Industrial training in oeko tex group by Md Papon

“Industrial Training” In Oeko Tex Group

Introduction Bangladesh is one of the leading readymade garments exporters of the world. Every year Bangladesh exports more than one third of the total garments requirement of the RMG market of the world. Every year Bangladesh earns more than 76% of its foreign currency from this sector .That is why the study of garments technology does deserve well practical practice. OEKO-TEX GROUP is a truly Exclusive fashion house that deals with lots of stuff like fabric quality, garments quality, embroidery quality, washing quality. The Garments Division has the capability to offer a complete product range for the 100% export to EU & USA market. The vision of the Garment Division is to become the preferred partner for sourcing high quality value added garments from Bangladesh. With an urge to developing local human resource, the Garments Division has the potential to make an important contribution to the nation’s growing RMG export sector to make it more competitive.

Factory profile Company Status Type

OEKO-TEX GROUP Private Limited Company 100%Knit Garments Manufacturing Factory

Established

22nd August, 2002

Year Of Established

11 Year

Daily Capacity

20,000 Pc’s Per Day.

Annual Turnover

$18 Million

Product

All Types Of Knit Garments.

Total Employee

10,000 Persons, Male 40%, Female 60%

Office

House#103, Northern Road, DOHS, Baridhara, Dhaka-1206 South Panishail, Zirani Bazar, Kashimpur, Gazipur Sadar, Gazipur

Factory Concern Business Unit

Contact Website

OEKO TEX LTD. YASIN KNITTEX LTD. EQUITEX ASSURANCE. EQUI TEX ACCESSORIES SAJID PROPERTIES Tel:+88-02-7702713; Fax:+88-02-7788139; www.oeko-texltd.co

# SATELLITE VIEW OF OEKO TEX GROUP: # ADMINISTRATIVE BUILDING

# OEKO TEX. LTD; #YASIN KNITTEX LTD

Vision: To produce the high quality products in the most environmentally friendly way possible, harmony and Employees. Mission: o Provide on time quality service. o Concentrated on employee’s welfare. o Committed for greener and cleaner environment. o Friendly working environment through open communication and mutual trust .

OEKO-TEX GROUP OEKO-TEX GROUPValues:

o Customers satisfaction o Fairness o Ethical Business o Environment o Commitment o Innovation o Integrity

ORGANOGRAM

CHAPTER-3 GARMENTS MERCHANDISING Merchandising: Definition: 1. “Garments merchandising is the combination of some works like buyer development, work order collection, prizing, sample development approval of sample, fabrics and accessories collection, production follow up, documentation, delivery in time etc.” 2. “To know about garments for selling is called garments merchandising”. Responsibilities of Merchandiser: 1. To negotiate the prize for the seller, if prize is high, then it is less chance to get the order. On the other hand if prize is low, then there is a chance to incur loss for the factory, so it is very risky job for a merchandiser and have to remember it. 2. Have to give more competitive prize without compromising the quality. 3. They have to maintain good relation with the buyer for getting more business in the future.

4. Have to purchase all material (fabrics & accessories) within competitive prize for making the garments as per buyer instruction regarding quality. 5. To execute the order within limited time that is timely delivery shipment is must, otherwise if goods are not shift in time, then buyer will not accept the goods, in that case it will be loss for a factory.

Talk to buyer (Buyer developing) Receive order, information of buyer Consumption of material Costing of material including cm Negotiation with buyer Order received (L/C Back to back L/C opening for purchasing Sample approving Approval for mass bulk production Related work to production planning Start bulk production Line inspection Final inspection by buyer or buyer representative Shipment to buyer Sending document to buyer for payment Payment received from bank

GARMENTS MERCHANDISING The term “merchandising” is well known to the persons specially involved in garments trade. The term merchandising has been derived from the term merchandise. Merchandise means goods that are bought & sold. The term “merchandiser” may be defined as the person who merchandises the goods. Garments merchandising means buying raw materials & accessories, producing required garments, maintaining required quality level and exporting the garments within time frame. We can assume that a person involved in garments merchandising need a wide range of knowledge & skill to perform his job successfully a merchandiser should possess the following basic knowledge and skill. a) b) C) d)

Command of English and adequate knowledge of technical terms for accurate and efficient communication. Knowledge of yarn, fabric, and dyeing, printing, finishing, dyes color fastness garments production, etc. Conception of usual potential quality problems in the garments manufacturing. Knowledge of the raw materials inception systems & garments inspection systems.

\ Activities of Merchandising Activities of Merchandising Department are as follows:  Communication with Buyers Procure Order & Order confirmation

Factory Scheduling / Planning

Order Follow up: all steps of production & Quality

Costing

Consumption

Ensure On Time Delivery

Price Quoting

Sample Control & Approval

Liaison with the customer during Design, Sourcing, Production & Shipping

Potential Sourcing of Materials & Approval Fabric, Trims & Accessories

Conduct coordination Meeting with other departments / Pre production meeting

Lab dipping & Approval

Attend Buyer’s meeting

Purchasing of Materials

Ensure Customer Satisfaction

Testing

Product Development etc.

Fabric Consumption Calculation of a Knit T-Shirt Back Part 75 cm ( length) x 50 cm ( Chest width) Front Part

3750 scm

75 cm ( Front length) x 50 cm ( Front chest width)

3750 scm

Sleeve 24 cm ( Sleeve length) x 40 cm ( Armhole width) x 2 ( 2 sleeves) Total Fabrics Consumption

1920 scm 9420 scm

Let us make the 9420 scm into Meters than Kg: 9420 scm divided by 10000 scm ( 100 x 100 = 10000 scm)

0.942 m

Let us say 1 square meter fabric weight 140 gm divided by 1000 0.942 m fabric weight ( 0.942 x 0.14)

140 gm 0.14 kg 0.13188 kg

1 Pc Knit T Shirt Weight Therefore, 12 Pcs Knit T Shirt Weight (0.13188 X 12)

0.13188 Kg 1.59 Kg

GARMENTS ACCESSORIES Garments accessories means all items used in the garment except the basic is called garments trims. There are hundreds of items used to manufacture the garments which are used as trims. Accessories: 1) Sewing threads and sew able item d. Back board a. Thread e. Neck board b. Button f. Collar inside c. Main label g. Butter fly (Single, Double) d. Size label h. Tag pin e. Care label i. Tissue paper f. Velcro (Hook and loop fastener) j. Draw string and stopper g. La k. Scotch Paper 1) Finishing item: l. Tissue Paper a. Price ticket m. Plastic: clip b. Hang tag n. Collar insert c. Poly bag o. Collar bone 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. 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. Ensuring on time shipment: Once the inspection is done and the goods found ok for shipment, then the goods handed over to the clearing and forwarding agent for on time shipment. Cost Calculation System During the fixation of price following notes are to be followed carefully: • Cost of fabric Cost of accessories /Doz. garments. • C. M (Cost of manufacturing)/Doz. Garments • Cost of transportation from factory to sea port or airport. • Clearing & forwarding cost

• •

Overhead Cost. Commission/Profit.

