ACKNOWLEDGEMENT

We are living in the era of competition, without having practical knowledge in the
business arena an executive can not take the prudent decision in the critical situation &
unable to direct a group of people for achieving the goal of the company. Considering
such matter to broaden the practical acknowledge as well as partial fulfillment of the
requirement for the Bachelor degree of Apparel manufacturing management &
technology the AMM Department of Shanto-Mariam University of Creative Technology
does arrange the internship program in various industries for the on going B.A.(hons.)
students. Being a student of this department I am to complete my internship program in
Harvest Rich Limited. Going to the practical work, first I pay my gratitude to my
estimable supervisor Faculty & coordinator Engr. A.J.S.M. Khaled for his excellent
direction, pragmatic guide line & wise decision that make me inspired & venturous to
complete such massive internship program. I extremely owe to Mrs. Nusrat Bari Asha for
her kind cooperation & advice about company etiquette I am indebted to Mr. Mohammad
Maruf Hasan Divisional Manager Merchandising & Marketing of HRL, Mr. Syed Abu
Mohammad Saleh Senior Merchandiser of HRL, and Mr. Mahesh Product Development
Chief of HRL & Mr. Mahboob Product Development Executive of HRL. My thanks go
to the management & the faculty members of Fashion Design & Apparel manufacturing
Management Department of SMUCT. My thanks go to all the stuffs, workers and
management of Harvest Rich Ltd. I am very much pleased with my group mates for their
massive collaboration. Lastly, I also send my pleasure to my honorable seniors of
SMUCT as Mr. Rassel, Mr. Sunny for their good suggestion. I express my thanks heartily
to all of my friends.

PREFACE

Theoretical knowledge may not be enriched without having the trivial touch of practical
learning, considering this matter Apparel Manufacturing Management Department of
Shanto-Mariam University of Creative Technology has introduced the provision of
internship program in any company or other field as per the rule of B.A.(hons.)
ordinance. Being a student of B.A.(hons.) program in Apparel Manufacturing
Management Department I am compelled to complete my internship program. I have
conducted my work in HRL on Product Development, Merchandising, CAD room &
Cutting, Sewing room & Production & Finishing Department under the supervision of
my respected teacher Engr. A.J.S.M. Khaled with due permission of the Department
Head of AMM. For this massive task I visit HRL for one and half month. I try my level
best to observe & perform my task with the cordial help of company authority. If I make
any involuntary mistake I earnestly request my supervisor & other concerning authorities
to take it in the eyes of forgiveness.
 INTRODUCTION

As a hons. Student of apparel manufacturing management. We have to make an

internship which we term it as factory placement. In my placement I really want to make
it in garment factory. There is a possibility to show creativity in garment manufacturing
process. That is why I choose my placement in a garment factory name HARVEST RICH
LTD. My placement was 6 weeks long. In placement are just look, listen, hear and to
learn. There is no way of the give any suggestion. I have learnt a lot of which I kept for
dissertation. Here I just give the ideas and observation area. So thanks for cooperation
who ever help me to make it fulfill.

BRIEF HISTORY OF THE ORGANIZATION

Harvest Rich Limited is a leading Woven & Knit ready-made garments manufacturing
organization. This organization is a public limited company has established itself in
Bangladesh as a confident supplier of both Knit fabric & Knit & Woven garments. In
1992, the company first started as a private limited company & step by step, in 1997 after
several expansions & joint ventures, the company transferred to a public limited
company. Currently over 4,500 people are working with 150 people in the management
positions. The Board of Directors includes the representation of several domestic &
international renowned institutions that have invested capital in HRL because of its
reputation & most importantly for its potential in the textile business in the region. HRL’s
corporate character is reflected in its distinguished multinational team of shareholders
such as Industrial Promotion Development company (co-financed by Commonwealth
Development Corporation, CDC), German Investment & Development Company (DEG),
Abu-Dhabi fund for Development (UBICO) & Local group of Companies. The company
has its investment of over US$ 20 million & US$ 12 million both as project cost &
working capital respectively. Harvest Rich Limited is an ISO-9001:2000 & WRAP
certified organization.

THERE OBJECTIVES TO OFFER:

 Offer production capacities of Polo Shirts & other Knit Garments.

 Offer production capacities of Trouser & Bottoms.
 Offer for selling Knit Fabrics – all structured mentioned in the above table.

HARVEST RICH LTD. & ITS UNITS:

Harvest Rich Ltd. units are:

1. Harvest Rich Woven Garment Factory

2. Harvest Rich Knit Garment Factory
3. Harvest Rich Undergarment Factory
4. Harvest Rich Knit Fabric Plant
 5. Harvest Rich Dyeing & Finishing Plant
6. Harvest Rich Wet Processing Plant
7. Harvest Rich Garment Printing Plant
8. Harvest Rich Embroidery Plant

(All above units are situated in one place).

A BRIEF PROFILE OF HARVEST RICH & ITS PRODUCTS:

Sl. UNITS PRODUCT/FEATURE CAPACITY REMARKS

No. /DAY
1. Woven  Chino Trousers 960 Sewing Machine
Garment  5 Pocket Trousers of Japan / USA
Factory  Cargo / Carpenter Trousers origin.
 Stretch Trousers 10,400 Pcs.
 Shorts Sewing / Finishing
 Over / Shorts All Floor = 60,000 sq.ft.
 Sportswear
2. Under  All types of Men’s boxers & briefs 47,200 Pcs. 162 fully automated
Garment machines from
Factory Yamato, Japan.
3. Knit Garment  Basic T-shirt Polo Shirt – 888 Sewing machine
Factory  Polo Shirt 7040 Pcs. of Japan / USA
 Turtle Neck T-shirt & origin.
 Sports wear others –
 Sleep wear 45,000 Pcs. Sewing / Finishing
Floor = 140,000 sq.ft.
4. Knit Fabric  Single Jersey 22,000 kg. Established with
Plant  All types of Ribs latest generation
 All types of Pique & La Pique German Mayer &
 Full feeder Spandex Fabrics Cie, Knit Circular
 Drop Needle machines.
 Various designed & structured fabrics
5. Dyeing &  Knitting in all variations. 22,500 kg. Established with
Finishing  Computerized color matching by data latest generation
Plant color spectro-photo meter. These Dyeing
 Dyeing in all ranges, fully machines & Ruckh &
computerized dyeing process from lab Ruckh-Calator
dyeing, sample dyeing to production finishing machines of
process. Any fabric up to 140 c – Germany & Sweden
tubular knit fabrics. Due to shortest origin.
process time gentle treatment for the
fabrics.
 We use Azo free /
Environmentally Friendly
European chemical & dyestuff.
6. Wet  Germent Wash / Power Rinse 2,000 Dzn. Machine &
Processing  Silicon Wash technology from
Plant  Enzyme / Enzyme Stone Wash Singapore & China.
 Stone / Chemical Stone Wash
 Bleach Wash Drying on steam
 Destroy Wash only.
 Sand Blast
 Spray Wash
 Micro-Sanded Green Wash
 Retro-Reactive & Tie-Dye
7. Garment  All types of Garment / Chest & 2,500 Dzn. Italian Technology.
Printing component printing

8. Embroidery  Solid embroidery 20,00,000 JINTEL, Japan-

Plant  Appliqués Stitches / Chinese Technology.
 Embroidery patch Machine

THE CORRESPONDING BUYERS:

EUROPE USA
H&M, Sweden H&M
Sara Lee Pintables, Germany Sara Lee
Sara Lee Branded Apparels, Europe Target
PUMA World Cat, Germany Reebok
Charter House, UK Mothers work
Carrefour, France Wal-Mart
Tesco, UK
Marks & Spencer
Tchibo, Germany
TOM TAILOR, Germany

Sample & Production Development Center: Run by fashion merchandising experts &
equipped with required modern machinery including CAD/CAM from Investronica,
Spain.
Laboratory: Equipped with spectrophotometer, data color & other relevant apparatus,
equipment for lab-dip & fabric quality development.
Technology & Production:
 Production Management in place.
  Sophisticated technology, machinery & equipment acquired.
 Production process technology acquired.
 Employment, training & human resource development schemes executed.

Technology & System:

 All hardware / software – in place.
 E-mail for communication with overseas & regional offices.
 LAN Server Pentium-3 500 MHz PC Server with 2x9.1 GB SCSI-3 HD, 256 MB
RAM. New LAN Server Xeon 3.2 GHZ IBM Series 226 with 4x73 GB. SCSI
HDD DAT 72, 2GB RAM.
 Digital Audio Tape (DAT 8) – Data backup.
 System Analyst, Programmers employed, Developing Systems & Designing need
based software.
 Management Reports on Production, Marketing, Statutory & Management
Accounts & MIS.

Auxiliary / Capital Machinery:

 Prime Power Generator GAS Operated 2150 KVA, 5 Sets, USA origin.
 Industrial GAS Fired Boiler, 7.84 TPH each, 2 Sets, USA origin & 3.5 TPH 1 Set
from Italy.
 Industrial Transformer, 1000 KVA, France Origin.
 Industrial Air Compressor, 700 CBM / hour, German Origin.
 Water Treatment Plant (WTP), 500 CBM / hour, Italy & Indian Origin.

Financial Systems & Controls:

 Budget, Statutory & Management Accounts.
 Periodical Internal & Annual External Audit.
 Level of Authorities & Compliance.
 Documentation, Recording & Controlling with full dependence on Hardware &
Software.
 Shareholders & BOD confirmation through periodical meetings.

Fulfillment of Standard Requirements:

HRL’s promises are not only for their products & quality; they also want to be known for
taking responsibility for their business. That means:
 HRL is trying to create a better environment, better social & working conditions
in the country.
 HRL business principles are sound & they care about today’s & tomorrow’s
environment.

Environmental Commitments:
Harvest Rich Ltd. has set up / invested considerable amount in Water Treatment Plant
(WTP) so that the industrial waste produced from their dyeing mill & washing plant can
be cleaned from hazardous chemicals before draining it out from the factory.
 QUALITY PROCESS / AUDIT ASSURANCE OF THE GARMENTS

QUALITY PROCESS:
 Fabric Inspection: Using the 4 point system. At least 20% of the quality being
received. Prepare a shade continuity / card for shade checking.
 Trims Received / Inspection: Inspection of all trims & accessories received using
AQL 2.5.
 Cutting / Spreading Inspection: Checking procedure carried out during spreading
of fabric during cutting / laying. Check for ply height, uneven sizes, matching
plies, matching with the markers, loose of tight laying etc.
 Cut Panel / Block Checking: Checking procedure carried out after cutting which
is done by checking some cutting blocks whether it matches with the pattern.
Check also for rugged cutting, folded sides & crooked shapes, W/C does not
conforms to the pattern shapes.
 100% Cut Panel Inspection: Checking of all panels (front / back) to assure that
fabric defects will be sorted out prior to input to sewing line. (Defect Points :
Hole, Contamination & other Knitting & dyeing defects)
 In – Line: Inspection for Measurement – A random checking of measurement for
all the sizes that’s running in the sewing line. It is conducted every after 2 hours
covering all the sizes available in the production floor.
 In-line process Inspection: A checking process carried out on every sewing
operation / process. A dedicated line quality inspector will be checking 7 pcs of a
bundle using AQL 2.5. In the event that one piece defects would be found out of
the 7pcs, then entire bundle will be rechecked together with production
supervisor.
 End Line Table Inspection: A 100% inspection of all garments finished / output
from the sewing line. An inspection that covers all points of defects that needs to
be inspected. (Styling, trims, placement, workmanship etc.)
 100% Measurement Checking: A 100% inspection of all garments after ironing.
 Get-up / Presentation checking: An inspection carried out after ironing that covers
– checking for garments appearance & get-up after ironing.
 Daily Lot Audit: An audit carried out every day on whatever packed quality using
2.5 AQL. A dedicated auditor conducts the audit.
 Pre-Final Audit: An audit carried out on whatever ready PO’s / order prior to offer
for final inspection to the buyer. A dedicated pre-final auditor conducts the audit
using 2.5 AQL.
 In-house Garments wash test: A garments wash test carried out on whatever
running styles or Po’s in the production line. The test is conducted following the
washing instruction on the care label & so also with the washing procedure of
every buyer.
 Units of HRL/CTL & their Location, Lines, Machine allocation & Production Capacity:

Sl. Name of the Location Nos. of Nos. of m/c per Production to Capacity Per Line in Total
No. Unit Lines line/ total Manufacture Pcs. Capacity
Machine Per Hr Per 8 hrs In Pcs.
1. Polo Unit On Top  Polo Shirt 110 880 7040
Central 30 m/c per line  T-Shirt Cut &
Ware House 8 Line Sew
(including Total 240 m/c
mezzanine of
RMG Bldg.)
2. Blue Unit Level-3 of 5 Line 64 m/c per line Woven 90 720 3600
Main RMG  Bottom/
Bldg. Total 320 m/c Trouser

3. Green Unit Level-2 of 5 Line 64 m/c per line Woven 90 720 3600
Main RMG  Bottom/
Bldg. Total 320 m/c Trouser

4. Brown Unit Level-1 of 5 Line 64 m/c per line Woven 80 640 3200
Main RMG  Bottom/
Bldg. Total 320 m/c Special
Production Unit

5. Orange Unit Level-2 of 12 Line 18 m/c per line  T- 120 960 11520
(Sara Lee RMG Ext. Shirt/Knit
Exclusive) Bldg. Total 216 m/c RMG

6. Purple Unit Level-3 of 12 Line 18 m/c per line  Knit RMG 120 960 11520
RMG Ext.
Bldg. Total 216 m/c

7. Olive Unit Level-4 of 12 Line 18 m/c per line  Knit RMG 120 960 11520
RMG Ext.
Bldg. Total 216 m/c

8. Underwear Level-3 of 12(10+2) 13 m/c for briefs  Men’s/Boys Briefs 300 2400 24000
Unit (Hanes Dying Ext. 16 m/c for  Men’s/Boys Shorts 250 2000 4000
 Normal Briefs
Exclusive) 8 Line shorts 300 2400 19200
10m/c for
underwear

Total 242 m/c

9. World Cat Level-4 of 12 Line 20 m/c  Polo Shirt 110 880 10560
Unit (Puma Dying Ext.  T-Shirt/Cut &
Exclusive) Total 240 m/c Sew

10. Common Level 3 to 5 9 Line 54 m/c per line  Bottom/Trouser 90 720 6480
Threads Total 486 m/c
Limited(CTL) Level 6 2 Line 67 m/c per line
Total 134 m/c  Woven 95 760 1520
Products
G.Total 620 m/c
 Grand Total: 94 2950 m/c

SUMMERY:
Sl. Name Lines Daily Production in Pcs. Monthly Production in Pcs.
No. (8th hrs. Basis) (26 days Basis)
1. Woven Garments 26 18,400 478,400

2. Knit Garments 56 52,160 13,56,160

3. Underwear 20 47,000 12,22,000

Total: 102 117,560 30,56,560

COMPREHENSIVE LIST OF ALL MACHINERY & EQUIPMENT:

Sl. NAME OF NO. OF M/C CAPACITY PER DAY REMARKS

No. EQUIPMENT/ MACHINE
1. KNIT CIRCULAR 80 20 tons 22 hrs/day
MACHINE

2. DYEING MACHINE 12 20 tons 22 hrs, 2.75 batch/day

3. FINISHING 9 24 tons 22 hrs/day

4. WASHING 14 16,500 pcs 16 hrs/day

5. DRYER 12 16,500 pcs 16 hrs/day

6. LAYING/CUTTING 9 Set  Knit RMG: 110,000 pcs 8 hrs/day, at different

 U/W : 45,000 pcs places within the
 Woven : 22,000 pcs facility

7. SAMPLING 32 m/c 80 pcs 8 hrs

8. SEWING Knit RMG – 1344  Knit RMG: 52,160 pcs 8 hrs basis (based on
U/W – 162  U/W : 28,000 pcs basic style)
Woven RMG -  Woven RMG : 18,400 pcs
1024

9. EMBROIDERY 5 Machine with 20 500,000 stitch/hr

heads
10. PRINTING 16 Panel table & 12,000 pcs 22 hrs
Dryer
 ORGANIZATIONAL STRUCTURE
Managing Director

Marketing Manager & Director

General Manager (Finance) General Manager (Marketing & Merchandising)

Divisional Manager (Marketing & Merchandising)

Manager Merchandising

DGM RMG Production

Asst.Manager Merchandising

Officer-in-charge RMG Production Sr. Merchandiser

Merchandiser

Admin Purchase Accounts Production Manager Q/C PDS Store

QCM
A/M S/M A/M APM

Technician
W/S/I
Technician Shift in charge

Cutting In charge AFM Finishing in charge

Cutting Sewing W/S Finishing Maintenance

 ORGANIZATION WORK FLOW
Production-in-charge – 1

Production-in-charge – 2

Admin Production Store Cutting Sewing Maintenance Finishing Quality

Officer Merchandiser

In-Charge In-Charge In-Charge A.Q.M

A.P.M A.P.M

Supervisors Supervisors In-Charge

Supervisors

1 2 3 4 5 6 7 8 9 10

YEARLY CALENDER:
Yearly order projection needs to be consolidated into yearly order plan. Order plan is based on
already negotiated orders. Projection of orders is generally based on preliminary discussion &
guesswork but order plan is based on agreed contracts with the customers.

