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Industrial Attachment of SQ group

INTRODUCTION

Industrial Attachment is one of the best part to study a running processing technology of the industrial unit for the final year Student of textile Engineering Dept. Of Primeasia University. By going throw the industrial Attachment.

The incumbent was deputed to SQ Group(Color master Ltd).For practical mill training as per training programme arranged by University authority under the guidance of color master Sampath jayakoda (Srilankan) and supervision of Chowdury Jony Moin (Lecturer) &the industrial attachment report was prepared for 45 days long training programme in a composite mill.

PROJECT DESCRIPTION

General Information About the mill

Name of the Factory : SQ Group (color master Ltd)

Status : Private Ltd.Company.

Type : 100% Export Oriented Company.

Year of Establishment: 2003

Location :

Address

Factory : Jamirdia,Valuka ,Mymensingh,Bangladesh.

Head office : North tower (10^th floor),Uttara,Dhaka.

Tel: 8153669, 8116672 Fax :(880-2)8116673

Email :colormaster@sqgc.com Web :www.sqgc.com

Owner of the mill : Director, Mr. M Ghulam Faruq

Authorised capital : Approx.100 crore taka.

History of the Project development:

2003:Estublishment of the industry. First installmment of the machinary &started production.

2004: Instllment of the Garment dyeing Machine & started production

2005: Start of the construction of 3^rd and 4^th floor. Installment of the Sweater Garment making.

2006: Start of the construction of 5^th and 6^th floor &started production of Garment making.

2007: Installment of new project which are UK &Bangladesh Joint venture & started production at the end of the year.

Physical Infrastructure: Building -6 storied

Floor space: 60000sq.ft

Total area of the Industry : About 20500 sq.metre.

ORGANOGRAM

Chairman

?

Executive Director

?

? ? ?

Finance Director

D.G.M Admin & SA

D.G.M Production

?

? ?

Commercial Section

Accounts Manager

Executive Offecer

Knitting Dpt. Sr. Manager

Asst, G. M.(dyeing)

Garments dept Manager

Marcendising Section

?

Admunistrative Officer

? ?

Engineering section

Cutting

Sweing

Finishing

?

Computer section

?

Telephone Operatior

?

Transport Section

?

Security Section

?

Time Section

RESPONSIBILITIES OF PRODUCTION:

JOB DESCRIPTION:

SENIOR PRODUCTION OFFICER:

In a garments factory a senior production officer plays a great role in production and manpower management who are production related.Here we enlist the duties of senior production officer.

1) Follow up the garments production,

2) Regular observation of garments floor,

3) Prepare garment order status regularly,

4) Maintain the quality of the product,

5) To help the senior prod. Officer & co operate with others for fulfiling the required destination.

PRODUCTION OFFICER :

Production officer is the right hand of senior production officer and he is directly related with production manpower and inform senior prod.officer time to time . Here are his listed duties –

1) Follow up overall garments production ,

2) Decide every m/c utilization during production,

3) Recruit new labor ,

4) To inform the authority on the overall garments prod. And make it financial profitable,

5) Regular m/c maintenance,

6) Maintain sub –contract orders ,

7) Help knitting manager & also guide the junior officers of the section, etc.

REMARKS:

Production runs with the help of mechanical fiitrs. For any kind of mechanical fault of any machine they fix and work under technical in charge. Production officer’s takes account of daily production by running after the two supervisors and workers so on.

(MACHINE DESCRIPTION )

RAW MATERIALS

SL	Yarn Description	Yarn count
1	80% Cotton 20% polester CVC	NE 28/1
2	100% cotton carded	NE 30/1
3	100% Acrylic	NE 30/1
4	70% cotton 30% acrylic	NE 30/1
5	65/35 (cotton/acrylic)	NE 30/1
6	90% cotton 10% viscose	NE 28/1
7	Spandex/Lycra	70 Denier
8	99% cotton 1% Viscose	NE 30/1

(A) Yarn :

(B) Accessories

SL	Item Description	Quantity
1	Sewing Thread	4050 cone
2	Sewing Thread	cone
3	Filament	cone
4	Main Label	5912 doz
5	Size Label	Doz.
6	Care Label	Doz.
7	Single Poly	Doz.
8	Poly sticker	Doz.
9	Zipper	768 Doz.
10	Blister polybag	860 Doz.
11	Interlining	18 Roll
12	Cotton twil Tape	7700 Yds
13	Printed Gum Tape	300 Roll
14	Scotch Tape	100 roll
15	Button	G.G
16	Gum Tape	Roll
17	Carton	1790 pcs
18	Drawstring	Yds
19	Herringbone Tape	Yds
20	¼ cotton shoulder Tape	36300 yds
21	Printed carton sticker	310 Doz.
22	T/C shoulder Tape	5600 Yds
23	Printing of 100% knit fabric	Kgs
24	Woven Twil Tape	3900 yds
25	Mobilon Tape	Doz.
26	Single poly	Doz.
27	Spot Lifter	Pcs

Production Planning Sequences & Operation of Garments (Sweater) Making.

Study on Sixth floor

Knitting section

Total worker: 100

Floor worker commanding order:

Production manager

?

Assistant Production manager

?

Floor In charge

?

Line Chief

?

Supervisor

?

Operator

?

Helper

Total line in the knitting section:4

Line sequence: Line A, Line B, Line C & Line D.

MIC year line in knitting section:

Line A contains 12 knitting m/c.

Line B contains 10 knitting m/c.

Line C contains 12 knitting m/c.

Line, D contains 11 knitting m/c.

Floor knitting m/c list:

Brand Name	Model	Origin	M/C Gauge
Shima Seiki	SSF 152-T	Japan	12
Shima Seiki	SSF 152-T	Japan	07
Shima Seiki	SSF 152-T	Japan	05
Flying Tiger	2001/2003/201/2005	Taiwan	3
Flying Tiger	2001/2003/201/2005	Taiwan	5
Flying Tiger	2001/2003/201/2005	Taiwan	7
Flying Tiger	2001/2003/201/2005	Taiwan	12

Sequence of operations in knitting section:-

Sample fabric receive

Design analysis

Setting the machine for the specific design

Production

Inspection

Linking Section

Total worker:80

Floor worker commanding order:

Assistant Production manager

?

Floor Incharge

?

Supervisor

?

Operator

?

Helper

Total line in the Linking section:4

Line sequence: Line A, Line B, Line C & Line D.

MIC year line in Linking section:

Line A contains 10 Linking m/c.

Line B contains 10 Linking m/c.

Line C contains 08 Linking m/c.

Line, D contains 10 Linking m/c.

Sequence of operations in Linking section:-

Front part

Back part

Sleeve

Side way

Neck

Inspection

Production Process:

Knitting

?

Linking

?

Overlocking

?

Bar taking

?

Trimming ( procedure of cutting loose threads ,extra yarns or

extra ply.)

?

Mending (If have any hole,then repair it & sewing )

?

PQC (Primary Quality Check)

?

FQC (Final Quality Check)

?

Care Lebelling Adjustment

?

Ironing

?

Measurement

?

OK

?

FQC (get-up)

?

Taging

?

Dusting

?

Folding

?

Sizing

?

Assorting

?

Blistering / Poly packing

?

Cartooning

?

OK

?

Shipment

Note : During FQC if has any small stain then use zinclinc chemical for stain removing by spraying system

Linking Trimming

Bartaking Overlocking

Mending PQC &Measuring

Carelavelling adjustment Ironing

FQC,Folding,Sizing,Blistering Cartoning

Production Planning Sequences &

Operation of Garments(Sweater) Dyeing.

Acrylic Piece Dyeing Production:

100 % PAN Cahmilon

Colour: Green

M/C No: 01

No. Of Garments: 189 pcs.

Weight: 43.00 kg

M.L.R: 30

Paddle RPM: 18

Recipe:

Dyeing Chemicals	GPL/ %	Calculated amount
Rubine ES	1.0 g/l	1800.0 g
Megasoft BBK	1.5 %	645.0 g
Taigal PAN	1.21 %	520.3 g
Glauber Salt	5.0 %	2150.0 g
Dyeacid HP	0.22 g/l	396.0 g
PH =4.5

Dye stuff:

Name	%	Calculated	Used
Taicryl Yellow 4GNT	0.09458	40.669	40.26g
Maxilon Red GRL 150 %	0.00200	0.858	0.84g
Maxilon Blue GRL 150 %	0.01026	4.413	4.35g

Procedure:

Step 1

Add all Chemical at 70ºC run 05 min.

Add Dye at 70 ºC run 05 min

Step 2

Heating

85 ºC× 5 min

1.0 G/ min

Timer Setting

1 10 sec

2 5 sec

Step 3

Heating

92 ºC× 10 min

0.5 G/ min

Timer Setting

1 12 sec

2 3 sec

Step 4

Heating

99 ºC× 30 min

0.5 G/ min

Timer Setting

1 10 sec

2 3 sec

Step 5

Air cooling at70 ºC

Direct cool slight open valve to 40 ºC

Dark col. Additional rinsing.

