BGMEA UNIVERSITY OF FASHION & TECHNOLOGY
(BUFT)
Assignment
On
Cap Manufacturing Process
Submitted by
Name: Sajjad Hossain
ID: 201-049-4222
Batch: MBA 201 (01Year)
Subject: Textile Science (Fiber-Yarn-Fabric)
Submitted to
Dr. Abdul Baqui
Commonwealth Scholar & UNIDO Fellow
Associate Professor, Director of R&D,
Coordinator MSc Program, Department of Textile Engineering
BGMEA University of Fashion & Technology (BUFT)
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Content
Introduction
The importance of Cap & global market strategy.
What materials needs to be produce
Process flow chart of Cap manufacturing
Conclusion
Introduction
A cap is a form of headgear. Caps have crowns that fit very close to the head. They are
typically designed for warmth, and often incorporate a visor to block sunlight from the
eyes. They come in many shapes, sizes, and are of different brands.
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Importance
1. Caps help us protect our face from the rays of the sun.
2. Run from one side to the other, and you are always on time, wearing a cap will help you save
a lot of time at the time of combing all your hair.
3. A cap can add a lot more style to what we wear, if you wear casual, casual or sportswear is
always a good choice, is an accessory that will give an extra touch to our look whatever your
style and time and look much better.
4. The caps will prevent your head from getting too hot, and will prevent you from gettingdizzy
or possible headaches.
5. This is something that you will like very much, a recent survey revealed that many women
find more attractive to a man who is wearing a cap, so from now on we will all go out to the
street with a cap to see much more attractive to women, and if you are single, then who knows,
maybe you will find the love of your life wearing one of our caps!
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Process Flow Chart of Cap Industry
Ware House
Cutting Section
Panel Section
Visor Section
Crown Section
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Assembly Section
Finishing / Packing Section
Ware House
Sub Materials Use in a Cap
Snap Back
Sticker
Top Button
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Ring
Pin
Cap
Tape:
a) B Tape
b) S Tape
c) Print Tape
Paper Pad/Front Pad
Poly
NTQ (Sticker) (packing section)
Elastic Band
Thread (Spandex, Nylon etc.)
Visor
Peak Board (Plastic)
Visor:
a) Curve visor
b) Flat visor
Inch Tape
Label
a) Bar code Label
b) Bayer Label
c) Size Label
d) Care Label
e) Pattern Label. Etc.
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TC/ Buckram
Various type of TC:
1. Hard TC
2. Medium TC
3. Normal TC
TC Color:
Char Col
Ivory
**The main important things of visor are weight and thickness.
Raw Materials
Cotton Fabrics
Nylon Fabrics
Polyester Fabrics
Wool Fabrics etc.
Mesh Fabric.
Bukram etc.
Parts of Ware House
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After in house the entire product then have to done 30% inspection. But market fabric
will be check 100%.
*Fabric Inspection
*Trims Inspection
*Make Lot Card
*Make ending listing
*Make Fabric Swatch
Fabric Inspection:
4 Point fabric inspection system
0-3”= 1 point
3.1 - 6” = 2 point
6.1 – 9” = 3 point
Over 9”/ 1 yrd = 4 point
Make ending listing
Make ending listing
End listing has to make for make sure the color shade.
It has a way to set-up
First----middle---last
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Fig: End Listing
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Cutting Section Process flow Chart
Requisition according to shipment to warehouse
Fabric ready
Receive fabric
Date wise shipment/Narasy/Cutting
If front contains fusing ( bontax, lining, buckram) its sends to fusing section
Other parts direct sends to cutting m/c .Auto cutting m/c (auto lay) spreader
Fused parts send to (Auto spreader)
Cutting parts sends to output (lot wise) poly making
Panel input section
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Pattern
**The Pattern is use for fabric cutting. There have various type of pattern.
1.Visor Pattern
2. Top Button Pattern
3.Front Side Pattern
4Back Side Pattern
5.Left & Right Side Pattern
Pattern List
DS MOLD
VS MOLD
VISOR MOLD
AC MOLD
X MOLD
AJ MOLD
SD MOLD
MG MOLD
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LB/SD MOLD
VISOR MOLD
How to Cutting Ready Fabric for Cutting Process?
At first lay down the fabric to the cutting table by the spreading machine.
Then make fabric swatch checking fill.
Front part & visor cutting.
Back side sent to the cutting section Front part sent to the fusing m/c
Fabric Swatch Checking Fill:
Fabric cutting into 3 side of the lay
Right Middle Left
Cutting upper part of the fabric and lower part of the fabric.
