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My internship employer was Northern Group, a rising and promising business organization of Bangladesh. My practical supervisor was Mr. M. Saif Uddin present General Manager(Marketing & Planning) of Fashion Asia Ltd., a sister concern company of Northern Group.My internship took place at Fashion Asia Ltd., from 16-04-09 to 16-05-09. The report will give a good impression of how I spent and learned during my internship program at Fashion Asia Limited. I have frequently visited all of the departments of Fashion Asia Ltd.I observed there how every department working to achieve its organizational goal. I have collected information on the basis of a survey questionnaire provided by our faculty supervisor at BIFT. As a MBA student of Apparel Merchandising, I have emphasized my study on apparel merchandising in the apparel manufacturing business process. Merchandiser is the pivotal person who actually merchandises the product for seller to the buyer, starting from order process to profit realization. The job responsibility is very high and needs versatile knowledge. Garment merchandisers these days need to have not only solid product knowledge but also soft skills like project management, time management and negotiation to facilitate their work. Operational efficiency of the merchandising team therefore becomes a key factor in the success of an industry player in the apparel manufacturing business. A major objective of this paper is to analyze the competitive advantages and disadvantages of Fashion Asia Ltd.According to my analysis, I tried to find out substantial room for improvement to enhance its competitive advantages and the recommendations has been given accordingly. Time has become the most important factor of competitiveness. Merchandiser has to assign subordinates to help him in the order execution, and direct the procedures. To record preferences for all the planned activities, merchandiser can use different tools and techniques. The Merchandiser should find out exact reasons for time consumption. It is necessary to keep record of time value and keeping it safe, as it is going to be shared with concerned parties/buyers. It is certain that merchandising jobs need huge time planning. The garment industry has always been highly competitive, and in today’s globalize free market, the competition has become much fiercer. Today’s buyers have increasingly high expectations that their demands and preferences will be met - they are offered a nearly endless variety of apparel options. Customer are product savvy, price savvy, and information savvy and they have many choices to have their demands fulfilled. For an apparel manufacturing company to be competitive in today’s global market, providing the customer a product of the desired quality and price at the right time is essential. 41
2. BACKGROUND OF HOST ORGANIZATION 2.1 ORGANIZATIONAL PROFILE
◘ Name of the Organization ◘ Website ◘ Vision Statement
: : :
Northern Group www.northerngroup.com.bd “We Want To Be the Most Preferred
Name To Our Customers, Employees, Suppliers And society.”
◘ Mission Statement
◘ We will always strive for Best Quality. ◘ We give highest priority to our commitment. ◘ We will turn Human Resources into Best Asset. ◘ We work for the Society and Environment. ◘ Everywhere we increase our efficiency by 10% every year
Regency Place, House -9, Block-K Shoreward Avenue, Baridhara. Dhaka-1212, Bangladesh. Telephone: 880-2-9882516, 9882517, Fax: 880-2-9882610 Email: email@example.com
◘ Business Description
Northern Group, Bangladesh. Northern group is a group of companies; consist of Knitting units, Dyeing & Fabric Finishing units and several garment manufacturing units. These companies are 100% export oriented, exporting the knit apparels all over the world, especially in the Europe market. The group is enlisted with BGMEA, BTMA & EPB. 2611persons. Private Limited Company ……………………………. 41
◘ Employees ◘ Ownership Type ◘ Annual Turnover
: : :
◘ Group Companies
● Northern Corporation Limited ● Tosrifa Industries Limited ● Fashion Asia Limited ● Printers & Printers Limited ● Northern Knit Limited ● Northern Fashion Limited ● Northern Seed Limited ●Garments Industry Management Academy (GIMA) : Northern Group believes that our human resources can be the major assets of the country and society. Northern Group has been contributing the society by many social activities focusing on technical institutions especially:
◘Al-Haj Shafiuddin Ahmed Technical College ◘Garments Industry Management Academy.
◘ Social Responsibilities
◘ Environmental Safety Issue
Northern Group is very conscious about environmental pollution. Therefore they have built Wastage Water treatment Plant and have been using since long time on their own cost. Since Northern Group was always looking forward for the development in agriculture, they have established a agro-based company named Northern Seed Ltd. which involves in inventing & developing new variety of agricultural Seeds & Technologies which has been contributing the country’s economic growth as well as reducing global food crisis.
2.2 COMPANY PROFILE ◘ Name of the company : ◘ Type of the company ◘ Board of Directors : : ◘ Year of establishment : Fashion Asia Limited Private Limited company 2000 Mr. Sharifur Rahman (Chairman) Mr. Naim Hassan (Managing Director) Mr. Mohim Hassan (Director) ◘ Trade license Number : ◘ Bond license Number : ◘ Factory Location : 4763/0809, Issued on 11-08-2008. 108/lices-sbw/2001, Issued on 04-01-2001 The factory is situated at 135 Gopalpur, near by BSCIC, Tongi, Gazipur which is 6.3km away from Dhaka International Airport. Plot - 49/57(4th & 5th Floor) 135 Gopalpur, Monnunagar, Tongi, Gazipur. Phone: 9816201, 9816202 Regency Place (4th Floor) Plot-1, Road-Surhawardy Avenue, Block-K, Baridhara, Bangladesh. Phone: 9882516, 9882517, 9882607 Fax: 880-2-9882610 E-mail : firstname.lastname@example.org Web : www.northerngroup.com.bd Prime Bank Limited
Banani Branch, House - 62, Block – E, Kamal Attar Turk Avenue, Banani, Dhaka. Phone: 8816474
◘ Factory Address
◘ Head Office
◘ Nature of Business ◘ Organizational Setup ◘ Production Facilities ◘ Area of Business ◘ Production Capacity
: : : : :
Manufacturing (100%Export Oriented) Horizontal Sewing and Finishing. Knitwear Manufacturer. 14,000pcs/Day. 41
● USA (United States of America) ● EU (European Union) Cotton 90% & Synthetic 10%. Kid’s) ● North American Mills Inc. Baby wear. Ladies wear. (USA) ● Orientex Ind. A garment panel printing house with a capacity of 20.T-Shirt. ◘ Category of Items : ◘ Brand Handling/Buyer : ◘ Marketing Area(s) ◘ Fabric Used (%) ◘ Suppliers some local : : : ◘ Yearly Turnover ◘ Allied Business : Last year the company stood at 2. Fleece Jacket. (Canada) ● Carrefour (France) ● Lindex AB (Sweden) ● KappAhl AB (Sweden) ● GULDENPFENNING GmbH (Germany) ● Verburgt (Germany) ● Fashion Traders (Spain) ● Vanguard Trade International (Poland) ● Zaastex Ltd.Top management usually deals in supplier selection.Shorts. : Printers & Printers Limited. Special type’s fabric and special purposes they outsource fabric from Market/factories. Ladies/Girls. etc. 41 .But for some special purposes and urgent cases items are outsourced from other suppliers or sources.32 million US Dollar in terms of its total turnover. Knit Nightwear.Sweat Shirt. All (Men’s/Boys.◘ Manufacturing Items : All types of Knitwear such as Polo Shirt. Accessories-They have some nominated supplier to source the accessories.Inc.000 pcs of garment with its’ 4 semi automatic printing machines started in operation in order to support the in-house printing requirement of NCL group. (Canada) ● GETRACAR INC.Usually fabric is outsourced from its sister concern Northern Corporation Limited and Tosrifa Industries Limited. CVC 40% and CVS ax% Fabric.
