Introduction

Bangladesh is a country of 160 million people. Economic growth of this country largely

depends on the proper use of the people which is one of the great resources. Bangladesh is

known as the emerging tiger of South Asia because of the rapidly growth of our economy.

There are many sectors which helps our economy to grow faster. RMG is one of them.

Among RMG Sector, Knit Composite industry plays a significant role to promote our RMG

Sector through earning a huge amount of foreign currency by exporting knitted garments

worldwide.

Knit composite industry is an industry where functions are started with yarn receiving from

the spinning mills and end with shipment of knitted garments. Between this processes, we

have to follow several ladders which help us to attain the knitted garments to the customer

with the ensuring quality.

Bangladesh Export numerous knitted garments such as T-shirt, Polo Shirt, Singles, Tank top,

Leggings, Tights, Cardigan, Pullover, Play suit, Tunic, Knitted Trouser and so on. For

building this knitted garments we have to maintain several stages such a knitting, fabric

finishing, storing, cutting, sewing, quality checking, finishing, shipment etc. which assist us

in smoothly exporting the knitted garments.

Therefore, before going to the process flow of Knit Composite industry, the very beginning

we have to know the advantages of Knit Composite industry than woven composite industry.

Advantages of Knit Composite Industry in Bangladesh than Woven Composite

Industry:

Bangladesh is mainly Knitwear export oriented Country.

Profit is maximized due to backward linkage of knit industry.

Lead time can be controlled due to easier supply chain.

Higher production rate with lower cost supply chain.

Primary installment for knit composite factory is much lower than the woven

composite industry.

Transport cost is minimized in case in case of knit composite industry.

(Source: Engr. Prasad.R.K.2016.)

In this Study, we will briefly discuss about Process Flow of Knit composite industry – For a

basic item T-shirt. For that we have to know initially our objectives of the Study.

Objectives of the study

To assesses the function of each stage of knit Composite industry.

To understand the overall process flow of knit composite industry.

To find out the individual stage process flow.

To get knowledge about knit composite industry.

Process flow of Knitting Section

(Source: Kiron.M.I. 2012)

Process flow of Dying Section

Yarn Cone receive

Place the Yarn Cone in the creel

Feeding the Yarn

Set the machine as per design and GSM

Knitting

Withdraw the roll fabric and weighting

Roll Marking

Inspection

Numbering

Yarn dying (if required)

(Source: Textile fashion Study. February 20, 2012)

Process flow of Store Section

(Source: Raaz.N.A.2015)

Process flow of Cutting Section

Receive Textiles materials (Grey fabric, yarn etc)

Singeing

Desizing

Scouring

Bleaching

Mercerizing

Dyeing

Finishing

Receiving Product from Dying Section

Inventory

Inspection of product

Shade segregation

Issuing product

Sustaining Balance

Closing Summary

(Source: Islam.M.J 2015.)

Process flow of Sewing Section

(Source: Islam.M. July 14, 2015)

Pattern Received from Pattern Department

Cutting Ratio received from Merchandiser

Marker Making

Fabric Received from The store

Fabric Checking

Fabric Spreading

Cutting the fabric

Numbering

Checking

Sorting & Bundling

Send to the sewing department

Printing /Embroidery

Marker Placing on the Lay

Product Analysis

Setup Target for production

Distribution all processes

Cutting parts received for Cutting Section

Cutting parts Distribution

Sewing according to Distribution

Line Q.C Check

Line Quality Audit

Counting output according to target

Final Quality Check

Send to finishing section

Process flow of Finishing Section

(Source: Akter.J. 2014)

Finishing Input ( Color, style & size wise

Initial quality Check

Spot Removing

Ironing/Pressing

Inspection

Hang tag

Get Up change

Folding

Poly

Bar Code (if required)

Metal Check

Cartooning

Inspection

Dispatch shipment

Overall Process flow of Knit Composite industry for a basic T-shirt

Description

Order Receive: For production any kind of Garment, At first we have to receive order to

execute production for any kind of RMG factory. After receiving orders, knit composite

factory plan how to execute order ,which method they follow to execute order and they also

make sample for buyer approval as well as they also involve in material sourcing process.

Planning: Here Knit Composite factory makes time and action plan based on man, machine,

materials availability or their capacity to accomplish order. In this stage, authority decides

how to accomplish the order, how much man, machine, material requires accomplishing

order, how to they control overall process etc.

Sampling: Here factory makes sample according to buyer requirements and send the sample

to the buyer for the buyer’s comments so that they can rectify the fault in the sample.

Order Receive

Planning

Sewing

Material Sourcing

Knitting

Dying

Pp Sample Approval

Trims & accessories in house

Storing

PP Meeting

Cutting

Sampling

Printing/Embroidery

Finishing

Final InspectionShipment

PP Sample approval: After getting the buyer comments, the factory rectify the faults and

send sample to the buyer again before going to the bulk production. That’s why it is called

pre-production sample. After getting approval from buyer, the factory will be ready for bulk

production.

Material Sourcing: In the mean time, knit composite factory will be involved in Material

sourcing process. At first they booked yarn to produce fabric in their knitting section. After

making fabric, the grey fabric sends to the dying section for dying according to requirements.

