Textile Internship Report / A composite Textile Industry / Garments Industry / Industrial Attachment on knit composite ltd

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BGMEA University of Fashion & Technology
Industrial training report on
Green Life Knit Composite Ltd.
Submitted By
Name: T. M. Ashikur Rahman
Id: 191-097-801
Name: Iram Ahmed Leen
Id: 191-184-801
This internship report submitted in partial fulfilment of the requirements for the degree of
B.Sc. in Textile Engineering Department (TE) in the faculty of Textile Engineering of
BGMEA University of Fashion & Technology (BUFT).
Department of Textile Engineering
March 2023

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Industrial training report on
Green Life Knit Composite Ltd.
Submitted By
Name: T. M. Ashikur Rahman
Id: 191-097-801
Name: Iram Ahmed Leen
Id: 191-184-801
Submitted to
Department of Textile Engineering
In partial fulfillment of the requirements for the degree of Bachelor of Science in Textile
Engineering
Supervised by
Mr. Nafis Abir
Lecturer
Department of Textile Engineering,
March 2023

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Letter of Transmittal
13 th March, 2023
Mr. Nafis Abir
Lecturer,
Department of Textile Engineering,
Nishatnagar, Dhaka
Subject: Submission of Internship Report.
Respected Sir,
We are extremely indebted for your tremendous support and guidance throughout our long
journey at Green Life Knit Composite Ltd. and internship period. Being working with you, we
have earned valuable knowledge and were inspired by your innovativeness, which helped
enrich our experience to a greater extent. An internship report on “Green Life Knit Composite
Ltd.” is submitted to you for the partial fulfillment of the Bachelor of Science in Textile
Engineering Degree.
During our internship period, we have trained in four departments of “Green Life Knit
Composite Ltd.” we made sincere efforts to study related materials, observe operations
performed in Merchandising, Garments, Washing, Industrial Engineering which are the
sources of collected data to prepare the present report on Apparel Manufacturing Engineering.
We have to make this report as comprehensive as possible within the time limit. But there may
be some mistakes due to various limitations. For this reason, we beg your sympathetic
consideration. Finally, we pray for your blessing for our successful engineering career.
Thank you
Yours Faithfully
T. M. Ashikur Rahman
Id: 191-097-801
Iram Ahmed Leen
Id: 191-184-801

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Declaration of Examiners
The internship report on Green Life Knit Composite Ltd. is submitted by T. M. Ashikur
Rahman, Id 191-097-801 & Iram Ahmed Leen, Id: 191-184-801. The report is accepted as
satisfactory in partial fulfillment of the requirement for the degree of B.Sc. in Textile
Engineering.
Board of Examiners
Name Signature
1. Supervisor: Mr. Nafis Abir
Lecturer
Department of TE ….…………………….
2. Examiner 1: Mohammad Mamunur Rashid
Assistant Professor
Department of TE ….…………………….
3. Examiner 2: Mohammad Mizanur Rahman
Assistant Professor & Head
Department of TEM ..………………………

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ACKNOWLEDGEMENT
At first, we would like to thank Almighty Allah to give us strength and ability to complete the
industrial training and to write this report. Several people have made significant contributions
to make our training successful. Their advice and suggestions helped use a lot.
Firstly, we are very much grateful to “Green Life Knit Composite Ltd.” authority for giving
us the opportunity to do our internship work in their factory. Similar, profound gratitude goes
to our internship supervisors Assaduzzaman Chowdhury, Admin Director & Al- Amin Alex,
Merchandising Manager, Green Life Knit Composite Ltd. for their tremendous support and
guidance throughout our training period.
Special thanks go to our enthusiastic supervisor Mr. Nafis Abir, Lecturer, Department of
Textile Engineering, BUFT, who has been an amazing experience and we thank him
wholeheartedly, not only for her tremendous academic support, but also for giving us so much
wonderful opportunities.
And also, thanks go to Prof. Dr. Abu Bakar Siddique, Dean, Faculty of Textile Engineering
& Dr. Ranajit Kumar Nag, Asst. Professor & Head, Department of Textile Engineering,
BUFT. Who so generously Inspired & contributed to do this type of project work
I would like to extend thanks to our enthusiastic Prof. Dr. Engr. Ayub Nabi Khan, Pro Vice
Chancellor, BUFT, and Prof. Dr. S.M. Mahfuzur Rahman, Vice Chancellor, BUFT for their
Encouragement and valuable suggestions for continual improvement of the report.
Finally, thanks to BGMEA University of Fashion & Technology (BUFT) for creating such
a great environment for us. It is the first Textile based private university in Bangladesh.

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EXECUTIVE SUMMERY
“Green Life Knit Composite Ltd.” is a manufacturer of knit composites. It is a 100% export-
oriented hybrid knit textile unit dedicated to meeting the global demand for knit and casual
clothing in the twenty-first century. The project has surrounded the knitting, dyeing, and
processing of fabrics as well as the development of ready-made garments to be available from
one stop service in the context of changing global demand patterns, international trade climate,
particularly the withdrawal of quota system and GSP, and the availability of craftsmanship in
the country.
The project ensures that everything from sampling to supply of finished ready-made garments
comes from a single source, ensuring on-time delivery and quality compliance. The machines
& equipment setup for this project are procured from world class brands, names that are
renowned for their high quality, product integrity & dependable production. The manpower
engaged in this project to carry out the day-to-day business is all highly skilled, purely
professional, vastly experienced.
The unique combination of organized managerial and technical term on one hand and latest,
advanced and balanced technology on the other hand made the project one of the tops to be
referred in this field in the country. “Green Life Knit Composite Ltd.” is committed not only
to deliver world class products but also to quality assurance, price affordability & social
accountability. Considering all the above features to learn about the technology of textile
manufacture as well as management & maintenance, “Green Life Knit Composite Ltd.” was
surely a good choice. I feel very lucky to complete our industrial attachment here.

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Table of Content
Letter of Transmittal ...................................................................................................................i
Declaration of Examiners ..........................................................................................................ii
ACKNOWLEDGEMENT....................................................................................................... iii
EXECUTIVE SUMMERY.......................................................................................................iv
Table of Content ........................................................................................................................v
List of Table........................................................................................................................... viii
List of Figure..............................................................................................................................x
01 Introduction.........................................................................................................................1
1.1 Introduction......................................................................................................................1
1.2 The Background of Internship .........................................................................................1
1.3 The Objectives of Internship............................................................................................1
02 General Introduction of the Mill .......................................................................................2
2.1 Introduction......................................................................................................................2
2.2 Location & Site Plan of Factory ......................................................................................2
2.3 Factory Details.................................................................................................................3
2.4 Vision...............................................................................................................................4
2.5 Mission.............................................................................................................................4
2.6 The Market Places............................................................................................................5
2.7 Different Department of Green Life Knit Composite Ltd. ..............................................8
03 Manpower Management ....................................................................................................9
3.1 Organogram of the Factory..............................................................................................9
3.2 Permitted Manpower in Different Department..............................................................10
3.3 Shift changes..................................................................................................................10
3.4 responsibilities of production of officer.........................................................................10
3.5 Job description ...............................................................................................................11
04 Product Mix & Their Sequence of Operation ................................................................12
4.1 Main Products................................................................................................................12
4.2 Types of yarn used.........................................................................................................13
4.3 Yarn source....................................................................................................................13
4.4 Fabric used in the Factory..............................................................................................13
4.5 Trims..............................................................................................................................13
4.5.1 Different Types of Trims ............................................................................................14
4.6 Accessories ....................................................................................................................16
4.6.1 Different Types of Accessories...............................................................................16
05 Machine Description.........................................................................................................18

