Chapter one

Internship report

1 BACKGROUND OF COMPANY
Busana apparel group is the largest woven apparel exporter in Indonesia.We own and operate
world-class factories in various location across Indonesia and Ethiopia powerd by 26,165 skilled
workers in 23 factories. Our production capacity can handle 47.4 million pieces per year.

Starting with a small factory at central java Indonesia, in 1975 pt ungaran sari garments has
developed to become one of the largest apperal manufacturers in Indonesia PT Ungaran sari
Garments has 3 locations in central java. Indonesia. As of 2016,a new location has been
established in Hawassa, Ethiopia under the name of century garments PlC.

The capabilities of PT ungaran sari garments covers the whole spectrum of garment
development and production from design and pattern making to fabric and trim sourcing,to
sewing and washing finished garments. Mens shirts and ladies soft dressing are the main
product special capabilities include baking,non iron taping, handling of fine fabrics and
decorative stitchesWe provide integrated manufacturing solutions to pre- eminent customers in
the US,UK,EU,Australia,japan and other sophisticated global market.

Century garments plc was established in 2016 with the production of mens shirt commencing in
2017.the plant consists of four factory bulidings with a total area of 22000 squares meters
.Century garments plc is amongst the first group of 14 investors who have decided to invest in
the hawssa industrial park, ethipia .

The government of ethipian and the invetors aspire to make the hawassa industrial park one of
the best industrial parks in Africa and in the the world.The ultimate aims is to deliver quality
products and gain customer sastsfaction.

Vision

 To be the leading integrated solutions provider in the world of life style and
fashion.

Mission

 We will excel in design development and sourcing to deliver the right products
and services competitively with a focus on quick response.
1.2 overall organizational structure

1.3 main
rawmaterial supplear,customer and product of the
company

Supplear of Supplear of customer product

accessores fabric
Nile button Jb tex Van hussen mask
Wan shing Pen fabric tonny shirt
avery jiangsu Calvin claim
Tin shing nantong pvh
Nex gen
Winner bag
 1.4 company quality management system
1.4 General Requirements
1.4.1 Quality Management System processes
4.1.1.1 The Quality Management System (QMS) is also called as Good
Manufacturing Practice (GMP) is designed as a system of interrelated
processes. All main activities of the system are defined as Quality System
Processes (QSPs) and are grouped into the following four categories (refer to
the Quality System Processes Map):
 Product Realization Processes (PRP),
 Measurement, Analysis and Improvement Processes (MIP),
 Management Responsibility Processes (MRP), and
 Resource Management Processes (RMP)
And are organized into a Plan-Do-Check-Act loop.
4.1.1.2 The sequence and interrelation between the four groups and individual QSPs
are illustrated in the QMS Processes Map diagram. Each QSP is further broken
down into its sub-processes, as defined in the QMS Processes Matrix included
after the diagram.
4.1.1.3 QSPs and their sub-processes are documented in this Quality Manual and in
associated Quality Procedures and Work Instructions. This documentation
defines

