Industrial Attachment of Norban Comtex Ltd.

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INDUSTRIAL TRAINING

Course Code: Tex -4036

Industrial Attachment MENT

NORBAN COMTEX LTD.

Prepared & Submitted By

Supervising faculty:

Adnan Zaber Mahmud Lecturer,

Department of Textile engineering,

Southeast University

NAME ID BATCH GROUP

001 Md. Faridul Islam Rumman 2012000400116 19TH

GMT

02 MD. Abul Hasan Rasel 2012000400139 19TH

GMT

03 Masrura Mahmud 2012000400135 19TH

GMT

Submission Date: 06 January 2016

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Letter of Transmittal

Prof. Syed Fakhrul Hassan Chairman,

Department of Textile Engineering


Subject: Submission of the “Industrial attachment Report”.

Dear Sir,

We are pleased to submit our “Industrial attachment Report” This is submitted under the

Program of B.Sc. in Textile Engineering in Southeast University.

The Report has been completed in accordance with the knowledge that we have gather

During our Industrial Training in “ NORBAN COMTEX LTD”. and the guidelines received

from our honorable teachers and

Our group members.

We tried to make this Report is to give a clear picture on Fabric Manufacturing Technology,

Wet processing Technology & Garments Manufacturing Technology practically used on

Norban Comtex Ltd... However, we will always be ready to provide any further clarification that

You may require.

Yours Sincerely,

NAME ID BATCH GROUP

001 Md. Faridul Islam Rumman 2012000400116 19TH

GMT

02 MD. Abul Hasan Rasel 2012000400139 19TH

GMT

03 Masrura Mahmud 2012000400135 19TH

GMT

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Department of Textile Engineering

Supervising Faculty’s Approval

…………………………………………………

Supervisor:

Adnan Zaber Mahmud Lecturer,

Department of Textile engineering,


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Acknowledgement

At first my gratefulness goes to almighty Allah, the creator of the universe, the most powerful,

the most Merciful and the Sustainer of the world for giving me the strength and capability to

complete this project.

Now, I would like to thank a lot of people who helped and supported me during the completion

of this report.

Adnan Zaber Mahmud, Lecturer, Dept. of Textile Engineering, my supervisor, to whom I

am extremely indebted for his tremendous support and guidance throughout internship.

I also like to thank Md. Minhaz Ahmed, Lecturer, and Dept. of Textile Engineering who

helped me very much. He guided me very well during my internship. Being working with him I

have not only earned valuable knowledge but was also inspired by his innovativeness which has

helped enrich my experience to a greater extent. His ideas and way of working were truly

remarkable.

We should like thank the management of Norban Comtex Ltd, for giving us opportunity to do

the industrial training successfully and also their valuable suggestions.

I would like to thank Md. Jamal Uddin Ahmed, A.G.M (Knitting) at Norban Comtex Ltd.

for arranging my internship.

Our heartiest thank to MD. Mostofa Ahmed Manager (Merchandising) Norban Comtex Ltd,

who supervised us & all production officers in all section for their information and cooperation.

We are graceful to all other Sr.Executive of different departments for assisting us to gather

information about various process and term.

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Table of content

Serial Title Page no.

Chapter 01:Company Profile

01 Introduction 7

1.1 At a Glance 8

1.2 Factory Information 9

1.3 Vision & Mission 10

1.4 Items of Product & Customer 11

1.5 Factory Location 12

1.6 Meaning and consequences for Norban Comtex Ltd 13

Chapter 02: Man Power Management

2.1 Human Resource Department 14

2.2 Responsibility 15

Chapter 03: Machine Description

3.1 knitting Section 17

3.2 Dyeing Section 20

3.3 Garments Section 24

Chapter 04: Raw materials

4.1 Different types of raw materials 28

4.2 Different types of yarn 28

4.3 Name of Chemical and Auxiliaries 29

4.4 Accessories List 30

Chapter 05: Production Planning, Sequence & Operations

5.1 Production Planning 31

5.2 Garments Production Processes 31

5.3 Step Wise Flow Chart 34

5.4 Production parameter 40

5.5 Production Calculation 40

Chapter 06: Quality Assurance System

6.1 Quality Assurance System 42

6.2 Faults Found in QC Department 43

6.3 Online quality control 44

6.4 Offline quality control 46

Chapter 07: Maintenance

7.1 Objective of maintenance 47

7.2 Types of maintenance 48

7.3 Maintenance procedure 49

7.4 Preventive maintenance (sewing) 49

7.5 Advantage of maintenance 50

7.6 Maintenance tools and their equipment 51

Chapter 08: Compliance & Utility Service

8.1 Compliance 53

8.2 Utility 55

Chapter 09: Store & Inventory Control

9.1 Classification of Store Section 56

9.2 Description of storage 56

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Table of content

Serial Title Page no.

Chapter 09: Store & Inventory Control

9.3 Inventory system for raw material 57

9.4 Gray fabric store 57

9.5 Dyes and chemical store 57

9.6 Accessories store 58

9.7 Engineering store 59

Chapter 10: Cost Analysis

10.1 Consumption Formula of Knitted fabric 60

10.2 Types of carton 62

10.3 Button Liner 63

10.4 CBM 64

Chapter 11: Marketing Activities

Manpower 65

11.1 Buyer and Exporting Country 62

11.2 Marketing strategy 66

11.3 Product label 66

11.4 Duties & Responsibilities of Marketing Officer 66

Chapter 12: Conclusion

12.1 Conclusion 67

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CHAPTER-1

1. INTRODUCTION

Practical knowledge is very much essential for the education of textile engineering and

technology. Practical knowledge makes us capable and perfect to apply theoretical knowledge in

practical life.

The Textile Sector has the capability to offer a complete product range for the export textile

markets. The goal of the Textile Sector is to become the preferred partner for sourcing high

quality fabrics and clothing from Bangladesh. With highly advanced technology and an

emphasis on developing local human resources.

That is why B.Sc. in textile technology course is extruded over four years followed by two

mounts industrial training in mills. It is attached to our study curriculum to achieve adequate

practical knowledge and develop adoption power with industrial environment.

We preferred this attachment in NORBAN COMTEX LTD. which is a 100% export

oriented composite Knit dyeing industry. It is fully approved by several multinational

inspections.

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1.1 AT A GLANCE:

Name of Company : NORBAN COMTEX LTD.

Address : Mouza Sarabo, Kashimpur Union,

Gazipur, Bangladesh.

Corporate Office : House # 8/B, Road # 1, Gulshan-1,

Dhaka, Bangladesh

Tel: +88(0)2 8833413-20,

Fax: +88(0)2 8833423,

Email : [email protected]

mailto:[email protected]

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1.2Factory information

Nature of business : 100% Export Oriented Knitted Textiles, Garments &

Printing Factories.

Name of the contact persons : Mr. Wahidul Haque Siddique

Chairman / Managing Director

Norban Comtex Ltd.

Total employees : Male: 650, Female: 584

Total: 1234

Number of machine : Sewing: 300, Kniting: 20, Dyeing: 18

Garments production capacity: Knitting Capacity 6,000 kgs per day

Dying/ finishing capacity 15,000 kgs per day

Item of Product: 50,000 pcs per day.

Floor Space : 426,500 Sq. Feet (39,623.3 Sq. meters).

Name of the Bank : Brac Bangla Bank

Legal Form of Company : Private Limited Company.

