Report onIndustrial Training Viyellatex GroupPrepared For: (IE Department)

Eng. Mr. Faruque Ahmed Training Supervisor

Prepared By: (IPE, 12th Batch) Saiful Islam-2006334032 Mahmydul hasan-2006334033 Raj Narayan-2006334034 Tanvir Ahmed-2006334037 Zakirul Hasan-2006334038 Monuj Kumar Das-2006334039 Aminul Islam-2006334040

Department of Industrial and Production Engineering Shahajalal University of Science & Technology Sylhet 28 October 2010

October 21, 2010 To Engr. Mr. Faruque Ahmed Assistant Manager of IE Department Viyellatex Group. 297, Khortoil, Gazipura, Tongi, Gazipur1712, Bangladesh.

Sir,Subject: Submission of the report on Industrial Training on Viyellatex Group. We are pleased to submit the report titled Industrial Training on Viyellatex Group as part of partial fulfillment of requirements for our training course. This is a paper focusing on different departments of viyellatex group as an IE. This paper is basically an overview of different departments of viyellatex group that accumulates the IE areas and their associated findings. While writing the report we have tried our level best to draw relevant information keeping in mind the instructions regarding the report writing. We sincerely believe that the paper will significantly help to understand about Viyellatex group and also helpful for industrial engineers in garments sector. Sincerely yours, 1. Tanvir Ahmed 2. Raj Narayan Acharjo 3. Mahmudul hasan 4. Saiful islam 5. Aminul Islam 6. Monoj Kumar Das 7. Zakirul Hasan IPE, 12th batch Department of Industrial & Production Engineering, Shahajalal University of Science & Technology

2

Acknowledgement

First and foremost, we are extremely grateful to my course supervisor, Mr. Abdul Malek. We would like to thank to our supervisor of this project, Mr. Faruque Ahmed for the valuable guidance and advice. He inspired us greatly to work in this training. His willingness to motivate us contributed tremendously to our project we also would like to thank him for showing us some example that related to the topic of our training. Besides, we would like to thank the authority of Viyellatex Group for providing us with a good environment and facilities to complete this training. Also, we would like to take this opportunity to thank to the Dept of IE of viyellatex for offering these subjects. It gave us an opportunity to participate and learn about the operations and procedure of a complete garment industry. In addition, we would also like to thank our coordinator Mr. Nizam Uddin who provides us valuable information as the guidance of our training, also thankful to Engr. Md. Nipun, Engr. Md. G.M. Arshdullah, for their every second supervision to us in preparing this paper we show my great gratitude to all the people of different departments covered for this report especially to Engr. Mahbubul Islam in printing, Mr. Iqbal in planning, Mr. topu in Knitting, Mr. Saikat in Dying, Mr. Jahangir in sample, Mr. Kawsar in CAD, Mr. Razzak in Cutting. Finally, an honorable mention goes to our families and friends for their understandings and supports on us in completing this training. Without helps of the particular that mentioned above, we would face many difficulties while doing this project.

