TABLE OF CONTENTS

1.0 Executive Summary..................................................................................................................

2.0 Information about Factory........................................................................................................
2.1 Introduction..........................................................................................................................
2.2 History of the factory............................................................................................................
Organogram of Tosrifa Industries Limited..................................................................................
2.3 Profile of Tosrifa Industries Limited......................................................................................
2.4 Mission.................................................................................................................................
2.5 Vision....................................................................................................................................
3.0 Description Of Attachment.....................................................................................................
3.1 Knitting:...............................................................................................................................
3.1.1 Organogram.................................................................................................................
3.1.2 Flow chart of Knitting:..................................................................................................
3.1.3 Types of yarn used for knitting:....................................................................................
3.1.4 Basically two type of Knitting:......................................................................................
3.1.5 Different parts of knitting machine:.............................................................................
3.1.6 Yarn count uses for knitting:........................................................................................
3.1.7 There are two types of stripe for knitting:...................................................................
3.1.8 GSM.............................................................................................................................
3.1.9 Different G.S.M for different yarn count in different fabrics:.......................................
3.1.10 List Of Circular Knitting Machineries:.....................................................................
3.1.11 Fabric faults found in knitting:...................................................................................
3.1.12 Some photos of knitting section:...............................................................................
3.2 Merchandising:...................................................................................................................
3.2.1 Flowchart of merchandising:........................................................................................
3.2.2 Merchandiser:..............................................................................................................
3.2.3 Most important things for a Merchandiser:.................................................................
3.2.4 Job Responsibilities of Merchandising.........................................................................
3.2.5 Fabric purchasing knowledge for Merchandiser:.........................................................
3.3 Sampling:............................................................................................................................
3.3.1 Flowchart of sampling process:....................................................................................
3.3.2 Sample procedure:.......................................................................................................
 3.3.3 Types of sample:..........................................................................................................
3.3.4 Sampling stages...........................................................................................................
3.3.5 Total Machine in sample section:................................................................................
3.4 CAD:....................................................................................................................................
3.4.1 Process flow chart of CAD department:.......................................................................
3.4.2 Explain of this process:.................................................................................................
3.4.3 Processing after approval:............................................................................................
3.5 Cutting:...............................................................................................................................
3.5.1 Flow Chart of cutting:...................................................................................................
3.5.2 Cutting room equipment:............................................................................................
3.5.3 Fabric Lay height standard:..........................................................................................
3.6 Printing:..............................................................................................................................
3.6.1 Flow chart of printing:..................................................................................................
3.6.2 Types of print :.............................................................................................................
3.6.3 Print name & capacity per hour:-.................................................................................
3.6.4 Printing faults:..............................................................................................................
3.6.5 Printing Machine’s:......................................................................................................
3.7 Embroidery:........................................................................................................................
3.7.1 Number of Machine’s:.................................................................................................
3.7.2 Embroidery thread brand & Measurement :...............................................................
3.7.3 Stitch types of Embroidery:..........................................................................................
3.7.4 Thread used in Embroidery section:............................................................................
3.7.5 Embroidery Faults:.......................................................................................................
3.8 Sewing:...............................................................................................................................
3.8.1 Flow chart of sewing department:...............................................................................
3.8.2 Different sewing M/C with their operation:.................................................................
3.8.3 Objective of using machine:.........................................................................................
3.8.4 Total sewing machine:.................................................................................................
3.8.5 Per hour production output & m/c needed:................................................................
3.9 Quality control....................................................................................................................
3.9.1 Quality control:............................................................................................................
3.9.2 Quality assurance:........................................................................................................
3.9.3 Purpose of quality control department:......................................................................
3.9.4 Quality control Flow chart of composite unit:.............................................................
 3.9.5 Four principles in Delta Group follow to maintain quality:..........................................
3.9.6 Quality Assurance System:...........................................................................................
3.9.7 Point calculation system:.............................................................................................
3.9.8 Defects found in the final inspection:..........................................................................
4.0 Impact of internship...............................................................................................................
4.1 Knitting................................................................................................................................
4.2 Merchandising....................................................................................................................
4.3 Sampling.............................................................................................................................
4.4 CAD.....................................................................................................................................
4.5 Cutting section....................................................................................................................
4.6 Printing...............................................................................................................................
4.7 Embroidery.........................................................................................................................
4.8 Sewing section....................................................................................................................
5.0 Conclusion..............................................................................................................................

