LETTER OF TRANSMITTAL November, 03, 2016

To,

The Supervisor

Saiful Islam Tanvir

Assistant Professor

Shanto-Mariam University of Creative Technology

Subject: Submission of Internship report

Dear Sir,

It gives me enormous pleasure to submit the internship report on

“Industrial Attachment at Fakir Apparels Limited” as per the supervisor’s

instruction. I expect this report to be informative as well as

comprehensive.

I demonstrate my best mark of respect and gratitude to you for providing

us the opportunity to do our internship. We feel the 8 weeks experience

will facilitate us a lot in our future career life. For any further

explanations about the report please summon us, we will be gladly

available to clarify the ins and outs.

Sincerely Yours

Md.Shaidur Rahman

ID-132011301

Shanto-Mariam University of Creative Technology

DECLARATION

We, hereby declare that this internship report on “Industrial Attachment at Fakir

Apparels Limited” submitted by us to Fakir Apparels Limited, in partial

fulfillment of the requirement for the degree of BA(Hons) in Apparel

Manufacturing Management and Technology is an original work. It has

not been submitted earlier, either partly or wholly to any other

Organization, University or Institution for the award of Degree, Diploma,

and Fellowship or other similar titles or prizes and that the work has not

been published in any journal or magazine.

Md.Shaidur Rahman

ID-132011301

Md. Safayet Alam

ID-132011235

Md. Ahaduzzaman SohanID-131011006

Department of AMMT

Shanto-Mariam University of Creative Technology

CERTIFICATE

This is to certify that the internship report on “Industrial Attachment at Fakir

Apparels Limited” submitted in partial fulfillment of the requirement for the degree of

BA (hons) of Shanto-Mariam University of Creative technology. Md. Shaidur Rahman ID-132011301, and Md. Rezaul Karim ID# 101-

090407. Have worked under my supervision and guidance and that no

part of this has been submitted for the award of any other Degree,

Diploma, Fellowship or other similar titles or prizes and that the work

has not been published in any journal or magazine.

Certified

Saiful Islam Tanvir

Assistant Professor

Shanto-Mariam University of Creative Technology

ACKNOWLEDGEMENT

At first, we would like to express our gratitude to almighty Allah for enabling us the strength and opportunity to complete the report in the schedule time successfully.

We are deeply indebted to our supervisor Saiful Islam Tanvir, Course Coordinator, department of Textile Engineering for his stimulating inspiration, kind guidance, valuable suggestions & sagacious advices during our internship period. His suggestions & guidance have made the report in a good manner.

We express our sincere gratitude to Engr. Kawsar Alam Sikder, General Manager of Fakir Apparels Limited, who has guided us by giving his valuable suggestions. Special thanks to the personnel of knitting section for guiding us. We also express our gratitude to Mr. Mostak Ahmed, Assistant Manager of Quality Lab. We put our special thanks to Jewel sir who has provided us a lot of information and his valuable knowledge & suggestions in dyeing section.

We are loaner to merchandising manager Mr. Rafiqul Islam for his guidance and helps. We are also thankful to other personnel of merchandising section for their helping attitude. We are thankful to the personnel of printing section for their inspiration and helps.

We would like to express our deep sense of gratitude and thanks to Mr. Md. Foyez Uddin and Mr. Rafi of HRM department for his kind cooperation and observation, for their guidance, valuable knowledge & suggestions during my internship period.

We would like to convey our best regards to all the officials and workers of the Fakir Apparels Limited. We especially like to thank our parents & all of our family members for extending their helping hand at a time when we need it most.

We remember all the care and love of our friends who made our every existence more meaningful and worthy. Finally we would like to put special thanks to the authority of Fakir Apparels Limited for allowing us in their organization.

EXECUTIVE SUMMARY

The internationally recognized Buyers or clients are looking for those countries for producing their apparel products where different types of mills have established as a one stop source for the global apparel market, 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. And also assure complete compliance with the international quality standards and also to provide the employees internationally acceptable working condition/standards. In Bangladesh, there are different types of Textile

Industry those are producing high quality textile and apparel product. Fakir Apparels Limited. is one of them. Fakir Apparels Limited. is Composite Knit Garments Manufacturer & Exporter, having all state of the art facilities with the annual turnover US $ 30 Million. They have Different types of knitting, Dyeing, Cutting, Sewing, and Finishing machines supplied by mostly Japan, Taiwan, U.K, USA, China, etc. which are very latest. It has high production where 30 tons of knitted and finished fabrics are produced per day. The production is controlled by technical persons. All of the decision makers of production sector in Fakir Apparels Limited are textile graduates. All the Yarn, Chemicals and dyes use for Knitting, dyeing and finishing are well branded. They produce their product for their buyer and client those are coming from international market like USA, U.K, Sweden, Ireland, France, Germany, Belgium, Spain. They follow all the system for their machines maintenance so production cannot hamper.

In this report, we have tried to give some information about Fakir Apparels Limited. And we have observed that Fakir Apparels Limited. Produce high quality fabric and fulfill the special requirements from the different types of buyers by following different internationally recommended standard method.

