Frehiwot Eyasu Finall Project
Frehiwot Eyasu Finall Project
Sub.date:17/10/2016
Declaration
My name is Frehiwot Eyasu I am fourth year Garment engineering student
in Wolkite University have undertaken my internship experience in Desta
garment plc. From period of March 15\03\2016 to June 30\06\2016 under
the guidance of Mr.Alemayu (academic adviser) and Ms. Nabila (company
adviser).
I assure this the report contains actual data and project I assigned to work on
the intern ship stay. The content of the report are my own and has not been
submitted to any other university or institute.
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ACNOWLEDGEMENT
First of all I would like to thanks my God for his unspeakable gift and his
help of my entire life. Next thanks to my profound gratitude and deep
regard for Wolkite University for this internship experience. I would like
to thank my advisor Mr. Alemayu for the guidance, monitoring and
constant encouragement throughout the course of this project. And also I
would like thanks to my parent and family for providing me with the best
of opportunities and having faith in my abilities. I wish to thank all my
friends who share your idea.
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Executive Summary
This final report covers my internship practice which I have been working
in garment evolution factory from March, 2016 up to June 2016. For the
past three months. It is a clear fact that the knowledge of garment
engineering cannot be up graded without practical experience in each
field of the subject matter.
This paper is a written report about the internship program which was
planned is a written report about the internship program which was planned
to help apparent students grasp practical know- haw of engineering projects,
their design, implementation, evaluation and management in general
This report has different section and also discusses about this
departments. The report covers three chapters, chapter one: discusses
about the historical background of the company, customers, products,
location, mission, vision. Organizational structure and also discusses
about main departments of this company.
iii
Chapter three conclusion and recommendations which I recommend to
the internship experience and the references I used are written at the end
of this project report.
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Table of Contents
ACNOWLEDGEMENT ........................................................................................... ii
Executive Summary ................................................................................................. iii
1 CHAPTER ONE HISTORICAL BACKGROUND OF DESTA GARMENT
PLC 1
1.1 The objective of Desta plc. ....................................................................... 2
1.2 The mission of Desta plc........................................................................... 3
1.3 The vision of Desta plc. ............................................................................ 3
1.4 DESTA STRATEGIES ............................................................................. 3
1.5 THE MAIN MATERIAL FOR PRODUCT ............................................. 4
1.6 PROCESS FLOW OF THE COMPANY ................................................. 5
1.7 Organizational structure ............................. Error! Bookmark not defined.
1.8 Available machine in the company ........................................................... 7
1.9 Finishing room available machine .......................................................... 10
1.10 Product variety in garment evolution factory.......................................... 11
1.11 Department detail .................................................................................... 11
1.11.1 Designing and Sample making ....................................................... 11
1.11.2 Cutting and spreading department .................................................. 14
1.11.3 Embroidery room ............................................................................ 17
1.11.4 Sewing room ................................................................................... 18
1.11.5 Finishing section ............................................................................. 21
Store room....................................................................................................... 22
1.11.6 Merchandising................................................................................. 23
1.11.7 Quality controlling .......................................................................... 24
1.12 Some of Desta garment major customer and partners are listed below .. 24
1.13 Variety of product and style .................................................................... 25
2 CHAPTER TWO: IMPROVING ERGONOMICS ON SEWING SECTION
IN DESTA GARMENT .......................................................................................... 27
v
2.1 Introduction ............................................................................................. 27
2.2 LITRATURE REVIEW .......................................................................... 27
2.3 PROBLEM STATEMENT ..................................................................... 30
2.4 OBJECTIVE OF STUDY ....................................................................... 31
2.4.1 General objective ............................................................................ 31
2.4.2 Specific objective ............................................................................ 31
