Sepal Dairy Correction

Report on Industrial Attachment | SEPAL GROUP 1

INTRODUCTION

As all Engineering subjects are practical oriented subject. Specially Textile

Engineering is lame without sound practical knowledge. So practical implication is

very essential for any textile person, engineer or students. It is said that textile

industry is the heart of Bangladeshi economy. Industries are run by successful,

skilled engineers. So it will not be wrong if it is said nowadays Textile Engineers are

the main weapon for our economical Success.

Industrial training as offered by the Bangladesh University of Textiles is very useful

which gives the directions & ideas about the production, manufacturing, capacity,

power etc. of a certain mill and with this ideas getting adopted a student can

flourish his debut in the engineering field.

We had been attached in Sepal Group for two months starting from 1st August to

30th September. There are four factories, one washing plant, and one buying

house in Sepal Group. We successfully ended our training while gathered some

useful things like mill management, production, quality assurance, maintenance,

planning, machine operation, merchandising etc.


Chapter 1

Project Description

CONTENTS

Name Of The Company

Type Of The Company

Year Of Establishment

Product Mix Of The Company

Annual Production Capacity

Project Cost

History Of The Project Development

Different Departments Of The Company

Physical Infrastructure Of The Building

Remarks


INTRODUCTION

Sepal Group is one of the leading ventures in the garment industry operating from

Dhaka, Bangladesh. Being a 100% export oriented industry they have been

approved by the Board of investment of Bangladesh and have their own garment

manufacturing and washing units all under one roof. The commencement of

business was in 1986 and from the time of inception till now the group has grown

many folds as it has always maintained quality and punctuality. The group has

gainer name and fame since its inception and herded by a team of dedicated,

hardworking and efficient management and staff who are always on the lookout

for a challenge. They at Sepal make garments the same way that a painter

composes his art on canvas.

The group comprises of the six companies as listed below

1. Sepal garments ltd.

2. Orchid garments ltd.

3. Creative garments ltd.

4. Glory fashion wear ltd.

5. Sepal washing ltd.

6. Mastrade International Garments ltd.

We the students of Bangladesh University of Textiles have joined in Sepal Group

from 1st August to 30 September for our industrial attachment. We came here and

knew how this company is running & the management of this company. We also

learned how to make a garments production as well as merchandising of the

garments.


ADDRESS

Head Office

Sepal Group

247/248, Tejgaon Industrial Area,

Dhaka, Bangladesh

Tel: 88-02_8827707, 9885341, Fax: 88-02-8823026

E-Mail: [email protected]

Associate Office

Apexfair Holdings Ltd.

Flat# 3, Building# 1, 1st Floor,

Ataur Park, Sion – Trombay Road,

Chember, Mumbai – 40071, India

Tel: 91-22-5567255, 5510852, Fax: 91-22-5563549


NO. OF FACTORIES : Five

1. Sepal Garments Ltd.

2. Orchid Garments Ltd.

3. Creative Garments Ltd.

4. Glory Fashion Wear Ltd.

5. Sepal Washing Ltd.

PRODUCT MIX

Mainly woven garments. Major items are

Trouser

Pant

Shirt

Bermuda

Skirt

Shorts etc.

mailto:[email protected]



PRODUCTION CAPICITY

1) SEPAL GARMENTS Cutting capacity : 6000 pcs /day

Sewing capacity : 4000 pcs/ day

Laundry capacity : 30000 pcs /day

Production line : 5

2) ORCHID GARMENTS Cutting capacity : 6000 pcs/day

Sewing capacity : 4000 pcs /day

Laundry capacity : 30000 pcs/ day

Production line : 5

3) GLORY FASHION WEAR Cutting capacity : 4800 pcs /day

Sewing capacity : 3200 pcs /day

Laundry capacity : 30000 pcs/day

Production line : 5

4) CREATIVE GARMENTS Cutting capacity : 6000 pcs day

Sewing capacity : 4000 pcs day

Laundry capacity : 30000 pcs

Production line : 5

5) SEPAL WASHING UNIT

Wet processing (Based on 60-minute stonewash / day) 15000 pcs

Garment dying (based on medium shade in direct process type) 7500 pcs

Dry processing (based on standard specialty) 5500 pcs

ANNUAL PRODUCTION CAPACITY

As a group, Sepal group export approximately 45000 dozens of various garments every

month and these range from newborns, infants, ladies & men’s wear such as Ladies

Dresses, Vests, Jackets, Shortfalls, Overalls, Jumpers, Shirts, Pants, Shorts & Skirts. Annual

production capacity is approximately 540000 dozens.


DIFFERENT DEPARTMENTS

Whole sepal group building has different department. Every department is well

decorated and perfectly maintained by the management of the company. We

have visited every department of this building during our training period. Here we

gave name some of the department.

Merchandising department.

Sewing department.

Cutting department.

Sampling department.

Buying house department.

Custom & security department.

Welfare department.

Child care department.

Medical & maternity department.

Fire department.

Building maintenance department.

Electricity & generator controlling department.

Store

Canteen

Training center

Recreation club etc.

HISTORY OF THE PROJECT DEVELOPMENT

Sepal group is one of the leading ventures in the garments industry operating

from Dhaka, Bangladesh. Being a 100% export oriented industry we are approved

by the board of investment of Bangladesh and having their own garment

manufacturing and washing unit all under one roof. The commencement of


many folds as it has always maintained quality and punctuality.

In 1986, the year of establishment of sepal groups the picture was not alike as

present. At first sepal garments was started with some simple plain sewing

machines and with a few operator and one supervisor .In that time garments


factory was not familiar in this city. So many difficulties were appeared.

Nevertheless, this factory survived against all odds and has achieved impressive

success. Day by day it has increased its profit and extended. More five factory also

established, which are seems to results of success along the way of achievement

since 25 years for sepal group. Now it has own huge factory building in tejgaon

industrial area. Though the founder of this company is TIPU MUNSHI, now it is as

ltd company.

PHYSICAL INFRASTRUCTURE

It is thirteen-storied building. It also attached with another five-storied building

which is an additional to factory building.

1) Sepal garments floor measurement is 30,500 square feet & total floor

measurement of the company office is 5000 square feet.

2) Orchid garments floor measurement is 30,500 square feet.

3) Glory fashion wear floor measurement is 19,800 square feet & total floor

measurement of the company office is 5000 square feet.

4) Creative garments floor measurement is 30,500 square feet.

5) Sepal washing total floor measurement of the factory is 11,000 square feet &

total floor measurement of the company office 1000 square feet. It has three lifts

one is used for cargo and another two is used as a passenger lift.

The company of the cargo lift is 2000 kilogram and the passenger lift is 800

kilograms. There are three stare inside the building and another one is outside of

the building.

FLOOR BY FLOOR DESCRIPTION OF THE BUILDING

- Twelve floor :Training center, CNF office.

- Eleventh floor : Reception clubs, directors’ rest room.

- Tenth floor : Apex square (buying house), sample section -1.

- Ninth floor : Sample section -2.

- Eighth floor : Canteen, kitchen, M/C storage room, office.

- Seventh floor : Sewing floor (creative), office.


- Sixth floor : finishing and store section of creative garments ltd.

Medical care section.

- Fifth floor : Merchandising section, sewing and cutting section of

sepal garments ltd.

- Fourth floor : Finishing section of sepal garments ltd. Cutting and

store section of orchid garments ltd.

- Third floor : Sewing section of orchid garments ltd. Administration

office.

- Second floor : Director’s office, finishing section of orchid garments

ltd. Child care section, store.

- First floor : Sepal washing unit, boiler, generator, store,

reception.

- Basement : Parking, ETP.

ADDITIONAL BUILDING : Glory fashion wear ltd.

SEPAL Group at a glance

Company name SEPAL GROUP

Type & business of the company A 100% export oriented woven &

washed garments manufacturer and

exporter

Factory location 247/248, Tejgaon Industrial Area, Dhaka,

Bangladesh

Year of Establishment 1986

Number of employee Around 5000

Factory Floor Space 1,22,300 sq. ft.

Factory equipments Different types of sewing, inspection,

finishing and washing machine and

generator, boiler effluent treatment

plant.

Main production Mainly woven garments including

trousers, pants, dresses, Bermudas,

skirts, shorts, jackets, vests, jumper etc.

Production Capacity Approximately 45000 dozen of various


garments every month

Main market USA, Canada , China etc

Key personnel Mr. Deepak V. Bhojwani

Chairman

Mr. Tipu Munsi

Managing director

Mr. Anil. D. Rao

G.M Operations

Mailing Address Sepal Group


Dhaka, Bangladesh

Phone Number 88-02-9898259,9898475

Fax Number 88-02-8826072

Website www.sepalgroupbd.com

DIFFERENT SECTION OF SEPAL GROUP


REMARKS

It is the introduction of our project. We will stay here about two month and

gradually we will know every part and every section of this building as well as

sepal group. Here every portion of this sepal group building is very much secure,

neat and clean as well. Every person in sepal group must have company’s ID card.

And everybody should bear it during working hour. We also got ID card from

company. We were surprised to see that our attendances are kept by modern

punching machine.

Sepal group is one of the leading export oriented garments manufacturer in our

country. It is also developing its knit and dyeing factory. Overall we want to say

Sepal Garments and all other four garments factories of sepal group is technology

base modern garments.


Chapter 2

Man Power Management

CONTENTS

Organ gram

Man-power Administration

Production

Management system

Shift change system

Responsibilities of Production Officer

Job description

Remarks


INTRODUCTION

Management

Management controls, in the broadest sense, include the plan of organization,

methods and procedures adopted by management to ensure that its goals are

met. Management controls include processes for planning, organizing, directing,

and controlling program operations. A subset of management controls are the

internal controls used to assure that there is prevention or timely detection of

unauthorized acquisition, use, or disposition of the entity's assets.

Methodology of management system

The art and science of management have developed and changed over the years ,

and so too have definitions of management. Some early theorists viewed

management simply as the ability to work through others. But contemporary

managers work with many resources and tools, so this definition of management

must be broadened beyond the human aspects. Today, management can be

defined as the process of achieving organizational goals through planning,

organizing, leading, and controlling the human, physical, financial, and information

resources of the organization in an effective and efficient manner.

By this definition, management is a distinct process, a set of ongoing, coordinated

activities that managers engage in as they pursue the organization's goals.

Therefore, a manager is someone who actively participates in the management

process through the four functions of planning, organizing, leading, and

controlling the resources of the organization. Managers in various organizations

are confronted by different challenges and call on different resources, elements

such as raw materials, people, information, and money that the organization

needs to produce goods or services.

Depending on their situation and on their resources, managers stress one or

another of the four management functions to accomplish their goals. For example,

the chairmen and CEOs of different companies want to focus on leading and

motivating to build their business. Naturally, all of these executives, and the

managers at every level in every organization, shift their focus from one

management function to another as conditions dictate.


Management of Sepal group

Management system of sepal group is very much modern one. And the

management of this company is very strong as well as friendly to all. It has

improved managing power to make all employee hard working and dedicated.

Organ gram


TOP MANAGEMENT

Mr. Deepak V. Bhojwani

Chairman

Mr. Tipu Munshi

Managing Director

Mr. Mobarak Ali Sikder

Executive Director

Mr. Anil D. Rao

G.M Operations

CONTACT INFORMATION

Head Office Sepal Group


Dhaka, Bangladesh

Tel: 88-02_8827707, 9885341, Fax: 88-02-8823026


Associate Office

Apexfair Holdings Ltd. Flat# 3, Building# 1, 1st Floor,

Ataur Park, Sion – Trombay Road,

Chember, Mumbai – 40071, India

Tel: 91-22-5567255, 5510852, Fax: 91-22-5563549





SAPAL MERCHANDISING DIVISION

KEY PERSONNEL TO CONTACT FOR SEPAL MERCHANDISING DIVISION

Name Phone E-mail

Anil D. Rao 9885941 [email protected]

Aftab A. Sayed 9885341 [email protected]

T. Hossain Ejaz 9898005-12 [email protected]

Monzurul Haque 9898005-124 [email protected]

PRODUCTION

As a group, Sepal group export approximately 45000 dozens of various garments

every month and these range from newborns, infants, ladies & men’s wear such as

Ladies Dresses, Vests, Jackets, Shortfalls, Overalls, Jumpers, Shirts, Pants, Shorts &

Skirts.

MANAGEMENT SYSTEM

Sepal Group comprises of the six companies as below-

1. Sepal Garments Ltd.

2. Orchid Garments Ltd.

3. Mastrade International Garments Ltd.

4. Creative Garments Ltd.

5. Glory Fashion wear Ltd.

6. Sepal Washing Unit

So the management system of this company is a little bit critical. There are four

garments factory and one washing factory in that thirteen storied building, where

we worked. Two sampling section is for that four garments factory and four


cutting section, four storing section for accessories. Management system of

Washing Unit is a little bit different, which will be discussed in another part.

The management system of all four garment factory are almost same. There are

four production managers for four factories. They supervise all activities related

production. All staffs related to production are accountable to production

manager directly. In the factory, ten to twelve operator works under a supervisor,

a few supervisor works under a line chief. All line chief of all production lines

directly accountable to production manager. Besides them, there are also some

QA manager, inline inspectors, mechanic and many other persons of different

positions are related and responsible to the production.

Here employee information of Sepal Garments Ltd. is given to describe the

management system of that factory.

EMPLOYEE INFORMATIONS OF SEPAL GARMENTS LTD.

Employee Position Number Employee

QA Manager 2

Inline Inspectors 60

Final QA Inspectors 20

Mechanics 6

Cutting Operators 3

Cutting Supervisors 3

Sewing Supervisors 20

Sewing Operators 340

Sewing Helper/finish.hel. 160

Finishing 60

Packing 25

Pressman 17

staff 34

Male 260

Female 490

Total Staff 750


EMPLOYEE INFORMATIONS OF ORCHID GARMENTS LTD


QA Manager 2



Mechanics 6

Cutting Operators 3





Finishing 60

Packing 28

Pressman 20

staff 34

Male 220

Female 520

Total Staff 778

EMPLOYEE INFORMATIONS OF ORCHID GARMENTS LTD


QA Manager 2



Mechanics 5

Cutting Operators 3





Finishing 50


Packing 22

Pressman 15

staff 31

Male 227

Female 423

Total Staff 650

EMPLOYEE INFORMATIONS OF CREATIVE GARMENTS LTD


QA Manager 2



Mechanics 6

Cutting Operators 3





Finishing 60

Packing 30

Pressman 20

staff 40

Male 274

Female 521

Total Staff 795

The management system of these four factories is same. The management system

of the company is different. The director supervises all the activities and the

decision maker. In this company there are more directors for different section. At

present the managing director of this company is Tipu Munshi. Two more director

are Tania Munshi and Patric E.A.


