WOLKITE UNIVERSTY

COLLEGE OF ENGINEERING AND TECHNOLGY

DEPARTMENT OF GARMENT ENGINEERING

HOSTING COMPANY BIGM

TITLE: -DESIGN AND DEVELOPMENT OF APPAREL

PRODUCT FROM WASTE FABRIC

PREPARED BY: BIRHANU ALEMU

ID NO…........................................098/05
ACADEMIC ADVISOR: MR.ABDULHAB

Submission date: 01/02/2012 E.C

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DECLARATION
My name is BirhanuAlemufourth year Garment engineering student. At the beginning of my
work (internship program) I have announced myself to the company by using the form, which
is accepted from institute of EITEX and the company Then to exchange plant to plant up to
four months to finishes the task one or reports to give the reports for the company managers
and academic adviser side by side to assess the problem. I hereby declare that the work which
is being presented in this thesis entitled“Fabric utilization and waste minimization” is
Original work of my own, has not been presented for a degree of any other university and all
the resource of materials uses for this thesis have been duly Acknowledged.
This is to certify that the above declaration made by the candidate is correct to the best of my
knowledge.

ABEDULAHIB
Name of the Academic Advisor Signature Date

BIRHANU ALEMU
Name of Student Signature Date

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ACKNOWLEDEMENT
With sincerity, I extend my warm and deep appreciation and gratitude to my advisor,
Abidulaband my company advisor Nurdine for their unreserved guidance and Support to
come up with this project work. Above all, I praise the Almighty Father a Lord Jesus Christ
who gave me His enabling grace to successfully complete this project work within the given
time. I would also like to thank all who responded to my questionnaires and interviews, which
helped me in coming up with this project.
Finally, I thank my fatherAlemuGebire, my motherBeletekefaleand my Dormitory friends.

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EXCUTIVE SUMMERY
Internship is a proven way to gain relevant knowledge, skill and experience while establishing
important connection in the field. For the last fourmonths in our internship in BIG M
GARMENT PLC. We got the required experience and, in this report, I have tried to list the
Overallaspects of the internship experience. In the first partof the report, it provides
information about the hosting company. It starts from the brief history of the company ,about
workers, work flow of company, organization structure, accessories store, intra and
interdepartmental communication format, specification sheet and interpretation ,spreading
table, cutting department, marker making procedure, cutting and bundling procedures, cutting
department, operation break down ,fabric swatch, packing procedure, quality control
procedure, company main product, main customers, main sub-contractors. And we provide
time study sheet for each operator to prove the working capacity of the company based on
operator’s performance.
In second part of the report, I provide which is used me to investigate project so as
observation in specialized areas like product engineering example production improvement,
quality improvement, quality assurance, pattern making, plant lay out, work flow of company,
Also this part contains the main finding of the problem and its solution. While we are work on
thus project all things are not as we have expected so the challenges that I had faced during
the internship experience and solutions to overcome thus difficulties are also include in this
report.
Third Part of the report is describes the overall benefits that I have gained from this Internship
in terms of improving our practical skill, theoretical knowledge, Communication

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Table of Contents
DECLARATION ................................................................................................................... ii
ACKNOWLEDEMENT .......................................................................................................iii
EXCUTIVE SUMMERY ...................................................................................................... iv
1.2.1 Vision .................................................................................................................... 3
1.2.2 Mission .................................................................................................................. 3
1.2.3 Objectives .............................................................................................................. 3
1.2.4 Value ..................................................................................................................... 3
1.3 Organization structure................................................................................................... 4
1.4. Departments and Their Responsibilities ....................................................................... 5
A. Production Planning and Control Department ................................................................ 5
B. Quality Control............................................................................................................ 5
C. Design and Sample Development Department ............................................................. 5
E. Marketing and Sales Department ................................................................................. 6
F. Administration and Human Resources Department ...................................................... 6
G. Finance Department .................................................................................................... 6
1.5 Work flow procedure .................................................................................................. 10
1.6 Garment Departments ................................................................................................. 10
1.6.1 Fabric Store .......................................................................................................... 10
1.6.2 Accessory storage................................................................................................. 12
1.6.4 Designing and sampling department ..................................................................... 13
1.6.6 Marker Making Department ................................................................................. 16
1.6.7 Spreading Department .......................................................................................... 16
1.6.8 Cutting Department .............................................................................................. 18
1.6.9 Ticketing and Bundling ........................................................................................ 20
1.6.10. Printing and Embroidery Section ...................................................................... 21
1.6.12. Maintenance Department ...................................................................................... 24
1.6.13. Inspection Section ............................................................................................. 25
1.6.13 Finishingand Packaging Section ......................................................................... 25
1.7 Material Handling System ....................................................................................... 27
1.10 Market and Business Analysis ............................................................................... 29

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 1.11 Source of Supply ................................................................................................... 29
1.12 Present layout flow of company ............................................................................ 29
1.13 Material Flow Processes of company ..................................................................... 30
1.14 Types of Flow Patterns .......................................................................................... 30
1.14.1 Horizontal flow pattern....................................................................................... 31
1.14.2 Vertical flow pattern ....................................................................................... 31
1.15 BIG-M apparel/Garment Manufacturing System ................................................... 31
1.16 General Plant Condition ........................................................................................ 32
1.17 Strength and Weakness of Big-M Apparel/Garment Factory Plc. .............................. 32
1.17.1 Big-M Apparel/Garment Plc Strength ................................................................. 32
1.17.2 Big-M Apparel/Garment Plc Weakness .............................................................. 33
2.4 Benefits of the Study................................................................................................... 35
2.5Limitation of the Project .............................................................................................. 36
2.6Scope of the study........................................................................................................ 36
2.7Literature Review ........................................................................................................ 36
2.8.1Data Gathering Procedure ......................................................................................... 38
2.8.2 Method of Data Collection ....................................................................................... 38
2.8.2.1 Primary data collection: ..................................................................................... 38
2.8.2.2 Secondary data collection ...................................................................................... 39
2.9.1 Medium and Large Waste ..................................................................................... 40
2.9.2 Small Wastes ........................................................................................................ 41
2.10 Waste Percentage ...................................................................................................... 42
2.12 Result and Discussion ............................................................................................... 44
Cost Calulation For Small Components ............................................................................ 44
Cost calculation For Medium And Large Waste ................................................................ 46
Total Profit Gained from Wastes ...................................................................................... 47
2.13.1 Conclusion ............................................................................................................. 48
2.13.2 Recommendation ................................................................................................... 49
Diagram about stage of waste ............................................................................................... 49
3.2. Benefits I gained from internships .......................................................................... 50
3.3. Practical skill ............................................................................................................. 50

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3.4. Problem solving skill ................................................................................................ 51
3.5. Team playing skill .................................................................................................... 51
3.6. Leadership skill ........................................................................................................ 51
3.7. Work ethics issues and industrial psychology ......................................................... 51
3.8. Interpersonal communication skill.......................................................................... 51

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List of figures
Figure 1company background ............................................................................................................ 2
Figure 2company profiles ................................................................................................................... 2
Figure 3 fabric store in big-m apparel/garment factory plc. ............................................................. 11
Figure 4 accessory store in big-m apparel/garment factory plc. ......................................................... 12
Figure 5 fabric inspection machine ................................................................................................... 13
Figure 6 sample design department in big-m apparel/garment factory plc. ........................................ 14
Figure 7 marker making in big-m apparel/garment factory plc .......................................................... 16
Figure 8 spreading big-m apparel/garment factory plc. ..................................................................... 17
Figure 9 cutting in big-m apparel/garment factory plc....................................................................... 20
Figure 10 ticketing and bundling in big-m apparel/garment factory plc. ............................................ 21
Figure 11 printing in big-m apparel/garment factory compound ........................................................ 22
Figure 12 sewing section in big-m apparel/garment factory plc. (Operators during sewing) .............. 23
Figure 13 Inventory machines in sewing room ................................................................................. 23
Figure 14 maintenance room in big-apparel/garment factory plc. ...................................................... 24
Figure 15 packaging (packed products) in big-m apparel/garment factory plc ................................... 26
Figure 16 warehouse/store department in big-m apparel/garment factory plc. ................................... 26
Figure 17 material handling equipment’s in big-m apparel/garment factory compound ..................... 27
Figure 18 different type of products produced in Big-m apparel/factory plc. ..................................... 28
Figure 19 Waste Deposition in BIG-M apparel/garment factory plc .................................................. 39
Figure 20 medium and large waste in big-m apparel/garment factory plc .......................................... 40
Figure 21 small and big waste in big-m apparel/garment factory plc. ................................................ 41
Figure 22 men’s cape, sample checking, short products &tie ............................................................ 42

