Industrialattachmentofopexgroup 140511101158 Phpapp02

Industrial Attachment Report
2013
INDUSTRIAL TRAINING
Course Code: Tex -4036
INDUSTRIAL ATTACHMENT
OPEX GROUP
OPEX GROUP
2013
Industrial
Attachment
Report
At
OPEX GROUP
2013
OBJECTIVE OF INDUSTRIAL ATTACHMENT

B. Sc in Textile Technology is the combination of theoretical knowledge along
with the practical experience. We as the Graduates of Textile Technology
must acquire adequate practical knowledge to cope up with the challenge
that we will face in future. This is the why the Industrial Training has been
included in our academic curriculum.
The main objective of this training is to comprehend our theoretical

knowledge along with the practical knowledge. It also enables us to orient
ourselves with the practical environment that we will work in future. We
systematically learned about various steps of garment manufacturing.
Moreover we knew about the man management technique. We also learned
about merchandising and buyer co-ordination.
OPEX GROUP
2013
INTRODUCTION
By achieving practical knowledge it is possible to apply the theoretical
knowledge in the technical field. For any technical education, practical
experience is almost equally necessary in association with the theoretical
knowledge. The industrial attachment is the most effective process of achieving
the practical experience. It provides us sufficient practical knowledge about
production management, productivity, evaluation, work study, efficiency,
industrial management, production planning & control, production cost analysis,
inventory control, purchasing, utilities and Maintenance of machinery and their
operation technique etc.
Industrial attachment is an essential part of four years B.Sc. in Textile

technology course of College Of Textile Technology under University of Dhaka.
We had the opportunity to perform the industrial attachment with OPEX
GROUP LTD. During 60 days long attachment, we studied the man, machine,
material, quality control section, planning section, grey fabric inspection,
finished fabric inspection, dyeing & finishing section, merchandising section of
the mill. We also had a short visit in the garments section of the factory.
OPEX GROUP
2013
Table of Content
Chapter
Contents
Chapter-i
Chapter-ii
Chapter-iii
Chapter-iv
Chapter-v
Project description
Manpower management
Machine description
Raw materials
Production planning, sequences &
operations
Quality assurance system
Maintenance
Utility services
Store & inventory control
Cost analysis
Marketing activities
Garments washing
Merchandising
Conclusion
Chapter-vi
Chapter-vii
Chapter-viii
Chapter-ix
Chapter-x
Chapter-xi
Chapter-xii
Chapter-xiii
Chapter-xiv
OPEX GROUP
Page
no.
6-12
13-18
19-25
26-27
28-33
34-37
38-44
45-48
49-50
51-52
53-57
58-70
71-70
73-77
2013
CHAPTER- I
(PROJECT DESCRIPTION)
OPEX GROUP
2013
Name:
OPEX FASHION LTD. (a sister concern of OPEX & SINHA TEXTILE GROUP)
Type:
Ready made garments(100% Export oriented Woven& knit garments Industry).
Status:
Private limited company
Location: Mirpur-13 , Dhaka.

Year of establishment: 1984
Sponsors:
Address:
Anisur Rahman Sinha
a. Dhaka office:
56/1,Block#C,Section-13,Mirpur,
Dhaka-1216
Bangladesh.
Tel: 8015446
8015241
8023726-7
Fax: 880-2-8013522
b. Head Office:
House # 368, Road # 28, New DOHS, Mohakhali
Dhaka-1206, Bangladesh.
Tel: 88-02-8828860-4, 9891390-1
Fax: 880-2-8828856-7
c. Kanchpur Office:
Sinha Textile Complex,Kanchpur ,
Sonargaon,Narayanganj
Tel:7618066,7618055,7617788.
d. Hongkong Office:
Joyful Miles Ltd. 16B Alpha House
Tel: 2721-1950(5 lines), Fax: 2721-1967
E-mail: mhkhan@opexhkg.com.hk
OPEX GROUP
2013
Factory Location:
Banani
Cantonment
Kachu
Khet
Mirpur-10
Mirpur-14
OPEX
OPEX GROUP
2013
PRODUCT MIX:
a) Woven Garments: Shirt,Jacket,Pant/Trousers,Shorts Jeans item,Ladies &
Children item.
b) Knit garments:
T-shirt, polo shirt, Short / trouser, Knitted pant, Vests
DAILY PRODUCTION CAPACITY:
Garments: 40000 pcs (Dhaka Zone)
No. of line: 32(Dhaka zone) &100 (Kanchpur zone)
MONTHLY EFFICIENCY:
Daily production: 40000 pcs Approx.
Daily production capacity: 45,000 pcs
So, monthly production: 1040000 pcs
Monthly production capacity: 1170000 pcs
So, Monthly production efficiency= 88%
PROJECT COST:
US$1,0000000per year (approx) in 2007
US$1,5000000Projection for 2008.
DIFFERENT DEPARTMENTS:
1. Marketing and Merchandizing
2. Lab department
OPEX GROUP
2013
3. Quality Assurance
4. Garments& GGT Lab
. Cutting
Sewing
Finishing
Inspection
Packing
5. Stores
6. Technical Department (Maintenance)
7. Human & Resource and Administration
8. Account and commercial section
9. Batching section
TOTAL AREA OF THE INDUSTRY: 15000 sq. feet & 4 building,

