Industrial attachment of divine group of industries limited (dgi).

INDUSTRIAL TRAINING Course Code: Tex -4036 INDUSTRIAL ATTACHMENT OF Divine Group of Industries Limited DGI... at Chandra, Housed in four floors of 24,000 square foot, employees of 750 s

INDUSTRIAL TRAINING Course Code: Tex -4036

INDUSTRIAL ATTACHMENT OF

Divine Group of Industries Limited (DGI).

Introduction

The industrial attachment is the process, which builds understanding, skills and attitude of the performer, which improves his knowledge in boosting productivity and services University education provides us vast theoretical knowledge as well as more practical attachment, in despite of all these industrial attachment helps us to be familiar with technical support of modern machinery, skillness about various processing stages

It also provides me sufficient practical knowledge about production management, work study, efficiency, industrial management, purchasing, utility and maintenance of machinery and their operation techniques etc The above mentioned cannot be achieved successfully by means of theoretical knowledge only This is why it should be accomplished with practical knowledge in which it is based on Industrial attachment makes me reliable to be accustomed with the industrial atmosphere and improve courage and inspiration to take self-responsibility

Textile education can’t be completed without industrial training Because this industrial training minimizes the gap between theoretical and practical knowledge and make us accustomed to

industrial environment I got an opportunity to complete two-month long industrial training at Divine

Group Ltd In the field of ever changing moderns fashion work Divine Group Ltd considers it

prime mission to every new test Which & demand of customers from around the World & all strains

human culture Divine Group of Industries Limited (DGI) acts on the basis premise that fashion is

an exploration in to the images people seek to convey about themselves & the way they live It has well planned & equipped Knit fabric dyeing-finishing and Garment units in addition to facilitate knitting and knitwear manufacturing

I have prepared this report as required in competition of my attachment course in regarding guideline given by the university authority which will lead to a strong guideline and milestone for

my future carrier

Name of Company : Divine Textile Ltd

Address : Chandra, Kaliakoir, Gazipur, Bangladesh Phone : 06822-51229

Head Office : House No: 348, Road No: 26, New DHOS, Mohakhali, Dhaka – 1206, Bangladesh

Fax Number : + 88-02-9885032

Certification & Awards : ISO 9001:2000 & WRAP

Production Capacity : Knitting : 15.5 tons/day (Average)

Dyeing : 15.5 ton/day (Average) Sewing : 100000 pcs/day (Average) Main Production : Basic T-Shirt, Tank top, Long Sleeve, T-Shirt,

Polo Shirt, Shorts, Pajama, Set, Ladies ,Kids Knitwear & all kinds of knit garments & Knit fabrics

In the backdrop of a mercurial, ever-changing fashion world, Divine Group of Industries Ltd considers its prime mission to suit every new taste, whim and demand of customers from around the world and all strains

Mr Hasanuzzaman,

Managing Director

The Chief Executive of Divine Group of Industries Ltd

Divine Group has started manufacture and export of garments since late 1997 Its mission is ti produce the latest design; quality knit fabrics and apparels for international markets

Divine Group is one of the few elite private sector business groups, which contributed wealth as well as welfare to the struggling economy of Bangladesh

As time is essential to space so is taste to its products The secret is love-which, paired with meticulous efficiency and a keen sensitivity to style, makes Divine Group an emerging brand destined to light up horizon

of fashion

Divine Group has team of skilled and dedicated technocrats backed by adequate number of modern USA and European machinery and equipment’s to match international standard of all kinds of knitwear products

Within only a decade, Divine Group by hyper-growth has been transformed into a futuristic entrepreneurial saga Its production has branched out into eight full-fledged factories at four locations- Chandra, Kaliakoir in Gazipur, Chowgasa in Jessore and Mirpur Dhaka

Divine Group Chandra premise houses an ultra-modern Divine Textile Ltd, with forth story building as the main one Divine Textile Ltd Unit-2 a new 09-story building in the same premises

Divine Fabric Ltd a new 3rd story building is under construction at Chandra, Gazipur