The management system of whole production activities is directed by production

director of the Sepal Group Ltd. At present Mr. Anwarul Islam is the production

director of Sepal Group. Production director supervises the activities of production

managers, electric managers, finishing mangers and cutting managers.

Quality manager supervises all the activities of quality inspectors and officers.

Moreover the whole quality section is separate section which is directed by quality

chief. The fire department and medical care and training center is directed by own

department manager.

MANAGEMENT TEAM

Managing Director : Mr. Tipu Munshi

Director : Tania Munshi

Petric E.A

Production Director : Mr. Anwarul Islam

Production Manager : 1. Anisur Rahman(Sepal)

2. Shah Alom (Orchid)

3. Alomgir Hossain(Glory)

4. Ala Uddin(Creative)

Production Coordinator : Ariful Islam

Manager (sample section) : Nasir Uddin

Cutting master : Mathus

Quality Chief : Shiva

Technical Compliance Officer : Jullian Hawladar

William

CTPAT Officer : Kazi Shahidul Islam

Store in Charge : 1. Sofikul Alom(Sepal)

2. Mubarok Hossain (Orchid)

3. Sri Bimol(Glory)

4. Anisur Rahman(Creative)

Administration Head : Ershadul Alom

Welfare Manager : Taposhi Rabeya


IT Officer : Forhad Akbar

Custom in charge Officer : Rajib Sarkar

Training center Head : Lili Gomaje

Fire Department Head : Shahin Alom

SHIFT CHANGE

The shift of work of this factory is one shifted for all four garments factories. But

the washing unit is three shifted factory. Every shift is of eight hours. Normally the

shift begins at 8:00 am and ends at 5:00 pm for staffs. In the middle of working

hour there is a break of an hour for lunch. The weekly off day of the factory is

Sunday.

RESPONSIBILITIES OF PRODUCTION OFFICER

To assist Production Executive on departmental related operation matters.

To lead a group of leader(s)/Assistant leader(s), production floor

assistant(s) and/or production assistant(s) to achieve production schedule

and meet customers’ requirements.

Co-ordinate and interact with relevant groups to ensure quality and

productivity targets are met.

Monitor, update daily production progress and report to Production

Executive if the production target is affected by machine problems or if

reschedule is required.

Responsible for production work order creation (if any), updating of

manufacturing output into weekly report and ERP system and prepare

monthly manufacturing closing.

Train and lead subordinates on upgrading their jobs knowledge.

Involved and guide/assist the team in any improvement assignment/project

related to the department operation and comply any additional

responsibilities when assigned by the company.

Reports to the Production Manager Operations.


Monitor and control shift wise production, plant utilization, waste

generation etc, implement correct work methods and maintain all records

related to production.

Responsible for systematic planning and execution of production programs.

Adequate control over process in order to achieve quality of products,

better waste management and to reduce the occurrence of defective yarn.

Monitor shift wise production, utilization etc and take corrective action for

any shortfall.

Maintain all the procedure of his department and shall incorporate

amendments as and when required in the procedure.

Liaise with maintenance department for evaluating the performance of the

machinery and to take corrective actions.

Responsible for monitoring the performance of manpower under him and

identification of training needs.

Co-ordinate with other department heads such as Engineering,

Commercial, marketing and HR so as to achieve the objectives of the

company.

REMARKS

The management system of Sepal Group Ltd. is very smooth and strong as well as

friendly to all staffs. The management acts as power behind all of its achievement.

All of its Managers, Officers, Staffs are very responsible about their duty. Overall

the relationship among the staffs and employee is very fine and discipline is

noticeable as well.


CHAPTER 3

Machine Description

Contents

No. of M/C

Brand name

Main specification

Machine lay out plan

List of Machinery

Remarks


INTRODUCTION

Sepal group is an extra-vigorous project which has a huge reputation for the

garment industry. It has four garments and one washing unit which contain

various types of machines and technology. Here are production machines, sample

machines , dryers, extractors , sand blast machines, dryers, transports equipments

etc. all the description are given below-

NUMBER OF MACHINES

In the sepal Group they have four Garments. No. 01-Creative, no.02- Sepal, no.03-

Glory and the last one is Orchid. All the garments use same machines for their

products . So, we are giving number of machine for all the garments including

Sepal. The things are showing below:

Name Creative Sepal Glory Orchid

1. Plain Machine 208 208 215 208

2. Over lock

Machine

36 35 35 35

3. Feed of the

arm

12 10 10 10

4. Two needle

Machine

30 30 30 30

5. Button hole

Machine

6 4 7 4

6. Button stitch

Machine

6 6 5 6

7. Bar take

Machine

8 11 11 11

8. Snap button

Machine(power)

6 25 8 25

9. Snap

button(power)

2 21 4 21


10. Kansai

special (pmd)

6 6 5 6

11. Flat

lock(kansai)

1 2 1 2

12. Blind stitch

Machine

1 1 1 1

13. cloth cutting

Machine

3 5 5 5

14. Pocket 2 2 2 2

15. Flat lock

(Pegasus)

1 6 2 6

16. Eyelet/B/H

Reece

3 4 4 4

17. Collar

training

5 5 4 5

18. Threat

sucker

1 1 1 1

19. Fusing

Machine

1 1 1 1

20. cloth

winding

inspection

Machine

1 1 1 1

21. Core

winding

Machine

1 1 1 1

22. Velcro

attaching

2 2 1 2

23. Metal

detector

Machine

1 1 1 1

24. Vacuum iron

Machine

10 12 10 12

25. Marker

computer

pattern machine

1 1 1 1


26. End cutter

Machine

1 2 2 2

27. Label

Machine

6 2 5 2

28. Chain stitch

T/N

10 0 0 0

Total 371 405 373 405

All together : 371+405+373+405= 1554

Washing Plant

Washing Machine : 11 (Golden Resources, Hong Kong), 500 lbs Each.

Sample machines : 3 (Golden Resource, Hong Kong) 110 lbs each.

Dryers : 15 (7 steam + 8 Gas)

Extractors : 3 (golden resource, Hong Kong)

Sand Blast m/cs : 6 (six)

Generators : 2 (1 diesel 930 KVA + 1 Diesel 400 KVA)

Boiler : 1 (2.4 tones)

Transports : 3 (three)

Employees : 153

MACHINE BRAND NAME

In Sepal Group we are using various kind of Machine. Such as, Kansai, Plain

Machine, Eyelet etc. We are giving such types of brand names which are

mentioned on below:

Number Brand Company Country

1. Kansai Brother Japan

2. Plain m/c Brother Japan

3. plain automatic machine Sun star China

4. Eyelet Brother Japan

5. computerized Eyelet M/C Brother Japan

6. Chain stitch M/c Typical China


7. Button hole Brother China

8. Over lock(5 threat) Juki Japan

9. Over lock (4 threat) Juki Japan

10. Feed of the arm Brother Japan

11. Vertical machine Brother Japan

12. Flat lock Pegasus Japan

13. Button stitch Brother China

14. Fusing machine Hashima Japan

15. Straight Knife Blue streak-II USA

16. Lay cutting machine Eastman USA

17. Light box - -

All the machines we are specified here are using various types of products. all the

machines are very important for the better production according to the buyer

requirement.

MACHINE SPECIFICATION

Here, we have described about the specification of the machine. Description of

the machine given below-

Name Model No. Speed

Control

Needle

No.

Needle

Size

1. Kansai (Brother,

Japan.)

DFB1411PXF PULLY UOX113 11-22

2. Plain machine

(manually, Brother,

Japan.)

H7200A40B - DBX1 9-18

3. Plain auto(sun star,

China.)

KM250B-75 - DBX1 9-18

4. Eyelet (Brother,

Japan.)

RH-9820-01 - EBX7 14-18

5. Eyelet

(computerized,

RH-9820-02 - DOX558 14-20


Brother, Japan.)

6. Button Hole

(Brothers, China,)

HE806A-2 - - -

7. Over lock (5 threat,

Juki, Japan.)

MO-67165 - DCX1 9-20

8.Over lock(4 threat,

Juki, Japan

mo-67145 - dcx1 9-20

9. Feed of the arm

(inside seam, Brother,

Japan.)

DA-9820-8 Three

stitches-, 6

threads.

UYX128 11-20

10. Vertical machine

(cutting and swing,

Brother, Japan.)

EI77B-3 - - -

11. Flat lock(Belt loop,

Pegasus, Japan)

W500 5 threads,

three

needles

- -

12. Button stitch

(Brothers, China.)

BE-438D - - -

13.Auto Marker - - - -


SOME MACHINES USED IN SEPAL GARMENTS


REMARKS

We have described all the machines specifications, their brand names, a lay out of

a short pant and now we can realize how many machines would be required for a

garment and what would be their arrangement. Though it always varies for

different design or type of garments, it depends on the basic stitch type. We have

collected quite a few lay out plan for different garments and special design.

Sepal group consists of number of factories so that it is difficult to collect all the

specification and other information about all machineries. We have tried our best

to collect them. We are grateful to our supervising teacher Mr. Julian for his help

while collecting these data.


CHAPTER 4

Raw Materials

CONTENTS

Raw materials types

Raw materials Price

Raw materials Source

Annual Requirement

Remarks


INTRODUCTION

Raw material means the accessories, fabrics and the other trimmings which all are

needed to produce a garment. In another word all the material are needed to

produce a garment item or apparel except the machineries and man power could

be considered as raw material. These raw materials play a vital role during

production. If any kind of defect or disassembly is present then the product quality

will be hampered. Beside this raw material must be used in garments factory for

ornamentation of the product as well as they provides necessary information.

Raw materials used tell a lot about the product and its impact on the potential

buyer. As for e.g.: A company who supplies organic food or recycled,

environmentally-safe products or services would send wrong signals to buyers if

the hang tag or swing ticket was made of aluminum or plastic. Thereby, lays the

careful selection of raw material for making tags and swing tickets.

Raw material can be classified in two types:

1. Fabrics

2. Trimming or accessories

Fabric

This is the main raw material of a garment. Except this ready made garments can

not be thought. Different types of fabric can be used for different garment. It can

be varied by color, design, construction etc. Moreover in a particular garment

different fabric can be used to produce different parts. Mainly woven fabrics are

used for shirt, trouser, pant etc. Basically denim fabrics are used to produce pant

& jackets. Knit fabrics are used for knitted goods like T-shirt, polo shirt etc.

Sepal group is one of the leading garments in Bangladesh which manufactures a

huge quantity of woven garments. Basically they import their required fabric

according to buyer recommendation. The most of fabrics are imported from

Shanghai & Hong Kong.

Realty Textile of Shanghai is one of favorable industry from which most of fabrics

are imported for Sepal Group. Some fabrics are also imported from U.S.A. The

pocketing fabric are not imported these are collected from local market.


Trimmings

All the materials except fabric required to make a garments are known as

trimmings or accessories. For example: sewing thread, button, zipper, label etc.

And there are many other trimming are used in garment factory such as Badge,

Bag and box, Belt, Button, Bra-strap, Card, Cord and piping, Fastener, Fashion

jewelry, Film, Glasses strap, Key chain, Lanyard, Label, Patch, Packaging paper,

Seal, Stickers, Tag, Tape, Transfer, Trims, Zipper pull and miscellaneous.

Here we have given some information about different trimming used in this

factory with their source from where they are collected. Later we will give the

description of most important trimmings item.

No Name of item Description Source

1. Thread Polyester, linen, polyester coated,

single ply, multiple ply of different

Tex.

Local Market.

e.g. Twice, Coarse

etc.

2. Pocketing Fabric Simple plain fabric of different

color. but basically white color is

mostly used.

Local Market.

3. Interlining Fusible interlining white color

natural. For denim temp is 149.

Local Market.

e.g. Vilene

4. Lining Extra fabric or wedding are used

mainly in jacket.

Local Market.

5. Button Sew-On Button, garment Button,

Metal button :

Material: Brass Size: 9-25mm

Color: Paint-plating Customer's

designs, colors and logos

Jeans button:

Size: 17mm Materials: Brass and

stainless steel Cap with diamond

and be painted Customer's logo

Snap Button:

Mould: 831#, 201#, 633#, 655#,

203#, 833# Sizes: 10mm, 11.5mm,

12.5mm, 14mm, 15mm, 17mm

Local Market &

Imported

Brand items must

be imported.


etc. Colors: Various materials:

Brass.

Polyester / Resin / Plastic Button:

Polyester Button/Resin

Button/Plastic Button/Nylon

Button Materials: Polyester In a

Variety of Designs and Fashion

style.

Coat Button:

Material: Polyester Shape: Many

shapes, round, square, triangle,

rectangle, abnormity Color: Chalk

and DTM.

Metal Button: materials: Brass,

zinc alloy and others Shape:

Round, rectangle, oval, other

shapes Design: Different pattern,

with logo Color: Enamel colors,

anti brass, nickel, black nickel,

gold imitation.

Fabric Cover Button :

Fabric covered button 1. Style:

Round, square, heart shape,

eyelet holes, plastic shank, metal

wire shank 2. Size: 12L, 14L, 16L,

18L, 20L, 22L, 24L, 28L, 30L, 32L,

36L, 40L, 44L, 60L etc.

6. Zipper nylon zipper, metal zipper, plastic

zipper, aluminum zipper Metal /

Brass Zipper, Nylon Zipper

Imported

7. Poly Bag Used for covering the garments.

And its size and color depends on

product type and design.

Local Market

8. Label Size label, Main label, Care code

label, price label, composition

label etc.

Local Market &

Imported

Brand items must

http://www.made-in-china.com/showroom/jeanst/product-detailHemnxTCyqYWr/China-Polyester-Resin-Plastic-Button.html

http://jhyga001.en.made-in-china.com/product/FoaEykJZXDWn/China-Coat-Button.html

http://jhyga001.en.made-in-china.com/product/jefxOtKHnikh/China-Metal-Button.html

http://twoscn.en.made-in-china.com/product/qMunziYjZlVs/China-Fabric-Cover-Button.html

http://www.made-in-china.com/showroom/henglizip/product-detailAQmJbXpMRxad/China-Metal-Brass-Zipper.html



http://www.made-in-china.com/showroom/fffzipper/product-detailTqhQoseHbuWR/China-Nylon-Zipper.html


Barcode Label, Ticket, Waist Card

for Clothing (SLYK0032):

Equipped with most advanced

barcode machine, apply to

different specs of barcode label,

hangtag, price ticket, sticker and

washable label Supports both

separate and continuous printing.

