Industrial project

1May 11, 2015
INDUSTRIAL ATTACHMENT
INDUSTRIAL TRAINING
Course Code: Tex -4036
Industrial Attachment
NORBAN COMTEX LTD.
Prepared & Submitted By
Supervisor :
Prof. Syed Fakhrul Hassan
Chairman,
Department of Textile engineering,
Southeast University
Submission Date: 11th
May, 15
S/L NAME ID BATCH GROUP
01 ISTIAK AHMED 2011000400002 16TH
FMT
02 SHAHRIAR ALAM 2011000400006 16TH
GMT
03 ASIM BARMAN 2011000400008 16TH
FMT

2May 11, 2015
Letter of Transmittal
11h May,15
Chairman,
Department of Textile Engineering
Subject: Submission of the “Industrial Attachment Report”.
Dear Sir,
We are pleased to submit our “Industrial attachment Report” This is submitted under the
program of B.Sc in Textile Engineering in Southeast University.
The Report has been completed in accordance with the knowledge that we have gather
during our Industrial Training and the guidelines received from our honorable teachers and
our group members.
We tried to make this Report is to give a clear picture on Fabric Manufacturing Technology,
Wet processing Technology & Garments Manufacturing Technology practically used on
Micro Fibre Ltd. However, we will always be ready to provide any further clarification that
you may require.
Yours Sincerely,
Istiak Ahmed 2011000400002 16th
Shahriar Alam 2011000400006 16th
Asim Barman 2011000400008 16th

3May 11, 2015
Department of Textile Engineering
Supervising Faculty’s Approval
…………………………………………………
Supervisor :
Chairman,
Department of Textile engineering,

4May 11, 2015
Acknowledgement
At first my gratefulness goes to almighty Allah, the creator of the universe, the most powerful,
the most Merciful and the Sustainer of the world for giving me the strength and capability to
complete this project.
Now, I would like to thank a lot of people who helped and supported me during the completion
of this report.
Prof. Syed Fakhrul Hassan, Chairmen, Dept. of Textile Engineering, my supervisor, to
whom I am extremely indebted for his tremendous support and guidance throughout internship.
I also like to thank Mr. Minhaz Ahmed, Lecturer, Dept. of Textile Engineering who helped
me very much. He guided me very well during my internship. Being working with him I have
not only earned valuable knowledge but was also inspired by his innovativeness which has
helped enrich my experience to a greater extent. His ideas and way of working were truly
remarkable.
We should like thank the management of NorbanComtex Ltd, for giving us opportunity to do
the industrial training successfully and also their valuable suggestions.
I would like to thank Mr. Mahmood ,Exucative at Al Arafa Islami Bank & Mr. Sahariar,
Exucative at yarn dyeing in Norban Comtex Ltd. for arranging my internship.
Our heartiest thank to MD. Shahadat Hossain Manager(Merchandising) NorbanComtexLtd,
who supervised us & all production officers in all section for their information and cooperation.
We are graceful to all other Sr.Executive of different departments for assisting us to gather
information about various process and term.

5May 11, 2015
Table of content
Serial Title Page no.
Chapter 01:Company Profile
01 Introduction 7
1.1 At a Glance 8
1.3 Vision & Mission 10
1.4 Items of Product & Customer 11
1.5 Factory Location 12
1.6 Meaning and consequences for Norban Comtex Ltd 13
Chapter 02: Man Power Management
2.1 Human Resource Department 14
2.2 Responsibility 16
Chapter 03: Machine Description
3.1 knitting Section 17
3.2 Dyeing Section 18
3.3 Garments Section 22
Chapter 04: Raw materials
4.1 Different types of raw materials 25
4.2 Different types of yarn 25
4.3 Name of Chemical and Auxiliaries 26
4.4 Accessories List 26
Chapter 05: Production Planning, Sequence & Operations
5.1 Production Planning 28
5.2 Garments Production Processes 28
5.3 Step Wise Flow Chart 31
5.4 Production parameter 37
5.5 Production Calculation 37
Chapter 06: Quality Assurance System
6.1 Quality Policy 39
6.2 Quality Control 40
6.3 Quality Assurance System 41
Chapter 07: Maintenance
7.1 Types of maintenance 44
7.2 Maintenance Tools & Their Equipment 48
Chapter 08: Utility Service
8.1 Compliance 51
8.2 Different compliance issues 52
7.3 Utility 53
Chapter 09: Store & Inventory Control
9.1 Classification of Store Section 54
9.2 Inventory System for Raw Material 55

6May 11, 2015
Table of content
Serial Title Page no.
Chapter 09: Store & Inventory Control
9.3 Dyes & Chemicals store 54
9.4 Accessories Store 55
9.5 Trim card contain 56
9.6 Engineering store 56
Chapter 10: Cost Analysis
10.1 Consumption Formula of Knitted fabric 57
10.2 Types of carton 59
10.3 Button Liner 60
10.4 CBM 61
Chapter 11: Marketing Activities
Manpower 61
11.1 Buyer and Exporting Country 62
11.2 Marketing strategy 62
11.3 Product label 63
11.4 Duties & Responsibilities of Marketing Officer 63
Chapter 12: Conclusion
12.1 Conclusion 64

7May 11, 2015
CHAPTER-1
1. INTRODUCTION
Practical knowledge is very much essential for the education of textile engineering and
technology. Practical knowledge makes us capable and perfect to apply theoretical knowledge
in practical life.
The Textile Sector has the capability to offer a complete product range for the export textile
markets. The goal of the Textile Sector is to become the preferred partner for sourcing high
quality fabrics and clothing from Bangladesh. With highly advanced technology and an
emphasis on developing local human resources.
That is why B.Sc. in textile technology course is extruded over four years followed by two
mounts industrial training in mills. It is attached to our study curriculum to achieve adequate
practical knowledge and develop adoption power with industrial environment.
We preferred this attachment in NORBAN COMTEX LTD. which is a 100% export oriented
composite Knit dyeing industry. It is fully approved by several multinational inspections.

8May 11, 2015
1.1 AT A GLANCE:
Name of Company : NORBAN COMTEX LTD.
Address : MouzaSarabo, KashimpurUnion,
Gazipur, Bangladesh.
Corporate Office : House # 8/B, Road # 1, Gulshan-1,
Dhaka, Bangladesh
Tel: +88(0)2 8833413-20,
Fax: +88(0)2 8833423,
Email: info@norbangroup.com

9May 11, 2015
1.2Factory information
Nature of business : 100% Export Oriented Knitted Textiles, Garments &
Printing Factories.
Name of the contact persons : Mr. Wahidul Haque Siddique
Chairman / Managing Director
Norban Comtex Ltd.
Total employees : Male : 650, Female: 584
Total: 1234
Number of machine : Sewing: 300, Kniting: 20, Dyeing: 18
Garments production capacity: Knitting Capacity 6,000 kgs per day
Dying/ Finishing capacity 15,000 kgs per day
Item of Product: 50,000 pcs per day.
Floor Space : 426,500 Sq. Feet (39,623.3 Sq. meters).
Name of the Bank : Dutch Bangla Bank
Legal Form of Company : Private Limited Company.
Year of Incorporation : 2007
Project cost : 250 cores
Main Production : Basic T-Shirt, Tank top, Long Sleeve- Shirt, Polo Shirt, Shorts,
Ladies & Kids Knitwear & all kinds of knit garments & Knit fabrics.
Minimum Age of Worker : Minimum 18 years

