Report On

Operational Practices for Garment Industry

Of Esquire Knit Composite Ltd

By
Md. Osman Gone
19281172

Post Graduate Diploma in Knitwear Industry Management (PGD-KIM)

Executive Development Center,
BIGD, BRAC UNIVERSITY
April 2021

i
 Report On
Esquire Knit Composite Ltd
Operational Practices for Garment Industry

By

Md. Osman Gone

19281172

An internship report submitted to the Executive Development Center, Brac Institute of

Governance and Development (BIGD), Brac University in partial fulfillment of the
requirements for the degree of
Post Graduate Diploma in Knitwear Industry Management (PGD-KIM)

Executive Development Center,

BIGD, Brac University
April 2021

©2021. Brac University

All rights reserved.

ii
Declaration

It is hereby declared that

1. The internship report submitted is my/our own original work while completing degree at

Brac University.

2. The report does not contain material previously published or written by a third party,

except where this is appropriately cited through full and accurate referencing.

3. The report does not contain material which has been accepted, or submitted, for any other

degree or diploma at a university or other institution.

4. I/We have acknowledged all main sources of help.

Student’s Full Name & Signature:

___________________________________________
Md. Osman Gone
19281172

Academic Supervisor’s Full Name & Signature:

___________________________________________
SayadaJannatunNaim
Assistant Director-EDC
BRAC Institute of Governance and Development (BIGD)
BRAC University, Mohakhali, Dhaka-1212, Bangladesh

ii
Letter of Transmittal

SayadaJannatunNaim
Assistant Director – EDC
BRAC Institute of Governance and Development (BIGD)
BRAC University, Mohakhali, Dhaka-1212, Bangladesh

Subject: Submission of Industrial Attachment on Operational Practices for Garment Industry.

Dear Madam,

This is my pleasure to submit my final industrial attachment on operational practices from

Esquire Knit Composite Ltd. as a part of completion degree of Post Graduate Diploma in

Knitwear Industry Management (PGD-KIM).

I have attempted my best to finish the report with the essential data and recommended

proposition in a significant compact and comprehensive manner as possible.

I trust that the report will meet the desires.

Sincerely yours,

_______________________
Md. Osman Gone
19281172
Executive Development Center, BIGD
Brac University
Date: April, 2021

iii
Non-Disclosure Agreement

This agreement is made and entered into by and between Esquire Knit Composite Ltd. and

the undersigned student at EDC, BIGD, Brac University…………………………………….

Student’s Full Name & Signature:

___________________________________________
Md. Osman Gone
19281172

Industry Supervisor’s Full Name & Signature:

___________________________________________
Prabhakar Gupta Rauniyar
Sr. Manager, Department of Industrial Engineering
Esquire Knit Composite Ltd.

iv
Acknowledgement

It is my pleasure for completion my final report on Operational Practices for Garment

Industry from Esquire Knit Composite Ltd. First of all, I am grateful to Almighty for giving

me massive chance to complete this report.

I would like to give thanks to my honorable academic supervisor SayadaJannatunNaim.

She helped very much providing lots of information and techniques for completing this
report.

I also want to express my thanks to my honorable industrial supervisor Mr. Prabhakar

Gupta Rauniyar. He gave me lots of time during this report. He taught me lots of technical
things for completion this final report.

Besides all the members of EKCL when I worked for completing this report, thanks and
grateful to all the members.

At last my special thanks to Brac university concern who created this learning environment

on Garment industry. It helps me to go ahead a long for my carrier.

Sincerely yours,

Md. Osman Gone

19281172
Executive Development Center,
BIGD, Brac University

v
Executive Summary

I completed this report on the basis of three-monthOperational Practices for Garment Industry

from Esquire Knit Composite Ltd. There are lots of department available in EKCL. Among

them I worked on operation.

