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SUBMITTED BY:

Name ID

Jotan Banik 2010110000077 Batch: 25th (B)

Department of Business Studies

Southeast University

Date of Submission: 9th

April, 2013

Southeast University

SUBMITTED TO:

Mrs Zerin Tasnim Rahman

Lecturer

Department of Business Studies

Southeast University

Course Title: Production and Operation

Management

Course Title: MGT-2323

REPORT

On

PRODUCTION PROCESS OF A

PRODUCT

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LETTER OF TRANSMITTEL

09-04-2013

Course Teacher

Production & Operations Management.

Subject: Report on “PRODUCTION PROCESS OF A PRODUCT”.

Dear Madam,

With due respect, I am the following students in Southeast University of 25th

Batch of BBA

program. A few days ago you gave us an assignment topic and that was “PRODUCTION

PROCESS OF A PRODUCT” and instructed us to prepare a details report on this topic. In a

meantime I work on this topic. Already complete this assignment. Here I am submitting my

report.

For this purpose, I have gone through different books, factory visit, and different intelligent

persons for the relevant information of the assigned topic. I work on this topic only for

academic purposes. If any person try to use this assignment in other sector than I will be not

reliable for this.

So, I am grateful to you for your guidance and kind cooperation at every step of my attempt

on this report. I shall remain deeply grateful if you kindly go through the report and evaluate

my performance.

Sincerely yours,

Jotan Banik

ID NO: 2010110000077

Batch: 25th

(B)

Department of Business Studies

Southeast University

………………………………...

Jotan Banik

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ACKNOWLEDGEMENT

At first I desire to express my deepest sense of gratitude of almighty Allah. With profound

regard I gratefully acknowledge my Southeast University and respected course teacher Mrs.

Jerin Tansim Rahman, Course teacher of Business Production & Operations Management,

Lecturer of Business Studies, for his generous help and day to day suggestion during

preparation of the report.

I like to give thanks especially to my friends and many individuals, for their enthusiastic

encouragements and helps during the preparation of this report us by sharing ideas regarding

this subject and for their assistance in typing and proof reading this manuscript.

I especially thank to G.M of ALAMA TEXTILE, another employee, and worker for giving

their most valuable time to me & my group. If they don’t help it can be so difficult to

complete this report on “Production Process of a Product”

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TABIL OF CONTENT

Topic

Page No.

1) Introduction 05

2) Abstract 06

3) Company’s Overview 07-09

4) Objectives of the study 10

5) Methodology of the study 10-11

6) Manufacturing Process 11-17

7) Precedence Diagram 18-19

8) Drawback 20-21

9) Forecasting 21

10) Opinion 22

11) Conclusion 23

12) Reference 24

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PRODUCTION PROCESS OF ALEMA

TEXTILE (PVT). LTD (Shirt)

INTRODUCTION:

Being the biggest contributor to the country's foreign exchange- around 76 percent- and

employing around 2.2 million people, 80 percent of them women, the importance of nurturing

a sector as vibrant and thriving as the garments industry, cannot be emphasized enough. With

export of Ready Made Garments (RMG) reaching 9.2 billion in 2007 and predictions of it

rising to 12 billion or more in the next two years, it is obvious that the industry is growing at

an exponential speed. Greater demand for our garments abroad indicates the improvement in

quality of the products as well as greater customer confidence, which translates to further

expansion of the industry, more employment, more consumers in the domestic market and a

huge boost to the economy. However, there are many jolts and stumbles along the road to

economic freedom and overcoming them will determine whether we can sustain the boom

that is waiting to happen.

Readymade garment industry has occupied a unique place in the industrial scenario of our

country by generating substantial export earnings and creating lot of employment. Its

contribution to industrial production, employment and export earnings are very significant.

This industry provides one of the basic necessities of life. The employment provided by it is a

source of livelihood for millions of people. It also provides maximum employment with

minimum capital investment. Since this industry is highly labour-intensive, it is ideally suited

to Bangladeshi condition. This project report is prepared for the manufacture of shirts as they

find wide acceptance in international markets. Any person having the knowledge of cutting

and stitching operations can easily set up such establishments.

Readymade garments are the choice of urban people. It is also gaining wider acceptance in

semi-urban and rural areas. The huge charges made by tailors and delay in delivery have

made people to switch over to readymade garments. In export market, it has made spectacular

progress in the last decade. This industry is becoming very exciting and lot of foreign

investment driving in this industry because of low risk and high earning nature of this

industry. As these products are fashion oriented, entrepreneurs should always keep in mind

the changing fashion styles. Considering its advantageous position, it is assumed that there

will be no constraint in marketing of gent’s readymade garments.

