Alim Knit BD Ltd. Internship Report

Ahsanullah University of Science & Technology
AUGUST 2022
DEPARTMENT OF TEXTILE ENGINEERING
Course No: Tex 500

Course Title: Industrial Training
Academic Semester: Fall 2020
Industrial Training Report at
Student ID Name
170206052 Sajid Alam Chowdhury
170206061 Masud Rana
170206063 Mahmud Riad
170206075 Md. Hassin Sahariar Rhythm
Supervised By
Mrs. Nasrin Akter
Associate Professor
Department of Textile Engineering
Ahsanullah University of Science & Technology
Acknowledgement
At first, we would like to give our sincerest gratitude to almighty Allah for giving the divine
blessings, which enabled us to complete the industrial training at Alim Knit (BD) Ltd.
successfully.
We would like to express our deep sense of indebtedness to our supervisor Mrs. Nasrin Akter,
Assistant Professor, Department of Textile Engineering, Ahsanullah University of Science
and Technology (AUST), for his thoughtful suggestions, proper guideline, necessary
instructions, co-operations and encouragements through the progress of this Industrial
Training.
We would like to give our special thanks to Prof. Dr. Lal Mohan Baral, Head of Department
of Textile Engineering (AUST) for his valuable suggestions and official permission for
internship at Alim Knit (BD) Ltd.
Our deepest appreciation goes to Mr. Abdul Alim Mondol, The Director and Mr. Rubel
Mallik, Deputy Manager (HRD), Alim Knit (BD) Ltd. for allowing us to complete the
internship in his factory.
In addition, we would like to express our heartiest gratitude to Mr. Rajib General Manager
(Dyeing), Mr. Sakhawat Hossein Sunny, Manager (Dyeing) and Mr. Manabendro Biswas,
Manager (Quality), Alim Knit (BD) Ltd. for helping us with necessary advice and directions
regarding our industrial attachment.
We would also like to express our immense Mr. Protim Chakma General manager (Knitting)
Alim Knit (BD) Ltd, for their valuable time support and valuable advices during Industrial
Training.
We are also grateful to all the executives, officers, supervisors, technicians, operators and all
other staffs of Alim Knit (BD) Ltd. who were most cordial and helpful to us during the tenure
of industrial training. We are also thankful to all employees who helped us & guided us.
Last but not the least, thanks go to our parents for their never-ending support and love in every
stage of my life, which helps us to go ahead in our life
Table of Contents
Chapter 1: Introduction .............................................................................................................. 1
1.1 Introduction: ..................................................................................................................... 2
1.2 Objective .......................................................................................................................... 2
CHAPTER-2: General Information about the Factory .............................................................. 3
2.1 Basic Information: ............................................................................................................ 4
2.2 Board of Directors: ........................................................................................................... 5
2.3 Location and Contacts: ..................................................................................................... 5
2.4Satellite View of the Factory:............................................................................................ 5
2.5 Way to Alim Knit (BD) Ltd: ............................................................................................ 6
2.6 Certifications: ................................................................................................................... 7
2.7 Organization Goals:.......................................................................................................... 8
2.8 Mission and Vision of the Factory: .................................................................................. 8
2.9 Products of Alim Knit (BD) Ltd.: .................................................................................... 8
2.10 Major Buyers:................................................................................................................. 9
2.11 Different Section of the Factory: .................................................................................. 11
2.11.1 Production Departments: ....................................................................................... 11
2.11.2 Management Departments: .................................................................................... 11
2.12 Organizational Structure of Alim Knit (BD) Ltd.: ....................................................... 12
Chapter 3: Knitting .................................................................................................................. 13
3.1 Introduction: ................................................................................................................... 14
3.2 Layout of Knitting Section: ............................................................................................ 14
3.2.1 Layout of Circular Knitting Machine Section: ........................................................ 14
3.2.2 Layout of Flat Bed Knitting Section: ...................................................................... 15
3.3 Raw materials of cotton field ltd.: .................................................................................. 16
3.4 Flow Chart of Knitted Fabric Production:...................................................................... 19
3.5 Flow Chart to produce Single Jersey Fabric (100% Cotton): ........................................ 19
3.6 Some Sample of Knitted Fabric ..................................................................................... 21
Sample-1 ........................................................................................................................... 21
Sample-2 ........................................................................................................................... 22
Sample-3 ........................................................................................................................... 23
Sample-4 ........................................................................................................................... 24
Sample-5 ........................................................................................................................... 25
Sample-6 ........................................................................................................................... 26
Sample-7 ........................................................................................................................... 27
Sample-8 ........................................................................................................................... 28
Sample-9 ........................................................................................................................... 29
Sample-10 ......................................................................................................................... 30
Sample-11 ......................................................................................................................... 31
Sample-12 ......................................................................................................................... 32
3.7 Machine & Equipment: .................................................................................................. 33
Specifications of Knitting Machines: ............................................................................... 33
Circular Knitting Machines Profile: ................................................................................. 34
Machine-1: ........................................................................................................................ 34
Machine-2 ......................................................................................................................... 34
Machine-3 ......................................................................................................................... 35
Machine-4, 5, 6 ................................................................................................................. 35
Machine-7, 8 ..................................................................................................................... 36
Machine-9, 10 ................................................................................................................... 36
Machine-11 ....................................................................................................................... 37
Machine-12, 13 ................................................................................................................. 37
Machine-14 ....................................................................................................................... 38
Machine-15, 16, 17 ........................................................................................................... 38
Machine-18 ....................................................................................................................... 39
Machine-19 ....................................................................................................................... 39
Machine-20 ....................................................................................................................... 40
Machine-21 ....................................................................................................................... 40
Machine-22 ....................................................................................................................... 41
Machine-23 ....................................................................................................................... 41
Machine-24 ....................................................................................................................... 42
Machine-25 ....................................................................................................................... 42
Machine-26 ....................................................................................................................... 43
Machine-27 ....................................................................................................................... 43
Machine-28, 29 ................................................................................................................. 44
Machine-30, 31 ................................................................................................................. 44
Machine-32, 33 ................................................................................................................. 45
Machine-34 ....................................................................................................................... 45
Machine-35 ....................................................................................................................... 46
Machine-36 ....................................................................................................................... 46
Machine-37 ....................................................................................................................... 47
Machine-38 ....................................................................................................................... 47
Machine-39 ....................................................................................................................... 48
Machine-40 ....................................................................................................................... 48
Machine-41 ....................................................................................................................... 49
Machine-42 ....................................................................................................................... 49
Machine-43 ....................................................................................................................... 50
Machine-44 ....................................................................................................................... 50
Machine-45, 46, 47, 48 ..................................................................................................... 51
Machine-49 ....................................................................................................................... 51
Machine-50 ....................................................................................................................... 52
Machine-51 ....................................................................................................................... 52
Machine-52 ....................................................................................................................... 53
Machine-53 ....................................................................................................................... 53
Machine-54 ....................................................................................................................... 54
Machine-55 ....................................................................................................................... 54
Flat Bed Knitting Machine Profile ................................................................................... 55
Jacquard Knitting Machine:.............................................................................................. 55
Machine 1-8 ...................................................................................................................... 55
Flat Bed Knitting Machine: .............................................................................................. 55
Machine-1-12.................................................................................................................... 55
3.8 Products in Knitting Floor:............................................................................................. 56
3.9 Picture of Some Knitting Machines: .............................................................................. 57
Gong Lih Single Jersey Knitting Machines:..................................................................... 57
Jiunn Long Single Jersey Knitting Machines: .................................................................. 58
Gong Lih Double Jersey Knitting Machines: ................................................................... 59
FEITUEWITT Flat Bed Knitting Machine: ..................................................................... 60
SHIMA Jacquard Knitting Machine: ................................................................................ 60
3.10 Different parts of Circular knitting machine: ............................................................... 61
Creel.................................................................................................................................. 61
Creel Tube ........................................................................................................................ 61
QA Pulley ......................................................................................................................... 61
CAM ................................................................................................................................. 61
Yarn Guide ....................................................................................................................... 62
Cylinder ............................................................................................................................ 62
Indicator ............................................................................................................................ 62
Sinker ................................................................................................................................ 62
Fan .................................................................................................................................... 63
Needle ............................................................................................................................... 63
Air Nozzle......................................................................................................................... 63
Storage Wheel................................................................................................................... 63
3.11 Production & Efficiency Calculation of Knitted Product: ........................................... 64
Type 1: Single Jersey Fabric ............................................................................................ 64
Type 2: RIB Fabric: .......................................................................................................... 66
Type 3: Three-Thread Fleece: .......................................................................................... 70
3.12 Inspection: .................................................................................................................... 72
3.13 Quality Policy:.............................................................................................................. 72
3.14 Scope: ........................................................................................................................... 72
3.15 Equipment: ................................................................................................................... 72
3.16 ....................................................................................................................................... 73
4-point Inspection System: ................................................................................................... 73
3.17 Measuring System of 4-point system: .......................................................................... 73
In following cases the complete roll shall be rejected: ..................................................... 74
3.18 Calculations: ................................................................................................................. 74
3.19 Some common faults of fabric in Cotton Field Ltd.: ................................................... 74
Set Up ............................................................................................................................... 75
Fly Contamination ............................................................................................................ 75
Oil Mark ........................................................................................................................... 75
Pin Hole ............................................................................................................................ 76
Needle Mark ..................................................................................................................... 76
Yarn Miss ......................................................................................................................... 76
Barre ................................................................................................................................. 77
Slub ................................................................................................................................... 77
Chapter 4: HR Section ............................................................................................................. 78
4.1 Definition of HR: ........................................................................................................... 79
4.2 Daily Checklist for Floor HR: ........................................................................................ 79
4.3Compliance: .................................................................................................................... 80
4.4 Health: ............................................................................................................................ 80
4.5 Toilet: ............................................................................................................................. 81
4.6 Fire: ................................................................................................................................ 81
4.7 Personnel policies:.......................................................................................................... 81
4.8 Salary:............................................................................................................................. 82
4.9Leave: .............................................................................................................................. 82
4.10 Training program: ........................................................................................................ 82
4.11 Different terms and definition: ..................................................................................... 83
Chapter 5: Sample Section ....................................................................................................... 84
5.1 Sample Development: .................................................................................................... 85
5.2 Working process of sample development: ..................................................................... 85
5.3 Importance of sewing line: ............................................................................................. 85
5.4Machine Flow Chart (T-shirt): ........................................................................................ 86
5.5 Stitch class:..................................................................................................................... 87
5.6 Different type of sample:................................................................................................ 87
Figure: 5-Thread Covering Stitch ..................................................................................... 87
Figure: Chain Stitch .......................................................................................................... 87
Figure: 3-Thread Overlock Stitch ..................................................................................... 88
Figure: Lock Stitch ........................................................................................................... 88
Figure: 4-Thread Overlock Stitch ..................................................................................... 89
5.7 Some Definition: ............................................................................................................ 89
5.8 Difficulties of sewing: .................................................................................................... 89
Chapter-6: Dyeing & Printing Section ..................................................................................... 90
6.1: Printing: ......................................................................................................................... 91
6.2 Some of the samples are below: ..................................................................................... 92
Chapter-7: I.E. Section ............................................................................................................. 93
7.1 Introduction: ................................................................................................................... 94
7.2 SMV: Standard minute value ......................................................................................... 94
7.3 Cycle Time: .................................................................................................................... 94
7.4 Lean Production system: ................................................................................................ 95
7.5 8D Rule: ......................................................................................................................... 95
7.6 80-20 Rule: ..................................................................................................................... 96
7.7 ......................................................................................................................................... 96
7-waste of Lean Manufacturing system: .............................................................................. 96
Chapter-8: Merchandising & Marketing .................................................................................. 97
8.1 Introduction: ................................................................................................................... 98
8.2 Responsibilities of a Merchandiser: ............................................................................... 98
8.3 Knit Garment Merchandiser: .......................................................................................... 98
8.4Merchandising Flowchart:............................................................................................. 100
8.5 Tech Pack: .................................................................................................................... 101
Teck Pack of MANGO buyer ......................................................................................... 101
8.6 Cost Sheet: ................................................................................................................... 102
8.7 Fabric Consumption: .................................................................................................... 102
8.8 Fabric Booking: ............................................................................................................ 103
Fabric booking example ................................................................................................. 103
8.9 Production File: ............................................................................................................ 104
8.10 P/O Sheet:................................................................................................................... 104
8.11 Pro forma Invoice: ...................................................................................................... 105
8.12 Letter of Credit (L/C): ................................................................................................ 105
8.14 FOB: ........................................................................................................................... 105
8.15 Trim Card: .................................................................................................................. 106
8.16 Strike Off:................................................................................................................... 106
8.17 Proto Sample: ............................................................................................................. 107
8.18 Fit Sample: ................................................................................................................. 107
8.19 Size Set Sample: ......................................................................................................... 107
8.20 Salesman Sample (SMS): ........................................................................................... 107
8.21 PP Sample: ................................................................................................................. 107
8.22 Development sample: ................................................................................................. 107
8.23 TOP Sample: .............................................................................................................. 108
8.24 Shipment Sample: ...................................................................................................... 108
Chapter 1: Introduction
Report on Industrial Training Performed at Alim Knit (BD) Ltd. & Cotton Field (BD) Ltd
Page-1
1.1 Introduction:
In Textile field, the industrial training is the training of a student for gaining Industrial
Knowledge which minimizing the gap between theoretical and practical knowledge. For any
technical education, practical experience is equally important in association with the theoretical
knowledge. Our classrooms provide us with all the theoretical knowledge and industrial
training helps us to be familiar with them technically, along with modern machineries and skills
about various processing stages.
Textile engineering education is based on industrial ground and cannot be accomplished
without industrial training. Industrial training provides us sufficient practical knowledge about
production management, work-study, efficiency, industrial management, procurement, utility
and maintenance of machinery and their operation techniques.
At last, we got an opportunity to complete our 8-week long Industrial training successfully at
Alim Knit (BD) Ltd and Cotton field Limited. These are an export oriented composite factory.
This program provided us with practical work experience and environment of a factory.
1.2 Objective:
The objectives of an industrial training program are-
• Know about actual factory environment.
• Fill in the gap between academic study & industrial works.
• Know about the duties, responsibilities & opportunities of a professional engineer in
the textile industry.
• Improve communication ability.
• Learn about the processes and procedures that an industry follows.
• Developing a professional network.
Page-2
CHAPTER-2: General Information about the Factory
Page-3
2.1 Basic Information:
Name of the factory : Alim Knit (BD) Ltd.
Year of establishment : November 2009
Factory Type : 100% export oriented knit dyeing and ready-made garments
Factory
Total factory area : 297503 Square Feet.
Production Capacity : 2.2 Million pieces per Month
Number of employees : 3100
Annual turnover : 45 Million USD
Page-4
2.2 Board of Directors:
Chairman: Mr. Haji Abdul Majid Mondol
Managing Director: Mr. Abdul Momin Mondol
Director: Mr. Abdul Alim Mondol
Operational General Manager: Mr. Tarun Kumar Mistry
2.3 Location and Contacts:

Head Office: Le Méridien Dhaka, 5th Floor (North Corner, Office Block-2, 3, 6), 79/A,
Commercial Area, Airport Road, Nikunja-02, Dhaka-1229, Bangladesh.
Phone: +88 2 41040176 to 41040184
Fax: 880-2-8955005
Factory Location: Nayapara, Kashimpur, (Zitar Moor), Gazipur, Bangladesh
Phone: 880-2-9298557-8, 880-2-9298766
Fax: 880-2-9298556 2.4
2.4Satellite View of the Factory:
Page-5
2.5 Way to Alim Knit (BD) Ltd:
Page-6
2.6 Certifications:
Page-7
2.7 Organization Goals:
Goals and objectives are important to any business enterprise, as they clarify the purpose of the
business and help identify necessary actions. Therefore, they also have a specified goal to strive
for significant business growth every year as far business volume and revenue are concerned.
To accomplish their goal, they believe in repeat business from the same customer however,
they ensured a bunch of self-driven and motivated work force to meet the ultimate goal of
customer satisfaction.
2.8 Mission and Vision of the Factory:

Mission:
Alim Knit (BD) Ltd. is promised to produce world class knit garment of men’s, women’s,
children’s and kids. They strive to make sure their customer satisfaction with their product’s
quality and on time shipment schedule.
Vision:
Their vision is to create a single channel for satisfying diverse and high-class needs of their
valued partners.
2.9 Products of Alim Knit (BD) Ltd.:

Men’s Wear:
• Basic T-Shirt
• Hoodies
• Joggers
• Sweatshirts
• Shorts
• Polo Shirt
• Sports Wear
Women’s Wear:
• Jump Suits
• T-shirts
• Tank Tops
• Camisoles
• Sweat Dresses
• Shorts
• Leggings
• Sweatshirts
Page-8
Kids Wear:
• Onesies
• Kid’s jump suits
• T-shirts sets
• Shorts
• Hoodies
• Sweatshirts
• Caps
2.10 Major Buyers:
Country of Origin
Buyer Name Logo
(Headquarters)
Carryfour France
Perry Ellis USA
Carter’s USA
Next UK
Target Australia
Page-9
Mango Spain
Sergent Major France
Tokmani Finland
Bizzbee France
Jules France
Chori Japan
Etam France
Debenhams UK
Lidl Germany
Page-10
2.11 Different Section of the Factory:
2.11.1 Production Departments:
• Fabric Store
• Batching Section
• Chemical Store
• Water Treatment Plant
• Effluent Treatment Plant
• Dyeing Lab Section
• Dyeing Section
• Cutting Section
• Garments Sewing Section
• Finishing Section
• Quality Control Lab
• Utility
• R&D Section
• Sample Section
• Accessories Store
2.11.2 Management Departments:
• Merchandising
• Marketing
• Information Technology
• Human Resource Development
• Finance & Accounting
• Medical
• Personal Administration
• Security
• Child Care Section
Page-11
2.12 Organizational Structure of Alim Knit (BD) Ltd.:
Page-12
Chapter 3: Knitting
Page-13
3.1 Introduction:
Alim Knit (BD) Ltd. books cotton and yarn as its raw materials for its initial production for
knitted fabric to produce garments. The factory has no spinning section of its own. So, it
depends on other spinning and knitting factories of home and aboard to produce or collect raw
fabric as per its requirements. Cotton Field (BD) Ltd. is one of the sister concern of this group
from where they collect raw material & knitting goods for producing garments.
3.2 Layout of Knitting Section:
3.2.1 Layout of Circular Knitting Machine Section:
Page-14
3.2.2 Layout of Flat Bed Knitting Section:
Page-15
3.3 Raw materials of cotton field ltd.:
Yarn Manufacturer’s Yarn Fiber Yarn
Name Name Type Content Count
14/1 Ne,16/1
Ne,
GLORY, AA,
24/1 Ne,26/1
AKBAR,VAIBAV
Ne,
,
28/1 Ne,30/1
MONDOL,RISIN Carded 100% Cotton
Ne,
G,
32/1 Ne,34/1
DELTA,FUJIAN,
Ne
V-TEX
36/1 Ne,40/1
Ne
Cotton
MAKSON,SPOTK
24/1 Ne,26/1
ING,NAHAR,MS
Ne,
A, Combed
28/1 Ne,30/1
PT BUDI,AA, & 100% Cotton
Ne,
SHREEDHER, Organic
32/1 Ne
AKBAR,SQUARE Combed
34/1 Ne,40/1
,
Ne
SANKO
PO-CHINA
50D(34F)
Polyeste ZINSHUALY, Filament 100%
75D(36F),
r SQUARE,FUJIAN Polyester
150D(108F)
Page-16
60% Cotton
+
30/1 Ne
40%
Polyeste INDOTHAI, Polyester
r Cotton SQUARE,AA CVC 80% Cotton
+
16/1 Ne
20%
Polyester
Carded
100%
Viscose PT ELEGANT & 36/1 Ne
Viscose
Combed
Carded Slub 100% Cotton
Combed Slub 100% Cotton

20/1 Ne,26/1
Ne
Slub BROS
30/1 NE
60% Cotton
CVC +
Slub 40%
Polyester
Page-17
5% Dyed
Dyed Viscose Viscose
& + 28/1 Ne
Grey Cotton 95% Grey
Cotton
10% Dyed
Gray
PHP & + 30/1 Ne
Mélange
Cotton
15% Dyed
& + 34/1 Ne
Cotton
2% Dyed
Ecru
PHP & + 34/1 Ne
Mélange
Cotton
LYCRA,INDORO
100% 20D,30D,40D,
Spandex MA, Spandex
Lycra% 75D
ACEPORA,PHP
Page-18
3.4 Flow Chart of Knitted Fabric Production:
Receive an order
Central Planning
Needed Yarn Requisition
Floor receives the required yarn
Master makes the knitting plan
Creel
Production running
Inspection
Deliver the grey fabric
Fabric is wound down by cloth roller
Page-19
3.5 Flow Chart to produce Single Jersey Fabric (100% Cotton):
Creeling
Yarn Passes Through The Creel
Yarn Guide
Knot Catcher
Yarn Passes Through The Magnetic

Tensioner
Inlet Stop Motion
For Positive Feeding Yarn is

wrapping in the Storage Wheel
Outlet Stop Motion
Feeder
Needles Catch the Yarn for Loop

Formation
Take Down Roller Pulls the

Produced Fabric
Fabric Is Wound Down by Cloth

Roller
Page-20
3.6 Some Sample of Knitted Fabric
Sample-1
Specification Swatch
Machine
30”
Diameter
Machine
28
Gauge
Yarn Count 32 Ne
Stitch Length 2.90
GSM 150 Face Back

Single Jersey
Design
Plain
Diagrammatic Notation:
Needle set out:
kkkkkkkkkk
1
kkkkkkkkkk
kkkkkkkkkk 2
kkkkkkkkkk
kkkkkkkkkk Cam Arrangement:
kkkkkkkkkk F1 F2
kkkkkkkkkk
4 4
kkkkkkkkkk
4 4
kkkkkkkkkk
kkkkkkkkkk
Page-21
Sample-2
Machine
34”
Diameter
Machine
24
Gauge
Yarn Count 26 Ne
Stitch Length 2.78
GSM 160
Face Back
Single Jersey
Design
Lycra
Needle set out:
kkkkkkkkkk
1
kkkkkkkkkk
kkkkkkkkkk 2
kkkkkkkkkk
kkkkkkkkkk F1 F2
kkkkkkkkkk
4 4
kkkkkkkkkk
4 4
kkkkkkkkkk
kkkkkkkkkk
Page-22
Sample-3
Swatch
Specification
Machine
34”
Diameter
Machine Gauge 24
34 Ne
Yarn Count (95% Cotton, Face Back
5%Viscose)
Stitch Length 2.80
GSM 150
Single Jersey
Design
(Grey Melange)
Needle set out:
kkkkkkkkkk
1
kkkkkkkkkk
kkkkkkkkkk 2
kkkkkkkkkk
kkkkkkkkkk F1 F2
kkkkkkkkkk
4 4
kkkkkkkkkk
4 4
kkkkkkkkkk
kkkkkkkkkk
Page-23
Sample-4
Machine
28”
Diameter
Machine Gauge 24
Yarn Count 24 Ne
Stitch Length 2.00
GSM 210 Face Back
Design Single Lacoste
Needle Setout:
kkkkkkkkkk
1
ktktktktkt
kkkkkkkkkk 2
tktktktktk
ktktktktkt F1 F2 F3 F4
kkkkkkkkkk 4 4 4 5
tktktktktk
4 5 4 4
Page-24
Sample-5
Machine Diameter 28”
Machine Gauge 24
Yarn Count 24 Ne
Stitch Length 2.00
GSM 210 Face Back

Single Jersey Plain
Design
(Feeder Stripe)
Needle set out:
kkkkkkkkkk × 34 (White)
1
kkkkkkkkkk × 40 (Orange)
2
Cam Arrangement:
F1 F2
4 4
4 4
Page-25
Sample-6
Machine
28”
Diameter
Machine
24
Gauge
Yarn Count 26 Ne
Stitch Length 2.62
GSM 225 Face Back

Double
Design
Lacoste
Needle set out:
kkkkkkkkkk
1
ktktktktkt
ktktktktkt 2
kkkkkkkkkk
tktktktktk Cam Arrangement:
tktktktktk F1 F2 F3 F4 F5 F6
4 4 4 4 5 5
4 5 5 4 4 4
Page-26
Sample-7
Machine
36”
Diameter
Machine Gauge 18
Yarn Count 34 Ne
Stitch Length 2.70
GSM 150 Face Back
Design 1x1 Rib
Needle Setout:
DDDDDDDD
Dial 1
DDDDDDDD
Cylinde
1
DDDDDDDD r
Cam Arrangement:
F1
Page-27
Sample-8
Machine
34”
Diameter
Machine
18
Gauge
20 Ne
Yarn Count
70D (Lycra)
Stitch Length 3.20
GSM 410 Face Back
Design 2x1 Rib
Needle set out:
Dial 1
Cylinde
1 1
r
Cam Arrangement:
F1
Page-28
Sample-9
Swatch
Specification
Machine Gauge 18
Yarn Count 40 Ne
Face Back
Stitch Length 3.40
GSM 310
Design 6X10 Rib
Diagrammatic Notation
Needle Set out:
Dial 1 1 1 1 1 1 1 1 1 1
Cylinder 1 1 1 1 1 1
Cam Arrangement:
F1
Page-29
Sample-10
Machine
34”
Diameter
Machine Gauge 24
Yarn Count 30 Ne
Stitch Length 2.62

