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Faculty of Engineering

Department of Textile Engineering

Supply Chain Management in Apparel Order


Process

Course code: TEA-504 Course title: Project

Submitted by:
Md.Raihan Islam
171-32-339

Supervisor:
Prof. Dr. Md. Mahbubul Haque
Head, Department of Textile Engineering

A thesis submitted in partial fulfillment of the requirements for the degree of


Master of Science in Textile Engineering

Month, Year
Acknowledgement
Project is an academic function of Daffodil International University. I express my heartiest
thanks and gratefulness to almighty God for His divine blessing and possible to complete this
project successfully. Many people helped me in conducting this thesis and I would like to
thank all of them in particular, my parents who encouraged and support me a lot in all the
way of work, my teachers and seniors of Shyamoli Textile Engineering College and my
teachers of textile department of Daffodil International University. I am highly delighted to
express my regards and gratitude to honorable Prof. Dr. Md. Mahbubul Haque, Head of the
Textile Department Daffodil International University for giving me the opportunity to
accomplish the project on “supply chain management in apparel order process”.

Above all, I would like to acknowledge my deep debt to my teachers of textile department for
their kind inspiration and help made it possible to complete this thesis.

I would like to acknowledge that I tried to acquire and give the accurate information in the
report. I remain responsible for the inadequacies and errors, which doubtless remain in the
following report.
Declaration

This project report prepared by Raihan Islam, bearing ID: 163-32-328 is approved for partial
Fulfillment of the requirement for the Degree of Master of Science in Textile Engineering.
The student has completed her project on “Supply Chain Management In Apparel Order
Process” under my supervision. During the project period I found him Sincere, hardworking
and enthusiastic.

Supervisor
Prof. Dr. Md. Mahbubul Haque
Head, Department of Textile Engineering
Daffodil International University
List Content
Abstract
Bangladesh industry improvement is desired in reducing the provision time needed to
provide and fulfill the orders placed by foreign corporations. To decrease the supply time
needed for manufacturing RMG is to increase domestic linkage growth way we are able to
have deep level enhancements within the RMGI too. Provide time refers to the time needed
for activity ordered garment product when the export order has received. Exploitation
fashionable quick and effective machinery will cut back time taken to deliver the order. The
implementation of SCM had been helpful as this helped in rising the communication
channels, production and services of the businesses. Considering the vital role of attire
makers inside the worldwide chain, I conducted a look on the Bangladesh clothes trade and
concentrate on many vital provide chain operational problems. The objectives unit to analyze
attire provides chain matters like new orders, raw materials provide, production processes
and provide related to finished product delivery. I collect information for trade statistics,
conducted structured interviews and send survey questionnaires to garment makers. Analysis
shows attire makers unit Endeavour for property business growth. I determine connected
provide chain practices influencing the trade, set pointers for improvement and provide
recommendations for property.
Chapter-1:

Introduction
1.1 Introduction
The trend commercial enterprise should be a most important sector in Bangladesh. For this
reason, corporations in operation at intervals this commercial enterprise need to then be
capable to apply commercial enterprise approaches that may additionally facilitate preserve
the enlargement of the wear sector. This implies that by way of editing a range of the current
commercial enterprise procedures of the apparel corporations, like their offer chain
administration systems, non-stop development and improvement inside the commercial
enterprise is additionally ascertained. By suggests that of attribute the present provide chain
administration practices of some Bangladesh garment corporations, commercial enterprise
areas for improvement may also be known. This successively might change the formula of
higher provide chain administration practices that may also make contributions to the
persistent development of the garment industry? The activities of the provision chain
administration at some stage during this Bangladesh sector can also possible support its
regard to the international market. provide chain management, the data between commercial
enterprise companions rectangular measure optimized and collaborated; most importantly ,
provide chain administration systems facilitate in decreasing inventories, that successively
will decrease operational prices, compress order cycle time, beautify plus productivity
moreover as expand the companies’ responsiveness to the market (1997). Other than these
edges, the garment enterprise is in a very role to get quick response through cost effective
provide chain administration practices (1998). Quickly response got to be a assemble relating
the collaboration and sharing or info among makers, suppliers and distributors, allowing them
to retort quicker to the wants of the patrons. Previous research have stated that QR assemble
led to by way of provide chain administration is high-quality to the rag trade moreover on
fashion-oriented businesses (1995; 1998). Another issue that relates the industry to SCM is
that the companies’ relevancy the retailers. Whereas some apparel companies distribute their
product on to shoppers, most makers make use of the offerings of the retailers. The
equipment of accomplice degree SCM machine on the contrary hand helps in strengthening
the hyperlink between each birthday celebration moreover as in accomplishing high-quality
commercial enterprise outcomes. Considering that the apparel region encounters the count
number of demand uncertainty, SCM permits the businesses to speak with their retailers; this
feature of the SCM approves them to forecast product demand collectively. The participation
of the outlets with the SCM machine of the corporate facilitates the apparel companies to
induce treasured customer understanding like end-customer demand levels; this may then
assist in reducing the manufacturers’ mistakes in determinative fabric and manufacturing
volume. Order time administration is one in each and every of the big issues for Asian united
states readymade trend industry. Foreign emptor is possibly going to desire short main time
for producer the attire. As a result of apparels is seasonal demand. Patrons provide the orders
for his or her consumer demands. If the meeting construct lengthen emptor can’t wedged the
season. Within the start of Nineties, the interval wont to be 120-150 days (Azad, 2004)
alternatively in 2007, it certainly was once reduced to 30-50 days, i.e. at now it's 90-100 days
(Khan, 2007). China needs completely thirty days due to their material and extraordinary
backward linkage services additionally as export pleasant administration and Supporting,
policy. Its 45-60 days in Bharat and Pakistan (Nuruzzaman, 2008). So it appears that inside
this state of affairs Asian us RMG exchange might not be prepared to vie successfully inside
the worldwide marketplace for the existence of remarkably while interval. this may be
specifically the foremost disadvantage area of present evaluation.

1.2 Object of study


The study on Bangladesh industry is that the foremost important supply for monetary
development of Bangladesh demands examination and evaluation of four-dimensional aspect
of garment sector and its affect on the circumstance of Bangladesh.

In such a context, the foremost goal of the determine about is to appear at, appraise and
analyze Business technique and buyers order time, provide chain administration industry and
judge the strategies utilized by some attire business operators in land.

1.3 Aim of the Research


The universal intention of the evaluation is to suppose about the People's Republic of
Bangladesh garment administration methods employed in the textiles and apparel sector. This
could be self-addressed through case research of firms at completely unique points of the
chain, ranging from fiber producers downstream within the chain to makers and foreigners.

1.4 Research Methodology


The information is collected on main also as on secondary basis. The secondary information
used to be utilized in the study. Those have been collected from different publications, books,
Bangladesh Economic assessment and consequently the annual reports, audit reports,
Interview of key individual of the garments industrial plant, overseas consumers. During this
evaluation qualitative methodology has been used. Within the qualitative methodology we
are in a position to confirm on the other hand men and women experience or what they have
confidence a chosen disadvantage that rectangular measure terribly applicable for the
duration of this analysis. In the principal the descriptive evaluations approach. Has been
used. However inside the searching section of the analysis, in-depth interviews are conducted
with the suppliers /manufacturers (Owners) and consequently the applicable bodies and
affiliation.
Chapter-2:

Literature Review
2.1 Literature Review

of knit materials unit foreign to create clothes for export (Rashid, 2006; Rahman and Anwar,
2006). That’s why this sector must maintain an extended provide chain (backward and
forward). Besides rudimentary application of ICT and inefficient port management limits its
ability to retort quickly to push amendment that's incredibly essential within the style market
(Abdullah, 2008). So this trade takes most interval to method AN order (Hege, 2004;
Nuruzzaman, 2008; Kabir, 2007; Siddiqi, 2007). In Bachelor of Divinity the interval for
attire export varies between 90-120 days, whereas the time for Sri Lanka is concerning 19-45
days, China 40-50 days and for state 50-70 days for similar merchandise (Rahman and
Anwar, 2006; Kabir, 2007).