Year of Incorporation : 2007

Project cost : 250 cores

Main Production : Basic T-Shirt, Tank top, Long Sleeve- Shirt, Polo Shirt, Shorts,

Ladies & Kids Knitwear & all kinds of knit garments & Knit fabrics.

Minimum Age of Worker : Minimum 18 years

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1.3 Vision & Mission of Norban comtex Ltd.

Mission:

At Norban Comtex Ltd, we strive to provide world class service and the best value to our

customers. We thrive for excellence and work for ensuring a pleasant, clean and professional

working condition for our employees and the people we do business with

Vision:

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Gain market leadership in high value added apparel in USA & Europe.

Use “Innovation” and “Speed” as prime drivers, rather than cotton & cheap labor.

Dominate these market in high quality

Men’s T-shit & polo shirt

Ladies item

Kids wear

1.4 Item of Product:

1.5 Our Present Customers

C&A

PRIMARK

MGB

CENTERLINE

KITARO

DEBENHAMS

NCL

Area of Manufacturing Type of Manufacturing

Children

Wear Ladies

Wear Men’s Wear

T-shirt

Polo shirt

Sweat

Jacket

Tank Top

Men’s Underwear

Leggings

Others on specific demand

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1.6Factory Location:

SEU

Campus

W

S Nabisco

Savar

Abdullah Pur

Bai pail

Maymansing

Road

DEPZ DEPZ

SFMMC NCL

chokroborti

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1.7 Meaning and consequences for Norban Comtex Ltd:

•We will follow this way stringently with all of our business partners.

•We will have an open communication policy with all stakeholders on that.

•We will develop our supply chain along that way.

•Our complete team, workers and staff will be permanently trained to fulfil our requirements.

•Our requirements will be written in our “sustainability policy”.

Norban`s “Go Green“philosophy:

•Creation of closed loops for all materials

•Waste becomes resource

•Non-bio-degradable waste leads to up-cycling

•Complete usage of renewable energies

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CHAPTER-2

2. COMPOANY ORGANOGRAM

2.1 Human Resource Department

Human resource is a term with which many organizations describe the combination of

traditionally administrative personnel functions with performance management, Employee

Relations and resource planning. The objective of Human Resources is to maximize the return

on investment from the organization's human capital and minimize financial risk. It is the

responsibility of human resource managers to conduct these activities in an effective, legal, fair,

and consistent manner.

Human Resource department (HRD) practices Human Resource Management in an organization

(HRM). This is the strategic and coherent approach to the management of an organization's most

valued assets - the people working there who individually and collectively contribute to the

achievement of the objectives of the business. The terms "human resource management" and

"human resources" (HR) have largely replaced the term "personnel management" as a

description of the processes involved in managing people in organizations. Human Resource

management is evolving rapidly. Human resource management is both an academic theory and a

http://en.wikipedia.org/wiki/Resource_%28economics%29

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business practice that addresses the theoretical and practical techniques of managing a

workforce.

The basic concept that HRD practices is that humans are not machines; therefore we need to

have an interdisciplinary examination of people in the workplace. Fields such as psychology,

industrial engineering, industrial and organizational psychology, industrial relations, sociology,

and critical theories: postmodernism, post-structuralism play a major role.

Human resources management comprises several processes. Together they are supposed to

achieve the above mentioned goal. These processes can be performed in an HR department, but

some tasks can also be outsourced or performed by line-managers or other departments.

Workforce planning,

Recruitment,

Induction and Orientation,

Skills management,

Training and development,

Personnel administration,

Compensation in wage or salary,

Time management,

Employee benefits administration,

Personnel cost planning,

Performance appraisal etc.

2.2 Responsibility:

Responsibility of Production officer

To make the programmed card according to daily production plan.

Prepare sewing lines of floor & report to A.G.M. in three time everyday

Receives cutting fabrics according style, color and size form cutting section.

To check the layout of garments.

Maintain floor discipline & cleanness.

Any other works as & when required by the management.

http://en.wiktionary.org/wiki/induction

http://en.wiktionary.org/wiki/orientation

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

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

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

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

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

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

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

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Responsibility of Production Manager

To the programmed card according to daily production plan.

Cutting check and proper installation of cutting fabric for sewing.

Control of supervisor, operator, asst. operator &helper of garments floor.

To match different part of garments according to approve sample.

To find out sewing fault as early as possible.

To rectify the finished garments this rejected from quality control department.

Remarks:

The manpower management system of this factory is well arranged. Every officers &

stuffs are responsible for their duty. But there are some textile engineers in the industry

for Garments and Merchandising. It is prevent for fluent production. The efficiency of

the worker should be increased for more quality production.

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CHAPTER -3 3. Different section and Machine Description

3.1 KNITTING SECTION

Figure: Knitting section of Norban Comtex Ltd

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MACHINE DESCRIPTION OF CIRCULAR KNITTING SECTION

Circular Knitting Machine: 17

Flat knitting: 16

Total no of M/C: 33

Machine No. Specification Capacity Brand

Brand

Circular Auto striper-

01 DIA- 34X24/28G Auto Striper Single Jersey 120 Kg/Day PAILUNG PAILUNG





Circular Knitting- 01 DIA- 42X18/24G (1X1 RIB) 350 Kg/Day LISKEY LISKY






Circular Knitting- 07 DIA- 36X24G Single Jersey 300 Kg/Day LISKEY LISKY






Circular Knitting- 07 DIA- 36X18/20/24/28G Single Jersey 300 Kg/Day LISKEY LISKY




Circular Knitting- 11 DIA- 36X18/20/24/28G Fleece/Heavy Jersey 350 Kg/Day LISKEY LISKY







Flat Knitting- 01 Flat Collar/Cuff, Bed- 72 Inch, 14 G 300/600 Pcs LISKEY


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Fig. s/j knitting m/c

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3.2 DYEING SECTION

FIGURE: DYEING SECTION OF NORBAN COMTEX LTD

MACHINE DESCRIPTION OF DYEING SECTION:

Machine N0. Specification Capacity Brand Origin

Dyeing-01 Innoecology HT1 XC1 200 Kg Brazzoli Italy

Dyeing-02 Innoflow HT1 XC2 250 Kg Brazzoli Italy







Dyeing -09 Dynamica EF-1XJ HT 200 Kg MCS Italy

Dyeing -10 Dynamica EF-1XJ HT 200 Kg MCS Italy

Sp Dyeing-11 Overflow MOD HT-50 50 Kg Brazzoli Italy

Sp Dyeing-12 Aquarius Dyeing

Machine

50 Kg Brazzoli Italy

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Sp Dyeing-13 Aquarius Dyeing

Machine


Sp Dyeing-14 Overflow Dyeing

Machine MOD MBC-

50



Machine MOD RCL-

25



Machine MOD MBC-

25


Turning-01 Fabric Reversing

Machine

10000 Kg Beneks Turkey

Auto Dyes

and Chemical

Dissolving

System

Dyestuff check and

weighting system,

Dissolving System,

Chemical reserving and

auto dispensing

3GDOS/

Brazzoli

Italy

Different type of dyeing machine:

Fig. Dyeing M/c

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Fig. Stenter & Compactor M/C

Slitter Machine

Slitter machine is used for tubular knit fabric to make it in open form. In open form fabric

finishing line; slitter machine is used after hydro-extractor, de-watering and drying machine.

