Bahir Dar University

Bahir Dar Institute of Technology

Faculty of Mechanical and Industrial Engineering
INDUSTRIAL INGINEERING PROGRAM
INTERNSHIP REPORT

Project Title: Improving Layout of Garment Section in Kombolcha Textile S.C

Hosting Company: Kombolcha Textile Share Company

By: Selamawit Belayneh

Id No: BDU0601444UR

Mentor: Eng. Azmeraw Tadesse

Company Supervisor: Eng. Hiwot Yimer

Jan/ 2017

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 DECLARATION

The project is original and written by following Bahir Dar University-Bahir Dar institute of
technology Industry Linkage office internship report writing guideline.
As the student’s academic advisor, the internship report written by the student is her original work
and is written following Bahir Dar institute of technology Industry Linkage office internship
report writing guideline ice and based on my guidance.

Mr. AZMERAW TADESSE

---------------------------------------- -------------------- ------------------
Name of the Academic Advisor Signature Date

SELAMAWIT BELAYNEH
--------------------------------------- --------------------- ------------------
Name of Student Signature Date

Mrs. HIWOT YIMER

--------------------------------------- ---------------------- -------------------
Name of the Company supervisor Signature Date

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 Acknowledgements

Before and above all, I would like to thank “GOD” for making me healthy and happy in order to
carry out this project.
First, my grateful thank goes to my academic advisor Engineer Azmeraw Tadesse for his support
and encouragement while doing the project. He helped me to acquire lots of knowledge and skills
during my stay in Kombolcha textile share company.
All I learnt from the company and the project are value adding for my future carrier, and hence I
would like to thank his for all contributions.
I really thank my company advisor Engineer Hiwot Yimer for her timely, encouraging, genuine,
valuable and unreserved support to come up with this project. And I would like to thanks
Companies planning manager Mr. Firesew Arega, Processing and Garment manager Engineer
Aminat, Spinning Forman Engineer Alula, Processing Forman Engineer Dawit, Garment manager
Engineer Mohamed, Processing Forman Engineer Ebrahim, Singer Trainer Mr. Asnake,
Management information system experts , research and development experts and other employees
of the company for their support in different activities related with the project.
Last but not least, I would like to thank my company training managers Mr. Asefa, Mr. Seid and
Mr. Ermias. Finally, I great thanks to my family and friends who give me moral and
encouragement while doing this project.

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 Executive Summary
Internship is a proven way to gain relevant knowledge, skill and experience while establishing
important connection in the field.

The first part of the project provides information about the hosting company. It starts from the
brief history of the company and continues to the companies’ raw material, accessory supplier and
raw material quality parameters. In addition, the overall work flow of each department, its main
product and main customers, the overall organizational structure and responsibilities of functional
area of the company is dealt.

The second part of the project describes the overall benefits of the internship in terms of work
task, tools and techniques, challenges, practical skill, theoretical knowledge, communication skills
and team playing skills, leadership skills, work ethics, and finally entrepreneurship.

The last part of the project describes mainly about the overall internship experience starting from
description of the title and sections to the different types of tasks accomplished including the
objective of the task, the work flow, detailed problems. This part also deals with the main finding
of the problem and its solution.

Furthermore, the challenges that faced during the internship experience and solutions to overcome
thus difficulties are also included.

