Acknowledgement

At first, I would like to express my deepest gratitude to our honorable Director of Institute
of Leather Engineering & Technology, Professor Dr. Aftab Ali Shaikh, Ph.D. who made
this industrial training possible.
I am grateful to our guide teacher Mr. Sobur Ahmed, Assistant Professor, Institute of
Leather Engineering & Technology, University of Dhaka for guiding us throughout the
entire training.
I am also grateful to Mr. Md. Shahnewaz, General Manager (Operation) of US-Bangla
Leather Products Ltd. for allowing us to train in his industry and providing us necessary
support.
Special thanks to Mr. Shahjahan Ahmed, Factory Manager, Mr. Divine Chakma, AGM
(Production) and Mr. Md. Allama Iqbal Hossain, Manager (Design, cost & efficiency)
for their valuable support.
Also, thanks to Mr. Mohim bosu and Mr. Rashedul Hasan, Executives, US-Bangla
Leather Products Ltd.
 Index

1. Executive summery 2
2. Aims and objectives 2
3. Introduction 3
4. Weekly progress 4
5. An overview of US-Bangla Leather Goods Ltd. 5
6. Plant information 6
7. Organogram 7
8. Machineries 8
9. Work environment 11
10. R&D section 13
11. Leather goods unit 14
12. Footwear unit 17
13. Storage and showroom 20
14. Safety measures 21
15. Manufacturing of a wallet 22
16. Manufacturing of a shoe upper 24
17. Products 28
18. Suggestions 31
19. Conclusion 31

Page | 1
 Executive summery

The report describes the details about the industrial training to US-Bangla Leather Products
Ltd. by Jahirul Islam Shovon, Department of Leather Products Engineering, University of
Dhaka, Session: 2014-15, Roll: 314. It includes weekly progress, an overview of the
industry, plant information, machineries, manufactured products, work environment,
safety measures and some recommendations at the end.

Aims and objectives

1. To train in a footwear and leather goods industry.

2. To get practical knowledge about footwear and leather goods manufacturing
process.
3. To get an idea about mass production system.
4. To learn the functions of different machines.
5. To compare between manual and automated manufacturing process.
6. To compare between institutional and industrial working procedures.
7. To observe the management and planning system in an industry.
8. To be acquainted with working environment.

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 Introduction

On 15 May, 2018, I, along with three other students from department of Leather Products
Engineering, Institute of Leather Engineering & Technology, University of Dhaka, started
two months’ industrial training at US-Bangla Leather Products Ltd. During those two
months, we observed manufacturing procedure of different leather products and footwear,
management system, and function and importance of different departments along with
machineries in the industry.
We had the opportunity to visit each and every departments and operate each and every
machinery under supervision. We made two wallets, a derby shoe, an oxford shoe and a
moccasin shoe using the factory resources. We also observed the manufacturing procedures
of some other leather products as well as footwear. The management along with the
workers were very helpful and patient with us the whole time.
Beside practical knowledge about production, we also learned about quality requirements,
quality assessment, administrative system, shipping procedure, marketing, accounts
handling, current situation and future of leather, leather products and footwear industry in
Bangladesh. In short, we got the opportunity to learn about each and every aspects of an
entire industry.

Page | 3
 Weekly Progress

Week-1 1. Visiting leather products section,

2. Observing machineries,
3. Observing materials and accessories,
4. Being introduced to different personnel,
5. Learning about the general measurements and manufacturing
procedures of wallet and ladies bag.
Week-2 1. Creating patterns for a bi-fold wallet from a given sample.
2. Manufacturing the bi-fold wallet,
3. Submitting the wallet to The General Manager,
4. Making corrections as per instructions.
Week-3 1. Creating patterns for a bi-fold wallet from own design.
2. Manufacturing the bi-fold wallet,
3. Submitting the wallet to The General Manager,
4. Making corrections as per instructions.
Week-4 1. Visiting footwear section,
2. Observing machineries,
3. Observing materials and accessories,
4. Being introduced to different personnel,
5. Learning about the general measurements and manufacturing
procedures of shoes.
Week-5 Eid holiday.
Week-6 1. Creating patterns for a derby shoe from a given sample.
2. Manufacturing the derby shoe,
3. Submitting the shoe to The General Manager,
4. Making corrections as per instructions.
Week-7 1. Creating patterns for an oxford shoe from a given sample.
2. Manufacturing the oxford shoe,
3. Submitting the shoe to The General Manager,
4. Making corrections as per instructions.
Week-8 1. Creating patterns for a moccasin shoe from a given sample.
2. Manufacturing the moccasin shoe,
3. Submitting the shoe to The General Manager,
4. Making corrections as per instructions.

