Sepal Dairy Correction

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 1 st 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.
Report on Industrial Attachment | SEPAL GROUP
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. 2. 3. 4. 5. 6. Sepal garments ltd. Orchid garments ltd. Creative garments ltd. Glory fashion wear ltd. Sepal washing ltd. 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: anil@apexfair.com 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 E-Mail: apexfair@hathway.com NO. OF FACTORIES : Five 1. 2. 3. 4. 5. Sepal Garments Ltd. Orchid Garments Ltd. Creative Garments Ltd. Glory Fashion Wear Ltd. Sepal Washing Ltd.
PRODUCT MIX
Mainly woven garments. Major items are Trouser Pant Shirt Bermuda Skirt Shorts etc.
PRODUCTION CAPICITY
1) SEPAL GARMENTS Cutting capacity Sewing capacity Laundry capacity Production line Cutting capacity Sewing capacity Laundry capacity Production line Cutting capacity Sewing capacity Laundry capacity Production line Cutting capacity Sewing capacity Laundry capacity Production line : : : : : : : : : : : : : : : : 6000 pcs /day 4000 pcs/ day 30000 pcs /day 5 6000 pcs/day 4000 pcs /day 30000 pcs/ day 5 4800 pcs /day 3200 pcs /day 30000 pcs/day 5 6000 pcs day 4000 pcs day 30000 pcs 5
2) ORCHID GARMENTS
3) GLORY FASHION WEAR
4) CREATIVE GARMENTS
5) SEPAL WASHING UNIT
Wet processing (Based on 60-minute stonewash / day) Garment dying (based on medium shade in direct process type) Dry processing (based on standard specialty)
15000 pcs 7500 pcs 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 & mens 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 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. 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
Report on Industrial Attachment | SEPAL GROUP 6
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
Eleventh floor Tenth floor Ninth floor Eighth floor Seventh floor
:Training center, CNF office. : Reception clubs, directors rest room. : Apex square (buying house), sample section -1. : Sample section -2. : Canteen, kitchen, M/C storage room, office. : 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 : Directors office, finishing section of orchid garments ltd. Child care section, store. First floor : Sepal washing unit, boiler, generator, store, reception. Basement : Parking, ETP. : Glory fashion wear ltd.
ADDITIONAL BUILDING
SEPAL Group at a glance

Company name
Type & business of the company
SEPAL GROUP
A 100% export oriented woven & washed garments manufacturer and exporter 247/248, Tejgaon Industrial Area, Dhaka, Bangladesh 1986 Around 5000 1,22,300 sq. ft. Different types of sewing, inspection, finishing and washing machine and generator, boiler effluent treatment plant. Mainly woven garments including trousers, pants, dresses, Bermudas, skirts, shorts, jackets, vests, jumper etc. Approximately 45000 dozen of various
Factory location Year of Establishment Number of employee Factory Floor Space Factory equipments
Main production
Production Capacity
Main market Key personnel
Mailing Address
Phone Number Fax Number Website
garments every month USA, Canada , China etc Mr. Deepak V. Bhojwani Chairman Mr. Tipu Munsi Managing director Mr. Anil. D. Rao G.M Operations Sepal Group 247/248, Tejgaon Industrial Area, Dhaka, Bangladesh 88-02-9898259,9898475 88-02-8826072 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 companys 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.
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Chapter 2
Man Power Management
CONTENTS
Organ gram Man-power Administration Production Management system Shift change system Responsibilities of Production Officer Job description Remarks
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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.
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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
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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 247/248, Tejgaon Industrial Area, Dhaka, Bangladesh Tel: 88-02_8827707, 9885341, Fax: 88-02-8823026 E-Mail: anil@apexfair.com
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 E-Mail: apexfair@hathway.com
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SAPAL MERCHANDISING DIVISION
KEY PERSONNEL TO CONTACT FOR SEPAL MERCHANDISING DIVISION