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List of table
Table 1Total work force in big m apparel and garment factory ............................................... 7
Table 2 available sewing machines in BIG-M apparel ............................................................ 8
Table 3 Different type of available machines in BIG-M apparel ............................................. 9
Table 4departments for wastage source ................................................................................ 41
Table 5 about waste fabric in kilograms (kg) ........................................................................ 44
Table 6 products and their amount gained from small waste fabric ....................................... 45

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 CHAPTER ONE
BACK GROUND OF THE COMPANY
1.1 Introduction
This report is written on the practical attachment done for 4 month in partial fulfillment of the
required of the community oriented internship course to realize the practitioner skill
Development. I was attached to Big M apparel & garment PLC (public limited company).Life
is a result of experience and practice. There is a saying that says practice makes perfect and
this perhaps can be applied to my internship session. For it is flashing light to understandings,
concerning to apparel & garment engineering aspects that I should know (about).In order to
fit the target market base sales representative will purchase Varity of sizes colors and styles.
The management will rely on customer feedback suggestions and sales report to introduce or
eliminate certain brands .styles and sizes. The products produced by big apparel are coat,
jacket, shirt, trouser, long dress, hair cover, masks, bags, shoeshine, and much more up on
specific request. Among the criteria’s that makes BIG apparel makes differentiate from others
are it maintains detailed record on each customer base while logging address, purchase size
and brand for customer follow up the location of the company is central to its target
customers base and on time delivery and fit of offer are manifests its strength from others.
Big-M also out sourcing shop for merchandize with manufacturers who have a regional
representative show room located at Mercator business center in addition to that it is also
solidify relationship with largest and leading manufacturers and exporters of garmenting and
accessories and tailoring material from china. The technology used by the company advanced
be utilize to maintain stock levels and track sales it also use peach tree accounting software
for financial and accounting purpose for inventory management and point of sale transaction
utilize inventory control expert software.
Big-M Apparel and Garment PLC is one of sister companies of MIDEROK Ethiopia
Investment Group in 2011. Among two partner of Sheik Mohammed Hussein Alahmudyand
Ato Elias Meshesha. It is located at Akaka/quality sub city, Worde 10, Addis Ababa,
Ethiopia. The company office resides at this same location. Company covers a total of about
7977m² areas Land holding/Building area 7000m² a job opportune nifty for about 306

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workers (male 78 and female 228) of which more than 70% of the total labor force work in
the garment manufacturing unit. It works only in one shift period.
Apparel and garment sales by economic condition, demography, trend and pricing fashion,
while important for an individual company, plays a limited role in overall market demand. In
terms of composition, woven products took the lion share with 75.63%, followed by textiles
11.56%, yarn at 7.04% and handicraft product at 5.74%. The total machine Capacity is 700
units (currently/ up to now the company is only utilizing 30% of its total Machinery capacity.
In order to fit the target market base sales representative will purchase Varity of sizes colors
and styles. The management will rely on customer feedback suggestions and sales report to
introduce or eliminate certain brand styles and sizes.

Figure 1company background

Figure 2company profiles

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  The company’s main functions are divided into the following areas:
 Management  Cutting area
 Administration  Quality control
 Finance and Accounting  Production area
 Human resource  Printing area
 Sample and design  Finishing area
development area  Finished goods storage area
 Fabric and Trim storage area (shipping)

1.2.1 Vision
To become a number one reference in the Ethiopian garmenting industry and abroad.

1.2.2 Mission
Offering quality style and named brand in an assortment of sizes to accommodate all varying
body shapes.

1.2.3 Objectives
 To Creating best shopping environment that caters to the apparel needs of the urban
and rural.
 To earn 80% of market share and building powerful brand recognition.
 To achieve and receive a profit.

1.2.4 Value
Creating employment opportunity, acquiring skill developed communicated and motivated
employees with good working habit or culture and also producing different types of product.

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1.3 Organization structure

Managing director

Business General Executive

consultant Manager secretary

Deputy
Manager

Production Administra Sales and Finance

Design tion marketing Receiving
merchandise shipping

Screen printing
Store Human Promotion
Cutting
resource
Sewing
Maintenance
Quality control
Anresorce

Diagram 1, organizational structure of Big-m apparel/garment factory plc

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1.4. Departments and Their Responsibilities

a. Production Planning and Control Department

b. Sample and Development Department
c. Maintenance Departments
d. Marketing and Sales Department
e. Finance Department
f. Human Resources Department

A. Production Planning and Control Department

This department is responsible for ensuring the manufacturing of products on controlled and
planned time table that goes along with on time delivery and of acceptable quality within
controlled and installed product quality management system. It is also responsible for
maintaining all kind of necessary documents to achieve the required efficiency level. It is the
sole task and responsibilities of the Production department to enhance productivity. Installing
best production techniques and system so that the desired productivity and production volume
by considering the company resources such as skilled manpower, time and available
machineries to the best benefit of the Company.

B. Quality Control
Maintain Quality of the product is the primal function of the Production Department along
with its subsidiary section such as the quality personnel. This tasks ranges for activities from
the developing stage up to finishing stage and controls the total process on quality level. In
order to do this it uses various techniques including using fabric and trim cutting, stitching,
ironing and packing. Quality managements system is important tool to verify and validate the
quality of products so that the production processes underway can maintain the consistency of
the product. As we are relatively new for this process, we are expecting the support of experts
to provide training to our staff as per international level of inspection.

C. Design and Sample Development Department

This department conducts all kind of product development and samples approval. We still use
manual pattern making, we hope to introduce CAD system in the near future. This technology
is important to maintain quality and efficiency. The design of every product is made by this

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department, which makes the right consumption of fabrics required by any given product
along with the manpower requirement and time it take to make single product. Once such
department makes the design, the mass production of the product will be on the production
process, and the Production department will carry out manufacturing process of the product.

D. Maintenance Department

This department is responsible for maintaining machines including looking into electrical
disturbances, maintaining transport facilities and water resources. The Department is also
responsible for doing preventive and protective maintenance of machines.

E. Marketing and Sales Department

Marketing and Sales Department is currently working on the Sales part since this section is
mainly engaged with receiving work orders from customers and then placing such job orders,
it afterwards informs to the production department so that production department could
produce according to the requirements set such as quantity, size, color, and other required
information on the quality of the product and it follows up on the process of production until
the customer or buyer receives its final product as per the requirement set.

F. Administration and Human Resources Department

This Department handles all kind of routine activities, which relate to recruitment, training,
keeping staff records, such as annual leave, sick leave, holidays, overtime and other
employees benefits; it also protects the company by ensuring that government rules and
regulations are employed and maintained within the company administration. It is also
responsible to the safety and security of company properties such as office equipment’s and
furniture, factory machines and equipment’s, vehicles health and security, and factory
buildings as well. It ensures that proper insurance is entered and other safety precautions are
done such as the installation of fire extinguisher and appropriate safety measures in relation to
accidents that could occur in the company compound. It also makes sure that trade and other
government licenses are renewed and properly kept.

G. Finance Department
This department along with stock management system activates all the internal and external
financial transaction proceedings. It prepares quarterly and annual financial reports; it submits

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financial reports to the government tax office annually so that it facilitates in way that the
company trade license could be renewed. It submits financial and other require financial
reports to the top management for its information, consideration and judgment and planning.
It is also responsible for the overall financial transactions and activities of the company in
general.

