INTERNSHIP REPORT IN MAA-GARMENRT COMPANY 2024

AKSUM UNIVESITY

AKSUM INSTITUTE OF TECHNOLOGY

FACULTY OF TEXTILE
AND
FASHION TECHNOLOGY

DEPARTMENT OF FASHION DESIGN

INTERNSHIP REPORT

CAMPANY NAME;- MAA GARMENT

AND TEXTILE FACTORY

PROJECT TITLE;- GROW UP TOGETHER

CAMPANY ADVISOR NAME;- Mr. YEMANE A.

ACADAMIC ADVISOR NAME;- Mr. TESFAY G.

ID NO.
PREPARE BY ASHEBR NEGA AKU 1209364
YBRAH NEGASH AKU 1300044
MIKIELE HAGOS AKU 1208056

Date of submission 9/21/2024

August, 2024 G.C

AKSUM, ETHIOPIA
 INTERNSHIP REPORT IN MAA-GARMENRT COMPANY 2024

ACKNOWLEDGEMENT

First of all, we would like to thank the almighty God for all the blessings he has given
to me.

Next, we would like to recognize Aksum university and Faculty of textile and fashion
technology for its provision of this curriculum.

We also want to express my deepest gratitude to the project manager (PM) Mr.
Yemane Araya for this great support and guidance throughout the program.

We would also like to acknowledge my universities mentor instructor T. Tesfay

Gebremariam for this guidance and support.

Finally, we would like to express my gratitude to all MAA garment and textile factory
workers for giving full information about this research occupation

i
 INTERNSHIP REPORT IN MAA-GARMENRT COMPANY 2024

DECLARATION/INTERNSHIP CERTIFICATE

The under signed declare to the department of Fashion design in the college of
Faculty of textile and fashion design at Aksum university Adwa campus is that this
final internship report is our own work and all source of materials used to the final
report for internship program has been done. we assure that in my signature this
internship report has not been submitted to the Institute by any other.

Student name signature date 9/17/2024

Ashebr Nega

Ybrah negash

Mikiele hagos

The under signed approve that the above student has completed his internship
program for this time period under supervisor.

Approval of company advisor/supervisor

Name;- Yemane Araya signature; date

Approval of academic advisor/supervisor

Name;- T. Tesfay Gebremariam signature; date

ii
 INTERNSHIP REPORT IN MAA-GARMENRT COMPANY 2024

EXCUTIVE SUMMERY

This report focus on internship at MAA garment & Textile Company. But at the
garment factory it explains detailed and the textile factory is high lightly from the
input of cotton fiber up to the finishing of dyeing. And the other it has company
profile, organization chart, process flow of the company, raw materials, accessories,
and other materials input to the company, source of row material and their main
suppliers, machinery infrastructure in the garment factory and product varieties &
style with picture.

iii
 INTERNSHIP REPORT IN MAA-GARMENRT COMPANY 2024

LIST OF FIGURES
Figure 1.1: Work flow of spinning ............................................................................................ 4
Figure 1.2: Flow chart of knitting.............................................................................................. 5
Figure 1.3: Flow chart of knitting.............................................................................................. 8
Figure 1.4: workflow of planning .............................................................................................. 9
Figure 1.5: flow chart of customers sample order ................................................................... 11
Figure 1.6: Work flow for activities to develop pattern ........................................................... 12
Figure 1.7: Work flow for activities to develop new design .................................................... 13
Figure 1.8: Work flow of production department .................................................................... 16
Figure 2.1: Inspiration board ................................................................................................... 20
Figure 2.2: theme board and mood board ................................................................................ 21
Figure 2.3:motif board and color board ................................................................................... 21
Figure 2.4: fabric board and accessories board ....................................................................... 21
Figure 2.5 Illustration board and flat sketch ............................................................................ 22
Figure 2.6: Story board & client board .................................................................................... 22
Figure 2.7: products ................................................................................................................. 23
Figure 2.8: design one ............................................................................................................ 24
Figure 2.9 : design two ............................................................................................................ 25
Figure 2.10 : design three ........................................................................................................ 27
Figure 2.11: design four........................................................................................................... 30
Figure 2.12: design five ........................................................................................................... 33
Figure 3.1: Printing technique ................................................................................................. 39
Figure 3.2: Electronic weight balance ..................................................................................... 45
Figure 3.3:Measuring mass with an electronic balance ........................................................... 45

iv
 INTERNSHIP REPORT IN MAA-GARMENRT COMPANY 2024

LIST OF TABLES
Table 1.1: materials................................................................................................................... 2
Table 1.2: parameters of cotton ................................................................................................. 2
Table 1.3: trim and accessories .................................................................................................. 3
Table 1.4 : Main customer of the company ............................................................................. 18
Table 2.1 : specification sheet of design one ........................................................................... 24
Table 2.2 : measurement chart of design one .......................................................................... 24
Table 2.3: operation break down of design one ....................................................................... 24
Table 2.4 : bill material of design one ..................................................................................... 25
Table 2.5: direct labor cost & total cost of design one ............................................................ 25
Table 2.6: specification of design two ..................................................................................... 25
Table 2.7 :measurement chart of design two ........................................................................... 26
Table 2.8: operation break down of design two....................................................................... 26
Table 2.9 : bill material of design two ..................................................................................... 27
Table 2.10 : Direct labor cost & total cost design two ............................................................ 27
Table 2.11 : specification sheet of design three ....................................................................... 27
Table 2.12 : measurement chart design three .......................................................................... 28
Table 2.13: operation break down design three ....................................................................... 28
Table 2.14: : bill material design three .................................................................................... 29
Table 2.15: : labor cost design three ........................................................................................ 30
Table 2.16: Total cost design three .......................................................................................... 30
Table 2.17: : specification of design four ................................................................................ 30
Table 2.18: measurement chart of design four ........................................................................ 31
Table 2.19: operation break down of design four .................................................................... 31
Table 2.20:bill material of design four .................................................................................... 32
Table 2.21: direct labor of design four ................................................................................... 32
Table 2.22: Total cost of design four ....................................................................................... 33
Table 2.23: Specification sheet of design five ......................................................................... 33
Table 2.24: measurement chart of design five ......................................................................... 34
Table 2.25: operation break down of design five .................................................................... 34
Table 2.26: bill material of design five .................................................................................... 36
Table 2.27: direct labor of design five ..................................................................................... 36
Table 2.28: total cost of design five ......................................................................................... 36

v
 INTERNSHIP REPORT IN MAA-GARMENRT COMPANY 2024

ACRONYMS

TDF = Tigray defense force

CBE = Commercial bank of Ethiopia
w/c = which
EMB = embroidery
Cons. = consumption
h = hour
min = minute
m = meter
meas. = measurement
allow. = Allowance
kg = kilogram
prod/n= production
TPC = Total production cost
DLC = direct labor cost
TMC = total material cost
4THOL = four thread over lock
SN = single needle
M/c = machine

vi
 INTERNSHIP REPORT IN MAA-GARMENRT COMPANY 2024

TABLE OF CONTENT

ACKNOWLEDGEMENT...........................................................................................................i
DECLARATION/INTERNSHIP CERTIFICATE ......................................................................ii
EXCUTIVE SUMMERY .......................................................................................................... iii
LIST OF FIGURES ................................................................................................................... iv
LIST OF TABLES ...................................................................................................................... v
ACRONYMS ............................................................................................................................ vi
TABLE OF CONTENT ............................................................................................................ vii
CHAPTER 1 COMPANY PROFILE ....................................................................................... 1
1.1 Background ..................................................................................................................... 1
1.3.2 Vision . ...................................................................................................................... 1
1.3.2 Mission ..................................................................................................................... 1
1.3.2 Strategies .................................................................................................................. 1
1.3.2 Management principles ............................................................................................ 1
1.3.2 Objectives ................................................................................................................. 2
1.2 Raw materials and accessories (input material of the company) ..................................... 2
1.3.2 Materials ................................................................................................................... 2
1.3.2 Trim and Accessories ................................................................................................ 2
1.3 Work flow of the company .............................................................................................. 3
1.3.2 Textile factory ........................................................................................................... 3
1.3.2 Garment factory ....................................................................................................... 7
1.3.2 Quality assurance department ............................................................................... 16
1.3.2 Fabric and trim &accessories store ........................................................................ 18
1.4 Main customer of the company ..................................................................................... 18
1.5 Main product of the company (output of the company) ................................................ 20
CHAPTER 2 OUR PROJECT................................................................................................. 20
2.1 Topic – grow up together ............................................................................................... 20
CHAPTER 3 SOLVE PROBLEM .......................................................................................... 36
3.1 How to minimize waste in printing section ................................................................... 36
3.2 How to increase local market ........................................................................................ 46
CHAPTER 4 SUMMERY ....................................................................................................... 48
4.1 learning experience........................................................................................................ 48
4.2 conclusion and recommendation ................................................................................... 48
4.3 Reference ....................................................................................................................... 49

vii
INTERNSHIP REPORT IN MAA-GARMENRT COMPANY 2024

BLANK

viii
 INTERNSHIP REPORT IN MAA-GARMENRT COMPANY 2024

CHAPTER 1 COMPANY PROFILE

1.1 Background
The company KEBIRE ENTERPRISES is a privately owned company established
and registered in April 2001. under the commercial laws of the Federal Democratic
Republic of Ethiopia. MAA Garment and Textile Factory, established in June 2004 in
the northern part of Ethiopia-Mekelle is wholly owned by Kebire enterprises Plc. The
newly established project (MAA TEXTILE) which comprises Spinning, Knitting,
dyeing & finishing is started since 2007.

