Bangladesh University of Business & Technology (BUBT)

Industrial Attachment Report

On
“The Montex Fabrics Ltd.”

Course Code: TXE-448

Course Title: Industrial Training & Practice
Semester: Fall, 2019-20

Supervised By,
Saitham Al Sagir Rakin
Lecturer
Department of Textile Engineering
Bangladesh University of Business & Technology (BUBT)

Submitted By
Intake ID Name
17th 15162107007 Md. Sohel Rana
17th 15162107008 Md. Rajib Sikder
17th 15162107024 Md. Ramzan Ali
Department of Textile Engineering
January -2020

i
Bangladesh University of Business & Technology (BUBT)

Approval of Industrial Attachment Report

------------------------------------------------------------------
Saitham Al Sagir Rakin
Lecturer
Department of Textile Engineering
BUBT

-----------------------------------------------------------------
Dr. Mohammed Rubaiyat Chowdhury
Professor & Chairman
Department of Textile Engineering
BUBT

ii
 Letter of Transmittal

Date:
To
Dr. Mohammed Rubaiyat Chowdhury
Professor & Chairman
Department of Textile Engineering
BUBT

Subject: Submission of Industrial Attachment

Dear Sir,
We, the students of Textile Engineering Department, Bangladesh University of
Business & Technology, have successfully completed our industrial Attachment. We
are submitting our Industrial Attachment on “The Montex Fabrics Ltd.” As part of
the credit requirement for B.Sc Degree to be awarded by Bangladesh University of
Business & Technology.
We therefore, request and expect that, you will appreciate us with any sort of
recommendation & valued suggestion and will cordially receive this Industrial
Attachment for your kind assessment.

Sincerely yours,

Name ID Signature
Md. Sohel Rana 15162107007 ________________
Md. Ramzan Ali 15162107008 ________________
Md. Rajib Sikder 15162107024 ________________

Department of Textile Engineering

Bangladesh University of Business & Technology (BUBT)

iii
 ACKNOWLEDGEMENT

First of all, we would like to express our gratitude to Almighty Allah who enables
us to complete the training without any complications and submit the report on time.
For the successful completion of the training, we must recall the name of the
personalities who made our training easier and helped us to enrich our knowledge.
Their insight, advice and suggestion helped us a lot. We would like to pay special
thanks to Dr. Mohammed Rubaiyat Chowdhury, Professor and Chairman,
Department of Textile Engineering (BUBT). We express our sincere
acknowledgement to our Supervisor Saitham Al Sagir Rakin , Lecturer,
Department of Textile Engineering (BUBT). Her ideas and advices helped us to
complete the training as well as to write the report successfully. We would like to
give thanks to the Managements of “The Montex Fabric Ltd.” for giving us the
opportunity to make our industrial attachment at the “The Montex Fabric Ltd.” The
internship opportunity we had with “The Montex Fabric Ltd” was a great chance for
learning and professional development. At last our thanks to the Supervisors,
Technicians, Operator & all the other staffs of “The Montex Fabric Ltd” who are
most helpful to us.

iv
 Industrial Attachment On The Montex Fabric Ltd.

Table of Contents

Chapter Contents Page No.

Title Page i
Approval of Industrial Attachment ii
Letter of Transmittal iii
Acknowledgement iv
Table of Content v
List of Figure vi
List of Table vii
Chapter-1 Project Description 1-10
Chapter-2 Manpower Management 11-17
Chapter-3 Raw Material 18-19
Chapter-4 Machine Description 20-27
Chapter-5 Production Planning, Sequence & Operation 28-43
Chapter-6 Quality Control System 44-50
Chapter-7 Maintenance 51-54
Chapter-8 Utility Services 55-57
Chapter-9 Store & Inventory Control 58-60
Chapter-10 Embroidery 61-64
Chapter-11 Merchandising 65-70
Chapter-12 Compliance 71-74

v
 List of Figure
Figure Figure Name Page
Number Number
01 Location of Montex Fabrics Ltd 4
02 Major Buyer 5
03 Major Buyer 6
04 Main Product 09
05 Main Product 10
06 Relaxation M/C 20
07 Fabric Spreading M/C 21
08 Morgan Cutting M/C 21
09 Straight Knife Cutting M/C 21
10 Plain M/C 23
11 Overlock M/C 23
12 Flatlock M/C 23
13 Button Hole M/C 24
14 Button Attach M/C 24
15 Plotter M/C 25
16 Sclavos Dyeing M/C 26
17 Dilmenler M/C 26
18 Fong Dyeing M/C 27
19 Nuvas Dyeing M/C 27
20 Sample Section Layout 29
21 Cutting Section Layout 30
22 Sewing Section Layout 31
23 Finishing Section Layout 32
24 PDCA Cycle 49
25 Fire & Safety Device 73
26 First Aid Box 74
27 Medical Centre 74
28 Workers Canteen 74

vi
 List of Table
Table Table Name Page
Number Number
01 Cutting Section M/C 20
02 Sewing Section M/C 22
03 CAD Section M/C 25
04 Dyeing Section M/C 26
05 AQL Chart 46
06 Maintenance Tools 52
07 Utility Sources 55
08 Costing Sheet 69
09

vii
 Chapter-1
Project Description

Serial Number Content Page Number

1.1 Introduction 2
1.2 Factory Profile 2
1.3 Production Capacity 3
1.4 Location 3-4
1.5 Major Buyer 5-6
1.6 Sister Concern 7
1.7 Achievements 7
1.8 Supplier 7
1.9 Bank & Insurance 7
1.10 Main Product 8-10

1
1.1 Introduction
Industrial attachment is an important and essential part of 4 years B. Sc in Textile Engineering
Course. Actually industrial attachment is the practical experience for every Textile Engineer
Which is needed to be familiar with not only the industry but also all over the necessary job
related to continue in any industry.
Practical knowledge is very much essential for the education of Textile Engineering. Practical
knowledge makes us capable and perfect to apply theoretical knowledge in practical life.
The textile division has the capability to offer a complete product range for export markets. The
goal of textile division is to become the preferred partner for sourcing high quality fabrics and
clothing from Bangladesh. With highly advanced technology and an emphasis on developing
local human resources.
That is why B. Sc in Textile Engineering course is extruded over four years followed by eight
weeks industrial training in factories. It is attached to our study curriculum practical knowledge
and develops adoption power with industrial environment.
We preferred this attachment in The Montex Fabrics Ltd. which is a hundred percent export
oriented composite knit industry. For continuing the study of internship in the Montex Fabrics
Ltd. we almost worked all the sections of this company and tried to find out the activities,
planning and many other things as well. In context, we are discussed about these things
deliberately to let you know about.

