Overview RMG (Ready Made Garment) sector
RMG (Ready Made Garment) is very Important and helpful for our Bangladesh.
Bangladesh has emerged as a key player in RMG (Ready Made Garment) sector since 1978. Textiles and clothing account for about 85% of total export earnings of Bangladesh. Out of which, 75% comes from the apparel sector which covers the major products of knit and woven shirts, blouses, trousers, skirts, shorts, jackets, sweaters, sports wears and many more casual and fashion items. The sector currently employs approximately 1.5+ million workers, mostly females from underprivileged social classes. The completed this report on the basis of all the department of RMG sector such as Merchandising Department, Commercial Department, Production Department, Supply Chain Department, Human Resource Department, Compliance Department, MIS Department, and relevant organization like BGMEA, BKMEA, Export Promotion Buru, Yarn suppliers, Chittagong Port, Insurance Company, Shipping Company. So by completing this report get overall idea about RMG sector, so its carry more value than any books.
Objective means the purpose of this report. The objectives of this report are as follows:
- Its documents for future.
- To know detail about RMG sector.
- Information gathers about commercial.
- Getting idea about shipping procedure.
- Concept develop about spinning, knitting.
- Comparison between class room learning and practical learning.
- Knowledge gather about RMG sector related other organization.
- To achieve new idea about knit garments manufacturing process.
- To know about the management and technical process of apparel industry.
· To know the management Procedure in Garments Industry.
· To mark a comment over the whole Internship Report.
· To mark out the important part of Internship Report.
· To focus on the valuable part of Internship Report.
- To have skill labor for quality product.
- To study the trend of garment product development and its composition in order to analyze the product portfolio and its diversification.
- To study the present market composition for the Bangladeshi garment product about Market diversification.
- To analyze the recent labor unrest in the garment industry of Bangladesh.
- Opportunity of behavioral theory practice in our garments sector.
- Regularly behavioral theory practice in garments industry.
- Identifying the trade agreements that might affect the export growth.
- Finding out the type of linked industries that might be affected.
- Understanding the employees better.
- To do a merchandising practice in the factory.
- Identify the additional services that the existing companies are going to avail.
- Identify the factors that will lead to the knitwear in the post MFA period.
- To investigate the manager’s roles and responsibilities prior to using groupware and collaborative systems.
- To identify advantages and disadvantages of using groupware and collaborative systems into the managers’ roles and responsibilities.
- To relate the use of groupware and collaborative systems with future trends in managers’ roles and responsibilities.
- To identify merchandising and total production system.
Methodology means how we make this report. How many ways have used are as follows-
- Different organization.
- Class lecture
- Class sheets
- Annual report.
· To collect information what seeing in practical in Internship Program.
· To collect information what in practical what was done by me for practical knowledge.
· To make a comment over the project we have to understand the whole project.
Scope means how many uses for completing this report space. The scopes are given bellow-
- Buying House
- Library work
- Class lecture
· Some of our senior brothers can help us.
· Can collect information various books and relevant paper what related with apparel industry.
Limitation means obstacle. For completing this report have faced many obstacles such as-
- Time limitation.
- Merchandiser doesn’t have enough time to give the information elaborately.
- Short time visit in different organization.
· Lack of organizing chain of command.
· Lack of instruction book, they are following traditional business.
· may have to suffer for lack of supply chain management.
· Lack of good organized management.
· Commanding style is very slow.
02. CORPORATE OFFICE:
2.01. Company profile.
ANAN SOCKS Ltd.
THE WELL-TEX LTD.
THE WELL-TEX – 1INC
WELLTEX DENIM Ltd. **
WELL-TEX CLOTHING Ltd**
ADIB DYEING MILLS LTD. **
BROTHERS GARMENTS Ltd **
(A) * (B) **
53, MEHER SUPER MARKET, MULAID, MAWNA,
TONGI BAZAR, TONGI-1710, SREEPUR, GAZIPUR,
GAZIPUR. BANGLADESH. BANGLADESH.
HEAD OFFICE :
53, MEHER SUPER MARKET,
TONGI BAZAR, TONGI-1710,
TEL : 880-2-9801937/8, 9802742
FAX : 880-2-9802242,9811293
QUALITY COMMITMENT RELIABILITY
“Business with global view” has always been motto. Nearly two decades back, when pioneered this business, had several things in mind:
- Bangladesh is the most populated country in the world, which requires employment of so many hands after offering proper and adequate training. And garments manufacturing is such a labour intensive sector where can create more and more employment scope for my countrymen.