Cost and differentiation advantages are known as positional advantages since they describe the firm's position in the industry as a leader in either cost or differentiation. The goal of much of business strategy is to achieve a sustainable competitive advantage. the firm is said to possess a competitive advantage over its rivals. Michael Porter identified two basic types of competitive advantage: • • Cost advantage Differentiation advantage A competitive advantage exists when the firm is able to deliver the same benefits as competitors but at a lower cost (cost advantage).1 DEFINITION: COMPETITIVE ADVANTAGES When a firm sustains profits that exceed the average for its industry. Thus.3. COMPETITIVE ADVANTAGES 3. The following diagram combines the resource-based and positioning views to illustrate the concept of competitive advantage: A Model of Competitive Advantage Resources Cost Advantage Or Differentiation Advantage Distinctive Competencies Value Creation Capabilities 41 . a competitive advantage enables the firm to create superior value for its customers and superior profits for itself. or deliver benefits that exceed those of competing products (differentiation advantage). A resource-based view emphasizes that a firm utilizes its resources and capabilities to create a competitive advantage that ultimately results in superior value creation.
This decision is a central component of the firm's competitive strategy. in order to develop a competitive advantage the firm must have resources and capabilities that are superior to those of its competitors. the firm 41 . These competencies enable innovation. Such capabilities are embedded in the routines of the organization and are not easily documented as procedures and thus are difficult for competitors to replicate.◘ Resources According to the resource-based view. ◘ Value Creation The firm creates value by performing a series of activities that Porter identified as the value chain. A firm positions itself in its industry through its choice of low cost or differentiation. quality. all of which can be leveraged to create a cost advantage or a differentiation advantage. differentiation advantage. The following are some examples of such resources: • • • • • Patents and trademarks Proprietary know-how Installed customer base Reputation of the firm Brand equity ◘ Capabilities Capabilities refer to the firm's ability to utilize its resources effectively. Without this superiority. Another important decision is how broad or narrow a market segment to target. and customer responsiveness. In addition to the firm's own value-creating activities. Resources are the firm-specific assets useful for creating a cost or differentiation advantage and that few competitors can acquire easily. Porter formed a matrix using cost advantage. The firm's resources and capabilities together form its distinctive competencies. efficiency. and a broad or narrow focus to identify a set of generic strategies that the firm can pursue to create and sustain a competitive advantage. ◘ Cost Advantage and Differentiation Advantage Competitive advantage is created by using resources and capabilities to achieve either a lower cost structure or a differentiated product. An example of a capability is the ability to bring a product to market faster than competitors. the competitors simply could replicate what the firm was doing and any advantage quickly would disappear.
To achieve a competitive advantage. the firm must perform one or more value creating activities in a way that creates more overall value than do competitors. Superior value is created through lower costs or superior benefits to the consumer (differentiation).Buyers are likely to place orders in the compliance factories so it is very much essential to obtain compliance certificates from the respective authorities by ensuring all compliance issues. providing the customer a product of the desired quality and price at the right time is essential.com/strategy/competitive-advantage/] 3. 41 .Besides buyers are very much conscious regarding the compliance issues.2 COMPETITIVE STRATEGY A winning competitive strategy is founded on consistently understanding and predicting changing market conditions and customer needs. [Source: http://www.quickmba. For an apparel manufacturing company to be competitive in today’s global market.operates in a value system of vertical activities including those of upstream suppliers and downstream channel members.
The card is also used to keep attendance by automatic electronic punching system. ◘ Wages and Benefits : Fashion Asia Limited pays at above the minimum wage to the workers as per the minimum wage declared by the minimum wage board.g. The company and its top management is very much initiative in this regard. Wages of every worker is paid within five working days from the last day of the wage period. Fashion Asia Limited has been audited by SGS. ◘ Working Hours : Regular working hours 8am to 5pm that I found at FAL and overtime don’t exceeded more than two hours. because they have ISO 9001:2000 and OKO-tex certification in Northern corporation Limited.3. ◘ Leave and Holidays : Weekly holiday and public holidays provided according to the customs and rules. are given to the workers as per rules and regulations. Overtime payment and other benefits e. 7:30am to 4:00pm is the scheduled working hours followed during Ramadan. yearly bonus.3 COMPLIANCE & CERTIFICATION ◘ Oganogram of the Company : Organogarm Diagram has been attached separately with this section. usually 1st to 7th day of a month fixed as the wage period at FAL. ◘ Compliance Certification : At present FAL has no compliance certification but they have compliance infrastructure and adopting other compliance issues. 41 . ◘ Identity Card : Every worker has an Identity Card issued by Fashion Asia Limited . BSCI and COLES. group insurance etc. incentives. WRAP certification is on the process in Tosrifa Industries Limited. ◘ Child labor Abandonment : Fashion Asia limited has a strict policy under which the hiring of underage employees is absolutely prohibited.
more over the lavatory is also near by and having good washing facilities. fire extinguishers. ● Washing Facilities : There are six Basins in the sewing floor. The contracted clinics are: ■ Abeda Clinic Private Ltd. There is a first aid team consisting of 14 members who are trained in first aid medical applications.They provide some primary medicines to their patients free of cost.g.a security guard were wounded by the tempest and high waves and that was an mishap. The factory complex also has the smoke detectors to be alert automatically and emergency exit and emergency lighting system. Among them 40 persons are especially well trained. It has a big reservoir of water and own source of water.One senior physician and two full time nurses are serving the best to heal the health hazards of the staffs and workers of the FAL. ◘ Health Facilities : ● Ambulance Room : Fashion Asia Limited has an ambulance room with an area of 200sqft and equipped moderately . Fashion Asia Limited has fire fighting team consisting of 120 members. smoke detectors and other fire fighting equipments.FAL authority immediately sent the wounded person to their contracted private general clinic for the treatment.◘ Fire Safety Arrangement : The infrastructure of Fashion Asia Limited is a piece of modern manufacturing unit which has maintained space allocation and have a good architectural concept. which happens once in a month in FAL during my internship period. The Factory complex has four wider stairs at the four corners with wider exit ways. The factory is well equipped with fire fighting equipments e. ● First Aid Box with Policy Board: Fashion Asia has 07 First aid boxes in the floor and 07 first aid policy boards. Smoking is strictly prohibited in the factory compound. fire alarm. hose pipe. ■ Marie Stopes Clinic.One general clinic and another is specialized in mother & maternity care. I found regular fire drill. During my internship period . Fire extinguishers checked regularly by the authority. 41 . ● Agreement with Clinics : Besides ambulance room they have agreement with two clinics which is near by the factory.
packing. ● Dust and Fume Preventives : Though it is compulsory to use musk during working in the floor. 05 for executives and 10 for male workers and 20 for female workers. Aprons. Musk. 41 . Adequate numbers of waste bin are placed in the right manner. ● Alternative Stairs : Fashion Asia Limited has two alternative stairs which remains always open and it is 72” wide. ● Other Safety Measures : Safety measures in parking. loading and unloading areas followed in accordance with C-TPAT. ◘ Safety Facilities : ● Personal Protective Equipment : The factory provides personal Protective equipment (PPE) to the workers to avoid hazards during work. ● Ventilation and Temperature : The Factory is well ventilated and Temperature is maintained by cooling system. Authority is trying their best to grow the awareness among the workers for the matter.● Sanitation Facilities : They have adequate sanitation facilities. etc. ● Group Insurance for worker : The workers of Fashion Asia Ltd are covered by group insurance facilities. The exit way has “EXIT” signboard which is lighted even in loadsheding. but found that workers less motivated and initiative. Mesh gloves. ● Cleanliness : Fashion Asia Limited has 14 cleaner who cleans everywhere on regular basis. The equipments are Needle guard. ● Walk-way in the Floor : Walk-way between machine lines has adequate space in the floor and the aisles are well marked. Emergency exit way aisle is marked with red color and a layout plan design indicating emergency exit way is well placed. ● Pure Drinking Water Supply : They have maintained a sufficient supply of pure drinking water at the suitable points and conveniently situated for all workers.
