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MERCHANDISING
SECTION

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INTRODUCTION OF MERCHANDISING
The “Merchandising” is known to the persons specially involved in garments trade.
The term merchandising has been derived from the ‘merchandise”. Merchandise
means buying and selling huge amounts of goods.
The term “MERCHANDISING” may be defined as Person who merchandises the
goods, specifically for export purposes. Garments merchandising means buying
raw materials & accessories, producing garments, maintaining required quality
level and exporting the garments within scheduled time.
NEED OF MERCHANDISER
The position "Merchandiser" is playing a vital role in the RMG sector today.
Merchandiser is the person who handles around 75% of the cost related to the
garment & the production cost is only be almost about 25% of the garment. There
by the role of Merchandiser in the apparel sector plays the most responsible part
mainly for the financial benefit of the Company. The Merchandiser's small mistake
will affect 75% of income of the order which will leads to a big disaster. This has
to be understood by the Merchandisers seriously.
RESPONSIBILITY OF MERCHANDISER
Now days, major companies are adopting merchandising concepts, which comply
with all procedures to execute and dispatch the shipment on time, considering
quality, cost and time. Merchandisers are serious in the success of any garment
retail business. They provide the right products at the right time, enabling a
company to match with latest market trends and meet the market demand. In the

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merchandising concept, time management is a gig to manage one's time properly,
so he can focus on value adding actions.
Today's garment merchandisers have to move with frequent changes in demand
and the developing technologies utilized in manufacturing and production. To find
out customer requirements, they regularly visit retail outlets, and come up with
latest updates from frontline staff. In order to keep an eye on developments in
sourcing, site visits are made every week to mainland factories to meet suppliers
and study production.
In garment merchandising, there is no specific rule, so it's important to be able to
think on one's feet.
The main procedures of merchandisers are as followed:
UNDERSTANDING SAMPLE ORDER
Merchandiser has to understand the buyer's requirements after receiving
specification in the sample order. In many cases, there are modifications pertaining
to the specifications in the order to dispatch on time and the right quality.
He has to talk with the in-house veterans on the execution problems of sample
orders, as the right information is required in decision making.
MANAGING ORDER ROUTE CARD AND PRODUCTIONTIMETABLE
Merchandiser has to manage every single production schedule and order route card
that helps to follow-up the execution in the planned way. It is expected to be
acknowledged of the various descriptions like: design, no. of modules, no. of
operators, how many processes, and date of dispatch, quantity, output capacity, and
deadlines in the schedules.

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The sub-ordinates are normally assigned to follow-up with execution of the plan.
Merchandiser plans the activities depending on the essentials or non-essentials, and
top priority are given to the most essential tasks. This is customary that the
essential activities are handled personally or with the support of junior
merchandisers/sub-ordinates.
In a "daily schedule", merchandiser has to carry-out and categorize which is the
most significant and urgent task. The activity that has to be focused with full
attention to sweep-off nonessential activities and have to be to be corrected by
prioritizing to meet the deadlines.
USING ROUTE CARD TO RESCHEDULE ACTIVITIES
To get updated on the current status on the order, the route cards should be utilized.
The latest status can be fed into the computers. In case, the buyer ask for the goods
prior to the deadline, then merchandiser has to reorganize the schedules to
accomplish tasks, output capacity, no. of pieces to be produced daily, substitute
arrangements, time availability, supply time, scheduling critical ratio, etc.
SUBMITTING PRE-PRODUCTIONSAMPLES
The pre-production samples should be provided on time to the concerned buyers.
Quality of the sample must be verified. If required, revised samples should be
made available to the buyers. Merchandiser should adjust to the required changes
demanded by the buyer. The execution of bulk orders should be made only after
samples are approved by the buyer. In-process inspection denote between any tasks
in order-execution. In case of non- conformation, it is better to focus on the
concerns of quality. Merchandisers that work on complete orders have to check
deviation to the production teams so that any amendments can be done to avoid the
non-conformities.

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SOLVING SHORTAGE PROBLEM
The merchandiser should know about the dearth of any commodity such as fabric,
yarn, etc. From the beginning actions should be taken immediately to arrange
required materials, after discovering the shortage. It is expected that the
merchandisers should verify quality of the goods prior to execution of the order. If
the material is found unavailable, the superior should be informed about the
concern.
COMMUNICATING WITHASSOCIATED PEOPLE AND BUYER
It is essential to communicate with the buyers regarding the order. It is expected to
give some time to the buyer to read the sent messages. Merchandiser should to go
through the messages received from the buyer and reply on time. In many cases,
merchandisers have to provide order status to the buyers. Also, merchandiser has to
communicate with the people that are in-house, venders, contractors and job-
workers. Only through the right communication can one meet deadline for the
concerned orders.
CONCLUDER REMARK ON MERCHANDISING
Apart from the above mention procedures, merchandiser has to assign subordinates
to help him in the order execution, and direct the procedures. He has to revise his
knowledge from time-to-time to know current market trends. To record preferences
for all the planned activities, use daily or time log systems.
The Merchandiser should find out exact reasons for time consumption. It is
necessary to keep record of time value and keeping it safe, as it is going to be
shared with concerned parties/buyers. It is certain that merchandising jobs need
huge time planning.

