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Chapter: 1
Executive Summary
STANDARD|GROUP
1. Executive Summary
Actually industrial attachment is the practical experience for every Textile Engineer which is
needed to be familiar not only the industry but also all over the necessary job related to continue
in any industry. During student life a student cannot know about the practical condition so its
badly needed for every student for attain for the industrial attachment .Standard Group is truly an
excellent industry from my point of view. All types of modern technology are well arranged
here. Every section Specially Garment in here helps me so much by giving information during
my training period which was unbelievable. Standard Group is one of the largest Textile
industries in Bangladesh. It has the state of the machinery and follows modern mechanism for
production. It produces woven fabrics, so it is the leading Garments industry. Woven garments
are the latest addition in the list of commodities of Bangladesh. The foundation stone of the
Standard Group was laid on 1969. From the very beginning, it has maintained anon-
compromising position with its high quality. As a result, it has gained huge popularity in the
market. Due to increase of demand, company increases its capacity to provide the actual demand.
STANDARD|GROUP
Chapter: 2
Information about Factory
STANDARD|GROUP
2.1. Introduction:
Bangladesh is one of the leading readymade garments exporters of the world. Every year
Bangladesh exports more than one third of the total garments requirement of the RMG market of
the world. Every year Bangladesh earns more than 80% of its foreign currency from this sector
.That is why the study of garments technology does deserve well practical practice. So our
university provides 8 weeks industrial training in a RMG factory. As a student of garment
technology we have completed this industrial training in Standard Group Ltd. From garments
making to decorating garments. Standard Group Ltd. is a truly Exclusive fashion house that deals
with lots of stuff like fabric quality, garments quality, washing quality etc. The Garments
Division has the capability to offer a complete product range for the 100% export to UK & USA
market. The vision of the Garment Division is to become the preferred partner for sourcing high
quality value added garments from Bangladesh. With an urge to developing local human
resource, the Garments Division has the potential to make an important contribution to the
nations growing RMG export sector to make it more competitive.
Sewing and Finishing. Now days, Garments manufacturing part has become the largest
manpower utilizing industry in Standard Group.
In the year 2001, the group started their Hong Kong office as Standard Sourcing HK Ltd. To
have a better grip and control on quality level of materials.
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Standard group also made roaring step into Sweater manufacturing in the year 2004.
Standard group also established its Washing plant at Dhaka and Gazipur.
For backward linkage support, Standard Group established Garments Accessories, Printing,
Standard Group in specialized for all kinds of woven and sweater products for mens, womens
boys girls and kids
All garments items are exported to Europe, America and Canada for following Buyers:
Besides these, Standard Group has its diversified business in the arenas of banking, Insurance
and Real Estate, etc.
Since the inception , Standard Group is opening its business smoothly and contributing in
National economy and development, hence for Business support and quality product Standard
Group achieved various National and Export Award at different times.
The corporate office was formerly located at New Elephant Road, Dhaka, has now been Shifted
to its own 20- storied building named Civil Engineers Bhaban at 69, Mohakhali Commercial
Area, Dhaka, Bangladesh.
STANDARD|GROUP
Address:
Location of Garments: Civil Engineers Tower
Avenue Line, Sec: 12, Block: E, Kalshi,
Mirpur- 12, Dhala-1216
2.8 Organogram:
Organogram of Management:
ADMISTRATION
DIRECTOR
PERSONAL PRINCIPAL
TIME SECURITY MECHANICAL ELECTRICAL
INCHARGE
AGM AGM
SECURITY
SUPERVISOR
PRODUCTION
DIRECTOR
PRODUCTION AGM AGM AGM WORK STUDY
b) Garments Section
Fabric Inspection
BC section
Sample section
CAD section
Pattern and Marker section
Cutting section
Printing section
Embroidery section
QA Section
Sewing section
IE Dept.
Washing
Finishing section
c)Maintenance section
Electrical
Mechanical
d) Store section
e)Administration section
f) Security Section
g)Marketing Section
g) Compliance
STANDARD|GROUP
Mens Pants
Ladies Pants
Kids Pants
Shorts
Basic pants
Long pants
Tops
The company is one of the pioneers in employing the latest technologies for top wear, including
shirts for men, women, and kids/children. The types of Woven Top Wears we manufacture
include:
Casual Shirt
Top Wear
Dress Shirt
Flannel Shirt
Outerwear
Standard Group started in 1984 making outer wear. As a result, the company has embedded in its
capability to produce various types of outer wear. Our production teams have become outer wear
experts with all the experience gained over the years.