Metal Label / Charm / Plate for

Garment, Bags:

Features: Product name: Lloyd

label/metal label 1) materials:

Alloy with gold electroplating or

chrome electroplating. 2) Various

shapes, sizes and designs available

3) Buyers’ logos and designs.

Metal: Features: Product name:

Lloyd label/metal label 1)

material: Alloy with gold

electroplating or chrome

electroplating. 2) Various shapes,

sizes and designs available 3)

Buyers’ logos and designs. Paper

Label (DY0086):Item: Hangtag 1)

Materials: 1mm cardboard 2)

Surface Disposal: Glossy or matte

lamination, spot UV, varnish are

available 3) Printing: 4 color

printing or Pantone color printing

4) With metal clip.

Woven Labels: Woven labels are

the most common and

economical way of identifying

your garments or products.

Polyester Label Tape, Garment

be imported.

http://www.made-in-china.com/showroom/whsinicline/product-detaileqiJhWzAbDkv/China-Barocde-Label-Ticket-Waist-Card-for-Clothing-SLYK0032-.html

http://www.made-in-china.com/showroom/whsinicline/product-detaileqiJhWzAbDkv/China-Barocde-Label-Ticket-Waist-Card-for-Clothing-SLYK0032-.html

http://www.made-in-china.com/showroom/whsinicline/product-detailsolEijHKLDVk/China-Metal-Label-Charm-Plate-for-Garment-Bags-SLML0035-.html

http://www.made-in-china.com/showroom/whsinicline/product-detailsolEijHKLDVk/China-Metal-Label-Charm-Plate-for-Garment-Bags-SLML0035-.html

http://cnhzdy.en.made-in-china.com/product/hqXnkYsxHzVu/China-Paper-Label-DY0086-.html



http://chriswkt.en.made-in-china.com/product/moyJxbrkTntL/China-Woven-Labels-1-.html

http://www.made-in-china.com/showroom/yamaribbon/product-detailIQEmWgTKjJqU/China-Polyester-Label-Tape-Garment-Label-Band-Label.html


Label, Band Label. Yuma ribbon

and bows company can supply

good quality woven edge label for

garment and home textile. Woven

Labels (LJ060): Material: Printing

label or woven label Application:

Textile clothes attached at the

inside the back of shirt. For

marking. Paper Label

(HEDY004):Name paper label

Material paper Size 4.5*3.0CM

(material PVC Size customize)

9. Hand Tag Plastic, paper, woven, printed

hand tag etc. mainly contain

product and company’s brand

name.

Features: 1) Size of paper hang

tag: According to clients'

specifications 2) Materials of

paper hang tag: Ivory card paper,

white paper board, glossy art

paper 3) Function: Labels, tags,

name cards,

Local market

10. Match Box To matching size and bundle

number.

Local market

11. Sticker Hologram Sticker : Hologram

Sticker, 1. Item: Hologram Sticker

2. Material: sticker 3. Size,

Printing, Design according to

customer's requirements. Label:

label, tag, sticker tag, logo, paper

sticker 1) Safe and non-toxic, no

harm, no radiation 2) Material

PVC, PET, paper, self-adhesive

sticker 3) Different materials,

designs and sizes available

Local market

http://www.made-in-china.com/showroom/logoella/product-detailaoMQvfDAqnGw/China-Woven-Labels-LJ060-.html



http://cnwinpro.en.made-in-china.com/product/MeVmqOxXElki/China-Paper-Label-HEDY004-.html



http://loren888.en.made-in-china.com/product/fbPQWvBdZiVR/China-Hologram-Sticker-LE-HS-001-.html


12. Tag Pin Pin: Tag gun, Tag pin, loop pin,

hook pin, cable tie, twin tag pin

Standard tag gun and fine tag gun.

Pin available size from 15mm to

75mm to 125mm. Material Nylon

and PP. Multi-colors.

Pin: Tag pin The tag needle is for

tagging and labeling use For

standard tag gun Available in

various length.

Pins: Tag Pin 1) Used for hanging

various kinds of merchandise

brands 2) Sizes: 8 - 225mm (PP

regular); 10 - 75mm (micro pin)

3)Material: PP and Nylon Packing:

5000pcs/box, 20box/ctn.

Local market

13. Button sticker Transparent or may be colored. Local market

14. Button poly Simple colored poly. Local market

15. Hanger wooden hangers, metal hangers,

Aluminum hangers, Laminated

wooden hangers, plastic hangers

and etc.

Local market

16. Hanger Sizer According to products size and

buyer Recommendation different

color is used.

Local market

17. Poly sticker Hologram Sticker: Hologram

Sticker, 1. Item: Hologram Sticker

2. Material: sticker 3. Size,

Printing, Design according to

customer's requirements

Local market

18. Packaging paper Transpired or colored paper of

plastic.

Local market

19. Bra-strap Bra Strap (DS-FW-

004):Commodity name: Bra

Local Market &

Imported

http://loren888.en.made-in-china.com/product/fbPQWvBdZiVR/China-Hologram-Sticker-LE-HS-001-.html

http://fashionwindhk.en.made-in-china.com/product/qonQMGvdXIhL/China-Bra-Strap-DS-FW-004-.html

http://fashionwindhk.en.made-in-china.com/product/qonQMGvdXIhL/China-Bra-Strap-DS-FW-004-.html


Strap(DS-FW-004) Material:

Cuprum, Rhinestone, nickel-free

electroplating Color: Silver

Specification: Main chain 32cm,

subsidiary chain 17cm without

length of buckle Strap:

Compositions: 100% copper,

rhinestone, nickel-free

electroplating Specifications:

Various styles are available and

customized designs are accepted

Colors: Silver, gold, black, bronze.

Commodity name: Fabric bra

strap(FS-FW-Y016) Material:

Spandex belt Color: Yellow

(Different color as per your

requirement) Specification:

Length 40cm, extended 60cm

Brand items must

be imported.

20. Buckle, hook &

loop

Loop: Hook and loop Material:

100% nylon, or nylon mixed with

polyester. Width: 16mm, 20mm,

25mm, 38mm, 50mm, 100mm,

125mm, 150mm Colors: 300 kinds

of colors Used for garments,

Hook and Loop (HL1003): Hook

and loop Several quality grade &

type to reach customers' various

requirement. 1. Normal Hook &

loop 2. Adhesive hook & loop 3.

Back to back hook & loop

Local Market &

Imported

Brand items must

be imported.

21. Seal Company seal: Rubber, metal seal

etc.

Local Market

22. Card PVC Card (Plastic Card): Material:

PVC or paper Size: 86mmx54mm

or other size as required.

Local Market

http://www.made-in-china.com/showroom/ningbosunshine/product-detailsbTJZHxYYPWD/China-Hook-and-Loop-HL1003-.html

http://gdjxjk.en.made-in-china.com/product/AeiQgqLybHhb/China-PVC-Card-Plastic-Card-.html


Thickness: 0.3mm; 0.5mm;

0.76mm or others. Printing: Full

color, encoding.

23. Cord and piping Used in waist band wedding and t-

shirt. Mainly soft knitted fabric.

Local Market

24. Tape TPU Tape, Mobil on Tape (NCB-

2):1)Product name: TPU TAPE

2)color: Transparent, semi-

transparent, black, bluish etc.

3)width: 3mm-16mm(or to

requirement) 4)thickness:

0.08mm-0.30mm(or to

requirement)

Local Market

25. Zipper puller PVC Zipper Puller: Material: Soft

pvc or silicon Standard: Can pass

EN71, Cadmium and non

phthalate test With one-sided or

double-sided logo About OEM

Sample. Alloy Zipper Puller (FZY-Z-

078): Zipper puller Material: Alloy

customer zed color & design.

Leather Zipper Puller: Brass

Zipper, Aluminum Zipper, Nylon

Zipper, Polyester Zipper, Plastic

Zipper, Rhinestone Zipper

Local Market &

Imported

Brand items must

be imported.

26. Belt

27. Key chain Key Chain: Watermarks indicate

the serial NO. And size of each

hangtag

Local Market

28. Hanger bag PVC Hanger Bag (YX12):Material:

0.12mm PVC Size:

23.5cm(L)*18cm(W) Daily Output:

10000pcs/day Package:

50pcs/bag, 1000pcs/ctn MOQ:

1000pcs Printing: Silk printing or

offset printing

Local Market

http://www.made-in-china.com/showroom/dgyigao/product-detaileqDxfNcrbzko/China-PVC-Zipper-Puller.html

http://www.made-in-china.com/showroom/dgfangzhiyuan/product-detailjbImcWldLPhe/China-Alloy-Zipper-Puller-FZY-Z-078-.html

http://www.made-in-china.com/showroom/dgfangzhiyuan/product-detailjbImcWldLPhe/China-Alloy-Zipper-Puller-FZY-Z-078-.html

http://www.made-in-china.com/showroom/henglizip/product-detailVoznveGcaTkU/China-Leather-Zipper-Puller.html

http://www.made-in-china.com/china-products/productviewrbkQdzLOHaVf/Key-Chain.html

http://yongxinbag.en.made-in-china.com/product/bocQjWxEaiVr/China-PVC-Hanger-Bag-YX12-.html


29. Cuff Links,

Button

Cuff Links, Button:

Introducing yourself to your

clients, this is the best way,

putting your own Logo in a little

gift, common but everybody

needs. 1) Material: brass 2)

Golden and satin finish 3

Local Market

ANNUAL REQUIREMENT

Thread : 60000 tons approximately. Basically depends on order.

Fabrics : 500000 tons approximately. Basically depends on order.

Others : Depends on order.

http://www.made-in-china.com/china-products/productviewyixnltEuRmSh/Cuff-Links-Button.html




Some Trimmings


REMARKS

Raw materials and accessories are the major term of garment production. We can

say that this term is the heart of a garments industry. We have tried our label best

to collect all data about raw materials though it was not an easy task to do.

More over Sepal group maintain a good fame by using brand item and qualified

raw material. A number of people are always checking the quality of these items.

They also inspected them and keep documents by the time.

The store house is very much secured and only authorized person can enter that

room. We are thankful to our supervising teacher Mr. Julian for his help while

collecting these data.

We are also grateful to our respectful teacher Mr. Moshiur Rahman Khan for

giving important check routine and advice.


CHAPTER 5

Production Planning Sequences & Operations

CONTENTS

Production Parameters

Description of production process

Daily production report

Monthly average production

Production flow chart

Monthly efficiency

Remarks


INTRODUCTION

Production planning is the very first step to start a production. At first the

company gets an order from buyer and then they start the production planning.

Here in Sepal group production planning and production process is specified and

extra ordinary. In this chapter we have described all the procedure and the

necessary document related to run a production. We also included a sample and

all of its information. The ID no of the product is 00247619.

There is disclosed a system for fastening together different pieces of an article of

clothing so as to enable a customer to select a specific clothing style and design by

selection of different garment pieces. The fastening creates a garment seam

equivalent to a sewn seam yet provides non-permanent closures for garment

assemblage and thus allows a garment to be created specifically to the customer's

wish. There is also disclosed a system for producing garments from a plurality of

different garment pieces and a simplified design and production schedule.

A garment production process wherein garment parts are knitted in a continuous

length of knitted material with water soluble yarns being formed in the knit

construction between the garment parts. The length of material is moved along its

length and bathed with a heated aqueous solution to dissolve the water soluble

yarns and separate the garment parts. The separated garment parts are dried and

vibrated and passed to subsequent garment making stations. The temperature of

the bathing and drying steps and the vibration of the garment parts serve to heat

set the garment parts.

DESCRIPTION OF PRODUCTION PROCESS

Here we have described the whole production processes which are followed by

the Sepal Group after getting an order. We described the processes step by step

according to our limitation. We have also attached an order sheet, PID file, a

sample, production lay out plan and production flow chart and some other

documents to enrich our assignment.


STANDARD INSPECTION PACKET (SIP)

Sepal Group will have to maintain a SIP file for all orders at the factory. Factory

will have to make sure that all tests are timely done and approved. The following

information has to be in the SIP:

PID and any changes to order.

MTL Fabric Testing Reports.

MTL Pre Production Sample Testing Reports.

MTL TOP Sample Testing Reports.

Interlining Testing reports.

Invoices of all Trims / Fabric that have been ordered from the nominated

suppliers.

Factory Pre Final/Final inspection reports.

TCPS Final inspection reports.

Approved fabric swatches and Trim samples

Fit and Pre production approval comments

Pre-production meeting reports

FABRIC INSPECTION PROCEDURE

Sepal Group must maintain the following fabric inspection procedure:

10 % of all fabric shipments should be inspected prior to cutting.

Records should be maintained for every fabric invoice packing list and

inspection report.

Fabric inspections should be done by using the 4 point system and on the

Rotary fabric inspection machine.

Fabric inspection cannot be done while spreading.

Fabric should be inspected for color accuracy as well as shading (side to

side, end to end, roll to roll and number of shade lots).

All rolls that are out of the color shading guidelines should be rejected.


All roles with color defects such as side-to-side shading, side-center-side

shading, and end-to-end shading will not be given points, but should be

rejected.

All fabric inspection forms should have the defects classified separately.

E.g.:- Stains, Weaving defects, Holes, Slubs, etc.

The Four Point system classifies defects as shown in Table 1:

Table 1: Four Point System

Size of defect Penalty

3 Inches or Less 1 Point

Over 3, But not over 6 Inches 2 Points

Over 6, But not over 9 Inches 3 Points

Over 9 Inches 4 Points

Note - A Maximum of four points can be charged to any one linear yard.

The length of defect should be used to determine the penalty points. Only major

defects are considered. (A major defect is any defect that, if found in a finished

garment, would classify that garment as a second.) No penalty points are recorded

or assigned for minor defects.

Major Defects for woven fabrics is classified as follows

a. Slubs

b. Hole

c. Missing Yarn

d. Conspicuous Yarn

e. Variation

f. End Cut

g. Soiled Yarn

h. Wrong Yarn.


