BGMEA University of Fashion & Technology

Faculty of Apparel Manufacturing & Technology (AMT)

Internship Report
Industrial Attachment At

An Industrial Training
By
Md. Shazzad Hossain
ID: 142-006-0-145
Batch: 142, AMT
Program: B.Sc.
Department of Apparel Manufacturing & Technology

Supervised By
Sabbir Ahmed Abir
Lecturer Dept. of AMM
BGMEA University of Fashion & Technology (BUFT)

This internship report has been submitted in partial fulfillment of the requirements for
the degree of B.Sc. in Apparel Manufacturing & Technology in the Faculty of Apparel
Manufacturing & Technology (AMT) of BGMEA University of Fashion and
Technology (BUFT)

Department of Apparel Manufacturing & Technology

12th September, 2020

Page i
 Department of Apparel Manufacturing & Technology (AMT)

An Industrial Training
By
Md. Shazzad Hossain
ID: 142-006-0-145
Batch: 142, AMT
Department of Apparel Manufacturing & Technology

Supervised By
Sabbir Ahmed Abir
Lecturer Dept. of AMM
BGMEA University of Fashion & Technology (BUFT)

Exam Committee:

Examiner1 (Supervisor): Signature:

Examiner2 (External Member): Signature:

Examiner3 (External Member): Signature:

12th September, 2020

Page ii
 Executive Summary

Radiance Group started its journey with only 9 machines from China and 7 machines
from local market. In 1991 we shipped out our first consignment of basic T-shirt to ETC
JEAN BUISSART ET CIE in France. After that we never looked back and our
shipments continued without interruption. Now Radiance Group has established a strong
position in the Ready-Made Garments (RMG) sector. We now have a park of 2548
industrial machines with daily manufacturing capacity of 1,00,000 pes basic T-shirt of
knitwear, 30,000 pes woven ware , 40,000 kg dyeing , accessories, printing and
packaging item. Always thinking about quality, industrialization and future
developments we are introducing latest technology machines and hiring talented people.
To become the benchmark manufacturing company for the textiles and garments industry
providing world-class products through the integrity, teamwork and creativity of our
people driven by our constant commitment to outstanding overall customer satisfaction.

Page iii
 Letter of Transmittal

Date: 12th September, 2020

To
Sabbir Ahmed Abir
Lecturer Dept. of AMM
BGMEA University of Fashion & Technology (BUFT)
Nishatnagar, Turag, Uttara, Dhaka-1230.

Subject: Submission of the Internship Report on “Radiance group”

Sir,
With great pleasure, here I submit my internship report on “Industrial Training in Garments
Industry (Radiance group) that you have approved & assigned as a compulsory requirement of
GMT-4204 course. I have tried my level best to bring out the original scenario of Radiance
group full of effectiveness & efficiency.

I have really learned a lot and have gained valuable experience and knowledge while collecting
information for the report. It was certainly a great opportunity for me to work on this real life
project to actualize my theoretical knowledge of this course in the practical arena and some
more which is out of this course.

I am optimistic enough to believe that you will find this report’s worth for all the labor I have
put in it. I welcome your entire query & take pride to answer them.

Signature
Md. Shazzad Hossain
ID: 142-006-0-145
Batch: 142, AMT
BGMEA University of Fashion & Technology

Page iv
 DECLARATION

I hereby declare that this internship report has been done by me under the supervision of
Sabbir Ahmed Abir, Lecturer, Department of AMM and BGMEA University of Fashion &
Technology. I completed my internship from 1st July, 2020 3rd August, 2020.

.....................................
Md. Shazzad Hossain
ID: 142-006-0-145
Batch: 142, AMT

Page v
 ACKNOWLEDGEMENTS

I would like to extend thanks to Honorable Founder Chairman, Board of Trustees Mr.
Muzaffar U. Siddique, BUFT, for not only for his tremendous academic support, but also
for giving me/us so many wonderful opportunities and logistic supports to do this Report.

Special thank goes to my/our enthusiastic Prof. Prof. S.M. Mahfujur Rahman, Vice
Chancellor, BUFT & Prof. Engr. Ayub Nabi Khan, Pro Vice Chancellor, BUFT. who so
generously inspired & contributed to do this type of report work.

Special thanks go to my enthusiastic supervisor, Sabbir Ahmed Abir, Lecturer, Department

of AMM, BGMEA University of Fashion & Technology has been an amazing experience and
I thank him wholeheartedly, not only for his tremendous academic support, but also for
giving me so many wonderful opportunities. Similar, profound gratitude goes to HOD, who
has been a truly dedicated mentor.

I would like to extend thanks to all of persons, who contributed to the work presented in this
project. Especially I have to mention the name of Industrial Personnel Md. Saiful Islam, Sr.
Deputy General Manager, Radiance group.

Finally, thanks go to some technical persons Md. Sazzad Hossain (IE Officer) Radiance
group.

Page vi
 Table of Contents

Contents
Executive Summary /Introduction......................................................................................................ii
Letter of Transmittal...............................................................................................................................iv
Table of Contents....................................................................................................................................vii
CHAPTER ONE:.....................................................................................................................................1
Organization Description.........................................................................................................................1
CHAPTER TWO:....................................................................................................................................5
Man Power Management.........................................................................................................................5
2.1 Man power management/Organogram:.......................................................................................5
2.2 Shift change:...................................................................................................................................5
2.3 Responsibilities of officer:..............................................................................................................6
2.4 Job description of the officers:......................................................................................................6
CHAPTER THREE:................................................................................................................................7
Machine Description................................................................................................................................7
3.1 Knitting Section:.............................................................................................................................7
3.1.1 Machinery layout plan:.............................................................................................................7
3.1.2 Machine Description:..............................................................................................................8
3.1.3Quality Section:.......................................................................................................................10
3.1.4 Research and Development (R&D) .....................................................................................11
3.1.5Main objectives of R&D Department:..................................................................................11
3.1.6 R&D Work.............................................................................................................................11
3.1.7 SMV Calculation....................................................................................................................12
3.2 Dyeing Section:.............................................................................................................................14
3.2.1 Dyeing machinery layout.......................................................................................................14
3.2.2 Sample Machine:...................................................................................................................15
3.2.3 Production Machine:.............................................................................................................15
3.2.4 Dyeing Finishing Machine:...................................................................................................16
3.2.5Machineries of Dyeing chemical lab:.....................................................................................17
3.2.6 Machineries of physical lab:.................................................................................................18
3.2.7Some picture of Physical lab:.................................................................................................18
3.3 Garments Section:........................................................................................................................20
3.3.1 CAD:.......................................................................................................................................21
3.3.2 Cutting Section:.....................................................................................................................23
3.3.3 Flow Chart of Cutting Section:.............................................................................................23

Page vii
 3.3.4 Sewing Section:......................................................................................................................25
3.3.5 Machineries flow chart 0f sewing section:............................................................................25
N.......................................................................................................................................................25
3.3.6Some picture of sewing machine:..........................................................................................28
3.3.7 Machine Used in Sample Section & their specification.......................................................28
3.3.8 Washing Section:...................................................................................................................29
Asko/Sweden....................................................................................................................................29
3.3.9 Printing Section:....................................................................................................................30
3.3.10 Embroidery Section:............................................................................................................30
CHAPTER FOUR: Material management...........................................................................................31
4 .1Material management..................................................................................................................31
4.2 Materials planning and control:..................................................................................................31
4.3 Materials Management's Scope:..................................................................................................31
4.4 Raw Materials:..............................................................................................................................32
CHAPTER FIVE: Production planning & sequence...........................................................................34
5.1 Process flow chart of knitting:.....................................................................................................34
5.2 End products of circular knitting machine.................................................................................34
5.3 Production Calculation:...............................................................................................................35
5.4 Production parameter:.................................................................................................................37
5.5 Sample of various type of knitted fabric:....................................................................................37
5.6 Faults& their causes:....................................................................................................................38
5.7 Different types of faults:...............................................................................................................40
5.8 Process flow chart of dyeing:.......................................................................................................41
5.9 Dyeing Lab....................................................................................................................................41
5.10 sample dyeing flow chart............................................................................................................42
5.11 bulk dyeing flow chart................................................................................................................42
5.12 Dyeing process for bulk:.............................................................................................................43
5.13 polyester dyeing process.............................................................................................................44
5.14 Process flow chart of cutting:.....................................................................................................46
5.15 Process flow chart of sewing:.....................................................................................................46
5.16 Procedure of IE department in Garments section:..................................................................47
5.17 Target Calculation –...................................................................................................................48

CHAPTER SIX: Quality Assurance.....................................................................................................49

6.1 Quality Assurance:.......................................................................................................................49

Page viii
 6.2 Objects of quality control:...........................................................................................................49
6.3 Scope of quality control, quality assurance and testing:............................................................49
6.4 Quality assurance Procedure:......................................................................................................49
6.5 Activities of Quality Department:...............................................................................................50
CHAPTER SEVEN: Maintenance........................................................................................................56
7.1 Maintenance of Machinery:.........................................................................................................56
7.2 Maintenance Procedure:..............................................................................................................57
7.3 Preventive maintenance check list sample..................................................................................59
7.4 Preventive maintenance Check list of Gas Generator:..............................................................60
7.5 Maintenance work request form:................................................................................................61
CHAPTER EIGHT: Utility services.....................................................................................................62
8.1Available Utility Facilities:............................................................................................................62
8.2 Problem associated for hard water in boiler:.............................................................................63
8.3 Power plant:..................................................................................................................................64
8.4 Compressor:..................................................................................................................................65
CHAPTER NINE: Store & Inventory Control....................................................................................66
9.1 Store and Inventory Control:......................................................................................................66
9.2 Frequency of Inventory Update:.................................................................................................66
9.3 Inventory Control System for Raw Materials:...........................................................................66
9.4 Inventory Control System for Finished fabric:..........................................................................67
9.5 Inventory Control System for Spare Parts:................................................................................67
CHAPTER TEN: Cost analysis.............................................................................................................68
10.1 Sample Calculation Sheet...........................................................................................................68
10.2 Sample Calculation (Image form).............................................................................................69
CHAPTER ELEVEN: Marketing activities.........................................................................................70
11.1 Duties and Responsibilities of Commercial Department.........................................................70
11.2 Duties and Responsibilities of Accounts Department..............................................................71
CHAPTER TWELVE: Others..............................................................................................................74
12.1 Water Treatment Plant:.............................................................................................................74
12.2 There are different types of water softening process:..............................................................74
12.3 Base Exchange process:..............................................................................................................75
12.4 Effluent Treatment Plant:..........................................................................................................77
12.5 Process sequence:........................................................................................................................82
12.6Used chemicals:............................................................................................................................82
12.7Testing lab instrument:...............................................................................................................83
12.8Waste Water Treatment Plant (WWTP)...................................................................................83

Page ix
 12.9 Safety and security......................................................................................................................84
12.10 FKL is maintaining the following COC issues:......................................................................84
12.12 Disciplinary Practices/ Harassment:.......................................................................................85
Impact of the Internship........................................................................................................................88
CONCLUSION.......................................................................................................................................89

Page x
 CHAPTER ONE

Organization Description

Fig: 1.1 Radiance Group

Page 1
AWARDS AND ACHIEVEMENTS :

Factory & Head Office: House # 521, Road # 10, DOHS Baridhara, Dhaka-1206,

Bangladesh.

