Industrial attachment of opex group

Industrial Attachment Report 2013

1OPEX GROUP

INDUSTRIAL TRAININGCourse Code: Tex -4036

INDUSTRIAL ATTACHMENTOPEX GROUP


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IndustrialAttachment

ReportAt


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OBJECTIVE OF INDUSTRIAL ATTACHMENTB. Sc in Textile Technology is the combination of theoretical knowledge along

with the practical experience. We as the Graduates of Textile Technology

must acquire adequate practical knowledge to cope up with the challenge

that we will face in future. This is the why the Industrial Training has been

included in our academic curriculum.

The main objective of this training is to comprehend our theoretical

knowledge along with the practical knowledge. It also enables us to orient

ourselves with the practical environment that we will work in future. We

systematically learned about various steps of garment manufacturing.

Moreover we knew about the man management technique. We also learned

about merchandising and buyer co-ordination.


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INTRODUCTION

By achieving practical knowledge it is possible to apply the theoreticalknowledge in the technical field. For any technical education, practicalexperience is almost equally necessary in association with the theoreticalknowledge. The industrial attachment is the most effective process of achievingthe practical experience. It provides us sufficient practical knowledge aboutproduction management, productivity, evaluation, work study, efficiency,industrial management, production planning & control, production cost analysis,inventory control, purchasing, utilities and Maintenance of machinery and theiroperation technique etc.

Industrial attachment is an essential part of four years B.Sc. in Textiletechnology course of College Of Textile Technology under University of Dhaka.We had the opportunity to perform the industrial attachment with OPEXGROUP LTD. During 60 days long attachment, we studied the man, machine,material, quality control section, planning section, grey fabric inspection,finished fabric inspection, dyeing & finishing section, merchandising section ofthe mill. We also had a short visit in the garments section of the factory.


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Table of Content

Chapter Contents Pageno.

Chapter-i Project description 6-12Chapter-ii Manpower management 13-18Chapter-iii Machine description 19-25Chapter-iv Raw materials 26-27Chapter-v Production planning, sequences &

operations28-33

Chapter-vi Quality assurance system 34-37Chapter-vii Maintenance 38-44Chapter-viii Utility services 45-48Chapter-ix Store & inventory control 49-50Chapter-x Cost analysis 51-52Chapter-xi Marketing activities 53-57Chapter-xii Garments washing 58-70Chapter-xiii Merchandising 71-70Chapter-xiv Conclusion 73-77


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CHAPTER- I

(PROJECT DESCRIPTION)


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Name: OPEX FASHION LTD. (a sister concern of OPEX & SINHA TEXTILE GROUP)

Type: Ready made garments(100% Export oriented Woven& knit garments Industry).

Status: Private limited company

Location: Mirpur-13 , Dhaka.

Year of establishment: 1984

Sponsors: Anisur Rahman SinhaAddress:

a. Dhaka office:56/1,Block#C,Section-13,Mirpur,Dhaka-1216Bangladesh.

Tel: 801544680152418023726-7

Fax: 880-2-8013522

b. Head Office:House # 368, Road # 28, New DOHS, MohakhaliDhaka-1206, Bangladesh.Tel: 88-02-8828860-4, 9891390-1Fax: 880-2-8828856-7

c. Kanchpur Office:

Sinha Textile Complex,Kanchpur ,Sonargaon,NarayanganjTel:7618066,7618055,7617788.

d. Hongkong Office:

Joyful Miles Ltd. 16B Alpha HouseTel: 2721-1950(5 lines), Fax: 2721-1967E-mail: [email protected]


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Factory Location:

Mirpur-10

OPEX

BananiCantonment

Mirpur-14

KachuKhet


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PRODUCT MIX:

a) Woven Garments: Shirt,Jacket,Pant/Trousers,Shorts Jeans item,Ladies &Children item.

b) Knit garments:

T-shirt, polo shirt, Short / trouser, Knitted pant, Vests

DAILY PRODUCTION CAPACITY:

Garments: 40000 pcs (Dhaka Zone)

No. of line: 32(Dhaka zone) &100 (Kanchpur zone)

MONTHLY EFFICIENCY:

Daily production: 40000 pcs Approx.Daily production capacity: 45,000 pcsSo, monthly production: 1040000 pcsMonthly production capacity: 1170000 pcsSo, Monthly production efficiency= 88%

PROJECT COST:

US$1,0000000per year (approx) in 2007

US$1,5000000Projection for 2008.

DIFFERENT DEPARTMENTS:

1. Marketing and Merchandizing

2. Lab department


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3. Quality Assurance

4. Garments& GGT Lab

. Cutting

Sewing

Finishing

Inspection

Packing

5. Stores

6. Technical Department (Maintenance)

7. Human & Resource and Administration

8. Account and commercial section

9. Batching section

TOTAL AREA OF THE INDUSTRY: 15000 sq. feet & 4 building,

OPEX FASHIONS LTD : 10 Storeyed

OPEX STYLE WEAR LTD: 8STOREYED

SINHA STYLE WEAR LTD : 12 Storeyed


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COMPANY PROFILE:OPEXOpex is one of the largest garment manufacturing conglomerates in Asia and has a complete verticalintegrated setup in woven, knit and sweater with most modern and state of the art machineries fromUSA, Europe and Japan. It is a private owned company with an annual turn over of US $ 350 millionand annual export is about US $ 250 million.

Garments DivisionOpex has over 18000 sewing machines distributed to 300 production lines including 40 Knit garmentlines and 2000 Sweater machinery. It produces over 220,000 pieces of garment every day. Theproduction lines are broadly earmarked as Bottom lines, Shirt lines and Knit lines.

Bottom FactoriesOpex has about 210 bottom production lines and they produce over 140,000 pieces of garments daily.These are organized into dress pant lines, casual pant lines, cargo short/ pants lines and denimproduction lines.Dress and casual pant lines have some specialized sewing machines like pocket welting machines,zigzag operations machines, blind stitch machines, front fly J-stitch machines, etc. Finishing of casualand dress pant is done with lager and topper press machines, seam opening and pressing machines,curing oven etc. Other than standard denim production line Opex has 16 dedicated specialized denimproduction lines, equipped with fully automated computerized sewing and finishing range machinesfrom Italy. Each line produces 230-250 pieces of 5-pocket jeans in one hour, totaling to 34000-37000pieces daily.

Shirt factoriesOpex has 48 dedicated shirt lines which produces 35,000 to 40,000 pieces of casual, sports and formaldress shirts daily. The formal and dress shirt lines are equipped with Droukoff Adler sewing machinesof Germany fitted with servo motors and trimmers which ensures consistency in sewing and eliminatespuckering effects. Collar & cuff making and setting, placket making, pocket making & setting and armhole fusing are all done with computer controlled automatic machines. The finishing units haveautomatic collar, cuff, arm hole and body pressing machines for perfect finish.

