Industrial attachment of four knit wear limited

SOUTHEAST UNIVERSITY
Department of Textile Engineering
INDUSTRIAL ATTACHMENT
Four Knit wear Limited
(15
th
September, 2012 to 15
th
November, 2012)
(Four Knit wear Limited)Pathamtuli,
Shiddhhirganj, Narayanganj. Bangladesh
SOUTHEAST UNIVERSITY
Department of Textile Engineering
INDUSTRIAL ATTACHMENT
Four Knit wear Limited
(15
th
September, 2012 to 15
th
November, 2012)
(Four Knit wear Limited)Pathamtuli,
Shiddhhirganj, Narayanganj. Bangladesh
SOUTHEAST UNIVERSITY
Department of Textile Engineering
INDUSTRIAL ATTACHMENT
Four Knit wear Limited
(15
th
September, 2012 to 15
th
November, 2012)

(Four Knit wear Limited)Pathamtuli,
Shiddhhirganj, Narayanganj. Bangladesh
2
SOUTHEAST UNIVERSITY
Department of Textile Engineering
Supervising Faculty:
Professor Syed Fakhrul Hassan
Chairman
Department Of Textile Engineering
Southeast University
Supervising Officer:
Mahmud Rahat Chowdhury
Executive Director
Four Knit Wear Limited
3
REPORT ON INDUSTRIAL TRAINING
IN
Four Knit Wear LTD
TRAINING PROGRAM FOR THE DEPARTMENT OF TEXTILE ENGINEERING.
SOUTHEAST UNIVERSITY, DHAKA
FROM 15.09.2012 TO 15.11.2012
COPY FOR SOUTHEAST UNIVERSITY
SUBMITTED BY:
Mohammad Rasel Miah
Southeast University.
Banani, Dhaka
Date Of Submission: 14
th
January 2013.
4

Abstract
The aim of industrial practice is to make us familiar with any kind of industry, the whole process
going on the industry, its environment and also with the management system of the industry. As
a student of Southeast University, the target of any student should be to know the production
process and the management system. It is because of the fact that to run any industry not only
production department is obvious but also the capability of managing the whole system is a n
obvious matter. It is also a responsibility of an engineer is to develop the ongoing process into a
better system to cope with the present competition. Thus a diversified challenge emerges in front
of the manufacturer and other organizations. With a view to overcome this consequence a new
generation of engineering graduates with leadership skills and management capabilities
altogether are in demand.
The students of Southeast University were sent to different industries and assigned to different
tasks. I had assigned to Four Knit Wear Ltd. This report is a presentation of my experience in the
garments and also a details presentation of my works in that industry.
4
Abstract
The aim of industrial practice is to make us familiar with any kind of industry, the whole process
going on the industry, its environment and also with the management system of the industry. As
a student of Southeast University, the target of any student should be to know the production
process and the management system. It is because of the fact that to run any industry not only
production department is obvious but also the capability of managing the whole system is a n
obvious matter. It is also a responsibility of an engineer is to develop the ongoing process into a
better system to cope with the present competition. Thus a diversified challenge emerges in front
of the manufacturer and other organizations. With a view to overcome this consequence a new
generation of engineering graduates with leadership skills and management capabilities
altogether are in demand.
The students of Southeast University were sent to different industries and assigned to different
tasks. I had assigned to Four Knit Wear Ltd. This report is a presentation of my experience in the
garments and also a details presentation of my works in that industry.
4

Abstract
The aim of industrial practice is to make us familiar with any kind of industry, the whole process
going on the industry, its environment and also with the management system of the industry. As
a student of Southeast University, the target of any student should be to know the production
process and the management system. It is because of the fact that to run any industry not only
production department is obvious but also the capability of managing the whole system is a n
obvious matter. It is also a responsibility of an engineer is to develop the ongoing process into a
better system to cope with the present competition. Thus a diversified challenge emerges in front
of the manufacturer and other organizations. With a view to overcome this consequence a new
generation of engineering graduates with leadership skills and management capabilities
altogether are in demand.
The students of Southeast University were sent to different industries and assigned to different
tasks. I had assigned to Four Knit Wear Ltd. This report is a presentation of my experience in the
garments and also a details presentation of my works in that industry.
5
Acknowledgement
At first we express our heartiest thanks to almighty Allah for finish ing my work properly.
My attachment was the first practical experience of working in the industry. On the whole course
I have got a lot of helps from my respective teachers, and also a great help from our supervisor in
Four Knit Wear LTD.
I also would like to gratefully acknowledge to the authorities of Four Knit Wear LTD industry
for giving me permission to carry out my Industrial Practices in their industry. I want to thank
our
1. Mohammad Mahmud Russel- Managing Director
2. Mahmud Rahat Chowdhury – Executive Director
3. Khan Mohammad Al Mamun- General manager Of Merchandiser.
For his great help with his experience.
I place my thanks to all the official staffs of administration, production department, maintenance
department, quality control for their cordial behavior and helpful support to gather information
regarding to the industrial attachment.

