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Submitted By-
Submission: January 19, 2015
Md. Sadiq Uddin Vhuiyan Student of MBA
Product & Fashion Merchandising
Class ID: 122151002, 4th
Semester, 4th
Batch,
Shanto-Mariam University of Creative Technology
Shanto-Mariam University of Creative Technology
Submitted To-
Moinuddin Ahmed Lecturer of AMT
Module: Internship, Module Code: MMBA- 806
Shanto-Mariam University of Creative Technology
DECLARATION
I hereby declare that, this project has been done by myself under the supervision of
Moinuddin Ahmed, Lecturer of AMT Department, Shanto-Mariam University of
Creative Technology. I also declare that neither this project nor any part of this project
has been submitted elsewhere for award of any degree or diploma.
Supervised by:
Moinuddin Ahmed Lecturer of AMT Department,
Shanto-Mariam University of Creative Technology.
Submitted by:
Md. Sadiq Uddin Vhuiyan ID: 122151002
Batch: 4th, Semester: 4
th
MBA on Product and Fashion Merchandising.
Shanto-Mariam University of Creative Technology.
Acknowledgement
A warm felicitation goes for me to acknowledge the people, who hold the desirability
for encouraging, praising, assisting as well as believing me on the tasks of
merchandising activities what I have worked through my internship period. First of all
I would like to take the opportunity to thank Mr. Moinuddin Ahmed, Senior Lecturer
& my internship supervisor, Shanto-Mariam University of Creative Technology for
providing me guidelines, help in assisting my report. He was constantly supporting me
with his inspiring personality. I will always be always thankful for his extraordinary
reinforcement.
I would like to take the opportunity to thank Mr. Ahsanul Islam, Associate Professor
of MBA, Shanto-Mariam University of Creative Technology, He always guide us
about everything, Overall he is a nice person, he teach us how can we move in front
with positive approach.
I would like to take the opportunity to thank Md. Mamunul Islam Jewel, General
Manager, Woven Division, Zyta Apparels Limited for being my on-site supervisor &
providing me time to time information, suggestion as well as procedures to work with
my topic.
I also want to thank Mr. Mostafa, Manager, Merchandising of Zyta Apparels Ltd.
Woven Division for being so cooperative in my work.
I also thank Mr. Sk. Mujibur Rahman Mukul & Mr. Raisul Islam, Quality Manager,
Zyta Woven Division for creating a friendly environment & assist me with the
information of my project.
Finally, I will show my gratitude to all the Management & Non-Management Staffs
who have helped me during the internship period and the entire persons who somehow
have impact on me in completing my whole report.
Executive Summary
Zyta Apparels Limited is a concern of Armana Group. Armana is one of the largest
groups in Bangladesh and well GDP contributor. Here, this is a great chance for me to
do my internship in one of its concern organization Zyta Apparels Limited a sister
concern of Armana’s Woven Division. This is a large factory with all the facilities to
manufacturing woven bottom. Here the production process runs from fabric and from
fabric to finished garment. In this age, Bangladesh is flourished with RMG sector
where this division has its immense contribution. As a large industry Zyta Apparels
has large numbers of employees but the productivity is getting slow day by day. So, it
is a matter of concern that why this huge industry is doing stagnant profit. In the whole
procedure of exporting garments to the retailer of abroad and to communicate with
them, merchandisers have a great influence and responsibilities. When, the order is
taken from buyer the duty comes to the floor of merchandisers and before going
production they do almost everything to make the business smooth. So, the work starts
with the order taking and making business relationship. Then sample making,
planning, booking of every single material for samples and getting approval are all the
key responsibilities of merchandisers. In case of production, sample goes in bulk so,
the responsibilities become huge and it comes to the relation with operation also. I was
selected for the buyer Gap (Old Navy) and this team is really supporting from any side
I wanted their help. Gap is full with new styles and different designs which push
merchandisers to face huge stress and deal with lots of challenges. Here, these all
procedures are tried to be written as the team tried their best to help in preparing this
report.
Ref: SMUCT/MMBA/MBA-2014-002 Date: 18-08-2014
HR Manager Zyta Apparels Limited Industrial Plot No. 4 Section 7 Mirpur, Dhaka Bangladesh
Subject: Request for extending and opportunity for doing internship at your
organization.
Dear Sir/ Madam,
It is our pleasure to inform you that Md. Sadiq Uddin Vhuiyan (ID: 122151002), is a student of MBA (Product and Fashion Merchandising) program of Shanto-Mariam University of Creative Technology. He is currently completing his final semester. As a partial requirement of his program, he has to undergo an internship program in any reputed organization undertaking to groom up in his field of specialization.
As our students have very little chance to gain an on the job experience during the academic program at the private university in our country, and as a part of your corporate social responsibility; we are expecting your kind co-operation to make him fit for today’s highly competitive and dynamic corporate environment.
We shall be thankful if you kindly extend your benign hands of co-operation by accepting him as an internee in your organization for at least three months period. We assure you that the data/ information to be supplied by your organization will be kept confidential and utilized for research purposes only.
Best Regards,
Ahsanul Islam Coordinator, MBA (Product and Fashion Merchandising) Program
House No: 01, Road No: 14, Sector: 13
Uttara, Dhaka-1230, Bangladesh
Phone: 880-2-8918932, 8919366, 8952610, 8958048
Fax: + (880-2)-8915308
E-mail: [email protected], [email protected]
Web: www.shantomariamedu.com
Letter of Transmittal
Mr. Moinuddin Ahmed
Lecturer of AMMT
Shanto-Mariam Univrsity of Creative Technology.
Subject: Internship report on Merchandising and production process in
garments Industry.
Dear Sir,
With great pleasure, here I submit my internship report on ―Special Effect on Denim
Wash‖ at Zyta Apparels Limited that you have approved & assigned as a compulsory
requirement of MMBA-806 course. I have tried my level best to bring out the original
scenario of Zyta with full of effectiveness & efficiency.
I have really learned a lot and have gained valuable experience and knowledge while
collecting information for the report. It was certainly a great opportunity for me to
work on this real life project to actualize my theoretical knowledge of this course in
the practical arena and some more which is out of this course.
I hope that this project paper has been to your expectation, if you come across any
question or quarries regarding these cases, it will be my pleasure to clarify your
questions.
Sincerely yours,
Md. Sadiq Uddin Vhuiyan
ID- 122151002
4th
Semester, 4th
Batch
MBA on Product and Fashion Merchandising
Shanto-Mariam University of Creative Technology.
INDEX
Contents Page No
Chapter 01
Introduction 1
Objectives 2
Methodology 3
Scope 3
Limitations 4
Chapter 02
Company Profile 5
Company Organogram 6
Products 7
Mission 7
Vision 7
Facilities 8
Customers 8
Chapter 03
Departments/ Sections for Production 9
Total Machines List of Zyta Apparels Limited 10-11
Zyta Apparels Partners with Major Retailers & International Brands 12
Commitment to the Environment 13
About Health & safety 13
Social Compliance - Code of Conduct 13
Corporate strategy 14
Motivational techniques and training 14
General Management Training Manual or Workers Training Manual 14-16
Chapter 04
Trimming & Accessories Store Section 17-19
Fabric Store Procedure 20
Merchandising Department 21-35
Cutting Section 36-38
Sewing Section 39-43
Chapter 05 (Special Effect on Denim Wash)
Washing Section 44
Garments Washing 44
Objective of Garments Washing 44
Different Type of Garments Washing In our country 44
Types of wet wash Process 45
Types of dry wash Process 45
Characteristics of Denim Fabric 46
Basic Denim wash Principals 46
Some important steps in the process of Denim wash 46-47
Methods of removing sizes from Denim Jeans 47
Enzyme and Stone washing process of Denim Garments 47-48
Clean-up 49
Trinting & Dyeing 49-50
Denim are dyed by Indigo Dye 50
Indigo Background 50
Denim Fabric Process 50
Decision about Enzyme Wash 51
Enzyme 51
Objective 52
Types of Enzyme 52
Decision 52
Denim For Bleach Washing 52
Bleach 52
Chemical Instruction 53
Chemistry 53-54
Bleaching Washing 54
Objectives 54
Different types of Bleaching 54
Reaction Shown 55
Degradation of Cotton by Bleach 55
Oxidation Potential of the Bleaching Agent 55
Activation of Sodium Chlorites 55
Chemistry 55
Mechanism of Bleach Action 55-56
Change 56
Decision 56
Softening Process 56
Minimization of Yellow Risk 56
Production Sequence of Washing 57
Machine Summery of Washing Section 58-59
Some Washing Chemical List 60
Sample Development 61
Pumice Stone 61
Enzyme 62
List of some Dyes with Market Price (Approx.) 62
Denim Mock-up wash during my internship period 63
Super Light Wash 64
Medium Wash 65
Dark Wash 66
Acid Wash 67
Non Wash Denim Fabric Image 68
Pocketing Fabric Image 69
Personal Assessment about Denim Wash 70
Chapter 06
Finishing Section 71
Finishing Section Work flow-chart 72-73
Some Images During Finishing Works 73-75
Chapter 07
Merchandising Activities On Goods Delivery To Buyers Destination 76
Internal Challenges 77
External Challenges 77-78
Chapter 08
Recommendation 79
Conclusion 80
References 81
Introduction
RMG (Ready Made Garment) is very important and helpful for our Bangladesh. Bangladesh has
emerged as a key player in RMG (Ready Made Garment) sector since 1978. Textiles and clothing
account for about 85% of total export earnings of Bangladesh. Out of which, 75% comes from the
apparel sector which covers the major products of knit and woven shirts, blouses, trousers, skirts,
shorts, jackets, sweaters, sports wears and many more casual and fashion items. The sector currently
employs approximately 1.5+ million workers, mostly females from underprivileged social classes. I
have completed this report on the basis of all the department of RMG sector such as Merchandising
Department, Commercial Department, Production Department, Supply Chain Department, Human
Resource Department, and Compliance Department. So by completing this report I get overall idea
about RMG sector, so its carry more value than any books. I preferred this attachment in Zyta
Apparels Ltd, which is a 100% export oriented woven industry. For continuing the study of
internship in the Zyta Apparels Ltd. I worked all the sections of this company and tried to find out
the activities, planning and many other things as well. In context, we have discussed about these
things deliberately to let you know about.