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 TABLE OF CONTENT

Contents Pages
2. Background of Kombolcha Textile Share Company ................................................................................ 10
2.1 History of the Company ......................................................................................................................... 10
2.1.1 Introduction ..................................................................................................................................... 10
2.1.2 Location ........................................................................................................................................... 10
2.1.3 Objectives of the Company ............................................................................................................. 10
2.1.4 Plant Capacity .................................................................................................................................. 11
2.1.5 Raw Materials and Utilities ............................................................................................................. 11
2.1.6 Finance ............................................................................................................................................ 11
2.1.7 Marketing ........................................................................................................................................ 12
2.1.8 Main Products or Services ............................................................................................................... 12
2.1.9 Main Customers............................................................................................................................... 12
2.2 Organizational Structure ......................................................................................................................... 12
2.3 The overall Work Flow of the Company ................................................................................................ 13
2.3.1 Spinning........................................................................................................................................... 14
2.3.2 Weaving ........................................................................................................................................... 15
2.3.3 Processing and Garment .................................................................................................................. 15
3.1 The overall benefit I gained from the internship .................................................................................... 17
3.2 Sections in which I have worked ............................................................................................................ 17
3.2.1 Cutting section ................................................................................................................................. 17
3.2.2 Spreading ......................................................................................................................................... 18
3.2.3 Sewing Section ................................................................................................................................ 18
3.3 work task ................................................................................................................................................ 18
3.4 Tools and Techniques ............................................................................................................................. 18
3.5 Challenges during internship .................................................................................................................. 19
3.6 Regarding improving practical skills ...................................................................................................... 19
3.7 Gained in upgrading theoretical knowledge ........................................................................................... 19
3.8 Gained in improving team playing skills ................................................................................................ 20
3.9 Gained in improving leadership skills .................................................................................................... 20
3.10 Gained in understanding work ethics ................................................................................................... 20
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3.11 Gained in improving entrepreneurship skill ......................................................................................... 21
3.12 Gained in improving interpersonal communication skills .................................................................... 22
4.1 Summary of the Project .......................................................................................................................... 23
4.2 Problem Statement and Justification ................................................................................................ 24
4.3 Objective of the Project .......................................................................................................................... 24
4.3.1 General Objective ............................................................................................................................ 24
4.3.2 Specific Objectives .......................................................................................................................... 24
4.4 Significance of the Project ...................................................................................................................... 25
4.4.1 Literature Review ............................................................................................................................ 25
4.4.2 Methodology of the Project ............................................................................................................. 27
4.4.2.1 Introduction .............................................................................................................................. 27
4.4.2.2 Data Source............................................................................................................................... 27
4.4.2.3 Data Collection Method............................................................................................................ 27
4.5 Analysis, Results and Discussion ........................................................................................................... 28
4.5.1 Floor space calculation .................................................................................................................... 28
4.5.2 Workforce ........................................................................................................................................ 31
4.5.3 Existing Production process ............................................................................................................ 32
4.5.4 Product transporting System ............................................................................................................ 32
4.5.5 Challenges on New Layout.............................................................................................................. 33
4.5.6 Operator Motivation ........................................................................................................................ 33
4.5.7 Existing different production line .................................................................................................... 33
4.6 Conclusions and Recommendation................................................................................................... 36
4.6.1 Conclusion ....................................................................................................................................... 36
4.6.2 Recommendation ............................................................................................................................. 36
5.1 CONCLUSION AND RECOMMENDATION ..................................................................................... 37
5.1.1 Conclusion ....................................................................................................................................... 37
5.1.2 Recommendation ............................................................................................................................. 38
References .................................................................................................................................................... 39
Appendix A: Production data for export articles in piece before and after preparing the layout for 7:30 hr.
per shift for 5 working days .......................................................................................................................... 40
Appendix B: drawing showing machine arrangement before preparing the layout ..................................... 41
Appendix C: drawing showing Machine Arrangement after Preparing the Layout ..................................... 42
Appendix D: Photo showing Machine Arrangement before Preparing the Layout ...................................... 43
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Appendix E: Photo showing Machine Arrangement after Preparing the Layout ......................................... 44
Appendix F: kaizen implementation on company ........................................................................................ 44
Appendix G: certificate of appreciation ....................................................................................................... 45

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List of table page

Table 1: Total floor space breakdown………………………………………………………31

Table 2: Total number of workers in garment section………………………………………31

Table 3: Production data before preparing layout………………………………….……….34

Table 4: Production data after preparing layout………………………………….…………34

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List of figures page

Figure 1: Organizational structure of the Company…………….…………………………..13

Figure 2: Overall work flow of the company……………………………………………….13

Figure 3: Flow chart of spinning process………………………………….………………..14

Figure 4: Flow chart of weaving process………………………………….………………...15

Figure 5: Flow chart of finishing process………………………………….………………..16

Figure 6: production process in garment…………………………………………………….32

Figure 7: product comparison before and after preparing the layout……………………......35

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 PART TWO

2. Background of Kombolcha Textile Share Company

2.1 History of the Company
2.1.1 Introduction
Kombolcha textile Share Company was established in 1984 at Kombolcha town. Following its
effort and export performance, the government has made huge investment on it. With this
investment, the company has renovated its old production line by the new state of art technology
and started production in the 2005e.c budget year.

It is integrated textile company producing 100% bleached, dyed and printed with different sizes
and market Yarns.

2.1.2 Location
The integrated textile Share Company is located at Kombolcha town in South Wollo
administration zone of the Amhara regional state and 380km north of Addis Ababa while the
marketing liaison office is located at Addis Ababa, Ethiopia.

2.1.3 Objectives of the Company

The main objectives for establishment of the company are:-
 The existence of unsatisfied demand for textile production in the country

 Bring socio-economic change in the region as well as in the country

 Create employment opportunity

The share company’s business objectives as per memorandum of association are:

 To manufacture yarn and all kinds of grey and finished fabric from cotton, Synthetic or
blended fibers and filament.

 To prepare goods for household use from cotton yarn, fabric and by products.

 To sell its product locally and abroad

 To engage generally in any other trade or business conductive to the attainment of its
objective

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2.1.4 Plant Capacity
At full capacity, the annual production of the company was 22 million square meters of fabrics
but after substituted by the new machines it can produce 25 million square meter of fabric.

The spinning department has 13,200 modern ring frame spindles and 10,600 old ring spindles and
528 open end rotor. Open end rotor machine is very advantageous because it eliminates some
processes (roving and winding) due to this; requirement of man power, electrical consumption
and space utilization decrease.

Weaving department has 98 modern new rapier looms (Dornier, picanol and sulzer
machines).those machines are used to manufacture export products like flat bed sheet and pillow
case fabrics. And there are also125 old versamat looms. This type machines are used to
manufacture local products.

In processing department there are two sub sections. The first section in this department is
pretreatment. Pretreatment is the process of treating (i.e. singing, scouring, bleaching and
mercerization) grey fabrics that comes from weaving department, before the fabric is set for
finishing. A finishing plant has with a capacity of dyeing, printing and 30 million square meter of
finished fabric is produce per annum.