Slitting is a process that is applied for cutting the tubular fabric through the intended break

Wales line on lengthwise direction prior to stenter processing. During slitting, it is required to be

aware about the cutting line otherwise, fabric faults can be occurred there.

Figure: Slitter machine.

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Fabric Finishing Machineries Details:

Machine N0. Specification Brand

Stenter-01 Flat Stenter IC-10 of 8

Chamber for Drying and Heat

setting

Icomatex, Spain

Dryer-01 Santex Dryer Type, 5

Chamber

Santex/DIPL-Ing.

Stephan Heinrich-,

Switzerland

Compector-01 Revolution 2500 with 9.7 M

Tender/Equalizer Model E-

2500

Ferraro, Italy

Compector-02 Decatizing

Calender/Compacting

Machine, Model CUD/FV

1500, Working width 1.35 M

(Tubular)

Ferraro, Italy

High speed Brush sueding

Machine

Model: Lisa 4 Knit Plus(open

width and tubular processing)

Mario Crosta, Italy

High speed Double Drum

Raising machine

Model MC20/24 GF knit open

tub(open width and tubular

processing)

Mario Crosta, Italy

Slitting-01 Superslit Slitting Line 2400

MM

Corino, Italy

Squeezer-01 Tubular Spreading and double

ballooning with double

stretcher

Bianco, Italy

Back Sewing-01 Edge Sewing Machine Beneks, Turkey

Tumble Dryer-01 GDP-150 Drying Machine Guangzhou Panyu






Hydro Extract -01 KZ-125 Kg Dewater Machine Guangzhou Panyu

Hydro Extract -02 KZ-125 Kg Dewater Machine Guangzhou Panyu

Inspection Machine-01 Tensionless Inspection

machine with metering system

Hsing Cheng

Inspection Machine-02 Tubular Fabric Inspection

machine

Hsing Cheng

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3.3 Garments Section:

Different types of sewing machine:

Straight knife cutting machine

Machine name : K.M company cloth cutting m/c

Model : K.M KS_AUV

Producer : made by K.M cutting m/c co, JAPAN

Type : Heavy duty industrial cloth cutting m/c self-sharpening

Dimension : 8 inch width * 11 inch length * 24 inch height

Weight : 33.5 lbs.

Current : A.C (3.3/2.6 amps)

Speeds : 3000/3600 r.p.m

Figure: Straight knife cutting machine

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Sewing Machines:

Plain Machine

The S-1110A (Replaces: model SL1110) is Brother's new standard industrial high speed single

needle lockstitch sewing machine.

S-1110A-3 single needle straight stitch flatbed lockstitch machine for light to medium material

(5500spm) complete with stand, table and with the added bonus of the 240volt single phase

servo motor (silent) runs only when the machine is in operation (assembled).

Servo Motor: An electronically controlled motor which only works when you start to sew, unlike

the conventional clutch motor which runs once you turn the power on, consuming electricity.

With the advancement in energy-saving technology, using a servo motor, can give you a power

consumption saving of up to 60% as proved in manufactures tests against a standard clutch

motor.

Figure: Plain machine

Overlock Machine:

Specifications:

Brand: Pegasus

Origin: Japan

Max. Speed: 8500 r.p.m

Stitch Length: 0.6mm-5.2mm

Over edge width: 1.5mm-8mm

Presser foot lift: up to 8mm

Differential feed ratio: 1:0.4-1:3.2

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Flat lock machine:

Specification:

Completely block oil leakage, adopting a state-of-the-art "Oil Barrier" technology!

Produces beautiful and quality decorative stitches which are soft to the skin.

Figure: Flat lock stitching machine.

Remarks:

Some of the machines are too old. The catalogues of these machines are no longer available in

industry, also in website. That’s why those machines specifications can’t be described.

Bar tag machine:

Bar tack is a series of hand or machine made stitches used for reinforcing areas of stress on a

garment, such as pocket openings, bottom of a fly opening or buttonholes. It consists of a series

of close-set zig-zag stitches (machine) or whip stitches (hand), usually 1/16"-1/8" in width and

1/4"-3/8" in length. In denim jeans, it is often in a contrasting color, such as orange or white.

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Figure: Bar tack machine

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CHAPTER-4

Raw materials:

The raw materials for garments are the fabric, thread and trimmings. Different types of fabric of

wide range of GSM are used. In fabric store section I had the chance to know about different

fabrics of different GSM used in Norban comtex Ltd. I also have known different fabric

manufacturer/suppliers name for this garments section i.e. sources of fabrics. Single jersey,

Lacoste, pique, rib, interlock and other fabrics are used for garments.

In garments section different types of raw materials are used .They are describe below

Fabrics:

Single jersey

Lycra single jersey.

1*1 Rib

2*2 Rib

Interlock

3- thread fleece

Single Lacoste

Double Lacoste

Knit Denim

Double jersey.

Polo pique.

Mélange.

Fleece fabric.

Knitting Section:

Different types of yarn:

Yarn count used:

20s

22s

24s

26s

28s

30s

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32s

40s

44s etc.

Lycra:

20 D

40 D

Dyeing Section:

Name of Chemical and Auxiliaries Used:

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Garments Section:

Accessories list

Hanger sizer: Identify the size of the garment by hanger

Label: Labels are the most important trimmings by which customer easily, know about the

product. Here two types of label are available:

1. Main label: It contains the name of buyer and country. Ex. Wal-Mart, USA etc.

2. Sub label:

i. Size label: It contains the size of the garment

ii. Care label: It contains care construction. Different types of care label are given

below.

a. Washing code

b. Bleaching code

c. Ironing code

d. Dry cleaning code

e. Drying code

iii. Cost label: It contains the cost of garments.

iv. Composition: It contains fiber composition of the fabric. Ex 65% cotton,

35%polyester.

Sewing thread:

Different types of sewing treads are available in store room. Such as

60/3 (100% polyester)

50/3 (core spun yarn)

40/3 (100% polyester)

20/3 (100% cotton) etc.

Button:

Many types of button are available in store room. Some examples of button are given below.

Horn button

Purl button

Shank button

Snap button

Coconut button

Chalk button

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CHAPTER-5

5. Production Planning, Sequence & Operations:

5.1 Production Planning:

Production planning is a suitable & clear study and pre-arranging the technique involve to a long

series of operation for achieving best possible time by using men, machine, materials present in

industry.

Production Engineering:

The engineering approach which is used applied in every stage of a production process of a

product is known as production engineering.

Production engineering includes:

Ensure smooth production

Involves with maintenance management

It is applied in every stages of production.

5.2 Garments Production Processes:

Design/Sketch:

For the production of knit garments, or woven garments a sketch of a particular garment

including its design features is essential to produce on paper so that after manufacturing of that

garment could be verified or checked whether could be done manually or with the help of

computer.

Pattern Design:

Hard paper copy of each component of the garment of exact dimension of each component is

called pattern. The patterns also include seam allowance, trimming allowance, dirt’s, and pleats,

ease allowance, any special design etc. affairs. Pattern design could also be done manually or

with the help of computer.

Sample Making:

The patterns are used to cut the fabric. Then the garment components in fabric form are used to

sew/assemble the garment. Sample garment manufacturing is to be done by a very efficient and

technically sound person.

