DIRD GROUP by regan ahmed

View with images and charts A REPORT ON DIRD GROUP Introduction Dird started it’s journey in 1983 with it’s engineering company named Dird Private Ltd. In 1984 Dird stepped into the garment sector with it’s first woven garment named Dipta Garments Ltd, which was one of the leading woven bottom manufacturing company at that point of time. Driven by its own inveterate urge for excellence and growth, Dird has today diversified into: • • • • • • • •

Dird Private Ltd. (Leader in Geo-textiles and foundation consultancy and engineering). Dird Garments Ltd. (A ISO certified woven Garment factory). Dipta Garments Ltd. (A ISO certified woven Garment factory). Dird Washing Plant. (A ISO certified modern washing plant). Dipta Orchid Ltd. ( First export oriented orchid firm in Bangladesh) and Dird Composite Textiles Ltd. (A state of the art composite textile). Dird Printing & Embroidery Ltd. Dird Felt Ltd.

Vision of Dird Composite Textile: • • • • • • • •

To establish themselves as a one stop source for the global Knit Apparel market. To satisfy and meet customer’s expectation by developing and providing products and services on time, which offer value in terms of quality, price, safety & social responsibility. To assure complete compliance with the international quality standards. To provide the employees internationally acceptable working condition / standards. To promote the development and best use of human talent & equal opportunity employment. To procure the most advanced & sophisticated technology suitable for producing desired product. To attain highest level of competence through continuous development of the professional management system and To ensure complete transparency in all aspects of business.

Dird Composite Textile At a Glance: Name of the company

: Dird Composite Textiles Limited.

Location

: 35 Kilometer from the ZIA airport. (Appx. 45 minutes drive)

Year of establishment

: 2005.

Type of the company

: Private Ltd.

Commencement of Production

: 2006

Type of factory

: 100% export oriented knit, dyeing and sewing Factory.

Total Manpower

: 2833, Total Worker – 2541 Male- 1224 (48%), Female – 1317 (52%) Staffs-292

Total Land Area

: 520000 SFT.

Total factory Area

: 250000 SFT.

Production Area

: 160000 SFT.

Warehouse

: 30000 SFT.

Utility

: 20000 SFT.

Administrative area

: 40000 SFT

Total Toilet

: Male – 92 Female – 55

Total Fire Equipment

: 254, ABC-149, CO2 – 99, Foam-6, Hose Reel- 23, Gas Mask- 10, Lock cutter- 10, Bitter-13, Hook-13, Helmet- 13 Bucket-62, Belcha-13, Stretcher- 8, Hand gloves-13Pair, Smoke Detector-130

No. of Trained Fire Fighters

: 734 and Trained by BGMEA-79

Lead Time

: For local yarn 60 days after receive the L/C, For imported yarn 90 days after receive the L/C.

Yearly Turnover

: US $ 25 million

Nos. of Sewing Lines

: 30 lines.

Yearly Turnover

: US $ 25 million

Nos. of Sewing Lines

: 30 lines.

Details of First Aid

: Nos. of First Aider: 75, Nos. of First Aid boxes: 26 boxes

Product Fabric

:Jersey, Elastane jersey, Auto stripe and feeder stripe jersey, 3 thread fleece ( with or without elastane ) Pique, Back pique, Elastane pique, Auto stripe and feeder stripe pique, Rib, Rib with elastane, Interlock, Terry, Terry with Elastane, Flat knit collar and cuff and other CAM design fabrics.

Garment

: T-shirt, Polo shirt, Tank top, Cut and sewn T-shirts and polo shirts, Sweat shirt, Jackets, Hoody, Turtle neck, Strap Tee, Shorts, Trouser and other fancy dresses.

Capacity

: Fabric – 17000 Kgs. / Day and Garment – 40000 pcs. / day. Monthly 1200000 Pcs

Banker

:Pubali bank Ltd. Kawran Bazar Corp. Branch. Kawran Bazar C/A, Dhaka, Bangladesh. Phone : 880-2-9111093 Fax : 880-2-8114080 SWIFT : PUBABDDHA215

Certificates a) b) c) d) e) f) g) h) i) j) k) l)

Oekotex 100 for 100% cotton. Oekotex 100 for cotton / viscose and Oekotex 100 for cotton / polyester. Oekotex Garments WRAP Fair trade Certified BSCI compliant SEDEX certified Marks & Spencer approved. George Approved. Wal-Mart approved G Star Approved.

No. of Factories: (Eight). • • • • • • • •

Dird Private Ltd. (Leader in Geo-textiles and foundation consultancy and engineering ). Dird Garments Ltd. (A ISO certified woven Garment factory). Dipta Garments Ltd. (A ISO certified woven Garment factory). Dird Washing Plant. (A ISO certified modern washing plant). Dipta Orchid Ltd. ( First export oriented orchid firm in Bangladesh ) Dird Composite Textiles Ltd. (A state of the art composite textile). Dird Printing & Embroidery Ltd. Dird Felt Ltd.

Product Mix: Fabric : • • • • •

Jersey, Elastane jersey, Auto stripe and feeder stripe jersey, 3 thread fleece ( with or without elastane ) Pique, Back pique, Elastane pique, Auto stripe and feeder stripe pique, Rib, Rib with elastane, Interlock, Terry, Terry with

• •

Elastane, Flat knit collar and cuff and other CAM design fabrics.

Garment: T-shirt, Polo shirt, Tank top, Cut and sewn T-shirts and polo shirts, Sweat shirt, Jackets, Hoody, Turtle neck, Strap Tee, Shorts, Trouser and other fancy dresses Annual Production Capacity: As a group, Dird exports approximately 80000 dozens of various garments every month and these range from newborns, infants, ladies & men’s wear such as Ladies Dresses, Vests, Jackets, Shortalls, Overalls, Jumpers, Shirts, Pants, Shorts & Skirts. Annual production capacity is approximately 90000 dozens. Different Departments: Whole Dird group building has different department. Every department is well decorated and perfectly maintained by the management of the company. I have visited every department of this building during my training period. Here, I gave the name of some of the departments: • • • • • • • • • • • • • • • •

Merchandising department. Sewing department. Cutting department. Sampling department. Buying house department. Custom & security department. Welfare department. Child care department. Medical & maternity department. Fire department. Building maintenance department. Electricity & generator controlling department. Store Canteen Training center Recreation club etc.

History Of The Project Development: Dird group is one of the leading ventures in the garments industry operating from Dhaka, Bangladesh. Being a 100% export oriented industry, approved by the board of investment of Bangladesh. The commencement of business was formed the time of inception till now the group has grown many folds as it has always maintained quality and punctuality. At the year of establishment of Dird group, the picture was not alike as present. At first Dird garments was started with some simple plain sewing machines and with a few operator and one supervisor. So many difficulties were appeared. Nevertheless, this factory survived

against all odds and has achieved impressive success. Day by day it has increased its profit and extended. CHAPTER TWO: Man power Management Introduction: Management controls, in the broadest sense, include the plan of organization, methods and procedures adopted by management to ensure that its goals are met. Management controls include processes for planning, organizing, directing, and controlling program operations. A subset of management controls are the internal controls used to assure that there is prevention or timely detection of unauthorized acquisition, use, or disposition of the entity's assets. Methodology of management system: The art and science of management have developed and changed over the years. Some early theorists viewed management simply as the ability to work through others. But contemporary managers work with many resources and tools, so this definition of management must be broadened beyond the human aspects. Today, management can be defined as the process of achieving organizational goals through planning, organizing, leading, and controlling the human, physical, financial, and information resources of the organization in an effective and efficient manner. By this definition, management is a distinct process, a set of ongoing, coordinated activities that managers engage in as they pursue the organization's goals. Therefore, a manager is someone who actively participates in the management process through the four functions of planning, organizing, leading, and controlling the resources of the organization. Managers in various organizations are confronted by different challenges and call on different resources, elements such as raw materials, people, information, and money that the organization needs to produce goods or services. Depending on their situation and on their resources, managers stress one or another of the four management functions to accomplish their goals. For example, the chairmen and CEOs of different companies want to focus on leading and motivating to build their business. Naturally, all of these executives, and the managers at every level in every organization, shift their focus from one management function to another as conditions dictate. Management of Dird Composite Textile: Management system of Dird group is very much modern one. And the management of this company is very strong as well as friendly to all. It has improved managing power to make all employees hard working and dedicated. Objectives: • • • •

To know the company profile and organ gram of Man-power administration. To know the management system & shift change procedure. To know the responsibilities of production office To know the Job description.

Management Team Executive Director

Marketing & Merchandizing

: SH Siddique (Happy) happy@dirdgroup.org Cell: 01811410456 : Humayun Kabir salim Sr. GM (Marketing & Development)

humayun@dirdgroup.org Cell: 01811410460 Harun or Rashid GM (Marketing & Development harun@dirdgroup.org Cell: 01817045876 Admin, HR & Compliance gmadmin@dirdgroup.org

: Md. Aktaruzzaman, GM Cell: 01817156045

Production

: A. K. Azad, Production Director director_production@dirdgroup.org Cell: 01819257788

Dird Merchandising Division Key Personnel to contact for Dird Merchandising Division in my area of training: Name Harun Rashid Muhamad Shah Jalal Md. Mohibullah Raza Md. Saiful Islam (Suzan)

Phone 8825397 9201184-5 9201401-4 9201184

E-mail harun@dirdgroup.org jala@dirdgroup.org mohib_dctl@dirdgroup.org suzan@dirdgroup.org

Production As a group, Dird group export approximately 1200000 Pcs of various garments every month and these range from newborns, infants, ladies & men’s wear such as Ladies Dresses, Vests, Jackets, Shortalls, Overalls, Jumpers, Shirts, Pants, Shorts & Skirts. Responsibilities of Production Officer • Reports to the Production Manager Operations. • Monitor and control shift wise production, plant utilization, waste generation etc, implement correct work methods and maintain all records related to production. • Responsible for systematic planning and execution of production programs. • Adequate control over process in order to achieve quality of products, better waste management and to reduce the occurrence of defective yarn. • Monitor shift wise production, utilization etc and take corrective action for any shortfall.