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 An overview of US-Bangla Leather Products Ltd.

US-Bangla Leather products Ltd. is an emerging 100% export-oriented leather goods

manufacturer in Bangladesh. It is a joint venture initiative between United States of
America and Bangladesh which has emerged as one of the vital concern of US-Bangla
Group in the process of Group business diversification. They intend to provide various
range of leather bags, ladies bag and various leather goods & services precisely developed
to the needs of each client, focusing due emphasize on the management of their brands.
They prioritize product development and design, merchandising follow-up, quality control
and Just-In-Time (JIT) delivery.
Mission
To provide best quality leather products with competitive price to the International market
through maximum utilization of the country’s hides & skins with continuous growth in
order to have major market share. Their immediate motto is to explore the right market and
hit the target with vigorous propulsion to redefine the leather fashion technology in the
existing global leather products market.
Vision
1. To be one of the best leather goods manufacturing industry in the world by 2020
and be the company that their customers, shareholders and the society want.
2. To be the preferred and most trusted name in the leather goods manufacturing arena
in the world by 2020.
Core Values
1. Customer first
2. Loyalty
3. Commitment
4. Cutting Edge/State of the Art/Pioneering Technology
5. Creativity
6. Integrity
7. Social Responsibility

Page | 5
 Plant information

Factory Address: US-Bangla Leather Products Ltd., Holding # 38/1, Kuturia, Ashulia,
Savar, Dhaka 1344.
Corporate Office US-Bangla Leather Products Ltd., House # 77, Sohrawardy Avenue,
Baridhara Diplomatic Zone, Dhaka -1212.
USA Office: Bangladesh Plaza, 37-15, 73ST, Suite-202, Jackson Height, NY-11372
Website: www.us-banglaleather.com

Total factory area: 80,000 sq. ft.

Total workers: 400
Total store area: 15,000 sq. ft.
Total production area: 50,000 sq. ft.
Total office and showroom: 10,000 sq. ft.

Factory capacity: US-Bangla Leather Products Ltd. currently produces 15,000 bags, 20,000
small leather goods and 20,000 shoes per month. The details information has been given
according to the production lines for bags, small leather goods and shoes.

Additional Facilities:
1. Day care center
2. Health care center
3. Canteen
4. Guest house for buyers
5. Prayer room.

Page | 6
 Organogram
Management

GM
(Operation)

Quality
AGM Factory AGM
Control In-
(Accounts) Manager (Production) charge
Manager
Senior Merchandising Commercial Production
(Design, Cost,
Executive manager Manager Manager Efficiency)

Senior Senior Senior Senior

Executive Merchandiser executive Executive Executive

Junior
Merchandiser Executive Executive Executive
Executive

Junior Junior Junior Junior

Merchandiser Executive Executive Executive

Workers

Operator

Assistant
Executives Supervisor Helper
Supervisor

Line man

Page | 7
 Machineries
Leather Goods Unit
No. Section Description No. of machines
1. Atom 3
2. Clubbing press 7
Cutting section
3. Stip 1
4. Bim press 1
Total 12
5. Skiving machine 11
Skiving section
6. Splitting machine 1
Total 12
7. Emboss machine 1
8. Dryer machine 2
9. Color section Spray booth 1
10. Color machine 10
11. Coul machine 1
Total 15
12. Flatbed machine 36
13. Cylinder bed machine 23
14. Post-bed machine 2
15. CNC machine 3
16. Eyelet setting machine 1
17. Lactic spray machine 1
18. Sewing section Hot mirk machine 2
19. Folding machine 1
20. P.P machine 1
21. Hot iron 1
22. Hot marking machine 1
23. Thread burning machine 4
24. Baking machine 1
Total 77
Grand total 116

