INTERNSHIP REPORT AT LUCY GARMENT INDUSTRY 2008 E.

COLLEGE OF ENGINEERING AND

TECHNOLOGY
DEPARTMENT OF GARMENT
ENGINEERING

HOSTING COMPANY: - LUCY GARMENT

INDUSTRYPLC

TITTLE: PRODUCTIVITY IMPROVING THROUGH

SKILL MATRIXS OF OPERATORS.

-FINAL INTERNSHIP REPORT & PROJECT

Submitted By: Miftah Mohammed….ENGR/257/05

Advisor ---------- TEWODROS TOLOSA

Prepared By miftah Mohammed ID NO ENGR/ 257/05

I
 INTERNSHIP REPORT AT LUCY GARMENT INDUSTRY 2008 E.C

I DECLARATION.
I declare that this project work is my own work and I have not used any of others idea or
data, which is done before in this company but the origin, is my mind. Thus to use this
project work as reference it is obligated to mention the author of this title
PRODUCTIVITY IMPROVEMENT THROUGH IMPROVING SKILL MATRIXS
OFOPERATORS In addition, compiled according to the internship report writing
guideline given by the Institute-Industry Linkage office of the Institute.
My name is miftah Mohammed and I’m fourth year garment engineering student. I have
completed my internship program in Lucy garment industry plc.

_TEWODROS TOLOSA________ _____________

___________
Name of academic advisor Signature Date

MIFTAH MOHAMMED ______________ __________

Name of the student Signature Date

Prepared By miftah Mohammed ID NO ENGR/ 257/05

II
 INTERNSHIP REPORT AT LUCY GARMENT INDUSTRY 2008 E.C

II Acknowledgement.

First I would like to thanks and admire the all might of Allah who make me healthy and
happy in order to carry out this project and who help me throughout my study. Secondly
I would like to express my deepest gratitude to my academic adviser teacher tewodros
tolosa and my company adviser tarekengn tegeny for their valuable and continues
suggestions, constructive comments and unlimited guidance for over all enrichment of
this project.
Thirdly I express my gratitude to plant managers m/r binium workuwho provide me all
the
Necessary information whenever I need it.
Finally I would like to my friends abdulsamed tamam who give me transportation to
the company at morning and afternoon to home by a car throughout a semester and I
would like to thanks all the company’s workers in Lucy Garment Industry P.L.C

Prepared By miftah Mohammed ID NO ENGR/ 257/05

III
 INTERNSHIP REPORT AT LUCY GARMENT INDUSTRY 2008 E.C

III EXECUTIVE SUMMARY

Internship is a proven way to gain relevant knowledge, skill and experience while
establishing important connection in the field.
In my internship to Lucy garment industry .plc. For a specific period I spent. I was
tried to get the required experience skill and knowledge and I have tried to list the over
all aspects of the internship experience.
In the chapter oneof the project, it provides information about the Lucy garment
industry .plc. Brief history, objectives, Visionand mission of the company organizational
structure, process flow of the company, main company clients, Store keeping procedures,
cutting room available, machinery, sewing room products and as well as working
procedure of , operation break down with time study for medical trouser industrial
engineer function ,quality control and, finishing department etc.
In the second chapterI tried to describe my mainly particular project. I have executed in
the company .it starts by describing title introduction about the problem, objectives of the
project statements of the problems, data collection, and presentation and analysis
methods to accomplish the project work. And final result of the project.
In third chapter theoverall benefits from internship experienceand At the end
Conclusion and recommendations .reference and appendix.of the project..

Prepared By miftah Mohammed ID NO ENGR/ 257/05

IV
 INTERNSHIP REPORT AT LUCY GARMENT INDUSTRY 2008 E.C

Contents

I DECLARATION.................................................................................................ii
II Acknowledgement. ............................................................................................. iii
III EXECUTIVE SUMMARY ..................................................................................... iv
1 CHAPTER ONE ................................................................................................... 4
1.1 HISTORICAL BACKGROUND OF THE COMPANY........................................... 4
1.1.2 Detail profile of the company .................................................................... 5
1.2 OBJECTIVES OF THE COMPANY .................................................................... 7
1.2.1 Vision of the company ........................................................................... 7
1.2.2 Mission and competitive advantages of the company ........................... 7
Prepared By miftah Mohammed ID NO ENGR/ 257/05
1
 INTERNSHIP REPORT AT LUCY GARMENT INDUSTRY 2008 E.C

1.3 Organizational Structure and Manpower ................................................... 7

1.3.1 Total Workers of the organization with category ................................ 8
1.3.2 Organizational structure of the company .............................................. 8
1.3.3 Responsibility of functional organizational structure. ........................... 9
1.4 THE COMPANY’S PLAN ............................................................................. 10
1.4.1 Planning Department. ......................................................................... 10
1.4.2 Job or Task Scheduling: ....................................................................... 11
1.4.3 Material Resource Planning (Inventory) .............................................. 11
1.4.4 MATERIAL INPUTS ............................................................................... 11
1.4.5 Sourcing Material: ............................................................................. 11
1.5 Product Type .............................................................................................. 12
Figure1.2 product type. ........................................................................................ 13
1.6 maintenance Department. ....................................................................... 13
1.6.1 Main functions of Maintenance department....................................... 13
1.6.2 Gaps Identified in Maintenance Department .................................... 13
1.6.3 Recommendation to Maintenance department ................................ 14
1.7 work flow process ...................................................................................... 14
Figure.1.3 work flow structure ......................................................................... 14
1. 8 Store Keeping Procedure ........................................................................... 14
1.9 Accessories .............................................................................................. 15
1.10 Cutting room ............................................................................................ 15
1.10.1 Main Responsibilities of Cutting Room .............................................. 16
1.10.2 Process sequence in cutting room ..................................................... 17
2 1.10.3 Machines and equipment’s in cutting section ................................ 18
Figure 1.7 ..................................................................................................... 18
1.10.4 Type of machine and their function in cutting room. ........................ 18
1.11 Sewing room .......................................................................................... 19

Prepared By miftah Mohammed ID NO ENGR/ 257/05

2
 INTERNSHIP REPORT AT LUCY GARMENT INDUSTRY 2008 E.C

1.12 Industrial Engineering Department .......................................................... 28

Figure 1.10structure of industrial engineering. ................................................ 28
1.13 FINISHING SECTION .................................................................................. 28
1.14 Quality Control ........................................................................................ 29
CHAPTER two ....................................................................................................... 30
2.1 Project Works............................................................................................. 30
ABSTRACT ........................................................................................................ 30
2.2 Back ground of project ............................................................................. 30
LITRATURE REVIEW .......................................................................................... 31
2.2 INTRODUCTION. ....................................................................................... 31
2.3 Objective .................................................................................................... 33
2.3.1 General objectives ........................................................................ 33
2.3.2 Specific objectives of the project ......................................................... 33
2.4 SIGNIFICANCE OF THE STUDY ................................................................... 33
2.5 Scope of the study...................................................................................... 34
2.6 Statements OF PROBLEM. ....................................................................... 34
2.7 Methodology.............................................................................................. 34
2.7.1 Data collection methods ......................................................................... 34
2.7.2 Primary data collection methods ....................................................... 34
2.7.3 Secondary data collection methods .................................................... 34
2.7.4 through interview method: ................................................................. 35
2.8 Limitations of the study............................................................................. 35
2.9 PROJECT APPLICATION ............................................................................... 35
2.10 The benefinefitiory of the project .......................................................... 35
2.11 The performance individual operators. .................................................... 36
2.12 Data collection and presentation. ........................................................... 39
To present data I used Formula for the solution. .............................................. 39

