Table of content

SL No: Topics Page

Number
1. Factory profile
Executive Summary
1.1 Introduction
1.2 List of Buyer
1.3 Product Details
2. Knitting Department:
2.1 Types of machine names
2.2 Process of flow chart
2.3 Different type of knit fabric
2.4 Product of knit items
3. Store department
3.1 Introduction
3.2 Process Flow Chart
3.3 Organogram
3.4 Types of details
3.5 Accessories&Trims item’s
4 Dyeing Department:
4.1 Dyeing process
4.2 Types of Dyeing
4.3 Process of Flow Chart
5 CAD & Sample Department
5.1 Introduction
5.2 Process Flow Chart
5.3 Organogram
5.4 Pattern
5.5 Marker
5.6 Purpose Of using CAD in Garments
6 Cutting Department:
6.1 Introduction
6.2 Process of Flow Chart
6.3 Organogram
6.4 Fabric Spreading
6.5 Fabric Relaxation
6.6 Fabric Cutting Process
6.6 Methods of Fabric Cutting
6.7 Preparation of cut work of Sewing room
6.8 Before cutting procedure
6.9 After cutting procedure
6.10 List of tools and equipments
6.11 Protective cutting tools policy
7 Printing Department:
 7.1 Process of printing
Sewing Department:
8.1 Introduction
8.2 Elements of Sewing Section
8.3 Organogram
8.4 Types of Sewing Machine
8.5 List of Sewing Machine
9 Finishing Department
9.1 Introduction
9.2 Process Flow Chart

9.3 Organogram
10 Packaging Department:
10.4 Packaging process
10.5 Packaging Material
10.4 Cartooning
10.5 Final inspection
11 Merchandising Department
11.1 Introduction
11.2 Business Development procedure
11.3 Buyer Approval then production Procedure
11.4 Trim booking
11.5 Fabric booking
11.6 PI sheet & its items
14.7 Master L/C confirmation procedure
11.8 Buyer approval procedure of fabrics, color and
accessories
11.9 Garments costing
11.10 Price Quotation for fabrics &
Accessories
11.11 Price negotiation procedure
12 HR, Administrative & Compliance
12.1 Introduction
12.2 Job Responsibilities
12.3 Activities
12.4 Compliance Issue
13 Conclusion
 FACTORY PROFILE

Total land area: 4,00,000 S f t.

Year of establishment: 8th December 2005
year of production: 2007
production capacity :2.5 million pcs /month

Capacity information:
• Knitting capacity :12 tons /days
• Dyeing & finishing capacity :30 tones/days
• Cutting capacity :80000 pcs
• Sewing capacity :100000 pcs
• Printing capacity :500000 pcs
• Embroidery capacity: 100000 pcs
 Executive Summary

Libas Textile Ltd is a 100% export oriented composite knit composite industry. It has well
planned & equipped yarn dyeing, fabric dyeing, and finishing & garments units in addition to facilitate knitting &
knitwear manufacturing. The main reason to select Libas to complete my
industrial attachment as it is a vertically set up composite industry and every operation can be done here. It is
a great chance to see these operations visually and gather practical knowledge. Wide range of fabrics likes
single Jersey, Rib, Interlock, etc. and Grey Fabric, Spandex, Dyed fabric and Printed fabrics are produced here.
All types of knit wears, especially Basic & Fancy T- Shirt for all ranges, Polo Shirt, Night wear, Shorts, KIDS
items, Tank Top etc. are maximum time produced here. I have seen the process & technique to maintain
quality

INTRODUCTION

Libas Textile LTD is a composite industry. A composite industry means there has to have all
the process of making a garment like knitting, dyeing, printing, sewing, sewing etc. Libas
Tetile Ltd has all these process. Now, WE are going to know about these process.

LIST OF BUYERS

Client Country of Origin

Okaidi France
OVS Italy
Bonmax Japan
Columbus India India
H&M Sweden
C&A Belgium/Germany
Polo (Ralph Lauren) United States
FB-Pia Germany
Shana Spain
PRODUCTS DETAILS
All kind of inner & outwear in knit for male,female & children.

Menswear:
T-SHIRT
Polo
Co-ord Set
Trouser
Hoodie

Womenswear:
Tank Top
Long Tshirt

Kidswear:
Tshirt
Trouser
Knitting Department :

The machines used for the manufacturing of knit fabrics are called knitting machine. Knitting
are two types; warp knitting and weft knitting. So, primarily knitting machines can be classified
as weft knitting machine and warp knitting machines. It can also be classified as flat knitting
machines and circular knitting machines.
 Types of knitting machine name:

1. Single Jersey Knitting Machines

2. Double Jersey Knitting Machines
3. Rib Knitting Machines
4. Interlock Knitting Machines
5. Jacquard Knitting Machines
6. Terry Knitting Machines
7. Fleece Knitting Machines
8. Tricot Knitting Machines
9. Crochet Knitting Machines
10. Milanese Knitting Machines