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ABSTRACT

This project is on “Study on shirt manufacturing process”. shirt manufacturing process is one

of the most valuable parts in terms of Garments Manufacturing to control and follow up the

total process to fulfil the buyer’s requirement. This project profile is for the setting up of unit

for manufacturing of Shirts. The Knitted Shirts are used and liked by the people because of

its special characteristics like good softness and absorbency of sweating. Wearing garment is

a basic need for every human being. The demand of using Shirts is increasing day to day

with the change of fashion/life styles. Manufacture of Shirts is very simple and easily

manageable process. Manufacture of the cotton Knitted fabric in different colours is spread

on a table and is cut with fabric cutting machine as per required size and shape of the

garments. The cut pieces are skewed by sewing machines and embellishments are attached. It

is very important to design the product as per latest fashion trend. The garments are then

pressed and packed for marketing.

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ALEMA TEXTILE (PVT).

LTD

Company’s overview

Alema Textile, within a short span of time, firmly established itself one of the successful

organization in Bangladesh. The company is registered in 2010, follow & obey the rules and

regulations of Government Republic of Bangladesh. The vision of the group is to be the

market leader and the mission is to grow faster, cope up with technological changes, add

value to the client’s satisfaction and practice sound business ethics while ensuring highest

customer satisfaction level and thus offer product and services of the highest standard in

order to become a socially responsible organization.

Alema Textile plays very important role for the economic development of Bangladesh

.Alama Textile always looks for excellence and it has an insatiable appetite for quality and

customer satisfaction.

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Vision

Our vision is to grow faster, cope up with technological changes, add value to the client’s

satisfaction and practice sound business ethics while ensuring highest customer satisfaction

levels and thus offer product and services of the highest standard in order to become a

socially responsible organization.

Mission

The mission of the Alema Textile is to be the market leader

Aims and Objectives

Alema Textile has been established for reducing unemployment, to create opportunities for

self-employment, to reduce poverty and to ameliorate ethics and morality that we can match

the advanced nations of the world

Corporate Philosophy

We are committed to nation for sustainable environment and also believe in contribute to its

progress and welfare. Business Ethics-Always keeps honesty, integrity and respecting laws.

Fairness- Fairness and justice in all our business and individual dealing. Gratitude-Always

repay the kindness of our customers, associations, community, nation and friends worldwide

with gratitude.

Company’s Profile:

Basic Information

Founder: Md. Azad Islam

Company

Name:

Alema Textile(Pvt.)Ltd.

Business Type: Manufacturer

Main Products:

Kni t fabr ic . T shirt, Shirt, polo, all knitting

garments

Number of Employees: 1020 Employees

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Trade & Market

Main Markets: Europe, USA, Japan

Main Customers:

G.A.T., J.S.E. tenny, KOHL’s, V.S.Asia, Asmara,

Lia & Firm, P.V.H. etc

Export Percentage:

100%

Factory Information

Corporate office: Vogra , Basan sarak, Gazipur

Bangladesh

Number of

Production Lines:

Above 20

Mail:

masud@mimgroup.com

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OBJECTIVES OF THE STUDY:

The primary objectives of this study is to prepare a production process of any product with

the growth and sustainability. I also attempt to seek the factor that making this project

vulnerable in terms of growth potentials. Along with these we had tried to design

recommendations for the developments of our selected product or sectors. Besides these

primary objectives there are some secondary objectives of the study as follows-

# To identify the various buyers of this industry,

# To know about their various product, and

# To increase knowledge by factory visit.

METHODOLOGY OF THE STUDY:

To complete our Project in a decision we use some method. To collect information we search

internet, read newspaper, and utilize our personal observation and organizational profile. We

collect some information from primary sources through direct interview of the Alama textile

authority and workers. Our secondary information collected through internet and

organizational profile.

#Research period:

Ist April- O5 April - within this period we collect both primary & secondary data for

developing our project.

#Research Approach:

This study is qualitative in nature, but little quantity. This analysis was done in a formal and

inflexible fashion to draw inference about the opinion of the employee & managers.

#Instruments.

To collect the data from the employee & managers, a structured questionnaire had been

followed.

Primary data have been gathered through interviewing the respondents in their respective

workplaces.

Two questionnaires had been used to collect the data from two areas such as from the

Managers, and worker in that industry.

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# The sampling frame:

Category of sample Sample size Description

Managers 05 Whose managers are authorized by the authority

for the purpose of industry

Workers 20 Whose workers are employed by the managers

or authority.

