most importents of textile related students

1. SelimReza
B.Sc Hon”s InApparel ManufacturingTechnology(AMT)
Trims and accessories
Fabricand accessoriesdept.workingwell forgettingthe rightqualityintimely.Butsomewhere
accessoriesins.Deptisnotavailable,store iscompletingthe responsibilities.
Store QualityCheckList:
BuyerApprovedTrimsCardCheck.
BuyerApprovedSample Wise Main,Size &Care Label Check.
BuyerApprovedSample Wise Care Symbol Check.
ThreadColorShading& QualityCheck.
BuyerWise Hang tag & Price StickerCheck.
All materialsbuyerwiseandstyle wise input.
All trimsandaccessoriespreservedinaracking system
All machine toolsalsostoredinseparate place.
Carton storingina dry place otherwise itwillbe damaged.
Maintainingall recordcarefully
FlowChart of AccessoriesManagementinGarments Industry
Receivedtechnical sheet
↓
Receivedapprovedtrims
↓
Accessoriesreceived
↓
Inventory
↓

2. Decision
↓
Storage accessories
↓
Delivers
Garments Washing Process
The technologywhichisusedtomodifythe outlook,appearance,fashionandcomfortabilityof
garmentsiscalledgarmentswashing.Garmentswashingare the aestheticfinishgiventothe denim
fabricto enhance the appeal andto provide strength.Garmentswashingcanbe done by followinga
processflowchart,whichisdeeplydiscussedinthisarticle.
Process Flow Chart of Garments Washing:
Actual processflowchart forgarmentswashingare mentionedinthe following-
Garmentsreceive fromsewingdepartment
↓
Garmentssentto the dry process(If there’sanydryprocess)
↓
Hand scrapping
↓
Whiskering
↓
Tacking
↓
Garmentssentto the wetprocess
↓
Garmentsloadingintothe washingmachine

3. ↓
Washing(Maintainingwash reference)
↓
Extracting
↓
Drying
↓
Garmentssentto the dry process(If there’sneededanymore dryprocess)
↓
P.Pspray (If the processneeded)
↓
P.Psprayedgarmentssenttothe wetprocess
↓
P.Psprayedgarmentsloadingintothe washingmachine
↓
Washing(Completingrestof the wetprocess)
↓
Extracting
↓
Drying
↓
Garmentssentto the dry process(If there’sneededanymore dryprocess)
↓
3D (If needed)
↓

4. Curing
↓
Qualitycheck(Q.C)
↓
Sendto the finishingdepartment.
IE dept. in garment industry
At presentIndustrial Engineering(IE) isone of the importantdepartmentforeachgarmentsortextile
factory.Today’smaximumfactoryisrun byindustrial engineers,wheretheyhave tofollow aprocess
flowchart.By whichtheycan easilycontrol the whole garmentsproductionprocesses.Suchkindsof
processflowchart hasdiscussedinthisarticle.
Process Flow Chart of Industrial Engineering (IE):
Negotiationwithgarmentsmerchandiser
↓
Garmentsanalysis
↓
Make P.Pmeetingif all the requiredfabrics, trimmingsandaccessoriesare inhoused
↓
Productiontarget
↓
Setmachine layout
↓
Line setting
↓
Line balancing
↓
Continuousproductionmeeting

5. ↓
Collectingproductiondata
↓
Preparingproductionreport
↓
Productionreportanalysis
↓
Reportsubmitto factorymanager
Quality Control in Sewing Section
Qualityreferstothe buyer’ssatisfactionorrequirements.Now aday’sreadymade garmentsbusinessis
fullybasedonquality,whichiscarriedoutinvarioussections.Garmentssewingsectionisone of those.
As itsimportance ingarmentsmanufacturing,todayIwill presenthere the processflowchartof quality
control in sewingsection.
Process Sequence of Quality Control in Sewing Section:
Inputmaterial checking
↓
Cuttingpanel andaccessorieschecking
↓
Checkingsewingmachine
↓
Sewingthreadchecking
↓
Sewingneedle checking
↓
Embroideryandprintingpanel checking(If there)
↓

