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Internship Reporton

Production & Operations inRTML

Regent Textile Mills Limited,East Kalurghat, Bandar, Chittagong.

Submitted to:

Mr. Md. Monowar HossainAssistant Professor

Department of Management StudiesUniversity of Chittagong

Submitted by:Mohammad Mozammel Hossain

MBA Examination: 2005,Examination Roll No: 2005/1,International Management

Class Roll No: 14687,Registration No.10666

Date of Submission: July 19, 2008

University of ChittagongChittagong, Bangladesh


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Internship Report(As a part of MBA academic program)

On

Production and Operations in RTML

(Regent Textile Mills Limited),East Kalurghat, Bandar, Chittagong.


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Regent Textile Mills Limited,East Kalurghat, Bandar, Chittagong.

Internship Report(As a part of MBA academic program)

Submitted to:

Mr. Md. Monowar HossainAssistant Professor

Department of Management Studies

University of Chittagong

Submitted by:

Mohammad Mozammel Hossain

MBA Examination: 2005,

Examination Roll No: 2005/1,

International Management

Class Roll No: 14687,

Registration No.10666

Date of Submission: July 19, 2008


Dated: July 19 2008


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ToHonorable Sir and Supervisor,Mr. Md. Monowar Hossain

Assistant ProfessorDepartment of Management Studies


Sub: Submission of the Internship Report.

Dear Sir

With due respect, I would like to submit my internship report tilted Production andOperations in Regent Textile Mills Limited. I chose the production and operationsas scope of my study in Internship and in preparing the report because I think theseexperiences will help me a lot in my practical career in merchandizing.

This is the last part of my educational life in Chitagong University and I am verymuch eager to make and mark this last part into a wonderful experience in and ahallmark for my life. Moreover, I want to present RTML an excellent report in orderto make a good image of our department and our university so that they maycontinue inviting our junior batch-students to RTML for their internship. With theabove objectives in my mind, I worked very hard on the production floors in RTMLand now in preparing this report. It is worth mentioning here that due to somelimitations and caveats the report may not be like my dream report .But I hope thereaders will like it very much. The main achievement of my internship is that now Iknow painstakingly how a textile mill operates in practical. I hope this will certainlyhelp me in my upcoming career.

Although I enclose acknowledgement later in the report, here I would like to give

thanks to our honorable Chairman Sir for giving me a good placement, to MySupervisor and Sir for allowing me to work at my own will, to MR. Md. Yasin Ali forallowing me to work in his RTML and all the members of RTML for giving me theirvaluable time and sharing their knowledge and experiences.

Finally, I cordially and humbly do request you to accept my internship report andoblige thereby.

Sincerely Yours,

Mohammad Mozammel HossainMBA Examination: 2005,Examination Roll No: 2005/1,International ManagementClass Roll No: 14687,Registration No.10666Session: 2004-05.


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Preface

After completing my MBA, (major in International management)written and oral examinations from Department of ManagementStudies, I have been placed in Regent Textile Mills Limited (RTML)for my internship, which is a part of our MBA academic program inUniversity of Chittagong. The duration of the internship was aboutsix to eight weeks in formal. Now after successfully completing myinternship in RTML for more than eight weeks I am about to preparemy internship report titled Production and Operations in RegentTextile Mills Limited.

I chose production and operations for my internship because

completed my MBA in International Management. Moreover, I aminterested to build my career on Merchandising because there arebright futures for RMG and textile sectors in perspective ofBangladesh. Thus there is also a good career opportunity formerchandisers as well.

This is the last part of my educational life in Chitagong Universityand I am very much eager to make and mark this last part into awonderful experience and as a hallmark for my life time. Moreover, Iwant to present RTML an excellent report in order to make a good

image of our department and our university so that they maycontinue inviting our junior batch-students to RTML for theirinternship. With the above mottos in my mind, I worked very hardon the production floors in RTML and now in preparing this report. Itis worth mentioning here that due to some limitation and caveatsthe report may not be like my dream report .But I hope the readerswill like it very much.

Naturally, as custom properly dictates, I am responsible forwhatever errors in fact, deficiencies in coverage or exposition, andoversights that remain.

At last, I would like to conclude by mentioning that the scope of thisreport is production and operations only, leaving many otherimportant facts unrevealed in RTML. I hope further researches byjunior batch students will add up to this report to a wider scope andto an array of new features and new options.

