Industrial attachment of four knit wear limited

1. SOUTHEAST UNIVERSITY SOUTHEAST UNIVERSITY SOUTHEAST UNIVERSITY Department of Textile Engineering Department of Textile Engineering INDUSTRIAL ATTACHMENT INDUSTRIAL ATTACHMENT INDUSTRIAL ATTACHMENT Four Knit wear Limited Four Knit wear Limited Four Knit wear Limited (15thSeptember, 2012 to 15thNovember, 2012) (15thSeptember, 2012 to 15thNovember, 2012) (15thSeptember, 2012 to 15thNovember, 2012) (Four Knit wear Limited)Pathamtuli Shiddhhir Shiddhhirg ganj, Narayanganj anj, Narayanganj. Bangladesh Shiddhhir Shiddhhirg ganj, Narayanganj anj, Narayanganj. Bangladesh Shiddhhir Shiddhhirg ganj, Narayanganj anj, Narayanganj. Bangladesh (Four Knit wear Limited)Pathamtuli (Four Knit wear Limited)Pathamtuli Pathamtuli, , . Bangladesh . Bangladesh . Bangladesh Pathamtuli, , Pathamtuli, ,

2. SOUTHEAST UNIVERSITY Department of Textile Engineering Supervising Faculty: Professor Syed Fakhrul Hassan Chairman Department Of Textile Engineering Southeast University Supervising Officer: Mahmud Rahat Chowdhury Executive Director Four Knit Wear Limited 2

3. REPORT ON INDUSTRIAL TRAINING IN Four Knit Wear LTD TRAINING PROGRAM FOR THE DEPARTMENT OF TEXTILE ENGINEERING. SOUTHEAST UNIVERSITY, DHAKA FROM 15.09.2012 TO 15.11.2012 COPY FOR SOUTHEAST UNIVERSITY SUBMITTED BY: SUBMITTED BY: Mohammad Rasel Miah Southeast University. Banani, Dhaka Date Of Submission: 14 Date Of Submission: 14 th thJanuary 2013. January 2013. 3

4. Abstract Abstract Abstract The aim of industrial practice is to make us familiar with any kind of industry, the whole process The aim of industrial practice is to make us familiar with any kind of industry, the whole process The aim of industrial practice is to make us familiar with any kind of industry, the whole process going on the industry, its environment and also with the management system of the industry. As going on the industry, its environment and also with the management system of the industry. As going on the industry, its environment and also with the management system of the industry. As a student of Southeast University, the target of any student should be to know the production a student of Southeast University, the target of any student should be to know the production a student of Southeast University, the target of any student should be to know the production process and the management system. It is because of the fact that to run any industry not only process and the management system. It is because of the fact that to run any industry not only process and the management system. It is because of the fact that to run any industry not only production department is obvious but also the capability of managing the whole system is an production department is obvious but also the capability of managing the whole system is an production department is obvious but also the capability of managing the whole system is an obvious matter. It is also a responsibility of an engineer is to develop the ongoing process into a obvious matter. It is also a responsibility of an engineer is to develop the ongoing process into a obvious matter. It is also a responsibility of an engineer is to develop the ongoing process into a better system to cope with the present competition. Thus a diversified challenge emerges in front better system to cope with the present competition. Thus a diversified challenge emerges in front better system to cope with the present competition. Thus a diversified challenge emerges in front of the manufacturer and other organizations. With a view to overcome this consequence a new of the manufacturer and other organizations. With a view to overcome this consequence a new of the manufacturer and other organizations. With a view to overcome this consequence a new generation of engineering graduates with leadership skills and management capabilities generation of engineering graduates with leadership skills and management capabilities generation of engineering graduates with leadership skills and management capabilities altogether are in demand. altogether are in demand. altogether are in demand. The students of Southeast University were sent to different industries and assigned to different The students of Southeast University were sent to different industries and assigned to different The students of Southeast University were sent to different industries and assigned to different tasks. I had assigned to Four Knit Wear Ltd. This report is a presentation of my experience in the tasks. I had assigned to Four Knit Wear Ltd. This report is a presentation of my experience in the tasks. I had assigned to Four Knit Wear Ltd. This report is a presentation of my experience in the garments and also a details presentation of my works in that industry. garments and also a details presentation of my works in that industry. garments and also a details presentation of my works in that industry. 4