Major Defects for Knit fabrics are classified as follows:

a. Mixed yarn

b. Yarn Variation

c. Runner

d. Needle line

e. Barre

f. Slub

g. Hole

h. Press off.

The inspection procedure listed below details the steps involved in performing the

piece goods inspection in the correct manner. These steps must be followed by

the Fabric Inspector/Auditor.

Review the packing list and determine how much total fabric to inspect and

then how much of each color. Determine how many rolls of each color to

inspect and then choose from the packing list and the physical rolls, which

rolls are to be inspected.

Count the rolls in the shipment to make sure they match the packing list

and then mark the rolls that are to be pulled for inspection.

Check the packing of the rolls in the shipment to make sure all the packing

and markings are correct.

Move all the rolls to be inspected to the inspection machine and load the

first roll on the machine. As the roll is put on the machine check to make

sure the inner packing is correct and proper. Also check to make sure the

roll is rolled on the tube squarely and that the tube does not stick out of

the end of the roll more then 1 inch on each end. Also make sure the first 3

meters of fabric is rolled properly, not creased or distorted, and that it is

clean from dirt and marks.

Cut off the first 6 inches and last 6 inches of fabric from each roll and mark

it with the roll number, whether it is from the head or tail of the roll, which

is the right and left side of the fabric and which side is the face side of the

fabric. These strips will then be used in the light box for reviewing end-to-

end, side-to-side and roll-to-roll shading. Use the head strip to check for

end-to-center shading during the inspection.


Inspect the fabric using the recommended form that is included in the

manual and mark the faults and their points. Run the inspection machine at

a speed that allows you to see the defects properly, yet keeps the fabric

moving in a steady and smooth manor. Make sure that you have the proper

and adequate light at the machine shining on the face of the fabric.

Check the length of the fabric on the roll and compare it to the ticket

yardage for the roll. Note this on the “Inspection Form.”

Check the width of the fabric at the beginning and end of the fabric as well

as at least once in the middle of the roll. Mark this on the “Inspection

Form.‟

Check for skewing, bias, and bowing, compare this to the standards and

note findings on “Inspection Form”.

When inspection is completed do calculations on the „Inspection Form” to

determine the point count for each roll and whether or not it passes or is a

“second roll.” Make sure all „second rolls” are separated.

Calculate the percentage of the average point count for the shipment per

square yard. This will determine if the shipment passes or fails.

ACCEPTANCE CRITERIA

Example

Total yards inspected : 700 yards

Width of the fabric : 1.6 yards

Total points found : 300 points

i.e. 700 X 1.6 = 1120 Square yards

300 x 100 / 1120 sq yards = 26.78 points

Result : Pass


ACCEPTANCE POINT COUNT

The max defective points accepted are 28 points per 100 Sq yards.

The max defective 1 point accepted is 14 points per 100 Sq yard.

SHRINKAGE REPORTS

For washed products the factory should see that shrinkage is checked for a

minimum of 10% rolls per color for every shipment.

A test run must be made before starting bulk to ensure shrinkage control

techniques and patterns. Test run is the most important check point to verify if the

technique and patterns are all correct.

Fabrics with a spandex mixture in its composition have to be handled very

carefully due to high shrinkage variance between rolls.

If the noticed shrinkage variation is more than the garment tolerance then it is

recommended that 100% rolls get checked for shrinkage and factory makes

groups and different patterns for different groups.

It is always recommended to make a average pattern by considering only ½ the

tolerance give to the spec. for example if the hip tolerance is 1” you should only

consider ½” while making patterns for different shrinkages. Factory will have to

study the tolerances given in the spec for Bottoms and tops and decide

accordingly on the different patterns required

Factory will have to maintain a file on shrinkage reports. All shrinkage tests need

to be done on a minimum 50 cm x 50 cm square marking – factories have to make

a square marking template.

Factory will also have to mention the wash recipe and time used to dry the

garment in the shrinkage report file. The wash recipe and time that is once set;

can not be changed for the full program.


PRE PRODUCTION SIZE SET PROCEDURES

The factory will check if the shrinkage allowance that is added to the

pattern is good enough to start the test run.

Size sets have to be made for all colors and for all different shrinkage

groups.

The Pre production pattern has to be used as a base and if the shrinkage of

the bulk fabric matches with the shrinkage of the pattern used for the pp

sample then the same pattern has to be graded and used for bulk.

Any adjustments that are required to make different patterns for different

colors and shrinkage groups have to be made to the base pattern.

All the stitching details and techniques that factory is planning to use in

bulk must be check for accuracy.

The factory Quality manager and Quality Auditor will have to check the size

set and make a spec report of before wash and after wash to verify that the

shrinkage allowances that were added in the pattern is ok or needs to be

adjusted.

The before wash spec evaluation of the size set has to match with the

before wash spec with zero tolerance. If the before wash spec does not

match, the inspector will have to analyze and see if the error is in the

pattern or if the operators took wrong seam allowances while making the

sample. Factory will have to remake samples if the before wash spec

doesn’t match.

The Factory Quality manager will then write all the comments on one of the

sample and make it a production reference sample which will be hung on

the production floor.

The factory Quality manager and Quality auditor will have to make sure

that all patterns and templates are signed by the pattern master.

Shrinkage percentage has to be mentioned on all patterns for review.


PRE-PRODUCTION MEETING PROCEDURE

Required Attendees

1. Buyers Representatives (if required)

2. Production Director

3. Finishing Manager and Supervisors

4. Factory Quality Manager

5. Factory Quality Auditor

6. Factory Production Managers

7. Factory Pattern Master

8. Line supervisors

9. Store-in-charge

10. Maintenance-in-charge

OBJECTIVES OF PRE PRODUCTION MEETING

Review PID package and all information pertaining to the production

program.

Review all the machine and folder requirements to make sure that

factory is fully equipped to handle style.

Review an approved sample and all the specification will be

discussed and confirmed with everyone present in the meeting.

Review all critical process and measurement with allowances and

tolerance. It must be made sure that everyone present understands

and works accordingly.

Trims card test results for Fabric, Zipper, Button and Interlining etc.

will be shown and presented for understanding.

Review on the time and action plan to perform the order timely.

Plan all shipment and FRI inspection dates.

Review the preproduction sample with the factory production

sample.

Ensure all approvals are in place.

Factory will have to make an additional spec for all the

measurements that are not mentioned in the PID.


Factory will have to make a before wash spec for in line Quality

inspectors to measure and see that garments that come off line are

as per required. This will also be a check point to see if operators in

line are following proper seam allowances.

Review all the marking templates and techniques.

Factory advise on methods of construction, tolerances, production

lay out and techniques as applicable to the product.

Verification of all product test reports. MTL fabric, MTL Pre

Production.

Verification of all care instruction approvals

Review of the Floor ready spec.

Review all Fit and Pre production comments – so that all points are

clearly understood and taken care off.

Check the spec of any garment based on the how to measure

manual to make sure that the factory uses the correct measuring

method.

All concerned will be advised to co-operate for achieving smooth

execution of the production process as per the assigned target.

OTHER RESPONSIBILITIES

To make sure all technical issues that are production related are cleared

and understood.

To make sure all that is discussed and agreed on during the meeting is

followed in production.

To ensure that a test run performed prior to bulk production.

To ensure that a production sample is hung in the production floor with all

the comments and placements written.

To ensure that factory is maintaining the schedule and all that was

discussed is been followed. In case some changes need to be made,

approval was be taken from the Buyer first.

To ensure that all junior production staff are clear on the method of

measuring the garment.


PRODUCTION TEST RUN

OBJECTIVE OF TEST RUN

The test run is the most important check point in the full production

process.

The information gathered from the test run will verify that the techniques,

patterns, machinery and the systems are all ready for bulk production.

Factory can also make the necessary adjustments for issues that are found

in the test run so that they. can be avoided in the bulk production

The test run is a replica of bulk so every process and procedure should be

exactly as planned for bulk.

The test run will also give factory the final before wash spec that will be

used by all quality auditors.

TEST RUN PROCEDURE

Factory has to plan a cut of minimum 30 layers. It is very important that

factory takes every layer from different rolls.

The numbering has to be done from 1 to 30, Numbers have to be written or

labeled on the garment so that it can be identified after wash. This will help

in checking the shrinkage variations.

The cutting marker that factory will use for the test run has to be exactly

the same as what they will use in bulk production.

Garments have to be then produced in line using the same techniques as

bulk.

4 size sets will be then measured for before wash and the same garments

will be then checked after wash. Garments have to be numbered with a

water proof pen so as to check them against their respective before wash

measurements.

The size sets have to be specked after wash and after pressing.

The needle work, stitching techniques, sewing quality has to be scrutinized

and documented.

Garments will have to be then ironed and packed the same way as bulk

requirements.


OTHER RESPONSIBILITIES:

To follow the procedures as discussed in the Pre-Production meeting

To check the spec on 4 size sets before and after wash.

To check the spec on the size sets after pressing.

To finalize the before wash spec.

To approve the final pattern for bulk by adding the correct shrinkage.

To make a report on the packed pieces.

To make sure that all the issues noticed during production are corrected

and taken care of.

To finalize the method or procedure to make the product.

CUTTING PROCEDURE

All cutting machine operators must use metal hands gloves while cutting to

avoid cut injury on the finger.

All cutting department employees must use dust mask while cutting to

avoid breathing in cutting dust.

Before starting the size set cutting process, all reports and tests should be

completed on the fabric to be cut. The size set cutting process should be

based on the findings from these reports:

1. Fabric Inspection Report

2. Shrinkage Report

3. Blanket Report

4. Shade Band Report

To confirm the shading the fabric should be joined side to side, side to

middle and front to end and compared for color variation, if all is ok then

size set cutting process should proceed

Before and after wash swatch boards must be made for all approved fabric

swatches with all kinds of parts (body fabric, pocketing, binding, inside

w/band etc. These must be matched under buyer approved light box before

wash & after wash.


All lay/cuts must be inspected prior to cutting. The following points that will

need to be checked:

1. Marker Length

2. Marker Placement

3. Counts

4. Tension

5. Leaning

6. Ends

7. Splice

8. Fabric Flaws

Total defects found and action taken towards the defects will need to be

noted

After cutting the parts, they need to be checked with hard pattern to see if

there is any variation between the pattern and cut parts.

Nested pattern has to be kept ready before the pilot run cutting.

Cutting layer should be selected from one dye lot however if mixed dye lot

needs to be used then paper lay must be placed with correct identification

information between each dye lot.

Cutting table needs to be always clean. If there is any damage on the

tables, they need to be repaired immediately.

After cutting is complete parts numbering needs be 100 percent accurate

for all the cutting parts to avoid size and shading problem on the sewing

floor.

All cuts must be inspected prior to issue in the line. All cut parts (Top /

Middle and Bottom) must be inspected from each layer and recorded. This

record includes the name of the component inspected. Variation found

(Actual compared with paper pattern) and the action taken towards the

defects.

NEEDLE PROCEDURE

A) All the broken needle must be deposited before new needle issue to the

worker.


B) A written record must be maintained line wise what type of needle is

broken and who is depositing.

C) Broken parts must be found out from the machine area or garments. If

necessary hand needle detector or magnet might be used.

D) The broken needle with its part must be paste and preserved separately

in a needle log register.

E) All kids’ garments after preparation must be checked thoroughly in a

Needle Detector Machine for any unseen needle. If the parts are not

located in the garments/parts, it must be rejected and kept in a

quarantine box.

F) PM and compliance personnel should check the needle daily. So that

there is no anomaly in preserving the broken needle.

PRODUCTION PROCEDURE

All operators must use dust mask while operating the sewing machine.

Needle guards have to be fixed & needs to be checked before starting the

work.

Cutter, Scissors & Point pin have to attached to the machine with a

drawstring

Approved daily goal, swatch card and garment sample must be posted

before starting a new input or style.

S.P.I. needs to be checked everyday before starting the work.

Parts numbering must be matched and followed 100% during all relevant

processes.

Bundling system needs to be followed 100% cutting wise to avoid size

mistake and shading.

The Machine Mechanics must check all sewing machines before the start of

work for problems and record their finding in the inline machine

adjustment log.

All machine issues found must be fixed before starting work.

The operators have to check the needle point everyday by following the

needle points check procedure.

All mechanics, operators, supervisors and line chiefs must check to see if

the machine thread handling systems are clean and correct.


Before starting the production every operator has to clean their machine.

While sewing all operators must keep the stitch quality as per the buyers

requirement.

All factory PM, Line Chiefs, Supervisors and QA inspectors must maintain

production and quality goals discussed during PP meeting.

All operators must follow parts attaching mark and pay particular attention

to all difficult processes like pocket, flap, waist band & loop attachment as

per buyer requirement.

All production employees must maintain and follow the correct bundle

serial and numbering systems to avoid size mistake.

If any parts are rejected during sewing process, the particular part must be

replaced by selecting another piece from the same fabric roll to avoid any

kind of shading.

All mechanics must adjust the machine to control and minimize oil marks.

All employees must maintain cleanliness to control stains and dirty spots on

garments

No garments or parts can be kept on the floor and must be kept in the

assigned place.

SAMPLE LAYOUT

Actually, Sepal Group maintains all quality products in the world. Here, we have

described a layout for cargo short pant. The number of machines and other things

needed described on below-

Production target per hour 90pcs

PID# 222217

BELTED WALKING SHORT PANT

Machine name Type Number

1. Front rise O/L 3TH O/L 1

2.Front pocket piping P/M 1


3. Front pocket same +

tuck

P/M 2

4. White pocketing 5

thread

O/L 1

5. Zipper Joint P/M 1

6. S/Fly body attach +

D/Fly tuck

P/M 1

7. J/stitch P/M 1

8.R/part+D/Fly Joint P/M 1

9. Front rise Joint 1/32 +

top stitch ¼

P/M 2

10. Back rise 5th O/L 1

11. Back rise +side pocket

ruling

D/N 1

12. Back rise taken + top

stitch

P/M 3

13. White pocketing Joint P/M 1

14. Fashung 3 thread O/L 1

15. Bone Joint + Bone

make

P/M 3

16. White pocketing Joint P/M 2

17. Bone top stitch P/M 3

18. White pocketing top

stitch

P/M 3

19. Side Joint 5th O/L 1

20. side top stitch D/N 1


21. Side pocket making P/M 4

22. Side pocket Joint P/M 2

23. Belt tuck P/M 1

24. Pippen P/M 1

25. Belt make P/M 2

26. Belt Joint C/S 2

27. Label Joint P/M 1

28. Mouth close P/M 1

29.Belt loop stitch D/N 4

30.Inseam 5 thread O/L 1

31.Loop make & top

stitch

D/N 1

32.Loop joint & tuck P/M 4

33.Hem P/M 2

34.Bartake stitch B/M 1

35.Button hole stitch Button hole m/c 1

36.Button attaching Button attaching m/c 1

TOTAL 59

REQUIRED NO. OF M/C

M/C types No. of M/C

Plain Machine 42

Double Needle Machine 7


Chain stitch Machine 2

Over Lock Machine 6

Zigzag stitch m/c 2

Others 2

OPERATION SEQUENCE OF BOOT-CUT CHINO PANT

Back Part:

1. Back part marking at knee position.

2. Marking at bon-pocket position by means of hard pattern.

3. Fold and stitching at both side .

4. Pocketing fabric and back part joining.

5. Stitching at facing.

6. Back rise overlock ( 2 back parts joined).

7. Back rise top stitch.

8. Bon pocket top stitch (1st one)

9. Bon decoration stitch (2nd one)

10. Bon facing join (fusing side).

11. Bon top stitch (pocketing fabric is folded first, then stitched)

12. Facing join.

13. Stitching at three sides to make pocket.

14. Back pocket tuck

15. back part completed.

