full process flow of knit composite factory with reference

1. Introduction
Bangladesh is a country of 160 million people. Economic growth of this country largely
depends on the proper use of the people which is one of the great resources. Bangladesh is
known as the emerging tiger of South Asia because of the rapidly growth of our economy.
There are many sectors which helps our economy to grow faster. RMG is one of them.
Among RMG Sector, Knit Composite industry plays a significant role to promote our RMG
Sector through earning a huge amount of foreign currency by exporting knitted garments
worldwide.
Knit composite industry is an industry where functions are started with yarn receiving from
the spinning mills and end with shipment of knitted garments. Between this processes, we
have to follow several ladders which help us to attain the knitted garments to the customer
with the ensuring quality.
Bangladesh Export numerous knitted garments such as T-shirt, Polo Shirt, Singles, Tank top,
Leggings, Tights, Cardigan, Pullover, Play suit, Tunic, Knitted Trouser and so on. For
building this knitted garments we have to maintain several stages such a knitting, fabric
finishing, storing, cutting, sewing, quality checking, finishing, shipment etc. which assist us
in smoothly exporting the knitted garments.
Therefore, before going to the process flow of Knit Composite industry, the very beginning
we have to know the advantages of Knit Composite industry than woven composite industry.
Advantages of Knit Composite Industry in Bangladesh than Woven Composite
Industry:
 Bangladesh is mainly Knitwear export oriented Country.
 Profit is maximized due to backward linkage of knit industry.
 Lead time can be controlled due to easier supply chain.
 Higher production rate with lower cost supply chain.
 Primary installment for knit composite factory is much lower than the woven
composite industry.
 Transport cost is minimized in case in case of knit composite industry.
(Source: Engr. Prasad.R.K.2016.)

2. In this Study, we will briefly discuss about Process Flow of Knit composite industry – For a
basic item T-shirt. For that we have to know initially our objectives of the Study.
Objectives of the study
 To assesses the function of each stage of knit Composite industry.
 To understand the overall process flow of knit composite industry.
 To find out the individual stage process flow.
 To get knowledge about knit composite industry.
Process flow of Knitting Section
(Source: Kiron.M.I. 2012)
Yarn Cone receive
Place the Yarn Cone in
the creel
Feeding the Yarn
Set the machine as per
design and GSM
Knitting
Withdraw the roll fabric
and weighting
Roll Marking
Inspection
Numbering
Yarn dying (if required)

3. Process flow of Dying Section
(Source: Textile fashion Study. February 20, 2012)
Process flow of Store Section
(Source: Raaz.N.A.2015)
Receive Textiles materials
(Grey fabric, yarn etc)
Singeing
Desizing
Scouring
Bleaching
Mercerizing
Dyeing
Finishing
Receiving Product from
Dying Section
Inventory
Inspection of product
Shade segregation
Issuing product
Sustaining Balance
Closing Summary

4. Process flow of Cutting Section
(Source: Islam.M.J 2015.)
Process flow of Sewing Section
(Source: Islam.M. July 14, 2015)
Pattern Received from Pattern Department
Cutting Ratio received
from Merchandiser
Marker Making
Fabric Received from The
store
Fabric Checking
Fabric Spreading
Cutting the fabric
Numbering
Checking
Sorting & Bundling
Send to the sewing
department
Printing /Embroidery
Marker Placing on the Lay
Product Analysis
Setup Target for production
Distribution all processes
Cutting parts received for
Cutting Section
Cutting parts Distribution
Sewing according to
Distribution
Line Q.C Check
Line Quality Audit
Counting output according to
target
Final Quality Check
Send to finishing section

5. Process flow of Finishing Section
(Source: Akter.J. 2014)
Finishing Input ( Color, style
& size wise
Initial quality Check
Spot Removing
Ironing/Pressing
Inspection
Hang tag
Get Up change
Folding
Poly
Bar Code (if required)
Metal Check
Cartooning
Inspection
Dispatch shipment

6. Overall Processflow of Knit Composite industry for a basic T-shirt
Description
Order Receive: For production any kind of Garment, At first we have to receive order to
execute production for any kind of RMG factory. After receiving orders, knit composite
factory plan how to execute order ,which method they follow to execute order and they also
make sample for buyer approval as well as they also involve in material sourcing process.
Planning: Here Knit Composite factory makes time and action plan based on man, machine,
materials availability or their capacity to accomplish order. In this stage, authority decides
how to accomplish the order, how much man, machine, material requires accomplishing
order, how to they control overall process etc.
Sampling: Here factory makes sample according to buyer requirements and send the sample
to the buyer for the buyer’s comments so that they can rectify the fault in the sample.
PP Sample approval: After getting the buyer comments, the factory rectify the faults and
send sample to the buyer again before going to the bulk production. That’s why it is called
Order Receive
Planning
Sewing
Material Sourcing
Knitting
Dying
Pp Sample Approval
Trims & accessories in
house
Storing
PP Meeting
Cutting
Sampling
Printing/Embroidery
Finishing
Final InspectionShipment