5. Acknowledgement Acknowledgement Acknowledgement At first we express our heartiest thanks to almighty Allah for finishing my work properly. At first we express our heartiest thanks to almighty Allah for finishing my work properly. At first we express our heartiest thanks to almighty Allah for finishing my work properly. My attachment was the first practical experience of working in the industry. On the whole course I have got a lot of helps from my respective teachers, and also a great help from our supervisor in Four Knit Wear LTD. Four Knit Wear LTD. Four Knit Wear LTD. My attachment was the first practical experience of working in the industry. On the whole course My attachment was the first practical experience of working in the industry. On the whole course I have got a lot of helps from my respective teachers, and also a great help from our supervisor in I have got a lot of helps from my respective teachers, and also a great help from our supervisor in I also would like to gratefully acknowledge to the authorities of Four Knit Wear LTD industry for giving me permission to carry out my Industrial Practices in their industry. I want to thank our our our I also would like to gratefully acknowledge to the authorities of Four Knit Wear LTD industry I also would like to gratefully acknowledge to the authorities of Four Knit Wear LTD industry for giving me permission to carry out my Industrial Practices in their industry. I want to thank for giving me permission to carry out my Industrial Practices in their industry. I want to thank 1. Mohammad Mahmud Russel- Managing Director 1. Mohammad Mahmud Russel- Managing Director 1. Mohammad Mahmud Russel- Managing Director 2. Mahmud Rahat Chowdhury – Executive Director 2. Mahmud Rahat Chowdhury – Executive Director 2. Mahmud Rahat Chowdhury – Executive Director 3. Khan Mohammad Al Mamun- General manager Of Merchandiser. 3. Khan Mohammad Al Mamun- General manager Of Merchandiser. For his great help with his experience. For his great help with his experience. For his great help with his experience. I place my thanks to all the official staffs of administration, production department, maintenance department, quality control for their cordial behavior and helpful support to gather information regarding to the industrial attachment. regarding to the industrial attachment. regarding to the industrial attachment. I place my thanks to all the official staffs of administration, production department, maintenance department, quality control for their cordial behavior and helpful support to gather information department, quality control for their cordial behavior and helpful support to gather information I place my thanks to all the official staffs of administration, production department, maintenance On my whole way i would like to express my gratitude to Professor Prof. Syed Fakhrul Hassan, Chairman, department of Textile Engineering, Southeast University. Hassan, Chairman, department of Textile Engineering, Southeast University. Hassan, Chairman, department of Textile Engineering, Southeast University. On my whole way i would like to express my gratitude to Professor Prof. Syed Fakhrul On my whole way i would like to express my gratitude to Professor Prof. Syed Fakhrul 5

6. Table Of Content Serial No Topic Page No 1 Abstract 4 2 Acknowledgement 5 3 Company Profile 7-10 4 Garments Section 11-33 5 Knitting and Dyeing 34-38 6 Merchandising Section 39-45 7 Utility Section 46-47 8 Compliance 48-50 9 Conclusion 51-52 6

7. Company Profile Four Knitwear LTD 7

8. Vision: To establish as a one stop source for the Global knit Apparel market and to satisfy and meet customer's expectation by developing and providing products and services on time, which offer value in terms of Quality, Price, Safety & Environmental impact. Assuring complete compliance with the international quality standards and also providing the employees internationally acceptable working condition and standards. To promote the development and to use human talent & equal opportunity of employment. They procure the most advanced & sophisticated technology suitable for producing desired product and attain highest level of competence through continuous development of the professional, management system and to ensure complete transparency in an aspects of business. Mission: Four Knitwear LTD realizes the need to stake out a competitive segment in the changing global market of today through technological excellence and human expertise. Four Knitwear LTD is committed to transpose its local success to the world scene. 8

