Industrial attachment of four knit wear limited

The Sample Section has been decorated by One Sample In charge who is responsible togive all sorts of direction to making the sample.. Sample is the proto type or model of the garments, u

Shiddhhirganj, Narayanganj Bangladesh

Shiddhhirganj, Narayanganj Bangladesh

Shiddhhirganj, Narayanganj Bangladesh

Southeast University

Supervising Officer:

Mahmud Rahat Chowdhury

Executive Director Four Knit Wear Limited

REPORT ON INDUSTRIAL TRAINING

IN Four Knit Wear LTD

TRAINING PROGRAM FOR THE DEPARTMENT OF TEXTILE ENGINEERING.

SOUTHEAST UNIVERSITY, DHAKA FROM 15.09.2012 TO 15.11.2012

COPY FOR SOUTHEAST UNIVERSITY

of the manufacturer and other organizations With a view to overcome this consequence a newgeneration of engineering graduates with leadership skills and management capabilitiesaltogether are in demand.

The students of Southeast University were sent to different industries and assigned to differenttasks I had assigned to Four Knit Wear Ltd This report is a presentation of my experience in thegarments and also a details presentation of my works in that industry.

of the manufacturer and other organizations With a view to overcome this consequence a newgeneration of engineering graduates with leadership skills and management capabilitiesaltogether are in demand

The students of Southeast University were sent to different industries and assigned to differenttasks I had assigned to Four Knit Wear Ltd This report is a presentation of my experience in thegarments and also a details presentation of my works in that industry.

of the manufacturer and other organizations With a view to overcome this consequence a newgeneration of engineering graduates with leadership skills and management capabilitiesaltogether are in demand

The students of Southeast University were sent to different industries and assigned to differenttasks I had assigned to Four Knit Wear Ltd This report is a presentation of my experience in thegarments and also a details presentation of my works in that industry.

At first we express our heartiest thanks to almighty Allah for finishing my work properly

My attachment was the first practical experience of working in the industry On the whole course

I have got a lot of helps from my respective teachers, and also a great help from our supervisor inFour Knit Wear LTD

I also would like to gratefully acknowledge to the authorities of Four Knit Wear LTD industryfor giving me permission to carry out my Industrial Practices in their industry I want to thankour

1 Mohammad Mahmud Russel- Managing Director

2 Mahmud Rahat Chowdhury – Executive Director

3 Khan Mohammad Al Mamun- General manager Of Merchandiser

For his great help with his experience

I place my thanks to all the official staffs of administration, production department, maintenancedepartment, quality control for their cordial behavior and helpful support to gather informationregarding to the industrial attachment

On my whole way i would like to express my gratitude to Professor Prof Syed Fakhrul

Hassan, Chairman, department of Textile Engineering, Southeast University.

Acknowledgement

At first we express our heartiest thanks to almighty Allah for finishing my work properly

My attachment was the first practical experience of working in the industry On the whole course

I have got a lot of helps from my respective teachers, and also a great help from our supervisor inFour Knit Wear LTD

I also would like to gratefully acknowledge to the authorities of Four Knit Wear LTD industryfor giving me permission to carry out my Industrial Practices in their industry I want to thankour

1 Mohammad Mahmud Russel- Managing Director

2 Mahmud Rahat Chowdhury – Executive Director

3 Khan Mohammad Al Mamun- General manager Of Merchandiser

For his great help with his experience

I place my thanks to all the official staffs of administration, production department, maintenancedepartment, quality control for their cordial behavior and helpful support to gather informationregarding to the industrial attachment

On my whole way i would like to express my gratitude to Professor Prof Syed Fakhrul

Hassan, Chairman, department of Textile Engineering, Southeast University.

Acknowledgement

At first we express our heartiest thanks to almighty Allah for finishing my work properly

My attachment was the first practical experience of working in the industry On the whole course

I have got a lot of helps from my respective teachers, and also a great help from our supervisor inFour Knit Wear LTD

I also would like to gratefully acknowledge to the authorities of Four Knit Wear LTD industryfor giving me permission to carry out my Industrial Practices in their industry I want to thankour

1 Mohammad Mahmud Russel- Managing Director

2 Mahmud Rahat Chowdhury – Executive Director

3 Khan Mohammad Al Mamun- General manager Of Merchandiser

For his great help with his experience

I place my thanks to all the official staffs of administration, production department, maintenancedepartment, quality control for their cordial behavior and helpful support to gather informationregarding to the industrial attachment

On my whole way i would like to express my gratitude to Professor Prof Syed Fakhrul

Hassan, Chairman, department of Textile Engineering, Southeast University.