OPEX FASHIONS LTD :
10 Storeyed
OPEX STYLE WEAR LTD:
8STOREYED
SINHA STYLE WEAR LTD : 12 Storeyed
OPEX GROUP
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2013
COMPANY PROFILE:
OPEX
Opex is one of the largest garment manufacturing conglomerates in Asia and has a complete vertical
integrated setup in woven, knit and sweater with most modern and state of the art machineries from
USA, Europe and Japan. It is a private owned company with an annual turn over of US $ 350 million
and annual export is about US $ 250 million.
Garments Division
Opex has over 18000 sewing machines distributed to 300 production lines including 40 Knit garment
lines and 2000 Sweater machinery. It produces over 220,000 pieces of garment every day. The
production lines are broadly earmarked as Bottom lines, Shirt lines and Knit lines.
Bottom Factories
Opex has about 210 bottom production lines and they produce over 140,000 pieces of garments daily.
These are organized into dress pant lines, casual pant lines, cargo short/ pants lines and denim
production lines.
Dress and casual pant lines have some specialized sewing machines like pocket welting machines,
zigzag operations machines, blind stitch machines, front fly J-stitch machines, etc. Finishing of casual
and dress pant is done with lager and topper press machines, seam opening and pressing machines,
curing oven etc. Other than standard denim production line Opex has 16 dedicated specialized denim
production lines, equipped with fully automated computerized sewing and finishing range machines
from Italy. Each line produces 230-250 pieces of 5-pocket jeans in one hour, totaling to 34000-37000
pieces daily.
Shirt factories
Opex has 48 dedicated shirt lines which produces 35,000 to 40,000 pieces of casual, sports and formal
dress shirts daily. The formal and dress shirt lines are equipped with Droukoff Adler sewing machines
of Germany fitted with servo motors and trimmers which ensures consistency in sewing and eliminates
puckering effects. Collar & cuff making and setting, placket making, pocket making & setting and arm
hole fusing are all done with computer controlled automatic machines. The finishing units have
automatic collar, cuff, arm hole and body pressing machines for perfect finish.
Knit Garment Factories
Opexs 40 Knit garment lines have over 2000 sewing machines and it produces about 60,000 pieces of
T-Shirt, Polo Shirts daily. These lines can also be converted to produce shirts or ladies dresses by
changing and adding few machines.
Sweater Factory
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Our major production is on 12 gauge. However we have production facilities in 10 gauge, 7 gauge, 5
and 3 gauge. Presently we have about one hundred thousand production capacity per month but
recently have gone into expansion this will have capacities from Dec 08 about two hundred per
month.
Dry and Wet Processing Facilities
The in house dry and wet processing units of Opex includes sand blasting, brushing, chemical
spraying, laser blasting, heavy, medium and light wash facilities and post cure wrinkle
free processing facilities.
Opex has one of the most modern denim washing facilities in the country equipped with computer
controlled European machines. Denim wash capacity is about 1,00,000 pieces daily. It also has 55
belly type Chinese machines to take care of other washes. It has two modern dry finish units with
modern equipment with curing oven.
Backward Linkage and Vertical Setup of Opex
Customers increasing need of varied range of fabric, shorter lead time, sharper price and consistent
quality, led Opex to set up its own vertical set up in 1995, named as Sinha Textile Group. The
objectives of these facilities are; attaining consistency in fabric quality, developing specialized fabric &
offering competitive price and shorter lead time.
Opex today has the entire chain of backward linkage facilities of spinning, weaving, yarn dyeing, fabric
dyeing & finishing, knitting, knit dyeing and finishing. State of the art machines, Textile experts from
home & abroad have been combined together to make wide range of high quality woven fabric for
bottom, shirt & Knit fabric.
Supporting Establishments
To support garments manufacturing, Opex has its own button factory, label factory, Sewing Thread
manufacturing unit and Embroidery unit. It also has its own Carton and Poly manufacturing factory.
We have also joint venture with IDEAL Zipper factory in Bangladesh.
Opex has done massive expansion in increasing its garments production, washing and finishing
capacities as well as increasing capacity and adding new technology in its backwards integration units
like compact yarn, producing high density fabric, wet sueding and different types of fabric finishing
etc.
Denim Village.
Recently, we have established a massive project named denim village where we are producing, Denim
fabric, Denim garments, Denim Washing, and different types of finishing in one complex.
Opex can convert all its fabric into Garments and will produce about 65000 pcs Denim Jeans and
Jacket per day.
Conclusion.
Opex with over 45,000 work forces is in business for more than two decades. It always tries and
maintains its commitment of on time delivery, quality and competitive price. Over the years, the
business relations with all customers and partners have grown stronger based on mutual trust and
commitment.
Opex is an ethical and compliant company, putting in maximum emphasize on developing human
values, qualities of human life and comfort of work environment. It is committed to ensure ethical
source place for the customer.
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CHAPTER- II
(MANPOWER MANAGEMENT)
OPEX GROUP
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ORGANOGRAM MANPOWER:
Chairman
Executive Director
General Manager
Deputy General Manager
Asst. General Manager
Merchandising Manager
Sinior Merchandiser
Merchandiser
Production Manager
Sample incharge
Operator
Helper
Cutting incharge
Cutting executive
Cutting supervisor
Marker man
Sewing incharge
Line supervisor
Operator
Helper
OPEX GROUP
Quality inchare
Operator
Helper
14
2013
Cutterman
MANAGEMENT SYSTEM:
GARMENTS SECTION: 8 hours per day.8 AM-5 PM. Overtime: 2hours.
Offday: Thursday in a week.
RESPONSIBILITIES OF PRODUCTION MANAGER:
RESPONSIBILITIES OF SAMPLE ROOM INCHARGE:
To make pattrn from specification sheet.
When there is no measurement chart then he make specification chart by
his own idea, then send to buyer,if it is ok then he make pattern.
After making sample he check the sample if it is ok , then he order to
make 4 pcs of the sample.
RESPONSIBILITIES OF CUTTING INCHARGE:
Check the relaxation of fabric,order wise quantity measure, patterncutting
with signature,befor sewing to communicate the print embroidery.
To ensure equal input & output.
To check fabric shrinkage, twisting repair.
To make the cutting plan according to operation breakdown.
To give target and style devide in every table.
RESPONSIBILITIES OF QUALITY INCHARGE:
To control the overall quality of the garments.
To brief the incharge about tentative problem of quality.
To make size set of the garments.
To check the measurement of the garments, if required increase or
decrease
RESPONSEBILITIES OF PRODUCTION OFFICER: From getting an

order of upper level all responsibilities are on the production officers. They
work with a troop of operators, helpers, fitters etc. to finish the production in
due time. In the meantime
OPEX GROUP
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2013
Production officers bear all hazards, problems. They have to explain to the
manager for any type of production hamper. So all production activities and its
success depend on the production office.
MANPOWER MANAGEMENT
ADMINISTRATIVE STRUCTURE OF OPEX GROUP:
CHAIRMAN
EXECUTIVE
DIRECTOR
ADMIN
&EESTB
DGM
AGM
CLEANER
&
SANITER
Y
INCHARG
PERSON
E
AL
TIME
ACCOUNT
S
STORE
GM
AGM
UNIT-INCHARGE
INTERNAL
&
EXTERNAL
ADMIN &
DAY
CARE
SECURITY
INCHARG
E
UNIT-INCHARGE
INCHARG
E
TRAINING
INSTITUTE
PRINCIPAL
SECURITY
SUPERVIS
OR
COMPUT
ER
COMPLINCE
D.G.M.
UNIT-INCHARGE
INCHARG
E
MEDICAL
OFFICER
UNIT-INCHARGE
TECHNIC
AL
DGM
MECHANICAL
ELECTRICAL
AGM
AGM
OPEX GROUP
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2013
ORGANOGRAM OF QUALITY CONTROL DEPARTMENT:

GENERAL MANAGER (QUALITY )
ASST. GENERAL MANAGER
MANAGER
ASST. MANAGER
QUALITY- IN-CHARGE
QUALITY CONTROLLER
LINE Q.C.
ORGANOGRAM OF WASHING DEPARTMENT:
OFFICER-IN-CHARGE (O.I.C.)
ASST. OFFICER-IN-CHARGE
MANAGER
FLOOR-IN- CHARGE
ASST. MANAGER
QUALITY INSPECTION CONTROLLER
QUALITY CONTROLLER
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SUPERVISOR
DESCRIPTION
MERCHANDISING STUFF
IT STUFF
SAMLE MAN
Q.A-RAW MAT.
INSPECTOR
Q.A-IN-LINE INSPECTOR
FLOOR Q.C
Q.A AUDITORS
CUTTING SECTION
SEWING SECTION
TRIMMING/ FINISHING
PRESSING & PACKING
PACKING
ELECTRICIAN/MECHANICS
WASHING,SAND
BLASTING & SAND
BRUSHING
PRINTING
PACKAGING
POLY
QUILTING
EMBROIDERY
OFFICE STUFF & OTHERS
NO OF EMPLOYEES
40
04
150
10
250
50
30
200
3200
500
600
250
150
200
TOTAL EMPLOYEES
5976
12
50
30
30
20
200
OPERATOR
TOTAL EMPLOYEES:
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REMARKS:
Production runs with the help of mechanical fitters. For any kind of mechanical
fault of any machine they fix and work under knitting manager. Production
officer takes account of daily production by running after the two supervisors
& workers so on.
CHAPTER-III
(MACHINE DESCRIPTION)
OPEX GROUP
19
LOCK STITCHM/C
2013
LOCK STITCH M/C
H/S D/N LOCKSTITCH
4-holed button sewing
OPEX GROUP
20
CHAIN STITCH BUTTON SEWER
2013
4 NEEDLE DOUBLE CHAINSTITCH
MULTI-NEEDLE DOUBLE CHAIN STITCH
OPEX GROUP
MAIER BLIND STITCH MACHINE
21
SIMPLE PUSH-BUTTON TYPE STITCH
OVERLOCK MACHINES
2013
FLAT-LOCK SEWING MACHINERY
STRAIGHT KNIFE CUTTING M/C
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2013
MACHINE DESCRIPTION
MACHINE DESCRIPTION
Type of Machine
Quantity(Sets)
Sewing Capacity
A. General Sewing
Machine
Single Needle
Double Needle
Over lock
Kansai
Bar Tack
Button Stitch
Button Hole
Eyelet Button Hole
Bottom Hem
Flat Lock
Snap Button
Blind Stitch
Feed of the Arm
Cutter m\c
Heat Cutter
Fusing m\c
Over lock Elastic Attaching
m\c
Arm Hole Sewing m\c
Total
1000
421
320
50
200
150
100
25
50
65
30
25
150
100
15
15
6
40,000 pieces per day
15
2737
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B. Specialized Sewing
Machine
Auto Patch Pocket Setting
Auto Welt Pocket Setting
Waist Belt Setting
Seam Sealing
Zigzag
Elastic Attaching
Pattern Sewing
Auto Loop Attaching
Snap Testing m\c
Pattern(Collar& Cuff) m\c
Pocket Facing
Picoting
Velcro Cutter
Feather Filling
Total
m\c
Cutting Room
Fabric Inspection m\c
Light Box
Gerber Cam
Gerber Auto Spreader
Manual Cutting Table
Manual Cutter
Finishing Room
Needle Detector
Hang Tagger Attaching
Steam Iron
Thread Sucking m/c
CAD Room
Gerber CAD
Gerber Plotter
Gerber Digitizer
Support
Steam Boiler
Generator
Other Projects
Poly Bag Making Project
Carton Making Project
Printing Project
Quilting
Embroidery
2
10
15
15
10
12
10
5
5
5
10
2
10
4
115
05
02
2
5
20
100
5
20
Cutting Capacity
50,000 yards/day
Finishing Capacity
20,000 pieces per day
150
15
2
1
1
02
02
OPEX GROUP
Capacity
1.5 MW
20 heads on each end and up

24
2013
to 15 colors
Pin Point Stitch m/c

Vacuum Iron Table
Lay End Cutting m/c
Washing Plant
Type of Machine
Quantity (Sets)
Sample Washing m/c
05
Washing m/c
14
Washing
5
m/c(Tonello+Yilmak)
Hydro Extractor
8
Dryer
12
Sand Blast m/c
02
Laser Blasting
2
Sand Brush m/c
10
E.T.P
1
Average Production Capacity
OPEX GROUP
Capacity
500 lbs
40,760 lbs
12600 lbs
2,610 lbs
32,600 lbs
1000 pcs per day
500 pcs per day
3000 pcs per day
80 cubic meter per hour
30,000 pieces of gt per day
25
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CHAPTER-IV
RAW MATERIALS
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RAW MATERIALS OF OPEX FASHIONS LTD
Garments Section:
Soucing tag
Fabric woven
Price ticket
Button
Hanger
Zipper
Sizer
Sewing thread
Size sticker
Main label
Poly bag
Care label
Cartoon
Tag pin
SOURCES OF RAW MATERIALS

Required raw materials are purchased from following countries through agent :
a. Taiwan
b. Philippines
c. India
d. Germany
e. Brazil
f. Pakistan
g. South China
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CHAPTER-V
(Production Planning,
Sequences & Operations)
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DESCRIPTION OF PRODUCTION PROCESS(GARMENTS SECTION):

]
Squence Operation for Sample Section:

Product Package
Make Pattern
If not OK
Make Sample
Send to Buyer through Merchandiser
If OK
Collect the approved Sanple
Sequence Operation for Cutting Section:
Fabric Inspection & relaxation
Fabrid spreading
Fabic cutting
Parts numbering
Part inspection
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If any defect is found then make this part

Sequence Operation for Sewing Section:
Front Yoke joining
Elastic join
Topstich
Sleeve join
Front Yoke join
Sleeve join
Elastic tuck
Elastic tuck
Elastic join
Back part piping
Front Yoke+Sleeve+Back Yoke Joining
Elastic Stiching
Vertical tuck
Sleeve opening tuck
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Side seam
Chup tuck
Sleeve opening chup tuck
Hem
Inspection
OPERATION BREAKDOWN : FIVE POCKET JEANS (JC PENNEY)

BACK PART MAKING
Serial
Name of Operation
Machine used
No
1
Back Pocket Rolling
2 Needle Machine
2
Marking Table
3
Back Yoke Joining in Folder System
Feed of the Arm m/c
4
Back Rise Joining
Plain Stitch m/c
5
Back Rise Top
Feed of the Arm m/c
6
Back Pocket Positioning on Marker
Table
7
Back Pocket Joining
Plain Stitch m/c
8
Stitch on Pocket Joining
Plain Stitch m/c
FRONT PART MAKING
Serial
Name of Operation
No
1
Pocket Matching
2
Ironing
3
Coin Pocket Attaching
4
Label Joining
5
Coin Pocket Attaching with Front
Facing
Machine used
2 Needle m/c
Plain Stitch m/c
Plain Stitch m/c
OPEX GROUP
No of Machine
1
1
1
1
1
1
No of Machine
1
1
1
31
6
7
8
9
10
11
12
13
14
15
16
17
Number Match with Front Part

Coin Pocket Joining with Front Part
Front Pocket Rolling
Pocket Tuck
Pocketing Over Lock
Single Fly Join with Top Stitch
Pocket Top Stitch
Front Pocket with Front Tucking
Zipper Joining
J - Stitch
Double Fly Joining
Front Rise Stitch
BODY SECTION
Serial No
Name of Operation
1
Back & Front Part Match on
Table
2
In Seam
3
Top Seam on In Seam
4
Side Seam
5
Hemming
6
Waist Belt Matching by
Number
7
Waist Belt Sewing
8
Edge Neatening of Down Part
of the Waist
9
Waist Top Part Making
10
Waist Top Part Edge
Neatening
11
Checking by LQC
12
Belt Loop Matching
13
Loop Tuck on Down Side of
Waist
14
Loop Joining with Top Side of
Waist
15
Final Inspection
16
Loop & Back Part Bar Tacking
17
Side Pocket Tucking
2013
Plain Stitch m/c

2 Needle m/c
Plain Stitch m/c
Over Lock m/c
Plain Stitch m/c
Plain Stitch m/c
Plain Stitch m/c
2 Needle m/c
2 Needle m/c
Plain Stitch m/c
2 Needle m/c
2
1
1
1
1
1
1
1
1
1
1
Machine used
No of Machine
Plain Stitch m/c

