4. Pressing table should also be checked and charge the cloths on the table.
5. Vacuum pressure should be controlled and adjusted.
6. Preventive maintenance card should be hanged beside the machine.
TOOLS
The tools which are used to maintain machinery are
1. nut
2. screwdriver
3. hammer etc
OILING
It is one kind of maintenance. Oiling is done regularly on machine.
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SAMPLE CHARTS FOR MAINTENENCE
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CHAPTER 9
Utility Services
Contents
Utility facilities available
Capacity & other technical details
Source of utility
Cost of different utilities
Remarks
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INTRODUCTION
Utility means service that will provide different facilities or advantage for the
factory or mandatory one. In the every factory utilities service is not available and
production capacity also depends on that service. The utilities service of sepal
Group is available and they don’t have any lack of gas, generator system and other
Facilities.
We have seen all the utility section of Sepal Group and tried our best to collect the
necessary document and information. Though it is a huge building the control
management is very good.
MAIN UTILITIES FACILITY
Boiler
Generator
Water pumps
Electricity control room
Fire defense facility
ETP
BOILER
The m/c which generates steam and supply to the all necessary activities to the
factory is termed as boiler.
Object of boiler
1. To produce steam according the requirement.
2. To supply steam and boil water.
3. It mainly supply steam to the washing m/c and ironing m/c.
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No. of boiler
There is only one boiler in the sepal group.
Capacity of the boiler:
Capacity - 2400kg.
Steam hour delivery – 2400kg.
It is run by gas or electricity.
Company
The company name : KAMINS.
Origin : U.K
Different chemical used for boiler running
The entire chemical collected from the local market.
Management system of boiler:
1. One supervisor officer.
2. One boiler in charge and two electricians are working in the area.
Chemical name amount use
Doggy chemical (soluble) 250gm/8hr to lessen water hardness
Auto scaling (NaOH) 1200gm/day -
NaCl 25kg/48hr To remove carbonate.
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GENERATOR
The m/c which converts the mechanical power to electronic power is generator.
Object of generator
To generate electricity by using fuel such as oil, gas etc.
No. of generator
There are two generators in this group.
Company of those generators
1) KAMINS – U.K
2) CATER PILER – U.K.
Capacity, load and fuel required to the generator
Capacity
1. 930 KVA
2. 500 KVA
Load
1. 600 A
2. 510 A
Fuel
Generators are run by diesel in Sepal Group.
1. 90 L per hour
2. 35 L per hour
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MANAGEMENT SYSTEM OF THOSE GENERATORS
Supervisor officer: E.M Francis Gomege.
Electrician: 3 people.
Operator: 2person/shift.
ETP
ETP means effluent treatment plant all the effluent or wastage /usage water reach
to the ETP plant and there the chemical water is treated by various chemical and
than supply to drain by removing wasteful / hazardous chemical from water. it is
suited at below the ground floor.
PROCESSING OF WATER TREATMENT IN ETP:
At first water come from the washing, dying and other machineries reaches to the
collection tank and then treated water tank. In the treated water tank, there is a
net which hinders to reach powder from chemical to go to the equalization tank.
From the equalization tank the water are collected to the mixing tank. in the
mixing tank ,there is wheel driven by motor. The wheel helps to isolate chemical
and water. then all the wastage and chemical which are harmful for environment
is collected from the mixing tank and there those are neutralized that are not
harmful for environment but the water from mixing tank are reached to the
foliation tank and there poly electrolyte and a lam are mixed that remove the
harmful chemical from water and then goes to sludge tank and the filter press
tank. After all the process the water is dispatched to the environment from the
fresh water tank.
CHEMICAL USED IN ETP PLANT
Chemical name amount Source
Poly electrolyte 1 kg/day China
Alum 18 kg/day China
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COST OF THOSE CHEMICAL
Poly electrolyte: 380 taka/kg.
Alum: 36 taka/kg.
MANAGEMENT SYSTEM OF ETP
One supervisor: Mr. Pannu.