02. A developing country, as we are, has very few ways of earning foreign exchange. But exporting garments can open the avenues of earning the same. So put relentless effort of expand the business.
03. Business activities are run in a society. So all my thinking and views are sketched considering the welfare of all the related and interest groups in the society as well as the people working in the factories. Thus the social responsibility of a business is performed. A balanced and harmonic progress of the total society then can bring and ensue happiness of human being.
04. For these, in this era of globalization, always plan and march strategically, proactively to ensure greater benefit of business mates— buyers meeting quality, commitment & reliability besides all others.
With the positive response of so many buyers Well-Tex and its associate concerns Well-Sweaters, Sababa Apparels, Adib Dyeing Mills Ltd and newly The Welltex Ltd. are expanding day by day. Services and your response take us & my countrymen to the doorstep of the cherished prosperity.
(Majedul Hoque Chisty Shameem)
Adib Dyeing Mills Ltd ( with washing unit)
The Well-Tex Ltd.
MACHINE LIST OF WELLTEX ( at Tongi)
1. ESTABLISHED IN : 1986
2. PRODUCTION AREA : 60,000 SFT.
3. TOTAL EMPLOYESS : 1725
4. MACHINERY LIST : ( 12 nos master Line )
|Sl No:||Name of Machine||Brand||Quantity|
|1||Single needle lockstitch machine||Juki||550|
|2||Double needle lockstitch||Juki||40|
|3||Double needle chain stitch||Juki||4|
|5||Flat Lock Machine||Juki||15|
|8||Single needle lockstitch button hole||Juki||15|
|9||Single needle button stitch/lockstitch||Juki/Sunstar||17|
|10||Eyelet hole machine||Reece/Brother||3|
|11||Single needle vartical machine||Juki||2|
|12||Feed of the arm||Juki/China||20|
|16||Loop Cutter||Weda, Germany||2|
|17||Thread Re-cone machine||Local||1|
|19||P.P Belt machine||Packway/Toyo||2|
NEW WOVEN FACTORY “THE WELL-TEX LTD”
( at Mawna)
1. ESTABLISHED IN : 2009
2. PRODUCTION AREA : 2, 83,000 SFT.
3. TOTAL EMPLOYESS : 5,000
4. MACHINERY LIST : ( 40 nos master Line )
Presently running 20ns master line & rest of 20 nos will start from 1st May 2011
|Sl No:||Name of Machine||Brand||Quantity|
|1||Single needle lockstitch machine||Sunstar||1483|
|2||Single needle lockstitch Auto Trimmer||Sunstar||100|
|3||Double needle Lockstitch||Sunstar||160|
|4||Double needle Angular||Sunstar||28|
|5||Overlock 4 thread||Sunstar||65|
|6||Overlock 5 Thread||Sunstar||235|
|7||Bartack (Computerized) Machine||Sunstar||93|
|8||Button Hole (Computerized)||Sunstar||34|
|9||Button lockstitch ( Computerized)||Sunstar||28|
|10||Eyelet hole ( Computerized)||Sunstar||14|
|11||Single needle vartical machine||Sunstar||28|
|12||Feed of the arm ( Computerized)||Sunstar||84|
|15||Decorative Pattern Sewer Machine||Sunstar||2|
|19||Mini Compact Press Fusing Machine||Hashima,Japan||1|
|22||Micro Computer Velcro Tape Cutter||Three King||2|
|24||Cartoon Strapping Machine||Packway||5|
|25||Full Steam Iron||Nisho||40|
|26||Vaccum Ironing Table||Nisho||40|
|27||Thread Winding Machine||Oshima||4|
|28||Fabric Inspection Machine||Modern||1|
WE HAVE OUR OWN 4 NOS COMPUTERIZED EMBROIDERY MACHINES FACILITY IN THIS FACTORY.
WE HAVE OUR OWN PRINTING FACILITY IN THIS FACTORY, WHERE WE CAN DO GARMENT SCREEN PRINT, RUBBER PRINT, DISCHARGE PRINT, FLOCKY PRINT ETC.