Feed of the Arm m/c
Over Lock m/c
Plain Stitch m/c
KANSAI
Plain Stitch m/c
1
1
2
1
2
2
Plain Stitch m/c
Plain Stitch m/c
Plain Stitch m/c
Bar Tack m/c

Plain Stitch m/c
2
1
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SUMMERY
Plain Stitch Machine - 36
2 Needle Machine
- 07
Over Lock Machine
- 04
Bar Tack Machine
- 02
KANSAI
- 02
Feed of Arm Machine 04
Production
- 1000 pieces per day
Manpower
- 94 persons
REMARKS:
As OPEX FASHION LTD a big project; its production quantity is huge.
Production quantity varies as according as buyers demand. It gives approximately 500-ton and
1000000 pcs production per month. In Bangladesh, there are a few mills, which can produce
such quantity of garments.
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CHAPTER-VI
(Quality assurance system)
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2013
QUALITY ASSURANCE SYSTEM:

All rolls are kept in front of the inspection m/c time to time and are inspected over
the grey inspection m/c visually in a pre-set speed against light. For any major or minor faults
like thick-thin, barre marks, fall out, contamination, fly, holes, oil lines, needle lines, slubs,
etc are recorded in grey inspection report to classify the fabric based on the four point system.
Collar & cuff are inspected visually under light box, any major & minor faulty
collar/cuff like having wrong ply, hole, needle lines, slubs, wrong design, first line problem
etc properly counted and recorded.
QUALITY ASSURANCE PROCEDURE:
Based on the sequence of grey inspection, the inspector serially numbers each roll
ensuring that all rolls having complete details of the roll.
1) After production of fabric rolls of 8 to 25 kg, m/c operators cut them from the
cloth or batch roller and they are carried to inspection section by the helpers.
2) Almost four inspection workers are for every shift to check the fabric rolls. For
any kind of fault they are checked thoroughly. Skilled inspectors find them and indicate them
by the scissors in some cases.
3) Quality is specified on the basis of 4-points system. Here is the point distribution
for different kinds fault in this system: FOUR POINT GRADING SYSTEM
Size of defects
Penalty
3 inches or less
1 point
Over three inch but not 6 inch
2 point
Over 6 inch but not 9 inch
3 point
Over 9 inch
4 point
QUALITY CLASSIFICATION
1
<20
OK
2
20-30
ASK
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30>
REJECT
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2013
LIST OF EQUIPMENTS:
In this factory OFL the list of equipments to assure quality: 1) Inspection machine
2) Scissors
3) Weight balance & Microbalance
4) GSM cutter
5) Seal (CHECK-1, OK, REJECT.).
Rejection criteria for Fabrics:
No.
Faults
Response
1.
2.
Needle marks
Stripe
Major needle line is rejected.

Major needle line is rejected.
3.
Barre marks
Rejected
4.
5.
6.
7.
Slubs
Wrong design
Pin holes
Fly & contamination
1 point
Rejected
1 point
Acceptable for color but not for white
8.
9.
Sinker marks
Uneven tension
Do
Discuss with manager
10.
Missing yarn
Use 4 point
11.
Crease line
Do
12.
Uneven tension
13.
Oil stripe/line
Do
14.
Thick-thin place
Rejected
15.
Mixed yarn
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Rejection criteria for collar & cuff: Following table shows common collar & cuff faults
and response taken by grey inspection section.
No.
Faults
Response
1.
2.
3.
Wrong ply
Hole
Needle line
Reject
Reject
Reject
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
Slubs
Wrong design
Wrong tripping
Fly & contamination
First round problem
Uneven tension
Missing yarn
Crease line
Rust line
Oil stripe
Thick-thin
Wrong tube
Reject
Reject
Reject
Acceptable for color but not for white
Reject
Reject
Reject
Reject
Reject
Reject
Reject
QUALITY STANDARD:
Here is the quality standard:1) Fabric width
7) Broken needle /2
2) Fabric length
8) Thick /thin yarn
4) Slub
9) Barre/ Stripe
3) Fabric weight
10) Dirt
5) Hole
11) Oil
6) Needle / Sinker line
12) Press off
REMARKS:
There is hardly any chance of any roll to pass through production on to any buyers by to
by unchecked or disqualified. The inspections are too much experience and they are aware
about their duties and responsibilities. The factory authority and production related personnel
are happy and satisfied with their works
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CHAPTER-VII
(Maintenance)
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MAINTENANCE:
Maintenance of machineries is very important for any type of industries and it is a
must for a knit composite mill. All machines and machines parts of Washing, dyeing and
garments are maintained with extreme care. Because production quality and quantity, both
depends on the maintenance with regularity. OPEX FASHIONLTD lead maintenance with a
troop of skilled mechanical fitters.
MAINTENANCE OF MACHINERY:
In the knitting floor of OFL all machine are maintained regularly and as
necessity requirements. Here, different type of maintenance of machinery, which is taken,
different time on the machineries.
ROUTINE:
1) Daily Maintenance: Every machine is taken maintenance daily by the

operators during production. When the operator starts a production after handing over from
previous shift operator, he takes a routine maintenance on the
machine. He cleans the machine, assures yarn is fed to all needles, cleans the eye pot of
feeder, memminger, signal lamp sensor etc. Before a while of a roll cut from batch or cloth
roller, operator cleans needles, cylinder base plate etc. All around of the machine are kept neat
and clean as if there is no dirt with yarn in the fabric.
2) Schedule/Routine Maintenance: Every machine has a schedule of maintenance
of 10 or 15 days. According to date, schedule maintenance is taken on the machines.
Operators are informed about the time of maintenance. After pre-estimated production, they
hand over the machine to the fitters. Thus, fitters assure all machines are OK. For any time.
3) Break down maintenance: When product quality hampered and to complete
production in due time break down maintenance is taken. There are many faults seen in the
fabric during production due to needle, sinker, take down roller etc. Then operators inform the
mechanical fitters and they fix it.
4) Restorative maintenance: Restorative maintenance is taken for design change
or new design development. According to advice or order of production officer, a machine is
fixed for new design and mechanical fitters rearrange cam and needle system.
Planned and preventive maintenance are not taken on the machineries in this mill.
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MAINTENANCE OF SEWING M/C:

Lubrication:
Since the life of the m/c and its correct working depend to a large extend adequate
and proper lubrication. It is recommended that the instructions given in the lubrication charts
be followed conscientiously. The Company can not be need responsible for faults that arise
from wrong or inadequate lubrication.
Oiling Needles:
Too much oil is preferable to too little. Dark vertical lines in the fabric originate not
from excessive oiling .
The Cleaning of Needle:
Thin oil is most suitable for this work, about one point heated to a temperature not
exceeding 160F poured into the oiling position of the m/c.
General Cleaning Schedule:
Long m/c life, maximum output & trouble free running depend upon proper care
and maintenance. A general overhaul should take place annually when single shifts are
worked & correspondingly at more frequent interval.
MAINTENANCE PROCEDURE:
1) For there is any mechanical fault of machine, which is responsible for
production hamper, operator informs mechanical fitters in duty. Mechanical fitters come and
observe the problem firstly, and then they begin to fix it.
2) If mechanical fitters were unable to fix it, then they inform technical in-charge,
he then comes in spot and fixes it.
3) For there is any electrical problem of machine or serious founding mechanical
problem, mechanical and electrical department are informed, they come and fix the problem.
4) For restorative maintenance, senior production officer orders mechanical
fitters to fit required machine for cam and needle arrangement and other necessary
requirements in case of new design development.
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MAINTENANCE TOOLS/EQUIPMENTS & THEIR FUNCTIONS:

Maintenance tools/equipments
Functions
1. Adjustable wrench
Used for setting nut & bolts
2. Air suctioner
For cleaning machine
3.Spanner
Fixed Spanner for nut & bolts fitting
4.Socket spanner
Handle system for nut & bolt fitting
5. Hammer
To apply load where required
6. Screw driver
To release any screw
7. Punch
Used to fit any worn out shaft
8. Lock opener
To open the clip of bearing
9. Hack saw
To cut any metallic thing
10. Outside calipers
To measure outside dia
11. Inside calipers
To measure inside dia
12. Cutting pliers
To cut thin wires
13. Pulley key
To loosen pulleys
14. Chain ton
To lift heavy load
15. Welding machine
To join metallic parts
16. Grinding machine
To make the smooth fabrics
17. Tester
To test electric circuit
18. Pliers
To grip anything & cut anything
19. Star driver
Screw unlocking
20. Steel tape
To measure length, width & height
21. Chisel
To cut any metal
22. L-key
For loosen & tighten the screw
23. File
To smooth the rough surface
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Repair, maintenance and setting and replacement of different parts of

lockstitch machine:
Apparatus:
1. Flat screw driver
2. Star screw driver
3. Hammer
4. Pliers
5. Lubricating oil
6. Grease
Standard atmospheric condition:
Temperature28c
Relative humidity..62%
Procedure: The repair, maintenance, setting and replacement procedure are described below:1. Repair: Repair work is carried out when a component requires slight modification.
To carry out such job the machine needs to be switched off first. The component
under repair is then screwed off by suitable apparatus. After repairing, the part is
fixed to its designated place and hence its correctness is measured by running the
machine. In a lockstitch machine bobbin case, bobbin, check spring, feed dog.
Motor belt etc can undergo repair job.
a. Maintenance: Maintenance can be of different types. But following types are
important in this aspect.
b. Routine maintenance: lubrication and regular inspection are the constituent of
routine maintenance. Lubrication ensures long life and safe working of all the
equipment. Inspection tries to detect faults in equipment so that repairs and
replacement may be under taken at the right time.
c. Scheduled maintenance: this type of maintenance provides for inspection,
overhaul lubrication and servicing of the machine, cleaning of all components is
normally done in this manner. It involves opening of the machine into its smallest
component and carry out lubrication.
2. Setting: the setting of the lockstitch machine is of immense importance. Following
setting points need to be ensured before running the machine.
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Stitch density controller: It controls the no of stitch per inch. Before starting the
machine, stitch per inch is determined by rotating the knob and fixing it at the
desired position.
b. Motor: Motor rpm depicts the speed of the machine. The rpm is controlled by
tightening or looseness the belt over machine & motor pulley.
a.
c. Needle: needle undergoes accurate setting to ensure proper sewing. Needle is

attached by means of a screw which needs to be tightened enough to produce easy
sewing. Again the needle size is also important from fabric point of view.
d. Pressure foot: The type of pressure foot to be used & its proper setting is
important which is ensured by proper attachment with the motor through machine
pulley.
e. Feed dog: It is often found that due to random working the feed dog is subjected to
be loose which may cause accident also. Thus the feed dog must be set properly
with the screw.
3. Replacement: The replacement is revealed when the retention of equipment is no
more remain an economical proposition. A replacement is affected when the
equipment is subjected to complete breakage which cannot be used even after repair
or the component has become so obsolete that affects production or it has crossed
its expire date. Replacement can be affected to any components of the machine at
any time. In lockstitch machine components like needle, pressure foot, feed dog etc
undergo frequent replacement.
Precaution: Following precautions must be taken when repair, setting maintenance is carried
out in the lockstitch machine.
1. All repair & maintenance work must be carried out by switching off the
machine.
2. Right tools should be used at right place.
3. Skilled personnel should be involved for specialized job.
4. Careful handling of all the components is necessary.
5. The components should not be too tight or too loose.
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Remarks: The experiment has provided us wide idea regarding the repair, maintenance,
setting & replacement of different components of lockstitch machine .It has given us a basic
knowledge on machine maintenance as a whole. It has also oriented us with different machine
tools & their use those are required for the said job. The gathered knowledge will indeed help
us in our practical life. We hope to important our learning in the days to come.
This mill has a strong maintenance fitters troop to fix up all types problem. Two
groups of two shifts obey their duties responsibly and sincerely. With their different tools or
equipments they perform their duties skillfully
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CHAPTER-VIII
(UTILITY SERVICES)
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UTILITY FACILITIES AVAILABLE:

For smooth functioning of any production unit, uninterrupted and
required utility services are indispensable. Success of any industry largely depends
on this factor. Any irregularity or lack in the required utility services immediately
results in unexpected halt of the production process. An Industry needs various
utilities depending on its manufacturing process.
In OFL the major utilities are available- Power (Electricity)
- Water
- Natural gas
- Compressed air
- Steam
- ETP
SOURCES OF UTILITIES:
The main utility, which is used by OFL, is natural gas. From
natural gas generator produce electricity. From natural gas and electricity in
association with mechanical and electrical apparatus, OFL produce other utilities
like water, steam, compressed air etc.
CAPACITY AND OTHER TECHNICAL DETAILS:
Power (Electricity):
Generator house is the main power producing plants of NCL
There are two generator in generator house.
Generator Type: gas generator
Brand name: Caterpillar
Origin: USA
Frequency: 100 Hz
Voltage: 400 V
STEAM:
Boiler produces the required steam. There is two boiler in OFL
Boiler specification:
Brand name: Industrial boiler Ltd
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Capacity: 8ton / hr
Blower motor: 25 HP
Water supply for the boiler:
Water required for steam production is supplied by deep tube well.
Pretreatment of the boiler water:
Boiler feed water needs special standard. Any deviation from the
required standard may result in scale formation, which eventually reduces the
efficiency of the boiler. This ultimately affects the cost of steam generation and
makes the production cost high. To maintain the required standard of the water,
there should be some means to pretreat the boiler feed water. To protect scale
formation of boiler, NELCO is used as chemical in water feed tank. 200 gm NELCO
is injected per 12 hrs. In OFL there are water softeners that act before the water
enters the boiler.
.
No. Of the softener :
There is one water softener to pretreat the boiler feed water.
COMPRESSED AIR:
The compressed air is supplied from air compressor. There two -air
compressors in OFL.
Compressor Brand name Hitachi Screw Compressor
Origin: Japan
Model no. OSP-55S5 ARI
Maximum working pressure: 15 bar
Average working pressure: 6.5-7.5 bar
Year of construction: 2004
WATER:
The water source OFL is deep tube well.
Water treatment plant: There is no Water treatment plant in Mirpur but one in
Kanchpur.
GAS:
The source of gas is government agency. Gas is required mainly for

generation of electricity, boiler to produce steam, the burners of heat setting m / c.
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As OFL generates their own electricity, the gas consumption is quite high. The gas
consumption is 250-350 m / hr.
COST OF DIFFERENT UTILITIES:
Electricity cost:
REB =3.8 TK / KW-HR
Gas generator = 2.70 TK / KW-HR
Diesel generator = 6.50 TK / KW-HR
Gas cost:
4.94 Tk/m for boiler