1.2 Factory Profile

Name: Montex Fabrics Ltd
Type: 100% export oriented Knit composite
Establishment Year: 1991
Investor: Mr. Haji Abdul Majid Mondol
Total Manpower: 30,000
Production Capacity: 7 Million pcs/month
Member of: BGMEA & BKMEA
Fax: 9989113
Url: http://www.mondol.net

2
1.3 Production Capacity

Garments:

• 35,000 Pieces Basic Garment.

• 20,000 Pieces Casual Garment.
• 5,000 Pieces Loop back / brush Back Jacket / Polo / Fashion trends GMT.

Textile:

• Dyeing : 25 Tones fabrics white & color.

• Printing : UNICA - 5400 mt per hr- digital and sublimation 620 sqm per hr.
• Embroidery : 5,000 Kg fabrics per day.

1.4 Location
Address: Nayapara, kashimpur,
Thana: Gazipur Sadar
District: Gazipur
Division: Dhaka,
Country: Bangladesh

3
Google Map View of Montex Fabrics Ltd.

Fig. 01: Location of Montex Fabrics Ltd.

4
1.5 Major Buyer:

Fig. 02: Major Buyer

5
Fig. 03: Major Buyer

6
1.6 Sister Concern: Montex Fabrics ltd is a sister concern of Mondol Group

1.7 Achievements:
Mondol Group Started export in 1995.Initially in 1995 the annual export was $3.20 million dollars.Within 19
years this annual turnover dramatically increased.Here we showed last five years annual turnover.In 2012
turnover was $172.00 million dollars.Gradually in 2013,2014,2015,2016 the annual turnover was $237.07
million, $246.48 million, $289.48 million and the last its significantly increased to $300.00 million dollars.

1.8 Suppliers

a) Bashar Spinning Mill

b) Youth Spinning Mill
c) Prime Spinning Mill
d) JK Spinning Mill
e) AKIJ Spinning Mil
f) Alim Knit (BD) Ltd.
g) Montrims Ltd

1.9 Bank & Insurance

a) PRIME BANK LTD

MOTIJHEEL C/A, DHAKA-1100
BANGLADESH

b) JANATA BANK
MOTIJHEEL C/A, DHAKA-1100
BANGLADESH

c) UCBL
32L GULSHAN NORTH C/A
DHAKA, BANGLADESH

7
1.10 Main Product

a) T-Shirt,
b) Polo- Shirt,
c) Tank top,
d) Hood Jacket,
e) Trouser,
f) Swim wear,
g) Kids Knit wear,
h) Shorts,
i) Long Pant,
j) Long sleeve T-Shirt
k) Girls Fancy
l) Night Gown
m) Pajama

8
Main Product Photos :

Fig. 04: Main Product

9
Fig. 05: Main Product

10
 Chapter-2
Manpower Management

Serial Number Content Page Number

2.1 Main Organogram 12
2.2 Section-wise Organogram 13-16
2.3 Male/Female Worker 17
2.4 Working Hour 17

11
 2.1 Main Organogram

Upper Level Organogram:

Chairman &
MD

Directors

Marketing &
Production Utility
Merchandising
Directors Directors
Directors

12
2.2 Section-wise Organogram:

a) Cutting Section:

Cutting
Manager

Cutting
Supervisor

Cutting
Man

Cutting
Helper

13
b) Sewing Section:

ED

DGM

AGM

PM

APM

Line Chief

Supervisor

Operator

14
c) Dyeing Section:

ED

DGM

AGM

Dye Manager

Dye Deputy
Manager

Asst. Manager

Sr. Production
Officer

Production
Officer

Executive
Supervisor

Operator

15
d) Finishing Section:

Manager

Incharge

Supervisor

16
 2.3 Male/Female worker

a) Male:

b) Female:

Number of Worker:

Section wise Worker:

1) Cutting Section:
2) Sewing Section:
3) Dyeing Section:
4) Finishing Section:
5) Sample Section:
6) printing & Embroidery Section:
7) Batch Section:

2.4 Working Hour

Break: 1 Hour
Lunch: 1:00-2:00
Holiday: Friday
Overtime: 2-3 Hours

17
 Chapter-3
Raw Material

Serial Number Content Page Number

3.1 Raw Material 18-19

3.1 Raw Material

Types of Raw- Material:

a) Yarn
b) fabrics
c) Trimmings & Accessories
d) Dyes & Chemicals

a) Name & Source of Yarn:

Name of The Yarn Source of the Yarn
Cotton Yarn Square Spinning Mill, Aman Spinning Mill, AKIJ
Spinning Mill, Fariha Spinning Mill etc
Polyester Yarn Kader Synthetics, China
Lycra Korea, China, Japan
Mellange Thermax

b) Fabrics: Fabric is a planar textile structure produces by interlacing yarns, fibers, or filaments.
It may be woven, knitted and Nonwoven

1. 100 % Cotton fabric

2. CVC fabric
3. PC fabric
4. 2*2 Lycra rib fabric
5. Lycra S/J fabric
6. Viscose Lycra
7. Plain Interlock
8. 100% Polyester fabric
9. Grey mélange etc

18
 c) Trimmings & Accessories:

1) Cartoon
2) Gum Tape
3) Printed label
4) Sewing Thread
5) Poly Bag
6) PVC Poly Bag
7) Zip lock ploy bag
8) Leather Badges
9) Elastic Lace
10) Elastic
11) Rubber Patch
12) Motive
13) Collar stand
14) Lining
15) Interlining
16) Label
17) Zipper
18) Button

d) Dyes & Chemicals:

1. Reactive dye
2. Disperse dye
3. Acid dye
4. Basic dye
5. Direct dye
6. Sulfur dye
7. Azoic dye
8. Sequestering agent.
9. Lubricants / Anticreasant.
10. Pretreatment Chemicals
11. Levelling and Dispersing Agent.
12. Sequestering, Dispersing and Levelling Agent for Reactive dyeing.
13. Antifoam.
14. pH Control and buffer system.
15. Desizing Agent
16. Yarn Lubricant
17. Mercerising agent
18. Dye fixing agent
19. Optical Brightener
20. Soaping Agent / Washing off Agent.