Process Flow Chart for Knitting

Yarn in package form

↓
Place the yarn package in the creel
↓
Feeding the
yarn
↓
Set the m/c as per design & GSM
↓
Knittin
g
↓
Withdraw the roll fabric and weighting
↓
Roll marking
↓
Inspectio
n
↓
Numberin
g
 ↓
Dispatchin
g
 Different types of Knit Fabrics:

1. Single Jersey
2. Double Jersey
3. Rib
4. Interlock
5. Tricot
6. Fleece
7. French
8. Lycra
9. Mesh

Product of knit items

 T-SHIRTS.
 POLO SHIRTS.
 FLEECES.
 TROUSERS.

STORE DEPARTMENT

Introduction:
The defined place where all raw materials are stored is called a Store Department. Finished and packed garments
are stored in designated racks in the store department and are transported to the buyer. Many garments have
started using robotics to maintain their store department. This department usually maintains a book for issuing
packing lists – they register details like date, time, lot no., color, quantity, shipping location, etc. There are three
types of stores in the garments manufacturing industry, they are Trims and Accessories Stores, Fabrics Stores,
and Finished Goods Stores. The store is the central storage of fabrics and trims required for production. Stores
will take care of fabric lots received from the vendor as per the standard procedures. When the fabric is received
from the supplier, it is usually received along with an invoice that contains the order reference number and the
buyer’s name. The fabric rolls/trims boxes are then cross-checked for quantity. The paperwork is followed by
stacking the raw material into designated racks in the store.

Process Flow Chart:

Receiving Product
↓
Inventor
y
↓
Inspection of
product
↓
Shade segregation
↓
Issuing
Product
↓
Sustaining Balance
↓
Closing Summary
Product Receive:Here invoice is collected by the Merchandiser, without an invoice it is notpossible to make the
inventory, because there is a list of Goods In the invoice.
Inventory:After Comparing the invoice with the received goods, the goods are placed in
inventory.
Inspection of Goods:Generally, 10% of goods are inspected, if found defects more than tolerance, the lot will be
declared as rejected and informed supplier for replacement. Trims and accessories will be inspected at 10% of
the total quantity. If defects are more than tolerance then declared as reject.
Shade segregation:Here pieces of fabric from all rolls have to be cut and made into a blanket to segregate shade.
Shrinkage Test:From the fabric roll, a 10% roll will be selected for the shrinkage test. A pieceof fabric is cut
from each roll at 50cm ×50cm and sent for a shrinkage test. Shrinkage testrepost then send to Pattern Section.
Issuing Product: The store always issues products for the cutting and sewing section as perpre-requisition from
that department.
Sustain balance:The store always keeps the sustain record after the issuing product incutting and sewing section.

Organogram:
Store manager
Store senior
officer Store
inspection Store
junior officer Store
officer Supervisor
Helper

Types & Details:

There are three types of store-
a. Fabric Store
b. Trims & Accessories Store
c. Finished Goods Store
a. Fabric Store:
Before starting the garment production, the required amount of fabric has to be stored in the garments. All the
next processes such as spreading, cutting, sewing, etc. have been done by taking the fabric from here. As a result,
this department plays an important role in smooth production.
Flow
Chart:

Fabric dispatched from supplier

↓
Fabric receiving
↓
Fabric checking
↓
Fabric checking by security guards
↓
Shade checking
↓
Send to the merchandiser for approval
↓
Quality checking for defects
↓
Fabric lot rejection
↓
Kept in store
All the above activities are explained in the following:
1. Fabric dispatched from supplier:
Here, the required amount of fabric is dispatched from the definite fabric supplier.
2. Fabric receiving:
It is the second task of any fabric store department in the garment manufacturing industry. Here, the store in
charge receives fabric from the fabric supplier by the following invoice.
3. Fabric checking:
Here, the fabric is checked by following a four-point system.
4. Fabric checking by security guards:
The number of fabrics should be confirmed here by security guards according to the invoice. If it’s found short
then immediately should inform the garment merchandiser.
5. Shade checking:
It’s a very important task for the fabric store department. Fabric shade should be checked here by following
different types of shade that are already approved by the buyer. Here, various fabric shades have been
found which should be kept in lot wise.
6. Fabric lot rejection:
According to the grading of fabric such as A, B, C, D, etc., the fabric lot has to be rejected here. This task
is performed by Q.C (quality controller).
7. Send to the merchandiser for approval:
Here, the apparel merchandiser receives all the information related to the supplied fabric from the fabric store
department. If found any major defects or faults then the merchandiser discusses them with the suppliers and
takes the necessary steps to solve those.
8. Quality checking for defects:
In this section, the quality controller checks fabric quality according to the buyer’s quality recommendation.
9. Kept in store:
After completing all the above information, finally, fabrics are kept in store for support into the next processes
such as cutting, sewing, etc.
Fabric in the store:







Fabric Inspection:
Fabric Inspection is a systematic observation of fabrics to decide whether it meets the client’s specification in
terms of count/construction, color, design, measurement specifications, hand/feel, and other specific quality
parameters laid down by the clients.
This will minimize the quantity of panels or garments rejected for fabric faults, thereby ensuring the quality of
the finished goods. Fabric inspection is also considered a pre-production inspection for garments or other textile
products.

