Download - Dewdrops Finishing Garments
Topic:
Problems and Prospects of Finishing sector of Textile Industry in Bangladesh:
A Case Study on Dew Drops Wash Works
Md.Mamunur Rashid
ID#0621061
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1.0. Introduction
The Textile Sector in Bangladesh moving fast. It starts in the late seventies as a minor
non-traditional sector. It contributes about 75% of the total exports of the country. In
2007-08 this sector contributed to 13.5% of total Gross Domestic Product (GDP) and
earned US$ 14.2 billion in which the contribution of RMG alone was US$ 10.4 billion.
The sector creates lots of employment opportunity. About 1.6 million people woke there
where 80% is women worker. In this sector create employment and help to solve
unemployment problem in the country.
Exhibit 1.1: Contribution of RMG export to GDP.
.Garments finishing sector includes dyeing and washing plant. Most clothing items that
people wear have been finished. This idea of finishing means that it has gone under some
process to alter or enhance it. It has been assumed that, there are about 4000 washing
plants in Bangladesh among which 3000 is situated in Dhaka. However there were few
number of washing plants before 90’s.This situation changed in of 90’s. Most of the
washing plant situated Dhaka&Chittagong.
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1.2. Origin of the Report:
This report is prepared as a partial fulfillment of the internship program of Bachelor of Business
Administration of Independent University, Bangladesh. Under this program, every student has to
submit a report on any topic based on three-month attachment with any business organization.
This topic concern on prospect&probles washing plants are facing. Data are collected from Drew
Drops Wash wok.
1.3 Objective:
Describe overall picture of finishing sector of textile industry.
To get an overall idea on how to operate a washing plant.
To observe and an idea of various finishing (washing) process.
To chalk out the prospects and challenges that the washing plants are enduring
1.4 Scope:
The first part of this report contains garments washing process. The second part
contains overview dew drops wash work, and washing procedure, management and
company. In the conclusion the repot tries to indicate some suggestion which can help to
increase productivity.
1.5 Limitation of the study:
Report is prepared on findings one washing plant.
Proper document and information was not found.
Competitive positions were unknown to the manager.
To chalk out the prospects and challenges that the washing plants are
enduring
1.6.1. Methodology:
Methodology comprises of all the activities that is required to conduct the study and generate it
into a report. The methodology of this study has been described on the context of the following
aspects- Problem identification, research design, sampling and data collection
1.6.2 Research Design:
From the view point of objective it is an “Applied Research” and from the view point of function
it is “Descriptive Research” that is concerned with an unvaried question. Again from the view
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point of research place it is both “Field and Desk Research ” and last but not the least from the
view point of Nature of Data it is also both “Primary and Secondary research”.
1.6.3 Nature and sources of data:
Type of Data Source
Primary Field visit
Questioner
Observation
Secondary Journals
1.6.4 Data Collection:
Field Visit:
To collect the data field visit is the best way. Acquiring data in this way is very useful.
Questioner:
Structured and unstructured questionnaire are use to collect data to know their working
condition.
Observation:
It also uses to collect the data.
Sampling:
The primary sample units for the study are the washing plants which are currently in
business in Bangladesh. Secondary sample unit is (Dew Drops Wash Work Ltd) which
was chosen using convenient sampling procedure.
1.6.5 Problem Statement:
Specific information on textile finishing sector of Bangladesh is not well documented.
There is substantial data available on the overall RMG sector. To get acquainted with the
growth story of RMG sector would shed some light on the growth of textile finishing
sector i.e. washing plant in Bangladesh.
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The RMG sector has a venerable history of about 25 years. RMG-led export growth is
thought to have transformed the country from a predominantly aid-dependent country to a
largely trade-dependent nation. Being a labor intensive sector coupled with provider of
employment mostly to women, the RMG sector has had a strong influence on poverty
alleviation and human development in Bangladesh.
Started contribution 1.1% in1982-1983 of the countries total export, and earning more
than $10 billion in the fiscal year 2007-2008.