16. Inspection

Front Part:

1. Front part marking at knee position.

2. Front rise overlock.

3. Double fly.

4. Front part + zipper joined.

5. Marking and stitching at fly piece.

6. Double fly join (zipper’s face side).

7. Thigh part top stitch.


8. Bon marking.

9. Another pocketing fabric joining.

10. Joining front bon.

11. Bon hole is made/cut manually.

12. Ironing.

13. Bon pocket top stitch.

14. Decoration stitch.

15. Pocketing fabric joining by stitching.

16. Coin pocket stitching at 3 sides.

17. Pocket facing attaching with pocketing fabric.

18. 2nd facing attaching with pocketing fabric.

19. Marking at pocketing fabric.

20. Front pocket joining.

21. Front pocket top stitch.

22. Joining with marked line.

23. Pocket making by tucking.

24. Stitching at lower part.

25. Front part completed.

26. Inspection.

Assembly (joining front & back part) :

1. Matching the serial number of front & back part.

2. In-seam making (overlock).

3. Top stitch by Feed of the Arm m/c.

4. Hemming formed by ironing.

5. Side overlock at one side.

6. Side overlock at the other side.

7. Inspection of in-seam & side seam.

Fusing at waist band joining :

1. Fusing for belt are joined.

2. Piping joining with fusing fabric.

3. Take another blue color fabric , folding with help of folder and then

stitching.

4. Fusing fabric with piping and belt fabric.

5. Top seam applied.


6. Marking for pocket.

7. Marking at both sides to equal pocket.

8. Belt joining.

9. Pocket joining.

10. Label joining.

11. Mouth tongue joining.

12. Cutting at mouth tongue.

13. Inspection.

14. Ironing at belt.

15. False stitch applied to prevent slipping.

16. Top stitch for belt.

17. Opening false stitch.

18. Inspection

19. Marking for loop.

20. 1st loop attaching at lower position.

21. Folding top loop stitch.

22. Bottom hem made.

23. Final inspection.

24. Bar tack stitching.

25. Bar tack stitching at belt.

26. Bar tack stitching at pocket.

27. Back pocket hole and front pocket hole made.

28. Inspection.

Production rate : 110 pieces / hour.

PACKING PROCEDURE / POLICY

1) To check and confirm the carton size, dimension, volume and printed

stickers as per buyer requirement.

2) To check the cartons weight and quality before putting poly packed

garments into the cartons.

3) To check poly size, quality & weight and printed information before packing.

4) To confirm the pressing quality and folding before putting inside the poly.

5) To confirm the assortment ratio and pieces.

6) Stack the cartons size wise in the carton area separately.


PRE FINAL AUDIT PROCEDURE (FINISHING)

Pre final audit will be done by the factory QA when 10%, 50%, 70% goods are packed. The audit procedure has to be just like the daily pre-final audit done by the factory packing department QC. 1. The cartons that will be pulled for inspection have to be taken from the total

cartons packed at that time.

2. The QA report will have to be shown to the Buyer’s GQC when they come for their regular audits.

3. If goods fail the QA audit, then factory will have to re-check and after all issues are corrected the goods will be offered to the Buyer for their regular audit.

4. The factory QA will select the cartons that are packed at random based on the square root of the total. (The audit will be done as per AQL 2.5).

WASHING PROCEDURES IN WASHING UNIT

Factory QA Manager will receive approved wash standard from

merchandisers for hand feel, shade and grinding.

Factory QA Manager will ask for wash recipe from the washing plant.

Factory QA Manager will provide approved wash standard to the washing

plant.

Factory QA Manager will provide approved wash standard to the

production / QA file.

Factory QA Manager will provide approved wash standard to the wash

quality auditor / checker.

QA Manager will check pre-wash spec against each & every dye lot prior to

sending for washing. All pre-wash garments should be stored in a particular

place.

All subcontract inventory control reports must be maintained in a register.

All washed garments must be stored in a particular place.

All washed garments spec must be checked and verified for hand feel,

shade and grinding against each and every dye lot prior to sending for bulk

thread trimming.


All wash damaged garments must be stored in a particular area by

maintaining proper a record.

DAILY PRODUCTION REPORT:

Daily production capacity of Creative garments ltd.

Cutting capacity = 6000 pc

Sewing capacity = 4000 pc

Laundry capacity = 30000 pc

Production line = 5

Production capacity of a line per hour: Per hour a production line can produce 80-

100 pc of garments. Thus per hour creative garment ltd. can produce up to five

hundreds pc garment. In this factory there are eight working hour in a day. Hence

the total production of a day is 3200 to 4000 pc. Sometimes more working hour is

needed which are considered as over time to maintain the production rate in

time.

Note: Here we also added some daily production report.

MONTHLY AVERAGE PRODUCTION

Monthly production of this factory is about 87500 pc.

MONTHLY EFFICIENCY

Daily optimum production = 4000 pc

Daily actual production = 3200 pc

Daily efficiency = 3200/4000*100%

= 80%

Monthly optimum production = 100000 pc

Monthly actual production = 87500 pc

Monthly efficiency = 87500/100000*100%

= 87%


REMARKS

Garment production is a very complex work to do because of it needs a huge

number of machineries and large man power system as well. To maintain

production rate with in shipment time is very important and it is difficult as well.

We worked hard to know the whole procedure of a production process. We have

collected all the documents are needed to run a production. Some of them we

have attached. We have tried our best to collect them. We are grateful to our

supervising teacher Mr. Julian for his help while collecting these data.




Chapter 6

Inspection and audit

CONTENTS

Quality Audit

Audit Procedure

DUPRO Audit

Final Inspection

Remarks


INTRODUCTION

Quality audits are performed to verify conformance to standards through review

of objective evidence. A system of quality audits may verify the effectiveness of a

quality management system. This is part of certifications such as ISO 9001. Quality

audits are essential to verify the existence of objective evidence showing

conformance to required processes, to assess how successfully processes have

been implemented, for judging the effectiveness of achieving any defined target

levels, providing evidence concerning reduction and elimination of problem areas

and are a hands-on management tool for achieving continual improvement in an

organization.

To benefit the organization, quality auditing should not only report non-

conformances and corrective actions but also highlight areas of good practice and

provide evidence of conformance. In this way, other departments may share

information and amend their working practices as a result, also enhancing

continual improvement.

COMPARING FIRST PRODUCTION UNIT TO THE CLIENT’S APPROVED

SAMPLE

The QC department along with the production team must follow the

procedures mentioned below while comparing first production unit to the

clients approved sample:

The QA manager / Line QC will randomly select and pull the first produced

garments from the output table and summon all the relevant production

employees along with PM to the inspection room for a meeting

The approved client sample has to be compared with the first produced

units by the QA manager

The first units should be checked and verified according to clients

specifications

Accurate measurements should be taken

Trim attachment and positions should also be checked and noted

Construction with all critical processes should also be checked and

compared

http://en.wikipedia.org/wiki/ISO_9001


If any non conformity is found, these are identified per Buyers Defect

Classification List and shown to the production personnel for rectification

The defects should be discussed and their causes identified and explained

to the production personnel

A corrective action plan should be formulated to avoid the same issues

again

All points should be documented and acknowledged by all present

Records must be retained for future reference.

OPERATOR WISE IN-PROCESS AUDIT PROCEDURE

In line quality inspectors have to check every operator at-least twice a day

especially for critical sewing work. The Quality inspectors will pick a bundle that is

complete and pull out 7 pieces at random. If they find any defect then the

inspection fails. The inspector records the details which will include the operator

name, operation, number of pieces inspected, number of defect found, the DPCI

number and action taken towards the defects. Steps to be followed in case of a

failed bundle inspection:

All the pieces of the rejected bundle have to be checked for defects by the

operator and fixed before they proceed with the next bundle. At this stage

the inspector will have to attach a red ticket to the bundle and also attach a

red flag to identify the machine and operator for possible quality problems.

The corrected bundle has to be then rechecked by the line supervisor to

make sure all defects are fixed before the operator is allowed to proceed

with the next bundle.

The very next bundle of that operation will have to be also inspected for

defects. If no defects are found the operator can then proceed with the

third bundle. If the bundle gets rejected then the operator will have to

recheck all pieces and alter all the defects. The corrected bundle will have

to be re-inspected by the line supervisor to make sure all defects are fixed

before the operator can proceed with the next bundle.

The third bundle will also be audited and if passed then the flag will be

taken of and the operator can proceed with the operation. If this bundle

gets rejected then the operator will be stopped from resuming production


and sent for re-training. The factory manager will have to be notified and

he will have to sign on the quality form related to that quality operator. The

factory manager will have to approve the return of the operator after the

training is complete.

Note: The Factory manager and the Production team have to analyze all defects

that are found at the red flag area. The machinery and tools used by the operator

will also have to be checked for improper setting and defects. If the problem is

with the machinery and tools then necessary action has to be taken to correct the

issue.

PROCESS END TABLE DEFECT TALLY AUDIT PROCEDURE

A defect tally must be maintained for every line. It is very important that the

managers analyze the defects and makes sure that the total defects found per

operation decrease as the days pass by. The defect tally must have the following

information:

a) Operation type

b) Defect type

c) Hourly tally DPCI number

d) Day’s total defects

e) Previous day’s total

f) Corrective action taken

Before wash spec on critical positions has to be checked on 100% garments with a

template that is fixed on the checking table. The defected garments have to be

recorded on an hourly basis. The production team has to analyses all defected

garment for spec to see if operators take in the proper seam allowance while

stitching. Tolerance of not more than ¼” has to be given to spec before wash

garments.

All reports have to be signed and analyzed by the quality auditors, line supervisors

and the production manager. Defects that do not show any improvements and


appear on a daily basis will have to be checked 100 % in line in front of the sewing

machines that produces that particular operation.

Offline DUPRO audit and before-wash spec check procedure

The audit must be done on the out put from each sewing line as per AQL 2.5 for

workmanship and AQL 4 for Fit. The quality inspector must base the sampling plan

based on the days out put per line. The process will be similar as the DUPRO

inspection and form used will be Form # 6. All defects will be identified by DPCI

number and a defect trend will be analyzed with the factory production team.

Before wash spec has to be checked every day and attached to every audit report.

Four pieces per size is the minimum one should check. Factory will have to wash

the pieces that were measured and re check if they are ok to spec after wash and

after ironing. Tolerance of not more than ¼” has to be given to the before wash

spec and only at some of the spec points. If the before wash spec fails then the

immediate conclusion has to be that the operators are either taking a wrong seam

allowance or cutting extra at the marrow stitch . Early detection of this problem

will help in solving spec issues.

Inline DUPRO Audit Procedure

Factory QA will have to do a DUPRO audit when the factory has completed 10%,

30%, 50% and 90% of production. The factory QA will select pieces from all the

lines at random. The Factory QA will also use Form Ref # 6 to do his inspection.

The specifications that will be checked during these audits have to cover all sizes

and a minimum of 4 pieces per size. The Factory QA will also have to get all pieces

measured, washed and then rechecked both before and after ironing. All

measurements have to be checked in details during this audit. All defects will be

identified by DPCI number and defect trends will be analyzed with the factory

production team. The process for DUPRO Audit is as follows:

The Inspector has to first decide on the sample selection based on the

factory’s daily output.

The pieces have to be selected at random from all lines.

Only garments that have passed the output check will be selected for the

audit.


AQL 1.5 STD has to be used to evaluate whether goods passed or failed for

workmanship and AQL 4.

Defects have to be identified by using DPCI number and a defects trend will

have to be made while analyzing the report.

Defect classification code will have to be used for specifying every defect.

Every defect in the garment will be recorded on the report but only one

garment will be counted for major and minor defect evaluation.

A defect trend will be made and analyzed with the factory production team.

The inspector has to make sure that all defects that are found are attended

to inline so that the root cause of the problem is solved immediately.

The pre-wash specs have to be checked on 4 pieces per size – the garments

have to be measured to the specs with a tolerance of ¼ inches. If the

measurements are out of tolerance, the production team will have to see

that all operations are re-checked to verify if the operators are taking

excess seam allowance (excess seam allowances and cutting at the narrow

seams will cause the spec on the garments to differ from the before wash

specs).

DUPRO Audit Procedures before Pre-Final Audit

Factory QA will have to do a DUPRO audit. When the factory has completed

10% - 30% and 50% goods are packed. The audit procedures have to be

same as the pre-final audit done by the factory QA and they are as follows:

The cartons that will be pulled for the inspection have to be taken from the

total cartons packed at that time.

All the information gathered during inspection will have to be kept in a

DUPRO report.

The report will have to shown to the Buyer’s GQC when they come for their

regular audits.

If goods fail the audit then factory will have to re-check and offer the

factory QA for re-audit after all issues have been fixed.

The factory QA should only select cartons that are packed at random based

on the square root of the total. (The audit will be done as per AQL 2.5)


Final Table Checker Defect Tally Procedure

The final checkers will have to maintain a defect tally list – Form Ref # 7 for

analyzing the defects and to make sure the specific defects found on the finished

product are controlled and proper action is taken. The defects have to be totaled

on a daily basis and proper steps have to be taken by the factory managers to

make sure that all issue are controlled in the process. NOTE – Factories have to

make a defect trend history style wise to keep in records and records have to be

analyzed often with the factory manager so that factory can make improvements

in systems and procedures to get better in future orders.

