College of engineering and technology

Department of garment engineering

I
Declaration
I eyob nguse a 4th year student of wolkite university taking apparentship at gmm garment for
four month.i was working effectively on the company and the company approved my existence
with their certificate. I give my regards to all peoples but after this anyone who like to use this
paper have to mention the outer of this project.

MR. Gebeyaw Mossy

Name of the Academic Advisor Signature Date
EYOB NGUSE
Name of Student Signature Date

II
Acknowledgment
Before the beginning of anything I would like to thank god and his mom for the endless
blessing. Next to that I need to give condolence thanks for who participate in this paper
and make the dream true, my university advisor MR.gebeyaw and company advisor
MR, destaw mekonen I like to thanks my families for the best motivation, friends, the
Gmm garment plc stuffs specially the hr. maza, production manager destaw pattern
making and sampling asefa, cutting room john, husen, abeje meseret, line supervisors
alemnesh, zewiditu, folding mekdes embroidery room hana and tiruye quality checking
hanan, kalkidan packing etaferaw maintenance anwar, tsegaye, ayantu thanks all for
your shearing everything what u have got. Finally my Collins Ebenezer lemma and
suleman from bahir Dar University and all employee at Gmm garment plc. And all
employee of the GMM garment.

III
 INTERNSHIP AT GMM GARMENT PLC 2008E.C/2016 G.C

Executive summery
This paper have three main chapters. The first chapter is about the GMM garment plc.
The company is located in Addis Ababa Ethiopia and the company produce verity
product for the export market. The second chapter focus on the final project titled
productivity improvement by reducing rework in sewing section which recorded well
and implemented by making operator training manual and preventive maintenance
schedule. The final chapter focus on the learning experience of the internship time.

IV
INTERNSHIP AT GMM GARMENT PLC 2008E.C/2016 G.C

Contents
Declaration ............................................................................................................................ II
Acknowledgment.................................................................................................................. III
Executive summery .............................................................................................................. IV
Chapter one company profile................................................................................................ 1
1 Introduction ........................................................................................................................ 1
1.1 Expansion Project ............................................................................................................ 1
1.1.1 Establishment ............................................................................................................... 2
1.1.2 Vision ............................................................................................................................ 2
1.1.3 Mission ......................................................................................................................... 2
1.1.4Values ............................................................................................................................ 2
1.1.5 Organizational Structure of GMM ................................................................................ 3
1.1.6 Manufacturing Flow Chart Process .............................................................................. 4
1.2 MACHINES ....................................................................................................................... 8
1.3 Products......................................................................................................................... 14
1.3.1 Customers................................................................................................................... 15
1.4 Departments.................................................................................................................. 15
1.4.1 Store room.................................................................................................................. 15
1.4.2 Designing, pattern making and sampling ................................................................... 17
1.4.3 Cutting room .............................................................................................................. 19
1.4.4Marker making ............................................................................................................ 20
1.4.5 Spreading .................................................................................................................... 21
1.4.6Cutting ......................................................................................................................... 21
1.4.7Bundling....................................................................................................................... 21
1.4.8 Ticketing ..................................................................................................................... 22
1.4.9 Fusing.......................................................................................................................... 22
1.4.10 Embroidery room ..................................................................................................... 23
1.4.11 Sewing room ............................................................................................................. 24
1.4.12 Quality inspection..................................................................................................... 25
1.4.13 Ironing ...................................................................................................................... 26
1.4.14 Folding and packing .................................................................................................. 27
1.4.15 MAINTENANCE IN GMM CAMPANY ......................................................................... 28

V
 INTERNSHIP AT GMM GARMENT PLC 2008E.C/2016 G.C

1.5 Warehouse .................................................................................................................... 29

2 Chapter two ...................................................................................................................... 31
Final project on productivity improvement by reducing rework ......................................... 31
2.1 Introduction ................................................................................................................... 31
2.2 Problem statement........................................................................................................ 33
2.3 Objective........................................................................................................................ 33
2.3.1 General Objective ....................................................................................................... 33
2.3.2 Specific Objective ....................................................................................................... 33
2.4 Scope of the Study ......................................................................................................... 33
2.5 Limitation of the Project ................................................................................................ 34
2.5.1 Significance of the Project .......................................................................................... 34
2.6 Literature Review .......................................................................................................... 34
2.7 METHODOLOGY ............................................................................................................. 35
2.7.1 DATA COLLECTION Method ........................................................................................ 36
2.7.1.1 Primary data collection methods ............................................................................ 36
2.7.1.2Secondary data ......................................................................................................... 36
2.7.2 Data Collections and Analysis ..................................................................................... 37
2.7.2.1Operation breakdown .............................................................................................. 37
2.8 Result and discussion .................................................................................................... 43
2.9 Conclusion ..................................................................................................................... 43
3 Chapter three ................................................................................................................... 45
3.1 internship experience .................................................................................................... 45
3.1.1 Practical skills.............................................................................................................. 45
3.1.2 Theoretical skill ........................................................................................................... 45
3.1.3 Communication skill ................................................................................................... 45
RECOMMANDATION AND COMMENT ................................................................................ 46
Reference ............................................................................................................................ 48

Figure 1Gmm Company ............................................................................................................ 1

Figure 2 further expansions of gmm garment ............................................................................ 1
Figure 3 product of gmm garment ........................................................................................... 14
Figure 4product mix of gmm garment ..................................................................................... 15
Figure 5 store room of GMM garment .................................................................................... 16
Figure 6 fabric store of gmm garment ..................................................................................... 16
Figure 7 pattern making tools of gmm garment ....................................................................... 18
Figure 8 sampling room and sample card ................................................................................ 19
Figure 9 marker making........................................................................................................... 20
Figure 10 cutting....................................................................................................................... 21
Figure 11 Ticketing material ...................................................................................................... 22
Figure 12 Fusing machine .......................................................................................................... 22

VI
 INTERNSHIP AT GMM GARMENT PLC 2008E.C/2016 G.C

Figure 13 embroidery machine of gmm garment..................................................................... 23

Figure 14 embroidery samples ................................................................................................. 23
Figure 15 sewing section of gmm garment .............................................................................. 24
Figure 16 iso 9001 of gmm garment ........................................................................................ 25
Figure 17 quality checking....................................................................................................... 26
Figure 18 Ironing machines ..................................................................................................... 27
Figure 19 folding and packing ................................................................................................. 27
Figure 20 maintenance room of gmm garment ........................................................................ 28
Figure 21 warehouse of gmm garment .................................................................................... 29
Figure 22 power consumption ................................................................................................. 29
Figure 23 waste disposition, water and toilet ........................................................................... 30
Figure 24 productivity chart..................................................................................................... 32
Figure 25 pie chart of the defect category ............................................................................... 40
Figure 26 line chart of rework ................................................................................................. 42
Figure 27 line chart of total pass .............................................................................................. 42
Figure 28 final chart of rework, pass and reject ....................................................................... 43

Table 1 machine list of gmm garment ..................................................................................... 11

Table 2 machine list of cutting section .................................................................................... 13
Table 3 machine list of finishing section ................................................................................. 14
Table 4 Sample card .................................................................................................................. 18
Table 5 Operation break down................................................................................................. 37
Table 6 percentage categorization of the defect....................................................................... 40
Table 7 data recording ............................................................................................................. 41

VII
Chapter one company profile
1 Introduction
GMM Garment P.l.c is driven by strong values, advancing with quality and efficiency
.We strive to become the leading garment manufacturing company both locally and
internationally while being socially compliant. Professionalism is our belief we value
in all our products. GMM Garment is a private limited company, established in Addis
Ababa, Ethiopia, by three women entrepreneurs. It was established in September 2004
G.C. Their aspirations were to reveal to the world the beauty and rich heritage of
Ethiopia through their product, while contributing to the empowerment of women and
the economic development of their country.
factory is located in Nefas Silk/Lafto Sub-city, Kebele 12, Block 15, in Lebu
Industrial Zone. It has some 2,000 meter square of land leased from the government.
The production area is housed on 500 square meters of modern building. GMM is
mostly engaged in the production of different kinds of garment for the export market.
Currently the factory has over 170 skilled employees working on full time. The
current capacity is 270,000 pieces per year.