In 1983-84, the total apparel exports of Bangladesh were only $31.57 million, 3.9% of
total exports. During this period there were only 134 factories, which employed around
400,000 workers. The breakthrough occurred during 1985-86, when the number of
factories increased to 594 and volume of export grew to $131.5 million.
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Exhibit 1.2: Growth trend of Apparel export in Bangladesh
Cumulative average growth rate(CAGR) grew at 40% during 1985-90.This sector total
export $1018 billion.
Export increased 64% and earning $2.2 billion in FY95.1995 cumulative average growth
rate grew 29%.
Export increased by 76% and earns $4.35 billion next five years. Several internal and
external factors contributed to the phenomenal growth of the RMG sector. The key factor
behind the growth was the quota regime under the Multi-Fibre Arrangement (MFA). The
General System of Preferences (GSP) facilities and RoO (Rules of Origin) offered by the
developed nations also helped Bangladesh to accelerate its export.
Bangladesh possessed a number of comparative advantages, growing share of local inputs
(particularly in knit fabrics) and competence in mass-produced basic garments (such as
knit cotton and woven cotton products), low labor costs compared to other Asian
economies.
The apparel industry also received support from the government, which is beyond
warehouse facilities, tax holidays, zero tariffs on machinery input; export development
fund, duty drawback facilities etc.The number of factories in our country increased by
4000 to 4.740 in FY04 to FY08, and also increased employment by 2 million to 2.5
million. The apparel faced many problems such as political instability, gas and power
supply, hartals etc.
Previous years the RMG sectors mostly depend upon imports. But the labor cost in here
is low and it attracts the foreign investor to invest here. So such investment flourished
backward and forward industry in Bangladesh. At present Knitwear required 85% meet
by the backward industries.
The knit sub-sector grew at a faster rate than the rest of the sub-sectors. During the period
under review, the share of knit sub-sector grew from 15.14% of the total RMG export to
29.16%, whereas that of the woven sub-sector fell from 84.86% to 70.84%.(See Exhibit
1.3) The predominant reason for the faster growth of the Knit sub-sector is the extent of
backward linkage that this sub-sector could achieve. A large number of composite knit
garment manufacturers have emerged during this period that produce their own fabric,
have their own dye houses and thus can compete very effectively in price and delivery
lead time.
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Exhibit 1.3: Trend of Apparel export Woven Vs Knitwear
In June 2000 as indicated in Table 1.1, the sector consists of about 3000 RMG units
producing 150 million dozen garments, 141 spinning mills (units) with a production
capacity of 335 million kg of yarn, 117 weaving and composite mills with a capacity of
420 million meters of fabric, 282 dyeing, printing and finishing units capable of
processing 677 million meters of woven fabric and 155 knitting, dyeing and finishing
composite units capable of producing 225 million kg of knit fabric. Investment in the
sector is gaining momentum. As many as ten spinning units and a number of composite
knit fabric mills have been added to the sector in the year 2001 alone.
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Sub-sector No. of units Installment Capacity
Product Capacity
Textile Spinning 141 2,967,53860,184
YarnYarn
334,622,00 Kg
Weaving 105 2,0254,837
Grey PGGrey PG
222,613,000 Mtr
Dyeing and finishing
282 676,764,000 Mtr
Composite mills 12 540
1,901
576
Yarn
Grey PG
Finished PG
13,485,000
80,050,000
117,450,000
Kg
Mtr
mtr
Knitting ,Dyeing & finishing
155 2,048 Grey
Finished
104,751,000
121,837,000
Kg
kg
Spl. Textile 1029 21,985 Grey PG 429,046,000 Mtr
Export oriented RMG
3000 RMG 150,000,000 dz
Table 1.1: Overall scenario of textile sector in Bangladesh (2002)
Source: Bangladesh Textile Mills Assciatiation.
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2.0. Company Overview:
Dew Drops Wash Work Ltd started at2006.From its beginning it marched a long path.
Now it’s a well known brand in the RNG factories.
2.1. Dew Drops Wash Work at a quick picture:
ADDRESS- M/S Dew Drops Wash Work Ltd
1124,East Nasirabad I/A
Textile Gate,Chittagong
Bangladesh.