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 Footwear Unit
No. Section Description No. of Machines
1. Sewing arm cutting machine 10
2. Travelling head cutting 1
machine
3. Splitting machine 1
4. Pneumatic lining stamping 2
machine
5. Pneumatic insole stamping 1
machine
Cutting section
6. Thermo adhesive attaching 1
machine
7. Vamp climping machine 1
8. Pneumatic seam pressing & 1
taping machine
9. Cutting boot splitting 1
machine
10. Skiving machine 6
Total 25
11. Shank skiving machine 1
12. Shank riveting machine 1
Insole section
13. Insole molding machine 1
14. Insole trimming machine 1
Total 4
15. Post-bed single needle 25
16. Post-bed double needle 8
17. Post-bed heavy duty single 2
needle
18. Zigzag 4
19. Flatbed single needle 2
Sewing section
20. Interlock 1
21. Strobel 1
22. Cylinder bed single needle 2
23. Toe puff attaching 1
24. Lining trimming 4
25. Pressure machine 1
Total 49
26. Lasting & finishing Back part molding machine 1
27. section Toe humidifier machine 1
28. Toe lasting machine 1

Page | 9
29. Side & back humidifier 1
machine
30. Heel & seat lasting machine 1
31. Automatic heat setter 1
32. Heel-seat pounding machine 1
33. Ladies shoe pounding 1
machine
34. Flat/hand ironing machine 2
35. Thermo ironing/hot air 4
Lasting & finishing blower machine
36. section Brushing machine 3
37. Roughing machine 3
38. Reactivating machine 1
39. Hydraulic universal sole 1
attaching machine
40. Vacuum sole attaching 2
machine
41. Chiller unit 1
42. Delasting machine 1
43. Pneumatic nailing machine 1
44. Boot leg ironing machine 1
45. Top lining preforming 1
machine
46. UV germ killer machine 1
47. Pneumatic moccasin 1
preforming machine
48. Spray booth 1
49. Humidifier for finished 1
goods in warehouse
Total 33
Grand total 111

Page | 10
 Work environment

The work environment at US-Bangla Leather Products Ltd. is quite good. They have
sufficient work space. The factory is well equipped with necessary machineries. There are
proper light and air in the work area. There is canteen, day care center and prayer room for
the workers. The behavior of supervisors with workers is quite friendly. The workers
seemed to be working with satisfaction.

Fig: Workers working.

There are two different sections for leather goods and footwear. There is also a R&D
section for creating new and unique design to compete with the outer world in design and
quality.

Fig: Outside of the factory.

The overall area of the factory is kept clean. Maintenance is done regularly and efficiently.
The outside environment of the factory is also clean and healthy.
According to the environmental policy of the company, they are committed to:

Page | 11
 1. Establish, implement, maintain and improve a ISO:14001 compliant Environmental
Management System.
2. Set, monitor and review environmental objectives, targets and programs yearly.
3. Comply with all compliance obligations and other requirements related to its
environmental aspects.
4. Implement measures to reduce adverse environmental impacts and prevent the
pollution by continual improvement.
5. Document, implement, maintain and communicate the Environmental Policy to all
their employees through environmental education and awareness-raising activities.
6. Make this Environmental Policy available to the interested parties (consumers,
citizens, local and national authorities) and to create good communication with
customers and communities at the local and international levels.
All staff has a responsibility in assisting the company to consistently meet high quality and
environmental performance standards identify improvements in operational practices
where possible.