Acrylic Garments Dyeing Production:

100 % PAN Cahmilon

Colour: Rose

M/C No: 01

No. Of Garments: 355 pcs.

Weight: 65.00 kg

M.L.R: 30

Paddle RPM: 18

Recipe:

Dyeing Chemicals	GPL/ %	Calculated amount
Rubine ES	1.0 g/l	1800.0 g
Megasoft BBK	1.5 %	645.0 g
Taigal PAN	1.62 %	1053.0 g
Glauber Salt	7.0 %	4550.0 g
Dyeacid HP	0.22 g/l	396.0 g
PH =4.5

Dye stuff:

Name	%	Calculated	Used
Maxilon G. Yellow GL 400 %	0.00775	5.038	5.04g
Maxilon Red SL 200 %	0.0159	10.322	10.32g
Maxilon Blue SL 200 %	0.0020	1.326	1.33g

Procedure:

Step 1

Add all Chemical at 70ºC run 05 min.

Add Dye at 70 ºC run 05 min

Step 2

Heating

85 ºC× 5 min

1.0 G/ min

Timer Setting

1 10 sec

2 5 sec

Step 3

Heating

92 ºC× 10 min

0.5 G/ min

Timer Setting

1 12 sec

2 2 sec

Step 4

Heating

95 ºC× 30 min

0.5 G/ min

Timer Setting

1 12 sec

2 3 sec

Step 5

Air cooling at70 ºC

Direct cool slight open valve to 40 ºC

Dark col. Need Additional rinsing.

Acrylic Piece Dyeing Production:

100 % PAN Cahmilon

Colour: Mid Blue

M/C No: 01

No. Of Garments: 406 pcs.

Weight: 65.00 kg

M.L.R: 30

Paddle RPM: 18

Recipe:

Dyeing Chemicals	GPL/ %	Calculated amount
Rubine ES	1.0 g/l	1800.0 g
Megasoft BBK	1.5 %	975.0 g
Taigal PAN	1.30 %	845.0 g
Glauber Salt	8.0 %	5200.0 g
Dyeacid HP	0.22 g/l	396.0 g
PH =4.5

Dye stuff:

Name	%	Calculated	Used
Maxilon G. Yellow GL 400 %	0.0004	0.260	0.26 g
Maxilon Red SL 200 %	0.00076	0.494	0.49 g
Maxilon Blue SL 200 %	0.012	7.800	7.80 g

Procedure:

Step 1

Add all Chemical at 70ºC run 05 min.

Add Dye at 70 ºC run 05 min

Step 2

Heating

85 ºC× 5 min

1.0 G/ min

Timer Setting

1 10 sec

2 5 sec

Step 3

Heating

92 ºC× 10 min

0.5 G/ min

Timer Setting

1 10 sec

2 4 sec

Step 4

Heating

95 ºC× 20 min

0.5 G/ min

Timer Setting

1 6 sec

2 4 sec

Step 5

Air cooling to70 ºC

Direct cool slight open valve to 40 ºC

Dark col. Need Additional rinsing.

Production Planning Sequences & Operation of Yarn Dyeing.

BATCH : C02450700400 MACHINE : PMD – 1RECIEPE NO: BL-81791007 PROCEDURE : 705 CUSTOMER : PROMOD KNITWEAR YARN LOT : D-1 QUALITY : 32/2 100% CO NO.OF PKG :104 ORDER : SPB-245/07 COLOUR NO : SEA BREAZ BATCH WEIGHT : 106 LIQOUR AMOUNT (L) : 690 LIQOUR RATIO : 6.51

NAME REL. AMOUNT IN RECIPE AMOUT UNIT

BLEACHING @ 98’C* 40’

01 EMERALD DLJ 1.0000g/l 0.6900kgINATEX MD 0.5000 g/l 0.3450 kg SECORON – 540 0.5000 g/l 0.3450 kg STABILIZER SOF 0.5000 g/l 0.3450 kg

02. CAUSTIC SODA 2.0000 g/l 1.9800 kg

03HYPROZEN PEROXIDE 2.0000 g/l 1.9800 kg

04. ERIOPON 0.5000 g/l 0.3450 kg

05. ACETIC ACIDE 0.5000 g/l 0.9450 kg

COTTON DYEING @ 60’C*30’

06.CIBACEL DBC 1.000 g/l 0.6900 kgLADIQUEST1097 0.5000 g/l 0.3450 kg KOLASOL CAD 0.2000 g/l 0.1380 kg

07. GLOBAR SALT 15.0000 g/l 10.3500 kg

08. SODA ASH 2.5000 g/l 1.7250 kg

SODA ASH 5.0000 g/l 3.4500 kg

09CIBA YALLOW FN -2R 0.00565% 0.0059 kgCIBA RED FNR 0.022032 % 0.0234 kg CIBA BRI. BLUE FNG 0.218900 % 0.02320 kg

SOAPING @ 95’C*20’

10. ACTIC ACID 0.5000 g/l 0.3450 kg

11. ERIOPON R 0.5000 g/l 0.3450 kg

12 ERIOPON R 0.5000 g/l 0.0000 kg

FINISHING @40’C*20’

13. ACTIC ACID 0.0700 g/l 0.04830 kg

14 TUBINGAL 1.0000 g/l 1.0600 kg

BATCH : C02430700100 MACHINE : SPMD RECIEPE NO: RE-53120107-CON PROCEDURE : 531 CUSTOMER : PROMOD KNITWEAR YARN LOT : Q-6 QUALITY : 20/2 100% CO NO.OF PKG : 04 ORDER : SPB-243/07 COLOUR NO : RED BATCH WEIGHT : 600 LIQOUR AMOUNT (L) : 33 LIQOUR RATIO : 0.06

NAME REL. AMOUNT IN RECIPE AMOUT UNIT

BLEACHING @ 98’C* 40’

01 EMERALD DLJ 1.0000g/l 33.000gmTINOCLORITE COM 5.000 g/l 165.000 gm

02. CAUSTIC SODA 2.0000 g/l 66.000 gm

03HYPROZEN PEROXIDE 2.0000 g/l 66.000 gm

04. ERIOPON R 0.5000 g/l 16.5000 gm

05. ACETIC ACIDE 0.5000 g/l 16.5000 gm

COTTON DYEING @ 60’C*30’

06.CIBACEL DBC 1.000 g/l 33.000 gmLADIQUEST1097 0.5000 g/l 16.5000 gm KOLASOL CAD 0.2000 g/l 6.6000 gm

07. GLOBAR SALT 80.0000 g/l 2640.000 gm

08 SODA ASH 5.0000 g/l 165.000 gm

09 IMCO YALLOW E -3R 1.926000% 11556.0000gmIMCO RED E3BF 7.500000 % 45000.0000 gm IMCO BLUE ERL O.O31000 % 186.0000gm

SOAPING @ 95’C*20’

10. ACTIC ACID 0.5000 g/l 16.5000 gm

11. ERIOPON R 2.5000 g/l 82.5000 gm

12 ERIOPON R 2.0000 g/l 33.0000 gm

FINISHING @40’C*20’

13. ACTIC ACID 0.0700 g/l 2.3100 gm

ALFABIX ECO 3.0000 % 1800.0000 gm

14 TUBINGAL 2.0000% 12000.0000gm

BATCH : C02510700100 MACHINE : SPMD-1 RECIEPE NO: BK-84471107-D PROCEDURE : 500 CUSTOMER : MANTRUST LOT : Q-6 QUALITY : 20/2 100% CO NO.OF PKG :04 ORDER : SPB-251/07 COLOUR NO : BLACK BATCH WEIGHT : 4.72 LIQOUR AMOUNT (L) : 33 LIQOUR RATIO : 6.99

NAME REL. AMOUNT IN RECIPE AMOUNT UNIT

WASH @ 80’C* 10’

01WETANAL SN 1.5000g/l 0.0495kgEMERALD DLJ 1.5000g/l 0.0495kg WASH@70’C*10’ WETANAL SN 1.5000 g/l 49.5000 kg EMERALD DLJ 1.5000g/l 49.5000kg SECORON – 540 0.5000 g/l 16.5000kg ACETIC ACID 2.3000 g/l 75.9000 kg

COTTON DYEING @ 60’C*30’

06.CIBACEL DBC 1.000 g/l 33.0000 gmLADIQUEST1097 0.5000 g/l 16.5000 gm KOLAZOL CDA 0.2000 g/l 6.6000 gm

07. GLOBAR SALT 80.0000 g/l 2640.0000 gm

08. SODA ASH 5.0000 g/l 165.0000 gm

CAUSTIC SODA 0.75000g/l 24.7500 gm

09 SUNFIX YALLOW MFD 0.140000% 6.6080 gmSUNFIX RED MFD 0.048000 % 2.2656 gm SUNJOL BLACK DN 06.528000 % 308.1216gm

SOAPING @ 95’C*20’

10. ACTIC ACID 0.5000 g/l 16.5000 gm

11. ERIOPON R 2.0000 g/l 66.0000gm

12 ERIOPON R 2.0000 g/l 66.0000 gm

FINISHING @40’C*20’

13. ACTIC ACID 0.0700 g/l 02.3100 gm

14 TUBINGAL 1.0000 % 47.2000 gm

Operation Sequences of Wet Lab.

