Factory visiting Report: NIAGRA
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Transcript of Factory visiting Report: NIAGRA
COURSE NAME : INT. TO FASHION & CLOTHING RELATED INDUSTRY IN BD
COURSE CODE : GMT-1101
ASSIGNMENT ON FACTORY VISIT IN
DATE OF FACTORY VISIT
26th JUNE 2013
REPORT SUBMITTED TO
MD.MARUF SARKER
{LECTURER,BUFT}
REPORT PRESENTED BY THE GROUP OF
RAWD FASHION HOUSE
NAME & I.D. OF THE GROUP MEMBERS
SL NO. NAME OF THE STUDENT IDENTITY NUMBER
1 ISA AHMED 131-088-0-135
2 KAIF AL AZAD 131-089-0-135
3 MOSTAFIZUR RAHAMAN 131-090-0-135
4 RIYAD SHEIKH 131-091-0-135
5 S.M.NAZMUL ALAM 131-092-0-135
6 SOHAG REZA 131-094-0-135
REPORT PRESENTATION DATE
09th JULY 2013
Origin of the Report:
To expand the practical knowledge by implementing theoretical knowledge through the
in the factory visiting program that would make a student to become a competitive with
the world’s industrial sector. That program not only increases the knowledge but also
give the idea about organizational activities before entering into an organization.BGMEA
University of Fashion & Technology is one of the reputed private university in
Bangladesh, has designed the curriculum of AMT,KMT & FDT course such way that
international graduates will be produced. After competing 1’st semister, one student
need to go for further factory visiting programs in a commercial organization. From this
visiting program students get the opportunity to learn facing the real business world.
Our faculty supervisor Md. Maruf Sarker, Lecturer, BUFT, approved the topic and
authorized me to prepare this report as part of the fulfillment of factory visiting
requirement. The report thus was on NIAGARA textiles mills Ltd.
Objectives of the report: General Objective: The primary objective of this report is to explore of visiting performance analysis of
Niagara textiles Ltd.
Secondary Objective: To show an overview of the company(vision, mission, value, product offerings, associates
companies)
To present an overview of mechinarise objects.
Methodology:
While conducting the report, sources were explored for primary information and
data. But hardly any updated data could be found. In the absence of updated
information or data dependence on secondary has been inevitable. However,
wherever possibly primary data has been used. Data were also collected by
interviewing the responsible officers and from the mechinary. There have been used
some statistical tools (Microsoft Office Excel table) and graphical representation
(Microsoft Office Excel chart) to find out different types of analytical results and
interpretations.
Introduction of Niagara NIAGARA Textiles Ltd. is one of the top class & leading Textile products manufacturing
company in Bangladesh which starts it’s operation in 2001 which is at Chandra in Gazipur.
The company is managed by a group of dynamic professionals, working proactively in a
challenging environment. NIAGARA is committed to provide excellent services to its clients. It
is dedicated to focus on quality in order to excel in its performance.
This factory effort to delight its customers by producing best quality Textile products at an
optimum price through efficient utilization of available resources. They manufacture and export
high quality textile products at an affordable price produced in an environmental friendly process
and practicing high level of integrity and fairness in dealing with our stakeholders. The mission
is to provide excellent quality and value added textile products at a competitive price for ultimate
satisfaction of its customers.
Since 1980 to till date the Apparel sector of Bangladesh has passed through different huddles &
obstacles and now has reached a stage where it can compete with all its competitors in price and
quality as well as variety. In this scenario, Niagara Textiles Ltd. was incorporated in 2001 as a
public limited company and listed with our national stock exchanges, which are Dhaka Stock
Exchange, and Chittagong Stock Exchange. The company was initially formed for processing
and export of knit garments, however subsequently, state of the art plant and equipment was
added for handling all kinds of knitted fabrics and now Niagara is a leading manufacturer and
exporter of all kinds of textiles knitted garments.This is a vertically set up textiles unit In a short
span of time Niagara Textiles Ltd. has gone from strength to strength to become one of the
significant entities into sphere of activity. The factory is well equipped with high performance
machinery and experienced technicians are engaged here to ensure the quality and customer
satisfaction. We can produce international standard fabric and garments of any quality and
quantity. Niagara always keeps pace with latest technology of Textiles industry.