Company: Harvest Rich Ltd. Item of Production: Denim Trouser

2007 Target Quantity in Tesco Triburg Jecko Total
pcs
Qty in US $
January Qty in pcs 10,000 5,000 10,000 25,000
Amount US 160,000 125,000 150,000 435,000
$
February Qty in pcs 7,000 3,000 8,000 18,000
Amount 280,000 150,000 300,000 730,000
March Qty in pcs 5,000 3,000 5,000 13,000
Amount 150,000 100,000 150,000 400,000
April Qty in pcs 10,000 5,000 10,000 25,000
Amount 450,000 100,000 500,000 1,050,000
May Qty in pcs 30,000 20,000 25,000 75,000
Amount 1,350,000 800,000 1,000,000 3,150,000
June Qty in pcs 20,000 20,000 30,000 70,000
Amount 800,000 750,000 135,000 1,850,000
July Qty in pcs 39,500 15,000 10,000 64,500
Amount 1,850,000 600,000 400,000 2,850,000
August Qty in pcs 25,000 5,000 10,000 40,000
Amount 1,000,000 200,000 450,000 1,650,000
September Qty in pcs 10,000 5,000 10,000 25,000
Amount 450,000 200,000 400,000 1,050,000
October Qty in pcs 8,000 16,000 10,000 34,000
Amount 360,000 720,000 450,000 1,530,000
November Qty in pcs 30,000 7,500 10,000 47,500
Amount 1,350,000 300,000 450,000 2,100,000
December Qty in pcs 25,000 30,000 12,000 67,000
Amount 655,000 800,000 300,000 1,755,000
Total Qty in pcs
Total Amount

THE EXECUTION OF ORDER PLAN BY PRODUCTION PLAN

Description of Events:
Order confirmation & preparing TNA calendar: At first the merchandiser takes a
sample or sketch & then from that sketch & measurement sheet send to sample
room department to develop the sample. Afterward the ready sample send it to the
buyer for at first confirm the order. In the mean time the merchandiser have to
make a time & action calendar for monitoring the whole order.
Fit sample submission: For the coordination of Sample room & product
development department the merchandiser have to submit a Fit sample to the
buyer. Fit sample is send it to buyer to check if the fitting of the garment is ok or
not only on the dress form but also on model in motion, necessary modification
should be done to the pattern & then sample must be prepared to achieve quality
& Fit. So satisfy target group. Unusually the Fit sample is made in using
alternative fabric & accessories & it is made in mool which ever comes at the
middle of the export order sizes. For example: if the export order sizes are S, M &
L, the Fit sample will be in M size.
Fit sample approval: After submission of the Fit sample merchandiser have to
take approval from the buyer about the fit sample that is also called Fit comment.
Lab-dip submission: Buyer gives the color plate from that color plate
merchandiser have to submit a color plate which will match with the color plate
given by the buyer. That is called lab-dip submission.
Lab-dip approval: After submission of the Lab-dip merchandiser have to take
approval of lab-dip from the buyer.
Receiving the Master L/C: After approvals of the style the buyer comes to
negotiate the order price or cost. After the negotiation the merchandiser have to
collect the master L/C from the buyer to execute the order.
Yarn/Fabric/Trim Booking placement: After getting the master L/C, with in 48
hrs. Merchandiser has to give booking of Yarn/Fabric/Trim from the source of
supplier.
L/C opening for Yarn/Fabric/Trim bookings: Than merchandiser have to open the
B/B L/C for Yarn/Fabric/Trims for booking confirmation & give the order as per
consumption.
PP sample submission: Pre-production sample have to submit to buyer before go
for the Bulk production. That means with original fabric & accessories using the
PP sample is made. This sample represents the fabric & accessories used in bulk
production. PP sample should include all the colors of the style.
PP sample approval: The buyer checks the PP samples & after the buyer gives
approval on PP samples then merchandiser execute run for the bulk production of
the order. This approval not only for size, fit & workmanship but quality of
texture, color, accessories as buyer required.
Trims submission: Trims/Accessories submitted to buyer as per requirement for
approvals.
Trims approval: Than merchandiser have to take approval of trims from the
buyer.
Yarn/Fabric/Trims in-house date: Than the merchandiser give a dead-line to the
suppliers to in-house all the yarn/fabric/trims to the factory as before the bulk
production starts.
Inventory of received Yarn/Fabric/Trims: Merchandiser have to send a inventory
report to the buyer that all the received yarn/fabric/trims are ok & ready to use for
production.
Bulk Fabric/Test reports submission: Merchandiser has to make a test report of
the bulk fabric & submitted to buyer before start bulk production.
Bulk Fabric/Test reports approval: Merchandiser has to get approval from the
buyer about the bulk fabric test reports to go for the bulk production.
Pre-Production Meeting/Trial Run/Pilot Run: In this meeting everybody
concerned with the style sits together to make sure that everybody is on the same
page and understands the product. Hence, this meeting has the merchandiser,
production in-charge, cutting, finishing, fabric in-charge, line supervisor, pattern
master, sample master etc. All tentative problems are discussed and solutions
sought to execute the order smoothly. Once pre-production meeting is done the
factory does PILOT RUN. Factory cuts 100 – 200 garments based on the order
quantity. The pilot run is done on the assembly line and is aimed at ensuring that
the operators of the assemble line understand the required quality levels. This is
very essential since all samples prior to the pilot run (fit samples, PP & size set)
are made in the sampling unit. Once PILOT RUN is approved the factory goes
into bulk production. In line and interim inspections are preformed during the
production process to ensure that the final product quality meets the required
quality level. In the other hand PP meeting can be done between the production
manager, planner, merchandiser & buyer. PP meeting is basically for made
confirm or negotiation between buyer & the merchandiser & production manager
that assuring that the style of this respective volume will be produce in this dead
line. If sometime the style is very difficult or critical than the production become
slowly in that case if buyer need to hurry about the production than there is some
modification comes up. For example their may be some modification on the style,
their may some modification on the shipment date, their may some modification
on the production line balancing. All the terms & conditions are considered
during the pp-meeting. But pp-meeting is basically a meeting is for making a
solution about the problems on the production. Finally it is a meeting of
negotiation with the buyer where the buyer gives the decision or his requirements
of shipment with solving the problem of the garment production shipment.
Bulk Production: After the pp-meeting when the merchandiser gives the green
signal than the production manager go for bulk production or actual quantity for
producing goods.
Test of Production Sample Submission: When the production started on the
factory than the merchandiser collect the production sample from the bulk
production line & test the production sample that every requirement of the buyer
is being fulfilled or not & assure that the garment is producing on the highest
mark or not. Than the checked sample merchandiser has submitted to the buyer
for production approval & waiting for the comments.
 Top Sample Approval: Buyers gives his/her comments or approval on the Test of
Production sample.
Final Inspection: When the buyer comes for the final inspection than the
merchandiser have to stay with the buyer to assuring & convincing the buyer that
the quality of the garments are as per the requirements of the buyer & it is a
highest quality garment.
Ex-Factory Date: Ex-Factory date means when bulk production loaded on the
container cargo & goes for shipping or on the way to port that is Ex-Factory date.
Cut off date: Cut off date means when the ship starts to sail from the port that is
called cut off date.
Receipt of Bill of Lading / AWB: For the individual order the merchandiser than
collect or receipt of Bill of Lading from the buyer bank to the Beneficiaries bank.
That is the last job of the merchandiser of that particular order.

