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


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


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


Garments Division--

Cutting section (Capacity: 50,000 kg/day)


Cutting M/C KM 09

Cutting Table Local 08

Sewing Section (Capacity: 50,000 pcs./day)


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”



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)


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:

http://niagaratex.com/web/?attachment_id=915

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}

factory visiting report: niagra

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