Industrial Attachment of SQ group INTRODUCTION Industrial Attachment is one of the best part to study a running processing technology of the industrial unit for the final year Student of textile Engineering Dept. Of Primeasia University. By going throw the industrial Attachment. The incumbent was deputed to SQ Group(Color master Ltd).For practical mill training as per training programme arranged by University authority under the guidance of color master Sampath jayakoda (Srilankan) and supervision of Chowdury Jony Moin (Lecturer) &the industrial attachment report was prepared for 45 days long training programme in a composite mill. PROJECT DESCRIPTION
General Information About the mill Name of the Factory : SQ Group (color master Ltd) Status : Private Ltd.Company. Type : 100% Export Oriented Company. Year of Establishment: 2003 Location : Address Factory : Jamirdia,Valuka ,Mymensingh,Bangladesh. Head office
: North tower (10th floor),Uttara,Dhaka. Tel: 8153669, 8116672 Fax :(880-2)8116673 Email :firstname.lastname@example.org Web :www.sqgc.com
Owner of the mill Authorised capital
: Director, Mr. M Ghulam Faruq : Approx.100 crore taka.
History of the Project development: 2003:Estublishment of the industry. First installmment of the machinary &started production. 2004: Instllment of the Garment dyeing Machine & started production
2005: Start of the construction of 3rd and 4th floor. Installment of the Sweater Garment making. 2006: Start of the construction of 5th and 6th floor &started production of Garment making. 2007: Installment of new project which are UK &Bangladesh Joint venture & started production at the end of the year. Physical Infrastructure: Total area of the Industry
Building -6 storied Floor space: 60000sq.ft : About 20500 sq.metre.
ORGANOGRAM Chairman ↓ Executive Director ↓ ↓
D.G.M Admin & SA
↓ Commercial Section
Executive Offecer Knitting Dpt. Sr. Manager
Asst, G. (dyeing)
↓ Admunistrative Officer
Engineering section ↓ Computer section ↓ Telephone Operatior
↓ Transport Section ↓ Security Section
↓ Time Section
RESPONSIBILITIES OF PRODUCTION: JOB DESCRIPTION: SENIOR PRODUCTION OFFICER: In a garments factory a senior production officer plays a great role in production and manpower management who are production related.Here we enlist the duties of senior production officer. 1) Follow up the garments production, 2) Regular observation of garments floor, 3) Prepare garment order status regularly, 4) Maintain the quality of the product, 5) To help the senior prod. Officer & co operate with others for fulfiling the required destination. PRODUCTION OFFICER : Production officer is the right hand of senior production officer and he is directly related with production manpower and inform senior prod.officer time to time . Here are his listed duties – 1) Follow up overall garments production , 2) Decide every m/c utilization during production, 3) Recruit new labor , 4) To inform the authority on the overall garments prod. And make it financial profitable, 5) Regular m/c maintenance, 6) Maintain sub –contract orders , 7) Help knitting manager & also guide the junior officers of the section, etc. REMARKS: Production runs with the help of mechanical fiitrs. For any kind of mechanical fault of any machine they fix and work under technical in charge. Production officer’s takes account of daily production by running after the two supervisors and workers so on.
(MACHINE DESCRIPTION )
RAW MATERIALS (A) Yarn : SL Yarn Description 1 80% Cotton 20% polester CVC
Yarn count NE 28/1
2 3 4 5 6 7 8
100% cotton carded 100% Acrylic 70% cotton 30% acrylic 65/35 (cotton/acrylic) 90% cotton 10% viscose Spandex/Lycra 99% cotton 1% Viscose (B) Accessories
NE 30/1 NE 30/1 NE 30/1 NE 30/1 NE 28/1 70 Denier NE 30/1
SL 1 2 3 4 5 6 7 8
Item Description Sewing Thread Sewing Thread Filament Main Label Size Label Care Label Single Poly Poly sticker
Quantity 4050 cone cone cone 5912 doz Doz. Doz. Doz. Doz.
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27
Zipper Blister polybag Interlining Cotton twil Tape Printed Gum Tape Scotch Tape Button Gum Tape Carton Drawstring Herringbone Tape ¼ cotton shoulder Tape Printed carton sticker T/C shoulder Tape Printing of 100% knit fabric Woven Twil Tape Mobilon Tape Single poly Spot Lifter
768 Doz. 860 Doz. 18 Roll 7700 Yds 300 Roll 100 roll G.G Roll 1790 pcs Yds Yds 36300 yds 310 Doz. 5600 Yds Kgs 3900 yds Doz. Doz. Pcs
Production Planning Sequences & Operation of Garments (Sweater) Making. Study on Sixth floor Knitting section Total worker: 100 Floor worker commanding order: Production manager ↓ Assistant Production manager ↓ Floor In charge ↓ Line Chief ↓ Supervisor ↓ Operator ↓
Helper Total line in the knitting section:4 Line sequence: Line A, Line B, Line C & Line D. MIC year line in knitting section: Line A contains 12 knitting m/c. Line B contains 10 knitting m/c. Line C contains 12 knitting m/c. Line, D contains 11 knitting m/c. . Floor knitting m/c list: Brand Name Shima Seiki Shima Seiki Shima Seiki Flying Tiger Flying Tiger Flying Tiger Flying Tiger
Model SSF 152-T SSF 152-T SSF 152-T 2001/2003/201/2005 2001/2003/201/2005 2001/2003/201/2005 2001/2003/201/2005
Origin Japan Japan Japan Taiwan Taiwan Taiwan Taiwan
Sequence of operations in knitting section:Sample fabric receive Design analysis Setting the machine for the specific design Production Inspection
Linking Section Total worker:80 Floor worker commanding order:
M/C Gauge 12 07 05 3 5 7 12
Assistant Production manager ↓ Floor Incharge ↓ Supervisor ↓ Operator ↓ Helper Total line in the Linking section:4 Line sequence: Line A, Line B, Line C & Line D. MIC year line in Linking section: Line A contains 10 Linking m/c. Line B contains 10 Linking m/c. Line C contains 08 Linking m/c. Line, D contains 10 Linking m/c.