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Acknowledgement

I have benefited from the help of many people in completing myinternship and in preparing this report. Discussion with my Honorable Sir &Supervisor, materials supplied by my friends-everything helped me in anunfold number of ways in shaping this report. My intellectual debt to all ofthem who blazed me with helps.

I am particularly indebted to our honorable Chairman Sir, MySupervisor, and Mr. Md. Yasin Ali for allowing me to complete myinternship in his well esteemed organization. It is worth mentioning herethe name of the following members in RTML for their help in particular:

1. Mr. A. k. M. IliasGM (accounts & Finance) andCompany Secretary

2. Mr. Mohammad Masud HossainDirector Marketing

3. Mr. MD. Kamal Uddin AhmedGeneral Manager-Operation

4. Mr. A .K. Bhattacharyya

Deputy General Manager (A&F)

5. Mr. Md. Altafur RahmanSenior Manager-Weaving

6. Mr. Ahmed Rafiq ImtiazManager-Administration

7. Mr. S.M. Abdur RahmanProduction Manager

8. Mr. Mukti Brata DasAssistant Manage-marketing

9. Mr. Shamim ShahAssistant Engineer Mechanical- Weaving

10. Mr. Ratan MitraStore Officer

I am in fact indebted to every members of RTML and without whose helpthis would not be possible for me to complete my internship and to publishthis report.

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Contents in Brief

Particulars Page Number

Chapter One Introduction 1-2

Chapter Two Weaving Department 3-14

ChapterThree

Dyeing Department 15-29

Chapter Four Stitching andOther Departments

30-39

Chapter Five concluding Part 40-42

Appendices: 43-56

Annexure: 57-88

List of Figures and Flow charts

Particular PageNumber

Flow Chart: Production Operations inRTML

2

Flowchart: Weaving Department 8Flowchart: Dyeing Department 15

Figure: Washing Machine 20

Figure: Rotary Printing Machine 24

Flow Chart: Printing Section 25

Flowchart: Inspection and DeliveryDepartment

28

Flowchart: Stitching Department 30

Contents in Detail

Particulars PageNumber

Abstract 12Chapter One:Introduction

Objective of The Report 1

Introduction to RTML 1Flow Chart: ProductionOperations in RTML

2

Chapter Two:WeavingDepartment

Weaving: A Classic Art 3

History Weaving As a Industry 3

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Modern Weaving in TextileFactories

Weave Types 5

Weaving Process 6

Different Types ofWeaving Techniques

7

Weaving Department in

RTML

Flowchart: Weaving

Department

8

Warping Machine 9Sizing Machine 10

Dressing Section 11Looming Machines 12Warehousing 13

Metering 14

Mending 14

Grading 14

Folding 14

ChapterThree:

DyeingDepartment

Introduction To Dyeing 15

Flowchart: DyeingDepartment

15

Singeing and De-sizing 16Scouring and Bleaching 16

Drying 18Mercerization 18

Washing 18Figure: Washing Machine 20Dyeing and Printing Dyeing 21

Printing 23Printing in RTML 24Figure: Rotary PrintingMachine

24

Flow Chart: PrintingSection

25

Fabric Finishing 26Inspection and Delivery 27

Flowchart: Inspectionand DeliveryDepartment

28

ChapterFour:Stitching and

OtherDepartments

Introduction to StitchingDepartment in RTML

30

Flowchart: StitchingDepartment

Laying And SpringCuttingSewing

30

Quality Control 31Finishing 31Delivery and Shipment 32

Introduction to Lab 32

Lad Dip Matching 32Chemical Test 32

Physical Test 32

Fabric Analysis:Yarn Size,Yarn Substance

3333

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Fabric Analysis:Fabrics WeightCalculation

34

Dimensional Stability 35Quality Control Colorfastness to Wash 35

Colorfastness to Light,

Colorfastness toRubbing, Colorfastnessto Perspirations

36

3636

Shrinkage 36Store Department 36Marketing Department 38Other Departments 39

Chapter Five:concludingPart

Conclusion 40

Limitations and Caveats 40Weaknesses and Threats 41

Strengths andOpportunities 41

Recommendations 42Appendices:

Appendix 1: The ClassicCloth Making Process:Weaving a SimpleTablemat Using RagShuttle and Two Harnesses