1.3.2 Vision
To become an exemplary organization in both the local and international textiles
and apparel markets in three years.
1.3.2 Mission

The main mission is to realize vision by generating a reasonable return to the

shareholders through proper utilization of resources and continuous customer
satisfaction.

1.3.2 Strategies

 Develop a strong customer relationship.

 Engage in a continuous product development endeavors.
 Devise and implement methods of reducing cost of production without
affecting
 Quality of products.
 Focus on both local and export markets.

1.3.2 Management principles

 The management should always strive to keep the equilibrium between

company and employees’ interests.
 Senior managers need to spend most of their time at the production floor.
 Communication from top-bottom and vice versa need to be smooth, fast and
effective.

1
 INTERNSHIP REPORT IN MAA-GARMENRT COMPANY 2024

1.3.2 Objectives
To produce high quality wearing apparels that can compete in the international
market

 To attract capital and technological know-how.

 To generate reasonable profit.

1.2 Raw materials and accessories (input material of the company)

1.3.2 Materials
Table 1.1: materials

No. Material units Source

Import local
1 Cotton In kg Middle Awash,
metema
2 Dye stuff Indian, china Adis Abeba
3 Chemicals Indian, china Adis Abeba
Cotton fiber: - currently the company uses cotton fiber only. Most of time there source
of cotton fiber is from middle Awash and the sample tests by the following
parameters: -
Table 1.2: parameters of cotton

No. Parameter Functions Standard of the company

1 Stable To measure the length of cotton For open end spun yarn < 27mm For
length fiber.
ring line spun yarn >27mm
2 Short fiber To measure the No. of short fiber For open end spun yarn > 12%
content in %
For ring line spun yarn < 12%
3 Micronaire To indicate fineness of cotton fiber To take one gram then read the m/c
To measure of the air permeability 3-4.5 pass and less than 3 fail/reject
and maturity
4 Trash To check the amount of dirty in the It must be the trash of cotton ≤3%
content 100gram for sample but it is >3% the cotton is reject
5 Nep tester To measure the amount of nep in If the amount of nep / gram is
one gram ≤200nep/g = accept, If the amount
of nep / gram is >200nep/g = reject
6 Color The appearance of the cotton White color

1.3.2 Trim and Accessories

2
 INTERNSHIP REPORT IN MAA-GARMENRT COMPANY 2024

No. Accessories units Source

Import local
1 Sewing and EMB Thread meter China, India
2 Button Gros Adis Abeba
3 Hang tang Pcs Adis Abeba
4 Poly bag Kg Adis Abeba
5 Main, size & care labels Pcs Adis Abeba
6 Plaster Pcs Adis Abeba
7 Carton Kg Adis Abeba
8 Elastic Adis Abeba
Table 1.3: trim and accessories

1.3 Work flow of the company

1.3.2 Textile factory
1.3.2.1 Spinning
The spinning process capacity is to produce 4 tons of yarn per day with the following:

 4 tons of ring spun card yarn per day by average count of 25.4Ne
 The ring frame machines can produce from 20Ne up to 40Ne (yarn count).
 Rotor spun yarn machine and ring spun combed machines are available in
this company but does not use in this time. because now they haven't a
customer for rotor spun yarn and ring spun combed yarn machines.

The process of spinning is starts from blown room to finishing

In blown room starts the process and take place cleaning cotton fiber and input row
cotton then output chute matt

In carding the chute matt to convert to card sliver

In draw frame the card sliver converts to drawn sliver

In roving the drawn sliver convert in to rove

In Ring frame, the rove converts in to ring cops and wind in winding then finish the
yarn.

3
 INTERNSHIP REPORT IN MAA-GARMENRT COMPANY 2024

Work flow of spinning

Input of cotton fiber

Uni flock

Uni clean

Ring line Open end

Uni mix
Combed Uni mix

Uni flex
Uni flex
Draw frame 1
Condenser
Condenser
Carding Uni loop
Carding
Carded comber
Draw frame 1
Draw frame 1
Draw frame 2
Draw frame 2 Draw frame 2
Roving
Roving winding
Ring frame
Ring frame

Winding Winding

Combed yarn
Carded yarn

Figure 1.1: Work flow of spinning

1.3.2.2 knitting
Knitting is forming of fabric by interloping or intermeshing of yarn.
In maa garment company there are weft knitting machines only.
These machines are

Circular knitting machine or single jersey machine – This machine produces

single jersey, pique(pk) and fleece fabrics.
Rib knitting machine – It produce rib fabric

4
 INTERNSHIP REPORT IN MAA-GARMENRT COMPANY 2024

Interlock knitting m/c –

-It produce interlock fabric.
Flow chart of knitting
-The face of fabric is the same.
Yarn in package form receive from spinning
Flatbed knitting machine –
-It produce collar and cuff fabric. Place the yarn package in creel
Inspection m/c –
Feeding the yarn
-to check quality of fabric.
Set the m/c as per design and GSM

Start knitting

Withdraw the roll fabric and weighting

Roll marking

Transfer Write information or numbering Inspection

to store
Figure 1.2: Flow chart of knitting

1.3.2.3 Dyeing
This plant comprises the latest laboratory & HPHT dyeing Machines & color kitchen.
The HPHT machineries can dye knitted, woven made of 100% cotton & blends. The
laboratory comprises Spectrophotometer, automatic dispenser (data color), sample
dyeing machine, light fastness tester, Crock meter, per pyrometer, shrinkage tester,
washing fastness machine, dryer & light cabinet equipment’s. Dyeing section has a
capacity up to 8.1 tons per day.

Three methods of order

 Swatch fabric  Wave length  Panton number

Panton number – two types

TPX – textile paper number TCX – textile cotton number

Common parameter of dye

 Temperature
 Time
 PH
 Liquor ratio

5
 Dyeing: - in maa garment company they reactive dye and occasionally.

Before dyeing take place pretreatment process

Three types of pretreatment

 Full bleach  Scouring

 Half bleach
Common axillary

 Costic Soda ash – used for remove wax

 Soda ash – used for fixation
 Acetic acid – used for neutralization
 Salt and soap – used for remove dirty material
 (H2O2) – used for wash with skin contact

There are two types of salt – gluber textile salt

-Common salt

At the end we check chemical test

 Washing fastness test  Light fastness test

 Raping fastness test  Perspiration test

Physical test

 Shrinkage test (dimensional test)

 Length test
 Width test
 Spirally test (diagonal rotation of the fabric)

Difference b/n fading and bleeding fastness test

Fastness – color fastness (poor resistance of )

Fading test – loose of color intensity

Bleeding test – excess bleeding of dyed from the fabric (especially during wash)
Dye stain – unwanted mark happens on the fabric (discolor on the fabric)

6
There are four machines in dyeing
Machine A – this is the first machine and it uses test for the grey (undyed) fabric and this
is one machine. It holds 150 KG – 200 KG
Machine B – there are two machines under machine B and it holds from 300 KG – 350
KG grey fabric.
Machine C – there are three machines under machine C and it holds from 400 KG – 450
KG.
Machine D – there are five machines under machine D and it holds from 700 KG – 750
KG.
Corino (slit) machine – it used to cut(slit) for the fabric and use spread for fabric by
absorbing the fabric.
Dryer machine – it uses dry for the fabric when that comes from Corino(slit) machine.
Compacter machine
 it uses to ironing  Width decreases
 GSM increase  Crease mark – off set
 Hand feeling smooth
1.3.2 Garment factory

1.3.2.1 marketing department

Marketing is the process of communicating the value of company product or service to
customers and they determine a customer for the wastage fabric. These are stands to
make good profitable for the company and to produce a good quality garment for the
customer.

