Argaw K. B

WOLKITE UNIVERSITY
COLLEGE OF ENGINEERING AND TECHNOLOGY

DEPARTMENT OF GARMENT ENGINEERING
INTERNSHIP FINAL PROJECT
HOSTING COMPANY: -ADAMA GARMENT INDUSTRY
TITTLE:DESIGN AND DEVELOPMENT OF MATERIAL

HANDLING EQUIPMENT FOR ADAMA GARMENT
INDUSTRY
PREPARED BY: ARGAW KASA ……… ID NO 120/08

ACADAMIC ADVISIOR: MR. EYOB NIGUSIE
SUBMISSION DATE: 1/02/2012

DECLARATION
Iam ARGAW KASA, fourth year garment engineering student have undertaken my internship
program in ADAMA GARMENT PLC. From a period of march 2/2011 E.C to July 2/2011 under
the guidance of EYOB NIGUSE (academic advisor) and Mr. ABDURAHMAN KEDIR (company
advisor).
I certify that my work is original and compiled according to the internship report writing guideline
given by Wolkite University Garment department
ARGAW KASA_____________ ____________________
Student Name Signature Date
EYOB NIGUSE _____________ ____________________
Academic Advisor 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. EYOB NIUGUSE and company advisor Mr. ABDURAHMAN
KEDIR. I also gratitude to the whole company employee of Adama garment industry/AGI.
Finally, my friends I don’t have any words to thanks, love, tolerance, respect, working together
these whole things made me to miss the internship practice come again and again. I understand
that the benefit of working together is harder than iron.
iii
EXECUTIVE SUMMARY
Internshipis a certified way to gain relevant knowledge, skill and experience while establishing
important connection in the field. In our internship in for the specified period of time, we got the
required experience and knowledge and in this report I have tried to list the overall aspects
of the internship experience.
In the first part of the project, it provides information about the hosting company’s brief
history and overall organizational structure. Also in this chapter I will try to present the different
manufacturing units in garment production department. And continues to describe the overall
organizational work flow, available machinery infrastructure, main products of the company
and their customers, then comes to mention the raw material sourcing regions and also the working
procedure of each department.
In the second part the project work, it describes mainly the particular project I have
executed in the company. It starts by describing the title, objective and significance of the study.
Then after it continues to tell the data collection, presentation and analysis methods to accomplish
the project work. The last part of the report explains the overall benefits that I have gained from
this internship period.
iv
Table of Contents
DECLARATION ............................................................................................................................ ii
ACKNOWLEDGMENT................................................................................................................ iii
EXECUTIVE SUMMARY ........................................................................................................... iv
CHAPTER ONE ............................................................................................................................. 1
1. COMPANY PROFILE ............................................................................................................... 1
1.1 Introduction ............................................................................................................................... 1
1.2. Vision ....................................................................................................................................... 1
1.3. Mission..................................................................................................................................... 2
1.4.Objective of the industry........................................................................................................... 2
1.5.Core Business of the industry ................................................................................................... 2
1.6.Core Values of the company ..................................................................................................... 2
1.7.Major products of the AGI ........................................................................................................ 3
1.8.The main local and foreign customer of Adama garment industry .......................................... 3
1.9. Organizational structure of Adama garment factory ............................................................... 4
1.10. Responsibility of each functional area ................................................................................... 5
1.11. Flow process of garment manufacturing system in AGI ....................................................... 7
1.12. Operation of Cutting during Garments manufacturing are given below in details: ............. 10
CHAPTER TWO .......................................................................................................................... 29
2. FINAL PROJECT ON DESIGN AND DEVELOPMENT OF MATERIAL HANDLING
EQUIPMENT FOR ADAMA GARMENT INDUSTRY ............................................................ 29
2.1. Introduction ............................................................................................................................ 29
2.2 Statementof Problem ............................................................................................................... 30
2.3. Objective of the Study ........................................................................................................ 30
2.3.1. General Objectives ...................................................................................................... 30
2.3.2. Specific objective ........................................................................................................ 30
2.4. Scope of the Study.............................................................................................................. 31
2.5. Limitation of the Project .................................................................................................... 31
2.6. Significance of the project.................................................................................................. 31
2.7. Literature review ................................................................................................................ 31
2.8.Methodology ....................................................................................................................... 34
2.9.1 Data collection method ................................................................................................. 34
v
2.9.2 Data analysis and interpretation ................................................................................... 36
2.10. Benefit of this Project ....................................................................................................... 38
2.11. Result and discussion ....................................................................................................... 38
2.11.1 Result .......................................................................................................................... 38
2.11.2 Discussion ................................................................................................................... 39
2.12. CONCLUSION ................................................................................................................ 39
2.13 Recommendation ............................................................................................................... 40
CHAPTER THREE ...................................................................................................................... 41
3.1.Improving my practical skills:............................................................................................. 42
3.2.Improving interpersonal communication skill .................................................................... 42
3.3.Improving my team plays skill ............................................................................................ 42
3.4. Improving my leadership skills .......................................................................................... 42
3.5. Improving my work ethics skill ......................................................................................... 43
3.6. Improving my entrepreneurship skill ................................................................................. 43
REFERENCES ..............................................................................Error! Bookmark not defined.
vi
LIST OF FIGURE
Figure1.1 company view ................................................................................................................. 1

