Meghna Knit Composite LTD.: Industrail Training Report 2014
Meghna Knit Composite LTD.: Industrail Training Report 2014
Meghna Knit Composite LTD.: Industrail Training Report 2014
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Declaration
We sincerely declare that:
This Industrial Attachment has been done by me under the supervision of Md. Abdullah Al
Mamun, Assistant Professor, and Department of Textile Engineering Daffodil International
University. We also declare that neither this Industrial Attachment nor any part of this
Industrial Attachment has been submitted elsewhere for award of any degree or diploma.
Signature : ________________________
ID No. : 111-23-2409
Signature : ________________________
ID No. : 111-23-2526
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Dedication
At first we want to dedicate this Industrial Training report to almighty Allah for giving us a
better opportunity to prove ourselves. Without his help nothing is possible.
We also declare this report to Md. Abdullah Al Mamun, Assistant Professor of Daffodil
International University who helps us to complete this report.
And our parents who give us chance to study in Textile Engineering and support us all time.
Specially Dedicate this report & Muzaffor Ahmed, Merchandiser (Marketing &
Merchandising) Of Meghna Knit Composite Ltd. And all the people who have helped us in
the Meghna Knit Composite Ltd. To complete this report.
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Acknowledgement
At first my gratefulness goes almighty Allah to give me strength and ability to complete the
industrial and this report.
Now we wish to take this opportunity to thank a lot of people who have assisted and inspired
me in completion of my training period.
We are also expressing our gratitude to Prof. Dr. Mahbubul Haque Head, Department of
Textile Engineering, for his support and continuous guidance throughout our long journey in
Daffodil International and industrial training.
We should like thank the management of Meghna Knit Composite Ltd, or giving us
opportunity to do the industrial training successfully and also their valuable suggestions.
It‗s a great pleasure to express our satisfaction to The Meghna Knit Composite Ltd.
Authority for their sincere and cordial co-operation and we are very much indebted to
Muzaffor Ahmed Merchandiser, for his association in completion of our training
successfully. Our training would never been completed without his convenient helps and
supports.
Finally, we must acknowledge our Parents with due respect for their constant support,
patients and believe on our ability which drives us in the successful completion of this
report.
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Contents
1. Executive Summery ...................................................................................................................... 1
2. Information about Factory ................................................................................................................. 3
2.1 Introduction: ................................................................................................................................ 3
2.2 Positioning: .................................................................................................................................. 3
2.3. General information about factory ............................................................................................. 4
2.4. Layout......................................................................................................................................... 5
2.5. Organogram .............................................................................................................................. 6
2.6. Sister Concerns ........................................................................................................................... 7
2.7. Product mix ................................................................................................................................ 8
2.8. Brief profile (numbers of worker, area, total machineries, etc) ................................................ 8
2.9. Plant Layout ............................................................................................................................. 11
2.10. Major buyers with their Logo ................................................................................................. 12
2.11. Mission and Vision of Meghna .............................................................................................. 13
3. Description of the Attatchment ...................................................................................................... 15
3.1 Sample Section .......................................................................................................................... 15
3.1.1 Layout of Sample Section ................................................................................................... 16
3.1.2. Organogram of Sample Section ......................................................................................... 17
3.1.3. Flow sequence of sample section ...................................................................................... 17
3.1.4 Types of sample produce .................................................................................................... 18
3.2. CAD section ............................................................................................................................. 20
3.2.1 Working sequence 0f CAD section .................................................................................... 20
3.2.2. Pattern making .................................................................................................................. 21
3.3. Cutting section.......................................................................................................................... 21
3.3.1. Cutting Layout ................................................................................................................... 22
3.3.3. Fabric Inspection ............................................................................................................... 24
3.3.4. Fabric Relaxation ............................................................................................................... 24
3.3.5. Fabric relaxation time ........................................................................................................ 25
3.3.6. Fabric Spreading ................................................................................................................ 25
3.3.7. Types of Fabric spreading .................................................................................................. 26
3.3.8. Ideal Lay height for cutting: .............................................................................................. 27
3.3.9. Requirements of fabric spreading: ..................................................................................... 27
3.3.10. Spreading system in factory: ........................................................................................... 27
3.3.11. Marker making ................................................................................................................ 27
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3.3.12. Objects of marker making: .............................................................................................. 27
3.3.13. Types of marker making: ................................................................................................. 28
3.3.14. Factors considered during marker making ...................................................................... 29
3.3.15. The factors which influence the Marker Efficiency ........................................................ 30
3.3.16. Marker collection from CAD section ............................................................................... 30
3.3.17. Marker setting ................................................................................................................. 30
3.3.18. Fabric cutting ................................................................................................................... 31
3.3.19. Methods of Fabric Cutting: ............................................................................................. 31
3.3.20. Different Types of Cutting Machine: .............................................................................. 32
3.3.21. Numbering ....................................................................................................................... 34
3.3.22. Bundling ........................................................................................................................... 34
3.3.23. Machine & Equipment used in cutting section ............................................................... 35
3.3.24. Limitation of Cutting Section: ......................................................................................... 36
3.4. Sewing Section.......................................................................................................................... 36
3.4.1. Lay out of sewing floor: .................................................................................................... 37
3.4.2. Element of sewing ............................................................................................................. 38
3.4.3. Flow chart of sewing section ............................................................................................. 38
3.4.4. Sewing thread: ................................................................................................................... 39
3.4.5. Sewing needle:................................................................................................................... 39
3.4.6 Sewing machine.................................................................................................................. 40
3.4.7. Thread used in different Machine ...................................................................................... 40