Esquire Knit Composite ltd is a leading garments factory of Bangladesh. Lots of improving

areas in here which need to know in others garments factory. From starting to end product

lots of techniques I have seen what not maintained in others factory. Lean makes of many

elements what I observed in existing in EKCL. Latest automation has been installed in EKCL

which improving productivity and pressure down man power. There is a design studio which

is very unique in EKCL. Lots of lessons are available in design studio of EKCL. Largest

production volume is produced of EKCL with innovative system. In operation each

department has to be followed and maintained such as OCD, OTT, and PCD. How to increase

productivity in cutting production it a big example of EKCL. Before couple years their

production was very low but now up to the mark positive they reached by using modern

technology and proper utilizing man , machine , resources . Industry engineering department

of EKCL is very bold. They are busy to work how to reduce production cost and inventing

new system which simplify the work tasks for the workers. At this work environment

becomes safety. EKCL sample section has various machine what are not available in other

industry sample section.

So, in my report I basically focused on Garments Operation & I assume EKCL is the best

place to learn.

Keywords: Operational practices, Apparel Industry, Industrial Engineering, EKCL

Operation, Garments Industry Development, Cost Factor of Apparel.

vi
Table of Contents

Declaration................................................................................................................................ii

Letter of Transmittal ............................................................................................................. iii

Non-Disclosure Agreement .................................................................................................... iv

Acknowledgement .................................................................................................................... v

Executive Summary ................................................................................................................ vi

Table of Contents ...................................................................................................................vii

List of Figures .......................................................................................................................... ix

List of Acronyms ...................................................................................................................... x

Glossary ................................................................................................................................... xi

Chapter 1 About Organization ............................................................................................... 1

1.1 Overeview of Esquire Knit Composite Ltd ............................................................. 1

1.2 Vision & Mission ..................................................................................................... 2

1.3 Goals & Objectives .................................................................................................. 3

1.4 Organization Hierarchy............................................................................................ 4

1.5Organizational structure, Organogram, Branches and Departments .................................... 5

1.6 Products/services produced by the Industry ............................................................ 6

vii
Chapter 2 Description about task accomplishment .............................................................. 7

2.1 Merchandising & Marketing .................................................................................... 8

2.2 Product Development............................................................................................. 10

2.3 Cutting Section....................................................................................................... 11

2.4 Sewing Section....................................................................................................... 13

2.5 Quality Section....................................................................................................... 14

2.6 Industrial Engineering ............................................................................................ 15

Chapter 3 Critical assessment of Internship work ............................................................. 17

3.1 Application of Generic and Industry specific courses during internship ............... 18

3.2 Suggestion for industry improvement ................................................................... 19

3.3 Learning for self improvement .............................................................................. 23

Chapter 4 Conclusion ........................................................................................................... 25

References ............................................................................................................................... 26

Appendix A. ............................................................................................................................ 27

viii
List of Figures

Figure 1: Organization Hierarchy .............................................................................................. 4

Figure 2: Organization organogram ........................................................................................... 5

Figure 3: Buyer .......................................................................................................................... 6

Figure 4: Merchandising Activities ........................................................................................... 9

Figure 5: Technical Team Activities........................................................................................ 10

Figure 6: Sample Team Activities ........................................................................................... 11

Figure 7: Cutting Activities ..................................................................................................... 12

Figure 8: Sewing Activities ..................................................................................................... 13

Figure 9: Quality Section Activities ........................................................................................ 14

Figure 10: Preproduction Activities ......................................................................................... 15

Figure 11: IE Activities ............................................................................................................ 16

ix
List of Acronyms

CM Cost of Making

EPZ Export Processing Zone

PD Product Development

M&M Merchandising & Marketing

RMG Ready Made Garments

BGMEA Bangladesh Garment Manufacturers and Exporters Association

BKMEA Bangladesh Knitwear Manufacturers and Exporters Association

EKCL Esquire Knit Composite Ltd

IED Industrial Engineering Department

PGD Post Graduate Diploma

KIM Knitwear Industry Management

OCS Online Clothing Study

CAD Computer Aided Design

KPI Key Performance Indicator

JD Job Description

JIT Just in Time

x
Glossary

Work Study Work study is a generic term for those techniques,

particularly method study and work measurement, which

are used in all its context and which lead systematically to

the investigation of all the factors, which effect the

efficiency and economy of the situation being reviewed in

order to effect improvement.