the Quality System processes and their sequence and interaction, and instructs
on how to implement and apply them throughout the organization.
4.1.1.4 QMS documentation also defines criteria and methods needed to ensure that
the operation and control of Quality System processes are effective. This
includes assignment of responsibilities and allocation of resources for the
process, instructions on how to carry out (or operate) the process, and
definition of methods for monitoring and/or measuring the effectiveness of the
process.
4.1.2 Resources and information
 The Management Representative is responsible for determining
resource and information requirements necessary to support the
operation and monitoring of quality system processes, and for
communicating these requirements to the top management.
 Top management is responsible for ensuring the availability of
necessary resources and information.
4.1.3 Monitoring and measuring
 Performance of Quality Management System processes is
systematically monitored and measured. This is to ensure their
effectiveness and identify opportunities for improvement.
 Performance of Quality Management System processes is monitored
through Internal Quality Audits. To help with the auditing, the Quality
System Process Matrix defines for each process the areas to be audited.
 The overall performance of the Quality Management System is
monitored by measuring customer satisfaction .
 Quality Management System processes are reviewed and analyzed by
the Management Review of the Quality.
4.1.4 Continual improvement
 Quality Management System processes are regularly reviewed by the
top management to identify any possible failures or breakdowns, as
well as opportunities for improvement. Actions necessary to address
actual or potential problems and to improve the quality system are
implemented through corrective and preventive actions and through
quality objectives.
 it define how the quality management system itself ensures its own
compliance and continual improvement.
4.1.5 Outsourced processes
 When processes that affect product conformity are outsourced, special controls
are implemented to ensure that these processes meet specified requirements. Such
controls include, as applicable:
 Evaluation and pre-qualification of suppliers;
 Flow-down of customer (contract) requirements,
 Monitoring of supplier quality performance;
 Requirements for process control, inspection, testing and other such record
demonstrating product conformity.
 Receiving inspection of the supplied product.
  It define these purchasing control processes, Ensuring control over outsourced
processes does not absolve CGPL of the responsibility to conform to all customer
and regulatory requirements.
4.2 Documentation and Records
4.2.1 Documentation
 CGPL QMS documentation comprises the following categories of documents:
 Quality Manual, including a Quality Policy and Quality Objectives;
 Quality Procedures, Work instructions, Forms;
 Product, labeling and packaging specifications;
 Manufacturing, installation and servicing specifications;
 Quality Assurance/control procedures, specifications; records; and
Standards and codes.
4,2,2 Quality Manual Requirements
 CGPL will establish and maintain this Quality Manual that includes:
 The scope of the Quality Management System, including details and justification
for any exclusion.
 The documented procedures established for the Quality Management System, or
reference to them, and
 A description of the interaction between the processes of the QMS.
4.2.3 Control of Documents
 CGPL is gradually transitioning from paper to electronic documentation. As this
transition progresses, new categories of documents are transferred from paper to
electronic document control system. Both systems are currently used, and are
defined .
 The document control system defined in ensures that:
 Documents are reviewed for adequacy and are approved prior to release;
 Documents are reviewed and updated as necessary, and revised documents are re-
approved;
 Documents are identified, to include their current revision status and changes;
 Documents are distributed to, and are available at locations where they are used;
 Documents remain legible and readily identifiable;
 Document distribution is controlled; and
 Obsolete documents are withdrawn from points of use, and/or are clearly
identified to prevent their unintended use.
4.2.4.1 Control of Records
 Records are established and maintained to provide evidence of conformity to
requirements and of the effective operation of the Quality Management System.
 Records will remain legible, readily identifiable and retrievable.
 Records are organized into the following categories:
 Purchase and Deliverable documentation
 Annual Quality Assessments
 Quality Manual and Revisions thereto
 Quality Management System Master Records
 Detail Order files and their documentation
 Sub-contractor Quality Records
 Control of Records defines more specifically what records are maintained in each
category and designates their storage locations and retention periods. It also
defines the process for ensuring that records are clearly identified, are stored in
appropriate locations and conditions, are adequately protected, and are easily
retrievable.
1.5 work flow of the company

1.6 company department

1.6.1 Store fabric and accessories department

 Warehouse is responsible for receiving materials test and

inspections of fabrics deliver to cutting. In this department
every material are placed in their rank until they are used for
production. Every material which comes from the buyer are
checking quality based on their packing list.
 Store Accessories are a place where accserries are placed
like polybag,size sticker,button,collar band,paper
colar,butterfly,button tag,collar stay,insert
board,thread,silver head pin.
 Flow process store fabric(store inhouse process)
 Document Containear Total boxes or roll
registrationd checking checked

Select 10 % Total package

Quality inspected
inspection 10% checked

Confirm received
Grouping process Racking process
to ppmc

Claim process(if
grn Follow up po
any)

Material finish
Bin card Mr to production
production

1.6.2 cad and ggt department

 Flow process
1. Detail order received from buyer
2. They request store fabric (getting the fabric they want)
3. Test shrinkage (measure the fabric before and after ironing (length,width)
4. Make pattern deign
5. Make marker(may be for pilot or bulk production)
6. Send to Indonesia for approval
7. Printed out in gerber garment technology
8. Sample garment stitching(pilot)
9. Pilot compare with pps which is orered from buyer .(pre product sample)
10. If it is ok go for bulk production
 In this department 4 types of test are performed these are calibration test
 Flow process to make test Flow process to make test Flow process
square linning mr fabric for
5
test shrinkage