H. Overview of Human Resource

Just three years in the history of Big–M apparel and Garment plc, the company has achieved a
considerable amount of progress when it comes to human resources. Up to now, we have
recruited above 350 skilled machine operators. The main challenge we face is the high
turnover of the labor force due to circumstances that relate to the living standard of this
country as the becoming nature of the garment sector in the country.

Our company has currently a total number of 375 employees; out of which 290 are female; 60
are male and a nonpermanent or contracted employee consists of 25. The female population
within the company is 78%, which is dominant factor as the work force of the Company. It
gives priority to female as the much of the work force is and is discharging its social
accountability, obligation and responsibilities.

I. Currently Total Work Force and Machine in Big M Apparel Factory

Total workforce in BIG-M apparel

Table 1Total work force in big m apparel and garment factory

NO Name of department Quantity

1 Administration 1
2 Designing 2
3 Finance 1
4 Marketing 1
5 Human resource 2
6 Law 1
7 Cafeteria 4
8 Secretary 2
9 Maintenance 3
10 Security 6
11 Clean 14

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12 General service 14
13 Cutting 11
14 Finishing 17
15 Printing 6
16 Sales & measurement 6
17 Shipping 2
18 Store 3
19 Bar tack 18
20 Sewing line 217 + 9 contract operators
21 Super visors 13
Total 318
J. Machines available in Big- M apparel and their origin

Sewing machines
Table 2 available sewing machines in BIG-M apparel

No Brand Model Description Machine Quan

origin tity
1 Juki DDL-8300N 1needle lock stitch machine China 183
2 Juki DDL-8700-7- 1needle lock stitch under China 50
WB/AK85/SC910/M911 trimmer with EE10BT
motor
3 Juki MO-670450E44OH 1needle three thread server China 25
4 Juki MO-6714SBE644H/G39 1 needle three thread Mack China 65
safety stitch machine
5 Juki MO-6716SDE64OH 2needle 5-thread safety China 12
stitch machine
6 Juki MB-373NSOOS Chain stitch button server China 14
7 Juki LBH-781U Lock stitch button hole Japan 14
stitch
8 Juki LBH-780U Inch knife for cutting 6,4 to Japan 6
38
9 Juki MS-1190D Feeds of arm 2-needle chain Japan 9
stitch
10 Juki MH-382U dabble needle chain stitch Japan 2

8
11 Juki LH-3128(WITH CENTERE Electronic bar-tack machine Japan 8
KNFE ATTACH)
12 Juki LK-1900ASS0000 2-needle lock stitch machine Japan 8
13 Juki/ca MF-7823-U10-B64 3needle top &bottom cover Japan 12
mion stitch cylinder 64mm
special
14 Juki MF-760ST-UO6-B64/HOL- 3needle top &bottom cover Japan 44
B48 stitch hated bed 6,4/48mm
15 Ks DFB-1404P For short front Japan 2
16 Ks DFB-1404P For waist band USA 2
Total 456
K. Extra machines available in Big- M apparel

Table 3 Different type of available machines in BIG-M apparel

No Name of machine Purpose of machine Quantity

1 Fabric inspection For yardage identification 1
machine And defect identification
2 Straight knifes For the purpose of lay cutting 3
3 Band knife For the purpose of cutting but it is an ideal position 1
4 Fueling machine To fuse of entering of small components 4
5 End cutter For the purpose of cutting the end of pug 1
Printing
1 4head rotary Hold different screens 1
machine
2 Heater(dryer To drag the paste on the print 2
softener –to fasten
the print)
Total 12

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1.5 Work flow procedure
Order receiving Sample making Iteration Pattern production

Grading Marker making Spreading Cutting Ticketing and

Bundling Printing and Embroidery Sewing Inspection Ironing

Packing Warehouse Dispatch.

1.6 Garment Departments

Stock Keeping Department

As the building structure of Big-M apparel and garment plc the store department section is
located in the ground floor of the building. It covers 1000 meter square of the company total
area. The store contains both fabric and accessories it has enough space to accommodate the
material but the responsible person doesn’t utilize the space effectively.

1.6.1 Fabric Store

Big m apparel and garments factors are fabrics to receive locally china textile factory to inter
fabric room to put shelf, carton, plastics, socks and ground. There are woven fabric they have
different types of fabrics like: -cotton, polyester, viscous,tetron and twill.

The company have a stock card which is a card used to control the balance of the material by
writing down amount of received material and the amount of fabric (material) which utilized.
the store item are stock and controlled by using stock card in which every fabric rolls and
accessories and some spare part which found in store will have its own stock card to control
its balance through the listing down in and out of the materials.

Work Flow in Fabric Store

Receiving of material

Allocate card number

Check out balance Documentation

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In and Out Communication Format in Fabric Store

Goods receiving voucher used to record and register when fabric / materials comes in to the
factory store.

The store issue voucher these one is used to with draw materials from the store when the
customer order is received.

Material requisition format is another type of format which used to request the material
which found in the store.

Material return format which is used to register the returned material from the order
requirement to the store after completing the work.

Order distribution format this type of format have different contents such as order quantity
specific style based on color, size, fabric type, based on such specification the order will
distribute.

Purchasing requisition format it is a requisition format they used these type of format when
some material or item is not available in the store to be bought from the market most of the
time for local market be request using these format.

Stock card which used to control the balance of the material or item and sometimes used to
specify location which the material are grouped and placed within the store.

Figure 3 fabric store in big-m apparel/garment factory plc.

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1.6.2 Accessory storage
Garment accessories are an important element in a garment, however garment accessories
provide good finish and it gives good quality to the garment. This store is responsible for
sorting, neatly and purely the trims received from the locally and foreign suppliers.In
accessory storage there are many finishing and decorative material or anted in dozen within
matched size, color and their end use there is kaizen principle on their work plan but they did
not apply it in formal ways.

Figure 4 accessory store in big-m apparel/garment factory plc.

Different Types of Trims and Accessory

 Buttons hooks and Zippers in different size
 Labels : wash care, size, brand and fit, brand
 Fusible labels, Laces
 Needles and Threads i.e. sewing and embroidery
 Packing materials: hangers, collar stand, brand label, packing box, poly bag
 Feed dog, presser foot, and throat plat
 Ruler Bobbin Elastics and Cutting blade.

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 1.6.3 Fabric inspection machine

Fabric inspection machine checks this parameter like: -shade variation, fabric Hole, tick
yarn, slack yarn, hole fiber and to measure the fabric by yard.

Figure 5 fabric inspection machine

Strength of the store room are: -

Different type of fabrics are available in the plant

The factory records in and out of fabrics by using card this prevents from stock out
Every type of fabric have been recorded and consist full information such as length
color meter type etc. it minimizes time to find.

Weakness of store room is:-

Un necessary space use due to unplanned arrangement of accessories

It is difficult to differentiate individual fabric type from the other
Space utilization is not considered
Kaizen rule not correctly used
The fabric inspection machine is manual many of errors/faults are observed by looking
observer’s eye so it leads to loss of production it should have been change in to
automatic machine.

1.6.4 Designing and sampling department

All kind of product development and samples approval are conducted by this department. We
still use manual pattern making, we hope to introduce CAD system in the near future. This

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technology is important to maintain quality and efficiency. The design of every product is
made by this department which makes the right consumption of fabrics required by any given
product along with the manpower requirement and time it take to make single product. Once
the design is made by such department, the mass production of the product will be on the
production process, and manufacturing process of the product will be carried out by the
Production department. This department develops patterns for the required order received
samples that the customer brings. The designer makes the sample based on the customer order
specification sheet. After the customer approved the design sample the designer generates the
production pattern according to the specification made before.

Figure 6 sample design department in big-m apparel/garment factory plc.

Available Machines in Sampling Room

 Single needle lock stitch machine

 3thread over lock
 2needle flat lock stitch
 2needle cover stitch machine
 Button hole, Button attachéand Ironing machine

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 1.6.5 Work Flow in Sample
Through direct measurement

Order receiving with the specification

Order with customer sample

Level of the required sample pattern

Receive the required fabric type from the store for the sample

Prepare a sample for customer specification based

Send the sample prepared for the approval to the customer

Sample approved

Costing by sales department

Finally prepare production pattern

Some of the strength/observations from the sample room are: -

 They have enough machinery and skilled sewing operators and designer.
 There is clean and good working environment.
 There is a lot of worked pattern to minimize time wastage.