Line Balancing Leveling work load among the worker.

SMV A compete product making time from starting to end

procedure.

One Piece Flow It’s one of modern technique of production. In this system

wip need less and productivity becomes more.

xi
Chapter 1

About Organization

1.1 Overview of the Industry

Esquire Knit Composite Ltd. has been established for 21 years. Having the industrial

knowledge of over 25 years from sister concern companies namely Esquire Dyeing

Industries,FizaTex Ltd, L-Esquire Ltd, Tamanna Tex Ltd, Esquire Knit has focused on its

business and successfully established the name as a world class Garment Manufacturer under

one roof having a composite facilities of yarn dyeing, knitting, fabric dyeing, finishing up to

garments make it a right choice for one stop solution for all kind of knitted garments. Fully

automated State of art eco-friendly machinery and own design studio. Lab accredited by

NABL, ESPRIT, C&A, NEXT.

Esquire Knit Composite exports readymade garments for different brands to Europe &

American buyers. The main buyers are C&A, Best Seller, Ostin, Esprit, Mascot, Celio, Next,

Tee Jays, Lidl, Pentex, P&C, Puma, Guess, Max, TBH etc.

EKCL is exporting RMG to the EUROPE & AMERICAN chain store, fashion brands and

super markets. the major international buyers of the Company such as C&A, Best Seller,

Ostin, Espirit, Mascot, Celio, Next, Tchibo, Pull & Bear etc. EKCL is proud member of The

Bangladesh Garment Manufacturers and Exporters Association (BGMEA), Bangladesh

Knitwear Manufacturers & Exporters Association (BKMEA), Bangladesh -German Chamber

of Commerce, Bangladesh -Spain Chamber of Commerce, Bangladesh- France Chamber of

Commerce

Esquire Knit Composite Limited has successfully certified to ISO 9001 (quality management

system), ISO 14001 (environmental management system), ISO 18001 (occupational health

1
&safety management system) under the scope of UKAS (United Kingdom Accreditation

Service), system certification scheme. EKCL is also oeko-tex standard 100 certified

Company for usage of environmental friendly dyes stuffs and chemical approved by

Hohenstein Textile Testing Institutes, Germany as well as Global Organic Textile Standard

(GOTS), Organic Content Standard (OCS-IN) certification.

Esquire has a very sophisticated and most modern testing lab – accredited by National

Accreditation Board for Testing and Calibration Laboratories- Nabl, Esprit, C&A& Next.

EKCL is fully compliant with frequent random evaluation by world renowned institutes like:

Business Social Compliance Initiative (BSCI), ITS, SGS, BV, UL etc.

1.2 Vision & Mission

Vision

The vision of Esquire Knit Composite is to continue self-improvement to serve customers

with best quality product and service so that customer is satisfied to Esquire Knit Composite.

Mission

The mission of Esquire Knit Composite is to ensure quality products & services to the

customers within the shortest possible lead time based on optimum utilization of the

resources (Man, Machine, Materials) to achieve sustainable growth. It wants to make sure

that the overall purpose and scope of the business is meeting stakeholder’s expectations

through maintaining business ethics and caring of the environment and extortion towards

green planet.

2
1.3 Goals & Objectives

Goals

 Becoming world class brand

 Becoming leading position in Bangladesh

 Fulfilling customer satisfaction with best quality

 To achieve 70 % efficiency utilizing optimum resources

 Creating employment and removing poverty from Bangladesh

 Maintain Defect percentage below 0% which will be top in Bangladesh.

Objectives

 To achieve the manufacturing excellence

 To make a skilled manpower & wellbeing

 Earning the foreign currency for Bangladesh

 Skilling up Mid management & Upper management

 To make standard life style of the employee.