Niagara textiles is 100% export oriented, vertically integrated knitting, dyeing, finishing and
garment manufacturing company with production capacity of about 15 million pieces of
garments per year. The products of the Company include Pique Polo-shirts, Jersey Polo-shirts,
Bubble knit Polo-shirts, Golf shirts, Sweat shirts, Hooded Sweat shirts, Polo shirts, Sweat Pants,
Basic Tee-shirts, Track suits, Tank Tops, Big Tee-shirts, Heavy Tee-shirts, Jogging Suits, Turtle
Neck Tee-shirts, Jackets, Underwear, Children wear, men wear, babies wear etc.
This commpany is a fully compliant factory.It’s never allow slave, child or prison labor or even
force labor.This commpany always provide all necessary safety measures & ensure the
workplace safe, healthy & comfortable.To manufacture quality products as well as customer
satisfaction is its ultimate goal.This commpany certified by Oeko-Tex & WRAP. We have also
awarded as one of the best compliant factory by Labor Ministry of Bangladesh Govt. and
BKMEA. Effluent Treatment Plant (ETP) established for hazard free environmentFacilities
available hare like in-house printing section and own covered van for carrying products on time.
Our Associate Company in garments, a fashionable ladies brassieres and brassiare-panty sets
manufacturer and exporter of Bangladesh.
Board Directors of this Commpany:
1.Mr.Ahsan Habib; Chairman
2.Mr.Nurul Hasan; Managing Director
3.Md.Shahinoor Islam;Director
4.Mr.M.A.bakar; Director
Company Details
Primary Information
Company Name : NIAGARA TEXTILES LTD
BKMEA Membership Number : 594
Membership Type : Ordinary Member
Year of Registration : 2001-07-12
Contact Information
Contact Person Name : MR. MD. NURUL HASAN
Contact Person Mobile Number : 06822-51233-4
Contact Person Designation :
Managing Director Factory Address :CHANDRA CIRCLE, KALIAKAIR,GAZIPUR
Telephone :88-02-935328, 9340945, 9345807
Fax :88-02-06822-51231
Email :[email protected]
Core Values:
1.New Philosophy 5.Advancement
2.Integrity 6.Respect
3.Accountability 7.Attiude
4.Goal Orianted
Eeport Countries for this company:
1.European Union 4.Middle East
2.Japan 5.U.S.A
3.Canada
Main buyers:
1.H & M 5.Demix
2.Big Star 6.Sears
3.Lazy jacks 7.Huba
4.Techibo 8.DISTRA
Profile
♥ Manpower: Existing workforce: 5,000 employees (Approx.)
♥ Member of:•Bangladesh Knitwear Manufactures & Exporters Association (BKMEA)
•Bangladesh Garment Manufacturers and Exporters Association (BGMEA)
•Industrial and Bussiness Welfare Foundation (IBWF)
♥ Bank details:
:: Islami Bank Bangladesh Ltd.
:: Shahjalal Islami Bank Ltd.
♥ Product Type:: All kinds of knitted tops and bottom like : Single/ Double Jersey , Single/
Double Lacoste, Pique, Wafle, Fleece, Terry, Interlock, Interlock Pique, Pleated Jersey, Mesh
Fabric, Rib etc. (with or without Spandex).
♥ Capacity :
Textiles Division – 20,000 Kg fabric / day
Garments division – 50,000 pcs/day (based on basic items)
♥ Area details :
♥ Textile division:
Knitting : 15,000 Sft
Dyeing : 40,000 Sft
Total : 55,000 Sft
♥ Garments division:
Cutting : 20,000 Sft
Sewing : 60,000 Sft
Finishing : 20,000 Sft
Sample room : 2,000 Sft
Office : 5,000 Sft
Store : 6,500 Sft
Total : 1,13,500 Sft
Bonded warehouse – 40,000 Sft
G.Total = 2, 08,500 Sft
Factory Wings:
The wings are as follows:-
• Knitting Division
:: Knitting Section (Capacity: 20,000 kg/day)
• Dyeing Division
:: Dyeing Section (Capacity: 25,000 kg/day)
• Garments Division
:: Cutting Section (Capacity: 50,000 pcs./day)
:: Sewing section (Capacity: 50,000 pcs./day)
:: Finishing Section (Capacity: 50,000 pcs./da)
Different Facilities:
Facility Quantity
Dining 02
Prayer place 03
Staff Toilet 17
Male Toilet 115
Femalen Toilet 58
Medical Center 01
Childcare Center 01
Canteen 01
Photocopy center 01
Training & Seminar Hall 01
Product Information:
Textiles Division--
01.Single /Double Jersey 08.Interlock Pique
02.Single / Double Lacoste 09.Pleated
03.Pique 10.Jersey
04.Waffle 11.Mesh
05.Fleece 12.Fabric
06.Terry 13.Rib etc
07.Interlock
Garments Division—
All kinds of knitted tops & bottoms.