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CHRONOLOGICAL PROCESS OF MERCHANDISING
(A). Salesman Samples, Counter Samples, Approval Samples, Photo
Samples, Preproduction Samples, Production Samples, Shipping Samples.
(B). Swatch and Trims, Trim’s related Affairs, Communication in international
Business.
Sample: Reference garment corresponds to -
 The artwork (styling) done by designer and/ or developer
 Particular purchase order
 Any revision to the style work
 Confirm with any specific requirement etc.
SEQUENCE OF SAMPLE
Name of Sampling-
 1st Pattern
 2nd Pattern
 Counter Sample
 Sales Man Sample
 PHOTO Sample
 Approval Sample (Size Set, Mock-up)
 Pre-production Sample
 Production Sample
 Shipping Sample
FIRST PATTERN
First physical version of any garment as per the artwork is done by designer or
developer.

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HUMAN MIND > SKETCH > PAPER PATTERN > SAMPLE
Purpose: See the DESIGN work & test the FITTING
Status: Nothing specific
Material: Available
Price: Not conformed
Quantity: 1 (for customer) + 1 (for Merchandiser)
Delivery: As per URENGECY
SECOND PATTERN
Usually designer/ developer always ask for some changes to the first pattern.
Second pattern is made as per comments.
COUNTER SAMPLE
Where first pattern is made on designers artwork, Counter sample is to make not on
designer’s artwork, has to follow another sample given by the merchandiser.
Purpose: See the workmanship &test the factory skill
Status: Nothing specific
Material: Available
Price: Not conformed
Quantity: 1 (for customer) + 1 (for self-keeping)
Delivery: As per request
SALES MAN SAMPLE:
Sample is made when price is confirmed and orders are on speculation, usually in
L size in all color combinations of expected order. Buyer arranges a meeting with
its customer and records their response on order quantity per color, size etc. and
finally place order to their vendor.
Purpose: Sales Meeting by Retailers, Market Appraisal, Demand / Order forecast
Status: Final stage of the order confirmation
Material: Actual
Price: Confirmed

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Quantity: There is minimum quantity per color combination
Delivery: Very important to meet the delivery date.
PHOTO SAMPLE
Samples are made with actual color and material to be worn by the models on the
event of shooting for catalog.
APPROVAL SAMPLE
In any discrete period of time, whenever it required any revision in the sample, a
new sample is made (sometimes mock-up is workable too) as per new
specification. It is sent to buyer for his approval of the conformity that- the revision
is done correctly.
SIZE SET
In size set, consists of 1 piece from each size for each color combination.
MOCK UP
Any part of the garment to make for particular purpose, not complete garment.
Sometimes it is necessary to send to the buyer any part of the garments, such as
sleeve, collar, neck etc and some accessories.
PRE-PRODUCTIONSAMPLE
When material for bulk production arrived, factory makes a sample with the actual
material and sends to buyer.
PRODUCTION SAMPLE
It is a reference to the buyer that the bulk is being produced as per specification.
Buyer wants to be assured that correct material is sourced and line workmanship
confirm to the quality.

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SHIPPING SAMPLE
A sample is kept from every Pre Shipping inspection to be referred, if required,
after the order has been delivered. Usually for any disputes (e.g. Claim) shipping
sample is important.
SWATCH
Swatch is a presentation of all the materials is (Fabric & Accessories) used for any
specific style/order. Usually small piece of fabric and each piece of accessories are
attached in board paper in a systematic manner. Swatch is very important for
production line to make the correct construction of a garment and QC department
ensures it. Concerned merchandiser should confirm/approve the swatch.
TRIMS
Trims cover all the items used in the garment except the basic fabric. There are
hundreds of items used to manufacture the garments, proper selection of trims and
its quality are very important for styling, otherwise the garment may be rejected or
returned by the customers.
Following is a part of list that covers some names of the trims:
 Zipper/Fastener
 Sewing Thread
 Main Label
 Flag Label
 Button
 Elastic
 Eyelet
 Tags
 Tag pin

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 Plastic clip
 Sticker
 Hanger
 Poly bag
 Scotch tape
 Gum tape
 Photo Board
 Back Board
 Tissue
 Carton. Etc.
COMMUNICATION IN INTERNATIONALBUSINESS
 Telephone Conversation.
 Fax/ E-Mail
 Formal Meeting
 Lunch & Dinner
THE INFORMATION NORMALLYGETS ABOUT AN ORDER
 Factory Loading
 Factory Capacity
 Factory History
 Factory Setup Details
 Market Reputation
 Type of Buyers Dealing
HOW A MERCHANDISERMEET BUYER’S REQUIREMENTS
 Merchandiser detail to buyer about factory profile.

