Industrial attachment of sea moss knitwear ltd

INDUSTRIAL TRAINING
Course Code: Tex
-4036


INDUSTRIAL ATTACHMENT OF
SEA MOSS KNITWEAR LTD.

At a glance SEA MOSS KNITWEAR LTD.
Name of the factory : SEA MOSS KNITWEAR LTD
Year of Establishment : 2004
Status (Legal Structure) : Private Limited Company
Export Market : Europe
Sales Turnover : 22 Million USD
Annual GMT production : 1 Million Pcs/ Year
Total manpower : 700
Buyer :Newtop, Plummy, SBP, Zxy,T ex geoup, H&M
etc
PRODUCT : LADIS :BRIEF, BIKINI, BOYSHORT, PANTY, THONG,
HI-CUT, STRING, BRA, KAMISOL, AND OTHER
LINGERIES.
: MENS : MEN’S BOXER, UNDER GARMENTS
KIDS : BODY SUIT
:GIRLS/BOYS : ALL TYPES UNDERGARMENTS,
SLEEPWEAR & DRESSES



CAPACITY : 80,000 DZNS -100,000 DZNS PER MONTH
SHIPMENT PORT : SEA -CHITTAGONG-BANGLADESH
AIR – DHAKA, BANGLADESH


TRADE TERMS : CMT/ F.O.B/ CNF
MODE OF PAYMENT : IRREVOCALE LETTER OF CREDIT AT SIGHT
T/T
BANKER : SOUTHEAST BANK LIMITED, KAWRAN

BAZAR BRANCH, DHAKA, BANGLADESH.
Factory : 228, Pial Cottage, Kawlar, Dakhinkhan, Dhaka-
1229, Bangladesh
Telephone Number : +88-2-8933461












TABLE OF CONTENT


CHAPTER-1
INTRODUCTION…………………………………………………6
CHAPTER 2
FACTORY PROFILE…………………………………………….7
CHAPTER-3
GARMENTS MERCHANDISING …………………………… 9
CHAPTER-4
STORE OR INVENTORY SYSTEM………………………… 18
CHAPTER-5
SAMPLE, PATTERN, MARKER …………………………… 24
CHAPTER-6

CUTTING SECTION ……………………………………………34
CHAPTER-7
SEWING SECTION………………………………………………50
CHAPTER-8
FINISHING SECTION……………………………………….… 60
CHAPTER-9
Compliance/HR………….………………………………….64

CHAPTER-10
Conclusion……….…………………………………………68





INTRODUCTION


In Sea Moss Knitwear Ltd. there consists a Training Center which is
exceptional from the other factory. It is seen that majority percent of
factories has no Training center. This center trains the fresh worker. This is
help for bulk production and increase the efficiency and ultimately
production is increased. There consists all type of sewing machine for
practice. For supervision a manager and two supervisor trains the worker.
They guide all day long. It is added here that some time a worker who
trains for someday has to give for making local garments and with the
concentration of the factory those sell in local market. By this practice a
worker can get the proper idea about the floor level production.

This training section also helps the worker to-

 operation of a sewing machine
 Familiar with the different parts of a sewing machine
 Give a brief idea about the adjustable portion of a sewing
machine
 Make them as the identification where they are suitable for work
in different section
 Know about the process sequence of different garment






FACTORY PROFILE

Sea Moss Knitwear Ltd. based in Bangladesh, is a woven factory with sustained
goodwill and expertise in exports oriented ready-made garment manufacturing.
Sea Moss Knitwear Ltd. has earned unrivalled success and remarkable distinction
in the field of ready made garments local and international trading. The company
started their ready-made garment manufacturing unit in the year of 2000. At the
beginning they started with two lines of garments production unit with 200
manpower. But now a day they have 10 garments production lines with 700
manpower. Coming soon they started a largest Textile Composite unit. For this
they purchases 170 acres land area Dhakkinkhan, Dhaka Industrial Area .