Knit Garment FactoriesOpex’s 40 Knit garment lines have over 2000 sewing machines and it produces about 60,000 pieces ofT-Shirt, Polo Shirts daily. These lines can also be converted to produce shirts or ladies dresses bychanging and adding few machines.

Sweater Factory


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Our major production is on 12 gauge. However we have production facilities in 10 gauge, 7 gauge, 5and 3 gauge. Presently we have about one hundred thousand production capacity per month butrecently have gone into expansion this will have capacities from Dec ’08 about two hundred permonth.

Dry and Wet Processing FacilitiesThe in house dry and wet processing units of Opex includes sand blasting, brushing, chemicalspraying, laser blasting, heavy, medium and light wash facilities and post cure wrinklefree processing facilities.Opex has one of the most modern denim washing facilities in the country equipped with computercontrolled European machines. Denim wash capacity is about 1,00,000 pieces daily. It also has 55belly type Chinese machines to take care of other washes. It has two modern dry finish units withmodern equipment with curing oven.

Backward Linkage and Vertical Setup of OpexCustomer’s increasing need of varied range of fabric, shorter lead time, sharper price and consistentquality, led Opex to set up its own vertical set up in 1995, named as Sinha Textile Group. Theobjectives of these facilities are; attaining consistency in fabric quality, developing specialized fabric &offering competitive price and shorter lead time.Opex today has the entire chain of backward linkage facilities of spinning, weaving, yarn dyeing, fabricdyeing & finishing, knitting, knit dyeing and finishing. State of the art machines, Textile experts fromhome & abroad have been combined together to make wide range of high quality woven fabric forbottom, shirt & Knit fabric.Supporting EstablishmentsTo support garments manufacturing, Opex has its own button factory, label factory, Sewing Threadmanufacturing unit and Embroidery unit. It also has its own Carton and Poly manufacturing factory.We have also joint venture with IDEAL Zipper factory in Bangladesh.

Opex has done massive expansion in increasing its garments production, washing and finishingcapacities as well as increasing capacity and adding new technology in its backwards integration unitslike compact yarn, producing high density fabric, wet sueding and different types of fabric finishingetc.

Denim Village.Recently, we have established a massive project named denim village where we are producing, Denimfabric, Denim garments, Denim Washing, and different types of finishing in one complex.

Opex can convert all its fabric into Garments and will produce about 65000 pcs Denim Jeans andJacket per day.

Conclusion.Opex with over 45,000 work forces is in business for more than two decades. It always tries andmaintains its commitment of on time delivery, quality and competitive price. Over the years, thebusiness relations with all customers and partners have grown stronger based on mutual trust andcommitment.

Opex is an ethical and compliant company, putting in maximum emphasize on developing humanvalues, qualities of human life and comfort of work environment. It is committed to ensure ethicalsource place for the customer.


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CHAPTER- II

(MANPOWER MANAGEMENT)


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ORGANOGRAM MANPOWER:

Chairman

Executive Director

General Manager

Deputy General Manager

Asst. General Manager

Merchandising Manager

Sinior Merchandiser

Merchandiser

Production Manager

Sample incharge Cutting incharge Sewing inchargeQuality inchare

Cutting executive Line supervisorOperator Operator

Cutting supervisor Operator

Helper HelperMarker man Helper


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Cutterman

MANAGEMENT SYSTEM:

GARMENTS SECTION: 8 hours per day.8 AM-5 PM. Overtime: 2hours.Offday: Thursday in a week.

RESPONSIBILITIES OF PRODUCTION MANAGER:

RESPONSIBILITIES OF SAMPLE ROOM INCHARGE:To make pattrn from specification sheet.When there is no measurement chart then he make specification chart by

his own idea, then send to buyer,if it is ok then he make pattern.After making sample he check the sample if it is ok , then he order to

make 4 pcs of the sample.

RESPONSIBILITIES OF CUTTING INCHARGE:Check the relaxation of fabric,order wise quantity measure, patterncutting

with signature,befor sewing to communicate the print embroidery.To ensure equal input & output.To check fabric shrinkage, twisting repair.To make the cutting plan according to operation breakdown.To give target and style devide in every table.

RESPONSIBILITIES OF QUALITY INCHARGE:To control the overall quality of the garments.To brief the incharge about tentative problem of quality.To make size set of the garments.To check the measurement of the garments, if required increase or

decrease

RESPONSEBILITIES OF PRODUCTION OFFICER: From getting anorder of upper level all responsibilities are on the production officers. Theywork with a troop of operators, helpers, fitters etc. to finish the production indue time. In the meantime


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Production officers bear all hazards, problems. They have to explain to themanager for any type of production hamper. So all production activities and itssuccess depend on the production office.

MANPOWER MANAGEMENT

ADMINISTRATIVE STRUCTURE OF OPEX GROUP:

CHAIRMAN

EXECUTIVEDIRECTOR

ADMIN&EESTB

STORE ACCOUNTS

COMPUTER COMPLINCE

DGM GM D.G.M.

UNIT-IN-CHARGE

UNIT-IN-CHARGE

INCHARGE

UNIT-IN-CHARGE

INCHARGE

UNIT-IN-CHARGE

TECHNICAL

DGM

MEDICALOFFICER

TRAININGINSTITUTE

PRINCIPAL ELECTRICALMECHANICAL

AGMAGM

AGMAGM

INTERNAL&EXTERNALADMIN &DAYCARE

CLEANER&SANITERYINCHARGEPERSONAL

TIMESECURITYINCHARGE

SECURITYSUPERVISOR


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ORGANOGRAM OF QUALITY CONTROL DEPARTMENT:

GENERAL MANAGER (QUALITY )↓

ASST. GENERAL MANAGER↓

MANAGER↓

ASST. MANAGER↓

QUALITY- IN-CHARGE↓

QUALITY CONTROLLER↓

LINE Q.C.

ORGANOGRAM OF WASHING DEPARTMENT:

OFFICER-IN-CHARGE (O.I.C.)↓

ASST. OFFICER-IN-CHARGE

↓MANAGER

↓FLOOR-IN- CHARGE

↓ASST. MANAGER

↓

QUALITY INSPECTION CONTROLLER↓

QUALITY CONTROLLER


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↓

SUPERVISOR

↓OPERATOR

TOTAL EMPLOYEES:

DESCRIPTION NO OF EMPLOYEES TOTAL EMPLOYEESMERCHANDISING STUFF 40

5976

IT STUFF 04SAMLE MAN 150

Q.A-RAW MAT.INSPECTOR

10

Q.A-IN-LINE INSPECTOR 250FLOOR Q.C 50

Q.A AUDITORS 30CUTTING SECTION 200SEWING SECTION 3200

TRIMMING/ FINISHING 500PRESSING & PACKING 600

PACKING 250ELECTRICIAN/MECHANICS 150

WASHING,SANDBLASTING & SAND

BRUSHING

200

PRINTING 12PACKAGING 50

POLY 30QUILTING 30

EMBROIDERY 20OFFICE STUFF & OTHERS 200


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REMARKS:

Production runs with the help of mechanical fitters. For any kind of mechanicalfault of any machine they fix and work under knitting manager. Productionofficer takes account of daily production by running after the two supervisors& workers so on.

