Meghna Knit Composite LTD.: Industrail Training Report 2014

INDUSTRAIL TRAINING REPORT 2014
Meghna Knit Composite Ltd.

Gilarchala, Sreepur, Gazipur, Bangladesh
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©Daffodil International University
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 : ________________________
Name : Md. Shamsul Haque
ID No. : 111-23-2409
Signature : ________________________
Name : Ripon Kumer Ghos
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.
Md. Abdullah Al Mamun, Assistant Professor of Daffodil International University our

supervisor, to whom we are extremely indebted for his tremendous support and guidance
throughout our training period. Being working him we have not only earned valuable
knowledge but also inspired by his innovativeness which helped enrich my experience to
greater extent. His idea and way of working was truly remarkable.
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:
Foucusing solely in knitwear apparel lines,MKCL has adopted a structure by

reengineering its value chain to deliver high quality products in shorter lead time
with flexibility in order size.Moreover,having endless efforts to ensume internationally
accepted employment practice,our cleints recognize us as a partner to protect their
value system and images among final consumer.
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2.3. General information about factory
Company Name : Meghna knit Composite Ltd.
Legal Status : Private Limited Company.
BKMEA Membership Number : 834

Membership Type : Ordinary Member
Year of Establishment : 2006
Head office adress : House.49,Sharwardy Avenue Block-k, Gulsan-Baridara

Dhaka-1212
Phone : +880-2-9854591-6,
Fax : +880-2-9854597
E-mail : [email protected]
Web : www.meghnagroup-bd.com
Factory Address : Gilarchala Sreepur Gazipur Bangladesh
Name of the Banker :1) Prime Bank Limited. Principal Branch. 82,
Motijheel Commercial Area, Dhaka-1000, Bangladesh.
2) United Commercial Bank Ltd. Principal Branch. 58,
Motijheel C/A, Dhaka-1000, Bangladesh.
Nature of Business : Completely 100% export oriented knitwear manufacturing &

exporting Industry. Also have the permission to import
materials related with export.
Contact Person : M Moklasur Rahman pinto - Managing Director.
Mohammad Monjur Hasan– Sr.General Manager
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
Meghna group‘s concerns……….
 MEGHNA MAINETTI LTD.
Joint venture project with Mainetti of Italy producing hangers for export oriented
garment industry of Bangladesh.
 UNIGLORY PACKING LTD.
Automated corrugated carton manufacturing unit.
 BETA PACKAGING LTD.
Automated corrugated carton manufacturing unit.
 M&U PACKAGING LTD.
Poly bag & carton manufacturing unit
 CYCLE LIFE
Sole distributor of Raleigh bikes from UK and Phoenix Bickes of China in

Bangladesh.
 EXECUTIVE MACHINES
Sole agent of Apple computers
 EXECUTIVE TECHNOLOGIES
Sole agent of Acer computers from Taiwan
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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.
2.8. Brief profile (numbers of worker, area, total machineries, etc)

Total Manpower Summery
Section No of Manpower
Accounts Section 03
Batch Section 51
Cutting Section 200
Cutting Quality 67
CAD Section 04
Design & PD Section 02
Driver 15
Dyeing 108
Dyeing Finishing 188
Embroidery 54
Finishing(Garments) 393
Finishing Quality 113
Garments Section 74
House Keeping 71
HR, Admin & Compliance 26
Knitting 103
Lab 19
Maintenance 40
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Management 02
Marketing & Merchandising 23
Planning 05
Planning & Reporting 02
Quality(Textile) 46
R&D 03
RQS 08
Sample 41
Security 60
Sewing Section 1401
Sewing Quality 192
Store Section 107
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
Buyer Name Major Markets Logo

H&M Sweeden
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.
 Ultimate satisfaction through providing on-time delivery with correct Quality

Products & Services.
 Excellent working environment in compliance with national & international

rules.
 Building a strong relationship.
 Reaching the highest level.
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
3.1 Sample Section
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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
PATTERN MASTER (CAD)
SAMPLE SUPERVISER
SAMPLE MAN
IRON MAN
QC
CUTTING MAN
HELPER
3.1.3. Flow sequence of sample section
Receive developed sheet from

buyer
Develop the sample
Send the sample to buyer for

approval
Approval of sample/comments
about the sample (if necessary)
Send pre-production sample to

buyer
Start bulk production
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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.
4. Ad or photo shoot sample:
 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.
5. Sales man / Marketing /Showroom sample:
 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.
7. GPT sample (Garment Performance Test):
 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.
8. Pre- production sample: (PP sample)
 PP sample is considered to be a contract between the buyer and the factory.

