Merchandising of Men’s Shirt in Bangladesh – A Case Study
A case study on Men's shirt manufacturing in a Garment factory in Bangladesh
More than 60% of the export share of Bangladesh is now contributed by ready-made garments. Due to the advent of containerization multimodal transport has created a new era in international trade.
Costing
For, the Production Process Merchandisers need to collect the cost of all the fabric and trims. They need to calculate the consumption of fabric here and also the pattern size. The complicacy of the style and the trim price is also included to count the cost of any garment. Accessories like the label, hangtag price is also included with the costing sheet. Here, for completing the costing part merchandise needs the pattern file first for assuming the consumption of fabric and then, they need to count the trim’s price attached in the garment. In this case, they also need the spec sheet.
Then, the production team needs the labor cost. There is an Industrial Engineer who calculates the time that every part of samples needs to sew and the cost of the labor for these hours. The price of trims is very important in case of measurement of the garment. In some cases, it captures a very big part of the cost. Here, in the case of Harriet shirt, polyester fabric and fusing are used in the design of this shirt both of these are very special items, and these are not very easily available to the source. So, the cost of this type of item is a bit high, and adding the profit margin it reaches the crossline buyer wants to agree. So, this is the moment of challenge a supplier faces to ship its clothes.
Garment Specifications
Table 13: Harriet Style Shirt Specifications
Fabric Type | Georgette |
Composition | 100% Polyester |
GSM | 100 |
Fusing Type | Interfacing |
Composition | 100% Polyester |
GSM | 80 |
Fabric Consumption of a single garment
Component | Required Fabric Formula | Example |
---|---|---|
Back part: The part of a garment, which covers the back part of the human body. | [(Center Back Length + Allowance) x (1/2 Chest + Allowance)/36] / 44 | [(31″ + 2″) × (24″ + 2″) /36] / 44= 0.541yds |
Yoke: A shaped piece of fabric in a garment, fitted about or below the neck and shoulders, from which the rest of the garment hangs. It can be split in two, called the ―split yoke. | [(Yoke Length + Allowance) x (Yoke Width + Allowance)/36] / 44 | [(21″ + 4″) × (4″+ 1″) / 36] / 44= 0.079yds |
Front part: The front part of a shirt. | [(Body Length + Allowance) x (1/4 Chest + Allowance) x 2 /36] / 44 | ([{31″-1 ¼” + 1″} × {12″ + 2 ½”}] 2″ /36) / 44= 0.562 yds |
Sleeve: The part of a garment that covers the arm and is usually cut wider than the cuffs. Most sleeve lengths fall between 32 and 36 inches. | [Sleeve Length – (1/2 Drop Shoulder + Allowance) x (Arm Hole Depth + Allowance)} x 2 / 44 x 36 | ([{34 ½” -11″} +1″] × {21″ +1″} × 2 /36) / 44= 0.68yds |
Cuff: A fold or band serving as a trimming or finish for the bottom of a sleeve. Some cuff styles include French Cuffs and Barrel Cuffs. | [(Cuff Length + Allowance) x (Cuff Width + Allowance) x 2] /36 x44 | [(9″ + 3″) × (2 ½” + ½”) ×2 /36] / 44= 0.05yds |
Collar: The part of a shirt that encompasses the neckline of the garment, often to fold or rollover. Comes in various shapes, depending on the face shape and occasion. | [(Collar Length + Allowance) x (Collar Width + Allowance) x 4] /36 x44 | [(16″ + 5″) × (2″ +1″) × 4/36] / 44=0.159yds |
Total Consumption for one Garment | 0.541+0.079+0.068+0.05+0.159 = 0.766 yds/per piece |
Marker Planning
The marker shown above has width = 1.55 yds and length = 11.54 yds, so the area of the marker = 17.887 yds2 and has accommodated all the panels of 20 complete Formal Shirts in it.