Some of the weakness/observations from the sample room are:-

 Lack of cad system, they work manually to prepare pattern and also grade pattern
done by manual system and then placed away from their original placement after use.
 There is un- digitized pattern in the department.
 UN suitable room light positions that make shadow and glare at the needle led it is
difficult to the operator to insert the thread.
 Deficiency of paper, ruler , table, pattern maker& sample maker

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1.6.6 Marker Making Department
Marker is a diagram of a precise arrangement of pattern pieces for a specific style and the
sizes to be cut from a single spread.

Marker Making is the process of determining the most efficient layout of pattern pieces for a
specified style, fabric, and distribution of sizes (requires time, skill and concentration). The
next step after sampling is marker making. This has one marking table that have 2m width, 20
m length and 90 cm height from the ground. The operation is 100% done manually by the
experienced operators in good efficiency.

Figure 7 marker making in big-m apparel/garment factory plc

Some of the strength/observations fromMarker making are:-

Excellent utilization or efficiency of fabric.

Experienced marker makers.

Some of the weakness/observations from Marker making are:-

Misunderstanding of information with production manager.

Marker making operators have less speed when they work.

1.6.7 Spreading Department

Spreading is the process of unwinding large rolls of fabric onto long, wide tables and laying
them in superimposed plies of specified length. In this Garments are spread 100%manually
spreading system, factory there is no individual spreading method but it have its own
position or place which the spreading together and cutting process are done in it. They have

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two spreading table which have length, is 20 m, height is 90 cm to the ground and width is
2m. On spreading table, the worker forces are:-4 operators’, who spreads, control tensions,
align edges to put clump and dead weight and to cuts end.

The duty and responsibility of this room are:

 Count the number of plies

 Ply alignments Check width of fabrics and Controlling tensions
 Spread the right amount of fabric with the right type of color
 They are responsible for fine and accurate cutting by arranging fabrics

Figure 8 spreading big-m apparel/garment factory plc.

Some of the strength/observations from spreading are:-

 They have a very long spreading table.

 They have enough equipment’s such as clumps, dead weight and man power.
 There are different materials handling equipment’s to carry fabric rolls for spreading.

Some of the weakness/observations from spreading are:-

 Spreading tables are long.

 They don’t use technology.
 Poor ergonomics.

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1.6.8 Cutting Department
The objective of cutting room is cutting of garment parts accurately and economically and in
sufficient volume to keep the sewing room supplied with work. Breaking a bulk of laying
garments for mass production, cutting fabric into necessary shapes and sizes of garment.

The four processes involved in cutting room are:-

 The planning, and if appropriate the drawing and reproduction of the marker
 The spreading of the fabric to form a lay
 The cutting of the fabric.
 Preparation for sewing

Cutting is one the most important department for ultimate of the productivity and quality of
the finished garment and it is the main and essential supplier of sewing room. It is the second
department which placed next to the design and sample room according to the company lay
out. It has a combined element of spreading, cutting, ticketing, numbering and bundling the
pieces.

The department head create a suitable and appropriate cut order plan to finish the required
order based on the order specification accordingly the marker will developed and prepare for
effective utilization of cutting the fabric.

The machine available in cutting department

 Three white longest marker and spreading table.

 Straight knife cutter: -for the purpose of cutting the spread fabric which we want.
 End cutter: - these one is used for the cutting fabric after the required length of lay
the fabric from the total fabric roll.

Main responsibilities of cutting department

 Issuing the best quality of fabric spreading

 Inspecting fabric color variation between the roll
 Issuing the cutting quality effectively
 Cutting the fabric according to the master pattern with hundred percent correct

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  Ticketing, numbering and bundling the cut fabric pieces
 Supply all cut pieces to the sewing room
 Finally record the document that how many pieces are cut and dispatch

Cutting and Spreading Procedure

Production order format receive from the production manager

The required fabric type receives from the store

The roll fabric spread according to the required amount

The Single fabric which is marker placed at the top of the spread

Cut the spread

Numbering the Cut pieces

Sorting and bundling according to size

Issuing the pieces to sewing department

Communication Formats within the Department

Production order formats these format is used in the department as the order which received
from the customer what looks like (what specification does the order contain) such as size of
the order, color of the fabric which they order, quantity of the order, Name of the customer.

Consumption record format this type of format used to describe the amount of fabric
consumption for the specific order given by the sales person. The marker making person will
understand and he will try to minimize the consumption during the marker making process.

Goods receiving format the last format which found in the department is goods receiving
format which used to receive goods like fabrics, chock, pencils, pen, measuring tap, and other
materials.

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 Figure 9 cutting in big-m apparel/garment factory plc.

Some of the strength/observations from the cutting are: -

 There are experienced and many number of cutting operators.

 Suitable working conditions and cutting equipment’s
 Experienced cutting operators.

Some of the weakness/observations from the cutting are:-

 There is lack of precise cut fabric parts.

 Absence of uniformity during cutting (no enough consistent of cutting).
 There is no smooth interaction between cutting and pattern design or sample room.
 The most critical point is there are excess amount of fabric wastage due to lack of
effective fabric utilization during marker making. Misunderstanding of production
order format with production manager.
 The last but the most essential thing is unstable and unsuitable ergonomic condition.
 Misunderstanding about fabric properties during cutting

1.6.9 Ticketing and Bundling

Is process whereby each cut piece of fabric is given unique number so that cut pieces of
different shades and sizes do not get mixed and sewn together and, cut pieces after passing
through ticketing and printing need to be bundled or tied up together before goes to the
sewing room.
Numbering is to give a number for all cut garment components.

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Ticketing is about the bundle information (operation name, number of component and
operator name).
Bundling means tying the cut fabric size by size (numbering and tying).It contains one
garment component required for one operation.

Figure 10 ticketing and bundling in big-m apparel/garment factory plc.

Some of strength/observations from the ticketing and bundling are:-

 There is enough human power in this department
 There are different writing materials like pencil chalk pen and soap.
 There is bundle checker which checks if they write correct number with the right cut
garment component.
Some of weakness/observations from the ticketing and bundling are:-
 There is no checker/controller if mistake is happen
 Bundle garment components are transported manually to sewing room so it takes time
and exposed for dirt.
 Size and shade variation occur due to missed number and repeated numbers.

1.6.10. Printing and Embroidery Section

Printing is the process of applying color to fabric in definite patterns or designs. In properly
printed fabrics the color is bonded with the fiber, so as to resist washing and friction.
Printing means one or more colors are applied to it in certain parts only, and in sharply
defined patterns.

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Screen-printing is the most flexible printing process. It can be used to print on a wide variety
of substrates, including paper, paperboard, plastics, glass, metals, fabrics, and many other
materials including paper, plastics, glass, metals, nylon and cotton.
The advantage of screen printing over other print processes is that the press can print on
substrates of any shape, thickness and size. Like embroidery, screen printing is wholly
determined by the customer and may be requested to put logos or other graphics on garments
or to print brand and size information in place of affixing tags.

Figure 11 printing in big-m apparel/garment factory compound

1.6.11. Sewing Room

Sewing room is one of the main and critical departments of changing a cut fabric piece in to
different dimension with different shape of garments which needs to be fit and balance the
required person (customer). In these room the operators receive a cut bundle fabric through
the lines supervisors and repeatedly sew the required product and the end of the lines there is
a quality assurance is perform to ensure that the produced garment will constructed in full
garment.

This room covers 80% of the company man powers present, assembling of the garments in
each operator in one garments, They have 12 lines one line have 20 machine and 18
operators in totally 240 machine and each lines has their own supervisors. The room
possesses the majority of the working force. Almost all the operators are skilled and semi-
skilled operators.

Responsibilities of sewing room: Stitch garment components efficiently effectively and

accurately with quality.