On my whole way i would like to express my gratitude to Professor Prof. Syed Fakhrul
Hassan, Chairman, department of Textile Engineering, Southeast University.
5
Acknowledgement
At first we express our heartiest thanks to almighty Allah for finish ing my work properly.
My attachment was the first practical experience of working in the industry. On the whole course
I have got a lot of helps from my respective teachers, and also a great help from our supervisor in
Four Knit Wear LTD.
I also would like to gratefully acknowledge to the authorities of Four Knit Wear LTD industry
for giving me permission to carry out my Industrial Practices in their industry. I want to thank
our
1. Mohammad Mahmud Russel- Managing Director
2. Mahmud Rahat Chowdhury – Executive Director
3. Khan Mohammad Al Mamun- General manager Of Merchandiser.
For his great help with his experience.
I place my thanks to all the official staffs of administration, production department, maintenance
department, quality control for their cordial behavior and helpful support to gather information
regarding to the industrial attachment.
On my whole way i would like to express my gratitude to Professor Prof. Syed Fakhrul
Hassan, Chairman, department of Textile Engineering, Southeast University.
5
Acknowledgement
At first we express our heartiest thanks to almighty Allah for finish ing my work properly.
My attachment was the first practical experience of working in the industry. On the whole course
I have got a lot of helps from my respective teachers, and also a great help from our supervisor in
Four Knit Wear LTD.
I also would like to gratefully acknowledge to the authorities of Four Knit Wear LTD industry
for giving me permission to carry out my Industrial Practices in their industry. I want to thank
our
1. Mohammad Mahmud Russel- Managing Director

2. Mahmud Rahat Chowdhury – Executive Director
3. Khan Mohammad Al Mamun- General manager Of Merchandiser.
For his great help with his experience.
I place my thanks to all the official staffs of administration, production department, maintenance
department, quality control for their cordial behavior and helpful support to gather information
regarding to the industrial attachment.
On my whole way i would like to express my gratitude to Professor Prof. Syed Fakhrul
Hassan, Chairman, department of Textile Engineering, Southeast University.
6
Table Of Content
Serial No
Topic
Page No
1
Abstract
4
2
Acknowledgement
5
3
Company Profile
7-10
4
Garments Section
11-33
5
Knitting and Dyeing
34-38
6
Merchandising Section

39-45
7
Utility Section
46-47
8
Compliance
48-50
9
Conclusion
51-52
7
Company Profile
Four Knitwear LTD
8
Vision:
To establish as a one stop source for the Global knit Apparel market and to satisfy and meet
customer's expectation by developing and providing products and services on time, which offer
value in terms of Quality, Price, Safety & Environmental impact.
Assuring complete compliance with the international quality standards and also providing the
employees internationally acceptable working condition and standards.
To promote the development and to use human talent & equal opportunity of employment.
They procure the most advanced & sophisticated technology suitable for producing desired
product and attain highest level of competence through continuous development of the
professional, management system and to ensure complete transparency in an aspects of business.
Mission:
Four Knitwear LTD realizes the need to stake out a competitive segment in the changing global
market of today through technological excellence and human expertise. Four Knitwear LTD is
committed to transpose its local success to the world scene.
9
 Company Name:

 Four knitwear LTD.
 Status: Private Ltd. Company
 Type: 100% Export oriented knit Industry.
 Year of establishment: 2004.
 Address: Pathantuli , Godnail , Narayanganj -1400
Management:
 Chairman : Mamun Choudhury
 Contact Number : 01711 56 16 58

 Managing Director : Mahmud Russel Choudhury
 Contact Number : 01819 22 74 09
 Email :

 Executive Director : Mahmud Rahat chowdhury
 Contact Number : 01675-063088
 Email :

 Marketing Director : Mahmud Russel Choudhury
 Contact Number : 01819 22 74 09
 Email :

 Manager Merchandiser : Khan Mohammed Al Mamun
 Contact Number : 01817-535591
 Email :
Production Capacity:
Production per 08 (Eight) hours :
Basic T– shirt : 12,000 Pcs
Polo shirt : 5,000 Pcs
Others : It depends on style & fabrics
10