After dying fabric & booking trims and accessories, stock up the fabric & trims and

accessories in the store and inspection the product.

Trims and Accessories: Knit Composite must have to ensure trim and accessories are in

house before going to bulk production as per required quality and quantity.

Knitting: Here several steps are followed. Very First, yarn received from the spinning mill ,

then dyed the yarn if required. After that, place the yarn cone in the creel and feeding the yarn

and knitting the fabric. After knitting fabric, withdraw fabric roll from the machine and

inspect the roll and give the roll number. So that, we can identify the specific roll by the

number.

Dying: After Grey fabric knitting, fabric sends to the dying section for dying fabric roll

according to required color. Before dying several stages have to be maintained such as

desizing, scouring, bleaching, mechanizing etc.

Storing: Before going to the bulk production , the factory have to ensure all the equipment

are available in store and store department inspect all the materials and makes a summery

about shade segregation ,issuing product amount, sustaining balance and closing the

summery.

PP meeting: Based on the planning, sample approval, and material sourcing and store

department inspection report pp meeting are held to decide how to finally execute the bulk

production depends on what necessary step should be taken, how works will be divided,

section wise responsibility will be distributed through this meeting.

Cutting: As per PP meeting decision, cutting section received pattern as per style, cutting

ratio and then cutting master making the marker. After that fabric receive from the store,

fabric checking to see if it’s okay for cutting or not, then spread the fabric on the cutting table

and create lay, then marker place on the lay and start cutting. After cutting check the parts to

see if there is any cutting fault or not , then numbering the cutting pieces to avoid shade

variations, then sorting & bundling the parts and send to the printing and embroidery section

if required or send to the sewing section for further process.

Sewing Section: At this juncture at first PP sample analysis is done ,setup line target ,

distribute processes to the workers .Then cutting parts received from cutting or

printing/embroidery section (if there is) and distribute the parts to workers in the same way as

process distribution and workers sewing the parts .In the mean time, line Q.C check and Q.C

audit has been occurred so that we can accomplish required quality. After that finally

counting output according to target and full garment quality ensuring is done, and garments

are send to the finishing section.

Finishing Section: It is one of the most important part of knit composite unit. After inputting

garments, first initial quality check is done to find out the fault of the garments. Here, spot

removing, ironing/pressing, inspection, hang tag attach ,get up change , folding the garments

as per requirements , poly the garments, metal checking etc are done to give product aesthetic

value. After that goods cartooning or packing to box is done for buyer’s inspection.

Inspection: Buyer’s representatives or buyer inspect the cartoon randomly to find out if the

product produces according to requirements. If they find satisfactory result then the goods

will be accepted otherwise the entire shipment will be rejected.

Shipment: After inspect the goods as per predetermined condition , If buyer find satisfactory

result then the goods will be accepted for shipment otherwise the entire shipment will be

rejected.

Conclusion

Bangladesh is mainly knitwear export oriented country .Bangladesh has more than 200 Knit

composite factory and the number is increasing day by day and Bangladesh knitwear is

unbeatable in price advantage in the world. Bangladesh provides not only a cheap labor force,

which is unbeatable but they are also peerless in stitching capability. Knitwear is exported to

153 countries of the world from Bangladesh. (Source: Strength of knitwear sector of

Bangladesh: BKMEA) So knit composite industry’s importance is increasing gradually. As a

result, process flow of knit composite factory is an important part of RMG sector which assist

us to ensure smoothing exporting and contribute our GDP.

References

1.Engr.Prasad.R.K.(2016).Lecture: Introduction to cut & sew knitwear, Uttara, BGMEA

University of Fashion & Technology.

2.Kiron.M.I. (2012). Process flow chart of Knitting Technology. Retrieved from

http://textilelearner.blogspot.com/2012/09/process-flow-chart-of-knitting.html.

3.Textile fashion Study (2012).Process flow chart of Dyeing Textile Materials, Basic

structure of Wet processing Technology (2012) Retrieved from

http://textilefashionstudy.com/process-flow-chart-of-dyeing-textile-materials-basic-structure-

of-wet-processing-technology/

4.Raaz.N.A.(2015).Working Flow Chart of Store Department in Garment Industry(2015).

Retrieved from http://textileflowchart.blogspot.com/2015/11/working-flow-chart-of-store-

department.html

5.Islam.M. July14, 2015. Process Chart of Garments Cutting Section (2015). Retrieved from

http://www.garmentsmerchandising.com/flow-chart-of-garments-cutting-section/

6. Islam.M. July 14, 2015. Process flow for Garments Sewing Department (2015). Retrieved

from http://www.garmentsmerchandising.com/process-flow-chart-for-garments-sewing-

department/

7.Akter.J.Dec 21,2014. Process Flow Chart of Garment Finishing Section (2014). Retrieved

from http://textileflowchart.blogspot.com/2014/12/flow-chart-of-garment-finishing-

process.html

8. Strength of knitwear sector of Bangladesh: BKMEA. Retrieved August 22, 2016, from

http://www.bkmea.com/Strength-of-Knitwear-Sector-of-Bangladesh.html