wastage

Department of Textile Engineering

Project OnSuggestive Solutions To Minimize Wastage % From a Knit Composite

Submitted by:

Name ID

Tahmidur Rahman 2012200400014

What is Wastage?Waste and wastes are unwanted or unusable materials. Waste is any

substance which is discarded after primary use, or it is worthless,

defective and of no use.

Wastage is the common issue in garment industry, because it cost a

lot of money. It affect costing directly.

Objects To identifying the fabric wastage in each stage in a particular Garment of

a Knit Composite To identify the reasons of wastage in every section. To provide Suggestive solution for those wastage

Product Details

Order No. TGH/BLK04212

Buyer EF

Item Name Girl’s Shirt

Fabric construction Y/D Stripe:95% cotton, 5%Elastan S/JLayer Solid: 95% Cotton, 5%Elastan S/J

Fabric GSM Y/D: 180Solid: 180

Color Ebony

Order Quantity 7200

Style 424317

Knitting Wastage%Knitting

y/d Total yarn received 861 kg

Total lycra received 36 kg

Total gray fabric should be produce 897 kg

fabric produced 883.63 kg

wastage 13.37 kg

Wastage% 1.490524 %

solid Total yarn required 304 kg

Total lycra required 13 kg

Total gray fabric should be produce 317 kg

Fabric produce 313.44 kg

Wastage= 3.56 kg

Wastage% 1.123028 %

Cause of Wastage in KnittingFault Image

Lycra off

Set-off

Loose winding of cone

Reason of Wastage in knitting

Dyeing WastageDyeing

solid Grey fabric received 313.44 Kg

Finished fabric 249.672 Kg

Wastage 63.768 Kg

Wastage% 20.34456 %

y/d Fabric Received 883.63 Kg

Finished fabric 877.56 Kg

wastage 6.07 Kg

Wastage% 0.686939 %

Internal Wastage in Dyeing

Process Wastage in kg Wastage in parcentage

Scouring, Bleaching & Enzyme 38.14kg 12.17%

Stenter 15.98kg 5.1%

Peach Finish 9.62kg 3.07%

Reason of Wastage in Dyeing

Cutting Wastage%Cutting

y/d weight of a Ply 1.42 kgTotal lay quantity 618Total weight of fabric 877.56 kg

Total weight of cut pcs 781 kgWastage= 96.56 kgWastage% 11.00324 %

solid weight of a Ply 0.404 kgTotal lay quantity 618Total weight of fabric 249.672 kgTotal weight of cut pcs 245.17 kgWastage 4.502 kgWastage% 1.803166 %

Cutting Wastage image

Reason of Wastage in Cutting

Printing Wastage%

PrintingTotal cut pieces 7436 Pieces

Total rejection in printing 25 pieces

Weight of cut pieces 11 gm

Total weight of printed pieces 81.521 kg

Total weight of reject printing pieces 275 gm

Wastage 0.275 kg

wastage% 0.1 %

Wastage in Printing

Reason of Wastage in Printing

Garments Wastage%

GarmentsSewed Garments 7411 Piece

sTotal Rejection of Garments 69 Piece

sWeight of garments per Pieces 120 gmtotal garment weight 889.32 KgTotal weight of reject garments 8280 gmwastage 8.28 Kgwastage% 0.9310

48%

Reason of Wastage in Garments

Knitting Wastage 16.93 Kg

Gray Fabric 897 KgWastage% 1.887402 %

Dyeing & Finishing

Wastage 69.83 KgGray Fabric 897 KgWastage% 7.784838 %

Cutting


Printing


Sewing & QC

Wastage 8.28 KgGray Fabric 897 kgWastage% 0.923077 %

Total Wastage% 21.89242 %

Total wastage

Gray Fabric 897 Kg

Total wastage 196.385 Kg

Total wastage % 21.89353 %

Total Wastage in 100%

Knitting Wastage 8.59%

Dyeing & Finishing Wastage 35.77%

Cutting Wastage 51.30%

Printing Wastage 0.14%

Sewing Wastage 4.20%

Cost of Wastage in all sectionProcess Price /kg Producing cost Wastage in kg Cost of wastage

Knitting Y/D 5.64 $ 4983.68 $ 13.37 kg 75.41 $

Solid 3.84 $ 1218.96 $ 3.56 kg 13.67 $

Dyeing Y/D 6.54 $ 5778.94 $ 6.07 kg 39.70 $

Solid 5.84 $ 1830.49 $ 63.77 kg 372.41 $

Cutting Y/D 6.54 $ 5739.242 $ 96.56 kg 631.50 $

Solid 5.84 $ 1458.084 $ 4.50 kg 26.29 $

Printing Y/D 6.79 $ 553.5276 $ 0.28 1.87 $

Garments 2.47 $ / pieces 18305.17 69.00 pieces 170.43 $

Total Producing cost 39868.09 Total cost of wastage 1331.27 $

Knitting Dyeing & Finishing Cutting Printing Sewing0

10

20

30

40

50

60

0

100

200

300

400

500

600

700

8.59

35.77

51.3

0.144.2

89.08

412.11

657.79

1.87

170.43

Pareto chart for Wastage% & cost

Series1 Series2 Series3

Process

Was

tage

%

Cost

of

was

tage

in $

Overall Summary

After finishing all calculation & analysis on Pareto Diagram, bar chart, pie chart we found that major wastage happened in cutting section.in cutting section, Marker efficiency depends on style of a product

In this project we work on a baby product. The marker efficiency of a baby product is low. So the wastage % is high. If we arrange the marker pieces in cad manually the efficiency may be increase.

After cutting section we found most of the wastage in dyeing & finishing section. We found that scouring, bleaching, enzyme, peach finish are mostly responsible for dyeing wastage. On the other hand addition of dyeing is also responsible for dyeing wastage.

Then most of the wastage occurred in knitting section. We found wastage for loose winding of cone & cone weight variation. We also found wastage for lycra off, set off. If knitting m/c operators are more skilled and conscious the knitting wastage can be minimized.

In sewing less faults are found so that wastage is less. Measurement problem & stitch problems are mainly responsible for that wastage. If the sewing m/c operator skilled & aware, wastage can be minimize.

In this product there are little amount of wastage in printing section

Suggestive Solution

Process Name Causes of Wastage Suggestive Solutions

Knitting 1.Lycra out & Set-off2.Loose cone

1. increase the awareness &skill of worker2.By re-winding these loose cone

Dyeing & Finishing 1.Quality of Fabric 1.Improve yarn quality

Cutting 1.Marker Efficiency2.Style of Garment

1.Improve marker efficiency2.By manual pattern arrangement in CAD

Printing 1.Print Problem2.Size Mistake

1.Improve the Quality of print chemical 2.increase awareness3. Automated M/C cam be used.

Sewing & QC 1.Measurement Problem2.Stitch Problem

1.Improve skill of worker2.Maintanance machine regularly

Conclusion

By this project I can get the real knowledge about wastage in every section in textile industry. We enjoyed each and every bit of work we had put into this project. This project has some limitations. Further if we get opportunity to analyze this project more deeply we can apply the solution in practically. Project is further extensible.

wastage

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