INTERNSHIP REPORT

on
Quality Management of Alif Dress Composite Ltd.

Submitted to:

Nashid Bintey Hayder

Lecturer

Department of Business Administration

BGMEA University of Fashion & Technology.

Submitted by:
Student’s Name
ID No.:
Batch:
Major in Apparel Merchandising

Masters of Business Administration (MBA)

Department of Business Administration

BGMEA University of Fashion & Technology (BUFT)

Submission Date:
Quality Management of Alif Dress Composite Ltd.
 INTERNSHIP REPORT
on
Quality Management of Alif Dress Composite Ltd.

Submitted to:

Nashid Bintey Hayder

Lecturer

Department of Business Administration

BGMEA University of Fashion & Technology.

Submitted by:
Students Name
ID No.:
Batch: 181
Major in Apparel Merchandising

Masters of Business Administration (MBA)

Department of Business Administration

BGMEA University of Fashion & Technology (BUFT)

Submission Date:
 STUDENT’S DECLARATION

I am-------------------------, a student of MBA of 161 batch, ID: -----------at the Department of

Business Administration, BGMEA University of Fashion & Technology (BUFT), do hereby
declared that the internship report on “Quality Management of Alif Dress Composite Ltd.” is
a work done under the supervision of Nashid Bintey Hayder, Lecturer, Department of
Business Administration. I also declared that this report is and original work and no part of
this report have been copied from elsewhere. Furthermore, this report has not been published
or submitted for being awarded any degree, diploma or recognition earlier.

…………………………………………..

Name

Program: MBA in Apparel Merchandising

ID No.: 161-041-4111

Batch: 161

Department of Business Administration

BGMEA University of Fashion & Technology (BUFT)

i
 LETTER OF TRANSMITTAL
Date:

To

Internship Placement Committee

Dept. of Business Administration

BGMEA University of Fashion & Technology (BUFT)

Subject: Submission on Internship Report.

Dear Sir,

With great pleasure, here I am submitting the attached report on “Quality Management of
Alif Dress Composite Ltd.” that you have approved & assigned as a compulsory requirement
of MBA Program. I have tried my level best to bring out the original scenario of Alif Dress
Composite Ltd. with full of effectiveness & efficiency.

I pray and hope that you will kindly accept the report and also hope that you will find this
report as satisfactory.

Sincerely,

…………………………..

Name

ID No.: 161-041-4111

Batch: 161

Major in Apparel Merchandising

Masters of Business Administration (MBA)

 OFFICIAL CERTIFICATION

This is to clarify that Student’s Name, Program: MBA major in Apparel Merchandising,
Batch: 181, ID no.: 161-041-4111 has completed his internship report on “Quality
Management of Alif Dress Composite Ltd.” under my supervision as a part of partial
fulfillment of the requirements for the Degree of Masters of Business Administration (MBA)
in Apparel Merchandising in the Department of Business Administration of BGMEA
University of Fashion & Technology. This report can be accepted for evaluation.

………………………………………………….

Nashid Bintey Hayder

Lecturer

Department of Business Administration

BGMEA University of Fashion & Technology (BUFT)

iii
Internship Certificate from Industry Supervisor
 ACKNOWLEDGEMENTS

A warm felicitation goes for me to acknowledge the people, who hold the desirability for
encouraging, praising, assisting as well as believing me the task on quality management what
I have worked through my internship period.

First I would like to take the opportunity to thank Nashid Bintey Hayder, Lecturer,
Department of Business Administration, BGMEA University of Fashion & Technology & my
internship supervisor for providing me guidelines, help in assisting my report. She constantly
supported me with her inspiring personality. I will always be thankful for her reinforcement.

I would like to thank Md. Azom, Manager (Merchandising & Marketing) of Alif Dress
Composite Ltd. for being on-site supervisor & providing me time to time information,
suggestion as well as procedures to work with my topic.

I also want to thank Mr. Shawon, HR & Admin, (Alif Dress Composite Ltd.) for being
cooperative in my work and helping me to get accustomed with all the activities and also
want to thank him for assisting me with information of my project.

Finally, I will show my gratitude to all the management & Non- Management Staffs who
have helped me during the internship period and the entire persons who somehow have
impact on me in completing my whole report.
 Executive Summary

Quality may be defined as the level of acceptance of a goods or services. For the textile and
apparel industry, product quality is calculated in terms of quality and standard of fibers,
yarns, fabric construction, color fastness, designs and the final finished garments. In
Bangladesh, different garments factory follow different quality control and management
systems especially different inspection systems for garment inspection. This article contains
the quality control processes as well as quality management procedures followed by different
garment factory of Bangladesh and the feasibility of these processes. Quality control in terms
of garment manufacturing, pre-sales and posts sale service, delivery, pricing, etc. are essential
for any garment manufacturer, trader or exporter. Certain quality related problems, should
never be over looked. The consumers want to get high quality products in low price. The
products should reach the consumers with right quality depends on the cost. Quality
management is the aspect of the overall management function that determines and
implements the quality policy. Quality assurance covers all the process within a company that
contributes to the production of quality products. The inspection is carried out by
representatives of the current production and the result record on control chart. The aim of
garment inspection is to visually inspect articles at random from a delivery in order to verify
their general conformity and appearance with instruction/description and/or sample received.
 Table of Contents
Content Page No.