CHAPTER-III

(MACHINE DESCRIPTION)


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LOCK STITCHM/C LOCK STITCH M/C

H/S D/N LOCKSTITCH 4-holed button sewing


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CHAIN STITCH BUTTON SEWER 4 NEEDLE DOUBLE CHAINSTITCH

MULTI-NEEDLE DOUBLE CHAIN STITCH MAIER BLIND STITCH MACHINE


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SIMPLE PUSH-BUTTON TYPE STITCH FLAT-LOCK SEWING MACHINERY

OVERLOCK MACHINES STRAIGHT KNIFE CUTTING M/C


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MACHINE DESCRIPTION

MACHINE DESCRIPTIONType of Machine Quantity(Sets) Sewing Capacity

A. General SewingMachine

40,000 pieces per day

Single Needle 1000Double Needle 421Over lock 320Kansai 50

Bar Tack 200Button Stitch 150Button Hole 100Eyelet Button Hole 25

Bottom Hem 50Flat Lock 65Snap Button 30Blind Stitch 25Feed of the Arm 150

Cutter m\c 100Heat Cutter 15Fusing m\c 15

Over lock Elastic Attachingm\c

6

Arm Hole Sewing m\c 15Total 2737


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B. Specialized SewingMachine

Auto Patch Pocket Setting 2Auto Welt Pocket Setting 10

Waist Belt Setting 15Seam Sealing 15Zigzag 10Elastic Attaching 12Pattern Sewing 10Auto Loop Attaching 5Snap Testing m\c 5Pattern(Collar& Cuff) m\c 5Pocket Facing 10

Picoting 2Velcro Cutter 10Feather Filling 4

Total 115

Cutting Room Cutting CapacityFabric Inspection m\c 05

50,000 yards/dayLight Box 02Gerber Cam 2Gerber Auto Spreader 5Manual Cutting Table 20

Manual Cutter 100Finishing Room Finishing CapacityNeedle Detector 5

20,000 pieces per dayHang Tagger Attachingm\c

20

Steam Iron 150Thread Sucking m/c 15

CAD RoomGerber CAD 2Gerber Plotter 1Gerber Digitizer 1

Support CapacitySteam Boiler 02 1.5 MWGenerator 02

Other ProjectsPoly Bag Making ProjectCarton Making ProjectPrinting ProjectQuilting

Embroidery 20 heads on each end and up


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to 15 colorsPin Point Stitch m/cVacuum Iron TableLay End Cutting m/c

Washing PlantType of Machine Quantity (Sets) CapacitySample Washing m/c 05 500 lbs

Washing m/c 14 40,760 lbsWashingm/c(Tonello+Yilmak)

5 12600 lbs

Hydro Extractor 8 2,610 lbsDryer 12 32,600 lbs

Sand Blast m/c 02 1000 pcs per dayLaser Blasting 2 500 pcs per day

Sand Brush m/c 10 3000 pcs per dayE.T.P 1 80 cubic meter per hour

Average Production Capacity 30,000 pieces of gt per day


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CHAPTER-IV

RAW MATERIALS


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RAW MATERIALS OF OPEX FASHIONS LTD

Garments Section:

Fabric woven

Button

Zipper

Sewing thread

Main label

Care label

Tag pin

SOURCES OF RAW MATERIALSRequired raw materials are purchased from following countries through agent :a. Taiwanb. Philippinesc. Indiad. Germanye. Brazilf. Pakistang. South China

Soucing tag

Price ticket

Hanger

Sizer

Size sticker

Poly bag

Cartoon


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CHAPTER-V

(Production Planning,Sequences & Operations)


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DESCRIPTION OF PRODUCTION PROCESS(GARMENTS SECTION):

]

Squence Operation for Sample Section:

Product Package

Make PatternIf not OK

Make Sample

Send to Buyer through Merchandiser

If OK

Collect the approved Sanple

Sequence Operation for Cutting Section:

Fabric Inspection & relaxation

Fabrid spreading

Fabic cutting

Parts numbering

Part inspection


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If any defect is found then make this part

Sequence Operation for Sewing Section:

Front Yoke joining

Elastic join

Topstich

Sleeve join

Front Yoke join

Sleeve join

Elastic tuck

Elastic tuck

Elastic join

Back part piping

Front Yoke+Sleeve+Back Yoke Joining

Elastic ¼ Stiching

Vertical tuck

Sleeve opening tuck


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Side seam

Chup tuck

Sleeve opening chup tuck

Hem

Inspection

OPERATION BREAKDOWN : FIVE POCKET JEANS (JC PENNEY)BACK PART MAKINGSerialNo

Name of Operation Machine used No of Machine

1 Back Pocket Rolling 2 Needle Machine 12 Marking Table3 Back Yoke Joining in Folder System Feed of the Arm m/c 14 Back Rise Joining Plain Stitch m/c 15 Back Rise Top Feed of the Arm m/c 16 Back Pocket Positioning on Marker

Table7 Back Pocket Joining Plain Stitch m/c 18 ¼” Stitch on Pocket Joining Plain Stitch m/c 1

FRONT PART MAKINGSerialNo

Name of Operation Machine used No of Machine

1 Pocket Matching2 Ironing3 Coin Pocket Attaching 2 Needle m/c 14 Label Joining Plain Stitch m/c 15 Coin Pocket Attaching with Front

FacingPlain Stitch m/c 1


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6 Number Match with Front Part7 Coin Pocket Joining with Front Part Plain Stitch m/c 28 Front Pocket Rolling 2 Needle m/c 19 Pocket Tuck Plain Stitch m/c 110 Pocketing Over Lock Over Lock m/c 111 Single Fly Join with Top Stitch Plain Stitch m/c 112 Pocket ¼” Top Stitch Plain Stitch m/c 113 Front Pocket with Front Tucking Plain Stitch m/c 114 Zipper Joining 2 Needle m/c 115 J - Stitch 2 Needle m/c 116 Double Fly Joining Plain Stitch m/c 117 Front Rise Stitch 2 Needle m/c 1

BODY SECTIONSerial No Name of Operation Machine used No of Machine

1 Back & Front Part Match onTable

2 In Seam Plain Stitch m/c 13 Top Seam on In Seam Feed of the Arm m/c 1

4 Side Seam Over Lock m/c 25 Hemming Plain Stitch m/c 16 Waist Belt Matching by

Number7 Waist Belt Sewing KANSAI 28 Edge Neatening of Down Part

of the WaistPlain Stitch m/c 2

9 Waist Top Part Making10 Waist Top Part Edge

NeateningPlain Stitch m/c 2

11 Checking by LQC12 Belt Loop Matching13 Loop Tuck on Down Side of

WaistPlain Stitch m/c 2

14 Loop Joining with Top Side ofWaist

Plain Stitch m/c 2

15 Final Inspection16 Loop & Back Part Bar Tacking Bar Tack m/c 217 Side Pocket Tucking Plain Stitch m/c 1


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SUMMERYPlain Stitch Machine - 362 Needle Machine - 07Over Lock Machine - 04Bar Tack Machine - 02KANSAI - 02Feed of Arm Machine – 04Production - 1000 pieces per dayManpower - 94 persons

REMARKS:As OPEX FASHION LTD a big project; its production quantity is huge.