9.  Company Name:  Four knitwear LTD.  Status: Private Ltd. Company  Type: 100% Export oriented knit Industry.  Year of establishment: 2004.  Address: Pathantuli , Godnail , Narayanganj -1400 Management:  Chairman  Contact Number   Managing Director  Contact Number  Email   Executive Director  Contact Number  Email   Marketing Director  Contact Number  Email   Manager Merchandiser :  Contact Number  Email : : Mamun Choudhury 01711 56 16 58 : : Mahmud Russel Choudhury 01819 22 74 09 : rusel@rockfreight.com : 01675-063088 : Mahmud Rahat chowdhury : rahat.4knitwear@gmail.com : : : Mahmud Russel Choudhury 01819 22 74 09 rusel@rockfreight.com Khan Mohammed Al Mamun 01817-535591 mamun.4knitwear@gmail.com : : Production Capacity: Production per 08 (Eight) hours : Basic T– shirt : 12,000 Pcs Polo shirt : 5,000 Pcs Others : It depends on style & fabrics 9

10. Product: Single Jersey Pique Lacoste Interlock Rib French Terry Cotton Fleece /Cvc Fleece Flat Knit Cotton Viscose          Some Major Buyers: CARODEL, SMYK, BABOLAT, CATBALU, ATIMA, PCL, ATIMA, FIRSTTEXTILE. Certificate & Achievement:  BGMEA  BKMEA 10

11. Garments Section Garments Section 11

12. Sampling Unit : In RMG sector Sampling plays a vital role. Morning shows the day. Only morning can show what kind of nature will be the day, similarly only Sample can say what kind of garments is going to be made as bulk. We have one line Sample section which is set up at the 1stfloor of our Factory. The Sample Section has been decorated by One Sample In charge who is responsible to give all sorts of direction to making the sample. One Sample Q C, One supervisor, 10 sample men and 7wo assistant. We have a individual Sampling unit for urgent Sampling , Pattern making, Checking, Marker drawing all pre production are done by this unit before go for bulk. We always try to approved our sample like, Proto, SMS, Pre production . 12

13. Sample is the proto type or model of the garments, upon what the buyer can decide on how and whether to confirm the order or not. It makes for buyer approval and before a bulk of production to minimize faults and errors and also find the easy process for bulk production. The details attached to the garments sample: After the confirmation of order, each sample sent the buyer has the following details attached to it, with the help of a tag. It contains the details pertaining to both, what the buyer has demanded and what supplement fabric/ trim etc they have used .         Ref no Color Fabric Composition Description Quantity Style no Store There may be a separate sampling department in a company. But as the merchandiser is the person who is interacting with the buyer regarding sample and other requirements, this sampling department will work under the supervision of merchandising department. We have to send many sample to buyers. They are        Salesmen sample Proto sample Counter sample Wash test sample Photo sample Pp sample Shipment sample 13

14. Work flow of sample section: receive tec pack from buyer cad and pattern making sample making approval size setting evluation the sample pp meeting grading of sample sending sample to the buyer approval grading of sample marker making sendint sample to the cutting section production starts 14

15. Sample production sequence: scouring the fabric and accessories for making the garments cutting emblishment sewing iron quality control pre check from buyer qc forwarding collect from the merchandiser sending sample to the buyer 15

16. Types of sample:         Proto sample Size set sample Additional sample Contract seal sample Pp sample Production sample Sales man sample Rack sample Proto sample: When we work with some buyer continuously, we will have to keep on sending sample to them very often. Whenever they have enquiries, buyer may need samples. Buyer may like to see the garments in a new fabric. For one enquiry they need samples in different fabrics to choose from. If they want to develop new style in new fabric, then also we will have to send these sample. Also we will have to send samples to the newly contacted buyers to show our workmanship, product range, quality standers and price level. These samples should be sent so that they would attract the buyers. Sales man sample: Some buyer needs these sample for getting the order from their customers. If the buyer is having 5 salesman sample in his office, then the buyer will ask us to make 5 sample in each style. The salesman will book the orders from their customers, by showing these samples. Buyer will place the order to us accumulating the quantities. Photo sample: These sample are to be made after sheets. These sample are needed to check the measurements, style and fit. So they can be made in available similar fabrics but in the actual measurements and specifications. Counter sample: These sample are to be made in actual fabrics with actual trims. If the order is for 3 colors buyer may need samples in any one color and swatches in other colors. These samples should be strictly as per the specifications in the order sheets. We have to get the approval for these samples from the buyer before starting production. 16