Student’s Declaration i

Letter of Transmittal ii

Official Certification iii

Internship Certificate from Industry Supervisor iv

Acknowledgments v

Executive Summery vi

Table of Contents vii-viii

Acronyms ix

Chapter One: Introduction

1.1 Prelude 1

1.2 Problem Statement 2

1.3 Objectives of the Study 2

1.4 Scope of the Study 2

1.5 Limitations of the Study 3

vii
 Chapter Two: Methodology
4
2.1 Selection of the Study Area
4
2.2 Sources of Data
5-24
2.3 Processing and Analysis of Data

Chapter Three: Overview of the Organization

Historical Background 25
3.1
Mission and Vision 25
3.2
Features 27
3.3
Capital of the Organization 28
3.4
Different Departments 29
3.5
Organogram 30
3.6

Chapter Four: Results and Discussion

04 Results and Discussion 31

Chapter Five: Conclusion and Recommendation

Conclusions 32
5.1
Recommendation 32
5.2
References 33
 ABBREVIATION AND ACRONYMS

BGMEA : Bangladesh Garment Manufacturers & Exporters Association

BKMEA : Bangladesh Knitwear Manufacturers andexporters Association
BTMC : Bangladesh Textile Mills Corporation
BUFT : BGMEA University of Fashion & Technology
CAD : Computer Aided Design
CIF : Cost, Insurance & Freight
C&F : Cost & Freight
CM : Cost of Making
QC : Quality Controller
QI : Quality Incharge
QM : Quality Manager
 CHAPTER ONE: INTRUDUCTION

Prelude:
Quality is defined as the level of acceptance of a good or service. It is a very essential
requirement for any kind of product. Every product should maintain the standard quality
level. In this 21st century of globalization market is becoming more and more complex, that’s
why every industry is facing a high level of competition for their business. So the product
must fulfill the customer requirement. For this reason, every product should maintain the
quality level. For the textile industry and apparel industry, product quality is calculated in
terms of quality standard of fiber, yarn. Fabric construction, color fastness, design and the
final finished garment. Nowadays buyers are very much quality conscious. If it is possible to
maintain a high Quality system of inspection policy, the buyers shall be motivated and more
quality products can be made.

The fitness for use concept can be applied to garment. For a garments to be fit for use
provided its style acceptable.

1. It must be free from defects such as stain, material defects, open seam, loose
hanging thread, misaligned buttons and button holes, defective zipper etc.
2. Must fit properly for the labeled size.
3. It must perform satisfactorily in normal use, meaning that a garment must be
abler to withstand normal laundering / dry cleaning / pressing cycle without
color loss or shrinkage, seams must not come apart, fabric must not tear and
so on.
But maintaining an adequate standard of quality also costs effort. From the first
investigation to find out what the potential customer for a new product really wants,
through the processes of design, specification, controlled manufacture.

1
Statement of the Problems:
The study will deal with the element which are effected the QI to make the QC Process and
a quality management system is the framework of policies, strategies, processes, routines,
and responsibilities that organization uses to achieve their goals and fulfill customer
requirements. These are the things that we want to find from this study.
Objectives of the Study:
Board objective:
The broad objective of this study is to analyze the Quality Management of Alif Dress
Composite Ltd, how the QI & QM do the QC process.

Specific Objectives:

Specific objectives are given below:

 To maximize the production of goods within the specified tolerances correctly the
first time.

 To achieve a satisfactory design of the fabric or garment in relation to the level of

choice in design, styles, colors, suitability of components and fitness of product for
the market.

 To find out the duties and responsibilities of quality controllers.

 To find out how QC keep good relationship with buying house & buyer QC.

Scope of the Study:

For any business student only curriculum activities are not enough for handling the real
business situation. Internship is a part of the Masters of Business Administration (MBA)
degree that provides a job experience for the students. Internship program is a perfect match
of the theoretical and practical knowledge. The report is originated to fulfill the requirement
of the internship program under MBA program.

I tried to collect more information about the importance of QC section for the
export oriented knit garments industry. The principle of the company is to
develop and maintain strong relation with buyers and retailers.
 • The study will also help me to understand the quality control management in
garments sector.

• The study will give a clear idea about the quality control management of Alif
Dress Composie Ltd.
• The guiding principle of the company is to develop and maintain strong,
secure relation with buyers and retailers and to support the customers.

Limitations of the Study:

1. Foreign buyers English are not that much clear.

2. The answer of certain questions I had go through peoples’ opinion. While doing the
survey lots of people did not want to respond to many questions. Sometimes they
even did not fill out the questionnaire properly for the busy schedule.

3. Time was one of the major constraints. As our internship program is only few
months long, it was difficult to cover and collect all the necessary materials for
completion of such a large report within this time boundary.

4. The people of qc Incorporation are under tremendous workload. Although, they

wanted to cooperate with me in writing my report, their busy schedules sometimes
did not allow them to do so.

5. There are many code names in garments industry that is very important for
production process, and I have memorized those codes.

6. In garments factory most of the employee doesn’t have any educational background
they do their job only with experiences.

7. Political unrest of our country such as strike or hartal was major problem in this
regard as it is difficult to go out and work during that time and to maintain the work
schedule.
 CHAPTER TWO: METHODOLOGY

Selection of the Study Area:

It was clearly mentioned in my joining letter that I was supposed to give regular attendance at
the place where I would depend to work on my project. As an internee I was supposed to
perform the following departments.

