ADAMA INDUSTRY PLC @2016

ID NO.ENGR/ 081/05

PREPARED BY BELETE ENGIDA

ADAMA INDUSTRY PLC @2016

DECLARATION

I declared that, this written report is prepared by Beleteengida.It contains the data which I was
got from company as well as final project which I was set apart of something for some purpose
to work in garment factory stay. So that, this report contents are not has been taken fromubmit to
any other university or garment factory
I have under taken my internship experience in Adama Garment industry from March up to June
2008 E.C under the guidance of Mr. Mustafa Abase{Wolkite university garment engineering
lecture} and Mrs. Merete {Adama garment industry production manager}

BeleteEngida ---------------- -------------

Student name signature date

Mustefa Abas -------------- --------------

Advisor name signature date

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ACKNOWLEDGEMENT

I would like to thanks my friends for this time and advice during the cause of this project would
also like to thank my GOD. I would also thank my adviser Mustafa Abas advice during the
project. I would like to thank my Friend and all my family for providing me with the best of
opportunities and having faith in my abilities. Finally, I wish to thank all my friends who have
made my stay away from home a happy experience.

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EXECUTIVE SUMMARY

This internship report and final project is come to a conclusion, by more than four months. I stay
in ADAMA GARMENT FACTORY Knowledge of garment engineering cannot be upgraded
only by theory part or without practical experience garment manufacturing process is not totally
understand. This written report about the internship program which was planned to help students
as they develop their knowledge on garment engineering projects, design process,
implementation of new method, evaluation and general management . It also about the back
ground of our host garment company including its production system, management system and
major achievements, general internship experience, the knowledge of practical and theoretical
applied in garment manufacturing process and the challenge which applied in production
process. The contents of the report have been divided into four chapters. The first part of the
project I provide information about the hosting company history and overall organizational
structure. Also in this chapter I will try to present the different departments of the company and
the organization of the company. I explain main products of company, foreign and local
customers. In the second chapter of the project I describe mainly the particular project. I doing
my project in sewing department Improve quality, I trying to explain how much increase
productivity and . I explain this and other things in this chapter. At the end this chapter I give
solution of the problem. In the third chapter I explain over all benefit to gain from the inter ship
and to give all recommendation and solution to the all problems of the company. chapter four
finding

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

Acknowledgement ....................................................................................................................................... iii

Executive summary ...................................................................................................................................... iv

1.1 HISTORY OF THE COMPANY .................................................................................................................... 1

1.2 VISION AND MISSION OF THE ADAMA GARMENT COMPANY ................................................................ 1

1.3 OBJECTIVE OF THE ADAMA INDUSTRY ....................................................................................... 2

1.4 CORE BUSSINESS OF THE INDUSTRY ....................................................................................................... 2

1.5 CORE VALUES OF THE COMPANY............................................................................................................ 2

1.5.1 Duty of the Industry ............................................................................................................................. 2

1.5.2 TYPES OF RAW MATERIALS USED IN COMPNAY .................................................................................. 3

1.5.3 Canvas .................................................................................................................................................. 3

1.5.4 TYPES OF ACCESSORIES Used inAdama garment Industry .................................................................. 3

1.5.5 Fabric suppliers of Adama Garment Industry ...................................................................................... 3

1.5.6 Accessories suppliers of Adama Garment Industry ............................................................................. 4

1.5.7 Canvas suppliers of Adama Garment Industry .................................................................................... 4

1.5.8 Leather suppliers of Adama Garment Industry ................................................................................... 4

1.5.9 Thread suppliers of Adama Garment Industry .................................................................................... 5

1.6 work force adama garment industry ...................................................................................................... 5

1.7 Main products of Adama Garment Industry plc ..................................................................................... 6

1.8 The main local customer of Adama garment industry ........................................................................... 7

1.9 The main foreign customers of Adama garment industry ...................................................................... 8

1.9.1 Export/import ...................................................................................................................................... 8

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1.10 DIFFERENT SECTION OF ADAMA GARMENT INDUSTRY........................................................................ 8

1.11 ORGANIZATIONAL STRUCTURE OF THE INDUSTRY ............................................................................. 11

1.12 PROCESS Flow of Adama Garment industry. ...................................................................................... 13

2 CHAPTER TWO
PROJECT TITTLE .................................................................................................................... 29

2.1 INTRODUCTION................................................................................................................. 29

2.1.1Method study ....................................................................................................................... 29

2.2 Statement of the problems.................................................................................................... 29

2.3 There are two types of objective; ......................................................................................... 30

2.3.1 General objectives .............................................................................................................. 30

2.3.2 Specific objective ................................................................................................................ 30