Name Anil D. Rao Aftab A. Sayed T. Hossain Ejaz Monzurul Haque Phone 9885941 9885341 9898005-12 9898005-124 E-mail anil@apexfair.com aftab@apexfair.com ejaz@apexfair.com monjzut@apexfair.com
PRODUCTION
As a group, Sepal group export approximately 45000 dozens of various garments every month and these range from newborns, infants, ladies & mens wear such as Ladies Dresses, Vests, Jackets, Shortfalls, Overalls, Jumpers, Shirts, Pants, Shorts & Skirts.
MANAGEMENT SYSTEM
Sepal Group comprises of the six companies as below1. 2. 3. 4. 5. 6. Sepal Garments Ltd. Orchid Garments Ltd. Mastrade International Garments Ltd. Creative Garments Ltd. Glory Fashion wear Ltd. 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
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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
QA Manager Inline Inspectors Final QA Inspectors Mechanics Cutting Operators Cutting Supervisors Sewing Supervisors Sewing Operators Sewing Helper/finish.hel. Finishing Packing Pressman staff Male Female Total Staff
Number Employee
2 60 20 6 3 3 20 340 160 60 25 17 34 260 490 750
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EMPLOYEE INFORMATIONS OF ORCHID GARMENTS LTD
Employee Position
Number Employee
2 65 20 6 3 3 24 355 160 60 28 20 34 220 520 778
EMPLOYEE INFORMATIONS OF ORCHID GARMENTS LTD
Employee Position
QA Manager Inline Inspectors Final QA Inspectors Mechanics Cutting Operators Cutting Supervisors Sewing Supervisors Sewing Operators Sewing Helper/finish.hel. Finishing
Number Employee
2 50 17 5 3 3 15 290 142 50
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Packing Pressman staff Male Female Total Staff
22 15 31 227 423 650
EMPLOYEE INFORMATIONS OF CREATIVE GARMENTS LTD
Employee Position
Number Employee
2 60 20 6 3 3 25 360 170 60 30 20 40 274 521 795
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.
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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 Director Production Director Production Manager : : : : Mr. Tipu Munshi Tania Munshi Petric E.A Mr. Anwarul Islam 1. Anisur Rahman(Sepal) 2. Shah Alom (Orchid) 3. Alomgir Hossain(Glory) 4. Ala Uddin(Creative) Ariful Islam Nasir Uddin Mathus Shiva Jullian Hawladar William : Kazi Shahidul Islam 1. Sofikul Alom(Sepal) 2. Mubarok Hossain (Orchid) 3. Sri Bimol(Glory) 4. Anisur Rahman(Creative) Ershadul Alom Taposhi Rabeya
Production Coordinator Manager (sample section) Cutting master Quality Chief Technical Compliance Officer CTPAT Officer Store in Charge
: : : : :
Administration Head Welfare Manager
: :
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IT Officer Custom in charge Officer Training center Head Fire Department Head
: : : :
Forhad Akbar Rajib Sarkar Lili Gomaje 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.
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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.
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CHAPTER 3
Machine Description
Contents
No. of M/C Brand name Main specification Machine lay out plan List of Machinery Remarks
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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.03Glory 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 1. Plain Machine 2. Over lock Machine 3. Feed of the arm 4. Two needle Machine 5. Button hole Machine 6. Button stitch Machine 7. Bar take Machine 8. Snap button Machine(power) 9. Snap button(power)
Creative 208 36 12 30 6 6 8 6 2
Sepal 208 35 10 30 4 6 11 25 21
Glory 215 35 10 30 7 5 11 8 4
Orchid 208 35 10 30 4 6 11 25 21
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10. Kansai special (pmd) 11. Flat lock(kansai) 12. Blind stitch Machine 13. cloth cutting Machine 14. Pocket 15. Flat lock (Pegasus) 16. Eyelet/B/H Reece 17. Collar training 18. Threat sucker 19. Fusing Machine 20. cloth winding inspection Machine 21. Core winding Machine 22. Velcro attaching 23. Metal detector Machine 24. Vacuum iron Machine 25. Marker computer pattern machine
6 1 1 3 2 1 3 5 1 1 1
6 2 1 5 2 6 4 5 1 1 1
5 1 1 5 2 2 4 4 1 1 1
6 2 1 5 2 6 4 5 1 1 1
2 1
2 1
1 1
2 1
10 1
12 1
10 1
12 1
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26. End cutter Machine 27. Label Machine 28. Chain stitch T/N Total
1 6 10 371
2 2 0 405
2 5 0 373
2 2 0 405
All together : 371+405+373+405= 1554
Washing Plant
Washing Machine Sample machines Dryers Extractors Sand Blast m/cs Generators Boiler Transports Employees : 11 (Golden Resources, Hong Kong), 500 lbs Each. : 3 (Golden Resource, Hong Kong) 110 lbs each. : 15 (7 steam + 8 Gas) : 3 (golden resource, Hong Kong) : 6 (six) : 2 (1 diesel 930 KVA + 1 Diesel 400 KVA) : 1 (2.4 tones) : 3 (three) : 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 1. 2. 3. 4. 5. 6. Brand Kansai Plain m/c plain automatic machine Eyelet computerized Eyelet M/C Chain stitch M/c Company Brother Brother Sun star Brother Brother Typical Country Japan Japan China Japan Japan China
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7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.
Button hole Over lock(5 threat) Over lock (4 threat) Feed of the arm Vertical machine Flat lock Button stitch Fusing machine Straight Knife Lay cutting machine Light box
Brother Juki Juki Brother Brother Pegasus Brother Hashima Blue streak-II Eastman -
China Japan Japan Japan Japan Japan China Japan USA USA -
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 1. Kansai (Brother, Japan.) 2. Plain machine (manually, Brother, Japan.) 3. Plain auto(sun star, China.) 4. Eyelet (Brother, Japan.) 5. Eyelet (computerized,
Model No. DFB1411PXF H7200A40B
Speed Control PULLY -
Needle No. UOX113 DBX1
Needle Size 11-22 9-18
KM250B-75 RH-9820-01 RH-9820-02
DBX1 EBX7 DOX558
9-18 14-18 14-20