3.4.8. Different Sewing Machine ................................................................................................ 41
3.4.9. Different types of sewing: ................................................................................................. 43
3.4.10. Layout of a T-shirt: .......................................................................................................... 45
3.4.11 Layout of a polo shirt: ...................................................................................................... 45
3.4.12. Sewing Quality checking points ...................................................................................... 47
3.4.13. Sewing Line quality Check List: ..................................................................................... 47
3.4.14. Sewing Table Quality Check List:................................................................................... 47
3.4.15 Sewing Defects: ................................................................................................................ 48
3.4.16. Sewing problems in ―factory‖: ........................................................................................ 48
3.5. Finishing Section..................................................................................................................... 49
3.5.1. Finishing Lay Out: ............................................................................................................. 49
3.5.2. Garments Finishing ........................................................................................................... 50
3.5.3. Process Flow Chart of Garment Finishing: ....................................................................... 50
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3.5.4. Object of Finishing: ......................................................................................................... 50
3.5.5. Work flow in the Finishing Room: .................................................................................... 51
3.5.6. Machine Description of finishing section .......................................................................... 51
3.5.7. Different types of Machine used ....................................................................................... 51
3.5.8. Materials used in garment finishing: ................................................................................. 53
3.5.9. Spot removing ................................................................................................................... 54
3.5.10. Ironing: ............................................................................................................................ 55
3.5.11. Garment Inspection: ........................................................................................................ 55
3.5.12. Trims: .............................................................................................................................. 56
3.6. Quality Section ......................................................................................................................... 57
3.6.1. Quality objectives .............................................................................................................. 57
3.6.2. Machines required for quality............................................................................................ 57
3.6.3. Inspection Area .................................................................................................................. 58
3.6.4. Faults Found in QC Department ........................................................................................ 58
3.6.5. Quality Assurance System ................................................................................................. 58
3.6.6 Online Quality control: ....................................................................................................... 58
3.6.7. Off line quality control: ..................................................................................................... 59
3.7. Merchandising Section ............................................................................................................. 59
3.7.1. Merchandising: .................................................................................................................. 59
3.7.2. Merchandising department: ............................................................................................... 60
3.7.3. Flow Chart of Garments Merchandizing: .......................................................................... 61
3.7.4. Merchandising Calculation:............................................................................................... 61
3.7.5. Price of Different Knitted Charge: .................................................................................... 63
3.8. Marketing Section .................................................................................................................... 64
3.8.1. Marketing Activities: ......................................................................................................... 64
3.8.2. Manpower:......................................................................................................................... 64
3.8.3. Marketing strategy: ............................................................................................................ 64
3.8.4. Product label: ..................................................................................................................... 65
3.8.5. Package size & label:......................................................................................................... 65
3.8.6. Duties & Responsibilities of Marketing Officer: .............................................................. 65
3.9. Effluent Treatment Plant ......................................................................................................... 65
3.9.1. Description of the ETP process:........................................................................................ 65
3.9.2 FUNCTIONS OF DIFFERENT INGREDIENTS USED IN E.T.P PLANT:..................................... 66
3.9.3. Capacity of ETP: ................................................................................................................ 67
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3.10. COMPLIANCE.......................................................................................................................... 67
3.10.1 COMPLIANCE: ............................................................................................................... 67
3.10.2. HEALTH: ........................................................................................................................ 68
3.10.3 TOILET: ........................................................................................................................... 68
3.10.4 FIRE: ................................................................................................................................ 68
3.10.5 SAFETY GUARD: ........................................................................................................... 69
3.10.6 OTHERS: ......................................................................................................................... 69
3.11. Print & Embroidery Section ................................................................................................... 69
4. Impact of internship ........................................................................................................................ 72
4.1. Sample development............................................................................................................... 72
4.2. CAD Section: ........................................................................................................................ 72
4.3. Cutting ................................................................................................................................. 72
4.4. Sewing ...................................................................................................................................... 72
4.5. Finishing ................................................................................................................................... 72
4.6. Quality ...................................................................................................................................... 72
4.7. Merchandising Section ............................................................................................................ 73
4.8. Marketing Section.................................................................................................................... 73
4.9. ETP ............................................................................................................................................ 73
4.10. Compliance ............................................................................................................................ 73
4.11. Print & Embroidery Section ................................................................................................... 73
5. Conclusion ....................................................................................................................................... 75
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1. Executive Summery
This report is titled ―Report on Industrial Attachment at Meghna Knit Composite Ltd‖. By
achieving practical knowledge from the industrial attachment it is possible to apply the
theoretical knowledge in the technical field. For any technical education, practical
experience is almost equally necessary in association with the theoretical knowledge. The
industrial attachment is the most effective process of achieving the practical experiences. It
provides us sufficient practical knowledge about Production Management, Productivity,
Evaluation, Work Study, Efficiency, Industrial Management, Production Planning &
Controlling, Utilities and Maintenance of Machineries and their Operation Techniques etc.
