What is RFT, RFT Factors and Calculation in Apparel Industry

What does Right First Time (RFT) Mean?

Right First Time is lean tools that mean doing the thing right in the first time which can remove eliminate or repair and defects producing in garments manufacturing. RFT percent is one of the key performance indicator tools in Garments quality control. In this article, we will discuss What is RFT, RFT Factors and Calculation in Apparel Industry.

What is RFT, RFT Factors and Calculation in Apparel Industry

What is RFT, RFT Factors and Calculation in Apparel Industry

Advantages/Benefits/Importance of Producing Right the First time

  1. Reduce cost and penalty of quality failure
  2. Improve quality and productivity
  3. Remove re-work and repairing
  4. Save time and energy
  5. Save defects rectification cost
  6. Improve work accuracy

RFT calculation for Cutting, sewing, finishing, and Quality Control

Right First Time = (Number of passed goods or Lot / Number of total produced Garments or Lot) x 100

For example, If 200 pcs Garments is produced in the sewing section, found 13 pcs defect by QC then first pass quantity is =(200-13)= 187 pcs.

So, Sewing RFT will be = (187/200*100) % = 93.5%

Date RFT Defect %
4/11/2017 95.67% 4.33%
5/11/2017 96.54% 3.46%
6/11/2017 96.57% 3.43%
7/11/2017 95.80% 4.20%
8/11/2017 96.20% 3.80%
9/11/2017 96.74% 3.26%

Actual and Target RFT

Date Actual RFT Target RFT Total Check Quantity
1-Jul 93.40% 96% 2500
2-Jul 93.50% 96% 2600
3-Jul 93.10% 96% 2400
4-Jul 94.20% 96% 3000
5-Jul 94.60% 96% 3500
6-Jul 93.50% 96% 2500

RFT Key Factor Areas of Garments Manufacturing

There may have others area you need to count RFT, I am giving here what I know. Surely RFT is a performance measuring tool of quality control.

  1. Cutting panels quality
  2. Sewing output garments quality
  3. Finishing packed garments quality
  4. Final Audit RFT.

Written by

A.M. Amirul Islam (Washim)
Email: [email protected]

Linkedin: A.M. Amirul Islam

Kanban Board in Garments Manufacturing Production Floor

Kanban Board in Garments Manufacturing Production Floor

What is Kanban? Kanban is a visual card or billboard; Japanese word which meaning Cards or board, a tool of lean manufacturing for visualization entire production teamwork to control production focusing on creating a production system more effective and efficient, focusing mainly in the production and logistics activities. Kanban is a visual system as ‘Signal card’ indicate what to do, items will put when needed, Kanban cards order necessary task, update with time and surely reduce wastage. In this article, you will have an idea of how kanban board in garments manufacturing production floor is used.

Kanban Board in Garments Manufacturing Production Floor

Types of Kanban System

Generally, two types of Kanbans or Kanban Cards used in the apparel industry:

Production Kanban

Production Kanban is the first step of Kanban implementation, production Kanban takes the place of standard production orders in material requirements planning (MRP) push.

Transportation Kanban

Transportation Kanban system is very important that carried on the trolley, containers that are associated with the transportation to move through the loop again.

Importance of Implementation Kanban Board in Apparel Industry

  1. Reduce idle time in a production process.
  2. Increase productivity, more effective and efficient production
  3. Visualize work and optimize the flow of the work
  4. Reduce WIP (Work in Process)
  5. Improve workflow
  6. Avoidance of over-production and limitation of stocks
  7. Higher availability of materials
  8. Reduce inventories
  9. Improve communication between management and operational staff

Garments Kanban Board Information Includes

  1. Backlog
  2. To do list
  3. Doing List/ work-in-process List
  4. Work completed List
  5. Plan list
  6. Lot name
  7. Process name

This content also have the answer of below points

  • Kanban system in Apparel manufacturing
  • Set up Kanban board in the production floor
  • Kanban board in sewing floor

If you have any confusion then please let me know.