Prepared By miftah Mohammed ID NO ENGR/ 257/05

3
 INTERNSHIP REPORT AT LUCY GARMENT INDUSTRY 2008 E.C

2.12.1 Data analysis system. ........................................................................ 39

2.13 Benefit of the project. .............................................................................. 43
2.13 Skill matrix’s chart. ................................................................................. 44
CHAPTER three. ................................................................................................... 49
3.1 BENEFITS FROM INTERNESHIP EXPERIENCE ............................................... 49
3.1 Internship Experience ................................................................................ 49
3.2 Benefits I Gained From Internships ............................................................ 49
3.3 Practical Skill .............................................................................................. 50
3.4 Theoretical Knowledge............................................................................... 50
3.5 Problem Solving ......................................................................................... 50
3.6 Team Playing Skill ....................................................................................... 50
3.7 Leader Ship Skill ......................................................................................... 50
3.8 Work Ethics Issues and Industrial Psychology ............................................ 51
3.9 My Practical skill: - ..................................................................................... 51
3.10 My Work ethics and industry psychology: -.............................................. 52
Conclusion ....................................................................................................... 53
Recommendation ............................................................................................ 54
Appendix .......................................................................................................... 56

1 CHAPTER ONE
1.1 HISTORICAL BACKGROUND OF THE COMPANY
Lucy garment industry PLC is one of the leading private limited garment manufacturing
companies in Ethiopia which began operation in Addis Ababa, saris industrial zone in
September 2011.

Prepared By miftah Mohammed ID NO ENGR/ 257/05

4
 INTERNSHIP REPORT AT LUCY GARMENT INDUSTRY 2008 E.C

It is a specialized garment manufacturing company producing high end men’s and ladies
formal shirt and as well as occasional medical gowns for export and local markets Using
the latest technology and state of the art machineries adopting the high standard way of
manufacturing methods of Turkish companies with a view of satisfying both the
international and local market

Figure 1 company image

1.1.2 Detail profile of the company

Lucy garment industry is a private limited company which is established in Addis Ababa
saris industrial zone in September 29,2003 .The company has 10,000 share with 1000 per
value.
It is established mainly for the manufacturing of high quality men’s and ladies shirt with
the intention of satisfying both the local as well as for foreign market medical gown.
At present the company is equipped with the state of art technology and diligent
management team. This team has proven record of managing the production of modern
dress shirt using arrange of different models and integrating its professionals with up to
date garment technology. The company uses Turkish style shirt manufacturing system
using highly imported special machineries for producing a high quality shirts and in
addition it has individuals trained all its production stuff for more than a year using
highly experienced Turkish production personals.

Prepared By miftah Mohammed ID NO ENGR/ 257/05

5
 INTERNSHIP REPORT AT LUCY GARMENT INDUSTRY 2008 E.C

The products of the factory are ready made at a daily capacity of Installed daily
production capacity =1,500 pcs of dress shirts but currently reached a daily production
of= 900-1000 pcs
Lucy garment industry is situated in the capital city industrial zone having easy access to
various infrastructures, like the airport and customs and the market at large.
It is recently opened company sells most all of its production in Ethiopian as high quality
shirts and medical gowns in its retail stores since there are incentives to export, it is
looking to expand its operations to also supply export customers.
All workers are Ethiopian 95% women. Base salary is EBR 750($40)/month plus
productivity incentives.
With low productivity Ethiopian workers can make 750-1000 shirts/day.
General Manager’s goal is to increase productivity to 1,200shirts/day. Three shareholders
own it.
Address and location of the company
Lucy garment industry PLC is located in Addis Ababa saris Industrial zone
woreda 09 Keble 12/13.
Tel:-251-4426188/251-5525285
Fax;-251-114430580/251-115536072
E-mail:-lucygarm@ethionet.et,lucygarment@gmail.com
Land and building of the company
Compound area:-2511 metre square
Factory (G+0): -1019.59 metre square
Office (G+0):- 101.76 metre square
Canteen (G+0):-56.50 metre square
Guard (G+1):-16 metre square
Compound asphalt road:-1250 metre square
Total built area 2,334 metre square and remaining area is for garden area
.

Prepared By miftah Mohammed ID NO ENGR/ 257/05

6
 INTERNSHIP REPORT AT LUCY GARMENT INDUSTRY 2008 E.C

1.2 OBJECTIVES OF THE COMPANY

To produce quality shirt at a price that is affordable to most of its customers in addition it
to contributes to the national economy by creating job opportunity and paying taxes and
mainly to serve the demands of many private and government institutions by providing
quality and world class outfits and uniforms in order to add value to their jobs.
To manufacture high quality classic and fashionable shirts and medical gowns to both
domestic and foreign markets. With this the company will be able to achieve a dual
objective of generating foreign currency to the country by exporting the product abroad
and substituting imports of shirts there by helping the country save its scarce foreign
currency reserves.

1.2.1 Vision of the company

To be a premier regional- brand in Africa in the production of men’s and ladies shirt.
To secure sound markets share in the global market at large.
To aspire and to have the leading position in its products in the market place in which it
operates and delighting its esteemed customers
.

1.2.2 Mission and competitive advantages of the company

Conductive investments climate investment climate (task holyday, import duty, tax
exemption, foreign exchange remittance etc.)
Possession of relatively highly skilled technical staff
Disciplined work force achieving high productivity levels.

1.3 Organizational Structure and Manpower

A general manager leads Lucy garment industry PLC and plant lay out manager. The
plant manager under his control has a responsibility for all technical and supporting
departments like production, human resource, finance, quality assurance marketing, and
procurement and supplies management

Prepared By miftah Mohammed ID NO ENGR/ 257/05

7
 INTERNSHIP REPORT AT LUCY GARMENT INDUSTRY 2008 E.C

1.3.1 Total Workers of the organization with category

Regular workers
Office workers 16
Cleaner and guard 9
Production workers 150
Production supervisors 6
Total
181
Part time workers
Mechanic 1
Guard 4
Messenger 1
Total 6
Grand total
190

Table 1 total workers of company

1.3.2 Organizational structure of the company

Prepared By miftah Mohammed ID NO ENGR/ 257/05

8
 INTERNSHIP REPORT AT LUCY GARMENT INDUSTRY 2008 E.C

Fig 1.1 organizational structure of Lucy

1.3.3 Responsibility of functional organizational structure.

1. General Manager- controls the overall activities of the company.
2. Executive leadership-selecting target markets and identifying appropriate markets
3 .Legal service –responsible for what problem happen in the company
4 .plant layout manager-responsibility for all technical & supporting departments’ like
production, human resource, finance, quality assurance marketing, and procurement &
supplies management.
5.Human resource Department (HR) – control promotions, annuals and discipline of
community in the company
6. Supply Dep’t– purchasing of materials depending up on department demand and
distribution
7 .Finance Dep’t- controls and supply payment custom clearance/cost analysis.
Prepared By miftah Mohammed ID NO ENGR/ 257/05
9
 INTERNSHIP REPORT AT LUCY GARMENT INDUSTRY 2008 E.C

8.Planning and product development– plan the production capacity and assessment of
each department according to production orders.
9. Maintenance department; controls over all activates and managing the maintenance
cycle
10.Quality Assurance:– controls the quality product of the company.
11.Marketing Dep’t– control goals and study cost/price of product and promotion of
products.
12.Industrial engineer - controls the way of products are developed by using different
scientific methods. And studding different problems of accompany

1.4 THE COMPANY’S PLAN

The company has medium and short term plan. On its short term plan, it will finalize
staff recruitment and trainings import of adequate raw materials and accessories, and
engage in full production scale and distribution of products. It also assesses possibilities
of local supply for raw materials including the knitted fabrics by approaching textile
large factories AYKA Addis for substitution of imported raw materials. In addition to
these efforts the company is working intensively to improve productivity of its
employees, creating conductive working environment and devising mechanisms to
retain its employees by reducing employees’ turn over which is the headache of the sub
sector there by finding their commitment and increasing their loyalty to the company.

