Production Procedure of the Bag

Introduction

I make this report as my expression of my Industrial training and a overall report of my training session during tow month from 21^st April to 21^st June.

PICARD

Picard Bangladesh Ltd. is a joint venture company which was established in 1995 in conjunction with PICARD Leather Waren Gmbh Co. & KG. The company manufacturing leather goods for export in the international market. The picard brand was originally established in Germany in 1928. The company is family owned and is currently in its fourth generation of ownership.

Picard Bangladesh Ltd. has come a long why since its inception. The factory started with about 60 worker in a small production floor of about 2000 sat. Currently the factory is located in the heart of the new industrial area at kondo bag Zirabo, Leather, Dhek.

In addition to manufacturing for the picard, we are also involved is production for our other customer based in Australia Europe. Canada, Japan and Singapore. The company’s objective has always been to manufacturing and export high wality leather goods at the best price possible for our valued customer.

Background of the Report

This report is my kind and complete document of my training experience. I make this report because-

• It is the final report of my training.
• It is the scope where I can express my knowledge about training.
• This report is related to my internship certificate.
• It is a scope where I can give my over opinion.
• I want to accumulate work of all section of the production procedure of bag.

 Objects of my Report

The subject of my report is “Production procedure of the bag.” The report has the following objectives-

• To know a qualityful bang production procedure
• To know the cost production in leather industry.
• To find out the quality value of bang.
• To develop shilling quality wanted during manufacturing.
• To develop manufacturing according to manufacturing pattern.
• To learn practice knowledge about bad manufacture.

To earn experience about –

• Cutting, splitting, skiving making
• To accuse knowledge about any type of operation during manufacturing from sample to production
• To get knowledge about colour
• To improve sence about clearing and finishing
• To knows the mathe of packaging.

 Methodology

I collect all this data in the whole time in my training rerian from sample reson to packaging section.

And all employee including – officials stuff, markers all are the helping hand to me. With the help of all them I can make my report.

Scope

It is my industrial training report.

I train is the industry “PICARD Bangladesh Ltd.” and It is the best industry in Bangladesh for manufacturing specially for beg.

The slogan of this industry is “PICARD means quality and right time shipment.

This report mostly applicable for PICARD Bangladesh Ltd. but for best quality and shipment it also applicable for all type of industry which product bang male.

Chapter-Two

Sample

Introduction

Sample section is the brain of all production section. It is the main part of manufacturing process of a bag. Whole production system depend on the desision and determination of sample. From sample room the now production of bag is done. Depends on its quality and accury then the final production starts.

Role of Sample (Step – 1)

• Learn about bugen expection.
• Learn about all parts of given bag which is sent for buying.
• Learn all things included is machine the bag – UK, living, Reinforcement, atting, thead and Qiecessonies
• Get complete knowledge about colour texture surface about leather.
• Learn about living such as plain, cotton, valuate, picard an Picar world living.
• Learn about colour and thickness about reinforcement.
• Learn about skiving, spiriting and stitching of the product
• At least get complete idea about required outlook of the product.
• After learning all this thing sample master first made the master pattern
• Then he cut the cutting pattern of leather.
• After cutting the leather cutting pattern of living.
• At least cut the cutting pattern of reinforcement
• In the master pattern all types of stitch overalap and folding are indicated.
• In cutting pattern all types of allounce are indicated by nock moral
• When fielding, stitching, underlay and other attaching operation are indicated in cutting pattern by various indication cut.
• Then all the pattern to the required bugger sample is complete.

 Step – 2

• After completion all the pattern then cut leather, living and reinforcement according to the requirement.
• Then assemble all the parts the product.
• After asble all parts according to design then the final stitch is done.
• The last is done is cutting table for edge cutting.
• Then clean and edgeing is done and complete the sample bags.
• In this section all type of cut is done by hand and very sensitively.

 Responsibilities and duties in sample section

Work done in the sample room beg fair steps-

• To understand all type of instruction and designee give by the bugen.
• To make firstly two bags as buyek choice sample.
• It is granted then make the sale sample.
• After the success of sale sample the make the whole production procedure.

All this are disenabled below-

Step – 1

To understand all types of design and instruction.

In one time 35 to 50 types of products one order for buyer sample. This can be done by three may-

• Buyer sent the sample bags
• Send a book or sheet in which photo and all dimension of all parts and overall products are give
• Send only dimension and instruction for bags by online.

In every case the responsibility of the sample man is to learn everything which the buyer want.

 Step – 2

Make buyer sample

• After learn all the requirement of the buyer the sample man cut the pattern.
• Then he cut the materials need to produce the bag.
• In this case for every product two buyer sample is produce
• Then are sample is kept in the sample room and the other sample is sent to buyer.
• After that the buyer examine the needed bags.
• Bags which fulfill their requirement one selected for next step and which one not the they return to the previous step.

 Step – 3

• The granted bags one then selected to produce sale sample.
• But the selection is done by a method.
• First make range by the accumulation of same similar types design.
• In a range a least is types products are accumulated.

This selection done an the basic of same matter.

Design

Colour of leather

• Texture of leather
• Requirement
• Sale ability
• Productivity
• Let we emazine a range of BLG while contain is bags such as –

1. Wallet
2. Card holder
3. Key holder
4. Comera care
5. Purse

All these are in one range is base of their similar surface texture of same leather & logo.

