BGMEA University of Fashion & Technology (BUFT)

Assignment On
“A Product – Denim”
Course Title: Corporate Social Responsibility Course Code: CSR 4203

Submitted To:

Md. Monirul Islam (Rajib)

Asst. Professor,

Dept. of Apparel Manufacturing & Technology

(AMT)

BGMEA University of Fashion & Technology

Submitted By:
ID: 171-193-0-145

171-211-0-145

171-213-0-145

171-218-0-145

171-284-0-145

(AMT-3)

19 July, 2020
 TABLE OF CONTENT
Topic Page No.
Introduction 3-4

IDENTIFICATION PARTS OF 5-11

DENIM JEANS

DIFFERENT SUPPLY CHAIN 12-14

STAGES OF DENIM

DIFFERENT
UNSUSTAINABLE ISSUES 15-21
WITH EACH STAGE

PRACTICABLE SOLUTIONS
OF STAGE’S 22-27
UNSUSTAINABLE ISSUES

CONCLUSION 28-29

2
INTRODUCTION

3
DENIM

Denim is one fabric that will never go out of fashion. It is the most
casual and comfortable outfit that anyone can think of wearing. Denim is
most commonly worn in the form of jeans but this fabric is also made
into skirts, shirts, caps, jackets, bags and dresses. Denim is one of those
fabrics that is very versatile and can be styled in any way. The original
color of denim is blue but it is also dyed into different colors like black,
brown and olive green.

In the 18th century, denim or jean was worn by slave labors or cotton
plantation workers because of its strength and did not wear out easily.
Denim is also known as blue jeans, dungarees, or Levi’s. A writer for
American Fabrics magazine wrote in the year 1969 "denim is one of the
world's oldest fabrics, yet it remains eternally young."

4
IDENTIFICATION PARTS OF DENIM
JEANS

5
PARTS OF DENIM JEANS

Jeans is very unique among all the other types of garments we have
today. The parts and characteristics that lend the jeans the quality of an
icon. (Drawn picture)

Waist Band
Button
Watch Pocket
Front Pocket
Metal Rivet
Fly

Crotch Point
Inseam

Bottom Hem
Front

6
 Belt Loop
Back Yoke
Label
Back Pocket
Metal Button
Back Rise

Side Seam

Knee Line

Bottom Hem
Back

7
Anatomy of Jeans –
1 Waistband

2 Belt loops

3 Leather labels /patch

8
4 Metal buttons

5 Fly & fasteners

6 Front curved pockets

9
7 Fifth pocket aka watch pocket

8 Rivets

9 Back pocket & decorative stitches

10
10 Back Yoke

11 Jeans Seam stitching and thread

12 Denim washes

11
DIFFERENT SUPPLY CHAIN STAGES OF
DENIM

12
The
Journey of Jeans

Since the birth of “waist overall” in 1873, denim jeans have grown into a
huge global market.
Levi Strauss & Co. is one of the world’s largest brand-name apparel
companies and a global leader in jeans-wear. Levi’s products are sold in
more than 110 countries worldwide through a combination of chain
retailers, department stores and a global footprint of approximately
2,800 retail stores and shop-in-shop.

Independent
LEVI’S
Producer

Supply Chain Stage from Cotton to Consumer

COTTON FABRIC PROCESS TRANSPORT WAREHOUSE DISTRIBUTE RETAIL CONSUMER

13
Supply Chain Stage Detail –
From cotton to consumer, denim production brings people, machines
and materials together in a complex workflow.

First, cotton spun into yarn. 325 pairs of jeans can be made out of a
single bail of cotton.
Then yarn is dyed and threads woven into fabric. 4 strands of yarn
make up classic denim fabric, 1 white for every 3 blue.
After that, denim cut, assembled, applying hardware, washing,
pressing, embroidery/labeling all process are done in factory.
Goods then transport into warehouse.
Soon jeans shipped to store and retailed for sell.
At last, ready-made jeans are purchased by consumers.

