Report on Industrial Training in Bata Shoe Company Bangladesh Ltd.
Bata is a worldwide Shoe Manufacturing Company, with operations across 5 continents managed by 4 regional meaningful business units
L (MBUs). Each unit benefits from synergies specific to their environment,such as product development, sourcing or marketing support. Each MBUL is entrepreneurial in nature, and can quickly adapt to changes in theMarket place and seize potential growth opportunities.
Bata Bangladesh is affiliated to the Bata Shoe Organization, the world’s largest footwear manufacturing and marketing organization. Started its operation in Bangladesh in 1962, Incorporation in Bangladesh in 1972.
Currently, Bata Bangladesh operates 2 manufacturing plant Tongi and Dhamrai, Bata Bangladesh is producing around 110,000 pairs of shoes daily. It has a modern tannery with the latest technological facilities to process 25,000 square feet of leather per day. The Tannery is equipped with a high-tech effluent treatment plant ensuring a pollution free environment for both workers and locality where we operate. Bata Bangladesh sells all kinds of footwear which are classified in alignment with market sectors as follows:
Domesticmarket – under the trademarks of “Bata”, “Power”, “Weinbrenner” Bubblegummers”, and “Marie Claire”, through a countywide distribution network comprising retail stores, DSPs and independent dealers.
Overseas market- under the trademarks of its customers, and also markets its own brands to sister companies send the Middle East.
Associate Business Unit
This is a department in Dhamrai plant through which outsourcing is done to Bata family. Complete, partly completed and job works are done from others by this wing. Which run under the complete supervision and guidance of ABU manager. Bata office fixes some footwear industry outside their plant from where different operation, part or full of different footwear manufacturing operation is done. This is done under Bata’s own quality policy. This strategy helps the company to serve there valued customer more quickly, widely and in a competitive price. About 70% of total estimated production is supplied from these ABUs. Thus this company try to rich grass root level of the shoe consumers. ABU offer three type of works
i. Ready component
ii. Cut to Stitch
iii. Only Stitching.
Those companies which supplies ready component is called Satellite.There are about 30 ABU s under Dhamrai plant.
Within these30, 10 Companies supply readycomponent
10 Companies supply Sole 2 Companies work only stitching operation 8 Companies Cut to stitch operation.
Objectives of ABUs:
i. To increase productivity with less investment
ii. To supply product with a competitive price
iii. To meet up high manual work content,
iv. To increase the capacity of production.
Selection of a factory as an ABU:
There is a standard/strategy to select a factory as an ABU which is widely known as SWOT.This is an abbreviated word which means S for Strength: Man, Machine/equipments etc that is infrastructure facilities of a factory. W for Weakness:Problem faced, Unskill operators/Entrepreneur etc. O for Opportunity: Land, vehicles, expansion facilities etc. T for Threat: Risk of getting back and proper use of materials and component of BSO.
Mohammadia Leather and Footwear Ltd.:
This is an ABU of BATA which is about 15 minutes Rickshaw distance in north along Dhaka-Aricha high way from Dhamrai plant. Here Cut to Stitch operation is done. All types of Weinbrenuer, gent’s unlined sandal and closed shoe insole are prepared here. All type of raw materials is supplied from BATA. Machines of this unit also supplied from BATA. Only different operations are done here. These operations are also supervised by BATA officers. So quality is maintained as like as in house production. There are two section of this factory-
i. Bottom manipulation section,
ii. ii. Upper manipulation section.
Grouping of Cutting Dice:
Group-8- Size 5-8; Gents Group-4- Size 2-4; Gents Group-3- Size 1-9; Children Group-1- Size 5-8; Infant
Sequence of operation of Leather Board Cutting for Sandal insole:
Leather board cutting in Hydraulic Press machine
Cutting piece embossing throughout the edge
the edge (Dark Ked)
Screen Printing (Price and Size) Hand marking for slotting
Hand punch (Front middle)
Check and Supply
Dispatch to BATA.
Sequence of operation of Insole board (Carry board) Cutting for Shoe insole:
Insole board (Carry board) Cutting
Shank board (Half insole) skiving at the trade line
Adhesive apply for shank board attaching
Shank board fixing
Beveling at the edge Check and Supply.
Machines Used in Bottom Section:
|Hydraulic Press||Cutting||Atom, Italy||Model: 300 MTH Serial: 201580 Min detectable object: >40mm Response time <ms Working Temp. 0-50°||4||Active|
|Embossing||Emboss||2||1 under maintenance|
|Riveting||Attach Rivet||Torielli, Italy||Model: 69-SC-9||1||Active|
|Moulding||Insole Moulding||Vicevano, Italy.||1||Active|
|Skiving||Skive at the edge||Tostuna, Germany.||Bon-602-60/3||2||Active|
|Beveling||Bevel atthe insole edge||Mohrbach, Germany.||BGF-8||1||Active|
|Slotting||Make slot||Torielli, Italy.||2||1 under maintenance|
|Swing arm Clicking||Cutting||Atom,Italy.||SE-20||4||Active.|
Sequence of operation of Screen Printing:
Print of Required design on the tracing paper Wooden Frame (14″X16″) tightly fitted with Bolting Cloth (140 mesh) Sunacoat and Potassium Chloride (10:1) mixture apply on the cloth on the other side of the placement of tracing paper Dry (by Dryer) Apply lighting camera (intense light source) 10’Normal water wash of screenDrying of Screen. Printing with required color by rubber pad drying.