Cost Calculation of a Garment item

width

consumption

unit price $

amount $

58”

3 YDS

0.75

2.25

Shell “B” Lining

65/35 TC PU Coating 65/35 TC NT 210 T PD

58” 60”

0.11 YDS 2.59 YDS

0.70 0.73

0.08 1.89

insulation Padding

AFD 500 D 150 GM

60”

2 YDS

0.80

1.60

fabric Shell “A”

N/P 44” 0.35 YDS 0.30 KCX-3 38” 0.38 YDS 0.12 Sub Total accessories Zipper V # 5 One Way 1.02 PCS 0.35 Plastic Button 1.02 PCS 0.02 (Small) Plastic Button (Big) 13.26 PCS 0.02 Eyelet 8.16 PCS 0.01 Main Label Woven 1.02 PCS 0.20 Size Label Print 1.02 PCS 0.10 Care Label 1.02 PCS 0.10 Thread 60S 0.20 CONE 0.69 Stopper 4.08 PCS 0.05 Stopper Bead 4.08 PCS 0.01 Velcro Pile 25 MM 0.15 YDS 0.10 Velcro Hook 25 MM 0.23 YDS 0.10 Cotton String 6 MM 4 YDS 0.04 Hang Tag 1.02 PCS 0.15 Packing Poly, Blister, Carton etc 1.02 0.25 Sub Total Material Total Cost of Manufacturer Cost of Production Transport Cost from factory to sea port or airport (0.5% Of Cost of Production) Clearing & forwarding Cost (2% Of Cost of Production) Overhead Cost (0.5% Of Cost of Production) Total Cost Commission (10% of Total Cost) Net FOB Price - SOME BUYER’S NAMES:  Lotto, Trinova, Spring field, Women Secret, sela. USA

JC PENNY FILA LEE

0.105 0.046 5.97 0.36 0.02 0.27 0.08 0.204 0.102 0.102 0.14 0.20 0.04 0.02 0.02 0.16 0.15 0.26 2.13 8.10 1.00 9.10 0.05 0.18 0.05 9.38 0.94 10.32

CANADA

OTHERS

MERKS & SPENCER CELIO SPORTS, -

GAP -

ZARA

NIKE ZELLERS HUDSONâ&#x20AC;&#x2122;S BAY COMPANY

VOILANCE (BROUCHU) SPARKLES W-Mart

TYPES OF ORDER: FOB (Free on Board) Order: This is the export term of delivery and price quotation. The sellers send the goods for export and deliver them on board. The risk is past from seller to buyer, when the goods are loaded in the ship at the port at departure. The buyer pays the freight charge and the seller does not include the freight charge with his costing. FOA (Free on Air) Order: The seller delivers the goods to the air carrier at the airport of departure. The buyer bears the risk from that moment and pays air transport cost. The seller bears the cost of materials and making, does not include air freight. C & F (Cost and Freight) Order: The seller sends the goods for export, pays the freight charge also and delivers the goods on board. The seller bears the cost of materials, making also freight charge. CMC (Cutting, Making and Carton) Order: Like CM order, the seller does not add the price of fabrics and trimmings but add the price of the carton with carton. CIF (Cost Insurance Freight) Order: An agreement between a buyer and a seller in which the seller is responsible for paying for shipping and providing a minimum amount of insurance coverage up to the named port of destination, while the buyer is responsible for the transportation risk beyond the minimum coverage as soon as the good or product is loaded onto the ship. Legally, risk transfers when the good or product crosses the outer rail of the ship. CIFC (Cost, Freight, Insurance and Commission) Order: At this order seller include the cost of insurance, freight and commission for local buying house. CMT (Cost of Making and Trimming) Order: In this case the buyer fixes the rate of CMT with the factory, so the seller does not add the price of fabric with his costing, but at L/C buyer gives all money to the factory, factory

collects only C.M money from bank and balance return to fabric supplies. The order system is following the tailoring shop. CM (Cost of Making) Order: In this case buyer fixes the rate of CM only with factory. So the seller does not include the prize of fabric and trimmings with his costing, but at L/C buyer gives all money to factory. Factory collects only CM money from the bank and balance money return to trimmings and fabric supplies.

TT (Telephonic Transfer) Order: When order quantity is very small and need urgent delivery, in that case buyer gives purchase contract instead of L/C and sends money to seller bank by TT. After getting money seller sends the goods to the buyer. Subcontract Order: It is indirect order. The order received by another factory and when it is not possible for that factory to complete the production within the time in that case they share the order with other factory by giving subcontract. The subcontract factory only get the CM charge by local money from the order taker. Exchange order: In this case the buyer did not pay any money against by garment from Bangladesh. Instead of money they are giving us another goods or product which is surplus in their country. But we need it very much. This type of business is very rare. They use L/C for doing this type of business. 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 fabric is back to the supplier. The types of fabric defect are check in 4 point inspection system. -

Oil spot

- Net.

Missing yarn

- Knot

Dye defect

- Broken yarn.

Hole

Color yarn

Drop pick

- Slub yarn - Color shading.

4- Point inspection system: Defects (length wise): 1. 2. 3. 4. 5.

Penalty point:

0-3 inch……………………………1 3-6 inch……………………………2 6-9 inch……………………………3 9 inch & above…………………....4 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 36 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, zippers, 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 stored 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. ii.

iii. iv.

