Industrial attachment of Olio apparels ltd (envoy group)

1. INDUSTRIAL TRAINING Course Code: Tex -4036 INDUSTRIAL ATTACHMENT OF OLIO APPARELS LTD (ENVOY GROUP). Page | 1

2. Objectives of Internship : Objective: The objective of the report is to learn about the overall activities of different departments in OLIO APPARELS LTD (ENVOY GROUP). A primary textile industry Academic knowledge is not perfect without practical knowledge. Specific Objectives: This intern paper has been prepared for fulfilling the following specific objectives: To enlarge the dimension of knowledge regarding garments manufacturing as well as others. To define and evaluate the performance of garments manufacturing Department as well as others. To observe the effectiveness of garments manufacturing as well as others. To get the additional knowledge in different sections of the organization. To interchange opinions of the officials regarding their organization. To know the economic condition of RMG in Bangladesh through Olio apparels Ltd. To identify the difference between theory (what we have learned from the text) and practice (what is really happened). To compare the improvement of the present condition of the Olio Apparels Ltd (Envoy Group). with the previous years. To mention the problems that Olio apparels Ltd (Envoy Group). face in the process of production and delivery of garments & give some suggestions. To identify the strengths, weaknesses, opportunities and threats of the Olio Apparels Ltd (Envoy Group). Page | 2

3. SUMMERY: Industrial attachment is an important and essential part of 4 year B.Sc. in Textile Engineering Course of PRIMEASIA UNIVERSITY. Actually industrial attachment is the practical experience for every Textile Engineer which is needed to be familiar not only the industry but also all over the necessary job related to continue in any industry. During student life a student cannot know about the practical condition so its badly needed for every student for attain for the industrial attachment .The Olio apparels ltd (Envoy Group) is truly an excellent industry from our point of view. All types of modern technology are well arranged here. Every section in here helps us so much by giving information during our training period which was unbelievable. Specially merchandising section with management maintain the buyer managing System, a vital role for the companies smooth operation and development, We are so satisfied and lucky student to completed our Industrial Attachment in Envoy Group. We think this Industrial Attachment will be outstanding helpful in our future career life. Page | 3

4. PROJECT DESCRIPTION: Olio apparels ltd. 1/1, North Kamlapur,Motijiheel,Dhaka-1217,bangladesh It is the largest complex of its kind in South Asia producing high quality garments. Swiss, Italian, German, and French made manual and computer-controlled machineries have been installed in each of the divisions to deliver quality textiles, which meet the demand of European and American customers. Major portion of turnover of the textile segment are for RMG units. Total fabrics requirement for the group RMG segment is around 50 million yards per year. To mention apart from cost advantage, sourcing from own backward linkage ensures quality of the product as well as lead-time advantage for the RMG segment. The OLIO APPARELS LTD. RMG division has an annual capacity of 6 million dozen of RMG unit with a lead time of 90- 120 days. It comprises of 28 companies with 170 standards production lines and a total covered factory space of 1088000 square feet. The main product of Olio Apparels Ltd. are in both woven and denim fabrics; such as – pants with imported fabrics from all over the world. Page | 4

5. Company profile: CORPORATE HEAD QUARTER : Envoy Tower, 18/E, Lake Circus, Kalabagan, West Panthapath, Dhaka - 1205, Bangladesh. Tel- 880-2-9102583 - 90. Fax – 880-2-9103128 - 29 ENVOY TOWER Page | 5

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15. OVERVIEW ABOUT of OLIO APPARELS LTD: Mission: We are committed to providing excellence at all levels of production. OLIO APPERELS LTD. established in 14th june 2003, which means infinite or unlimited in Bengali, embraces the spirit of global trade. The company is dedicated to excellence in merchandising, product development, production and logistics. We have earned a reputation throughout the global apparel industry. Asone of the foremost factories in Bangladesh for our commitment to quality, timely delivery and total value. Through our extensive sourcing network, we have the ability to effectively procure the best materials. Our customers rely on us to deliver the best quality products and superb service, which enables them to successfully compete in the emerging market place. COMPANY NAME : OLIO APPARELS LTD(ENVOY GROUP) Olio apparels ltd. 1/1, North Kamlapur,Motijiheel,Dhaka-1217 Total Floor Area: 60,000 SFT Total Worker: 2000 Persons (75% Female & 25% Male) Total Machineries: 1150 Nos. Main Production Item: DENIM PANTS, WOVEN PANTS. Production Capacity: 28,000 to 32,000 DOZENS PER MONTH. DENIM & WOVEN :28,000 to 32,000 DOZENS PER MONTH DEPENDING ON STYLE. Payment terms: confirmed irrevocable letter of credit Page | 15