Figure1.2 products of AGI .............................................................................................................. 3
Figure1.3company organizational structure.................................................................................... 5
Figure1.4 process flow chart of garment manufacturing ................................................................ 7
Figure1.5 store room ....................................................................................................................... 8
Figure1.6Fabric spreading machine .............................................................................................. 11
Figure1.7Numbering machine ...................................................................................................... 12
Figure1.8 Straight knife cutting machine...................................................................................... 13
Figure 1.9 Band knife cutting machine ......................................................................................... 13
Figure1.10 Drill cutting machine .................................................................................................. 14
Figure1.11Sewing section ............................................................................................................. 15
Figure1.12Pressing machine with vacuum table .......................................................................... 16
Figure1.13Welt pocket stitch machine ......................................................................................... 16
Figure1.14 Packing machine ......................................................................................................... 25
Figure1.15 Embroider machine .................................................................................................... 25
Figure1.16 Mixer machine ............................................................................................................ 26
Figure1.17 Spreader machine ....................................................................................................... 26
Figure1.18 printing machine ........................................................................................................ 27
Figure1.19 draying machine ......................................................................................................... 27
Figure1.20 Weaving section product (Piston belt) ....................................................................... 28
Figure1.21 Heavy duty section ..................................................................................................... 28
Figure 2.1 transporting of machine and product ........................................................................... 35
Figure 2.2 Design of manual material handling equipment ......................................................... 37
Figure2.3 new material handling equipment ................................................................................ 38
vii
LIST OF TABLE
Table1 :-The main local customers of Adama Garment Industry ................................................................. 3
Table 1:- lists of sewing machine on line 1 in work shop two .................................................................... 16
Table 2:- lists of sewing machine on line 2 in work shop two .................................................................... 18
Table 3:- lists of sewing machine on line 3 in work shop two ................................................................... 20
Table 4:- lists of sewing machine on line 4 in work shop two ................................................................... 22
viii
CHAPTER ONE
1. COMPANY PROFILE
1.1 Introduction
Adama Garment Industry was established in 1980 E.C in order to enhance the readiness for
combat of the Army by producing different canvas and lather products. It is located at about 105km
away from Addis Ababa and 5km on the way Adama to wonji town. It occupies a total area of
113,500 square meters and currently it has four factories, they are Heavy duty factory; Garment
factory; Cabin and Décor factory; and mission parachute and Drag Shute factory.
Figure1.1 company view

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
(AGI). This industry cover 85% of the demand of clothes and related military product and 15% of
commercial product.
1.2. Vision
The vision of Adama garment industry is to see the industry as leading a model garment industry
and to be competitive on east African market.
1
To development work, create collaboration with different organization and introduce new and
technological achievement to the country.
1.3. Mission
Creating national industrial technology network is competent on the given field and sell products
in reasonable price and quality to the domestic and East African market to see the industry as
leading model which plays important role in Garment Industry Sector and Garment Engineering
skill centre. Creating national industry technology to be competent on the given field and sell
Products in reasonable price and quality to domestic and international customers. Obtain hard
currency by selling different products to the market Conducting researches and development work.
Create collaboration with different organizations and introduce new technological Achievements
to the country. Obtain hard currency by selling different garment products to the market.
1.4. Objective of the industry

Develop technologies Objective that satisfy armed force garments and military requirements at the
desire time and place; perform engineering activities that support industrial development and
specifically the garment industry.
1.5. Core Business of the industry

Manufacturing of commercial products, military uniform, gown(for many purpose),sleeping bags,
waist belt, covers(for many vehicle),raincoats, parachutes, shoes, gloves, smart clothing for chairs
of cars, trains, air plane and automobiles dashboard covers and etc.
1.6. Core Values of the company

The factories 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 plan.

 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.
 Increasing productivity is our target.
2
 Improvement is the growth for our development.
 Honesty, industriousness, good work habit and open mindedness are the best features of
our work.
1.7.Major products of the AGI

 Military uniforms.
 Uniforms/for many purpose/
 Different canvas made bags/duffels.
 Sleeping bags.
 Suspenders; waist belt.
 Canvas covers for different vehicles.
 Different size tents and caps.
 Different canvas and lather made products.
Figure1.2 products of AGI
1.8.The main local and foreign customer of Adama garment industry

A, Local customers
Table1 :-The main local customers of Adama Garment Industry
3
 Dajen aviation industry  Military defenses logistics
 Beshoftu automotive industry  Military defenses foundation
 Power engineering industry  Military collages
 Adama agriculture machinery production  Bekelcha industry
industry  Metehar sugar industry
 Akaki basic metals industry  Fenicha sugar industry
 Ethio plastic industry  Wonji sugar industry
 Hitake industry  Awash melkasa aluminum sulfate
 Metal fabrication industry and sulfuric acid production
 Homicho ammunition industry
 Brana printing industry
B, Foreign customers of AGI
 Somalia , South Sudan,

 Rwanda , Djibouti
1.9. Organizational structure of Adama garment factory

Organizational structure is the indication of how the information flows from head of the company
administrative to operator. The Industry has five parallel divisions under the General
Manager,ViceManager, Human Resource Administration Development, Material Administration
and Marketing and Sales Management.
4
Figure1.3 company organizational structure
1.10. Responsibility of each functional area

1. Chief executive officer (CEO):- Control general manager and other departments.
2 .General Manager: - controls all departments’ activity.
3. Finance department: - responsible for the sailing and receiving during the overall process of the
organization there is two division under the finance manager this are general accountant and cost
and budget.
4. Design department:- It has three divisions sample making, pattern making and marker making
divisions. When customers ordered makes a pattern based on the customer take beak (order sheet)
and makes sample based customer size. If the customer accepts the samples and order mass
production the marker maker makes marker to cutting section with in high efficiency.
5
5. Planning departments:-receive order sheet from marketing and evaluate customer order
according available materials and machine, time, layout (operation) and employers. Textile
planner, garment planner and industrial engineering. .
6. Production departments: - It has three sections cutting section, embroidery section and stitching
section. Cutting section concern to identify number of layer, length and width for marker making
and also grain line of the fabric.
7. Maintenance department: - is mantic the company machines and the electricity. Under this
department has Maintenance supervisor and electrical supervisor.
8. Marketing department: - Receive every customers order, share Information to concern

department and discuss with customer. It is promoting our product verity to customer and sending
the products to customer. It has two divisions’ local marketing and foreign marketing.
9. Quality department: - Quality department responsively for inspect the products of the company
according international standard of quality parameters.
10.Human resource (HR) ; -managers are involved with recruitment, training, career development,
compensation and benefits, employee relations, industrial relations, employment law, compliance,
disciplinary and grievance issues, redundancies etc.
11.merchandising; -communicate customer with manufacturers.
6
1.11. Flow process of garment manufacturing system in AGI
Design
Order received Sample making
sketching
Spreading Production
Marker makinng
section pattern
Cutting and On-line

Sewing section
bundling inspection
Final inspection Ironing Trimming
Packing Dispatching
Figure1.4 process flow chart of garment manufacturing
Raw material storing room
Objective
 To know the fabric style in storing