TABLE OF CONTENTS

S L. Topic Page

No NoLetter of transmittal I

Declaration IICertificate III

Acknowledgement IV

Executive summary VOVER VIEW OF THE FACTORY 1

General Information of The Factory 2-3Certificates 4

Buyers 5Product Mix 6

Departments Related with Production 6Supporting Department 7

Plant Location 8KNITTING SECTION 9

Organogram 10Knitting 11

Raw Material for Knitting 11-12Machine List of Knitting Section 13

Specification of Circular Knitting Machine 13-18Others Machines in Knitting Section 18

Sequence of Operations in Knitting Section 19Process flowchart 20

Product Mix 20-21Considerable Points to Produce Knitted Fabrics

21-22

Production Calculation 22-23Basic Knitting Elements 23-24

Different Parts of Knitting Machine 24-25Quality Checking Flowcharts 26

Types of Knit Fabric Produce By FAL 27-28

Knitting Faults 29-35

BATCH SECTION 36

Batching 37 Function of Batch 37

Proper batching Criteria 38 Batch Management 38

COLOR LAB 39

Color Lab 40Sequence of Operation 40-41

Spectrophotometer 41-42Verivied Cabinet 43-44

Working Flowchart 45Lab Dyeing Procedure for Cotton 46

Lab dyeing process for levafix ca/ remazol rr/ remazol ultra rgb

47

Lab Dyeing Process for All Dye 48-51 DYEING SECTION 52

Organogram 53 Responsibility of Production Officer 54

Job Description 54 Dyeing machine Capacity 55-56

Dyeing Machine Specification 57-58 Raw Material for Dyeing 58-60

Dyes List 60 Chemical and Auxiliaries List 61

Flowchart for Dyeing 62 Pretreatment and Dyeing Process 61-69

Main Parts of Dyeing Machines 70-72 Dyeing Parameter Control Chart 72-73

Common Dyeing Faults with Their remedies

73-76

FINISHING SECTION 77

Finishing 78

Objective of Finishing 78Types of Finishing 78

Organogram 79Flow Chart of Finishing Section 80

Flow Chart for Peach finish 80-81Slitting Machine 81-83

Stenter Machine 83-84Open Compactor 85

Squeezer 86Dryer 87

Tube Compactor 88-89QUALITY LAB 90

Laboratory Machine with Its Specification 91-92Yarn count test. 93

Evenness test of yarn. 93Fabric GSM tests. 93

TPI test. 93Calculation of shrinkage & Twist % of garments.

94

PH test 94-95Pilling test of fabric. 95

Formaldehyde test ISO 14184–1 JISA JISB 95Color fastness to Rubbing. 96

Color fastness to Washing. 96Color fastness to perspiration. 97

GARMENTS CUTTING SECTION 98

Machine Specification 98

Standard Operating Procedure of CuttingSection

99-100

PRINTING SECTION 101

General Overview 102 Types of printing 102-103

Machine Brand 103 Flowchart of printing Section 104-105

Expose Room 106 Print wise Curing 108

Common Print Defects 109 Major Causes of Print Defects 111-112

Sewing Section 112

Sewing 113

Organogram of Sewing Section 113

Floor Layout Plan of Sewing Section (4th Floor): 114Name of the Machines Used in Sewing Section

115

Activities of Sewing Section 115-116

Different Types of Stitches 116-117

Different Types of Sewing Machines 117-119Machine wise Sewing Thread Consumption (for 1st Stitch)

120

Different Types of Seam 121Different types of Defects 122

Process Flow of Some Products 122-123

Garments Finishing Section 124

Process Sequence of Garments Finishing 125-127 Floor Layout Plan of Garments Finishing 128

Machine Description of Garments Finishing

129

Material Used in Garments Finishing

130

The General Rules of Spot Removing

130

Flow Chart of Garments Inspection

131

Packaging 132

Photo Gallery of Finishing

133

MERCHANDISING SECTION 134

Introduction 135Need of Merchandiser 135

Responsibility of Merchandiser 135-138Main Procedures of Merchandisers 138

Chronological Process of Merchandising 139Sequence of Sample 139-142

Trims 142-143Communication in International Business 143

The Information Normally Get About an Order

143

How a merchandiser meet buyers requirements

143

Methods of purchasing raw materials 143Procedures of imported goods 143

How does the accepted order is passed on the floor

143

How a merchandiser track his/her 144

production. INDUSTRIAL ENGINEERING

SECTION

145

Introduction 146 Activities of IE 146

Objectives of IE 147 Function of an Industrial Engineer 147

Techniques of IE 148-149

IE Job Profile 149-150Organogram of IE Department in FAL 150

IE Tools 150Some Terms and Definition Used in IE 150-153

Some Formula 154QUALITY ASSURANCE

SECTION

155

QA system 156Quality Management System 156

Online Quality Control 157Offline Quality Control 158

MAINTENANCE DEPARTMENT 159

Maintenance 160 Types of Maintenance 161

Flowchart of Maintenance 162 Maintenance Tools 162

Maintenance Procedure of Different Machine

163

UTILITY SERVICE 165

Utility Service 165

Electricity 166Compressed Air 167

Water Treatment Plant 167

Method of Water Softening 168

Sequence of Water Treatment plant 169

Measurement of Water Hardness 169 STORE AND INVENTORY 170

Inventory 170 Causes of Maintain Inventory 170

Inventory Management for Raw Material 171 COST ANALYSIS 172

Costing system 172

Price of Different Operation 173

Remarks 173 MARKETING STRATEGY 173

Marketing Information 173 Marketing Strategy 173

Major buyer 174 Exported Country 174

CONCLUSION 174

BIBLIOGRAPHY 175