Srabonti Ghosh (181-226-801) Intern Report (AVL)

BGMEA University of Fashion& Technology
(BUFT)
Faculty of Textile Engineering
REPORT ON
INDUSTRIAL ATTACHMENT
AT
“APPARELS VILLAGE LIMITED”
(15th Nov 2021 to 26th Jan 2022)
37, Khagan, Birulia, Savar, Dhaka.
Prepared By:
Srabonti Ghosh
Batch: 181, TE-06
ID:181-226-801
Program: B.Sc. in Textile Engineering
Supervising Faculty:
Farhana Afroz
Assistant Professor &Acting Head
Department of Textile Engineering
BGMEA University of Fashion & Technology
This Internship Report Submitted in Partial Fulfillment of the requirements for

the Degree of B.Sc. in Textile Engineering in the Faculty of Textile Engineering of
BGMEA University of Fashion and Technology (BUFT).
i
BGMEA University of Fashion& Technology

(BUFT)
Faculty of Textile Engineering
REPORT ON
INDUSTRIAL ATTACHMENT
At
“Apparels Village Ltd”
37, Khagan, Birulia, Savar, Dhaka.
Prepared By:
Srabonti Ghosh
Batch: 181, TE-06
ID:181-226-801
Program: B.Sc. in Textile Engineering
Project Supervisor:
Farhana Afroz
Assistant Professor &Acting Head
Department of Textile Engineering
Exam Committee:
Supervisor: FARHANA AFROZ Signature:
Examiner 1 : Signature:
Examiner 2: Signature:
Date:
ii
EXECUTIVE SUMMARY
Materials and dress will consistently be fundamental merchandise for individuals. Turning and
weaving were the fundamental exercises that drove the Industrial Revolution in the eighteenth
century. From that point forward the material business has been a main industry in the
underlying period of industrialization in numerous nations in various timeframes on the planet.
Bangladesh is a significant maker and exporter of sew RMG items. There are around 4500
articles of clothing manufacturing plants running in Bangladesh. Development of pieces of
clothing production lines began in Bangladesh around 1980. Be that as it may, presently almost
80% of our outside money is pieces of clothing. Articles of clothing are sent out to the USA,
Canada, Japan, Australia, Middle East and numerous different nations on the planet. Least
expensive work cost is the greatest favorable position for Bangladeshi articles of clothing
makers and exporters.
Temporary job has given me this chance. Since I have learned hypothetical information most
recent three years yet because of the absence of appropriate mechanical information on my
course, I would not have been called a total specialist. Mechanical connection worked for us. I
have partaken in this modern connection in Apparels Village Ltd. Attire Village Ltd. is one of
the prestigious 100% fair situated industries in Bangladesh. The manufacturing plant is
concerned with the creation of weaving, sew coloring and completing and sew pieces of
clothing. Because of the adjustment in the current situation, the material division is confronting
an extraordinary test here. Attire Village Ltd is totally arranged to confront this circumstance.
The objective of Apparels Village Ltd. is to turn into the favored accomplice for sourcing great
textures and attire from Bangladesh. Attire Village Ltd. has exceptionally created development
innovation and an accentuation on creating neighborhood HR. The Textile Division can
possibly make a significant commitment to the country's developing RMG trade segment.
The national behind the current structure and future development of the Textile and fiber
Division is to catch esteem included at each phase of the material assembling process.
Regardless of Bangladesh is absence of indigenous cotton generation ability, it is getting a
charge out of lower work cost favorable position and fare intensity to the greatest. This
processing plant is completely whined and especially worries about the work law and
compliances. This industrial facility is likewise worried about ecological issues as they have
settled the Effluent Treatment Plant (ETP). In Apparels Village Ltd, I have finished 2 months
in length modern preparing in weaving and articles of clothing area. During the preparation
time frame we confronted a great deal of specialized issues, which I have understood by
counseling with the related people. Whatever the information I have gain during my preparation
period, it will assist us with building up our profession as a Textile Technologist
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DECLARATION OF THE INDUSTRIAL TRAINING
Here with I that I have done industrial internship in APPARELS VILLAGE LTD, which is
supervised by, FARHANA AFROZ, Assistant professor and Acting Head, Department of
Textile Engineering, from 15th Nov 2021 to 26th Jan 2022.
Name: Srabonti Ghosh

ID: 181-226-801
Signature:
iv
ACKNOWLEDGEMENTS
I would like to extend thanks to Honorable Founder Chairman, Board of Trustees Mr.
Muzaffar U. Siddique, BUFT, for not only for his tremendous academic support, but also
forgiving me so many wonderful opportunities and logistic supports to do this project.
Special thank goes to my enthusiastic Prof Dr S.M. Mahfuzur Rahman and Prof. Dr. Engr.
Ayub Nabi Khan, Pro Vice Chancellor , (BUFT) who so generously inspired & contributed
to do this type of project work.
Special thanks go to my enthusiastic supervisor , FARHANA AFROZ, assistant professor

And acting head of the textile engineering department has been an amazing experience and I
thank her wholeheartedly, not only for her tremendous academic support, but also for giving
me so many wonderful opportunities.
Finally, thanks go to some technical persons and Lab-Men for almost unbelievable support.
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LETTER OF TRANSMITTAL
March’22
Farhana Afroz
Lecturer,
BGMEA University of Fashion & Technology
Nishatnagar, Turag, Dhaka-1230, Bangladesh.
Subject: Internship report on (APPARELS VILLAGE LIMITED)
Dear Mam,
With great pleasure, here I submit my internship report that fulfills partial requirements for
B.Sc. in Textile Engineering. It is very significant for a student and information to undergo a
practical field of study.
I completed my internship report on (Apparels Village Limited). In this report I have tried to
accommodate your valuable comments and suggestions. I tried my level best to gather practical
and theoretical knowledge. I went to the factory 8 weeks. Every day I tried to visit a specific
section and then I shared my knowledge with my factories supervisor after complete that
section. In this concern if you need any further clarification, please email/call.
Now, I would like to share my knowledge with you and want to learn more from you. It will
be great pleasure for me if you share your vast knowledge with me.
Regards,
Srabonti Ghosh
Batch: 181, TE-06
ID:181-226-801
Department of Textile Engineering.
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TABLE OF CONTENT
EXECUTIVE SUMMARY .................................................................................................ii
DECLARATION OF THE INDUSTRIAL TRAINING ....................................................iii
ACKNOWLEDGEMENTS ................................................................................................ iv
LETTER OF TRANSMITTAL ............................................................................................ v
CHAPTER: 01 PROJECT DESCRIPTION .............................................................1-2
1.1 Introduction: ............................................................................................................ 1
1.2 Objectives…………………………………………………………………………1
1.3 Scope of study…………………………………………………………………….2
CHAPTER: 02 FACTORY PROFILE…………………………………………….3-9
2.1 Company Name:………………………………………………………………….3
2.2 Introduction:……………………………………………………………………3-4
2.3 History of the factory: ............................................................................................. 4
2.3.1 Faiyaz Group………………………………………………………...……...4
2.3.2 AVL & The Faiyaz…………………………………………………..……...4
2.4Factory Profile ………………………………………………………………….…5
2.5 Google Location of Apparel Village Ltd: ............................................................... 6
2.6 Department of the factory ....................................................................................... 6
2.7 Major production: ................................................. Error! Bookmark not defined.
2.8 Number of Machine in AVL: .................................................................................. 7
2.9 Major Logo of byer: ................................................................................................ 7
2.10 Certifications & Achievements: ............................................................................ 8
2.11 Company focus: .................................................................................................... 8
2.12 Company objectives: ........................................... Error! Bookmark not defined.
2.13 Company code of conduct: ................................................................................... 8
2.14 Mission and vision: ............................................................................................... 9
CHAPTER: 03 MANPOWER MANAGEMENT ..................................................9-15
3.1 Manpower organogram: ........................................ Error! Bookmark not defined.
3.2 Supporting Deparment: ......................................... Error! Bookmark not defined.
3.3 Management Information System(MIS)………………………………………...11
3.3.1 Shiftng……………………………………………………………………..11
3.3.2 Order Flow Sequence……………………………………………………..12
3.4 Duties & Responsibility of Different Post………………………………………13
3.4.1 Chief Executive officer…………………………………………...………13
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3.4.2 Genaral manager………………………………………………………….13

3.4.3 Senior production officer…………………………………………………13
3.4,4 Production officer…………………………………………………………14
3.4.5 Shift in charge…………………………………………………………….14
3.5 Employment practices…………………………………………………………...15
3.6 Law Practice………….………………………………………………………….15
CHAPTER: 04 KNITTING SECTION .................................................................16-39
4.1 Knitting section: .................................................................................................... 16
4.2 Machines Use for Knitting: ................................................................................... 16
4.3 Process Requirements: .......................................................................................... 17
4.4 Knitting Layout: .................................................................................................... 18
4.5 Flowchart……………………………………………………………………...…19
4.5.1 Flow Chart of Knitting Process……………………………………………19
4.5.2 Flow chart of knitting Procedure…………………………………………..20
4.6 Knitting machines list: ..................................... Error! Bookmark not defined.-24
4.7 Flat bed Knitting Machine: ................................................................................... 25
4.7.1 Knittig Machine parts………………………………………………….25-26
4.8 Classification of knitting: .................................................................................... 266
4.9 Used yarn: ........................................................................................................... 266
4.10 Yarn count uses for knitting……………………………………………………26
4.11 Different fabric and GSM and Yarn count: ........................................................ 27
4.11.1 Single jersey……………………………………………………………...27
4.11.2 Pique……………………………………………………………………..27
4.11.3 1*1 Rib…………………………………………………………………..27
4.11.4 Interlock…………………………………………………………………28
4.12 GSM…………………………………………………………………………...28
4.13 Samples from knitting section…………………………………………………29
4.14Fabric Faults:…………………………………………………………………..30
4.14.1 Hole:……………………………………………………………………..33
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4.14.2 Slub……………………………………………………………………...31
4.14.3 Loop……………………………………………………………………...31
4.14.4 Oil spot…………………………………………………………………...32
4.14.5 Oil line……………………………………………………………………33
4.14.6 Press off…………………………………………………………………..33
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4.14.7 Broken Needle……………………………………………………………34

4.14.8 Needle line:………………………………………………………………34
4.14.9 Lycra out………………………………………………………………….35
4.15 Calculation: ......................................................................................................... 35
4.15.1Production………………………………………………………………...35
4.15.2 Efficiency………………………………………………………………...35
4.15.3 Acceptable Calculation……………………………………………….35-36
4.16 Quality Management:.......................................................................................... 36
4.17 Fabric inspection machine: ................................................................................. 36
4.18 Quality control process: .................................................................................37-39
CHAPTER: 05 BATCHING SECTION................................................................39-43
5.1 Batching: ............................................................................................................... 40
5.2 Batch Card: ........................................................................................................... 40
5.3 Batch Process Flow Chart: .................................................................................... 41
5.4 Batch preparation: ................................................................................................. 41
5.5 Calculation for Reel speed: ................................................................................... 41
5.6 Batch Card: ........................................................................................................... 42
5.7 Aims / Purpose of Batch Section: ......................................................................... 43
CHAPTER: 06 DYEING SECTION .....................................................................44-58
6.1 Introduction: .......................................................... Error! Bookmark not defined.
6.2Dyeing lab: ............................................................................................................. 46
6.3 Objectives: ............................................................................................................ 44
6.4 Process in dyeing lab: ........................................................................................... 44
6.5 Dyeing m/c and chemical in lab: ........................................................................ 452
6.6 Elements of A dyeing Machine………………………………………………….46
6.7Layout in dyeing section in AVL………………………………………………...46
6.8 Picture of Dyeing floor Dyeing machine………………………………………..47
6.9 Flowchart...…………………………………………………………………..48-51
6.9.1 Flowchat for dyeing………………………………………………………..48
6.9.2Knit fabric Dyeing process(cotton)………………………………………...49
6.9.3 Process flowchart for pretreatment………………………………………...50
6.9.4 Process flowchart for after-treatment……………………………………...51
6.9.5 Process Flowchart of final Inspection……………………………………..51
6.10 Raw material for Dyeing:.................................................................................... 52
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6.11Recipe of Different stage in Dyeing: ................................................................... 52