Production Capacity
As final product 50,000 Pcs ready made garments per day based on items.
Department wise Production Capacity as follows -
Knitting Section : 20,000 kg/day
Dyeing & Finishing Section : 25,000 kg/day
Curring : 65,000 Pcs/day
Garments Division : 50,000 Pcs ready made garments per day
Printing Section : 50,000 Pcs/day -(One Color Basic Rubber Print)
Sewing :60,000 Pcs/day -(One Color Basic Rubber Print)
Finishing : 60,000 Pcs/day
Strength:
We are committed to provide best quality products and services to our stakeholders in a
cost effective and efficient manner. In this process, we have develop and utilized our
human, technical and material resources most effectively. This policy will be reviewed
from time to time to ensure continued suitability.
Machinery Strength---
Textile Division:
No Name of Machine Brand Dia Gauge No of Set
01
Rib (8-Lock)
Torret,Germany
30” 18 01
36” 18 01
Pai lung, Taiwan 34” 18 01
36” 18 01
38” 18 01
40” 18 01
42” 18 01
02 Interlock (8-lock) Torret, Germany 30” 22 01
34” 22 01
36” 22 02
03 Single Jersey Pailung, Taiean 20” 24 01
21” 24 01
22” 24 01
23” 24 01
24” 24 01
25” 24 05
34” 24 01
36” 24 02
Orizeo, Italy 30” 24 02
04 3-Thread fleece Ozizio, Italy 30” 20 02
05 Flat knit Stoll, Germany 84” 14 01
Kaoheng/Taiwan 54” 14 25
Total no.Machines 53
Dyeing & Finishing Division
Name of Machine Brand Capacity in kgs No. of set
Atmospheric winch PMM, Turkey 025 03
100 01
200 01
300 01
400 01
600 01
750 01
800 01
Name of Machine Brand Capacity in kgs No. of set
High Temperature Winch PMM, Turkey 025 03
300 01
DMS Turkey 025 01
150 01
300 01
450 01
ACMI, Taiwan 050 01
600 01
1200 02
1500 01
Dewatering & De twisting Bianco , Italy Open width 01
Heliot , France Tubular 01
Beneks , Turkey Tubular 01
Dryer PMM, Turkey Tube 8 ton 01
Stenter LK & LH, Taiwan Open 10 ton 01
Compactor Tubetex , USA Tubular 01
Serteks , Turkey Tubular 01
Bianco, Italy Open width 01
Total no of Machines 46
Dyeing Laboratory
Washing Plant
Name of Machine Brand No. of Set
Washing machine Flying Tiger 01
Hidro Stractor DH 02
Dryer Ta Ting, flying tiger 04
Total no of Machines 07
Name of Machine Brand No. of set
Spectrophotometer Datacolor 01
Spectra flash Model- SF 600x 01
Lab Sample Dyeing Ahiba Nuance, Swiss
Fongs, Hong Kong
01
02
Wash & Shrinkage testing Machine Wascator 01
Color Machine Cabinet Veri vide, England 05
Washing Machine Ariston 02
Rubbing Crock Meter Roaches, England 01
Total no of Machines 14
Brushing Machines
Name of Machine Brand No. of Set
Raising Machine Arttex 01
Spectra Flash Model-SF 600x 01
Lab sample Dyeing Ahiba, Nuance Swiss 01
Total no of Machines 03
Garments Division--
Cutting section (Capacity: 50,000 kg/day)
Name of Machine Brand No. of set
Cutting M/C KM 09
Cutting Table Local 08
Sewing Section (Capacity: 50,000 pcs./day)
Name of Machine Brand No. of set
Plain Juki 564
Over lock Pegasus 243
Over lock Yamaha 21
Over lock Juki 05
Flat Lock Pegasus 124
Flat Lock Juki 22
Flat Lock Yamaha 06
Button Hole Juki 16
Button Stitch Juki 17
Snap Button Nagishing 06
Peaconting Juki & Kansai 05
DFD Kansai 01
PMD Kansai 02
Fit of the Arm Juki 02
Re-cone Hashima 02
Rib Cutting IDEA 08
Back tape Kansai 02
Bertack Computer Juki 02
Two Needle Juki 02
Fusing Hashima 01
Machine wise sewing thread consumption per inch:
Machine No. of needles Thread
consumotion/inch Plain machine 1 needle 2.5”
Plain machine 2 needles 5;
Over lock 3 threads 16”
Over lock 4 threads 18”
Over lock 5 threads 21”
Flat lock 3 threads 19”
Flat lock 5 threads 32”
Bar tack stitchingButtone
hole stitching