1.0 Executive Summary

The 100 percent export- oriented readymade garments (RMG) industry has witnessed
remarkable growth since its inception in the late 1970s. By exporting only one item in
the early of export business from Bangladesh in the mid 1970s to the East European
countries, now it has been the most flourishing sector in Bangladesh. In this case, the
total achievement goes to the private entrepreneurs who opened the eyes of import
and export business in Bangladesh. From the study on Prospects of Garment industry
in Bangladesh we quote that export of RMG increased day by day. It also has
increased per capital income as well as standard value of living. From the study of
internship we know that the dynamic performance of the RMG industry has made the
country susceptible to the foreign customers who come to Bangladesh and source
their expected business.
I preferred this attachment in Northern Group which is a 100% export oriented
composite knit industry. For continuing the study of internship in the Northern Group
I almost worked all the sections of this composite company and tried to find out the
activities, planning and many other things as well. In context, I have discussed about
these things deliberately to let you know about.
 2.0 Information about Factory
2.1 Introduction
The industrial attachment training is an essential component of the curriculum of
Textile Engineering of Daffodil International University
The attachment period is usually a maximum of eight weeks, during which the
students are expected to acquire additional practical experience to supplement, their
course of study in the university. They are also exposed to the real world of work and
its challenges which will prepare them towards their future careers.
This report is the outcome of the eight weeks practical training I had at Northern
Group

2.2 History of the factory

Northern group is a group of companies; consist of knitting units, Dyeing & Fabric
Finishing units and several garment manufacturing units. These companies are 100%
export oriented, exporting the knit apparels all over the world, especially in the
Europe market. The group is enlisted with BGMEA, BTMA & EPB. They took the
privilege to disclose to every person about their new additions of some state-of-the-art
technology, which is equipped with sophisticated machinery in our fabric section in
order to provide more service to their honorable buyers. They appreciate your effort to
go through the following to get informed about such additions and new installations.
Organogram of Tosrifa Industries Limited
2.3 Profile of Tosrifa Industries Limited
At a Glance
Name of Company NORTHERN CORPORATION LTD
Address B43-45, BSCIC I/E TONGI, GAZIPUR
TEL.: 9810483, 9802367, FAX: 9800338
Corporate Office HOUSE-91 (4th FLR.), BLOCK-K,
SUHRAWARDY AVENUE, BARIDHARA,
DHAKA-1212, BANGLADESH
TEL.: 9882516-7, 9882607 FAX: 880-2-9882610
E-mail: [email protected]
Establish 1990
OWNERSHIP LIMITED COMPANY
BANKER EASTERN BANK LIMITED
MEMBERSHIP a) BANGLADESH GARMENTS
MANUFECTURER & EXPORTER
ASSOCIATION, REG. NO- 1469
b) EXPORT PROMOTION BUREAU OF
BANGLADESH
REG. NO.-1507
c) BANGLADESH TEXTILE MILLS
ASSOCIATION
REG. NO.-501
INTERNATIONAL ISO 9001:2000
CERTIFICATE OKO-TEX STANDARD 100, GERMANY
ANNUAL SALES U.S.$ 18.00 MILLION (APPX.)
PRODUCTION CAPACITY 9 Million GARMENTS PER YEAR
MARKETS 90% EUROPE, 10% OTHERS
CATEGORIES MENS, LADIES AND CHILDREN
PRODUCT KNIT T-SHIRT, POLO SHIRT, TANG TOP,
SPORTS WEAR etc.
Factory spaces 110,000 SFT.

NUMBER OF WORKER 1050 (Male/Female)

2.4 Mission
• We will always strive for best Quality.
• We give highest priority to our commitment.
• We will turn Human resources into best Assets
• We work for the society and Environment
• Every year we increase our efficiency by 10%.
•

2.1 Vision
We want to be the most preferred name to our customer, Employees, Suppliers and
Society.

3.0 Details of Attachment

3.1 Knitting:
Knitting is a pre-requisite of a garments factory. As a backward linkage it’s essential
before the bulk production. Knitting is one kind of manufacturing process in which
fabric is produced by interloping among loops formed by single or several yarns
feeding simultaneously. Knitting fabric produced with stitch formation.