6.11.1Recipe for machine's heavy wash…………………………………………52
6.11.2 Recipe for scouring………………………………………………………52
6.11.3 Recipe for enzyme……………………………………………………….53
6.11.4 Bleaching…………………………………………………………………53
6.11.5 The fiber which can dyed by reactive dye………………………………..54
6.12Dyed fabric finishing: .......................................................................................... 54
6.12.1 Mechanical Finished……………………………………………………..54
6.12.2 Name of machanical finished………………………………………….…54
6.13 Finishing Machines: .......................................................................................55-56
6.13.1 Turning M/C…………………………………………………………….55
6.13.2Squeezen M/C……………………………………………………………55
6.13.3 Compactor Machine……………………………………………………..56
6.14 Common Dyeing Faults with Their Remedies: .............................................56-58
6.14.1 Uneven dyeing…………………………………………………………..56
6.14.2 Batch to batch shade variation…………………………………………..57
6.14.3 Patta Dyeing effect………………………………………………………57
6.14.4 Roll to roll variation……………………………………………………..57
6.14.5Crease Mark cause………………………………………………………58
6.14.6 Dye spot…………………………………………………………………58
6.14.7 Softner mark……………………………………………………………..58
CHAPTER: 07 SAMPLE SECTION.....................................................................59-61
7.1 Sample Section: .................................................................................................... 59
7.2 Flow Chart: ........................................................................................................... 59
7.3 Types of sample: ................................................................................................... 60
7.3.1 Proto sample………………………………………………………………60
7.3.2 Size set / Flitting sample………………………………………………….60
7.3.3 Seal sample………………………………………………………………..60
7.3.4 PP sample…………………………………………………………………60
7.3.5 Sales man sample…………………………………………………………60
7.4 Types of Machine are used in Sample department: .............................................. 60
7.5 Sample production Capacity: ................................................................................ 61
CHAPTER: 08 PATTERN SECTION ..................................................................62-63
8.1 Pattern section: ...................................................................................................... 62
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8.2 Pattern types: ......................................................................................................... 62

8.2.1 Working pattern…………………………………………………………...62
8.2.2 Production pattern………………………………………………………...62
8.3 Pattern Making Flow Chart:.................................................................................. 63
8.4 Pattern Making Method: ....................................................................................... 63
CHAPTER: 9 CUTTING SECTION.....................................................................64-70
9.1 Cutting Section: .................................................................................................... 64
9.2 Process Flow Chart of Fabric Cutting Department: .............................................. 64
9.3 Equipment of Cutting Section:.........................................................................65-66
9.4 Fabric Lay height standard: ................................................................................ 667
9.5 Description of Cutting Machine: .......................................................................... 68
9.6 Cutting Plan Preparation: ...................................................................................... 69
9.7 Cutting Inspection: ................................................................................................ 69
9.8 Cutting faults:........................................................................................................ 70
CHAPTER: 10 SEWING SECTION .....................................................................71-79
10.1 Sewing Floor: ...................................................................................................... 71
10.2 Sewing………………………………………………………………………….71
10.3 Flow Chart of Sewing Department: ...............................................................71-72
10.4 Output: ................................................................................................................ 72
10.5 The Different Machines: ................................................................................73-76
10.6 Machine specification of sewing section AVL: .................................................. 77
10.7 Lay out of sewing section in AVL……………………………………………..77
10.8 Various types of faults and their figure: ........................................................78-79
CHAPTER: 11 STORE DEPARTMENT .............................................................80-81
11.1 Store Department: ............................................................................................... 80
11.2 Working Flow Chart of Store Department in Garment Industry: ....................... 80
12.3 Item Stored in the Store Department: ................................................................. 81
CHAPTER: 12 FINISHING SECTION ................................................................82-85
12.1 Finishing Section: ............................................................................................... 82
13.2 Process Flow Chart of Garments Finishing: ..................................................82-83
12.3 Garment Inspection: ............................................................................................ 84
12.4AQL:……………………………………………….……………………………85
12.5 If AQL is failed then the following problems are introduced………………….85
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CHAPTER: 13 MERCHANDISING SECTION ..................................................86-95

13.1 Merchandising: ................................................................................................... 86
13.2Merchandiser:…………………………………………………………………...86
13.3 Organogram of Merchandising Department: ...................................................... 87
13.4 Job Responsibilities of Merchandising in Apparels Village Ltd…………...87-89
13.5 Garment Costing:…………………………………………………………...889-
91
13.6 Consumption Preparation:…………………………………………………..92-94
13.7 Fabric Booking: .................................................................................................. 94
13.8 Trim Booking: ..................................................................................................... 95
CHAPTER: 14 COMPLIANCE...........................................................................96-102
14.1 Compliance: ........................................................................................................ 96
14.2 Compliance of Apparels Village Ltd. ..........................................................97-100
14.3 Effluent Treatment Plant (ETP): ................................................................100-102
CHAPTER: 15 IMPACT ON INTERNSHIP ...................................................103-104
15.1 Definition: ......................................................................................................... 103
15.2 Benefits of an Internship: .................................................................................. 103
15.3 Leadership and Skill Development: .................................................................. 103
15.4 Networking and Establishing Mentors and References: ................................... 104
15.5 Resume Enhancements: .................................................................................... 104
CHAPTER: 17 CONCLUSION ................................................................................ 105
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CHAPTER: 01
PROJECT DESCRIPTION
1.1 Introduction:
Internship is the mandatory for all Textile students to fulfill his Bachelor Degree because it
gives 1st hand experience of the complexities of practical life. As a result, it benefits the
students to relate our acquired knowledge with practical job life. The prime objective of the
internship program is to work under organizational environment so that, we can turn up
ourselves as professionals with practical experience and can get an opportunity to reconcile
the theoretical knowledge with real life situation. The technical education & practical
experience is the most important as well as the theoretical knowledge.
The main object of this project is to acquire knowledge about weaving & present condition
of weaving market in Bangladesh. It also enables us to orient ourselves with the partial
environment that wills works in future we systematically learned about various steps of
fabric process & market Apparels Village Ltd(Faiyaz Group). Is a truly integrated
undertaking. The textile division has the capability to offer a complete product range for the
Export & domestic textile market. The goal of textile division is to become the preferred
partner for high quality clothing from Bangladesh with high advance technology & an
emphasis on developing local human resource. Textile division has a potential to make and
important contribution to the nation’s growing readymade garments Export sector.
1.2Objectives of the study:
The study attempted to explore and examine the present market situation of Textile and the
Marketing Implications in Garments Industry specially the objective of the study as follows:
1.To know the present scenario of the market of Apparels Village Ltd.
2.To identify the marketing objectives of Apparels Village Ltd.
3.To analyze the marketing mix strategies of Apparels Village Ltd.
4.To learn about the product manufacturing policies of Apparels Village Ltd.
5.To know the quality control system of Apparels Village Ltd.
6.To know the market controlling policies of Apparels Village Ltd.
7.To find out the operational procedure of Apparels Village Ltd.
8.To learn about the different challenging segments of Apparels Village Ltd.
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1.3 Scope of the Study:
During our internee duration in Apparels Village Ltd. We have got chances to visit all the
area of the factory.
Supervise a whole production process in garments and different sections. Somewhere these
processes are very similar to our theoretical part but somewhere these are demonstrating
slightly different from the theoretical part that mean it may be more practical. From the
industries, we research so many matters & acquired so many experiences. We will try to
elaborate our experiences in our career & the production of a garments factory. In this report
we will try to describe our experience which we achieved during the internship period and
the production of a garments industry.
3
CHAPTER: 02
FACTORY PROFILE
2.1 Company Name:

Apparels Village Ltd(Faiyaz Group)
Figure ure 2.1: Factory View from main gate
2.2 Introduction:
Bangladesh, a country of 170 million people. Once she was the proud producer of world famous
muslin fabric. Bangladesh was the best in producing muslin. Our muslin was world famous form
the beginning of the 17th century, however history fades away like many other things we lost
our capability of muslin production. Then came jute the golden fiber, contributed a lot to our
economy. Form the late 70s Bangladesh started producing and exporting ready-made garments
to Europe. RMG, the large scale production of readymade garments is a relatively new
phenomenon in Bangladesh. The hundred percent export-oriented RMG industry experienced
phenomenal growth over the years. In 1978, there were only 9 export- oriented garment
manufacturing units, which generated export earnings of hardly one million dollars. Some of
these units were very small and produced garments for both domestic and export markets. Within
a short period, Bangladeshi entrepreneurs acquired the expertise of mobilizing resources to
export oriented RMG industries. 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 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
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number of garment factories increased to 587. The number of RMG factories shot up to 5440 in
2012-2013. The industry has grown at the rate of 59% comparing from 1998- 1999 to 2012-
2013. In 2012-2013, the export earning of the RMG sector was $20 billion with growth than the
previous year.
In July-December period of the current fiscal year, export earnings from the readymade garment
sector went up by 15.65% to US$17.08 billion, which was US$14.77 billion in the same period
last year, according to Export Promotion Bureau (EPB) data released today.
2.3 History Of the Factory:
2.3.1 Faiyaz Group

Faiyaz Group has begun its journey as “Faiyaz Apparels” in the year 1991 as a vendor/sourcing
agent in Bangladesh. Since its inception, the organization being run by highly qualified,
experienced, professional management and Staff accelerated by latest machinery/technology,
skilled workmanship with substantial marketing. The proficient management of the company
was able to gain the confidence and won the respect of the customers in terms of quality
assurance and on time delivery. Thus one customer introduce us many other customer.
2.3.2 AVL & The Faiyaz

“Apparels Village Limited” and “The Faiyaz” are our two production facilities being run under
the Banner of “Faiyaz Group” and are “WRAP” certified factory, producing best quality
products.
Textiles and Clothing are the leading industry of Bangladesh. These sectors are earning country’s
major portion of foreign exchange and creating huge job opportunities every year since 1980.
Keeping this prospect in mind, Apparels Village Ltd(AVL). was established in 2001 in a small
scale. With the passage of time, it has been expanded in a large scale with good facilities of
Knitting, Dyeing- finishing and Sewing.
Now, the total land area is 2,48,503 Sq. feet & total covered area 2,78,535 Sq. feet.
Our factory is located at the outskirt of Dhaka city. The location is 37 Khagan, Birulia Bazar,
Savar, Dhaka-1341.
The main instruments of our success are the team work, skilled personnel and professionalism.
The factory is designed to meet all compliances & human right requirements.
5
2.4Factory Profile:
Table 1.1: Company Profile of Apparels Village Ltd
Company name Apparels Village Ltd.

Head Office Level-5, Plot-7/1, Block A,Aurongozeb Road,
Mohammadpur,
Dhaka-1207, Bangladesh.
Factory 37 Khagan, Birulia,
Savar, Dhaka-1340
Bangladesh.
Factory Contact Details: Administrative.
Apparels Village Limited. A.K.M Azizul Islam.
General Manager (Admin).E-mail: admin@faiyaz-
group.com
Work expedition Knitting,Dyeing,Finishing,Garments(Woven,knitting)
Business Type
Knitting: 105
Tons/month Dyeing :
Production Capacity 195 Tons/month
Garments: 8lakh Pcs/month (Knitting) +4
lakh Pcs/month(Woven)
No. of Employees 480
No. of Workers 4600
Table 1.1: Company Profile of Apparels Village Ltd

6
2.5 Google Location of Apparels Village Ltd.
Figure ure 2.2:Location of Apparels Village Ltd Factory
2.6 Department of the factory

• Inventor
• HR compliance
• Marketing department
• Store
• Product Development
• Knitting
• Dyeing
• Cutting
• Sampling
• Printing
• Sewing
• Merchandising
• Finishing
2.7 Main production
• T-shirt
• Polo Shirt
• Tank tops
• Shirt
• Baby suits
• Pant
7
• Trousers
2.8 Number of Machine in this factory

Knitting m/c: 19
Dyeing m/c: A.Dyeing lab 4 m/c
B.Dyeing flour: 14
C.Finishing : 6m/c
Printing : 7m/c
Garments : A. Knitted Garments:819
B. Woven Garments:781
Fushing m/c: 7m/c
2.9 Major Logo of buyer:
Figure :2.3 (a)woven buyer’s & (b)Knit buyer’s

8
2.10 Certifications & Achievements
Figure :2.4 Certification & Satisfied client
2.11 Company Focus:

We Focus on production of top quality garments in fully compliant environment meeting timely
delivery.
2.12 Company Objectives:

Conforms and surpasses the customer expectation, improve productivity, minimize rejection
rate, development of employees to meet future challenges and continual improvement.
2.13 Company Code of Conduct:

➢ Legal Requirements:
As reputed company Apparels Village Ltd. has been maintaining all legal and statutory
requirements of the country.
➢ Employment:
Company is maintaining wages, hours of work, overtime and other related requirements as per
prevailing law of the country.
➢ Wages, Pay Slips, Attendance:
Company is maintaining worker’s attendance, wages, pay slips, leave records etc. electronically
through computer software and swift cards.
➢ Child labor:
Child labor is strictly prohibited in the factory and below 18 years no worker is allowed for any
employment. Birth Certificate, Doctor’s Age determination documents and physical appearances
are verified before offering any employment to any worker.
➢ Forced Labor:
Forced labor is strictly prohibited in the factory and there is no prisoner, bonded labor or any
kind of forced labor.
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➢ Non-Discrimination:
It is Apparels Villages Ltd.’s policy to ensure affirmative action in providing equal opportunities
without regard to race, religion, creed, color, sex, age or national origin except where age or sex
is a bona fide occupational qualification. Further it is prohibited to conduct any kind of maternity
test before selection of any female worker for employment.
➢ Security Concern:
Company is very much concern about Access Controls, Physical Security, Procedural Security,
Personnel Security and Education & Awareness Training on all security concerns. Further all
measures are in place to prevent any kind of un-authorized or un-identified access to the factory
premises.
➢ Right of Association:
Workers are allowed to form Lawful Association.
➢ Harassment & Abuse:
It is the company’s strict policy to make sure no harassment or abuse inside the factory premises
and whoever gets involve or encourage such activities will be dealt immediately based on
company policy for disciplinary actions. Further management of the company has very positive
attitude towards workers’ grievances and takes all grievances very seriously.
2.14 Mission and Vision:
At our all members we strive to maintain our position as global leaders in the field of high
quality apparel.
We are devoted for the consistent improvement in the system of the customers through on time
delivery & enhancing customers’ satisfaction by means of superiority. The company is
committed to being a safe and healthy work place that provides its employees with the
opportunity to grow and develop. Attain market leadership with top notch and unique product
quality through honest. The company is committed to continue to grow. And environmental
responsibilities and stewardship through out the process.
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CHAPTER: 03
MANPOWER MANAGEMENT
3.1 Manpower Organogram:

Managing Director
Chief Operation Officer Director
Manager Senior manager GM-Pdn DGM- Com. Quality Head

Admin\HR
Knit Dyeing Factory work study Quality

manager Manager Manager Manager Manager
.
Knit officer Production Cutting Finishing QA

Manager Manager Manager
Knit Floor in Cutting Finishing Quality

Operator Charge Incharge Supervisor Inspector
Supervisor and line Cutting poly. iron, packer,

Incharge supervisor finishing asst
Operator Cutter maker

Helper man
Figure ure 3.1: Manpower Organogram of Apparels Village Ltd

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3.2 Supporting Department:

a. Personnel Administration
b. HRD
c. Marketing
d. Procurement
e. Finance and accounting
f. Security department
3.3 Management Information System (MIS):

The company has skilled administration, management and marketing team guided by proficient,
dexterous & experienced leaders of offer right solution for the consumers with the right eminence
& with the shortest lead-time for the export market in Bangladesh. The best use of continuous
development of human resources by providing them International standard equal opportunity is
the keys for achieving comprehensive competence in all level of the organizational hierarchy.
3.3.1 Shifting:
There are three shifts in the industry. So, the shifts are changed at every 8 hours. Shift Change/
for worker of Security:
General shift 09:00 am– 05:00 pm

A Shift 06:00 am – 02:00 pm
B Shift 02:00 pm – 10:00 pm
C Shift 10:00 pm – 06:00 am
12
3.3.2 Order Flow Sequence:
G.M
A.G.M
D.M
D.A.M
Sr. P.O
P.O
Supervisor
Operator
Helper
Flow Chart 3.1: Oder Flow Sequence of Apparels Village Ltd.

13
3.4 Duties & Responsibility of Different Post:
3.4.1 Chef Executive officer (CEO)

• To deal with the buyer and merchandiser.
• To set up price for the product.
• To plan apply and control all administrative functions.
• To follow up the instruction of managing director and chairman.
3.4.2 General manager (GM)

• To supervise the personal working under him
• To plan the sequence of production
• To arrange necessary raw materials for the production problems.
• To find out the possible reasons which are responsible for less production
• To follow up the instruction of CEO as well.
3.4.3 Senior Production Officer

• Overall supervision of dyeing and finishing section.
• Batch preparation and pH check.
• Dyes and chemicals requisition issue and check
• Write loading/unloading time from machine.
• Program making, sample checking color measurement.
• Control the supervisor, operator, asst. operator and helper of dyeing machine.
• Any other work as and when required.

14
3.4.4 Production Officer

• To collect the necessary information and infrastructure from the previous shift for the
smooth running of the section.
• To match production sample with target shade.
• To match production sample lot sample matching next production.
• To observed dyed fabric during finishing running and also after finishing process.
• To identify disputed fabrics and report to PM/Gm for necessary action.
• To discuss with PM about overall production if necessary.
• To sign the store requisition and delivery challenge in the absence of PM
• To execute the overall floor work.
• To maintain loading/unloading paper.
3.4.5 Shift in Charge

• To follow the worker’s movement.
• Should discuss with the production Officer about what is happening.
• To maintain the production sequence.
• To check the sample at certain time interval.

15
3.5 Employment Practices:

Minimum Age 18 Years
Minimum Wage 8000 BDT (Including House Rent, Food

Allowance, Transport Allowance & Medical
Allowance)
House Rent Basic * 50%
Bonus (Festival) 2 time per year (50% of Gross Wages)
Leave Practice as per local law Instruction .
Overtime Calculation (Basic /208)X 2
Monthly Working Hour 208 (If working Days26)
Normal Daily Working Hours 8(After 8 hours it will be treated as a OT)
Maximum weekly OT Hours 12
Job Agreement Employment letter , Hand book & Service

book, ID Card
Holyday Weekly holiday & Festival holiday Total 67

days in a year
Canteen Facility Yes
Lunch time Noon 1.00 PM to 2.00 PM
Table 3.2: Employment Practices of Apparels Village Ltd.
3.6 Law Practice:

❖ Local & National Labor code
❖ ILO convention
❖ Buyer Code of Conduct
16
CHAPTER: 04
KNITTING SECTION
4.1 Knitting section:

Knitting is the method of creating fabric by transforming continuous stands of yarn into a series
of interlocking loops, each raw of such loops hanging from the one immediately preceding it.
Inter-looping consists of forming yarns into loops, each of which is typically only released after
a succeeding loop has been formed and intermeshed with it, so that a secure ground loop structure
is achieved. The loops are also held together by the yarn passing from one of the next.
4.2 Machines Use for Knitting:

• Single Jersey
• Rib / Interlock
• Auto Stripes
• Flat Knit
• Fabrics Inspection
Single Jersey:
It requires only one set of needles. The loops are intermeshed in only one direction so the
appearance of the face and back of the fabric are different
Ex: Plain single jersey, Pique, Birds Eye Pique, Single & Double Lacoste, Popcorn,
Popcorn Lacoste, Fleece, Terry, Heavy Jersey, Herringbone terry, Diagonal Terry,
Double Face, Design Jersey, Y/D Single Jersey, Slub Single Jersey etc.
Rib
It also called 'Double-knit’. Rib requires two sets of needles operating in between each other so
that wales of face stitches and wales of back stitches are knitted on each side of the fabric. Rib
fabrics are knitted on machines with two sets of needles.
Ex: (1x1) Rib, (2x2) Rib, (2x1) Rib, (3x1) Rib, (3x2) Rib, (3x3) Rib, (4x1) Rib, (4x2)
Rib, (4x3) Rib, (4x4) Rib, (8x3) Rib, Flat back Rib, Mini waffle, waffle, Ottoman Rib,
Twill Jersey, Bonded, Double face jersey etc.
17
4.2.3 Interlock
Fabric is produced by using both long and short needles. It has a smooth surface on both
sides.
Ex: Plain Interlock.
4.3 Process Requirements:

In Apparels Village Ltd. three types of machines are used for producing and inspecting
knitted fabrics.
These are:
1) Circular knitting machine (Single& Double Jersey Machine).

2) Flat knitting Machine (Cuff & Collar).
3) Fabric inspection machine
And the whole knitting section is divided in four sections,
1. Circular knitting section

2. Flatbed knitting section
3. Fabric inspection section
4. Store section
Figure ure:4.1 Circular Knitting machine (Auto Stripe)

18
4.4 Knitting layout :
2 3
This Photo by
1
13 11 7
6 16
15 13
10
12 5
9
12 8 4
14
Figure ure:4.2 Knitting Machine Layout of Apparels Village Ltd.
Here,
1-11:Single jersey knitting machine
12: Rib Knitting machine
13:Interlock Knitting machine
14:Fabrics inspection
15:Flatbed machine
16:Auto stripe machine
19
4.5 Flow Chart:
4.5.1 Flow Chart of Knitting Process:
Knit Fabric Dyeing

Yarn Dyeing Knitting
Dyeing Finishing
Embroidery Screen Print Allover print Washing
Knit Knit
Knit
Cutting Garments
Patterning
gg
Flow Chart 4.1: Process Flow Chart of Knitting.

20
4.5.2 Flow Chart of Knitting Procedure:
Collect approved Sample and sample parameter


Source the Yarn for required fabric

M/C Cam design according to design

Yarn collection

Cone settings

Yarn feeding into the knitting m/c

Check the stitch length and GSM

Inspection the fabric after making it

Fabric is checked continuously in the production time

Cut the fabric roll according to required production

Send fabric for inspection

Send to the store

Finally, it is delivered into dyeing section for next process
21
4.6 Knitting Machine List:

Total number of machine in AVL is 19
Total number of single jersey knitting machine is 14 & number of Rib machine is 5.
Total flat bed m/c is 8.
Machine No-01
Machine Name : Single Jersey Circular Knitting Machine
Brand Name : Mayer &Cia
Origin : Germany
Machine Gauge: 24
Machine dia; 26
Machine no -2
Machine Name : Single Jersey Circular Knitting Machine
Origin : Germany
Machine Gauge: 24
Machine dia: 30
Machine no -03
Machine Name : Rib Circular Knitting Machine
Origin : Germany
Machine Gauge 18
Machine Dia 30
Machine no -04
Origin : Germany
Machine Gauge 18
Machine dia 34
22
Machine no -05
Machine Name : Single Jersey Knitting Machine
Brand Name : Sun Da Circular Knitting Machine
Origin : Taiwan
Machine Gauge 24
Machine dia 24
Machine no 06
Machine name : Single Jersey Knitting Machine
Brand name : Mayer &Cia
Origin : Germany
Machine Gauge 24
Machine dia 36
Machine no-07
Origin : Germany
Machine Gauge 24
Machine dia 32
Machine no -08
Origin : Germany
Machine Gauge 24
Machine dia 32
Machine no 09
Machine Name : Rib Circular Knitting Machine.
Origin : Germany
Machine Gauge 24
Machine dia 30
23
Machine no -10
Brand name : Sun Da Circular Knitting Machine
Origin : Taiwan
Machine Gauge 24
Machine dia 24
Machine no-11
Origin : Germany
Machine Gauge 24
Machine dia 28
Machine no-12
Origin : Germany
Machine Gauge 24
Machine dia 34
Machine no-13
Origin : Germany
Machine Gauge 24
Machine dia 34
Machine no-14
Origin : Germany
Machine Gauge 24
Machine dia 34
24
Machine no-15
Origin : Germany
Machine Gauge : 24
Machine dia 34
Machine no-16
Machine Name : Auto Stripe S/J Knitting Machine
Origin : Germany
Machine Gauge 24
Machine dia 34
Machine no-17
Origin : Germany
Machine Gauge 24
Machine dia 30
Machine no-18
Brand Name : Mayer &Cia Germany
Origin : Germany
Machine Gauge 24
Machine dia 34
Machine no-19
Origin : Germany
Machine Gauge 24
Machine dia 34
25
4.7 Flat bed knitting machine:
Figure 4.3: Flat-bed Knitting M/C.
4.7.1 knitting Machine Parts:
Yarn passing though the machine and its function is given below:
1. Creel: It holds the yarn package.
2. Guide pipe: It ensures the path way of the yarn from creel zone to machine
(Knot Catcher). It also saves yarn from any unwanted twist with another.
3. Knot Catcher: It catches removes knot from yarn before knitting.
4. Yarn Tensioner: It supplies yarn to the machine at constant tension.
5. Sensor: The function of sensor is to detect the brakeage of yarn and stop the
machine immediately with the help of stop motion before positive feeder.
6. Yarn Guide: It guides yarn through the machine.
7. Positive Feeder: Positive feeder holds yarn & control the supply of the
yarn to the machine.
8. Sensor: The function of sensor is to detect the brakeage of yarn and stop
the machine immediately with the help of stop motion after positive feeder.
26
9. Yarn Guide: It guides yarn through the machine.
10. Light Detector: Its function is to give signal where yarn becomes broken.
11. Feeder: It supplies the yarn to the needle.
12. Needle: It forms loop.
13. Take down Roller: It takes fabric at a specific tension from the machine.
14. Cloth Roller: It winds the cloth
4.8 Classification of Knitting:

Basically, there are two types of knitting:
i) Warp knitting
ii) Weft knitting
4.9 Used Yarn:

In Apparels Village Ltd they use types of yarn:
i) Card yarn
ii) Combed yarn
iii) Rotor yarn
iv) P/C (polyester 65%) + cotton 35%)
v) CVC (cotton 60%+Polyester 40%)
vi) Lycra yarn
vii) Viscose
viii) Mélange yarn.
4.10 Yarn Count Uses for Knitting:

Types Of Yarn Count
Carded Yarn 18s,20s, 24s,26s,30s,32s,34s,36s
Combed Yarn 20s, 22s, 24s, 26s, 28s,30s,32s,34s,36s
Polyester yarn 75,100,150 Denier
Pc ( Polyester 65% + 35% Cotton) 24s, 26s,28s,30s
Rotor Yarn 7,10,12,14,16 Ne
Lycra 20, 30,40,50,70 Denier
Table 4.5: Yarn Count Uses for Knitting.
27
4.11 Different fabric and GSM and Yarn count:
4.11.1 Single Jersey

Fabric Name G.S.M Yarn Count
Single jersey 280 11s
4.11.2 Pique
Fabric Name G.SM Yarn cone
pique 250-260 20s
pique 230-240 24s
pique 210-225 26s
pique 190-205 28s
pique 160-170 32s
4.11.3 1x1 Rib

Fabric Name G.S.M Yarn count
1x1 rib 280-300 20s
1x1 rib 260-280 22s
1x1 rib 240-260 24s
1x1 rib 220-240 28s
1x1 rib 200-220 30s
1x1 rib 180 34s
28
4.11.4 Interlock
Fabric name G.S.M Yarn count
Interlock fabric 280-300 28s
4.12 GSM:
GSM means gram per square meter. GSM is very important parameter for a certain quality of
knit fabrics. The production of Knitted fabric is calculated in weight.
CPI x WPI x SL (M M) x 0.9158

Formula =
Ne
CPI = Course per inch
WPI = Wales per inch
SL = Stitch length
Stitch length: Stitch length is theoretically a single length of yarn which includes one needle
loop and adjacent needle loops or either side of it.
29
4.13 Samples from Knitting Section:
Sample Fabric Details Fabric Sample
Fabric type :(1x1) Rib

GSM 170
Stitch length :2.65
Dia x Gauge :34x18
Fabric type : (2x2) Rib

GSM 320
Stitch length :2.90
Dia x Gauge :32x18
Fabric type : Flat back rib

GSM 320
Stitch length :3.5
Dia x Gauge :38x18
Fabric type : FLEECE

GSM 280
Stitch length :4.7
Dia x Gauge :30x20
Fabric type : S/J Stripe

GSM 170
Stitch length : 2.9
Dia x Gauge : 38x24
30
4.14 Fabric Faults

Whenever a fault occurs during the production of knit- wear, the machine has to be stopped,
thus promoting some loss in productivity. The faulty element needs to be located in order to be
removed, and some repairing procedures are required, depending on the severity of the
damage. The main Fabric faults which can be found in Apparels Village Limited are:
1. Press-off.
2. Miss-stitch.
3. Needle Mark.
4. Sinker Mark.
5. Oil Stain.
6. Crease Mark.
7. Holes.
8. Slubs.
9. Spirility.
10. Broken Needle.
11. Pin Hole.
12. Tight Course.
13. Missing Yarn.
14. Course Yarn.
15. Soiled Fly.
16. Weight variation
17. Twist variation
18. Excessive Hairines
19. Bowing
Common Fabric faults & Causes and Remedies:
4.14.1 Hole:
Figure: Hole.
31
Causes:
1) Uneven tension on yarn.
2) Improper work of needle latch.
3) Too tight take down mechanism.
4) Imperfect stitch setting.
5) Badly tied knot.
6) Wrong positioning of feeder.
Remedies:
1) Adjusting the yarn tension.
2) Change the needle.
3) Control take down mechanism.
4) Proper stitch setting.
5) Knot should be given properly.
4.14.2 Slub:
Figure: Slub.
Causes:
1) Low quality yarn.
Remedies:
1) Use good quality yarn.
4.14.3 Loop:
Figure ure: Loop.

32
Causes:
1) Uneven tension.
2) Faulty needle latch.
3) Wrong settings of feeder ring.
4) Wrongly placed cylinder.
Remedies:
1) Control the tension
2) Replace the faulty needle.
3) Correct the feeder ring setting.
4) Perfectly placed the cylinder.
4.14.4 Oil Spot:
Figure: Oil spot.
Causes:
1) Excessive supply of oil.
2) Bleeding of oil due to unwanted mechanism.
Remedies:
1) Lubrication must be in control.
2) Proper cleaning of machine at proper time.
33
4.14.5 Oil Line:
Figure: Oil line.

Causes
1) Excessive oil.
2) Bleeding of oil.
Remedies:
1) Control the flow of oil.
2) Remove the faulty/broken parts.
4.14.6 Press off:
Figure: Press off.
Causes:
1) If both needle & sinker remain inactive simultaneously during operation, press
off will take place.
2) Loss take-down tension.
Remedies:
1) Machine should be stopped as early as possible and checking should be done for
both needle and sinker.
2) Control the take-down tension
34
4.14.7 Broken Needle:
Figure: Needle Break

Causes:
1) High yarn tension.
2) Breakage of latch or butt of the needle.
3) Old needle.
Remedies:
1) Control the tension.
2) Remove faulty needle.
3) Replace old needle.
4.14.8 Needle Line:
Figure: Needle line.

Causes:
1) Broken latch or butt.
2) Too high tension.
3) Wrong feeder setting.
Remedies:
1) Replace the faulty needle.
2) Control the tension.
3) Perfect settings of feeder.
35
4.14.9 Lycra out:
Figure: Lycra out.

Causes:
1) If needle fails to catch the any one spandex thread, this problem will occur.
Remedies:
1) The settings of spandex attachment and the observation of spandex delivery should
be done carefully.
4.15 Calculation:
4.15.1 Production
𝑅𝑃𝑀×𝑁𝑜.𝑜𝑓 𝐹𝑒𝑒𝑑𝑒𝑟𝑠×𝑁𝑜.𝑜𝑓 𝑁𝑒𝑒𝑑𝑙𝑒𝑠×𝑆𝑡𝑖𝑡𝑐ℎ 𝐿𝑒𝑛𝑔𝑡ℎ (𝑚𝑚)×𝐸𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦%×60𝑥8
• Production = 10×2.54×36×840×𝑌𝑎𝑟𝑛 𝐶𝑜𝑢𝑛𝑡 (𝑁𝑒)×2.2046
17×108×2714×2.85×1×60×8
= 10×2.54×36×840×24×2.2046
= 166.73 kg/Shift
4.15.2 Efficiency
𝐴𝑐𝑡𝑢𝑎𝑙 𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛
• Efficiency = 𝐶𝑎𝑙𝑐𝑢𝑙𝑎𝑡𝑒𝑑 𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛= × 100%
110
= 166.73 × 100%
= 65.58%
4.15.3 Acceptance Calculation:

36000
• 𝐺𝑆𝑀
Actual dia= 𝐹𝑖𝑛𝑖𝑠ℎ 𝐷𝑖𝑎 ∗ 𝑟𝑜𝑙𝑙 𝑤𝑒𝑖𝑔ℎ𝑡
3600∗𝐹𝑎𝑢𝑙𝑡
• 4 Point = 𝐴𝑐𝑡𝑢𝑎𝑙 𝑑𝑖𝑎
𝐹𝑖𝑛𝑖𝑠ℎ 𝑑𝑖𝑎
36
The acceptance level of grading is given below-

Up to 3” 1Point
Above 3” to 6” 2point
Above 6” to 9” 3 Point
Above 9” to up (4point rejected)
4.16 Quality Management:

Quality management is very important matter in fabric manufacturing. In order to maintain best
quality, fabric inspection is done in every factory during fabric production. Various defects in
the fabric might change the appearance or affect of these desired characteristics. So the produced
fabric must be examined thoroughly before releasing it for dispatch so that proper quality goods
reach the customers. There are various fabric inspection system. In Apparels Village Ltd., 4-
Point System is being used for fabric inspection.
4.16 Fabric inspection machine:

Machine name: Fabric Inspection Machine
Model no: K1
Serial no: AKK-001
Figure ure : Fabric Inspection Machine.
Figure 4.6: Fabric Inspection M/C of Apparels Village Ltd.

37
4.18 Quality control process:

There are two types of quality control process:
1. Online quality control process.
2. Offline quality control process.
4.18.1 Online quality control process:

This type of quality control process is done during the continuous production of fabric. Factors
that are being checked in online quality control process:
1. Fabric fault.
2. Machine RPM.
3. Machine setting.
4. Fabric design.
5. Fabric color.
4.18.2 Offline quality control process:

This process is done after completing the production. Steps of off-line quality control process:
Step 1: First of all fabric is cut down as roll form with the help of knife from the machine.
Figure: Step 1
38
Step 2: Then the details of the fabric is written on the roll(such as M/C dia and Gauge, fabric
structure, yarn type, lot number, buyer name, GSM, stitch length).
Figure: Step 2
Step 3: Then the rolled fabric is taken to the inspection machine with the help of trolley.
Figure: Step 3
Step 4: After that the fabric is passed through the inspection machine and Faults are detected.
Figure: Step 4
39
Step 5: The lab inspector write down the faults details on a paper and put grade on the
inspected fabric.
Figure: Step 5
Step 6: Rejected fabric is separated for the decision of their further process and accepted
fabric is folded again.
Figure: Step 6
40
CHAPTER: 05
BATCHING SECTION
5.1 Batching:
Batching is the receiving section of grey fabric and sending section of grey fabric to the dyeing
section which will dye. Batching is the process to get ready the fabrics which should be dyed
and processed for a particular lot of a particular order.
5.2 Batch Card:

Batch card contains
• Programmed/Job no
• Shade Indication
• Buyer/Brand Name
• Style no
• Lot no
• Specific Treatment of That Fabric
• Wash type
• Finish type
• Fabric Construction
• Tube diameter
• Required Width
• Required GSM
• Issue Date etc.
41
5.3 Batch Process Flow Chart:

Flow chart of Batching Section is given bellow:
Fabric Received & stored

↓
Fabric Divided according to Diameter after buyer’s recommendation
↓
Supervisor batches the fabric according to quantity by Calculation
↓
Inspection
↓
Send for Dyeing
5.4 Batch preparation:

Production planning for dyeing is called Batch Plan. According to the batch number, color,
width, style and construction the batch plan is made. For easy understand, this section gives
some „T‟ cards. „T‟ cards are serialized according to the priority of delivery. The batches and
„T‟ cards are also serialized as to dye light shade at first and lastly the dark shades, since faulty
shade and can be converted to dark color later.
5.5 Calculation for Reel speed:

Let,
Fabric weight = 1000kg
Per nozzle fabric weight =250kg
Fabric Diameter (open) = 56 inch
Cycle time or Dwell time = 2.5-3.0 m per minute
G.S.M =180
We know,
GSM = gram / meter2

42
= gram / (Length × Diameter)
Or, Length = gram / (GSM × Diameter)
= (250×1000×100) / (56×2.54×180)
= 976 meters
Fabric Length/ nozzle= (Fabric weight(kg) × 1000 × 100)/ Fabric GSM × Fabric diameter ˝ ×
2.54 cm × number of nozzle
So, Reel Speed = per nozzle Fabric length / Cycle time
= 976 / 3 meter/minute
= 325 meter/minute
5.6 Batch Card:
Figure 5.1: Batch Card

43
5.7 Aims / Purpose of Batch Section:

1. To receive the grey fabrics roll from knitting section or other source.
2. To turn out the tubular fabric to safe the face side of the fabric from any type of friction
during dyeing.
3. To prepare the batch of fabric for dyeing according to the following criteria… … …
▪ Order sheet (Receive from buyer)

▪ Dyeing shade
▪ M/c available
▪ Type of fabrics (100% cotton, PC, CVC etc.)
▪ Emergency
4. To send the grey fabric to the dyeing floor with batch card.
5. To keep records for every previous dyeing.
Figure 5.2: Fabric Inspection for batching

44
CHAPTER: 06
DYEING SECTION
6.1 Introduction:
A dyeing process is the interaction between a dye and a fibre, as well as the movement
of dye into the internal part of the fibre. A dyeing or printing process is complicated, since it
involves fibre kinds, yarn or fabric structures, dyes and chemical auxiliaries, as well as
dyeing technology. The majority of natural dyes are derived from plant sources: roots, berries,
bark, leaves, wood, fungi and lichens. Most dyes are synthetic, i.e., are man-made from
petrochemicals.
6.2Dying lab:
Dyeing lab is the heart of the dyeing factory. Before bulk production a swatch of fabric test
dyed to hit a color standard. It is a process by which buyer's supplied swatch is matched with the
varying dyes percentage in the laboratory with or without help of spectrophotometer
6.3 Objectives:
Main objectives of lab dip are as follows-----
• Calculate the recipe for sample dyeing,