• • • •

Maintain all the procedure of his department and shall incorporate amendments as and when required in the procedure. Liaise with maintenance department for evaluating the performance of the machinery and to take corrective actions. Responsible for monitoring the performance of manpower under him and identification of training needs. Co-ordinate with other department heads such as Engineering, Commercial, marketing and HR so as to achieve the objectives of the company.

Remarks The management system of Dird Group Ltd. is very smooth and strong as well as friendly to all staffs. The management acts as power behind all of its achievement. All of its Managers, Officers, Staff are very responsible about their duty. Overall the relationship among the staffs and employee is very fine and discipline is noticeable as well. CHAPTER THREE: Machine Description Introduction Dird group is an extra-vigorous project which has a huge reputation for the garment industry. It has garments and one washing unit which contain various types of machines and technology. Here are production machines, sample machines , dryers, extractors , sand blast machines, dryers, transports equipments etc. all the description are given belowMachinery List

Circular Knitting Machine BRAND MODLE NO PAI LUNG PL-XR2B/C PAI LUNG PL-XR2B/C PAI LUNG PL-XR2B/C PAI LUNG PL-XS3B/A/C PAI LUNG PL-XS3B/A/C PAI LUNG PL-XS3B/A/C PAI LUNG PL-XS3B/A/C PAI LUNG PL-XS3B/A/C PAI LUNG PL-XS3B/A/C PAI LUNG PL-XS3B/A/C Mayer & Cie MLBF MW4/2 LISKY LTK/90 FSJ-4 LISKY LTK/90 FSJ-4 LISKY LTK/90 FSJ-4 LISKY LTK/90 SJ-4 LISKY LTK/90 SJ-4 LISKY LTK/90 SJ-4 LISKY LTK/90 SJ-4 FLAT KNITTING M/C:

M/C TYPE

M/C GAUGE

Rib/Interlock Rib/Interlock Rib/Interlock Jersey 4 Track Jersey 4 Track Jersey 4 Track Jersey 4 Track Jersey 4 Track Jersey 4 Track Jersey 4 Track 3 T. Fleece 3 T. Fleece 3 T. Fleece 3 T. Fleece Jersey 4 Track Jersey 4 Track Jersey 4 Track Jersey 4 Track

18/24 18/24 18/24 24 24 24 24 20/24/28 24 24 20 20 20 20 24 24 24 24

BRAND

MODLE

M/C TYPE

M/C DIA

JY-LEH

JL-303

Semi - Jacquard

NO. OF M/C 2 2 2 1 1 1 1 3 1 1 3 2 2 2 1 1 1 1

M/C GAUGE 14

DI A

ORIGIN

30 34 36 20 21 22 24 30 34 36 30 30 32 34 17 18 19 25

TAIWAN TAIWAN TAIWAN TAIWAN TAIWAN TAIWAN TAIWAN TAIWAN TAIWAN TAIWAN Germany TAIWAN TAIWAN TAIWAN TAIWAN TAIWAN TAIWAN TAIWAN

NO.OF M/C 10

ORI GIN TAI WA N

Dyeing Section: BRAND

H.T.H.P.

NO. OF NO.OF. MAX.LOADING ORIGIN CHAMBER M/C CAPACITY 1 1 200 KG CHINA

ECO-6

H.T.H.P.

400 KG

ECO-6 HSJ HSJ ECO-38 ECO-38

H.T.H.P. H.T.H.P. H.T.H.P. A.T. A.T.

4 4 6 3 6

1 1 1 1 1

800 KG 840 KG 1680 KG 600 KG 1200 KG

FONGS

MODLE NO ECO-6

FONGS FONGS FONGS FONGS FONGS FONGS

TYPE

CHINA

FONGS

ECO-38

A.T.

800 KG

FONGS

ECO-38

A.T.

400 KG

FONGS

ECO-38

A.T.

200 KG

FONGS

ECO-6

H.T.H.P.

20 KG

FONGS LOCAL LOCAL

ECO-6 SAMPLE SAMPLE

H.T.H.P. A.T. A.T.

1 1 1

40 KG 20 KG 40 KG

Finishing Section : TYPE OF MACHINE

BRAND

SQUEEZER SQUEEZER WITH SLITTER TENSIONLESS DRYER COMPACTOR ( TUBE ) COMPACTOR ( TUBE ) COMPACTOR ( OPEN ) SUEDING

CORINO CORINO ENTEMA SANTEX TUBETEX SANTEX MARIO CROSTA I KUANG LK / PLEVA (Germany )/FINE

RAISING STENTER (8 CHAMBERS)

NO OF MACHIN E 01 01 01 01 01 01 01

ORIGIN

02 01

TAIWAN TAWIAN

ITALY ITALY TURKEY SWITZERLAND USA SWITZERLAND ITALY

Laboratory Section: LAB – DYEING MACHINE Color Assessment Cabinet

: verivide ( u.k. )

Color Matching System

: data color ( usa ) 600

All Lab Testing Equipments

: James H. Heal, U.K. / Sweden

Crockmaster

: Model No. 670

Gyrowash

: Model No. 415/16

Washcator

: Model No. FOM71CLS

Orbitor

: Model No. 516/2

BRAND MODEL Ahiba

Nuance Eco 20

Garment section :

NO. BEAKER 20 X 2

OF TYPE HIGH TEMPERATUR E

ORIGI N USA

Utilities : A) Water Treatment Plant

: Local

B) Boiler

: MechMar ( Malayasia )

C) Power Catterpiller Gas.

In-House

Power

Plant

From

generator 1.2 MW. USA D) Standby power

: Catterpiller disel generator. USA

E) Compressor

:Worthington Creyssensac. France

F) Effluent Treatment Plant

: India.

G) Fork Lift Transport Agency

: 1 pc : Speed Cargo Ltd. Janata Bank rd Bldng, 3 Floor, 7/BFDC road, Dhaka – 1208, Bangladesh

Remarks: We have described all the machine’s specifications, their brand names, a lay out of a short pant and now I can realize how many machines would be required for a garment and what Quantity Descriptions PLAIN MACHINE OVERLOCK 4 THREAD FLAT LOCK FEED OF THE ARM BACK TAPE BARTEK MACHINE BUTTON HOLE BUTTON STITCH PICOTING RIB CUTTER CUTTING MACHINE TWO NEEDLE THREAD SUCKER SNAP BUTTON Needle detector Vacuum iron table Steam iron Total

170 SET 134 SET 68 SET 08 SET 06 SET 01 SET 08 SET 08 PCS 02 PCS 04 PCS 06 PCS 03 PCS 02 PCS 02 PCS 01 Set 70 Set 70 Set 528 Set.

would be their arrangements. Though it always varies for different design or type of garments, it depends on the basic stitch type. I have collected quite a few lay out plan for different garments and special design. Dird group consists of number of factories so that it is difficult to collect all the specification and other information about all machineries. CHAPTER FOUR: Raw Materials Introduction: Raw material means the accessories, fabrics and the other trimmings which all are needed to produce a garment. In another word all the material are needed to produce a garment item or apparel except the machineries and man power could be considered as raw material. These raw materials play a vital role during production. If any kind of defect or disassembly is present then the product quality will be hampered. Beside this raw material must be used in garments factory for ornamentation of the product as well as they provides necessary information. Raw materials used tell a lot about the product and its impact on the potential buyer. As for e.g.: A company who supplies organic food or recycled, environmentally-safe products or services would send wrong signals to buyers if the hang tag or swing ticket was made of aluminum or plastic. Thereby, lays the careful selection of raw material for making tags and swing tickets. Raw material can be classified in two types: 1. Fabrics 2. Trimming or accessories Fabric: This is the main raw material of a garment. Except this ready made garments can not be thought. Different types of fabric can be used for different garment. It can be varied by color, design, construction etc. Moreover in a particular garment different fabric can be used to produce different parts. Mainly woven fabrics are used for shirt, trouser, pant etc. Basically denim fabrics are used to produce pant & jackets. Knit fabrics are used for knitted goods like T-shirt, polo shirt etc. Dird group is one of the leading garments in Bangladesh which manufactures a huge quantity of woven garments. Basically they import their required fabric according to buyer recommendation. The most of fabrics are imported from Shanghai & Hong Kong. Realty Textile of Shanghai is one of favorable industry from which most of fabrics are imported for Dird Group. Some fabrics are also imported from U.S.A. The pocketing fabric are not imported these are collected from local market. Trimmings:

All the materials except fabric required to make a garments are known as trimmings or accessories For example: sewing thread, button, zipper, label etc. And there are many other trimming are used in garment factory such as Badge, Bag and box, Belt, Button, Bra-strap, Card, Cord and piping, Fastener, Fashion jewelry, Film, Glasses strap, Key chain, Lanyard, Label, Patch, Packaging paper, Seal, Stickers, Tag, Tape, Transfer, Trims, Zipper pull and miscellaneous. Here we have given some information about different trimming used in this factory with their source from where they are collected. Later we will give the description of most important trimmings item. No 1. 2.

