Garments Manufactring technology,,, Men’s s/s round neck T-shirt.
Product name: Men’s s/s round
neck T-shirt.
Sketch Design of sample : The
sketch design of this product attached in next page
Buyer Order Sheet : The Buyer
order sheet of this product attached in next page
Description of the product:
The buyer Premark from Italy ordered Apparels
village limited for by Men’s s/s round neck T-shirt, white color about 31,050
pcs continuously shipment, all ready we were shipment 12975 pcs 5 January, 2012
and 8025 pcs T-shirt will be shipment within 30 January, 2012.we prefer to work
in this production of T- shirt .all requirements are maintained according to
the buyer requirements. The buyer requirement sheet is included to this
report.
Basic operation of short sleeve
T-shirt:
Cutting section:
1. Pattern.
2. Cat-Marker
3. Lay.
4. Put the
marker.
5. Cutting
6. Bundle
7. Numbering
sticker.
Sewing Section:
Input table
↓
Solder1st
→ over lock m/c.
↓
Neck
binning→ over lock m/c.
↓
Back
neck top → plane m/c.
↓
Back
neck top seam→ plane m/c.
↓
Pipene
pluck→ plane m/c.
↓
Second
solder tack→ plane m/c.
↓
Second
solder join→ over lock m/c.
↓
Pressure
tack→ plane m/c.
↓
Sleeve
hem→ flat lock m/c.
↓
Sleeve
join→ over lock m/c.
↓
Side
join→ over lock m/c.
↓
Body hem→ flat lock m/c.
Finishing section:
Thread
sucking m/c.
↓
Iron
table→ vacuum table/normal table.
↓
Finishing
Q.C.table.
↓
Spot
table.
↓
Final
Q.C.table.
↓
Folding
table→ folding man.
↓
Hand brash.
↓
Back board.
↓
Poly man.
↓
Accord
table for buyer requirement.
↓
Packing for carton.
Core Temperature:
This produced core temperature is 30°C or
85°F. Mainly this produced used hot weather or summer season. Heat is both
required and produced at the cellular level. The environment acts as either a
heating or a cooling force on the body. The body must be able to generate heat,
retain heat, and discharge heat depending on the body activity and ambient
external temperature.
Trim Card : The trim card of this
product attached in next page
Merchandising:
Recently those who
are related with textile business, they all are known with the word of
merchandising. The word merchandising has great important in garments
production. Because the loss & profit of a factory fully depend on a
merchandiser.
The main works of merchandiser are given below:
1.
Procuring orders from buyer
2.
Arranging raw materials
3.
Garments production
4.
Shipment of
garments
5.
Receiving of payment for garments
Merchandising department and its activities:
The “Merchandising” is known to the
persons specially involved in garments trade. The term has been derived from
the merchandise. Merchandise means goods that are bought & sold.
The term “Merchandising” may be
defined as: Person who merchandises the goods, specifically for export purpose.
Garments merchandises means buying raw materials & accessories, producing
garments, maintaining required quality level and exporting the garments within
schedule time. From the above definitions, we can say that a person involved in
garments merchandising needs a wide range of knowledge & skill to perform
his job successfully. The job itself is “technical and general as well”.
Merchandisers
should have the following basic qualifications:
ü
Good
Command in English and adequate knowledge of technical terms for accurate and
efficient communication.
ü
Good
knowledge of fiber, yarn, fabric, dyeing, printing, finishing, dyes, color
fastness, garments production. Etc.
ü
Clear
conception of the usual potential quality problems in the garments
manufacturing.
ü
Good
knowledge of the usual raw material inspection systems & garments
inspection systems.
ü
Merchandiser should be graduate
ü
Merchandiser should have knowledge about fiber,
yarn, weaving, knitting, dyeing, finishing & garments production
ü
Merchandiser should know good spoken &
written English
ü
Merchandiser should know the function of MS
word, Excel, E-mail property
Highlights of merchandising works:
- To collect buyers addresses.
- To establish contact with the buyers sending formal letters/profile.
- Receiving buyer’s response and providing price quotation along with making of sample as counter/approval.
- Receiving samples comments from the buyer.
- To furnish the pro-forma invoice and sending the buyer.
- Taking necessary steps to develop lab-dips of the materials (FAB & ACC)
- To confirm floor booking of the order with factory.
- To confirm transfer authentication of the L/C in favor of fact.
- Pushing the factory taking initial procurement to open the back-to-back L/C by bank.
- Searching reliable fabric and accessories sources and finalize supplying of the required materials relevant tot the order.
- To monitor the shipment of raw materials and arrival in the factory.
