Concorde Garments Internship Report on Running an RMG Factory

An Internship report on Concorde Garments Group
1. Internship Report on How to run an Export Oriented RMG factory and why worker
unrest happening in Bangladesh BY MD.MATIUR RAHMAN 1 EXECUTIVE SUMMARY:
The Readymade Garment (RMG) industry of Bangladesh tells an impressive story of
country successful transition towards a major export- oriented economy. Starting its
journey in the late 1970s with relatively small investment, the industry flourished in
1980 and 1990 and has become the largest industry in Bangladesh. The
contributory factors of the RMG industry in Bangladesh are global trading
agreement, cheap labor cost, government policy support and dynamic private
entrepreneurship. All these things have helped Bangladesh to gain a handsome
share in the global garment business. From early 1990 onwards the RMG industry
has become the largest foreign exchange earning sector in the economy. In 2005-
06, Bangladesh earned nearly $ 8 billion by exporting garment products and RMG
cover 75 percent of the total export of the country, having the lions share of the
countrys exchange. Contribution of RMG is very positive in Bangladesh economy,
sharing 13 percent of the total national GDP. Moreover the industry has become a
vehicle for further industrialization of the country. The focal point of Concorde
Garments Group (CGG) has been founded in 1983 and since then accelerated to its
journey with the commitment to the society to build prosperous Industrial backbone
for socio-economic development of the country. After almost 21st economic years, it
has established a number of diversified and potential buyers throughout the world
for manufacturing and marketing of a wide variety of consumers and export
oriented products. Presently, Concorde Garments Group (CGG) is one of the leading
Garments Companies in Bangladesh, which has been contributing buyer agency
activities in a large extent of the country by providing quality branded-generic
Garments. The organization believes in 'Quality never ends' and refuses to settle for
anything until it exceeds the existing standard. The company has been awarded
with the ISO-9001: 2000 Certificate in January 1985 for serving its valued customers
with products of excellent quality. As the principal aims and objectives of Concorde
Garments Group (CGG), are to improve professionalism in the contemporary
garments ware business arena as well as to realize the authentic demands of
garment goods throughout the 3rd world countries. Thus CGG organizes seminars,
discussion forums, workshops, professional training courses, continuing education
programs, cultural events and publishes newsletters etc. as parts of its professional
unrest happening in Bangladesh BY MD.MATIUR RAHMAN 2 activities. All this
activities has been done to observe out the actual current SWOT analysis
circumstances of the organization. By which the executive board gets some feasible
idea of future strategic moves of the organization. However, CGG always believes
that a creative Human Recourse can build a modern country. Because, fairly a well-
established human resource management can built a constructive organization
likewise some constructive organizations can build a modern country. However,
nowadays HR Department is considerate as the Mutual Bridge of making eventually
understandable decisions between all the departments among an organization. How
and why is that? The answer is Since each department is Human Oriented and
HRM deals with every individual human being or employee working in an
organization, this statement is true as well as valid one. So HRM decrease the
distances and conflicts between the employees of all the departments as well as
enhance the work efficiency of the workforce which eventually results a certain
amount of profit maximization for the companionship. Finally a profitable company
must contribute to the economy of the countrys development.
unrest happening in Bangladesh BY MD.MATIUR RAHMAN 3 PRESENT SITUATION OF
RMG SECTOR IN BANGLADESH: There is that old adage, dont kill the golden goose.
Why I compare Bangladesh garments sector with the golden goose? The reason is
the garment sector in Bangladesh has been giving for many years. Bangladesh is
the second largest exporter of readymade garment products trailing China
according to the McKinsey report (2011). Bangladeshs garment exports during July-
June 2012-13 period climbed by about 12.7 percent to US$ 21.515 billion over
exports of US$ 19.089 billion made during the corresponding period of 2011-12. In
2012-13, the top three export destinations for Bangladesh garments were Europe,
which accounted for US$ 12.56 billion, followed by the US and Canada, which
accounted for US$ 4.99 billion and US$ 980 million, respectively. But now it has
received bad news. Recent incidents like fire in the Tazreen Fashions factory in
November 2012 that killed more than 110 and the collapse of the Rana Plaza
garment factory building in April 2013 that killed over 1,100 people and more than
2,500 were injured in the disaster. It may be the second biggest industrial accident
in recent history. As a result, The President Barack Obama-led US government in last
year June suspended Bangladesh from the Generalized System of Preferences
(GSP), which allows duty-free entry of over 5000 goods to the US market from least
developed countries. Now, RMG products (which make up most of the US import
from Bangladesh) are not included in the list of duty-free products in GSP, there will
an export fall of about $40 million .At present, Bangladesh exports about $5 billion
worth of goods (mostly RMG products) to the USA every year and hence, the
suspension from US GSP will account for a fall in export of about 0.8 %. Losing the
GSP facility will cost Bangladesh millions of dollars in taxes. It is also influence the
European Union to take similar action, which would have a much bigger impact on
Bangladesh and its garment sector. In August, Garment factory workers clashed
demanding a Taka 8,000 minimum monthly wage. Many factories closed for
clashing. The owners finally agreed to pay Taka 5,300 as prescribed by a
government- endorsed wage board on Nov 4. In November, 18,800 people lost their
work for fire in Standard Group. The factory was among the ten biggest in the
country and it was the biggest supplier of Gap from Bangladesh. The loss to the firm
could run into more than US$100 million. In December, The European Parliament
has threatened to withdraw GSP, the duty and quota-free access to EU market that
Bangladesh enjoys. The European Union buys more than $12 billion in Bangladeshi
garments each year, or roughly three-fifths of the countrys production. If the EU
were to withdraw or suspend the facility, the price per unit of garment will rise and
this may lead to many European buyers turning their backs on our products.
unrest happening in Bangladesh BY MD.MATIUR RAHMAN 4 So, Bangladesh would
suffer a huge setback. Due to the recent political unrest, Bangladesh RMG sector
losses in billions of taka every day. The blockades have put the garment sector in a
tight corner as exporters are counting losses from order cancellation and rising
transport costs. Buyers are cancelling orders as exporters fail to meet the lead time
due to transport crisis. Some buyers are also imposing penalties in case of delayed
shipment, cutting prices of garment products and transport costs have surged by
around 30 percent due to expensive air shipment. Many factories have halted
production as they cant bring imported raw materials from ports. The BGMEAs
research and development team has collected three-day data (December 1-3) from
10 exporters to assess the overall losses caused by the blockade. Orders worth
$3.96 lakh were cancelled during the period, while the exporters spent $3.08 lakh
on air shipment. Many small factory owners may go bankrupt due to failing
shipment on time. So thats the trap: the golden goose is caught between a rock
and a hard.
unrest happening in Bangladesh BY MD.MATIUR RAHMAN 5 PART: 01
ORGANIZATION PROFILE & OVERVIEW
unrest happening in Bangladesh BY MD.MATIUR RAHMAN 6 01. INTRODUCTION: At
independence in 1971, most observers of the newly emerged country took a
pessimistic view about the developmental prospect of Bangladesh. Many thought
that the country would remain permanently locked in a below poverty level
equilibrium trap. Although there is little room for complacency Bangladesh has
come a long way from there. About two-fifths of the economy is now connected with
the global economy through exports, imports, factor and commodity markets; the
degree of openness of the economy currently stands at 40%. Bangladesh can now
rightfully claim that she has graduated from a predominantly aid receiving nation to
a trading nation. The export-oriented RMG sector has made crucial contribution to
this above mentioned transformation of the Bangladesh economy. The role of our
RMG entrepreneurs, domestic fiscal and financial, institutional policy support and
incentives put in place by successive governments, substantial RMG-supportive
linkage activities within the domestic economy and global market opportunities
combined to create a story which is, to be honest and true, unparalleled in the
developing world. When jute and jute goods were losing their traditional markets,
with the prospect of drastic fall in forex earnings it is the RMG sector which came in
first to replace it, and then to overtake it. While traditional export sector could not
yield expected results, the RMG sector gradually injected dynamism in the export as
well as in the domestic economy though backward and forward linkage economic
activities. The export-oriented readymade garments (RMG) sector in Bangladesh
started its journey in late 1970s as a small non-traditional sector of export.
Bangladesh exported RMG worth only US$ 69 thousand when Reaz Garments
exported its first consignment to USA in 1978. By FY 2002, within a span of about
two decades exports have gone up to US$4.5 billion. Over the past decade alone,
the sector registered a phenomenal growth rate of 15 percent per annum, which is
impressive by any standard. In fact, this was an exceptionally high growth rate for
an emerging industry anywhere in the world. The industrial base which sustained
such high growths also enjoyed a robust expansion, from less than 50 factories in
1983 to more than 3,400 in 2002, with the number of RMG workers reaching
approximately 1.5 million. Despite many difficulties faced by the sector over the
past years, it continued to show robust performance, competitive strength and, of
no less importance, social commitment. RMGs contribution to Bangladesh economy
is well-known, well-appreciated and well-respected. However, often times the
magnitude of its multiplier impact and implications will justify the support that this
sector has been given over the past years and also the support it is currently
seeking from the government? In FY2002
unrest happening in Bangladesh BY MD.MATIUR RAHMAN 7 Bangladesh exported
RMG products worth 4.5 billion US dollars. Here share in total US imports of apparels