TYPES OF ITEMS ARE PRODUCED IN THE FACTORY

WOVEN DIVISION:
1. Kids Trouser.
2. Kids Shorts.
3. Men’s Trouser.
4. Ladies Trouser.
5. Ladies Shorts / Shirts / Skirts.
6. Men’s Shorts.

KNIT DIVISION:
1. Men’s T-shirt / Polo / Long sleeve / Short sleeve.
2. Men’s Trouser.
3. Men’s Sweet Shirt.
4. Ladies T-shirt / Polo.
5. Men’s Trunk / Boxer.
6. Ladies Brief.
7. Men’s Tank Top.
8. Ladies Tank Top.
9. Boys Trunk / Boxer.
10. Kids T-shirt.
11. Men’s Jacket.
12. Men’s Thermal Set.
13. Sports Wear Men’s / Kids – Jacket + Trouser.
14. Ladies Night Wear.
15. Men’s Vest – Tops.
16. Ladies Vest – Tops.
TREND OF CURRENT ORDER IN RESPECT OF VOLUME & VARIED STYLE:

WOVEN DIVISION:
1. Ladies Cargo Pant -------------------------------------------- 5, 13,940 pcs.
2. Boys Denim Trouser ----------------------------------------- 19,875 pcs.
3. Boys Cargo Trouser ------------------------------------------ 9,113 pcs.
4. Ladies Tops ---------------------------------------------------- 18,400 pcs.
5. Boys Trunk ----------------------------------------------------- 27,000 pcs.
6. Ladies Skirt ----------------------------------------------------- 16,350 pcs.
7. Ladies Trouser ------------------------------------------------- 47,720 pcs.
8. Men’s Jogging Suit ------------------------------------------- 3, 32,000 pcs.
9. Men’s trouser -------------------------------------------------- 7, 40,000 pcs.

KNIT DIVISION:
1. Men’s T-shirt / Polo for PUMA ----------------------------------- 7, 47,875 pcs.
2. Ladies Night Wear -------------------------------------------------- 2. 20,500 pcs.
3. Sports Wear ---------------------------------------------------------- 85,000 pcs.
4. Ladies Tank top ----------------------------------------------------- 48,750 pcs.
5. Men’s Sweet Shirt -------------------------------------------------- 72,850 pcs.

SAMPLE ROOM & PRODUCT DEVELOPMENT DEPARTMENT:

In the product development or sample room department at first their work is to collect the
sketch which is come from the buyer with specification sheet to develop individual
product. Sometimes they got the measurement sheet from the buyer or sometimes they
have to follow measurement by calculating from the sample or garment given. At the
sample room department their responsibility is to make a mini marker for figure it out the
fabric consumption for specific style. Basically the sample room department firstly get
sample or measurement chart with style sketch from via merchandising department than
in the sample room the pattern maker make the pattern manually. After the pattern
making its goes to cutting to cut the fabric, after cutting the pattern pieces from the fabric
it comes to the sample room sewing section. Than sewing section make the garment as
per requirement. Than ready garment goes for washing. When the washing is completed
it’s come back to the sample room department for finishing purpose. When the finishing
is completed than the sample room department send this sample to the merchandising
department for sending the sample to the buyer for correction or approval. For the sample
making merchandiser has to arrange the fabric & accessories for specific style if not
available than the sample room department has their own store from which they will took
fabric & accessories to make the sample. They mostly make the samples which are as
follows:
1. Quotation sample.
2. Style sample.
3. Fit sample.
4. Size set sample.
5. Counter sample.
 6. Pre-production sample.
7. Production sample.
8. Photo sample.
9. Proto sample.
10. Shipment sample.
Basically in this organization the CAD/CAM room is attached with the sample room
department. In the product development or sample room department their responsibility is
to collect & store various types & style of garment collection with specification data,
fabric swatch collection with construction, trims & accessories collection with
specification, sample development update data filing, modular construction system store,
TSA measurement, MPI, collect additional information. At CAD/CAM room they
basically make the mini marker for consumption making for fabric otherwise for the
factory they make the marker manually for lay fabric on cutting section.