7. pre-production sample. After getting approval from buyer, the factory will be ready for bulk
production.
Material Sourcing: In the mean time, knit composite factory will be involved in Material
sourcing process. At first they booked yarn to produce fabric in their knitting section. After
making fabric, the grey fabric sends to the dying section for dying according to requirements.
After dying fabric & booking trims and accessories, stock up the fabric & trims and
accessories in the store and inspection the product.
Trims and Accessories: Knit Composite must have to ensure trim and accessories are in
house before going to bulk production as per required quality and quantity.
Knitting: Here several steps are followed. Very First, yarn received from the spinning mill ,
then dyed the yarn if required. After that, place the yarn cone in the creel and feeding the yarn
and knitting the fabric. After knitting fabric, withdraw fabric roll from the machine and
inspect the roll and give the roll number. So that, we can identify the specific roll by the
number.
Dying: After Grey fabric knitting, fabric sends to the dying section for dying fabric roll
according to required color. Before dying several stages have to be maintained such as
desizing, scouring, bleaching, mechanizing etc.
Storing: Before going to the bulk production , the factory have to ensure all the equipment
are available in store and store department inspect all the materials and makes a summery
about shade segregation ,issuing product amount, sustaining balance and closing the
summery.
PP meeting: Based on the planning, sample approval, and material sourcing and store
department inspection report pp meeting are held to decide how to finally execute the bulk
production depends on what necessary step should be taken, how works will be divided,
section wise responsibility will be distributed through this meeting.
Cutting: As per PP meeting decision, cutting section received pattern as per style, cutting
ratio and then cutting master making the marker. After that fabric receive from the store,
fabric checking to see if it’s okay for cutting or not, then spread the fabric on the cutting table
and create lay, then marker place on the lay and start cutting. After cutting check the parts to
see if there is any cutting fault or not , then numbering the cutting pieces to avoid shade

8. variations, then sorting & bundling the parts and send to the printing and embroidery section
if required or send to the sewing section for further process.
Sewing Section: At this juncture at first PP sample analysis is done ,setup line target ,
distribute processes to the workers .Then cutting parts received from cutting or
printing/embroidery section (if there is) and distribute the parts to workers in the same way as
process distribution and workers sewing the parts .In the mean time, line Q.C check and Q.C
audit has been occurred so that we can accomplish required quality. After that finally
counting output according to target and full garment quality ensuring is done, and garments
are send to the finishing section.
Finishing Section: It is one of the most important part of knit composite unit. After inputting
garments, first initial quality check is done to find out the fault of the garments. Here, spot
removing, ironing/pressing, inspection, hang tag attach ,get up change , folding the garments
as per requirements , poly the garments, metal checking etc are done to give product aesthetic
value. After that goods cartooning or packing to box is done for buyer’s inspection.
Inspection: Buyer’s representatives or buyer inspect the cartoon randomly to find out if the
product produces according to requirements. If they find satisfactory result then the goods
will be accepted otherwise the entire shipment will be rejected.
Shipment: After inspect the goods as per predetermined condition , If buyer find satisfactory
result then the goods will be accepted for shipment otherwise the entire shipment will be
rejected.
Conclusion
Bangladesh is mainly knitwear export oriented country .Bangladesh has more than 200 Knit
composite factory and the number is increasing day by day and Bangladesh knitwear is
unbeatable in price advantage in the world. Bangladesh provides not only a cheap labor force,
which is unbeatable but they are also peerless in stitching capability. Knitwear is exported to
153 countries of the world from Bangladesh. (Source: Strength of knitwear sector of
Bangladesh: BKMEA) So knit composite industry’s importance is increasing gradually. As a
result, process flow of knit composite factory is an important part of RMG sector which assist
us to ensure smoothing exporting and contribute our GDP.

9. References
1.Engr.Prasad.R.K.(2016).Lecture: Introduction to cut & sew knitwear, Uttara, BGMEA
University of Fashion & Technology.
2.Kiron.M.I. (2012). Process flow chart of Knitting Technology. Retrieved from
http://textilelearner.blogspot.com/2012/09/process-flow-chart-of-knitting.html.
3.Textile fashion Study (2012).Process flow chart of Dyeing Textile Materials, Basic
structure of Wet processing Technology (2012) Retrieved from
http://textilefashionstudy.com/process-flow-chart-of-dyeing-textile-materials-basic-structure-
of-wet-processing-technology/
4.Raaz.N.A.(2015).Working Flow Chart of Store Department in Garment Industry(2015).
Retrieved from http://textileflowchart.blogspot.com/2015/11/working-flow-chart-of-store-
department.html
5.Islam.M. July14, 2015. Process Chart of Garments Cutting Section (2015). Retrieved from
http://www.garmentsmerchandising.com/flow-chart-of-garments-cutting-section/
6. Islam.M. July 14, 2015. Process flow for Garments Sewing Department (2015). Retrieved
from http://www.garmentsmerchandising.com/process-flow-chart-for-garments-sewing-
department/
7.Akter.J.Dec 21,2014. Process Flow Chart of Garment Finishing Section (2014). Retrieved
from http://textileflowchart.blogspot.com/2014/12/flow-chart-of-garment-finishing-
process.html
8. Strength of knitwear sector of Bangladesh: BKMEA. Retrieved August 22, 2016, from
http://www.bkmea.com/Strength-of-Knitwear-Sector-of-Bangladesh.html