43

Appendix 2: Lists forPopular Fabric-TypesAvailable in Market

47

Appendix 3: List for

Common Fabrics Offeredby RTML

49

Appendix 4: List for YarnSizes

51

Appendix 5: Sub-SectorStudy onTextile Dying and Printingin Bangladesh

52

Appendix 6: Bibliography 56Annexure: Annexure1: Specimen for

Salary Sheet57

Annexure 2: Specimen forDaily Production Report

58

Annexure 3: Specimen forDyeing Recipe

59

Annexure 4: Specimen forOrder Program (RMG)

60

Annexure 5: Specimen forLetter of Credit

61

Annexure 6: Specimen forProforma Invoice

62

Annexure 7: Specimen forPacking List

63

Annexure 8: Specimen forDelivery Order

64

Annexure 9: Specimen forGate Pass

65

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Annexure 10: Specimen forDelivery Challan

66

Annexure 11: Specimen forFinished Fabric DeliveryStatus Report

67

Annexure12: Specimen for

Finished Fabric InspectionReport Form

68

Annexure13: Specimen forFinished Fabrics Report

69

Annexure14: Specimen forRequisition

70

Annexure15: Specimen forPurchase Requisition

71

Annexure16: Specimen forMaterials ReceivedRegister

72

Annexure17: Specimen forMaterials Receipt andInspection Report

73

Annexure18: Specimen ForBin Card

74

Annexure19: Specimen forBatch Card

75

Annexure20: Specimen forStock Register

76

Annexure21: Specimen forStore Requisition AndIssue Note

77

Annexure22: Specimen forDaily Store & Spares

Received Status In GeneralStore

78

Annexure23: Specimen forYarn Stock Status

79

Annexure24: Specimen forCommercial Invoice

80

Annexure25: Specimen forWeighting List

81

Annexure26: Specimen forBill of Lading

82

Annexure27: Specimen forBeneficiary Statement(Certificate Of Inspection)

83

Annexure28: Specimen forMembership Certificate

84

Annexure29: Specimen forCertificate Of Origin

85

Annexure30: Specimen ForBill of Entry

86

Annexure31: Specimen forAirway Bill

87

Annexure32: Specimen forInsurance

88

Abstract

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Regent Textile Mills Limited, often abbreviated as RTML in this report, is one ofthe leading textile mills in Bangladesh. It offers only weaving fabrics for their ownhome textile production and for Ready-made Garments for the outside customers.It is situated at east kalurghat, bandar, about fifteen kilometers far from the heart

of chittagong city. This organization is 100% export oriented and their mainbuyers are from Europe. This organization is running with the help of total 1231numbers of personnel. The business operations of this organization are brieflyoutlined below:

a. Marketing Department contacts to the buyers by offering their productswith prices- quoted.

b. Buyers replied and sent a sample of swatch to Marketing Department toensure whether it is possible for them to supply this fabrics or not.

c. Marketing Department forwards this swatch sample to General Manager

(Operation) to know whether it is possible for his team or not. GM furtherforwards it to the Production Manager who in turn sends it to LaboratoryDepartment for testing and analysis.

d. After taking the report from the lab through the production manager, GMsends s it to Marketing Department with decisions-mentioned.

e. Marketing Department now answers the buyer positively or negatively asper GMs decisions. When the decision is positive, the MarketingDepartment also sends the sample made by Lab (under supervision of GM)in order for the buyers physical analysis.

f. If the buyer is satisfied with the sample then place orders and opens aLetter of Credit and sends it to the Marketing Department through bank.

g. After completing the documentation and getting confirm orders, theMarketing Department advises the GM to start the productions and givescopies of the documents to him to take necessary actions at his part.

h. Now GM instructs his team members through Production Managers to startproductions. The Production Managers prepares the programs and theactual production starts. First, the fabrics are woven in weavingdepartment then dyed in the dyeing department then inspected anddelivered/shipped to the buyers in case of RMG. But in case of hometextile, the fabrics are now sent to stitching department for lying, cutting,

stitching, finishing, QC, and packing, cartooning and then makingshipments. In this course of time, the Marketing Department keep contactwith the GM and get up-to-date information on the production andoperations.

i. After the goods are shipped, the buyer sends the Bill Of Lading to theMarketing Department. Marketing Department sends this document to thehead office Accounts and Finance Department and they collect thepayment through the bank.

j. After receiving the goods, the buyers sends to the Marketing Departmenta receipt letter to let them know whether they are satisfied or not. If the

buyer is not satisfied, say for example, they found a 100 meters roll isdefective then they tell it to the Marketing Department and the Marketing

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Department replies that they will re-send the 100 meters roll with the nextconsignment.

k. Thus the business takes place in a continuous manner. They usually do notsuffer from any big problem because most of their buyers are permanent.