Size label: It contains the size of the garment 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 Cost label: It contains the cost of garments. 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 pc’s. 750 gross =144×750=108000 pc’s. Toggle: Special type of accessories used in jacket, bags etc. To reduce and increase the length and also for better fitting, it is used. Interlining: Types of interlining are available in store room are given below. o o o o o

Dot fuse. Paper fuse. T.C interlining. Woven fabric fuse. Non fuse etc.

Packing section: Various types of packing accessories are available in store room such as polybag, packing board, tissue paper, hanger, scotch tape, gum tape, carton etc. Flow sequence of packing section is given below: Make shipping mark according to P/O, PDM sheet Approve from buyer Carton measurement confirm from Q.C dept Sample make (carton) Re-approved from buyer Ensure net and gross weight Go to bulk production Complete the carton with garment Cartons are made according to buyer instruction and length wise it contains the buyer name, widthwise it contain the measurement, net & gross weight. Carton contain the information are printed by screen print style. Quality for Inventory/Storage: Fabrics or other Raw Materials and Accessories should be safe from the following: 1. Soiling, 2. Mechanical damage, 3. Environmental damage due to temp. & R.H% which may cause dimensional changes,

4. Fungal Attack, 5. Fadding due to light exposure, 6. Damage during Handli Industrial Engineering: The main function of this department is to re- engineering the garment from the sampling stage so that it would be production friendly for the production as well helps to increase the productivity through machine layout, time and motion study. In the sewn products industries we must continually ensure that we remain competitive and profitable whilst also striving to improve our personal and community’s standard of living. Productivity improvements may be achieved through: Industrial Engineering Department : -

the

Time study

Capacity study

Workers training

development

M/c sequence lay out

SMV calculation & Line

Thread consumption

target

Operator Interview

production process -

Work

process

Efficiency control

Duties and Activities of a Work Study Officer: •

Style details collect

•

SMV make

•

Layout make

•

Machine arrange

•

Attend P.P meeting

•

First week production plan

•

Line feeding

•

Work aid arrange

•

Method study (innovation) & take video & record

•

Time study

•

Line capacity find out

•

Bottle neck operation find out

•

Individually follow up bottle neck operation and try To increase production

•

Capacity & efficiency wise target setting & try to achieving

•

Line balancing

•

Motivation the worker

•

Maximum time stay in production line & try to solve any kinds of production related problem

•

Monitoring the production achievement hourly & daily

•

Loss time record

•

Overall, try to increases the productivity.

All work study- techniques are classified into two main groups the specimen bellows by typical:

METHOD STUDY

Layout Work flow Machinery Standardize method Quality specification Capital investment appraisal Attachment Sewing method specification

WORK MEASUREMENT

Time standards Hourly targets Production checks Line balancing Training curves Maintain payment systems

Method Study May be defined as: The systematic recording and critical examination of existing and alternative methods of work, to facilitate the introduction of more efficient and cost effective methods. The basic procedure: Select: identifies the areas where results can be achieved these are usually where there are: Bottlenecks increased cost persistent overtime working, Excess fatigue safety hazards high labor turnover high absenteeism Record: Record though observation all of the exact details of an operation with regard to: Machinery used attachments used operator method quality specification Handling system work place layout sequence position online Examine: critically examine all of the recorded method details. Question each detail: Can it be eliminated? Can it be combined? Can the sequence be changed? Can it be simplified?

Easy motions characteristics The methods analyst should strive to incorporate the following into methods: Minimum:

Using finger, wrist, and elbow movements rather than making shoulder and body movements. Simultaneous: Using both hands at same time whenever possible. Symmetrical: Left and right arms moving at the same time in opposite directions. Natural:

Free sewing movements are faster and easier then controlled movements.

Continues:

Continuous curve movements are better than straight line movements involving sudden or Sharpe changes in directions. Smooth automatic movements must be encouraged.

Rhythmic: Habitual: `

Movements that have become automatic as they do not require additional Concentration.

Workplace layout: The layout of a workplace impacts directly on the pattern of movements and consequently time taking to perfume and operation When analyzing a method the following steps should be considered: Step 1: Sketch the existing workplace layout. Sketch the shape of the work table noting any modification to the standard, e.g. extensions or cut downs Sketch the position and clearly identify any work aids or attachments e.g. guides, reel feed etc. Sketch in the position of products parts before they are processed; clearly identify the part of parts Sketch where the parts are placed after processing Step 2: analyzed how to products parts are moved within the work place Know: How part is first obtained how the operators holds the part Where the part is move to how the part is presented to the machine How the part is disposed of by the operator where the part is disposed to. Step 3: Describe the method in simple movements; GSD is the best analysis tool for this. The motions are typically: Pick up Position align Sew Measure Cut/ trim Place aside Step 4: From the list of movements the key points for attention should be identified Finger/ hand position

Number of sewing bursts Quality specification- tolerances, notch alignment, fabric position etc. Special skill requirements Step 5: The critical examination stage: Identify and eliminate excess movements’ e.g. checking, smoothing and positioning motions that are not fundamental to the method or company policy. Identify and eliminate stretching or body movements. Strive to achieve a method that contains only motions with “Easy Characteristics” Work measurement: There are number of different techniques that can be used to carry out work measurement within the sewn products industries, the traditional alternative to general sewing data is time study. The skills required are: 1. The ability, skill and experienced to read and operate a stopwatch. 2. The ability, skills and experienced to assess the rate of working (performance) of individuals workers. Time study: This is the process by which we calculate the SMV (standard minute value) in “in process inspection”. There are two types of SMV such as estimate SMV and garments SMV. It is done by following formula, Take a stop watch and take times for 10 times for a operation and finally calculate the SMV of this operation and production per hour. .Steps in taking time study: A glossary of terms is contained in the manual so that the student may refer to it for specific definitions. 1. Prior to commencement it is essential that there are commutations to all interested parties. Manager’s

supervisor’s

workers representative’s

operators

2. Ensure the prevailing conditions are suitable for a reliable time study. •

The operators are properly trained and skilled – not trainees

•

The materials being used are of the correct quality.

•

There is sufficient work available for a time study to be completed without interruption.

•

The machine, equipment and work aids are correct and in working order

•

Ensure that health and safety rules are observed

•

The work place and working method meets the official special specifications.