In marketing department there are three departments these are marketing, merchandise
and supply. But during this time, they work together in one.
The main function of marketing department is
 To bring customers  To prepare costing
 To communicate with customers

7
 INTERNSHIP REPORT IN MAA-GARMENRT COMPANY 2024

Marketing works flow

Order necessary material for
Pricing process production and follow up

Confirmed price Start production and follow up

Sample process Make sure goods ready for shipment

Confirmed sample
Prepare document for shipment
(Way bill, PL and invoice
Get customer issue po

Ship out goods

Arrange delivery

Open LC or sign contract

Figure 1.3: Flow chart of knitting

1.3.2.2 planning department

In planning department there are three sub department these are;

 IE = industrial engineering, the main function of IE are;

 Timing
 Line balancing
 Machine layout
 Textile planner; the main function of textile planner are;
 He invents from spinning to dying order and go up to store fabric
 Garment planner, the main function of garment planner are;
 He invents from cutting to finishing order

8
 INTERNSHIP REPORT IN MAA-GARMENRT COMPANY 2024

work flow of planning department

Received POS from

merchandizing division

Calculate necessary Schedule the time of starting Determine the

materials for the specific & delivery depending on line to be
order daily out assigned for the

Request for the purchase the

Control daily cut Control daily Control
material non available on
output & daily input
store
make daily
Consolidate with
Checking for the material POS Qty Summarize the data in
arrival to the factory the input
Checking the
Check and take
Communicate with consumption by
action the balance to
commercial dept. for the comparing with the plan
input the garments
purchasing of the material consumption per pieces

Report to the
Action taken if consumption is exceeded concerned department
than the approved consumption for the

Figure 1.4: workflow of planning

1.3.2.3 Design and sample department

This Department has a major role in getting market by making the required product
practically as per the customer's requirement.
This department the measurement uses from specific measurement sheet, most time of
receipt from customer and sometimes develop from own measurement sheet.
In design room uses manual and digitalized pattern making
Manual pattern making methods; pattern making, pattern grading and pattern marking
makes by hand in hard copy paper and it is time consuming method and difficult for
working.
Digitalized pattern making;
 Gerber technology version 8.1 CAD software
This uses to develop, making pattern, grading pattern and making marker. In addition,
this software is capable to manage auto consumption maker with good marker efficiency,

9
 INTERNSHIP REPORT IN MAA-GARMENRT COMPANY 2024

can manage markers for strip & check fabrics and also can make markers for tubular
fabrics.
 DB IV 3648 model digitizer
Uses to digitalize (insert the customer's original pattern to their computer), Sometimes
customers need to use their own pattern so they must first digitize the customer's pattern
to fulfill the customers need and uses for further grading and making marker. While they
digitalize one pattern exact shape and size will be created in their computer that means
the customers pattern (hard copy) inserted to their computer (changed to soft copy).
 P2000 model plotter
The plotter takes a paper in a roll form with a maximum weight of 32Kg and maximum
width of 180cm. We use this plotter for production making markers or the digitalized
marked pattern convert to hard copy.
Objective of the Department
 To Make MAA Garment & Textile factory one of the best competent and
profitable factory in the world garment market by satisfying their customer with
the ordered samples in quality & delivery.
 To rich the world’s bench mark and be best competitor in marker efficiency
(consumption making) since this affects highly in price quotation of products.
 To use resources efficiently especially ruminant fabrics and accessories from
production by developing new & demandable designs for local and export.

Main function of the department

 Making consumption of materials for any garment which uses for pricing &
production.
 Developing, grading pattern for sample making & production.
 Making samples for customers.
 Developing new designs for local sales
Activities performed for making consumption of a garment
Receipt of consumption order sheet
Consumption order sheet will be received from merchandising. The Consumption Order
Sheet should have: -
 Technical file of the item which includes measurement chart, fabric construction
(knitted), diagram of the item if complicated & detail accessories that item
require
 GSM (gram per meter square) of the fabric

10
 INTERNSHIP REPORT IN MAA-GARMENRT COMPANY 2024

 Width of the fabric that they are going to use

 Order breaks down by size and quantity.
The activities to make consumption of garment looks like as follows.
Merchandising prepares consumption order sheet
Required information fulfills? If no return to the above
Develop pattern
Make consumption
Fill to format (MAASPD- 01) & sign by the head
Give the consumption to merchandising
Flow chart of customers sample order
Receive sample order sheet from marketing
Request merchandising to
NO resend the pattern
Required information fulfills?
YES
Is the pattern from customer? yes NO
Is it soft copy? yes Is it Compatible to our
NO NO yes
Develop pattern as per Is it customer's fabric?
technical file or original Digitize and plot
sample then check
Get shrinkage report and adjust the pattern accordingly yes

Request and get fabric as per merchandising information

NO
Cut fabric & make sample

Self-check and correct if any problem Hand over to QAD

yes fail pass

Rework Can be reworked? Pass or fail? Hand over to
finished goods
NO store
Identify problem and correct whatever correction

Figure 1.5: flow chart of customers sample order

11
 INTERNSHIP REPORT IN MAA-GARMENRT COMPANY 2024

To see the work flow for the activities divide it in to two ways
Work flow for activities to develop new design pattern from production ruminant
Discuss with Merchandising order sample or POS
merchandising Get customer comment.
Is there technical file? shrinkage report from QC
NO
yes
Is there original
Is the pattern for Digitize the pattern w/c
sample
production or sample? made for sample
Sample
Check required sample size Adjust the pattern as per the
customers comment and shrinkage
Develop pattern
Grade the pattern as per the order ratio

Add seam allowance & shrinkages if required

Plot
Make templates and finished patterns
Check the plotted is it ok with QC
Hand over to sample room and adjust
if there are comments by discussion Make marker
Figure 1.6: Work flow for activities to develop pattern

work flow for developing new designs from stocked fabrics in the store:
The initial point for the work flow of developing new designs from stocked fabric is an
idea generated from the department. This has four main targets

 To convert stocked materials to money

 To develop skilled the Designer, Sample makers, Operators
 To increase performance of factory
 To add impression on customer fand develop good image of the company.

Fabric swatches will be collected from stocked fabrics and categorized as per color,
texture and fabric type for men, women and kids to be collected from stocked fabrics and
set in computer then by applying the same color of the fabric swatches color combination
will be done in the computer.

12
 INTERNSHIP REPORT IN MAA-GARMENRT COMPANY 2024

Work flow for activities to develop new design from stocked fabric
Check fabric from stoke or from cutting wastage to D/G/Manager

Collect fabric swatch from stoke Check west fabric from cutting

Category by color, fabric type & Measure the wastages width & length
texture to men, women & kids
Category the fabric for men.
Create ideal design women or kids

Sketch in computer & select color

Develop pattern

Check over look & fitness?

Make consumption

Give marketing for POS preparation

Figure 1.7: Work flow for activities to develop new design

1.3.2.4 Production department

In production works and finished it the garment and it includes five sections these are;
4.1 cutting section: It is the first stage for garment manufacturing and pattern making is
the base

Garment section first specific sheet (size wise, fabric consumption, color, GSM, fabric
type, delivery date) receive from marketing. It includes the following parts;-

A. Mini marker: this makes by the mini marker maker depending on the width of the
fabric and ratio of the product order (order sheet). It makes by the Gerber s software and
prints by Gerber plotter.

B. Spreading: the object of spreading is to phase the number of plies fabric that the
production

planning process has dictated

13
 INTERNSHIP REPORT IN MAA-GARMENRT COMPANY 2024

To the length of marker plan

In the color required

Correctly aligned as to length and width

Adequate tension (neither strength nor slackness in the fabric layer)

C. Marking:

They follow two types of markering system. These are

 Manual  Computerized

D. Cutting: There are two type cutters

1, handle cutter (straight knife); it uses to cut the large amount of pieces or patterns

2. band knife; there are two in number they use to cut the small patterns

E. Numbering; -it uses to control the color variation and size wise for the pieces at the
numbering system for each layer of pattern the starting and end number is the same
unless if they are different, they understand there is mistake on numbering

G. Bundling: Is the selection of the pattern component in one garment which means if
the garment is t-shirt they select sleeve, back and front body, rib. and they attaché an
information card on the bundled fabric.

H. Fusing: It is the attachments of the printed paper by the Gerber plotter to the layer
fabric Stoke shelf: -it is the place which uses to put the bundled pieces.

4.2 Embroidery section

The embroidery includes under cutting section to start embroidery They receives product
order from planning, the design comes from customer by the soft copy or hard copy. If it
is hard copy, they make scan and arrange. its size In MAA garment factory the
embroidery makes by the computer which have wilcomsoft ware.

MAA garment company have two type of embroidery machines. These are

Barudan: It have 20 heads and also in each head it has 9 needles for nigh color variation.

14
 INTERNSHIP REPORT IN MAA-GARMENRT COMPANY 2024

tajuma there are four machine each machine has 10/10/1/1, heads respectively and also
in each machine head there are nine needles for nine color variation.

4.3 printing section

In MAA garment factory they use screen printing. The design comes from customer then
they design it by depending the customer order. For this design they use adobe Photoshop
software after they finish the design, they prepare the pigments.

They use two types of color: 1, pigment 2. plastisol

4.4 sewing section

They receive the product order from planner and their job starts from the input of bundled
piece (the end processes of cutting section) and the accessories from satellite store. The
machine prepared by the order of the customer (depending on its layout).

In MAA garment factory currently, they use two types of layouts to construct a garment
1." Z "layout 2. "I" layout
Types of machines currently uses

 Single needle lock and  Inter lock m/c  bar tuck m/c
chain stich m/c  Button attach m/c  Flat lock m/c
 4 Thread over lock m/c  Buttonhole m/c  Chain stitch m/c
 3 Threads over lock m/c  pippin m/c
4.5 finishing section

Is the applying of necessarily things like trim, ironing, folding, measuring. packaging for
the manufactured garment.

