Assignment on garments factory visit.pdf

Assignment on a garments factory visit.

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BGMEA University of Fashion & Technology (BUFT)



Apparel Manufacturing & Technology (AMT)
COURSE NAME: INTRODUCTION TO FASHION & CLOTHING RELATED INDUSTRY
IN BANGLADESH
COURSE CODE: GMT-1100

ASSIGNMENT ON FACTORY VISIT IN

East West Industrial Park Ltd.

DATE OF FACTORY VISIT
2nd October 2019

REPORT SUBMITTED TO

Md. Monirul Islam (Rajib)
Asst. Professor
Department of Apparel Manufacturing & Technology

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SUBMITED BY

SL. NAME ID
01 Md. Rafiquzzaman 192-071-101
02 Mamunur Rashid Tashin 192-072-101
03 Adham Mahin 192-073-101
04 Debashis Goswami Rudra 192-074-101
05 Shah Abir Mustab 192-075-101





REPORT PRESENTATION DATE
18th November 2019

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Contents

SL. Name of Contents Page
01 Origin of the Report 04
02 Objectives of the report 04
03 Methodology 04
04 Company Introduction 05
05 Company Details 06-08
06 Goal for 2019 08
07 Business units 09-10
08 Types of Department 10-20
09 Recommendation 20
10 Conclusion 21
11 References 21

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Origin of the Report:
To expand the practical knowledge by implementing theoretical knowledge through the in the
factory visiting program that would make a student to become a competitive with the world’s
industrial sector. That program not only increases the knowledge but also give the idea about
organizational activities before entering into an organization.BGMEA University of Fashion &
Technology is one of the reputed private university in Bangladesh, has designed the curriculum
of AMT,KMT & FDT East West Industrial Park se such way that international graduates will be
produced. After competing 1’st semester, one student need to go for further factory visiting
programs in a commercial organization. From this visiting program students get the opportunity
to learn facing the real business world. East West Industrial Park faculty supervisor Md. Monirul
Islam (Rajib), Asst. Professor, BUFT, approved the topic and authorized us to prepare this report
as part of the fulfillment of factory visiting requirement. The report thus was on East West
Industrial Park Ltd.


Objectives of the report:
General Objective: The primary objective of this report is to explore of visiting performance
analysis of East West Industrial Park Ltd.
Secondary Objective:
➢ To show an overview of the company(vision, mission, value, product offerings,
associates companies)
➢ To present an overview of machineries objects.



Methodology:
While conducting the report, East West Industrial Park ltd. were explored for primary
information and data. But hardly any updated data could be found. In the absence of updated
information or data dependence on secondary has been inevitable. However, wherever possibly
primary data has been used. Data were also collected by interviewing the responsible officers
and from the machinery. There have been used some statistical tools (Microsoft Office Excel
table) and graphical representation (Microsoft Office Excel chart) to find out different types of
analytical results and interpretations.

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Company Introduction:
The company is managed by a group of dynamic professionals, working proactively in a
challenging environment. East West Industrial Park is committed to provide excellent services to
its clients. It is dedicated to focus on quality in order to excel in its performance.
This factory effort to delight its customers by producing best quality Textile products at an
optimum price through efficient utilization of available res East West Industrial Park ltd. They
manufacture and export high quality textile products at an affordable price produced in an
environmental friendly process and practicing high level of integrity and fairness in dealing with
East West Industrial Park stakeholders. The mission is to provide excellent quality and value
added textile products at a competitive price for ultimate satisfaction of its customers.
East West Industrial Park Ltd. was initiated by chairman Mr. Harun-Ar-Rashid in 1979. He was
born in 1947 in comilla, Bangladesh. After his completion of Master’s Degree in chemistry from
Rajshahi University in 1969, he went to U.S.A in 1973. In 1980 he came to Bangladesh from
U.S.A. permanently with his family. East West Industrial Park visionary chairman MD Harun-
ar-Rashid along with his Director’s board initiated the first garments unit East West Fashion
Garments Ltd. in Mirpur, Dhaka to established the export of Dress Pant, Blazers and Suits in the
worldwide market, We are one of the pioneers of the Formal Trousers and Suits product. It
opened a new ERA concerning of textile export from Bangladesh.
By 1986 another unit, Fashion Trousers Ltd., was started. For better manufacturing capability
these two units moved to 186, Tejgaon Industrial Area, Dhaka in 1988. After 8 years, to compete
in the global RMG sector, of the 90’s lead the company to move further with their quality and
manufacturing capacity. East West bought 6 Acres of land in 1996 in chayadana, Gazipur. East
West Industrial Park objective was to create and design an international standard RMG
manufacturing complex with the most latest and ethical infrastructure. By January 1997, East
West Industrial Park first 5- storied building was completed. Now we have East West Industrial
Park separated buildings and total 400,000 sft floor spaces & 7500+ workers with run East West
Industrial Park central team. We believe in quality craftsmanship and development as East West
Industrial Park business goal. This philosophy, along with East West Industrial Park central
team, run various operations of the company including- Compliance & Safety, Production &
Planning, Industrial Engineering, Merchandising & Product Development, Quality Assurance &
Technical. These teams are always in the process of improvement to serve you, East West
Industrial Park valuable customers.
We set up East West Industrial Park own textile mill unit named “East West Suiting Mills Ltd.”
in Savar with an annual capacity of weaving 9 lak yards of woven fabric. We produce 100% Poly
and 100% Cotton fabric mainly.
Currently, all East West Industrial Park units are running in Gazipur along with a unit of washing
plant. East West Industrial Park Tejgaon building is the corporate head office and showroom for
East West Industrial Park brand Fit Elegance, which is the retailer of men’s and ladies wear.

