Industrial Attachment at Envoy Fashions LTD: Rahman, Md. Zillur

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Textile Engineering Internship Report
2018-03-15
Industrial attachment at Envoy fashions ltd
Rahman, Md. Zillur

Daffodil International University
http://hdl.handle.net/20.500.11948/2983
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Faculty of Engineering
Department of Textile Engineering
REPORT ON
Industrial Attachment
At
ENVOY FASHIONS Ltd

Ashulia | Dhaka
Course Title: Industrial Attachment

Course Code: TE-431
Submitted By
Md. Zillur Rahman ID: 131-23-3338
Supervised By
Sharmin Akter
Lecturer
Dept. of Textile Engineering
This Report Presented in Partial Fulfillment of the Requirements for the Degree of
Bachelor of Science in Textile Engineering.
Advance in Apparel Manufacturing Technology
Duration: From 10th January,2018 to 15th March, 2018

Declaration
I am the student of Daffodil International University; hereby declare that, the Industrial Attachment
Report on “Envoy Fashions Ltd” is an original and authentic work done by us for the fulfillment of the
Degree of “B.Sc. in Textile Engineering” as a part of academic curriculum.
It has been not submitted to any university or institutions for any degree or for other similar purposes.
Submitted By
………………..
Md.Zillur Rahman
ID: 131-23-3338
Department Of Textile Engineering
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Approval Sheet
This Industrial attachment of “Envoy Fashion Ltd” at Daffodil International University, 2018’’
prepared and submitted by Md. Zillur Rahman, Id: 131-23-3338 in partial fulfillment of the requirement
for the degree of BACHELOR OF SCIENCE IN TEXTILE ENGINEERING has been examined and
here by recommended for approval and acceptance.
Supervised by:
Sharmin akter
Lecturer
Department of Textile Engineering, Faculty of Engineering
Daffodil International University.
@Daffodil International University ii | P a g e

Acknowledgement
At first i want to give thanks to Allah who gave us our life. We are here for this reason. For blessing
Allah i complete my Industrial report.
I am greatly indebted to many people who helped me lot for preparing this industrial attachment for
completing my Bsc in Textile Engineering. Their guideline, advice and suggestions helped me a lot. At
first, I would like to thank Dr.Md.Mahbubul Haque, Head of the department of Textile Engineering. I also
thank to Prof. Dr. Mahbub-UL Haque Majumdar, Founder & Dean of FSIT Daffodil International
University whose directions have taken me to my destination.
I am also grateful to Sharmin Akter , Lecturer, department of Textile Engineering, Daffodil International
University for her scholastic guidance, formative criticism, painstaking help constant inspiration and
advice from the very beginning till the completion of this work.
Finally, the authority of the Envoy Fashions Ltd., who gave me the opportunity to complete my industrial
attachment with great success, is remembered with honor over here. Thanks goes to all Engineers,
officers, technicians, employees, stuffs, all section in-charges for their cordial behavior and help &
especially Factory AGM, Md Mounjur Mourshed,AGM of Admin HR & Compliance , Envoy Fashions
Ltd.
Finally, i like to express my gratitude and appreciation to my parents for their blessing, support and
love.
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Table of Contents
Contents description Page No
Declaration ii
Approval sheet iii
Acknowledgement iv
Table of Contents v-viii
List of Figures ix,x
Chapter-1 Executive Summary 1
Chapter-2 General information about the factory 2

2.1 Introduction 2
2.2 History of the factory 2
2.3 Founder & Directors 3
2.4 General information 3
2.5 Layout 4
2.6 Organogram 6
2.7 Sister concern 7
2.8 Product Mix 7
2.9 Brief Profile 8
2.10 Main Buyers 8-9
2.11 Vision 10
2.12 Mission 11
Chapter-3 Description of the Attachment 12

3.1.1 Store & Inventory 12
3.1.2 Organogram 13
3.1.3 Store flow chart 13
3.1.4 Function of store section or inventory 14
3.1.5 Scope of inventory control 14
3.1.6 Inventory store system for accessories 14
3.1.7 Raw material warehouse 15
3.2 Embroidery Section 16
3.3 Fabric Inspection section 17
3.3.1 Fabric inspection 17
3.3.2 Inspection Procedure 17-18
3.3.3Criteria of penalty points based on defects and defect length 18
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3.3.4Shrinkage & GSM Test 19
3.3.5 GSM test 20
3.3.6 Skew Test 20
3.3.7 Bowing Test 20
3.3.8 Shading Segregation 20
3.3.9 Shade Separation 20-21
3.4 Quality Control Section 22
3.4.1 Quality 22
3.4.2 Quality Control 22
3.4.3 Organogram 22
3.4.4 Importance of Quality Control 23
3.4.5 Objectives of Quality Control 23
3.4.6 Classification of Quality Control 23
3.4.7 Quality Control Section 24
3.4.8 AQL 25
3.4.9 Standard AQL sheet 25
3.4.10 Checking points for quality inspection 26
3.4.11 Initial works at QC table 27
3.4.12 Check list at QC table 27
3.5 Sample & CAD section 28
3.5.1 Sample Section 29
3.5.2Organogram 30
3.5.3 Machine details 31
3.5.4 Flow chart of sample section 32
3.5.5 Flow chart of pattern section 33
3.5.6 Marker Section 33
3.5.7 Flow chart of marker section 34
3.5.8 Process of marker making 34
3.5.9 CAD section 35
3.6 Cutting Department 36
3.6.1 Cutting 36
3.6.2 Layout 37
3.6.3 Organogram 38
3.6.4 Flow chart of cutting section 39
3.6.5 Function 39
3.6.6 Equipment of cutting 39
3.6.7 method of fabric cutting 40
3.6.8 Description of cutting machine 40-43
3.6.9 safety Equipment 44
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3.7 Sewing Section 45
3.7.1 Sewing 45
3.7.2 Organogram 46
3.7.3 Process sequence of sewing section 47
3.7.4 Name of machines are used in sewing section 47
3.7.5 Activities of sewing section 48
3.7.6 Equipment & Machine Details 48-51
3.7.7 different types of needle used for sewing 52
3.7.8 Some defects of sewing operation 52-53
3.8 Washing Department 54
3.8.1 Front view 54
3.8.2 Organogram 54
3.8.3 Flow chart of washing 55
3.8.4 machine types 56
3.8.5 Dryer machine 56
3.8.6 Types of washing 56
3.8.7 Chemical used in the plant 57
3.8.8 Names of lab equipments 57
3.9 Finishing Department 58
3.9.1 Finishing section 58
3.9.2 Organogrom 59
3.9.3 Objectives of finishing 59
3.9.4 Process flow chart of garments finishing 59
3.9.5 Description of the machine 60-61
3.9.6 Chemical used to remove spot 61
3.9.7 Packing 62
3.9.8 Cartooning 62
3.9.9 Dispatch 63
3.10 Industrial Engineering Department 64
3.10.1 Organogram 64
3.10.2 Layout 64
3.10.3 Process Break Down 64
3.10.4 Target Fixing 65
3.10.5 Line balancing 65
3.10.6 training of Operators 65
3.10.7 calculating incentives 65
3.10.8 Equations of IE 65-66
3.10.9 IE responsibilities 66
3.11 Merchandising Department 67
3.11.2 Merchandising 68
3.11.3 Merchandiser 68
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3.11.4 Responsibilities of a merchandiser 68
3.11.5 Qualities of a merchandiser 69
3.11.6 flow chart of merchandising 70
3.11.7 Required documents for shipment 70-71
3.11.8 Chronological process of merchandising 71-76
3.11.9 Consumption & Costing 76
3.12 HR & Compliance department 77
3.12.2 Compliance issue maintained by Envoy Fashion 77-79
3.12.3 Code of Conduct maintained by Envoy Fashion 79-80
Chapter-4 Impact of Internship 81