Sequence of operations in Linking section:Front part Back part Sleeve Side way Neck Inspection
Production Process: Knitting
↓ Linking ↓ Overlocking ↓ Bar taking ↓ Trimming ( procedure of cutting loose threads ,extra yarns or
extra ply.) ↓ Mending (If have any hole,then repair it & sewing ) ↓ PQC (Primary Quality Check) ↓ FQC (Final Quality Check) ↓ Care Lebelling Adjustment ↓ Ironing ↓ Measurement
↓ OK ↓ FQC (get-up) ↓ Taging ↓ Dusting ↓ Folding ↓ Sizing ↓ Assorting ↓ Blistering / Poly packing ↓ Cartooning ↓ OK ↓ Shipment Note : During FQC if has any small stain then use zinclinc chemical for stain removing by spraying system
FQC,Folding,Sizing,Blistering Cartoning Production Planning Sequences & Operation of Garments(Sweater) Dyeing. Acrylic Piece Dyeing Production: 100 % PAN Cahmilon Colour: Green M/C No: 01 No. Of Garments: 189 pcs. Weight: 43.00 kg M.L.R: 30 Paddle RPM: 18 Recipe: Dyeing Chemicals Rubine ES Megasoft BBK Taigal PAN Glauber Salt Dyeacid HP PH =4.5
GPL/ % 1.0 g/l 1.5 % 1.21 % 5.0 % 0.22 g/l
Calculated amount 1800.0 g 645.0 g 520.3 g 2150.0 g 396.0 g
Dye stuff: Name Taicryl Yellow 4GNT Maxilon Red GRL 150 % Maxilon Blue GRL 150 %
% 0.09458 0.00200 0.01026
Calculated 40.669 0.858 4.413
Used 40.26g 0.84g 4.35g
Procedure: Step 1 Add all Chemical at 70ºC run 05 min. Add Dye at 70 ºC run 05 min Step 2 Heating
Heating 92 ºC× 10 min 0.5 G/ min
85 ºC× 5 min 1.0 G/ min
Timer Setting 1
Step 4 Heating 99 ºC× 30 min 0.5 G/ min
Air cooling at 70 ºC Direct cool slight open valve to 40 ºC Dark col. Additional rinsing.
Acrylic Garments Dyeing Production: 100 % PAN Cahmilon Colour: Rose M/C No: 01 No. Of Garments: 355 pcs. Weight: 65.00 kg M.L.R: 30 Paddle RPM: 18 Recipe: Dyeing Chemicals Rubine ES Megasoft BBK Taigal PAN Glauber Salt Dyeacid HP PH =4.5
GPL/ % 1.0 g/l 1.5 % 1.62 % 7.0 % 0.22 g/l
Calculated amount 1800.0 g 645.0 g 1053.0 g 4550.0 g 396.0 g
Dye stuff: Name Maxilon G. Yellow GL 400 % Maxilon Red SL 200 % Maxilon Blue SL 200 %
% 0.0077 5 0.0159 0.0020
Procedure: Step 1 Add all Chemical at 70ºC run 05 min. Add Dye at 70 ºC run 05 min
Step 2 Heating 85 ºC× 5 min 1.0 G/ min
Timer Setting 1
Heating 95 ºC× 30 min
0.5 G/ min
92 ºC× 10 min 0.5 G/ min
Air cooling at 70 ºC Direct cool slight open valve to 40 ºC Dark col. Need Additional rinsing.
Acrylic Piece Dyeing Production: 100 % PAN Cahmilon Colour: Mid Blue M/C No: 01 No. Of Garments: 406 pcs. Weight: 65.00 kg M.L.R: 30 Paddle RPM: 18 Recipe: Dyeing Chemicals Rubine ES Megasoft BBK Taigal PAN Glauber Salt Dyeacid HP PH =4.5
GPL/ % 1.0 g/l 1.5 % 1.30 % 8.0 % 0.22 g/l
Calculated amount 1800.0 g 975.0 g 845.0 g 5200.0 g 396.0 g
Dye stuff: Name Maxilon G. Yellow GL 400 % Maxilon Red SL 200 % Maxilon Blue SL 200 %
% 0.0004 0.00076 0.012
Calculated 0.260 0.494 7.800
Used 0.26 g 0.49 g 7.80 g
Procedure: Step 1 Add all Chemical at 70ºC run 05 min. Add Dye at 70 ºC run 05 min
Step 2 Heating
85 ºC× 5 min 1.0 G/ min
Heating 95 ºC× 20 min
0.5 G/ min
Heating 92 ºC× 10 min
Air cooling to 70 ºC Direct cool slight open valve to 40 ºC Dark col. Need Additional rinsing.
0.5 G/ min
Production of Yarn Dyeing.