Executive Summary

3

Viyellatex is a fast growing privately owned multi-dimensional business group in Bangladesh. It is head-quartered in Khortoil,Tongi,Gazipur. Starting in 2001 as a knit garments manufacturing, viyellatex has expanded its seven business units in nine years with a 100% knit composite setup. Among this seven, two new business units have been started recently. Viyellatex Group is operating in five different industries with its seven units. A Chief Operating Officer (COO)/Managing Director (MD) runs these units and they reports to the Chairman and Vice Chairman. Garments: swing The core strategic business unit of viyella tex group is the garments unit, its main product is basic knit wear with other knit garments. Product capacity of this unit is 2 million units of readymade garment every month. Viyellatex Embroidery unit is a sub unit producing 1.9 billion stitched embellishments per month. Fabric: Knitting, dyeing, washing. The fabric unit supports the garments manufacturing unit. It has produced 800 tons of dyed fabric. The knit products vary within single jersey, double jersey, pique, lacoste, rib, interlock and auto stripe fabric. Interfab shirt manufacturing Ltd. Is woven garments manufacturing unit of the group. Its capacity of 1 million units of formal and casual shirt per month. Printing: Gothic Design Ltd. Works as the printing unit of the group. It is located in the main premise in organization with a printing capacity of 1.8 million units per month. Yarn: viyellatex spinning Ltd. Is a 100% export oriented cotton yarn manufacturer. The fabric units cotton yarn requirement is fully satisfied by its spinning units. It produces ring (carded and combed) and rotor (open ended) yarn with its 40320 spindle ring and 1280 spindle motor machine. Monthly production of ring and rotor yarn sums up to 900 tons. Accessories: Fashion plastic & packaging Ltd. (FPPL), accessories units of the group. It produces poly bags, hangers, labels, etc. Logistic management: Logistics Management Services Ltd. (LMS) works as a unit to look after the logistics and warehouse management services primarily for RMG sector. It also serves other companies in garments industry as well as its sister concerns. It was established on 530,000 sq. ft. of land which includes 73,000 sq. ft. of covered area. CAD department design and makes marker and design cutting alignment which efficiency is 85%

4

Planning department serve the capacity planning according to capacity they received order and fixed delivery date. Every department has his own planning people and they adjust capacity. And last our main concern about IE department that is Industrial Engineering department this department concern about Check and ensure the layout. Balance the line to ensure minimum Work - In - Process (WIP). Analyze the bottle - neck process. Method study. Grade the operator for new or existing. Follow - up the production and take necessary action for achievement. Update skill inventory regular basis. Maintain liaison with planning & IE for productivity improvement and input. Ensure the instructions of the Industrial Engineering Department. Ensure the follow - up of the cut bundle sheet in the line to ensure efficient assembly operation without any system loss. Implement GSD method in the production floor. Ensure the process flow through proper bundling system. Layout the machine by maintaining proper sequence of operation to ensure best workflow.

5

Table of Contents

Abstract Key-Words Prelude Specific Objectives and Motives Approach Viyellatex at a glance Knitting Dyeing Sampling CAD Cutting Printing & embroidary Swing IE Planning Techno

7 7 7 7 8 8 12 15 16 17 18 21 22 24 25

business25 5S ..28 Discussion .29 Conclusion ..29

6

List of Tables, charts and Figures

Chart 1: Organogram of viyellatex Group Table 1: Viyellatex Timeline Table 2: Viyellatex Awards Table 3: Capacity of knitting Chart 2: Process flow chart of Knitting Chart 3: process flow chart of dyeing & Finishing. Chart 4: Sample making procedure Chart 5: Process flow chart of CAD department Chart 6: Process Flow Chart for Cutting section 20 Fig 1: Printing example Chart 7: IE department Fig 2: SAP modules Chart 7: Total integrated system procedure in Garments manufacturing

9 10 10 13 13 16 17 19

27 29 30

7

1.1.

Abstract:

Viyellatex is a Bangladeshi garments manufacturing company and one of the highest regarded companies in the country for their superior products, for their fair and equal treatment of their workers and for their dedication to various community causes including preserving the environment. The main objective of this study is to give an overview of different departments of viyellatex group that accumulates the IE areas and their associated findings. 1.2. Key-words: IPE, productivity, improvement, cost minimize, renowned, Maintain,

contribution, quality, lean, efficient, Follow up, Method study. 1.3. Prelude

This paper is based on industrial engineering view on garments sector. IPE, industrial and production engineer, in a word productivity improving & cost minimizing machine. They are doing their best in all manufacturing industry. In garments sector IPE doing extremely good. Although Bangladesh is not developed in industry, it has been enriched in Garment industries in the recent past years. In the field of Industrialization garment industry is a promising step. It has given the opportunity of employment to millions of unemployed, especially innumerable uneducated women of the country. It is making significant contribution in the field of our export income. But it is the competitive sector in whole world so for existing in this garments world IPE is needed for improving the quality product as well as productivity with minimizing cost. Viyellatex is a renowned textile & apparel manufacturer in Bangladesh. Its setup is completely vertical with a variety of operational and functional units such as knitting, dyeing, washing, printing, embroidery, stitching etc. Its monthly production varies from 1.5 to 2.00 million pieces. The products are mostly of high fashion. Viyellatex has an IE department which serves very efficiently to company and they doing continuous improvement. Thats why viyellatex is taking position in garments world still now. 2.1. Specific Objectives and Motives