Name Of Directors Mr. Taybur Rahman (Chairman)Mr. Helal Uddin(Managing Director)Mr. Ahsanul Hoque. (Director).Mr. Chandan Dev. (Director).
CONTACT PERSON Mr. Ahsanul Hoque. (Director).
INPUT GARMENTS Twill cotton pant, Denim Jeans
MACHINERIES Grinding, Sand Blasting, Hydro, Industrial
Laundry, Tumbler dryer
WASHES Acid wash, Normal wash, Enzyme stone
wash, Enzyme Acid wash, Enzyme Silicon
Wash, Bleach enzyme wash, Stone wash,
Sand blasting
FACTORY WORKERS 50(2 Shifts)
PROD.&OFFICESTAFF 12
CLIENTS Wal-Mart,Gap,Marks and Spencer, Levi’s,
Diesel
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2.2 Mission Statement:
“The company believes adding value by clean and fresh looking their garment product
and makes it soft, comfortable to use”.
2.3 Client:
Jarqs
Reliance denim Ltd (Salim and Brothers Ltd)
Aero Fashion Ltd
Neox Denim Ltd
Also work for Levi’s, Wal-mart, Marks and Spencer 2.4 Start cost:
Dew Drops start cost are below
Particular Amount(Lac)
Land, Building 20
Motor Vehicle 10
Furniture 8
Machinery 40
Miscellaneous 30
2.5 Objectives:
Short term:
Increase productivity 20% by year 2010
Increase profit volume 20% by year 2010
Long term:
Market leader in the sector of washing plant by 2015.
2.6 Dew Drops Services:
Normal wash
Enzyme stone wash
Enzyme Acid wash
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Enzyme Silicon wash
Bleach enzyme wash
Stone wash
Acid wash
Sand Blasting
Hand PP
Grinding
2.7 Ownership:
Ownership control among Taybur Rahman, Chandan Das, Ahsanul Hoque, Helal
Uddin.Among them Taybur Rahman have own 70% and all rest of the member own 10%
each.
2.8 Current Management Team:
Dew Drops is small organization. So it has small number of manager and employee to
operate the business. All partners are the member of board of directors. Taybur Rahman
has the power of decision making.Helal Uddin as Managing Director. Chief Operation
Manager role perform by Mukitur Rahman. Ahsanul Hoque as Marketing Manager And
Chandan Dev as Accountant.
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Exhibit 2.1: Organogram of Dew Drops
2.9 Job Description:
2.9.1 Managing Director:
Give decision about major issue
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2.9.2 Marketing Manager:
Collect new order by convincing new clients.
Collect sample from clients.
Maintain long term customer relationship.
2.9.3 Operation Manager:
Find out machine fault
Ensure machine limitations are not exceeded
2.9.4 Accounts Manager:
Preparing bill for client
Preparing delivery receipt for client
Calculate daily expenses and also prepare income statement
2.9.5 Chemicals use by Dew Drops:
Enzyme:1. Acid enzyme2. Neutral Enzyme
Acid:1. Acetic acid2. Oxalic acid
Desizer:1. Antiback2. LP-30
Silicon softner Hydrogen Peroxide Sodium Hypochlorite Brightener :Red/Blue/white Dyeing color:Yellow,Black,Brown,Indigo,Orange Caustic Soda
2.9.6 Operation procedure of Dew Drops Wash work.
Dew Drops facility are service such as washing, dyeing and finishes such as grinding and
sandblasting.50 peoples are work there.
From the receiving the garments are load to the per-wash inspection area. Make to sure
that the garments are suitable for wash. The pre-wash colour standard is also checked.
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Then the garments are sent for wash. If the inspection fails the garments are put on hold
while the client is advised. If no confirmation is received the garments are return to
client.
Then the garments are sent to the washing machines to wash. Different types of washes
such as bleach washes, stone washes etc are under go there. After washing the garments
are sent to the dryers for drying after the water is extracted from them.