Meghna Knit Composite Ltd is a modern textile industry based on knit garments production.
Our approach was to know and work with all the parameters of each section and practice
with technical experts. As our academic advance study was in Apparel Manufacturing
Technology our emphasis was in understanding and learning of Garments. Industrial
attachment is an essential part of four years B.Sc. in Textile Engineering course of Daffodil
International University. We had the opportunity to perform the industrial attachment with
Meghna Knit Composite Ltd. During 2 Months long attachment, we studied the Man,
Machine, Material and Planning, Grey Fabric Inspection, Finished Fabric Inspection,
According to our studies in the whole chain of the factory we have prepared the following
report and would like to present as our internship report. B.Sc. in Textile Engineering is the
combination of theoretical knowledge and the practical experiences. The main objective of
this training is to comprehend our theoretical knowledge along with the practical knowledge.
It also enabled us to orient ourselves with the practical environment which is our place of
future work.
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2. Information about Factory
2.1 Introduction:
Meghna knit composite Ltd.instigated its journey in the last quarter of 2006,with a vision
of becoming the most recognized knitwear manufacturer of the country as well as to
make the widely known reputation of bangladesh as a global clothing leader to a new
height by offering the best blend of quality and efficiency. Meghna knit composite Ltd
(MKCL) is equiped with the most advanced textile technology from the
US,Europe,Hong Kong and Japan.We have not only ensured the best ever technology but
also a band of highly skilled,professionally dedicated industrial manpower and
mangement team toexelin tune with our technology.this built-in composition is ti ensure
quality in producing levit textiles for onward manufacturing of readya-to-wear knit
garments and knit fabrics-all under one roof.
2.2 Positioning:
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2.3. General information about factory
Company Name : Meghna knit Composite Ltd.
Manpower : 1800
Machinery setup : Complete sewing & stitching setup for 20-lines.
Complete setup for producing 6.00 MT knit fabrics (finish) per
day. Computerized Embroidery setup for own garments
production. Complete Screen Printing setup with latest curing
machine for own production.
Export Market : Italy, Germany, France, UK, Sweden, Japan.
Product wise capacity : High Fancy/Polo shirt = 2.40 Million Pcs.
(Annually) Basic knit/T-shirt & others = 6.00 Million
Annual Export Turnover : USD 24.00 million
(in US$)
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2.4. Layout
Sample Section
Cutting section
Sewing Section
Printing Section
Finishing Section
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2.5. Organogram
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2.6. Sister Concerns
Joint venture project with Mainetti of Italy producing hangers for export oriented
garment industry of Bangladesh.
CYCLE LIFE
EXECUTIVE MACHINES
EXECUTIVE TECHNOLOGIES
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2.7. Product mix
Men/Ladies/Girls/Boys/Infants Knitted Fancy T-shirt,
Polo Shirt
Tank Top
Shorts
Skirts
Tank Dress with quality prints
beading plating
hand works
Embroidery etc.
Accounts Section 03
Batch Section 51
Cutting Quality 67
CAD Section 04
Driver 15
Dyeing 108
Embroidery 54
Finishing(Garments) 393
Garments Section 74
House Keeping 71
Knitting 103
Lab 19
Maintenance 40
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Management 02
Planning 05
Quality(Textile) 46
R&D 03
RQS 08
Sample 41
Security 60
Work Study 15
Total 3434
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Machinary list:
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2.9. Plant Layout
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2.10. Major buyers with their Logo
C&A Germany
Next UK
P&C Germany
Tesco UK
Cubus UK
Perry Ellis UK
Gymboree USA
Mayoral Spain
Dressmann Norway
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2.11. Mission and Vision of Meghna
From 2006 till now, Meghna Group always expands itself. Meghna group offers a
proficient production facility, even for smaller volume orders which attached an overall
efficiency to serve both volume customers as well as upper class buyers. Meghna‘s
products export in different countries such as Japan, Italy, France, Sweden, Norway,
Finland, UK & Canada. Our production management is ISO 9001:2000 certified and our
fabrics quality is Oeko-Tex certified. Day-by day our production has been increased
along with our experience. We always give priority to hard work perseverance, which
bring us today in this admirable and viable position.