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DIFFERENT UNSUSTAINABLE ISSUES
WITH EACH STAGE

15
Nasty Jeans!

Practically everyone has a favorite pair of denim jeans they pull on when
all else fails. But unfortunately, the mass appeal of denim has turned into
a problem for our environment and for the people who produce it.
Denim is one of the dirtiest garments in the clothing industry.

A single pair of traditionally-made jeans has required an embarrassing

amount of chemicals, thousands of liters of water and energy
consumption that has been almost comically outsized compared to the
finished product.

16
Unsustainable issues of supply chain stage for
jeans –

Stage 1 Cotton
Causes enormous environmental impact as the course of rivers.
The amount of water for irrigation can be as high as 25.000 liter
per kg of cotton produced.
Soil become very salty, as the evaporating water leaves its salt
content behind.
Heavy use of fertilizers and pesticides has powerful negative effect
on the environment and on killing many organisms.
Large amounts of energy are used for transporting the cotton to the
factories. In total the energy consumption will be around 60 MJ/kg
(which is equivalent to 2 m3 of natural gas).
Deforestation increase in carbon dioxide.

Water & Pesticide

Water Disaster

17
Stage 2 Fabric

As 20,000 tons of indigo are produced annually for sole purpose

of dyeing denim. These dyes are extremely toxic and companies
flush out runoff in nearby water sources and lands. Which cause
dangerous pollution such as Groundwater pollution,
Microbiological pollution, Anthropogenic Soil Pollution.
Damage ecosystems.
People suffer severe health complications staying in affected area.

Land Pollution Anthropogenic Soil Pollution

Stage 3 Process
Burning coal for energy increase CO2 and air pollution.
Synthetic waste element.
Air pollution which linked to respiratory and heart disease.
Dyes and phenol xenobiotic compound wastage.
Various health hazards like eczema, contact dermatitis, asthma
from dyes, aniline, caustic soda, acids, bleaching powder, metal
ions etc.

18
 The use of metal accessories such as buttons, zippers and rivets
such as leather-look labels and composition and care labels used
in jeans production makes it difficult to recycle them.
Chemical bleaching, Sand blasting wash for jeans increase
hazardous environment and health risk.
Denim workers suffer additional health complications. Workers in
the toxic indigo dyeing and washing process also experience
severe impacts.
Unsustainable labour working conditions.
Insufficient wages and security.

Denim Waste-Water Denim Sand-Blasting Wash

Stage 4 Transport
Increase in duties imposed on delivery of product.
Increase in tax rate on the vehicles and fuel cost.
Due to the sluggish transport mode the components do not arrive
on time and the finish line is damaged.
Risk of theft occurs.

19
Stage 5 Warehouse
Inaccurate and inefficiency in handling inventory.
Picking problems arise when pickers rely on inaccurate
information.
Redundant processes and poor facility layout.
Seasonality in demand and high labour costs.

Stage 6 Distribute
Poor standards of service such as late deliveries, inaccurate
invoicing.
Problems in partner selection, training and development and
effectiveness monitoring of partner sales and marketing staff.
Not using identity standards creates a loss of brand strength.

20
 Stage 7 Retail
Operational inefficiency.
Complicated shift in the working model and e-commerce
players.
Difficult Country-specific politics.
Complicated trade and tariff law.

Stage 8 Consumer
Poor customer service.
Delivery delays.
Higher costs.

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 PRACTICABLE SOLUTIONS OF
STAGE’S UNSUSTAINABLE ISSUES

22
How To Be A Good Jeans!

Denim industry valued at more than $57 billion, according to P&S

Market Research, which also says the sector will experience an annual
growth rate upward of 6 percent through 2023. Denim jeans have been a
fashion staple for over 150 years so it is not going anywhere soon.
That’s why the industry needs to find ways to help clean up the process
and build a more sustainable supply chain.

Levi Strauss was one of the first brands to introduce ecologically aware
technology in denim production that reduces the amount of water used in
finishing the garment by 28 per cent. The brand has also launched denim
made from plastic bottles.