2.5 Scope of the project ................................................................................ 32
2.6 Significance of the project ...................................................................... 32
2.7 Limitations of the study .......................................................................... 33
2.8 METHODOLOGY ................................................................................. 33
2.8.1 Primary data .................................................................................... 33
2.8.2 Secondary data ................................................................................ 34
2.9 Data analysis ........................................................................................... 34
Current setting chair............................................................................................ 35
.......................................................................................................................... 36
2.10 RECOMMENDATION .......................................................................... 37
3 Chapter three: benefits gained from internship ............................................... 38
3.1 Practical skills ......................................................................................... 38
3.2 The basic practical skills I improved ...................................................... 39
3.3 Theoretical knowledge ............................................................................ 40
3.4 Interpersonal communication skill .......................................................... 40
3.5 Team playing skill................................................................................... 41
3.6 Leadership skill ....................................................................................... 41
3.7 Work ethics and industry psychology: - ................................................. 42
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. ...................................................................... 42
3.8 Being familiar for Entrepreneur-ship skill: -........................................... 42
3.9 CONCLUSION ....................................................................................... 43
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3.10 RECOMMENDATION .......................................................................... 43
3.11 Reference ................................................................................................ 44
3.12 Appendix ................................................................................................. 44
TABLE
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1 CHAPTER ONE HISTORICAL BACKGROUND OF
DESTA GARMENT PLC
Bekele Abshiro PLC was established in 1959. Since and currently
company deal with import and export of a wide range of products;
including fitness equipment, raw material for shoe making, confectionary
brands, and building materials, all from twenty countries including the
United States, Germany, Korea, Japan, England, South Africa, UK and
Taiwan. It is located Bole, Addis Ababa Ethiopia.
Desta will continue to invest more resources into this sector to be more
competitive and maintain the high quality standard required in the
international market. It has already invested in the expansion of high
quality textile accessories production to compliment the growing demand
for export.
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1.1 The mission of Desta plc.
As part of the movement for global justice, and support
garment workers’ demands through strategic action aimed to
those are involved in the production, marketing and
consumption of clothing
Thoroughly understand and satisfying diversified garment
demand and enhancement of the quality of the quality of life
of its customer and community.
Develop technologies of Varity of Garment style to satisfy
domestic and International market.
3
Devise and implement method of reducing cost of production
without affecting quality of products. Provide continuous personnel
training and capacity building.
Accessory
4
1.5 PROCESS FLOW OF THE COMPANY
GRADING
PRODUCTION PATTERN
SEWING/ASSEMBLING INSPECTION
5
2 Secretary 01
3 Merchandiser 01
4 Asset Merchandiser 01
5 Purchaser 01
6 Store in charge 01
7 Asset Store 02
8 Design & sample in charge 01
9 Pattern maker 02
10 Sample maker 04
11 Cutting in charge 01
12 Embroidery Operator 09
13 Spreading Operator 09
14 Bundle operator 09
15 Data Clerk 04
16 Marker Maker & Cutter 03
17 Sewing line supervisor 04
18 Sewing operator 112
19 Line QC 04
20 Final QC 08
21 Auditor 01
22 Finishing Supervisor 01
23 Ironing operator 10
24 Folding Packing operator 10
25 Senior mechanics 01
26 Junior mechanic 01
27 Electrician 01
28 Helper 24
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1.6 Available machine in the company
Table 1 Sewing room available machines
Available
1 Single DB*1 1 36
needle
lockstitc
h
machine
2 Two dp*5 2 2
needle
lockstitc
h
3 Over Dc*27 3-5 38
7
lock
4 Chain TV*7 4-5 9
lock
stitch
5 Zigzag Dp*5 2 1
machine
6 Button DP*17 2 2
attach
7 Button Dp*5 2 2
hole
8 Bar tack Dp*5 2 1
9 Cover UY*128 3&5 26
stitch
machine
10 Feed of uY*128 4-5 2
arm
11 Snap - 2
button
12 Pico tic DP*5 4 1
8
Table 2 Cutting room machines available
2 Cloth drill 1 -
3 Fusing machine 1 -
4 Spreading table 2 -
5 Bundling/sorting 1 -
/ table
6 Pressing 1 -
machine
7 Straight knife 2 Straigh
t
9
8 Band knife 1 straight
Hunger
Gun tag
Polly bag
Cartons
Plaster
10
Gun tag Hunger
• Shirts
• Trousers,
• Polo- shirt
• Sport wear
• T-shirts
• Pajama etc…….