Company Profile

Four Knitwear LTD

To establish as a one stop source for the Global knit Apparel market and to satisfy and meetcustomer's expectation by developing and providing products and services on time, which offervalue in terms of Quality, Price, Safety & Environmental impact

Assuring complete compliance with the international quality standards and also providing theemployees internationally acceptable working condition and standards

To promote the development and to use human talent & equal opportunity of employment

They procure the most advanced & sophisticated technology suitable for producing desiredproduct and attain highest level of competence through continuous development of theprofessional, management system and to ensure complete transparency in an aspects of business

Mission:

Four Knitwear LTD realizes the need to stake out a competitive segment in the changing globalmarket of today through technological excellence and human expertise Four Knitwear LTD iscommitted to transpose its local success to the world scene

 Company Name:

 Four knitwear LTD

 Status: Private Ltd Company

 Type: 100% Export oriented knit Industry.

Some Major Buyers:

CARODEL, SMYK, BABOLAT, CATBALU, ATIMA, PCL, ATIMA,FIRSTTEXTILE

Certificate & Achievement:

 BGMEA

 BKMEA

Garments Section

Sampling Unit :

In RMG sector Sampling plays a vital role Morning shows the day Only morning can showwhat kind of nature will be the day, similarly only Sample can say what kind of garments isgoing to be made as bulk We have one line Sample section which is set up at the 1stfloor of ourFactory The Sample Section has been decorated by One Sample In charge who is responsible togive all sorts of direction to making the sample One Sample Q C, One supervisor, 10 samplemen and 7wo assistant We have a individual Sampling unit for urgent Sampling , Patternmaking, Checking, Marker drawing all pre production are done by this unit before go for bulk

We always try to approved our sample like, Proto, SMS, Pre production

.

Sample is the proto type or model of the garments, upon what the buyer can decide on how andwhether to confirm the order or not.

It makes for buyer approval and before a bulk of production to minimize faults and errors andalso find the easy process for bulk production

The details attached to the garments sample:

After the confirmation of order, each sample sent the 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 demandedand what supplement fabric/ trim etc they have used

We have to send many sample to buyers They are

Work flow of sample section:

production starts sendint sample to the cutting section

marker making grading of sample approval sending sample to the buyer grading of sample

pp meeting evluation the sample size setting approval sample making cad and pattern making receive tec pack from buyer

Sample production sequence:

sending sample to the buyer forwarding collect from the merchandiser

buyer qc pre check from quality control

iron sewing emblishment cutting scouring the fabric and accessories for making the garments

If they want to develop new style in new fabric, then also we will have to send these sample.Also we will have to send samples to the newly contacted buyers to show our workmanship,product range, quality standers and price level These samples should be sent so that they wouldattract the buyers.

Sales man sample:

Some buyer needs these sample for getting the order from their customers If the buyer is having

5 salesman sample in his office, then the buyer will ask us to make 5 sample in each style Thesalesman will book the orders from their customers, by showing these samples Buyer will placethe order to us accumulating the quantities

Photo sample:

These sample are to be made after sheets These sample are needed to check the measurements,style and fit So they can be made in available similar fabrics but in the actual measurements andspecifications

Counter sample:

These sample are to be made in actual fabrics with actual trims If the order is for 3 colors buyermay need samples in any one color and swatches in other colors These samples should bestrictly as per the specifications in the order sheets We have to get the approval for thesesamples from the buyer before starting production

Wash test samples:

If these sample are sent before starting production and if we get some remarks or comments onthese sample, we can correct them in production But some buyers will need us to send thesesamples from production before shipment In this case these sample may be considered asshipment samples

Pre production samples:

These sample are almost like approval samples They have to be made in actual production fabricwith actual bulk trims They will represent that the production will be like these samples

Production sample:

These samples are to be sent before shipment to get the buyers confirmation for shipment.Hence these sample are needed to be perfect in all manners Buyers may check these samples foreverything or anything

Shipment sample:

These samples are to be sent after shipment They should be sent in actual packing with alllabels, tags etc

Types of machine are used in sample section:

SL No Name Of Machines No Of Machines Remarks

01 Over lock ( 3 Thread ) 1 Set

02 Over lock ( 4 Thread ) 1 Set

03 Over lock ( 5 Thread ) 1 Set

05 Lock ( Cylinder Bed ) 1 Set

Cutting :

First stage of readymade garment production, cutting is the most important and major part of ultimate quality of the production In this point of view our cutting section has design to achieve the maximum production Cutting section have been designed in 1 st floor of the factory space There are two types of cutting system, one of them Machine cutting and another is Manual cutting Two cutting men is engaged

in machine cutting and there about 12 cutting men are working continuously There is an cutting in charge, One supervisor and one QC to perform the activities maintaining quality and required quantity.

Cutting is the process which cut out the pattern pieces from specified fabric for makinggarments Once the marker is made, pattern pieces must be cut out of the specified fabric, aprocess called "cutting." Currently, several cutting techniques exist, ranging from low- to high-tech Although scissors are used very rarely-only when working with very small batches orsensitive fabrics-cutting continues to be done by hand, particularly in many lower volumeestablishments Here, cutters guide electric cutting machines around the perimeter of patternpieces, cutting through the fabric stack An electric drill may be used to make pattern notches.Computerized cutting systems are achieving more widespread use as technology costs decreaseand labor costs rise These computer-driven automated cutters utilize vacuum technology tohold stacks of fabric in place while cutting Cutting blades are sharpened automatically basedupon the type of fabric being cut Gerber Garment Technology manufactures one of the mostcommonly used cutting systems This technology has the advantage of being highly accurateand fast, but does cost considerably more than other cutting techniques

Types of Cutting

Fully manual:

 Hand operated scissor

Manually operated power knife:

Computerized methods of fabric cutting:

 Computer controlled knife cutting

 Cutting by Laser beam

 Cutting by Water jet

 Cutting by Plasma torch

Cutting Q.C : Upon receiving any batch of fabric it required to check Dia, Gsm, Colour

fastness, tone matching and shrinkage are duly checked by our cutting Q.C makes a report onthe fabric to get the cutting approval from merchandiser department

Lay cutting : Mostly we make all fabrics in lay form and cut it by marking as per pattern, so the fabric is getting more relaxation to avoid further shrinkage and all the hole, Running shade etc can clearly find out and remove There are about 15 workers are engaged to do the work properly so that we can meet the shipment date with maintain quality We always try our best to meet the 100% Quality label.

We have four line for sewing what is consisted with various Machines like Over lock, Flat lock,Plain Machine, Button hole, Rib Cutter, Khansai etc There are two hundred and sixteenMachines for various kinds of buyer’s requirement We have been maintaining need basedmachine settings as required by needle type like 3 Thread, 4 Thread, 5 Thread and even BallPoint needle We some time do the chore hem when it is required Buyer US POLO Chicco andSMYK are the exemplification of such type of Hem

Main Sewing Unit :

The main sewing floor are designed by 4 line of selected machinery Each line are headed

by 1 Supervisor and 1 input Assistant Required Operator and Helper as Lay out base on theGarments style and design

Sewing process flow Chart:

forward it to the finishing section

garments inspection get full garments as output

sewing started print & embroidery check measurement check

input

Machinery of Main Unit

SL NO Name Of Machines No Of Machines

01 Over lock ( 4 Thread ) 60 Set

02 Over lock ( 5 Thread ) 25 Set

04 Lock ( Cylinder Bed ) 26 Set

Process Flow of a Basic T-Shirt:

Inspection Thread cutting Button attaching machine Button hole machine side band tape join (Plain machine) Placket stitching of bottom part (Plain machine) Attaching twill tape with neck (Plane machine)

Cuff shape (Overlock) Stitching Collar (Overlock) Collor tag (Plain machine) Shoulder top seam (Plain machine) Stitching twill tape (Plane machine) Attaching care level (Plane machine) Stitching shoulder (Overlock, 4 thread) Separating placket & stitching nose cut (Plain machine) Placket attached with front part (Plain machine) Moon attached with back part (Plain machine)

Indicating placket mark Machine front and back part

Q.C :

In line inspection :

A team of 4 Q.C inspector are working in the every stage of the total production In order to meet up the instant quality and predictability.

Out line inspection (RANDOM) :

Each garment get enter to “out line inspection area” are duly check by a 25

members Q.C team as random inspection.