Independent Apparels Ltd.
Independent Apparels Ltd.
Contents
Letter of Submission ..................................................................................................................3
Acknowledgement......................................................................................................................6
1 Introduction .............................................................................................................................8
1.2 Objective...........................................................................................................................8
1.3 Methodology.....................................................................................................................9
1.5 Limitations........................................................................................................................9
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3.5 Planning Department ......................................................................................................18
6 Conclusion.............................................................................................................................28
7 Reference...............................................................................................................................28
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Letter of Submission
Dear sir,
It is a great pleasure for me to submit the Apparel Industry Visit report. An Explorative study
on Independent Apparels Ltd. I have acquired vast knowledge during the preparation of this
report. Without sincere co-operation and proper guidance of you it will not be possible for me
to prepare this kind of Apparel Industry Visit report. I have tried my best to gain practical
experiences and also tried to reflect the same in Apparel Industry Visit report. My effort will
be rewarded only if it can satisfy you and exceed your expectation.
It‘s a great pleasure for me to submit you this report within due time. I should be honored if
this report serves its purposes. I am ready to explain anything to you if necessary. I wish your
hearty consideration, if there is any deviation in my report.
Sincerely yours,
Sajjad Hossan
Roll No: 1903087
B.sc (Hon ‘s) Dept. Of Apparel Manufacture & Technology (AMT)
Chattogram BGMEA Institute of Fashion & Technology.
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Student Declaration
I would like to declare that Apparel Industry Visit report result of my extensively study under
the supervision of Imon Biswas Shuva from the Department of Apparel Manufacture &
Technology (AMT), Chattogram BGMEA Institute of Fashion & Technology. It is further
declared that neither this Apparel Industry Visit report not any part of has been submitted for
any degree or diploma. I have tried to complete this report as per many research objectives
and the guidance provided our supervisor.
Besides, I have collected all the real data from the place of my Visit and prepared this report.
As an innovative topic, there may exist certain minor mistake, for which I beg pardon of the
examiners and others readers.
Sincerely yours,
Sajjad Hossan
Roll No: 1903087
B.sc (Hons) Dept. Of Apparel Manufacture & Technology
Chattogram BGMEA Institute of Fashion & Technology
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Letter of Acceptance
This is to certify that, this Apparel Industry Visit report has made by Sajjad Hossan, a student
of Apparel Manufacture & Technology Department, Chattogram BGMEA Institute of
Fashion & Technology bearing ROLL NO: 1903087, has successfully completed his Apparel
Industry Visit report. An Explorative study on Independent Apparels Ltd. Under my
supervision. The candidate has fulfilled the conditions of the resolution regulations
appropriate for the degree of Bachelor of science (Hons) in Apparel Manufacture &
Technology, from the Chattogram BGMEA Institute of Fashion and Technology and the
candidate is qualified to submit this report to apply for that degree.
I have taken care of the study throughout the preparation and strongly approved the style and
contents of this report.
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Acknowledgement
At first, I thanks to Almighty Allah to give me ability and strength to complete industrial
attachment.
The special thank goes to my helpful supervisor Imon Biswas Shuva, Lecturer, Department
of Apparel Manufacture & Technology, Chattogram BGMEA Institute of Fashion &
Technology. The supervision and support that he gave truly help the progression and
smoothness of the Apparel Industry Visit program. The co-operation is much indeed
appreciated.
My grateful thanks also go to sir Engr. Abdul Mannan, principal of Chattogram BGMEA
Institute of Fashion & Technology, for his support and continuous guidance throughout my
long journey in Chattogram BGMEA Institute of Fashion and Technology.
All projects during the program would be nothing without the enthusiasm and imagination of
Merchandising GAP Team at Independent Apparels Ltd. The generous support is greatly
appreciated.
Finally, I express my sincere thanks to all those who have either directly or indirectly helped
me in this industrial attachment.
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Executive Summary
Independent Apparels Ltd is a garments factory in Bangladesh and a GDP contributor. The
factory with all the facilities to manufacture woven & knit product. Here the production
process runs from fabric to finished garment. In this age, Bangladesh is flourished with RMG
sector where this division has its immense contribution. In the whole procedure of exporting
garments to the retailer of abroad and to communicate with them, merchandisers have a great
influence and responsibilities. When, the order is taken from buyer the duty comes to the
floor of merchandisers and before going production they do almost everything to make the
business smooth. The report is originated in result of my Apparel Industry Visit which I have
done as a requirement of B.sc (Hons) program. The report is based on my visit at Independent
Apparels Ltd. under HR Department.