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5.1 Knitting Department ......................................................................................................18
5.1.1 Knitting Machine Specification ..............................................................................18
5.1.2 Knitting Machine Layout........................................................................................20
5.2 Machine Used in Fabric Inspection Department ...........................................................21
5.2.1 Fabric Inspection Machine Specification.................................................................21
5.3 CAD Section..................................................................................................................22
5.3.1 CAD Machine Specification...................................................................................22
5.4 Sample Section...............................................................................................................23
5.4.1 Sample Section’s Machine Specification................................................................24
06 Production planning & sequence & operation...............................................................29
6.1 Production Process.........................................................................................................29
6.1.1 Description of production process ..........................................................................29
6.2 knitting Process..............................................................................................................30
6.2.1 Knitting Process Flow Chart...................................................................................31
6.3 Fabric Store Process Flow Chart....................................................................................31
6.4 Merchandising................................................................................................................32
6.4.1 Planning of merchandising department ..................................................................32
6.4.2 Types of Merchandising .........................................................................................33
6.4.3 Organogram of Merchandising Section..................................................................33
6.4.4 Process of Merchandising.......................................................................................34
6.5 Organogram of Sample Section.....................................................................................36
6.5.1 Process Flow of Sample Section.............................................................................36
6.5.2 Working Process of Sample Section.......................................................................37
6.6 Working Flow Chart of CAD Section ...........................................................................38
6.6.1 The procedure of CAD Section...............................................................................38
6.7 Process Flow of Cutting Section....................................................................................39
6.8 Organogram of IE Section .............................................................................................39
6.8.1: Process Flow Chart of Industrial Engineering.......................................................40
6.8.2 Some Formulas for IE Section................................................................................40
6.9 Finishing process flow chart ..........................................................................................41
6.10 Daily & Monthly Production Report ...........................................................................42
07 Quality management system ............................................................................................43
7.1 Quality Management Procedure ....................................................................................43
7.1.1 Quality Assurance Procedure..................................................................................43
7.2 Quality Standard (ISO) ..................................................................................................43
7.2.1 Quality Standard Certificate ...................................................................................44
7.3 Defects and Their Causes & Remedies in Knitting .......................................................45

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7.4 Defects & Their Causes in Sewing Section...................................................................47
08 Maintenance ......................................................................................................................49
8.1 Maintenance Machinery.................................................................................................49
8.2 Types of Maintenance....................................................................................................49
8.2.1 Preventive maintenance ..........................................................................................49
8.2.2 Predictive maintenance ...........................................................................................49
8.2.3 Breakdown Maintenance ........................................................................................50
8.3 Manpower for Maintenance Department.......................................................................50
8.4 Maintenance Equipment ................................................................................................51
09 Utility Services...................................................................................................................53
9.1 Utility facility available .................................................................................................53
9.2 Source of Utility.............................................................................................................53
9.3 Cost of Different Utilities ..............................................................................................53
9.4 Utility Machine Information..........................................................................................54
9.5 Remarks .........................................................................................................................55
10 Inventory Management ....................................................................................................56
10.1 Inventory system..........................................................................................................56
10.2 Inventory System for Raw Materials.....................................................................56
10.2.1 Inventory System Flow Chart ...............................................................................56
10.3 Raw Materials of inventory control .............................................................................57
10.4 Store Capacity..............................................................................................................57
11 Marketing activities ..........................................................................................................58
11.1 Consumer of the products............................................................................................58
11.2 Product label ................................................................................................................58
11.3 Package size and label .................................................................................................58
11.4 Local Market................................................................................................................58
11.5 Importing countries......................................................................................................58
11.6 Marketing Strategy.......................................................................................................59
11.7 Duties & responsibilities of marketing officer.............................................................59
11.8 Remarks .......................................................................................................................59
12 Social and environmental information............................................................................60
12.1 Environment Management System..............................................................................60
12.2 Fabric and Accessories Wastage Management System...............................................60
12.3 Electrical and Mechanical Wastage Management System ..........................................60
12.4 Empty Chemical / Dye Container Management System .............................................61
12.5 Health & Safety............................................................................................................61
12.6 No Child Labor ............................................................................................................61

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12.7 Corporate Social Responsibility (CSR) .......................................................................62
12.7.1 Core Values...........................................................................................................62
13 SWOT Analysis.................................................................................................................63
13.1 SWOT ..........................................................................................................................63
13.2 Strength........................................................................................................................63
13.3 Weakness .....................................................................................................................63
13.4 Opportunity..................................................................................................................64
13.5 Threats..........................................................................................................................64
14 Conclusion & Recommendation......................................................................................65
14.1 Conclusion ...................................................................................................................65
14.2 Limitation of The Report .............................................................................................65
14.3 Recommendation .........................................................................................................66

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List of Table
Table 2.5: Factory Information..................................................................................................3
Table 2.6: Client’s Name ...........................................................................................................5
Table 3.2: Manpower List........................................................................................................10
Table 4.1: Main Products of Green Life Knit Composite Ltd. ................................................12
Table 4.5.1: Different Types of Trims.....................................................................................14
Table 4.6.1: Different Types of Accessories ...........................................................................16
Table 5.1: Knitting Machines ..................................................................................................18
Table 5.2: Fabric Inspection Machine .....................................................................................21
Table 5.2.1: Fabric Inspection Machine’s Specification ..........................................................21
Table 5.3: Fabric Inspection Machine’s Specification ............................................................22
Table 5.3.1: CAD Machine’s Specification.............................................................................22
Table 5.4: Machine in Sample Section ....................................................................................23
Table 5.4.1: Machine Specification in Sample Section ...........................................................24
Table 7.3: Faults & Causes in Knitting....................................................................................45
Table 8.3: Manpower for Maintenance Department................................................................50
Table 8.4: Maintenance Equipment.........................................................................................51
Table 9.2: Source of Utility .....................................................................................................53
Table 9.3: Cost of Utilities.......................................................................................................53
Table 9.4: Utility Machine’s Technical Data...........................................................................54
Table 10.4: Store Capacity Information...................................................................................57

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List of Figures
Fig. 2.2: Factory Location on Google Map................................................................................2
Fig. 2.7: Different Sections of Green Life Knit Composite Ltd................................................8
Fig. 3.1: Organogram of the Factory .........................................................................................9
Fig. 5.1.2: Layout of knitting Section......................................................................................20
Fig. 6.1: Production Process Diagram of Green Life Knit Composite Ltd..............................29
Fig. 6.2.1: Knitting Process......................................................................................................31
Fig. 6.3: Fabric Store Process Flow Chart...............................................................................31
Fig. 6.4.1: Planning of merchandising department in garment industry..................................32
Fig. 6.4.2: Types of Merchandising.........................................................................................33
Fig. 6.4.3: Organogram of Merchandising...............................................................................33
Fig. 6.4.4: Process flow of merchandising section ..................................................................35
Fig. 6.5: Organogram of Sample section in Green Life Knit Composite Ltd..........................36
Fig. 6.5.1: Process flow of sample section...............................................................................36
Fig.6.6: Working Flow of CAD Section..................................................................................38
Fig. 6.7: Flow Chart of Cutting Section...................................................................................39
Fig. 6.8: Organogram of IE section .........................................................................................39
Fig. 6.8.1: Process flow of IE section ......................................................................................40
Fig.6.7: Finishing Process Flow Chart.....................................................................................41
Fig. 6.10: Production Report....................................................................................................42
Fig. 7.1.1: Quality Management Procedure.............................................................................43
Fig. 7.2.1: Certificate of Green Life Knit Composite Ltd. ......................................................44
Fig. 8.2: Maintenance Type .....................................................................................................49
Fig. 8.2.3: Breakdown Maintenance Procedure.......................................................................50
Fig. 10.2.1: Inventory Flow Chart ...........................................................................................56
Fig. 12.2: Sustainable Recycled Accessories...........................................................................60
Fig. 12.5: Health & Safety.......................................................................................................61
Fig. 12.7.1: Core Values of Green Life Knit Composite Ltd. .................................................62
Fig.13.1: SWOT In Brief .........................................................................................................63

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01 Introduction
1.1 Introduction
An internship is a program that provides students or recent graduates with hands-on work
experience in a specific industry or profession. The purpose of an internship is to offer practical
training, build professional networks, and gain valuable insights into a particular field.
Internships can be found in a wide range of industries, including business, engineering,
healthcare, media, and more. They can be paid or unpaid and can vary in length, depending on
the employer and the program. Some internships may last for a few weeks, while others can
extend for several months or even a year. During an internship, participants work alongside
experienced professionals in their field of interest, gaining practical experience and developing
industry-specific skills. Interns may also attend training sessions, workshops, and networking
events to expand their knowledge and professional connections.
1.2 The Background of Internship
An internship is a period of temporary work experience offered by an organization to a student
or a recent graduate. Internships are typically designed to provide practical experience and
exposure to a particular industry or profession, with the goal of helping the intern develop
professional skills, gain insights into their chosen field, and build professional networks.
1.3 The Objectives of Internship
• Results in terms of knowledge, attitude, skill, aspiration, and behavior
• Participant performance, rather than trainer performance or instructional procedure
• By applying theoretical knowledge and learn more about the technical knowledge
• To know about the company and their work environment
• Observe different types of operations/processes
• To learn about the machines/equipment that used in the factory
• To learn about different types of problems and their solutions

