BAHIR DAR UNIVERSITY

ETHIOPIAN INSTITUTE OF TEXTILE AND FASHOIN TECHNOLOGY(EiTEX)

Host campany:MAA Garment And Textile Company

DONE BY: GEBRETSADKAN ASEFA

ID No: 0804379

Project Title: Reduction of Fabric Wastage in Cutting

Section by Improving Marker Efficiency

Academic advisor: Mr. G/HiwotAsfha

Company Advisor: Tewodros Embaye

July 2019
Bahirdar University GED 2019

DECLARATION

I am student of Bahir Dar University Ethiopia institute of technology for textile and
fashion technology. This report stays in MAA garment textile factory and all source
material and picture used while compiling. These reports get fully experience and
knowledge. My work is original and based on the internship report writing guideline
given by the institute Industry Linkage office of the Institute.

G/hiwotAsfha ––––––––––– –––––––––––

Name of the Academic Advisor Signature Date

G/tsadkan Asefa ––––––––––– –––––––––––

Name of Student Signature Date

Tewodros Embaye ––––––––––– –––––––––––

Company adviser Signature Date

i
Bahirdar University GED 2019

EXECUTIVE SUMMARY

Internship is a certified way to gain relevant knowledge, skill and experience while
establishing important connection in the field. In our internship in MAA garment factory
plc. For the specified period of time, we got the required experience and knowledge and
in this report I have tried to list the overall aspects of the internship experience. In the
first part of the project, it provides information about the hosting company’s brief history
and overall organizational structure. Also in this chapter I will try to present the
manufacturing process of garment production. And continues to describe the overall
organizational work flow, available machinery infrastructure in each department, main
products of the company and their customers, then comes to mention the raw material
sourcing regions and also the working procedure of each department. In the second part
the project work, it describes mainly the particular project I have executed in the
company. It starts by describing the title, objective and significance of the study. Then
after it continues to tell the data collection, presentation and analysis methods to
accomplish the project work. Also this part contains recommendation and solution of
problems. While I was working on this project all things are not as I have expected. So
the challenges that I had faced during the internship experience are also include in this
project. The last part of the report explains the overall benefits and special activities
(practical activates working during outstanding time) that I have gained from this
internship period.

ii
Bahirdar University GED 2019

ACKNOWLEDGMENT

First of all, I would like to thank for Bahir Dar University for giving me the opportunity
to join this intern ship program. Secondly, I would like to thank my advisor
G/hiwotAsfha whose invaluable advice and guidance has helped shape this internship
research paper and how to complete the internship duration. Then, I would like to thank
my supervisor, for his continued support throughout internship duration. Lastly, I would
like to express my genuine appreciation for the workers of MAA garment and the
managements of MAA garment and textile factory, who coordinated and helped me
directly and indirectly during the internship duration to conduct this research.

iii
Bahirdar University GED 2019

TABLE OF CONTENTS

Contents Page
DECLARATION .............................................................................................................................. i

EXECUTIVE SUMMARY ............................................................................................................. ii

ACKNOWLEDGMENT................................................................................................................. iii

LIST OF TABLE ............................................................................................................................ vi

LIST OF FIGURE ......................................................................................................................... vii

LIST OF ACRONOMYS ............................................................................................................. viii

CHAPTER ONE .............................................................................................................................. 1

BACK GROUND OF THE COMPANY......................................................................................... 1

1.1 Introduction ...................................................................................................................... 1

1.1.1 Vision and Mission ...................................................................................................... 2

1.1.2 Vision ....................................................................................................................... 2

1.1.3 Mission..................................................................................................................... 2

1.2 core values ....................................................................................................................... 2

1.2.1 Quality policy........................................................................................................... 2

1.2.2 Management Philosophy .......................................................................................... 2

1.2.3 Regulator and social process .................................................................................... 3

1.2.4 Duty Free Advantage ............................................................................................... 3

1.2.5 Garmentproduction ...................................................................................................... 3

1.2.6 Sample Room & Design Team ................................................................................ 4

1.2.7 Spreading ................................................................................................................. 5

1.2.8 Cutting section ......................................................................................................... 6

1.2.9 Embroidery section .................................................................................................. 7

1.2.10 Sewing section ......................................................................................................... 7

1.2.11 Finishing section ...................................................................................................... 8

iv
Bahirdar University GED 2019

1.2.12 Finished Goods Warehouse ..................................................................................... 9

1.2.13 Accessories warehouse & satellite store ................................................................ 10

1.2.14 Fabric warehouse ................................................................................................... 11

1.2.15 Current customers .................................................................................................. 11

CHAPTER TWO ........................................................................................................................... 13