Price negotiation & Order confirmation :
Price
negotiation is the most important part of merchandising and marketing. Order
confirmation depends on how cleverly and logically one can negotiate price with
buyer. Competitive price is the key element of price negotiation. To make
competitive price first of we have to know about the product that buyer want to
buy from us. Then we will calculate the raw material price, manufacturing cost
& shipping terms of the product.
FOB means ‘free
on board’ i.e. exporter doesn’t bear the cost of freight of ship or air. It is
buyer (Importer) who himself bears the freight of ship or air.
C & F means
Cost of Freight i.e.
FOB (Cost) +
Freight of Ship = C & F.
In the case ship
or air freight is carried by the exporter while quoting price, the exporter
quotes price a bit higher than FOB. The whole responsibility including the
sending of goods to the selected port of the importer is shouldered by the
exporter ship or air. Freight may very from place to place and shippers to
shippers.
CIF means cost
insurance & Freight. In this case in addition to the bearing of freight the
cost of insurance is also borne by the exporter. The exporter, while quoting
CIF price, quotes much higher than C&F value i. e; C & F + Insurance
=CIF. Normally we can add 1-2% insurance charge with CIF price.
During the
fixation of FOB price of a T-Shirt following notes are to be followed
carefully:
- Cost of fabrics/Dzn. garments.
- Cost of Accessories/Dzn. garments.
- C.M (Cost of Manufacturing) /Dzn. Garments.
- Cost of embellishment (if any) like print, embroidery, etc
- Commercial cost.
- Commission (if any)
Fabrics Price:
Knit fabric
price is the sum of the below factors-
- yarn price per kg (approx $6.40)
- Knitting price per kg (approx $0.15)
- Dyeing price per kg (approx $1.5)
- finishing price per kg (approx $0.50)
Thus the fabric
price per kg comes ($6.40+$0.15+$1.5+$0.50)= $8.55
Fabrics
consumption for a European T-Shirt is 3.00 kgs per dozen.
So fabrics price
per dozen is (3.00 X 8.55) = $25.65
Trimming Price:
Trims cover all
the trims used in the garments except the basic fabric. There are hundreds of
items used to manufacture the garments, proper selection of trims and its
quality are very important for styling, otherwise the garment may be rejected
or returned by the customers.
As our
assignment is based on basic T-Shirt, normally care label, main label, size
label, sewing thread, poly bag, price ticket, carton, tag pin, gum tape, etc
trim are used in a basic T-Shirt.
Normally the
trim cost per dozen comes approx. $2.00 for basic T-Shirt.
CM calculation:
CM means cost of
cutting to making. It includes the cost of cutting, cost of sewing and the cost
of packing. It also includes the overhead cost of the plant and the profit
margin.
Generally CM per
dozen of a basic T-Shirt is $5.00
Other embellishment calculation:
Other
embellishment means print, embroidery, patch etc that makes any garment more
attractive for customer.
As our
assignment is based on basic T-Shirt we are not calculating any embellishment
cost.
Commercial cost:
Commercial cost
includes LC commission, UD commission, EXP commission, Documentation cost,
Goods send to forwarder cost, etc.
For basic
T-Shirt it will safe if we calculate commercial cost $1.00 per dozon.
Final garments cost & order
confirmation:
Now the final
garments cost per dozen is the sum of fabrics cost, trimming cost, CM cost,
other embellishment cost & commercial cost.
So the garments
price per dozen comes ($25.65+$2.00+$5.00+$1.00)= $33.65
T-Shirt per
piece is ($33.65/12)= $2.81
Thus we make
manufacturing price & negotiate this price with Buyer.
After negotiate
price with buyer we receive order confirmation & L/C from buyer to execute
the order.
Merchandising activities on Product development:
Product
development is another important responsibility for RMG merchandisers. Before
go to bulk production various stage of sampling has to pass in order to develop
a product for end user.
Sequence of Sampling:
- Counter sample/Style sample/Salesmen sample
- Fitting sample/ Size set sample
- Pre-Production.
- Production Sample.
- Shipping Sample.
- Photo/ Advertisement/ Catalog Sample
Steps of Garment Sample Approval:
Step-1
Style sample (Closest available
fabrics)
Step-2
Size
Set sample (Closest available fabrics)
 |
Step-3
Pre- production sample (In Actual)
Step-4
Production
sample (In Actual)
Fabrics Selection:
Approval Fabrics (for hand feel &
Approval)
Test done from official Testing House
1st Bulk Fabrics in each
Color
Test
report in each color
Merchandising activities on production
follow up:
Production plan:
After receive a
purchase order from buyer merchandiser have to sit with production planner to
make a production plan. Production plan contain below things:
1)
Planned date to start knitting to make the required
fabrics.
