Introduction:
Padma Poly Cotton Knit Fabrics Ltd. is one of the 100% export oriented industry in Bangladesh. By means of the practical knowledge it’s possible to apply the theoretical knowledge in the practical field. For any technical education practical experience is almost equally important in association with the theoretical knowledge.
The industrial attachment is the process which builds understanding skills and attitude of the performer, which improves his knowledge in boosting productivity and services. University education provides us vast theoretical knowledge as well as more practical attachment, despite all these industrial attachment help us to be familiar with the technical support of modern machinery, skill ness about various operation stages.
It also provides us sufficient practical knowledge about production management, productivity evaluation, work study, efficiency, industrial management, production planning and control, production cost analysis, inventory management, purchasing, utility and maintenance of machinery and their operation techniques etc. the above mentioned can not e achieved successful by means of theoretical knowledge only. This is why it should be accomplished with practical knowledge in which it is based on industrial attachment makes us reliable to accustomed with the industrial atmosphere & improve courage & inspiration to take self responsibility.
I have prepared this report as required in completion of my attachment course in regarding guideline given by the university authority which will lead to a strong guideline and milestone for our future carrier.
In Padma Poly cotton fabrics Ltd. I have completer 8 (eight) Weeks long industrial training in the sections, namely-Kilting, Dyeing, Finishing & Garments.
Location of the Industry
Vision:
To be one of the leading composite textile mill in Bangladesh.
To build a true marketing led enterprise with motivated workforce, innovative vision and more vale added produce portfolio, customer sails factiom and under standing global market.
Mission:
Padma Poly Cotton Knit Fabrics Ltd. Firmly believes that in final analysis, they are accountable to each of the constituents with whom they interact namely their employs, customers and business associates.
History of the Project:
First of all it was a printing press in 1993, then the owner planned to produce fabric specially knit fabrics in 1995, after that they started to dye the fabric in the middle of 1995. When they had got the approval of buyer. They started to produce the garments by subcontract. Then they decided to set up garments section.
In the year 1996 they started to produce garments by their own factory. In the year 1997 they started to print the fabric according to the buyer requirements. After that embroidery was started in the middle of 1997. Now they are self established. At present they plan to set – up spinning factory to produce yarn.
History of the project Development:
Year
Details
1995
Establishment of the mill. 1st installment of the machinery.
1999
Installment of the 800 kg and 200 kg H.T.H.P m/c.
2003
Start of the construction of 3rd and 4th Floor. Installment of the 1800 kg H.T.H.P machine.
2004
Start of the construction of 4th and 5th floor.
2005
Installment of the 6 winch m/c and De-watering m/c.
2006
Starting a new project of dyeing and finishing and washing.
2008
Start of the construction of 6th floor.
Physical Infrastructure:
The total area of this industry is 3.34,00 square feet. It is actually a sixth floor production unit. The ground floor is designed with dyeing and finishing section. The section is placed on the 1st floor.
The maintenance section is placed on the sixth floor. The batch section is also placed on the sixth floor. The other floors are designed with cutting, sewing, Printing, Embroidery and Garment finishing etc.
Production Capacity:
Knitting : 12 tones per day
Dyeing : 20 tones per day
Garment : 40,000 pieces per day.
Remarks:
The objects of the project are to produce knit wear and knit garments. The industry has the ability to maintain the finest quality products. To fulfill the buyer requirements the factory has strong management and modern machineries.
Maintenance:
The act which is done to keep the factory plants, equipment machine tools etc. in an optimum working condition, minimize the break down of machines to improve productivity of existing m/c tools and avoid sinking of additional capacity and to prolong the useful life to the factory plant & machinery is called maintenance.
In Padma Poly Cotton Knit Fabrics Ltd. there is a good maintenance schedule which increases the productivity of the factory.
Objects:
To keep the factory plants, equipments, m/c, tools in an optimum condition.
To ensure specified accuracy to product and time schedule at delivery to customer.
To keep the downtime of machines minimum thus to have control over the production program.
To keep the production cycle smooth and modify by the m/c tools to meet the need for production.
Types of maintenance:
Break down or Overhaul Maintenance
Schedule Maintenance
Preventive Maintenance
Planed Maintenance
In Padma Poly Cotton Knit Fabrics Ltd. Maintenance Schedule is as fallows:
Daily: Cheek Bad sound of pump & machine parts, excessive heat Generation of motor.
Weekly: Check oil & all beaching, values.