Vision:
The main vision of Meghna Group is to provide the best service with quality product. With a
slogan of ‗From yarn to the ultimate garments‘ Falcon is developing step by step through its
honesty, integrity and hard work. Till-to-date, the top management intensively supervises &
keeps in touch with the production, merchandising & sourcing, which often comes handy for
our buyers. The communication with buyers is strongly maintained by us that develop as
bond of reliance.
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3. Description of the Attatchment
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3.1.1 Layout of Sample Section
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3.1.2. Organogram of Sample Section
SAMPLE MANAGER
Sr. EXECUTIVE
SAMPLE SUPERVISER
SAMPLE MAN
IRON MAN
QC
CUTTING MAN
HELPER
Approval of sample/comments
about the sample (if necessary)
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3.1.4 Types of sample produce
1. Design development:
This is the first sample which is made for any style by most of the buyer.
Design development is either done by buyer or factory
The main purpose is to take the decision to proceed with the same line or not.
2. Proto sample:
Proto sample is developed at very initial stage and normally order is confirmed to the factory based on proto
sample only.
Normally, buyer send proto sample request to 2-3 factories.
The factory which submits the good quality and optimum price will get confirmation from buyer.
Proto sample are normally prepared in similar fabric if actual fabric is not available.
Substitute Trims can be used on proto.
As proto sample is given first time to the factory to buyer, so to develop the proto sample buyer need to
provide necessary information along with the proto request. These are: Specification Sheet (Tech Pack), Bill
of Material, Development sample (optional), Paper patterns (optional), Sample of novelty trims, Sample of
fabric yardage (it may be send by buyer or asked to develop), Details of Print or Embroidery, if any.
Generally proto request is responded within the 7-10 days by merchandiser.
Factory need to submit at least 4 proto samples (quantity may change buyer to buyer)
If buyer does not approve the proto sample, factory needs to submit the 2nd proto sample to get approval.
Once proto get approved buyer asks to start working on fit sample.
3. Fit sample
Fit sample is made and send to conform the fit of the garment on live models or on dummy and for approval
of construction details.
At this stage of sampling, buyer makes sure that factory understands thoroughly the construction and quality details
and standards The sample sent mostly in medium and large sizes mentioned by the buyer.
The fabric used for fit sample production is the actual fabric which is going to be used for bulk production or
sample yardage fabric is used.
In order to promote the new style in the market normally buyer asks for AD sample for photo shoot.
Buyer uses this photo for marketing purpose either on catalogue or various media like, print, TV or websites
to see the response of the consumer.
This sample mainly sends in medium to large or sizes specified by buyer.
The main purpose of salesman sample is to collect the order from the retailers.
In Sales man sample actual accessory, actual fabric is used or sample yardage need to be used.
This sample also very important stage of sampling as the sales of buyer depends upon this sample
presentation, look, feel of fabric is important.
The quality of the sample should be up to the mark of the buyer; hence merchandiser should aware and
make sure that product development team is well aware about the sample quality parameters.
The cost of sample production is given by buyer or sometimes buyer may give 150% of FOB.
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6. Size set sample:
The main purpose of size set sample is to check the factory's capability to make the sample in all sizes.
The size set sample should be made in the actual fabric and trims.
The samples can be made in the sampling room or actual production floor, as required by the buyer.
Bulk cutting of fabric for production should start only after size-set sample get approved.
Normally, 1-2 samples (or quantity specified by buyer) of each size need to send to buyer.
If sizes are more in number then buyer may ask to skip some sizes, called jump size set sample.
The main purpose of GPT is to perform the physical and chemical testing on garment to ensure the
performance of the garment.
The tests done on garments are: Shrinkage, Color Fastness, Seam performance etc.
Garments for GPT sample can be done along with Size Set sample.
Normally, GPT Sample is sent to 3rd party inspection and results are sent to both factory as well as buyer.
If same style is having 3-4 different colours then only one color sample is tested completely and other
colours samples are tested only with colour way test i.e. only colour fastness tests are conducted.
9. Wash sample:
Wash sample is made and submitted to buyer for assessment of feel and handle of fabric after washing of
Denim or shirt washing program, hence either at size set stage or PP stage washing sample is sent to buyer
for approval and carry forward of washing program.