4.1 Store and Inventory 81
4.2 Embroidery Section 81
4.3 fabric Inspection section 81
4.4 Quality control department 81
4.5 Sample and CAD section 82
5.6 Cutting section 82
4.7 Sewing section 82
4.8 Finishing section 83
4.9 Washing Section 83
4.10 Industrial Engineering Department 83
4.11 Merchandising 83
4.12 HR & Compliance Department 84
Chapter-5 Conclusion 85
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FIGURE LIST
SL No Fig. No Fig. Name Page No
01 Fig 2.1 Envoy fashion master plan 04
02 Fig 2.2 Google Map location of the factory 05
03 Fig 2.3 Front view 05
04 Fig 3.1.1 Store section 12
05 Fig 3.1.2 Layout of store section 12
06 Fig 3.1.3 Fabric warehouse 15
07 Fig 3.2.1 Embroidery machine 16
08 Fig 3.3.1 Fabric inspection machine 19
09 Fig3.3.2 Defect board 19
10 Fig 3.3.3 Segregation of blanket preparation 20
11 Fig 3.3.4 Blanket Grading 21
12 Fig 3.4.1 Quality Control Department 22
13 Fig 3.4.2 Standard AQL Chart 25
14 Fig 3.5.1 Sample & CAD Department 28
15 Fig 3.6.1 Cutting Floor 36
16 Fig 3.6.2 Layout cutting section 37
17 Fig 3.6.3 Auto spreader m/c 40
18 Fig 3.6.4 Auto cutter m/c 41
19 Fig 3.6.5 Fully automatic end cutter 41
20 Fig 3.6.6 Straight knife cutting m/c 42
21 Fig 3.6.7 Band knife cutting m/c 42
22 Fig 3.6.8 Heat seal m/c 42
23 Fig3.6.9 Fusing M/c 43
24 Fig 3.6.10 Safety equipments 44
25 Fig3.7.1 Sewing Floor 45
26 Fig3.7.2 Plain/Lockstitch sewing machine 48
27 Fig3.7.3 Flat lock machine 49
28 Fig3.7.4 Over lock machine 49
29 Fig3.7.5 Bar tack machine 49
30 Fig3.7.6 Button holing machine 50
31 Fig3.7.7 Button attaching machine 50
32 Fig3.7.8 Feed of the arm 50
33 Fig3.7.9 Blind Stitch Machine 51
34 Fig3.7.10 Snap button attaching machine 51
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35 Fig3.7.11 vertical lock stitch machine 51
36 Fig3.8.1 Front view of Laundry 54
37 Fig3.8.2 Industrial Washing m/c 56
38 Fig3.9.1 Finishing Department 58
39 Fig3.9.2 Thread sucker machine 60
40 Fig3.9.3 Ironing Machine 60
41 Fig3.9.4 Metal Detector Machine 62
42 Fig3.9.5 Garments Packing 62
43 Fig3.9.6 Garments Cartooning 62
44 Fig3.9.7 Ready for shipment 63
45 Fig3.11.1 Merchandising Department 67
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CHAPTER 1
1.EXECUTIVE SUMMARY:
The ready-made garment (RMG) industry of Bangladesh started in the late 1970s and became a
remarkbale sector in the economy within a short period of time. The industry has contributed to export
earnings, foreign exchange earnings, employment creation, poverty alleviation and the empowerment of
women. The export-quota system and the availability of cheap labor are the two main reasons behind
the success of the textile industry in Bangladesh. In the 1980s, the RMG industry of Bangladesh was
concentrated mainly in manufacturing and exporting woven products. From the study on Prospects of
Woven Garment industry in Bangladesh we quote that export of RMG increased day by day. Envoy
Fashion Ltd is one of them. Envoy Fashion Ltd is Garments Manufacturer & Exporter, having all
state of the art facilities with annual turnover 150 million US doller. They have different types of
Cutting,Sewing,and Finishing machines supplied by mostly Japan, Taiwan, U.K, USA,
Singapore,China etc. which are very latest. It has high production rate finished garments are produced
per day.
Textile education can’t be completed without industrial training. Because this industrial training
minimizes the gap between theoretical and practical knowledge and make us familiar to industrial
environment. For continuing the study of internship in the Envoy Fashion Ltd i almost worked all the
sections of this garments industry and tried to find out the activities, planning and many other things as
well.
@Daffodil International University 1|P a g e

CHAPTER 2 :INFORMATION ABOUT THE FACTORY
2.1. INTRODUCTION:
In Bangladesh Ready Made garments(RMG) is increased day by day.However, the Ready Made
Garments (RMG) sector has emerged as the biggest earner of foreign currency. In 1972, the World
Bank approximated the GDP of Bangladesh at USD 6.29 billion, in 2014, the GDP stood at USD
173.82 billion, growing by almost 27 times in a matter of four decades.Bangladeshi exports industry
alone comprised USD 31.2 billion in FY 2014-15, 81.69% of which was made up by ready-made
garments. In 1978, there were only 9 export- oriented garment manufacturing units, which generated
export earnings of hardly one million dollar. Some of these units were very small and produced
garments for both domestic and export markets. Foreign buyers found Bangladesh an increasingly
attractive sourcing place. To take advantage of this cheap source, foreign buyers extended, in many
cases, suppliers credit under special arrangements. In some cases, local banks provided part of the
equity capital. The problem of working capital was greatly solved with the introduction of back-to-back
letter of credit, which was also facilitated import of quality fabric, the basic raw material of the
industry. Till the end of 1982, there were only 47 garment manufacturing units. The breakthrough
occurred in 1984-85, when the number of garment factories increased to 587. The number of RMG
factories shot up to 5440 in 2012-13. The industry has grown at the rate of 59% comparing from 1998-
1999 to 2012-13. Bangladesh’s global market share in RMG rose to 6.4 percents in 2016, an increase of
0.50 per cent over the previous year according to the World Trade Statistical Review 2017 by the World
Trade Organization. It is a positive sign that Bangladesh's global market share increased, but the big
question is how much our entrepreneur’s reaped profit from RMG export in future.
2.2HISTORY OF THE FACTORY:

Envoy fashion ltd started its journey in the year of 2004 which combined with Manta Apparels Ltd and
Envoy Design Ltd. It’s a associated company of Giant business group ENVOY in Bangladesh. Working
with the private entrepreneurs ENVOY group has earned unrivaled success in different sectors in
Bangladesh and Garment industry is one of them. The Government of Bangladesh has honored Envoy
group by awarding the prestigious “PRESIDENT’S EXPORT TROPHY” and the “NATIONAL
EXPORT TROPHY”

2.3 FOUNDER & DIRECTORS:
Group Chairman: Engr Mr. Kutubuddin Ahmed
Managing Director:Abdus Salam Mursedy
Executive Director:Sultan Md. Noorani, PPM
E-mail : [email protected]
Chief Operating Officer: Mr. Kanishka Perera
E-mail : [email protected]
2.4 GENERAL INFORMATION ABOUT THE FACTORY:
Envoy Fashion Ltd is a sister concern of ENVOY Group. Envoy Group established in 1984 and
Envoy Fashion Ltd. Established in 2004.Its located in Ashulia,Savar,Dhaka. This factory is
100% export oriented .The main products of this factory are Men’s, Ladies, Boys & Girls
Knitted Items, Woven
Tops & Bottom etc.Denim Shirts & Jackets, Bottom Long & Shorts, Men’s Shirts, Fancy Dress
(Infant & Boys), Polo Shirts, T-Shirts etc.This factory work with reputated buyer all over the
world.Its also 100% compliance factory. Since its inception, Envoy Fashion Ltd. has never
stopped growing – in quality, quantity, and everything in between.
Over the last couple of years, conceding to its growth requirement, using most contemporary
machines and equipment of German, Swiss, USA, Japan, Italy, China and UK origin, it has
nearly doubled its capacity. Highly skilled and dedicated human resource, most contemporary
western machinery as well as IT and automation have optimized both of its costing and
operational efficiency.

