The document discusses the production flow from raw materials to garments. It begins with an overview of textile raw materials including natural and man-made fibers used. It then outlines the processes of yarn manufacturing including spinning and fabric manufacturing through weaving, knitting, and non-woven methods. The document details the various departments involved in garments manufacturing from merchandising to quality control. It provides process flow charts for sampling approval, material in-house flow, general production, bulk production, and order progress tracking. Finally, it discusses approaches like JIT, MRP, Six Sigma and Lean that can be used to improve production results.

1. Production Flow
steering on
COTTON TO
GARMENTS
PRODUCTION
MOHAMMAD SHAHADAT HOSAIN

2. Mohammad Shahadat Hosain
MOHAMMAD SHAHADAT HOSAIN

3. TEXTILES
PRODUCTION
FLOW
TEXTILE RAW MATERIAL
(NATURAL /MAN-MADE)
YARN MANUFACTURING
(SPINNING)
FABRIC MANUFACTURING
(WEAVING/KNITTING)
TEXTILE PROCESSING
GARMENTS MANUFACTURING
MOHAMMAD SHAHADAT HOSAIN

4. TEXTILES RAW MATERIALS
RAW MATERIALS TYPES
NATURAL FIBERS MAN-MADE FIBERS
ANIMAL VEGITABLE
SILK/WOOL/H
AIR COTTON/FLAX/J
UTE
MINERAL BASE
(ASBESTTOS)
SYNTHETICS REGENERATED
POLYESTER
/NYLON/ACRYLI
C/POLYRETHAN
E
VISCOSE/RAYO
N/CUPRO/ACE
TATES/RUBBER
MINERAL BASE
(GLASS/METAL)
Nature presents a lager
variety of fibres. Beside this it is
possible today to produce a
number of different kind of man-
made fibres but a relatively small
amount of this is actually used in
textile industry. Fibres is a matter
which includes flexibility, fineness
and a high ratio of length to
diameter ratio is 1000 to consider
a fibres. Some additional
characteristics are the required for
textile fibres, such as stability at
high temperature, a certain
minimum strength & extensibility.
MOHAMMAD SHAHADAT HOSAIN

5. YARN MANUFACTURING PROCESS BLOWROOM
CARDING
DRAWING
ROVING
RING FRAME
COMBING
MOHAMMAD SHAHADAT HOSAIN

6. YARN TO FABRIC PROCESSING
Types of Fabric Manufacturing
Weaving Knitting Non-Woven
Weaving
Preparation
Weaving
mechanism
Warp
knitting
Weft
Knitting
Winding
Warping
Sizing
Tappet
Dobby
Jacquard
Types of fabric manufacturing :
In generally three types of fabric are produced
namely-
Woven fabric: are composed of longitudinal
or warp threads and transverse or weft
threads interlaced with one another according
to the class of structure and form of design
that are desired.
•Knitted Fabric: which is produced by one set
of yarn by interloping are called knitted fabric.
•Non-Woven fabric: are produced by
connecting yarns with gummy substances or
bonded material. Non-woven are flexible
porous products consisting of one or more
fibre layers. They are bonded by chemical or
mechanical process into textile products.
MOHAMMAD SHAHADAT HOSAIN

7. FLOW OF WEAVING
Pirn WindingTying-in
MOHAMMAD SHAHADAT HOSAIN

8. DEPARTMENT OF GARMENTS MANUFACTURING
Merchanding Dept
Sampling Dept
Fabric store Dept
Trims and accessories store dept
Spreading & cutting Dept
Sewing Dept
Washing dept
Quality Assure Dept
Finishing & Packing Dept
Logistic & Commercial Dept
Finance and Account Dept
HR & Admin Dept
MOHAMMAD SHAHADAT HOSAIN

9. PROCESS FLOW IN GARMENTS MANUFACTURING UNIT
Buyer &
Supplier
Meeting
Production
Order placed
Sampling
BOM
Generation
Raw material
Parcurement
Raw Materils
Inspection
Fabric washing
PP Sample
Bulk
Production
Inline
Inspection
Production
Sample
Finishing Packing
Final
Inspection
Shipment
MOHAMMAD SHAHADAT HOSAIN

10. APPROVAL FLOW CHART
Customer Technical Dept
Receive Tack Pack
Sample
Section
Pass
Not
Pass
Not
Approve
d
Quality CheckProto / PP sample
Remake
Sample Submission for approval
If
Missing
If Not
Check Teck
Pack
Start Customer Order
Sample
Evaluation
Approved
Flow chart for Sample
Approval
There are lost of
circumstance to
placement an order to
any supplier. However
After select a supplier
they have to get
sample approval from
customer technical
department. The flow
chart are providing
information how the
supplier get the
approval from the
customer.
MOHAMMAD SHAHADAT HOSAIN