If sample is not approved or approved with comments, factory needs to submit 2nd sample to get approval.
After feel assessment buyer may suggest the changes in washing program.
The top of production is sent to the buyer as soon initial pieces are come out of sewing line with suggestion
of QA department.
In TOP sample Buyer tries to evaluate the actual manufacturing of the style.
Buyer check whether bulk production is as per submitted sample or not.
TOP sample also checked by the buyer for the packaging.
Few buyers may ask for the shipment samples which factory needs to pull form the actual shipment and
sent to buyer.
The main purpose of this sample is to assure buyer about the actual shipment dispatch.
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3.2. CAD section
In CAD section at first the pattern put on the digitizer to take clear image of the
pattern part inside the CPU.
After making all required size patterns using the software pattern parts are aligned in
the mini marker. Then it is sent to CPU of CAM section for approval and checking
the length & width of marker and pattern parts alignment.
After getting approval from CAM section then
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3.2.2. Pattern making
After receiving an order in most cases buyer gives them a complete pattern and they
make sample according to given pattern. But in some cases they prepare the pattern
by own when buyer don not give any pattern.
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3.3.1. Cutting Layout
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3.3.2. Process Sequence of a cutting section
Fabric receive from Dyeing/Store
Fabric Relaxation
Marker setting
Fabric cutting
Numbering
Bundeling
Quality Checking
Recut
Cutting Store
Forward to sewing
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3.3.3. Fabric Inspection
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Fig: Fabric relaxation
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3.3.7. Types of Fabric spreading
1) Automatic Spreading
2) Manual Spreading
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3.3.8. Ideal Lay height for cutting:
Fabric weight Woven Knits
Heavy weight 4-5˝ 5-4˝
Medium weight 3-4˝ 3-3.5˝
Light weight 2.5-3˝ 2-2.25˝
Marker is a thin paper which contains all the pattern pieces of a garment. It is made
just before cutting and its purpose is to minimize the wastages. The width of a
marker is equal to the width of the fabric and it should not be greater than the width
of the fabric i.e. the width of the marker is kept less than or equal to the width of the
Fabric.
The pattern pieces should be placed very carefully in such a way that it will
obviously minimize wastages.
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- To facilitate large scale production.
The man performs it by himself using his hands. It is a conventional system and
requires more time.
Manually two types of marker are made –
1. Full size marker:
Full size marker is made for production purpose.
2. Miniature type marker:
Miniature type marker is sometime made and its purposes are to plan or schedule and
learn or study i.e. for planning and learning purposes.
b. Computerized Method:
Now the commonly used system of marker making is computerized method. In this
system, a man performs it by himself using computer software (CAD and CAM) and
it requires considerably less time than manual system. Two types of marker are
generally made using computerized system –
1. Full size marker:
Using ‗Digitalizing Board‘ the pattern pieces are input into the computer. Computer
uses software and a marker paper is printed out that will be used in the production.
2. Miniature type marker:
Only for learning, practicing, and planning purposes this type of marker is printed
from the computer.
To get the optimum efficiency of markers as well as to minimize fabric wastage they
done marker by computerized marker making system (VEITH). It has the digitizer by
which the patterns are make grade and with the help of the software as well get
output as marker with the plotter. The VEITH system is discussed in below.
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FIG: PLOTTER MACHINE
5. Production planning:
Different types and sizes if garments manufacturing may un at a time in an industry.
So during marker making it should be considered.
6. Size of marker:
During marker making we have to think about the table size, length of the fabric, etc.
7. Marker Efficiency:
The ratio between the total areas of the pattern pieces to the total area of the maker
paper is technically termed as Marker Efficiency. It is expressed in percentage. If it is
denoted by the symbol ή then –
Marker Efficiency (ή) = (Total areas of the pattern pieces/Total area of the Marker paper) *
100
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3.3.15. The factors which influence the Marker Efficiency
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Fig: Marker setting
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Computerized Method
Straight knife cutting (GERBER Cutter)
Water jet cutting
Laser beam cutting, and
Plasma torch cutting etc.
Mainly two methods of manual cutting are used in factory
Scissor
Straight knife
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Machine parts of Straight knife Cutting machine
- Base plate
- Terminal block
- Plug
- Clamp washer
- Pressure foot
- Blade
- Sharpener pulley
- Pulley spring
- On/off switch
Features of Straight knife cutting machine
Possible to cut pattern pieces directly from the fabric lays
Could be used to cut for higher depth of fabric
High cutting speed
Sharp and heavy corners can be cut
Blade could be sharpened by attaching grinding facilities
Blade height 10 to 33 cm
Blade stroke 2.5 to 4.5 cm
Special attachment such as sew edge or serrated edge can be provided for heavy fabric such
as canvas or denim.