But first of all, the denim industry should create an ecosystem. Denim
supply chain paradigm needs new process, new tools, new thinking. The
industry should examine every supply chain standard and finding areas
where they lack. Once that happens, a sustainable foundation is possible.

23
Solutions for stage's unsustainable issues –

Stage 1 Cotton
Wisely managing water supplies by learning simple, cost-effective
techniques.
Not using child labor or slave labor.
Increase the production of organic cotton.
Better Cotton Initiative can supported farmers in their move to
reduce water usage by 39%.

Stage 2 Fabric
Blending denim in Tencel lyocell fibers made from sustainably
harvested tree pulp to cut water and energy use.
Using eco-friendly concentrated sulphur dyes which helps them to
bond better with cotton.
Create recycled cotton fabric.
Using water-reducing D-Clear technology. The technology uses 40
percent less water in the indigo dyeing process and 83 percent less
water during finishing, and reduces the volume of chemicals used
per meter by 94 percent.
Increase use of eco-friendly dyeing rather than sodium hydroxide
and hydrogen peroxide.

24
Stage 3 Process
Using a new process known as 'Advanced Denim'. This budding
green process can reduce 92% of water consumption, 30% of
energy consumption and almost no wastewater while producing a
pair of jeans compared to the traditional methods. Moreover, the
process also reduces cotton waste by 87%.
Potential Solutions like laser technology, Ozone Technology can
be used rather than sand blasting, stone wash etc.
Use natural resources like- Sun light, Air and water for energy
supplies.
Increase capacity and recycle of after use wastage.
Reducing discrimination between man and woman.
Adopting the Green factory mechanism for a sustainable
industrial build-up.
Implement social consensus and fire safety measures in factories
Using Effluent Treatment Plant (ETP) treatment method which is
designed to purify industrial waste water for its reuse and release
safe water to environment from the harmful effect caused by the
effluent.

ETP Plant

25
Stage 4 Transport
Increase standardization of transportation, logistics processes and
policies.
Giving importance in transportation flexibility in terms of time,
items, quantity, location, or delivery sequencing.
Reduce overall network transportation cost.
Improve carrier relations.
Rationalize carrier base.

Stage 5 Warehouse
Under all circumstances, communication among team members
and even customers should be number one priority.
Make use of vertical storage and vertical lift module can help
reduce malfunction.
Access products from multiple floors.
Use hydrogen for reducing the fuel costs.
Developing the right expertise through workforce planning and
hiring only necessary skills for smoother logistics operations.

Stage 6 Distribute
Have adequate knowledge of products and markets.
Produce a set of customer service standards and communicate
them to distributor teams.
Use identity standards in communications.

26
 Using logistics management software.

Stage 7 Retail
Balance demand and supply.
Respond to demand signal in near real time.
Must opt for the latest ERP systems to keep pace with the
operations function rather than relying on traditional spreadsheets.
Ensuring real-time network visibility.

Stage 8 Consumer
Ensuring quality customer service.
Offer Direct-to-Consumer communication.
Study Complaints and Compliments.
Demonstrate Product Knowledge.
Provide Additional Benefits.
Focus on local culture.

27
CONCLUSION

28
Every ending is a new beginning

It must be possible to design a pair of jeans which has less than 50% of
environmental impact compared to the present jeans. First examples of
more environment friendly jeans are commercially available, but there
still is room for improvement.

Also jeans were particularly good at absorbing pollution. Although only

small amounts of pollution -- a pair of jeans weighing 500 grams could
absorb around two grams of pollution. (CNN Business,2012)

The environmental performance can be improved by the selection of the

materials, improved processing using (inkjet) printing technologies,
reduction of the mechanical finishing, application of a anti-soiling and
anti-microbial finish in order to reduce the frequency of wash and care
cycles, and the use of design for recycling principles in the selection,
processing and production of a pair of jeans.

29