3.1.1 Flow chart of Knitting:

Yarn collect by cone package from spinning

Setup yarn on creel

Yarn passage through different tensioned and positive feeder.

Adjust stitch length and GSM by VDQ pulley.

Inspection the fabric after making approximately ½ inch

If the fabric is ok then continuously run but not ok then find out the problem

And solved it.

 Cut the roll of fabric

Marking the roll

Inspection and grading according to quality control.

Transfer the fabric to grey store.

3.1.2 List of Circular Knitting Machineries:

Name Of Quantity Brand Origin Model Unit Total Remarks
Machine Price Price

01) Single 01 Set Mayer Germany

Jersey / & Cie
Pique

02) Single 01 Set Mayer Germany

Jersey / & Cie
Pique

03) Single 02 Sets Mayer Germany

Jersey / & Cie
Pique

04) Single 02 Sets Mayer Germany

Jersey / & Cie
Pique

05) Single 01 Set Mayer Germany

Jersey & Cie
(Lycra
Attachment)

06) Single 02 Sets Mayer Germany

Jersey & Cie
(Lycra
Attachment)

07) Rib 02 Sets Mayer Germany

(Lycra & Cie
Attachment)

08) Rib 02 Sets Mayer Germany

(Lycra & Cie
Attachment)

09) Inter 02 Sets Mayer Germany

Lock & Cie

10) Inter 01 Set Mayer Germany

Lock & Cie

11) 01 Set Mayer Germany

Rib/Inter & Cie
Lock
(Lycra
Attachment)

12) 05 Sets Mayer Germany

Rib/Inter & Cie
Lock
(Lycra
Attachment)

13) 03 Sets Mayer Germany

Rib/Inter & Cie
Lock
(Lycra
Attachment)
14) Single 01 Set Camber UK
Jersey /
Pique

15) Single 01 Set Camber UK

Jersey /
Pique

16) Single 02 Sets Camber UK

Jersey
/Pique

17) Single 02 Sets Camber UK

Jersey /
Pique

18) Single 06 Sets Camber UK

Jersey /
Pique

19) Single 10 Set Camber UK

Jersey /
Pique

20) Single 01 Set Camber UK

Jersey /
Pique

21) Single 05 Sets Camber UK

Jersey /
Pique

22) Single 01 Set Camber UK

Jersey
/Pique

23) Single 01 Set Camber UK

Jersey
/Pique

24) Single 01 Set Camber UK

 Jersey
/Pique

25) Single 01 Set Camber UK

Jersey /
Pique

3.2 Merchandising:
Merchandising is a business on marketing activities responsible for ensuring a
products description both quality and quantity. Merchandising means total
responsibility of a Merchandiser.

3.2.1 Flowchart of merchandising:

Buyer Developing

Sample/sketch and specifications with

details from buyer

Price quotation

Required of price quotation

Price accepted by buyer

L/C received

Approval sample sending to buyer

Counter/ Proto sample sending to the buyer

Approval of proto sample

Production start and sending production sample to buyer

Production running and sending salesman sample to buyer

Production finish and final inspection

Shipment of goods & shipment sample send

 Preparation of shipping documents

Submit document to bank

Payment received at bank

Payment received by factory

3.2.2 Merchandiser:
 A man who collect order from customer sourcing raw materials Production on
time with quality and maintains lead time.
 Garments merchandising means buying raw materials & accessories, producing
garments, maintaining required quality level and exporting the garments within
scheduled time

3.2.3 Most important things for a Merchandiser:

 Communication.
 Planning
 Production follow Up

3.2.4 Job Responsibilities of Merchandising

 Development & Costing
 Order Confirmation
 Sampling
 Bulk Fabric
 Bulk Trim
 Embellishment
 Filing & Corresponds
 Production & Planning
 Quality

3.2.5 Fabric purchasing knowledge for Merchandiser:

 Fabric composition.
 Fabric construction.
  Kinds of yarn.
 Width of fabric.
 Dyeing types.
 Color fastness.
 AQL- Acceptable Quality Level.
 Finishing type.
 Packing.
 Shipping.
 GSM/Weight.
 Tubular/opened width.

3.3 Sampling:
Sampling process is the most important department in a garments factory. Without
proper sample one can not achieve enough order. Sample is the prototype or model of
the garments, upon what the buyer can decide on how and whether to confirm the
order or not.