11. MATERIAL INHOUSE FLOW CHART
Purchase Order to
Supplier
Inhouse Materials
Materials
Inspection
BOM Check
Prepare BOM
Misst
ake
Correction
Appro
ved
Inventory check
Not
Ok
Material Processing
OK
Not
Ok
Ok
Payment Release
Materials Inhouse Flow
chart
After getting approval
the supplier need to
inhouse all materials for
bulk production. The
flow chart are showing
how a factory are
inhouse materials. The
critical point in the chart
to check the quality
before inhouse raw
goods.
MOHAMMAD SHAHADAT HOSAIN

12. GENERAL PRODUCTION FLOW CHART
Pass
Not
Pass
Inline Inspection
Production Start
Trial Production
TP check
Correct
ive
acction
Bulk Production
Pass
Not Pass
Pre Final
Inspection
Corrective action
Finishing Production
Pass
Not Pass
Final Inspection
Production Flowchart
Production flowchart are showing how the production are moving
forward with in quality. trial production is most important to check
the production process / design / style are efficient for required
production items. If anything need to be correct the factory could do
corrective action and improve it. The bulk production flowchart are
below but inline inspection are conduct once the goods are running
and start to making carton, at least 5 to 15 percent of good should
be in carton.
MOHAMMAD SHAHADAT HOSAIN

13. BULK PRODUCTION FLOW CHART
Fabric Received in
cutting
Fabric Spreading Fabric Marking
Bulk Production
Fabric
Inspection
Pass
Not Pass
Fabric CuttingFabric BundingPrint/ Embrodery
Sewing Process
Fabric Bundle check
& correction
Print/ Embroidery
Quality check
Pass
Not
Pass
Sewing Input
Line Quality
check
Pass
Not
Pass
Sewing Output
Output
Inspection
Pass
Not
Pass
Corrective
Action
Finishing InputThread Sucking
Needle Checking Ironing
Measurement
Check
Pass
Not
Pass
Attach Hangtag,
Folding & Making
Poly
Making CartonFinal InspectionReady for shipment
Pass
Not
Pass
Corrective
Action
Corrective
Action
Corrective
Action
Corrective
Action
Corrective
Action
Bulk Production Flow chart
The Bulk Production flowchart are
showing how the production are moving
forward with in quality. Each major
section like cutting, print, embroidery,
sewing, finishing must need to be quality
check. On the other side each line need
to quality control to make sure the
quality are as per standard. Some of the
section the production could check and
make corrective action during the check
needle checking or thread sucking but
some of section they need to resend to
starting process for correction. If inline
inspection were fail during production
need to do immediate corrective action
and once 70 to 80 percent goods are
ready than pre-final inspection should be
conduct and once 100% goods are ready
than final inspection would be conduct. If
final inspection are fail in some reason
than the customer will decided and give
instruction for next ether accept/reject or
to correct.
MOHAMMAD SHAHADAT HOSAIN

14. SAMPLE FOR FINAL INSPECTION REQUIREMENTS:
MOHAMMAD SHAHADAT HOSAIN

15. DESCRIBE & PROPOSITION OF METHOD ( JIT/ MRP/ 6SIGMA / LEAN)
PRODUCTION TO IMPROVEMENT OF RESULT.
JIT (JUST IN TIME): JIT concept is very much are
effect in this production process. If some materials
are not arrive in time then production will hamper,
some time its also effect on quality. For instance
shading, ratio of mistake will be increase as well as
process will be loss. Hence production need to
conduct strong follow up everything are control
and in time. There are couple of tools are used to
make efficient follow-up Like TAC(time action
calendar).
MATERIAL REQUIREMENTS PLANNING (MRP): in
terms of required quality & quantity assurance
MRP are useful as well as required shipment date.
Gantt chart is one of best tools for MRP system.
SIX SIGMA: are using to make sure in proper
quality and accuracy. Its reduces variation, and
improves quality though its full tools are not
directly use.
MOHAMMAD SHAHADAT HOSAIN

16. LEAN: system use for removes waste and increase
SMV / speed of production. This system are removes
non-value added process steps, and fixes connection
between process steps. Lean manufacturing or lean
production often simply ‘’Lean’’, is a systematic
method for the elimination of waste within a
manufacturing system. It also take into account waste
created through overburden and waste created
though unevenness in workloads. The core idea is to
maximize customer value while minimizing waste.
DESCRIBE & PROPOSITION OF METHOD ( JIT/ MRP/ 6SIGMA /
LEAN) PRODUCTION TO IMPROVEMENT OF RESULT.
The Best follow-up for production is OPS-order progress sheet,
TAC-Time action calendar, as well as Gantt chart are more
effective to execute a production. Since JIT, MRP, Six sigma,
Lean are focused in different areas there for so many
companies are using those methodology in specific areas in
certain output.
MOHAMMAD SHAHADAT HOSAIN

17. SAMPLE OF OPS (ORDER PROGRESS SHEET)
In OPS generally it’s a follow-chart;
mentioning/make note each steps of
production.
MOHAMMAD SHAHADAT HOSAIN

18. SAMPLE OF TAC (TIME ACTION CALENDAR)
TAC : are shows all the date of major
operation/ steps. So that all counter
part are prepare they plan
accordingly.
MOHAMMAD SHAHADAT HOSAIN

19. Thanks to all
MOHAMMAD SHAHADAT HOSAIN