 To know stock keeping procedure
 To determine the type of accessory and
 To determine other raw material
7
Storing room is the room which raw material like fabric, accessory and other materials
which required for produce the product is stored.
The weakness or problem in storing room
 Lack of day light use and enough light, so that not enough brightness in this room.
 Movement space is not good , It is very narrow . additionally on some area, it
closed by carton and by other materials.
 There is not enough ladder for handling the roll fabric from the shelf.
 The lack of cleanness .so that dust is store with raw materials.
 The arrangement of roll fabric and other material is not better for take it easily.
.
Figure 1Figure1.2 store room
Types of raw materials used in AGI
 100% cotton fabric

 PC (polyester and cotton) fabric
 Polyester viscose fabric
 Canvas
 Trim and accessories
 Leather
 Thread with different color
 Label/like size label/
8
Order taking:
This 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 they meet or
discuss about the order, they make decision about the product delivery time, shipment (to foreign
country or inside the country), sourcing material (from local market or foreign markets) and etc.
Design and development

In this section they make design for specific order according to the given specification or re-
engineering (deconstructing the garment and taking measurements) and patterns are made in this
section and also grade the patterns in the given order of sizes.
Figure1.5design and development room
Cutting room
Cutting is one of the major process in garments manufacturing. Here garments parts are cutting
according to the pattern. In garments cutting department, a process flow chart have to maintained
to send the right measurement parts in the next process for making quality garments.
The objective of cutting room is cutting of garments parts accurately and economically and in
sufficient volume to keep the sewing room supplied with work. Some of the objectives of cutting
room are below:-
 To separate fabric parts from the spread of lay according to the dimension of marker.
 To make the garments according to required design and shape.
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 Breaking bulk.
Flow of fabric cutting.
1, Marker making.
2, Fabric spreading/fabric layering.
3, Spreading marker on the fabric lay.
4, Fabric cutting.
5, Numbering.
6, Sorting and bundling after quality checking.
7, sending for sewing section.
1.12. Operation of Cutting during Garments manufacturing are given below in

details:
Take the fabric from store:
For cut the every style of garment, cutting in charge receive fabric from store.
Check the fabric:
Cutting supervisor inspect the fabric faults like, fabric holes, color shading, and any other defects
on fabric
Marker making:
A marker is a diagram of a precise arrangement of pattern pieces for a specific style and the sizes
to be cut from a single spread.Marker making is the process of determining the most efficient
layout of pattern pieces for a specified style, fabric, and distribution of sizes. Marker is the tracing
of pattern pieces used to guide the cutting process. The marker is usually created on the fabric and
placed over the top layer of a spread (lay). Kept on-grain, the patterns are fitted next to each other
in the most efficient manner possible for the marker mode required.
10
Fabric spreading:
In this stage, fabrics are spread in cutting table according to correct lay height and ply tension.
Figure1.6Fabric spreading machine
Marker setting on lay:
When fabric spreading completely done, then the different size and styles of marker set on the top
layer of the fabric lay.
Fabric cutting:
Finally fabric cutting is done here.
Numbering:
As i can see in Adama garment industry, when the cutting process is finish then numbered the
every style of fabric parts to avoid the mixing.
11
Figure1.7Numbering machine
Cutting quality check:
In this stage check the all cutting fabrics quality.
Sorting and Bundling:
Fabric cutting and parts are storing and bundling here according to color, size and style. Bundles
are sending to the sewing section for bulk production. Finally all bundles are sending to the sewing
section for completing bulk production.
Different Types of Fabric Cutting Machines Used in AGI
Various types of cutting machine are used in cutting room. According to the working process, the
cutting machine can be classified in to three categories. Such as-
1) Manual cutting machine:

Hand operated scissor, scissor only used when cutting only single or double plies. But it takes huge
time fir fabric cutting. So it is not used in bulk production.
2) Semi- automatic cutting machine:

Different types of semi- automatic cutting machine used in AGI are:-
 Straight knife of cutting machine.

 Band knife cutting machine.
 Drill machine.
12
Various semi-automatic cutting machines with their functions .Such as:-
Straight knife of cutting machine:
Straight knife cutting machine is the most popular and versatile cutting machine. It is widely used
clothing industry. Because it’s production speed is very higher. It is comparatively cheap and can
be transferred from one place to another easily.
Figure1.8 Straight knife cutting machine
Band knife cutting machine:
This cutting machine works automatically according to the height of the relevant material. It is
fixed machine that means don’t move place to place, so that the materials used for cutting are go
to this machine then cut it.
Figure 1.9 Band knife cutting machine
13
Drill cutting machine:
Sometimes it is needed to mark on the end of components of dresses especially for the position of
pockets, darts and similar features, a hole is often drill through all the plies of fabric on the lay.
Figure1.10 Drill cutting machine
3) Fully Automatic/computerized cutting machine:
This cutting machine provides the most accurate possible cutting at high speed. It is suitable for
large scale production.
Cutting room problem:
As i seen in AGI there are various problems in cutting room, so according to my suggestion. I try
to give the solution for this problem.
Problem:
 Marker making is made by manual, so it takes more time. As well as effect on efficiency.
E.g. as I record a time of marker which its length is 12m and its garment is 7; to make this,
it took 3 o, clock .so it required time.
 Lack of skill able operator.
 Lack of any window and ventilation for air refresh, due to this the weather condition in
cutting room is very hot, because of that the interests of the operator have to do work is
weakness.
 Improper set up of the roll of the fabric.
14
Solution:
 Proper the set-up of the roll of fabric suitable for every work.
 Use the ventilation for air refresh.
 To save the time pay on marker making, facilitate the CAD system and etc.
 Give training for workers, in order to improve the fabric utilization problem.
Sewing section:
Sewing is an important operation in apparel manufacturing. It is called the heart of garment

manufacturing industry. It is the room in which the way of each piece part of pattern joins together
by means of sewing to produce cloth.
Objective of sewing room study
 Work place layout

