Professional Documents
Culture Documents
Methodology:
Its a desk research because secondary materials are available from different sources. These are particularly
published materials of Group QA and surveys performed by others from internet and the data available
from the internal sources of the company which have been taken up for the analysis and interpretation.
Page 1 of 30
CHAPTER-: 01
Overview of RMG Sector
1.1
Introduction:
The Ready-Made Garments (RMG) industry occupies a unique position in the Bangladesh economy. It is
the largest exporting industry in Bangladesh, which experienced phenomenal growth during the last 25
years. By taking advantage of an insulated market under the provision of Multi Fiber Agreement (MFA) of
GATT, it attained a high profile in terms of foreign exchange earnings, exports, industrialization and
contribution to GDP within a short span of time. The industry plays a key role in employment generation
and in the provision of income to the poor. Nearly four million workers are directly and more than twelve
million inhabitants are indirectly associated with the industry. Over the past twenty five years, the number
of manufacturing units has grown from 180 to over 4000. The sector has also played a significant role in
the socio-economic development of the country.
The quota came to an end at 2004 but it continued to show robust performance, competitive strength and,
of no less importance, social commitment. RMGs contribution to Bangladesh economy is well-known,
well-appreciated and well-respected.
Garments industry is the largest export industry for our country and it contributes 75% of total export. The
industry is associated with its strength, weakness, threat and opportunity.
In this study an attempt has been made to describe the overall scenario of Bangladesh Ready Made
Garments industry . At this time of free economy everyone may be interested to know about the largest
export industry and the mechanism of doing business here. The present study has been undertaken with
consideration of this fact.
Agriculture has been the backbone of economy and chief source of income for the people of Bangladesh,
the country made of villages. Government wants to decrease poverty by getting highest productivity from
agriculture and achieve self-reliance in food production. Apart from agriculture, the country is much
concerned about the growth of export division. Bangladesh have accelerated and changed her exports
substantially from time to time. After Bangladesh came into being, jute and tea were the most exportoriented industries. But with the continual perils of flood, failing jute fiber prices and a considerable
decline in world demand, the role of the jute sector to the countrys economy has deteriorated (Spin anger,
1986). After that, focus has been shifted to the function of production sector, especially in garment
industry.
Page 2 of 30
1.2
Year
1970-1980
1982-1985
1985
1990
1993
2003
2005
2006
2007-2008
Issue
Early period of growth
Boom days
Imposition of quota restriction
Knitwear sector developed significantly
Child labor issue and its solution
Withdrawal of Canadian quota restriction
Phase out of quota restriction
Riots and strike by garments labor
Stable growth
Source: Compiled by the databases of the Bangladesh Garment Manufacturers and Exporters
Association, and the Export Promotion Bureau, Bangladesh.
Currently, there are more than 4,000 RMG firms in Bangladesh. More than 95 per cent of those firms are
locally owned with the exception of a few foreign firms located in export processing zones (Gonzales,
2002). The RMG firms are located mainly in three main cities: the capital city Dhaka, the port city
Chittagong and the industrial city Narayangonj. Bangladesh RMG firms vary in size. Based on Bangladesh
Garment Manufacturers and Exporters Association (BGMEA) data, Mainuddin (2000) found that in 1997
more than 75 per cent of the firms employed a maximum of 400 employees each. Garment companies in
Bangladesh form formal or informal groups. The grouping helps to share manufacturing activities, to
diversify risks; horizontal as well as vertical coordination can be easily found in such group activities.
Ready-made garments manufactured in Bangladesh are divided mainly into two broad categories: woven
and knit products. Shirts, T-shirts and trousers are the main woven products and undergarments, socks,
stockings, T-shirts, sweaters and other casual and soft garments are the main knit products. Woven
garment products still dominate the garment export earnings of the country. The share of knit garment
products has been increasing since the early 1990s; such products currently account for more than 40 per
cent of the countrys total RMG export earnings (BGMEA website).
Although various types of garments are manufactured in the country, only a few categories, such as shirts,
T-shirts, trousers, jackets and sweaters, constitute the major production-share (BGMEA website; and Nath,
Page 3 of 30
2001). Economies of scale for large-scale production and export-quota holdings in the corresponding
categories are the principal reasons for such a narrow product concentration.