PRODUCT DEVELOPMENT & SAMPLE ROOM DEPARTMENT

WORK FLOW
Product Development Chief – 1

Product Developer Officer – 2

Pattern Master – 3

Cutting Man – 1

Woven Garment Operator – 6 Knit Garment Operator – 3

Quality Controller – 1

Sample Man – 1

Finishing Man – 1

Helper – 1
CUTTING DEPARTMENT WORK FLOW
Order sheet through Merchandiser

Fabric booking sheet follow-up through Merchandiser

 Fabric delivery & received report

Making Trim card for fabric

If not passed than return to the dyeing

Swatch/Trim card will follow before cutting

Make the marker preparation considering the style

By the required of marker fabric lay made

Manual marker set on fabric

Find out size wise consumption

Cut lay into pieces

Part of pieces should be numbering

Cut panel inspection

Bundling – Fail/Pass for rejection Poly cut pieces

PRODUCTION MERCHANDISING PROCESS FLOW
Input
Production merchandising process starts once the order / fabric commitment is received
and the product development department hands over the file to production merchandiser
and ends when the goods reach the buyers. The entire cycle involves all activities directly
or indirectly related to procuring of materials, planning and monitoring of the order. A
brief outline of the procedure of their factory is given below:
 RECEIPT OF ORDER

PREPARE FABRIC ORDERING TRIM ORDERING FIT CYCLE

DETAILED T&A
FABRIC PO, TRIM PO,
PI, LC PI
FIT
PILOT YARDAGE IN- APPROVAL
HOUSE
INSPECTION
SIZE SET &
ALL DEPARTMENTS SHRINKAGE TEST
SEALER SAMPLE
ADVISED OF THE
APPROVAL
T&A
BULK IN-HOUSE BULK IN-HOUSE
INSPECTION INSPECTION
TEST REPORTS TEST REPORTS

PRE-PRODUCTION MEETING

PILOT RUN APPROVAL

BULK
AUDITS DONE AT
CUTTING VARIOUS STAGES
OF PRODUCTION,
SEWING TOP/PRS
SAMPLES SENT
FINISHING TO BUYER AS PER
REQUIREMENTS.
PACKING

FINAL AUDIT

SHIPMENT OF GOODS

CUTTING DEPARTMENT ORGANOGRAM

CUTTING MANAGER – 1

CUTTING IN-CHARGE – 1

CUTTING COORDINATOR – 1
 CUTTING SUPERVISOR - 2

MARKER MAN – 2

CUTTER MAN – 3

FABRIC RECEIVER – 2

CUTTING ASSISTANT – 2

BUNDLE BUNDLE NUMBER/STIKER INPUT MAN – 2 SPREADING

WRITTER – 4 MAN – 4 MAN – 2 MAN – 24

CUTTING DEPARTMENT WORKING PROCESS & DOCUMENTATION:

In the cutting section at first there is an order sheet comes from the merchandising
department. From that order sheet they are making plan for the whole month which is
called order sheet & fabric allocation for the month of delivery than fabric booking sheet
follow up by the merchandiser through cutting. After completing the fabric inspection on
the fabric store fabric is delivery from the main store to the sub-store of the cutting floor
with inspection report. They have individual sub-store for individual cutting floor. The
fabric receiver man is received the fabric & alignment it on the sub-store. Than cutting
section maintain a swatch or fabric trim card to allocate quality & color. If the inspection
fabric is not passed for cutting than the fabric return to the dyeing for shade matching or
any other defect on fabric will acknowledge to the merchandiser & cutting manager. The
cutting section has to follow the swatch or trim card before start cutting. After that the
fabric lay on the cutting table for cut fabric as per marker preparation. The required
marker has been placed on top of the fabric lay as per buyer requirement. Basically they
make the marker manually but sometimes they put CAD marker also. For marker
preparation the cutting always maintains a size wise ratio for saving fabric when cutting.
After placing the marker on top of the fabric lay they cut the fabric by the cutting
instruction of the marker. Than the cutting pieces send to the numbering table to put
numbers on part of pieces. After that there is a cut panel inspection which is consist of
style number, cutting number, lay quantity, for part check, defects numbers, total
defected parts & remarks. Based on that format they maintain buyer name & cutter name
& date of cut. After that they make bundling with inspection report they make for
pass/fail which is required for there cutting policy. Than poly the cut pieces & make
ready for input for the sewing floor. For marker preparation buyer mention that it will be
a 4pieces marker or 6pieces marker. If the buyer not give any instruction on marker
preparation than the cutting will prepare there own marker preparation. For style
preparation they consider order quantity size wise, booking quantity size wise & marker
preparation. They maintain a trial cutting quality report which consists of a quality
inspection sheet on which all the spec measurement is written down. The tolerance limit
+/- 1/2 record for cutting is being written on that format by side to side to recognized that
it up to the buyer tolerance required.

For each order they maintain so many format sheets & make record of every attempt
related to this individual order or style. They maintain much documentation during the
order running on which are as follows:

1. Cutting Quality Control Sheet.

2. Spreading Quality Control Sheet.
3. Daily Cutting Output Status Sheet.
4. Cutting Information Chart.
5. Marker Preparation Chart.
6. Cut Panel Inspection & Replacement Report.
7. Fabric Shrinkage Report.
8. Spreading Sheet.
9. Input Record.
10. Marker Check Report.
11. Cutting Plan.
12. WIP Report – Per Day.
13. Cutting Report Size wise Ratio.
14. Cutting Forecast Plan.
15. Consumption Report.
16. Bundle Card Report.
17. Bundle Ticket Sheet.
18. Daily Cutting Report.
19. Style – P.O wise Cutting Status Sheet for the month & weekly.
20. Daily Cutting Input Status.

CUTTING ROOM MANAGEMENT

Function: - Material control > Fabric wastage control and proper utilization

@ Material control ≤ Material control in the cutting room begins with establishing
material estimates. This will include a standard usage for a certain garment.
@ Material control ≤ Material control in the cutting room may take place in three areas.

1. Fabric issue:-
* The storekeeper knows the length and width of pieces in store and issue cloth against a
copy of the cutting sheet.
* Control consists of comparing expected usage (material estimate × no of garments cut)
with actual usage (issued fabric minus returned fabric)
2. Marker Making
* Control may involve checking that a copy marker is the same length as the original i.e.
master marker length = 25 yds 04"
Copy marker length = 25 yds 04"
3. Spreading
* Control of end losses, edge alignment damages which affects material utilization and
control (material width 43", fabric width 44" not allow 45")

SUB-STORE ON CUTTING FLOOR:

Sub-store department work is to make store of trims, accessories & fabric from the main
store which they are called the RMG Store. When the Sewing & Cutting Section gives
requisition to the sub-store for trims, accessories & fabric than the sub-store department
duty is to make sources or collect & store proper style trims, accessories & fabric. As per
requisition sub-store delivery trims & accessories to the sewing floor & fabric to the
cutting floor. For delivery of such items the sub-store department maintains a register
book which consists of date, style number, and description of goods, size ratio, issue date,
received date, issued quantity, balance, issue signature & received signature.