 It has to be made in original fabric and trims
 Washing, embroidery and printing should match to actuals.
 PP Sample is the standard for production and bulk production garments should be identical to PP sample.
 The factory can start the production of bulk garment only after the approval of preproduction sample.
 PP sample sends in only one size 1-2 samples or specified by buyer.
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.
10. TOP sample (Top of Production):
 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.
11. Shipment sample:
 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
Fig: CAD Section

Printer is used to print out the whole real marker then this marker as well as mini
marker is provided to the CAM section for cutting the fabric.
3.2.1 Working sequence 0f CAD section
Receiving of pattern parts
Taking the image of pattern in CPU by Digitizer
Modernizing of all pattern parts by the software
Aligning all size pattern parts in the marker by the software
Completing the marker
Taking approval from CAM section
Bringing out the marker through plotter
Fig: Computerized Marker Making
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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.
3.3. Cutting section

The definition of cutting is very complex. In garments industries fabric is cut from lay
and spreading with accuracy and properly which is termed as fabric cutting. Marker
outline is used to cut the fabric. Fabric cutting is very important as if something is cut in
wrong way, cannot be rectified.
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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 Inspection (Shade & GSM)
Fabric Inspection (4-point System)
Fabric Relaxation
Receive Fabric to cutting table
Fabric Spreading (Manually or automatically)
Marker collect from CAD
Marker setting
Fabric cutting
Numbering
Bundeling
Quality Checking
Recut
Cutting Store
Forward to sewing
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3.3.3. Fabric Inspection
Fig: 4 – point system inspection
Fig: GSM inspection
3.3.4. Fabric Relaxation
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Fig: Fabric relaxation
3.3.5. Fabric relaxation time

Type of Fabric Relaxation time
Cotton Fabric 24 hours
Lycra Fabric 36 hours
Pique/ Lacoste Fabric 36 hours
Polyester Fabric 36 hours
Spandex Fabric 36 hours
Cotton+ Polyester Fabric 24 hours
3.3.6. Fabric Spreading

Spreading means the smooth laying out of the fabric in superimposed layers of
specific length. The cutting marker paper is laid in the top of the fabric layer. During
spreading number of the plies should be not more than three hundreds but it depends
on the thickness of the fabric and the height of the cutting knife.
For example: if the thickness of the fabric is higher than the number of plies
mentioned above would not valid and in case of straight knife cutting instrument the
maximum lay height should be 70% of the blade height
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3.3.7. Types of Fabric spreading
1) Automatic Spreading
2) Manual Spreading
Fig: Automatic Spreading
Fig: 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˝
3.3.9. Requirements of fabric spreading:

Spreading must achieve a number of specific objectives:
1. Alignment of fabric plies
2. Correct ply tension
3. Elimination of fabric faults
4. Correct ply direction and adequate lay stability
5. Elimination of static electricity
6. Avoidance of fusion of plies
7. Avoidance of distortion in spread
8. Easy separation of the cut lay into bundles
9. Fabric must be flat
10. Matching checks or strips.
3.3.10. Spreading system in factory:

 Manual spreader group : 3 group
 Gerber Spreader : 5 pcs
3.3.11. Marker making
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.
3.3.12. Objects of marker making:

- To reduce cost;
- To improve the quality of the garments;
- To reduce the cutting time;
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- To facilitate large scale production.
3.3.13. Types of marker making:

Generally there are two methods by which marker can be made –
a. Manual Method of Marker:
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.
28
FIG: PLOTTER MACHINE
3.3.14. Factors considered during marker making

The important factors considered during marker making are –
1. Nature of the Fabric:

The fabric may be either symmetric or asymmetric. Thus the nature of the fabric
should be considered during marker making.
2. Lay planning of patterns:
Improper lay planning of patterns may create more wastage. Thus it should be taken
under consideration.
3. Alignment of the pattern pieces according to the grain line:
It is also another important factor that must be considered. The warp direction of a
fabric is very much important for a garment and the grain line indicates the warp or
wale direction.
4. Requirements of cutting: Before placing the pattern pieces on to the marker or
during marker making the cutting allowances are considered where necessary and
where is not. It may produce more wastage and may reduce the dimensions of
patterns.
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
29
3.3.15. The factors which influence the Marker Efficiency
 Manufacturers of the marker;

 Size of pattern pieces;
 Length of the marker;
 Pattern Engineering;
 Nature of the fabric;
 Method of marker making;
 Marker width;
 Kinds or design of garments.
3.3.16. Marker collection from CAD section
Fig: Marker collection
3.3.17. Marker setting
30
Fig: Marker setting
3.3.18. Fabric cutting
Fig: Fabric cutting
3.3.19. Methods of Fabric Cutting:

Fabric cutting methods are as follows:
Manual Method:
 Scissor
 Straight knife
 Band knife
 Round knife
 Die cutting
 Notcher ,and
 Drill etc.
31
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
3.3.20. Different Types of Cutting Machine:

Straight knife cutting machine
Machine name: K.M company cloth cutting m/c
Model: K.M KS_AUV
Producer: made by K.M cutting m/c co, JAPAN
Type: Heavy duty industrial cloth cutting m/c self
Sharpening
Dimension: 8 inch width * 11 inch length * 24 inch height
Weight: 33.5 lb
Current: A.C (3.3/2.6 amps)
Speeds: 3000/3600
Fig: Straight knife cutting machine
32
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.
Fig: Straight knife cutting machine
Advantages of straight knife

 Comparatively cheap and can be transferred easily from one place to another.
 Higher lay of height can be cut very easily.
 Round corners can be cut more precisely then even round knife.
 Production speed is very good as up to 10 heights can be cut at a time.
 Garment components can be directly separated from fabric lays.
33
 Fabric can be cut from any angle.
Disadvantages of straight knife

 Sometimes deflection may occur due to the weight of the motor.
 Knife deflection is high in risk, when lay height is too high
Sometimes accident may happen.
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
34
Feature of a bundle card
490- BE (Style No.)
C-4 (Cutting No.)
B-29 (Bundle No.)
L-29 (Large size, 29 pcs)
638-657 (20 pcs in Bundle no. 29)
FR-6985 (Front part, batch no.)
Bundling according to card no.

In this stage all number parts are bundled according to serial number.
Quality Check (Panel check)
a) Oil spot
b) Dirty spot
c) Crease mark
d) Needle mark
e) Foreign yarn
f) Slub
g) Contamination
h) Hole
Then same numbers of sticker are matched fold & bundled.
After cutting store
All bundles are put in the input rack then send to sewing section.
3.3.23. Machine & Equipment used in cutting section

Sl No. Machine & Equipment Name
01 Straight Knife Machine
02 Bend Knife Machine
03 End Cutter Machine
04 Spreading Machine
05 Drilling Machine
06 Inkjet Printer
07 Cutting Table
35
08 Cutting Gloves
3.3.24. Limitation of Cutting Section:
1. Input problem
2. There is may be no group for any table
3. Preparing the bundle cards by writing on a piece of fabric
4. Check, variegated rib fabric lay quantity may be excess. As a result reject percentage may be
increase.
5. Fabric spreading
3.4. Sewing Section
The process of joining of fabrics by the use of needle and sewing thread or by other techniques is
called sewing.
36
Fig: Sewing Section
3.4.1. Lay out of sewing floor:

37
3.4.2. Element of sewing
 Sewing thread
 Needle and
 Sewing machine
3.4.3. Flow chart of sewing section
38
Input from cutting
Initial inspection part

by part
Stitching with process

wise quality check
Table quality check
Size wise garments

count
Sucker machine
Sewing output
3.4.4. Sewing thread:

Almost all garments produced have one component in common, the sewing thread. Whilst sewing
thread is usually a relative a small percentage of the cost of garments, it has an extremely
significant influence on the appearance and durability of the finished product, the production of
sewing thread is an extensive and complex subject.
Sewing thread used in factory
 Cotton
 Flaming thread
 Elastic thread
 Lorex thread
3.4.5. Sewing needle:

A sewing needle is long slender tool with a pointed tip. The first needles were made of bone or
wood, modern ones are manufacturing from high carbon steel wire, nickel or gold plated for
corrosion resistance. The highest quality embroidery needles are made of platinum. Needle sixe is
denoted by a number on the packet. The convention for sixing is that the length and thickness of a
needle increases as the size number decreases. For example, a size 1 needle will be thicker and
39
longer, while a size 10 will be shorter and finer. The action of needle has a direct effect on seam
strength and garments performances.
Function of a needle: The functions of a sewing needle are -

To produce a hole in the material for the thread to pass through without causing any damage
to material.
To form a loop that will be picked up by the hook of bobbin case.
To pass the needle thread through the loop formed by the looper mechanism on machines
other than lock stitch.
3.4.6 Sewing machine

Types of sewing machine
 Plain m/c (S/N)
 Double needle m/c (D/N)
 Over lock m/c
 Flat lock m/c
 Kanshai m/c
 Button hole m/c
 Button join m/c
 Bar take m/c
 Cylinder bed m/c
 Flat bed m/c
3.4.7. Thread used in different Machine