Monthly: Check oil level of the circuit Air filter.
Month 2: Check electrical contract, power transmission, All electrical components in general.
Month 6: Open and check motor and varnish its coil, clean & maintenance the machine properly.
Maintenance Tools:
Hand Tools : Hammer, Hacksaw blade, Slide Wrench etc.
Machine Tools : Grinding stone, Grinding past, Drilling m/c, Drill bit etc.
Electrical & Electronics Tools: Cable cutting, Cable, Punch, Multimeter, Threat, Dies etc. Screw Driver, Oscilloscope, Tachometer, Thermometer, Hygrometer etc.
Remarks:
To ensure serviceability of machines, buildings & others necessary equipments maintenance is essential. It minimizes cost through controlling repair and rejection. The maintenance cost should be as minimum as possible as thereby leading to a reduction in factory overheads and prolongs the useful life of the machines and factory plant. During my training period I found that maintenance staffs and overheads of maintenance department were skill enough and efficient.
Utility Services:
Utility Facilities available:
– Electricity / power
Government Supply (PDB)
Factory own generator
– Air compressor
– Natural Gas
– Steam Supply
– Air Dryer
– WTP (Water Treatment Plant)
– ETP (Effluent Treatment Plant)
Others Utility Service:
Electricity and Generator:
Padma Poly Cotton Knit Fabrics Ltd. Electricity gets from Power Development Board. But the factory has a generator of its own which is automatic in action.
Electricity:
Sub-center : Begun-bari
Supply : 440 volts
No of step down transformer : 1
Capacity : 1000 KW
Steam Supply:
Steam generates of boiler is usually a closed vassal made of steel. There are two boilers in Padma Poly Cotton Knit Fabrics Ltd.
FUNCTIONS:
Boiler’s function is to transfer the heat produced by the combustion of fuel (Gas) to water and ultimately to generator steam. The steam Produced may be supplied in Wet processing department for –Heating cylinder dryer, Steaming during dyeing.
WATER PUMP:
Description of Water pump
No. of m/c
Capacity
Centrifugal pump for water supply to dyeing and other section
20 HP Pedrollo pump
4 unit
4000 L/min
10 PH Pedrollo pump
1 unit
60 L/min
5.5 PH Pedrollo pump
1 unit
350 L/min
Spare pump motor pedrollo 20 HP
1 unit
1000 L/min
PRESSURE:
Air Compressor:
There are five compressors in this factory to supply compressed air where necessary.
Name : BPGE. Compressor with Refrigeration.
Model : SF – 10010
Line Pressure : 6.8 bar
System pressure : 7.2 bar
Power consumption of Different Utilities:
Boiler : 30 Kw.5 Kw (For Boiler 1 & 2 respectively)
Generator : 630 Kw, 450 Kw (For generator 1 & 2 respectively)
Compressor : 37 Kw, 22 Kw, 22 Kw, 57 Kw, 37 Kw
Air Dryer : 5 Kw, 5 Kw, 5 Kw.
Cost of different Utilities (approx.):
Boiler : 1,20,000,00 BDT
Generator : 1,00,000,00 BDT
Compressor : 50,00,000 BDT
Air Dryer : 6,00,000 BDT
STORE :
Store is the place where every type of paw materials, finished goods are kept in proper system Inventory control means the accurate calculation and data of every type of rare materials spares & finished goods in time to store for inventory control are nevessary because-
– To know about the required amount of raw material
– To know about the job no which would be processed.
– To be continued the production process.
– To find out the profit and loss of a company.
– Stock and stock value for consumption measuring.
Inventory update:
– (Monthly inventory control)
– (Annual inventory control)
Procurement system:
– Directly cash purchase.
– Credit basis parched.
In other way: Local purchase, Imported.
Inventory control parameters:
– Periodically control
– Perpetual control (Department wise)
Cost Analysis:
The following points are considered for costing the Padma Poly Cotton Knit Fabrics Ltd .
Total dyes and chemical cost.
Total Utility cost.
Salary.
Payment.
Transport Cost.
Lunch / Ifter.
Entertainment cost.
Miscellaneous cost.
Government cash incentive.
Price of the Product.
Actually the price of the product determined by the communication between merchandiser and buyer. (The local merchandiser factory) Firstly Quoted the price of the product and send to the foreign buyer merchandiser. The foreign buyer merchandiser approved the quoted by discussion with the buyer of the product.