(+88 02)8412151, 8414697, 8416113, 8829371, 8812093, 8816113

(+88 02) 9884546

info@radiancegroup-bd.com, www.radiancegroup-bd.com

Managing Director : Md. Shahidul Islam (Shahed)

Year of Establishment: 1991
Area of Premises : 550000 sqft
Number of Employee: 9500 (Approximately)

Bank : Dutch Bangla Bank Limited

One Bank
United Commercial Bank Ltd

Our Major Customer:

Page 2
Board of Director

MD. SHAHIDUL ISLAM (SHAHED)

MANAGING DIRECTOR
Cell : +880-1711-52 19 12
Telephone No. : +880-2-8829371
Email : shahed@radiancegroup-bd.com ,
Email : s_islam@radiancegroup-bd.com

SALMAN FARSY SUNNY

DIRECTOR
Email : salman@radiancegroup-bd.com
Email : gt3600@yahoo.com

MD. FAZLUR RAHMAN

DIRECTOR(CHQ)
Commodore (E) psc, BN(Retd)
BSc Engg(BUET), MESC(India), MDS, ISMC(USA), FIEB
PHONE : +880-2-8414697, 8417385, 8416113
Cell : +880-1730-35 29 57
Email : shipping@radiancegroup-bd.com

MD. ABDUL HAFIZ

General Manager(Audit)
Cell : +880-1714-01 76 13
Email : audit@radiancegroup-bd.com

MD. SAIFUL ISLAM

Sr. Deputy General Manager (A & F)
Cell : +880-1738-24 50 63
Email : saiful@radiancegroup-bd.com

MD. MIZANUR RAHMAN

General Manager(Admin & HR)
Cell : +880-1713-43 51 54
Email : mizan@radiancegroup-bd.com

MD. NURUL ALAM

General Manager (Banking)
Cell : +880-1730-35 29 67
Email : mis@radiancegroup-bd.com

Page 3
Production Capacity of Radiance group (According to their 2015 s announcement)

SL No Section Capacity

01 Knitting 30 tons/day

02 Dyeing 45 tons/day

03 Dyeing Finishing 47 tons/day

04 Garments 2,00,000 pcs/day

05 Garments Washing 30,000 pcs/day

06 Printing 1,00,000 pcs/day

07 Embroidery 200 head

Mission & Vision: Strive to provide world class service and the best value to customers. Thrive
for excellence and work for ensuring a pleasant, clean and professional working condition
employees and the people do business with company.

Page 4
 CHAPTER TWO

Man Power Management

2.1 Man power management/Organogram:

Managing
Chairman
Director

Director(Admistrati
Executive
on/Finance
/Merchandising Director

General Maneger(Productio
Maneger( Productio n/Quality/
n/Quality) Merchandising)

Assistant
Manager(Productio
Line Chief n/Quality/Merchan
dising)

Supervisor/ Operators &

Inspector Helper

2.2 Shift change:

► Working Hours:
Regular working hours for the factories are from 08:00 Hours with one hour lunch break for six
days a week. Fridays are observed as weekly holidays.
Overtime is voluntary. An average of two hours overtime is allowed per day with a limit of 52
hours per month.

► Two shifts: each of 12 hrs

 Shift 1: 6:00 a.m. to 2:00 p.m.

 Shift 2: 2:00 p.m. to 10:00 a.m.
 Shift 3: 10:00 p.m. to 06:00 a.m.

Page 5
2.3 Responsibilities of officer:

 To give factory program slip.

 To match production sample with target product.
 To collect production sample for sample matching nest production.
 To observed production during finishing running & also after finishing.
 To identify disputed fabrics & report to production manager for necessary action.
 To discuss with production manager about overall production if necessary.
 To sign the store requisition.
 Also to execute overall floor works.

2.4 Job description of the officers:

 Report to : Assistant Production Manager

 Job Summary: To plan, execute & follow up the production activities & control the
quality

Page 6
 CHAPTER THREE

Machine Description

3.1 Knitting Section:

3.1.1 Machinery layout plan: E

W N
Entry S

H-1 G-1 F-1 E-1 D-1 C-1 B-1 A- Office

1
H-2 G-2 F-2 E-2 D-2 C-2 B-2 A-
2
H-3 G-3 F-3 E-3 D-3 C-3 B-3 A-
3

H-4 G-4 F-4 E-4 D-4 C-4 B-4 A- R&D

4 Section
H-5 G-5 F-5 E-5 D-5 C-5 B-5 A-
5
H-6 G-6 F-6 E-6 D-6 C-6 B-6 A-
6 Wash
H-7 G-7 F-7 E-7 D-7 C-7 B-7 A- room
7
H-8 G-8 F-8 E-8 D-8 C-8 B-8 A-
8

H-9 G-9 F-9 E-9 D-9 C-9 B-9 A- Store

9 Room
H-10 G-10 F-10 E-10 D-10 C-10 B-10 A-
10
H-11 G-11 F-11 E-11 D-11 C-11 B-11 A-
11
H-12 G-12 F-12 E12 D-12 C-12 B-12 A-
12

P-1 P-2 P-3 P-4 P-5

Emergency Exit Emergency Exit

Page 7
3.1.2 Machine Description:

Circular knitting machine: Single Jersey, Double Jersey, Auto Striper & Jacquard.

Circular Knitting Machine Brand No’s

Single Jersey / Single Jersey Lycra (Open) Masa + Jiunn Long 27 pcs
Single Jersey (Tube) Mayar & CE, Jiunn Long, Quantex, 41 pcs
Masa.
SingleJersey(Tube)+Jacquard Santec , Jiunn Long 02 pcs
Rib Jersey / Rib Jersey Lycra Jiunn Long, Terrot, Masa 18 pcs

Interlock Jiunn 12 pcs

Auto Striper (sj) Fukuhara 02 pcs
Pollar Fleece Sanda 05 pcs
3th Fleece Jiunn 02 pcs
Auto stripe ( rib+interlock) 08 pcs

Total No Machines 117 PCS

No of lines 10 pcs

Pollar fleece
Sanda 24 pcs

In Total 141 pcs

Other machines in knitting section:

Machine name Brand Origin Quantity
Flat Bed Knitting m/c Stoll (Jacquard) Germany 07 pcs
Gray Fabric Ins. m/c Uzu cloth insp. m/c Thailand 3 pcs open ,5 pcs tube

We have also:
1. Electrics balances fabric weight 15 no’s
2. Electrics balances for GSM CHECK 20 no’s
3. Winding machine 5 no’s

Page 8
Some Pictures of Machines:

Figure 1: Single jersey circular knitting machine

Figure 2: Double jersey circular knitting machine

Figure 3: Inspection machine

Page 9
 Figure 4: Auto stripe circular knitting machine

3.1.3 Quality Section:

Yarn inspection (as guideline)

Production sample inspection (as guide line)

Knitted fabric inspection (as per guide line)

Outside knitting sample inspection (as per guide line)

Batch inspection (as per guideline)

Finished fabric inspection (as per guide line)

Make report

Page 10
3.1.4 Research and Development (R&D) section:
Research & Development is defined as the process of productivity improvement through
standardization of operation for easy in work and best utilization of all available resources

3.1.5Main objectives of R&D Department:

 Develop Productivity & reduce Wastage

 Study existing old method & implement standard method
 Operator training & motivation programmer
 Develop operation & target
 Time study
 Method study
 Line balancing
 Solve the bottle neck
 Develop operator & performance & efficiency
 Line layout plan & manpower allocation
 Production planning (Right operator to right operation as per SMV)
 SMV Calculation
 New and Old worker Assessment
 Designing the most appropriate machine layout for the particular style.
 Reducing rework and re-process.
 Improving efficiency and ultimately contributing to production cost reduction.

3.1.6 R&D Work

 Time study:
Time study is a tried and tested method of work measurement for setting basic times and hence
standard times for carrying out specified work. The aim of time study is to establish a time for a
qualified worker to perform specified work under stated conditions and at a defined rate of
working.
Conditions:
 The practitioner (observer) must be fully qualified to carry out Time Study,
 The person performing the task must be fully trained and experienced in the work,
 The work must be clearly defined and the method of doing the work must be effective
 The working conditions must be clearly defined.
 Capacity Study
Capacity is a word which describes the workability of a worker or a group of workers for a
particular working process. It shows that in standard & general condition how much output work
is getable from the worker (s) per/hour. It is very important to determine the hourly capacity of a
working process in order to maintain the uniform tempo in that process for an entire working day.
In R&D section, capacity of an individual worker for a particular process is determined by hourly
production study.

Page 11
  Efficiency
Efficiency in general, describes the extent to which time, effort or cost is well used for the
intended task or purpose. Generally, Efficiency is expressed as percentage and has the following
formula which is maintained for the calculation of Efficiency (%):
Production∗SMV
Efficiency %= ∗100
Working hour∗Worker∗60

EXAMPLE:
If, Manpower = 28
SMV = 8.01
Working hour = 8 hours
Production = 1400 pieces
Efficiency % = ?