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Process Flow Chart of Panel Section
Front Part Sinny
Front Part Double Needle
Back Part Sinny
Back Part Double Needle
Thimery Tape Single/Double Needle
(N: B )The crown has 6 parts.
Front Right & Front Left
Left side & Right side
Left Back & Right Back.
(The panel section only work left and right front ,left and right back)
Panel Section
**Some Operation Name:
Front part sinny
Front part double stitch
Back part sinny
Back part double stitch
Thimery single needle
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Thimery double stitch
Eyelet make etc.
**Machine Use in Panel Section:
Eyelet Machine
Plane Machine
Over Lock Machine
Double Needle Lock Stitch Machine
Grinding Machine
Front Ironing Machine
Metal Machine
Iron
Scissors
**Quality Control Check:
Fabric Spot Check
Buckram Spot Check
Tape Spot Check
Eyelet Check
Label Check
Back Tape Check
Thimery Round Check
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Machine Use in Panel Section
Fig: Single Needle Lock Stitch M/CFig: Double Needle Lock Stitch M/CFig: Eyelet M/CFig: Picture of Eyelet
Front Press Ironing:
1. Best temperature of iron is 115 Degree C
2. Before ironing front part it must be placed correctly on the machine.
3. Ironing time = 12 seconds
4. During front ironing keep the hand away from the machine
5. Operator must wear shoes during operating the machine
Types of reject in panel section
1. Fabric spot
2. Front tape displace
3. Label displace
4. Back tape displace
5. Un-cut thread
6. Fabric reject
7. Back seny open
8. Loose thread tension
9. Loose seny tension
10. Eyelet nil
11. Fabric shading
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**Machine Use in crown section:
Plane machine/ single needle lock stitch machine
Double needle lock stitch machine
Over lock machine
Gomet attach machine
Seam sealing machine
Seamless machine
Seam sealing OYP
Thread winding machine
Types of cap :
Normal cap
Themary cap
Jockey cap
Hat Cap
Delta Cap
V style Cap
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Process flow chart of normal cap / Flexfit cap
Front part seny
Front part double needle and tape joint
Back part seny
Back part double needle and tape joint
Bar seny
Crown double needle and tape joint
Extra tape cut
Over lock if required
Inch tape joint
Output QC check
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Machines use in Crown Section
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Process Flow Chart of Assembly Section
Receive from crown section
Visor
S-Band
Label
Front Stitch
Adjuster (Jikuri)
Bertake
Output table
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Process Flow Chart of a Flexfit Cap
Visor join
Visor joins QC checking manual
S-Band point marking
S- Band joins
Label joins (TB Label, Main Label, and Size Label)
S-B bertake
CF hammering
Front Stitch
Front stitch, Label, S-B extra thread cutting
Output table
Fig: Flex fit Cap
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Machine Use in Assembly Section
Single needle lock stitch machine (Plane machine)
Size measurement machine
Pattern machine ( S/B point marking)
Posta Machine
Bartack Machine
Front Stitch Machine
Kansai Machine
Velcro Fusing Machine
S/B Heat Cutting Machine
Fabric Cutting Heat Machine
S/B Tape Join Machine
Front Part Hammering (Manual)
Label punch machine
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Flow Chart of Normal S Band Making
Fabric , Foam & Vinyl sewing by kansai machine
Size wise cutting by cutting machine
Final S Band QC checking
Flow chart of Packing/Finishing section
Receive input from assembly section
Air cleaning
Ironing
First QC check
Top Button Making
Top button attach
Paper pad attach
Sticker attach
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Hang tag attach
Final QC check
Air cleaning
Drying
QC check
Poly making
Inner box making
AQL
Cartooning
Send to store
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Cartooning
1 cartoon = 4 inner = 72 Piece
1 cartoon = 6 inner = 144 Piece
1 cartoon = 2 inner = 48 Piece
AQL
Inspecton Lot Quantity Random Quantity AQL Level
1 4
1 to 8 2
… …
9 to 15 3 … 1
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Conclusion
Cap is one of the most important outer wear for human being. Cap protects and safe us from
ultra Violet ray, which is very dangerous for our body skin. It is also use for different type of
style for men and women and children. When playing sports, it gives us very comfort. When
wearing a cap, it looks very attractive.
References:
1. www.coinmarketcap.com
2. https://en.m.wikipedia.org/wiki/cap
3. www.quora.com/What-are-the-advantage-of-wearing-a-head-cap
4. www.youtube.com
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