Clean machine and give oil Do test linning after get

result from test square Marking
inside machine
form mr and
fill material
Plot marker test lining which is
Plot marker test square use algotex machine ordered
with the length 3 yard and
width 55 inch

Plot cutter test lining use After get

card board cutter register
Plot cutter test square machine number
with length 1 yard and from store
width 1 yard use machine acc,take
cardboard cutter Template cutter test fabric in
lining on marker test store fabric
linning, the shape must
Measure result of marker be same form both
test square from algotex marker and cutter
Take fabric
machine the measurement
with
must be fix
measurment
Fill register test 1 yard
calibration machine
Square the shape must be every morning and every
same form both marker change paper
and cutter

flow process to make test shrinkage pilot

Measure fabric with Then mark with pen to Make tes shrinkage with
measurement 35cm avoid missing mark ironing based on character
1 35cm at both side after iron or wash fabric and pc code

Measure result of test Do relaxation after ironing or

shrinkage washing around 1 hour
1.6.3 cutting department
1.13.2 Cutting and spreading Section
This section is the most important department where many activities are done and needs the
most care of all this sections includes various activities like spreading, fusing and cutting.
The objective of cutting room is cutting of garments parts accurately.
Main Responsibilities in this section
Issue a pattern from design room
Spread a fabric on cutting table

Issue a fabric from store

Put marks on the patterns so that operators match components easily during assembly
Cut the fabric with the marked pattern shapes
Cutting Department Machines
Number of machineries in Cutting, spreading and fusing section of century.

Machine type model quantity

End cutter Su lee 4
Straight knife Ks-au-v 4
Auto cutter bullmer 1
Band knife Bk 900AR 4
Die cutter SE25-EX-T25 2
Spare compacter ADT 320 2
Cut interlling NS-11305 2
Auto spreader OSHIMA 2
Martin group X600KEL-PLFC 3
Bx 1oo cu VEIT 2
FUSING RELIANT TM 1

Equipment’s used in this section

 Rulers Different kinds of paper

 Metal Weights  Fabric scissors
 T-square  Measuring tape
 Rubbers  Plasters
  Clamping devices
 Pencils
The duty and responsibility of quality checkers in cutting and spreading sections is seeing and
control the following things:-

 Check number of markers

 Check fabric quality (weaving defect or stain)
 Adjust the width of marker
 Check efficiency of marker
 check shade variation

Generally the quality checker make sure that the fabric are being cut as per the order quality
parameters.

Work flow in cutting department

spreading cutting numbering fusing

Bundle with Collect

bundle tiket

Spreading

Standard operating procedure of spreading

1 Ensure the availability of spreading form ,marker that has been checked qc ,pps /pilot
approval ,pp /pilot meeting resume ,fabric inspection report ,trim chart of fabric
approval before spreading .

2 Check fabric color , shade/lot fabric ,fabric width ,fabric pattern color ,and fabric
quantity needed when taking fabric. ensure that it is in accordance with spreading form
,do ,and trim chart.

3 Qc and spreading supervisor must check and monitor spreading process to ensure
that fabric width fits to marker width fits to marker width ,face side center line ,grand
line ,fabric repeat ,fabric direction ,and fabric pattern color are match to pps /pilot
approval and trim chart.

4 If there is defect found and less hang tag ,inform supervisor ,qc ,and material record
to be proceed to ppmc and fabric store.
5 After spreading process ,ensure that the spreading layer quantity is match to layer
quantity is match to layer quantity plan in spreading form .put marker on the unrolled
fabric ,check the center line ,grand line ,fabric repeat ,and fabric direction (one way ir
two way)

6 Layer stack height is a maximum of 3 inch

7 Spreading form and marker identity must be submitted to cutting record to make
cutting list, qc check the spreading to ensure that the face side ,center line ,fabric width
and length fit to markers width and length ,shade color ,and fabric direction are match
to pps /pilot approval and trim chart ,and attach cutting number(lot no).