Packing: -It is the inserting of fabric to the poly bag. in this the uses two types of poly
bag depending on the customer order. These are

 Individual poly bag: -this only one cloth is inserts to one poly bag.
 master poly bag: - in this poly bag they inset more than two cloths to one poly
bag. The master poly bag makes in two ways as per the customer order.
o The poly bag w/c has from 1-5 pcs o The poly bag w/c has from 30-

15
 Packaging: -It is the insert or posting of the poly bag to the box (carton).in MAA garment
factory They uses different types of packaging system.

 Solid packing  Mixed packing

Assortment: - In this they insert the poly bag which has different garments.

Auditing: -is the checking of packed as per customers order, maybe it is 3%,15% or 20%

Work flow of production department

Receive POS from Receive pattern from design room Receive fabric and
marketing accessory from store

Mark Layering Relax Check the fabric with POS like size, color, GSM…

. Bundling
Cutting Numbering QC check Transfer to line (sewing)

QC check Sewing
Ironing Packing QC check Trimming

Transfer to finished goods store audit by customer or company Louding

Figure 1.8: Work flow of production department

1.3.2 Quality assurance department

These are works at all garment process even though at every section (from spinning to
packaging) to check the quality of the product.

In MAA GARMENT company uses four-point system for the defects

Four-point system

The 4-point system derives its name from the basic grading rule that a maximum of four
penalty point can be assessed for any single defect and that no linear method meter can be
assigned more than four points regardless of the number of defects within that piece.

The standard penalty point evaluation of maa garment some are;

 Hole, pross of, needle hole, stain…they give 4 points

16
 INTERNSHIP REPORT IN MAA-GARMENRT COMPANY 2024

 Slab, contamination…they give 1 point

Formula= 91.44m*D/L D=No of defects L= total length

If the result is less than or equals to 40% It is ‘A’ grade

If the result is greater than 40% it is rejected by the standard of this company

1.Quality check of yarn

In spinning to check;- -Card sliver, drawn sliver, rove, cops & yarn counts

-Cv, thickness, thinness of yarn

Spinning quality two types of machines to check the product these are

To measure count of yarn by two systems direct and indirect measurement

Direct system is used for the measurement of weight per unit length of yarn.
When count increases, fineness decreases. ( count↑ fineness↓ )
Commonly used units in this system of measurement are:-
 Tex (1g/1000m), tex=1000*weight(g)/length(M)
 dtex (grex)/deci-tex (1g/10000m), dtex=10000*weight(g)/length(M)
 denier (1g/9000), denier=9000* weight(g)/length(M)

Indirect system is used for the measurement of length per unit weight of yarn.
When count increases, fineness increases. (count↑ fineness↑ )

Commonly used subsystems of indirect system are:-

 English system (Ne)(Ne=1hank/1b), Ne=length(yard)/840*weight(lb)
 Metric system (Nm)(Nm=1km/1kg), Nm= length(m)/weight(g)
To measure cv, thickness and thinness of the yarn

The main defects of spinning QC

 Thickness and thinness place  Contamination

 Yarn mixed
2.Quality check of knitting

In knitting they had one inspection machine

The main defects are;

17
  Pin hole  Contamination  Oil stain
 Pross hole  Shade variation  Slip
 Needle line  Yarn variation  Thick and thin
 Sink mark  Lycra jump place

3.Qaulity check of dying

In dying quality check uses one inspection machine and In dying quality to check the
GSM of the fabric.

Common defects of dying

 Dye unlevel  Shade variation  Width variation

 Oil station  White batch  Dark mark

4. Quality check of production

A. Quality check of cutting section :-The main defects are

 Color variation  N/line  GSM

 Stain  Folding  Salvage
 L/jump  Hole  uneven

B. quality check of embroidery section:- Common defects of embroidery

 shrinkage which makes by the  Color of thread

slackness of the frame  Design & Size of embroidery

C. quality check of sewing section:- the common defects of sewing section are

 Uneven stitching  Thread tension issues  Irregular hemming

 Broken or skipped  Untrimmed threads  Improper buttonholes
stitching  Incorrect SPI  Uneven parts

D. quality check of finishing section :-the common defects of finishing section are

 unwanted mark on the fabric  pine holes

 missed zipper teeth  water spots
 button threads missing

18
 1.3.2 Fabric and trim &accessories store
1.3.2.1 Fabric store
This store uses to put the dyed fabric. In the fabric store to receive the fabric they check it
by inspection machine. After finish the inspection they attach an information card to the
fabric. This information card has

 received date  inspected by  customer name  fabric type

 color  width of fabric  length  GSM
 grade of fabric  batch no  roll no
Verity of fabric at fabric store

 single jersey  Lycra single jersey  Collar and cuff

 single pique  fleece
 Rib fabric  double pique
1.3.2.2 Trim &Accessories
These are the most important to decorative or functional purpose for the garment. Those
accessories are buy by the agreement of the company and its customer, in the accessory
store there are so many types of accessories are present. From those

 Button d/t types  Elastic d/t types  Hangtag  Poly bag

 Hanger  Care label  Size label  Main label
 Zipper d/t types  Cartoon  Stickers
Thread: -it uses for stitching purpose. There are two types of thread in MAA garment factory.

 Sewing thread: -It uses to sewing purpose for the garment. It made from 100%polyester
 Embroidery thread: -It uses to make embroidery at the garment. It is made from
mercerized cotton and poly ester & it has lustrous behavior

1.4 Main customer of the company

Currently the company uses local market and currently local customers are the following
Table 1.4 : Main customer of the company

No Customer Description Quantity No Customer Description Quantity

1 TDF T-shirt 100000 4 HA Uniform 800
2 CBE polo shirt 2000 5 Abel Kids polo 30000
3 Awash bank Polo shirt 2500 abraha shirt

18
 INTERNSHIP REPORT IN MAA-GARMENRT COMPANY 2024

1.5 Main product of the company (output of the company)

 T -shirt  Polo shirt  yarn
 Dyed fabric  Gray fabric (undyed)

CHAPTER 2 OUR PROJECT

2.1 Topic – grow up together
Objective
 To develop our skill
 To increase fabric utilization
Definition: - meaning of the topic is using together that means we use to develop our intensity
and skills for us. While the company to uses how to understand utilization of waste material. For
example the waste material utilize by two or more waste pcs make get together and the large size
wastes to change or down grade to the small sizes and it can produce amazing and impressive
garment.
Inspiration board
Our inspiration is bird. We took different color and style from the bird. The reason we made this
type of clothing is that it is useful for summer and winter and by our research in and around
mekelle it is we assumed that people in this area could easily use it.

Figure 2.1: Inspiration board

20
 INTERNSHIP REPORT IN MAA-GARMENRT COMPANY 2024

Theme board Mood board

Figure 2.2: theme board and mood board

Motif board Color board

Figure 2.3:motif board and color board

Fabric board Trim and accessories board

Figure 2.4: fabric board and accessories board

21
 INTERNSHIP REPORT IN MAA-GARMENRT COMPANY 2024

Illustration board Flat sketch board

Figure 2.5 Illustration board and flat sketch

Client board
Story board

Figure 2.6: Story board & client board

22
INTERNSHIP REPORT IN MAA-GARMENRT COMPANY 2024

Our products

Figure 2.7: products

23
 INTERNSHIP REPORT IN MAA-GARMENRT COMPANY 2024

Specification sheet of design one

Table 2.1 : specification sheet of design one

Style No Maa-006
Description Mans’ raglan t-shirt,
Inspiration & size Bird & Medium
Fabric type Single jersey
Collar type Round neck
Color Red, blue and yellow
Season Autumn
Specific finishing Trimming
Customer Ethiopian man
Age group &Gender 10-40 & Men
Category Causal wear Figure 2.8: design one
Measurement chart
Table 2.2 : measurement chart of design one

Pcs Unit Meas. Allow. Pcs Unit Meas. Allow.

Body length Cm 71 +2 Sleeve opening Cm 33 +2
½ chest Cm 48 +2 Rib length Cm 1.5 +1
Neck width Cm 18 -2 Pippin length Cm 3.175
Back neck drop Cm 2 A Cm 3 +1
Front neck drop Cm 9.5 B Cm 21 +2
Sleeve length Cm 30 +5 C Cm 24 +1
Biceps Cm 42 +2 D Cm 44 +3
GSM Single jersey g/m2 160 Rib g/m2 240
Operation Break down
Table 2.3: operation break down of design one

M/c type Operation Unit Meas. M/c type Operation Unit Meas.
4 THOL Back sleeve attach cm 62 Interlock Bottom hemming cm 102
4 THOL Front sleeve attach cm 58 SN Sleeve hemming cm 48
SN Sleeve decorative cm 104 4 THOL Rib cm 52
4 HTOL Body decorative cm 202 SN Top stitch at back cm 21
with body rib
4 THOL Side seam cm 44 Pippin Back rib cm 21
Bill of material