Dyeing Lab:

Machine no : 01

Brand name : AHIBA NUANCE

Machine name (Functional): Sample Dyeing m/c

Capacity : 19 Samples.

Manufacturing Country : U. S. A.

Manufacturing Year : 2001

Machine no : 02

Brand name : Ariston

Machine name (Functional): Tumble Drier

Capacity : 6 kg

Machine no : 03

Company name : Data color

Machine name (Functional): Color fastness test (CCM)

Manufacturing Country : U S A.

Manufacturing Year : 2001

Machine no : 04

Company name : Verivide

Model : CAC 60

Machine name (Functional): Color match / Metamerism Test

Manufacturing Country : Halifax England

Manufacturing Year : 2001

Machine no : 05

Company name : James H Heal & Co Ltd

Brand name : Microsol

Machine name (Functional): Light-Fastness Tester

Manufacturing Country : Halifax England

Measuring system : Blue scale / Data color

Manufacturing Year : 2001

Machine no : 06

Company name : RAININ Instrument Co Ltd

Machine name (Functional): Pipeting

Manufacturing Country : USA.

Manufacturing Year : 2001

Special features of Rapid Sample dyeing Machine:-

• 19 samples can be dyed at the same time
• Auto time & temperature controller
• Speed controller unit
• Good steam inlet & outlet system
• Good movement of liquor

Procedure of Lap dip-

The main objectives of lab dip preparation:-

# For good dyeing.

# For good shade matching.

# Mass production suitable.

Lab Procedure for the 100 % cotton fabric:-

• Calculate the recipe.
• Weight the fabric.
• Take the beaker keep the fabric in to the beaker.
• Then the dyes, chemicals & required amount of water take in to the beaker by the digital pipeting.
• Then weight the salt by the electric balance and add in to the beaker.
• Then the beaker set in to the lab dyeing machine for dyeing.
• Start the program for dyeing the whole dyeing time 60 min at 60 °C temperature. (The dyeing time and temperature depends on which classes of dyes are used for dyeing.)
• After 30 min add the then add the soda ash. By pipeting.
• Again run the program next 30 min at the same temperature.
• Finished the dyeing time then the sample taken from the beaker first cold wash & then cold wash.
• Then acid wash as for neutralization.
• Then soaping required soap solution 10 min at 90° C temperature.
• After the fabric again cold.
• Then dry the lab dip and compare with the standard.

Amount of salt soda used on the basis of shade %:

	REACTIVE/REMA RR/CIBA

Shade %	Salt mg/l	Soda mg/l
0-0.49	20	10
0.5-0.75	30	12
0.76–1.0	40	16
1.1 – 1.5	45	17
1.6 – 2.0	50	18
2.1 – 2.5	55	18
2.6 – 3.0	60	20
3.1 – 3.5	65	20
3.6 – 5.0	70	20
5.1 – 8.0	80	20

Merchandising Management

MERCHANDISING

BIG ORDERRRRRR!!!!!!!!!!!!!

Merchandising is the business art of matching sellers’ needs to the needs and

preferences of customers to ensure satisfaction with products.

Merchandiser has a lot of responsibilities. Some major responsibilities are as follows:

· Sourcing, Negotiation

· Consumption and costing

· Order receiving

· Product development and Sample controlling

· Fabrics, Yarn, Trims & Accessories purchasing & tracking

· Factory scheduling and production tracking

· Customer liaison during design, sourcing, production &

shipping.

Merchandising Procedure:

1. Contact with Buyer

· Introducing letter

· Vendor Inspection/ Evaluation

· Vendor approval

2. Order receiving process flow:

· project sheet

Competition for order!!!

· prepare costing

· price quotation

· meeting with buyer or face auction

· competition

· getting initial/optional order

3. Order development process

· Order confirmation (with qty,qly.m/c,

· sketch,del dt.

· fab,trim.accss lab dipping

approval

· sample making + development

4. Execute order in time

· fab + accss consumption calculation

· order placing to supplier(booking)

· follow up supplier delivery date

· store/ warehouse

5. Garments manufacture

Cutting

Sewing

Finishing

6. Final inspection

7. Pack list, weight list, Release letter

8. Ready for Export

Functions to execute export order perfectly in time

RUSH HOUR!!!

1. Fab requirement calculations

Fabric requirement = Order qty / 12 x Consumption

Consumption = Length x Chest / 10000 x GSM / 1000 x 2 x 12

2. Accessories requirement calculation

Sewing thread = Color wise order qty / 4000 (cone) x

consumption

Consumption = (3 x stitch length) + (2 x material thickness)

· Interlining requirement = Order qty / 12 x Consumption

· Shoulder Tape requirement = (Order qty x Consumption) / 36”

· Gum Tape requirement = (Order qty / Carton qty) / 6

· Stopper requirement = (Color wise order qty x No. of

stopper per Gmt x 5% allowance) / 12

· Rib = Order qty / 12 x Consumption

· Draw cord = (Order qty x Consumption) / 36”

· Main label, Sz & Cr lbl, Poly = (Order qty x 5%) / 12

· Barcode requirement = (Order qty x 10%) / 12

· Carton requirement = Total no. of pack / No. of pack per

ctn

3. Sources of Fab

4. Sources of Accessories

5. Possible date of arrival of fabrics & accessories in gmts fty

6. Costing

7. Gmts production planning

8. Pre shipment inspection schedule

9. Shipment documents

Various types of sales terms:

· FOB = Free On Board

· C&F = Cost and Freight

· CIF = Cost, Insurance and Freight

· FOA = FOB Airport

· FAS = Free Along Sideship

Various files in use:

· Price quotation & Project sheet

· Accessories supplier file

· Production file

· Master sheet

· Incoming & Outgoing File

UNDER SEVERE PRESSURE!!!!

· P/I File

· Sub contact file

· Recap

· Claim file

· Yarn & knit stock register

· Fabric booking

· Master L/C

· Fabric register book

· Shipment Status

· Release letter

QUALITY ASSURANCE SYSTEM

Store Dept:

Raw material quality is the first step to ensure the quality of the product. But the raw

material purchased from the good suppliers not ensures the quality. For that solution we

need to control the quality according to the buyers’ specification we need to emphasis

to the quality of purchased raw material by the quality inspection.

For the good production flow, the company deviled sousing. Finishing trims and

accessories into different places which are obviously the good idea for maintaining or

supplying the products. Those are called-

According to the buyers’ zone-

1. EUROTEN buyers’ store

2. U.S.A buyers’ zone

In SQ Group (CML). we have visited in two different stores. The stores are-

1. Fabric stores
2. Trim and accessories store

Fabric Store:

It is a store where the fabric was kept up according the buyer mains and order. The main

function of this store is to inspect the fabric and send it to the cutting according to

cutting requirement. In SQ Group (CML) I found that they have followed 4 point system

for fabric inspection. The inspection sequences for fabric inspection SQ Group (CML)

are as follows:

1. Collect the fabric from the suppliers.
2. Prepare general defective swatch board for all fabric.
3. Select the sample size randomly from the lot.
4. Mark the defects.
5. Inspect for the sample according to 4 point system.
6. Report to the quality control personnel.

1. Collect the fabric from the suppliers:

According to the purchase order sheet the store in charge receive the fabric to color,

shade and quantity.

2. Prepare the general defective swatch:

Common defects that can arise during inspection are prepared earlier as swatch, which

is hanged on the wall. Those defective swatches are helped for identify the defect to

the responsible persons.

3. Sample size selection:

The sample is 10% of total lot and it is selected randomly. The points that are

considered during selections are-

1. Color

2. Quality

3. Construction

If the quality does not exceed the acceptance quality level they will go for another 10%

inspection. If it also misses the accepted quality they will go for 100% inspection.

4. Mark the defects:

Often inspectors are given the responsibility if inspecting garments without adequate

training in fabric and their causes. The ultimate solution, of course, is to provide actual

examples or photographs of both major and minor defects. The quality control manager

can provide this list to inspectors as a particular tool for achieving uniform inspector

inspection decision.

Major defects:

A defect that, it conspicuous on the finished product would cause the item to be

second. (A second is a garment with a conspicuous defect that affects the salability or

serviceability of item.)