2.4 Significance of the project .................................................................................................... 30

2.5 Scope of project ..................................................................................................................... 30

2.6 methodology........................................................................................................................... 31

2.7.1 Observation ........................................................................................................................ 32

2.7.2 Interviews.......................................................................................................................... 32

2.8 SECONDARY DATA. .......................................................................................................... 33

2.9 DATA ANALYSIS ................................................................................................................ 33

2.9.1 Detail description of my topic ........................................................................................... 33

2.9 RECOMMENDATION ........................................................................................................ 36

2.10 CONCLUSION ................................................................................................................... 36

3 Benefits from internship .......................................................................................................... 37

3.1 Practical Skill ........................................................................................................................ 37

3.1.1 Theoretical Knowledge ...................................................................................................... 37

3.1,2 Interpersonal Communication .......................................................................................... 38

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3.1.3Team playing skill ............................................................................................................... 38

3.1.4 Leadership Skills ................................................................................................................ 39

3.1.5 Work Ethics ........................................................................................................................ 39

3.2 Conclusion ............................................................................................................................. 39

3.3 LIMITATION OF THE PROJUCT ................................................................................... 40

3.4 Recommendation................................................................................................................... 40

3.5 REFERENCE ........................................................................................................................ 41

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1 CHAPTER ONE

ADAMA GARMENT INDUSTRY

1.1 HISTORY OF THE COMPANY

Adama garment industry was established in 1980 E. C FROM capital city of Addis Ababa 105
KM western region of Adama town. The factory was established by gating the support from
Korea Republic about 500000{US dollar} this money used to buy different kind of machine. The
rest covered by Ethiopia government. At the establishment Adama garment industry was known
by people by Nazareth canvas sewing factory This factory occupies 113,500m 2 .This company
follows from 1980-1990 E.C under the commission of defense and engineering industry, from
1990-1994 E.C under metal and agency also from 1995 up to now under metal and engineering
corporation under the name of metal and engineering and Adama garment industry. This industry
cover 85% of the demand of clothes and related military product and 15% of commercial product
, currently it is the only industry that supplies tent to all peace keeping force of deployed by UN
.In Adama garment industry there are totally five manufacturing units. These are:

1 Heavy duty

2 parachute and drug chute

3 Garment manufacturing

4 Calvin and finishing manufacturing but from those units shoes and gloves Manufacturing is
placed at northern part of Ethiopia at Adowa town.

1.2 VISION AND MISSION OF THE ADAMA GARMENT COMPANY

The vision and mission of the garment industry is to see the industry as leading model which
plays important in garment industry sector and garment engineering skill center creating national
industrial technology to be competent on the given field and sell products in the reasonable price
and quality to domestic and international customer obtain good feedback by selling different

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product to the market, conducting research and development work, create collaboration with
different organization and introduce new and technological achievement to the country.

1.3 OBJECTIVE OF THE ADAMA INDUSTRY

Develop technologies that satisfy armed force garment and military requirements at the desire
time and place perform engineering activities that support industrial development and
specifically the garment industry.

1.4 CORE BUSSINESS OF THE INDUSTRY

Manufacturing of commercial products, military uniform, gown {for many purpose}, sleeping
bag , waist belt , covers {for many purpose} rain coats , parachute , shoes , gloves , smart clothes
for chairs of cars , trains , air plane and automobile dashboard covers and etc....

1.5 CORE VALUES OF THE COMPANY

The factory have different prospective such as work core values, work philosophy, systematic
core values, organizational work culture and have the following core values:

 Everything we work is by our plain.

 Our workers are the main resources for the industry
 The first target in our industry is to satisfy our customer
 corruption is the main challenge for our development
 Team work is our culture

Improvement is the growth for our development

1.5.1 DUTY OF THE INDUSTRY

The factory has legal organization and they have their own duties such as:-Produce and sell
canvas, leather and twill products. Produce different types of civil clothes.

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Produces and sell canvas products. Buy raw materials from local and foreign markets. Be
profitable and to be a Produce military uniforms clothes and title showing signs(defense, police
and federal marimya bet signs) Sources of income for military defense.