3. It is vital that all relevant details are recorded before the start of study e.g. Study number date

name of work study engg.

Style reference size

color

fabric type

Date of study

trim details

product type

quality specifications

Department work aids.

line/team/section machine type machine speed stitch density Attachments

4. Before commencing the study break the operations down into elements so that observed Assessment of rate of working and time taken can be recorded during the study.

After completing the study: 1. Record the watch elapsed time and calculate the observe study time . Then calculate unaccounted time and watch error. The tolerance allowed - Âą 2% 2. Extend the observe elemental /operation rating and times into basic time 3. Calculate the average basic time for each element /operation cycle. 4. Apply the appropriate relaxation, Delay and contingency allowances to the basic times in order to calculate the standard time either for each element or the operation as a hole. 5. Where an appropriate some all of the elemental standard times in order to compile a standard time for the operation. 6. As appropriate convert the standard time to the standard time allowed time by applying the appropriate performance factor to the standard time using the formula below.

SAM= SMV Ă&#x2014; Line balancing: Line balancing is the allocation of sewing machine according to style and design of garment. It depends of that what type of garment we have to produce. The Objectives of Line Balancing: Line balancing is a main part of a mass production. These kinds of systems, regardless of being different in details, are workstations in a sequence. Row material is included in the line at the beginning or in the middle. Parts included in the system transfers from one workstation through the other and at the end leaves the system as a completed product. Transfer lines uses manpower very little when compared to assembly lines. The certain properties of Transfer lines are transfer and process of a product automatically through a line. Objectives that should be gained balancing an assembly line are as follows; o

Regular material flow;

Maximum usage of man power and machine capacity;

Minimum process times;

Minimizing workstations;

Maximum outputs at the desired timed;

Agreed quality maintenance of the garments;

Reduce production costs.

Importance of Line Balancing: The importance of line balancing could be summarized as follows – •

Good line balancing increases the rate of production;

•

This is the pre-condition for smooth production;

•

Line balancing helps to compare the required machinery with the existing one and make a balance;

•

It also helps in the determination of labor requirement;

•

Good balancing reduces production time;

•

Profit of a factory can be ensured by proper line balancing;

•

Proper line balancing ensures optimum production at the agreed quality;

•

It reduces faults in the finished products;

•

Line balancing helps to know about new machines required for new styles;

•

It becomes easier to distribute particular job to each operator;

•

It becomes possible to deliver goods at right time at the agreed quality for least costs.

Steps in Line Balancing: Now-a-days, Standard Minute Value (SMV) is used as a tool for the line balancing, production control and the estimation of efficiency. In a similar way, the time taken to do a job for making garments like shirt/trouser/blouse/dresses could depend upon a number of factors like – 

The length of the shirt/trouser/blouse/dress;



The number of stitches per inch;



The presentation of item;



The pricing of garments. Sample section

Introduction: Sample section is the most important section in the Garment industry. Here all types of sample are developed. Sometime developing section help to develop a new type of sample. Here the operator and the managerial level are very much efficient than the other section. Here the operator is selected according to their work efficiency & also the experience. Skilled operator is allowed to work in this section. Because sample must has to be unique & the best quality, out looking also very good. Without a skilled setup this is impossible. Process sequence:

Buying office reference merchandiser Merchandiser to pattern section Pattern making Sample cutting Sample sewing Quality inspection Ironing Quality final inspection & measurement Folding & packing Send to buyer Types of sample produce by OEKO GROUP 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. Proto/ 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. 5. Wash sample: Shade of wash sample must be matched with original sample after washing. It also determined by grey scale. 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 Pattern section: In this section normally pattern is modified. The main pattern of garment is made by the buying house (Shing on) and sends to the sample section thru merchandising department. Pattern making: After receiving an order in most cases buyer gives them a complete pattern and they make sample according to given pattern. But in some cases they prepare the pattern by own when buyer don not give any pattern. Working procedure of this section: • • • • • • • • • •

Collect pattern from merchandising department. Check pattern by following the tech pack. If the measurement is correct then make a sample and send it for wash. After washing check the measurement again, if any shrinkage is found then modify the pattern according to shrinkage and again send for washing. Again check the garment, if it is correct then send it to the merchandising department for getting approval. After getting approval make samples according to buyer’s requirement and send it for wash. And check the measurement after getting the garment from washing section and send it to the merchandising department for approval. If it is approved then send the modified pattern to the CAD section for pattern grading. Then made different sizes of sample buyer asked and send it to them thru merchandising department for approval. After getting approval working procedure of sample section is finished

MARKER Marker making: Marker is a thin paper which contains all the pattern pieces of a garment. It is made just before cutting and its purpose is to minimize the wastages. The width of a marker is equal to the width of the fabric

and it should not be greater than the width of the fabric i.e. the width of the marker is kept less than or equal to the width of the Fabric. The pattern pieces should be placed very carefully in such a way that it will obviously minimize wastages.

Objects of marker making: -

To reduce cost;

To improve the quality of the garments;

To reduce the cutting time;

To facilitate large scale production.

Possibilities of marker making:

Generally there are two methods by which marker can be made – MANUAL METHOD: The man performs it by himself using his hands. It is a conventional system and requires more time. Manually two types of marker are made – 1. Full size marker: Full size marker is made for production purpose. 2. Miniature type marker: Miniature type marker is sometime made and its purposes are to plan or schedule and learn or study i.e. for planning and learning purposes. COMPUTERIZED METHOD: Now the commonly used system of marker making is computerized method. In this system, a man performs it by himself using computer software (CAD and CAM) and it requires considerably less time than manual system. Two types of marker are generally made using computerized system – 1. Full size marker: Using ‘Digitalizing Board’ the pattern pieces are input into the computer. Computer uses software and a marker paper is printed out that will be used in the production. 2. Miniature type marker: Only for learning, practicing, and planning purposes this type of marker is printed from the computer. Computerized system is also two types – Interactive:

Manually it is done by using computer. Generally a computer operator can do it and requires less time. Automatic: The pattern pieces are replaced on to the marker by programming. A high technician can do so and it requires more time. Factors considered during marker making: The important factors considered during marker making are â&#x20AC;&#x201C; Nature of the Fabric: The fabric may be either symmetric or asymmetric. Thus the nature of the fabric should be considered during marker making. Lay planning of patterns: Improper lay planning of patterns may create more wastage. Thus it should be taken under consideration. Alignment of the pattern pieces according to the grain line: It is also another important factor that must be considered. The warp direction of a fabric is very much important for a garment and the grain line indicates the warp or wale direction. Requirements of cutting: Before placing the pattern pieces on to the marker or during marker making the cutting allowances are considered where necessary and where is not. It may produce more wastage and may reduce the dimensions of patterns. Production planning: Different types and sizes if garments manufacturing may un at a time in an industry. So during marker making it should be considered. Size of marker: During marker making we have to think about the table size, length of the fabric, etc. Marker Efficiency:

The ratio between the total areas of the pattern pieces to the total area of the maker paper is technically termed as Marker Efficiency. It is expressed in percentage. If it is denoted by the symbol ή then – Marker Efficiency (ή) = (Total areas of the pattern pieces/Total area of the Marker paper) * 100 The factors which influence the Marker Efficiency – •

Manufacturers of the marker;

•

Nature of the fabric;

•

Size of pattern pieces;

•

Method of marker making;

•

Length of the marker;

•

Marker width;

•

Pattern Engineering;

•

Kinds or design of garments.

Constraint of Marker making: The hinders of marker making are –

Grain Line: Grain line is a more effective constraint of marker making. Because of grain line sometimes it is tough to place the pattern pieces on to the marker, even though it is possible the wastage become higher. Design of Garments: Sometimes the designs and repeats of the fabric are regarded as constraints of marker making. The patterns may miss the designs or may overlap the designs. Nature of the Fabric: Nature of the fabric may sometimes be regarded as a constraint of marker making. Nature of the fabric includes symmetric and asymmetric. Cutting Accuracy: Accurate cutting may be one of the constraints of marker making. Production Planning: Production planning includes rate of production, types of garments, sizes of garments, etc.

Fabric wastages inside and outside of the marker: INSIDE WASTAGE: That wastage that is obtained from the inter-spaces of the pattern pieces in the marker paper. It depends on the efficiency of the marker maker and on the size of the patterns as well. OUTSIDE WASTAGE: Besides the inside wastages, some fabric is wasted outside of the marker â&#x20AC;&#x201C; Ends of the ply losses: Generally each ply of the fabric losses up to 4 cm at both sides (Two sides * 2 cm). End of fabric losses: The length of fabric may sometimes not cover the ply, it may finish its end at less than 5 yards (cut piece). This piece of fabric goes through wastage and is called end of fabric losses. Selvedge losses: Generally selvedge losses are 2% to 3%. Purchase losses: Sometimes losses may arise from purchase. Wrong consumption calculation may cause huge wastage. Computerized marker making system: To get the optimum efficiency of markers as well as to minimize fabric wastage they done marker by computerized marker making system (Lectra). It has the digitizer by which the patterns are make grade and with the help of the software as well get output as marker with the plotter. The Lectra system is discussed in below. Cutting section: Cutting In-charge implement the instruction of the production manager. It is very necessary to ensure available of fabric, machine, marker, paper, and accessories. Cutting ration is done as per number of size. In this section fabrics are inspected thoroughly by spreading it on the table. Quality table is used for major checking; main purpose of the quality table is to remove the rejected part. The whole fabric will be rejected if there is even a minor problem. After checking fabric properly the next steps are to ensure markers according to consumption and spreading. Various operations are carried out in cutting department. Cutting section is divided into three sections:

Marker planning.

Spreading.

Cutting.

Flow sequence of cutting: Fabric inspection Fabric send to store Fabric received from store Marker making Fabric spreading Setting marker on the fabric lay Fabric cutting Numbering Prepare the bundling card Bundling Quality inspection & part back is fold together Store Cutting machine: Machine name: k.M. company cloth cutting m/c Model

: K.M KS_AUV

Producer

: Made by K.M. cutting m/c co, JAPAN

Type

: Heavy duty industrial cloth cutting m/c self sharpening

Dimension

: 8 inch witch Ă&#x2014; 11 inch length Ă&#x2014; 24 inch height

Weight

: 33.5 lb

Current

: A.C (3.3/2.6 amps)

Speeds

: 3000/3600

Machine parts : Base plate Terminal block

Plug Clamp washer Pressure foot Blade Sharpener pulley Pulley spring On/off switch

Fig: Straight knife cutting m/c Straight knife blades: Straight knife blades available for most industrial straight knife cloth cutting machines. All popular blades available from stock. Special or hard to find blades can be made to order. Straight edge blades in sizes 4" to 14" Wavy edge blades in sizes 4" to 14" Coated blades in sizes 4" to 14"

Advantages: • • • •

Cutting could be done for up to 10 inch depth of the lay. Quick fabric cutting. Grinding could be done during cutting. Could be cut at any angle.

Disadvantage: • •

Knife deflection may result due to heavy weight of the motor. Higher the depth of the lay, higher will be the deflection.

•

Possibility of accident is higher.

Machine and equipments used in: • • • • • • • • • • • • • • • • • • • •

• • • •

Fabric inspection machine Pattern Marker Marker paper Tracing wheel CAD system Cutting table Auto Spreader (Garber & Lectra) Auto Cutter (Garber) Measuring tape Pencil Gum tape/ scotch tape Weight scale Spreading stand Auto spreader (computer control) Clamp Spike Ruler Scissors Cutting machine -Straight knife -Band knife -Round knife -Die press -Hot Notcher -Computer controlled cutting machine. Drill machine Metal globes Bundle card Rack

Fabric spreading Before fabric laying a thin paper as like as marker that is marker size and thin paper size is same, then thin paper attach with spreading table by gum tape then spread the fabric according to marker size. Fabrics Roll spreading Inspection: • • • •

Roll number, GSM, Shade number, No. of lays, Ends of Bits

Spreading Quality Control (Defects):

• Table marking, • Ends, • Splices or Joints, • Leaning, • Tension, • Counts, • Remnants, • Fabrics flaws, • Marker placing Setting marker on the fabric lay Spread down the marker paper over the fabric lay with gum tape

SPREADING MACHINE MACHINE

MANUAL CUTTING

Fabric cutting Fabric lay is cutting by straight knife cutting machine then separated cutting part Cutting section (CEC): •

Gerber spreader

•

Kouris spreader

•

TSM spreader

: 5 pcs

•

Gerber cutter

: 3 pcs

•

BM Auto Arm Cutter

: 9 pcs

•

Lay End Cutter

•

Hand Cutter

: 50 pcs

•

Auto Strip Cutting Machine

: 1 pcs

•

Cutting Table

: 20 pcs

: 4 pcs : 2 pcs

: 7 pcs

Cutting Section Quality Control: The step by step process by which we check quality in the Cutting Section. Quality Inspection for Marker: • • •

Every parts Measurement check, Calculate the total no. of parts of each Garments, Marker length & width determined.