CALCULATION:
Production∗SMV
Efficiency %= ×100
Working hour∗Worker∗60

1400× 8.01
= × 100
8 × 28 ×60

= 0.834375×100 = 83.44%

3.1.7 SMV Calculation

The full form of SMV is Standard Minute Value. It indicates the period of time an individual
worker needs to complete a particular process in standard conditions. Basically, SMV depends on
four crucial factors what are combined called “4M factor”. Here 4M indicates to-
Man (Personnel),
Machine,
Material &
Method.
If these four factors are found in standard condition then the required period of time to complete a
particular process will be considered as the SMV of that process.
In R&D, the SMV of a particular process or operation is multiplied by 60 to convert the actual
time into the required format of time in seconds.
Target: A target is an object chosen for aiming, especially as an object for attack. Target is also
the name of a discount retail store chain, which uses a bull’s eye as its logo.

Page 12
EXAMPLE:
If, Manpower-28
SMV-8.01
Working hour- 480 mints
Expected Efficiency-70%
Find out target=?
CALCULATION:

Manpower ×Working Hour ×60

Terget= × Expected Efficiency
SMV
28× 8 ×60
¿ ×70 %
80.1

= 1175/8 hour Shif

Page 13
 3.2 Dyeing Section:
3.2.1 Dyeing machinery layout
Entry Entry

s N
Sample Machineries E

Chemical Room
Dyeing machineries

Batching Area

Wash Room

Dyeing machineries

Office room

Dyeing store room

Dyeing machineries

Emergency Exit
Emergency Exit

Page 14
3.2.2 Sample Machine:

Sl No Machine name Brand Capacity per day No’s

01 Winch Fongs 30kg 05
02 Winch Fongs 60kg 08
03 Winch Fongs 120kg 02

04 Winch Pmm 40 kg 03
05 Winch Pmm 100 kg 03

3.2.3 Production Machine:

Sl No Machine name Brand Capacity per day Nos

01 Winch Fongs 250 kg 3
02 Winch Fongs 400 kg 2
03 Winch Fongs 500 kg 2
04 Winch Fongs 500 kg 8
05 Winch Fongs 600 kg 8
06 Winch Fongs 750 kg 8
07 Winch Fongs 800 kg 3
08 Winch Fongs 1000 kg 4
09 Winch Fongs 1200 kg 2
10 Winch Fongs 1000 kg 2
11 Winch Sclavos 1000kg 3
12 Winch Sclavos 1000kg 1

13 Winch Sclavos 750 kg 1

Total Dyeing Capacity: 50 Tons/Day

Figure 5: Dyeing machine

Page 15
3.2.4 Dyeing Finishing Machine:

Sl No Machine Name Brand Country No’s

01 Stenter Bruckner Germany 03
02 Stenter ACC Turkey 01
03 Stenter Chengfu Taiwan 01
04 Open Compactor Lafer Italy 03
05 Open Compactor Ferraro Italy 01
06 Slating EL Italy 02
07 Slating MTG Italy 02
08 Bag Sewing Osthoff Italy 02
09 Singcing Lau (Has) Germany 03
10 Sueded M/C I kuang Turkey 01
11 Combing I kuang Taiwan 01
12 Shewing AB Calator Taiwan 01
13 Squeezer AKAB Sweden 01
14 Squeezer Kromson Sweden 02
15 Squeezer Fab-Con Turkey 01
16 Tube Compactor Specttorimar U.S.A 01
17 Tube Compactor Ferraro Italy 01
18 Calender AMS Italy 01
19 Dryer Obermaier Turkey 01
20 Dryer Lafer (Has) France 01
21 Tube Compactor Dilmiler Turkey 01

Total dyeing finishing capacity:50 tons per day.

Figure 6: Finishing Section

Page 16
3.2.5Machineries of Dyeing chemical lab:

Sl No Machine name Brand Country Total no’s

01 Spectra Photometer Gretag Macbeth U.S.A 02
02 Lab Sample Dyeing IRDYER Taiwan 03
M/C
03 Lab Sample Dyeing RAPID Taiwan 02
M/C
04 Lab Sample Dyeing Turkey 02
M/C ATAC
05 Auto lab system m/c Lawer Italy 01
Dispensing
06 Squeezer ATAC Turkey 01
07 Hydro Extractor ATAC Turkey 01
08 Dryer ATAC Turkey 02

09 Mixer M/C ATAC Turkey 02

10 Heater ATAC Turkey 02

11 Electronic balance SHIMADZU Japan 02
12 Light Box VERIVID U.K 03

Figure 7: Chemical Lab

Page 17
3.2.6 Machineries of physical lab:

Serial No. Machine Name Machine Brand Machine Origin Machine No.
1 ICI Pilling SDL ATLAS Anhui, China 1
Machine M0027
2 Martindale Pilling JAMES HEAL Anhui, China 2
Machine
3 PNU Burst SDL ATLAS, England 3
M229P
4 Color Fastness of JAMES HEAL China 4
Rubbing
5 pH meter METTLER China 5
TOLEDO
6 Digital balance ECS1200 India 6
7 Rota wash SDL ATLAS China 7
M228
8 Tumble Dryer SDL ATLAS 8
9 Per spirometer JAMES HEAL China 9
10 Waikato FOM7ICLS China 10

3.2.7 Some picture of Physical lab:

Figure 8: color fastness to washingFigure 9: color fastness to rubbing (wet & dry)

Page 18
Figure 10: ICI pilling tester Figure 11: sample weight machine

Figure12: PH meter

Page 19
3.3 Garments Section:
Process flow chart of garments section:

Design

Pattern design

Sample making

Production pattern

Grading

Marker making

Spreading

Cutting

Bundling

Sewing

Inspection

Finishing

Packing.

Page 20
3.3.1 CAD:

CAD is an important section for a factory. An efficient CAD section can makes profit for
the factory. Because off fabric carries 60% cost of the total garment. So if they can save
fabric by creating an efficient marker they can make a huge profit for the factory.
There are 4 famous CAD systems in the world

1. LECTRA CAD.
2. EURO CAD.
3. Gerber Garment Technology.
4. Assyet CAD.

Organogram of the FKL CAD section

CAD GM

CAD AGM

CAD Manager

Sr. CAD operator

CAD operator

Assistant CAD operator

FKL CAD section –

There are two CAD systems in the factory –
 Lectra CAD.
 EURO CAD.

Four hardware’s are –

 Plotter (printer).
 Digitizer (Scanner).
 Computer.
 Printer.

Page 21
Three software’s are –
 Modariec – This is used for size increase & decrease.
 Diamino – Creates marker.
 Vigiprint/Justprint – Direction setting.

EURO CAD Combines with five instruments. Its total package is $ 5,500.
 Pattern designer.
 Auto marker.
 Auto digitizer.
 Spread & cut plan.

Figure 9: cam system

Page 22
3.3.2 Cutting Section:
3.3.3 Flow Chart of Cutting Section:

Fabric relaxation

Fabric checking

Fabric spreading

Clamping

Marker spreading

Cutting

Numbering

Bundling

Cut panel checking

Racking

Delivered to the Printing / Embroidery / Sewing section

Page 23
In Cutting Section:1. No of Auto Spreader: 6
2. No of Auto Cutter: 4
3. Each machine has 30,000 PCS/ Day cutting capacity.
4. FKL cutting division has 4 units.
5. Cutting Capacity in Cutting division is 1, 80,000 pcs/day
6. Available manual cutting machine or straight knife cutting machine

Figure 11: Auto spreader

Figure 11: Hand Knife

3.3.4 Sewing Section:

3.3.5 Machineries flow chart 0f sewing section:

Page 24
 N

W E
Entry *Total sewing unit: 10
*Every single floor consists 10 sewing line

Bundle Table Line: 1 Sewing machinesQuality Table Finishing area

Bundle Table Line: 2 Sewing machinesQuality Table Finishing area

Bundle Table Line: 3 Sewing machines Quality Table Finishing area

Bundle Table Line: 4 Sewing machines Quality Table Finishing area

Bundle Table Line: 5 Sewing machines Quality Table Finishing area

Bundle Table Line: 6 Sewing machinesQuality Table Finishing area

Bundle Table Line: 7 Sewing machinesQuality Table Finishing area

Bundle Table Line: 8 Sewing machinesQuality Table Finishing area

Bundle Table Line: 9 Sewing Machines Quality Table Finishing Area

Bundle Table Line: 10 Sewing machines Quality Table Finishing Area

Page 25
Machines 0f FKL unit wise:

Machine Unit 1 Unit 2 Unit 3 Unit 4 Unit 5 Unit 6 Unit 7 Unit 8 Unit 9 Unit 10
name
Plain 48 48 36 36 36 36 46 46 48 48
machine
Over Lock 48 48 36 36 36 36 46 46 48 48
machine
Flat Lock 48 48 36 36 36 36 46 46 48 48
m/c
Button Hole 24 24 12 12 12 12 18 18 24 24
m/c
Button 24 24 12 12 12 12 18 18 24 24
Stitching
m/c
Bar Tack 24 24 12 12 12 12 18 18 24 24
m/c
Pico ting 24 24 12 12 12 12 18 18 24 24
m/c
Zigzag m/c 36 36 24 24 24 24 36 36 36 36

Kansai m/c 36 36 24 24 24 24 36 36 36 36

Shuttle 24 24 24 24 24 24 18 18 24 24
Stitching
m/c
Two N/J 24 24 12 12 12 12 18 18 24 24
Stitching
m/c

Page 26
Machines of FKL:

Sl No Machine name Brand Origin

01 Plain machine BROTHER JAPAN

02 Over Lock machine JUKI JAPAN

03 Flat Lock m/c JUKI JAPAN

04 Button Hole m/c TYPICAL CHAINA

05 Button Stitching m/c TYPICAL CHAINA

06 Bar Tack m/c BROTHER GERMANY

07 Pico ting m/c BROTHER JAPAN

08 Zigzag m/c STAGER JAPAN

09 Kansai m/c PIGASUS CHAINA

10 Shuttle Stitching m/c PIGASUS CHAINA

11 Two N/J Stitching m/c JUKI JAPAN

3.3.6Some picture of sewing machine:

Page 27
 Figure 12: over lock sewing machine Figure 12: plain sewing machine

Figure 12: flat lock sewing machine Figure 12: snap button

3.3.7 Machine Used in Sample Section & their specification:

Total Unit: 01
Total Line: 05
Sl No Machine name Brand Origin Origin

01 Over Lock JUKI JAPAN 18

02 Flat lock JUKI JAPAN 15

03 Plain machine BROTHER JAPAN 15

04 Cylinder lock BROTHER JAPAN 15

05 Compressor machine JUKI JAPAN 18

3.3.8 Washing Section:

We believe the word SUCCESS” is the other name of “START”. This belief haunts us, as
well astakes us towards new horizons of knitwear and knitwear finishing sector. We have
included bestefficient garment washing plant that has a capacity of 40000 pcs garment
(Normal Wash) &Pigment washing 25,000 pcs garments per day.