• Compare dyed sample with swatch by light box or Spectrophotometer,
• Calculate revise recipe for sample dyeing,
• Totally approved Lab Dip.
6.4Process in dyeing lab:

Sample/Swatch/ TCX no. from the buyer
↓
Determination of sample’s possible color combination by the help of manual
↓
Dispersion by autodoser
↓
Trial dyeing of first recipe
↓
45
Unload
↓
Normal wash
↓
Hot wash with detergent
↓
Oven drying
↓
Ironing
↓
Shade matching in light box ( If not ok then again done those previous sequence for matching
shade)
↓
If ok then send to byer for approval
↓
Bulk production by considering the buyer’s approved sample as standard
6.5 Dyeing M/C and chemical in lab:
Figure :6.1 Dying machine and chemical in lab

46
6.6 Elements of A Dyeing Machine:

• Main Vessel or Chamber
• Winch roller or Reel
• Heat Exchanger
• Nozzle
• Reserve Tank
• Chemical dosing tank
• Controlling unit or Processor
• Fabric Plaiter
• Different types of motors & Valves
• Main Pump
• Utility lines. Ex: water line, drain line, steam inlet
6.7 Layout in dyeing section in apparel village ltd:
Figure 6.2: Dyeing floor Layout

47
6.8 Picture of Dyeing floor Drying machine:
Figure :6.3 Dying machine in dying floor
Apparels Village Dyeing is covered by the 7 sample dyeing machines and 11 production dying
machines & 2 Turning machines and machines are Taiwan,Thie’s,Dilmenler branded. The
capacity of sample dying machine is (200-250)kg and the capacity of production dying machine
is (1000-1500)kg. 24 hours running our dyeing section by the three shift 3 hundred workers are
working in our dyeing section.
48
6.9 Flow chart:
6.9.1 Flow Chat for dyeing:
Grey fabric received from knitting section
Batching
Select M/C No
Fabric loading
Select production program
Pre treatment
Select recipe for dyeing
Recipe confirm by DM/ SPO
Dyeing
Post treatment
Unload
49
6.9.2 Knit fabric Dying process (Cotton):

Fabric loading
Scouring (1500c, 60 min)
Cooling (5 min)
Scouring hot (800c, 10 min)
Cooling (5 min)
Leveling agent
Run time 20 min
Color dosing (600c, 30-50 min)
Soda dosing (20 min run time)
If shade of then
Bath drop (BD) water drain

50
BD wash (600c, 20-30 min)
Soaping
Wash until water clean
Unload
Softner procedure
PH check
Acetic acid
Softner dosing at 45-60
Run time (10-20 min)
Unload.
6.9.3 Process Flow Chart For Pretreatment:

Scouring, Bleaching & Enzyme treatment including in pre-treatment i.e.
Scouring + Bleaching
Enzyme.
This procedure already I have shown.

51
6.9.4 Process Flow chart for after-treatment:

Acetic Acid
Soaping agent (if Dark) or Only Hot (if light)
Enzyme
Fixing
Softner (450c, 20 min)
6.9.5 Process flow chart of final Inspection:

After completing finishing process here firstly cheek the shade as per buyer standard with
dimensional Stability from lab
Cheek dia with fabric while fabric weight/G.S.M
Cheek fabric surface or appearance as per buyer standard.
Every Roll with every meter cheek as per 4 point system
Make a report
If ok then ready for delivery
If not ok then identify the fault

.
If it is knitting fault, then inform the knitting department by job card and mail requested the
fabric for replacement.
If it is dyeing fault & if we make sure that it is reprocess able then we give job card to dyeing
department for correction & if it is not ok reprocessable then we reject the quantity.
52
6.10 Raw Material for dyeing:

Raw Materials used in the dyeing section are:
1. Grey fabric
2. Dyes
3. Chemicals.
Grey Fabrics:
Following types of grey fabrics are dyed-
1. Single jersey 6. 11 rib
2. Single Jersey 7. 22 rib
3. Single Jersey 8. P.K fabric
4. Double Lacoste 9. Different types of collar & cuff
5. Fleece
6.11 Recipe of Different stage in Dyeing:
6.11.1 Recipe for machine’s heavy wash:

Detergent 0.5 gm/L
Caustic soda 1 gm/L
Hydrous 2 gm/L
Time 60min
Temperature 90.c
Table:6.1 Recipe for heavy wash
6.11.2 Recipe for scouring:

Actually scouring depends or the types of the fiber, fabric, fiber color, fiber cleanliness, twist &
count of yarn and fabric construction.
Detergent 1.3%
Wetting agent 0.2 gm/L
Stabilizer 0.2 gm/L
Anti-creasing agent 0.3 gm/L
53
Caustic 2%
Hydrogen per oxide 2%
Sequestering agent 0.2%
Temperature & time 1020C, 60 min.
Table:6.2 Recipe for scouring: (for cotton)
6.11.3 Recipe for Enzyme:

The enzyme is used in the washing to soften the fabric and also remove yarn.
Acetic acid 2 gm/L

Enzyme .75 gm/L
PH check 4.5-5.5
Temperature & time 550C. 60 min
Table:6.3Recipe for enzyme treatment: (For Cotton)
6.11.4 Recipe for Reduction (Polyester):
Caustic 2 gm/L
Hydrous 2.5 M/L
Temperature & time 900C, 20 min
Table:6.4 Recipe for reduction(polyester)
6.11.5 Bleaching:
Bleaching is the process for improving the whiteness of textile materials with removing the
natural coloring matters.
Detergent 1 gm/L
Hydrogen per oxide (H2O2) 3 gm/L
Stabilizer 1 gm/L
Sequestering agent 1 gm/L
Detergent 1 gm/L
54
Wetting agent 1 gm/L

Temperature & time 1050C, 60 min.
Table:6.5 Recipe for Bleaching:
6.11.6 The fiber which can be dyed by reactive dye:

1) Cotton, Rayon and other cellulose fibers.
2) Nylon & wool fiber.
3) Silk and acetate fiber.
6.12 Dyed fabric finishing:

There are two types of dyed fabric finishing. Like below
➢ Mechanical Finished
a) Temporary
b) Permanent
➢ Chemical Finished
a) Temporary
b) Durable
6.12.1 Mechanical Finished:

Mechanical finishing is a general term to describe process carried out on a prepared and dyed
fabric in order to improve its suitability for the desire end use.
6.12.2 Name of Mechanical Finished

1. Calendaring
2. Raising
3. Dimensional change/ Compressive shrinkage
55
6.13 Finishing Machines:

In Apparels Village Ltd. They are using Following Finishing M/C:
6.13.1 Turning M/C:
Figure :6.4 Turning M/C

Purpose:
Tubular Fabric Turning Machine is suitable for tubular fabric of cotton, wool, silk, chemical
fiber to process automatic turning before dyeing or washing.
6.13.2 Squeezer Machine:
Figure :6.5 Squeezer Machine
Purpose:
Slitter machine is used for tubular knit fabric to make it in open form. In open form
fabric finishing line; slitter machine is used after hydro-extractor, de-watering and drying
machine.
56
6.13.3 Compactor Machine:
Figure ure:6.6 compactor machine
Purpose:
• To control the shrinkage of the fabric.
• To control fabric width.
• To adjust the GSM of the fabric.
• To achieve fabric smoothness.
6.14 Common Dyeing Faults with Their Remedies:
6.14.1 Uneven Dyeing:

i) Uneven pretreatment (Scouring & bleaching)
ii) Improper color dosing
iii) Uneven heat setting in case of synthetic fiber.
57
Remedies:
i) By ensuring even pretreatment.
ii) By ensuring heat-setting in case of synthetic fiber
6.14.2 Batch to Batch Shade Variation:

i) Fluctuation of Temperature.
ii) Batch to Batch weight variation of dyes & chemicals.
iii) Improper pretreatment.
Remedies:
i) Use standard dyes and chemicals
ii) Follow the standard pretreatment procedure.
iii) Make sure that the operators add the right bulk chemical at the same time and
temperature in the process.
6.14.3 Patchy dyeing effect:

i) Faulty infection of alkali.
ii) Improper addition of color.
iii) Due to the hardness of water.
iv) Due to improper salt addition.
Remedies:
i) By ensuring proper pre treatment
ii) Proper dosing of dyes and chemical
iii) Proper salt addition
6.14.4 Roll to roll variation/meter to meter variation:

i) Improper dyes solubility.
ii) Hardness of water.
iii) Faulty machine speed.
Remedies:
i) Use standard dyes & chemical
ii) Proper machine speed.
iii) Use & soft water.
58
6.14.5. Crease mark cause:

i) Shock cooling of synthetic material
ii) Due to high speed M/C running
Remedies:
i) Lower rate rising and cooling the temperature.
ii) Reducing the M/C Load.
6.14.6. Dye Spot:

i) Improper Dissolving of dye particle in bath.
ii) Improper Dissolving of caustic soda particle in bath.
Remedies:
i) By proper dissolving of dyes & chemical.
6.14.7 Softner Mark:

i) Improper mixing of the softner.
ii) Improper running time the fabric during application of softner.
Remedies:
i. Proper mixing of the softner before addition.
59
CHAPTER: 07
SAMPLE SECTION
7.1 Sample Section:

Sampling process is the most important department in a garments factory. Without proper sample
one cannot 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.
7.2 Flow Chart:

There is the sample procedures after pattern making, they (Apparels Village Ltd.) are as
follows:
Sourcing the Fabric and Accessories for making the Garment
↓
Cutting (For Sample Only)
↓
Embellishment
↓
Sewing
↓
Iron
↓
Quality Control
↓
Recheck Form
↓
Buyer QC
↓
Forwarding from the Merchandiser
↓
Sending Sample to the Buyer
60
7.3 Types of sample:

1. Proto or development sample
2. Size set/ Grade/ Fitting sample
3. Additional sample
4. Contract seal/ seal sample
5. Pre-Production sample
6. Production sample
7. Sales Man Sample
8. Rack Sample
9. Counter sample
7.3.1 Proto Sample:

This is the first stage of the sample. Someone called development sample. In this stage, to convert
the pattern into actual garments.
7.3.2 Size set/ Fitting sample:

In this stage, correction of the proto sample. Someone called grading sample. Actually in this
stage- to make the fit the styling of the garments.
7.3.3 Seal sample:

It’s another name is contract seal. In this stage, to gain approval before the bulk production.
7.3.4 PP Sample:
PP sample means pre-production sample. It’s also to gain approval before the bulk Production.
7.3.5 Sales man Sample or SMS Sample:

This sample to make for show room. To gain approval for bulk production also.
61
7.4 Types of Machine are used in Sample department:
S/L Description Brand Country of Origin Quantity

1 Overlock PEGASUS Japan 4
(2 Needle 4 Thread, 2Looper)
2 Over Lock PEGASUS Japan 3
(3 Needle 6 Thread, 2Looper)
3 Flat Lock (Flat Bed) PEGASUS Japan 2
4 Flat Lock (Cylinder Bed) PEGASUS Japan 2
5 Plain M/C (Single Needle) BROTHER Japan 5
Total 16
Table 7.1: Sample, Machine List of Apparels Village Ltd.
7.5 Sample production Capacity:
The sample department produces 190 Pcs of samples everyday including SMS.
About 4000Pcs of sample dispatches every month with negligible rate of rejection of 2%.
62
CHAPTER: 08
PATTERN SECTION
8.1 Pattern section:

Pattern is a hard paper which indicates the individual component of a garment according to the
design. A pattern, from the French patron, is type of theme of recurring events of or objects,
sometimes referred to as elements of a set. These elements repeat in a predictable manner. It
can be a template or model which can be used to generate things or parts of a thing, especially
if the created have enough in common for the underlying pattern to be inferred, in which case
the things are said to exhibit the unique pattern.
8.2 Pattern types:

Pattern is two types:
1. Working pattern
2. Production Pattern
8.2.1 Working Pattern:

The pattern which is made for sample making is called working pattern. It is made for a particular
style with net dimension or with allowance. That is
Working = Basic Block + Allowance.
8.2.2 Production Pattern:

To make a pattern by following the approved sample along with allowance is necessary before
production. These patterns with allowance are called production pattern.
63
8.3 Pattern Making Flow Chart:
Tec-pack Received from DPD Department

↓
Sketching Pattern
↓
Plotting/Printing
↓
Pattern Cutting Manually
↓
Pattern Development
↓
Pattern Grading
8.4 Pattern Making Method:

Pattern can be made both manually and automatically. In the manual method, pattern is made in
hand and then digitized by digitizer machine. On the other hand, automatic pattern is made by
using CAD software.
8.4.1 Hardware and Software used in Pattern Making:

1. CAD Software, Garber Garments Technology (GGT).
2. Marker making software- 2 pcs.
3. Garber Digitizer- 1 pcs.
4. Pattern design software (PDS), Optitex- 4 pcs.
8.4.2 Manually Equipment used in pattern Making:

1. Marker Paper
2. Pattern Board
3. Pencils
4. Rubber
5. Measurement Tape
6. Set Square
7. Metric Grading Squares
8. French Curves
64
CHAPTER: 9
CUTTING SECTION
9.1 Cutting Section:
Cutting is one of the major process in garments manufacturing. Here garments parts are cutting
according to the pattern. In garments cutting department, a process flow chart have to maintained
to send the right measurement parts in the next process for making quality garments. As its
importance in garments manufacturing, a process flow chart for garments cutting department is
presented in this article.
9.2 Process Flow Chart of Fabric Cutting Department:

Pattern received from pattern department
↓
Cutting ratio received from merchandiser
↓
Marker making
↓
Fabric received from the store
↓
Fabric Checking
↓
Fabric Spreading
↓
Marker placing on to the lay
↓
Cutting the fabric
↓
Numbering
↓
Checking
↓
Sorting and Bundling
↓
Send to the sewing department
65
9.3 Equipment of Cutting Section:

➢ Cutting Table
➢ Perforated Paper
➢ Marker
➢ Auto Stitching M/C
➢ GSM Tester
➢ GSM Cutter
➢ Electric Balance
9.3.1 Received approval Pattern:

Cutting Department received approval pattern from pattern department.
9.3.2 Received Marker paper:

Cutting department received marker from CAD department.
9.3.3 Trail cutting:

Trail cutting do the short quantity of cutting. It can do for sample cutting.
9.3.4 Development:
Finished the trial cut of fabric cutting manager will take decision if any measurement need
development or not.
9.3.5 Spreading:
Fabric spreading is a process as marker length and width for the easy process of cutting. It can
do-
▪ Save time for the garment.
▪ Minimize production cost.
Figure :9.1 Fabric Spreading.

66
9.3.6 Laying Fabric:

In Apparels Village ltd they are laying fabrics manually and computerized Gerber M/C. Easily
can find fabric fault & shading uses for laying.
9.3.7 Laying marker paper:

After completing the laying fabric then lay the marker paper.
9.3.8 Attach Clamp:

Finishing lying attach the clamp with marker paper.
9.3.9 Cutting:
Two method of cutting. Such as –
i) Manually
ii) Computerized.
In Apparels Village ltd they cut fabrics manually by scissor and computerized cutting use Gerber
machine.
9.3.10 Part Change:

After completion of cutting they change parts as per garments panel wise, size wise, roll wise
and color wise.
9.3.11 Numbering:
After completing the changing parts, they can do the numbering as per size, color wise.
9.3.12 Bundling:
Completion the Numbering then bundle all panel of garments as per size and color wise.
9.3.13 Embellishment:
If any embellishment, then go to the concern department.
9.3.14 Cheek embellishment:

Cutting Quality cheek all the embellishment of garments.
67
9.4 Fabric Lay height standard:

➢ Single jersey = 7cm
Number of lay = 120-130 pcs
➢ 1 x 1 rib = 9-10 cm
The number of lay = 110-120 pcs
➢ Pique interlock = 10-12 cm
The number of lay = 90 pcs
➢ Fleece =12-14 cm
The number of lay = 70 pcs
Cutting capacity: 25000-0000 pcs per day.
Figure :9.2 Fabric Lay
9.4.1 Fabric relaxation:

Lycra = 24 hours
1x1 rib = 6-7 hours
2x2 rib =24 hours
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9.5 Description of Cutting Machine:
S/L.No. Name Specification

01 Straight knife Knife height:10”
Stroke:4
02 Cutting Table No.of Table:03

03 Replace Table No.of Table:01
Table 9.1: List of Cutting Knife and cutting tables.
Figure 9.3: Fabric cutting.

69
9.6 Cutting plan preparation

Parameter:
Packing Ratio: As per pack
Fabric quantity = 2000 kg
Consumption/garment =0.48 kg
Hence total pcs = 2000/0.48
= 4166 pcs
Ratio of packing:
XS M L Total Pcs
500 2000 2000 = 4500
Cut Ratio = 4166/4500

= 0.9257
Total No. of XS = 500 × 0.9257 = 462

Total No. of M = 2000 × 0.9257 = 1852
Total No. of XS = 500 × 0.9257 = 1852
Total No. of Garments for cut at a time=4166pcs
9.6.1 Formula of cutting efficiency:

𝐴𝑐𝑡𝑢𝑎𝑙 𝑐𝑢𝑡𝑡𝑖𝑛𝑔
Cutting efficiency = × 100
𝑇𝑎𝑟𝑔𝑒𝑡 𝑔𝑎𝑟𝑚𝑒𝑛𝑡 𝑐𝑢𝑡𝑡𝑖𝑛𝑔
4166
= × 100
4500
=92.578 %
9.7 Cutting Inspection:
9.7.1After cutting inspection:

i. Pattern check
ii. Notches/cut mark
iii. Miss cut
iv. Matching place
70
9.7.2 Before cutting inspection:

i. Table Mark
ii. Shading
iii. Splices
iv. Tension
v. Leaning
vi. Count
vii. Marker
viii. Marker Placement
ix. Narrow goods
9.8 Cutting faults:

i. Shade variation
ii. Cutting mistake
iii. Fabric faults
iv. Numbering faults
v. Size mistake
vi. Imprecision cutting
71
CHAPTER: 10
SEWING SECTION
10.1 Sewing Floor:
Apparels Village Ltd. sewing section which is located in 3rd, 4th, 5th floor in production
building.
10.2 Sewing:
Sewing means two or more fabric attached by using needle and thread is called sewing. sewing
is main functional work to made garments.
10.3 Flow Chart of Sewing Department:
Input token

AQC sample and necessary paper arrange

Cutting (size wise)

Store requisition and other

Cutting to take input by counting

Store to take thread

Sewing to put the accessories

To arrange the PP meeting

Lay out submit

Sewing input

Out body confirm by reporter
Size wise finishing input
72
10.3.1 Input Token:

sewing department receives input token from planning department before bulk production.
10.3.2 Input Cutting Part:

After receive token sewing department collect cut fabric to show the token is cutting
department. When cut panels will complete in
Cutting department then cutting parts will input in sewing floor.
10.3.3 Accessories Collect from Store:

Sewing department collect accessories from store department before the bulk
production.
10.3.4 Pre-production meeting:

All the concern person of the department in garments sector present who are involved in
meeting for bulk production is called pre- production meeting
10.3.5 Line Layout:

According to product design, production manager will do line layout in attend supervisor
technician and quality in charge.
10.3.6 Inline Inspection:

After completion of the garments the front of every line will do the inspection of every
garment.
10.4 Output:
Completing the inspection, the gate then output garments.
10.4.1 Send washing:

As per buyer requirement if any wash go to the concern department.
10.4.2 Finishing:
When sewing & wash function complete then sent to the finishing department.
73
10.5 The Different Machines:

There are many different machines used in Apparels Village Ltd. As like
Figure 10.1: Single needle lockstitch sewing machine
Purpose: It can be used for making any type of apparel especially it is used for collar, front
placket, bottom hem etc.
Figure 10.2: Double needle lockstitch sewing machine
Purpose: Used to sew the loop of the pants.

74
Figure 10.3: Feed of the arm
Purpose: Used in sewing the side seam of pants
Figure 10.4: KANSAI sewing machine
Purpose: Used to join the waistband with the pant.

75
Figure 10.5: Flat lock sewing machine
Purpose: Normally used in the hemline of T-shirt.
Figure 10.6: Pocket Facing
Purpose: Used to attach the pocket facing with the pocket of a pant
Figure 10.7: Button Attaching machine
Purpose: Used to attach buttons.

76
Figure 10.8: Button–Hole machine
Purpose: Used to make the button hole of a pant
Figure 10.9: Overlock sewing machine (3/4/5 threads)
Purpose: Used to connect two pieces of fabric and prevent it from fraying.
Figure 10.10: Barteck machine

Purpose: Used to Increase the strength in corner of pockets
77
10.6 Machine specification of sewing section in AVL:
Name of Machine Total

Plain Machine (Auto) 263
Plain Machine (Manual) 83
Over lock 232
Flat lock C/B 84
Flat lock F/B 29
Button Hole 13
Button Stitch 13
Rib Cutter 10
Picoding 2
Eskabling 2
Kansai (PMD) 5
Feed of the Arm 9
Snap Button 15
Barteck 8
Cutting Machine 11
Heat Transfer 3
Metal Detector 1
783
Table 10.1: Machine specification of sewing section in AVL.
10.7 Lay out of sewing section in AVL:
Figure 10.11: Layout of sewing floor(4th floor)

78
10.8 Various types of Faults and their figure:

Fault Name: Oil mark
Figure10.12: Oil mark
Fault Name: Stitch Gathering
Figure 10.13: Stitch Gathering
Fault Name: Level missing
Figure 10.14: Level missing

79
Fault Name: Shade variation
Figure10.15: Shade variation
Fault Name: Open seam or broken seam
Figure10.16: Open seam
Fault Name: Cutting hole
Figure10.17: Cutting Hole

80
CHAPTER: 11
STORE DEPARTMENT
11.1 Store Department:

The fabric stores department is centralized in apparel industry and all the fabric comes to this
unit first from the supplier and audited here and kept until it is distributed to other units. For an
export oriented and bulk production Garment Industry. it is essential to maintain a well-
organized & well-equipped inventory system. The main responsibility of this department is to
store all the raw material necessary to produce garments. This department is sub divided into
three sections. Store keeper follows a strong and appropriate working procedure. Their work
process flow is given below
11.2 Working Flow Chart of Store Department in Garment Industry:
Receiving Product
↓
Inventory
↓
Inspection of product
↓
Shade segregation
↓
Issuing Product
↓
Sustaining Balance
↓
Closing Summery
81
11.3 Item Stored in the Store Department:
1.Button
2.Zipper
3.Label
4.Jackron
5.eyelet
6.polybag
7.Hanger
8.Carton
9.Gum Tape
10.Scotch Tape
11.Tag Pin
12.Lock Pin
13.Twill Tape
14.Velcrow
15.Plain Elastic
16. Hole Elastic
17. Price Tag
18.Rider
19.Sticker
20.Hang Tag
21. Sewing Thread and Mainly
22. Fabric
82
CHAPTER: 12
FINISHING SECTION
12.1 Finishing Section:

Garments finishing is an important section in readymade garments sector. It’s the last section
of garments department. As all the others section of garments manufacturing, garments
finishing section has also followed a process flow chart, which has explained below
12.2 Process Flow Chart of Garments Finishing:
Sewn garments received in finishing section

↓
Initial quality check
↓
Spot removing if there’s any spot
↓
Ironing or pressing
↓
Inspection
↓
Hang tag attaching
↓
Folding
↓
Poly bag
↓
Metal check
↓
Packaging or Cartooning
83
S/L No. Process Procedure

01 Sewn garments received in finishing Here, sewn garments are received for
section finishing the garments.
02 Initial quality check Sewn garments are checked here by the
quality controller. If found major sewing
problems then garments sent again to the
sewing section for rectification.
03 Spot removing if there’s any spot Sometimes garments contain various
types of spots which are removed here
carefully.
04 Ironing or pressing It’s one of the important processes in
garments finishing. Here garments are
ironed by following measurement chart
of that garments.
05 Inspection After completing ironing or finishing,
garments are inspected again here by
quality controller to confirm the correct
measurement of the garments.
06 Hang tag attaching In this section, hang tag have to attach
with the garments.
07 Folding After completing all the above processes,
garments are folded here.
08 Poly bag Garments are poly bagged here to keep
the garments dust, dirt and other
impurities free. send the garments safely
in to the buyer.
09 Metal check In this section, garments should be
passed through a metal detector machine
to identify metal lies in the garments.
10 Packaging or cartooning Finally all the garments should pack to
send the garments safely in to the buyer.
Table 12.1: All the processes of garments Finishing
84
12.3 Garment Inspection:
12.3.1 Primary Inspection sequence for ladies jagging before pack:

Loop cutting
Thread cutting
Loop area check
Back pocket thread cutting
Back pocket quality check

Bottom hem trimming
Bottom hem check
Body turning
Inside trimming
Inside quality check
Body turning
12.3.2 Final Inspection includes the following tasks:

Measurement
Final Get-up
(QC batch sealing)
QA Audit
AQL Identification
Note: If any kinds of fault are found then it is sent to alter section so that rectification of the fault
is done.
85
12.4 AQL:
A statistical measure of the maximum number of defective goods considered acceptable in a
particular sample size. If the acceptable quality level (AQL) is not reached for a particular
sampling of goods, manufacturers will review the various parameters in the production process
to determine the areas causing the defects.
AQL 1.5 means-No more than 1.5% defective items in the whole order quantity will be accepted.
Example:
In a lot size of = 1201 – 3200
Sample Size = 50
For AQL 1.5% Acceptable = 2 defects Reject= 3 defect
12.5 If AQL is failed then the following problems are introduced:

i. On time shipment is not achieved
ii. Loss of commitment
iii. Management has to face economic losses
iv. Running production is hampered
v. Reschedule is necessary
vi. Working hour is to be increased
vii. Workers have to be given overtime incentive
86
CHAPTER: 13
MERCHANDISING SECTION
13.1 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.
13.2 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.
13.2.1 Most importance things for a Merchandiser is-

• Communication.
• Planning
• Production follow Up
In Apparels Village Ltd, merchandising department divided in three divisions. Such as-
• Sales & Distribution (SD)

• Material & Management (MM)
• Production & Planning (PP)
87
13.3 Organogram of Merchandising Department:
Manager Merchandising
Senior Merchandiser Senior Buyer Co-ordinator
Assistant Merchandiser Junior Buyer Coordinator
Junior Merchandiser
13.4 Job Responsibilities of Merchandising in Apparels Village Ltd.
13.4.1 Development & Costing:

▪ Reviewing the development packs received from buyer.
▪ Passing packs to sample section for development sample.
▪ Clarify all necessary information with buyer as much as possible.
▪ Follow up on the development sample deadline.
▪ Work out the initial costing & final costing.
▪ Price negotiation with buyer.
▪ Follow up with buyer registration the feedback of the sample & costing.
13.4.2 Order Confirmation:

▪ Checking all the details in the order sheet once received from buyer.
▪ Communicate with buyer registration any discrepancy in the order sheet.
▪ Quoting the delivery dates to buyer after checking factory’s capacity situation.
▪ Signing & passing order confirmation sheet to buyer.
▪ Passing L/C request from to buyer.
▪ Passing the correct order sheet to all concerned department; i.e. planning, production,
commercial etc.
88
13.4.3 Sampling:
▪ Sending sample request to sample section.
▪ Updating sample section regarding different sample requirement of buyer at various
stage (proto, sales man, Fit, counter card, pp sample etc.)
▪ Arranging fabrics & trims for sales sample.
▪ Follow up sales sample until buyer’s hand.
▪ Checking the quantity requirement of each sample.
▪ Passing the necessary paper work for each sample.
▪ Follow up with buyer registration each sample comments & passing to sample section
for updating pattern.
13.4.4 Bulk Fabric:

▪ Work out the consumption for each style from marker provided from CAD.
▪ Provide fabric booking to the fabric department with correct quantity & all information.
▪ Follow up on the lab dips/strike off submission & chase approval comments.
▪ Follow up on the fabric delivery against critical path.
13.4.5 Bulk Trim:

▪ Preparing the cost sheet/checklist for individual trim require for style.
▪ Preparing care level layout & send for approval.
▪ Submitting required trims to buyer for approval.
▪ Provide booking for individuals trims to the approved source.
▪ Chasing the P/I from trim suppliers.
▪ Monitoring the L/C or TT payment.
▪ Follow up with trim suppliers to ensure on time delivery.
13.4.6 Embellishment:
▪ Chasing the artwork for all print/embroidery from buyer.
▪ Developing the artwork, checking the strike off & pass it to buyer.
▪ Checking the capacity of print/embroidery plant in advance & booked accordingly.
▪ Embellishment price negotiation
▪ Submitting bulk embellishment strike off for buyer approval.
▪ Passing approved copy of the strike off to the respective plant.
89
▪ Approving first pc (embellishment) for starting bulk product.

▪ Monitoring the panels sent & receives dates to ensure smooth production flow.
▪ Claim amount calculation for excess wastage & prohibited substance.
13.4.7 Filing & Corresponds:

▪ Maintaining style file for all running orders.
▪ General correspondences with buyer & suppliers.
▪ Updating buyer for audit schedule, production status, etc.
13.4.8 Production & Planning:

▪ Passing the correct work sheet to all concerned department.
▪ Following up bulk production.
▪ Requesting commercial team to take necessary steps to ship the garments.
▪ Internal meeting with production, planning, quality, commercial & HRD.
▪ Following up bulk inspection & collecting inspection report and pass it to concern
commercial.
▪ Following up export document sending.
▪ Checking basic information’s of export document.
▪ Sending delivery performance report to buyer with shipment details.
13.4.9 Quality:
▪ Discuss quality standard of individual buyer with quality & production team.
▪ Monitor the quality of merchandise &update production ant quality team for production
required quality garments.
13.5 Garment Costing:

In order to achieve perfect garment costing, one must know about all the activities
including purchase of fabrics, sewing, packing, transport, overheads, etc.
90
13.5.1 Cost Sheet & Consumption Sheet Preparation:
Particulars Light colors Medium colors Dark colors

34's combed yarn Tk.135.00 Tk.135.00 Tk.135.00
Fabric cost per Tk.38.06 Tk.40.13 Tk.44.27
garment
Cost of Trims Tk.0.85 Tk.0.85 Tk.0.85
CMT Charges Tk.11.00 Tk.11.00 Tk.11.00
Cost of accessories Tk.1.35 Tk.1.35 Tk.1.35
Rejection of Tk.1.50 Tk.1.50 Tk.1.50
garments
(commonly 3%)
Cost of Garment Tk.52.76 Tk.54.83 Tk.58.97
Local Transport Tk.1.00 Tk.1.00 Tk.1.00
Profit@15% appro. Tk.6.90 Tk.8.20 Tk.8.90
Commission/ pc Tk.2.00 Tk.2.00 Tk.2.00
Price of Garment Tk.63.66 Tk.66.03 Tk.70.87
Table14.1: The freight charges for the Men's Basic T-shirt. Price of garment estimation is
given
13.5.2 Shipping Charges:

For men's basic T-shirt, the delivery terms in the buyer enquiry as 'FOB'. So sea freight
charges are not added. But the local transport with the cost of garment has to be added.
Finally, we have to convert the Indian rupee value to USD or Euro.
During the fixation of FOB price of a garment following notes are to be followed carefully:
1. Cost of fabrics/Dzn. garments.
2. Cost of Accessories/Dzn.garments.
3. C.M (Cost of Manufacturing) /Dzn. Garments.
4. Cost of embellishment (if any) likes print, embroidery, etc
5. Commercial cost.6. Commission (if any)
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13.5.3 Fabrics Price:

Knit fabric price is the sum of the below factors-
1. Yarn price per kg (approx. $6.40)
2. Fabric price per yard (approx. $0.15)
3. Dyeing price per kg (approx. $1.5)
4. Finishing price per kg (approx. $0.50)
Thus the fabric price per kg comes ($6.40+$0.15+$1.5+$0.50)= $8.55
Fabrics consumption for a European T-Shirt is 3.00 kgs per dozon.
So fabrics price per dozon is (3.00 * 8.55) = $25.65
13.5.4 Trimming Price:

Trims cover all the trims used in the garments except the basic fabric. There are hundreds
of items used to manufacture the garments, proper selection of trims and its quality are very
important for styling, otherwise the garment maybe rejected or returned by the customers.
As our assignment is based on basic T-Shirt, normally care label, main label, size label,
sewing thread, poly bag, price ticket, carton, tag pin, gum tape, etc trim are used in a basic
T-Shirt. Like, normally the trim cost per dozen comes approx. $2.00 for basic T-Shirt.
13.5.5 CM Calculation:
CM means cost of cutting to making. It includes the cost of cutting, cost of sewing and the
cost of packing. It also includes the overhead cost of the plant and the profit margin. Like,
Generally CM per dozen of a basic T-Shirt is $5.00
13.5.6 Final garments cost & order confirmation:

Now the final garments cost per dozen is the sum of fabrics cost, trimming cost, CM cost,
other embellishment cost & commercial cost. So as example if a basic style is taken- the
garments price per dozen comes ($25.65+$2.00+$5.00+$1.00)=$33.65 T-Shirt per piece is
($33.65/12)= $2.81 Thus we make manufacturing price & negotiate this price with Buyer.
After negotiate price with buyer we receive order confirmation & L/C from buyer to execute
the order.
92
13.6 Consumption Preparation:
13.6.1 Fabric consumption:

The garments manufactured in many sizes to fit for everybody. Generally, they are in
sizes Small (S), Medium (M), Large (L), Extra-large (XL) and Double Extra Large
(XXL). The quantity ratio or assortment can be any one of the following approximate
ratio.
As the price is the same for all these sizes of garments, the author has taken the center size large
(L) for average calculation. Generally, the quantity of L size will be higher or equal to the
quantity of each of other sizes.
13.6.2 Men's Basic T-shirt

Description: Men's Basic T-shirt-short sleeves- 100% Cotton 140 GSM Single jersey - 1
x 1 ribs at neck - solid dyed - light, medium and dark colours in equal ratio.
Sizes: S, M, L, XL, XXL Ratio: 1: 2: 2: 2: 1
Export carton: 7 ply -120 GSM virgin corrugated - sea worthy. Cartons are to be
strapped with 2 nylon straps.
Measurements in cm: (Finished garment)
Size: L
Chest - 60 cm
Length - 78 cm
Sleeve length - 24 cm
Neck rib width - 3 cm Hem - 3 cm
Patterns are generally made with the seam allowance and cutting allowance. Generally,
12 cm is added with the total of body length and sleeve length.
That is,
Fabric consumption = (Body length + Sleeve length + allowance) * (Chest + allowance)
* 2 * GSM /10000
= (70 + 24 + 12) * (60 + 3) * 2 * 140/10000
= 187 grams
Body & Sleeves: 187 grams
Neck rib: 10 grams (approximately)
Gross weight: 197 grams Therefore, the fabric consumption per garment is 197 grams.
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13.6.3 Gross weight & net Weight:

The above weight is the gross weight of fabric. It means the weight of the fabric bits cut in
tubular form without taking shapes is called gross weight. This is the consumed fabric for
the particular garment. Hence costing is to be made as per this gross weight. The weight of
the cut pieces after taking the shape according to the pattern is called net weight of fabric.
Fabric cost per kg (in Rs) (all charges approximately):
Cost of fabric per kg is calculated and given in

Particulars Light colours Medium colours Dark colours
34's combed yarn Tk.135.00 Tk.135.00 Tk.135.00
Knitting charge Tk.8.00 Tk.8.00 Tk.8.00
Dyeing charge Tk.35.00 Tk.45.00 Tk.55.00
Compacting charge Tk.6.00 Tk.6.00 Tk.6.00
Fabric wastage @ 5% Tk.9.20 Tk.9.70 Tk.10.70
Fabric cost per kg Tk.193.20 Tk.203.70 Tk.224.70
Fabric consumption 197 gms 197 gms 197 gms

per garment
Fabric cost per Tk.38.06 Tk.40.13 Tk.44.27

garment
13.6.4 Cost of Trims:

The accessories which are attached to the garments are called Trims. Now the author have
taken Men's Basic T-shirts, as example. Let us see what are the trims required for this style.
Labels: Woven main label (2.5 cm width x 7 cm length): Tk 0.35
Polyester printed wash care label: Single colour print: Tk 0.10
Hang tag: Tk 0.40
So the total cost of trims is Tk 0.85 per garment.
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13.6.5 Cost of Accessories:
Polybags: Normal - Tk 0.30 per garment

Master Polybag: Tk 2 per master polybags to contain 8 garments - Tk 0.25 per garment.
Export carton: Normal: Tk. 40 per carton to contain 48 garments - Tk 0.80 per garment.
So the total cost of accessories is Tk 1.35 per garment.
Consumption calculation of fabrics, Accessories & cartoons Fabric consumption
calculation:
Body length = 73 cm.