Production Pattern:

The patterns of the approved sample garment are used for making production pattern. During

production pattern making, sometimes it may be necessary to modify patterns design if buyer or

appropriate authority suggests any minor modification.

Grading:

Normally for large scale garments production of any style needs different sizes to produce from

a set of particular size of patterns, the patterns of different sizes are produced by using grade rule

which is called grading.

http://textilelearner.blogspot.com/2012/02/garments-pattern-pattern-making-to-make.html

http://textilelearner.blogspot.com/2012/02/list-of-trimmings-for-shirt-trouser-and.html

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Marker making:

Marker is a thin paper which contains all the pattern pieces of a garment. It is made just before

cutting and its purpose is to minimize the wastages. The width of a marker is equal to the width

of the fabric and it should not be greater than the width of the fabric i.e. the width of the marker

is kept less than or equal to the width of the Fabric.

The pattern pieces should be placed very carefully in such a way that it will obviously minimize

wastages.

Objects of marker making:

- To reduce cost;

- To improve the quality of the garments;

- To reduce the cutting time;

- To facilitate large scale production.

Spreading

Spreading means the smooth laying out of the fabric in superimposed layers of specific length.

The cutting marker paper is laid in the top of the fabric layer. The usable width of the fabric

constraints the maximum width of the marker paper. During spreading number of the plies

should be not more than three hundreds but it depends on the thickness of the fabric and the

height of the cutting knife.

For example: if the thickness of the fabric is higher than the number of plies mentioned above

would not valid and in case of straight knife cutting instrument the maximum lay height should

be 70% of the blade height.

Fabric Cutting:

On the fabric lay/spread the marker paper is placed carefully and accurately, and pinned with the

fabric to avoid unwanted movement or displacement of the marker paper. Normally straight

knife cutting machine is used to cut out the garment component as per exact dimension of each

patterns in stack form, care must be taken to avoid cutting defects.

Sorting/ Bundling:

After cutting the entire fabric lay, all the garments components in stack form is shorted out as

per size and color. To avoid mistake in sorting, it is better to use code number on each pattern.

Sewing or Assembling:

It is the most important department/ section of a garment manufacturing industry. Sewing

machines of different types are arranged as a vertical line to assemble the garments. Sequence of

types of sewing machine arrangement depends on sequence of assembling operations. Number

of sewing machine per line varies from 20 nos to 60 nos depending on the style of the ga4rmnet

to be produce. Production per line per hour also varies from 100 to 150 pieces depending on

specific circumstances. Number of sewing machines.

http://textilelearner.blogspot.com/2012/02/bar-tack-sewing-machine-study-on-bar.html

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Inspection:

Each and every garment after sewing passes through the inspection table/ point, where the

garments are thoroughly and carefully checked to detect/find any defect if present in the

garment. The defects may be for example variation of measurement, sewing defect, fabric

defects, spots etc. if the defect is possible to overcome, then the garment is sent to the respective

person for correction. If the defect is not correction able, then the garment is separated as

wastage.

Pressing/ Finishing:

After passing through the inspection table, each garment is normally ironed/ pressed to remove

unwanted crease and to improve the smoothness, so that the garments looks nice to the customer.

Folding of the garment is also done here for poly packing of the garments as per required

dimension.

Final Inspection:

It is the last stage of inspection f the manufactured garments on behalf of the garment

manufacturing organization, to detect any defective garments before packing.

Packing:

After final inspection, the garments are poly-packed, dozen-wise, color wise, size ratio wise,

bundled and packed in the cartoon. The cartoon is marked with important information in printed

form which is seen from outside the cartoon easily.

Dispatch:

The cartoons of the manufactured garments are delivered or placed in the dispatch department or

finished products go down, from where the garments lot is delivered for shipment.

http://textilelearner.blogspot.com/2012/03/wastage-recycling-process-recycling.html

http://textilelearner.blogspot.com/search/label/Garments%20Manufacturing

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5.3 Step Wise Flow Chart

PROCESS FLOW CHART OF KNITTING IN NORBAN

Sample fabric

↓

Design analysis

↓

Machine selection

↓

Setting the machine for the specific design

↓

Yarn in cone form

↓

Feeding the yarn cone in the creel

↓

Feeding the yarn in the feeder via trip-tape

↓

Positive feeding arrangement and tension devices

↓

Knitting

↓

Withdraw the rolled fabric and weighting

↓

Inspection

↓

Numbering

Stepwise garments manufacturing sequence on industrial basis is given below:

Design / Sketch

↓

Pattern Design

↓

Sample Making

↓

Production Pattern

↓

Grading

↓

Marker Making

↓

Spreading

↓

Cutting

↓

Sorting/Bundling

↓

Sewing/Assembling

↓

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Inspection

↓

Pressing/ Finishing

↓

Final Inspection

↓

Packing

↓

Send to buyer /Dispatch

Flow sequence of sample section is given below:

Receive developed sheet from buyer

Develop the sample

Send the sample to buyer for approval

Approval of sample/comments about the sample (if necessary)

Send pre-production sample to buyer

Start bulk production

Flow Chart of Cutting section:

Receive the Fabric

Fabric Inspection

Relaxation

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Fabric Spreading

Manual Automatic

Marker Making

Manual CAD

Placing the Marker Paper on the Lay

Cutting

Manual cutting Automatic cutting

Numbering

Bundle Card

Bundling According to Card Number

Quality (Panel Check)

Replacing

Solid printing/Embroidery

Quality Check

Matching

Size Wise Arrange/ cutting Number

http://articles.textileclass.com/comparative-study-between-manual-cad-marker-making-system/

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Bundling

Rib/Piping/Cuff

Master Bundling

Sewing Input

Flow Chart of Sewing Section:

Input from cutting

Initial Inspection part by part

Stitching with Process Wise Quality Check

Table Quality Check

Size Wise Garments Count

Sucker Machine

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Sewing Output

Flow chart of finishing section:

Garments wash

Loop cutting

Thread trimming

Alter checking

Stitch others

Button attach

Ironing (In side)

Inspection (inside & outside)

Batch label attach

Final ironing

Joker tag attach

Needle detector check

Size tag attach

Waist belt attach

Hanger attach

Poly packing

Cartooning

Shipment

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Flow Chart of Garments Merchandizing:

Buyer Correspondence & Meeting

↓

Recap Preparation

↓

Lab Dip & Yarn Dip

↓

Sample Fabric Booking

↓

Accessories for Sample

↓

Initial Sample Preparation

↓

Fitting Sample Preparation

↓

Photo Sample with actual specification

↓

Pre-Production Sample Preparation

↓

Bulk Accessories Booking after Buyer’s Approval

↓

Bulk Fabric Booking

↓

Size Set Sample/ Trial Cutting

↓

Production Start

DESCRIPTION OF PRODUCTION PROCESS:

In every mill, there maintains a sequences in production processing. It is also followed in this

mill where we were in industrial attachment. The process sequences are in list below:

1) Firstly, knitting manager gets a production shit from the merchandiser as accordance as

consumer requirements then he informs or orders production officer about it.

2) Production officer informs technical in charge and knows about machine in which the

production will be running.

3) Technical in charge calls for leader of mechanical fitter troops, they two take decision about

machine for production considering machine condition, production capacity, maintenance

complexity, etc.

4) Production officer with experienced mechanical fitter adjusts required stitch length and grey

GSM for required final GSM.

