Process flow of knit composite factory- for a basic t-shirt
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Bangladesh's knit composite industry plays a significant role in the country's economy by exporting knitted garments and earning foreign currency. The industry involves several stages from yarn receiving to product shipment including knitting, dyeing, cutting, sewing, finishing, and quality inspections. A basic t-shirt goes through yarn processing, fabric production, cutting, sewing, finishing, and inspection before final shipment. The knit composite industry is advantageous for Bangladesh compared to woven composites due to lower costs, higher production rates, and stronger backward linkages in the supply chain.
Process flow of knit composite factory- for a basic t-shirt
- 1. Introduction Bangladesh is a country of 160 million people. Economic growth of this country largely depends on the proper use of the people which is one of the great resources. Bangladesh is known as the emerging tiger of South Asia because of the rapidly growth of our economy. There are many sectors which helps our economy to grow faster. RMG is one of them. Among RMG Sector, Knit Composite industry plays a significant role to promote our RMG Sector through earning a huge amount of foreign currency by exporting knitted garments worldwide. Knit composite industry is an industry where functions are started with yarn receiving from the spinning mills and end with shipment of knitted garments. Between this processes, we have to follow several ladders which help us to attain the knitted garments to the customer with the ensuring quality. Bangladesh Export numerous knitted garments such as T-shirt, Polo Shirt, Singles, Tank top, Leggings, Tights, Cardigan, Pullover, Play suit, Tunic, Knitted Trouser and so on. For building this knitted garments we have to maintain several stages such a knitting, fabric finishing, storing, cutting, sewing, quality checking, finishing, shipment etc. which assist us in smoothly exporting the knitted garments. Therefore, before going to the process flow of Knit Composite industry, the very beginning we have to know the advantages of Knit Composite industry than woven composite industry. Advantages of Knit Composite Industry in Bangladesh than Woven Composite Industry: Bangladesh is mainly Knitwear export oriented Country. Profit is maximized due to backward linkage of knit industry. Lead time can be controlled due to easier supply chain. Higher production rate with lower cost supply chain. Primary installment for knit composite factory is much lower than the woven composite industry. Transport cost is minimized in case in case of knit composite industry. (Source: Engr. Prasad.R.K.2016.)
- 2. In this Study, we will briefly discuss about Process Flow of Knit composite industry – For a basic item T-shirt. For that we have to know initially our objectives of the Study. Objectives of the study To assesses the function of each stage of knit Composite industry. To understand the overall process flow of knit composite industry. To find out the individual stage process flow. To get knowledge about knit composite industry. Process flow of Knitting Section (Source: Kiron.M.I. 2012) Yarn Cone receive Place the Yarn Cone in the creel Feeding the Yarn Set the machine as per design and GSM Knitting Withdraw the roll fabric and weighting Roll Marking Inspection Numbering Yarn dying (if required)
- 3. Process flow of Dying Section (Source: Textile fashion Study. February 20, 2012) Process flow of Store Section (Source: Raaz.N.A.2015) Receive Textiles materials (Grey fabric, yarn etc) Singeing Desizing Scouring Bleaching Mercerizing Dyeing Finishing Receiving Product from Dying Section Inventory Inspection of product Shade segregation Issuing product Sustaining Balance Closing Summary
- 4. Process flow of Cutting Section (Source: Islam.M.J 2015.) Process flow of Sewing Section (Source: Islam.M. July 14, 2015) Pattern Received from Pattern Department Cutting Ratio received from Merchandiser Marker Making Fabric Received from The store Fabric Checking Fabric Spreading Cutting the fabric Numbering Checking Sorting & Bundling Send to the sewing department Printing /Embroidery Marker Placing on the Lay Product Analysis Setup Target for production Distribution all processes Cutting parts received for Cutting Section Cutting parts Distribution Sewing according to Distribution Line Q.C Check Line Quality Audit Counting output according to target Final Quality Check Send to finishing section
- 5. Process flow of Finishing Section (Source: Akter.J. 2014) Finishing Input ( Color, style & size wise Initial quality Check Spot Removing Ironing/Pressing Inspection Hang tag Get Up change Folding Poly Bar Code (if required) Metal Check Cartooning Inspection Dispatch shipment
- 6. Overall Processflow of Knit Composite industry for a basic T-shirt Description Order Receive: For production any kind of Garment, At first we have to receive order to execute production for any kind of RMG factory. After receiving orders, knit composite factory plan how to execute order ,which method they follow to execute order and they also make sample for buyer approval as well as they also involve in material sourcing process. Planning: Here Knit Composite factory makes time and action plan based on man, machine, materials availability or their capacity to accomplish order. In this stage, authority decides how to accomplish the order, how much man, machine, material requires accomplishing order, how to they control overall process etc. Sampling: Here factory makes sample according to buyer requirements and send the sample to the buyer for the buyer’s comments so that they can rectify the fault in the sample. PP Sample approval: After getting the buyer comments, the factory rectify the faults and send sample to the buyer again before going to the bulk production. That’s why it is called Order Receive Planning Sewing Material Sourcing Knitting Dying Pp Sample Approval Trims & accessories in house Storing PP Meeting Cutting Sampling Printing/Embroidery Finishing Final InspectionShipment