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02 General Introduction of the Mill
2.1 Introduction
Green Life Group is a 100% garment export group of company who believes in the art of
producing honest and approving garments and fabric to the world of fashion and clothing
industry. While positioning ourselves as a reliable supplier of global brands, we allow us to
explore the potential and create a niche in the export business. We are strictly maintaining a
very high standard of compliance even within the smallest concern of our group. This is another
key reason which attracts the leading buyers. Our range covers the offerings of fashion needs
for men, women and kids across apparels and accessories, all in tune with the current market
trend.
Since inception, with a commitment of delivery on time with perfect quality, we have made
sure to offer the highest level of buyer satisfaction throughout the globe. All of our factories
are situated in factory owned land. With accumulate production capacity of 15 million piece
garments a year, the annual turnover of the group is USD 60 Million.
2.2 Location & Site Plan of Factory
Fig. 2.2: Factory Location on Google Map

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2.3 Factory Details
Table 2.5: Factory Information
Company Name Green Life Knit Composite Ltd.
Legal Status One Stop knit & Woven Solution
Established 2010
Total Number of
Employees
2420 Person
Establishment Info Self-owned 5 storied independent complex comprising of
25,000 square feet of floor space.
Nature of Business Knit Fabric Manufacturing, Knit Fabric Dyeing, Print,
Embroidery & Wash
Current Exports USA, Europe, and Canada
Financial Information Bank: Al-Arafah Islami Bank Ltd.
Insurer: Takaful Islami Insurance
Factory Address Tongabari, Ashulia, Savar, Dhaka, Bangladesh
Telephone +8809612451500
Fax +8802 7913989
Website www.greenlifebd.com
Email info@greenlifebd.com
Contact Person Details Name Rafiqul Islam Siddique
Designation Executive Director
Mobile +8801886-500444
+8801714-589589
Email ed@greenlifebd.com
Name Assaduzzaman Chowdhury
Designation Admin Director
Mobile +8801714138393

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Turnover (In USD) USD $ 20 Million/Year
Sampling Capacity 400 pcs/Day
Sample Lead Time 45 Days
Lead Time 90 Days
Production Capacity 36 units of Circular Knitting Machine
12,000 Kg/Day (Knitting)
12,000 Kg/Day (Dyeing)
20,000 pcs/Day (Garments)
Terms of Sale FOB/CIF Confirmed and irrevocable Letter of Credit, NFE
2.4 Vision
Having made a strong presence in the Export business while successfully managing the global
market of garments by endorsing the latest technologies, competitive pricing and best quality
have led us to become a driving force in the industry. Through this, our vision is: "To deliver
the highest standards of quality products at best price to meet the needs of clients that will
enrich their business and to be the global exports company admired for its people, products and
trust."
Our vision makes us:
• Derive, develop and deliver quality garment products within time line.
• Be a company that's known for integrity, sustainability and valued responsibility to the
society and the planet.
• Earn the admiration of all our stakeholders - investors, clients, communities and our
employees - not only for the goals we achieve but how we achieve them.
2.5 Mission
We are different in our approach and make that difference a leading example of accuracy in
our products. Which is we why we are ready to take our Quality Mission forward.
• To have a keen sense of customer understanding by meeting their demands according
to buyer requirements.
• To expand our distribution market from existing presence of USA, Europe, and Canada.

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• To achieve all of the above through highest touch of professionalism, best quality and
planned merchandising, sustained commitment and not faltering on our business ethics.
2.6 The Market Places
Table 2.6: Client’s Name
Brand Name Logo Country
Kappa Italy
Ahlens Sweden
P&C Italy
Cecil Germany
Malboro Classics Italy
Street One Germany

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Snap Germany
Bon Marche England
Meca United States
Marina Militare Italy
Nimbus Denmark
Promo Stars California
Teddy Smith United Kingdom

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Slazenger United Kingdom
Pomp-De-Lux Denmark
Miniconf Italy
S. Oliver Germany
Peacocks UK
IKKS Franch

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2.7 Different Department of Green Life Knit Composite Ltd.
Fig. 2.7: Different Sections of Green Life Knit Composite Ltd.
Store Section
Sample Section
Cutting Section
Knitting Section
IE & Planning Section
Sewing Section
QC & Finishing Section
Dyeing Section
Washing Section
Printing Section
Embroidery Section
CAD Section
Merchandising Section
HR & Compliance
Department
Commercial Department
Testing Lab

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03 Manpower Management
3.1 Organogram of the Factory
Fig. 3.1: Organogram of the Factory

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3.2 Permitted Manpower in Different Department
Table 3.2: Manpower List
Sl. No. Department Permitted
01 Admin Department 43
02 Maintenance Department 22
03 Security Department 28
04 Accounts Department 06
05 Store Department 12
06 Sample Department 83
07 Cutting Department 106
08 Quality Department 80
09 Sewing Department 1163
10 Washing Department 87
11 Production Department 72
12 Knitting Department 148
13 Dyeing Department 96
14 Finishing Department 327
Sub Total 2273
3.3 Shift changes
Two shifts (A, B):
A Shift: 8 AM to 8 PM
B Shift: 9 PM to 8 AM
General Shift: 8 AM to 6 PM
3.4 responsibilities of production of officer
Their obligations comprise of planning generation, overseeing generation workers, checking
stock levels, filling orders from deals agents, and directing hardware support. The
responsibilities of a Production Officer can vary depending on the industry and specific
company they work for, but generally include:

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• Planning and organizing production schedules.
• Overseeing production processes.
• Monitoring production output.
• Ensuring equipment is maintained.
• Training and managing production staff.
• Ensuring safety and health regulations are followed.
• Analyzing and resolving production issues.
• Implementing process improvements.
• Collaborating with other departments.
• Maintaining production records.
3.5 Job description
Senior Product Owner ((SPO): A Senior Product Owner is a senior-level professional who
is responsible for the overall product vision, strategy, and roadmap. They work closely with
stakeholders and development teams to ensure that the product meets the needs of the business
and users.
System Requirements (SR): A System Requirements Engineer (SR) is a professional who is
responsible for gathering, documenting, and managing the requirements for complex software
systems. Their role is critical in ensuring that the software is developed to meet the needs of
the end-users, stakeholders, and business goals.
Product Owner (PO): A Product Owner (PO) is a professional who is responsible for defining
and prioritizing the product backlog, ensuring that the development team is delivering value to
the customer. They work closely with the development team to ensure that the product is
delivered on time, within budget, and to the desired quality.

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04 Product & Raw Materials
4.1 Main Products
Table 4.1: Main Products of Green Life Knit Composite Ltd.
Name Picture Name Image
T-Shirt Hoodie
Polo Shirt
Sports
Wear
Short Pant
Active
Wear

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4.2 Types of yarn used
• CVC: 85% cotton & 15% polyester
• Carded Yarn
• Combed Yarn
• Siro Yarn
• Melange
• Cotton
4.3 Yarn source
• Maksons Spinning Mills Ltd.
• Syed Spinning & Cotton Mills Ltd.
• Karotoa Spinning Mills Ltd.
• Far East Spinning Industries Ltd.
• Matin Spinning Mills Ltd.
4.4 Fabric used in the Factory
• Cotton
• Single jersey AOP
• Single jersey with Lycra
• Fleece
• Terry
• PK
• Rib
4.5 Trims
Trims are functional materials which are mandatory for making a garment other than fabric.
Such as sewing thread, button, zipper etc. Sometimes trims can be used as a decorative material.
The raw materials used in sewing room other than fabric are called Trims. On the other hand,
materials are directly attached to the fabric to make a garment are called trims. Like: Threads,
buttons, lining, Interlining, zippers, labels, care labels, etc. (Interlining is used as shape
forming/preserving materials.)

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4.5.1 Different Types of Trims
Table 4.5.1: Different Types of Trims
Sl. No. Name Function Image
01 Sewing
Thread
To join cut components together using
a sewing machine.
02 Interlining
Used between two fabric layers in
garments to support, reinforce, and
control areas of garments and retain
actual shape.
03 Lining
Used to maintain the shape of the
garment to the hang and comfort by
allowing it to slide over other
garment.
04 Zipper
Used device for binding together two
edges of fabric.
05 Lace
It provides a decorative, patterned
edge to the fabric of the item.
06 Button
Joins two pieces of fabric together by
slipping through a loop or by sliding
through a buttonhole.