Planning Sequences & Operation
BATCH : C02450700400 MACHINE : PMD – 1 RECIEPE NO: BL-81791007 PROCEDURE : 705 CUSTOMER : PROMOD KNITWEAR YARN LOT : D-1 QUALITY : 32/2 100% CO NO.OF PKG :104 ORDER : SPB-245/07 COLOUR NO : SEA BREAZ BATCH WEIGHT : 106 LIQOUR AMOUNT (L) : 690 LIQOUR RATIO : 6.51 NAME REL. AMOUNT IN RECIPE AMOUT UNIT BLEACHING @ 98’C* 40’ 01 EMERALD DLJ 1.0000g/l 0.6900kg INATEX MD 0.5000 g/l 0.3450 kg SECORON – 540 0.5000 g/l 0.3450 kg STABILIZER SOF 0.5000 g/l 0.3450 kg 02. CAUSTIC SODA 03HYPROZEN PEROXIDE
2.0000 g/l 2.0000 g/l
1.9800 kg 1.9800 kg
04. ERIOPON 05. ACETIC ACIDE COTTON DYEING @ 60’C*30’ 06.CIBACEL DBC LADIQUEST1097 KOLASOL CAD 07. GLOBAR SALT 08. SODA ASH SODA ASH 09CIBA YALLOW FN -2R CIBA RED FNR CIBA BRI. BLUE FNG SOAPING @ 95’C*20’ 10. ACTIC ACID 11. ERIOPON R 12 ERIOPON R FINISHING @40’C*20’ 13. ACTIC ACID 14 TUBINGAL
0.5000 g/l 0.5000 g/l
0.3450 kg 0.9450 kg
1.000 g/l 0.5000 g/l 0.2000 g/l 15.0000 g/l 2.5000 g/l 5.0000 g/l 0.00565% 0.022032 % 0.218900 %
0.6900 kg 0.3450 kg 0.1380 kg 10.3500 kg 1.7250 kg 3.4500 kg 0.0059 kg 0.0234 kg 0.02320 kg
0.5000 g/l 0.5000 g/l 0.5000 g/l
0.3450 kg 0.3450 kg 0.0000 kg
0.0700 g/l 1.0000 g/l
0.04830 kg 1.0600 kg
BATCH : C02430700100 MACHINE : SPMD RECIEPE NO: RE-53120107-CON PROCEDURE : 531 CUSTOMER : PROMOD KNITWEAR YARN LOT : Q-6 QUALITY : 20/2 100% CO NO.OF PKG : 04 ORDER : SPB-243/07 COLOUR NO : RED BATCH WEIGHT : 600 LIQOUR AMOUNT (L) : 33 LIQOUR RATIO : 0.06 NAME REL. AMOUNT IN RECIPE AMOUT UNIT BLEACHING @ 98’C* 40’ 01 EMERALD DLJ 1.0000g/l 33.000gm TINOCLORITE COM 5.000 g/l 165.000 gm 02. CAUSTIC SODA 2.0000 g/l 66.000 gm 03HYPROZEN PEROXIDE 2.0000 g/l 66.000 gm 04. ERIOPON R 0.5000 g/l 16.5000 gm 05. ACETIC ACIDE 0.5000 g/l 16.5000 gm COTTON DYEING @ 60’C*30’ 06.CIBACEL DBC 1.000 g/l 33.000 gm LADIQUEST1097 0.5000 g/l 16.5000 gm KOLASOL CAD 0.2000 g/l 6.6000 gm 07. GLOBAR SALT 80.0000 g/l 2640.000 gm 08 SODA ASH 5.0000 g/l 165.000 gm 09 IMCO YALLOW E -3R 1.926000% 11556.0000gm IMCO RED E3BF 7.500000 % 45000.0000 gm IMCO BLUE ERL O.O31000 % 186.0000gm SOAPING @ 95’C*20’ 10. ACTIC ACID 11. ERIOPON R 12 ERIOPON R FINISHING @40’C*20’ 13. ACTIC ACID ALFABIX ECO
0.5000 g/l 2.5000 g/l 2.0000 g/l
16.5000 gm 82.5000 gm 33.0000 gm
0.0700 g/l 3.0000 %
2.3100 gm 1800.0000 gm
BATCH : C02510700100
12000.0000gm MACHINE : SPMD-1 PROCEDURE : 500 LOT : Q-6 NO.OF PKG :04 COLOUR NO : BLACK LIQOUR AMOUNT (L) : 33
RECIEPE NO: BK-84471107-D CUSTOMER : MANTRUST QUALITY : 20/2 100% CO ORDER : SPB-251/07 BATCH WEIGHT : 4.72 LIQOUR RATIO : 6.99 NAME WASH @ 80’C* 10’ 01WETANAL SN EMERALD DLJ
REL. AMOUNT IN RECIPE 1.5000g/l 1.5000g/l WASH@70’C*10’ 1.5000 g/l 1.5000g/l 0.5000 g/l 2.3000 g/l
WETANAL SN EMERALD DLJ SECORON – 540 ACETIC ACID COTTON DYEING @ 60’C*30’ 06.CIBACEL DBC LADIQUEST1097 KOLAZOL CDA
1.000 g/l 0.5000 g/l 0.2000 g/l
07. GLOBAR SALT 08. SODA ASH CAUSTIC SODA 09 SUNFIX YALLOW MFD SUNFIX RED MFD SUNJOL BLACK DN SOAPING @ 95’C*20’ 10. ACTIC ACID 11. ERIOPON R 12 ERIOPON R FINISHING @40’C*20’ 13. ACTIC ACID 14 TUBINGAL
80.0000 g/l 5.0000 g/l 0.75000g/l 0.140000% 0.048000 % 06.528000 %
0.0495kg 0.0495kg 49.5000 kg 49.5000kg 16.5000kg 75.9000 kg 33.0000 gm 16.5000 gm 6.6000 gm 2640.0000 gm 165.0000 gm 24.7500 gm 6.6080 gm 2.2656 gm 308.1216gm
0.5000 g/l 2.0000 g/l 2.0000 g/l
16.5000 gm 66.0000gm 66.0000 gm
0.0700 g/l 1.0000 %
02.3100 gm 47.2000 gm
Operation Sequences of Wet Lab. Dyeing Lab: Machine no : Brand name : Machine name (Functional): Capacity : Manufacturing Country : Manufacturing Year :
01 AHIBA NUANCE Sample Dyeing m/c 19 Samples. U. S. A. 2001
Machine no : Brand name : Machine name (Functional): Capacity :
02 Ariston Tumble Drier 6 kg
Machine no Company name
03 Data color
Machine name (Functional): Manufacturing Country : Manufacturing Year :
Color fastness test (CCM) U S A. 2001
Machine no : Company name : Model : Machine name (Functional): Manufacturing Country : Manufacturing Year :
04 Verivide CAC 60 Color match / Metamerism Test Halifax England 2001
Machine no : Company name : Brand name : Machine name (Functional): Manufacturing Country : Measuring system : Manufacturing Year :
05 James H Heal & Co Ltd Microsol Light-Fastness Tester Halifax England Blue scale / Data color 2001
Machine no : Company name : Machine name (Functional): Manufacturing Country : Manufacturing Year :
06 RAININ Instrument Co Ltd Pipeting USA. 2001
Special features of Rapid Sample dyeing Machine:• • • • •
19 samples can be dyed at the same time Auto time & temperature controller Speed controller unit Good steam inlet & outlet system Good movement of liquor
Procedure of Lap dipThe main objectives of lab dip preparation:# # #
For good dyeing. For good shade matching. Mass production suitable.