1.1 Expansion Project

Figure 1Gmm Company

Figure 2 further expansions of gmm garment

1
 INTERNSHIP AT GMM GARMENT PLC 2008E.C/2016 G.C

The new factory will have state of the art production machinery and equipment to
compete on quality on the international market. This expansion program is expected
to boost production capacity and efficiency and to add new product lines. In addition
to the polo shirts, the plan is to produce medium to high quality dress and casual shirts
for the international and local markets.

1.1.1 Establishment
Gmm garment is a private limited company. Established in Addis Ababa Ethiopia by three
women entrepreneurs.it was established in September 2004 G.C. the factory is located in
nefas , silk/lafto sub-city,kebele 12,block 15 in lebu industrial zone.it has some 2000 meter
square of leased from the government on which 500 meter square modern building house
the factory. Gmm is mostly engaged in the production of different kinds of garment for the
export market.

1.1.2 Vision
The vision is to become an exemplary organization in both the locally and
international market.

1.1.3 Mission
 To continuously advance in quality and efficiency while being socially
compliant.
 Become the leading garment manufacturing company both to local and
internationally.

1.1.4Values
 Quality and efficiency

 Professionalism
Production and operation
 Production area= 500sq.mt,
 Current capacity/year=374400pieses
 Number of operator = over 170 skilled employee

2
 1.1.5 Organizational Structure of GMM

Share holder

Marketing Finance Administration

Pattern &
Purchas Sales Accountant Store Personnel General Line Final
Maintenanc Prod, Sample maker
Service inspectio inspecti
e head leader & trainer
n on

Clerks Guard Cleaner Driver Cutting Sewing

Sup line sup
&packing

sup
 INTERNSHIP AT GMM GARMENT PLC 2008E.C/2016 G.C

1.1.6 Manufacturing Flow Chart Process

Order receiving

Planning Sample Material sourcing

making
 Man power
 Materials
 Machine

PP sample Material
approval inspection

Fail

PP meeting

Pass
Cutting

Embroidery Sewing

Fail
Inspection

Pass
Finishing

Fail
Final
inspection

PREPARED BY EYOB NGUSE

 INTERNSHIP AT GMM GARMENT PLC 2008E.C/2016 G.C

Packing

Shipment audit

Shipping /Delivery

1) Design and Sampling Department

Specs receiving

Pattern making

Sample making

Check sample fitting

Fail
Sample approval

Make Production pattern

Grading pattern

Make production sample

Fail
Production sample approval

Start marker

2) Production planning & controlling

PREPARED BY EYOB NGUSE

PPC
 INTERNSHIP AT GMM GARMENT PLC 2008E.C/2016 G.C

PRODUCTION PRODUCTION
PLANNING CONTROL
 Planning  Dispatching
 Routing  Following Up
 Scheduling  Inspection
 Loading  Corrective

3) Store Department

Receiving materials
↓
record and stock
↓
withdrawal materials
↓
record and balance

4) Quality Department

Sample comments follow-up measurement

↓
Pattern grading checking
↓
Fabric inspection (GSM, color shade etc)
↓
bundle checking
↓
Embroidery checking
↓
inline inspection
↓
sewing output inspection
↓
final inspection
↓
shipment auditing

5) Production Department

a) Cutting section

PREPARED BY EYOB NGUSE

 INTERNSHIP AT GMM GARMENT PLC 2008E.C/2016 G.C

Marker making
↓
spreading fabric
↓
cutting
↓
sorting and bundling

b) Sewing section

Product analysis
↓
set up machine layout
↓
set up operator on the basis of layout
↓
Line setup
↓

Bundle distribution to the operator and helper

↓
assembling
↓
trimming

c) Finishing section

Pressing
↓
packing
↓
cartooning/packaging
↓
dispatching for shipment

PREPARED BY EYOB NGUSE

 INTERNSHIP AT GMM GARMENT PLC 2008E.C/2016 G.C

1.2 MACHINES

GMM GARMENT P.L.C

Fixed Assets Inventory Sheet
Plant , Machinery and Equipment
ITEM
No A/C Code Serial No Description UOM Qty
1803-01-
1 01 4D0ZA11054 single needle lock stitch pcs 1
1803-01-
2 02 4D0FE16314 single needle lock stitch pcs 1
1803-01-
3 03 4D0FE16539 single needle lock stitch pcs 1
1803-01-
4 04 4D0ZA11069 single needle lock stitch pcs 1
1803-01-
5 05 4D0FE16768 single needle lock stitch pcs 1
1803-01-
6 06 8M0YM22772 4 thread over lock pcs 1
1803-01-
7 07 8D0ZA10973 single needle lock stitch pcs 1
1803-01-
8 08 4D0ZA11057 single needle lock stitch pcs 1
1803-01-
9 09 8M0YM22727 pcs 1
1803-01-
10 10 8M0YM22709 4 thread over lock pcs 1
1803-01-
11 11 JM-500N INTER LOCK pcs 1
1803-01-
12 12 8M4YJ11010 cover stitch pcs 1
1803-01-
13 13 2L02F00906 button hole pcs 1
1803-01-
14 14 130802800 button attach pcs 1
1803-01-
15 15 4D0ZA11062 single needle lock stitch pcs 1
1803-01-
16 16 4D0ZA10947 single needle lock stitch pcs 1
1803-01-
17 17 BJ1313047 4 thread over lock pcs 1
1803-01-
18 18 4D0ZA11071 single needle lock stitch pcs 1
1803-01-
19 19 4D0FF16772 single needle lock stitch pcs 1
1803-01-
20 20 4D0ZA11053 single needle lock stitch pcs 1
PREPARED BY EYOB NGUSE
 INTERNSHIP AT GMM GARMENT PLC 2008E.C/2016 G.C

1803-01-
21 21 4D07A11060 single needle lock stitch pcs 1
1803-01-
22 22 4D0FE16456 single needle lock stitch pcs 1
1803-01-
23 23 4D07A11068 single needle lock stitch pcs 1
1803-01-
24 24 8M0ZB21750 5 thread over lock pcs 1
1803-01-
25 25 8M0YM22721 4 thread over lock pcs 1
1803-01-
26 26 AJ1400216 cover stitch (inter lock) pcs 1
1803-01-
27 27 8MAYJ11007 cover stitch pcs 1
1803-01-
28 28 1053198 button attatch pcs 1
1803-01-
29 29 2L0YM00455 button hole pcs 1
1803-01-
30 30 4D0ZA11055 single needle lock stitch pcs 1
1803-01-
31 31 4D0ZA11064 single needle lock stitch pcs 1
1803-01-
32 32 4D0Z10946 single needle lock stitch pcs 1
1803-01-
33 33 4D0FE16562 single needle lock stitch pcs 1

ITE
M UO
No A/C Code Serial No Description M Qty
1803-01-
34 34 4D0ZA11074 single needle lock stitch pcs 1
1803-01-
35 35 4D0ZA11077 single needle lock stitch pcs 1
1803-01-
36 36 090901674 5 thread over lock pcs 1
1803-01-
37 37 BJ1313046 4 thread over lock pcs 1
1803-01-
38 38 4D0ZA10959 Sewing Machine pcs 1
1803-01-
39 39 4D0ZA10911 single needle lock stitch pcs 1
1803-01-
40 40 4D0ZA11070 single needle lock stitch pcs 1
1803-01-
41 41 4D0ZA11072 single needle lock stitch pcs 1
1803-01-
42 42 090901695 5 thread over lock pcs 1