REDUCTION OF FABRIC WASTAGE IN CUTTING SECTION BY IMPROVING MARKER
EFFICIENCY ................................................................................................................................ 13
2.1 Introduction .................................................................................................................... 13
2.2 Statement of the problem ............................................................................................... 14
2.3 Objective ............................................................................................................................ 14
2.3.1 General objective ................................................................................................... 14
2.3.2 Specific objectives ................................................................................................. 14
2.4 Scope of the project ....................................................................................................... 15
2.5 Significance of the project ............................................................................................. 15
2.6 Limitations of the project ............................................................................................... 15
2.7 Literature review ............................................................................................................ 16
2.7.1 Fabric Waste .......................................................................................................... 16
2.7.2 Marker .................................................................................................................... 17
2.7.3 Marker making ....................................................................................................... 17
2.7.4 Objectives of marker making ................................................................................. 18
2.7.5 Marker Efficiency .................................................................................................. 18
2.7.6 Factors of marker efficiency .................................................................................. 19
2.7.7 Objectives of marker efficiency ............................................................................. 19
2.8 Methodology .................................................................................................................. 19
2.8.1 Methods of problem explanation ........................................................................... 19
2.8.2 Methods of Data Collection ................................................................................... 21
2.8.3 Primary Data Collection by Oral interview ........................................................... 21
2.8.4 Secondary Data Collection..................................................................................... 21
2.9 Data Analysis ................................................................................................................. 21
2.9.1 Actions take to improve the efficiency of the marker ............................................ 24
2.9.2 Data analysis after .................................................................................................. 25

v
Bahirdar University GED 2019

2.9.3 Result and Discussion ............................................................................................ 26

2.10 Conclusion and Recommendation ................................................................................. 28
2.10.1 Conclusion ............................................................................................................. 28
2.10.2 Recommendation ................................................................................................... 28
CHAPTER THREE ....................................................................................................................... 29
Benefits Gained From the Internship ......................................................................................... 29
3.1 Developing practical skill .............................................................................................. 29
3.2 Up-grading theoretical knowledge ................................................................................. 31
3.3 Problem solving skill ..................................................................................................... 31
3.4 Team playing skill.......................................................................................................... 31
3.5 Management and leader ship ......................................................................................... 32
3.6 Work ethics and industrial policy .................................................................................. 32
3.7 Entrepreneur skill ........................................................................................................... 32
3.8 Inter personal communication skill ................................................................................ 33
References ...................................................................................................................................... 34

LIST OF TABLE

Table 1. 1: cutting machines and equipments ................................................................... 12

Table 2. 1: Pattern length .................................................................................................. 22
Table 2. 2: Total fabric weight .......................................................................................... 22
Table 2. 3: Total fabric weight, actual weight and difference .......................................... 23
Table 2. 4: total weight, actual weight and difference of the fabric after mixing ............. 26
Table 2. 5: Result before and after in weight and efficiency comparing .......................... 27

vi
Bahirdar University GED 2019

LIST OF FIGURE

Figure 1. 1: Profile Company.............................................................................................. 1

Figure 1. 2: Products of the industry................................................................................... 4
Figure 1. 3: Sample room and design room ........................................................................ 4
Figure 1. 4: Spreading section ............................................................................................ 5
Figure 1. 5: Cutting section ................................................................................................. 6
Figure 1. 6: M/cs of cutting room ....................................................................................... 6
Figure 1. 7: Embroidery room ............................................................................................ 7
Figure 1. 8: Sewing section ................................................................................................. 8
Figure 1. 9: Finishing section ............................................................................................. 9
Figure 1. 10: Finishing and packing room ........................................................................ 10
Figure 1. 11: Accessories store ......................................................................................... 11
Figure 1. 12: Fabric warehouse ......................................................................................... 11
Figure 2. 1: Problem marker making ................................................................................ 14
Figure 2. 2: Assembly of Fabric Wastage in Cutting Room ............................................. 17
Figure 2. 3: Mixing marker making .................................................................................. 24
Figure 2. 4: Result by mixing sizes ................................................................................... 25
Figure 3. 1: Practical skill in sewing ................................................................................. 29
Figure 3. 2: Practical skill in marker making .................................................................... 30
Figure 3. 3: Practical skill in ironing ................................................................................ 31

vii
Bahirdar University GED 2019

LIST OF ACRONOMYS
EFFI-------------------------efficiency

DIFF-------------------------difference

PLC---------------------------privative limited company

PCS----------------------------pieces

M/C----------------------------machine

GSM---------------------------gram per meter square

OPR----------------------------operator

WTO---------------------------world trade organization

GSP---------------------------generalized system of preference

viii
Bahirdar University GED 2019

CHAPTER ONE

BACK GROUND OF THE COMPANY

1.1 Introduction

The Company Kebire Enterprises is a privately owned company established and

registered in April 2001 under the commercial laws of the Federal Democratic of
Ethiopia.

MAA Garment Factory began its operation in June 2004 in the northern part of Ethiopia,
Tigray, Mekelle wholly owned by Kebire Enterprises PLC.