WE HAVE OUR OWN WASHING FACILITY IN THIS FACTORY FOR 25,000 PCS DENIM /JEANS PER DAY WITH ITS OWN ETP PLANT.
MACHINE LIST FOR WELL SWEATER’S ( at Mawna)
|01.||KNITTING MACHINE||7 GAUGE||150||FLYING TIGER Taiwan|
|02.||KNITTING MACHINE||5 GAUGE||250||FLYING TIGER Taiwan|
|03.||KNITTING MACHINE||3 GAUGE||80||FLYING TIGER|
|04.||KNITTING MACHINE||12 GAUGE||300||RUNNING TIGER|
|05.||LINKING MACHINE||7 GAUGE||80||FLYING TIGER|
|06.||LINKING MACHINE||5 GAUGE||30||FLYING TIGER|
|07.||LINKING MACHINE||12 GAUGE||100||RUNNING TIGER|
|08||WINDING 12 SPENDEL||20||AMAR (INDIA)|
|09.||PLAIN MACHINE||20 PC||JUKI|
|10.||OVER LOOK||20 PC||JUKI|
|11.||BOILER||01 PC||Delim Koria|
|PP BELT MACHINE
TOTAL= 1085 PCS
****ALSO OUR SWEATER YARN DYEING PROJECT NAMED BY ADIB DYEING MILLS LTD. IS RUNNING WITH ETP PLANT.
5. PRODUCT : (A) All types of Woven Pant, Shorts & other bottoms.
(B) All types of Fleece top / bottom Items.
(C)Woven Jogging Suit & Woven Jacket.
(D)All Types of Sweater.
6. PRODUCTION CAPACITY:
(A) WOVEN—————Presently 50,000 DZ per Month & Expected 120,000 DZ From Dec,2010.
(B) SWEATER————10,000 DZ PER MONTH
(C) YARN DYEING——(a) Hanks Dyeing 20 M.Ton/Day
(b) Cone Dyeing 8 M.Ton/Day
(D) DENIM WASHING—-25,000 pcs per day.
7. ANNUAL TURNOVER : (a) Presently US$ 48.00 Million.
(b) Expected US$ 100.00 Million from Dec,2010.
8. LEAD TIME : 90~~120 Days from the date of receipt of L/C.
9. BANKER : (a) BASIC BANK LTD.
(b) DHAKA BANK LTD.
10. MAIN CUSTOMER (WOVEN):
(a) H&M, Sweden
(b) Kids Headquarters, USA
(brand : US POLO, CK, Timberland, Rock wear)
(c) Kids Concept, USA
(d) Frenz Group ,USA
(e) Bonnie Togs, Canada
(f) Hadson Bay Co, / Zellers, Canada
(g) KIK, Germany
(h) The Haddad Brands, USA
11. MAIN CUSTOMER (SWEATER) :
(a) Wal* Mart, USA
(b) Kids Headquarters, USA
(brand : US POLO, CK, Timberland, Rockwear)
(c) Hadson Bay Co, / Zellers, Canada
(d) Frenz Group ,USA
(e) EZ Apparel, USA
(f) KIK, Germany
(g) Marisol, Brazil
QUALITY ASSURANCE SYSTEM
|WE ARE FOLLOWING QUALITY LAVEL AQL 2.5|
|AQL CHART (AQL 2.5)|
|Shipment units||Sample Unit Inspected||Defective Units Acceptable||Defective Units Unacceptable|
CODE OF CONDUCT :
We operate in full compliance with the applicable laws, rules and regulations, including those relating to labour, worker health & safety and the environment.
- CHILD LABOUR
We employ only workers who meet the applicable minimum legal age requirement or are at least 18 years of age, whichever is greater.
- FORCHED LABOUR
We don’t use involuntary labour of any kind. We do not force any worker to remain in employment, for any period of time against his or her will.
- WAGES AND HOURS
We set working hours, wage and overtime pay in compliance with all applicable laws.
- MEDICAL FACILITIES
We provide free medical facilities and consultancy to workers.
- METAL DETECTOR
We are using METAL DETECTOR to detect broken needle tips or other ferrous contaminants during garment production.
- PNEUMATIC PRESS SNAP BUTTON MACHINE
We are using accident-proof compressed air snap button machine to attach buttons, eyelets, rivets etc. during garment production to achieve required pull and push pressure.