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 Merchandiser Understand the Order sheet.
 Arrange the all component for order execution.
 Production Tracking.
 Timely Shipment.
METHODS OF PURCHASING RAW MATERIALS:
Here fabric and some related accessories are the main raw materials. They are:
 Lab-Dip
 Approval the Lab-Dip
 Collect price Quotation
 Negotiation
 P.I. Received
 Back to Back L/C transfer
 Delivery Chelan received
PROCEDURES OF IMPORTED GOODS
 Procure of IRC
 Price Inquiry (Quotation )
 P.I. Received and Placing Order
 L/C Opening
 Received Shipping Advice
 Facing Customs
 Closing Transaction
HOW DOES THE ACCEPTED ORDER IS PASSED ON THE FLOOR
 Merchandiser searches the scope of knitting machine according to required
Gauge.
 Make production schedule

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 Trim & Accessories Card Prepare
 Make well finishing according to buyer requirement in case of –
• Labeling
• Zippering
• Buttoning
• Ironing
• Packaging
• Cartooning
HOW A MERCHANDISERTRACKHIS/HER PRODUCTION:
 Follow-up yarn supply in factory
 Knitting follow-up
 Linking follow-up
 Accessories supply
 Finishing follow-up
 Ready for export

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INDUSTRIAL
ENGINEERING
SECTION

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INTRODUCTION OF INDUSTRIAL ENGINEERING
Industrial Engineering is concerned with the design, improvement and installation
of integrated system of men, materials and equipment. It draws upon specialized
knowledge and skills in the mathematical, physical sciences together with the
principles and methods of engineering analysis and design to specify predict and
evaluate the results to be obtained from such systems.
The prime objective of industrial engineering is to increase the productivity by
eliminating waste and non-value adding (unproductive) operations and improving
the effective utilization of resources
ACTIVITIES OF INDUSTRIAL ENGINEERING
1. Selection of processes and assembling methods.
2. Selection and design of tools and equipment. Design of facilities including
plant location, layout of building, machine equipment.
3. Design and improvement of planning and control system for production,
invent quality and plant maintenance and distribution systems.
4. Development of time standards, costing and performance standards.
5. Installation of wage incentive schemes.
6. Design and installation of value engineering and analysis system.
7. Operation research including mathematical and statistical analysis.
8. Performance evaluation.
9. Supplier selection and evaluation.
OBJECTIVESOF INDUSTRIAL ENGINEERING
1. To establish methods for improving the operations and controlling the
production costs.
2. To develop programmers for reducing costs
FUNCTIONS OF AN INDUSTRIAL ENGINEER
1. Developing the simplest work methods and establishing one best way of
doing the work.
2. Establishing the performance standards as per the standard methods
(Standard Time).

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3. To develop a sound wage and incentive schemes.
4. To aiding the development and designing of a sound inventory control,
determination of economic lot size and work in process for each stage of
production.
5. Development of cost reduction and cost control programmers and to
establish standard costing system.
6. Sound selection of site and developing a systematic layout for the smooth
flow of work without any interruptions.
TECHNIQUES OF INDUSTRIAL ENGINEERING
1. Method study: To establish a standard method of performing a job or an
operation after thorough analysis of the jobs and to establish the layout of
production facilities to have a uniform flow of material without back
tracking.
2. Time study (work measurement): This is a technique used to establish a
standard time for a job or for an operation.
3. Motion Economy: This is used to analyses the motions employed by the
operators do the work. The principles of motion economy and motion
analysis are very useful in mass production or for short cycle repetitive jobs.
4. Value Analysis: It ensures that no unnecessary costs are built into the
product and it tries to provide the required functions at the minimum cost.
Hence, helps to enhance the worth of the product.
5. Financial and non-financial Incentives: These helps to evolve at a rational
compensation for the efforts of the workers.
6. Production, Planning and Control: This includes the planning for the
resources (like men, materials and machine) proper scheduling and
controlling production activities to ensure the right quantity, quality of
product at predetermined time and pre-established cost
7. Inventory Control: To find the economic lot size and the reorder levels for
the items so that the item should be made available to the production at the
right time and quantity to avoid stock out situation and with minimum
capital lock-up.
8. Job Evaluation: This is a technique which is used to determine the relative
worth of jobs of the organization to aid in matching jobs and personnel and
to arrive at sound wage policy.
9. Material Handling Analysis: To scientifically analysis the movement of
materials through various departments to eliminate unnecessary movement
to enhance the efficiency of material handling.