Production quantity varies as according as buyers demand. It gives approximately 500-ton and1000000 pcs production per month. In Bangladesh, there are a few mills, which can producesuch quantity of garments.


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CHAPTER-VI

(Quality assurance system)


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QUALITY ASSURANCE SYSTEM:

All rolls are kept in front of the inspection m/c time to time and are inspected overthe grey inspection m/c visually in a pre-set speed against light. For any major or minor faultslike thick-thin, barre marks, fall out, contamination, fly, holes, oil lines, needle lines, slubs,etc are recorded in grey inspection report to classify the fabric based on the four point system.

Collar & cuff are inspected visually under light box, any major & minor faultycollar/cuff like having wrong ply, hole, needle lines, slubs, wrong design, first line problemetc properly counted and recorded.

QUALITY ASSURANCE PROCEDURE:Based on the sequence of grey inspection, the inspector serially numbers each roll

ensuring that all rolls having complete details of the roll.

1) After production of fabric rolls of 8 to 25 kg, m/c operators cut them from thecloth or batch roller and they are carried to inspection section by the helpers.

2) Almost four inspection workers are for every shift to check the fabric rolls. Forany kind of fault they are checked thoroughly. Skilled inspectors find them and indicate themby the scissors in some cases.

3) Quality is specified on the basis of 4-points system. Here is the point distributionfor different kinds fault in this system: -

QUALITY CLASSIFICATION

1 2 3<20 20-30 30>OK ASK REJECT

FOUR POINT GRADING SYSTEMSize of defects Penalty

3 inches or less 1 pointOver three inch but not 6 inch 2 pointOver 6 inch but not 9 inch 3 pointOver 9 inch 4 point


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LIST OF EQUIPMENTS:

In this factory OFL the list of equipments to assure quality: -

1) Inspection machine2) Scissors3) Weight balance & Microbalance4) GSM cutter5) Seal (‘CHECK-1’, ‘OK’, ‘REJECT’.).

Rejection criteria for Fabrics:

No. Faults Response

1. Needle marks Major needle line is rejected.2. Stripe Major needle line is rejected.3. Barre marks Rejected4. Slubs 1 point5. Wrong design Rejected6. Pin holes 1 point7. Fly & contamination Acceptable for color but not for white8. Sinker marks Do9. Uneven tension Discuss with manager10. Missing yarn Use 4 point11. Crease line Do12. Uneven tension Discuss with manager13. Oil stripe/line Do14. Thick-thin place Rejected15. Mixed yarn Discuss with manager


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Rejection criteria for collar & cuff: Following table shows common collar & cuff faultsand response taken by grey inspection section.

No. Faults Response

1. Wrong ply Reject2. Hole Reject3. Needle line Reject4. Slubs Reject5. Wrong design Reject6. Wrong tripping Reject7. Fly & contamination Acceptable for color but not for white8. First round problem Reject9. Uneven tension Discuss with manager10. Missing yarn Reject11. Crease line Reject12. Rust line Reject13. Oil stripe Reject14. Thick-thin Reject15. Wrong tube Reject

QUALITY STANDARD:

Here is the quality standard:-1) Fabric width 7) Broken needle /2’’2) Fabric length 8) Thick /thin yarn4) Slub 9) Barre/ Stripe3) Fabric weight 10) Dirt5) Hole 11) Oil6) Needle / Sinker line 12) Press off

REMARKS:

There is hardly any chance of any roll to pass through production on to any buyers by toby unchecked or disqualified. The inspections are too much experience and they are awareabout their duties and responsibilities. The factory authority and production related personnelare happy and satisfied with their works


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CHAPTER-VII

(Maintenance)


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MAINTENANCE:

Maintenance of machineries is very important for any type of industries and it is amust for a knit composite mill. All machines and machines parts of Washing, dyeing andgarments are maintained with extreme care. Because production quality and quantity, bothdepends on the maintenance with regularity. OPEX FASHIONLTD lead maintenance with atroop of skilled mechanical fitters.

MAINTENANCE OF MACHINERY:In the knitting floor of OFL all machine are maintained regularly and as

necessity requirements. Here, different type of maintenance of machinery, which is taken,different time on the machineries.

ROUTINE:1) Daily Maintenance: Every machine is taken maintenance daily by the

operators during production. When the operator starts a production after handing over fromprevious shift operator, he takes a routine maintenance on themachine. He cleans the machine, assures yarn is fed to all needles, cleans the eye pot of

feeder, memminger, signal lamp sensor etc. Before a while of a roll cut from batch or clothroller, operator cleans needles, cylinder base plate etc. All around of the machine are kept neatand clean as if there is no dirt with yarn in the fabric.

2) Schedule/Routine Maintenance: Every machine has a schedule of maintenanceof 10 or 15 days. According to date, schedule maintenance is taken on the machines.Operators are informed about the time of maintenance. After pre-estimated production, theyhand over the machine to the fitters. Thus, fitters assure all machines are OK. For any time.

3) Break down maintenance: When product quality hampered and to completeproduction in due time break down maintenance is taken. There are many faults seen in thefabric during production due to needle, sinker, take down roller etc. Then operators inform themechanical fitters and they fix it.

4) Restorative maintenance: Restorative maintenance is taken for design changeor new design development. According to advice or order of production officer, a machine isfixed for new design and mechanical fitters rearrange cam and needle system.

Planned and preventive maintenance are not taken on the machineries in this mill.


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MAINTENANCE OF ‘SEWING M/C:

Lubrication:Since the life of the m/c and its correct working depend to a large extend adequate

and proper lubrication. It is recommended that the instructions given in the lubrication chartsbe followed conscientiously. The Company can not be need responsible for faults that arisefrom wrong or inadequate lubrication.

Oiling Needles:Too much oil is preferable to too little. Dark vertical lines in the fabric originate not

from excessive oiling .

The Cleaning of Needle:Thin oil is most suitable for this work, about one point heated to a temperature not

exceeding 160ºF poured into the oiling position of the m/c.

General Cleaning Schedule:Long m/c life, maximum output & trouble free running depend upon proper care

and maintenance. A general overhaul should take place annually when single shifts areworked & correspondingly at more frequent interval.

MAINTENANCE PROCEDURE:

1) For there is any mechanical fault of machine, which is responsible forproduction hamper, operator informs mechanical fitters in duty. Mechanical fitters come andobserve the problem firstly, and then they begin to fix it.

2) If mechanical fitters were unable to fix it, then they inform technical in-charge,he then comes in spot and fixes it.