1.4.1Planning Department.
Receive order sheet from marketing and evaluate customer order according available
materials and machine, time, layout (operation) and employers.

Prepared By miftah Mohammed ID NO ENGR/ 257/05

10
 INTERNSHIP REPORT AT LUCY GARMENT INDUSTRY 2008 E.C

1.4.2 Job or Task Scheduling:

Preparation of time and action calendar for each order from order receiving to shipment.
The job schedule contains list of tasks to be processed for the styles. Against each tasks
planner mentions when to start a task and what is dead line for that task. Name of
responsible person (department) for thejob is being listed. For example, scheduling
planned date (PCD), line leading date etc.

1.4.3 Material Resource Planning (Inventory)

Preparation of Material requirement sheet according to sample product and buyer

specification sheet. Consumption of material (fabric, thread, button, and twill tape) is
calculated and estimated cost of each material.
Process selection & planning: Processes needed to complete an order vary style to style.
According to the customer order requirement PPC department select processes for the
orders. Sometime extra processes are eliminated to reduce cost of production.

1.4.4 MATERIAL INPUTS

Full cotton and mixed fabrics such as TC, CVT, poly cotton, sateen, oxford...etc.
High standard fibre and polyester threads and high quality button and woven label.
Highest standard packaging materials with full set of accessories.

1.4.5Sourcing Material:
All materials required for production purpose based on specific order sourced from the
storeIf the material is unavailable the company made buying decision internationally to
import from foreign.

No Inputs Supplies
1 Cotton china and turkey
2 Polyester china and turkey

Prepared By miftah Mohammed ID NO ENGR/ 257/05

11
 INTERNSHIP REPORT AT LUCY GARMENT INDUSTRY 2008 E.C

3 Label china and turkey

4 Button china and turkey
5 Elastic hanger loop china and turkey
6 Care label china and turkey
7 Main label china and turkey
8 Sewing thread china and turkey
9 Metal clip china and turkey
10 Chamber china and turkey
11 Plastic china and turkey
12 Soft paper china and turkey
13 Hard paper china and turkey
14 Butterfly china and turkey
15 Holy bag china and turkey
16 Brand tab china and turkey

Table 1.2material sourcing

1.5 Product Type

Casual/Sport
Classical
Formal

Casual /Sport
Mens shirt Regular
Formal

Casual/sport
Products
Slimfit

Formal
ladies Shirt Normal

Necktie

Prepared By miftah Mohammed ID NO ENGR/ 257/05

12
 INTERNSHIP REPORT AT LUCY GARMENT INDUSTRY 2008 E.C

Figure1.2 product type.

1.6 maintenance Department.

Machine breakdown is one of the major problems that can affect the productivity of the
industry. During the field study it was observed that there is no planned and
unsatisfactory recording of maintenance system.

1.6.1 Main functions of Maintenance department

 Get Operation Bulletin from Floor Industrial engineering department
 Check availability of machine and attachments and make request if any further
machinery and attachments are required.
 Daily machine cleaning
 Perform Preventive maintenance as per planned maintenance.
 General Safety deals with safety equipment’s like fire extinguisher and
emergency exits.

1.6.2Gaps Identified in Maintenance Department

 Absence of Preventative Maintenance systems
 No Autonomous Maintenance
 Machine breakdown record is not there
 Broken Needle replacement policy is not followed properly
 No proper maintenance area for preventive maintenance
 There is no documented machinery data base
Prepared By miftah Mohammed ID NO ENGR/ 257/05
13
 INTERNSHIP REPORT AT LUCY GARMENT INDUSTRY 2008 E.C

1.6.3 Recommendation to Maintenance department

 Use Preventative Maintenance systems.
 AdaptAutonomous Maintenance to a company.
 Try to to record Machine breakdown
 Prepare proper maintenance area for preventive maintenance

1.7 workflow process

Figure.1.3 work flow structure

1. 8 Store Keeping Procedure

Store is a place where raw materials, accessories, work aids, finished goods and
machineries are placed or stored up to they changed to the product.The well-designed
material storage is very important in that it ensures the smooth flow of material in
working area.
In Lucy garment industry plc. There is two stores. fabric ,for shirt accessories,
interlining store and there is also other stores export materials but there is no exaptional
stores for finished products it is put same floor to the sewing, in especially packaged
cartons.
In this storing room there are three workers for monitor the received materials
and utilized materials In this everything considering store clear to pick wanted material
and there is also simply of stoke keeping.

Prepared By miftah Mohammed ID NO ENGR/ 257/05

14
 INTERNSHIP REPORT AT LUCY GARMENT INDUSTRY 2008 E.C

Fig 1.4 store of accessories and interlining

Figure1.5 fabric store

1.9 Accessories
Garment accessories are an important element in a garment. Preparation.
However garment accessories provide good finish and quality to the garment
. Accessories are. - Zippers, buttons, waist elastic, threads, Trims, Labels, hang-tag,
thread.

1.10 Cutting room

Cutting rooms in Lucy have no its own separated section rather it is within the same floor
of sewing and finishing sections. Marker making also on same table with cutting table
and the room is in the same floor of cutting section.
Cutting rooms have 5 workers including supervisions and quality checkers after marker is
done on the cutting tables. This section includes marker making, spreading and cutting
sorting bundling a cut pieces activities.

Prepared By miftah Mohammed ID NO ENGR/ 257/05

15
 INTERNSHIP REPORT AT LUCY GARMENT INDUSTRY 2008 E.C

: - in marker making room there are about 3 workers and they trace or arrange the pattern
pieces on fabric. Here the marker is not done on paper rather it is done on the fabric.
Materials used in marker making room are pattern pieces, marker making table marking
table.
There is one marker making table which is 1.6m width by 15m length and 0.78m from
the ground and it is also useful for spreading.
The marker making process is done 90% manually and 10%by machines.
The workers in marker making section have the long-time year experience in tracing but
they have no information about markers mode, marker type markers and making method.
This section includes marker making, spreading and cutting activities.

1.10.1 Main Responsibilities of Cutting Room

 Issuing of spreading
 Inspection of fabric and rolls according to customer requirement
 Issuing of quality cutting
 Ticketing, numbering and bundling of cut pieces
 100% issuing of all cut pieces to sewing room
 Dispatching of cutting pieces
 Documentation of total cut piece

Prepared By miftah Mohammed ID NO ENGR/ 257/05

16
 INTERNSHIP REPORT AT LUCY GARMENT INDUSTRY 2008 E.C

1.10.2 Process sequence in cutting room

Offloading (cleaning table)Marker makingSpreading fabric with required sizesPlacing

marker paper on the tableFabric cuttingCh ecking size and partsSorting and
bundlFigur1.6 process flow in cutting.