17. Wash test samples: If these sample are sent before starting production and if we get some remarks or comments on these sample, we can correct them in production. But some buyers will need us to send these samples from production before shipment. In this case these sample may be considered as shipment samples. Pre production samples: These sample are almost like approval samples. They have to be made in actual production fabric with actual bulk trims. They will represent that the production will be like these samples. Production sample: These samples are to be sent before shipment to get the buyers confirmation for shipment. Hence these sample are needed to be perfect in all manners. Buyers may check these samples for everything or anything. Shipment sample: These samples are to be sent after shipment. They should be sent in actual packing with all labels, tags etc. Types of machine are used in sample section: SL No Name Of Machines No. Of Machines Remarks 01 Over lock ( 3 Thread ) 1 Set 02 Over lock ( 4 Thread ) 1 Set 03 Over lock ( 5 Thread ) 1 Set 04 Lock ( Flat ) 1 Set 05 Lock ( Cylinder Bed ) 1 Set 06 Plain machine 2 Set 17

18. Cutting : First stage of readymade garment production, cutting is the most important and major part of ultimate quality of the production. In this point of view our cutting section has design to achieve the maximum production. Cutting section have been designed in 1stfloor of the factory space. There are two types of cutting system, one of them Machine cutting and another is Manual cutting. Two cutting men is engaged in machine cutting and there about 12 cutting men are working continuously. There is an cutting in charge, One supervisor and one QC to perform the activities maintaining quality and required quantity. Cutting is the process which cut out the pattern pieces from specified fabric for making garments. Once the marker is made, pattern pieces must be cut out of the specified fabric, a process called "cutting." Currently, several cutting techniques exist, ranging from low- to high- tech. Although scissors are used very rarely-only when working with very small batches or sensitive fabrics-cutting continues to be done by hand, particularly in many lower volume establishments. Here, cutters guide electric cutting machines around the perimeter of pattern pieces, cutting through the fabric stack. An electric drill may be used to make pattern notches. Computerized cutting systems are achieving more widespread use as technology costs decrease and labor costs rise. These computer-driven automated cutters utilize vacuum technology to hold stacks of fabric in place while cutting. Cutting blades are sharpened automatically based upon the type of fabric being cut. Gerber Garment Technology manufactures one of the most commonly used cutting systems. This technology has the advantage of being highly accurate and fast, but does cost considerably more than other cutting techniques. 18

19. Types of Cutting Fully manual: Hand operated scissor  Manually operated power knife: Straight knife Band knife Round knife Die cutting Notcher Drill       Computerized methods of fabric cutting: Computer controlled knife cutting Cutting by Laser beam Cutting by Water jet Cutting by Plasma torch     Cutting Q.C : Upon receiving any batch of fabric it required to check Dia, Gsm, Colour fastness, tone matching and shrinkage are duly checked by our cutting Q.C makes a report on the fabric to get the cutting approval from merchandiser department. 19

20. Lay cutting : Mostly we make all fabrics in lay form and cut it by marking as per pattern, so the fabric is getting more relaxation to avoid further shrinkage and all the hole, Running shade etc can clearly find out and remove. There are about 15 workers are engaged to do the work properly so that we can meet the shipment date with maintain quality. We always try our best to meet the 100% Quality label. 20

21. Sewing: We have four line for sewing what is consisted with various Machines like Over lock, Flat lock, Plain Machine, Button hole, Rib Cutter, Khansai etc. There are two hundred and sixteen Machines for various kinds of buyer’s requirement. We have been maintaining need based machine settings as required by needle type like 3 Thread, 4 Thread, 5 Thread and even Ball Point needle. We some time do the chore hem when it is required. Buyer US POLO Chicco and SMYK are the exemplification of such type of Hem. 21

22. Main Sewing Unit : The main sewing floor are designed by 4 line of selected machinery. Each line are headed by 1 Supervisor and 1 input Assistant Required Operator and Helper as Lay out base on the Garments style and design. 22

23. Sewing process flow Chart: input measurement check print & embroidery check sewing started get full garments as output garments inspection forward it to the finishing section 23

24. Machinery of Main Unit SL NO 01 02 03 04 05 06 07 08 09 10 11 12 Name Of Machines Over lock ( 4 Thread ) Over lock ( 5 Thread ) Lock ( Flat ) Lock ( Cylinder Bed ) Feed of the arm Plain machine Button hole Button stretch Rib cutter Back tape Cutting machine Iron ( Steam ) No. Of Machines 60 Set 25 Set 18 Set 26 Set 8 Set 56 Set 01 Set 01 Set 02 Set 02 Set 02 Set 15 Set 24