Chest = 60cm.
Sleeve length = 22cm GSM = 220
2(B. L+S.L) * Chest * GSM
= 2(73+22) * 60 * 220 / 10000000
= 190 * 60 * 220 / 10000000
= 1.9 * .60 * .22
= 0.250 kg/pes *12
= 3.0096 kg/DZ + 10% (10% Wastage)
= 3.0096 kg/DZ +0.30
= 3.3096 kg/DZ Carton
13.7 Fabric Booking:
After receiving order confirmation from buyer merchandisers chase buyer to provide PO sheet
(purchase order) which includes colour & size wise break down of the total quantity.
Then they will go for denim/knit or the necessary fabrics booking. In case of knit, yarn is the
first element of knit fabric. So to make fabric they have to book suitable yarn from home or
abroad. To import yarn from abroad it need approx. 44/45 days and to buyer yarn from
Bangladesh it need approx. 20/30 days. After receive yarn we go for fabrics knitting and then
coloring of the fabrics. After dyed fabrics is ready to make garments. In case of denim the
process is same but some cases it fluctuates in terms of price.
95
14.8 Trim Booking:

After getting trim information from Buyer they have to develop the same to get approval. Then
they book trims from respective supplier to get cheaper price to minimize the cost. And, for
shipment process they need to store every trim in-house so that production cannot get hampered.
The all processes go parallel when an order is confirmed. When the size set sample is confirmed,
the processing of production starts.
96
CHAPTER: 14
COMPLIANCE
14.1 Compliance:
Compliance means conformity of certain standard.
Some contents of compliance with ILO and Bangladesh Labor Laws are given below:
• No child labors.
• No forced labor.
• Transport facilities of worker.
• Hours of work.
• Voluntary over time.
• Intervals for rest.
• Weekly holidays.
• Annual leave.
• Festival holidays & leaves with bonus.
• Maternity protection.
• Worker’s welfare committee.
• Mineral drinking water.
• Sanitary facilities.
• First aid box.
• Canteen services.
• Day care center.
• Health care activities for the worker & employ company doctor.
• Fire extinguisher each & every floor & conduct fire drill at least 12 times a
year.
97
• Other safety department (no discrimination)
• Compensation cases department.
• The development of compliance programmer.
• Environment developer.
• Smoking free zone.
• Disciplinary practices/Harassment.
• Freedom of association and right to collective bargaining.
• Welfare facilities.
14.2 Compliance of Apparels Village Ltd.

Here is a list of compliance in which some points maintained fully and some are partially.
• Compensative for holiday
• Leave with wages
• Health register
• Time care
• Accident register
• Workman register
• Equal remuneration
• National festival holiday
• Overtime register
• Labor welfare
• Weekly holiday
98
• Sexual harassment
• Child labor abolition policy
• Anti-discrimination policy
• Zero abasement policy
• Working hour policy
• Hiring/recruitment policy
• Environment policy
• Security policy
• Buyers code of conduct
• Health and safety committee
• Canteen
14.2.1 Health:
• Drinking water at least 4.5 1/days/employee
• Cup availability
• Drinking water supply
• Water cooler, heater available in canteen
• Drinking water sign in native language and English locate min

20 feet away from work place
• Drinking water vassal clean at once in a week
• Water reserve at least once a weak

99
14.2.2 Toilet:
• Separate toilet from women and men
• A set of proper policy and lock facility
• Urinal accommodation
• Effective water sewage system
• Toilet soap
• Water soap
• Dust bins
• Toilet while washed one in every four months
• Daily cleaning log sheet
• No-smoking signs
• Ladies/gents toilet signs both in native language and English
• Disposal of wastes and effluent.
14.2.3 Fire:
• Sufficient fire extinguisher and active
• Access are without hindrance
• Fire sign in both languages
• Photo of fire certified person
• Emergency exit
14.2.4 Safety Guard:

• Metal glows on good condition
• Rubber mats & ironers
• First trained employees

100
• Ironers wearing sleepers
• Motor/needle guard
• Eye guard
• Mask
• Nurse
• Doctor
• Medicine
• Medicine issuing register
• Welfare officer
• First aid box
14.3 Effluent Treatment Plant (ETP):

ETP is essential to purify the waste water which comes from different types of manufacturing
industry like textile, ternary, dyes and chemical manufacturing industry, pharmaceuticals etc.
Different environment saving organizations are trying to protect the environment from the
harmful effect of effluent.
14.3.1Effect of ETP on environment:

• Destroys the quantity of water body which effect in marine life.
• Harmful effect on sewerage handling system.
• Harmful effect on agriculture land.
• Dissolved solid accelerates algal growth.
• Dissolved solid cause disease & discomfort.
• Dissolved solid increases the hardness of water.
• Suspended solid increase the turbidity.
• Suspended solid interfere with the light transmitting property.
14.3.2 Standard of ETP for discharge to environment:

• pH : 5.5-9.0
• Temperature : Less than 40⁰C
• Suspended solid : Less than 100mg/Litre
• Dissolved solid : Less than 210mg/ Litre
101
• BOD : Less than 100mg/ Litre

• COD : Less than 250mg/ Litre
• Dissolved oxygen : Less than 5mg/ Litre
• Phenolic Compound : Less than 5mg/ Litre
• Chromium : Less than 2mg/ Litre
• Sulphide : Less than 2mg/ Litre
• Oil & Grease : Less than 10mg/ Litre
14.3.3Process sequence of ETP:

Main Inlet: Effluent from the dye house comes to the main inlet & before that primary filtration
is done. Primary filtration is done to remove the fabric fragment from the liquor. Net screen is
used to do this operation. In this stage pH of the water is quite high around 10 and temperature
is 35⁰C.
Chemical Mixing Tank: Then the effluent is transferred to the chemical mixing tank for the
correction of pH and to coagulate the dyes and other chemical that effluent keeps. Following
chemicals are commonly used in water treatment.
1. Lime powder: It is used to clarify the water. But correspondingly it
increases the pH of water.
2. Ferrous Sulphate: Function of Ferrous Sulphate is to lower the pH that is
to clarify the water increased by the lime powder.
3. Hydrochloric Acid: It is used to correct the pH from 10 to around 7.
4. Polymer: It is used to coagulate the chemical and produce sludge.
5. Anti-Foaming Agent: This agent reduces the foam through the treatment
Clarify Tank: Then the effluent is taken out from the chemical mixing tank to clarify tank.
Here sludge and water becomes separated. Water is taken to Aeration tank and sludge is taken
to Sludge tank.
Aeration Tank: Here water gets contact with some bacteria and dissolved solid is separated.
Tube Settler Tank: This tank is a special type of tank that contains a large number
of perforated tube. Water makes collusion with the tube and comparatively higher
weight molecule PPT and stick to the aid of the tube.
Less clear water Tank: Then the water is taken out from tube settler tank to less clean water
tank in order to filter it. Then this water is passed through two filter ARF (Activated Resign
Filter)/Sand filter and ACF (Activated Carbon Filter) one after another.
102
Treated Water Tank: Then the water is collected to the treated water tank and then this water
becomes ready to discharge.
Filter Vessel: It consists of a number of filters. Sludge are forced to run through the vessel and
then dried up.
Equalizer: Water treatment plant of Apparels Village ltd starts with Equalizer. Here fragment
of cloth are screened and removed. . In this stage pH of the water is quite high around 10 and
temperature is 35⁰C. DO is 2.3.
Storage and Homozinity Tank: All the effluents are taken out form the equalizer tank. Here
the homozygous mixtures of effluents are produced & stored. No chemical added here but only
air is blown.
Neutralization Tank: Effluent are taken from the previous tank and neutralized by
the addition of Sulphonic acid. After neutralization pH downs to 7.
Distribution Tank: The function of distribution tank is to distribute all the effluent to
Biological Oxidation tank.
Biological Oxidation Tank: Here some oxidative bacterial is used. Here dissolved
oxygen increases from 2.5 to 5.5. Here water loses his temperature.
Decoloring Tank: Discoloring chemical is to coagulate all the solid material and dyes.
Sedimentation Tank: Here sludge and water are separated. Water are taken out
and discharged to nature. Sludge is taken off to sludge return pump.
Sludge Return Pump: Residual water are taken off from sludge and sent to distributor.
Then sludge is transferred to Excess Sludge tank. Sludge is stored here before filtration.
Filtration: Sludge are filtered and dryed.

103
CHAPTER: 15
IMPACT ON INTERNSHIP
15.1 Definition:
• A structured work experience related to a student's major and/or career goal
• An experience that should enhance a student's academic, career, and personal
development
• Supervised by a professional in the field
• An experience that can be one academic term (summer, spring, fall) or multiple
academic terms in length
• Paid or unpaid, part-time or full-time
• An experience that is mutually agreed upon by the student, supervisor and/or faculty
member
• Meets registration requirements for 0 credit hour or academic internship course
• It’s important to note that to qualify as an internship the position does not have to be
labeled “internship”. Many part time jobs, volunteer opportunities, or even summer jobs can
qualify as an internship. Internships might also be called a practicum or co-op.
15.2 Benefits of an Internship:

Career Exploration
• Learn about a career field from the inside and decide if this is the right career field
• Work alongside a professional in chosen career area
• Observe the work place and see if it matches expectations
15.3 Leadership and Skill Development:

• Learn new skills and add to knowledge base while gaining confidence in abilities
• Opportunity to practice communication and teamwork skills
• Gain industry knowledge first hand from an organization and professionals
• Provide evidence that have initiative, are reliable, and have a sense of responsibility
• Apply some of the ideas learned in school and provide a bridge between school and the
professional world
• Achieve a sense of accomplishment by contributing to an organization
104
15.4 Networking and Establishing Mentors and References:

• Meet new people and practice networking skills while establishing a network of
professional contacts, mentors, and references
• Open to door to advice for the next steps to take on your career path
15.5 Resume Enhancements:

• Gain valuable experience and accomplishments to add to your resume and/or enhance your
application to Graduate School
• Create an advantage over other job or graduate school applicants Potential for a full time job
offer at the end of the internship based on performance
105
CHAPTER: 16
CONCLUSION
In conclusion I can say that this internship report is really essential for every student of business
studies to get idea about textile industry. By completing this report I have got overall idea of
RMG sector and these may be helpful to know about the technical and management knowledge
of garments industry also these sector related organizations. This is a huge sector and yet to
discover the whole.
I want to thank my department Head for giving me great opportunity of learning. This Internship
program will help me in the further challenges of life. I try my best to make this project enriched
with lots of apparel related documents. Apparels Village Ltd. is really a good experience for me
because every person of there so much helpful and give me the proper methods of practical
learning. So, at last, there is a hope of eradicating all the obstacles and become the leader of
garment industries in near future.

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BGMEA University of Fashion& Technology

This Internship Report Submitted in Partial Fulfillment of the requirements for

BGMEA University of Fashion& Technology

DECLARATION OF THE INDUSTRIAL TRAINING

Name: Srabonti Ghosh

Special thanks go to my enthusiastic supervisor , FARHANA AFROZ, assistant professor

Subject: Internship report on (APPARELS VILLAGE LIMITED)

3.4.2 Genaral manager………………………………………………………….13

4.14.7 Broken Needle……………………………………………………………34

6.11Recipe of Different stage in Dyeing: ................................................................... 52

8.2 Pattern types: ......................................................................................................... 62

CHAPTER: 13 MERCHANDISING SECTION ..................................................86-95

1.2Objectives of the study:

1.3 Scope of the Study:

2.1 Company Name:

Figure ure 2.1: Factory View from main gate

2.3 History Of the Factory:

2.3.1 Faiyaz Group

2.3.2 AVL & The Faiyaz

Company name Apparels Village Ltd.

Table 1.1: Company Profile of Apparels Village Ltd

2.5 Google Location of Apparels Village Ltd.

Figure ure 2.2:Location of Apparels Village Ltd Factory

2.6 Department of the factory

2.7 Main production

2.8 Number of Machine in this factory

2.9 Major Logo of buyer:

Figure :2.3 (a)woven buyer’s & (b)Knit buyer’s

2.10 Certifications & Achievements

Figure :2.4 Certification & Satisfied client

2.11 Company Focus:

2.12 Company Objectives:

2.13 Company Code of Conduct:

Workers are allowed to form Lawful Association.

➢ Harassment & Abuse:

2.14 Mission and Vision:

3.1 Manpower Organogram:

Chief Operation Officer Director

Manager Senior manager GM-Pdn DGM- Com. Quality Head

Knit Dyeing Factory work study Quality

Knit officer Production Cutting Finishing QA

Knit Floor in Cutting Finishing Quality

Supervisor and line Cutting poly. iron, packer,

Operator Cutter maker

Figure ure 3.1: Manpower Organogram of Apparels Village Ltd

3.2 Supporting Department:

3.3 Management Information System (MIS):

General shift 09:00 am– 05:00 pm

3.3.2 Order Flow Sequence:

Flow Chart 3.1: Oder Flow Sequence of Apparels Village Ltd.

3.4 Duties & Responsibility of Different Post:

3.4.1 Chef Executive officer (CEO)

• To set up price for the product.

• To plan apply and control all administrative functions.

• To follow up the instruction of managing director and chairman.

3.4.2 General manager (GM)

• To plan the sequence of production

• To arrange necessary raw materials for the production problems.