Machine type Thread type
Plain/ Auto plain m/c 1 needle thread
40
1 bobbin thread
Double needle m/c 2 needle thread

2 bobbin thread
Over lock m/c 2 needle 2 needle threads

2 lopper thread
Cylinder bed m/c 3 needle thread

1 spreader thread
1 lopper thread
Flat bed m/c 3 needle thread

1 spreader thread
1 lopper thread
3.4.8. Different Sewing Machine

Name of m/c: Plain machine.
Brand name: Juki.
Origin: Japan.
Model: DDL-9000 SS
Needle type: DB×1
Stitch type: Lock stitch.
Motor type: servo motor.
Rpm: 400-4000
Name of m/c: Overlook machine.
Brand name: Juki.
Origin: Japan.
Model: MO-3914, TO-42.
Needle type: DC×1, DC×11, DC×14.
Stitch type: Chain stitch.
Motor type: Servo motor.
Rpm: 400-8000.
41
Name of m/c: Flat lock machine.
Brand name: Juki.
Origin: Japan.
Model: MF-7823, U-10-B-56.
Stitch type: chain stitch.
Motor type: clutch motor.
Rpm: 2600.
Name of m/c: Button hole machine.
Brand name: Juki.
Origin: Japan.
Model: LBH-1790SS
Needle type: DP×5
Stitch type: lock stitch.
Stitch design: 19.
Rpm: 400-8000
Name of m/c: Button attach machine.
Brand name: Juki.
Origin: Japan.
Model: LK-1903A-SS.
Needle type: DP×5, DP×17.
Stitch type: lock stitch.
Needle: 01.
Rpm: 400-2700.
Name of m/c: KANSAI (special).
Brand name: Juki.
Origin: Japan.
Needle: Maximum 11.

42
Needle type: UO×128
Stitch type: Chain stitch.
Motor type: Clutch motor.
Rpm: 260
3.4.9. Different types of sewing:

Stitch Name: Single thread blind stitch
ISO Stitching Code number: 103 (Blind Stitch)
Use in process: Blind hem, belt loop etc.
Face View
Stitch Name: Lock Stitch (it is the most common stitch
Face View
Back View (bobbin thread)
Stitch Name: Double needle Lockstitch

Face View
Back View (bobbin thread)
Stitch Name: Zig Zag Lockstitch

Face view
Back View
43
Stitch Name: Chain stitch
Face View
Back View (Looper Thread on bottom)
Stitch Name: 2 needle chain stitch

Face View
Back View (double looper thread on bottom)
Stitch Name: Two needle cover stitch

Face View
Back View (Looper thread)
Stitch Name: Three needle cover stitch

Face View
Back View
Stitch Name: Three Thread Over edge

Face View
Back View
44
3.4.10. Layout of a T-shirt:
Shoulder join
Rib tuck
Neck join
Neck piping
Size label join
Main label join
Neck top seam
Sleeve join
Sleeve hem
Sleeve tuck
Side seam
Finish tuck
Body hem
3.4.11 Layout of a polo shirt:

Placket rolling
Placket join
45
Placket top seam
Placket nose tuck
Shoulder
Shoulder top seam
Collar tuck
Collar join
Back tip top seam
Label top seam
Ben top seam
Placket top seam
Placket 1/60 top seam
Box
Sleeve hem
Sleeve join
Arm-hole seam
Side seam
Side bar tuck
Body gem
Twill tape join
Twill tape top seam
Hole
46
Button attach
3.4.12. Sewing Quality checking points
 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
3.4.13. Sewing Line quality Check List:

1. Buyer Approved Sample & Measurement Sheet Check.
2. Sample Wise Input Check.
3. Buyer Approved Trims Card Check.
4. Buyer Approved Sample Wise Style Check.
5. All Machine Thread Tension Check.
6. Style Wise Print & Embroidery Placement Check.
7. All Process Measurement Check.
8. All Machine Oil Spot Check.
9. All Process S.P.I Check as Per Buyer Requirement.
10. Input Time Shading, Bundle Mistake & Size Mistake Check.
11. Buyer Approved Wise Contrast Color Check.
12. As per Buyer Requirement Wise Styling Check.
13. All Machine Stitch Tension Balance Properly.
3.4.14. Sewing Table Quality Check List:

1. Style Wise Garments Check.
2. All Process Measurement Check..
47
3. Front Part, Back Part, Sleeve & Thread Shading Check.
4. S.P.I check for all process.
5. Print/Embroidery Placement Check.
6. Main Label, Care Label, Size Label &Care Symbol Check.
7. Size Mistake Check.
8. All Process Alter Check.
9. Any Fabric Fault /Rejection Check.
3.4.15 Sewing Defects:

 Needle damage,
 Skip stitches,
 Thread Breakages,
 Broken Stitches
 Seam Grin
 Seam Puckering
 Pleated Seam
3.4.16. Sewing problems in ―factory‖:

 Input problem
 Shortage of skilled operator
 To achieved the overtime, they worked slowly
1. If any problem will create during production then
 Nobody will take the responsibility,
 Nobody will give the instant decision.
2. Sewing line production may be depends on in charge.
3. Needle hole- due to friction, needle eye is to large, mistake of needle selection.
4. Measurement problem- from cutting section
5. Seam pucker
 Due to unequal tension of feed dog and pressure foot on two plies of fabric.
 Due to unequal thread tension.
 Shrinkage of either fabric or sewing thread.
6. Broken stitch
 Due to tension variation between needle & bobbin thread.
 Tension of needle thread is more.
 Low quality sewing thread.
 Needle heating or hook heating.
 Sharp edge of throat plat, hook plate, bobbin cage, needle groove etc.
 Faulty fitting of bobbin cage.
 Sharp edge of bobbin cage, looper eyes and spring.
7. Skipped/ Slipped stitch
48
 If the timing between needle & looper or bobbin is not proper. Needle thread loop is
not picked up by bobbin thread loop when required.
 If the loop of needle becomes smaller in size, slipped stitch occurs.
 Unequal tension between sets of threads.
 Deflection or vibration of needle.
8. Variable stitch density
 If fabric cannot move forward properly due to lack of pressure of pressure foot.
 Due to faulty feed mechanism.
3.5. Finishing Section

Finishing is the final steps of Garments processing technology. A textile products either it is dye or
printed it needs to add some finishing feathers before marketing.
3.5.1. Finishing Lay Out:
Garments wash
Loop cutting
Thread trimming
Alter checking
Stitch others
Button attach
Ironing (In side)
Inspection (inside & outside)
Batch label attach
Final ironing
Joker tag attach
Needle detector check
Size tag attach
Waist belt attach
Hanger attach
49
Poly packing
Cartooning
Shipment
3.5.2. Garments Finishing

Garment finishing through wet processing is responsible for adding beauty to the garment. Proper finishing
could provide better look to the garment, change the feel of the fabric and bring about a change to the texture
of the fabric. There are various types of finishes like peach finish, anti-microbial finish, wrinkle free finish,
aroma finish, UV guard finish, acid wash, enzyme wash, etc.
3.5.3. Process Flow Chart of Garment Finishing:
Thread Suction (Thread Sucker M/c)

↓
Ironing sewing defect check
↓
Quality Check
↓
Metal Detection Spot defect check
↓
Accessories Attach
(Hang Tag, Price Tag, Hanger, Sticker, Security Alarm etc.)
↓
QA Inspection
↓
Folding/Rolling
↓
Assortion
↓
QA Supervision
↓
Cartooning/Packaging
↓
Ready to shipment
3.5.4. Object of Finishing:
 To enhance the suitability of the fabric for end use.

 To improve appearance and sale appeal for comport and utility.
50
To give desirable qualities to the fabric like-
1. Softness
2. Lustre
3. Drape
4. Dimensional stability
5. Crease recovery
6. Soil repellence
3.5.5. Work flow in the Finishing Room:

As mentioned earlier, workflow in the Finishing Department is shown here for reference:
 Eliminate micro-dust and residual thread from the garment;

 Press/iron garments as specified by buyer or as per requirements;
 Fold the garments as required by customer;
 Fix necessary tickets (Price tickets) or tags (hang tags),etc to the garments at this stage;
 Insert garments into poly bags;
 Divide garments as per size and color (assortment);
3.5.6. Machine Description of finishing section

Machine Number
1. Heat Iron 06
2. Steam iron 72
3. Metal detector 02
4. Neck press 02
5. Thread sucker 05
3.5.7. Different types of Machine used

Metal detection machine:
51
Fig: Metal Detector M/C (Brand name: HASHIMA)
Thread sucker machine:
Fig: Thread Sucker M/C