3) For there is any electrical problem of machine or serious founding mechanicalproblem, mechanical and electrical department are informed, they come and fix the problem.

4) For restorative maintenance, senior production officer orders mechanicalfitters to fit required machine for cam and needle arrangement and other necessaryrequirements in case of new design development.


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MAINTENANCE TOOLS/EQUIPMENTS & THEIR FUNCTIONS:

Maintenance tools/equipments Functions

1. Adjustable wrench Used for setting nut & bolts

2. Air suctioner For cleaning machine

3.Spanner Fixed Spanner for nut & bolts fitting

4.Socket spanner Handle system for nut & bolt fitting

5. Hammer To apply load where required

6. Screw driver To release any screw

7. Punch Used to fit any worn out shaft

8. Lock opener To open the clip of bearing

9. Hack saw To cut any metallic thing

10. Outside calipers To measure outside dia

11. Inside calipers To measure inside dia

12. Cutting pliers To cut thin wires

13. Pulley key To loosen pulleys

14. Chain ton To lift heavy load

15. Welding machine To join metallic parts

16. Grinding machine To make the smooth fabrics

17. Tester To test electric circuit

18. Pliers To grip anything & cut anything

19. Star driver Screw unlocking

20. Steel tape To measure length, width & height

21. Chisel To cut any metal

22. L-key For loosen & tighten the screw

23. File To smooth the rough surface


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Repair, maintenance and setting and replacement of different parts oflockstitch machine:

Apparatus:1. Flat screw driver2. Star screw driver3. Hammer4. Pliers5. Lubricating oil6. Grease

Standard atmospheric condition:Temperature………………28cRelative humidity………..62%

Procedure: The repair, maintenance, setting and replacement procedure are described below:-

1. Repair: Repair work is carried out when a component requires slight modification.To carry out such job the machine needs to be switched off first. The componentunder repair is then screwed off by suitable apparatus. After repairing, the part isfixed to its designated place and hence its correctness is measured by running themachine. In a lockstitch machine bobbin case, bobbin, check spring, feed dog.Motor belt etc can undergo repair job.

a. Maintenance: Maintenance can be of different types. But following types areimportant in this aspect.

b. Routine maintenance: lubrication and regular inspection are the constituent ofroutine maintenance. Lubrication ensures long life and safe working of all theequipment. Inspection tries to detect faults in equipment so that repairs andreplacement may be under taken at the right time.

c. Scheduled maintenance: this type of maintenance provides for inspection,overhaul lubrication and servicing of the machine, cleaning of all components isnormally done in this manner. It involves opening of the machine into its smallestcomponent and carry out lubrication.

2. Setting: the setting of the lockstitch machine is of immense importance. Followingsetting points need to be ensured before running the machine.


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a. Stitch density controller: It controls the no of stitch per inch. Before starting themachine, stitch per inch is determined by rotating the knob and fixing it at thedesired position.

b. Motor: Motor rpm depicts the speed of the machine. The rpm is controlled bytightening or looseness the belt over machine & motor pulley.

c. Needle: needle undergoes accurate setting to ensure proper sewing. Needle isattached by means of a screw which needs to be tightened enough to produce easysewing. Again the needle size is also important from fabric point of view.

d. Pressure foot: The type of pressure foot to be used & its proper setting isimportant which is ensured by proper attachment with the motor through machinepulley.

e. Feed dog: It is often found that due to random working the feed dog is subjected tobe loose which may cause accident also. Thus the feed dog must be set properlywith the screw.

3. Replacement: The replacement is revealed when the retention of equipment is nomore remain an economical proposition. A replacement is affected when theequipment is subjected to complete breakage which cannot be used even after repairor the component has become so obsolete that affects production or it has crossedits expire date. Replacement can be affected to any components of the machine atany time. In lockstitch machine components like needle, pressure foot, feed dog etcundergo frequent replacement.

Precaution: Following precautions must be taken when repair, setting maintenance is carriedout in the lockstitch machine.

1. All repair & maintenance work must be carried out by switching off themachine.

2. Right tools should be used at right place.3. Skilled personnel should be involved for specialized job.4. Careful handling of all the components is necessary.5. The components should not be too tight or too loose.


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Remarks: The experiment has provided us wide idea regarding the repair, maintenance,setting & replacement of different components of lockstitch machine .It has given us a basicknowledge on machine maintenance as a whole. It has also oriented us with different machinetools & their use those are required for the said job. The gathered knowledge will indeed helpus in our practical life. We hope to important our learning in the days to come.

This mill has a strong maintenance fitter’s troop to fix up all types problem. Twogroups of two shifts obey their duties responsibly and sincerely. With their different tools orequipments they perform their duties skillfully


45OPEX GROUP

CHAPTER-VIII

(UTILITY SERVICES)


46OPEX GROUP

UTILITY FACILITIES AVAILABLE:

For smooth functioning of any production unit, uninterrupted andrequired utility services are indispensable. Success of any industry largely dependson this factor. Any irregularity or lack in the required utility services immediatelyresults in unexpected halt of the production process. An Industry needs variousutilities depending on its manufacturing process.

In OFL the major utilities are available-

- Power (Electricity)- Water- Natural gas- Compressed air- Steam- ETP

SOURCES OF UTILITIES:The main utility, which is used by OFL, is natural gas. From

natural gas generator produce electricity. From natural gas and electricity inassociation with mechanical and electrical apparatus, OFL produce other utilitieslike water, steam, compressed air etc.

CAPACITY AND OTHER TECHNICAL DETAILS:

Power (Electricity):Generator house is the main power producing plants of NCL

There are two generator in generator house.

Generator -Type: gas generatorBrand name: CaterpillarOrigin: USA

Frequency: 100 Hz

Voltage: 400 V

STEAM:Boiler produces the required steam. There is two boiler in OFL

Boiler specification:

Brand name: Industrial boiler Ltd


47OPEX GROUP

Capacity: 8ton / hrBlower motor: 25 HPWater supply for the boiler:

Water required for steam production is supplied by deep tube well.

Pretreatment of the boiler water:Boiler feed water needs special standard. Any deviation from the

required standard may result in scale formation, which eventually reduces theefficiency of the boiler. This ultimately affects the cost of steam generation andmakes the production cost high. To maintain the required standard of the water,there should be some means to pretreat the boiler feed water. To protect scaleformation of boiler, NELCO is used as chemical in water feed tank. 200 gm NELCOis injected per 12 hrs. In OFL there are water softeners that act before the waterenters the boiler.

.

No. Of the softener :There is one water softener to pretreat the boiler feed water.

COMPRESSED AIR:The compressed air is supplied from air compressor. There two -air

compressors in OFL.

Compressor -Brand name Hitachi Screw CompressorOrigin: JapanModel no. OSP-55S5 ARIMaximum working pressure: 15 barAverage working pressure: 6.5-7.5 barYear of construction: 2004

WATER:The water source OFL is deep tube well.

Water treatment plant: There is no Water treatment plant in Mirpur but one inKanchpur.