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07 Size Label Indicates the size of the garments.
08 Care Label Contains various care instructions
09 Main Label
Contains the brand name or the
buyer’s brand logo.
10 Twill Tape
Used in sewing and tailoring to
reinforce seams, make casings, bind
edges, and make sturdy ties for
closing garments.
11 Velcro Tape
Provide a neat and simple way to
bundle objects and make a great
handle for carrying bulky things like
blanket
12 Elastic
Used in clothing as well mostly for
fitting reasons.

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4.6 Accessories
Accessories are the materials which are not mandatory for making a garments but use for
decorative purpose or value adding purpose.
4.6.1 Different Types of Accessories
Table 4.6.1: Different Types of Accessories
Sl.
No.
Name Function Image
01 Carton
A carton box is needed to deliver the
finished goods to the buyer.
02 Hanger
Hanger is a hanging goods in the
shape.
03 Draw cord/
String
It is used to "draw" (gather, or
shorten) fabric or other material.
04 Collar stay
They work by keeping the collar
smooth and flat.
05 Patch
They are used to cover up holes in
clothing and other fabric items.
06 Gum Tape
Gummed tape is a cost-effective
method of sealing cartons.
07 Poly bag
Providing durable protection when
materials and items are in storage.

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08 Safety Pin
Used to fasten pieces of fabric or
clothing together.
09 Tag pin
Used to attach a price tag onto a
garment.
10 Tissue paper
Helps to keep whites stay whiter,
keeps colors remain vibrant, and
prevents transfer during long-term
storage.
11 Arrow sticker
Marking the error
12 Numbering
sticker
Help other departments to identify
the order number, style number,
size, fabric lot number of the
garment from the serial number
printed on the sticker
13 Barcode
Allow precise tracking of the
inventory
14 Plastic clip
Used for packaging of shirts, tee
shirts, children’s clothes and many
more garments.

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05 Machine Description
5.1 Knitting Department
Table 5.1: Knitting Machines
Name Number
Total Knitting Machine 40
Single Jersey Tube 14
Fleece 12
Single Jersey Open 08
Rib 06
5.1.1 Knitting Machine Specification
Table 5.1.1: Knitting Machine’s Specification
Name Description Image
Machine No
M/C Type
Model
Specifications
Net Weight
Motor
Voltage
Build
06
S/J Tube
LFS Series Version Tube
34*24G*108F
2100KG
7.5HP
380
2015

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Machine No
M/C Type
Model
Specification
Net Weight
Serial
Motor
Build
Voltage
15
Fleece
LFS Series Version Fleece
34*20G*108F
2100KG
BD1277/23
7.5HP
2015
380V
Machine No
M/C Type
Model
Specifications
Net Weight
Serial
Motor
Build
Voltage
39
RIB
LFS Series Version RIB
42*18G*84F
4200KG
BD1277/40
7.5HP
2015
380V
Machine No
Type
Model
Specifications
Net Weight
Motor
Build
Voltage
23
S/J Open
LFS Series Version Open
32*24G*102F
3000KG
7.5HP July
2015
380V

20
5.1.2 Knitting Machine Layout
Fig. 5.1.2: Layout of knitting Section

21
5.2 Machine Used in Fabric Inspection Department
Table 5.2: Fabric Inspection Machine
Name Number
Total Inspection Machine 06
Fabric Inspection Machine 02
Light Box Machine 01
GSM Cutter Machine 03
5.2.1 Fabric Inspection Machine Specification
Table 5.2.1: Fabric Inspection Machine’s Specification
Machine Name
Brand Name
Company
Model NS
Country of Origin
Purpose To
Fabric Inspection Machine
Ngai Shing
JB Century Resources Ltd
58L72
China
Inspect fabric
Machine Name
Brand Name
Model
Country of Origin
Purpose To
Light Box Machine
Tilo
Tilo p60
Netherlands
Inspect fabric

22
Machine Name
Brand Name
Company
Model
Country of Origin
Purpose
GSM Cutter Machine
XINGYUN
Jinan Xinguai Co. Ltd.
XHF-02
China
Cutting fabric to measure
GSM
5.3 CAD Section
Table 5.3: Fabric Inspection Machine’s Specification
Computer 07
Printer 01
5.3.1 CAD Machine Specification
Table 5.3.1: CAD Machine’s Specification
Color & Page
Gross Power
Type
Place of Origin
Brand Name
Model Number
Voltage
Automatic Grade
Dimensions(L*W*H)
Plate Type
Using
Multicolor
400W
Rotogravure Printing M/C
Tianjin, China
Richforever
MF 160
220v
Semi-Automatic
2570*600*1190mm
Gravure
Computerized pattern
grading & marker making

23
5.4 Sample Section
Table 5.4: Machine in Sample Section
Serial Description of machines Total number
01 Plain machine 40 sets
02 4 & 5 Thread over lock machine 07 sets
03 Button hole machine 03 sets
04 Button attaching machine 02 sets
05 Two needle machines 02 sets
06 Feed of the arm m/c 02 sets
07 Bar tack machine 03 sets
08 Kansai special machine 02 sets
09 Flat lock machine 03 sets
10 Snap button attaching machine 02 sets
11 Eyelet hole 02 sets
12 Zigzag machine 02 set
13 Chain stitch/bland stitch 02 sets
14 Iron 02 sets
15 Cutting M/C 02 sets
Total number of machines 76 sets

24
5.4.1 Sample Section’s Machine Specification
Table 5.4.1: Machine Specification in Sample Section
Machine Name
Brand Name
Company
Model
Country of Origin
No of Thread
Type of stitch
Single Needle Plain
Machine
Brother Industries ltd.
S 6200A-403
Japan
01
Single needle chain stitch
Machine Name
Brand Name
Company
Model
Country of Origin
No of Thread
Type of stitch
Purpose
Over Lock Machine
Brother
FB-N110-3020-0553
Japan
4 (2Needle,2Looper)
Over Lock
Securing fabric edge
Machine Name
Brand Name
Company
Model
Country of Origin
No of Thread
Type of stitch
Purpose
Button Holing Machine
Brother
HE-800 A-2
Japan
02
Lock stitch
Button holing

25
Machine Name
Brand Name
Company
Model
Country of Origin
No of Thread
Type of stitch
Purpose
Blind Stitch Machine
Brother
Z-8560A
Japan
01
Lock Stitch
Sewing
Machine Name
Brand Name
Company
Model
Country of Origin
Number of threads
Type of stitch
Purpose
Chain Stitch Machine
Juki
RACING Company Ltd.
MH-380FU
Taiwan
4
chain stitch
Sewing
Machine Name
Brand Name
Company
Model
Country of
Origin
Number of threads
Purpose
Flat-lock Machine
KANSAI
MORIMOTO
KS 1021202
Japan
4
Type of stitch Flat-lock
For Flat-lock stitch

26
Machine Name
Brand Name
Company
Model
Country of
Origin
Vertical Machine
Golden Wheel
CHEE SIANG
KM-506-7S
China
Type of stitch Lock stitch
Machine Name
Brand Name
Model
Country of Origin
No of Thread
Purpose
Snap Button attaching M/C
Toyo
TY-93
Japan
1
Snap Button attaching
Machine Name
Brand Name
Company
Model
Country of Origin
No of Thread
Type of stitch
Purpose
Eyelet Holing Machine
Brother
RH-9820-01
Japan
3 (1Needle, 2Looper)
Chain Stitch
To create eyehole in belt

27
Machine Name
Brand Name
Company
Country of
Origin
No of Thread
Type of stitch
Purpose
Button Attaching M/C
Brother
Model BE-430D
Japan
3 (1Needle,2Looper)
Lock Stitch
Attaching Button
Machine Name
Brand Name
Model
Country of Origin
No of Thread
Type of stitch
Bar Tack Machine
Brother
KE-430F
Japan
3 (1Needle,2Looper)
Lock Stitch
Machine Name
Brand Name
Company
Model
Country of Origin
No of Thread
Type of stitch
Purpose
Waist Band KANSAI M/C
KANSAI
MORIMOTO
DFB 1404 PMD
Germany
12 (6Needle, 6Looper)
Multithread Chain Stitch
Waist band attaching