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Figure 12 sewing section in big-m apparel/garment factory plc. (Operators during sewing)

Figure 13 Inventory machines in sewing room

Available machines in sewing room

.Single needle sewing machine • Snap attaching machine

• Double needle sewing machine • Button holing machine

• 3 thread over lock machine • Button attaching machine

• 4 thread over lock machine • Ironing machine and Pressing machine

Some of the strength/observations from the sewing room are:-

 Sewing operators make different types of product

 They have good relation with supervisor and production manager
 They have bonus and incentive when they have done above the target production

Some of the weakness/observations from the sewing room are:-

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  The primary thing is a bad and poor working condition (Poor Ergonomics)
 Side to side operator talk
 Absence of natural air flow routs on the building floor
 The sewing department lay out is arranged by experiences
 Absence of line balance
 The department didn’t give training for the new operators

1.6.12. Maintenance Department

This department is responsible for maintaining machines including looking into electrical
disturbances, maintaining transport facilities and water resources .The Department is also
responsible for doing preventive & proactive ways. They have 3 operators to working
procedures are passive working process means one problem happen to reach and solve daily
problem of each sewing line machine.

Maintenance store have: - pinsa, screw, test light, joder, hammer and different tools which
used for maintenance.

Figure 14 maintenance room in big-apparel/garment factory plc.

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1.6.13. Inspection Section
Inspection consist activities, such as measuring, examining, testing, gaging one or more
characteristics of a product or service, and comparing these with specified requirements to
determine conformity.
Inspection is simply identification of defects. There are 4 inspection operators to inspect
each products by eye in total part of the garment like: - J-shape, arm hole, button hole, button
attach, shade variation, collar, to check every points to put correct position of every
component and to pass to packaging.

1.6.13 Finishingand Packaging Section

Finishing in Big-M apparel/garment factory finishing is done only by ironing to give the
garments a pleasant look. After a garment is fully sewn and assembled, it is transferred to the
ironing section for final pressing. Each ironing station consists of an iron and an ironing
platform. The irons are similar looking to residential models, but have steam supplied by an
on-site boiler. Workers control the steam with foot pedals and the steam is delivered via
overhead hoses directly to the iron.In most facilities, the ironing platforms are equipped with
a ventilation system that draws steam through the ironing table and exhausts it outside.

Finishing Is the final process of the products to check to size, name of order, button and
button hole to overall check the garments and to pressing, folding and send to ware house.
Packaging is putting the finished products in to bags plastics box cartoons etc. products are
packaged according to customer specifications. Also, garments may be placed in protective
plastic bags, either manually or using an automated system, but in these company the process
is done by manually to ensure that the material stays clean and pressed during shipping.
Lastly, garments are placed in cardboard boxes and shipped to client distribution centers to
eventually be sold in retail stores.

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Figure 15 packaging (packed products) in big-m apparel/garment factory plc

1.6.15. Ware House

In big m apparel ware house department can store finished product until its delivery date or
dispatching. There are various finished products stored in warehouse products are arranged on
shelf by their categories and according to their customer.

This department contains 2 workers it also follow formal way documental based work flow.
In ware house products are put in shelf in company name, identification of customers, order
type and finishing department to report in finance department to calculate their cost and to
shipment by the interval of 3 –6 days.

Figure 16 warehouse/store department in big-m apparel/garment factory plc.

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1.7 Material Handling System
Materials handling is the science and artinvolving the moving, packing and storing of
substance in any form, and includes the preparation, placing and positioning the material to
facilitate their movement or storage. It has been estimated that at least 15 to 25% of the cost
of the product is attributable to materials handling activities.
Materials handling is the primary activity of every manufacturing organization.
The Materials – products, items, substances and/or people which are being moved,
transported, or physically relocated.
The Move – (origin, travel path, destination, frequency) to be made.
The Method – (equipment, people, procedures, physical facilities) to be used to make the
move.
The Material handling system that applied in the production area are mainly for storage of cut
pieces and to hold the bundles in the line when transfer from operator to operator and tables
for sorting finished garment before transfer to packaging room.

Figure 17 material handling equipment’s in big-m apparel/garment factory compound

1.8 Big-M Main Product

 Over Coat, Chief Coat, Safari Coat, Pocket Over Coat

 Waiter jacket, Lined jacket and Double Brest Jacket
 Shirt, Polo Shirt,
 Nurse Top, Nurse Coat,
 Coverall, Bib Coverall,
 Trouser, Elastic Trouser,

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  Cleaners cloth
 Student uniforms
 Suits
 Long Dress, V Neck Long Dress,
 Hair Cover, Crown Hat, Baseball Cap, Police Type Cap,
 Vest and Double Brest Vest and much more upon specific request and

Figure 18 different type of products produced in Big-m apparel/factory plc.

1.9 Secured Local Customers

More than 60 MIDROC Companies are our secured customers which we think that further
advertising and promotion works are done, Our Company has already maintained business
relationship with almost half of the MIDROC companies, and we expect that we will fully be
engaged with all of them. Additional to midroc company there are a lot of customers listed
below.

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Nyala Motors, United Auto Maintenance Service, Mamco Plc., Equatorial Business Group,
International Cargo Aviation Service, Star Soap and Detergent, Sheraton Addis, Hora Food
Complex, Addis International Catering, ABC Car Rental, Addis Park, Unlimited Packaging
plc and so on.

1.10 Market and Business Analysis

At present every garment and any kind of business is affected by three main factors of the
market aspect in the world, which are:
1. Low cost
2. on time delivery
3. Acceptable Quality
In order to combat these business and market challenges, our company seek it essential to
make its own business analysis even though it is in its rudimentary stage of investigation and
process of market and business analysis it should make within the country so as to penetrate
the entire market not only within domestic market but also with at least in regional areas and
markets too. One of the important tools and strategies it adopts is to have its own department
in its organizational structure such as the Marketing Department along with selling activities
it performs which mainly focuses on doing market researches and market intelligence works.

Big M Apparel and Garment plc has recognized its strength, weaknesses, opportunities as
well as threats. The company management is looking into the strength and opportunities for
developing the business and is looking into the market scenario both domestic and export.

1.11 Source of Supply

In the Big-M apparel and garment there are two main sourcing regions of fabrics, accessories
and spare part in the company those are abroad from foreign country (by importing) from
different places. In Big M company fabric and accessories comes from different source of
region. Fabric (polyester, poly viscos, twill and fusing) comes from India and China.
Accessories (button, hook, zipper…) import from China retailor.

1.12 Present layout flow of company

History of in Ethiopian apparel and garment industry are used in traditional lay out system.
There work flow are did not considered with correct plant lay out and material handling

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 system Because of this they lose high amount of cost, time waste, and highly movement over
long distance And they make confuse to control work flow. Factory lay outs refers to as the
arrangement of physical facilities such as machinery equipment and Office Proper and
efficient utilization space, material to assure that work proceeds from one point to another
point Without any delay.

Big-M Apparel/Garment Factory have not an organized lay out for production flow because
of the structure of building it is (G+1) and managers are not willing to change the present lay
out. There are two floors where work is done they follow multi-story factory building.

1.13 Material Flow Processes of company

Order receiving
Iteration

Marker making
Pattern production Grading

Ticketing
Cutting And bundling.
Spreading

Printing and Sewing Inspection Ironing

Embroidery

Packing Warehouse Dispatch

1.14 Types of Flow Patterns

Flow patterns can be classified either

 Horizontal
 Vertical

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Our company follows Vertical flow pattern for production flow and U-shape layout
structure for raw materials, component and operators movement.

1.14.1 Horizontal flow pattern

These flow patternsare used for single story building and they are best for expansion.

1.14.2 Vertical flow pattern

Vertical flow pattern exist both in single-story and multistory buildings. Utilization of
overhead space has focused great attention on the design of vertical flow pattern.

Building type of company

There are two types of building

Single story building

Multi story building

1. Single-Story Buildings

Most of the single story buildings also have mezzanine floors built in to give additional floor
space commonly used by managers to keep hawk’s eye over the entire production floor.
2. Multi-Story Buildings

Our company built Multi-story building because they are suitable for industries using
relatively lighter raw materials.