Objectives:
Objective means the purpose of this report. The objectives of this report are as follows:
Its documents for future.
To know detail about RMG sector.
Information gathers about commercial.
Getting idea about shipping procedure.
Comparison between class room learning and practical learning.
Knowledge gather about RMG sector related other organization.
To know about the management and technical process of apparel industry.
To know the management Procedure in Garments Industry.
To mark a comment over the whole Internship Report.
To mark out the important part of Internship Report.
To focus on the valuable part of Internship Report.
To have skill labor for quality product.
To study the present market composition for the Bangladeshi garment product about Market
diversification.
To analyze the recent labor unrest in the garment industry of Bangladesh.
Opportunity of behavioral theory practice in our garments sector.
Regularly behavioral theory practice in garments industry.
Identifying the trade agreements that might affect the export growth.
To do a merchandising practice in the factory.
Identify the additional services that the existing companies are going to avail.
To relate the use of groupware and collaborative systems with future trends in managers'
roles and responsibilities.
To identify merchandising and total production system.
To find the current scenario of backward supply chain status of Zyta Apparels Ltd.
To find the ways of improving the backward linkage of the supply chain for Zyta Apparels
Ltd.
Methodology:
Methodology defines how we go through all the processes of research and how I have proceeded on.
Here includes the steps of conducting the report and the explanation of the sources of data.
Factory
Different organization.
Books
Discussion Internet
Class lecture
Library
Annual report
To collect information what I am seeing in practical in My Internship Program.
To collect information what I did in practical what was done by me for my practical
knowledge.
To make a comment over the project we have to understand the whole project.
Scopes:
Scope means how many uses for completing this report space. The scopes are given bellow-
Factory
Buying House
Discussion Internet
Some of our senior brothers can help us.
I can collect information various books and relevant paper what related with apparel industry.
Limitations:
Limitation refers the obstacles I have to face for completing this report and what I could not cover
for this limitation.
Time constraint
Merchandiser doesn’t have enough time to give the information elaborately.
Short time visit in different work stations
Lack of organizing chain of command
Lack of instruction book, and any change.
They are following traditional business.
I may have to suffer for lack of supply chain management.
No other garment’s data has been compared with Zyta Apparel’s data.
There might be some discrepancies with other factories‟ supply chain scenario‖
Due to high employee turnover rate and lack of good reporting practices in the factory,
problems with collecting data have been faced.
Company Profile
Zyta Apparels Limited one of the concern of Armana Group which is Established in 1994, Armana
has successfully transitioned from being a buying agent to a RMG manufacturing & export company,
having operations in Bangladesh, exporting woven bottom wear to the USA & Europe. Growing at
an average rate of 20% (year on year), we are presently a group having an export of $150 million.
Spread over 4 production facilities & 2 laundries, we have an installed capacity of 1.8 million units a
month. They ship to 40 countries worldwide, with USA & EEC being the major destination.
Company Contact Information of Zyta Apparels Limited
Corporate Office
House 26, Road 71, Gulshan - 2,
Dhaka – 1212,
Bangladesh
Tel: +8802-989 8456
Fax: +880-2-989 9669
Web: www.armanagroup.com
Factory (Zyta Apparels Limited)
Industrial Plot No- 4,
Milkvita Road,
Mirpur, Dhaka- 1216.
Email – [email protected] ; [email protected]
Company Organogram
Organizational chart bearing vital importance for a company, often represented by a schematic
diagram. The organizational chart of Zyta Apparels Ltd. is given below:
Board of Direction
Chairman
Managing Direction
Manager (Marketing
& Procurement) Chief Executive
Officer (CEO) DGM HR &
Administration
Policy farming
&
implementation
Recruitment
Training & Staff
Development
HR Control
Market
Research
Input
Procurement
Product
Selling
GM Operation, QC
& Maintenance Manager (R& D) Manager (Accounts
& Finance)
Process
Research
Product
Planning &
Development
General
accounts &
MIS
Payroll
Share Issues
Operation
Quality
Control
Maintenance
Inventory
Products
Zyta’s facilities are world class units specializing in production of all kind of woven bottoms with a
specialization on denim. The group has its own laundry facilities, which are a vital process link, in
our manufacturing process. These are state of art laundries having the best equipment, infrastructure
& technicians, on par with any facility globally. Our product crosses over all gender & size groups –
from Infants to Adults. We have in place R&D and design teams, on site & in Europe, who are
constantly working on fabric sourcing & design innovations. In conjunction, to the above, we also
have brand partners whom we partner, to design their new lines, for the upcoming seasons.
Mission:
Zyta Apparels Ltd. is a full service factory with strong vertically integrated production facilities as
well as creative & analytical capabilities which clearly set us apart from most other South Asian
factories.
Vision
To stay focused on our strengths which is to deliver a quality product at the right price.
To ensure we operate within the fair practice policy, ensuring every individual in the
organization is treated with the utmost respect – professionally & financially. Their growth
propels our growth as a company.
To constantly endeavor & challenge the teams for better sourcing at merchandising & higher
efficiencies at production.
To be virtually vertical by having the right partnership formula with strategic mills, to ensure
mutual business advantages.
Have a systemized re-investment plan, year on year, wherein we add value to the company
not only from a turnover point of view, but where we can attain higher performance value &
be perceived as a TRUE-VALUE partner by our suppliers & buyers.
Facilities
Armana group comprises of four manufacturing facilities & two laundries.
Zyta Apparels Ltd. …. (Established 1994)
Armana Apparels…. (Established 1994)
East West Services... (Established 1996)
Denimach Ltd …. (Established 2007)
Jeans Culture Washing (established 2000)
Denimach Washing … (established 2005)
All of our facilities are on par with any world class unit, and are fully compliant with local laws &
international standards, as laid down by our buyers & certified auditors.
We have in place strong health & safety systems, especially those with regard to fire & chemical
hazards – one of the best in the industry.
Zyta’s facilities are equipped with some of the best manufacturing equipment’s (sewing & washing
machinery) bought from Germany, Japan & UK.
We are also proud of our in-house sampling & development centre which constantly works on
servicing customer needs with regards to design & innovation.
Our personnel skill sets are the back bone of our organization & we pride ourselves in having the
right work force and management teams – centrally & localized in every individual facility. They are
the real engine of our business & are truly one of the best teams in the country.
Customer
Zyta is shipping worldwide to all markets in the Americas, Europe & Asia. Partnering with brands &
retailers, our client profile include retail giants such as Gap Inc, Levi's, Gant, Abercrombie & Fitch,
Next, H&M, Motherhood (DMC), Benetton and many more.
Departments/ Sections for production:
Administration department
Merchandising Department
Commercial & Compliance Section
Planning Section
Sample Section
Cutting, Sewing and Q.C Section
Finishing section
Mechanical & Electrical section
Total Machine List of Zyta Apparels Limited
Sl
No Description Brand Model No Qty
1 Sngl Needle Auto lock Stitch Juki DDL-8700-7, DDL-8500-7 384
2 Sngl Ndl Lockstitch Juki 5530N 130
3 Dbl Ndl Lockstitch Auto Juki LH3528A-7 20
4 Dbl Ndl Lockstitch Normal Juki LH3178 48
5 Dbl Ndl Lockstitch Angoler Juki LH3168, LH3568S 28
6 Overlock 5 Thread Juki 6716S 43
7 Overlock 5 Thread Pegasus MX3216-03 29
8 Overlock 6 Thread Pegasus MX3244 12
9 Overlock 4 Thread Juki 6714S 6
10 Feed of the Arm (3 Ndl) Juki MS1261 49
11 Kansai Special Kansa Spcl DFB1411SPF 27
12 Dbl Ndl Chain Stitch Juki MH380 25
13 Loop Kansai Kansa Spcl B-2000C 8
14 Button Hole Normal Juki LBH781 6
15 Button Hole Auto Juki LBH 1790-S 7
16 Bartech Normal Juki LK1850 9
17 Bartech Auto Juki LK1900AHS 37
18 Button Stitch Computer Juki LK1903ASS, 1930HS 12
19 Eye Hole Normal Rise AMF, S-101 1
20 Eye Hole Computer Juki MEB3200J 6
21 APW Auto Machine Juki LH895 4
22 Pocket Decorator Juki AMS210D 4
23 Belco Attached Juki AMS 210EN 4
24 Pocket Heming Juki MH380 2
25 Zigzag Stitch Juki LJ2284-N 4
26 Saddle Stitch Zoje ZA200 3
27 Blind Stitch M/C Nisho NJ364Z 3
28 Snap Button M/C Nagashing NS-47 28
29 Snap Button M/C Prime PP5/600 6
30 Thread Shaking N55H NS54 4
31 Coting M/C (10) KM/TS
MAN KSAUH 13
32 Lay Cutting M/C KM KC2NHL 6
33 Plastic Stapler Denison ST9000 5
34 Sngl Ndl Side Cutter Juki DLM5200ND 6
35 Pocket Fetching M/C Kansai Spcl WX8842 9
36 Flat Lock M/C Juki/Kansai MF7723 3
37 Fusing M/C VEIT BX1000MCD 1
38 Fusing M/C Hasima HPM600BA 1
39 Fabric Inspection M/C Nagashing NS-58 1
40 Fabric Shed M/C VCRIVIDE CAC60 1
41 Safe Q Stasp Testing IMADA T441-8077 1
42 Spot Remove M/C Hasima NS3302, N-796 2
43 PP Belt M/C Hasima - 2
44 Thread Re-coning M/C Hasima HW20 2
45 Thread Trimming UNISUN US3262 20
46 Band Knife Cutting KM KBK900 1
47 Needle Detector Hasima HN770G 1
48 Needle Detector Cintex 17890 1
49 Finishing Steam Iron VEIT - 35
50 Finishing Steam Iron Naomoto - 8
51 Finishing Steam Iron Sewoong - 7
52 Vacuum Ironing Flt Table VEIT - 20
53 Vacuum Ironing Flt Table Naomoto - 18
54 Generator Energypack - 1
55 Boiler M/C Universal - 2
Total 1116
Zyta Apparels Partners with Major Retailers & International Brands
Commitment to the Environment
Zyta Apparels Ltd. is very committed to preserve a healthy and pollution-free environment. It has a
very efficient waste collection and disposal system. In order to reduce air pollution by exhaust of gas
from engine-generators, it maintains a costly plant that uses the exhaust gas to generate steam for
chilling unit. Above measures not only help keep the water & air free from pollution but also help
save cost of water treatment & air conditioning.