The price of the products is given below:
Ladies T-Shirt : 3.90 US $ Per piece
Gents T-Shirt : 3.75 US $ Per piece
Hooded jacket : 4.80 US $ Per piece
Kid’s Shirt : 3.50 US $ Per piece
Pull over : 5.80 US $ Per piece
Costing of Product:
In Padma Poly Cotton Knit Fabrics Ltd. Costing of the product is done by the following way:
Firstly they get an order from buyer and they calculate the consumption of yarn, fabric, garments, accessories etc.
Order item : Hooded jacket (4500 pieces)
Fabric : 100 % Cotton (1X1) Rib
GSM : 220 to 225
Condition : Enzyme wash + Soft Finished.
Size
Body Length : 65.00 cm
Sleeve : 62.00 cm
1 / 4 : 46.00 cm
Consumption Procedure:
Yarn Consumption depends on the fabric consummator generally 15 % Allowances added.
Fabric Consumption for the above mention order:
Calculation :
(Body length + Sleeve length + 10 cm Allowance) * (1/2 chest + 5) Ne 2/10.000
GSM / 1000* 12* 110 %
= (65 + 62 + 10) * (46 + 5) * 2 / 10.000 * 225 / 1000* 12 * 1.10
= 4.150 Kgs / dozen
Dia selection
{(1/2 Chest + 5) + (1/2 Chest + 5)} / 2.54
= 40.125 + 2 cm extra fabric
= 42 cm tube dia for knitting.
Pricing of the Product:
Yarn charge : 4.5 Kgs X $3.10 = $ 13.95
Knitting Charge : 4 Kgs X $ .15 = $ 0.675
Dyeing Charge : 4 Kgs X $ 0.40 = $ 1.8
Dyeing & Finishing charge : 4 Kgs X $ 0.30 = $ 1.35
Lycra yarn Charge : = $ 0.12
Trimmings (all accessories) : = $ 2.00
Cutting & making charge : = $ 4.00
Printing Charge : = $ 1.00
Embroidery C charge : = $ 0.50
Test Charge : = $ 0.45
Zipper Charge : = $ 0.60
———————————————-
= $ 26.445 / dozen
= 2.21 / piece.
Production Cost = $ 2.21 + 5 % commission for buying house.
= $ 2.32
Net Profit = Actual price – Product cost
= 4.80 US $ – 2.32 US $
= 2.48 US $
Remarks:
Cost analysis is an important factor and the fabric consumption should be calculated very carefully because a little bit mistakes can occur great hamper in the factory’s turnover. Padma Poly Cotton Knit Fabrics Ltd. is very aware about it and its management is very concern.
Marketing Section:
A marketing division is responsible for “shaping and strengthening the image of a company and it products through promotion, optimizing sales opportunities and developing alternate strategies for corporate growth.
Responsibilities of marketers:
Conduct and report customer research.
Position the firm relative to target markets.
Position the firm relative to the competition.
Develop the firm’s image.
Propose marketing programs
Propose advertising /promotion strategies.
Forecast sales.
MARKETING:
The Padma Poly Cotton Knit Fabrics Ltd. is a 100 % export oriented industry. All the goods produced in this industry are exported into various foreign countries.
Name of main buyers of the products are given below:
Tom Tailor
S. Oliver
Edward
IC Company
MASHKKOS
New Look
ASMARA
Q. Solution
ALGODON
UPZ DATE & UMBRA.
Total Market:
Europe: 90 %
America: 10 %
Importing Countries:
Germany
Netherlands
Denmark
United Kingdom
Switzerland
Mexico
Canada
United States
Marketing strategy:
Marketing strategy is a very importing factors to sale the products to the buyer. If the marketing strategy is not so developed, it will be very hard to reach the goal. In case of garments marketing the dealings with the buyer is a very important factor.
Padma Poly Cotton Knit Fabrics Ltd. mainly Production Director, Senior marketing officers, Merchandiser and higher officers deal with the buyers. There are some fixed buyers in this industry. Marketing officers and Merchandisers communicate with the buying house to collect the orders. By both side under Standing the rate and order quantity are fixed.
In Padma Poly Cotton Knit Fabrics Ltd. marketing of the product can be controlled by the following way:
– Shipment Control.
– Realization.
Sampling stage:
Color standard for working lap dip
Design Sheet for making sample
Fabric program
Yarn arrange
Knitting
Dyeing
Fabric delivery to cutting Section
Sample making
Dispatch
Waiting for getting final order sheet:
Fabric program
Accessories booking
Color standard Checking.