Advantages of Multi-Story buildings:

 Lower site cost.

 Electricity, water, gas, compressed air, telephone and another service runs are smaller.
 Gravity flow of materials from upper to lower floor is possible which reduces the
handling cost of material.
 Sitting of general facilities such as toilets, canteen etc. for staff is easier.

1.15 BIG-M apparel/Garment Manufacturing System

There are two types of garment manufacturing system.

 Pull manufacturing system

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  Push manufacturing system
Garment companies follow their appropriate manufacturing system our company follows pull
manufacturing system they produce products depend on orders received from customer.

Pull system: Pull type production or (make to order) is a manufacturing process in which
manufacturing starts only after a customer order is received. Pull system is manufacturing
system in which production is based on actual daily demand (sales) and information flows
from market to management.

Push system: Is garment manufacturing system in which production is based on a projected

production plan and information flows from management to the market. In push marketing, a
company tries to push its production through the distribution channel. It advertises to
intermediaries such as wholesaler and retailers who then try to generate demand from end
uses.

1.16 General Plant Condition

Currently, the company is working and using 75% of its available machines 25% is inventory
since it is bounded by the market supply and production process is mainly dictated by the
market flow and what the market supplies to our company. However, the Company can
actually produce with 250 machines at hand with a daily output of 1000 units per day. When
full capacity is utilized, it goes far beyond this amount of production quantity per day.

1.17 Strength and Weakness of Big-M Apparel/Garment Factory Plc.

1.17.1 Big-M Apparel/Garment Plc Strength

 BIG-M apparel/garment Company creates a lot of job opportunity for different
workers.
 Good relationship between worker, manager, administration, production manager, and
supervisors.
 Much Availability of raw materials such as labor force, machine, materials and
workers.
 Presence of service’s for workers like free launch, transport, playing pitch area toilet
and bath room etc.

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  Also in transport bus top manager try to make suitable condition for female worker,
elder peoples and Disable persons.
 There is Presence of incentive payment system and bonus to help their families.
 Give permission for some special case like during pregnancy, illness, and for different
ceremony.
 Big-M have a clinic in the compound if an accident happen during working area.
 They have a good expansion area when a huge number of order is received.
 They have enough production machine and Presence of Good inventory system.
 Hard working from top manager to operator.

1.17.2 Big-M Apparel/Garment Plc Weakness

 High number of idle machine/ maximum holding cost
 Absence of quality department/quality assurance
 Un-necessary movement in work place
 High stress/ fatigue on operator some times
 Absence of allowance between working time
 Lack of technology advancement
 Labor turnover due to un-necessary cutting of salary when operators absent.
 Incorrect layout.
 Sewing room has very hot temperature.
 Difficulty of knowing capacity of operator per day/week/month.

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 CHAPTER –TWO

PROJECT WORK

DESIGN AND DEVELOPMENT OF APPAREL PRODUCT

FROM WASTE FABRIC

2.1 Introduction
Among the various department of garment factory cutting and marker making department is
the major area where the fabric waste is generated. In cutting department, much attention
should be given to re-use the fabric wastage. One of the primary methods is to make the waste
change to finished product this makes the company profitable and it protects the environment.
The company to minimize the fabric wastage so, they must use the most efficient marker
making system. But Big-m plc has not much skilled marker maker in the company to create
the most efficient marker.

Recycling is the reuse, remanufacturing, or reprocessing of a material or product with the aim
of reducing waste. There is a much amount of fabric wastage in Big-m plc. Fabric wastage of
in landfills every year in Big-m plc. Fabric wastage is huge problem to gate the company high
profit. And recycling is one of the most easily understood and effective ways to gate profit
and to protect the environments of the company.

Waste minimization is the process and the police of reducing the amount of west by the
person or society. Waste minimization involves efforts to minimized resources and energy use
during manufacture Waste minimization should be seen a primary focus forms management
strategies.
Proper waste management can require significant amount of time and resources therefore it is
important to understand the benefit of waste minimization should can be implemented in all
sector of the economy in an effective safe and sustainable manner. This project report
discusses on how to producte development fabric and waste minimization.

34
2.2 Statement of the problem
On my internship stay I have seen so many problems in Big-m Garment plc one of them is
waste fabric. Currently these waste fabrics cover wide space in store and cutting area.
Mostly these fabrics are count from 1m up to 1.5m to see this wide wastage fabric not good
for company respect and satisfaction. Due to this, after cutting section the department use the
company’s raw materials for the purpose of making uniforms and the rest cut waste fabrics are
sell by tender but we can use wastages between one meter and less is used for making different
products.
2.3 OBEJETIVE OF PROJECT
2.3.1GeneralObjective
Design and Development of Apparel Product from Waste Fabric

2 .3.2 SPECIFIC OBJECTIVE

 To identify the problem of the company
 To develop new design at minimum price for those who are low income group.
 To registering end bit and sorting according to their length and type.
 To develop the best marker making and spreading techniques for this industry
 To produce deferent material and reduce waste by effective cost techniques.

2.4 Benefits of the Study

This project work is very significant for company profit to add a general profit so it is a
method for saving money and minimize waste fabric.
The following are some benefits of the study: -
 To create awareness on the organization’s loss due to wastage efficient production
practices. Waste minimization can achieve more output of product per unit of input
of raw materials.
 To serve as a reference for other researchers in the area of garment wastages in BIG-
M apparel, and on how to re-use the organizational wastages;
 To provide information for BIG-M apparel/garment on how to re-use the wastages.
 Quality of products produced. New innovation and technological practices can
reduce waste generation and improve the quality of the inputs in the production
phase.
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2.5Limitation of the Project
 They are not willing full to tell for me about fabric cost, product cost, waste cost.
 They haven’t recorded the amount of daily weekly and monthly waste.
 There is no written/full information document and controller in the wastage to
differentiate the wastes either they are able to re-use them or not.

2.6Scope of the study

This project is connected in BIG-M apparel/garment factory especially waste fabrics that
occurred on the Cutting section. The project focuses on converting or processing
different waste fabric in to products by recycling, scanning, designing after waste it is
created rather than eliminating the creation of waste in the initial phases of production
and developing of kids wear from waste fabric, example shorts, caps, shefe capes and
ties.

2.7Literature Review
Coming to the Garment industry, there is a desire to reduce Waste to a great extent during
Production. The Prevention of Waste at source, that is eliminating Waste before it is created,
must be the way of the future. Waste Management often results in substantial saving through
reduced purchasing costs and more efficient practices. (International journal of academic
research in business and social science 2013)
Waste due to processing could be controlled only to some extent. The remainingWaste
cannot be avoided. In addition to Wastage caused during processing, there is other. Wastage
like waste due to ineffective estimate of cost and underutilization of time and resource which
could be effectively controlled Wastage is at various level of organization without wastage the
organization cannot run. But the wastage should be less(Asia pacific journal of research 2014)
Some wastage cannot be controlled but some wastage can be controlled to maximum extent if
it is properly planned and handled. Waste helps to identify the high-risk areas affecting
production that leads to waste. By finding the causes for the waste, the employees could be
trained to work efficiently and reduce waste. Moreover, job satisfaction of the employee could
be gained (Asia pacific journal of research 2014)
The concept of sustainable fashion design decreases the waste of fabric and demand of natural
sources(Nam 2010) investigated that sustainable design is a design concept that takes

36
environment, economy, and society into consideration (Dickson M. et al 2012) also suggested
that Sustainable fashion is not a trend; it is way of designing the styles as per positive future
demands (Kim 2008) stated that sustainable designs can be obtained by the six different
methods listed below: using organic fabric or new materials, order-made, reform, reuse, waste
reuse, recycle, and designing multi-functional products.
Zero Waste fashion designing is a method of patternmaking that particularly aims to eliminate
fabric waste from garment production. It is based on age-old practices of using a piece of
fabric so that none is wasted, and it has recently been highlighted as a useful tool for
sustainability in fashion design (RCBC 2002) reported that s number of companies have
successfully embraced the zero waste concept including Hewlett-Packard, Kimberly Clark,
and The Body Shop.
Advantage of Waste Minimization
Excess cost Productivity
Defects Profit
Lead time Quality
Inventory Capacity
Space Job opportunity and
Customer satisfaction.

