1. Welcome to the Presentation
MD. Mustafijur Rahman
Operation Department
EPYLLION Style LTD, Banglabazar,
Gazipur, Bangladesh.
M: +88-01733484867
.

2. Epyllion Group started its journey as a house of Ready-made Garments (RMG)
engaged in manufacturing and exporting of Knit Apparels since 1994 and has
been considered today as one of the emerging pioneer in RMG sector with
substantial establishment of its backward linkage of all kinds of knit garments,
textile, wet processing & garments accessories. It has the state of art vertically
integrated garments manufacturing facility which ensures one stop service to the
buyers. We have established ourselves as an important garments manufacturer for
a number of renowned brand apparels of Europe, USA, Asia & Africa.
Epyllion Group

3. Epyllion
Group
Retail
Brand
Textile
Garments
Garments
Accessories
Real Estate
Testing LAB
Washing
Plant
Food &
Beverage
Overview of Epyllion Group

4. Knitting section
Objectives:
 To produce fabric from yarn
Products:
 Single jersey fabric
 Double jersey fabric
 Fleece fabric
 Derivatives of above (polo pique , single lacoste ,double lacoste etc)
Core Jobs
 Maximum use of yarn and best quality product production with the
maximum efficiency.
 Maximum use of manpower.
Epyllion Fabrics Ltd.

5. Machines:
 Circular knitting machine
 Flat bed machine
Relation with the other departments:
 Store
 Dyeing, Finishing, Q.A
 Garments.
Strength-:
 Skilled Man-power
 Team Work
 Q.A
Knitting section (contd.)

6. Weakness:
 Insufficient light entrance at the floor.
 Sometimes machines are not in separate core which may cause fabric
contamination.
 If there is lack of power supply at the very first knitting is made to stop.
 Fabric width & GSM variation.
Knitting section (contd.)

7. Objectives:
 Coloration of fabric,collar,cuff etc.
Core Jobs:
Dyeing related all activities such as-
 Maintain specific Shade
 Hand feel
 GSM
Relation with the other departments:
Knitting, Store, Batch Section, Finishing, Quality, Planning, Cutting etc.
Dyeing section

8. Strength:
Auto dosing m/c
 Skilled and Hard working manpower
Weakness:
Unfavorable working condition,
 Toxic chemicals
 Too high temperature
Dyeing section (contd.)

9. Objective:
To treat effluent and dispatched it in pure condition as possible.
Strength:
 Digital screen to see the PH level. Generally 7.5
 Application of the law of fluid mechanics to control temperature.
 Continuous circulation of oxygen.
 Reuse of sludge.
Weakness:
PH level is little bit in the higher region.
Effluent Treatment Plant(ETP)

10. Objective:
To wash the Garments, fabric,
 For required appearance.
 To add value & maintain quality as well as style as per buyer
requirement.
Washing Section

11. Washing section (Contd.)
Machine Name No. of Machines/Operation Capacity (In Use)
Belly Machine 10 Pcs 40 kg each
Dryer Small (12 Pcs) 40 kg each
Medium (2 Pcs) 60 kg each
Tumbler Dryer 80 – 100 kg
Sample Dryer Belly m/c (1Pcs)
E- Flow Machine Spray operation 25 kg
Front Loading Machine All in One
(Washing, Hydro, dryer)

12. Product & Service:
Silicon wash
Fixation/ Bleed
control
Enzyme wash
Bleach wash
Acid wash
Over dyeing
Burn out
Dip bleach
Dip dyeing
Oil wash
Washing Section (Contd.)
Strength:
 Skilled Man-power
 Crucial operations performed
Weakness:
 Short space that’s why handling problem.
 Very few software based machines.
 Poor drainage system.
 No CCTV camera.
 No size wise monitoring.