- METAL GLOVES
We provide metal gloves to protect any accident during fabric cutting.
- FIRE SAFETY
There are two emergency stairs out of three stairs in our factory.
To develop awareness and confidence of the workers we perform at least one mock evacuation exercise a month. Well trained fireman watching all over the factory during working hour. There are required number of the extinguishers, fire blanket, water bucket etc. in our factory.
We organize picnic, cultural function etc. at least once in a year.
· GOALS & OBJECTIVES
We consider greater benefit of our valued business clients.
For this we set goals & objectives as follow:
· More reasonable pricing
· On time deliver
· Better quality and reliability
· Product development and modification.
2.02. Company Organ gram.
2.03. What is Corporate Policy Strategy?
The Council provides a wide range of specific services (Education, Planning, Social Work, Cleansing etc) but there are also a number of issues which require a corporate approach. These include such regular matters as Equalities, Best Value, Public Performance Reporting, the Citizen Panel and strategic issues like Asylum Seekers and Refugees.
Generally speaking the Chief Executive, as principal policy advisor to the Council, has responsibility for providing a corporate policy and strategic lead to the Council. Sometimes individual services are requested to take the lead on relevant issues. The Council’s Social Work Service is building a partnership with the local health board in response to the Government’s Joint Futures initiative for example.
The Corporate Policy Unit within the Chief Executive’s Department has the lead responsibility for several key policy areas; develops relevant strategies to handle significant policy issues and supports both senior elected members and the Council’s Corporate Management Team.
2.04. Visions Mission and Objectives. Vision
Quality is always the combination of the highest intent, sincerest effort with an accurate execution, and delivering high-valued-added products and quality services, all tailored to the specific needs of every one of our individual customers.
The Mission Statement is a crucial element in the strategic planning of a business organization. Creating a mission is one of the first actions an organization should take. This can be a building block for an overall strategy and development of more specific functional strategies. By defining a mission an organization is making a statement of organizational purpose.
“A good mission statement captures an organization’s unique and enduring reason for being, and energizes stakeholders to pursue common goals. It also enables a focused allocation of organizational resources because it compels a firm to address some tough questions: What is our business? Why do we exist? What are we trying to accomplish?”
- Source quality
- Make quality
- Delivery quality
2.05. CSR (Corporate Social Responsibility) Procedure.
Corporate social responsibility (CSR), also known as corporate responsibility, corporate citizenship, responsible business, sustainable responsible business (SRB), or corporate social performance, is a form of corporate self-regulation integrated into a business model. Ideally, CSR policy would function as a built-in, self-regulating mechanism whereby business would monitor and ensure its adherence to law, ethical standards, and international norms. Business would embrace responsibility for the impact of their activities on the environment, consumers, employees, communities, stakeholders and all other members of the public sphere. Furthermore, business would proactively promote the public interest by encouraging community growth and development, and voluntarily eliminating practices that harm the public sphere, regardless of legality. Essentially, CSR is the deliberate inclusion of public interest into corporate decision-making, and the honoring of a triple bottom line: People, Planet, and Profit.
The practice of CSR is subject to much debate and criticism. Proponents argue that there is a strong business case for CSR, in that corporations benefit in multiple ways by operating with a perspective broader and longer than their own immediate, short-term profits. Critics argue that CSR distracts from the fundamental economic role of businesses; others argue that it is nothing more than superficial window-dressing; others yet argue that it is an attempt to pre-empt the role of governments as a watchdog over powerful multinational corporations. Corporate Social Responsibility has been redefined throughout the years. However, it essentially is titled to aid to an organization’s mission as well as a guide to what the company stands for and will uphold to its consumers.
Social awareness and education
The role among corporate stakeholders to work collectively to pressure corporations is changing. Shareholders and investors themselves, through socially responsible investing are exerting pressure on corporations to behave responsibly. Non-governmental organizations are also taking an increasing role, leveraging the power of the media and the Internet to increase their scrutiny and collective activism around corporate behavior. Through education and dialogue, the development of community in holding businesses responsible for their actions is growing .