This study attempts to achieve the following objectives:

8

1. To generate idea about viyellatex and its different department. 2. To know what and how IPE do in garments sector. 3. To give any suggestions and comments to improving the productivity.

2.2.

Approach

Upon collection, data has been sorted out according to the subject areas of the paper. This also helped to figure out the major, minor and untouched areas. After sorting, we have prepared summary of individual paper and its findings in short, so that it provides a view on the paper issue. This is basically a short paper where anyone can easily obtain his/her desired information without any colossal effort about different process of garments sector and activities of IPE. Beside that, it will also enable to sort out the common findings or any similar types of findings that is close to each other. 3.1. Viyellatex at a glance

Viyellatex is a renowned textile & apparel manufacturer in Bangladesh. Its setup is completely vertical with a variety of operational and functional units such as knitting, dyeing, washing, printing, embroidery, stitching etc. Its monthly production varies from 1.5 to 2.00 million pieces. The products are mostly of high fashion. Its exporting mainly to Europe. The major buyers are Gstar, Puma, Marks & Spencer, Esprit, S.Oliver, Gerry Webber etc. The yearly turnover of the company is close to $150 million. Viyellatex is using mostly state of the art modern machines in its lines. It has also integrated Information Technology with its business process. To derive maximum value of the IT, the company has introduced SAP ERP in addition to other world famous softwares like Fast React for garment production planning, General Sewing Data (GSD) for controlling the timing & motion of every garment sewing operation, Orgatex for centrally controlling dyeing machines, Garber & Optitex for Pattern Design System (PDS) and a sophisticated local software called KORMEE for accurate payroll processing & human resource management. Although the company is relatively new but within this time it has earned many laurels both from home & abroad. The Company is ethically compliant & maintains transparency at all levels of its business process. The company is committed to human rights and environmental charter. Vision: to be the most regarded company in Bangladesh by 2015. Mission: We strive to provide quality services on time, based on best practices for the satisfaction of our mutual partners & stakeholders. We foster friendly working environment through open communication and respect. We encourage initiative,

9

innovation and teamwork. Workers welfare and right is our premier focus. We are committed for cleaner and greener environment. We are driven by our responsibility to the society as a corporate body

3.2

Viyellatex Values: Integrity Commitment Customer satisfaction Innovativeness Fairness Environment Act in VIYLLATAXs Best interest Be the rare responsible person Self-motivating self-disciplined self-improving acts like a leader doesnt wait to be told what to do never feels thats not my job behave like an owner

3.3. Slogan of the Group:

3.4.

Organogram of viyellatex Group Chart 1: Organogram of viyellatex Group

3.5. Viyellatex Timeline 1996 1998 2002 2003 2005 2007 2009 Viyellatex Garments Woven: Interfab Shirt Manufacturing Ltd. Knit Fabric Unit (Knitting, Dyeing, Washing) Accessories: Fashion Plastic & packaging Ltd. Spinning: Viyellatex Spinning Ltd. Printing & Embroidery: Gothic Design Ltd Tea Estate : Ruthna Tea Estate

10

2009 3.6. Awards Bureau Best Business Award BGMEA Award Gold

Logistics: Logistic Management & Support

Table 1: Viyellatex TimelineNational Export Trophy Export promotion In 2005-20006 DHL-Daily star 2007 PVH Gold Award CIP (Commercially Important Bangladesh Garments Manufacturers In 2007 Standard Bank Express Workers Friendly Factory Best Workers friendly Knitwear industry 2010 For works friendly In 2008 Awaj Foundation In 2008 & & Exproters Association CSR Award Chartered Financial Industrial relations Award HSBC Excellence Award Knitwear Industry In 2010 Export Awaj In 2009 For Export In 2010 Excellence Business Foundation person) status Strategic Partner Award Puma In 2009 Ministry of industry 2009 In 2008 & 2009

(Labour union)

performance

Table 2: Area, Sub-Area and Number of Papers.