13. Objective:
To produce accessories for garments.
Production Units:
Epyllion Ltd
Units
Carton Auto Carton
Semi- Auto Carton
Poly
Gum Tape
Label & Price Ticket
Narrow Fabric Elastic
Draw String
Twill Tape
Printing Press
Ball Press/ Butterfly

14. Order
receive
Production
planning
Raw
material
requisition
Sample
preparation
Sample
approval
Bulk
production
Quality
inspection
Transfer of
finished
goods
General process flow of all department in
EPL

15. Machines:
Plastic Bag Converting Machine
 PE (Polyethylene) machine- 4 Pcs
 PP (Polypropylene) machine- 1 Pcs
Bottom Sealing Machine- 2 Pcs
Side Sealing machine- 2 Pcs
Die cutting machine
Foil printing machine
Lamination machine
Polar cutting machine
Epyllion Ltd (contd.)

16. Strength:
Shorter lead time
Nice working environment
Generally low rejection of final products
PPE in use at gum tape section & other noisy areas.
Weakness:
Idle machine.
Lack of basic knowledge in root level.
Violation of NOISH lifting rules.
Epyllion Ltd (Contd.)

17. Basic Manufacturing Process
Epyllion Style LTD
Fabric
Receive
Inspection
Cutting
Sewing
Non-Wash Wash
Send to
Washing plant
Finishing
Embellishment

18. Objectives:
• Fabric cutting in order to produce cut panels.
• Grouping or bundling
• Quality check.
Machines:
Auto spreader
Auto cutter(CAM machine)
Straight knife machine(30-35 Pcs)
In cutter machine(8 Pcs)
Fusing machine(2 PCS)
Over lock machine(6 Pcs)
Band knife machine(2 Pcs)
Cutting Section

19. Relaxation
Table
preparation
Measurement Layout Moving
Cutting
Sorting Numbering Rack
Numbering
General Process Flow of Cutting Section &
Fabric Relaxation Time
Fabric Type Relaxation time (hr)
Lycra fleece 48
Lycra mix other fabrics 24
Interlock 24
Pique 24
Viscos 24
Polyester 48

20. Thick & thin
Uneven brush effect
Contamination
Crease mark
Pin holes
Miss yarn
Needle line
Oil spot
Lycra out/damage
Knot
AOP print defect
Fabric Defects
 Slab
 Hole
 Panel shape out
 Running shade
 Slant
 Improper cut mark
 Set up
 Dirty spot
 Softener spot
 Sinker mark

21. Table
preparati
on
Moving Pining Marker
Draw
(Marker
man)
Bottom
FittingPining
Cutter
man
cuts
Body
&
Sleeve
Fitting
Cutting section (Contd.)
Flow diagram of cutting in case of yarn dyeing
Strength:
Quick changeover and shorter lead time.
Strong & efficient team players.
Following YY calculator for consumption.
In case of yarn dyeing pining is performed efficiently.
PPE in use while using straight cutter
Weakness:
 At label section manual cutting in stead of using machine.

22. Machines:
Lock stitch m/c
Over lock m/c
Flat lock m/c
Kansai m/c
Feed of act arm
Button hole m/c
Button attach m/c
Bar teck m/c
Snap button m/c
Smoke m/c
Chain stitch m/c
Sewing section
Objectives:
Sewing of cut panels to form garments.
Strength:
 High production rate (49 sewing lines)
 In line inspection & final inspection.
 Flexible machines.
 Continuous monitoring.
Weakness:
 Non-uniform rejection rate.
 Line balancing (insufficient).
 Tendency of skipping work.

23. Objectives:
Packing garments after final inspection and finishing work(if needed).
Finishing section
Strength:
 Secure workspace protected from general’s entry.
 Proactive workforce.
 Effective monitoring.
Weakness:
 Rejection alarm at the last moment.
 Lack of communication.