Lam and Postle (2006) have reviewed the thinking of supply chain administration in fabric
and apparel supply chain administration in Asian nation. They referred to the strengths and
troubles long-faced by using the Asian country fabric apparel provide chains. They argued
that Asian country garment enterprise is normally no longer attentive to the concept of grant
chain administration and industrial benchmark for every producing and advertising and
marketing industries in Bangladesh and consequently the supply chain overall performance is
beneath the globe average.
Due to the developing depth of opposition in every native and worldwide commercial
enterprise sectors, many companies and repair suppliers have complete the necessity to
improve extra strategic techniques for managing supply chains. These affectional elements
and recognition then junction rectifier to the match of tradition SCM structures up to the
superior structures firms follow at the present. The evolution of provide chain administration
took place for the duration of the 1990s; at now, collaboration between makers and suppliers
had been set up so as to boost historical procedures in supply administration functions. At
equal time, shops in addition as wholesalers had built-in their provision operations moreover
as a consequence on attain greater aggressive advantages (2002).

yarn, to fabrics, to accessories, to clothes, to commerce and to promoting. The strange traits
of apparel supply chain is quick product existence cycle, high volatility, low foregone
conclusion and high impulsive getting. These elements convey air mass to apparel outlets to
control their supply chains. Furthermore in today’s aggressive surroundings, markets are
getting extra international, dynamic, and customer-driven and customers are exacting extra
selection, greater high-quality and repair, collectively with each accountability and quicker
delivery.
Yurif (2009) on his article regarding “Uzbekistan’s textile industry: alternatively will its
improvement attainable be captured? Center for Economic Development annual report”
determined that thanks to excessive opposition in native and worldwide commercial
enterprise sectors, most players inside the trend enterprise have resorted to innovative
approaches that of dealing with supply chains. Such initiatives end result in the enlargement
of unique SCM structures to a lot of technically superior and accelerated approaches that.
There has been dynamical of grant chain administration came about from the Nineteen
Eighties up to gift. With a lot of cooperation amongst makers and suppliers, SCM has been
improved greatly. However, there are a unit nonetheless huge challenges due to the fact the
resources don't appear to be definitely used and new fashions ought to be created to make an
improved commercial enterprise setting.

Christopher & Peck (1997) file the three standards inside the apparel market, time to
market; time to serve and time to react honestly suggests that the planet commercial
enterprise placing is consistently making an attempt to locate methods that of decreasing
interval so as to serve clients higher. Interval discount is imperative in supply chain due to
the fact it comes with cost saving, charge for money and consumer royalty.

2.2 Supply Chain Management in Apparel Industry

2.2.1 Supply chain and supply chain management:


Figure 1: Supply chain management

Moreover in today’s aggressive atmosphere, markets have come to be extra international,


dynamic, and customer driven, at any place clients rectangular measure stern extra selection,
greater quality, and repair, as properly as irresponsibleness and faster delivery. Therefore, to
verify growth, it is grow to be fundamental for the rag alternate to be extra participative and
reconciling. Ancient, provide chains square measure seen as a go with the flow line, at any
place enter enters at one end and transforms to output at the contrary finish. This can be
pretty static and is relevant for product that rectangular measure dynamic much less often.