Objective Of Fabric Inspection:

Fabric inspection ensures to minimizationof the rejection of cut panels or rejected garments due to fabric faults.
Cutting inspected and approved fabric ensures not only finished garment quality but also reduces rejects, and
improves efficiency and timely deliveries.

Inspection Process:
There are two methods available in the garments industry. They are 4 point system and 10 point system.
However, the 4-point system is widely used in the garment industry for fabric inspection. Normally 4 point
system is used for better-quality fabric inspection. In the apparel industry, a 4-point system is calculated on the
basis of fabric cut marks and holes or openings. They are as follows-
 INCHES ( ˝ ) (MM) POINTS
From 0 > 3″ length/width Up to 75mm 1 point
From 3.1″ > 6″ length/width 75mm > 150mm 2 points
From 6.1″ > 9″ length/width 150mm > 230mm 3 points
More than 9″ length/width More than 230mm 4 points
Only major defects are taken into account. A serious defect is any defect that would cause a final garment to be
considered a second.

Inspection Procedure:
1. Prepare for Inspection. Before starting the inspection, it is important to make sure that you have all
the necessary tools and equipment;
2. Visual Inspection;
3. Measurements;
4. Fabric Quality Check;
5. Inspection of Fabric Construction;
6. Identify Defects;
7. Record Results;
8. Report Findings;
9. Communicate with suppliers. Store Keeping System:
Store Keeping System:
 Unload fabrics
 Inventory in the warehouse.
 Fabrics inspection
 Recording in the register book and Excel sheet.
 Updated information put in Bin Card (It is an updated information card for bin or
rack, Possible Fabric Defects:
 Horizontal lines
 Shade variation
 Dirt/stains
 Uneven dyeing
 Drop stitches
 Misprinting
 Crease marks
 Barre
 Neps/knots
 Abrasion marks
 Splicing
 Holes
 Defective selvage
 Snags
 Thick place/thin place
 Bowing and skewing
 Needle lines
 Coarse pick
 Coarse end
 Broken pick
 Broken end
 Missing end
 Filling bar

Trims & Accessories Store:

To fulfill the design objectives we need different kinds of materials. Fabrics are the main material, used for
garment manufacturing. We also need other materials, which make the garments aesthetic, functional, and
commercially required. Usually other than fabrics these materials used for making garments are called trims and
accessories.

 Flow Chart of Accessories Management in the Garments Industry

Received technical sheet
↓
Received approved trims
↓
Accessories
received
↓
Inventor
y
↓
Decisio
n
↓
Storage accessories
↓
Deliver
s

Accessories & Trims items

The materials, that are used to make a garment attractive for sale and packing, other than fabrics and trims, are
called Accessories.

Types of Accessories:
  Visible accessories e.g. Button, Sewing thread, Zipper, Velcro, etc
 Invisible accessories e.g.
Interlining Accessories items in the store:
  Polybag
 Elastic bag
 Mini Polybag
 Master Carton
 Inner Carton
 Size Clip
 P.P.Band
 Tag Pin
 Brass Pin
 Collar Stand
 Safety Pin
 Gum Tape
 Arrow Sticker
 Scotch Tape
 Barcode
 Defect Indicator
 Tissue Paper
 Backboard
 Neck Board
 Butterfly
 Numbering Stickers
 Hanger
 Size Stickers
 Carton Pad
 Both Side Tape
 Plastic Staple
 Iron Seal
 Clip
 Ball chain
 Size Tag
 Carton Sticker
 Safety Sticker
 Plastic Clip

Trims:
The raw materials used in the sewing room other than fabric are called Trims. On the other hand, materials
directly attached to the fabric to make a garment are called trims. Like: Threads, buttons, lining, Interlining,
zippers, labels, care labels, etc (Interlining is used as shape forming/preserving materials.)