Mission and Vision:

Mission:
Starting from the beginning, Sea Moss Knitwear Ltd. has put emphasis
on quality and credibility which helped a lot in earning buyers
confidence upholding a customer centered perspective. Highly
professionals of Sea Moss Knitwear Ltd. are working consistently to
ensure best support to the valuable clients. For regular buyers
dedicated lines of production and specific merchandisers are
there to customize the service and ensure successful execution of
order.
Vision:
1. To build up an organization that runs with a motivated work
force, beliefs in customer satisfaction, posse’s good
marketing strategy.
2. To be one of the leading composite factory in Asia
subcontinent within ten years.
3. To create & recruit 1 lac employee in Sea Moss Knitwear Ltd. within

the year of 2030.





MERCHANDISING
The Merchandiser

An individual, who acts as a coordinator, follows-up and takes
total responsibility of an order form booking to shipment and
beyond, for the customer who placed it and for his company’s
management.

Merchandising

The Merchandising is known to the persons specially involved
in garments trade .The term merchandising has been derived
from the merchandise. Merchandise means goods that are
bought & sold.
The term merchandising may be defined as person who
merchandises good ,specially for
export purposes. Garments merchandising means buying
raw materials & accessories, producing garments, maintaining
required quality level & exporting the garments within schedule
time.

Merchandising Management system:
Buyer sends an order copy by e-mail or sometimes swatch also.
E-mail is taken hand from (Order copy)
The measurement of various parameters are inserted by coding
number in the order copy like-
 Quantity of garments,
 Yarn type,
 Count,
 Fabric type,
 Color,
 Body measurement,
 Shipment date etc.
 Before ultimate order a development sample is sent to buyer.
 Lab-dip is approved
 Sampling is carried out.
 The sample is sent to buying house to check.
 After approved the sample then accessories
 and fabrics are booked.
Finally shipment is done after all clearance.

The merchandiser basically follows up with all concern
production departments for their ordered products.
The major functions/steps of a merchandiser:
 Procuring the garments order.
 Procuring the raw materials.
 Production of garments.
 Shipments of garments.
 Receiving of payment for garments

GARMENTS MERCHANDISING

Flow sequence of merchandising section:
Received PDF Sheet

Consumption

Costing

Negotiation with Buyer

Order Received

Purchase Order Sheet Received

L.C Opening

Purchase Fabric & Accessories

Time & Action Setting

Approval For Bulk Production

Related To Production Planning

Start Bulk Production

Inspectio

The steps are shown as diagramacally:
a
Buyer confirms a order to a factory




Production planning and pre production meeting:
 Initial planning is prepared by the merchandising department
when the order confirmed.
 Based on the sample approval and shipment date, the
production department makes the planning of the production
only.
 The planning is done following the styling of the product and
the machine lay out to calculate the number of pieces
production per hour.
 Before production commence, pre production meeting is
necessary with all concerned departments to get the correct
productions.

Production: sample development, planning, quality control
and inspection (AQL)

Quality Control and Inspection [AQL]:
 Customer wise the quality requirement will get vary and
merchandisers are responsible to communicate with
customers to get the correct quality requirements and need to

co-ordinate with factory quality control department so that
they will well understand the requirement and can take care of
the bulk productions.
 Inspections are done during production which is called in line
inspection. Later the final inspection done by the factory QC
as well as buying office QC to make sure that the final
products is shipping with right quality.


 Mentioned that, the right quality not good quality as the
‘quality’ refers to customer’s requirement.