19
 Chapter-4
Machine Description
Serial Number Content Page
4.1 M/C List of Garments 20-25
Section
4.2 M/C list of Dyeing Section 26-27

4.1 M/C List of Garments Section

a) Cutting Section
Machine Name Brand Quantity
Relaxation M/C Winda 4
Fabric Spreader M/C Morgan Tecnica 6
Morgan Cutting M/C Morgan Tecnica 6
Straight Knife Cutting M/C KM 9
Table, 01: Cutting Section M/C

Fig. 06: Relaxation M/C

20
 Fig. 07: Fabric Spreader M/C

Fig. 08: Morgan Cutting M/C

Fig. 09: Straight Knife Cutting M/C

21
 b) Sewing Section

Machine Name Brand Quantity

Lock Stitch (Single Needle) Brother/Juki 387
Over Lock Pegasus 304
Cylinder Interlock Pegasus/SIRUBA Golden Wheel 115
Flatbed Double Chain Stitch Pegasus 33
Flatbed Interlock Pegasus 34
Interlock M/c Pegasus 30
Elastic Inserting Attaching M/c(PMD) Kansai 8
Button Hole Brother 29
Button Sewing Brother 27
Double Chain stitch Feed-of-the-arm Brother 6
Lock Stitch Bar Tacking Brother 13
Two Needle Lock Stitch Brother 10
Fabric Inspection OSHIMA 3
Cloth Inspection UZU 1
Cloth Cutting M/c KM 10
Fusing Press M/c HASHIMA 1
Rib Cutting M/c PL-LU-992 6
Pi coating M/c Kansai 3
Shell Stitching M/c Kansai 2
Spot Removing OSHIMA 5
Steam Iron OSHIMA 124
Vacuum Iron Table OSHIMA 124
Needle Detector CINTEX/OSHIMA 3
Bar tack Brother 13
Zig Zag Lock Stitch Juki 02
Wave Design Stitch Golden Wheel 06
Cutting Spreader Kawakami 01
Snap Button Attach Prime/NISHO 20
Shuttle Stitch NISHO 03
Band Knife Max 03
Thread Sucker China 04

Table, 02: Sewing Section M/C

22
 Fig. 10: Plain M/C

Fig. 11: Overlock M/C

Fig. 12: FlatLock M/C

23
Fig. 13: Button Hole M/C

Fig. 14: Button Attach M/C

24
 c) CAD Section:
Machine Name Brand Quantity
Plotter M/C Graphtec
Pattern Cutter M/C
Table, 03: CAD Section M/C

Fig. 15: Plotter M/C

25
4.2 M/C List of Dyeing Section

Machine Name Brand Quantity

Sclavos Dyeing M/C Sclavos 6
Dilmenler Dyeing M/C Dilmenler 6
Nuvas Dyeing M/C NUVA 4
Fong Dyeing M/C FONG 3
Table, 04: Dyeing Section M/C

Fig. 16: Sclavos Dyeing M/C

Fig. 17: Dilmemler Dyeing M/C

26
Fig. 18: Fongs Dyeing M/C

Fig. 19: Nuvas Dyeing M/C

27
 Chapter-5
Production Planning, Sequence & Operation

Serial Number Content Page

5.1 Introduction 28
5.2 Floor Plan Layout 29-32
5.3 Working Flow Chart 33-36
5.4 Description 37-43

5.1 Introduction

The main aim of production planning is to provide a system along with a set of procedures for
effective conversion of raw materials, labor and other inputs into final product (garment). The
three key elements determining production planning in industry are
• Volume of production
• Nature of production process
• Nature of operation

Volume of production:
The intensity and quantity of production planning could be determined by the volume and
character of the processes and the nature of the production processes. For example, production
planning for manufacture of 10,000 garments would be different from the planning for a 1000
garments.

Nature of production process:

In a job shop, the production planning would be very casual and informal and creating work
methods are up to the skill of the individual person. But in the case of high volume production,
many garment designers, process engineers and industrial engineers (IEs) are involved.

Nature of operations:
Comprehensive planning is necessary for cyclic operations, for example, in continuous
manufacturing of a single standardized style of garment.

The alternatives in manufacturing approach are:

• Manufacturing to order, which may or may not be repetitive at regular intervals
• Manufacturing for stock and sell – batch or mass production
• Manufacturing for stock and sell – continuous process manufacturing

28
5.2 Floor Plan Layout

a) Sample Section

Fig. 20: sample Section Layout

29
b) Cutting Section

Fig. 21: Cutting Section Layout

30
c) Sewing Section

Fig. 22: Sewing Section Layout

31
d) Finishing Section

Fig. 23: Finishing Section Layout

32
5.3 Working Flow Chart

a) Working Flow Chart of Sample Section

33
b) Working Flow Chart of Cutting Section

Pattern received from pattern department

↓
Cutting ratio received from merchandiser

↓
Marker making

↓
Fabric received from the store

↓
Fabric Checking

↓
Fabric Spreading

↓
Marker placing on to the lay

↓
Cutting the fabric

↓
Numbering

↓
Checking

↓
Sorting and Bundling

↓
Send to the sewing department

34
c) Working Flow Chart of Sewing Section

Set up target for production

↓
Set up machine layout on the basis of target

↓
Set up operator layout on the basis of target

↓
QC check of product

↓
Line balancing

↓
Line setup

↓
Distribution all the processes

↓
Cutting parts received section

↓
Cutting parts distribution to the operator and helper

↓
Complete parts making individually

↓
Online QC check

↓
Online quality audit

↓
Counting output and checking with the target

↓
Final quality check (for each Garment)

35
d) Working Flow Chart of Garments Finishing Section

Finishing input (style, color & size wise)

↓
Initial quality check
↓
Spot Removing
↓
Ironing/Pressing
↓
Inspection
↓
Hang tag
↓
Get up change
↓
Folding
↓
Poly
↓
Bar code (buyer wise sticker)
↓
Metal check
↓
Cartooning/Packaging
↓
Final inspection by buyer

36
 5.4 Description

Sample: The sample is a product which represents a group of product or lot. The sample will reflect
the quality and workmanship of the exporter or manufacturer. Garment samples are inevitably important
part of exporting. Sampling of garments is given great emphasis. Sample of garment can either make or
break the further procedure of getting orders from buyers. Sampling plays a vital role in getting orders
from the buyers. Samples are developed and tested before starting the bulk production.

