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 AminEngr. Khondoker Md. Mainul AhadAmin & Jahan Corporation Ltd.
2 Gratitude In Association with: Diamond Sponsors: Gold Sponsor Sponsors Media PartnerWeb PartnerInternational Web Partner
3 Unite for sustainability InvokesUnite for sustainabilityCreate knowledge based industrial and business communityThrough….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 glanceTheme: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: www.aminjahan.com A&J at a glancePeople:Year of establishment: 2008(has been incorporated to Amin & Jahan Corporation Ltd. from Amin & Jahan Corporation in 2012)Board Members: 5Number of Full Time Employees: 25Number of part time editors, consultants & researchers: 21Places & Contact:Corporate office: (3720 sqf)Unit 601, House # 145, Road # 3, Block A, Niketon, Gulshan 1, Dhaka 1212Tel: , 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 glanceWorking in collaborationsGerman 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 SectorNo. of unitsInstalled Machine CapacityProduction Capacity/yearTextile Spinning3858.7 ml. spindleml. kg0.23 ml. rotorTextile Weaving/Fabric Manufacturing72117250 shuttleless13500 shuttleml.mtrSpecialized Textile and Power Loom1,06523,000 SL/SLLml.mtrHandloom148,3423,13,245 (running loom)ml.mtrKnitting, Knit Dyeing:2800a. Export Oriented120012,000 Knit/dy/M3, ml.mtrb. Local Market16005000 knit/dy/Mml.mtrDyeing & Finishing (Woven):a. Semi Mechanizedb. Mechanized352952572000 ml. meter Export Oriented RMG5150ml. dozenJute Industriesa. BJMCb. BJMAc. BJSA2710170337 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 industry90% of knit fabrics for knit RMG and 40% of woven fabrics for woven RMG provided by local basic textile industries90% of domestic fabrics and 95% of yarn for requirement of knit garments are met by local primary textile industrySome 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 activities90% of this industry is export orientedNumber 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 exportBangladesh is the 2nd largest apparel exporter in the worldBangladesh 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 generationMoving to a sustainable coal use seems mandatory to keep things movingReport 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: PDBOnly 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 gasCurrent 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.
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 UtilizationA study from A&J and other sources reveals that Specific Consumption of Resources Per Kg Fabric is:Diesel and CNG are also usedData: A&J CP ObservationsAverage factory in BangladeshAverage good factories in BDWorld’s best PracticesWater (Liter)60-70Electricity (kWh)Natural Gas (cubic meter)Steam (Kg)8-105-6
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 implementedMore energy conservation should be approachedWater 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 ProcessState of the art technologies and machinery under operationUse of CAD/CAM in ProductionUse of Enterprise Resource Planning (ERP) software by the manufacturing organizationsOverall good managerial practices in all aspect including Human Resource Management (HRM)Skill development of the employees through in house and institutional trainingInvest 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 SectorManpowerTextile Spinning400,000Textile Weaving (Larger machine)80,000Specialized Textile and Power Loom43,000Handloom793,000Knitting, Knit Dyeing:a. Export Oriented300,000b. Local Market24,000 Dyeing & Finishing:a. Semi Mechanized10,000b. Mechanized23,000 Export Oriented RMG3,500,000Jute Industries100,000Others:600,000Grand Total6,100,000Provide 6.1 million of employment where 80% of them are women15 million of people in support industries depending on this tradeProvide 0.2 million jobs in waste recycling industry related to textiles
23 Education & TrainingLevel of CourseType of InstitutionPresent Total Intake per AnnumM. Sc. In Textile Engineering2 Public Universities1 Private University1004 year B.Sc. in Textile EngineeringBangladesh University of Textiles (Butex), 4 Textile Colleges under DOT,1 (one) Textile College under BTMA,2 (two) Private Colleges, BIFT2 (two) Depts. in Public Universities,15 depts. in Private Universities5000Diploma in Textile Engineering61 private textile diploma college &3 institutes under DOT3000Vocational (SSC-10 class level) under DOT40 Vocational Institutes15001 Year Long Course in Textile TechnologyNITTRAD50Total-9650Source: PPMA team survey & review of secondary sources.Quality of education must be ensured in each level of education
24 Education & TrainingA 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, BestsellerM&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.
28 How A&J can contribute in resource utilization Consultancy ServicesCleaner Production (CP) for the Processing PlantsEnergy AuditingChemical Management and AuditingHealth, Safety & Environmental Audit and Fire Safety AuditZero Discharge & Green Factory Set-upCompilation & Preparation of IEE & EIA for processing plantsQuality AssuranceGarment Productivity & Quality Increment etc.
29 Resource Utilization- Example Cleaner Production pilot project of IFC-SEDF at 6 factories save yearly:Steam: 19,557 TonsElectrical Load: 1,916 kVAElectrical Energy: 5,380 MWhWater: 426,023,000 LiterNatural Gas: 6,374,568 Cubic meterGHG reduction: 13,079 Tonns of CO2Overall Financial Saving: USD 934,544 directly per annumSource: 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' inboth human development indicators and economic growth in recent decadesDaily Prothom-Alo 23rd Nov, 2012