2.1.5 Raw Materials and Utilities

Raw materials and utilities required by the factory at full capacity would be 7,000 tons of lint
cotton per annum, 400,000 cubic meters of water per day, and 21million KWH of electric power
per annum.

2.1.6 Finance
The finance of the Company has been obtained from different sources; such as Equity of the
Ethiopian government, Loans of local banks and Credits secured from the government of the
German and Italy.

The total investment of the project based on contractual agreement and payment effects up to the
end of Jun 1984 is estimated to be birr 22 million of with 62% is raised locally through
government equity and bank loans and 38% is raised through credits obtained from the three
governments mentioned above.

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2.1.7 Marketing
Based on the present operational experience of Kombolcha, it is assumed that what is produced
will be sold in that same period. Bed sheets, try towels, grey fabrics and yarn being exported to
different countries. The company’s products are also being distributed locally to various
wholesalers and being super markets. Except for price and limited design variety the company’s
products still enjoy acceptance in terms of quality in the domestic market.

2.1.8 Main Products or Services

Among the company’s products, the major ones are printed and dyed flat bed sheets including
queen and king sizes, fitted bed sheet, poplin, drill, French twill, terry towel, twill, sheeting and
Abujedid. In addition to these, the company produces different fabrics and market yarns on order.

2.1.9 Main Customers

The main customers of the company’s products are regional distributors, wholesalers, super
markets and garment factories for fabrics and knitwear fabrics and blanket plant for yarn. Major
local and foreign customers of the company are as follows

Local (Domestic Market)

 Kombolcha, Dessie, Addis Ababa and Mekelle
 Blanket factories, Garment industries, Regional distributors, Knitting factories, Ministry and
etc.
Export (Foreign Market)
 America, Italy, china, Switzerland, Sweden and German

2.2 Organizational Structure

According to the present organizational structure, the company has four departments and four
services. These are; administration department, finance department, commercial department,
production and technical department, planning service, quality service and information and audit
service.

Currently, the company has 1510 employees of whom 820 are male and 690 are female. In terms
of term of employment, the company creates job opportunity for 1370 permanent employees, 64
contract employees and 76 temporary employees.

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 BOARD OF DIRECTOR

AUDIT SERVICE

GENERAL MANAGER

D/GENERAL MANAGER

PLANNING AND
QUALITY INFORMATION SERVICE
CONTROL SERVICE

STORE AND PROPERTY

ADMINSTRATION SERVICE

ADMINISRATION
FINANCE COMERCIAL PRODUCTION AND
DEPARTMENT
DEPARTMENT DEPARTMENT TECHNICAL DEPARTMENT
Figure 1: Organizational structure of Kombolcha textile

2.3 The overall Work Flow of the Company

Kombolcha textile Share Company is integrated company which processes 100% of cotton from
spinning up to finishing and some garment processing machines. The main Production Process as
shown in figure 2 below;

Spinning Weaving Processing Garment

Figure 2: Overall work flow of the company

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But the detail of work flow will be seen while seeing about each main section.

2.3.1 Spinning
It is the first steps and major part of the textile industry. It is part of the textile manufacturing
process where three types of fiber are converted in to yarn, then fabrics, which undergo finishing
processes such as bleaching to become textiles.

Objective of spinning

 To produce drafted and small twisted to be spun in a yarn

 Improvement of material evenness
 To produce suitable packages to next stage
 To produce yarn from un order fiber
 To produce a quality slivers

Blow room

Carding

Drawing

Roving Open end

Ring frame Roter spling

Cone windind Yarn store

Twisting

Figure 3: Flow chart of spinning process

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2.3.2 Weaving
The first step of weaving departments are preparatory room is necessary for moving impurities
from fibers and for improving their aesthetic appearance and process ability as fabrics prior to
dyed, printing and mechanical and functional finishing.

Objective of Weaving

 To convert yarns to fabric by using the basic mechanisms of weaving

 To produce grey sheeting products
 To produce flat bed sheets and others

Cone winding
warping Sizing Drawing in
from yarn

Grey
Folding Shearing Weaving loom
Inspection

Fabric Store Processing

Figure 4: Flow chart of weaving process

2.3.3 Processing and Garment

In textile manufacturing, finishing refers to the process that converts the woven fabrics in to
usable material and more specifically to any process performed after dyeing the fabrics to
improve appearance and removing dusts from the fabric surface in order to achieve the final end
use product or feel of the finished textile or clothing.

After the finished fabric is inspected then it is taken to garment section to cut and swing according
to willing of customer and their type and they will packed and taken to selling shop.

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 Objective of Processing and Garment

 To make the fabric suitable for end use and hence satisfy customers requirements
 To increase smoothness and uniform application of colors and finishes must be ensured
 To convert fabric from hydrophobic to hydrophilic state
 To remove dust, dirt,… from the fabric
 To achieve the degree of desired whiteness

Gray fabric Singeing De sizing Scouring

Drying Washing Batching Bleaching

Mercerizatio Dyeing and

stentering washing
n Printing

Garment Inspection Calendering

Figure 5: Flow chart of finishing process

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 PART THREE

3.1 The overall benefit I gained from the internship

During my stay in the company, I have acquired many things regarding improving my practical
skill, upgrading my interpersonal knowledge, improving my interpersonal communication skills
in the working environment, involving in the team work and improving my team playing skill
than before I have in the university, in terms of improving my leadership quality and increasing in
knowing and understanding the ethics and related issues about the work environment.
In the time of my internship schedule, I have observed the entire processes starting from raw
material store up to finished fabric store, the material handling, the responsibility of each personal
in each plant and section, process and machine parameters in each plant.
So, I will try to explain what I gained during my stay.

