It is very important project paper of production process.

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SUBMITTED BY:
Name ID
Jotan Banik 2010110000077
Batch: 25th
(B)
Department of Business Studies
Southeast University
Date of Submission: 9th
April, 2013
Southeast University
SUBMITTED TO:
Mrs Zerin Tasnim Rahman
Lecturer
Department of Business Studies
Southeast University
Course Title: Production and Operation
Management
Course Title: MGT-2323
REPORT
On
PRODUCTION PROCESS OF A
PRODUCT

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LETTER OF TRANSMITTEL
09-04-2013
Course Teacher
Production & Operations Management.
Subject: Report on “PRODUCTION PROCESS OF A PRODUCT”.
Dear Madam,
With due respect, I am the following students in Southeast University of 25th
Batch of BBA
program. A few days ago you gave us an assignment topic and that was “PRODUCTION
PROCESS OF A PRODUCT” and instructed us to prepare a details report on this topic. In a
meantime I work on this topic. Already complete this assignment. Here I am submitting my
report.
For this purpose, I have gone through different books, factory visit, and different intelligent
persons for the relevant information of the assigned topic. I work on this topic only for
academic purposes. If any person try to use this assignment in other sector than I will be not
reliable for this.
So, I am grateful to you for your guidance and kind cooperation at every step of my attempt
on this report. I shall remain deeply grateful if you kindly go through the report and evaluate
my performance.
Sincerely yours,
Jotan Banik
ID NO: 2010110000077
Batch: 25th
(B)
Department of Business Studies
Southeast University
………………………………...
Jotan Banik

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ACKNOWLEDGEMENT
At first I desire to express my deepest sense of gratitude of almighty Allah. With profound
regard I gratefully acknowledge my Southeast University and respected course teacher Mrs.
Jerin Tansim Rahman, Course teacher of Business Production & Operations Management,
Lecturer of Business Studies, for his generous help and day to day suggestion during
preparation of the report.
I like to give thanks especially to my friends and many individuals, for their enthusiastic
encouragements and helps during the preparation of this report us by sharing ideas regarding
this subject and for their assistance in typing and proof reading this manuscript.
I especially thank to G.M of ALAMA TEXTILE, another employee, and worker for giving
their most valuable time to me & my group. If they don’t help it can be so difficult to
complete this report on “Production Process of a Product”

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TABIL OF CONTENT
Topic Page No.
1) Introduction 05
2) Abstract 06
3) Company’s Overview 07-09
4) Objectives of the study 10
5) Methodology of the study 10-11
6) Manufacturing Process 11-17
7) Precedence Diagram 18-19
8) Drawback 20-21
9) Forecasting 21
10)Opinion 22
11)Conclusion 23
12)Reference 24

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PRODUCTION PROCESS OF ALEMA
TEXTILE (PVT). LTD (Shirt)
INTRODUCTION:
Being the biggest contributor to the country's foreign exchange- around 76 percent- and
employing around 2.2 million people, 80 percent of them women, the importance of nurturing
a sector as vibrant and thriving as the garments industry, cannot be emphasized enough. With
export of Ready Made Garments (RMG) reaching 9.2 billion in 2007 and predictions of it
rising to 12 billion or more in the next two years, it is obvious that the industry is growing at
an exponential speed. Greater demand for our garments abroad indicates the improvement in
quality of the products as well as greater customer confidence, which translates to further
expansion of the industry, more employment, more consumers in the domestic market and a
huge boost to the economy. However, there are many jolts and stumbles along the road to
economic freedom and overcoming them will determine whether we can sustain the boom
that is waiting to happen.
Readymade garment industry has occupied a unique place in the industrial scenario of our
country by generating substantial export earnings and creating lot of employment. Its
contribution to industrial production, employment and export earnings are very significant.
This industry provides one of the basic necessities of life. The employment provided by it is a
source of livelihood for millions of people. It also provides maximum employment with
minimum capital investment. Since this industry is highly labour-intensive, it is ideally suited
to Bangladeshi condition. This project report is prepared for the manufacture of shirts as they
find wide acceptance in international markets. Any person having the knowledge of cutting
and stitching operations can easily set up such establishments.
Readymade garments are the choice of urban people. It is also gaining wider acceptance in
semi-urban and rural areas. The huge charges made by tailors and delay in delivery have
made people to switch over to readymade garments. In export market, it has made spectacular
progress in the last decade. This industry is becoming very exciting and lot of foreign
investment driving in this industry because of low risk and high earning nature of this
industry. As these products are fashion oriented, entrepreneurs should always keep in mind
the changing fashion styles. Considering its advantageous position, it is assumed that there
will be no constraint in marketing of gent’s readymade garments.