GAS:The source of gas is government agency. Gas is required mainly for

generation of electricity, boiler to produce steam, the burners of heat setting m / c.


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As OFL generates their own electricity, the gas consumption is quite high. The gasconsumption is 250-350 m³ / hr.

COST OF DIFFERENT UTILITIES:

Electricity cost:REB =3.8 TK / KW-HRGas generator = 2.70 TK / KW-HRDiesel generator = 6.50 TK / KW-HR

Gas cost:4.94 Tk/m³ for boiler3.66 Tk/m³ for generator4.5 Tk/m³ for domestic purpose

Steam cost:4.30 Tk per kg fabric.

REMARKS:For smooth running of factory main utilities like gas, electricity or

steam is very essential. Sometimes gas pressure is low than required pressure. Whenthe gas pressure is low, then diesel generator run. Government should have to ensureproper gas supply for Industrial purpose.


49OPEX GROUP

(CHAPTER-IX)

STORE & INVENTORY CONTROL


50OPEX GROUP

INVENTORY SYSTEM OF RAW MATERIAL:

It is previously speak that OFL. is a Woven composite industry. The mainraw material of OFL is grey fabric. Grey fabric first produce in knitting departmentof this company. Weaving section of OPEX GROUP Produces grey fabric as perbuyers order. Dyeing section get grey fabric from Weaving section. Grey fabric storeofficer receive the grey fabric and store the grey fabric in storeroom. Then hedelivers the grey fabric to batch preparation section according to shipment date oraccording to production manager of dyeing section instruction.

Other raw materials of OFL are dyes and chemicals. Dyes andchemicals store officer always keep stock report of dyes and chemicals and alsoknow the daily or monthly requirements of each dyes or chemicals. If the stock isbellowing30days then he gives requisition to head office for each product. Headoffice indent dyes and chemicals.

SPARES:Spare store officer keep the spare part in store & make a list of spare parts.

If the spare parts are little in stock he gives requisition to maintenance manager.Technical manager give requisition to Head office. Head office indent spare parts orbuy local market as per requirements.

FINISHED GOODS INVENTORY:Finish fabrics from the compactor go to inspection team. From the

inspection table the fabric weighted in weight meter & go to finish fabric storeroom.Here finished fabric store officer make a list of total finished products. He sends thefinished fabric to OPEX FASHION LTD as per shipment date or requirements ofproduction manager of OPEX FASHION LTD. He also keeps the delivery list.

REMARKS:Inventory control system and storing system of OFL. is over all good.


51OPEX GROUP

CHAPTER -X

(COST ANALYSIS)


52OPEX GROUP

INTRODUCTION:Costing is a process by which the setting price of a product is calculated. It is a

very important task for a factory, which runs for business purposes.And it is also strictly followed in the OFL. Costing of the products considering the rawmaterials expenditure, salary and wages of officers and workers, distributions andadvertisement expenses etc. all direct and indirect expenses is done in this factory. It isdetermined by a troop of accountants with advice and consultancy of executive director.

PRICE OF THE PRODUCT:Generally price of product is determined by the required profit adding to the total

expenses. So,

Price of products= (Direct expenses + Indirect expenses + FactoryOverhead) + Required profit

PRICE RANGE OF DIFFERENT PRODUCTS:Shirt = $11.75 - $28.50 /PcsJacket =$15.00 - $35.50 /PcsKids Wear ==$10- $29/Pcs

REMARKS:Costing is very important for a productive factory. Without proper costing all production

curriculums will go to vain. Because a factory cannot reach to its goal without achieving goodprofit and good profit is not possible without skillful costing. In OFL there are some skillfulpersonnel to do this job.


53OPEX GROUP

CHAPTER-XI

(MARKETING ACTIVITIES)


54OPEX GROUP

Marketing Strategy:Marketing strategy is a very important factors to sale the products to the buyer. If the

marketing strategy is not so developed, it will be very hard to reach the goal. In case ofgarments marketing the dealings with the buyer is a very important factor.

In Standard Group mainly senior marketing officers, merchandiser & higher officialsdeal with the buyer. There are some fixed buyers of the industry. The buyers give their orderscontinuously all over the year. The marketing officers & the merchandisers communicate withthe buying houses to collect the orders.

By both side understanding the rate & the order quantity are fixed.

Duties & responsibilities of marketing officer:Dealing with the buyer & convince the buyer is the main duty of marketing officer. A

marketing officer also has some other duties. The main duties & responsibilities of amarketing officer are given bellow-

To prepare cost sheet by dealing with the buyer To take different steps by discussing with the high officials & merchandisers To maintain a regular & good relationship between commercial officer &

merchandisers To maintain a communication with the buyers and buying houses Communicate with better criteria of the products

Actually the responsibilities & duties of marketing officer begins from getting order ofbuyer & ends after receiving foods by the buyer. So, he should be always smart, energetic& sincere.

:Marketing activities are done of NCL by a skillful team of marketing officers under

the Executive Director. Here are the details of marketing activities.

CONSUMER OF THE PRODUCTS:The mill has a great number of renowned and international consumers. Following

are some regular consumers:1) JC Penney 2) Carryfour3) Levis 4) TCP5) Oshkosh 6) Target7) AMC 8) American Eagle


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PRODUCT LABEL:There are following labels used by this mill:

1) Care Label: It contains washing in hot or cold water, chemical cleaning,drying conditions etc.

2) Size Label: It contains size of garments.3) Composition Label: It contains the fabric composition of different fibre type.4) Decorative Label: Decoration is as buyer or consumer choice wise.

PACKAGE SIZE & LABEL:Most common sizes are

S - SmallM - MediumL - LargeXL - Extra largeXLL - Very very large2XLT3XLT

.

REMARKS: OPEX Group has a well learned marketing & merchandising team. They alwayscommunicate with the buyers. Standard Group has some fixed buyers. The marketing sectionalso looks the quality & quantity buyers.

Marketing activities are very important tasks for a productive factory. In this mill,there having highly qualified marketing officers. As a result, the mill rises up day by day.

FAULTS OF GREY FABRICS:

1. Patta

Causes:1. Yarn count variation2.Yarn tension variation


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Remedies:Proper yarn count & tension should be maintained.

Remarks:For dark color & plain single jersey patta very sensitives. But in case of

derivatives of single jersey, rib &interlock light patta considerable.

2. Contamination:

Causes:1.For unlearned machine & floor.2.Little space between two adjacent machines.3. For hairy & color yarn.

Remedies:1.Proper cleaning of machine & floor.

Remarks:Protection of every machine from dust & fly. In case of light color

contamination is very bad appearance. As a result garments rejected.

3.Needle mark:

Causes:For bent hook & latch.

Remedies:Immediately change faulty needle.

Remarks:Needle mark is a common faults of knitting because unconscious of

operator. It has very bad effective for dyeing & causes a great loss of company.

4.Hole:

Causes:1. For needle breakage & wrong adjustment of machine parts.2. For uneven yarn & deposit of fibre.