16. Fire/First Aid Equipment: TYPE OF EQUIPMENTS First Aid Box Co2 ABC Dry Power Fire Extinguisher Foam Fire Extinguisher Gas Mask Fire Bucket Bucket stand Belch Fire Hook Fire Beater Smoke Detector Fire Alarm Gong Bell Hand Gloves Lock cutter Stretcher Manila Rope Fire Hose Cabinet Reserve Water Drum Fire Switch Helmet TOTAL 20 58 114 02 32 32 08 08 08 08 56 08 08 16 08 04 04 08 16 16 16 Page | 16

17. OUR MAJOR BUYERS: BUYER LOGO Marks & spencer,UK H&M,SWEDEN Walmart,USA Carrefour,france Tema, Turkey Page | 17

18. Asia,USA ZARE GAP TESCO DEBENHAMS Page | 18

19. HUMAN RESOURCE MANAGEMENT: ORGANISATION STRUCTURE Page | 19

20. The objectives of human resource management system activities can be listed as follows: To ensure that the organization apply equal employment opportunities and other government obligations. To conduct job analysis to specify different requirements of jobs in an organization. To identify personnel requirements that led the organization to achieve its objectives. To develop and implement a plan that meet personnel and job requirements. To recruit employees needed by the organization in order to achieve its objectives. To select personnel in order to fill vacant positions within an organization. To provide orientation and training to the employees. To design and implement management and organizational development programs. To design and implement performance appraisal systems to evaluate employee performance. To assist employees in developing career plans. To design and implement compensation systems for employees. To mediate the relationship between organizations and its units. To design systems for discipline and grievance handling. To develop employee communication systems. •To develop employee health and safety programs Page | 20

21. HR DPARTMENT: Functions of Human Resource Department A typical Human Resource Department is carries out the following functions: Manpower Planning It involves the planning for the future and finding out how many employees will be needed in the future by the business and what types of skills should they possess. It depends on the following factors The number of people leaving the job The projected growth in sales of the business Technological changes Productivity level of the workers Job analysis and Job description HR Department is also involved in designing the Job analysis and Job description for the prospective vacancies. A job analysis is the process used to collect information about the duties, responsibilities, necessary skills, outcomes, and work environment of a particular job. Job descriptions are written statements that describe the: duties, responsibilities, most important contributions and outcomes needed from a position, required qualifications of candidates, and reporting relationship and co-workers of a particular job. Page | 21

22. Determining wages and salaries HR Department is also involved in conducting market surveys and determining the wages and salaries for different position in an organization. These decision may be taken in consultation with top management and the Finance department. Recruitment and Selection One of the most important jobs HR department is to recruit the best people for the organization. This is of crucial importance as the success of any organization depend on the quality of its workforce. Performance Appraisal Once the employees are recruited , the HR Department has to review their performance on a regular basis through proper performance appraisals. Performance appraisal is the process of obtaining, analysing and recording information about the relative worth of an employee. The focus of the performance appraisal is measuring and improving the actual performance of the employee and also the future potential of the employee. Its aim is to measure what an employee does. On the basis of performance appraisal the HR Department will set up an action plan for each employee. If the employees needs any training then he provided that. Training and Development HR department is constantly keeping a watch over the employees of the organization. In order to improve the efficiency level of the employees they have go undergo regular trainings and development programmes. All trainings and development needs are carried out by this department. Training might include on the job or off the job training. Page | 22