1.5.2TYPES OF RAW MATERIALS USED IN COMPNAY

 100% cotton fabric

 PC (polyester and cotton) fabric
 Polyester viscose fabric
 Teheran 6000 fabric

1.5.3 CANVAS

 Accessories
 Leather
 Thread

1.5.4TYPES OF ACCESSORIES USED INADAMA GARMENT INDUSTRY

 Buttons
 Buckle
 Twill tape
 Eyelet
 Snap button
 Grommet
 D-ring
 Two holes (plastics)
 Two holes (metals)
 Three holes (metals)

1.5.5FABRIC SUPPLIERS OF ADAMA GARMENT INDUSTRY

Alameda T.S.C

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ADAMA INDUSTRY PLC @2016
Awash T.S.C

SygenDema factory

Aica Addis factory

M lead limited company

Amaga L.C

Indonesia

India

1.5.6ACCESSORIES SUPPLIERS OF ADAMA GARMENT INDUSTRY

Gafat armament industry

Cotebe metal factory

Hiberet manufacturing industry

DNLM

Merkato market

1.5.7CANVAS SUPPLIERS OF ADAMA GARMENT INDUSTRY

Almeda T.S.C

Double S business group

Hambone general trading

WS business group

Mshiref

1.5.8 LEATHER SUPPLIERS OF ADAMA GARMENT INDUSTRY

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Mojo leather factory

Coleba leather factory

Ethio leather industry

1.5.9 THREAD SUPPLIERS OF ADAMA GARMENT INDUSTRY

Ethio thread factory

Ember thread factory

Salina trading

1.6 WORK FORCE ADAMA GARMENT INDUSTRY

TheAdama garment industry employees are many according the department of company. Those
employees are done in one shift. they are four types of department in Adama Garment Company.

Those department are;

1 Heavy duty

2 parachute and drug chute

3 Garment manufacturing

4 Calvin and finishing manufacturing

SO, in AGI the total employees are around one thousand employees.

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1.7 MAIN PRODUCTS OF ADAMA GARMENT INDUSTRY PLC

Product is the outcome of a production process supplied to the public at large .it should to the
society in the required amount quantity and time as well as at reasonable price.

At the Garment company produces woven (plain, twill) that they store in the form of gray fabrics
before sending to garment department.

The Adama garment department can produce the following products as listed bellow

 Trousers
 T-shirts
 Shirt
 cap
 Gown/over coat
 Field jacket
 Bed cover/sheet…etc

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Figure 1Adama product

1.8 THE MAIN LOCAL CUSTOMER OF ADAMA GARMENT INDUSTRY

 Beshoftu automotive industry

 Hilbert machinery and construction
 Power engineering industry
 Adama agriculture machinery production industry
 Metal fabrication industry
 Homicho ammunition industry
 Zequla steel production industry
 Briana printing industry

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 Akaki plastic industry
 Hitak industry
 Military defense logistics
 Military defense foundation
 Military collages
 Bekelcha industry
 Metehar sugar industry
 Awash melkasa aluminum sulfate and sulfuric acid production
 Fenicha sugar industry
 Wangi sugar industry
 Agriculture and production development
 Eletderash transport
 Ethiopia commercial bank
 Federal police
 Maremeia bet police
 Regional police Etc.

1.9 THE MAIN FOREIGN CUSTOMERS OF ADAMA GARMENT INDUSTRY

 Somalia
 South Sudan
 Rwanda {Rwanda} Djbutee and other

1.9.1EXPORT/IMPORT

Adama garment industry is the best industry which manufactured different product.
But they do not export

1.10DIFFERENT SECTION OF ADAMA GARMENT INDUSTRY.

Garment Factory

This unit is the second factory after heavy duty in the company. In this factory different kind of
products are produced. Some of them are; ranger for solider and officer, jam per overall, shirt

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Figure 2 garment factory

Heavy duty

Heavy duty it’s the oldest of all in the company. Heavy duty from the name we understand that
heavy material that directly related to solider or military purpose is manufacture here. Some of
the products produced in this unit are: vest, bullet proofing jacket, gun holder, bullet bag, holster
and different tent.

Figure 3Heavy duty

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Weaving Section

In this section the main product is military belt. One spinning machine was there that used to
change the thread in to the cone form, it’s used to facilitate the weaving section. Six weaving
machines where settle one into the other

There are two new machines that produce belt using nylon thread. The other two machines
producing using nylon cotton blend (NC) thread but the rest two machines were not working

Figure 4Weaving section

Parachute and Drag shut

This is also the newest factory than the rest of the company factories. This factory did not start
production still now this because of there is no ordered. Currently, they produce small quantity
of products that support for garment unit through producing quantity items

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1.11ORGANIZATIONAL STRUCTURE OF THE INDUSTRY

Organization chart is a graphic portrayal of the various positions in the enterprise and the
formal relationship, among them. It provides a bird’s eye view of the relationship, between
different department and division of an enterprise as well as the relationship between people
at various levels. It is a blue print of the company’s organization structure. Among different
types of charts or organizational structure, Adama garment Factory is used vertical types.