3
1.4 Organization Hierarchy

Honorable Chairman

Managing Director

Chief Executive Officer (CEO)

Chief Operating Officer (COO)

General Manager

Assistant General Manager

Manager

Assistant Manager

Senior Executive

Executive

Staff

Worker
Figure 1: Organization Hierarchy

4
1.5 Organizational structure, Organogram, Branches and Departments

Figure 2: Organization Organogram

5
1.6 Products/services produced by the Industry

Esquire Knit Composite manufactures & provided lots of product or service by Textile &

Garments to different customers in different countries.

Women / Girls Items :Long sleeve tee shirt, Tops, Sweet shirt, Bottoms, Long dress

Mens / Boys : Short sleeve tee shirt, Polo shirt, Pants, Hoodies

Children/ Kids : Kids hoody, tee shirt, top-bottom set, tang top

Fancy items: Tops, jacket, long dress, frill long bottom

Figure 3: Products

6
Chapter 2

Description about task accomplishment

Basically, in this chapter I tried to discuss during 70 days intern-ship time how many sections
I visited, I figured out those sections activities of Esquire Knit Composite Ltd. In garments
basically whole manufacturing process is sorted out in 2 segments. They are textile
processing and garments manufacturing operation. Textile processing is based on Knitting,
dyeing, printing, Embroidery etc. Garments manufacturing operation is based on
Merchandising, Product development, Cutting, Sewing, Finishing, Quality, Industrial
engineering and etc. I have discussed regarding garments manufacturing operation in this
chapter in below mentioned sections.
1. Merchandising & Marketing
2. Product development
3. Cutting
4. Sewing
5. Quality
6. Industrial Engineering
I passed my days during inter at mentioned section. I just figured out in the below with
working days in the respective sections.
Serial number Name of section Intern days

1 Merchandising & 12 days

Marketing

2 Product development 16 days

2 Cutting 13 days

4 Sewing 10 days

5 Quality 6 days

6 Industrial Engineering 13 days

Total 70 days

So now discussion is giving in the below:

7
2.1 Merchandising & Marketing

In EKCL Merchandising & Marketing called M&M in short. Eventually M&M is called heart

of garments. This section is very core section of a garment for business. An order from

starting to end merchandiser is to look after. So it’s important is massive.

In EKCL Merchandising & Marketing is divided in 2 segments in their work way,

1. Marketing

2. Operation

Marketing merchandiser of EKCL basically communicate with buyer. They confirm order,

they negotiate price with buyer & so on activities they do.

On the other hand, Operation merchandisers normally follow up and communicate with

others departments. For example, operation merchandiser is to contact with sewing’s concern

person, cutting concern person, IE section, Quality concern persons and etc. Both

merchandisers (Marketing & Operation) following task they do:

8
The following task does the Merchandiser:

From buyer side Merchant take technical pack

According to technical pack sample development

Order confirmation

Technical pack analysis

Take master L/C from buyer

Order execution

Order goods collection

Open back to back L/C based on mater L/C

Consumption & SMV costing find out

Contact with Accessories suppliers

Price negotiation with suppliers

As per requirement testing guideline build up

Trim card making & send to operation team

Arrange meeting with PD, IE, Production, QA and
other relevant department
Various types of sample making as per requirement

Get approval for bulk

Communicate with buyer for developing product

Final inspection booking, vessel booking and send
goods as per shipment date
Post communicate with buyer for next order

Figure 4:Merchandising Activities

Personally, how many days I stayed at M & M department I learned a lot. I worked very

closely with merchandising team there I have find out to improvement area more. In the next

chapter I will discuss regarding points.