This is an orientation report that contains the real-life day by day working experience of
different tasks in several department of Independent Apparels Ltd. The unique design and
variations of products are researched here by some efficient designers as well as fashion
merchandisers.
In here, at first, I highlighted here general introduction about the company. Secondly, I
discussed about the different sector of the company and briefly discussed about those sectors
that directly and indirectly plays an important role for the company. In this report I have tried
to discuss whole process as I could.
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1 Introduction
1.1 Introduction
RMG (Ready-made Garments) sector is one of the important export sectors in our country.
Bangladesh has emerged as a key player in this sector from the 1978. From this sector,
Bangladesh earns a lot of foreign currency as well as the majority percent of people conduct
their livelihood by this sector. The garment industry of Bangladesh has been the key export
division and a main source of foreign exchange for the last 35-40 years. At present, the
country generates about $36 billion of products each year by exporting garment. The industry
provides to about 4.5 million workers of whom 80% are women. All of us know that, Labor
is the key in this sector. If the target of our nation to achieve $50 billion in 2022, so it’s too
much necessary to ensure proper benefit for them so that they can lead a better life. In the
very beginning, the sector faced a lot of problem like unskilled operator, infrastructure,
foreigner ‘s dependability for technical problem solving, insufficient raw material and
machinery etc. But time to time the total situation changed and the nation grow-up in a
sustainable way in this business. Now, Bangladesh stayed second position in this sector. If it
is possible to keep continuous improvement in this sector, then dream comes into true and we
will achieve the big challenge of $50 billion in 2022.
As I am studying on this technical subject, I believe that by the hard-work I can contribute in
this sector to achieve the challenge of big billion of $50 in 2022.That why, for achieving real
experience of factory, after completing my educational activities I enter into the factory as an
internee. In here, I achieve practical knowledge of different section in garments industry.
From this, I easily realize my knowledge of theory which I achieve from my educational
institute in comparison to practical activities.
1.2 Objective
➢ To know broadly about the Independent Apparels Ltd. & know about the working
process of different department.
➢ To know about the update technology and department in that factory as well as taking
idea about their capability in this department.
➢ To know about the order execution or handling process of the buyer GAP in the
Independent Apparels Ltd.
➢ To find out the critical analysis & the SWOT analysis of Independent Apparels Ltd.
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1.3 Methodology
This report has been completed by taking information from different relevant sources like
company website, employee, working and observing different department in the factory.
However, the total report created based on the real scenario/data of that individual company
which divided into two groups (primary & secondary data)
Primary Data
➢ Questionnaire
➢ Work experience with individual department
➢ Investigation
➢ Having information from their employees like Department Head, others employees.
Secondary Data
➢ For the secondary source/data, data mainly collected from the website of the
Independent Apparels Ltd.
➢ Some apparel related books as well as I also take help from different apparel related
website.
➢ I also get information from different specimen of report which are provided by
Independent Apparels Ltd.
1.5 Limitations
During the visit in this company (Independent Apparels Ltd.), I faced some limitations in
terms of having access to information belonging to the company. As I am a student in that
place, so I did not have access to many information which prevented me from including up a
lot of information and details about certain topics of the report. Although, I worked all the
department of the production process of that company. Although, I had this limitation,
however I have tried my level best to fulfill the objectives of this Apparel Industry Visit
report properly.
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2 Company Profile
2.1 Overview of the organization
2.1.1 History of Independent Apparels Ltd.
Independent Apparels Ltd is a one of a kind RMG factory that has built its foundations on the
principles of putting people and quality first. This company was established in 1997 by SM
Abu Tayyab in Chattogram. Since 1997, They invest most of the time and resources making
sure the factory is up-to-date with all the necessary and current machinery that helps them
maintain lead times and efficiency, while being uncompromising on quality. Independent
Apparels Ltd goes above and beyond its social responsibilities through its various CSR
Campaigns, projects and programs catering to the needs of its stakeholders, including the
marginalized of society at large, employees, customers, etc. Independent Apparels Ltd.
strongly believes that a business has a role in the greater community that extends far beyond
monetary benefits. They are constantly thriving to make Independent Apparels Ltd diverse,
and inclusive for all. We believe in a transparent and sustainable future for all. Here at
Independent Apparels Ltd.