2.8 METHODOLOGY

In order to find out what problems are affecting the factory fabric cost in the cutting room
mainly using primary and secondary data were collected using deferent techniques. The data
for this project where collected from techniques used interview, personal observation and
some research works, company inter and intra department format, recorder sheet.

Idea Generation Observation Problem

Identification

Data Analysis Data Collection

Data Presentation
37
2.8.1Data Gathering Procedure
Before collecting data, the researcher asked the organization to get the permission of
collecting the necessary information from the staff. Then the production and technical
manager permitted the research to be held. Then I gathered necessary data from the
appropriate departments.

2.8.2 Method of Data Collection

1, primary data collection

2, secondary data collection

2.8.2.1 Primary data collection:

 Observation:

The Question is for the Interview.

1. Except using the tender system, in what way do you think the wastage could be
removed without time taking? (For e.g. using the wastage fabric between one meters,
for the children)
2. In a daily base how match amount of wastage fabric came in to the waste store?
3. To move the wastage from cutting room to the store what amount of human resource
do you use?

These questions are the method to get accurate answer for the above questions my project is
considered to save the company cost and to add the profit for the company and worker. By
practically changing wastage fabrics in to other small garment components or product.

38
Different wastes are measured by gram example for cutting room all wastage fabrics are
measured by kilogram. For spreading marker making section wastes are record by measuring
the waste by using meter but measuring all wastage fabric is so difficult.

2.8.2.2 Secondary data collection

 Secondly in Different reference

Different big m factory workers

 Design and sampling room manager

 Marker-making cutting and sewing operators
 Hand out, textbook and internet.

2.8.3 Method of Data Analysis

To analyze the collected data, qualitative and quantitative data analyzing techniques were
used. The results were presented using in the appropriate statement, table, diagram and chart
forms.

2.9 Waste Disposition

In BIG-M apparel/Garment factory Plc. They sell the waste garments in their kilograms
because they cannot use the fabric for other purpose.

Figure 19 Waste Deposition in BIG-M apparel/garment factory plc

39
 Large wastes greater than 1m

Medium wastes 1m and less

Small wastes less than 1/2m and less

Diagram 2, Wastage Pyramid

The main waste for my project are number one and two medium and large waste fabrics
these are simple to recycle or to convert them to small garment component or
Kids wear. Next how the wastage material or fabric in BIG-M apparel/Garment factory Plc. is
divided in to section. Therefore, the lower parts of wastage are like trash not properly to re-
use for products simply the company sells them in tender.

2.9.1 Medium and Large Waste

In Big-M company medium and large wastes are disposed in sack but no one can check them
after thrown they are a combination of different type of fabrics, colors, length and width the
large wastes are above or below 1m fabric and this waste is used completely for kids wear
either for top clothes or bottom cloth for less than 7 years. If the wastes not cover front or
back part of garment, in center front or other part I stitch them by giving styles. For example
for making a new style product I can mix different type of fabric colors but they are same type
of fabric.

Figure 20 medium and large waste in big-m apparel/garment factory plc

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 2.9.2 Small Wastes
Big-M factory sells all type of wastes in tender but observe that many of small wastes are
came from cutting and marker making section due to unnecessary cutting and marker making
they don’t use maximum efficiency of marker they didn’t utilize full fabric space.

Half of small wastes, which are thrown as waste, are useful by scanning them we can
differentiate some/half of wastes used for making small new garment components such as
cuff, j-shape, binding, piping, collar, collar stand, pocket, pocket flaps and different shapes etc

Dividing Wastage source by section/department

Figure 21 small and big waste in big-m apparel/garment factory plc.

Table 4departments for wastage source

No Department Type of Wastage source

wastage
1 Marker making Medium and Caused by poor utilization of fabric consumption
and spreading large wastage and remained fabrics during spreading.
section.
2 Cutting section. Small waste. Mostly in cutting room wastes are minimum
caused by effective utilization of fabric
consumption, skilled operator and proper cutting

3 Sewing section. Small medium  Color variation

and large waste.  Fabric faults
 Sewing defects
 Damaged and rework fabric
 Cut fabric by unskilled operator.

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2.10 Waste Percentage
The criteria to say small, medium and large waste is based on their length

 Small waste count for less than 0.25 meter

 Medium waste count for 1meter and less
 Large waste count for above 1meter

50%

35%

15%

Type of waste Small Medium Large

Picture 3, bar graph about waste percentage

2.11 Products Made from Waste Fabrics

Figure 22 men’s cape, sample checking, short products &tie

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  Fabric type– stretchable polyester
 Fabric consumption - 1.5m
 Color – green, yellow and red
 Sewing thread – white, blue and gray
 Product type –color mix t-shirt
 Accessory-none

Fabric type – grey fabric

 Fabric consumption - 1.5m

 Color - blue, black, gray and light blue
 Sewing thread–white and gray
 Product type – cape
 Accessory – elastic material
 Cost = 50 birr

Note: These factories have many inventory machines in the company for example sewing
machines as you seen the picture in chapter-1.

Some of available machines are listed below-

 55 non-automatic SNLS sewing machine

 25 automatic SNLS sewing machine
 20 over lock sewing machine and
 6-ironing table with 24 automatic iron.

So, we can produce the right amount of waste product without any investment and we create
job opportunity for workless peoples or operators. And our operators can also cover it by
overtime if we give them incentive.

The other thing is I will take less cost for both garment components and the finished
garment/cloth because the factory is not willing to give me fabric cost and product cost. We
ask the appropriate person for the answer to Mr. Nuredin but he replied me that we did not
give any cost for any of our workers. Even we give the product costs for our customer by
covering with envelop because to be competitive in the market with other companies or
factories we cannot tell cost unless other companies took our customer by less cost.

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As a student, we are learned that to solve problems and create a job opportunity for jobless
peoples not to reduce/fire workers from the factory so my idea can create a job for many
peoples. Let’s see the needed work force in each department: -

 1 fabric carriers from cutting room to waste store

 1 waste scanner which selects useful fabric
 1 designer for kid’s cloth
 1 ironing and over lock maker
 1 cutter
 1 Spreader
 1 Marker maker
 2 – 4 sewing operators
 Generally, we need 8-10 operators because when one operator is absent they
can cover for each other and our major aim is to create job opportunity it is not
only my aim it is also the factory philosophy. .

2.12 Result and Discussion

Cost Calulation For Small Components

From the above table we have got 11/12 kg daily small fabric wastes among this wastes 7 kg
wastes are useful the rest 4/5 kg wastes are trashes they are not used for anything.

Daily Fabric Wastage in Kilograms (Kg)

Table 5 about waste fabric in kilograms (kg)

NO TYPE OF DAY- DAY- DAY- DAY- DAY- DAY- DAY- DAY- DAY- AVERAGE
WASTE 1 2 3 4 5 6 7 8 9 WASTE
1 SMALL 9 Kg 11 Kg 8 Kg 13 14 Kg 9 Kg 10 Kg 11 Kg 17 Kg 11.4≈12kg
Kg
2 MEDIUM 8 Kg 8 Kg 7 Kg 6 Kg 9 Kg 5 Kg 10 Kg 9 Kg 7 Kg 7 kg

3 LARGE 5 Kg 6 Kg 4 Kg 5 Kg 3 Kg 7 Kg 5 Kg 6 Kg 4 Kg 4.8 ≈ 5 kg

We calculate the average waste kilogram by using arithmetic mean formula

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 Arithmetic mean formula X = X1+X2+X3+X4+……………… Xn

From the above table we have got 11/12 kg daily small fabric wastes among this wastes 7 kg
wastes are useful the rest 4/5 kg wastes are trashes they are not used for anything. So the
scanned 7 kg wastes are used for making small garment components such as j-shape, piping,
binding, pocket, collar, belt loop and collar stand.

