Efficient Use of Resources in Textiles Production

Report
Theme:
Efficient Use of Resources in Textiles Production
Engr. A S M Tareq Amin
Engr. Khondoker Md. Mainul Ahad
Amin & Jahan Corporation Ltd.
Gratitude
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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.
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: 88-02-9863105, Fax: +8802 9854132. Email: [email protected]
Editorial & Registered Office: (1000 sqf)
House # 41 (2nd Floor), Road # 5, Block B, Monsurabad R/A, Adabor, Dhaka 1207
www.aminjahan.com
A&J
Working in collaborations
at a glance
• German Technical Corporation (GIZ) - On training and publication.
• The company has been working together with Switzerland based
consulting firm Gherzi, www.gherzi.com 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.
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.
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.
What are your next top 3 sourcing
country hotspot for the next five years?
100
90
80
70
60
50
40
30
20
10
0
Bangladesh
Vietnam
Indonesia
Cambodia
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’.
Structure of The Textile & Garment Industry
Source: BTMA Annual Report 2011 & Economic Review 2011 (MOTJ)
Sub Sector
Textile Spinning
Textile Weaving/Fabric
Manufacturing
Specialized Textile and
Power Loom
Handloom
Knitting, Knit Dyeing:
a. Export Oriented
b. Local Market
Dyeing & Finishing (Woven):
a. Semi Mechanized
b. Mechanized
Export Oriented RMG
Jute Industries
a. BJMC
b. BJMA
c. BJSA
No. of units
385
721
Installed Machine Capacity Production Capacity/year
8.7 ml. spindle
2050.00 ml. kg
0.23 ml. rotor
17250 shuttleless
2150.00 ml.mtr
13500 shuttle
1,065
23,000 SL/SLL
400.00 ml.mtr
148,342
2800
1200
1600
352
95
257
5150
3,13,245 (running loom)
837.00 ml.mtr
12,000 Knit/dy/M
5000 knit/dy/M
3,600.00 ml.mtr
500.00 ml.mtr
27
101
70
2000 ml. meter
561.00 ml. dozen
337 thou. tons
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.
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
19.09 billion of total
400 billion apparel
export.
On this 19.09 billion
export net retention
is only 40%.
Other
52%
China
36%
India Turkey Bangladesh
5%
3%
4%
Gas situation for the industry
Sector Specific Natural Gas Demand FY12-13
Others
3%
CNG
5%
Household
12%
Power
33%
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
Industry
20%
Fertilizer
9%
Captive Power
18%
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.
12000
• Natural Gas Consumption is
710 BCF against annual average
demand of 912 BCF and
increasing ….
Natural Gas Situation in
Bangladesh
10000
• Only 6.49 TCF gas reserve is left
in Bangladesh …
MMCF Gas
8000
6000
Dry Natural
Gas
Production
(MMCF)
4000
Proved
Reserves of
Natural Gas
(MMCF)
2000
0
2000
2005
2010
2015
Year
Source: US Energy Information Administration
•According to the projection, the
total annual demand of Natural
Gas for the year 2014-2015
would be 1335 BCF.
• Projection gives: Before 2025
Natural Gas will be depleted!
Power Sector Situation of The Country
Estimated daily demand supply gap (MW Power) up to year 2016. 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.
Water Table of Dhaka is Declining….
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.
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:
Average factory in
Bangladesh
Average good
factories in BD
World’s best
Practices
Water (Liter)
140-250
110-150
60-70
Electricity (kWh)
0.56-2.51
0.5-1.0
0.4-0.6
Natural Gas (cubic
meter)
1.2-2.5
0.5-1.0
0.3-0.5
Steam (Kg)
4.3-13.5
8-10
5-6
•
Diesel and CNG are also used
Data: A&J CP Observations
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
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 productionfrequent article change is hindering production.
More research is needed in the product development to get maximum
benefit from the existing machines and raw materials.
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.
Employment in Textile & Apparel Industry
Sub Sector
Textile Spinning
Textile Weaving (Larger
machine)
Specialized Textile and Power
Loom
Handloom
Manpower
400,000
80,000
43,000
Provide 6.1 million of
employment where 80%
of them are women
793,000
Knitting, Knit Dyeing:
a. Export Oriented
300,000
b. Local Market
24,000
15 million of people in
support industries
depending on this trade
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 0.2 million jobs
in waste recycling
industry related to
textiles
Education & Training
Level of Course
Type of Institution
M. Sc. In Textile Engineering
2 Public Universities
1 Private University
4 year B.Sc. in Textile Engineering
Vocational (SSC-10 class level) under DOT
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
61 private textile diploma college &
3 institutes under DOT
40 Vocational Institutes
1 Year Long Course in Textile Technology
NITTRAD
Diploma in Textile Engineering
Total
Present Total
Intake per
Annum
100
5000
3000
1500
50
-
9650
Source: PPMA team survey & review of secondary sources.
Quality of education must be ensured in each level of
education
Education & Training
Demand & Supply of Engrs.
50000
40000
30000
20000
10000
0
2007-08 2008-09 2009-10 2010-11 2011-12 2012-13 2013-14 2014-15
Demand of B.Sc. Engr.
Supply of B. Sc. Engr.
Demand of Diploma Engr.
Supply of Diploma Engr.
A good blend of engineers and technician only can come out from a nicely
structured education system
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
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.
Global Sustainable Initiatives
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.
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.
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…
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
THANK YOU

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