Sewing Quality Control SOP

Sewing Quality Control SOP

Sewing is the key process of apparel industry. Sewing produce full garments. Cutting section just cut garments as per marker. Finishing section mainly does decorative work, add ticketing items and ironing. As Garments construct through Sewing; sewing quality control is most important factor in Apparel industry. Sewing quality team controls all the necessary quality criteria. There are some rules for controlling quality of sewing. These standard rules are well known as sewing quality standard operating procedure (SOP). Let see, what are the basic things a sewing quality controlling SOP includes:

Standard Operating Procedure of Sewing Quality Control, Sewing Quality Control SOP

Sewing Quality Controlling Standard Operating Procedure

Here is the standard operating procedure of sewing quality control

  1. Quality inspectors check sample and trim card of his process at the very beginning of a style. Inspector also checks SPI, thread, label and First Bundle specially and will have to take over his work from Quality controller for new style.
  2. Inspectors know his all measurement of his check point and will have to explain clearly if anybody ask.
  3. No defect allowed passing from QI check point and defect will be limited in one bundle in any process.
  4. Bundle cut have to maintain as per cutting report, short and mistake bundle not to pass by QC check point.
  5. Measurement tape hanging on every QI neck
  6. Every in-process report to be updated, to be signed by QC and line supervisor in every hour.
  7. Any process mistake and size mistake body go back to operation making correction.
  8. Every running style Sample and Trim card showing operation clearly displayed on each line.
  9. Every quality inspector following up machine cleaning before breaking up factory every day and 100% machine having oil card.
  10. Washed Garments not allowed keeping sewing line. If there any GMTS in sewing line, Output QI and Line QC have to handover in finishing.
  11. Every Line QC is responsible for all types of buyer requirement of his line.

You can download a common form of SOP both in Bengali and English

Sewing Quality SOP (English)

Sewing Quality SOP (Bangla)

Written by

A.M. Amirul Islam (Washim)

Facebook: Amirul Islam Washim

E-mail: [email protected]

Sand Blasting Washing

Sand blasting is mechanical dry washing process by which AL2O3 is passing through a nozzle with the help of high speed compress air. Doll can be used for this type of washing.  Basically sand blasting is used in heavy garments like; denim, twill, Canvas, corduroy etc.

Sand Blasting Washing (SiO2)

Sand blasting is performed combine with the wash like; Bleach wash, Normal / Rinse wash, Stone enzyme wash, tinting/ dyeing, Stone wash etc.

Sand BlastingWashing

Objective of Sand Blasting

  • The main objective of sand blasting washing is to color fading from the specific surface area on the garments.
  • For making fashionable apparel.

Objective of SandBlasting

Principles of Sand Blasting

Al203 is passed through a nozzle with the help of compress air. So rubbing is occurred and color is fade from the specific area on the apparel surface.

Precaution of Sand Blasting

Proper protection is needed for operator so that any threat can be avoided

  1. Protection eye glass,
  2. Using mask,
  3. Ear plug,
  4. Should use helmet, Cap.
  5. Using apron

Procedure of Sand Blasting

A standard process flow of sand blasting washing is as flows: Close Chamber => Table => Place Apparel => Sand Blasting => Color Fading => Apparel Washing.

Sand Blasting Washing Process Flow chart

Demerits/Disadvantage of Sand Blasting

  • Not Environment friendly.
  • Health hazardous, harmful for operator.
  • There is chance of fabric damage.

Now a days Sand Blasting Washing process is isolate due to health hazardous, it may be causes cancer. On the other hand, buyers do not prefer this type of washing because of health issue.

Md. Mashud Rana Opurbo

Industrial Engineer.

Email: [email protected]

Cell: 01928-186429

Calculation of Earnings and Loss for Garments Industry

Calculation of Earnings and Loss for Garments Industry

Calculation of earnings and loss for garments industry is required to monitor whether factory operation is generation expected revenue or not. Based on your calculation of earnings and loss you can set production target to meet your expected level of profit for your business.

Calculation of Earnings and Loss Template

As sewing is one of the main operation of garments, you can take sewing as a factor and calculate earnings accordingly. You can use same formula for calculating profit or loss of your industry after shipment of your final product.

Calculation of Earnings and Loss for Garments Industry

Let’s see the calculation at a glance.

