You are on page 1of 57

Bangladesh University Of

Textiles

Industrial Report on
Fakir Apparels Limited

Supervised By
Dr. Shekh Md. Mamun Kabir
Asstant Professor
Dept. Of Wet Process Engineering
Submitted By:
Name ID

MASRUR SABIR NAFEE 2012-1-3-039


MD. ABID RAHMAN 2012-1-3-041
SHAHED SADIQUR RAHMAN 2012-1-3-048
MEHEDI HASAN MASUM 2012-1-3-052
MD. JONAYET CHOWDHURY 2011-1-027
Table of Content
Chapter 1 : Introductory Part
Chapter 2 : About the Organization
Chapter 3 : Organizational Activity
Chapter 4 : Findings and Recommendations
Chapter 5 : Conclusion
Introductory
Part
Objectives
To get idea about a Industry.
To know about several activity of a business.
To have a general idea about the production
process.
About the
Organization
About Fakir Apparels Limited
Fakir Apparels Limited. is Composite Knit Garments
Manufacturer & Exporter, having all state of the art
facilities with the annual turnover US $ 30 Million.
They have Different types of knitting, Dyeing, Cutting,
Sewing, and Finishing machines supplied by mostly Japan,
Taiwan, U.K, USA, China, etc. which are very latest.
It has high production where 30 tons of knitted and
finished fabrics are produced per day.
All of the decision makers of production sector in Fakir
Apparels Limited are textile graduates.
They produce their product for market like USA,U.K,
Sweden, Ireland, France, Germany, Belgium, Spain. They
follow all the system for their machines maintenance so
production cannot hamper.
Company at a Glance
Area of Premises : 700, 000 square feet
Yearly Turnover : $ 75 million USD.
Manpower : 7500
Garments : 140,000 pcs/day
Garment Line :90 lines
Knitting :20 tons/day
Dyeing :40 tons/day
Dyeing Finishing : 42Tons/ Day
Garments Washing :30,000 pcs/Day
Printing :1,00,000 pcs/day
Embroidery :200 Head
Statistically Progress Bar for the
Production From 2011-2014
Products
Products
All types of knit wears, specially Basic & Fancy T-Shirt for all ranges, Polo Shirt, Night wear, Shorts ,
KIDS items, Tank Top etc.
Wide range of fabrics like single Jersey, Rib, Interlock, etc..
Grey Fabric, Spandex, Dyed fabric and Printed fabric
Fabric dia ranging from 14 to 32
Customer specified GSM
Dyed yarns for knitting
Production of knitted fabrics 20000 kgs per day Brand new circular knitting machine from Mayer &Cie
(Germany) are installed in our factory. We can produce the following types of knitted fabrics:
Single Jersey
Pique (Lacoste)
Double thread fleece
Selanik
Interlock
Rib and others.
All knitted fabrics can be produced with addition of spandex (Lycra) up to 60-70% percent.
Chapter-3

Organizational
Activities
Vission & Mission
Vision:
To build true marketing led enterprise with motivated workforce,
innovative vision & more value added product portfolio, customer
satisfaction & understanding of global market.
To be a world-class quality apparels manufacturer by satisfying
social, ethical and environmental commitment.
To be one of the best leading composite mill in the Bangladesh.
Mission
Execution of Lean manufacturing system in manufacturing
processes
Corporate practice in management system
Be maximum flexible and transparent with our valued customers
and suppliers
Production
Operation
PRODUCT MIX
100% cotton.
CVC (Chief value of cotton).
PC/TC (The more % of polyester).
Mlange-
1.Grey mlange : 10% viscose + 90% cotton
: 15% viscose + 85% cotton.
2.Anthra mlange : > 50% viscose.
3.Ecro mlange : 2% viscose + 98% cotton.
4.Camel mlange : 1% viscose.
DEPARTMENTS RELATED WITH
PRODUCTION
Yarn store.
Knitting section.
Raw fabric store & inspection section.
Batching
Chemical Store
Color lab section.
Dyeing Section.
Finishing section.
Quality control Section
Maintenance
Water Treatment plant
Knitting
Knitting is the process of creating fabric by the
intermeshing of loops of yarn. Each row of
such loops hanging from the one immediately
preceding it. There are two types of knitted
fabric
Warp knitted fabric
Weft knitted fabric
Knitting Machines
WITHDRAW THE
YARN IN PACKAGE
ROLLED FABRICAND INSPECTION
FORM
WEIGHTING

PLACE THE YARN


PACKAGE IN the KNITTING NUMBERING
creel

SET THE M/C AS PER


FEEDING THE YARN
DESIGN &GSM
KNITTING SECTION IS DIVIDED IN
FOUR SECTIONS:
Inspection section
Flat knitting section
Circular Knitting section
Store section
Knitting Division
Circular Knitting Machine
Single Jersey, Double Jersey, Auto Striper & Jacquard
BATCHING OR BATCH

According to TextileGlossary.com
A group of units of products of the same type,
structure, color and finish, class and composition,
manufactured under essentially the same conditions
and essentially at the same time, and submitted at any
one time for inspection and testing.
Types of Batching:
Solid batch
Assort batch

No of Machine : 08
Function or Purpose of Batch Section
To receive the grey fabric roll from knitting section or other
source.
Turn the grey fabric if require.
To send the grey fabric to the dyeing floor with batch card.
To keep records for every previous dyeing.
To use maximum capacity of existing dyeing Machine.
To minimize the washing time or preparation time & Machine
stoppage time.
To keep the no. of batch as less as possible for same shade.
To use a particular Machine for dyeing same shade.
COLOR LAB
Lab Unit
SEQUENCE OF LAB OPERATIONS