Foreign buyers are concerned about the different compliance of law. So, they were bothered about the
child labor issue of Bangladesh. But later on this problem is salute and now garments are restricted to
employ child labor. In 2005 the quota facilities for Bangladesh was withdrawn. Everybody thought it
would be a great shock for garments industry. But in reality Bangladesh has faced this challenge with great
courage. The fact is that the export of garments product has increased after the withdrawn of this quota.
And the last two years were really good time for garment industry. The political situation was stable under
the countrys state of emergency and this boost the growth of the industry.
Page 4 of 30
1.5.2 Weakness
1.5.3 Opportunity
EU is willing to establish industry in a big way as an option to china particularly for knits,
including sweaters
Bangladesh is included in the Least Developed Countries with which US is committed to enhance
export trade
Sweaters are very economical even with china and is the prospect for Bangladesh
If skilled technicians are available to instruct, prearranged garment is an option because labor and
energy cost are inexpensive.
Foundation garments for Ladies for the FDI promise is significant because both, the technicians
and highly developed machinery are essential for better competence and output
Japan to be observed, as conventionally they purchase handloom textiles, home furniture and
garments. This section can be encouraged and expanded with continued progress in quality.
1.5.4 Threat
The exporters have to prepare themselves to harvest the advantages offered by the opportunities.
Amount
3812.00
6218.00
13078.00
27008.00
80.00
22.00
10619.00
3058.00
2681.00
15411.00
43368.00
Source: Bangladesh bank ( April to June)
Page 6 of 30
Export of RMG
Total Export
1976-77
1977-78
1978-79
1979-80
1980-81
1981-82
1982-83
1983-84
1984-85
1985-86
1986-87
1987-88
1988-89
1989-90
1990-91
1991-92
1992-93
1993-94
1994-95
0.012
0.069
0.104
0.672
3.36
6.99
10.84
31.57
116.20
131.48
298.67
433.92
471.09
624.16
866.82
1182.57
1445.02
1555.79
2228.35
417.00
493.74
618.81
749.44
709.85
625.90
686.60
811.00
934.43
819.21
1076.61
1231.20
1291.56
1923.70
1717.55
1993.90
2382.89
2533.90
3472.56
% of RMG Export to
Total Export
0.02
0.01
0.02
0.09
0.47
1.12
1.58
3.89
12.44
16.05
27.74
35.24
36.47
32.45
50.47
59.31
60.64
61.40
64.17
Page 7 of 30
1995-96
1996-97
1997-98
1998-99
1999-00
2000-01
2001-02
2002-03
2003-04
2004-05
2005-06
2006-07
Source: Export
promotion Bureau
2547.13
3001.25
3781.94
4019.98
4349.41
4859.83
4583.8
4900.0
5700.00
6300.00
7900.8
9211.2
70563.03
3882.42
4418.28
5161.20
5312.86
5752.20
6467.30
5986.09
6396.87
7600.00
8422.46
10526.2
12177.9
65.61
67.93
73.28
75.67
75.61
75.14
76.57
76.60
76.00
74.80
75.06
75.64
Total
This table reveals the RMG export from the initial stage of the industry till 2007 and its contribution to
total export. The RMG sector enjoys a continuous growth from the beginning of the industry but the initial
level was tough. From the last ten years it is viewed that RMG export is contributing 75% of the total
export. The following graph can give clear view of growth in RMG export for the last 10 years.
Page 8 of 30
CHAPTER-: 2
PROFILE OF GROUP QA
2.1 HISTORICAL P ROFILE OF GROUP QA
The journey of Group QA has been a long one. In 1965, One dynamic thinking entrepreneur cplanned the
first seeds of the Group QA. Nearly three decades later, those early seeds have matured into large trees
with branches spread over various growth sectors.
The decentralized management structure of the corporation has ensured that efficiency and productivity
have not been hampered due to the organizations growth and expansion.
Over the years, Group QA has remained true to providing customers with the very best in product selection
and service. The group continually invests in modernizing its management system and designs specific inhouse training programs targeted towards improving the creative abilities of its people. Group QA is
confident that the trust and goodwill of its customers, vast experience of its management, and the
dedication of its workforce will enable the organization to lead Bangladesh towards a prosperous future.