Basic Jacket
Basic Lined Jacket
Bomber Jacket
Down Jacket
Function Jacket
Padded Jacket
Woven Pullover
Sealed Jacket
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Sun dress
Woven vest
Denim outer wear
Sports Pants
Sports Jackets
Sports Jersey
Promotional Jersey
Nylon and Wool Award Jackets
Corduroy Jackets
Twill Poplin Jackets
Supplex Jackets
Satin Jackets
Action Fleece Jackets
Sports Sweats
Swim Parkas
Band Parkas
Warm-Up Suits
Inner wear
Inner wear is all about comfort and Standard Group uses the finest production techniques and
sources the most comfortable materials to ensure the products satisfy all needs. Standard Group
has been producing various types of inner wear for many years now.
Overall wear
Overall wear has been the major garment for kids and men at work. Standard Group uses a
variety of technologies to ensure that the production of overalls maintains top quality.
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Body
Full Body
Work wear
Gap
Sears
Khols
Fila
Kids Us
Mountain Gear
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Wrangler
Sean John
Gymboree
Jc Penney
Perry Ellis
In Canada
Jacob
London Fog
Pacific Trails
In E.U
Marks Spencer
H&M
Espirit
Rip Curl
Celio
Charles Vogele
Zara
Tom Tailor
Mexx
The Stadium
Georeg Clothing
Mackays
Dunnes Store
STANDARD|GROUP
Quebrama Oxbow
C&A
Vision:
To satisfy buyer & customer expectation by developing & producing products which offer value
in terms of quality, price etc.
STANDARD|GROUP
Chapter: 3
Description of the Attachment
STANDARD|GROUP
10-Point System.
Graniteville "78" system.
Dallas system.
4- Point system.
STANDARD|GROUP
4-Point System:
The 4-Point System, also called the American Apparel Manufacturers (AAMA) point-grading
system for determining fabric quality, is widely used by producers of apparel fabrics and is
endorsed by the AAMA as well as the ASQC (American Society or Quality Control).
The 4-Point System assigns 1, 2, 3 and 4 penalty points according to the size and significance of
the defect. No more than 4 penalty points can be assigned for any single defect. Defect can be in
either length or width direction, the system remains the same. Only major defects are considered.
No penalty points are assigned to minor defects.
In this system, one should inspect at least 10 per cent of the total rolls in the shipment and make
sure to select at least one roll of each colour way.
Total defect points per 100 square yards of fabric are calculated and the acceptance criteria is
generally not more than 40 penalty points. Fabric rolls containing more than 40 points are
considered "seconds".
The formula to calculate penalty points per 100 square yards is given by:
No more than 4 penalty points can be assigned for any single defect.
The fabric is graded regardless of the end-product.
This system makes no provision for the probability of minor defects.
4 point system is most widely used system in apparel industry as it is easy to teach and
learn.
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Merchandiser is a person who interacts with the buyer and seller, and also puts efforts into
proper relation between buying offices/ buying agents/ agency and seller/ exporter in terms of
executing an order.
Before calculate the woven fabric consumption, you must need the followings information as
mentioned below:
Here,
Length = length of the specific parts + allowance
Sewing thread is required for seam sewing/assembling, over locking, various types of stitching,
buttonholing, label attachment etc. Clear conception in sewing thread consumption calculation of
garments is essential for a merchandiser to estimate the total number of cones required for a
specific order and to purchase the sewing thread accordingly.
Garments trims and accessories means all the items used in the garment except the main raw
material (Fabric). There are hundreds of items used to manufacture the garments, which are used
as trims and accessories. A list of few important trims and accessories mentioned here.
Ring button
Shank button
Eyelet button
Rivet button
Interlining It is used in
collar/ cuffs/
front placket and
waist band etc
Padding It is used in
padding jacket
Care Label
Size label
Hanger To hang
garments
Price sticker
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Name of Item Type of Item Quantity Unit Price/ Rate Total (Taka)
Commission = TK. 6
Costing....................................................................Send to Buyer
Approved Sample
Production Pattern ( By Hand or Computer )
Design or Sketch:
It is nothing but one kind of engineering art including all measurement of particular style.
Basic Block:
It is an individual component of garments without any design or style.
Working Pattern:
To make pattern for a particular style with net dimension.
Sample Garments:
The garments which is needed for bulk production, is called sample garments.
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Approved Sample:
The sample which is approved by buyer is called approved sample.
Send to Buyer:
When all process are done, then the garments are sent to buyer.
Production Pattern:
To make pattern for a particular style with net dimension along with allowance.
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Working Pattern: The pattern which is used to make sample garment that is called
working pattern.
Production Pattern: The pattern which is used for bulk production that is called
production pattern.
The following tools & equipments are used for pattern construction:
Working surface
Paper
Pencils
Marker pen
French curves
Compass
Set square
Scissors
Measuring tape
Rubber, scale, scotch tape
3.4.3 CAD:
The full meaning of CAD is Computer Aided Design. The marking is done by helping of
computer. So it is names as Computer Aided Design (CAD).