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10. Ergonomics (Human Engineering): It is concerned with study of
relationship between man and his working conditions to minimize mental
and physical stress. It is concerned with man-machine system.
IE JOB Profile
It was just a couple of years back that demand of an industrial engineer has
increased many times. Reason, an Industrial engineer can do a lot to improve
performance of the company. But the fresh student passed out from educational
institute (Fashion institutes) acquired limited knowledge about the job profile of an
Industrial engineer. Maximum works are learnt in factory by working. There is
number of tools and techniques which are used in by industrial engineers to
establish an effective production system in the company. Without having such
tools earlier production managers and line supervisors faced difficulty in
measuring work content, garment costing, and production planning correctly, even
it was difficult to finalize orders. Our team has worked to find out important tasks
those are important for an engineer, and needs detailed understanding of
production fields, included in the following. Though job profile of an Industrial
Engineer varies company to company, most of the job profile fall under following
list.
• Knowledge about various sewing production systems
• Knowledge of all types of Sewing machine necessary for the company
• Time study (Cycle timing)
• Motion analysis of the operations
• Operation break down
• Preparation of OB (Operation bulletin)
• SAM Calculation
• M/C Layout and Work station layout
• Line Set up (Production estimation of a line)
• Work Sampling
• Method Study (Seeing Movements of an operation)
• WIP Control
• Line Balancing
• Capacity study
• Cost estimation of a garment
• Developing and Maintaining Skill Matrix
• Incentives schemes
• Calculating Thread Consumption

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• Work aids, Guide and Attachment
• Performance Rating
An industrial engineer must have knowledge and skill on each tool and technique.
Implementation of all tools at a time is not needed. Engineer has to go step by step.
Almost all work study tools and methodology are adopted from others industries
and implemented to the garment industry. So each work study tool has guaranteed
benefit if it is used effectively.
ORGANOGRAM OF IE DEPARTMENT IN FAKIR
APPARELS LTD
INDUSTRIAL ENGINEERING TOOLS
• Lean Manufacturing
• 5S
• JIT (Just In Time). Kanban.
• KAIZEN
Manager
Assistant Manager
Senior IE Officer
IE Officer
Assistant IE Officer
ManagementTrainee

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SOME TERMS AND DEFINITION USED IN IE
Work Study
Work study is the systematic examination of the methods of carrying on activities
so as to improve the effective use of resources and to set up standards of
performance for the activities being carried out.
Method Study
Method study is the systematic recording and critical examination of ways of doing
things in order to make improvements.
Time Study
Time study is a work measurement technique for recording the times of performing
a certain specific job or its elements carried out under specified conditions, and for
analyzing the data so as to obtain the time necessary for an operator to carry it out
at a defined rate of performance.
Work Measurement
Work measurement is the application of techniques designed to establish the time
for a qualified worker to carry out a task at a defined rate of working.
Work Sampling
Work sampling is a method of finding the percentage occurrence of a certain
activity by statistical sampling and random observations.
Work Content
The work content of a job or operation is defined as: basic time + relaxation
allowance + any allowance for additional work – e.g. that part of contingency
allowance which represents work.
Time Study
Time study is a work measurement technique for recording the times of performing
a certain specific job or its elements carried out under specified conditions, and for
analyzing the data so as to obtain the time necessary for an operator to carry it out
at a defined rate of performance.
Qualified Worker

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A qualified worker is one who has acquired the skill, knowledge and other
attributes to carry out the work in hand to satisfactory standards of quantity, quality
and safety.
Element
An element is a distinct part of a specified job selected for convenience of
observation, measurement and analysis.
Work Cycle
A work cycle is a sequence of elements which are required to perform a job or
yield a unit of production. The sequence may sometimes include occasional
elements.
Rating
Rating is the assessment of the worker’s rate of working relative to the observer’s
concept of the rate corresponding to standard pace.
Standard Performance
Standard performance is the rate of output which qualified workers will naturally
achieve without over-exertion as an average over the working day or shift,
provided that they know and adhere to the specified method and provided that they
are motivated to apply themselves to their work.
This performance is denoted as 100 on the standard rating and performance scales.
Basic Time
Basic time is the time for carrying out an element of work at standard rating,
i.e. (Observed time x observed rating)/ Standard rating
SelectedTime
The selected time is the time chosen as being representative of a group of times for
an element or group of elements. These times may be either observed or basic and
should be denoted as selected observed or selected basic time.
RelaxationAllowance
Relaxation allowance is an addition to the basic time intended to provide the
worker with the opportunity to recover from the physiological and psychological

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effects of carrying out specified work under specified conditions and to allow
attention to personal needs. The amount of allowance will depend on the nature of
the job.
Standard Time
Standard time is the total time in which a job should be completed at standard
performance.
Predetermined Time
A predetermined time standard is a work measurement technique whereby times
established for basic human motions (classified according to the nature of the
motion and the conditions under which it is made) are used to build up the time for
a job at a defined level of performance.
Work Specifications
A work specification is a document setting out the details of an operation or job,
how it is to be performed, the layout of the workplace, particulars of machines,
tools and appliances to be used, and the duties and responsibilities of the worker.
The standard time or allowed time assigned to the job is normally included.
Productivity
The definition of Productivity is given as “OUTPUT” compared to “INPUT”.
According to Marsh, Brush (2002) in his article Journal of industrial technology,
productivity is a measure of the efficiency and effectiveness to which
organizational resources (inputs) are utilized for the creation of products and/or
services (outputs). Productivity measurement is both a measure of input utilization
and an assessment as to whether or not input utilization is growing faster than
output.