PREPARED BY EYOB NGUSE

 INTERNSHIP AT GMM GARMENT PLC 2008E.C/2016 G.C

1803-01-
43 43 4D0ZA11044 single needle lock stitch pcs 1
1803-01-
44 44 4D0ZA11076 single needle lock stitch pcs 1
1803-01-
45 45 2L1YM01386 bar tuck pcs 1
1803-01-
46 46 7033010257 cover stitch (inter lock) pcs 1
1803-01-
47 47 4D0ZA11052 single needle lock stitch pcs 1
1803-01-
48 48 8M4YJ11003 cover stitch pcs 1
1803-01-
49 49 4D0ZA11063 single needle lock stitch pcs 1
1803-01-
50 50 090901901 5 thread over lock pcs 1
1803-01-
51 51 4D0EF16781 single needle lock stitch pcs 1
1803-01-
52 52 090901937 pcs 1
1803-01-
53 53 0526044 cover stitch pcs 1
1803-01-
54 54 0513862 cover stitch pcs 1
1803-01-
55 55 1397040 single needle lock stitch pcs 1
1803-01-
56 56 3444477 single needle lock stitch pcs 1
1803-01-
57 57 1306863 single needle lock stitch pcs 1
1803-01-
58 58 3061011794 single needle lock stitch pcs 1
1803-01-
59 59 M0517292 feeddog arm removed pcs 1
1803-01-
60 60 422-100 bt removed pcs 1
1803-01-
61 61 58016 binder pcs 1
1803-01- 142-131/6-
62 62 263/1B pcs 1
1803-01-
63 63 493405 single needle lock stitch pcs 1
1803-01-
64 64 1305193 single needle lock stitch pcs 1
1803-01-
65 65 557-34 eyelet pcs 1
1803-01-
66 66 103-95 3 thread over lock pcs 1

PREPARED BY EYOB NGUSE

 INTERNSHIP AT GMM GARMENT PLC 2008E.C/2016 G.C

1803-01-
67 67 M6501125 3 thread over lock pcs 1
1803-01-
68 68 J10216078 MH (CHAIN STITCH) pcs 1
1803-01-
69 69 J0216076 MH (CHAIN STITCH) pcs 1
1803-01-
70 70 single needle lock stitch pcs 1
1803-01-
71 71 446250 single needle lock stitch pcs 1
1803-01-
72 72 135 3 thread over lock(remold) pcs 1
1803-01-
73 73 103-90 3 thread over lock (remold) pcs 1
1803-01-
74 74 3 thread over lock (remold) pcs 1
1803-01- 627-00-200-
75 75 2co-31 4 thread over lock(remold) pcs 1
1803-01- 627-00-200-
76 76 2co-45 4 thread over lock (remold) pcs 1
1803-01- 4 thread over lock (remold)
77 77 11-65-01-125 brother pcs 1
Table 1 machine list of gmm garment

ITEM
No Model Serial No Description UOM Qty
1 DDL8700 4D0DF17300 One needle lock stitch Pcs 1
2 DDL8700 4D0DF17336 One needle lock stitch Pcs 1
3 DDL8700 4DOEA28640 One needle lock stitch Pcs 1
4 DDL8700 4DOEA28683 One needle lock stitch Pcs 1
5 DDL8700 4DOEA28946 One needle lock stitch Pcs 1
6 DDL8700 4DOEA28589 One needle lock stitch Pcs 1
7 DDL8700 4DODF17638 One needle lock stitch Pcs 1
8 DDL8700 4DOEA28616 One needle lock stitch Pcs 1
9 DDL8700 4DOEA28632 One needle lock stitch Pcs 1
10 DDL8700 4DOEA28939 One needle lock stitch Pcs 1
11 DDL8700 4DOEA28957 One needle lock stitch Pcs 1
12 DDL8700 4DODF17263 One needle lock stitch Pcs 1
13 DDL8700 4DOEA28486 One needle lock stitch Pcs 1
14 DDL8700 4DOEA28944 One needle lock stitch Pcs 1
15 LH3568A 3L3DG00662 Two needle lock stitch Pcs 1
16 LH3568A 3L3DG00663 Two needle lock stitch Pcs 1
17 Mo6716s 8MODK13710 Five thread over lock Pcs 1
18 Mo6716s 8MODK13684 Five thread over lock Pcs 1
19 Mo6716s 8MODK13700 Five thread over lock Pcs 1
20 Mo6716s 8MODK13697 Five thread over lock Pcs 1

PREPARED BY EYOB NGUSE

 INTERNSHIP AT GMM GARMENT PLC 2008E.C/2016 G.C

21 Mo6716s 8MODK13698 Five thread over lock Pcs 1

22 Mo6714s 8MODK11043 Four Thread Over lock Pcs 1
23 Mo6714s 8MODK11033 Four Thread Over lock Pcs 1
24 Mo6714s 8MODK11039 Four Thread Over lock Pcs 1
25 Mo6714s 8MODK11051 Four Thread Over lock Pcs 1
26 Mo6714s 8MODK11045 Four Thread Over lock Pcs 1
27 Mo6714s 8MODK11054 Four Thread Over lock Pcs 1
FC1511-
28 400 46065 Embroidary Machine Pcs 1

NEW SNLS MACHINE

SN. MODEL SR.NO.
1 MH-481 3MIJH01244
2 MH-481 3MIJH01247
3 MH-481 3MIJH01243
4 MH-481 3MIJH01256
5 MH-481 3MIJH01255
6 MH-481 3MIJH01249
7 DLNS410-N-7 PD3JF00024
8 DLNS410-N-7 PD3JF00018
9 DDL-9000B-MS 8DOJF03110
10 DDL-9000B-MS 8DOJF03112
11 DDL-9000B-MS 8DOJF03114
12 DDL-9000B-MS 8DOJF03099
13 DDL-9000B-MS 8DOJF03099

NEW 4 THREAD OVERLOCK MACHINE

SN. MODEL SR.NO.
1 MO-6714DA 8MOHL00310
2 MO-6714DA 8MOHL00334
3 MO-6714DA 8MOHL00307
4 MO-6714DA 8MOHL00307
5 MO-6714DA 8MOHL00317
6 MO-6714DA 8MOHL00306
7 MO-6714DA 8MOHL00305
8 MO-6714DA 8MOHL00321
9 MO-6714DA 8MOHL00296
10 MO-6714DA 8MOHL00302
11 MO-6714DA 8MOHL00300
12 MO-6714DA 8MOHL00311
13 MO-67145 8MOHE15058(UBT)B.L
14 MO-67145 8MOHE15047(UBT)B.L

PREPARED BY EYOB NGUSE

 INTERNSHIP AT GMM GARMENT PLC 2008E.C/2016 G.C

15 MO-67145 8MOHE15056(UBT)B.L
16 MO-67145 8MOHE1569(UBT)B.L

NEW COVER STITCH MACHINE (UBT)

S.N MODEL S.R NO.
1 MF-7923 8M4JH00856
2 MF-7923 8M4JH00882
3 MF-7923 8M4JH00861
4 MF-7923 8M4JH00863
5 MF-7923 8M4JH00850
6 MF-7923 8M4JH008879
7 MF-7923 8M4JH00886
8 MF-7923 8M4JH00865
9 MF-7923 8M4JH00855
10 MF-7923 8M4JH00881

CUTTING SECTION
BAND KNIFE MACHINE
1 778SL/3031 KLD749S5L
DRILLING MACHINE
1 550 2949
END CUTTER MACHINE
1 ECS
HEMMING CUTTER MACHINE
1 TY-911A 1406583
STRAIGHT KNIFE
S.N MODEL S.R NO.
1 629X F87132
2 3 14102148
3 SW-3 9545
Table 2 machine list of cutting section

FINISHING SECTION
STEAM BOILER MACHINE
S.N MODEL S.R NO.
1 NHEB9ST 1401002
2 PVT 38 11H32488
3 PVT 38 11H32490
4 NO530 NF1055
5 N6FABBIO4637
IRONING TABLE
S.N MODEL S.R NO.