CAD/CAM FACILITIES:

1. Investronica System , Version – 7.0

2. PX Change – 32 (Software Converter)
3. HPGL – Software
4. Facilities to receiving patterns & sending the same also.

SAMPLE DEPARTMENT
1. 32 Machine (Including FLATSEEMER)
2. Heat Transparent Machine
3. Two Headed embroidery machine
4. 24 key person – (Including 3 Pattern Maker)

PRODUCTION / SEWING DEPARTMENT

PRODUCTION / SEWING DEPARTMENT ORGANOGRAM

PRODUCTION MANAGER

A.PRODUCTION MANAGER

QUALITY CONTROLLER
 LINE CHIEF Q.C.SUPERVISOR

SUPERVISOR QUALITY INSPECTOR

OPERATOR MESUREMENT CHECKER

HELPER

PRE-PRODUCTION MEETING
Buyer G.B- Regular Date 07/08/06
Description Girls L/slv top with chest print Factory Delta composite
Fabric quality 1x1 Rib Order no 2510543.00.82
GSM 230 Article
GG - Delv. date 8th sep.2006
Wash type -

CUTTING SECTION:
1 The cutting marker should be head since the fabric is in the tube width form.
2 No. of lays should not exceed 25-30lays.
3 Piece good should be checked 100% for all type of defects and conformity of shape as
per pattern.
4 Cutting must be done lot wise and the lot wise ratio must be maintained.
5 Factory must provide Daily color wise rejection figure at the cutting stage to S. Oliver
QC.
6 Bundle size must be maintained to 20pcs.
7 All cut goods must be checked 100% for printing before giving input in the sewing
line.
8 Use 96% & 4% cotton elastane 1x1 rib for collar.

SEWING / LINKING SECTION:

1 In must be taken color wise. Factory to advise sewing line.
2 Cut #’s must be followed in the sewing line.
3 # 9 Ball point needle must be used at all times.
4 The top seam SPI must be 11-12 and over lock must be 13-14.
5 Cut mark must be flowed while joining sleeve and the cut marks must be done at
sewing floor.
6 Auto cutter machine must be used for bottom hem. No raw edges are acceptable.
7 Cotton elastane 1x1 color height must be 1.2 cm with .03 cm double top stitch all
 around the neck line.
8 Shoulder drop must measure to 1 cm.
9 Silicon tape 0.5 cm must be used to cover the shoulder seam allowance.
Sleeve hem and bottom hem height must measure to 1.5 cm. the double stitching gap
must measure to .03 cm.
10 Bottom hem must be tacked by plain machine at the side seam point.
11 Main label X_OT_0012 must be centered to the neck line and should be evenly
inserted in the neck rib.
12 Care label # X_AG_C110 must be fixed on inside seam of wearer’s left side sem 10
cm above bottom hem.
13 Second care label # X_AG_C111 must be attached with the main care label.
14 Print artwork # GB_1007 must be placed on the center front panel as per the graded
specs.
15 Quality stations during the sewing process must be as discussed. Neck and sleeve
join.

FINISHING & PACKING SECTION:

1 Inside ironing of the garment is required to set the seam allowance.
2 The vacuum Tables tope must be marked size wise as per pattern to maintain correct
shape.
3 The garments should not be ironed Head. Do not iron on print.
4 Folding and packing approval must be taken from S. Oliver QC.
5 All approved shades must be packed separately.

WORKMANSHIP ON SAMPLE:
1 Please follow new measurement for sleeve length.
2 Care label # X_AG_C110 is wrong.
3 Care label # X_AG_C111is missing.
4 Sleeve hem and bottom hem height uneven.

QC: - Factory: -

P.P. METING INSTRUCTIONS

HARVEST RICH LTD.

VULTA, NARAYANGANJ, DHAKA.
TESCO

1. Both sleeve m/be even.

2. Neck contrast m/be even.
3. Fabric crises mark totally unacceptable.
4. Ndl. mark totally unacceptable.
5. Cutting start 22.08.06.
6. P.P (size set) submits date 24.08.06.
7. Final Inspection 20.09.06.
8. Goal seal sample submit date 30.08 (Covering color & size 2 set)
9. Shoulder drop A/hole side 1cm neck side zero. (Follow the paper pattern).

H&M

1. Placket s/be even.

2. Sample submit date same as TESCO.
3. Ship date 17.09.06.

PUMA

1. Sample submits date 27.08.06.

2. Goal seal sample date 30.08.06.
3. Input 23.08.06.
4. Ship date 20.08.06.

PP meeting is basically carried out before the bulk production starts. PP meeting is a
meeting where the production people, merchandiser & the buyer set for solving some
problems arising during the production period. Sometimes some styles is very difficult to
produce & critical in stitch so on that meeting production team wants some facilities like
extension on shipment, some modification on style if possible (which is a very critical
style), if buyer need any changes on style, marker length, width, lay height requirement if
buyer wishes. After the PP meeting about that particular style is started for bulk
production on the result based. When the bulk production is started than no changes can
be taken. Any changes on style should be settled on PP meeting. Because after that no
changes will be accepted by the buyer.

DOCUMENTATION MAINTAIN FOR PRODUCTION

1. Order sheet with fabric allocation.

2. Requisition paper.
3. Summary of daily production record.
4. Hourly Line Q.C report
5. In-line inspection report.
6. Daily machine check report.
7. Trial inspection report.
8. Daily line wise quality inspection report.
9. Sewing Quality report.
 10. In-line re – audit sheet.
11. Table inspection report.
12. Stitches monitoring report.
13. Production plan sheet.
14. Pre-final area report.
15. Hourly in-line measurement & quality check report.
16. In-line production quality checks report.