Corporate Headquarter:
Group QA
228/A, Tejgaon Industrial Area, Dhaka-1208
Page 9 of 30
Sole Distributor
BOSCH, Germany
Skill , Fishcer , China
Page 10 of 30
Yearly Turnover
Markets
Product Range
Page 11 of 30
H&M
C&A
S Oliver
INDITEX
ASH CITY
Cotton
and Polyester Blnded base fabrication. Have been working with them
since 2004.
CHARLSE VOGELE
Polyester base fabrication.
Chapter-: 03
The marketing strategy, activities, goal and corrective action plan based on
a Case Study: Post Rana Plaza tragedy era
After the Rana Plaza incident the RMG business of Bangladesh takes new shape and the marketing
strategy of the local suppliers changed accordingly. This new era required to deal with competitive market
environment and concentration on building and fire safety issues.
Segmentation: The two major segment of markets are the EU and US market. Most of the suppliers from
Bangladesh work with these two segment.
Targeting: As in the case study the factory is working with three major importer of EU our study will
concentrate on the EU portion.
3.1
Building and fire safety is a critical requirement and plays vital role on the marketing of a factory product.
Page 13 of 30
500,000
375,000
175,000
75,000
Between 25 to 50 Million
37,500
Page 14 of 30
Between 10 to 25 Million
17,500
Between 1 to 10 Million
10,000
1,000
This funding will be specifically for the activities of the Steering Committee, the Safety Inspector and
Training Co-coordinator. This funding does not cover remediation such as structural repairs or renovations
on factories. These bands may change annually as the budget changes.
3.1.5 Funds for cost of structural repairs
Under the Accord, Companies are responsible for ensuring sufficient funds are available to pay for
structural repairs or renovations. This includes negotiating commercial terms with suppliers to ensure that
it is financially feasible for factories to maintain safe workplaces and comply with any structural repairs or
safety improvements, and where appropriate, the use of alternative means such as joint investments, loans,
accessing donor or government support.
3.1.6 The inspection Schedule
Independent inspections of a first batch of 10 factory started in November 2013. Since February 2014
inspection teams are in the field inspecting more than 50 factories per week. . The Accord intends that all
initial inspections and, where needed, renovation plans will be completed by October 2014. In addition,
some companies are already conducting their own inspections and information from these will be
incorporated into the work of the Accord where appropriate.
3.1.7 The Initial inspection Team
For the initial inspections the Accord has contracted four international engineering firms: Woosun
(electrical); Hughes (fire) and Arup & WSP (structural). Combined they have approximately 110
international and local engineers and technical experts working on the inspections. Additionally, the
Accord Chief Safety Inspector will recruit a team of more than 25 permanent Bangladeshi Accord staff
engineers.
3.1.8 Publication of factory information
A single aggregated list of all factories in Bangladesh under the Accord was first published on 3 October
2013. The factory data management of the Accord is an ongoing process. Accord signatory brands update
their factory data on an ongoing basis submitting it directly to the Fair Factories Clearinghouse (FFC). The
publicly available list on the Accord website is updated monthly.
3.1.9 The government of Bangladesh says it is inspecting many factories. The relation of the
inspection with the ACCORD system
The Accord welcomes the decision of the Bangladesh Government to renew its commitment to inspect
factories. It is the intention of the Accord to work with all relevant stakeholders including Government, to
build capacity for a safe and sustainable Bangladeshi Ready Made Garment industry.
Page 15 of 30
3.2
According to the contract agreement with the buyers the Accord team inspected the Factory
building of Group QA. During the audit they have provided their observation. According the
observation and recommended time frame the factory management takes corrective action
plan (CAP) which have been given in the following tables:
Page 16 of 30
Item
No
1
Accord Inspection
Observation
No protection between
the transformer and
surrounding area.
Accord
Timeline
6 Months
Arcing horns on HT
bushings of
transformer, not
installed.
Cables terminating to
transformer bushings
are not supported.
Within 1
Month
3 Months
Barrier/separators
between different
phases are not
installed.