Written by

A.M. Amirul Islam (Washim)
Email: [email protected]

Linkedin: A.M. Amirul Islam

Management Levels and Their Functions in Textile and Apparel

Management Levels and Their Functions in Textile and Apparel Industry

If you are involved with the apparel industry or you have an interest in working in any levels of management, then you must know the Management Levels in Garments Factory. When you clearly know the Management Levels and Their Functions in Textile and Apparel industry, you can easily decide who is responsible for what. Generally, you can find three levels of management in the Apparel Industry.

  1. Top level management in Apparel Industry
  2. Middle-level management in Apparel Industry
  3. Lower level management in Apparel Industry

Management Levels and Their Functions in Textile and Apparel

Top Level Management in Textile and Apparel Industry

Top level management has the Supreme authority and most of owning a share in a garments factory. Their designation titled as MD (Managing Director), Director, Chairman, CEO (Chief executive officer), COO (Chief operating officer). They are mainly responsible for setting company policy, objective, ethics and employee code of conduct of employees as their job role.

Functions of Top Management in Garments Factory

  1. To establish company policies, define goal and objectives
  2. Set up company structure and form a company’s core ethics
  3. Leading Middle-level management
  4. Appointing mid-level management
  5. Taking strategic decisions and giving direction in a critical situation
  6. Take the decision about Staff increment, employee promotion
  7. Follow up factory profits loss and giving decision any types of financial matters
  8. Keeping good relation with the buyer (Customer)
  9. Follow up factory productivity and quality performance

Middle-Level Management in Textile and Apparel Industry

Middle-level management is called executory level subordinate of senior management but above of lower level management. Generally, in the Textile and Apparel industry, their job titles are Production manager (PM), Executive officer, Officer, Manager etc. Company performance depends on Middle-level management.

Functions of Middle Management in Garments Factory

  1. Lead low-level management /operational staff directly.
  2. Manage both top and lower level management
  3. Appoint low-level management employees
  4. Set production target and taking responsibility of production
  5. Implement company goals, strategy, and policies
  6. Implement all types of customer requirement
  7. Responsible for company profit, losses, and performance to the buyer
  8. Working for top level and customer satisfaction
  9. Contact with all level of management

Lower Level Management in Textile and Apparel Industry

Lower level management is in supervisory level, supervise worker directly. They also are known as operational staff who report directly to the mid-level management. In textile and Apparels industry their job title as Supervisor, controller and in-charge. Low-level management directly connected with work and ultimately responsible for company performance.

Functions of Lower Level Management in Textile and Apparels

  1. Supervise all Worker directly
  2. Fulfill the production target
  3. Follow buyer SOP
  4. Report Middle-level management
  5. Solve any problem of worker

Management levels and their functions in Apparel Industry pdf

Written by

A.M. Amirul Islam (Washim)
Email: [email protected]

Linkedin: A.M. Amirul Islam

Compliance Audit Checklist in Apparel Industry

Compliance Audit in Apparel Industry

A compliance audit is one kind of audit which is specially designed for auditing the compliance issues related with the apparel industry. Different regulatory authorities set different type of regulatory issues. And buyers of garments ask from the company whether they are following their required compliance or not. These issues are checked by the auditing process which is known as compliance audit. After a compliance audit, they provide/ issue certificate. From the Compliance Audit Checklist in Apparel Industry a garments makers will be able to know what are the things buyers may ask from the company.

Compliance Audit in Apparel Industry

Compliance Audit Checklist in Apparel Industry

Compliance Audit is very important for garments manufacturing factory. To get an order from the buyer, your company must have to pass social Compliance Audit. Buyer may cancel the order if your company fails to pass the Compliance Audit. In this article, I am giving a checklist for any buyer Compliance audit preparation.

