BGMEA University of Fashion & Technology

Industrial training report on

FARDAR Fashions LTD
Submitted By

Name: Shamima Sultana

ID: 201-047-801

This internship report submitted in partial fulfilment of the requirements for the degree of B.Sc. in Textile Engineering from TE Department in the faculty of
Textile Engineering of BGMEA University of Fashion & Technology (BUFT).

Department of Textile Engineering

BGMEA University of Fashion & Technology
February, 2024

Industrial training report on

FARDAR Fashions LTD

Submitted By

Name: Shamima Sultana

ID: 201-047-801

Submitted to

Department of Textile Engineering

In partial fulfillment of the requirements for the degree of Bachelor of Science in Mechanical Engineering

Supervised by

Md. Raijul Islam

Assistant Professor,

Department of Textile Engineering, BUFT

 Department of Textile Engineering,
BGMEA University of Fashion & Technology
February 2024
 Letter of Transmittal
th
28 February, 2024
Md. Raijul Islam
Asst. Professor,
Department of Textile Engineering,
BGMEA University of Fashion & Technology
Nishatnagar, Dhaka
Subject: Submission of Internship Report.
Dear Sir,
I am extremely indebted for your tremendous support and guidance throughout my long journey at "FARDAR Fashions Ltd" and internship period. By working
with you, I have earned valuable knowledge and was inspired by your innovativeness, which helped enrich my experience to a greater extent. An internship
report on " FARDAR Fashions Ltd." is submitted to you for the partial fulfillment of the Bachelor of Science in Textile Engineering Degree.
During my internship period, I was trained in all departments of FARDAR Fashions Ltd.; I made sincere efforts to study related materials, and observe operations
performed in Cutting, Patterns, Garments, Washing, Finishing and Merchandising which are the sources of collected data to prepare the present report on Apparel
Manufacturing Engineering.
I have to make this report as comprehensive as possible within the time limit. But there may be some mistakes due to various limitations. For this reason, I beg
your sympathetic consideration. Finally, I pray for your blessing for my successful engineering career.
Thank you
Yours Faithfully
Shamima Sultana
Id 201-047-801
BGMEA University of Fashion & Technology

Declaration of Examiners
The internship report on “FARDAR Fashions Ltd” is submitted by Shamima Sultana, ID 201-047-801. The report is accepted as satisfactory in partial fulfillment

of the requirement for the degree of B.Sc. in Textile Engineering.

Board of Examiners

Name Signature

1. Supervisor: Md. Raijul Islam,

Asst. Professor,

Department of Textile Engineering,

BUFT.

2. Examiner 1: Taslima Ahmed Tamanna,

Asst. Professor,

Department of Textile Engineering,

 BUFT.

3. Examiner 2: ……………………

ACKNOWLEDGEMENT

First, I would like to thank Almighty Allah for giving me the strength and ability to complete the industrial training and to write this report

Several people have made significant contributions to make my training successful.

Special thanks go to my enthusiastic supervisor, Mr. Md. Torikul Islam, (Senior Manager, Marketing and Merchandising, FARDAR

Fashions Ltd) has been an amazing experience and I thank him from the bottom of my heart.

Special thanks go to Md. Raijul Islam, Assistant Professor, Department of Textile Engineering, BUFT. Who so generously Inspired and

contributed to have made significant contributions to make my training successful.

Special thanks go to Dr. Ranajit Kumar Nag, Associate Professor & Head, Department of Textile Engineering, BUFT. Who so generously

Inspired and contributed to this type of project work.

Additionally, we would like to express our gratitude to the esteemed Prof. Dr. Abu Bakar Siddique, Dean of Faculty of Textile

Engineering, BUFT. for her outstanding academic support and for being an unforgettable experience.

Special thank goes to my enthusiastic Prof. Dr. Engr. Ayub Nabi Khan, Pro Vice Chancellor, BUFT, who so generously inspired & and

contributed to this type of project work.

Special thanks go to our enthusiastic Prof. Dr. S.M. Mahfuzur Rahman, Vice Chancellor, BUFT for their Encouragement and valuable

suggestions for continual improvement of the report.

I would like to express my heartfelt gratitude to BUFT for providing me with the opportunity to Start as an intern. The experience I gained

during my internship has been invaluable, and I am truly grateful for the support and guidance extended to me throughout this journey.
 Executive Summary

By learning Practical Knowledge, it is possible to apply theoretical knowledge in the technical field. So, for any technical education especially in

Textile Engineering, practical experience is the most important as well as theoretical knowledge. For any technical education, practical experience is

almost equally necessary in association with theoretical knowledge.

In my study life it’s a great chance for me to combine theoretical knowledge with practical knowledge in the “Industrial Attachment period”. In

addition, the knowledge I gathered from the industrial training is reflected in the report of the industrial attachment notebook.

So industrial training is the process where the trainee can blend his theoretical knowledge with practical knowledge increasing his/ her ability to work,

skill, performance attitude, and so on. It also provides sufficient knowledge about production management, productivity evaluation, work-study &

efficiency, industrial management, production planning and control, production cost analysis, inventory management, utility, maintenance, and so on.

Industrial attachment makes me reliable to be accustomed to the industrial atmosphere and also improves courage and inspiration to take self-

responsibility.

FARDAR Fashions Ltd is a 100% export oriented woven, knit and sweater manufacturer under one roof. It offers customers access to a low-cost

business model with a competitive edge. Mixed product experience and know-how, with practical application, in turn presenting an advanced capability

that goes beyond the capacity of other similar refional competitors.

I have prepared this report according to the BGMEA University of fashion and technology’s management.

Table of Contents

Letter of Transmittal........................................................................................................................................................................................................................... i

Declaration of Examiners.................................................................................................................................................................................................................. ii

Acknowledgment............................................................................................................................................................................................................................. iii

Executive Summary.......................................................................................................................................................................................................................... iv

Table of Contents............................................................................................................................................................................................................................. vi
List of Figure.................................................................................................................................................................................................................................. xiv

List of Table................................................................................................................................................................................................................................... xvi

Chapter 1.......................................................................................................................................................................................................................................... 1

1.1 Introduction...................................................................................................................................................................................................................... 1

1.2 Objective........................................................................................................................................................................................................................... 2

Chapter:2......................................................................................................................................................................................................................................... 3

2.1 General Information about the Company......................................................................................................................................................................... 3

2.2 Site location of the Factory from (BUFT) Campus.......................................................................................................................................................... 3

2.3 Company Profile............................................................................................................................................................................................................... 4

2.4 Sister concern of the company.......................................................................................................................................................................................... 4

2.5 Membership certification.................................................................................................................................................................................................. 5

2.6 Manpower Management................................................................................................................................................................................................... 5

2.7 Production Capacity of FARDAR FASHIONS LTD....................................................................................................................................................... 5

2.8 List of Buyers of FARDAR FASHIONS LTD.................................................................................................................................................................6

2.9 Organogram of FARDAR FASHIONS LTD................................................................................................................................................................... 8

2.10 Social Policy of FARDAR FASHIONS LTD............................................................................................................................................................... 9