PREPARED BY EYOB NGUSE

 INTERNSHIP AT GMM GARMENT PLC 2008E.C/2016 G.C

1 FBA-Y-6512 672063
2 FBA6512 P17016
3 FBA6512 P1702017
4 167-761 O3773
5 167-701 O3772
Table 3 machine list of finishing section

1.3 Products
GMM developed its image in the garment industry with products such as shirts, polo
shirts, rain jackets and even touched the home fashion sectors. Currently, GMM is one
of the major producers of polo shirt for the export market. Home fashion with a
unique and authentic Ethiopian designs for interior was also part of our major
projects.
We are taking traditional Ethiopian textiles out of our limitations by bringing state-of
the art technology to us without compromising our unique beauty. Using the long
stable Ethiopian cotton with its superior qualities as our primary input, we produce a
range of high quality textiles both for home interiors and garments.

Figure 3 product of gmm garment

PREPARED BY EYOB NGUSE

 INTERNSHIP AT GMM GARMENT PLC 2008E.C/2016 G.C

Figure 4product mix of gmm garment

1.3.1 Customers
We have successfully exported and continue to export finished garments to the
following companies.
 Blein Dco of Germany

 Frank walder of Germany

 TA s.r.l. of Italy
 Ereea of Italy
 Marina Kaneva of London
 NEIA of USA,
 Brany’s Store of USA
 Lemlem of USA
 Superior Uniform Group of USA
Prospective customer
 H&M of Sweden

New Contracts
 Superior Uniform Group USA
 Golden Touch Group USA

1.4 Departments
1.4.1 Store room

PREPARED BY EYOB NGUSE

 INTERNSHIP AT GMM GARMENT PLC 2008E.C/2016 G.C

Figure 5 store room of GMM garment

Figure 6 fabric store of gmm garment

Store Is the place where items may be accumulated or materials, stocks and supply’s
where kept. The Gmm garment store there are raw materials where they kept to
transfer in to other departments. The Gmm garment company is in further expansion
so the warehouse is used for store purpose.

PREPARED BY EYOB NGUSE

 INTERNSHIP AT GMM GARMENT PLC 2008E.C/2016 G.C

Materials that are located in store.

Trims
• Fasteners
Buttons, zippers, snaps, loops, d-rings, buckles
• Decorative
Linear Trims, elastic, shaped edges, ruffles, Braids, ribbons,, embroidery, patches
• Others-belts, pockets
• Velcro
• Lighter
• Packing materials
• Pattern making tools
• Labels
• Office tools
• Shelf’s (pallets)
• Ladder
• Tag pun
• Weight balance
• Washing materials
• Store room tools and computers etc

1.4.2 Designing, pattern making and sampling

Designing is the art making design for textile goods or clothes.
Pattern making is the method of pattern development. It uses engineering precision to
establish pattern lines directly on pattern paper by using body measurement and ease
allowance.
Pattern making tools
- Devante front
- dos back
- Seassor
- Ruler
- l shape
- tracing wheel
- weighting load
- Pencil
- tailoring chalk
- Notches
- Curve ruler
- Clipper
- Stapler
- Stapler realizer
- Transparent paper
- Table etc.
The Gmm garment is in the further expansion program so the designing and pattern
making room is don’t have its own room. The company most of the time follows
export market. Due to this reason the buyer itself will give the pattern order in two
ways
1 when the order is come the buyer will give the basic pattern.

PREPARED BY EYOB NGUSE

 INTERNSHIP AT GMM GARMENT PLC 2008E.C/2016 G.C

Figure 7 pattern making tools of gmm garment

Sample making
The gmm garment have a separate room for the sample making in the further
expanshion.so the sample that the buyer asked is done in the sampling section. If there
is any missing procedure the 2nd party auditor will correct the sample.

GMM
GARMENT PLC

Customer Name;

Description

Composition

Style Number;

Sample size;

Color;

Season;

Weight;

Date ;
Table 4 Sample card

PREPARED BY EYOB NGUSE

 INTERNSHIP AT GMM GARMENT PLC 2008E.C/2016 G.C

Figure 8 sampling room and sample card

1.4.3 Cutting room

Working procedures in cutting room

Delivering of fabric
from store

Relaxation of fabric

Spreading the fabric

Lay checking

Laying of marker

Checking of age

Cutting the lay

PREPARED BY EYOB NGUSE

 INTERNSHIP AT GMM GARMENT PLC 2008E.C/2016 G.C

Cut panel inspection

Sorting, numbering

Bundling

Deliver to sewing room

1.4.4Marker making
Marker making is the arrangement of pattern pieces by tracing the pattern on
marker paper.
Marker modes – nap one way, nap up and down, nap either way
The gmm garment company accept all the marker from the buyer. That means the
buyer send the hard or soft copy of the makes marker with the use of lectra
software which is the most efficient way to save fabric.

Figure 9 marker making

PREPARED BY EYOB NGUSE

 INTERNSHIP AT GMM GARMENT PLC 2008E.C/2016 G.C

1.4.5 Spreading
The process of rolling out layer after layer of cloth, smoothly without wrinkles, in
such a manner that the selvedge on one side of the cloth is straight, and parallel to
that edge of the cutting table.
Ply is a single element of fabric.
Lay is a group of plays

1.4.6Cutting
Cutting of fabric in to necessary pattern shapes is the first stage in the garment
manufacturing process. The cutting room has a greater effect on excessive
manufacturing costs than any other department concerned with the actual
production of garments.

Figure 10 cutting

1.4.7Bundling
Tying of parts or components by grouping components and size categories.
Bundling information
- Bundle
- Cut
- Lot
- Size
- Qty
- Color
- Part name

PREPARED BY EYOB NGUSE

 INTERNSHIP AT GMM GARMENT PLC 2008E.C/2016 G.C

1.4.8 Ticketing
Giving a number for the garment pieces.by ticketing equipment. Small part
numbering
Give number and sort out the small parts like collar and cuffs. (i.e. cuff measured
by cuff measurement chart.)

Figure 11 Ticketing material

1.4.9 Fusing
The process of making crease on the components which need additional
strength.by using inter facing. Then it will transfer to the band knife machine.

Figure 12 Fusing machine

PREPARED BY EYOB NGUSE

 INTERNSHIP AT GMM GARMENT PLC 2008E.C/2016 G.C

1.4.10 Embroidery room

Figure 13 embroidery machine of gmm garment

Figure 14 embroidery samples

This department is also found in the ground floor, receives garment bundle from
cutting room. They can make different type of embroidery design according to
customer specification& the design is come from costumer.
Available machines;
 Thread Winder Machine
 Electronic ten head Automatic Embroidery Machine

Working procedure Receive bundles from cutting room

Mark embroidery placement

PREPARED BY EYOB NGUSE

 INTERNSHIP AT GMM GARMENT PLC 2008E.C/2016 G.C

Lay on the head of embroidery machine

Form (set) the design on the computer

Start to make design

1.4.11 Sewing room

Figure 15 sewing section of gmm garment

The company sewing section is arranged in progressive bundle production system.
The progressive bundle system (PBS) of garments production gets its name from the
bundles of garment parts that are moved sequentially from operation to operation.
This system, often referred to as the traditional garments production system, has been
widely used by garments manufacturers for several decades and still is today. The
Gmm garment have three lines. Two lines produce garment and the other line is the
training center and sampling line.