process of cutting:-this is the operation in the process and a combination operation, it is

an operation where by raw material/fabrics are spread and cut to obtain parts in this
stage fabrics are layered on a table layer by layer up to a certain height, according to the
ability of cutting machine fabric are cut into garment shapes or pattern and separated
by the layer fabric layering is possible both manual spreading and automated spreading
parts are then numbered and bundled and send to sewing room
Offloading:-offloading means cleaning the cutting table before all process of cutting.
Marker making:- a marker is a diagram of a precise arrangement of pattern pieces,
marker making is a process of finding the most efficient layout of pattern pieces for a
specified style so that waste during cutting can be minimized, the operation can be done
manually by tracing pattern pieces on to a fabric
Spreading: is the process of layering the fabric on the spreading for process of cutting
Cutting :after the completion of the above operation the laid fabric will be separated into
the exact copy of the pattern pieces by the operation cutting by straight knife.
Ticketing:-is process whereby each cut piece of fabric is given unique number with it is
size so that cut pieces of different shades do not get mixed and sewn together resulting in
garment rejection
. Bundling:-cut pieces after passing through ticketing and fusing need to be bundled or
tied up together before taken to the sewing operation
Bundling done after the cutting lay is numbered in a required amount to dispatch for
sewing room most of the tone 1 bundle contain 10-20 pieces of layer

Prepared By miftah Mohammed ID NO ENGR/ 257/05

17
 INTERNSHIP REPORT AT LUCY GARMENT INDUSTRY 2008 E.C

1.10.3 Machines and equipment’s in cutting section

Cutting table, Straightknife, End cutting, spreading machine, Scissor Point drill ,Clipper
Pen or pencil, Lodes, Rulers ,Pattern piece .Band knife and Die cutter

View of pattern pieces View of straight knifeview of drill View Cutting table
Figure 1.7Machines and equipment’s in cutting section

1.10.4 Type of machine and their function in cutting room.

No Type machines Brand Quant Description

1 Straight knife Brute 4 It cuts patterns accurately
2 Driller Microto 1 It drills shape point of pattern

3 End cutting spreading machin Cuts fabric used used for spreading
Serkon 1
4 Flat iron Magma 1 Used to iron &prevent from fabric sliding
5 Loads - 2 To prevent sliding during cutting
6 Clips - 4 To hold curved areas during cutting
7 Scissors - 6 To cut fabric, treads etc.
8 Band knife Serco 1 To cut collar and band curves
9 Die cutter Kasma 1 This machine cuts interlining for collar, cuff and.

10 Interlining spreading table - 1 To spread interlining

Prepared By miftah Mohammed ID NO ENGR/ 257/05

18
 INTERNSHIP REPORT AT LUCY GARMENT INDUSTRY 2008 E.C

Table 1.3type of machine in cutting.

1.11 Sewing room

This is the largest section of the floor which covers about 65% of the total floor. From the
total area of sewing section 80% is occupied by sewing machines lines and the other 20%
occupied by other machines and free space the one sewing line but the machines are
arranged in five lines including special machines are found.
Sewing operation is started by yoke attach with body and ended by button setting
operation. After yoke attach both right front and left front is prepared. On right front
placket folding and sewon left front buttonhole sewing pocket sewing then shoulder is
attached. After this sleeve is prepared and attached on armhole and side seam sewing.
After then prepared and sewn collar and band is sewn together and finally attached with
body with stitching and prepared and sewn cuff attached and stitched with sleeve pleat
making. After cuff stitching button place marking and button setting process is carried
and then transported to finishing department.

receiving production order from pm

receiving cut part from cutting

sewing

inline quality checking

delivery to final inspection and finishing

Figure 1.9 Process flow for sewingg

s/no Types of machine Model/brand Quantity
1 Single needle&double needle Juki &jacki 62
2 Special machine Kansi&protect 10
3 Over look Juki 9

Prepared By miftah Mohammed ID NO ENGR/ 257/05

19
 INTERNSHIP REPORT AT LUCY GARMENT INDUSTRY 2008 E.C

4 Button hole making Juki 2

5 Button setting machine Juki 3
6 Quality table 4
7 Packing table 1

Table 1.1.7 Type of machine and equipment in Lucy garment industry sewing section.

Machine type Brand Description

1 Double needle chain stitch Juki This machine used for lapped seam sewing like side seam
2 Juki Used to attach collar
3 Doubleneedle chain stitch ms Juki Used to sew armhole
Button setting Juki Used for button setting
4
5 Button hole sewing Juki To sew buttonholes

s.no Machine type Brand Description

1 Single needle lock stitch Juki Used for collar sewing
2 Single needle lock stitch Juki Used to sew cuff
3 Single needle lock stitch Juki Used to stitch collar and cuff stitch
4 Single needle lock stitch with cutting blade Juki It cuts extra collar band etc.
5 Doubleneedle chain stitch machine Juki Used to sleeve and side seam sewing

Table1.8different machines and their function in sewing.

Prepared By miftah Mohammed ID NO ENGR/ 257/05

20
 INTERNSHIP REPORT AT LUCY GARMENT INDUSTRY 2008 E.C

Viewof sewing

Figure1.9 product variety of company

Prepared By miftah Mohammed ID NO ENGR/ 257/05

21
 INTERNSHIP REPORT AT LUCY GARMENT INDUSTRY 2008 E.C

Figure 1.10 view of different machine in sewing

Time study for long sleeve shirt and Operations break down

time study
IND
collar preparation ACT ACT
collar fusing 0.543 0.543
collar sewing 0.270 0.270
collar cutting 0.100 0.100
collar turning and sharpening 0.093 0.093
collar pressing aand stay insert 0.390 0.390
collar top stich 0.342 0.342
collar tip cutting by scissor 0.113 0.113
band fusing 0.525 0.525
band rolling 0.212 0.212
band cutting by scissor 0.277 0.277
collar and band sewing 0.277 0.277
ironing collar and band 0.613 0.613
collar edge stitch 0.250 0.250

Prepared By miftah Mohammed ID NO ENGR/ 257/05

22
 INTERNSHIP REPORT AT LUCY GARMENT INDUSTRY 2008 E.C

marking band by pencil 0.432 0.432

band cutting by machine 0.172 0.172
cuff preparation 0.000
cuff fusing 0.135 0.135
fused cuff ironing 0.327 0.327
cuff sewing 0.283 0.283
cuff turning and ironing 0.235 0.235
cuff stitching 0.172 0.172
sleeve preparation 0.000
gambol pressing 0.140 0.140
placket pressing 0.160 0.160
gambol attach on sleeve 0.570 0.495
gambol attach on sleeve 0.570
gambol attach on sleeve 0.440
gambol attach on sleeve 0.400 0.300
placket attach on sleeve 0.670
placket attach on sleeve 0.680
placket attach on sleeve 0.670
placket attach on sleeve 0.670
placket attach on sleeve 0.680 0.674
exta placket and gambol cutting 0.233 0.233
BACK PREPARATION 0.000
brand label attach on yoke 0.395
brand label attach on yoke 0.428 0.412
back and yoke attach 0.555 0.555
back and yoke iron and shoulder
cutting 0.313 0.313
POKET PREPARATION 0.000
ironing pocket for run stitch 0.170 0.170

Prepared By miftah Mohammed ID NO ENGR/ 257/05

23
 INTERNSHIP REPORT AT LUCY GARMENT INDUSTRY 2008 E.C

pocket folding to shape 0.200 0.200

pocket run stitching 0.154 0.154
LEFT FRONT PREPARATION
left front pressing 0.580 0.580
button hole making on left front 0.585 0.585
button hole making on left front 0.398 0.398
port attach on left front 0.830
pokrt attach on left front 0.677 0.753
RIGHT FRONT PRESSING 0.000
RIGHT FRONT PRESSING 0.602 0.602
right front hemming 0.302 0.302
ASSEMBLY LINE 0.000
sholder sewing 0.338 0.338
sleeve attach with body 0.532
sleeve attach with body 0.830 0.681
armhole top stitch 0.937
armhole top stitch 0.927 0.932
collar attach with body 0.545
collar attach with body 0.665 0.605
collar close 0.728
collar close 0.703 0.716
bottom cutting 0.530 0.530
bottom hemming 0.457 0.457
cuff attach on sleeve 0.830
cuff attach on sleeve 0.830
cuff attach on sleeve 0.830 0.830
button hole making on cuff, band
and placket 0.398
button hole making on cuff, band 0.800 0.599