- 7. pre-production sample. After getting approval from buyer, the factory will be ready for bulk production. Material Sourcing: In the mean time, knit composite factory will be involved in Material sourcing process. At first they booked yarn to produce fabric in their knitting section. After making fabric, the grey fabric sends to the dying section for dying according to requirements. After dying fabric & booking trims and accessories, stock up the fabric & trims and accessories in the store and inspection the product. Trims and Accessories: Knit Composite must have to ensure trim and accessories are in house before going to bulk production as per required quality and quantity. Knitting: Here several steps are followed. Very First, yarn received from the spinning mill , then dyed the yarn if required. After that, place the yarn cone in the creel and feeding the yarn and knitting the fabric. After knitting fabric, withdraw fabric roll from the machine and inspect the roll and give the roll number. So that, we can identify the specific roll by the number. Dying: After Grey fabric knitting, fabric sends to the dying section for dying fabric roll according to required color. Before dying several stages have to be maintained such as desizing, scouring, bleaching, mechanizing etc. Storing: Before going to the bulk production , the factory have to ensure all the equipment are available in store and store department inspect all the materials and makes a summery about shade segregation ,issuing product amount, sustaining balance and closing the summery. PP meeting: Based on the planning, sample approval, and material sourcing and store department inspection report pp meeting are held to decide how to finally execute the bulk production depends on what necessary step should be taken, how works will be divided, section wise responsibility will be distributed through this meeting. Cutting: As per PP meeting decision, cutting section received pattern as per style, cutting ratio and then cutting master making the marker. After that fabric receive from the store, fabric checking to see if it’s okay for cutting or not, then spread the fabric on the cutting table and create lay, then marker place on the lay and start cutting. After cutting check the parts to see if there is any cutting fault or not , then numbering the cutting pieces to avoid shade
- 8. variations, then sorting & bundling the parts and send to the printing and embroidery section if required or send to the sewing section for further process. Sewing Section: At this juncture at first PP sample analysis is done ,setup line target , distribute processes to the workers .Then cutting parts received from cutting or printing/embroidery section (if there is) and distribute the parts to workers in the same way as process distribution and workers sewing the parts .In the mean time, line Q.C check and Q.C audit has been occurred so that we can accomplish required quality. After that finally counting output according to target and full garment quality ensuring is done, and garments are send to the finishing section. Finishing Section: It is one of the most important part of knit composite unit. After inputting garments, first initial quality check is done to find out the fault of the garments. Here, spot removing, ironing/pressing, inspection, hang tag attach ,get up change , folding the garments as per requirements , poly the garments, metal checking etc are done to give product aesthetic value. After that goods cartooning or packing to box is done for buyer’s inspection. Inspection: Buyer’s representatives or buyer inspect the cartoon randomly to find out if the product produces according to requirements. If they find satisfactory result then the goods will be accepted otherwise the entire shipment will be rejected. Shipment: After inspect the goods as per predetermined condition , If buyer find satisfactory result then the goods will be accepted for shipment otherwise the entire shipment will be rejected. Conclusion Bangladesh is mainly knitwear export oriented country .Bangladesh has more than 200 Knit composite factory and the number is increasing day by day and Bangladesh knitwear is unbeatable in price advantage in the world. Bangladesh provides not only a cheap labor force, which is unbeatable but they are also peerless in stitching capability. Knitwear is exported to 153 countries of the world from Bangladesh. (Source: Strength of knitwear sector of Bangladesh: BKMEA) So knit composite industry’s importance is increasing gradually. As a result, process flow of knit composite factory is an important part of RMG sector which assist us to ensure smoothing exporting and contribute our GDP.
- 9. References 1.Engr.Prasad.R.K.(2016).Lecture: Introduction to cut & sew knitwear, Uttara, BGMEA University of Fashion & Technology. 2.Kiron.M.I. (2012). Process flow chart of Knitting Technology. Retrieved from http://textilelearner.blogspot.com/2012/09/process-flow-chart-of-knitting.html. 3.Textile fashion Study (2012).Process flow chart of Dyeing Textile Materials, Basic structure of Wet processing Technology (2012) Retrieved from http://textilefashionstudy.com/process-flow-chart-of-dyeing-textile-materials-basic-structure- of-wet-processing-technology/ 4.Raaz.N.A.(2015).Working Flow Chart of Store Department in Garment Industry(2015). Retrieved from http://textileflowchart.blogspot.com/2015/11/working-flow-chart-of-store- department.html 5.Islam.M. July14, 2015. Process Chart of Garments Cutting Section (2015). Retrieved from http://www.garmentsmerchandising.com/flow-chart-of-garments-cutting-section/ 6. Islam.M. July 14, 2015. Process flow for Garments Sewing Department (2015). Retrieved from http://www.garmentsmerchandising.com/process-flow-chart-for-garments-sewing- department/ 7.Akter.J.Dec 21,2014. Process Flow Chart of Garment Finishing Section (2014). Retrieved from http://textileflowchart.blogspot.com/2014/12/flow-chart-of-garment-finishing- process.html 8. Strength of knitwear sector of Bangladesh: BKMEA. Retrieved August 22, 2016, from http://www.bkmea.com/Strength-of-Knitwear-Sector-of-Bangladesh.html