1. Cutting section

2. Sewing Section.

3. Washing Section.

4. Finishing Section.

Sources of Data:

The report is based on both primary and secondary data. But maximum data used in this
report are collected from secondary sources. Exact sources of the secondary sources will be
mentioned. Thus the report is basically qualitative in nature. However, primary data is also
used depending on the requirement.

For my report, I have collected information from both primary and secondary data. Data
were collected during 1st February, 2020 to 30th August, 2020.This time factory was shut
down due to this pandemic COVID-19 aka Corona Virus.

Primary Data: I got the data or information through directly from the employees and the
head of the departments by observing the environmental behavior, facts, record and present
condition of the industry through conversation with the QC managers, Line Managers and
regular employees.

Secondary data: I have collected the secondary data from Alif Dress profile, export volume
report, audit reports, documents, related books and articles on garments industry, BGMEA,
BKMEA etc. Besides, I also collected data through browsing internet also.
Processing and Analysis of Data:
Quality Control:

Quality is of prime importance in any aspect of business. Customers demand and expect
value for money. As producers of apparel there must be a constant endeavor to produce work
of good quality. "The systems required for programming and coordinating the efforts of the
various groups in an organization to maintain the requisite quality". As such Quality Control
is seen as the agent of Quality Assurance or Total Quality Control.

Satisfactory quality can only be ensured through:

1. Knowing the customer need.

2. Designing to meet them.

3. Faultless construction.

4. Certified performance and safety.

5. clear instruction manual

6. suitable packaging

Satisfaction quality can be ensured from the customer’s point of view by providing:

1. Right product.

2. Right quality.

3. Right time.

4. Undamaged condition.

To ensure the quality level of a garment we need to observe some specific sector:

 Fault free fabric.

 Shade matching of the garments.

 Making the pattern as per buyer requirement.

 All the different parts of the garment should have the perfect size.

 Good stitching, seam formation should be perfect.

 Additional accessories such as button, zipper, tag, level is in right position.

 Packing and packaging.

Quality section: Quality control in garments production are operated in the different sector:

 Cutting section
 Sewing Section.
 Washing Section.
 Finishing Section.

Different section of quality checking:

Quality checking is done by different section followed by a sequence to ensure the production
of 100% good quality product. Step by step quality checking is done to identify every defect
and each section whose identify the defects take action to solve the problem. The fabric
inspection is done primarily. Then the fabric goes to the cutting section, in the cutting section
quality checking is done by every part of the processing, the identified problem solved there.
As the same process the sewing section, washing and finishing section do their work. As a
result, the good quality product can be produced which helps to fulfill the buyers requirement
The various Steps of Garments manufacturing where in-process inspection and quality
control are done are mentioned below-

1. Fabric inspection.

2. Inspection in fabric cutting section

3. Inspection in sewing section

4. Inspection of washing section

5. Inspection in pressing & finishing section

 Quality policy:

Q.M

.…………………………………………………………………………………………..

Cutting quality control

Store Q.I Finishing quality
Sewing quality control
Trims and accessories inspection
Fabric relaxation and shade band Q.I
Quality supervisor
Shrinkage and GSM test Q.I
Quality supervisor

After iron inspection Q.I

Line Q.C
Fabric inspection SR Q.I

Process Q.I
Measurement check Q.I
Spreading quality control

Process Q.I
Marker checking Q.I Final getup inspection Q.I

After cutting O.I

Hangtag & Barcode
Process Q.I inspection Q.I

Bundle inspection ram dam Q.I Output final inspection Q.I in Two hours audit
side/Top side

Ratio & size inspection Q.I

Cut fabric panel check

Pre-final
 Activities to be done by Quality team:

Inspection of Fabric and Accessories:

To fabric which will be used to make the garments, matching with the approved swatch card.
To inspect fabric and accessories before start the processing.
Fabric Test: The following tests are carried on based on 4 points system. There are used a
glass table. The fabric laid on the table and under the glass a light used to check clearly.

 Shade matching.
 Different types of spot checking.
 Side-Centre-Side shade check.
 End-End shade check.
 Shrinkage Test.
Spreading Quality
Control:

100% fabric lay spreading should be based on 4 points on a wooden table.

Cutting quality control:

Block check- taking 7 blocks of different size of any one cutting.

Bundle check- 100% check of cutting no, bundle no, and size serial etc.

Panel check – 100% of cutting table inspection.

After cutting Quality Report:

Sl.no Buy Styler/r Color Type of Cut. Cut. Checked Name Size Miss M/c Pattern Top/In Defect Defect Rate
er ef.no fabric of plies check maintain Qty
no Quantit Qty parts cut
yty

01 suns 403 Purple Pique 42 1260 126 Back XXL 1 OK OK OK 3 2.38%

burr
y

02 suns 403 Purple Pique 42 1260 126 Front L Not OK OK OK 2 1.59%

burr foun
y d

03 suns 403 Purple Pique 42 1260 126 Sleeve M 1 OK OK OK 3 2.38%

burr
y

04 suns 403 Purple Pique 42 1260 126 Moonx S Not OK OK OK 1 .79%

burr l foun
y d
Stitch monitors Record: To check the stitch counting them twice in a day, such as- after
starting sewing in the morning and after lunch break.