It is spearheaded by dynamic local staffs combined with expatriate from Turkey,

Pakistan & Philippines, with production set-up fully equipped with state of the art
machineries & equipment’s from renowned manufacturers in the world like Juki,
Brothers; Myers & Cie. MAA Garments is emerging to be one of the leading apparel
manufacturers not only in Ethiopia but also in the rest of the world.

Our company’s recognition has reached its utmost peak since its establishment and our
produced goods have revealed our energy in the industry of garments. Embedding
methods and solutions to our production system has allowed us to blend in objective was
to export garments internationally; we’ve engaged ourselves to fulfill the needs of the
domestic market as well. We intend to incorporate and upgrade our infrastructure,
maintaining the concern with our environmental and social responsibilities.

Figure 1. 1: Profile Company

1
Figure 1
Bahirdar University GED 2019

1.1.1 Vision and Mission

1.1.2 Vision
• To become the most customer oriented manufacturing by creating by creating equality
excellence in the textile and garment fields in Africa.

1.1.3 Mission

• To continuously produce and export quality textile & garment products to the world
market with consistent performance and productivity using state of the art technology and
skilled manpower applying a quality management system by creating a healthy, creative,
respectful, and fun working environment, in which our employees are fairly compensated
and encouraged to respect the customer and the quality of the products we produce.

1.2 core values

1. Customer satisfaction

2. Reliability

3. Commitment

4. Good governance

1.2.1 Quality policy

• To make continuous and persistence efforts to meet customer needs and expectation
offering quality textile and garment products and superb service with active expectation
of all our employees through a system of constant communication and interaction with an
objective of continually improving through implementation of kaizen to meet present and
future quality challenges.

1.2.2 Management Philosophy

• The top management ensures the involvement of Quality control circle and stakeholders
at all levels of the organization for the achievement of customers’ need and excellence in
performance to attain the company objective and hence benefit all company’s
stakeholders and shareholders.

2
Bahirdar University GED 2019

1.2.3 Regulator and social process

Being a responsible corporate citizen we ensuring company and employees are

complying with national and regional laws and regulation.

1.2.4 Duty Free Advantage

AFRICA region enjoys duty free advantage compare to other regions giving it a
competitive price advantage.

• GSP- Generalized System of Preferences – for Europe market.

• AGOA – African Growth & Opportunity Act. – For USA market.

Further to international trade agreements, Ethiopia is expected to become a member

of WTO - World Trade Organization by 2014.

1.2.5 Garment production

• Garment is currently producing different types of wearing apparels for the local &
international market. The company has very flexible &brand new state-of-the art
technology in its design & pattern making, make up, finishing, Embellishment & quality
control units.

• Currently, the factory has a total of 836 sewing

• Design capacity for one shift 550,000 Pcs per month and for two shifts 1,100,000 Pcs
per month

• Machines, about 99%age of them are juke type of different varieties. The cutting unit
with full size cutting table is strengthened by the design & pattern making unit, equipped
with Semiautomatic machines.

3
Bahirdar University GED 2019

Product types produced in MAA factor are:

 Basic T-shirt
 Polo T-shirt
 Brief
 Pajama
 Classical shirt
 Classical trouser
 Casual Trouser
 Work wear
 Military Uniform
 Caps
 Jeans Shirt
 Jeans Trouser
 Bed sheets
 Bed Cover and
Figure 1.2
Figure 1. 2: Products of the industry
 Other Fashionable clothes

1.2.6 Sample Room &

Design Team

• Computerized Pattern making unit-Investronica-P2000/1, Plotter, drawing board –

(Spain), Gerber Plotter (Germany).

Figure 1. 3: Sample room and design room

4
Bahirdar University GED 2019

1.2.7 Spreading
There are two spreading automatic machine by itself after the required fabric is brought
into the cutting section from the stores. It is the most important in saving time and
minimizes number of workers, but he use Most of time for woven fabric.

The number of lays depends upon the requirement of the sewing and the number of the
garment to be produced. After the fabric is laid, if the fabric is knitted it’s directly cut

Because it’s already marked by chalk, but in case of others the marker paper is spread on
the lay where the pattern is already drawn and it is cut to know the consumption of the
fabric for the garment.

The spreading operators carry out aligning operation on the side of the lay by considering
the way in which they improve their speed and also way in which they minimize wastage
at the start and at the end of the roll.

The other consumption in this section, the cutting of interlining is carried out without any
fault by using band knife cutter.

Figure 1. 4: Spreading section

5
Bahirdar University GED 2019

1.2.8 Cutting section

 The cutting units with full size cutting table is strengthened by the design and
pattern making Spreading machine-FK-group (Italy), Cutting Machine Eastman-
(USA), KMSB-(Italy), Band Knife-Mario Folio- (Italy)
 Cutting is just preparing components of garment based on the pattern drawn on
the marker.