Page | 12
 R&D Section

The Research and Development section creates designs and patterns for manufacturing
products. The sequence of operation in R&D section is as follows:
Design phase
Recognition of needs
↓
Problem definition
↓
Synthesis
↓
Analysis and optimization
↓
Evaluation
↓
Presentation
Pattern making phase
Preparation of basic pattern
↓
Preparation of working pattern
↓
Preparation of cutting pattern
↓
Pattern grading
↓
Identification marking
↓
Checking

The patterns created in R&D section are then sent to Leather Goods Department and
Footwear Department for product manufacturing.

Page | 13
 Leather Goods Unit
The products made in this department are ladies bag, ladies purse, gents bag and wallet.
The sequence of operation in leather goods department is as follows:
Receiving pattern
↓
Cutting leather and lining
↓
Skiving
↓
Assembling
↓
Stitching
↓
Finishing
↓
Packaging
↓
Storing
Cutting section

Fig: Cutting section.

The leather and lining materials are cut with hydraulic swingarm cutting press machine in
this section. The sequence of operation in cutting section is as follows:

Page | 14
 Receiving pattern
↓
Selecting dies according to pattern
↓
Checking material for defects
↓
Placing material in cutting machine
↓
Placing dies on material
↓
Cutting materials by running machine
↓
Checking cut materials
↓
Sending cut materials to skiving section
Skiving section

Fig: Skiving section.

The cut components are skived with skiving machine. The sequence of operation in this
section is as follows:
Receiving components
↓
Checking components
↓
Skiving as per marking
↓
Checking skived components

Page | 15
Assembling section
The cut and skived components are assembled into product in this section. The assembled
product is then sent to sewing section for stitching.

Fig: Assembling section.

Finishing section
The assembled products are finished in this section. Lace, strap etc. are attached, stamping
is done, glazing is done and finally the product is packaged and stored.

Fig: Finishing section.

Page | 16
 Footwear Unit
The products made in this department are ladies court shoe, gents oxford shoe, gents derby
shoe, sandals and boot. The sequence of operation in footwear department is as follows:
Receiving pattern
↓
Cutting leather and lining
↓
Skiving
↓
Edge and topline treatment
↓
Reinforcement
↓
Decorative operation
↓
Back part moulding
↓
Toe puff attaching
↓
Upper and lining attaching
↓
Feather edge stitching
↓
Insole attaching
↓
Upper conditioning
↓
Lasting
↓
Heat setting
↓
Toe pounding
↓
Heel crowning
↓
Surface preparation
↓
Heat reactivation
↓
Sole attaching

Page | 17
 ↓
Shoe finishing
↓
Labelling
↓
Packaging
↓
Storing
Cutting section
The cutting section of footwear department is different from that of leather goods
department but the working procedure and machineries are same.

Fig: Cutting section.

Skiving section
The skiving section of footwear department is also different from that of leather goods
department but the working procedure and machineries are same.

Fig: Skiving section.

Page | 18
Closing section
In this section the shoe upper is closed. Then the upper is sent to lasting section.

Fig: Closing section.

Lasting section
The pre-lasting, lasting and post-lasting operations are performed in this section.

Fig: Lasting section.

Finishing section
Shoe finishing, lacing, ornamentation, labeling, packaging, storing etc. operations are
performed in this section.

Page | 19
 Storage and Showroom

The leather goods and footwear department use the same storage for keeping stock leather.
The storage room for keeping finished products is different but again same for leather
goods and footwear.

Fig: Storage.
The US-Bangla Leather Products Ltd. has an in-house showroom. Some samples of
finished leather goods and footwear are kept there for guests and buyers.

Fig: Showroom.

Page | 20
 Safety measures

The safety and security of US-Bangla Leather Products Ltd. is very good. Some aspects of
their safety and security system are as follows:
1. Security camera
2. 24 hours monitoring
3. Fire alarm
4. Fire extinguisher
5. Fire hose
6. Fire bucket
7. Emergency exit
8. Emergency safety training for workers
9. Standard operating procedure

Fig: Safety equipment.