In- Line Inspection: The garments check in every line in everyday, At least 20 to 30 machine
operator works under the quality inspector. He checks the garments in his line.

Table inspection: This is the last part of sewing section. The table inspection is done in the
final line of every sewing line. The garments when completed sewing then it goes to the table
for inspection. Keep the record hourly after checking the product.

Final Inspection: The garments check 100% at final inspection line before the product
deliver. Keep the record hourly after checking the product.

Initial finishing inspection: checking done prior to pressing of the garment at finishing
room is known as initial finishing.

Final finishing Inspection: After pressing garments are again checked and passed for tagging
and packing.

Fabric Quality Inspection:

Fabric inspection:

Inspection in reference to the apparel industry can be defined as the visual examination or
review of raw materials like fabric. The quality of a final garment depends on the quality of a
fabric when it is received as a roll. Even the most outstanding manufacturing methods cannot
compensate for defective materials. Normally, we inspect 10% of the rolls we receive and
evaluate them based on a four-point system. This way, we can avoid fabric related quality
problems before it is put into production. Normally four systems are used for inspection of
finished garments.

1. 4 point system

2. 10 point system

3. Graniteville "78" system.

4. Dallas system.
But among them 4 points system is widely used. Now a short description of 4 points
inspection system is given below:

4 points system:

The 4-Point System, also called the American Apparel Manufacturers (AAMA) point-grading
system for determining fabric quality, is widely used by producers of apparel fabrics and is
endorsed by the AAMA as well as the ASQC.The 4-Point System assigns 1, 2, 3 and 4
penalty points according to the size and significance of the defect. No more than 4 penalty
points can be assigned for any single defect. Defect can be in either length or width direction,
the system remains the same. Only major defects are considered. No penalty points are
assigned to minor defects. In this system, one should inspect at least 10 per cent of the total
rolls in the shipment and make sure to select at least one roll of each color way.

Fabric defects are assigned points based on the following:

Total defect points per 100 square yards of fabric are calculated and the acceptance criteria
are generally not more than 40 penalty points. Fabric rolls containing more than 40 points are
considered "seconds".

Formula:

Points/100 sq yards = Total defect points/Total length of fabric in yard X 100/1 X 36

inch/Width of fabric in inch.

Finished Fabric Inspection Report:

When the fabric inspect, many types of fault has to check

Yarn fault:

-Naps

-Slubs.

-Thick and thin place.

-Dead cotton.

Knitting construction fault:

-Loop

-Oil stain.

-Needle mark.

-Sinker mark.

-Hole.

Dyeing fault:

-Dye spot.

-Uneven.

-Crease mark.

-Softener spots.

-Hole.

-Adration mark.

Finishing fault:

-Dirt or soil.

-Hole

knitting fabric fault and remedies:

Drop stitch (Holes): - It is a common problem occurs in the garments. Holes obtained when
yarn breaks during loop formation.
Cause:

 High yarn tension.

 Less strength of yarn which breaks during loop formation.
 Presence of mineral particle in yarn.
 Incorrect gap between the Dial & Cylinder rings.
 Yarn feeder not properly set.

Solution:

 For holes problems solution use proper count of yarn.

 Yarn strength is important.
 It should be free from all kind of foreign particle.

The gap between the Cylinder & the Dial should be correctly adjusted as per the knitted loop
size.

Very small holes appeared in the fabric.

Cause:

 Due to break down of latch or bend.

Solution:

 Change the needle.

 Different drive has to maintain.

Needle broken/ laddering:- These defects occur due to broken needle. The loop does not form
in the wale.

Cause:

 High yarn tension.

 Wrong cam setting.
 Breakage of hook or butt.

Solution:

 Defective needle should be chang2

 Needle setting should be right.
 Yarn tension has to minimize.
 Needle must be cleaned before production of any new fabric.
Fabric Cutting Inspection:
Fabric Cutting:

Fabric cutting is the preliminary section in garments industry. The fabric cut into parts of
garments here. This is most important section of garments for inspection because the fabric
spread of 60 to 70 plies on the table for cutting. If there make any mistake for measurement
in cutting it can cause a serious damage for many garments product. So it required skilled
operator and high level of inspection.

Process Sequence of Fabric Cutting Section:

 Fabric spreading: 60 to 70 plies of fabric spread on the cutting table. The fabric
spread is very important. All the fabric measurement is kept same for from one edge
to another edge. Tension of all plies will be same. Marking process:

 Marking process: This is the second step of cutting section. The pattern parts place
on the fabric plies and draws according to pattern measurement. Marking is done
compactly for possible amount of fabric can save from wastage.

 Fabric Cutting: After making is done the cutting process begin. High speed cutting
machine cut the fabric plies by the operator. The operator should be skilled for this
process because the fabric has to cut by exact marking measurement.

 Numbering: When the fabric cut into parts has finished all the parts numbered by the
sticker. This is done for all the parts of a garments can assembled by the same fabric.
So it can minimize the risk of shade variation.

 Bundling: after numbering the parts has to bundled and sent to the sewing section
Prepared bundling card according to fabric lay report this card maintain.
 Program No
 Cutting No
 Size No
 Pies
 Roll No
Quality Control in fabric spreading & cutting:

 Fabric spreading according to correct alignment with marker length and width
 Maintain requirements of spreading
 Lay contains correct number of fabric ply
 Correct Ply direction
 Tension control
 The dimension of the pattern and the cut piece should be same and accurate
 Cut edge should be smooth and clean
 Avoid blade deflection
 Maintain cutting angle

Fault occurs in cutting section and its remedies:

Misalignment of plies: Plies misaligned, resulting in garment parts getting cut with bits
missing in some plies at the edge of the spread.