2)
Planned date to start dyeing to color the fabrics.
3)
Planned date to start cutting fabrics.
4)
Planned date to start sewing the required garments.
5)
Planned date to start packing the required garments.
6)
Planned date to hand over finished goods to buyer
nominated sea or air forwarder.
Trail/ Test cutting:
Before start
bulk cutting to adjust pattern we cut each size and each color 10/15 pcs. This
is called trail or test cutting. After approved trail or test cutting we can go
for bulk cutting.
Sewing :
Sewing section
is the section where cutting part are joined to make a garments. In sewing
section sewing machines are set up according to the kind of final product.
Packing:
After sewing
garments is packed into packing section. Here we put iron on garments, add
various kinds of hangtags, poly bags and make garments ready to ship to the
buyer.
Merchandising activities on Quality control:
The main
objective of quality control is to ensure that goods are produced to the first
customer (Direct Order) and hopefully to the second customer (Recorder/Alter
order/ new order) as well. If both customers can be satisfied then the
manufacturer products are more likely to continue to be in demand.
Satisfactory
quality can only be ensured through (from the manufacturer pint of view)
ü
Knowing the customers needs.
ü
Designing to meet them
ü
Faultless construction- manufacture.
ü
Certified performance and safety.
ü
Clear instruction manuals.
ü
Suitable packing.
ü
Prompt delivery.
ü
Feed back of field experience.
Satisfaction
quality can be ensured from the customer from the customer’s point of view by
providing:
ü
Right Product.
ü
Right Quality.
ü
Right Time.
ü
Undamaged Condition.
Merchandising activities on goods delivery
to buyers destination:-
Booking to
forwarder:
After making
final inspection merchandiser received packing list from packing section which
contain the list of carton, how many
pieces garments in the carton, weight of the carton, number of pieces of
garment to be shipped etc. Refer to this information merchandiser make booking
to sea or air forwarder.
Export Documentation:
The documents
which to be submitted by a C&F agent for export:
An exporter
should have to submit the following documents to the customs authority of a
station:
- Shipping bill of entry.
- Export L/C.
- Packing List.
- Commercial Invoice.
- UD/UP.
- VBF-9A. From to be supplied by the C&F agent.
- Export Permission form (EXP).
Bill of Landing (B/L):
It is document
issued by an eerier (railroad, steamship, or trucking Company) which serves as
a receipt for the goods to be delivered to a designed person or to his order.
B/L describes
the conditions under which the goods are accepted by the career and details
ü
The quantity of the goods.
ü
Name of vessel
ü
Identified marks and numbers
ü
Destination
Invoice: Below point are including in
the invoice:
ü
Name and address of the buyers and the seller.
ü
The Date and term of the sale.
ü
A description of the goods,
ü
The price of the goods and
ü
The mode of transportation.
Payment release:
After
prepared invoice, bill of landing and other required documentation we send it
to buyer’s nominated bank for payment release.
Order comes from buyer and how it is
accomplished:
Merchandisers
basically accomplishes their tasks in 5 steps---
I.
Procuring garments order
II.
Procuring of raw materials
III.
Production of garments
IV.
Shipment of garments
V.
Receiving of payments for garments
1. Procuring garments order
The main task of
a garments business is to procure garments order from foreign buyers. A
merchandiser of any buying house perform this task that is to procure orders
from buyer by communication throw phone, Fax, E-mail or even face to face etc.
The order of any garments production comes mainly in two ways--
ü
Order is given by buyers by his own wish
ü
Order is chosen by the buyer what is provided by
buying house
At first a
buying house obtain order inquiry from buyer by merchandiser. Then merchandiser
carry out costing and fixed a unit on the basis of order inquiry and then a
merchandiser carry out price code to buyer. On the basis of price code,
merchandiser & buyer negotiate each other to confirm a garments order. The
things need to be checked out by merchandiser after confirming an order are
given bellow :
ü
Item description according to order
confirmations
ü
Garments unit price
ü
Date of order delivery
ü
Way of shipment ( by sea or air )
ü
Order quantity
2. Procuring of raw materials
After confirmation an order it is required to manage
required raw material and accessories as soon as possible. These tasks are done
by a merchandiser basically.