23. Employee welfare and motivation Happy employees mean a healthy organization. HR Department conducts various employee welfare activities which might include employees get together, annual staff parties etc. HR department also reviews organizational policies and its impact on the motivation of the employees. Addressing employees grievances HR department is the link between the workers and the management. Employees grievances related work environment are usually entertained and resolved by the HR Department. Labor management relations For the smooth operation of any organization, it is crucial to have good labor management relations. HR department has to ensure that these relations are cordial. In case of any labor-management conflict the HR Department will play a vital role in bringing both management parties to the negotiation table and resolving the issue. Implementing organizational policies HR Department has to coordinate with line manager and see that the organizational policies are being implemented in a proper manner. Disciplinary action can be initiated against employees who are not following organizational rules and regulations. All these actions are conceived and implemented by the HR department. Dismissal and redundancy HR Department has to take firm actions against employees who are not following the organizational code of conduct, rules and regulations. This can result in the dismissal of the employee.Sometimes, an organization may no more require the services of an employee. The employee may be made redundant. HR Department has to see that organizational and government regulations are being followed in this process. Page | 23

24. ADMINISTRATION DEPARTMENT: Depending on the sector, the role may also include many of the following: using a variety of software packages, such as Microsoft Word, Outlook, Powerpoint, Excel, Access, etc., to produce correspondence and documents and maintain presentations, records, spreadsheets and databases; devising and maintaining office systems; booking rooms and conference facilities; using content management systems to maintain and update websites and internal databases; attending meetings, taking minutes and keeping notes; managing and maintaining budgets, as well as invoicing; liaising with staff in other departments and with external contacts; ordering and maintaining stationery and equipment; sorting and distributing incoming post and organizing and sending outgoing post; liaising with colleagues and external contacts to book travel and accommodation; organizing and storing paperwork, documents and computer-based information; photocopying and printing various documents, sometimes on behalf of other colleagues. Other duties may include: recruiting, training and supervising junior staff and delegating work as required; manipulating statistical data; arranging both in-house and external events. Page | 24

25. SOCIAL POLICY: Management Systems Assessment and Certification The Envoy Gr0up is committed to the best human workplace practices. Their goal is to continuously improve their Human resource policies and procedures through education, training, communication and employees involvement. BSI Group is the world‘s largest certification body. It audits and provides certification to companies worldwide who implement management systems standards. BSI also provides a range of training courses regarding implementation and auditing to the requirements of national and international management systems standards. It is independently accredited and delivers assessments for a wide range of standards and other specifications including: • ISO 9001 (Quality), • ISO 14001 (Environment), • ISO 22222 (Financial Planning), • ISO 50001 (Energy management systems), • OHSAS 18001 (Occupational Health and Safety), • ISO/IEC 27001 (previously BS 7799 for Information Security), • ISO/IEC 20000 (previously BS 15000 for IT Service Management); • PAS 99 (Integrated Management), • BS 25999 (Business Continuity), • Greenhouse Gas Emissions Verification, • SA8000 (Social Accountability) and Page | 25

26. FLOW CHART OF GARMENTS MANUFACTURING: DESIGN BASIC BLOCK WORKING PATTERN SAMPLE MAKING APPROVED SAMPLE COSTING PRODUCTION PATTERN PATTERN GRADING MARKER MAKING FABRIC SPREEDING CUTTING Page | 26

27. STORTING & BUNDLING INSPECTION SEWING INSPECTION WASHING PRESSING & FINISHING INSPECTION PACKING CARTONING FINAL INSPECTION SHIPMENT OR DISPATCH Page | 27

28. MACHINE DESCRIPTION: Production machine description PATTERN MAKING MACHINE: 1. High speed and accuracy supported by servomotor, straight lead rail and integrated circuit block. 2. Easy to operate. 3. Compatible with any CAD software. 4. Stable performance with long using lifetime Marker drawing machine: LECTRA PLOTTER & DIGITIZER SYSTEM HARDWARE: FL-DEGIPLAN 3 A0, FL-LC-FOOT, PLOTTER ALYS 60. SOFTWARE: MODARIS (MODE PRO V5R2): FOR PATTERN DESIGN, GRADING & EDITING DIAMINO (MARKPACK V5 R2): FOR PRODUCTION MARKER MAKING Page | 28

29. PATTERN CUTTING MACHING: Brand name: WINDA Product Description Pattern Cutting Plotter Winda series cutting machine is consisted by a fixed table, automatic feed-up device and operating software. It is widely used in garment, shoes and box-bag industry, etc. The high quality machine guarantees extreme precision and rapidity. Features: •Dual head for drawing and cutting, both head working separately; •Fully automatic feeding device; •Cutting material thickness up to 2mm; •High precision cutting to improve the quality of your product; •Save cost, save time, save labor force (3~5workers), save energy, save material. Page | 29