Numbering In this stage sticker is attached with all part of cutting part for shade matching. The sticker number maintains cutting number, size number, serial number. Prepared the bundling card Prepared bundling card according to fabric lay report this card maintain 1. Program No

3. Size No.

2. Cutting No

4. Pies

3. 5. Roll No. Bundling In this stage all number parts are bundled according to serial number. Quality inspection &front part-back part are fold together Here all part are checked according to following fault a. 17. Oil spot b. 18. Dirty spot c. 19. crease mark d. 20. needle mark e. 21. foreign yarn f.

22. slub

g. 23. contamination h. 24. hole Then same number of sticker are matched fold & bundled After Cutting store All bundles are put in the input rack then send to sewing section The sequence of the operation in Cutting Section is as follows FLOW SEQUENCE OF CUTTING

Fabric inspection Fabric send to store Fabric received from store Marker making Fabric spreading Setting marker on the fabric lay Fabric cutting Numbering Prepared the bundling card Bundling Quality inspection & front part- back part is fold together Store LIMITATIONS OF CUTTING SECTION : 1. Input problem. 2. Scissor man cuts the tubular fabric to spread randomly and send to cutting floor and then find out the desired fabric to lay on the table. 3. There is may be no group for any table 4. Quality inspection & front part & back part are fold together. The faulty body parts are rejected but the rest ok body is not match by the same batch. 5. Cutting quality man may not be trained 6. Check, Variegated rib fabric lay quantity may be excess. As a result reject percentage may be increased. 7. Fabric spreading 8. There is may be no identification number to the rest of the cutting piece of the lay 9. There is no individual marker man for any unit. 10. Three cutting man cuts the fabric according to the marker.

Machine identification

There are three types of garment industry in RMG sector: • Woven Garment Industry: The industry manufacturing garments and using woven fabric. Ex: Shirt, Trouser, Blouse, Steeping gown etc. • Knit Garment Industry (cut & sews): The Industry producing garments and using knitted fabric. Ex: T-shirt. Polo shirt, Tank top etc. • Fully Fashion Garment Industry: The Industry producing knitted garments and using yarn as main materials instead of fabric Ex: Sweater, Pullover, Cardigan etc. Machine Identification : Types of sewing machine : • • • • • •

• • • • •

Plain m/c (S/N) Double needle m/c (D/N) Overlock m/c (O/L) Flat lock m/c (F/L) Kanshai m/c

Thread use in different Machine: Machine type

Thread type

Plain / Auto plain m/c

1 needle thread 1 bobbin thread

Double needle m/c

2 needle thread 2 bobbin thread 2 needle thread 2 looper thread

Over lock m/c 2 needle thread Cylinder bed m/c

3 needle thread 1 spreader thread 1 looper thread

Flat bed m/c

3 needle thread 1 spreader thread 1 looper thread

Different sewing machine parts:

Button hole m/c Button join m/c Bartake m/c Cylinder bed m/c Flat bed m/c .

Single needle sewing machine or plain m/c Fig: plain m/c

Machine Parts: • • • • • • • • • • • • •

Thread Stand Thread Clamp Thread Retainer Thread up lever guide Thread up lever guide Thread guide Tension disk Pressure screw Pressure bar Pressure feet Hand lifter Needle clamp Needle

Over lock sewing machine

Fig: Over lock sewing machine

• • • • • • • • • • • •

Needle Plate Feed dog SPI adjust Reverse lever Bobbin winder Pulley Oil sight winder Pulley belt cover Leg lifter Foot Safety guide Motor

Machine Parts: • Thread Stand • Thread Clamp • Thread Retainer • Thread Guide • Tension Disk • Pressure Screw • Pressure Bar • Pressure Feet • Pressure Spring • Eye Protection Glass • Upper & Lower Looper

• • • • • • • • • • •

Needle Clump Needle Needle Plate Feed dog SPI Adjustor Pulley Oil Sight Window Pulley Belt Cover Leg Lifter Safety Guide Motor

Cylinder bed machine:

Fig: Cylinder bed machine Machine Parts: • Thread Stand • • Thread Clamp • • Thread Retainer • • Thread Guide • • Tension Disk • • Pressure Screw • • Pressure Bar • • Pressure Fee • • Eye Protection Glass • • Looper • Flat bed sewing machine:

Needle Clamp Needle Needle Plate Feed dog SPI Adjustor Spreader Mechanism Oil Side Window Pulley Belt Cover Safety Guide Motor

Fig: Flat bed machine Machine parts: Thread stand Thread clamp Thread retainer Thread up lever guide Thread guide Tension disk Pressure screw Pressure bar Pressure foot Hand lifter Needle clamp Needle Needle plate Feed dog

SPI adjustor Revers lever Bobbin winder Pulley Oil sight window Pulley belt cover Leg lifter Safety guide Motor Eye protection guide Lopper Spreader mechanism Piping mechanism (Folder)

Sewing: The process of joining fabric or seam is called Sewing. Elements of Sewing: • Sewing Thread, • Needle & • Sewing Machine

SEWING Flow-Sequence of Sewing Section:

Cutting fabric load in sewing section Line plan according to style or design Marking Matching according to bundle no. Sewing according to Gmts. design or style Quality inspection during sewing Quality inspection after sewing Excess Thread cutting Remove dirt & dust from Gmts. surface Quality Audit Send to next process. SEWING THREADS:- Cotton