5) Supervisor checks daily production regularity and make operator conscious about finishing tin

due time.

6) Operators operate machine in high attention as if there were no faults in the fabrics. If he

thinks or sure about any fabric fault, then he calls for the mechanical fitters in duty. Mechanical

fitter then fixes it if he can or he informs technical in charge. Then he comes in spot.

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5.4 PRODUCTION PARAMETER

1. Machine Diameter;

2. Machine rpm (revolution per minute);

3. No. of feeds or feeders in use;

4. Machine Gauge;

5. Count of yarn;

6. Required time (M/C running time);

7. Machine running efficiency.

8. Shade%

RELATIONSHIP BETWEEN KNITTING PARAMETERS:

1. Stitch length increase with the increase of GSM.

2. If stitch length increase then fabric width increase and WPI decrease.

3. If machine gauge increase then fabric width decrease.

4. If yarn count increase (courser) then fabric width increase.

5. If shrinkage increases then fabric width decrease but GSM and WPI increase.

6. for finer gauge, finer count yarn should use.

7. Grey GSM should be less than finish GSM.

5.5 PRODUCTION CALCULATION:

A. Production/shift in kg at 100% efficiency

=RPM×No of feeder×No of needle× SL(mm)

80 .3527×count Yarn

B. Production/shift in meter

=𝐶𝑜𝑢𝑟𝑠𝑒/𝑚𝑖𝑛

𝑐𝑜𝑢𝑟𝑠𝑒/𝑐𝑚

=RPM×No of feeder×60×12 ×efficiency

𝑐𝑜𝑢𝑟𝑠𝑒/𝑐𝑚×100

G.S.M. It is technical term that indicates the weight of the fabric per square meter.

Responsibilities of production officer:

•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 product, better waste management.

•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 procedure.

•Responsibilities for monitoring the performance of manpower under him and identification of

training needs.

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5.6 METHODS OF INCREASING PRODUCTION:

By the following methods the production of knitted fabric can be increased –

1. By increasing m/c speed: Higher the m/c speed faster the movement of needle and ultimately

production will be increased. But it has to make sure that excess tension is not imposed on yarn

because of this high speed.

2. By increasing the number of feeder: If the number of feeder is increased in the

circumference of cylinder, then the number of courses will be increased in one revolution at a

time.

3. By using machine of higher gauge: The more the machine gauge, the more the production is.

So by using machine of higher gauge production can be increased.

4. By imposing automation in the m/c:

a) Quick starting & stopping for efficient driving system.

b) Automatic m/c lubrication system for smoother operation.

5.7 Industrial Engineering Department:

To follow up the production process

Work process development

SMV calculation & Line target

Efficiency control

Time study

Capacity study

Workers training

M/c sequence lay out

Thread consumption

Operator Interview

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CHAPTER-6

6. Quality Assurance System:

This chapter deals with the QC Department of Cotton Club BD Ltd. Its Specifies the objective

and function of QC Department. Besides, it also mentions the test perform in QC Department

and faults found in textile products.

Quality Policy

It is the policy of Norban Comtex Ltd. to produce quality dyed knit fabrics that meet or exceed

customers’ expectations & needs. To implement this policy the top management of Norban

Comtex Ltd. Is committed to provide adequate resources in terms of good raw materials and

trained personnel & continually improve / upgrade its processes and systems.

Quality objectives

Overall material/product loss (Level of rejection) for the company during the production

process (in a year) shall not exceed 1.5 %

Defects during dyeing & knitting operations to reduce by 10%.

Process capability shall be maximized by maximizing the m/c breakdown time. M/c

breakdown time should be reduced to 20 % from its current status/position

To ensure better work environment for the personnel working in the organization.

Machines Required

Wash Fastness Tester

Light fastness tester

Rubbing fastness tester

Electronic balance

G.S.M. cutter

Fabric inspection table

Light box

Shrinkage (%) meter.

Inspection Area

Shade match of fabric

Fabric diameter

Wash fastness

Light fastness

Rubbing fastness

Faults: Dyeing faults

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6.1 Faults Found in QC Department

Dyeing faults:

Uneven shade

Running shade

In fastness property

Finishing faults:

GSM variation

Spirality

Shrinkage control: Length wise

1QUALITY CONTROL:

Quality control is concerned with the evaluation of test data and its application to control of the textile

process. Raw materials, intermediate products and final products. It is concerned not only with quality

level and cost of maintaining this quality level but also concerned with the presentation of tangible values

to measure quality and changes in quality. In order to control quality one must about the consumer’s

expectations.

Object of quality control:

• Research/analysis

• Selection of raw materials.

• Process control and development

• Product testing

• Specification testing.

• Quality assurance.

List of equipment for quality control:

PHMeter

Iron

Lap Dyeing Machine

Pilling Tester

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Quality control Flow chart:

Yarn receiving

↓

Sample knitting

↓

Batching

↓

Enzyme wash

↓

Bleaching

↓

Dyeing (check diameter, pretreatment, shrinkage & GSM)

↓

Stantoring

↓

Compacting

↓

Final inspection

↓

If sample ok go for bulk production

6.2 Quality Assurance System

Quality assurance system can be divided into following steps:

1. On line Quality assurance system and

2. off line Quality assurance system.

Again on line Quality assurance system can be divided into the following steps:

(a) Raw material control.

(b) Process control.

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6.3 Online Quality control:

Raw material control: Norban Comtex Ltd. always very concern about the quality of the

product. So, they knit grey fabric from the best quality yarn & utilizes technical evaluation in

every stage of the production, as we know the quality product depends on the raw material

quality.

Process control: The method chosen for process must be provided with the necessary accurate

parameters. In the every stage pH should be maintained sincerely.

Fabric testing:

All the off-line tests for finished fabrics can be grouped as follows:

1. Physical test

2. Chemical test

1. Physical test:

• Fabric inspection by 4-point system.

• GSM test

• Width of the fabric measure.

• Rubbing test

• Pilling test

• Shrinkage test

2. Chemical test

• Color fastness to water

• Color fastness to wash

• Color fastness to rubbing

• Color fastness to perspiration

• Oxidative test

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6.4 Off line quality control:

After dyeing the material is received by the finishing section. Before receiving the following

things are checked:

1. Shade condition.

2. Wash fastness.

3. Condition of softening.

4. Condition of enzyme wash.

Before delivery the finished fabric to the customer it should be passing against the requirements.

The following tests are done-

1. GSM check.

2. Shrinkage test.

3. Shade check.

4. Rubbing test.

5. Wash fastness test.

6. Color fastness to perspiration.

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CHAPTER-7

7. Maintenance:

Maintenance is very important department to maintain the production. All activities that

maintenance facilities & equipment in good working order that a system perform as intended.

Without good Maintenance department, we never achieve the better quality production.

7.1 Objective of Maintenance:

Maximizing production or increasing facilities availability at the lowest cost and at the

highest quality and safety standards.

Reducing breakdowns and emergency shutdowns.

Optimizing resources utilization.

Reducing downtime.

Improving spares stock control.

Improving equipment efficiency and reducing scrap rate.

Minimizing energy usage.

Optimizing the useful life of equipment.

Providing reliable cost and budgetary control.

Identifying and implementing cost reductions.

In The Norban comtex Ltd 2 types of maintenance are done:

1. Break down maintenance

2. Routine maintenance

1. Break down maintenance: Break down maintenance is done instantly when problem arises in

machine. In this case, repairs are made after the equipment is out of order and it cannot perform its

normal functions.