3.7. Social Contribution: Green (Environment) initiative: Viyellatex is most renowned environment friendly textile production facility in he world. Our renowned environment initiatives have been well recognized not only by other international business organization but also by World Bank & Asian Development bank as well. Few exemplary initiatives:

11

More than 280000 liters of treated effluent water is being used for 7000 workers toilet flush every day, saving 75 M liters of underground water every day. 250000 square feet roof top is being 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 Viyellatex Spinning Mill. Also in the fabric plant, it is planning to use 3 MW generator exhaust in the Boiler. Both technology saves substantial energy and minimizes global warming. Re-condensed steam water is being transported to the boiler feeder tank which increases the temperature by 15-20 C, saves hefty energy and minimizes global warming.

Fabric dryer exhaust is being redirected to air inlet and feed into the burner toreduce the energy consumption. A simple innovative technique which Viyellatex started to use3 years back and now incorporated by famous GMBH textile Machine manufacturer, Bruckner in their latest series of stenter. 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.

Instead of air condition Viyellatex installed Energy saving evaporing coolingsystem to apparel production floors. Viyellatex is constantly doing projects with International Partners to develop ecofriendly textile products. It did the Carbon foot print project to minimize the carbon emission in the wet processing with the assistance of the world recognize company BASF. Become self-reliant in the society & unique return for any business group of Bangladesh. 4. Different Departments of Viyellatex & possible IE activities: 4.1. Knitting The knitting unit supports the garments manufacturing unit. It has produced 800 tons of fabric. The knit products vary within single jersey, double jersey, pique, and Lacoste, rib, interlock and auto stripe fabric

4.2.

Type of yarn used in knitting unit:

12

THERE ARE VARIOUS TYPE OF YARN USED IN KNITTING IN VIYELLATEX. SOME OF THEM ARE 1. 2. 3. 4. 5. 6. 7. 8. 9. CARD YARN COMB YARN ROTOR YARN ORGANIC YARN MODEL COTTON FARE TRADE YARN SLOB YARN POLY ESTERS LYCRA YARN

Fig: knitting unit of viyellatex

4.3.

Machine used in knitting unit

4.3.

Knitting Process: Chart 2: Process flow chart of Knitting

4.4.

Capacity: KGS/Day Machine types Single jersey RIB Fleece Auto stripe Total Collar & cuff number 35 19 10 8 72 25 Table 3: Capacity of knitting capacity 11200 6500 2500 800 21000 7060 sets/day

13

4.4. KNITTING FAULTS:

1. Barrre. 2. Press-off. 3. Miss-stitch. 4. Needle Mark. 5. Sinker Mark. 6. Oil Stain. 7. Crease Mark. 8. Holes. 9. Slubs. 10. Spirility. 11. Broken Needle. 12. Pin Hole. 13. Tight Course. 14. Missing Yarn. 15. Course Yarn. 16. Soiled Fly. 17. Etc.4.5. 4.6. Maintenances: Use Air gun to pass the yarn through miminger pipe. Tension of yarn should be lower otherwise it will be discarded. Check the polyester visibility. Use same loose or intake licra. Possible IE Activities: Thread consumption. Planning. Statistical Inspection.

14

4.7.

Problems:

The study of this problem has led to the identification of two main categories of defects in knitted fabrics: horizontal and vertical variations. While the first category is mainly due to the yarn (quality and management), the second category is related with the knitting elements: needles, sinkers, feeders, and so on. According to workers information approximately 3 hours are spoiled to readjust the yarn.