1. One range many also contain 30 bags.
2. Then in next step same rand accumulate to make a collection.
3. And sale sample is andened as collection.
4. Sale sample are also produce by hand cut but is assemble in table but in bag section they assenable in sample section.
5. Then they are sent as sale sample.

Step – 4

1. After that the success of sale of sale sample buyers give their order for large …. products.
2. It that case it is slow that many collection is order is are time.
3. This situation is called neutered
4. Duration of every tried is develops on the production of time.
5. Officers of sample room combine the order, time and shipment.
6. Then he give the final decision of Neutried.

Flow chart of sample

 Official formalities

In sample room all types of product design, material selection, color selection and knife making are done.

Sample Instruction Sheet

Upper Fold’s Emboss Print

 Livin selection sheet

PICARD Bangladesh Ltd.

Production sample

Style No. 2810                                                               Date:

Range                   :

Colour        :

Season        :

Remarks     :

Debess        :

Emboss       :

Metals         :

Logo           :

Instrument

Tools used in sample room

1. Cutting mate
2. Anti Cutter
3. Scale

a)     6 inch

b)    12 inch (wide 2.1 and 2.9 cm)

c)     40 inch

d)    52 inch

1. Pinner
2. Measeening tape
3. Divider
4. Compus
5. Lead pencil
6. Mannual pencil
7. Pen
8. Marking tape
9. Set square
10. Franch cuzve
11. Selver pen

Materials used in sample

1. Leather
2. PVC
3. Living
4. Reinforcement
5. Zipper
6. Clearing material
7. Cutting material
8. Accessories

Leather

Description types of leather are used according to sample. Some of these are shown in section in this report.

PVC

PVC mainly use for reinforcement but sametime bag also produce by it. According to design various types of PVC is used. Some common colour-

1. Black
2. White
3. Gray
4. Coffee
5. Off white
6. Red etc.

Living

Living is used for inner covering and reinforcement. Various types of living are used in production. Some of this are shown in star section report.

Reinforcement

1. Plastic sheet or fibre

Use : In galaxy tap cover and bag section

2. EVA: Two types – for thickness a) 1 mm 2) 3 mm

3. Bleton

4. Bleton tap : Two types (according to thickness)- a) 3 mm b)  1 cm

5. Inerbring

6. PE board: Two types according to thickness- a) 1 mm b) 0.7 mm

7. Taxan:

14. White board are pattern paper

15. Steel sheet – Cutt in various thickness but mostly in 7.5 m

16. Plastic disc- Use in gobxy table mobile cover

Reinforcement use for attacking purpose

1. Adhesive: Three types-

a)     Desting / hard adhesip

b)    Rubber solution / noroud

c)     Aica

2. Adhesive tape or bath side tope

Two types – according to thickness –

a)     3 mm

b)    6 mm

3. Living tape

Two types according to colour.

a)     White

b)    Black

4. Three types according to thickness

a)     2.5 cm

b)    3 cm

c)     9 mm

5. Zipper

Two types according to material –

a)     Metal zipper

b)    Nylon zipper

Three types according to wide –

a)     3 mm

b)    5 mm

c)     8 mm

6. Cleaning materials

1. Plastic
2. Clean pen
3. Adhesive pinner
4. Rubber solution
5. Skiner
6. Machine oil
7. Soft oil
8. Soft cloth
9. Gum tape

7. Cutting materials

1. Trimmer
2. Thread burner
3. Cutter
4. Ruber
5. Anti cutter
6. Punch
7. Hommer
8. Rafi
9. Two blade knife
10. Sharping paper
11. Sharping stone

8. Accessories

1. Button
2. Revit
3. Lock
4. Hoot
5. Ring
6. Chain
7. Polor

All types of various accessoring accordemy sample.

Safety Measures

1. Mask
2. Gloves
3. Finger Gnip
4. Gaggles
5. Cap

 Compliance (For PICARD Bangladesh Ltd.)

1. Layout of sample norms area not good.
2. In SLG section sample tables are stay with production table.
3. In SLG sale samples are produce in production table and in sewing
4. No Bag and SLG sample has post bed sewing m/c
5. Splitting and skining machines are aksent in sample room.
6. There is no nevit, button, bags joining table in sample.
7. There is no manking and ambase m/c in sample.
8. Electrical auto seming m/c is absent in sample
9. After assembling cutting is done is production table.
10. Overall look of both sample section is very enjoy used.

 Suggesion

1. Need aa cleans and proper loyout
2. SLG need a separate sample section
3. Need post bed sewing machine
4. More selles are required for proper annealing of sample bags.
5.  Give individual sikiving skilliting machine.
6. At least are marking and are ambose machinery is need is sample room
7. It is essention to stay a table for post assenbling and during assenbling cutting, color and punch.
8. Need a table for joining and attaching purpose.
9. Proper finishing is need for better outlook.
10. More cutting space need when sale samples are produce.

 Store

Introduction

Sufficient store is essential for a good production. In a industry store is most secured and costly section. All of materials and equipments are hept in the stap almost all budyet in a production is best in a store.

 Leather industry generally need seven section of store

1. Leather store
2. Living store
3. Zipper and chain and polor
4. Thread and Needle store
5. Stan for accessories
6. Store for other reinforcing material
7. Store for sample and montage bags.