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1.12PROCESS FLOW OF ADAMA GARMENT INDUSTRY.

Order taking:

Process is done by the customer {owner of the order} and company manager treaty or dell which
is either by phone, email, Posta or /and face to face communication. After the meet or discuss
about the order they make discussion about the product delivery time, shipment {to foreign
country or local country} sourcing material {from local or foreign markets} and etc

Design and development

Figure 5 Design development

This section is doing the all of the sample making to the whole company but each factory has its
own design and sample making rooms. In this section they make design for specific order
according to the given specification or re-engineering {deconenttructing the garment and taking
measurement} and pattern is made in this section and also grade patterns in the given order of the
sizes. In Adama garment industry orders comes in two forms: Customers may send specification
sheet, the develop pattern based on the specification sheet. Customers may send a sample and
they develop based on the sample. But I seen most time the customers send sample and they are
determine fabric and tell the customers Sourcing of materials
All materials required for production purpose of specific order is received from main store and

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may temporarily store in the satellite of the section where it is to be produced, the section head is
reasonable to retrieve these materials from the satellite store for production in controller manner.

Design room problem

Marker making is made by manual, so it takes more time. As well as affect on efficiency. E.g. as
at time of marker which its length is 14m and its garment is 9; to make this, it took 4 o, clock .so
it required time.

 In this section there is no any window and ventilation for air refresh.
 There is no adjustable chair for designer and marker maker. For this, they always
standing for doing this job .so ergonomically is difficult to the workers.

To solve this problem

To save the time pay on marker making, facilitate the CAD system.

Generally, to improve productivity, facilitate the things which required for the workers like,
adjustable chair, ventilation, etc.

Sample making section

Products in the order they takes different sizes Sample making also cover by cuttingroom.
Sample makers is work the model of one garment before mass production .in sample making
section there are eight(8) sewing machine and other materials for construction garment .depend
on this equipment the sample of order garment is done.

The requirement of sample making before mass production is:-

•For time study

•For operation break down

•Give correction of fitness

•Modify and develop the pattern

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Sample making section problem

 The placement of light is not on correct position.

 There is no enough attachment of work aid on their machine.
 Their chair is ergonomically not good.
 As other section there is no window as well as no use of day light, for sample workers.

Recommendation

 Add work aid attachment on the machine for simplify the work.
 Improve the light position
 Modify the chair for workers

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Marker making section

This is the pre-production section by which all component parts making up the products are trace
on the required rolled fabrics. The operation is done by using pattern in the size of the parts in

Figure 6 Marker making section

Tracing section.

In this section doing two operators .They are take the pattern and tracing on the fabric manually.
They know traditionally one cloth how much fabric went and they assume the whole order and
tracing. All pieces of the garment are tracing on the single ply and cut the fabric.

Spreading section

In this section the fabric are spread on the spreading table and make sure that the edge of the
fabric correctly matched. Spreading is the pre-processing of the cutting. it is used to spread the
fabric ply accurately as per length of the marker with minimum waste at end of ply.

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Cutting section

Figure 7 Cutting section

Cutting is the next operation after spreading and it is making each component parts ready for
sewing operation. This done by machines such as straight band knife {to cut large component
and band knife {cut small pieces or components} and also by using other machineries.
Totally spreading section they are 12 operators are working. The table length is 12m and at one
4time they are spreading 110 plies. At one day they are cutting two times. After cutting operation
is completed each component parts are coded and numbered and
Garment cutting room manufacturing process

Design Get pattern get marker check marker quality

numbering spreading fabric

check cut cutting
panel

check if embroidery/ fussing Input into sewing.

bundling

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Machine available in cutting room

s/no Machine name Quantity Machine

code

1 Straight knife 2

2 Band knife 2

3 Driller machine 1

4 Scissor 3

5 Numbering machine 2

Total 10

 The total employs working in cutting room are 13.

 Tables available in cutting room

s/no Types of table Quantity Length in meter Width in meter

1 Wood and metal 2 12 1.70

Total 2 12 1.70

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Problems in work process flow of cutting room Adama Industry.

 The oldest pattern method.

 The natural light in blocked by painted window.
 The absenteeism of the pins in the spreading and cutting room.
 Lack of working condition.
 Lack of use computerized technology.
 Absent of vacuum fabric in spreading time.
 Problem of wrong alignment.
 There is no machine catch the fabric edge during spreading.
Safety (glove)

Recommendation.

Change the old table

Check the alignment of fabric before cutting.
Using new style and size pattern.
Check color variation during numbering.
Give training for employers.
Worker carefully marked, spreading, cutting and numbering.
Using glove for safety specially in cutting sections.
Change working condition as necessary for worker in ergonomically.