These main production and operations in RTML are performed by the followingdepartments:

a. Marketing Departmentb. Weaving Departmentc. Dyeing Department

d. Stitching Department

Apart from the above mentioned, there are also the following departments thatsupplement the main departments. These are as follows:

a. Department of Labb. Department of Store

c. Department of Management Information System(MIS)

A brief explanation of each department is given below:

Weaving Department

Weaving is an ancient textile art and craft that involves placing two sets ofthreads or yarn called the warp and weft of the loom and turning them into cloth.This cloth can be plain (in one color or a simple pattern), or it can be woven indecorative or artistic designs, including tapestries.

The flow chart for weaving is as follows

Figure: The Flow-Chart Of the Weaving

Department.

The main purpose of this department is to produce grey fabrics.

Dyeing Department

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1WARPING

2SIZING

3DRESSING

6MENDING

5METERING

4LOOMING

7GRADING 8FOLDING


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After fabric is woven from the weaving department, this gray fabric is pushedforwarded to Dyeing Department. From its name it is clear that the mainpurpose of the dyeing department is to dye the gray fabric in different colors asper buyers demands. The dying process is different for knit and woven fabrics.But in Regent Textile Mills Limited, only woven fabrics are made and forwardedfor dyeing.

However the overall dyeing process for woven fabrics in Regent Textile MillsLimited is outlined as under:

Figure-Flow chart of Dying Department in Regent Textile MillsLimited

Now from the last stage-Inspection and delivery, RMG fabrics are delivered butthe fabrics for Home textile forwarded to next stitching department. The summaryflow chart for this section is as follows:

Figure: Flow chart for Inspection and DeliveryDepartment

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1

Woven fabrics

from weaving

department

2

Singeing

&

Desizeing

3

Scouring

&

Bleaching

4Drying

For

Mercerization

5Mercerization

6Washing

After

Mercerization

7

Drying

For

Dyeing/Printin

8

Dyeing

And/or

Printing

9

Washing

After

Dyeing/Printin

10

Drying

For

Finishing

11

Finishing

12

Inspection

And

Delivery

Rolling Inspection

Delivery

Forwarded to

Stitching section


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Stitching Department

Stitching department in RTML is for home garments. After inspection and deliverysection under he dyeing department the RMG fabrics are delivered to thecustomers but the home textile fabrics are proceed to this stitching departmentfor stitching.

The flow chart for this department is outlined as under:

Figure: Flowchart for the StitchingDepartment

Lab

Lab is a special department in Regent Textile Mills Ltd. Every other departmentseeks helps from the lab to continue their jobs. Daily they need much vitalinformation and testing which are provided by the lab. In short, Lab in Regent

Textile Mills Ltd performs the following operations which are described in short:

a. Lab dip matchingb. chemical testc. physical testd. Quality controle. shrinkage

Marketing Department

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1Fabrics

come from

Inspection

& deliverysection

2Laying

or

Spring

3Cutting

4Sewing

5Quality

Control

6Finishing

7Delivery


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Marketing department, like all other organizations, play a vital role in the businessoperations of RTML. This department is running with a few but qualified personnel.They are devoted to their works. Because they are very few in numbers and theirall buyers are foreigners they could not give us much time in spite of beinginterested. Therefore, the following paragraphs are about marketing, in veryshort.

The main marketing policy to grasp buyer-orders is to offer quality products incheap rate. In this respect, the credit goes to the production personnel for bothquality and cheap rate.Because their all buyers are foreigners in Europe they keepcommunication through E-mail. Their mains are outlined briefly in below:

1. To grasp orders by convincing buyers: this is a tuff job in fact.

2. To make sure that the delivered goods will satisfy the buyers demands.

3. To keep communication with every individual buyers with a view to makethem permanent customers.

4. To perform supply chain management operations to make sure that thedelivered goods are reached to buyers in good conditions and in time.

5. To keep tight delivery schedules and so to win over the productionpersonnel to produce in due time.

These are all about Marketing department in RTML, in short.

Other Departments

There are also a MIS Department, Store Department and a few administrativepersonnel in RTML.