was 3.2% in EU it was 3.3% and in Canada it was 3.0%. Bangladesh is known in
these countries as a small country with a strong presence. Everywhere, RMG serves
as a flagship product of our country, inducing peoples interest in Bangladesh both
as a tourist and investment destination. These are the impacts which are difficult to
quantify, yet without which the country perhaps would not have been able to project
itself to a trajectory of high growth and higher standards of living. Thus, RMGs
contribution to Bangladesh, both direct and indirect, needs to be recognized for
what it is. In the following pages, an attempt is made to quantify the key role that
RMG has come to play in the economy of Bangladesh. The RMG sector has also
played a significant role in the social metamorphosis in a broader context. This
paper attempts to qualify aspects such as women empowerment, population
control, education, environmental awareness, elimination of child labor which
contributed to overall improvement in the HDI (Human Development Index)
Indicators. It should be noted that the study is not exhaustive, and can be further
improved upon. 01.01. THE RMG SECTOR IN BANGLADESH: 01.01.02. OVERVIEW OF
THE RMG SECTOR: The economy of Bangladesh is largely dependent on agriculture.
However, in recent years, the Ready-Made Garments (RMG) sector has emerged as
the biggest earner of foreign currency. The RMG sector has experienced an
exponential growth since the 1980s. The sector contributes significantly to the GDP.
It also provides employment to around 4.2 million Bangladeshis. An overwhelming
number of workers in this sector are women. This has affected the social status of
many women coming from low income families. The readymade garment (RMG)
sector is one of Bangladesh's most important industries for employment. (Reaz-Bin-
Mahmud, Skills development in Bangladesh RMG sector, 2014) 01.01.03. HISTORY:
In the 1950s, labors in the Western World became highly organized; forming trade
unions. This and other changes provided workers greater rights including higher
pay; which resulted in higher cost of production. Retailers started searching for
places where the cost of production was cheaper. Developing economies like Hong
Kong, Taiwan and South Korea
unrest happening in Bangladesh BY MD.MATIUR RAHMAN 8 presented themselves
as good destinations for relocations because they had open economic policies and
had non-unionized and highly disciplined labor force that could produce high quality
products at much cheaper costs. In order to control the level of imported RMG
products from developing countries into developed countries, Multi Fiber Agreement
(MFA) was made in 1974. The MFA agreement imposed an export rate 6 percent
increase every year from a developing country to a developed country. It also
allowed developed countries to impose quotas on countries that exported at a
higher rate than the bilateral agreements. In the face of such restrictions, producers
started searching for countries that were outside the umbrella of quotas and had
cheap labor. This is when Bangladesh started receiving investment in the RMG
sector. In the early 1980s, some Bangladeshis received free training from Korean
Daewoo Company. After these workers came back to Bangladesh, many of them
broke ties with the factory they were working for and started their own factories.
01.01.04. FACTS & FIGURES: In the 1980s, there were only 50 factories employing
only a few thousand people. Currently, there are 4490 manufacturing units. The
RMG sector contributes around 76 percent to the total export earnings. In 2007 it
earned $9.35 billion. This sector also contributes around 13 percent to the GDP,
which was only around 3 percent in 1991. Of the estimated 4.2 million people
employed in this sector, about 50 percent of them are women from rural areas. In
2000, the industry consisting of some 3000 factories employed directly more than
1.5 million workers of whom almost 80% were female. USA is the largest importer of
Bangladeshi RMG products, followed by Germany, UK, France and other E.U
countries. 01.01.05. THE FUTURE: The RMG sector is expected to grow as many
small and medium industries have grown here over the years. To meet high demand
from low-end garment makers, zippers, buttons, labels, hooks, hangers, elastic
bands, thread, backboards, butterfly pins, clips, collar stands, collarbones and
cartons are the major garment accessories that are being produced in Bangladesh.
(Source: http://www.thefinancialexpress-bd.com/index.php) Several studies have
shown that Bangladesh has immense potentials for garment business in the coming
years. International buyers are shifting to Bangladesh with the increased orders,
unrest happening in Bangladesh BY MD.MATIUR RAHMAN 9 as the cost of
production in other competing countries including China has soared abnormally.
However, there is no dispute that the most vital role behind our RMG sectors
success is playing by cheap labor, which has given the Bangladesh garments sector
an extra advantage with its rivals. 01.01.06. CONCORDE GARMENTS GROUP
PROFILE: Concorde Garments Group, one of the oldest readymade garments
manufacturer and business houses in Bangladesh, is a market leader in the
manufacturing and exporting of garments, textiles, IT and glass products. CGG
relentless pursuit towards high quality products, created by talented and hard-
working workforce, who are amongst the most experience and well-trained in the
country, have enabled CGG to be in the position that enjoy today. Concorde Group,
based in Bangladesh, is a group of Industries with sustained goodwill and expertise
in exports oriented ready-made garment manufacturer. Founded in 1983 by Mr.
Sayeeful Islam, the current Managing Director. The 7th garment factory in
Bangladesh. Set up with the help of German and Korean technicians. Located
in Mirpur (Concorde Garments Ltd.) and Elephant Road area (Tulip Garments Ltd.),
which are at the center of Dhaka, Bangladesh. Concorde Group post MFA strategy
has been based on quality and reliability supported by large production capacities,
backward linkage, professional management, refined technology, and market-
oriented value-added basics. An ISO 9001:8000 certified factory Has three
decades of manufacturing and exporting garments; one of the pioneers in the
garments industry in Bangladesh One of the few factories in Bangladesh that can
make fully-taped shirts CGG is run by expats with decades of experience in this
field Sample section is right next to CGGs merchandising section; as such, CGG
are very good in developing new styles and products for their buyers. From 1st
January, 2011, Bangladeshi products, even those with single-stage conversion, will
have duty free access to the EU.
10. Internship Report on How to run an Export Oriented RMG factory and why
worker unrest happening in Bangladesh BY MD.MATIUR RAHMAN 10 CGG have
been in the ethical shirt and blouse manufacturing business for over three decades
now, and the company believes that they can lay claim to be a market leader and
trendsetter in this industry in Bangladesh. Throughout the decades of their
existence they concentrated on specializing in the production of a single category:
woven tops shirts and blouses, and created their own niche in the market. CGGs
biggest asset they feel their workers, many of whom have been with them for
decades, who with their training that CGG have provided over the years, and their
experience and efforts, have grown to be amongst the best in their field, in the
country. CGGs total factory area, located in 2 centers in the heart of Dhaka, the
capital of Bangladesh in is approximately 125,000 square feet in two premises,
which are socially complied with all local laws, and as per the requirements of the
best retailers in the world. CGG has over 2500 employees and a highly trained,
skilled, efficient & dedicated manpower and management system. New and state of
the art machinery enables them to continue to sustain a high quality production & a
prompt delivery schedule. CGG takes on the challenges of change in the apparel
industries and also keep up to date with current fashion trends and requirements.
CGGs factory has achieved the below globally recognized certifications with
regards to social compliance: GSV ISO 9001: 2008 CT-PAT WRAP
Worldwide Responsible Apparel Production WCA Workers Conditions
Assessment
worker unrest happening in Bangladesh BY MD.MATIUR RAHMAN 11 01.01.07.
STATISTIC / CAPACITY: CONCORDE GARMENTS LTD. 15 production Lines;
700 sewing machines, about 40% of which are auto-trimming. 1850 employees
95,000 sq. feet factory area. Monthly production capacity: 450,000 ~ 500,000
PCs. Specialized production capacity out of total capacity. Armhole & Side Seam
Fused shirts 300,000 pieces each per month. Fully taped/Fused shirts 2,
50,000 pieces/month. TULIP GARMENTS LTD. 4 production Lines 225 sewing
machines, about 40% of which are auto-trimming. 500 employees. 35,000 sq.
feet factory area. Monthly production capacity: 100,000 ~ 125,000 PCs. By
mid-2014, with CGGs new unit, CGG is expecting the combined capacity will
increase up to Total 30 production Lines; Total 900,000 PCs Shirts and Ladies
Blouses per month By mid-2014, with CGGs new unit, CGG is expecting the
combined capacity will increase up to: Total 32 production Lines; Total
900,000 PCs Shirts and Ladies Blouses per month
worker unrest happening in Bangladesh BY MD.MATIUR RAHMAN 12 01.01.07. LIST
OF ALL MACHINE IN CONCORDE GARMENTS GROUP: Sl. No Name of Machine
Quantity 1 SNLS(with thread trimmer) 1122 2 SNLS(with Edged cutter) 153 3 SNCS
153 4 DNLS 102 5 5 Needle Over lock 51 6 FOA(Feed of the arm) 102 7 MNLS
(Kansai) 51 8 Button Hole machine 153 9 Button attach machine 102 10 Bartack
machine 51 11 Fusing Machine(Coller and Calf) kannegiesser 4 12 Body part fusing
machine 17 13 Electric fabric cutting machine 56 14 Coller forming machine 18 15
Coller turning machine 51 16 Thread shucker machine 15 17 Steam iron table and
iron 135 18 Coller band machine 5 19 Metal detector machine 3 20 Barcode
checking machine 4 Total Quantity of Machine in CGG Factory 2348 Fig 01.01: ALL
MACHINE IN CONCORDE GARMENTS GROUP
worker unrest happening in Bangladesh BY MD.MATIUR RAHMAN 13 01.01.08. All
MACHINE PICTURE WHICH USING IN CONCORDE GARMENTS: Fig 01.02: All MACHINE
PICTURE USING IN CONCORDE GARMENTS
ORGANIZATIONAL STRUCTURE: CGG employ around two thousand one hundred
skilled workers and one hundred and fifty supervisory and managerial staff in CGGs
production facilities. Planning, Production, Procurement, Merchandising,
Marketing, Human Resources, and Administration are located at the Mirpur site
while finance, shipping, logistics and information systems are located in CGG
corporate office at Karwan Bazar, Dhaka. Eighty percent of the workforce is
women, which is a significant contribution to women's empowerment in a
developing country like Bangladesh. Management staff consists of a healthy
combination of national and international recruits, designed to provide CGG with the
necessary capacity to successfully compete in global manufacturing and export.