Table Specs Check Procedure

Factory has to make a template and fix it on the table for checkers to check the

critical specs on 100% garments. Defected garments for spec have to be recorded

on an hourly basis.

Daily Pre-final Audit Procedure

Pre final audits have to be done on a daily basis using form Ref# 8. Goods that fail

the audit have to be rechecked the following day. All inspections have to be done

based on AQL 2.5 for workmanship. The cartons that will be pulled by the

inspectors have to be signed and pulled at random to get a proper statistics on the

goods. The Square root method will be used to select the quantity of cartons that

need to be pulled for every inspection. All inspection reports should have a

measurement spec report done based of AQL 4. The factory has to see that a

minimum of 4 pieces per size per color is taken for a spec audit.

FRI (Final Random Inspection) Procedures

The final inspection will be done by the factory QA based on the form Ref # 9. The

audit will be done only when 80% - 100% of the cartons are packed. The final

inspections will be based on AQL 2.5 for workmanship and AQL 4 for spec (fit

audit). The number of cartons to be selected will be based on the square root

system. The QA will have to check the spec on a minimum of 4 pieces per size.

Goods that fail the audit will have to be rechecked and corrected before offering


the buyer to perform their final inspection. The inspector should make sure that

he has the following before the starting of the audit:

Buyer’s Standard Inspection Package

Red tag Sample

Inspection Forms.

AQL Chart.

Wash /shade band approved samples.

Packing List.

MTL/CTL test passing reports.

Note: Shipment will not be released with out the required passing test reports.

The audit can be started when 80% goods are packed provided the balance

20% gets packed while the inspection is in process. The balance 20% then

has to be inspected at the end of the audit.

The inspector has to then decide on the sample size for the workmanship

audit based on the shipment quantity as per the AQL 2.5

(MIL-150E Single Sampling plan Level 2.)

The quantity of cartons that need to be pulled will be based on the square

root rule.

The Fit evaluation has to be done based on AQL 4 (MIL – 150 E Single

Sampling plan level 2). At least 4 pieces per size need to be measured.

The cartons have to be stacked properly in rows of equal height and should

be easily accessible. The carton quantity has to be verified first based on

the packing list.

The cartons that are selected for the audit have to be signed by the auditor

and accompanied to the inspection room.

The size and color ratio, shading in carton size and printing and paper trims

have to be compared with approved samples and the placement has to be

checked as per floor ready specs. Packing and folding instructions also have

to be verified as per the floor ready specs.

All finished pieces have to be stacked size-wise. Inspectors have to then

check for care instruction, size on all labels and hangtags.

Inspectors will pick two pieces at a time and pair the waist together to

check if it matches. This will ensure a 100% check on all size label mistakes.


Garments have to be checked inside out. Zippers and buttons have to be

checked for functionality

FABRIC & TRIMS INSPECTION AND STORAGE PROCEDURE

The approved swatch card has to be collected from the merchandising

department and kept in the store.

All trims must have bin cards affixed on top of the rack where they are

stored and they must be stored color and size wise.

10 % percent of all trims must be checked and findings noted in a trims

report. Only 1 percent defect is a acceptable rate. The trims report has to

be affixed on the bin card.

Any one of Hang Tags may be checked from each bundle using a bar code

machine and a printed copy must be retained.

All trims have to be checked using a UL3000 light source.

All rejected trims must be kept in the reject room and disposed of following

the buyers recommended disposal process

All excess trims must be accounted for and stored in a secure place and a

record must be kept for reference until further notice from the buyer.

Fabrics have to be kept on pallets.

The bin card must be attached to fabric rolls dye lot wise

Shrinkage and Fabric Inspection Report should be on the bin card.

All fabrics must be issued shade-wise for cutting.

All rejected fabric must be placed in the reject room and disposed per

buyers disposal process

All access fabric must be accounted for and stored in a secure place.

Records must be retained for reference until further notice from buyer.

Note: Please see the fabric inspection procedure for fabric inspection process.


Target Defect classification list

Fabric

Defect Code Description Classification

F001 Holes where the yarn is cut, broken ends, drop stitch that runs major F002 Vertical or horizontal lines permanently knit or finished into fabric (i.e. needle lines, compactor creases, barre, light/heavy ends). Visible at arms length major F003 Soil, oil spots with contrast visible at arm's length, adversely affecting appearance major F004 Not cut on grain line as specified affecting appearance or shrinkage major F005 Significant snags and/or slubs distinguishable when viewed at arm's length, adversely affecting appearance major F006 Knitted in, off color fly visible at arm's length major F007 Misweaves, mispicks (wovens) major F008 Washing/Dyeing Defects (streaks, uneven dyeing) major F009 Shaded parts/thread and/or visible components, adversely affecting appearance major F010 Printing defects: Wrong, missing or incomplete coverage of color, misregistered, over 1/16" major F011 Poor hand feel of product - not as specified major F012 Knit/Woven structure not to standard minor F013 Product (including all items in selling unit) not visually matching Archroma standard or approved shadeband major F014 Conspicuous pilling; not to agreed upon standard major F015 Mismatched stripe/plaid: side seam 1/8”-1/4” minor F016 Skewed, bowed or biased fabric, solid or stripe over 1/2" side to side for softlines; over 3% side to side for soft home major F017 Conspicuous repair (this covers knits and wovens) major F018 Mismatched stripe/plaid: side seam over 1/4”, pocket over 1/8”


Components and Trim

Defect Code Description Classification

C001 Unapproved components or trim added or substituted affecting performance (Bias cut binding vs. warp cut; incorrect interlining etc.) major C002 Any specified trim or component missing, damaged, or not operational as intended. (Snaps won't snap, zipper won't zip or slider won't lock, fusible not bonded as per manufacturers instructions) major C004 Rivet, snap, clasp, grommet, or any closure device which is defective, damaged, incorrectly placed or attached which is likely to cause damage to wearer or property major C005 Buttons omitted, broken, damaged, defective or inverted; buttons that do not confirm to specification; misaligned or improperly spaced buttons major C006 Fusible interfacing must be compatible to garment without bubble or pucker; in a lined garment, the liner must not extend below hem or the shell major C007 Zippers: any malfunction; tape shade that does not closely match color specified; tape stitched too loose or tight resulting in excessive bulge on tape or placket when closed; exposed zippers that detract from appearance of garment; exposed edges of zipper tapes that would scratch or irritate wearer's skin; zipper not placed high enough in placket causing gap to top edge; aluminum zippers should not be used; zipper size and length should be appropriate to garment end use or as specified major C008 Hook and Eyes: Omitted or sewn in wrong places; hook and eyes misaligned when fastened causing bulge or twist as the point of closure; all metal parts must be rustproof, washable, dry cleanable, and attached securely; size appropriate to location and specification major C009 Belt color not as specified; width of belt out of specification in excess of 1/4"; eyelets out of alignment in excess of 1/4"; number of eyelets not as specified; end of belt not shaped according to spec; irregular belt width in excess of 1/4"; top stitching of belt is uneven or crooked; belt loop size not appropriate to belt width, missing or insecure loops; belt length must be appropriate to garment size; middle eyelet is not standard fit; any metal parts rusted or oxidized major


CHAPTER 7

QUALITY ASSUARANCE SYSTEM

Contents

Quality assurance system

Procedure

List of machineries

Quality report


INTRODUCTION

Quality assurance system

Introduction: Now a day’s quality makes a product perfect. In textile sector quality

is very necessary in every step of textile processing assurance of quality level is

important. In garments industry keeps a good quality all time.

Quality of garment means a garment free from all kind of defects such as oil spot,

uneven sewing, Raw edge, frying, defect frees accessories etc. Measurement of

quality is done in industry in two ways. One is testing and another is inspection. In

SEPAL GROUP inspection is mainly done. Testing procedure is done by APPEXFAIR

BUYING HOUSE.

Quality assurance procedure

To assure a good quality it is very vast job .Spreading, cutting, sewing, finishing in

every where producer has to maintain and check the garments quality.

FEBRIC TESTING

At first the quality of fabric should be checked. If there found any kind of defect

such as hole, knot, spot etc upper than limit then fabric is rejected. Here use 4

point system to detect fabric quality.

By 4 point system we find the number of defective points of 1oo yds fabric. It is

done by the use of fabric spreading machine. it has a chart. According to this chart

with mathematical calculation we find fabric defects.

firstly fabric is spreading on machine surface and then the defect is counting per

100 yds of a roll. the chart is given below

THE LENGTH OF DEFECT IN WARP AND

WEFT DIRECTION

POINT

Beyond 3 inch 1

3 inch-6 inch 2

6 inch-9 inch 3


Above 9 inch 4

FOR HOLE & OPENING

1 inch or low 2

Getter than 1 inch 4

After detect fault need of calculation. the theory is given bellow:

points/100yds=total defect pt/total fabric length in yds*100-1*36 inch/width of

fabric

The limitation of defective point is done by buyer will.

BLANKET: to detect shade of color this experiment is done. Shade testing is also

done by the use of LIGHT BOX machine. Here 6 types of ray is used to differentiate

shade as buyers rule.

DURING SPREADING

The rules are given below:

1. Check that the marker is placed on the spread with the edge parallel to

selvedge to the placed goods variety that all cut peaces will be

completed.

2. We check all shedding unless ply marked

3. Check for table marks as the table is marked allows no minus tolerance

for the splices .

4. We have to ensure no marker is creased damage.

5. After compilation of spread we check the splices to see that both plies

extend past the marked splice lie between 0.5 inch to 1 inch.

6. After complete we check the fur edge of the spread to see that all plies

are extended beyond marker line.

7. Then we check the tension and count.

8. At last we keep marking the roll which is necessary when reject part is

replaced.


DURING CUTTING

The process is given below:

1. We check the miscut

2. We check the top middle & bottom ply compare those to a hard pattern

comparison with a hard patterns best tolerance +0.5 inch to -0.5 inch.

3. we check the notch location by placing the pattern over the top ply

tolerance +1/8 to – 1/8 inch.

4. To compare the marker to pattern paper to ensure .

DURING SEWING

It’s very crucial time for quality control. There is lot of inspection done in this

section. Before sewing need fusing. Here we check bonding strength. Then it’s

come to sew Inline 7 pcs inspection is the most important inspection. It is invented

by a USA buyer MR.JESSYPENY. Here we take 7 pcs garments from bundle of 20

pcs and then check and alter the defective parts.

Needle point check up is done daily by one kind of hand shocks. To have uniform

tension we daily check machine.

Daily goal report is one kind of audit or calculation to reach the goal with quality.

We always check the stitch condition. Specially backrise, outseam, inseam, front

fly, etc. We make a report to see that. This is called SPI(stitch per inch) report.

ALTERATION REPORT is one kind of table inspection. It is expressed as time

duration.

Defect tally is another kind of quality assurance procedure. Here we must check

back part, front part, waist band, side seam etc.

DURING FINISHING:

There are different lay out for different garment .Finishing layout also depend on

buyer. Quality assurance system in finishing is given below

a. Remove or cut extra thread

b. Inside check

c. Thread from garments surface is being slashed with the help of

slashing machine.


d. Inside ironing

e. Final inside quality check

f. Outside qualities check.

g. Top side ironing.

h. Measurement.

i. Final quality check.

j. Thread & lint cleaning area(if required)

If we get any spot we send it to spot removing lab. By the help of spot removing

gun or chemical treatment we remove the spot. At last we make a bundle called

blister.

In case of shirt or trouser we check button strength by button pulling test. Those

are all the procedure of quality assurance system.

LIST OF MACHINARIES

1. Atom hydraulic cutting press Secom platting machine

2. Thread slashed machine.

3. Needle detector machine

4. Spot remover gun.

5. Button pull test machine.

6. Fabric shrinkage test machine


IMAGES OF SOME QUALITY CONTROL EQUIPMENTS


SEPAL GARMENTS LTD QC SYSTEMQC SYSTEM FLOW CHART


PICTURES SOME DEFECTS


CHAPTER 8

Maintenance

Contents

Manpower set up

Procedure

Tools

Oiling


INTRODUCTION

Maintenance of machinery

Maintenance of machineries is very important in Garments industry. Because m/c

is subjected deterioration due to their use. If that remains unchanged then

everything will be standstill. So m/c is checked by routine. In SEPAL GROUP

machineries are checked on the routine.

Manpower set up

In SEPAL GROUP it has 4-5 line men who are set for machine control. They work

under a mechanical in charge. There are one mechanic and one electrician.

MAINTANANCE PROCEDURE

The procedure of SEPAL GROUP is given below:

1. Every machine must have two types record.

#Preventive Maintenance Record

#Daily Check List

2. Preventive maintenance records card should be hanged on the machine.

3. Everyday mechanic has to check the machine through the daily check list’

4. If found any problem in the machine, the operator must hang a red flag to the &

to the

Machine & mechanic must fix the problem.

5. The in charge must maintain the machinery per the manufacturer guideline

following all safety

& health condition.

6. The mechanic must ensure that the all necessaries equipments of machine

work of correct

Setting and has to adjust any equipment if required.


7. If any fault found the responsible person must put down the machine in

breakdown status.

8. After repairing the machine should check for safety run.

9. All records must be updated with the necessary information

PREVENTIVE MAINTENANCE PROCEDURE FOR PRESSING

1. Service all the pressing machine monthly to keep the pressing machine un-

interrupted.

2. Steam lines and pressure should be proper.

3. The next servicing / maintenance date should be mentioned.

4. Pressing table should also be checked and charge the cloths on the table.

5. Vacuum pressure should be controlled and adjusted.

6. Preventive maintenance card should be hanged beside the machine.

TOOLS

The tools which are used to maintain machinery are

1. nut

2. screwdriver

3. hammer etc

OILING

It is one kind of maintenance. Oiling is done regularly on machine.


SAMPLE CHARTS FOR MAINTENENCE



CHAPTER 9

Utility Services

Contents

Utility facilities available

Capacity & other technical details

Source of utility

Cost of different utilities

Remarks


INTRODUCTION

Utility means service that will provide different facilities or advantage for the

factory or mandatory one. In the every factory utilities service is not available and

production capacity also depends on that service. The utilities service of sepal

Group is available and they don’t have any lack of gas, generator system and other

Facilities.

We have seen all the utility section of Sepal Group and tried our best to collect the

necessary document and information. Though it is a huge building the control

management is very good.