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Remedies:Correct adjustment of machine parts &clean machine.

5.Lycra out & tension variation of Lycra:

Causes: Breakage of Lycra yarn & uneven tension of Lycra.

6. Oil mark

7. Tara &loop.


58OPEX GROUP

CHAPTER-XII

(WASHING)


59OPEX GROUP

SAMPLE WASHING MACHINES (INDIA) No. of machines: 05

Manufacturing company: STEFAB INDIA LIMITED

Model no: LXS 35.

Manufacturing country: India.

Features:

° Single door, front-loading, open pocket.

° Machine body and essential parts are made of stainless steel.

° Automatic timed. Auto reverse. Automatic 5 water level & auto digital

temperature control.

° Electric solenoid water & steam valves.

° Non-clog motorised drain valve.

° Full electric protection.

Specifications:

° Capacity: 35 kg (Dry: Wet =1:10)

° Inner cylinder: 950 mm dial X 500mm

° Wash motor: 0.75 KW

° Extract speed: 200 RPM

° Main door opening: 500 mm dial

° Water connection consumption: 25 mm dial, 120 litres.

° Drain: 75 mm dial, 1 way out

° Steam connection consumption: 15 mm dial, 25 Kg/hr.

° Electric heating: 12 KW

° Overall dimension: 1100mm(W) X 1430mm(D) X 1700mm(H)


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INDUSTRIAL WASHING & DYEING MACHINES (CHINA) No. of machines: 14

Manufacturing Company :PANYUA XIN XIN Washing Machine Company Limited.

Manufacturing country: CHINA.

Features:

° Single door design for general washing, sample washing.


° Preset front and backward rotation.

Specifications:

o Model-AIW-550(5)

o Rated Voltage-380 V

o Steam Pressure-0.4-.06 MPa

o Input Power-7.5 KW

o No Of Production-W.10583

o Related Washing Capacity-250kg

o Related Frequency -50 Hz

o Gross Weight-1900kg

o Overall Dimension -3.2X1.95X2.10

INDUSTRIAL WASHING PROCESSING & DYEING MACHINES No. of machines: 05

Manufacturing company: STEFAB INDIA LIMITED,

Model no: LXS 280.


Features:

° Single door, front-loading, open pocket.


° Automatic timed. Auto reverse. Automatic 5 water level & auto digital

temperature control.


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° Electric solenoid water & steam valves.

° Non-clog motorised drain valve.

° Full electric protection.

Specifications:

° Capacity: 280 kg (1:10)

° Inner cylinder: 1750 mm dial X 1180mm

° Wash motor: 7.5 KW

° Extract speed: 130 RPM

° Main door opening: 1000 mm dial

° Inspection door opening: 300 mm dial

° Water connection consumption: 50 mm dial, 960 litres.

° Drain: 115 mm dial, 2 ways out

° Steam connection consumption: 25 mm dial, 200 Kg/hr.

° Thermal fluid connection consumption: 1.5” X 1.5” BSP, 80000 KCAL/Hr.

° Overall dimension: 1950mm(W) X 2500mm(D) X 2100mm(H)

HYDRO EXTRACTORS (CHINA) No. of machines: 08

Manufacturing company: Tongxin Ltd.

Manufacturing country: China.

Features:

° Due to its solid constructions it can be positioned onto firm floorings to

operate.

° It has excellent electrical layout in prevention of electricity leakage, shock,

which is important in wet conditions in the operations.

° Machine operations are made easy, with convenient start-stop operations for

maximum efficiency.

° The inner stainless steel is well balanced, thus achieving longer life span and

assuming energy efficiency of machine.


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° Shock absorbers are well paced in the three suspension points to reduce

vibrations.

° Stainless steel constructions in major parts ensure durability.

Specifications:

° Model no: SHE-42° Capacity: 280 LBS° Inner cylinder: 1067dial X 419mm° Over all dimensions: 2150 mm (W) X 1650 mm (D) X 1050 mm (H).° Wash motor: 7.5 KW° Extract speed: 860 RPM

SAMPLE DRYING MACHINES No. of machines: 01

Manufacturing company: STEFAB INDIA LIMITED,


Features:

° Stainless steel inner cylinder and large S.S. loading-unloading door. Outer

body not painted. Long rust free life and sheen.

° Built in solvent filter housed in the top tank receives soiled from the base tank

through a powerful centrifugal pump which pushes the soiled solvent through

several fine mesh cylindrical filters for reuse. Maximum recovery of clean

solvent.

° Low spin extract. Separate motors for dryclean & extract. Vibrationless during

extraction. Low spin extract makes articles lighter to unload. No solvent

dripping. No wastage of solvent.


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° Automatic timed. Auto reverse. Full electrical protection against single phasing

& motor overload. Operator’s convenience & machine safety. Efficient

cleaning.

Specifications:

° Capacity: 18 Kg

° Basket size: 700 mm (dial) X 470 mm

° Volume: 180 Litres

° Dry clean motor: 0.37 KW

° Extract motor: 1.5 KW

° Extract speed: 220 rpm

° Loading door opening: 400 mm (dial)

° Base tank capacity: 250 Litres

° Filter tank capacity: 250 Litres

° Overall dimensions: 1000mm(W) X1080mm (D) X 1730mm(H)

DRYING MACHINES No. of machines: 12

Manufacturing company: Bengal Heavy Electric Engineering.

Manufacturing country: Bangladesh.

Features:

° Stainless steel inner cylinder and large S.S. loading-unloading door. Outer

body painted.

° Low spin extract. Vibration less during extraction. Low spin extract makes

articles lighter to unload.


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° Automatic timed. Full electrical protection against single phasing & motor

overload. Operator’s convenience & machine safety. Efficient cleaning.

Specifications:

° Capacity: 35 Kg

° Basket size: 950 mm (dial) X 500mm

° Volume: 350 Litres

° Dry clean motor: 0.75 KW

° Extract speed: 200 rpm

° Loading door opening: 500mm (dial)

° Overall dimensions: 1300mm(W) X 1250mm(D) X 2000mm(H)

GARMENTS SAND-BLASTING MACHINES

INDUSTRIAL SAND-BLASTIG GUNS No. of machines: 03

Manufacturing company: Made in China

Features:

° Single door design for general washing, sample washing.


° Preset front and backward rotation.

Specifications:

° Model: SBT-650

° Capacity: 200 Litres

° Dimension: 800mm X 1000mm X 1250mm

° Sand contains: 200 Kg


65OPEX GROUP

OTHER COMPONENTS/ACCESSORIES

No. of cabinets: 03

Hopper (for controlling dust in cabinets): 02

Helmet: 07 Pcs

Musk: 07 Pcs

Gloves: 07 pairs.

Air preserver-1, capacity of 2000 c.c.

Air preserver-2, capacity of 900 c.c.

OTHER MACHINES Spray machines: 03 Nos.Manufacturing country: Hong Kong Compressor: 03 Nos.