Receive Patterns
After developing pattern, pattern master decreases or increases master pattern stepwise, it is
called pattern grading. Like this:
S M L XL
Before making a sample pattern making according to sketch and measurement or directly from
sample is a very important. The construction of pattern is done by two methods like:
3.4.8 Marker:
Marker is a large thin paper which contents the required pattern pieces of various sizes for a
particular style of apparel. This marker making is an important task because it determines the
efficiency of a marker. Marker making is the next step of pattern grading.
Various objectives are gained by maker making. Followings are the objectives of marker
making.
It is the ratio between the area covered by pattern pieces and the total area of marker paper. It is
expressed by %. Mathematically,
Marker Efficiency : (Area covered by pattern pieces / Total area of marker paper) X 100
Manual method
Computerized method
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3.5.1Types of Cutting:
Fully manual:
Straight knife
Band knife
Round knife
Die cutting
Notcher
Drill
C.Q.I (Embroidery)
Marker Making
Fabric Spreading
Placing Marker Paper on to the Lay
Fabric Cutting
Numbering
100% checking & Parts Replacing if needed.
Shorting & Bundling
Sewing/Assembling
2. Stepped spreads- this as the name suggests, is built up in steps, with all the plies in one step
having the same length. A stepped spread is generally used when the quantities to be cut
precludes the use of a flat spread. The cut order plan details the colors and ply lengths for a
stepped spread, if it is needed.
1. Alignment of plies in both length and width direction- length and width of fabric must be at
least equal to marker length and width.
2. Elimination of fabric defects/flaws- any faults identified on the incoming fabrics will be
tagged and will be avoided.
3. Correct ply direction (especially for asymmetrically printed fabrics)- all faces up, all faces
down, face to face etc.
4. Correct ply tension- ply tension must be uniform and as much less as possible.
5. Avoidance of distortion in the spread during cutting- polythene sheets are used under the
bottom ply to resist friction of the bottom ply with the base plate of the knife.
6. Fabrics must be flat and free from any crinkle & crease- these cause defect in garments
due to variation in dimension.
Not enough plies to cover quantity of garments required. Plies misaligned, resulting in garment
parts getting cut with bits missing in some plies at the edge of the spread. Narrow fabric, causes
garment parts at the edge of the lay getting cut with bits missing. Incorrect tension of plies, i.e.
fabric spread too tight or too loose. This will result in parts not fitting in sewing, and finished
garments not meeting size tolerances.
CAD section making marker as per given fabric roll measurement. Before plot the marker lay
length must be measured and checked by supervisor. As per marker requisition, plot marker
supply to the table supervisor. On the table marker length, width checked by consumption
checked supervisor. After lay cuter man checked the mini marker and lay marker like job, style,
buyer, then cutting. At the time of cutting cuter man must careful when cut critical shape, half
fold, notch, apart and others issue and signature on docket.
3.5.10 Sorting/Bundling:
The sorter sorts the patterns according to size and design and makes bundles of them. This step
requires much precision because making bundles of mismatched patterns can create severe
problems. On each bundle there are specifications of the style size and the marker too is attached
with it.
3.5.11 Sewing/Assembling:
The sorted bundles of fabrics are now ready to be stitched. Large garment manufacturers have their own
sewing units other use to give the fabrics on contract to other contractors. Stitching in-house is preferable
because one can maintain quality control during the processing.
Figure: Embroidery
After receive the garments components from cutting section, all the garments parts are joined
and sewn as sequentially. Obviously all the components are sewn respects on buyer requirement.
Sewing section is the most important department of a garment manufacturing industry. Sewing
machines of different types are arranged as a vertical line to assemble the garments. Sequence of
types of sewing machine arrangement depends on sequence of assembling operations.
A list of sewing machines which is used in apparel manufacturing and their application area-
1. Lock stitch/Plain/Regular sewing machine: This type of machines is used for all types
of garments.
2. Two needle lock stitch machine: This type of machines are used for decorative purpose.
It is used specially for sew woven fabric.
3. Chain stitch machine: It is used for sew both knit and woven fabric.
4. Double chain stitch machine: It also used for both knit and woven fabric sewing.
5. Over lock machine: It is used for knit and woven fabric sewing. In shirt over lock is
used in side seam, arm hole and sleeve.
6. Safety stitch over lock machine: It is used for give safety sewing in side seam, arm hole
and sleeve of a shirt. Knit and woven fabric both can be sewing by this machine.
7. Flat lock machine: flat lock machine is used for covering chain stitch. Flat lock is must
for producing knit wear. Bottom hole is produced by this machine.
8. Feed off the arm or Flat seamer with cylinder bed: It is used specially for the sleeve
inseam joining and inside seam joining of the pant.
9. Button hole machine: this machine is used for make hole in the apparel.
10. Button sewing machine: this machine is used for sew the button with the apparel.
11. Bar tack machine: Bar tack machine is mainly used in pant for belt loop joining, pocket
corner and zipper fly.