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SOME IMPORTANT FORMULA
1. BPT (Basic Pitch Time)
2. SPT (Standard Pitch Time) = BPT(Basic Pitch
Time) × 1.05
3. LPT (Lowest Pitch Time)
4. Capacity
5. BMV (Basic Minute Value) = Observed Time ×
6. SMV (Standard Minute Value) = Observed Time ×
7. Input Hour = Operator × Working
Hour
8. Output Hour
9. Target
10.Efficiency
11.Performance
×100%
12.Productivity =
13.Worker Potential Pcs/Hour

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QUALITY ASSURANCE

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QUALITY ASSURANCE SYSTEM
Quality control:
Quality control concerned with the evaluation of test data & its application of the
textile process, raw materials, intermediate products & final products.
It is related not only with the cost of maintaining but also concerned with the
presentation of tangible values to measure quality & change in quality. In order to
control quality one must know about the consumers’ expectations.
Quality assurance:
Quality assurance is defined as all those possible planned & systematic actions
necessary to provide adequate confidence than a product or service will satisfy
given requirements for quality. The Quality Assurance Department is assigned to
maintain consistently uniform quality of the material in process & various stages of
its manufacturing.
Object of quality
control:– 1. Research/
analysis.
2. Selection of raw material.
3. Product testing.
4. Specification test.
5. Should be given economic requirements.
6. Quality assurance & so on.
Quality Management System: Quality assurance procedure may be provided by
the following two major parts–
Quality control
On line Off line

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ON LINE QUALITY CONTROL:
On line quality control comprises with the new raw material, process control &
finish fabric inspection.
1. Raw material control: As the quality productdepends upon the raw
material quality assurance department must ensure that the best quality of raw
material are used in the production.
a. The chemical should be with a known concentration & high degree of purity.
b. The dye & chemical should be compatible with each other.
c. The fabric must be without faults, with uniform absorbency, & whiteness as
per requirement of the subsequent process.
2. Process control: The method chosen for the process must be provided with the
necessary parameters, Temperature, PH, water level, Specific gravity should be
checked at each stage of processes.
a. During dyeing samples are taken, & shade match with lab dip & when match
allow for bath drop.
b. If not properly match topping is done until the required shade come.
c. After neutralization sample is collected & match with lab dip.
d. Sample is collected after fixation & matched.
e. Last of all after softening sample is collected & match with lab dip.
f. Each batch should be match with each other.
g. During finishing temperature, speed, padder pressure, over feed should be
controlled as per recommendation.
h. G.S.M, width, spirality etc should be maintained as per buyer requirement.
3. Finish Fabric Inspection: To ensure that only acceptable quality fabric is used
for producing garments & proper quantity of shipment is received from the
supplier.
POINT CALCULATION SYSTEM:
Defectarea Point
1”–3” 1
3”–6” 2
6”–9” 3
9”– above 4

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For hole in fabric 4
Calculationof point is done by–
Actual grade point = × 100
• If point grade is below 40 then the fabric is ok. If the grade point is more than the
40 points then inform it to respective officer.
• The fabric is also checking for the shading defect in side by side & length. Any
nonconformilities/ shading will be notified to the manager using inspected
reports. Roll wise color uniformity card is maintained for identification of shade
variations. The result of fabric inspection shall be recorded in fabric inspection
report.
ON-LINE TEST:
1. For pretreatment – PH test.
• Absorbency test.
• Residual peroxide test.
• Whiteness test.
• Water quality test.
2. For Dyeing–
• Shade matching check.
• PH check.
• Wash fastness check.
3. Machine checking.
OFF-LINE QUALITY CONTROL:
Fakir apparels limited have all the facility for off-line quality control of the
materials used & processed materials. There are two types of material are tested in
laboratory for the purpose of quality control. There are–
a. Fabric
b. Raw materials.
Fabric testing:
All the off-line tests for finished can be grouped as follows–
a. Physical tests.
b. Chemical tests.

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a. Physicaltest:
• Fabric inspection by-4 point system.
• GSM test.
• Width of the fabric measure.
• Rubbing test.
• Pilling test.
• Shrinkage test.
b. Chemicaltest:
• Color fastness to water.
• Color fastness to wash.
• Color fastness to rubbing.
• Color fastness to perspiration etc.
Raw material:
a. Water : PH & Hardness test.
b. Chemical : Purity test.

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MAINTENANCE
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. Now a day’s maintenance is essential for the modern time
industrialization.
OBJECTIVESOF MAINTENANCE:
a. To avoid any kind of accident by checking the m/c parts & changing the parts
which are damaged.
b. To ensure production & delivery time to customer.
c. To avoid the breakdown of m/c to facilitate the smooth running of production.
d. To get the maximum constant production from m/c.
e.To modify the machine tools to meet the need for production.
TYPES OF MAINTENANCE:
PERIODIC MAINTENANCE:
Periodic maintenance of different machines is carried out by expert engineer period
of time. Normally in case of dyeing machine, complete checking of different
important parts are done after 30 days.
PREVENTIVE MAINTENANCE:
Preventive maintenance is a predetermined routine wise maintenance to prevent
any kind of accident or breakdown of m/c which facilitates smooth running of
production.
Maintenance
dicPerio
anicalMech
icalElectr
Preventive
Mechanical
Electrical
Breakdown
Mechanical
Electrical

