Orientation Report PDF

Training Report
GARMENTS WET
PROCESSING (GWP)
CRESCENT BAHUMAN LIMITED | 1

UMAIR AHMAD
Management Trainee Officers (GQWP)
GRADE: (M6)
DATE: 21stMarch 2016

Acknowledgment
In the name of Allah, the most Gracious, the most merciful

“All praises be to Allah, the Lord of the World, The Beneficent and the Merciful.
Owner of the Day of Judgment, Thee (alone) we worship; Thee alone we ask for
help. Show us the straight path, the path of those whom thou hast favored; Not (the
path) of those who earn Thine anger nor of those who astray.”
(Al Quran)

TABLE OF CONTENTS PAGE#
INTRODUCTION TO GWP
1) SECTIONS
2) GENERAL PROCESS FLOW
LOCAL ABRASION
1. DRY ABRASION

1) SCRAPING
2) WHISKERS
3) DENNISON KNOTTING/CABLE TIE
4) 5LASER SECTION
2. WET ABRASION
1) PP SPRAY
2) RESIN SPRAY
3) RESIN DIP
4) WRINKLES
WASHING
3. WASHING TYPES

1) STONE WASH
2) BLEACH WASH
3) RANDOM WASH
4) RINSE WASH
5) OVER DYE _
TRIMS ATTACHMENT
RESCREENING
4. PROCESS FLOW
1) TRIMMING
2) QUALITY
3) MEASUREMENT
4) INSPECTION
5) MENDING
6) MENDING VERIFICATION

7) SALVAGING
8) SALVAGING VERIFICATION
9) TOP PRESS & IRON PRESS
SUNDRIES ATTACHMENT
SUNDRIES VERIFICATION
ONLINE QUALITY & SUPER SIX METHOD
INSPECTION
FOLDING & PACKING
SHIPMENT

Introduction to GWP
GWP section gives value to the rigid garment. There are four sections in GWP.
In GWP all operations are done to add value to the garment. Wet processing is
responsible for adding beauty to the garment, change look of the garment & bring
about a change to the texture of the fabric.
Garment processing provides garment an identity and exclusive appearance,
different looks, finishing and design can be made.
Sections
The major sections of GWP are:
1. Rigid Inventory
2. Local Abrasion

3. Washing
4. Trims Attachment
5. Rescreening
6. Shipment
General Flow process
LOCAL ABRASION
“Local Abrasion includes all those operations which are performed to produce the
fashion effect on garments in order to fulfill the customer needs & requirement”
There are two sub sections of local abrasion

1. Dry Abrasion
2. Wet Abrasion

DRY ABRASION
“Dry abrasion includes the operations which are performed without using
chemicals to produce the abrasive effect on the garments”
It includes the operations:
1. Scraping
2. Whiskers
3. Cable Tie
4. Laser Action
5. Denison Knotting
Scraping
“Scraping is the operation which is performed to produce the abrasive effect on

fashion garment”
Scraping Tool
The main tool of scraping is:
01.Sand paper

“Sand paper is the coated abrasive that consist of sheets of paper or cloth with
abrasive material glued to one face”
Types of sand paper
According to shade level there are three main types of sand paper which are:
For Light shade: Paper# (320,400)
For Medium shade: Paper# (210,220)
For Heavy shade: Paper# (110,120)
02. Machine Tool
Scraping Types
According to the method used, there are two main types of scraping which are:
1. Horizontal Scraping
2. Vertical Scraping
Horizontal Scraping
“It’s the type of scraping in which abrasive effect on the garments is produce with
horizontal scraping machine”
Horizontal Scraping Types
The horizontal scraping is carried out by two ways which are:
1. Small Part Scraping
2. Half & Full body Scraping

Small Part Scraping
The scraping machine is used to produce the abrasive effect on the small parts of
the garment.
It includes the scraping of the following parts:
a) Front pockets
b) Watch pocket
c) Facings
d) Fly
e) Waistband
f) Yokes
g) Back pockets
Standard Operating Procedure
There are two heads and four operators on one machine. The 1st operator pick
garment from the trolley which is on the left side and insert the garment on the
tubes. Press the button to fill the air. Then both operators perform the scraping
operation on small parts at a time. Then the air is released and 2nd operator pulls the
garment and disposes on the 2nd trolley which is on the right side of the 2nd
operator.
(Note: The face of the garments should be on top which is required for scraping.
The direction of the pickup garment (1st trolley) is opposite to the deposed
garments (2nd trolley)
Half & Full body Scraping

“It is performed on the full or half panels (front & back) to produce abrasive effect
on the garment”
Procedure
I. Place the bundle on stand which is on the back side of the operator
II. Pick up garment, insert it so that required penal should be on top on which
scraping is to be done
III. Fill the air
IV. Scrap with sand paper for hard scraping
V. Release air
VI. Pull out garment
VII. Dispose garment on stand near machine head
Quality Points
“Quality points are necessary to finalize the product/garment according to the

customer needs and expectations”
There are three main points of quality which are necessary for scraping &whiskers
1) Shape Variation
2) Wrong Placement
3) Intensity Variation