Yarn Collection.
Knitting
Dyeing
Fabric Delivery
Planning to make.
Considering Control parameter:
Merchandising Department:
1. Marketing
2. Procurement Section
3. Sample Section
4. Sub-Contract Section
Merchandising Department:
A merchandising division surrounds the concept of the target customer and translates customer preferences into a product line for the rest of the apparel firm. Merchandising is the planning, development and presentation of product line for identified target market with regard to prices, assortment, styling and timing.
Function of Merchandiser:
The merchandising process interacts with and may be limited by the business plan and the marketing plan. The primary components of merchandising activities included following—
1.Line planning is the formulation of the parameters that guide line development and presentation and influences sourcing and production process
2.Line development has subcategories of the concept, creative design, line adoption, and technical design. Line development included the actual merchandise that will fill out the line plane through some combination of product development and selecting goods at wholesale.
3.Line presentation with subcategories of internal, wholesale, and retail Line presentation involves process required to evaluate the line and make the line visible salable. .Line presentation results in evaluation and sale of the product offering.
Procurement section:
The basic function of Procurement is as follows:
Right product or materials
Right time
Right quantities
Right price
Right quality
Right delivery.
Sample Section:
Basic patterns or blocks are developed to reflect the firm sizing standard and fit. A basic block pattern is a set of pattern pieces for the simplest garments of the particular type that reflects a set of measurement in the sample size. The terms basic blocks sloper, and master pattern may be used interchangeably. Firms have basic blocks for each type of product in their product line — skirts, pants, shirts, jackets, etc
Style blocks are variations of the individual pieces of the basic block that have been modified to include styling case. Style blocks contain both comfort and styling case.
Draping involves developing a pattern by manipulating fabric directly on a body form. To reduce costs, some firms prefer to have their designers work with Muslin first before fashion fabric are draped since the pattern may be draped several times before it is finalized .
Production Department:
Cutting section
sewing section
Finishing Section
Maintenance Section
Production department:
Production-along with marketing, merchandising, operation, finance is one of the Essential functions in apparel manufacturing. Apparel production involves the conversion of materials (INPUT) into completed, salable garments (output) flat pieces of goods are cut, shaped, assemble, and trimmed as they converted into specific styles to meet customer needs. Production process may be carried out in a firm’s own plant and sourced from other firms located in any place. Production plants specialize in a certain types of materials and finished goods because of the limitation of equipment, skills and expertise available.
CUTTING SECTION:
Cutting is the production process of spreading (Sectioning, carving, serving ) a spread into garment parts that are the precise size and shape of the pattern pieces on a marker. The cutting process may also involved transferring marks and notches from the marker to garments parts to assist operator in sewing. Chopping or sectioning a spread blocks of pieces goods may precede precision cutting of individual pattern shapes. This is often done to allow for accurate machine of fabrics design or easier manipulation of a cutting knife.
Fabrics pieces may be cut to predetermined length for matching patterns or for additional processing such as screen printing. Spreads of plaid fabrics may be pre sectioned into block so the design on the fabrics can be perfectly matched before cutting to the shape of the pattern pieces. Per sectioned pieces may be also be also garment parts knitted to specific finished lengths such as sweater bodies. Per sectioned pieces such as leather or other specialty fabrics may be spread and cut as a single ply or laid up and cut as a multiple – ply spread.
Function of cutting in charge:
The most important functions of cutting in charge:
Examine incoming orders and width and availability of pieces goods
Determine volumes size ratios, sectioning procedure for making marker
Determine whether the file maker are available or new ones are needed
Determination specification for optimum marking and fabrics utilization
Determining most effective use of spreading and cutting equipments
Issuing orders for making spreading and cutting
Function of pattern and marker:
All the patterns in each size of a style are verified that is cheeked very carefully before sending them to cut order planning. Pattern verification includes checking the followings—
Correctness of grade incremental
Competitively of reading with styles specifications
Length and alignment of adjoining seam allowances
Notch placement and alignment with adjoining pattern pieces
Placement of internal markings \Placement of grain marking.