Product:
 Single Jersey
 Pique
 Lacoste
 Interlock
 Rib
 French Terry
 Cotton Fleece /Cvc Fleece
 Flat Knit
 Cotton Viscose
Some Major Buyers:
CARODEL, SMYK, BABOLAT, CATBALU, ATIMA, PCL, ATIMA,
FIRSTTEXTILE.
Certificate & Achievement:
 BGMEA
 BKMEA
11
Garments Section
12
Sampling Unit :
In RMG sector Sampling plays a vital role. Morning shows the day. Only morning can show
what kind of nature will be the day, similarly only Sample can say what kind of garments is
going to be made as bulk. We have one line Sample section which is set up at the 1
st
floor of our
Factory. The Sample Section has been decorated by One Sample In charge who is responsible to
give all sorts of direction to making the sample. One Sample Q C, One supervisor, 10 sample
men and 7wo assistant. We have a individual Sampling unit for urgent Sampling , Pattern
making, Checking, Marker drawing all pre production are done by this unit before go for bulk.
We always try to approved our sample like, Proto, SMS, Pre production

.
13
Sample is the proto type or model of the garments, upon what the buyer can decide on how and
whether to confirm the order or not.
It makes for buyer approval and before a bulk of production to minimize faults and errors and
also find the easy process for bulk production.
The details attached to the garments sample:
After the confirmation of order, each sample sent the buyer has the following details attached to
it, with the help of a tag. It contains the details pertaining to both, what the buyer has demanded
and what supplement fabric/ trim etc they have used .
 Ref no
 Color
 Fabric
 Composition
 Description
 Quantity
 Style no
 Store
There may be a separate sampling department in a company. But as the merchandiser is the
person who is interacting with the buyer regarding sample and other requirements, this sampling
department will work under the supervision of merchandising department.
We have to send many sample to buyers. They are
 Salesmen sample
 Proto sample
 Counter sample
 Wash test sample
 Photo sample
 Pp sample
 Shipment sample
14

Work flow of sample section:
production starts
sendint sample to the cutting section
marker making
grading of sample
approval
sending sample to the buyer
grading of sample
pp meeting
evluation the sample
size setting
approval
sample making
cad and pattern making
receive tec pack from buyer
15
Sample production sequence:
sending sample to the buyer
forwarding collect from the merchandiser
buyer qc
pre check from
quality control
iron
sewing
emblishment
cutting
scouring the fabric and accessories for making the garments
16
Types of sample:
 Proto sample

 Size set sample
 Additional sample
 Contract seal sample
 Pp sample
 Production sample
 Sales man sample
 Rack sample
Proto sample:
When we work with some buyer continuously, we will have to keep on sending sample to them
very often. Whenever they have enquiries, buyer may need samples. Buyer may like to see the
garments in a new fabric. For one enquiry they need samples in different fabrics to choose from.
If they want to develop new style in new fabric, then also we will have to send these sample.
Also we will have to send samples to the newly contacted buyers to show our workmanship,
product range, quality standers and price level. These samples should be sent so that they would
attract the buyers.
Sales man sample:
Some buyer needs these sample for getting the order from their customers. If the buyer is having
5 salesman sample in his office, then the buyer will ask us to make 5 sample in each style. The
salesman will book the orders from their customers, by showing these samples. Buyer will place
the order to us accumulating the quantities.
Photo sample:
These sample are to be made after sheets. These sample are needed to check the measurement s,
style and fit. So they can be made in available similar fabrics but in the actual measurements and
specifications.
Counter sample:
These sample are to be made in actual fabrics with actual trims. If the order is for 3 colors buyer
may need samples in any one color and swatches in other colors. These samples should be
strictly as per the specifications in the order sheets. We have to get the approval for these
samples from the buyer before starting production.
17

Wash test samples:
If these sample are sent before starting production and if we get some remarks or comments on
these sample, we can correct them in production. But some buyers will need us to send these
samples from production before shipment. In this case these sample may be considered as
shipment samples.
Pre production samples:
These sample are almost like approval samples. They have to be made in actual production fabric
with actual bulk trims. They will represent that the production will be like these samples.
Production sample:
These samples are to be sent before shipment to get the buyers confirmation f or shipment.
Hence these sample are needed to be perfect in all manners. Buyers may check these samples for
everything or anything.
Shipment sample:
These samples are to be sent after shipment. They should be sent in actual packing with all
labels, tags etc.
Types of machine are used in sample section:
SL No
Name Of Machines
No. Of Machines
Remarks
01
Over lock ( 3 Thread )
1 Set
02
Over lock ( 4 Thread )
1 Set
03
Over lock ( 5 Thread )
1 Set
04