28
Machine Name
Brand Name
Company
Model
Country of Origin
Type of stitch
Purpose
Zigzag Machine
Brother
Brother Industries Ltd.
Z-8560A-431
China
Lock Stitch
To produce Zigzag stitch
Name
Brand
Origin
Power
Speed
Blade size
Stroke
Weight
Dimensions
Straight Knife Cutting M/C
Butterfly knives
China
110V/220V, 65 H.P
3,400 rpm
8”
1-1/2”
32 lbs
8” x 12” x 20.5’’
Name
Usage
Power
Voltage
Length
Width
Height
Steam Ironing M/C
Industrial
2 kw
220V/380V
1300 mm
2500 mm
200 mm

29
06 Production planning & sequence & operation
6.1 Production Process
Fig. 6.1: Production Process Diagram of Green Life Knit Composite Ltd.
6.1.1 Description of production process
After receiving order planning department start to production planning. Trims and accessories
that the factory received. The quarantine area is then kept for inspection. If the material passes
inspection, it moves from the store to the inventory. Trims and accessories are kept separate
and ready for use after all necessary information has been entered in the register log book (with
bin card). The fabric is received in the same manner and is kept in the quarantine area for
inspection. After the fabric inspection is completed and found to be successful, the inventory
enters all necessary information using a bin card. The preproduction stage was then planned
(PP meeting, Size set sample preparation, Buyer & internal meeting, meeting with QC, line
layout & man power allocation etc.). The fabric then moves through the cutting portion for a
Yarn Store Knitting
Gray Fabric
Store
Batching
Dyeing
Fabric
Finishing
Fnished
Fabric Store
Cutting
Sewing Washing/Ironing Folding Poly/Sticker
Packing
Final
Inspection
Finished
Goods Store
Shipment

30
cut. Cutting section confirmed production pattern & marker consumption start to spread. After
Cutting the fabric then Cut fabric parts are sorting, numbering, bundling (according to the Size)
& QC inspection the cut panel. Then the Cut fabric are ready for input.
The start of production occurs simultaneously. For production, the first line layout is planned
with the items in mind. The production is then advanced by allocating man and machine. In
charge & supervisor provide certain information for sewing the product once man machine is
allocated the line. Then, after continuously stitching the same area of the garment, one operator
passes the finished area to the following one. As an illustration, the first worker might sew the
pocket facing to the body of the garment, and the second worker might stitch the pocket seam
to the body. After complete the garments it keeps in specific area for QC checked the garments.
After garments are QC passed then ready for wash.
Washing section received the garments & separate the garments according to the shade.
Garments wash according the buyer requirement & merchandiser providing sample. After wash
garments are passed to finishing section. For finishing section at first Shade check, loop cut,
thread cut, Inside & outside inspection. Then garments pass the ironing table iron. Then it
passes the final inspection table QC checked critical process & measurements the garments.
Then it passes input table for attach hang tag, waist tag. QIC match the hang tag, care label
with waist tag & checked the barcode with PO number. Then garments pass the metal detector
machine for check.
Clothes are then folded, packed, and cartooned in accordance with the buyer's packing
requirements. The hourly carton audit was then scheduled. The auditor upholds the carton's
quality. The last step is to keep the clothes in a finished, clean place for pre-final inspection.
Afterwards it's prepared for shipping.
6.2 knitting Process
Knitting is the process of creating fabric by interlocking loops of yarn or thread using knitting
needles or a knitting machine. To start knitting, you need to choose your yarn and needles, and
then cast on the stitches onto the needle. Once the stitches are cast on, you can begin the knitting
process by working the stitches in various patterns such as knit, purl, or cable stitches. You can
also change colors, add stitches or decrease stitches to create patterns or shapes. Once you have
completed your project, you can bind off the stitches and cut the yarn.

31
6.2.1 Knitting Process Flow Chart
Fig. 6.2.1: Knitting Process
6.3 Fabric Store Process Flow Chart
Fig. 6.3: Fabric Store Process Flow Chart
Yarn in cone form
Feeding the yarn cone on the creel
Feeding the yarn in the feeder via positive feeding arrangement
Tension device
Knitting
Withdraw the Rolled Fabric and Weighting Inspection
Inspection
Fabric Receive From Supplier
Inventory & Keep Record
Blanket Cutting
Shrinkage Test & Twisting Test
10% Fabric Inspection
Shade & Color Control Record
Shade Wise Fabric Storage with Bin card

32
6.4 Merchandising
The word merchandising comes from the word merchandise in late 13century, means
commodities of commerce,". Merchandising can be defined as “Planning involved in
marketing right merchandise, at right place at right time in the right quantities at the right
price”. Merchandiser is the bridge between the industry and the buyer. A merchandiser has to
look after every job like buying the raw material which is required to finish the product, making
the garment, finishing the garment, documentation, finally shipping. He is the responsible
person to make the product. A garment export unit generally has many department-like stores,
cutting, production, packing, checking etc. in which Merchandising department a linking
device of all. The job of a merchandiser is to co-ordinate with the entire department in the
office as well as the customers. The merchandiser is the one who creates a good relationship in
between exporter and buyer.
6.4.1 Planning of merchandising department
Fig. 6.4.1: Planning of merchandising department in garment industry
Right
Product
Right
Quality
Right
Location
Right
People
Right Time
Right
Process

33
6.4.2 Types of Merchandising
6.4.3 Organogram of Merchandising Section
Fig. 6.4.3: Organogram of Merchandising
Merchandising
GM
Merchandising
AGM
Merchandising
Manager
Assistant
Manager
Senior
Merchandiser
Merchandiser
Junior
Merchandiser
Merchandiser
Trainee
Merchandiser
Fig. 6.4.2: Types of Merchandising
Merchandising
Retail
Merchandising
Visual
Merchandising
Apparel
Merchandising
Fashion
Merchandising

34
6.4.4 Process of Merchandising

35
Fig. 6.4.4: Process flow of merchandising section
Execution of Order by Entering Details in ERP
Prepare Sample as per Buyer Requirement
Forward Sample to Buyer for Approval
Approval
PP Meeting with
Concern Dept.
Comments Received
& Rework on Sample
to Resubmit
Yes No
Execute Bulk Order
Follow up with Production
Dept. & Update to Buyer
Submit Require Documents
to Documentation Dept.
Offer Garments for Final
Inspection
Follow Up on the Payments
for Goods
End

36
6.5 Organogram of Sample Section
Fig. 6.5: Organogram of Sample section in Green Life Knit Composite Ltd.
6.5.1 Process Flow of Sample Section
Fig. 6.5.1: Process flow of sample section
Sample Manager
Pattern Executive
Sample Officer
Asst. Sample Officer
Supervisor (Fabric & Accessories)
Supervisor (Sewing)
Sample Cutter, Sample Maker, QC Inspector, Ironer
Received Tech Pack
from the Buyer
Pattern Making
Fabric
Cutting
Print or Embrodery (If
required)
Sewing
Finishing QC Chake
Send to The Buyer for
Approval

37
6.5.2 Working Process of Sample Section
• Received Tech Pack from the Buyer: Merchandiser receives all the tech pack from
the buyer. Where tech pack contains all the required information about the garments
order viz: reference sample, measurement chart, print instruction, embroidery
instruction, wash instruction, and so on.
• Pattern Making: A sample pattern has to develop according to the tech pack provided
by the buyer.
• Fabric Cutting: After developing a sample pattern, the fabric has to cut here by
following the pattern.
• Print or Embroidery (If required): If the tech pack contains print or embroidery
instructions then those should be completed in the cutting fabrics according to the tech
pack.
• Sewing: Garments are sewn according to the measurement chart.
• Finishing: Ironing or pressing has done the garments here according to the
measurement.
• QC Check: A quality controller inspects the sample garment here by following the
tech pack.
• Send to The Buyer for Approval: Garment sent to the buyer for approval. If it
approves by the buyer then the garments merchandiser can start the next processes for
the garments production.