MAIN UTILITIES FACILITY

Boiler

Generator

Water pumps

Electricity control room

Fire defense facility

ETP

BOILER

The m/c which generates steam and supply to the all necessary activities to the

factory is termed as boiler.

Object of boiler

1. To produce steam according the requirement.

2. To supply steam and boil water.

3. It mainly supply steam to the washing m/c and ironing m/c.


No. of boiler

There is only one boiler in the sepal group.

Capacity of the boiler:

Capacity - 2400kg.

Steam hour delivery – 2400kg.

It is run by gas or electricity.

Company

The company name : KAMINS.

Origin : U.K

Different chemical used for boiler running

The entire chemical collected from the local market.

Management system of boiler:

1. One supervisor officer.

2. One boiler in charge and two electricians are working in the area.

Chemical name amount use

Doggy chemical (soluble) 250gm/8hr to lessen water hardness

Auto scaling (NaOH) 1200gm/day -

NaCl 25kg/48hr To remove carbonate.


GENERATOR

The m/c which converts the mechanical power to electronic power is generator.

Object of generator

To generate electricity by using fuel such as oil, gas etc.

No. of generator

There are two generators in this group.

Company of those generators

1) KAMINS – U.K

2) CATER PILER – U.K.

Capacity, load and fuel required to the generator

Capacity

1. 930 KVA

2. 500 KVA

Load

1. 600 A

2. 510 A

Fuel

Generators are run by diesel in Sepal Group.

1. 90 L per hour

2. 35 L per hour


MANAGEMENT SYSTEM OF THOSE GENERATORS

Supervisor officer: E.M Francis Gomege.

Electrician: 3 people.

Operator: 2person/shift.

ETP

ETP means effluent treatment plant all the effluent or wastage /usage water reach

to the ETP plant and there the chemical water is treated by various chemical and

than supply to drain by removing wasteful / hazardous chemical from water. it is

suited at below the ground floor.

PROCESSING OF WATER TREATMENT IN ETP:

At first water come from the washing, dying and other machineries reaches to the

collection tank and then treated water tank. In the treated water tank, there is a

net which hinders to reach powder from chemical to go to the equalization tank.

From the equalization tank the water are collected to the mixing tank. in the

mixing tank ,there is wheel driven by motor. The wheel helps to isolate chemical

and water. then all the wastage and chemical which are harmful for environment

is collected from the mixing tank and there those are neutralized that are not

harmful for environment but the water from mixing tank are reached to the

foliation tank and there poly electrolyte and a lam are mixed that remove the

harmful chemical from water and then goes to sludge tank and the filter press

tank. After all the process the water is dispatched to the environment from the

fresh water tank.

CHEMICAL USED IN ETP PLANT

Chemical name amount Source

Poly electrolyte 1 kg/day China

Alum 18 kg/day China


COST OF THOSE CHEMICAL

Poly electrolyte: 380 taka/kg.

Alum: 36 taka/kg.

MANAGEMENT SYSTEM OF ETP

One supervisor: Mr. Pannu.

Operator: 3 people.

And other technicians and helper are about 5 person.

TOTAL COST FOR ETP PLANT SET UP

Approximately the cost of ETP plant set up is 1 core 60 lack taka.

PUMP

The m/c which collects water from source is called pump. There are three pumps

in the base ground of this factory.

Capacity of the pump

1.) 85 H.P

2.) 40 H.P

3.) 20 H.P

Management system for those pumps

Six operators are working for those pumps.2 people / shift.


ELECTRICITY

Electricity is not available all the time. So they use gas and generator. The

electricity bill of sepal group is about 14 lack /month.

REMARKS

Those all the utilities are mandatory for a factory. To run a factory these utilities

play an important role. Moreover productivity of a factory is depending on it very

much. We have observed the total utility service is available here. It was not a

easy work to do but since the staffs were very helpful so it became easier to us to

collect information.

The ETP section is situated at the basement floor and we have collected a lay out

plan of this which was attached with the assignment file. We are thankful to our

supervising teacher Mr. Julian for his help while collecting these data.




CHAPTER 10

Store & Inventory Control

CONTENTS

Inventory system of raw material

Different inventory cost

Spares

Finished Goods

Others

Remarks


INTRODUCTION

There are four garment in the sepal group they are sepal, orchid, creative and

glory. The entire floor is same area. But in one floor there are different section

such as store, cutting swing, washing and finishing section. All the section is

involved with different working.

AREA AND OBJECTIVE OF THE STORE ROOM

We know that there are four factories in sepal group. Their store room is also in

the individual floor and all the store room is same. Now we are describing about

one store room. The area of store room of sepal is 500sq foot.

The main objects of store room are following

I. To keep the material imported from foreign or local market.

II. To install the accessories from local or foreign market.

III. To remain different spare parts of different machine.

IV. To hang swatch board / term board on the wall.

V. To maintain a fixed relative humidity e.g. 76

THE TEST AND PROCESS OF STORE ROOM

Mainly the fabric is imported as lot and in one lot there are 100 or 120 yards of

fabric. When fabric is needed in the letting see lion then taken from the store

room.

TESTING SYSTEM OF STORE ROOM

There are different testing and inspection system in the store room.

1. 4 point system

2. 7 pious inspection system

3. 10 inspection system and

4. Other different inspection system such as shrinkage, strength,

elasticity and the evenness of the fabric.


There is also a machine in the store room which name is fabric spreading and

quality checking m/c. By this m/c the length, width and shade of the fabric are

checked.

MANAGEMENT SYSTEM OF THE STORE ROOM

In every store room there is well arranged management system. In each store

room there are

1. one supervisor officer and

2. twelve workers

3. one stone in charge

4. two guards

THE WORK OF THE STUFF

The supervisor officer receives all the fabric and accessories from the local or

foreign market according to production director officer and supply the fabric and

accessories to the other section according to requirement. The store in charge

handles the worker to manage the test and other inspection. The workers look

after the store room.

INVENTORY CONTROL

Inventory in a widen sense is defined as any idle resource of in enterprise in order

to meet expects of demand or distribution. It is commonly used to indicate

materials, raw materials, finished, packing and stocked products. It is basically

necessary to keep hold inventory of various kinds to act as a cushion bet supply

and demand. It is almost necessary to maintain same inventory for the smooth

functioning of an organization.

CAUSES OF MAINTAINING INVENTORY CONTROL

1. It takes time to complete one operation and more products from

one store to another

2. To run manufacturing operation economically.


3. To take care of uncertainties like uncertainties in demands from

customers and uncertainties in producing the materials in time.

4. To reduce the critical cost and to take advantage of discounts and

transportation.

FUNCTION OF INVENTORY CONTROL

1. To develop policies, plans and standard to achieve inventory control

objectives.

2. to build up a logical and workable plan for doing job satisfactorily

3. to provide necessary physical facilities

4. to develop methods that will bring desire result economically

5. To maintain overall control by checking result and adopting

corrective actions.

TYPES OF INVENTORIES

Inventions is following 5 categories

Production invention: It means which to inter the final products e.g. raw

materials.

In process inventories: Semi finished products at various stage of production.

Finished goods inventories: Compel products ready for dispatch.

Maintenance repair and operating: Though those are not form a part of final

product they are used in production process like spare parts.

Miscellaneous inventories: They are spare and obsolete item which are not to be

disposed off.


OBJECTIVES OF INVENTORY CONTROL

Financial objectives

Here the goal is to keep inventory cost within limit of funds available and the

position of its working capital.

Property protection objectives:

a) To safe an important asset against theft, waste and measurable

damage.

b) To make certain that the value of this asset is correct stated in the

company s book.

Operating objectives

To obtain the best overall balance bet products and inventory caring cost on one

hand and customer service to others.

Advantage of inventory control

A well planed and property administered system of inventory control will bring

rise to the following benefits.

a. Improvement of customer’s frictions: This is achieved through maintenance

of better balance among the quantities of finished items on hands.

b. Improvement of labor and community relations.

c. Increase in the effectiveness of key personnel’s:

d. Reduction in manufacturing cost:

e. Strengthens financial position: This is achieved by onward inventory

controls.


Different inventory cost

The important step in the inventory analysis is the identification. The following

classes of cost are usually involved in inventory control / decision.

1. Cost of ordering

2. Inventory costing cost

3. Colt of shortage

Now they are described below.

Cost of ordering:

Out of many other costs the order cost of inventory is the most difficult cost to

measure precisely. Placing of order is just one of the many other activities of

purchasing. So it is difficult to isolate and identify the cost of the cost of ordering

and measure them precisely.

There are two types of cost of ordering:

A. fixed

B. variable

Cost per order= Total cost in running purchasing dept/Total no. of order during

the year.

Inventory caring cost:

Inventory caring cost is also known as holding cost.

a. Cost that depends on quality of inventory: This cost includes.

1. Cost of storage space – light, rent maintenance etc.

2. Cost of hold stock e.g.: Pilferage spoils age, deterioration and protection.

b. Cost that depends on the value of inventory:


1. Cost of capital, inter of cost.

2. Cost of insurance.

Cost of shortage:

When a demand arises and the item needed is not in stock then it is the

Cost of shortage of stock out of cost.

In the back order case there are two types of costs.

External Internal

-Loss of good will -over time

-Loss of future sales. - Special ad minis dative efforts

Spares:

Basically spares are the machine parts that are kept in the store room from the

different sewing and after m/c and made the reusable.

Now different spares are followings:

1. folder

2. guide 1/4 CR

3. guide 1/4 CL

4. guide 1/16CR

5. guide 1/16 CL

6. guide 3/16 CR

7. guide zipper

8. guide hanger

9. guide hamming

10. guide plain feet

11. guide gathering

12. guide CT

13. guide magnet

14. guide vertical


15. guide thread

16. guide hook

17. guide piping

18. p/m bobbin

19. p/m needle plate

20. p/m rotary hook

21. p/m back stitch

22. p/m feed dog

23. p/m 60’’poly

24. p/m magnet screw

25. p/m thread stand

26. p/m tension spring

27. p/m needle bar cap

28. p/m pressure nut

29. p/m guide CR

30. o/l knife set

31. o/l upper holder set

32. o/l upper lopper

33. o/l lower lopper

34. o/l lower knife

Finished goods:

The term finished goods means the products that are ready for export. In the

sepal garment different types of garment are made for export such us.


CHAPTER 11

Marketing Activities

Contents

Marketing service

Marketing plane & strategy

Consumer of the product

Product level

Package size & local level market

Importing countries

Man power

Duties & responsibilities of marketing officer

Remarks


INTRODUCTION

Marketing is an integrated communications-based process through which

individuals and communities are informed or persuaded that existing and newly-

identified needs and wants may be satisfied by the products and services of

others.

Marketing is used to create the customer, to keep the customer and to satisfy the

customer. With the customer as the focus of its activities, it can be concluded that

Marketing is one of the premier components of Business Management - the other

being Operations (or Production).

The term marketing concept pertains to the fundamental premise of modern

marketing. This concept proposes that in order to satisfy its organizational

objectives, an organization should anticipate the needs and wants of consumers

and satisfy these more effectively than competitors

MAIN BUYER

MARKETING SERVICE

Marketing is a social and managerial process by which individuals and groups

obtain what they need and want through creating and exchanging value with each


others. Actually, the process by which companies create value for customers and

build strong customer relationship in order to capture value from customers in

return.

In Sepal group, Marketing is a special branch of the garments sector. We have

mentioned earlier that Sepal group consists of four garments factory under one

roof so they have a strong marketing department. They need a lot of raw

materials to purchase as well as they need to convince buyers to sell their

product. So the marketing department should be strong and skillful as well. In

Sepal group some raw materials are collected from local market and rest are

imported from abroad. It is easy to say that buying them from this country or

abroad is not a easy work to do. That is why here marketing accumulation is

broadly opened. We have observed the account office and the marketing

department and collected some invoice. We were also introduced with some

marketing officer. They helped us by giving us information and documents.

MARKETING PROCESS

The marketing concept of building an organization around the profitable

satisfaction of customer needs has helped firms to achieve success in high-growth,

moderately competitive markets. However, to be successful in markets in which

economic growth has leveled and in which there exist many competitors who

follow the marketing concept, a well-developed marketing strategy is required.

Such a strategy considers a portfolio of products and takes into account the

anticipated moves of competitors in the market.

For marketers planning is an essential task that must be continually undertaken.

As we will see, shifting market conditions, including changing customer needs and

competitive threats, almost always insure that what worked in the past will not

work in the future, thus requiring revisions in how a product is marketed.

Marketing planning is also important since it is often a prerequisite for obtaining

funding whether one is a marketer in a large corporation seeking additional

money for his or her department or is part of a small startup company looking for

initial funding.


To aid in our understanding of planning we introduce a key concept in marketing:

the Product Life Cycle. We will see the Product Life Cycle offers valuable insight

and guidance for marketing decisions. In this tutorial we also discuss different

types of marketing strategy that can be followed to meet marketing objectives.

Additionally, we look at how innovative products are adopted within a market and

how this impacts marketing planning.

We can describe the objectives also in following steps:

For creating value for customers and building customer relationship.

Understand the marketplace and customers needs and wants.

Construct a customer driven marketing strategy.

Design a marketing program that delivers supplier value.

Build profitable relationship and create customer delight.

Capture value from customer in return.

In our word we can say simply at first a marketing officer has to understand

customers need wants and demands. In Sepal group the needs are identified at

the states of left deprivation. Then the wants are calculated by the form needs

take as shaped by buyer and individual personality. The demand is however wants

that are backed by buying power.

MARKETING STRATEGY

There is a sequence of marketing strategies like following

Undifferentiated (mass) marketing

Differentiated (segmented) marketing

Concentrated marketing

Micro marketing (local or individual marketing )

In Sepal Group they have much extra ordinary marketing strategy. We were trying

to understand that clearly but could not understand thoroughly. We have

described below what we have understand.

They have segmented the marketing field in five ways:

On the basis of benefit


On the basis of behaviors

On the basis of occasion

On the basis of user status

On the basis of loyalty status

CONSUMER OF THE PRODUCT

Marketing occurs when people decide to satisfy needs and wants through

exchange relationship. Exchange is the act of obtaining a desired object from

someone by offering something in return.

As we have mentioned earlier that Sepal Group is a 100% export oriented garment

company so the consumers and the customers are the foreigner normally.