About Health & safety
Name of the section Health & Safety
Doctor 1 Personal
Nurse 2 Personals
Fire Fighter 100 Persons
Fire Drill Once every month
First Aid Box 13 Pcs
Fire extinguisher 62 Pcs
Smoke Detector 08 Pcs
Water hose pipe 04 Pcs
Medicine Support 100%
Note: on any emergency employees are communicated with loud speakers.
Social Compliance - Code of Conduct
Zyta Apparels Ltd. is a responsible apparel producer and embodies, both in spirit and practice,
internationally established codes of social accountability and ethical business practices. It recognizes
and respects cultural differences and employs individuals solely on the basis of their qualification for
the job. They identify and work with suppliers and buyers who as individuals and in the conduct of
their business abide by local laws and have ethical standards compatible to it. The bases of the
various parameters that comprise the code of conduct are drawn from the following:
Ethical Trading Initiative
Global Sourcing Principles of Key Customers
ILO Conventions
Local Legislation
Corporate strategy
The Council provides a wide range of specific services (Education, Planning, Social Work,
Cleansing, etc.) but there are also a number of issues which require a corporate approach. These
include such regular matters as Equalities, Best Value, Public Performance Reporting, the Citizen
Panel and strategic issues like Asylum Seekers and Refugees. Generally speaking the Chief
Executive, as principal policy advisor to the Council, has responsibility for providing a corporate
policy and strategic lead to the Council. Sometimes individual services are requested to take the lead
on relevant issues. The Council’s Social Work Service is building a partnership with the local health
board in response to the Government’s Joint Futures initiative for example. The Corporate Policy
Unit within the Chief Executive’s Department has the lead responsibility for several key policy
areas; develops relevant strategies to handle significant policy issues and supports both senior elected
members and the Council’s Corporate Management Team.
Motivational techniques and training
Motivation is the psychological feature that arouses an organism to action toward a desired goal and
brings out, controls, and sustains certain goal directed behaviors. If the textile and apparel sub sector
industries in Bangladesh are to achieve World Class Manufacturing Standards then the problems of
collision and low productivity which the consultants have highlighted need to be addressed by
structured training programs relevant to each level of company employee.
Mostly no training provision is introduced in garment manufacturing and textile industries. (Training
and Vocational Education) All of the companies generally recognize the importance of skilled
sewing machine operators and training in other skills particularly cutting and pressing. The training
of the operators takes place on the production line and they are taught basic skills on one type of
machine only. There was no structured programmed that would include training on a number of
different machines, the achievement of the appropriate quality standards and output targets. Similarly
those individuals carrying out the training had, themselves, not been trained in the instruction
techniques. Even, in case of management body training is necessary for better working environment
and productivity. There is a belief that anyone will start learning by working himself so most
employees come out of nowhere and then start learning gradually so the frequency of mistakes is
higher. The consultants find few companies using a formal recruitment policy or the formal testing of
potential employees during the selection process.
General Management Training Manual or Workers Training Manual
Management Techniques
Management techniques are those management concepts or strategies, which are followed to run an
organization efficiently and profitably. Management techniques, whether pertaining to employees,
the customers of the organization or the partners, in case of partnerships, should be chosen only after
evaluating the needs of all three. An example of a management technique pertaining to employees is
the use of incentives, so as to motivate them, or to provide them with training in order to update their
skills. Management techniques pertaining to customers are usually aimed at keeping them happy and
satisfied, so that they keep on coming back. An example of this could be the various discount offers
that are given to the customers on special occasions, such as Christmas. Whatever management
techniques are chosen by organizations, the main thing to consider is that they should fulfill the
needs of the organization and also, of the employees, customers and the partners.
According to business experts, the most effective techniques are those that are a mix of all the styles.
The management styles that are followed should depend upon the situation that an organization is
facing. In the fast changing business environment, it will neither be practical nor profitable, to stick
to only one style. That is why the management gurus, when giving management tips, always insist
that only the organizations that evolve their management techniques, according to the ever changing
corporate culture, will survive to see the future.
There is a need to encourage local individuals to become involved in this aspect of the industry and
to provide structured training programs. The consultants identified the following areas of textile and
apparel specific training that needs to be addressed in order to assist the industry maintains its
international competitive advantage.
Supervisory management training
Operator instructor training
Operator flexibility training
Recruitment / selection training
Technical / mechanic training
Training of Industrial Engineers
System development procedure
Zyta believes in sustainable development and gives highest priority to preservation of nature and
ecological balance. The entire industry site is harmoniously integrated with the surrounding
landscape and the native eco system of the area has been delicately preserved. Zyta Appares Ltd.
have Biological Treatment and Energy Conservation Program. State-of-the-art technology has been
used in the effluent treatment plant in their dye house for biological treatment of waste. Zyta also
uses comprehensive energy conservation program. This feeds back all recyclable energy into our
various systems, especially for our air-conditioning purpose. Their investment in this program has
made us energy efficient and environmentally conscious entity.
Trimming & Accessories Store Section
Style File:
Complete style file receive from the merchandising department to be available in the stores before
receiving the trims, accessories or fabrics for the style. Testing and quality standards and requirement
sheet should be including in the style file. Stores to be followed the style file when the receiving and
issuing related to each and every style to make sure that all and correct items will be received and
issued.
Style Requirement Sheet Fabric and accessories)/ Bill of Material (BOM):
Style requirement sheet to be received by stores from merchandising department before receiving the
purchase order copies form merchandising to stores. PO’s to be copied to stores before receiving the
trims, accessories and fabrics for the style. Stores should cross check and update’s the PO’s and
receiving goods according to the BOM and make sure to receive all required items and required
quantities.
Purchase order (Work orders) sent to supplier and stores copy:
All the purchase orders (Work orders) sent to the suppliers to be copied and updated to the stores by
the merchandising and purchase department. Stores will follow and update the concern department
and designation on goods receiving against to the PO’s and agreed time. Stores to follow up the
requirement sheet (BOM) and PO’s against the production plan to make sure the goods are in house
on time as required and not to have any delay, wish effect to production department.
Factory Purchasing Procedure will be as mentioned below:
a. Purchase for the items source by Merchandiser:
Purchase order raise by the Merchandiser through the software system.
Purchase order should rise as per the approved BOM.
Purchase order raise by the Merchandiser will be approved by authorized person for
sourcing.
Merchandiser will send PO’s to supplier.
PO’s sent to suppliers will be copied to stores automatically by software system.
b. Purchase for the general items source by purchasing department:
Company has to define the minimum order levels for the general items.
Software system will be automatically tracked the minimum stock levels and
providing the alert to store keeper.
After receive the minimum stock level alert by system, store keeper will raise a
request note for purchase the item.
Request note will be forwarded to authorized person for approval for each supplier.
After approval of requisition it will automatically be converted to a PO’s by the
system.
c. Other Purchased (Special Items)
Requisition (Manual) to be made through the department head of the concerned
department.
Requisition (Manual) will be submitted and approved by the concerned person.
Approved requisition will be submitted to store keeper to prepare the requisition in
the system.
System requisition will be submitted to the concerned person for final approval.
After approval of requisition, it will automatically to convert to a PO by the system.
Style Follow-up’s:
Stores must be maintained the style follow up procedure with maintaining a separate report for each
style. This style follow up report should include the style requirement list with work order (Purchase
orders sent to supplier including agreed delivery date for each item) details. Store management to be
followed the items to be received in each style against to the requirement list, quantity and agreed/
requires date to make sure the all goods receive on time as per the production plan.
Some Other Procedure done by Store Department
Trim Card quality standard and inspection.
Fabric Segregation.
Good Receiving procedure and GRN (Goods Receiving Notes).
Production Plan and daily issuing preparation.
Good Issuing procedure, GRN and SRN.
Goods Transferring procedure and GTN (Goods Transfer Note).
Goods Return Procedure, records and FRN (Factory Return Note).
Ledger.
Bin Card.
Inventory item in and out without the companies.
Left over records, summery and non-moving items.
Style Reconciliation.
Fabric Store Procedure:
Figure: Work flowchart of store department
Merchandising Department:
RMG sector of Bangladesh is gaining ground in the world market at breakneck speed, but still not
flourished at the fullest extent. Although the resources are available abundant with a powerful
foundation of fabric and spanning sector to support. The key factors behind this are low
technological development, lower output, cut throat competition, high raw material cost, inadequate
infrastructure, traditional productivity, unfavorable regularity policies, and globalization in fact.
However, there a fair list of the producers, suppliers, and exporters that are fully acknowledge with
regularity policies and formalities, international marketing policies and procedures. The only concern
is in executing their productivity initiatives, and meeting with order deadlines. Garments
merchandising means the work to buy raw material and accessories to produce garments
(Merchandise) against a particular work order of garment and have to export these under the same
work order within time schedule, maintaining required quality level of buyer. The Merchandising is
the important activities, term and section of a garment that is not possible to run and deliver
successfully. The term ―merchandising‖ is well known to the persons specially involved in garments
trade. The term merchandising has been derived from the term merchandise. Merchandise means
good that are bought & sold. Merchandising is a business on marketing activities responsible for
ensuring a products description both quality and quantity. Merchandising means total responsibility
of a Merchandiser. Merchandiser Duty of merchandiser describes himself like this-
A man who collects order from customer sourcing raw materials production on time with
quality and maintains lead time.
Garments merchandising means buying raw materials & accessories, producing garments,
maintaining required quality level and exporting the garments within scheduled time.
If anybody has to be designated as Merchandiser then the word itself demands some qualities from
that individual, now let us see what all are the hidden meanings there in the word
„‟MERCHANDISER¨.