- Silk

- Synthetics

- Wool

- Core spun

- Linen

SEWING NEEDLE: A sewing needle is a long slender tool with a pointed tip. The first needles were made of bone or wood; modern ones are manufactured from high carbon steel wire, nickel- or gold plated for corrosion resistance. The highest quality embroidery needles are made of platinum. Needle size is denoted by a number on the packet. The convention for sizing is that the length and thickness of a needle increases as the size number decreases. For example, a size 1 needle will be thicker and longer, while a size 10 will be shorter and finer. FUNCTION OF NEEDLE: ** To produce a hole in the material for the thread to pass through without causing any damage to material. ** To from a loop that will be picked up by the hook of the bobbin case. PARTS OF A SEWING NEEDLE:

Fig: Sewing Needle 1. But: It is the 1st part of a needle which is specially shaped so that the needle can easily set in the needle bar or clamp. 2. Shank: After butt we find the shank which is adjusted with needle bar. It may be cylindrical or flat. It is the coarser & stronger part of needle. 3. Shoulder: It is the meddle part pf shank and blade. When needle penetrates in the fabric Shoulder also penetrates .it help to make larger hole, then friction between needle and fabric become less. 4. Blade: From shoulder to needle eye long part of needle. in this portion friction between needle and fabric is maximum. 5. Long groove. The long and thin groove between needle eye and shoulder .When needle penetrates in fabric needle thread take position in long groove. As a result friction between needle thread and fabric become less. So lower heat is generated less possibility of damaging fabric. 6. Eye: In front of needle there is a hole which is known as needle eye. Eye size is very important the eye which is coarser than the blade is use for sewing heavy fabric. It create problem during sewing thin fabric. 7. Scarf: The groove of needle above needle eye is called scarf .It help for closer setting of needle and looper.

8. Needle Point: From eye to tip is known as point. Point is so shaped that cannot damage the fabric. 9. Tip: The last part of needle. It helps to make hole. SEAM: The line of joining fabric is called seam. Different types of seams with sketch : Types of seams: 1. Class -1 (Supper imposed seam) 2. Class - 2 (Lapped seam) 3. Class - 3 (Bound seam) 4. Class - 4 (Flat seam) 5. Class - 5 (Decorative seam) 6. Class -6 ( Edge neatening) 7. Class -7 ( no descriptive name) 8. Class -8 ( no descriptive name) 1. Class -1 (Supper imposed seam) : i) This the most common seam & simplest. ii) This seam is formed by superimposing the edge of one piece iii) The edge of two fabric are in same direction . Use : shirt, pant etc

2. Class - 2 (Lapped seam) : i) This seam is formed by lapping two pieces of fabric. ii) this is not common in clothing iii) this produced very strong seam in garments iv) Comparatively the thickness of seam higher than other seam. v) this create discomfort to wear vi) twin needle sewing m/c with folding devices is used vii) use: Jeanswear

material on another

3. Class - 3 (Bound seam) i) This seam consist of an edge of material, which is bound by another material ii) Generally colored material is used for binding iii) This seam is use to prevent fraying iv) Twin needle sewing m/c with folding devices is used v) Used: T-shirt, bag etc.

4. Class - 4 (Flat seam) : i) This seam preferred as flat because two fabric edge donâ&#x20AC;&#x2122;t overlap ii) Twin needle sewing m/c iii)Use in underwear

5. Class - 5 (Decorative seam) : I) this class of seam not regarded as seam was given the name Stitching in the old British standard Ii) Multi needle sewing m/c with folding devices is used iii) use: decorative purpose like Cardin

6. Class -6 ( Edge neatening) : i) this seam prouced by over lock m/c ii) one or multi needle sewing m/c with folding devices is used

7. Class -7 ( no descriptive name) : i) This type seam use edge of the garments part ii) It is similar to the lapped seam iii) Use additional component Use: Lace

8. Class -8 (no descriptive name): In this class of seam one piece of material needs in constructing the seam. Use use in belt loop on jeans , rain coat etc Twin needle sewing m/c with folding devices is used Properties of seam: Properties of seam are assessed on the following aspectsAppearance: After sewing, the sewn area is observed for any defects, if present which affects outlook. Normally it is expected that there will be no defective view of stitches, seam pucker, or unsightly view. Performance: Performance of a seam is assessed according to following criteria•

Seam Strength: Strength of a seam should be equal to or slightly less than the fabric strength.

•

Seam elasticity: Elasticity property of a seam should be equal to or greater than the fabric elasticity.

•

Durability:

Durability of a seam equal to or greater than the durability of the fabric.

Especially during wear and washing, the seam should not fail or damage due to frictional forces and tension. •

Security: During normal use of apparels, the seam should not fail due to simple reason. Confidence of normal stability of seam is the security of the seam. If the seam fails due to normal reason the situation might be undue.

•

Comfort ability: Apparels, during normal use should not create any irritation or problem to body and health as well.

Special property: If clothing has any special property like water proof, fire proof, chemical resistant, etc then in manufacturing this apparel the seam should be produced in such a way that the seams have also such special property. Sewing Quality Checking Points• Skip/Drop/Broken Stitch • Raw Edge • Size Mistake • Uneven Hem • Uneven Cuff • Uneven Neck • Uneven Shoulder • Uneven Placket • Uneven Pocket • Twisting

• • • • • • • •

Without Care Label Open Tack Sleeve Up-Down Stripe Up-Down Open Seam Four Point Up-Down Spot Shading, Etc

Sewing Defects:

• • • • • •

Needle damage, Skip stitches, Thread Breakages, Broken Stitches Seam Grin Seam Puckering

Pleated Seam Wrong stitch density Uneven stitch densityS Staggered stitch Improperly formed stitches Minimizing slack times.

SEWING PROBLEMS “factory” •

Input problem.

•

Shortage of skilled operator.

•

Poor m/c maintenance.

•

Sometime bulk production will start without layout as a result there is no production target. Example-program No:1635

•

To achieved the overtime, they worked slowly .

•

In line quality man may be not skilled. They do not check the all process correctly .so alter & reject % are increased in Q.I table. That’s why production may be hampered.

1. If any problem will create during production then -

Nobody will take the responsibility,

Nobody will give the instant decision,

Decision will take after huge production as a result alter or reject percentage will increase.