Suppose, Your Factory’s last 3 Month Expenditure= 1466400$

So, Per month Expenditure = (1466400$/3) = 488800$

So, Daily Expenditure = (488800$/26) = 18800$ [if fty run 26 days per month]

Your fty produced = 8800 Units per day

Per GMTS CM= 2.20$ (It’s vary style to style, you need to calculate style wise from buyer given CM)

Then, Daily Earnings = (8800 X2.20$) $ = 19360$

So, Your Daily Earnings = (19360$-18800$) = 560$

Production Report

Template for Calculating Earnings and Loss for Garments Industry

I have developed an excel template to calculate earnings and loss for your convenience. You can use this template for any industry; specially for your daily garments production. I hope this will give you well understanding.  You can download this template for free, just click on daily production & CM earnings report.

Daily Production & CM Earning Report

This template includes:

  1. Production report
  2. Production chart
  3. Earning calculation and report
  4. Per unit CM (Style wise)

This template can be very helpful for any Garments professional. Based on the output of this template you can prepare your report maintaining professionalism.

You will get not only earnings and loss report but also production report. In this way it will be helpful for everybody to see actual status of a factory. If you face any problem of understanding then please do not hesitate to contact with me.

Written by

A.M. Amirul Islam (Washim)

Facebook: Amirul Islam Washim

E-mail: [email protected]

Cutting Section SOP in Garments Industry

Cutting Section Standard Operating Procedure in Garments Industry

Cutting Section Standard Operating Procedure (SOP) is develop to provide guidelines for the workers so that they have proper knowledge of working. SOP is written in a simplest way to ensure better understanding for all people who are involved directly or indirectly with that particular activities. In a garments industry you may find different form of SOP and it can vary company to company and also department to department. Each and every garments company always try make best adaptable standard operating procedure. You know that cutting section is very crucial part of garments manufacturing, keep in mind the importance of this section I made a simple Standard Operating Procedure (SOP) for cutting section of garments so that can make SOP for your company. Now a day’s it is mandatory to make SOP and hang it to the working place of each section in apparel industry for better understanding of the procedure and to minimize operational error.

Cutting Section SOP in Garments Industry

Cutting Section SOP

Sample form of Cutting Section Standard Operating Procedure is as flows:

Fabrics Relaxation Procedure

  • Spandex fabrics will be relaxed minimum 24 hour making unroll in cutting section.
  • Relaxation date and time must be recorded. After spreading, will relax 2 hours before cut.

Before Cutting Procedure

  • Receive marker and quality check by cutting QC.
  • Fabric Spreading will be done based on Shade chart/Shade grouping provided by fabrics warehouse.
  • Spreading report will be made after spreading with related all necessary data.
  • Spreading Quality check point: -Table marking -Ends -Leaning –Tension -Narrow Goods -Remnants -Counts -Ply High -Marker Placing -Fabric Flaws
  • Highest lay for woven fabrics is length 14 meter and height 3 inch.
  • Lay chart should be maintaining roll wise.
  • Quality inspector will control quality inspection during fabrics lay.
  • Cutting spreader man will spread marker after finishing lay.
  • For stripe and check fabrics, alignment to be correct by using hook, thread.
  • Before cutting cutter man will attach clamp, Gum tap on the layer.
  • Shade chart will be hanged during lay.
  • Cutting Quality check points: -Miss cut –Rugged Cutting –Notches-Matching Plies and pattern check.

After Cutting Procedure

  • Quality will check every bundle using hard pattern three different position of the bundle.
  • Numbering and bundling separation done by following spreading report and identify each bundle by style, Cutting number, Bundle number, size, Serial number, Shade number and Parts name.
  • 100% cut panel will be inspected
  • If any defective panel found, will be replaced from lay chart wise remnants by following shade and pattern grain line.
  • Light color bundle will bind with light color string; deep color bundle will bind with deep color string
  • Light color Fabrics will be covered by poly in rack or pallet.
  • Then all cut panels will be ready to delivery in sewing.

You can download cutting section SOP in Garment Industry from here.