11
In these room their many problems, among the problem the following are
shown
12
in normal 8 hours.
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1.9.2 Cutting and spreading department
In desta Garment PLC cutting section locate at first Flore.
Spreading taken please most of the time at one end of cutting table only,
and these create other work to move the spread of fabric from that end
other one by sliding by group of people. The fabric roll holder is one, so it
is difficult to spread two spreads at once.
The Quality checker allows check pattern peaces with cut pieces at the
last upper few pieces. Numbering, Sorting, bundling is done in these
section on.
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Numbering and ticketing: - numbering and bundling are done in the
factory by writing on parts. Numbering and ticketing is done by checking
for defective peace inspection and color variation. . After numbering is
given the dispatcher will count and bundle parts for overall 20-30 pieces
at one bundle.
SPREADING
There are four spreading table, after the required fabric is brought into the
cutting section from the .The number of lays depends upon the requirement
of the sewing and the number of the garment to be produced. After the
fabric is laid, if the fabric is knitted its directly cut because its already
marked by chalk, but in case of others the marker paper is spread on the lay
where the pattern is already drawn and it is cut to know the consumption of
the fabric for the garment. The spreading operators carry out aligning
operation on the side of the lay by considering the way in which they
improve their speed and also way in which they minimize wastage at the
start and at the end of the roll.
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Figure 5 spreading machine1
Make the marker making copy from the pattern.
The using of marker mode is either way.
The using of spreading mode is nap one way.
The arranging of cutting lay size by size.
The factory using of splicing method is without splicing method.
bundling the fabric size by size (numbering &tying)
Cutting and fusing machine fusing
There are two types of cutting machine need to the factory
Straight knife
Bund knife
MARKER MAKING
This operation is the main activities where the pre-production operations
are carried out. In this section the marker maker make marker plan
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efficiently for different fabric according to different fabric characteristics.
For carrying out this activity there is supervisor
Twenty thread
Six thread
Twelve thread
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9-Thread 6-Thread
12-Thread CPU
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sample is hanged in the front of lines or at the line end. Daily target
hourly and daily production write on white bored.
This will create awareness of what expects from workers and incite
workers for better work.
In this room there is eight teams each team has two lines. Line A and line
B. each line constancies 12 machine. Operator’s helper and one or two
supervisor and quality checkers in every line.
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.
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Figure 8 sewing room
Trimming
Ironing
Final quality checking
Packaging and label attaching or hanging
The finishing section has not fully infrastructure in all needed materials.
Employees are work at ergonomically bad work conditions. Workers
work at standing position but the table is not properly designed for stand
up work position. Work area is not well organized there is not material
handling equipment for transportation and for other work. In this section
factory does not use any special machinery except steam iron. There are
rectangular shaped hard paper used as folding toll
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Figure 9 finishing room
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Store room
This room is constructed with heavy duty during the time of
establishment this room is developed to satisfy the heavy duty by keeping
stock for production time. But during different unit expansion there is no
expansion in the store room. They think to solve the problem is by
making satellite store in every unit that can store the amount required by
the section. the stock keeping procedure is the required amount of the raw
material is purchased using purchasing requisite format and they send to
different local textile company and if its need to be imported them send to
different agent. They buy material there commonly purchased from
almeda and hawasa T.S.C some time raw material come from china.
During the time they prepare store room issue send to different satellite
stores in every section.
For finished goods they have temporary ware house that stock finished
goods.
1.9.6 Merchandising
In garment industry merchandiser is the bridge between management
(industry)and buyer. The merchandising department of the factory mainly
works on the marketing strategy. The following are main tasks of
merchandising design different market penetrating strategieshandling and
searching new potential buyers and customers. Import different type of
input materials based factory interest and customer satisfaction
preparation export document give order to preproduction department to
prepare sample based on customer specification sheets and sample
participating in different bodies exposed to show factories products from
privies customer orders and their own design.