. Embroidery machine

There are three embroidery machine .two of them has18 head machine and one has 15 head
machine. Embroidery and screen printing are two processes that occur only if directly specified
by the customer; therefore, these processes are commonly subcontracted to off-site facilities.
Embroidery is performed using automated equipment, often with many machines concurrently
embroidering the same pattern on multiple garments. Each production line may include between
15 and 18 embroidery stations or head at a time. Customers may request embroidery to put logos

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or other embellishments on garments.

Figure 8Embroidery section

Printing machine

Screen printing is the process of applying paint-based graphics to fabric using Presses and textile
dryers. Specifically, screen printing involves sweeping a rubber blade across a porous Screen,
transferring ink through a stencil and onto the fabric. The screen printed pieces of fabric are then
dried to set the ink. This process may have varying levels of automation or may largely be
completed at manually operated stations. Like embroidery, screen printing is wholly determined

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by the customer and may be requested to put logos or other graphics on garments or to print
brand and size information in place of affixing tags.

Figure 9 Printing section

Sewing and in process ironing:

Sewing is the main operation of the section that assembles each component parts which is
prepared by the cutting operation in the desired shape and size. Sewing operation including:-
stitching, ironing, quality inspection, and etc... Other operation such as accessory are also
included under this process step. There is a continues long table between machines which serves
the material flow from one operator to another. Once the operator finished his/her operation to
the next operator in the table and his process continuous to the end.

This section is the largest room from the totalarea room of the company. This sewing has eight
lines and special machine. The operations break down and the movement of material from
operation to operation is not appropriate. Therefore, back tracking is occurs. The manufacturing

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system of this section lean manufacturing system. The operation of this section is stitching,
ironing, quality inspection and others. The line balance of this section department contains the
most complex activity of the garment manufacturing process of sewing. It is one of production
output of garment factory. The sewing process involves a number of sewing operators, who deal
with for the assembly of different sub assembly operations, and textile Engineers who have an
ample experience in the manufacturing of garment sub assembly operation.

After the completion of each sub assembly and main assembly operation, the sewn garment
taken in to the quality control department for quality inspection and sewing audition. Mechanics
activities and reliable support given to the production line contributes to the success of the
sewing department solving quickly the machine break down situation also helps the sewing line
to have continuities and avoid unbalancing situation.

Figure 10 Sewing section

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Machine available in sewing section.

s/no Machine type Brand Quantity

Jack single needle JK-8700 43
1
Zoje single needle ZJ 9701R-D3/PF 43
2
Double needle spelt ZJ 8750-5 1
3
parser foot zoje
Single needle juki DDL-8300N 10
4
Typical single needle GC5550 24
5
Zoje single needle ZJ 9701R 4
6
Zoje single needle ZJ 5300R-02B 3
7

8 Zoje single needle 120401005 2

Zoje Zigzag zJ457B 4
9
Blind Stitch ZJ600 2
10
Double needle juki LH_3128 9
11

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Ms Juki LH-3128 4
12
MSGEMSY LH-3128 3
13
Welting M/C(juki) LH/895 1
14
Cuff Irons STP/15 1
15

16 Collar Iron STc/T 1

Over lock(pagasus) LS2-o1 2
17
Inter lock GEMSY GEM_757FXH 2
18
Over lock GEMSY GEM-737-F 2
19
Over Lock(pagasus) L52-o1 2
20
Siruba inter lock 516m2-55 7
21
Waist band Zoje ZJ1508PR 1
22
Hailet machine Juki MAX-03 1
23

24 Button Hole Juki LBH-1790-5 5

Button Attach Juki LK-1903AN-SS 4
25
Bar tacking Juki LK-1903AN-ss 8
26
Steam Iron(VM) 270G Sucking 1
27
KM-Clothing cutting KS-AUV 2
28
Clothing Drilling - 1
29

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Single Parking EL-MA60/3/P 2
30
machine
Bag Clot Her DA_HEAU- 1
31
DUTY

32 Steam Iron (Vm) - 1

Over Lock GEMSY500-01 2
33
Seread(GEMSY)
Electric Steam Iron RMODALE 1
34
Garment Machine - 1
35
MS Zoje ZJ928-PL 1
36
Button Hole Gemsy GEM11888 1
37
Air Compressor 270 L ABAC 1
38
Table Vise - 1
39

Problem which may face in sewing section.

 Layout of machine and operators
 Production system
 Material handling equipment.
 Quality of the product.
 Absenteeism and waste time.
 Time transportation.
 Order flow process.

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Recommendation

Adjust working condition.