Machine Name and Specification:

Sl No Machine name Brand /origin Capacity Total no’s
01 Garments Washing Asko/Sweden 40000 pcs/day 15
Machine

Page 28
 Figure 10: Washing section

3.3.9 Printing Section:

Printing unit is well equipped with necessary equipments including Auto Print Machine. We
arecapable to print various types including flock, discharge, emboss, and sugar print, all types
ofstone and studs heat transfer and many special types of printing. We can print 100000 pcs/day.

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 Figure 11: printing process

3.3.10 Embroidery Section:

Radiance groups Ltd. Has sophisticated computerized embroidery unit with sequins, beading &
roof embroidery. The embroidery unit is capable of 80 million stitches per day.

Sl No Machine name Origin Brand No of head Total no

1 Electric multi head Japan Tajima 20 20
automatic Machine

2 Applic Laser Cutter China Golden n/a 4

3 Fusing Machine Japan Hashima n/a 4

Total Production Capacity In Embroidery: 20,000 pcs/day.

CHAPTER FOUR: Material management

4 .1Material management

The goal of materials management is to provide an unbroken chain of components for production
to manufacture goods on time for the customer base. The materials department is charged with

Page 30
releasing materials to a supply base, ensuring that the materials are delivered on time to the
company using the correct carrier. Materials is generally measured by accomplishing on time
delivery to the customer, on time delivery from the supply base, attaining a freight budget,
inventory shrink management, and inventory accuracy. The materials department is also charged
with the responsibility of managing new launches.

4.2 Materials planning and control:

Materials required for any operation are based on the sales forecasts and production plans.
Planning and control is done for the materials taking into account the materials not available for
the operation and those in hand or in pipe line. This involves estimating the individual
requirements of parts, preparing materials budget, forecasting the levels of inventories, scheduling
the orders and monitoring the performance in relation to production and sales.
Purchasing: Basically, the job of a materials manager is to provide, to the user departments right
material at the right time in right quantity of right quality at right price from the right source. To
meet these objectives the activities undertaken include selection of sources of supply, finalization
of terms of purchase, placement of purchase orders, follow up, maintenance of relations with
vendors, approval of payments to vendors, evaluating, rating and developing vendors.
Stores: Once the material is delivered, its physical control, preservation, minimization of
obsolescence and damage through timely disposal and efficient handling, maintenance of records,
proper locations and stocking is done in Stores.
Inventory control: One of the powerful ways of controlling the materials is through Inventory
control. It covers aspects such as setting inventory levels, doing various analyses such as ABC,
XYZ etc. fixing economic order quantities (EOQ), setting safety stock levels, lead time analysis
and reporting.

4.3 Materials Management's Scope:

The scope is vast. Its sub functions include Materials planning and control, Purchasing, Stores and
Inventory Management besides others.
Basically, under its scope are:
• Emphasis on the acquisition aspect
• Inventory control and stores management
• Material logistics, movement control and handling aspect
• Purchasing, supply, transportation, materials handling etc.
• Supply management or logistics management

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• All the interrelated activities concerned with materials
Materials management can thus also be defined as a joint action of various materials activities
directed towards a common goal and that is to achieve an integrated management approach to
planning, acquiring, processing and distributing production materials from the raw material state
to the finished product state. In its process of managing, materials management has such sub fields
as inventory management, value analysis, receiving, stores and management of obsolete, slow
moving and nonmoving items. The various activities represent these four functions:
• Planning and control
• Purchasing
• Value analysis and
• Physical distribution

4.4 Raw Materials:

Yarn
The raw materials for knitting is the yarn. Different types of yarn of wide range of different count
areused. Both Carded & Combed yarn is used for knitting.
Generally used yarn & their count:
Yarn type Count
Cotton 24s, 26s, 28s, 30s, 32s, 34s, 40s
Polyester 75 D, 100 D
Spandex Yarn 20D, 40D, 70D
Grey Mélange 24s , 26s
PC ( 65% Polyester & 35% Cotton ) 24s, 26s, 28s, 30s
CVC 24s, 26s, 28s, 30s

Fabric
Radiance groups Ltd is a knit composite textile industry. In the industry fabric is used as raw
material in dyeing.
Grey Fabric
Flowing types of grey fabric are dyed
 Single jersey
 Single jersey with lycra
 Polo Pique
 Single Lacoste
 Fleece
 Interlock
 Interlock with lycra
 Rib

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  Rib with lycra
 Different types of collar & cuff

Dye Chemicals
List of chemicals used in Radiance groups Ltd.
Basic chemicals
1. Detergent & Scouring agent
2. Levelling Agent
3. Sequestering Agent
4. Salt
5. Whitening Agent
6. Softener
7. Fixing Agent
8. Reducing Agent
9. Bleaching Agent
10. Enzyme
11. Ant creasing Agent
12. PH Controller
13. Per-Oxide
14. Antifoaming agent
15. Brands are:
 Sumifix
 Boductive
 Ciba
 Livafix
 Terafix
 Supra

Remarks:
As quality is the prime concern of the factory. Qualitative raw materials are always bought by the
management of the factory. Besides there is enough space to keep those raw materials in the
factory.

CHAPTER FIVE: Production planning & sequence

Page 33
5.1 Process flow chart of knitting:

Sample fabric Design analysis

Setting the
production machine for
specific design

Quality Sample making

verification for production

Fabric
Store
inspection

Send to
batching section

5.2 End products of circular knitting machine:

 Single Jersey M/C:
a) S/J Plain.

 Melange.
 Viscose.
 CVC.
 PC.
 Stripe.
b) Single lacoste.
c) Double lacoste.
d) Single pique.
e) Double pique.
f) Fleece.
G) Lycra mini terry.
H) Waffle.

 Double jersey M/C:

a) 1*1 Rib fabric
b) 2*1 Rib fabric.
c) 2*2 Rib fabric
d) Interlock.

5.3 Production Calculation:

 Production/day in kg at 100% efficiency

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 RPM × No . of Feeder × No. of Needle × SL( mm)∗60∗24
=
2 .204∗25. 4∗36∗840× Yarn count

T∗S∗L
 GSM = ; Here, T= yarn count in tex
100
S= stitch density
L= stitch length in mm

Actual production
 Efficiency = ×100 %
Calculated Production
Calculation for S/J:
S×f×n×l×60×24
Calculated production =
25.4×36×840×2.2046×Ne Here,
RPM, S = 21.4
21.4×84×2120×2.75×60×24 Needle, n = 2120T
= Feeders, f = 84
25.4×36×840×2.2046×28
Stitch length, l = 2.75mm
= 319 Kg /day Count, Ne = 28

Actual production = 301 kg /day

Actual production
Efficiency = ×100
Calculated production

301
= ×100
319
=94%
Calculation for Lycra S/J: s×f×n×l×60×24
Calculated prodn for cotton=
25.4×36×840×2.2046×Ne Here,
RPM, s = 20.6
20.6×102×2544×2.90×60×24 Needle, n = 2544T
= Feeders, f = 102
25.4×36×840×2.2046×36
Stitch length, l = 2.90mm
= 366 Kg /day

Calculated production for Lycra :

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 20.6×102×2544×2.90×60×24
= Count, Ne = 36
25.4×36×840×2.2046×213 Again,
Count25D

= 61 Kg/day
Count= 213Ne
Total calculated production = (366+61) Kg/day
= 427Kg/day
Actual production = 350Kg/day

Actual production
Efficiency = ×100
Calculated production
350
= ×100
427
= 81.96%

Calculation for D/J:

S×f×n×l×60×24
Calculated production =
25.4×36×840×2.2046×Ne Here,
RPM, S = 21.7
21.7×75×1880×2.8×60×24 Needle, n = 1880T
= Feeders, f = 75
25.4×36×840×2.2046×28
Stitch length, l = 2.8mm
= 260.19 Kg /day Count, Ne = 28

Actual production = 183 kg /day

Actual production
Efficiency = ×100
Calculated production
183
= ×100
260.19
=70.33%

Page 36
5.4 Production parameter:

 Machine Diameter;

 Machine rpm (revolution per minute);

 No. of feeds or feeders in use;

 Machine Gauge;

 Count of yarn;

 Required time (M/C running time);

 Machine running efficiency.

5.5 Sample of various type of knitted fabric:

Figure 12: fleece fabric Figure 13: Auto stripe single jersey

Figure 14: stripe plain single jersey Figure 15: Full stripe single jersey

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 Figure 16: single jersey Figure 17: 2 x 2 Rib

5.6 Faults& their causes:

 Name : Hole mark

Cause: a. Due to yarn breakage.

b. Faulty yarn count.

c. Faulty feeder setting.
d. Badly knot or splicing.

 Name: Needle mark.

Cause: a. Due to needle breaks during the knitting cycle.

b. If a needle or needle hook is slightly bends then needle mark comes on the fabric.

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 Name: Sinker Mark.

Cause: a. when sinker corrodes due to abrasion the sometimes cannot hold a new loop as a
result sinker marks comes.
b. If sinker head bend then sinker mark comes.