Processes like grinding, curing, hand-sanding, spraying, tying, painting also known as the
special finishes are done in a separate area. The manual work done here is what most
clients require and it is what adds value to the garment. Majority of the work force is
involved in these manual processes. Grinding is the process where garments such as jeans
are made to look old and worn by shredding the ends. Dew Drops has multi-skill program
where employees acquire more than one skill, which helps the company to retain people.
The final stop for a garment that had been through Dew Drops Finishing is the final
dispatch area, where it will arrive after the washing, dyeing, finishing and inspection.
When the garments are ready for dispatch, the client, on collection is required to count
simultaneously with a Dew Drops Finishing representative, so as to avoid any conflict in
the numbers.
To run the full process large amount of water is required. There is a waste water
treatment plant at Dew Drops Finishing which treats the water that is contaminated in the
washing, dyeing and finishing of garments
Exhibit 2.2: Flow chart of Operating procedure of Dew Drops Wash works Ltd.
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2.9.7 Machine used by Dew Drops
Exhibit 2.3: Machineries available at Dew Drops
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2.9.8 Composite washes performed by Dew Drops:
2.9.9 Wash Type: Enzyme Stone Wash
Garments: Jeans Pant
Phase: 1
First the garments are put in the washing machine. Then, Desizer LP-30/Anti back
(200gm) is used for removal of starch and sizes from the fabric or garments. The process
runs for 20 minutes. After that the used water are let out and new water is added to the
system automatically. The garments are rinsed in fresh water for about 5 minutes.
Phase: 2
Enzyme 700gm is then stone added 12kg.Ph controller /Buffer Acid is used
500gm.Oxallic Acid (Acetic Acid):300gm.Process runs for 55-60 minutes.
Phase: 3
1kg of Bleach is applied to the garments. The more time is the garments is bleached the
more thinner the shade becomes. So the time has to be carefully set to match the buyers
recommended shade. Sodium Hypo chloride (1kg) is applied for 10 minutes Hydrogen
peroxide (500gm) is applied and the machine runs for 10 minutes.Brightner (200gm) is
then applied. Machine runs for another 5 minutes.Brightner is available in Blue, Red,
yellow, white color and is used depending on shade of the original shade. Silicon Softner
(200gm) is then added.
Phase: 4
Black Dye 25 gm, Brown Dye 5 gm, Yellow Dye 10gm is then added to the garments by
sprayer. Two Kg of salt is also added in the dye.
Phase: 5
The wet garments are squeezed and inserted into Hydro Extractor machine. This machine
extracts 70-75% water from the freshly washed garments in about 10%.
Phase: 6
The final step is to sent the garments into Tumbler Dryer. The dryer machine runs for an
hour and the garments are ready for delivery.
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Exhibit 2.4: Enzyme stone wash
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2.9.10 Wash Type: Enzyme Wash
Garments: Jeans Pant
Phase: 1
First the garments are put in the washing machine. Then, Desizer LP-30(500gm) is used.
The Machine runs for 30 minutes. After that the used water are let out and new water is
added to the system automatically. The garments are rinsed in fresh water for about 5
minutes.
Phase: 2
Enzyme (500gm) is then added to the garments. To reduce the ph level of water into
tolerable level of 4.5-5 Citric Acids (400ml) is used. LP 30(200gm) is then added again
followed with Chemical 808(200gm).The machine runs for 120 minutes. After that the
used water are let out and new water is added to the system automatically. The garments
are rinsed in fresh water for about 5 minutes.
Phase: 3
1kg of Bleach is applied to the garments .The more time is the garments is bleached the
more thinner the shade becomes. So the time has to be carefully set to match the buyers
recommended shade. Sodium Hypo chloride (1kg) is applied for 10 minutes Hydrogen
peroxide (500gm) is applied and the machine runs for 10 minutes.Brightner (200gm) is
then applied. And machine runs for another 5 minutes.Brightner is available in Blue, Red,
yellow, white color and is used depending on shade of the sample provided by client.