The sub quality points which are necessary to fulfill the above points are:
a) Heavy shade
b) Less/Excessive Feathering
c) Panel-penal variation
d) Pleats
e) Broken stitches
f) Uneven shade
g) Thread effect
h) Less quantity
Corrective Action
These are the main methods of taking a corrective action against the rejection.
1) If the scraping is heavy then put the paper on the scraping area and spray the
remaining area in order to make it light & smooth the intensity of scraping.
2) If the scraping is light then make it heavy by using the following sand paper
( P-120, A-120, P-110, A-110)

Horizontal Scraping Machine
It is the machine tool by which scraping operation is to be carried out on the
garments.
Scraping Machine Details
Horizontal No of Heads OK NOT OK

Scraping M/c
Small Parts 12 8 4
Half/Full body 56 26 30
Horizontal Machine Parts
1. Machine Arms or Dummies:

It is the main parts of machine which are used to fasten the rubber tubes.
2. Tubes
They are used to fill the air. The good quality tubes have the ability to adjust them
according to the required size of the garments. The tubes are put onto the machine
arms and tighten with tape or strip so that there is no leakage of air or pressure.
3. Control Panels:
The control panels are contains on different buttons which are used to fill or release
the air to insert & pull out the garments.
4. Stand:
It is used to support the garments when the scraping operation is to be carried out.

Vertical Scraping
“It is the type of scraping in which abrasive effect on garments is produce with
vertical scraping machine”
Vertical Scraping M/c Details
Vertical No of Heads Ok Not Ok

Scraping M/c
Small 144 71 73
Parts/Half &
Full body
Standard Working Procedure

Operator picks garments from the 1ststand which is on the left side of him. Then
Insert it as its side on which scraping is required should be on top. Then he fills air.
Then scrape separately both front or back according to the requirement. Then
release the air. Then he Pull out garment and drop it on the disposed2ndstand which
is on the right side of the operator.

WHISKERS SECTION
Whiskers
“Whisker is the combination of lines which is drawn on the specific parts of the
garment by using a specific pattern or template in order to produce the fashion
effect on the garment according to the customer needs & requirement”
Whisker Types
1) Thigh Whiskers
2) Knee Whiskers
3) Panel Whiskers
4) Bottom Whiskers
Whisker Tools
There are five (5) types of whisker tools which are:
1) Mold
It is the main tool used for making whiskers. It is the template which contains the
same pattern of whiskers which are required on the garment. Garments are put on it
so that the required area of garment on which whisker operation is to be carried out
should be on the pattern.
2) Roll Whiskers
They are made by rolling of sand paper in 4x4 sizes.
3) Manual Strip

It is also used instead of roll to make the whiskers. It is the thin strip made by
cutting the sand paper into 4x1 sizes.
4) Stand
The mold or pattern is adjusted on it. There are two patterns is adjusted on same
stand.
5) Sand Paper
It is selected according to the wash or shade of the garment. According to the shade
level the main type of scrap paper are:
Light shade: (320,400)
Medium shade: (220)
Heavy shade: (110,120)
As light shade is required for whiskers so sand paper of number (320, 400) are
used.
Quality Points
There are three main points of quality which are necessary for whisker operation
1) Shape Variation
2) Wrong Placement
3) Intensity Variation
The sub quality points are:

a) Light
b) Heavy
c) Thick
d) Thin
e) Improper shade
f) Pleats
g) Broken stitches
h) Damage
i) Wrong pattern
j) Thread effect
k) Less quantity
l) wrong sand
m) Short/ long pattern
n) Panel-panel variation
Corrective Action
These are the main methods of taking a corrective action against the rejection.
1) If the scraping is heavy then put the paper on the scraping area and spray the
remaining area in order to make it light & smooth the intensity of scraping.
2) If the scraping is light then make it heavy by using the following sand paper
(110,120)
Dennison Knotting

“It is the operation which is used to avoid the specific area or parts of garments
from washing. Pins are inserted at the edges of these parts.
Tool
Machine: Plastic Stapler Attacher
Total m/c= 9 (all are operable)
Procedure
The operator pick garment from trolley which is on the left side of the operator. Put
it on his lap and insert the pins and then dispose the garment stand which is on the
right side of the operator.
Laser Section
The laser light is used to produce the abrasive effect on the garment. It performs
the operation of scraping, whiskers, grinding with uniform shade.
Standard Working Procedure

The supervisor or technical person saves the image of garment into control
machine with required settings. The whole operation of scraping, whiskers &
grinding is performed by following the image of garment.
The operator picks the garments from trolley which is on the left side of operator.
The side of the garment where scraping, whiskers or grinding operation is required

is on the top. After picking the garment the operator insert it into tubes and hold by
clamp and fill air and press the green button to start the operation. Then the
machine perform the laser action automatically after it operator release the air and
pull out garment and dispose it on the trolley which is on the right side of operator.
Laser Machine Detail
Laser Machine Total M/c Single Headed Double Headed