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ABSTRACT
This project is on “Study on shirt manufacturing process”. shirt manufacturing process is one
of the most valuable parts in terms of Garments Manufacturing to control and follow up the
total process to fulfil the buyer’s requirement. This project profile is for the setting up of unit
for manufacturing of Shirts. The Knitted Shirts are used and liked by the people because of
its special characteristics like good softness and absorbency of sweating. Wearing garment is
a basic need for every human being. The demand of using Shirts is increasing day to day
with the change of fashion/life styles. Manufacture of Shirts is very simple and easily
manageable process. Manufacture of the cotton Knitted fabric in different colours is spread
on a table and is cut with fabric cutting machine as per required size and shape of the
garments. The cut pieces are skewed by sewing machines and embellishments are attached. It
is very important to design the product as per latest fashion trend. The garments are then
pressed and packed for marketing.

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ALEMA TEXTILE (PVT).
LTD
Company’s overview
Alema Textile, within a short span of time, firmly established itself one of the successful
organization in Bangladesh. The company is registered in 2010, follow & obey the rules and
regulations of Government Republic of Bangladesh. The vision of the group is to be the
market leader and the mission is to grow faster, cope up with technological changes, add
value to the client’s satisfaction and practice sound business ethics while ensuring highest
customer satisfaction level and thus offer product and services of the highest standard in
order to become a socially responsible organization.
Alema Textile plays very important role for the economic development of Bangladesh
.Alama Textile always looks for excellence and it has an insatiable appetite for quality and
customer satisfaction.

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Vision
Our vision is to grow faster, cope up with technological changes, add value to the client’s
satisfaction and practice sound business ethics while ensuring highest customer satisfaction
levels and thus offer product and services of the highest standard in order to become a
socially responsible organization.
Mission
The mission of the Alema Textile is to be the market leader
Aims and Objectives
Alema Textile has been established for reducing unemployment, to create opportunities for
self-employment, to reduce poverty and to ameliorate ethics and morality that we can match
the advanced nations of the world
Corporate Philosophy
We are committed to nation for sustainable environment and also believe in contribute to its
progress and welfare. Business Ethics-Always keeps honesty, integrity and respecting laws.
Fairness- Fairness and justice in all our business and individual dealing. Gratitude-Always
repay the kindness of our customers, associations, community, nation and friends worldwide
with gratitude.
Company’s Profile:
Basic Information
Founder: Md. Azad Islam
Company
Name:
Alema Textile(Pvt.)Ltd.
Business Type: Manufacturer
Main Products:
Knit fabric. T shirt, Shirt, polo, all knitting
garments
Number of Employees: 1020 Employees

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Trade & Market
Main Markets: Europe, USA, Japan
Main Customers:
G.A.T., J.S.E. tenny, KOHL’s, V.S.Asia, Asmara,
Lia & Firm, P.V.H. etc
Export Percentage: 100%
Factory Information
Corporate office: Vogra , Basan sarak, Gazipur
Bangladesh
Number of
Production Lines:
Above 20
Mail: masud@mimgroup.com

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OBJECTIVES OF THE STUDY:
The primary objectives of this study is to prepare a production process of any product with
the growth and sustainability. I also attempt to seek the factor that making this project
vulnerable in terms of growth potentials. Along with these we had tried to design
recommendations for the developments of our selected product or sectors. Besides these
primary objectives there are some secondary objectives of the study as follows-
# To identify the various buyers of this industry,
# To know about their various product, and
# To increase knowledge by factory visit.
METHODOLOGY OF THE STUDY:
To complete our Project in a decision we use some method. To collect information we search
internet, read newspaper, and utilize our personal observation and organizational profile. We
collect some information from primary sources through direct interview of the Alama textile
authority and workers. Our secondary information collected through internet and
organizational profile.
#Research period:
Ist April- O5 April - within this period we collect both primary & secondary data for
developing our project.
#Research Approach:
This study is qualitative in nature, but little quantity. This analysis was done in a formal and
inflexible fashion to draw inference about the opinion of the employee & managers.
#Instruments.
To collect the data from the employee & managers, a structured questionnaire had been
followed.
Primary data have been gathered through interviewing the respondents in their respective
workplaces.
Two questionnaires had been used to collect the data from two areas such as from the
Managers, and worker in that industry.