4.8.

Solution:

The solutions encountered for solving these problems are, for the first category, a careful selection and management of the yarn, and for the second, the correction or substitution of the defective elements. In order to deal with these problems, various studies have been conducted and some specialized systems were developed, which can detect abnormalities in the yarn being fed, defects in the knitted fabric and defects in the knitting elements. For the detection of yarn problems most systems will stop the knitting machine when the yarn input tension falls below some limits. The systems based on the detection of knitted fabric faults are basically photoelectric cells located very near to the fabric, inside or at one side of the machine cylinder. With the help of a lamp conveniently orientated, these systems detect holes and dropped stitches. The systems used for the surveillance of defective knitting elements are normally optical or capacitive sensors analyzing, respectively, the shadow produced by the knitting element or the electric field variation produced by the elements, looking for broken needles, closed latches and broken sinkers. These systems are very effective and are capable to detect with high accuracy the position of the defect, stopping the knitting machine immediately, thus reducing loss. Unfortunately they are much specialized and usually do not give further information related with the knitting process and the cause of a defect. Furthermore some abnormalities pass through without being detected.

15

5.1.

Dyeing

Viyellatex Dyeing is covered by the 22 dyeing machines & 2 Turning machines and every machines are German branded and we have 30 tons per day dyeing capacity. 24 hours running our dyeing section by the three shift 3 hundred workers are working in our dyeing section.

5.2.

Dyeing procedure:

Chart 3: process flow chart of dyeing & Finishing

16

5.3.

Finishing

Viyellatex Finishing section in the Fabrics unit

equipped 18 machines. It 24

hours running as per dyeing production by the 3 shift & 300 workers. We have both open width & tubular fabric finishing facilities including brushing, seeding, Teflon and nanotex special finishes.

Chart 4: process flow chart of dyeing & Finishing

5.4 MACHINES USED IN DYEING UNIT: MACHINES SLITTING M/C OPEN COMPACTOR STENTER DRAYER TUBE TEX COMPACTOR HYDRO EXTRACTOR DYEING MACHINE 5.5. IE Activities: Planning & Statistical Inspection. Sample: QUANTIT Y 4 1 2 2 1 1 19

OPEN

6.1.

Generally 3 types of sample are made for byer Proto sample Fit sample Sales man sample If SMS is rejected then siling sample are made if silling sample is accepted then it is called Golden sample. 6.2. Sample making Procedure: Chart 4: Sample making procedure. 6.3. IE activities:

17

Decision making that these types of garments can be possible to make with our existing system, is there any types of new machines or workers are needed or not by seeing tag pack. CAD

7.1.

In viyellatex they use OPTITEX-PSD 10 software for garments design and ACCUMARK EXPLORER for marker design. Its the advanced software they used for making marker which efficiency is more than 85%. Now we have to know what difference is between CAD Marker Making & Manual Marker Making. Comparison between CAD Marker Making & Manual Marker Making: 1. In manual system the system is used to make maker for garment making is traditional. But in CAD system marker making is done in modern system.2. Marker efficiencies are not visible in manual system. Other hand, marker efficiency is visible in CAD system. 3. Marker length is not visible in manual system. Marker length is visible in monitor screen at CAD system. 4. In manual, once marker is made, not possible to increase its efficiency. But in CAD it is possible to increase the efficiency at any time. 5. Marker copying is not possible manually. In CAD, by using Plotter as much as possible copy can be done. 6. Manual marker making is very time consuming method whereas, CAD is a faster method. 7. In manual system quality cannot be assured. It has quality assurance. 8. Manual system costing is low but CAD is expensive. 7.2. Process of making CAD marker:

1. Take the Software for pattern making and marker making. 2. Install this software on computer. 3. Here some garment measurement is needed. 4. Free hand sketching of each part of garment on monitor by mouse. 5. Check shape and measurements on each 6. Save this work. 7. Automatic grading is carried out. 8. Again Save it. 9. Then start marker making by one another software in the same network. Principles of Pattern Making: A garment sewing patterns or garment fabric & patterns draft is developed by calculating, taking account of the following measurements: 1. Direct Sample. 2. Specification Sheet/ Measurement Chart. 3. Actual body size measurements. 4. Easy Allowances. 5. Sewing Allowance.