2.5 LAYOUT:
Fig 2.1:Envoy Fashion layout plan


Contact Address:
Envoy Fashion Ltd
Jamgora, Yearpur, Ashulia
Savar Dhaka- 1341
Tel:7790680, 7790681
Fax: 880-2-7790351


Transport direction:
Fig2.2:Google map location of (Envoy Fashion ltd.)
 Factory Front view:
Fig 2.3: Front view

2.6 Organogram:
MD
G.M
A.G.M
Merchandising & (GM) Production

Director QA(Technical)
Ass. General Manager
QC manager
Senior Manager
QC in-charge
Assistant Manager
QC supervisor
Sr. Merchandiser
Line quality
Merchandiser
Table quality
Jr Merchandiser
Cutting manager P.M Finishing
Manager
Cutting in-charge Floor In-charge
Supervisor In-charge
Line chief
Cutting master supervisor

Supervisor
Marker maker
Operator
Iron Folding Packi
Spreading man
Helper Man man ng
man
Helper

2.7 Sister Concerns:
1. Envoy Design Ltd.

2. Manta Apparels Ltd
3. Envoy Garments Ltd.
4. Armour Garments Ltd.
5. Fontina Fashions Ltd.
6. Nadia Garments Ltd.
7. Astras Garments Ltd.
8. Regal Garments Ltd.
9. Pastel Apparels Ltd.
10. Epoch Garments Ltd.
11. Supreme Apparels Ltd.
12. Dornick Apparels Ltd.
13. Olio Apparels Ltd.
14. Envoy Textile Ltd.
15. Laundry Industries Ltd. (Washing Plant)
16. NSS (Computer Division)
17. Lunar International (Trading Division)
18. West Air International (Freight Forwarder)
2.8 PRODUCT MIX

Men’s, Ladies, Boys & Girls Knitted Items, Woven Tops & Bottom etc.
Denim Shirts & Jackets, Bottom Long & Shorts, Men’s Shirts, Fancy Dress (Infant & Boys),
Polo Shirts, T-Shirts etc.

2.9 BRIEF PROFILE
Factory Establishment Year : 2004
Sewing line: 34
Production Capacity:
Woven : 27,230 Pcs (Per day) -7,07,980 Pcs / 58,990 Doz (Monthly)
Knit : 7,900 Pcs (Per day) -2,05,400 Pcs / 17,116 Doz (Monthly)
Total Capacity : Per Day = 35,130 Pcs or Per Month = 9,13,380 Pcs (Woven & Knit)
Website: www.envoy-group.com
Annual Turnover : Confidential
BUSNESS REGISTRATION PAPERS :
1. Trade License
2. Factory License
3. Fire License
4. EPB License
5. Bond License
6. Import License
7. Export License
8. Board of Investment License
9. BGMEA Certificate
10. Boiler Certificate
11. TIN Certificate
12. Certificate of In-corporation
2.10 Main Buyer: Major export Markets:USA=60%

Europe=30%
Others =10%
Major Customer : For USA Market :
American Eagle, VF-Asia, Wal-Mart, Jordache, Haggar Clothing Co.

Bon-Ton Stores Inc. Cintas, Charming Shoppes Inc, Wrangler Inc.,
Aramark, Sanmar, Sears, Fruit of the Loom (Russell Corporation), PVH
etc.

For Europe Market :
Next UK, C & A, Carrefour, Zara, Asmara, Gartex etc.
For Others Market :
Yakka, King Gee, Li & Fung etc.
Percentage of Buyers Work
01) American Eagle = 30%

02) VF-Asia = 25%
03) Jordache = 15%
04) Carrefour = 10%
05) Haggar = 10%
06) Others = 10%

2.11MISSION AND VISION:
Vision:
To achieve a global dominance through.
To become vertically integrated manufacturer for fabric and garments.
Excellence in Product quality.
Diversify products through continuous product innovation. Customer orientation and cost
effectiveness
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Mission :Recipe of a winning combination.

CHAPTER 3 DESCRIPTION OF THE ATTACHMENT
CHAPTER 3.1 Store &Inventory
Fig 3.1.1: Store section
3.1 STORE & INVENTORY:
3.1.1 Layout
Fig:3.1.2 Layout Story & Inventory

3.1.2 Organogram:
Manager
↓↓
Asst. Manager
↓↓
In-charge
↓↓
Senior Store Officer
↓↓
Officer
↓↓
Junior Officer
3.1.3 Store flow chart:

3.1.4 Function of store section or inventory:
• To smooth production follow up
• To meet relate demand
• To protect against stock outs
• To take advantage of quality discounts
3.1.5 Scope of inventory control
• Raw materials inventory.
• Finished good inventory
• Maintenance, repair and operational inventories.
3.1.6 Inventory store system for accessories:

In Envoy Fashion Ltd. there are accessories store in the factory. All types of accessories are stored as
for garments making, buyer wise.
• Main Label.
• Care Label.
• Price Tag
• Security Label(RFID)
• Size label.
• Sewing thread.
• Button.
• Zipper
• Elastic.
• Poly Bag
3.1.7 Raw Materials Ware House:
After inspection, raw materials are stored in the raw materials ware house named Accessories ware
house & fabrics ware house. In the ware house, materials are separated from Buyer to Buyer and Shade
to Shade on the ground floor.
Fig 3.1.3:Fabric Warehouse

3.2 EMBROIDERY SECTION:
Fig3.2.1: Embroidery m/c
The embroidery section is stood beside the store section on the ground floor of the factory. There are
total six machine of embroidery. All of these are from China, brand name Jintel Embroidery Machine,
model 00915,each of the machine contains twenty heads.

CHAPTER -3.3 Fabric Inspection Section
3.3.1Fabric Inspection:
Inspection of fabrics is necessary in order to find the defects in a fabric lot.By the inspection it
ensure that the quality of the fabric .Fabric inspections are done according to a flow chart. The
flow chart is given below:
3.3.2 Fabric inspection procedure:

4 Point system fabric inspection (10% or 100%):
4 Point system for fabric inspection is widely used in apparel industry for fabric quality inspection. To

use this system below things should be in concern.
• Fabric inspection method or preparation
• Criteria of giving penalty points based on defects and defect length.
• Calculation method of total penalty points for total defects found in a fabric roll.
• A Check sheet or format for recording data
• Knowledge of different types of defects (how a defect looks and its appearance)
3.3.3 Criteria of giving penalty points based on defects and defect length:
In the following Standard Sheet penalty evaluation points has been given for different length of fabric
defect and dimension of holes:
Size of Defect(length) Point

< 3 inch……………………………………….. 1
<3-not more than 6……………………………. 2
<6-not more than 9………………………….… 3
<9 …………………………..…………………..4
For hole, one &less than one inch…....................2

More than one inch……………………….……..4

Fabric Inspection machine:
Fig 3.3.1: Fabric inspection machine
Envoy Fabric Defect board:
Fig .3.3.2: Defect board
3.3.4 Shrinkage & GSM Test:
Shrinkage is the process in which a fabric becomes smaller than its original size, through the process of
laundry. Cotton fabric suffers from two main disadvantages of shrinking and creasing during
subsequent washing. There are two types of shrinkage occurs during washing
1. Length wise

2. Width wise
3.3.5 GSM Test:
GSM (Gram per meter square) or weight test is done with the GSM cutter. At first the fabric is taken in
and GSM cutter is put upon the fabric. Then the fabric is cut and the weighted. The weighted value is
multiplied by 100 to find the GSM of the fabric.
3.3.6 Skew Test: The straight-line distortion of a marked filling yarn, knitting course, designated
printed line, or designated design is measured from its normal perpendicular to the selvage or edge.
3.3.7 Bowing Test: A straightedge is placed across the fabric between two points at which a marked
filling yarn, knitting course, designated printed line, or designated design meets the two selvages or
edges. The greatest distance between the straightedge and the marked filling line, knitting course,
designated printed line, or designated design is measured parallel to the selvage.
3.3.8 Shade Segregation (Blanket):

Shade segregation is a process of combining all the shades of a lot together. For doing this samples of
6 inch X 6 inch is collected from each roll of fabric and then stitched together. This is known as
Blanket. Samples are collected from 10% or 100% roll of a lot.
Blanket is prepared like below:
Roll 3 Roll 1 Roll 4


Figure 3.3.3 :Segregation of Blanket preparation
Blanket is prepared to compare and separate the different shades in the same lot.
3.3.9 Shade Separation:

Shade separation is done according to the shade. Variation in shades are marked different from each
other and same types of shades are marked as same as previous. After shade separation they are
marked as below:

 
Shade B Shade A Shade C
Shade C Shade C Shade A
Shade B Shade A Shade B
Figure3.3.4:Blanket(Grading)
From here it can be seen, all the same shades are marked as same. Shade A, Shade B and Shade C are
the shades found in the blanket.