2.2.2 Responsiveness of supply chain:


In a in a timely fashion ever-changing aggressive world, there may be a want to improve
companies and supply chains that place unit appreciably a lot of responsive than the existing
ones. The responsiveness of the availability chain gadget are regularly outlined due to the fact
the potential of the availability chain to reply purposefully associate degreed internal an
suitable time-frame to customer requests or adjustments inside the marketplace. Attire
markets location unit comparable with fast modification and as a result, industrial success or
failure is really decided by using the organization’s responsiveness.
Across commercial enterprise sectors, like trend merchandise, non-public computers,
customer bodily science, and cars, firms place unit thinking about approaches to lengthen
their responsiveness to fulfill patron needs by way of providing excessive product selection
with short lead instances.

2.2.3 Investigation of Apparel Supply Chain:


In most case attire producing organization is harried to form the downy offer chain so as to
deliver clothes to the customer on time in addition as gain the margin of profit by reducing
superfluous waste or muda from chain.
Figure 2: Supply chain of typical apparel manufacturer
Figure 3: Proposed apparel supply chain network for the manufacturers
2.3 Impact of Imposition of GSP & Quota

2.3.1 Short term impact:

2.3.2 Long Term Impact:


2.3.3 Role of Preferential Treatment under MFA and GSP:

3.2 RMG Business Structure

Source: Nuruzzaman, 2007


Figure3.1: Business structure and raw materials collection process
Chapter-3:

Materials and Methods


3.2 Analysis of Supply Management of Apparel Orders
3.2 Analytical Work
It may want to be already stated that producing RMG is a client dominating offer chain
device at any place garment producers have a truly limited role as most of the companies in
People's Republic of Bangladesh rectangular measure of CM especially based. Contrary, even
with a confined position in offer chain industrial plant have to take in high-quality strain to
fulfill the time interval. During this specific business, suppliers are not static and giant
numbers of suppliers rectangular measure concerned to create one shirt of a precise vogue.
For identical client it’s now not truly that supplier’s list and matters are identical. The
quantity of suppliers varies counting on vogue specifications. Mr. Kajal, leading a team of
merchandisers, hip that there rectangular measure in reality twenty things needed for one
shirt.

Table 3: A list of common items/materials

Produc Items
t
Men’s Main Sewing Finishing
woven Thread, Pin, Poly, Carton,
Shirt Fabri Button, Plastic clip, M-
c Clip,
Interlining, Butterfly, Neck
label (main, board, Back board,
size, fit, Collar insert, Collar
care, bone, Poly sticker,
barcode), Tag pin, Carton
Zipper, sticker, Price ticket,
Elastic, etc. Tie (if needed).
days for latest order with native materials. This can be essential to say here that in knit and
denim substances People's Republic of Bangladesh is sort of independent currently. From
then on pinnacle of interviews the interval in two definitely distinct intervals is showed, as
below- Table 4: Previous and Present Lead Time

Year 2000 2014

Woven 120 – 150 days 60- 75 local

(imported)

90- 120 imported

Knit 90 -120 days 30 – 45 days repeat

– local

60 -75 days fresh


Mr. Afzal, the industrial plant supervisor of twenty-one lines, commented that greater than
shortened interval maintains their manufacturing group underneath giant pressure. He said,
worker’s abilities and productiveness conjointly superior than that of a long time before.

Ms. Sadeka, a bourgeois in an exceedingly shirt industrial plant offers with five clients of
quite a number countries. To manipulate all those customers, she follows a imperative Path
System. In preserving with her, pretty ninetieth cases, she can’t preserve accomplice initial
arrange. Within the integral path she continues accomplice order standing into three phases –
a) Plan: She makes arrange supported order confirmation of the patrons, it’s the each parties’
agreement. b) Forecast- once obtaining the information from the fabric provider on explosive
hint detection (Expected Date of Departure) she forecasts date of cloth arrival c) Actual – It’s
the date of execution of any arrange.