Cutting Standard Operating Procedure SOP English

Cutting Standard Operating Procedure SOP Bangla

Written by

A.M. Amirul Islam (Washim)

Facebook: Amirul Islam Washim

E-mail: [email protected]

Statistical and Pareto Analytical Excel Template for Textile and Garments

Statistical and Pareto Analytical Excel Template for Textile and Garments

We are living in the era of 4th industrial revolution where we have to work with big data, that’s why we prefer to work with data analytic. Now a days Statistical and Pareto Analysis is used in every industry to reduce defect. It is one of the most popular tools of 7 QC. Statistical and Pareto Analytical Excel Template will give you easiest solution for your textile and garments. For your convenience we developed a Microsoft Excel data sheet where you can analysis your data in a way that will help you through sorting your data year to year, month to month, and week to week. In addition to these excel will arrange Pareto Chart automatically.

Pareto Chart of Fabric DefectsTwo templates are given here for your experience.

  1. Fabric Defect statistical and Pareto analysis

  2. Sewing Quality statistical and Pareto analysis

Sewing Quantity and RejectsStatistical and Pareto Analytical Excel Template for Textile and GarmentsThese templates can be used for any industry. You can get this template for free. All you need to do is to download and use accordingly.

Stitch Control ChartThese excel templates includes:

  • Statistical Analysis
  • Pareto Analysis
  • Pareto Chart
  • Data Sorting

Hope these will be helpful for you to bring work efficiency. If you have any confusion or want to develop these types of data sheet for your company then please do not hesitate to contact with me.

Written by

A.M. Amirul Islam (Washim)

Facebook: Amirul Islam Washim

Phone: +8801929643301
E-mail: [email protected]

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Quality Control in Garment Manufacturing

Quality Control in Garment Manufacturing

Quality is of prime significance in any part of the business. Clients request and expect an incentive for cash. Quality is characterized by the level of acknowledgment of a decent or administration. It is an extremely fundamental necessity for any item. Each item ought to keep up the standard quality level. In this 21st century of globalization showcase is ending up increasingly intricate, that is the reason each industry is confronting an abnormal state of rivalry for their business. As makers of clothing, there must be a consistent quality control in garment manufacturing to create work of good quality.

Quality Control Framework

The frameworks required for programming and planning the endeavors of the different gatherings in an association to keep up the imperative quality.” Quality Control is the implementation and monitoring of Quality Assurance or Total Quality Control operations. The Testing technique comprises different significant method to ensure that manufacturing procedure is following all the essential principles and the materials used in piece of clothing creation are of great quality. It is likewise critical to test the hardware for attempting to their most extreme limits and for not harming the texture and different materials itself. Diverse sorts of testings are being done consistently to screen the procedure and the result of the assembling. Those testings differ amongst concoction and physical ones. Physical testings incorporate the checking of catches, dimensional soundness of the texture et cetera. Concoction testings are identified with reviews of shading speed to washing, warmth, lighting and different conditions. Furthermore, by and large, every one of them has one motivation behind guaranteeing a quality item toward the end.

Garment Manufacturing Testing

Testing can be led either in the lab of the creating industrial facility itself or in other testing research centers that are had practical experience in the quality control and affirmation of the article of clothing generation. For the most part, an outsider directed testing be best because of the better fixation and fair-minded checking process. It is likewise vital to believe the quality confirmation testing method to particular experts to guarantee the most extreme quality and productivity, by testing all materials and apparatus utilized amid assembling. The tests equipment which can be utilized for the quality inspection garments includes Hydrostatic Head Tester& Air Permeability Tester.

Hydrostatic Head Tester

Hydrostatic Head Tester

Hydrostatic Head Tester

Hydrostatic Head Tester, utilized for deciding the protection of textures and movies to water infiltration underweight while immovably cinched in the test apparatus of the standard region, by methods for dynamic test technique and static test strategy. The bank is connected to a test go to which the example is cinched rapidly and steadily by methods for a programmed brace.

Air Permeability Tester 

Quality Control in Garment Manufacturing

Air Permeability Tester

Air Permeability Tester is stacked to the test zone of the instrument effectively by methods for a programme holder by pushing down the holder to begin the test. So essentially, review method incorporates all phases of the piece of clothing generation beginning from crude materials and parts, trailed by the real assembling and observing of the work, and consummation the procedure with the investigation and examination of the completed item.