10May 11, 2015
1.3 Vision & Missionof Norban comtex Ltd.
Mission:
At Norban Comtex Ltd, we strive to provide world class service and the best value to our
customers. We thrive for excellence and work for ensuring a pleasant, clean and professional
working condition for our employees and the people we do business with
Vision:
 Gain market leadership in high value added apparel in USA & Europe.
 Use “Innovation” and “Speed” as prime drivers, rather than cotton & cheap labor.
 Dominate these market in high quality
 Men’s T-shit & polo shirt
 Ladies item
 Kids wear

11May 11, 2015

12May 11, 2015
1.4 Item of Product:
1.4 Our Present Customers
- C & A, Germany
- MGB, Germany
-PEEK & CLOPPENBERG, Germany
-BRAX, Germany
-VIA APPIA, Germany
-KATAG, Germany
-MS MODE, The Netherlands
-DEBENHAMS, UK
-Gueldenpfennig, Germany
-FILA, Italy
-Coolcat, The Netherlands
- Center Line
Area of Manufacturing Type of Manufacturing
Children
Wear Ladies
Wear Men’s Wear
T-shirt
Polo shirt
Sweat
Jacket
Tank Top
Men’s Underwear
Leggings
Others on specific demand

13May 11, 2015
1.5Factory Location:
Seu Campus
W
S
Nabisco
Savar
Abdullah Pur
Baipail
Maymansing
Road
DEPZ
DEPZ
SFMMC
NCL
chokroborti

14May 11, 2015
1.6 Meaning and consequences for Norban Comtex Ltd:
•We will follow this way stringently with all of our business partners.
•We will have an open communication policy with all stakeholders on that.
•We will develop our supply chain along that way.
•Our complete team, workers and staff will be permanently trained to fulfil our requirements.
•Our requirements will be written in our “sustainability policy”.
Norban`s “Go Green“ philosophy:
•Creation of closed loops for all materials
•Waste becomes resource
•Non-bio-degradable waste leads to up-cycling
•Complete usage of renewable energies

15May 11, 2015
CHAPTER-2
2. MAN POWER MANAGEMENT
2.1 Human Resource Department
Human resource is a term with which many organizations describe the combination of
traditionally administrative personnel functions with performance management, Employee
Relations and resource planning. The objective of Human Resources is to maximize the return
on investment from the organization's human capital and minimize financial risk. It is the
responsibility of human resource managers to conduct these activities in an effective, legal,
fair, and consistent manner.
Human Resource department (HRD) practices Human Resource Management in an
organization (HRM). This is the strategic and coherent approach to the management of an
organization's most valued assets - the people working there who individually and collectively
contribute to the achievement of the objectives of the business. The terms "human resource
management" and "human resources" (HR) have largely replaced the term "personnel
management" as a description of the processes involved in managing people in organizations.
Human Resource management is evolving rapidly. Human resource management is both an

16May 11, 2015
academic theory and a business practice that addresses the theoretical and practical techniques
of managing a workforce.
The basic concept that HRD practices is that humans are not machines; therefore we need to
have an interdisciplinary examination of people in the workplace. Fields such as psychology,
industrial engineering, industrial and organizational psychology, industrial relations,
sociology, and critical theories: postmodernism, post-structuralism play a major role.
Human resources management comprises several processes. Together they are supposed to
achieve the above mentioned goal. These processes can be performed in an HR department,
but some tasks can also be outsourced or performed by line-managers or other departments.
 Workforce planning,
 Recruitment,
 Induction and Orientation,
 Skills management,
 Training and development,
 Personnel administration,
 Compensation in wage or salary,
 Time management,
 Employee benefits administration,
 Personnel cost planning,
 Performance appraisal etc.
2.2 Responsibility:
Responsibility of Production officer
 To make the programmed card according to daily production plan.
 Prepare sewing lines of floor & report to A.G.M. in three time everyday
 Receives cutting fabrics according style, color and size form cutting section.
 To check the lay out of garments.
 Maintain floor discipline & cleanness.
 Any other works as & when required by the management.

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Responsibility of Production Manager
 To the programmed card according to daily production plan.
 Cutting check and proper installation of cutting fabric for sewing.
 Control of supervisor, operator, asst. operator &helper of garments floor.
 To match different part of garments according to approve sample.
 To find out sewing fault as early as possible.
 To rectify the finished garments this rejected from quality control department
Remarks:
 The manpower management system of this factory is well arranged. Every officers &
stuffs are responsible for their duty. But there are some textile engineers in the industry
for Garments and Merchandising. It is prevent for fluent production. The efficiency of
the worker should be increased for more quality production.

18May 11, 2015
Chapter 3
3.Machine Description
3.1 KNITTING SECTION
MACHINE DESCRIPTION OF CIRCULAR KNITTING SECTION
Circular Knitting Machine:
Single Jersey: 13
Flat knitting: 4
Circular Auto striper- 3
Total no of M/C : 20
Machine No. tSpecification Capacity Brand
Circular Auto striper- 01 DIA- 34X24/28G Auto Striper Single Jersey 120 Kg/Day PAILUNG
Circular Knitting- 01 DIA- 42X18/24G (1X1 RIB) 350 Kg/Day LISKEY
Circular Knitting- 07 DIA- 36X24G Single Jersey 300 Kg/Day LISKEY
Circular Knitting- 07 DIA- 36X18/20/24/28G Single Jersey 300 Kg/Day LISKEY
Circular Knitting- 11 DIA- 36X18/20/24/28G Fleece/Heavy Jersey 350 Kg/Day LISKEY
Flat Knitting- 01 Flat Collar/Cuff, Bed- 72 Inch, 14 G 300/600 Pcs LISKEY

19May 11, 2015
Fig. Engg. Stripe M/C
Fig. s/j knitting m/c

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3.2 DYEING DIVISION
MACHINE DESCRIPTION OF DYEING SECTION:
Machine Nr. Specification Capacity Brand Origin
Dyeing-01 Innoecology HT1
XC1
200 Kg Brazzoli Italy
Dyeing-02 Innoflow HT1 XC2 250 Kg Brazzoli Italy
Dyeing -09 Dynamica EF-1XJ
HT
200 Kg MCS Italy
Dyeing -10 Dynamica EF-1XJ
HT
200 Kg MCS Italy
Sp Dyeing-11 Overflow MOD
HT-50
Sp Dyeing-12 Aquarius Dyeing
Machine
Sp Dyeing-13 Aquarius Dyeing
Machine
Sp Dyeing-14 Overflow Dyeing
Machine MOD
MBC-50
Machine MOD
RCL-25
Machine MOD
MBC-25
Turning-01 Fabric Reversing
Machine
10000 Kg Beneks Turkey
Auto Dyes and
Chemical
Dissolving
System
Dyestuff check and
weighting system,
Dissolving System,
Chemical reserving
and auto
dispensing
3GDOS/ Brazzoli Italy

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Fig. Dyeing M/c
Fig. Stenter & Compactor M/C
Fig. Yarn Dyeing M/C

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Slitter Machine
Slitter machine is used for tubular knit fabric to make it in open form. In open form fabric
finishing line; slitter machine is used after hydro-extractor, de-watering and drying machine.
Slitting is a process that is applied for cutting the tubular fabric through the intended break
Wales line on lengthwise direction prior to stenter processing. During slitting, it is required to
be aware about the cutting line otherwise, fabric faults can be occurred there.