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Brother, Japan.) 6. Button Hole (Brothers, China,) 7. Over lock (5 threat, Juki, Japan.) 8.Over lock(4 threat, Juki, Japan 9. Feed of the arm (inside seam, Brother, Japan.) 10. Vertical machine (cutting and swing, Brother, Japan.) 11. Flat lock(Belt loop, Pegasus, Japan) 12. Button stitch (Brothers, China.) 13.Auto Marker
HE806A-2 MO-67165 mo-67145 DA-9820-8
Three stitches-, threads. -
DCX1 dcx1 UYX128 6 -
9-20 9-20 11-20
EI77B-3
W500
BE-438D -
5 threads, three needles -
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SOME MACHINES USED IN SEPAL GARMENTS
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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.
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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 1. Name of item Thread Description Polyester, linen, polyester coated, single ply, multiple ply of different Tex. Simple plain fabric of different color. but basically white color is mostly used. Fusible interlining white color natural. For denim temp is 149. Extra fabric or wedding are used mainly in jacket. 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 Source Local Market. e.g. Twice, Coarse etc. Local Market.
2.
Pocketing Fabric
3. 4. 5.
Interlining Lining Button
Local Market. e.g. Vilene Local Market. Local Market & Imported Brand items must be imported.
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6.
Zipper
7.
Poly Bag
8.
Label
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. nylon zipper, metal zipper, plastic zipper, aluminum zipper Metal / Brass Zipper, Nylon Zipper Used for covering the garments. And its size and color depends on product type and design. Size label, Main label, Care code label, price label, composition label etc.
Imported
Local Market
Local Market & Imported Brand items must
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Barcode Label, Ticket, Waist Card be imported. 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
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9.
Hand Tag
10. Match Box 11. Sticker
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) Plastic, paper, woven, printed Local market hand tag etc. mainly contain product and companys 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, To matching size and bundle Local market number. Hologram Sticker : Hologram Local market 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
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12. Tag Pin
Pin: Tag gun, Tag pin, loop pin, Local market 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. Transparent or may be colored. Simple colored poly. wooden hangers, metal hangers, Aluminum hangers, Laminated wooden hangers, plastic hangers and etc. According to products size and buyer Recommendation different color is used. Hologram Sticker: Hologram Sticker, 1. Item: Hologram Sticker 2. Material: sticker 3. Size, Printing, Design according to customer's requirements Transpired or colored paper of plastic. Bra Strap (DS-FW004):Commodity name: Bra
13. Button sticker 14. Button poly 15. Hanger
Local market Local market Local market
16. Hanger Sizer
Local market
17. Poly sticker
Local market
18. Packaging paper 19. Bra-strap
Local market Local Market & Imported
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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 20. Buckle, hook & Loop: Hook and loop Material: loop 100% nylon, or nylon mixed with polyester. Width: 16mm, 20mm, 25mm, 38mm, 50mm, 100mm, 125mm, 150mm Colors: 300 kinds of colors Used for garments,
Brand items must be imported.
Local Market & Imported Brand items must be imported.
21. Seal 22. Card
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 Company seal: Rubber, metal seal Local Market etc. PVC Card (Plastic Card): Material: Local Market PVC or paper Size: 86mmx54mm or other size as required.
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23. Cord and piping 24. Tape
25. Zipper puller
Thickness: 0.3mm; 0.5mm; 0.76mm or others. Printing: Full color, encoding. Used in waist band wedding and tshirt. Mainly soft knitted fabric. TPU Tape, Mobil on Tape (NCB2):1)Product name: TPU TAPE 2)color: Transparent, semitransparent, black, bluish etc. 3)width: 3mm-16mm(or to requirement) 4)thickness: 0.08mm-0.30mm(or to requirement) 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-Z078): 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 Local Market
Local Market & Imported Brand items must be imported.
26. Belt 27. Key chain
28. Hanger bag
Key Chain: Watermarks indicate Local Market the serial NO. And size of each hangtag PVC Hanger Bag (YX12):Material: Local Market 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
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29. Cuff Button
Links, 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 Fabrics Others : 60000 tons approximately. Basically depends on order. : 500000 tons approximately. Basically depends on order. : Depends on order.
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Some Trimmings
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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.
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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
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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.
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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.
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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 3 Inches or Less Over 3, But not over 6 Inches Over 6, But not over 9 Inches Over 9 Inches Penalty 1 Point 2 Points 3 Points 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. b. c. d. e. f. g. h. Slubs Hole Missing Yarn Conspicuous Yarn Variation End Cut Soiled Yarn Wrong Yarn.
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Major Defects for Knit fabrics are classified as follows:

a. b. c. d. e. f. g. h. Mixed yarn Yarn Variation Runner Needle line Barre Slub Hole 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-toend, side-to-side and roll-to-roll shading. Use the head strip to check for end-to-center shading during the inspection.
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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 Width of the fabric Total points found : 700 yards : 1.6 yards : 300 points
i.e. 700 X 1.6 = 1120 Square yards 300 x 100 / 1120 sq yards = 26.78 points Result : Pass
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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 the tolerance give to the spec. for example if the hip tolerance is 1 you should only consider 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.
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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 doesnt 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.
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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.
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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.
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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.
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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.
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All lay/cuts must be inspected prior to cutting. The following points that will need to be checked: 1. 2. 3. 4. 5. 6. 7. 8. Marker Length Marker Placement Counts Tension Leaning Ends Splice 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.
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B) C) D) E)
F)
A written record must be maintained line wise what type of needle is broken and who is depositing. Broken parts must be found out from the machine area or garments. If necessary hand needle detector or magnet might be used. The broken needle with its part must be paste and preserved separately in a needle log register. 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. 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 belowProduction target per hour PID# 222217 90pcs
BELTED WALKING SHORT PANT Machine name 1. Front rise O/L 3TH 2.Front pocket piping O/L P/M Type 1 1 Number
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3. Front pocket same + P/M tuck 4. White pocketing 5 O/L thread 5. Zipper Joint P/M
1 1
6. S/Fly body attach + P/M D/Fly tuck 7. J/stitch 8.R/part+D/Fly Joint P/M P/M
1 1 2
9. Front rise Joint 1/32 + P/M top stitch 10. Back rise 5th O/L
1 1
11. Back rise +side pocket D/N ruling 12. Back rise taken + top P/M stitch 13. White pocketing Joint 14. Fashung 3 thread P/M O/L
1 1 3
15. Bone Joint + Bone P/M make 16. White pocketing Joint 17. Bone top stitch P/M P/M
2 3 3
18. White pocketing top P/M stitch 19. Side Joint 5th 20. side top stitch O/L D/N
1 1
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21. Side pocket making 22. Side pocket Joint 23. Belt tuck 24. Pippen 25. Belt make 26. Belt Joint 27. Label Joint 28. Mouth close 29.Belt loop stitch 30.Inseam 5 thread 31.Loop stitch make &
P/M P/M P/M P/M P/M C/S P/M P/M D/N O/L
4 2 1 1 2 2 1 1 4 1 1
top D/N
32.Loop joint & tuck 33.Hem 34.Bartake stitch 35.Button hole stitch 36.Button attaching TOTAL
P/M P/M B/M Button hole m/c Button attaching m/c
4 2 1 1 1 59
REQUIRED NO. OF M/C