 Role of Store

1. Store is the collection of materials. Which are use in production.
2. Store is the secure place for keeping all valuable things.
3. Sufficient store means proper supply of equipments.
4. Sufficient store provide smith production.
5. Store also keeps the sample bags and balace bag safely and protect them from destry
6. Mayor rant of cost of a production store maintenance and store keeping.
7. The primary cost of production is kept is store.
8. Store is the supplied of all storage thing in right time and in right amount.
9. Sometimes store keeps some exclusive and none collection for certain use.
10. Without a proper store an industry never run because it need to wait long time for required material and things.\

 Prescription of stores

1. Leather stores

Leather store contain various types of L/R. Some of there are very none and exclusive. Some leather keep in store in shown with name below-

1. Cow Milan

Cognae

2. Hngnappa

Cognac

3. Cow Fasil

Khak

4. Cow premaineroc

Black

5. King happa

Abeemenzin

6. Cow King nappa

Jeans

7. Cow Melone

Silvek

8. Cow Agsha

Black

9. Pontabelb

Jeans

10. Cow Fomil

Ziegee

11. Cow Sysha Jeans

12. Cow Tods black

13. Cow feelme blach

14. Cow Soncetenoco cofe

15. Cowking rappa cofe

16. Cow Spratenoco cagnac

17. Kingnapa Red.

18. Cowmilana red

19. Cowking napa Mong

20. Cow feolme shy

21. Cow tadsi black

22. Cow sprot crew black

23. Cowjade yellow

24. Cow Sysha mide

25. Knighl Pastozi

26. Cow fomil kisel

27. Cow Sysha Anthrezit

28. Cow Rasal Red.

29. Pontobel cofel

30. Cow Jafe viols

31. Cosoblanca nature

32. Pantobell white

33. Cow jate petnal

34. Cow spratenew nino

35. Cow Antique comel

36. Pontobelle rine

37. Cow sauvage cafe

38. Cow milana cafe

39. Cow lobby black

40. Cow sauvage black

41. Cow juo limette

42. Preneincnoco vino

43. Cow Bragb

44. Cow Aysha yellow

45. Pontakelb Anthrazit

46. New eneco cagnae

47. Cow vagetable splite Brown

48. Cow kingnappa creme

49. Cow premiln croc planer

50. Kingnappa Aqua

51. Cow casablance Ton

52. Parto bello orange

5. Cow milana sand

54. Pontabello pink

55. Cow fassil cagae

56. Cow tods caneen

57. Cow pssil nuture

58. Premen cnoes anthnaz

59. Cow casablanca black

60. Cow aysha cafe

61. Cow rassel coegnae

62 Kingnappa ozean

63. Cow jade ziegel

64. Pontabello red

65. Pontobello cagnac

66. Portabellow mongo

67. Cow kingnappa white

68. Cow fossil flider

69. Kingnappa red

70. Comanan tabuck

71. Cow brogla cafe

72. Cow aysha ziegel

73. Cow labby cafe

74. Cow sprotcroco orange

75. King nappa patrol

76. Pantebells bluck

77. Milana white

78. Cow spratenoc petrol

79. Cow jui cognac

80. Cow antique kastone

81. Cow laphat cray

82. Cow tads yellow

83. Pantobels ozean

84. Cow Antique kastains

85. Cow tod’s red

86. King nappa orange

87. Cow ayshe green

88. King nappa limette

89. Cow spridcnoco tacepe

90. Cow kingnappa anthrazit

91. Cow minan black

92. King nappa smonad

93. Cow bragea cagnae

94. Portabell aqua

95. Cow tod’s orange

96. Cow milano creme

97. Premcincroco black

98. Portobello smonad

99. Cow casalanca kastone

100. Cow jade ziegel

101. Cow jade panpel

102. Kingnappa Beany

103. Banline leather red.

Worksheet for store

Date :

 Living Store

In PICARD Bangladesh Ltd. living store kept living and also kept all type of reinforcement materials because example of some living is show below-

1. Huudy P.S.L red / cinime
2. Govontin creom
3. Picard world brown living
4. PICARD world white / cream
5. PICARD world black
6. HL-2 red
7. HL-2 gray
8. HL-2 coffee
9. HL-2 black
10. Picard tuscona
11.  HL-2 Nevy
12.  HL-2 cream
13.  Gravartio neavy
14.  Gravartio khaki
15. Gravartio Black
16. Huady 251 No
17. Huady – 248 No
18. Huady – 15A brown
19. Huady 334 No
20.  420D conace
21. 420D cream
22. Gavertin Gray
23. Feandy
24. Valuale black
25. Valuable coffee
26.  Valuale conage
27. Local caffe
28. Local black
29. Local red
30. Local orange
31. Flower living

Reinforcement

Examples of same reinforcement is show below-

1. PVC

a)     Aromatic white

b)    Some PVC red

c)     0.58 mm PVC milano cafe

d)    Hanghang PVC

e)     Thin black

f)      Sava Black

g)     Nylol sause

h)    Local black

2. EVA

a)     3 mm EVA black

b)    1.5 mm gray

c)     1.5 mm yellow

3. Foam

a)     Thin foom (1 mm)

b)    Thick foam (3 mm)

4. Titex

a)     3 mm

b)    6 mm

c)     9 mm

5. Interliving

a)     Whtie

b)    Black

6. PE board

a)     1 mm board

b)    0.7 mm board

7. Reboush

8. Texan

9. 1.5 mm board

10. White board

11. Fibre/ plastic sheet

12. Blotan

13. White board

14. Bath side white board / packaging board

Others

1. Mesh

a)     Black

b)    White

c)     Brown

2. Cellular

a)     International

b)    Local

3. Masti/Adhesive erasen

4. Ambase and debase tape

a)     Adhesive tape

b)    Interlining tape

3. Store of Accessories

In PICARD all types of accessories one kept in this store. Also many attaching element and packaging elements are also ketp in this store. Some of their example is given below-