Minor defects:

A defect that would not cause the product to be termed a second, either because

severity of location. When inspecting piece goods prior to cutting it is necessary as

major. Since the inspection will not know where the defect may occur or the items.

Equipment Uses:

1. Light source:- For the inspection of the fabric fault we need sufficient light. The

sources of light are tube light.

2. Top light: There is 1 tube light in perpendicular to the direction of the fabric and

another is back light.

3. Machine: For inspection the need power driven fabric inspection machines

which brand name TSSM.

4. Arrow sticker
5. Measuring tape

Various Files in use:

• Order Sheet

• Delivery chalan

Inspect the sample according to 4 point system:

They apply 4 point system for fabric inspections are as follows:

Size of the defects (length) Penalty points

1. Up to 3” 1 point

2. 3” to 6” 2 point

3. 6” to 9” 3 points

4. Over 9” 4 points

Only major defects are considered for the penalty points.

Major defects are classified as follows:

slubs

hole

soil

shading

dye defect

printing defect other fabric defects

Lacking existing in the fabric inspection:

1. The space of the fabric inspection is not enough to ensure the quality.
2. The lighting positioning is not correctly maintained.
3. The light power is not enough to ensure or specified the defects.
4. All important points are not identified to the swatch board or no list can used in

the comfortable.

5. Bowing and skewing are ignored during the inspection.
6. The RPM of the inspection m/c are not better during inspection.

Suggestions against the fabric inspection:

1. The place should be increased with proper lightings.
2. All the important defects should be specified in the inspection room.
3. The RPM of the m/c must be adjusted according fabric and defects.
4. Skewing and bowing should be considered during fabric inspection

Lacking of the fabric storage:

1. Storing/placing one by one not good or correct for that any types of permanent
2. effect can be happen to the fabric.
3. The segmentation of buyer wise block is not maintained perfectly.
4. No use of order/color/shade wise demarcation and racking system. For that any

mistake can be occurred.

5. The ventilation system for ensures the quality is not maintained for that present

ordered fabric condition and the excess or extra fabric can be damage without any trace.

The suggestions against the fabric storing:

1. The fabric lot should be stored with crossly one another.
2. The fabric should be segmented with the demarcation and shade wise for the

order basis.

3. The ventilation system should be increased to maintain the temperature.
4. The racks can be used for the fabric storing

Trims and accessories store:

It is a small store where trim and accessories are arranged in the rack according to buyer wise. The main function of this store is to prepare or an inventory report compared with purchase order and input packing goods. They also prepare an

accessories swatch board to get approved from buyer.

Process flow:

• P.O. sheet,booking sheet.

• Order sheet follow up.

• Supplier contact

• Goods in-house

In case of local supplier

· Delivery chalan

· Inventory

In case of imported accessories

Supplier commercial invoice, packing list

· Good receive

— Chalan

— Joint inventory with supplier parts

— Reporting to supplier

· Goods style vs buyers’ mention

· Putting onto the rac

· Rac vim cart

In inspection sequence those maintained by SQ Group (CML) are as follows:

1. Compare with purchase order specification.
2. Select the sample size.
3. Categories the defective accessories from each product.
4. Compare the defective accessories with the limit of AQL 2.5
5. Report to the quality control personnel.

Sample size:

The sample size should be 10% lot of total quality. If it is rejected then they will go for

another 10% of total lot. If the total quality is within 500 they check 100% of lot. Lastly if

the last inspection failed then they go for the total lot inspection.

Categorized defective accessories:

They usually check individual product separately.

1. Sewing thread
2. Button
3. Price ticket

AQL measures:

The Consumer Products Limited has accepted accessories quality if the defective

sample is over 4% of the sample size.

Compare with P.O sheet:

After receiving the goods the quality in charge compare with P.O sheet specification.

Such as

1. Size
2. Color
3. Types
4. Etc

Lacking of the Store:

1. Insufficient light.
2. They don’t inspect all the time quality of the accessories.
3. Storing of the fabric is incorrect positioning.
4. Don’t consider the thread tenacity and thread elongation and running

View With Charts And Images  

INTRODUCTION

Industrial
Attachment is one of the best part to study a running processing technology of
the industrial unit for the final year Student of textile Engineering Dept. Of
Primeasia University. By going throw the industrial Attachment.

The
incumbent was deputed to SQ Group(Color master Ltd).For practical mill training
as per training programme arranged by University authority under the guidance
of color master Sampath jayakoda (Srilankan) and supervision of Chowdury Jony
Moin (Lecturer) &the industrial attachment report was prepared for 45 days
long  training programme in a composite
mill.

PROJECT DESCRIPTION

Name
of the Factory : SQ Group (color
master Ltd)

Type : 100% Export Oriented
Company.

Year
of Establishment: 2003

Address

Head office : North tower (10^th
floor),Uttara,Dhaka.

Tel:
8153669, 8116672 Fax :(880-2)8116673

colormaster@sqgc.com Web :www.sqgc.com

Owner
of the mill : Director, Mr. M Ghulam
Faruq

Authorised
capital   : Approx.100 crore  taka.

History
of the Project development:

2003:Estublishment
of the industry. First installmment of the machinary &started production.

2005:
Start of the construction of 3^rd and 4^th floor.
Installment of the Sweater Garment making.

2006:
Start of the construction of 5^th and 6^th floor
&started production of Garment making.

2007:
Installment of new project which are UK &Bangladesh Joint venture &
started production at the end of the year.

Physical
Infrastructure: Building -6
storied 

Floor space: 60000sq.ft

Total
area of the Industry : About 20500
sq.metre.

ORGANOGRAM

Chairman

?

Executive Director

?

? ?  ?

Finance Director

D.G.M Admin & SA

D.G.M Production

?

Commercial Section

Accounts Manager

Executive Offecer

Knitting Dpt. Sr. Manager

Asst, G. M.(dyeing)

Garments dept Manager

Marcendising Section

?

Admunistrative Officer

Engineering
section

Cutting

Sweing

Finishing

Computer
section

Telephone
Operatior

Transport
Section

Security
Section

?

Time Section

RESPONSIBILITIES OF PRODUCTION:

JOB
DESCRIPTION:

SENIOR PRODUCTION OFFICER:

PRODUCTION OFFICER  :

Production officer is the right hand of senior
production officer and he is directly related with production manpower and
inform senior prod.officer time to time . Here are his listed duties –

1)
Follow
up overall garments production ,

2)
Decide
every m/c  utilization during production,

3)
Recruit
new labor ,

4)
To
inform the authority on the overall garments prod. And make it financial
profitable,

5)
Regular
m/c maintenance,

6)
Maintain
sub –contract orders ,

7)
Help
knitting manager & also guide the junior officers of the section, etc.

REMARKS:

Production runs with the help of mechanical fiitrs. For
any kind of mechanical fault of any machine they fix and work under technical
in charge. Production officer’s takes account of daily production by running
after the two supervisors and workers so on.

 (MACHINE DESCRIPTION)