01.01.10. ACCEPTABLE QUALITY LEVEL (AQL): Concorde Garments group has been
working with 2.5% AQL for their best quality service to their customers.
worker unrest happening in Bangladesh BY MD.MATIUR RAHMAN 15 01.02. BOARD
OF DIRECTORS: Sl. No. Name Designation 1 Mr. Sayeeful Islam Managing Director 2
Mr. Raiyan Islam Director 3 Brigadier general Rabbani (Ret.) CEO 4 AKM Sohan Alam
CFO 5 Mr. Induka N Sudirikku Director Production 6 Major general Aktaruzzaman
(Ret.) GM-HR 7 Mr. Aktar Hossain DGM- Marketing Fig 01.03: BOARD OF DIRECTORS
01.03. ORGANOGRAM OF CONCORDE GARMENTS GROUP: Fig 01.04: ORGANOGRAM
OF CONCORDE GARMENTS GROUP
worker unrest happening in Bangladesh BY MD.MATIUR RAHMAN 16 01.04.
PRODUCTION PROCESS AND TECHNOLOGY: Modern apparel manufacturing
techniques have been adopted to ensure optimum efficiency. The factory has the
latest in labor saving and time efficient machinery to enable it to compete in the
world market. Style analysis, risk analysis, layout planning and production targets
based on Standard Minute Values (SMV) are defined by the Industrial Engineering
department to ensure that planning is meticulous and shipments are on time.
Production monitoring system using bar coded tickets ensures accurate recording of
work-in-progress and provides management with live production data. This helps
production management to be proactive in correcting potential imbalances within
the process and provides invaluable data to monitor operators' efficiency. 01.05.
CGG UNIQENESS: Bangladesh has a mature garment industry with a tradition of
more than thirty years of Export to international markets. Its society has a thousand
year old history of harmony and homogeneity among major religious and ethnic
denominations, and is founded upon ethical, social and family values. Bangladesh is
a signatory to major international Treaties upholding labor and human rights.
Concorde Group has successfully harnessed the benefits of its investments and
managerial expertise to cater exclusively to ethically complied high street retailers
and department stores around the world. Innovative and Higher quality products,
response to fashion trends and market needs as well as large Production capacities
have established it as a well-known vendor of woven-tops from Asia. Best Quality
Best Product Safety Best Price Training Production Process and
Technology
CONCORDE GARMENTS GROUP TIME LINE: Year Progress 1983 Founded Concorde
Garments Limited (Mirpur) 1985 Founded Tulip Garments Limited 1988 Formed in a
Group of Company 1992 Founded Osman Interlinings Limited 1995 Opened C&F
Agency 1998 Formed Architectural Glass Manufacturing Company 2003 OIL teamed
Join ventured with Doublegull Interlinings Ltd 2004 Formed SSL Wireless 2005
Formed Osman Accessories Ltd 2014 Newly Inaugurate Concorde Garments Limited
(Kathgora) Fig 01.05: CONCORDE GARMENTS GROUP TIME LINE 01.07. SISTER
CONCERN OF CONCORDE GARMENTS GROUP: 01. Concorde Garments Limited
(Mirpur) 02. Tulip Garments 03. Osman Interning 04. Osman Accessories Limited 05.
Architectural Glass 06. Concorde Garments Limited (Kathgora, Savar) 01.08.
PRODUCTS: Concorde Garments Group Produces vast category garments products
ranging from various types of shirts, pants, ladies blouses, knit wares, sweaters etc.
to other products like decorative glass and software. It is well-known for its
uncompromising product quality which uses state of the art technology in
production.
GARMENTS: The garments sections of Concorde Garments Group produces different
types Of shirts, blouses, Knits, pants, sweaters, suits, jackets and undergarments.
01.10. JUTE PRODUCTS: With the growing demand for Eco-friendly products
nowadays, Jute has become extremely popular in the recent past, its demand being
for products such as bags, fabric, carpets, ropes, wine bags, etc. We will be able to
fulfill all your needs with regards to jute, also popularly known as The Golden Fiber
and its related products. Having an office in Bangladesh, the world leader in jute
products, we are able to provide the highest quality jute products at the most
competitive prices. 01.11. SRATEGIC BUSINESS UNITES: We have taken our
manufacturing skills and expanded the knowledge and management skills and have
own various other strategic business units to produce various products. We also
have sound joint ventures with Chinese manufacturers to produce Interlining. Each
of the business units has kept to some degree of their unique identities, which helps
customers and staff to remember the long and proud histories of CONCORDE
GROUP.
INTERLINING: Osman Interlinings Limited (OIL), a concern of Concorde Garments
Group, was formed in 1992 to supply high quality interlinings to the garments
industries. In 2003, OIL Teamed up with Double gull Interlinings Ltd., the largest
interlining manufacturer in the Peoples Republic of China, and formed OTL-Double
gull Manufacturing Company, a Joint venture company that currently manufactures
interlinings, and is located in the Export Processing Zone (EPZ) in Dhaka,
Bangladesh. Currently, OTL-Double gull Manufacturing Company is the largest
manufacturers of woven and non-woven Interlinings in Bangladesh. OTL-Double gull
Manufacturing Company's interlinings are nominated for all high-end buyers, and
current manufactures about 200 types of Interlinings. Interlinings are made here
under strict quality controlling mechanisms. A Thorough company profile of OIL can
be provided on request. 01.13. ACCESSORIES: Keeping in mind the need for quick
delivery of accessories, Concorde Garments Group formed Osman Accessories Ltd.
(OAL) in 2005 to source high quality accessories for itself and the emerging
garments factories of Bangladesh; OAL is currently sourcing all required
accessories from different accessories factories under strict quality monitoring
processes and supplying to the leading garments industries.
worker unrest happening in Bangladesh BY MD.MATIUR RAHMAN 20 01.14. C & F
AGENCY: We have our own C&F agency to help import and export our products. Our
C&F personnel are located at all regulatory port areas like Dhaka Airport, Dhaka ICD,
Chittagong Port, Benapole Port, etc. Having own C&F agency helps us release
imported goods quickly, at relatively competitive cost. This also helps while
exporting the goods. We also have our partnered transport agency to transport our
raw materials from various ports to our production units and export the same to
nominated ports. This reduces the hassle to wait for transportation in case of
urgency and during rush season. 01.15. SOCIAL COMPLIANCE - CODE OF CONDUCT:
Concorde Garments Group is a responsible and ethical apparel producer and
embodies, both in spirit and practice, internationally established codes of social
accountability and ethical business practices. It recognizes and respects cultural
differences and employs individuals solely on the basis of their qualification for the
job. It identifies and works with suppliers and buyers who as individuals and in the
conduct of their business abide by local laws and have ethical standards compatible
to its own. The basis of the various parameters that comprise the code of conduct
are drawn from the following: Ethical Trading Initiative Global Sourcing
Principles of Key Customers ILO Conventions Local Legislation CGG factory has
received the following high level certifications due to CGG quality and social
compliance standards, and CGG commitment to constantly improving the working
conditions of CGG employees: Worldwide Responsible Apparel Production (WRAP)
Gold level ISO 9001: 2008 Workers Conditions Assessment (WCA)
Assessment Award Global Security Verification (GSV)
worker unrest happening in Bangladesh BY MD.MATIUR RAHMAN 21 The following
are some characteristics of our factories: Safety features: Protective gear for
Operators. Clearly marked aisles and exits. Separate spot removing room with
exhaust fan. Boiler room surrounded by 10 inch thick concrete wall. Needle-
guard for every sewing machine. Metal Hand-Gloves for Cutting Operators. 01.16.
SECURITY FEATURES: CTPAT (Customs-Trade Partnership against Terrorism)
Approved. Barbed wire all along factory walls; Secure warehouse for safe
storage of fabric, accessories and finished goods; Close Circuit TV for
surveillance; Well trained security personnel; Carton and Finished Goods
Storage section accessible ONLY by authorized personnel 01.17. MICSLLENIOUS
FEATURES: No child labor Time card system Employee notice board to keep
them aware of their rights and latest developments Welfare officers constantly
training the employees about their rights, and other relevant issues facing them
Loud speakers to make announcements if necessary 2% of the workers are
trained in using CPR Floor mats provided to all employees with standing jobs
Training center for giving necessary education to employee Separate clean toilets
with for males and females with liquid soap and hand dryers
worker unrest happening in Bangladesh BY MD.MATIUR RAHMAN 22 Lockers for
all employees to safely keep their valuables Water cooling system to provide
workers a comfortable temperature to work in About 4% of the workers are
trained in how to administer First Aid. Employee benefits: No excess overtime
Paid Maternity leave benefit as per Govt. law Doctors room with full-time doctor,
nurse and 1 bed for every 500 workers Eid (religious festival for the Muslims)
Bonus given during the two Eids of the year Safe drinking water for all
employees (ground water that further goes through a Process of filtration)
Childcare room with a bathroom, located near exit Canteen with seating
arrangement for 30% of the workforce Dry Food shop for all employees
Clean and congenial working environment Unused Annual Leave Payment Airy
and well-lit workplaces First Aid Box for every 100 workers Fig 01.06: YEAR ON
YEAR PROGRASS Year on Year Progress 0 20 40 60 80 100 120 140 160 1983-1990
1991-1995 1996-2000 2001-2005 2006-2010 2011-2013 Yearly Turnover In Million
USD
worker unrest happening in Bangladesh BY MD.MATIUR RAHMAN 23 01.18. MAJOR
CLIENTS OF CONCORDE GARMENTS GROUP: Fig 01.07: MAJOR CLIENTS OF
CONCORDE GARMENTS GROUP
BUSINESS ACHIVEMENT OF THE GROUP: In our constant endeavors to improve our
factory and conditions of our workers, Concorde Garments Ltd has achieved the
following high-level certifications in the field of quality, ethical trade and social
compliance: Certification Name Certificate Global Group ISO 14001 ISO 9001:2008
WRAP Sedex GSV WCA (http://www.concordegarments.com/index.php/garments-
units/achievements)
CORPORATE SOCIAL RESPONCIBILITY: Concorde Garments CSR commitments are as
mentioned below: Recruitment of physically challenged individuals TVET Project
with CRP and ILO Yearly Eye Camp for employees Quarterly 0-5 Clinic for
workers children Free ultra-sound and medicine for pregnant female workers
Sponsored IT laboratory in Dhaka University and BAF Shaheen School, Dhaka
Distributing free newspapers among students and teachers in various universities
Contribution for SIDR effected people Garments & Blankets for poor
people during winter Co-sponsored to Asian Games qualifying round Hockey