24
 INTERNSHIP REPORT IN MAA-GARMENRT COMPANY 2024

Fabric one consumption (red color), Con/n in kg = length*width*GSM + wastage

= [[73cm*50cm*2*160g/m2 ]/10000000]+3%=0.117kg
Fabric two consumption (blue color), Con/n(kg)=length*(width+ biceps) *2 *GSM + wastage
=[[47cm*(50cm+44cm) *2*160g/m2 ]/10000000]+3%=0.1456kg
Fabric three consumption (yellow color), Con/n in kg = length*width*GSM + wastage
= [[23cm*8cm*2*160g/m2 ]]/10000000+3%=0.0062kg
Fabric 4 consumption (red color) rib, Con/n in kg = length*width*GSM + wastage
= [[1.5cm*46cm*300g/m2 ]/10000000]+3%=0.0021kg
Table 2.4 : bill material of design one

Material Material Color Cons. Cost Trim & Color Cons. Cost
name description in kg accessories in m
Fabric 1 Single jersey Red 0.117 58.5 Sewing Blue 12.5m 0.188
Fabric 2 Single jersey Blue 0.146 72.8 thread Red 79.1m 1.1863
Fabric 3 Single jersey Yellow 0.006 3.1 Yellow 2.97m 0.0445
Fabric 4 Rib Red 0.002 1.28 Label 1 pcs 0.1
Total material cost 139.2
Table 2.5: direct labor cost & total cost of design one

Cost center S.A.M Wage / h Cost in Cost of Cons. Cost in birr:

(actual) in birr birr comp.
Pattern maker 30 38.46 19.23 TMC 136.2
Marker making 8 18 3.2 DLC 98 mi 36.854
Cutting 10 28.8 4.8 OHC 20% of DLC= 7.4
Sewing 40 14.4 9.6 TPC 180.4
Finishing 10 14.4 2.4 Profit TPC +30%
Total 98 114.06 36.854 Selling p. 234.52

Specification sheet of design two

Table 2.6: specification of design two
Style No Maa-007
Description women’s t-shirt, have
decorative at bottom
Inspiration & Season Bird & Autumn
Fabric type & Size Single jersey & Medium
Color Red, black & blue
Specific finishing Trimming
Customer Ethiopian women
Gender & Age group Women &15-40
Category Special wear

Figure 2.9 : design two

25
 INTERNSHIP REPORT IN MAA-GARMENRT COMPANY 2024

Measurement chart
Table 2.7 :measurement chart of design two

Pcs Unit Meas. Allow. Pcs Unit Meas. Allow.

Body length Cm 65 F=+5 Pippin length cm 3.175
B=+2
½ chest Cm 47 +2 Decorative cm 26
line(F) length
½ waist cm 45 +2 Decorative(G) cm 19.5 +2
length
½ bottom cm 48 +2 Decorative(G) cm 8 +2
width
Across shoulder cm 40.5 +2 A cm 41 +1
Neck width cm 17.5 -2 B cm 30 +1
Back neck drop cm 2 C cm 33 +1
Front neck drop cm 9.5 D cm 42 +1
Sleeve length cm 26 +2 E diameter cm 4 +1
Biceps cm 40 +2 H cm 26 +1
GSM g/m2 160
Operation Break down
Table 2.8: operation break down of design two

Machine type Operation Unit Quantity or

measurement
Single needle Bottom front body hemming cm 158
4 Thread over lock Top & bottom front body attach cm 108
4 Thread over lock Bottom & top back body attach cm 57
Single needle Top stitch on back body cm 55
4 Thread over lock Right shoulder attach cm 15
Piping Neck circumference cm 56
4 Thread over lock Left shoulder attach cm 15
4 Thread over lock Sleeve attach (armhole) cm 100
4 Thread over lock Side seam cm 107
Pippin Decorative line(F) cm 52
Single needle Specific decorative(G&E) cm 236
Single needle Decorative with body attach cm 14
Interlock Back bottom hemming cm 63
Interlock Sleeve hemming cm 100
Bill of material
Fabric one consumption (blue color) Con/n in kg = length+ sleeve length*width*GSM + wastage
=[[(39cm+28cm) *50cm*2*160g/m2 ] /10000000]+3%=0.11kg

26
 INTERNSHIP REPORT IN MAA-GARMENRT COMPANY 2024

Fabric two consumption (red color), Con/n in kg = length+ sleeve length *GSM + wastage
= [[63cm*50cm*2*160g/m2 ] /10000000]+3%=0.1kg
Fabric 3 consumption (black color), Con/n in kg = length+ sleeve length*width*GSM + wastage
=[[6cm*6cm*4*160g/m2 ]/10000000]+3%=0.0023kg
Table 2.9 : bill material of design two

No Material name Material Color Consumption in Cost in birr

description kilogram
1 Fabric 1 Single jersey Red 0.1 50
2 Fabric 2 Single jersey Blue 0.11 55
3 Fabric 3 Single jersey Black 0.0023 1.152
Trim and accessories
4 Thread Sewing thread Blue 51.24 0.7686
Red 104.35 80.2034
Black 1.7 0.029
5 Label 1 0.1
Total material cost 187.3
Direct labor cost Total cost
Table 2.10 : Direct labor cost & total cost design two

Cost center S.A.M Wage / h Cost in birr Cost of comp. Cons. Cost in birr
Pattern maker 120 38.46 76.92 TMC 187.3
Marker making 12 18 3.6 DLC 239 min 112.2
Cutting 15 28.8 7.2 OHC 20 %of DLC
22.44
Sewing 90 14.4 21.6 TPC 321.94
Finishing 12 14.4 2.88 Profit TPC+30%
Total 239 148.96 112.2 Selling p. 418.5
Specification sheet of design three
Table 2.11 : specification sheet of design three

Style No Maa-008
Description Women’s blouse
Inspiration Bird
Fabric type 2 2 rib & single jersey
Size & season Large & summer
Color Drow cord & anthracite
Specific finishing Trimming
Customer Ethiopian women
Age group 20-40
Category Special wear
Figure 2.10 : design three
27
 INTERNSHIP REPORT IN MAA-GARMENRT COMPANY 2024

Measurement chart
Table 2.12 : measurement chart design three

Pcs Unit m/t Allow. Pcs Unit M/t Allo

w.
Full Front cm 93 +1 Small Decorate sleeve length * width cm 10*8.5 +2
length Back cm 114 +1 Large decorate sleeve length *width cm 10*11 +2
A cm Body decorative length * width cm 13.5 *4 +2
½ chest cm 51 +2 A cm 32 +2
½ waist cm 42 +2 B cm 40
½ hip cm 55 +2 ½ Biceps cm 22 +2
Across shoulder cm 22 +2 Sleeve opening cm 58 +2
Neck width cm 9.5 GSM 2 by 2 g/m2 230
Back neck drop cm 2 Single jersey g/m2 160
Sleeve length cm 32 +1
Operation Break down
Table 2.13: operation break down design three

Machine type Operation Unit measurement

4 Thread over lock Bottom front body hemming cm 146
4 Thread over lock Bottom & top back body attach cm 58
Single needle Top stitch on back body cm 58
Single needle Back rib hem cm 22
4 Thread over lock shoulder attach cm 38
4 Thread over lock Sleeve attach(armhole) cm 110
Single needle Sleeve decorative cm 400
Single needle Body decorative cm 360
4 Thread over lock Side seam up to back bottom hemming cm 190
4 Thread over lock Sleeve hemming with sl. Decorative cm 148
Single needle Top stitch back bottom hemming cm 58
Single needle Top stitch sleeve hemming cm 148
Single needle Front body tuck cm 18.5

28
 INTERNSHIP REPORT IN MAA-GARMENRT COMPANY 2024

Bill of material
Fabric one consumption (brown color ), Con/n in kg = length+ sleeve length+ back top
body*width*GSM + wastage
=[[(100cm+36cm +34)*70cm*230g/m2 ]/10000000]+3%=0.28kg
Fabric two consumption (anthracite color), Con/n in kg = length+ sleeve length+ length back top
body*width body +width body front*GSM + wastage
=[[(100cm+36cm )*(70cm+84cm)*230g/m2 ]/10000000]+3%=0.48kg
Fabric 3 consumption (red color), Con/n in kg = length*width *GSM + wastage
=[[15.5cm*13cm*22*160g/m2 ]/10000000]+3%=0.09kg
Fabric 4 consumption (blue color), Con/n in kg = length*width *GSM + wastage
=[[15.5cm*13cm*20*160g/m2 ]/10000000]+3%=0.09kg
Fabric 5 consumption (red color), Con/n in kg = length*width *GSM + wastage
=[[15.5cm*13cm*18*160g/m2 ]/10000000]+3%=kg
Table 2.14: : bill material design three

No Material name Material Color Consumption Cost

description in kilogram
1 Fabric 1 2 2 rib brown 0.28 148.4

2 Fabric 2 2 2 rib Anthracite 0.48 254.4

3 Fabric 3 Single jersey Red 0.09 45
4 Fabric 4 Single jersey Blue 0.09 45
5 Fabric 5 Single jersey yellow 0.059 29.5
Trim and accessories
4 Thread Anthracite 7.242 0.11
Sewing thread Brown 5.919 0.088
Yellow 0.287 0.0043
Red 0.363 0.0054
Blue 0.363 0.0054
5 Label 1 0.1
Total material cost 522.5

Direct labor cost

29
 INTERNSHIP REPORT IN MAA-GARMENRT COMPANY 2024

Table 2.15: : labor cost design three

Cost center S.A.M Wage / Cost in birr Cost S.A.M Wage / Cost in
h in birr center h in birr birr
Pattern maker 60 38.46 38.46 Sewing 90 14.4 21.6
Marker making 10 18 3 Finishing 12 14.4 2.88
Cutting 10 28.8 4.8 Total 182 114.06 66
Total cost
Table 2.16: Total cost design three

Cost of component Cons. Cost in birr Cost of component Cons. Cost in birr
Total Materials cost 522.5 Total prod/n cost 601.7
Direct labor cost 182min 66 Profit TPC+ 15%
Overhead cost 20% of DLC=13.2 Selling price 692

Specification sheet of design four

Table 2.17: : specification of design four
Designer name Ashebr nega, Ybirah negash
&Mikiele hagos
Style No Maa-009
Description Women’s pant
Inspiration Bird
Fabric type fleece
Size Medium
Color Red, sky blue & yellowish orange
Season Summer
Specific finishing Trimming
Customer Ethiopian women
Gender Women
Age group 14-40
Category casual wear
Figure 2.11: design four

30
 INTERNSHIP REPORT IN MAA-GARMENRT COMPANY 2024

Measurement chart
Table 2.18: measurement chart of design four

Pcs Unit Meas. Allow. Pcs Unit Meas. Allow.