RAW MATERIALS

SL	Yarn Description	Yarn count
1	80% Cotton 20% polester CVC	NE 28/1
2	100% cotton carded	NE 30/1
3	NE 30/1
4	70% cotton 30% acrylic		5		6		7	Spandex/Lycra	70 Denier
8	99% cotton 1% Viscose	(A) Yarn  : (B) Accessories SL Item Description Quantity 1 Sewing Thread 4050 cone 2 Sewing Thread cone 3 Filament cone 4 Main Label 5912 doz 5 Size Label Doz. 6 Care Label Doz. 7 Single Poly Doz. 8 Poly sticker Doz. 9 Zipper 768 Doz. 10 Blister polybag 860 Doz. 11 Interlining 18 Roll 12 Cotton twil Tape 7700 Yds 13 Printed Gum Tape 300 Roll 14 Scotch Tape 100 roll 15 Button G.G 16 Gum Tape Roll 17 Carton 1790 pcs 18 Drawstring Yds 19 Herringbone Tape Yds 20 ¼ cotton shoulder Tape 36300 yds 21 Printed carton sticker 310 Doz. 22 T/C shoulder Tape 5600 Yds 23 Printing of 100% knit fabric Kgs 24 Woven Twil Tape 3900 yds 25 Mobilon Tape Doz. 26 Single poly Doz. 27 Spot Lifter Pcs Production Planning Sequences & Operation of Garments (Sweater) Making. Study on Sixth floor   Knitting section Total worker: 100 Floor worker commanding order: ? Assistant Production manager Floor In charge ? ? ? ? Helper Total line in the knitting section:4 Line sequence: Line A, Line B, Line C & Line D. MIC year line in knitting section: Line A contains 12 knitting m/c. Line B contains 10 knitting m/c. Line C contains 12 knitting m/c. Line, D contains 11 knitting m/c. . Floor knitting m/c list: Brand Name Model Origin M/C Gauge Shima Seiki SSF 152-T Japan 12 Shima Seiki SSF 152-T Japan 07 Shima Seiki SSF 152-T Japan 05 Flying Tiger 2001/2003/201/2005 Taiwan 3 Flying Tiger 2001/2003/201/2005 Taiwan 5 Flying Tiger 2001/2003/201/2005 Taiwan 7 Flying Tiger 2001/2003/201/2005 Taiwan 12 Sample fabric receive Design analysis Setting the machine for the specific design Production Inspection Linking Section Total worker:80 Floor worker commanding order: Assistant Production manager Floor Incharge ? ? Helper Total line in the Linking section:4 Line sequence: Line A, Line B, Line C & Line D. MIC year line in Linking section: Line A contains 10 Linking m/c. Line B contains 10  Linking m/c. Line C contains 08 Linking m/c. Line, D contains 10 Linking m/c. Sequence of operations in Linking  section:- Front part Back part Sleeve Side way Neck Inspection Production Process: ? Linking ? Overlocking ? Bar taking ? extra ply.) Mending (If have any hole,then repair it & sewing ) ? ? FQC (Final Quality Check) ? Care Lebelling Adjustment ? ? Measurement ? ? ? Taging ? ? Folding ? ? ? Blistering / Poly packing ? Cartooning ? OK ?  Shipment Note : During FQC if has any small stain then use zinclinc chemical for stain removing by spraying  system Bartaking Overlocking Mending PQC &Measuring     Carelavelling adjustment Ironing     Production Planning Sequences & Operation of Garments(Sweater) Dyeing. Acrylic Piece Dyeing Production: 100 % PAN Cahmilon Colour: Green M/C No: 01 No. Of Garments: 189 pcs. Weight: 43.00 kg M.L.R: 30 Paddle RPM: 18 Recipe: Dyeing Chemicals GPL/ % Rubine ES 1.0 g/l 1800.0 g Megasoft BBK 1.5 % 645.0 g Taigal PAN 1.21 % 520.3 g Glauber Salt 5.0 % 2150.0 g Dyeacid HP 0.22 g/l 396.0 g PH =4.5 Dye stuff: Name % Calculated Used Taicryl Yellow 4GNT 0.09458 40.669 40.26g Maxilon Red GRL 150 % 0.00200 0.858 0.84g Maxilon Blue GRL 150 % 0.01026 4.413 4.35g Procedure: Step 1 Add all Chemical at 70ºC run 05 min. Add Dye at 70 ºC run 05 min Heating 85 ºC× 5 min Timer Setting 1   10 sec 2   5 sec Heating 92 ºC× 10 min Timer Setting 1   12 sec 2   3 sec Heating 99 ºC× 30 min Timer Setting 1   10 sec 2   3 sec Air cooling at 70 ºC Direct cool slight open valve to 40 ºC Dark col. Additional rinsing. 100 % PAN Cahmilon Colour: Rose M/C No: 01 No. Of Garments: 355 pcs. Weight: 65.00 kg M.L.R: 30 Paddle RPM: 18 Recipe: Dyeing Chemicals GPL/ % Rubine ES 1.0 g/l 1800.0 g Megasoft BBK 1.5 % 645.0 g Taigal PAN 1.62 % 1053.0 g Glauber Salt 7.0 % 4550.0 g Dyeacid HP 0.22 g/l 396.0 g PH =4.5 Dye stuff: Name % Calculated Used Maxilon G. Yellow GL 400 % 0.00775 5.038 5.04g Maxilon Red SL 200 % 0.0159 10.322 10.32g Maxilon Blue SL 200 % 0.0020 1.326 1.33g Procedure: Step 1 Add all Chemical at 70ºC run 05 min. Add Dye at 70 ºC run 05 min Heating 85 ºC× 5 min Timer Setting 1   10 sec 2   5 sec Step 3 92 ºC× 10 min Timer Setting 1   12 sec 2   2 sec Step 4 Heating 95 ºC× 30 min Timer Setting 1   12 sec 2   3 sec Air cooling at 70 ºC Direct cool slight open valve to 40 ºC Dark col.  Need Additional rinsing. Acrylic Piece Dyeing Production: 100 % PAN Cahmilon Colour: Mid Blue M/C No: 01 No. Of Garments: 406 pcs. Weight: 65.00 kg M.L.R: 30 Paddle RPM: 18 Recipe: Dyeing Chemicals GPL/ % Rubine ES 1.0 g/l 1800.0 g Megasoft BBK 1.5 % 975.0 g Taigal PAN 1.30 % 845.0 g Glauber Salt 8.0 % 5200.0 g Dyeacid HP 0.22 g/l 396.0 g PH =4.5 Dye stuff: Name % Calculated Used Maxilon G. Yellow GL 400 % 0.0004 0.260 0.26 g Maxilon Red SL 200 % 0.00076 0.494 0.49 g Maxilon Blue SL 200 % 0.012 7.800 7.80 g Procedure: Step 1 Add all Chemical at 70ºC run 05 min. Add Dye at 70 ºC run 05 min 85 ºC× 5 min Timer Setting 1   10 sec 2   5 sec Heating 92 ºC× 10 min Timer Setting 1   10 sec 2   4 sec 95 ºC× 20 min Timer Setting 1   6  sec 2   4 sec Air cooling to 70 ºC Direct cool slight open valve to 40 ºC Dark col.  Need Additional rinsing. Production Planning Sequences & Operation of Yarn Dyeing. RECIEPE NO: BL-81791007 PROCEDURE  : 705 CUSTOMER : PROMOD KNITWEAR YARN LOT : D-1 QUALITY : 32/2 100% CO NO.OF PKG   :104 ORDER : SPB-245/07   COLOUR NO : SEA BREAZ BATCH WEIGHT : 106   LIQOUR AMOUNT (L)   : 690 LIQOUR RATIO : 6.51 NAME REL. AMOUNT IN RECIPE AMOUT UNIT BLEACHING @ 98’C* 40’ 01 EMERALD DLJ   1.0000g/l   0.6900kg INATEX MD 0.5000 g/l 0.3450 kg SECORON – 540 0.5000 g/l 0.3450 kg STABILIZER SOF 0.5000 g/l 0.3450 kg 02. CAUSTIC SODA 2.0000  g/l 1.9800 kg 03HYPROZEN PEROXIDE  2.0000 g/l   1.9800 kg 04. ERIOPON 0.5000 g/l   0.3450 kg 05. ACETIC ACIDE   0.5000 g/l   0.9450 kg COTTON DYEING @ 60’C*30’ 06.CIBACEL DBC 1.000 g/l 0.6900 kg KOLASOL CAD 0.2000 g/l 0.1380 kg 07. GLOBAR SALT   15.0000 g/l 10.3500 kg 08. SODA ASH 2.5000 g/l 1.7250 kg 09CIBA YALLOW FN -2R 0.00565%   0.0059 kg CIBA RED FNR 0.022032 %   0.0234 kg SOAPING @ 95’C*20’ 10. ACTIC ACID 0.5000 g/l   0.3450 kg 11. ERIOPON R 0.5000  g/l   0.3450 kg 12 ERIOPON R   0.5000  g/l   0.0000 kg FINISHING @40’C*20’ 13. ACTIC ACID   0.0700 g/l 0.04830 kg RECIEPE NO:  RE-53120107-CON PROCEDURE   : 531 CUSTOMER : PROMOD KNITWEAR YARN LOT : Q-6 QUALITY : 20/2 100% CO NO.OF PKG   : 04 ORDER : SPB-243/07 COLOUR NO : RED BATCH WEIGHT : 600 LIQOUR AMOUNT (L)   : 33 LIQOUR RATIO : 0.06 BLEACHING @ 98’C* 40’ 01 EMERALD DLJ   1.0000g/l 33.000gm TINOCLORITE COM 5.000 g/l 165.000 gm 02. CAUSTIC SODA 2.0000  g/l   66.000 gm 03HYPROZEN PEROXIDE 2.0000 g/l 66.000 gm 04. ERIOPON R 0.5000 g/l   16.5000 gm 05. ACETIC ACIDE   0.5000 g/l  16.5000 gm COTTON DYEING @ 60’C*30’ 06.CIBACEL DBC 1.000 g/l 33.000 gm KOLASOL CAD 0.2000 g/l 6.6000 gm 07. GLOBAR SALT   80.0000 g/l 2640.000  gm IMCO RED E3BF 7.500000 %   45000.0000 gm SOAPING @ 95’C*20’ 10. ACTIC ACID 0.5000 g/l   16.5000 gm 11. ERIOPON R 2.5000  g/l   82.5000 gm 12 ERIOPON R   2.0000  g/l   33.0000 gm FINISHING @40’C*20’ 13. ACTIC ACID   0.0700 g/l 2.3100 gm 14 TUBINGAL   2.0000% 12000.0000gm RECIEPE NO: BK-84471107-D PROCEDURE : 500 CUSTOMER : MANTRUST LOT : Q-6 QUALITY : 20/2 100% CO NO.OF PKG   :04 ORDER : SPB-251/07   COLOUR NO : BLACK BATCH WEIGHT : 4.72   LIQOUR AMOUNT (L)   : 33 LIQOUR RATIO : 6.99 WASH @ 80’C* 10’ 01WETANAL SN 1.5000g/l 0.0495kg WASH@70’C*10’ WETANAL SN 1.5000 g/l  49.5000 kg EMERALD DLJ 1.5000g/l   49.5000kg SECORON – 540 0.5000 g/l 16.5000kg ACETIC ACID 2.3000 g/l 75.9000 kg COTTON DYEING @ 60’C*30’ 06.CIBACEL DBC 1.000 g/l    33.0000 gm KOLAZOL CDA 0.2000 g/l   6.6000 gm 07. GLOBAR SALT   80.0000 g/l 2640.0000  gm 08. SODA ASH 5.0000 g/l 165.0000 gm SOAPING @ 95’C*20’ 10. ACTIC ACID 0.5000 g/l   16.5000 gm 11. ERIOPON R 2.0000  g/l   66.0000gm 12 ERIOPON R 2.0000  g/l 66.0000 gm FINISHING @40’C*20’ 13. ACTIC ACID   0.0700 g/l 02.3100 gm Operation Sequences of Wet Lab. Dyeing Lab: Machine name (Functional): Sample Dyeing m/c Machine name (Functional): Tumble Drier Machine name (Functional): Color fastness test (CCM) Machine name (Functional): Color match / Metamerism Test Machine name (Functional): Light-Fastness Tester Machine name (Functional): Pipeting   Special features of Rapid Sample dyeing Machine:- 19 samples can be dyed at the same time Speed controller unit Good movement of liquor Procedure of Lap dip– The main objectives of lab dip preparation:- # For good dyeing. # For good shade matching. # Mass production suitable. Lab Procedure for the 100 % cotton fabric:- Calculate the recipe. Weight the fabric. Take the beaker keep the fabric in to the beaker. Then the dyes, chemicals & required amount of water take in to the beaker by the digital pipeting. Then weight the salt by the electric balance and add in to the beaker. Then the beaker set in to the lab dyeing machine for dyeing. Start the program for dyeing the whole dyeing time 60 min at 60 °C temperature. (The dyeing time and temperature depends on which classes of dyes are used for dyeing.) After 30 min add the then add the soda ash. By pipeting. Again run the program next 30 min at the same temperature. Finished the dyeing time then the sample taken from the beaker first cold wash & then cold wash. Then acid wash as