CHAPTER 3.4:QUALITY CONTROL DEPERTRMENT
Fig 3.4.1:Quality Control Department

3.4.1 Quality
Quality of a product or service refers to the perception of the degree to which the product
or service meets the customer's expectations.Actually quality depends on the buyer,when
a buyer will satisfy with the delivered product then it means the product fulfill the quality
3.4.2 Quality Control:
A system for verifying and maintaining a desired level of quality in an existing product
Or service by careful planning, use of proper requirement, continued inspection and
corrective action as required.
3.4.3 Organogram
QC Manager
↓↓
Assistant QC Manager
↓↓
Quality Control Incharge

↓↓
Supervisor
↓↓
Helper

3.4.4 Importance of Quality Control
• Reduce the fault during production
• Increases the productivity and cost effective
• To ready the product for the final inspection of buyer.
3.4.5 Objectives of quality Control

• Confirm buyer fulfillment
• Ensure the product quality
3.4.6 Quality control can be classified into two classes
1.In-line quality control(Flow chart)
Pattern making inspection

↓↓
Marker making inspection
↓↓
Cutting inspection
↓↓
Sewing inspection
↓↓
Pressing and finishing inspection
↓↓
Packing and cartooning inspection

2.Off-line quality control (Flow diagram)
Fabric lot no. check
Buyer’s order No check
Style No. check
Product quality check according to buyer’s requirement
Inspection and testing of the produced garments
3.4.7 Quality Control Section:
To ensure the quality of the garments and to identify the defects if there any and rectify those if
possible is the main work in quality control section. Quality Controller is responsible for
implementation of final inspection system and verifies the inspection. Final Table Quality inspection
received garments from Final Assembly section of sewing section and are responsible to check 100%
garments quality and check the measurement as explain bellow:
• The garments are inspected from inside and outside to check stitching defects as explained in
Sewing Defect Standard.
• Using arrow Stickers identifies defects and the defected garments are segregated. The results are
recorded on table on table Alteration report.
• On hourly basis Quality Controller will verify the final Table Quality Inspection by re
checking the segregated defected garments on random basis and sign to the Table
alteration Report.
• Once the In-line Quality Controller have verified, the Line Supervisor will take the defected
garments for repair, and they are re-inspected with normal production

3.4.8 Definition of AQL
The AQL (Acceptable Quality Level) is the maximum percent defective that for the purpose of
sampling inspection can be considered satisfactory as a process average.
Every buyer of Envoy ltd. Follows1.5 major 2.5 minor for their order
3.4.9 Standard AQL sheet:
Fig:3.4.2 Standard AQL chart

3.4.10 Checking points for quality inspection
• Measurement points
• Chest
• Bottom
• Waist
• Body length
• Shoulder
• Arm hole
• Sleeve length
• Sleeve width
• Neck width
• Placket width
• Raw Edge
• Run off/down stitch
• Color
• Oil spot
• Skip stitch
• Broken stitch
• Open seam
• Main label side
• Pullness
• Back pocket high /low.
• Side seam

.
3.4.11 Initial works at Q/C table:

• Visual Inspection for measurement with proper scaling
• Inner and Outer parts are inspected for any types of damage or sewing faults i.e. seam
problem, broken stitch etc
3.4.12 Check List at Q/C Table:

• Broken Stitch, Tension loose, Open Stitch
• Spot, Shading, Thread Cutting
• Placement of label
• Chest, Waist, Sleeve and Back Length check.

After checking all the parameters if the product meets the quality standard then it is given pass
code from the quality section and the garments is then ready to be transferred to the finishing
section.

CHAPTER 3.5 :SAMPLE & CAD SECTION
Fig3.5.1:Sample and CAD department
3.5 :SAMPLE & CAD

Sample & CAD is one of the main section of a garments. In Enoy Fashion Ltd. This section is divided
into following sections:
1. Sample section
2. Pattern section
3. Marker section

4. CAD section.
3.5.1 Sample section:

Sample section is the first section of garment manufacturing industry as well as Envoy Fashion Ltd.
Garment samples are inevitably important and are developed tested before starting the bulk production.
It means making a sample of the garment /fabric which requires to be sold. Sampling is one of the main
processes in Garment Industry and it has a vital role in attracting buyers. Because the buyers generally
places the order after they are satisfied with the quality of the samples.
Samples are always made in sample section, which differ from production floor. In this section,
garments are making as sample to send the buyer for approval. After that, it will be ready for
production. To make the correct sample as per buyer requirement is the first function of the sample
section.There are
4 sewing line in sample section.
Enoy Fashion Ltd. sends many samples to buyers. They are:
1. Development sample
2. Sales Marketing Sample(SMS)
3. Proto Sample
4. Approval Sample
5. Size set Sample
6. Pre-production Sample

3.5.2 Organogram

3.5.3 Machine details :
Name of m/c Brand Origin Quantity

Digitizer m/c China 1
Winda
France 1
Lectra
USA 1
Gember
Plotter m/c IMA Italy 1
China 2
Winda
USA 1
Gember
Pattern cutter m/c China 1
Winda
Gember Japan 1

3.5.4 Flow chart of sample section:
Receive Technical pack from Merchandiser

↓↓
Review sketch & read all information for clear understanding
To make pattern & maker
↓↓
Patterns are made according to the Spec. sheet
↓↓
produce the proto Sample
↓↓
Send it to Buyer
↓↓
Corrections from Buyer(if necessary)
↓↓
Send color selection Sample
↓↓
Approval from Buyer

↓↓
Send size set sample
↓↓
Comments/correction from buyer
↓↓
counter sample make and send to buyer
↓↓
Approval/ order confirmation from Buyer
↓↓
Send production sample to buyer
↓↓
Approved by buyer

3.5.5:Flow Chart of Pattern Section :
Measurement sheet given by buyer

↓↓
Develop the pattern according to Tech pack
↓↓
Based on development pattern, development sample
produced
↓↓
Development sample sent to buyer and prepare a costing
marker
↓↓
After that several samples are prepared and then buyer
comments on the samples
↓↓
Re-correct the pattern according to the buyer comment
↓↓
After that counter sample is produced and sent to buyer
↓↓
After order confirmation, pre-production meeting
↓↓
Cutting start
↓↓
Bulk production start
3.5.6Marker Section:
Marker is a thin paper which contains all the necessary pattern pieces for all sizes for a particular
style of garments. It gives special instructions for cutting. It can be both manually and
computerized method. In Envoy Fashion Ltd. they are using computerized method (Lectra)
marker which all information’s are stored in the pre fashioned data file and operator helps the
computer to make the best choice.

Marker Making Method: There are two types
1. Manual method 2. Computerized method.
3.5.7 Flow chart of Marker making :
3.5.8 Process of Marker making:

1. Normal Marker: Random one garments one way. i.e : Basic polo shirt.
2. Selvedge Marker: One way/two way/Group selvedge. i.e: shading fabrics.
3. Warp Marker: Twill fabrics.
4. Check Marker: Check fabrics.

3.5.9 CAD Section:
In Envoy Fashion Ltd. there is a CAD section. This room is used for make pattern and marker by
CAD software. By using CAD system Patterns are created to exact measurements and adjacent
pattern curves can be forced to be the same length ensuring patterns make up with no puckering
and you will end up with a quality, professional looking garment. CAD tools enabling to modify
patterns to unique requirement.CAD software introduces a unique system of grading patterns that
has simplified this process in a miraculous way by removing all the hard work yet leaving in
control. It is manage to grade patterns proportionally while keeping the shape, fit and balance of
the original design. It is easy to grade any blocks and styles and create fully professional
collections. GARBER, OPTITEX, Lectra software are popular CAD software.
In Envoy Fashion Ltd. Lectra is used as CAD software.

CHAPTER 3.6 CUTTING DEPARTMENT :
Fig 3.6.1:Cutting Floor
3.6.1 Cutting:
Cutting is very complex and important section of garments. In garments industries fabric is cut
from lay and spreading with accuracy and properly which is termed as fabric cutting. Marker
outline is used to cut the fabric. Fabric cutting is very important as if something is cut in wrong
way, cannot be rectified.