Following parameter are checked thoroughly at this stage:

  • Texture development
  • Shading quickness
  • Completed article of clothing

These days’ purchasers are particularly quality cognizant. If it is conceivable to keep up a fantastic arrangement of investigation strategy, the purchasers should be spurred, and greater quality items can be made. Learn more.

Garments Washing

Garments Washing:

Normally we use the word ‘washing’ to mean cleaning. But in case of garments, washing is not limited to this function. For garments, washing is not only required for cleaning but also required for improving fabric quality, increase softness of fabric, reduce shrinkage, removing of dirt and for creating color effects. In other sense washing is a technique which used to remove impurities dirt, dust, oil etc. from the surface of garments, softness feeling of cloths, outlook fashion of the apparel and increasing color fastness.

Garments Washing Process

Garments Washing

Classification of Garments Washing

According to the process of washing, garments washing is basically of two types; one is wet process and other is dry process.

Objectives of Garments Washing

Though garments washing is done to meet several objectives, but among those followings are the most common.

  • To remove size materials
  • Impurities remove
  • To increase color fastness
  • For color fading
  • For soft hand feel
  • Fashion Garments.

Chemicals use for Garments Washing

Several chemicals are used for garments washing. Here is the list of chemicals use in garments washing.

  • Detergent
  • Bleaching agent ( H2O2, KMNO4)
  • Acid ( Acetic acid, phosphoric acid)
  • Desizing agent
  • Softener
  • Enzime ( Bio- Chemicals)
  • Anti-staining agent
  • Soda
  • Salts Etc.

Washing plant of Garments

Washing plant can be automated, semi-automated. An engineer is responsible for all process to control such as Garments, m/c, H2O, Chemicals, PH etc.

Washing Condition of Garments

  • Temperature up to 60̊ C
  • Time Up to 60 min
  • PH
  • Concentration of chemicals Up to 15 g/L

Process Flow of Garments Washing

Batch selection => Loading into washing m/c => M: L (add water) => M/c running => Add chemical at adjust temp. and set time => Drain out => Hot wash/ cold wash => Softening => Unload => Hydro extracting => Drying => Quality check => Finishing

Flow Chart of Garments Washing

Flow Chart of Garments Washing

Written By: Mashud Rana Opurbo

Bsc in Textile Engineering (DIU) “24th Batch”

Industrial Engineer at Radisson Garments Ltd.


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Increase Your Professional Communication Skill

Way to Increase Your Professional Communication Skill

Every day in our professional life we have communicate with internal and external parties. For each communication it is required to ensure minimum to high level of professionalism. Internal communication is not that much formal but in case of communication with external parties we always have to maintain required professionalism. For official purpose most of the professionals prefer written communication (Email) because of its higher acceptance of record keeping for future reference and formality. You need to keep in mind few sentences which is commonly used in professional communication those can increase your professional communication skill.

In this writing I am going to share 25 commonly used sentence that would help you to increase your professional communication skill in a good manner. And you can use these sentences for any kind of formal communication with other parties or to provide customer’s feedback.

These Commonly Used Sentences May Help You To Increase your Professional Skill

Increase Your Professional Communication Skill

  1. Hope you are doing well
  2. Your kind cooperation in this regard will be highly appreciated
  3. Please go through by below mail
  4. I am seeking your kind approval
  5. I would like to invite you that
  6. Let me check with boss/anybody you can mention
  7. Would you explain more frankly?
  8. We wish to apologies for the delay to submit the paper
  9. I will notify you once I get update
  10. We have gone through all the points
  11. I am working on it to solve the problem
  12. We are chasing our team bring it back
  13. Need your special attention to get best possible result
  14. Please keep secret since this data is very confidential
  15. Tomorrow is our public holiday therefore we will able to send goods the day after tomorrow
  16. Would you please share your comments once reviewed
  17. Allow me to jump in
  18. Allow me to write here
  19. Let me know you by tomorrow
  20. Sorry for inconvenience, resend due to typo mistake
  21. Can you write more details about this?
  22. Please acknowledge after receiving this email
  23. I would be glad if you read this message
  24. We are waiting for your quick feedback for this issues
  25. I am interested to know about your company, hopefully we will be able to build up long term business relationship.

Written by

A.M. Amirul Islam (Washim)

Facebook: Amirul Islam Washim

Phone: +8801929643301
E-mail: [email protected]

If you like this article please do not forget to share on facebook and put your valuable comment.