2.11 Management Team of FARDAR FASHIONS LTD................................................................................................................................................... 10

2.12 Mission and Vision of FARDAR FASHIONS LTD...................................................................................................................................................10

2.13 Departments of FARDAR FASHIONS LTD.............................................................................................................................................................. 10

Chapter 3........................................................................................................................................................................................................................................ 11

3.1 Detail About Industrial Training.................................................................................................................................................................................... 11

3.2 Layout Plan of Weaving Preparatory Section:................................................................................................................................................................ 11

3.3 Winding.......................................................................................................................................................................................................................... 13

3.4 Types of winding package:............................................................................................................................................................................................. 14

3.5 Parallel Winding:............................................................................................................................................................................................................ 14

3.6 Non Parallel Winding:.................................................................................................................................................................................................... 15

3.7 Cross Winding:............................................................................................................................................................................................................... 15

3.8 Process flow chart of warping........................................................................................................................................................................................ 16

3.9 Types of warping done at FARDAR FASHIONS LTD:................................................................................................................................................ 16

3.10 Changes of yarn due to Sizing..................................................................................................................................................................................... 17

3.11 Sizing Machine Specification:..................................................................................................................................................................................... 18

3.13 Drawing-in and Denting.............................................................................................................................................................................................. 20

3.14 Objects of Drawing-in and Denting............................................................................................................................................................................ 21

3.15 Looming...................................................................................................................................................................................................................... 21

3.16 Weaving Machine Details of FARDAR FASHIONS LTD:........................................................................................................................................23

3.17 Different Parts of Air Jet Loom:.................................................................................................................................................................................. 23

3.18 Daily production list in weaving section:.................................................................................................................................................................... 24

3.20 Fabric Inspection System at FARDAR FASHIONS LTD.......................................................................................................................................... 26

3.21 Mending...................................................................................................................................................................................................................... 26

Chapter 4........................................................................................................................................................................................................................................ 27

4.1 Batch:.............................................................................................................................................................................................................................. 27

4.2 Activities of Batching..................................................................................................................................................................................................... 27

4.3 Machine Specification of Batching................................................................................................................................................................................. 28

Chapter 5........................................................................................................................................................................................................................................ 29

5.1 Pretreatment.................................................................................................................................................................................................................... 29
5.2 Singeing & Desizing....................................................................................................................................................................................................... 29

5.3 Machine Specification.................................................................................................................................................................................................... 30

5.4 Singzing & Desizing process sequence.......................................................................................................................................................................... 30

5.5 Recipe for Desizing..................................................................................................................................................................................................... 31

Chapter 6..................................................................................................................................................................................................................................... 34

6.1 Scouring & Bleaching.................................................................................................................................................................................................. 34

6.2 Objective of Scouring & Bleaching............................................................................................................................................................................. 34
6.3 Specification of Machine:............................................................................................................................................................................................ 34
6.4 chemical application Scouring and Bleaching Process: Prewash:...............................................................................................................................36
6.5 Process Sequence of combined Scouring & Bleaching;.............................................................................................................................................. 37
6.6 process parameter:....................................................................................................................................................................................................... 38

Chapter 7..................................................................................................................................................................................................................................... 39

7.1 Mercerization:.............................................................................................................................................................................................................. 39
7.2 Objective of Mercerization:......................................................................................................................................................................................... 39
7.3 Recipe for Mercerization............................................................................................................................................................................................. 39
7.4 Mercerization Process:................................................................................................................................................................................................. 40
7.5 Process sequence.......................................................................................................................................................................................................... 40
7.6 Process sequence of Mercerization:............................................................................................................................................................................. 41
7.7 Peaching....................................................................................................................................................................................................................... 41

Chapter-08.................................................................................................................................................................................................................................. 42

8.1 Dyeing.......................................................................................................................................................................................................................... 43
8.2 Machine specification:................................................................................................................................................................................................. 43
8.3 Recipe for Pad Dry Pad Steam:................................................................................................................................................................................... 43
8.4 Pad Dry Pad Steam Process:...................................................................................................................................................................................... 44
8.5 Pad Dry Pad Steam Dyeing Process:......................................................................................................................................................................... 45

8.6 Advantages of Pad Dry Pad Steam:............................................................................................................................................................................. 47

8.7 Cold Pad Batch Dyeing.................................................................................................................................................................................................. 47

8.8 Cold Pad Batch Dyeing Process:...................................................................................................................................................................................... 48

8.9 Cold Pad Dyeing Process................................................................................................................................................................................................ 48

8.10 Advantages of Cold Pad Batch:................................................................................................................................................................................... 49

8.11 Disadvantages of Cold Pad Batch:.............................................................................................................................................................................. 50

Chapter 9........................................................................................................................................................................................................................................ 50

9.1 Jigger Machine................................................................................................................................................................................................................ 50

9.2 Objective......................................................................................................................................................................................................................... 51

9.3 Machine Specification:................................................................................................................................................................................................... 51

9.4 Advantages of Jigger Dyeing Machine:.......................................................................................................................................................................... 51

9.5 Disadvantages of Jigger Dyeing Machine:..................................................................................................................................................................... 51

9.6 Process sequence of jigger Machine............................................................................................................................................................................... 52

Chapter 10...................................................................................................................................................................................................................................... 53

10.1 Finishing...................................................................................................................................................................................................................... 53

10.2 Working sequence of Finishing Section:..................................................................................................................................................................... 53

10.3 Stenter Machine:......................................................................................................................................................................................................... 54

10.4 Objective of stenter:.................................................................................................................................................................................................... 54

10.5 Different kind of Finishing.......................................................................................................................................................................................... 55

10.6 Process Sequence of Stenter machine......................................................................................................................................................................... 55

10.7 Sanforizing machine.................................................................................................................................................................................................... 56

10.8 Process Sequence........................................................................................................................................................................................................ 57

Chapter 11...................................................................................................................................................................................................................................... 57

11.1 Quality Control............................................................................................................................................................................................................ 57

11.2 Quality Control System:.............................................................................................................................................................................................. 58

11.3 On- Line Quality control System:............................................................................................................................................................................... 58

11.4 Dyeing process:........................................................................................................................................................................................................... 58

11.5 Finishing process......................................................................................................................................................................................................... 58

11.6 Off-line Quality control System:................................................................................................................................................................................. 59

11.7 Tear Strength Tester.................................................................................................................................................................................................... 61

11.8 Color fastness to washing............................................................................................................................................................................................ 62

11.9 Color fastness to perspiration:..................................................................................................................................................................................... 62

11.10 Color fastness to light:............................................................................................................................................................................................. 63

11.11 Color fastness to Saliva............................................................................................................................................................................................ 63

11.12 Color fastness to water............................................................................................................................................................................................. 64

Chapter 12...................................................................................................................................................................................................................................... 66

12.1 Inspection.................................................................................................................................................................................................................... 66

12.2 Inspection of Fabric..................................................................................................................................................................................................... 66

12.3 Inspection of fabric by 4-point system:....................................................................................................................................................................... 66

12.4 Procedure of Four Point System:................................................................................................................................................................................. 66