3.6.2 Layout:
Fig:3.6.2 layout cutting section

3.6.3 Organogram:
Manager
↓↓
Deputy Manager
↓↓
In-charge
↓↓
Supervisor
↓↓
Helper

3.6.4 Flow Chart of Cutting Section:
3.6.5 Function: There are three basic function of the Cutting Section as
  Material control


Fabric wastage control and

Proper utilization of fabric.
3.6.6 Equipment of Cutting: Some equipment used in cutting section, like:


 Cutting table

 Straight knife

 Spreader machine

 Clip

Band knife cutting machine

 
Fusing etc.
3.6.7 Method of fabric cutting:

This industry is following two methods.
1. Manual.
Hand operated scissor.
Straight knife Or Hand Cutter M/c.
2. Automatic:
Lectra auto lay cutter machine.
Lectra auto lay end cutter machine
3.6.8 Description of cutting machine:

Various type of cutting machine are uses in the cutting section.
Specification of the machine :

Machine No.01
Machine Name: Auto Spreader

Machine
Brand: Lectra
Model:KW-71
Capacity: 100 pcs/h
Fig:3.6.3 Name: Auto Spreader Machine

Use : To spread fabric smoothly one
above another

Machine No.02
Machine Name :Auto cutter machine
Brand: Lectra
Use: To cut fabric lay very Fig3.6.4: Auto cutter machine

preciously according to marker
Machine No.03
Machine name: Fully automatic

end cutter machine.
Brand: Eastman
Model:Ec-9N
Power:230W
RPM:100 Fig3.6.5: Fully automatic end cutter

machine.
Use: To cut end of fabric.

Machine No.04
Machine Name: Straight knife cutting machine.

Brand: Kmmack
Weight:15.6 Kg
Cutting Capacity: Maximum 5 in.
(29.2cm)height.
Fig3.6.6:Straight knife cutting

Quantity:31
machine.
Use: Cut fabric manually
Machine No.05
Machine Name: Band Knife

Cutting Machine
Brand: Eastman
Model: EC-700N
Capacity: can cut up to 6 inch
(maximum)
Quantity:2
Use: To cut edge of fabric Fig3.6.7: Band knife cutting

machine.
Machine No.06
Machine name: Heat seal machine(pressing machine).

Brand: Hashima.
Model:Needle Search
Quantity:1
Use: To attach seal on the fabric
Fig3.6.8:Heat seal machine

Machine No.07
Machine name: Fusing machine.
Brand: Hashima
Quantity: 4
Use: To attach fusing part with

fabric.(collar, waist band, cuff etc)
Fig3.6.9: Fusing machine.

3.6.9 Safety of Cutting section: Any accident can happen during cutting the fabric
layer.For this reason different safety equipments are stored and used in cutting floor.
Fig 3.6.10 Safety equipments

CHAPTER 3.7:SEWING SECTION :
Fig 3.7.1:Sewing floor

3.7.1 Sewing :
Sewing section is the most important department of a garment industry. Sewing machines of
different types are arranged as a vertical line to assemble the garments. Sequence of types of
sewing machines arrangement depends on sequence of assembling operations. There is 34 sewing
lines in this section. But the capacity of every line is not same.
After receive the garments components from cutting section, all the garments parts are joined and
sewn as sequentially. Obviously all the components are sewn according to buyer requirement.
The main purpose of sewing is to produce seam.

3.7.2 Organogram:
GM
↓↓
Manager
↓↓
Ast. Manager
↓↓
Production manager
↓↓
Incharge
↓↓
Supervisor
↓↓
Operator
↓↓
Helper

3.7.3 Process Sequence of Sewing Section:
Bundle receiving of various parts from cutting section
Place it in the end of the line to a helper
Opening of the bundle
Through it to sewing
Sewing
Finished sewing
Inspection
Sent to finishing section
3.7.4 Name of the machines used in sewing section are :


 Single needle lock stitch Machine

 Double needle lock stitch Machine

 Single needle chain stitch Machine

 Double needle chain stitch Machine

 Multi needle chain stitch Machine

 3 thread Over lock Machine

 5 thread Over lock Machine

 Bar tack Machine

 Button hole Machine

 Button attaching Machine

 Snap button attaching Machine

 Feed of the arm Machine.

 Vertical Stitching Machine

 Kansai M/c

 APW M/c

Sleeve attach M/C
 
SholderPad M/c

3.7.5 Activities of sewing section:
3.7.6 Equipment& Machine Details:

Industrial Sewing
machine specification
Machine NO: 1.
Machine name: Plain/Lockstitch sewing machine
Brand: Juki & Brother
Model: SL1010-3, DDL8300N
Origin: China
Application: Collar join, Zipper attach, placket attach,
Label attach etc.
Fig:3.7.2 Plain/Lockstitch sewing machine

Machine NO: 2.
Machine name: Flat lock machine
Brand: Juki,Yamato
Model CF2303M, MH481
Origin: China
Application: Top stitch, hemming etc.
Fig3.7.3 : Flat lock machine
Machine NO:3
Machine name: Over lock machine
Brand: Juki & Brother
Model: FBN310, MD 6716
Origin: China
Application: Edging, hemming.
Fig3.7.4: Over lock machine
Machine NO:4
Machine name: Bar tack machine
Brand: Brother, Juki
Model: KE4300, LK1900ASS
Origin: China
Application: To create bar tack stitches in
garments,Inseam, pocket of trouser etc.
Fig3.7.5:Bar tack machine

Machine NO:5
Machine name: Button holing machine
Brand: Brother,Juki
Model: HE800A, LBH1790
Origin: China
Application: Button holing
for ordinary Cloth Knit etc .
Fig3.7.6: Button holing machine
Machine NO: 6
Machine name: Button attach machine
Brand: Brother,Juki
Model: BE438D, LK1903ASS
Origin: China
Application: Button attaching for
ordinary cloth, knit etc.
Fig3.7.7 : Button attaching machine
Machine no:7
Machine name: Feed of the arm
Brand:Brother,Juki
Model: DA9280, MJ1261
Origin: China
Use: Side seam (jeans pant), top seam.
Fig3.7.8:Feed of the arm

Machine no: 8
Machine name: Blind stitching machine

Brand :Treasure
Model : BS101
Use: Bottom hem
Fig3.7.9: Blind Stitch Machine
Machine no: 9
Machine name: Snap button attaching machine
Brand: Nagai Shing
Model:EB
Origin: China
Use: Attaching hook, button attaching
Fig3.7.10:Snap button attaching machine
Machine no:10
Machine name: Vertical lock stitch machine
Brand: Golden Wheel
Origin: Japan
Use: Selvedge sensing and stitching in a straight line.
Fig3.7.11:vertical lock stitch machine.

3.7.7 Different types of Needle used in different Sewing M/c:
Machine Name Size of Needle

Plain Machine DB X 7,8,9,10,11
Over lock Machine DC X 7,8,9,10,11
Button Hole Machine DP X 9,10,11
Button Attaching machine DP X 17, TQ X 11,14

Kansai UO X 9,11
Flat Lock Machine DP X 8,9,10,11
3.7.8 Some defects of sewing operation:

 √ Skip/ Drop stitch
 √ Uneven stitch
 √ Over stitch
 √ Joint stitch
 √ Raw edge
 √ Tension loose
 √ Broken stitch
√

Puckering
√ Open stitch
√ Oil spot Shading

√ Incorrect stitch per inch
√ Pleat
√ Needle cut
√ Wrong Thread
√ Wrong size/ care label
√ Slanted
√ Wrong button placement
√

Run off stitch

CHAPTER 3.8 WASHING DEPPARTMENT
3.8.1 Organogram
Manager
↓↓
Deputy Manager
↓↓
In-charge
↓↓
Supervisor
↓↓
Helper
3.8.2 Front view:
Fig 3.8.1:Fornt view of Laundry

3.8.3. Washing process Flow chart:
Garments from stored section

↓↓
Quality Check
↓↓
Batching
↓↓
De-sizing (if necessary )
↓↓
Washing
↓↓
Hydro-extracting
↓↓
Drying
↓↓
Quality Checking
↓↓
Packing
↓↓
Delivery

3.8.4 Machine type:
In this factory there are total 32washing machine, capacity of those machines are
(550LBS).
Fig3.8.2: Industrial washing machine.
3.8.5

Dryer machine

: There two types of dryer machine.
 Gas dryer

Steam dryer.
Washing plant both use in dryer machine. In this plant there are 38 gas dryer and ten
steam dryer machine. Maximum capacity of this machine 300 LBS per m/c.
3.8.6Types of Washing:
 
 Rinse wash √ Sand Blasting

 Garments wash √ Ultra soft wash
 
 Heavy wash √ Destroy wash
 
 Enzyme wash √ Silicon wash
 
 Heavy enzyme wash √ PP spray
 
 Enzyme stone wash √ Crinkle
 
Enzyme bleach wash √ Garments Dyeing

3.8.7 Chemical used in washing plant:

 DSS Softener- (Denire U TEAR)

 Clear sit –Silicon oil

 Detergent-(Ferol MILT-4)

 Enzyme
Neutral (powder)
Liquid (Cozyme
4BT)

 Acetic acid

 Liquid solve(spot removal)

Hydrogen per oxide(bleaching agent)
3.8.8 Name of some lab test equipment:


 Washing machine

 Tumble dryer

 Rubbing tester(color fastness to rubbing)

 GSM cutter

 PH meter

 Ironing machine

Light box.