Total 25

THE MANUFACTURING PROCESS:

Garment manufacturing process consists of series of different steps. These steps are broadly

divided into two categories pre-production and production process. The preproduction

process consists of designing the garment, pattern design, sample making, Production pattern

making, grading and marker making. Once the sample is approved for commercial

production, final marker is made for cutting. The production process Consists of cutting,

stitching (preparatory and assembly) and finishing all these process are described here

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FLOW CHART:

Value added

Input Transformation Output

Land

Labor Goods

Capital

Information

Feedback Feedback

Production Process

The following steps outline the entire manufacturing process of our t-shirts, from dirt to shirt.

This is just the first step in our commitment to giving you all the facts about the shirts you're

wearing:

Control

Input Transformation process Output

Land

Labor

Capital

Information

Cloth

Button

Thread

Needle

Bokles

Colour

Deterjent

equipment

Dying(a)

Printing(b)

Cutting(c)

Shaping(d)

Making serial no.( e,f,g )

Sewing(h)

Washing(i)

Drying(j,k)

Ironing(l)

Folding(m)

Packing(n)

Leveling(o)

Bundling(p)

Shirt

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(1) Designing

(2) Dying

(3) Printing

(4) Cutting

(5) ShappingSerialing no.

(6) Sewing

(7) Washing

(8) Drying

(9) Ironing

(10)Folding

(11)Packing

(12)Levelling

(13)Bundling

Registering the Design

The completed screens are then fitted into the press. A system of clamps and screws allows

for very minute adjustments to the position of the screen. If the design features only one

colour, then the screen must simply be straight, if there are two or more colours, the design

must be registered, or lined up perfectly. Screens are generally made with cross-hair

registration marks to aid in this process.

Dying:

Because of the special print process we use, our shirts are garment dyed after

printing. Though there are many dye methods available, paddle dye tubs are used because of

their ease of operation and maintenance.

After dyeing, the shirts are inspected and shipped to the customer.

CotC shirts are dyed with low-impact, bi-functional reactive dyes, offering superior wash-

and light-fastness in addition to their low environmental impact.

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Printing the Shirt

The next step is to fit the shirts onto the press. Ink is poured into the screen, which is

"flooded"---completely spread with ink. The ink is scraped across the screen with a squeegee

with enough pressure to push it through the mesh in the stencil area. For a multicolor design,

the shirt is dried briefly before a second color is printed to avoid smudging.

Cutting Department

The first step of the production process is to draw a shirt pattern on a large paper. Next, the

fabric is overlaid in layers according to the number of orders. Then, the large patterned paper

is laid on top of the fabric and the fabric is cut according to the pattern. Later, the cut pieces

are inspected by our experienced Q.C. staff to ensure the fabric quality.

Serial Numbering Then different pieces are included in different no by shapping or cutting size-Middle, Long,

Short, Extra large, etc.

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Sewing: Sewing is the most important step in the actual construction of the shirt itself,

and is the most labor-intensive.

After receiving the bodies, sleeves, and collars from the cutter, the sewers use an array of

sewing machines to attach each piece via a batch assembly line.

Sewing Department consists of 2 sections:

Sewing Section – In this section, cut pieces of fabric are sewn together and inspected for

sewing quality before passing to assembly section.

Assembly Section - Responsible for assembling shirts and measuring the size. If the shirts are

in required sizes, they will later be processed in a thread vacuum machine to remove the

remnants of thread.

Washing

For cleaning products need to be washed, so that any spots or germs are removed and

products are shown shining.

Drying & Ironing the Shirt When the shirt is washed it is taken off the machine and put through a conveyor-belt dryer to

set the ink. In between colors of a multicolor design, a flash dryer is used to allow the shirt to

be dried while it is still on the press and also it need to be ironed. In the case company after

washing there is thread cleaning section followed by ironing.

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Folding

For pacing folding must be needed. If they do not folding the shirt, they can’t packing this.

Packing & Bundling

The individual pieces are pressed by steam presses to remove any wrinkle marks and packed

in the carton boxes. After packing, they define the level of different shirts. Then, In carton

boxes, they arranges the shirt pieces in accordance to the buyers order that one carton’s will

fill up 10 pieces of long gents & ledis T-shirt, 20 pieces of short & middle gents shirts.

Quality Control:

The quality of garments mainly depends on quality of fabric used. Therefore, care must be

taken while purchasing fabrics to ensure good colourfastness properties, uniformity in shade

etc. Generally garments are made as per customer's specification in respect of size, design

and fashion.

According to per hour (200-250):

These are the different workstation and those task, task period. In one hour, Alama Textile

produce 200-250 shirt. Given below the task time and those steps workstation-

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Task Task time Forword

a

b

c

d

e,f,g

h

i

j,k

l

m,n,o

p

5 min

5 min

15 min

5 min

4 min

3 min

12 min

4 min

3 min

3 min

4 min

c

c

d

e,f,g

h

i

j,k

l

m,n,o

p

end.