4 3 1
Machine Parts
The main parts of laser machine are:
I. Control Panels- These are used to control the operation or functions of the
machine.
II. Laser screen- It shows the output /image of the garment under scraping,
whiskers or grinding operation.
III. Moveable Clamper- It is used to hold the garment for required operation.
IV. Dummy- The garment is wears on it.
V. Foot Presser- It is used to fill & release the air from tubes.
VI. Green Button- It is used to start the operation.
VII. Emergency Button- It is used to aware from the emergency situation.
Garment Receiving at Staging:
When required local abrasion operations have been preceded on the cut, the

garments will go to washing. A complete bundle will move from scraping to
staging and then will ready for washing. Here in washing different operations will
allow proceeding on garments as per wash.
Receiving Procedure:
● After quality inspection, ok bundles will handed over to staging operator by

local abrasion operator.
● WIP operator will verify the bundle as per COR sheet.
● Staging operator will sign the COR sheet when ok bundle is being handed
over to him.
● Local abrasion operator will sign the COR sheet when the ok bundle is being
handed over to staging operator.
Note: Only the complete bundle can move to staging from local abrasion.
Staging Procedure:
To ensure the preparation of a load for tumbling and washing process, bundles are
loaded, stacked on trolleys and sent for processing.
● Staging operator will take a trolley and will load garments.
● Operator will ensure the order #, style #. Process #, cut # and bundle #
before making a load.
● Load should make of weight 110 Kg to 152 Kg, as per wash.
● Load will be made at weighting balance plate.
● An identification card will be prepared and attached with every load.
● The colour of card may change for every new wash.
● Wash #, batch #, cut #, bundle #; size, style and quantity of bundles in a

batch will be written on ID card.
● Bundle gone for processing after loading will be moved marked on COR
sheet.
● After taking all necessary records, Trolley will be moved for process with ID
card.
TUMBLING:
Tumbler is a main process of washing which will operate on garments. Many of

the programmes have been feeded in the tumblers memory by management. The
required programme is being operated by operators on which desizing and abrasion
is made as per wash. During desizing the enzymes should be used as per standard
and requirement of recipe. Stones should be used as per standard and requirement
of recipe (fully new or mixed with old).operators should check at least three pieces
(top, middle and bottom) and will ensure that bundle produced is according to
quality standard.
There are 16 Tumblers available in washing section, in which Tumbler from 1 to
12 belongs to BRAUN Company of USA; Tumbler # 13 & 14 belongs to
COSMOTAX Company and finally the Tumbler # 15 & 16 belongs to TONELLO
of ITALLY.
BRAUN TUMBLER:
Company G.A Braun Incorporation USA

Model 145 STOLUSPV

Voltage 415 V
Frequency 50
Speed 120 rpm
Maxi. Capacity 500 LBS
PARTS OF MACHINE:
Following are the main parts of this machine….

1) Seal rubber door frame and glass.
2) Clamp door and cylinder pneumatic L/R.
3) Lock / hook and cylinder pneumatic.
4) V ring lip seals.
5) Seals SS main shaft.
6) Main shaft bearing and tilting hinges.
7) Belts.
8) Pulleys belts and hubs.
9) Basket S.S.
10) Valve air regulator and pressure.
11) Cover machine and bolts / nuts.
12) Hydraulic oil filter and level glass.
13) Gauze and oil pressure.
14) Valve W/actuator hot / cold / steam.
15) Hose rubber and clamps.
16) Water level and air chamber.
17) Pump diaphragm feeding system.
18) Bolt / nut foundation pump.
19) Housekeeping area for machine.

TUMBLER USAGE PROGRAME # 12
Total steps : 14

Load weight: 120
STEP # 1:
Filling of water : 120 gallons
Addition of any detergent : soaping agent
Timing : 03 minutes
STEP # 2:
Alarm ringing
STEP # 3:
DESIZING
Add more water : 6 0 gallons

Increase temp with steam : 140 F
Addition of desizer : Ultrazyme, Redesizer.

STEP # 4:
Draining
STEP # 5:
RINSE
Water : 260 gallons

Time : 02 minutes
STEP # 6:
Draining of water
STEP # 7:
Alarm ringing
STEP # 8:
ABRASION
Water : 120 gallons
Temperature : 145 F

Stone addition : new or old mixed (as required).
Enzyme addition : Valumax.
Addition of anti-stain : as per requirement.
Time : 30---60 minutes. (With respect to
shade)
STEP # 9
Draining of water
STEP # 10:
RINSE
Water : 240 gallons

Time : 02 minutes
STEP # 11:
Draining of water
STEP # 12:
RINSE

Water : 240 gallons
Time : 02 minutes
STEP # 13:
Extraction
Time : 03 minutes.
STEP # 14:
Unloading
*PROCESS HAS BEEN COMPLETED*

WASHING TYPES
The five common types of washing are:

1) Rinse Wash
2) Bleach Wash
3) Stone Wash
4) Random Wash
5) Over Dye
STONE WASH
Wash# 1002

Weight- 110kg
Quantity: 135 Garments

BLEACH WASH
Wash # 6261
Load= 20 Kg

DEROCKER:
During tumbling process, stones were added in garments to get shade (abrasion).
De-Rocker is used to separate the garments from stones. Two operators get the
trolley and place with the machine. De-rocking procedure is given below….
● Operators should get garments from trolley and will left to the opening end
of De-rocker.