Arrange machine for the same product.
Use progressive/modular production manufacturing system.
Supervisor properly manage the operators
Use material handling equipment for the minimization time transportation.
Give training for supervisor and operators

Finishing room

Finishing system in this industry is through ironing mechanism to improve the garment
appearance or pleasant look. In this system they transfer the garment after all part of the garment
is join or assemble garment, they press the specific area of the garment. They have 12 ironing
machines

Those machines have the same model and it has steam means that, it is steam iron Machine. It
also has sucking mechanism. Which, used for flat the garment when, put on it for pressing.

Quality control

Quality monitored by the line checkers and the final production quality checkers.

They control the quality by the process of detect the defect on each part of the garment. Such as:
stitch quality, fitness of each join part, shade variation, as it trimmed, as it pressed etc.

Among those defect, if one is there they return to back this garment as give correction for it. In
this company there are two type of quality cost:-

Appraisal cost
Internal failure cost

Means that by they detect the defect, Appraisal cost is there and if, while, defect of this garment
is correct before the customer is received, it is internal failure cost.

Generally, in this company by using this type of quality they, satisfy their customers.

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This system is reduced the productivity by some amount, rather than this, if they use prevent
quality cost, their productivity is increase via reduction of rework.

Trimming operation: ‐
Trimming operation used to remove extra sewing threads which enhance the quality of the
product. This step is the next to sewing and before the quality checking operation. Final ironing
operation is to increase the attractiveness of the product. This might be the final operation made
to the product.

Final ironing operation:

Is to increase the attractiveness of the product. This might be the final operation made to the
product

Inspection

The final garment from last operation is fully checked and corrected immediately for any defect.

Matching and packing:

This is the last operation of the section and involved in matching product according to the
similarities and/or as required. After matching is completed the products will be packed as
specific in the requirement and shipment

Production packing flow process

Information include on carton is: - barcode, items description on, unit of measurement, quantity,
made in, weight, and brand log. Material used for packing is:-

 Poly bag
 Carton
 Plastic fastener
 Waist tag

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The packing department after the above process finished, transfer the garment as classified into:-

 Style name
 Size (S, M, L, XL, ...)
 Color of fabric
 Customers’ name

Packing supervisor work in progress the input to packaging depends on order of, deliver report to
factory manager, and merchandiser. Record packed product shall be maintained using finished
product reporting from and the balance has to match with received number of garment which
finishing, printing and packing. Packing section head responsible is to maintain the following
records:-finish production record and production report.

Weakness of this room

 The space movement is not enough for use rack transportation

 There is no day light use and the light they use is not correct position with sewing
machine •There is no any ventilation and window for refresh of air.
 The chair of operators are not adjustable .so ergonomically problem is there.
 Many transportation wastes are there.
 There is not enough line balance on the line.

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2 CHAPTER TWO

PROJECT TITLE

MINIMIZATION OF TIME WASTAGE DURING MAINTENANCE

THROUTH METHOD STUDY

2.1 INTRODUCTION

Maintenance is work that is carried out to preserve an asset (such as a roof or a heating boiler), in
order to enable its continued use and function, above a minimum acceptable levelofperformance,
over its design service life, without unforeseen renewal or major repair activities

2.1.1METHOD STUDY

Method study is the systematic recording and critical examination of ways of doing things in
order to make improvement.
Methods improvement: to maximize the proportion of actual sewing time in the time attended by
the operator.

2.2 STATEMENT OF THE PROBLEMS

The following problems happened in the adama garment due to the lack of working standard in
the maintenance department.

The technician is not understanding or identify whether the machine have problem not
The office of technician is far from production line
Lack of technician maintenance.
Machine is not maintained on time.
Lack skill man of technician in line.
Lack of spare part/material
The technician has no tool box
No adjustment of needle timing

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2.3 THERE ARE TWO TYPES OF OBJECTIVE;

1 general Objective

2 specific Objective

2.3.1 GENERAL OBJECTIVES

Increase productivity by reduce time wastage of maintenance

2.3.2 SPECIFIC OBJECTIVE

 By exist technician in off line

 By Adjusting of the machine properly
 By improving time wastage by using carding method.
 To increase moral satisfaction of operators
 To give quick response
 By reducing operators fatigue

2.4 SIGNIFICANCE OF THE PROJECT

 To minimize of time wastage by through methodstudy

 To increase the profit by using carding system
 To control the calling technician time

2.5SCOPE OF PROJECT

This project is doing on minimization time wastage during time maintenance through method
Study for Adama garment industry in sewing section. The maintenance function has not always
received the importance if deserves. If is sometimes looked up on as an ancillary activity that is
performed sporadically and when necessary some production managers feel that stopping a
machine or a productivity line to effect inspections or carry out preventive maintenance is an