M- Should have good Managerial capacity.
E- Efficient in both English written and spoken.
R- Having high sense of Responsibility.
C- Always keep commitment.
H- Leads honest life.
A- Attitude should always be positive in resolving any problem.
N- Never does any argue with buyers and seniors.
D- Fully devoted to his service.
I- Always well Informed about his all orders.
S- Sincere in office and daily works.
E- Enthusiastic in nature.
R- Regular in e-mail correspondence.
Most importance things for a Merchandiser is Communication. Planning Production Follow Up
The responsibilities of a smart Merchandiser are handling order at four stages.
1. Sourcing for future orders/Buyers
2. New Order
3. Confirmed Order
4. Running Order
Business Development Procedure:
Apparel industry must be developed with the trend of market otherwise they cannot extend their
business. To collect new buyer and business with them a company must follow the procedure of
business development. Buyers have been chosen by two ways. Firstly, Buyer chooses the supplier
and the second one sometimes, Zyta Apparels Ltd. want to work with a particular buyer and then
contact with them according to that. Zyta Apparels Ltd. follow the procedure of business
development, this are given below-
Buyer Selection
Know about the nature of buyer
First E-mail to the buyer
Collect audit pass report from buyer
Offer to buyer for visit the company
Company arrange a meeting with buyer for business
Sampling stage
Price negotiation
Price conforms and order place from buyer
First email to buyer for business development
For new business development sellers have to communicate with buyer. Email is the easiest and
swift way of communication so when seller will contract first time with buyer by email at that time
have to mention some important information about company. Which kind of things should be include
here this are-
Information about you and your company.
Products information about your company.
Capacity and productivity.
Which buyer work with you.
Attachment a beautiful sample photograph.
Wearing for feedback.
This kind of information should be included in this email. On the other hand this email will be
minimum word and maximum communication.
Sample of first email
Dear Sir,
I am X,
SR Merchandiser of Zyta Apparels Ltd.
We are the manufacturer & exporter of readymade garments in Bangladesh.
―Zyta Apparels Ltd.‖ began its journey into the garments sector in 1994 as garments in Bangladesh.
Since then the organization being run by highly qualified, experienced and professional management
and stuff along with Sophisticated Machineries, Latest Technology, Skilled Workmanship,
Substantial Marketing and Proper Discipline. We are ready and able to give you 100% quality, best
price and service. We believe it is possible to us to enter into the marathon of global market.
Our Factory is 100% export oriented. Our previous practice is the best quality of products and on
time delivery. We are always committed to the buyers.
Our Products: Denim, Twill, Linen- Bottom (Men’s, Women’s, Kids, Maternity).
Please send us your current inquiry for sampling & costing.
Your kind co-operation would be highly appreciated.
Thanks & Best Regards,
X
Zyta Apparels Ltd.
Industrial Plot no- 4, Milkvita Road
Mirpur, Dhaka.
Feed –back from buyer in response to first email
Dear X,
I am pleased about your company, so I want to make a business with you. So you should send some
original sample include with FOB price.
Best regards,
Y
This is happened in case of choosing buyer by Zyta Apparels Ltd. itself but mostly the buyer choose
the supplier and in that case they send a product pack first and then supplier send the product
according to their requirement.
If Buyer accept the worded and approve for production then
Negotiation (price) process & ending of negotiation
Arrange a meeting
Show the price to buyer
Arguments about price with buyer
Make win situation
Fixed price
Place a new order
Ending the negotiation by dinner
Finishing product
Fabric booking after receiving order confirmation from buyer merchandisers chase buyer to provide
PO sheet (purchase order) which includes color & size wise break down of the total quantity. Then
they will go for denim/knit or the necessary fabrics booking. In case of denim the process is same but
some cases it fluctuates in terms of price and place.
Trim booking
After getting trim information from Buyer they have to develop the same to get approval. Then they
book trims from respective supplier to get cheaper price to minimize the cost. And, for shipment
process they need to store every trim in-house so that production cannot get hampered. The all
processes go parallel when an order is confirmed. When the size set sample is confirmed, the
processing of production starts.
PI sheet & its items
In foreign trade transaction, a proforma invoice is a document that states a commitment from the
seller to reserve some goods to be sold to a certain person, the buyer. the buyer places an order and if
the seller agrees, it extend a proforma invoice and agrees to all the terms specified in it, the goods are
send and the proforma is replaced by a commercial invoice. The POI sheet depends on the demand of
buyer. What are the items will include in this sheet are-
Top part:
Name and address of seller
Invoice number and date.
Buyer name and address.
Body/middle part:
Product description.
Unit price.
Total price.
Bottom part:
Shipment date.
Shipment terms FOB or C&F.
Country of origin.
Terms of payment, at sight or 120 days.
Others special terms.
Master L/C checking procedure & important items should be included in Master L/C
A documentary Master L/C is an orderly payment security instrument offering high quality payment
security to a business transaction for both parties the seller and buyer. The seller will receive
payment for his goods if he meets all conditions prescribed by the letter of credit. Without M L/C
opening the order won’t be confirmed. So its carry more value than other documents in export and
import business. M L/C Check list items and those items must be included in this L/C.
Types of L/C.
Issue date.
Expiry date.
Issuing bank details.
Advising bank details.
Seller name and address.
Total amount.
Currency of payment.
Tolerance (2-5% plus or minus)
Port of loading.
Description of goods.
Shipping terms (FOB/ C&F)
List of documents required.
Master L/C confirmation procedure
M.L/C must be declared by UCP version
Check important items
Confirm M/L/C by E-mail
Buyer approval procedure of fabrics, color & accessories
Fabric and accessories approval from the buyer is very important. According to the buyer color wise
you have to outsourcing of the fabric. After collection of the fabric lap dip is done and show the
fabric on the swatch submission card for better understanding of the buyer. After getting buyer’s
confirmation about order it is important because to maintain the quality they expected it should be
fulfilled and as new buyer it should be well concerned.
Fabric Construction
Fabric GSM
Color Shade
Wash and light test
Accessories Quality Check
Label Barcode Check
Check Finishing Accessories
Give the approval
Fig: Buyer approval procedure
Procedure of receiving of price quotations for fabrics & accessories
Pricing is very important factors for any kind of business. After discussion with the supplier price is
fixed. For fixing the price some points are followed such as-
Low price.
Quality of the goods.
Sampling.
Price negotiation procedure with different suppliers
Arrange meeting with different suppliers
Collect price different suppliers
Select some price
Argument with selected suppliers
Win situation
Fixed Price
Order to supplier
Preparation of production files for production starting
Approval Sample
Order sheet
Measurement sheet
Assortment
Fabric quantity
Packing list
Carton measurement
Sending procedure of pre-production samples approved by buyers, production file & pattern
to in charge of factory
Collect approved sample, production file and approved pattern from buyer.
Merchandiser arrange meeting with production manager.
Give clear idea about approved sample, production file and approved pattern.
Than handover these items to PM.
Preparation & conducting of pre-production meeting in factory required for production
planning in factory Pre-production meeting in factory:
Pre-production meeting – once pre-production (PP) sample is approved (also called sealer sample)
and most of the trims are sourced, merchants or production planning department conduct pre-
production meeting with production team, quality team and sourcing team. All important comments,
procedures to be followed, dos and don’ts are discussed. Scheduling of PCD (planned cut date) and
shipment date is announced to all teams. Production plans, Material planning and line planning – to
start production on time and ship the order on time planning is must. Planning is needed for material
sourcing, production capacity, line planning. Scheduling of jobs and responsibility is defined at this
stage.
This meeting should be conducted directly after the merchandise manager approves the concept for
development. The purpose of the meeting is to review the preliminary product and package
specifications and to ensure that the supplier is aware of the companies‟ quality and product
development procedures. The meeting should be of a technical nature. Therefore, the supplier should
bring to the meeting the appropriate representation from their staff. Expect to discuss the
manufacturing process in detail and address any potential manufacturing concerns or limitations.
In regard to manufacturing the particular item being discussed. In this meeting, the supplier should
be provided an initial specification file with details of the garment that is to be manufactured. The
supplier should be requested within a short period of time to formally acknowledge their
understanding of the requirements. It is a good idea to obtain this in writing.
Merchandising activities on Product development
Product development is another important responsibility for RMG merchandisers. Before go to bulk
production various stage of sampling has to pass in order to develop a product for end user.
Sequence of Sampling
Counter sample/Style sample/Salesmen sample
Fitting sample/ Size set sample
Pre-Production.
Pre-Shipment Sample.
Shipping Sample.
Photo/ Advertisement/
Catalog Sample
Sequence of Sampling
Counter sample/Style sample/Salesmen sample
Fitting sample/ Size set sample
Pre-Production
Pre-Shipment Sample
Shipping Sample
Photo/ Advertisement/ Catalog Sample
Steps of Garment Sample Approval:
Step-1 Style sample
(Closest available fabrics and trims)
Step-2
Size Set sample (actual fabric and closest available trims)
Step-3
Pre- production sample (In Actual)
Step-4
Pre-Shipment sample (In Actual)
Fabrics Selection Approval
Fabrics (for hand feel & Approval) Test done from official Testing House
1st Bulk Fabrics in each Color Test report in each color
Swatch
Swatch is a presentation of all the materials is (Fabrics & Accessories) used for any specific
style/order. Usually small piece of fabrics and each piece of accessories are attached in board paper
in a systematical manner. Swatch is very important for production line to make the correct
construction of a garment and QC departments ensure it. Concerned merchandiser should
confirm/approve the swatch.
Style sample development
The main object to develop style sample is to approve the styling of a product that a designer
imagine first. This sample is usually made by available color but actual design, construction and
weight. But some time buyer ask sample to make by actual color
Size set sample development
The main object to develop size sample is to confirm the measurement, body fitting etc. This sample
is also made by available color but actual construction and weight.
Pre-production sample development
The main object to develop Pre production sample is to confirm the final product from buyer. After
receive pre-production sample we can start final/bulk production.
Pre-Shipment sample development
The main object to develop Production sample is to confirm ultimate buyer that what we produced
and ship to sell for end user.