1. Sliding buckle
2. Metal pullar
3. D-Pullar
4. Metal – P
5. Key ning
6. Redangle rang
7. Triangle rang
8. Pin buckle
9. Rollan pin buckle
10. Slider
11. Buttan stap
12. Fome
13. Push bek
14. Magnetic bach
15. Pin port
16. Press button
17.  Push hook
18. Eylet
19. Bar metal
20. Turn bek
21. Chain
22. Logo plate
23. Regitand plate

a)     Register plate GLP 28 G

b)    Reister plate GLP 28 BB

1.  Metal reenper K500N
2. Rivit A171N
3. Revit A10M
4. RevitA169N
5. Revit K397N
6. Revit A201N
7. Revit A230N
8. Runner – 3,5,8 (Gol
9. O-Ring – BP3N#12
10. SL Buckle D171NB
11. SL Buckle D119N
12. SL Buckle K249N
13. SL Buckle K2480B
14. D- Ring B39B
15. Ring D181NB
16. Ring D181NB
17. Ring BLP- 146 NM
18. D Ring K-678 LG
19. D Ring K-331 NB
20. D Ring K-209BB
21. D Ring 299JB
22. Dag hash K-301N
23. Dag hash K-341LG
24. Dag hash K366NB

Colours of Accessories

1. Nickle
2. Mat nickle
3. Nickle brush
4. Brange
5. Gold
6. Mat gold
7. Light gold
8. Gold brush
9. Gun brush
10. Siner

PICARD Bangladesh Limited

Accessories Card

NO:

Article……………………………. Price……………………….

Supplier…………………………… Colour……………………

 Zipper, Chain and polar store

An industry produce various kinds ok Bags and small products. Bags one of various colours. So an industry need various machine colours chain zipper and polar. In an production it need a large space for store chain, zipper and polar. PICARD Bangladesh Ltd. also has and store for chain, zipper and polar. Types of their collection is shown below-

 Zipper

1. Nylon Zipper

a)     3 mm 1 no zipper

b)    5 mm 1 no zipper

c)     8 mm 1 no zipper

2. Metal Zipper

a)     3 mm 1 no zipper

b)    5 mm  no zipper

c)     8 mm 1 no zipper

3. Polar

Polar are also 3 Number

a)     3 no polar

b)    5 no polar

c)     8 no polar

Colors of Metal Chain and polar

1. Nick

Stan for Thread and Needle

An industry also need machine and unlimited colour collection of thread. One colour thread also have different number. So, they also need and store room with their needle some example are given below-

Semeing……………………….

Store for other attaching packaging and colouring elements

In a production a lat of attaching material and packaging thing are needed. So, they also need luge place for heepeing them. Some of their same is giving below-

1. Adhesive – Three types

a)     Pasting

b)    Rubber

c)     Mica

2. Adhesive tape / both side tape

Two types –

a)     6 mm

b)    5 mm

3. Lining tape

Three types –

a)     2.5 cm

b)    3 cm

c)     9 mm

4. Bleem tape

Two types –

a)     3 mm

b)    1 cm

5. Super glue

Packaging materials

Instrument, Material and Tools used in Packaging

1. Sticker
2. Silica get
3. White band
4. Safety level (for only safety level buyer x – hansbat)
5. Safety level inch
6. Rubben for bending
7. Gennady card –

Shiltan

Picard Germany

P. Singapore

1. Scostape
2. Gum
3. Cesen
4. Screw driver
5. Anti cuton
6. Stuffing stick
7. Tag
8. Tag pin
9. Tag gan m/c
10.  6 mm tape
11.  Gum tape m/c
12. Permanent manher
13. Law quality board
14. Level
15. Bronded bag box
16. Purch m/c
17. Calculator
18. Hand tag
19. Hand pin
20. Jran
21. Staffin paper
22. Timue paper (Far covering the bag)
23. Style number card
24. Picard cand (Japan)

For special buyer

Store for sample and maste bags

In a international factory where all times high quality production is quantity of sample is also high. So, they need a safe room for keep them. And this type of store can be divided into three types according to size of goods-

a)     Small leather goods

b)    Medium leather goods

c)     Big leather goods

Complains for Picard

1. In generally a leather industry need seven stores but in picard there five sore
2. They kept lining and reinforcement in one store
3. Store one very overloaded
4. Layout of store in very conjusted
5. Ventilation is not sufficient
6. Space of leather store is store than necessary
7. Door is the only may for air circulation. So it has not sufficient inhaletion opportunity.
8. Lightation is very few completely depend an artificial light.
9. Store keepers have more responsibility than their ability and salary.
10. Through stores have lack of ventilation and lightation. So manhers and keepers are is risk of respiration.

 Suggesion

1. Stores need proper layout
2. Stores need proper lightation and ventilation facilities
3. In every floor for lange industry it is need to keep store for quick material supply
4. Safety measures must maintain into store
5. Fine extinguisher and air adjusting for muster keept in store.

Dire Making Room

Various types of dire and steel plates are used in production of bag.

These dires are produce inside of the industry. Deses are made from two types of material.

a)     Wend

b)    Nylon boond

Machineries and tools

1. Various types of moad cutting and finishing m/c
2. Nylan boond cutting machine
3. Buffing machine
4. Rate
5. Shanping paper

Complains

1. In PICARD dires are made with an adjustment room with colouring section.
2. It is very space
3. The room tem is much at
4. Machineries used in these section are very risky
5. Safety mesures are not
6. There is no fine extinguisher is this section.