Cause:

 Different plies spread too tight or too loose.

 All the plies do not spread from the edge at same
measurements. Solution:
 All fabric should spread at same tension.
 Measurement should be equal at all measurement for the edge.
Less marker efficiency: less marker efficiency cause of increasing wastage and result a wrong
cutting.

Solution: Check the marker is placed on the spread with the edge parallel to the selvage of the
goods. It must ensure that no plies is creased, damage, or have overlapped parts. It must be
ensured that possible amount of wastage can reduce.

Incorrect tension of plies: Improper tension during spreading can spoil the right
measurements of the cutting parts
Solution: Check the tension during spreading. It is very important for knit fabric.
Wrong cutting: This occur due to
 Careless cutting operator
 Deflection of blade.
 Unsharpened blade.
 Roller jams during

cutting Solution:

 Blade should be sharpened.

 Regular checking of cutting machine
 Should be careful when cutting.

Numbering mistake: The cutting parts numbered by the sticker to assemble the garments
from same fabric. If operator misses any parts to number all the parts after from there will be
wrong numbered.
Cause:
 Lack of concentration by the operator during
numbering. Solution:
 The operator has to be alert when he numbered the parts that no parts cannot be
missed from numbering.

Sewing Quality Inspection:

Sewing section: After finishing the cutting process the cutting parts come here for sewing. It
is mainly an assembly section in the garments factory. Different parts of the garments joined
together here and attach other accessories like button, zipper make a complete product.

Quality Control in Sewing Section:

1. Input material checking

2. Accessories checking

3. Machine is in well condition

4. Thread count check

6. Needle size checking

7. Stitching fault should be checked

8. Garments measurement check

9. Seam fault check

10. Size mistake check

12. Shade variation within the cloth

13. Wrong placement of interlining

14. Creased or wrinkle appearance control

Defects occur in sewing section and remedies:

Skipped stitch:
Some place in the stitch line where the stitch does not formed
:

Cause:
 Failure of needle to enter loop at correct time
 Needle deflection or bent needle
 Thread loop failure due to incorrect needle size for thread size
 Incorrect sewing tension in the needle
 Thread loop failure due to incorrect setting of thread control mechanism
 Flagging of fabric due to poor presser foot control
Solution:
 The sewing tension in the needle should be proper.
 Perfect needle size for thread size

Needle breakage defect:

Scratch on the sewing product by the needle tip when several stitches are performed and
needle is broken during sewing.

Cause:

 Excessive tension in needle thread

 Excessive needle heat, groove or eye blocked with melted fabric
 Thread fraying at needle
 Thread trapped at thread guide
 Thread trapping at the base of cone

Solution:

 The needle has to change immediately. If the scratch on the garments is very big or
deep the product should be rejected.
 Use stronger thread or adjust tension.
 Reduce Increase thread guides and reduce disc tension
 The overhead guide should be directly above cone or the thread package. Also ensure
that thread package shouldn’t get tilted during off winding.

Uneven (sleeve, armhole): sleeve or armhole edge fold has a measurement. Uneven means
when the measurement is not same in all place. This occur due to careless operating by
sewing operator

Solution:

 the uneven place seam has to open and again stitch with right measurement.

Main level not in centre point:

 Buyer gives instruction where to place the main level. If it is placing in the wrong
area this is a fault.
Solution:

 Main level has to attach in the right place.

Oil mark in garments:

Oil mark occur from the sewing machine lubricants and spot is appeared on the garments

Cause: During the sewing operation oil can accidentally slick out from the machine and drop
on the fabric and spotted.

Solution: Spot lifter chemical use to remove the oil the mark of the garments. At first the spot
lifting chemical spray on the garments spot then air blown by the machine. The spot remove.

Side seam not in line: Side seam are not at the side line. It may come forward or backward.
Cause: If the front and back part of the garments do not cut by correct measurement or
operator make mistake of sewing the seam formation in the side come forward or backward
from the side formation.

Solution: Cutting parts must have right measurement and oprator have to be conscious about
that. Sometimes it can recover by stitching again or it can be reject.

Seam Pucker: After sewing when the fabric is puckered in the seam area. It is the wrinkle, or
corrugation of the sewn fabric running across the seam
Cause:

Fabric and / or thread instability

Poorly controlled fabric feed

Extension in sewing thread

Incorrect tension setting

Structural jamming or inherent pucker

Solution:
 Adjust feed timing and fabric control for maximum pulling of the fabric.
 Check tension level in the thread, Sew with minimum tension possible. Always adjust
bobbin thread tension first then needle thread tension.
 Check if the coefficient of friction of the thread with metal is high.

Shade problem: It is the problem appeared when the two parts shade looks different in the
garments

Causes: It is also may be a problem in cutting section where this parts made numbering
mistake.For the lack of experience or concentration of worker and if different parts are mixed
by worker.

Solution: Shade problem parts are separate and actual parts are attached

Kacha problem: If unexpected parts are shown by the garments from sewing area then this
problem is occurred

Causes: For lack of experience or concentration of worker.