Lock ( Flat )
1 Set
05
Lock ( Cylinder Bed )
1 Set
06
Plain machine
2 Set
18
Cutting :
First stage of readymade garment production, cutting is the most important and major part of ultimate
quality of the production. In this point of view our cutting section has design to achieve the maximum
production. Cutting section have been designed in 1
st
floor of the factory space. There are two types of
cutting system, one of them Machine cutting and another is Manual cutting. Two cutting men is engaged
in machine cutting and there about 12 cutting men are working continuously. There is an cutting in
charge, One supervisor and one QC to perform the activities maintaining quality and required quantity.
Cutting is the process which cut out the pattern pieces from specified fabric for making
garments. Once the marker is made, pattern pieces must be cut out of the specified fabric, a
process called "cutting." Currently, several cutting techniques exist, ranging from low - to high-
tech. Although scissors are used very rarely-only when working with very small batches or
sensitive fabrics-cutting continues to be done by hand, particularly in many lower volume
establishments. Here, cutters guide electric cutting machines around the perimeter of pattern
pieces, cutting through the fabric stack. An electric drill may be used to make pattern notches.
Computerized cutting systems are achieving more widespread use as technology costs decrease
and labor costs rise. These computer-driven automated cutters utilize vacuum technology to
hold stacks of fabric in place while cutting. Cutting blades are sharpened automatically based
upon the type of fabric being cut. Gerber Garment Technology manufactures one of the most
commonly used cutting systems. This technology has the advantage of being highly acc urate

and fast, but does cost considerably more than other cutting techniques.
19
Types of Cutting
Fully manual:
 Hand operated scissor
Manually operated power knife:
 Straight knife
 Band knife
 Round knife
 Die cutting
 Notcher
 Drill
Computerized methods of fabric cutting:
 Computer controlled knife cutting
 Cutting by Laser beam
 Cutting by Water jet
 Cutting by Plasma torch
Cutting Q.C : Upon receiving any batch of fabric it required to check Dia, Gsm, Colour
fastness, tone matching and shrinkage are duly checked by our cutting Q.C makes a report on
the fabric to get the cutting approval from merchandiser department.
20
Lay cutting : Mostly we make all fabrics in lay form and cut it by marking as per
pattern, so the fabric is getting more relaxation to avoid further shrinkage and all the
hole, Running shade etc can clearly find out and remove. There are about 15 workers
are engaged to do the work properly so that we can meet the shipment date with
maintain quality. We always try our best to meet the 100% Quality label.
21
Sewing:
We have four line for sewing what is consisted with various Machines like Over lock, Flat lock,
Plain Machine, Button hole, Rib Cutter, Khansai etc. There are two hundred and sixteen

Machines for various kinds of buyer’s requirement. We have been maintaining need based
machine settings as required by needle type like 3 Thread, 4 Thread, 5 Threa d and even Ball
Point needle. We some time do the chore hem when it is required. Buyer US POLO Chicco and
SMYK are the exemplification of such type of Hem.
22
Main Sewing Unit :
The main sewing floor are designed by 4 line of selected machinery. Each line are headed
by 1 Supervisor and 1 input Assistant Required Operator and Helper as Lay out base on the
Garments style and design.
23
Sewing process flow Chart:
forward it to the finishing section
garments inspection
get full garments as output
sewing started
print & embroidery check
measurement check
input
24
Machinery of Main Unit
SL NO
Name Of Machines
No. Of Machines
01
Over lock ( 4 Thread )
60 Set
02
Over lock ( 5 Thread )
25 Set
03

Lock ( Flat )
18 Set
04
Lock ( Cylinder Bed )
26 Set
05
Feed of the arm
8 Set
06
Plain machine
56 Set
07
Button hole
01 Set
08
Button stretch
01 Set
09
Rib cutter
02 Set
10
Back tape
02 Set
11
Cutting machine
02 Set
12
Iron ( Steam )
15 Set
25

Process Flow of a Basic T-Shirt:
Inspection
Thread cutting
Button attaching machine
Button hole machine
side band tape join (Plain machine)
Placket stitching of bottom part (Plain machine)
Attaching twill tape with neck (Plane machine)
Cuff shape (Overlock)
Stitching Collar (Overlock)
Collor tag (Plain machine)
Shoulder top seam (Plain machine)
Stitching twill tape (Plane machine)
Attaching care level (Plane machine)
Stitching shoulder (Overlock, 4 thread)
Separating placket & stitching nose cut (Plain machine)
Placket attached with front part (Plain machine)
Moon attached with back part (Plain machine)
Indicating placket mark
Machine front and back part