Phase: 4
The wet garments are squeezed and inserted into Hydro Extractor machine. This machine
extracts 70-75% water from the freshly washed garments in about 10%.
Phase: 5
The final step is to sent the garments into Tumbler Dryer. The dryer machine runs for an
hour and the garments are ready for delivery
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Exhibit 2.5: Enzyme wash
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2.9.11Wash Type: Enzyme Acid Wash
Garments: Twill Cotton
Phase: 1
First, the garments are put in the washing machine. Desizer LP-30(400gm) is used
for removal of starch from the fabric or garments. Chemical 808(200gm) is then applied
in the garments. The machine runs for 20 minutes. After that the used water are let out
and new water is added to the system automatically. The garments are rinsed in fresh
water for about 5 minutes.
Phase: 2
Enzyme (300gm) is then added to the garments. The higher Ph value of the water hinders
the effectiveness of the Enzyme .To reduce the ph level of water into tolerable level of
4.5-5 Acetic acid (400ml) is used.LP 30(200gm) is then added again followed with
Chemical 808(200gm).The machine runs for 50 minutes. After that the used water are let
out and new water is added to the system automatically. The garments are rinsed in fresh
water for about 5 minutes.
Phase: 3
Silicon softener (1500gm) is then applied to the garments. This softener makes garments
supple and comfortable to wear .Machine runs for another 15 minutes.
Phase: 4
The wet garments are squeezed and inserted into Hydro Extractor machine. This machine
extracts 70-75% water from the freshly washed garments in about 10%.
Phase: 5
The final step is to sent the garments into Tumbler Dryer. The dryer machine runs for an
hour and the garments are ready for delivery
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Exhibit 2.6: Enzyme Acid wash
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3.0 Literature Review:
Important of finishing process of garments:
The washing process of garments adds value to the garment. It removes most
contaminants, making the artwork such as garments paints, batik easier. There is a risk of
the garments affected by shringing, but the washing process makes it risk free. Many
clients want product that is pre-shrunk. Garment washing enables you to provide pre-
shrunk product.
3.1 Classification of garments wash:
Two types of garments washes for garments.
1. Mechanical Wash
2. Chemical Wash
3.1.1 Mechanical wash:
Mechanical washes include micro sanding and stone wash. These washes are only use
fore denim garments.
3.1.1.1 Micro Sand wash:
This type of finish became popular around the 1980 and still popular because sand wash
make jeans look gorgeous. A sanded finish for denim is achieved through a combination
of pumice stones, enzymes and sand; used to create the illusion of aged denim jeans.
Although the purpose of this is generally for aesthetics, this process also loosens the
fibers in the denim, making the denim fit more comfortably and move more easily.
Sanding jeans creates an uneven, worn look, which is ideal for daily casual wear, and also
for pairing with solid colors or denim jackets. . It is a necessity to finish denim in order to
get a final soft touch. Most denims are enzyme washed or stonewashed for an overall
softness, however, it is essential to sand-wash, or sandblast, for a more strategically
placed worn and frayed finish.
There are three types of micro sanding: sandblasting, machine sanding, and hand sanding.
The sandblasting process is the most unique and starts by sending a very abrasive
substance through a nozzle at the denim at high speed and pressure.
In most cases, the sand-washing process also has the same softening effect on the hand
of the print. The abrasion of the sand-washing process wears away a portion of the print's
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surface, resulting in a decoration with a softer feel than it had prior to washing. The sand-
washing process also removes a small amount of color from the fabric. The abrasion of
the fabric causes fibrillation--fibers standing out or
breaking loose from the printed ink film--which adds
to the worn appearance of the finished garment.
Hand sanding is done with a fine grain sand paper
by hand. This allows you to be very precise on what
gets sanded. Machine sanding is done by using a
machine similar to one that you would use to sand
down wood furniture in your home.