12.5 Different Faults & their points:................................................................................................................................................................................... 67

12.6 Calculations and Result............................................................................................................................................................................................... 68

12.7 Meter to meter shade variation:................................................................................................................................................................................... 70

Chapter 13...................................................................................................................................................................................................................................... 71

13.1 Maintenance................................................................................................................................................................................................................ 72

13.2 Objectives:................................................................................................................................................................................................................... 72

13.3 Type of maintenance................................................................................................................................................................................................... 72

13.4 Duties of Mechanical maintenance department:......................................................................................................................................................... 72

13.5 Duties of Electrical maintenance department.............................................................................................................................................................. 73

Chapter 14...................................................................................................................................................................................................................................... 73

14.1 Utility Service............................................................................................................................................................................................................. 73

14.2 Water supply............................................................................................................................................................................................................... 74

14.3 Specification of generator........................................................................................................................................................................................... 74

14.4 Air Compressor:.......................................................................................................................................................................................................... 75

14.5 Specification of Air Compressor:................................................................................................................................................................................ 75

14.6 Boiler:.......................................................................................................................................................................................................................... 76

14.7 Specification of Boiler:............................................................................................................................................................................................... 76

Chapter 15...................................................................................................................................................................................................................................... 76

15.1 Water Treatment Plant:............................................................................................................................................................................................... 76

15.2 Process Flowchart:...................................................................................................................................................................................................... 77

15.3 Function of different parts:.......................................................................................................................................................................................... 78

15.4 Effluent Treatment Plant:............................................................................................................................................................................................ 80

15.6 Effluent Treatment Process:........................................................................................................................................................................................ 81

15.7 Treatment Methods:.................................................................................................................................................................................................... 81

15.8 Physical Treatment:..................................................................................................................................................................................................... 81

15.9 Flow Equalization Tank.............................................................................................................................................................................................. 82

15.10 Process Sequence of Physical Unit Operations:.......................................................................................................................................................82

15.11 Chemical treatment:................................................................................................................................................................................................. 83

15.12 Process Sequence of Chemical Unit Operation:...................................................................................................................................................... 84

15.13 Biological Treatment:.............................................................................................................................................................................................. 85

15.14 Process Sequence of Biological Unit Operation:.....................................................................................................................................................86

Chapter 16...................................................................................................................................................................................................................................... 87

16.1 Compliance & Corporate Social Responsibility..........................................................................................................................................................87

16.2 Compliance policy of FARDAR FASHIONS LTD ltd Health................................................................................................................................... 87

Chapter 17...................................................................................................................................................................................................................................... 89

17.1 Conclusion............................................................................................................................................................................................................................... 89
 List of Figure

Figure No.................................................................................................................................................................................................................. Page No.

Figure 1: Location of the Factory from BUFT Campus.................................................................................................................................................................. 3

Figure 2: Organogram of FARDAR FASHIONS LTD.................................................................................................................................................................. 5

Figure 3.2: Layout Plan For NZ Sizing....................................................................................................................................................................................... 12

Figure 3.3: Layout Plan For NZ Sizing....................................................................................................................................................................................... 13

Figure 3.4: Weavers beam........................................................................................................................................................................................................... 15

Figure 3.5: Warping..................................................................................................................................................................................................................... 16

Figure 3.6: warping machine....................................................................................................................................................................................................... 17

Figure 3.7: Sizing Process........................................................................................................................................................................................................... 18

Figure 3.8: BENINGER Sizing Machine.................................................................................................................................................................................... 19

Figure 3.9: Drawing in and Denting............................................................................................................................................................................................ 21

Figure 3.10: Air Jet Loom........................................................................................................................................................................................................... 23

Figure 3.11: Daily production report weaving section................................................................................................................................................................ 25

Figure 3.12: Fabric Inspection..................................................................................................................................................................................................... 25

Figure 3.13: 4 Point Fabric Inspection System............................................................................................................................................................................ 26

Figure 5.1: Singeing and desizing Machine................................................................................................................................................................................. 32

Figure 5.2: Gas burner................................................................................................................................................................................................................. 35

Figure 5.3: Desizing bath............................................................................................................................................................................................................. 32

Figure 6.1: 20 Process Sequence of combined Scouring & Bleaching........................................................................................................................................35

Figure 6.2 Fabric In & Normal Washing (4 times)................................................................................................................................................................... 37

Figure 6.3: Normal Washing (3 Time)........................................................................................................................................................................................ 39

Figure 6.4: Bleaching & Steaming Process................................................................................................................................................................................. 37

Figure 6.7: Width controlling chain............................................................................................................................................................................................. 39

Figure 6.8: Washing chamber.................................................................................................................................................................................................... 41

Figure 6.9: Dryer (24 air dram)................................................................................................................................................................................................... 43

Figure 6.10: Cooling Dryer & Fabric out.................................................................................................................................................................................... 41

Figure 8.1: Process Diagram of PDPS Dyeing............................................................................................................................................................................ 46

Figure 8.2: Fabric in + Padding + IR chamber............................................................................................................................................................................ 48

Figure 8.3: Dryer chamber (3 chamber)..................................................................................................................................................................................... 46

Figure 8.4: Fabric out from IR chamber........................................................................................................................................................................................ 48

Figure 8.5: Chemical Steaming & Cold water lock........................................................................................................................................................................ 46

Figure 8.6: Washing (Normal, Acid).............................................................................................................................................................................................. 49

Figure 8.7: Drum Drying & Dyed Fabric out................................................................................................................................................................................. 47

Figure 8.9: Cold Pad Batch Machine.............................................................................................................................................................................................. 49

Figure 9.1: Jigger Machine............................................................................................................................................................................................................. 53

Figure 10.1: Stenter Machine......................................................................................................................................................................................................... 55

Figure 10.2: Sanforizing Machine.................................................................................................................................................................................................. 57

Figure 11.1: Rubbing fastness tester............................................................................................................................................................................................... 60

Figure 11.2: Tear Strength Tester:.................................................................................................................................................................................................. 61

Figure 11.3: Wash, Perspiration & Saliva Tester........................................................................................................................................................................... 65

Figure 12.1: Inspection machine.................................................................................................................................................................................................... 71

Figure 14.1: Gas Generator............................................................................................................................................................................................................ 75

Figure 14.2: Air Compressor.......................................................................................................................................................................................................... 76

Figure 14.3: Boiler.......................................................................................................................................................................................................................... 78

Figure 15.1: Process Diagram of Water Treatment Plant............................................................................................................................................................... 80

Figure 15.2: Water Treatment Plant............................................................................................................................................................................................... 80

Figure 15.3: Screening.................................................................................................................................................................................................................... 82

Figure 15.4: Collection................................................................................................................................................................................................................... 82

Figure 15.5: Cooling tower............................................................................................................................................................................................................. 85

Figure 15.6: Equalization Tank...................................................................................................................................................................................................... 83

Figure 15.11: Aeration Unit.......................................................................................................................................................................................................... 85

Figure 15.16: Nutrient Adding Unit............................................................................................................................................................................................... 86

Figure 15.17: Biological sludge settled............................................................................................................................................................................................ 89

Figure 15.18: Sludge collection...................................................................................................................................................................................................... 87

Figure 16.1: Fire Safety Equipment............................................................................................................................................................................................... 89

Figure 16.2: Medical Room ..................................................................................................