Solution: The unexpected part is cut out precisely.

Stitch line uneven:

Stitch line is not straight position, it is displaced from its line.

Cause: This fault is occurred by operator.

Solution: The stitch has to open and again sewing.

Non matching thread: Some times when sewing is done, the garments and the sewing thread
looked shade variation.

Cause: If garments color and sewing thread does not match with color

Solution: The sewing thread must have the same color with the garments. To ensure that
before sewing the thread must check with the garments.

Washing Quality Inspection:

Washing section:

Washing process of garment is done to create wash look appearance. After washing the
garments create a new looks which seems the new touch of fashion. Washing technique
create new fashion such as tagging, grinding, destroy, Blasting, whiskering, permanent
wrinkle, deep dye, tie dye, p.p spray, hand crapping, p.p spoon zing etc. Which is also seems
the best touch of garments. The main and important function of washing is to reduce size
materials as a result the garment become size free and become soft hand feel. When these soft
garments are touched then it seems to best touch of garments. To attraction the
customers/Buyer by different types of Fashionable washing and market developments. Due to
washing, shrinkage occurs in the garments. There is no possibility of further shrinkage of
wash garments. Any dirt, spot or germ if added in the garments during manufacturing is also
removed due to washing

Quality control in washing section:

1. Shade variation check.

2. Uneven check.
3. Maintain time schedule for each process.
4. Maintain exact temperature for each process.

Fault occur in washing and remedies:

Shade variation: Shade variation is a common problem in washing process. One garments
shade might be deep and another is light.
Cause:

 Selection of wrong recipe

 Lot variation
Solution:

 If shade is deep then the garments again rewash and if it is light then re-dye the
garments.

Wash hole:

Before washing if the garments have any hole, it can be increased during washing process.

Solution: When any hole in the garments appeared, it does not process to washing.

Fabric may damage by excessive whickering:

If fabric damage by whickering, to minimize it denim pen is used.

Solution: Mark on the garments where effect to create by the denim pen.

Destroying of the fabric:

if destroying process done before washing it can damage the fabric.

Solution: So after washing and before P.P spray destroying is done, and then washes for a
short time. So the garments get the desired effect.

Enzyme wash: Excessive enzyme use or excess time can change the shade.

Solution: So appropriate amount of enzyme should use to maintain the reaction time.

Uneven problem: Any uneven problem occurs in the garments.

Solution: Denim pen or diamond pencil use to match with the desired shade.

Finishing Quality Inspection:

Finishing section:

This is the final section of the garments industry. Various types of fault check here. This is
the important section where finally the product has to inspect and solve the defect of the
garments.
Quality Control in Finishing Section:

 Proper inspection of the garments including measurement, spot, dirt, impurities

 Shading variation check
 Smooth and unfold in pocket
 In secured or broken chain or button
 Wrong fold
 Proper shape in garment
 Properly dried in after pressing
 Collar closing

Fault occur in finishing section and its remedies:

Ironing problem: Some ironing problem occurred are giving bellow most
Shoulder up down: During ironing if the shoulder side is not placed correctly
Causes: It is also the mistake of the worker.
Remedies: Shoulder placed correctly and ironing again.
Bottom up down: If top and bottom are not placed correctly
Causes: For the lack of experience or concentration of worker.
Remedies: Bottom and top placed correctly and ironing again.
Puckering: Crease if brought in the fabric and ironing.
Causes: For the lack of concentration of worker if he ironing the garment on the crease area.
Remedies: Remove the crease from the fabric and ironing again.
Poor folding resulting poor appearance: Due to poor folding the garments
Appearance looks odd or not appreciating.
Solution: The garments should fold properly according to buyers instruction.
Incorrect packing: The packing should do by following instruction from the buyer.
Solution: The product has to pack properly
Size mistake: Different size sign are used in garment and lock pin label
Causes: It’s a mistake or lack of concentration of worker.
Solution: Place the lock pin which size are shown in the product
Barcode problem: If the main label and hang tag barcode are not similar.
Causes: It’s a mistake of worker.

Solution: Same barcode of main label and hang tag are placed.

Quality Management System (QMS) generally employs the following measures,

techniques to ensure that only high quality good are produced:

 Inspect the all incoming, in-process & final goods to ensure quality of goods.
 Make sure that all patterns & pattern grading are okay.
 Check the markers, marker making methods, marker efficiency if it is okay and within
consumption.
 Inspect spreading, cutting & numbering process in detail.
 Ensure the relaxation time that was given to knit fabric.
 Install in-line inspector in the sewing lines.
 To monitor quality in production line they install Traffic Light Chart system or other
system.
 Inspect 100% goods delivered from sewing lines.
 Inspect the table quality inspection for in line passed garments with Statistical
Technique.
 Control the reject garment so that they do not mix up with quality passed garment.
 Have to control repairable goods, washable goods so that they can be double checked
to ensure quality.
 Check garment with right machine, tools and equipment’s and in right conditions.
 Inspect the right ironing or pressing, folding techniques.
 Make repeat inspection of garments prior to poly-bagging.
 Inspect poly-bagging & assortment.
 Make sure the actual measurements of carton and complete packaging
process according to the buyer requirements.
 Manufacturer conducts final inspection in prior to shipment of garment.
 Transmit training quality assurance personnel so that they can easily identify defects
& understand the causes of defects.
 Also arrange training for quality assurance (QA) personnel on Statistical Methods.
 Make continuous improvement plans & implement them.
 Chapter Three: Overview of the Organization

Historical Background:
ALIF DRESS COMPOSITE LTD. is one of the successful RMG manufacturers in
Bangladesh. A country with great potential in the field of garment-manufacturing. ALIF has
acquired a versatile production chain to cater flexible orders in shorter lead-time. Being an
industry-standard certificate holder, ALIF assures the perfect blend of quality and efficiency.