Two compressors with same following specifications.o Brand: ELGIo Capacity: 10 Jule/Baro Made in INDIA

One compressor with following specifications:o Brand: OSDo Made in ITALYo Includes Change Overo MCCBo Capacity: 10 Jule/Bar

Boiler:Brand name: SaccaManufacturer: Made in ITALYProduction capacity: 1.5 Tons/Hr.Pressure: 7.5 Jule Bar (5.0 Bar used)Supply system: Automatic Pressure control.


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Chimney: 50 Feet with 12-inch diameter.

Generator

Four stroke, diesel engines with 1500 RPM by "DEUTZ" and "VOLVO Penta"

production; "STAMFORD"(ST), "MECC Alte"(ME), "Marelli"(MA), "SINCRO"(SI)

alternators. All alternators are three phase, four pole, single bearing, synchronous type,

cosj=0.8, 50Hz.

Water supply pump: 03 Nos.

02 PCs. Deep Tube wells are Submersible, Made in ITALY, BG brand with 30 Horse

Power.

01 PC. Deep Tube well is Sigma branded, Made in ITALY with 42 Horse Power.

PROCESS TECHNIQUE OF SOME WASHING METHODS

ENZYME-BLEACH WASH WITH TINTING:Batch 60 PCs. Liquor 400 Litre

Step 01 Water is added (400 Lt)

Desizing Garments are added

Machine started running

500 gm Soda Ash added


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500 gm Caustic Soda added

200 gm Bio. D added

Steam to raise temp 60°C

Process time 25 minutes

Drop liquor

Wash down twice


Enzyme Wash Machine started running

200 ml liquid, 400 gm powder

type Enzyme added

150 ml Acetic Acid Added

200 gm Anti back added


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10 Kg Peumic Stone added



Drop liquor


Bleaching Machine started running

4 Kg KCI (35% Cl2) added

500 gm Soda Ash added



Drop liquor


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Neutral Wash Machine started running

500 gm Hypo sulphide added



Drop liquor


Tinting Machine started running

0.02% Direct Brown GTL &

0.01% Direct Black V-200 added

4 Kg Salt added


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Check Shade

Drop the liquor

Step 06 Garments are then taken out

Drying Hydro extracted

Send to dryer for drying of garments.

REMARKS

No live industry can keep place with the advance of technology without continuous

renewal & transformation of its production facilities. Existing equipments must be kept on the

defensive, compelled always to justify its tenure against the challenge of new & more modern

machines. If any piece of existing equipment fails to meet this challenge, it must be displaced,

regardless of its age or condition & regardless of whether it is physically “worn out”.

Keeping the above in view, this industry is always replacing its existing machines in

order to increase productivity & improve quality.


71OPEX GROUP

CHAPTER-XIII

(COMPLIANCE)


72OPEX GROUP

Compliance12.1 Responsibilities & Duties

1. To floor visit at least thrice a day.2. To ensure workers fire safety, fire prevention, fire equipment, health & safety &

comfortable environment at work place.3. To aware the workers about personal protective equipment.4. To receive grievance, complain, demand & suggestion from the workers & after

receiving the issue discuss with related persons & local management immediately.5. Try to find out emotional problem of an employee. The problem may be work related

or personal or family which affects his/her work performance.6. To provided supportive counseling the sick worker for medicinal support on the

worker’s requests, complain or situational demand.7. Try to make aware the existing workers about by company provided all facilities &

necessity of compliance.8. To perform when social compliance audit.9. To follow up aisle mark free, fire extinguisher no blocked, emergency exit free, fire

equipment free, stair free from carton in the floor.10. To check all production related register if any date mentioned of holiday or not.11. To conduct orientation program for newly appointed worker.12. Try to motivate & make them conversant with the company objective, rules &

regulations, buyer code of conduct & local laws.13. To briefing the employees about all facilities of company, mandatory safety

instruction including all “do’s & Don’ts”.14. To make aware the employees about leave procedure, maternity benefits, working

hour & over time system according to local laws.15. To make aware the employees about personal health & hygiene, HIV/ AIDS/STD.16. To conduct awareness programs the pregnant workers about safe motherhood.17. To ensure that no employee each maltreated mentally or physically abused & they

should be treated with respect & dignity.18. And any other work assigned by the Management.


73OPEX GROUP

CHAPTER-XIV

(MERCHANDISING)


74OPEX GROUP

Garment merchandising is an intricate and detail oriented job. If it can be done properly canbe very rewarding. On the country, if it is done with lack of knowledge, insufficient skill andthoroughness, it can be destructive.In the Standard Group very skilled and experienced personnel run the merchandising section.After receiving an order, the merchandiser with the help of pattern master calculates the totalconsumption of fabric. Then according to the cost detail sheet and the price mentioned by thebuyer costing is done. After the price is negotiated with the buyer order is placed to thesuppliers of raw material and accessories.The manufacturing factory as per the requirement suppliers the fabric and a ledger ismaintained regularly to assess the production status. The accessories such as label, button,zipper, sewing thread, packing materials are collected from outside [sometime mentioned bythe buyer] through back-to-back L/Cs. The merchandising department also looks for thesources for procuring yarns to produce fabric.Merchandising section monitors the production status regularly and ensure timely delivery ofthe shipment.


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Main Buyers

- GAP- JC PENNY- SEARS- AMERICAN EAGLE OUTFITTERS- H & M- TCP- OSHKOSH- VF ASIA- LEVIES- DOCKERS- PERILIES- MIRZA FASHION- AMC


76OPEX GROUP

CHAPTER-XV

(CONCLUSION)


77OPEX GROUP

CONCLUSION:OPEX GROUP is a pioneer group in garments sector in our country.Bangladesh is adeveloping nation. RMG Sector earns the Prime share of our foreign currency.Development of this sector will definitely bring good fortune for our country. Webeing the graduates of Textile Engineering must give our sincere effort to the futureadvancement of RMG and related sector. Moreover from 1 January 2005, we willenter into the quota free world where quality, lesser lead-time and low price will bethe key to success.

When the development of the country was at a stand still positiondue to the legacy of shattered economy and the industrialization was stagnant, theexport oriented textile and RMG sector had shown the ray of hope by its all-pervasive positive impact on the national economy. At the fag end of the eighty, thissector started expanding and within a short period of its existence, this nascentindustry became the largest foreign exchange earner.

Standing at the verge of a new millennium, Textile and RMGsector is now the heart of our national economy. Even after all this achievements,this industry faces the major challenge of global adjustment in the coming yearswhen it has to respond the new trading arrangement after 2004.

OPEX GROUP LTD being a part of this decisive sector will haveto take necessary measure to cope with the change of globalization. Modification ofthe technical arrangement with the advancement of technologies and good positiveapproach will help to survive in this ever-changing global economy.

Hopefully, the confidence and foresight of the entrepreneurs andthe enthusiastic teamwork of the professionals will take OPEX GROUP LTD to aneven better position.

Industrial attachment of opex group

Engineering

Transcript of Industrial attachment of opex group