38
6.6 Working Flow Chart of CAD Section
Fig.6.6: Working Flow of CAD Section
6.6.1 The procedure of CAD Section
• In the CAD section at first, the pattern put on the digitizer to take a clear image of the
pattern part inside the CPU.
• After making all required size patterns using the “Diamino” software pattern parts are
aligned in the mini marker. Then it is sent to CPU of CAD section for approval and
checking the length & width of marker and pattern parts alignment.
• After getting approval from the CAD section the printer is used to print out the whole
real marker then this marker, as well as a mini marker, are provided to the CAD section
for cutting the fabric.
Receiving of pattern parts
Taking the image of the pattern in CPU by the digitizer
Modernizing of all pattern parts by the software (Modernizer)
Aligning all size pattern parts in the marker by the software (Diamino)
Completing the marker
Taking approval from CAD section
Bringing out the marker through the plotter

39
6.7 Process Flow of Cutting Section
Here garments parts are cutting according to the pattern. In the garments cutting department, a
process flow chart has to be maintained to send the right measurement parts in the next process
for making quality garments.
Fig. 6.7: Flow Chart of Cutting Section
6.8 Organogram of IE Section
Fig. 6.8: Organogram of IE section
Manager
Assistant
Manager
Senior IE
Officer
Management
Trainee
Assistant
Officer
IE Officer

40
6.8.1: Process Flow Chart of Industrial Engineering
Fig. 6.8.1: Process flow of IE section
6.8.2 Some Formulas for IE Section
1. Standard Pitch Time (S.P.T) = Basic Pitch Time (B.P.T) + Allowances (%)
2. Target = (Total manpower per line*Total working minute per day*100%)/SAM
3. Theoretical Manpower = Target per hour/Process capacity per hour
4. Line Labor Productivity = Total output per day per line/Number of worker work
5. Line Machine Productivity = Total number of output per day per line/Number of
machine used
6. Line Efficiency = [{(Total output per day per line+SMV)/(Total manpower per
line+total working minutes per day)}*100%
7. GSD = (Man power * Work hour) / Target
8. SMV = Basic time + (Basic time * Allowance)
9. Basic time = Observed time * Rating
10. Observed time = Total Cycle time / No of cycle
11. Rating = (Observed Rating * Standard rating) / Standard rating
12. Efficiency = (Earn minute * Available minute) * 100
Negotiation
with garments
merchandiser
Garments analysis
Make P.P meeting if all
the required
fabrics, trimmings, and
accessories are in-
housed
Production target
Continuous
production
meeting
Line balancing
Line setting
Set machine
layout
Collecting
production data
Preparing
production report
Production report
analysis
Report submitted
to the factory
manager

41
6.9 Finishing process flow chart
Fig.6.7: Finishing Process Flow Chart
Goods Received from Sewing Section
Thread Sucking by Machine
Thread Sucking by Machine
Measurement Check by QC
Attach Price Tags and Accessories
Metal Detection
Folding
Poly
Bar code (buyer wise sticker)
Packing
Assortment
Cartooning
Final Inspection
Ready to Ship Goods

42
6.10 Daily & Monthly Production Report
Fig. 6.10: Production Report

43
07 Quality management system
7.1 Quality Management Procedure
Quality management refers to the processes, systems, and techniques that an organization uses
to ensure that its products or services consistently meet or exceed customer requirements and
expectations. The goal of quality management is to continuously improve the quality of an
organization's processes, products, and services in order to achieve and maintain customer
satisfaction. Quality Management Procedure are:
• General
• Plan-do-check-Act cycle
• Risk based thinking
• Relationship with other management system standards
7.1.1 Quality Assurance Procedure
A Quality Assurance Procedure (QAP) is a documented process that outlines the steps an
organization follows to ensure that its products or services meet the desired quality standards.
The purpose of a QAP is to provide a systematic approach to quality management and to ensure
that the organization's processes are consistent and repeatable.
Fig. 7.1.1: Quality Management Procedure
7.2 Quality Standard (ISO)
ISO (International Organization for Standardization) is an independent, non-governmental
international organization that develops and publishes international standards for a wide range
of industries and sectors. ISO standards provide specifications, guidelines, and best practices
for quality management, environmental management, occupational health and safety, and other
areas. ISO 9001 is the most widely recognized and implemented standard for quality
Assurance
On Line Off line

44
management systems. The standard focuses on customer satisfaction, process improvement,
and the involvement of all employees in the quality management system. Other ISO standards
related to quality management include:
ISO 14001: Environmental management system
ISO 45001: Occupational health and safety management system
ISO 27001: Information security management system
ISO 50001: Energy management system
ISO standards are voluntary, but many organizations choose to adopt them to demonstrate their
commitment to quality and continuous improvement, and to gain a competitive advantage in
the global marketplace.
7.2.1 Quality Standard Certificate
Fig. 7.2.1: Certificate of Green Life Knit Composite Ltd.

45
7.3 Defects and Their Causes & Remedies in Knitting
Table 7.3: Faults & Causes in Knitting
Defects Image Causes Remedies
Star Mark
Un-effectiveness or
buckling of latch of
needle.
Low GSM.
Yarn tension variation.
Maintain same Yarn
tension during
production.
Use good conditioned
needles.
Hole
Wrong stitch attachment.
Yarn breakage.
Yarn tension variation.
Defective needle.
Use proper count of
yarn.
Correctly set of yarn
feeder.
Knot should be given
properly.
Needle Mark
Needles hook breakage.
Needle latch breakage
Dirt in needle slot
Needle line
Needle should be
straight as well as
from broken latch.
Bent needle should
be changed
Drop Stitches
Take-down mechanism
too loose.
Insufficient yarn tension.
Badly set yarn feeder.
Needle should be
straight & well.
Proper feeding of
yarn during loop
formation.
Oil Stain
When oil lick through the
needle trick then it passes
on the fabrics and make a
line.
Ensure that oil does
not pass on the
fabrics.
Well maintenance as
well as proper oiling.
Pin Hole
Due to break down or
bend of the latch, pin
hole may come in the
fabric.
Change the needle
Fly Dusts
In knitting section too
much lint is flying to and
for that are created from
yarn due to low twist as
well as yarn friction.
By cleaning the floor
continuously.
Over all ensure that
lint does not attach to
the fabric.

46
Yarn
Contamination
If yarn contains foreign
fiber, then it remains in
the fabric even after
finishing,
If lot, count mixing
occurs
By avoiding lot,
count mixing.
Fault less spinning.
Lycra out
Breakage of Lycra yarn
& uneven tension of
Lycra.
To maintain uniform
tension.
Yarn Miss
Yarn breakage due to any
reason and not pass
through the yarn guide. It
may be occurred for
tension variation.
Yarn guide and
tensioner must be
used.
Bunching Up
Thick place in yarn.
The fabric takes up too
weak in the knitting
process.
Faulty yarn should be
avoided in knit fabric
manufacturing.
Vertical
Stripes
Heavily running needle.
Defective needle latch.
Defective needle hook.
Bent needles.
Damages on other
knitting elements.
A fault-free needle
latch and needle hook
should be used in
knitting.
Double Loop
or Stitches
Fabric take-up too weak
in the knitting process.
The too much higher
setting of the dial-in
knitting machine.
Course density
should be set
correctly.
The proper sliding
ability of yarn is used
in knitting.
Horizontal
Stripes
Deflectors in dial cam
brought into a tuck
position.
At all feeders couriering
not constant.
Proper setting of yarn
feeder should be
maintained.
Couriering should be
constant at all the
feeders

47
7.4 Defects & Their Causes in Sewing Section
Table 7.4: Defects & Causes in Sewing
Defects Image Causes Remedies
Seam
Puckering
Uneven stretching on
to plies of fabric
during sewing.
Improper thread
tension.
Feed dog, eyelets and
thread guides should
be checked
periodically for
damages.
Open seam
Improper handling of
the parts of garments.
Improper setting and
timing between needle
and looper or hook
etc.
Clear markings for
stitch line.
Proper setting and
timing between needle
and looper or hook.
Broken Stitch
It appears due to
improper trimming or
machine usage.
Needle plate, presser
foot and feed dog
should be checked
periodically for
damages.
Drop stitch
It appears due to
improper handling of
cut pieces or machine
usage.
Placing of needle
properly.
Needle size & thread
size must be adjusted.
The pressure of
pressure foot must be
adjusted accurately.
Uncut/ loose
thread
It appears due to
improper trimming or
finishing.
UBT/thread trimmer
should be used
Operator training.
Garments finishing
should be checked
properly.
Seam
Slippage
This happens when
the yarns in the fabric
are pulled out of the
seam and are more
frequent in fabrics.
French seam type can
be tried.
Seam width can be
increased.

48
Needle
Threads
Breakage
Irregularities or
damages in needle
guard, throat plate,
bobbin case and
needle eye.
Ensure that the re-
threading is done
correctly.
Replace the needle
with one of better
quality.
Unbalance
Stitch
Incorrect tension of
sewing thread.
Used incorrect thread
path.
Using of accurate
thread path.
Setting of accurate
tension to the
thread.
Uneven
Stich
If made speed
variation of garments
during
sewing.
When about to start
sewing must look at
right sewing speed
meter.
Needle
Mark
Trace of hole of
sewing machine
needle due to
resewing.
Right needle needs to
choose.
That’s means choose
right size
of needle for every
fabric.
Pitch
Error
Stitch length is
changed by change of
feed force, cloth
slippage, etc.
This phenomenon is
apt to occur between
high and low speed
sewing.