● Cheap Value Shop : Fashion Asia Limited has no cheap Value Shop at present. ● Transport Facilities : Transport facilities only provided for the top management. They have a well arranged sound setup in their sewing floor which is controlled from PM’s room and used for announcement. ● Canteen Facilities : They don’t have any canteen facilities for the employees though they have a setup but I didn’t find it running.◘ Maternity Benefits : Maternity benefits exist in Fashion Asia Limited complying with the rule and regulations of Bangladesh.washing facilities etc. a rich and sumptuous meal and a raffle draw. They do have meetings regularly on different issues. stuffs and workers.adequate supplies of pure drinking water. music play and some other things. The festival included cultural program organized by them. ● Dining Facilities : Adequate dining Facilities have been provided for the workers so that they can have their meal that they bring along with them. ● Accommodation Facilities : Fashion Asia Limited doesn’t provide any accommodation facilities or dormitory facilities to the employees.Dining is facilitated with dining tables. Among them 6 person is from management side and another 6 person is from workers side. No means of transport is provided for the executives. 41 . The dining area is above 2400sqft.They have future plan to build separate building for ambulance/medical room and well equipped child/day care centre. Workers can share their problems with the higher management in the welfare committee’s meeting. ● Entertainment Facilities : During my internship they have celebrated their yearly program “Nababarsho”. ◘ Worker Welfare Facilities : ● Worker Welfare Committee : Fashion Asia has a worker welfare committee consisting of 12 members.They have also a facilitated dining for the executives. ◘ Child Care/Day Care Centre : At present they have a child care room in a temporary structure and the area is 200sqft.
transportation logistics. 41 . The Textile Supply Chain Management program focuses on efficiently satisfying demand. sourcing.4 SUPPLY CHAIN MANAGEMENT The supply chain consists of all the operations necessary to produce and distribute a product. It includes studying approaches to solve problems in manufacturing. I didn’t get enough scope to collect information on supply chain management at FAL.3.So. A good supply chain management ensures high productivity with right quality & quantity at the right place in the right time. the management of modern technologies. and ending with the delivery of the finished product. starting with the procurement of the raw material used in making the goods. I am not going to give any description about it but it’s an important thing for gaining the competitive advantages in garments manufacturing business. and timely delivery.
W.S Officer Production Supervisor Supervisor Reporter Quality Inspector Worker Worker Store Officer Quality Departmen t Work-Study Department Marketing Department Accounts Department MIS Department Administration Sr.5 ORGANOGRAM OF FASHION ASIA LTD. Store Officer Store Assistant Executive HR Trainee Management Time Keeper Medical Officer Nurse Office Peon Security Guard Cleaner 4.S Officer Jr. Chairman General Manager Production Department APM Line Chief Quality Officer W. Executive Admin Auditor & Compliance Executive Admin Store Department Assistant Admin Asst. W.] Labor/Loader 41 .S PMQ.3.A Merchandiser Department Executive Executive Officer Manager Accounts MIS Assistant Merchandiser Assistant Accounts Assistant MIS Auditor Sr. ORGANIZATIONAL STRUCTURE 4.1 PRODUCTION AREA [Source: From Fashion Asia Admin Dept.
(Approximately) Approximately 300 decimals. 800 Sq Feet.2 EMPLOYEES • Number of Total Employees : 41 726 . 2000Sq Feet. . 1000Sq Feet. 4. 240 Sq Feet. 1200 Sq Feet.30 • • • • Total Floor Space of the Factory : Factory boundary area : 38000 Sq Feet.• • • • • • • • • • • Sewing Floor Area Cutting Floor Space Finishing Floor space Packing Floor space Ware House Floor Space Loading /Unloading Area Parking Space Office Space Dining Space Area Child Care Room Space Number of Toilets Number of Basin Facilities Generator Facilities horse : : : : : : : : : : : : : 7560 Sq Feet. 1200Sq Feet 2400 Sq Feet. Executives Workers 06 basins They have a 100KV with 144amp diesel generator and the Power is 108. 4140 Sq Feet.08 . 1600Sq Feet.
SUB TOTAL STORE DEPARTMENT(FABRIC & ACCESSORIES) STORE INCHARGE FABRIC STORE ACCESSORIES SUB TOTAL SAMPLE DEPARTMENT INCHARGE SAMPLE SUPERVISOR 1 1 1 8 1 6 9 16 5 16 5 1 1 1 7 1 6 10 21 1 7 3 11 1 1 2 6 10 3 8 50 35 5 2 3 103 35 35 20 35 35 35 35 25 3 258 21 21 15 21 21 18 17 12 21 18 33 33 20 35 35 32 33 25 1 6 40 30 4 2 3 1 1 2 6 1 7 2 21 10 10 11 12 13 CUTTING SAMPLE MAN SUB TOTAL FABRIC CONTROL DEPARTMENT QUALITY ASSURANCE DEPARTMENT CUTTING SEWING FINISHING SUPERVISOR INCHARGE AUDIT DEPT SUB TOTAL SEWING DEPARTMENT LINE-A LINE-B LINE-C LINE-D SEWING OPERATOR LINE-E LINE-F LINE-G LINE-H RIB CUTTER MAN SUB TOTAL LINE-A LINE-B LINE-C LINE-D LINE-E 10 3 85 247 SEWING HELPER 41 . PRODUCTION MANAGER ADMIN DEPARTMENT EXECUTIVE ACCOUNTS& FINANCE MARKETING & MERCHANDISING DEPARTMENT WORK STUDY WITH REPORTER SEWING MANAGEMENT DEPARTMENT SUPERVISOR LINE CHIEF/TECH.• SL NO 1 2 3 4 5 6 7 8 List of the Employees : REQUIRED MAN POWER EXISTING MANPOWER 9 DESCRIPTION GENERAL MANAGER PRODUCTION MANAGER ASST.
LINE-F LINE-G LINE-H SUB TOTAL CUTTING DEPARTMENT INCHARGE SUPERVISORS ISSUE MAN HELPER CUTTER-MAN SUB TOTAL FINISHING DEPARTMENT INCHARGE SUPERVISOR HELPER FOLDING & POLY PACKING IRON MAN SUB TOTAL MAINTENANCE DEPARTMENT INCHARGE SUPERVISOR SR.3 MACHINES Fashion Asia limited has 334 sets of Sewing machines in their factory.g. Pegasus and Kansai special) and 41 . MECHANIC MECHANIC HELPER 21 21 15 156 1 2 3 40 6 52 1 3 20 20 10 18 72 1 1 2 1 1 1 7 14 2 2 8 26 745 19 12 13 130 1 1 2 40 6 50 1 3 20 20 10 16 70 1 1 2 1 1 1 7 14 2 2 6 24 682 14 15 16 ELECTRICIAN NEEDLE MAN SUB TOTAL OTHERS CLEANER/CHECKER 17 PEON SWEEPER SECURITY GURD SUB TOTAL GRAND TOTAL [Source: From Fashion Asia Daily Attendance Report Sheet] Table -01 List of Employees 4. Brothers. Most of the machines are branded (e. Juki.
4 LAYOUT ● Line Layout Design ● Number of Lines 41 : : Traditional 8 . The machine list of Fashion Asia limited is shown below in a table: Machine List of Fashion Asia Limited S/N Machine Name Quantity 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Single Needle Lock Stitch Over Lock Flat Lock Back Tape Kansai Special (PMD) Rib Cutter Button Hole Button Stitch Snap Button Thread Re-cone Bar-Tack Cutting Machine Steam Iron Label Cutter Compressor Fusing Pico-ting Needle Detector Thread Sucking Fabric Inspection Machine Total Machines: 149 Set 95 Set 64 Set 04 Set 03 Set 03 Set 05 Set 05 Set 04 Set 01 Set 01 Set 04 Set 19 Set 02 Set 01 Set 01 Set 02 Set 01 Set 01 Set 03 Set 368 Set Table-02 List of Machines [Source: From Fashion Asia profile] 4.models are latest featured with cutting edge technology.