2. Routine maintenance: After a particular period of operation, the machines are cleaned & reordered,

that is routine or schedule maintenance. The maintenance department does it once in a month. Schedule

maintenance varies, time in time & also depends on situation according to types of machines, because

maintenance is directly related to production. Most of the time, all the screws, nuts, bolts & levers are

checked, lubrication is also done. Workers inform about the problem areas of the machines. Depending

on their information maintenance is done. Maintenance engineer analyze the records and take steps

according to requirement.

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7.2 Types:

1. Routine maintenance: Through curing all points of machine minor adjustment not

setting wherever applicable, maintenance of chemical equipment.

2. Preventive maintenance: Machinery inspection & diagnostic checks at

predetermined intervals of then part which have varying as quality & production.

3. Predictive maintenance: Test made when the machine is in operation bearing failure

test with the aid of stethoscope or by feel or by noise eccentricity measure by dial

gauge.

4. Restorative maintenance: Overhauling & modernization.

5. Emergency maintenance: Attending to the unforeseen breakdown of the machine

6. Remedial maintenance: it mainly covers study of failure & changing the design

materials or working condition to avoid repetition of the above failure. Increasing the

capability of the machine by changing or improving the design so that they become

fits to withstand to increase the loads & speeds & improving the retention of the

lubricants & reduce the wear & fear of parts.

In the textile sector the mostly used maintenance type is Preventive maintenance:

7.3 Procedure:

Preventive maintenance (cutting):

1. Cutting Machine:

Mechanic shall do daily and weekly maintenance of cutting machine as per Maintenance

Checklist.

2. Cutting Spreader Lay Machine:

Daily, weekly and monthly maintenance shall be done by Mechanic for this machine.

3. CAD Machine: Daily, weekly and monthly maintenance shall be done by Mechanic for this

machine.

4. Button Pulling Machine: Operator shall do daily check and record maintain in Snap Strength

Calibration Record.

5. Needle Detector Machine: Operator shall check daily this machine. Supplier Technician

shall calibrate this machine once in every 3 (three) months and record maintain in Calibration

Report.

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7.4 Preventive maintenance (sewing):

1. Daily Maintenance:

Cleaning the machine head and motor with compressor air, brush and soft fabric.

Check the lower knife for sharpness of dull then re-shape.

Record Maintain in Preventive Maintenance Plan.

2. Weekly Maintenance:

Checking the oil and oil level.

Needle bar bush clean.

Thread control eyelets checking and clean.

Check electric loose connection.


3. Monthly Maintenance:

Check the condition of V-belt.

Oil level, oil condition checking or fill-up, if needed.

Check the lubrication control system.


4. Quarterly Maintenance:

Check and adjust needle bar height.

Check needle to shuttle relation

Check timing, looper, thread com guide tension.

Check electric loose connection

Needle system and bobbin loose, check according to its operator.


5. Half Yearly Maintenance:


6. Yearly Maintenance:

Changing oil filter, oil.


Preventive maintenance (finishing):

Iron Table: Monthly cleaning and steam check if iron table shall be done by the mechanic.

Utility:

1. Gas Generator:

Operator shall monitor all parameter and record maintain daily in Gas Generator

Operating Log Sheet. Manager Maintenance shall review the report daily.

Generator Operator shall routinely check the generator as per Gas Generator checklist.

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Supplier shall be called for schedule maintenance as per service contract. Record of this

type of maintenance shall also preserve in the file. Schedule for this maintenance shall be

followed up by the Manager Maintenance.

2. Gas Boiler:

Boiler operator shall operate boiler as per instruction given in the Gas Fired Boiler

Operating Log Sheet and maintain reading or record in the same format.

Daily maintenance of boiler shall be done by the operator and record detail of the

maintenance in the Gas Boiler Maintenance Log Register.

7.5 Advantage of maintenance:

To keep the factory plants, equipment, machine tool etc. in optimum working condition

To ensure accuracy of product and time schedule to delivery customers

To minimize down time of machine

To prolong the useful life of factory plant and machine

To modify or improve productivity of existing machine to meet the need for production

and thus avoid sinking of additional capital.

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7.6 Maintenance Tools & Their Equipment:

The most important maintenance tools that are used frequently are tabulated:

Maintenance Tools Function

Grease Lubrication

Tread tape Joining of broken metallic parts

Cutting disc For cutting pipes, rods.

Globe valve Fitting for stem line.

Maintenance Tools Function

Union Fittings for water, steam line.

Union elbow Fittings for water, steam line.

Cutting oil Lubrication

Gear oil Lubrication

Hydraulic oil Lubrication

Oil gun Oil application

Spanner Tightening of nut bolts

Master range Tightening of nut bolts

Flat screwdriver Screw tightening & loosening

Star screwdriver Screw tightening & loosening

Hacksaw blade Cutting

Hacksaw frame Cutting

Spray gun WP40 Spaying a chemical named WP40 that

lubricates bearings.

Drill machine Drilling to make holes

Grinding machine Grinding

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Maintenance Procedure: (Mechanical)

Machine: Dyeing Machines

No

Item needed to be checked &

Serviced

01 Comp: air system Checking

02 Steam and cond. System checking

03 All motor/pump sound and

temperature checking

04 Water system checking

05 Oil level(Pump/gear box) checking

06 All belt tight/Adjusting

07 Gear oil checking/Renlling

08 All bearing cleaning

09 Checking all control panels

10 Lubrication of all motors bearing

Machine: Gas Boiler

No Item needed to be checked &

Serviced

01 Lub oil leveling checking

02 Cooling water system checking

03 Better water level checking

04 All belt tight/Adjusting

05 Panel board cleaning

06 All bearing greasing

07 All cable terminal tighten

08 Cleaning and maintenance of PHE

and CT

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CHAPTER-08

8. Compliance & Utility Service:

8.1 Compliance:

Compliance means comply something i.e. yield to the wishes another. The main aim of

compliance is to ensuring the all labor rights and facilities according to buyer code of conduct.

Different compliance issues which they are obeyed:

Admin & HR department:

Personnel policies:

o Recruitment policy

o Leave and holiday policy

Attendance and leave register card:

o Their weekly working hour not more than 66 hours including overtime in a week.

o They have the approved manpower list.

Health & hygiene:

First aid ensures.

Medicine registers.

Maternity and pregnancy register.

Pure drinking water

Towel for hand dry.

Safety:

Safety committee

Firefighting committee

Rescue committee

Broken needle register

Needle detector

Fire alarm & switch

Evacuation plan

Rubber mats to every iron man.

Welfare:

Welfare committee

Day care center

Canteen facility

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Salary and wages:

Fix wages in considering minimum wages which is declared by the government.

Salary and wages given before 7th

day of month.

Physical security:

They have separate cargo entrance area (receiving and unloading) from the front

side.

They do not keep any partially filled/ completed cartons on the floor at the end of

any working day. They keep it to finished goods store.

Education and training program:

They arrange security training program on regular basis for all employee of the factory.