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MISSION & VISION:
East West Industrial Park Ltd. mission is to be the consumers’ number one choice in apparel
products by providing our valued customers with a range of the finest quality apparel, through
commitment to innovation, service and value. Our products are only good as our service and it is
why we are committed to serve our customers with the attention and service that they deserve.
We want to bring tomorrow’s fashion today.

Company Details:
Primary Information:
Company Name: East West Industrial Park Ltd.
BKMEA Membership Number: 501
Membership Type: General Member

Contact Information:
HEAD OFFICE
AL-AMIN
Head of Merchandising
• [email protected]
• [phone]
• [phone]

Nusrat Islam Eva
Deputy General Manager
• [email protected]
• [phone]
• [phone]


FACTORY
Chayadana, P.O. National University
Gazipur, Bangladesh.
• [email protected]
• [phone]
• [phone]

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Export Countries for this company:
1. European Union 4. Middle East
2. Japan 5. U.S.A
3. Canada 6. U.K etc.

Main buyers:
1. Raymond
2. H&M etc.

Profile:
Manpower: Existing workforce: 7500+ employees (Approx.)

Member of:
• Bangladesh Garment Manufacturers and Exporters Association (BGMEA)
• Industrial and Business Welfare Foundation (IBWF)

Product Type: Pant, Blazers, Trousers and Suits.

Buildings: East West Industrial Park Ltd. have five buildings.

Area details: Total 400,000 Sft. floor spaces.


Production capacity:
Blazer: 225,000 pcs
Trouser: 350,000 pcs
Waist Coat: 100,000 pcs

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PS. Waist coat capacity convertible into trouser.

Sample Room Capacity:
Blazer: 200 pcs per month
Trouser: 550 pcs per month

Goal for 2019:

No. Indicator Parentage
1 Sewing Target Achievement (%) 98%
2 Sewing Efficiency (%) 65%
3 End - Line DHU (Sewing) < 6.0
4 End - Line DHU (Finishing) < 4.0
5 Rejection Rate (%) (Sewing) < 0.2%
6 Rejection Rate (%) (Finishing) < 0.2%
7 Sewing Non-Productive Time (NPT) (%) < 2%
8 Docket Release OTD rate (%) 70%
9 Rejection Rate Due to Fabric Quality (%) < 0.02%
10 Laboratory Audit Pass Rate (%) 100%
11 Cutting Rejection Rate (%) < 1.0%
12 Sample On-Time Delivery (OTD) Rate (%) 100%
13 Sample RFT (Right at First Time) (%) 100%
14 Initial Pass Rate (%) 100%
15 Inline Pass Rate (%) 100%
16 Final Inspection Rate (%) 100%
17 Customer Complain / Stop-order rate (%) 0%
18 Employee Absenteeism (%) < 2%
19 Employee Turnover Ratio (%) < 2%
20 Worker Injury Rate (%) 0%

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Business units:

RUMANA FASHION LTD.
Established : 1998
Product Range : Blazer & Suits.
Per Day Capacity : Men’s 2,200Pcs, BTS 2,600Pcs
EAST WEST FASHION GA RMENTS LTD.
Established : 1985
Product Range : Dress Pants, Trousers, Shorts & Skurts
Per Day Capacity : Trs 2,500Pcs, Bts 4,000Pcs
FASHION SKIRTS & TRO USERS LTD.
Established : 1997
Product Range : Dress Pants, Trousers, Pinafore
Per Day Capacity : Trs 2,500Pcs, Bts 4,500Pcs
FASHION TROUSERS LTD .
Established : 1986
Product Range : Dress Pants, & Semi-Casual Pants
Per Day Capacity : Trs 2,600Pcs, Bts 5,400Pct
UNITED FASHION TROUS ER LTD.
Established : 1998
Product Range : Dress Pants, Trousers
Per Day Capacity : Trs 2,200Pcs, Bts 4,000Pcs
PANTALOON FASHION LTD.
Established : 2009
Product Range : Trousers
Per Day Capacity : 2,500Pcs
FASHION SUITS & TROU SERS LTD.
Established : 2000
Product Range : Suits & Blazers
Per Day Capacity : 1000Pcs

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ALIZA FASHION LTD.
Established : 2010
Product Range : Suits & Blazers
Per Day Capacity :Bts 3,600Pcs

ALVIN FASHION LTD.
[Established: 2010
Product Range: Suits & Blazers
Per Day Capacity: Bats 3,600Pcs]

EAST WEST SUITING MI LLS LTD.
Weaving section has 40 set machine which is smith rapier loom (Italy) & Tsudakoma (Air jet
High Speed).The machine capacity per day is 15000 Yards. Dyeing section has 9 set machine
which is Jet dyeing machine (Sky-Korea) & Jigger dyeing machine (Sky-Korea).The machine
capacity per day is 30,000 yards. Finishing section has 5 sets stented Decca Dosing Machine,
Sulfurizing Machine, Fabric Inspection Machine & Fabric rolling machine.

Types of Department:
Marker:
Marker is a thin paper on which all pattern pieces for all sizes for a particular style of garments
are drawn in such way that maximum fabrics will be used and fabric wastage will be minimum.


Figure: Marker

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Store Department:
For a bulk production industry it is essential to maintain a well-organized & well equipped
inventory system. The main responsibility of this department is to store all the raw material
necessary to produce garments. This department is sub divided into three sections.


Figure: Store section

Cutting Department:
Cutting section is one of the most important sections for manufacturing garments in garments
industry. Cutting means to cut the garment pieces from fabric lay with the help of cutting tools
and markers.
Two types of cutting machines are used in this garment: Straight knife cutting machine. Band
knife cutting machine. Activities of the cutting room in the garments: At first received fabric
from the store room. After that fabric relaxation. Making marker on marker paper by pattern.
Spreading fabric on cutting table. After that marker paper is spread on fabric layout. Fabric cut
by straight knife cutting machine and band knife cutting machine. All cutting parts are
numbering. All cutting parts are checked by the pattern. 100% cut panel check. Bundling all
panels and counting all parts. Replacing cutting (if any fault parts).East West Industrial Park
have fully complete digital Cutting section.

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Figure: Manual cutting machine

Figure: Digital Cutting machine

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Sewing Department:
Sewing section is one the most important department for manufacturing garments in garment
industry. All the parts of garments are joined by stitch with the help of needle and thread.
Different types of sewing machine name: Lock stitch machine. Kansai machine. 2 needle
machine. Chain stitch machine. Feed off the machine. Bar tack machine. Button hole machine.
Button attach machine. Fusing machine. Vertical plane machine. Thread removed machine.
Collar cutter machine. Formic machine. Turning machine etc. Activities of sewing section in
garment: Received the cutting parts from cutting room. After that all the cutting parts are joined
by stitching. East West Industrial Park have fully complete digital Sewing section.

Figure: Sewing section

Labeling Department:
A garment label is a communicator between the buyer and product. A garment label contains
various types of information of that garments, such as buyer name, country of origin, types of
fabric, types of yarn, fabric composition, garments size, special instruction about care etc.
Without any types of label a garment cannot be sold in the foreign market.

Figure: Label section

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Finishing Department:
Finishing section finishing section is one the most important section in read made garments
sector. It’s the last section of garments manufacturing department. Here, all garments are finally
prepared such as checking, ironing, measuring, poly and packing. Working process: In side
checking. 100% outside quality check. 100% measurement check. Size ration checking and color
shade checking. Price tags attach. Packaging or cartooning. East West Industrial Park have fully
complete Finishing section.