24. ORGANOGRAM
DGM
Operation
Dept.
Manager
Ass.
Manager
Asst.
Executive
MT
IE Dept.
Sr.
Manager
Asst.
Manager
Sr.
Executive
Executive
Asst.
Executive
MT
Quality
Dept.
AGM
Sr.
Manager
Asst.
Manager
Sr.
Executive
Executive
Asst.
Executive
MT
MCD
Dept.
Manager
Asst.
Manager
Sr.
Executive
Executive
Asst.
Executive
MT
Cutting
Dept.
Asst.
Manager
Sr.
Officer
Officer
Sr.
Supervisor
Supervisor
Marker
Man
Cutter
Man
Operator
Helper
Production
Dept.
Manager
Asst.
Manager
Sr.
Officer
Production
Officer
Line
Chief
Supervisor
Operator
Helper
Finishing
Dept.
Manager
Asst.
Manager
Sr.
Officer
Officer
Line
Chief
Supervisor
Operator
Helper
Planning
Dept.
AGM
Sr.
executive
Asst.
Executive
MT

25. Units Department Key Feature
ESL Merchandising • Order finalize with buyer
• Price negotiation
• Material requirement
identification
• Overall order shipment
monitoring.
ESL Planning • Making & follow up T&A
calendar.
• Fast react(Planning software).
Corporate Supply chain • Take necessary steps to provide
tools after requisition.
ESL MCD • Performs same as inventory.
• Quality inspection.
Brief Discussion on some Departments

26. Objectives of IE:
To set target and submit balance report within schedule time.
To spread production planning information.
Activities:
1.Discuss with planning about new style.
2. Collect sample and discuss with PO and technician about it.
3. Prepare operation bulletin
4. Prepare lay out & handover it to PO, LC & technician
5. Arrange pre- flight meeting.
6. Monitoring line feeding.
7. Line balancing.
8. Make QCO report.
9. Set target.
Day to day object & activities of IE

27. Target Setup & Efficiency Study:
SMV=Basic Time + Allowance
Basic Time=Cycle Time*Performance Rating
IE Contd.
Personal Allowance
Machine Allowance
Bundle Allowance

28. Efficiency =
Total Producton∗SMV
𝑇𝑜𝑡𝑎𝑙 𝑀𝑎𝑛𝑝𝑜𝑤𝑒𝑟∗𝑊𝑜𝑟𝑘𝑖𝑛𝑔 𝐻𝑜𝑢𝑟∗60
∗ 100%
Target=
𝑁𝑜.𝑂𝑓 𝑊𝑜𝑟𝑘𝑠𝑡𝑎𝑡𝑖𝑜𝑛∗𝑤𝑜𝑟𝑘𝑖𝑛𝑔 𝐻𝑜𝑢𝑟∗𝐸𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦
𝑆𝑀𝑉
Example:
Let,
SMV=10
Total Production=2000pcs
Working Hour=8
Total Manpower=70
IE Contd.
Efficiency=60%
Target=3360pcs

29. Operation Department

30.  Collect & maintain material booking calculation & P.O sheet from
merchandiser.
 Arrange Pre Production(PP) Meeting.
 Maintain 'Input-Output sheet' before PP meeting for proper size wise
monitoring.
 Maintain Input-Output panel.
 Directly monitor each & every process to find out process wise wastage%
 Maintain “Fabric Study report” to calculate actual fabric wastage%
 Communicate with textile for extra fabric if fabric wastage is more than
allowed%
 Cut maximum & ship maximum with the received fabric quantity.
 Communicate with Merchandiser if extra raw material required to ship
maximum quantity.
 Maintain required MIS.
Job Responsibility

31. Fabric
Pillowcase
Cutting
Off-cut
Short Pcs
Defect Panel
Size Set
Embellishment
Reject
Washing
Reject
Shade
Approval
Sewing
Reject
Finishing
Reject
Left-Over
Sample
Process Wise Wastage

32. MBC UPDATED .xlsx
Material Booking Calculator
INPUT-OUTPUT SHEET
INPUT -OUTPUT (EKL-160510).XLSX
INPUT-OUTPUT MONITORING SHEET(BLANK).XLSX

33. THANK YOU
THANK YO