 Name: Star mark.

Causes: a. Yarn tension variation due to production.

b. Buckling of the needle latch.
c. Low G.S.M fabric production.

 Name: Drop stitches

Causes: a. Defective needle.

b. Take down mechanism too loose.
c. Insufficient yarn tension.
d. Improper setting of feeder.

 Name: Oil stain

Causes: a. when oil lick through the needle trick then it pass on the fabric & make a line.
b. Excess oil pressure in the oil line.

 Name: Rust stain.

Causes: If any rust on the machine parts.

 Name: Pin hole.

Causes: Due to break down or bend of latch, pin hole may come in the fabric.

 Name: Lycra contamination

Causes: a. improper tension.

b. Dust deposit in the pull
 Name: Yarn contamination

Causes: a. If yarn contains foreign fibre then it remains in the fabric even after finishing.
b. If lot, count mixing occur.

Page 39
5.7 Different types of faults:

Defect Image
Holes

Barrie

Broken needle

Dropped stitch

Fly

Oily yarns

Knots

Thin yarn

Page 40
5.8 Process flow chart of dyeing:
Checking challan
Received from Dia wise batch
with order sheet
knitting challan in batching formation

Squeezing Dyeing
Compactio
Stanter n
QCcheck

Qc pass Reject/
doods Defect

Delivery

5.9 Dyeing Lab

According to recipe preparation of salt, soda color

Preparation of solution

Fabric normal wash

Fabric dyeing with solution

Wash

Fabric dry

Shedding check

If not approve, need to check recipe & re-dye

Buyer approve

Work order for sample

Page 41
5.10 sample dyeing flow chart

Work order for bulk

Recipe

Dye

Shedding check

Sample approve

5.11 bulk dyeing flow chart

Work order for bulk

Batching

Bulk dye

Finishing

Delivery

Page 42
5.12 Dyeing process for bulk:

Cotton dyeing

Demineralization

Scouring & bleaching-95c x 60

Normal hot wash- 70c x 20

Acetic acid- 50c x 20

Enzyme wash -50c x 60

Normal wash- 70c x 20

Dye Bath-60c x 20

Color dosing-60c x 30

Run at-60c x 30

Salt dosing-60c x 20

Run at-60c x 15

Soda dosing-60c x 15

Run at -60c x 15

Swatch cutting

Rinsing 10 min

Normal wash 40c x 10

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 Hot wash-95c x 30

Acetic Acid-50c x20

Fixing-40c x20

Softener-40c x 30

Unload

5.13 polyester dyeing process

Demineralization

Scouring & bleaching-95c x 60

Normal hot wash- 70c x 20

Acetic acid- 50c x 20

Dye Bath-60c x 20

Color dosing-60c x 30

Heating up to -130c x 60

Reduction -80c x 20

Enzyme wash-80c x 20

Dye bath-60c x 20

Color dosing-60c x 30

Page 44
 Run at-60c x 30

Salt dosing-60c x 20

Run at-60c x 15

Soda dosing-60c x 15

Run at -60c x 15

Swatch cutting

Rinsing 10 min

Normal wash 40c x 10

Hot wash-95c x 30

Acetic Acid-50c x20

Fixing-40c x20

Softener-40c x 30

Unload

Page 45
5.14 Process flow chart of cutting:

Receive
from dyeing
Relaxation Dia check

Marker Marker received

from CAD
check

Lay strat &

complete
Marker cetting
and check cutting

Bundling Numbering

Cut panal Qc pass

check reject/defect

5.15 Process flow chart of sewing:

Received Style wise

from cutting lay out

Machine
Input clean

Process Process
Work check

Complete
Send garments

Check
table

Page 46
5.16 Procedure of IE department in Garments section:

Technique to improve productivity –

 Method study.

 Time study.

 Motion economy.

 Financial & non-financial incentive.

 Value analysis.

 Production planning & control.

 Inventory control.

 Job evaluation,

Method study & Time study is very important to improvement of the production. Industrial
Engineering (IE) & planning department is doing this job. They have many responsibilities to
improve the production. They give the layout & machine arrangement of all particular style. They
give the target of all individual workers & helpers & also take there achievement. For a new style
they give the target by doing the SMV calculation of all individual workers. Then they give the
line target. They make a machine layout that means they find out how many machines are needed
to make it complete. They try to do this as a standard. Then they find out the total SMV for that
style from the previous record. Then also take line efficiency for that particular style. This
efficiency is varies from style to style. Simple style’s efficiency is high near about 85/90 % & for a
critical style efficiency is low. It may be 50-55%.

Page 47
Functions of planning department –

 Production planning.

 Work study.

 Time study.

 Method study.

 SMV calculation.

 Individual target giving.

 Line target giving.

 Daily efficiency reporting.

 Problem finding.

 Reporting for solving the problem.

 Schedule making to meet the lead time.

5.17 Target Calculation –

Machine / Operator – 15
Helper – 10
Total SMV – 7 (Standard Minute Values)
Efficiency – 70%
Formula – [{(60 / Total SMV) x Total worker} x 70 %]
So = [{(60/7) x (15+10)} x 70 %]
= [{8.57 x 25} x 70 %]
= [214.25 x 70%]
= 149.97
= 150 pcs/hr

Page 48
 CHAPTER SIX: Quality Assurance
6.1 Quality Assurance:
Radiance grop is more concern about quality. In this factory quality assurance is more preferred
than quality control, but both are in advancement. The Quality Assurance Department is assigned
to maintain consistently uniform quality of the material in process and various stages of its
manufacturing

6.2 Objects of quality control:

 Research.
 Selection of raw materials.
 Process control.
 Process development.
 Product testing.
 Specification test

6.3 Scope of quality control, quality assurance and testing:

 Testing Lab
 Machine auditing system
 A good training system.
 Excellent analytical backup.
 Technical expertise
6.4 Quality assurance Procedure:
 On line quality control
 Off line quality control
Off-Line Tests:
Physical Tests: Chemical Tests:
Threads per inch Fastness to washing
Fabric weight Fastness to light
Width test Fastness to heat
Tensile strength Fastness to actual laundering
Tear strength Fastness to sea water
Seam slippage Fastness to Chlorinated water
Abrasion resistance Fastness to water spotting
Pilling resistance Fastness to perspiration
Thermal stability
Crease resistance
Stretchability& growth recovery

Page 49
 Yarn Processing
(Yarn test)

Pass Fail

Knitting
Send to spinning mill

Grey fabric inspection

Pass Fail

Grey store
Send to store as reject
Batch making

Fail
Dyeing Shade check
Redyeing

Pass
Finishing

Fabric checking
Physical Lab Inspection Shade

Fail
Pass

Delivery Reprocess reject

Send to store as reject

Figure 18: Quality control flow chart

6.5 Activities of Quality Department:

In laboratory:

> Prepare swatch card from buyer according to their requirement,

> Recipe prediction for sample dyeing,

> Sample dyeing until matching with swatch card,

> Fastness & other tests of the fabric or yarn are done her

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In dyeing section:

>According to the buyer's sample, sample dyeing is done in sample dyeing Machine in dyeing
shed &again matched with the approved sample.

>If result is OK then bulk production.

>During dyeing, samples are taken until accurate shade matching. The interval may be 30-40 min.

>After dyeing sample is collected after softening matching is done.

>Then sample is collected after fixation & matched.

>Then allowed the fabrics to be finished.

In finishing section:

1. By using a series of finishing Machines correct width, softness & appearance are maintained
according to requirements.
2. Then sampling is done for several times to test GSM, shrinkage & fastness properties
3. Finally fabric is inspected &prepared for delivery.

Physical Test & Chemical Test:

1. Tensile strength
2. Tearing strength
3. Lycra property
4. Piling test
5. Abrasion test
6. Rubbing test
7. Fabric width
8. Fabric GSM
9. Count
10. Seam Slippage

Fabric GSM:

 Machine used: GSM cutter

 Performance standard: According to buyer's standard

 Procedure: 3 samples are cut with GSM cutter. Find their average
GSM

Page 51
Width test:1. Machine used: Measuring tape. 2. Procedure: Manual measurement by tape

Tensile strength:

 Machine used: Titan universal Strength Tester.

 Manufacturer: James H. Heal & company, Halifax, England

 Procedure: A sample of 20cmX10cm is taken and placed on jaws of

the Machine. Machine increase its 4.pressure on the sample until it

breaks down. Final applied pressure is shown on the display

Tear strength:

 Machine used: Tearing Tester

 Procedure: A sample of 10cm*6.3cm is taken and placed on the jaws

of machine. Jaws move opposite and tears the sample. Force applied

is shown on the display.

Seam slippage:

 Machine used: Titan universal Strength Tester.

 Manufacturer: James H. Heal & company, Halifax, England

Abrasion resistance:

 Machine used: Nu-Martindale Abrasion & pilling Tester.

 Manufacturer: James H. Heal & company, Halifax, England

Procedure:

 At first cut the fabric into 4 pieces according to the

measurement of the instrument.

 Weight these 4 pieces of fabric samples.

Page 52
  Now place these samples in the instrument under a certain

load as supplied in the instrument.

 Now start the machine and observe the counter of abrasion no.

 After an abrasion of 200 bring out the first sample and weight it.

 After an abrasion of 300 bring out the second sample and weigh it.

 Similarly after abrasion of 400 and 500 bring out the third

and fourth sample and take their weight.

 Now put the weights before and after abrasions in a table

and find out their wear index.

Fastness to wash:

 Fabric size: 10cm x 4 cm

 Temperature: 60°C

 Time: 30min.
 Chemical: Soap or detergent & soda.

 Operation procedure:

A) Adjust the Machine to maintain the required temperature & time as test required,

b) Pre heat the canister & steel ball to set the temp, of the Machine,

c) Check the temp, by using thermometer,

d) Pour the container with the detergent,

e) Place the sample with adjacent fabric

f) Clamp on the cover & fasten the canister vertically into the color of the Machine,

g) Start the Machine,

Page 53
h) Stop the Machine when the buzzer on after completion of the test,

Fastness to water:

 Machine used: Per spirometer chemical kit &carbolite incubator.