Lab Procedure for the 100 % cotton fabric:• • • • • • •
Calculate the recipe. Weight the fabric. Take the beaker keep the fabric in to the beaker. Then the dyes, chemicals & required amount of water take in to the beaker by the digital pipeting. Then weight the salt by the electric balance and add in to the beaker. Then the beaker set in to the lab dyeing machine for dyeing. Start the program for dyeing the whole dyeing time 60 min at 60 °C temperature. (The dyeing time and temperature depends on which classes of dyes are used for dyeing.)
• • • • • • •
After 30 min add the then add the soda ash. By pipeting. Again run the program next 30 min at the same temperature. Finished the dyeing time then the sample taken from the beaker first cold wash & then cold wash. Then acid wash as for neutralization. Then soaping required soap solution 10 min at 90° C temperature. After the fabric again cold. Then dry the lab dip and compare with the standard.
Amount of salt soda used on the basis of shade %: REACTIVE/REMA RR/CIBA
0-0.49 0.5-0.75 0.76--1.0 1.1 – 1.5 1.6 – 2.0 2.1 – 2.5 2.6 – 3.0 3.1 – 3.5 3.6 – 5.0 5.1 – 8.0
20 30 40 45 50 55 60 65 70 80
10 12 16 17 18 18 20 20 20 20
Merchandising is the business art of matching sellers’ needs to the needs and preferences of customers to ensure satisfaction with products. Merchandiser has a lot of responsibilities. Some major responsibilities are as follows: • • •
Sourcing, Negotiation Consumption and costing Order receiving
• • • •
Product development and Sample controlling Fabrics, Yarn, Trims & Accessories purchasing & tracking Factory scheduling and production tracking Customer liaison during design, sourcing, production & shipping.
Merchandising Procedure: 1. Contact with Buyer • • •
Introducing letter Vendor Inspection/ Evaluation Vendor approval
2. Order receiving process flow: •
Competition for order!!! • • • • •
prepare costing price quotation meeting with buyer or face auction competition getting initial/optional order
3. Order development process • • •
Order confirmation (with qty,qly.m/c, sketch,del dt. fab,trim.accss lab dipping approval
sample making + development
4. Execute order in time • • • •
fab + accss consumption calculation order placing to supplier(booking) follow up supplier delivery date store/ warehouse
5. Garments manufacture Cutting Sewing Finishing 6. Final inspection 7. Pack list, weight list, Release letter 8. Ready for Export Functions to execute export order perfectly in time
1. Fab requirement calculations Fabric requirement = Order qty / 12 x Consumption Consumption = Length x Chest / 10000 x GSM / 1000 x 2 x 12 2. Accessories requirement calculation Sewing thread = Color wise order qty / 4000 (cone) x consumption Consumption = (3 x stitch length) + (2 x material thickness) • • • •
Interlining requirement = Order qty / 12 x Consumption Shoulder Tape requirement = (Order qty x Consumption) / 36” Gum Tape requirement = (Order qty / Carton qty) / 6 Stopper requirement = (Color wise order qty x No. of stopper per Gmt x 5%
• • • • •
allowance) / 12
Rib = Order qty / 12 x Consumption Draw cord = (Order qty x Consumption) / 36” Main label, Sz & Cr lbl, Poly = (Order qty x 5%) / 12 Barcode requirement = (Order qty x 10%) / 12 Carton requirement = Total no. of pack / No. of pack per
ctn 3. 4. 5. 6.
Sources of Fab Sources of Accessories Possible date of arrival of fabrics & accessories in gmts fty Costing
7. Gmts production planning 8. Pre shipment inspection schedule 9. Shipment documents
Various types of sales terms: • • • • •
FOB = Free On Board C&F = Cost and Freight CIF = Cost, Insurance and Freight FOA = FOB Airport FAS = Free Along Sideship
Various files in use: • • • • •
Price quotation & Project sheet Accessories supplier file Production file Master sheet Incoming & Outgoing File
UNDER SEVERE PRESSURE!!!! • • • • • • • • • •
P/I File Sub contact file Recap Claim file Yarn & knit stock register Fabric booking Master L/C Fabric register book Shipment Status Release letter
QUALITY ASSURANCE SYSTEM
Store Dept: Raw material quality is the first step to ensure the quality of the product. But the raw material purchased from the good suppliers not ensures the quality. For that solution we need to control the quality according to the buyers’ specification we need to emphasis to the quality of purchased raw material by the quality inspection. For the good production flow, the company deviled sousing. Finishing trims and accessories into different places which are obviously the good idea for maintaining or supplying the products. Those are calledAccording to the buyers’ zone1. EUROTEN buyers’ store 2. U.S.A buyers’ zone In SQ Group (CML). we have visited in two different stores. The stores are1. Fabric stores 2. Trim and accessories store Fabric Store: It is a store where the fabric was kept up according the buyer mains and order. The main function of this store is to inspect the fabric and send it to the cutting according to cutting requirement. In SQ Group (CML) I found that they have followed 4 point system for fabric inspection. The inspection sequences for fabric inspection SQ Group (CML) are as follows: 1. 2. 3. 4. 5. 6.