 List of Table

List of Table......................................................................................................................................................................... Page No.

Table 2.1: Production Capacity of FARDAR FASHIONS LTD.................................................................................................................................................06

Table 2.2: List of Buyers of FARDAR FASHIONS LTD............................................................................................................................................................07

Table 3.1: Sizing Parameters...................................................................................................................................................................................................... 20

Table 5.1: Process parameter of Singeing.................................................................................................................................................................................... 31

Table 5.2: Process parameter of Desizing.................................................................................................................................................................................... 31

Table 5.3: Recipe for Desizing chemicals................................................................................................................................................................................... 31

Table 6.1: Recipe of combined Scouring & Bleaching................................................................................................................................................................ 36

Table 8.1: Recipe for Pad Dry Pad Steam Dyeing....................................................................................................................................................................... 43

Table 8.2: Process Parameter:...................................................................................................................................................................................................... 48

Table 10.1: Chemical................................................................................................................................................................................................................... 55

Table 10.2: soft finishing............................................................................................................................................................................................................. 55

Table 10.3: Water repellent.......................................................................................................................................................................................................... 55

Table 11.1: Recipe of Color fastness to perspiration................................................................................................................................................................... 62

Table 11.2: Color fastness to light............................................................................................................................................................................................... 63

Table 11.3: Color fastness to Saliva............................................................................................................................................................................................ 64

Table 12.1: Inspection of Fabric Faults by 4-point...................................................................................................................................................................... 67

Table 12.2: Fabric defects point values…………………………………………………... 67

CHAPTER 3 MACHINE DE-
SCRIPTION
3.1 Machines used in Garments Sample section:
Table 3.5: Machine used in Sample section

Machine Name Quantity(Pcs) Brand

Single Needle Lock Stitch Machine 10 Juki

Button Attaching Machine 1 Juki

Bar tack machine 1 Pegasus

Flat Lock machine 3 Juki

Over lock machine 4 Juki

Iron 3

3.2 Machine used in Cutting section

Figure 3.4: Machines in Cutting section

Table 3.6: List of Machines in Cutting section

Name Quantity(Pcs) Brand Origin

Cutting machine 12 KM Japan

3.3 Machines used in Sewing Section

Figure 3.5: Over lock sewing machine Figure 3.6: Button attaching machine

Figure 3.7: Flat lock sewing machine Figure 3.8: Kansai sewing machine

Figure 3.9: Single Needle sewing machine

 Table 3.6: List of Machines in Sewing Section

Machine Name Quantity (Pcs)

Plain Machine 400

Over Lock (4 Thread) Machine 70

Over Lock (5 Thread) Machine 3

Flat Lock Machine 35

Feed of the Arm Machine 30

2 needle plain Machine 4

Button Stitch Machine 15

Button Hole Machine 10

Bartack Machine 20

Kansai Special Machine 3

Pikutting kansai Machine 4

Zigzag Plan Machine 7

Bas Machine 2

Fleximar Machine 2

Flat Lock Lessing Machine 6

Back tap Machine 7

Plain Machine Chain 1

Figure 3.5: Machines used in Sewing Section

3.4 Garments Finishing machine & tools

 Dummy

 Iron

 Metal Detector Machine

 Button Pull Test Machine

 Boiler

 Button attached machine

 Carton staple machine (P.P Brand)

 Compressor

 Final inspection table

 Iron cap

 Measurement tape

 Plastic staple attached

 Scissor

 Snap button attached machine

 Spray gun ( For spot remove)

 Steam iron (For pressing or Ironing)

 Tag gun

 Thread sucker

 Trimmer

 Vacuum table

 Weight scale
 CHAPTER 4 RAW MAT-

TERIAL
4.1 Raw Materials of Woven Fabric
The raw materials of woven fabric are the yarns that are interlaced at right angles to form the fabric structure. The yarns can be made from natural or synthetic fibers, such as cotton,

wool, silk, polyester, nylon, etc. The properties of the yarns, such as their fineness, strength, twist, color, and texture, affect the appearance and performance of the woven fabric. The

yarns are arranged in two sets: the warp and the weft. The warp yarns run along the length of the fabric and are held under tension on a loom. The weft yarns run across the width of

the fabric and are inserted over and under the warp yarns by a device called a shuttle or a rapier. The pattern of interlacing the warp and weft yarns is called the weave. There are

three basic types of weave: plain, twill, and satin. Each type of weave has different characteristics and applications in various types of woven fabrics.

4.2 Types of Fabric

The Fabrics that are familiar in FARDAR Fashions Ltd. are given below-

Table 4.1: Different Fabrics

Fabric Name Figure Fabric Name Figure

Corduroy Fabric Sheeting Fabric

Denim Fabric Poplin Fabric

Drill Fabric

Flannel Fabric

Gabardine Fabric

4.3 Trims and Accessories

Table 4.2: Trims and Accessories

Trims Accessories

Label Poly bag

 Button Elastic bag

Zipper Mini Poly bag

Padding Master Carton

Interlining Inner carton

Elastic Both side tape

Thread Tag pin

Twill Tape Carton Sticker

Stopper Safety pin

Piping Cord Gum tape

Velcro tape Arrow sticker

Logo print Scotch tape

Elastic Threads Barcode Sticker

Eyelet/ Grommet Tissue paper

Buckle Plastic staple

Rivet Numbering sticker

Weaving belt Hanger

Hook & Eye Size sticker

4.4 Remarks
FARDAR Fashions Ltd. is very careful & conscious about its raw materials. The raw materials are always collected from reputed suppliers.
 CHAPTER 5

PRODUCTION, PLANNING, SEQUENCE & OPERATION

 5.1 Basic Procedure of Production Planning and control:

One of the key factors that contribute to the success of any project or endeavor is planning. Planning involves setting clear and realistic goals, identifying the necessary steps and re -

sources, and allocating time and budget accordingly. Without planning, it is very difficult to achieve the desired outcomes within the expected timeframe. Planning also helps to

avoid or mitigate potential risks and challenges that may arise during the execution of the task. Therefore, planning is an essential and indispensable skill that should not be over-

looked or underestimated. Planning provides a structured and organized way of completing a task successfully. But production planning and control is not an easy task. Its basic

working procedure is as follows-

 Taking order from marketing division.

 Analyzing the orders.

 Planning for Garments making

It is only a basic procedure. It may change according to the type of order. Sometimes the order is placed only for finishing the materials or only for dyeing the goods. Then some

steps are minimizing for planning.

 Taking order from marketing division:

Marketing division supplied fabric orders to the planning and control division by a specific format.

 Analyzing the orders:

After getting the fabric order, this section analyzes the orders according to buyers order quantity, type of orders (i.e. type of fabric, color to be dyed etc.), delivery

date etc. This section plans for required quantity of fabric to be knitted (order quantity + 10% of the order quantity), knitting balance, fabric to be dyed, dyeing

balance, RFD (ready for delivery), RFD balance, delivery fabric & delivery balance etc.