 Fabric size: 10cm x 4 cm
 Temperature: 37°C
 Time: 4hrs.
 Chemical: No chemical used.

Fastness to perspiration:

 Machine used: Per spirometer chemical kit &carbolite incubator.

 Frequency: Whenever required.

 Fabric size: 10cm x 4 cm

 Temperature: 37°C

 Time: 4hrs.

 Chemical: Acid, Alkali & Sea water.

Fastness to rubbing:

 Machine used: Crock meter.

 Manufacturer: James H. Heal & company, Halifax, England.

 Procedure : Take sample fabric , mount it on bed of crock meter, take another white

bleached sample of 5cmX5cm and mount it on the finger of crock meter and rub it against sample

fabric for 10 seconds and 10 cycles

 Remove the specimen and take a wet sample and rub it against the fabric sample following

above procedure

 Compare two samples using grey scale.

Page 54
pH:

 Machine used: pH meter.

 Procedure: After production, collect 4m of fabric sample & dissolve in hot distilled water
of 200ml, then the sample with water is conditioning & test in the pH meter.

List of Equipment’s/ Machines used in QA

 GSM Cutter

 Electric Balance

 pH meter

 Crock meter

 Micro-Woven

 Titan universal strength tester

 Elmatear James H. Heal Digital Tear Tester

 Nu Martindale Abrasion & Pilling tester

 Incubator

 Spray Tester

 Gyrowash James H.Heal

 Whirpool washing machine

 Whirpool Drying machine

 Orbitor Pilling & Snagging Tester

Page 55
 CHAPTER SEVEN: Maintenance

Maintenance is the process by which equipment is looked after in such a way that trouble free.
Services and increased machine life can be ensured and specific product quality required by the
customer is sustained. Maintenance can increased machine life and ensured trouble free service

Objectives of Maintenance:
 To keep the factory plants, equipment’s, machine tools in an optimum working
condition.
 To ensure specified accuracy to product and time schedule of delivery to customer.
 To keep the downtime of machines to the minimum thus to have control over the
production program.
 To keep the production cycle within the stipulated range.
 To modify the machine tools to meet the need for production

7.1 Maintenance of Machinery:

Maintenance

Preventive Maintenance Routine Maintenance Corrective Maintenance

Mechanical MaintenanceElectrical MaintenanceMechanical MaintenanceElectrical MaintenanceMechanical Maintenance

Electrical Maintenance

Preventive Maintenance:
Preventive Maintenance is a predetermined routine actively to ensure on time inspection or
checking of facilities to uncover conditions that may lead to production break downs or harmful
description.
Routine Maintenance:
Maintenance of different machines is prepared by expert engineers of the maintenance department.
Normally in case of dyeing machine maintenance after 30 days complete checking if different
important parts are done.

Page 56
Corrective Maintenance:
Corrective Maintenance is done after a failure has occurred. Radiance group. Has an expert team
for maintenance. When problem occurs they actively solve the problems

7.2 Maintenance Procedure:

As a part of maintenance normally Radiance group. Follows preventive maintenance. During
maintenance procedure following points has to be checked.
Maintenance : Mechanical
Machine : Dyeing

S/l No. Items need to be checked and serviced

1 Complete cleaning of machine

2 Check air supply of the machine

3 Cleaning of inside of the m/c

4 Greasing of unloading roller bearings

5 Check water supply of the machine
6 Checking of cooling valve
7 Checking of steaming valve
8 Checking exhauster
9 Checking of heat exchanger

Maintenance Electrical:
Machine: Dyeing
S/l No. Items need to be checked and serviced

1 Check all motor terminals.

2 Check main panels.

3 Clean main inverter.

4 Check all circuit breaker.

Page 57
 5 Check all pressure switches.

Notes:

The maintenance department of Radiance group is well equipped. It has sufficient

maintenance manpower including mechanical and electrical engineers. They perform
maintenance tasks of the machines during the holidays and vacations. Otherwise, they
perform breakdown maintenance.

7.3 Preventive maintenance check list sample

Preventive maintenance Check list of Boiler:

Mechanical Checking list

SL Items Types and Weekly Monthly Half

No: description of yearly
maintenance/service
1 Boiler Visual inspection 
2 Header steam valve Checking 
3 Steam pressure gauge Visual inspection 
& gas pressure gauge
4 Softener Checking softing  
water
5 Burn air dumper& Checking & cleaning 

Page 58
 modulating link
6 Valve of feed water Checking & cleaning 
line
7 Airline net & gas Checking & cleaning 
filter
8 Water level control Checking & cleaning 
system
9 Ignition electrode Opening , cleaning 
and reset
10 Gas line solenoid Checking & cleaning 
valve, auxiliary
switch, thermo static
control
11 Boiler tubes Open manhole, 
checking boiler tube
12 Safety valve Checking & greasing 
13 Blow down valve and Checking & greasing 
system
14 Hydrolic test Hydrolic test pump 
15 Smoke tube Cleaning by brush 
&Chamber

7.4 Preventive maintenance Check list of Gas Generator:

Electrical Checking:-

SL Items Description of Maintenance Weekly Monthly Yearly

NO:
1 Indicating lamp Visual inspection 
2 Ignition coil Visual inspection 
3 Air pre cleaner lamp Check per cleaner filter if 
red signal
4 Battery changer Checking 
5 Ignition cable: Visual inspection 
primary and secondary

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 cable
6 All connection Checking & tighten 
7 Engine protection Test & calibration 
device
8 High tension wires Checking & replacing if 
needed
9 Ignition primary Checking & replacing if 
terminals needed
10 CEC Ignition module Cleaning & inspection 
timing disc magnets
12 Costume engine Inspect harness connection 
control detonation &groud wire
sensing module
13 custom engine control Inspect harness connection 
air &groud wire
14 Water pump Inspect harness connection 
&groud wire
15 Motor Checking & cleaning 
16 Panel Board Paint if needed 
17 Motor (cooling tower) Checking, cleaning& 
tighten if needed

7.5 Maintenance work request form:

Radiance group wears Ltd maintenance department always moves on systematic way.
When they change any parts of a machine they fill up a maintenance request form.
A sample of a maintenance work request form with example:

Maintenance work request form

Requested by:
____________________________ Post ______________________

Date: _ _ _ __ _ _ __ _ _ _ _ _ _ _ _ _ _ _ _ Unit/ section __________

Machine:

Problem _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __

_ _by_ __ _ __ _ __ _ __ _ __ _ __ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
Requested form receive

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Date: _ _ _ _ _ _ _ _ __ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Time ________________

Machine handed over to _ _ _ _ _ _ _ _ _ _ ___ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

Date: _ _ _ _ _ _ _ _ __ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Time ________________

CHAPTER EIGHT: Utility services

8.1Available Utility Facilities:

 Electricity
 Gas
 Water
 Compressed air
 Boiler etc.
Gas:
Mainly gas is delivered from TITAS. It is mainly used for steam production. Generally 36 m3 gas
is required to produce 1 ton of steam.
Boiler:
Boiler is mainly used to produce and deliver steam to different section as required.

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 Figure 19: Boiler machine

8.2 Problem associated for hard water in boiler:

1. Scale formation in boiler:

Ca(HCO3)2 Ca CO3 + CO2 + H2O

Mg (HCO3)2 Mg CO3 + CO2 + H2O

MgCO3 + H2O Mg (OH)2 + CO2

CaCO3 + Mg (OH)2 Boiler scale

Scale thickness Heat loss (%)

1 mm Approx 10
3 mm Approx 17
5 mm Approx 22
10 mm Approx 30
20 mm Approx 43

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 2. Reaction with soap:
RCOONa + MgSO4 (RCOO)2Mg + Na2SO4
RCOONa + CaSO4 (RCOO)2Ca + Na2SO4

3. Corrosion of boiler:
Fe + H2O + CO2 Fe CO3 + H2

FeCO3 + H2O Fe(OH)2 + CO2

Five Boilers have been use by Radiance group Ltd.

Model Serial no Brand Country Type Total no’s

DDHI 5.0-10 188/9 Omnica Germany 2
Fire tube
UL-S-1000 103730 Loos Germany 3

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8.3 Power plant:

Figure 21: Operating panel Figure 20: water supply to power channel

Our Country’s most important issue is power sector. The government faces lots of problem for
supplying the power for industrial sector. Considering all these, at the very beginning of
establishment of Radiance group wears Ltd; Radiance group Ltd. using their own power generator.
They have vast setup for the own power source and generating 24 hour power system to
successfully running our whole project. They have:

Electricity:
The main utility electricity is supplied by generator.

Gas Generator:

Total Manufact Volt RP Hz A KV KW Generate/ Used Duty Origi

No’s urer s M A Day) /Day n
04 Waukesh 415/ 1000 50 1565 1125 900 3.6 Mw 2.8 Conti USA
a Power 24 MW nuous
Systems hrs.

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 Figure 22: Power supply

Total power is then distributed as per requirements of different section like knitting, Dyeing (yarn/
fabric), Finishing, Maintenance, WTP, ETP etc.

8.4 Compressor:

Compressor is mainly used to deliver compressed air to different section as required. In

Radiance group Ltd. they used compressors to produce and deliver compressed air to different
section.

Name Model Brand Country of Total Total No. of

Origin No’s Reserve Tank
Dryer ASD-147 Kaeser Germany 5

02
Compressor (Big) CSD-102 Kaeser Germany 5
Compressor (Small) TEL-141 Kaeser Germany 5
Generator VHP5904GSID WAUKESHA U.S.A. 6

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 CHAPTER NINE: Store & Inventory Control

9.1 Store and Inventory Control:

1. Raw materials 
a) Dye store
b) Other chemicals
c) Gray fabric
d) yarn
2. Finished fabric
3. Spare parts

9.2 Frequency of Inventory Update:

1. Monthly inventory control
2. Annual inventory control

9.3 Inventory Control System for Raw Materials:

Dye store & other chemicals store 

 Both of these are received by the store in charge.
 First he sends these to quality in-charge for inspection. If they are found to be of required
quality then they are taken to store by the storekeeper.
 Store in-charge supplies these when required and records the date, type of material, quantity
and section in which supplied, in his register book.
Grey fabric store 
 Grey fabric is usually stored in another storeroom, which is separate from dyeing shade.
 Grey fabric is first sent to the QC department for quality assurance and then taken to the
storeroom.
 Grey fabric is received by fabric store in-charge.
 He supplies the fabric as per requirement and records the date, type of material, quantity and
section in which supplied, in his register book.