PREPARED BY EYOB NGUSE

 INTERNSHIP AT GMM GARMENT PLC 2008E.C/2016 G.C

Sewing is the process of stitching fabric on the seam line which is used to change the
2D fabric in to 3D garment which need to be fit the body of the human. Garments are
sewn in an assembly line, with the garment becoming more complete as it progresses
down the sewing line. Sewing machine operators receive a bundle of cut fabric and
repeatedly sew the same portion of the garment, passing that completed portion to the
next operator. For example, the first operator may sew the collar to the body of the
garment and the next operator may sew a sleeve to the body. Quality assurance is
performed at the end of the sewing line to ensure that the garment has been properly
assembled and that no manufacturing defects exist. When needed, the garment will be
reworked or mended at designated sewing stations. This labor-intensive process
progressively transforms pieces of fabric into designer garments
GMM has three production lines each line contains 26-28 machines depend on the
design and it has 89 operators, 11 line helpers, 3 supervisors and 1 sample maker and
1 dispatcher
Capable of producing 74 pcs per hour each line and 1800 pcs per day all lines depend
on the design
GMM is capable of producing 561600 pcs of garment per annum
Number of operator in sewing room
Capacity = number of operator x working time x efficiency
Efficiency = operator performance x factory performance x absenteeism.
Capacity = 90 *8.15=733.5
Capacity= 733.5*60*0.6/17 =1554 pieces per day

1.4.12 Quality inspection

Inspection `
Activities, such as measuring, examining, testing, gaging one or more characteristics
of a product or service, and comparing these with specified requirements to determine
conformity.
Final Inspection
Final inspection consists of inspecting finished garments from the consumer’s point of
view; size measurement; form fitting (putting garments on the proper-size
mannequins to see if they properly fit the labeled sizes); and live modeling if
necessary (again to see if the garments properly fit the labeled sizes).
Final inspection may occur before or after garments are packed in polybags and
boxes. If it is done after garments are packed, then proper size and style markings on
the package can also be checked. In any case, there should be a list of points to be
checked in a garment, including a table of finished measurements.
The GMM garment company is focused on quality. The company have the license of
international quality organization

Figure 16 iso 9001 of gmm garment

PREPARED BY EYOB NGUSE

 INTERNSHIP AT GMM GARMENT PLC 2008E.C/2016 G.C

ISO 9000 - Quality management

• The standards provide guidance and tools for companies and organizations who
want to ensure that their products and services consistently meet customer’s
requirements, and that quality is consistently improved.

• ISO 9001
• Quality assurance in design/development, production, installation, and servicing.

Figure 17 quality checking

1.4.13 Ironing
• Removal of unwanted creases from garment or piece of cloth or make deliberate
crease on garment or piece of cloth using hot iron or other device”
• Pressing is the application of heat, moisture and pressure to shape, mold and crease
fabrics or garment.

PREPARED BY EYOB NGUSE

 INTERNSHIP AT GMM GARMENT PLC 2008E.C/2016 G.C

Figure 18 Ironing machines

1.4.14 Folding and packing

Folding is the process of bending the cloth over so that it comes in contact with
itself.
The process of pack the garment in the packaging material Mostly Plastic (poly
bags) then after that cartooning the cloth, finally give information to the carton by
bar tags then transfer to ware house.

Figure 19 folding and packing

PREPARED BY EYOB NGUSE

 INTERNSHIP AT GMM GARMENT PLC 2008E.C/2016 G.C

1.4.15 MAINTENANCE IN GMM CAMPANY

Figure 20 maintenance room of gmm garment

Preventive maintenance And break down maintenance
Preventive maintance type of maintance done by the action of maintain the machine
when the machine is fail in the line
Such as oiling, greasing, cleaning, inspection
Oiling: oiling takes place by identifying the machine type after this oiling done daily,
weekly and monthly.
Greasing: This type of inspection is done in the needle part of the machine.
INSPECTION: It is proses of identifying the machine detirer part to repairer’s or
restore the machine to its normal condition
Proactive maintance (opera fishing) : one machine isfaileafter repairing the failed part
using that part until check wetherthere is loosen part or whether there e is machine
adjusting part through vibration.
Common maintance problem
This problem slows the production of the line that raise operators training these are:
Machine break down

PREPARED BY EYOB NGUSE

 INTERNSHIP AT GMM GARMENT PLC 2008E.C/2016 G.C

1.5 Warehouse
Is the store that the finished goods kept until shipment takes place. The company uses
two container as warehouse.

Figure 21 warehouse of gmm garment

Power system in the company
The gmm garment have direct installation of electric power that planted for the
Industry zone located in the area. If the power is not available they have a generator
which turn on automatically. The boiler also available in the company for the
machines which need a boil water to operate like the finishing machines. Additionally
There is an air compressor for the machines which are pneumatic.

Figure 22 power consumption

PREPARED BY EYOB NGUSE

 INTERNSHIP AT GMM GARMENT PLC 2008E.C/2016 G.C

Waste disposition
The gmm garment company sell the waste garment in their kilo grams because they
can’t use the fabric of the buyer for other purpose.

Figure 23 waste disposition, water and toilet

The company have toilet, cafe but with small size they have consider the size of the
café and toilet also shower in the further expansion project. Also the water is linked to
the main water line but if there is a shortage of water they have three water tankers.

PREPARED BY EYOB NGUSE

 INTERNSHIP AT GMM GARMENT PLC 2008E.C/2016 G.C

2 Chapter two
Final project on productivity improvement by reducing rework

2.1 Introduction
GMM Garment P.l.c is driven by strong values, advancing with quality and efficiency
.We strive to become the leading garment manufacturing company both locally and
internationally while being socially compliant. Professionalism is our belief we value
in all our products. GMM Garment is a private limited company, established in Addis
Ababa, Ethiopia, by three women entrepreneurs. It was established in September 2004
G.C. Their aspirations were to reveal to the world the beauty and rich heritage of
Ethiopia through their product, while contributing to the empowerment of women and
the economic development of their country. Our factory is located in Nefas Silk/Lafto
Sub-city, Kebele 12, Block 15, in Lebu Industrial Zone. It has some 2,000 meter
square of land leased from the government. The production area is housed on 500
square meters of modern building. GMM is mostly engaged in the production of
different kinds of garment for the export market. Currently the factory has over 170
skilled employees working on full time. The current capacity is 270,000 pieces per
year.
As the global economic condition changing in a rapid motion, generally in an
industry more focus is given on profit margin, customer demand for high quality
product and improved productivity. In garment manufacturing, it is usual few rejected
garments after shipment. Reason, most of the manufacturers believe that garments are
soft goods and non-repairable defect may occur due to low quality raw materials or
faulty process or employee casual behavior. However, factory must have check points
to control over this issue. There is no ready-made solution that can reduce rejection
percentage overnight. Each order is unique. But this paper works suggest how to
handle this issue and bring down rejection rate to minimum. We see a lot of rejected
garment after shipment. Most of the organization termed these garments as rejected
because those garments can’t be
repaired by any means. Reworks in the garments industry is a common works that
hampers the smooth production rate and focus poor quality products having an impact
on overall factory economy. Minimization of reworks is a must in quality and
productivity improvement. Rework is a vital issue for poor quality product and low
production rate. Reworks are the non -productive activities focusing on any activity
that customer are not willing to pay for. Non-productive activities describe that the
customer does not consider as adding value to his product. By reacting quicker in
minimization of reworks to make a product as per customer demand with expected
quality, the company can invest less money and more costs savings.
Keyword: Productivity improvement by reducing rework
Productivity is: The Ratio between OUTPUT and INPUT