for neutralization. Then soaping required soap solution 10 min at 90° C temperature. After the fabric again cold. Then dry the lab dip and compare with the standard. Amount of salt soda used on the basis of shade %:   REACTIVE/REMA RR/CIBA   Shade % Salt mg/l Soda mg/l 0-0.49 20 10 0.5-0.75 30 12 0.76–1.0 40 16 1.1 – 1.5 45 17 1.6 – 2.0 50 18 2.1 – 2.5 55 18 2.6 – 3.0 60 20 3.1 – 3.5 65 20 3.6 – 5.0 70 20 5.1 – 8.0 80 20 Merchandising Management  MERCHANDISING BIG ORDERRRRRR!!!!!!!!!!!!! Merchandising is the business art of matching sellers’ needs to the needs and preferences of customers to ensure satisfaction with products. Merchandiser has a lot of responsibilities. Some major responsibilities are as follows: · Sourcing, Negotiation · Consumption and costing · Order receiving · Product development and Sample controlling · Fabrics, Yarn, Trims & Accessories purchasing & tracking · Factory scheduling and production tracking · Customer liaison during design, sourcing, production & Merchandising Procedure: Contact with Buyer · Introducing letter · Vendor Inspection/ Evaluation · Vendor approval Order receiving process flow: · project sheet · · price quotation · meeting with buyer or face auction · competition · getting initial/optional order Order development process · Order confirmation (with qty,qly.m/c, · sketch,del dt. · fab,trim.accss lab dipping · sample making + development Execute order in time · fab + accss consumption calculation · order placing to supplier(booking) · follow up supplier delivery date · store/ warehouse Cutting Sewing Finishing Functions to execute export order perfectly in time 1.  Fab requirement calculations Fabric requirement = Order qty / 12 x Consumption Consumption = Length x Chest / 10000 x GSM / 1000 x 2 x 12 2.  Accessories requirement calculation Sewing thread = Color wise order qty / 4000 (cone) x consumption Consumption = (3 x stitch length) + (2 x material thickness) · Interlining requirement = Order qty / 12 x Consumption · Shoulder Tape requirement = (Order qty x Consumption) / 36” · Gum Tape requirement = (Order qty / Carton qty) / 6 · Stopper requirement = (Color wise order qty x No. of stopper per Gmt x 5% allowance) / 12 · Rib = Order qty / 12 x Consumption · Draw cord = (Order qty x Consumption) / 36” · Main label, Sz & Cr lbl, Poly = (Order qty x 5%) / 12 · Barcode requirement = (Order qty x 10%) / 12 · Carton requirement = Total no. of pack / No. of pack per ctn Various types of sales terms: · FOB = Free On Board · · CIF = Cost, Insurance and Freight · FOA = FOB Airport · FAS = Free Along Sideship Various files in use: · Price quotation & Project sheet · Accessories supplier file · Production file · Master sheet · · P/I File · Sub contact file · Recap · Claim file · · Fabric booking · Master L/C · Fabric register book   · Shipment Status · Release letter QUALITY ASSURANCE SYSTEM Store Dept: Raw material quality is the first step to ensure the quality of the product. But the raw material purchased from the good suppliers not ensures the quality. For that solution we need to control the quality according to the buyers’ specification we need to emphasis to the quality of purchased raw material by the quality inspection. For the good production flow, the company deviled sousing. Finishing trims and accessories into different places which are obviously the good idea for maintaining or supplying the products. Those are called- According to the buyers’ zone- 1. EUROTEN buyers’ store 2. U.S.A buyers’ zone In SQ Group (CML). we have visited in two different stores. The stores are- Fabric stores Trim and accessories store Fabric Store: It is a store where the fabric was kept up according the buyer mains and order. The main function of this store is to inspect the fabric and send it to the cutting according to cutting requirement. In SQ Group (CML) I found that they have followed 4 point system for fabric inspection. The inspection sequences for fabric inspection SQ Group (CML) are as follows: Collect the fabric from the suppliers. Prepare general defective swatch board for all fabric. Select the sample size randomly from the lot. Mark the defects. Inspect for the sample according to 4 point system. Report to the quality control personnel. Collect the fabric from the suppliers: According to the purchase order sheet the store in charge receive the fabric to color, shade and quantity. Prepare the general defective swatch: Common defects that can arise during inspection are prepared earlier as swatch, which is hanged on the wall. Those defective swatches are helped for identify the defect to the responsible persons. Sample size selection: The sample is 10% of total lot and it is selected randomly. The points that are considered during selections are- Color Quality Construction If the quality does not exceed the acceptance quality level they will go for another 10% inspection. If it also misses the accepted quality they will go for 100% inspection. 4. Mark the defects: Often inspectors are given the responsibility if inspecting garments without adequate  training in fabric and their causes. The ultimate solution, of course, is to provide actual examples or photographs of both major and minor defects. The quality control manager can provide this list to inspectors as a particular tool for achieving uniform inspector inspection decision. Major defects: A defect that, it conspicuous on the finished product would cause the item to be second. (A second is a garment with a conspicuous defect that affects the salability or serviceability of item.) Minor defects: A defect that would not cause the product to be termed a second, either because severity of location. When inspecting piece goods prior to cutting it is necessary as major. Since the inspection will not know where the defect may occur or the items.     Equipment Uses: Light source:- For the inspection of the fabric fault we need sufficient light. The sources of light are tube light. Top light: There is 1 tube light in perpendicular to the direction of the fabric and another is back light. Machine: For inspection the need power driven fabric inspection machines which brand name TSSM. Arrow sticker Measuring tape Various Files in use: • Order Sheet • Delivery chalan   Inspect the sample according to 4 point system: They apply 4 point system for fabric inspections are as follows: Size of the defects (length) Penalty points 1. Up to 3” 1 point 2. 3” to 6” 2 point 3. 6” to 9” 3 points 4. Over 9” 4 points Only major defects are considered for the penalty points. Major defects are classified as follows: slubs hole soil shading dye defect printing defect other fabric defects Lacking existing in the fabric inspection: The space of the fabric inspection is not enough to ensure the quality. The lighting positioning is not correctly maintained. The light power is not enough to ensure or specified the defects. All important points are not identified to the swatch board or no list can used in the comfortable. Bowing and skewing are ignored during the inspection. The RPM of the inspection m/c are not better during inspection.   Suggestions against the fabric inspection: The place should be increased with proper lightings. All the important defects should be specified in the inspection room. The RPM of the m/c must be adjusted according fabric and defects. Skewing and bowing should be considered during fabric inspection   Lacking of the fabric storage: Storing/placing one by one not good or correct for that any types of permanent effect can be happen to the fabric. The segmentation of buyer wise block is not maintained perfectly. No use of order/color/shade wise demarcation and racking system. For that any mistake can be occurred. The ventilation system for ensures the quality is not maintained for that present ordered fabric condition and the excess or extra fabric can be damage without any trace. The suggestions against the fabric storing: The fabric lot should be stored with crossly one another. The fabric should be segmented with the demarcation and shade wise for the order basis. The ventilation system should be increased to maintain the temperature. The racks can be used for the fabric storing   Trims and accessories store: It is a small store where trim and accessories are arranged in the rack according to buyer wise. The main function of this store is to prepare or an inventory report compared with purchase order and input packing goods. They also prepare an accessories swatch board to get approved from buyer. Process flow: • P.O. sheet, booking sheet. • Order sheet follow up. • Supplier contact • Goods in-house In case of local supplier · Delivery chalan · Inventory In case of imported accessories Supplier commercial invoice, packing list · Good receive — Chalan — Joint inventory with supplier parts — Reporting to supplier · Goods style vs buyers’ mention · Putting onto the rac · Rac vim cart In inspection sequence those maintained by SQ Group (CML) are as follows: Compare with purchase order specification. Select the sample size. Categories the defective accessories from each product. Compare the defective accessories with the limit of AQL 2.5 Report to the quality control personnel.   