3.2 Sections in which I have worked

During my internship period, I have gotten so many experiences during the first month of intern
ship period I have studied the overall structure of the company and in other months left, I have
worked my project on specific problem which I have selected from the list of problem that I have
seen during the first month.
I have worked my activities and project in garment section of the company these sections of
Kombolcha textile are cutting section, sewing section, and temporary storage for shipments.

3.2.1 Cutting section

The first stage in the manufacture of garments is the cutting of materials into the necessary article.
Where large quantities of a garment style must be cut, a lay is created which consists of many
plies of fabric spread one above the other. From this, all the garment pieces for all the sizes that
have been planned for that lay are cut.
Cutting room includes spreading and cutting activities.

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3.2.2 Spreading
 Spreading is the process of unwinding large rolls of fabric onto long, wide tables and
laying them in superimposed plies of specified length.
 The number of lays depends upon the number of garments desired and the fabric
thickness.
 The cutting marker is laid on the topmost layer.

3.2.3 Sewing Section

All the production departments have intra and inter departmental communication formats. The
raw materials or goods never pass through the next process unless the formats are seen and
checked by an authorized body.

Available machines
 Single needle sewing machine
 Over lock machine
 Double needle sewing machine

3.3 work task

I work or executing some work tasks during my internship period
These work tasks are:
 Maintaining the machineries that are found in the sewing section.
 Inspecting the finished fabric in off line inspection area.
 Help the workers by arranging the fabric for making it convenient for function of sewing
machine.
 Help the workers by recording daily production.
 Help the workers by man power coordination.

3.4 Tools and Techniques

I am working on sewing machine (single needle, double needle, and over lock). I want to inspect
the machine layout by using facility layout course.

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3.5 Challenges during internship
Measures taken to overcome challenges during my project working
 Increasing my relation with the workers to be familiar
 Appreciating there working skill and knowledge
 Asking of different workers for the same types of question
 To increase the reliability and accuracy of the information

3.6 Regarding improving practical skills

In spending my internship of the company for a semester provides me the opportunity to gain
practical skill on work experience that I just can’t get by attending in the class room. An
internship can be seen as the principal of my undergraduate education and give me the chance to
use the skills I have learnt in the class room in a real world setting. It is a chance to prove the
work of my qualifications and to show that I can perform in the role I have been given. Getting
experience in the real working environment is a great way in building confidence. In terms of
practical skills I gain a lot of advantage during the internship program starting from maintaining
of parts. So I can say that I am now able to use practical ways to do any activity because I have
learnt that even if I don’t know the real solution, I can ask my friends also search it from the
internet.

3.7 Gained in upgrading theoretical knowledge

During my internship program I have got many things from the working members in theoretical
aspect. My improvement in the theoretical knowledge starts from the guards of the company and
goes up to president. I have read a lot of hand books of the machines in the company. My
supervisor gives me a lot of hand books that help me to improve my theoretical knowledge that
are performed in the section which enable me to know more about the machines and the process.
Some of theoretical knowledge’s are:
 How to use each machine
 How to maintain each machine
 How to clean each machine
 How to keep the safety in each machine

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3.8 Gained in improving team playing skills
In this internship I got a chance that working in a team increase the work performance, as well as
creates a proper working flow and information distribution between team members which insured
that project is completed in a timely and efficient manner. During my internship, I improve the
following qualities of effective team member leant to speak up and express my though has and
ideas clearly, direction, honestly, and with respect for others and for the work of the team
 Good listeners are eventually for team to function effectively .So I understand that teams
need team prayers who can absorb, understand, and consider ideas and point of ravels
from center people without debating and arguing ever point such a team member also can
receive criticisms without reacting defensively.
 Work as an active participant
 Wilting to share information, knowledge and experience and to take the initiative to keep
other members of team informed.
 Work at a problem slyer
 Treating others in a respecting and supportive manner.

3.9 Gained in improving leadership skills

As a leader many issues may came from different directions regarding to the company. Therefore,
the leader must responsible to invite each and every issue properly. In our section, I have met
different chairman and I have seen how they treat us in different issues. I also got different skills
from them, starting from the Forman to the mangers.

3.10 Gained in understanding work ethics

From all the benefits the internship program was more interesting in the improvement of ethical
work habit of a student. I have provided with experience that will make me stronger in the
environment where ever I go. Since it is regional supreme coast ethics in the working place is the
most essential thing that any employees should have.
In addition to this, my work ethic is increased, and I have been confident in my alibis of dealing
with things. It also allows me to learn about time management, discipline, and effective
communication skills. It is important to mentally be able to work effectively by organizing my
thoughts. For instance, setting up a good work schedule enables me not to only organize my work
projects, but also to organize how I will mentally manage my time and react to the stressful
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situations in the work place. I also have good experience in handling customers that come to my
service.
I gain a lot of benefits from the factory. Some of them are:
 Performing service only in an area of competence.
 Being punctual at work and leave work by the right time.
 Being responsible in analyzing and interpreting gathering of data.
 Learning career- related skills such as public speaking, dealing with customers etc.
 Being tolerant and patience i.e. when someone is absent, they will cover his /her work by
coordinating.

