Survey of Bangladesh
Prepared by
Introduction:
The case study of Y Knitting Mills Ltd. is situated at Valuka, Mymensing. In respect of technical point of views (machines, raw materials, production planning, sequence and operation, maintenance, utility service, store and inventory control, cost analysis), it is a very good graded Knit Dyeing Mill and a strong base of financial aspect and marketing activities, this Mill is 100% export oriented and running up to now with profit.
A brief description of X1 Weaving Mills Ltd:
1. Name of the Mill : Y Knitting Mills Ltd
2. Nature of the Ownership : Private Limited Company
3. Year of Establishment : 2005
4. Authorized Capital : Tk: 39.07
5. Paid-up Capital : Tk: ?
6. Land Area : 5 Bighas
7. Physical Structure : Pucca + Pre-Fabricated
8. Type or Nature of Mill : Knitting
9. Machine and Equipments, Capacity and Capacity Utilization:
SlNo.
|
Name of the Machine
|
Origin and Year of Purchase
|
No. of Machine
|
Installed Capacity Kg/Day
|
Target Production Kg/Day
|
Capacity Utilization (%)
|
1
|
Circular Knitting
|
Mayer &Cie
|
24
|
10368
|
9331
|
90
|
2
|
Dyeing Machine
|
Origio, Itally
|
20
|
8400
|
7560
|
90
|
10. Stock Position and Volume of Shortfall (July 2007-December 2007)
Types of Stock
|
Stock (Kg)
|
Value of Stock (Tk)
|
Yarn
|
45000
|
5,40,0000
|
There was no shortage of raw material in the mill during July 2007 to December 2007.
11. Last Three Years Production (in Kg)
Sl. No.
|
Product
|
2005-06
|
2006-07
|
2007 (July07-Dec 07)
|
1
|
Cotton Fabric
|
85,00,000 yds
|
95,00,000 yds
|
51,00,000 yds
|
2
|
Total
|
85,00,000 yds
|
95,00,000 yds
|
51,00,000 yds
|
Production history of last two years.
12. Production and Shortfall During July 2007-December 2007
SlNo. | Name of the Machine | No. of Machine | Installed Capacity Yds/Day | Target Production Yds/Day | CapacityUtilizatio Yds/Day | Shortfall |
1
|
Ball Warping
|
3
|
72000
|
65000
|
33000
|
49%
|
2
|
Dyeing Machine
|
1
|
72000
|
65000
|
33000
|
49%
|
3
|
Long Chain Beamer
|
8
|
72000
|
65000
|
33000
|
49%
|
4
|
Loom
|
100
|
65000
|
60000
|
33000
|
45%
|
5
|
Sizing
|
1
|
60000
|
58000
|
33000
|
43%
|
13. Calculation of Sale
Products
|
Cost of Production
|
Total Revenue
(Tk)
|
Profit
(Tk)
| |
Woven Fabric
|
127.65 Tk/Yd
|
140.42 Tk/Yd
|
65,10,15,000
|
6,40,05,000
|
14. Reason of Production Shortfall During July 2007-December 2007
Sl. No.
|
Reason of Production
|
Shortfall During The Quarter
|
1
|
Electricity Failure
|
X
|
2
|
Shortage of Raw Material
|
X
|
3
|
Shortage of Working Capital
|
X
|
4
|
Lack of Proper Planning
|
X
|
5
|
Misleading Lead Time/Procurement Time
|
X
|
6
|
Lack f Spare and Accessories
|
X
|
7
|
Strike/Unrest
|
X
|
8
|
Natural Disaster
|
X
|
9
|
Shortage of Skilled Manpower
|
√
|
From the above table it is clear that shortfall of production is only for shortage of skilled manpower. It is assumed that huge 50% production shortfall occurs due to shortage of Textile Technologists.
15. Cost of Good Sold
 |
| CHART OF COST OF THE FACTORY |
16. Number of Shifts, Working Hours and Days During July 2007-December 2007
No. of Shifts/Day
|
Total No. of Shifts During July 2007-December 2007
|
Total No. of Days During July 2007-December 2007
|
Total No. of Working Hours During the Quarter
|
2
|
312
|
156
|
2496
|
17. Raw Material/Input Used During July 2007-December 2007
2808000 Kg
18. Wastages in terms of % (During the Quarter Ended Decmber 2007)
Yarn
|
Fabric
|
Total
|
0.5%
|
0.5%
|
1%
|
19. Investment:
Fixed Assets in Tk
|
Working Capital in Tk
| |
Original Value
|
Present Depreciated Value
|
In Cost Price as on
|
39.01 Cores
|
2.5 Cores
| |
20. Wages and Salaries (Tk) as in December 2007
Period
|
Officers and Staffs
|
Labour
|
December 2007
|
13,50,000.00
|
16,50,000.00
|
21. Manpower as on 31st December 2007 :
Level of Skill ness
|
Education
|
Requirement
|
Existing
|
Shortfall
|
Shortage (%)
|
Managerial Level
|
B. Sc/M.Sc./MBA
in Textile Engg.
|
1
|
0
|
0
|
100%
|
High Skill/Expertise Level
|
B. Sc in Textile Engineering
|
6
|
5
|
1
|
17%
|
Moderate Skill Level
|
Diploma in Textile Engineering
|
15
|
10
|
5
|
33%
|
Specialized Skill Level
|
Trade Course
|
25
|
15
|
10
|
40%
|
Skilled /Unskilled Labour
|
Skilled by Experience
|
390
|
410
|
20
|
(+5)%
|
From the above table we have a clear idea about the present condition of overall situation of different mills and we can simulate this case in real/practical fields forenginners and technicians in the following ways.
 |
| Figure: Requirement of Textile Engineers and Technologists at Different Level. |
22. Product Diversification Matching with the Need of RMG Sector and Quality
Improvement
Sub-Sector
|
Existing Supply/Yr of Products to RMG Sector
|
Scope of Additional Production and Supply to RMG Sector
|
Scope for Improvement of the Product
| |||
Products
|
Quantity
|
Yes/No
|
How?
|
Yes/No
|
How?
| |
Weaving
|
Fabric
|
99,00,000Yds
|
Yes
|
By Increasing Skilled Manpower
|
Yes
|
By Increasing Skilled Manpower
|
23. Conclusion:
From the above study, it is clear that the reason of shortfall of product is only due to shortage of Textile Technologists/Engineers. We have seen that there is about 40% shortage of Textile Technologists/Engineers at different levels. It is possible to achieve 100% target production and also quality by recruiting Textile Technologists/Engineers. So it is essential to appoint Textile Technologists/Engineers at different levels in all the textile mills within short time to face the challenge of 21st century.
Wish You Good Luck..................................
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