PREPARED BY EYOB NGUSE

 INTERNSHIP AT GMM GARMENT PLC 2008E.C/2016 G.C

Figure 24 productivity chart

Traditional Approach
PRODUCTIVITY = OUTPUT
INPUT
Lean Approach
PRODUCTIVITY = VALUE
TIME
According to V.K.R. Menon, productivity implies development of an attitude of mind
and constant urge to find better, cheaper, easier, quicker and safer means of doing a
job, manufacturing a product and providing service.
Re work
Re work is one of Eight Deadly Manufacturing Wastes
 Overproduction
 Inventory
 Waiting
 Motion
 Transportation
 Rework (Defective products)
 Over processing
 Unused employee creativity

Waste of Rework (Defective products)

Rework of production of goods and service inconsistent with customer requirements
Problems: Loss of materials, labor, and capacity at bottleneck operation

Causes: Poor training, non-standard operations, difficult or lack of quality at the

source, deficient planned maintenance, and Customer needs not understood, defective
information.

PREPARED BY EYOB NGUSE

 INTERNSHIP AT GMM GARMENT PLC 2008E.C/2016 G.C

2.2 Problem statement

In GMM garment P.L.C, there are different problems in the sewing section
(production room) such as UN scheduling operator training, unskilled operator
,number operator absentees increase, number of line supervisors decrease due to this
the root cause of the problem is not knowing, machine problem ,operator trained for
specific operation for this reason operators cannot handle the operation (operators
have not multi -skilling)due to this the amount of rework is increase, ,lack of
communication with in the company ,lack of operator arrangement with in the sewing
lines (lack of technical person that decrease/ minimize the problem ,machine
adjustment, new operator inter to the production lines without adapt the training
course. . When increasing productivity improvement and reduce rework within the
company they should be series follow up and see the above problems every parts of
the product process step by step carefully. Hence, factory can make more profit
through productivity improvement reducing rework. I have mentioned a problem
where you can focus and start working on improving productivity and reducing
rework.

2.3 Objective
2.3.1 General Objective
The general objective of this project is minimizing rework or eliminating rework on
short sleeve raglan polo shirt with pocket and improving productivity in the GMM
garment P.L.C between the linkages of production manager’s and lines supervisors.

2.3.2 Specific Objective

o To decrease the amount of rework produce per hour time.
o To find out the root cause of rework in GMM garment P.L.C
o Identify the source of problem.
o Regular material flow
o Better adjustment and reduce the re-work.
o Utilize labor efficiently
o Utilize space efficiently
o Maximum output at the desired time

2.4 Scope of the Study

This project is done on GMM garment factory that found in Addis Ababa Ethiopia,
specifically called Lebu Industrial Zone. The project focuses only on productivity
improvement reduce rework through work aid, operator training, and preventive
maintance in the sewing lines GMM garment factory. It is done on short sleeve raglan
polo shirt with pocket.

PREPARED BY EYOB NGUSE

 INTERNSHIP AT GMM GARMENT PLC 2008E.C/2016 G.C

2.5 Limitation of the Project

While doing the project there are some limitations. Those are lack of information
from related person/supervisors, and there is no written full information document
concerning this problem in the company.

2.5.1 Significance of the Project

The significance of the project is that if all the principles of the project are applied
correctly in GMM garment factory. The following results are being shown;
o Improve productivity reducing rework by operator training and preventive
maintenance .
o create new line layout of operator if necessary

Reduce the amount of fatigue doing in rework, utilize space efficiently/good material
handling
Reduce or Eliminate rework produce within the GMM sewing lines.
Increase productivity in the production line per hour the same time reduce rework in the
production lines

2.6 Literature Review

Productivity in the Workplace is when it comes to increasing productivity in the
workplace, there are a lot of things that you can do. There are really two aspects to
workplace productivity. The first is in a group setting such as if you are running a
company. The success of your company will depend on just how productive your
team is. The second is your own productivity. This is especially true if you work for
yourself. Thefreedom to do what you want can be liberating but at the same time, it
can also lead to laziness and inefficiency. Let’s look at some of the things that you
can do to help increase productivity in both settings.
The first thing we will look at is personal productivity. Whether you work at the
company office or you work from your home office, running a business can be quite
exciting and is something many people dream about doing. Although you have the
luxury of doing what you please, if you’re not productive with your time, you will
quickly learn that this is a big problem. Many people believe that running a business
is easy for whatever reason but it isn’t. It’s not that the mechanics is difficult or
anything, it’s the time management and discipline that’s the toughest part. If you can
get yourself to do what you need to do at exactly the time you told yourself you would
do it, then you’ll be in good shape. The more productive you are, the more you will
produce (greater outcome), and the more you produce, the more money you will
make. Not everyone is set out to be a business owner. Most people would really be
better off being told what to do; it’s the only way to get them to consistently produce.
So what are some things that you can do to help increase productivity in the
workplace? Here are a couple of tips.
1. Have the right daily plan.
The key is to know what sort of outcome you want each day or week and to do
whatever it takes to make it happen. Before you start creating to-do lists, you must

PREPARED BY EYOB NGUSE

 INTERNSHIP AT GMM GARMENT PLC 2008E.C/2016 G.C

first pinpoint the tasks that will yield the most results. Many people will get involved
in what is known as “busy work.” This is basically things that you do that makes you
think you’re busy but in actuality, doesn’t really do much for your bottom line.
In every business, there are about 20% of things you can do that will make up 80% of
your results. If you are running a service business then most of your time needs to be
obtaining jobs. If your business is about making sales then most of your time needs to
be spend face to face with a potential client. If you have a product based business,
then the majority of your time needs to be spend on attracting customers. Unless you
know what the most important tasks are in your business, it’s easy to end up spending
a lot of time doing things like “preparing” to work, checking emails, and other things
that won’t make you money.
2. Have deadlines.
One of the easiest things to do when running your own business is putting things off.
Since there isn’t a boss pressuring you to get your work done, it’s easy to “do it later”.
This habit or mentality will probably cause the death of your business. In order to
overcome this, you will need to set some deadline for yourself, just like in a job
setting. By doing this, you will be more focused and will have a much better chance
of completing what you need to get done. This will also cause you to allocate your
time more wisely as well.
3. Improve time management.
If you can get more done with the same amount of time, then you will make more
money. Many people don’t use their time efficiently. In order to do this, you need to
do followthe first two suggestions. Once you know what to focus on and have a
deadline, you will then need to manage your time better. Workplace productivity
comes down to how much you can get done in 15 minutes. It’s easy to blow 15
minutes doing something pointless but if you can get into the habit of getting as much
as you can possibly get done in a 15 minute period, you’ll be surprised of how much
you can get done when you expand that time frame out to an hour.
4. Outsource.
If the goal is to produce, then you might need to do some outsourcing to increase
productivity. Although there’s a handful of tasks that will make up the majority of
your results, let’s face it, the other stuff needs to get done as well. This time
consuming tasks can be outsourced to someone else. This will help free up your time
so you can spend it to work on more important things.
In the next article, we’ll talk more about how to improve productivity in the
workplace as in a company setting. Knowing how to get your employees to be
productive could help your company grow and beat out the competition. Now
knowing how to do this can cause you to lose money and even go under./productivity
and work study text book.