The Divine Textile Ltd at Chandra, Housed in four floors of 24,000 square foot, employees of 750 staff with

a daily production capacity of 12,000 pieces of complete garments, while 2650 staff of Divine Textile Ltd unit -2 at the same premises produce around 50,000 pieces of garments a day

Divine Group of Industries Ltd has its own water pre-treatment plan and 24,500 cubic feet water reservoirs in its Chandra, campus The Chandra premises has its own power Generators plant where 2,200 kw power generators guarantee smooth and uninterrupted power supply to its every operation

Divine Group of Industries Ltd has its own Wastage water treatment plan (ETP) and 24,500 cubic dyed water has been treated in this campus and go through the outside

Divine Group home base is Gazipur - a city furnished with the largest garments factory of Bangladesh It had been a center of Textiles and garments in this region ever since the middle ages - a time when it was world famous for its ethereal muslin - and has continued in that tradition as the happening place for Knitwear A busy area, availability of skilled artisans, and a range of other facilities and possibilities render it the ideal ground for Divine Group

Since its inception, Divine Group has never stopped growing - in quality, quantity, capacity and everything in between Its production has branched out into nine fledged factories at four locations - Chandra in Gazipur, Chowgasa in Jessore, Mirpur in Dhaka and near EPZ in Savar Divine Group at present has a daily production

capacity of over 20 tons of knitted fabric, 25 tons of dyed fabric, 30 tons of finished fabric, 10 tons of yarn dyeing and 60,000 pieces of complete Garments per day

In the way of becoming a massive success story, Divine Group became one of the few garment houses in Bangladesh that implemented Oeko-Tex mark certificate The Government of Bangladesh, too, recognized its excellence by awarding the status of a Commercially Important Person ( CIP ) to its chief executive, Mr Hasanuzzaman, the founding Managing Director of Divine Group, since 1997 without any break

Management Meeting

After successful operation in Divine Textile Limited, the owner had decided to start a fully information & technology based along with the social accountability and quality controlled modern

readymade composite knit garments industry in large scale In this connection Mr Salim Reza had decided in a resolution to start a company in Chandra, Kaliakoir, Gazipur in the year 1997 to manufacture knitwear garments for the international market Right from inception the policy of the company has been to provide total customer satisfaction by offering quality knitwear in time To meet the commitments of quality and prompt delivery, Divine Textile Limited Decided to integrate the manufacturing process in a planned manner Over the years the entire process has been integrated

by importing sophisticated machinery from world-renowned manufacturers

Working on new concepts in styling & content of the knitwear is a continuous activity in Divine Textile Limited with an objective to up the quality and the value of merchandise In 1997, the year in which International business was started; Divine Textile Limited concentrated all its strengths and resources in developing a wide range of knitwear for the international market

The mission and vision of Divine Textile Ltd is to manufacture and deliver high quality readymade garments (RMG) to its customers The core objective is to attain and enhance customer satisfaction

by providing on time delivery of desired quality readymade garments and also to increase efficiency

of workforce

To attain these objectives, the management of Esquire Knit Composite Ltd has decided to adopt the following-

1 To increase awareness regarding customers requirements throughout the organization

2 By providing training to develop efficiency of the employee

3 To collect customer’s feedback regularly to know about their conception about their company and to take timely appropriate action

4 To reduce the percentage of wastage / rejection minimum by 2% per annum’s implement and monitorISO 9001:2000 quality management system within the organization

1 Security office

2 Gas Pump

3 Knitting section Unit – I & Air Compressor Room (1st Floor) + Garment section (2rd -4th Floor)

4 Color Store (1st Floor) + Medical Care (2nd Floor) + Quarter (3rd Floor)

5 Chemical Store

6 Fabric dyeing (Unit – I ) & Tube finishing section + Boiler Room

7 Dyeing Lab + Open Finishing Section

8 Fabric Dyeing Unit – II +Boiler Room

9 Generator

10 Yarn & Hanger Store

11 WTP Plant

12 Dyes & Chemical Store (Under Ground) + Kniting & Fabric Inspection Section & Air

Compressor Room (1st Floor) + Garment Section (2nd – 6th Floor) + Garment Printing Section + Office Room, Merchandising Section, HR Department (8th Floor)