 Suggesion

1. Kept this section with cutting section
2. Air adjusting for must be attached in this section
3. Safety measures must be token
4. At least one fire extinguish kept in this section
5. Try to decrease noise

 Introduction

Table section is the most important section in production. All types of assembling, attaching, joining are done is this section. Table section need long number of worker than other sections and more concertation

Table

Assembling process of table section

• After cutting of the leather, lining, interlining, PVC etc are marked and then assemled in table by adhesive (solution based) of if possible by both side adhesive tape.
• Marking is done following the patterns using silver marker pen to identity where the rest of parts will be attached.
• When marking is complete then attaching is done very carefully according to the machine and do then learning precisely.
• Some parts of a bag needs to assembly after doing sewing in few pertions they come. back to table further assembly

 Machineries used in table

More are some machineries, which are mostly important to reach the quality of final product some are on the table of a few are close to the table to aid the manufacturing process. These are given below:

 Auto adhesives and folding m/e

There are folding machines are used her folding of bottom, beach front or C.C pocket etc prots of rest of one is for belting and for, belt looping. Temperature required 14 and 135⁰c

Plastic adhesive use in this machine in presence of heat

 Riveting machine

For attaching rivet in proper location and to ensure not to displace riveting machine is used. There are-

Riveting machines available

Precantion :

Operate carefully, othersive finger will be affected

Firstly machine

There is a fusing machine to attach first the interfining with lining.

Besides these foling done for folding, one bag to shape, critical edges are also used.

 Gluing machine

Automatic gling machine, which words automatically haveing to part, one is heated guide and moving hammer or roller mores resose direction and a reserve place which carries adhesive and passes adhesive at a given rate.

Belt’s loog cutting

This device is used for cutting the loog of the belt. There are also belt looping and belt pressing machine.

 Hot/dry air blowing machine

To blow not air at a given rate for burning the loose, thread ends of a products, loops, polar etc.

Embossing machines

To embose and debase different logo / monogram on the grain side of leather.

 Strap / Belt cutting machine

To cut the belt for the large bagages, briefcases etc an automatic cutting machine with guide.

 Zipper cutting machine

There is a zipper cutting machine to cut zipper at preafer speed thean manually. But this is currently not acibuble

 Creasing / Marking machine

To mark the CC pocket this machine is used. It operate with air pressure.

Hammering machine

Hammering machine is used for press the folding area, where two leather is overlaping. There are 1 homering machine in this section.

Manufacturing Process

We have learn about the following manufacturing process-

1. Matching the sample
2. Joining
3. Folding –

a)     Concave folding

b)    Convex folding

c)     Straight folding

d)    Round folding

e)     Join folding

f)      Lining folding

1. Sewing –

a)     Close seam

b)    Binding

c)     Lapped seam

d)    Decorative seam

1. Credit card pocket preparation and at sewing
2. Pen holder pocket preparation
3. Gusest preparation
4. Partition preparation
5. Zipper attachment
6. Handy pocket preparation
7. Auto folding
8. Manual riveting
9. Accessories attachment
10. Registered plate attaching
11.  Pesting
12. Handle preparation
13. Pullar making
14. Zipper band preparation and zipper attaching
15. Strap and ring attaching
16. Partition lining preparation
17. Final assembly
18. Shamping the different parts

 Precaution of Quality Improvement

1. Take extra caution while sewing zipper
2. Take extra caution while attach accessories
3. Require the exact of width of each credit card pocket

 The bags which are manufactured at the time of our training on table and sewing section-

Range – Style

Sport Craft – 70074

Sport Craft – 70087

Barlin – 7813

Barlin – 4817

Alison – 8614

Really – 8253

Lords – B – 080

Lords – B – 085

SOHO – 8586

Conclusion

In the section, there is a huge amount of both side adhesive tape are used for the quality improvement of the product. Everybody are very familiar about their own work and very conscious about the shipment of the product timely.

Accessories used in bag –

1. Dog hook
2. D-ring
3. O-ring
4. Sliding buckle
5. Metal pullar
6. P-Pullar
7. Metal – P
8. Key-ring
9. Rectangle ring
10. Triangle ring
11. Pn buckle
12. Roller pin buckle
13. Slider
14. Button stop
15. Frame
16. Push
17. Push lock
18. Magnetic lock
19. Pin post
20. Press button
21. Push hook
22. Eylet
23. Bar mental
24. Turn lock
25. Chain
26. Zipper
27. Logo plate
28. Registered plate etc.

Colors of accessories

1. Nickle
2. Mat nickle
3. Nickle brush
4. Bronge
5. Gold
6. Mat gold
7. Ligh gold
8. Gold brush
9. Gun brush

Tools used in table

1. Bending dies
2. Folding bone
3. Scale – 6, 12, 40, inchs
4. Glue pot
5. Glue brush
6. Cutter
7. Scissor
8. Piner
9. Hammer
10. Three leg stand
11.  Calculator
12. Poly bag
13. Pes bolder
14. Pencil
15. Silver marker
16. Masking lape
17. Plus
18. Clean pek
19. Wexo blade
20. Cutter (two blade)
21. Toxy box
22. Fixed pattern (made by red broad and steel sheet)
23. Paper weight
24. Tiles
25. Deestkin

Thread size

1. 8 – Number
2. 10 – Number
3. 15 – Number
4. 20 – Number
5. 30 – Number
6. 40 – Number
7. 60 – Number

1. Zig – Zey suzer
2. Adhesive brush (4 typer)

Tools used in cutting table

1. Rular – 12 inch (wide 21 and 2.9 cm)
2. Anti cutter (two type)
3. Cutting blade
4. Hat mark (hand m/e)
5. Hand pattern (5 mm, 1.4 cm)
6. Iron hetter
7. Various hand pattern
8. Rafi
9. pinner
10. Punch (various types)
11. Tooth brush
12. Skiver colour
13. Two blode knife
14. Sharping stan
15. Sharping paper
16. Rectangle iran stan
17. Cradit land.