25. Process Flow of a Basic T-Shirt: Machine front and back part Indicating placket mark Moon attached with back part (Plain machine) Placket attached with front part (Plain machine) Separating placket & stitching nose cut (Plain machine) Stitching shoulder (Overlock, 4 thread) Attaching care level (Plane machine) Stitching twill tape (Plane machine) Shoulder top seam (Plain machine) Collor tag (Plain machine) Stitching Collar (Overlock) Cuff shape (Overlock) Attaching twill tape with neck (Plane machine) Placket stitching of bottom part (Plain machine) side band tape join (Plain machine) Button hole machine Button attaching machine Thread cutting Inspection 25

26. Q.C : In line inspection : A team of 4 Q.C. inspector are working in the every stage of the total production. In order to meet up the instant quality and predictability. Out line inspection (RANDOM) : Each garment get enter to “out line inspection area” are duly check by a 25 members Q.C team as random inspection. 26

27. Final inspection : Final inspection : Final inspection : Even though A garment passed by the random inspection team are duly check and approved by them before ironing. and approved by them before ironing. and approved by them before ironing. Even though A garment passed by the random inspection team are duly check Even though A garment passed by the random inspection team are duly check 27

28. Garment finishing Process flowchart of garment finishing: Garment finishing Process flowchart of garment finishing: finishing input ironing inspection hang tag get up change folding poly bar code ( buyer wise sticker) bar code ( buyer wise sticker) metal check cartooning final inspection by buyer 28

29. Faults inspected in tte end table:                       Broken Sto Skip Sto Drop Sto Join Sto Unven Sto Over Sto Unven seam allowance Open seam Puckering Uneven shape Rawedge Dirty stain Oil stain Incorrect measurement Shading Bad tension Incorrect size level Unmatched side Reverse attachment Needle hole Wrong trims Missing trims (D) Ironing section : The ironing section of the total production line are equipped by 12 set of steam ironing system. 29

30. Iron Q.C : The final inspection team is also take care of the garments after ironing and the ultimate measurement shrinkage are duly check before packing. Packing and Cartooning Section : A separate team of some skill worker are working in the final stage of production line”. Who those have very fast working speed and knowledge about “ PRESENTATION & DECORATION” of the final product. “ Total A 10 members team are working for cartooning with the experience of proper counting,setting, assorting and balling of the carton. 30

31. PRINTING: In four knit wear lLd. hand screen printing is carried out. Here various types of screen printing are done. They are mentioned below: 1. Base/pigment printing 2. Rubber printing 3. High density printing 4. Plastisol 5. Discharge 6. Metallic 7. Puff 8. Foil 9. Glitter 10. Transfer 11. Flock 12. Water jetpoint 13. Pearl Process flow chart: Design obtained from swatch Design selection and colour separation Production of design repeats by using software Preparation of screen manually and adding photo sensitive polymer Design is replaced in mesh fabric by exposing to light Placing the fabric on the printing table as measured taken 31

32. Printing paste preparation Printing the fabric by screen Curing the fabric at required temperature(140-180ºC)for 1-3 mins Software used for design: 1. 2. 3. Abobe photoshop Adobe illustrator Corel draw Paper used: Delta laser sheet Sometimes tracing paper is also used for small motif. Mesh of fabric: 16(Dot design) , 90(High density printing) , 110 , 60 etc. Screen size: 1. 14´´× 16´´ 2. 16´´× 18´´ 3. 18´´× 20´´ 4. 28´´× 32´´ etc. 32

33. Squeeze: 1. China : For dot printing 2. Bangladesh : For solid Printing Table: Dimension 1. 4ft×80ft 2. 100ft×2.5ft Made of : 1. Local: Hard board and rexin 2. China: Glass Drier used: Drier (Ahjin machine company). Production: 6000 Pcs basic print per day with drying arrangement. In four knit wear has own printing Unit in order to meet up urgent sampling and bulk production and minimize the costing. 33