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unnecessary .Its only when such machines breakdown that the importance of maintenance
becomes apparent .yet the losses incurred from poor maintenance can be enormous for apart
from stoppage and lost production there is the cost of product defects due to lack of maintenance
and losses due to shorter machine life which can be substantial in developing countries. Since
machines are replaced by drawing on scarce foreign exchange

2.6 METHODOLOGY

The most popular methods & use of collecting data for project are; Data Collection is a process
through which data is collected and prepared. It forms the basis of project data collection are:
2.7 literature review

Maintenance concept

The primary process in an industrial organization is production in which the primary

production input (material, energy, manpower) is transformed into the primary production
output (the desired product ) . This transformation process makes use of technical systems. A
technical system is a collection of physical elements fulfilling a specifiable function. The
state of a technical system is the physical ability considered relevant to fulfillment of its
function. External causes, ageing and use impair its state, inevitably leading to a
secondary production output; maintenance demand. On being carried out, this leads to a
secondary production input; that is potential production capacity. Maintenance is the total
of activities required to retain the systems in, or restore them to the state necessary for
fulfillment of the production function. In this destination, “retaining in” corresponds to
preventive maintenance, “restoring to” with corrective.

In other way Maintenance is the total of activities serving the purpose of retaining the production
units or retaining them to the state considered necessary for fulfillment of their production
function. Traditionally, maintenance was an activity that was put into action to solve production
problems.

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2.7.PRIMARY DATA..

 Observation

 interview

2.7.1OBSERVATION
I Observation is another useful method to collecting a lot of data. It also means you are
not reliant on people having to give you the information and their time. Observation can
be used to measure things such as traffic or foot fall of a business I observed that in
Adama garment industry by moving from line to line the operator are no have excess
knowledge on stitch there is no skill man on the quality..

2.7.2 INTERVIEWS
Interviews can give you more detailed data and can be ideal to scratch beneath the
surface of an issue. Although fairly time consuming and not always completely relevant
data or information (there may be various parts of an interview that are never used), it is
still a useful method of research. And to ask considered the problem of system and write
on my document

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2.8SECONDARY DATA.

Hand out:

 Internet accesses:

Internet accesses are another useful method to collecting general a lot of data. It also another
great way of collecting data. This is used to gate real data.

 Hand out: to collecting data for the project work we check or refer handout

2.9DATA ANALYSIS

2.9.1 DETAIL DESCRIPTION OF MY TOPIC

In Adama garment sewing section there is no use of carding method in terms of this there
is time wastage during maintenance why because of the technician office are far from
sewing section so ,when machine are some problem obtained the operator want to call
technician run from his room regarding to this I stand to minimization of time wastage by
using carding method this carding use for mainly purpose for running of one product in
garment factory generally I try to by this method reduce time wastage during
maintenance by carding methods to improve productive and profit of company so that

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when machine are some problem the operator shows this cards this card have two color
those are Red and Yellow colors Red represent electric service and Yellow also represent

Day Types of Number of Causes Idle time %

machines machines
Double 2 Thread 20 minute 16
Monday
needle & tension
single needle
Single needle 3 Needle 25 minute 25
Tuesday
breakage
And thread
tension
Single needle 4 Thread 22minute 33
Wednesday
tension
Single needle 4 Power 29minute 33
Thursday
problem
double needle 3 Needle 24minute 25
Friday
single needle breakage

Single needle 3 Treadle loose 26minute 25

Saturday
29 146minute
Total

When used in calculation forms given:

A time takes for calling to the technician from his store to the machine we try to see how
much is the time affect the production
The SMV of one cape production = 35 min
Total working hour = 480 min

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Number of machine = 12
Operator target/day = 480/35 = 14
Number of idle machine = 4
Machine idle time = 24 min
If one operator produces 14 capes/day how much will be produce in 12 operators
14*12 = 168 pieces per day
When we try to see how much production loose in one day
 If one machine produce 14 pieces/day how much pieces can produce within 4 machines?
 14*4 = 56 pieces per day
 56*6 = 336 pieces per week
 56*26 = 1450 pieces per month

Production loose in terms of cost

Per day:
The price of one cape = 40 birr
56 pieces = 2,240birr

Per week

2240*6 = 13,440 birr

So that as a Garment engineer we have to reduce this production loose by using carding system.
A carding system is a technique of calling the maintenance operator by rising different color of
cards this system let the maintenance operator to go easily to the machine after he see the card
which raised from the operator.