23May 11, 2015
Fabric Finishing Machineries Details:
Machine Nr. Specification Brand
Stenter-01 Flat Stenter IC-10 of 8
Chamber for Drying and
Heat setting
Icomatex, Spain
Dryer-01 Santex Dryer Type, 5
Chamber
Santex/DIPL-Ing.
Stephan Heinrich-,
Switzerland
Compector-01 Revolution 2500 with 9.7 M
Tender/Equalizer Model E-
2500
Ferraro, Italy
Compector-02 Decatizing
Calender/Compacting
Machine, Model CUD/FV
1500, Working width 1.35 M
(Tubular)
Ferraro, Italy
High speed Brush
suedingMachine
Model: Lisa 4 Knit Plus(open
width and tubular processing)
Mario Crosta, Italy
High speed Double Drum
Raising machine
Model MC20/24 GF knit open
tub(open width and tubular
processing)
Mario Crosta, Italy
Slitting-01 Superslit Slitting Line 2400
MM
Corino, Italy
Squeezer-01 Tubular Spreading and
double ballooning with double
stretcher
Bianco, Italy
Back Sewing-01 Edge Sewing Machine Beneks, Turkey
Tumble Dryer-01 GDP-150 Drying Machine Guangzhou Panyu
Hydro Extract -01 KZ-125 Kg Dewater Machine Guangzhou Panyu
Hydro Extract -02 KZ-125 Kg Dewater Machine Guangzhou Panyu
Inspection Machine-01 Tensionless Inspection
machine with metering
system
Hsing Cheng
Inspection Machine-02 Tubular Fabric Inspection
machine
HsingCheng

24May 11, 2015
3.3 Garments Section:
Straight knife cutting machine
Machine name : K.M company cloth cutting m/c
Model : K.M KS_AUV
Producer : made by K.M cutting m/c co, JAPAN
Typ : Heavy duty industrial cloth cutting m/c self
sharpening
Dimension : 8 inch width * 11 inch length * 24 inch height
Weight : 33.5 lb
Current : A.C (3.3/2.6 amps)
Speeds : 3000/3600
Sewing Machines:
Plain Machine
The S-1110A (Replaces: model SL1110) is Brother's new standard industrial high speed single
needle lockstitch sewing machine.
S-1110A-3 single needle straight stitch flatbed lockstitch machine for light to medium
material (5500spm) complete with stand, table and with the added bonus of the 240volt single
phase servo motor (silent) runs only when the
machine is in operation (assembled).
Servo Motor: An electronically controlled motor
which only works when you start to sew, unlike
the conventional clutch motor which runs once
you turn the power on, consuming electricity.
With the advancement in energy-saving
technology, using a servo motor, can give you a power consumption saving of up to 60% as
proved in manufactures tests against a standard clutch motor.
Specification:
 Brand name: Brother
 Origin: Japan
 Max. Speed: 5500spm(sewing speed)
 Max. Stitch Length: 4.2mm
 Needle bar stroke: 31mm

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 Foot lifter height: 6mm (manual), 13mm (knee lifter)
 Rotary hook
 Fully automatic lubrication
 Bed size: 476x178mm
 Arm pocket size: 266.5x127mm
Bar tack machine:
Specifications
 Brand name: Brother
 Origin: Japan
 Max. sewing area (X-Y): 40 X 30 mm
 Stitch length: 0.05-12.7 mm
 Number of stored data: 89 sewing patterns as standard
 Max. number of stitches: 210,000 stitches
 Max. sewing speed: 3,200 rpm
 Thread trimmer, thread wiper, and thread nipper equipped as standard
Overlock Machine:
Specifications:
 Brand: Pegasus
 Origin: Japan
 Max. Speed: 8500 r.p.m
 Stitch Length: 0.6mm-5.2mm
 Over edge width: 1.5mm-8mm
 Presser foot lift: up to 8mm
 Differential feed ratio: 1:0.4-1:3.2

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Flat lock machine:
Specification:
 Completely block oil leakage, Adopting a state-of-the-art "Oil Barrier" technology!
 Produces beautiful and quality decorative stitches which are soft to the skin.
Remarks:
Some of the machines are too old. The catalogues of these machines are no longer
available in industry, also in website. That’s why those machines specifications can’t be
described.

27May 11, 2015
Chapter 4
Raw materials:
The raw materials for garments are the fabric, thread and trimmings. Different types of fabric
of wide range of GSM are used. In fabric store section I had the chance to know about different
fabrics of different GSM used in Norban comtex Ltd. I also have known different fabric
manufacturer/suppliers name for this garments section i.e. sources of fabrics. Single jersey,
lacost, pique, rib, interlock and other fabrics are used for garments.
In garments section different types of raw materials are used .They are describe below
Fabrics:
 Single jersey
 Lycra single jersey.
 1*1 Rib
 2*2 Rib
 Interlock
 3- thread fleece
 Single lacost
 Double lacost
 Knitt Denim
 Double jersey.
 Polo pique.
 Mélange.
 Fleece fabric.
Knitting Section:
Different types of yarn:
Yarn count used:
 20s
 22s
 24s
 26s
 28s
 30s
 32s
 40s
 44s etc.

28May 11, 2015
Lycra:
 20 D
 40 D
Dyeing Section:
Name of Chemical and Auxiliaries Used:

29May 11, 2015
Garments Section:
Accessories list
Hanger sizer: Identify the size of the garment by hanger
Label: Labels are the most important trimmings by which customer easily, know about the
product. Here two types of label are available:
1. Main label: It contains the name of buyer and country. Ex. Wal-Mart, USA etc
2. Sub label:
i. Size label: It contains the size of the garment
ii. Care label: It contains care construction. Different types of care label are given
below.
a. Washing code
b. Bleaching code
c. Ironing code
d. Dry cleaning code
e. Drying code
iii. Cost label: It contains the cost of garments.
iv. Composition: It contains fiber composition of the fabric. Ex 65% cotton,
35%polyester.
Sewing thread:
Different types of sewing treads are available in store room. Such as
 60/3 (100% polyester)
 50/3 (core spun yarn)
 40/3 (100% polyester)
 20/3 (100% cotton) etc
Button:
Many types of button are available in store room. Some examples of button are given below.
 Horn button
 Purl button
 Shank button
 Snap button
 Coconut button
 Chalk button

30May 11, 2015
Chapter 5
5. Production Planning, Sequence & Operations:
5.1 Production Planning:
Production planning is a suitable & clear study and pre-arranging the technique involve to a
long series of operation for achieving best possible time by using men, machine, materials
present in industry.
Production Engineering:
The engineering approach which is used applied in every stage of a production process of a
product is known as production engineering.
Production engineering includes:
 Ensure smooth production
 Involves with maintenance management
 It is applied in every stages of production.
5.2 Garments Production Processes:
Design/Sketch:
For the production of knit garments, or woven garments a sketch of a particular garment
including its design features is essential to produce on paper so that after manufacturing of that
garment could be verified or checked whether could be done manually or with the help of
computer.
Pattern Design:
Hard paper copy of each component of the garment of exact dimension of each component is
called pattern. The patterns also include seam allowance, trimming allowance, dirts, and
pleats, ease allowance, any special design etc affairs. Pattern design could also be done
manually or with the help of computer.
Sample Making:
The patterns are used to cut the fabric. Then the garment components in fabric form are used
to sew/assemble the garment. Sample garment manufacturing is to be done by a very efficient
and technically sound person.
Production Pattern:
The patterns of the approved sample garment are used for making production pattern. During
production pattern making, sometimes it may be necessary to modify patterns design if buyer
or appropriate authority suggests any minor modification.