34. KNITTING KNITTING And dyeing And dyeing 34

35. Knitting Sub Contract: In order to meet up Bulk knitting with in short time. We have good arrangement with our associates who those working with us since long under a associates partnership business agreement. Associate factory’s details are as follows: Elora Knitting : Address: B-179/180 BSCIC Industrial area, Fatullah, Narayanganj.-14000 . Type of Machine Single Jercy with lycra ,, ,, ,, ,, Brand FUKAHAMA FUKAHAMA FUKAHAMA FUKAHAMA FUKAHAMA Dia 23 24 25 26 28 Qty 1 Set 1 Set 1 Set 1 Set 1 Set ,, FUKAHAMA 30 1 Set Rib/Inter lock with lycra FUKAHAMA 28 1 Set ,, FUKAHAMA 30 1 Set ,, FUKAHAMA 32 1 Set ,, FUKAHAMA 34 1 Set ,, FUKAHAMA 36 1 Set ,, FUKAHAMA 38 1 Set ,, FUKAHAMA 40 1 Set 35

36. 2) Rahman Sports Wear: Address: B/369,370,371 BSCIC Industrial area Fatullah, Narayanganj-14000 Type of Machine Single Jercy with lycra ,, ,, ,, ,, ,, ,, ,, ,, ,, ,, ,, ,, Rib/Inter lock with lycra Brand FUKAHAMA FUKAHAMA FUKAHAMA FUKAHAMA FUKAHAMA FUKAHAMA FUKAHAMA FUKAHAMA FUKAHAMA FUKAHAMA FUKAHAMA FUKAHAMA FUKAHAMA JIUNN LONG Dia 16 17 18 19 20 21 22 23 24 25 28 30 40 36 Qty 1 Set 1 Set 1 Set 1 Set 1 Set 1 Set 1 Set 1 Set 1 Set 1 Set 1 Set 1 Set 1 Set 1 Set 3) M/S. SAYAM KNIT FEB. : Address: A/97 BSCIC Industrial area Fatullah, Narayanganj-14000 Type of Machine Rib/Inter lock with lycra Brand JIUNN LONG Dia 30 Qty 1 Set Rib/Inter lock with lycra JIUNN LONG 32 1 Set Rib/Inter lock with lycra JIUNN LONG 34 1 Set Rib/Inter lock with lycra JIUNN LONG 36 1 Set Rib/Inter lock with lycra JIUNN LONG 38 1 Set Rib/Inter lock with lycra JIUNN LONG 40 1 Set 36

37. Dyeing Unit : M/S IBRAHIM KNITEX. Address : Ailpara, Pathantoli, Siddirgonj, Narayanganj are one of the most reputation dyeing unit with all kinds of latest Machinery’s for better quality dyeing and shrinkage free finishing line are equipped with following Machinery’s :- A. LAB- MACHINERIES : 01. Dyeing-Machine ........Rapid.............Taiwan............................ 20 Pots. 02. Dyeing-Machine ........Rapid............ Taiwan.......................... 12 Pots. 03. Washing-Machine..... Ariston......... Italy ............................... 5.0 Kg. 04. Light box-Available light Sources : I) Sun Light .........................D-65, D-50. II) Cool Day Light, Illua CWF, UV, TL 84. B. DYEING MACHINERIES : M/C no. Name of the Company Manufacturing Country Capacity Model no Number of Mac. 01. Fongs 02. Fongs 03. Fongs 04. PMM 05. Fongs 06. Fongs 07. Fongs Hongkong ECO-38 1SET 600 KG Hongkong ECO-38 1SET 400 KG Hongkong ECO-38 1SET 250 KG Turkey Hongkong ECO-38 Hongkong ECO-38 1SET Hongkong ECO-38 1SET 30 KG 1SET 750 KG 1000 KG 1SET 600 KG 37

38. C. FINISHING MACHINERIES : 01 Allooning Squeeze (Double-Nips) Dong Name Korean...Per Day Production- 07 Tons 02, Dryer Machine (3 Chamber, 3 Passage System)..Dong Name Korean Per Day Production- 07 Tons 03, Soft Setting Calendar Dong Nam. Korean Per Day Production- 05 Tons 04 Compacting Machine Tube-Tax’s Per Day Production- 08 Tons 38