Tournament in 2006 and 2010 Early Childhood Development (ECD) project
with USAID and Save the Children. 01.21. GREEN (ENVIRONMENT) INITIATIVE:
CONCORDE GARMENTS GROUP is one of most renowned environment friendly
textile production facility in Bangladesh. Our environment initiatives have been well
recognized not only by other international business organization but also by World
Bank & Asian Development Bank as well. Few examples are: More than 280,000
liters of treated effluent water is being used for 8000 workers toilet flush every day,
saving 75M liters of underground water every year. 250,000 square feet roof top
is being used to collect approx. 45 million liters of rain water which is later used in
textile wet processing without utilizing the valuable underground water and saving
extra chemicals of water softening. 5 MW gas generator exhaust used in co-
generation chiller to support 750 MT of air cooling in the Concorde Garments Group
Spinning Mill. Also in the fabric plant, it is planning to use 3MW generator exhaust in
the Boiler. Both technology saves substantial energy and reduced carbon emission.
Re-condensed steam water is being transported to the boiler feeder tank which
increases the temperature by 15-20C, saves hefty energy and minimizes global
warming.
worker unrest happening in Bangladesh BY MD.MATIUR RAHMAN 26 Fabric dryer
exhaust is being redirected to air inlet and feed into the burner to reduce the
energy consumption. A simple innovative technique which Concorde Garments
Group started to use 3 years back and now incorporated by famous GMBH Textile
Machine Manufacturer, Bruckner in their latest series of Stinger. Per year approx.
50 Tons of food residue created during lunch of 7000 employees, are being used to
develop natural fertilizer and being distributed among the neighboring farmers at
free of cost-an initiative which avoids environment pollution and supports the
community.
worker unrest happening in Bangladesh BY MD.MATIUR RAHMAN 27
PART: 02 DIFFERENT DIPERTMENTS ACTIVITIES IN CGG
worker unrest happening in Bangladesh BY MD.MATIUR RAHMAN 28 02. LIST OF
DEPARTMENT OF CONCORDE GARMENTS GROUP: 1. Finance and Commercial
department 2. HR department 3. Merchandising department 4. Sample department
5. Store/warehouse 6. Cutting and Fusing department 7. Sewing and production
department 8. Finishing and Packaging department 9. Quality control department
10. Compliance
FINANCE AND COMMERCIAL DEPARTMENT: Concorde garments groups corporate
house at Jahangir tower 4th floor where the finance and commercial department
situated. Basically, finance department runs the financial accounting system and
perform functions such as: 02.01.01. ACTIVITIES OF THIS DEPARTMENT: Help in
Management Decision Making. CGG financial accounting system records all the
transactions happening in the organization on a day to day basis. To make decisions
managers need information. Necessary information can be generated through
financial accounting system as it record actual transactions happening in the
company. Provide Information to Potential and Present Investors to Make Their
Investment Decisions. MD sir expects a return on the investment they make. If the
return is satisfactory they hold/buy the investment. If it is not satisfactory they sell
the investment. To decide whether to buy/hold or sell the investment investors need
information. This investment information can be generated through financial
accounting system. Meet Legal Obligations. In certain period, it is a legal
obligation of the companies to maintain ledger accounts and final accounts. It is a
legal obligation of the companies to carry out an independent audit to obtain an
opinion about financial statements. CGG are under obligation to provide necessary
accounting information to tax authorities to calculate the tax liability of the
organization. Forecast Future Performance. When forecasting future
performance, the CGG needs to analyze the past information to find out the trend.
For an example, if the company wants to forecast sales for a future period they
need the past sales records to identify the trend. In such a situation relevant
information can be generated through financial accounting system.
worker unrest happening in Bangladesh BY MD.MATIUR RAHMAN 30 02.02. HR
DEPARTMENT: Concorde garments groups current major production department at
Mirpur-07 where the HR department situated Major general AK Akhtaruzzaman
(Retd.) is the head of HR department of CGG. CGG HR is a critical component of
employee well-being in RMG production business, no matter how small or bigger.
CGG HR dept. responsibilities include payroll, benefits, hiring, firing, and keeping up
to date with state and federal tax laws. Any mix-up concerning these issues can
cause major legal problems for CGG, as well as major employee dissatisfaction. But
small businesses often don't have the staff or the budget to properly handle the
nitty-gritty details of HR. Because of this, more and more small businesses are
beginning to outsource their HR needs. CGG HR outsourcing services generally fall
into four categories: PEOs, BPOs, ASPs or e-services. The terms are used loosely, so
a big tip is to know exactly what the outsourcing firm you're investigating offers,
especially when it comes to employee liability. 02.02.01. ACTIVITIES OF THIS
DEPARTMENT: A Professional Employer Organization (PEO) Business Process
Outsourcing (BPO) Application service providers (ASPs) E-services Risk
management Hiring and Firing of personnel Complaints & problems of workers
Enforcement and compliance with employment laws Health care benefits
Trained to worker and staffs Keep all bio data related all skill information
individually
MERCHANDISING DEPARTMENT: Concorde garments groups merchandising
department situated near to their production department at Mirpur-07. In
elaborately, Merchandising is a process through which products are planned,
developed, executed and presented to the buyer. It includes directing and
overseeing the development of product line from start to finish. Marketing and
merchandising department: A team of merchandisers and marketers work together
under a profit controls head. Merchandisers handle the foreign buyers. The teams
are made according to the buyers being handled. 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. 02.03.01. ACTIVITIES OF
THIS DEPARTMENT: Product Development Market and product Analysis
Selling the concept Booking orders Confirming Deliveries Designing and
Sampling Costing(CM, C&F, CIF, FOB) Raw Material book Flow Monitoring
Production Follow Ups Payments Follows Internal & external communication,
Sampling Lab dips order Accessories & trims booking Preparing internal
order sheets Preparing purchase orders Advising and assisting production,
worker unrest happening in Bangladesh BY MD.MATIUR RAHMAN 32 Advising
quality department about quality level Mediating production and quality
departments Giving shipping instructions and following shipping, Helping
documentation department Taking responsibility for inspections and Following
up the shipment. 02.03.02. MERCHANDISING FUNCTION: Fig 02.01: MERCHANDISING
FUNCTION
MERCHANDISING DEPARTMENT STRUCTUR: Fig 02.02: MERCHANDISING
DEPARTMENT STRUCTUR
MERCHANDISER SHOULD HAVE THE FOLLOWING BEASIC QUALIFICATION: Good
command in English and adequate knowledge of technical terms for accurate and
efficient communication. Good knowledge of fiber, yarn, fabric, dyeing, printing,
finishing, dyes, different fastness properties, garments production, etc. Clear
conception of the usual potential quality problems in the garments manufacturing.
Good knowledge of the usual raw materials inspection systems and garments
inspection systems. Knowledge of the quota system used in each of the
producing countries; duty rates; customs regulations; shipping and banking
documentation, etc. 02.03.04. MERCHANDISER IS A DATA BUS BETWEEN BUYER
AND SELLER: Merchandiser is he who builds up relationship with the buyer and acts
as a seller. He plays a vital role in an organization in a sense that he bears more
responsibility than other in regards to execution of an order. The responsibilities
which he bears on the job are as follows: He represents as a buyer to the factory.
He represents as a seller to the buyers. He inspects all the qualities as a buyer
(from the buyers point of view); He negotiates a price for the sellers. He looks
at the deal from sellers point of view. He looks into the business to flourish
more in the future. He tries to offer the deal more competitive without
compromising the quality. His object is to satisfy the buyers to progress more of
the future business. His aim is to impress the buyers by means of Right Products,
Right Quality, Right Quantity, Right Time, and Undamaged Condition.
PROCUREMENT: Procurement is an organization system meant with specifying and
acquiring goods, services and work of the required quantity, of the right quantity,
on the right delivery (Date & Place), at a reasonable price and from the right third
party considering the best quality at minimum price of purchased goods/services
and focusing on getting better value for money invested in procurement. Why
Procurement is Important: Company spends more than 50% of their Budget a
year on procuring goods and services to deliver their core services. Failure to
purchase cost effectively can put the achievement of key objective at risk.
Procurement directly influences profit margin and sales volume. The Major
Procurement Problems: Undesired quality of goods/services and inadequate
quantity. High cost of purchased goods/services. Disastrous delay in delivery
of goods/services. High cost of inventory. Bad conditions of payment
Unsecured sources and uncertainty of continuous supply. Absenteeism of
supplier management. Failure to meet buyers needs. 02.03.06. PRODUCTIVE
PROCUREMENT SYSTEM IS THE RADICAL SOLUTION: Fig 02.03: PRODUCTIVE
PROCUREMENT SYSTEM IS THE RADICAL SOLUTION Right Inputs in the Right Time
Procurement Department Right Outputs in the Right Time
worker unrest happening in Bangladesh BY MD.MATIUR RAHMAN 36 Right Inputs:
Right items specifications and predetermined standards Effective lead time
Right payment system Supportive organizational structure Adequate
Authorization Right material planning system Right inventory control system
Right support from the higher Authority Right Technology Right Outputs:
Enough, qualified, sustaining and well managed sources (Suppliers) Required
quality and adequate quantity of goods. Just in time delivery goods, services and
works Better value for money invested in procurement Zero stock (approach)
Buyer satisfaction Optimal payment terms Fig 02.04: ENVIRONMENT OF
PROCUREMENT SYSTEM Procurem ent Departme nt Finance Departm ent High
Author ity Suppliers Merchandi sing Departme nt Store
worker unrest happening in Bangladesh BY MD.MATIUR RAHMAN 37 02.04. SAMPLE
DEPARTMENT: Garment Sampling: 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
processes 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 The samples decide the ability of an exporter. The buyer will
access the exporter and his organization only by the samples. If the samples are of
