Industrial attachment of sea moss knitwear ltd

SAMPLE, PATTERN, MARKER SAMPLE Sample making is one of the most important activities in the garment manufacturing process.. Original sample: This type of sample made of original fabri

INDUSTRIAL TRAINING Course Code: Tex -4036

INDUSTRIAL ATTACHMENT OF

SEA MOSS KNITWEAR LTD.

At a glance SEA MOSS KNITWEAR LTD

Year of Establishment : 2004

Status (Legal Structure) : Private Limited Company

Export Market : Europe

Sales Turnover : 22 Million USD

Annual GMT production : 1 Million Pcs/ Year

etc

PRODUCT : LADIS :BRIEF, BIKINI, BOYSHORT, PANTY, THONG,

HI-CUT, STRING, BRA, KAMISOL, AND OTHER LINGERIES

: MENS : MEN’S BOXER, UNDER GARMENTS KIDS : BODY SUIT

:GIRLS/BOYS : ALL TYPES UNDERGARMENTS, SLEEPWEAR & DRESSES

TRADE TERMS : CMT/ F.O.B/ CNF

MODE OF PAYMENT : IRREVOCALE LETTER OF CREDIT AT SIGHT

T/T

BAZAR BRANCH, DHAKA, BANGLADESH

1229, Bangladesh

INTRODUCTION

In Sea Moss Knitwear Ltd there consists a Training Center which is

exceptional from the other factory It is seen that majority percent of

factories has no Training center This center trains the fresh worker This is

help for bulk production and increase the efficiency and ultimately

production is increased There consists all type of sewing machine for

practice For supervision a manager and two supervisor trains the worker

They guide all day long It is added here that some time a worker who

trains for someday has to give for making local garments and with the

concentration of the factory those sell in local market By this practice a

worker can get the proper idea about the floor level production

This training section also helps the worker to-

 operation of a sewing machine

 Familiar with the different parts of a sewing machine

 Give a brief idea about the adjustable portion of a sewing

FACTORY PROFILE

Sea Moss Knitwear Ltd based in Bangladesh, is a woven factory with sustained

goodwill and expertise in exports oriented ready-made garment manufacturing

Sea Moss Knitwear Ltd has earned unrivalled success and remarkable distinction

in the field of ready made garments local and international trading The company

started their ready-made garment manufacturing unit in the year of 2000 At the

beginning they started with two lines of garments production unit with 200

manpower But now a day they have 10 garments production lines with 700

manpower Coming soon they started a largest Textile Composite unit For this

they purchases 170 acres land area Dhakkinkhan, Dhaka Industrial Area

Mission and Vision:

Mission:

Starting from the beginning, Sea Moss Knitwear Ltd has put emphasis

on quality and credibility which helped a lot in earning buyers

confidence upholding a customer centered perspective Highly

professionals of Sea Moss Knitwear Ltd are working consistently to

ensure best support to the valuable clients For regular buyers

dedicated lines of production and specific merchandisers are

there to customize the service and ensure successful execution of

order

Vision:

1 To build up an organization that runs with a motivated work

force, beliefs in customer satisfaction, posse’s good

marketing strategy

2 To be one of the leading composite factory in Asia

subcontinent within ten years

3 To create & recruit 1 lac employee in Sea Moss Knitwear Ltd within

the year of 2030

The Merchandiser

An individual, who acts as a coordinator, follows-up and takes

total responsibility of an order form booking to shipment and

beyond, for the customer who placed it and for his company’s

management

Merchandising

The Merchandising is known to the persons specially involved

in garments trade The term merchandising has been derived

from the merchandise Merchandise means goods that are

bought & sold

The term merchandising may be defined as person who

merchandises good ,specially for

export purposes Garments merchandising means buying

raw materials & accessories, producing garments, maintaining

required quality level & exporting the garments within schedule

time

Merchandising Management system:

Buyer sends an order copy by e-mail or sometimes swatch also

E-mail is taken hand from (Order copy)