3.11 Gained in improving entrepreneurship skill

Entrepreneurship is a key driver of economic growth and job creation. It provides many people
with earner opportunities that better fit their preferences than waged employment. From this
aspect the internship make me to think about having my own business that I desiring to work on.
Because working on the government organization is not that much satisfactory in terms of salary,
and employer’s antics profession is not so much and the job opportunity is not good.
I notice such kind of works is so practicable if worked in private organization. As an
entrepreneur, I learnt:
 How to act as leader.
 How to coordinate a work.
 How to communicate with my team mate.
 How to solve challenges that face me.
The following entrepreneurship skills are gained from the internship.
 Being risk taker for what I have worked.
 Hiring dreams and aspirations about becoming a successful entrepreneur.
 Setting goal is so important to be satisfied. As I saw some employees of the company
works, is hard to improve their status by setting their own goal.
 Giving customer oriented services.
 The successful entrepreneur is willing to overcome mistakes, meet new challenges head-
on and adapt to change.
 Be confident for working decisions made.

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3.12 Gained in improving interpersonal communication skills
Communication is fundamental pare of human existence. During my internship, I learnt to be
patient to listen properly (to be good listener) to what others say in order to have accurate
information. In this period, understanding my team mates greatly helped me to say in a good
relation with them. So I improved myself not to only to understand my project but the need to
understand my team makes. Follow up meeting helped to develop effective and standard ways of
communication in engineering careers.
During this period I show different offices, when I went to the company for different purposes. In
addition to this, in work place there are many workers, laborers and I must be easily
communicated with these persons. Because, to upgrade my theoretical knowledge with practical
work, even I must ask the labors, since they are better than me in practical knowledge.

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 PART FOUR

4.1 Summary of the Project

Best quality improvement is required for Kombolcha textile Share Company to become more
competitive both locally and globally, for customer satisfaction on its reputation for price,
delivery, and others. Most people now recognized that best quality and productivity is the most
important of these competitive weapons.
All processes within the company and the degree to which present and future needs of the
customers are met. Currently this section is suffering from layout related problems. Because of
these problems the company is used in old production process and it is less production.
The main objective of the project was to improve the Layout of Garment Section in Kombolcha
Textile Share Company while the specific objectives were to prepare an optimized Layout of
Garment Section in Kombolcha Textile Share Company, to estimate the cost required for shifting
the machines in Garment Section, to estimate the production cost after shifting the machines and
to compare the production cost before shifting and after shifting the machines.
In order to achieve the objectives, both primary and secondary data collection system were
employed and found that the total production after preparing layout is increased.

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 4.2 Problem Statement and Justification
KTSC has four main sections or departments. Among those sections, the garment section is
selected specifically focusing on work flow of the production line. Through physical observation
of the production system of this line, it is found that there is poor allocation of manpower or
manpower planning problem, less production or low productivity in the production line, Improper
sequence of equipment variation, Increased bottleneck for Supervision, Dirty /stain, Dead time
elapsed, Product mix after finishing, Less effusively to employee morale, Boring transportation of
work, Maintenance imposition and Loss of room ornament. Since productivity is the measure of
total output to the inputs used, it is possible to say there is low production in the production line.
Because the production line uses many manual workers and sewing machines with operators, but
the output is low. This implies that there is ineffective time during production. In addition to the
above problems, the production line is not balanced.
Therefore, doing a project for solving production line unbalancement and eliminating bottleneck
operations through product layout technique has a paramount importance for reducing ineffective
time and proper utilization of material and manpower and at the end improve productivity in
product systems.

4.3 Objective of the Project

4.3.1 General Objective

 The general objective of the project is to improve the Layout of Garment Section in
Kombolcha Textile Share Company

4.3.2 Specific Objectives

1. To prepare an optimized Layout of Garment Section in Kombolcha Textile Share
Company
2. To estimate the total production before preparing layout of machines in the Garment
Section
3. To estimate the total production after preparing layout of machines in Garment Section
4. To compare the total production before and after before preparing layout of the machines
in Garment Section

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 4.4 Significance of the Project
First and for most this project enabled me to relate the theoretical knowledge I gained teaching
and learning process of the university to the practice in the Industry, to have an idea about
problem identification for research project, to have a general understanding about how research
project will be carried out and to develop different skills.

Secondly, this project may benefit the company for Proper and efficient utilization of available
floor space, to utilize labor efficiently, to minimize loss unnecessary cost, to reduce unnecessary
cost , to properly arrange machines, to maintain room ornament , to increase employee morale, to
provide for volume and product facility, to provide easy for supervision and managements, to
facilitate co-ordination communication, to provide safety and health, to allow easy of
maintenance, to proper utilization of production capacity, to transportation of work from one
point to another point without any delay.