Trims items in the store:

 Labels
 Buttons
 Zippers
  Padding Interlining
 Down
 Elastic
 Thread
 Twill Tape
 Stopper
 String/Draw Cord
 Piping Cord
 Emblem
 Logo Print
 Swivel Hook
 Eyelet/ Grommet
 Collar Stay
 Cord Bell
 Buckle
 Rivet
 Weaving Belt
 Hook and Eye
 Velcro Tape
 Seam Sealing tape
 Shoulder pad
 Cable (steel ware)
 Adjuster
 Recco
 Elastic Threads
c. Finished Goods
Store:
The finished goods storehouse of the garments industry is the goods storage area where finished garments are in
a carton as per the buyer's required packing list. Many garment factories have CTPAT (Customs-Trade
Partnership against Terrorism), a restricted block area covered by security. The finished goods warehouse is a
very restricted area, only related employees are allowed here. Carton should be handled sensitively here; carton
quality is a big issue to customers, and crushed carton affects product quality

Register& Report use in Store:

 Needle Change register
 Different types of needle balance register
 In House fabric Inspection report (4 Point system)
 Fabric Shade report
 Accessories Inspection Report
 Shrinkage test Report
 Fabric receive packing List
 Button issue register

Good Lighting in Store Room:

Adequate lighting conditions are important for the store room. According to many employers having proper
lightening make productivity improved by 10% and decreased errors by 30%. On the other hand, eye
strain, fatigue and headache can be caused due to poor lightening.

Inventory:
Inventory is the stock of any item or resource used in an organization. In the case of fabric inventory, various
types of fabric and accessories such as sewing thread, buttons, interlining, zippers, labels, etc. are stored in the
storeroom. For bulk production in the garments industry, it is essential to maintain a well-organized &and well-
equipped fabric inventory system.

Inventory control in Garments:

Proper inventory control in the apparel and textile warehouse will ensure market competitiveness in the
international market.

Frequency of Inventory control:

 Daily inventory control
 Monthly inventory control
 Yearly inventory control

Benefits of Inventory:
 Information transparency.
 Save cost.
 Save time.
 Increase in efficiency.
 Data Management

Purpose of Inventory:
1. To Manage Your Overall Costs
2. To Reduce Your Carrying Cost
3. To Better Your Supply Chain Management
4. To Improve Customer Service
5. To Get Better Sales Channel Management
6. To Get Better Sales Channel Management
7. To Get Better Forecasting and Reports
8. To Elevate Communication with Business Partners
9. To Scale for Business Growth
10. To Automate Accounting Processes
Store Capacity:
Materials Name Weight(kg or pounds)

Fabric

Trims & Accessories

Spare parts

Finishing Goods

Dyeing
Color is applied to fiber, yarn, fabric or garment by different methods of dyeing for different types of
fiber and at different stages of the textile production process. Dyeing can be done during any stage in the
textile manufacturing process. Textiles may be dyed as fiber, as yarn, as fabric, as garments, depending
upon the type of the fabric or garment being produced.

Objetive of Dyeing
 To impart color to textile material uniformly

 To achieve acceptable durability of color to further treatment in production and in normal use.

Dyeing Process

The dyeing process for knitwear garments involves several steps. First, the garments
are grouped based on their fabric type, color, and size. Then, they undergo pre-
treatment to remove impurities and prepare them for dyeing. Afterward, pigment
dyes are applied to the garments according to the dyeing recipe ratio. The dyed
garments are then tested for color fastness and shade. Excess water is removed from the
dyed garments through hydro-extraction. The garments are then tumble-dried for curing
the dyeing. Finally, the garments are inspected for defects and uniformity before being
packed and stored .
 Process of Flow chart

Process Flow Chart of Knit Dyeing

Grey fabric inspection

↓
Batchin
g
↓
Fabric
turning
↓
Loading to the
m/c
↓
Pre-treatment (Scouring & Bleaching)
↓
Dyein
g
↓
Dewaterin
g
↓
Dryin
g
↓
Compacting & Calendaring
↓
Final inspection & packing

CAD & Sample Department:

Introduction
In the garment industry, CAD(Computer Aided Design) is a software tool that is used for designing and drafting,
generating reports, three-dimensional modeling, finite element analysis, and as an input source for computer-
aided manufacturing (CAM) .CAD has become an essential tool for designing and manufacturing with
computers. The process of CAD includes three phases: designing the geometric model, analysis of generated
model against various physical quantities, optimization and visualization of computer graphics based on results
and analysis . CAD is a very powerful tool for the manufacturing industry, offering several benefits such as
improved product design, increased productivity, higher utilization, and better quality control .