2.7 METHODOLOGY
Methodology is the systematic theoretical analysis of the method applied to a field of
study. It comprises the theoretical analysis of the body of methods and principles
associate with a branch of knowledge. Typically it encompasses concept such as
paradigm theoretical model, phase, quantitative or qualitative techniques. From the
definition above I visualize different methods of the project analysis. To complete this
project report data collection methods like direct observation, interview and reviewing

PREPARED BY EYOB NGUSE

 INTERNSHIP AT GMM GARMENT PLC 2008E.C/2016 G.C

documentation are used. Observation is done within the garment section. Then I have
identified the problems which are reducing rework and improving productivity on
short sleeve raglan polo shirt with pocket and this project can improve productivity
and reducing rework on short sleeve raglan polo shirt with pocket of garment with
identifying the main problems..
Another way informal interview (oral interview) are done for some responsible
persons who are engaged in the quality checker .They are operators who perform the
activities, supervisors who supervises the operator’s peoples in the management
position.
This methodology includes:
- Primary data
- Secondary data
- Data analysis and data collection

2.7.1 DATA COLLECTION Method

When I collect the data for the project the two data collection methods are appropriate

2.7.1.1 Primary data collection methods

Interview and direct observation
Interviews:

Direct Observation
Direct observation is used as a means to study and assess the existing rework and to
collect some essential data.
The design of the interviews was based on the project objectives Interview was the
major instrument I used in orders to collect some information. And I asked those
questions to whom it concerned to quality checker and operator and supervisors were
involved. It is also used to gather additional information to daily activities.
Interview for the quality checker

don’t transfer to the quality area so what is the cause for this

Problem.

carelessness; the supervisor numbers shortage, both supervisor and operators

communication deficiency, line supervisor and operators are not clearly communicant
to each other the rework so the operators sew the garment carelessly, by the cause of
this they cannot improve productivity and increase rework .

2.7.1.2Secondary data

PREPARED BY EYOB NGUSE

 INTERNSHIP AT GMM GARMENT PLC 2008E.C/2016 G.C

2.7.2 Data Collections and Analysis

Improving productivity reduce rework for 3days follow up sheet cause study on short
sleeve raglan polo shirt with short sleeve

2.7.2.1Operation breakdown
no. machine
s/n operation operator type
1 placket attach 2 SNLS
2 make placket box 2 SNLS(UBT)
5 join shoulder 1 SNLS
6 join collar tip to body 2 SNLS
7 collar attach 1 SNLS
8 binder attach 1 SNLS
9 upper placket stitch 1 SNLS
10 lower placket stitch 1 SNLS
upper placket top
11 stitch 1 SNLS
13 close collar binder 2 SNLS
14 sleeve attach 2 OL
16 join side seam 2 OL
17 bottom hemming 2 CS
18 make button hole 1 BH
19 attach button 1 BA
20 tack sleeve cuff 1 BT
TOTAL no. of operator 23
TOTAL no. of helper 9
Total man power 32
Table 5 Operation break down

operation Machine type Defect type cause

Pocket attaching Snl skipped stich machine
Graze/armhole Snl Puckering $labeling Machine
sewing $operator
Collar Snl labeling operator
Sleeve attaching Two needle Skipped stich machine
machine
bottom Heming two needle Skipped stich machine
Placket Bar tak machine Bar tack not sewing operator

PREPARED BY EYOB NGUSE

 INTERNSHIP AT GMM GARMENT PLC 2008E.C/2016 G.C

Placket Snl Boxing thread not operator

joining
Pocket Snl Allow of sewing is operator
high
Graze Snl Sewing not straight operator
Boxing Snl strihgting Operator
Button Button buttonhole operator
attach machine
Placket Snl Not equal left and operator
right side
Box Snl slanting operator
Collar Snl Skipped stich operator
Placket Snl Not striating operator
Placket Snl Skipping stich operator
Graze Snl skipping operator
Collar Snl labeling operator
Graze Snl slapping operator
buttonhole Button hole damage operator
machine
Box Snl Not striating operator
Placket Snl Forming circles operator
Button Button attach marking operator
machine
Collar Snl loosing operator
Collar Snl labeling operator
Collar Snl damage operator
labeling Snl Not centering operator
Button attaching Button attaching marking operator
machine
Collar Snl loosing operator
Collar Snl labeling operator
Collar Snl damage operator
labeling Snl Not centering operator
buttonhole Bham marking operator
Collar Snl puckering operator
Sleeve hemming Two needle Skipping stich machine
Graze Snl Not striating operator
Sleeve hemming Two needle jumping machine
machine

PREPARED BY EYOB NGUSE

 INTERNSHIP AT GMM GARMENT PLC 2008E.C/2016 G.C

Box Snl loosing operator

Selves attach Snl not working operator
labeling Snl Not centering Operator
Graze Snl Skipped stich operator
collar Snl Skipped stich operator
placket Snl skipped stich machine
Placket t Snl Not straight operator
Box Snl Beyond with the operator
center
Box Snl not equal operator
placket Snl Not strighting operator
Bottom hemming two needle Skipping stich machine
Collar Snl puckering operator
buttonhole Button hole Marking problem operator
machine
Sleeve hemming Overclock puckering machine
machine
Boxing Snl box uneven operator
Collar Snl Collar puckering operator
pocket Snl Pocket unequal operator
bottom Heming two needle Loosing/skipping machine
pocket Snl skipped stich machine
Box Snl skipped stich operator
placket Snl loosing operator
Box Snl box uneven operator
Placket Snl not sewing operator
Sleeve Snl Sleeve opening machine
bottom Heming Two needle Zigzag ing operator
machine
Collar Snl Collar puckering operator
bottom Heming Two needle bottom hole machine
P pocket attach Snl Mar king Operator
vent sewing Snl vent unequal operator
buttonhole Button hole marking Operator
machine
vent sewing Snl Turing point operator
collar attaching Snl Collar up and down operator
Collar binding Snl Skipped stich machine

PREPARED BY EYOB NGUSE

 INTERNSHIP AT GMM GARMENT PLC 2008E.C/2016 G.C

Sleeve hemming two needle Not striating operator

side seam Snl Not strighting operator
Collar marking Sn l centering operator
La bling $placket Snl slanting operator
Sleeve topstitch Snl stritghing operator
box sewing interlock puckering machine
Button placement Bm marking operator
Button marking operator centering operator
bottom Heming Two needle skipped stich machine
Button attach Button attach loosing operator
machine
NO
1 Machine 6 7.5%
2 Operator 66 82.5%
3 work aid 8 10 %
Table 6 percentage categorization of the defect
The obvious observation here is that the differences are not significant. The largest
bulk of the rework are caused by human errors.
From studies made by various days it is evidence that most rework is occurred in
operators
With these guidelines, reworks are analyzed to determine their origins. A
collection of such dates will help in doing the root cause analysis. The reworks are
classified based on their types. A Pareto chart is prepared to show the cause category
with the highest frequency of occurrence.

Chart Title

machine operator working aid

Figure 25 pie chart of the defect category

PREPARED BY EYOB NGUSE

 INTERNSHIP AT GMM GARMENT PLC 2008E.C/2016 G.C

Secondary data
The secondary data taken from the feedback of the end line quality checker, online cloth
and third party audit.