ALIF has passed few year of accomplishment, aiming to lead the competitive knitwear-
organizations of Bangladesh. It has arduously re-engineered each step of its value-chain to
match the dynamism of the fashion market. the organization being run by highly qualified,
experienced, professional management and Staff accelerated by latest
machineries/technology, skilled workmanship with substantial marketing. The proficient
management of the company was able to gain the confidence and won the respect of the
customers in terms of quality assurance and on time delivery. Thus, one customer introduces
us many other customers.
ALIF has expanded its capacity, developed a skilled workforce and introduced integrated
technologies, to remain globally up-to- date. It is truly an organization with a glorious past
and a bright future.

Vision, Mission and Values:

Alif Dress has following vision, mission and values
Vision
Alif Dress Composite ltd. aims to be one of the top world class manufacturer of RMG
through producing diverse range of products for the global apparel market.

Mission

Provide highest quality in every regard.

Use quality products at the best price possible.
Provide cutting edge technology for enhancement of online business and increase
connectivity between buyer and seller.

Values

We believe in integrity, transparency and accountability, and also values professionalism

that will provide a high standard of services to all customers and suppliers.
Journey for Excellence:
ALIF started its journey in as Garments manufacturers – under the leadership of its
experienced entrepreneurs, aiming to become the trendsetter it is today.
ALIF was aware of the fact that short lead-time played a vital role in the modern apparel-
industry. So, it located itself in Gazipur, the new industrial city & attire-manufacturing hub
of Bangladesh.
ALIF will compliant for the BSCI Social Compliance Standard and FSA, ESA, SSA
standard of TUV, SUD. So, it has emerged as a compliant and customer- focused
organization. It has contributed in social development and is reputed as an eco- friendly
organization.
Today, after over a decade of progression, ALIF is one of the successful factory of the
Garments-industry of Bangladesh and the first choice of many foreign retailers. It has
grown from fabric-manufacturer to RMG manufacturer, with a massive capacity of over
100 thousand pieces of garment and 6 tons of fabric per month. The mountain holds the
limits for ALIF.

Buyer Details are Given Below:

Red Tag
RRJ
MR. Lee
Gold Wing
Twenty4
R&B
Avenue Super Mart
Lager 157
Apparel FZCO
WIBRA (KFL)
KIABI
Features:
Products
Over the years, ALIF has manufactured a wide variety of basic products, such as: polo-shirt,
sweat-shirt, ladies & kids- wear, Tank Top, etc. Currently, ALIF has evolved to the level of
manufacturing specialized knitwear-products, by keeping the track of the latest market-
trends.
ALIF has crossed the border of using only ordinary yarns, such as: Cotton, Polyester, CVC,
PC, etc. and it can now make use of Organic and Modal yarns. ALIF manufactures
technical garments. ALIF vast infrastructure allows manufacturing almost every knitwear
product for men, women and kids. It specializes in value- added products, such as: Peach-
Finished, Pigment- Piece-Dyed, and Heavy Enzyme-Washed and Eco-Friendly products. It
is currently concentrating on Knit products, which is soon expected to have a massive
impact on the Fashion-market.

Readymade Garments:

T-Shirt (Basic/ Fancy)

Polo Shirt (Basic/ Fancy)
Sweat Shirt & Sweat Pant
Ladies Wear
Tank Top
Children Item

Used Fabrics:

Single Jersey (S/J)

S/J with Lycra Alternate/Full Feeder
Cotton Slub Jersey
Cotton Slub PQ
Heavy Jersey
Automan Jersey
Honeycomb Pique
Lycra Pique
Diamond Pique
Single Lacoste
Double Lacoste
1 X 1 RIB
2 X 2 RIB
1 X 1 RIB With Lycra
2 X 2 RIB With Lycra
Flat Back RIB
Irregular RIB
Interlock
Interlock Double Lacoste
Fleece
French Terry
Herringbone
Thermal/ Or Waffle
Yarn Dyed
Capital of the Organization:

Capacity:

ALIF has always been pushing the limits of its capacity, and can now handle volume orders
with ease. As a RMG manufacturer, ALIF advanced from knitting to garment-manufacturing
at a massive scale by Nominated Supplier. ALIF Fabric Unit, powered by superior
machineries, is capable of In-Housing 6 tons of fabric per day ALIF has been increasing its
manufacturing-capacity over the years, to convey volume orders of clients, in a shorter lead-
time. It can successfully 2,26,000 pieces of garment per month.