Operator: 3 people.
And other technicians and helper are about 5 person.
TOTAL COST FOR ETP PLANT SET UP
Approximately the cost of ETP plant set up is 1 core 60 lack taka.
PUMP
The m/c which collects water from source is called pump. There are three pumps
in the base ground of this factory.
Capacity of the pump
1.) 85 H.P
2.) 40 H.P
3.) 20 H.P
Management system for those pumps
Six operators are working for those pumps.2 people / shift.
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ELECTRICITY
Electricity is not available all the time. So they use gas and generator. The
electricity bill of sepal group is about 14 lack /month.
REMARKS
Those all the utilities are mandatory for a factory. To run a factory these utilities
play an important role. Moreover productivity of a factory is depending on it very
much. We have observed the total utility service is available here. It was not a
easy work to do but since the staffs were very helpful so it became easier to us to
collect information.
The ETP section is situated at the basement floor and we have collected a lay out
plan of this which was attached with the assignment file. We are thankful to our
supervising teacher Mr. Julian for his help while collecting these data.
We are also grateful to our respectful teacher Mr. Moshiur Rahman Khan for
giving important check routine and advice.
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CHAPTER 10
Store & Inventory Control
CONTENTS
Inventory system of raw material
Different inventory cost
Spares
Finished Goods
Others
Remarks
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INTRODUCTION
There are four garment in the sepal group they are sepal, orchid, creative and
glory. The entire floor is same area. But in one floor there are different section
such as store, cutting swing, washing and finishing section. All the section is
involved with different working.
AREA AND OBJECTIVE OF THE STORE ROOM
We know that there are four factories in sepal group. Their store room is also in
the individual floor and all the store room is same. Now we are describing about
one store room. The area of store room of sepal is 500sq foot.
The main objects of store room are following
I. To keep the material imported from foreign or local market.
II. To install the accessories from local or foreign market.
III. To remain different spare parts of different machine.
IV. To hang swatch board / term board on the wall.
V. To maintain a fixed relative humidity e.g. 76
THE TEST AND PROCESS OF STORE ROOM
Mainly the fabric is imported as lot and in one lot there are 100 or 120 yards of
fabric. When fabric is needed in the letting see lion then taken from the store
room.
TESTING SYSTEM OF STORE ROOM
There are different testing and inspection system in the store room.
1. 4 point system
2. 7 pious inspection system
3. 10 inspection system and
4. Other different inspection system such as shrinkage, strength,
elasticity and the evenness of the fabric.
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There is also a machine in the store room which name is fabric spreading and
quality checking m/c. By this m/c the length, width and shade of the fabric are
checked.
MANAGEMENT SYSTEM OF THE STORE ROOM
In every store room there is well arranged management system. In each store
room there are
1. one supervisor officer and
2. twelve workers
3. one stone in charge
4. two guards
THE WORK OF THE STUFF
The supervisor officer receives all the fabric and accessories from the local or
foreign market according to production director officer and supply the fabric and
accessories to the other section according to requirement. The store in charge
handles the worker to manage the test and other inspection. The workers look
after the store room.
INVENTORY CONTROL
Inventory in a widen sense is defined as any idle resource of in enterprise in order
to meet expects of demand or distribution. It is commonly used to indicate
materials, raw materials, finished, packing and stocked products. It is basically
necessary to keep hold inventory of various kinds to act as a cushion bet supply
and demand. It is almost necessary to maintain same inventory for the smooth
functioning of an organization.
CAUSES OF MAINTAINING INVENTORY CONTROL
1. It takes time to complete one operation and more products from
one store to another
2. To run manufacturing operation economically.
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3. To take care of uncertainties like uncertainties in demands from
customers and uncertainties in producing the materials in time.
4. To reduce the critical cost and to take advantage of discounts and
transportation.
FUNCTION OF INVENTORY CONTROL
1. To develop policies, plans and standard to achieve inventory control
objectives.