 Planning for Garments making:

Garments schedule are same as the finishing. After finishing, materials go to the garments section. However, this section always forces to all the departments to

delivery time given by the buyers. Thus, it plays a very important role in the success of the company.

5.2 Sample Section

The process of creating and testing garment samples is essential for the success of any fashion business. Garment samples are the prototypes or models of the clothing items or fabrics that

the business intends to sell in the market. By making and testing garment samples, the business can ensure that the quality, design, fit, and functionality of the products meet the expectations

of the customers and the industry standards.

The sample section of FARDAR Fashions Ltd. is a crucial part of the business operations and has a significant impact on attracting and retaining buyers. The buyers usually make their pur-

chasing decisions based on the quality of the samples they receive from the business. Therefore, the sample section of FARDAR Fashions Ltd. strives to produce high-quality samples that

showcase the best features and benefits of the products

5.2.1 Sample making process flow chart

Order Sheet/Technical data collected from merchandising section

26
 Pattern making

Cutting

Print/Embroidery

Sewing

Finishing

QC check

Send to the Buyer for approval

27
5.2 Pattern Making

Pattern is a hard paper which is made by following each individual component for a style of garment or apparel. Pattern making is one of the important process for

making apparel. There aredifferent methods of pattern making process but in FARDAR Fashions Ltd. mainly hard paper pattern and computerized pattern making

process is carried out.

Figure 5.7: Hard Paper Pattern and Computer Pattern

During manual or computer aided construction of pattern the pattern draft is developed by calculation based on the following instructions-

 Actual body size

 Size charts or sample

 Grading increment

 Easy allowances

5.16.1 On pattern instructions must be marked-

 Name of the pattern

 Style

 Size

 Grain direction

 Seam allowances

28
  Balance mark

5.16.2 Tools and equipment used for pattern construction-

 Working surface

 Paper

 Pencils

 Eraser

 Marker pen

 French curves

 Compass

 Set square

 Scissors

 Measuring tape

 Rubber, scale, scotch tape etc.

5.3 Marker Making

It is a process of cutting arrangement during large quantity of garments production. During marker making, pattern of garment parts drawn on a big paper considering

fabric width, garments size ration, fabric fault and cutting table width, length etc.

5.17.1 Preparations of Marker Making:

Before the marker making, some preparatory processes would be followed. In

FARDAR Fashions Ltd. These processes are followed strictly:

1. Marking Grain Line: Before marker making, the grain line of pattern and fabric must be marked.

2. Fabric Measurement: Before marker planning, the fabric must be measured carefully. Because, marker width is

relevant to the fabric width.

29
 3. Fabric Faults: Fabric faults would be also under consideration. In a fabric roll, where any faults found, that points

must be avoided for quality production and to least the fabric wastage.

4. Cutting Table: Marker planner should consider the cutting table length before making marker. Marker length

must be less than the cutting table length.

5.17.2 Methods of Marker making

There are two methods usually used for marker making in FARDAR Fashions Ltd.

1. Manual method.

2. Computerized method.

Figure 5.8: Manual and Computerized marker

5.4 CAD Section

In Fardar Fashions Ltd. CAD is used to produce pattern and marker. CAD is the contraction which stands for Computer Aided Design. This term means different

things to different people involved in designing, manufacturing and mechanical engineering. CAD or Computer Aided Design has brought a revolution in the Textile

industry, especially in apparel industry. The time consuming and cumbersome process of textile designing has been made easier by CAD. Now thoughtful and innova-

tive designs are available to the textile designers and textile manufacturers at the click of a mouse.

30
5.18.1 Process Sequence of CAD Section in FARDAR Fashions Ltd.

Receiving of pattern parts

Taking the image of pattern in CPU by digitizer

Modernizing of all pattern parts by the software (Modernizer)

Aligning all size pattern parts in the marker by the software (Floater)

Completing the marker

Taking approval from CAM section

Bringing out the marker through plotter

5.18.2 CAD software used in FARDAR Fashions Ltd.

i. Assist AVM

ii. WINDA Software

5.5 Fabric Relaxation

Fabric relaxation is done when the fabric comes from the dyeing and finishing, the fabric remains a slightly hot. Also in dryer, stenter and compactor

heat is applied on fabric and moisture is removed from the fabric and it is not in actual condition. So we have to relaxed the fabric by keeping the fabric

in normal temperature and pressure for a certain time, for that the fabric absorbs moisture from the atmosphere and regains its original nature. Fabric re-

laxation is performed for a certain period. This time is varied from fabric to fabric. But the minimum time of relaxation is twelve (12) hours. This time

also may vary according to the buyer’s recommendation.

Fabrics Relaxation steps

Received Fabrics from Warehouse

Fabrics Unrolling through Machine

Keeping Fabrics in Relaxation Rack in a certain period

31
(Relaxation time will depend on Fabrics Nature)

Fabrics spread/ Lay for cutting

Relax Fabrics two hour

Start Cutting

Figure 5.9: Fabric Relaxing

32
 Table 5.1: Fabric Relaxation Time

Serial No. Fabric Type Fiber Content Relaxing Time

1. Twill Fabric 100% Cotton 24 Hours

2. Twill Fabric Cotton + Spandex 48 Hours

3. Denim Twill Cotton 24 Hours

4. Denim Twill Cotton + Spandex 48 Hours

5. Rib (1/1, 2/2) 100% Cotton 24 Hours

6. Rib Lycra Mix 48 Hours

5.6
If readyCutting Sectioncollects sample marker & fabrics (for size set) from sample section, CAD section and fabric store.
cutting department

The process of fabric cutting begins after the fabric spreading is completed. The main objective of fabric cutting is to separate the fabric lay into individual pieces of garment components ac-

cording to the exact dimension of the patterns in the marker. The quality and accuracy of fabric cutting depend on several factors, such as the methods of cutting and marker planning, the

sharpness of the cutting knife, and the skills of the operators. If the fabric cutting is done manually, then these factors are more crucial. Fabric cutting should be performed with utmost preci -

sion and care, as it affects the fit and appearance of the final garment.

Figure 5.10: Cutting Section

5.20.1 Standard Operation Procedure of Cutting

Cutting department receive TECH PACK from mercendiser and PP sheet of a style from IE.

Cutting department checks whether sample, Master pattern and fabrics are ready or not.

33
 Cutting department gives lay for size set sample, cut, sew. Sew in the size set line, print, wash, embroidery all are done and measurements are taken in all the
steps.

If cutting
Then it is found that an adjustment
department is required
collect fabric for bulkinproduction
the masterfrom
pattern,
storethen
andcutting manager,the
check whether buyer,
GSMQC and pattern
of every roll ismaster check
for or not andand make
check thenecessary corrections
width of fabric for the
lot. as per grading and inform pattern and CAD section.

If fabric GSM is ok, cutting department sent into the CAD section containing in which width and ratio of fabric they are going to cut that
particular cutting.