52
Fig: Ironing M/C
3.5.8. Materials used in garment finishing:

 Neck board
 Back board
 Collar stand
 Butterfly
 Tie placket support
 Vanishing loop
 Fit label
 M-clip
 T-clip
 Metal clip
 Cuff link
 Droop loop
 Cable tie
 Boa tie
 Full board
 Hand tag
 Tag pin
 Tissue paper
53
 Al pin
 Ball pin
 Elastic clip
 Hanger
 Poly bag
 Size sticker
3.5.9. Spot removing
The General Rules of Spot Removing:
1. The longer a stain remains, the tougher it is to remove.
2. Always treat a stain before laundering.
3. Blot gently — never rub; and don't ever blot with hot water.
Stain Removal:
STAIN TYPE USED CHEMICAL (COMMERCIAL

NAME)
1. Oil stain Spot lifter
2. General stain Thinner
3. Termeric stain MRS
4. Ink stain MR
5. Glue stain(Polymer based ) Heat gun
6. Rust stain Markvill
7. Print mark Printvill
54
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.
Basic Ironing Symbols:
Do not iron
Cool iron (110°)
Medium iron (150°)
Hot iron (200°)
3.5.11. Garment Inspection:

Flow Chart of Garment Inspection
Confirmation of Quantity
↓
Confirmation of accessories
↓
Size specification inspection
↓
in side Inspection
↓
Out side Inspection
↓
Final Inspection
↓
Packing
55
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:
56
 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.
3.6. Quality Section
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.
3.6.1. Quality objectives

 Overall material/product loss (Level of rejection) for the company during the production
process (in a year) shall not exceed 1.5 %
 Defects during dyeing & knitting operations to reduced by 10%.
 Process capability shall be maximized by maximizing the m/c breakdown time. M/c
Break down time should be reduced to 20 % from its current status/position
 To ensure better work environment for the personnel working in the organization.
3.6.2. Machines required for quality
 Wash Fastness Tester

 Light fastness tester
 Rubbing fastness tester
 Electronic balance
57
 G.S.M. cutter
 Fabric inspection table
 Light box
 Shrinkage (%) meter.
3.6.3. Inspection Area

 Shade match of fabric
 Fabric diameter
 Wash fastness
 Light fastness
 Rubbing fastness
 Faults: Dyeing faults
3.6.4. Faults Found in QC Department
Dyeing faults:
 Uneven shade
 Running shade
 In fastness property
Finishing faults:
 GSM variation
 Spirality
 Shrinkage control: Length wise
3.6.5. Quality Assurance System

Quality assurance system can be divided into following steps:
1. On line Quality assurance system and
2. off line Quality assurance system.
Again on line Quality assurance system can be divided into the following steps:
(a) Raw material control.
(b) Process control.
3.6.6 Online Quality control:

58
Raw material control: Cotton Club (BD) Ltd. always very concern about the quality of the
Product. So, they knit grey fabric from the best quality yarn & utilizes technical evaluation in every
stage of the production, as we know the quality product depends on the raw material quality.
Process control: The method chosen for process must be provided with the necessary accurate
parameters. In the every stage pH should be maintained sincerely.
3.6.7. Off line quality control:

After dyeing the material is received by the finishing section. Before receiving the following things
are checked:
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. Merchandising Section
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.
59
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.
Fig: Merchandising Department
60
3.7.3. Flow Chart of Garments Merchandizing:
Buyer Correspondence & Meeting
Recap Preparation
Lab Dip & Yarn Dip
Sample Fabric Booking
Accessories for Sample
Initial Sample Preparation
Fitting Sample Preparation
Photo Sample with actual specification
Pre Production Sample Preparation
Bulk Accessories Booking after Buyer‘s Approval
Bulk Fabric Booking
Size Set Sample/ Trail Cutting
Production Start
3.7.4. Merchandising Calculation:

Fabric or Body Calculation:
 (Body length+ Sleeve length+ Allowance x Chest + Allowance x 2 x GSM / 10000000) x
12 x 10% (+)
= Result kg./dozen.
NB:
 BL+SL+ Allowance= 10 cm. Allowance.
 When keep the chest allowance then body width, chest width and bottom width which is big
(cm) with (4 cm+) Added.
 10% overall Process Loss.
 1 dozen= 12 pcs.
Body Consumption By Marker:
 Length x width x GSM x12 / 1000 / 1550 / Ratio x 12%
61
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:
 Neck opening or Width + Neck drop x 2 /2.54