3.66 Tk/m for generator
4.5 Tk/m for domestic purpose
Steam cost:
4.30 Tk per kg fabric.
REMARKS:
For smooth running of factory main utilities like gas, electricity or
steam is very essential. Sometimes gas pressure is low than required pressure. When
the gas pressure is low, then diesel generator run. Government should have to ensure
proper gas supply for Industrial purpose.
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(CHAPTER-IX)
STORE & INVENTORY CONTROL
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INVENTORY SYSTEM OF RAW MATERIAL:

It is previously speak that OFL. is a Woven composite industry. The main
raw material of OFL is grey fabric. Grey fabric first produce in knitting department
of this company. Weaving section of OPEX GROUP Produces grey fabric as per
buyers order. Dyeing section get grey fabric from Weaving section. Grey fabric store
officer receive the grey fabric and store the grey fabric in storeroom. Then he
delivers the grey fabric to batch preparation section according to shipment date or
according to production manager of dyeing section instruction.
Other raw materials of OFL are dyes and chemicals. Dyes and
chemicals store officer always keep stock report of dyes and chemicals and also
know the daily or monthly requirements of each dyes or chemicals. If the stock is
bellowing30days then he gives requisition to head office for each product. Head
office indent dyes and chemicals.
SPARES:
Spare store officer keep the spare part in store & make a list of spare parts.
If the spare parts are little in stock he gives requisition to maintenance manager.
Technical manager give requisition to Head office. Head office indent spare parts or
buy local market as per requirements.
FINISHED GOODS INVENTORY:
Finish fabrics from the compactor go to inspection team. From the
inspection table the fabric weighted in weight meter & go to finish fabric storeroom.
Here finished fabric store officer make a list of total finished products. He sends the
finished fabric to OPEX FASHION LTD as per shipment date or requirements of
production manager of OPEX FASHION LTD. He also keeps the delivery list.
REMARKS:
Inventory control system and storing system of OFL. is over all good.
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CHAPTER -X
(COST ANALYSIS)
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INTRODUCTION:
Costing is a process by which the setting price of a product is calculated. It is a
very important task for a factory, which runs for business purposes.
And it is also strictly followed in the OFL. Costing of the products considering the raw
materials expenditure, salary and wages of officers and workers, distributions and
advertisement expenses etc. all direct and indirect expenses is done in this factory. It is
determined by a troop of accountants with advice and consultancy of executive director.
PRICE OF THE PRODUCT:
Generally price of product is determined by the required profit adding to the total
expenses. So,
Price of products= (Direct expenses + Indirect expenses + Factory
Overhead) + Required profit
PRICE RANGE OF DIFFERENT PRODUCTS:
Shirt = $11.75 - $28.50 /Pcs
Jacket =$15.00 - $35.50 /Pcs
Kids Wear ==$10- $29/Pcs
REMARKS:
Costing is very important for a productive factory. Without proper costing all production
curriculums will go to vain. Because a factory cannot reach to its goal without achieving good
profit and good profit is not possible without skillful costing. In OFL there are some skillful
personnel to do this job.
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CHAPTER-XI
(MARKETING ACTIVITIES)
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Marketing Strategy:
Marketing strategy is a very important factors to sale the products to the buyer. If the
marketing strategy is not so developed, it will be very hard to reach the goal. In case of
garments marketing the dealings with the buyer is a very important factor.
In Standard Group mainly senior marketing officers, merchandiser & higher officials
deal with the buyer. There are some fixed buyers of the industry. The buyers give their orders
continuously all over the year. The marketing officers & the merchandisers communicate with
the buying houses to collect the orders.
By both side understanding the rate & the order quantity are fixed.
Duties & responsibilities of marketing officer:

Dealing with the buyer & convince the buyer is the main duty of marketing officer. A
marketing officer also has some other duties. The main duties & responsibilities of a
marketing officer are given bellow
To prepare cost sheet by dealing with the buyer

To take different steps by discussing with the high officials & merchandisers
To maintain a regular & good relationship between commercial officer &
merchandisers
To maintain a communication with the buyers and buying houses
Communicate with better criteria of the products
Actually the responsibilities & duties of marketing officer begins from getting order of
buyer & ends after receiving foods by the buyer. So, he should be always smart, energetic
& sincere.
Marketing activities are done of NCL by a skillful team of marketing officers under
the Executive Director. Here are the details of marketing activities.
CONSUMER OF THE PRODUCTS:
The mill has a great number of renowned and international consumers. Following
are some regular consumers:
1) JC Penney
2) Carryfour
3) Levis
4) TCP
5) Oshkosh
6) Target
7) AMC
8) American Eagle
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PRODUCT LABEL:
There are following labels used by this mill:
1) Care Label: It contains washing in hot or cold water, chemical cleaning,
drying conditions etc.
2) Size Label: It contains size of garments.
3) Composition Label: It contains the fabric composition of different fibre type.
4) Decorative Label: Decoration is as buyer or consumer choice wise.
PACKAGE SIZE & LABEL:
Most common sizes are
S - Small
M - Medium
L - Large
XL - Extra large
XLL - Very very large
2XLT
3XLT
REMARKS: OPEX Group has a well learned marketing & merchandising team. They always
communicate with the buyers. Standard Group has some fixed buyers. The marketing section
also looks the quality & quantity buyers.
Marketing activities are very important tasks for a productive factory. In this mill,
there having highly qualified marketing officers. As a result, the mill rises up day by day.
FAULTS OF GREY FABRICS:

1. Patta
Causes:
1. Yarn count variation
2.Yarn tension variation
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Remedies:
2013
Proper yarn count & tension should be maintained.
Remarks:
For dark color & plain single jersey patta very sensitives. But in case of
derivatives of single jersey, rib &interlock light patta considerable.
2. Contamination:
Causes:
1.For unlearned machine & floor.
2.Little space between two adjacent machines.
3. For hairy & color yarn.
Remedies:
1.Proper cleaning of machine & floor.
Remarks:
Protection of every machine from dust & fly. In case of light color
contamination is very bad appearance. As a result garments rejected.
3.Needle mark:
Causes:
For bent hook & latch.
Remedies:
Immediately change faulty needle.
Remarks:
Needle mark is a common faults of knitting because unconscious of
operator. It has very bad effective for dyeing & causes a great loss of company.
4.Hole:
Causes:
1. For needle breakage & wrong adjustment of machine parts.