M/C types Plain Machine Double Needle Machine No. of M/C 42 7
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Chain stitch Machine Over Lock Machine Zigzag stitch m/c Others
2 6 2 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 (zippers 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.
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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.
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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 Buyers 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.
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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 Sewing capacity Laundry capacity Production line = 6000 pc = 4000 pc = 30000 pc =5
Production capacity of a line per hour: Per hour a production line can produce 80100 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 Daily actual production Daily efficiency Monthly optimum production Monthly actual production Monthly efficiency = = = = = = = = 4000 pc 3200 pc 3200/4000*100% 80% 100000 pc 87500 pc 87500/100000*100% 87%
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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. We are also grateful to our respectful teacher Mr. Moshiur Rahman Khan for giving important check routine and advice.
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Chapter 6
Inspection and audit
CONTENTS
Quality Audit Audit Procedure DUPRO Audit Final Inspection Remarks
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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 nonconformances 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 CLIENTS 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
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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) Days total defects e) Previous days 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 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
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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 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 factorys 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 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 Buyers 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)
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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: Buyers 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.
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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.
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Target Defect classification list
Fabric
Defect Code
F001 F002
Description
Classification
major
F003 F004 F005 F006 F007 F008 F009 F010 F011 F012 F013 F014 F015 F016 F017 F018
Holes where the yarn is cut, broken ends, drop stitch that runs Vertical or horizontal lines permanently knit or finished into fabric (i.e. needle lines, compactor creases, barre, light/heavy ends). Visible at arms length Soil, oil spots with contrast visible at arm's length, adversely affecting appearance Not cut on grain line as specified affecting appearance or shrinkage Significant snags and/or slubs distinguishable when viewed at arm's length, adversely affecting appearance Knitted in, off color fly visible at arm's length Misweaves, mispicks (wovens) Washing/Dyeing Defects (streaks, uneven dyeing) Shaded parts/thread and/or visible components, adversely affecting appearance Printing defects: Wrong, missing or incomplete coverage of color, misregistered, over 1/16" Poor hand feel of product - not as specified Knit/Woven structure not to standard Product (including all items in selling unit) not visually matching Archroma standard or approved shadeband Conspicuous pilling; not to agreed upon standard Mismatched stripe/plaid: side seam 1/8-1/4 Skewed, bowed or biased fabric, solid or stripe over 1/2" side to side for softlines; over 3% side to side for soft home Conspicuous repair (this covers knits and wovens) Mismatched stripe/plaid: side seam over 1/4, pocket over 1/8
major major major major major major major major major major minor major major minor major major
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Components and Trim Defect Code