Name of item Thread

Pocketing Fabric Interlining

Lining

Button

Description Source Polyester, linen, polyester coated, single Local Market. ply, multiple ply of different Tex. e.g. Twice, Coarse etc. Simple plain fabric of different color. But Local Market. basically white color is mostly used. Fusible interlining white color natural. For Local Market. denim temp is 149. e.g. Vilene Extra fabric or wedding are used mainly in Local Market. jacket. Sew-On Button, garment Button, Metal Local Market & button : Imported Material: Brass Size: 9-25mm Color: Paint- Brand items must plating Customer's designs, colors and logos be imported. Jeans button: Size: 17mm Materials: Brass and stainless steel Cap with diamond and be painted Customer's logo Snap Button: Mould: 831#, 201#, 633#, 655#, 203#, 833# Sizes: 10mm, 11.5mm, 12.5mm, 14mm, 15mm, 17mm etc. Colors: Various materials: Brass. Polyester / Resin / Plastic Button: Polyester Button/Resin Button/Plastic Button/Nylon Button Materials: Polyester In a Variety of Designs and Fashion style. Coat Button: Material: Polyester Shape: Many shapes, round, square, triangle, rectangle, abnormity Color: Chalk and DTM. Metal Button: materials: Brass, zinc alloy and others Shape: Round, rectangle, oval, other shapes Design: Different pattern, with logo Color: Enamel colors, anti brass, nickel, black nickel, gold, imitation. Fabric Cover Button :

Zipper

Poly Bag

Label

Fabric covered button 1. Style: Round, square, heart shape, eyelet holes, plastic shank, metal wire shank 2. Size: 12L, 14L, 16L, 18L, 20L, 22L, 24L, 28L, 30L, 32L, 36L, 40L, 44L, 60L etc. nylon zipper, metal zipper, plastic zipper, aluminum zipper Metal / Brass Zipper, Nylon Zipper Used for covering the garments. And its size and color depends on product type and design. Size label, Main label, Care code label, price label, composition label etc. Barcode Label, Ticket, Waist Card for Clothing (SLYK0032): Equipped with most advanced barcode machine, apply to different specs of barcode label, hangtag, price ticket, sticker and washable label Supports both separate and continuous printing. Metal Label / Charm / Plate for Garment, Bags: Features: Product name: Lloyd label/metal label 1) materials: Alloy with gold electroplating or chrome electroplating. 2) Various shapes, sizes and designs available 3) Buyersâ&#x20AC;&#x2122; logos and designs. Metal: Features: Product name: Lloyd label/metal label 1) material: Alloy with gold electroplating or chrome electroplating. 2) Various shapes, sizes and designs available 3) Buyersâ&#x20AC;&#x2122; logos and designs. Paper Label (DY0086): Items: Hangtag 1) Materials: 1mm cardboard 2) Surface Disposal: Glossy or matte lamination, spot UV, varnish are available 3) Printing: 4 color printing or Pantone color printing 4) With metal clip. Woven Labels: Woven labels are the most common and economical way of identifying garments or products. Polyester Label Tape, Garment Label, Band Label. Yuma ribbon and bows company can supply good quality woven edge label for garment and home textile. Woven Labels (LJ060): Material: Printing label or woven label Application: Textile clothes attached at the inside the back of shirt. For marking. Paper Label (HEDY004):Name paper label Material paper Size 4.5*3.0CM (material PVC Size

Imported Local Market Local Market & Imported Brand items must be imported.

Hand Tag

10. Match Box

customize) Plastic, paper, woven, printed hand tag etc. Local market mainly contain product and companyâ&#x20AC;&#x2122;s brand name. Features: 1) Size of paper hang tag: According to clients' specifications 2) Materials of paper hang tag: Ivory card paper, white paper board, glossy art paper 3) Function: Labels, tags, name cards, To matching size and bundle number. Local market

11. Sticker

12. Tag Pin

Local market Hologram Sticker : Hologram Sticker, 1. Item: Hologram Sticker 2. Material: sticker 3. Size, Printing, Design according to customer's requirements. Label: label, tag, sticker tag, logo, paper sticker 1) Safe and non-toxic, no harm, no radiation 2) Material PVC, PET, paper, self-adhesive sticker 3) Different materials, designs and sizes available Pin: Tag gun, Tag pin, loop pin, hook pin, Local market cable tie, twin tag pin Standard tag gun and fine tag gun. Pin available size from 15mm to 75mm to 125mm. Material Nylon and PP. Multi-colors. Pin: Tag pin The tag needle is for tagging and labeling use For standard tag gun Available in various length.

13. Button sticker

Pins: Tag Pin 1) Used for hanging various kinds of merchandise brands 2) Sizes: 8 225mm (PP regular); 10 - 75mm (micro pin) 3)Material: PP and Nylon Packing: 5000pcs/box, 20box/ctn. Transparent or may be colored. Local market

14. Button poly

Simple colored poly.

15. Hanger

wooden hangers, metal hangers, Aluminum Local market hangers, Laminated wooden hangers, plastic hangers and etc. According to products size and buyer Local market Recommendation different color is used. Hologram Sticker: Hologram Sticker, 1. Local market Item: Hologram Sticker 2. Material: sticker 3. Size, Printing, Design according to customer's requirements

16. Hanger Sizer 17. Poly sticker

Local market

18. Packaging paper 19. Bra-strap

Transpired or colored paper of plastic.

Local market

Local Market & Bra Strap (DS-FW-004):Commodity name: Imported Bra Strap(DS-FW-004) Material: Cuprum, Brand items must Rhinestone, nickel-free electroplating be imported. Color: Silver Specification: Main chain 32cm, subsidiary chain 17cm without length of buckle Strap: Compositions: 100% copper, rhinestone, nickel-free electroplating Specifications: Various styles are available and customized designs are accepted Colors: Silver, gold, black, bronze Fabric Bra Strap(FS-FWY016):Commodity name: Fabric bra strap(FS-FW-Y016) Material: Spandex belt Color: Yellow (Different color as per requirement) Specification: Length 40cm, extended 60cm 20. Buckle, hook & Loop: Hook and loop Material: 100% Local Market & loop nylon, or nylon mixed with polyester. Imported Width: 16mm, 20mm, 25mm, 38mm, Brand items must 50mm, 100mm, 125mm, 150mm Colors: be imported. 300 kinds of colors Used for garments,

21. Seal

Hook and Loop (HL1003): Hook and loop Several quality grade & type to reach customers' various requirement. 1. Normal Hook & loop 2. Adhesive hook & loop 3. Back to back hook & loop Company seal: Rubber, metal seal etc. Local Market

22. Card

Local Market

PVC Card (Plastic Card): Material: PVC or paper Size: 86mmx54mm or other size as required. Thickness: 0.3mm; 0.5mm; 0.76mm or others. Printing: Full color, encoding. 23. Cord and piping Used in waist band wedding and t-shirt. Local Market Mainly soft knitted fabric. 24. Tape Local Market TPU Tape, Mobil on Tape (NCB2):1)Product name: TPU TAPE 2)color: Transparent, semi-transparent, black, bluish etc. 3)width: 3mm-16mm(or to requirement) 4)thickness: 0.08mm0.30mm(or to requirement) 25. Zipper puller PVC Zipper Puller: Material: Soft pvc or Local Market & silicon Standard: Can pass EN71, Cadmium Imported and non phthalate test With one-sided or Brand items must

double-sided logo About OEM Sample. be imported. Alloy Zipper Puller (FZY-Z-078): Zipper puller Material: Alloy customerized color & design. Leather Zipper Puller: Brass Zipper, Aluminum Zipper, Nylon Zipper, Polyester Zipper, Plastic Zipper, Rhinestone Zipper 26. Belt 27. Key chain 28. Hanger bag

29. Cuff Button

Local Market Key Chain: Watermarks indicate the serial NO. And size of each hangtag PVC Hanger Bag (YX12):Material: Local Market 0.12mm PVC Size: 23.5cm(L)*18cm(W) Daily Output: 10000pcs/day Package: 50pcs/bag, 1000pcs/ctn MOQ: 1000pcs Printing: Silk printing or offset printing

Links, Cuff Links, Button: Introducing to clients, Local Market this is the best way, putting own Logo in a little gift, common but everybody needs.

Remarks: Raw materials and accessories are the major term of garment production. we can say that this term is the heart of a garments industry. We have tried my label best to collect all data about raw materials though it was not an easy task to do. More over Dird group maintain a good fame by using brand item and qualified raw material. A number of people are always checking the quality of these items. They also inspected them and keep documents by the time. The store house is very much secured and only authorized person can enter that room. CHAPTER FIVE: Production Planning Sequences and Operations Introduction: Production planning is the very first step to start a production. At first the company gets an order from buyer and then they start the production planning. Here in Dird group production planning and production process is specified and extra ordinary. In this chapter we have described all the procedure and the necessary document related to run a production. Literately review about garment production:

There is disclosed a system for fastening together different pieces of an article of clothing so as to enable a customer to select a specific clothing style and design by selection of different garment pieces. The fastening creates a garment seam equivalent to a sewn seam yet provides non-permanent closures for garment assemblage and thus allows a garment to be created specifically to the customer's wish. There is also disclosed a system for producing garments from a plurality of different garment pieces and a simplified design and production schedule. A garment production process wherein garment parts are knitted in a continuous length of knitted material with water soluble yarns being formed in the knit construction between the garment parts. The length of material is moved along its length and bathed with a heated aqueous solution to dissolve the water soluble yarns and separate the garment parts. The separated garment parts are dried and vibrated and passed to subsequent garment making stations. The temperature of the bathing and drying steps and the vibration of the garment parts serve to heat set the garment parts. Objectives: • • • • • •

To know about the Production parameters. To learn and describe the Production Process. To collect daily production report. To calculate monthly average production. To know Production flow chart and M/C lay out. To know the monthly efficiency.