Prepared By miftah Mohammed ID NO ENGR/ 257/05

24
 INTERNSHIP REPORT AT LUCY GARMENT INDUSTRY 2008 E.C

and placket
position marking for button setting 0.548
position marking for button setting 0.608 0.578
button setting 0.623
button setting 0.633
button setting 0.620 0.625
Trimming 0.960 0.960
Inspection 0.700 0.700
FINSHING SECTION
under yoke ironing 0.640 0.640
neck pressing 0.517 0.517
Buttoning 0.011 0.011
inserting butterfly and plastic 0.550 0.550
ironing shirt 0.770
ironing shirt 0.707 0.738
folding shirt 1.200
folding shirt 1.300
folding shirt 1.300
folding shirt 1.200
folding shirt 1.300 1.260
inserting packing and design label 0.622
inserting packing and design label 0.433 0.528
poly bag 0.330 0.330

Table1.10 time study of long sleeve shirt.

Allowances
 Personal needs allowance =5%
 Basic fatigue allowance =4%
 Standing allowance =2%
Prepared By miftah Mohammed ID NO ENGR/ 257/05
25
 INTERNSHIP REPORT AT LUCY GARMENT INDUSTRY 2008 E.C

 Abnormal position allowance =2%

 Machine delay allowance for SNLS =9%
 Machine delay allowance for DNLS =14%


Time study for medical trousers.

Style#1141 52

S. OPERA cycle time Aver AL BT tar/hr tar/day tar/d no of

N TION age L @100 ay opera
@6 tor
5
1 Attach 0. 0. 0. 0. 0. 0.81 0.1 0.9 74 611 397 1
pocket 75 9 8 9 7 1 23
piece
2 Top 0. 0. 0. 0. 0. 0.828 0.1 0.9 72 598 389 1
stitch on 77 75 86 86 9 2 44
pocket
3 pocket 0. 0. 0. 0. 0. 0.65 0.0 0.7 92 762 495 1
sew 75 65 55 65 65 9 41
4 back and 1 1 1 1 1 1 0.1 1.1 60 495 322 1
front rise 4 4
O/L
5 Pocket 0. 0. 0. 0. 0. 0.5 0.0 0.5 120 990 644 1
o/l 5 5 5 5 5 7 7
6 side 0. 0. 0. 0. 0. 0.5 0.0 0.5 120 990 644 1
seam 5 5 5 5 5 7 7
crouch
sew

Prepared By miftah Mohammed ID NO ENGR/ 257/05

26
 INTERNSHIP REPORT AT LUCY GARMENT INDUSTRY 2008 E.C

SNLS
7 Side 0. 0. 0. 0. 0. 0.93 0.1 1.0 65 532 346 1
seam 96 93 9 95 91 3 6
O/L
8 inseam 1. 1 1 1 1 1.05 0.1 1.1 57.1 471.429 306 1
O/L 25 5 97 429
9 bottom 1 1 1 1 1 1 0.1 1.1 60 495 322 2
hemming 4 4
10 Label 0. 0. 0. 0. 0. 0.25 0.0 0.2 240 1980 128 1
attach 25 25 25 25 25 4 85 7
11 elastic 0. 0. 0. 0. 0. 0.25 0.0 0.2 240 1980 128 1
sew on 25 25 25 25 25 4 85 7
waist
O/L
12 Waist 0. 0. 0. 0. 0. 0.25 0.0 0.2 240 1980 128 1
O/L 25 25 25 25 25 4 85 7
13 Elastic 0. 0. 0. 0. 0. 0.5 0.0 0.5 120 990 644 1
cunsine 5 5 5 5 5 7 7
14 bar tack 3 3. 3. 3 3 3.116 0.4 3.5 19 159 103 3
sew 3 28 4 52
15 table 0. 0. 0. 0. 0. 0.25 0.0 0.2 240 1980 128 1
quality 25 25 25 25 25 4 85 7
16 ironing 3 3 3 3 3 3 0.4 3.4 20 165 107 1
2 2
17 final 1 1 1 1 1 1 0.1 1.1 60 495 322 2
quality 4 4
TOTAL 15.88 2.2 18.
4 2 11
Table 1.11 time study of medical trouser.

Prepared By miftah Mohammed ID NO ENGR/ 257/05

27
 INTERNSHIP REPORT AT LUCY GARMENT INDUSTRY 2008 E.C

1.12 Industrial Engineering Department

Role of the Department industrial engineering
• Operation bulletin preparation
• SAM calculation
• Garment costing
• Thread consumption calculation
• Style Feasibility decision
• Machine requirement plan and Report
• Incentive Planning
• Method Study
• Motion Study
• New Method Implementation

Plant Manager

I/E Head

Data Entry
Data Entry Clerk
Clerk

Figure 1.10structure of industrial engineering.

1.13 FINISHING SECTION
In finishing section: - The first work is trimming the thread from the finished products
and goes to inspection table to inspect those inspected threads and if the problem is
occurring they work again. After inspection neck pressing operations and buttoning then
passes through ironing and inserting butterfly on neck band and back and poly packaging
Prepared By miftah Mohammed ID NO ENGR/ 257/05
28
 INTERNSHIP REPORT AT LUCY GARMENT INDUSTRY 2008 E.C

by inserting labels and those packaged in the carton and transported temporary store to
store.
There is 12 ironing machines in this section and these machines responsible for its work
during inline process and after production.
Finishing section machine
Types of machines Brand Model Quantity Description
1 Neck pressing m/ce - Pemaxs 1 Used to shape neck
2 Steam machine Malran - 1 It releases steam
3 Ironing machine Malran MS-4929 12 Used to shape garments
4 Inspection table - - 7 All products are inspected here
5 Packaging table - - 1 Used to packaging
6 Buttoning table - - 1 Used to button
7 Steamer machine Malran MS-4929 1 It gives steam for ironing m/ce
8 Temporary product - - 3 Used to put any products
putting tables
Table 1.12 sewing section
1.14 Quality Control
Quality control is done through the end line checkers. In the line the product is checked
by the supervisor (line supervisor). Each supervisor are checked the product randomly.
But if this garment can have error, it is back to the rework. At the station before moving
to the next operation in order to prevent damage at the source.

Plant
Manage
r
Figure1.11 quality
Quality
Head department structure.
Patrol Final
checker Trimmers
s and
Prepared By miftah Mohammed checkers ID NO ENGR/ 257/05
29
 INTERNSHIP REPORT AT LUCY GARMENT INDUSTRY 2008 E.C

CHAPTER two
2.1 Project Works
PRODUCTIVITY IMPROVEMENT THROUG IMPROVING SKILL
MATRIXS OF OPERATORS
ABSTRACT
Within companies across many garment industries, there is a growing realization that
human capital provides the greatest force for economic competitiveness. Indeed, this
realization is true of companies in a wide variety of industries, as well as national
governments. In Lucy garment industry Furthermore, harnessing this human capital,
referred to as employees’ skills and abilities, will contribute towards improved
organizational performance. That is, the effective utilization of a company’s personnel,
through the most appropriate application of their skills and competencies, can improve
performance thus aiding the achievement of sustained competitiveness. This paper
highlights the need for organizations to gain measures of the skills and competencies held
by the members of their workforces. Consequently, the company has been able to identify
skill gaps, along with competency deficiencies, within its workforce

2.2 Back ground of project

Productivity improvement is the process of achieving the requirement goals. Improving
skill of operators Productivity improvement is the process of achieving the requirement
goals.
Analysis of the production process that is designed to improve efficiency performance of
by identifying loss time production per day per hour identifying time study line
production per day, efficiency of operator efficiency of line .