Collect the fabric from the suppliers. Prepare general defective swatch board for all fabric. Select the sample size randomly from the lot. Mark the defects. Inspect for the sample according to 4 point system. Report to the quality control personnel.
1. Collect the fabric from the suppliers: According to the purchase order sheet the store in charge receive the fabric to color, shade and quantity. 2. Prepare the general defective swatch: Common defects that can arise during inspection are prepared earlier as swatch, which is hanged on the wall. Those defective swatches are helped for identify the defect to the responsible persons. 3. Sample size selection: The sample is 10% of total lot and it is selected randomly. The points that are considered during selections are1. Color 2. Quality 3. Construction If the quality does not exceed the acceptance quality level they will go for another 10% inspection. If it also misses the accepted quality they will go for 100% inspection. 4. Mark the defects: Often inspectors are given the responsibility if inspecting garments without adequate training in fabric and their causes. The ultimate solution, of course, is to provide actual examples or photographs of both major and minor defects. The quality control manager can provide this list to inspectors as a particular tool for achieving uniform inspector inspection decision. Major defects: A defect that, it conspicuous on the finished product would cause the item to be second. (A second is a garment with a conspicuous defect that affects the salability or serviceability of item.)
Minor defects: A defect that would not cause the product to be termed a second, either because severity of location. When inspecting piece goods prior to cutting it is necessary as major. Since the inspection will not know where the defect may occur or the items. Equipment Uses: 1. Light source:- For the inspection of the fabric fault we need sufficient light. The sources of light are tube light. 2. Top light: There is 1 tube light in perpendicular to the direction of the fabric and another is back light. 3. Machine: For inspection the need power driven fabric inspection machines which brand name TSSM. 4. Arrow sticker 5. Measuring tape Various Files in use: • Order Sheet • Delivery chalan Inspect the sample according to 4 point system: They apply 4 point system for fabric inspections are as follows: Size of the defects (length) 1. Up to 3” 2. 3” to 6” 3. 6” to 9” 4. Over 9”
Penalty points 1 point 2 point 3 points 4 points
Only major defects are considered for the penalty points. Major defects are classified as follows: slubs hole soil printing defect other fabric defects Lacking existing in the fabric inspection:
shading dye defect
1. The space of the fabric inspection is not enough to ensure the quality. 2. The lighting positioning is not correctly maintained. 3. The light power is not enough to ensure or specified the defects. 4. All important points are not identified to the swatch board or no list can used in the comfortable. 5. Bowing and skewing are ignored during the inspection. 6. The RPM of the inspection m/c are not better during inspection. Suggestions against the fabric inspection: 1. 2. 3. 4.
The place should be increased with proper lightings. All the important defects should be specified in the inspection room. The RPM of the m/c must be adjusted according fabric and defects. Skewing and bowing should be considered during fabric inspection
Lacking of the fabric storage: 1. Storing/placing one by one not good or correct for that any types of permanent 2. effect can be happen to the fabric. 3. The segmentation of buyer wise block is not maintained perfectly. 4. No use of order/color/shade wise demarcation and racking system. For that any mistake can be occurred. 5. The ventilation system for ensures the quality is not maintained for that present ordered fabric condition and the excess or extra fabric can be damage without any trace. The suggestions against the fabric storing: 1. The fabric lot should be stored with crossly one another. 2. The fabric should be segmented with the demarcation and shade wise for the order basis. 3. The ventilation system should be increased to maintain the temperature. 4. The racks can be used for the fabric storing Trims and accessories store: It is a small store where trim and accessories are arranged in the rack according to buyer wise. The main function of this store is to prepare or an inventory report compared with purchase order and input packing goods. They also prepare an accessories swatch board to get approved from buyer. Process flow: • P.O. sheet, booking sheet. • Order sheet follow up. • Supplier contact • Goods in-house In case of local supplier
Delivery chalan Inventory
In case of imported accessories Supplier commercial invoice, packing list •
Good receive --- Chalan --- Joint inventory with supplier parts --- Reporting to supplier
• • •
Goods style vs buyers’ mention Putting onto the rac Rac vim cart
In inspection sequence those maintained by SQ Group (CML) are as follows: 1. 2. 3. 4. 5.
Compare with purchase order specification. Select the sample size. Categories the defective accessories from each product. Compare the defective accessories with the limit of AQL 2.5 Report to the quality control personnel.
Sample size: The sample size should be 10% lot of total quality. If it is rejected then they will go for another 10% of total lot. If the total quality is within 500 they check 100% of lot. Lastly if the last inspection failed then they go for the total lot inspection. Categorized defective accessories: They usually check individual product separately. 1. 2. 3.
Sewing thread Button Price ticket
AQL measures: The Consumer Products Limited has accepted accessories quality if the defective sample is over 4% of the sample size. Compare with P.O sheet:
After receiving the goods the quality in charge compare with P.O sheet specification. Such as 1. 2. 3. 4.