Furthermore, the project may initiate other researchers to conduct further research and project to
solve the problems facing the company.

4.4.1 Literature Review

Plant layout is the most effective arrangement and coordination of the physical plant facilities to
allow greatest efficiency in the combination of materials and machines necessary for operation of
any unit of a plant or business
Have quickest flow of material at the lowest cost and with the least amount of handling in
processing the product from the receipt of material to the shipment of the finished product.
Plant layout can be classified as:

1. Process or functional layout

2. Product or line layout

3. Mixed or combined layout

4. Static or fixed layout

5. Group technology layout

So this project type is product or line layout.

As per Mikell P (2007) Product layout is referred as “a production system where the work stations
and equipment are located along the line of production, as with assembly lines”.

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The product layout approach involves setting up on the production facilities around the steps
involved in manufacturing the product. The product goes from one step to another as it is
manufactured.
David I. 2009 suggested that “A product layout groups different workstations together according
to the products they work on. Workstations in a product layout can quickly transfer small batches
of semi- finished goods directly to the next station in a production line. Product layouts can be
ideal for smaller manufacturing businesses with lower volume than their large corporate
competitors. As a business manufacturing output grows, however, it is wise to at least consider
implementing a process layout.”

Characteristics of product layout

 Special-purpose equipment are used

 Changeover is expensive and lengthy

 Material flow approaches continuous

 Material handling equipment is fixed

 In-process inventory is relatively low

 Operators need not be as skilled

 Little direct supervision is required

 Planning, scheduling and controlling functions are relatively straight-forward

 Production time for a unit is relatively short

Advantages of product layout

Low cost of material handling, due to straight and short rout and absence of back tracking,
Smooth and uninterrupted operations, Continuous flow of work , Optimum use of floor space,
Shorter processing time or quicker output, Less congestion of work in the process , Simple and
effective inspection of work and simplified production control, Low material handling cost,
Established routing and scheduling

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Disadvantages of product layout

Creates dull, repetitive jobs, poorly skilled workers may neglect maintenance and quality, fairly
inflexible to changes in volume, highly susceptible to shut downs and needs preventive plans are
impractical.

4.4.2 Methodology of the Project

4.4.2.1 Introduction
The methodology part of this project deals with source of data, data collection method, the project
methodology frame work and data analysis method.

4.4.2.2 Data Source

The sources of data for conducting the project are both primary and secondary sources. The
primary data was collected should be observation, and Interviewing while the secondary data was
collected from reference book, handout, journals and company report and other written documents
of the company.

4.4.2.3 Data Collection Method

Different data collection methods are available for a research project. Among the methods, visual
observation was employed. In addition, data was collected by interviewing the company manger,
company supervisor, and staffs in company training center to make the data reliable, description
and for better understanding the practice.
The data collected was presented using tables and figures.

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 4.5 Analysis, Results and Discussion
4.5.1 Floor space calculation

For singers along the width

Given
Width of the building= 24
Column length= 0.65
Cart width= 0.84
Electric power bank width= 1.50
Basket length= 1.24
Free space between singers= 1.44

Required
1) Available space for singers along the width of the building
2) Space for one singer including Basket, Cart and Free space
3) Number of singers along the width

Solution
1) Available space for singers along the width of the building = Width of the building-
2(Column length)- Electric power bank width

= 24-2(0.65)-(1.50)

=24-1.30-1.50

=21.20 meters

2) Space for one singer including Basket, Cart and Free space = Basket length+ Cart width+
Free space between singers
= 1.24+0.84+1.44
=3.52
3) Number of singers along the width = Available space for singers along the width of the
building/ Space for one singer including Basket, Cart and Free space
= 21.20/3.52
=6.02
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For singers along the length

Given
Length of the building = 67

Column length = 0.65

Basket width = 0.84

Cart length = 1.33

Circulation area = 0.03

Space for emergency door opening = 1

Total number of singers = 66

Required
1) Number of singers along the length
2) Total length covered by 11 singers of one row
3) Total area covered by 66 singers

Solution
1) Number of singers along the length = Total number of singers/ Number of singers along
the width
= 66/6
=11
2) Total length covered by 11 singers of one row = Cart length+ Basket width+ Circulation
area* Number of singers along the length + Space for emergency door opening
= 1.33+0.84+0.03
= 2.20*11+1
= 25.20
3) Total area covered by 66 singers = Total length covered by 11 singers of one row*
Available space for singers along the width of the building
= 25.20*21.20
=534.24m2

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For spreading tables

Given
Large spreading table length = 19.80

Large spreading table width = 3.60

Small spreading table width = 2.70

Cutter tables width = 2.20

Distance between spreading tables and singers = 1.02

Distance between spreading tables and Inspection door = 3.77

Total width of circulation space = 10.90

Required
1) Total width for spreading tables including circulation space
2) Total length for spreading table include circulation space

Solution
1) Total width for spreading tables including circulation space = Large spreading table
width+ Small spreading table width+ Cutter tables width+ Total width of circulation space
=3.60+2.70+2.20+10.90
=19.40
2) Total length for spreading table include circulation space = Large spreading table length+
Distance between spreading tables and singers+ Distance between spreading tables and
Inspection door
=19.80+1.02+3.77
=24.60