Sewing section:
Sewing section can be divided into following sub-section on the basis of their functions:
Function of production managers:
Production managers are responsible for managing in a firm’s styles through conversion process. Managing production in owned facilities involves people, process, equipment and facilities. Managing production through vendors involves evaluation of production facilities, negotiation of price quotas and delivery and monitoring quality
Production managers are the head of production department. He is who takes all the decision in the development of the desired requirement of the buyers. He takes all the decision in the decision making table. His main job may be divided into planning and coordinating function.
Planning:
Production standards are used in production planning to do the following:
Estimate the rate or production for completion of each operation
Determine the required capacity for an order or style
Determine production start dates and completion dates for orders
Plane the daily volume that should be completed
Determine the back inventory needed to support the work flow
Determine how many operators and machine should be performing each operation
Function of floor chief:
The function of floor the floor chiefs are to control the floors attain the maximum output from the floor. He coordinates among the worker in the floor. He is accountable to the production manager. He follows the instruction received from the product manager.
His main function is as follows:
Floor layout
Setting line layout
Manpower setting in a line
Allocation of manpower
Setting machine and accessories
Setting over time
Allocation of the line for particular style to increase productivity
Helping or supporting the line chief
Coordinative functions with other departments like cutting, finishing, quality and sub store as well as sample section
Allocation of line chief and supervisor in a particular time
Function of line chief:
Line chief is accountable to the floor chief. He coordinates with the supervisor and operates as well. The following are the functions of line chief.
Target achievement
Quality assurance
Proper utilizations of worker
Line layout and assembly of the machine in a particular line as per line layout diagram
Allocates operators for particular job
Sequential of production process in the assembly line
Machine layout
Allocation of folders and accessories
Coordination among the supervisors and floor chief.
In case of problem, which can not be solved by the supervisors
Preparation of the over time in case of needed
Solving bottleneck
CUTTING SECTION:
Cutting is the production process of spreading (Sectioning, carving, serving ) a spread into garment parts that are the precise size and shape of the pattern pieces on a marker. The cutting process may also involved transferring marks and notches from the marker to garments parts to assist operator in sewing. Chopping or sectioning a spread blocks of pieces goods may precede precision cutting of individual pattern shapes. This is often done to allow for accurate machine of fabrics design or easier manipulation of a cutting knife.
Fabrics pieces may be cut to predetermined length for matching patterns or for additional processing such as screen printing. Spreads of plaid fabrics may be pre sectioned into block so the design on the fabrics can be perfectly matched before cutting to the shape of the pattern pieces. Per sectioned pieces may be also be also garment parts knitted to specific finished lengths such as sweater bodies. Per sectioned pieces such as leather or other specialty fabrics may be spread and cut as a single ply or laid up and cut as a multiple – ply spread.
The cutting process may also involve in sewing.
Function of cutting in charge:
The most important functions of cutting in charge:
Examine incoming orders and width and availability of pieces goods
Determine volumes size ratios, sectioning procedure for making marker
Determine whether the file maker are available or new ones are needed
Determination specification for optimum marking and fabrics utilization
Determining most effective use of spreading and cutting equipments
Issuing orders for making spreading and cutting
Function of pattern and marker:
All the patterns in each size of a style are verified that is cheeked very carefully before sending them to cut order planning. Pattern verification includes checking the followings—
Correctness of grade incremental
Competitively of reading with styles specifications
Length and alignment of adjoining seam allowances
Notch placement and alignment with adjoining pattern pieces
Placement of internal markings \Placement of grain marking.
Sewing section :
Sewing section can be divided into following sub-section on the basis of their functions:
Function of production managers:
Production managers are responsible for managing in a firm’s styles through conversion process. Managing production in owned facilities involves people, process, equipment and facilities. Managing production through vendors involves evaluation of production facilities, negotiation of price quotas and delivery and monitoring quality
Production managers are the head of production department. He is who takes all the decision in the development of the desired requirement of the buyers. He takes all the decision in the decision making table. His main job may be divided into planning and coordinating function.
Planning:
Production standards are used in production planning to do the following:
Estimate the rate or production for completion of each operation
Determine the required capacity for an order or style
Determine production start dates and completion dates for orders
Plane the daily volume that should be completed
Determine the back inventory needed to support the work flow
Determine how many operators and machine should be performing each operation
Function of floor chief:
The function of floor the floor chiefs are to control the floors attain the maximum output from the floor. He coordinates among the worker in the floor. He is accountable to the production manager. He follows the instruction received from the product manager.