Parts of a bag attaching in table section

 Production control sheet

Picard Bangladesh Ltd.

Kandalbag Zenalso, Savar

Picard schedule of month (AB) of 2013

Pass par

P/CARD Bangladesh Ltd.

Gate pass (Day / Night)

Date:

 Sheet of presentation

Total presentation: Workers

Factory name:

Section:                                                       Date:

 Production Board

Date: 26-05-2013

25-05-2013 – Table output target     Date: 25-05-2013

26-05-2013 – Table output target

25-05-2013 – Total present

– Total leave

– Total absent

– Total manpower

26-04-2013 – Total present

– Total leave

– Total absent

– Total manpower

Next shipment

Shipment quality

Quality Check Sheet

 Date:

Table section

Range:

Style no

 Checked by:

Sewing

After onebling the parmanent operation of a bag is sewing. Sewing stability and durability. All of mater related to sewing are describe below.

Description of sewing

Flat bed sewing machine

1. General plain stitch is done by that bed leather sewing machine.
2. Linings are always and stitched a in flat bed lining sewing machine called (flan machine).

 Cylinder bed machine

Decorative and constructive generally critical curved atitched and when 2 or more parts are stitched where greiled working are required there is used, ie gusseted parts, pocket parts with greated difficult etc.

Post bed machine

Where more working area is and required than cylinder bed m/c for better working this m/c is used, like the joining of loop, belts, straps of bags etc.

Handi pocket sewing machine

To sew elasticated handi pocket and to give a better appearance and to make work easy. One peace is available.

Automatic sewing machine

Setted program is instated and the most decorative stitches are done in this type of m/c. Like, plan stitching decorative stitch of loops, embroidery etc.

Stitch Name                             Distance from the edge

1 / 60 stitch          –        2 / 2.5 / 3 mm

1 / 4 stitch            –        6 mm

Sewing tools

1. Scale
2. Cutter
3. Hammer
4. Scissor
5. Reinforcement tape
6. Stop watch

Defect of sewing

1. Stitch length defect
2. Unwanted pleat during stitching
3. Unwanted stitching
4. Thread break
5. Thread fraying
6. Fault stitching
7. Thread block
8. Loop missing

Thread color list

N.B. Thread use according to sample requirements.

Stone

Relation between needle point and needle no

 Thread per inch

 Relation between thread no needle no

Working condition

The working condition in PICARD Bangladesh Ltd. is excellent. Especially, layout, lighting, ventilation, working space and walking area all are good enough.

 Production

Production capacity of bagages in table sewing section approximately 500 pices, varies with the design of bages.

Productivity

Productivity is less then expected, due to excess product variety and excess movement of and materials it those can be reduced productivity can be increased upto to 10 – 15%.

 Compliance

1. Reinforcement attaching for register plate at the back lining part were slightly diagonal. So it hampers the quality. Because when the opening the zipper part, it is seen that register plate slight diagonally appeared.

Suggestion

The distance of reinforcement attaching should be accurate.

2. The distance of credit card pocket are not aqurate.

Suggestion

It should be accurate.

3. There is an excessive material movement in the sewing section due to unproper layout, that cause bottles neck problem.

Suggestion

Need to organize the layout properly. We think for the productivity improvement, canvear system can be used.

4. There is a gossiping in the table section. It lowers the productivity.

Suggestion

Need a proper observation  by the table incharge and supervisor

5. When a fault is noticed in the table section, one claim to another, that’s why production ultimately production goes to hamper.

Suggestion

Need a proper investigation by the supervisor.

Some worker have very unconscious mind. That hampers the production and increase the wastage.

Suggestion

Make and improve the self motivation for work among them and also have to increase the interest about their own work.

Cutting Section

Cutting is the term used for cutting leather components, linings foam and other reinforcement using for production of leather goods. In “Picard Bangladesh Ltd.” there are many kinds of automatic, hand cutting machine are used. These machines help not only to increase the volume of production, but also ensure quality of product.

A flow chart of different step of cutting section are as follows:

Steps of cutting

First cut flap – Final part ® Back penk

Others < certez < Bottam ¬ Greessed

Wastage

30% SLG

Table : Operation step of cutting section

Machineries of cutting section are as follows:

A. Clicking machines

The sequence of operations to fabricate an article begins with the clicking machine. Different panels of components of a leather product are cut in this machine. Cutting dies are used to cut the components and on an average about 400 components can be cut in an hour.

The qty of cutting machine are as follows-

Name of machines

1. Clicking machine one hand punch (Swingarm) Two hand punch
2. Auto cutting machine
3. Hand cutting machine – Lining cutting machine (Special)
4. Hand lining cutting machine
5. Strap cutting machine

Sewing arm clicking machine

In the one hand punch clicking machine worker/ cutting man use one hand to hold the knife and punch by other hand for cutting.