3.1.1.2 Stone Wash:
Stone washing is done to give denim a worn out look. Today, stone wash remains a
highly popular finish for jeans. All jean companies were offering some sort of vintage
style denim, including stone wash. In order to stone
wash jeans, the original way, they are washed with
pumice stones (jeansinfo.org) Since the pumice
stones have a rough surface they will scrap off a
layer on the denim so that some of the white threads
from the cloth will become more visible
(jeansinfo.org). This is what causes the jeans to
appear naturally worn. However, this method for stone washing jeans is very hard on the
denim fabric. Using the pumice stones shortens the life span of the jeans and has negative
effects on the environment (novozymes.com). Also, it is hard to control the amount of
wear and tear the fabric will undergo during this process. However, more importantly,
there is a problem with disposing of environmental waste and grit caused by this process
(ezinearticles.com). There is also an issue concerning the amount of water that must be
used to achieve the desired stone wash finish. In order for the manufacturers to achieve
this finish, the jeans must be thrown in the washer several times (novozymes.com). This
is why manufacturers have come up with an alternative method to achieve the stone wash
finish.
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Exhibit 3.1: Sand wash
Exhibit 3.2: Stone washed jeans
Manufacturers to day use enzymes instead of stone, because enzyme method conserves
water and strong the fabric. When the stones were being used, manufacturers would have
to do a number of rinse cycles to achieve the desired stonewash finish. However, by
using the enzymes, the same look can be achieved without the same negative effects on
the environment.
3.1.2 Chemical Wash:
3.1.2.1 Acid Wash:
The process of acid washing is more similar to that of stone washing. The process was
named 'acid wash' as a marketing tool. Basically, acid wash technology uses chlorine to
remove indigo dyes, which gives denim a lighter, more worn look. The process also
reduces the stiffness of denim. Acid wash treatment
creates significant contrasts in the color of the denim
material. To create a random, irregular, patched and
shaded, acid wash look, the dry denim cloth is first
bleached. The material is then put into a rotating drum
in close proximity with granulated pumice soaked with
the prepared hypochlorites. This process fades the cloth
both chemically, through bleaching, as well as
mechanically, as the rough granules scrapes the fiber. After tumbling together for some
time, the granules are removed and the cloth is washed and dried in order to neutralize
any left over hypochlorites.
3.1.2.2 Enzyme Wash:
An enzyme is a biological chemical compound that reduces complex organic compounds
to simpler compounds. Enzyme wash is organic and non-harmful to the environment.
Enzyme washing products are also much more potent than other laundry products,
requiring people to use far less, in terms of volume. The main purpose of the enzyme
wash is to make the denim appear worn, rugged, broken in and used. The enzymes are
used in denim finishing as an alternative to stonewashing, meaning that stonewashes and
enzyme washes are very similar, but the enzyme wash still has its advantages. Jeans tend
to be softer with the enzyme wash as a result of the organic enzymes that eat away at the
fabric from the cellulose
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Exhibit 3.3: Acid washed jeans
3.2 Drawbacks of garments wash:
There are some effects of garment washes. Enzyme wash, stone wash, acid wash are
mainly create bad effects, because various types of chemical are use to wash the
garments.
Surface Abrasion:
The physical process of garment washing can cause "pilling" on the surface of some knit
fabrics. This is a normal result. If pilling is unacceptable by the client washer has to use a
cellulose enzyme treatment. When properly applied, this enzyme can reduce or eliminate
pilling caused by the garment dye process.
Shrinkage:
Most shrinkage takes place in the dryer. Make sure that after wash dimensions
correspond with your requirements. The most frequently encountered are torque,
identified by the twisting or displacement of lengthwise seams. This usually occurs in
long pants, skirts, and dresses. Torque is created in the yarn formation, knitting, and
fabric finishing process. It is a condition that is considered "normal and accepted" in the
industry. No one yet knows how to eliminate torque and, therefore, Style Source nor any
other fabric manufacturer that we know of warrants against it in totality
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4.0 Findings:
SWOT analysis of Dew Drops Wash Works:
4.1.1 Strength:
Permanent buyer:
Permanent buyers are like angle to any business. Permanent buyers are less price
sensitive and loyal. Dew Drops has been able to retain hood number of client who sent
their garments regularly.