Merchandising activities on production
Merchandising activities on production follow up
Production plan
After receive a purchase order from buyer merchandiser have to sit with production planner to make
a production plan. Production plan contain below things:
Planned date to start knitting/ weaving to make the required fabrics.
Planned date to start dyeing to color the fabrics.
Planned date to start cutting fabrics.
Planned date to start sewing the required garments.
Planned date to start packing the required garments.
Planned date to hand over finished goods to buyer nominated sea or air forwarder.
Cutting Section
Work flowchart of cutting section:
Cutting section is the most important section of Garments. Cutting sections perform the
following tasks.
Fabric Inspection.
Fabric Relaxation.
Different tests i.e. Shrinkage test, Twisting, Fastness test, Fabric dia, Shed consumption etc.
Marker Making.
Fabric Spreading.
Cutting.
Sorting and Bundling.
Cut Panel Checking.
Input to the sewing.
Working Flow of Cutting Section:
The Cutting section is running according to the following flow chart.
Finished fabric from dyeing & finishing
Fabric Inspection
Relaxation
Test of GSM, Diameter, shed, shrinkage, twisting, fastness etc.
Test cutting
Approval
Marker making
Fabric spreading
Cutting
Sorting (Sticker, Numbering)
Bundling
Cut panel checking
Input section
Send to sewing section
All these tasks can be accomplished by classifying them into following main processes.
Processes of cutting Section
Preparatory processes.
Marker Making.
Fabric Spreading.
Cutting.
Sorting and Bundling.
Cut Panel Checking.
Inputting.
After receiving the fabric from the dyeing and finishing section, there are some processes to prepare
the fabric for bulk production. All these processes combined can be called preparatory processes.
When the fabric is ready for bulk production, then marker is made to reduce the fabric wastage
during cutting. According to the marker plan, the fabric is being spreader on cutting table and the
marker is being replaced onto the fabric layer.
Then cutting process is performed. After cutting sorting and bundling is done. Then the cut fabrics
are taken to the cut panel check area for checking. After checking the fabric is sent to the input
section for inputting in sewing section.
Cutting Moments
Sewing Section
After receive the garments components from cutting section, all the garments parts are joined and
sewn as sequentially. Obviously all the components are sewn respects on buyer requirement.
Sewing section is the most important department of a garment manufacturing industry. Sewing
machines of different types are arranged as a vertical line to assemble the garments. Sequence of
types of sewing machine arrangement depends on sequence of assembling operations.
Sewing sequence/ layout of Denim pant manufacturing process:
Single Fly O/L
Double Fly O/L
Front Raise O/L
Coin Pocket attach with facing
Facing attach with Pocketing
Coin pocket attach position mark on facing
Pocketing select with front
Pocketing joint with pocket mouth
Front pocket mouth top stitch
Front pocket mouth opening tack & raw stitch mouth
Front pocket bag O/L
Front pocket bag corner safety tack
Single fly join with Front & Edge stitch
Zipper joins with single fly
J stitch makes position mark
Single fly excess cut
J stitch make
Double fly join with zipper
Double fly tack
Front rise join with double fly
Zipper close stitch
Front rise tack
Front rise top stitch
Double fly excess cut
Coin pocket mouth rolling
Front Part
Back pocket mouth rolling
Back pocket excess cut and select
Back yoke join by folder
Back pocket iron
Back pocket mouth iron
Coin pocket iron
Coin pocket mouth iron
Back pocket attach position & Side mark
Back pocket attach with back
Back pocket second stitch makes position mark
Back pocket second stitch makes
Back Part
Assembly
Front part and Back part select
Front part side & top waist mark
Inseam join
Inseam top stitch
Side seam join
Side cord Stitch make
Waist band two parts join
Waist band iron
Waist band join position mark and select
Waist band point mark
Waist band join
Label tack
Label attach with body
Sade label attach, waist band excess cut, waist band false tack
Waist band mouth excess cut, waist band mouth close
Waist band top stitch
Front Part Back Part
Waist band bottom top stitch
Loop make by folder
Loop attach position mark, Loop size cut & sew with body
Loop top & bottom tack
Hem make
False tack removes
Loop & body Bartack
Washing Section
Garments Washing:
It is a new technology by which outlook, size, comfort ability & fashion etc. Properties are
changed of a Garment are called Garment Washing. The technology was first developed
in 1988. Before this washing was done in Hong Kong, Singapore & some other country.
WASHING MACHINE
Objective of Garments Washing:
To Develop Softness in Garments.
To introduce Fading effect.
To create new fashion.
To satisfy the customer.
To remove dirty thing from the garments.
To remove starch or size material.
There is Different type of Garments Washing In our country.
Normal Wash.
Pigment Wash.
Bleach Wash.
Caustic Wash.
Acid Wash.
Enzyme wash.
Enzyme Wash with Stone.
Stone Wash.
Supper White Wash.
Wash and Over Dyeing.
Special effect on Garments can be obtained by the following process which is known as a
Dry Process.
Scraping
Tearing
Whickering
P.P spray.
Curing
Tagging
Grinding
Sand Blasting etc.
TYPES OF WET WASH PROCESS:
Normal wash/ garments wash/ rinse wash.
Pigment wash.
Caustic wash.
Silicon wash.
Stone wash.
Enzyme wash.
Stone Enzyme wash.
Acid wash.
Bleach wash.
Tinting wash
TYPES OF DRY WASH PROCESS:
Sand Blasting.
Hands scraping.
Over all wrinkles.
Permanent wrinkle.
Grinding &Destroy.
Broken & tagging.
P P Spray & P P Sponging, etc.
Characteristics of Denim Fabric:
It is for long wearing.
It is hard wearing.
It is very strong and durable.
It resists snags and tears
It creases easily.
Basic Denim Washing Principles:
Below is the brief introduction to common steps done & followed in denim garments washing in
Laundries across the world. Different kind & make of machines being used across the globe to hit
similar results.
Every small step in denim washing makes a big difference because indigo dye has very poor wet
& dry rubbing fastness. All parameters are critical to maintain for repetitive results. Eg Many
laundries across the Globe ignore the importance of pH M:L:R & R P M of machine.
Some important steps in the process of Denim Washing:
1. Pre-treatment ( Desizing, Rinsing, Scouring etc)
2. Enzyme or Stone wash
3. Clean up to adjust the desire effect
4. Bleaching
5. Tinting / Dyeing
Softening & Much more…..
This is very first & basic step but most important step of washing. Here the fate of denim garment is
decided that it’s going to appear good or bad. Good Pre-treatments avoid streaking, stiffness &
colour loss. This process removes impurities, starch & stains during handling of fabric.
This step is also called desizing (Removal of Size applied during denim fabric making in weft yarn).
All the woven fabric contains size on them due to reasons to strengthen the yarn for weaving. There
are many types of sizes available in the market but they can be divided in two major groups.
1. Water Soluble (CMC or PVA based sizes ) and
2. Dissolvable sizes in water (Starch based ). Starch based sizes are most commonly
used due to cheap prices & readily availability.
Methods of Removing Sizes from Denim Jeans……
· Washing with High Alkaline agents (i.e. Soda ash )
· Washing with High Acidic agents (i.e. Acetic acid)
· Washing with Oxidative chemicals (i.e. Hydrogen Peroxide)
· Enzymatic desizing with Alfa amylase... This is eco-friendly & convenient.
Enzyme & Stone Washing Process of Denim Garments:
There are four kind of Enzymes available in market for Denim Laundry business..
Amylase …. Desizing
Cellulose …. For Salt & pepper effect , contrast
Laccase…. … bio bleaching
Catalase …… Peroxide killer
Enzyme is kind of protein that is obtained from fermentations method from naturally existing
bacteria & fungi. The structure of Enzyme is a biological polymer and it can be found in every
cell. Generally called as Cellulose & it works on cotton( Cellulosic fiber ) only. Enzyme are living
organisms which will attack a specific molecular group.
There are mainly three kind of Cellulose being used for Denim washing, Neutral, Acid and Bio
polishing Enzyme. Enzyme are very sensitive with parameters in washing cycle i.e., pH,
Temperature & time. If any of these parameters are not up to the mark, result will not be accurate.
The reaction of enzyme can be easily controlled, its biodegradable products, so they eco-friendly.
Bio Polishing Cellulose are being used to have protruded fiber removal from denim & oven fabric.
This is also widely known as Anti pilling enzyme.
Any Cellulose used in process must be cleaned/killed after the process completion by simply
disturbing the parameters i.e. by raising high temp. Or raising pH to alkaline where no Cellulose
withstands.
Cellulose are available in 3 categories
Neutral Acidic & Hybrid enzymes.
Neutral enzyme gives better salt & pepper effect with very less back staining & it’s generally
come sin powder form & also retains better strength of fabric than acidic Cellulose. Whereas
acidic cellulose give faster results but with too heavy back staining & cuts down the indigo color,
also affects the strength of fabrics.
Now a days laundry people needs faster results in less time & money hence chemical suppliers
combined Neutral & acid cellulose in such way that it works faster & with better results than acid
cellulose with cost effectiveness & known as Hybrid enzyme.
Laccase is bio bleaching agent & alternative for conventional bleaching agents. This impart greyer
cast to blue denim & enhances salt & pepper effect. But due to high cost & low self-life, laundries
do not prefer it.
Clean Up:
After finishing Enzyme wash it is must to add clean-up process for better results & garments
appearance & that can be done in various ways & methods. As clean-up is a must process to be
carried out after every chemicals steps done for any garments which allows next process to happen
smoothly. All processes mentioned below kill/ deactivate the active enzymes process which is
necessary in order to protect/retain garment strength……
a) Hydrogen peroxide in alkaline pH clean up enhances the brightness & rich blue tone of
indigo.
b) By using non-ionic detergents in medium to high temperature
c) By doing two good hot water rinses etc…
Tinting & Dyeing
Tinting is a process where very less amount of tint is involved & mainly direct dye is being used to
do this process. This is being done to change hue/cast/tone of indigo. As soon as quantity of tint
color increases & it cover up indigo, reaches the level of dyeing.