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# The sampling frame:
Category of sample Sample size Description
Managers 05 Whose managers are authorized by the authority
for the purpose of industry
Workers 20 Whose workers are employed by the managers
or authority.
Total 25
THE MANUFACTURING PROCESS:
Garment manufacturing process consists of series of different steps. These steps are broadly
divided into two categories pre-production and production process. The preproduction
process consists of designing the garment, pattern design, sample making, Production pattern
making, grading and marker making. Once the sample is approved for commercial
production, final marker is made for cutting. The production process Consists of cutting,
stitching (preparatory and assembly) and finishing all these process are described here

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FLOW CHART:
Value added
Input Transformation Output
Land
Labor Goods
Capital
Information
Feedback Feedback
Production Process
The following steps outline the entire manufacturing process of our t-shirts, from dirt to shirt.
This is just the first step in our commitment to giving you all the facts about the shirts you're
wearing:
Control
Input Transformation process Output
Land
Labor
Capital
Information
Cloth
Button
Thread
Needle
Bokles
Colour
Deterjent
equipment
Dying(a)
Printing(b)
Cutting(c)
Shaping(d)
Making serial no.( e,f,g )
Sewing(h)
Washing(i)
Drying(j,k)
Ironing(l)
Folding(m)
Packing(n)
Leveling(o)
Bundling(p)
Shirt

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(1) Designing
(2) Dying
(3) Printing
(4) Cutting
(5) ShappingSerialing no.
(6) Sewing
(7) Washing
(8) Drying
(9) Ironing
(10)Folding
(11)Packing
(12)Levelling
(13)Bundling
Registering the Design
The completed screens are then fitted into the press. A system of clamps and screws allows
for very minute adjustments to the position of the screen. If the design features only one
colour, then the screen must simply be straight, if there are two or more colours, the design
must be registered, or lined up perfectly. Screens are generally made with cross-hair
registration marks to aid in this process.
Dying:
Because of the special print process we use, our shirts are garment dyed after
printing. Though there are many dye methods available, paddle dye tubs are used because of
their ease of operation and maintenance.
After dyeing, the shirts are inspected and shipped to the customer.
CotC shirts are dyed with low-impact, bi-functional reactive dyes, offering superior wash-
and light-fastness in addition to their low environmental impact.

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Printing the Shirt
The next step is to fit the shirts onto the press. Ink is poured into the screen, which is
"flooded"---completely spread with ink. The ink is scraped across the screen with a squeegee
with enough pressure to push it through the mesh in the stencil area. For a multicolor design,
the shirt is dried briefly before a second color is printed to avoid smudging.
Cutting Department
The first step of the production process is to draw a shirt pattern on a large paper. Next, the
fabric is overlaid in layers according to the number of orders. Then, the large patterned paper
is laid on top of the fabric and the fabric is cut according to the pattern. Later, the cut pieces
are inspected by our experienced Q.C. staff to ensure the fabric quality.
Serial Numbering
Then different pieces are included in different no by shapping or cutting size-Middle, Long,
Short, Extra large, etc.

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Sewing:
Sewing is the most important step in the actual construction of the shirt itself,
and is the most labor-intensive.
After receiving the bodies, sleeves, and collars from the cutter, the sewers use an array of
sewing machines to attach each piece via a batch assembly line.
Sewing Department consists of 2 sections:
Sewing Section – In this section, cut pieces of fabric are sewn together and inspected for
sewing quality before passing to assembly section.
Assembly Section - Responsible for assembling shirts and measuring the size. If the shirts are
in required sizes, they will later be processed in a thread vacuum machine to remove the
remnants of thread.
Washing
For cleaning products need to be washed, so that any spots or germs are removed and
products are shown shining.
Drying & Ironing the Shirt
When the shirt is washed it is taken off the machine and put through a conveyor-belt dryer to
set the ink. In between colors of a multicolor design, a flash dryer is used to allow the shirt to
be dried while it is still on the press and also it need to be ironed. In the case company after
washing there is thread cleaning section followed by ironing.

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Folding
For pacing folding must be needed. If they do not folding the shirt, they can’t packing this.
Packing & Bundling
The individual pieces are pressed by steam presses to remove any wrinkle marks and packed
in the carton boxes. After packing, they define the level of different shirts. Then, In carton
boxes, they arranges the shirt pieces in accordance to the buyers order that one carton’s will
fill up 10 pieces of long gents & ledis T-shirt, 20 pieces of short & middle gents shirts.
Quality Control:
The quality of garments mainly depends on quality of fabric used. Therefore, care must be
taken while purchasing fabrics to ensure good colourfastness properties, uniformity in shade
etc. Generally garments are made as per customer's specification in respect of size, design
and fashion.
According to per hour (200-250):
These are the different workstation and those task, task period. In one hour, Alama Textile
produce 200-250 shirt. Given below the task time and those steps workstation-

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Task Task time Forword
a
b
c
d
e,f,g
h
i
j,k
l
m,n,o
p
5 min
5 min
15 min
5 min
4 min
3 min
12 min
4 min
3 min
3 min
4 min
c
c
d
e,f,g
h
i
j,k
l
m,n,o
p
end.