 WIP (work in progress)
 Management system
Sewing is the dominant process in garment assembles. Means that, the area in which 2D is change
into 3D (garment) by means of sewing. Sewing section is the wide area and the area contains many
operators rather than other section. B/c sewing of one garment is containing many operation breaks
down. So work in process increase due to its system.
Figure1.11 Sewing section
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Figure1.12 Pressing machine with vacuum table
Figure1.3Welt pocket stitch machine
Different types of sewing machine in work shop two

Table 1:- lists of sewing machine on line 1 in work shop two
No m/n of serial
Types of machine Model Summary q/t
number
Line 1
1 Single needle typical GC -5550 0 6053588 single needle typical 7
2 Single needle typical GC -5550 0 6053566 single needle zoje 11
3 Zoje single needle

Zoje Zj 9701r-d3pf 110601229 single needle Jack 2
4 Single needle zoje ZJ 9701r-d3pf 20401003 single needle Juki 1
16
5 Fusinge Machine
Single needle typical GC -5550 0 6053570 hashima 1
6 Single needle typical GC -5550 0 6053630 Juki 2
7 Zoje single needle

Zoje Zj 9701r-d3pf 1105012007 Juki 1
8 Single needle zoje Zj 9701r-d3pf 110601055 Brother single needle 3
9 Single needle zoje Zj 9701r-d3pf 110501159 TOTAL 28
10 Single needle Jack JK 8700 60805523
11 Single needle typical GC -5550 0 6053666
12 Single needle zoje Zj 9701r-d3pf 11060101313
13 Single needle Juki DDL 8300N 4DDY1109182
14 Single needle zoje ZJ 9701r-d3pf 110601220
17 Single needle typical ZJ 9701r-d3pf 110501165
19 Single needle jack JK 8700 60805536
20 Single needle zoje Zj 9701r-d3pf 110601306
22 Fusinge Machine h HASHIMA ----
23 JUKI ZJ9610 110301007
24 JUKI ZJ9610 110301016
25 JUKI AMS -221EN 2A3MC00267
26 Brother single needle DB2 -B755 M89105666
17
No m/n of serial
Types of Machine Model Summary q/t
number
Line 2
1 Inter lock pagasses EX5214M-83 769447 Inter lock pagasses 3
2 Double needle Juki LH-3128 3LYD01052 over lock 1
3 Single needle Typical GC 5550 0 6053556 Double needle Juki 3
4 Single needle zoje Zj5300r-d2b 120401006 single needle Typical 5
5 Single needle zoje Zj5300r-d2b 120401016 single needle zoje 15
6 Single needle Typical GC 5550 0 6053664 single needle jack 10
7 Single needle Typical GC 5550 0 6053633 Top center KANSAI 1
8 Single needle jack JK -8700 60805545 Inter lock siruba 1
9 Top center kansai -- KS-1616466 Button Attach juck 3
10 Juki button hole LBH-1790S 2LOFE00279 Button hole juck 2
11 ZJ9701r-
Single needle zoje d3/pf 110602571 single needle juki 1
12 Single needle zoje Zj9701r-d3/pf 110601051 MS Juki 1
13 ZJ9701r-
Single needle zoje d3/pf 110601025 Buttan Attach juki 1
14 ZJ9701r-
Single needle zoje d3/pf 110601461 Café Iran 1
15 Single needle zoje Zj9701r-d3/pf 110601312 Collar Iron 1
16 Single needle jack JK-8700 60805511 MS Gemsy 1
18
17 single needle jack JK-8700 60805514 brother single needle 2
18 Single needle jack JK-8700 60805542 TOTAL 52
19 Inter lock siruba 516M2-55 24007397
20 Button hole juck LBH-17905 2LOFE00034
21 Button Attach juck lk-1903an-55 2LOFE00718
22 Inter lock pegasses EX5214M-83 769434
23 Single needle Typical GC 5550 0 6053618
24 Double needle Juki LH-3128 3LYD01418
25 Single needle juki DDL-8300N 4DOYH09146
26 Single needle Jack JK-8700 60805559
28 ZJ9701r-
Single needle Zoje d3/pf 110601217
29 ZJ9701r-
30 Single needle Zoje Zj9701r-d3/pf 110602539
32 Single needle Taypical GC 5550 0 6053674
34 Single needle Zoje ZJ9701R-D3 110601460
35 ZJ9701r-
36 ZJ9701r-
37 Single needle Zoje Zj9701r-d3/pf 110501241
38 Inter lock Pegasses M932-86 5006543
19
39 Over lock Pegasses L52-01 8334314
40 MS Juki MS-261 T06572
42 Singel needle zoje Zj9701r-d3/pf 110602538
43 Bartacker juki Lk-1900a-h5 2L1EH02808
44 Buttan Attach juki Lk-1903an-55 2LLFE00719
45 Singele needle jack JK-8700 60807505
46 Double needle JUKI LH-3128 3L3YB01081
47 Café Iran STT/LS 020/2005
48 Collar Iron STC/T 019/2005
49 Bartacker juki Lk-1900a-h5 2L LEJ00472
50 MS Gemsy --- ---
No m/n of serial
Types of machine Model Summary q/t
number
Line 3
1 Inter lock sirba 516M2-55 24005935 single needle juki 1
2 Single needle Typical GC 5550 0 6053645 over lock pagasses 1
3 Single needle Jack JK-8700 60807509 Double needle Juki 2
4 Single needle Zoje Zj970 lr-d3/pf 110601254 single needle Typical 3
5 Double needle juki LH-3128 3L3YD01495 single needle zoje 11
6 Double needle zoje ZJ8750-5 80401016 single needle jack 10
20
7 Single needle Zoje ZJ970 lr-d3/pf 110601328 Inter lock sirba 1
8 Single needle Zoje Zj970 lr-d3/pf 110601023 Inter lock siruba 2
9 Single needle jack JK-8700 60805520 Button Attach juck 1
10 Single needle juki DDL8300N 4DOYH09163 Button hole juck 2
11 single needle Zoje Zj970 lr-d3/pf 110601357 single needle juki 1
12 MS Machine 261 TO6571 MS Juki 1
13 Single needle Zoje Zj970 lr-d3/pf 110601410 Bartacker juki 3
14 Single needle Jack JK-8700 60807504 Welting machine 1
15 Single needle Zoje Zj970 lr-d3/pf 110601019 Button Attach juki 1
16 single needle Jack JK-8700 60805509 Brother single needle 1
17 over lock Pegasses LS2-01 8334617 TOTAL 42
18 Bartacker juki Lk-1900a-hs 2LLEJ00473
19 Button Attach Juki Lk-1903an-ss 2LLFE00359
20- Single needle Zoje Zj970 lr-d3/pf 110601346
21 Double needle juki LH-3128 3L3YD01531
22 single needle Jack JK-8700 60805547
24 Single needle Typical GC 5550 6053628
27 Inter lock sirba 516M2-55 24007365
28 Single needle Zoje Zj970 lr-d3/pf 110602572
29 Single needle jack JK-8700 60805510
30 Single needle Zoje Zj970 lr-d3/pf 110601231
21
31 zj5300lr-
32 Single needle Typical GC 5550 0 6053560
33 Single needle Zoje ZJ970 lr-d3/pf 110601026
34 Brother single needle DB2 – 755 M89105715
35 Button Hole Juki LBH-17905 2LOFD00102
36 Button Hole Juki LBH-17905 2LOFC00240
37 Bartacker juki Lk-1900a-hs 2LIEJ00468
38 Bartacker juki Lk-1900a-hs 2LIEH02827
40 Button Attach juki LK-1903B-55 2L LKH00912
41 Inter lock sirba 516M2-55 24007098
42 Welting machine
(Juki) LH896N 244KF00077
No m/n of serial
Types ofmachine Model Summary q/t
number
Line 4
1 Single needle zoje Zj970 lr-d3/pf 110601442 over lock pagasses 1
2 Double needle zoje ZJ8750-5 80401013 Double needle Juki 3
3 Double needle juki LH-3128 3L3YD01414 single needle Typical 2
4 Double needle juki LH-3128 3L3YD01403 single needle zoje 12
5 Single needle jack JK-8700 60805535 single needle jack 9
6 Single needle jack JK-8700 60805560 Double needle zoje 1
7 Single needle zoje ZJ970 lr-d3/pf 110601028 Inter lock siruba 3
22
8 Inter lock sirura 516M2-55 24005645 Button Attach juck 1
9 Single needl zoje ZJ970 lr-d3/pf 110601354 Button hole juck 2
10 Inter lock sirura 516M2-55 24007045 single needle juki 2
11 Single needle zoje ZJ970 lr-d3/pf 110602560 MS Juki 1
12 Single needle jack JK-8700 60805513 Bartacker juki 2
13 Single needle zoje ZJ970 lr-d3/pf 110601233 Ms zoje 1
14 Single needle zoje ZJ970 lr-d3/pf 110601350 Gemsy 1
15 Single needle jack JK-8700 60805512 kansn (top senter) 1
16 Single needle juck DDL-8300N 4DOYH09154 TOTAL 42
17 Inter lock sirura 516M2-55 24007251
18 Button Hole juki LBH-17905 2LOFC00237
19 Button Attach juki Lk-1903an-ss 2LLFE00714
20 Double needle juki LH-3128 3L3YD01394
21 Single needle zoje ZJ970 lr-d3/pf 110601355
23 Single needle Typicla GC 5550 0 6050681
24 Single needle Typicla GC 5550 0 6053589
25 Single needle zoje Zj970 lr-d3/pf 110602558
28 Over lock pagasses L52-01 8334601
29 Ms juki MS-261 0220-3
23
35 Single needle juki DDL-8300N 4DOYH09176
37 Batracker juki Lk-1900a-hs 2LLEJ00474
38 Batracker juki Lk-1900a-hs 2LLEH00837
39 Gemsy GEMS00-01 5093010405
40 Button juki LBH-781 2lodg00524
41 Kansn(top senter) FBX1104P KS 559514
42 Welting machine
(Juki) LH -896N 2A4LL00068
Finishing And Packaging Section