Compliance Audit Checklist in Apparel Industry

Areas/Categories of Garments Compliance Audit

  1. Licenses, permits and Facility Information
  2. Child and under-aged worker
  3. Forced labor and Discrimination
  4. Freedom of Association and collective bargaining
  5. Right of worker
  6. Disciplinary Practice
  7. Working Hours
  8. Wages, Benefits & Compensation
  9. Workplace Safety
  10. Occupational Health & Welfare
  11. Environment Management
  12. Management Practice & Sub-contractor /supplier control
  13. Training records
  14. Company Policies

Licenses, Permits and Facility Information

  • Factory profile
  • Architectural & Structural Drawing Approval
  • Soil Test Report Approval
  • Trade license
  • Factory license
  • Fire license
  • Boiler license
  • Generator permission
  • Electrical permission/ Sub-station permission
  • TIN certificate
  • Export registration certificate and Import registration certificate
  • Export promotion bureau certificate
  • Bond license
  • Rent agreement

Child and under-aged worker

  • Child labor remediation process
  • Recruitment policy
  • Personal file
  • Agreement with the service provider/sub-contract

Forced labor and Discrimination

  • Any harassment or discrimination issues
  • Policy on a prohibition of forced labor
  • Awareness/Training register
  • Job responsibility of security guard

Freedom of Association and Collective Bargaining

  • Policy on freedom association
  • Awareness/Training register
  • Formation procedure of worker association/trade union
  • Meeting minutes of worker participatory committee
  • Register for complain /Suggestion
  • Grievance handling procedure

Right of Worker

  • Personal file of worker
  • Service book
  • Employee ID card

Disciplinary Practice

  • Policy on disciplinary practice or rules
  • Leave Record
  • Orientation training on factory code of conduct & legal requirement
  • All kind of policy
  • Disciplinary action log & record
  • Awareness/training register
  • Final settlement
  • Others legal facilities

Working Hours

  • Working hour Approval
  • Working hour record for all section
  • Overtime hour record
  • Attendance Register
  • Declared holiday list
  • Manpower list

Wages, Benefits & Compensation

  • Wages/payroll sheet (last 1 year)
  • Overtime wages sheet (last six months)
  • Payslips (last 1 year)
  • Wages Increment record
  • Maternity Benefit register & Record
  • Group Insurance with manpower update list
  • Policy on wages, overtime, payment date, calculation method, leaves & holidays etc.

Workplace Safety

  • Sub-soil/Geological investigation report
  • Building structural plan/approval
  • 3rd party assessment report
  • Firefighting training record
  • Fire drill record
  • Firefighting team
  • Firefighting equipment list
  • Fire safety plan
  • Personal file of Fire Officer
  • Electrical & Mechanical Equipment periodical checklist
  • Competency certificate of Electrician
  • Competency certificate of Boiler Operator
  • Chemical Handling Training
  • Health checkup record
  • Chemical list
  • Safely machine operating training register
  • Needle stock register, Broken & Missing Register
  • Sharp tool policy
  • Emergency evacuation diagrams
  • Emergency exit doors
  • Building structure safety
  • PPE (personal protective equipment) use
  • Aisle or Stairway

Occupational Health & Welfare

  • Personal file of Welfare officer
  • Drinking water test report
  • First aid training & List of the first aider
  • Medical agreement
  • Competency certificate of Doctor
  • Competency certificate of Nurse
  • Personal file of care governance
  • Childcare register
  • Canteen committee

Environment Management

  • Environmental risk assessment as per section
  • Emergency procedure to reduce risk
  • Environmental clearance certificate
  • Waste disposal agreement /procedure
  • Wastewater test report in-house and outside
  • Energy survey/ Assessment record

 Management Practice & Sub-contractor /Supplier Control

  • Awareness training record for new & old workers
  • Mid Management training record
  • Internal Audit record
  • Policy on Sub-contract control
  • Sub-contract control procedure & record

Training Records

  • Emergency evacuation & fire drill record
  • List of firefighters trained by fire service/BGMEA
  • Disciplinary Rules communication
  • First Aid training record
  • Chemical Training record
  • Machinery safety training record
  • Health and safety training record
  • Training on KIABI compliance