9
2.2 Product Development

Product Development is called PD department in Esquire Knit Composite Ltd. This

department is very vital department for developing product. In EKCL this department has

massive team and strong team. Basically, these department activities have been divided in 2

segments:

1. Technical Team

2. Sample team section

Technical Team of EKCL see the technical part of every order. The following activities do

the Technical team of EKCL:

Making requirement as per buyer and analysis the

Technical pack

Making fabric, thread, binding consumption

Technical instruction sheet making

Giving all kind of technical help

If sewing faces any difficulties, Technical team

provide support

If consumption varies in sewing it analysis from

Technical

Risk analysis meeting arrange for all style

Figure 5: Technical Team Activities

10
Sample section follows the requirement of Technical pack or others sample which are

approved from buyer. Sample team of EKCL sees and does the following activities:

Various sample making as per buyer instruction

Measurement and others issues ensuring

Pattern making by CAD

Easy Technique sample making for bulk

Pre sample development meeting arrange

Figure 6: Sample Team Activities

I closely worked this their team I have learned many things. How to do thread costing in short

and easy way I knew. Before I knew but that was not the practical way. Besides I learned

CAD activities, Pattern knowledge from this team in easy and effective way. But I have some

observations regarding this section of work which I will share in next chapter.

2.3 Cutting section

Cutting section is very Important area for getting quality product. In the EKCL a strong

cutting is available that work effectively. They cut the panel according to pattern. A specific

process flow they follow and work accordingly. If cutting team is weak not to get quality

product from that organization.

11
A process follow chart is given the following of EKCL:

Receiving fabric from store

Pattern department will receive pattern

Cutting ratio collection

Marker makes

Fabric received

Relaxing fabric & Spreading fabric

Placement of marker on the lay

Fabric cutting

Numbering of all parts

Checking

Sorting & Bundling

Quality check

Cut panel send to sewing

Figure 7: Cutting Activities

I have observed closely their activities at the same time lots of new things I learned from

EKCL cutting team. Basically, in EKCL 2 types of m/c used in cutting. One is Automatic

cutting & spreading machine and straight knife machine and manual spreading. Automation

usually is used for solid panel and manual cutting and spreading is used for stripe panel.

12
2.4 Sewing section

Sewing section is called the main operation from where manly product making happened.

A quality sewing product becomes a good quality garments it is proved. There are total

101 sewing lines in EKCL. Product categories become different. In a line has to be done

T-shirt, Polo shirt, sweat shirt, Jacket, Bottoms etc. In EKCL this section worker has to

be sorted out in 2 categories they are Operator and helper. In the following the follow

chart of sewing section is figured out:

Follow the sign off plan of Planning

According to the sign off a plan set for a month

Pre-production activities like pattern, guide, folder arrangement

Communicate with Sore, Marchant team

Take paper layout from IE

Machine arrangement accordingly paper layout of IE

Making machine layout and critical process analysis

Provide manpower according to IE paper layout

Coordinate with IE, Planning, Quality

Sewing line balancing every morning

DHU level maintain

Hourly target maintains as per smv

Quality goods pass to the finishing

Final inspections attended

Figure 8: Sewing Activities

Lots of practical knowledge I have learned from sewing concern. In the EKCL lots of skilled

operators work. I have had a good idea about operators rating observing their work. I have

13
introduced with many new machines which are not seen before. How to make pattern I have

cleared ideas from this team. In the EKCL they follow several types of layout. In the practical

way I have learned those points.

2.5 Quality Section

Quality section is very vital for any company of garments. Quality section always co-operate

with production team. I the EKCL quality team is also big and strong team. Their working

area has defined as below

Pre-production meeting arrange

Cut panel check before entering line

5-piece report during layout

Process wise DHU control

End table DHU control

Traffic system monitoring

Critical areas solution by discussing

concern dept.

Finishing area measurement check

Work on inspection

Coordinate with Production, IE,

Merchandiser

Figure 9: Quality Section Activities

14
2.6 Industrial Engineering

Industrial Engineering is a branch of engineering where uses lots to techniques for improving

higher production and efficiency by reducing cost. This department main act is to use

optimization of man, machine, material, method. In EKCL this team is very large. Basically,

this section has made for to reduce cost at the same time for increasing higher productivity.