● Before putting in machine, operators will give maximum jerks to garments
to separate the stones.
● In the inside of machine, a basket having a lot of holes in it is rotating to
separate garments from stones.
● Garments are being received at the other end of the machine after processing
the operation.
● The trolley of separated garments is moved for washing process.
● No stone must be found in garments after process, because if any stone
found in later processes, which may cause of shade variation and stain
problem.
● Stones are deceived out from the steel tub placed under the De-rocker for
future use as old stones.
*** De-rocking process has been completed ***
WASHER

Washing of garments is another main process of washing section which will
operate on every cut. Many of the programmes have been feeded in the washer's
memory by management. The required programme is being operated by operators
on which washing, over dye and neutralization is done as per wash. During process
chemicals should be used as per recipe. Some washes are being washed directly
known as direct wash. Some washes are being washed one time and some washes
are washed twice, as first wash (before spray) and as 2nd wash (after spray).
There are 18 washers available in the washing section. The washers from 1 to 16
are of BRAUN company and the washer # 17, 18 are of TONELLO company.
Here the detail of both company's washers is given below.
TONELLO WASHER:
Company : TONELLO (Italy)

Anno : 2 008
Voltage : 380 volts
Frequency : 50 Hz
Corr. Norm. : 63 A
Pot. Norm. : 25 KW
Grade IP : 54

PARTS OF MACHINE:

● Seal rubber door frame and glass.
● Clamp door and cylinder pneumatic L/R.
● Lock / hook and cylinder pneumatic.
● V ring lip seals.
● Seals SS main shaft.
● Main shaft bearing and tilting hinges.
● Belts.
● Pulleys belts and hubs.
● Basket S.S.
● Valve air regulator and pressure.
● Cover machine and bolts / nuts.
● Hydraulic oil filter and level glass.
● Gauze and oil pressure.
● Valve W/actuator hot / cold / steam.
● Hose rubber and clamps.
● Water level and air chamber.
● Pump diaphragm feeding system.
● Bolt / nut foundation pump.
● Housekeeping area for machine.

BRAUN WASHER:
Company : G.A. Braun incorporation USA.

Model : 5 00 NOLUDPV
Amps : 25
Voltage : 4 15
Phase : 03
No of places to grease : 27
Wash speed reversing : 22---35 RPM
Extra speed clock wise : 5 62 / 281 RPM
Max. Capacity : 500 LBS

PARTS OF MACHINE:

● Seal rubber door frame and glass.
● Clamp door and cylinder pneumatic L/R
● Lock / hook and cylinder pneumatic.
● Belts.
● Pulleys belts and hubs.
● Basket S.S.
● Valve air regulator and pressure.
● Cover machine and bolts / nuts.
● V ring lip seals.
● Seals SS main shaft.
● Main shaft bearing and tilting hinges.
● Hydraulic oil filter and level glass.
● Pump diaphragm feeding system.
● Bolt / nut foundation pump.
● Gauze and oil pressure.
● Valve W/actuator hot / cold / steam.
● Hose rubber and clamps.
● Water level and air chamber.
● Housekeeping area for machine.
WASHER PROGRAME # 05

Load weight: 120Kg
Total steps : 14
● Load the machine...
STEP # 01 RINSE

Temperature : 120 F
Timing : 04 minutes
STEP # 2
Draining of water
STEP # 3: BLEACHING

Water : 230 gallons
Add fixer : Chemfix
Temperature : 130 F
Time : 8 minutes
STEP # 4: SHADE MATCHING STEP
Time : as per shade
STEP # 5:
Draining of water
STEP # 6: RINSE

Temperature : 120 F

Timing : 02 minutes
STEP # 7:
Draining of water
STEP # 8:
Ringing Alarm
STEP # 9: NEUTRALIZATION

Temperature : 130 F
Timing : 06 minutes
Chemical : hydrogen per oxide or other as per
requirement
STEP # 10:
Draining of water
STEP # 11: RINSE

Temperature : 120 F
Timing : 02 minutes
STEP # 12:
Draining of water
STEP # 13: SOFTNESS STEP

Temperature : 120 F
Timing : 05 minutes
Softener : As per requirement
STEP # 14:
Extraction
Note:

Quantity of chemicals and other additions will be measured to get the shade as per
standard.
***PROCESS HAS BEEN COMPLETED***
EXTRACTER:
Extractor is another common using machine in the washing process. When

the garments are washed in the washer, after it garment goes to extractor to extract
the water from garments for the next process.
DRYER:
To dry the garments, extracted garments are received here in drying area. After the
washing and extracting, the garments are sent to drying section from washing
section for dry process.
WORKING OF THE DRYER:

● Loading of the machine
● Selection and execution of the required program
● Unloading the machine
PROGRAME # 05
● Loading of the machine
Temperature : 180 F

Rotations : 30 minutes
Cooling : 03 minutes
● Unloading the machine
SPRAY:

Spray is a necessary process which is done on the garments. Spray is done to get
the shine on shade and to get the intensity of shade as per standard.
Here in the spray section, we have two types of spray as given below.
I. KMNO4 SPRAY:
In the KMNO4 spray, the spray of solution of the KMNO4 is used in different
ratios with the addition of different ratios of an ACID, for different washes.
Some ratios of KMNO4 spray are given below.
SOLUTION TYPE KMNO4 ACID
1.5% 300 Gms ----------

2.5 % 500 gms 1 % (10 ml
3% 600 gms 1.5 % (ml
0.7 % 140 gms -----------
0.8 % 160 gms 0.5 % (0ml)
1.2 % 120 gms --------------

1.00 % 100 gms ---------------
1.0 100 gms 0.5 % (5 ml)
● These upper given ratios are used commonly to make KMNO4 spray on
garments. These different ratios are used for different washes as per
requirement of shade.
II. RESIN SPRAY:
Resin spray is used in different ratios with different chemicals as like MAR, MIR
& NKR for different washes to get the result as per requirement. Those washes are
resin dipped which have an effect of spots on the garments if they are resin dipped.
RESIN DIP
There are three numbers of tubs available.
1) Solution capacity of a tub is 2200 liters in a tub.

2) Dip time of a bundle is 30 seconds.
3) 4 to 5 bundles can dip fully in a resin tub in the same solution.
After the decreasing of the dip level of a tub, an addition of some more solution is
added in the tub to get the required level.

CHEMICALS OF RESIN DIP:
● Rosoko 3D creaz
● MAR legafinish.
● MIR legefinish.
● NKR legeflex.
WRINKLES:
Wrinkles are made on the garments as per standard given. Wrinkles are made on
the wrinkle machine. This one machine has three heads where three operators can
work at a time.
GRINDING:
Grinding is made on the required washes on the grinding machines as per standard
given.
OVEN:

Oven is used for drying and curing of the garments. There are two ovens which are
in use at present in which one oven is of small size and the other one is large in
size.
CONSTRUCTION AND WORKING:
COMPANY:
Both of the ovens are of MATOD MAKINA Company
SOURCE OF WORKING:
There are used two gasses as source
1) NATURAL GASS
2) LPG

PARTS:
1) ELECTRIC BURNER:
It has some capacitors and an electric motor it. When the oven is get on, this burner
creates the electric sparking due to which the incoming gas gets fire.
2) MAIN BURNER:
It is the main burner of the oven. It has a lot of tubes inside it, in which the gas is
burning as like a pool of fire. This heat is sent to inside of oven to get in action.
3) BLOWERS:
It is another main part of the oven. It blows the heat created in the main burner to
inside the body of oven. It pushes the hot air from the main burner to oven through
a pipe of size 10—12 inches.
4) EXAST FANS:
These fans exit the extra heat and carbon particles out from the oven.

5) BEFALLS:
Befalls are also the main part of the oven. These are adjusted at front end from
where the garments enter and exit from the oven. These fans pull the hot air and
push to the upper side of the oven, due to which the heat cannot go out from the
entrance and exited point of garments and will not create the difficulty for the
operators during work.
6) CONVAYER SYSTRM:
It is the main system which controls the speed of rotations of garments. It has two
main parts as given below.
7) VIRM GEAR:
It has an electric motor in it which creates the movement in the conveyer chain. It
has small pulleys in it also, which work like gears due to which it is known as virm
gear or gear box.
8) CONVAYER CHAIN:
It is another main part of the conveyer box. It is a chain on which main hangers are
adjusted. Every main hanger has three sub hangers on which three garments can be
hanged for process.

REWASH
Garments are rewashed after spray to anti-chlore or neutralize them.
RE-EXTRACTION
After rewash, garments will be re-extracted for drying.
RE-DRY
Re-dry process of garments is done after wash and extraction.
OZONE
Ozone machine gives the sharp and soft looking effect on the garments. This
process is done on the required washes.

SORTING
On sorting, garments are received after dry process. Here in sorting garments are
separated as per size, bundle, wash, order and cut number
.
SHADE BOOTH
● Shade audit is done to ensure the shade of the garments as per customer
standard.
● In shade audit, wash shade and local abrasion shade is being audited.
● Auditor will pick three or five garments of a bundle and will make their
audit.
● The ok bundles will forward to the WIP area for next process.
● The rejected bundles will be sent back for rewash.
● If the bundle was dark then it will be rewashed to get light shade.
● If the bundle is bluer then it will sent back for Tint again as per requirement.
● After rewash, the ok bundles will be sent to the WIP.