Face Back
GSM 160
Design 1x1 Interlock
Needle set out:
IIIIII 2
Dial
IIIIII 1
1
Cylinder
2
Cam Arrangement:
5 4
4 5
F1 F2
4 5
5 4
Page-30
Sample-11
Swatch
Specification
Machine Gauge 20
28 Ne (Base)
Yarn Count 76.623 Ne (Binding)
16 Ne (Loop) Face Back
4.4 mm (Base)
Stitch Length 3.9 mm (Binding)
1.55 mm (Loop)
GSM 285
Design Fleece
Needle set out:
Diagrammatic Notation: 1
kkkkkkkk 2 2
kkkkkkkk 3
tmmmtmmm
kkkkkkkk Cam Arrangement:
kkkkkkkk F1 F2 F3 F4 F5 F6
mmtmmmtm 4 4 5 4 4 6
4 4 6 4 4 6
4 4 6 4 4 5
Page-31
Sample-12
Machine Gauge 20
36 Ne (Base)
76.623 Ne
Yarn Count
(Binding)
24/2 Ne (Loop)
4.48 mm (Base)
Stitch Length 3.20 mm (Binding)
1.72 mm (Loop) Face Back
GSM 340
Design Diagonal Fleece
Needle set out:
kkkkkkkk
1
kkkkkkkk
2
tmmmtmmm
3
kkkkkkkk
kkkkkkkk 4
mtmmmtmm
Cam Arrangement:
kkkkkkkk
F1 F2 F3 F4 F5 F6 F7 F8 F9
kkkkkkkk
4 4 5 4 4 6 4 4 6
mmtmmmtm
4 4 6 4 4 5 4 4 6
4 4 6 4 4 6 4 4 5
4 4 6 4 4 6 4 4 6
Page-32
3.7 Machine & Equipment:
Specifications of Knitting Machines:
SL No. Machine Name Brand Origin Quantity
1 Single Jersey GONAG LIH China 21
2 Single Jersey TA-YU China 13
3 Single Jersey JIUNN LONG Taiwan 1
4 Fleece GONAG LIH China 8
5 Rib GONAG LIH China 12
Jacquard
7 Knitting FEITUEWITT China 8
Machine
V-bed Knitting SHIMA SEIKI

8 Japan 12
Machine MFG LTD
Page-33
Circular Knitting Machines Profile:
Machine-1:
Specification
Machine Diameter 24
Machine Gauge 24
Feeder 74
Needle 1800
Manufacturer GOANG LIG
Machine Type 3.00 F
Design Single jersey
Machine-2
Specification
Machine Diameter 25
Machine Gauge 24
Feeder 74
Needle 1884
Machine Type 2.96 F
Page-34
Machine-3
Specification
Machine Diameter 27
Machine Gauge 24
Feeder 108
Needle 2028
Manufacturer TA-YU (Xiamen)
Machine Type 4F
Machine-4, 5, 6
Specification
Machine Diameter 30
Machine Gauge 20
Feeder 96
Needle 1860
Machine Type 3.20 F
Page-35
Machine-7, 8
Specification
Machine Diameter 34
Machine Gauge 20
Feeder 2112
Needle 2112
Machine Type 3.20 F
Machine-9, 10
Specification
Machine Diameter 36
Machine Gauge 24
Feeder 108
Needle 2712
Machine Type 3.00 F
Page-36
Machine-11
Specification
Machine Diameter 32
Machine Gauge 20
Feeder 96
Needle 1992
Machine Type 3.00 F
Machine-12, 13
Specification
Machine Diameter 32
Machine Gauge 20
Feeder 96
Needle 2010
Machine Type 3.00 F
Page-37
Machine-14
Specification
Machine Diameter 34
Machine Gauge 24
Feeder 102
Needle 2544
Machine Type 3.00 F
Machine-15, 16, 17
Specification
Machine Diameter 34
Machine Gauge 24
Feeder 102
Needle 2556
Machine Type 3.00 F
Page-38
Machine-18
Specification
Machine Diameter 32
Machine Gauge 24
Feeder 96
Needle 2406
Machine Type 3.00 F
Machine-19
Specification
Machine Diameter 30
Machine Gauge 24
Feeder 90
Needle 2544
Machine Type 3.00 F
Page-39
Machine-20
Specification
Machine Diameter 32
Machine Gauge 18
Feeder 68
Needle 1800
Machine Type 2.10 F
Machine-21
Specification
Machine Diameter 30
Machine Gauge 18
Feeder 60
Needle 1688
Machine Type 2.00 F
Page-40
Machine-22
Specification
Machine Diameter 38
Machine Gauge 18
Feeder 80
Needle 2148
Machine Type 2.10 F
Machine-23
Specification
Machine Diameter 38
Machine Gauge 16
Feeder 76
Needle 1908
Manufacturer TA-YU
Machine Type 2.00 F
Page-41
Machine-24
Specification
Machine Diameter 29
Machine Gauge 24
Feeder 86
Needle 2184
Machine Type 2.96 F
Machine-25
Specification
Machine Diameter 28
Machine Gauge 24
Feeder 89
Needle 2106
Machine Type 3.17 F
Page-42
Machine-26
Specification
Machine Diameter 32
Machine Gauge 24
Feeder 96
Needle 2406
Machine Type 3.00 F
Machine-27
Specification
Machine Diameter 34
Machine Gauge 24
Feeder 51
Needle 2560
Machine Type 1.5 F
Page-43
Machine-28, 29
Specification
Machine Diameter 34
Machine Gauge 24
Feeder 102
Needle 2556
Machine Type 3.00 F
Design TERRY
Machine-30, 31
Specification
Machine Diameter 34
Machine Gauge 24
Feeder 102
Needle 1908
Machine Type 3.00 F
Page-44
Machine-32, 33
Specification
Machine Diameter 36
Machine Gauge 24
Feeder 108
Needle 2704
Machine Type 3.00 F
Machine-34
Specification
Machine Diameter 40
Machine Gauge 18
Feeder 80
Needle 5427
Machine Type 2.00 F
Design Double Jersey
Page-45
Machine-35
Specification
Machine Diameter 40
Machine Gauge 18
Feeder 84
Needle 4521
Manufacturer TA-YU
Machine Type 2.10 F
Machine-36
Specification
Machine Diameter 36
Machine Gauge 18
Feeder 78
Needle 4060
Manufacturer TA-YU
Machine Type 2.16 F
Page-46
Machine-37
Specification
Machine Diameter 34
Machine Gauge 18
Feeder 72
Needle 3845
Manufacturer TA-YU
Machine Type 2.11 F
Machine-38
Specification
Machine Diameter 34
Machine Gauge 18
Feeder 69
Needle 3845
Manufacturer JIUUN LONG
Machine Type 2.00 F
Page-47
Machine-39
Specification
Machine Diameter 36
Machine Gauge 18
Feeder 73
Needle 1908
Machine Type 2.00 F
Machine-40
Specification
Machine Diameter 42
Machine Gauge 18
Feeder 80
Needle 4750
Machine Type 1.9 F
Page-48
Machine-41
Specification
Machine Diameter 40
Machine Gauge 18
Feeder 88
Needle 4520
Machine Type 2.20 F
Machine-42
Specification
Machine Diameter 38
Machine Gauge 24
Feeder 114
Needle 2864
Manufacturer TA-YU
Machine Type 3.00 F
Page-49
Machine-43
Specification
Machine Diameter 36
Machine Gauge 24
Feeder 108
Needle 2708
Manufacturer TA-YU
Machine Type 3.00 F
Machine-44
Specification
Machine Diameter 34
Machine Gauge 24
Feeder 102
Needle 2560
Machine Type 3.00 F
Page-50
Machine-45, 46, 47, 48
Specification
Machine Diameter 36
Machine Gauge 24
Feeder 108
Needle 2708
Machine Type 3.00 F
Machine-49
Specification
Machine Diameter 34
Machine Gauge 24
Feeder 102
Needle 2560
Machine Type 3.00 F
Page-51
Machine-50
Specification
Machine Diameter 34
Machine Gauge 24
Feeder 102
Needle 2560
Manufacturer TA-YU
Machine Type 3.00 F
Machine-51
Specification
Machine Diameter 32
Machine Gauge 24
Feeder 96
Needle 2556
Machine Type 3.00 F
Page-52
Machine-52
Specification
Machine Diameter 32
Machine Gauge 24
Feeder 96
Needle 2556
Manufacturer TA-YU
Machine Type 3.00 F
Machine-53
Specification
Machine Diameter 30
Machine Gauge 24
Feeder 90
Needle 2260
Manufacturer TA-YU
Machine Type 3.00 F
Page-53
Machine-54
Specification
Machine Diameter 36
Machine Gauge 24
Feeder 108
Needle 2710
Machine Type 3.00 F
Machine-55
Specification
Machine Diameter 34
Machine Gauge 24
Feeder 108
Needle 2770
Machine Type 3.00 F
Design Single Jersey
Page-54
Flat Bed Knitting Machine Profile
Jacquard Knitting Machine:
Machine 1-8
Specification
Machine Diameter 80
Machine Gauge 14
Feeder 16
Needle 2240
Manufacturer SHIMA SEIKI MFG LTD.
Origin Japan
Machine Type Modern (Computerized)
Flat Bed Knitting Machine:

Machine-1-12
Specification
Machine Diameter 60
Machine Gauge 14
Feeder 8
Needle 1680
Manufacturer FEITUEWITT
Origin China
Machine Type Automated(Old)
Page-55
3.8 Products in Knitting Floor:
Single Jersey:
• Single Jersey Plain
• Full Feeder Lycra Single Jersey
• Single Lacoste
• Double Lacoste
• Polo Pique
• 50% Tuck Fleece
• Cross Fleece
• AD Fleece
• Terry
Double Jersey:
• Full Feeder 1×1 Rib
• Half Feeder 1×1 Rib
• Full Feeder 2×1 Rib
• Half Feeder 2×1 Rib
• 4×6 Rib
• 6×10 Rib
• Plain Interlock
• Waffle
Jacquard Knitting Machine:
• Collar
• Cuff
Page-56
3.9 Picture of Some Knitting Machines:
Gong Lih Single Jersey Knitting Machines:
Fig: Gong Lih Single Jersey Circular Knitting Machine
Page-57
Jiunn Long Single Jersey Knitting Machines:
Page-58
Gong Lih Double Jersey Knitting Machines:
Page-59
FEITUEWITT Flat Bed Knitting Machine:
SHIMA Jacquard Knitting Machine:
Page-60
3.10 Different parts of Circular knitting machine:
Creel
Creel is a metallic stand that holds the
yarn package and feeds it to the machine.
Fig: Creel
Creel Tube
The main purpose of the creel tube is it
transfers the yarn to the positive feeder.
Fig: Creel Tube
QA Pulley
It is used to regulate the fabric's Stitch
Length. The Stitch Length is
Proportional to the VDQ pulley
diameter. Therefore, if the diameter of
the pulley increases the stitch length or
produced fabric also increases.
Fig: QA Pulley
CAM
It converts the rotary machine drive into a
suitable reciprocating action for the
needle.
Fig: Needle Cam
Page-61
Yarn Guide
Yarn guide is an element, which uses to
guide the yarn.
Fig: Yarn Guide
Cylinder
In the cylinder, all needles present in-
group together.
Fig: Cylinder
Indicator
It is used to indicate the yarn breakage for
which machine stopped
Fig: Indicator
Sinker
Principle function of sinker is to
pull the newly laid yarn into a loop
Fig: Sinker
Page-62
Fan
It keeps the knitting area free of dust,
flies etc.
Fig: Fan
Needle
It is the principle knitting elements of a
knitting machine.
Fig: Needle
Air Nozzle
It is responsible for supplying oil to the
machine
Fig: Air Nozzle
Storage Wheel
It is where the yarn coils are stored.
There are two types of stop motion:
• Inlet stop motion
• Outlet stop motion
Fig: Storage Wheel
Page-63
3.11 Production & Efficiency Calculation of Knitted Product:
Type 1: Single Jersey Fabric
M/c Number Fabric Type Actual Production
12 Single Jersey 102 kg/shift
M/c Diameter, D= 30”

M/c Gauge, G= 28G
No of feeder= 88
M/c RPM= 22
Stitch Length= 2.90
Yarn Count= 32
Efficiency= 80%
Time= 8 hours
We know,
Calculated Production
!" "$ !%%&'%×!" "$ $%%&%)×*+,×-./.01 2%34.1×5/6%×7$$/0/%308
= 9:×;.=>×?>:×;.;:>×@A×BC)3 D"E3.
@.9>9A×@:×;?×??×;;×;.F:×?×A:×:.?:
= 9:×;.=>×?>:×;.;:>×@A×@;
= 105.02 𝑘𝑔 ⁄𝑠ℎ𝑖𝑓𝑡 ≈ 105 𝑘𝑔/𝑠ℎ𝑖𝑓𝑡
Efficiency
G0.EC' +)"&E0./"3
= DC'0E'C.%& +)"&E0./"3 × 100
9:;
= 9:= × 100
= 97.14%
Page-64
16 Single Jersey Lycra 122 kg/shift

M/c Gauge, G= 24G
No of feeder= 102
M/c RPM= 23
Stitch Length= 2.78
Yarn Count= 26
Lycra Count= 20D
Lycra % = 4.5%
Efficiency= 85%
Time= 8 hours
We know,
!" "$ !%%&'%×!" "$ $%%&%)×*+,×-./.01 2%34.1×5/6%×7$$/0/%308
= 9:×;.=>×?>:×;.;:>×@A×BC)3 D"E3.
@.9>9A×@>×;>×9:;×;@×;.H?×?×A:×:.?=
= 9:×;.=>×?>:×;.;:>×@A×;A
= 154.97 𝑘𝑔 ⁄𝑠ℎ𝑖𝑓𝑡
Weight of spandex
9=>.FH×>.=
= 𝑘𝑔= 6.975 kg
9::
Total calculated production

= (154.97+6.975) kg/shift
= 161.945 kg/shift≈ 162 𝑘𝑔/𝑠ℎ𝑖𝑓𝑡
Efficiency
G0.EC' I)"&E0./"3
= DC'0E'C.%& +)"&E0./"3 × 100
9;;
= 9A; × 100 = 75.30%
Page-65
Type 2: RIB Fabric:
21 1x1 Rib 73 kg/shift

M/c Gauge, G= 18G
No of needle = 3.1416x34”x18x2= 3845
No of feeder= 72
M/c RPM= 16
Stitch Length= 2.60
Yarn Count= 30
Efficiency= 85%
Time= 8 hours
We know,
!" "$ !%%&'%×!" "$ $%%&%)×*+,×-./.01 2%34.1×5/6%×7$$/0/%308
= 9:×;.=>×?>:×;.;:>×@A×BC)3 D"E3.
@?>=×H;×9A×;.A:×?×A:×:.?=
= 9:×;.=>×?>:×;.;:>×@A×@:
= 92.51 𝑘𝑔⁄𝑠ℎ𝑖𝑓𝑡 ≈ 93 𝑘𝑔/𝑠ℎ𝑖𝑓𝑡
Efficiency
G0.EC' +)"&E0./"3
= DC'0E'C.%& +)"&E0./"3 × 100
H@
= F@ × 100= 78.49%
Page-66
26 1x1 Rib Lycra 80 kg/shift

M/c Gauge, G= 18G
No of needle = 3.1416x34”×18×2= 3845
No of feeder= 72
M/c RPM= 12
Stitch Length= 2.80
Yarn Count= 26
Lycra Count= 70D
Lycra % = 2.26%
Efficiency= 85%
Time= 8 hours
We know,
!" "$ !%%&'%×!" "$ $%%&%)×*+,×-./.01 2%34.1×5/6%×7$$/0/%308
= 9:×;.=>×?>:×;.;:>×@A×BC)3 D"E3.
@?>=×H;×9;×;.?:×?×A:×:.?=
= 9:×;.=>×?>:×;.;:>×@A×;A
= 86.22 𝑘𝑔⁄𝑠ℎ𝑖𝑓𝑡
Weight of spandex
?A.;;×;.;A
= 𝑘𝑔= 1.95 kg
9::
Total calculated production

= (86.22+1.95) kg/shift = 88.17 kg/shift ≈ 88 𝑘𝑔/𝑠ℎ𝑖𝑓𝑡
Efficiency
G0.EC' I)"&E0./"3 ?:
= DC'0E'C.%& +)"&E0./"3 = ?? × 100 = 90.91%
Page-67
M/c Diameter, D = 38”

M/c Gauge, G = 18G
@
No of needle = (3.1416 × 38” × 18× ;
= 3223
No of feeder = 76
M/c RPM = 14
Stitch Length = 2.60 mm
Yarn Count = 28
Efficiency = 80%
Time = 8 hours
We know,
!" "$ !%%&'%×!" "$ $%%&%)×*+,×-./.01 2%34.1×5/6%×7$$/0/%308
= 9:×;.=>×?>:×;.;:>×@A×BC)3 D"E3.
@;;@×HA×9>×;.A:×?×A:×:.?:
= 9:×;.=>×?>:×;.;:>×@A×;?
= 72.23 𝑘𝑔⁄𝑠ℎ𝑖𝑓𝑡 ≈ 72 𝑘𝑔/𝑠ℎ𝑖𝑓𝑡
Efficiency
G0.EC' +)"&E0./"3
= DC'0E'C.%& +)"&E0./"3 × 100
=>
= H; × 100
= 75%
Page-68
M/c Diameter, D = 36”