18

7.3.

How the CAD department works

Chart 5: Process flow chart of CAD department

8.1. Cutting: From CAD the markers have come to cutting department and then it cut by manually or Garber cutter.

8.2.

Process Flow Chart for Cutting section

Chart 6: Process Flow Chart for Cutting section 8.3. 9.1. Possible IE activities: Check and ensure the layout. Balance the line to ensure minimum Work - In - Process (WIP). Analyze the bottle - neck process. Method study. Grade the operator for new or existing. Maintain liaison with planning & IE for productivity improvement and input. Ensure the instructions of the Industrial Engineering Department. Ensure the follow - up of the cut bundle sheet in the line to ensure efficient assembly operation without any system loss. Ensure the process flow through proper bundling system. Printing department:

Printing is a process for reproducing text and image, typically with ink on paper, cloth using a printing press. It is often carried out as a large-scale industrial process, and is an essential part of publishing and transaction printing. Gothic Design is situated in viyellatax garments unit-2 building at 1st & 6th floor. There have 4 automatic machine & 25 production table and 50,000(50 thousand) per day production capacity and around 3 hundred male & 130 female workers working at two floor.

19

Fig 1: Printing example There are many types printing are done here like type etc. 9.2. 9.3.

Robber type, Discharge type, Silicon

Step of printing 1st made frame Made the design of print on the frame Use water flash for wash the frame By colour combination made desire colour for pi Use printing machine for printing on fabric printing is also done by manually After printing use dryer for dry the print Use curin temp. Machine for dry the print hardly Quality inspection If quality is ok then it sends to the cutting Dept. IE activities: Implement GSD method in the production floor. Ensure the process flow through proper bundling system. Layout the machine by maintaining proper sequence of operation to ensure best workflow. Check and ensure the layout. Balance the line to ensure minimum Work - In - Process (WIP). Analyze the bottle - neck process. Method study. Grade the operator for new or existing. Follow - up the production and take necessary action for achievement. Update skill inventory regular basis.

Comment: problem in supply chain there are few idle man and line. 10. Embroidery department Viyellatex Embroidery unit is situated at ground floor unit-2 building. Embroidery unit equipped by the 8 machines 2 shift & around 150 workers working and per day production capacity 14,000(14 thousand) pcs Embroidery 2 types Applicable Non-applicable Types of stitch in Embroidery Molf stitch Run stitch Tatami stitch Jig jag stitch Motiv stitch

20

11.1.

Chain stitch Loop stitch Swing Department:

Sewing or stitching or tailoring is the fastening of cloth, leather, furs, bark, or other flexible materials, using needle and thread. Its use is nearly universal among human populations and dates back to Paleolithic times (30,000 BCE). Sewing predates the weaving of cloth. Viyellatex is an export oriented knit garment manufacturing unit established in 1996. Now it is the single largest ISO certified knit garments in Bangladesh. Currently it has 80 sewing lines with auto trimmer and mostly oil-free dry head machine with the capacity of 2.50-3.00 million pcs. 11.2. There Type of sewing machine in viyellatex: Plane machine Over lock machine Flat lock machine Chain stitch machine Button stitch machine Hole stitch machine Blind stitch machine Smoking machine Rip cutter Back cutter Kansai machine Vertical trim machine are 3 types of garments according to operation time Basic- SMV < 10 min Semi-critical < 15 min Critical > 15 min

Here a procedure of Swing a basic garment Garments: G.star 9405 Process Back front match Shoulder join Main label join Neck binding Neck finishing Plain label making Care label Slip match Slip join Machine Manual OL PL FL CS PL PL Manual OL