CAD prepare marker & sent to cutting section. If in that style self fabric for neck is required, cutting increase informs the
spreading m/c
.Operator to keep particular amount of fabric from each roll.

Spreading starts and completed

34
 Maker is placed on the lay and take is attached.

Cutting parts are transferred to stickering table A spread sheet containing number or layer in that cutting, How many
Spreading starts and completed Bundle card come to bundle area.
sticker, how many parts in a single garments, goes to the sticker
section by spreading m/c operator.

Bundling starts
Maker & made
is placed on ready.
the lay and take is attached.

Cutting started & completed

Stickers are made ready. Bundle card are made ready.

Bundling starts & made ready.

Rejection cutting starts & completed.

Print & Embroidery parts. If other operations are needed such as print, embroidery. Cutting department Solid Parts.

sends cut panels to the store & later collect them from store & check whether there is any alter or not.

35
 Print & Embroidery panels are checked & if some alter & rejects are found the bundle card are re-written making Store in the cutting input
necessary adjustment. rack.

5.20.2 Factors involved in Cutting Fabrics

Factors affect the cutting process for fabrics are as follows:-

 Nature of fabric (grain line shade, twill etc.)

 The thickness of fabric.

 Design characteristics of a finished garment.

 Machines and tables used.

5.20.3 Requirements of the Cutting Process:

1. Precision of cut

2. Clean edge

3. Infused edge

4. Support of the lay

5. Consistency

5.20.4 Cutting Method

In FARDAR Fashions Ltd. Following cutting methods are carried out-

1. Manual

 Hand operated scissor

2. Manually operated power knife

 Straight knife cutting

36
5.20.5 Cutting Quality Control:

 Follow up fabric receiving by cutting section.

 Check rolls ticket information/ report.

 Check lab test report.

 If shade/ shading are OK, then allow to layer.

 Prepare layer report.

 Maintain log book.

5.20.6 Cut Panel should be checked for-

 Miss cut

 Matching plies

 Notches

 Ragged Cutting

5.7 Sewing Section

After receiving the garments components from cutting section, all the garments parts are joined and sewn as sequentially. Obviously all the components are sewn re-

spects on buyer requirement.

Sewing section is the most important department of a garment manufacturing industry. Sewing machines of different types are arranged as a vertical line to assemble

the garments. Sequence of types of sewing machine arrangement depends on sequence of assembling operations.

37
5.21.1 Process Flow Chart for Garments Sewing Department:

Product analysis

Set up target for production

Set up machine layout on the basis of target

Set up operator layout on the basis of target

QC check of product

Line balancing

↓ Line

setup

Distribution all the processes

Cutting parts received section

Cutting parts distribution to the operator and helper

38
 ↓

Complete parts making individually

Online QC check

Online quality audit

Counting output and checking with the target

Final quality check (for each Garment)

39
5.21.2 Sewing Process of a POLO shirt
Table 5.2: Sewing Process of a POLO shirt

Process Name Machine Used No. Of Operator

Shoulder Joint Over Lock 1

Placket Marking Hand Marking Chalk 1

Sleeve Rib Attaching Over Lock 1

Sleeve Joint Over Lock 2

Placket Making Single Needle 1

Placket Attaching with body Single Needle 2

Collar Rib Cutting As Per size Over Lock 1

Collar point Attach Single Needle 2

Collar Attaching Over Lock 1

Back Tip Attaching Flat Lock 1

Lower Face Single Needle 1

Upper Face Single Needle 1

Top Stitch Single Needle 1

Box Making Single Needle 1

Collar Top Stitch Single Needle 1

Bottom Hem Flat Lock 1

Care Label Preparing Single Needle 1

Care Label Attaching + Side Seam Over Lock 3

Sleeve Tuck (Back) Single Needle 1

Sleeve Tuck (Front) Single Needle 1

Side Band Piping Flat Lock 1

Side Band Tuck Single Needle 1

Side Band Top Stitch Single Needle 2

Button Hole Button Hole M/C 1

Button Attaching Button Attaching M/C 1

Motif Attaching On Sleeve Single Needle 2

Main Label Attaching Single Needle 1

Summary Total M/C: 24 Total: 34

5.21.3 Elements of sewing section:

1. Sewing thread

40
 2. Needle

3. Sewing Machine

4. Trims

5.21.4 Sewing Defects:

 Needle damage

 Skip stitches

 Thread breakages

 Broken stitches

 Seam puckering

 Pleated seam

 Wrong stitch density

 Uneven stitch density

 Staggered stitch

 Improperly formed stitches.

5.21.5 Attachments with machines:

 Light

 Piping Folder

 Compensating foot

41
  Rack guide

 Auto cutting of thread

 Elastication

5.8 Finishing Section

Garments finishing is an important section in readymade garments sector. It’s the last section of garments manufacturing department. It consists of a series of finish-

ing operations performed in the garment to improve its aesthetics, handle and functional properties.

In finishing section of FARDAR Fashions Ltd. the processing operations can be either or both mechanical and chemical in nature, which are performed in stitched

garments as single or batch. Several finishing techniques applied to the fabric can be applied to manufactured garments.

Figure 5.12 : Finishing Section of FARDAR Fashions Ltd.

42
 5.22.1 Finishing Process Flow Chart

Sewn garments received in finishing section

Initial quality check

Spot removing if there’s any spot

Ironing or pressing

↓ Inspection

Hang tag attaching

↓ Fold-

ing

↓ Poly

bag

↓ Metal

check

↓ Packaging or carton-

ing

5.22.2 Finishing Process:

i. Pressing: Pressing is a finishing process done by a cloth to heat and pressure with or without stream to remove creases and to impact a flat appearance to

the cloth or garments. In garment industries pressing is also called ironing. After completing pressing the garments have to be folded.

ii. Folding: After completing pressing, the garments are folded with a predetermine area. Garments are folded according to the buyer’s

direction, requirements in standard area.

iii. Packing: After folding, garments are packing the size of polythene packet is permanent. Specially, it is needed to ensure the placement of sticker

in proper place.

43
iv. Assortment: After completing the packing of garments, it must be placed the garments in a predetermined pack by sorting according to the size

and color then garments are packed into inner box according to the size and color. This process working in order is called assortment.

v. Metal Check: Checking the metal type component into the garments or with its accessories like button, zipper etc. is called metal check.

vi. Spot Removing: Spot removing is one of the special inspections which are done after initial quality check.

vii. Cartooning: At last cartoning or packing of the garments is done according to Buyer command. The process of packing of inner boxes

entered into the carton is called cartoning. The carton is properly warped by the scotch tape. Some information like carton box no, size, shipping

mark and the destination are printed on the carton.

5.9 Final inspection

Final inspection is made by buyer. He checks the garments according some rules like AQL. For complete garment that is not in bundle form, it is recommended that statis-

tical inspection done based on AQL. The defects may be identified in finished garments:

 Broken ends

 Broken picks

 Broken pattern

 Thick and thin place

 Rough surface cloth

 Iron stain

 Holes in the cloth

 Shading

44
 Figure 5.14: Final Inspection

5.10 Remark
FARDAR Fashions Ltd. strictly follows up the working flow chart and production planning, sequence & operation of cutting, sewing & finishing. Textile engineers of this factory

are highly skilled and they have best experience.