After sewing of the garment, all peace are cheeked by off line quality checker to ensure that
garments are to ensure that garment are being made as per buyer quality standard checking is
normally done for visual appearance and measurement .
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.
24
Figure1.14 Packing machine
Embroidery product factory
In this section different type of defense rank insignia, federal police insignia and different name
tagging is done. In this room 3 embroidery machines are there. From those the smallest is used
to make sample rank of insignia. The rest 2 machines have 12 head and 10 needles used to
produce in quantity also there is in grooving machine that used to print name in the steel
and different sewing machines are arranged in a line.
Figure1.15 Embroider machine
Different components of embroider machine
Mixer
This machine is used to mix the chemical that used during printing and have a circular small part
that is used to hold the chemical. It is heavy and use electric for power and computerized
adjustment board.
25
Figure1.16 Mixer machine
Spreader
This machine is used to stretch the nylon fabric and the area is 120*120cm2. It uses pneumatic
lifter to hold the spreading table to move. Also, there are 10 hand holders in one way. So, totally
40 holder is there to stretch the fabric.
Figure1.17 Spreader machine
Printing machine
This machine is the main part of the room and it is heavy and need much space than the rest. This
machine is having 12 small printing tables. This is 40*60cm2 that can hold the garment to be
printed. This machine has computerized adjustments for each table.
26
Figure1.18 printing machine
Draying machine
These machines have a conveyer belt, used to transport the garment printed on the other machine.
Figure1.19 draying machine
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 also this weaving machines are the same in
principal of working with the other but the main difference is they produce small width. There
are 2-new machines that produce belt using nylon thread. The other 2-machines producing using
cotton thread but the rest 2-machines were not working because of lack of maintenance.
27
Figure1.20 Weaving section product (Piston belt)
Heavy duty section

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. Some of the products produced
in this unit are: tents (in different sizes), canvas covers (for different vehicles such as for Toyota,
Volvo, oral and etc.), bomb holder, bullet bags and military bags.
Figure1.21 Heavy duty section
28
CHAPTER TWO
2. FINAL PROJECT ON DESIGN AND DEVELOPMENT OF MATERIAL