good quality and with reasonable price naturally the buyers will be forced to place
the order. So it is essential that the samples should be innovative and with optimum
quality. The purpose of sampling is not only to get bulk orders and also give some
additional benefits to the exporters. By doing sampling the exporter can estimate
the yarn consumption for developing the fabric, a clear idea on costing more ever
the manufacturing difficulties. Besides by doing sampling only the exporter can
optimize the processing parameters for mass production, which helps to avoid all
kind of bottlenecks. All these works are carried out by the sampling department,
which us led by a sampling in charge. The Details Attached to the Garment Sample:
Confirmation of order, each sample sent 0 the buyer has the following details
attached to it, with the help of a tag. It contains the details pertaining to both, what
the buyer has demanded and what supplement fabric/trim etc. they have used (if
applicable).After the Ref no. Color Fabric Composition Description
Quantity Style n0/ Size Store
SAMPLE SECTION PROCESS: Design / Sketch Pattern Design Sample Making
Production Pattern Grading Marker Making Spreading Cutting
Sorting/Bundling Sewing/Assembling Inspection Pressing/ Finishing Final
Inspection Packing Dispatch Fig 02.05: SAMPLE SECTION PROCESS 02.04.02.
TYPES OF SAMPLE: Broadly garment samples are categorized as development
samples and production samples. Samples that are made in development stage are
as following: 1. Proto Sample 2. FIT sample 3. Salesman Sample/Photo shot Sample
4. Size set Sample 5. Pre-production Sample
worker unrest happening in Bangladesh BY MD.MATIUR RAHMAN 39 In production
stage factory need to submit few more samples that includes 6. Top of Production
Sample 7. Shipment sample 1. Proto Sample: These samples are proto type of new
design created by designers. This is the first sample in product development stage.
Proto sample is made to communicate the design of a style or a line or to present
garment structure. In proto samples fit and fabric detailing is not been considered.
2. FIT Sample: Once proto sample is approved, FIT is being made with actual
measurement. Modification on the pattern is done to get desired fit of the garment.
FIT is one of the most important factor to be considered during sample
development. FIT sample is being tested on live model or Dress form for to verify
garment fit and fall. 3. Salesman Sample: Salesman samples are made to put on
display in the retail showroom. Salesman sample (SMS) are displayed for assessing
customer's feedback and according to customers response buyers forecast demand
of a particular style. Sales samples are made with actual fabric and trims and
accessories. Buyer pays for salesman samples to the developer. 4. Size set Sample:
The purpose of the size set is to check fit of the garment in different sizes. In this
stage factory develops samples in multiple sizes. Generally, buyers ask size set
sample in jump sizes, like S, L, and XXL. Buyer check size set sample and give
feedback to factory if anything need to be corrected. 5. Pre-production Sample: All
the above samples are made in sampling department. Buyer wants pre-production
sample (PP sample) to be made in actual production line, so that operators know
what they are going to make. This sample is made with actual fabric, trims and
accessories and made by sewing line tailors. PP sample must be approved by buyer
or buying house merchants (technical persons) prior to proceeding actual
production.
worker unrest happening in Bangladesh BY MD.MATIUR RAHMAN 40 6. Top of
Production Sample (TOP sample): Once production is online, few pieces is taken out
in the middle of the production. Production pieces are sent to buyer as TOP sample.
All buyers do not ask for TOP sample. Purpose is to cross-check whether factory is
following PP sample specification or not. 7. Shipment Sample: When style is being
finished and packed for shipment, 2-3 finished and packed pieces with all packing
details are kept for future reference. Shipment sample is kept by factory merchants
and buyers merchant. The approved shipment is sent directly to warehouse and
merchants at the buyer do not get garment out of the shipment. That is why they
keep shipment sample for future reference. 02.04.03. OBJECTIVE OF SAMPLE: To
allow the buyer to judge the production capabilities of the manufacturer. To
provide a means for making revisions in the bulk production process. To let the
manufacturer estimate the thread and fabric consumption, and develop cost
quotations
STORE/WAREHOUSE: 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. Warehouse is the stock of any
garments item or accessories resources used in an Organization. Where kept
everything before production. 02.05.01. STORE PROCESS DIAGRAME: Fig 02.06:
STORE PROCESS DIAGRAME Raw Materials Received. Security check as per C-
TPAT procedures. Goods are verified against invoice. Shortage Marked for
inventory/ inspection . Store with Bin cards in bins or steel pallets. Storing
buyer wise and lot wise. Trims are keeping on rack with bin cars. Inspection
10% inspection of fabrics and trim from bulk. If fail another 15% inspect. Still
fail another 25% inspect. Still fail inform to MMD & reject full quantity with rd
sticker. Inventory Excess or shortage inform to MMD & commerc ial dept.
Delivery invoice is forwarde d to C& F.
WORKING FLOWCHART OF FABRIC STORE DEPARTMENT: They follow a strong and
appropriate working procedure. Their work process flow is given below: Invoice
Waiting for inventory QC inspection Inventory Pass goods area Cutting input report
(size break down) Sewing line Requisition Issue sewing line Fig 02.07: WORKING
FLOWCHART OF FABRIC STORE DEPARTMENT Invoice: Invoice collect from
supplier by Merchandiser. Without invoice it is not possible to make the inventory,
because there is list of goods in invoice. After comparing invoice with received
goods, received goods are placed as inventory. Waiting for inventory: When
receive goods are not in pass goods are waiting for inventory. Count goods are as
per invoice which gets from Merchandiser. Time of waiting inventory is maximum
24hrs. QC Inspection: To cheek the quality of received goods. Rules of QC
inspection: 10% inspection of received goods. 2.5% defects are equal, over
2.5% will be failed. Non-confirm goods: It means something defects but it is
acceptable.
worker unrest happening in Bangladesh BY MD.MATIUR RAHMAN 43 Inventory:
When ware house gets invoice from Merchandiser, responsible persons match
invoice with received goods that is inventory. If there is any shortage, they are to
inform to Merchandiser to solve the problem. Pass Goods Area: When all
activities are finished like inspection, register, count etc. goods are allowed for pass
goods area. And also goods are ready to going for production. Cutting Input
Report (size breakdown): As per cutting sections requirement break out quantity in
the cutting input report on the basis of PO, Style etc. Sewing Line Requisition: It is
based on PO, order quantity, style and consumption as per sewing line requirement.
Issue Sewing Line: As per sewing line requirement, compare requisition slip with
break down size report. Then it is issued by responsible person and recorded in the
Register book. 02.05.03. ACCESSORIES: Sewing Line Accessories: Yarn Thin
yarn: 4/2,5 /2,6/2 Fat yarn: 20/2 (2yarn together), 20/3 (3yarn together) Button
Interlining Main Label: It contains the names of buyer & country, Ex. PVH, ASH
City etc. Sub labels Size Label: It contains the size of the garments. Care
Label: It contains the care construction. Different types of care label are given
below. Washing code Bleaching code Ironing code Dry cleaning code
Drying code
worker unrest happening in Bangladesh BY MD.MATIUR RAHMAN 44 Finishing Line
Accessories: Neck board Hangtag with sticker Tissue (when folding shirts)
Poly back Po sticker (If required) Button packs measurement: 1 GR = 144pcs
12 GR= 1GG 1GG=1728pcs Elastic Measurement: 1 GR = 144 yards 12
GR= 1GG 1GG=1728 yards Yarn Measurement: 1 con=4000 meters.
02.05.03.01. PROCESS OF ACCESSORIES RECIVING: Receiving invoice Unload
materials Inventory Inventory report submit to Merchandiser Stock Register entry
Supply as Requisition Stock register balance Fig 02.08: PROCESS OF ACCESSORIES
RECIVING
worker unrest happening in Bangladesh BY MD.MATIUR RAHMAN 45 Issuing record
for Trim & Accessories: Issues Trim & Accessories as per customer PO, Trim &
Accessories supplier invoice, lot & trim card. Issue items as per process and to
person responsibilities. Process of Received Goods: Inventory register as per
customer PO number. 10% inspection. Inspection report in register. Factory
name. Style number. PO (purchase order) number. Invoice. Trims &
Inspection details. Storage location. Issuing record for Received Goods: Issuing
fabrics as per PO, style, supplier invoice, lot and swatch. Fabrics Receiving &
Inventory: The process of fabrics receiving & inventory as like as Accessories
receiving & invoice. 4 points system wise fabric inspection: Defects Penalty Point 0-
3 1 3.1-6 2 6.1-9 3 9.1-Up 4 Note: Up to 28 points per 100 SQ MTS/YDS are
acceptable defects. Fabrics inspection: 50cm fabrics cut from a roll and send to
washing plant as per buyers requirements. Fabrics Monitoring System:
worker unrest happening in Bangladesh BY MD.MATIUR RAHMAN 46 Cutting
fabrics as per PO, style and inspection by approved machine. Compare FAB roll
number with shade form. Check slip approved by cutting section. To check
fabrics layer for defects while spreading fabrics. Number all cut panels and parts,
log register form. Fabrics purchasing issue: As per PO, order quantity and
consumption, fabrics purchase is to issue on the basis of buyer requirements.
Fabrics Register: After comparing goods with suppliers invoice, goods are recorded
in the register book. Cutting Line Requisition: Fabrics issue on the base of PO, order
quantity and consumption as per cutting line requirement. Fabrics consumption
approved by buyer. Store Keeping System: Unload fabrics Inventory in
warehouse. Fabrics inspection Recording in register book and XL sheet.
Updated information put in Bin Card. Bin Card: It is updated information card for bin
or rack, where is in quantity, out quantity and stock quantity, also description of
goods. C-TPAT: To ensure the buyer that, we can give you better security, when
receiving goods, storing goods, packing and ware housing goods. Also ensure the
buyer; we have break point while receiving goods for making garments and shipping
finished goods by covering VAN or Cargo in one the way.
worker unrest happening in Bangladesh BY MD.MATIUR RAHMAN 47 C-TPAT 7
point Inspection system: Appearance part of container/covered van. Left part
of container/covered van. Under part of container/covered van. Inside part of
container/covered van. Back parts door part of container/covered van. Right
part of container/covered van. Roof or Top part of container/covered van.
CUTTING AND FUSING DEPARTMENT: Garment production starts with the cutting