Different arrangements of machines in sewing lines are aimed towards optimal floor area utilization. right from material receiving till the finished goods go out of the factory. besides better housekeeping and conformance to compliance. the aim is to maximize the use of floor area and easy maneuvering of machines to achieve efficiency in production.● Average Number of Machine per Line ● Average Number of Operator per Line ● Average Number of Helper per Line ● Helper-Operator Ratio ● Number of Supervisor per Line ● Number of Line Chief per Line ● Number of Quality Inspector per Line ● Man Machine Ratio (MMR) ●Description of Layout : : : : : : : : : 30 30 12 2:1 01 01 01 2:1 A good factory layout is directly associated with good work flow. 20. 4. Fashion Asia Ltd has a good factory layout. easier supervision.5 PRODUCTIVITY & INCENTIVES ◘ Production Capacity of the Factory : SL NO 1 Product Polo/Golf Shirt Production Capacity/Month 3. 41 . Their sewing line layout is designed horizontally. throughput time and flexibility.000 pcs. have better controls. Whatever type of plant layout a firm develops. it should be designed to optimize quality.FAL has the compliance layout which has the better controls easier supervision and better housekeeping. and controlled installation and running costs. There is no right or wrong layout as such.
Fashion Asia Limited uses different types of industrial tools and techniques in different stages of production. 55% 40% 40% 60% 30% 15% ● Productivity per Line per Shift (8hrs) : ● Targeted Organization Efficiency ● Actual Organization Efficiency ● Average Line Efficiency ● Highest Line Efficiency ● Lowest Line Efficiency ● Defect / Alter Percentage per Line : : : : : : ● Work Study Team : Work study team continuously working with the production department to enhance its productivity.000 pcs.000 pcs per Month.000 pcs.000 pcs. Table-03: Monthly production Capacity [Source: From Fashion Asia profile] ● Production Capacity per Line : 52. They are described below ◘ Pre-Production Planning : 41 . ● Incentives : Fashion Asia limited does provides incentives among the workers for full filling the targets in weekly/monthly basis. process study. 50.100 pcs per Shift. 30. 2. 5. 2. Work study team works in each section from cutting section to finishing section. They frequently doing time study.00.2 3 4 Basic T-Shirt Romper/Baby Set Fleece Sweat Shirt 4. ● Work Study Methods : A dedicated team is always fighting for the quality and productivity by using different methods and techniques. During my intern I found them announcing 4. and set their target productivity and at the end of the day they prepare a report which indicates all the parameters and achieved efficiency level.6 INDUSTRIAL ENGINEERING TOOLS AND TECHNIQUES the incentives for the most efficient line of month/week.
◘ Engineering Developments in Garments Industries: 41 . The individual sewing tasks are organized in a systematic fashion and specialized sewing machines have been developed for the individual tasks. Besides other sections of production department do planning about their course of action. A worker receives a bundle of unfinished garments. Work is organized such that each worker is specialized in one or a few operations. the assembly stage remains highly labor intensive and involves delicate handling and sewing operations that do not lend themselves to automated progress. I had an opportunity to attend a pre-production meeting. They apply different types of folders for the accuracy and productivity. performs her single task and precedes the bundle for the next operation. The basic production technology is characterized by the progressive bundle system. The fabric is first cut and then grouped by parts of the garment. although the use of high-speed motors and automatic needle positioning on the machines have added to increased production output. Merchandiser is the person who is responsible for arranging and as well as conducting a successful Pre-production meeting. The most critical stage of this business is production stage because of the errors. Nevertheless. ◘ Production Stage : The primary advances in sewing have been developed in the methods used to handle parts of garments. It takes about 25 operations to complete a single basic T-shirt. productivity and lead time. Then before starting of the production they conduct a pre-production meeting. Merchandiser should describe about his order packages with all essential information and should concentrate on the critical points that may arise in the time of bulk production. complicated design needs more operations.After receiving of each conformed order sheet work study team prepare a work breakdown sheet which contains list of processes and the SMV data’s to have an idea of production layout planning. Work study team always working on how they can improve their productivity and accuracy by implementing different types of industrial techniques and with the help of different types of industrial tools of garments manufacturing technology. Machines have hi speed motors and some special features that. alter percentage. ◘ Industrial Engineering Tools : Fashion Asia Limited is equipped with branded latest model sewing machines which added competitive value to them. delay timing. tied into bundles (pre-assembly) and then sewed together. if utilized properly can enhance their efficiency in productivity and quality. The pre-production meeting I attended was lack of co-ordination and low profiled presentation. They also supply different types pattern board regarding running styles to make easy and to consume less time for the critical operations.
MANUFACTURING PROCESS ◘ Manufacturing Process at Fashion Asia Ltd : The Garment Manufacturing starts after receiving the processed fabric. which can be categorized into 3-sub section: 41 .The basic Multi Purpose Sewing Machines are equipped with Electronic Motors which perform certain functions automatically at a very high speed resulting in error free production. 5. The basic machines would be equipped with Automatic Back Tacking function that would ensure stitches of any component of the garment is firmly secured at both ends. savings in other raw material consumption’s and time saving for operators. All these three would contribute significantly to overall high standard of quality and low production cost of the garments. This in turn will eliminate the possibility of loose stitches. These machines are also equipped with proper needle positioning to make sure considerable reduction in handling time for the operator coupled with Thread Trimming Device which would cut the thread at the end of each operation to reduce thread wastage and give a neat finish to the garment.
for special types of styles they done the CAD marking from their sister concern Tosrifa Industries Ltd which situated at the same factory building. so cut panel bundles supplied to the operator’s as per operations. Work study team sets machine layout. Machine layout setup done according to the operation breakdown of the specific styles and designs of the garment to be produced. Also it improves accuracy in cutting and precise fitting of garments for all sizes. ◘ Button Hole and Button Stitch Buttons holes and button stitching on the garments done on specialized automatic Button Hole and Button Stitch machine to give proper shape of button hole and proper attachment of button at a very high speed. which has the capability to cut unto 300 layers at a time.• • • Cutting Section Sewing Section Finishing Section 5. Several parts joints together in the different stages of the production. Sewing techniques at FAL is written down below : ◘ Automated Plain Stitches This section has been balanced perfectly with multipurpose Sewing Machine as well as specialised machines with a high level of automation.2 SEWING SECTION From the cutting section cut panels in bundles supplied to the sewing section for sewing all together to produce a garment. FAL has no CAD/CAM systems their own. 5. Consumption of fabric is calculated by marking the body pattern parts of the garments on a certain width of fabric. The cutting of the fabric will be undertaken by automated Straight Knife Cutting Machine. After marking fabrics up to 150 t0 200 layers would be spread on the Tables. Thereafter the pattern marker on the basis of which the garment is to be stitched will be placed on the fabric. Marking can be done both manually and by CAD/CAM. ◘ Special Purpose Machines 41 . They do the marking job manually for Basic styles.1 CUTTING SECTION The in-house fabric will be spread out in layers on the Cutting Tables as per required consumption unit of fabric.
After the garments are pressed. 6. For export consignment garments are packed in carton boxes according to the instruction given on buyer’s purchase order to reduce their handling and distribution cost. This gives smooth finish to stitched edges of garment for better comfort in wearing. Garments would thereafter be placed in polythene bags and sorted size wise and Design wise as per specification given by buyer. 5.Over lock Machines and Flat lock machines join sleeves and seaming sides.3 FINISHING SECTION ◘ Pressing & Packing The Garments will be ironed using steam irons installed with and integrated Boiler System. ◘ Quality Control Quality checks have been built at various stages of the production process Quality Control process began at the stage of production of the fabric from Knitting section . In addition to this there will be a 100 inspection of garment before finishing process starts. These machines sew parts of a garment together and simultaneously cut waste fabric. Only quality. DEPARTMENTS AND POLICIES The entire management process comprises of the following units: 6.approved fabric is received to store from where it would be issued to cutting section. in one operation. the Finishing Section will make a final inspection to confirm measurement and finishing of garment before sent for final packing.TIL that would be checked several times for knitting defects. quality of fabric produced by knitting section of NCL. While arriving at the manpower requirement provision has been made for quality control inspectors at each stage.1 MERCHANDISING DEPARTMENT 41 .