Figure 1. 5: Cutting section

Machines used for cutting

 Band Knife
 Straight knife
 Scissors
 Clamper
 Numbering
 Driller

Figure 1. 6: M/cs
of cutting room

6
Bahirdar University GED 2019

1.2.9 Embroidery section

In MAA garment factory it has 3 embroidery machines, 2 machines are 10/10/1/1 heads&
one machine 20 heads totally 42 heads which can able to produce up to 9 colors. This
embroidery machine made of Bermudan and Tajima with a total of 42 heads adds value
to our products. You have contain computerized automated embroidery machines enable
us on providing highly precise smaller letter designs, excellent trimming system with
stable performance.

Figure 1. 7: Embroidery room

1.2.10 Sewing section

This department contains the most complex activity of the garment manufacturing process of
sewing. It is one of production output of garment factory. The sewing process involves a number
of sewing operators, who deal with for the assembly of different sub assembly operations, and
textile Engineers who have an ample experience in the manufacturing of garment sub assembly
operation.

The lines also have a line supervisor, for supervising the sewing operator to work
according to the engineer direction. The sewing process carried out according to the sub
and main assembly work. The total line new happening are 14, they are contain each
individual supervisor for each line.

The sewing process starts after receive of cut parts in bund. For This bund form is then
distributed to the sewing operator by line supervisor. The distribution for each specific

7
Bahirdar University GED 2019

operator is according to the layout of the sewing line which is made by the engineer
depending on the styles and order .There are also in line quality control operator, who
are responsible for the identification any fault during the specific main assembly
operation.

Figure 1. 8: Sewing section

1.2.11 Finishing section

In this department ironing and packing operation are carried out. It is the final output of
garment prepare for packaging. For the purpose of making a proper packing from part of
work wear are ironed in this section. An operator in this department insert pin the folded
garment in the invisible place of bags. For the purpose of improving the quality of folding
template are prepared. After products are processed the last part of production is pressing
and packing pressing could be done manually on the ironing tables blown mannequins
and manual pressing equipment or automatic using latest technologies of pressing for t-
shirt, shirt, trousers, jacketsetc.Packing can be done manually or automatically using
automatic packing system. A high degree of attention is played by the packing operator.
Based on the client request, product need to be tags with bar codes label stickers, based
on production orders, number, and size.

8
Bahirdar University GED 2019

Figure 1. 9: Finishing section

1.2.12 Finished Goods Warehouse

A. Folding

It makes depending on the customer order that means for different customers they use
different folding system.

B. Packaging

It is the inserting of fabric to the poly bag. In this the uses two types of poly bag
depending on the customer order. These are

1, individual poly bag: - in this only one cloth is inserts to one poly bag.

2, master poly bag: - in this poly bag they insets more than two cloths to one poly bag.
The master poly bag makes in two ways as per the customer

C. Packing

It is the insert or posting of the poly bag to the box (carton).in Maa garment factory they
uses different types of packaging system.

9
Bahirdar University GED 2019

 Solid packing:-this they insets the poly bags which have the same type of cloths
by color and size.
 Mixed packing:-It is the inserting of the poly bag which has the cloth with the
same color and different in size or vice versa.
 Assortment: - in this they insert the poly bag which has the cloth with mixed
color and mixed size. Box (carton sticker):- it is an information card. It explains
about the packaged garment & it attaches at the outside part of the carton.

D. Auditing: - is the checking of packed as per customers order.

Figure 1. 10: Finishing and packing room

1.2.13 Accessories warehouse & satellite store

These are the most important to decorative or functional purpose for the garment. Those
accessories are buying by the agreement of the company and its customer.

 Hangtag
 Hanger
 Care label
 Size label
 Main label
 Cartoon

10
Bahirdar University GED 2019

Figure 1. 11: Accessories store

1.2.14 Fabric warehouse

Fabric warehouse is used to store finished garments temporarily up to shipping to the
customers.

Figure 1. 12: Fabric warehouse

1.2.15 Current customers

 KIKS
 H&M
 TAKKO
 NJ GEORGE
 TESCO

11
Bahirdar University GED 2019

 HANHS
 BERNE
 CID RESOURCES

Table 1. 1: cutting machines and equipments

Cutting Machineries and equipment

S/No Machine Description Machine Make Quantity
1 Cloth Spreading Machine FK GROUP 2
2 Loader For Spreader 480 Series FK GROUP 2
3 Cloth Spreading Tables FK GROUP 2
4 Manual Cutters( 8 " Cutters) KMSV 5
5 Manual Cutters( 13" Cutters) EASTMAN 629 2
6 Band Knif e Cloth Cutting Machine Mario Fronio,Italy 2
7 Cloth Drilling Machine Global CD-10 3
8 Click Press Cutting Machine ATOM S 125 3
9 Numbering Device (Manual Type) TOVEL 12

Design Machineries
S/N Machine Description Machine Make Quantity
1 Computerized Pattern Making Unit INVESTRONICA 1

N.B. The Pattern making unit consists of Plotter, Digitizer

,CPU and CAD System(Software) ..