Stages of Sample development: Sampling is a multi-stage process of product

development whereby we assist the buyer or client in identifying the most efficient means of production
while retaining the essential stylistic integrity and maximizing the functional value of the garment. The
samples decide the ability of an exporter to deliver desired style, fit, design and best quality in a particular
order. The process of sampling varies from context to context.
Garment samples are categorized as development stages and production stage. Samples that are made
in the development stage are as follows -

• Proto Sample
• FIT sample
• Salesman Sample/Photo shot Sample
• Size set Sample
• Pre-production Sample

In the production stage, the factory needs to submit a few more samples that include

• Top of Production Sample

• Shipment Sample

37
Cutting (CAD):
a) Cut Plan: Cut order planning is the problem of planning the fabric cut for a set
of apparel orders. A specified set of garments is ordered by the customer to be
produced by a given date. Affiliated with this order is a set of garment sizes, and
patterns for cutting each size. The fabric for cutting the order must be arranged on
the cutting table in such a way as to minimize the cost of cutting the order. This
plan must incorporate a partition of the pattern pieces to be arranged on top of the
fabric layout.
b) PP meeting: PP meeting refers to Pre-Production meeting before starting of bulk
production. There are various types of garments order, types of styling and buyer
requirement. So, PP meeting is very important for garments manufacturing to discuss and
do all experiment for production. All department head of apparel industry present in PP
meeting so that everyone can be concerned about the requirement of production.

c) Splice: Splicing is a process of cutting fabric across its width and overlapping
layers in between the two ends of a lay. Splicing of lay is required some times to
avoid faults found in the fabric into the garment components. After splicing cut end is
pulled back to overlap plies as far back as the next splicing mark. The overlapping
length depends on splicing mark to cover complete garment components

d) Faults:

Miss cut
Running shade
Number &bundling
Bowing
Notch mark
Narrow goods
Rugged cut
Fabric way
Measurement
Tension Loos

38
Sewing:
1) Operation Breakdown of a Basic T-Shirt:

Shoulder Join (Overlock m/c)

Shoulder Top Stitch(Flatlock m/c)

Neck Rib tack(Plain m/c)

Neck Rib Join(Overlock m/c)

Neck Tape Join (Plain m/c)

Sleeve Join (Overlock m/c)

Side Seam (Overlock)

Care label join (Plain m/c)

Sleeve Heam (Flatlock)

Body Heam ( Flatlock)

Bar tack (Bartack m/c)

Main Label join (Plain m/c)

39
 2) Operation Breakdown of a Polo-Shirt:

Serial Operation Machine

No.
1 Shoulder Join Overlock
2 Shoulder Top Stich Flatlock
3 Upper Placket Rolling SNLS
4 Lower Placket Servicing SNLS
5 Body Mark For Placket Attach Helper
6 Upper Placket Attach SNLS
7 Lower Placket Attach SNLS
8 Body/ Placket Opening & Scissoring Helper
9 Placket Base Tack SNLS
10 Upper & Lower Placket Top Stich Flatlock
11 Placket Box Make SNLS
12 Upper Placket Nose Tack SNLS
13 Collar Attach SNLS
14 Back Neck Binding SNLS
15 Mark for Main Label Attach Helper
16 Main Label Attach SNLS
17 Body Hem Flatlock
18 Sleeve Attach Overlock
19 Side Seam Overlock
20 Sleeve Hem Flatlock
21 Side Slit Binding Flatlock
22 Side Slit Tack SNLS
23 Side Slit Top Stich Flatlock
24 Care Label Attach SNLS
25 Button Hole Button Hole M/C
26 Mark for Button Attach Helper
27 Button Attach Button Attach M/C
28 Side Slit Bar tack Bar Tack M/C
29 Collar Mending Helper
30 Final Thread cut Scissor

40
Finishing:
a) Packing Instruction:

Packing is one of the most important parts of apparel manufacturing process. After completing
the entire manufacturing task, apparel is required to pack. In finishing section, packing is the last
steps before storing. Various types of packing are done and it depends on the type of apparel.
After packing, it placed in carton as per instruction. After cartooning, carton is stored in store
section. Then carton is delivered from the store for export.

Types of Packing in Finishing Section: Different types of packing are done in finishing
section.
Followings are the most used packing types.
1. Stand up pack : Shirt (90 angle)
2. Flat pack : Sportswear/ shirt/ trouser
3. Hanger pack : Blazer, coats, pants etc
4. Semi stand up pack : Shirt
5. Half fold pack : Pant

41
CBM Calculation:
Before starting the CBM, we should find the below information at first;
• Carton length;
• Carton width;
• Carton height;
• And carton quantity for an order;

We need to use centimeter to find out the CBM. If we found Length, Width and height in 'Inch'
then we need to convert into "centimeter" by multiplying 2.54 ( We know 1 inch = 2.54 cm).
Example Of CBM Calculation With Formula :
Formula: Length (cm) X Width (cm) X Height (cm) X Cartoon Quantity / 10,00,000

Suppose, A carton have length 25 inches, width 15 inches and height 15 inches. Now find out the
CBM for 500 cartons ?