Tinting being used to give garments a used / vintage & muddy look. This process takes from 5
minutes to 15 minutes time for better results followed by dye fixing & clean-up of superficial dye.
Dyeing is being done on very light shade of Indigo, Ecru/ grey denim & Ready for dyeing denim.
There are various Types of Dye. The comparison of these dyes is given in the chart here below:
1. Direct Dyes
2. Reactive Dyes
3. Pigment Dyes
4. Sulpher Dyes
Direct Dyes Reactive Dyes Pigment Dyes Sulphur Dyes
Economical Costly Cost Efficient Economical
Wide range of shades Wide range of shades Styling ( limited to
dull shades) Shades are dull
Short Cycles Long Cycle Short to long Cycle Short to long Cycle,
depends upon shade
Ease of application Water Consumption
High
Machine
contamination, but
hard to obtain
consistency, harsh
hand feel
Sulphur Odour &
harsh hand feel
Smooth Appearance Smooth Appearance Smooth Appearance Smooth Appearance
Denim Are Dye By Indigo Dye: Indigo Background
Indigo, or indigo tin, is a dyestuff originally extracted from the varieties of the indigo and woad
plants. Indigo was known throughout the ancient world for its ability to color fabrics a deep blue.
Egyptian artifacts suggest that indigo was employed as early as 1600 B.C. and it has been found in
Africa, India, Indonesia, and China.
The dye imparts a brilliant blue hue to fabric. In the dying process, cotton and linen threads are
usually soaked and dried 15-20 times. By comparison, silk threads must be died over 40 times.
After dying, the yarn may be sun dried to deepen the color. Indigo is unique in its ability to impart
surface color while only partially penetrating fibers. When yarn died with indigo is untwisted, it
can be seen that the inner layers remain uncolored. The dye also fades to give a characteristic wom
look and for this reason it is commonly used to color denim. Originally extracted from plants,
today indigo is synthetically produced on an industrial scale. It is most commonly sold as either a
100% powder or as a 20% solution
Denim Fabric Process:-
Desizing → Enzyme → Caustic → bleaching → Hypo → Softening → Hydro extractor→ Dryer
m/c → Garments Delivery.
Discussion about Enzyme Wash:
Enzyme
What Is Enzyme?
Enzymes are proteins Bio catalyze.Its has huge life cell .The cell is the basic structural and
functional unit of all known living organisms. It is the smallest unit of life that is classified as a
living thing, and is often called the building block of life.Some organisms, such as most bacteria,
are unicellular (consist of a single cell). Other organisms, such as humans, are multicellular.
(Humans have an estimated 100 trillion or 1014 cells; a typical cell size is 10 µm; a typical cell
mass is 1 nanogram.) The largest known cell is an unfertilized ostrich egg cell. In enzymatic
reactions, the molecules at the beginning of the process are called substrates, and the enzyme
converts them into different molecules, called the products. Almost all processes in a biological
cell need enzymes to occur at significant rates. Since enzymes are selective for their substrates and
speed up only a few reactions from among many possibilities, the set of enzymes made in a cell
determines which metabolic pathways occur in that cell.
As all catalysts, enzymes do not alter the position of the chemical equilibrium of the reaction.
Usually, in the presence of an enzyme, the reaction runs in the same direction as it would without
the enzyme, just more quickly. However, in the absence of the enzyme, other possible
uncatalyzed, ―spontaneous‖ reactions might lead to different products, because in those conditions
this different product is formed faster.
Furthermore, enzymes can couple two or more reactions, so that a thermodynamically favourable
reaction can be used to ―drive‖ a thermodynamically unfavourable one. For example, the
hydrolysis of ATP is often used to drive other chemical reactions.
Enzymes catalyse the forward and backward reactions equally. They do not alter the equilibrium
itself, but only the speed at which it is reached. For example, carbonic anhydrase catalyses its
reaction in either direction depending on the concentration of its reactants.
(In tissues; high CO2 concentration)
(In lungs; low CO2 concentration)
Nevertheless, if the equilibrium is greatly displaced in one direction, that is, in a very exergonic
reaction, the reaction is effectively irreversible. Under these conditions the enzyme will, in fact,
only catalyze the reaction in the thermodynamically allowed direction.
Enzyme Wash Finishes for Denim:
Enzyme wash is more popular in present world textile industries. Enzymes are bio chemical
substances that are have as catalysts toward specific reactions. What makes very interesting the
enzymes under a chemicals point of view is their high specificity or in other words, their ability to
attack selectively on to a substrate.
Objective:
1. To remove the size material from the garments.
2. To remove the starch present on the garments.
3. For soft feeling to wear the garments.
4. To increase the colour fastness and rubbing fastness.
5. Especially develop the ―Bio-polishing’’ affect cotton/Denim.
6. Enzyme improves the anti-pilling properties.
7. Enzyme attacks more the surface of the fabrics and gives a very smooth surface.
Types of Enzyme:
Mainly two types of Enzyme:
1. Acid Enzyme
2. Neutral Enzyme
a. Powder b. Liquid form.
After enzyme washing we get these change:
Color
GSM decrease
Softener
Strength
Decision:
Enzyme is suitable for environment .Enzyme is not hazardous but bleach is hazardous process. So
enzyme is popular in washing sectors.
Denim for Bleach washing
What Is Bleach?
Bleach is a chemical that removes colors or whitens, often via oxidation. Common chemical
bleaches include household chlorine bleach, a solution of approximately 3–6% sodium
hypochlorite (NaClO), and oxygen bleach, which contains hydrogen peroxide or a peroxide-
releasing compound such as sodium perborate, sodium percarbonate, sodium persulfate,
tetrasodium pyrophosphate, or urea peroxide together with catalysts and activators, e.g.
tetraacetylethylenediamine and/or sodium nonanoyloxybenzenesulfonate. To bleach something is
to apply bleach, sometimes as a preliminary step in the process of dyeing. Bleaching powder is
calcium hypochlorite.
Many bleaches have strong bactericidal properties, and are used for disinfecting and sterilizing.
Most bleaches are hazardous if ingested or inhaled, and should be used with care.
Chemical Interactions:
Hypochlorite and chlorine are in equilibrium in water; the position of the equilibrium is pH
dependent and low pH (acidic) favors chlorine
Cl2 + H2O H+ + Cl- + HClO
Chlorine is a respiratory irritant that attacks mucous membranes and burns the skin. As little as
3.53 ppm can be detected as an odor, and 1000 ppm is likely to be fatal after a few deep breaths.
Exposure to chlorine has been limited to 0.5 ppm (8-hour time-weighted average—38 hour week)
by OSHA in the U.S
Sodium hypochlorite and ammonia react to form a number of products, depending on the
temperature, concentration, and how they are mixed. The main reaction is chlorination of
ammonia, first giving chloramine (NH2Cl), then dichloramine (NHCl2) and finally nitrogen
trichloride (NCl3). These materials are very irritating to eyes and lungs and are toxic above certain
concentrations. Lastly there is bleach containing sodium perchlorate.
NH3 + NaOCl –> NaOH + NH2Cl
NH2Cl + NaOCl –> NaOH + NHCl2
NHCl2 + NaOCl –> NaOH + NCl3
Additional reactions produce hydrazine, in a variation of the Olin Raschig process.
NH3 + NH2Cl + NaOH –> N2H4 + NaCl + H2O
The hydrazine generated can further react with the monochloramine in an exothermic reaction.
2 NH2Cl + N2H4 –> 2 NH4Cl + N2
Industrial bleaching agents can also be sources of concern. For example, the use of elemental
chlorine in the bleaching of wood pulp produces organochlorines, persistent organic pollutants,
including dioxins. According to an industry group, the use of chlorine dioxide in these processes
has reduced the dioxin generation to under detectable levels. However, respiratory risk from
chlorine and highly toxic chlorinated by products still exists.
Chemistry:
The process of bleaching can be summarized in the following set of chemical reactions:
Cl2(aq) + H2O(l) H+(aq) + Cl-(aq) + HClO(aq)
The H+ ion of the hypochlorous acid then dissolves into solution, and so the final result is
effectively:
Cl2(aq) + H2O(l) 2H+(aq) + Cl-(aq) + ClO-(aq)
Hypochlorite tends to decompose into chloride and a highly reactive form of oxygen:
ClO- Cl- + O2
This oxygen then reacts with organic substances to produce bleaching or antiseptic effects.
MECHANISM OF BLEACH ACTION:
Colour in most dyes and pigments is produced by molecules, such as beta carotene, which contain
chromophores. Chemical bleaches work in one of two ways
An oxidizing bleach works by breaking the chemical bonds that make up the chromophore.
This changes the molecule into a different substance that either does not contain a chromophore, or
contains a chromophore that does not absorb visible light.
A reducing bleach works by converting double bonds in the chromophore into single bonds. This
eliminates the ability of the chromophore to absorb visible light.
Bleaching Washing
This way is considered as a preparatory process of mercerizing, dyeing, or printing. Therefore
proper bleaching should be carried out other wish the subsequent process would be fault.
Objective:
To remove the size material from the garments.
To remove the starch present on the garments.
For soft feeling to wear the garments.
To increase the color fastness and rubbing fastness.
Especially develop the ―Bio-polishing’’ affect cotton/Denim.
Enzyme improves the anti-pilling properties.
Enzyme attacks more the surface of the fabrics and gives a very smooth surface.
Different Type of Bleaching:
1. Oxidizing Agent:
2. Ozone (O3)
3. Hydogen Peroxide (H2o2)
4. Sodium Hypochloride (Naocl)
5. Sodium Chlorite (Naclo2)
6. Potassium Dichromate (K2cr2o7)
7. Reducing Agent
8. Zinc Dust (Zno)
9. Sodium Hypo-Sulphite (Na2s2o2)
10. Hydrogen Sulphide (H2s)
Sodium hypochlorite (NaOCl): sodium hypochlorite is the salt of hypochlorous acid (HOCl) does
not exist in the solid from but an aqueous solution of the same can be prepared. The stability of the
solution of depend on:
Temperature
The ph
Storage condition
Concentration
Presence of impurities
Reaction shown:
NaOCl +NaClO2 NaCl+NaClO2
This reaction having activation energy of 20 kcal/mole. It is a very fast reaction.