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Yarn 
 Both of these are received by the store in charge.
 First he sends these to quality in-charge for inspection. If they are found to be of required
quality then they are taken to store by the storekeeper.
 Store in-charge supplies these when required and records the date, type of material, quantity
and section in which supplied, in his register book.

9.4 Inventory Control System for Finished fabric:

 Finished fabric from the compactor or stenter goes to inspection team. Here inspection is done
by a four points system.
 Required GSM, width (diameter), shrinkage, Spirality, wash fastness, rubbing fastness etc are
tested from the lab before packaging.
 After finishing the fabric is kept in package before their transfer to the garments department.
 It is controlled by the finishing in-charge who keeps a list of total finished product. He also
keeps a list of delivery products.
 He supplies the fabric as per requirement and records the date, type of material, quantity and
section in which supplied, in his register book.

9.5 Inventory Control System for Spare Parts:

 Spare store officer keeps the spare parts in store and makes a list of spare parts.
 If the spare parts are little in stock he gives requisition to maintenance manager.
 Maintenance manager gives requisition to head office. Head office imports spare parts or buys
from local market as per requirement.
 As new spare parts arrive to store officer, he receives and catalogues them.
 He supplies the spare parts as per requirement and records the date, type of material, quantity
and section in which supplied, in his register book.

Note: Radiance group Ltd. Maintain their store and inventory control very carefully.

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 CHAPTER TEN: Cost analysis

Cost analysis in garment Manufacturing, as the topic implies, deals with the work of Costing a
garment which involves the expenses for fabric, trims, cuttings, labor, overhead, sales
commission, manufacturer’s profit & transportation. The production cost of the garment must be
determined in order to set the wholesale price, the price that retailers‟ pay for goods that they
purchase from manufacturers.

10.1 Sample Calculation Sheet

Materials: First the total amount of fabric needed for the garment is estimated and then multiplied
by its cost per meter to find the total material cost per garment. Since higher volume allows more
flexibility in making the marker and thus a more efficient use of fabric, material cost is somewhat
reduced for high volume styles, while extra expenses has to be allowed for low- volume styles.
Trimmings: Unit costs are multiplied by the amount of trimmings needed for each garment.
The sum of these figures is the total trimmings cost per garment.

Production, patternmaking, grading & marking: Most companies allow for these costs in
general overhead that also covers the design department. However if these functions are performed
outside by pattern service, the total cost is divided by the no. of units they estimate will be cut to
find the cost per unit. If the garment is later re cut there will be no new cost for patterns and
grading.

Spreading & cutting: The cost for cutting done in house is based on the cutters hourly wage
multiplied by the no. of hours it take to cut the style and divided by the no of units cut. If the
cutting is done by a contractor, the total negotiated cutting cost is figured on the no of garments to
be cut. The contractor adds his/her fee to this amount.

Assembly Construction: Labor includes all sewing including finishing

Freight: The cost of shipping completed garment from the contractor to the manufacturer must be
calculated. For domestic shipments, the garments are usually trucked. If the garments are
imported, then a percentage of the air or sea fright cost must be added to the cost of each garment.
Obviously, the sea transportation is cheaper and therefore, adds less cost to the garment, but

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valuable lead time is for forfeited. The cost of shipping garments to the retailer is generally paid
by the retail store. But manufacturers must pay air freight if they are late with their delivery.
Additional Cost for imported garments: This includes the quota charge and import duty and
agent fee.

Duty and Quota: In the case of imports, there are additional cost for duty and quota. These are
included if a „package‟ price is negotiated. Costing is undertaken by costing department and staff
working in close conjunction with the company cost accountant and receiving his technical
instruction from the designer.

10.2 Sample Calculation (Image form)

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 CHAPTER ELEVEN: Marketing activities

11.1 Duties and Responsibilities of Commercial Department

The function of commercial department starts with receiving master LC and the cycle completes
With realizing Master LC and receiving Cash benefits in the form of cash incentive. During this
cycle, all relevant export and import documents are collected and prepared and submitted to
relevant authorities. The tasks and responsibilities are mainly organized based on Import and
Export works. These are highlighted below.
Export
1. Collection of Master LC: How an LC is received from buyer through mail to advising bank,
functions of issuing bank, functions of advising bank, functions of negotiating bank, negotiation
with banks.
2.Study Master LC: Key components of an LC, terms and conditions, LC value, beneficiary,
applicant, partial shipment, transshipment, penalty clause, Pro forma Invoice,
Uniform Customs rules and Practice (UCP-600), making amendment, undertaking, contacting with
both advising and beneficiary bank.
3. Obtain Workable LC: Confirming terms and conditions, informing buyer and beneficiary bank.
4.Yarn and Fabric Consumption: Calculation of maximum values for back-to-back LC for both
deemed and direct export, Planning yarn requirement for garments production placing order for
yarn, cash incentive facility, bonded warehouse facility, duty drawback facility, consumption
template for fabric and accessories.
5. Plan Yarn BBLC: Planning back-to-back LC by receiving yarn and fabric consumption,
preparing entire set for opening back-to-back LC.
6. Open BBLC: Contacting with supplier for PI, submitting back-to-back application along with
necessary documents.
7. Update OTS: Updating LC information in Kandaree software.
8. Preparing Export documents: Preparation of entire set of documents for submitting to
beneficiary bank for the realization of LC proceeds. Preparation of commercial invoice,
preparation of packing list, receiving Bill of lading, contacting with clearing and forwarding agent,
getting clearance from customs, contacting with shipping
9. Agent for vessel booking, receiving regular production updates for exact date of shipment,
preparation of GSP documents, Non-negotiable documents, preparing utilization declaration for
bonded warehouse facility.

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10. Cash Incentive: Collecting proceeds realization certificate, collection of export documents,
Master LC, certificate of origin, certificate from domestic yarn supplier, utilization declaration,
providing support to audit.

Import
1. Obtain Fabric Requirement: Getting requirement of fabric for calculating requirement of
Yarn and placing order for yarn.
2. Plan Yarn BBLC: Calculation of consumption of yarn, receiving wastage calculation.
3. Open BBLC
4. Enter BBLC Data in OTS
5. Collect Fabric LC: Intercompany transaction between H.R. Textile Mills and Fashion
Knit Garments Limited for issuing and receiving fabric LC.
6. Open Yarn LC and Enter Data
7. Send Yarn LC and Enter Data: Sending back-to-back LC to supplier for yarn
9. Monitor and Confirm Transit Time: Receiving pro-forma invoice, issuing bill of
Exchange, receiving counter-signed delivery Challan, releasing payment for back-to-back
LC.
10. Prepare Clearance Papers: Giving acceptance for realizing payment by suppliers

11.2 Duties and Responsibilities of Accounts Department

A. Export-Import Related Tasks

1. Checking the status of ongoing LC

2. Verifying and identifying correction of Import and Export Vouchers
3. Preparing Fabric and Accessories consumption
4. Export documentation negotiation
5. Making adjustment and realization
6. Making Import payment
B. Record-Keeping Tasks
1. Subcontract and local bills entry into the system
2. Maintaining monthly, half yearly and yearly accounts for audit purpose
3. Preparing monthly report for management
4. Preparing financial reports and statements
5. Submitting verified and corrected vouchers to audit
6. Keeping records of bills payable and receivable in the system

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C. Budgeting

1. To meet working capital requirement.

2. To meet petty expenditures.
3. To meet procurement purpose.
4. To meet outstanding expenses.
5. To make LC payment.

>LC
Export

• Collection of Master LC
• Study Master LC
• Obtain Workable LC
• Update OTS
• Yarn and Fabric Consumption
• Obtain Fabric Requirement
• Plan Yarn BBLC
• Open BBLC
Import

• Obtain Fabric Requirement

Plan Yarn BBLC
• Open BBLC
• Enter BBLC Data in OTS
• Collect Fabric LC
• Open Yarn LC and Enter Data
• Send Yarn LC and Enter Data
• Monitor and Confirm Transit
Time
• Prepare Clearance Papers
• Clear Goods by C&F
• Obtain UD and Enter Data
>Documentation and Forwarding
Fabric export documentation:
• Bill of Exchange
• Packing List
• Certificate of Origin
• Delivery Challan
• Truck Challan
• Export Permit
• Commercial Invoice

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Major Buyer

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 CHAPTER TWELVE: Others

12.1 Water Treatment Plant:

Water for a textile plant may come from various sources. But this water cannot be used directly in
textile processing because it contains various salts. These salts are mainly the carbonates (CO 32-),
Hydrogen carbonates or bi-carbonates (HCO3-), Sulphates (SO42-) and Chlorides (Cl-) of Calcium
(Ca2+), and Magnesium (Mg2+). These are called hardness in the water. These must be removed
though water treatment plant.
Water is supplied in different sections continuously by using submersible and centrifugal pumps.

Methods of expressing the water hardness:

1. In Degrees, and
2. PPM (parts per million)

Hardness measurement calculation:

Required EDTA * 1000 * EDTA factor

PPM=
Total amount of water

12.2 There are different types of water softening process:

1. Soda lime process.

3. Base Exchange process.
4. Demineralization.
5. Soda alum process.
6. Aeration process.
7. Chelation on sequestration.

In Radiance group Ltd. follow the base Exchange water softening process for softening the hard
water.

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12.3 Base Exchange process:

This methods depends upon the use of zeolite or Base Exchange complexes. The zeolites are
hydrated silicates of sodium & aluminum with a general formula.

(Na2O)X (Al2O3)Y(SiO2)Z (H2O)n

The following reaction occur when contact with hard water.