His main function is as follows:
Floor layout
Setting line layout
Manpower setting in a line
Allocation of manpower
Setting machine and accessories
Setting over time
Allocation of the line for particular style to increase productivity
Helping or supporting the line chief
Coordinative functions with other departments like cutting, finishing, quality and sub store as well as sample section
Allocation of line chief and supervisor in a particular time
Function of line chief:
Line chief is accountable to the floor chief. He coordinates with the supervisor and operates as well. The following are the functions of line chief.
Target achievement
Quality assurance
Proper utilizations of worker
Line layout and assembly of the machine in a particular line as per line layout diagram
Allocates operators for particular job
Sequential of production process in the assembly line
Machine layout
Allocation of folders and accessories
Coordination among the supervisors and floor chief.
In case of problem, which can not be solved by the supervisors
Preparation of the over time in case of needed
Solving bottleneck
Function of Supervisor:
Supervisor is called the first line the executive in the floor. Their functions as follows:
Supervisor operates and helpers in all the operation
Constant monitoring the of materials and the accessories
Ensure quality output
Ensure productivity
Solving operational problems in case of productivity
Solving bottleneck
Training operator to achieve desired output
Development of skilled operator
He is a motivator
Supervising operators and helpers in a line
Allocation of job to operators and helpers
Development of helper to operator
Function of operator:
Operator is the one who occupies the maximum number in the assembly .They are the one who really sweat for the productivity in an organization. Their outcome is the outcome of the company. They are the one who contribute more in the garments sectors the operator is the most important person in the factory.
The function pf operator is as follows:
Assembling parts
Proper handling of machine and parts
Ensures quality
Ensures capacity target
Ensures measurement of garments as per instruction
Ensures allowances as requirements and instruction
Ensures productivity
Reduce wastage, alter and rejections
Informing supervisors in case of handicap in regards to operations and machine as well
Ensures utilization of numbers to reduce quality rejects
Finishing section:
Finishing section help in the development of exports before shipment. The whole proceeding before shipment has been made in this department .
Function of the finishing section:
The functions of the finishing section are as follows:
Process control
Pressing
Folding
Hang tag and others attachments
Poly bag
Assortment
packing
Pre shipment audits
Shipment
Maintenance section:
Maintenance department work in the development of the process through or by the help of machines. Their job is to ensure fault free machines at good conditions. Ensures delivery of right machines at the right place.
The functions of maintenance department work in the development are as follows:
Supply of equipment for assembly and pressing
Discuss issues related to equipment selection
Explain mechanization and automation relative to general and special purpose machines
Examine the basic components of sewing machines work aids and finishing equipment
Examine the effect equipment on product quality and performance
Procurement of those machines required for the production process
Preventive maintenance
Training of man in the section for specialized machines
Break down maintenance
Supply of accessories like folder or attachments
Export and import section :
Major function of Export and import section :
Making all the procedures for the clearance of the good from point of origin to the sea port to a manufacture
The arrangement of shipment from the point of production to the point of sale
Involved in the development of negotiation in most of the cases
Responsible for the customer formalities
Arranging procedural matters in the development of back to back L/C based on master L/C.
Responsible for receiving the materials both local and foreign
Insurance is one of the functions
Damage claims
Banking Section
Issuance of quota
Involved in the development of arranging all the formularies like BGMEA EPB and shipment
Recommending for correct utilization of fabrics/yarn/ acrylic/wool
Giving permission for inner bond sub-contract of bonded warehouses goods
Issuing utilization declaration (U/D), export orders for clearance of raw materials factories.
Helping disposal of stock lost of fabric
Human Resource &Administrative Department :
Information system selection
Recruitment & career development and training section
compliance section
Inventory management section
Human Resource &Administrative Department:
People are a firm’s greatest resource. Employees and their degree of motivation have more to do with the success of a firms then any other single factor. Motivation may be compensation for completed work recognition by peers or management, a feeling of accomplishment a desire to learn. Trainer and managers need to be aware of motivational factors in developing training programs and compensation systems. Motivation is very closely aligned with job satisfaction.