Size Color Types Etc
Lacking of the Store: 1. Insufficient light. 2. They don’t inspect all the time quality of the accessories. 3. Storing of the fabric is incorrect positioning. 4. Don’t consider the thread tenacity and thread elongation and running performance of sewing thread so that accurate sewing threads are not specified. 5. The store temperature is not controlled for the stability of the product. This can reduce quality. 6. For the inspection of the accessories there no specific table and space. 7. The store is not all time controlled by the quality control department. 8. During the inspection the shade variation are not consider very important. 9. The last order was not stocked in a rule. 10. The quality pass not specified. After the 10% check which can mix up with other in inspected material. Delivery to Floor/ Fty: --- Fabric cutting statement to supervisor --- Supervisor statement & requisition --- Submit to store --- Examine & follow up the requisition --- Delivery to floor --- Store delivery man resubmits requisition to store officer --- Issue into the register book & stock the balance. Sample Section Samples must be checked by the quality control personnel before sending it to the buyer.Important points to be checked whether the samples are as per buyers’ specifications or not such as style description, sketch, measurement sheet, photograph etc. and workmanship has to be checked with reference samples or related documents provided by the buyer. Report to be submitted to the merchandiser as well as to the superior. Work process flow: • •
Analyze Spec & Meas Chart Preparing consumption
• • •
Sample cutting & sewing M/C check Send to buyer
• • •
Comment from buyer / buyers’ agent Reprocess & resubmission (if needed) Sample approval
Size set pattern making for all sizes Test cutting order placed to cutting section Pattern correction (if needed)
Order place for final cutting
Lacking of the Sample section: 1. The inspection place is congested. 2. The inspection table is not sufficient high. 3. There is no quality pass. Cutting Floor Process flow: • Collect PO sheet from merchandising department • Collect pattern from sample section • As per ratio wise marker sketching • Receive Fabricss from store
• Fab layup as per marker lenth • Marker setting on fab • Cutting • Numbering • Bundling / Sorting • Cut panel inspection • Send to sewing dept.
Cutting: Plan to measure, mark and cut the binding and border strips before cutting patches from the same fabric. Cut larger patches before smaller ones. For best use of fabric, arrange patches with cutting lines close or touching.
Patches for hand piecing require precisely marked seam lines. To mark the patches, place the template face down on the wrong side of the fabric and draw around it
accurately with a sharp pencil. Leave approximately 1/2" between the patches for seam allowances. After marking, cut outward from the seam line 1/4", measuring the distance by eye. For machine piecing, accurate cutting of the patches is very important. Place template face down on the wrong side of the fabric and mark the cutting line Reverse (r) templates for both hand and machine piecing should be placed face up on the wrong side of the fabric. Templates for appliqué do not include turn-under allowances. Place the template face up on the right side of fabric (face down on right side for a reverse patch); draw around it with a pencil. Cut out each appliqué patch about 3/16" from the penciled line Grainline: One or more straight sides of the patch should follow the lengthwise or crosswise grain of fabric, especially the sides that will be on the
outside edges of the quilt block. We indicate lengthwise or crosswise grain with an arrow on the pattern piece. Various files in use: • Daily cutting report • Daily input statement • Bundle chart • Cut panel checking report • Fab inspection report Cutting Section: There are various types of work done by the cutting section. We can divided their work by following:
A) Pattern/Marker: Pattern and marker must be checked by the quality control personnel. B) Spreading: During spreading some important points to be checked such as fabric relaxation, incorrect tension of plies etc. C) Cutting: Inaccurate cutting, notches, misplaced, drill mark, careless knife cut, frayed edges are to be checked. D) Beside these bundle card ,numbering, wrong size, fused parts, cleanliness, proper issuing are to be checked. Lacking of the cutting section: 1. We have found the quality control personnel were gossiping when they are working. 2. There are not enough quality personnel in the cutting room. 3. Spreading is not checked by the quality control personnel. Knitting section • •
Flat knitting section Circular knitting section
Process flow --- Getting order --- Yarn count selection & purchase --- Machine type selection --- Making grey program --- Start production --- Supply to dyeing dept. Various files in use:
1. 2. 3. 4.
Order sheet file Sample order sheet Daily production report Progress report
• • • •
Short manpower Lack of production officer Lack of quality section No engineering dept.
Sewing floor List of some machineries: 1. Plain stitch
7. 3-5 Thread flatlock
2. 3. 4. 5. 6.
3-5 Thread Overlock Two needle stitch Kanchai special Button hole Button stitch (attach)
8. Fab cutting machine 9. Steam Iron 10. Spot remover 11. Eyelet hole 12. Fusing machine
• • •
Taking cutting statement from cutting section Receive cut pc Sorting
Operation sequence of POLO Shirt: • • • • •
Placket making Placket marking Front part marking Placket join with body Back & front part join
• • • • •
Sleeve hem Sleeve join Collar join Collar piping join Send to finishing section
Finishing section This is the final section to make the product saleable condition and finishing process should be controlled to achieve the quality target. For wash garments 100% check is required after receiving the garment from the washing plant. Defective garments should be rectified and reject pieces should be sorted out. Process flow: a) Iron/press b) Folding c) Folding getup check d) Tagging/sticking
e) Packing f) Audit g) Pre-final inspection h) Final inspection.
Maintenance Maintenance is a procedure by which we can maintain active functioning in operation according to the behavior and utility of a particular element. In engineering, we use this terminology for maintaining smooth and uninterrupted performance of machines, tools and metallurgical characteristics in practical uses.
Three types of maintenance are performed in SQ GROUP (Color master Ltd): 1. Preventive Maintenance 2. Routine / Schedule Maintenance 3. Breakdown Maintenance 1. Preventive Maintenance: Actions performed periodically (or continuously) prior to functional failure to achieve the desired level of safety and reliability for an item. These actions are performed to prevent or reduce consequences of failures. 2. Schedule maintenance: It is a time based maintenance and pre-planned to perform on machine and equipments. This plan usually made on monthly basis. 3. Breakdown maintenance: In this type of maintenance when the machine remains stop that time the maintenance is done. Maintenance Tools, Equipments & their functions:
Name of Tools
Hammer Slide Wrench Spanner Pliar Hacksaw Pipe Wrench Chesel File Clamp Vice
To give shape. Tightening and opening bolt. Tightening and opening bolt. Cutting, Holding, Joining wire, Gripping. Cutting. Tightening, opening, gripping pipe. Shaping, Cutting. Shaping. Gripping.