6. Stitchingfaultchecking
↓
Seamfaultchecking
↓
Measurementchecking
↓
Shade variationchecking
↓
Size mistake checking
↓
Trimmingschecking
↓
Interliningchecking
↓
Crease or wrinkle appearance checking
Garments Sewing Department
Sewingisanimportantdepartmentin garmentsmanufacturingindustry.All the partsof a garmentare
joinedhere bymakingstitchwiththe helpof needle andthread.Where,sewingprocessflow charthelps
to make a complete garmenteasily.Bymaintainingsewingprocessflow chart,anordercan be
completedintimely.
Process Flow Chartfor Garments Sewing Department:
Productanalysis
↓
Setup target forproduction
↓
Setup machine layoutonthe basisof target

7. ↓
Setup operatorlayoutonthe basisof target
↓
QC checkof product
↓
Line balancing
↓
Line setup
↓
Distributionall the processes
↓
Cuttingpartsreceivedsection
↓
Cuttingpartsdistributiontothe operatorandhelper
↓
Complete partsmakingindividually
↓
Online QCcheck
↓
Online qualityaudit
↓
Countingoutputandcheckingwiththe target
↓
Final qualitycheck(foreachGarment)
Garments Cutting Section

8. Cuttingisone of the majorprocessin garmentsmanufacturing.Here garmentspartsare cutting
accordingto the pattern.Ingarmentscuttingdepartment,aprocessflow charthave to maintainedto
sendthe rightmeasurementpartsinthe nextprocessformakingqualitygarments.Asitsimportance in
garmentsmanufacturing,aprocessflowchartfor garmentscuttingdepartmentispresentedinthis
article.
Process Flow Chart of Fabric Cutting Department:
Patternreceivedfrompatterndepartment
↓
Cuttingratioreceivedfrommerchandiser
↓
Marker making
↓
Fabricreceivedfromthe store
↓
FabricChecking
↓
FabricSpreading
↓
Marker placingonto the lay
↓
Cuttingthe fabric
↓
Numbering
↓
Checking
↓

9. Sortingand Bundling
↓
Sendto the sewingdepartment
Letter of Credit (L/C):
L/C meansLetterof Credit.It isthe familiarwordinapparel industry.L/Csetupis the workof
merchandisingsectioningarmentfactory.A merchandisershouldhave clearconceptonletterof credit.
Letterof Credit(L/C) alsoknownasDocumentaryCreditisa widelyused termtomake paymentsecure
indomesticandinternational trade.So,L/Cisveryimportantinapparel merchandising.Novice
merchandiserdon’tknowhowtoL/C open.Now,Iam givingaflowchartof L/C opening.
Sample Letterof Credit
FlowChart of L/C OpeninginGarmentsMerchandising

10. Requirementof material withspecification
↓
To informaboutrequirementtothe headof the management
↓
Managementwill searchforthe requirement
↓
Variouscompanyresponse withthose specification
↓
The managementwill selectsome offers
↓
Thendiscussionwillheldamongtwomanagement
↓
Managementwill signthe agreementwiththe selectedcompanyoragencies
↓
Thennegotiationwill take place amongmanagementandagencies
↓
Submissionof the final PI
↓
Bank will openL/C
Garment Finishing Process
Garmentfinishingisthe laststepof garmentmaking.All of the finishingprocessesare done here.The
termGarmentsfinishingmainlyappliestopressing,folding,packingandcartooningof garments.
Flow Chart of Garment Finishing Process
Finishinginput(style,color&size wise)
↓

11. Initial qualitycheck
↓
SpotRemoving
↓
Ironing/Pressing
↓
Inspection
↓
Hang tag
↓
Get up change
↓
Folding
↓
Poly
↓
Bar code (buyerwise sticker)
↓
Metal check
↓
Cartooning/Packagingtobox
↓
Inspectionof readytoshipgoods
↓
Dispatchshipment

12. Garments Sample:
Samplingisone of the mainprocessesingarmentmanufacturinganditplaysvital role inattracting
buyersandconfirmingthe order,asthe buyersgenerallyplacesthe orderonce satisfiedwiththe quality
and responsivenessof the sampling.Garmentsamplesare somuchimportantandare developedtested
before startingthe bulkproduction.The buyerwill accessthe exporterandhisorganizationonlyby the
samples.Inpreviousarticle Ihave givenflow chartof garmentmanufacturingprocess.Now I’mgiving
the processflowchart of apparel sample making.
Flow Chart of Garment Sample Making
GarmentsDesignor Sketch( Manuallyor Computerized)
↓
Basic Block( Manuallyor Computerized)
↓
WorkingPattern( ByMachine )
↓
Fabriccutting
↓
Print/Embroidery(If required)
↓
Sewing
↓
Finishing
↓
Sample Garments( Manually)
↓
Problemof ProductionorProductionRelatedMatter
↓