Description of production process: Here we have described the whole production processes which are followed by the Dird Group after getting an order. We described the processes step by step according to my limitation. Standard Inspection Packet (SIP): Dird Group will have to maintain a SIP file for all orders at the factory. Factory will have to make sure that all tests are timely done and approved. The following information has to be in the SIP: • • • • • • • • • •

PID and any changes to order. MTL Fabric Testing Reports. MTL Pre Production Sample Testing Reports. MTL TOP Sample Testing Reports. Interlining Testing reports. Invoices of all Trims / Fabric that have been ordered from the nominated suppliers. Factory Pre Final/Final inspection reports. TCPS Final inspection reports. Approved fabric swatches and Trim samples Fit and Pre production approval comments

•

Pre-production meeting reports

Fabric Inspection Procedure Dird Group must maintain the following fabric inspection procedure: • 10 % of all fabric shipments should be inspected prior to cutting. • Records should be maintained for every fabric invoice packing list and inspection report. • Fabric inspections should be done by using the 4 point system and on the Rotary fabric inspection machine. • Fabric inspection cannot be done while spreading. • Fabric should be inspected for color accuracy as well as shading (side to side, end to end, roll to roll and number of shade lots). • All rolls that are out of the color shading guidelines should be rejected. • All roles with color defects such as side-to-side shading, side-center-side shading, and end-to-end shading will not be given points, but should be rejected. • All fabric inspection forms should have the defects classified separately. E.g.:- Stains, Weaving defects, Holes, Slubs, etc. The Four Point system classifies defects as shown in Table 1: Size of defect 3 Inches or Less Over 3, But not over 6 Inches Over 6, But not over 9 Inches Over 9 Inches

Penalty 1 Point 2 Points 3 Points 4 Points

Table 1: Four Point System Note - A Maximum of Four points can be charged to any one linear yard. The length of defect should be used to determine the penalty points. Only major defects are considered. (A major defect is any defect that, if found in a finished garment, would classify that garment as a second.) No penalty points are recorded or assigned for minor defects. Major Defects for woven fabrics is classified as follows: a. Slubs b. Hole c. Missing Yarn d. Conspicuous Yarn e. Variation f. End Cut g. Soiled Yarn h. Wrong Yarn. Major Defects for Knit fabrics are classified as follows:

a. Mixed yarn b. Yarn Variation c. Runner d. Needle line e. Barre f. Slub g. Hole h. Press off. The inspection procedure listed below details the steps involved in performing the piece goods inspection in the correct manner. These steps must be followed by the Fabric Inspector/Auditor. •

Review the packing list and determine how much total fabric to inspect and then how much of each color. Determine how many rolls of each color to inspect and then choose from the packing list and the physical rolls, which rolls are to be inspected.

•

Count the rolls in the shipment to make sure they match the packing list and then mark the rolls that are to be pulled for inspection.

•

Check the packing of the rolls in the shipment to make sure all the packing and markings are correct.

•

Move all the rolls to be inspected to the inspection machine and load the first roll on the machine. As the roll is put on the machine check to make sure the inner packing is correct and proper. Also check to make sure the roll is rolled on the tube squarely and that the tube does not stick out of the end of the roll more then 1 inch on each end. Also make sure the first 3 meters of fabric is rolled properly, not creased or distorted, and that it is clean from dirt and marks.

•

Cut off the first 6 inches and last 6 inches of fabric from each roll and mark it with the roll number, whether it is from the head or tail of the roll, which is the right and left side of the fabric and which side is the face side of the fabric. These strips will then be used in the light box for reviewing end-to-end, side-to-side and roll-to-roll shading. Use the head strip to check for end-to-center shading during the inspection.

•

Inspect the fabric using the recommended form that is included in the manual and mark the faults and their points. Run the inspection machine at a speed that allows you to see the defects properly, yet keeps the fabric moving in a steady and smooth manor. Make sure that you have the proper and adequate light at the machine shining on the face of the fabric.

•

Check the length of the fabric on the roll and compare it to the ticket yardage for the roll. Note this on the “Inspection Form.”

•

Check the width of the fabric at the beginning and end of the fabric as well as at least once in the middle of the roll. Mark this on the “Inspection Form.”

•

Check for skewing, bias, and bowing, compare this to the standards and note findings on “Inspection Form”.

•

When inspection is completed do calculations on the “Inspection Form” to determine the point count for each roll and whether or not it passes or is a “second roll.” Make sure all “second rolls” are separated.

•

Calculate the percentage of the average point count for the shipment per square yard. This will determine if the shipment passes or fails.

Acceptance Criteria: Example: Total yards inspected: 700 yards Width of the fabric: 1.6 yards Total points found; 300 points i.e. 700 X 1.6 = 1120 Square yards 300 x 100 / 1120 sq yards = 26.78 points Result: Pass Acceptance Point Count: • The max defective points accepted are 28 points per 100 Sq yards. • The max defective 1 point accepted is 14 points per 100 Sq yard. Shrinkage Reports: For washed products the factory should see that shrinkage is checked for a minimum of 10% rolls per color for every shipment. A test run must be made before starting bulk to ensure shrinkage control techniques and patterns. Test run is the most important check point to verify if the technique and patterns are all correct. Fabrics with a spandex mixture in its composition have to be handled very carefully due to high shrinkage variance between rolls. If the noticed shrinkage variation is more than the garment tolerance then it is recommended that 100% rolls get checked for shrinkage and factory makes groups and different patterns for different groups. It is always recommended to make an average pattern by considering only ½ the tolerance given to the spec. for example if the hip tolerance is 1” one should only consider ½” while making patterns for different shrinkages. Factory will have to study the tolerances given in the spec for Bottoms and tops and decide accordingly on the different patterns required Factory will have to maintain a file on shrinkage reports. All shrinkage tests need to be done on a minimum 50 cm x 50 cm square marking – factories have to make a square marking template.

Factory will also have to mention the wash recipe and time used to dry the garment in the shrinkage report file. The wash recipe and time that is once set; can not be changed for the full program. Pre Production Size Set Procedures: • • • • • • •

• • •

The factory will check if the shrinkage allowance that is added to the pattern is good enough to start the test run. Size sets have to be made for all colors and for all different shrinkage groups. The Pre production pattern has to be used as a base and if the shrinkage of the bulk fabric matches with the shrinkage of the pattern used for the pp sample then the same pattern has to be graded and used for bulk. Any adjustments that are required to make different patterns for different colors and shrinkage groups have to be made to the base pattern. All the stitching details and techniques that factory is planning to use in bulk must be check for accuracy. The factory Quality manager and Quality Auditor will have to check the size set and make a spec report of before wash and after wash to verify that the shrinkage allowances that were added in the pattern is ok or needs to be adjusted. The before wash spec evaluation of the size set has to match with the before wash spec with zero tolerance. If the before wash spec does not match, the inspector will have to analyze and see if the error is in the pattern or if the operators took wrong seam allowances while making the sample. Factory will have to remake samples if the before wash spec doesn’t match. The Factory Quality manager will then write all the comments on one of the sample and make it a production reference sample which will be hung on the production floor. The factory Quality manager and Quality auditor will have to make sure that all patterns and templates are signed by the pattern master. Shrinkage percentage has to be mentioned on all patterns for review.

Pre-Production Meeting Procedure: Required Attendees 1. Buyers Representatives (if required) 2. Production Director 3. Finishing Manager and Supervisors 4. Factory Quality Manager 5. Factory Quality Auditor 6. Factory Production Managers 7. Factory Pattern Master 8. Line supervisors 9. Store-in-charge 10. Maintenance-in-charge Objectives

• • • • • • • • • • •

• • • • • • • •

Review PID package and all information pertaining to the production program. Review all the machine and folder requirements to make sure that factory is fully equipped to handle style. Review an approved sample and all the specification will be discussed and confirmed with everyone present in the meeting. Review all critical process and measurement with allowances and tolerance. It must be made sure that everyone present understands and works accordingly. Trims card test results for Fabric, Zipper, Button and Interlining etc. will be shown and presented for understanding. Review on the time and action plan to perform the order timely. Plan all shipment and FRI inspection dates. Review the preproduction sample with the factory production sample. Ensure all approvals are in place. Factory will have to make an additional spec for all the measurements that are not mentioned in the PID. Factory will have to make a before wash spec for in line Quality inspectors to measure and see that garments that come off line are as per required. This will also be a check point to see if operators in line are following proper seam allowances. Review all the marking templates and techniques. Factory advise on methods of construction, tolerances, production lay out and techniques as applicable to the product. Verification of all product test reports. MTL fabric, MTL Pre Production. Verification of all care instruction approvals Review of the Floor ready spec. Review all Fit and Pre production comments – so that all points are clearly understood and taken care off. Check the spec of any garment based on the how to measure manual to make sure that the factory uses the correct measuring method. All concerned will be advised to co-operate for achieving smooth execution of the production process as per the assigned target.

Other Responsibilities: • • • •

To make sure all technical issues that are production related are cleared and understood. To make sure all that is discussed and agreed on during the meeting is followed in production. To ensure that a test run performed prior to bulk production. To ensure that a production sample is hung in the production floor with all the comments and placements written.

•

To ensure that factory is maintaining the schedule and all that was discussed is been followed. In case some changes need to be made, approval needs to be taken from the Buyer first.

•

To ensure that all junior production staff are clear on the method of measuring the garment.

Production Test Run Procedure: Objective: • • • • •

The test run is the most important check point in the full production process. The information gathered from the test run will verify that the techniques, patterns, machinery and the systems are all ready for bulk production. Factory can also make the necessary adjustments for issues that are found in the test run so that they. can be avoided in the bulk production The test run is a replica of bulk so every process and procedure should be exactly as planned for bulk. The test run will also give factory the final before wash spec that will be used by all quality auditors.