Within 1
Month
3 Months
3 Months
Within 1
Month
Page 17 of 30
Insufficient working
area in front of the
panel (Operating area)
Sufficient clearance in
front
of the panel shall be
provided.
Within 1
Month
Within 1
Month
Item
No
1
Accord Inspection
Accord Action Plan
Observation
The
Separate the
Boiler/Generator/Transformer Boiler/Generator/Transformer
room is not separated by fire- room by a minimum 2-hr fire
rated doors from the
rated construction. Seal
surrounding areas.
and/or protected all openings
to maintain the required fire
separations.
Accord
Timeline
Within 03
Months
Within 3
Months
Within 3
Months
right sourcing,
financial
availability, import
terms and
availability of
Engineers &
designers we feel
the time required is
justifiable.
Moreover this is a
running factory and
we have to face
interuption within
the production
work. Due to the
mentioned reason
time may vary from
the planed schedule.
We are agree to
inslatted Fire rated
doors in mentioned
area. But due to
existing structure,
right sourcing,
financial
availability, import
terms and
availability of
Engineers &
Designers we feel
the time required is
justifiable.Moreover
this is a running
factory and we have
to face interuption
within the
production work.
Due to the
mentioned reason
time may vary from
the planed schedule.
work will be done
as per
recommendation.
Due to existing
structure, right
sourcing, financial
availibility, import
Page 19 of 30
terms and
availibility of
Engineers
&designeers we feel
the time required is
justifiable to
installed the
appropriate firerated doors instead
of existing doors.
Immediate
Already removed
all the storage items
from exit stair and
egrees paths
accordingly and it
will be continued in
future.
We are planning to
install Fire rated
doors instead of
collapsible gates
and sliding door.
But due to existing
structure, right
sourcing, financial
availability, import
terms and
availability of
Engineers &
Designers we feel
the time required is
justifiable.
Moreover this is a
running factory and
we have to face
interuption within
the production
work. Due to the
mentioned reason
time may vary from
the planed schedule.
Page 20 of 30
Design
within 6
months,
install
within 12
months
10
Within 3
months
We have decided to
provide automatic
sprinkler system
throughout the
building. But due to
existing structure,
right sourcing,
financial
availability, import
terms and
availability of
Engineers &
Designers we feel
the time required is
justifiable.Moreover
this is a running
factory and we have
to face interuption
within the
production work.
Due to the
mentioned reason
time may vary from
the planned
schedule.
This will be done
within the time
frame.
Item
No
1
Accord Inspection
Observation
The additional work
area atop the roof slab
applies loads of an
additional storey to the
columns beneath it.
Accord
Timeline
Demolish existing
rooftop work area
Within 6
Weeks
applies loads of an
additional storey to the
columns beneath it.
Ground floor storage
loads exceed allowable
limits in localized
areas.
Building composed of
flat slabs lacks an
apparent lateral
restraint system.
Building composed of
flat slabs lacks an
apparent lateral
restraint system.
and remove
demolition remnants
from the roof
Immediate
6 Weeks
As per recommendation a
committee has been formed to
monitor this issue properly.
Within 6
Weeks
Within 6
months
Within 6
months
6 months
Reduce and
distribute storage at
ground floor level to
allowable loads
indicated by slab
loading plan.
Develop and
implement protocols
for the monitoring of
slab loading in
accordance with
existing slab loading
plans.
Factory engineer to
conduct a review of
design, loads and
column stresses
throughout the
factory.
Amend existing
loading plan
according to findings
of engineering
review mentioned
above
Factory engineer to
conduct a review of
structure's lateral
stability system.
If required,
implement measures
to bolster lateral
stability.
Page 22 of 30
3.3 Production, complacence and quality management system with production process
For factories to get approval it must comply with the critical minimum ethical and quality
complacence audit done by different Buyer or representative from the buyer.
3.3.1 Case Study : New Factory Approval Flow Chart for Marks and Spencer
MANDATO
RY OR
OPTIONAL?
1. FACTORY
CAPABILITY
MANDATO
RY
CRITICAL
REQUIREMENT
mandatory or
optional?
WHAT MUST
FACTORY
DEMONSTRATE?