3.3.21. Numbering
In this stage sticker is attached with all part of cutting part for shade matching. The sticker number
maintains cutting number, size number, serial number.
Numbering section
Striker machine : 13pcs
Fig: Numbering
3.3.22. Bundling
Prepare bundling card according to fabric lay report this card maintain
Date
Style No
Size Number
Card Serial
Quantity
Color
Lot Number
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Feature of a bundle card
04 Spreading Machine
05 Drilling Machine
06 Inkjet Printer
07 Cutting Table
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08 Cutting Gloves
1. Input problem
4. Check, variegated rib fabric lay quantity may be excess. As a result reject percentage may be
increase.
5. Fabric spreading
The process of joining of fabrics by the use of needle and sewing thread or by other techniques is
called sewing.
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Fig: Sewing Section
Needle and
Sewing machine
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Input from cutting
Sucker machine
Sewing output
Cotton
Flaming thread
Elastic thread
Lorex thread
Origin: Japan.
Model: DDL-9000 SS
Rpm: 400-4000
Origin: Japan.
Rpm: 400-8000.
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Name of m/c: Flat lock machine.
Origin: Japan.
Rpm: 2600.
Origin: Japan.
Model: LBH-1790SS
Rpm: 400-8000
Origin: Japan.
Model: LK-1903A-SS.
Needle: 01.
Rpm: 400-2700.
Origin: Japan.
Rpm: 260
Face View
Stitch Name: Lock Stitch (it is the most common stitch
Face View
Back View
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Stitch Name: Chain stitch
Face View
Back View
Back View
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3.4.10. Layout of a T-shirt:
Shoulder join
Rib tuck
Neck join
Neck piping
Sleeve join
Sleeve hem
Sleeve tuck
Side seam
Finish tuck
Body hem
Placket join
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Placket top seam
Shoulder
Collar tuck
Collar join
Box
Sleeve hem
Sleeve join
Arm-hole seam
Side seam
Body gem
Hole
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Button attach
Skip/Drop/Broken stitch
Raw edge
Size mistake
Uneven hem
Uneven cuff
Uneven neck
Uneven shoulder
Uneven placket
Uneven pocket
Twisting
Without care label
Open tack
Sleeve up-down
Stripe up- down
Open seam
Four point up-down
Shading etc
Garments wash
Loop cutting
Thread trimming
Alter checking
Stitch others
Button attach
Final ironing
Hanger attach
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Poly packing
Cartooning
Shipment
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To give desirable qualities to the fabric like-
1. Softness
2. Lustre
3. Drape
4. Dimensional stability
5. Crease recovery
6. Soil repellence
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Fig: Metal Detector M/C (Brand name: HASHIMA)
3. Blot gently — never rub; and don't ever blot with hot water.
Stain Removal:
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3.5.10. Ironing:
Ironing is the use of a heated tool (an iron) to remove wrinkles from fabric. The heating is
commonly done to a temperature of 180–220 °Celsius, depending on the fabric. Ironing works by
loosening the bonds between the long-chain polymer molecules in the fibers of the material. While
the molecules are hot, the fibers are straightened by the weight of the iron, and they hold their new
shape as they cool. Some fabrics, such as cotton, require the addition of water to loosen the
intermolecular bonds.
Do not iron
Confirmation of Quantity
↓
Confirmation of accessories
↓
Size specification inspection
↓
in side Inspection
↓
Out side Inspection
↓
Final Inspection
↓
Packing
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3.5.12. Trims:
Trims cover all the items used in the garment except the basic fabric. There are hundreds of items
used to manufacture the garments. Proper selection of trims and its quality are very important for
styling; otherwise the garment may be rejected or returned by the customers.
Following is a part of list that covers some names of the items:
Zipper/Fastener:
Teeth : Nylon, Vislon, Metal
Color : Tape color, Teeth color
Size : #3, #5, #8, etc.
Length : As per requirement 18 cm, 72 cm
End : Close End (C/E), Open End (O/E)
Slider : One way, Reversible.
Sewing Thread:
Shade, color fastness, etc.
Tensile strength, Elasticity, Shrinkage, Moisture Regain, Abrasion Resistance, etc.
30s, 60s, 20/2, 40/9 Ne, etc.
Labels:
Main label
Size label
Care label
Content
Price
Patch, etc.
Button:
Horn and
Metal buttons are very common in use.
ELASTIC:
Cotton
Polyester, etc.
Eyelet:
Antique
Matching, etc.
Velcro:
Hook and Pile
String/Cord:
Cotton
Polyester, etc.
Tags:
Price tags
Hang tags, etc.