Page | 21
 Manufacturing of a Wallet
We made two wallets- one from a given sample and one from our own design at US-Bangla
Leather Products Ltd. during our training period. The basic manufacturing procedure is
same for all wallets. The procedure is as follows:

Fig: Wallet made from given sample.

Measurement:
Name Size Folding allowance Cutting allowance
Upper leather 23.4×9.5 cm -- 2mm all over
Upper lining 23.2×9.5 cm -- 2mm all over
Upper Testa 23.4×1.5 cm -- 2mm (left &right)
2nd part leather 22.7×4 cm 10 mm (top) 2mm (left & right)
2nd part lining 22.7×9 cm -- 2mm (3 sides)
Asther 22.4×8.7 cm -- --
Pinali 9.8×5.1 cm 8mm (top & right) 2mm (left &
bottom)
CC 0.9×9.8 cm 6mm (top), 2mm (left), 9mm
8mm(right) (underlay)
CC1 0.9×9.8 cm 8mm (right) 2mm (top &
bottom)
Middle part 4×8.7 cm -- 2mm (top-bottom)
Binding 8.7×1 cm -- --
Flap 7.5×8.3 cm 6 mm (3 sides) --
Counter flap 3.6×8.3 cm -- 2mm all over
Coin pocket 8.3×7 cm 8 mm (3 sides) 2mm (bottom)

Page | 22
 Gusset 3.5×7 cm 6 mm (top & --
left/right)

Procedure:
1. Necessary basic and working patterns are created.
2. Components are cut according to the patterns.
3. Necessary splitting and skiving are done.
Splitting measurements
Pinali 1.3 mm Flap 1.2 mm
CC 0.9 mm Flap counter 0.7 mm
CC1 1.0 mm Coin pocket 1.3 mm
Side binding 0.4 mm 2nd part 0.7 mm
Gusset 0.5 mm Upper testa 0.7 mm
Middle part 0.8 mm

4. Pinali, CC pockets and CC1 are attached.

5. Side binding is attached and stitched with it.
6. Flap and counter flap are attached and stitched.
7. The prepared flap is stitched with the base for pocket.
8. Lining is attached with the coin pocket.
9. Upper part of the coin pocket is folded.
10. One side of each of the gussets are attached with the coin pocket.
11. It is then attached with the pocket base.
12. Middle part is attached and stitched with the asther lining.
13. The left and right part are placed and attached with the asther lining.
14. Net cut is done.
15. The second part leather and lining are attached and stitched.
16. The second part is attached with the asther part on three sides.
17. The upper leather and lining are attached.
18. The upper testa is attached and stitched with the upper leather and lining.
19. Net cut is done.
20. The complete upper part is placed behind the asther and second part accordingly.
21. Stitching is done on three sides.
22. Trimming is done accordingly.
23. Edge coloring is done along the raw edges.

Page | 23
 Manufacturing of Shoe Upper
We made three shoes- a derby, an oxford and a moccasin, during the training period at US-
Bangla Leather Products Ltd. The manufacturing procedure of the derby shoe is given
below:

Fig: Derby upper made from sample.

1. A size 42 last is masked.
2. Design of the shoe is created on the masking tape.
3. Masking is removed and set on a pattern board.
4. Mean form, standard and sectional patterns are created.
5. Components are cut according to the sectional patterns.
6. The materials and components are checked for damage.
7. Skiving is done along the edges of toe cap, vamp upper, quarter upper and counter
upper.
8. Stitch marks are given.
9. Counter and quarter are attached using adhesive and stitched.
10. Reinforcement tap is attached along the topline.
11. The topline is folded using adhesive and stitched.
12. Heel grip and quarter lining are attached and stitched.
13. The upper and the lining parts are attached using adhesive.

Page | 24
 14. Stitching is done across the topline.
15. The excess lining material along the topline is trimmed.
16. Four eyelet holes on each side are made.
17. The tongue and vamp lining are attached and stitched.
18. The vamp upper and toe cap are attached and stitched.
19. The combined vamp upper and the vamp lining are attached and stitched.
20. The combined parts of step 12 and 15 are attached keeping quarter over vamp and
stitched.
21. Finally, the derby shoe upper is closed.