39. Merchandising Section 39

40. Merchandizing can be metaphorically termed as a pivot point around which the whole organization rotates. Unlike other departments or functions of an organization which are serially linked ,merchandizing acts as a cross road where the data from different parts of an organization is communicated, monitor , distributed and channeled in such a way that the goal is achieved within the agreeable limits of time, money and man power. Merchandizing plays a foremost vital role in generating orders for the organization so that the production may not be idle and the company can be managed Thus merchandizing can be viewed as an interface between the external and internal environment of an organization. By external environment from export house point of view we are referring to the buyers who provide orders to an export house, the market information, demand, current trends, technology up gradation requirements etc. On the other hand internal environment encompasses various departments within an organization such as purchase, production, dry processing, cutting, washing, finishing, stores, and planning etc. Procurement of garments exports order: The most critical work is the procurement of garment export order. Normally garments export order is found from the potential garment importers called garment buyer. Anybody wants to collect garments export order, should be able to convince the buyer. When the buyer is convinced about garment production, garments quality, garments costing and garment delivery/shipment ability of a garments exporter. he or she can think about issuing a garments export order. To convince the buyer it is better if you can visit his/her office in abroad with your produced some sample garments & company profile, Even it will be more helpful , if you can invite & arrange the visit of your prospective buyer to your office, factory to see production facility, product quality, so that the buyer gets confidence about your garments export ability. Without clear confidence between buyer & exporter from both sides, may be a risky business deal. If a garment exporter can continuously deal with only two or three buyer with buyers satisfaction. it will be sufficient enough to run garment production & garment export business smoothly round the year. Requirements of order of style; 1. Fabrication. 2. Measurement list. 3. Art work. 4. Description page. 40

41. Fabrication: It includes; a. Fabric compositions. b. Fabric constructions. c. Fabric GSM. Consumption: In the garments trade, consumption means quantity of raw materials with a view to determine the price of garments. In order to calculate the garments quantity, how much fabric, sewing thread, zipper, button & other accessories required to produce a garments up-to the exporting is called consumption. Fabric consumption calculation by two processes; 1. From marker (it is accurate). 2. From measurement, (it is approximate). Basic information relevant to consumption: 1. Measurement with technical specification sheet. 2. Style description. 3. Fabric description. 4. Fabric weight & width. 5. Washing shrinkage. Consumption calculation formula: Consumption formula for T-shirt is given below; [{(length × width) × 2 × 12 × GSM} / 10000000] + Wastages % 41

42. How to prepare a price quotation for buyers: In here are three processes for fixation of export prices which are as under :- a. FOB (Free on board). b. C & F (Cost & Freight). c. CIF (Cost, insurance & Freight). FOB means 'Free on Board` I.e. exporter does not bear the cost of freight of ship or air. It is buyer (Importer) who himself bears the freight of ship or air. During the fixation of FOB price following notes are to be followed carefully: 1. Cost of fabric / Doz. Garments (Woven/Knit)or Cost of yarn /Doz. garments (in case of sweater). 2. Cost of accessories /Doz. garments. 3. CM (Cost of manufacturing)/doz. Garments. 4. Cost of transportation from factory to seaport or airport. 5. Clearing &f0nuarding cost. 6. Overhead Cost. 7. Commission/Profit. C&F means Cost of Freight I.e. FOB (Cost) + Freight = C & F. In the case ship or airfreight is carried by the exporter while quoting price, the exporter quotes price a bit higher than FOB. The whole responsibility including the sending of goods to the selected port of the importer is shouldered by the exporter ship or air. Freight may vary from place to place and shippers to shippers. CIF means Cost insurance & Freight. In this case, in addition to the bearing of freight the Cost of insurance is also borne by the exporter. The exporter, while quoting CIF price, quotes much higher than C & F value i.e. C & F + Insurance = CIF. Normally we can add 1% to 1.5% insurance charge with CIF Price. 42

43. Costing process: Finish fabric cost: (Yarn price + Knitting cost + dyeing cost) Body fabric cost: (Total fabric consumption + Total yarn consumption) Cost of making (CM):……………………………$ Accessories cost:…………………………………$ Overhead cost……………………………………$ Others cost:……………………………………….$ Buyer commission:……………………………….$ Total cost...$ DOCUMENTS The merchandising department maintains the following documents:-  Job Card  Order confirmation document.  Lab Testing Report  Order Tracking Sheet And Its Status  Shrinkage Testing Report  Cost Sheet  Trim Card Job Card: Job card is used to keep a close watch on the time spent by a worker on each job. It can be prepared by hand or machine. There are four types of job cards that are generally used such as: Combined time and job card. Job card for each worker. Job card for each job. Piece work card.     43