Figure: Finishing section

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Sample Department:
Garment samples are inevitably important and are developed tested before starting the bulk
production. It means making a sample of the garment /fabric which requires to be sold. Sampling
is one of the main process in Garment Industry and it has a vital role in attracting buyers.
Because the buyers generally places the order after they are satisfied with the quality of the
samples.



Sampling Process Flow Chart:

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Merchandising Department:
Merchandiser is the interface between Buyer & Exporter. He is the responsible from order
analysis to shipment. So Merchandising is the very valuable department in the Apparel Industry.
This Article explains the main responsibilities of merchandisers.

Merchandising is the department which mediates marketing and production departments.
Sometimes, merchandising department will have to do costing and pricing also. In any case, the
merchandiser is the person whose responsibility is to execute the orders perfectly as per the
costing and pricing. So it is a very valuable department.

CAD Department:
CAD is the contraction which stands for Computer Aided Design. This term means different
things to different people involved in designing, manufacturing and mechanical engineering.
CAD or Computer Aided Design has brought a revolution in the Textile industry, specially in
apparel industry. The time consuming and cumbersome process of textile designing has been
made easier by CAD.




Figure: Cad section

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Quality Control Department:
We know that every manufacturing process, ensure product quality is very important. Without
ensuring the quality than the products or goods are not accepted. So we need to ensure the best
quality of products. Quality is a relative term which varies according to the customer demand. In
sense, quality means customer needs is to be fulfilled. Quality control is a very important term
for garments export order execution. In this competitive world, there has no other option of
quality. World’s business trend is now ensuring the product quality, not to quantity. In the
garment business buyer’s satisfaction is the main and essential goal. In this article, I will give
Quality control flow chart in garment section.

Figure: Quality Control

Quality Control Flow Chart in Garments Section:
Order receive from the buyer
⇓
Material receiving
⇓
Fabric & accessories
⇓
Pre-production meeting
⇓
Cutting section
⇓
Spreading

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⇓
Spreading inspection 100%
⇓
Cutting
⇓
Cutting inspection random
⇓
Numbering & bundling
⇓
100% Cut panels
⇓
Line input
⇓
Test cutting inspection
⇓
End line 100% component inspection
⇓
End line 100% inspection
⇓
Finishing section
⇓
Finishing inspection inside / top side
⇓
Finishing final after iron
⇓
Finishing statistical audit
⇓
Carton packing section

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⇓
Daily Pre-final audit on finished cartons.
⇓
The final audit was done by buyer representative.
⇓
Audit pass
⇓
Cargo leaves the factory


Garment Packaging:
Garment packaging is the procedure of wrapping, compressing, filling or creating of goods for
the purpose of protection too their appropriate handling. This is the concluding procedure inward
the production of garments, which prepares the finished trade for delivery to the customer. It is
an of import part of the garment manufacturing process.


Figure: Packaging

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Shipment:
After packaging final products delivered to the buyer by air, road or ship. It is the last stapes of
the company work.

Shipment


Recommendation:
1. Should provide tiffin for the workers.
2. They should provide 2 brakes time with 30 mentis for work efficiency.
3. As soon as they should convert to green factory to save nature.
4. Ensure all workers so that uses the mask

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Conclusion:
East West Industrial Park Ltd. is one of the leading textile industries having history of
decades, is providing premium quality textiles. It has achieved this far-fetched position
by following strong commitment to the clients by giving them top quality products and
services.

Strong sense to adopt latest technical innovation, having a glance over worldwide vogue
in garments industry and giving full fledge dedicated services to the clients is the main
key factor of East West Industrial Park Ltd. vertical growth.

East West Industrial Park Ltd. has a marked position in International garments Industry
for its commitment and responsiveness to customers’ satisfaction.

East West Industrial Park Ltd. produces complete variety of garments ranging from grey
fabric to highly profiled made ups. Its export vicinity has vast borders from Europe,
USA, North & South America, Russia & CIS States to Scandinavian countries.

With the slogan “We Are the Safe Suppliers” East West Industrial Park Ltd. is
transforming this ideology into reality through excellent, skilled and dedicated, above
2500 employees who assure the best availability of products & services in the hands of
clients. East West Industrial Park Ltd. Quality Assurance Department insures the best
quality of products at every following step.


References:
1. https://www.eastwestindpark.com/main/
2. https://www.eastwestindpark.com/main/about-us-ew/
3. https://www.eastwestindpark.com/main/cutting/
4. https://www.fibre2fashion.com/industry-article/5743/merchandising-in-an-apparel-
industry