2. For uneven yarn & deposit of fibre.
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Remedies:
2013
Correct adjustment of machine parts &clean machine.
5.Lycra out & tension variation of Lycra:
Causes: Breakage of Lycra yarn & uneven tension of Lycra.
6. Oil mark
7. Tara &loop.
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CHAPTER-XII
(WASHING)
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SAMPLE WASHING MACHINES (INDIA)
No. of machines: 05
Manufacturing company: STEFAB INDIA LIMITED
Model no: LXS 35.
Manufacturing country: India.
Features:
Single door, front-loading, open pocket.
Machine body and essential parts are made of stainless steel.
Automatic timed. Auto reverse. Automatic 5 water level & auto digital
temperature control.
Electric solenoid water & steam valves.
Non-clog motorised drain valve.
Full electric protection.
Specifications:
Capacity: 35 kg (Dry: Wet =1:10)
Inner cylinder: 950 mm dial X 500mm
Wash motor: 0.75 KW
Extract speed: 200 RPM
Main door opening: 500 mm dial
Water connection consumption: 25 mm dial, 120 litres.
Drain: 75 mm dial, 1 way out
Steam connection consumption: 15 mm dial, 25 Kg/hr.
Electric heating: 12 KW
Overall dimension: 1100mm(W) X 1430mm(D) X 1700mm(H)
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INDUSTRIAL WASHING & DYEING MACHINES (CHINA)
No. of machines: 14
Manufacturing Company :PANYUA XIN XIN Washing Machine Company Limited.
Manufacturing country: CHINA.
Features:
Single door design for general washing, sample washing.
Preset front and backward rotation.
Specifications:
o Model-AIW-550(5)
o Rated Voltage-380 V
o Steam Pressure-0.4-.06 MPa
o Input Power-7.5 KW
o No Of Production-W.10583
o Related Washing Capacity-250kg
o Related Frequency -50 Hz
o Gross Weight-1900kg
o Overall Dimension -3.2X1.95X2.10
INDUSTRIAL WASHING PROCESSING & DYEING MACHINES
No. of machines: 05
Manufacturing company: STEFAB INDIA LIMITED,
Model no: LXS 280.
Features:
Single door, front-loading, open pocket.
Automatic timed. Auto reverse. Automatic 5 water level & auto digital
temperature control.
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Electric solenoid water & steam valves.

Non-clog motorised drain valve.
Full electric protection.
Specifications:
Capacity: 280 kg (1:10)
Inner cylinder: 1750 mm dial X 1180mm
Wash motor: 7.5 KW
Main door opening: 1000 mm dial
Inspection door opening: 300 mm dial
Water connection consumption: 50 mm dial, 960 litres.
Drain: 115 mm dial, 2 ways out
Steam connection consumption: 25 mm dial, 200 Kg/hr.
Thermal fluid connection consumption: 1.5 X 1.5 BSP, 80000 KCAL/Hr.
Overall dimension: 1950mm(W) X 2500mm(D) X 2100mm(H)
HYDRO EXTRACTORS (CHINA)
No. of machines: 08
Manufacturing company: Tongxin Ltd.
Manufacturing country: China.
Features:
Due to its solid constructions it can be positioned onto firm floorings to
operate.
It has excellent electrical layout in prevention of electricity leakage, shock,
which is important in wet conditions in the operations.
Machine operations are made easy, with convenient start-stop operations for
maximum efficiency.
The inner stainless steel is well balanced, thus achieving longer life span and
assuming energy efficiency of machine.
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Shock absorbers are well paced in the three suspension points to reduce
vibrations.
Stainless steel constructions in major parts ensure durability.
Specifications:
Model no: SHE-42

Capacity: 280 LBS
Inner cylinder: 1067dial X 419mm
Over all dimensions: 2150 mm (W) X 1650 mm (D) X 1050 mm (H).
Wash motor: 7.5 KW
SAMPLE DRYING MACHINES
No. of machines: 01
Manufacturing company: STEFAB INDIA LIMITED,
Features:
Stainless steel inner cylinder and large S.S. loading-unloading door. Outer
body not painted. Long rust free life and sheen.
Built in solvent filter housed in the top tank receives soiled from the base tank
through a powerful centrifugal pump which pushes the soiled solvent through
several fine mesh cylindrical filters for reuse. Maximum recovery of clean
solvent.
Low spin extract. Separate motors for dryclean & extract. Vibrationless during
extraction. Low spin extract makes articles lighter to unload. No solvent
dripping. No wastage of solvent.
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Automatic timed. Auto reverse. Full electrical protection against single phasing
& motor overload. Operators convenience & machine safety. Efficient
cleaning.
Specifications:
Capacity: 18 Kg
Basket size: 700 mm (dial) X 470 mm
Volume: 180 Litres
Dry clean motor: 0.37 KW
Extract motor: 1.5 KW
Extract speed: 220 rpm
Loading door opening: 400 mm (dial)
Base tank capacity: 250 Litres
Filter tank capacity: 250 Litres
Overall dimensions: 1000mm(W) X1080mm (D) X 1730mm(H)
DRYING MACHINES
No. of machines: 12
Manufacturing company: Bengal Heavy Electric Engineering.
Manufacturing country: Bangladesh.
Features:
Stainless steel inner cylinder and large S.S. loading-unloading door. Outer
body painted.
Low spin extract. Vibration less during extraction. Low spin extract makes
articles lighter to unload.
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Automatic timed. Full electrical protection against single phasing & motor
overload. Operators convenience & machine safety. Efficient cleaning.
Specifications:
Capacity: 35 Kg
Basket size: 950 mm (dial) X 500mm
Volume: 350 Litres
Dry clean motor: 0.75 KW
Extract speed: 200 rpm
Loading door opening: 500mm (dial)
Overall dimensions: 1300mm(W) X 1250mm(D) X 2000mm(H)
GARMENTS SAND-BLASTING MACHINES

INDUSTRIAL SAND-BLASTIG GUNS
No. of machines: 03
Manufacturing company: Made in China
Features:
Single door design for general washing, sample washing.
Preset front and backward rotation.
Specifications:
Model: SBT-650
Capacity: 200 Litres
Dimension: 800mm X 1000mm X 1250mm
Sand contains: 200 Kg
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OTHER COMPONENTS/ACCESSORIES
No. of cabinets: 03
Hopper (for controlling dust in cabinets): 02
Helmet: 07 Pcs
Musk: 07 Pcs
Gloves: 07 pairs.
Air preserver-1, capacity of 2000 c.c.
Air preserver-2, capacity of 900 c.c.
OTHER MACHINES
Spray machines: 03 Nos.
Manufacturing country: Hong Kong
Compressor: 03 Nos.
Two compressors with same following specifications.
o Brand: ELGI
o Capacity: 10 Jule/Bar
o Made in INDIA
One compressor with following specifications:
o Brand: OSD
o Made in ITALY
o Includes Change Over
o MCCB
o Capacity: 10 Jule/Bar
Boiler:
Brand name: Sacca
Manufacturer: Made in ITALY
Production capacity: 1.5 Tons/Hr.
Pressure: 7.5 Jule Bar (5.0 Bar used)
Supply system: Automatic Pressure control.
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Chimney: 50 Feet with 12-inch diameter.
Generator
Four stroke, diesel engines with 1500 RPM by "DEUTZ" and "VOLVO Penta"
production; "STAMFORD"(ST), "MECC Alte"(ME), "Marelli"(MA), "SINCRO"(SI)
alternators. All alternators are three phase, four pole, single bearing, synchronous type,
cosj=0.8, 50Hz.
Water supply pump: 03 Nos.