49
08 Maintenance
8.1 Maintenance Machinery
Maintenance is carried out by electrical & mechanical departments. It is a process by which
equipment is looked after to give the best service of it. Machine, building, etc. are subjected to
deterioration due to the use & expose to environmental condition. In industry it is carried out
regularly after a certain period of time to extent their life time in such a way that it is
economically& physically possible to do so. Modern time industrialization.
8.2 Types of Maintenance
Three types of maintenance are performed in “Green Life Knit Composite Ltd.”
Fig. 8.2: Maintenance Type
8.2.1 Preventive maintenance
In this maintenance system, maintenance is done before breakdown of the equipment. These
actions are performed to prevent or reduce consequences of failures. This type of maintenance
is done in monthly and yearly. Normally full machine checkup, looper and folder maintenance
and oil circulation are checked in this maintenance system.
8.2.2 Predictive maintenance
It is time-based maintenance and pre-planned to perform on machine and equipment. This plan
usually made on daily, weekly and monthly basis. In this maintenance system clearing of the
machine, all moving parts checking, oil checking and feed dog checking is done. In Green Life
Knit Composite Ltd. predictive maintenance held for 15 consecutive days.
Preventive Maintenance
Predictive Maintenance
Breakdown Maintenance

50
8.2.3 Breakdown Maintenance
In this type of maintenance, when the breakdown occurs and machine remains stop that time
the maintenance is done. This maintenance is often most expensive because worn equipment
can damage other parts and cause multiple damages and accident. Maintenance procedure is:
Fig. 8.2.3: Breakdown Maintenance Procedure
8.3 Manpower for Maintenance Department
Table 8.3: Manpower for Maintenance Department
Section Designation Permitted
Maintenance Department
Manager 01
IN charge +Asst. IN charge 04
Mechanic 10
Mechanic Supervisor 02
Electrician 3
Electrician Supervisor 1
Boiler In charge + Generator operator 1
Sub Total 22
Problem arise
Inform to maintenance
department
Problem detection
Problem can be solved
by repairing or replace

51
8.4 Maintenance Equipment
Maintenance equipment are that equipment used in maintenance of a machine. Several types
of maintenance equipment are used in “Green Life Knit Composite Ltd.” for different
machines every day. Names are given below:
Table 8.4: Maintenance Equipment
Minus Screw
Driver
It is used for screws with a straight
linear intrusion across the head.
It is used to turn fasten or loosen screws
and bolts.
Star Screw
Driver
The unusual star shaped head makes
them far more secure than regular flat
head or cross head screws and allows
higher torque transmission so screw
and bolts can be tightened more
securely.
Rotary
Hook
It continuously rotates in place.
Hooking the upper thread each time its
pointed tip passes the 12 o’clock
position.
Ring
Range
Used to open ring nut.
Wrench
Used to turn fasten or loosen a nut or
bolt.
Only adjustable spanner can grip
fasteners of all sizes jaw.
Nose Pliers
Used to grip small object.
Work involving smaller gauge wire.
Cutting Pliers
Used for cutting wires, nails, rivets
close to work.
For work involving cutting and
skinning wires.
High Pliers
Used for holding and gripping small
articles or for bending and cutting
wire.

52
Plastic Hammer
Soft-face hammers with inter-
changeable heads for use in project that
require force without working surface.
It is used for metal forming, crafting.
Metal/Ball Peen
Hammer
Used for metal working, rounding
edges, punching and riveting.
Brush/Pastry
Brush
It is used for cleaning.
In machine, the brush used for cleaning
small particles or dust.
Rotary Hook
The bobbin case is filled in this.
Hooking the upper thread each time its
pointed tip passes the 12 o’clock
position.
Emery Paper It is a type of abrasive paper or
sandpaper.
It is used to abrade (remove material
form) surface or mechanically finish a
surface.
Allen Key
This is used for the installation and
removal of fasteners with a hexagonal
head.
Turning this clockwise will tighten the
fasteners.
Measuring Tape Use for various measurement.
Drill machine Used to drill holes in hard materials.
Grinding
Machine
To achieve fine finishes or light cuts on
metals and other materials.

53
09 Utility Services
9.1 Utility facility available
There are 06 types of utility available in “Green Life Knit Composite Ltd.”
• Electricity
• Gas
• Steam
• Compressed Air
• Water
• Temperature Control
9.2 Source of Utility
Table 9.2: Source of Utility
Sl. No. Utility Source No. of M/C or Line
01 Electricity
DESCO 01
Generator 03
02 Gas Titas 01
03 Steam Boiler 02
04 Compressed Air Compressor 02
05 Water Pump 03
06 Temperature Control Chiller 02
9.3 Cost of Different Utilities
Table 9.3: Cost of Utilities
Sl. No Utility Name Cost (Approx) BDT
01 Electricity
DESCO
2-4 Lakh
Generator
Water
02 Gas
Titas
3-5 Lakh
Steam
Compressed Air

54
9.4 Utility Machine Information
Table 9.4: Utility Machine’s Technical Data
M/C No
Brand
Model
Power
Manufacturer
Year of Manufacture
Generator-01
FBWILSON
P-660FS
600 KVA
Energypac Engineering Ltd.
2010
M/C No
Brand
Model
Power
Manufacturer
Year of Manufacture
Generator-02
DUETZ
GSW5600
560KVA
Rahimafrooz Ltd.
2012
M/C No
Brand
Model
Manufacturer
Year of Manufacture
Boiler-01
MEL
250TL-100N
Modern Electronics Ug Ltd.
2017
M/C No
Brand
Model
Manufacturer
Year of Manufacture
Boiler-02
MEL
250WT-100
Modern Electronics Ug Ltd.
2010

55
M/C No
Brand
Model
Manufacturer
Year of Manufacture
Air Compressor-01
ATLAS COPCO
GAe22PA10
Rashid Enterprise
2014
M/C No
Brand
Model
Manufacturer
Year of Manufacture
Air Compressor-01
ELG
Not Found
IFAD
2010
M/C No
Brand
Model
Manufacturer
Year of Manufacture
Fire Engine Pump- 01 & 02
UL CERTIFIED
Not Found
Naffco
2015
M/C No
Brand
Model
Power
Manufacturer
Year of Manufacture
Transformer-01
Energypac
750-186
750KVA
Energypac Engineering Ltd.
2010
9.5 Remarks
Utility services are the heart of a textile processing mill. It should need proper maintenance to
run the mill efficiently.

56
10 Inventory Management
10.1 Inventory system
An inventory system is a process used to track stock, supplies and sales through an entire supply
chain. Companies use inventory systems to ensure they know exactly what items they have
available and where they are located. Inventory systems provide detailed records of new and
returned products as they are entering or leaving the warehouse to help companies organize
and account for their stock. They can also track data such as the number of units, cost per unit,
serial number, lot numbers, purchase dates and production dates.
10.2 Inventory System for Raw Materials
• Raw materials partially received from production planning & directly from suppliers.
• Material Receiving & Inspection Report is prepared. Received quantity is mentioned.
• Submitted to QC department. Some are OK & few rejected.
• Entry of data of goods in DATATEX.
• Goods are arranged according to OK or rejected Groups.
• As per requisition materials supplied & this record is noted down.
10.2.1 Inventory System Flow Chart
Fig. 10.2.1: Inventory Flow Chart
Raw material receive
Material Receive Report (MRR)
Store in main go-down by bin card
Running go-down
Production floor

57
10.3 Raw Materials of Inventory Control
• Finished fabric
• Trims & Accessories
• Spare parts & Maintenance parts
• General store
• Capital equipment
10.4 Store Capacity
Table 10.4: Store Capacity Information
Sl. No. Name Capacity (tons) Image
01 Dyes & Chemical 20-25
02 Yarn Storage 65-70
03 Grey fabric 90-95
04 RFD 160-170
05 Trims & Accessories 2.5
06 M/C Parts Not Found