Length waist to bottom cm 97 +6 ½ hip cm 49 +2
½ waist cm 42 +2 A cm 80 +5
Crotch depth cm 26 +1 B cm 51 +5
Bottom opening cm 42 +4 C cm 19.5
Front pocket length cm 25 +9 D cm 73 +3
Front pocket width cm 32 +2 E cm 9 +2
Elastic length cm 4 GSM g/m2 230
Operation Break down

Table 2.19: operation break down of design four

Machine type Operation Unit Meas.

4 Thread over lock Back top at side seam with bottom attach Cm 74
4 Thread over lock Front top at side seam with bottom attach Cm 71
Single needle Pocket attach Cm 55.5
Single needle Top stitch at pocket Cm 55.5
4 Thread over lock Pocket Cm 38
4 Thread over lock Top back at center with bottom attach Cm 192
4 Thread over lock Top front at center with bottom attach Cm 184
4 Thread over lock Side seam Cm 221
Button hole Button hole Cm 1.5
Single needle Elastic tuck Cm 20
4 Thread over lock Elastic attach first Cm 88
Inter lock Elastic attach finish Cm 88
4 Thread over lock In seam Cm 159
Inter lock bottom hemming Cm 90
Bill of material

31
 INTERNSHIP REPORT IN MAA-GARMENRT COMPANY 2024

Fabric one consumption (red color), Con/n in kg = length*width *GSM + wastage

=[80cm*19.5.5cm*4*230g/m2 ]/10000000]+3%=0.08kg

Fabric two consumption (sky blue color), Con/n in kg = length*width *GSM + wastage
=[73cm*25cm*4*230g/m2 ]/10000000]+3%=0.08kg
Fabric 3 consumption (Yellowish orange color), Con/n in kg = length*width *GSM + wastage
=[51cm*11cm*4*230g/m2 ]/10000000]+3%=0.173kg
Table 2.20:bill material of design four

No Material Material Color Cons. in kg Cost in birr

name description
1 Fabric 1 Fleece Red 0.19 104.2
2 Fabric 2 Fleece Sky blue 0.173 95.15
3 Fabric 3 Fleece Yellowish orange 0.053 29.2
Trim and accessories
4 Thread Sky Blue 7.546 0.113
Sewing thread Red 17.562 0.265
Yellowish orange 3.938 0.059
5 Elastic Black 29cm 5
6 Drow cord 10
7 Label 1 0.1
Total material cost 224
Direct labor cost
Table 2.21: direct labor of design four

Cost center S.A.M (actual) Wage per hour in birr Cost in birr
Pattern maker 60 38.46 38.46
Marker making 11 18 3.3
Cutting 10 28.8 4.8
Sewing 89 14.4 21.36
Finishing 10 14.4 2.4
Total 180 114.06 70.32
Total cost

32
 INTERNSHIP REPORT IN MAA-GARMENRT COMPANY 2024

Table 2.22: Total cost of design four

Cost of component Consumption Cost

Total Materials cost 224
Direct labor cost 180min 70.32
Overhead cost 20% of DLC=14
Total production cost 308.4
Profit TPC+30%
Selling price 400.92
Specification sheet of design five

Figure 2.12: design five

Table 2.23: Specification sheet of design five

Style No Maa-009
Description & Season Men’s double face & Summer
Inspiration & Color Bird & Red, sky blue & yellowish orange
Fabric type & size fleece & Medium
Specific finishing Trimming
Customer Ethiopian women
Gender & Age group Women &14-40
Category casual wear

33
 INTERNSHIP REPORT IN MAA-GARMENRT COMPANY 2024

Measurement chart

Table 2.24: measurement chart of design five

Pcs Unit Measurement Allowance Pcs Unit Measurement Allowance
Full length cm 63 +2 A cm 4
Across shoulder cm 48 +2 B cm 18.5
½ chest cm 52 +2 C cm 13
½ bottom hemming cm 48 +2 D cm 6
Neck width cm 20 -2 E cm 9.5 +1
Back neck drop cm 2 F cm 19 +2
Front neck drop cm 10 G cm 3 +2
Armhole straight cm 23 H cm 6 +1
Sleeve length cm 53 +2 K cm 23 +2
Sleeve opining cm 25 +2 L cm 3 +2
Cuff width cm 21 +2 M cm 6 +1
½ biceps cm 20 +1 N cm 38 +2
Hoody length cm 34 +2 O cm 22 +1
Hoody decorative cm 9 +2 P cm 6 +2
diameter
Operation break down
Table 2.25: operation break down of design five

M/C type Operation Unit Meas.

SN Pocket attach cm 153
4 THOL Top internal front body attach with body decorative cm 55
4 THOL Top and bottom internal front body attach cm 55
SN Top stitch on internal front body cm 110
4 THOL Top &bottom sleeve with decorative cm 152
SN Top stitch on sleeve cm 152
4 THOL Top internal back body attach with body decorative cm 55
4 THOL Top and bottom internal back body attach cm 55

34
 INTERNSHIP REPORT IN MAA-GARMENRT COMPANY 2024

SN Top stitch on internal back body cm 110

4 THOL Internal body shoulder attach cm 28
4 THOL Internal body Armhole cm 98
4 THOL External (top & bottom front body) cm 126
4 THOL External (top & bottom back body) cm 126
4 THOL External (sleeve with panel sleeve) cm 220
4 THOL External body armhole cm 98
SN Hoody with decorative hoody cm 98
SN Hoody hemming cm 144
4 THOL Hoody cm 57
4 THOL Hoody with body attach cm 62
4 THOL Side seam cm 350
SN Cuff & bottom hemming cm 56
4 THOL Cuff cm 55
4 THOL Bottom hemming cm 100
Bill of material
Fabric one consumption (red color)
Con/n in kg = full length*width(across shoulder+ ½ chest)*2 *GSM + wastage
=[65cm*(50cm+ 54cm)*2*230g/m2 ]/10000000]+3%=0.32kg
Fabric two consumption (sky blue color)
Con/n in kg = external fabric length*(bottom+ external width + external sleeve width )*2 *GSM
+ wastage
=[52cm*(54cm+ +21cm +34cm)*2*230g/m2 ]/10000000]+3%=0.25kg
Fabric 3 consumption (yellowish orange color)
Con/n in kg = (sleeve length+ decorative length body)*width*2 *GSM + wastage
=[(55cm+ 5cm)*54*2*230g/m2 ]/10000000]+3%=0.15kg
Fabric 4 consumption (black color)
Con/n in kg = length*width *4 *GSM + wastage
= [11cm*11cm*4*180g/m2 ]/10000000]+3%=0.009kg
Fabric 5 consumption (cyan blue color)
Con/n in kg = length*(bottom width+ cuff width) *4 *GSM + wastage
= [14cm*(23cm+50cm)*2*210g/m2 ]/10000000]+3%=0.044kg

35
 INTERNSHIP REPORT IN MAA-GARMENRT COMPANY 2024

Table 2.26: bill material of design five

No Material Material Color Consumption Cost in birr
name description in kilogram
1 Fabric 1 Fleece Red 0.32 176
2 Fabric 2 Fleece Sky blue 0.25 137.5
3 Fabric 3 Fleece Yellowish orange 0.15 82.5
4 Fabric 4 Pk 4 Black 0.009 4.5
5 Fabric 5 2 2 rib Cyan blue 0.044 23.32
Trim and accessories
4 Thread Cyan Blue 21.471 0.322
Sewing thread Red 13.387 0.2
Black 0.3 0.0045
5 Drow cord 10
6 Label 1 0.1
Total material cost 434.5
Direct labor cost
Table 2.27: direct labor of design five
Cost center S.A.M (actual) Wage per hour in birr Cost in birr
Pattern maker 80 57.7 77
Marker making 20 24 8
Cutting 20 38.46 12.82
Sewing 120 14.4 28.8
Finishing 12 14.4 2.88
Total 252 148.96 129.5
Total cost
Table 2.28: total cost of design five

Cost of component Consumption Cost in birr

Total Materials cost 434.5
Direct labor cost 252 min 129.5
Overhead cost 20% of DLC=25.9
Total production cost 590
Profit TPC+20%
Selling price 708 birr

CHAPTER 3 SOLVE PROBLEM

3.1 How to minimize waste in printing section

General objective; -

36
 INTERNSHIP REPORT IN MAA-GARMENRT COMPANY 2024

 Material utilization in printing

Specific objective:-

 To make high quality of print  To save time

 To reduce material wastage
Theoretical background

Printing is a process for reproducing text and design. It looks at the face or right side of the garment but
it is not visible at the wrong side.