Test Run Procedure: • • • • • • • •

Factory has to plan a cut of minimum 30 layers. It is very important that factory takes every layer from different rolls. The numbering has to be done from 1 to 30, Numbers have to be written or labeled on the garment so that it can be identified after wash. This will help in checking the shrinkage variations. The cutting marker that factory will use for the test run has to be exactly the same as what they will use in bulk production. Garments have to be then produced in line using the same techniques as bulk. 4 size sets will be then measured for before wash and the same garments will be then checked after wash. Garments have to be numbered with a water proof pen so as to check them against their respective before wash measurements. The size sets have to be specked after wash and after pressing. The needle work, stitching techniques, sewing quality has to be scrutinized and documented. Garments will have to be then ironed and packed the same way as bulk requirements.

Other Responsibilities: • • • • •

To follow the procedures as discussed in the Pre-Production meeting To check the spec on 4 size sets before and after wash. To check the spec on the size sets after pressing. To finalize the before wash spec. To approve the final pattern for bulk by adding the correct shrinkage.

• • •

To make a report on the packed pieces. To make sure that all the issues noticed during production are corrected and taken care of. To finalize the method or procedure to make the product.

Cutting Procedure •

All cutting machine operators must use metal hands gloves while cutting to avoid cut injury on the finger.

•

All cutting department employees must use dust mask while cutting to avoid breathing in cutting dust.

•

Before starting the size set cutting process, all reports and tests should be completed on the fabric to be cut. The size set cutting process should be based on the findings from these reports: 1. Fabric Inspection Report 2. Shrinkage Report 3. Blanket Report 4. Shade Band Report

•

To confirm the shading the fabric should be joined side to side, side to middle and front to end and compared for color variation, if all is ok then size set cutting process should proceed

•

Before and after wash swatch boards must be made for all approved fabric swatches with all kinds of parts (body fabric, pocketing, binding, inside w/band etc. These must be matched under buyer approved light box before wash & after wash

•

All lay/cuts must be inspected prior to cutting. The following points that will need to be checked: 1. 2. 3. 4. 5. 6. 7. 8.

• • • • •

Marker Length Marker Placement Counts Tension Leaning Ends Splice Fabric Flaws

Total defects found and action taken towards the defects will need to be noted After cutting the parts, they need to be checked with hard pattern to see if there is any variation between the pattern and cut parts. Nested pattern has to be kept ready before the pilot run cutting. Cutting layer should be selected from one dye lot however if mixed dye lot needs to be used then paper lay must be placed with correct identification information between each dye lot. Cutting table needs to be always clean. If there is any damage on the tables, they need to be repaired immediately.

• •

After cutting is complete parts numbering needs be 100 percent accurate for all the cutting parts to avoid size and shading problem on the sewing floor. All cuts must be inspected prior to issue in the line. All cut parts (Top / Middle and Bottom) must be inspected from each layer and recorded. This record includes the name of the component inspected. Variation found (Actual compared with paper pattern) and the action taken towards the defects.

Production Procedure • • • • • • • • • • • • • • • • • • • •

All operators must use dust mask while operating the sewing machine. Needle guards have to be fixed & needs to be checked before starting the work. Cutter, Scissors & Point pin have to attached to the machine with a drawstring Approved daily goal, swatch card and garment sample must be posted before starting a new input or style. S.P.I. needs to be checked everyday before starting the work. Parts numbering must be matched and followed 100% during all relevant processes. Bundling system needs to be followed 100% cutting wise to avoid size mistake and shading. The Machine Mechanics must check all sewing machines before the start of work for problems and record their finding in the inline machine adjustment log. All machine issues found must be fixed before starting work. The operators have to check the needle point everyday by following the needle points check procedure. All mechanics, operators, supervisors and line chiefs must check to see if the machine thread handling systems are clean and correct. Before starting the production every operator has to clean their machine. While sewing all operators must keep the stitch quality as per the buyer’s requirement. All factories PM, Line Chiefs, Supervisors and QA inspectors must maintain production and quality goals discussed during PP meeting. All operators must follow parts attaching mark and pay particular attention to all difficult processes like pocket, flap, waist band & loop attachment as per buyer requirement. All production employees must maintain and follow the correct bundle serial and numbering systems to avoid size mistake. If any parts are rejected during sewing process, the particular part must be replaced by selecting another piece from the same fabric roll to avoid any kind of shading. All mechanics must adjust the machine to control and minimize oil marks. All employees must maintain cleanliness to control stains and dirty spots on garments No garments or parts can be kept on the floor and must be kept in the assigned place.

Procedure for comparing first production unit to the client’s approved sample •

The QC department along with the production team must follow the procedures mentioned below while comparing first production unit to the clients approved sample:

• •

The QA manager / Line QC will randomly select and pull the first produced garments from the output table and summon all the relevant production employees along with PM to the inspection room for a meeting The approved client sample has to be compared with the first produced units by the QA manager

•

The first units should be checked and verified according to clients specifications

•

Accurate measurements should be taken

•

Trim attachment and positions should also be checked and noted

•

Construction with all critical processes should also be checked and compared

•

If any non conformity is found, these are identified per Buyers Defect Classification List and shown to the production personnel for rectification

•

The defects should be discussed and their causes identified and explained to the production personnel

•

A corrective action plan should be formulated to avoid the same issues again

•

All points should be documented and acknowledged by all present

•

Records must be retained for future reference.

Operator Wise In-process Audit Procedure: In line quality inspectors have to check every operator at-least twice a day especially for critical sewing work. The Quality inspectors will pick a bundle that is complete and pull out 7 pieces at random. If they find any defect then the inspection fails. The inspector records the details which will include the operator name, operation, number of pieces inspected, number of defect found, the DPCI number and action taken towards the defects. Steps to be followed in case of a failed bundle inspection: •

All the pieces of the rejected bundle have to be checked for defects by the operator and fixed before they proceed with the next bundle. At this stage the inspector will have to attach a red ticket to the bundle and also attach a red flag to identify the machine and operator for possible quality problems. The corrected bundle has to be then rechecked by the line supervisor to make sure all defects are fixed before the operator is allowed to proceed with the next bundle.

•

The very next bundle of that operation will have to be also inspected for defects. If no defects are found the operator can then proceed with the third bundle. If the bundle gets rejected then the operator will have to recheck all pieces and alter all the defects. The corrected bundle will have to be re-inspected by the line supervisor to make sure all defects are fixed before the operator can proceed with the next bundle.

•

The third bundle will also be audited and if passed then the flag will be taken of and the operator can proceed with the operation. If this bundle gets rejected then the operator will be stopped from resuming production and sent for re-training. The factory manager will have to be notified and he will have to sign on the quality form

related to that quality operator. The factory manager will have to approve the return of the operator after the training is complete. Note: The Factory manager and the Production team have to analyze all defects that are found at the red flag area. The machinery and tools used by the operator will also have to be checked for improper setting and defects. If the problem is with the machinery and tools then necessary action has to be taken to correct the issue. Process End Table Defect Tally Audit Procedure: A defect tally must be maintained for every line. It is very important that the managers analyze the defects and makes sure that the total defects found per operation decrease as the days pass by. The defect tally must have the following information: a) Operation type b) Defect type c) Hourly tally DPCI number d) Day’s total defects e) Previous day’s total f) Corrective action taken Before wash spec on critical positions has to be checked on 100% garments with a template that is fixed on the checking table. The defected garments have to be recorded on an hourly basis. The production team has to analyses all defected garment for spec to see if operators take in the proper seam allowance while stitching. Tolerance of not more than ¼” has to be given to spec before wash garments. All reports have to be signed and analyzed by the quality auditors, line supervisors and the production manager. Defects that do not show any improvements and appear on a daily basis will have to be checked 100 % in line in front of the sewing machines that produces that particular operation. Offline DUPRO audit and before-wash spec check procedure: The audit must be done on the out put from each sewing line as per AQL 2.5 for workmanship and AQL 4 for Fit. The quality inspector must base the sampling plan based on the days out put per line. The process will be similar as the DUPRO inspection and form used will be Form # 6. All defects will be identified by DPCI number and a defect trend will be analyzed with the factory production team. Before wash spec has to be checked every day and attached to every audit report. Four pieces per size is the minimum one should check. Factory will have to wash the pieces that were measured and re check if they are ok to spec after wash and after ironing. Tolerance of not more than ¼” has to be given to the before wash spec and only at some of the spec points. If the before wash spec fails then the immediate conclusion has to be that the operators are either taking a wrong seam allowance or cutting extra at the marrow stitch . Early detection of this problem will help in solving spec issues. Inline DUPRO Audit Procedure:

Factory QA will have to do a DUPRO audit when the factory has completed 10%, 30%, 50% and 90% of production. The factory QA will select pieces from all the lines at random. The Factory QA will also use Form Ref # 6 to do his inspection. The specifications that will be checked during these audits have to cover all sizes and a minimum of 4 pieces per size. The Factory QA will also have to get all pieces measured, washed and then rechecked both before and after ironing. All measurements have to be checked in details during this audit. All defects will be identified by DPCI number and defect trends will be analyzed with the factory production team. The process for DUPRO Audit is as follows: •

The Inspector has to first decide on the sample selection based on the factory’s daily output.

•

The pieces have to be selected at random from all lines.

•

Only garments that have passed the output check will be selected for the audit.

•

AQL 1.5 STD has to be used to evaluate whether goods passed or failed for workmanship and AQL 4.

•

Defects have to be identified by using DPCI number and a defects trend will have to be made while analyzing the report.

•

Defect classification code will have to be used for specifying every defect.

•

Every defect in the garment will be recorded on the report but only one garment will be counted for major and minor defect evaluation.