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Precedence Diagram:

E K M

A C D F H I L N P

G J O

Fig: Precedence diagram For Dying

E K M

B C D F H I L N P

G J O

Fig: Precedence diagram for Printing

The process of assembly line balancing involves these steps:

a) Cycle Time: Cycle time is whose workstation’s time needs to be highest.

Cycle Time: 15 mnt.

b) Minimum no. of workstation: What minimum no. of workstation must be needed for

a production process, that is minimun no. of workstation.

∑ each workstation

Minimum no. of Workstation: ……………………..

Cycle time

60 mnt

=…………

15 mnt

= 4 workstations

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c) Maximum no. of workstation: It is the summation of all workstation.

Maximum no. of workstation: 5+5+15+5+4+3+12+4+3+3+4

=60mnt

d) Idle Time: It is calculated by-

I = nc-∑t

=4*15-60

= 0 mnt.

e) % of Idle Time: It is calculated by-

% of I = I/nc

=0/4*60 *100

= 0%

f) Efficiency rate: It is calculated by-

Efficiency rate = 100%-%of I

=100%-0%

= 100%

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Draw backs:

There are several draw backs in any factory. Some of them are – power fall, absent of

workers, defect product, equipment fall, crisis of raw materials, ending inventory, political

issues, foreign issues, labour relation, management issues etc.

� Power fall:

Anytime electricity can be gone, causes planet power fall. Resulting huge loss of

production in every minute.

� Absent of workers:

About thousands of workers works in a factory and each of them have specific

responsibilities. If any of them cant present due to any reason, it’s causes negative

impact on production.

� Defect products:

In every hour, factory produces thousands of finished goods. During the production

process may many defective products can be produced, which recognized as loss.

� Equipment fall:

Most of the equipments are being used for long time. Its causes sudden fall of

equipment. For repairing or resetting this equipment needs so many cost and time as a

result production process can be hampered.

� Crisis of raw materials:

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In several times in market, raw materials prices remain so high due to unavailable

supply of raw materials. It is a threat for a factory.

� Foreign issues:

In any foreign issue, forecasting may not be right or production can be fall.

� Ending inventory:

If any product or raw material are produced or bought, more than demand or order, it

may create inventory. As a result it creates cost of time and space.

� Management issues:

If management team is not skilled, production process, as well as there no sector can

not operate effectively.

� Political issues:

Political issues can be hampered in production and supply process.

� Labor relation:

Production can be hampered because of any specific issues in labor relation.

� Unskilled labor:

An unskilled labor can’t operate production process effectively.

FORECASTING:

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Generally, company don’t forecasting on forecasting term. Actually, R&G factory’s

forecasting depend on their production capacity. How much they can be produced, depending

that they keep the order of the customer. Production depends on several factors-(a) Political

Ground, (b) Manpower, (c) Machineries, (d) raw material, etc. If sometimes the order is more

than their estimate, they complete their order through overtime, bonus, extra salary, other

facility, etc.

Their order also is differentiated based on season. Different season’s production must be

different. So in a sense, it can be called in seasonal variation or seasonal forecasting.

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Opinions:

We can see before that factory faces some problems due to several reasons. A factory can

improve such situations by –

� Having alternate power supply. Ex- generator, solar energy etc.

� Every worker need to know about every sector basic tasks, so that they can offset the

loss.

� If factory follows JIT system, they can reduce the rate of defective units.

� Efficient technical team should be hired to fix the equipment problems.

� According to forecast, raw material should be bought and finished goods should be

produced, resulting no or small lot size inventory.

� Training should be held for unskilled labor.

� Management team should be skillful.

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CONCLUTION:

They are the group of Mim Group., and have an excellent track record in apparel

manufacturing for the last 20 years and are now ranges the 2nd

largest company in the

country.

Quality and on time delivery is the corner stone of our success. Customer satisfaction is the

key to our establishment. We ensure timely shipment and delivery to gain faith and

confidence to our valued customer.

We make all types of bottoms and tops (Pants, Shirts, Ledis, Dress, Overall shorter, Sweater,

etc)

In this study the lean manufacturing tools and techniques were studied and used in case

company (garment manufacturing industry). It is the first growing company carrying out

business on 3 foundation principles-

a) Customer services

b) High quality

c) Quick response

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Company follow these ideologies for growing their market in rapidly with customer

satisfaction. Throw this study we identify some disadvantages of this company, and in against

we given some opinion. Although they are very efficient in every step, in spite if they follow

our suggested opinion, we ensure they would be effective, and rapidly will be the market

leader.

References

1. Www.wikipedia.com.

2. Www.mimgroup.com.

3. Www. productionprocess.com.

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