Sample size: The sample size should be 10% lot of total quality. If it is rejected then they will go for another 10% of total lot. If the total quality is within 500 they check 100% of lot. Lastly if the last inspection failed then they go for the total lot inspection. Categorized defective accessories: They usually check individual product separately. AQL measures: The Consumer Products Limited has accepted accessories quality if the defective sample is over 4% of the sample size.   Compare with P.O sheet: After receiving the goods the quality in charge compare with P.O sheet specification. Such as Size Color Types Etc   Lacking of the Store: Insufficient light. They don’t inspect all the time quality of the accessories. Storing of the fabric is incorrect positioning. Don’t consider the thread tenacity and thread elongation and running performance of sewing thread so that accurate sewing threads are not specified. The store temperature is not controlled for the stability of the product. This can reduce quality. For the inspection of the accessories there no specific table and space. The store is not all time controlled by the quality control department. During the inspection the shade variation are not consider very important. The last order was not stocked in a rule. The quality pass not specified. After the 10% check which can mix up with other in inspected material. Delivery to Floor/ Fty:   — Fabric cutting statement to supervisor — Supervisor statement & requisition — Submit to store — Examine & follow up the requisition — Delivery to floor — Store delivery man resubmits requisition to store officer — Issue into the register book & stock the balance. Sample Section Samples must be checked by the quality control personnel before sending it to the buyer.Important points to be checked whether the samples are as per buyers’ specifications or not such as style description, sketch, measurement sheet, photograph etc. and workmanship has to be checked with reference samples or related documents provided by the buyer. Report to be submitted to the merchandiser as well as to the superior. Work process flow: • Analyze Spec & Meas Chart • Preparing consumption • Sample cutting & sewing • M/C check • Send to buyer • Comment from buyer / buyers’ agent • • Sample approval • Size set pattern making for all sizes • Test cutting order placed to cutting section • Pattern correction (if needed) • Order place for final cutting Lacking of the Sample section: The inspection place is congested. The inspection table is not sufficient high. There is no quality pass. Cutting Floor Process flow: • Collect PO sheet from merchandising department • Collect pattern from sample section • As per ratio wise marker sketching • Receive Fabricss from store • Fab layup as per marker lenth • Marker setting on fab • Cutting • Numbering • Bundling / Sorting • Cut panel inspection  • Send to sewing dept. Cutting: Plan to measure, mark and cut the binding and border strips before cutting patches from the same fabric. Cut larger patches before smaller ones. For best use of fabric, arrange patches with cutting lines close or touching. Patches for hand piecing require precisely marked seam lines. To mark the patches, place the template face down on the wrong side of the fabric and draw around it accurately with a sharp pencil. Leave approximately 1/2″ between the patches for seam allowances. After marking, cut outward from the seam line 1/4″, measuring the distance by eye. For machine piecing, accurate cutting of the patches is very important. Place template face down on the wrong side of the fabric and mark the cutting line Reverse (r) templates for both hand and machine piecing should be placed face up on the wrong side of the fabric.   Templates for appliqué do not include turn-under allowances. Place the template face up on the right side of fabric (face down on right side for a reverse patch); draw around it with a pencil. Cut out each appliqué patch about 3/16″ from the penciled line Grainline: One or more straight sides of the patch should follow the lengthwise or crosswise grain of fabric, especially the sides that will be on the outside edges of the quilt block. We indicate lengthwise or crosswise grain with an arrow on the pattern piece. Various files in use: • Daily cutting report • Daily input statement • Bundle chart • Cut panel checking report • Fab inspection report   Cutting Section: There are various types of work done by the cutting section. We can divided their work by following: Pattern/Marker: Pattern and marker must be checked by the quality control personnel.   Spreading: During spreading some important points to be checked such as fabric relaxation, incorrect tension of plies etc. Cutting: Inaccurate cutting, notches, misplaced, drill mark, careless knife cut, frayed edges are to be checked. Beside these bundle card ,numbering, wrong size, fused parts, cleanliness, proper issuing are to be checked. Lacking of the cutting section: We have found the quality control personnel were gossiping when they are working. There are not enough quality personnel in the cutting room. Spreading is not checked by the quality control personnel. Knitting section · Flat knitting section Circular knitting section  Process flow — Getting order — Yarn count selection & purchase — Machine type selection — Making grey program — Start production — Supply to dyeing dept. Various files in use: Order sheet file Sample order sheet Daily production report Progress report Problems: · Short manpower · Lack of production officer · Lack of quality section · No engineering dept. Sewing floor Process flow: · Taking cutting statement from cutting section · Receive cut pc · Sorting Operation sequence of POLO Shirt: · Placket making · Placket marking · Front part marking · Placket join with body · · Sleeve hem · Sleeve join · Collar join · Collar piping join · Send to finishing section Finishing section This is the final section to make the product saleable condition and finishing process should be controlled to achieve the quality target. For wash garments 100% check is required after receiving the garment from the washing plant. Defective garments should be rectified and reject pieces should be sorted out. Process flow: Iron/press Folding Folding getup check Tagging/sticking Packing Audit Pre-final inspection Final inspection. Wow!!Shipment gone!!! Maintenance Maintenance is a procedure by which we can maintain active functioning in operation according to the behavior and utility of a particular element. In engineering, we use this terminology for maintaining smooth and uninterrupted performance of machines, tools and metallurgical characteristics in practical uses. Three types of maintenance are performed in SQ GROUP (Color master Ltd): Preventive Maintenance Routine / Schedule Maintenance Breakdown Maintenance Preventive Maintenance: Actions performed periodically (or continuously) prior to functional failure to achieve the desired level of safety and reliability for an item. These actions are performed to prevent or reduce consequences of failures. Schedule maintenance: It is a time based maintenance and pre-planned to perform on machine and equipments. This plan usually made on monthly basis. Breakdown maintenance: In this type of maintenance when the machine remains stop that time the maintenance is done. Name of Tools Functions Hammer To give shape. Slide Wrench Tightening and opening bolt. Spanner Tightening and opening bolt. Pliar Cutting, Holding, Joining wire, Gripping. Hacksaw Cutting. Pipe Wrench Tightening, opening, gripping pipe. Chesel Shaping, Cutting. File Shaping. Clamp Gripping. Vice Name of Equipments Functions Grinding m/c. Grinding. Cutting m/c. Cutting. Drill m/c. Drilling. Shaping m/c. Shaping. Lathe m/c. To make something. Bending m/c. Bending. Maintenance Procedure: Preventive Maintenance: They always follow preventive maintenance. Break-down maintenance: When a problem occurred the operator informed the supervisor, then the supervisor informed the production officer, then the production officer called the maintenance officer. The maintenance officer visits the problem and takes necessary steps to solve the problem. Flow chart of maintenance Problem occurred Operator Supervisor Production officer Maintenance officer Solution Remarks: Utility Services UTILITY SERVICES Introduction: DESCRIPTION OF MACHINE NO. OF CAPACITY MACHIENE Generated Power: Prime Power generation, Cruascar Gas Generator 636 KW Model FGLD 480 – Origin Spain. Stand by – Diesel Generator, Puma, Origin 140 KW England A. Sub station 1000 KVA Total Connected load 1776 KW Air Compressor: Kaeser Screw Compressor, Model AS44, 30 KW, 4 2 Units M3/Min each. Omgersp:-Rand Reciprocating Compressor, I unit 8.00 M³/Min Model-SSR ML-50 57.5 Kw Capacity of Air Discharge Ingersoll-Rand Reciprocating Compressor, Model 2 Units 4.40 M³/Min 3000. 22 Kw SWAN Reciprocating Compressor, Model C40-80 1.00 M³/Min 10KW TOTAL AIR DISCHARGE CAPACITY Water Pumps Centrifugal Pump for water supply to Dyeing & Others Section. 