Out of higher than 10 orders none of them was shipped as at first planned. Generally
industrial plant has got to keep cargo date even as soon as 10 days’ late begin, because of
buyers’ fault. The import branch offers the vessel role of foreign substances towards any
express order(s) and updates the clearing documents' standing. supported the forecasted
vessel and tentative clearing date, the meeting designing branch allocates the assembly line(s)
in consultation with all the concerned to catch the buyer's nominative and authorized vessel.
Within the chain-production method, the total perform can also give way because of any
missing or susceptible links. At the time of importation, if any instrumentation rolls over at
transit or gets delayed in clearing or pile at ports due to the fact of hartal (general strike) or
choice political platform, the meeting lines can continue to be vacant. Contrary, shoppers
make plans to show their merchandise at the show rooms primarily based on their pre-
approved vessel's ETA (expected time of arrival).

Table 5: Deviations among plan, forecast, and actual dates


Their classified ads attain the shoppers consequently, and if it is for the manufacturers' fault,
then they are doing no longer once in a while prolong their cargo date. Ultimately, the
makers bought to entire the air freight at their price to satisfy the buyers' ETA. Except
substances delay, workers’ absence -- a actually frequent downside for the trade build matters
worst. To conceal the target production, a manufactory needs to pay overtime, extra-overtime
to the staff. Even this immoderate work isn't viable pro re nata, on compliance floor.
Chapter-4:

Discussion of Results
4.1 Discussion of Results

The RMG enterprise of East Pakistan nonetheless plays the role of tailor inside the clothes
business. the preferred substances and confined add-ons until currently return from abroad.
The business is closely enthusiastic smitten by imports and had to pay about 55-75 days to
import substances from overseas (Nuruzzaman, 2007). This surroundings is that the foremost
reason for long time interval. Bangladesh garment export in extent is growing @ 15-20 p.c
for the last 20 years, whereas Bangladesh RMG are relying completely on Chittagong port
(Nuruzzaman, 2007). The facilities of Chittagong port haven't exaggerated at a similar rate.
The containers unbroken caught up inside the port and plenty of containers remain packed for
15-20 days, that is needed to be unharness at intervals three days. If the uncooked substances
continue to be idle within the instrumentation at Chittagong port for 10-15 days, the garb
enterprise would positively face a heavy negative influence (Kutubuddin Ahmed, 2002). Per
companion estimate, it takes concerning four days for merchandise to succeed in Chittagong
from Singapore. However in a {very} very sharp distinction, it takes concerning 18 to 19
days or nearly three weeks on the average for a similar merchandise to jaunt the upcountry
instrumentation depot (ICD) at Kamalapur in country wide capital. Besides the dilatory and
cumbersome customs system and port operations conjointly extensively prolong the motion
or unleash of products. In Chittagong port it takes regarding vi days to unload merchandise
from a ship whereas for a comparable merchandise it takes simply few hours in Singapore
(M. Taheruddin, 2004). Regarding port management man. Anisul Haque, MD of
Mohammadi cluster and former president of BGMEA explicit, “Unfortunately we have a
tendency to are disbursal 15-20 days to get hold of our materials from ocean port to our
manufacturing plant and it is taking section in the most position to lengthen lead time”. as
Figure: 4.1 Basic Supply chains of Bangladeshi RMG Industries

The existing calculable time from cause Q to motive R is senseless. Here the most duties is
unloading the instrumentation and carry it to the producing purpose. The total process may
also be performed by using completely a pair of or three days thru comparatively cheap
administration in port and smart facility. However due to the fact of unskillfulness of port
management and poor facility it takes fifteen to twenty. From then on top of remark it's clear
to U.S. that, solely for import of raw substances Bangladeshi makers’ rectangular measure
forced to pay 55-75 days additional. Therefore import dependency for materials is that the
predominant cause of longer interval. From then on top of discussion, it looks that the makers
of RMG region in the essential face "order lead time" drawback and this disadvantage
occurred inside the provide chain because of inefficient management. Time ate up within the
preliminary 4 steps within the provide chain is that the fundamental reasons for growing
interval. It’s viable to scale returned a serious portion of order interval by way of rising the
contrary 3 areas particularly, communication, port administration and transport
administration inside the offer chain. We will get a transparent sketch regarding interval
inside the offer chain via thinking about the equation of interval and location average
calculable time accumulated from the interviews for each step. We all know that;