2. Sewing line production may be depends on in charge.

3. Needle hole – due to friction, needle eye is to large, mistake of needle selection. 4. Measurement problem – From cutting section 5. Seam pucker -

6. Broken stitch –

•

Due to unequal tension of Feed–dog and pressure foot on two plies of fabric.

•

Due to unequal thread tension.

•

Shrinkage of either fabric or sewing thread.

•

Due to tension variation between needle & bobbin thread.

•

Tension of needle thread is more.

•

Low quality sewing thread.

•

Needle heating or hook heating.

•

Sharp edge of throat plate, hook plate, bobbin cage, needle groove etc.

•

Faulty fitting of bobbin cage.

•

Sharp edge of bobbin cage, looper eyes and spring.

7. Skipped / Slipped stitch •

If the timing between needle & looper or bobbin is not proper. Needle thread loop is not picked up by bobbin thread loop when required.

•

If the loop of needle becomes smaller in size , slipped stitch occurs.

•

Unequal tension between two sets of threads

•

Deflection or vibration of needle

8. Variable stitch density •

If fabric cannot move forward properly due to lack of pressure of pressure foot.

•

Due to faulty feed mechanism.

Finishing section: This final section to make the product saleable condition and the finishing processes should be controlled to achieve the quality target. For wash garments100% check is required after receiving the garment from the washing plant. Defective garments should be rectified and reject pcs. Should sort out. Checking: Iron / press Folding Tagging /sticking Packing Iron problem  Sometimes they do not use pattern in pocket folding. That’s why alter & reject % may be increased due to uneven pocket folding.  Trained iron man may be required.  Less pressure of steam. Finishing Lay Out: Flow chart of finishing section:

Garments wash Loop cutting Thread trimming Alter checking Stitch others Button attach Ironing (In side) Inspection (inside & outside) Batch label attach Final ironing Joker tag attach Needle detector check Size tag attach Waist belt attach Hanger attach Poly packing Cartooning Shipment Trims: Trims cover all the items used in the garment except the basic fabric. There are hundreds of items used to manufacture the garments. Proper selection of trims and its quality are very important for styling; otherwise the garment may be rejected or returned by the customers. Following is a part of list that covers some names of the items: Zipper/Fastener: Teeth

Nylon, Vislon, Metal

Color

Tape color, Teeth color

Size

#3, #5, #8, etc.

Length

As per requirement 18 cm, 72 cm

End

Close End (C/E), Open End (O/E)

Slider

One way, Reversible.

Sewing Thread: •

Shade, color fastness, etc.

•

Tensile strength, Elasticity, Shrinkage, Moisture Regain, Abrasion Resistance, etc.

•

30s, 60s, 20/2, 40/9 Ne, etc.

Labels:  Main label •

Size label

•

Care label

•

Content

•

Price, Patch, etc.

•

Horn and

•

Metal buttons are very common in use.

•

ELASTIC:

•

Cotton

•

Polyester, etc.

•

Antique

•

Matching, etc.

•

Hook and Pile

•

Cotton

•

Polyester, etc.

•

Price tags

•

Hang tags, etc.

Button:

Eyelet:

Velcro: String/Cord:

Tags:

Polybag: Strength, Chemical mixture, Thickness (micron/mm; 1mm = 1000 micron). Blister Bag:

Carton:

•

0.05 mm in thickness;

•

Loaded capacity is higher than poly bag.

•

3 ply

•

5 ply

•

7 ply

•

Hook and Pile.

Size (L, W, and H).

Sticker: Plastic Clip:

U-shape,V-shape,T-shape

Scotch Tape:

Gum Tape.

MECHANICAL STORE: Maintenance of machinery: Here mainly two maintenance systems are followed: 1. Schedule maintenance 2. Breakdown maintenance For maintenance Log card is hanged in eqach machine. Log cards also maintained for needle. Needle is very important because buyer always wants needle free garments. Maintenance Procedure: Here standard system is to service a machine once per 15 days. But it is done once per month. 1. Some machines needed oil in oil tank. In that case, a pump once per two months changes oil. 2. Machines that have rotary hook are oiled once per week. 3. At first the service system of machines is written on the machine log card with machine’s remarks & next schedule. 4. To confirm the document is also registered on a register in each floor. 5 .Trouble form is also filled-up in each floor. Name of different maintenance equipment’s or tools: 1. Screw driver (Flat & Star) 2. Hand Socket Wrench Set 3. Manual & Digital Slide Calipers 4. Phil (Half round, round, triangular, flat, square) 5. Pliers (Normal & Nose) 6. Stop ring pliers (Inside & Outside) 7. Timing gauge 8. Table vice

9. 10. 11. 12. 13. 14. 15. 16. 17.

Hand vice Hand drill machine Stand drill machine Hammer Ball pin Hammer Mobil gun Grinder Welding machine Drill bit,tester,multi meter, electronic balance

Compliance: Compliance means comply something i.e. yield to the wishes another. The main aim of compliance is to ensuring the all labor rights and facilities according to buyer code of conduct.

Different compliance issues which they are obeyed: Admin & HR dept.: • Personnel policies: o Recruitment policy o Leave and holiday policy • Attendance and leave register card: o Their weekly working hour not more than 66 hours including overtime in a week. o They have the approved manpower list. Health & hygiene: • First aid ensures. • Medicine registers. • Maternity and pregnancy register. • Pure drinking water • Towel for hand dry. Safety: • • • • • • • •

Safety committee Fire fighting committee Rescue committee Broken needle register Needle detector Fire alarm & switch Evacuation plan Rubber mats to every iron man.

Welfare: • • •

Welfare committee Day care centre Canteen facility

Salary and wages:

• •

Fix wages in considering minimum wages which is declared by the government. Salary and wages given before 7th day of month.

Physical security: •

They have separate cargo entrance area (receiving and unloading) from the front side.

•

They do not keep any partially filled/ completed cartons on the floor at the end of any working day. They keep it to finished goods store.

Education and training program: They arrange security training program on regular basis for all employee of the factory. Compliance item:

Some example of compliances item are given below: •

First aid box

•

Exhaust fan

•

Water pot

•

Emergency exit/light/ light set

•

Toilet

•

Smoke detector

•

Wash basin

•

Fire extinguisher

•

Complain box

•

Hose cabine

•

Evacuation plan