GUIDELINES
Factory demonstrates
it has a competent
system to inspect
product on the
production line, and
for final product
inspection, with clear
feedback and
corrective actions
supported by factory
Factory management
demonstrate professional
competence to manage and
deliver this process, and an
approved correctly constructed
garment is available for
reference by the production
and inspection manager
mandatory
2. INSPECTION
PROCESS
INLINE AND END
OF LINE
Page 24 of 30
management
CRITICAL
REQUIREMENT
mandatory or
optional?
WHAT MUST
FACTORY
DEMONSTRATE?
GUIDELINES
3. LABEL
MANAGEMENT
mandatory
Factory must
demonstrate a
competent system
which checks all
incoming labels
against customer
contract, that these
are then issued to
appropriate
production lines
accurately, with no
risk of different
customers labels
being mixed on
product
mandatory
CRITICAL
REQUIREMENT or
optional?
GUIDELINES
WHAT MUST
FACTORY
DEMONSTRATE?
4. CONTRACT
AND SEWING
LINE DETAILS
AVAILABILITY
Factory must
demonstrate clear
evidence of
customer contract
details, and a clear
specification of the
garments
construction details
for the sewing line
manager to work to
mandatory
Page 25 of 30
mandatory
CRITICAL
REQUIREMENT or
optional?
GUIDELINES
WHAT MUST
FACTORY
DEMONSTRATE?
5. NEEDLE AND
METAL
PROCEDURE
Factory can
demonstrate it has a
metal and needle
control procedure
that minimises the
risk that a needle
whole or broken
can pass through the
factory undetected,
and into the final
garment
mandatory
mandatory
CRITICAL
REQUIREMENT or
optional?
GUIDELINES
WHAT MUST
FACTORY
DEMONSTRATE?
Factory can
demonstrate it has
systems, and
equipment as
appropriate, to
deliver sewn-on
buttons or poppers
(or similar types of
snap-type security
trims) which remain
secure on the
finished product as
delivered to the
customer
mandatory
CRITICAL
REQUIREMENT or
optional?
Childrens clothing
GUIDELINES
WHAT MUST
FACTORY
DEMONSTRATE?
Page 26 of 30
7. PREPRODUCTION
PROCESS AND
POLICY
mandatory
Factory can
demonstrate that for
each product line a
risk assessment, and
suitable follow up
plan of action, is
created and carried
out
CRITICAL
REQUIREMENT
mandatory or
optional?
WHAT MUST
FACTORY
DEMONSTRATE?
GUIDELINES
8. INDEPENDENT
QUALITY
RESPONSIBILIT
Y
mandatory
Factory can
demonstrate its
Quality Manager(s)
are responsible
directly to the
Factory Director or
Manager, and not to
the Production
Manager
3.4 Case Study: Marks And Spencer Quality Audit and Group QA
The Marks and Spencer Audit of Quality Standard has been performed by the Group.On different
operational process the self audit before the final audit by the Buyers team has shown a 83% compliance
on different required field.
Page 27 of 30
Departments
Max. Adjusted
Value Value
Actual
Score
Complacence
77
77
65
84%
2. Pre-Production Control
42
42
38
90%
3. Cutting Room
30
30
20
73%
30
30
30
100%
15
15
0%
10
10
10
100%
5. Sewing Room
100
100
87
87%
15
15
12
80%
10
10
60%
10
10
70%
9. Pressing
10
10
90%
10
10
70%
25
25
19
76%
15
15
13.5
90%
30
25
25
100%
14. Total
429
424
350.5
83%
Page 28 of 30
Page 29 of 30
There were no strict and well coordinated Building, Fire and Health safety policy and its
implementation existed before Rana Plaza incident
The EU is now strictly implemented Building, Fire and Health safety policy in the factories
The marketing and promotional activity is now to deal with the changed requirements with
respect to Safety, quality and production process issues
The marketing goal is to fulfillment of the critical requirements of the safety, quality and
production issues and strive to achieve high performance in the other components of
marketing
Case study shows a significant areas need to be corrected in the inspection of Accord with
respect to Electrical, Fire and Structural audit in Group QA
Appendix:
a) www.bgmea.com.bd
b) www.group-qa.com
c) www.epb.com.bd
Page 30 of 30