12
Bahirdar University GED 2019

CHAPTER TWO

REDUCTION OF FABRIC WASTAGE IN CUTTING SECTION BY

IMPROVING MARKEREFFICIENCY

2.1 Introduction

This project is done on waste minimization in the cutting room in MAA garment factory.
As the fabric is the major raw material in a garment, the saving of very less amount of
fabric per garment can save quite a large sum of fabric, which can increase the profit of
the organization substantially. In MAA garment much amount of fabrics is waste in order
due to low marker efficiency .it is necessary for the management to have good
understanding of spreading performance and the distribution of various types of fabric
losses in the cutting process for proper material management. Proper investigation of the
fabric losses during the cutting process can help the management to minimize material
wastage.

Among the various processes of garment production cutting is the major area where
fabric waste is generated. In the cutting room much attention should be given to reduce
the fabric wastage.

Waste (wastes) is unwanted or unusable material. Waste is any substance which is

discarded after primary use, or is worthless, defective and of no use.

13
Bahirdar University GED 2019

2.2 Statement of the problem

In Maa garment and textile factory has a problem in cutting section. The problem is
weakness in marker making. When the maker marks by individual sizes of small(S),
medium (M), large (L), and extra-large (2XL), which means the marker maker marks one
size only in one time, or marking small size only at a time (marking large size only at a
time), but this method has more fabric wastage. Using the method of one size marker
making has an affect for the factory like reduction of products and less marker efficiency.

Figure 2. 1: Problem marker making

2.3 Objectives
2.3.1 General objective

Reduction of fabric wastage in cutting section by improving marker efficiency

2.3.2 Specific objectives

To reduce fabric wastage
To Identify Causes for fabric wastage
To increase production by minimizing fabric wastage
To increase marker efficiency

14
Bahirdar University GED 2019

2.4 Scope of the project

In MAA garment factory there are many causes of fabric wastage and different problem
solving methods which needs long time and broad study, due to this, the project is limited
to study and explain all the cases and problem solving methods.

The project investigated few causes of fabric wastage and solves some of the problem in
the study and increase the fabric utilization percentage. This project works on waste
minimization related problems in Maa garment plc treading mainly focused on the cutting
section and also this project answer how to minimize wastages in the company.

2.5 Significance of the project

This project is very essential for further effectiveness of factory objective on a good use
of fabrics. Also it is more significant for the cutting department head, marker makers, and
production department, this project profits for Maa garment industry in cutting section.

It creates awareness for the factory on waste minimization method and task for marking
and cutting department operators.

It is necessary for the factory to increase fabric utilization in cutting department.

Minimization of fabric waste is basic important for the garment company, so this project
to the company is increasing the production of garment, the task of marker makers,
marker efficiency, how to make the marker and cut fabric pattern and minimizing
profitness or cost for the company.

2.6 Limitations of the project

While doing this project there are some limitations in Maa Garment Company my
internship as lack of full information in cutting department, in marker making section and
luck of computer to make for this project.

15
Bahirdar University GED 2019

2.7 Literature review

2.7.1 Fabric Waste

Waste is a material that is deemed unusable for its original purpose by the owner. Textile
waste can include fashion and textile industry waste, created during fiber, fabric, textile
and clothing production, and consumer waste, created during consumer use and disposal.
The compositions of different wastes have varied over time and location, with industrial
development and innovation being directly linked to waste materials. The global textile
industry today is massive. Fueled by the apparel, home, automotive, and other industries,
it is the biggest it has ever been, and is producing more textile waste than ever before.
The first part of the textile waste problem is pre-consumer textile waste. This is all the
waste involved in the manufacturing processes occurring before a garment is ready to be
sold. An MIT report stated in 2015, the global apparel industry was expected to produce
more than 400 billion square meters of fabric per year, representing nearly enough
material to cover the state of California annually. Yet the scale of textile generated is
actually unknown since it is difficult to measure or track. Because of the natural shapes
that make up a garment, there’s always10-30% of the fabric that is cut away and
discarded during the cutting process. There is also dead stock or damaged yardage, which
is another source of hard to measure waste. There are some systems in place for value
recovery of cutting room waste in some countries, but in cases, the scrap material is being
turned into material down the value chain, thus losing the value of the scraps to be used
in its highest value in fabric form, or the worst case, it is ending up in the landfill or
incinerator. There are some amazing programs turning denim scraps into building
insulation, melting polyester or nylon scraps into new yarns, and age-old processes
recycling cashmere and wool into new yarns. Yet these programs are mainly limited to
fabrics that are nearly 100% of single fiber, leaving not much else to do with the ever-
popular blended fiber fabrics. If the small companies and big companies out there did
their part in developing solutions in reducing textile waste, then maybe actually eliminate
textile waste together. Waste is an unwanted or desired material or substance and
resources consumed by inefficient or non-essential activities and it may lead disposal of
materials as well as, cause pollution according to (Morra, 1997).