CHAPTER 3.9 FINISHING DEPARTMENT
Fig3.9.1: Finishing department

3.9.1:FINISHING SECTION:
It is important section because when the garments sewed then its can not be packaging or can
not be folded for shipment. In the section the garments are finished by machines, the extra
threads are sucked by sucking machine, ironing removes wrinkle from the garments the
garments. There is no more procedure after the finishing section so packing and cartooning are
also included in this section .The needle detector machine ensure that there is no broken needle
or any metal part in the garments during manufacturing.

3.9.2 Organogram :
GM
↓↓
Manager Finishing
↓↓
Deputy Manager
↓↓
In-charge
↓↓
Supervisor
↓↓
Helper
3.9.3 Objective of finishing:
To enhance the suitability of the fabric for end use.

To improve appearance and sale appeal for comport and utility.
3.9.4 Process Flow Chart of Garment Finishing:

Goods received from sewing section
↓↓
Threads suck my machine
↓↓
Ironing
↓↓
Measurement check by QC
↓↓
Attach price tag and other accessories
↓↓
Metal Detection
↓↓
Folding
↓↓
Packing
↓↓
Assortment
↓↓
Cartooning
↓↓
Final Inspection

3.9.5 Description of finishing machines:
Thread sucker machine:
All garments checked by thread sucker machine to remove loose thread. This machine sucks
loose threads from garments and makes it free of loose threads.
Fig 3.9.2: Thread sucker machine
Ironing:
All garments are ironed by steam. Ironing temperature is determined by buyer. This
ironing is help to garments for fixing their shape.
Fig 3.9.3: Ironing Machine.
Basic Ironing symbols:
Do not iron

Cool iron (110°)
Medium iron (150°)
Hot iron (200°)

Metal Detection:
the garments which are inspected and then passed through the metal detection machine. The
machine determines whether the garment contains any ferrous components or not. If a garment
contains any ferrous item or broken needle, the garment will fail to pass the machine and it will
come back. Fail garments are kept in rejected box kept beside the metal detector machine. The
passed garments are kept to the quarantine area.
Fig3.9.4 : Metal Detector Machine
3.9.6 Chemical Used to Remove Spot:

Dyeing Spot: Lifter
Cutting Spot: Thinner
Printing Spot: Thinner
Oil Spot: Thinner or Power
Sewing Spot: Lifter
Thinner:
Thinner is used to remove the soil spot, color spot, dust and dirty spot, etc.
Lifter:
Lifter is used to remove the oil spot, soil spot, sewing spot etc.

Water:
Water is used to remove the dirty spot, ink color, etc.
3.9.7 Packing:
According to size, there are different sized polybags which are stored in the packing area.
Various size garments are put in the proper size polybags and then sealed with stickers.
Fig3.9.5 : Garments Packing
3.9.8 Carton:
After packing, cartooning takes places according to the size ratio or assortments.
Sometimes buyer gives special instruction regarding cartooning and they are followed
strictly by the packing section. Types of carton :
3Ply
5Ply
7Ply
Fig3.9.6 : Garments Cartooning

3.9.9 Dispatch :After all the procedure the garments are stored in warehouse to dispatch.
Fig3.9.7: Ready for shipment.

CHAPTRE 3.10 INDUSTRIAL ENGINEERING DEPARTMENT
3.10 Industrial Engineering
Industrial engineering is concerned with the design, improvement and installation of
integrated system of man, machine and equipment drawing upon specialized knowledge
and skill in the technical, economics and human sciences, either with the principles or
methods of engineering analysis and design to specify, predict and evaluate the results to
be obtained from such system.
3.10.1 Organogram
Manager
↓↓
Asst. Manager
↓↓
Sr. IE Executive
↓↓
Executive
↓↓
Sr. Officer
↓↓
Officer
3.10.2 Layout:
Machine layout is made according to process break down. Machine layout gives a
freedom of work in a flow to each individual worker so it is a very important thing which
is also related to production & worker efficiency.
3.10. 3 Process break down:
In this segment individual garments sewing steps one after another is prepared. The sample

garment which is developed for production is observed carefully to prepare the process
break down.
3.10.4 Target fixing:
An initial target is fixed by the IE section. Afterward, when bulk production starts, the initial
target is changed and new target is implemented.
3.10.5 Line Balancing:

Adding or removal of machines according to need and to increase the production, line
balancing is done by IE section.
3.10.6 Training of operators:

Training of new operators is done by the IE section. Sufficient training for optimum
production from an individual worker is done.
3.10.7 Calculating Incentives:

Over time incentive or production base incentives are calculated by the IE section and also
implemented.
3.10.8 Equations used for various calculation the IE department is given below:
Target Calculation= Manpower×Working hour×60 ×Efficiency

SMV
Efficiency Calculation= Earn mins %
works mins

SMV×Outputx100
Manpower ×Working hr×60
Total SMV
Tact time =
Total manpower
SMV Calculation=Basic time (mins)+ Allowance
• Basic Time = Cycle time ×Rating
3.10.9 Work Study Officer &IE Responsibilities :

 Operation breakdown & Machine Layout.
 Buyer & Style wise operation breakdown & Layout.
 Prepare Man machine report.
 Buyer & style wise capacity study & line balancing.
 Train up production staff on efficiency.
 Production Monitoring&Achieve the line Target.
 Daily line wise Target setup.
 Wastage control at the production floor.
 To prepare daily, weekly, monthly production plan (Cutting, Printing, and Sewing)
 Arrange trims & accessories just in time.
 Prepared daily Crisis report& SMV calculation.
 Follow up daily output per production line & achieve the line.
 Method study & Motion Study.
 Data collect & efficiency report
 Prepare skill inventory & grading of the operator
 Nonproductive time (Lost Time) record.
 Ensure optimum use of machine.
 Daily quality statistical report presentation.

CHAPTER 3.11 MERCHANDISING DEPARTMENT
Fig3.11.1:Merchandising Department
3.11.1 Organogram
Merchandising Manager
↓↓
Deputy Merchandising Manager
↓↓
Sr. Merchandiser
↓↓
Merchandiser
↓↓
Asst. Merchandiser
↓↓
Trainee Merchandiser

3.11.2 Merchandising:
Merchandising is the department which mediates marketing and production departments. It is

the methods, practices, and operations used to promote and sustain certain categories of
commercial activities. It includes directing and overseeing the development of product line from
start to finish.
Marketing and merchandising department: A team of merchandisers and marketers work

together under a profit controls head. Merchandisers handle the foreign buyers. The teams
are made according to the buyers being handled.
3.11.3 Merchandiser:
The person who is related in merchandising is called merchandiser. The

merchandiser coordinates with the design team to effectively present the product or
product line. He or she develops colors and specifications, and performs market
research to determine the most effective ways to sell and promote the product. This
person needs strong communication and negotiation skills and visual and analytical
abilities. He or she also needs to be a creative and innovative thinker.
3.11.4 Responsibilities of merchandisers :


 Internal & external communication,

 Sampling,

 Lab dips,

 Accessories & trims,

 Preparing internal order sheets,

 Preparing purchase orders,

 Advising and assisting production,

 Advising quality department about quality level,

 Mediating production and quality departments,

 Giving shipping instructions and following shipping,

 Helping documentation department,

Taking responsibility for inspections and





 
Following shipment.
3.11.5 Qualities of a merchandiser:


The most important quality is that he must be educated. He must have the brought
 knowledge about Textile.

He must be very skilled in English language as he has to communicate with the foreign
 buyers and suppliers.