process. In this process, fabric is being cut into components (shapes or patterns of
different garment parts, i.e. front, back, sleeve, collar shapes etc.). In mass
production multiple layers of fabrics are laid on a table and large number of
garments is being cut at a time. The laid fabric stack is called as lay. The cutting
process includes number of sub-processes and flow of the processes is as following.
Each process is briefly explained in the following. Ratio for marker Marker Laying
Marker setting and cutting Scissoring Numbering Re-lay Finish cutting Bundle
handling Input to sewing line Fig 02.09: CUTTING AND FUSING DEPARTMENT Marker:
Marker is a thin paper which contains all the necessary pattern pieces for all sizes
for a particular style of garments. It is made just before cutting and its purpose is to
minimize the wastages. The width of the marker is equal to the width of the fabric
and it should not be greater than the width of the fabric, i.e. fabric width is greater
than or equal to marker width. The pattern pieces should be placed very carefully in
such a way that it would minimize wastages.
worker unrest happening in Bangladesh BY MD.MATIUR RAHMAN 49 Objects of
Marker Making: The garment industry has to pay a great attention to the marker
planning because when the cutting room cuts cloth it spreads around half the
companys turnover. Any reduction in the amount of cloth used per garment leads
to an increase in profit. Marker planning is a conceptualizing, open and creative
process. In order to plan efficiently, it is necessary to visualize the marker as a
whole or to see it at a glance. The main objects can be summarized as follows: To
reduce cost through controlling over wastages. To improve the quality of the
garments. For a large scale of production Types of Marker: Normally they can
make this type of marker: Normal marker. Group Marker. (Width wise)
Shade marker. (length wise) Block marker. All garments one way. One
garments one way. Factors considered during marker making: The important factors
considered during marker making are: Nature of the Fabric: The fabric may be
either symmetric or asymmetric. Thus the nature of the fabric should be considered
during marker making. Lay planning of patterns: Improper lay planning of
patterns may create more wastage. Thus it should be taken under consideration.
Alignment of the pattern pieces according to the grain line: It is also another
important factor that must be considered. The warp direction of a fabric is very
much important for a garment and the grain line indicates the warp or wale
direction. Requirements of cutting: Before placing the pattern pieces onto the
marker or during marker making the cutting allowances are considered where
worker unrest happening in Bangladesh BY MD.MATIUR RAHMAN 50 necessary and
where is not. It may produce more wastage and may reduce the dimensions of
patterns. Production planning: Different types and sizes of garments
manufacturing may run at a time in an industry. So during marker making it should
be considered. Size of marker: During marker making we have to think about the
table size, length of the fabric, etc. Marker efficiency: It may be defined as the
ratio of the total area of all the pattern pieces in the marker to the total area of the
marker plan. It is expressed in percentage (%). Marker efficiency =Total area of the
pattern pieces/ Total area of the Marker paper 100% The higher the marker
efficiency, the lower will be the fabric wastage i.e. least fabric will be required to
make a definite number of garments. So increase in marker efficiency is very
important. Efficiency 90%-93% is good marker. Quality control in marker making:
The objectives of quality control in marker making can be summarized as: To
ensure the markers are made to a size ratio that gives the required quality and
quantity per order by reducing the wastage of fabrics. To ensure no garment part
is missed in the marker and the marker is of comparable length and width of the
fabric being laid. Cutting section starts with the receipt of piece goods and ends
with the completion of the bundles of cut parts ready for sewing. The preparation
for cutting is very important prior to the cutting operation. Accurate cutting
simplifies the sewing and pressing operation. Cutting of fabrics or trims to size,
where possible, eliminates considerable measuring, matching, shaping and
trimming in the sewing room. Proper punching of holes and notching is important
for accurately locating parts.
worker unrest happening in Bangladesh BY MD.MATIUR RAHMAN 51 Quality
inspection procedure for markers: Locations with manual marker making system:
In these locations, the markers should be inspected by the Quality Control
Department before the fabric is laid. This will leave sufficient time to make any
correction to the marker that is necessary. Locations with computer marker
making (CAD) system: In location that uses the CAD system, the marker information
needs to be cross-checked by an operator other than one who compiled the marker,
before the marker is printed. This is to ensure that no operator error has occurred.
The marker can then be re-inspected by the Quality Control Department after it has
been placed on the lay of fabric prior to cutting. Computerized marker making
system: To get optimum efficiency of markers as well as to minimize fabric wastage
they done marker by computerized marker making system .It has the digitized by
which the patterns are make grade and with the help of the software as well get
output as marker with the plotter. 02.06.01. PROCEDURE OF CAD SECTION: In
CAD section at first the pattern put on the digitizer to take clear image of the
pattern part inside the CPU. After making all required size patterns using the
software pattern parts are aligned in the mini marker. Then it is sent to CPU of CPM
section for approval & checking the length & width of marker and pattern parts
alignment. After getting approval from CAD section then printer is used to print
out the whole real marker then this marker as well as mini marker are provided to
the CAD section for cutting the fabric.
WORKING PROCEDURES OF CAD SECTION: Fig 02.10: WORKING PROCEDURES OF
CAD SECTION Pattern / Marker: According to the design and fit, patterns of different
garment parts are made on the pattern paper and cut into pattern pieces. For
manual marker these pattern pieces are used for marker making. On the other hand
in CAD system patterns are made in computer. Later using a plotter markers are
made on sheet. In the second case cutting department receive ready marker. Cut
ratio receiving: Prior to cutting, cutting department get a job sheet from planning
department or merchandiser or production manager that includes total quantity of
garment pieces to be cut, sizes ratio of the garments and color-wise size break up.
According to the size and color ratio cutting team prepare one marker or multiple
markers. Marker length and number of lay to be cut are planned in this stage.
worker unrest happening in Bangladesh BY MD.MATIUR RAHMAN 53 Fabric
receiving: Fabric requirement for an order is calculated according to the average
consumption of the fabric from the marker. In case of multiple color order, color
wise requirement is made. Fabric department issue fabric to cutting against the
fabric requirement (generally requisition slip is used). Fabric relaxation: This process
is optional. Specially used for knits fabric. During rolling of fabric it get stretched. So
it is essential to bring the fabric on stable form otherwise garment would shrink
after making. To relax the fabric roll or than is opened and spread and kept for about
24 hours. Spreading (Fabric Layering): In this stage fabric sheet is layered one
above another maintaining pre-defined maker length and correct ply tension. Fabric
is layered up to a certain height to avoid cutting quality problem. Spreading is done
by manual layering or automatic layering machine can be used. During layering of
the fabric, fabric edge is aligned at one side. Marker Making: After layering of a lay,
pre made paper patterns (or ready markers made by plotter) are placed on the top
layer of the lay. In manual marker making, marking is done around each pattern
shape using marking chalk. This process is called as marker making. In a marker all
garment components are placed. Cutting: Lay is cut following the marked lines on
the top of the lay. Cutting is done using straight knife or other cutting means. In
cutting process garment component are separated. On the basis of pattern shape
different cutting method/ machine are selected. Numbering: Separated garment
components are numbered to ensure that in stitching all components from same
layer are stitched together. It is important to avoid shade variation in a garment.
Between the cutting and sewing processes cut components may be passed through
other processes like printing and embroidery. There is maximum chance of mixing of
the components. If there is layer number in each component then at the time of
stitching only correct components will be stitched together.
worker unrest happening in Bangladesh BY MD.MATIUR RAHMAN 54 Sorting:
According to production system (Make through, progressive bundle or one piece
flow system) cut components are sorted. In sorting all component of a garment
placed together. Size wise sorting and in case multiple colors are cut in a single lay,
color wise sorting will be required. Bundling: As per the production line requirement
a certain number of pieces with all component are tied together. This process is
known as bundling. Each bundle is marked with bundle number, style name, size
number and quantity of pieces in that bundle. At this stage cutting are ready to
send to production line for stitching. Fusing Alter Name: 1. BUBBLE AT A/H, S/SEAM,
BK YOKE, SLV PLKT, CLR, CUFF ETC. 2. GLUE MARK AT A/H, S/SEAM, BK YOKE, SLV
PLKT, CLR, BOX PLATE ETC. 3. BROKEN AT A/H, SLV PLKT & BTM HEM. 4. SHINIHG AT
S/SEAM, BOX PLATE & A/H. 5. EDGE GUP AT BOX & BTN PART, SLV PLKT. 6.
DELAMINATION AT A/H, S/SEAM & BTM HEM. 7. RUPPING AT S/SEAM & BTM HEM. 8.
INTERLINING REVERSE AT BOX PLKT. 9. LOW BONDING AT BOX PLATE, CLR & CUFF.
10. ZIK ZAK AT A/HOLE. 11. SHRINKAGE AT BOX PLATE, BTN PART, CLR & CUFF. 12.
SPOT AT A/H, S/SEAM, CLR & CUFF. 13. PLATE AT A/H & S/SEAM. 14. HAND FEEL
REMOVE AT BOX PLATE, CLR & CUFF. 15. COLOUR CHANGE AT BOX PLATE, CLR &
CUFF. 16. EXTRA GLUE MARK AT A/H, S/SEAM & BK YOKE. 17. A/H, S/SEAM, SLV PLKT
BUBBLE OR GLUE MARK FOR TAPE ATTACH UN-EVEN.
worker unrest happening in Bangladesh BY MD.MATIUR RAHMAN 55 02.07. SEWING
AND PRODUCTION DEPARTMENT: The project of joining fabric or seam is called
sewing. Element of sewing: Sewing thread Needle & Sewing Machine.
02.07.01. FLOW SEQUENCE OF SEWING SECTION: Cutting fabric load in sewing
section Line plan according to style or design Marking Matching according to bundle
no Sewing according to garments design or style Quality inspection during sewing
Quality inspection after sewing Excess thread cutting Remove dirt & dust from
garments surface Quality audit Send to next process Fig 02.11: FLOW SEQUENCE OF