= Result.
Pant & Trouser or Pajama Consumption:
 (Length + Allowance x dia x 2 x GSM / 10000000) x 12 x 10 %(+)
= Result kg. / Dozen.
NB:
 L + Allowance # with self-fabric waist minimum (12 cm) Allowance added.
 Without self-fabric waist minimum (8 cm) Allowance added.
 Allowance minimum 15 cm added with Hip or Dia.
 DIA = Hip + Allowance / 2.54
NB:
 1 inch = 2.54 cm.
Pocket Consumption:
 Length + Width + Allowance.
NB:
 Allowance minimum 5 cm added with ( L+ W).
Carton Dimention:
 Length + Width + Allowance x Width + Height + Allowance x2 / 10000
= Result / SQM.
NB:
 L + W + Allowance = 6 cm.
 W + H + Allowance = 3 cm
 2 = Double part.
Button Liner (Find Out Formula):
 1 GG = 144 Dozen.
 1 GG = 1728 pcs.
 Liner = Button Dia / 0.61
= Result / liner.
NB:
 Always Button liner is plural number.
 As like 16,18,20,22,24
Yarn Booking:
 Fabric yarn (kg) + Process Loss.
= Result / kg.
NB:
62
 Process loss keep the 10% added with total fabric.
Sewing Thread Consumption:
 Cone Quantity = per garments thread x garments qty. x qty. in cone.
 Plain Machine : 1‖ for 2.75‖
 Over lock (3 Thread) : 1‖ for 14.5 ―
 Over lock (5 Thread) : 1‖ for 18.5‖
 Flat lock (3 Thread) : 1‖ for 13.5‖
 Flat lock (4 Thread) : 1‖ for 16‖
 Picot : 1‖ for 21‖
 Zigzag : 1‖ for 22‖
 Kanchai Machine : 1 ― for 11‖
Calculation Cubic Meter (Cbm):

 CBM = Carton length x Carton width x Carton height x Carton Qty. / 1000000
= CBM / Result.
NB:
 100 cm x 100 cm x 100 cm = 1000000
 20 Feet = 28-31 CBM
 40 Feet = 56-62 CBM
Marker Consumption (Formula):

 Open Dia = Marker length x 2.54 x Marker width x 2.54 x GSM / 10000000 / Marker
Pcs x 12 x 10% (+).
= Result kg. / Dozen
 Tube Dia = Marker length x 2.54 x Marker width x 2.54 x GSM /1000000 / Marker Pcs
x 12 x 10% (+).
= Result kg. / Dozen
3.7.5. Price of Different Knitted Charge:

Jersey $ 0.15
Jersey with Elastan $ 0.35
Y/D jersey $ 0.25 (feeder stripe) 1.76 (auto stripe)
Y/D jersey with Elastan $ 0.45 (feeder stripe) 2.00 (auto stripe)
1x1 rib $ 0.18
1x1 rib with Elastan $ 0.38
Y/D 1x1 rib $ 0.25 (F.S)
Y/D 1x1 rib with Elastan $ 0.40 (F.S)
2x1 rib $ 0.25
2x1 rib with Elastan $ 0.45
Y/D 2x1 rib $ .30 (feeder stripe)
Y/D 2x1 rib with Elastan $ 0.48
63
Pique $ 0.25
Pique with Elastan $ 0.45
Y/D pique $ 0.35 (feeder stripe) 1.76 (auto stripe)
Y/D pique with Elastan $ 0.50 (feeder stripe) 2.00 (auto stripe)
Interlock $ 0.35
Interlock with Elastan $ 0.50
Y/D interlock $ 0.40 (feeder)
Y/D interlock with Elastan $ 0.55 (feeder)
Terry $ 0.40
Terry/lycra $ 0.50
3.8. Marketing Section
3.8.1. Marketing Activities:
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
3.8.3. Marketing strategy:

Marketing strategy is a very important factors to sale the products to the buyers. If the Marketing
strategy is not so developed, it will be very hard to reach the goal. In case of garments marketing
the dealings with the buyer is a very important factor.
In MKC mainly General Manager, Marketing Executives, Merchandisers & higher officials deal
with the buyer. There is some fixed buyer of the industry. The buyer gives their orders continuously
all over the year. The marketing officers & the merchandisers communicate with the buying houses
to collect the orders. By both side understanding the rate & the order quantity are fixed.
64
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.
3.8.5. Package size & label:

Most common sizes are
S - Small
M - Medium
L - Large
XL - Extra large
XXL - Very very large.
3.8.6. Duties & Responsibilities of Marketing Officer:

Dealing with the buyer & convince the buyer is the main duty of the marketing officer. A
marketing officer also has some other duties. The main duties responsibilities of a marketing officer
are given below:-
 To prepare cost sheet by dealing with the buyer.
 To take different steps by discussing with the high officials & merchandisers.
 To maintain a regular & good relationship between commercial officer & merchandisers.
 To maintain a regular communication with the buyer & buying houses.
 Communicate with the new buyers.
 Display the better criteria of the products.
3.9. Effluent Treatment Plant