3. Production of garments
After receiving required fabrics and accessories on hand a merchandiser
make a tream card. The tream card consists of order number and other
specifications of fabric and accessories. Tream card is then given to a store
and the store makes four copies of that tream card. Then, these four cards
along with original tream card are given to merchandiser. Then he tests these
very carefully and if possible he makes it approved by buyer. Then these are
given to store, production manager, quality controller, sample section and one
is kept to him (merchandiser). After stating production merchandiser observes
it carefully that all works are being done on every phases according to tream
card. He will also keep communication with production employees. After completion
of production, these are inspected very carefully and then these are packed up
according to packing list and send them for shipment.
4. Shipment of Garments
Merchandising division makes the plan of production and shipment kipping
the delivery date in mind. They inform commercial division about probable
inspection date and delivery date kipping communication with production division.
After final inspection production division sends the quantity of products to
merchandising and commercial division and then it is sent to port. Commercial
division sent the product information to CNF agent. After obtaining the
products CNF agents take care of the products until custom’s inspection and
shipping. Merchandising division collects the data up to shipping of products
by kipping communication with production, commercial and CNF agents. Then
merchandising division send fax or email describing about commercial invoice,
detailed packing list and probable time of departing sheep from port. After
obtaining BL/AWB these are also sent to buyer through fax or email.
5. Receiving of Payment for Garments
After exporting an order, commercial division submits all original copies
of relevant tasks to bank following the rules of master L/C. A copy of bank
document is sent to buyer’s bank. Then buyer’s bank informs it to buyer and
wants to know is there any objection about taking this product. If there is no
objections about taking sending products then buyer receives that bank document
and discharges the products from port. And buyer’s bank send payment
information to Bangladesh Bank. Then buying houses’ bank receive the payment
through its bank. In case buyer does not accept export document then buyer’s
bank informs it to buying houses’ bank. Then this problem is solved through
negotiation.
If we draw a
flow chart of a merchandiser’s job starting from taking an order from a buyer
to receiving of payment for garments, it will looks like below :
Receiving
an order from buyer
 |
Carrying
out costing for the order on the basis of technical sheet/order sheet
 |
|||
 |
|||
Fixing
an unit price for an unit garment
 |
Sending
the cost sheet to the buyer
Receiving
and sending buyers opinion
 |
Negotiation
between buyer and merchandiser to fix the cost
Placing
an order to the merchandiser
Opening
L/C buyer bank to factory bank
Procuring
raw materials and accessories
 |
Follow up of buying house
Sending
a pre-production sample to buying house then buyer
 |
Receiving
comments
 |
Production
of garments
 |
Inspection
of Garments through various tests
 |
Packing
up according to packing list
|
Sending
garments to sea port/air port for shipment
 |
Sending
fax or email by merchandiser describing about commercial invoice and departing
time of sheep or air
 |
Submitting
all original copies of relevant tasks to the bank by commercial division
|
Receiving
all copies by buyer’s bank
 |
Accepting by buyer
Paying
payments by bank
Core Temperature:
Smart cloths
well for a citizen due to his characteristics. They simplify the settings of
sensors and daily activities.
Four elements is
composed by marsian , such as:-
Ø
A smart T-shirt (core temp, body flow)
Ø
A smart glove (skin potential,skin temp.)
Ø
A wrist device (Amplification)
Ø
A data longer (continuous recording)
Body Core Temperature:
1. Heat is both required and
produced at the cellular level. The environment acts as either a heating or a
cooling force on the body. The body must be able to generate heat, retain heat,
and discharge heat depending on the body activity and ambient external
temperature.
2. Body temperature is a measure
of the metabolism - the general level of chemical activity within the body.
3. The hypothalamus is the major
center of the brain for regulating body temperature. It is sensitive to blood
temperature changes of as little as 0.5 degrees Celsius and also reacts to
nerve impulses received from nerve endings in the skin.
4. The optimum temperature for
chemical reactions to take place in the body is 98.6 degrees F. Above 105 F
many body enzymes become denatured and chemical reactions cannot take place
leading to death. Below 98.6 F chemical reactions slow down with various complications
which can lead to death.
5. Core = the
internal body organs, particularly the heart, lungs, and brain.
Periphery = the appendages, skin, and muscle tissue.
Periphery = the appendages, skin, and muscle tissue.
6. Core temperature is the
temperature that is essential to the overall metabolic rate of the body. The
temperature of the periphery is not critical.
Core temperature:
|
Boiling point
|
100°C
|
212°F
|
|
Hot weather
|
30°C
|
85°F
|
|
T-shirt/Shirt
|
24°C
|
75°F
|
|
Long sleeve
shirt or pants
|
15°C
|
60°F
|
|
Freezing
|
0°C
|
32°F
|
|
Jacket weather
|
10°C
|
50°F
|
Average
room temperature =21°C or 70°F
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