On the other hand, the sample department in the garment industry is responsible for creating samples of
garments to be produced in bulk. The department is responsible for communicating with buyers, merchandisers,
and production personnel, coordinating among them, maintaining records of pattern sets, shrinkage,
measurement, and other technical information . The sampling department is responsible for preparing different
samples and getting the buyer’s approval, informing quality-related problems encountered during preparing
samples to QC, and minimizing operations and consumption .
 Organogram of Sample Section in Garments Industry

Manager / Technical
↓
Executive/ Pattern
↓
Officer /
Sample
↓
Asst. Officer / Sample
↓
Supervisor/Fabric & Accessories
↓
Supervisor/ Sewing
↓
Sample Cutter ↔ Sample Maker ↔ Quality Inspector ↔ Ironer

Proecss of Flow Chart

Initial Tech-pack/ PDM receive From Merch Dept

↓
Create a New Pattern
↓
Calculate Fabrics Consumption by Electric mini marker in Yardage Yield (YY)
↓
Send Consumption to Buyer
↓
Consumption Approval
↓
Order Confirmation
↓
Receive E-Pattern, block and Fit Sample from a buyer
↓
Pattern
Grading
↓
Submit Pattern to buyer
↓
Approve→ Reject→ Remake
↓
Marker Making for Sample
↓
Shrinkage and Sewing loss adjustment
↓
Sample making for bulk production
↓
Approve sample from Buying House
↓
Marker making for size set
 ↓
Marker
printing
↓
Cut size set
↓
PP meeting
↓
Pattern correction
↓
Marker printing by plotter
↓
Send Marker to cutting
↓
Marker Lay
↓
Bulk cutting

Flow Chart of Garment Sample Making

Garments Design or Sketch ( Manually or Computerized )

↓
Basic Block ( Manually or Computerized )
↓
Working Pattern ( By Machine )
↓
Fabric
Cutting
↓
Print/ Embroidery (If required)
↓
Sewin
g
↓
Finishin
g
↓
Sample Garments ( Manually )
↓
The problem of Production or Production Related Matter
↓

Send to Buyer
↓
Approved Sample
↓
Production Pattern ( By Hand or Computer )
 Pattern
A pattern is used as a template to cut out fabric that matches the required specifications to sew
a garment.Separate patterns are made for each part of the garment. These patterns are used to paint each part
of the garment on the cloth or on marker paper before cutting the cloth.

Marker
A marker is a thin paper that contains all the required pattern pieces for all the sizes for a particular style
of clothing. The marker gives special directions for completing the fabric cutting. Marker can be done both
manually and computerized method.
In the case of the computerized method, all the required information is stored in the refashioned data file,
where an operator helps the computer to make the best choice.

Objectives of marker making:

 To reducecost
 To improve the quality of the garments
 To reduce the cutting time

Marker Efficiency:

The ratio between the total areas of the pattern pieces to the total area of the maker paper is
technically termed as Marker Efficiency. It is expressed in percentage.
If it is denoted by the symbol ή then –
 Marker Efficiency (ή) = (Total areas of the pattern pieces/Total area of
the Marker paper) *100.

The Details Attached to the Garment Sample :

After the confirmation of order, each sample sent to the buyer has the following details attached to it, with the
help of a tag. It contains the details of both, what the buyer has demanded and what the supplier fabric/trim etc
they have used.
 Ref no.
 Color
 Fabric
 Composition
 Description
 Quantity
 Style no/ Size
 Store
 5.6.Purpose of using CAD in Garments:
1. For reducing time in marker making.
2. For reducing Marker Wastage.
3. For increasing marker efficiency.
4. To make the marker accurate.
5. To calculate the fabric consumption accurately

Cutting Department

Introduction

The cutting department is responsible for cutting fabrics and feeding the sewing department with cuttings.
The cutting department’s capacity is planned based on the daily feeding requirement of the sewing lines. The
cutting department is set up with a cutting department head, cutters, spreaders, quality checkers and helpers
for sorting, ply numbering and bundling. The activities of the cutting department are explained in this post.
Organogram
Cutting Manager

Cuttung Incharge

Cutting Floor Supervisor

Cutting Operator

Cutting Helper

Process Flow Chart

Pattern received from pattern department

↓
Cutting ratio received from merchandiser
↓
Marker making
↓
Fabric received from the store
↓
FabricCheckin
g
↓
FabricSpreading
↓
Marker placing on to the lay
↓
Cutting the fabric
↓
Numberin
g
 Fabric Relaxation:
Spandex fabrics will be relaxed minimum 24 hour making unroll in cutting section.
Relaxation date and time must be recorded. After spreading, will relax 2 hours before cut.

Fabric Cutting Process

Cutting is the process of separating a spread into garment components as a replica of pattern
pieces on a marker. It also involves transferring marks and notches from the marker to
garment components to facilitate sewing. The cutting process is frequently done in two
stages: rough cutting and the final accurate cutting.

Objectives of cutting : The main purpose of cutting is to separate fabric plies as

replicas of the patterns in the marker plan. In attaining this objective, certain requirements
must be fulfilled.

Methods of Fabric Cutting:

Generally there are two types of fabric cutting techniques; they are portable cutting and
stationary cutting. With the advancement in technology there have been improvements in
fabric techniques also like Automated, Numerically Controlled cutting systems, which has
Automatic blade cutting, Laser cutting, Water jet cutting, Die cutting etc. I have published a
comprehensive article on methods of fabric cutting.
Accuracy of cut: The garment components have to be cut accurately and precisely as per the
shape of the pattern to facilitate assembling process and for better fitting of garments. The
effortlessness in achieving this accuracy is based on the cutting method engaged and on the
marker.