The measurement of various parameters are inserted by coding

number in the order copy like-

 Shipment date etc

 Before ultimate order a development sample is sent to buyer

 Lab-dip is approved

 Sampling is carried out

 The sample is sent to buying house to check

 After approved the sample then accessories

 and fabrics are booked

Finally shipment is done after all clearance

The merchandiser basically follows up with all concern

production departments for their ordered products

The major functions/steps of a merchandiser:

 Procuring the garments order

 Procuring the raw materials

 Production of garments

 Shipments of garments

 Receiving of payment for garments

 Negotiation with Buyer

 Order Received

 Purchase Order Sheet Received

 L.C Opening

 Purchase Fabric & Accessories

The steps are shown as diagramacally :

a Buyer confirms a order to a factory

Production planning and pre production meeting:

 Initial planning is prepared by the merchandising department

when the order confirmed

 Based on the sample approval and shipment date, the

production department makes the planning of the production

only

 The planning is done following the styling of the product and

the machine lay out to calculate the number of pieces

production per hour

 Before production commence, pre production meeting is

necessary with all concerned departments to get the correct

productions



Production: sample development, planning, quality control

and inspection (AQL)

Quality Control and Inspection [AQL]:

 Customer wise the quality requirement will get vary and

merchandisers are responsible to communicate with

customers to get the correct quality requirements and need to

co-ordinate with factory quality control department so that

they will well understand the requirement and can take care of

the bulk productions

 Inspections are done during production which is called in line

inspection Later the final inspection done by the factory QC

as well as buying office QC to make sure that the final

products is shipping with right quality

 Mentioned that, the right quality not good quality as the

‘quality’ refers to customer’s requirement

 Also below cost elements need to consider during costing

~ Pricing for Fibers & Yarns

~ Pricing for fabric manufacturing

~ Pricing for garment manufacturing

~ Cost of accessories

~ Commercial cost

~ Break even point

~ Consumption of fabric and accessories with wastage

percentage

~ Total cost analysis [how much does it cost to provide

merchandise to end customer

Commercial

 LC: Letter of Credit- Once the order is confirmed, buyer’s

bank issues a Letter of Credit (LC) to the manufactures Bank

With this LC, manufactures can start procurement of yarn,

fabric, accessories etc necessary for particular order

execution

 If the LC delayed from buyers end, it will impact on the

delivery date and merchandisers need to follow this up with

buyer to get the LC for on time delivery

 Back to Back L/C: To procure the yarn, fabric and

accessories, suppliers need to open another LC for secondary

suppliers bank based on the master LC This secondary

suppliers LC is called back to back LC

j Draw string and stopper etc

Order follow-up and execution:

They do it during running the production As a result if any fault occurring it

rectified in the primary stage

Here, a example is given below how way a order is follow-up and done

Buyer Development Process:

1) Reports & exports documents

Arranging final inspection:

After completion the garment making merchandiser arrange final inspection date

with quality department Inspection is also depending on the wishes of buyer

Now a days most of the buyer follow 2.5% AQL.Here given Bellow 2.5% AQL

STORE OR INVENTORY SYSTEM

Inventory:

Inventory is the stock of any item or resources used in an Organization

Fabric storage:

Supplied Grey fabrics are first subjected to the 4 point inspection system and fabric

allowance point is 28 per 100 yards Only those goods are stored here which are

passed from the quality control department And defected fabrics are back to the

FIG: FABRIC STORE

4- Point inspection system:

Defects (length wise): Penalty point:

1 0-3 inch………1

2 3-6 inch………2

3 6-9 inch………3

4 9 inch & above……… 4

5 Any hole& miss pick……… 4

Example: Suppose inspected fabric length=100 yds, fabric width=50 inch, and following faults are found Faults length No of faults 0-3 inch 3