HANDLING EQUIPMENT FOR ADAMA GARMENT INDUSTRY
2.1. Introduction
Material handlingis loading, moving and unloading of materials. One of the definitions adopted
way back by the American Materials Handling Society is: Materials handling is the art and science
involving theMoving, packaging and storing of substances in any form. Some of the other
definitions are: (Allergi, 2002)
Materials handling is the movement and storage of materials at the lowest possible cost through
the use of proper methods and equipment.
Materials handling is the moving of materials or product by any means, including storage, and all
movements except processing operations and inspection. (R., 2007)
Materials handling is the art and science of conveying, elevating, positioning, transporting,
packaging and storing of materials. Material handling system plays an important role in improved
material flow and increasing production performance in the ready-made garment industry. In this
post we’ll be discussing different types of material handling systems found in the readymade
garment industry. Material handling is one of the production functions that have been the focus of
attention for many manufacturing industries especially discrete parts manufacturing. Therefore,
quick and appropriate material handling selection is important in a production system, since it can
increase productivity, flexibility of the manufacturing time and it also reduces cost. (Apple, 2003)
The Material handling selection system assist design engineers in selecting the most suitable and
appropriate material handling equipment type for the task being considered. By the reduction and
improvement on the transfer time and transportation cost, the efficiency of the material flow and
productivity will increase and the production cost will reduce.
In the actual implementation, various materials handling equipment’s are aggregated or combined
into a materials handling system for a specific purpose. As such, appropriate specifications and a
suitable configuration of the system are important aspects that must be addressed in order to satisfy
the requirements of a particular application. The design of the material handling system depends
on the material to be handled, quantities and distances to be moved and type of production facility
29
served by the handling system. Usually, the design of material handling system is divided into four
phases. These are conceptual design phase, detailed design phase, launching phase and fully
operational phase (Ulgen and Upendram, 1995). The first and the most important phase is
conceptual design. Conceptual design is done at a high abstraction level. In general, the conceptual
design phase involves issues such as; what a material handling system is, what it can do and how
it is intended to be used. As a result, material handling equipment with different capabilities and
specifications are available for a wide range of applications. Various considerations such as the
efficiency and effectiveness of a production system and other economic issues need to be
considered before a suitable material handling equipment can be selected. This means used for
transporting work (like fabrics, cuttings, bundles, finished garments and general items) from one
place to another, storing materials and protecting material from damage, are called material
handling system.
2.2 Statementof Problem

AGI haven`t material handling equipment that used for transportation of sewing machine from one
place to another place. Due to this reason a good MHE for the transportation of sewing machine
was required in AGI. Some problem are no effective material handling equipment from cutting
room to sewing section, unnecessary workers fatigue, workers motivation becomes to decrease,
disprove personal comfort, critical defect is happened due to tearing of roll fabric, extra number
of operator can be needed during transport roll of fabric from store room to cutting section, very
high cost, no safety aspect and handling less production due to very low movement material,
overcrowding and lack of supplies.
2.3. Objective of the Study

2.3.1. GeneralObjectives
The general objective of this project is design and development of material handling equipment
for Adama garment industry.
2.3.2. Specific objective

 To produce material handling machine
 To Reduce unwanted man power, fatigue,
 To prepare safe working condition
 To reduce time loss
30
 To increase production
2.4. Scope of the Study

The project focuses on design and development of material handling equipment for adama garment
industry.
2.5. Limitation of the Project

There are some limitations on this project such as, availability of spare part, duration of the
machine and space consumption.
2.6. Significance of the project

In adama garment industry the materials are transported by man.it takes high labor
energy and cost. Therefore the material I have done is used to reduce the labor cost,
reduce lost time, increase productivity, to ensure on time and accurate delivery,
create good working condition, and avoid placing materials on the floor in case of
tiring
2.7. Literature review

According to (Stock & Lambert, 2001; Chopra &Mend, 2001).Grover (2001) Materials handling
makes production flow possible, as it gives dynamism to static elements such as materials,
31
products, equipment’s, layout and human resources highlights that despite its importance,
materials handling is a topic that frequently is treated superficially by the companies. However,
other authors have perceived its relevance. Shingo (1996) indicated that, the production was treated
as a process of a sequence of operations. In the Production Function Mechanism, the concepts are
directly related to a production analysis focus. A process analysis consists of an observation of the
production flows that turn raw materials into final products. From this concept, the author
highlights that the main analysis is the one associated with the process, because it follows the
production object. The analysis of the operations comes later because it focuses on production
subjects (operators and machines). When making this distinction, it is possible to perceive the
relevance of materials handling. Beyond the basic function of movement, it is also relevant to cite
the functions of storage and information transfer, which occurs simultaneously and has both
strategic and operational dimensions. According to Badi (2004) material handling refers to the
movement material inside the work premise from raw material stage to finished product storage,
maximum movement activities takes place on work on progress.
According to Asef-Vaziri&La Porte (2005) an important proportion of manufacturing expenses