Data analisis
daily quality controlling report format sewing

garment type polo shirt

defect type
date

placket edge

collar stitch

skip stitch

sleeve opening

bottom shape

box

placket

broken stitch

button

button ho

pkt posit

collar puc

oil stain

uneven align

overlock

vent

Reject

total rework

pass
6/5/2016 9 5 15 20 2 7 4 62 111
7/5/2016 5 1 9 8 2 5 1 31 83
9/5/2016 11 5 25 13 9 63 95
10/5/2016 23 15 6 49 23 11 15 23 165 405
11/5/2016 35 4 3 4 25 9 4 17 5 2 108 415
12/5/2016 42 4 7 5 12 6 14 9 3 102 380
13/5/2016 14 6 2 32 2 6 13 17 92 341
14/5/2016 25 16 35 19 4 2 15 1 117 437
16/5/2016 36 14 15 4 31 1 8 18 1 128 409
17/5/2016 1 13 55 15 18 13 1 116 401
18/5/2016 5 9 24 9 1 7 55 306
27/5/2016 13 9 14 36 56
28/5/2016 25 24 17 18 1 85 201
30/5/2016 36 37 16 55 49 8 201 244
31/5/2016 18 22 16 26 33 2 6 33 7 8 7 178 273
1/6/2016 8 17 43 23 42 66 25 26 2 26 278 229
2/6/2016 20 8 38 37 44 115 22 1 3 288 363
3/6/2016 8 2 39 24 20 39 25 1 158 367
4/6/2016 9 7 10 10 13 21 7 77 195
6/6/2016 19 4 11 16 27 12 7 18 114 329
7/6/2016 18 34 13 29 40 6 6 28 174 304
8/6/2016 16 12 9 18 28 14 1 98 420
9/6/2016 18 20 13 45 28 17 17 35 193 411
350 219 192 211 572 112 34 4 32 90 291 15 2919 6775

Table 7 data recording

PREPARED BY EYOB NGUSE

 INTERNSHIP AT GMM GARMENT PLC 2008E.C/2016 G.C

Days Total rework Total reject Pass

6/5/2016-9/6/2016 2919 15 6775
in 1 line

total rework
350

300

250

200

150

100

50

0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

Figure 26 line chart of rework

The above chart shows the total number of rework that recorded in one month

pass
500

400

300

200

100

0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

Figure 27 line chart of total pass

The above chart shows that the pass no o the garment from the inspection
Computing all

PREPARED BY EYOB NGUSE

 INTERNSHIP AT GMM GARMENT PLC 2008E.C/2016 G.C

final

7000
6000
5000
4000
3000
2000
1000
0
rework reject pass

Figure 28 final chart of rework, pass and reject

This chart shows that the rate of rework, reject and pass garment pieces
Based on the above data decide to work on the operator training module.

2.8 Result and discussion

The operator training module increase the skill of the operator and the supervisor.
The company able to understand the necessity of highly operator training .the
preventive maintenance schedule fully accepted by top managers and maintenance
department, as per the company have iso standard the schedule is fully approved by
the iso standard organization. To maintain the preventive maintenance schedule there
should be a following up format so I prepared a format for that so they must follow
the format. To be more competitive in the garment sector rework must be reduced so
the training and schedule is an essential part. The gmm garment have the mission to
be more competitive in the international market so its great opportunity for me to be
the part of the company.

2.9 Conclusion
The suggestive tools developed in this article cover a comprehensive series of aspects
in minimizing reworks in the sewing section of apparel industries by ensuring quality
production. The explosive growth of the GMM company in the country, however, has
not been enough supported by the growth of backward linkage facilities. So
manufacturing the quality product is mandatory to sustain in this global competitive
market. Quality is ultimately a question of customer satisfaction. Good Quality
increases the value of a product or service, establishes brand name, and builds up good
reputation for the garment exporter, which in turn results into consumer satisfaction,
high sales and foreign exchange for the country. The perceived quality of a garment is
the result of a number of aspects, which together help achieve the desired level of
satisfaction for the customer. However, we should bear in mind that 1% defective
product for an organization is 100% defective for the customer who buys that defective
product. The study clearly indicates that by eliminating non-productive activities like

PREPARED BY EYOB NGUSE

 INTERNSHIP AT GMM GARMENT PLC 2008E.C/2016 G.C

reworks in the apparel industries time as well as cost are saved by ensuring quality
production which have an important impact on overall factory economy.

PREPARED BY EYOB NGUSE

 INTERNSHIP AT GMM GARMENT PLC 2008E.C/2016 G.C

3 Chapter three
3.1 internship experience
The apparent ship time in the GMM garment company was very interesting the
experience which I get from this company divided in to three main parts

3.1.1 Practical skills

 Production controlling skill
 Team playing skil
 Problem solving skill
 Line supervisor skill
 Packing
 Embroidery section
 Cutting room
 Dispatching
 Quality room
 Maintenance
 New machine setting skill
 audit

3.1.2 Theoretical skill

 Human resource
 Marketing
 Planning and following up
 ISO training
 Work ethics and industry psychology
This internship made me to have a strong willing to work and how I do with work place
rule and regulation. With a strong willing to work ethic I am always committed to the
work and will stay until the task is complete.
The internship made me to avoid personal issues on work time and to keep my positive
attitude and I remember that I have smaller tasks to handle prior to my large, more
important ones.

3.1.3 Communication skill

 The next role of my working life
 Improving interpersonal communication skills
 Interview with the skilled and experienced operators
 Annual celebration of the company introduce me with employees
 Knowing the value chain in the garment sector

PREPARED BY EYOB NGUSE

 INTERNSHIP AT GMM GARMENT PLC 2008E.C/2016 G.C

RECOMMANDATION AND COMMENT

The Garment Engineering Program is imparting education in crucial areas of
technology application in garment manufacturing. After completion of 4th Year first
Semester study of this five year degree programme the students are exposed to four
months industry internship with leading garment manufacturing organizations all over
Ethiopia as a part of course curriculum. Then we have passed our 4 moth in the gmm
garment . in this time we have get a lot of expriance in both practical and theoretical
aspect.we like to give some comment and recommendation based on the time we
passed hear.
Comment and recommendation

The gmm garment is in the further expansion so the company is now have suitable
store room but the material handling cost is higher so the company should have a
satellite store.

service.

room must have to be modernized, full of equipment, man power and the company
must to use the creativity of the sampling maker.

Cutting
Cutting of fabric in to necessary pattern shapes is the first stage in the garment
manufacturing process. The cutting room has a greater effect on excessive
manufacturing costs than any other department concerned with the actual production
of garments. Problems
- Space
- Ergonomics issue
- Safety guards
- Back tracing in band knife and fusing
tion

The company sewing section is arranged in progressive bundle production system.

The progressive bundle system (PBS) of garments production gets its name from the
bundles of garment parts that are moved sequentially from operation to operation.
This method of production is having a higher problem in side talking, higher degree
rework and work in progress due to the difference in sewing skill.so the company
should add the number of supervisors, give training for the operators, motivate the
employee and develop the relation between the operators and managers also
department heads.

It’s obvious that the company value is highly connected with the quality so it’s
advisable that to keep it up. But the company is following or highly focused on the
PREPARED BY EYOB NGUSE
 INTERNSHIP AT GMM GARMENT PLC 2008E.C/2016 G.C

reactive aspect its advised that the company must have follow the quality assurance
method, the company should add the number of in line quality checker.
 Maintenance room
In the modern world things must have to be preventive before that happened and
delay our productivity so the gmm garment company must have
1. A preventive maintenance schedule
2. A life history of the machine
3. Different skill upgrading trainings
4. Sufficient store room and skilled store kipper.
5. following up of the schedule is mandatory

PREPARED BY EYOB NGUSE

 INTERNSHIP AT GMM GARMENT PLC 2008E.C/2016 G.C

Reference
[1] 8 Steps to Success in Maintenance Planning and Scheduling By mike gehloff On
September 27, 2012
[2] Attachments from MR.areda batu
[3] Introduction to work study by George kanawaty
[4] International Journal of Engineering and Applied Sciences
[5] Onlineclothingstudy.com.
[6] WOLKITE university garment engineering lecturing slides
[7] www.gmmgarment.com

PREPARED BY EYOB NGUSE