31May 11, 2015
Grading:
Normally for large scale garments production of any style needs different sizes to produce
from a set of particular size of patterns, the patterns of different sizes are produced by using
grade rule which is called grading.
Marker making:
Marker is a thin paper which contains all the pattern pieces of a garment. It is made just before
cutting and its purpose is to minimize the wastages. The width of a marker is equal to the width
of the fabric and it should not be greater than the width of the fabric i.e. the width of the marker
is kept less than or equal to the width of the Fabric.
The pattern pieces should be placed very carefully in such a way that it will obviously minimize
wastages.
Objects of marker making:
- To reduce cost;
- To improve the quality of the garments;
- To reduce the cutting time;
- To facilitate large scale production.
Spreading :
Spreading means the smooth laying out of the fabric in superimposed layers of specific length.
The cutting marker paper is laid in the top of the fabric layer. The usable width of the fabric
constraints the maximum width of the marker paper. During spreading number of the plies
should be not more than three hundreds but it depends on the thickness of the fabric and the
height of the cutting knife.
For example: if the thickness of the fabric is higher than the number of plies mentioned above
would not valid and in case of straight knife cutting instrument the maximum lay height should
be 70% of the blade height.
Fabric Cutting:
On the fabric lay/spread the marker paper is placed carefully and accurately, and pinned with
the fabric to avoid unwanted movement or displacement of the marker paper. Normally
straight knife cutting machine is used to cut out the garment component as per exact
dimension of each patterns in stack form, care must be taken to avoid cutting defects.
Sorting/ Bundling:
After cutting the entire fabric lay, all the garments components in stack form is shorted out as
per size and color. To avoid mistake in sorting, it is better to use code number on each
pattern.
Sewing or Assembling:
It is the most important department/ section of a garment manufacturing industry. Sewing

32May 11, 2015
machines of different types are arranged as a vertical line to assemble the garments. Sequence
of types of sewing machine arrangement depends on sequence of assembling operations.
Number of sewing machine per line varies from 20 nos to 60 nos depending on the style of
the ga4rmnet to be produce. Production pr line pr hour also varies from 100 to 150 pieces
depending on specific circumstances. Number of sewing machines.
Inspection:
Each and every garment after sewing passes through the inspection table/ point, where the
garments are thoroughly and carefully checked to detect/find any defect if present in the
garment. The defects may be for example variation of measurement, sewing defect, fabric
defects, spots etc. if the defect is possible to overcome, then the garment is sent to the
respective person for correction. If the defect is not correction able, then the garment is
separated as wastage.
Pressing/ Finishing:
After passing through the inspection table, each garment is normally ironed/ pressed to
remove unwanted crease and to improve the smoothness, so that the garments looks nice to
the customer. Folding of the garment is also done here for poly packing of the garments as
per required dimension.
Final Inspection:
It is the last stage of inspection f the manufactured garments on behalf of the garment
manufacturing organization, to detect any defective garments before packing.
Packing:
After final inspection, the garments are poly-packed, dozen-wise, color wise, size ratio wise,
bundled and packed in the cartoon. The cartoon is marked with important information in
printed form which is seen from outside the cartoon easily.
Despatch:
The cartoons of the manufactured garments are delivered or placed in the dispatch
department or finished products go down, from where the garments lot is delivered for
shipment.

33May 11, 2015
5.3 Step Wise Flow Chart
PROCESS FLOWCHART OF KNITTING IN NORBAN
Sample fabric
↓
Design analysis
↓
Machine selection
↓
Setting the machine for the specific design
↓
Yarn in cone form
↓
Feeding the yarn cone in the creel
↓
Feeding the yarn in the feeder via trip-tape
↓
Positive feeding arrangement and tension devices
↓
Knitting
↓
Withdraw the rolled fabric and weighting
↓
Inspection
↓
Numbering
Stepwise garments manufacturing sequence onindustrial basis is given
below:
Design / Sketch
↓
Pattern Design
↓
Sample Making
↓
Production Pattern
↓
Grading
↓
Marker Making

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↓
Spreading
↓
Cutting
↓
Sorting/Bundling
↓
Sewing/Assembling
↓
Inspection
↓
Pressing/ Finishing
↓
Final Inspection
↓
Packing
↓
Send to buyer / Dispatch
Flow sequence of sample section is given below:
Receive developed sheet from buyer
Develop the sample
Send the sample to buyer for approval
Approval of sample/comments about the sample (if necessary)
Send pre-production sample to buyer
Start bulk production

35May 11, 2015
Flow Chart of Cutting section:
Receive the Fabric
Fabric Inspection
Relaxation
Fabric Spreading
Manual
Automatic
Marker Making
Manual CAD
Placing the Marker Paper on the Lay
Cutting
Manual cutting Automatic cutting
Numbering
Bundle Card
Bundling According to Card Number
Quality (Panel Check)

36May 11, 2015
Replacing
Solid printing/Embroidery
Quality Check
Matching
Size Wise Arrange/ cutting Number
Bundling
Rib/Piping/Cuff
Master Bundling
Sewing Input

37May 11, 2015
Flow Chart of Sewing Section:
Input from cutting
Initial Inspection part by part
Stitching with Process Wise Quality Check
Table Quality Check
Size Wise Garments Count
Sucker Machine
Sewing Output

38May 11, 2015
Flow chart of finishing section:
Garments wash
Loop cutting
Thread trimming
Alter checking
Stitch others
Button attach
Ironing (In side)
Inspection (inside & outside)
Batch label attach
Final ironing
Joker tag attach
Needle detector check
Size tag attach
Waist belt attach
Hanger attach
Poly packing
Cartooning
Shipment

39May 11, 2015
Flow Chart of Garments Merchandizing
Buyer Correspondence & Meeting
↓
Recap Preparation
↓
Lab Dip & Yarn Dip
↓
Sample Fabric Booking
↓
Accessories for Sample
↓
Initial Sample Preparation
↓
Fitting Sample Preparation
↓
Photo Sample with actual specification
↓
Pre Production Sample Preparation
↓
Bulk Accessories Booking after Buyer’s Approval
↓
Bulk Fabric Booking
↓
Size Set Sample/ Trial Cutting
↓
Production Start

40May 11, 2015
DESCRIPTION OF PRODUCTION PROCESS:
In every mill, there maintains a sequences in production processing. It is also followed in this
mill where we were in industrial attachment. The process sequences are in list below:
1) Firstly, knitting manager gets a production shit from the merchandiser as accordance as
consumer requirements then he informs or orders production officer about it.
2) Production officer informs technical in charge and knows about machine in which the
production will be running.
3) Technical in charge calls for leader of mechanical fitter troops, they two take decision about
machine for production considering machine condition, production capacity, maintenance
complexity, etc.
4) Production officer with experienced mechanical fitter adjusts required stitch length and grey
GSM for required final GSM.
5) Supervisor checks daily production regularity and make operator conscious about finishing
tin due time.
6) Operators operate machine in high attention as if there were no faults in the fabrics. If he
thinks or sure about any fabric fault, then he calls for the mechanical fitters in duty. Mechanical
fitter then fixes it if he can or he informs technical in charge. Then he comes in spot.
5.4 PRODUCTION PARAMETER
1. Machine Diameter;
2. Machine rpm (revolution per minute);
3. No. of feeds or feeders in use;
4. Machine Gauge;
5. Count of yarn;
6. Required time (M/C running time);
7. Machine running efficiency.
8. shade%
RELATIONSHIP BETWEEN KNITTING PARAMETERS:
1. Stitch length increase with the increase of GSM.
2. If stitch length increase then fabric width increase and WPI decrease.
3. If machine gauge increase then fabric width decrease.
4. If yarn count increase (courser) then fabric width increase.
5. If shrinkage increases then fabric width decrease but GSM and WPI increase.
6. For finer gauge, finer count yarn should use.
7. Grey GSM should be less than finish GSM.