Each of the merchandiser has one or several accounts of the buyer and they are responsible for that buyer. L/C open.They have four senior merchandiser and two assistant merchandiser who merchandise the products to the buyer. Garment merchandisers these days need to have not only solid product knowledge but also soft skills like project management.export. Administration department is headed by Sr. Price negotiation done by the top management as it is a very sensitive matter. time management and negotiation to facilitate their work. Merchandiser is the pivotal person who actually merchandises the product for seller to the buyer.One Commercial Logistic officer works under administration department . Executive Admin & Compliance.Fashion Asia Ltd. so it needs multi skills in a person. starting from order process to profit realization. has a merchandising department headed by GM (Marketing & Planning). By nature merchandising job is to co-coordinating a set of jobs. They total 09 employees in this department. Now merchandiser becomes responsible for the order . Also fixes his sourcing strategy for required materials that are needed to fulfill the production. or any 6. Assistant merchandiser helps senior merchandisers to reduce the workload and equipped themselves with practical knowledge. Design and product development is an integral part of any apparel manufacturing.3 ADMINISTRATION DEPARTMENT other Banking activities. The Logistic officer is responsible for documentation. Operational efficiency of the merchandising team therefore becomes a key factor in the success of an industry player in the apparel manufacturing business. Besides other responsibilities of this department is to 41 .2 COMMERCIAL DEPARTMENT There is no separate commercial department at FAL. hence there should be a proper understanding among them. This department is very important for every garment industries and garment related buying house. 6. A merchandiser should be able to understand and communicate with the sample section and production people in a comfortable manner both should have a common lingo since both the merchandiser and the sample and production people work in close proximity. import.Head office looks after most of the major commercial activities. Then conformed order place to a merchandiser for the successful execution of the order.so he sends detailed order package to all respective sections and departments. Administrative jobs are the main function of this department. total transportation activities.
6. He collects broken and useless needles and replaces new needles. threads. His main responsibilities is to maintain petty cash. Accounts and Commercial logistic officer also attached to this department. etc. process of all types of bills (incoming & outgoing). Compliance issues. They have one NEEDLE-MAN who deals with only needle problem. As they don’t involved in any chemical process so they do not have any chemical waste.Daily needs purchased by the factory maintaining proper documentation with accounts department.They have only wastage of small piece of fabric.7 INDUSTRIAL WASTE DISPOSAL POLICY They depose waste properly on regular basis. 6. 6. replacement of parts or total replacement of the item. They have one Jr.co-ordinate HR issues.4 ACCOUNTS & AUDIT DEPARTMENT All the accounts of the organization are controlled by the head office of Northern Group. 41 . salary & overtime and all sorts of payments & bill collection.6 MAINTENANCE POLICY Maintenance is defined as the restoring of an item to its original condition or to working order. Executive accounts & finance who works under administration department. This can be achieved by repair. 6. Fashion Asia has a well equipped maintenance section with required manpower.5 PURCHASING POLICY Corporate head office of northern group controls purchasing policy of Fashion Asia ltd.
Has no CAD system presently. Top management is always trying to enhance the performance of the sample section.7. Total number of machines is eleven.1 DESCRIPTION OF THE SAMPLE ROOM Fashion Asia has a well equipped modern sample section which has a 425 sqft floor space. 7.2 TYPES OF SAMPLES They are capable to produce all types of samples as per buyer’s requirement.3 MONTHLY AVERAGE PRODUCTION OF SAMPLE Their targeted production of samples is 300pcs per month. But the average production of sample is 150-200pcs per month. 41 . SAMPLE MAKING FACILITIES 7. They can produce any types of samples as per buyer’s requirement.Their target is to produce 300 samples in each month.But they done the jobs for the critical & complicated styles from their sister concern Tosrifa Industries Ltd as they having the CAD/CAM system.They have six multiskill sample men along with other four employees(cutting-02. The sample section is headed by Sample In charge who should be a pattern master. quality-01 and supervisor -01). Samples they usually produce listed below: • • • • • • • • • • • • Development samples Proto samples Salesman samples Photo Shoot Sample Revision sample Size set sample Preproduction sample Pre-Line Sample Wash Sample Dummy/Fit Sample Counter sample Shipment sample 7.They do pattern making.grading and marking manually for the basic styles. 7.4 Use of CAD/CAM System Fashion Asia Ltd.
IMPORTANCE OF SAMPLING IN GARMENTS INDUSTRIES Fashion is defined well as the prevailing mode or shape of dress designed by those lead is accepted. Besides by doing sampling the exporter can optimize the processing parameters for mass production. So it is essential that the samples should be innovative and with optimum quality. economic and cultural forces.The samples. Besides by doing sampling only the exporter can optimize the processing parameters for mass production. All these works are carried out by the sampling department. The buyer will access the exporter and his organization only by the samples. head gear.1 IMPORTANCE AND NEED OF SAMPLING Designing and sampling are the main process in Garment Industry and it as a vital role in attracting buyers. So it is essential that the samples should be innovative and with optimum quality. Our ancient civilization identified status or power with visual elements like clothes. which helps to avoid all kinds of bottle necks . priests or warriors. a clear idea on costing more ever the manufacturing difficulties. In any given period.a clear idea on costing and manufacturing difficulties. The buyers will assess the exporter and his organization only by the samples . If the samples are of good quality and with reasonable price naturally the buyers will be forced to place the order. The samples decide the ability of an exporter.After a time. worn by the kings . Sampling is the best way to place an order.A product or activity is in fashion or is fashionable during the period of time that a large segment of society accepts it . which us led by a sampling in charge. 41 . By doing sampling the exporter can estimate the yarn consumption for developing the fabric.If the samples are of good quality and with reasonable price naturally the buyers will be forced to place the order. which helps to avoid all kind of bottlenecks. By doing sampling the exporter can estimate the yarn consumption for developing the fabric . however the same product or activity becomes old-fashioned when the majority of people no longer accept it. The purpose of sampling is not only to get bulk orders and also give some additional benefits to the exporters. decide the ability of an exporter.8. Design and product development is an integral part of any organization. 8. A fashion remains popular for a few months or years before being replaced by yet another fashion . The purpose of sampling is not only to get bulk order and also it gives some additional benefits to the exporters. embellishments.ministers. Because the buyers generally places the order after they are satisfied with the quality of the samples. Though it is a difficult and time ending process it will help the exporter to get the order from the buyer. fashion reflects the social.
Able to plan a development process suitable for your company needs. Awareness of reducing development and company costs and improve customer service. The increasing use of computer aided design and manufacturing has helps all types of Textile businesses to speed up the process of sample development and to do this more cost effectively. As a result some smaller companies adapted the whole of their production. Innovation and creativity are necessary for any business to move forward and take advantage of prevailing market conditions. Larger organizations may have departments devoted to the research and development of products or Sampling departments who are constantly producing new samples and ranges. Economic / Market Place Needs are Identified Forming First Concepts/Ideas Developing concepts into Prototype Sample Prototype Specification Written Modifying Prototype until Approved Amendments to Specification Finalized First Sample & Specification to Retailing 8. For example.2 ADVANTAGES OF SAMPLING • • • • • • • • • • • • Gain a full understanding of the sample development process. the fashion knitwear manufacturer now makes the hosiery industry.8. Able to strengthen your team’s awareness and understanding of other department needs.3 MODERN CUTTING-EDGE TECHNOLOGY FOR SAMPLING 'Big may be beautiful in manufacturing but the textile industry is dominated by numerous small to medium sized businesses and sample development is a vital to the survival and success of Textile business whatever its size or type of production it enhance. Find ways of minimizing risk factors and maximizing quality parameters. Many organizations large and small have been able to identify and exploit such markets or a gap in the market for specialized samples. the weft knitter who now 41 .