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FIGURE: Logo
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2.1.3 Policies & Procedure
➢ All the employees, customers/consumers and suppliers are behaved with morality.
➢ All types of corruption must be prevented when and where it is occurred.
➢ To recognize the contribution of all workers and help others to contribute.
➢ To ensure the equal facility for all workers and to avoid all types of partiality.
➢ Always ensure the maximum utility of wealth and resources.
➢ To ensure the health care of employees and provide the safe work environment.
Independent Apparels Ltd. is working with leading fashion retailers from US & UK. They
have also started exporting to central / South America. They are exporting new market to
expand diversify our customer base. They are expanding their export base to Asian markets
like China, Hong Kong, Malaysia, Singapore and Thailand.
Its main buyers are: Starter, Russel, Danskin, Hind, Family Dollar, Layer, Pro-player, Tapout, Euro
Soccer, IFG group.
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Buyer Name LOGO Buyer Name LOGO
Starter Layer
Russel Pro-player
Danskin Tapout
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2.2 Organizational Structure
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3 Activities of different Department
In an apparel industry the activities of different department divided into two processes
In the below, chart given by showing all the necessary department in the RMG Industry.
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3.1 Merchandising Department
Merchandising is the bridge between the buyer and the seller. From the order execution to
order shipment the total works process done by this department. According to American
Marketing Association (AMA), merchandising encompasses ―planning involved in
marketing the right merchandise or service at the right place, at the right time, in the right
Quantities, and at the right price‖. In a brief, merchandising is the heart of the garments
sector.
L/C receiving
Line Inspection
Shipment to Buyer
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3.2 Design Department
Aim of Design Department: This is the department where a designer creates unique design
skills to resume fashion sectors competing state in globalizing world and to manufacture high
value-added products. In this context, Design department is thought to be sectors necessities
and aims to gain modern knowledge and skill in denim designing.
Objectives
➢ Understands the importance of modern technologies in fashion industry with the basic
principles in the field of design in denim.
➢ Takes responsibility as an in-Fashion designing at factory, design department, design
studios fashion.
➢ Takes responsibility about planning, marketing and product development of the
factory.
➢ Comprehends the duties and areas of fashion designer in factory.
3.3 CAD Department
CAD means Computer-aided design. In apparel Industry CAD system are mainly used in
making garments design, pattern preparation, pattern grading and marker making. Computer
aided design (CAD) is the use of computer technology for the design of objects, real or
virtual.
Procedure of CAD Department:
Supply to CAD
Sending to Plotter
Send to cutting
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➢ System management.
3.4 Sample Department
In garments Industry, the sample which is come from buyer and it is followed for bulk
production called sample. Generally, in a garments industry the sample department is the
most responsible for execution of an order. Because, if sample department make sample
according to the buyer instruction, then it will achieve the permission of bulk production.
That’s why, we can easily denoted sample department as a heart of production.
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3.6 IE Department
Industrial Engineering department which is the main point of the organization adjoining
which all other operations are carried out. An effective activity of all other departments
depends on the smoother running of the IE department. So the smoother running of the IE
department ensures company’s betterment as well as it ensures higher profit for a company.
Line layout is the most important part during the starting of a new production. Depending on
this line layout the sewing flow in the line will go on. If the layout is not properly planned the
production output of that particular line may not be the same as expected or as per the target.
Here TOYOTA/ZIGZAG system is used in line layout. Factory is using different methods of
line.
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3.9 Maintenance Department
Maintenance is the action taken to prevent a device or component from failing or to repair
normal equipment degradation experienced with the operation of the device to keep it in
proper working order.
Advantages of Maintenance:
➢ To keep the factory plants, equipment, machine tool etc. in optimum working
condition.
➢ To ensures accuracy of product & time schedule to delivery customers.
➢ To minimize downtime of machine.
➢ To prolong the useful life of factory plant & machine.
➢ To improve the factory environment.
Factory Manager/GM
Store Assistant
Labor/Worker
Fabric Inspection system: Fabric inspection system also done in the inventory department.