41May 11, 2015
5.5 PRODUCTION CALCULATION:
A. Production/shift in kg at 100% efficiency
=
RPM×No of feeder×No of needle× SL(mm)
80 .3527 ×count Yarn
B. Production/shift in meter
=
𝐶𝑜𝑢𝑟𝑠𝑒/𝑚𝑖𝑛
𝑐𝑜𝑢𝑟𝑠𝑒/𝑐𝑚
=
RPM×No of feeder×60×12 ×efficiency
𝑐𝑜𝑢𝑟𝑠𝑒/𝑐𝑚×100
G.S.M. It is technical term that indicates the weight of the fabric per square meter.
Responsibilities of production officer:
•Monitor and control shift wise production, plant utilization, waste generation etc.
•Implement correct work methods and maintain all records related to production.
• Responsible for systematic planning and execution of production programs.
•Adequate control over process in order to achieve quality of product, better waste
management.
•Monitor shift wise production, utilization etc and take corrective action for any shortfall.
•Maintain all the procedure of his department and shall incorporate amendments as and when
required in procedure.
•Responsibilities for monitoring the performance of manpower under him and identification
of training needs.
5.6 METHODS OF INCREASING PRODUCTION:
By the following methods the production of knitted fabric can be increased –
1. By increasing m/c speed: Higher the m/c speed faster the movement of needle and
ultimately production will be increased. But it has to make sure that excess tension is not
imposed on yarn because of this high speed.
2. By increasing the number of feeder: If the number of feeder is increased in the
circumference of cylinder, then the number of courses will be increased in one revolution at a
time.
3. By using machine of higher gauge: The more the machine gauge, the more the
production is. So by using machine of higher gauge production can be increased.
4. By imposing automation in the m/c:
a) Quick starting & stopping for efficient driving system.
b) Automatic m/c lubrication system for smoother operation.

42May 11, 2015
5.7 Industrial Engineering Department :
 To follow up the production process
 Work process development
 SMV calculation & Line target
 Efficiency control
 Time study
 Capacity study
 Workers training
 M/c sequence lay out
 Thread consumption
 Operator Interview

43May 11, 2015
Chapter 6
6. Quality Assurance System:
This chapter deals with the QC Department of Cotton Club BD Ltd. Its Specifies the objective
and function of QC Department. Besides, it also mentions the test perform in QC Department
and faults found in textile products.
Quality Policy
It is the policy of Norban Comtex Ltd. to produce quality dyed knit fabrics that meet or exceed
customers expectations & needs. To implement this policy the top management of Norban
Comtex Ltd. Is committed to provide adequate resources in terms of good raw materials and
trained personnel & continually improve / upgrade its processes and systems.
Quality objectives
 Overall material/product loss (Level of rejection) for the company during the
production process (in a year) shall not exceed 1.5 %
 Defects during dyeing & knitting operations to reduced by 10% .
 Process capability shall be maximized by maximizing the m/c breakdown time. M/c
breakdown time should be reduced to 20 % from its current status/position
 To ensure better work environment for the personnel working in the organization.
Machines Required
 Wash Fastness Tester
 Light fastness tester
 Rubbing fastness tester
 Electronic balance
 G.S.M. cutter
 Fabric inspection table
 Light box
 Shrinkage (%) meter.
Inspection Area
 Shade match of fabric
 Fabric diameter
 Wash fastness
 Light fastness
 Rubbing fastness
 Faults: Dyeing faults

44May 11, 2015
6.1 Faults Found in QC Department
Dyeing faults:
 Uneven shade
 Running shade
 In fastness property
Finishing faults:
 GSM variation
 Spirality
 Shrinkage control: Length wise
1QUALITY CONTROL:
Quality control is concerned with the evaluation of test data and its application to controlof the textile
process. raw materials, intermediate products and final products. It is concerned not only with quality level
and cost of maintaining this quality level but also concerned with the presentation of tangible values to
measure quality and changes in quality. In order to controlquality one must about the consumer’s
expectations.
Object of quality control:
• Research/analysis
• Selection of raw materials.
• Process control and development
• Product testing
• Specification testing .
• Quality assurance .
List of equipment for quality control:
 PH
Meter
 Iron
 Lap Dyeing Machine
 Pilling Tester

45May 11, 2015
Quality control Flow chart:
Yarn receiving
↓
Sample knitting
↓
Batching
↓
Enzyme wash
↓
Bleaching
↓
Dyeing(check diameter, pretreatment, shrinkage & GSM)
↓
Stantoring
↓
Compacting
↓
Final inspection
↓
If sample ok go for bulk production
6.2 Quality Assurance System
Quality assurance system can be divided into following steps:
1. On line Quality assurance system and
2. off line Quality assurance system.
Again on line Quality assurance system can be divided into the following steps:
(a) Raw material control.
(b) Process control.

46May 11, 2015
6.3 Online Quality control:
Raw material control: Norban Comtex Ltd. always very concern about the quality of the
product. So, they knit grey fabric from the best quality yarn & utilizes technical evaluation in
every stage of the production, as we know the quality product depends on the raw material
quality.
Process control: The method chosen for process must be provided with the necessary accurate
parameters. In the every stage pH should be maintained sincerely.
Fabric testing:
All the off-line tests for finished fabrics can be grouped as follows:
1. Physical test
2. Chemical test
1.Physical test:
• Fabric inspection by 4-point system.
• GSM test
• Width of the fabric measure.
• Rubbing test
• Pilling test
• Shrinkage test
2. Chemical test
• Color fastness to water
• Color fastness to wash
• Color fastness to rubbing
• Color fastness to perspiration
• Oxidative test

47May 11, 2015
6.4 Off line quality control:
After dyeing the material is received by the finishing section. Before receiving the following
things are checked:
1. Shade condition.
2. Wash fastness.
3. Condition of softening.
4. Condition of enzyme wash.
Before delivery the finished fabric to the customer it should be passing against the
requirements.
The following tests are done-
1. GSM check.
2. Shrinkage test.
3. Shade check.
4. Rubbing test.
5. Wash fastness test.
6. Colour fastness to perspiration.

48May 11, 2015
Chapter 7
7.Maintenance:
Maintenance is very important department to maintain the production. All activities that
maintenance facilities & equipment in good working order that a system perform as intended.
Without good Maintenance department, we never achieve the better quality production.
7.1 Objective of Maintenance:
 Maximizing production or increasing facilities availability at the lowest cost and at the
highest quality and safety standards.
 Reducing breakdowns and emergency shutdowns.
 Optimizing resources utilization.
 Reducing downtime.
 Improving spares stock control.
 Improving equipment efficiency and reducing scrap rate.
 Minimizing energy usage.
 Optimizing the useful life of equipment.
 Providing reliable cost and budgetary control.
 Identifying and implementing cost reductions.
In The Norban comtex Ltd 2 types of maintenance are done:
 1. Break down maintenance
 2. Routine maintenance
1. Break down maintenance: Break down maintenance is done instantly when problem arises in
machine. In this case,repairs are made after the equipment is out of order and it cannot perform its
normal functions.
2. Routine maintenance: Aftera particular period of operation, the machines are cleaned &
reordered, that is routine or schedule maintenance. The maintenance department does it once in a
month. Schedule maintenance varies, time in time & also depends on situation according to types of
machines, because maintenance is directly related to production. Most of the time, all the screws,
nuts, bolts & levers are checked,lubrication is also done. Workers inform about the problem areas of
the machines. Depending on their information maintenance is done. Maintenance engineer analyze the
records and take steps according to requirement.