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Table 1: The following table summarizes the results of the above calculations of total area
covered by garment section is 1608 m2. More specific details are given below:
Operation areas length Width Area (meter square)
sewing area 25.20 21.20 534.24
Spreading area 24.60 19.40 477.24
Folding area 10.80 13.60 146.88
Packing area 44.40 4.80 213.12
Power bank 23.50 1.50 35.25
office 7.69 3.70 28.453
Shelf 5.26 0.70 3.682
Total 1438.865
Table 1: Total floor space breakdown

4.5.2 Workforce

Table 2: The total number of workers in the garment section of the company is 193 peoples.
Manpower Career level Number of workers
Garment section head 15 1
Forman 12 2
Clark 7 2
Mechanic 7 2
head 6 6
Tailor 4 110
Mender 4 4
Folder 3 24
Packer 2 8
Cutter 2 16
belling 2 12
Transport 2 4
Cleaner 2 2
Total workers 193
Table 2: Total number of workers in garment section

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4.5.3 Existing Production process
Existing layout of the garment section is given in appendix B. In this layout, the products
received from the inspection section are transported using cart to the place where spreading is
done. After spreading, the products are then transported to the sewing part by cart. In the sewing
part, the spread parts are sawed in order to shape a final garment.

After sewing, the products are transported by cart and the quality of each product will be checked
by the quality control professionals to avoid defective parts and automatically pass over to the
folding part. Finally, the folded parts will be packed and transported by cart to the warehouse for
storage. For easy understanding, the production process is shown in figure below.

Figure 6: production process in garment

4.5.4 Product transporting System

There are different types of product transporting systems in garment manufacturing industries.
Some of them are traditional, like transporting manually or by cart. Among the different types of
product transporting systems in garment manufacturing industries, the company uses manual
transporting system and cart in garment section. Modern factories use the slow motion conveyor
to move the parts from one operation to another operation. This method is generally suitable for
single piece movement.

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In some industries, the work aids are designed such that the piece moves in forward directions.
When the first operator finishes his operation he gives it directly to the next operator with
the help of work aids, and this process continues.

Thus the selection of the product transporting method depends upon the financial capacity of the
owner, design layout, the technological availability and its advancement of the industry, skill,
knowledge and experience of the personnel, etc.

4.5.5 Challenges on New Layout

There are a few challenges on new layout. The first challenge is failure to believe that the new
layout improve company productivity and increase profitability at specific and brings change in
the company in general. Secondly, the workers in the garment section being careless and failure to
use their maximum effort to achieve the objectives of the company are another challenge.

4.5.6 Operator Motivation

In new layout, operators are motivated because all operators are working in multiple
operations in rotation. So there is no arguing that someone is doing a difficult operation and
others are working in easier operations. On the other hand, this is not possible in batch
production because of specific allocated work for the whole day. Similarly, in case of new
layout, operators are treated as a group inside the cell so their combined effort is to do
better and produce more. Likewise, operators cannot work carelessly because they will be
immediately caught by the next operator inside the cell, so the combined result of all these
factors motivates them to do better in each step.

4.5.7 Existing different production line

The company has four departments or sections these are spinning, weaving, processing and
garment. My project is concerned to one of this section that is garment section. In the garment
section there are different production lines. There are 66 machineries and 110 tailors in the
garment section. The types of export articles, production per day, and overall production per
product is shown in table 1 and 2 below.

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Table 3: Production data for export articles in piece before preparing the layout for 15hr per day
for 5 working days (from 6/12/2016-10/12/2016).
S. Export Article Day 1 Day Day 3 Day 4 Day 5 Overall
no 2 total
1. Sogesi flat bed shit production
160×290 827 1103 0 0 0
2. Ospedra flat bed shit
160×290 2825 598 1716 457 0
3. Servizitalia flat bed shit
160×290 0 2050 1778 5161 6476
Total production per
shift 3652 3751 3494 5618 6476 22991

Table 4: Production data for export articles in piece after preparing layout for 15 hr. per day for 5
working days (data on 20/12/2016-25/12/2016)
S. Export Article Day 1 Day Day 3 Day 4 Day 5 Overall
no 2 total
1. Sogesi flat bed shit production
160×290 0 0 2231 5022 7462
2. Ospedra flat bed shit
160×290 0 0 0 1444 0
3. Servizitalia flat bed shit
160×290 4900 4348 2109 0 0
Total production per
shift 4900 4348 4340 6466 7462 27516

After analyzing the production data as indicated in Table 3 and Table 4 above, the total
Production of export articles per day after preparing layout with the total number 196 human
resources in the garment section is increased when it is compared with the total Production of
export articles per day before preparing layout. In addition to production increment, the new
machine layout contributes for proper utilization of the human resources, for maintaining
occupational health and safety, reduces wastage, reduces dead time elapsed, motivates
employees to work, and reduces disturbance during work.