He has to be a computer literate, i.e. a good idea about computer operation e.g. office
 program like Ms Word, Ms Excel.

He must have enough knowledge about browsing e.g. sending and receiving e-
mail, searching on net etc.

 He must have a good appearance and should be smartly handled all kinds of situation .

He should be capable of thinking at multi-level stages because he has to maintain
communication outside the factory with buyer and supplier as well as inside the factory
with various sections like sample, marker, sewing etc.

A merchandiser should have adequate knowledge regarding followings:
Different types of wash/dry processing
Different types of dyeing and printing process of fabric
Different types of fabrics/accessories and current market price of them.
Different types of defects, their remedies, Inspection system etc.
A merchandiser should always have a mentality to impress the buyers by means of:

 Right Product.

 Right Qualities.

 Right Quantities.

Right Time.

3.11.6 Process Flow chart of Merchandising:
Received order details

↓↓
Consumption
↓↓
Costing
↓↓
Negotiation with buyer
↓↓
PO sheet receive
↓↓
L/C receive & B/B L/C open
↓↓
Sample approve
↓↓
Approve for bulk production
↓↓
Production planning
↓↓
Bulk production started
↓↓
Line inspection
↓↓
Final inspection
↓↓
Shipment to buyer
3.11.7 Require document for Shipment:


 For local Shipment:

 Invoice

 Packing list

 Delivery chalan

 Utilization declaration

For International Shipment:
By Sea


 Commercial invoice

 Packing list

 Bill of lading

Original document.
By Air

 Commercial invoice

 Packing list

AWB(Air way Bill)
3.11.8 Chronological Process of Merchandising:
 
Step 1: Marketing:
The first process is marketing. Marketing personnel has to market his company in order to
increase his customers and generate more and more revenues. It acts as a bridge between
buyers and the company for communicating each other. The Marketing personnel here
enclose a brochure and product picture with the mail and forward it to the prospective
buyer for their convenience. The interested buyers reply to the enquiry letter submitting a
sample product with measurement sheet(PO) to the merchandiser to follow the sample
going for production.
Step 2: Costing and Negotiation: Costing:
Merchandiser makes a cost sheet to see if the product is contingent or not in terms of cost
and revenue.Some tricky decision have to take here as a merchandiser.Merchandiser has
to calculate the cost of products including wastages and accessories to tell the final cost of
the product to his customers.
Negotiation: He/She (Merchandiser) must have a negotiating power on the price to convince his
buyers on specific price to lessen the chances of loss. If price is accepted by both parties then it’s
time to sample approval from buyer.
The aim of negotiation "Win solution" Both parties are benefited.
The skill for negotiation:


 Discovering common interest and removal of personal issues.

 Questioning skill

 Listening effectively

 Understanding body language.

 Look-out and judgment.

 impressing skills.
Step 3: Source Fabric:
After negotiating price the merchandiser have to find from where fabric can be found as
per buyers requirement. There are two sources of fabric.
1. Local source
2. Foreign Source.
Both local and foreign it needs to open a L/C. In textile sector generally back-to- back L/C
(B –B L/C)is used to collect Fabrics.
 
Step 4: Prepare Lab Dipping, Dyeing and Fabric printing :
It is an important part of sampling. If buyer wants color size product then he need to send
them for proper coloring. After that lab test is send to the buyer for approval.After
approval of the fabric is ready for the next process.
Step 5: Source Prepare Trims & Accessories:
For preparing a product a manufacturing company needs various types of trims and
accessories. These are very much important for textile product. Such as ,sewing thread
button,zipper,lace,tag, pin, twill tape,poly bag etc. so it is the duty of a merchandiser to
sourcing accessories before start production.
 
Step 6: Develop a Sample:
Sample is the physical form of buyer's specification or style/design. After draw a sketch a
sample is prepared for the buyer and sends to the buyer. Sampling may be in two ways.
1. Sampling after confirmation price.

2. Sampling before confirmation price.
For sampling a merchandiser need Fabrics, yarn, label, etc


 Step 7: Production execution and tracking:

Cutting the Fabrics:
After confirmation of production and approve of the cutting the fabrics from the buyer, the
cutting master started to cut the fabrics.Pattern and marker are produced to cut the fabric
efficiently.

Sewing:
In sewing section the finish fabrics are sewed. There are various types of sewing machine
that are given in the list of machineries in above section.

Washing :
It is most important factor in textile sector. In different stages of production, various spot
we found in products that are needed to wash or different looks/design are produced by
washing.Various spot we found in products that are given below:

 Oil spot

 Dirt spot

 Print spot

Fabrics spot
Ironing:
In iron section products are ironed for better finishing. Ironing product looks nice and
shines. For iron generally steam boiler is used. Steam boiler is so much useful for iron.
Sometimes iron shoes are used in iron for better ironing.

Packaging:
Packaging may be defined as the activities of designing and producing the vessel or the
wrapper for the product. Generally the packaging could be considered as the silent sells

man of the product. When the garments are exported to the buyer different type of
instruction should have to be followed by manufacturers.
 
Arrange Shipping Sample:
Shipping sample is much important for shipment. Shipping sample means the
representative of the product that manufacturer has produced for the buyer. Sample must
be repetitive according to color, size.
 
Follow- up Export Procedures
A merchandiser must follow the export procedures by himself.

 
Step 8: Export procedure:
Cargo lifting advice is fixed to custom clearing agent/ forwarder/ transportation.

Forwarder / clearing agent make arrangements for the custom clearance and booking of
the space at earliest vessel. Following documents are requisite for the custom clearance.
Detail is given following;
Invoice: In Invoice following criteria is required:


 Consignee and Applicant Addresses

 Garment statement

 Garment Price and Total Invoice value

 Net and Gross Weight of Garments

 PO (purchase order) no.

 From # & Date

L/C. # (letter of credit)
Packing list: There are following details in the packing list required as per buyer's instruction
or mentioned in L/C.

 Consignee and applicant addresses

 Product description

Style and color










 
 Net and Gross weight of Garments

in the Cartoon and Cartoon Dimension is also other necessary
No. Of Pieces
information
Export-from:
E-FORM is issued and attested by the concerned bank (National Bank Ltd.)
Bill of entry:
Applicable only in case of the imported materials used in the manufacturing of the
garments for the export intention.
Shipping bill:
Shipping bill is made by the forwarder. After the sub Management Information Systems
on of the custom documents, by the forwarder, custom authorities follow the documents.
And examine the shipment accordingly. They write the report on the backside of the
shipping bill and approve the shipment for the export from Bangladesh after following. All
these docs are then returned to the export department.
Visa process:
After receiving the Documents from the forwarder, Export Department prepares the Visa
documents, which are required for the export of garments to the following countries;
USA, CANADA, EUROPEAN countries.
Negotiation / Collection:
After the completion of the Visa process, we submit the documents in the Bank for the
negotiation/ collection. The docs are prepared according to the L/C or the buyer
requirement.
Document for the buyer:
Export department also prepare documents for the buyer for the custom clearance of the
shipment at the destination.

Payment procedure:
After the negotiation/ collection procedure of the documents, bank expresses the same to
L/C opening bank, to realize the payment. Foreign bank is bound to realize the same
within the 10 to 15 days.
Commercial invoice:
In the commercial invoice all the details are mentioned required under conditions of L/C
for custom clearance and other necessary purposes.
Packing list:
It consists of color, weight, product code/other, coding numbers, no. of cartoons, cartoon
dimension, and carton packing.
Bill of lading / Airway:
This is according to the L/C terms and conditions.
3.11.9 Consumption & Costing:
For 32000 pcs order quantity,
Gross Consumption =2.93 yrd/pcs (Mini marker)
Units price =3.00(Supplier)
So,
Fabric Consumption= Gross consumption × Unit price
= 2.93 × 3.00
Unit cost =$4.50

Total Value = $4.50×32000
=$144000.00

CHAPTER 3.12 HR & COMPLIANCE DEPARTMENT :
Compliance: Compliance means to comply something or yield to the wishes another.

Compliance is ensured all labor rights and facilities according to the buyer Code of
conduct(COC). The aim of compliance is to maintain strictly the labor law.
3.12.1 Organogram
Asst. Manager
↓↓
Sr. Executive
↓↓
Executive
↓↓
Officer
3.12.2 Compliance issues maintained by Envoy Ltd:
1. Admin & HR department:
a. Personnel policies:

 Recruitment policy

Leave and holiday policy

b. Attendance and leave register card:


 Their weekly working hour not more than 66 hours including overtime in a week.