Also, from the picture we see that the efficiency = 85.75% Now, to find the fabric required for 1 pc of Formal shirt,
Marker efficiency of the above marker = (Area of all the patterns / Area of the marker) x 100% 85.75% = [(Fabric reqd for 1 Shirt x 20) /17.887] x 100%
Fabric reqd for 1 Shirt = 0.766 yds2
Since the width of the marker is 56 inches = 1.55 yds and we will leave 4 inches of allowance at the time of cutting, so we will fabric of 60 inches = 1.66 yds
We found that the area of the fabric required to make 1 Shirt = 0.766 yds So, length of fabric required to make 1 Shirt = 0.766/1.66
= 0.461 yds
Cost of georgette fabric = $2.253/yds.
Total Fabric consumption of 1 Shirt = 0.461 yds
Cost of Fabric required to make 1 Formal Shirt = $2.253 x 0.461 = $1.0386
Cost of Fusible Polyester Interfacing = $0.9/yds. Total Fusing consumption of 1 Shirt = 0.03 yds
Cost of Fusing required to make 1 formal shirt = $0.9 x 0.03 = $0.0270
Cut-Trim Make
CUTTING
Cutting cost = (Cutting of the garment x Minute cost of the labor)/Line efficiency (%)
= (0.5 x 0.6)/0.6
= $0.5
STITCHING
Total SAM of the Shirt = 11.46
Total Stitching Cost to stitch 1 Shirt = $1.205
THREAD
0.25yds of thread is consumed to construct one Shirt and $0.250/yd is the price. So, $0.062 is the cost of thread required.
FINISHING
The average finishing cost per Shirt is approximately about $1.
BUTTONS
Table 14: Buttons Specifications
Specification Detail | (PB/2H-H) |
Material Plastic | Material Plastic |
Size | 16L |
Holes | 2 Holes (High) |
Color | Clear |
Finish | Imitation Corozo |
These specific buttons are used in Shirt which cost $0.036/pcs. 10 buttons are used in the So, to produce 1 Shirt, cost of buttons is $0.360.
LABEL
This H&M Shirt contains the following 3 labels attached to it.
- Main Label (CONSCIOUS 18001) which costs $0.1 per piece
- Care Label (HM30012) which costs $0.01 per piece
- Size Label (Conscious22000) which costs $0.005 per piece
PACKAGING MATERIAL
The following packaging materials are used in 1 Shirt Sleeve Binding = $0.025/pc
Hang Tag = $0.020/pc Poly Bag = $0.002/pc
Carton = $0.05/pc
OVERHEAD
Factory overhead includes both variable and non-variable indirect manufacturing costs. Factory overhead costs are exclusive to each industry; however, they are normally subdivided into:
- Indirect labor
- Factory occupancy costs
- Other overhead
Total Material Cost = Total Fabric Cost + Total Trims Cost + Total Packaging Material Cost
= 1.0386 + 0.0270 + 0.624
=$1.6896
Total Labor Cost = Cutting Cost + Production Cost + Finishing Cost
= 0.5 + 1.205 + 1
= $2.705
Total CMT = Total Material Cost + Total Labor Cost
=$1.69 + $2.705
=$4.395
Even though the Overhead Cost Percentage varies for every manufacturing unit, we have taken an average overhead percentage for Bangladesh Garment Industry i.e. 12%.
So, Overhead Cost of Shirt is:
= 12% of CMT
= 0.12 x $4.395
= $0.5274
OVERALL COST
The Manufacturing cost of the making of a Shirt is:
= CMT + Overhead cost
= $0.5274 + $4.395
= $4.9
Upon adding the Profit Margin of 15% of Mohammadi Group Ltd, we get:
=$4.9 + (0.15 x $4.9)
=$4.9 + $0.753
=$5.653
By applying a multiplier of 4 for H&M’s Brand value, we get the selling price of the H&M Shirt
= $22.612
The thesis is a brief about ‘Study of business strategy in a Bangladeshi knit garments buying. Exports of textiles, clothing, and ready-made garments (RMG) accounted for 77% of Bangladesh’s total merchandise exports in 2002. https://www.bdwear.com/
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