3-6 inch 5

6-9 inch 3

9 inch & above 2

We know,

Points/100 yds= Total penalty points*100*36

Fabric length*Fabric width

13 3

Points /100 yds = -×100× -

= 09.36 per 100 sq/yds

Fabric inventory:

Various types of fabric and accessories such as sewing tread, button,

interlining, label etc are stored in central room Here also machine sparse

parts and stationary are stored in store room

The flow sequence of fabric inventory is given below:

Received the fabric

Pre-inspection

Physical inventory

Make the swatch card

Prepare blanket shade

Shade segregation Issue fabric to cutting room

Fabric is separated and according to lot number

Accessories inventory:

Flow sequence of accessories inventory is given below

Import receive

Physical inventory

Swatch making

Swatch approval from buyer

Register/Record the entry

Supply to sub store according to demand

Issue to bulk production

Accessories inventory item:

Hanger size: Identify the size of the garment by hanger

Label: Labels are the most important trimmings by which customer

easily, know about the product Here two types of label are

available:

1 Main label: It contains the name of buyer and country Ex

Wal-Mart, USA etc

2 Sub label:

i Size label: It contains the size of the garment

ii Care label: It contains care construction Different types

of care label are given below

iv Composition: It contains fiber composition of the fabric

Ex 65% cotton, 35%polyester

Sewing thread:

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

Many types of button are available in store room Some examples of button

are given below

Amount determination of button:

There are two systems of determination the amount of amount These are

SAMPLE, PATTERN, MARKER

SAMPLE

Sample making is one of the most important activities in the

garment manufacturing process The manufacturer always

needs at least a sketch of the garment, original patterns,

specification and the designer’s sample to make high quality

sample garments at the contractor’s factories Garments

factories are used different name used for different types of

samples In the sample departments of garment factories

different type of sample are made for different purposes

Flow sequence of sample section is given below:

Receive developed sheet from buyer

 Develop the sample

 Send the sample to buyer for approval

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

 Send pre-production sample to buyer

 Start bulk production

Types of sample produce by Sample Section according to buyer demand:

There is various type of sample those are given below:

1 Original sample:

This type of sample made of original fabric and accessories according to buyer sketch

and measurement

2 Photo/ Develop sample:

Here measurement is very important but need not to match the fabric and accessories

For advertising of the product buyer want this type of sample

8 Sales man sample:

To supply the new product in different showroom, buyer wants this sample

9 Photo sample:

Only photograph of the product is send to buyer

10 Shipment/ Reference sample:

After completion the shipment of the garment some garment are kept in sample room

which are known as shipment or reference sample

11 Pre-line sample:

This type of sample is collected from anyone line during production

12 Lab-test sample:

Sample is tested by third party or buyer’s nominated lab

Pattern making

This department provides patterns of different design for sample preparation

Samples are not large scale production, they are small in quality So plotting

machines are not used for samples Patterns are made by drawing the design on

drawing papers and then cutting them manually A sequence can be shown:

Design → pattern → sample preparation

Generally, finished pattern is provided by buyer Then allowance is added and

patterns are graded

Pattern making process:

By Computer:

With Digitizing System - where master pattern is made manual on hard pattern

paper

-Patterns are laid-out on the sensitized table &placed cursor around the pattern

-Modified and graded them directly on screen

CAD Section work flow

CAD section Block pattern Pattern Digitizing by Digitizer machine Pattern Grading pointwaise

Marker Making Costing consumption marker

Booking Cutting

Go to bulk production

Marker making:

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

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

equal to the width of the fabric and it should not be greater than the width of the fabric

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

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

minimize wastages

Objects of marker making:

- To reduce cost;

- To improve the quality of the garments;

- To reduce the cutting time;

- To facilitate large scale production

Possibilities of marker making:

Generally there are two methods by which marker can be made –

MANUAL METHOD:

The man performs it by himself using his hands It is a conventional system and

requires more time Manually two types of marker are made –

1 Full size marker:

Full size marker is made for production purpose

2 Miniature type marker:

Miniature type marker is sometime made and its purposes are to plan or schedule and

learn or study i.e for planning and learning purposes

COMPUTERIZED METHOD:

Now the commonly used system of marker making is computerized

method In this system, a man performs it by himself using computer

software (CAD and CAM) and it requires considerably less time than

manual system Two types of marker are generally made using

computerized system –

1.Full size marker:

Using ‘Digitalizing Board’ the pattern pieces are input into the computer

Computer uses software and a marker paper is printed out that will be used

in the production

2.Miniature type marker:

Only for learning, practicing, and planning purposes this type of marker is

printed from the computer

Factors considered during marker making:

The important factors considered during marker making are –

Nature of the Fabric:

The fabric may be either symmetric or asymmetric Thus the nature of the

fabric should be

considered during marker making

Lay planning of patterns:

Improper lay planning of patterns may create more wastage Thus it should

be taken under consideration

Alignment of the pattern pieces according to the grain line:

It is also another important factor that must be considered The warp

direction of a fabric is very much important for a garment and the grain line

indicates the warp or wale direction

Requirements of cutting:

Before placing the pattern pieces on to the marker or during marker making

the cutting allowances are considered where necessary and where is not It

may produce more wastage and may reduce the dimensions of patterns

Production planning:

Different types and sizes if garments manufacturing may un at a time in an

industry So during marker making it should be considered

Size of marker:

During marker making we have to think about the table size, length of the fabric,

etc

Marker Efficiency:

The ratio between the total areas of the pattern pieces to the total area of the

maker paper is technically termed as Marker Efficiency It is expressed in

percentage If it is denoted by the symbol ή then –

Marker Efficiency (ή) = (Total areas of the pattern pieces/Total area

of the Marker paper) * 100

The factors which influence the Marker Efficiency –

 Manufacturers of the marker;

 Size of pattern pieces;

 Length of the marker;

 Pattern Engineering;

 Nature of the fabric;

 Method of marker making;

 Marker width;

 Kinds or design of garments

The hinders of marker making are –

Grain Line:

Grain line is a more effective constraint of marker making Because of grain

line sometimes it is tough to place the pattern pieces on to the marker,

even though it is possible the wastage become higher

Design of Garments:

Sometimes the designs and repeats of the fabric are regarded as

constraints of marker making The patterns may miss the designs or may

overlap the designs

Nature of the Fabric:

Nature of the fabric may sometimes be regarded as a constraint of marker

making Nature of the fabric includes symmetric and asymmetric

Fabric wastages inside and outside of the marker

INSIDE WASTAGE:

That wastage that is obtained from the inter-spaces of the pattern pieces in the

marker paper It depends on the efficiency of the marker maker and on the size of

the patterns as well

OUTSIDE WASTAGE:

Besides the inside wastages, some fabric is wasted outside of the marker –

Ends of the ply losses:

Generally each ply of the fabric losses up to 4 cm at both sides (Two sides * 2 cm)

End of fabric losses:

The length of fabric may sometimes not cover the ply, it may finish its end at less

than 5 yards (cut piece) This piece of fabric goes through wastage and is called

end of fabric losses

Selvedge losses:

Generally selvedge losses are 2% to 3%

Purchase losses:

Sometimes losses may arise from purchase Wrong consumption calculation may

cause huge wastage

Fabric inspection CUTTING SECTION

Fabric Inspection:

When the fabrics are received from the dyeing and finishing

section, it needs to be checked, because, faulty fabrics can be

supplied from dyeing and finishing But the cutting section has

to check it Otherwise the end products will be faulty For this,

the fabric is being inspected by the quality inspector of the

cutting section They check the fabric fully and find out the

faults Then mark it so that, these faulty portion of the fabric can

be rejected during spreading and cutting Then the fabric is

being stored for relaxation

.

Fig: Finished Fabric Inspection

5 Four point system calculation

6 Prepared fabric inspection report

7 Prepared weight sheet

8 Send to store (With Weight Sheet)