49May 11, 2015
7.2 Types:
1. Routine maintenance: Through curing all points of machine minor adjustment not
setting wherever applicable, maintenance of chemical equipment.
2. Preventive maintenance: Machinery inspection & diagnostic checks at
predetermined intervals of then part which have varying as quality & production.
3. Predictive maintenance: Test made when the machine is in operation bearing
failure test with the aid of stethoscope or by feel or by noise eccentricity measure
by dial gauge.
4. Restorative maintenance: Overhauling & modernization.
5. Emergency maintenance: Attending to the unforeseen breakdown of the machine
6. Remedial maintenance: it mainly covers study of failure & changing the design
materials or working condition to avoid repetition of the above failure. Increasing
the capability of the machine by changing or improving the design so that they
become fits to withstand to increase the loads & speeds & improving the retention
of the lubricants & reduce the wear & fear of parts.
In the textile sector the mostlyused maintenance type is Preventive maintenance:
7.3 Procedure:
Preventive maintenance (cutting):
1. Cutting Machine:
Mechanic shall do daily and weekly maintenance of cutting machine as per Maintenance
Checklist.
2. Cutting Spreader Lay Machine:
Daily, weekly and monthly maintenance shall be done by Mechanic for this machine.
3.CAD Machine: Daily, weekly and monthly maintenance shall be done by Mechanic for this
machine.
4. Button Pulling Machine: Operator shall do daily check and record maintain in Snap
Strength Calibration Record.
5. Needle Detector Machine: Operator shall check daily this machine. Supplier Technician
shall calibrate this machine once in every 3 (three) months and record maintain in Calibration
Report.

50May 11, 2015
7.4 Preventive maintenance (sewing):
1. Daily Maintenance:
 Cleaning the machine head and motor with compressor air, brush and soft fabric.
 Check the lower knife for sharpness of dull then re-shape.
 Record Maintain in Preventive Maintenance Plan.
2. Weekly Maintenance:
 Checking the oil and oil level.
 Needle bar bush clean.
 Thread control eyelets checking and clean.
 Check electric loose connection.
3. Monthly Maintenance:
 Check the condition of V-belt.
 Oil level, oil condition checking or fill-up, if needed.
 Check the lubrication control system.
4. Quarterly Maintenance:
 Check and adjust needle bar height.
 Check needle to shuttle relation
 Check timing, looper, thread com guide tension.
 Check electric loose connection
 Needle system and bobbin loose, check according to its operator.
5. Half Yearly Maintenance:
6. Yearly Maintenance:
 Changing oil filter, oil.
Preventive maintenance (finishing):
Iron Table: Monthly cleaning and steam check if iron table shall be done by the mechanic.
Utility:
1. Gas Generator:
 Operator shall monitor all parameter and record maintain daily in Gas Generator
Operating Log Sheet. Manager Maintenance shall review the report daily.
 Generator Operator shall routinely check the generator as per Gas Generator checklist.

51May 11, 2015
 Supplier shall be called for schedule maintenance as per service contract. Record of this
type of maintenance shall also preserve in the file. Schedule for this maintenance shall
be followed up by the Manager Maintenance.
2. Gas Boiler:
 Boiler operator shall operate boiler as per instruction given in the Gas Fired Boiler
Operating Log Sheet and maintain reading or record in the same format.
 Daily maintenance of boiler shall be done by the operator and record detail of the
maintenance in the Gas Boiler Maintenance Log Register.
7.5 Advantage of maintenance:
 To keep the factory plants, equipment, machine tool etc in optimum working condition
 To ensure accuracy of product and time schedule to delivery customers
 To minimize down time of machine
 To prolong the useful life of factory plant and machine
 To modify or improve productivity of existing machine to meet the need for production
and thus avoid sinking of additional capital.

52May 11, 2015
7.6 Maintenance Tools & Their Equipment:
The most important maintenance tools that are used frequently are tabulated:
Maintenance Tools Function
Grease Lubrication
Tread tape Joining of broken metallic parts
Cutting disc For cutting pipes, rods.
Globe valve Fitting for stem line.
Maintenance Tools Function
Union Fittings for water, steam line.
Union elbow Fittings for water, steam line.
Cutting oil Lubrication
Gear oil Lubrication
Hydraulic oil Lubrication
Oil gun Oil application
Spanner Tightening of nut bolts
Master range Tightening of nut bolts
Flat screwdriver Screw tightening & loosening
Star screwdriver Screw tightening & loosening
Hacksaw blade Cutting
Hacksaw frame Cutting
Spray gun WP40 Spaying a chemical named WP40 that
lubricates bearings.
Drill machine Drilling to make holes
Grinding machine Grinding

53May 11, 2015
Maintenance Procedure: (Mechanical)
Machine: Dyeing Machines
No Item needed to be checked & Serviced
01 Comp: air system Checking
02 Steam and cond. System checking
03 All motor/pump sound and
temperature checking
04 Water system checking
05 Oil level(Pump/gear box) checking
06 All belt tight/Adjusting
07 Gear oil checking/Renlling
08 All bearing cleaning
09 Checking all controlpanels
10 Lubrication of all motors bearing
Machine: Gas Boiler
No Item needed to be checked &
Serviced
01 Lub oil leveling checking
02 Cooling water system checking
03 Better water level checking
04 All belt tight/Adjusting
05 Panel board cleaning
06 All bearing greasing
07 All cable terminal tighten
08 Cleaning and maintenance of PHE
and CT

54May 11, 2015
Chapter 8
8. Compliance & Utility Service :
8.1 Compliance:
Compliance means comply something i.e. yield to the wishes another. The main aim of
compliance is to ensuring the all labour rights and facilities according to buyer code of conduct.
Different compliance issues which they are obeyed:
Admin & HR department:
 Personnel policies:
o Recruitment policy
o Leave and holiday policy
 Attendance and leave register card:
o Their weekly working hour not more than 66 hours including overtime in a week.
o They have the approved manpower list.
Health & hygiene:
 First aid ensures.
 Medicine registers.
 Maternity and pregnancy register.
 Pure drinking water
 Towel for hand dry.
Safety:
 Safety committee
 Fire fighting committee
 Rescue committee
 Broken needle register
 Needle detector
 Fire alarm & switch
 Evacuation plan
 Rubber mats to every iron man.