30. Sewing Machine Description: Which are used in sewing section: 1. Plain m/c 2. Over lock m/c 3. Flat lock m/c 4. Kansai m/c 5. Chain stitch m/c 6. Vertical m/c 7. Eyelet hole m/c 8. Two needle m/c 9. Feed of the Arm m/c 10. Zigzag m/c 11. Bar tack m/c 12. Button Holing m/c 13. Button attach m/c 14. Pocket welting or attach m/c # Description of the Machines Are Bellow: 1.PLAIN MACHINE: Brand name : JUKI Properties - • One needle FIG: plain m/c Page | 30

31. • Two tensioners • Three guide • One hook • Two thread • One bobbin case • One magnate guide Applications - • Bottom hemming • Belt top seem stitch • Belt joint stitch • Loop tack stitch • Pocket joint stitch • Zipper joint • Flap make • Flap top stitch 2.FLAT LOCK MACHINE: Brand name: JUKI FIG: flat lock m/c Page | 31

32. Properties: • 4tensioner • 3 thread • Contain a holder • 2needle Applications - • Zigzag stitch • Knit hemming • Loop making 3.OVER LOCK SEWING MACHINE: Brand name: JUKI Overlook stitching was invented by the MERROW Machine Company in 1881.An overlook stitch sews over the edge of one or two pieces of cloth for edging, hemming or seaming. Usually an overlook sewing machine will cut the edges of the cloth as they are fed through (such machines are called ‗SERGERS‘), though some are made without cutters. The inclusion of automated cutters allows over look machines to create finished seams easily and quickly. Specifications - • This over lock sewing machine is applicable to cover edging operation of thin, moderate and thick fabrics. Due to its automatic lubricating device. • The machine operates perfectly and smoothly at low sewing tension, and perfect stable stitches even at high speed seaming. • Suitable for thin, moderate and thick fabrics. 4 THREAD OVERLOCK SEWING MACHINE: BRAND NAME:JUKI Page | 32

33. Fig: 4 THREAD OVERLOCK SEWING MACHINE Properties - • 5 thread/4 thread/3 thread • 4tensioner • 2 knifes (up / down) • 2 needle for 5 thread • 1 needle for 3 thread • 3 lopper for 5 thread • 2 lopper for 3 thread Applications - *side seam *armhole *sleeve Page | 33

34. 2.BARTACK MACHINE: Brand name: JUKI The high speed bar tacking machine is designed for making reinforced stitching or various kinds of clothing such as suits/jeans and working clothes and also for eye let button hole tacking. Tack length can be easily adjusted. Reduction gear and some mechanism simplified to get improved durability and reliability. FIG: Bartack m/c Applications - *To created Barack stitches in garments. Bar tacking is a specialized sewing stitch designed to provide immense tensile strength to the garment or equipment it is used on. Bar tacking is commonly used on backpacks, tents, tactical gear, and other heavy wear sewn items where normally sewn stitches might give way at a crucial moment. In general, bar tacking is a sign of good quality, although the rest of the product should always be looked over carefully as well. When a sewing pattern calls for bar tacking, it indicates that the designer feels that section of the pattern is a critical area that needs extra reinforcement and following areas it can used. Page | 34

35. • Loop attach • Fly make • Pocket side • Front side • Back pocketing • side seam • In seem 2.KANSAI MACHINE: Brand name: Kansai special Kansai sewing machine is suitable for zigzag sewing, embroidery, abutted seam on light and medium material. It has excellent performance ratio and is conveniently arranged. It has bobbin winder integrated in the arm cover with in operator‘s view. It is suitable to sew underwear, corset, waist sections of ladies body suits, and swim suits. FIG: Kansai m/c Properties: • 2needle • 4 thread • 8tensioner • 21 lopper point(used two lopper depends on distance of stitches) Page | 35