20 H.P. Pedrollo Pump each pump, 1000 L/mi-n Flow rate 4 Units 4,000.00 L/Min 10 H.P. Pedrollo Pump Flow rate- 600 L/Min I Unit 600.OOL/Min 5.5 H.P. Pedrollo Pump Flow rate -350 L/Min I Unit 350.00 L/Mm Spare Pump Motor Pedrollo 20 H.P. I Unit 1,000 L/Min BOILER: Ciever Brooks Boiler 10 Ton/Hr Water treatment plant There are two deep tubeweel by the two side of the treatment plant. There are also two submersible pumps in the deep tubeweel one is 100 ft deep and another is 140 ft deep. The submersible pump transfer raw water in the water tank by creates force. The formation of oxidation of the water by showering with the help of another two pumps in the water tank. Iron content removes by the oxidation. Two circular transfer raw water in the (vessel no 1) Multigrade filter unit. The large size plastic, iron that means solid content are removed in the multigrade filter unit. The water is transferred in to the (vessel no 2) Activated carbon filter unit. In the (vessel no 2) Activated carbon unit to remove chlorine that means bad smell. The water then transfer in to the (vessel no 3) softener unit from the activated carbon unit at the presence of cationic resin (Zeolite) is reacted with water to remove the hardness of water. The water is transferred in to the reserve tank from the softener unit. The soft water is supplied from the reserve tank by the 7 Boosting pump in the different section of the factory. The back wash process to clean the vessel no 1, 2 , & 3 . The back wash process should be done after 8 -12 hrs .After 40-48 hrs later the regeneration process should be done. It should be done after back wash process. After back wash the common salt dissolved with water in to the STT (salt saturated tank) the solution of common salt is ringing the resin by the injector. The use of 18% salt in the total solution. (Suppose, 5000 lit of solution the amount of salt 600 kg). The resin is activated by the salt rising. Here used cationic resin (NaHSO3). If the pH of the water increase or decrease it should be control by the dosing chemical (Sodium Hypochlorite) from the chemical tank. Details on ETP: Effluent Treatment Plant (ETP) is a plant by which waste water is treated in order to make the waste water environmental friendly. Effluent Treatment makes sure that water releases meet Bangladesh Environmental Association water quality standard. It is very important and essential to keep the environment pollution free. Now a day ETP is the most important term to set a textile industry. Government, Environmental Association and foreign buyers are creating pressure to set ETP in every textile industry .So to ensure the proper growth of textile sector and pollution free environment every textile industries have to set up an ETP. There are three effluent treatment plants which are:- Ø Physico-chemical treatment plant Ø Chemical-biological plant Ø Biological treatment plant Chemical treatment plant:- In this process effluent water are mainly converted into sludge of metal complex by chemical reaction. Then it is separated from the water and dried and dipped into the soil. But the sludge remain activate which is harmful. Effluent ? Sludge of metal complex ? Dry sludge ? Dipped into soil (Activated hazardous) Biological treatment plant:- This process is mainly build up by using micro-organism. This is Bacteria, Amoeba, and Protozoa. Bacteria are two types, one is Anaerobic& Aerobic. First one is hazardous for our environment and second one is friendly for our environment. In here Bacteria break the bond of harmful chemical by enzyme secretion. As a result harmful chemical converted into environmental friendly. The sludge produces by this process is also used as different functions such as fertilizer, fuel in the brick field. · bacterial · amoeba · protozoa Bacteria: 1. Bacilli 2. Cocci 3. Beggiatoa 5. Vitereoeilla Protozoa: Ø  Paramecium caudatum Ø  Euplotes Ø  Colpidium Amoeba: v  Rotifiers v  Cillities v  Novcotidia Remarks: As the biggest project the SQ GROUP (Color master Limited) so the vast utility systems. There is a skill manpower group of engineers and other technical staffs to look after these utility services. They have to remain aware of solution on a great sense of responsibility for any type of problem due to utility supply. Store &Inventory Control INTRODUCTION: Inventory is planning and execution involves participation by most of the fundamental segment of business sales, production, purchase, finance and accounting. Inventory is a wider sense is defined as any idle resource of an enterprise however it is semi finished packing spares and other stocked in order to meet an expected demand or distribution. OBJECTIVES OF INVENTORY CONTROL: 1) Financial activities: a) To save amount of investment b) To know the cash position 2) Property Protection: a) Preventable waste b) Insurable damage c) Unauthorized use 3) Operating: a) To obtain the best overall balance between production and inventory carrying cost. b) To minimize losses, c) To avoid stock out and to keep inventory holding costs in costs in balance. The prime responsibility for the inventory management function in the company including the estimation of consumption quantities of raw materials over the forecast period and initiation of a purchase requisition keeping in view quantities is transit and an order and the adequacy as otherwise of material coverage during lead time is as follows: The Procurement Department is responsible primarily for the sourcing of raw material. The flow chart of requisition of raw materials is as follows: Factory requisition Audit Department Commercial Local   Import   Factory External Internal Accessory dyes / chemicals yarn   grey fabrics finished fabrics finished store     Inventory system of Raw materials: o Grey fabric is stored in the Grey store. The batch is prepared by taking Grey fabrics from Grey store. o There is a separate store for Dyes & Chemicals. Various types of Dyes & Chemicals are stored here according to company’s storing criteria. The operator takes Dyes & Chemicals from this store according to Recipe Sheet. Inventory system of Finished Goods: They do not store finished fabric. They make delivery of finished fabric to Garments just after completion of finishing. They only store some rejected fabrics. Remarks: Inventory management is good & satisfactory Cost Analysis Following information is unavailable- Price of the product Costing of the product  REMARKS Costing is as important as production for a productive factory. Without proper costing all production curriculums will go to in vain. Cause, a factory cannot reach to its goal without achieving good profit and good profit is not possible without skillful costing. Seeing the improvement of SQ GROUP (color master Limited ) day by day, I can assume that it follows the right and proper way of costing with skillful technical persons. Marketing Activities INTRODUCTION: Marketing activities are done in this mill, SQ Group (Color masterLimited)by a skillful team of marketing officers under the Executive Director. Here are the details of marketing activities. CONSUMER OF THE PRODUCTS: The mill has a great number of renowned and international consumers. Following are some regular consumers: 3) Primark PRODUCT LEBEL: There are following lebels used by this mill: 1) Care Lebel: It contains washing in hot or cold water, chemical cleaning, drying conditions etc. 2) Size Lebel: It contains size of garments. 3) Composition Lebel: It contains the fabric composition of different fibre type. 4) Decorative Lebel: Decoration is as buyer or consumer choice wise. PACKAGE SIZE & LEBEL: Most common sizes are S ? Small M ? Medium L ? Large XL ? Extra large XLL ? Very very large LOCAL MARKET: IMPORTING COUNTRIES: This mill relates to the countries for yam importing, they are 1) India 2) Korea MARKETING ACTIVITIVES Business style FOB Consumer of the products Foreigner (England) Optional buyers : Quantum clothing Mantrust MANPOWER: Almost ten marketing officers and ten others workers act under the Executive Director. 1) Executive director takes order from the buyer and gives order the marketing officer’s troops to produce a cost sheet. 2) Marketing officers are known the amount and design of product. 3) They collect the sample from the buyers and send to knitting and dyeing section. 4) Knitting section adjusts the amount of total yam and knitting conditions and dyeing sections adjust the amount of dyes and chemicals. They send a rough calculation to the marketing section. 5) Marketing officers adjust the amount of garments accessories with the help of their own experiences and their knowledge. They also take help of garments in charge. 6) Finally, they adjust their cost sheet after consulting with the Executive Director and copy several pieces of the cost sheet. REMARKS: Marketing activities are very important tasks for a productive factory. In this mill, there having highly qualified marketing officers. As a result, the mill rises up day by day Conclusion 40 days long training gave me actual picture about man, m/cs, money, material, method and market and interdependence. I have Learned the direct practical knowledge about the raw materials, actual running condition of the m/cs, works of technologist, administration. This mill does not follow the routine maintenance schedule of international standard. So I think that installation of raw materials quality control section will must. The Sample fabric inspection section is also so improved. During our training I visited administration section, godown, store, boiler house, generator room etc. Everywhere I  got cordial response from the employees. Above all this training for 40 days in the SQ GROUP (color master Limited )has given me a new experience for practical life.