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1.9.7 Quality controlling
In sewing area each line has inspection in line and off linen inspection
.inline inspection is before garment making random inspection inside
sewing area. Offline inspection is 100% inspection after garment
production out of sewing area and sort the control garment in two first
second quality and repairable garments. Spot cleaning this can be
reprocessed and reclassified as first or second quality garment again.
Quality is an issue greatly concerned in desta plc.garment factory. Quality
checking is done in different at stages to minimize defective garment
pieces are produce out. The quality controlling team of inside the
company members works at different section. . These are:
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1.11 Variety of product and style
25
Figure 10 Variety of product and style
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2 CHAPTER TWO: IMPROVING ERGONOMICS ON
SEWING SECTION IN DESTA GARMENT
2.1 Introduction
Ergonomics is the science of fitting jobs to people. The discipline
encompasses a body of knowledge about physical abilities and limitations
as well as other human characteristics that are relevant to job design.
Ergonomics can help prevent injuries and limit secondary injuries as well as
accommodate individuals with various disabilities; including those with
musculoskeletal disorders (MSDs).The clothing industry is generally seen
as a safe place to work. Compared to other industries, there are relatively
few serious accidents in clothing plants. The hazards we face are different.
The major health risks in this industry do not arise from immediate,
potentially fatal hazards. Instead, the risks that clothing workers face come
from more subtle hazards whose effect accumulate over time.
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This may require employees to work in awkward postures, perform the
same motion over and over again or lift heavy loads – all of which could
cause work-related musculoskeletal disorders (wmsd).These injuries often
start as minor aches and pains but can develop into disabling injuries that
affect our activities of daily living such as laundry, hobbies (knitting, golf,
etc.) and even the ability to pick up our children.
Chair is the most important part of is the company workstation. The chair
has to fit you and suit the tasks that you do. One style of chair may not suit
every worker.
For example, the “average” chair is designed in some instances to fit the
average male and may not suit other users.
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When looking for a chair it is important that the users have the option to try
several different designs prior to finalizing any purchase. A trial period
should be long enough to allow for an opportunity to try the chair (i.e.
several weeks) and to provide comments or concerns with the chair.
The following features are part of a good office chair. A chair is only
“ergonomic” if you can adjust it to fit you. Get to know your chair by
experimenting with the controls, so you can make adjustments quickly and
confidently.
Seat pan
◆ Adjustable in angle
◆ Padding for the low back area that is curved to fit the shape of your back
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◆ Adjustable angle with locking mechanism
Note:
When we sit, our back tends to lose some of its natural curvature. An
effective lumbar support of a chair is designed to help maintain the natural
curvature of the spine when sitting. It is important to provide appropriate
support for the spine so that there is no discomfort or pain . If you are
feeling pain while sitting, the lumbar support of your chair may not be
placed correctly.
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problem in sewing room
10% lithing
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Reduce work fatigue
Reduce material searching and access time To developing
the company’s availability workplace and creating a good
To improve working condition for the worker by
To improve health condition of the operators. By using
proper materials like chair, table, scissors etc……
To replace the unsuitable chairs with the new one.
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2.7 Limitations of the study
Lack of material,knowledge,disincentives, misunderstanding and internet
access to write and search important information for m y project. The
employee's willingness to participate with this study may alter the results.
2.8 METHODOLOGY
2.8.1 Primary data
Observation
Interview
The design of the interviews was based on the project objectives Interview
was the major instrument I used in order to collect some information. First I
prepare questions that related with this project and I asked those questions
to whom it concerned. Those persons are.
Operator
Ans1 :it is not comfortable
Ans 2: No it is not suitable, it create bend our body and create body
stress
Factory head ;
Ans: because if the chair comfortable production will be
decrease. They are not work properly there work
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2.8.2 Secondary data
By reading small written material like annual report, production process
report, and my formal academic course hand out.