12. Blind stitch machine: This machine is used for special purpose. It is used for sew
bottom hem of the pant.
13. Kansai special machine: For special purpose this machine is used. Front flacket and
waist band of pant is sewing by this type of machine. Also this is a two needle machine
but distance between two needles will be 0.5 to 2.50 inch.
STANDARD|GROUP
GM Production
Production manager
Floor In Charge
Line Chief
Supervisor
Operator
Helper
Bent needle
Wrong needle point
Improper needle adjust
o Unbalanced stitch (If bobbin thread dose not work, it produces hole & forms this stitch)
Causes:
Improper unwinding
Higher thread tension
Excess heating
Lower quality thread
2) Seam pucker : It is caused for five purposes as follows _
Unequal stitch on fabric due to limitation of feed m/c
Fabric dimensional stability due to unequal shrinkage of one ply then other for washing
Extension of sewing thread due to tension
Sewing thread shrinkage after washing or ironing
STANDARD|GROUP
Example:
Here,
SMV = 17
Produced garments = 920 pcs
Working hrs = 8 hrs
Manpower = 45 persons
Efficiency =?
Available min = 45 8 60
= 21600
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Technical Advisor
Washing Manager
Washing & Dyeing Manager
Asst Dyeing Manager
Asst Washing In-charge
Shift In-charge
Machine Operator
Helper
Shade segregation
Dyeing
Dryer
Inspection
Washing
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Dryer
Grinding
Softening( wash/Dry)
Inspection
Delivery
By the washing technique, faded/old look, color or tinted affect is created in the garments
which also seem the best touch of garments.
Washing technique creates new fashion such as tagging, grinding, destroy, Blasting,
whickering, permanent wrinkle, deep dye, tie dye, P. P spray, handcrapping, P.P
sponging etc. This also seems the best touch of garments.
The main and important function of washing is to reduce size materials as a result the
garment become size free and become soft hand feel.
When these soft garments are touched then it seems to best touch of garments.
Any dirt, spot or germ if added in the garments during manufacturing is also removed due
to washing
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Sand Blasting
Hand Scraping
Permanent wrinkle
P.P Spray
P.P Sponging
Pigment wash
Caustic wash
Enzyme wash
Stone wash
Acid wash
Silicon wash
Dip Dyeing
Boiler
Submersible Pump
Grinding Machine
Tagging Machine
Generator
Screw compressor
STANDARD|GROUP
Acetic Acid
Detergent
Antistain
Bleaching powder
Sodium hyposulfite
Caustic Soda
Soda Ash
Sodium Bicarbonate
Potassium permanganate
Buffer
Hydrogen peroxide
Stabilizer
Fixing agent
Catanizer
Optical Brightner
Resin
Sodium Metabisulphite
Desizing agent
STANDARD|GROUP
Whisker
To make whisker first, Buyers given design is plotted on a tracing paper. Then from the tracing
paper the design is transferred to the ply-wood or gas kit. The next step is to place foam rubber
according to the design on ply wood with the help of solution gum. Finally, the upper surface of
the rubber is grinded to a slope or spherical shape and the whisker pattern is prepared. Now this
pattern is entered through the front opening of the pant and rubbing is done by emery paper at
320 ppm to 500 ppm. Thus the effect produced on the pant is called whisker.
Figure: Whiskering
Wrinkle
The process is one kind of resin finishing process. In this process of applying resin on textile
materials, resin form cross-linking inside the amorphous region and block the free hydroxyl (-
OH) group and prevent hydrogen bond formation and thus improve wrinkle free finishing.
Mainly it is applied on twill fabric, single jersey and denim fabric.
STANDARD|GROUP
Figure: Wrinkle
Normal Wash:
Process in which heavy or slight soiling is removed and transferred to the water in the form of a solution
or dispersion. Washing has the effect of cleaning surfaces. The resulting effect is several physical/
chemical processes (Washing process). Washing and cleaning constitute a complex process, during which
soiling is removed by means of physical separation, with or without substance conversion, from a
substrate
Enzyme Wash:
Enzyme Wash is usually done on the garments made of heavy fabric like denim. For Enzyme
Wash we must use cellulose enzyme. The cellulose enzyme hydrolyses the
projecting hairy cotton fabrics on the fabric surface and also removes colors.
Bleach Wash:
Bleach wash or light stone wash refers to light blue shades of denim. The additional step is
bleaching to stone wash. This bleaching is usually carried out by strong oxidizing agents. In
industry, most widely used chemicals are sodium hypo-chlorite, calcium hypo-chlorite, hydrogen
per oxide and potassium permangate.