Cheap supply of chemical:
Mr. Taybur Rahman the director of Dew Drops has family business of chemicals. He
brings chemicals to Dew Drops at minimum cost from his family business. Chemicals are
very important of any wash plane. Dew Drops has been able to reduce cost of chemicals.
Management skill:
Good management is asset to any organization. Dew Drops has good managers who are
hard working, motivated experienced, and honest. This management ability help the
organization to get success.
Sand blasting unit:
Recently Dew Drops introduced a sand blasting unit.
This machine is an excellent tool for making
customizable shades on Denim. Sand blasting is very
costly unit. Not to many factory have this machine.
Dew Drops had to sub contract another wash plant for
the sand blasting finishing .Now they are doing it
themselves which is increasing their profit volume by
eliminating subcontract cost.
Goodwill:
Dew Drops has a good reputation for small size plant. From the beginning the factory
able to attract powerful buyers. Dew Drops quality’s high, from quality there is no
compromise.
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Exhibit 4.1: Sand blasting plant
4.1.2 Weakness:
Child labor:
Among the labors there is 30% are child labor whose age is 8 to 13 years. The reason for
using child labor is very clear .They demand less payment, they are more obedient. Child
labors are paid 1600 Tk monthly.
Unfair labor practice:
Eight hours of working per shift is standard. But Dew Drops do not maintain the
standard. Dew Drops working shift is 12 hours a day. Workers do not get extra
compensation for overworked.
Health problem:
Washing plants use lots of chemicals. Some of the chemicals are harmful to health. The
workers of Dew Drops not followed proper safety measure. Boots and gloves are
necessary to use in washing plants. These are absent in Dew Drops. So the worker suffers
painful ulceration in hands and legs.
No generator:
Load shedding is common problem in Bangladesh. Generator is very important machine
like washing plant. But short of capital Dew Drops is unable to get a generator in the
factory. So when load shedding occurs the washing process is stop. While the factory has
capacity to wash near about 20,000 units per day, they are only able to wash 7000-8000
per day on an average.
Factory infrastructure:
Factory infrastructure is very important factor in order to increase productivity. But Dew
Drops Facility is not good. The temperature of the floor is always elevated to an
intolerable degree (65◦c-70◦c) because of the heat emission of the dryer machine. There
is no cooling system or fan here. Lighting of production floor is not good as required
Worker shortage:
The factory depends less on labors because the machines they use are semi to full
automatic. Production manager says that they require only 10 men per shift including a
supervisor. In the observation there were only 6 people on average available in the
floor .This the reason of low wage rate. Male labor gets 2300 taka as monthly and female
gets at best 2000 taka per month which is very low because the work hard. Labor
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turnover rate is very high because wages are not paying in time. So management always
facing challenge to run the operation.
Depend on outside buyer:
Whole operation of washing plants depends on the Garments factories .If washing plant
is fails to catch order from garments they are in deep trouble to meet the fixed cost that
incur in a period
4.2 Opportunity:
Future growth opportunity:
Garments sector in Bangladesh is booming within a global recession; Dew Drops is
getting the full advantage of it. So one can only hope in first quarter of January 2010
when the recession is supposed to wear off the RMG sector would swell and Dew Drops
would get hefty share of this windfall.
4.3 Threat:
Pollution:
It is well known that Washing plant of finishing sector pollute the environment. Dew
Drops also pollute the environment tremendously. Waste from this factory is supposed to
be treated with in the Effluent Treatment Plant (ETP) of the plant. However in practice,
the ETP plant is offline and the sludge goes through the sewerage system untreated, that
directly leads to the chaktai canal. In fact, the Karnaphuli river have become a dumping
ground of all kinds of solid, liquid and chemical waste of bank-side population.
Competition:
Washing plant is a profitable sector so competition is becoming increases. There is about
4000 washing plant in our country. So it is easily understandable that competition is
increasing. These competitors are detrimental to Dew Drops in several ways. First of all,
they are driving away Dew Drops potential patrons. Furthermore they are reducing the
profit margin of Dew Drops by charging lower than Dew Drops and thus lowering the
total profitability of the sector.