Conclusion

This report is aimed at giving a clear picture about the flows of production andoperations in RTML. In order to keep pace with this objective, I gave emphasis onproduction and operations related subjects in preparing this report. At the sametime, I avoided discussions on other general topics like, administration, MIS,commercial, documentations etc. In fact, I do not want to make the readers boredwith traditional information. I mentioned only the information that is nottraditional but special and unique for RTML. Apart from this, I was stronglyinfluenced by certain other limitations in preparing this report. This part is comingin the forthcoming paragraphs.

Limitation and Caveats for the Report

I underwent the following limitation and caveats while preparing this report:

1. The internship duration is six to eight weeks in formal. But in fact, we couldwork for lees than the time mentioned above due to many practicalreasons. The textile operations are so vast that it is not possible tocomplete within this time limit. But I tried my level best to present you astandard report.

2. There is no remuneration allowed to the researchers by the management

of Regent Textile Mills Limited. Neither it is possible for a student to investhuge amount of money in this research. Hence, money acted as a stronglimitation for this report preparation.

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3. Regent Textile Mills Limited is 100% export oriented firm. So, theemployees are always on a run. Hence they cannot give us much timealthough we found them cordial and inclined.

4. The journey to the factory from city very lengthy. To reach there in the mill

from Chittagong city, we have to change vehicles for four times. Thismakes the journey boring and de-energizes us a lot.

5. As the mill is out of the city of Chittagong and the locality is still a ruralplace, we underwent many sufferings to get a good diet in lunch.

6. The production floor is very hot where we spent much of our times. It alsode-energizes us a lot.

These are the limitations in short that we have to accept and that influenced mein shaping the report, in fact.

Weaknesses and Threats

However I observed that this organization suffers from certain weaknesses as wellas is facing certain threats. It is worth mentioning here that these discussionsagain from the view point of only productions and operations. However, thesethreats and weaknesses are outlined below in brief:

1. The organization lacks in skilled production people.

2. The factory is about fifteen kilometers far from the Chittagong city. Neithermanagement can provide transport facilities to all employees.

3. The only canteen inside the factory premises is sub-standard.

4. There is lack of strategic/long term thinking.

5. There is high competition from both national and internationalperspectives.

6. No hindrance for new competitors to entry in the industry.

7. The organization is 100% export oriented for which it has to maintain tightproduction and shipment schedules.

8. The organization offers a wide range of product diversification.

9. The organization does not have sufficient backward and forward linkagefacilities.

Strengths and Opportunities

The organization also has some strengths and opportunities which are brieflyoutlined below. It is worth mentioning here that these discussions again from theview point of only productions and operations:

1. The organization can enjoy cheap labor.

2. The organization can enjoy both water and land transport facilitiesbecause the factory is situated on the bank of Karnaphuly River.

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3. The organization has strong capital back up because of havingsufficient banking facilities in Chittagong..

4. The organization has sphere spaces where it can expand it productionfacilities .It is very important for further product diversifications.

5. The textile industry is very big and growing day by day in Bangladesh.At present there are more than 400 textiles in Bangladesh.

6. The textile industry in Bangladesh is mainly export oriented for which The Regent Textile Mills Limited can enjoy positive governmentattitude.

7. There are available facilities for water, sewerage, electricity and gaswhich help it to minimize its production costs and thus make theorganization more competitive.

8. The organization belongs to Habib Group which has a spinning mill.Thus the organization can enjoy backward linkage facilities.

9. The organization is 100% export oriented and it has plenty of orders inhand now.

Recommendations

The organization has both positive and negative sides. Hence, it has a brightfuture if it can tackle its threats and weaknesses by using its strengths andopportunities. It is worth mentioning here that these discussions again from theview point of only productions and operations. However the following practicalrecommendations are offered for its bright future:

1. Expanding of production facilities to increase product diversifications.

2. Expanding of the housing facilities to provide sufficient housing facilities toits employees.

3. Establishing backward and forward linkage facilities to minimize productioncosts and to meet tight delivery schedules.

4. To arrange training for the production people.

5. To offer handsome remunerations to production people.

6. To provide sufficient transport facilities to its employees.

7. To make strategic directions for long time survival.

8. To provide standard canteen facilities to ensure that employees can re-energize and refresh themselves without going to outside the main gate ofthe factory. Because it interrupts the production and operations flow,

With all of the above mentioned recommendations I would like to conclude bysaying that Regent Textile Mills Limited deserves a very bright future and to bethe leading textile in Bangladesh and even in this sub continent.

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