The rise of ethics training inside corporations, some of it required by government regulation, is another driver credited with changing the behavior and culture of corporations. The aim of such training is to help employees make ethical decisions when the answers are unclear. Tullberg believes that humans are built with the capacity to cheat and manipulate, a view taken from (Trivers 1971, 1985), hence the need for learning normative values and rules in human behaviour (Tullberg 1996). The most direct benefit is reducing the likelihood of “dirty hands” (Grace and Cohen 2005), fines and damaged reputations for breaching laws or moral norms. Organizations also see secondary benefit in increasing employee loyalty and pride in the organization. Caterpillar and Best Buy are examples of organizations that have taken such steps (Thilmany 2007).
Crises and their consequences
Often it takes a crisis to precipitate attention to CSR. One of the most active stands against environmental management is the CERES Principles that resulted after the Exxon Valdez incident in Alaska in 1989 (Grace and Cohen 2006). Other examples include the lead poisoning paint used by toy giant Mattel, which required a recall of millions of toys globally and caused the company to initiate new risk management and quality control processes. In another example, Magellan Metals in the West Australian town of Experience was responsible for lead contamination killing thousands of birds in the area. The company had to cease business immediately and work with independent regulatory bodies to execute a cleanup.
Increasingly, corporations are motivated to become more socially responsible because their most important stakeholders expect them to understand and address the social and community issues that are relevant to them. Understanding what causes are important to employees is usually the first priority because of the many interrelated business benefits that can be derived from increased employee engagement (i.e. more loyalty, improved recruitment, increased retention, higher productivity, and so on). Key external stakeholders include customers,
Consumers, investors (particularly institutional investors), regulators, academics, and the media).
Globalization and market forces
As corporations pursue growth through globalization, they have encountered new challenges that impose limits to their growth and potential profits. Government regulations, tariffs, environmental restrictions and varying standards of what constitutes labour exploitation are problems that can cost organizations millions of dollars. Some view ethical issues as simply a costly hindrance. Some companies use CSR methodologies as a strategic tactic to gain public support for their presence in global markets, helping them sustain a competitive advantage by using their social contributions to provide a subconscious level of advertising. (Fry, Keim, Meiners 1986, 105) Global competition places particular pressure on multinational corporations to examine not only their own labour practices, but those of their entire supply chain, from a CSR perspective
03. MERCHANDISING DEPARTMENT:
The Bangladesh garment industry is gaining ground in the world market at breakneck speed, but still not flourished at the fullest extent. Although the resources are available plentiful with a powerful foundation of fabric and spanning sector to support. the key factors behind this are low technological development, lower output, cut throat competition, high raw material cost, inadequate infrastructure, traditional productivity, unfavorable regularity policies, and globalization in fact. However, there a fair list of the producers, suppliers, and exporters that are fully acknowledge with regularity policies and formalities, international marketing policies and procedures. The only concern is in executing their productivity initiatives, and meeting with order deadlines.
Now days, major companies are adopting merchandising concepts, which comply with all procedures to execute and dispatch the shipment on time considering quality, cost and time. Merchandisers are serious in the success of any garment business. They provide the right products at the right time, enabling a company to match with latest market trends and meet the market demand. In the merchandising concept, time management is a gig to manage ones time properly, so he can focus on value adding actions.
Garments merchandising means the work to buy raw material and accessories to produce garments (Merchandise) against a particular work order of garment and have to export these under the same work order within time schedule, maintaining required quality level of buyer
3.01. Business Development Procedure.
Apparel industry must be developed business otherwise they can’t extend their market. To collect new buyer and business with them a company must follow the procedure of business development. The WELL TEX GROUP. follow the procedure of business development, this are given below-
Know about the nature of buyer.
First E-mail to the buyer.
Offer to buyer for visit the company.
Collect audit pass report from buyer.
Company arrange a meeting with buyer for business.
Price conforms and order place from buyer.
3.02. First Email to Buyer for Business Development.
For new business development sellers have to communicate with buyer. email is the easiest and swift way of communication so when seller will contract first time with buyer by email at that time have to mention some important information about company. Which kind of things should be include here this are-
- Information about you and your company.
- Products information about your company.
- Capacity and productivity.
- Which buyer work with you.
- Attachment a beautiful sample photograph.
- Weating for feedback.
This kind of information should be included in this email. On the other hand this email will be minimum word and maximum communication.