•

A defect trend will be made and analyzed with the factory production team.

•

The inspector has to make sure that all defects that are found are attended to inline so that the root cause of the problem is solved immediately.

•

The pre-wash specs have to be checked on 4 pieces per size – the garments have to be measured to the specs with a tolerance of ¼ inches. If the measurements are out of tolerance, the production team will have to see that all operations are re-checked to verify if the operators are taking excess seam allowance (excess seam allowances and cutting at the narrow seams will cause the spec on the garments to differ from the before wash specs).

DUPRO Audit Procedures before Pre-Final Audit: •

Factory QA will have to do a DUPRO audit. When the factory has completed 10% 30% and 50% goods are packed. The audit procedures have to be same as the prefinal audit done by the factory QA and they are as follows:

•

The cartons that will be pulled for the inspection have to be taken from the total cartons packed at that time.

•

All the information gathered during inspection will have to be kept in a DUPRO report.

•

The report will have to shown to the Buyer’s GQC when they come for their regular audits.

•

If goods fail the audit then factory will have to re-check and offer the factory QA for re-audit after all issues have been fixed.

•

The factory QA should only select cartons that are packed at random based on the square root of the total. (The audit will be done as per AQL 2.5)

Final Table Checker Defect Tally Procedure: The final checkers will have to maintain a defect tally list – Form Ref # 7 for analyzing the defects and to make sure the specific defects found on the finished product are controlled and proper action is taken. The defects have to be totaled on a daily basis and proper steps have to be taken by the factory managers to make sure that all the issues are controlled in the process. NOTE – Factories have to make a defect trend history style wise to keep in records and records have to be analyzed often with the factory manager so that factory can make improvements in systems and procedures to get better in future orders. Table Specs Check Procedure: Factory has to make a template and fix it on the table for checkers to check the critical specs on 100% garments. Defected garments for spec have to be recorded on an hourly basis. Daily Pre-final Audit Procedure: Pre final audits have to be done on a daily basis using form Ref# 8. Goods that fail the audit have to be rechecked the following day. All inspections have to be done based on AQL 2.5 for workmanship. The cartons that will be pulled by the inspectors have to be signed and pulled at random to get a proper statistics on the goods. The Square root method will be used to select the quantity of cartons that need to be pulled for every inspection. All inspection reports should have a measurement spec report done based of AQL 4. The factory has to see that a minimum of 4 pieces per size per color is taken for a spec audit. Pre Final Audit Procedure: Pre final audit will be done by the factory QA when 10%, 50%, 70% goods are packed. The audit procedure has to be just like the daily pre-final audit done by the factory packing department QC. 1. The cartons that will be pulled for inspection have to be taken from the total cartons packed at that time. 2. The QA report will have to be shown to the Buyer’s GQC when they come for their regular audits. 3. If goods fail the QA audit, then factory will have to re-check and after all issues are corrected the goods will be offered to the Buyer for their regular audit.

4. The factory QA will select the cartons that are packed at random based on the square root of the total. (The audit will be done as per AQL 2.5). FRI (Final Random Inspection) Procedures: The final inspection will be done by the factory QA based on the form Ref # 9. The audit will be done only when 80% - 100% of the cartons are packed. The final inspections will be based on AQL 2.5 for workmanship and AQL 4 for spec (fit audit). The number of cartons to be selected will be based on the square root system. The QA will have to check the spec on a minimum of 4 pieces per size. Goods that fail the audit will have to be rechecked and corrected before offering the buyer to perform their final inspection. The inspector should make sure that he has the following before the starting of the audit: Buyer’s Standard Inspection Package •

Red tag Sample

•

Inspection Forms.

•

AQL Chart.

•

Wash /shade band approved samples.

•

Packing List.

•

MTL/CTL test passing reports.

Note: Shipment will not be released with out the required passing test reports. •

The audit can be started when 80% goods are packed provided the balance 20% gets packed while the inspection is in process. The balance 20% then has to be inspected at the end of the audit.

•

The inspector has to then decide on the sample size for the workmanship audit based on the shipment quantity as per the AQL 2.5

•

(MIL-150E Single Sampling plan Level 2.)

•

The quantity of cartons that need to be pulled will be based on the square root rule.

•

The Fit evaluation has to be done based on AQL 4 (MIL – 150 E Single Sampling plan level 2). At least 4 pieces per size need to be measured. The cartons have to be stacked properly in rows of equal height and should be easily accessible. The carton quantity has to be verified first based on the packing list.

• •

The cartons that are selected for the audit have to be signed by the auditor and accompanied to the inspection room.

•

The size and color ratio, shading in carton size and printing and paper trims have to be compared with approved samples and the placement has to be checked as per floor ready specs. Packing and folding instructions also have to be verified as per the floor ready specs.

•

All finished pieces have to be stacked size-wise. Inspectors have to then check for care instruction, size on all labels and hangtags.

•

Inspectors will pick two pieces at a time and pair the waist together to check if it matches. This will ensure a 100% check on all size label mistakes.

•

Garments have to be checked inside out. Zippers and buttons have to be checked for functionality

Fabric & Trims Inspection and Storage Procedure •

The approved swatch card has to be collected from the merchandising department and kept in the store.

•

All trims must have bin cards affixed on top of the rack where they are stored and they must be stored color and size wise.

•

10 % percent of all trims must be checked and findings noted in a trims report. Only 1 percent defect is a acceptable rate. The trims report has to be affixed on the bin card.

•

Any one of Hang Tags may be checked from each bundle using a bar code machine and a printed copy must be retained.

•

All trims have to be checked using a UL3000 light source.

•

All rejected trims must be kept in the reject room and disposed of following the buyers recommended disposal process

•

All excess trims must be accounted for and stored in a secure place and a record must be kept for reference until further notice from the buyer.

•

Fabrics have to be kept on pallets.

•

The bin card must be attached to fabric rolls dye lot wise

•

Shrinkage and Fabric Inspection Report should be on the bin card.

•

All fabrics must be issued shade-wise for cutting.

•

All rejected fabric must be placed in the reject room and disposed per buyers disposal process

•

All access fabric must be accounted for and stored in a secure place. Records must be retained for reference until further notice from buyer.

Note: Please see the fabric inspection procedure for fabric inspection process. Washing Procedures in Washing Unit •

Factory QA Manager will receive approved wash standard from merchandisers for hand feel, shade and grinding.

•

Factory QA Manager will ask for wash recipe from the washing plant.

•

Factory QA Manager will provide approved wash standard to the washing plant.

•

Factory QA Manager will provide approved wash standard to the production / QA file.

•

Factory QA Manager will provide approved wash standard to the wash quality auditor / checker.

•

QA Manager will check pre-wash spec against each & every dye lot prior to sending for washing. All pre-wash garments should be stored in a particular place.

•

All subcontract inventory control reports must be maintained in a register.

•

All washed garments must be stored in a particular place.

•

All washed garments spec must be checked and verified for hand feel, shade and grinding against each and every dye lot prior to sending for bulk thread trimming.

•

All wash damaged garments must be stored in a particular area by maintaining proper a record.

Remarks: Garment production is a very complex work to do because of it needs a huge number of machineries and large man power system as well. To maintain production rate with in shipment time is very important and it is difficult as well. We worked hard to know the whole procedure of a production process. We have collected all the documents are needed to run a production. Some of them I have attached. I have tried my best to collect them. CHAPTER SIX: Quality Assurance System Introduction: As products become more and more complex, and as customers - both Government Departments and individuals - become more conscious of the effects on their own economics of receiving a proportion of defective items, the effort required must continually increase. We have seen all the Quality sections of Dird Group and tried my best to collect the necessary document and information. Though it is a huge building the control management is very good. Dird Group will have to maintain a SIP file for all orders at the factory. Factory will have to make sure that all tests are timely done and approved. The following information has to be in the SIP: • • •

PID and any changes to order. MTL Fabric Testing Reports. MTL Pre Production Sample Testing Reports.

• • • • • • • •

MTL TOP Sample Testing Reports. Interlining Testing reports. Invoices of all Trims / Fabric that have been ordered from the nominated suppliers. Factory Pre Final/Final inspection reports. TCPS Final inspection reports. Approved fabric swatches and Trim samples Fit and Pre production approval comments Pre-production meeting reports

Fabric Inspection Procedure Dird Group must maintain the following fabric inspection procedure: • • • • • • • •

10 % of all fabric shipments should be inspected prior to cutting. Records should be maintained for every fabric invoice packing list and inspection report. Fabric inspections should be done by using the 4 point system and on the Rotary fabric inspection machine. Fabric inspection cannot be done while spreading. Fabric should be inspected for color accuracy as well as shading (side to side, end to end, roll to roll and number of shade lots). All rolls that are out of the color shading guidelines should be rejected. All roles with color defects such as side-to-side shading, side-center-side shading, and end-to-end shading will not be given points, but should be rejected. All fabric inspection forms should have the defects classified separately. E.g.:- Stains, Weaving defects, Holes, Slubs, etc.

The Four Point system classifies defects as shown in Table 1: Size of defect 3 Inches or Less Over 3, But not over 6 Inches Over 6, But not over 9 Inches Over 9 Inches

Penalty 1 Point 2 Points 3 Points 4 Points

b. Hole c. Missing Yarn d. Conspicuous Yarn e. Variation f. End Cut g. Soiled Yarn h. Wrong Yarn. Major Defects for Knit fabrics are classified as follows: a. Mixed yarn b. Yarn Variation c. Runner d. Needle line e. Barre f. Slub g. Hole h. Press off. The inspection procedure listed below details the steps involved in performing the piece goods inspection in the correct manner. These steps must be followed by the Fabric Inspector/Auditor. •

•

Count the rolls in the shipment to make sure they match the packing list and then mark the rolls that are to be pulled for inspection.