Degradation of Cotton By Bleach:
When the cotton cellulose is treated with an aqueous solution of solution hypochlorite the
decomposition of the hypochlorite takes place by different reactions:
3NaOCl 2NaCl+NaClO3
2NaOCl 2NaCl+O2
NaOCl+ cellulose NaCl + oxycellulose
Oxidation Potential of The Bleaching Agent:
Oxidizing agents may be arranged in the increasing order of their oxidizing ability as following:
NaClO3>NaClO2>H2O2>K2Cr2O7>KMno4<NaOCl
Activation of Sodium Chloride:
It is well established that aqueous solution under alkaline condition are extremely stable,
especially when stored away from light. As a result , alkaline solutions of sodium chlorite are
rarely used f or beaching purposes .The solutions are activated by lowering the pH ,when their
bleaching ability (oxidising power) is increased tremendously .These solution are decomposed by
various reaction ,such as chlorine dioxide evolution ,chlorate formation and oxygen evolution and
their relative extents depends on the pH .
Chemistry:
The process of bleaching can be summarized in the following set of chemical reactions:
Cl2(aq) + H2O(l) H+(aq) + Cl-(aq) + HClO(aq)
The H+ ion of the hypochlorous acid then dissolves into solution, and so the final result is
effectively:
Cl2(aq) + H2O(l) 2H+(aq) + Cl-(aq) + ClO-(aq)
Mechanism of Bleach Action:
Color in most dyes and pigments are produced by molecules, such as beta carotene, which contain
chromophores. Chemical bleaches work in one of two ways:
Oxidizing bleach works by breaking the chemical bonds that make up the chromophore. This
changes the molecule into a different substance that either does not contain a chromophore, or
contains a chromophore that does not absorb visible light.
Reducing bleach works by converting double bonds in the chromophore into single bonds. This
eliminates the ability of the chromosphere to absorb visible light.
After Bleach Washing We Get This Change:
Color
GSM decrease
Softener
Strength
Decision:
Bleaching is a hazard so it is harmful for environment & workers. So enzyme is popular then
bleach .It’s a hazardous process so it’s not suitable for environment.
Softening Process
Softening process of Denim is very critical. As denim is very heavy in compare with other fabrics
hence its needs softening. During this process there is a big problem -the discoloration of denim i.e
change in shade or loss of whiteness, giving a yellow tint is commonly known as yellowing. By
using normal softener will lead to ozone problem. Indigo dyed fabric are even more prone to
yellowing.
As it’s a widespread problem & there in no single reason for its cause. Instead a number of
condition can singly or in combination lead to the problem. Yellowing in not specific to certain
fibers, finishes or washing processes. It is not specific to chemicals or chemical treatment but
certainly some of the factors among these can lead to the yellowing. As cotton & all organic
polymers develop yellowing in time.
Light, acids, impurities, detergents & chemical contribute to yellowing problems.
Temperature of drying & curing can impart yellowing due to scorching of the cotton. Therefore
good control must be used to minimize this type of damage.
Hence its advisable to use Antiozonate softener which prolong ozone reaction of Indigo & keep
garment in good condition.
Minimization of Yellowing Risk:
It’s Impossible to eliminate yellowing but it is possible to prolong & reduce the conditions which
causes classical yellowing:
Ensure bleaching neutralization & rinsing is proper
Minimize back staining
Avoid use of chemicals which cause yellowing
Avoid leaving garment in open air for longer time
Control drying & curing temperatures
Using right Antiozonate softener with right pH
Production Sequence of Washing
Garments receive from sewing
↓
Scraping
↓
Tearing
↓
Whickering
↓
P.P spray
↓
Curing/Tearing
↓
Washing
↓
Drying Hot + cold
↓
Checking
↓
Disposes
Figure: Production Sequence of Washing
Machine Summary of Washing Section:
Ref
No. Type Of Machine Machine Brand
1 Washing Machine SMARTEX 225
2 Washing Machine SMARTEX 340
3 Washing Machine AVANTEC 340
4 Washing Machine NGAI SHING 2250
5 Washing Machine Sample RAMSONS
6 Washing Machine Sample NGAI SHING 2211
7 Washing Machine Sample SUNLEGUE-SLW-100(S)
8 Washing Machine Sample SUNLEGUE-SLW-250(S)
9 Hydro Extractor NGAI SHING
10 Hydro Extractor Sample RAMSON
11 Drying Machine NGAI SHING 2330
12 Drying Machine TRANSRERON
13 Drying Machine AVANREC
14 Drying Machine Sample RAMSON
15 Ironing Table RAMSON
16 Hot Pressing Machine RAMSON
17 Trouser Finisher MACPI
18 Trouser Finisher NGAI SHING
19 Jacket Dummy VE-CO
20 Scraping Motor
21 Teg Machine SPA 80
22 Compressor INGARSOL RAND
23 Compressor ATLAS COPCO
24 Sand Blasting MEC SHOT BLASTING+TM-JM.
25 Spray Gun -
26 Spray Baloons -
27 Grinding Machine -
28 Crock Master Testing -
29 Light Box VERIVIDE
30 Light Box MECHBATH
31 Lab Dip Machine ROACHRS
32 Oven AVANTEC
33 Oven RAMSON SUPER CARE
34 Photo Spectrometer DATA COLOR
35 Tag Machine DENISION
36 Steam Iron
37 Weighting Indicator. A&D
38 Vertical Dummy Concorde
39 Generator (320KW) Vibro Power
40 Washing Machine Sample SMARTEX 20KG
41 Scrunch MC GFK
42 TECA GFK
43 Popping Machine GFK
44 FMG(Fabric Grinding M/C) GFK
SOME WASHING CHEMICAL LIST
De-sizing Agent : De-sizing Hts, D-Peast
Anti-Back Stain Agent : Antistain – Lp-30
Fastness Improvers for Dyeing : Albafix®
Leveling Agents for Dyeing : Albatex®
Fastness Improvers for Dyeing : Albafix®
Enzyme : G Enzyme S89, G Enzyme – Sl, Innozyme Npe S89
Salt : G/Salt.
Alkali : Naso4
Ph Control : Using Buffer & Acid
Bleaching Agent : Sodium Hypochlorite Naocl;
15% Cl2 Available Calcium Hypochlorite.
Neutralizing Agent : Hydro Peroxide, Bisulphate or Thiosulphate.
Softener : Innosoft 1070
Hand sand Destroy
Sample Development
Pumice stone:
Those are silica-rich, viscose, high temperature melt products of explosive.
Volcanic eruption during ascent & expulsion of earth. These are light weight highly porous, rocky
substance which will float on water.
Major Pumice Stones Supplies Countries Are Usa, Turkey, Italy, Island, Newzeland, Japan,
Indonesia And Philippine.
This is one of the important components in the production of stone washed apparels. It is used
softer hands. Since the degree of abrasion may vary in different parts of garments, such as
trouser-, button slays and seaming parts, a number of natural patterns can be formed.
The degree of wash down or used look effect is depends on stone size, stone ratio, liquor ratio,
duration of treatment, garments load and garments fabric gsm. Stone size varies from 1cm
diameter to 7 cm.
In here two types of stone are mostly used:
1. Turkey : white color, light weight. More use for twill and denim;
2. Indonesia : Red color, weight. More use for denim, this type of stone size is big, that’s
reason there is a possibility to thread brakes. To prevent it needs to make it smaller size.
Enzyme
In here two types of enzyme are used:
1. Acid condition enzyme;
2. Neutral condition enzyme.
3. Acid condition enzyme: this is low cost, but risk of degraded.
4. Neutral condition enzyme: this is very costly, but mostly useful and working result is good.
List of Some Dyes with price (approximately)
Name Price
1. Cibacron Yellow
Fn2r Tk.1600/Kg
2. Novacron Blue
Ce Tk.1600/Kg
3. Novacron Deep Red S-
B Tk.2200/Kg
4. Cibacron Red
Fnr Tk.2000/Kg
5. Novacron Yellow
Ce Tk.1600/Kg
6. Novacron Orange W-
3r Tk.1600/Kg
7. Navy-W-
B Tk.1300/Kg
8. N. Navy-W-
B Tk.1700/Kg
9. Novacron Super Black
G Tk.1000/Kg
10. Reactive Deep Black-
N Tk.600/Kg
11. Direct Grey-
Cgl Tk.1200/Kg
12. Novacron Dark Blue W-
R Tk.2700/Kg
13. Novacron Red
Ce Tk.2000/Kg
14. Optisal Red -
7b Tk.1700/Kg
15. R. Blue-
3rl Tk.2500/Kg
16. Solar Turquoise Blue Fbl-
400% Tk.850/Kg
17. Ciba Turquoise-
Hgn Tk.1000/Kg
Denim Mock-up Wash Perform by me During
My Internship Period
Figure: Super light, Mid, Dark and Acid wash with Non-wash Denim Fabric
(100% Cotton)
1. Hand Sand
2. Laser Whisker
3. Wash
a. De-size
i. Caustic : 300 gm (60°C)
ii. Biode : 50 gm (20°C)
b. Enzyme
i. 3000L : 150 gm (45°C)
ii. Lp-30 : 50 gm (25°C)
c. Bleach
i. Bleaching : 55°C – 15 minutes (check three times/ 5 minutes)
d. Neutralization
i. Hydrogen Peroxide: 400 gm (55°C) – 5 minutes
4. Grinding
5. Destroy
6. PP Sprey
i. Potassium Permanganate : 5 gm
ii. Phosphoric Acid : 1 gm
iii. Water : 3 Liter
7. Neutralization
i. Lava Cone Max
8. Finishing
20 Minutes
20 Minutes
Garments Type: Denim Long Pant (Mock-up)
Type of wash: Super Light Wash
Quantity: 1 Pcs
Recipe + Process
1. Hand Sand
2. Pattern Whisker
3. Wash
i. Desize
i. Lp-30: 50 gm
ii. Biode: 100 gm
ii. Enzyme
i. 3000L: 150 gm
ii. Lp- 30: 50 gm
iii. Bleach
i. Bleaching - (60°C)
iv. Neutralization
i. Hydrogen Peroxide: 400 gm (50°C) – 5 minutes
v. PP spray
i. Potassium Permanganate: 5 gm
ii. Phosphoric Acid: 1 gm
iii. Water: 3 Liter
vi. Neutralization
i. Meta-bi-sulphite
vii. Trint
i. Yellow K2R: 0.50 gm
ii. Orange K3R: 0.150 gm
4. Finishing
Garments Type: Denim Long Pant (Mock-up)
Type of wash: Medium wash
Quantity: 1 Pcs
20 Minutes
(45°C) - 20 Minutes
(50°C)
Recipe + Process
1. Hand Sand
2. Pattern Whisker
3. Wash
a. Desize
i. Caustic : 300 gm (60°C)
ii. Biode : 50 gm (15°C)
b. Enzyme
i. 3000L: 100 gm
ii. Lp- 30: 50 gm
4. PP Spray
i. Potassium Permanganate: 5 gm
ii. Phosphoric Acid: 1 gm
iii. Water: 3 Liter
5. Neutralization
i. Meta-bi-sulphite
6. Wrinkle
i. Resional FM: 1 kg
ii. Consendol: 200 gm
iii. Water: 2 Liter
7. Finishing
Garments Type: Denim Long Pant (Mock-up)
Type of wash: Dark wash
Quantity: 1 Pcs
15 Min
(45°C)- 10 Min
Recipe + Process
1. Desize
a. Lp- 30: 50 gm
b. Biode: 100 gm
2. Enzyme
a. 3000L: 150 gm
b. Lp- 30: 50 gm
3. Acid Wash
a. Potassium Permanganate: 200 gm
b. Phosphoric Acid: 10 gm
c. Water: 20 Liter
4. Neutralization
a. Meta-bi-sulphite
5. Finishing
Garments Type: Denim Long Pant (Mock-up)
Type of wash: Acid wash
Quantity: 1 Pcs
(50°C)- 20 Min
(45°C)- 20 Min
Recipe + Process
Denim Fabric (Non-wash)
Figure: Non-wash Denim Fabric
Pocketing Fabric (TC) used in Production
Figure: Pocketing Fabric
Personal assessment about Denim Wash
Finally, in denim washing our country has a bright future due to wide spread market of denim
garments. We need thorough knowledge on denim treatment process and also on the fashion going
around the world. And this project will be a guideline for them who are interested in the sector.