The basic function of Human Resource:
Recruitment and placement
Designing salary and wages
Development of employees through training
Counseling
Motivation employees for the achievement of the organization goal
Development of “sense of belonging”
Bringing organization goal and the individual goal in the same wave line
Creation of better environment
Designing training need and the development of the personal to increase productivity
Ensuring payments both monthly and over time on a specific time and date
Retrenchment of employees
Administrative action in case of defalcation
Declaration of incentive
Upgrading employees
Function of Information Technology:
Save time and money
It saves energy and reduce wastage in all spheres of life
It brings more productivity outlook
Increase efficiency
Move to the department of professionalism
Help in the development of prompt decision process
visualization of the processes predictable
Education of theft and wastage of man and material ensures
Inventory Management section:
Inventory is defined as money the system invests in things that it intends to sell. Units of inventory have value based on the total investment in the item that may be well above the original cost. Value is added to materials throughout the production process and the value remains in the system until the style of sold
Market value of items may decrease with prolonged storage. Fashion goods tend to become obsolete rather quickly.
Three cost factors must be considered in evaluating inventory:
The original cost of the goods
the cost of maintaining the inventory including interest on borrowed money and restricted cash flow
The value added to the original materials
Inventory management has become a more sophisticated field because of computerization of inventory data, production planning, and real time production control, And costing systems. It is common for investment in inventory.
The major function of inventory management :
Right procurement and storing
Making inventory to coincides as per order
Ensures proper storage functioning to avoid pilferage and damage of the products
procurement of the product at the right time and the right quantities in many cases
proper issues of the material at the floor
Proper recording systems
Remarks:
The personnel working in the marketing department should be very innovative and should handle the buyer very carefully. In Padma Poly Cotton Knit Fabrics Ltd. there is a sound marketing strategy which is continuously increasing the reputation of the company.
Water Treatment Plant (WTP):
Raw water consists of different types of foreign materials such as Iron, Magnesium, Calcium carbonate or bisulphate or chloride. In water there may oily or gummy substances be present. The tested hardness of raw water is 100 to 126 PPM.
Therefore, the water is treated to remove those foreign materials and to make it softer. The tested hardness of soft water is less than 5 PPM.
Water treatment is done in three stages by three filter tanks. The circulation of water as different stages is controlled by different valves. There are back washing valves, drain valves, and supply valves. The back wash valves are open when the tank needs washing. Drain valves help to drain out the water in the air. Supply valves are used to control the water supply among the filter tanks. During back washing, a minimum pressure (approx 4 kg / cm2) is maintained; an indicator is attached with the tank which shows the amount of pressure applied.
There is a house in the treatment plant where soft water is stored. A pressure vessel is used for the supply of soft water to floor. A minimum pressure (Approx 4 – 5 kg / cm2) is maintained in the pressure vessel for the circulation of water. Air is act in the vessel to sustain the pressure in required.
The Circulation of soft water from soft house to the floor through the pressure vessel is occurred by the help of three parallel pumps and motors. A pressure indicator and water
level indicator are attached with the vessel. There is a panel board too near the vessel to control the operation (Here motor rpm is 2940, and capacity is 30hp.)
Standard Water Quality Dye House:
Parameter Permissible Concentration
Color Colorless
Odor / Smell No bad smell
Water Hardness Less than 5 PPM
PH value 1 to 8 (Neutral)
Dissolved solid Less than 1
Inorganic salt Less than 500 PPM
Iron (Fe) Less than 0.1 PPM
Manganese (Mn) Less than 0.01 PPM
Copper (Cu) Less than 0.005 PPM
Nitrate (NO3) Less than 50 PPM
Nitrate (NO3) Less than 5 PPM
(Process cost per cubic meter water in WTP of Padma Poly Cotton Knit Fabrics Ltd. is)
Boiler water parameter:
Hardness : 100 to 126 PPM
PH : 6.1 to 7.0
Iron (Fe) : 0.6 PPM
Silicon : 0.2 PPM
Effluent Treatment Plant (ETP):
Waste water form wet processing industries e.g. Dyeing, Printing, Finishing and Washing causes great harmful effect on our environment. As a result agricultural land loses its fertility. Natural water becomes polluter, aquatic life is destructed and crops are damages.
Effluent Treatment Plant is a plant by which waste water is treated in order to make the waste water environment friendly. Padma Poly Cotton Knit Fabrics Ltd. has Biological ETP, which is described is described as below:
USEAPA (United States Environment Protection Agency)
IWRA (International Water Resource Association)
GOB (Government of Bangladesh)
NB:
Value shown in the right column of the above table should obviously be maintained according to the rifles of WHO and World Bank; otherwise the respective factory will be regarded disqualified.
To make serviceability of machines. Building and other service facilities maintenance is very essential. It reduces maintenance cost as far as possible thereby leading to a reduction in factory overheads and prolongs the useful life of the factory plant.