After establishing this department lots of visual changed happened in EKCL. In the EKCL

this section’s activities have segregated in 2 ways,

 Pre-Production IE Team: Pre-Production team mainly follows the followingactivities:

Garment analysis

Different sample analysis & operation

breakdown making

Marketing SMV given

SMV saving & provide floor SMV

Threat consumption

Standard method implementation

SMV data bank make

Communicate with merchandiser

Figure 10: Preproduction Activities

15
  Operation IE Team: This team mainly acts the following activities

Following every month sign off plan

Pre-production activities such as-accessories,

pattern, folder etc.

Prepared machine layout

Critical operation operator training

Giving machine requirement

Feeding report making

Workplace arrangement

Doing capacity study

Line balancing

Bottle neck analysis and production study

Skilling up program for line chief, supervisor

Hourly production and efficiency monitoring

Report making

Figure 11: IE Activities

Industrial Engineering is very essential for every apparel industry. Basically, the main KPI of

EKCL is the given below:

 Reduction of cost

 Productivity enhancement

 Process standardization

 implication of process

 DHU level maintain

 Wastage elimination

16
Chapter 3

Critical assessment of Internship work

Lots of unknown topic I have learned from this three-month internship project. Basically,

during PGD-KIM course theoretically we were taught. I tried to match these points with

practical work. Successfully I found these things matched. After coming this intern project, I

became very clear regarding our full PGD-KIM course what sir / madam taught. Besides

going to various departments for intern I have seen different environment which I did not

seen ever. At this self-confidence has been grown up a lot. How to grow up professional

attitude, professional personality, technical knowledge, practical knowledge and so on learnt

from this 3-month long intern.

I have noticed and faced some critical points during three-month internship program and try

to solve through applying my knowledge. At this I have learned something new:

i. Individual People involvement align with company goal

ii. People with team involvement align with company goal

iii. Creating friendly environment for all

iv. Innovative development

v. Accountability assurance

vi. Chain of command follow

Mentioned points are new for me and I tried to utilized this chance. If an industry above

points are well organized, I assume that company or industry will be popular and worker

friendly in our country. A very interesting thing I have learnt also that is, In EKCL culture if

any problem comes, they think a door has opened to learn. It is very interesting and

outstanding theme for motivation. I grew up this theory in my mind that problem means

working opportunity.

17
3.1 Application of Generic and Industry specific courses during internship

I have learned lots of important things in generic and industry specific course during

internship. From generic knowledge it is possible to enhance technical knowledge. I found

below application of generic and industry specific course during internship.

Application of Generic:

 After completing generic course, it helped me to upgrade my communication skill.

Now it is far better

 I have learned how to take under pressure and give decision in that moment

 It made me my personality decent and acceptable to all

 Leader ship skill became strong and sustainable

 I helped for updating analytical skill and good decision maker

 I have learned by this course how to work as team, how to do self-reliance and self-

belief

 Increased the ability of problem finding ability & cost benefit analysis

 Understood profit and loss interaction

Application of industry specific course:

 Learned textile fiber to complete product making system

 Learned about Fabric types, embroidery & printing types

 Given knowledge regarding update cutting system in apparel industry

 Improved knowledge how an industry would be profitable and IE role in industry

 Showed lots of production system in Bangladesh as well as outside

18
  Learned how to reduce company cost

 Showed modern layout of Bangladesh and given knowledge about various machine

 Learned about standard quality level and international acceptance

 Lots of calculation we learned such as company capacity, line capacity, smv, fabric

cost, fabric consumption etc

 Learned how to supply chain management be strong and work effectively

3.2 Suggestion for industry improvement

During my internship periods I have lots of observations I assume it will be very effective if

follows. It is possible to turn around present situation to better situation in Apparel industry. I

have lots of suggestions among them main points are given below with detail:

1. Mid Management Skill up: In Bangladesh apparel industry mid management is very

weak. Except it this sector cannot be gone ahead. The main gaps are between mid and top

management. If a company has huge communication gap between them, it can’t be

improved.