Solution:
• Length 25 inches = So, 25 X 2.54 = 63.5 cm [ 1 inch = 2.54 cm]
• Width 15 inches = So, 15 X 2.54 = 38.1 cm
• Height 15 inches = So, 15 X 2.54 = 38.1 cm

Formula: Length X Width X Height / 10,00,000 X 500 [ 1 CBM = 10,00,000 square cm ]

= 63.5 X 38.1 X 38.1 X 500/10,00,000

= 46.08 CBM

Finally we know that, we need 46.08 CBM cargo for 500 cartons.

42
 b) Cartooning: Garments are delivered to the buyer in cartons. Garments in poly bags are
kept in a carton as per instruction of the buyer. Loading cartons with garments is called
packaging. Garments are loaded in cartons in a designated proportion of size and color.
This proportion is called assortment. Maintaining the designated assortment is very
important. This shows what sizes and colors should go with each carton. This is the
requirement of a store of buyer’s end for which the carton is designated.

Different types of cartooning are:

Assort color solid size
According to this strategy, color of garments is different while size is same.
For example, Garments quantity = 42 pcs
Color: Red & Blue
Size: medium

Assort color assort size

According to this strategy, all garments are of different color and different size
For example, Garments quantity = 42 pcs
Color: Red & Blue
Size: small & medium

Solid color assort size

According to this strategy, color of all pieces is same while there is variation in size
For example, Garments quantity = 42 pcs
Color: Red
Size: small, medium & large with ratio 1:2:1

Solid color solid size

According to this strategy, all garments are of same color and different size
For example, Garments quantity = 42 pcs
Color: Red
Size: medium

43
 Chapter-6
Quality Control System

Serial Number Content Page Number

6.1 Quality 44-50

6.1 Quality
Quality may define as the level of acceptance of goods or services. It is a relative term. It
completely depends on customer satisfaction. Actually product quality is based on product
attribute

a) Quality Control: QC is a set of activities for ensuring quality in products. The

activities focus on identifying defects in the actual products produced.

b) Quality Assurance: QA is a set of activities for ensuring quality in the processes by

which products are developed

44
c) Working Flow Chart of Quality Control:

d) Quality Control Tools:

1. Cause-and-Effect Diagrams / Fishbone Diagram

2. Pareto charts
3. Control Charts
4. Scatter diagrams
5. Histograms
6. Flowcharts
7. Checklists

45
AQL: AQL means Accepted Quality Level. AQL is designed as the maximum average defective
items in a lot. It is expressed in a percentage number of average defective items can simply be
identified by following a formula,

Average defective item

= No. of defective item found during inspection / Total no. of item inspection X 100.

The defects that are found during inspection are classified into 3 categories:
1. Critical: Must be 100% accurate. There is no range.
2. Major: Normally 2.5%
3. Minor : Normally 4%

Sampling Method:
1. Single Sampling method
2. Double Sampling method
3. Multiple Sampling method

Sample Acceptable Quality level

size 2.5 4.0 6.5
Code Sample
Lot or Batch size Letter Size Ac Re Ac Re Ac Re
2–8 A 2 0 1 0 1 0 1
9 – 15 B 3 0 1 0 1 0 1
15 – 25 C 5 0 1 0 1 0 1
26 – 50 D 8 0 1 1 2 1 2
51-90 E 13 1 2 1 2 2 3
91-150 F 20 1 2 2 3 3 4
151-280 G 32 2 3 3 4 5 6
251-500 H 50 3 4 5 6 7 8
501-1200 J 80 5 6 7 8 10 11

1201-3200 K 125 7 8 10 11 14 15

3201-10000 L 200 10 11 14 15 21 22

Table, 05: AQL Chart

46
Lot or Batch size: This means total how many pieces inspector is going to check or inspect.

Sample size Code letter: This code is indicative a range of batch size.

Sample size: It means that how many pieces will be picked up for inspection from the total
offered pieces (Batch).

Ac (Accepted): The number in this column denotes that if the inspector finds up to that much
defective pieces the shipment will be accepted by buyer.

Re (Rejected): On the other hand number in this column denotes that if the inspector finds that
much defective pieces or more than the listed number, the shipment will be rejected (or asked to
the manufacturer for 100% inspection and re-offer for final inspection) by buyer.
Single sampling plan - Normal inspection:
Assurance an AQL of 2.5 % and a lot size of 1200 garments and the sample size is 80 garments.
If the number of defective garments found is 5 the total lot is "Acceptable" suppose if the
defective garments found is 6, the total lot is "Reject/ Re-Check".
Double sampling plan - Normal Inspection:
Assurance an AQL 4.0% and a lot size is 1200 garments and the sample size is 80 garments. If
the Number of defective garments found is 7, the total lot is "Acceptable" suppose if the
defective garments found is 8 the total lot is "Reject/ Re-Check".

For Example:

▪ Total garments (lot Size) 1200 garments

▪ Sample size (selected for inspection) 80 garments
▪ AQL 2.5 / 4.0
If the major defective found is 5 and minor defective found is 7 the total garments is
"Acceptable". If the defective exceed (Above 5 major and 7 Minor), the total garments is Reject /
Re-check.

47
e) Other System of Quality Assessment:

48
 f) Quality Control Tools (PDCA): The quality control life cycle is an
ongoing cycle of planning, monitoring, assessing, comparing, correcting, and
improving products or processes. It is designed to improve the quality of a
product or process through continuous reinvention.

Act *Plan

Check Do

Fig. 24: PDCA Cycle

• Plan: identify and analyze the problem or opportunity, develop hypotheses about what the
issues may be, and decide which one to test.
• Do: test the potential solution, ideally on a small scale, and measure the results.
• Check/Study: study the result, measure effectiveness, and decide whether the hypothesis is
supported or not.
• Act: if the solution was successful, implement it.

49
 g) Factory Methodology: Montex Fabrics Ltd. use inspection method for the control of
quality of the product.

They Control Quality by following system:

Raw Material Inspection

In process Inspection

Final Inspection

h) Quality failure: Quality Failure is the phenomenon of the product which does not
meet customer demand or which are defect.