3.3.1 Flowchart of sampling process:

Receive Tech pack

CAD & pattern making as per style & measurement.

Sample making

Approval

Size setting ( on development stage)

Evaluation of the sample

Pre-production meeting

Grading of sample

Sending sample to the buyer

Approval

Grading of sample
 Marker making

Sending to the cutting section

Production starts.

3.3.3 Types of sample:

01. Proto sample
02. Size set / Fitting Sample
03. Seal Sample
04. PP sample
05. SMS sample

3.3.5 Total Machine in sample section:

Name of Quantity Brand Origin Model Unit Total Remarks
the Price Price
machine
1. Single 20
needle
lock
stitch
2. 4 12
Thread
over
lock
3. Flat 8
lock
4. Blind 1
lock
5. Chain 2
stitch
(Single
Needle)
6. Over 1
lock
open
 stitch
7. PMD 1
kansai
8. 1
Bartack
9. 1
Button
attach
10. 1
Button
whole
11. 1
Saddle
Stitch
12. 1
Thread
recone
13. Snap 1
Button
14. 1
Plane
Machine
Zigzag

3.4 CAD:
CAD means computer aided design. CAD department is used Lectra software which
is used for making pattern and marker for a particular garment in RMG Sector.
Basically the main objectives of CAD how to mitigate the fabric wastage and fabric
cost minimizes.

3.4.1 Process flow chart of CAD department:

Artwork + spread sheet from merchandiser
Marking pattern
 Computer Processing order art work

Marker making as per color art work

Manual working for neck rib, binding or back tape

Discuss with Knitting department

Marker Delivery

3.4.2 Explain of this process:

● Art work and spread Sheet received: This is the first stage of CAD process CAD
department Receives art work and spread sheet from merchandiser or DPD
department. It’s fully depends in individual factory.
● Making pattern: CAD department to making pattern as per spread sheet and art
work.
● Computer order processing model: Computer order processing model indicates
how many panels will be cut for a particular garments i.e., it’s maintained according
to cutting quantity.
● Marker making as per color art work: CAD operator marker made as per color
art work and panels quantity.
● Manual working for neck rib, binding or back tape: Basically these are made by
CAD on garments and must be cut manually.
● Discuss with knitting department: CAD department talked knitting department
about knitting dia.
● Marker delivery for approval: Marker will have to be delivered to the concerned
Merchandiser for approval.

3.5 Cutting:
Cutting department is very important for garments factory. Without cutting
department no garments can be made. In Garments trade cutting is a process that’s the
fabric is spreading, laying, Marking, cutting, Numbering, Bundling and
Embellishment of the fabric.

3.5.1 Flow Chart of cutting:

Received approval pattern

Received marker paper

Trial Cutting

Development

Spreading

Laying Fabric

Laying Marker paper

Attach Clamp

Cutting

Parts change

Numbering

Bundling

Embellishment

Check embellishments

Cutting output.

3.5.2 Cutting room equipment:

Name of Brand Model Origin Quantity Unit Total Remarks
the Price Price
equipment
1.Spreader 4
cutting
table
2.Rib 1
cutting
 table
3.Stripe 1
cutting
table
4.Manual 18
Cutter
5.GSM 1
Cutter
6.Stickering 4
table
7.Bundling 3
table
8.Scissoring 3
table
9.Manual 2
table

3.6 Printing:
Garment Printing offer printing and embroidery services nationwide including Screen
Printing, Embroidery, Transfer Printing, Direct To Garment Printing.

3.6.1 Flow chart of printing:

After getting work order from product Development Department.

Fabric design as per artwork

Exposed done

Screening

Sample preparation
 Approved sample

Bulk production

Screen preparation

Print paste preparation

Printing is done on the m/c or manually.

Drying

Curing

Final Inspection.