3.9.1. Description of the ETP process:
65
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.
3.9.2 FUNCTIONS OF DIFFERENT INGREDIENTS USED IN E.T.P PLANT:
Lime : Lime is used to change the color of effluent and to increase the transparency of water.
66
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.
Water quality of E.T.P:
Parameter Permissible concentration

BOD < 50 ppm
COD < 200 ppm
Color Colorless
Temperature Max m 380C
PH value 6–9
Total Dissolved solid (TDS) < 2500 ppm
Total suspended solid (TSS) < 100 ppm
Dissolved oxygen (DO) 4.5 – 8
3.9.3. Capacity of ETP:
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
67
 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:
68
 Sufficient fire extinguisher and active
 Access area without hindrance
 Fire signs in both languages
 Fire certified personal photo
 Emergency exit
3.10.5 SAFETY GUARD:

 Metal glows on good conditions
 Rubber mats & ironers
 First aid box one
 Ironers wearing sleepers
 First trained employees
 Motor/needle guard
 Eye guard
 Doctor
 Medicine
 Welfare officer
3.10.6 OTHERS:
 Room temperature
 Lighting facilities
Fig: Doctor Fig: First aid box Fig: Fire training
3.11. Print & Embroidery Section
69
Fig: Printing M/C
Fig: Embroidery M/C
70
71
4. Impact of internship
4.1. Sample development

We know what type of sample produced here
System of sample approval
We know what type of machine here
4.2. CAD Section:

We know about CAD.
We know how to make a pattern &
How it use in Garments.
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.
72
How quality is inspect.
Faults found in Quality Section.
How Quality Assurance works in garments.
We know about online quality & offline quality
4.7. Merchandising Section

We know what is merchandising & how merchandising works.
About process of merchandising
How Consumption & costing are done.
How receive order from buyer & negotiate with buyer.
4.8. Marketing Section

We know how marketing section use in garments.
How marketing & merchandising along with works.
Activities of marketing section.
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
4.11. Print & Embroidery Section

We know why print & embroidery is use in Garments
We know how print & embroidery is use.
73
74
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.
75

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INDUSTRAIL TRAINING REPORT 2014

Meghna Knit Composite Ltd.

Name : Md. Shamsul Haque

Name : Ripon Kumer Ghos

Md. Abdullah Al Mamun, Assistant Professor of Daffodil International University our

Foucusing solely in knitwear apparel lines,MKCL has adopted a structure by

Legal Status : Private Limited Company.

BKMEA Membership Number : 834

Year of Establishment : 2006

Head office adress : House.49,Sharwardy Avenue Block-k, Gulsan-Baridara

Nature of Business : Completely 100% export oriented knitwear manufacturing &

Contact Person : M Moklasur Rahman pinto - Managing Director.

Mohammad Monjur Hasan– Sr.General Manager

Meghna group‘s concerns……….

 MEGHNA MAINETTI LTD.

 UNIGLORY PACKING LTD.

Automated corrugated carton manufacturing unit.

 BETA PACKAGING LTD.

Automated corrugated carton manufacturing unit.

 M&U PACKAGING LTD.

Poly bag & carton manufacturing unit

Sole distributor of Raleigh bikes from UK and Phoenix Bickes of China in

Sole agent of Apple computers

Sole agent of Acer computers from Taiwan

2.8. Brief profile (numbers of worker, area, total machineries, etc)

Cutting Section 200

Design & PD Section 02

Dyeing Finishing 188

Finishing Quality 113

HR, Admin & Compliance 26

Marketing & Merchandising 23

Planning & Reporting 02

Sewing Section 1401

Sewing Quality 192

Store Section 107

Buyer Name Major Markets Logo

 Ultimate satisfaction through providing on-time delivery with correct Quality

 Excellent working environment in compliance with national & international

 Building a strong relationship.

 Reaching the highest level.

3.1 Sample Section

PATTERN MASTER (CAD)

3.1.3. Flow sequence of sample section

Receive developed sheet from

Develop the sample

Send the sample to buyer for

Send pre-production sample to

Start bulk production

4. Ad or photo shoot sample:

5. Sales man / Marketing /Showroom sample:

7. GPT sample (Garment Performance Test):

8. Pre- production sample: (PP sample)

 PP sample is considered to be a contract between the buyer and the factory.

10. TOP sample (Top of Production):

11. Shipment sample:

Fig: CAD Section

3.2.1 Working sequence 0f CAD section

Receiving of pattern parts

Taking the image of pattern in CPU by Digitizer