In MAA garment there is a printing that is a screen printing and heat transfer printing. The design
what printed in the garment component can be obtained by two ways that is

1. A design which is ordered by the customer that means a customer sends a sample either hard
copy or soft copy, then if it is hard copy they make it scan and they arrange it by adobe
Photoshop software.
2. A design which is created in the company by the printing maker.
But for both before enters to the work means the main order. The sample should be
seen for merchandiser and quality assurance then after this it approves by them and if it is ok
they continue to produce printing for the customer order.
.
They use two types of colors, 1. pigment 2. pilastisol
Screen printing
At the pigment printing they create a color by mixing of different color but the plastisol
prepares by its own company (they use it without increase chemical). After they prepare
the pigment (color) they start printing properly and the needed materials are
 frame  Lacker (fotolack)  Squeegee
 mesh  Design  Florescent
 transparent paper  Fabric  Pigment

The frame is prepared by the work shop then the mesh stretches with the frame by using
stapler ‘at this time they the mesh wisely because it is very expensive. after at this they
paint fotolack(lacker) for the mesh by using squeegee. The lacker prepare at darkroom
because it does not need a light after paint they dry it by the fan dryer.
37
 INTERNSHIP REPORT IN MAA-GARMENRT COMPANY 2024

They have a remover and thinner for the lacker they sprint they design onto the transparent
paper then this transparent paper spread on the wrong side of the light box (florescent)and
the mesh putt on the paper then the design burn to the mesh at the last they start printing.

Heat transfer printing

Heat transfer printing is the method of applying design or text on garment by using ironing
machine. Most of the time this printing is applies on the garment if the customer needs to
put the label through printing. This process will apply after cutting & when the process of
printing is completed continue to bundling

Literature review

Screen printing is a printing technique that uses to support an ink-blocking to receive a

desired image. The attached stencil forms open areas of mesh that transfer ink or other
printable materials which can be pressed through the mesh as a sharp-edged image onto
asubstrate. A fill blade or squeegee is moved across the screen stencil, forcing or pumping
ink into the mesh openings for transfer by capillary action during the squeegee stroke.
Basically, it is the process of using a stencil to apply ink onto a substrate, whether it is,
posters, stickers, vinyl, wood, or other material.

Screen printing is also a stencil method of print making in which a design is imposed on a
screen of polyester or other fine mesh, with blank areas coated with an impermeable
substance. Ink is forced into the mesh openings by the fill blade or squeegee and onto the
printing surface during the squeegee stroke. It is also known as silkscreen, serigraphy,
and serigraph printing. One color is printed at a time, so several screens can be used to
produce a multicolored image or design.

Printing technique

38
 INTERNSHIP REPORT IN MAA-GARMENRT COMPANY 2024

A. Ink.
B. Squeegee.
C. Image.
D. Photo-emulsion.
E. Screen.
F. Printed image.

Figure 3.1: Printing technique

A screen is made of a piece of mesh stretched over a frame. A stencil is formed by

blocking off parts of the screen in the negative image of the design to be printed; that is,
the open spaces are where the ink will appear on the substrate.

Before printing occurs, the frame and screen must undergo the pre-press process, in
which an emulsion is 'scooped' across the mesh and the 'exposure unit' burns away the
unnecessary emulsion leaving behind a clean area in the mesh with the identical shape as
the desired image. The surface (commonly referred to as a pallet) ensures that the
substrate will be printed against is coated with a wide 'pallet tape'. This serves to protect
the 'pallet' from any unwanted ink leaking through the substrate and potentially staining
the 'pallet' or transferring unwanted ink onto the next substrate. Next, the screen and
frame are lined with a tape. The type of tape used in for this purpose often depends upon
the ink that is to be printed onto the substrate. These aggressive tapes are generally used
for UV and water-based inks due to the inks' lower viscosities. The last process in the
'pre-press' is blocking out any unwanted 'pin-holes' in the emulsion. If these holes are left
in the emulsion, the ink will continue through and leave unwanted marks. To block out
these holes, materials such as tapes, specialty emulsions and 'block-out pens' may be used
effectively.

The screen is placed atop a substrate. Ink is placed on top of the screen, and a flood bar is
used to push the ink through the holes in the mesh. The operator begins with the fill bar at
the rear of the screen and behind a reservoir of ink. The operator lifts the screen to

39
 INTERNSHIP REPORT IN MAA-GARMENRT COMPANY 2024

prevent contact with the substrate and then using a slight amount of downward force pulls
the fill bar to the front of the screen. This effectively fills the mesh openings with ink and
moves the ink reservoir to the front of the screen. The operator then uses a squeegee
(rubber blade) to move the mesh down to the substrate and pushes the squeegee to the
rear of the screen. The ink that is in the mesh opening is pumped or squeezed by capillary
action to the substrate in a controlled and prescribed amount, i.e. the wet ink deposit is
proportional to the thickness of the mesh and or stencil. As the squeegee moves toward
the rear of the screen the tension of the mesh pulls the mesh up away from the substrate
(called snap-off) leaving the ink upon the substrate surface.

 There are three common types of screen printing presses. The flat-bed ‘,’ cylinder
and the most widely used type, the 'rotary'.

Textile items printed with multicolored designs often use a wet on wet technique, or
colors dried while on the press, while graphic items are allowed to dry between colors
that are then printed with another screen and often in a different color after the product is
re-aligned on the press.

Most screens are ready for re-coating at this stage, but sometimes screens will have to
undergo a further step in the reclaiming process called dehazing. This additional step
removes haze or "ghost images" left behind in the screen once the emulsion has been
removed. Ghost images tend to faintly outline the open areas of previous stencils, hence
the name. They are the result of ink residue trapped in the mesh, often in the knuckles of
the mesh (the points where threads cross).

While the public thinks of garments in conjunction with screen printing, the technique is
used on tens of thousands of items, including decals, clock and watch faces, balloons, and
many other products. The technique has even been adapted for more advanced uses, such
as laying down conductors and resistors in multi-layer circuits using thin ceramic layers
as the substrate.

Screen printing materials

40
 INTERNSHIP REPORT IN MAA-GARMENRT COMPANY 2024

Caviar beads
A caviar bead is a Glue that is printed in the shape of the design, to which small
plastic beads are then applied – works well with solid block areas creating an
interesting tactile surface.
Cracking ink
Cracking ink effect is when the ink produces an intentional cracked surface after
drying.
Discharge inks
Discharge ink is used to print lighter colors onto dark background fabrics, they
work by removing the dye of the garment – this means they leave a much softer
texture.
Expanding ink (puff)
Expanding ink, or puff, is an additive to plastisol inks which raises the print off
the garment, creating a 3D feel and look to the design. Mostly used when printing
on apparel.
Flocking
Flocking consists of a glue printed onto the fabric and then flock material is
applied for a velvet touch.
Foil
Foil is much like flock, but instead of velvet touch and look it has a
reflective/mirror look to it. Although foil is finished with a heat press process it
needs the screen printing process in order to add the adhesive glue onto the
material for the desired logo or design.
Four color process or the CMYK colour model
Four color processes when the artwork is created and then separated into four
colors (CMYK) which combine to create the full spectrum of colors needed for
photographic prints. This means a large number of colors can be simulated using
only 4 screens, reducing costs, time, and set-up. The inks are required to blend
and are more translucent, meaning a compromise with vibrancy of color.
Glitter/Shimmer

41
 INTERNSHIP REPORT IN MAA-GARMENRT COMPANY 2024

Glitter or Shimmer ink is when metallic flakes become an additive in the ink base
to create this sparkle effect. Usually available in gold or silver but can be mixed to
make most colors.
Gloss
Gloss ink is when a clear base laid over previously printed inks to create a shiny
finish.
Metallic
Metallic ink is similar to glitter, but smaller particles suspended in the ink. Glue is
printed onto the fabric, and then Nano-scale fibers applied on it. This is often
purchased already made.
Mirrored silver
Mirrored silver is a highly reflective, solvent based ink.
Nylobond
Nylobond is a special ink additive for printing onto technical or waterproof
fabrics.
Plastisol is the most common ink used in commercial garment decoration. Good
color opacity onto dark garments and clear graphic detail with, as the name
suggests, a more plasticized texture. This print can be made softer with special
additives or heavier by adding extra layers of ink. Plastisol inks require heat
(approx. 150°C (300°F) for many inks) to cure the print.
PVC and Phthalate Free
PVC and Phthalate Free is relatively new breed of ink and printing with the
benefits of plastisol but without the two main toxic components. It also has a soft
texture.
Suede Ink
Suede ink is a milky colored additive that is added to plastisol. With suede
additive you can make any color of plastisol have suede feel. It is actually a puff
blowing agent that does not bubble as much as regular puff ink. The directions
vary from manufacturer to manufacturer, but generally up to 50% suede can be
added to normal plastisol.
Water-Based inks

42
 INTERNSHIP REPORT IN MAA-GARMENRT COMPANY 2024

These penetrate the fabric more than the plastisol inks and create a much softer
feel. Ideal for printing darker inks onto lighter colored garments. Also useful for
larger area prints where texture is important. Some inks require heat or an added
catalyst to make the print permanent

Methodology of the problem

To collect the data am using an interview. That is why this is the better way than the
other. Because the person who give me information is on work then to save his time, and
also too rapid his work I get an interview the best way.