Compliance item:

Some example of compliances item are given below:

First aid box

Water pot

Toilet

Wash basin

Complain box

Evacuation plan

Exhaust fan

Emergency exit/light/ light set

Smoke detector

Fire extinguisher

Hose cabinet

Manila rope

Gas musk

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8.2 UTILITY SECTION

Utility Services Available:

Electricity

Gas

Water

Steam

Compressed air

Capacity & Other Technical Details:

Electricity :

Generally the factory doesn’t depend on electricity. They hardly use the government electricity. The

electricity is supplied form REB. The electricity supplied in the factory about 4200 KWH. But three

standby power generators are also kept to meet the need of electricity if necessary.

Gas :

Gas is mainly used for producing electricity, steam production and also used in generator and boiler. The

gas is supplied by TITAS GAS DISTRIBUTION CO. Gas consumption is 3, 20,000 – 3, 30,000 m3

monthly.

Generator Specification

Brand name :

PARAMETERS

GENERATO

R 1

GENERATO

R 2

Brand name GE Jenbecher

Cummins

Power

Generation

Origin Austria Singapore

Specfication

J 320

C250D5

Fuel Gas Driven Gas Driven

Power

1064 KW

440 KW

R.P.M 1500 1500

VOLTS. 400 400

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CHAPTER-09

9. Store & Inventory Control

This chapter deals with the store of Norban Comtex Ltd. and inventory system of different

inventories.

Equippedwithmoderninventoryandstoragesystems,theWareHousehasvaststoragecapacityandensu

resstocksofyarns,accessories,inputs,packingmaterialsandothermaterialsroundtheyear.Specialarran

gementsareinplacetokeepsufficientstockofdifferentcountsofyarnsatalltimestooffsetoccasionalshor

tageofyarnsintheintertionalmarket.

9.1 CLASSIFICATION OF STORE SECTION:

9.2 DESCRIPTION OF STORAGE:

In every mill, there maintains a sequences for keeping raw materials. It is also followed in this mill

where we were in industrial attachment. The process sequences are in list below:

1) Firstly, store manager gets a yarn &fabric booking shit from the merchandiser as accordance

as requirements then he informs or orders other officer about it.

2) Then purchase from source with purchase order.

3) After when the raw material comes then they also get the received Chelan

4) Take weight

5) For yarn quality check ,send to the testing section

6) Use Bin card to keep record

Store section

Fabric section

Yarn secton Accessories

section

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9.3 Inventory System for Raw Material:

In Cotton Club BD Ltd. there are different inventory systems for different raw materials. The

flow is given below —

Raw material receive

↓

Material Receive Report (MRR)

↓

Store in main go-down by bin card.

↓

Running go-down.

↓

Production floor.

9.4 Grey fabrics store:

All the grey fabrics are stored in the fabric store, near the batch section. Different types of

fabrics are listed in the sheet according to the fabric types, quantity & consumer’s requirements.

Fabrics GSM, shrinkage, diameter & other properties are also taken into consideration. The

bathes are prepared by taking the required fabrics from the grey store. At present the grey fabrics

store of CCL containing the following types of fabrics-

Single jersey.

1x1 Ribs.

2x2 Ribs.

2x1 Ribs.

Mélange.

Pique.

Single jersey (with Lycra attachment)

1x1 Rib (with Lycra attachment) etc.

9.5 Dyes & Chemicals store:

There is a different store for dyes & Chemicals. Various types of dyes & chemicals are stored

here according to the dyes & chemical company. Different types of dyes of dyes & chemicals are

Listed in a sheet. In the sheet the stored quantity of dyes & chemicals are also included. Every

day the is updated & a copy of this is supplied to the dyeing manager, Dye house & lab section.

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Spares:

In Cotton Club BD Ltd. required amount of spares of different machines are stored in the

mechanical storeroom. All the shares are listed in a sheet, which is controlled by the mechanical

& maintenance personnel. Spares are arranged in the storeroom according to their size, quantity

& requirements. There are shelves in the store room to keep the small spare parts.

Finished goods:

Cotton Clubs Ltd. supplies its finished dyed fabrics to its garments section. So, dyed finished

fabrics are stored for short time in the finishing section. All the delivered fabrics are noted on the

tally khata according to the Lot no., quantity, fabrics diameter, buyer’s name, colors, &

considering other parameters.

Others:

There is a central store at CCL. In that store the various types of forms, papers, stationary &

other necessary goods are kept.

9.6 Accessories Store:

According to Buyer and style number, store keeper arranged their rack for inventory. When an

order is confirm they communicate with merchandiser / suppler and confirm inventory. Store

keepers receive all accessories by counting.

If everything is ok then they give satisfactory comments and if found any kind of problem they

mention in challan sheet. After receive all accessories they give entry in computer & keep

arrange in rack for easily searching. Trim card make for different style & buyer wise for smooth

work.

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9.7 Trim card contain with:

Main, size & care label.

Back neck tape.

Button.

PSP paper.

Master carton.

Poly sticker.

Carton sticker.

Poly bag.

Logo gum tape.

Heat transfer.

Interlining.

Woven twill fabric.

Country flag sticker.

Hang tag.

Mobil on tape.

Security label

Engineering store:

Objectives: Keep store all kind of engineering, maintenance (needle, spare parts, feed dog etc.),

Dyes chemicals & stationary materials in engineering store for smooth production.

How to work: Engineering store place a requisition to procurement department by estimate of

all materials. After that procurement department send all of materials to engineering store.

Before receive all materials they ensure about quality & quantity, then they give entry in

computer and arrange in rack. When any requisition is come from any department, they give

issue to respective department.

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CHAPTER-10

10. Cost Analysis:

Costing is a very important part for selling or exporting any item. In case of a garment, before

costing, consumption is needed. When we find the required amount of raw material and their

prices we can calculate the cost of a product very easily.

10.1 Consumption Formula of Knitted fabrics:

FABRIC OR BODY CONSUMPTION:

(Body length+ Sleeve length+ Allowance x Chest + Allowance x 2 x GSM /

10000000) x 12 x 10% (+)

= Result kg. /Dozen.

So,

BL+SL+ Allowance= 10 cm. Allowance.

When keep the chest allowance then body width, chest width and bottom

width which are big (cm) with (4 cm+) Added.

10% overall Process Loss.

1 dozen= 12 pcs.

BODY CONSUMPTION BY MARKER:

Length x width x GSM x12 / 1000 / 1550 / Ratio x 12%

DIA MEASUREMENT:

Chest or Bottom + Allowance / 2.54

=Dia / Result

So,

1 inch = 2.54 cm

When I dia measurement then chest or bottom with (4-6 cm) allowance added.

SELF FABRIC OR RIB FABRIC NECK CONSUMPTION:

Total Neck Length = Front neck drop + Back neck drop x 2

= Total neck length / Result.

(Total Length + Allowance x Neck Width + Allowance x 2 x GSM /10000000) x 12

x 10 %(+)

= Result kg. / Dozen.

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So,

TL + Allowance = 2 cm

NW + Allowance = 2 cm

2 mean, Double part.

10% overall process loss.

SELF OR RIB FABRIC NECK DIA MEASUREMENT:

Neck opening or Width + Neck drop x 2 /2.54

= Result.

PANT & TROUSER OR PAJAMA CONSUMPTION:

(Length + Allowance x dia x 2 x GSM / 10000000) x 12 x 10 %(+)

= Result kg. / Dozen.

So,

L + Allowance # with self-fabric waist minimum (12 cm) Allowance added.

Without self-fabric waist minimum (8 cm) Allowance added.

