Knit Asia Operation Process
Operation (Production) Process of knit Asia Garments:
Production is the hart of the factory. knit Asia Limited Garment Division Production sequences are set down with combined work force of expatriate and local technicians. 15 Standard lines in total covered factory space 1,15,000 SFT has created opportunity to employee 2350 persons. Experts from world-class fashion houses frequently visit for necessary renovation to match with the latest creativity in the field of garment manufacturing. After getting the order from the customer Gold Limited Garment Division have a strong production process to fulfill the requirement & quality as per customer demand.
Production Flow statement of Knit Asia garments Fabric Received:
After receipt the Fabrics from the supplier for production, the following activities are to be taken.
KnitAsiaLimited
GarmentDivision inspection criterion is in accordance with standard set by world-class quality testing institutions. Fabric Inspection following method.
Completing the inspection step by step, all the fabrics are stored by roll in the racks & all the information’s will be keep by a strong data base system.
Cutting:
Inspected fabric is required to be cutted according to the pattern of production.
These are the following process:
- Marker
- Spreading (Shade/Lot wise)
- Numbering
- Cut pec. Inspection (100%)
- Bundling
- Fusing
- Storing as per order
Total Area of Cutting Department:
Cutting 12210 Area SFT.
Long x Width 196′- 8″ x 38′- 6″
Cutting Department
Total Area of Cutting Department :
Machines:
1. Pattern Cutting Machine,
2. Jig Pattern cutting Machine,
3. Eastman ( Cutting Machine),
4. Drill Marking Machine,
5. Band Knife,
6. Lay Cutter Machine,
7. Hand Lay Cutter Machine used for
Cutting on 5 Nos Standard Cutting
Tables.
8. Fusing Machine,
*** Knit Asia Limited Garment Division is taking the preparation to collect a modern new automatic cutting machine withen a few month.
Sewing:
15 Standard lines in total covered factory space 34711 SFT
( 296′ x 120-3″ Long x Width) has created opportunity to employee 1570 persons. Style wise the following sewing activities are undertaken after receipt of the cutting fabric.
1. Small Garments parts Inspection
2. Front Part making
Quality Inspection(Front Part)
3. Back Part Making
Quality Inspection(Back Part)
4. Assembly
5. Quality inspection (Assembly)
6.Thread Trimming
7. Finished Garment Inspection
8. Send for Wash
Sewing Machines:
- Plain M/c (Lock Stitch)
- Needle Feed Lock Stitch
- Vertical Trimming M/C
- Chain Stitch M/c
- Top Stitch M/c
- Two needle M/c (Lock /Chain)
- Over lock ( 3,4,5,6 ) M/c
- Bartack M/C
- Kansai special M/C
- Button hole M/c
- Eyelet button hole M/c
- Velcro Attach M/c
- Pin eyelet/Jigjag M/c
- Blind stitch M/c
- Button stitch (Lock/Chain)
- Loop Cutter
- Feed of the arm
- Flat Lock
- Hemming Machine
- Snap M/c
- PKT Welting M/c
- Saddle stitch M/c
- Solder join
- Collar Turing
Washing Section:
Knit Asia Limited Garment Division have capacity of washing 10,000 pcs/ day (Regular Garment ) in different washing method : Like – Garment Washing, Enzyme Washing, Enzyme + Stone Washing, bleaching Washing & Cap Washing.
Knit Asia Limited Garment Division have Expertise in Garment Dyeing & Functional Finish, i.e. Garment Dipping in Wirinkle – Free, Stain release & repellent & Moisture Management.