13 ETP Plant

14 Under Constructed Building

Divine Fabrics

1 Under Constructed Building

2 Garment Section (Which Construction is also running)

3 Grey Fabric Store + Printing Section + Knitting Section ( 2nd Floor)

4 ETP & WTP Plant

5 Fabric Dyeing & Open Finishing Section & Dyes, Chemical Store (1st Floor) + Dyeing & QC Lab (2ndFloor)

6 Yarn Dyeing + Yarn Dyeing Lab + Dyes & Chemical Store + Generator

Dyeing & Finishing Section

Helper

Sewing man

Squeeze Operator

Dryer Operator

Compactor Operator

Helper

Lab Technician

Q.C Technician

Divine Group can produce wide range of products and they deals with some renowned buyers from Europe and USA market some of those are with whom they worked and those whom they are still working Main buyers name of the company are given below-

Target Australia Carrefour

Lindex Charles Vogele Calvin Klien TCHIBO

H & M ( Hennes & Mauritz)

Duty time / shift change

For knitting & dyeing

The industry has three (3) shifts for the workers Shift duration of every shift is eight (8) hours

For garments section:

SHIFT FROM TO DURATION OVERTIMR

One shift 8.00 AM 5.00 AM 8 hours 2.00 hours

Receiving measurement chart from merchandiser

↓ Checking measurement chart

↓ Making pattern paper

↓ Checking the pattern paper

↓ Send to merchandiser for buyer approval

CHAPTER -03

CAD SECTION Pattern section

In this section normally pattern is modify After receiving an order buyer send the measurement chart to merchandisers Merchandisers send the measurement chart to pattern section Pattern master made the pattern according measurement chart if buyer sends the pattern paper that time pattern master modify that pattern paper

Flow chart of pattern section:

Types of pattern made in Pattern Section

These are used in sewing section

Contents of pattern paper:

Receive pattern

↓ Taking the image of pattern in CPU by digitizer

Or making pattern

↓ Modernizing of all pattern part by the software

↓ Pattern grading by software

↓ Aligning all sizes of pattern in the marker by the software

↓ Completing the marking

↓ Taking approval from cam section

↓ Print marker id delivered to cutting section

Before cutting and its purpose is to minimize the wastage The width of marker is equal to the width of the fabric and should not be greater then 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 will obviously minimize wastage

Marker section included in CAD SECTION-

Following equipment’s are consists in CAD Section-

Win da pattern cutter 01

Win da Plotter(Accu Plot) 01

Win da Digitizing Board 01

Sequence of Cad for garments:

Method of marker making in garments:

Marker can be made either in –

1 Manual method

2 Computerized method

a Digitizing system

b Scanning system

Computerized marker making method is of two (2) types They are -

1 Automatic Marker Making

2 Interactive Method

Interactive Method is used in Crossline Knit Fabrics Ltd It is a common process, here the marker planner plan markers by interacting directly with the system through a computer screen All the pattern pieces are displayed in the miniature form at the top of the screen They are dragged & dropped in the marker area After placing of all pattern pieces, it is possible to see the data like marker efficiency, marker length, and marker width etc information just below the parallel lines After completion of marker making, it is saved in the computer memory & it is possible to take the printout of the marker any time

Efficiency Measure:

Total placed area x 100%

Formula: Total marker efficiency% =

Length x Diameter

Efficiency (usually get)

For Tank top - 75%

For trouser - 78%

or t shirt - 85%

For polo shirt - 85%

N.B.: If a garment consist smaller parts then there efficiency is higher than the larger parts of a

garment

Fabric wastage:

1 Inside wastage

2 Outside wastage

 Ends of fabric losses: Sometimes some allowance needed to keep during fabric

spreading Usually 2” each side, total 4” each ply wastage occurs

 Selvedge losses: Each fabric has two selvedges 2-3% wastage occurs

 Purchase losses: For wrong consumption purchase losses occurs

CHAPTER -4

SAMPLE SECTION

Sampling in garment exports and its importance:

Sampling of garments is given great emphasis It determines the approval of future orders from buyers and fetches business for a garment manufacturing or export company Sampling is one of key elements of the pre-production processes in a garment industry Before a manufacturer produces bulk orders, a prior sampling of styles is done to get approvals and jumpstart the fabrication of garments Samples of garments work as a bridge between buyers and the producers

Machineries of sample section:

Overclock sewing machine 09

Flat lock sewing machine 04

Lock stitch machine 10

Button hole sewing machine 01

Button attaching sewing machine 01

Safe guard machine 01

Process sequence of sample section:

Buying office reference merchandiser

↓ Merchandiser to pattern section

↓ Pattern making

↓ Sample fabric cutting

↓ Sample sewing

↓ Quality inspection

↓ Ironing

↓ Final quality inspection & measurement

↓ Folding & packing

↓ Send to buyer

↓ Buyer approval / buyer rejection

↓ Production pattern

The details attached to the garment sample:

After the confirmation of order, each sample sent to buyer has the following details attached to it , with the help of a tag it contains the details pertaining to both, what the buyer has demanded and what supplement fabric/trim etc they have used (if applicable)

FIT Sample/Develop:

Once proto sample is approved, FIT is being made with actual measurement Modification on the pattern is done to get desired fit of the garment FIT is one of the most important factor to be considered during sample development FIT sample is being tested on live model or Dress form for

to verify garment fit and fall

Size set Sample:

The purpose of the size set is to check fit of the garment in different sizes In this stage factory develops samples in multiple sizes Generally, buyers ask size set sample in jump sizes, like S, L, and XXL Buyer check size set sample and give feedback to factory if anything need to be corrected

Pre-production Sample (PP sample):

All the above samples are made in sampling department Buyer wants pre-production sample (PP sample) to be made in actual production line, so that operators know what they are going to make This sample is made with actual fabric, trims and accessories and made by sewing line tailors PP sample must be approved by buyer or buying house merchants (technical persons) prior to proceeding actual production

Top of Production Sample (TOP sample):

Once production is online, few pieces is taken out in the middle of the production Production pieces are sent to buyer as TOP sample All buyers do not ask for TOP sample Purpose is to cross-check whether factory is following PP sample specification or not

Shipment Sample:

When style is being finished and packed for shipment, 2-3 finished and packed pieces with all packing details are kept for future reference Shipment sample is kept by factory merchants and buyers merchant The approved shipment is sent directly to warehouse and merchants at the buyer

do not get garment out of the shipment That is why they keep shipment sample for future

reference

CHAPTER -5

CUTTING SECTION

Cutting section is the most important and risky section in garment industry For a little mistake full order may be cancelled With the false measurement a big portion of garment may employed With very care this section is handled

Cutting section composed of following section-

 CAD section

 Fabric inspection

 Spreading & cutting section

 Cutting pieces inspection section

Following machines are available in cutting section

Machine name No of Machine

Fabric Inspection machine 01

Straight knife cutting machine 07

↓ Relaxation

↓ Shade Checking

↓ Prepare the fabric in the fabric spreading m/c

↓ Spreading

↓ Marker attachment

↓ Cutting

↓ Numbering

↓ Bundling

↓ Panel Check (QC)

↓

↓ Replace Cut

↓

↓ Print / Embroidery

↓

Checking & Counting (QC)

↓ Sewing

Producer : K.M Cutting Machine Co

Type : Heavy Duty Industrial Cloth Cutting M/C

Quality inspection of fabric before feeding:

Quality inspection of fabric during spreading:

 Crease mark  Marker length

Quality inspection of cutting pieces:

Following faults are checked-

 Oil spot  Hole

 Dirty spot  Yarn contamination

 Crease mark  Measurement

Prepared bundle card

Prepared bundle card according to fabric lay report this card maintain