I use internet as a data collection method to compare the real work with the
standard; and to get references such as;
www.clothing.com
www.garmentmanufacturing.com
Pain
Numbness and tingling
Stiffness or cramping
Inability to hold objects or loss of grip strength
It is un flexible for operator
It creates stress to operator because it is not comfortable.
It does not adjust for opera by their height
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Figure 12 Setting chair
Current setting chair
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Figure 13 Suggest chair for company
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5: Firm cushioning on the backrest and seat pan
Front to back
2.10 RECOMMENDATION
Give training for Operators:
Improving working condition for operator(VENTILETION,NATURAL
LIGHT)
Use comfortable chair for worker
To increase the product must use suitable working condition.
Avoid awkward postures
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3 Chapter three: benefits gained from internship
This internship is such a wonderful that make me to gain valuable
experience and to expand our personal network. It will definitely help in
deciding a career choice as well as getting experience in our future career.
Our internship gave me the opportunity to apply our theoretical knowledge
learned with the class room to real-world activity. It also gives me an in-
depth analysis of what it really likes to work within our field of study and it
benefited in that we were able to see all the different areas and we were
given a chance to create new relationships with both organization and staffs.
Before doing our internship we were not sure what we wanted to do when
we graduated, so we thought some real-life experience that would help to
set our future activities and we get more experience in our field of study.
Garment is such a broad field of study. There is so much we can do with
this field. After doing my internship we found that we wanted to work more
in our career goal before but our internship makes to like and do more and
also expanded our personal network in this field. This internship helps us to
apply our theoretical knowledge on to the real work.
Employers are usually more concerned with our work experience than our
qualification and this internship are often the only way to get work
experience we need to secure a job. In more competitive job market it is
essential to set us apart from others. Generally the overall benefits that I
have gained from this internship are;
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principle and parts of the machines. As a result, using the new skills and
knowledge we could know how work is done.
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When I was working in my company I tried to get all knowledge
available in the factory to sharpen my theoretical knowledge. This
program has helped me to know: - Work flow of the company
production, Preparation of office works, Engineering problems and their
solutions, Form work of the factory & how to prepare work schedule of
the company.
The works I was executing as assistance as shift leader engineer has
given me clue how to discharge my carrier in the future after graduation.
These tasks were; Supervise works under execution, Order works, check
the flow process, Check works after completion and Discuss on
challenges.
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approach. Having this nature the internship program helps us to develop our
interpersonal communication skills.
Generally it helps me;
To be good listener and speaker
Be polite
Attack ideas not people
Think legally
Avoid faulty generalization
Avoid confusing
Respect others etc.
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being influential
good decision making ability
administration skill
being confident on things done
create smooth relation with the workers but never cross the line
good speaking and convincing ability
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.
I also develop the following things after my internship program
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3.9 CONCLUSION
Generally an internship is an interesting engineering capacity building
program and must be continued for the future with an improved cooperation
of universities and governmental and non-governmental organizations.
Internship makes the interns to compare the student life and the real world
life and help them to develop new and real knowledge, build practical skill,
upgrade and apply theoretical knowledge and so on.
Internship also makes benefit able for the three parties involved in the
program. These parties are university, student and hosting companies. The
student are benefited by acquiring skills and knowledge and work
experiences for the future to be hired in the companies they are hosted. The
universities are benefited by achieving their goals i.e. the universities
graduate their students with full capacity to compute on the world market.
Whereas hosting companies are benefited from getting experienced workers
for their company.
No printing machine.
The spreading machines dose no work.
They are not use CAD system
There is short time for rest
3.10 RECOMMENDATION
Use printing machine to minimize cost of transportation, time money.
Maintain spreading machine and use it to speed their production time. Reduce
labor cost on spread fabric.
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3.11 Reference
www.ergonomics.org
www.osha.gov
3.12 Appendix
TPM- total productive maintenance
Ans- answer
Are suitable with stable and smooth working surfaces provided at the
necessary work stations?
Can the height chairs or benches be altered to suit different workers and
avoid unnecessary bending or high hand position?
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