Quality may fails due to:-

- Broken, skipped or missing stitches
- Untrimmed threads
- Dimensions out of tolerance
- Puckering
- Open Seams
- Incorrect Stitches per Inch
- Shade Variation

50
 Chapter-7
Maintenance

Serial Number Content Page

7.1 Maintenance 51-54

7.1 Maintenance: The work of keeping something in proper condition, care or upkeep
including: taking steps to avoid something breaking down (preventative maintenance) and
bringing something back to working order (corrective maintenance).

Types of Maintenance:
1) Preventive maintenance, also known as PM is "a routine for periodically inspecting" with the goal
of "noticing small problems and fixing them before major ones develop.

2) Corrective maintenance, where equipment is repaired or replaced after wear, malfunction or break
down.

3) Predictive maintenance, which uses sensor data to monitor a system, then continuously evaluates it
against historical trends to predict failure before it occurs

4) Breakdown maintenance, is maintenance performed on equipment that has broken down and is
unusable. It is based on a breakdown maintenance trigger. It may be either planned or unplanned

51
Maintenance Tools:

Serial
Tool Names Funtion
No.
1. Spanner Tightening & Loosening of Nuts & bolts
2. Socket Ratchet set Tightening of Nuts & bolts
3. Slide Range Tightening & Loosening of Nuts & bolts
4. Pliers Tightening & Loosening of Nuts & bolts
5. Pipe threat Cutting Tools To Cut the threat in Pipe.
6. Bearing Puller To assist the Opening of bearing from shaft.
7. Pipe Range Tightening & Loosening of Pipe Joint.
8. Pipe Cutting Tools For Pipe Cutting.
9. Hole Punch Punching the hole.
10. Divider For circle marking on metal & wood
11. Easy Opener To open the broken head bolt
12. Heavy Scissor Cutting of gasket & steel sheet.
13. Oil Can Oiling of moving Parts.
14. Drill M/C and Drill bit. For Drilling.
15. Grease Gum. For greasing of moving Parts of M/C.
16. Girding M/C For grinding & Cutting of mild steel.
17. Welding M/C For welding & Cutting.
18. File For Smoothing the Surface.
19. Hammer For Scaling & right angling.
20. Hacksaw blade For metal Cutting.
21. Handsaw (wood) For wood Cutting.
22. Grinding Stone For smooth finishing.
23. Grinding Paste For easy Cutting of metal.

Table 06: Maintenance Tools

52
Factory System:
Generally there are two types of maintenance system found in Montex Fabrics Ltd:

1. Breakdown Maintenance
2. Preventive Maintenance/Routine maintenance
1) Breakdown Maintenance
Breakdown Maintenance is the repair which generally done after equipment has attained down
state. Online mechanics set for breakdown maintenance sewing line for immediate support or
quick information system can be set to call mechanic, can set traffic lighting system in every
sewing line. Breakdown time should be recorded and track to see mechanic performance.
Machine breakdown time consider as loss time in garments manufacturing. These are
unpredictable or reactive type of maintenance and are more difficult to schedule than the above
categories. There are no routine maintenance tasks to perform and equipment is repaired or
replaced only when obvious problems occur. Breakdown maintenance works well if equipment
shutdowns don’t affect product quality or revenue generation.

2) Preventive maintenance/Routine maintenance

Preventive maintenance is periodical inspection (daily, weekly, monthly basis cleaning,
inspection, oiling and re-tightening) and service activities what are aimed to detected potential
failures and perform minor adjustments and repairs which will present major operating problems
in future. Sewing maintenance team does preventive maintenance as per their maintenance
schedule or calendar. It’s the preventive maintenance to retain the healthy condition of
equipment and prevent major breakdowns of failure by deterioration of facilities. It ranges from
such simple tasks as cleaning, inspection, equipment condition diagnosis checking, changing oil,
water, air, alignment, re-tightening etc. Routine maintenance consists of periodically inspecting,
servicing, lubricating and cleaning equipment and replacing parts to prevent sudden failure and
process problems to ensure continuing working condition.

53
Working Flowchart:

Problem occurred

Operator

Supervisor

Production officer

Maintenance officer

Solution

54
 Chapter-8
Utility Services

Serial Number Content Page Number

8.1 Utility Facilities 55
8.2 Source of Utility 55-57

8.1 Utility Facilities

a) Electricity
b) Steam Water
c) Drinking Water
d) Air Condition
e) Fire Extinguisher
f) Compressor

8.2 Source of Utility

Utility Source
Electricity PDB & Generator
Gas TITAS
Water Pumps
Compressed Air Compressor
Steam Boiler

Table, 07: Utility Sources

55
Electricity:
Description: Gas Generator is used for supplying electricity for the production & the office of
the Montex Fabrics Ltd. Total Power produced by Gas Generator 945 KW = 1134 KVA.

Boiler:
Description: Boiler is mainly used for produce & deliver steam to different section as required.
In Montex Fabric Lt. Four Boilers are used to produced & deliver steam to different section. All
are thr Fire Tube Boiler.
Brand: OMNICAL
Origin: Germany
Model: DDHI 60-10
Year: 2002
Power: 3.9 MW
No. of Boiler: 04

Compressor:
Description: Compressor is mainly used to deliver compressed air to different section as
required. In Montex Fabrics Ltd. Five Compressor are used to produce & deliver Compressed air
to different section.
Brand: BOGE
Capacity: 774 Lt air Compression / Sec
Origin: Germany
No. of Compressor: 05

56
Source of the Gas:
Description: Source of the Gas is TITAS Gas Ltd. The Gas is supplied to Gas Generator or
different section ( Boiler- for heating Water) from the main line of the TITAS Gas Ltd.
Type: Gas Generator
Manufacturer: Cummins Power Generation
No. of Generator: 03
Model: 315GFBA
Year: 2002

57
 Chapter-9
Store & Inventory

Serial Number Content Page

9.1 Store 58-60

9.1 Store
The fabric and accessories stores department is centralized in apparel industry and all the fabric
and accessories comes to this unit first from the supplier and audited here and kept until it is
distributed to other units. For an export oriented and bulk production of garment industry. it is
essential to maintain a well-organized & well equipped inventory system. The main
responsibility of this department is to store all the raw material necessary to produce garments.
This department is sub divided into three sections. Store keeper follows a strong and appropriate
working procedure.