Sales & Marketing.5 PERSONS INVOLVED IN SAMPLING • • • • • • • • • • • • Development team Designers/Sample developers.A designer creates and arranges garments and accessories in such a way that they are visually pleasing as well as functional. These enable new ideas and effects to be reproduced on computer and tried and tested in a most cost effective and visually acceptable way. Sourcing &Purchasing. Designers need to be aware of the trends and traveling provides them with opportunities to interpret their customer needs . Planning Control &. The first of these covers the development of the initial concept or design idea through to its approval by the customer and full review/risk analysis by the development and production teams. Designing a garment involves below mentioned steps: • • • • The design Making a toile Making a card pattern The finished dress. each of which has its own distinctive characteristics and most of which have been created by designers and only by them.4 DESIGNERS ROLE IN DESIGNING A GARMENT There are countless styles. Despite the diversity of textile products the development process is similar for all and the process has been transformed by the increasing use of CAD/CAM. computer aided design and computer aided manufacturing. Costing & Finance. Testing Quality control 41 . 8. 8. Customers/Clients. Textile technologists Garment technologists Packing & Dispatch. Production team.makes specialized medical samples and the warp knitter who produces geotextiles for engineering end use. The sample development process splits down into three main phases.
new yarns. testing the product and carry out trails once the finalized sample specifications has been drawn up. technical and medical products. cut and sewn garments.8. 41 . household products. The second phase covers the process following acceptance of the first prototype sample and includes the functions of sourcing and ordering component. the first phase covers the development of the initial concept or design idea through its approval by the customer and full review/risk analysis by the development and production teams. There are different phases of sampling. fabric structures .6 TYPES OF SAMPLES There are several types of sample that is produced in garments manufacturing business development.7 SAMPLING PROCESS The process of sample department varies from context to context. the third and final phase commences. Samples are produced as per buyer’s requirement in the different stages of the business process.finishes and surface effects and all types of made up products such as knitwear. The phase includes a range of activities that are carried out before large scale or bulk production capacity outside the home producer/developers wherever this is applicable. and the development process covers a wide range of diverse products from new fibers. fiber blends. Common and prevalent sample types are written down below: • • • • • • • • • • • • • • • • • • Proto sample Development sample FIT Sample Counter & Duplicate Counter Sample GFE Sample Sealed Sample [Red / Yellow-Sealed] Size set sample Preproduction sample Production Sample Bulk Production Sample Lab-Test Sample Pull Test Sample Flammability Test Sample Photo Shoot Sample Salesman Sample Shipment sample TOP [TOP OF THE PRODUCT] 8. hosiery.
8 ROLE OF MERCHANDISER IN FULFILLING THE SAMPLING In preparing sample the merchandiser places an optimal and pro-active role.8. 41 . Revised samples may be sending for approval purpose. The merchandiser is a person who has to follow all the activities which filled up sight from the manufacturing unit. Merchandiser should understand the specifications and requirement of the buyer and produce samples by considering: • • • • • Communication Optimizing situation Punctuality in giving details and samples to the buyers Efficient follow up Excellent negotiation skills The merchandiser has to consider all the quality parameters related to the samples to be developed in case of non-conformities in the sample developed. It is the duty of the merchandiser to dispatch the developed samples on the time to the concerned buyers.
Facimile facilities is available. 10.Fashion Asia Ltd encourage employees to have training on compliance issues (e.supervisor.9. In order to recruit skilled workforce in textile sector. Winning fashions are determined not simply by producing the best garment. 41 . Due to globalization seen in the textile industry out of these four elements of production. officers and security people. 11.They have hi-speed broadband internet connection with 512 kbps speed. Without effective information management strategies companies cannot hope to be effective suppliers in today's marketplace. There are four elements of production namely manpower. They have training facilities available for skill development for officers . TRAINING FACILITIES There is no specific training department at FAL for employees and executive. the two viz.e. but as importantly by delivering the right garment at the right time.) and material utilization & productivity. Thus many collaboration among many multinational companies and educational institutions is been observed. proper training programmes would thus facilitate in supply of well qualified workforce. HUMAN RESOURCE MANAGEMENT IN TEXTILE SECTOR Textile industry gives employment to millions of people.They have private domain address and website. manpower and time are to be cut down. Fashion Asia Limited has well telecommunication facilities. executive and managers. TELECOMMUNICATION FACILITIES Technological progress in telecommunications and transportation networks has made it easier for apparel manufacturers to divide the supply chain on an international basis and to perform the assembly stage in low-wage countries. Presently two laptops used within FAL by the high officials. materials and machines.first aid etc.They have TNT land phone and also wireless private land phone. time.They don’t have any video conferencing facilities yet and they don’t have any fiber communication. the right place and at the right price. i. But they provide training newly recruited workers. fire fighting. Thus the role of HRD has gained momentum in terms of employing manpower that satisfies the professional requirements of this sector and that is well skilled. Information and fashion go hand in hand in today's market.g.
But the scenario has changed as HRD departments have taken up their role in textile sectors. So to cope up with the market competition HRD is very essential element for the textile industry. In last decade we have seen not so good performance by textile sector. This has started since the foundation of WTO (World trade organization). Now-a-days a lot depends on the bargaining power of the labor. right recruitment of workforce. etc. production measures. but cut in the number of laborers. legal policies and the scenario of the labor market. In order to get increased productivity from workforce it is essential to have a well framed HRD system in the organization. subcontracting. Various training programmes pertaining to training of workforce. social security. creates homely environment. But due to globalization there is increase in competition as a result development of human resource has become essential. The advent of HR practices in textile sector was rather slow in comparison to other industrial sectors. It is also responsible to timely up gradation of skills of the workforce by organizing educative professional workshops or seminars. Due to the modern HR practices are affected by terms such as multiskilled. casual labor. this was because of lack of HRD department in many mills. textile related topics have helped in enhancing the overall performance of the textile companies. advantages of competition. The HRD department of any company is responsible recruiting skilled labors and executives. If the principles of HRD are adopted it could result in decrease in non-attendance by 20% and increase in productivity by 30%. feeling of ownership and positive working atmosphere. monitoring of workforce and performance appraisal. demolition of centralized system of decision making. This scenario is same in developed as well as developing nations where there is increased productivity due to advanced technology. HRD department is responsible for developing the feeling of motivation in the employees. However organized HR practices are being adopted mostly by the mill sector. this motivation in other words is the commitment of the employees towards the job and the organization. increased stability of the company. With the technological advancement in the textile industry the overall production with higher quality is been seen. flexible enough to cope up with futuristic developments and most important maximizes production. due to usage of high end machineries and technologies it has been a witnessed that the number of workers employed in the textile sector are facing job-loses.sacrificed as the invent of improved machines and the cost of materials. 41 . When the work of HRD is done effectively it would result into co-operation among team members. If HRD activities are carried out in proper professional manner it could result into minimization of cost and wastage. allocation and planning of work.
Weaknesses. the decision makers have to determine whether the objective is attainable. and Threats involved in a project or in a business venture. 41 .1 Definition and Use of SWAT analysis SWOT Analysis is a strategic planning method used to evaluate the Strengths. Strategic and Creative Use of SWOT Analysis ◘ Strategic Use: Orienting SWOTs to an Objective A SWOT analysis must first start with defining a desired end state or objective.12. are helpful to are harmful to achieving the the business's Identification of SWOTs is essential because subsequent steps in the process of planning for achievement of the selected objective may be derived from the SWOTs. Opportunities: external conditions that are helpful to objective. • • • • Strengths: attributes of the person or company that achieving the objective. A SWOT analysis may be incorporated into the strategic planning model. Weaknesses: attributes of the person or company that achieving the objective. If the objective is NOT attainable a different objective must be selected and the process repeated. Threats: external conditions which could do damage to performance. It involves specifying the objective of the business venture or project and identifying the internal and external factors that are favorable and unfavorable to achieving that objective. SWOT ANALYSIS 12. First. given the SWOTs. Opportunities.