16
Bahirdar University GED 2019

Figure 2.2: Assembly of Fabric Wastage in

Cutting Room

2.7.2 Marker
Marker is a large long thin paper which contents the required pattern pieces of various
sizes for a particular style of apparel. It’s an important task because it determines the
efficiency of a marker. Marker is the perfect way to reduce fabric wastage. Marker gives
the actual guide line for completing the flawless or correct fabric cutting. Marker making
can be done both ways like manually and computerized method. Marker width is greater
than or equal to the fabric width, marker length is mainly depends on the number of
patterns of the particular style of garments used for marker making(Nicole, 2018)

2.7.3 Marker making

During garments manufacturing process, Marker making is the most useful process to
draw the pattern pieces over a thin marker paper is placed on the fabric lay for
minimizing the fabric wastage. Marker making is the next step of pattern grading. After
pattern grading, pattern of different parts of apparel is placed on the marker. That’s
marker is placed on the fabric which will be cut to sewing. Marker making is the most
useful process to draw the pattern pieces over a thin marker paper and this marker paper

17
Bahirdar University GED 2019

is placed on the fabric lay for minimizing the fabric wastage. Marker making is a pre-
preparation of fabric cutting during huge amount of garment production. In the marker
making, different pattern parts are drawn on a big thin paper and to considering fabric
width, garments size ration, fabric fault and cutting table width, length marker efficiency
is depending on(Jacobs, 1991).

2.7.4 Objectives of marker making

 Marker is essential for huge quantity cutting
 Used as the cutting guide of fabrics
 Fabric wastages are minimized by using marker
 Similarities among the apparels are gained by the marker making
 It saves cost and time(Charlotte, 1991).
2.7.5 Marker Efficiency

Marker efficiency is determined by fabric utilization, the percentage of the total fabric
that actually used in garment part. The area not used in garment parts is waste. Marker
efficiency depends on how tightly the pattern pieces fit together within the marker. The
total surface area of the pattern pieces is compared to the total area of the marker to
calculate the percentage of fabric that is used. This is determined automatically by
marker-planning software. The marker planer measures his success by the efficiency can
be defined as follows: Marker efficiency is defined as the area occupied by the patterns in
marker expressed as percentage to total area of the marker plan/Marker efficiency is area
of pattern in the marker plan/total area of the marker plan(Hudson, marker efficiency
improvement, 1997).

18
Bahirdar University GED 2019

2.7.6 Factors of marker efficiency

The higher the marker efficiency the lower the fabric wastage makes the definite number
of garments for a particular design. The half cost to make garment is paid for its fabric.
The factors are:

 Marker planer
 Size of garments
 Marker length
 Marker width
 Method of marker making
 Fabric characteristics
 Style of garment(Heregth, 2013).

2.7.7 Objectives of marker efficiency

Examine how fabric utilization affects marker efficiency

Enumerate the factors affecting material utilization(Puri, 2006).

2.8 Methodology
2.8.1 Methods of problem explanation

I have used different mechanism to explore the problems found in the factory these are

Actual idea observation of the problems in cutting section

By comparing the information’s that I got from the factory each other and by evaluating
this information’s with respect to theoretical subjects.

In addition to this mechanism I have asked my industrial advisor, cutting supervisor and
marker makers about the main problems found in the cutting room as problem marker
making and how to marking.

19
Bahirdar University GED 2019

Idea generation

Data collection

Primary data Secondary data

Data analysis

Actions take to improve the

efficiency of the marker

Existing of weight and effi of the styles

Data analysis after

Result and discussion

Conclusion

Recommendation

20
Bahirdar University GED 2019

2.8.2 Methods of Data Collection

I have different opportunities to get information’s but for the reliability and originality of
my project I have selected information’s related to the cutting and marker making.

2.8.3 Primary Data Collection by Oral interview

 Marker makers
 Cutting supervisor
 Pattern maker
2.8.4 Secondary Data Collection
 Cutting department documents
 Data from internet
 Related text books

Finally I have tried to relate this information’s with my theoretical knowledge.

2.9 Data Analysis

Description: R-neck T-shirt

Color: royal blue and black

Style No: 202021

Size: Small, Medium, Large and extra large

They mark five, four or three garment at a time

Marker width: 188cm=1.88meter

GSM of fabric: 160g/m2.

Maximum lay spread at a time: 120

21
Bahirdar University GED 2019

Table 2. 1: Pattern length

Size Pattern Length(cm)

Small 64
Medium 69
Large 74
Extra-large 80

100cm= 1m

64𝑐𝑚∗1𝑚
64cm x = 0.64m
100𝑐𝑚∗𝑥

100cm= 1m

69𝑐𝑚∗1𝑚
69cm x = 0.69𝑚
100𝑐𝑚∗𝑥

100cm=1m

74𝑐𝑚∗1𝑚
74cm x = 0.74m
100𝑐𝑚∗𝑥

100cm= 1m

80𝑐𝑚∗1𝑚
80cm x = 0.80m
100𝑐𝑚∗𝑥

Existing Weight and Efficiency of the Styles

Table 2. 2: Total fabric weight

Size Total weight (Length*Width*GSM)

Small 0.64*1.88*160 = 193gm
Medium 0.69*1.88*160 = 208gm
Large 0.74*1.88*160 = 223gm
Extra-Large 0.80*1.88*160 = 241gm
865gm
Tota
l

22
Bahirdar University GED 2019

After cutting the pattern components, measured the actual weight of the sizes that means
actual weight for small, medium, large and extra-large, then we know the difference
among the total weight and actual weight.