TRIMMING AFTER WASH
When the bundles are ok for shade as per standard, then they will sent for trimming
(trimming after wash).Here in trimming, cutting of the extra threads takes place. It
is necessary for good look of garments, which is directly affected to good look of
garment and a best way to make more goodwill of company.
NEEDLE DETECTION
Needle detection process is an additional process on garments. It is proceeded on

washes in which needle detection is required.
WIP WORKING
After drying and sorting, the garments are received in WIP section. Here garments
are separated as per wash, customer and size. Garments are planed here to send to

the Re-screen section. Some other processes like needle detection, patches on
grinned places and garments turning are also performed here.
RESCREENING
All operations in the rescreening area are done to give presentable shape to
garment. Operations sequence of Green Line is:
✓ Trimming
✓ Quality check
✓ Measurement
✓ Vapour press
✓ Inspection
✓ Mending
✓ Mending verification
✓ Salvaging
✓ Salvaging verification
✓ Top press
✓ Sundries
✓ Sundries verification
✓ Online quality
✓ Inspection
✓ Folding Packing
Operation sequence

1. Trimming:
First operation of rescreening area is trimming. All extra threads or stuff is
trimmed.

Presentation of work:
1. Trolley loaded with one bundle placed after vapour press in WIP.
2. Garments are placed on stand in front of the operator.
3. Waistband leather patch towards the placed faced up.
Procedure:
● Bring bundle and position in front. Write code on bundle card

● Start trimming bottom and inseam plus out seam, complete bundle while
placed on trolley. Shift all garments on left side partition of trolley with
waist band
● Pick up garment from the right side trolley and hang the garment on hanger,
leather patch should be in front
● Start trimming from the right back of the garment.
● Start trimming from the right back of the garment.
● Rotate garment for Left Back Panel trim thread first Loops, waist band Left
back pocket.
● Open garment for trimming outside of front from waistband, Watch pocket,
facing, crotch, loops, and Fly bar tack.
● Open zip and stud and complete trimming of all inside upper area including
pocket bags etc.,
● Clean trimmed threads off garment, fold garment with front panels folded
inside, remove from hanger
● Give jerk to garment and dispose on same pickup trolley on right side
keeping right back panel with leather patch facing up.
● Dispose trolley up to the designated area and cut and paste coupon signing
etc.

2. Measurement:
Garment measurement includes three types of measurements
● Waist
● Length
● Half leg waist
Procedure:
● Bring trolley to the right side of the operator.
● Put three garments on the table.
● Check waist of the garment.
● Set garment.
● Check length of the garment.
● Check half-length waist.
● Fold garment and dispose.
Method of measurement:
Waist:
Garment is folded from watch pocket in such a way that both the rivets of watch
pocket are joint to gather, measure garment from watch pocket in two steps, from
watch pocket to half of the waist to end. There are two possibilities of waist
whether it is positive or negative.
Length:
Garment length is measurement from 2cm below the crotch centre than straight to
the bottom along the inseam in three steps.

14cm 17-18cm 34-36cm
Half leg width:

Width of the half leg is measured from two inch above the half leg. Fold garment
up to crotch centre than mark half leg. Then measure width of the half leg from 2
inch above the half leg.
3. Vapour Press:
In vapour press operation air or steam is blown inside the garment. Hot steam
presses the garment and normalizes the stretchiness of garment. Pressure required
depends upon the waist whether is negative or positive.
Parts of vapour press machine:
Head
● Fan blower
● Cooper steamer
● Cylinder pneumatics
● Up/down adjustment with handles
● Waist size regulator

Leg carriage assembly
● Cylinder pneumatic
● Clamp-left/right & seal rubber
● Roller Teflon leg carriage assembly
● Stainless steel jacquard
Procedure:
● Check size on bundle Card and adjust waist and inseam clamp of the m/c. as
● Pick up jeans with both hands from waistband side and hang it with the
clamp
● Adjust right bottom in left clamp by pressing foot pedal.
● Adjust left bottom in right clamp by pressing foot pedal.
● M/c activating time for pressing with Steam and Air.
Steam 16 sec
Air 16 sec
● Disengage garment from machine and dispose it on left side trolley.
Note:-
During the Steam and Air Time of pressing in every next garment, Operator will
fold the previous pressed garment face to face from Front side to make required
crease and then dispose it left side on trolley. Coupon signing and dispose trolley
up to the designated area of next.
4. Inspection:
There are ten tables of inspection are present in rescreening area two persons can
work on each table. Inspection is done clockwise. There are twenty one possible
faults which are listed below:

Procedure:
● Pick up garment from Trolley and put it in front on the table.
● Open stud and slider, check inside Waistband clockwise (check chain stitch,
woven label and printing if any).
● Turn the garment inside out from left side seam so that the entire pocket bag
is visible to operator, check left inside of side seam and pocket bag
● Turn the garment inside out from right side seam so that the entire pocket
bag is visible to operator, check right inside of side seam and pocket bag.
● Place the garment inside out in such a way that crotch and fly is in front of
operator, check crotch, inside front rise and fly’s.
● Flip the garment so that the inside back rise is visible up to crotch, check the
back seat, yoke seam and back pocket stitch from inside.
● Turn the garment, jerk it and place it on table so that the front scoop pockets,
fly, front rise and crotch are visible to operator.
● Close stud and slider and critically check crotch, front rise, J stitch, fly and
eyelet.
● Check outside waistband and loops from left to right, check right hip stitch,
pocket bag then left pocket bag and hip stitch and all rivets in between.
● Flip the garment so that the back pockets, back yoke and back rise are visible
to operator.
● Check waist band, loops and leather patch from right to left. Then check left
back pocket from outside and inside and similarly the right back
● Slide the garment upwards; check both bottoms from inside and outside up
to 4".
● Place the garment on table horizontally to check for leg length variation.
● Check out seam and inseam of both panels and also check spots on panel.
● Write on fault code slip and put it inside back pocket.
● Fold the garment and dispose it, if garment is OK, place it on left corner and
if faulted, place on right side of the table.

● After completing the bundle place the Ok Pcs on the trolley, then place a
separator card and place faulted Pcs on the top.
● Dispose the trolley to next operation.
5. Mending:
In mending operation faults found during inspection process are removed or repair.
Inspector inspect the garment and write fault code on slip if found. The whole
bundle moves to mending operation.
Procedure:
● Bring trolley from the designated area up to the left side of machine and take
position.
● Mender collects all faulted garments from trolley and place on right side
empty trolley. (Fixed) one garment on his / her lap.
● Put out rep. slip from back pocket and starts repairing whether by hand
needle or with machine, on described fault and place the fault slip
● Dispose this garment. On back to its original trolley if there is no any extra
fault on its and which is repairable on other machines otherwise place
● if operator have no other trolley for mending and is free of work, he / she
will drag this trolley up to the designated
Note:
Garment quantity for mending in a bundle is not fixed; it may vary from Bundle to
bundle.
6. Mending verification:
The inspector receive the complete bundle OK & not OK after their mending than
he/she again inspect the pieces and if got fault pieces again send to mending

operator. After mending completely he send complete OK garment for salvaging.
Procedure:
● Bring trolley from the designated area up to the left side of mending
verifier's table and take position.
● verifier collects all faulted garments from trolley and place on right side
empty trolley (fixed) and place the
● pick up one garment, put out rep. slip and start to check the mending ok or
not, enter the fault in paper, fold and dispose the
● Dispose trolley to the designated area for garment quality check on line audit
and come back to the workplace.
7. Salvaging:
After the process of washing there is possibility of shade variation which is
removed by the process of salvaging. Small invisible variation or spots on garment
are removed. China Pencil, marker or chook is used according to the shade.
Procedure:
● Bring trolley from the designated area up to the left side of salvaging table
and take position.
● Salvager collects all faulted garments from trolley and place on left side
empty trolley. ( fixed )
● Pick up one garment for salvaging and put out salvaging repairing slip,
spread garment. On table without folding disturb and salvage. Defective part
of the garment with required textile marker/ pencil. Enter record in register

respectively.
● Fold up to knee, dispose the repairing slip and place the garment. On its
original trolley.
● Dispose the trolley on designated place for mending verifier table if
repairing on all faulted garments is completed.
8. Top Press:
Top front, back and panel below the half leg is pressed by top press machine.
Procedure:
● To bring the trolley, arrange and take position for top pressing.
● Pick one garment and insert jeans in the top presser bed from waist band
side.
● Press left front pocket, rotate, press zipper fly, rotate, press right front pocket
(clockwise rotation) and pull out.
● Dispose garment. Properly to left side trolley.
● Move or dispose trolley towards designated area for next operation.
Manual press:
Garment panels and the areas which are not pressed by top press machine like
facing of the garment is pressed manually.
Procedure:
● Bring trolley from the designated area up to back of stand, waistband

towards the pressing stand.
● Pick up garment from waistband side and insert left leg in the stand
completely, keeping out seam bite on top and check for no pleat.
● hold the pressing iron with right hand and start pressing from bottom to top
on required place (use left hand for maintaining the out seam bite crease and
right hand for pressing) and place iron back on stand.
● Pull out garment with both hand and again insert from waistband side the
right leg in the stand and check for no pleat in right out seam bite with left
hand and hold the pressing iron with right hand.
● Complete pressing from bottom to top as well as in left out seam bite.
● Place the iron back on stand and disengage the garment from pressing stand
and dispose properly on left front side trolley.
● Dispose trolley up to the designated area and come back on work place.
9. Folding:
After top press and manual press operation garment is ready, now it is folded as
required by the customer.
Procedure:
● pick up garment from waist band with right hand and fold garment with front
panels folded inside and place on table as left back panel face up
● Align inseam and out seam of the garment.
● half fold garment by holding waistband with left hand and align with
bottom's end
● Dispose garment on the dispose trolley keeping right back panel with leather
patch facing up.
● Coupon signing and dispose trolley for next operation up to designated area.

