industrial process of a ready-made garments industry

readymade garment sector is a well grown industry in bangladesh.

this industry is greatly contributing in reducing unemployment in
lower income population of our country as well as in developing
foreign trade and remittance. from 1983 to 2009, we have seen
some 36 times increase in the number of rmg factories and that
certainly indicates the solid growth and development in the sector.

chart showing rmg income in % of chart showing rmg income in % of

total export income (2010) total export income (1983-2010)
bangladesh's rmg exports 26747.09 million us$ (2009 & 2010), 79.33% of total export
3.1 million manpower employed in 4,825 bgmea member factories,
2.38 million are women (85%)
case study

babylon group echo sourcing limited

mirpur , dhaka kaliakoir , gazipur
Established 1986 Established 2007
Daily production capacity 24000 pcs Working area 38500 sft
Working area 90000 sft 4500 employee
2000 employee in mirpur branch Winner of National Environment Award 2010
Total 12000 employee under the group characteristics :
Gold Compliance Award industrial context
characteristics : including textile production
urban context
comprises only RMG
page 01
typical process flowchart typical sampling department
buyers’ order buyers’ sample

sampling fabric collection

research &
development pattern design

pattern design fabric cutting

pattern developing
fabric cutting
CAD output

fabric inspection
sewing
& storage

fabric cutting embroidery

sewing button attaching

sewing button and accessories attachment

ironing, ironing
finishing & packing

pre shipment inspection and finishing

storage accessories attachment ironing
6'

pattern making in 3'-9"

sampling room

page 02
 fabric inspection & storage typical research & development

buyer approval final sample analysis

fabric collection
designing process of production

fabric inspection
fabric section designing production line

fabric storage

calculating fabric amount

accessories storage

storage maintenance & supply calculating accessories amount

inspection table

calculating every 100 sq. ft. fabric :

CAD & pattern development
total point 36” department
X X 100 = point per 100 sq. ft.
total examined length fabric width

attachment of more then 2 fabric is not acceptable pattern designed by the sampling
any size hole will be 4 points section on buyers requirement are
total point per 100 sq. ft. can not exceed 28 digitally converted at cad (computer
aided design) section .
rolls individually scoring 40 point will be rejected

10% of a total supply is checked randomly

If defect is higher ,additional 15% will be checked
4 point inspection system

Defect length 3” : 1 point digital drawings as patterns are created,

printed and sent to cutting section.
Defect length 3” -6” : 2 point
Defect length 6” -9” : 3 point
Defect length 9” : 4 point

page 03
typical cutting department

pattern drawing from cad section

fabric preparation and stacking

primary cutting

secondary cutting (detailing) fabric stacking fabric preparation primary cutting

in line inspection

fabric reordering

fabric tagging and bundling

detail cutting accessories cutting tagging

supply to sewing section

bundling ready for sewing

84’

6’6”

cutting table size

cutting ,machine safety gloves

page 04
typical sewing department

temporary bundle storage

cluster of sewing machines

in line ironing
cluster of sewing machines in line ironing in line inspection

in line inspection

embroidery

attaching additional parts

attaching additional parts embroidery button attaching

attaching buttons

attaching accessories

end line inspection end line inspection reject , recheck & repair box approved box

1'-10"

3'-7"

1'-9"

1'-10"

typical sewing machines sewing table and clearence

page 05
 typical finishing department

thread sucking inspection stain removal ironing fusing

thread sucking

inspection

alternation measurement
strain removal
ironing
arm pressing tagging pre-packing
paper trim attachment

folding
poly packing
100% assortment packing & checking
cartooning (metal free zone)
pre-shipment inspection audit folding poly packing (metal free) cartooning

Pre shipment storage

fusing machine bar tacking machine

thread sucker machine
prepared by : 0 5 0 1 0 2 4 0 5 0 1 0 3 4 0 5 0 1 0 4 0 0 4 0 1 0 5 6 page 06