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Theme: Efficient Use of Resources in Textiles Production

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Presentation on theme: "Theme: Efficient Use of Resources in Textiles Production"— Presentation transcript:

1 Theme: Efficient Use of Resources in Textiles Production
Engr. A S M Tareq Amin Engr. Khondoker Md. Mainul Ahad Amin & Jahan Corporation Ltd.

2 Gratitude In Association with: Diamond Sponsors: Gold Sponsor Sponsors
Media Partner Web Partner International Web Partner

3 Unite for sustainability
Invokes Unite for sustainability Create knowledge based industrial and business community Through…. Research, training & development programs. Publishing magazines & books. Consultancy. Seminars, conference & exhibitions. Competitions and awards for philanthropists & talents. Market intelligence report. Creative design, press & printing.

4 A&J at a glance Theme: Development of the industrial sectors of Bangladesh through building knowledge based community and linking all the executive bodies of the sector on a platform which is truly global. Integrating research development and consultancy activities with promotional tools is the approach to lead the industrial sectors to ultimate sustainability.

5 People: Places & Contact:
A&J at a glance People: Year of establishment: 2008 (has been incorporated to Amin & Jahan Corporation Ltd. from Amin & Jahan Corporation in 2012) Board Members: 5 Number of Full Time Employees: 25 Number of part time editors, consultants & researchers: 21 Places & Contact: Corporate office: (3720 sqf) Unit 601, House # 145, Road # 3, Block A, Niketon, Gulshan 1, Dhaka 1212 Tel: , Fax: Editorial & Registered Office: (1000 sqf) House # 41 (2nd Floor), Road # 5, Block B, Monsurabad R/A, Adabor, Dhaka 1207

6 Working in collaborations
A&J at a glance Working in collaborations German Technical Corporation (GIZ) - On training and publication. The company has been working together with Switzerland based consulting firm Gherzi, in the garmenting factory optimization. Better Works in Textile & Garment of BEST program of UNIDO - Joint workshop & seminar organizing with expertise in the Textile & Garments. Textile Institute (UK) - Joint conference and research program on Textile and Apparels. Bangladesh Textile Mills Association – Joint conference and research program on Textile and Apparels. Bangladesh University of Textiles - Joint conference and research program on Textile and Apparels.

7 Building a community for sustainability
A&J integrates institutions, organizations and industries to do research & consultancy to overcome limitations of expertise, equipments, resources and infrastructure.

8 Core Competences of Bangladesh for the industrial growth
Natural gas based captive power generation which is a reason of cheaper energy in the industries. Abundant good quality surface water and subsoil water. Huge population is the back bone for the labour intensive industries.

9 Core competencies are now core challenges!
Gas has turned into ‘not sufficient’ and power is no more cheap, it is costly now! Water is being ‘consumed quickly and polluted’. labour is not being ‘utilized or cared properly’.

10 Structure of The Textile & Garment Industry Source: BTMA Annual Report 2011 & Economic Review 2011 (MOTJ) Sub Sector No. of units Installed Machine Capacity Production Capacity/year Textile Spinning 385 8.7 ml. spindle ml. kg 0.23 ml. rotor Textile Weaving/Fabric Manufacturing 721 17250 shuttleless 13500 shuttle Specialized Textile and Power Loom 1,065 23,000 SL/SLL Handloom 148,342 3,13,245 (running loom) Knitting, Knit Dyeing: 2800 a. Export Oriented 1200 12,000 Knit/dy/M 3, b. Local Market 1600 5000 knit/dy/M Dyeing & Finishing (Woven): a. Semi Mechanized b. Mechanized 352 95 257 2000 ml. meter  Export Oriented RMG 5150 ml. dozen Jute Industries a. BJMC b. BJMA c. BJSA 27 101 70 337 thou. tons