Costing/Pricing
 Costing is the principal task of any merchandisers.
 Methods of Pricing:
 Calculate the fixed and variable costs associated with the
product.
 Also below cost elements need to consider during costing.
~ Pricing for Fibers & Yarns
~ Pricing for fabric manufacturing
~ Pricing for garment manufacturing
~ Cost of accessories
~ Commercial cost
~ Break even point
~ Consumption of fabric and accessories with wastage
percentage.
~ Total cost analysis [how much does it cost to provide
merchandise to end customer
Commercial

 LC: Letter of Credit- Once the order is confirmed, buyer’s
bank issues a Letter of Credit (LC) to the manufactures Bank.
With this LC, manufactures can start procurement of yarn,
fabric, accessories etc necessary for particular order
execution.
 If the LC delayed from buyers end, it will impact on the
delivery date and merchandisers need to follow this up with
buyer to get the LC for on time delivery.
 Back to Back L/C: To procure the yarn, fabric and
accessories, suppliers need to open another LC for secondary
suppliers bank based on the master LC. This secondary
suppliers LC is called back to back LC.





Accessories:
1) Sewing threads and sew able item
a. Thread
b. Button
c. Main label
d. Size label
e. Care label
f. Velcro (Hook and loop fastener)
g. lace etc.
2) Finishing item:
a. Price ticket
b. Hang tag
c. Poly bag

d. Back board
e. Neck board
f. Collar inside
g. Butter fly (Single, Double)
h. Tag pin
i. Tissue paper
j. Draw string and stopper etc.
Order follow-up and execution:
They do it during running the production. As a result if any fault occurring it
rectified in the primary stage.




Here, a example is given below how way a order is follow-up and done
Buyer: Guldenpfenning Gmbh
Order: 500074
Item: Girls Summer Dress
Article: 699,608 &635
Orde Quantity: 123504 Pcs/4156 Crt.
Factory: Shagore Garment Ltd.
Delivery: 30.01.2010
Buyer Development Process:
1) Reports & exports documents
2) Sample follow-up
3) Supplier/factory message
4) Buyer message
5) Order detailse
6) Trim approval
7) Fabric approval

8) Requirement break down
9) L/C
10) Pre-order papers






Arranging final inspection:
After completion the garment making merchandiser arrange final inspection date
with quality department. Inspection is also depending on the wishes of buyer.
Now a days most of the buyer follow 2.5% AQL.Here given Bellow 2.5% AQL
system:

AQL 2.5%:

Lot Size
Sample Size
Acceptable
Rejectable
26-50
8
1
2
51-90
13
1
2
91-150

20
1
2
151-280
32
2
3
281-500
50
3
4
501-1200
80
5
6
1201-3200
125
7
8
3201-10,000
200
10
11
10,001-35,000
315
14
15
35,001-150,000
500
21

22






STORE OR INVENTORY SYSTEM
Inventory:
Inventory is the stock of any item or resources used in an Organization.
Fabric storage:
Supplied Grey fabrics are first subjected to the 4 point inspection system and fabric
allowance point is 28 per 100 yards. Only those goods are stored here which are
passed from the quality control department. And defected fabrics are back to the
supplier.

The types of fabric defect are check in 4 point inspection system:
- Oil spot
- Missing yarn
- Dye defect
- Hole
- Color yarn
- Drop pick
- Net
- Knot
- Broken yarn
- Slub yarn
- Color shading

FIG: FABRIC STORE
4- Point inspection system:
Defects (length wise): Penalty point:
1. 0-3 inch……………………………1
2. 3-6 inch……………………………2
3. 6-9 inch……………………………3
4. 9 inch & above………………… 4
5. Any hole& miss pick…………… 4

Example: Suppose inspected fabric length=100 yds, fabric width=50 inch, and following
faults are found.
Faults length No of faults
0-3 inch 3
3-6 inch 5
6-9 inch 3
9 inch & above 2






We know,
Points/100 yds= Total penalty points*100*36
Fabric length*Fabric width
13 3

Points /100 yds = ×100×
100 50

= 09.36 per 100 sq/yds
Fabric inventory:
Various types of fabric and accessories such as sewing tread, button,
interlining, label etc are stored in central room. Here also machine sparse
parts and stationary are stored in store room.
The flow sequence of fabric inventory is given below:
Received the fabric
Pre-inspection
Physical inventory
Make the swatch card
Prepare blanket shade
Shade segregation
Issue fabric to cutting room.
Fabric is separated and according to lot number.