8 The fabric remnant or end roll must be attached with a clear identity that comprises
fabric pattern color, face side mark ,pos name ,style mode shade/lot ,roll remnant
quantity and roll number.

9 The fabric remnant or end roll must be returned to material record and place at fabric
rack.

Cutting

 standard operating procedure of cutting

• before cutting
1 check and ensure that the spreading from has lot number approved by cutting
supervisor and cutting qc

2 check and tidy up markers postion on the spreading

3 things to note in markers checking and placement setting

4 for solid fabric , the right side of marker must be match to the fabric edge and the left
side adjusting to the right

5 for plaid and stripe fabric , center line at the right marker edge must be match to the
actual center line at the fabric

6check center line of every front component and allowance of the componnet for re
pinning process.

7 attach stamp of lot number , layer quantity and non-iron identity at the panel of the
marker .
8 for all types of fabric use ballast on the marker to prevent marker from moving .

• cutting
1arrange marker on the stack of spreading by keeping the center line , grand line ,fabric
reapeta and direction

2 ensure the supervisor and qc have approved has spreading .attach mark/ numbering
that comprises lot number ,layer qunanity and non-iron identity for non - iron order.

3 before cutting process , ask the supervisor about cutting method of every style tat will
be cut

4 use metal glove in the left and right palm hand that is not handling machine.

5 turn on the machine and sharpen the knife if it is less sharp

6 put te ballast/catcher on the marker to keep marker on its position.

7 cut salvage fabric to ensure that pin hole at the fabric does not enter the edge of
marker

8 start cutting process

9 collect all the cutting result in accordance with the process order.

• After cutting
1 turn off cutting machine

2 keep all cutting equipment in orderly at its place.

Numbering process

Standard operating procedure of numbering

1 collect all components and check the lot no,size,and marker code before numbering
starts

2 count garments based on size and quantity

3 numbering process must be match to the quantity shown in the marker

4 there are two types of numbering process ,they are

Stamp numbering for bright colored components in yoke ,sleve ,front,back,and sleeve
plaket at the determined spot.

Sticker numbering for collar ,band ,and cuff components.

Note place sticker at the edege for top part and the middle for bottom part.

Place sticker at the edege for fused components and inside of components for the non
fused.

Fusing

Stanadard operating procedure

1 turninig on fusing machine.press on button,switch air pressure button on (check air
pressure),check machine temperature (minimum of 150c) and set conveyor speed at 10
second.

2 sow 1.5gram of kanfix from left to right side and rpeat every 1 meter .enter cleaning
cloth to conveyor for 5 to 15 minute (it depends on the thikness of glue on the
belt/conveyor )to clean interlings glue on the conveyour.

3 set the parameter setting (temperature,pressure,and speed)in accordance with the

parameter setting of fusing trial that has been approved by qc buyer

4 check the actual machine temperature using thermo paper to ee whether it has met
the standard or not.

5 stick the thermo paper in daily machine check book .

6 fabric and interlining panel bundle in accordance with style and model,fabric .

7 color,and interlining (color and its usage)as well as pp/pilot meeting resume in pp
meeting comment file (for standard matching ,heming,and heming cuff).

8 conduct bond strength test trial (daily trial)using fabric and interlining which the color
is similar to the bulk production (no 6)that comprises bond strength checking ,fuse/glue
line ,and quality checking (strike-through ,strike back,delimnation,puckering,shading
,etc)

9 fusing qc checks the trial result then conduct first out put trial to ensure that the
material used have been correct and there is no problem with the
pattern(shrinkage/elongation)
10 send the first output to qc approval ,then bulk production is ready to run

11 check machine belts cleaness periodically and clean it soon when ever there is glue
on the belt /conveyor.

12 clean belt with kanfix and cleaning cloth (no1)after fusing process before going
home.

13 turn off the tempratures ,machine pressure to zero (0),and slow down machine
speed (18 second)