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BreakdownMaintenance:
It is done when any kind of m/c part is out of order or broken & it cannot perform
its normal functions.
FLOWCHART OF MAINTENANCE (BREAKDOWN):
Problem arise
Inform to maintenance department
Problem detection
Problem can be solved by repairing or replace.
MAINTENANCE TOOLS:
The most important maintenance tools are given below–
Tools Function
Thread tape Joining of broken metallic part.
Cutting disc For cutting pipes, rods.
Globe valve Fitting for steam line.
Union Fitting for water, steam line.
Union Elbow Fitting water steam line.
Gear oil Lubrication.
Cutting oil Lubrication
Hydraulic oil. Lubrication
Oil gun Oil application
Spanner Tightening of nut, bolts.
Master range Tightening of nut, bolts.
Flat/ Star screw driver Screw tightening & loosening
Hacksaw blade Cutting.
Spray gun Spray chemicals

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Drill m/c To make hole by drilling.
Grinding m/c Grinding
Hacksaw Frame Cutting
Grease Lubrication
MAINTENANCE PROCEDUREOF DIFFERENTMACHINE:
Machine: Dyeing machine
Maintenance: Mechanical
Serialno Items need to be checked& service
1 Grease the winch bearing
2 Complete cleaning of machine.
3 Cleaning of drained valves, replace scale if required.
4 Check air supply filters, regulator, & auto drain seals.
5 Greasing of unloading rollers bearing
6 Checking of oil levels, & bolts, of unloading roller gear box.
7 Complete cleaning of machine.
8 Checking unloading roller coupling.
9 Checking & cleaning of main vessel level indicator.
10 Check the oil level pump bearing & refill if required.
11 Check the function of heat & coolmodulating valves.
12 Check all belts & belt tension.
13 Check all doorseals.
MAINTENANCE:Electrical
Serialno Items need to be checked& service
1 Check main panels.
2 Check all on/ off switch.
3 Check all indicating lamps.
4 Check calibration of heating/ cooling modulating valves.
5 Check setting of sensor.

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6 Check setting & operation of lid safety switches.
7 Check all motors terminal
8 Visual checking of all power & central cables.
9 Check all circuit breaker & motor overload.
10 Check all signal isolators.
11 Check main pump inverter & its cooling fan.

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UTILITY SERVICE
Utility Sources
Gas TITAS
Electricity Generator
Compressed air Compressor
Steam Boiler
Water Natural water by
pump
Temp. control Air chiller.
ELECTRICITY
Source Generator.
No. of generator 6
Brand Waukesha power steam
Origin USA
Model VHP 5904 GSD
Utility Natural gas, water, Lubricating
Mobil
Capacity 900 Kw-1165A
Gas consumption 11 Psi

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COMPRESSEAIR:
Source – Compressor
Brand– Fin.
Origin– Germany.
GAS: Generally 2500 CFT gas is required to produce 1 ton steam /hr. This amount
gas is supplied by TITAS.
Water: submersible water is used by using pump.
WATER TREATMENT PLANT
In Fakir Apparels Ltd they use submersible water. Natural ground water contains
many impurities which has negative impact on the wet processing technology. The
various salts present in the water depend on the geological formations through
which the water has followed. These salts are mainly the carbonates (CO3
2–), bi-
carbonates (HCO3
–) chlorides (Cl–) of Calcium (Ca2+), Magnesium (Mg2+).
Although Calcium & Magnesium carbonates in the limestone are relatively
insoluble in water. So in this reasons, water hardness can be divided in two ways–
Temporary Hardness: Ca (HCO3)2, Mg (HCO3)2 , Fe (HCO3)2
etc. Permanent Hardness: CaCl2, MgCl2, Ca (NO3)2, MgSO4,
CaSO4.
This water hardness causes some serious consequence in textile dyeing & finishing
industries & this are–
1. Precipitation of soap.
2. Redeposit ion of dirt & insoluble soaps on the fabric being washed this can
cause yellowing & lead to uneven dyeing & poor handle.
3. Scale formation on equipment & in boiler pipe lines.
4. Reduction of the activity of the enzymes used in washing.
5. Incompatibility with chemicals & so on.
Hardness is expressed by parts per million (ppm) of CaCO3 which is standard
hardness scale & it is also called American Hardness. The hardness of raw water is
100 ppm or more.
To use it in dyeing & in boiler this water must need to soft & foreign materials
needs to remove.