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2.9 RECOMMENDATION

1 giving training for technician

2 adjust the carding system in the garment factory
3 supply the raw material necessary for technician
4 prepared the office of technician as visible carding
5 maintain the machine before breakage/idle
6 prepared the schedule for maintenance
7 to make the tool box for technician
8 to add the technician
9 adjust timing for needle

2.10 CONCLUSION ;

Generally, the company gained profitability by minimizes the time wastage transportation
maintenance and operators. In case of minimize time wastage the company also increase
productivity and keep the delivery date.

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Chapter three

3 BENEFITS FROM INTERNSHIP

From the overall internship study program, I have gained the most critical knowledge, especially
in terms of improving my practical and theoretical skills. The theoretical knowledge that I got
during the last three years is greatly improved practically now.

Generally, the overall benefits I have gained from the internship study program include the
following related skills.

3.1 PRACTICAL SKILL

 Within an internship period different activities are taking place in the company and

 practice those activities and act to improve their problems through finding solutions.

 I developed the habit of being safe at work.

 Principles of quality control and the major parameters to taste finished products.

3.1.1 THEORETICAL KNOWLEDGE

 Understanding the company’s layout especially of machineries layout and analysis the
advantages and disadvantages of different machineries layout on the company productivity.

 It helped me to have deep knowledge about production process starting from design to
finishing. So, in this internship, I had improved the following theoretical knowledge.

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I had known the effect of maintenance on product quality, service life of the machine,
operators’ safety and productivity.
Analyzing the way, the managerial information flow from top level manager to
supervising (production floor level to effective management system)
Understanding the obligation and responsibilities of all section of the company. I.e. the
way the organizational goal is achieved.
Understand motivation methodology to be used for the company workers to increase the
productivity like: -
Scaling up worker’s position based on their performance.
Giving learning opportunity and other responsibilities.

3.1,2INTERPERSONAL COMMUNICATION

I had improved my speaking ability with different peoples especially with operators and
advisor. During this time, I had improved the way how to generate ideas, system of
communication, tolerance, the way how to respect other ideas, ability in generation of
constructive ideas.
The organizational structures of the company force me to know how to communicate with
the company society starting from guards to managerial level.
I use basic ways to communicate with the society. These are:
1. Orally

2. Through written document

3.1.3TEAM PLAYING SKILL

 I had improved my ability to perform within group how to work together with other
persons peacefully as well as to generate new ideas by discussing within groups.

 Even though there is no team task given to me, my project mate was on the way which
teach me how to cooperate and working together to solve an Engineering problems. I also
working with my friends in order to exchange point of view.

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3.1.4 LEADERSHIP SKILLS

 I had got the experience how to increase the productivity by having effective leadership.
For instance, when the shift leaders treat the operators positively, keep the operators morality and
respect them then the operators perform their work well.

 It helped me to grasp quality of effective leadership like confidence and improve highly
significant leadership qualities such as integrity, honesty, commitment, etc.

 Ability to motivate team members to do their best:

 Listening the idea of operators and solving their problems.

3.1.5 WORK ETHICS

 The work ethics I have developed through the internship was honesty and integrity. These
also play a great role in my life also and I understand how much integrity is so important to
do once work.

3.2 CONCLUSION

Generally, in this internship report, I gained enough practical experience in garment industry. In
this company there are so many problems that’s happen due to lack of skills and carelessness and
my project is also focusing to improve this problem by giving solution. To minimize
maintenance time and to reduce machine idle time.

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Any garment manufacturing companies have maintenance department in their production
system, the task of this department is to fix and check each and every machine in the
manufacturing process at the time of they stop working and also at the time of they not stop. So
that at this time what we have to know is in every maintenance the maintenance operators are
take time to fix or check the machine as we know that every garment manufacturing has working
time so this maintenance operation done its operation through this working hour this menace at
the time of the machine stops it will occur time waste and this time waste let the company less
productive. So that according to the knowledge of garment engineering we can reduce this time
waste. Carding system is one type of technique to minimization of time waste at the time
ofmaintenance operation.

3.3 LIMITATION OF THE PROJUCT

 Sours of material
 Communication problem
 Not get full information
 Layout of m/c
 Lack of CAD
 Absence of work measurement
General problem of Adama garment industry
 Layout of industry/m/c
 Working condition
 Operators absenteeism
 MHE (material handling equipment)
 Lack of training operators

3.4 RECOMMENDATION

 Arrange layout of m/c if possible change the company

 Using the ventilation
 Giving training for operator
 Adjust the work condition for operator

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 Check the machine before operation

3.5 REFERENCE

 Internet
 Hand out
 Productivity busses book
 Company document

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