Prepared By miftah Mohammed ID NO ENGR/ 257/05

30
 INTERNSHIP REPORT AT LUCY GARMENT INDUSTRY 2008 E.C

It is expected that regular measuring of skills will become commonplace, which could
contribute to improving organizational performance.. At an individual level within a
company, a means of assessing and measuring engineers’ skills and competencies is
required to aid managers in the decision-making process regarding which people should
work on which tasks. In turn, this will facilitate the effective allocation and utilizations of
engineers with regard to the varying tasks, given that each task requires particular skills
and levels of competency in these skills. It has been recognized that by not effectively
matching together employees’ skill ability and work, productivity can be greatly reduced
similarly

LITRATURE REVIEW
2.2 INTRODUCTION.
A skill matrix is a commonly used tools for assessing training needs that can be updated
and reviewed by a group of peoples in a single chart.
The skill matrix helps to identify skills and gaps within a team asses training
requirements and develop new skills.
The tool known as the skill matrix a technique that provides in sight in to individual skills
and group dynamics to more efficiently train the team`
There is a growing realization within companies across many garment industries, that
human capital provides the greatest force for economic competitiveness. In order to
channel this force and achieve sustained competitiveness, garment companies need to
facilitate the effective utilization of their personnel leading to efficient performance. A
pre-cursor to enabling the effective utilizations of the workforce is for a company to gain
an awareness of the skills and competencies of its individual members. Only by a
company being in possession of such knowledge, can advances be made in terms of
realizing the full potential of its workforce. Furthermore, such knowledge may also
provide the foundation for individual continuous development plans to strengthen the
workforce with the intention of simultaneously increasing productivity and stimulating an
efficient workforce or skill of workers In the current knowledge-based economy,

Prepared By miftah Mohammed ID NO ENGR/ 257/05

31
 INTERNSHIP REPORT AT LUCY GARMENT INDUSTRY 2008 E.C

employee skills and abilities, also referred to as human capital, are fast becoming an
organization’s most valuable asset a key driving force in economic development, and a
source of competitive advantage For example, it has been stated in particular, emphasis
has been placed on the importance of a company’s human capital – the value- creating
skills, competencies, talents, and abilities of its workforce – as an essential component of
gaining competitive advantage” . Indeed, human capital is high on the policy agenda of
national governments and international traditionally within manufacturing engineering
companies, decisions regarding the selection of the most appropriate individuals to
undertake particular tasks can involve managers and supervisors using their subjective,
but informed, judgment and experience. This decision-making is made more difficult
since people can be multi-skilled with varying levels of competency in these skills, and
different tasks require specific skills. As such, difficulties lie in knowing what specific
skills and level of competency in these skills the manufacturing engineers possess.
Further, failure to select the right individuals to undertake the work can result in extra
budget being consumed, missed deadlines, and accompanying compensation
payments to clients. Based on the difficulties highlighted, there is a requirement to
provide managers and supervisors with an assessment process enabling them to measure
and represent the skill competencies of theirmanufacturing engineers. Consequently,
managers and supervisors can establish important information related to skill gaps or
competency deficiencies in their workforce. In turn, this will inform the company’s
training and development needs,in addition to formulating skill and competency profiles
of manufacturing engineers it needs to recruit
Maintain a strategic approach to their business involving the continual assessment
of their strengths and weaknesses.
By identifying skill strengths and weaknesses within an organization, workload
can be better matched with skill strengths, and training strategies can be
developed to address skill weaknesses or skill gaps with respect to its future
business needs Companies have been noted as adopting several strategies in
response to perceived skill deficiencies including up-skilling by increasing

Prepared By miftah Mohammed ID NO ENGR/ 257/05

32
 INTERNSHIP REPORT AT LUCY GARMENT INDUSTRY 2008 E.C

training, in-skilling through intensified recruitment efforts, and out-skilling

through the use of third parties to undertake skilled work

Contact: G. Coates Durham University School of Engineering South Road Durham United
Kingdom Phone: +44 (0)191 334 2479 Fax: +44 (0)191 334 2377 e-mail:
graham.coates@durham.ac.uk

2.3 Objective
2.3.1 General objectives
 To improve productivity of a company through skill matrix’s of a company.

2.3.2 Specific objectives of the project

Improving productivity concerned with skill matrix’s of operators
 , performance of operator’s efficiency.
 To make acompany operator’s multi skilled
 To minimize the shortage multi skilled operators,
 To know the performance of individual operators
 To use operators skills in in correct ways

 Increasing the total productivity of the company trough increase quality through
skill of operators.

2.4 SIGNIFICANCE OF THE STUDY

The study of skill matrix is the most important skills.
 To minimize wastage
 To change the operator attitude
 To increase productivity of company.
 To avoid any bottle neck
 To make Smooth flow of work
 To make less supervision

Prepared By miftah Mohammed ID NO ENGR/ 257/05

33
 INTERNSHIP REPORT AT LUCY GARMENT INDUSTRY 2008 E.C

2.5 Scope of the study

The project has been done in Lucy garment industry plc. During my internship stay in
sewing sections to proof absenteeism of operators of a company.

2.6 Statements OF PROBLEM.

in Lucy garment industry of sewing sections there is a problems of ,, Disorders of
machine arrangements, Shortage of multi- skill operator Carelessness of the operators
Shortage of qualified and trained operator Not assigning the right worker at the right
place Poor performance and efficiency of the operators. And.Improper supervision etc.
These above problems are created due to skill matrixes of operators.

2.7 Methodology
In Lucy garment plc. Factory I was use different types of information of their time for
individual operations, loss time productions per hour, per day.I was used different
formulas and statements like basic time, observed time, normal time, performance,
efficiency formula and SAM of every operations etc.
In order to conduct the study and various sources like internet, academic books, direct
observation, reports and both primary and secondary data source.

2.7.1 Data collection methods

I was use two methods of data collecting method.
When I was done this project in Lucy garment industry I used different skills operators
Primary data collecting method and secondary

2.7.2 Primary data collection methods

Through observation
Exchanging one operators for different operation and take their data.
Through Interview the supervisors.
By collecting daily attendance of company.

2.7.3 Secondary data collection methods

 From internet access
 From different departments supervisors
Prepared By miftah Mohammed ID NO ENGR/ 257/05
34
 INTERNSHIP REPORT AT LUCY GARMENT INDUSTRY 2008 E.C

 From my education books etc.

Primary data collection is the process of gathering information from the sources directly
from the resources.
Example interviews, direct observation, questionnaires
I was use directly the problems through walking in the every lines operation see operation
break down the way flow of materials through operators and the output of products.

2.7.4 through interview method:

in this method I ask some questions by moving in to the different sections and ask some
of the supervisor and operators the problems mostly happen to them then I started my
project on this titles from the amongst problems which is appears in Lucy garment
industry

2.8Limitations of the study

 UN availability of written document.
 The releasing of operators I take time study from time to time.
 The miss understanding of some operators my study.

2.9 PROJECT APPLICATION

The project is applied on sewing department and finishing. In Lucy, garment
industry.