2. to build up a logical and workable plan for doing job satisfactorily
3. to provide necessary physical facilities
4. to develop methods that will bring desire result economically
5. To maintain overall control by checking result and adopting
corrective actions.
TYPES OF INVENTORIES
Inventions is following 5 categories
Production invention: It means which to inter the final products e.g. raw
materials.
In process inventories: Semi finished products at various stage of production.
Finished goods inventories: Compel products ready for dispatch.
Maintenance repair and operating: Though those are not form a part of final
product they are used in production process like spare parts.
Miscellaneous inventories: They are spare and obsolete item which are not to be
disposed off.
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OBJECTIVES OF INVENTORY CONTROL
Financial objectives
Here the goal is to keep inventory cost within limit of funds available and the
position of its working capital.
Property protection objectives:
a) To safe an important asset against theft, waste and measurable
damage.
b) To make certain that the value of this asset is correct stated in the
company s book.
Operating objectives
To obtain the best overall balance bet products and inventory caring cost on one
hand and customer service to others.
Advantage of inventory control
A well planed and property administered system of inventory control will bring
rise to the following benefits.
a. Improvement of customer’s frictions: This is achieved through maintenance
of better balance among the quantities of finished items on hands.
b. Improvement of labor and community relations.
c. Increase in the effectiveness of key personnel’s:
d. Reduction in manufacturing cost:
e. Strengthens financial position: This is achieved by onward inventory
controls.
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Different inventory cost
The important step in the inventory analysis is the identification. The following
classes of cost are usually involved in inventory control / decision.
1. Cost of ordering
2. Inventory costing cost
3. Colt of shortage
Now they are described below.
Cost of ordering:
Out of many other costs the order cost of inventory is the most difficult cost to
measure precisely. Placing of order is just one of the many other activities of
purchasing. So it is difficult to isolate and identify the cost of the cost of ordering
and measure them precisely.
There are two types of cost of ordering:
A. fixed
B. variable
Cost per order= Total cost in running purchasing dept/Total no. of order during
the year.
Inventory caring cost:
Inventory caring cost is also known as holding cost.
a. Cost that depends on quality of inventory: This cost includes.
1. Cost of storage space – light, rent maintenance etc.
2. Cost of hold stock e.g.: Pilferage spoils age, deterioration and protection.
b. Cost that depends on the value of inventory:
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1. Cost of capital, inter of cost.
2. Cost of insurance.
Cost of shortage:
When a demand arises and the item needed is not in stock then it is the
Cost of shortage of stock out of cost.
In the back order case there are two types of costs.
External Internal
-Loss of good will -over time
-Loss of future sales. - Special ad minis dative efforts
Spares:
Basically spares are the machine parts that are kept in the store room from the
different sewing and after m/c and made the reusable.
Now different spares are followings:
1. folder
2. guide 1/4 CR
3. guide 1/4 CL
4. guide 1/16CR
5. guide 1/16 CL
6. guide 3/16 CR
7. guide zipper
8. guide hanger
9. guide hamming
10. guide plain feet
11. guide gathering
12. guide CT
13. guide magnet
14. guide vertical
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15. guide thread
16. guide hook
17. guide piping
18. p/m bobbin
19. p/m needle plate
20. p/m rotary hook
21. p/m back stitch
22. p/m feed dog
23. p/m 60’’poly
24. p/m magnet screw
25. p/m thread stand
26. p/m tension spring
27. p/m needle bar cap
28. p/m pressure nut
29. p/m guide CR
30. o/l knife set
31. o/l upper holder set
32. o/l upper lopper
33. o/l lower lopper
34. o/l lower knife
Finished goods:
The term finished goods means the products that are ready for export. In the
sepal garment different types of garment are made for export such us.
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CHAPTER 11
Marketing Activities
Contents
Marketing service
Marketing plane & strategy
Consumer of the product
Product level
Package size & local level market
Importing countries
Man power
Duties & responsibilities of marketing officer
Remarks
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INTRODUCTION
Marketing is an integrated communications-based process through which
individuals and communities are informed or persuaded that existing and newly-
identified needs and wants may be satisfied by the products and services of
others.