They have the approved manpower list.
2. Health & hygiene:

First aid ensure.


 Medicine registers.

 Maternity & pregnancy register.

 Pure drinking water.

 Dustbin & spittoons.

 Wash basin.

Separate toilets for men & women.

3. Safety:

 Safety committee

 Needle detector

 Fire alarm & switch

 Emergency Exit plan

 Personal protective equipment

Rubber mats to every iron man



4. Welfare:
 
 Welfare committee
5. Workplace condition:

 Working place is safe and hygienic.

 Safety of building and machineries and other risky equipments.

Enough Lighting.

6. Leaves & holidays:


 Weekly holiday

 Annual leave with wages

 Festival holiday

 Casual leave

Sick leave

7. Salary & wages:


 Fix wages is considered with respect of Govt.

Salary and wages given before 7th day of month.


8.Environment:
Procedure and standards for waste management, handling and disposure of chemicals and
other hazardous materials, emissions & effluent treatment must or conquor minimum legal
requirements.
9.Employment relationship:
Communication & relationship between management and workers are very good.

10. Others:

 To maintain daily labor report

 Canteen facility.

Compliance item.
3.12.3 CODE OF CONDUCT of maintained by ENVOY Ltd:


Forced Labor: Envoy Limited does not used forced labor in any form person, bonded
 or otherwise.

 Child Labor: The factory does not employ any person below the age of 18.

Compensation: Envoy Limited provides each employee at least the minimum wages,
 or higher and provides each employee a clear, written accounting for every pay period.

Benefits: It provides each employee all legally mandated benefits. These include meal
subsidies, transportation or transportation subsidies: other cash allowances; health care;
pregnancy or sick leave; vacation; religious holidays; leave and contributions to

Provident Fund.

Hours of Work / Overtime: Envoy Limited complies with legally mandated work
hours; uses overtime when each employee is fully compensated according to local law;
and on a regularly scheduled basis provides one day off in seven days, and requires no
 more than 60 hours of work per week.

Management of environment, safety and health Envoy Lld. has written health and
safety guidelines, has a factory safety committee provides personal protective
equipment free of charge and mandates its policies which complies with all

applicable environmental, safety and health rules.

Every employee shall be treated with respect and dignity. No employee shall be any
physical, sexual, psychological or verbal harassment or abuse. Disciplinary procedure

shall be applied fairly among all workers in the factory.

CHAPTER 4: IMPACT OF INTERNSHIP:
As a part of course curriculum of Daffodil international university, students are sent for
industrial attachment for two months practice in related field. During the attachment students
worked as a trainee textile engineer and had to attend the official working days in general
working hours i.e. 8 am to 5 pm.
I have gained knowledge by the industrial training are following
4.1STORE & INVENTORY

 Operation of inventory Process.
 Concept about work-culture of store & inventory Section.
 Inventory process faults & their remedies.
 Different types of accessories name & function.
 How to store accessories by buyer wise.
 Idea about Inventory Report, Chalan etc.
 Source of accessories.
4.2EMBROIDERY SECTION
 Introduce with embroidery machine
 Practical knowledge of how embroidery is done
4.3FABRIC INSPECTION SECTION

 I Introduce with machine used in Fabric inspection section.
 I learn how to operate those machines.
 Performance of fabric inspection Process.
 Idea about the working process of fabric inspection Section.
 Fabric inspection process faults & remedies.
4.4QUALITY CONTROL SECTION

 I Introduce with machines used in quality control section.
 Operation of quality control Process.
 Idea about working process of quality control department.
 Run into work culture of this section.
 Quality control process faults & remedies.
 Quality checking procedure of different garments.










4.5 SAMPLE & CAD SECTION:

 Know about the machines used in sample & cad section in the factory.
 Now I know how to operate this machines.
 I have introduce with work culture of this section.
 Operations of sample & cad section.
 To know about working process of sample & cad section
 I Know about Faults & remedies of sample & cad section.
4.6CUTTING SECTION
 Practical experiences with machines of cutting section.
 I have learnt how to operate this machines.
 Operation of cutting Process and also the spreading process.
 Idea about work-culture of cutting Section.
 Cutting process faults & remedies.
 Numbering, bundling, spreading etc.
4.7SEWING SECTION
 Introduce with machine used in sewing section.
 Operation Process of sewing.
 I Know about working process of sewing Section.
 Faults & remedies of sewing section.
 Breakdown of sewing procedure of the factory.

4.8FINISHING SECTION
 To know about machines are used here.
 Operation of Finishing Process.
 Idea about work-culture of Finishing Section.Packing, Ironing, Checking process etc
4.9WASHING SECTION
 Acquainted with machine used in washing section.
 I have learned how to operate this machines.
 Operation of Washing Process.Idea about work-culture of Washing Section.
 Washing Process and different kinds of washing.
4.10 INDUSTRIAL INGINEERING DEPARTMENT

 Now I know about importance of IE department.
 Get idea about SMV breakdown, line balancing , botol neck.
 Know about lay planning
4.11 MERCHANDISING
 Operation of Merchandizing Process.
 Idea about all Merchandizing activities.
 Costing,TNA,Consumption of garments product

4.12 HR & COMPLIANCE
 Different Compliance Issues in garments.
 Idea about how to Maintain Complained Issues.
 How following Compliance issues in different section.
 Policy of worker requirement.

CHAPTER 5 :CONCLUSION :
I have completed my Industrial Training successfully by the grace of Allah. Industrial

Attachment sends me to the expected destiny of practical life. Envoy is a well known
reputed factory in the textile field of Bangladesh. The completion of the two months
industrial attachment at ENVOY FASHION LTD gave me the inspiration that factory is
one of the appropriate destiny to implement the theoretical knowledge. From this
industrial attachment I got the details idea about the factory environment, production
process, total management, etc.
ENVOY GROUP is well arrayed, and the working environment here is excellent. The
relation between top management to bottom level is also very nice. We are lucky to get the
opportunity of having training in this garment factory. The factory runs by a number of
efficient Textile Engineers, Skilled technical & Non- technical persons. All the Textile
Engineers, technical & Non-technical persons are very sincere, co-operative and helpful.
We wish good luck to them and also to this factory. It was really a productive practical
learning besides my four year academics, so I wish I will be able to implement my
learning and methodological knowledge successfully in the textile industry and the
betterment of the economy of our country.

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Daffodil International University Library

Digital Institutional Repository

Industrial attachment at Envoy fashions ltd

Rahman, Md. Zillur

ENVOY FASHIONS Ltd

Course Title: Industrial Attachment

Advance in Apparel Manufacturing Technology

Duration: From 10th January,2018 to 15th March, 2018

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Chapter-2 General information about the factory 2

Chapter-3 Description of the Attachment 12

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Chapter-4 Impact of Internship 81

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2.2HISTORY OF THE FACTORY:

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Group Chairman: Engr Mr. Kutubuddin Ahmed

Managing Director:Abdus Salam Mursedy

Executive Director:Sultan Md. Noorani, PPM

Chief Operating Officer: Mr. Kanishka Perera

2.4 GENERAL INFORMATION ABOUT THE FACTORY:

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Fig 2.1:Envoy Fashion layout plan

Jamgora, Yearpur, Ashulia

Savar Dhaka- 1341

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Fig2.2:Google map location of (Envoy Fashion ltd.)

 Factory Front view:

Fig 2.3: Front view

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Merchandising & (GM) Production

Cutting manager P.M Finishing

Cutting master supervisor

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1. Envoy Design Ltd.

2.8 PRODUCT MIX

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Factory Establishment Year : 2004

Annual Turnover : Confidential

BUSNESS REGISTRATION PAPERS :

2.10 Main Buyer: Major export Markets:USA=60%

Major Customer : For USA Market :

American Eagle, VF-Asia, Wal-Mart, Jordache, Haggar Clothing Co.

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Next UK, C & A, Carrefour, Zara, Asmara, Gartex etc.

For Others Market :

Yakka, King Gee, Li & Fung etc.

Percentage of Buyers Work

01) American Eagle = 30%

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