Acid Wash:
During Acid wash, pumic stones are used. By the action of pumic stones, irregular fading affect
is developed on the heavy garments like denims, thick canvas/twill, and sweater. The pumic
stones act a brushing action on the garment fabric surface. The area where more brushing action
takes place there more dicolour or fadding affect is developed and the area where less brushing
action takes place less brushing action and takes place less fadding affect will be developed. The
multi-layer fabric areas like collar, calf, pocket, placket, side seam etc area will be brushed
more than the single layer areas. As a result irregular fadding affect will be developed on the
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garments fabric surface. Thus in this way fading affect may be developed on the garment by acid
wash technique.
Stone wash:
Stone washing is a textile manufacturing process used to give a newly manufactured cloth
garment a worn-in (or worn-out) appearance. Stone-washing also helps to increase the softness
and flexibility of otherwise stiff and rigid fabrics such as canvas and denim.
The process uses large stones to roughen up the fabric being processed. The garments are placed
in a large horizontal industrial clothes washer that is also filled with large stones. As the wash
cylinder rotates, the cloth fibers are repeatedly pounded and beaten as the tumbling stones ride
up the paddles inside the drum and fall back down onto the fabric.
3.8.10 Process of Enzyme wash for twill skirt: Qty: 250 pcs
Process Chemicals Qty (gm) Temp Time(min) Water Rmks
1. Desizing
2. H. peroxide
Desizing 3. Caustic
4. Softener
5. Anti staining
Rinse Water By two times
1. Acetic acid 100 gm
2. Enzyme 1500 gm
Enzyme 3. Anti Stain 1000 gm 50 65 400 ltr
1st 4. Stone
Dyeing
10 g KMnO4 in 1 liter
0r + Lubricant 1%
5 g KMnO4 in 1 liter
Some finishing techniques such as bleaching and dyeing are applied to yarn before it is woven
while others are applied to the grey cloth directly after it is woven or knitted. Some finishing
techniques, such as fulling, have been in use with hand-weaving for centuries; others, such as
mercerization, are byproducts of the Industrial Revolution.
GM Production
Finishing Manager
Finishing In Charge
Finishing Supervisor
Finishing Helper
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Finishing input (style, color & size wise)
Initial quality check
Spot Removing
Ironing/Pressing
Inspection
Hang tag
Get up change
Folding
Poly
Bar code (buyer wise sticker)
Metal check
Cartooning/Packaging
Final inspection by buyer
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Pressing
Pressing is a finishing process done by a cloth to heat and pressure with or without steam to
remove creases and to impart a flat appearance to the cloth or garments. In garment industries
pressing is also called ironing. After completing pressing the garments have to be folded.
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Figure: Pressing
Folding
After completing pressing, the garments are folded with a predetermine area. Garments are
folded according to the buyers direction, requirements in a standard area.
Figure: Folding
Folding classification depends on the fabric types. There are mainly four types of folding. They
are
Semi stand up: Collar is folded with body and situated at 45 degree angle.
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Packing
After folding, garments are packing the size of polythene packet is permanent. Specially, it is
needed to ensure the placement of sticker in proper place.
Figure: Packing
Barcode
Barcode is a specially Buyer wise sticker.
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Figure: Barcode
Assortment:
After completing the packing of garments, it must be placed the garments in a predetermined
pack by sorting according to the size and color then garments are packed into inner box
according to the size and color. This process working in order is called assortment.
Figure: Assortment
Metal Check:
Checking the metal type component into the garments or with its accessories like button, zipper
etc. is called metal check.
Cartooning:
At last cartooning or packing the garments according to Buyer comment. The process of packing
of inner boxes entered into the carton is called cartooning. The carton is properly warped by the
scotch tape. Some information like carton box no, size, shipping mark and the destination are
printed on the carton.
Figure: Cartooning
Final inspection:
Final inspection is made by buyer. He checks the garments according some rules like AQL.
Spot Removing:
Spot removing is one of the special inspections which are done after initial quality check.
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3.10 IE Section:
Industrial engineering is a branch of engineering which deals with the optimization of complex
processes or systems. It is concerned with the development, improvement, implementation and
evaluation of integrated systems of people, money, knowledge, information, equipment, energy,
materials, analysis and synthesis, as well as the mathematical, physical and social sciences
together with the principles and methods of engineering design to specify, predict, and evaluate
the results to be obtained from such systems or processes.
1. Planning layouts
2. Monitoring Production flow system
3. Deicide the machines and attachments for all style
4. Pay system
5. Monitoring and improve the operator performance
6. Operator training
7. Production control system
8. Quality control
9. Others
Capacity Study:
It is exactly the measure of the operator same as capability. It means the operator is capable of
achieving the performance measured by the study. The major Need for capacity study is to set
Quotas, to motivate operator, and to measure the productions section capacity. By measuring the
individual operator capacities, supervisor can determine the overall capacity of their section. It is
simply the some of individual capacity.
1. Check targets
2. Motivate operators
3. Measure section production capability
Work Study:
It is a scientific method which ensures measurement of work content of a job & takes recourse to
better method of doing it & thus realizes the best utilization of human, machinery & other
resources of an organization.