 Advantages

Perfectly straight cutting is possible. Actually which components require straight cutting these are cut by the help of this machine. Mostly waist belts are cut by these machine.

 Disadvantages

Although perfectly straight cutting is possible than two hand punch cutting m/c. But there is a risk of accident mostly. That’s why two hand punch clicking machines are used in cutting section of picard.

 Two hand punch clicking machine

In two hand punch clicking machine first dies are kept on the selected position of materials then punch and cut the components.

 Advantages

There is low risk of accident than are hand punch clicking machine.

 Disadvantages

Perfectly straight cutting is very different than are hand punch clicking machine.

 Auto cutting machine

Functions of auto cutting machine are as follows

• To cut interlining and lining
• For wallet board cutting
• Used for PVC belt cutting
• For very small width strap cutting

Maximum cutting machine

By the step of hand cutting machine pattern board (for packing purpose), reinforcement etc cutting, straight flap edge cutting is done. Maximum cutting length is 100 cm.

Auto layer cutting machine

Auto layer cutting machine is mainly used for layering of lining and reinforcement materials. But it needs more time for layering and sometimes it is not accurate for these reason now hand layering of lining is done.

Hand lining cutting machine

Hand lining cutting machine is mainly used for lining pocket, apron etc cutting. By the help of these machine maximum 10 – 40 layer of material can be cut at a time.

Strap cutting machine

Strap for belt production, piping for different bags and long handles (shoulder straps) are and using strap cutting machine. The width of strap ranges from minimum 3 mm to maximum 150 mm, this machine can also perform the function of an embossing by changing the plain roller with embossed design roller.

Other tools used in cutting section

Stricker machine

This machine used fro numbering purpose to match the leather of components such as colour matching, grain matching etc.

 Filer

It is used to sharp the knife

Cutting Board (Nylon Board

Cutting board is used to cut the materials by using dies.

Cutting board leveling machine

It s used for leveling the board to smooth cutting. It is also used to clean the cutting board.

 Tolly

To carry knife, materials etc.

Staplar and clip

It is used to layer the lining materials.

Key points to be remembered during cutting

1. Make sure that it is correct dies of the article to cut.
2. Examine for defects, size and shape of hides/ skins.
3. Selective cutting must be practiced, the best part of the article demands the best part of hide / skin
4. Over cutting and under cutting must be avoided.
5. Knives must be placed in such a way to ensure quality, economy and minimum wastage.

 Cutting Procedure

• Before starting cutting it is needed to supply the schedule for that time consisting order no, range, style no, colour, order qty etc.
• Supply the sample article and the patterns to ensure the knife is selected is well suited and to avoid mislead.
• Cut the best part of leather for the most visible part, than. Other parts. Numbering or grading of leather according to quality.
• Before cutting check the leather is free from defects for which the leather is free from defects for which the leather can be rejected.
• Before starting cut an order first cut a few trial, for avoiding lose of company and to gain the target
• In case of cutting we can maintain the following formule First cut sleep, then cut front past, back past, gusset, bottom, counter and others continue.

 Safety measures and personal protective equipments need during cutting

1. Always using double push
2. Using chest guard
3. Using Mask & gloves
4. Carefulness in using knife
5. Fully concentrated mind
6. Don’t operate a machine in a bad condition

An Instruction sheet should be supplied to the concerned operator

Date:

Time:

Machine No:

Operator Name

Range

• Style

Order Qty

Leather

Leather name / lining

Color

Leather quality:            Ok / not ok                    Remarks

Knife qty

* Sampl bag                            Yes / No

Consumption

Leather qty

Cutting qty                    Leather / Lining

 Knife of cutting machine and other materials

There are different shapes of knives for various purpose. But the height of knife varies from 2.5 cm to 3.2 cm. I cut materials different pressure is required upto 5 to 9 of the regulator. The knife is mostly made of a alloy of spat steel. The cutting board is made of Nylon polymer.

Causes of rejected leather in PICARD Bangladesh Ltd.

 Quality check sheet (according to CSI) which is needed to follow in PICARD Bangladesh Ltd.

Quality Check Sheet

Date:

Range:

Style:

Total Order:

 Item No:

Checked by                                                          Authorized

1.

2.

Skiving

Skiving is the decreasing / reducing the substances at the edge of leather component mostly at flesh side. Here, PVs, Rabose etc also skived.

There are 17 skiving machine. All are made by “Fortune”, a German brand. It of them are old model and remaining are newer version of can be set skiving width, thickness by digit.

Objects of Skiving

1. To avoide discomfort is use
2. To reduce bulkiness which may came during one……..
3. To improve the appearance of the finished product.
4. To avoid fraying at the edge.
5. To make stitching operation easy
6. To aid construction.

These are the standard value of different item skiving according to their thickness. But these thickness should be changed according to the range and color/style of different item in Picard Bangladesh Ltd.

Leather Inspection Khata (Unit – 3)

Date : 12-05-2013

Style No- 8882

Range No- Venny

Under No- 36 Bag

Skiving Procedure / Technique

• When to set up with of skiving guide rother then must be changed it position (i.e. foreword or backward) with the help of guide screw.
• Keep the left hand right behind the feed roller to avoid fivyer cut.
• Keep attension cusy shaped portions.
• Thickness bar can adjust the skived thickness of the leather.
• For bag skiving, pressure foot must be set as slop. But white straight skiving is need, then pressure fost must be set as straight.