Clean edges: The fabric edges after cutting should not show fraying or snagging. These
defects are due to an imperfectly sharpened knife, which could result in heat generation due
to friction with fabric which leads to fabric damage. The heat generation during cutting with
knives could be reduced by means of using sharpened knife blades, serrated or wavy edge
knife, utilization of anti-fusion paper between fabrics, spraying of lubricant over the blades
and reducing the lay height and blade.

Support of the lay: The cutting method should provide the support for the fabric in addition
to allow the blade to pierce the lowest ply of a spread and separate all the plies.
Consistent cutting: Based on the method of cutting employed, the lay height will vary. To
get a consistent quality of cutting, the lay height should be as low as possible without
affecting the production planning and quality of cutting.

Preparation for Cutting: After the laying process has been completed, the spreader has to
recount the numbers of plies as in the cutting ticket. Then the following additional steps have
to done prior to cutting.

Moving the spreading machine aside: The spreading operator will place the spreading
machine aside and remove catchers if they were used. The spreading machine must be placed
 back far enough from the lay to permit the cutter to work.

Facilitating shrinkage of the lay: If the lay is knitted fabric, then the lay should be cut into
sections and left on the spreading table overnight to relax. These sections are cut at natural
splice sections in the lay. The cutter would cut between the components through the fabric
width to release the tension in the plies nearby the table.

Rechecking the marker: After the spreading process is completed, the marker is kept on top
of the spread. The beginning line in the marker is aligned at the starting point of the spread.

Printing

The Printing department is not a common department in the knitwear garment industry. However, sometimes
printing is required in the manufacturing process.
The word “printing” is derived from the Latin word meaning “pressing” and implies the application of
“pressure”. Textile printing is one branch of textile wet processing technology. The localised dyeing of textiles
(e.g. to develop a colored pattern) is called printing. Unlike dyeing, printing designs or patterns are usually
printed on only one side of the fabric. In a most simple approach, the dye containing paste is printed on the
textile fabric and the dye is fixed at elevated temperature (e.g. through steaming, drying). Then the excess paste
containing dye and thickener is removed by thorough washing.
 7.1 Process of printing

Artwork from merchandiser

↓
Design input
↓
Design development
↓
Positive/film
↓
Print taken
↓
Requisition by merchandiser
↓
Panel (cutting fabric parts)
↓
Expose (frame adjusted)
↓
Fila and frame adjusted
↓
Water spray
↓
Panel send to buyer
↓
Buyer approval
↓
Sale sample
↓
Counter sample
↓
P P production
↓
Accessories booking
↓
Requisition by merchandiser for fabric
↓
Fabric received and store
↓
Count the fabric
↓
Inspection the fabric
↓
Fabric adjusted
↓
Bulk production start
↓
 Hydro extractor from dryer
↓
Inspection
↓
Finishing
↓
Delivery

Types of
Printing
1.Screen Print
2.Gel Print
3.Flock Print

Sewing Department:

Introduction
In the apparel industry or clothing industry, sewing section is the main department for garments manufacturing.
The sewing department in the plays a crucial role in the overall garment manufacturing process. It is often
considered the heart of garment production. When all the garments are complete to cut in the cutting section, all
of these cutting parts are sending to sewing department for maki ng garment.
Organogram:
Production Manager
(Sewing floor & all Dept.)
↓
Asst. production Manager
↓
Quality controller Manager
(Byer Deal, knitting &
dyeing)
↓
Quality Asst Manager
(All quality, Production, Knitting)
↓
Quality
Incharge
(Total quality control)
↓
Quality
Inspector
( Line wise quality control)
↓
Floor In-charge
( Floor production Control)
↓
Supervisor
( Line Production Control )
↓
Sewing
operator
Sewingthread ↓
Needle Helper
SewingMachine
Elements of sewing section
 Sewing thread:
Sewing threads are special kinds of yarns that are engineered and designed to pass through a sewing machine
rapidly. They form efficient stitches without breaking or becoming distorted during the useful life of the product.
The basic function of a thread is to deliver aestheticsand performance in stitches and seams.

Needle: Needle is the central feature of any sewing machine. The manner in which fabric is pierced by the
needle during stitching has a direct impact on the strength of the seam as well as garment appearance
.

Sewing Machine:
Sewing machine plays an important role in readymade garments sector. Different sewing
machines are used for different purposes. There are a lot of sewing machines used in
garments manufacturing industry, which are mentioned in this article.