C001
Description
Classification
C002
C004
C005
C006
C007
C008
C009
Unapproved components or trim added or substituted affecting performance (Bias cut binding vs. warp cut; incorrect interlining etc.) 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) 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 Buttons omitted, broken, damaged, defective or inverted; buttons that do not confirm to specification; misaligned or improperly spaced buttons 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 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 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 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
major
major
major
major
major
major
major
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CHAPTER 7
QUALITY ASSUARANCE SYSTEM
Contents
Quality assurance system Procedure List of machineries Quality report
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INTRODUCTION Quality assurance system

Introduction: Now a days 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 POINT WEFT DIRECTION Beyond 3 inch 1 3 inch-6 inch 2 6 inch-9 inch 3
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Above 9 inch FOR HOLE & OPENING 1 inch or low Getter than 1 inch
4 2 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.
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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
Its 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 its 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.
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d. e. f. g. h. i. j.
Inside ironing Final inside quality check Outside qualities check. Top side ironing. Measurement. Final quality check. 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. 2. 3. 4. 5. 6. Atom hydraulic cutting press Secom platting machine Thread slashed machine. Needle detector machine Spot remover gun. Button pull test machine. Fabric shrinkage test machine
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IMAGES OF SOME QUALITY CONTROL EQUIPMENTS
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SEPAL GARMENTS LTD QC SYSTEMQC SYSTEM FLOW CHART
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PICTURES SOME DEFECTS
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CHAPTER 8
Maintenance
Contents
Manpower set up Procedure Tools Oiling
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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.
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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 uninterrupted. 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.
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SAMPLE CHARTS FOR MAINTENENCE
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CHAPTER 9
Utility Services
Contents
Utility facilities available Capacity & other technical details Source of utility Cost of different utilities Remarks
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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 dont 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.
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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 : Origin : KAMINS. U.K
Different chemical used for boiler running
Chemical name Doggy chemical (soluble) Auto scaling (NaOH) NaCl
amount 250gm/8hr 1200gm/day 25kg/48hr
use to lessen water hardness To remove carbonate.
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.
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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 2) CATER PILER U.K 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
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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 Poly electrolyte Alum
amount 1 kg/day 18 kg/day
Source China China
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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.
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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. We are also grateful to our respectful teacher Mr. Moshiur Rahman Khan for giving important check routine and advice.
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CHAPTER 10
Store & Inventory Control
CONTENTS
Inventory system of raw material Different inventory cost Spares Finished Goods Others Remarks
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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.
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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.
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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.
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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 customers 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 personnels: d. Reduction in manufacturing cost: e. Strengthens financial position: This is achieved by onward inventory controls.
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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:
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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 -Loss of good will -Loss of future sales. 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 Internal -over time - Special ad minis dative efforts
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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 60poly 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.
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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
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INTRODUCTION
Marketing is an integrated communications-based process through which individuals and communities are informed or persuaded that existing and newlyidentified 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.
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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: THE GAP J.C PENNY WALMART K-MART CHADWICKS OF BOSTON TARGET SEARS and many more. * * * * * * Importers- U.S.A market: KIDS INTERNATIONALS WORLD WIDE APPARELS RADIX APPARELS S.J TRADING FRANK & JANE LLC MILLENIUM CLOTHING
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.
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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.
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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 its 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:
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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.
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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.
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CHAPTER 12
Washing Plant
Content
Washing Dry Wash Wet Wash Wahing Machines Washing procedure Remarks
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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
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2. Dry wash -Sand Blasting -PP spray -Grinding -Whiskering -Tagging -Hand scraping
DIFFERENT TYPE WASH EFFECT
ADDRESSES
Sepal Washing Plant 247/248, Tejgaon Industrial Area, Dhaka, Bangladesh Tel: 88-02-9898248, 9898005-117 Fax: 88-02-8823026 e-Mail: info@sepalgroupbd.com
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FLOOR MEASUREMENT
Total floor measurement of the factory is 11,000 sq.ft Total floor measurement of the companys office is 1,000 sq.ft
MACHINE DESCRIPTION Production Machines Each. Sample Machines Each. Dryers Extractors Sand Blast Machines Generators Boiler Transports : 11 (Eleven) (Golden Resources, hong Kong) 550 Lbs : 3 (Three). (Golden Resources, hong Kong). 110 Lbs : 15 (Fifteen) ( 7 Steam + 8 Gas) : 3 (Three). (Golden Resources, Hong Kong). : 6 (Six) . : 2 (Two) (1 Diesel 930 KVA + 1 Diesel 400 KVA) : 1 (One) 2.40 Tones. : 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) Employee Position Dry Process Manager Dry Process Operator Dry Process Supervisors Number Employee 1 28 2
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Wet Process Manager Wet Process Operator Wet Process Supervisor Dying Supervisor Dye Lab Technicians Dye Manager/Master Development Operation Supervisors Q.A./Process Control Operators Staff Other Workers
1 14 6 2 1 1 2 5 3 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.
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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 Soda Ash Caustic Soda Detergent Anti stain Enzyme 10 L Acetic acid Phosphoric acid Hypo Ozone softener Pocket clear Global salt Jet Powder Brightener Meta Hydrogen per oxide Texanish-SF Silicon C-150 Rotto SL Enzyme 50L Origin Forester Forester Local market ECHOCHAME(India) Forester Local market Local market Local market GDS (India) GDS (India) & Forester Local market Local market Local market ACE chemical Local market ECHOCHAME(India) ECOSIL WS-150 (India) GDS (India) GDS (India) Price (approximate) 32tk /kg
25kg/gallon 410tk
140 tk/kg
38 tk/kg
40kg/gallon 410tk 40kg/gallon 410tk 40kg/gallon 410tk
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Enzyme 20L Enzyme BIO Polish Yellow Tenon Wetting agent
GDS (India) GDS (India) GDS (India) GDS (India) Local market
40kg/gallon 410tk 40kg/gallon 410tk 40kg/gallon 410tk 40kg/gallon 410tk
LAY OUT OF WASHING PLANT
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WASHING PROCESS OF SAMPLE WASHING LIQUID ENZYME WASH (WITH STONE) Sample : 2 pieces of legs of denim pant.
Step 1 : Desizing Recipe: Water Desizing agent (desizing enzyme) Anti-back staining agent Temperature Time
: : : : :
100 L 50 gm 20 gm 600C 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 Water Enzyme (enzyme-200) Anti-back staining agent Acetic Acid Temperature Time
: : : : : : :
2 kg 60 L 50 gm 20 gm 20 gm 450C 30 min.
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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. 8. Rinse twice with 150 L water. 9. Stop m/c. Step 3 : Neutralizing Step Recipe: Water Soda Ash Temperature Time
: : : :
100 L 20 gm 45 .C 3 min.
Process: 1. Add water 2. Run the machine. 3. Run m/c for 3 minutes with 450C temperature. 4. Rinse twice with 150 L water. 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.
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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
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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 Step nine Step ten : Hydro Extractor : Dryer : Quality check.
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MACHINERIES OF WASHING UNIT
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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 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. 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.
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INTRODUCTION

