Factory visiting Report: NIAGRA
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The document provides information about Niagara Textiles Ltd, including its objectives, history, facilities, production capacity, and machinery. It summarizes that Niagara Textiles Ltd is a leading textile manufacturer in Bangladesh established in 2001 with over 5,000 employees. It has separate knitting, dyeing, and garment divisions with a daily production capacity of 50,000 pieces of garments. The factory is well equipped with modern machinery and ensures compliance with environmental and social standards.
Factory visiting Report: NIAGRA
- 1. 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}
- 2. 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
- 3. 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.
- 4. 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.
- 5. 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.
- 6. 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 :info@niagratex.com
- 7. 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)
- 8. ♥ 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:-
- 9. • 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
- 10. 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.
- 11. 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.
- 12. 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
- 13. 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
- 14. 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
- 15. 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
- 16. 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
- 17. 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:
- 18. 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
- 19. The Organogram of the Niagara Textiles Ltd:
- 20. 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
- 21. 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
- 22. 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
- 23. 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}