Work measurement:
Work measurement is the technique designed to set up time required by a qualified worker to
accomplish a task at a define rate of working. This technique is used to standard time.
Types of PMTS:
1. G.S.D
2. Sew easy
Method study:
Method study is the systematic recording & critical analysis of ways of doing a job so as to make
improvements it analyzes how a work is being done currently to find out ways to improve so that
productivity increases. Method study discovers suitable and easier method of work so that the
task can be completed quickly.
Time study:
To determine the time it should take for a qualified worker to perform a specific task using a
specific method by directly observing an operator.
Time Study
Time study
SMV
Skill Effort
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SMV:
One of the tasks done by the IE department is to calculate the time taken to make a specific
garment. This is usually called a SAM ( Standard Allowed Minute ), although some factories call
this the Standard Minute Value (SMV).
SAM (or SMV) means the time (in minutes) that it takes a worker to complete a specific
operation or produce a specific garment. The SAM is often calculated by using a stopwatch.
Sometimes its done by looking at a special table of times that have already been calculated, for
every task needed to make a garment.
Calculation of SMV:
SMV = basic time + (basic time * allowance)
Basic time = observed time * rating
Observed time = total cycle time / no of cycle
If time for sewing a side seam of a T-shirt is 20, 20, 18, 22 and 20 seconds
3.10.5 Lean:
Lean is a Culture which ensures a beautiful and suitable environment of work. Under Lean
culture, working equipments must be well arranged, Working place must be clean, all the
workers and staffs must be disciplined and production of products is carried out following a
definite plan.
Lean is the systematic approach to identify and eliminate waste through continuous
improvement by flowing the product or service.
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Principle 1: Accurately specify value from customer perspective for both products and
services.
Principle 2: Identify the value stream for products and services and remove non-value
adding waste along the value stream.
Principle 3: Make the product and services flow without interruption across the value
stream.
Principle 4: Authorize production of products and services based on the pull by the
customer.
After Lean
3.10.8 5s system:
5 S Is a systematic 5 step method of organizing a work place / home or a school.
Objectives of 5s:
To reduce wasted effort
To reduce wasted time
To reduce wasted money
To reduce accidents
To reduce stress
To improve customer services
5s can be applied
In Homes
In Schools
In Offices
In Factories
In Hospitals
In Work-sites
In Military Establishments
In Fact anywhere
3.11Quality Assurance:
Quality Assurance refers to administrative and procedural activities implemented in a quality
system so that requirements and goals for a product, service or activity will be fulfilled. It is the
systematic measurement, comparison with a standard, monitoring of processes and an associated
feedback loop that confers error prevention. This can be contrasted with quality control, which is
focused on process output.
Customer satisfaction, and therefore, customer loyalty and repeat business and referral;
Timely registration of drugs by eliminating waste and the need for rework;
Operational results such as revenue, profitability, market share and export opportunities;
Alignment of processes with achievement of better results;
Understanding and motivation of employees toward the Company quality policy and
business objectives, as well as participation in continual quality improvement initiatives;
and
Confidence of interested parties in the effectiveness and efficiency of the Company as
demonstrated by the financial and social gains from Company performance and
reputation.
1) After production of fabric rolls of 8 to 25 kg, m/c operators cut them from the cloth
or batch roller and they are carried to inspection section by the helpers.
2) Almost four inspection workers are for every shift to check the fabric rolls. For any
kind of fault they are checked thoroughly. Skilled inspectors find them and indicate them by the
scissors in some cases.
3) Quality is specified on the basis of 4-points system. Here is the point distribution for
different kinds fault in this system:-
STANDARD|GROUP
Up to 3 in length: 1 Pt
Up to 6 in length: 2
Up to 9 in length: 3
Up to 9 in length: 4
Quality Pts / per 100 square meter= (Total point * GSM)/ (Roll weight*10)
Quality inspectors seal on the fabric rolls as CHECK-1, OK & REJECT as according as
quality classification.
/ =
1 2 3
<20 20-30 30>
OK ASK REJECT
STANDARD|GROUP
Example:
3.11.5 Following table shows common body faults and response by grey
inspection section
Visual inspection
during spreading Bias check Shrinkage test
Measurement
Final inspection before
Metal/ Needle check after
packing
check ironing
STANDARD|GROUP
AQL 2.5 4
Lot size Units to be inspect Acceptable Units to be inspect Acceptable
26-90 3 0 4 1
91-280 13 0 13 1
281-500 20 1 20 2
501-1200 32 2 32 3
1201-3200 50 3 50 5
3201-10000 80 5 80 7
10001-35000 125 7 125 10
35001-150000 200 10 200 14
150001-500000 315 14 315 21
500001-Over 500 21 315 21
STANDARD|GROUP
3.12 Labtex:
LabTEX Services is the first 3rd party local textile testing company in Bangladesh to achieve
ISO/IEC 17025:2005 certification. LabTEX started its commercial operation in September, 2005
to give quick, premium, and reliable laboratory and testing support to the various needs of
apparel and textile exporting companies in Bangladesh. Main services are testing garments,
fabrics, and accessories in accordance with different international standards. It also provide
technical consultancy for improving product quality, Quality assurance training for garments,
fabrics and accessories, as well as organize technical seminars.