44. The job card contains the following in formations such as: Job no, description, quantity required, quantity finished, time required for the job, total time to finish the job, normal time, over time, rate, amount, date, and quantity posse and accepted with the inspectors signature. The advantages of job card are as follows: It reduces normal idle time. It gives clear, logical and suitable information to the costing department. It provides a very useful link between the production control and costing. Job card gives information about number and particulars of job accurately.     Order confirmation document:  Copy of master LC  Contract sheet:  Contract no  Style no  Shipment date  A.Q.L  Order quantity &size ratio.  Fabric description  Labels and position.  Buyer’s comments and regarding approved sample.  Proved trim card. Components of a package: Package consists of the following components: 1. Cover Sheet 2. Fabric Mill Sheet 3. Sketch Sheet 4. Accessories Detail 5. Size Specification Sheet 44

45. 6. Packing Manual 7. Revision History 1. Cover Sheet: It contains the general information about buyer, style #, garment, season, division. 2. Fabric Mill Sheet: It contains the information about fabric for garment and it includes: Division, style, season, type of Fabric, type of yarn, gauge, diameter, GSM, GSM before and after wash, dyeing, details, finishing details and shrinkage etc. 3. Sketch sheet: It contains the information about front and back view. It also includes the stitching type i.e. (overlooks, main stitch, back stitch, folder, and flat lock). 4. Accessories Detail Sheet: It contains the complete information about stitching threads, button material, button color, and button thread. It also includes the size of button (16, 18, 20 or 22 line.) and that either buttons contain two holes or four. Line is the unit of button. 5. Size Specification Sheet: It contains the size of garments. TOL +/- 3 4/5 6 8 10 12 14 Désignation / Description TOTAL FRONT LENGTH FROM TIP SHOULDER / Longueur totale de l'épaule FRONT BREADTH /Carrure devant A 51 1 38 43 47 55 59 64 B 28 0.5 21 24 26 30 32 35 1/2 BUST MEASUREMENT /1/2 tour de poitrine 1/2 BOTTOM MEASUREMENT /1/2 tour de base RIB C 38 1 31 34 36 40 43 46 D 35 1 28 31 33 37 39 42 SHOULDER LENGTH /Longueur épaule E 8.5 0.5 6 7 8 9.5 10.5 11.5 SHOULDER SLOPE HEIGHT /Hauteur pente d'épaule SLEEVE LENGTH /Longueur de manche F 3 0.25 2.5 2.5 3 3 3.5 3.5 G 46 1 33 39 42 49 52 55 1/2 STRAIGHT ARMHOLE /1/2 Emmanchure droite 1/2 SLEEVE WIDTH UNDERARM /1/2 largeur haut de manche H 16.5 17.5 18.5 19.5 14 15 0.5 14 15 16 I 0.5 11 12 13 16 17 45

46. Utility Section Utility Section 46

47. UTILITY SECTION : A. BOILER MACHINE : 01. Ruston England 06 Tons B. GENERATOR : 01. Petbow 02. Dihutsu. Japan 500 K.V. A. England 250 K.V.A. C. WATER PUMP : 01. Summer Sear Pump Italy 4” x 12” 02. Summer Sear Pump Italy 4” x12” D.Generator : 1 Set ( 150 KV. ) 47

48. COMPLAIANCE COMPLAIANCE 48

49. In four knit wear ltd factory is full under processing for compliance with ILO and Bangladesh Labor Law. Their company policy is as follows:  No child labor.  No forced labor.  Transport facilities for worker.  Hours of work.  Voluntary over time.  Intervals for rest.  Weekly holidays.  Annual leave.  Festival holidays & leaves with bonus.  Maternity protection.  Worker's welfare committee.  Mineral drinking water.  Sanitary facilities.  First aid box. SAFETY G) FIRE EXTINGUISHER: G 1) CENTRAL FIRE FIGHTING SET WITH 6 BY PASS 5000 LTR CAPACITY G 2) SPRAY MACHINE G 3) EMERGENCY EXIT. 49

50. 50