Machine List:

SL NAME OF MACHINE MODEL BRAND QT Unit Total

WITH NEEDLE
1 PLANE MACHINE S- BROTHE 81 18000 1458000
2 OVERLOCK KANSAI 43 25000 1075000
3 FLATLOCK MACHINE KANSAI 40 32000 1280000
4 FLATLOCK MACHINE KANSAI 12 28000 336000 tk
5 BUTTON HOLE HE- BROTHE 2 35000 70000 tk
6 BUTTON STITCH BROTHE 2 35000 70000 tk
7 BACK TAPE BROTHE 1 33000 33000 tk
8 DOUBBEL NEEDLE UNICON 1 20000 20000 tk
9 KANSAI PMD KANSAI 2 40000 80000 tk
10 PICOTING MACHINE NISHO 1 26000 26000 tk
11 BARTACK BROTHE 2 35000 70000 tk
WITHOUT NEEDLE
12 RIB CUTTER LUOFEN 2 10000 20000 tk
13 FABRIC CUTTING KM 3 10000 30000 tk
14 SNAP BUTTON TY-93 TOYO 1 10000 10000 tk
15 THERD SUCKING UZU 2 15000 30000 tk
16 THERD GMC-20S GMC 1 8000 tk 8000 tk
17 VACCUM TABEL UZU 8 10000 80000 tk
18 STEM IRON PAN-520 SEWOO 8 1200 tk 9600 tk
19 ELECTRIC STEM SEWOO 3 1500 tk 4500 tk
20 GRANDING MAXTO 1 1500 tk 1500 tk
21 TABEL VICE CHINA 1 2200 tk 2200 tk
22 LEBEL CUTTER LOCAL 1 1000 tk 1000 tk
TOTAL 218 4714800
Different Departments:

SLNo Department ManPower/Person

1 Administration 11

2 Store 6

3 Sample 9

4 Cutting 36

5 Sewing 326

6 Quality 27

7 Finishing 49

8 Accounts 3

9 Commercial 3

10 Security 5

11 Loader 6

12 Cleaners 6

13 Sweepers 2
Total 489
Organogram:
 Chapter Four: Results and Discussion

Good quality products or processes can only be produced by the operatives. They cannot
produce quality without being fully aware of what exactly is required. Responsibility for the
production of good quality lies with, and is in the hands of, the person teaching the job,
primarily by good communication, by making the newcomer aware of specifications and
tolerances, faults themselves, their effect and the appropriate action to take. Such
communication or training if properly planned and executed will greatly assist in minimizing
the cost of poor quality. Only in this way will quality be controlled, costs remain at an
acceptable level and customers be satisfied. All the factors to be investigated must be covered
in the one trial. Extensions after the initial investigation and using the same samples do not
provide reliable results. So, at last we conclude that Quality is ultimately a question of
customer satisfaction. The perceived quality of a garment is the result of a number of aspects,
which together help achieve the desired level of satisfaction for the customer. Therefore,
quality control in terms of garment, pre-sales service, posts -sales service, delivery, pricing,
etc are essentials for any garment exporter the global requirement, by giving excellent
quality, quantity and new styles and varieties of garments with no time by using this
development. To full these requirements making use of the emerging technology and well
trained worker to give best output and complete planning before the production for what?
How? When? To whom? Can give the best result for the company and the countries income
and profit.
 Chapter Five: Conclusions and Recommendations

Conclusion:
From the above discussion we can say that controlling quality in apparel industry is really
tough task. If quality properly controlled, then costs remain at an acceptable level and
customers be satisfied. Because quality is ultimately a question of customer satisfaction. We
can say that quality control in terms of apparel manufacturing, pre-sales and posts sales
service, delivery, pricing, etc are essential for any garment manufacturer, trader or exporter.
For getting quality garments have to use latest technology and well trained worker to give
best output and complete planning before the production. In Bangladesh every garments
manufacturer should give first preference to its valued customers. Now-a-days buyers are
very much quality conscious. If it becomes possible to maintain a high quality system of
inspection policy, the buyers shall be motivated to place more orders in Bangladesh. So, it is
possible to set different modern quality procedures and quality management techniques in
Bangladesh for the betterment of its RMG sector.

Recommendations:
Alif Dress Composite Ltd. is quite able to ensure brilliancy in their performance but still I
think improve performance in the following area: Should implement different tools like 5’S,
6 Sigma etc for perfect quality management As inspection is always visual, sometimes
machine can be used for inspection of garments. The 4-point system has some limitations so
that this system should be used with proper care. Every test should be done as per
international standard as well as buyer’s requirement. Day final audit is very necessary for
any production process so that it is needed to implement in every garment manufacturing
unit. The proper training should be provided for quality related people.
 References:

 Factory profile of Alif Dress Composite Ltd. (2018). Factory profile, Retrieved
June 10th 2020, From: alifdcl.com

 Kakon, R. (April 24, 2017). Quality management system. Retrieved June14th 2020,
From:https://fashion2apparel.blogspot.com/2017/04/quality-management-system-
apparel.html

 Fakrul, M. (n.d).Garments quality control.Retrieved June 18th 2020,

From:https://www.assignmentpoint.com/science/textile/report-quality-control-
garments-production.html

 Rahman, F. & Mohan, L. (May 3, 2016) Quality management in garment industry of

Bangladesh.Retrieved June 25th 2020,
From:https://www.researchgate.net/publication/301789034_QUALITY_MANAGEM
ENT_IN_GARMENT_INDUSTRY_OF_BANGLADESH

 Insight. (Dec 12,2019). Quality control procedures.Retrieved June 29th 2020, From:
https://insight-quality.com/garment-quality-control-procedures/