SEWING SECTION
worker unrest happening in Bangladesh BY MD.MATIUR RAHMAN 56 Sewing
Defects: Needle damage Skip stitches Thread breakages Broken stitches
Seam puckering Pleated seam Wrong stitch density Uneven stitch density
Staggered stitch Improperly formed stitches Line balancing: Line balancing is
the allocation of sewing m/c according to style & design of garments. It depends on
what type garments we have to produced. It is done increase the productivity &
quantity. Objective of Line balancing: Line Balancing is a main part of a mass
production. Three kinds of systems regardless of being different in details are
workstations in sequences. Row material is included in the line at the beginning or
in the middle. Parts included in the system transfers from one workstation through
the other and at the end leaves the system as completed product. Transfer lines
uses manpower very little when compared to assembly lines. The certain properties
of transfer lines are transfer and process of a product automatically through a line.
worker unrest happening in Bangladesh BY MD.MATIUR RAHMAN 57 Objectives
that should be gained balancing an assembly line are as follows: Regular material
flow. Maximum uses of man power & m/c capacity. Minimum process time.
Minimizing slack time. Minimizing work station. Maximum output at the desired
time. Agreed quality maintenance of the garments. Reduce production cost.
The importance of line balancing could be summarized as follow: Good line
balancing increase the rate of production. Line balancing help to compare the
required machinery with the existing one & make a balance. It also helps in the
determination of labor requirement. Good balancing reduces production time.
Profit of a factory can be ensuring by proper line balancing optimum production at
the agreed quality. It reduces fault in the finished product. Line balancing
helps to know about new m/c required for new style. It becomes easier to
distribute to particular job to its operator. It becomes possible to deliver goods at
right time at the agreed quality for least cost. Steps in Line Balancing: Now-a-days,
Standard Minute Value (SMV) is used as a tool for the line balancing production
control and the estimation of efficiency. In a similar way, the time taken to do a job
for making garments like shirt/trouser/blouse/dresses could depend upon a number
of factors like. The length of the shirt/trouser /blouse/dress. The number of
stitches per inch. The presentation of item. The pricing of garments.
worker unrest happening in Bangladesh BY MD.MATIUR RAHMAN 58 Machine
description: For making a Basic Shirt, we need 7 types of sewing machines. They
are given below: 1. Plain Machine or Lock Stitch Machine 2. Over lock or Over edge
Stitch Machine 3. Button Holing Machine 4. Button Attaching Machine 5. Feed of the
Arm 6. Kansai or Multi needle chain stitch machine 7. SN (Single Needle) & DN
(Double Needle) Chain Stitch Machine (with or without edge cutter & thread cutting
mechanism) 02.07.02. ALL SEWING MACHINE DESCRIPTIONS ARE GIVEN BELOW: 1.
Plain Machine or Lock Stitch Machine: No. of needle: Generally 1 needle or 2
needle SPM (Stitches Per Minute) : 1500-5500 Stitch Length: 5mm in Juki (DDL-
5500 model). Automatic Thread Cutting. Automatic Bobbin Winging. Edge
Cutting System. Most commonly used for sewing of woven garments. 2. Over lock
or Over edge Stitch machine: No. of needle : one or 2 needle No. of thread : 2-
5 threads SPM : 6500-8000 Stitch length: maximum 4mm and stitch length can
be changed by push button. Stretching maximum 1:0.6 and Gathering maximum
1:4. Used for sewing both woven and knitted goods but extensively used for
knitted goods.
worker unrest happening in Bangladesh BY MD.MATIUR RAHMAN 59 3. Button
Holing Machine: Stitch group : lock or chain stitch Arrangement of button hole
size being small or larger Arrangement of stitch density being increased or
reduced. Button hole can be made to cut the hole before or after sewing a button
hole. 4. Button Attaching Machine: Productions lock stitch, chain stitch or hand
stitch. Various types button clamps needs for attaching various sizes and types of
button. The bottom may be 2 or 4 holes. 4 whole button may be sewed by cross
or parallel. If chain stitch is used, the sewing looks nice, but the security of stitch
is comparatively less. In case of lock stitch used no possibility of sewing opening.
But not looks nice. In fully automatic machines, button feeding and positioning
inside the button clamp is performed by a hopper and pipe. It can attach
predetermined number of buttons at a predetermined distance in acyclic order. 5.
Feed of the Arm: Number of needle : normally 2 SPM : 3000 -3200 Number
of thread : 4 threads Twist per inch : 15 20 Stitch group : chain stitch
Mainly sewing shirts, Jeans, Gridding goods & double stitching pants.
worker unrest happening in Bangladesh BY MD.MATIUR RAHMAN 60 6. Kansai or
Multi needle chain stitch machine: Number of needle : 6-17 Number of thread :
12 34 SPM : 4000 4500 Stitch group : Chain Stitch 7. Chain Stitch Machine:
No. of needle : one or more needle No. of thread : one or more thread (Single
thread or multi thread) SPM : 1800-6000 Stitch length : 1.4 to 4.5 mm
Automatic thread trimmer Various types of feed mechanism is adjusted to the
machine Used in knitted wear and jeans 02.07.03. INDUSTRIAL ENGEERING (IE):
The main function of this department is to re-engineering the garment from the
sampling stage that it would be production friendly for the production as well helps
to increase the productivity through machine layout, time and motion study. In the
sewn products industries we must continuously ensure that we remain competitive
profitable whilst also striving to improve our personal and communitys standard of
living. Productivity improvements may be achieved through: Industrial Engineering
department: To follow up the production process Work process development
SMV calculation & Line target Efficiency control Time study Capacity study
Workers training Machine sequence lay out
worker unrest happening in Bangladesh BY MD.MATIUR RAHMAN 61 Thread
consumption Operator interview Duties and activities of a work study officer:
SMV making. Layout makes. Machines arrange. Attend production planning
(P.P) meeting. First week production. Line feeding. Work aid arrangement.
Method study (innovation). To take video & record it. Time study. Line
capacity find out. Bottle neck operation. Individually follow up bottle neck
operation & try to increase production. Capacity & efficiency wise target setting
&try to achieving. Line balancing. Motivation of the worker. Maximum time
study in production line & try to any kind of production related problem.
Monitoring the production achievement hourly daily. Lost time record. Try to
increase the productivity.
FINISHING AND PACKAGING DEPARTMENT: LAY OUT OF FINISHING SECTION: Washing
(Spot Remover) Finishing button Thread trimming Iron Poly Packing Cartooning Final
Inspection Shipment Fig 02.12. LAY OUT OF FINISHING SECTION PROCESS SEQUINCE
OF THREAD TRIMMEING: Loop cut Pocket clean /Gun/ Hand Pocket raise cut Thread
trimming Q.C check Fig 02.13. PROCESS SEQUINCE OF THREAD TRIMMEING
worker unrest happening in Bangladesh BY MD.MATIUR RAHMAN 63 PROCESS
SEQUNCE OF IRON: Iron on waist Needle mark removes Button turn & button close
Brush on garments Final iron Q.C check Fig 02.14. PROCESS SEQUNCE OF IRON
PROCESS SEQUNCE OF POLY: Get up (Any process) Q.C. Check Poly table Tag
attached Price sticker attached by hand tag Brush & garments Garments fold Leg
sticker attached Insert poly Shade matching Poly close by scotch tape Poly sticker
attached Q.C pass sticker Fig 02.15. PROCESS SEQUNCE OF IRON
worker unrest happening in Bangladesh BY MD.MATIUR RAHMAN 64 PROCESS
SEQUNCE OF PACKING: Shade matching Body check by needle detector Fold on
garments Insert poly Poly close Assortment Final check /Inspection Packing (Ratio
pack) Pack close Pack sticker attached Send to buyer Fig 02.16. PROCESS SEQUNCE
OF PACKING Trims: Trims cover all the items used in the garment expect the basic
fabric. There are hundreds of items used to manufacture the garments. Proper
selection of trims & its quality are very important for styling; otherwise the
garments may be rejected or returned by the customers. Sewing Thread: Shade,
color fastness, etc. Tensile strength, Elasticity, Shrinkage, Moisture Regain,
Abrasion Resistance, etc. 30s, 60s, 20/2, 40/9Ne, etc.
worker unrest happening in Bangladesh BY MD.MATIUR RAHMAN 65 Labels: Main
label Size label Care label Content Price Patch Button: Metal buttons
are very common in use Elastic Cotton polyester, etc. String/Cord: Cotton
Polyester Tags: Price tags Hang tags, etc. Poly bag: Strength, chemical
mixture, Thickness (micron/mm: 1mm=1000 micron) Blister Bag: 0.05 mm in
thickness; Loaded capacity is higher than poly bag. Carton: 3 ply 5 ply 7
ply size (L, W, & H) Sticker: Hook and pile
worker unrest happening in Bangladesh BY MD.MATIUR RAHMAN 66 Plastic clip,
Tag pin, Hanger, Gum Tape. Finishing efficiency: Earn min = SMV Production
Available min/clock min = Total man power working min. Efficiency: Earn min
Available min100% in example If SMV 4, Production 1200, Total man power 65,
& Working min 600. Now efficiency: 4120065600100%=12.30%
worker unrest happening in Bangladesh BY MD.MATIUR RAHMAN 67 02.09. QUALITY
CONTROL DEPARTMENT: Quality as ultimate fulfillment of customers requirement in
product, services and timeline. CGG have two divisions to monitor quality: Quality
Control Department which is reporting to factory management and Quality
Assurance Department reporting to factory ownership for independent audits and to
convey true reflection of quality being produced by factory management. 02.09.01.
QUALITY CONTROL: During product manufacturing, CGG monitors quality of raw
material and final product through inspections at each step of product
manufacturing. Fabric Inspection and QC Procedures: Incoming fabrics are inspected
at JC Penneys recommended 4 Point system. 100% fabric is inspected by fabric
QCs. Each fault is given points keeping in view the nature and intensity of the
faults. 40 Points are allowed in 100 inspected yards. If number of faults/points
exceeded than 40 per 100 yard, the fabric roll is rejected. Lab test reports are also
taken from fabric suppliers and verified through internal and third party labs
randomly. Accessories Inspection: Accessories at the time of receipt in store are
randomly inspected by QCs/concerned persons at least up to 10% of the received
quantity. Cut Parts Inspection: 100% cut parts are inspected before input to sewing.
The rejected components are replaced from remnants or removed. Cut parts are
also inspected 100% before sending and after receipt from printing and/or
embroidery. Sewing Inline Inspection: During stitching operations, the inspections
are done on JC Penneys recommended 7-0 System. Inline QC inspects 7 pieces
randomly for each machine operator twice a day. If he finds any fault among these 7
inspected pcs, the Sewing operator has to inspect the whole bundle himself and
offer inspection again to Inline QC. If the inspection is fault free, then this sewing