Table 2. 3: Total fabric weight, actual weight and difference

Total weight Actual weight after

Size before cutting(gm.) Difference(gm.)
cutting(gm.)

Small 193 133 60

Medium 208 139 69
Large 223 145 78
Extra-Large 241 151 90
Total

865gm 568gm 297gm

So the waste of fabric in Maa Garment Company cutting section is 297gm which means
total weight of fabric minus actual weight (865gm-568gm=297gm). The cause of fabric
wastage was marker making the same sizes or marking one size only and the production
is less because the marker efficiency low and high fabric waste. The efficiency of marker
making is:

𝑤𝑒𝑖𝑔ℎ𝑡𝑜𝑓𝑢𝑠𝑎𝑏𝑙𝑒𝑓𝑎𝑏𝑟𝑖𝑐
Effi= 𝑡𝑜𝑡𝑎𝑙𝑤𝑒𝑖𝑔ℎ𝑡𝑜𝑓 𝑡ℎ𝑒 𝑓𝑎𝑏𝑟𝑖𝑐 ∗ 100%

Small:

133
Effi= 193*100%

Effi=69%

Medium:

139
Effi= 208*100%

23
Bahirdar University GED 2019

Effi=67%

Large:

145
Effi=223*100%

Effi= 65%

Extra-Large:

151
Effi=241*100%

Effi=63%

69+67+65+63 264
Average effi for S, M, L and XL= = = 66%
4 4

2.9.1 Actions take to improve the efficiency of the marker

I suggest to the company workers to make the marker in mixing (s, m, l and xl) form
to improve the efficiency of the marker; Because as the sizes are mixed the efficiency
will be increased as the same time fabric consumption also decreased; and I suggest
theme to use A4 paper to make the marker for local products; Because they were used
by trying the pattern on the lay of fabric.

Figure 2.3: Mixing marker making

24
Bahirdar University GED 2019

2.9.2 Data analysis after

L
S
M

xl

Figure 2. 4: Result by mixing sizes

After making by mixing the marker pattern four sizes the total fabric weight is
812gm,while the length 2.7m that means the result of 812gm is 2.7m times 160g/m2
times1.88m; but the actual weight is the same 568.

25
Bahirdar University GED 2019

Table 2. 4: total weight, actual weight and difference of the fabric after mixing

Size
Total weight actual Difference
(Length*Width*GSM) weight(gm.) in(gm)

2.7m*1.88m*160g/m2=
Four all sizes S, M, 812gm 568gm 244gm
L and XL

The waste of fabric in weight after mixing the four sizes marker making is 244gm that
means 812gm-568gm=244gm and by the reason of mixing sizes reduced the cause of
fabric waste. The production also increased by the reduction of fabric wastage and by
increasing marker efficiency.

Then the efficiency of marker is calculated by the next equation:

𝑤𝑒𝑖𝑔ℎ𝑡𝑜𝑓𝑢𝑠𝑎𝑏𝑙𝑒𝑓𝑎𝑏𝑟𝑖𝑐
Effi = ∗ 100%
𝑇𝑜𝑡𝑎𝑙𝑤𝑒𝑖𝑔ℎ𝑡𝑜𝑓𝑓𝑎𝑏𝑟𝑖𝑐

568𝑔𝑚
Effi=812𝑔𝑚*100 =70%

2.9.3 Result and Discussion

From the factors of fabric wastages one is marker making of individual size marking, so
to reduce the cause of this fabric wastage is marker making by mixing sizes of patterns,
while the industry gained 53gm of fabric. After mixing the marker sizes total weight of
fabric wastage is reduced from 297gm to 244gm that means the company saved (profits)
or increase the production by 53gm of fabric and the marker efficiency is increased from
66 percent to 70 percent or the marker efficiency increased by 4%.Where the result of
these 53gm and 4% are the following evaluated:

297gm - 244gm = 53gm

70% - 66% = 4%

26
Bahirdar University GED 2019

The result of this project solves the reduction of fabric waste by improving marker
efficiency, then the result of before and after solving is regarding of the below table based
on the weight and efficiency:

Table 2. 5: Result before and after in weight and efficiency comparing

Result in weight and Waste Before Waste After Difference

efficiency solving problem solving problem saved (gained)
Weight(gm.) 297gm 244gm 53gm
Efficiency (%) 66% 70% 4%

27
Bahirdar University GED 2019

2.10 Conclusion and Recommendation

2.10.1 Conclusion
In Maa garment factory has a problem in cutting section. The problem is weakness in
marker making. When the maker marks by individual sizes of small, medium, large, and
extra-large, which means the marker maker marks one size only in one time, or marking
small size only at a time (marking large size only at a time), but this method has more
fabric wastage. Using the method of one size marker making has an affect for the factory
like reduction of products, less marker efficiency, increasing of costs and others.