Sample of first email
“The WELL TEX GROUP. began its journey into the garments sector in 1998 as a garments in Bangladesh. Since then the organization being run by highly qualified, experienced and professional management and stuff along with Sophisticated Machineries, Latest Technology, Skilled Workmanship, Substantial Marketing and Proper Discipline. We are ready and able to give you 100% quality, best price and service. We believe it is possible to us to enter into the marathon of global market.
At present our knitting, garments & printing factory is and dyeing factory is Ibrahim knitex which are the sister concern of The WELL TEX GROUP” All the factories are 100% export oriented. Our previous practice is the best quality of products and on time delivery. We are always committed to the buyers.
T-shirt, Polo shirt, Tank top, Shorts, Trouser, Jacket (Cotton, Polyester, CVC, France terry, Waffle, etc.) and many more. We also produce all kinds of Woven & Sweater item.
Please send us your current inquiry for sampling & costing.
Your kind co-operation would be highly appreciated.
Thanks & Best Regards
Md. Zahidul Islam.
The WELL TEX GROUP
3.03. Feed-Back from Buyer in Response to First Email.
Dear Mr.Zahidul Islam,
The pleased about your company, so want to make a business with you. So you should send some original sample include with FOB price.
3.04. Sending Quality Samples to New Buyer for Better Understanding of
Workmanship of Factory.
Samples play a vital role to get new order. Without quality sample we can’t develop a new business, So sample should be better quality before bulk production. For that reason when we send quality sample to the buyer we have to follow some thing, those are:
If we follow this process to make quality sample and send as like this way, think after that buyer will be satisfied and get clear idea about workmanship of factory.
3.05. Approval Procedure of sales samples.
Sample is made when price is confirmed and orders are on speculation, usually is L size in all color combinations of expected order. Buyer held a meeting with its customer and record their response on order quantity per color, size etc. and finally place order to their vendor.
Sales sample basically use catalogue buyer.
3.06. Cost Sheet and Consumption Sheet Preparation.
Garment Costing: In order to achieve perfect garment costing, one must know about all the activities including purchase of fabrics, sewing, packing, transport, overheads, etc
|Table 2: The freight charges for the Men’s Basic T-shirt. Price of garment estimation is given|
|Particulars||Light colors||Medium colors||Dark colors|
|34’s combed yarn||Rs.135.00||Rs.135.00||Rs.135.00|
|Fabric cost per garment||Rs.38.06||Rs.40.13||Rs.44.27|
|Cost of Trims||Rs.0.85||Rs.0.85||Rs.0.85|
|Cost of accessories||Rs.1.35||Rs.1.35||Rs.1.35|
|Rejection of garments (commonly 3%)||Rs.1.50||Rs.1.50||Rs.1.50|
|Cost of Garment||Rs.52.76||Rs.54.83||Rs.58.97|
|Price of Garment||Rs.63.66||Rs.66.03||Rs.70.87|
For men’s basic T-shirt, the delivery terms in the buyer enquiry as ‘FOB’. So sea freight charges is not added. But the local transport with the cost of garment has to be added. Finally, we have to convert the Indian rupee value to USD or Euro
The garments manufactured in many sizes to fit for everybody. Generally they are in sizes Small (S), Medium (M), Large (L), Extra large (XL) and Double Extra Large (XXL). The quantity ratio or assortment can be any one of the following approximate ratio.
S: M: L: XL: XXL – 1:2:2:2:1
S: M: L: XL: XXL – 1:2:1:2:1
S: M: L: XL: XXL – 1:2:3:2:2
As the price is the same for all these sizes of garments, the author have taken the centre size large(L) for average calculation. Generally, the quantity of L size will be higher or equal to the quantity of each of other sizes.
Men’s Basic T-shirt
Description: Men’s Basic T-shirt-short sleeves- 100% Cotton 140 GSM Single jersey – 1 x 1 ribs at neck – solid dyed – light, medium and dark colours in equal ratio.
Sizes: S, M, L, XL, XXL Ratio: 1: 2: 2: 2: 1
Export carton: 7 ply -120 GSM virgin corrugated – sea worthy. Cartons are to be strapped with 2 nylon straps.
Measurements in cm: (Finished garment)
Chest – 60 cm
Length – 78 cm
Sleeve length – 24 cm
Neck rib width – 3 cm Hem – 3 cm
Patterns are generally made with the seam allowance and cutting allowance. Generally, 12 cm is added with the total of body length and sleeve length.