11 Structure of the Textile & Garment Industry
The industry is heading towards sustainability with good backward and forward industries: 90% of manufacturing industry is textile garment industry 90% of knit fabrics for knit RMG and 40% of woven fabrics for woven RMG provided by local basic textile industries 90% of domestic fabrics and 95% of yarn for requirement of knit garments are met by local primary textile industry Some heavy chemical industries are manufacturing textile chemicals, Some textile auxiliaries formulation unit has established, few petrochemical industries to manufacture textile auxiliaries are producing and few others to start production soon. Currently one reactive dyes manufacturing unit has established. Many garment accessories are being produced in Bangladesh, Some factories are producing man made yarn/fiber. Provide huge opportunities for the supporting Industry- Banking , Insurance, Shipping, Transport, Toiletries, Cosmetics, Hotel and other related economical activities 90% of this industry is export oriented Number of Textile and RMG companies are entering stock market by Initial Public Offerings (IPO) Only 40% of value addition of the final products can be done by our industry. More backward linkage industries are necessary to increase export retention.

12 Contribution in Export
Textile and apparel industry comprises 88% of total export Bangladesh is the 2nd largest apparel exporter in the world Bangladesh is still competitive as all other textile garments manufacturing countries had to raise their wages like Bangladesh. But still contributes less than 5% of total global apparel export. Global export leader China is leading with around 34% market and strongly believed to be more expensive day by day than other manufacturing countries. Bangladesh is comprising only billion of total 400 billion apparel export. On this billion export net retention is only 40%.

13 Gas situation for the industry
Almost 100% percent of the captive power is gas based, 40% of which is being affected by gas shortage and supply problem. We must look to the alternative sources of power generation Moving to a sustainable coal use seems mandatory to keep things moving Report said about 4000 crore of local investments in the textile apparel industry are yet to start production due to no gas or power connection. Many existing companies has sufficient orders and plan for expansion but pending on gas or power connection.

14 Only 6.49 TCF gas reserve is left in Bangladesh …
Natural Gas Consumption is 710 BCF against annual average demand of 912 BCF and increasing …. Only 6.49 TCF gas reserve is left in Bangladesh … According to the projection, the total annual demand of Natural Gas for the year would be 1335 BCF. Projection gives: Before 2025 Natural Gas will be depleted! Source: US Energy Information Administration

15 Power Sector Situation of The Country
Estimated daily demand supply gap (MW Power) up to year Data Source: PDB Only some apparel and allied small scale industry is using power from the supply. RMG industry is using only 400 MW of electricity from govt. Industrial captive power generation is 3000 MW. Almost full capacity is being run by gas Current energy crisis is impeding industrial growth. Government is moving towards a long term sustainable power policy which should be empowered and established 100%, not in a portion.

16 Water Table of Dhaka is Declining….

17 In Bangladesh: An average denim washing factory consumes monthly more than 9,650,000 (around 10 million) Liter water. Average Knit composite factory consume more than 75,000,000 (75 million) Liter water/month.

18 Resource Utilization in Knit Composite Ind.
Resource Benchmarking is the first step of the Resource Utilization A study from A&J and other sources reveals that Specific Consumption of Resources Per Kg Fabric is: Diesel and CNG are also used Data: A&J CP Observations Average factory in Bangladesh Average good factories in BD World’s best Practices Water (Liter) 60-70 Electricity (kWh) Natural Gas (cubic meter) Steam (Kg) 8-10 5-6

19 Technical Challenges for Resource Utilization
Wet Processing Industries (Dyeing & Finishing): Reprocessing percentage (Less than 0.5%) and process loss (less than 5%) should be reduced remarkably . Optimized use of existing machines and resources (Manpower & chemicals) is important. Optimized and prospective use of laboratory. More process optimization and control to approach RFT (Right Fast Time). Cleaner production practices should be implemented More energy conservation should be approached Water use should be measured to save

20 Technical Challenges for Resource Utilization
Spinning, Weaving & Knitting: State of the art machinery in most of the industries. Use of sophisticated hardware & software (Autoconer) to increase uniformity. Remarkably reduced material loss. More production by running the machines at higher speed. Optimized use of the machines. More specialized product manufacturing approach will increase production- frequent article change is hindering production. More research is needed in the product development to get maximum benefit from the existing machines and raw materials.