Marketing is used to create the customer, to keep the customer and to satisfy the
customer. With the customer as the focus of its activities, it can be concluded that
Marketing is one of the premier components of Business Management - the other
being Operations (or Production).
The term marketing concept pertains to the fundamental premise of modern
marketing. This concept proposes that in order to satisfy its organizational
objectives, an organization should anticipate the needs and wants of consumers
and satisfy these more effectively than competitors
MAIN BUYER
MARKETING SERVICE
Marketing is a social and managerial process by which individuals and groups
obtain what they need and want through creating and exchanging value with each
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others. Actually, the process by which companies create value for customers and
build strong customer relationship in order to capture value from customers in
return.
In Sepal group, Marketing is a special branch of the garments sector. We have
mentioned earlier that Sepal group consists of four garments factory under one
roof so they have a strong marketing department. They need a lot of raw
materials to purchase as well as they need to convince buyers to sell their
product. So the marketing department should be strong and skillful as well. In
Sepal group some raw materials are collected from local market and rest are
imported from abroad. It is easy to say that buying them from this country or
abroad is not a easy work to do. That is why here marketing accumulation is
broadly opened. We have observed the account office and the marketing
department and collected some invoice. We were also introduced with some
marketing officer. They helped us by giving us information and documents.
MARKETING PROCESS
The marketing concept of building an organization around the profitable
satisfaction of customer needs has helped firms to achieve success in high-growth,
moderately competitive markets. However, to be successful in markets in which
economic growth has leveled and in which there exist many competitors who
follow the marketing concept, a well-developed marketing strategy is required.
Such a strategy considers a portfolio of products and takes into account the
anticipated moves of competitors in the market.
For marketers planning is an essential task that must be continually undertaken.
As we will see, shifting market conditions, including changing customer needs and
competitive threats, almost always insure that what worked in the past will not
work in the future, thus requiring revisions in how a product is marketed.
Marketing planning is also important since it is often a prerequisite for obtaining
funding whether one is a marketer in a large corporation seeking additional
money for his or her department or is part of a small startup company looking for
initial funding.
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To aid in our understanding of planning we introduce a key concept in marketing:
the Product Life Cycle. We will see the Product Life Cycle offers valuable insight
and guidance for marketing decisions. In this tutorial we also discuss different
types of marketing strategy that can be followed to meet marketing objectives.
Additionally, we look at how innovative products are adopted within a market and
how this impacts marketing planning.
We can describe the objectives also in following steps:
For creating value for customers and building customer relationship.
Understand the marketplace and customers needs and wants.
Construct a customer driven marketing strategy.
Design a marketing program that delivers supplier value.
Build profitable relationship and create customer delight.
Capture value from customer in return.
In our word we can say simply at first a marketing officer has to understand
customers need wants and demands. In Sepal group the needs are identified at
the states of left deprivation. Then the wants are calculated by the form needs
take as shaped by buyer and individual personality. The demand is however wants
that are backed by buying power.
MARKETING STRATEGY
There is a sequence of marketing strategies like following
Undifferentiated (mass) marketing
Differentiated (segmented) marketing
Concentrated marketing
Micro marketing (local or individual marketing )
In Sepal Group they have much extra ordinary marketing strategy. We were trying
to understand that clearly but could not understand thoroughly. We have
described below what we have understand.
They have segmented the marketing field in five ways:
On the basis of benefit
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On the basis of behaviors
On the basis of occasion
On the basis of user status
On the basis of loyalty status
CONSUMER OF THE PRODUCT
Marketing occurs when people decide to satisfy needs and wants through
exchange relationship. Exchange is the act of obtaining a desired object from
someone by offering something in return.
As we have mentioned earlier that Sepal Group is a 100% export oriented garment
company so the consumers and the customers are the foreigner normally.
America and Canada is the main consumer of the product. Moreover Germany,
Hong Kong, Thailand, France, South Africa, Norway, Switzerland etc. are the main
consumer of the product.