The manufacturing procedure of the oxford shoe is given below:

Fig: Oxford upper made from sample.

1. A size 42 last is masked.
2. Design of the shoe is created on the masking tape.
3. Masking is removed and set on a pattern board.
4. Mean form, standard and sectional patterns are created.
5. Components are cut according to the sectional patterns.

Page | 25
 6. The materials and components are checked for damage.
7. Skiving is done along the edges of toe wing, vamp upper, quarter upper, facing and
counter upper.
8. Stitch marks are given.
9. Counter, quarter and facings are attached using adhesive and stitched.
10. Reinforcement tap is attached along the topline.
11. The topline is folded using adhesive.
12. Heel grip and quarter lining are attached and stitched.
13. The upper and the lining parts are attached using adhesive.
14. Stitching is done across the topline.
15. The excess lining material along the topline is trimmed.
16. Four eyelet holes on each side are made.
17. Tongue lining is attached with tongue upper.
18. The tongue is attached with facing and stitched.
19. Vamp lining is attached with quarter lining below the quarter upper and stitched.
20. Vamp upper and toe wing are attached.
21. The combined parts of step 15 and 16 are attached keeping vamp over quarter and
stitched.
22. The bottom middle part of the counter is stitched grain to grain.
23. Finally, the oxford shoe upper is closed.

The manufacturing procedure of the moccasin shoe is given below:

1. A size 42 moccasin last is taken and cleaned.
2. The last is properly wrapped with masking tape.
3. The heel point, toe point, instep point and vamp point are identified.
4. Necessary markings as per design are made over the masked last using pen.
5. An elongated hole is made beneath the foot from a position behind the flexing
point to that of heel portion.
6. The vamp portion and apron are separated and the bottom portion is prepared.
7. Demasking is done and the tape is flattened on a platform.
Page | 26
 Fig: Moccasin upper made from sample.
8. Form patterns are created.
9. Mean form patterns are made from forms.
10. Standard pattern is created through alteration of the mean form.
11. Sectional patterns are created adding necessary allowances to the standard
pattern.
12. Leather, lining, interlining and insole are cut using the pattern.
13. Necessary splitting and skiving are done on the upper components.
14. Interlining is fused with the upper applying heat and pressure.
15. Lining is attached with the upper using solution.
16. The backpart of the vamp is stitched together.
17. The topline is stitched with the vamp opening.
18. The apron is attached with the vamp using moccasin seam.
19. Insole is attached with the last bottom.
20. The last is inserted using force lasting method.
21. Toe is preformed in toe preforming machine.
22. Backpart is molded using backpart molding machine.
23. The completed part is heated and hammered to remove creases.
24. Finally, the moccasin upper is prepared.

Page | 27
 Products
Ladies bag:

Gents bag:

Page | 28
Ladies purse & Wallet:

Ladies shoe:

Page | 29
Gents shoes:

Boots:

Page | 30
 Suggestions

Though the working and management system US-Bangla Leather Products Ltd. are very
good, they still need to improve in some aspects. Here are some suggestions:

1. More skilled permanent personnel should be employed at management level.

2. Computerized technology should be used in designing to create more accurate
patterns.
3. Extra care should be taken in cutting to save material.
4. The working area should be cleaner and more disciplined.
5. Automated machines should be introduced in material handling.
6. Personal protective equipment (PPE) should be used.
7. There may be dress codes for workers at different sections to distinguish easily.
8. New and creative designs should be used.

Conclusion

Industrial training in student life is very essential for engineering students. Students can
get practical knowledge about their institutional education. Institutional education is
effective only if it can be applied in productive works. Otherwise, it will be worthless. An
industrial training helps us to know the lack in our institutional education. From this
industrial training, we have learned about new operations, technical works, product quality
and quality assurance which will help us in quick adaptation in the industry after
completing leather products engineering education.

Page | 31