10. Packer verification:
It includes the major verification of garment before packing. Major faults are
verified in the process.
Procedure:
● Bring trolley and place to the left side of the packing table.
● Pick the garment, spread on table.
● Cut off cut no. label (if req.), check major fault as per instruction.
● Fold and place right corner on packing table for packing in the box.
11. Packer:
Pack required number of garments in boxes.
Procedure:
● Pick up the bottom of box and place it on packing table.

● Place garments in the box in folding position as per required.
● cover the box with topper, paste the size and quantity detail sticker on it and
dispose the box up to the designated
12. Online quality audit:
Procedure:
● Bring trolley and place it to the right side of the quality table.
● collect 05 garments in random and place it on right corner of the garment
quality check table (in position)
● pick up top first garment, spread it on table and check l & S inseam, check
shade according to standard, (5 garments / bundle)
● Dispose this garment back on its original trolley, if found o.k. otherwise
place left side corner of the table.
● Complete documentation and forward the trolley for next operation and
come back to the garment quality check table.


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Training Report

CRESCENT BAHUMAN LIMITED | 1

CRESCENT BAHUMAN LIMITED | 2

In the name of Allah, the most Gracious, the most merciful

CRESCENT BAHUMAN LIMITED | 4

2) GENERAL PROCESS FLOW

CRESCENT BAHUMAN LIMITED | 5

3) DENNISON KNOTTING/CABLE TIE

CRESCENT BAHUMAN LIMITED | 6

CRESCENT BAHUMAN LIMITED | 7

9) TOP PRESS & IRON PRESS

ONLINE QUALITY & SUPER SIX METHOD

FOLDING & PACKING

CRESCENT BAHUMAN LIMITED | 8

CRESCENT BAHUMAN LIMITED | 9

General Flow process

There are two sub sections of local abrasion

CRESCENT BAHUMAN LIMITED | 10

“​Scraping is the operation which is performed to produce the abrasive effect on

CRESCENT BAHUMAN LIMITED | 11

CRESCENT BAHUMAN LIMITED | 12

Half & Full body Scraping

CRESCENT BAHUMAN LIMITED | 13

“​Quality points are necessary to finalize the product/garment according to the

CRESCENT BAHUMAN LIMITED | 14

CRESCENT BAHUMAN LIMITED | 15

Scraping Machine Details

Horizontal No of Heads OK NOT OK

Horizontal Machine Parts

1. Machine Arms or Dummies:

CRESCENT BAHUMAN LIMITED | 16

Vertical Scraping M/c Details

Vertical No of Heads Ok Not Ok

Standard Working Procedure

CRESCENT BAHUMAN LIMITED | 17

CRESCENT BAHUMAN LIMITED | 18

The sub quality points are:

CRESCENT BAHUMAN LIMITED | 19

CRESCENT BAHUMAN LIMITED | 20

Standard Working Procedure

CRESCENT BAHUMAN LIMITED | 21

Laser Machine Detail

Laser Machine Total M/c Single Headed Double Headed

Garment Receiving at Staging:

CRESCENT BAHUMAN LIMITED | 22

● After quality inspection, ok bundles will handed over to staging operator by

CRESCENT BAHUMAN LIMITED | 23

Tumbler is a main process of washing which will operate on garments. Many of

Company G.A Braun Incorporation USA

CRESCENT BAHUMAN LIMITED | 24

Following are the main parts of this machine….

CRESCENT BAHUMAN LIMITED | 25

Total steps ​ : ​14

Add more water ​ : 6​ 0 gallons

CRESCENT BAHUMAN LIMITED | 26

Water ​: ​ 260 gallons

CRESCENT BAHUMAN LIMITED | 27

Water ​: ​ 240 gallons

CRESCENT BAHUMAN LIMITED | 28

*​PROCESS HAS BEEN COMPLETED*

CRESCENT BAHUMAN LIMITED | 29

The five common types of washing are:

“Scraping is the operation which is performed to produce the abrasive effect on

“Quality points are necessary to finalize the product/garment according to the

Total steps : 14

Add more water : 6 0 gallons

Water : 260 gallons

Water : 240 gallons

PROCESS HAS BEEN COMPLETED

* De-rocking process has been completed *

Company : TONELLO (Italy)

Company : G.A. Braun incorporation USA.

Filling of water : 240 gallons

Time : as per shade

Filling of water : 280 gallons

STEP # 9: NEUTRALIZATION

Filling of water : 280 gallons

Filling of water : 150 gallons

PROCESS HAS BEEN COMPLETED

Temperature : 180 F

Some ratios of KMNO4 spray are given below.