can be attributed to material handling and the most critical material handling decisions in this area
are the arrangement and design of material flow patterns. This idea is shared by Ioannou (2002),
which argues that an important aspect of any production system is the design of a material handling
system (MHS) which integrates the production operations
The relevance also occurs in another context. Ballou (1993) states that the storage and handling of
goods are essential among the set of logistics activities, and their costs can absorb 12% to 40% of
its costs. According to (Stock & Lambert, 2001; Chopra &Mend, 2001) in addition, the MH
estimates that 20% to 25% of manufacturing costs are associated to handling. Grover
(2001)material handling accounts for 30–75% of the total cost of a product along the production
chain, and efficient material handling can be responsible for reducing the manufacturing system
operations cost by 15–30%.
For Bowers ox and Closs (1996), the main logistic responsibility in manufacturing is to formulate
a master-program for the timely provision of materials, components and work-in-process.
According to Stevenson (2001) understands that logistics (including materials and goods flowing
in and out of a production facility as well as its internal handling) has become very important to
32
an organization to acquire competitive advantages, as the companies struggle to deliver the right
product at the correct place and time. The main challenge is to promote, with low cost, a flow
whose velocity allows the execution of manufacturing process with the expected satisfaction level.
While designing fabric handling equipment the merit can enhance production continuity between
cutting and sewing sections, during manual handling the operation at sewing is delayed for certain
second due to discontinuity at cutting. Material handling equipment selection is an important
activity in the design of an effective manufacturing system. Handling activity generally account
for 30 to 40%of production cost and efficient material handling can be primarily responsible for
reducing the production cost by 15 to 30% (Kulak, 2005). Material Handling Industry of America
(Groover, 2001) defines material handling as the movement, storage, protection and control of
material throughout the manufacturing and distribution process including their consumption and
disposal.
Discontinuity at cutting operations occurs when more number of fabrics required lying to mass of
layers. The designed handling equipment can enhance comfort and make free us from suffering
health problem.
According to Magad and Amos (1995) in-house MHS is the art and science of moving, storing,
protecting and controlling material. MHS is about providing the right amount of material, at the
right time, at the right place and with the right method(s) (Kulwiec, 1985).
Mattsson (2012) defines in-plant MHS as a system that has material and immaterial exchanges
inside a factory where different departments and features are involved and working together to
create value for the end-users. He points out that despite suppliers and customers are not involved
in an in-house MHS, they do belong to the system’s environment and can have huge impacts on
its effectiveness.
In Ballou’s (1992) definition, in-facility MHS is a physical process of moving raw materials in
small quantities over relatively short distances.
In the light of definitions above, it can be stated that internal MHS is a physical process inside of
a factory between different departments with material and non-material exchanges (Stock &
Lambert, 2001). In Materials Handling Handbook, Mulcahy (1998) mentions several purposes that
product transportation concepts should achieve:
33
2.8. Methodology
Methodology is the systematic theoretical analysis of the method applied to the field of study.
Typically it encompasses concept such as quantitative and qualitative techniques.
Idea generation
Survey/analysis
Design preparation
Material identification
Prototype design
Evaluation
Presentation
2.9.1 Data collection method

It is the first stage of statistical investigation. The process of measuring, gathering, assembling the
raw data up on which the statistical investigation is to be based. When I collect the data for the
project the two data collection methods are appropriate. These two methods of data collection or
data sourcing are: -
34
 Primary data collection methods and
 Secondary data collection methods
Primary data collection method
Primary data collection method is a method of data collection that refers to generated or obtaining
data from original and first hand. The primary data’s can collect in the next two data gathering
method. These are:-
 Observation
 Interview and record
Observation
Direct observation is used as a means to study and assess the existing material handling system
and to collect some essential data.
Direct observation is done to know how sewing machine is transported from one to the anther
place and the method used at the time of manpower used. To transport this sewing machine
5operators required.
Figure 2.1transporting of machine and product
Interview
Interview was the major instrument I used in order to collect some information related to my
project. First, I prepared necessary questions to collect Primary data and information.
35
I asked the same questions to mechanics, mechanics leaders, mechanics manager, production
manager and Line leaders and other workers chosen randomly.
Secondary Data
Internet access
I use internet access in order to search and get detail information about material handling and
literature review about material handling equipment in a garment factory.
Different written documents
2.9.2 Data analysis and interpretation

Analysis of data involves extraction of relevant information from the collected data using some
mathematical and statistical tools. In other words, it involves extracting relevant information from
the data mainly through the use of elementary mathematical operation.
Feature of new material handling equipment
No Detail Measurements
1 Equipment holding weight 200kg
2 Equipment length 125cm
3 Equipment width 110cm

4 Equipment height 100cm
Solution Development of Manual material handling equipment
36
Figure2.2Design of manual material handling equipment
Material used for make new MHE
 Angle iron
 Circular tubular
 Chi bud
 Flatlamera
 Electrode
 Paint
 Grinder disc
 Cutter
 Meter
 Hammer
Components of new material handling equipment
No Components measurement
1 Tyre 0.5m
2 Circular tubular 2.70m
3 Flat lamera 3.30m
4 chi bud 2.35m
 Tyre or tire
 Chipood or card board
 Circular tubular
 Flat lamera
37
Figure2.3 new material handling equipment
2.10. Benefit of this Project
 To provide safe working conditions.

 To improve transportation method of materials.
 To minimize material movement time.
 To reduce worker’s fatigue.
 To improve personal comfort.
 To better protection of materials being handled.
 To help in manufacturing the quality standards.
 To improved morale of workers.
2.11. Result and discussion

2.11.1 Result
No Description Before machine After Machine

development Development
38
1 Unit load less amount of roll High amount of roll
fabric load fabric load
2 Production Less More
3 Transportation of material handling High transportation Low transportation

time time
4 Safe transportation Unsafe Save
5 Employee fatigue There is Unnecessary No unnecessary

worker fatigue fatigue of employee
2.11.2 Discussion
From the result the production of AGI company production increases after machine development than
before. Example Unit load before less amount of fabric than after. Production more after machine
developed than before. Transportation of material handlingtake low time after machine developed.
So material handling machine increase the profitability of AGI company than previously.
2.12. CONCLUSION
Good materials handling equipment are very important to improve productivity and also plays a
vital role on the side of use labor efficiently, increase production, reduce fatigue, reduce
transportation, reduce material handling and etc. Before improving material sorting and handling
systems has many disadvantage. But after the improvement of material handling and proposed new
39
sorting technology are more advantages. Generally we conclude that better material handling
systems are very crucial for one garment factory in different aspects: they are important for the
establishment of smooth material flow, reduction of non-productive times and reductions of
material handling processes.
Material handling expressed as the “necessary evil” which is the most necessary thing in any
manufacturing industry.
This leads to;
 Improve working condition.