4.2 Manufacturer Lead time


Total supply time = [{Information lead time} + {(Order lead time)}] Or, = [{Information
lead time} + {(time to manufacturing fabrics) + (time to shipment of fabrics)+(time to
unloading fabrics and customs formalities at port) + (time to take fabrics from port to
manufacturing point) + (time to sample approval and production of final product)+ Time to
shipment or export of final products)}] Or, 120 = [{7} + {(15)+ (25)+(14)+(6) + (23)+(30)}]
From the above equation, we can say that through the first four stages a manufacturer
received fabrics from the suppliers after 60 days on average. Out of this the shipping time of
25 days is constant. There is no chance to reduce this shipping time but we can reduce the
rest 35 days. There are two parties and various activities involved between suppliers and
manufacturers in the supply chain. It can be seen in the fig.-4 broadly. The activities and time
consumption area have been illustrated here through four boxes (A-D) or stages.

Figure 4.2: Lead-time and fabrics importing process


4.3 First Result

4.4 First Result


4.5 Second Result

4.6 Third Result

and different failure in reducing interval, one will draw a conclusion that if Sharman cluster
may avoid import and collect materials from the native market, the interval would be
between 45-60 days. It’ll be additional competitive if the customer would open an area
workplace in national capital. This may minimize sample approval method.
While team motion all the findings from the survey and consequently the case find out about
we will draw a conclusion that within the present day RMG enterprise makers face interval
draw back thanks to import dependency i.e. import of substances from overseas market. This
downside is exacerbated thanks to unskillfulness inside the offer chain management. interval
might also properly be more reduced via taking some relevant measures in producing,
unloading and transportation alternatively it would not facilitate the manufacturer to be extra
competitive. If the makers may additionally notice some a number of furnish of offer inside
the native market and acquire substances domestically. Which will be extra logical, relevant
and useful within the path of interval reduction. Considering all the on pinnacle of analyses a
brand new model of RMG business approach has been projected in fig.-7 that is envisioned
to be beneficial in lowering interval.

Table-4.1: Lead Time to Bangladesh selected Garment

Import Fabric Accessories Lead time

Sharmin Group 100% 8o% 120-140days

locally and 20%

imported

JC Penny USA 100% 90% Locally 116 days

100
Corona’ Italy 100% Local Fabric % 48 days

World matt 100% 80% 125 day

Landmark Group 100% local fabric 100% Locally 45-60 days

Source: Result find out from own research questioner and survey
Chapter-5:

Conclusion
5.1 Conclusion
Bangladesh has entered within the quota free market when 2005.After enter the free market
People's Republic of Bangladesh apparels face opposition from others contender .Analysis
has been discovered that import dependency on backward joined change is that the principal
issue for long interval. Quite eightieth foreign. Absence of spare backward linkage alternate
and for this reason a entire extra 55-75 days rectangular measure spent within the import
approach of substances by using RMG quarter of People's Republic of Bangladesh. As a end
result this quarter is dealing with long interval that is ninety to one hundred thirty days on the
typical. From the evaluation it is clear that they have an effect on of information interval is
distinctly negligible on complete interval. It contributes solely 6 June 1944... closing thinking
about the greater than analysis it is been observed that import dependency is tributary five
hundredth or a lot of inside the drawback of long interval and it's the most problem for the
depend of long interval inside the RMG area it's the fine interval to contend with the contrary
manufacturer and businessperson of the planet. It becomes workable simply for heading off
import of materials. as soon as the RMG zone make positive the comfort of material from the
native market by way of growing backward linkages industries specifically within the kitchen
equipment area and via setting up material mills via the patron for his or her personal
consumption.
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Appendix: 1

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