 Types of Skiving is SLG Section

Four types

a)     Normal skiving

b)    Vessfical skiving

c)     Slap skiving

d)    Special skiving

Materials which are skived show below-

 Instruction Sheet of Fault Parts Description for Skiving

Safety Measures of Skiving Section

• Switch off the machine when not in use
• Ensuring skiving knife is covered.
• Keep hand at a safe distance during changing knife
• Do not try to remove scrap while the machine is running. Use dust bins to store scrap
• Using mask and gloves.
• Attentively works to be start machine.

 Safety Measures of Skiving Section

Splitting

Splitting means the separation of a components through its length. It gives a reasonably required uniform thickness. We can split a component into several layers.

 Purposes of Splitting

• To make a leather uniform thickness
• To make a leather into several layers
• To aid construction

Instruction sheet of splitting in Picard Bangladesh Ltd.

Date:

Time:

Operation name:

Machine no:

Range:

Style no:

Total order qty:

Color:

Examples of Splitting

1. Normal spelitting
2. Medium spelitting
3. This spelitting

Skiving spilitting instruction for SLG according to range, style and color

1.       Packet part: split – 1 mm

Folding skiving – 0.8 cm

Normal shape – 1.5 cm

2.       Packet counter: split – 0.6 mm

Folding skiving – 1 cm

Normal shape – 1.2 cm

3.       Upper part : Folding skiving – 1 cm

Normal skiving – 8 mm

4.       Flap pinally : Split – 1 mm

          Folding skiving – 0.8 cm

          Vertical skiving – 0.6 cm

5.       Middle pinally : Split – 1 mm

          Folding skiving – 0.8 cm

          Normal skiving – 0.5 cm

6.       Flop upper : Split – 0.9 mm

          Folding skiving – 1 cm

          Normal skiving – 0.5 cm

7.       Flop counter : Split – 0.7 mm

          Folding skiving – 1 cm

          Normal skiving – 0.5 cm

8.       CC.1: Split – 0.8 mm

          Folding skiving – 8 cm

          Normal skiving – 0.5 cm

9.       Gusset : Split – 0.8 mm

3 side normal skiving – 0.9 cm

10.     Middle part : Split – 0.8 mm

          Folding skiving – 0.9 cm

          Normal skiving – 0.5 cm

11.     Flop testa : Split – 0.8 mm

          Folding skiving – 0.6 cm

          Normal skiving – 0.5 cm

12.     Almeta : Split – 0.6 mm

          Folding skiving – 0.8 cm

          Normal skiving – 0.5 cm

13.     CC part : Split – 0.7 mm

          Folding skiving – 0.6 cm

          Normal skiving – 0.5 cm

14.     Second part : Split – 0.8 mm

          Folding skiving – 0.6 cm

          Normal skiving – 0.5 cm

15.     Upper testa : Split – 0.7 mm

          Folding skiving – 0.7 cm

          Normal skiving – 0.5 cm

16.     Middle testa : Split – 0.7 mm

          Folding skiving – 0.8 cm

          Normal skiving – 0.5 cm

17.     Mash pipin : Split – 0.3 mm

          Normal skiving – 2 side

Skiving & Splitting Instruction for PVC

Range : Parts                 Style : 8371

No.                                 No.

1.       Position folding skiving 0.8 cm

          Shape – 2.4 cm

2.       Upper folding skiving – 1.2 cm

          (all side)

3.       Mash part split – 0.6 cm

          Folding skiving – 0.8 cm

          Normal skiving – 0.6 cm

4.       Pinaly folding skiving – 0.8 cm

          Normal skiving – 0.5 cm

5.       Big CCi: split – 0.8 cm

          Folding skiving – 0.8 cm

          Normal skiving – 0.5 cm

6.       Middle past skiving – 1 cm

          Normal skiving – 0.6 cm

          Middle part split – 0.8 mm

7.       Upper testa split – 0.6 cm

          Normal skiving – 0.5 cm

8.       CC split – 0.7 cm

          Normal skiving – 0.5 cm

9.       CCI split – 0.8 cm

          Folding skiving – 0.8 cm

          Normal skiving – 0.5 cm

10.     PVC folding skiving

11.     Pollar split 0.8 mm

12.     Zipper split 0.3 mm

Normal skiving – 0.4cm

Spelitting Instruction for Bag Section

 These measurements (thickness) should be up down with the range and color of leather or materials.

Quality check sheet of skiving and splitting section

 Remarks

The quality of final product mostly depends upon the cutting and skiving section and there is a chance to get wounded during skiving and splitting and cutting, so there is a first aid on is resent considering the no. of workers and davivs risk of the no. of first aid boxe can be increased.\

Due to huge working pressure of buyers order, the tables of final inspection in cutting and skiving, the manpower can be increased to do fast.

There are 3 single push swing arm cutting machines, are here from the begining of this company and full of riks to get finger cut so they can be replaced by newer cut so they can be replaced by newer double push swing arm cutting machines.

Some workers this the ensuring materials which are rest after cutting. Thats create excessive wastage in that time. Though sometimes productivity goes down in cutting and skiving due to unsuitable leather supply, more defects than preferable wrong specification for skiving section et causes, but PICARD Bangladesh Ltd. believes and maintains their slogal, Quality and timely shipment.

Suggestions

If we eleminate the careless intension of the cutter by proper supervision and by create self motivation, then we reduce this type wastage. Ultimately that time the productivity should be enhanced.