Swatch receives (physical std. Or


reflectance value)
Fabric & dye selection
Recipe prediction
Sampling & pipetting
Dyeing
Dispatch
Machineries of Dyeing Chemical Lab
Dyeing Division & Process
Dyeing Division & Process
Dyeing Section
After batching the next step is dying. Dyeing is the process of
coloration.
Total Dyeing Capacity: 40 Tons/Day
Machine specification of Unit-01:
Dyeing Division & Process
Machine specification of Unit-02:
Dyeing Division & Process
Machine specification of Unit-03
Dyeing Division & process
Finishing
Textile finishing, in a restricted sense, is the term used for a series of
processes to which all bleached, dyed, printed and certain grey fabrics are
subjected before they are put on the market. In fact, finishing includes the
final treatment of every kind of fabric made from every kind of fiber

Objective of finishing:
Improving the appearance Luster, whiteness, etc
Improving the feel, which depends on the handle of the material and its
softness , suppleness , fullness, etc.
Wearing qualities, none soiling, anticrease, antishrink, comfort, etc.
Special properties required for particular uses water proofing, flame
proofing, etc.
Covering of the faults in the original cloth.
Increasing the weight of the cloth.
Dyeing Division & Process
Dyeing Finishing Section
They have both Open and tubular fabric finishing line.
To have perfect finishing on fabric they are using world
class machine with most modern technology.
Dyeing Division & Process
Finishing Machines List
Garments Department
CAD Section
First stage in the production line is the pattern making
section. Their CAD division uses
1) Lectra Software
2) Euro CAD software

Cutting Section
The second stage in line is the cutting section. In this
section, materials are cut in the pattern determined and
designed in the previous section.
They have automated system for cutting the pattern.
Each machine has 30,000 PCS/ Day cutting capacity.
Cutting division has 5 units.
Cutting Capacity is 1,30000 pcs/day
QUALITY LAB
QUALITY LAB
M/C name: Brand Name Origin
Tearing Strength Tester Elmatear U.K
Bursting Strength Tester TruBurst U.K
Pilling Resistant Tester Impulse U.K
ICI Pilling Resistant Tester SDL ATLAS U.S.A
Crockmaster SDL U.S.A
Yarn evenness tester SDL ATLAS U.S.A
Wrap reel Yarn Count SDL ATLAS U.S.A
Tester
Weight Cutting Machine Samsung South Korea
(GSM)
Thermograph: SK Sato U.S.A
Shrinkage Tester Eltrolux U.K
Garments Department
Sewing Section
They have auto trimmers, Lock stitch Button
stitch, Chain stitch machines and Auto Button
Hole Machines.

Theyre using world renowned production


planning software named FASTREACT.

Sewing Machines: 2000 nos


Sewing lines: 100 lines
Garments Department
Finishing Section:
At this stage products goes through various stages like
removal of loose thread, folding etc & hanged with
hanger & poly bag. Some finishing machineries are
needle detector, thread blowing, strain removing,
carton box striping etc.
Garments processing flowchart
Washing Plant
Washing plant that has a capacity of 40000 pcs garment
(Normal Wash) & Pigment washing 25,000 pcs garments per
day.
Printing Section
They are capable to print various types including flock, discharge,
emboss,sugar print and many special types of printing. They can print
100000 pcs/day.

Area Covered= 2 flo0r


Manpower=450
Per table=12-13
Auto screen m/c=5
Heat press m/c= above 8
Curing m/c=2-3
Capacity of Printing= 100,000 pcs per day
Printing Section
Merchandising
Merchandising department is the heart of any textile,
because Merchandising is the only department having
maximum control over the departments and total
responsible for Profit and loss of the company.
The main objectives of their job description is 4R

Right Quantity: To supply right quantity of product


what buyer ordered.
Right Quality: To deliver right quality of product what
buyer ordered.
Right Cost: Everybody wants more from what they are
paid.
Right Time : Ensuring shipment within the right time as
per buyers order.
Quality Assurance
Quality Assurance

The QC team of FAL follows some international standards


such as 4-point Fabric Inspection System; Traffic Light
System; AQL 2.5; Needle Detection Report; 9-point Quality
Check System and many more.

QC activity
Pattern Test
Trial Inspection
In-line Process
Pre-final Process, and
Final Process
4 POINT CALCULATION SYSTEM
Utility
Sources of Utility
Utility Source

Gas TITAS

Electricity Generator

Compressed air Compressor

Steam Boiler

Water Natural Water by Pump

Temp. Control Air Chiller


ETP Plant
Taking steps for instance the establishment of ETP & WTP because nothing
is more important than the maintenance of pollution-free environment.
Fakir Apparels Ltd. Establish an ETP plant which is the biggest and no.1 ETP
plant in Bangladesh. Capacity of their ETP is 5000 m3
Buyers

H&M
TEMA
PRIMARK
PEACOCKS
PENNYES
ZARA
ALDI
Chapter-4
Findings &
Recommendation
Some findings are given below:
Lack of co-ordination among different division of
the company.
Lack of employee in administrative department of
the company

Some recommendations are:-


The inter-departmental work should be smoothed
and there should be more cooperation between the
departments.
Should concentrate more on increasing worker skill
and efficiency.
Conclusion
Conclusion
Fakir Apparels Ltd is the one of the popular
member in RMG family. They have started their
journey with lots of difficulties but now, they
have established themselves as the one of the
leading RMG company of our country. All the
departments are doing well to reach their goal.
The environment of the factory is really different
from other organizations. The environment is
very friendly and informal. If they keep their
current growth rate they will capture maximum
portion of RMG market of our country.
Thank You

You might also like