----------- 7-8”
Button attaching ----------- 6-7’
Feed of the arm ----------- 4”
Kansaiu stitching ----------- 4”
Finishing Section (Capacity: 50,000 pcs./day)
Name of Machine Brand No. of set
Iron Machine Mordern 39
Naomoto 08
Veit 12
Electronic Steam pressure Naomoto 03
Electronic spot remover NGAI SHING 02
Finishing table Local 20
Thread Sucker NGAI SHING 01
Mordern 01
Aatpr 01
Metal Detector Cintex , UK 01
Lock , England 01
Picture of this factory:
Power & Utilities Section
Name of Machine Average Capacity/Day in Pcs No. of set
Gas Generator 1125 KVA 2 Set
Diesel Generator 750 KVA 1 Set
Diesel Generator 600 KVA 1 Set
Boiler 8 Ton 2 Set
Compressor 30 BAR 4 Set
ETP 40 m3/H 2 Set
Hot water Plant 40m3/H 1 Set
Number of Machine :
SEWING : 1043
KNITTING : 58
DYEING : 28
Production Capacity : 1095000 PCS/MONTH
Number of Employee (Workers) : Male: 1706 | Female: 2560 | Total :4266
Yearly Turnover (In US$) : 1.095e+06
The Organogram of the Niagara Textiles Ltd:
Compliance
Compliant:
Government & BKMEA award winner for the best compliant factory
Its awarded as one of the best compliant factory for fulfilling major compliance issues which was
jointly organized by Labor Ministry of Bangladesh Govt. and BKMEA on 1st May, Labor Fair-
2008. Furthermore it was also awarded by Naari Uddug Kendra (NUK) for fulfilling core
standards on social compliance issues.
Fully Compliant with environmental ETP & other social welfare issues
Its very much concern for hazard free environment and have constructed an Effluent Treatment
Plant (ETP) that is running and rectifying waste water. And also concern about social welfare
issues of our worker, Social Welfare Officers regularly monitor these at floors.
Policies:
Safety Policy: • Company always strives to provide safe and hazard free atmosphere in production floors for all
workers.
• Every floor has two exits for incase of emergency & also have the Fire Evacuation Plan at the
point of exit.
• Every floor has sufficient number of firefighting equipments such as fire extinguisher, fire hose
cabinet, fire alarm switch etc.
• Every section has a group of people who have been trained for protect the emergency fire
hazard situation.
• Unannounced fire drill is arranged once in a month.
• Each floor has first aid box containing sufficient number of medicines in case of emergency.
• Each floor has sufficient number of Personal Protection Equipment such as mask, hand gloves,
goggles, metal gloves, air plug etc. are provided for ensuring safety.
• Pure drinking water is available in each floor.
• There is a medical center in the factory and a Doctor looks after the health of the workers.
Employee Welfare Policy: • All employees/ workers are entitled to free medical check up in the medical center in our
factory.
• Each floor has proper ventilation & sufficient ceiling fans exhaust fans are there for good air
supply.
• Each floor has sufficient number of washrooms.
• Each floor has sufficient lighting to facilitate production.
• All employees are entitled to overtime bonus, Eid festival bonus, house rent, medical
allowance, Friday & holiday allowances.
• A large dining hall is in our factory including pure drinking water & well sitting arrangement.
• A Group Insurance is made for entire employees of the company and already availed two
insurance claims due to death of workers against it.
• A child day care center is in our factory & children of workers take proper care and feeding.
• Maternity leave & maternity benefit for female workers are provided as per labor law.