Company Policies

  • Child Labor Policy
  • Child labor Remediation Policy
  • Disciplinary Rules/Policy
  • CSR Policy
  • Anti-Corruption/Bribery policy
  • Sub-contractor/Supplier Monitoring
  • Grievance Procedure
  • Environmental Policy
  • Energy efficiency plan
  • Environment emergency procedure
  • Deduction for late/after lunch assentation

Compliance Audit Checklist in Apparel Industry

Written by

A.M. Amirul Islam (Washim)
Email: [email protected]

Linkedin: A.M. Amirul Islam

Garments Washing Defects

Garments Washing Defects

Garments washing is the process to improve hand feel, appearance and better outlook of garments. That’s why washing plays a vital role in garments manufacturing. Because of various washing defect, rejection of garments increases. We need to reduce the rate of washing defects/faults at a minimum level. Rejection increases the cost of overall manufacturing. For this reason, reducing washing faults is the major concern for all apparel manufacturing industry. One major KPI points are to reduce washing rejection in the apparel industry. I made a list of all types of garments washing defects so that you may have a better idea of garments defects.

Garments Washing Defects

List of Garments Washing Defects

  1. Garments Discoloration
  2. Poor Hand Sanding
  3. Care Label Fading/Damage
  4. Off Shade
  5. Shade Variation
  6. Over Washing
  7. Washing Damage
  8. Washing Spot
  9. High pH Level
  10. Poor Grinding
  11. Lycra Out
  12. Poor Sand Blasting
  13. High Abrasion Effect
  14. Color Bleeding at Pocket Bag and Label
  15. Washing Mark
  16. Poor Hand Feel

Washed Garments

Washing Defect Description

Garments Discoloration

If garments or any parts of garments discolored in washing it’s called discoloration. It is one of the common defect problems.

Garments Discoloration

Poor Hand Sanding

Because of improper hand sanding, more or less hand sanding than the actual requirement.

Hand Sanding

 

Care Label Fading or Damage

Care label is an important part of garments. Sometimes label fades or damage in washing.

Off shade

All garments have an original buyer required shade/color standard. If washing fails to meet shade standard then it is considered as off shade defect.

Off Shade Washing Defects

Shade Variation

Various types of shade in a lot, when fabrication and washing are the same for a whole lot.

Shade Variation Defects

Over Washing

There a certain limit of garments washing time and temperature. Crossing washing limit is considered as over washing and defects have arisen for this is known washing defects of over washing.

Washing Damage

Garments damage in washing is called washing damage.

Washing Damage

Washing Spot

Creating a spot in washing is called washing spot defect.

High pH Level

pH level crossed the level of higher pH limit. pH level is the most important factor in garments washing. For higher level, pH quality of garments may reduce.

Poor Grinding

Because of improper grinding, more or less grinding than the requirement.

Lycra Out

Damage Lycra or Lycra coming out in the washing of spandex fabric.

Poor Sand Blasting

Improper sandblasting, more or less sandblasting than the requirement.

High Abrasion Effect

Much abrasion effect than the requirement.

Color Bleeding at Pocket Bag and Label

Generally, different fabric uses for a pocket bag and labels in any garments. Due to garments body, fabric and pocket bag fabric is different, color bleeding occurred frequently in pocket bag and label.

Washing Mark

Garments marked in different washing stages, by the different washing machine, dryer. Long spot mark created in any process of washing is called washing mark defects.

Washing MarkPoor hand Feel

If you find Rough hand feels after washing of garments then that considered as a poor hand feel defects of garments washing.

Garments Washing Defects pdf

Written by

A.M. Amirul Islam (Washim)
Email: [email protected]

Linkedin: A.M. Amirul Islam

Ready Made Garments Export of Bangladesh

The condition of RMG Ready Made Garments Export of Bangladesh 2018

Bangladesh is now one of the developing countries in the world. Ready Made Garments (RMG) has a huge contribution to the economic growth of this country. The current condition of RMG – Ready Made Garments Export of Bangladesh seems good because there is a positive growth of export earnings. According to Export Promotion Bureau of Bangladesh (EPB), for the year 2017 to 2018 (July 2017 to April), Bangladesh Apparel Export is growing at the rate of 9% which seems a significant amount.