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METHODS OF WATER SOFTENING:
There are mainly three methods by which hardness of water is removed in
Industrial scale– 1. Lime-Soda process.
2. Base Exchange process (Permutit process).
3. Demineralization process.
Above these three processes, “Fakir Apparels Ltd” used the Base Exchange
Process. By the help of pump hard water is collected from the water store tank.
Water treatment is done in three steps by three filter tanks.
FIRST STEP: water collected by the two parallel pump is followed to the stone
filter for filtration. Stone filter consists of six layers of stone of different size &
shape. Stone filter helps to remove iron from the water. There is a dosing pump
attach with the stone filter for the dosing of sodium hypo chloride. During stone
filtration sodium hypo chloride is added to resist the deposition of iron on stone
layers which might be rigid & hamper smooth operation.
SECOND STEP: After completion of stone filtration water is fed to active carbon
filter for second filtration for the removal of odor, oily, or gummy substances from
water.
THIRD STEP: At the end of the carbon filtration water is flowed to the resin filter
for final filtration. Here hard water is treated with base exchange complex or
zeolites to remove the hardness from water. Zeolites are naturally occurring
insoluble mineral of Sodium alumina silicate type complex (Na20.Z, Z= Al2O3SiO2,
H2O). When water is passed through a bed of the
small particles of such material ion exchanger an ion exchange reaction take place–
Na20.Z + Ca (HCO3)2 CaOZ + 2NaHCO3 Na20.Z +
MgSO4 MgOZ +Na2SO4.
Here the base part ( Ca, Mg, Fe) of hard water are replaced by Na. result is the salt
of Ca, Mg, Fe
& soften the water. After a certain period of times whole sodium of base exchanger
is replaced Ca, Mg, Fe then it is said to be exhausted because it will not soften hard
water anymore & then it is regenerated by NaCl.
CaOZ + 2 NaCl CaCl2 + Na20.Z.
Final filtration makes the water finally soft & drains it to the soft water reserve
tank with the help of a drain bulb. For the supply of soft water to the floor a
pressure vessel is used. A minimum pressure of (4-5 kg/cm3) is maintained in the
pressure vessel for calculation.

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SEQUENCE OF WATER TREATMENT PLANT IS GIVEN BELOW
Figure: Water treatment plant
MEASUREMENTOF WATER HARDNESS:
Necessary equipment &
chemicals– 1. Buffer soln.
2. Indicator.
3. Liquid EDTA soln.
4. Beaker.
PROCEDURE:
Take 50 ml water in a beaker which is treated by WTP-
plant Take 4-5 drops of buffer soln in a beaker.
Take 1 drop indicator in a beaker & form the violet color.
Now EDTA soln is dropped until the pink color is not form a
crystal color Here 1 drop EDTA soln =3 ppm.
Remarks:In industry hardness depends on the type of shade. For light, medium, &
dark shades hardness remain < 5, or <9 or < 12 ppm respectively by using
sequestering agent ( Ladiquiest, Neo-crystal 150F etc).
Hard water store tank Solution of NaCl
Primary filtration
Zeolities
Stone filtration Soft water delivery

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STORE & INVENTORY
INVENTORY: Inventory in a wider sense defined as any idle resources or assets
of an organization, however it is commonly used to indicate raw materials,
finished, semi-finished, packing, spears & other stocked in order to meet an
expected demand on distribution. Even though inventory of materials is an idle
resource in the sense & is not meant for the most immediate use but it is almost
necessary to maintain some inventories for the smooth function of an organization.
CAUSES OF MAINTAIN INVENTORY:
1. To run manufacturing operations economically.
2. To take care of uncertainties demand.
3. To reduce the clerical cost & to take advantage of discounts, transportation etc.
4. It takes time to complete one operation & more products from one stage to
another.
5. To take care of order cycles.
SCOPE OF INVENTORYCONTROL:
1. Raw materials inventories.
2. In process inventories.
3. Finished goods inventories.
4. Miscellaneous inventories. Etc.
FREQUENCYOF INVENTORYCONTROL:
1. Daily inventory control.
2. Monthly inventory control.
3. Yearly inventory control.
PROCUREMENTSYSTEM:
a. Fakir dyes & chemical is sister concern of Fakir Apparels Ltd. so Dyes (mostly
used like Sumifix, Cibacron & Remazol dyes) & chemical (regular items like
Sequestering agent, Anticreasing agent, Anti-foaming, Levelling agents,
Stabilizer etc) are collected from there.
b. Some dyes are purchased from local market if urgently required.

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INVENTORYMANAGEMENT FOR RAW MATERIAL:
In Fakir Apparels Ltd there are different inventory systems are maintained for
different materials.
GREY FABRIC STORE:
All the grey fabric is stored in the fabric store near the knitting section. Different
types of fabric are listed in the sheet according to fabric types, quantity, &
consumer’s requirement.
DYES & CHEMICAL STORE:
There is a different store for dyes & chemicals. Varies types of dyes & chemicals
are stored here according to dyes & chemicals companies. Different types of dyes
& chemicals are listed in a sheet. In the sheet the stored quantity of dyes &
chemicals are also included. Every day the sheet is updated & a copy of this sheet
is supplied to the factory manager, Dyeing manager, & Dye house & Lab section.
FINISHED FABRIC STORE:
In Fakir Apparels Ltd finished fabric are sent to the garments section. After use
in the garments excess fabrics are stored in finish fabric store according to the lot
no, quantity, order no, fabrics diameter, buyers name color, size other considering
technical parameters.
FINISHED GOODS STORE:
In garment section during production they always consider some allowances%.
After shipment the remaining garments are stored in the finished goods store to the
product name, order name, color name, & other subjected points.
SPARE PARTS STORE:
In Fakir Apparels Ltd required amount of spears of different machines are stored
in the mechanical store room. All the spears are listed in a sheet which is controlled
by the mechanical & maintenance personnel. Spares are arranged in the store room
according to their size, quantity, & requirements. There are shelves in the store
room to keep the small spare parts.
STORE CAPACITY:
Items Amount
Dyes 10-12 tons