Report on Industrial Attachment | SEPAL GROUP

Report on Industrial Attachment | SEPAL GROUP

Report on Industrial Attachment | SEPAL GROUP

Report on Industrial Attachment | SEPAL GROUP

3) GLORY FASHION WEAR

5) SEPAL WASHING UNIT

15000 pcs 7500 pcs 5500 pcs

ANNUAL PRODUCTION CAPACITY

Report on Industrial Attachment | SEPAL GROUP

HISTORY OF THE PROJECT DEVELOPMENT

FLOOR BY FLOOR DESCRIPTION OF THE BUILDING

Report on Industrial Attachment | SEPAL GROUP

SEPAL Group at a glance

Report on Industrial Attachment | SEPAL GROUP

Main market Key personnel

Phone Number Fax Number Website

DIFFERENT SECTION OF SEPAL GROUP

Report on Industrial Attachment | SEPAL GROUP

Report on Industrial Attachment | SEPAL GROUP

Man Power Management

Report on Industrial Attachment | SEPAL GROUP

Report on Industrial Attachment | SEPAL GROUP

Report on Industrial Attachment | SEPAL GROUP

Report on Industrial Attachment | SEPAL GROUP

SAPAL MERCHANDISING DIVISION

KEY PERSONNEL TO CONTACT FOR SEPAL MERCHANDISING DIVISION

Report on Industrial Attachment | SEPAL GROUP

EMPLOYEE INFORMATIONS OF SEPAL GARMENTS LTD.

Report on Industrial Attachment | SEPAL GROUP

EMPLOYEE INFORMATIONS OF ORCHID GARMENTS LTD

EMPLOYEE INFORMATIONS OF ORCHID GARMENTS LTD

Report on Industrial Attachment | SEPAL GROUP

Packing Pressman staff Male Female Total Staff

22 15 31 227 423 650

EMPLOYEE INFORMATIONS OF CREATIVE GARMENTS LTD

Report on Industrial Attachment | SEPAL GROUP

Administration Head Welfare Manager

Report on Industrial Attachment | SEPAL GROUP

Forhad Akbar Rajib Sarkar Lili Gomaje Shahin Alom

RESPONSIBILITIES OF PRODUCTION OFFICER

Report on Industrial Attachment | SEPAL GROUP

Report on Industrial Attachment | SEPAL GROUP

Report on Industrial Attachment | SEPAL GROUP

Report on Industrial Attachment | SEPAL GROUP

Report on Industrial Attachment | SEPAL GROUP

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

MACHINE BRAND NAME

Report on Industrial Attachment | SEPAL GROUP

7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.

Model No. DFB1411PXF H7200A40B

Speed Control PULLY -

Needle No. UOX113 DBX1

Needle Size 11-22 9-18

KM250B-75 RH-9820-01 RH-9820-02

DBX1 EBX7 DOX558

9-18 14-18 14-20

Report on Industrial Attachment | SEPAL GROUP

HE806A-2 MO-67165 mo-67145 DA-9820-8

Three stitches-, threads. -

DCX1 dcx1 UYX128 6 -

9-20 9-20 11-20

5 threads, three needles -