M/c Gauge, G = 18G
9A
No of needle = (3.1416×36”×18× ) = 5429
A
No of feeder = 76F
M/c RPM = 16
Stitch Length = 3.40 mm
Yarn Count = 40
Efficiency = 85%
Time = 8 hours
We know,
!" "$ !%%&'%×!" "$ $%%&%)×*+,×-./.01 2%34.1×5/6%×7$$/0/%308
= 9:×;.=>×?>:×;.;:>×@A×BC)3 D"E3.
=>;F×HA×9A×@.>:×?×A:×:.?=
= 9:×;.=>×?>:×;.;:>×@A×>:
= 127.28 𝑘𝑔 ⁄𝑠ℎ𝑖𝑓𝑡 ≈ 127 𝑘𝑔/𝑠ℎ𝑖𝑓𝑡
Efficiency
G0.EC' +)"&E0./"3
= DC'0E'C.%& +)"&E0./"3 × 100
FA
= 9;H × 100 = 75.59%
Page-69
Type 3: Three-Thread Fleece:
06 Fleece Three Thread 68 kg/shift
Machine Diameter, D = 30’’

Machine Gauge, G = 20
Stitch Length,
For Base Yarn = 4.4 mm
For Binding Yarn = 3.9 mm
For Loop Yarn = 1.55 mm
Yarn Count,
For Base Yarn = 28 Ne
For Binding Yarn (Polyester) = 70D = 76.623 Ne
For Loop Yarn = 16 Ne
Machine RPM = 18
No of Feeder = 90
No. of Needle = (3.1416×30×20) = 1885
Efficiency = 85%
Time = 8 hours
We know,
Calculated Production for Base side
!" "$ $%%&%'
(
×*+,×!" "$ 3%%&'%J×-./.01 '%34.1×5/6%×7$$/0/%308
= 9:×;.=>×?>:×;.;:>×@A×BC)3 0"E3.
@:×9?×9??=×>.>×?×A:×:.?=
= = 38.55 kg/shift
9:×;.=>×?>:×;.;:>×@A×;?
Calculated Production for Binding side

!" "$ $%%&%'
(
×*+,×!" "$ 3%%&'%J×-./.01 '%34.1×5/6%×7$$/0/%308
= 9:×;.=>×?>:×;.;:>×@A×BC)3 0"E3.
@:×9?×9??=×@.F×?×A:×:.?=
= = 12.49 kg/shift
9:×;.=>×?>:×;.;:>×@A×HA.A;@
Page-70
Calculated Production for Loop side
!" "$ $%%&%'
(
×*+,×!" "$ 3%%&'%J×-./.01 '%34.1×5/6%×7$$/0/%308
= 9:×;.=>×?>:×;.;:>×@A×BC)3 0"E3.
@:×9?×9??=×9.==×?×A:×:.?=
= = 23.77 kg/shift
9:×;.=>×?>:×;.;:>×@A×9A
Total Calculated Production

= (38.55 + 12.49 + 23.77) kg/shift = 74.81 kg/shift≈ 75 𝑘𝑔/𝑠ℎ𝑖𝑓𝑡
Efficiency
G0.EC' +)"&E0./"3
= DC'0E'C.%& +)"&E0./"3 × 100
A?
= H= × 100 = 90.67%
Page-71
3.12 Inspection:
Inspection can be defined as measuring, examining, testing, and gauging one or more
characteristics of a product on source comparing these with specific requirements to determine
conformity. Fabric Inspection is an important aspect followed prior to garment manufacturing
to avoid rejects due to fabric quality and facing with unexpected loss in manufacturing. Fabric
inspection is done for fault/defect rate, fabric construction, end-to-end or edge-to-edge shading,
color, hand or feel, length/width, print defect and appearance. Fabric inspection ensures to
minimize the rejection of cut panels or rejected garments due to fabric faults. Cutting inspected
and approved fabric ensures not only finished garment quality but also reduces rejects,
improves efficiency and timely deliveries.
The purpose of fabric inspection is to determine the quality and acceptability for garments. As
fabric is received, it should be inspected to determine acceptability from a quality viewpoint.
Some garment manufacturers rely on their fabric suppliers to perform fabric inspection and
fabric defects.
3.13 Quality Policy:

Cotton Field Ltd. is a knit fabric producer and supplier that focus solely on export. Their goal
is to continually delivering desired values through high-quality products that satisfy their
customers. They try to continuously improvement of the efficacy of the Management system
by developing, communicating, and reviewing quality objectives, as quality is an intrinsic
component of their business. In Cotton Field Ltd., 4-point inspection system is followed for
the quality control.
3.14 Scope:
It is applicable to all textile fibers in the form of grey fabric.
3.15 Equipment:
Inspection machine, Permanent Yellow Marker, Measuring Tape.
Page-72
3.16
4-point Inspection System:
The 4-Point System, also called the American Apparel Manufacturers (AAMA) point-grading
system for determining fabric quality, is widely used by producers of apparel fabrics and is
endorsed by the AAMA as well as the ASQC (American Society or Quality Control).
The 4-Point System assigns 1, 2, 3 and 4 penalty points according to the size and significance
of the defect. No more than 4 penalty points can be assigned for any single defect. Defect can
be in either length or width direction, the system remains the same. Only major defects are
considered. No penalty points are assigned to minor defects.
3.17 Measuring System of 4-point system:

Fabric defects are assigned points based on the following:
Size of defects Penalty points
Up to 3 inch 1 point
3 inch< Size of defect ≤ 6 inch 2 point
6 inch< Size of defect ≤ 9 inch 3 point
Above 9 inch 4 point
Holes & Opening
1 inch or less 2 point
above 1 inch 4 point
Page-73
In following cases the complete roll shall be rejected:
Ø Needle line in complete roll.
Ø Edge Mark/Sinker Mark in a complete roll.
Ø Wrong design in a complete roll.
Ø Barre/Yarn Patta.
Ø Star/Pin Hole/Hole in complete roll.
3.18 Calculations:
9FA?= × K%/41. "$ $CL)/0 /3 M4
• Length in Meters = N-, × 5EL% &/C /3 /301
5".C' +"/3.J × 9::
• Points/100 Linear Meter = 5".C' ,%.%)J
5".C' +"/3.J × @A
• Points/Square Yards = *"'' 2%34.1 × OCL)/0 K/&.1
3.19 Some common faults of fabric in Cotton Field Ltd.:
Faults Name Causes Faults Sample
• Needle breakage
• Hairiness in the yarn
• Weak spots in the yarn
Hole
• A misaligned yarn guide
• A malfunctioning take down
system
• Breakage of Lycra yarn and

Lycra Out
Lycra tension that is uneven.
Page-74
• Needle breakage.
Set Up • Yarn breakage.

• Feeder tension.
• Dust/foreign material in the air.

Fly • Fibers, both dyed and un-dyed,
Contamination
flying from a nearby machine.
Oil Mark • Oil leakage through needle trick
Page-75
• Break down or bend of the needle
Pin Hole
latch
• Defective needles
Needle Mark
• Broken needle latch
• Yarn breakage due to any reason

and not pass through the yarn
Yarn Miss guide

• It may be occurred for tension
variation
Page-76
• High yarn tension.
Barre • Count variation -Uneven

thickness in yarn.
• Poor yarn quality

• Poor air circulating system
Slub
• Fly formation of yarn
• Thick or heavy place in yarn
Page-77
Chapter 4: HR Section
Page-78
4.1 Definition of HR:
Human resource is the department within a business that is responsible for all things that worker
related. That includes recruiting, selecting, hiring on boarding, training, promoting, paying and
firing employees and independent contractors.
Function of Human Resource:
1. Recruitment Training and Development
2. Compensation and Benefits
3. Motivation
4. Maintenance
4.2 Daily Checklist for Floor HR:
Page-79
4.3Compliance:
Compliance means conformity of certain standard. PPC maintain a moderate working
condition for their employees. Though it is well-established project, there is some lacking of
proper compliance issues. Alim Knit BD strongly believes to actualize its corporate mission,
high level of corporate efficiency is essential at all levels of the whole organization. Therefore,
it commits a considerable number of resources for training, development, compliance and
motivation. Alim Knit BD complies with all provisions of the labor as well as the factory laws
and conventions applicable.
List of Compliance:
• Compensation for holiday
• Leave with wages
• Time care
• Health register
• Accident care
• Workman register
• National festival holiday
• Overtime register
• Labor welfare
• Weekly holiday fund
• Sexual harassment policy
• Child labor abolition policy
• Anti-discrimination policy
• Working hour policy
• Recruitment policy
• Environment policy
• Security policy
• Buyer’s code of conduct
• Health and safety committee
• Dining facilities
4.4 Health:
• Drinking water at least 4.5L/day/employee
• Cup availability
• Drinking water supply
• Water reserve at least a week
• Suggestion box registered
Page-80
4.5 Toilet:
• Separate toilet for men and women
• A set with proper privacy and lock facility
• Effective water sewage system
• Soap toilet
• Water tape
• Daily cleaning log sheet
• No smoking signs
4.6 Fire:
• Sufficient fire extinguisher and active
• Fire signs in both languages
• Fire certified personal photo
• Emergency exit
• Safety guard
• Metal glows on good condition
• Rubber mates and ironers
• First aid box once
• Ironers wearing sleepers
• First train employees
• Motor/needle guard
• Eye guard
• Nurse and doctor
• Medicines
4.7 Personnel policies:

• Recruitment policy
• Leave and holiday policy
• They have the approved man power list
Page-81
4.8 Salary:
There are 5 types of salaries-
• Basic
• House rent allowance (50% of basic)
• Food allowance
• Medical allowance
• Transport allowance
In law total food allowance
= (Food allowance+ Medical allowance+ Transport Allowance)
= (900+ 600+ 350) taka
= 1850 taka
Here,
5".C' JC'C)8P9?=:
Basic salary = 9.=
4.9Leave:
• Casual leave = 10 days
• Medical leave = 14 days
• Maternal leave = 16 weeks
• Annual leave/ Earn leave = 1 day after 18 days
• Weekly leave = 1 day
• Festive leave = 13 days
4.10 Training program:

• They arrange security training program on a regular basis for all employee of the factory
• Controlled room temperature
• Lighting facilities
• Ventilation system
Page-82
4.11 Different terms and definition:
1. Lefty:
When an employee becomes absent 10 days without any reason he will be considered
lefty.
2. Resign:
If an employee wants to leave his /her job, he/she has to acknowledge the company
before 7 days. If he/she leaves according to the law his/her 2 months, he/she should pay
basic salary. Again, if he/she informs the company before 1 month, then he/she has to
pay 1-month basic salary to the company.
3. Deduction:
If any employee does not attend the work without informing him/her 1 day, salary will
be cut from their basic salary.
Therefore, as part of its social commitment, Alim Knit dedicates a portion of its profit to run
an orphanage and its vocational training center at a remote and underprivileged place in the
country.
Page-83
Chapter 5: Sample Section
Page-84
5.1 Sample Development:
Actually, we can say sample development section as a heart of garments industries. Because
when garments merchandiser get any order through buyer then have to ready that sample in the
sample development section for confirmation that order. Therefore, we cannot approved any
order without sample development. Then we can checking the sample quality as per buyer
requirement. Moreover, buyer can easily judge the production capability of manufacturer by
the help of sample development section.
5.2 Working process of sample development:

First, Prepare mater pattern card by the help of CAD.
The pattern card put on the layer of fabric and cut the lay.
Then fabric have to dyeing by taking necessary step.
Then finished the dyed fabric
Then sewing the finished fabric by joining the necessary parts according to finished product.
Then inspected the finished product
5.3 Importance of sewing line:

In our sewing floor there has three-sewing line. In addition, each line has different type of
sewing machine such as lock machine, over lock machine, flat lock F-set machine, Flat lock
D-set machine, PMD machine, Feed of arm machine etc. These machines are arranged
according to finished product. Such as, there are different machine set up for basic T-shirt and
polo- shirt. Have to arrange the sewing line according to production efficiency that is mean
production efficiency depends on machine arrangement of sewing line.
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5.4Machine Flow Chart (T-shirt):
Overlock Machine (Shoulder joining).
Flat lock F-set (Neck piping).
Lock stitch machine (neck unstitch).
Overlock Machine (Neck servicing).
Lock machine (loop joining).
Feed of arm (Shoulder to shoulder joining).
Overlock Machine (sleeve joining).
Overlock machine (side seaming).
Flat lock D-set mini cylinder (sleeve hemming).
Flat lock D-set compressed (body hemming).
Trimmings.
Quality check.
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5.5 Stitch class:
Generally, stitch classes are group in six classes:
• Single thread chain stitch. (100)
• Hand stitch (200).
• Lock stitch (300).
• Multi thread chain stitch (400).
• Over edge stitch (500).
• Covering chain stitch (600).
5.6 Different type of sample:
Figure: 5-Thread Covering Stitch
Figure: Chain Stitch
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Figure: 3-Thread Overlock Stitch
Figure: Lock Stitch
Page-88
Figure: 4-Thread Overlock Stitch
5.7 Some Definition:

Guide: To guide the thread in proper way.
SPI: Total number of stitch per inch. Generally, 12 stitch are remain per inch.
Tension Adjustment: By this part, we can adjust the thread tension.
5.8 Difficulties of sewing:

• Needle breakage.
• Thread breakage.
• Defected looper.
• Defected bobbin.
• Unskilled worker.
• Lack of care.
Page-89
Chapter-6: Dyeing & Printing Section
Page-90
6.1: Printing:
Printing is a process for mass reproducing text and images using a master form or template.
The earliest non-paper products involving printing include cylinder seals and objects such as
the Cyrus Cylinder and the Cylinders of Nab nidus.
There are 13 printing table in Alim Knitwear Ltd. Moreover, one sample printing table.
Fig: Printing Machine
Page-91
6.2 Some of the samples are below:
Fig: Different types of Printed Samples
Page-92
Chapter-7: I.E. Section
Page-93
7.1 Introduction:
At present Industrial Engineering (IE) is one of the important departments for each garment or
textile factory. Industrial engineers run today’s maximum factory, where they have to follow a
process flow chart. By which they can easily control the whole garments production processes.
7.2 SMV: Standard minute value
It is used for the final product time length. Example: Basic T-shirt SMV is 3-8 min. & basic
polo shirt SMV value is 10-13 min.
SMV calculation:
SMV= Basic time + Allowance
Basic time= Cycle time × Operator performance rating
Allowance= Basic time × Allowance
So,
S.M.V. = Cycle time × Operator performance rating + Basic time × Allowance
7.3 Cycle Time:

The time, which is needed to complete a cycle, is called as cycle time.
Target= 60/SMV × Man power ×Time/hour × Efficiency%
Efficiency= Output / Input × 100
Here,
Input= Man power × Time
Output=Earned minutes
Page-94
7.4 Lean Production system:
Lean production is a production methodology focused on eliminating waste, where waste is
defined as anything that does not add value for the customer. Although Lean's heritage is
manufacturing, it is applicable to all types of organization and all an organization's process. It
is followed by 5S system. Which is below-
5S is a system for organizing spaces so work can be performed efficiently, effectively, and
safely.
7.5 8D Rule:
The Eight Disciplines of Problem Solving (8D) is a systematic, holistic and proven
methodology designed to identify the root cause of a problem, plan a quick fix, and implement
corrective actions and preventive actions to avoid their recurrence.
Page-95
7.6 80-20 Rule:
The 80-20 rule, also known as the Pareto Principle, is a familiar saying that asserts that 80% of
outcomes (or outputs) result from 20% of all causes (or inputs) for any given event. In business,
a goal of the 80-20 rule is to identify inputs that are potentially the most productive and make
them the priority.
7.7
7-waste of Lean Manufacturing system:
Page-96
Chapter-8: Merchandising & Marketing
Page-97
8.1 Introduction:
Merchandising department works as a mediator between factory and buyers. This department
is considered as heart and soul of the company. A merchandiser has to co-ordinates with buyers
for orders. He has to look after every job like buying the raw material, which is required to
finish the product, making the garment, finishing the garment, documentation, finally shipping.
He is the responsible person to make the product. A garment export unit generally has many
department-like stores, cutting, production, packing, etc. in which Merchandising department
a linking device of all. The job of a merchandiser is to coordinate with the entire department in
the office as well as the customers. Therefore, a merchandiser works in fabric follow up to
order execution.
8.2 Responsibilities of a Merchandiser:
• Internal and external communication
• Sample development
• Lab dips
• Give strike off for approval
• Accessories booking
• Preparing Re-cap
• Preparing production file
• Assisting production
• Follow up to produce a garment
• Advising about quality level
• Giving shipping instruction and follow up shipping
• Taking responsibility for inspection
• Shipment
8.3 Knit Garment Merchandiser:

1. Fabric follow up
2. Order execution
Fabric follow up: Order execution:

• Yarn booking & Requisition • Pattern making
• Fabric booking • Print and embroidery development
• Lab dip approvals • Fit sample making
• Accessories booking • Comments
• Knitting follow up • Cutting fabric
• Lab dip approval • Print and embroidery
• Fabric dyeing and in house • Sewing
Page-98
• Finishing & Q/C check and
shipment
Page-99
8.4Merchandising Flowchart:
Page-100
8.5 Tech Pack:
Teck pack is also known as Technical pack or Technical sheet. It is also known as specification
sheet. It is created by a technical designer, which is used to make a final garment. A Tech pack
is all the instructions a factory needs to produce a finished garment. It contains all the
information n about size, measurements, stitch type, trims, label, stitch length, technical sketch,
seam type, grading chart, tolerance etc.
Teck Pack of MANGO buyer
Page-101
8.6 Cost Sheet:
Cost sheet is one of the important part in garment manufacturing process. It is one of the critical
procedure, it is important because a garment’s profit depends on proper costing. In a cost sheet
all of the costing should be present from beginning to end.
A cost sheet contains-
Fabric price
Trimming price
CM cost
Commercial cost
Shipping charges
8.7 Fabric Consumption:
Fabric consumption means length or width of fabrics needed to make a garment. Fabric type
plays a vital role in fabric consumption. For a solid dyed fabric consumption is optimum but in
case of stripe fabric it is always higher that solid dyed fabric.
The basic consumption formula of a basic t-shirt is given below:
(𝐵𝑜𝑑𝑦 𝑙𝑒𝑛𝑔𝑡ℎ + 𝑆𝑙𝑒𝑒𝑣𝑒 𝑙𝑒𝑛𝑔𝑡ℎ + 𝐴𝑙𝑙𝑜𝑤𝑎𝑛𝑐𝑒 ) × (𝐶ℎ𝑒𝑠𝑡 𝑜𝑟 𝐻𝑒𝑚 + 𝐴𝑙𝑙𝑜𝑤𝑎𝑛𝑐𝑒 ) × 2 × 12 × 𝐺𝑆𝑀
100 × 100 × 1000
+ 𝑤𝑎𝑠𝑡𝑎𝑔𝑒%
A fabric consumption is calculated by using CAD, so that I gives accurate value.
Page-102
8.8 Fabric Booking:
Once buyer confirms or approves lab dip, a merchandiser should place fabric order to supplier
according to consumption based required quantity.
Fabric booking indicates how much fabrics are needed for execute a order. It is prepared by
fabric consumption.
Fabric booking example
Page-103
8.9 Production File:
Merchandiser those are working in a factory needs to prepare a production file. This is an
important task for him to start garment production. A production file is very important
A production file contains following things:
• Checklist
• Latest sample comments
• Size measurement chart
• Tech Pack
• Fabric booking
• Purchase order sheet
• Accessories layout
• Trim card
• Test report
• Pre-production sample
8.10 P/O Sheet:
PO sheet means Purchase Order sheet. A purchase order sheet is a formal document that buyer
send to supplier to authorize a purchase. It is beneficial for both buyer and seller.
Generally, a Purchase order contains the following things:
• PO number
• PO date
• Supplier’s ID
• Buyer’s information
• Supplier’s information
• Ship to details
• Billing address
• Shipping method
• Payment terms
• Delivery date
• Order details
• Taxes
• Total order value
Page-104
8.11 Pro forma Invoice:
A pro-forma invoice is a document before or with a shipment of goods. A pro forma invoice is
usually issued before the sale takes place. It is commonly used in export sales.
A proforma invoice contains-
• Proforma Invoice number
• Supplier name
• Item
• Quantity
• Value
• Shipment date of garments
• Garments quantity
• Sale’s contract number or L/C number
• Buyer name
• Reference number
Pro-forma invoice provide an estimate for goods or services before they are shipped or provided
but only once the customer has demonstrated commitment to a specific price.
8.12 Letter of Credit (L/C):

Letter of credit is payment term that used for international sales transaction. It is important for
both buyer and seller. It offers secured terms of payment to buyer and seller where banks are
involved. It is given by the buyer’s bank to pay the amount to the seller’s bank.
8.14 FOB:
FOB means Free On Board. It is a trade term that’s signifies a seller’s commitment to delivery
the required merchant or products to the destination that has chosen by the buyer. FOB is a
contract between a seller & a buyer that means the shift in the risk of loss from a seller to a
buyer. It holds the responsibility and the liability of the loss by the seller during the journey. A
seller pays shipping expenses and hand over the ownership at delivery point to the buyer
Page-105
8.15 Trim Card:
A trim card is a document which contains fabrics, trims and accessories that helps garments
QC and production team to use correct fabrics, trims and accessories in every style what exact
the buyer wants.
A Trim card contains:
• Fabric swatch
• Yarn thread
• Buttons
• Labels
• Care labels
• Price tag
• Size label etc.
Care label
8.16 Strike Off:

Strike Off is also a known term in merchandising. It is a development stage sourcing in the
sample development. Strike off is used for print fabric development. Strike off is the small print
color swatch approved from the buyer. A printed or embroidered sample send to buyer for
his/her approval is called strike off.
Page-106
8.17 Proto Sample:
Develop from the design sketch or the design concept. It is the first sample in production
development stage in apparel industry.
8.18 Fit Sample:

Fit sample is made to ensure the proper fit of the garment. Fit sample is made according to the
measurement of the buyer. Measurement and construction have to be accurate to pass the fit
evaluation. Purpose of developing Fit sample is checking the garment fit on the dress form or
on the human model.
8.19 Size Set Sample:

The purpose of making size set sample is to check the garment is fit of multiple sizes. Size set
samples can be in multiple size. Such as, XS, S, M, L, XL, XXL, XXXL. A number of size set
samples are required on the buyer’s requirements. Pattern grading should proper in size set
sample.
8.20 Salesman Sample (SMS):

Sales-man sample is another kind of sample that develops displaying the design in the retail
stores. It is develops using the original fabrics. It is also known as marketing sample.
8.21 PP Sample:
PP sample means Pre-production sample. PP sample is made for bulk production of the
garment. When the PP sample is approved from the buyer then the next stage is for bulk
production. PP sample is also made with actual fabric. It is made by the factory in production
line.
8.22 Development sample:

Development samples are those samples which made until the final factory get bulk production
approval. Once lab dip approves then development sample can be made. Size set sample, Fit
sample, Proto sample are considered as development sample.
Page-107
8.23 TOP Sample:
TOP sample means Top of Production sample. When the PP sample is approved then the bulk
production will be started. After that from first production randomly some samples are picked
by the buyer’s QA on purpose of quality checking. These samples are known as Top of
Production sample.
8.24 Shipment Sample:

Shipment sample or Shipping sample refers to the bulk sample that will be exported for
shipment. The product should be produced according to the requirements of the customer.
The packaging also should properly according to requirements. This is generally need to send
to the customer before shipment. Buyers need to keep a random garment piece from the final
shipment audit. Factory keeps 3 shipment sample
One for buyer
Second for factory
Third one for buying house merchant.
So, from the Merchandising and Marketing Department of Alim Knit BD. I have learned lots
of things from there about merchandising.
Page-108

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Ahsanullah University of Science & Technology

DEPARTMENT OF TEXTILE ENGINEERING

Course No: Tex 500

170206061 Masud Rana

170206063 Mahmud Riad

170206075 Md. Hassin Sahariar Rhythm

2.3 Location and Contacts:

2.8 Mission and Vision of the Factory:

2.9 Products of Alim Knit (BD) Ltd.:

2.10 Major Buyers:

Perry Ellis USA

Sergent Major France

Carded Slub 100% Cotton

Combed Slub 100% Cotton

Needed Yarn Requisition

Floor receives the required yarn

Master makes the knitting plan

Deliver the grey fabric

Fabric is wound down by cloth roller

Yarn Passes Through The Creel

Yarn Passes Through The Magnetic

Inlet Stop Motion

For Positive Feeding Yarn is

Outlet Stop Motion

Needles Catch the Yarn for Loop

Take Down Roller Pulls the

Fabric Is Wound Down by Cloth

Stitch Length 2.90

GSM 150 Face Back

Stitch Length 2.78

Stitch Length 2.80

Stitch Length 2.00

GSM 210 Face Back

Design Single Lacoste

Machine Diameter 28”

Stitch Length 2.00

GSM 210 Face Back

Stitch Length 2.62

GSM 225 Face Back

Stitch Length 2.70

GSM 150 Face Back

Design 1x1 Rib

GSM 410 Face Back

Design 2x1 Rib

Machine Diameter 36”

Stitch Length 3.40

Design 6X10 Rib

Needle Set out:

Stitch Length 2.62

Design 1x1 Interlock

Machine Diameter 30”

Needle set out:

SL No. Machine Name Brand Origin Quantity

1 Single Jersey GONAG LIH China 21

2 Single Jersey TA-YU China 13

3 Single Jersey JIUNN LONG Taiwan 1

4 Fleece GONAG LIH China 8

5 Rib GONAG LIH China 12

V-bed Knitting SHIMA SEIKI