Store Keeping System:

▪ Unload fabrics & Accessories

▪ Inventory in warehouse.
▪ Fabrics & Accessories inspection
▪ Recording in register book and Excel sheet.
▪ Updated information put in Bin Card (It is updated information card for bin or rack

58
Inventory Control System:
There are two different types of inventory control systems available today
▪ Perpetual Inventory Control System
▪ Periodic Inventory Control System

Perpetual Inventory Control System:

When you use a perpetual inventory system, it continually updates inventory records and accounts for
additions and subtractions when inventory items are received, sold from stock, moved from one location to
another, picked from inventory, and scrapped. Some organizations prefer perpetual inventory systems because
they deliver up-to-date inventory information and better handle minimal physical inventory counts. Perpetual
inventory systems also are preferred for inventory tracking because they deliver accurate results on a continual
basis when managed properly.

Periodic Inventory Control System:

Periodic inventory systems do not track inventory on a daily basis; rather, they allow organizations to know the
beginning and ending inventory levels during a certain period of time. These types of inventory control
systems track inventory using physical inventory counts. When physical inventory is complete, the balance in
the purchases account shifts into the inventory account and is adjusted to match the cost of the ending
inventory. Organizations may choose whether to calculate the cost of ending inventory using LIFO or FIFO
inventory accounting methods or another method; keep in mind that beginning inventory is the previous
period’s ending inventory

59
Shipping Instruction/ System: Shipping is a system process of model which covers
planning and execution of receipts, shipments, nominations and itineraries for ship, truck or
pipeline. It can handle world scale calculations and tracking of vessels and inventories at
multiple terminals and berths. This operational model includes all internal and external
movements.

Shipping management maintained such features:

• Able to track individual transactions or gross quantities
• Manages planned and actual transactions.
• External material transfers can be balanced against internal facility movements.
• Able to manage data multiple cargoes, cargoes with multiple shipment, shipments with
split ownership.
• Able to manage multiple versions of transaction quantities and qualities.
• Integrated with real-time instrumentation.
• Handles all supply chain movements including. Ship, truck and pipeline.

The latest track and trace technologies:

Modern trace and track systems that focus on the IT-based solutions. It is monitoring and
recording of shipment movements from origin to destination. In the apparel manufacturing
industry, garment products are tracked in terms of geographic location and time-delays. In this
modern tracing system, buyers and manufacturer know the status and physical conditions of the
goods.

Here I have mentioned some latest track and trace technologies for shipment:
• Global Positioning System (GPS)
• Java Mobile Cell Tracking
• Mobile Phone Approximated (AGPS)
• Radio frequency identification (RFID)
• Web-based telephone Tracking

60
 Chapter-10
Embroidery

Serial Number Content Page

10.1 Embroidery 61
10.2 Working Flow Chart 62-64

10.1 Embroidery:
Embroidery section is one of the most important sections of apparel manufacturing industry. It is
one of the special task which is done according to the buyer’s requirements. In the past embroidery
had done by using manual method. But now a day, it is done by applying computerized method.
In readymade apparel sector, computerized embroidery machine helps to produce very complex
design within a very short period of time.

Types of Embroidery Ued in Garments:

1. Whitework embroidery,
2. Candlewick embroidery,
3. Cross stitch embroidery,
4. Pulled thread embroidery,
5. Hedebo embroidery,
6. Drawn thread embroidery,
7. Hardanger embroidery,
8. Crewel embroidery,
9. Surface embroidery,
10. Goldwork embroidery,
11. Redwork embroidery,
12. Blackwork embroidery,
13. Bluework embroidery,
14. Sashiko embroidery.

61
10.2 Working Flow chart:
Art work from buyer

↓
Input to ES-65(Software)

↓
Design analysis

↓
Send to buyer

↓
Recommendation & correction from buyer

↓
Sample prepare

↓
Send to buyer

↓
If approved then for bulk production

62
Machine used in Embroidery Section:

Fig. 25: Sunster Precision

Fig. 26: Barudan

63
 Fig. 27: Recon M/C

Work= Cone is made for large or small

Japan =2 machine
Indian=4 Machine
Total machine = 6

64
 Chapter-11
Merchandising

Serial Number Content Page

11.1 Merchandising 65-66
11.2 Working Flow Chart 67-70

11.1 Merchandising
Merchandising is the department which mediates marketing and production departments.Some
times, merchandising department will have to do costing and pricing also. In any case, the
merchandiser is the person whose responsibility is to execute the orders perfectly as per the costing
and pricing. So it is a very valuable department of Montex Fabrics Ltd. Merchandising comes
from the word merchandise. Merchandise means commodities or goods to be bought and sold. In
textile and apparel industry, merchandising is the department which mediates marketing and
production department.

Types of Merchandising
Two type of merchandising done in garment exports

1. Marketing merchandising.
2. Product merchandising

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Functions of Merchandising Department:-

• Internal & external communication,

• Sampling,
• Lab dips preparing,
• Accessories & trims sourcing,
• Preparing internal order sheets,
• Preparing purchase orders,
• Advising and assisting production,
• Advising quality department about quality level,
• Mediating production and quality departments,
• Giving shipping instructions and following shipping,
• Helping documentation department,
• Taking responsibility for inspections and
• Following shipment.

Buyer Buyer, Standard Manual, Spec Sheet Merchandiser

BOM, Costing Sheet, Sample Approval

66
11.2 Marchandising Process Flow:-

Receive product package from buyer

Sample Development

Price Negotiation

Order confirmation

Receive order sheet

Lab approval

Size set/Fit sample

PP sample

Fabric Booking

67
Yarn receiving+Knitting+Dyeing

Sample Cutting

Size Set

Bulk Cutting

Embroidery/Printing

Sewing

Finishing

Arrange Final insperction

Shipment

68
Costing Sheet:
Costing sheet is a statement or format where all the costs are entered in orderly manner to ascertain
the total cost of a product or process. It is also known as working sheet or work sheet.