Its goal is to provide total satisfaction to our customers, through quality services and
maintaining complete security, confidentiality, and integrity of test results.
Its services include testing of garments, fabrics and accessories in accordance with different
international standards such as AATCC, ASTM, BSI, etc. We provide technical consultancy to
customers for improving product quality, as well as, conduct quality assurance training and
organize technical seminars.
Facilities:
ISO/IEC 17025: 2005 certified.
Over 6,000 Square Feet.
Frequent correlation program with ITS, Bureau Veritas, SGS, etc.
Lead in Substrate (XRF Screening Method), Munsell Hue & Ishihara test.
Yearly calibration and regular maintenance by certified technical persons.
1. Loading/ Unloading
2. Raw material stocks
3. Finished goods stocks.
Pre inspection
Physical inventory
Inspection
There is a different time for dyes & chemicals various types of dyes & chemicals are stored here
according to the dyes & chemical company.
Different types of dyes & chemicals are listed in a sheet. In the sheet the stored quantity of dyes
& chemicals are also included. Every day the sheet is updated & a copy of this sheet is supplied
to the AGM (production), Dye house & lab section.
Spares
In Standard Group required amount of spares of different machines are stored in the
mechanical store room. All the spares are listed in a sheet which is controlled by the mechanical
& maintenance personnel. Spares are arranged in the store room according to there size, quantity
& requirements. There are shelves in the store room to keep the small spare parts.
Finished goods
Standard Group supplies its finished dyed fabrics to its garments section. So, dyed finished fabrics
are stored for short time in the finishing section. All the delivered fabrics are noted on the tally
khata according to the lot no, quantity, fabrics diameter, buyers name, color & considering other
technical parameters.
Others
There is a central store at Standard Group In that store the various types of forms, papers; stationary &
other necessary goods are kept.
STANDARD|GROUP
Standard Group is always welcoming in new international standards and compliances measures
set by International Agencies as well as our customers. Standard Group maintains a professional
culture that abides by an ethics, employee standards, industry standards, and legal compliances.
Our business growth is directly transformed into reality within these compliances.
Safety Compliance
Standard Group follows rigorous safety compliance for the safety of all our employees as well as
for the safeguard of company resources. Standard Group prioritizes safety as a major concern.
These safety regulations include fire safety, movement, worker health and safety and various
others
Legal Compliances
Standard Group strictly maintains the legal compliances set by the Government of Bangladesh as
well as the demanding compliances set by our customers throughout the world.
.
Working environment
According to present world & demand of the buyer Standard Group has good environment policy
for their work. Following are the areas being gives to priority to ensure the provision of conduct
working environment.
Safety condition
Garments industry is playing a pioneer role in a industrial fire of the country. In garments
industry most of the fire accidents take place due to electrical short circuit results from defective
electrical wiring design and system, inadequate fire protection & safety system, lack of
awareness of the worker and management.
All machines and equipments should be set very carefully. Use the machine guard.
Goods keeping
All goods should be kept systematically in the store so that anybody can walk without
any risk. There should be 3 to 4 distance from rack to rack.
In the cutting machine there should be sufficient electricity and wearing should be good. No
machine should be set in the factory which is hazards for health.
Fire protection
There should be lot of fire protection equipment according to the instruction of fire service &
civil defense. Fire protection & exit layout of floor is posted at highly visible area of respective
floor. All emergency exit doors are able to be opened form the direction of exit travel without the
use of a key or any special knowledge or effort. Floor should have the fire alarm.
STANDARD|GROUP
Auto system
Factory has audio system so that any emergency announcement could be given in the audio
system. These are the policy this factory is applying for the safety condition. So we can say that
it is a well organized factory.
Whenever darts & refuges are accumulated, these are seeped by the cleaner at once, from the
floor and passages.
The factory profile is equipped with sufficient number of ceiling fans. South and east side of the
floor surrounded by the wider window which provides proper ventilation & circulation of the
fresh air.
Glass fitted water windows are available which provide enough natural light as south side is
being obstructed.
Medical facilities
Company has their own medical section with doctor to serve the employee of the factory.
Factory has a day care centre for his workers kids. The company is very much aware of and
maintaining the needs of buyer, worker management.
Brand new mosquito nets are provided to employees to protect employees from harmful
disease like Malaria and Dengue.
We help the community by providing free manufacturing skill training around various
parts of the nation.
Providing financial services to the community.