Polybag:
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Strength, Chemical mixture, Thickness (micron/mm; 1mm = 1000 micron).
Blister Bag:
0.05 mm in thickness;
Loaded capacity is higher than poly bag.
Carton:
3 ply
5 ply
7 ply Size (L, W, and H).
Sticker:
Hook and Pile.
Plastic Clip
Tag pin
Scotch Tape
Hanger
Gum Tape
Etc.
This section Control the quality of a product. It is committed to provide adequate resources in terms
of good raw materials and trained personnel & continually improve / upgrade its processes and
systems.
Dyeing faults:
Uneven shade
Running shade
In fastness property
Finishing faults:
GSM variation
Spirality
Shrinkage control: Length wise
Again on line Quality assurance system can be divided into the following steps:
Process control: The method chosen for process must be provided with the necessary accurate
parameters. In the every stage pH should be maintained sincerely.
1. Shade condition.
2. Wash fastness.
3. Condition of softening.
4. Condition of enzyme wash.
Before delivery the finished fabric to the customer it should be passing against the requirements.
The following tests are done-
1. GSM check.
2. Shrinkage test.
3. Shade check.
4. Rubbing test.
5. Wash fastness test.
6. Color fastness to perspiration.
3.7.1. Merchandising:
This chapter deals Merchandizing Department. It gives some information of merchandizing, then it
discusses about the requirement of different materials of making garments. It ends with the recent
price of different knitted fabric.
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3.7.2. Merchandising department:
Merchandising department is the star of the department among all the working departments in the
Export concern, because Merchandising is the only department having maximum control over the
departments and total responsible for Profit and loss of the company.
After LPG (Liberalization, Privatization & Globalization) the business gets more important and
now merchandising is on its hot seats. So, it is necessary to understand the day to day happenings
of the star department.
Merchandise- means goods bought and sold; and trading of goods.
Merchandising- is an activity of selling and promoting the goods.
Merchandiser in garment industries:
In the field of marketing and services, Merchandiser is at a position of utmost importance, He is the
person who co-ordinates with various departments for a uniform business.
Objects of Merchandising
Merchandising denotes all the planned activities to execute and dispatch the merchandise on time,
taking into consideration of the 4 Rs to replenish the customer.
Right Quantity: To dispatch right quantity of product what buyer ordered?
Right Quality: It should be with right quality as accepted both parties.
Right Cost: Everybody wants more from what they are paid.
Right Time: No one wants to wait idle even in a Restaurant. Keeping delivery schedule
is mandatory.
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3.7.3. Flow Chart of Garments Merchandizing:
Recap Preparation
Production Start
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Dia Measurement:
Chest or Bottom + Allowance / 2.54
= Dia / Result
NB:
1 inch = 2.54 cm
When I dia measurement then chest or bottom with (4-6 cm) allowance added.
Self or Rib Fabric Neck Dia Measurement:
This chapter deals with the marketing activities, marketing plans, and responsibilities of marketing
personnel of Meghna Knit Composite Ltd.
3.8.2. Manpower:
Marketing plays a vital role in the field of displaying/ showing the good criteria of the products to
the buyer & to communication with the buyer. There are about 7 peoples in the marketing section
of the industry.
Importing countries:
Following countries mainly imports products from CCL through many internationally well
recognized buyers.
Europe countries like UK, France, Germany, etc.
USA
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3.8.4. Product label:
There are following labels used by this mill:
1) Care Label: It contains washing in hot or cold water, chemical cleaning, drying conditions etc.
2) Size Label: It contains size of garments.
3) Composition Label: It contains the fabric composition of different fiber type.
4) Decorative Label: Decoration is as buyer or consumer choice wise.
5) Flag label: it indicates importing country.
6) Barcode label: it indicates hidden identity of product.
7) Price label: it indicates price of product.
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Equalization tank consist raw effluent. At the beginning, raw effluent is led to the mixing
tank/reaction tank by pumping.
1. In mixing tank, Lime and Ferus sulphate are added with effluent; blower is used to mix
properly.
2. At the end of the reaction the solution is led to the flocculation tank where poly Electrolyte/
poly Acrylamide is added for further reaction; blower is used here too.
3. From the flocculation tank solution is drained to Tube settler-1. Here, sludge is divided and
placed in the sludge sump.
4. After the operation of Tube settler-1, the solution is brought to PH correction chamber where
HCL is mixed to control the required PH.
5. After the completion of PH correction the solution is led to the biological reaction tank-1 &
2. In this tank BACTERIA MEDIA is used to absorb the harmful insects that exist in
effluent. A bit amount of DAP (Di-ammonium phosphate) + Urea (2:1) is also used here as
food of bacteria.
When the plant is stopped the mixture (DAP + Urea) is to use more.