•

Check the packing of the rolls in the shipment to make sure all the packing and markings are correct.

•

manor. Make sure that you have the proper and adequate light at the machine shining on the face of the fabric. •

Check the length of the fabric on the roll and compare it to the ticket yardage for the roll. Note this on the “Inspection Form.”

•

Check the width of the fabric at the beginning and end of the fabric as well as at least once in the middle of the roll. Mark this on the “Inspection Form.

•

Check for skewing, bias, and bowing, compare this to the standards and note findings on “Inspection Form”.

•

When inspection is completed do calculations on the „Inspection Form” to determine the point count for each roll and whether or not it passes or is a “second roll.” Make sure all „second rolls” are separated.

•

Calculate the percentage of the average point count for the shipment per square yard. This will determine if the shipment passes or fails.

The max defective points accepted are 28 points per 100 Sq yards. The max defective 1 point accepted is 14 points per 100 Sq yard.

Shrinkage Reports: For washed products the factory should see that shrinkage is checked for a minimum of 10% rolls per color for every shipment. A test run must be made before starting bulk to ensure shrinkage control techniques and patterns. Test run is the most important check point to verify if the technique and patterns are all correct. Fabrics with a spandex mixture in its composition have to be handled very carefully due to high shrinkage variance between rolls. If the noticed shrinkage variation is more than the garment tolerance then it is recommended that 100% rolls get checked for shrinkage and factory makes groups and different patterns for different groups.

It is always recommended to make a average pattern by considering only ½ the tolerance give to the spec. for example if the hip tolerance is 1” you should only consider ½” while making patterns for different shrinkages. Factory will have to study the tolerances given in the spec for Bottoms and tops and decide accordingly on the different patterns required Factory will have to maintain a file on shrinkage reports. All shrinkage tests need to be done on a minimum 50 cm x 50 cm square marking – factories have to make a square marking template. Factory will also have to mention the wash recipe and time used to dry the garment in the shrinkage report file. The wash recipe and time that is once set; can not be changed for the full program. Laboratory Machine Equipment Name (SDL England): SL No. 1. Laboratory Sample Dyeing Machine

Qnt y

Special Feature

Spectro Photometer

Colour Matching Cabinet

Rota wash 1 Colour Fastness Tester Type M228B

Crock meter

Wascator 1 FOM 71CLS lab

High Temperature Lab – dip Machine innovative metal conduction heating ultra fast cooling. No smoke, Air pollution & glycerin free 12 pots facility available for twelve colors. Especially effective for cotton polyester lab dips and other sophisticated fabric. Colour eye Textile colour control system 2180 UV /D412B Colour Eye 2180 UV is the most cost effective high accuracy, sphere based spectro photometer in its class. The only instrument in its class with an ultraviolet filter. It can be measured all types of fastness rating. For the visual assessment of colour under various light conditions. with membrane switch panel, digital hour meter & electronic ballast control used for reducing sound pollution. Available light sources D65, TL84 UV incandescent. To determine colour fastness to washing or dry cleaning to ISO, B.S. , A.A.T.C.C & S.D.C standards & M&S. fitted with automatic selection of all test method (COM) port for update including drain pump, inching facility lid interlock. To determine the colour fastness testing to dry & wet rubbing to B.S, ISO, AATC & M&S. Standard Reference washing machine. Micro processor controlled up to 999 washing & drying program. This unit is

washerExtractor with tumble dryer. Combine 1 Circular Sample Cutter (GSM Cutter) & Weighing Balance Digital PH 1 meter & Temp meter TYPE G202

Total:

programmed as standard with BS, ISO, & M&S Test Programs. Combine & universal manual lever sample cutter with a program. Battery operated electronic balance.

0-14 PH, 0-100 OC battery operated complete with probes leads calibration buffer solution used for checking core PH of dyed fabric which is required for baby wear. 08

Remarks: To run a factory quality plays an important role. Moreover productivity of a factory is depending on it very much. I have observed the total Quality service is available here. It was not an easy work to do but since the staffs were very helpful so it became easier to us to collect information. CHAPTER SEVEN: Store & Inventory Control Introduction: There are two garments in the Dird group they are Dird and Dipta. The entire floor is same area. But in one floor there are different section such as store, cutting sewing, washing and finishing section. All the section is involved with different working. Area and objective of the store room: I know that there are eight factories in Dird group. Their store room is also in the individual floor and all the store room is same. Now I am describing about one store room. The area of store room of Dird is 700sq foot. The main objects of store room are following I. To keep the material imported from foreign or local market. II. To install the accessories from local or foreign market. III. To remain different spare parts of different machine. IV. To hang swatch board / term board on the wall. V. To maintain a fixed relative humidity e.g. 76 The test and process of store room: Mainly the fabric is imported as lot and in one lot there are 100 or 120 yards of fabric. When fabric is needed in the letting see lion then taken from the store room.

Testing system of store room: There are different testing and inspection system in the store room. 1. 4 point system 2. 7 pious inspection system 3. 10 inspection system and 4. Other different inspection system such as shrinkage, strength, elasticity and the evenness of the fabric. There is also a machine in the store room which name is fabric spreading and quality checking m/c. By this m/c the length, width and shade of the fabric are checked.

Management system of the store room: In every store room there is well arranged management system. In each store room there are 1. one supervisor officer and 2. twelve workers 3. one stone in charge 4. two guards The work of the stuff: The supervisor officer receives all the fabric and accessories from the local or foreign market according to production director officer and supply the fabric and accessories to the other section according to requirement. The store in charge handles the worker to manage the test and other inspection. The workers look after the store room. Inventory control: Inventory in a widen sense is defined as any idle resource of in enterprise in order to meet expects of demand or distribution. It is commonly used to indicate materials, raw materials, finished, packing and stocked products. It is basically necessary to keep hold inventory of various kinds to act as a cushion bet supply and demand. It is almost necessary to maintain same inventory for the smooth functioning of an organization. Causes of maintaining inventory control: 1. It takes time to complete one operation and more products from one store to another 2. To run manufacturing operation economically. 3. To take care of uncertainties like uncertainties in demands from customers and uncertainties in producing the materials in time. 4. To reduce the critical cost and to take advantage of discounts and transportation. Function of inventory control: 1. To develop policies, plans and standard to achieve inventory control objectives.

2. 3. 4. 5.

to build up a logical and workable plan for doing job satisfactorily to provide necessary physical facilities to develop methods that will bring desire result economically To maintain overall control by checking result and adopting corrective actions.

Types of inventories: Inventions is following 5 categories Production invention: It means which to inter the final products e.g. raw materials. In process inventories: Semi finished products at various stage of production. Finished goods inventories: Compel products ready for dispatch. Maintenance repair and operating: Though those are not form a part of final product they are used in production process like spare parts. Miscellaneous inventories: They are spare and obsolete item which are not to be disposed off. Objectives of inventory control: Financial objectives: Here the goal is to keep inventory cost within limit of funds available and the position of its working capital. Property protection objectives: a) To safe an important asset against theft, waste and measurable damage. b) To make certain that the value of this asset is correct stated in the company s book. Operating objectives To obtain the best overall balance bet products and inventory caring cost on one hand and customer service to others. Advantage of inventory control: A well planned and property administered system of inventory control will bring rise to the following benefits. a. Improvement of customerâ&#x20AC;&#x2122;s frictions: This is achieved through maintenance of better balance among the quantities of finished items on hands. b. Improvement of labor and community relations. c. Increase in the effectiveness of key personnelâ&#x20AC;&#x2122;s: d. Reduction in manufacturing cost:

e. Strengthens financial position: This is achieved by onward inventory controls. Different inventory cost: The important step in the inventory analysis is the identification. The following classes of cost are usually involved in inventory control / decision. 1. Cost of ordering 2. Inventory costing cost 3. Colt of shortage Now they are described below. Cost of ordering: Out of many other costs the order cost of inventory is the most difficult cost to measure precisely. Placing of order is just one of the many other activities of purchasing. So it is difficult to isolate and identify the cost of the cost of ordering and measure them precisely. There are two types of cost of ordering: A. fixed B. variable Cost per order= Total cost in running purchasing dept/Total no. of order during the year. Inventory caring cost: Inventory caring cost is also known as holding cost. a. Cost that depends on quality of inventory: This cost includes. 1. Cost of storage space â&#x20AC;&#x201C; light, rent maintenance etc. 2. Cost of hold stock e.g.: Pilferage spoils age, deterioration and protection. b. Cost that depends on the value of inventory: 1. Cost of capital, inter of cost. 2. Cost of insurance. Cost of shortage: When a demand arises and the item needed is not in stock then it is the Cost of shortage of stock out of cost. In the back order case there are two types of costs. a. External

b. Internal

-Loss of good will -Loss of future sales.