Then the information what I get looks like this. First of all they didn’t have enough
material which helps to prepare the solution of printing. This will be having its own effect
on the quality of the printing. That means when using one material let say for example
spoon when they use one spoon for two chemicals which is difficult. this means that
when the spoon touch to one chemical and this spoon also inserts to other chemical
during this it may make a reaction simply then they can’t possible to prepare a good
quality printing and also the print which make by this solution is not stay for long time.
And also in case of the shortage of materials which spends much time. That is when
using one spoon for one chemical and if they want to take another chemical they clean or
wash the spoon. During this they spend much of time.

The way of using chemical will be so opened for wastage because it doesn’t have
measurement for those chemicals. Because they use for all chemicals the same material.
Not only this which is also difficult to mix with the accurate amount. Even if there is less
man power in this printing section, this will have its own effect on the delivery date. And
also they have a shortage of table it will follow that the defect on a design what could be
printed in case of uncomfortable the table.

Solution tasted

According to the data what I get from the person who makes in the printing section I am
solving the program which looks like this….

43
 INTERNSHIP REPORT IN MAA-GARMENRT COMPANY 2024

The best solution for this problem is that full filing the material what they didn’t available
in the printing section. For example there is a shortage of spoon. This will follow that is a
big problem on production. I.e. have the effect on the on the quality of the printed design.
But if there is enough material what the spoon for individual chemical. Indirectly this
spoon will play the great role. Not only these there are a lot of material like electronic
weight balance, cylinder, beaker, table, etc materials must be available at printing section.
Because if each material are full fill each chemical will be mixed with the accurate
amount. And this haps on the quality of the printed and also which used that is good on
using material wisely.

i.e. when the chemicals are mixed only by one material in case they didn’t get the right
amount because some amount of the chemical will stay on the material. Not only this but
also if directly insert the material without cleaning or washing it makes a reaction and
also which opened for wastage to the pigment.

The availability of the material will play on saving of time and man power. That is the
spends of time what use one material on one chemical doesn’t wash to use again to
another chemical. But if there is enough material it helps to reach on the time of one
order, i.e. the delivery date.

The necessarily materials which use for MAA garment to make printing are

Electronic weight balance

Capacity: 5000g; Deviation: From 0.1g; Display: LCD; Units: G, %, pcs, oz, ozt, dwt, ct,
lb, t; Pan Size: 175mm*175mm; Dimensions’: 176 (W) X 60 (H) X 272 (D)...

44
 INTERNSHIP REPORT IN MAA-GARMENRT COMPANY 2024

Figure 3.2: Electronic weight balance

Measuring mass with an electronic balance:

The electronic balance has many advantages over other types of balance. The most
obvious is the ease with which a measurement is obtained. All that is needed is to place
an object on the balance pan and the
measurement can be read on the display to
hundredths of a gram. A second advantage, using
the Zero button on the front of the balance, is less
recognized by beginning science students.
Because one must never place a chemical
directly on the balance pan, some container must
Figure 3.3:Measuring mass be used. Place the container on the balance and
with an electronic balance the mass of the container will be displayed. By
pressing the Zero button at this point, the balance will reset to zero and ignore the mass of
the container. You may now place the substance to be weighed into the container and the
balance will show only the mass of the substance. This saves calculation time and effort.
However, when the container is removed from the balance, the display will go into
negative numbers until the Zero button is pressed again.

45
 INTERNSHIP REPORT IN MAA-GARMENRT COMPANY 2024

the electronic balances also have a Unit button on the front. Pressing this button will
change the units being measured. Since they have very few times when they need
something other than metric units, you should not have to change the mode on the
balance. Because of the Unit and Zero buttons, there are two things you must always do
before placing objects onto an electric balance to be measured:

1. See that the display is reading 0.00

2. See that the unit sign in the upper right of the display shows g

When finished with the electronic balance, press the On/Off button and hold it down
until the display shows OFF.

Graduated
Beakers are the most
cylinder Used to make accurate
Beaker versatile glassware in the
measurements of liquid
lab and can be used for
volumes. The bumper
just about anything. The
ring on larger cylinders is
volume graduations on
to prevent breakage if
beakers should be used
tipped over. Keep it near
only for "ballpark"
the top.
estimates.

Conclusion

I conclude that if they use those materials they must be minimizes their wastage and their
print comes perfect, that means they can possible to do high quality print.

3.2 How to increase local market

General objective;-

 To increase their own local marketing

Specific objective;

46
 INTERNSHIP REPORT IN MAA-GARMENRT COMPANY 2024

 To utilize the waste materials

 To make profitable to the company
 To increase job opportunity

Theoretical background

Marketing is the usage of marketing techniques to promote clothing and accessories to

create a strong brand image and increase sales. It includes marketing on website (onsite
marketing), using social media ads, printed magazine ads, run way show and television
ads, as well as influencer content and promotional emails.

Marketing in maa garment company is using 90% of export marketing. The company
work by consulting external market and usually use online websites and others.
Occasionally, they utilize local market. When they acquire customers, they typically
bring their own design in the form of sample or photo of a garment. Then after
agreement, the product done by the process of the company. In maa garment currently use
local market only.

Literature review

Local marketing is a type of marketing that specifically targets customers who live
within a certain distance of the company’s location. This method allows businesses
to market goods and services to potential customers who live in a certain city or ZIP
code. Small businesses often overlook this marketing strategy, as many of them take
their marketing cues from larger conglomerates.

Methodology problem

I got the problem by interview of the employers and I got by observation. The
problems are as follow

Lack of Pre- market research and lack of customers.

In the past, most of the customers in Ma Garment Factory were foreign customers but due
to the corona virus and war in Tigray, the customers were able to stop.

47
 INTERNSHIP REPORT IN MAA-GARMENRT COMPANY 2024

As a result, the company has been able to weaken its productivity, and also there is lack
of local customers.

The reason for the weaknesses of local market is the lack of marketing management, lack
of quality product and the lack of material supply.

Solutions for their problem

We can develop local market by the following methods

Instead of always acquiring foreign customers turn the existing foreign customers to local
to grow the company and keep the company in business all the time. Because the
company has been using foreign customers like the current one but now when AGOA is
closed down the company should not stop or lose accordingly
By improving quality of the fabric for example we can possible to produce good and
comfortable fabric by adding Lycra and chemicals.
you have to know what the society need type of style, quality and color, and in where
condition it use. And also by adding garment surface ornamentation. And to minimize
cost to become competitive in the market.

CHAPTER 4 SUMMERY
4.1 learning experience
Since the time we started working my internship activity for the time we stayed. We have
experienced the following skills and knowledge.

Order management Order management

Design and material selection Making and material
Simple way of pattern making consumption and cost analysis
Marker making Quality control and standardizing
Build motivation and work ethics Operation breakdown and lay out
Cutting and production process
4.2 conclusion and recommendation
Conclusion

48
 INTERNSHIP REPORT IN MAA-GARMENRT COMPANY 2024

 We conclude that internship is most important to apply theoretical knowledge into

practical part.
 It is to gate more experience from different department how process flow of garment
production ordered from design room up to finishing room, how sample perform from
receiving order up to sample room and sample send to customer.
 we conclude that internship is more important in exchange of experience with company
and to know how important developing communication skill more necessary to
communicate with different customers.
 We conclude that it is important to give direction what to have doing for the future.

Recommendation

 Maa garment textile factory has more wastage fabric in cutting section. Then we
recommended that to use the method small size put in large size order during cutting in
order to decrease wastage fabric.
 We recommend that to increase strong relation with university industry linkage in order
to get new system to change the company into modernized.
 In same of department operate the process by lack of skill persons. Then we recommend
that to get more skill person in order to facilitate all activity in the company.
 It is used most of time manual method marker making than use plotter & pattern will be
made by try and error to get exact shape these are lade to cost of the company then we
recommend that to use most efficient method of computerized system and to use
modernize system of pattern making.
 We also suggest that, the company should host more intern students in the future for the
common good of the student and the company.

4.3 Reference
 Research on different part of the company
 Research on departments
 https://en.wikipedia.org/wiki/Units_of_textile_measurement#cite_note-
Textiles_for_modern_Living-5
 https://www.iperfumepackaging.com/screen printing/

49