DO (Dissolved Oxygen) is to cheek and control in both the reaction tank. The tested
temperature is approx. 400C here.
1. From the biological reaction tank water is again drained to Tube settler-2. Like Tube settler-
1, sludge is divided here too and placed in the sludge sump.
2. The main action of filter feed sump is to accelerate the cleaner effluent and make it flow the
pressure sand filter and Activated carbon filter for final filtration. After the filtration the
treated water is drained out in the air.
Before draining out the treated water, the BOD (Biological Oxygen Demand) and COD
(Chemical Oxygen Demand) are to cheek and keep it in required range. The tested
temperature of the outlet water is approx.380C.
1. The less contaminated liquid that is obtained from different operations except dyeing is
stored in the less contaminated reservoir. It needs filtering too before drain out.
2. In another operation, liquid sludge is collected from sludge sump and makes it inject into
Sludge thickening tank.
3. In sludge thickening tank, divination of raw sludge is occurred by centrifuge hydro extractor
and the filtrated liquid is led to the equalization tank further processing.
4. The centrifuge hydro extractor is used to convert the sludge into cake which is later brought
to the air by the help of hand-drum. After hydro extracting, the rest substance is drained to
the equalization tank for further processing.
5. The tested temperature of the equalization tank is approx. 420C. Here, blowers perform to
maintain proper circulation of the effluent.
Lime : Lime is used to change the color of effluent and to increase the transparency of water.
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Ferus Sulphate: Ferus Sulphate is used for the agglomeration of the foreign matters present in the
effluent.
Poly Electrolyte: Poly Electrolyte helps to make the agglomerated materials be gummy for easy
deposition below the surface of water.
Hydrochloric Acid: Hydrochloric Acid is used to sustain the required PH of the treated water.
Color Colorless
PH value 6–9
30 M3/hr.
3.10. COMPLIANCE
3.10.1 COMPLIANCE:
Compliance means conformity of certain standard. PPC maintain a moderate working condition for
their employees. Though it is well established project, there is some lacking of proper compliance
issues. Here is list of compliance in which some points are maintained fully and some are partially
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Compensation for holiday
Sexual harassment policy
Child labour abolition policy
Anti-discrimination policy
Zero abusement policy
Working hour policy
Hiring /recruitment policy
Environment policy
Security policy
Buyers code of conduct
Health and safety committee
Canteen
Equal remuneration
National festival holiday
Overtime register
Labour welfare
Weekly holiday fund
Time care
Accident register
Workman register
3.10.2. HEALTH:
Drinking water at least 4.5 L/day/employee
Cup availability
Drinking water supply
Water cooler ,heater available in canteen
Drinking water signs in Bangla and English locate min. 20 feet away from work
place
Drinking water vassal clean at once in a week
Water reserve at least once a week
Water center in charge person with cleanliness
Suggestion box register
3.10.3 TOILET:
Separate toilet for women and men
A seat with proper privacy and lock facility
Effective water sewage system
Soap toilet
Water tap
Dust bins
Toilet white washed one in every four month
Daily cleaning log sheet
No-smoking signs
Ladies /gents toilet signs both in bangle and English
Deposal of wastes and effluent
3.10.4 FIRE:
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Sufficient fire extinguisher and active
Access area without hindrance
Fire signs in both languages
Fire certified personal photo
Emergency exit
3.10.6 OTHERS:
Room temperature
Lighting facilities
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Fig: Printing M/C
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4. Impact of internship
4.3. Cutting
We know about cutting fabric
We know about method of cutting
Defect of cutting section
How to remove fabric wastage
4.4. Sewing
We know about many type of sewing machine
We know about function of sewing machine
I know about sewing fault and their remedies
We know about total production of this section
4.5. Finishing
We know about total production of this garments
To know about price tag, hang tag
To know about how to quality assurance
4.6. Quality
We know about Quality.
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How quality is inspect.
Faults found in Quality Section.
How Quality Assurance works in garments.
We know about online quality & offline quality
4.9. ETP
We know why ETP use in industry.
We know procedure of ETP.
How we benefit from ETP.
Functions of ETP.
4.10. Compliance
To know about their compliance system
We know about medical facilities
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5. Conclusion
Industrial attachment program send us to the expected destiny of practical life. Through The
completion of Two Month industrial attachment at MEGHNA KNIT COMOSITE Ltd, we
have got the impression that the factory is one of the most knit dyeing projects in Bangladesh.
Though it was established in 2006, it has earned very good reputation for its best performance
over any other knit dyeing project. During our industrial attachment program we had tried to
our best to do our duty. Our supervising officer also satisfied to us & offer co-operation in
every steps. It is completely a new experience in our life, which will be very effective in our
service life. During our training period we realized that practical experience is valuable for
service life.
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