Is It Possible to Minimize Systematic Risk

Is It Possible to Minimize Systematic Risk?

You may have question in your mind that is it possible to minimize systematic risk? If you have then I am right here with your answer. After reading this hope you will understand what actually systematic risk is, what are the factors related with this and is there any way to minimize systematic risk or not.

First of all let me explain the meaning of systematic risk. Risk associated with macro-economic factors like; market interest rate, inflation, rate of unemployment, economic recession, oil price etc. are the source of systematic risk. These factors cannot be changed or influenced by individual or organization. Normally risk which cannot be minimized through diversification of investment is considered as systematic risk. In other sense risk which is beyond the control of individuals or organization is systematic risk.

Minimizing risk is possible only through investing in negatively correlated financial securities. Here negatively correlated means the return of an individual security is not directly related with the return of other securities.

The main thing is, through diversification only we can minimize unsystematic risk portion which is arisen from the micro economic factors. Because micro economic factors can be controlled by individuals or organization through taking proper economic decision. So at this point we basically can say unsystematic risk is controllable and systematic risk is out of control, but the question is why systematic risk is out of control?

The influencing factors of systematic risk come from macroeconomic sources which is beyond our control. As an individuals we do not have control over unemployment rate of our country, we cannot reduce or control the inflation rate, we cannot fix the oil price, we cannot change the market interest rate, we cannot improve our unexpected economic recession situation by our own. Only proper economic policy taken by government can influence/ change or control these factors. That’s why as an individual’s we cannot minimize systematic risk.

It is not necessary that the percent of systematic risk always remain fixed. It can varies according to the change of economic condition. When there is recession, more systematic risk will be there. For economic boom situation, market provides more income, ensure less unemployment. And for these, there will have less systematic risk.

Is It Possible to Minimize Systematic Risk

Beta is the measures of Systematic Risk, which is the function of macroeconomic factors. We can calculate systematic risk by:

Systematic Risk (Beta) = Covariance between Individual Securities & Market/ Variance of Market

You know that a market beta (Systematic Risk) is always 1. If your investment (Securities) beta is less than 1 then your investment is more stable (less systematic risk) than the market. On the other hand if your investment (Securities) beta is more than 1 then your investment will more unstable (more systematic risk) compared with the market.

At the end of these brief explanation we can say that it is not possible to minimize the systematic risk. So it would be wise decision to work for minimizing unsystematic risk through diversifying your investment and try to make optimal portfolio.

If you like this article then please leave your comment, or if you have any confusion about this topic then let me know.

Is It Possible to Minimize Systematic Risk

Written by: Md. Nahian Mahmud Shaikat

Mail: [email protected]

Financial Analyst

Financing for Textile and Garments

Financing for Textile and Garments

A good financing decision works as a driving force for an organization to build a strong financial position. Financing decision varies industry to industry, organization to organization according to their financing requirement, financial strength and risk taking behavior of that particular parties. Here in this article you will have basic ideas of financing and how you can take financial decision for your textile and garments business.

Basically the objective of financing is to collect money from the least cost sources and then invest in the profitable sectors. Here the challenge is minimize the cost and maximize the profit of the investment. Financing is required for different stages of business, like initial startup of business, or for maintaining the operational expenditures or for expansion of business. The mechanism of these financing need varies business to business.

If you are going to finance for the manufacturing industry then you will be required a large amount of fund for startup or for expansion of your business, and for operating expenditure you will be required working capital which is much less than the initial investment. On the other hand for service industry you have to invest a large amount of capital in the initial year and the operation cost is not that much high.

Requirement of Money for Textile and GarmentsNow come to the point of financing for textile and garments industries, as this one is manufacturing industry which requires to buy different types of equipment (power and electricity generator, spinning machine, knitting machine, dyeing machine, printing machine, sewing machine, cutting machine and many more) we have to spends lots of money and our huge amount of capital will be invested for this purpose. In addition to this thousands of garments worker will be working here, for payment of salary and wages you will be required a larger amount of working capital. On the other hand for importing raw materials you will also be required huge amount of money.

If you want to expand your business to increase production capacity you have to invest huge amount of money for long term basis.

The question is how you can manage these required money and from where you can source this money. At the time of sourcing of money/ fund you always have to be careful about the cost of that fund, least costing source will be preferable.