-over time - Special ad minis dative efforts

Spares: Basically spares are the machine parts that are kept in the store room from the different sewing and after m/c and made the reusable. Now different spares are followings: 1. folder 2. guide 1/4 CR 3. guide 1/4 CL 4. guide 1/16CR 5. guide 1/16 CL 6. guide 3/16 CR 7. guide zipper 8. guide hanger 9. guide hamming 10. guide plain feet 11. guide gathering 12. guide CT 13. guide magnet 14. guide vertical 15. guide thread 16. guide hook 17. guide piping 18. p/m bobbin 19. p/m needle plate 20. p/m rotary hook 21. p/m back stitch 22. p/m feed dog 23. p/m 60â&#x20AC;&#x2122;â&#x20AC;&#x2122;poly 24. p/m magnet screw 25. p/m thread stand 26. p/m tension spring 27. p/m needle bar cap 28. p/m pressure nut 29. p/m guide CR 30. o/l knife set 31. o/l upper holder set 32. o/l upper lopper 33. o/l lower lopper 34. o/l lower knife Finished goods: The term finished goods means the products that are ready for export. In the Dird garment different types of garment are made for export such us. 1. a knit wear 2. pant lades

3. 4. 5. 6.

pant gents skirt shirt and sweater etc

Remarks: Actually the Dird garments is 100% export reinvented garments. All the management system of store and inventory system I well arranged. So its finished goods are attracting the people of the world by beauty. The store house is very much secured and only authorized person can enter that room. CHAPTER EIGHT: Marketing Activities Introduction: Marketing is an integrated communications-based process through which individuals and communities are informed or persuaded that existing and newly-identified needs and wants may be satisfied by the products and services of others. Marketing is used to create the customer, to keep the customer and to satisfy the customer. With the customer as the focus of its activities, it can be concluded that Marketing is one of the premier components of Business Management - the other being Operations (or Production). The term marketing concept pertains to the fundamental premise of modern marketing. This concept proposes that in order to satisfy its organizational objectives, an organization should anticipate the needs and wants of consumers and satisfy these more effectively than competitors Marketing Service: Marketing is a social and managerial process by which individuals and groups obtain what they need and want through creating and exchanging value with each others. Actually, companies use the process to create value for customers and build strong customer relationship in order to capture value from customers in return. In Dird group, Marketing is a special branch of the garments sector. We have mentioned earlier that Dird group has a strong marketing department. They need a lot of raw materials to purchase as well as they need to convince buyers to sell their product. So the marketing department should be strong and skillful as well. In Dird group some raw materials are collected from local market and rest are imported from abroad. It is easy to say that buying them from this country or abroad is not an easy work to do. That is why here marketing accumulation is broadly opened. We have observed the account office and the marketing department and collected some invoice. We was also introduced with some marketing officer. They helped us by giving us information and documents. Marketing Process:

The marketing concept of building an organization around the profitable satisfaction of customer needs has helped firms to achieve success in high-growth, moderately competitive markets. However, to be successful in markets in which economic growth has leveled and in which there exist many competitors who follow the marketing concept, a well-developed marketing strategy is required. Such a strategy considers a portfolio of products and takes into account the anticipated moves of competitors in the market. For marketers planning is an essential task that must be continually undertaken. As I will see, shifting market conditions, including changing customer needs and competitive threats, almost always insure that what worked in the past will not work in the future, thus requiring revisions in how a product is marketed. Marketing planning is also important since it is often a prerequisite for obtaining funding whether one is a marketer in a large corporation seeking additional money for his or her department or is part of a small startup company looking for initial funding. To aid in my understanding of planning I introduce a key concept in marketing: the Product Life Cycle. W will see the Product Life Cycle offers valuable insight and guidance for marketing decisions. In this tutorial I also discuss different types of marketing strategy that can be followed to meet marketing objectives. Additionally, We look at how innovative products are adopted within a market and how this impacts marketing planning. We can describe the objectives also in following steps: • •

For creating value for customers and building customer relationship. Understand the marketplace and customers needs and wants.

•

Construct a customer driven marketing strategy.

•

Design a marketing program that delivers supplier value.

•

Build profitable relationship and create customer delight.

•

Capture value from customer in return.

In our word we can say simply at first a marketing officer has to understand customers need wants and demands. In Dird group the needs are identified at the states of left deprivation. Then the wants are calculated by the form needs take as shaped by buyer and individual personality. The demand is however wants that are backed by buying power. Marketing Strategy: There is a sequence of marketing strategies like following • •

Undifferentiated (mass) marketing Differentiated (segmented) marketing

•

Concentrated marketing

â&#x20AC;˘

Micro marketing (local or individual marketing )

In Dird Group they have much extra ordinary marketing strategy. I was trying to understand that clearly but could not understand thoroughly. I have described below what I have understand. Consumer of the Product: Marketing occurs when people decide to satisfy needs and wants through exchange relationship. Exchange is the act of obtaining a desired object from someone by offering something in return. As I have mentioned earlier that Dird Group is a 100% export oriented garment company so the consumers and the customers are the foreigner normally. America and Canada is the main consumer of the product. Moreover Germany, Hong Kong, Thailand, France, South Africa, Norway, Switzerland etc. are the main consumer of the product. Customer/Buyer Details: Sl no. 1. 2.

Customer/Buy er Hanes

Country

Product

Germany

Menâ&#x20AC;&#x2122;s & Ladies T-Shirt, Polo Shirt, Tang top Sweat Shirt, Jogger

Marks Spencer Best Seller

& U.K

George

Ladies trouser, T-Shirt, Polo shirt T-Shirt & Polo Shirt

Tesco

T-Shirt & Polo Shirt

LPP

Poland

Under garments and Fancy Item

Sainsbury

Switcher

Switcher land

T-Shirt & Polo Shirt

Roochi

U.S.A

T-Shirt & Polo Shirt

Denmark

Polo Shirt

Product Level: Market consists of buyers and buyers can differ in one or more ways. They may differ in theirs wants, resources, location, buying attitudes and buying practices. Dird group divides large heterogeneous market into smaller segment that can be reached more Efficiently and effectively with products and services that match their unique needs. In Dird group, there are three levels of product

1. Core benefit product 2. Actual product 3. Argumentum product Package Size: Packaging refers to the development of a container and a graphic design for a product. Packaging can make a product easier to use safer and more versatile. Packaging can make an affect on consumersâ&#x20AC;&#x2122; altitude toward a product, which in turn affect their purchase decisions. In Dird group packaging serves a number of purposes. It protects the product and maintains its functional form. All the products in here are packaging with the recommendation of buyers. So that here present package who consider the promotional role of packaging using verbal and non verbal symbols which contains the product content, features, uses, advantages and hazards etc. Importing Countries: The main importing countries of Dird group are America and Canada. They bring their most raw material, accessories and other trimmings from there. Besides this the maximum machines have been bought from China, Japan and Hong Kong. Some are also been bought from Korea and Malaysia. The sewing machines in here are imported from Japan and China from Brothers companies. In washing unit boiler has been imported from China. There two generators in Dird group which are imported from U.K. Manpower: The whole marketing department of Dird Group works under the supervision of merchandising department. A number of marketing officer are worked under the G.M of the company. There worked in different section. As itâ&#x20AC;&#x2122;s an export oriented garment factory the merchandisers are always busy to get an order from abroad. Sometimes they do some sub contacted order. Most of marketing officer are doing the purchasing job in here. They buy the accessories and trimmings from here. There is also a custom department here for doing the activities related to shipment such as loading and unloading. They keep contact and make reasonable bargaining with the transport company. Duties and Responsibilities of a Marketing Officer: A marketing officer directs firm's overall marketing and strategic planning programs, and corporate communications. Facilitate client development through marketing and client services programs. 1. Design, implement, and facilitate annual marketing plan for the firm. Support and facilitate development and implementation of section business/marketing plans. 2. Plan and administer the firm's Marketing Operations budget; support development of regional marketing budgets.

3. Oversee the Charitable Contributions Foundation. 4.Organize and implement client relations including: 4.

client satisfaction surveys

6.client development activities 7.client skills training 8.special events 5. Supervise firm's RFP protocol process including soliciting RFPs from desirable prospective clients and writing proposals for new business; participate in planning and presentation sessions, when assigned. 6. Oversee business development activities including: · efforts through Business Development Coordinator · assisting attorneys in strategic planning for client presentations, beauty · contests, etc. · offer coaching for prospective client meetings, presentations, etc. · work with regional offices on designing and implementing prospecting and client contact systems. 7. Oversee corporate communications activities through Communications Coordinator including: · external communications and systems · internal communications and systems · public relations efforts · external vendors and consultants 8. Develop and administer marketing database which includes client and prospect information, mailing list applications, access to financial reports, etc. 9. Assist with and support firm's involvement in various legal networks including coordinating business development and marketing activities via these relationships. 10. Design and plan quarterly marketing training seminars for attorneys. 11. Oversee firm's electronic marketing efforts including supervision of Web site design and maintenance.

12. Supervise Marketing Assistant, Client Services Administrator, Communications Manager, Practice Development Manager and Regional Marketing Manager(s). Make staffing and hiring decisions within marketing department Remarks: In this sense, a firm's marketing department is often seen as of prime importance within the functional level of an organization. Information from an organization's marketing department would be used to guide the actions of other department's within the firm. As an example, a marketing department could ascertain (via marketing research) that consumers desired a new type of product, or a new usage for an existing product. With this in mind, the marketing department would inform the R&D department to create a prototype of a product/service based on consumers' new desires. The production department would then start to manufacture the product, while the marketing department would focus on the promotion, distribution, pricing, etc. of the product. Additionally, a firm's finance department would be consulted, with respect to securing appropriate funding for the development, production and promotion of the product. Inter-departmental conflicts may occur, should a firm adhere to the marketing orientation. Production may oppose the installation, support and servicing of new capital stock, which may be needed to manufacture a new product. Finance may oppose the required capital expenditure, since it could undermine a healthy cash flow for the organization. In Dird Group all this criteria are maintained so they have good marketing department. Every person of this department works as a team member that helps to reach the goal of the company. CONCLUSION For every person who is fresher in the field of textile, industrial training works like learning route. This course has given me the opportunity to move liberally in every section of the industry to learn the industrial work and follow the process sequence virtually. From my two months observation of the industry along with merchandising section especially, we can say that the knitting sector in this industry has very strong possibility because the industry is running with all modern machines and very knowledgeable persons are working all the time with their maximum limit. We just think the capacity of the industry should be developed with the amount of order the industry is being taking.