2.10The benefinefitioryof the project

 For the management less number of hire and fire operators and high productivity
 For the operators makes multi skilled and can be get high incentives.
 For the super visor simply identification individual operators performance.

Prepared By miftah Mohammed ID NO ENGR/ 257/05

35
 INTERNSHIP REPORT AT LUCY GARMENT INDUSTRY 2008 E.C

2.11 The performance individual operators.

Prepared By miftah Mohammed ID NO ENGR/ 257/05

36
 INTERNSHIP REPORT AT LUCY GARMENT INDUSTRY 2008 E.C

Prepared By miftah Mohammed ID NO ENGR/ 257/05

37
 INTERNSHIP REPORT AT LUCY GARMENT INDUSTRY 2008 E.C

Prepared By miftah Mohammed ID NO ENGR/ 257/05

38
 INTERNSHIP REPORT AT LUCY GARMENT INDUSTRY 2008 E.C

Table 2.1 operator’s performance.

2.12 Data collection and presentation.

To present data I used Formula for the solution.

2.12.1 Data analysis system.

1 Actual time (observed time) =the time (minute take to finished one operation)
2Rating = the individual rate of operators. =80
3 basic time (BT) =actual time (observed time)*rating/100
4 Allowance = basic time +0.2
5 standard time =basic time (BT) +allowance
6 Sam =BT*1.14
7 actual product =the amount of product in piece produced in8hrs (495minute)
8 Total working hour =Total amount of minutes in one day or 8hrs (495)
9 Loss time = the amount of minutes lost without product
10 Produced minute = Twh-loss time
11 Available minute = actual time *actual product
12 Performance=available minute/produced minute

Prepared By miftah Mohammed ID NO ENGR/ 257/05

39
 INTERNSHIP REPORT AT LUCY GARMENT INDUSTRY 2008 E.C

2.13.1 The formula for individual performance operators

Example for operator on Alemnesh on different operation.
The first Operation she can operate is pocket attach on the left front.
1 actual = 0.75min
2 rating = 80%
3 basic time (BT) = actual time (observed time*rating/100
BT = 0.75* 0.8/100=0.60 min
4 allowance = basic time +0.2
0. 60 min +0.2 =0.80min
5 standard time =basic time (BT) +allowance
0.60 min+ 0.80=1.80 hr/180min
6 SAM =BT*1.14 = 0.60*1.14 = 0.68min

7 actual product = 377 pcs

8 Total working hour (TWH) = Total amount of minutes in one day or8hrs (495)
=495min

9 Loss time =0(there is no loss time during this operation in 495minute)

10 Produced minute = Twh-loss time

495minute-0minute =495
11 Available minute = actual time *actual product
0.75*377 =283 min

12 Performance =available minute/produced minute = 283min/495*100=57.37% =57%

Therefore performance alemnesh on this operation is=== 57%

2 The second operation arm hole top stich

Prepared By miftah Mohammed ID NO ENGR/ 257/05

40
 INTERNSHIP REPORT AT LUCY GARMENT INDUSTRY 2008 E.C

1 Actual =1.00 min

2 Rating =80%
3 BT = actual time (observed time*rating/100 = 1.00*80/100=0.80min
4 allowance =basic time +0.2 = 0.80min+0.2=100min
5 standard time = basic time (BT) +allowance = 0.80min+100=180min
6 SAM =BT*1.14 =0.80minute*1.14=0.91
7actual product=332pcs
8 Total working hour =495min
9 Loss time =3 min
10 Produced minute =495minute-3min=492min
11 Available minute =1.00*332 = 332
12Performance =332/492=67%

Therefore the performance of alemnesh on arm hole top stitch is = 67%

3 The third operation of alemnesh is placket attach on sleeve
1 Actual= 0.93min
2 Rating =85%
3 BT = 0.93*85/100=0.79min
4 Allowance =0.79+0.2 =0.99
5standard time = 0.99+0.79=180 min
6 SAM= 0.79*1.14=0.90min
7 actual product=295pcs
8 Total working hour = 495min
9 Loss time =0 min
10 Produced minute =495-0= 495 min
11 Available minute =0.93*295 = 274min
12 Performance=274/495= 55%

In general the performance alemnesh is on different operation the above data and it is
studied for the multi skilled operators according to this above data so that the production
Prepared By miftah Mohammed ID NO ENGR/ 257/05
41
 INTERNSHIP REPORT AT LUCY GARMENT INDUSTRY 2008 E.C

can seat her in the better place her performance and also I was collect different data’s for
others of the following operation and for different operators to prepare skill matrix’s of
acompany.

The problems
The case of the studying of the problems of absenteeism in different case this project
In the Lucy garment industry during my intern ship duration.
So I was start case studying of this problems case and start to find solution for this
problems. That I was collected different data’s which is can be solve this problems,
Problems case if there much absenteeism number of operators are as I collect attendance
of the company.
In one day is =there is average10operators are absent from the company.

So the Solution I tried found in the company there is 26 working day

If 1day = 10 operators absent
26day X

1day*X/day=26day*10opreators /1day

X=260 operators are absent within a month fromthe company.

If in 1 month =260 operators are absent

In 12month X

X = 12month*260 operators /1 month=3120 operators are absent.

So in one month/in 26 day of work there is 260operators are absent

So if the productions of a company are per day is 1000pcs in 51 operators.

Prepared By miftah Mohammed ID NO ENGR/ 257/05

42
 INTERNSHIP REPORT AT LUCY GARMENT INDUSTRY 2008 E.C

So if 51operators= 1000pcs
1 operators*1000pcs/51 operators =19.6pieces are produced by 1 operators
19.6pcs*10 operators= 196
10 operators ? = 10operators*19.5pcs/1 operators= 196pcs of productions are

loss in one day

So that the total production loss
In a day=196pcs
In a month= 5096pcs loss
In a year=61152pcs
Therefore when I change this production in to cost.
The price of 1pcsof shirt=250birr ($12.5)
The company losses per day =12.5*196= $2450(49000)

Per month = 2450*26 =$63700(1274000)

Per year= $63700*12 =$ 764400 (15288000)

2.13 Benefit of the project Company gain in terms of cost.

In general Lucy garment industry losses yearly =$ 764400 (15288000) amount of costs
because
Of absenteeism of operators (absenteeism of skill matrix’s in the company.)
So before I do this project the company was loses =$ 764400 (15288000) amount of
costs because absenteeism.

After my project (skill matrix’s is prepared in the company at list =$ 764400

(15288000) this and above amount of cost is saved if the company apply this project.

Prepared By miftah Mohammed ID NO ENGR/ 257/05

43
 INTERNSHIP REPORT AT LUCY GARMENT INDUSTRY 2008 E.C

2.13 Skill matrix’s chart.

Prepared By miftah Mohammed ID NO ENGR/ 257/05

44
 INTERNSHIP REPORT AT LUCY GARMENT INDUSTRY 2008 E.C

Prepared By miftah Mohammed ID NO ENGR/ 257/05

45
 INTERNSHIP REPORT AT LUCY GARMENT INDUSTRY 2008 E.C

Prepared By miftah Mohammed ID NO ENGR/ 257/05

46
 INTERNSHIP REPORT AT LUCY GARMENT INDUSTRY 2008 E.C

Prepared By miftah Mohammed ID NO ENGR/ 257/05

47
 INTERNSHIP REPORT AT LUCY GARMENT INDUSTRY 2008 E.C

Prepared By miftah Mohammed ID NO ENGR/ 257/05

48
 INTERNSHIP REPORT AT LUCY GARMENT INDUSTRY 2008 E.C

Table2.2skill matrix’s sheet

REMARK
the operations that operators welloperate (operations they are
1 operating know)
2 the operations that operators secondly can operate additionally
3 the operations that operators can operate at third

This remark putting here according to interview of operators but

the real of their ability on each operation is can found on skill
sheet.