13. Costing............................................↓ ..................................SendtoBuyer
↓
ApprovedSample
↓
ProductionPattern( By Hand or Computer)
Garment Merchandiser:
Merchandiserishe whobuildsuprelationshipwiththe buyerandactsas a seller.He playsa vital role in
an organizationina sense thathe bearsmore responsibilitythanotherinregardsto executionof an
order.Works of merchandiseriscalledmerchandising.He carriesahuge importance fora garments
factorybecause on a merchandiserthe wholeprofitorlossesare depending.Because asillymistakeby
himcan be milliondollarloss.The aimof merchandiseristosell the garmentsatmore valuable price
than the total cost of fabric,accessories,othersthings,the laborcost,rentof factory,etc. Working
flowchartof an apparel merchandiserisgivenbelow.
Working Flow Chart of a GarmentMerchandiser
Sourcingof buyer(hostingwebpage,preparingprofile,visitingbuyinghouse etc)
↓
Receive ordersheet.
↓
Discusswithplanningdepartmentforavailabilityof productionspace.
↓
DiscusswithprodDir/GM forcapabilityof handlingsuchorderandprobable productivityperhr.
↓
Analyze productpackage andspace sheetforcosting.
↓
Findout the consumptionof fabric.
↓

14. Analyze the fabriccontent,knittingpattern,GSMand do fabriccosting.
↓
List outall Accessories,dothe consumptionandcosting.
↓
Analyze printing,embroidery,valueadditionworkwashingforcosting.
↓
Analyze productivityperHrwithmachine andmanpowerrequirement(Maytake helpfromproduction
people).
↓
Assesscostof makingperDozen.
↓
Confirmprice fromcomponentauthority
↓
Quote price to buyer
↓
Negotiate price withbuyer
↓
Confirmorderwithbuyer
↓
Prepare time andactioncalendar(withavailableproductionleadtime)
↓
Prepare Gantt chart (Insupportof T&A andincorporate all importantissuesandeventswithcompletion
date)
↓
Receive size colorbreakdownandcolorstandard.
↓

15. Prepare labdip,strike off,yarndipetcand arrange approval of the same.
↓
Receive artworkand sample forprinting,embroidery,value additionwork,washingandgetapproval
for the same.
↓
Developall samplesandsubmitthe same tobuyerfornecessaryapproval.
↓
Obtainand ensure all approval asperT&A and Gantt chart to facilitiesproductionasperplan.
↓
Receive masterL/C
↓
Prepare final costapproval sheettofacilitate openingof all BBL/C.
↓
OpenBB L/C for yarn,accessories,printing,embroideryetc
↓
Arrange all fabricand accessoriesandensure inhouse of the same as perT&A.
↓
Source for printing,embroidery,value addwork,washingandcomplete deedof agreementwiththem.
↓
Ensure inventoryof all itemsonarrival tostore to confirmthe qty,color, sizesandqualityasper
requirement
↓
Arrange all pre-productionmeetingandinspectionontime.
↓
Arrange all labtest ontime.
↓

16. Ensure dispatchand approval of all sampleswhichmayaffectthe final inspectionandshipment
↓
Arrange final inspectiononscheduledate.
↓
Do loadcalculationandensure bookingof all loadcarryingtransportwell inadvance.
↓
Ensure space bookingwithseaandair freightforwarder.
↓
Helpcommercial departmenttosubmitall documentstobankontime.
↓
Ensure realizationof full paymentaspershippedqtyandprice
Computer Aided Design (CAD)
CAD isthe contractionwhichstandsfor ComputerAidedDesign.Thistermmeansdifferentthingsto
differentpeopleinvolvedindesigning,manufacturingandmechanical engineering.CADorComputer
AidedDesignhasbroughta revolutioninthe Textileindustry,speciallyinapparel industry.The time
consumingandcumbersome processof textile designinghasbeenmade easierbyCAD.Now thoughtful
and innovativedesignsare availabletothe textiledesignersandtextile manufacturersatthe clickof a
mouse.
Working Sequence of CAD Section in Apparel Industry
Receivingof patternparts
↓
Takingthe image of patterninCPU by digitizer
↓
Moderizingof all patternpartsby the software (Moderizer)
↓
Aligningall size patternpartsinthe markerbythe software (Diamino)

17. ↓
Completingthe marker
↓
Takingapproval fromCAMsection
↓
Bringingoutthe marker throughplotter.