36. Applications - • Back yoke stitch • waistband stitch Front placket 2.CHAIN STITCH MACHINE: Brand name: JUKI Chain stitch is a sewing and embroidery technique in which a series of looped stitches form a chain-like pattern. Chain stitch is an ancient craft – examples of surviving Chinese chain stitch embroidery worked in silk thread have been dated to the Warring States period (5th-3rd century BC). Handmade chain stitch embroidery does not require that the needle pass through more than one layer of fabric. For this reason the stitch is an effective surface embellishment near seams on finished fabric. Because chain stitches can form flowing, curved lines, they are used in many surface embroidery styles that mimic ―drawing‖ in thread. FIG: Chain stitch m/c Properties - • 2needle • 2looper • 4thread & 4tensioner (back 2/front 2) Applications - • Back rise stitch Page | 36

37. • Back yoke stitch • Top seen ¼ stitch •Feed off the Arm m/c: Buyer name: JUKI FIG: Feed off the arm m/c Properties - • 2needle • 2Lopper • 4 thread (Lopper 2/needle 2) • Contains T & Magnate guide • 3tensioner Applications - • Back rise stitch • Inseam stitch • Back yoke top seen Page | 37

38. •BUTTON HOLING MACHINE: Brand name: JUKI Buttonholes are holes in fabric which allow buttons to pass through, securing one piece of the fabric to another. The raw edges of a buttonhole are usually finished with stitching. This may be done either by hand or by a sewing machine. Some forms of button, such as a Mandarin button, use a loop of cloth or rope instead of a buttonhole. Fig: EYE LET BUTTON HOLE MACHINE Properties - • 2 thread • 1 needle • 2tensioner • Contains bobbin case, hook & knife Applications - • To make button hole in garment Page | 38

39. •BUTTON ATTACH MACHINE: Buyer name: JIKET • This is a single needle chain stitch button sewing machine which inherits the excellent sewing capability and hassle; free operation. • The four hole button sewing mode can be easily switched over to two hole button sewing. • Number of stitches and stitching patterns are easily adaptable. • The machine ensures consistence sewing performances even at maximum speed 1500 rpm. • The thread trimming mechanism helps to produce beautifully finished seam with lesser thread consumption. • Suitable for all kinds of shirts, suits and work uniform. Fig: BUTTON ATTACHING MACHINE WITH AUTO TRIM Page | 39

40. Applications - • To attach button in garment. TWO NEEDLE MACHINE: Brand name: JUKI FIG: Two needle m/c Application: This type ofmachines are used for decorative purpose. It is specially used for sew woven fabric. ZIGZAG STITCH MACHINE: FIG: Zigzag stitch m/c Page | 40

41. BRAND NAME: JUKI STITCH SYSTEM: STANDERD ZIGZAG STITCH PATTERN: MAX. SEWING SPEED : 5000 stitch/ min. POCKET WELTING /ATTACH MACHINE : Brand name: FIG: Pocket welting m/c It is specially used for sew pockets in coats , blazer and trouser/pant. Sewing speed : 1000- 3000 stitch/min Kind of welts : parallel double welt/ single double welt Sewing length : min 18 – max 220 mm Machine head : 2 needle lock stitch machine Page | 41

42. BLIND STITCH MACHINE: Brand name: ZUSUN Fig: BLIND STITCH MACHINE FEATURES – Blind stitch means stitch is not visible on fabric. It is formed based on chain stitch ( 1 thread) and lock stitch (2 thread). The hem and facing are folded back and caught by the needle. In this machine curved needle is used which penetrate straightly in the fabric. Sewing speed of blind stitch is up to 3000 stitch/min. This machine is used for special purpose. It is used for sew bottom hem. METAL DETECTOR MACHINE: Brand name: BESTA CBS -400- M.A.S To detect metal in the accessories. Page | 42

43. RAW MATERIAL & STORE: Types of Raw Materials: Fabric: Woven & Denim Fabric Accessories: Thread, Button, Zipper, Fuse, Hook, Clip, Elastic, Hanger, Poly, Hang tag, Main Level, Size level, C/O level, Tag pin, Patch level, Price Ticket, Button, etc. Washing Chemical: Necessary raw materials required for stone, Pigment, Acid, bleach & Enzyme Wash These very according to the order of the buyer Sources of Raw Materials: Required raw materials are purchased from following countries through agent: a. Hong- Kong b. Taiwan c. Philippines d. India e. Germany f. Brazil g. Pakistan h. South china Store: It has big store room within fabric, trimming, accessories, box, readymade garments, contains difference types materials electrical and machinery accessories. Mainly it two sections store are: Page | 43