Costing Sheet of Polo Shirt

Buyer Champion Date 1.02.2019
Style Ld-Ps,04 Delivery 30.05.2019
Description Knitted polo shirt Quantity 10000pcs
Fabrication 100% cotton pique
Size S, M, XL, XXL
Factory Montex Fabrics Ltd.
Yarn 100% cotton (30/1) carded
GSM 160
Wash Instruction Silicon wash

(Fabric cost + Processing) Per Dozen

Fabrication Item Consumption Unit price($) Amount
($)
100% cotton Pique Solid Yarn 3kg 3.50 10.5
180 GSM Knitting 3kg 0.30 0.9
100% cotton 1×1 Rib Dyeing 3kg 1.20 3.6
Collar + Cuff
Total (Fabric cost + Processing) Per Dozen) per dozen 15.00
Accessories(Trimmings+ Packing + Embellishment) cost per dozen
Accessories Main Label 0.25
(Trimmings+ Packing + Care Label 0.15
Embellishment) cost per Sewing Thread 1.00
dozen Print 3.00
Washing 5.00
Zipper 0.60
Hang Tag 0.40
Poly Bag 0.50
Carton 0.90
Others 0.10
Total Accessories (Trimmings+ Packing + Embellishment) cost per dozen 11.9
Lab Test (Fabric and Garments) per dozen –
Total (Fabric + Accessories+ Lab test) cost per dozen 26.9
Cost of making (CM) including profit per dozen 10.00
Commercial cost 4% of total (Fabric + Accessories+ Lab test) cost /dozen 1.08
Total price per dozen 37.98
FOB price per pc 3.17
Table, 08: Costing Sheet

69
Order Sheet:
A order sheet contains-
• Order number
• Style number
• Price of products
• Item description
• Fabric details
• Styling
• Price
• Shipment date
• Quantity details

Order execution contains the following features:

1. Pattern making,
2. Print and embroidery development,
3. Fit sample making,
4. Comments,
5. Cutting the fabric,
6. Print and embroidery,
7. Sewing,
8. Finishing and QC check,
9. Shipment.

A Merchandiser distribute order sheet to-

❖ Commercial section
❖ Planning Section
❖ Store
❖ Production Section
❖ Quality Section
❖ Sample Section

70
 Chapter-12
Compliance

Serial Number Contex Page

12.1 Compliance 71-74

12.1 Compliance: Compliance can be defined as conformity to a given standard. The

garment industry is expected to maintain certain standards or compliance to operate. Some
of the common compliances required in garment industry include working hour policy,
holiday compensation, and wage for leaves, equal remuneration policy, antidiscrimination
policy, no child labour, health, and safety policy, etc. Compliance adherence in factories is
crucial to ensure a favourable working environment.

Compliance Policies:

In Montex Fabrics Ltd. there are different compliance policies such as:
Over working hour policy
Freedom of association policy
Recruitment policy
Child care Centre policy
Policy for resign
Grievance policy
Disciplinary action policy
Pregnancy policy
Maternity leave policy
Training policy

71
Consequences of Noncompliance:

Noncompliance with social regulations affects millions of workers worldwide, especially those in
garment manufacturing. It can drastically reduce workers’ quality of life, sometimes to inhumane
levels. These poor conditions can push people deeper into poverty and cause severe health
concerns. In some extreme cases, factories have even exploded or collapsed because working
conditions are so unsafe.

Uses of Compliance in Montex Fabrics Ltd:-

• No forced labor
• No child labor
• Hours of work
• Voluntary over time
• Interval for rest
• Weekly holidays
• annual leave
• Festival holidays
• Leaves with bonus
• Maternity leaves and protection
• Worker participatory committee
• Mineral drinking water
• Sanitary facilities
• First aid box
• Canteen
• Day care center
• Health care activities
• Smoking free zone
• Gratuity
• Insurance coverage

72
Fire and Safety
• Sufficient fire extinguisher and active
• Access area without hindrance
• Fire certified personal photo
• Emergency exit
• Rubber mats & ironers
• First aid box on
• Ironers wearing sleepers
• First trained employees
• Motor/needle guard
• Eye guard
• Nurse
• Doctor
• Medicine
• Medicine issuing register
• Welfare officer

Fig. 25: Fire & Safety Device

73
 Fig. 26: Frist aid box Fig. 27: Medical Centre

Fig. 28: Workers canteen

Facilities:
ISO: International Organization for Standardization
WRAP: Worldwide Responsible Accredited Production
BSCI: Business Social Compliance Initiative
SEDEX: Supplier Ethical Data Exchange

74
 Conclusion
The completion of the 8 Weeks industrial attachment and training at Montex Fabrics Ltd. have
given us the inspiration that factory is one of the appropriate destiny to implement the theoretical
Knowledge. Industrial Training is an essential and important part of 4years of B.Sc. in Textile
Engineering program, because its lead us to the actual destiny of practical life. Montex Fabrics
Ltd. is one of the biggest knit garment manufacturer which has given us the opportunity to undergo
8 weeks of industrial training there which was extremely beneficial for us. Because no knowledge
specially one like textile engineering cannot be fulfilled without practical knowledge.

In our training period we have observed that Montex Fabrics Ltd. produce high quality garments
and fulfill the special requirements from the different types of buyers by following different
internationally recommended method. In our training period we have learned many things like
different machines and their functions, different work flow process and methods, technique and
production systems and management system also. By this industrial training we have gathered the
practical knowledge about different production process, machinery maintenance, industrial
management and the environment of the industry, which will help us in our job life. From this
training we have learned how the desired product is made ready for shipment from starting to the
end. Although the time was limit, we have learned some important things for our job or
professional life. We have got idea about different departments and their responsibilities and also
what will be the industrial environment for a Textile Engineer.

At the end, we have completed our Industrial Training successfully. Industrial Attachment sends
us to the expected destiny of practical life. Montex Fabrics Ltd. is a well Known factory in the
textile field of Bangladesh. Every textile student should do their training attentively and regularly
because this training acts as catalyst to minimize gap between theoretical and practical knowledge.

Apendix:
GSM= Gram Per

SMV=

ISO=

WRAP=

75