Table 6 products and their amount gained from small waste fabric

Garment components Quantity in average

Piping 50
j-shape 40
Binding 40
Collar stand 35
Collar 35
Total 200 small garment components
Cost Calculation For Small Wastes
Daily garment component gained from waste = 200 component

Each garment component cost = 2 birr

Working day = 26 days

Solution

Daily profit/gained cost

Total garment component * one component cost

200*2 birr

Daily profit = 400 birr

Monthly profit/gained cost

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Daily profit * working day/month

400 birr*26

Monthly profit = 10400 birr

Yearly profit/gained cost

Monthly profit * number of months

10400 birr*12

Yearly profit = 124,800 birr

Generally, our company gaines 124,800 birr in ayear from small waste fabrics if they convert
them in to small garment components.

Cost calculation For Medium And Large Waste

 From the above table we have got - 7 kg from medium waste and-5kg from large waste.

Totally we have got 12 kg of daily medium and large waste. Among 12 kg of total waste 8 kg
was used for manufacturing children wears the rest 4 kg is not spliced or used for
manufacturing. When we change 8 kg medium and large waste in to meters it becomes 9
meters.

Fabric consumption for making 1 children wear is 1.5 meter for both top or bottom clothes
but my project is considering for making shirts and trousers.

Daily fabric gained from medium and large waste = 9m

Fabric needed for making 1 cloth/garment = 1.5m

Cost of 1 shirt/trouser = 50 birr

Working day = 26 days

Solution
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Daily gained garment/cloth

Daily gained garment/clothe = Total daily gained fabric

Consumption of 1 garment

= 12 m

1.5m

= 6 clothes

So we can produce 6 clothes in a day by converting small and medium waste fabrics in to
different products.

Daily profit/gained cost

Daily gained cost = daily gained garment * cost of 1 garment

= 6*50

= 300 birr
 Monthly profit/gained cost

Monthly profit/gained cost = daily profit * number of working day/month

= 300*26
= 7800 birr

 Yearly profit/gained cost

Yearly profit/gained cost = monthly profit * number of months

= 7800 birr * 12
= 93,600 birrs
 Generally, our company Gaines 93,600 birr in a year from medium and large waste
fabrics if they convert them in to children’s wear/garment.

Total Profit Gained from Wastes

 From small fabric wastes = 124,800 birr
 From medium and large fabric waste = 93,600 birr
Total gained profit from fabric wastes = Small fabric wastes+ Medium and large
fabric waste = 124,800 birr+93,600 birr = 218,400 birr

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2.13. Conclusion and Recommendation

2.13.1 Conclusion
Big-m apparel/garment factory plc.Produces different type of uniforms and orders. In Big-m,
apparel/garment factory plc. Compound there are two stores. In first store accessory and raw
materials are stored. In second wastage fabrics are stored in near to ware house. The factory
uses 2 people to take these waste materials from the cutting departments to the stores.

The factory gets about 40,000–50,000 birr from the waste fabric that gained from the tender.
Even though this tender does not give the company any loss, it will be better if the factory
uses this material for other purposes. In order to reduce the waste and improve the company
profit by application of making small garment components and children wear we earn a lot of
money.

These are some advantage of using waste fabric for Big-M Apparel/ Garment Factory Plc:-
 The company will be able to increase profit and its product line.
 By tender - 40,000 – 50,000 birr
 By making garment components and developing different products – 218,400 birr
1. The company will be able to minimizing wastage.
2. It minimizes space required for wastage fabric store.
3. It creates job opportunity for new workers.
4. Neat area of company
5. Clean environment
6. Increasing Company profit
7. Saving fabric cost

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2.13.2 Recommendation
Based on this project, during staying at Big-m apparel/garment factory plc. Observed a lot of
waste fabric throw a garbage in different production area at while different materials are
produced by them, so that this unnecessarily placed fabric of different in size and color
Sometimes hinder the working area of the company that is not appropriate and as well as
wastage of factories. Therefore, according to my opinion and my intervention during my stay
for four month in the factory I carefully watched the problem what is happening there and
realize for solution so I would like to recommend, whenever garment factories are planted or
established the responsible bodies or shareholders should consider the problem mentioned
above and produce different materials from waste fabric (or products) so that additional work
opportunity and income generation can be created.

Diagram about stage of waste

Generally, recommend Big- m apparel factory that
If they can they have to invest on preventing waste before the waste is created.
1. We cannot eliminate waste (zero defect) but we can reduce waste in maximum extent
2. Reuse waste fabrics which are used for making kids wear and garment component
3. Finally, if the wastes are not recycled or re processed we can dispose them in one
place and sell them by tender this is another method to increase factory profit.

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 CHAPTER THREE
INTERNSHIP BENEFIT
3.1. Internship experience
In my internship work, I believe that doing an internship is more essential than that I learn
theoretically for long time. I got new skill, and I try to develop my professional interest,
industrial work in manufacturing process what it look likes and valuable work experience. my
first task was finding an organization which has some applications which are related with my
study/department .when I am finding I feel that manufacturing companies can give me the
valuable work experience and to expand my theoretical knowledge manufacturing companies
are good and to apply the knowledge I have learned in the class room to real world life.

3.2. Benefits I gained from internships

The benefit of internship which I acquired during my internship includes the following:

 Up grading of theoretical knowledge to practical skill

 Industrial problem solving skill
 Work ethics and industrial psychology
 To straggle different challenges
 Inter personal communication skill
 To developed knowledge + confidence
 Entrepreneurship skill

3.3. Practical skill

The four-month internship program benefited me to have practical skill. Example how
spreading, cutting, cutting in garment industry is performed. I had taught this theoretically I
Apply it on practical work that can make me full confidence on my activity and what learn
before in class room. Experienced this practically in my internship program after I have
completed my internship program I am able to upgrade my theoretical knowledge. When I
was learning in the class there was many theories which seems me ideal and not true. But,
after I had completed this internship program I have checked that those I have learned in
theory are real and are found in the practical world like production planning.

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3.4. Problem solving skill
Before my internships, I can try to solve any problem happen around garment manufacturing
processes but know I will do it .Completing this internship program makes me to identify the
problems and then how to solve them if happened. My internship gave the opportunity to
apply some problem solving skill learned with in the class room to real world activity within
the industry.

3.5. Team playing skill

Doing internship me enables me to develop my team playing skill. It enables me working
with my colleagues who have substantial experience within the garment factory. I develop my
understanding on my contribution to the company as a member the group on the entire
objective to be succeeded.

3.6. Leadership skill

Doing an Internship made me to build my confidence and knowledge on leadership skill i.e. I
am able work with my colleague and prior goal of the company and become effective without
creating any disagreement with my colleagues and finally I got work experience paper from
company within fair negotiation.

3.7. Work ethics issues and industrial psychology

This internship made me to have a strong willing to work and how I do with work place rule
and regulation. With a strong willing to work ethic I am always committed to the work and
will stay until the task is complete. The internship made me to avoid personal issues on work
time and to keep my positive attitude and I remember that I have smaller tasks to handle prior
to my large, more important ones.

3.8. Interpersonal communication skill

It also understands that employees who work together well and are happy in their jobs can
significantly strengthen a business or organization. At the end of my internship program I am
able to identify how employee behaviors and attitudes can be improved through hiring
practices, training programs, and feedback and management systems psychologists also help
organizations transition among periods of change and development.

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REFERANCE

[1] WALKER, T. (2014), Creating total quality improvement that lasts, National
Productivity Review, 114, 2008, 473-478.
[2] WEISS, W.H., Promoting Quality and waste Control: Why It Works, International
Performance’’, Supervision, 2012.
[3] FOSTER, S. T., Managing Quality and waste: An Integrated Approach. Upper Saddle River,
New Jersey, 2010.
[4] Baden, Sally, and Catherine Barber. 2005. The Impact of the Second-Hand Clothing Trade

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Appendix
I. Except using the tender system, in what way do you think the wastage could be
removed without time taking?
II. In a daily base how match amount of wastage fabric came in to the waste store?
III. To move the wastage from cutting room to the store what amount of human resource
do you use?

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