If the threats or weaknesses cannot be converted a company should try to minimize or avoid them ◘ Internal and external factors The aim of any SWOT analysis is to identify the key internal and external factors that are important to achieving the objective. The internal factors may be viewed as strengths or weaknesses depending upon their impact on the organization's objectives. and so on. as well as changes in the marketplace or competitive position. legislation. as well as personnel. SWOT analysis groups key pieces of information into two main categories: ●Internal factors – The strengths and weaknesses internal to the organization. many times: • • • • How can we Use and Capitalize on each Strength? How can we Improve each Weakness? How can we Exploit and Benefit from each Opportunity? How can we Mitigate each Threat? ◘ Matching and converting Another way of utilizing SWOT is matching and converting. and socio-cultural changes. 41 . Converting is to apply conversion strategies to convert threats or weaknesses into strengths or opportunities. finance. technological change. It is particularly helpful in identifying areas for development. on the other hand. • • Matching is used to find competitive advantages by matching the strengths to opportunities. ◘ Creative Use of SWOTs: Generating Strategies If. by asking and answering each of the following four questions. The results are often presented in the form of a matrix. The external factors may include macroeconomic matters. the SWOTs are used as inputs to the creative generation of possible strategies. opportunities and threats. weaknesses. These come from within the company's unique value chain. the objective seems attainable. An example of conversion strategy is to find new markets. ●External factors – The opportunities and threats presented by the external environment to the organization. manufacturing capabilities. What may represent strengths with respect to one objective may be weaknesses for another objective.The SWOT analysis is often used in academia to highlight and identify strengths. The factors may include all of the 4P's.
projects plans for strategy implementation Monitoring results – mapping against plans. taking corrective action which may mean amending objectives/strategies. SWOT analysis may also be used in pre-crisis planning and preventive crisis management. Examples include: non-profit organizations. SWOT analysis may be used in any decision-making situation when a desired end-state (objective) has been defined. resource. This may include gap analysis which will look at environmental factors Strategic Issues defined – key factors in the development of a corporate plan which needs to be addressed by the organization Develop new/revised strategies – revised analysis of strategic issues may mean the objectives need to change Establish critical success factors – the achievement of objectives and strategy implementation Preparation of operational. then that organization will use a systematic/rigorous process known as corporate planning.◘Use of SWOT Analysis The usefulness of SWOT analysis is not limited to profit-seeking organizations. SWOT analysis may also be used in creating a recommendation during a viability study. SWOT alongside PEST/PESTLE can be used as a basis for the analysis of business and environmental factors. and individuals. governmental units. ◘ Corporate planning As part of the development of strategies and plans to enable the organization to achieve its objectives. this should determine relevance from the results of an internal/external appraisal. 41 . this needs to include an assessment of the present situation as well as a portfolio of products/services and an analysis of the product/service life cycle Analysis of existing strategies. • • • • • • • • • Set objectives – defining what the organization is going to do Environmental scanning Internal appraisals of the organization's SWOT.
Some reputed buyer working with Northern Group for a long time.They ascertained spacious layout to facilitate good working environment. ●Good Working Environment: A good working environment exists in Fashion Asia Limited. ●Cross Cultural Communication: In FAL there are near about 800 employees who are from different environments and having different cultures but fortunately there is no cross cultural communication.The Factory is well ventilated and Temperature is maintained by cooling system. ●Handling Famous buyers: Northern Group has long experience in handling various famous buyer’s from Europe. ●Quick Adaptations of ISO Standards: Fashion Asia Limited is adopting quickly ISO Standards Quality management system. ●Experienced Workforce: Fashion Asia has good number of experienced employees who are working in northern group for a longtime. Quick Adaptations of ISO Standards would enable management efficient to achieve their organization goal.12. ●Positive Attitude towards Employees: They always shows positive attitude towards their employees in any regards. 41 . ●Market Reputation: Northern Group is one of the major Group’s in Bangladesh that’s why they have a strong reputation in RMG sector. ●A Dedicated Top Management: A decent striver dedicated Top Management is always working along with the employees to achieve the best. America and Canada.2 SWOT ANALYSIS of Fashion Asia Limited ◘ STRENGTHS: ●Having own diesel Generator: FAL having own diesel generator plant which is can produce 100kv with 144 amp and the horse power is 108.
●High Wastage percentage: According to my observation wastage percentage is high at FAL as they does mostly manually marking in cutting section and high alter percentage in sewing line. ●Delay in order shipment: The delivery of each contract is always not done on time. Sometimes they have to ship the goods by Air Freight to fulfill their commitment to buyers. They are not working to train the employees and making appraisals to evaluate them. May be they confirm each and every thing from each other but still they make mistakes and blame each others to safe them. Some implementation is on the process among the employees and management process but slacken adaptation have been observed.◘ WEAKNESSES: ●Employee’s motivational level: The one weakness of FAL is that their employees are not motivated enough to act as a team player and with the best effort to achieve their common organizational goal This is the responsibility of HR department to find out at to see at the time of hiring them that what the thing is that their employees can be motivated. ●Team Building: A major problem is team building. Each person is doing individually and performing his/her activities. There is almost no concept of team. ●Communication Gap: There are a little bit gaps in communication and coordination between the departments. The customer has to wait to get his/her desired product. ●HR Department: Fashion Asia doesn’t have any HR Department at present but they have one HR executive who performs only some routine activities. ●Casual Attitude: The attitude among the employees is very casual. They are not so conscious regarding the rules and regulations of the company. That activity doesn’t add any extra value to the company. 41 . ●Material Management: Material management is found not so strong rather flabby.
41 . They can find the motivation level of their employees and give them incentives to motivate them. ●Motivating the employees: HR department can prove and show them they are here for employees by motivating the employees performing their best. Enterprise resource planning (ERP) is a company-wide computer software system used to manage and coordinate all the resources. FAL has the opportunity to adopt new technologies which would cost large amount initially but if considered long-term investment then it would be more beneficial . efficiency and decrease the cost of production. information. This will transform their vertical setup into horizontal setup and uphold their market reputation also. ●Horizontal Setup: Northern Group has been initiated to set up a Spinning Mill which would support their sister concerns and as well as local market. So they have a wide scope to contribute to the society by developing quality human resources with proper course content and training.◘ OPPORTUNITIES: ●New Technology: The technology has been improved for the garments industry and these technologies are being acquired by the international competitors as well as by local competitors so they are producing good quality textile products and increasing the efficiency as well as decreasing the cost of production. ●ERP software: ERP (Enterprise Resource Planning) can be installing to have the better control over resource planning. As Northern Group feels that human resources can be the major assets of the country and society. ●Up gradation of GIMA: GIMA is one of the sister concern of Northern Group that can introduce new courses with new collaboration. and functions of a business from shared data stores.Latest technology can improve the production quality.