*** The following process are held in the washing section :
1. Shade wise segregation(Before wash)
2. Washing
3 Centrifugal Hydro Extractor
4. Drying
5. Shade wise segregation( After Wash)
6. Delivery to finishing section
Knit Asia Washing Machines:
- Washing Machine Valley Type, China, 16Nos
- Dryer, Hong Kong, 24 Nos
- Hydro Extractor, Hong Kong, 6 Nos
- Airing Machine, China,2 Nos
- Chemical Spray Machine, China, 4 Nos
- Squeezing Machine, 1 No
- Sand Blastin Maching, 2 Nos
Total Area of Washing Department :
The following step are included in this section :
1. Thread Trimming
2. Inside Checking
3. Top Side Checking
4. Button Attaching & Ironing
5. Measurement(100%)
6. Get-up (Final Garments Checking)
7. Hourly
8. Folding/Poly packFolding & Poly Packing
9. Carton packing
10. Final Audit (AQL 2.5)
Knit Asia Finishing Machines:
- Pressure Iron
- Vacuum Iron
- Trousers Finisher
- Carton Binding
- Auto Tag Gum
- Vertical Trimming
- Thread Sucking
- Metal Detector
Garment Inspection:
“Highest achievable quality”
They strive to materialize In every sequence. Their own Q.C. staffs keep n eye on the production sequences to ensure on process quality. Comments of Q.C. Team reflect in production planning & process. They follow AQL 2.5 method.
Goods are ready for shipment to Buyer Destination after the finial inspection by buyer representative
Product design:
Knit Asia garments used to add customer value is through distinctive product style and design .It can be one of the most powerful competitive weapons. Design is a large concept than style. It contributes to product usefulness. Company has reputations for outstanding design. As competition intensifies, company design will offer one of the most potential tools for differentiating and positioning a company’s products and services. All Knit Asia garments products are designed on a standard, but there is some options to supply products as customer’s order.
Product feature:
Knit Asia garments have its own product feature that is a competitive tools for differentiation the company’s product from competitor’s product. Company identify new features and decide which one to add to its product. Pant, trouser, Skirts, Short pant ,jacket belong to its own feature for customer.
Knit Asia garments can create higher-level models by adding more features. Features are a competitive tools for differentiation the company’s product from competitor’s products. Knit Asia garments can asses each feature’s customer value versus its company cost. Features that customers value little in relation to costs should be dropped. Those that customers value highly in relation to costs should be added. Garments Industry differentiates its products feature by offering:
- AZO free
- Exact color to your choice
- Shortest delivery time
- No minimum order quantity.
Product Quality:
Knit Asia garments always emphasis to ensure better quality for its customer. Quality levels always support the product’s position in the target market. Its always follow the Total Quality Management(TQM) program to improve product and process quality constantly in every phase of their operations. The ultimate goal of TQM is to improve customer satisfaction and value. In developing a product ,company first choose a quality level that will support the product’s position in the target market, because quality is one of the major positioning tools. Product quality stands for the quality of a product to perform companies functions. It includes the product’s overall durability ,reliability ,precession, ease of operation and repair, and other valued attributes.
Product levels of Knit Asia garments:
In market offering planning of Company , the management need to think through five levels of the product. Each level adds more customer value, and the five constitute a customer value hierarchy. The most fundamental level is the core benefit: the fundamental services or benefit that the buyers really buying. At the second level, the marketer has to turn the core benefit
into a basic product. At the third level, the company prepares an expected product. The Knit Asia garments include better service than competitors and also try to supply the better Garments as per buyer requirement. At the fourth level, the management prepares an augmented product that exceeds buyer expectations. The company sometimes arrangement different parties for satisfying the buyer, At the fifth level stands the potential product, which encompasses all the possible augmentations and transformations the product might undergo in the future.
Products Guarantee of Knit Asia garments :
There are seven guarantees of Garments Products such as:
- Best Quality
- High Strength
- AZO Free
- Competitive Price
- Shortest Delivery Time
- Exact Color To Your Choice
**No Minimum Order Quantity.**
Product Life Cycle of Knit Asia garments:
A Garments industry is differentiating and positioning strategy must change as the product, market, and competitors change over time. Here we will describe the concept of the product life cycle and the changes that are normally made as the product passes through each stage of the life cycle. The concept of the Product Life-Cycle: To say that a product has a life cycle is to assert four things. Knit Asia garments has product life cycle. From life cycle we can easily realize about the sector.
- Companies Products has a limited life
- Companies product sales pass through distinct stages, each posing different challenges, opportunities, and problems to the seller.