According to the operating system, there are two types of sewing machines are available in
the readymade garment garments sector. Those are-
1. Manually operated sewingmachine,
2. Electrically operated sewingmachine
 List of sewing machine
1. Double chain stitch machine (four needle elastic insertingmachine),
2. Double chain stitch m/c (double needle with reverse feed),
3. Fed of the arm (Double chain stitch m/c with
three needles),
4. Interlock machine (twine needle, 5- Over lockmachine)

6. Lock stitch m/c (single needle with automatic thread trimmer),

7. Lock stitch m/c (single needle sewingmachine),
8. Lock stitch machine (two needle with split needle barsewing),
9. Lock stitch m/c (twin needlefeed),
10. Lock stitch sewing m/c (one needle with vertical trimmer wiper and reversefeed),

Sewing Defects:
Needle damage.
Skipped stitch.
Thread drawnoff.
Seampucker.
Wrong stitchdensity.
Unevenstitch.
Staggeredstitch.
Defected stitch.
Oil spot. Seamingdefects:
Unevenwidth.
Uneven seamline.
Not secured by backstitch.
Twisting.
No matching of check orstripe.
No matching ofseam.
Unexpected materials are attached with theseam.
Not sewn by matching face side or back side offabrics.
Use of wrong stitchtype.

Finishing Department
9.1.Introduction:

In the production department garments are stitched by sewing machines. Stitched garments are finished in the
finishing department. Finishing activeties are performed prior packing garments into poly bags. The major
activities of a finishing department include thread trimming, checking garments and ironing.
Thread trimming: After stitching, there will be some hanging sewing threads on the finished
product. Trimming is the operation of removing these extra hanging threads .

Checking garments: All garments are checked at the finishing stage for visuals and measurement

Button attach and Butting holing: Buttons are attached to the garments and buttonholes are made .

Removing stains: Sometimes, finished products get stained during the production process. Finishing
department is responsible to remove those stains by using different wetting agents.

Repair work and mending: Some of the sewn products may also have some open seams or other stitching
faults. The finishing department repairs such products before packing .

Ironing garments: The sewn products are pressed to remove the wrinkles and to enhance the look of the
garment .

Folding and tagging: The folding, tagging and packing of garments are done in the packing section in the
finishing department .

Packing garments: Finishing activities are performed prior packing garments into poly bags

9.2 Process Flow Chart of Finishing department:

Sewn garments received in finishing section
↓
Thread
trimming
↓
checking garments
↓
Button holing and Butting attach
↓
Inspection
↓
Removing stains
↓
Repair work and mending
↓
 Ironing garments
↓
Tagging and folding
↓
Packing garments
↓
Preparation of packing list
↓
Internal shipment audits
↓
Documentation and reporting
↓
Shipment

Packaging
In the knitwear garment industry, packaging is one of the most important parts of the apparel manufacturing
process. After completing the entire manufacturing task, apparel is required to pack. In the finishing section,
packing is the last step before storing. Various types of packing are done and it depends on the type of apparel.
After packing, it is placed in the carton as per instruction.

Packaing Process
The packaging process involves several steps, including labeling, price tag attaching, folding, primary
packaging, secondary packaging, final packaging, metal detecting, and final inspection.

Packing Materials:
The simple packaging materials used in garment and related items are paper, plastic, film,
wood, nails, staples, cords, gum tape and metal bands.
A. Wood cases and crates are generally used as packing materials for bulk exports or
rugged shipments where shipment handling is higher.
B. Paper and plastic film packaging materials are used in the garment and related industries.
The paper types such as Kraft, crepe, tissue, paper foil, paper board and waterproof are
typically used as packing materials. Plastic films have a major advantage over paper because
of clarity in range

Cartooning
Cartooning is done after packing the garments . There are various types of cartooning are
used in the finishing section for the finished goods.

Types of Carton Packing:

After garment packaging, the process of cartooning is carried out based on the size of the
apparel and its color. Most used packing types are given below.
1. Solid color solid sizepac
2. Solid color assorted
sizepack 3.Assorted color solid
sizepack

Final inspection

Garments are inspected by AQL. In this system samples are collected inspected by
statistically from the lot sire and will decide the lot of garments to be granted or rejected.
AQL is mainly used in final Inspection after garment making
Acceptable quality level (AQL) sample Inspection methods have been proven to be accurate
over A long run. However, the quality level of merchandise at destination is sometimes
lower than the Per-shipment inspection results. Defect Classification: The client defines the
AQL

and the
maximum
number of
defective
goods
allowed in
the sample
size.
 Merchandising

Introduction:
Knit garments merchandising denotes all the planned activities to execute and dispatch the merchandise on
time taking into consideration the 4 R’s of expediting Right Cost, Right Quantity, Right Quality and Right Time.