RMG Export Growth Over the Year 2010 to 2018

Here you can see that the growth rate of RMG export is always fluctuating, the reason behind this is a change in market demand, increase in the cost of making, political condition, market competitiveness, and the exchange rate of USD to BDT.

Year

Total Export Million USD

Growth
2010 14855 25%
2011 19214 29%
2012 19788 3%
2013 23501 19%
2014 24584 5%
2015 26603 8%
2016 28668 8%
2017 29213 2%

Export Growth of Ready Made Garments (RMG) of Bangladesh

Bangladesh RMG Growth for the Year 2017-2018

Ready Made Garments industry is growing at the rate of nine percent compared with the previous year. But in 2016-17 this growth rate was only 2%. So there is a significant positive change in the export.

Total RMG Export Growth 2017-2018
Year Woven Knit Total Growth
2016-2017 10,785 10,144 20,929           –
2017-2018 11,513 11,321 22,834 9%

Broad RMG Export Category of Bangladesh

Product Type Million USD Percent
Woven 11,513 50.42%
Knit 11,321 49.58%
Total 22,834 100%

We mainly divide our apparel product into two broad categories. One is knit and other is woven.

Ready Made Garments Export of Bangladesh

Monthly RMG Export Growth for the year 2017-2018

Although the growth of Ready Made Garments increased in every month there was an exception for the month of September 2017. It is not clear why suddenly growth rate reached to a negative figure.

Monthly Ready Made Garments Export Growth 2018

Main Apparel Export Items of Bangladesh for the Year 2016-2017

Bangladesh is mainly exporting Shirts, T-shirt, Trousers, Jackets Sweater among these Trousers and T-Shirt are exporting a huge amount, which is contributing at the rate of 29% and 28%. So these two products added significant value to the export earnings of Bangladesh.

Item

Million USD

Percent
Shirts 2108 10%
Trousers 6027 29%
Jackets 3547 17%
T-Shirt 5862 28%
Sweater 3362 16%
Total 20905 100%

Bangladesh Main RMG Export Product Type

Bangladesh RMG Export to the World 2017-2018

Most of our RMG is Exported to the European Union, where we export about 65% of our total export of apparel. Our second biggest client is the USA and the third one in Canada.

Region

Million USD

Percent
EU Countries 14735 65%
USA 3929 17%
Canada 713 3%
Others 3457 15%
Total 22834 100%

Bangladesh RMG Export to the World

Top 10 European Union (EU) Countries Bangladesh Export their RMG

  1. Germany
  2. UK
  3. Spain
  4. France
  5. Italy
  6. Netherlands
  7. Poland
  8. Belgium
  9. Denmark
  10. Sweden

Top European Union Ready Made Garments (RMG) Buyers of Bangladesh

Export of RMG by Bangladesh in European Union (EU)

Here look into this list that for the last 10 month EU countries is contributing 14734.69 million dollars. So there is no question of EU is the largest buyers of garments in our country.

EU Countries Million USD Percent
Germany 4205 28.537%
U.K. 2847 19.322%
Spain 1714 11.633%
France 1328 9.012%
Italy 1086 7.371%
Netherlands 717 4.866%
Poland 645 4.381%
Belgium 534 3.626%
Denmark 504 3.420%
Sweden 395 2.679%
The Czech Republic 352 2.386%
Ireland 131 0.890%
Slovakia 64 0.433%
Portugal 50 0.338%
Slovenia 44 0.298%
Greece 40 0.270%
Finland 22 0.152%
Austria 22 0.147%
Romania 13 0.086%
Croatia 10 0.069%
Malta 5 0.033%
Bulgaria 2 0.013%
Hungary 2 0.012%
Lithuania 2 0.011%
Cyprus 1 0.006%
Estonia 1 0.006%
Latvia 0.5 0.004%
Total 14735 100%

RMG Export Market of Bangladesh Source: Export Promotion Bureau of Bangladesh, BGMEA

Written by

Md. Nahian Mahmud Shaikat

Email: [email protected]