21

Side sim join Side hem join Body hem join Patch label attach QC table Measurement check

OL FL FL PL Manual manual

Table 4: Basic garments Swing procedure 11.3. IE activities:

Priority activities. SMV calculation Check and ensure the layout. Balance the line to ensure minimum Work - In - Process (WIP). Analyze the bottle - neck process. Method study. Grade the operator for new or existing. Follow - up the production and take necessary action for achievement. Update skill inventory regular basis. Maintain liaison with planning & IE for productivity improvement and input. Ensure the instructions of the Industrial Engineering Department. Implement GSD method in the production floor. Ensure the process flow through proper bundling system. Layout the machine by maintaining proper sequence of operation to ensure best workflow. 12.1. Industrial Engineering Department:

One of the major departments in viyellatex group is IE department. IE department arrange technical meetings where all the decision are made so it can be said that IE department Coordinate all others department in Viyellatex group. 12.2. IE Activities Check and ensure the layout. Balance the line to ensure minimum Work - In - Process (WIP). Analyze the bottle - neck process. Method study. Grade the operator for new or existing. Follow - up the production and take necessary action for achievement. Update skill inventory regular basis. Maintain liaison with planning & IE for productivity improvement and input. Ensure the instructions of the Industrial Engineering Department. Ensure the follow - up of the cut bundle sheet in the line to ensure efficient assembly operation without any system loss. Implement GSD method in the production floor. Ensure the process flow through proper bundling system. Layout the machine by maintaining proper sequence of operation to ensure best workflow. Risk analysis Thread consumption Arrange technical meeting. Priority activities.

22

12.3.

SMV calculation Costing Create lean environment IE department works with two wings

IE Department

Operational Team

Analytical eam

Chart 7: IE department Operational team set the targets and analytical team takes necessary steps to achieve this targets. 13. Planning department:

Planning department has done capacity planning to the whole organization. They have done it in a year basis. And they receive order from the byer according to the capacity. They coordinate all the planning people in others department. They select line where the garments run. 14.1. Techno business department

When textile manufacturer Viyellatex Group needed to integrate and standardize realtime data and business processes across its independent business units, it chose the SAP ERP application. SAP Enterprise Support services, provided by the SAP Active Global Support organization, helped Viyellatex meet its goals. 14.2. Why SAP? Close collaboration and continued engagement with SAP Best-practice implementation methodology Protection of mission-critical operations combined with fast and predictable resolution of major project issues Enablement of integrated and standardized solution operations 14.3. Challenges and Opportunities Implement the SAP ERP application to harmonize real-time data and business processes across various independent business units and divisions Achieve operational excellence Ensure transparency, enhance productivity, and reduce wastage 14.4. Objectives Implement SAP ERP and the SAP Apparel and Footwear application with minimal disruption to business Establish guaranteed service-level agreements

23

14.5. Benefits High level of confidence in IT organization Maximum value from investment in SAP solutions Continuous quality checks to help ensure smooth implementation and subsequent operations Quick issue resolution with service-level agreements for mission-critical situations 14.6. SAP Solutions and Services SAP ERP SAP Apparel and Footwear SAP Enterprise Support services, delivered by the SAP Active Global Support organization

14.7. SAP Modules:

Fig 2: SAP modules.

24

15.

Total integrated system procedure in Garments manufacturing:

Planning SD Sample16. Impementing 5S System in Garments Sector

SD

Impact of 5S implementation reduce inventory, efficient on workplace usage, reduce time for searching spare part, reduce oil / water / air spilled, reduce un- SD stabilization, preventive of machine function, cleaning checking machine condition, improve working condition, reduce work accident, increase discipline, follow procedure, and better relationship among employee. Keys to successful implementation of 5S IE GET EVERYONE INVOLVED 5S is not being the responsibility of a concerned few. It is a concern of every one to act. All levels of management should take part in decision making required to ensure 5S implementation. Incorporate 5S activities as part of companys small group activities. GET COMPANY AUTHORIZATION 5S activities should not be performed in a secret or disguised such as overtime work. Get management approval for all 5S activities. Make signs and posters as means to promote 5S for everyone. Conduct a general monthly meeting where company and managers can address 5S issues and themes. FINAL RESPONSIBILITTY RESTS WITH THE PRESIDENT: The 5Ss will not be taken seriously until the managers and even the company president take personal responsibility and interest on its implementation. Nothing could be worse for the success of 5S implementation than to have managers who pass the 5S implementation buck to their subordinates. Company managers must take a strong leadership role in 5S promotional meetings and other 5S events. MAKE YOURSELVES UNDERSTOOD & AWARE OF: Dont leave people wondering Why are we sticking red tags on things? or Is all this 5S stuff really necessary before we can make any improvements? Hold 5S promotional meetings to clearly explain 5S and to entertain all questions from all participants. Present actual examples of successful 5S implementation, or take participants on tour to successful 5S workplaces. DO IT ALL THE WAY: When establishing proper arrangement, make sure to carry out red tag campaigns and use correct red-tagging formats and procedures. When establishing orderliness, use signboards. Make sure the signboards have proper format, descriptions, and locations. Prepare your companys own 5S manual, complete with all the necessary details. THE PRESIDENT SHOULD INSPECT THE GEMBA (SHOPFLOOR) PERSONALLY: The President should personally inspect offices and point out their various positive and negative conditions. The President should help by pointing out specific improvement items and proposing improvement themes at 5S promotional meetings. GEMBA should work individually as well as in groups to study and report on improvement methods taken in response to improvements suggested by the President.

25

DONT STOP HALFWAY IN ESTABLISHING 5S: Dont do things halfway. Once the 5S promotional organization and methods have been established, get started and stick with it. When developing red tagging and signboards throughout the company, make sure gets everyone involved. Once you have laid the foundation by establishing proper arrangement and orderliness, start developing discipline habit to keep the foundation strong. 5S IS A HALFWAY TOWARD OTHER IMPROVEMENTS: Dont stop with 5S: Follow through with Zero Defects, Cost Reduction, and other Productivity & Quality improvements. Once the office has been cleaned up, start putting casters on drawer cases to make them easily movable. Eliminate defects as close to their source as possible and implement flow process. By implementing 5-S, eventually productivity, efficiency and working spirit will be promoted. It is not only useful to manage work place physically but also useful to develop employees attitudes and discipline.

17. Discussion: Viyellatex. is a Bangladeshi garments manufacturing company and one of the highest regarded companies in the country for their superior products, for their fair and equal treatment of their workers and for their dedication to various community causes including preserving the environment, employing the disabled and being the only Bangladeshi company represented in the United Nations Global Compact. I was excited to see how garments are made and I learned a lot. I have a new appreciation for the clothes that we wear and the work that goes into making them and preparing them for purchase. I have learned how IE works whats kinds of works they do.

18.

Conclusion:

In order to obtain information about the extent of lean production practices and manufacturing performance improvement in the selected Bangladeshi garment firms, the study examined the adoption of various lean tools and the benefits derived from these lean practices. The study also identified the supporting and hindering factors in lean implementation. An analysis of the available data indicate that, in the selected garment firms in Bangladesh, lean practices have a significant relationship with a number of positive outcomes. These outcomes include: decrease of unit production cost, up-scaling quality of products, reduction of lead time in the production process, reduction of manufacturing waste in all forms, reduction of manufacturing cycle time, reduction of inventory of raw materials and finished goods. When compared to similar studies, the results of the present study demonstrates that the Bangladeshi garment firms are experiencing similar barriers, benefits, as well as improvements etc. to the implementation of improvement initiatives. This indicates that the companies in the EPZ represent the best possible environment for Bangladeshi companies and so represent the best case scenarios and a benchmark for other companies in Bangladesh. For this lean practice the company should recruit Industrial Engineers.

26