Accessories inventory:


Flow sequence of accessories inventory is given below

Import receive

Physical inventory

Swatch making

Swatch approval from buyer

Register/Record the entry

Supply to sub store according to demand

Issue to bulk production












Accessories inventory item:

Hanger size: Identify the size of the garment by hanger
Label: Labels are the most important trimmings by which customer
easily, know about the product. Here two types of label are
available:
1. Main label: It contains the name of buyer and country. Ex. Wal-
Mart, USA etc
2. Sub label:
i. Size label: It contains the size of the garment

ii. Care label: It contains care construction. Different types
of care label are given below.
a. Washing code
b. Bleaching code
c. Ironing code
d. Dry cleaning code
e. Drying code
iii. Cost label: It contains the cost of garments.
iv. Composition: It contains fiber composition of the fabric.
Ex 65% cotton, 35%polyester.


Sewing thread:
Different types of sewing treads are available in store room. Such as


 60/3 (100% polyester)
 50/3 (core spun yarn)
 40/3 (100% polyester)
 20/3 (100% cotton) etc
Button:
Many types of button are available in store room. Some examples of button
are given below.
 Horn button
 Purl button
 Shank button
 Snap button
 Coconut button
 Chalk button
Amount determination of button:

There are two systems of determination the amount of amount. These are
given below.
1. 1G.G =12GRS
2. Each cartoon contain 750 gross
1 gross =144 pcs
750 gross =144×750=108000 pcs
Interlining:
Types of interlining are available in store room are given below.

o Dot fuse.
o Paper fuse.
o T.C interlining.
o Non fuse etc






SAMPLE, PATTERN, MARKER

SAMPLE
Sample making is one of the most important activities in the
garment manufacturing process. The manufacturer always
needs at least a sketch of the garment, original patterns,
specification and the designer’s sample to make high quality
sample garments at the contractor’s factories. Garments
factories are used different name used for different types of
samples. In the sample departments of garment factories
different type of sample are made for different purposes.

Flow sequence of sample section is given below:
Receive developed sheet from buyer

Develop the sample

Send the sample to buyer for approval

Approval of sample/comments about the sample (if necessary)

Send pre-production sample to buyer

Start bulk production





Types of sample produce by Sample Section according to buyer demand:
There is various type of sample those are given below:
1. Original sample:
This type of sample made of original fabric and accessories according to buyer sketch
and measurement.
2. Photo/ Develop sample:
Here measurement is very important but need not to match the fabric and accessories
3. Seal sample:
Seal sample is approved by the buyer with tag.
4. Size set:
All sizes of sample are produced such as S, M, L, XL, etc, and send to buyer.

6. Pre-production sample:
First garment of bulk production is called pre- production sample.
7. Add sample:
For advertising of the product buyer want this type of sample.
8. Sales man sample:
To supply the new product in different showroom, buyer wants this sample.
9. Photo sample:
Only photograph of the product is send to buyer.
10. Shipment/ Reference sample:
After completion the shipment of the garment some garment are kept in sample room
which are known as shipment or reference sample.
11. Pre-line sample:
This type of sample is collected from anyone line during production.


12. Lab-test sample:
Sample is tested by third party or buyer’s nominated lab.
Pattern making
This department provides patterns of different design for sample preparation.
Samples are not large scale production, they are small in quality .So plotting
machines are not used for samples. Patterns are made by drawing the design on
drawing papers and then cutting them manually. A sequence can be shown:

Design → pattern → sample preparation

Generally, finished pattern is provided by buyer. Then allowance is added and
patterns are graded.
Pattern making process:
 Manually
 By Computer

By Computer:
With CAD System -Concept drawing accomplished by computer
With Digitizing System - where master pattern is made manual on hard pattern
paper.
-Patterns are laid-out on the sensitized table &placed cursor around the pattern.
-Modified and graded them directly on screen.