45
 CHAPTER 6

Merchandising Department

6.1 Merchandising

The merchandising department in the garment industry is one of the most important functions of the industry's supply chain. It plays a crucial role in bridging the gap between manufacturers

and retailers, ensuring that the right products are available to the consumers at the right time, in the right quantities, and at the right price. The department encompasses a variety of activities

that are essential for driving sales, increasing brand visibility, and maintaining profitability in the garment industry.

One of the primary responsibilities of the merchandising department is product selection and development. This involves identifying the latest trends, understanding consumer preferences,

and creating new designs that meet the demand of the market. The department needs to ensure that the products created are of high quality, meet the brand's standards and are cost-effective.

Another crucial aspect of merchandising is forecasting and demand planning. It involves predicting the demand for a particular product and ensuring that the right quantities are produced to

meet the demand. If the department overestimates the demand, it leads to unsold inventory, leading to financial loss. On the other hand, if the department underestimates the demand, it leads

to a shortage of the product, leading to lost sales and dissatisfied customers.

Inventory management is also a critical responsibility of the merchandising department. The department must ensure that the inventory levels are optimal, neither too high nor too low. An

46
excessive inventory level leads to increased warehousing and storage costs, while a shortage of inventory leads to lost sales. The department must also ensure that the products in the inven-

tory are not outdated and are in good condition.

6.2 Standard Operation Procedure of Merchandising

SOPs are shown for the following activities of merchandising department:

1. Preparation of bill of material (BOM)

2. Time & Action Calendar

3. Approval of Samples, fabric and trims

4. Production File

5. PP Meeting

6.

1. Preparation of bill of fabric (BOM)

a) Initiate TNA Calendar preparation after receiving order confirmation

b) First TNA Calendar to be submitted after at some point of order receiving

c) Analyze style and identify processes to be finished the design

d) Discuss with PPC department about production process capacity

e) Prepare TNA Calendar supported process capacity and order quantity

f) Mail TNA Calendar to Management, PPC department, Store and QA

g) Update TNA Calendar day to day and enter actual date of completion of a specific task

h) Initial Plan date shouldn't be modified

i) Modify TNA Calendar if required and circulate modified TNA Calendar with concerned department.

2.Time & Action Calendar

a) Initiate TNA Calendar preparation after receiving order confirmation

b) First TNA Calendar to be submitted after one day of order receiving

c) Analyze style and identify processes to be done for the style

d) Discuss with PPC department about production process capacity

e) Prepare TNA Calendar based on process capacity and order quantity

f) Mail TNA Calendar to Management, PPC department, Store and QA

47
 g) Update TNA Calendar daily basis and enter actual date of completion of a particular task

h) Initial Plan date should not be modified

i) Modify TNA Calendar if required and circulate modified TNA Calendar with concerned department.

3. Production File

a) Prepare production file prior to PP Meeting

b) Cover page of the production file to mark as

 Style #, Buyer name

 Order quantity,

 PP Meeting Date

 Ex-factory date

 Merchant’s Name who is handling particular account

C) A Production file must include following items

 Production file check list

 Apparel Tech pack

 Purchase Order (PO)

 Approved Fabric Swatches (all color ways)

 Approved Trim card

 Approved print and Embroidery design for color and artwork

 PP comments

 Buyer’s comment on samples, swatches and approvals

 Special instruction for line supervisor/QA

 Approved production pattern

 PP Meeting comments (Minutes of the meeting)

 Copy of TNA Calendar (style wise)

 Packing Specification

d) Production file to be handed over to Production Team and Quality Team at the time of PP meeting

e) Number of production files to be made to be decided by internal team

f) T&A calendar to be reviewed at the time of PP Meeting and if required re-planning to be done

48
g) Responsibility of each task (process) to be discussed

4. Approval of Bulk Fabrics & Trims

a) Receive Trim card (3 sets) from trim store on receiving of bulk trims (prior to PP Meeting).

b) Merchant need to provide approvals to each fabric for - (a) Trims quality, (b) Shrinkage and color fastness and (c) Shade variation (DTM tapes, buttons)

c) One Trim card to be given to Store, One for production file and one for merchandiser

d) Receive Trim card (3 sets) from trim store on receiving of bulk trims (prior to PP Meeting).

e) Merchant need to provide approvals to each fabric for - (a) Trims quality, (b) Shrinkage and color fastness and (c) Shade variation (DTM tapes, buttons)

f) One Trim card to be given to Store, One for production file and one for merchandiser

6.Conducting PP Meeting

a) Prior to PP Meeting prepare production file.

b) Prior to PP meeting take approval on PP sample (sealed sample).

c) Intimate PP Meeting date one day in advance to all concerned department heads/personnel.

d) PP Meeting to be attained by

o Merchandiser

o Sampling team

o Fabric and Trim store, fabric checker

o Cutting team

o Production team

o PPC

o Quality Assurance

o Finishing and Packaging team

e) Minute of the meeting (MOM) to be prepared by QA (or any other assigned person) and to be signed by all participants.

f) Copy of the MOM to be filed in the production file.

g) Revisit production planning of the style (order) and do necessary modification of dates and processes if required.

49
 h) Responsible person for each task to be assigned in Style planning sheet.

6.3 Process Flow Chart of Apparel or Garments Merchandising:

Order received from the Buyer with details

Sample Development

Price negotiation with the Buyer

Confirmation of order and receive the order sheet

Make buyer requirement sample (Fit, Proto, etc) for approval

Make requisition for bulk fabric

Make requisition for accessories

Swatch board making and approval

Raw material collection and also receive it in factory

Check and also listing

Make P.P (pre-production Sample) with all actual

Pre-production meeting

Start bulk production

Collect daily production and quality report

Make online inspection by strong quality team

50
 ↓

Sample sent to third party testing center

Make final inspection for bulk production

Shipment

Send all documents to the Buyer

Receive payment from Bank

6.4 Remark
FARDAR Fashions Ltd has a remarkable merchandising department that ensures the quality and efficiency of its products. The merchandisers are skilled and experienced in sourcing, de-

signing, and marketing the garments that meet the needs and preferences of the customers. The merchandising department also coordinates with the production, finance, and logistics depart-

ments to deliver the orders on time and within budget. FARDAR Fashions Ltd is proud of its merchandising department and its contribution to the success of the company.

51
 CHAPTER 6 QUALITY CONTROL

SYSTEM

52
 6.1 Organogram of Quality Assurance Department

Manager/Asst. Manager

Sr. Principle Officer/Production Officer

Quality Controller (QC)

Sr Supervisor /Supervisor/Jr Supervisor

Finished Fabric

Asst. Quality Controller (AQC)

On Line System Off Line System

Sr Supervisor /Supervisor/Jr Supervisor Sr Supervisor /Supervisor/Jr Supervisor

Asst. Quality Controller (AQC) Asst. Quality Controller (AQC)

Quality Controller (QC) Quality Controller (QC)

Figure 6.1: Organogram of QAD

53
6.2 Process Flow Chart of Final Inspection (QAD):

n
r finishing
After completing process
2 dly check dia here
/withfirstly
whitecheck
fabricthe shadeoras-per
weight GSM.buyer STD with dimensional stability from lab.
3 dly check fabric surface or appearance as-per buyer STD.