Stores & Importers of Sepal Group:
Stores-U.S.A market: Importers- U.S.A market:
THE GAP * KIDS INTERNATIONALS
J.C PENNY * WORLD WIDE APPARELS
WALMART * RADIX APPARELS
K-MART * S.J TRADING
CHADWICKS OF BOSTON * FRANK & JANE LLC
TARGET * MILLENIUM CLOTHING
SEARS and many more.
PRODUCT LEVEL
Market consists of buyers and buyers can differ in one or more ways. They may
differ in theirs wants, resources, location, buying attitudes and buying practices.
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Sepal group divides large heterogeneous market into smaller segment that can be
reached more
Efficiently and effectively with products and services that match their unique
needs. In Sepal group, there are three levels of product
1. Core benefit product
2. Actual product
3. Argumentum product
PACKAGE SIZE
Packaging refers to the development of a container and a graphic design for a
product. Packaging can make a product easier to use safer and more versatile.
Packaging can make an affect on consumers’ altitude toward a product, which in
turn affect their purchase decisions.
In Sepal group packaging serves a number of purposes. It protects the product and
maintains its functional form. All the products in here are packaging with the
recommendation of buyers. So that here present package who consider the
promotional role of packaging using verbal and non verbal symbols which contains
the product content, features, uses, advantages and hazards etc.
LEVEL LOCAL MARKET
We know that all the finished goods are prepared in here for exporting in the
foreign countries. For that leveling local market is not sufficiently necessary in
Sepal group.
IMPORTING COUNTRIES
The main importing countries of Sepal group are America and Canada. They bring
their most raw material, accessories and other trimmings from there. Besides this
the maximum machines have been bought from China, Japan and Hong Kong.
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Some are also been bought from Korea and Malaysia. The sewing machines in
here are imported from Japan and China from Brothers companies. In washing
unit boiler has been imported from China. There two generators in Sepal group
which are imported from U.K.
MANPOWER
The whole marketing department of Sepal Group works under the supervision of
merchandising department. A number of marketing officer are worked under the
G.M of the company. There worked in different section. As it’s an export oriented
garment factory the merchandisers are always busy to get an order from abroad.
Sometimes they do some sub contacted order. Most of marketing officer are
doing the purchasing job in here. They buy the accessories and trimmings from
here. There is also a custom department here for doing the activities related to
shipment such as loading and unloading. They keep contact and make reasonable
bargaining with the transport company.
DUTY AND RESPONSIBILITIES OF A MARKETING OFFICER
A marketing officer directs firm's overall marketing and strategic planning
programs, and corporate communications. Facilitate client development through
marketing and client services programs.
1. Design, implement, and facilitate annual marketing plan for the firm.
Support and facilitate development and implementation of section
business/marketing plans.
2. Plan and administer the firm's Marketing Operations budget; support
development of regional marketing budgets.
3. Oversee the Charitable Contributions Foundation.
4. Organize and implement client relations including:
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· client satisfaction surveys
· client development activities
· client skills training
· special events
5. Supervise firm's RFP protocol process including soliciting RFPs from
desirable prospective clients and writing proposals for new business;
participate in planning and presentation sessions, when assigned.
6. Oversee business development activities including:
· efforts through Business Development Coordinator
· assisting attorneys in strategic planning for client presentations, beauty
· contests, etc.
· offer coaching for prospective client meetings, presentations, etc.
· work with regional offices on designing and implementing prospecting and
client contact systems.
7. Oversee corporate communications activities through Communications
Coordinator including:
· external communications and systems
· internal communications and systems
· public relations efforts
· external vendors and consultants
8. Develop and administer marketing database which includes client and prospect
information, mailing list applications, access to financial reports, etc.
9. Assist with and support firm's involvement in various legal networks including
coordinating business development and marketing activities via these
relationships.
10. Design and plan quarterly marketing training seminars for attorneys.
11. Oversee firm's electronic marketing efforts including supervision of Web site