The objective of this project is to reduce fabric waste, increasing marker efficiency,
increase production by minimizing fabric wastage.

The result of this project solves the reduction of fabric waste by improving marker
efficiency.

Generally After mixing the marker sizes total weight of fabric wastage is reduced from
297gm to 244gm that means the company saved (profits) 53gm of fabric and the marker
efficiency is increased from 66 percent to 70 percent or the marker efficiency increased
by 4%.

2.10.2 Recommendation
This project recommends to the cutting section employees and managers to implement all
the solutions.
Assign a qualified person in cutting department since experience challenge to accept new
work culture and improvement.
Aware about fair and polite treat towards workers, accept and involve worker`s
suggestions and opinions, long-term worker´s experience increases efficiency and
quality. As I have seen in the company cutting section there is a problems in the marker
making after this project implement the company need to achieve their target I want to
recommend to improve and give focus the aspects to do more and to improve the marker
efficiency, reduce of the cost and minimizing of wastages.

28
Bahirdar University GED 2019

CHAPTER THREE

Benefits Gained From the Internship

During the internship program I gained immense experience that can help me in my
career. Such as social interaction and real life experience. Furthermore I experience as
follows:

3.1 Developing practical skill

My staying in the Maa garment factory I develop my practical skills. I have seen each
process of garment starting from design to finished product as I learnt in the class. My
practical skills are some examples of in the below:

Figure 3. 1: Practical skill in sewing

29
Bahirdar University GED 2019

Figure 3. 2: Practical skill in marker making

30
Bahirdar University GED 2019

Figure 3. 3: Practical skill in ironing

3.2 Up-grading theoretical knowledge

After I have accomplish my internship program in the factory, I am able to up-grade the
theoretical knowledge I had in the previously class, also able to compare the factory
working method with the global factory’s. I know a theoretical knowledge from different
text books, internet, and by asking supervisors and managers of the company.

3.3 Problem solving skill

Completing this internship program allows me to identify the factory problems, so that I
can be able to solve them.

The internship program gives me the opportunity to apply some of the problem solving
skill that I learned with in the class room to real world activity within the industry. It
gives me an in-depth analysis of the industrial problems and how to solve them.

3.4 Team playing skill

While I was an internee everything in the factory is done with a group, there isn’t a single
operation done by group, and we also have done better with my internee mates.

Also I develop my understanding on my contribution to the company as a member of the

group on the entire objective to be succeeded.

31
Bahirdar University GED 2019

3.5 Management and leader ship

Doing an Internship made me to build my confidence and knowledge on leadership skill.

The most necessary thing in production factory is understand and learn managing of
employee is the main difficult part as far as I understand from my practice.

I have realized a few important guidelines for achieving better leadership

 Positive attitude
 Clear instruction
 Personal contact
 Team work
 Communication skill etc.
3.6 Work ethics and industrial policy

Understanding the factory ethics and policies such as

Being punctual

Knowing your duty and responsibility

Good relations with workers

Share knowledge etc.

3.7 Entrepreneur skill

My internship program held for four month creates the chance to meet a lot of different
entrepreneurs.

Entrepreneur is someone who searches for changes, responds to it, exploits it as an

opportunity and is a risk taker.

Internship help me developed some of the elements of entrepreneur some of them are:

 Being visionary and goal oriented

 Risk taking and self-disciplined
 Capable of organizing skill
 Planner, implementer, strongly motivated and achievement oriented.

32
Bahirdar University GED 2019

Generally entrepreneur decide on the product acquire facility, and brings together the
labor force, capital, and production material.

3.8 Inter personal communication skill

The communication skill that I developed during my internship helped me to approach

sort of people who are from different aspects disciplines and regions and it show me the
way how to approach professionals who are on the field. The internship helps me to
develop independency, confidence, hardworking, responsibility, and transparency,
truthfully and multi dimensionality in any department.

33
Bahirdar University GED 2019

References
Documents from the industry

Charlotte, J. (1991). objectives of marker making. oslo.

Heregth. (2013). factors of marker efficiency. pakkistin.

Hudson. (1997). marker efficiency improvement. international journal trade , 76-78.

Hudson. (1991). marker efficiency. combodya.

Hudson. (2013). marker efficiency improvement. nataka.

Hudson. (1991). marker making improvement. international journal trade , 76-78.

Jacobs, C. (1991). Marker making development. Torontoo.

Morra. (1997). fabric wastage. New york.

Nicole, D. (2018). marker. brazilia.

Puri. (2006). objectives of marker efficiency. Chainees.

34