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Precedence Diagram:
E K M
A C D F H I L N P
G J O
Fig: Precedence diagram For Dying
E K M
B C D F H I L N P
G J O
Fig: Precedence diagram for Printing
The process of assembly line balancing involves these steps:
a) Cycle Time: Cycle time is whose workstation’s time needs to be highest.
Cycle Time: 15 mnt.
b) Minimum no. of workstation: What minimum no. of workstation must be needed for
a production process, that is minimun no. of workstation.
∑ each workstation
Minimum no. of Workstation: ……………………..
Cycle time
60 mnt
=…………
15 mnt
= 4 workstations

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c) Maximum no. of workstation: It is the summation of all workstation.
Maximum no. of workstation: 5+5+15+5+4+3+12+4+3+3+4
=60mnt
d) Idle Time: It is calculated by-
I = nc-∑t
=4*15-60
= 0 mnt.
e) % of Idle Time: It is calculated by-
% of I = I/nc
=0/4*60 *100
= 0%
f) Efficiency rate: It is calculated by-
Efficiency rate = 100%-%of I
=100%-0%
= 100%

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Draw backs:
There are several draw backs in any factory. Some of them are – power fall, absent of
workers, defect product, equipment fall, crisis of raw materials, ending inventory, political
issues, foreign issues, labour relation, management issues etc.
Power fall:
Anytime electricity can be gone, causes planet power fall. Resulting huge loss of
production in every minute.
Absent of workers:
About thousands of workers works in a factory and each of them have specific
responsibilities. If any of them cant present due to any reason, it’s causes negative
impact on production.
Defect products:
In every hour, factory produces thousands of finished goods. During the production
process may many defective products can be produced, which recognized as loss.
Equipment fall:
Most of the equipments are being used for long time. Its causes sudden fall of
equipment. For repairing or resetting this equipment needs so many cost and time as a
result production process can be hampered.
Crisis of raw materials:

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In several times in market, raw materials prices remain so high due to unavailable
supply of raw materials. It is a threat for a factory.
Foreign issues:
In any foreign issue, forecasting may not be right or production can be fall.
Ending inventory:
If any product or raw material are produced or bought, more than demand or order, it
may create inventory. As a result it creates cost of time and space.
Management issues:
If management team is not skilled, production process, as well as there no sector can
not operate effectively.
Political issues:
Political issues can be hampered in production and supply process.
Labor relation:
Production can be hampered because of any specific issues in labor relation.
Unskilled labor:
An unskilled labor can’t operate production process effectively.
FORECASTING:

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Generally, company don’t forecasting on forecasting term. Actually, R&G factory’s
forecasting depend on their production capacity. How much they can be produced, depending
that they keep the order of the customer. Production depends on several factors-(a) Political
Ground, (b) Manpower, (c) Machineries, (d) raw material, etc. If sometimes the order is more
than their estimate, they complete their order through overtime, bonus, extra salary, other
facility, etc.
Their order also is differentiated based on season. Different season’s production must be
different. So in a sense, it can be called in seasonal variation or seasonal forecasting.

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Opinions:
We can see before that factory faces some problems due to several reasons. A factory can
improve such situations by –
Having alternate power supply. Ex- generator, solar energy etc.
Every worker need to know about every sector basic tasks, so that they can offset the
loss.
If factory follows JIT system, they can reduce the rate of defective units.
Efficient technical team should be hired to fix the equipment problems.
According to forecast, raw material should be bought and finished goods should be
produced, resulting no or small lot size inventory.
Training should be held for unskilled labor.
Management team should be skillful.

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CONCLUTION:
They are the group of Mim Group., and have an excellent track record in apparel
manufacturing for the last 20 years and are now ranges the 2nd
largest company in the
country.
Quality and on time delivery is the corner stone of our success. Customer satisfaction is the
key to our establishment. We ensure timely shipment and delivery to gain faith and
confidence to our valued customer.
We make all types of bottoms and tops (Pants, Shirts, Ledis, Dress, Overall shorter, Sweater,
etc)
In this study the lean manufacturing tools and techniques were studied and used in case
company (garment manufacturing industry). It is the first growing company carrying out
business on 3 foundation principles-
a) Customer services
b) High quality
c) Quick response

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Company follow these ideologies for growing their market in rapidly with customer
satisfaction. Throw this study we identify some disadvantages of this company, and in against
we given some opinion. Although they are very efficient in every step, in spite if they follow
our suggested opinion, we ensure they would be effective, and rapidly will be the market
leader.
References
1. Www.wikipedia.com.
2. Www.mimgroup.com.
3. Www. productionprocess.com.

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