The every roll with every meter check as-per 4-point system.

Make a report.

If ok then ready for delivery.

If not ok then identify the fault.

If If it knitting
it is is Dyeing fault
fault & inform
then if we make suredepartment,
knitting that it is re-process able
by Job card then
and we& give
mail the job
requested thecard to Dyeing
fabric Dpt. for correction and if is not re-
for replacement.

process able then we reject the fabric & inform the dyeing to replace the reject

Qty.

54
6.3 Quality Objectives Department
The quality objectives are defined at organizational and functional levels in measurable term. They are also reviewed in the review meetings and any change or amendment record is

maintained.

The Quality Objectives of M-Yew Fashion Limited is defined to develop the following areas:

 To identify the requirements of the customers.

 To build quality into every product.

 To institute the required systems and procedures for continuous improvements.

 To allocate resources for training and workplace improvements

6.4 Quality Management System Planning

a) It is the responsibility of the Management Representative to ensure that requirements provided in Section 4.1., quality management system plan-

ning assesses the following:

 The processes needed for the quality management system.

 The resources needed for the quality management system.

 The quality objectives and other mechanisms for continual improvement.

 Changes, which may impact the quality management system.

b) Quality Management System Planning also ensures that the integrity of the quality management system is maintained when changes to the

quality management system areplanned and implemented.

c) Quality Management System Planning shows our commitment to the development, correction, maintenance, and continual improvement of our

quality management system.

6.5 Remark
FARDAR Fashions Ltd. always aware about the quality of the product. The quality of the product is always approved by the buyer. They sent the quality report to the buyer time to

time.

55
CHAPTER 7 MAINTE-

NANCE

56
7.1 Maintenances
Maintenance of M/C's are very essential to prolong the m/c life and good maintenance is important consideration. In this industry maintenance program is done by expert mainte-

nance team so very few times production are hamper due to m/c problem. There is ON-LINE reporting for maintenance so rest result can be obtained in shortest time.

7.2 Objectives of Maintenance

 To increase life time of m/c.

 For smooth running of m/c.

 To reduce the totals break down time.

 To achieve maximum efficiency.

7.3 Types of Maintenance

A. Daily Maintenance.

B. Weekly Maintenance.

C. Monthly Maintenance.

D. Yearly or Half yearly Maintenance.

7.4 Flow Chart of Maintenance

Problem occurred

↓ Operator

↓ Supervisor

Production officer

↓ Maintenance officer

Solution

57
7.5 Maintenance Tools with Function
Table 7.1: Maintenance Tools

Maintenance tools Function

Tread trap Joining of broken metallic parts

Cutting disc For cutting pipes, rods

Globe valve Fitting for steam line

Union Fitting for water, steam line

Union Elbow Fitting for water, steam line

Gear oil Lubrication

Cutting oil Lubrication

Hydraulic oil Lubrication

Oil gun Oil application

Spanner Tightening of nut bolts

Master range Tightening of nut bolts

Flat/Star screw driver Screw tightening & loosening

Hacksaw blade Cutting

Spray gun WP40 Spraying a chemical named WP40

Drill m/c Drilling to make hole

Grinding m/c Grinding

Grease Lubrication

7.6 Remarks
The maintenance department of FARDAR Fashions Ltd. is well equipped and it has a vast compliance system within the factory for both worker and staffs. It has

sufficient maintenance manpower including mechanical and electrical engineers .The maintenance of the machines should be carried out when the machine is out of

action.

58
 CHAPTER 9

STORE AND INVENTORY CONTROL

59
9.1 Inventory

An inventory management system (or inventory system) is the process by which you track your goods throughout your entire supply chain, from purchasing to production to end

sales.

9.2 Scope of inventory control

- Raw materials inventories

- In process inventories

- Finished goods inventories

- Maintenance, repair and operational inventories

- Miscellaneous inventories.

9.3 Function of inventory

- To smooth production requirement

- To meet anticipate demand

- To protect against stock outs

- To take advantages of order cycles

- To take advantages of quality discount

9.4 Store
9.4.1 Grey Fabric Store:

All the grey fabrics are stored in the fabric store near the batch section. Different types of fabric are listed in the sheet according to fabric types, quantity and consumer’s require-

ment.

9.5.1 Dyes and Chemicals store:

There is a different store for dyes and chemicals. Varies types of dyes and chemicals are stored here according to dyes and chemicals companies. Different types of dyes and chemi-

cals are listening a sheet. In the sheet the stored quantity of dyes and chemicals are also included. Every day the sheet is updated and a copy of this sheet is supplied to the dyeing

manager, dye house and lab section.

60
9.5.1 Finished goods store:
In M-Yew Fashionltd supplies it’s finished dyed fabrics to its garments section. So, dyed finished fabrics are stored for short time in the finishing section. All the delivered fabrics

are noted on the tally khata according to the lot no, quantity, fabrics diameter, buyer's name, color & considering other technical parameters.

9.5.2 Spares part store:

In FARDAR Fashions Ltd required amount of spares of different machines are stored in the mechanical store room. All the shares are listed in a sheet which is controlled by the me-

chanical & maintenance personnel. Spares are arranged in the store room according to their size, quantity & requirements. There are shelves in the store room to keep the small spare

parts.

9.5.3 Frequency of inventory control:

- Daily inventory control

- Monthly inventory control

- Yearly inventory control

9.5.4 Re-order Point

The re-order point is stated in terms of level of inventory at which an order should be placed for replenishing the current stock of inventory. Re order quantity depends on the lead

time of the product with some additional safety period. It also depends on the store capacity of factory. For example if the lead time of a product is two month then normally re or-

dering quantity may be for two and half months.

9.5 Remark
FARDAR Fashions Ltd has individual stores for raw material finish goods. There is not enough space to store the finish goods. It required increasing the store area.

Conclusion

Technical education and its adoption in practical field we involved inextricably. Without the implementation of the knowledge gathered in technical education its success bound to

suffer. Therefore, two month internship program as a partial fulfillment of our B.Sc. in textile engineering course helped us accomplish the gap between the theoretical and practical

knowledge by providing an elementary idea about industrial environment processing machines, tools, equipment production system and maintenance, administration and manage-

ment system. Our selected “FARDAR Fashions Ltd” may be regarded as the pioneer of oldest modern mill in our country. It was established many years ago with latest model of

efficient machinery. Within a very short time it earned name and fame at home and abroad for its quality in production and administrative facilities. It is now not only providing knit-

61
ted fabric to the local market, but also exporting them to foreign countries at a stationary level. It mainly uses online process control and it’s qualify control department helped us to

achieve a profound knowledge about spinning mills production sequence maintenance, quality control & assurance as well as it’s organization structure. We tried our best to gather

all necessary information but it is true that within this short period it is quiet impossible to achieve 100% success as a whole this industry visiting was a satisfactory.

62