Here, they check the quality, shade, defect or any type hole which introduce the fabric as a
low quality. Generally, one operator conducts his operation for 2 hours. After 2 hours later,
another operator conducts this operation. This process is highly maintained for the safety of
eye of the operator. They mainly follow these rules for the one shade color fabric like white
fabric.
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3.11 Cutting Department
Functions of Cutting Department:
➢ Examine incoming order.
➢ Determining volumes, size ratio & sectioning procedure for marking marker.
➢ Determining whether the file markers are available or new ones are needed.
➢ Determining specification for optimum marking and fabric utilization.
➢ Determining most effective use of spreading & cutting Department.
➢ Issuing orders for making, spreading & cutting.
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Cutting Room Process Flow Chart:
In cutting department, the fallowing equipment’s are used. These are given below:
➢ Garments Garber technology (G.G.T)
➢ Plotter
➢ Digitizer Board
➢ Fabric cutting Machine
➢ Band Knife Machine
➢ Cutting Table
➢ Metal Hand Gloves
➢ Fabric Inspection Machine.
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Cutting Procedure:
Numbering & send to again sewing section and finally send to washing section for finishing.
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There have several types of printing at Independent Apparels Limited. These are:
➢ Screen printing
➢ Silicon printing
➢ Foil printing
➢ Glitter printing
➢ Discharge printing
➢ Pigment printing
QC Check of product
Line Balancing
Line setup
Online QC check
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3.14 R & D (Washing) Department
The technology which is used to modify the appearance, outlook comfortable and fashion of
the garments is called garment washing. Normally, garments washing means cleaning of dirty
garments with soap or detergent. But it is not that garments washing. Washing is aesthetic
finish given to the fabric to enhance the demand and to provide strength. It is the process
which makes the garments more attractive and unique look. Depending on garments
construction different types of washing process can be done.
Twill / canvas/ knitted -- Normal, pigment, caustic, Silicon wash.
Denim /jeans/gabardine -- Enzyme / stone / bleach /acid wash.
Grey fabric -– Super white wash.
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3.16 Quality Assurance Department
QAD which means the quality assurance department. To carry out all those planned and
systemic actions necessary to provide adequate confidence that product or service will satisfy
given requirements for quality is called to the quality assurance and the department is known
as the quality assurance department. Quality assurance department ensures the best quality
for each department of RMG factory. Such as following:
➢ Store quality
➢ Cutting quality
➢ Sewing quality
➢ In line process quality inspection
➢ Finishing quality
4 Own Creation
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5 SWOT Analysis
5.1 Strength: -
➢ Innovative fashion reproducibility.
➢ Low EMI Score concept
➢ Sustainable: Green product development & utilize it, which are environment free.
➢ Less natural resource like water, energy required due to more use of sustainable wash.
➢ Environment Eco-friendly wash procedure which are more useful for the worker who
works in R & D department.
5.2 Weakness: -
➢ Highly depend on foreigners for update wash technology.
➢ Less Ingredients available.
➢ They depend on foreign wash technician for update wash procedure like laser,
sustainable wash etc. That means, local expert technician is too much poor compared
to demand.
5.3 Opportunities: -
➢ They can create new innovative wash procedure with collaboration of different
competitor ‘s countries through the sharing of experience, manpower or technology.
5.4 Threats: -
➢ Focusing on few renowned buyers.
➢ Production capacity in R & D (Washing) is comparatively less than the competitors.
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6 Conclusion
At last, I can say that the management portion of all departments of Independent Apparels
Ltd. is performing its job efficiently. In fact, the all departments are most important equally to
increase the productivity by low cost and to maintain the well reputation. Beside the
executives are very industrious and serious in performing their jobs. Though there are also
some who are not much committed. The executives hardly try to achieve 90% efficiency. The
organization is maintaining a high-quality work environment in accordance with the labor
Act of Bangladesh. Workers get adequate wages and they get their wages timely. So, the
workers are satisfied and there is no industrial dispute or labor unrest. If the Company
follows the recommendations made in this report, I believe that it can overcome the present
problem. And in the long run the company will be benefited and it may become the market
leader inner future. There is no doubt that Pacific Jeans has created a good reputation in the
market by its quality product and service. It should maintain the quality and try to diverse its
business.
7 Reference
http://www.textileflowchart.com
http://textilelab.blogspot.com
http://www.pacificjeansgroup.com
http://en.wikipedia.org
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