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5.0 Recommendations:
5.1 For Micro Level (Dew Drops):
The overall working condition of Dew Drops Wash work is way below the standard of
Occupational Safety and Health Administration (OSHA) and International Labor
Organization (ILO). For future growth of the factory the below mentioned steps should
be adopted as soon as possible.
Management-labor relations should be enhanced:
Labors should treat fairly without any physical and psychological harassment. They
should be given proper training, and wages in due time.
ETP Plant:
ETP plant should be operational for not only environmental cause but also for the sake of
business itself. It is evident that within 3-4 years all textiles and other major water
consuming industries would need to recycle their wastewater for primary use, since they
won't get water from the bore well. That is why a cost effective, small, technically
sophisticated ETP, with a provision for future recycling options, should be the only
solution for the textile and other water polluting industries like Dew Drops.
Abolition of child labor:
Child labor should not be an option in the labor force. It is very unfair to work with child.
Infrastructure should be improved:
Good infrastructure can help any organization to increase productivity. Dew Drops
should make investment to improve their infrastructure that can boost the overall
productivity. The wash plant should install additional two exhaust fan. To improve the
working condition at least four ceiling fan should be installed to keep the temperature
level of the plant within tolerable limit
5.2 For Macro Level (Textile Industry):
Developing fashion institution:
Our apparel sector is about three decades old. but no significant drive was taken to cater
to the high-end market and explore our opportunity in that segment. There is only a
handful of fashion designing institutions in Bangladesh, like the BGMEA Institute of
Fashion & Technology, National Institute of Fashion Design, etc. Some private
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universities have also initiated fashion designing courses. However, we are yet to see the
results. Government and private sector authorities should develop this new sector to
support product development as per consumer demand, promote our products in world
markets
Identifying new destinations:
The apparel sector is vulnerable to any possible downturn in major export destinations.
So new destination is very important to grow this sector. With in Asia Bangladesh
exported$10 million to china, $15 million to Singapore and $20 million to Hong Kong,
These are all new markets for Bangladesh. And also enhance our trade. It is important to
remember that reaching new destinations is also closely linked with capacity. Hence,
capacity development and proper utilization is also very important.
Enhancing labor productivity:
Enhancing labor productivity and efficiency is one of the greatest challenge. One of the
prime causes behind low labor productivity is the prevailing labor shortage in the apparel
sector. It is essential to up skill the labor force to derive optimum level of productivity
and capacity utilization. Furthermore, major shifts in production technologies are factors
that may seriously affect the competitiveness of manufacturers in Bangladesh. RMG
entrepreneurs of Bangladesh.
Addressing safety and security issues:
It is important to ensure the safety and security in this sector. The productivity of the
workers in our country's apparel sector is low compared to neighboring countries. So,
productivity will not increase if we do not take any aggressive measures to address the
safety and security issues.
Minimum wage policy:
In Bangladesh, as per the minimum wage policy, a new worker draws only $24 per
month. After working for three months, the worker gets to draw $29 to $36 a month,
whereas a skilled worker gets paid around $45 a month. Hence, the garment company
owners need to offer a competitive, encouraging and engaging pay package to retain the
workers and.
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5.3 Conclusion:
Textiles and garments manufacturing, which emerged and flourished in England for
decades, eventually became uncompetitive and migrated to Japan and Korea; eventually
migrating there to lower wage countries like Bangladesh.
This sector is not only helping the country's economy by earning significant amount of
foreign exchange, but has also brought about a major shift in developing support
industries, employment generation, and women empowerment.
The government should come forward with policy agenda by offering competitive
exchange rates, streamlining customs procedures, providing further incentives in bonded
warehouse facility, developing infrastructure, improving port efficiencies and ensuring
uninterrupted flow.
Small washing plants like Dew Drops are now in the global war of skill and capability; it
is the war of price and value maximization. And in this war the winner wins all the trust
and confidence of the buyers. So it is imperative that, the Dew Drops with aid from
government should shake off all of its incompetence’s and become a global standard
washing plant.
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