58
11 Marketing activities
11.1 Consumer of the products
“Green Life Knit Composite Ltd.” is a100% export-oriented industry. All the goods
produced in this industry are exported into various foreign countries. Name of the main buyers
of the products of the industry are given below:
• Kappa • Meca
• Ahlens • Marina Militare
• P&C • Nimbus
• Cecil • Promo Stars
• Malboro Classics • Teddy Smith
• Street One • Slazenger
• Snap • Pomp-De-Lux
• Bon Marche • Miniconf
• S. Oliver • Peacocks
11.2 Product label
Product label differs from buyer to buyer. The product labels are prepared according to fabric
criteria and the buyer requirements.
11.3 Package size and label
Package size and label differs from buyer to buyer. The package size and labels are prepared
according to fabric criteria and the buyer requirements.
11.4 Local Market
“Green Life Knit Composite Ltd.” is a 100% export-oriented industry. All the goods
produced in this industry are exported into various foreign countries. So, goods are not supplied
into local markets.
11.5 Importing countries
The countries which are importing goods from “Green Life Knit Composite Ltd.” are given
below:

59
• Italy
• Sweden
• Germany
• United Kingdom
• Denmark
• Franch
11.6 Marketing Strategy
In “Green Life Knit Composite Ltd.” mainly senior marketing officers and merchandiser are
deal with buyer. There are some fixed buyers of the industry. The buyers give their orders
continuously all over the year. The marketing officers and by both side understanding the rate
and the order quantity are fixed.
11.7 Duties & responsibilities of marketing officer
The main duties and responsibilities of a marketing officer are given bellow:
• To prepare cost sheet by dealing with the buyer.
• To take different steps by discussing with the high officials and merchandiser.
• To maintain a regular & good relationship between commercial officer & merchandiser.
• To maintain a regular communication with the buyers & buying houses.
• Communicate with the new buyer.
• Display the criteria of the products.
Actually, the responsibilities & duties of marketing officer begins from getting order of buyer
& ends after receiving goods by the buyer. so, he should be always smart, energetic & sincere.
11.8 Remarks
“Green Life Knit Composite Ltd.” has a well learned marketing & merchandising team. They
always communicate with the buyers. The marketing section also looks for the quality &
quantity buyers.

60
12 Social and environmental information
12.1 Environment Management System
“Green Life Knit Composite Ltd.” recognizes that its activities impact the environment
through day-to-day internal operations, infrastructure development, and impact and impact on
the wider community. It recognizes its responsibility and commitment to protecting the
environment at all levels and strives to minimize the potentially harmful effects of such
activities whenever possible. They are fully compliant with the application of environmental
law in the garment industry. Therefore, as part of our ongoing pursuit of quality in all respects,
we are developing a comprehensive political system that allows us to set goals that allow us to
regularly measure and monitor our efforts to improve the environment in a sustainable way.
Causes of environmental hazards on factory premises:
• Waste from fabrics, accessories and other storage areas
• Electronic waste and other storage
• Empty chemical container
• Wastewater (factory wastewater)
12.2 Fabric and Accessories Wastage Management System
Waste baskets are positioned on the factory floor. During working hours, cleaners and loaders
collect floor waste in a basket. When the basket is nearly full, the loader transports all of the
garbage to the waste designated area, which is 100 yards outside the main manufacturing
building. When 80 percent of trash storage facilities are full, the waste is sold to the client.
Fig. 12.2: Sustainable Recycled Accessories
12.3 Electrical and Mechanical Wastage Management System
Electrical wastage will be stored in the designed area of the factory complex and maintenance
department disposed of the wastage by burning or selling.

61
12.4 Empty Chemical / Dye Container Management System
Empty chemical containers are stored in designed chemical wastage area and sold to outside
people or disposed of by burning in the desire area on weekly basis.
12.5 Health & Safety
Fig. 12.5: Health & Safety
12.6 No Child Labor
As mentioned above no one under the legal age of 18 years is employed by the organization.
We unconditionally support and affirm the National and International Convention and
Programs for Children’s Right.

62
12.7 Corporate Social Responsibility (CSR)
We can sense that textile export business for Bangladeshi manufacturer is becoming more and
more challenging ahead. Our strategy is to meet the customer demand through maintaining
product quality, on time delivery and strong professionalism. Code of Conduct is the Urmi
Garments Ltd. policy for appropriate business behavior and “Green Life Knit Composite
Ltd.” commitment to its employees, business partners and other stakeholders. We are fully
aware of our Code of Conduct that includes business principles, environmental principles and
human rights and workplace practices. We are taking all steps to ensure that our factories are:
• Compliant with Social standards stipulated in Bangladesh.
• Providing a safe and healthy work environment for all employees.
• Local Environmental standards are met.
• Dignity of Labor and Human Rights are upheld.
• Our factories are therefore ready for compliance audit by Buyers at all times.
12.7.1 Core Values
Our core values & principles are our cornerstones of success. We are ethical, socially
responsible and want to a good citizen.
Fig. 12.7.1: Core Values of Green Life Knit Composite Ltd.
Core Values of
Green Life
Knit
Composite Ltd.
Integrity
Trust
Ownership
Leadership
Entrepre-
neurship
Passion
for
Excellence

63
13 SWOT Analysis
13.1 SWOT
Fig.13.1: SWOT In Brief
13.2 Strength
Characteristics of the “Green Life Knit Composite Ltd.” that give it an advantage over others.
• Good reputation in the market.
• Companies have skilled & long-term experienced management system.
• Own Land.
• Strong Security System.
• Strong relationship with buyers.
• Quality.
• Competitive pricing.
• Huge production capacity.
• Worker transportation.
13.3 Weakness
Characteristics that place the “Green Life Knit Composite Ltd.” at a disadvantage relative to
others.
• Lack of high skilled labor.
• Limitations for some modern machinery in some specific sectors.
Threat
Opportunity
Weakness
Strength
S W
T
O

64
• Employee turnover.
• Inaccessibility of public information.
• Sourcing capability moderate.
13.4 Opportunity
Elements in the environment that the business or project could exploit to its advantage.
• Take the advantage of competitor’s weakness.
• Good reputation of product quality in outside world will increase more option.
• Government provides subsidy and also minimizes the tax for RMG exporter.
• Long term business module.
• Capable to increase concern group.
• Implementing sustainable innovation.
13.5 Threats
Elements in the environment that could cause trouble for the business or project.
• Rise of competitiveness in export market inside and outside (India, China, and
Combodia, Africa etc.) of the country.
• Political unrest situation of the country & world.
• Rise of price of raw materials.
• Labor unrest in RMG factories.
• Environmental pollutions are threat for survival.

65
14 Conclusion & Recommendation
14.1 Conclusion
We have to completed our internship report successfully by the grace of almighty Allah.
Industrial training is an essential part for textile education because it minimizes the gap
between theoretical and practical knowledge. Undoubtedly, this industrial training has taught
me a lot about textile technology, production processes, textile machineries, industrial
management, and made me comfortable to industrial life. Besides it gave me the first
opportunity to work in industry.
“Green Life Knit Composite Ltd.” is a well-known factory in the textile field of Bangladesh.
The administrative, management, chain of command all are the well-organized. They are well
equipped with all of the modern machineries and the working environment is excellent. The
relation between top management to bottom level is so nice & devoted to satisfy the customer
demand by their activities.
Factory regulated utility to provide all the appropriate support for production during twenty-
four hours. In my industrial secondment program, I tried to do my job as well as I could. My
supervisor was satisfied with my behavior and offered to cooperate step by step. The training
partners, on this regard, were also very much co-operative and friendly. I am sure that the
knowledge I have gathered from this training will make a positive influence in my future
profession. It was a whole new experience in my life that will be very fruitful of service.
14.2 Limitation of The Report
• Because of the secrecy act, the data on costing and marketing activities has not been
supplied and hence this report excludes these chapters.
• We had a very limited time. In spite of our willing to study more details it was not
possible to do so.
• Some of the points in different chapters are not described as these were not available.
• This whole process is not possible to bind in such a small frame as this report, hence
our effort spent on summarizing them.

66
14.3 Recommendation
“Green Life Knit Composite Ltd.” is notable to produce all types of knit garment. We think
their accuracy will increase to a maximum level. For sewing, they need using modern machine
& that their product quality will be higher. For cutting they are using manual straight knife
cutting machine but if they use computerized cutting m/c their accuracy will increase & their
efficiency will increase to a maximum level. We think if they improve the above things their
product quality, their efficiency & their accuracy will be maximum.
The End

Textile Internship Report / A composite Textile Industry / Garments Industry / Industrial Attachment on knit composite ltd

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