Name of Equipments
Grinding m/c. Cutting m/c. Drill m/c. Shaping m/c. Lathe m/c. Bending m/c.
Grinding. Cutting. Drilling. Shaping. To make something. Bending.
Maintenance Procedure: Preventive Maintenance: They always follow preventive maintenance. Break-down maintenance: When a problem occurred the operator informed the supervisor, then the supervisor informed the production officer, then the production officer called the maintenance officer. The maintenance officer visits the problem and takes necessary steps to solve the problem. Flow chart of maintenance Problem occurred Operator
Supervisor Production officer Maintenance officer Solution
Remarks: Their maintenance procedure is very good & effective as a result they have a good efficiency.
Utility Services UTILITY SERVICES Introduction: SQ Group (Color master Limited) is a big project and so of course having a vast project of utility service. 1'rom different source it collects necessary utilities at a cost to knitting, dyeing & finishing section and garments section. Here is the total account of utility facilities -available. Power & Utilities section: DESCRIPTION OF MACHINE
NO. OF MACHIENE
Generated Power: Prime Power generation, Cruascar Gas Generator Model FGLD 480 - Origin Spain. Stand by - Diesel Generator, Puma, Origin England A. Sub station Total Connected load Air Compressor: Kaeser Screw Compressor, Model AS44, 30 KW, 4 M3/Min each. Omgersp:-Rand Reciprocating Compressor, Model-SSR ML-50 57.5 Kw Capacity of Air Discharge Ingersoll-Rand Reciprocating Compressor, Model 3000. 22 Kw SWAN Reciprocating Compressor, Model C40-80 10KW TOTAL AIR DISCHARGE CAPACITY
CAPACITY 636 KW 140 KW 1000 KVA 1776 KW
4.40 M³/Min 1.00 M³/Min 21.4 M³/Min
Water Pumps Centrifugal Pump for water supply to Dyeing & Others Section. 20 H.P. Pedrollo Pump each pump, 1000 L/mi-n Flow rate 10 H.P. Pedrollo Pump Flow rate- 600 L/Min 5.5 H.P. Pedrollo Pump Flow rate -350 L/Min Spare Pump Motor Pedrollo 20 H.P.
I Unit I Unit I Unit
600.OOL/Min 350.00 L/Mm 1,000 L/Min
BOILER: Ciever Brooks Boiler 10 Ton/Hr Water treatment plant There are two deep tubeweel by the two side of the treatment plant. There are also two submersible pumps in the deep tubeweel one is 100 ft deep and another is 140 ft deep. The submersible pump transfer raw water in the water tank by creates force. The formation of oxidation of the water by showering with the help of another two pumps in the water tank. Iron content removes by the oxidation. Two circular transfer raw water in the (vessel no 1) Multigrade filter unit. The large size plastic, iron that means solid content are removed in the multigrade filter unit. The water is transferred in to the (vessel no 2) Activated carbon filter unit. In the (vessel no 2) Activated carbon unit to remove chlorine that means bad smell. The water then transfer in to the (vessel no 3) softener unit from the activated carbon unit at the presence of cationic resin (Zeolite) is reacted with water to remove the hardness of water. The water is transferred in to the reserve tank from the softener unit. The soft water is supplied from the reserve tank by the 7 Boosting pump in the different section of the factory. The back wash & regeneration process: The back wash process to clean the vessel no 1, 2 , & 3 . The back wash process should be done after 8 -12 hrs .After 40-48 hrs later the regeneration process should be done. It should be done after back wash process. After back wash the common salt dissolved with water in to the STT (salt saturated tank) the solution of common salt is ringing the resin by the injector. The use of 18% salt in the total solution. (Suppose, 5000 lit of solution the amount of salt 600 kg). The resin is activated by the salt rising. Here used cationic resin (NaHSO3). If the pH of the water increase or decrease it should be control by the dosing chemical (Sodium Hypochlorite) from the chemical tank. Details on ETP: Effluent Treatment Plant (ETP) is a plant by which waste water is treated in order to make the waste water environmental friendly. Effluent Treatment makes sure that water releases meet Bangladesh Environmental Association water quality standard. It is very important and essential to keep the environment pollution free. Now a day ETP is the most important term to set a textile industry. Government, Environmental Association and foreign buyers are
creating pressure to set ETP in every textile industry .So to ensure the proper growth of textile sector and pollution free environment every textile industries have to set up an ETP. There are three effluent treatment plants which are: 1.
Physico-chemical treatment plant Chemical-biological plant Biological treatment plant
Chemical treatment plant:In this process effluent water are mainly converted into sludge of metal complex by chemical reaction. Then it is separated from the water and dried and dipped into the soil. But the sludge remain activate which is harmful. Effluent → hazardous)
Sludge of metal complex → Dry sludge → Dipped into soil (Activated
Biological treatment plant:This process is mainly build up by using micro-organism. This is Bacteria, Amoeba, and Protozoa. Bacteria are two types, one is Anaerobic& Aerobic. First one is hazardous for our environment and second one is friendly for our environment. In here Bacteria break the bond of harmful chemical by enzyme secretion. As a result harmful chemical converted into environmental friendly. The sludge produces by this process is also used as different functions such as fertilizer, fuel in the brick field.
Micro organism is the main raw material for Biological plant: • • •
bacterial amoeba protozoa
Bacteria: 1. 2. 3. 4. 5.