Educational loans and medical loans are provided to the community.
Collection Tank
Storage Tank
Mixing & Cooling
Neutralization
Chemical Coagulation
Biological Oxidation Tank
Sedimentation & Separation of Sludge
Sludge Thickener
Filtration
Discharge to Drain
STANDARD|GROUP
Where,
3.17 Utility
3.17.1 Boiler:
Figure: Boiler
Boiler Specification
Boiler: 01
Types of boiler : Manufacturer
Capacity of the boiler : 10 ton/ hour
Source of the foul : Directly gas used
Gas consumption : 345 m3/shift
Rating : Min 8000 Max 8500 KW
Supply process : Min-15 Max-500 m bar
Control voltage : 230 V
Main volt : 400 V
Electric rating : 2389 KW
Type of burner : G70/ 2-A
Safety valve set : 10.5 kg
Manufacturer : LOSS INTERNATIONAL (GERMANY)
Boiler: 02
Types of boiler : Fire tube boiler
Capacity of the boiler : 8 ton/ hour
Source of the foul : Directly gas used
Gas consumption : 280 m3/shift
Rating : Min 8000 Max 8500 KW
STANDARD|GROUP
Supply process : Min-15 Max-500 m bar
Control voltage : 230 V
Main volt : 400 V
Electric rating : 2389 KW
Type of burner : G70/ 2-A
Safety valve set : 8.5 kg
Manufacturer : LOSS INTERNATIONAL (GERMANY)
3.17.2 Generator:
Figure: Generator
Generator Specification
Generator: 01
Type : Gas Generator
Brand Name : CATERPILLAR
Quantity : 2 Pieces
Origin :USA
Model No : G- 3516
Rated Power : 1287KVA
Frequency : 50 Hz
Engine R P M : 1500
Voltage : 400 Volts
Power Factor : 0.8
Water Temperature : 94 C
Mobile Pressure : 55 P S I
Gas Pressure : 10 P S I
STANDARD|GROUP
Generator: 02
Type : Gas Generator
Brand Name : Guascor
Quantity : 2 Pieces
Origin :USA
Model No : GU- 05246
Rated Power : 1190 KVA
Frequency : 50 Hz
Engine R P M : 1500
Voltage : 350 Volts
Power Factor : 0.8
Water Temperature : 87 C
Mobile Pressure : 55 P S I
Gas Pressure : 10 P S I
Generator: 03
Type : Diesel Generator
Brand Name : CATERPILLAR
Quantity : 3 Pieces
Origin :USA
Model No : 650-F
Rated Power : 591 KVA
Frequency : 50 Hz
Engine R P M : 1500
Voltage : 415/ 240 Volts
Power Factor : 0.8
Phase :3
Rated Current : 822.2 A
Water Temperature : 25 C
Generator: 04
Generator: 05
Generator: 06
Machine No: 01
Model : E15-8, 5
Manufacturing Year : 2009
Motor : 15 KW
Capacity : 2, 27 M/ min
Rated Pr. : 8 kg/ cm
Quantity : 1 Piece
Machine No: 02
Model : E45-7, 5
Manufacturing Year : 2005
Motor : 45 kw
Capacity : 7, 561 M/ min
Rated Pr. : 7 kg/ cm
Quantity : 3 Pieces
STANDARD|GROUP
Machine No: 03
Model : E75-8
Manufacturing Year : 2008
Motor : 75 kw
Capacity : 13, 81 M/ min
Rated Pr. : 7 kg/ cm
Quantity : 5 Pieces
STANDARD|GROUP
Chapter: 4
Impact of Internship
STANDARD|GROUP
4. Impact of Internship
4.1 Garments Cutting Section:
I have acquainted Layout of Cutting Section.
I have learned Different types of marker.
I have acquainted of Fabric Spreading.
I have learned how to operate Cutting and numbering machine.
I have learned of Sewing thread consumption.
4.4 Store:
Chapter: 5
Conclusion
STANDARD|GROUP
5. Conclusion
Bangladesh is a developing nation. RMG Sector earns the Prime share of our foreign currency.
Development of this sector will definitely bring good fortune for our country. We being the
graduates of Textile Engineering must give our sincere effort to the future advancement of RMG
and related sector. Moreover from 1 January 2005, we will enter into the quota free world where
quality, less lead-time and low price will be the key to success. Standard Group being one of the
leading manufacturers of RMG gave us the opportunity to undergo two months of Industrial
training there which was extremely beneficial for us. Because no knowledge specially one like
Textile Engineering cannot be fulfilled without practical experience. It gives us the excellent
opportunity to combine our theoretical knowledge with the practical knowledge. Use of modern
equipments in manufacturing looking after the welfare of the workers, good management is the
key to success of a company which are well maintained in Standard Group. We sincerely hope
that this experience will give us the confidence required to apply our skill to boast this sector.