Financing for Textile and GarmentsFinancing for Textile and Garments can be for:

  • Initial startup of business.
  • Maintaining daily expenditures.
  • Expansion of Business/ Production Capacity.

Initial Expenditure for Starting a Textile and Garments Business

You already know that for starting a new setup for textile and garments you must spend a large amount of capital for purchasing capital machinery. The important thing is how you are going to finance for this, my suggestion is, and as capital machinery and equipment’s for long term it will be a better decision of financing from the long term sources. Available options of financing are:

  1. Long term bank loan (Debt Financing).
  2. Selling share (Equity Financing); in case of public limited company.
  3. Or you can choose both debt financing and equity financing (the ratio of debt to equity will be depend on the financial strength and the business risk of that company).

From the above alternatives, my personal suggestion is to choose third one because you cannot use fully debt financing because you have to bear a fixed cost (interest) for a certain interval of time for a period.

  • Fixed cost financing may increase your financial risk, so try to avoid fully debt financing.
  • On the other hand, equity financing is more costly as you have to share your all of your profit proportionately according to the contribution of equity capital.

The right choice is to use debt and equity to minimize the weighted average cost of capital. And you have to form your optimal capital structure by considering two major factors (business risk & financial strength). Taking loan for new business is not that much easy, that’s why initially we have to depend upon our own capital first. With the passes of time, for a successful business, it will be better to increase the debt percent so that taxable income can be reduced.

Financing for Maintaining Daily Expenditures

Actually maintaining daily expenditures means, managing working capital funds for your business operations or management of current assets and current liabilities. You may source your working capital either from long term or short term sources and the decision will be depend on the working capital management policy (hedging, conservative, aggressive) of yours. Before choosing working capital management policy you have to have brief idea of these policies:

  • Hedging Policy of Working Capital Management: Hedging policy is one of the popular policy of managing funds where a matching principle is used. Financing for current obligation is done from the current assets (current sources) and on the other hand financing for long term obligation is done for the long term assets (long term sources). That means for short term requirement of funds you need to collect from short term sources and for long term requirements you have to collect from long term sources.
  • Conservative Policy of Working Capital Management: In case of conservative policy company has the intention of taking low risk for financing current asset. Additional fund required for fixed assets company keeps extra fund for using as current asset. Here company financing (collecting) more funds from the long term sources for both current asset and fixed/long term assets. The main intention is to lowering the risk of financing for current asset.
  • Aggressive Policy of Working Capital Management: Aggressive policy of working capital management is risky policy in a sense that most of required funds for current and long term assets is to be financed from the short term sources, lower amount of funds will be collected from the long term sources. Basically money will be kept less than the required amount for working capital that why risk is higher.

Before taking a policy form all these above mentioned policies you must evaluate your ability to liquid your asset and liquid (cash) required for your business. Another thing is your risk taking behavior towards working capital management.

The question is from which sources you can finance for the maintaining daily expenditures? The probable source available for the textile and garments are:

  • Lowering the collection period of accounts receivables.
  • Delaying the payment of accounts payable.
  • Delaying the payment of salaries and wages.
  • Taking short term bank loan.
  • Purchasing raw materials on credit.

Financing for Expansion of Textile and Garments Business

As you already know that for business of textile and garments you will be required a lot of money. Expansion of business or expansion of production capacity requires larger investment to for purchase machinery and equipment, land, construct building etc. This is more or less similar with the initial investment for your business. In addition with acquiring capital assets, you have to hire workers and employees for supporting your business expansion. The thing is you have to pay wages and salaries, purchase of additional raw materials or any other operating expenditures. So you can manage these extra money from both long term sources and from short term sources. Whether you choose long term or short term source, is mainly depends on your financial strength and adequacy of money of your existing business. Normally a profitable textile and garments company has intention to expand when they find that the business is profitable and they can manage their extra required fund from their own profit.

Financing for Textile and Garments

After these discussion, I think that it is clear how you can finance for your textile and garments and which sources are available for financing. Careful analysis is to be done before any larger investment because for large investment risk is higher and involve cost also.

If you have any confusion then you can comment here. I will try to give you suggestion about financing and different problematic situations.

Written by: Md. Nahian Mahmud Shaikat

Financial Analyst

Mail: [email protected]