Allowance minimum 15 cm added with Hip or Dia.

DIA = Hip + Allowance / 2.54

So,

1 inch = 2.54 cm.

POCKET CONSUMPTION:

Length + Width + Allowance.

So,

Allowance minimum 5 cm added with (L+ W).

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10.2 CARTON DIMENTION:

Type of Carton

1. DEPEND ON PAPER:

o Khaki Carton Or Brown Carton

o Duplex Carton

o Box Carton

2. DEPEND ON STITCHING: Gum Pasting Carton.

3. DEPEND ON PLY:

3 Ply Carton

5 Ply Carton

7 Ply Carton

4. DEPEND ON LINER:

Both Side Liner Carton

Out Side Liner Carton

5. DEPEND ON SIZE:

Master Carton

Inner Carton m

Carton Measurement:

FORMULA (1) = (L+W) (W+H)X2 in cm

100X100(Without Wastage)

FURMULA (2) = (L+W+6) X (W+H+4) X 2

100X100 (Include Wastage)

PRICE = (L+W) (W+H) X 2

100x100 x Rate per Square Meter

= Rate/P

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10.3 BUTTON LINER (FIND OUT FORMULA):

1 GG = 144 Dozen.

1 GG = 1728 pcs.

Liner = Button Dia / 0.61

= Result / liner.

So,

Always Button liner is plural number.

As like 16,18,20,22,24

YARN BOOKING

Fabric yarn (kg) + Process Loss.

= Result / kg.

So,

Process loss keep the 10% added with total fabric.

10.4 SEWING THREAD CONSUMPTION:

Cone Quantity = per garments thread x garments qty. x qty. in cone.

Plain Machine : 1” for 2.75”

Over lock (3 Thread) : 1” for 14.5 “

Over lock (4 Thread) : 1” for 16.5”

Over lock (5 Thread) : 1” for 18.5”

Flat lock (3 Thread) : 1” for 13.5”

Flat lock (4 Thread) : 1” for 16”

Picot : 1” for 21”

Zigzag : 1” for 22”

Kansai Machine : 1 “ for 11”

So,

1 Cone = 4000 meter.

Should be 40% wastage with the following consumption.

It may more or less for sewing stitch.

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CALCULATION CUBIC METER (CBM):

CBM = Carton length x Carton width x Carton height x Carton Qty. / 1000000

= CBM / Result.

So,

100 cm x 100 cm x 100 cm = 1000000

20 Feet = 28-31 CBM

40 Feet = 56-62 CBM

10.5 MARKER CONSUMPTION (FORMULA):

Open Dia = Marker length x 2.54 x Marker width x 2.54 x GSM / 10000000 / Marker

Pcs x 12 x 10% (+).

= Result kg. / Dozen

Tube Dia = Marker length x 2.54 x Marker width x 2.54 x GSM /1000000 / Marker Pcs x 12

x 10% (+).

= Result kg. / Dozen

Costing: Merchandise makes a cost sheet to see if the product is feasible or not in terms of cost and revenue.

Merchandiser has to calculate the cost of products including all wastes and accessories to tell the final

cost of the product to his customers.

10.6 Price of Different Knitted Fabric: Jersey $ 0.15

Jersey with Elasthan $ 0.35

Y/D Jersey $ 0.25 (Feeder Stripe)1.76 (Auto Stripe)

Y/D Jersey with Elasthan $ 0.45 (Feeder Stripe)2.00 (Auto Stripe)

1X1 Rib $ 0.18

1X1 Rib with Elasthan $ 0.38

Y/D 1X1 Rib $ 0.25 (F.S)

Y/D 1X1 Rib with Elasthan $ 0.40 (F.S)

2X1 Rib $ 0.25

2X1 Rib with Elasthan $ 0.45

Y/D 2X1 Rib $$ 0.30 (Feeder Stripe)

Y/D 2X1 Rib with Elasthan $ 0.48

Pique $ 0.25

Pique with Elasthan $ 0.45

Y/D Pique $ 0.35 (Feeder Stripe)1.76 (Auto Stripe)

Y/D Pique with Elastane $ 0.50 (Feeder Stripe)2.00 (Auto Stripe)

Interlock $ 0.35

Interlock with Elasthan $ 0.50

Y/D Interlock $ 0.40(feeder)

Y/D Interlock with Elasthan $ 0.55 (feeder)

Terry $ 0.40

Terry/Lycra $0.50

Fleece $ 0.44

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CHAPTER- 11

11. Marketing Activities:

This chapter deals with the marketing activities, marketing plans, and responsibilities of

marketing personnel of Cotton Club BD Ltd.

Manpower:

Marketing plays a vital role in the field of displaying/ showing the good criteria of the products

to the buyer & to communication with the buyer. There are about 7 peoples in the marketing

section of the industry.

11.1Buyer and Exporting Country:

11.2 Importing countries:

Following countries mainly imports products from CCL through many internationally well recognized

buyers.

Netherlands

Germany

Spain

Turkey

Italy

- C & A, Germany

- MGB, Germany

-PRIMARK

-Center Line

-Kitaro

-DEBENHAMS, UK

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11.3 Marketing strategy:

Marketing strategy is a very important factors to sale the products to the buyers. If the Marketing

strategy is not so developed, it will be very hard to reach the goal. In case of garments marketing

the dealings with the buyer is a very important factor.

In CCL mainly General Manager, Marketing Executives, Merchandisers & higher officials deal

with the buyer. There is some fixed buyer of the industry. The buyer gives their orders

continuously all over the year. The marketing officers & the merchandisers communicate with

the buying houses to collect the orders. By both side understanding the rate & the order quantity

are fixed.

11.4 Product label:

There are following labels used by this mill:

1) Care Label: It contains washing in hot or cold water, chemical cleaning, drying conditions etc.

2) Size Label: It contains size of garments.

3) Composition Label: It contains the fabric composition of different fiber type.

4) Decorative Label: Decoration is as buyer or consumer choice wise.

5) Flag label: it indicates importing country.

6) Barcode label: it indicates hidden identity of product.

7) Price label: it indicates price of product.

Package size & label: Most common sizes are

S - Small

M - Medium

L - Large

XL - Extra large

XXL - Very very large.

Duties & Responsibilities of Marketing Officer:

Dealing with the buyer & convince the buyer is the main duty of the marketing officer. A

marketing officer also has some other duties. The main duties responsibilities of a marketing

officer are given below:-

To prepare cost sheet by dealing with the buyer.

To take different steps by discussing with the high officials & merchandisers.

To maintain a regular & good relationship between commercial officer & merchandisers.

To maintain a regular communication with the buyer & buying houses.

Communicate with the new buyers.

Display the better criteria of the products.

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CHAPTER-12

Conclusion:

Industrial attachment provides the learning scope to enhance the curiosity of my knowledge to

enter into the practical life.Norban comtex ltd is a well know factory in the textile field of

Bangladesh. The administrative, management, chain of command all are the well-organized.

They are well equipped with all of the modern machineries and the working environment is

excellent. The relation between top management to bottom level is so nice & devoted to satisfy

the customer demand by their activities.

The factory runs by a number of efficient textile engineers, skilled technical & Non-technical

persons. They are very sincere, co-operative and helpful.

All the information in this report about Norban comtex ltd is very much objective and practical

so that one can get the desire information about the factory.

THE END

Date post:	08-Apr-2017
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