operator will undergo follow up inspection of 03 Consecutive bundles. If 03 Follow
up Inspections are ok, the Inline QC moves to next machine operator. If during 1st
worker unrest happening in Bangladesh BY MD.MATIUR RAHMAN 68 follow up
inspection, the Inline QC finds any fault, then the said sewing operator has to go
under 2nd follow up inspection. If the 2nd follow up fails then operator has to stop
the work for two decisions to be made depending on the nature of the faults (either
machine to go under maintenance or sewing operator to go for training or
replacement). Sewing End Line Inspection: 100 % garments are checked on sewing
related faults after sewing completion. Both in and out sides of the garments are
inspected. Use of Auto Trimmer & Thread Sucking Machines: We are using Auto
Trimmers for clipping to avoid un-necessary clipping cuts during this process. We
are also using thread sucker machines to ensure that packed garments are free
from loose threads. Final QC Inspection: Garments are checked 100% on quality
after pressing for fabrication, finishing, appearance, sewing, shading, labeling etc.
to make sure that quality garments are packed into cartons. Measurement Specs
Control: Before packing, garments are 100% checked on measurements for key
measuring points. Internal Q.C Lab & Third Party Testing: Fabrics and garments are
randomly tested at internal QC lab on fabrics basic performance features like fabric
weight, shrinkages, torqueing, color fastness, PH Value etc. In addition to this,
garments are sent to third party labs (SGS, ITS, BV) for independent testing to make
sure that the outgoing goods are meeting customers required quality standards.
QUALITY ASSURENCE: QA conduct daily random audits of cut parts during cutting
process, inline audits during sewing. They also do Batch audits before packing. Only
QA passed garments are packed into cartons. Finished goods audits are also
conducted when shipment is ready. All internal QA audits are done at AQL 1.50 Level
II of military std. III. Quality Assurance Department is reporting to factory ownership
for independent audits and to convey true reflection of quality being produced.
COMPLIANCE DEPARTMENT: CONCORDE GARMENTS GROUP is totally a compliant
factory. CGG has wages and overtime calculation through computerized Human
Resources Management System based on employees in/out through employees
card swiping. Leave record is also maintained by system. All wages and
compensation/benefits are paid in time and as per local law. Employees are hired
irrespective of religion, gender, color, and race. No worker hired under the age of 18
years (age also verified before hiring through documents and by physician also). We
have Child Care facility, Fire hydrant system (including Fire Extinguishers and smoke
detectors), Medical facility, Blockage free Aisles-Exits-Stairs, Pure Drinking Water
Facility, broken needle log, workers grievance log and needle detector etc. Regular
fire drills are conducted to keep training more fire fighters. Have workers
participatory committee. GIZ-BGMEA Compliance Audit Pass on Feb 01, 2012 (Bale
no got 77 marks out of 100) BSCI Ready for it, can be done upon request of any
BSCI member buyer. WRAP Ready for it, can be done upon request of any
buyer. Sedex GSV: Global Security Verification WCA: Workplace Conditions
Assessment
worker unrest happening in Bangladesh BY MD.MATIUR RAHMAN 72 PART: 03 MY
ROLES & RESPONSIBILITIES AT MERCHANDISING DEPARTMENT
RESPONSIBILITES OF A MERCHANDISER: Merchandiser need to work in a systematic
way to ensure proper delivery of products at due date. They had to do their work
into daily, weekly, monthly and yearly basis. The activities are 03.01.01. DAILY
ACTIVITES OF A MERCHANDISER: I. Checking mails and faxes. They need to give the
reply within the day based on priority. II. Checking port status and convey to
concern department. III. Checking the shipments documents and inform concern
department. IV. Checking daily production status to understand shipment status V.
Checking shipment schedule and raw materials production status VI. Follow-up with
sample section for different buyers sample VII. Follow-up with store for fabric and
accessories received VIII. Follow-up with the production manager for the production
plan IX. Follow-up with the commercial people L/C,BTB L/C and L/C amendment X.
Price quotation and delivery confirmation to the buyer XI. Reporting to marketing
and merchandising chief on the daily activities. XII. Reporting to executive director
on the important issue like various meeting, customer visits compliances and code
of conduct 03.01.02 WEEKLY ACTIVITES OF A MERCHANDISER: I. Meeting with the
fabrics and accessories supplier. II. Meeting with the buyer and buying houses. III.
Prepare fabric and accessories requirement list, checking with concern and passing
it to supplier with proper specification. IV. Prepare purchase order with approval and
sign of proper authority. V. Issuing pro-forma invoice with the approval and sign of
the proper authority. VI. Providing cost break-down to commercial department
during L/C opening. 03.01.03. MONTHLY ACTIVITES OF A MERCHANDISER: I. Meeting
with the production people. II. Meeting with the quality people and pattern master.
YEARLY ACTIVITES OF A MERCHANDISER: I. Yearly self-assessment on the
performance based on number of buyers handled, shipment quantity, CM charge
negotiated, debit note settled with the supplier. 03.02. MY ACTIVITY: As an Intern I
am working as a trainee merchandiser in Concorde Garments Group. So I am getting
the opportunity to learn lots of things in practical. In this time I have done different
activities related to merchandising, production, store management, sampling in this
company. 03.02.01. MY DAILY ACTIVITY: I. Preparing and maintaining swatch card II.
Scanning documents III. Proper filling the documents IV. Sample follow-up V. Taking
the photos of samples VI. Mail communication VII. Collecting production information
VIII. Reporting to concern supervisor IX. Overviewing Production line X. Observing
how to run a sewing machine and other machine XI. Observing how to inspect
garments accessories and fabric XII. How to fold garments and pack in cartoon
03.02.02. MY WEEKLY ACTIVITY: I. Meeting with the fabrics and accessories supplier
II. Making accessories list III. Meeting with the buyer and buying houses 03.04.
RECOMMENDATION: My recommendation is that management should be stricter
about the sample section and they should provide a formal briefing or one or two
days workshop before starting internship program.
PART: 04 UNREST IN RMG FACTORY AND REASON PERESPECTIVE TO
BANGLADESH
INTRODUCTION: Everybody will agree that the ready-made garment (RMG) sector is
the lifeblood for the Bangladeshi economy. Maintaining higher export growth every
year, now the sector is the largest contributor not only to overseas trade but also to
the national economy. The sector alone directly employs 3.5 million skilled, semi-
skilled and unskilled workers. Indirectly, the garment sector, which started its
journey in Bangladesh since the early 1980s, employs a few cores of people in the
country. The multi-billion dollar worth garment sector has reached the current stage
after a long struggle as Bangladesh does not produce the majority of its raw
materials. Bangladesh is mostly dependent on imported cotton, fabrics, and yarn
and capital machinery. Yet, the country is in an advantageous position in global
trade market for its competitive workforce. Despite all those troubles, Bangladesh is
the second largest apparel supplier worldwide after China. The country is a lucrative
destination to the globally renowned brands and retail chains like Hugo Boss,
Adidas, Marks and Spencer, H & M, Zara, Olympus and many more because of price
competitiveness, enhanced sustainability standards and skilled workforce. In spite
of all the success stories, the garment sector is jolted with volatility. It faced severe
labor unrest for wage hike in 2006. Since then labor unrest took place in the sector
almost every year. Many experts and industry insiders describe it as a conspiracy by
certain national or international vested quarters, although it requires adequate
evidence to prove the involvement of such conspirators. Even during the latest
labor unrest at Ashulia in May and June, the sector people, experts, researchers,
government officials and lawmakers tried to know the real causes behind the unrest
as it was not related to wage hike. Records show that almost all incidents of
massive labor unrest, which have direct link with wage hike demand, took place in
2006 and 2010. Those incidents were resolved through discussion. In 2006, garment
workers demonstrated for a minimum wage hike and it was fixed at Tk. 1662.50. In
2010 the workers agitated again for revision of the minimum wage structure. After
negotiating for a long time, the government committee fixed the minimum wage for
the garment workers at Tk. 3000 per month which came into effect in November
2010. This year the nature of labor unrest at Ashulia was different. Primarily, the
unrest started from a rumor of a death of a storekeeper at Ha-Meem Group in May
11. Later the problem of unrest was resolved for a brief period of one month when
the missing Salman reappeared. But again the unrest started at the area despite
repeated negotiating sessions among the workers, their leaders, government high-
ups and the owners. When the unrest reached its pinnacle, the leaders of
Bangladesh Garment Manufacturers and Exporters
worker unrest happening in Bangladesh BY MD.MATIUR RAHMAN 77 Association
(BGMEA) were forced to keep shut 300 Ashulia based garment factories for a few
days since June 16. After a series of negotiation between the stakeholders and the
owners, the garment factories were reopened in June 21. In general, apart from
wage hike issue, other causes for unrest in the garment sector are rumors of death
and beating, fear of job loss, jhut business, cases with the police station, fear of
shutdown of the factories, arrears of salary, checking at entry point and identity
cards, pay hike and discrimination in grades, bad relations between workers and
mid-level management, provocation by the local influential people and international
conspirators and some NGOs, role of industrial police and division between
industrial police and normal police, sudden order cut by the international buyers,
piece rate production, problems of accommodation and increased house rent, lack
of motivational training system, inflation and so on. 04.02. RUMOR

Concorde Garments Internship Report on Running an RMG Factory

Transféré par

Informations du document

Titre original

Copyright

Formats disponibles

Partager ce document

Partager ou intégrer le document

Options de partage

Avez-vous trouvé ce document utile ?

Ce contenu est-il inapproprié ?

Droits d'auteur :

Formats disponibles

Concorde Garments Internship Report on Running an RMG Factory

Transféré par

Droits d'auteur :

Formats disponibles

An Internship report on Concorde Garments Group

Vous aimerez peut-être aussi