- Companies profits rise and fall at different stages of the product life cycle
- Products require different marketing, financial, manufacturing, purchasing, and human resource strategies in each stage of their life cycle
- Product Mix of Knit Asia garments :A product is anything that can be offered to a
Facilities provided for production safety & Security
Knit Asia garments shall provide adequate measure to ensure the security and safety of all its assets, consisting of its employee, administrative and production facilities, machineries ,equipment, finished goods, accessories ,supplies, and other materials.
Facility Security Policies
Employees
- No employee shall be allowed to enter the facility without proper identification card. All employee shall be issued the standard employee’s identification card duly signed & approved by the Management.
- Probationary employee shall be issued temporary ID cards.
- In the event of a change of position and card number, a new card shall be issued and the old one shall be surrendered to the Personnel Department.
- Un-issued cards are to be kept in the factory safe under the control of the Authorized person.
- All prospective employee/applicants shall be screened by performing background check and application verification especially prospective employees who will work in security position of in the packing-shipping receiving sections.
- All applicants shall be required to provide full information regarding their age,education,experience,and such other information as may be considered relevant by requiring the applicants to submit documents such as Bio-data/Curriculum Vitae, Educational Certificate,Age Certificate ,and First job experience /employment certificate (If any).The documents submitted shall be thoroughly scrutinized and verified.
- The factory shall disqualify ,or if warranted ,blacklist, any applicant who is found to have intentionally made any false statement regarding any information contained in his/her application and /or curriculum vitae, including attachments.
Factory Keys
a) A key register shall be maintained by the factory.This will be under the responsibility of the Admin section or any senior member of the staff designated by the management.
bThe key register shall record the holders of all keys relating to factory gates, production room, showroom & other rooms, safes ,padlocks, filing cabinets, etc.
c) The register will record the name and signature of holder of each key as well as the date the key was signed for. In the event that the safe has a combination, then the name of the folder of the combination is to be recorded in the same manner as that of a key holder.
d) Duplicate keys are to be hold by a nominated officer, who is not a key holder, and the combination details, if there’s any(contained in a sealed envelope) are to be held by the one of the Directors or as authorized by the Management.
Vehicles
a) No vehicle shall be allowed to enter the factory premises without proper authorization / identification.
b) All company vehicles are identified with registered plate numbers listed with guard on duty. The list of company vehicles authorized by Management to enter the factory premises shall be updated regularly.
c) Visitor car’s, Cargo truck’s & Container vehicle’s are not allowed to enter the facility unless with Authorization letter from nominated Cargo Agent/Trucking Companies and/or Shipping lines.
D0 Parking space for company and employees vehicles is located separately from the visitor’s car parking space.
Export/Import of Garments by Trucks/Container
a) Loading dock shall be restricted to authorize employees only. Authorized employees are the shipping Supervisor and Shipping Assistants.
b) Shipping dock, loading dock and cargo areas shall be monitored and secured. The shipped supervisors, Shipping Assistants, and Security In charge shall monitor all loading/unloading of cargo at specified place and check and monitor all incoming /outgoing cargoes for all shipments. Shortages and overages in incoming and outgoing goods shall be monitored and should be reported to customs.
c) All inbound and outbound containers shall be inspected for tampering and shall be loaded under the supervision of the shipping supervisor, shipping
assistants, and security in-charge. When containers are tampered/damaged/contaminated, customs and other law enforcement agencies shall be notified immediately.
d) Seals on inbound and outbound containers shall be checked and verified by the shipping supervisor to make sure that match shipping documents. All seal and container numbers shall be recorded in al logbook. When there are abnormalities with seals or seal number. Customs and other law enforcement agencies shall notify immediately.
e) Finished goods containers shall be sealed after loading by the shipping supervisor and factory Manager.
f) Empty and full containers shall be locked and in a designated and secured area to prevent unauthorized access.