21 Technical Challenges for Resource Utilization
RMG industry: Productivity of Average Bangladeshi RMG industries is 30-40%!! Productivity in the textile industries is much higher (60-70%). Modern production methods like Lean Manufacturing is being implemented in some factories which can easily increase the productivity to 60-70%. Automation in Production Process State of the art technologies and machinery under operation Use of CAD/CAM in Production Use of Enterprise Resource Planning (ERP) software by the manufacturing organizations Overall good managerial practices in all aspect including Human Resource Management (HRM) Skill development of the employees through in house and institutional training Invest not only to increase your production but also to increase your productivity. Make money not only through production but also through productivity.

22 Employment in Textile & Apparel Industry
Sub Sector Manpower Textile Spinning 400,000 Textile Weaving (Larger machine) 80,000 Specialized Textile and Power Loom 43,000 Handloom 793,000 Knitting, Knit Dyeing: a. Export Oriented 300,000 b. Local Market 24,000  Dyeing & Finishing: a. Semi Mechanized 10,000 b. Mechanized 23,000  Export Oriented RMG 3,500,000 Jute Industries 100,000 Others: 600,000 Grand Total 6,100,000 Provide 6.1 million of employment where 80% of them are women 15 million of people in support industries depending on this trade Provide 0.2 million jobs in waste recycling industry related to textiles

23 Education & Training Level of Course Type of Institution Present Total Intake per Annum M. Sc. In Textile Engineering 2 Public Universities 1 Private University 100 4 year B.Sc. in Textile Engineering Bangladesh University of Textiles (Butex), 4 Textile Colleges under DOT, 1 (one) Textile College under BTMA, 2 (two) Private Colleges, BIFT 2 (two) Depts. in Public Universities, 15 depts. in Private Universities 5000 Diploma in Textile Engineering 61 private textile diploma college & 3 institutes under DOT 3000 Vocational (SSC-10 class level) under DOT 40 Vocational Institutes 1500 1 Year Long Course in Textile Technology NITTRAD 50 Total - 9650 Source: PPMA team survey & review of secondary sources. Quality of education must be ensured in each level of education

24 Education & Training A good blend of engineers and technician only can come out from a nicely structured education system

25 Global Sustainable Initiatives
10 different brands participated in IFC-SEDF Cleaner Production 1st phase: H&M, Levi Strauss & Co, WE, Mothercare, Kappahl, Lindex, Tesco, Primark, New-Look, Bestseller M&S started Plan-A for environmental sustainability

26 Global Sustainable Initiatives
Organic, OE & BCI for environmentally friendly fibers. H&M RSL initiative to make their supply chain zero discharge of hazardous chemicals (ZDHC) by 2020.

27 Global Sustainable Initiatives

28 How A&J can contribute in resource utilization
Consultancy Services Cleaner Production (CP) for the Processing Plants Energy Auditing Chemical Management and Auditing Health, Safety & Environmental Audit and Fire Safety Audit Zero Discharge & Green Factory Set-up Compilation & Preparation of IEE & EIA for processing plants Quality Assurance Garment Productivity & Quality Increment etc.

29 Resource Utilization- Example
Cleaner Production pilot project of IFC-SEDF at 6 factories save yearly: Steam: 19,557 Tons Electrical Load: 1,916 kVA Electrical Energy: 5,380 MWh Water: 426,023,000 Liter Natural Gas: 6,374,568 Cubic meter GHG reduction: 13,079 Tonns of CO2 Overall Financial Saving: USD 934,544 directly per annum Source: As shared by IFC-SEDF in CP Final workshop.

30 Bangladesh Is The Crux of The Surprise!
GDP in export sector increased THREE FOLDS within a decade. The economic boom in Bangladesh due to the textile sector where the contribution of women workers are the highest (80%) In spite of limited natural resource and population density still Bangladesh’s economy has maintained a healthy growth rate in past years  ... accelerate Bangladesh's economic growth to 8% to be a middle-income country by 2021…

31 Bangladesh Is The Crux of The Surprise!
Bangladesh now belongs to a small group of countries that 'have done well' in both human development indicators and economic growth in recent decades Daily Prothom-Alo 23rd Nov, 2012


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