Before materials are cut a Dispatch ticket is given to cutter. Which after cutting give it with the cutting pieces. It moves with the material through out all operation and up to packing. Finally it acts as label of that consignment. This gives all necessary information. This ticket is as follows:
Ticket for Dispatching Materials
Dept:…………….Plan:……………Pair:………… Knife: ………….Trolley No:
Name of Cutter:…………………………………………… Count No………….
Type of Material: Learner board insole. Light Brown.
Dept. In charge
Sequence of Operation of Weinbrenner Insole:
Adhesive Apply on insole covering (Vivox) and EVA sheet
Drying Attaching of covering on EVA sheet
Edge folding of covering Cord Stitching around the edge leaving 5mm (Thread No-10)
Scouring at the bottom of lasting margin
Screen printing (Price and Size) Ready to Dispatch.
Quality Control Check Point in Bottom Manipulation:
Is right size insole cut?
Is embossing done properly?
Is insole spraying done properly?
Is right price and size printed?
Is slotting too big?
Insole board moulding pressure not too high?
Is right Shank board Selected?
Is the shank seated in right place?
> Leather board thicknesses are not adequate in all pieces.
> Some Machines are not in working condition.
> Hollow type skiving is doing Counter stiffener edge instead of shallow type.
> Shank is attached without marking.
> Insole moulding duel time is not fixed.
Upper Closing Section:
Cut parts of different types of upper are stitched in this section. Some types of upper leather are cut in mis factory and some are cut in BATA. These are supplied to this factory for stitching/closing operation. All operations are done under BATA specification and procedure. All materials needed to complete these operations are also supplied from BATA. And their respective person supervises manufacturing operations.
Machines used in Closing Section:
|Machine||Action||Origin||Properties||Number of Machine||Remark|
|Sewing||Sewing||PFAFF,Germany,||Model: 1 34-35||2||Active|
|Sewing||Sewing||PFAFF, Germany.||Model: 242||1||Active|
Upper Closing Operation:
Upper closing operations are done as individual requirement and specification.
> During my observation for vamp and quarter joining 110 size needle is used instead of 90 size needle in ongoing Oxford shoe.
> Placement of vamp and quarter of same shoes are not doing all time correct.
> Production schedule is not writing in per schedule board.
Quality Control Check Point for Upper Closing:
Is the folding in curve area are done smoothly?
Are the different uppers assembled accordingto marking?
Is the right type of needle and thread selected?
Are the eyelet holes in equal distance?
Are the loose threads cut?
Before starring operation a production schedule is hung on the wall. Both departments can out men- production according to this schedule. But in my observation period there was no change of this board and that was for past time. It was as follows:
Observation & Recommendations: Although BATA has own production unit they are doing out sourcing. But this products quality is not as own manufactured products. Because the outside operators are not as experienced as own. So there are some matters which should need more attention and precaution. Some are as follows:
For Bottom Manipulation:
•S Measure to maintain proper thickness of Leather Board.
•S During Screen printing operator should take adequate protection.
•S Accurate pressure and duel time of insole moulding should maintain. S Before shank attaching marking must needed.
S During Beveling ere protection and it can be placed in a separate place, so that it does not make noise pollution in production floor.
For Upper Closing:
S Folding at the round area should do more smoothly, accurately and attentively. S Quarter and vamp placement should done accurately so that eyelet facing area must be parallel.
•S Proper selection of needle before use as per specification must need. S Marking for placing counter stiffener is needed.
S In process quality control should take instead of quality control at the end of line.
•S More attention can be given to maintain complianceof operator.
Century Leather Works Ltd.:
It is another ABU of Bata. They produce ready component, sole insole of different types of footwear. It is situate in Hemayatpur, Savar area. It’s aria about 0.5 acres. There are four sections, insole preparation section, PVC granule preparation section, PVC sole preparation, upper and complete sandal preparation unit, hi complete shoe they supply complete shoe. They produce raw materials for PVC sole which is called PVC granules. Productivity of Insole section is about 5000 pairs per day.
Sole Unit 11000 pairs per day.
Complete Sandal 1000 pairs per day.
Observation and Recommendation:
In our visit ongoing complete sandal article is 48-49. In this Sandal there is placement mark of different straps are on the upper visible part. And the hand stitch for lasting is over that is more allowance in lasting area. But this marking should be given in flash side of upper by marking pen. And during lasting should take more precaution.
Conclusion: ABU operation was a new concept of out sourcing footwear component to me. So I have got clear and very good idea, i want to give thanks to Plant Manager, Leather Factory manager, ABU Manager and everyone associate with ABU operation for their help, support and their wise suggestion, instructions. It increases my knowledge and I have got practical working experience.