Recruitment Policy: • No child labor in our factory.
• No gender discrimination in our recruitment procedure.
• There is no force labor.
Other Policies: • Environment Policy: There is an Effluent Treatment Plant (ETP) in our factory premises to
refine industrial dust for hazard free environment.
• We comply the rules & regulations of different regulatory bodies such as factory inspection
authority, govt. & non-govt. agencies.
Quality Assurance
Niagara Textiles Ltd. is totally committed to provide quality products that always meet the
needs and expectations of customers for reliability, safety, economy and on-time delivery of
shipments. To achieve this objective, Niagara Textiles Ltd. provides all the necessary resources
to ensure a well equipped and adequately trained, and experienced manpower to take proper care
of customer requirements. Niagara Textiles Ltd. emphasizes that quality is the shared
responsibility of its entire staff. The company ensures that all personnel are familiar with, and
work to, the company’s work practices as well as in conformity with the legal and other
obligatory requirements and are determined to comply with the requirements of Buyer’s
expectations e.g. code of conduct, social compliance and continually improve its production and
the Quality Assurance Department. This QAD has brought the unique opportunity for Niagara
Textiles Ltd. to review the quality objectives and achieve business excellence through continual
improvement. To manufacture quality products and Customer satisfaction is the company’s
ultimate goal.
So, it committed to provide best quality products and services to our stakeholders in a cost
effective and efficient manner. In this process, we shall develop and utilize our human, technical
and material resources most effectively. This policy will be reviewed from time to time to ensure
continued suitability
Quality at a glance:
• Total goods are checked before shipment for quality assurance.
• Yarns are lab-tested for pilling resistance, color fastness etc.
• All kinds of raw materials are preserved in warehouses in a professional manner.
• Production only starts after Buyer’s approval & also prior approval on quality.
• All production floors keep clean and maintain all necessary safety measures according to
compliance.
Other developments/prospects:
Government & BKMEA award winner for the best compliant factory:
It has awarded as one of the best compliant factory for fulfilling major compliance issues which
was jointly organized by Labor Ministry of Bangladesh Govt. and BKMEA on 1st May, Labor
Fair-2008. Furthermore we have also awarded by Naari Uddug Kendra (NUK) for fulfilling core
standards on social compliance issues.
Fully Compliant with environmental ETP & other social welfare issues:
It also very much concern for hazard free environment and have constructed an Effluent
Treatment Plant (ETP) that is running and rectifying waste water & also concern about social
welfare issues of our worker, It’s Social Welfare Officers regularly monitor these at floors.
Computerized Automated Management Information System (MIS) by ERP (Enterprise
Resource Planning):
As part of automation, implemented in-house developed ERP database software for MIS
(Management Information System).
In-house Printing Section:
It has an in-house printing facility
Carrying facility by own covered van for timely shipment: It has own covered vans for carrying
products on time.
CAD/CAM (Computer Aided Design) Machine:
It has in-house CAD/CAM systems
Values:
Respect for people - Demonstrate respect by developing our people and helping them to achieve high performance standards. - Treat all people with dignity.
Integrity - Honesty - Walk the talk.
Sense of Urgency - Strive for speed and simplicity in everything we do.
Empowerment - Encourage and reward self-confidence and initiative - Require accountability
Conclution:
NiagaraTextile Mills is one of the leading textile industries having history of decades, is
providing premium quality textiles. It has achieved this far-fetched position by following strong
commitment to the clients by giving them top quality products and services.
Strong sense to adopt latest technical innovation, having a glance over world wide vogue in
textile industry and giving full fledge dedicated services to the clients is the main key factor of
Niagara Textile Mills vertical growth.
Niagara has a marked position in International Textile Industry for its commitment and
responsiveness to customers’ satisfaction.
Niagara produces complete variety of textiles ranging from grey fabric to highly profiled made
ups. Its export vicinity has vast borders from Europe, USA, North & South America, Russia & CIS
States to Scandinavian countries. Niagara has achieved the turn over of UA$ 60 Million per
annum since years.
With the slogan “We Are the Safe Suppliers” Niagara is transforming this ideology into reality
through excellent, skilled and dedicated, above 2500 employees who assure the best
availability of products & services in the hands of clients.
Niagara’s Quality Assurance Department insures the best quality of products at every following
step…..
Written by: S.M.Nazmul Alam{131-092-0-135}