55May 11, 2015
Welfare:
 Welfare committee
 Day care centre
 Canteen facility
Salary and wages:
 Fix wages in considering minimum wages which is declared by the government.
 Salary and wages given before 7th day of month.
Physical security:
 They have separate cargo entrance area (receiving and unloading) from the front
side.
 They do not keep any partially filled/ completed cartons on the floor at the end
of any working day. They keep it to finished goods store.
Education and training program:
They arrange security training program on regular basis for all employee of the factory.
Compliance item:
Some example of compliances item are given below:
 First aid box
 Water pot
 Toilet
 Wash basin
 Complain box
 Evacuation plan
 Exhaust fan
 Emergency exit/light/ light set
 Smoke detector
 Fire extinguisher
 Hose cabinet
 Manila rope
 Gas musk

56May 11, 2015
8.2 UTILITY SECTION
Utility Services Available:
 Electricity
 Gas
 Water
 Steam
 Compressed air
Capacity & Other Technical Details:
 Electricity :
Generally the factory doesn’t depend on electricity. They hardly use the government electricity. The
electricity is supplied form REB. The electricity supplied in the factory about 4200 KWH . But three
standby power generators are also kept to meet the need of electricity if necessary.
 Gas :
Gas is mainly used for producing electricity, steam production and also used in generator and boiler.
The gas is supplied by TITAS GAS DISTRIBUTION CO. Gas consumption is 3, 20,000 – 3, 30,000
m3 monthly.
Generator Specification
Brand name :
PARAMETER
S GENERATO
R 1
GENERAT
OR 2
Brand name GE Jenbecher Cummins
Power
Generation
Origin Austria Singapor
Specfication J 320 C250D5
Fuel Gas Driven Gas Driven
Power
1064 KW 440 KW
R.P.M 1500 1500
VOLTS. 400 400

57May 11, 2015
Chapter 9
9.Store & Inventory Control
This chapter deals with the store of Norban Comtex Ltd. and inventory system of different inventories.
Equippedwithmoderninventoryandstoragesystems,theWareHousehasvaststoragecapacityande
nsuresstocksofyarns,accessories,inputs,packingmaterialsandothermaterialsroundtheyear.Speci
alarrangementsareinplacetokeepsufficientstockofdifferentcountsofyarnsatalltimestooffsetocca
sionalshortageofyarnsintheintertionalmarket.
9.1 CLASSIFICATION OF STORE SECTION:
9.2 DESCRIPTION OF STORAGE:
In every mill, there maintains a sequences for keeping raw materials. It is also followed in this
mill where we were in industrial attachment. The process sequences are in list below:
1) Firstly, store manager gets a yarn &fabric booking shit from the merchandiser as
accordance as requirements then he informs or orders other officer about it.
2) Then purchase from source with purchase order.
3) After when the raw material comes then they also get the received Chelan
4) Take weight
5) For yarn quality check ,send to the testing section
6) Use Bin card to keep record
Store
section
Fabric
section
Yarn secton
Accessories
section

58May 11, 2015
9.3 Inventory System for Raw Material:
In Cotton Club BD Ltd. there are different inventory systems for different raw materials. The
flow is given below —
Raw material receive
↓
Material Receive Report
↓
Store in main go-down by bin card.
↓
Running go-down.
↓
Production floor.
9.4 Grey fabrics store:
All the grey fabrics are stored in the fabric store, near the batch section. Different types of
fabrics are listed in the sheet according to the fabric types, quantity & consumer’s requirements.
Fabrics GSM, shrinkage, diameter & other properties are also taken into consideration. The
bathes are prepared by taking the required fabrics from the grey store. At present the grey
fabrics store of CCL containing the following types of fabrics-
 Single jersey.
 1x1 Rib.
 2x2 Rib.
 2x1 Rib.
 Melange.
 Pique.
 Single jersey (with Lycra attachment)
 1x1 Rib (with Lycra attachment) etc.

59May 11, 2015
9.5 Dyes & Chemicals store:
There is a different store for dyes & Chemicals. Various types of dyes & chemicals are stored
here according to the dyes & chemical company. Different types of dyes of dyes & chemicals
are
listed in a sheet. In the sheet the stored quantity of dyes & chemicals are also included. Every
day the is updated & a copy of this is supplied to the dyeing manager, Dye house & lab section.
Spares:
In Cotton Club BD Ltd. required amount of spares of different machines are stored in the
mechanical storeroom. All the spares are listed in a sheet, which is controlled by the mechanical
& maintenance personnel. Spares are arranged in the storeroom according to their size, quantity
& requirements. There are shelves in the store room to keep the small spare parts.
Finished goods:
Cotton ClubBD Ltd. supplies its finished dyed fabrics to its garments section. So, dyed finished
fabrics are stored for short time in the finishing section. All the delivered fabrics are noted on
the tally khata according to the Lot no., quantity, fabrics diameter, buyer’s name, colors, &
considering other parameters.
Others:
There is a central store at CCL. In that store the various types of forms, papers, stationary &
other necessary goods are kept.
9.6 Accessories Store:
According to Buyer and style number, store keeper arranged their rack for inventory. When an
order is confirm they communicate with merchandiser / suppler and confirm inventory. Store
keepers receive all accessories by counting.
If everything is ok then they give satisfactory comments and if found any kind of problem they
mention in challan sheet. After receive all accessories they give entry in computer & keep
arrange in rack for easily searching. Trim card make for different style & buyer wise for smooth
work.

60May 11, 2015
9.7 Trim card contain with:
-Main, size & care label.
- Back neck tape.
-Button.
-PSP paper.
- Tag pin.
-Master carton.
-Poly stiker.
-Carton stiker.
-Poly bag.
-Logo gum tape.
-Heat transfer.
-Interlining.
-woven twill fabric.
-Country flag sticker.
-hang tag.
- Mobilon tape.
- Security label
Engineering store:
Objectives: Keep store all kind of engineering, maintenance (needle, spare parts, feed dog
etc.), Dyes chemicals & stationary materials in engineering store for smooth production.
How to work: Engineering store place a requisition to procurement department by estimate of
all materials. After that procurement department send all of materials to engineering store.
Before receive all materials they ensure about quality & quantity, then they give entry in
computer and arrange in rack. When any requisition is come from any department, they give
issue to respective department.

61May 11, 2015
Chapter 10
10.Cost Analysis :
Costing is a very important part for selling or exporting any item. In case of a garment, before
costing, consumption is needed. When we find the required amount of raw material and their
prices we can calculate the cost of a product very easily.
10.1 Consumption Formula of Knitted fabric:
FABRIC OR BODY CONSUMPTION:
 (Body length+ Sleeve length+ Allowance x Chest + Allowance x 2 x GSM /
10000000) x 12 x 10% (+)
= Result kg./dozen.
So,
 BL+SL+ Allowance= 10 cm. Allowance.
 When keep the chest allowance then body width, chest width and bottom
width which is big ( cm) with ( 4 cm+) Added.
 10% overall Process Loss.
 1 dozen= 12 pcs.
BODY CONSUMPTION BY MARKER:
 Length x width x GSM x12 / 1000 / 1550 / Ratio x 12%
DIA MEASUREMENT:
 Chest or Bottom + Allowance / 2.54
=Dia / Result
So,
 1 inch = 2.54 cm
 When I dia measurement then chest or bottom with (4-6 cm) allowance added.
SELF FABRIC OR RIB FABRIC NECK CONSUMPTION:
 Total Neck Length = Front neck drop + Back neck drop x 2
= Total neck length / Result.

62May 11, 2015
 (Total Length + Allowance x Neck Width + Allowance x 2 x GSM /10000000) x
12 x 10%(+)
= Result kg. / Dozen.
So,
 TL + Allowance = 2 cm
 NW + Allowance = 2 cm
 2 mean, Double part.
 10% overall process loss.
SELF OR RIB FABRIC NECK DIA MEASUREMENT:
 Neck opening or Width + Neck drop x 2 /2.54
= Result.
PANT & TROUSER OR PAJAMA CONSUMPTION:
 (Length + Allowance x dia x 2 x GSM / 10000000) x 12 x 10%(+)
= Result kg. / Dozen.
So,
 L + Allowance # with self fabric waist minimum ( 12 cm) Allowance added.
 Without self fabric waist minimum (8 cm) Allowance added.
 Allowance minimum 15 cm added with Hip or Dia.
 DIA = Hip + Allowance / 2.54
So,
 1 inch = 2.54 cm.
POCKET CONSUMPTION:
 Length + Width + Allowance.
So,
 Allowance minimum 5 cm added with ( L+ W).