For mid management skill up, first of all need training. Not only that practically they have to

be made sound knowledge. A specific time and schedule have to be given from top

management.

If it is done lots of improvement will come in out Apparel industry:

 Pressure will reduce from top management

 Foreign Management demand will be decrease

19
  New job position will create

 Factory will be benefited

2. None Productive Time Reduction: A company profit & loss depend on non-productive

time reduction. A company can reduce the more, that company becomes more profitable.

A single and every none productive minute has to be counted. For counting strong IE

team needed. They will record it and show them for whom none productive will come. At

this responsible section will be more conscious as a result NPT will reduce.

If it is possible, industry change will become surely:

 Wastage will be reduced

 Produce time will be grow up

 Product making cost will be possible to decrease than present cost

 Optimum Utilization possible Man, machine & material

3. New Technology &Automation: It’s very important for industrial improvement. The

more days gone technology will be change at the same time the modern technology has to

be applied otherwise not possible to sustain in business. Automation is the same.

For applying new technology must be update and see around the world. For implementing it

Industrial Engineer can play vital role.

If possible, to make understand its positive side to top management, they must connect with

that technology and automation.

 Pressure will be low down on Manual

 Company profit grow up

 Work simplification

20
  Work time reduction

4. Worker Training: It’s also very important tools. Worker are the main pillar of Apparel

industry. Without their upgradation not possible to turn this sector. For working lots of

things needed such as efficiency, targe, capacity, compliance etc if we can make them

understand floor productivity will be improved much.

A training calendar has to be set and followed. Compliance issue will teach them from HR

person. How to calculate target, capacity, efficiency, has to be taught from IE person. Besides

motivational program may arrange from management.

If this trend starts industrial environment and improvement will come very much:

 Productivity increase

 Friendly environment creates

 Optimum utilization possible

 Labor strike possible to stop

5. Technical Workshop Arrange: In organization lots of people work. All are not same

experienced in their work. That’s why technical workshop must need for industry

improvement.

According to designation this workshop will be set up. Here technical and practical

discussion and activities will be held. Respective head will present this workshop session.

This session may be inside factory or outside of factory.

If this is done lots of improvement areas will be visual,

 Practically sound

 Proper utilization of management

21
  Possible to simplify work task

 Profit percentage high

6. Incentive System: Incentive is just a reward for one’s work. At this he or she becomes

motivated. So, it is also very important point for industry improvement.

There are lots of ways to provide incentive among the workers. Basically, if a worker fills

up his daily target in a certain efficiency level, he or she will get the incentive. Incentive

amount will vary factory to factory and it will set from HR section.

If it is possible to establish the following output will come:

 Individual efficiency level will be high

 Overtime reduction

 Plan target meet

 On time Shipment possible

 Optimum utilization man, machine & resource

7. Discipline & Compliance Session: It is very vital part for a company. Buyer give

priority most in this point. If an industry exists satisfactory compliance level, lots of buyer

wants to work there.

This session has to be come from HR concern. They will draw a plan and execute it perfectly.

This knowledge is needed for all workers and staff. But should focus on workers for

enhancing this compliance knowledge. 5s should be maintain properly.

If it is possible to start the following matter will be come:

 Buyer satisfaction level high

 Final inspection pass

22
  Wastage possible to reduce

 Standard work environment set

3.3 Learning for self-improvement

During 3-month internship lots of learning area has been created. If these learning utilizes

properly our job field will be benefited much as well as our apparel industry will be grown up

more. In the following learning points are given:

 Analytical skills improvement: During my 3-month internship lots of analytical

skills became improved. During study time I have enhanced my knowledge regarding

m/c, way to work process etc. I will utilize it on my own job field.

 Improve negotiation skill: During 3-month internship when I was in merchandising

department, loss of negotiation skill I improved. On that time merchandiser negotiated

with their buyer on their product price. They followed several criteria to negotiate. So

now I am much better in negotiation. In my work field I will use it effectively.