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Chemicals 20-25 tons
Yarn storage 10-15 tons
Grey fabric 20-25tons
Finished fabric 30-35tons
REORDERPOINT:
The re-order point is stated in terms of the level of inventory at which an order
should be placed for maintaining the current inventory.
In other words, re-order point may be defined as the level of inventory when fresh
order should be placed with supplies for procuring additional inventory equal to the
economic order quantity.
COST ANALYSIS
COSTING SYSTEM:
Cost means the price of the product or goods which include some profit for the
supplies or manufacturer or seller. Costing system mainly describe the cost of final
product according to the buyer requirement by keeping some profit for the
company. As it is a garments manufacturing company merchandiser give the
consumption of fabric with specifications. Then how much yarn is required
dyestuff & chemicals required, labors, utility services & other things related with
manufacturing are calculated. After this the final cost is fixed including some profit
& the unit price is offered to the buyer for their approval.
COST INCLUDES FOLLOWINGS:
• Yarn cost.
• Knitting cost.
• Dyes & chemicals cost.
• Cost of dyeing & finishing.
• Cost of cutting, sewing, accessories etc.
• Cost of printing (if required).
• Labor cost (direct & indirect).
• Factory cost.
• Office & administrative cost Caring cost
• Other cost.
• Profit etc.

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PRICE OF DIFFERENTOPERATION:
Dyeing + finishing charge for light shade : 80~90 tk/Kg
Dyeing + finishing charge for medium shade : 85~90 tk/Kg
Dyeing + finishing charge for dark shade : 100~110
tk/Kg
Tube finishing (Dewatering+ Dryer+
Compactor)
:15~20 tk/Kg
REMARKS:
The costing of the product is most secret matter of the industry. They are not
interested to flash the data. So we could not collect the costing process of the
products.
MARKETING STRATEGY
MARKETING INFORMATION:
Fakir Apparels Ltd is 100% export oriented knit garments manufacturer. So, they
sold their product to export market. They also same initiative for market
development through communicating with new buyer & taking part in different
international garments fair. As it is an apparels manufacturing industry, its main
product is T-shirt, polo-shirt, Tank tops, children wear, fashion wear & sports wear
etc. Fakir Apparels Ltd ensures safe/ health hazard chemical free garments as per
customer requirements, through practice of quality control procedure.
MARKETING STRATEGY:
Now days the marketing strategy is key feature for a export oriented company. If
the marketing strategy is not good then it is not possible to survive in the
competitive global market. In case of marketing the garments a good dealing with
the buyer is very important.
In Fakir Apparels Ltd mainly the merchandising department & the higher
officers deals with the buyer. The company has some fixed buyers. These buyers
give their order continuously all over the year. The marketing officers & the
merchandising department communicate with the buying house all the year.

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MAJOR BUYER:
1. H & M.
2. C & A.
3. Tom Tailor.
4. Ahlens.
5. S.oliver.
6. All marks. 7. Peacock
8. G-star.
9. Kids etc.
EXPORTED COUNTRY:
Europe & USA.
CONCLUSION
We have completed our industrial attachment successfully by the grace of Allah.
Industrial attachment sends us to the expected destiny of practical life.
The
completion of the two months Industrial attachment at Fakir Apparels Limited,
we have got the impression that factory is one of the most modern export oriented
knit composite complex in Bangladesh. Though it was established only a few years
ago, it has earned “very good reputations” for its best performance over many
other export oriented textile mills.
During our training period, talking with the clients of this mill we knew
that the mill
is fulfilling the country’s best export oriented white finished fabric as well as very
good colored fabric due to its modern machinery & good management system.
Mill is settled with utility to give all convenient supports to the
productions for
twenty-four hours. It had self-power generator system to satisfy total power
consumptions of the mill.

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We are enough fortunate that we have got an opportunity of having a
training in
this mill. During the training period we are received co-operation and association
from the authority full & found all man, machines & materials on appreciable
working condition. All stuffs & officers were very sincere & devoted their duties to
achieve their goal.
There are some suggestions from us within our limited knowledge
Some Suggestions:
 The dyeing floor is watery most of the time: it should be cleaned all the time.
 To increase overall efficiency, more skilled labor should be used in a project.
 The machine stoppage time should be analyzed and minimized.
 The maintenance should be carried out when the machine is out of action
(wherever possible) and routine maintenance should be carried out regularly.
 There should be a yarn dyeing project.
 Sitting arrangement of production officers should be improved
 The knitting section should improve and modern machinery should add.