RMG STORE – MAIN STORE

In the main store when fabric or any trims & accessories come than the store received the
fabric & trims as per delivery challan, packing list & truck receipt. After that as per
delivery challan & packing list they make a inventory report. If the inventory report is not
match with the delivery challan & packing list than the inventory report is sending to
merchandiser to take action about the problem & investigate about the matter. The store
department inspected all the fabric & make fabric panel inspection report to the cutting
department. If panel inspection report is not as per required than its goes for replacement.
RMG store department also maintain a register book which as like as sub-store
department. After inspection completed they send or passed the documents to the
commercial department for approval. Store department also maintain a swatch card which
is made for basically color shading. Fabric color shading is made by grading & they give
report to the cutting quality department.

DOCUMENTATION PROCESS

1. Zipper documentation is maintained by color & size wise with order number.
2. Delivery challan.
3. Packing list.
4. Truck receipt.
5. Store requisition.
6. Material received report.
7. Fabric shrinkage report.
8. For Knit fabric report flow from received book to balance book to issue book by
the delivery challan reference come to store than record is issued firstly in the
received book & also in the balance book. After receiving the requisition of the
fabric from the cutting the balance will be minus & it issued to the issue book. For
knit fabric store maintain 3 books because of varieties of diameter variation on the
fabric.
9. Fabric inspection report: by 4point system.
10. Sign off card production: Fabric per color wise.
11. Sign off card production: Label & Hangtags:
 Material & Care Labels
 Main / Size Labels
 Badge Labels
 Security / Origin Labels
 Hangtags
  Patch Label
 Care & Size Label
12. Sign off card production: Accessories:
 Button
 Stopper
 Eyelet
 Zipper
 Cord draw
 Velcro
 Thread
 Piping
 Hidden Snap button
 Chalk Button
 Tag Pin
 Folder
13. Sign of card production:
 Lining
 Interlining
 Elastic Band
 Embroidery equipment
 Printing equipment

WORK FLOW: STORE PROCEDURE

Supplier
Raw Materials Inventory Receive
If anything to change or return

Sagricate & Keep Report Report Concerned Person

Attach Bin card Identification

H/O H/O
Purchase Dept. Merchandiser
 For
Approval Prepare Trims card Concerned Person

If Approved
Prepare Requirement Sheet

H/O Requisition
Prepare a Demand Note Issue Production
Accounts

If Required Put Entry in

Registry

Check the Stock Check the Balance

Physically Sheet

Receive Finished
Goods

Make Challan to Ship

Make Inventory Make Inventory Receive Left over

Report of Stocks Goods

FINISHING DEPARTMENT ORGANOGRAM

FINSHING IN-CHARGE

FINISHING COORDINATOR

FINSHING SUPERVISOR

THREAD IRON MAN FOLDING MAN ASSORTMENT & SHADE

SUCKER PACKER MAN MATCHING
MAN
 SIZE MAN
CARTOON SPOT
MAN REMOVER
HANGTAG MAN

POLLY MAN

HELPER

FINISHING QUALITY CONTROL DEPARTMENT

QUALITY MANAGER

QUALITY ASSISTANT MANAGER

QUALITY CONTROLLER

QUALITY SUPERVISOR

QUALITY INSPECTOR

MESUREMENT MAN
 FINAL GET-UP MAN

FINISHING DEPARTMENT WORKING PROCESS

After making the garment on the sewing floor garments comes to the Finishing
department. Firstly Quality Inspector in Table Q.I section garment is inspected for quality
assurance. Than the garment goes to the thread sucking to remove all the dust & threads
from the garment. But if buyer required garment wash than garment comes from sewing
floor to finishing department & after table quality check garment send for washing plant
to wash garment. In the other way round, if there is no wash required from the buyer (if
Knit garment) than after the quality check garment goes for thread sucking & than
garments are properly ironed. After ironing the garment it comes to size man which is
under folding section for proper measurement check. Than the garments send to the get-
up table to check the garment again to inspect properly that the garment is good quality or
not. The garment comes to folding table where the garment dust is removed manually by
using gum tape than the garment is folded with insert board. After folding the garment
properly it comes to the hangtag table to attach hangtag on the garment properly. Than
the garment poly properly & the barcode inserted on the poly bag. Poly garment is being
cartoon properly by following an assortment process which will be a size wise/color
wise/style wise ratio. The assortment man assorts the garments properly & packs it on the
cartoon. The finishing department offers a packing list to the pre-final inspection
department that the garment is being ready for shipment. After getting the packing list
there is a pre-final inspection done by the garment Q.C for total check. Than the buyer
comes for the final inspection. If inspection passed than garment goes for shipment if fail
than recheck offered by the buyer.

FINISHING DEPARTMENT MAINTAINED DOCUMENT

1. Inspection Report
2. Finishing Report.
3. Packing list.
4. Tag Pins / Broken needle Record.
5. Shipment document follow-up report sends to the planning & commercial
department.
6. Order quantity sheet.
7. Metal detector Report.
8. Finishing check Report – Spot/Alter/Rejection/Basket/Defect.

They have metal detector m/c which basically used by the finishing department after poly
the garments & before cartooning. This machine work is to trace metal on the garments
for safety reasons because any metal equipment is not allowed with the garment
shipment.

NEEDLE REPLACEMENT FLOW CHART

Needle for Replacement

Broken
General

All parts available

Replace by
taking old one
Yes No

Document

Provide Replacement Go for the Metal

detection for the
whole bundle
Document
 Found

Yes
No

Replace needle by taking all

Tell all concerned the need for
needle parts & placing in the
their extra care. Issue the new
broken needle register.
needle. Place available
components of broken needle in
Document broken needle register.

Stop production at that m/c.

Search the area. If nothing
found than that bundle will be
marked & inspected further
with conveyor.