 Increase productivity of the firm.
 Remove unnecessary movements.
 Remove unnecessary fatigue.
 Save time and cost.
2.13 Recommendation
AGI can produce different garment products but they cannot use Proper utilization of
resources.Proper utilization of resources can increase the productivity and competitiveness of the
company so the company applying the solution it will become competitive in global market and
high profitable.
I would like to recommend that:
40
 The company must increase awareness among the workers. Since employers are the
only internal customer. Because of previously they have no materials handling due this
difficult for employers and tired for employers to transports materials from room to
room.
 The company must give priority how to increase the profit of the company and how to
minimize the time lost. By reduce human power used for fabric transportations from
room to room.
Without movement space to take material is difficult. So give space material to material sorting
for movement.
CHAPTER THREE
In this internship program I have gained many benefits in different angle. It includes in terms of:
 Improving my Theoretical Skills

 Improving my practical skills
 Improving interpersonal communication skill
41
 Improving my team plays
 Improving my leadership skills
 Improving my work ethics skill
 Improving my entrepreneurship skill
It is obvious that, theory and practice related each other. Because without knowing something, you
can’t do anything that you want, and also even if you have enough knowledge in theory, it is
difficult to achieve your goal without practice it. Therefore as I have explained above, I have
performed many practical activities so this helped me to improve my theoretical skill.
3.1. Improving my practical skills:

Practical means it related to, governed by or acquired through practice or action rather than theory,
idea. It also means that practical guided by experience and observation rather than theory. And
practical skills means the ability of the person to being used or put in to effect, what he or she have
knowing in theory. There for I have improve my practical skill as much as possible. Because my
internship program was mainly concerned about doing tests, Observations and finding problems
by myself on the improvement of layout and by minimizing waste time in each section.
3.2. Improving interpersonal communication skill

Interpersonal communication skill refers to mental and communication algorithms to reach certain
effect or result in obtaining information.
3.3. Improving my team plays skill

Team work is an action performed by a team towards a common goal, each of whom typically has
different responsibilities. It includes common purpose, interdependence, contribution; satisfaction
from mutual workers. So, my team playing skill is improved.
3.4. Improving my leadership skills

Leader ship is organizing a group of people to achieve a common goal. It also means that you are
willing to take on a responsibility make choice for yourself. An effective leader needs to be able
to create more leaders on his or her team. Because if you want to be able to have the people
42
following you stand up and get notice, so they intern have other people following. So leadership
is effective.
3.5. Improving my work ethics skill

Work ethics is a set of moral principle like: getting to work on time, being self-directed, having
initiative, have a positive attitude with your follow workers and the customers, performing high
quality work, not being a clock watcher and most of all knowing how to be loyal to the company,
and the people you work with.
3.6. Improving my entrepreneurship skill

Entrepreneurship is the act of being an entrepreneur, which can be defined as one who under take
innovations finance and business acumen in an effort to transform innovation in to economic
goods. There for i develop the following in this internship program. Management skill (time,
money, energy) communication skill (e.g. the ability to sell ideas, search problems and know how
to solve) the ability to work both as part of a team and independently.able to research effectively
(available markets, supplier, customers and the competition) able to plan coordinate and organize
effectively self-motivated and disciplined. The ability to multi task and work under pressure
43
REFERENCES
[1]Allegri, T.H., ‘‘Materials Handling: Principles and Practice’’, CBS Publishers &
distributors. Delhi.
[2]Apple, J.A., ‘‘Material Handling System Design’’, John Wiley & Sons
[3]Asef-Vaziri, A. & Laporte, G. Loop based facility planning and material handling.
[4] Bark, P., TFK – Institutional for transport for skinning, 2002. Material handlingStockholm:
Industrial literature AB.
[5] Bolz, H. A and Hagemann, G. E (ed.), ‘‘Materials Handling Handbook’’, Ronald Press.
[6] Different kind of material handling system in garment industry (online clothing study), prasant
sarker, June 16, 2016.
[7]Domingo, R., Alvarez, R., Peña, M.M., and Calvo, R., 2007. Materials flows
improvement in a lean assembly line: a case study Assembly Automation.
Vol. 27 No.2, pp. 141-147
[8] Equipment, Bureau of Indian Standards.
[9] Expert Systems with Applications, n. 29, 2005, p. 310–319 Asef-Vaziri, A. & Laporte, and G.
Loop based facility planning and material handling.
44

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WOLKITE UNIVERSITY

COLLEGE OF ENGINEERING AND TECHNOLOGY

TITTLE:DESIGN AND DEVELOPMENT OF MATERIAL

PREPARED BY: ARGAW KASA ……… ID NO 120/08

SUBMISSION DATE: 1/02/2012

ARGAW KASA_____________ ____________________

Student Name Signature Date

EYOB NIGUSE _____________ ____________________

Academic Advisor Signature Date

Figure1.1 company view ................................................................................................................. 1

Figure1.1 company view

1.4. Objective of the industry

1.5. Core Business of the industry

1.6. Core Values of the company

 Everything we work is by our plan.

1.7.Major products of the AGI

Figure1.2 products of AGI

1.8.The main local and foreign customer of Adama garment industry

Table1 :-The main local customers of Adama Garment Industry

B, Foreign customers of AGI

 Somalia , South Sudan,

1.9. Organizational structure of Adama garment factory

1.10. Responsibility of each functional area

2 .General Manager: - controls all departments’ activity.

8. Marketing department: - Receive every customers order, share Information to concern

11.merchandising; -communicate customer with manufacturers.

Cutting and On-line

Final inspection Ironing Trimming

Figure1.4 process flow chart of garment manufacturing

Raw material storing room

 To know the fabric style in storing

The weakness or problem in storing room

Figure 1Figure1.2 store room

Types of raw materials used in AGI

 100% cotton fabric

Design and development

Figure1.5design and development room

 To make the garments according to required design and shape.

2, Fabric spreading/fabric layering.

3, Spreading marker on the fabric lay.

6, Sorting and bundling after quality checking.

7, sending for sewing section.

1.12. Operation of Cutting during Garments manufacturing are given below in

Check the fabric:

Figure1.6Fabric spreading machine

Marker setting on lay:

Finally fabric cutting is done here.

Cutting quality check:

In this stage check the all cutting fabrics quality.

Sorting and Bundling:

Different Types of Fabric Cutting Machines Used in AGI

1) Manual cutting machine:

2) Semi- automatic cutting machine:

 Straight knife of cutting machine.

Straight knife of cutting machine:

Figure1.8 Straight knife cutting machine

Band knife cutting machine:

Figure 1.9 Band knife cutting machine

Figure1.10 Drill cutting machine

3) Fully Automatic/computerized cutting machine:

Cutting room problem:

Sewing is an important operation in apparel manufacturing. It is called the heart of garment

Objective of sewing room study

ARGAW KASA_ ________

EYOB NIGUSE _ ________