 Improve communication level: Before internship I did not know how to

communicate with buyer. But how to communicate with buyer even worker level or

how to motivate others I knew it practically during internship. It will give me lots of

benefit in my real field.

 Challenges to be faced: Challenge may come any time and has to be prepared to

face that challenges. During internship I have seen in the sewing floor how line

balance they do when suddenly operator or helper absent. Besides suddenly any time

of problem come in factory and hamper the production. In that time situation handling

is very important. I captured it successfully. Hopefully I can utilize this in my job

field.

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 Technical knowledge sound up: Lots of new area I have gathered in my head.

Especially technical and practical knowledge I became sound. In every section when I

went new and innovative things I captured.

 Knowing about various machine in sewing, cutting, dyeing, knitting

 Innovation and Automation: In the EKCL lots of automation are used currently.

Those are very effective for up gradation. ERP software is used here its up to date

software nowadays. Besides lots of innovation which help to increase productivity.

Process merge, process development, motion reduction etc learned from IE section

during internship period. Those are very helpful for my job field.

 Working as a team and increased self confidence: Apparel industry is a large

industry. If anyone wants to work individually even if he does better, this betterment

will not bring any result. So team work in very important for achieving target. I

learned this point from here. At the same time self confidence I got from that. These

two tools help me in my career.

 Expert in making Report: Lots of report I have seen during internship period.

Especially I worked in Microsoft excel in IE department. Their report making I

followed then I myself did that report too. Hopefully those reports making knowledge

will help very muchin my practical life.

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Chapter 4

Conclusion

I observed all the activities from starting my internship program to end of the program. In

three months, I visited most important areas where are very needful. Operation’s six sections

I covered in that my internship time frame. Now a clear idea I have gathered in my account

on Knitwear industry operation through working with Esquire Knit Composite ltd team.

When a order is started to end full areas I covered by doing lots of activities and going

different departments. Business’s objective is to gain profit. But this profit comes when the

finished goods come through right process and quality level is satisfactory. Not only that

manpower utilization also a core point for a company profit/loss. This full process I learned

by this internship program in different section. I am very much confident that in operational

sides, dealing or negotiation now I can do.

Post Graduate Diploma in Knitwear Industry Management (PGD-KIM) made me confident

giving me lots of opportunities which help me for my future profession of RMG section. I

also believe I have been right candidate for the post.

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References

1. Esquire Knitwear Composite Limited (2014), Profile of EKCL, Retrieved from 2014,

from EKCL database

2. Esquire knitwear composite Limited, Profile, Retrieved from:

http://www.esquirebd.com/pdf/Esquire_Knit_Profile.pdf.

3. Industrial Engineering Database of EKCL

4. http://www.wikipedia.com/

5. http://bigd.bracu.ac.bd/index.php/academic/sub-menu-item-2/seip/129-

academic/professional-training/seip/982-about-pgd-kim

6. https://www.textileblog.com

7. https://www.onlineclothingstudy.com

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Appendix A.

KPI: Key Performance Indicators (KPIs) are measured to assess where the factory currently

stands and to find key focus areas where management needs to look into.

5S: 5S is about sorting of things in your workplace and inventory stores. Keep workplace and

floors clean and arrange things in right order for easy access.

Kanban: Kanban is a workflow system. Kanban tool improves visibility and limit Work in

Process. Where factories use Kanban, it helps to eliminate building excess work in process

(WIP) in production lines

Error proofing: Error proofing aka Poka-Yoke is any mechanism in a lean manufacturing

process that helps an equipment operator to avoid mistakes. It helps in designing a process in

such way that there would not be minimum chance of producing defective product. Its

purpose is to eliminate product defects by preventing, correcting, or drawing attention to

human errors as they occur. Even error proofing technique can be used in information

generation, reporting system.

Quick Changeover: Quick changeover, one of the lean manufacturing tools, is used in

reducing waste in garment making process. While setting a line with new styles, line losses

lot of time which is known as set-up loss. Quick changeover or SMED method provides

an efficient way to set lines for the new style in less time.

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