Bacilli Cocci Beggiatoa Spirillum Vitereoeilla
Protozoa: Paramecium caudatum Euplotes Colpidium Amoeba: Rotifiers Cillities Novcotidia
Remarks: As the biggest project the SQ GROUP (Color master Limited) so the vast utility systems. There is a skill manpower group of engineers and other technical staffs to look after these utility services. They have to remain aware of solution on a great sense of responsibility for any type of problem due to utility supply.
Store &Inventory Control
Inventory is planning and execution involves participation by most of the fundamental segment of business sales, production, purchase, finance and accounting. Inventory is a wider sense is defined as any idle resource of an enterprise however it is semi finished packing spares and other stocked in order to meet an expected demand or distribution. OBJECTIVES OF INVENTORY CONTROL:
1) Financial activities: a) To save amount of investment b) To know the cash position 2) Property Protection: a) Preventable waste b) Insurable damage c) Unauthorized use 3) Operating: a) To obtain the best overall balance between production and inventory carrying cost. b) To minimize losses, c) To avoid stock out and to keep inventory holding costs in costs in balance. The prime responsibility for the inventory management function in the company including the estimation of consumption quantities of raw materials over the forecast period and initiation of a purchase requisition keeping in view quantities is transit and an order and the adequacy as otherwise of material coverage during lead time is as follows: The Procurement Department is responsible primarily for the sourcing of raw material. The flow chart of requisition of raw materials is as follows: Factory requisition Audit Department Commercial
Accessory dyes / chemicals yarn
grey fabrics finished fabrics
Inventory system of Raw materials: Grey fabric is stored in the Grey store. The batch is prepared by taking Grey fabrics from Grey store.
There is a separate store for Dyes & Chemicals. Various types of Dyes & Chemicals are stored here according to companyâ&#x20AC;&#x2122;s storing criteria. The operator takes Dyes & Chemicals from this store according to Recipe Sheet. Inventory system of Finished Goods: o
They do not store finished fabric. They make delivery of finished fabric to Garments just after completion of finishing. They only store some rejected fabrics. Remarks:
Inventory management is good & satisfactory
Cost Analysis Following information is unavailable-
Price of the product Costing of the product
REMARKS Costing is as important as production for a productive factory. Without proper costing all production curriculums will go to in vain. Cause, a factory cannot reach to its goal without achieving good profit and good profit is not possible without skillful costing. Seeing the improvement of SQ GROUP (color master Limited ) day by day, I can assume that it follows the right and proper way of costing with skillful technical persons.
Marketing Activities INTRODUCTION: Marketing activities are done in this mill, SQ Group (Color masterLimited)by a skillful team of marketing officers under the Executive Director. Here are the details of marketing activities. CONSUMER OF THE PRODUCTS: The mill has a great number of renowned and international consumers. Following are some regular consumers: 1) Marks & Spencer 2) H&M 3) Primark 4) C&A etc. PRODUCT LEBEL:
There are following lebels used by this mill: 1) Care Lebel: It contains washing in hot or cold water, chemical cleaning, drying conditions etc. 2) Size Lebel: It contains size of garments. 3) Composition Lebel: It contains the fabric composition of different fibre type. 4) Decorative Lebel: Decoration is as buyer or consumer choice wise. PACKAGE SIZE & LEBEL: Most common sizes are S - Small M - Medium L - Large XL - Extra large XLL - Very very large LOCAL MARKET: SQ GROUP (Color master Limited) is 100% export oriented mill. So there is no local market involved in it. But the knitting section takes some sub-contact for knitting an amount of fabrics from their given yarn. IMPORTING COUNTRIES: This mill relates to the countries for yam importing, they are 1) India 2) Korea MARKETING ACTIVITIVES Business style FOB Consumer of the products Foreigner Main buyers: Marks &Spencer (England) In Wear (Germany) Tom Tailor (Germany) Hanes (Europe) H&M C&A etc. Optional buyers : Quantum clothing Mantrust Inter stoff etc. MANPOWER:
Almost ten marketing officers and ten others workers act under the Executive Director. DUTIES & RESPONSIBILITES OF MARKETING OFFICERS: 1) Executive director takes order from the buyer and gives order the marketing officer's troops to produce a cost sheet. 2) Marketing officers are known the amount and design of product. 3) They collect the sample from the buyers and send to knitting and dyeing section. 4) Knitting section adjusts the amount of total yam and knitting conditions and dyeing sections adjust the amount of dyes and chemicals. They send a rough calculation to the marketing section. 5) Marketing officers adjust the amount of garments accessories with the help of their own experiences and their knowledge. They also take help of garments in charge. 6) Finally, they adjust their cost sheet after consulting with the Executive Director and copy several pieces of the cost sheet. REMARKS: Marketing activities are very important tasks for a productive factory. In this mill, there having highly qualified marketing officers. As a result, the mill rises up day by day
Conclusion The industrial training gives me the first opportunity to work in mills. It was and experience of normal academic learning. 40 days long training gave me actual picture about man, m/cs, money, material, method and market and interdependence. I have Learned the direct practical knowledge about the raw materials, actual running condition of the m/cs, works of technologist, administration. SQ GROUP (color master Limited) is a 100% export oriented industry. The Whole factory building contains 4 sections, such as Sweater knitting, Yarn dyeing, finishing and garments dyeing. The machinery of this industry is most modern which can be produced quality knit goods. The mill is a well planned mill with enough expansion facilities. Their exist a wonderful employer and worker relation. Working environment for the labors is also good. This mill does not follow the routine maintenance schedule of international standard. So I think that installation of raw materials quality control section will must. The Sample fabric inspection section is also so improved. During our training I visited administration section, godown, store, boiler house, generator room etc. Everywhere I got cordial response from the employees. Above all this training for 40 days in the SQ GROUP (color master Limited )has given me a new experience for practical life.