For temporary hardness,

Ca (HCO3)2 + Na2O.Z CaO.Z + Na2CO3 + H2O

Mg (HCO3)2+ Na2O.Z MgO.Z + Na2CO3 + H2O
For permanent hardness,
CaSO4 + Na2O.Z CaO.Z + Na2CO3
MgSO4 + Na2O.Z MgO.Z + Na2CO3
In where Z is the abbreviation for the Al2O3 SiO2 H2O part of Zeolite.
Regeneration:
1 kg resin required = 200 gm salt
Salt : water = 1 kg : 4.5 L
Used water = 6500000 Ltr/Day
CaO.Z + NaCl NaO.Z + CaCl2

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The CaCl and residual NaCl washed away and the regenerated Na2O.Z can be used to soften the
hard water again.

Figure 23: water bowler Figure 24: water bowler

Figure 25: water storage line

Figure 26: Direct water line

Water hardness test:

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Water hardness test equipment and chemicals
1. Buffer
2. Indicator
3. EDTA solution
4. 50 ml biker
5. 200 ml biker
6. Syringe

Figure 27: Hanna hardness tester kit

12.4 Effluent Treatment Plant:

Effluent is the stream of excess chemical liquor extracted from an industry after using in original
operation. In the case of dyeing industry, the excess dye liquor extracted from textile industry after
dyeing is an effluent of that industry.

Radiance groupwear’s Ltd commitment to the environment can be gauged from the fact they seek
to meet all the legal norms. Taking for instance the establishment of ETP & WTP because they
have, nothing is more important than the maintenance of pollution-free environment. Radiance
groupwear’s Ltd. Establish an ETP plant which is the biggest and no.1 ETP plant in Bangladesh.
12.5 Knowing the different steps

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 Figure 28: Screener

The main aim of screener is to remove trash, garbage etc.

Ex: polythinbag, paper, wastage fabric etc

Figure 29: storage tank

Here all type of water is mixed through the air flow.

EX: different stage of dyeing drain water

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 Figure 30: Biological oxidation tank

Here, Energy-producing reactions in living cells involving the transfer of hydrogen atoms or
electrons from one molecule to another.

Figure 31: Distribution tank

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 Figure 32: Distribution tank

Figure 33: pH reader & Neutralization tank

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 Figure 34: Blower

Figure 35: Air filter blower

This machine used to produce air flow in the whole process. In this tank store sludge, water is
discharge from here for this reason sedimentation of sludge. Sludge are remove from here after 15-
20 day, that time is look like a cake is called sludge cake.

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12.5 Process sequence:
Screen brush

Lifting pump unit

Storage tank

Neutralization tank

Distributor tank

Biological oxygen tank

Sedimentation feeding tank

Sedimentation curve

Sludge return pump slump

Sludge thickener

Filter press

12.6Used chemicals:
 Sodium hypochlorite
 Nutrient salt
 Anti-foam
 Sulphuric acid
 Poly electrolyte
 decolorant

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12.7Testing lab instrument:

 microscope
 BOD sensor system
 Thermo reactor
 Spectrophotometer
 Digital muffle furnace
 Portable DO meter
 Portable DO meter
 Micro-processor PH meter
 Electrical balance

12.8Waste Water Treatment Plant (WWTP)

Parameter Unit Conc. Present Dept. of environment

govt. of Bangladesh
Inlet Outlet
BOD PPM 281 23 50
COD PPM 730 56 200
TDS PPM 2730 1811 2100
TSS PPM 204 31 150
EC PPM 5210 3403 1200
DO PPM 0.1 4.6 4.5 – 8
Chloride PPM - >200 600
Phosphate PPM 2.6 2.2 8
Nitrite PPM 0.15 0.08 50
Nitrate PPM 0.9 0.6 10
Ammonium PPM 0.09 .07 5
Sulphate PPM - 27 -
Arsenic PPM - - 0.2
Cobalt PPM - - -
Cynanide PPM - - -
PH - 10.2 7.8 6–7
Tepm. °C 41 37 40
Cadmium PPM - - 0.05
chromiun PPM - - 0.5

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12.9 Safety and security

Radiance groupwear’s Ltd. has a mission to fulfill by surpassing all the requirements of
Humanitarian Management & to make its working environment a role model for others as "A
BETTER WORKING PLACE" and unique in its field. Radiance group Ltd. do and will continue
to operate the factory in FULL COMPLIANCE with all the applicable rules and regulations of
native land as well as international standard. For improving the working conditions and setting a
better working place.

12.10 FKL is maintaining the following COC issues:

*Prohibition of Child Labor.

* Prohibition of Forced labor.
* No Discrimination.
* Occupational Health & Safety (OHS).
* Disciplinary Practices/ Harassment.
* Freedom of association and right to collective bargaining.
* Welfare facilities

Some basic lows:

Prohibition of Forced Labor:
The Company does not practice any type of forced labor and also does not support such practices.

Prohibition of Child Labor:

As per company policy, no individual below 18 years of age is recruited.
No Discrimination:
FKL employ and pay workers and provides benefits without regard to
race,color ,nationality, religion, age, maternity or marital status. Radiance group Ltd. Ensures
equal treatment for all workers in all matters.

12.11 OHS Management:

Radiance group Limited treats all workers with respect and dignity and provides them with a safe
and healthy environment. Factory complies with all applicable laws and international standard and
RMG industry standards of safety measurement to ensure a safe working environment. It
developed a complete trained safety team supervised by MR to ensure the secured safe and healthy
working environment in factory premises. Company directly mandates the provision of safe
working conditions. It ensures that working place is free from hazards and risks that may cause
any type of physical harm.

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12.12 Disciplinary Practices/ Harassment:

As a company policy the environment must be free of harassment, abuse or

corporal punishment.
Compliance means conformity of certain standard. FKL maintain a moderate
working condition for their employees. Though it is well established project, there is some lacking
of proper compliance issues. Here is list of compliance in which some points are maintained fully
and some are partially.

► Leave with wages.

► Health registers.
► Time care.
► Accident registers.
► Workman registers.
► Equal remuneration.
► National festival holiday.
► Overtime register.
► Labor welfare.
► Weekly holiday fund.
► Sexual harassment policy.
► Child labor abolition policy.
► Anti-discrimination policy.
► Zero abusement policy.
► Working hour policy.
► Hiring /recruitment policy.
► Environment policy.
► Security policy.
► Buyers code of conduct.
► Health and safety committee.
► Canteen.
Health –
 Drinking water at least 4.5 L/day/employee.
 Cup availability.
 Drinking water supply.
 Water cooler, heater available in canteen.
 Drinking water signs in Bangla and English locate min. 20 feet away from
work place.
 Drinking water vassal cleans at once in a week.
 Water reserve at least once a week.
 Water center in charge person with cleanliness.

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  Suggestion box register.
Toilet –
 Separate toilet for women and men
 A seat with proper privacy and lock facility
 Urinal accommodation
 Effective water sewage system
 Soap toilet
 Water tap
 Dust bins
 Toilet white washed one in every four month
 Daily cleaning log sheet
 No-smoking signs
 Ladies /gents toilet signs both in bangle and English
 Deposal of wastes and effluent
Fire –

 Sufficient fire extinguisher and active

 Access area without hindrance
 Fire signs in both languages
 Fire certified personal photo
 Emergency exit

Safety Guard
 Metal glows on good condition
 Rubber mats & ironers
 First aid box one
 Ironers wearing sleepers
 First trained employees
 Motor/needle guard
 Eye guard
 Nurse
 Doctor

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  Medicine
 Medicine issuing register
 Welfare officer

Others
 Room temperature
 Lighting facilities

Note:Radiance group Ltd. Social activity very good

Figure 36: Fire Extinguisher

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 Impact of the Internship

We can say that this internship report is really essential for every student of Wet Processing
student to get idea about textile industry. By completing this report we have got overall idea of
dyeing industry and these may be helpful to know about the technical and management knowledge
of dyeing industry. We want to thank my department Head for giving me great opportunity of
learning. This Internship program will help me in the further challenges of life. We try our best to
make this project enriched with lots of dyeing related documents. RADIANCE GROUP is well
equipped and the working environment is excellent.

The relation between top management to bottom level is so nice. The factory runs by a number of
efficient Textile Engineers, Skilled technical & nontechnical persons. All the Textile Engineers,
technical & non-technical persons are very sincere, co-operative and helpful. RADIANCE
GROUP is really a good experience for me because every person of there so much helpful and
give me the proper methods of practical learning. So, at last, there is a hope of eradicating all the
obstacles and become the leader of dyeing industries in near future. The completion of the two
months industrial attachment at this industry gave us the inspiration that factory is one of the
appropriate destiny to implement the theoretical knowledge. From this industrial attachment i got
the details idea about the factory environment, production process, total management, store &
inventory process, maintenance, utility etc.

We wish good luck for this factory.

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 CONCLUSION

We have completed our industrial attachment successfully by the grace of Almighty. Industrial
attachment sends us to the expected destiny of practical life. The completion of the two
months industrial attachment at Radiance group Ltd, we have got the impression that this is
one of the most modern knitting, dyeing, printing & Garments factory in Bangladesh and it has
earned very good reputations for its best performance over many other export oriented textile
mills.
However there are some points to be mentioned:

❖During the transport of the fabric in the dyeing floor & also during the loading of the
machine, fabrics are soiled for the contact with floor. This makes the fabric part of the fabric
dirty. It may require more scouring/bleaching agent or may create stain making it faulty.
❖The- dyeing floor is watery most of the time. It should be cleaned all the time.
❖Many time the dosing pipelines are clogged due to the careless dosing of the chemicals. The
supervisors should supervise the floor more sincerely.
❖The machine stoppage time should be analyzed & minimized. The maintenance should be
carried out when the machine is out of action (wherever possible).

Our Apology:

❖ The management of FKL were very helpful. Our respective seniors gave us time whenever

they got.

❖ Due to secrecy act, all the data on costing & marketing activities has not been supplied &

hence this report excludes these chapters.

❖ Some of the points in different chapter are not described as these were not available.

❖ The whole process is not possible to bind in such a small frame as this report, hence our

effort spent on summarizing them.

❖ But it must be said that FKL is a best place to get the practical knowledge about textile

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knitting, Dyeing, printing, Garments, Washing.

Page 90