CHAPTER three.
3.1 BENEFITS FROM INTERNESHIP EXPERIENCE
3.1 Internship Experience
When I am to do the internship has helped me to gain experience in my field of study and
I get different experience. I can develop my professional interest, and valuable work
experience. When I am finding a feel that manufacturing methods of a company is good
and to apply the knowledge I have learned in the class room to the practical way.

3.2 Benefits I Gained From Internships

Internship helps to me to get experience in my field of study. During internship we to
know more about my field. The benefits of internship is
Interpersonal communication skill
Prepared By miftah Mohammed ID NO ENGR/ 257/05
49
 INTERNSHIP REPORT AT LUCY GARMENT INDUSTRY 2008 E.C

Entrepreneurship skill
Practical skill
Solving problem in industrial
Team playing skill Practical skill
Upgrade theoretical knowledge by practical practicing
Industry problem solving skill
Interpersonal communication skill
Work ethics and industrial psychology
Team work skill
Entrepreneurship skill

3.3 Practical Skill

During internship program benefited me to have practical skill. Example, how to spread
the fabric, how to cut the fabric by using different machine in garment industry is
performed. I have learned this theoretically and I experienced this practically in
internship program.

3.4 Theoretical Knowledge

After I completed my internship program I am able to upgrade my theoretical knowledge.
When I was learned in the class it will be a theory. But after I had completed this
internship program. I have checked that those I have learned in theory are real and are
found in the practical like sewing room.

3.5 Problem Solving

After completed this internship program makes me to identify the problems and how to
solve this problem if it is happened. My internship gave the opportunities to apply some
problem solving skill. Learned in the class room to real world activity within the industry.

3.6 Team Playing Skill

During internship, I enable me to develop my team playing skill.

3.7 Leader Ship Skill

Doing an internship made me to build my confidence and knowledge on leader ship skill.
Prepared By miftah Mohammed ID NO ENGR/ 257/05
50
 INTERNSHIP REPORT AT LUCY GARMENT INDUSTRY 2008 E.C

3.8 Work Ethics Issues and Industrial Psychology

An internship made me to have a strong willing to work. With strong willing to work
ethic I am always committed to the work and will stay until the task is complete. The
internship made me to avoid personal issues on work time and to keep my positive
attitude and I remember that I have smaller tasks to handle prior to my large, more
important ones. I also develop the following things after my internship program,
Punctuality and accountability to a given task
Build motivation and work ethics
Transparency in working once duty etc.
Internship enables me to act as advisers, professionals, provide recommendations
for how to resolve conflicts, increase worker productivity, and improve employee
morale among other thing

3.9 My Practical skill: -

During the time of internship I develop operation break down, layout and SAM of
coverall shirts. Also in practical I know how to make a pattern for shirt, and I was trained
manual pattern making, grading. I also developed theoretical knowledge into practical.
I Upgrade my theoretical knowledge in to practical practice: -
When I was in the class and when I have completed this internship program I have
checked that those I have learned in theory are real and are found in the practical world. It
gives me an opportunity to apply the fundamentals learned in the classroom to real world
issues.
I developed Problem solving skill: -
Completing this internship program makes me to identify the industrial problems and
then how to solve them if happened. My internship gave the opportunity to apply some
industrial problem solving skill learned with in the classroom to real world activity within
the industry. It gives me an in-depth analysis of the industrial problems really and how to
solve them.
I develop my Personal communication skill and approach with others: -

Prepared By miftah Mohammed ID NO ENGR/ 257/05

51
 INTERNSHIP REPORT AT LUCY GARMENT INDUSTRY 2008 E.C

I have developed my personal communication skill until at the end of my internship

program. I developed both oral and communication skill. I got an experience on how to
approach to people who works in the company. I also developed how to communicate
with people in the factory using written communication method. They also helping me by
asking about different questions about general garment industry and this motivates me
what ever in the company.

3.10 My Work ethics and industry psychology: -

The internship made me to avoid personal issues on work time and to keep my positive
attitude and I remember that I have smaller tasks to handle prior to my large, more
important ones.
I also develop the following things after my internship program
Build motivation and work ethics
Punctuality and accountability to a given task
Transparency in working once duty
Respecting and friendship building with co-workers.
Strong working relations with operators in the company
Internship enables me to act as advisers, professionals, provide recommendations for how
to resolve conflicts, increase productivity, and improve employee morale, among other
things.
I developed Team work skill: -
Doing internship enables me to develop my team playing skill. It enables me working
with my colleagues who have substantial experience within this garment factory. I
develop my understanding on my contribution to the company as a member the group on
the entire objective to be succeeded. My internship was a great way to meet people in my
field of study. It allows me to meet people who help me land a job later on and give me
the contacts in the factory.
Being familiar for Entrepreneur-ship skill: -
Entrepreneurs are a people who are able to develop new business & affect the overall
condition of the global economy. When I was in Lucy garment factory I saw a lot of
business opportunity that can create wealth. In my 3 and half month internship industrial.
Prepared By miftah Mohammed ID NO ENGR/ 257/05
52
 INTERNSHIP REPORT AT LUCY GARMENT INDUSTRY 2008 E.C

Conclusion
Lucy garment industry loses large amount of products due absence of skill matrix’s of
operators or because of absenteeism of operators but If there is a well applications of
skill matrix’s operators this problem is can be solve.
Totally, good utilization of skill matrix’s of operator can increase productivity of the
company these leads the company to be more profitable and it can also solve the
problems that face the company in termsof skill matrix’s of operators of lucy garments
industrial have great production capacity of about 90%for both export and localmarket
.due to this it gain for our country and for foreign exchange
In general if this company correctly apply skill matrix’s operators it can get if the
actual skill matrix’s of sewing room operators is continuously done within a three months
and other systems are done in this company t
If the company applies this project it will have the following advantages:
 Competency in the market or being profitable.
 Customer satisfaction
 Gain another order for the production
 Save the inventory
 Fastest acceptance of customers order

Prepared By miftah Mohammed ID NO ENGR/ 257/05

53
 INTERNSHIP REPORT AT LUCY GARMENT INDUSTRY 2008 E.C

Recommendation

I put my recommendation for the company in different perspectives

Forthe company manger (production manager line supervisor) it has a lot of benefits

 Use skill matrix’s data base it simply identify the every operators performance
 Use these skill matrixes to confirm the skills, knowledge and interest of
your company operators.
 Train other operators regarding technical demonstrate a designated level
of technical skills in specific areas.
 Employee malti skilled operators as possible as beginning
 These formats must be up date within every 3 month.
For the operators develop skill on different operation to be multy skilled,
to get better incentives.
Therefore, if a company applies this project it can save the above loss product and
cost save for company.

Prepared By miftah Mohammed ID NO ENGR/ 257/05

54
 INTERNSHIP REPORT AT LUCY GARMENT INDUSTRY 2008 E.C

Reference

Monthly report
Company data
Hand out
From my advisor
From the internet

Prepared By miftah Mohammed ID NO ENGR/ 257/05

55
 INTERNSHIP REPORT AT LUCY GARMENT INDUSTRY 2008 E.C

Appendix

SNLS- Single Needle Lock Stitch

DNLS- Double Needle Lock Stitch
OL -Over Lock
Pcs -pieces
SAM -Standard Allowance Minute
Min- minute
PLC- private limited company
LGI Lucy garment industry

Prepared By miftah Mohammed ID NO ENGR/ 257/05

56