●International and Local Competitors: One of the major threats at international level which FAL and RMG sector of Bangladesh has to face. due to which the freight costs are increasing day by day and hence the cost of production. etc. high. local terrorism. unplanned infrastructure development. The companies who have their own electricity plants are save but those who don’t have are facing a major problem of shortage of electricity. their prices are going up and touching the sky. But like many other countries in the region. 41 . ●Shortage of electricity: The government of Bangladesh still unable to provide the required quantity of electricity and the demand of electricity is increasing day by day. ●The Running World-wide Economic Recession: Bangladesh's economy has weathered the downturn better than most. is also increasing rapidly which is becoming the reason of losing foreign customers of Bangladesh. sweats over plunging sales in key US and European markets and wonders whether job cuts for his and other firms could be just around the corner. The garments manufacturers. ●High petroleum cost: The high consumption of the petroleum is also the major issues because in international market.◘ THREATS: ●Political Instability: As we all know that the political situations of Bangladesh are not stable and it is getting into more complex situations. Each new government establishes its new rules and regulations which impact the industries badly. there are many companies in Bangladesh who are improving their product quality by acquiring new technologies. is international competition which is growing up and competitors are capturing the market share rapidly that’s why market share in foreign market is cutting down gradually. Reasons behind migration may be not getting desired salaries and incentives from the company or any other reasons. Now a day there are many major issues which are affecting the RMG sector like vandalism violent attack. ●Employee Migration: Migration of employees increased at Fashion Asia Limited. In local market. weaken policies and implementation. worker unrest. and wealthier countries slide into recession. its export sector has been badly affected as the crisis hits real economies elsewhere.
during my intern period. GM sir took me along with him in a pre-production Done meeting to have a practical experience. Study on knitting at knitting section of TIL. Done Done Done 23-04-09 25-04-09 26-04-09 41 .During my visit to the departments I tried to know about their setups and their work procedures.1 WORK PLAN AND TIME During my internship period I have visited every departments and sections of the organisation. Study on Sampling at sample section.Tongi as the intern employee Done and I was attached with Fashion Asia Ltd. Study on Cutting at Cutting section. I didn’t get much more scope to acquire in depth knowledge because of the time constrains. Study on Sampling at sample section.My workplan was directed by my practical supervisor. He assigned us with two of their factories at Gopalpur. Study on knitting at knitting section of TIL. GM sir briefed about the work plan and schedule. RESPONSIBILITIES AS A STUDENT INTERN 13. a sister concern of Northern Group to have the practical knowledge on knitting Done technology. characteristics of different types of knitted fabric that are producing. I was assigned to visit knitting section of Tosrifa Industries Ltd. My work plan and time is given below: Student’s Diary Date 15-04-09 Day 1 Day Wednesday st Job Description Remarks Report to the DGM at the corporate head office of Northern Group. I was assigned to visit and study on textile dyeing at dyeing unit of NCL at Tongi bscic.13. Done Done Done 16-04-09 2nd Day Thursday 3rd Day Saturday 18-04-09 19-04-09 20-04-09 21-04-09 4th Day Sunday 5th Day Monday 6th Day Tuesday 22-04-09 7th Day Wednesday 8th Day Thursday 9th Day Saturday 10th Day Sunday Study on Dyeing and special types of knitted Done fabrics at dyeing and knitting section at NCL at Tongi bscic.
operation breakdown for obtaining SMV’s for a garment. .27-04-09 28-04-09 29-04-09 30-04-09 11th Day Monday 12th Day Tuesday 13th Day Wednesday 14th Day Thursday 15th Day Saturday 16th Day Sunday 17th Day Monday 18th Day Tuesday 19th Day Wednesday 19th Day Thursday Were absent because of illness. I did consumption. Done Done Done Done 02-05-09 Done 03-05-09 04-05-09 05-05-09 Done Done Done Done 06-05-09 07-05-09 Study Merchandising Process at FAL.2 DAILY WORKING HOURS I followed their daily working hours according to their office time schedule. Study Merchandising Process at FAL. Usually 9am to 6pm is the office time schedule for the employees of FAL. Study on Sewing and stitching methods at FAL Sewing Department. Done 14-05-09 Last Day Thursday From 19th day to last day of my internship period I worked in merchandising department of Fashion Asia Limited. Study Merchandising Process at FAL. etc. Study on Sewing and stitching methods at FAL Sewing Department. Study on Printing at Printers & Printers a sister concern printing unit of Fashion Asia Ltd. Study on Sewing and stitching methods at FAL Sewing Department.GM (Marketing &Planning) sir was my Done mentor at FAL.costing. To Learn shipment process and documentation at FAL. during my internship period in Fashion Asia Limited.I have successfully accomplished the assignments given to me by my seniors at FAL. 13. Study on Finishing and Packing at Finishing section. Normally daily working hours are eight hours. 41 .
13. I have done consumption and costing for an enquiry.The new knowledge which I got from there that theory doesn’t go all together with real life situation. reviewing merchandising process at FAL. So to achieve the best we should cope with the situation and manage the work in little bit modification and technical approach. I feel proud that I had an opportunity to work with a modern structured apparel manufacturing company.Oneday due to illness of merchandisers I was assigned to reach some samples to the local liaison office of a multinational buying house. I have accomplished the job successfully. 41 .5 HOW EXPERIENCE IMPACTS MY CAREER This one month internship program will help me a lot to work in an apparel manufacturing industry. sampling process. 13.3 ACCOMPLISHMENTS During my Internship program I was given some assignments that have been accomplished successfully.4 NEW KNOWLEDGE ACQUIRED During my internship program I realized and acquired practical knowledge on production processs. I think this experience would be valuable asset for my future career. shipment process and mercahandising process.13.
fashion advertising. What we need a brand name for those products that all for marketing all those products? For these products a strong Brand name and strong product marketing is enough for promoting. Apparel and textile is only sector where processes of production. manufacturing. he/she may find entry-level opportunities as a management trainee. CONCLUSION Typically an apparel merchandising program is designed to prepare students to enter apparel merchandising positions in the apparel and textile industry. toiletry. and the promotion of fashion related products. luxuries products. To compete with others a company has to be technologically developed. fashion journalist. But in Apparel and Textile sectors the product comes after process. This experience will be my valuable asset for my future career path. event planner. assistant merchandiser. a Brand name and product marketing existed in this sector. fashion promoting. merchandise planner. As a Intern-Student I had the opportunity to visit all of the departments and sections of an apparel manufacturing unit. capacity. distribution. it is not strong enough for Apparels and Textile manufacturer to capture the market. If we take the example of another product say cosmetic. If anybody choose to become a apparel merchandising MBA graduate. Otherwise it will lose all the possible market in home ground and international ground. Although. they could open the door to various career paths. A degree in apparel merchandising provides students with product knowledge of textiles and apparel as well as an understanding of socioeconomic influences and business skills relevant to merchandising fashion.14. visual merchandiser. After a member of the apparel industry has an educational background in apparel merchandising. 41 . purchasing. With the acquired knowledge when I sent for the internship program in a manufacturing company I had the opportunities to justify acquired knowledge and also gain some practical experience on the subject. fashion photography. product development trainee. fashion forecaster. etc. and machinery. These positions include various aspects of design. machinery. quality control. and store managing. Merchandising is an exciting area of the fashion industry with abundant opportunities for those who commit themselves to their career goals. fashion display. and food products we always consider the product ultimate end items we never think about the process and machinery. fashion buying. and compliance come first than the product. capacity. In the class rooms we have been thought every thing that is needed for the apparel manufacturing business. fashion copyrighting. fashion boutique owner. They will have the knowledge to be professionally involved with fashion coordinating.
: Fashion Asia Limited. : Customs-Trade Partnership Against Terrorism. : Export Promotion Bureau. : Computer Aided Machine . : Tosrifa Industries Limited. : Cheap Value Synthetic. : Bangladesh Textile Manufacturers Association.15. : Standard Minute Value. : Bangladesh Garment Manufacturers and Exporters Association. : Northern Corporation Limited. : Computer Aided Design. 41 . : Personal Protective Equipment. : Garments Industry Management Academy : Human Resource Development. APPENDIX LIST OF ABRREVIATION BIFT BGMEA BTMA CAD CAM C-TPAT CVC CVS EPB FAL GIMA HRD MMR NCL PPE SMV TIL : BGMEA institute of fashion & technology. : Cheap Value Cotton. : Man Machine Ratio.