Study on export oriented woven fabrics produced in Bangladesh

STUDY ON EXPORT ORIENTED WOVEN FABRICS PRODUCED IN BANGLADESH Prepared By : Mazadul Hasan sheshir ID: 2010000400008 13th Batch (session 2009-2013) Department : Wet Processing Technology Email: mazadulhasan@yahoo.com Blog : www. Textilelab.blogspot.com (visit) Southeast University Department Of Textile Engineering I/A 251,252 Tejgaon Dhaka Bangladesh Prepared By : Total Textile Process at a Glance OUR MAIN PURPOSE IS TO FIND OUT WHY WE ARE PRODUCING ONLY 30% WOVEN FABRIC WHILE IMPORT AROUND 70% WOVEN FABRICS FROM ABROAD? We the men of Bangladesh are inborn weavers. If we turn back near future we can see that the local woven sector was very rich in product mix. But in recent times with the gradual development in knit sector, woven sector is day-by-day lagging behind. A matter of great sorrow that we only produce 30% of export oriented woven fabrics fabric while we import around 70% woven fabrics form abroad. What are the problems? What are the burdens towards the development of woven sector? We three friend tried our level best to sort out those problems. INTRODUCTION Some of their findings are given below:  Must improve our dye-stuff manufacturing capability.  Our bank interest rate is highest among all competiting countries. So we must have to reduce it.  Must improve our fabric design and research facilities.  We may utilize other fibres like Bamboo, Hemp etc.  Installation of solar power needs financing.  Must improve woven dyeing as well as finishing capacity.  Must improve our production capability of synthetic fibres.  Finally quality of woven fabric should be improved. LITERATURE SURVEY & SURVEY DATAS At the very beginning of our thesis, we have done a survey work. We have visited at least 5 big woven industries and some buying houses. We had met a number of fabric suppliers and merchandisers. They had given us much information according to our desire. List of factories are given below:  Beximco Textile Mills Limited.  Noman Weaving Mills Limited.  Zarba Textile Mills Limited.  Shabab Fabrics.  Unifill Group Limited.  Dewhirst Limited.  Noman Terry Limited. EXPERIMENTAL & SURVEY DATAS We have enlisted some important questions relevant to our topic before reaching those textile mills and buying houses. The list of questions is given below:  What are the reasons behind less number of woven projects in Bangladesh?  What are the difficulties found in woven fabric production?  Why we are not able to ensure acceptable quality limit of woven fabric?  Which types of fabric we import from foreign countries, and what are the reasons we import it rather than produce it locally?  Why we are not interested to produce variable types of woven fabrics?  Is there any problem in logistic supports associated with woven fabric production? EXPERIMENTAL & SURVEY DATAS PROBLEMS FOUND ABOUT WOVEN FABRIC PRODUCTION IN BANGLADESH  PRESENT PROBLEMS  GENERAL PROBLEMS Investment Capability Power Consumption Improper Utilization of Technical Persons Requirement of Space Process Difficulty Buyer Recommendations Environmental Policy Very Less Woven Dyeing Facility PROBLEMS FOUND ABOUT WOVEN FABRIC PRODUCTION IN BANGLADESH : PSYCHOLOGICAL PROBLEMS: OTHER REASONS: Lack of confidence Horizontally Integration High profit achieving tendency New Fabric Development Vendor don’t want to take risk Machine Conditions Factory Evaluation Lack of Modern Design Machine Lack of Government Patronizations [...]... spinning(cone) For warp Winding Warping Sizing Drawing and denting Knotting Looming Weaving Inspection Folding Packaging For weft Weft(cone) PROCESS DIFFICULTY Sequence of operation (Knitting): Yarn in cone form Feeding the yarn cone in the creel Feeding the yarn in the feeder via positive feeding arrangement and tension device Knitting Withdraw the rolled fabric and weighting Numbering Inspection Delivered...DESCRIPTION OF THE MAJOR PROBLEMS  INVESTMENT CAPABILITY Weak economic condition of Bangladesh  Limited big investors with less interest to invest in big projects  In our country an investment of about 30-50 million is considered as very big investment  In CHINA,INDIA,AUSTRALIA,PAKISTAN investment under 100 million is very uncommon  In some cases new factory without... Persons Now if we focused on woven sector the case is different in comparison of knit sector A data to show the increasing rate of woven garments & knit garments exporting rate is given below Improper Utilization of Technical Persons If we saw the table we can see that in first moment from 1990 to 2002 the woven garments exporting amount is increasing consistently which means consistent growth of woven. .. consuming and difficult to make skilled manpower for woven factory, so we only produce what we produce as usual  As the variation in production number of projects is very less, the textile expertise of Bangladesh lost their interest to be a woven fabric expert and thus the sector is going to the hand of non-tech people PROCESS DIFFICULTY Sequence of operation (Gray Woven Fabric) Yarn from spinning(cone)... production locally But after a period of the increasing rate of local woven garments production is very low or can say the growth rate is very slow To find out the reason why this happen we contact with BGMEA,BTMEA some leading buying house & some experienced Merchandiser as the woven projects are very few in number and it is very time consuming and difficult to make skilled manpower for woven factory,... Buyers Recommendation A RECOMMENDATION LIST OF BUYER FOR WOVEN PRODUCTION: Buyers Recommendation Buyers Recommendation Buyers Recommendation Buyers Recommendation PSYCHOLOGICAL PROBLEM LACK OF CONFIDENCE: ‘’ WHY WE ARE PRODUCING ONLY SOME COMMON FABRICS, WHY COULD NOT WE PRODUCE OTHER DIFFICULT DESIGN FABRICS? WHERE MOST OF THE CASES ALL FACILITIES ARE AVAILABLE!’’ Before answer that question we have to... doubt it on off the major problems  Lack of resource and investment  Lack of maintenance of existing power plants  Many capable groups are waiting for power supply in their big projects, those are already established, machines are available….but power supply is nil!  As we all know that before weaving, WARPING & SIZING is mandatory and it consumes huge power than knit industry Power Consumption A... factory, so we only produce what we produce as usual Improper Utilization of Technical Persons  They told us that,’’ For producing various types of quality woven fabric, we don’t have enough expertise and we can’t make enough skilled manpower timely.’’ For this reason the woven projects are not increasing gradually like knit projects in Bangladesh. ” As the woven projects are very few in number and... than knit industry Power Consumption A case study showed that a renowned woven factory named NOMAN WEAVING MILL’S per month needed power is 3723 kw(for 128 looms) While a renowned knitting factory named Mother Color having 128 circular knitting machines per month power consumption is only 768 kw So it is now clear that a huge power is needed to run a woven factory Requirement of Space 30 acr Requirement... we focus on these processes we can easily understand why woven fabric production is difficult and why variations can’t be easily brought in woven fabric in comparison with knit fabric ENVIRONMENTAL POLICY  Buyer evaluates the factory by find out their environmental policies  Most of our factories have no any specific environmental policies, even they have no any ETP  Factory owner’s main argument . warp Winding For weft Warping Weft(cone) Sizing Drawing and denting Knotting Looming Weaving Inspection Folding Packaging PROCESS DIFFICULTY Sequence of operation (Knitting): Yarn. Patronizations DESCRIPTION OF THE MAJOR PROBLEMS  INVESTMENT CAPABILITY Weak economic condition of Bangladesh  Limited big investors with less interest to invest in big projects.  In our country. in cone form Feeding the yarn cone in the creel Feeding the yarn in the feeder via positive feeding arrangement and tension device Knitting Withdraw the rolled fabric and weighting Numbering Inspection Delivered