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 8000

7000

6000

5000

4000
Before
3000
After
2000
1000
0
Day 1
Day 2
Day 3
Day 4
Day 5

Figure 7: product comparison before and after preparing the layout

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 4.6 Conclusions and Recommendation
4.6.1 Conclusion
From the above discussion, it is clear that a standard can be maintained in the garment especially
in product production line to get maximum production by using the time properly. Different time
is needed to perform different operations in the production line. As a result product variation is
must. Since the product production line is made with the help of different operators, time
limitation must be given to achieve the target production. To set standard target for different
operations, a good layout is mandatory. By making layout target production can be achieved.
As a result, shipment of particular product can be made in exact time and there would be no delay
to get the payment to the seller. In garment companies it is difficult to identify the key areas and
practices which can be used to improve the current system and situation in the operation.
Delivering high quality possible to map the current status and subsequently analyze to achieve
better target product at low cost in short lead time are the major challenges faced by the
government manufacturing.

4.6.2 Recommendation
In order to solve the company problem, putting the following recommendations into practices will
have paramount importance.
 It shall be better to change the existing chairs with quality and comfortable ones
 Replacing tailors Cart by small , easy , new and affordable carts
 It shall be better to clean the room and the roof in the weekend regularly
 The supervisors of the garment section should control the production line effectively since
some of the workers are careless for their work.
 Materials should be supplied in due time.
 Continuous professional development should be considered for the workers.
 Conduction research and applying the result to practice.
 Providing training to employees on Professional ethics.
 Emphasis should be given on proper allocation of manpower
 Preparing strategic manpower planning
 Strengthening the cooperation with international organizations

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 PART FIVE

5.1 CONCLUSION AND RECOMMENDATION

5.1.1 Conclusion

Generally in internship program I have gotten experience in practical that I have learned in
theoretical. In my internship program, I have observed and practice about the company managing
system in Kombolcha textile Share Company. And know how I can work in the company. In this
period I have found the problem in the company and I tried to solve this problem by working a
project.
My project is depending on production increased and less of cost is required for the Kombolcha
textile share company to become more competitive both local and international market and
customer satisfaction on its reputation for price, delivery, and others best production system on its
reputation for price, delivery, and others. Most people now recognized that product dead time is
the most important of these competitive weapons. As I have seen before there is production
efficiency of Garment and that are loses of company.
During our internship period, I have got relevant professional and practical experiences,
entrepreneurial skills and creative thinking etc. which are very important for me after graduation.
In our internship period, I have seen practical works in our company. In this practical work
period, I have got important knowledge about fabric making process and I have seen the real work
of Industrial Engineer in practical world.

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5.1.2 Recommendation

I recommended the company that they shall also continue this hosting behavior because of the
following reasons.
 To avoid Lack of machine spare part
 It should be appreciate the employees by giving some bonus.
 It should be pay incentive to operators to avoid operator carelessness and increases work
satisfaction of workers.

 It should be used preventive maintenance in every machine.

 The top managers communication shall not be limited at the middle level managers (room
heads) rather it shall be better to create better communication with the operators.
Consequently they will create the sense of owner effusiveness.
 To keep maintain respect and peaceful working environment between employees
 To keep promote effective communication between employees Forman
 Should continue their effort to make students Employee or top management relationship
effective and efficient
 Employees and top management of the company should continue their contribution for the
development of students skill, knowledge and experience
In addition to this, the company shall rectified small and large problems that are obstacles for the
payment adequate to employee and growth of it. They shall analyze such problems by taking care
in order to achieve their intended goal. All members of the company shall be cooperate together
to get profit and moral satisfaction.

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 References

1. David Ingram (2009). The difference between product and process layout manufacturing
2. Mikel P. Groover (2007). Work systems: The methods, measurement and management of work.
3. http//en.wikipedia.org/wiki/product layout

39
 Appendix A: Production data for export articles in piece before and after preparing the layout for
7:30 hr. per shift for 5 working days

S. Types of Day 1 Day 2 Day 3 Day 4 Day 5 Overall

no article Shift Shift Shift Shift Shift Shift Shift Shift Shift Shift total
A B A B A B A B A B
Export Article production
Before prepare layout
1. Sogesi flat bed 210 617 182 921 0 0 0 0 0 0 1930
shit 160×290
2. Ospedra flat bed 1785 1040 417 181 315 1401 457 0 0 0 5596
shit 160×290
3. Servizitalia flat 0 0 1212 838 1778 0 1720 3441 3156 3320 15465
bed shit 160×290
Total production 1995 1657 1811 1940 2093 1401 2177 3441 3156 3320 22991

per shift
After prepare layout
1. Sogesi flat bed 0 0 0 0 2231 0 2368 2654 3742 3720 14715
shit 160×290
2. Ospedra flat bed 0 0 0 0 0 0 724 720 0 0 1444
shit 160×290
3. Service Italy flat 3030 1870 2158 2190 0 2109 0 0 0 0 11357
bed shit 160×290
Total production 3030 1870 2158 2190 2231 2109 3092 3374 3742 3720 27516

per shift

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Appendix B: drawing showing machine arrangement before preparing the layout

41
Appendix C: drawing showing Machine Arrangement after Preparing the Layout

42
Appendix D: Photo showing Machine Arrangement before Preparing the Layout

43
Appendix E: Photo showing Machine Arrangement after Preparing the Layout

Appendix F: kaizen implementation on company

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Appendix G: certificate of appreciation

45