02 PCs. Deep Tube wells are Submersible, Made in ITALY, BG brand with 30 Horse
Power.
01 PC. Deep Tube well is Sigma branded, Made in ITALY with 42 Horse Power.
PROCESS TECHNIQUE OF SOME WASHING METHODS
ENZYME-BLEACH WASH WITH TINTING:

Batch 60 PCs.
Liquor 400 Litre
Step 01
Water is added (400 Lt)
Desizing
Garments are added
Machine started running
500 gm Soda Ash added
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500 gm Caustic Soda added
200 gm Bio. D added
Steam to raise temp 60C
Process time 25 minutes
Drop liquor
Wash down twice
Step 02
Enzyme Wash
200 ml liquid, 400 gm powder

type Enzyme added
150 ml Acetic Acid Added
200 gm Anti back added
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10 Kg Peumic Stone added
Drop liquor
Step 03
Bleaching
4 Kg KCI (35% Cl2) added
500 gm Soda Ash added
Drop liquor
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Step 04
Neutral Wash
2013
500 gm Hypo sulphide added
Drop liquor
Step 05
Tinting
0.02% Direct Brown GTL &

0.01% Direct Black V-200 added
4 Kg Salt added
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Check Shade
Drop the liquor
Step 06
Garments are then taken out
Drying
Hydro extracted
Send to dryer for drying of garments.
REMARKS
No live industry can keep place with the advance of technology without continuous
renewal & transformation of its production facilities. Existing equipments must be kept on the
defensive, compelled always to justify its tenure against the challenge of new & more modern
machines. If any piece of existing equipment fails to meet this challenge, it must be displaced,
regardless of its age or condition & regardless of whether it is physically worn out.
Keeping the above in view, this industry is always replacing its existing machines in
order to increase productivity & improve quality.
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CHAPTER-XIII
(COMPLIANCE)
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12.1 Responsibilities & Duties
2013
Compliance
1. To floor visit at least thrice a day.

2. To ensure workers fire safety, fire prevention, fire equipment, health & safety &
comfortable environment at work place.
3. To aware the workers about personal protective equipment.
4. To receive grievance, complain, demand & suggestion from the workers & after
receiving the issue discuss with related persons & local management immediately.
5. Try to find out emotional problem of an employee. The problem may be work related
or personal or family which affects his/her work performance.
6. To provided supportive counseling the sick worker for medicinal support on the
workers requests, complain or situational demand.
7. Try to make aware the existing workers about by company provided all facilities &
necessity of compliance.
8. To perform when social compliance audit.
9. To follow up aisle mark free, fire extinguisher no blocked, emergency exit free, fire
equipment free, stair free from carton in the floor.
10. To check all production related register if any date mentioned of holiday or not.
11. To conduct orientation program for newly appointed worker.
12. Try to motivate & make them conversant with the company objective, rules &
regulations, buyer code of conduct & local laws.
13. To briefing the employees about all facilities of company, mandatory safety
instruction including all dos & Donts.
14. To make aware the employees about leave procedure, maternity benefits, working
hour & over time system according to local laws.
15. To make aware the employees about personal health & hygiene, HIV/ AIDS/STD.
16. To conduct awareness programs the pregnant workers about safe motherhood.
17. To ensure that no employee each maltreated mentally or physically abused & they
should be treated with respect & dignity.
18. And any other work assigned by the Management.
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CHAPTER-XIV
(MERCHANDISING)
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Garment merchandising is an intricate and detail oriented job. If it can be done properly can
be very rewarding. On the country, if it is done with lack of knowledge, insufficient skill and
thoroughness, it can be destructive.
In the Standard Group very skilled and experienced personnel run the merchandising section.
After receiving an order, the merchandiser with the help of pattern master calculates the total
consumption of fabric. Then according to the cost detail sheet and the price mentioned by the
buyer costing is done. After the price is negotiated with the buyer order is placed to the
suppliers of raw material and accessories.
The manufacturing factory as per the requirement suppliers the fabric and a ledger is
maintained regularly to assess the production status. The accessories such as label, button,
zipper, sewing thread, packing materials are collected from outside [sometime mentioned by
the buyer] through back-to-back L/Cs. The merchandising department also looks for the
sources for procuring yarns to produce fabric.
Merchandising section monitors the production status regularly and ensure timely delivery of
the shipment.
OPEX GROUP
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2013
Main Buyers
-
GAP
JC PENNY
SEARS
AMERICAN EAGLE OUTFITTERS
H&M
TCP
OSHKOSH
VF ASIA
LEVIES
DOCKERS
PERILIES
MIRZA FASHION
AMC
OPEX GROUP
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2013
CHAPTER-XV
(CONCLUSION)
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CONCLUSION:
OPEX GROUP is a pioneer group in garments sector in our country.Bangladesh is a
developing nation. RMG Sector earns the Prime share of our foreign currency.
Development of this sector will definitely bring good fortune for our country. We
being the graduates of Textile Engineering must give our sincere effort to the future
advancement of RMG and related sector. Moreover from 1 January 2005, we will
enter into the quota free world where quality, lesser lead-time and low price will be
the key to success.
When the development of the country was at a stand still position
due to the legacy of shattered economy and the industrialization was stagnant, the
export oriented textile and RMG sector had shown the ray of hope by its allpervasive positive impact on the national economy. At the fag end of the eighty, this
sector started expanding and within a short period of its existence, this nascent
industry became the largest foreign exchange earner.
Standing at the verge of a new millennium, Textile and RMG
sector is now the heart of our national economy. Even after all this achievements,
this industry faces the major challenge of global adjustment in the coming years
when it has to respond the new trading arrangement after 2004.
OPEX GROUP LTD being a part of this decisive sector will have
to take necessary measure to cope with the change of globalization. Modification of
the technical arrangement with the advancement of technologies and good positive
approach will help to survive in this ever-changing global economy.
Hopefully, the confidence and foresight of the entrepreneurs and
the enthusiastic teamwork of the professionals will take OPEX GROUP LTD to an
even better position.
OPEX GROUP
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Industrial Attachment Report

Industrial Attachment Report

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OBJECTIVE OF INDUSTRIAL ATTACHMENT

The main objective of this training is to comprehend our theoretical

Industrial Attachment Report

Industrial attachment is an essential part of four years B.Sc. in Textile

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Ready made garments(100% Export oriented Woven& knit garments Industry).

Private limited company

Location: Mirpur-13 , Dhaka.

Anisur Rahman Sinha

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TOTAL AREA OF THE INDUSTRY: 15000 sq. feet & 4 building,

OPEX STYLE WEAR LTD:

SINHA STYLE WEAR LTD : 12 Storeyed

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RESPONSEBILITIES OF PRODUCTION OFFICER: From getting an

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ORGANOGRAM OF QUALITY CONTROL DEPARTMENT:

ASST. GENERAL MANAGER

QUALITY INSPECTION CONTROLLER

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LOCK STITCH M/C

H/S D/N LOCKSTITCH

4-holed button sewing

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CHAIN STITCH BUTTON SEWER

4 NEEDLE DOUBLE CHAINSTITCH

MULTI-NEEDLE DOUBLE CHAIN STITCH

MAIER BLIND STITCH MACHINE

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SIMPLE PUSH-BUTTON TYPE STITCH

FLAT-LOCK SEWING MACHINERY

STRAIGHT KNIFE CUTTING M/C

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40,000 pieces per day

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20 heads on each end and up

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Pin Point Stitch m/c

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RAW MATERIALS OF OPEX FASHIONS LTD

SOURCES OF RAW MATERIALS

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DESCRIPTION OF PRODUCTION PROCESS(GARMENTS SECTION):

Squence Operation for Sample Section:

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If any defect is found then make this part

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