Pioneer in the field of hard washing. And we believe that this project will be a guideline for the
washing plants in understanding and doing various treatments.
Finishing Section
In the real sense, finishing works start at the pattern to sewing stage. Good patterns, exact marker
preparation, precise cutting, bundling and careful sewing reduce undesired finishing touches. As
Zyta’s operators are self-controllers about these things and quality controllers are so vigilant and
cautious, Zyta Apparels Limited needs less repairing work in this stage. They have a hierarchical
system for Post Manufacturing Finishing and Quality Control. They have 80 QC and finishing
Stations including Automated Finishing operations and Ironing, Creasing and Folding are achieved
from Specialized Machines. Monthly Finishing Capacity is 3 to 3.5 lac pcs.
Instead it enjoys having ample time to do normal finishing works like counting garments which
come from the washing unit, checking washing and finishing effects, thread cutting and sucking,
gumming up any left thread or dust, attaching buttons and rivets, ironing, checking the safety of
products, applying correct labels at right places, shade checking, folding, packing, cartons, sorting
and shipping marks. They never forget the importance of finishing touches- even when they make a
very precise garment at sewing and washing stages. The garments may be of no use or cause
confusion or become un-saleable because of mistakes or inattentive works like placing a wrong price
code, shade checking, and mistakes in assortments or in destination marks.
And for all those finishing works, modern technologies with equipment, experiences and expertise
from local and abroad are highly considered here and the procedures were designed accordingly.
Their well-managed finished department is trained up in processes, traceability and precision of
garments.
Finishing Section Work Flow-chart
GMT comes from washing section
Input to finishing
Loop Cutting
Shade Checking
Size Checking
Extra Yarn Cutting
Front Pocket inside Cleaning
Reverse side Iron
Inside Check
Topside Check
Button & Rivet Attach
Button Hole Extra Yarn Remove
Dust Remove by Sucker M/C
Iron or Pressing
Get-up checking
Measurement
Trimming Attach
Trimming Attach Checking
Again Shade Checking
Spot Checking
Re-getup
GMT Check by Metal Detector
Send to Packing Section
Folding
Packing
Some images during finishing works:
Figure: Carton Ready for Shipment
Merchandising activities on goods delivery to buyers destination
Booking to forwarder After making final inspection merchandiser received packing list from packing
section which contain the list of carton, how many pieces garments in the carton, weight of the
carton, number of pieces of garment to be shipped etc. Refer to this information merchandiser make
booking to sea or air forwarder.
Export Documentation
The documents which to be submitted by a C&F agent for export: An exporter should have to submit
the following documents to the customs authority of a station:
1. Shipping bill of entry.
2. Export L/C.
3. Packing List.
4. Commercial Invoice.
5. UD/UP.
6. VBF-9A. From to be supplied by the C&F agent.
7. Export Permission form (EXP).
Bill of Landing (B/L)
It is document issued by an eerier (railroad, steamship, or trucking Company) which serves as a
receipt for the goods to be delivered to a designed person or to his order.
B/L describes the conditions under which the goods are accepted by the career and details
The quantity of the goods.
Name of vessel
Identified marks and numbers
Destination
Invoice:
Below point are including in the invoice:
Name and address of the buyers and the seller.
The Date and term of the sale.
A description of the goods,
The price of the goods and
The mode of transportation.
Payment release after prepared invoice, bill of landing and other required documentation we send it
to buyer’s nominated bank for payment release.
This is all about the job of Merchandisers where I have worked out for nine months. I have worked
with their team. So, here a brief introduction is described with the management body of Zyta
Apparels Limited related with it.
Internal Challenges
From the sample part or the development part, the problem Harriet has to face is the lace
problem. The matching of the lace was almost going impossible as buyer‟s expectation
because the lace is a fancy item and due to its shrinking it was needed to be sourced more and
more which was expensive and due to unavailability of it, the sample was hung for further
procedure.
Washing requirements was also a bit problem that Zyta needed to overcome that it wanted the
ACRU look which is the pure fade white type of color garment becomes after bleach wash.
This was hard to achieve because of trims color as in bulk production garments are washed in
heavy machine mixing huge amount of garments. So, when all the garments mix together
sometimes color split so, keeping the fresh look is a challenge. So, supplier needs to request
buyer to take the garment as closest as possible.
The fabric of Harriet is tencel which is an imported fabric and for this it takes generally 45
days for development to production. Generally it takes 25 days. They have 14 days to
shipment but the fabric needs more than this to be ready. So, this is a huge tension for
supplier to maintain the quality and workmanship with this constrained time for shipment.
Communication gap between the management stuffs can stretch the process as for their bit
ignorance an approval could have been sent for several times and organization can face a big
loss.
External Challenges
External problems include the monitory policy and the exchange rate of foreign transaction.
Zyta needs to import many items from abroad due to the unavailability of their production
capacity. So, the cost sometimes gets higher because locally sourced products cannot meet
the quality. In that case, if the exchange rate increases it has to face slight money constraint.
In case of RMG buyers China, Hong Kong, Taiwan is the competitor suppliers of
Bangladesh. So, buyers can choose anyone if they do not get in competitive price. This is also
depended on the relationship with the local office of buyers as they are the media of
communicating with suppliers. So, maintaining a good relationship is important for suppliers.
Price margin is fixed from buyer. So, supplier should have a bull’s eye forecast to maintain
the price margin given by buyer. If they cannot go with it then, the order can be cancelled.
Demand of buyer sometimes go beyond the possible capacities and can be changed at the
very last moment of time which is a big risk for supplier that at the last moment production
can be hampered as well as the assembly line.
Unrest of country’s political and business condition is a reason of losing the confidence of
buyer to continue the business with Bangladeshi supplier.
Recommendation
Zyta Apparels Ltd. is the largest woven factory in Bangladesh. It has outstanding reputation in the
domestic and global market for excellence. It is a woven factory where they have all the sections of
woven garments production. So, this is huge in case of production and maintenance.
However, this huge organization is not facing profit due to many of reasons what I have observed
from the internship period-
Supply chain or procurement department is not very strong in this company which causes that
the merchandisers procure all the raw materials of garments that’s why they feel more
pressure to complete shipment and sometime also over the shipment date then company
should pay the extra money for air shipment. So when supply chain department procure all
the raw materials then merchandiser can easily shipment the goods within lead time.
Planning department of operation should be strong and the time management should be
followed. Here, productivity is low due to less command of the authority towards the
production. It should be increased for the higher productivity.
Quality assurance system should be modernized because quality is the top priority of all
international buyers.
Working environment should be increased.
Pay scale is very poor which is needed to be increased because company will lose potential
employees due to their policy.
Distribution of power should be well managed and transparency among the workers and the
management should be followed.
The organization is one of the biggest organizations in Bangladesh and contributing the
highest amount of GDP in the economy but if it follows these areas then it will be among the
greatest in the region.
Conclusion
In conclusion I can say that this internship report is really essential for every student of business
studies to get idea about textile industry. By completing this report I have got overall idea of RMG
sector and these may be helpful to know about the technical and management knowledge of
garments industry also these sector related organizations. This is a huge sector and yet to discover
the whole. I want to thank my department Head for giving me great opportunity of learning. This
Internship program will help me in the further challenges of life. I try my best to make this project
enriched with lots of apparel related documents. Zyta Apparels Limited is really a good experience
for me because every person of there so much helpful and give me the proper methods of practical
learning. So, at last, there is a hope of eradicating all the obstacles and become the leader of garment
industries in near future.
References:
Zyta Apparels Limited Records
Merchandising Department of Zyta Apparels Limited.
Store Department of Zyta Apparels Limited.
Cutting Department of Zyta Apparels Limited.
Sewing Department of Zyta Apparels Limited.
Washing Department of Zyta Apparels Limited.
Finishing Department of Zyta Apparels Limited.