44. Technical Store: It contains various types electrical, machinery & materials which supply in many section of garments, such as Various types of sewing m/c and their parts Guide Clamp Shuttle carrier Zipper guide Belt Shuttle Feed dog Hand glove spring Folder Knife Bobbin winter Guard Blade Screw Lopper Roller covers Patty Attachments sate Needle Finger Bobbin Pressure feed Rotary hook Bobbin case Fabric &Accessories store: Standard commercial name of fabrics There are many types of standard commercial name of fabric i.e. are bellow Denim, Twill, Rib top, poplin, satin. Sateen, Mesh, Pure coated, Linen, T/C, Nylon, Micro fabric, Polo pique, Polar fleece, Polyester, Canvas, Corduroy, Single jersey etc. FABRIC CONSUMPTION: L*W=RESULT%2.54%36%FABRIC WIDTH Page | 44

45. FABRIC INSPECTION BEFORE INHOUSE: Different types of fabric defect are shown on the fabric. These defects will be overcome by inspection method. Some defects are given below: Foreign fiber, hole, slub / knots, stains / dirts, spot, splice, missing yarn, knitting defect, thick yarn, shading etc. As Paramount has ventured into making a range of fabric inspection machines called Check MASTERS. This machine is used to provide the common fabric defects and inspection methods for checking the fabrics. FIG: FABRIC DEFECT TEST M/C The acceptability level for first quality fabric is usually established by mutual agreement between the buyer and the seller. INSPECTION METHOD: The inspection of fabric has two primary functions; first to classify the products according to the different quality based on the demands of the buyer/market or client and second to provide the information about the quality being produced. During the inspection the fabric may be found to contain different defects. The defects depending on the magnitude, frequency of occurrence, position, Page | 45

46. importance, effect on the purpose, consequence in the further process etc., shall be classified and graded under various systems. During the inspection, the occurrences of various defects need to be examined and graded based on their magnitude and dimension as per the required system. There are two most common types of systems for grading the defects: • 4 – Point System. • 10-Point System. But 4- point system is followed for fabric inspection by making blanket in the ENVOY GROUP 4 – Point system: It is an inspection method used for the visual checking of fabric quality, faults are scored with penalty points of 1, 2, 3 and 4 according to the side and significance. The 4-point system, also called the American Apparel Manufacturers‘ Association (AAMA) point-grading system for determining fabric quality, is widely used by producers of apparel fabrics and by the Department of Defense in the United States and is endorsed by the AAMA as well as the ASQC. . Shrinkage test: Testing time: After dryer or before compacting. Equipment used: Shrinkage board, shrinkage scale, measurement tape, scissor, washing machine, detergent. Lengthwise shrinkage = (-ve) %. Lengthwise extension = (+ve) %. Test method: ISO 6330:2000. Shrinkage tolerance: ±5%. The fabric is cut according to the shrinkage board. Then the fabric is wahed by washing m/c with PCLF for 60 min. at 40. Then the shrinkage% is determined by the shrinkage scale. Note: before inhouse fabric inspection and shrinkage test must be done. Page | 46

47. IN HOUSE CONTROL FABRIC INSPECTION REPORT  Page | 47

48. FLOW CHART OR SEQUENCE OF FABRIC INVENTORY: Received the Fabric Inspection Physical Inventory Make the Swatch Card Prepare the Blanket Shade Head Segregation Issue Fabric to Cutting Page | 48

49. Fabric accessories There are many types of fabric accessories are used in garments manufacturing sectors, which are below- Thread, Button, Rivet, Zipper, Fuse, Hook, Clip, Elastic, Hanger, Poly, Hang tag, Main Level, care level, Twill tape, Velcro tape etc. FIG: FABRIC ACCESSORIES & TRIMMINGS THREAD CONSUMPTION: Total garments quantity*thread quantity% count wise thread quantity = total cone Others accessories are counted by yards, pcs Page | 49

50. FLOW CHART OR SEQUENCE OF ACCESSORIES INVENTORY: Received Accessories Inspection Physical Inventory Swatch Making Swatch Approval from Buyer Record the Entry Supply to the Sub-Store Use to Bulk Production Page | 50