America and Canada is the main consumer of the product. Moreover Germany,

Hong Kong, Thailand, France, South Africa, Norway, Switzerland etc. are the main

consumer of the product.

Stores & Importers of Sepal Group:

Stores-U.S.A market: Importers- U.S.A market:

THE GAP * KIDS INTERNATIONALS

J.C PENNY * WORLD WIDE APPARELS

WALMART * RADIX APPARELS

K-MART * S.J TRADING

CHADWICKS OF BOSTON * FRANK & JANE LLC

TARGET * MILLENIUM CLOTHING

SEARS and many more.

PRODUCT LEVEL

Market consists of buyers and buyers can differ in one or more ways. They may

differ in theirs wants, resources, location, buying attitudes and buying practices.


Sepal group divides large heterogeneous market into smaller segment that can be

reached more

Efficiently and effectively with products and services that match their unique

needs. In Sepal group, there are three levels of product

1. Core benefit product

2. Actual product

3. Argumentum product

PACKAGE SIZE

Packaging refers to the development of a container and a graphic design for a

product. Packaging can make a product easier to use safer and more versatile.

Packaging can make an affect on consumers’ altitude toward a product, which in

turn affect their purchase decisions.

In Sepal group packaging serves a number of purposes. It protects the product and

maintains its functional form. All the products in here are packaging with the

recommendation of buyers. So that here present package who consider the

promotional role of packaging using verbal and non verbal symbols which contains

the product content, features, uses, advantages and hazards etc.

LEVEL LOCAL MARKET

We know that all the finished goods are prepared in here for exporting in the

foreign countries. For that leveling local market is not sufficiently necessary in

Sepal group.

IMPORTING COUNTRIES

The main importing countries of Sepal group are America and Canada. They bring

their most raw material, accessories and other trimmings from there. Besides this

the maximum machines have been bought from China, Japan and Hong Kong.


Some are also been bought from Korea and Malaysia. The sewing machines in

here are imported from Japan and China from Brothers companies. In washing

unit boiler has been imported from China. There two generators in Sepal group

which are imported from U.K.

MANPOWER

The whole marketing department of Sepal Group works under the supervision of

merchandising department. A number of marketing officer are worked under the

G.M of the company. There worked in different section. As it’s an export oriented

garment factory the merchandisers are always busy to get an order from abroad.

Sometimes they do some sub contacted order. Most of marketing officer are

doing the purchasing job in here. They buy the accessories and trimmings from

here. There is also a custom department here for doing the activities related to

shipment such as loading and unloading. They keep contact and make reasonable

bargaining with the transport company.

DUTY AND RESPONSIBILITIES OF A MARKETING OFFICER

A marketing officer directs firm's overall marketing and strategic planning

programs, and corporate communications. Facilitate client development through

marketing and client services programs.

1. Design, implement, and facilitate annual marketing plan for the firm.

Support and facilitate development and implementation of section

business/marketing plans.

2. Plan and administer the firm's Marketing Operations budget; support

development of regional marketing budgets.

3. Oversee the Charitable Contributions Foundation.

4. Organize and implement client relations including:


· client satisfaction surveys

· client development activities

· client skills training

· special events

5. Supervise firm's RFP protocol process including soliciting RFPs from

desirable prospective clients and writing proposals for new business;

participate in planning and presentation sessions, when assigned.

6. Oversee business development activities including:

· efforts through Business Development Coordinator

· assisting attorneys in strategic planning for client presentations, beauty

· contests, etc.

· offer coaching for prospective client meetings, presentations, etc.

· work with regional offices on designing and implementing prospecting and

client contact systems.

7. Oversee corporate communications activities through Communications

Coordinator including:

· external communications and systems

· internal communications and systems

· public relations efforts

· external vendors and consultants

8. Develop and administer marketing database which includes client and prospect

information, mailing list applications, access to financial reports, etc.

9. Assist with and support firm's involvement in various legal networks including

coordinating business development and marketing activities via these

relationships.

10. Design and plan quarterly marketing training seminars for attorneys.

11. Oversee firm's electronic marketing efforts including supervision of Web site

design and maintenance.


12. Supervise Marketing Assistant, Client Services Administrator, Communications

Manager, Practice Development Manager and Regional Marketing Manager(s).

Make staffing and hiring decisions within marketing department

REMARKS

In this sense, a firm's marketing department is often seen as of prime importance

within the functional level of an organization. Information from an organization's

marketing department would be used to guide the actions of other department's

within the firm. As an example, a marketing department could ascertain (via

marketing research) that consumers desired a new type of product, or a new

usage for an existing product. With this in mind, the marketing department would

inform the R&D department to create a prototype of a product/service based on

consumers' new desires.

The production department would then start to manufacture the product, while

the marketing department would focus on the promotion, distribution, pricing,

etc. of the product. Additionally, a firm's finance department would be consulted,

with respect to securing appropriate funding for the development, production and

promotion of the product.

Inter-departmental conflicts may occur, should a firm adhere to the marketing

orientation. Production may oppose the installation, support and servicing of new

capital stock, which may be needed to manufacture a new product. Finance may

oppose the required capital expenditure, since it could undermine a healthy cash

flow for the organization.

In Sepal Group all this criteria are maintained so they have good marketing

department. Every person of this department works as a team member that helps

to reach the goal of the company.


CHAPTER 12

Washing Plant

Content

Washing

Dry Wash

Wet Wash

Wahing Machines

Washing procedure

Remarks


INTRODUCTION

Denim washing

Denim washing is the aesthetic finish given to the denim fabric to enhance the

appeal and to provide strength.

Dry denim, as opposed to washed denim, is a denim fabric that is not washed

after being dyed during its production.

Much of the appeal of dry denim lies in the fact that with time the fabric will fade

in a manner similar to that which artificially distressed denim attempts to

replicate. With dry denim, however, such fading is affected by the body of the

person who wears the jeans and the activities of their daily life. This creates what

many feel to be a more natural, unique look than pre-distressed denim.

Types of denim washes

1. Mechanical washes

- Stone wash

- Micro sanding

2. Chemical washes

- Denim bleaching

- Enzyme wash

- Acid wash

Again, denim washes are of 2 types depending on the presence of water or not:

1. Wet wash

-Normal wash

-Pigment wash

-Caustic wash

-Silicon wash

-Super white wash

-Enzyme wash

-Bleach wash

-Stone wash


2. Dry wash

-Sand Blasting

-PP spray

-Grinding

-Whiskering

-Tagging

-Hand scraping

DIFFERENT TYPE WASH EFFECT

ADDRESSES

Sepal Washing Plant


Dhaka, Bangladesh

Tel: 88-02-9898248, 9898005-117

Fax: 88-02-8823026

e-Mail: [email protected]



FLOOR MEASUREMENT

Total floor measurement of the factory is

11,000 sq.ft

Total floor measurement of the company’s

office is 1,000 sq.ft

MACHINE DESCRIPTION

Production Machines : 11 (Eleven) (Golden Resources, hong Kong) 550 Lbs

Each.

Sample Machines : 3 (Three). (Golden Resources, hong Kong). 110 Lbs

Each.

Dryers : 15 (Fifteen) ( 7 Steam + 8 Gas)

Extractors : 3 (Three). (Golden Resources, Hong Kong).

Sand Blast Machines : 6 (Six) .

Generators : 2 (Two) (1 Diesel 930 KVA + 1 Diesel 400 KVA)

Boiler : 1 (One) 2.40 Tones.

Transports : 3 (Three)

PRODUCTION CAPACITY

Wet processing (Based on 60-minute stonewash / day) 15000 pcs

Garment dying (based on medium shade in direct process type) 7500 pcs

Dry processing (based on standard specialty) 5500 pcs

MAN POWER MANAGEMENT

Employees : 153 (One Hundred & Fifty-three)


Dry Process Manager 1

Dry Process Operator 28

Dry Process Supervisors 2


Wet Process Manager 1

Wet Process Operator 14

Wet Process Supervisor 6

Dying Supervisor 2

Dye Lab Technicians 1

Dye Manager/Master 1

Development Operation Supervisors 2

Q.A./Process Control Operators 5

Staff 3

Other Workers 87

Major Items

Trouser, Pant, Dress, Bermuda, Skirt, Vest, Jacket, Blazer, Shorts, Overall,

Shortfall etc.

Working Roster

Number of shifts in operation 3 (Three)

Number of Hours (per shift) 8 (Eight)

Work Schedule- days per week 6 (Six)

Washing Procedures in Washing Unit

Factory QA Manager will receive approved wash standard from

merchandisers for hand feel, shade and grinding.

Factory QA Manager will ask for wash recipe from the washing plant.

Factory QA Manager will provide approved wash standard to the washing

plant.

Factory QA Manager will provide approved wash standard to the

production / QA file.


Factory QA Manager will provide approved wash standard to the wash

quality auditor / checker.

QA Manager will check pre-wash spec against each & every dye lot prior to

sending for washing.

All pre-wash garments should be stored in a particular place.

All subcontract inventory control reports must be maintained in a register.

All washed garments must be stored in a particular place.

All washed garments spec must be checked and verified for hand feel,

shade and grinding against each and every dye lot prior to sending for bulk

thread trimming.

All wash damaged garments must be stored in a particular area by

maintaining proper a record.

CHEMIMICAL USED IN WASHING PLANT

Name of chemical Origin Price (approximate)

Soda Ash Forester 32tk /kg

Caustic Soda Forester

Detergent Local market

Anti stain ECHOCHAME(India)

Enzyme 10 L Forester 25kg/gallon 410tk

Acetic acid Local market

Phosphoric acid Local market

Hypo Local market

Ozone softener GDS (India)

Pocket clear GDS (India) & Forester 140 tk/kg

Global salt Local market

Jet Powder Local market

Brightener Local market

Meta ACE chemical 38 tk/kg

Hydrogen per oxide Local market

Texanish-SF ECHOCHAME(India)

Silicon C-150 ECOSIL WS-150 (India) 40kg/gallon 410tk

Rotto SL GDS (India) 40kg/gallon 410tk

Enzyme 50L GDS (India) 40kg/gallon 410tk


Enzyme 20L GDS (India) 40kg/gallon 410tk

Enzyme BIO GDS (India) 40kg/gallon 410tk

Polish GDS (India) 40kg/gallon 410tk

Yellow Tenon GDS (India) 40kg/gallon 410tk

Wetting agent Local market

LAY OUT OF WASHING PLANT


WASHING PROCESS OF SAMPLE WASHING

LIQUID ENZYME WASH (WITH STONE)

Sample : 2 pieces of legs of denim pant.

Step 1 : Desizing

Recipe:

Water : 100 L

Desizing agent (desizing enzyme) : 50 gm

Anti-back staining agent : 20 gm

Temperature : 600C

Time : 15 min.

Process:

1. Put sample inside washing m/c.

2. Add water

3. Run the machine.

4. Add Desizing agent.

5. Add Anti-back staining agent.

6. Run m/c for 15 minutes with 60 .C temperature.

7. Rinse twice with 150 L water.

8. Stop m/c.

Step 2 : Enzyme wash

Recipe:

Pumice stone : 2 kg

Water : 60 L

Enzyme (enzyme-200) : 50 gm

Anti-back staining agent : 20 gm

Acetic Acid : 20 gm

Temperature : 450C

Time : 30 min.


Process:

1. Add pumice stone.

2. Add water

3. Run the machine.

4. Add enzyme.

5. Add Anti-back staining agent.

6. Add acetic Acid.

7. Run m/c for 30 minutes with 450C temperature.


9. Stop m/c.

Step 3 : Neutralizing Step

Recipe:

Water : 100 L

Soda Ash : 20 gm

Temperature : 45 .C

Time : 3 min.

Process:

1. Add water

2. Run the machine.

3. Run m/c for 3 minutes with 450C temperature.


5. Stop m/c.

Step 4 : Hydro-extracting

Load sample in Hydro-extractor and run the m/c for 60 seconds.

Step 5 : Drying

Load sample in Gas Dryer and run the m/c for 30 to 40 minutes at 70 to 80 .C

temperature.

Step 6 : Quality Checking.


Washing recipe and process sequence of Denim trouser. (enzyme + bleach wash)

Batch size: 90 pcs( 85 kg)

Step one: Desizing

caustic-500 g

Wetting agent-300 ml

Temperature -40 c

Time- 15 min

Water level-900L

Wash

Step two: Enzyme wash

Enzyme SL-500 ml

Pocket clear-200 ml

Acetic acid-300 ml

Temperature – 45 c

Time -60 min

Water level-700L

Wash

Step three: Neutral Wash

Soda ash- 200g

DP-7 -100ml

Temperature- 45 c

Time -60 min

Water level-700L

Wash

Step four: Bleach wash

Bleach – KCL-5kg

Bleach DANA-600g

Soda Ash- 200g

Temperature- 60c

Time -15min

Water level-700L


Wash

Step Five: Neutral Wash

Hydrogen per oxide-1L

Soda ash- 200g

DP-7-100ml

Caustic -100g

BT Red-100ml

Temperature- 50c

Time -15min

Water level-700L

Wash

Step six: Dyeing

Color –GTL -400g

Color Red BWS- .20% owf

Temperature- 40c

Time -2 min

Water level-400L

Wash

Step seven: softener

B. Red- 10g

Softener 3g

Acetic acid 100ml

Temperature- 40 c

Time -6min

Water level-500L

Wash

Step eight : Hydro Extractor

Step nine : Dryer

Step ten : Quality check.


MACHINERIES OF WASHING UNIT




CONCLUSION

The course industrial training gives us first opportunity to work into mills during

our four year course in textile technology. We are very much fortune that we get

the chance to do our industrial attachment sepal group of garments.

Sepal group is one of the leading ventures in the garments industry operating

from Dhaka, Bangladesh. Being a 100% export oriented industry we are approved

by the board of investment of Bangladesh and having their own garment

manufacturing and washing unit all under one roof. The commencement of


many folds as it has always maintained quality and punctuality.

In 1986, the year of establishment of sepal groups the picture was not alike as

present. At first sepal garments was started with some simple plain sewing

machines and with a few operator and one supervisor .In that time garments

factory was not familiar in this city.

Sepal group is one of the leading export oriented garments manufacturer in our

country. It is also developing its knit and dyeing factory. Overall we want to say

Sepal Garments and all other four garments factories of sepal group is technology

base modern garments.

We wish that the company will continue our national economy more effectively

and this practical knowledge we have achieved during this training period will be

helpful for us in our future life.

Documents

Sepal Dairy Correction