63May 11, 2015
10.2 CARTON DIMENTION:
Type of Carton
1. DEPEND ON PAPER:
o Khaki Carton Or Brown Carton
o Duplex Carton
o Box Carton
2. DEPEND ON STITCHING: Gum Pasting Carton.
3. DEPEND ON PLY:
3 Ply Carton
5 Ply Carton
7 Ply Carton
4. DEPEND ON LINER:
Both Side Liner Carton
Out Side Liner Carton
5. DEPEND ON SIZE:
Master Carton
Inner Carton m
Carton Measurement:
FORMULA (1) =
(L+W) (W+H)X2 in cm
100X100
(Without Wastage)
FURMULA (2) =
(L+W+6) X (W+H+4) X 2
100X100
(Include Wastage)
PRICE =
(L+W) (W+H) X 2
100x100
x Rate per Square Meter
= Rate/P

64May 11, 2015
10.3 BUTTON LINER (FIND OUT FORMULA):
 1 GG = 144 Dozen.
 1 GG = 1728 pcs.
 Liner = Button Dia / 0.61
= Result / liner.
So,
 Always Button liner is plural number.
 As like 16,18,20,22,24
YARN BOOKING
 Fabric yarn ( kg ) + Process Loss.
= Result / kg.
So,
 Process loss keep the 10% added with total fabric.
10.4 SEWING THREAD CONSUMPTION:
 Cone Quantity = per garments thread x garments qty. x qty. in cone.
 Plain Machine : 1” for 2.75”
 Over lock (3 Thread) : 1” for 14.5 “
 Over lock (4 Thread) : 1” for 16.5”
 Over lock (5 Thread) : 1” for 18.5”
 Flat lock (3 Thread) : 1” for 13.5”
 Flat lock (4 Thread) : 1” for 16”
 Picot : 1” for 21”
 Zigzag : 1” for 22”
 Kansai Machine : 1 “ for 11”
So,
 1 Cone = 4000 meter.
 Should be 40% wastage with the following consumption.
 It may more or less for sewing stitch.

65May 11, 2015
CALCULATION CUBIC METER (CBM):
 CBM = Carton length x Carton width x Carton height x Carton Qty. / 1000000
= CBM / Result.
So,
 100 cm x 100 cm x 100 cm = 1000000
 20 Feet = 28-31 CBM
 40 Feet = 56-62 CBM
10.5 MARKER CONSUMPTION ( FORMULA ):
 Open Dia = Marker length x 2.54 x Marker width x 2.54 x GSM / 10000000 / Marker Pcs
x 12 x 10% (+).
= Result kg. / dozen
 Tube Dia = Marker length x 2.54 x Marker width x 2.54 x GSM /1000000 / Marker Pcs x 12 x
10% (+).
= Result kg. / dozen
Costing:
Merchandise makes a cost sheet to see if the product is feasible or not in terms of cost and revenue.
Merchandiser has to calculate the cost of products including all wastes and accessories to tell the final cost
of the product to his customers.
10.6 Price of Different Knitted Fabric:
Jersey $ 0.15
Jersey with Elasthan $ 0.35
Y/D Jersey $ 0.25 (Feeder Stripe)1.76 (Auto Stripe)
Y/D Jersey with Elasthan $ 0.45 (Feeder Stripe)2.00 (Auto Stripe)
1X1 Rib $ 0.18
1X1 Rib with Elasthan $ 0.38
Y/D 1X1 Rib $ 0.25 (F.S)
Y/D 1X1 Rib with Elasthan $ 0.40 (F.S)
2X1 Rib $ 0.25
2X1 Rib with Elasthan $ 0.45
Y/D 2X1 Rib $$ 0.30 (Feeder Stripe)
Y/D 2X1 Rib with Elasthan $ 0.48
Pique $ 0.25
Pique with Elasthan $ 0.45
Y/D Pique $ 0.35 (Feeder Stripe)1.76 (Auto Stripe)
Y/D Pique with Elastane $ 0.50 (Feeder Stripe)2.00 (Auto Stripe)
Iterlock $ 0.35
Iterlock with Elasthan $ 0.50
Y/D Interlock $ 0.40(feeder)
Y/D Interlock with Elasthan $ 0.55 (feeder)
Terry $ 0.40
Terry/Lycra $0.50
Fleece $ 0.44

66May 11, 2015
Chapter 11
11.Marketing Activities:
This chapter deals with the marketing activities, marketing plans, and responsibilities of marketing personnel
of Cotton Club BD Ltd.
Manpower:
Marketing plays a vital role in the field of displaying/ showing the good criteria of the products to the buyer
& to communication with the buyer. There are about 7 peoples in the marketing section of the industry.
11.1Buyer and Exporting Country:
- C & A, Germany
- MGB, Germany
-PEEK & CLOPPENBERG, Germany
-BRAX, Germany
-VIA APPIA, Germany
-KATAG, Germany
-MS MODE, The Netherlands
-DEBENHAMS, UK
-Gueldenpfennig, Germany
-FILA, Italy
-Coolcat, The Netherlands
11.2 Importing countries:
Following countries mainly imports products from CCL through many internationally well recognized
buyers.
 Netherlands
 Germany
 Spain
 Turkey
 Italy

67May 11, 2015
11.3 Marketing strategy:
Marketing strategy is a very important factors to sale the products to the buyers. If the Marketing strategy is
not so developed, it will be very hard to reach the goal. In case of garments marketing the dealings with the
buyer is a very important factor.
In CCL mainly General Manager, Marketing Executives, Merchandisers & higher officials deal with the
buyer. There is some fixed buyer of the industry. The buyer gives their orders continuously all over the year.
The marketing officers & the merchandisers communicate with the buying houses to collect the orders. By
both side understanding the rate & the order quantity are fixed.
11.4 Productlabel:
There are following labels used by this mill:
1) Care Label: It contains washing in hot or cold water, chemical cleaning, drying conditions etc.
2) Size Label: It contains size of garments.
3) Composition Label: It contains the fabric composition of different fibre type.
4) Decorative Label: Decoration is as buyer or consumer choice wise.
5) Flag label: it indicates importing country.
6) Barcode label: it indicates hidden identity of product.
7) Price label: it indicates price of product.
Packagesize & label:
Most common sizes are
S - Small
M - Medium
L - Large
XL - Extra large
XXL - Very very large.
Duties & Responsibilities ofMarketing Officer:
Dealing with the buyer & convince the buyer is the main duty of the marketing officer. A marketing officer
also has some other duties. The main duties responsibilities of a marketing officer are given below:-
 To prepare cost sheet by dealing with the buyer.
 To take different steps by discussing with the high officials & merchandisers.
 To maintain a regular & good relationship between commercial officer & merchandisers.
 To maintain a regular communication with the buyer & buying houses.
 Communicate with the new buyers.
 Display the better criteria of the products.

68May 11, 2015
Chapter 12
Conclusion:
Industrial attachment provides the learning scope to enhance the curiosity of my knowledge to
entered into the practical life.Norban comtex ltd is a well know 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.
The factory runs by a number of efficient textile engineers, skilled technical & Non-technical
persons. They are very sincere, co-operative and helpful.
All the information in this report about Norban comtex ltd are very much objective and
practical so that one can get the desire information about the factory.

Industrial project

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