3.6.2 Types of print :

i) Water base
ii) Oil base
Water base
i) Pigment print
ii) Rubber print
iii) Discharge print
Oil base:
i) Plastic print
ii) High density print
Another print :
i)Crack print
ii)Glitter print
iii)Metallic print

3.6.5 Printing Machine’s:

 Name Of Brand Model Origin Quantit Unit Total Remarks
Machine y Price Price
1.Automatic 5
Printing
Machine
2.Manual 5
Printing
Machine

3.7 Embroidery:
To decorate of Fabric with needle Work is called embroidery. Its must do as per buyer
requirement.
Name Of Brand Model Origin Quantity Unit Total Remarks
Machine Price Price
1.Tajima
Embroidery
Machine

3.8 Sewing:
Sewing department is the soul of garments factory. The method of sewing in Delta
group follows the progressive bundling system. By the help of needle and thread
make the garments is sewing.

3.8.1 Flow chart of sewing department:

Input token

Input cutting parts

Accessories collect from store. Pre- production meeting

 Line layout

Inline inspection

Output

Send washing (if any)

Finishing

3.8.2 Different sewing M/C:

Name Of Brand Model Origin Quantity Unit Total Remarks
Machine Price Price
Single 970
needle lock
stitch
Flat lock 320
Over 380
lock(4thard)
Bach tape 8
m/c
Vertical 12
trimber
1 needle 9
chain stitch
2 needle 7
chain stitch
2 needle 5
lock stitch
Multi 6
needle
chain stitch
Button 17
 stitch
Button hole 20
Picoting 2
Snap button 8
Bartack 37
Zigzag m/c 4
lock stitch
Saddle 2
stitch

3.9 Quality control

We do mistake in production controlling - this mistake is quality control. When
control is properly implemented, there will be improvement .

3.9.2 Quality assurance:

Assurance means “Guaranty” & quality assurance means” Guaranty for quality” also
styling, material, conformity, measurement, workmanship etc. included with the
quality.

3.9.6 Quality Assurance System:

Quality assurance procedure may be divided into two major parts:
1. Online quality control
2. Offline quality control

3.9.4 Quality control Flow chart of composite unit:

Textile section:
Knitting QC

Dyeing& Finishing QC

All over print QC.

Garment Section:
Fabric inspection QC

Cutting section QC

Embroidery & screen print section QC

Sewing section QC

Washing section QC

Finishing QC.

3.9.5 Four principles in Delta Group follow to maintain

quality:

i) Fabric & Accessories Inspection.

ii) Cutting quality control.
iii) Sewing quality control.
iv) Finishing quality control.

4.0 Impact of internship

The completion of two months industrial attachment in Sinha Knitting Ltd. Gave me
inspiration that factory is one of the appropriate destiny to implement the theoretical
knowledge. This industrial training taught me lot about different textile technology,
on

4.1 Knitting
 I learnt about different types of knitting machine, their parts, function, use.
 About yarn, yarn count and their sources.
 Different types of fabrics and their GSM.
 About Cam, their types, function and arrangement.
 Needle, their function and arrangement.
 About fabric inspection, different types of faults.
4.2 Merchandising
 I have learned how to make Trim card.
 Get known to emailing procedure.
 Get known to different type of fabric and accessories.
 Gather knowledge on follow up process.
 Gather knowledge Buyer requirement and Inspection procedure.

4.3 Sampling
 I have learned about types of sample
 I have learned about Sampling stages
 I have learned about Flowchart of sampling process

4.4 CAD
 I have learned about Process flow chart of CAD department.
 I have learned about which software is used.
 I have learned about Processing after approval.

4.5 Cutting section

 Gather knowledge about fabric spreading and cutting.
 I have learned different types of cutting machine and their function.
 I have learned about numbering and bundling.

4.6 Printing
 I have learned different type of printing
 I have learned different type of printing machine.
 I have learned different types of printing process.
 I have learned different type of printing fault.

4.7 Embroidery
 I have learned different type of embroidery.
 I have learned different type of embroidery machine.
 I have learned different type of embroidery fault.

4.8 Sewing section

 In sewing section, about different types of sewing machine, their function and
use.
 I have learned different types of stitch.
 I have learned different types of sewing faults.
 I have learned sequences of different items such as T-shirt, polo shirt, laggings
etc.
 5.0 Conclusion
The administrative, management, chain of command all are well organized. They are
well equipped with all of the modern machineries and the working environment is
excellent. All the department like cutting, sewing, printing, finishing is well
organized. The relation between top management to bottom level is so nice & devoted
to satisfy the customer demand by their activities.
The factory runs by a number of efficient textile engineers, skilled technical & non-
technical persons. They are very sincere, co-operative and helpful.