Functions of Knit Garments Merchandisers:

 Execution of Sample orders

 Costing.
 Programming.
 Yarn Procurement Arrangements.
 Production Scheduling (or) Route CARD Drafting.
 Accessories arrangement (order placing follow-ups).
 Approval of various processors’s sewing operations and finishing processes.
 Pattern approval (or) Dummy size set approval.
 Size set approval.
 Preproduction sample follow-ups.
 Pilot run inspection.
 In process inspection.
 Production controlling.
 Identifying shortages and make arrangements for the shortages.
 Shortage quantity and quality following quality control procedures.
 Following quality assurance procedures.
 Maintaining the junior’s activities of in house and sub-contractor units.
 Buyer communication.
 Communication with production units, processing units and other third party’s (vendors).
 Proper reporting.
 Highlighting to the management.
 Record maintenance (Records pertaining to merchandising).
 Developing samples.
 Placement of orders.
 Taking measures for consistent production.
 Taking preventive actions to maintain the targeted performance level in all areas of merchandising.
  Attending meetings with superiors and furnishing the required details about merchandising.

HR, Administrative & Compliance

Department

Introduction:

HR and Compliance is a big part to make an efficient apparel industry.

Human resources compliance department deals with several rules,
employees’ legal right, laws and acts to consider, such as the Fair Labor
Standards Act, abuse and sexual harassment, antidiscrimination laws,
employee’s salary and many more. In export garments manufacturing
factory need to be 100% compliant to get order. HR is a part of
administration.

Job responsibilities

 Developing, implementing and managing an organization’s compliancestandard.

 Preparing and presenting clear and concise compliance reports to theBoard.
 Interacting with regulators on complianceissues.
 Coordinating efforts related to audits, reviews, andexaminations.
 Program Prepare and keep the documentation related to audit and compliance.
 Assist in developing, implementing, maintaining and reviewing of
companypolicies, rules and regulations in compliance with all applicable
employment laws and regulations.
 To monitor the floor for checking all kinds of complianceissues.
 To motivate the employees for maintaining all kind of personal safety.
 Train up all employees on all safety awareness issue; maintain all kinds of
training records.
 To aware the employees regarding health and safetyissues.
 Ensure the factories are compliance with social ethics & health and
safety requirements,etc.
 To find out the non-compliance issues by the daily monitoring & internal audit in
the factory. Conduct internal audit in the light of Labor Law, Factory Rules buyers
COC
 & other national & international legalinstruments.
 Monitor compliance certification BSCI, ICS, SEDEX, NEXT, INDITEX,
PRIMEMARK, ACCORD & Alliance etc. and handle their different
auditswith requirements.
 Maintain and implement Accord/Alliance (fire, electrical & structural) standard
for creating a safe working place.
  Communicate, maintain, handle and implement all social audits whether
buyer & certification/membership audit as, ICS, SEDEX, NEXT, INDITEX,
PRIMEMARK, ACCORD etc.
 Maintain every compliance mechanism/tools internally; through weekly,
monthly and yearly comparative statistical report &tools.
 Give Suggestions to the management regarding several
important pronouncementand decisions of Law & otherCOC.
 Conduct in house training for all employees on OH&S, EMS, Fire
Safety, Grievance etc. as advised by factorymanagement,
 To adopt, maintain and implement environmental, chemical standard as,
High Index for the sake of the organization in a sustainable manner etc.
 Conduct internal H&S and Environmental assessments in a regularinterval.
 Review and update all legal documents/certificate/license time to
timeby communicating with the specific authorities.
 Checking routine wise checklist and makereport
 Update to management all compliance reports in regular intervaletc.

Activities

 Coordinate interviewprocess.
 Conducting appointment, termination (closing) and in-serviceprocedures
 New employeeorientation.
 Compiling, sorting and generating periodicreports.
 Scheduling and coordination training and orientation sessions.
 Attendance and absent statusmanagement.
 Maintain and Update Employee PersonalFiles.
 Assist to coordinate Recruitment &Selection.
 ManpowerPlanning.
 Management & data entries intoHRMS.
 Handle Employee Resignation, Exit Interview, Clearance, Closing Activation
and Final Settlement asrequired.
 Handle disciplinary matters, legal affairs & industrial relations related
issues forall the factories. -Authorized to sign all kinds of letters related
with administrative activities & disciplinaryprocedures.
 Maintain employee’s (Factory) PFinvestment.
 Performance Appraisal.
 Confirmation, Promotion, Increment and associatematters.
 Employee counseling.
 Arrange all the event management issues for the office in different
occasion such as- Best Employee, Birthday and Farewell Program.

Conclusion
We are enough to fortunate that we are have got an opportunity to the visit period It was helpful to
learn about technology, production process, textile machineries, industrial management match
with industrial environment. The chain of command, management, and administration are all
extremely well-organized. They have good working conditions and are well-equipped with all the
latest machinery. The relationship between upper and lower management is excellent and focused
on using their actions to meet client demands. 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 Libas Textile Ltd. are very much objective and
practical so that one can get the desire information about the factory.