Properties and equipment
a) All factory properties and equipment including machineries, fabrics and accessories, finished goods, garment samples, garments for washing, scarp materials, office supplies, and other materials when brought out of the factory premises, shall be covered by an approved gate pass or equivalent documents like delivery challan or scrap sales invoice.
b) The security guard shall not allow any item to be brought outside of the factory premises without this covering document, which should bear the signature of the store In Charge/Admin Manager/Factory Manager/any official authorized by the Management to approve the gate pass/delivery challan/scrap sales invoice.
c) Factory properties may be brought out the factory premises for use in official transactions only or as authorized by the Management.
d) Likewise, all incoming goods and materials shall not be allowed to be brought inside the factory premise under authorized by the factory Manager/Admin manager / Store In– charge or as authorized by the management.
Meeting International Compliance:
Each individual customer has its own unique compliance requirement in additional to world standards. These additional requirements for vendors cover human rights & other ethical issues. We are known for strict measures in maintaining these major international buyers compliance relates for strict measures in maintaining these major international buyers compliance relates to :
- Laws of the Country
- Nondiscrimination
- Child Labor
- Forced Labor
- Harassment & Abuse
- Health & Safety Issue
- Minimum Wage & Benefits as per BEPZA Instructions
- Working Hours
- Overtime
- Workers Representation & Welfare Committee
- Setting Grievence
Employee Motivational factors of Knit Asia garments
Though it is a production base industry, its prosperity depend on production. Knit Asia Garments take necessary action to enrich in production by worker satisfaction.
There is no organization which can reach its goal without the motivation of its employees. Employee motivation arise when their needs and drive are fulfilled by the organization. When environment & culture of organization is favorable to employee needs and drive then employee are well motivated. Every organization take various necessary steps to motivate their employee well.
Knit Asia garments is located in Dhaka export processing zone, It is a 100% export oriented readymade garment industry. It began its operation with the object of highest level quality product & its development. Near about 2500 employee are engaged to continue its operation. All operations systems are conducted by the term and condition of BEPZA rules.
To motivate the different kind of employees & worker Knit Asia garments ensure the following facilities
Financial Incentives : Which include
- Salary
- Increment
- Provident fund
- Medical allowance
- Conveyance allowance & transport facility
- Group insurance
- Financial loan
- Incentive bonus
- Attendance allowance
- Holiday pay
Non- financial incentive : Which include
- Participation
- Group discussion
- Promotion
- Motivational reward
- Training
- Working environment
a) financial incentive : To demonstrate motivation company provide the following financial incentive:
Salary is the very important issue to motivate every employee. Employee come to an organization for earning money .The salary system of the company are followed by the BZPZA rules and condition. In every month salaries are paid on 10th day of the following month .
Yearly increment is provide to every employee at the rate of minimum 10 % of their salary .It also increased 70% according to their performance. Company consider performance according to attendance, behavior, skill , loyalty etc.
After confirmation every employee can get the provident fund facility .Company contribute from his side 8.33% of the basic for each employee.
The company has a medical center situated in the EPZ zone, Beside Knit Asia Garments has also one medical clinic. One MBBS doctor and one nurse always remain present to take care of any kind of patient. Moreover one ambulance always remain present to bring any kind of emergency patient.
Company provide free transport facility for employee.
To insure life security of employee, the company take group insurance scheme.
If needed emergency money leys any employee, the company has a loan facility system. Any employee can get this loan facility in case of emergency through loan application as per company rules.
To inspiration the employees working condition, the company give incentive bonus for the achievement of their targets.
For encouraging the employees, the work, reducing absence and turnover, attendance bonus is given by the company. If any employee attends regularly in his/her duty every month he/she will get the attendance bonus.
If company arrange any emergency work on any holiday, the employee is entitled for holiday allowance.
These kinds of incentives are as follows.
To develop employee responsibility and also to encourage their work participation, the company create scope for employee participation in decision-making.
Group discussion is held to consider any kind of emergency decision .From this discussion management can get many kind of information to handle the company smoothly and employee are motivated to fulfill their commitment to the company.
For better performance company give the promotion to the select employees .
To motivate employee and to encourage their work,company give reward for better work or performance .Every year, company arrange a party to give reward for the best employees from different section. So employee are motivated to get rewards by doing
their best performance.
To increase employee working ability, the company take necessary steps for training. such as first aid training ,fire fighting training, best work procedure training etc. company has also training facilities at home and abroad.
Company provide good working environment for retain employees long time and to ensure commitment.
