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.
Cost Sheet
Table 15: Cost Sheet of H&M Shirt
| S No. | Operations | SAM | Cal time(45%) | Labour cost/min | Total labour cost |
|---|---|---|---|---|---|
| PREPARATORY | |||||
| 1 | Pinning of profile | 0.23 | 0.34 | 0.052 | 0.018 |
| 2 | Run stitch collar | 0.22 | 0.32 | 0.052 | 0.017 |
| 3 | Trim collar | 0.29 | 0.41 | 0.0052 | 0.021 |
| 4 | Clip & turn collar | 0.22 | 0.32 | 0.052 | 0.017 |
| 5 | Crease collar | 0.38 | 0.55 | 0.052 | 0.029 |
| 6 | Top stitch collar | 0.42 | 0.6 | 0.052 | 0.032 |
| 7 | Run stitch collar band | 0.29 | 0.42 | 0.052 | 0.022 |
| 8 | Crease collar band | 0.32 | 0.46 | 0.052 | 0.024 |
| 9 | Insert collar in neckband | 0.80 | 1.16 | 0.052 | 0.060 |
| 10 | Turn & crease collar | 0.45 | 0.66 | 0.052 | 0.034 |
| 11 | Attach bias piece to cuff | 0.87 | 1.27 | 0.052 | 0.066 |
| 12 | Crease cuff(left) | 0.46 | 0.66 | 0.052 | 0.035 |
| 13 | Hem cuff | 0.50 | 0.73 | 0.052 | 0.038 |
| 14 | Run stitch cuff | 0.57 | 0.82 | 0.052 | 0.043 |
| 15 | Trim cuff | 0.36 | 0.52 | 0.052 | 0.027 |
| 16 | Turn cuff | 0.53 | 0.76 | 0.052 | 0.040 |
| 17 | Crease cuff bottom | 0.57 | 0.82 | 0.052 | 0.043 |
| 18 | Attach placket to sleeve | 0.80 | 1.15 | 0.052 | 0.060 |
| 19 | Lock & make diamond | 1.03 | 1.49 | 0.052 | 0.077 |
| 20 | Attach front placket | 0.60 | 0.87 | 0.052 | 0.045 |
| 21 | Sew pleats(2) | 0.24 | 0.35 | 0.052 | 0.018 |
| 22 | Hem pocket mouth | 0.28 | 0.41 | 0.052 | 0.021 |
| 23 | Attach pocket to the front | 0.86 | 1.25 | 0.052 | 0.065 |
| 24 | Attach brand & size label | 0.59 | 0.85 | 0.052 | 0.044 |
| ASSEMBLY | |||||
| 25 | Attach yoke to back | 0.48 | 0.69 | 0.052 | 0.036 |
| 25 | Join shoulder | 0.64 | 0.93 | 0.052 | 0.048 |
| 26 | Attach collar | 0.54 | 0.78 | 0.052 | 0.040 |
| 27 | Sleeve attach | 0.86 | 1.25 | 0.052 | 0.065 |
Cutting, Finishing, Trims, Accessories, Fabrics, and Overall
| CUTTING | Labor cost ($) | |||
| 1 | Collar (2) | 0.50 | ||
| 2 | collar band(2) | |||
| 3 | cuff(4) | |||
| 4 | Front(2) | |||
| 5 | Back | |||
| 6 | Yoke(2) | |||
| 7 | ||||
| 8 | Cuff fusing | |||
| 9 | Collar fusing | |||
| 10 | Ticketing & bundling | |||
| FINISHING | ||||
| 1 | Buttonhole | 1.00 | ||
| 2 | Button attach | |||
| 3 | Washing | |||
| 4 | Pressing | |||
| 5 | Folding | |||
| 6 | Packaging | |||
| Total | 2.705 | |||
| TRIMS & PACKAGING MATERIALS | ||||
| S no. | Items | ($)Rate/Pc | Consumption | Cost ($) |
| 1 | Main Label | 0.100 | 1 | 0.100 |
| 2 | Size Tab | 0.005 | 1 | 0.005 |
| 3 | 2-Hole Button | 0.036 | 10 | 0.360 |
| 4 | Thread | 0.250 | 0.25 yds | 0.062 |
| 5 | Sleeve Binding | 0.025 | 1 | 0.025 |
| 6 | Hang Tag | 0.020 | 1 | 0.020 |
| 7 | Poly bag | 0.002 | 1 | 0.002 |
| 8 | Carton | 0.050 | 1 | 0.050 |
| Total | 0.624 | |||
| FABRICS | ||||
| S no. | Items | Rate/yds | Consumption(yds) | Cost ($) |
| 1 | Fabric | 2.253 | 0.461 | 1.0386 |
| 2 | Fusing | 0.900 | 0.03 | 0.0270 |
| Total | 1.0656 | |||
| OVERALL | ||||
| 1 | Total Material Cost | 1.6896 | ||
| 2 | Total Labour Cost | 2.705 | ||
| Total CMT | 4.395 | |||
| Overhead cost | 12% | 0.5274 | ||
| Manufacturing cost | 4.9000 | |||
| Profit % | 15% | 0.753 | ||
| PRICE | $5.635 |
Sourcing
For Mohammadi Group Ltd, fabric and trims are the raw material that needs to be outsourced. Sourcing is basically determining the most cost-efficient vendor of materials, production, or finished goods at the specified quality and service level. It is closely associated and an important part of apparel merchandiser’s responsibility. Materials basically include piece goods that will be cut and converted into garments. Not only does the fabric have to be appropriate and suited to the garment design and end-use but it must also be made available at the precise time when it is needed.
Thus, lead times play an important role in sourcing and placing orders for the materials required for the production. Lead times required from a supplier can vary from as little as two weeks to as much as nine months. Trims are all the materials other than the piece goods that are required to make up a garment. Findings require the same careful planning as the piece goods. As soon as the fabric is in the stores, then only the sourcing of the threads starts because the color of the thread must match the buyer’s requirements. The ordering of the threads must be complete by the time fabric is cut ready to be fed to the sewing lines.
Following is the list of all the Suppliers of Fabric, Trims, and Packaging Materials, from where Mohammadi sources its goods
Fabric Sourcing (Locally)
Table 16: Local Fabric Suppliers
| Supplier Name | Item Name | Country |
|---|---|---|
| Envoy Textile Ltd | Fabric | Bangladesh |
| Shirtex Ltd | Fabric | Bangladesh |
| Amber Denim mills ltd | Fabric | Bangladesh |
| Amber Denim ltd | Fabric | Bangladesh |
| Nassa Taipei Denims ltd | Fabric | Bangladesh |
| Aaron Denim ltd | Fabric | Bangladesh |
Table 17: Global Fabric Suppliers
| Supplier Name | Item Name | Country |
|---|---|---|
| H.W. Textiles Co.Ltd | Fabric | Hongkong |
| Zaozhuang Hiyoung Dynasty Textile Co.,Ltd | Fabric | China |
| Shaoxing Yan Wu Textile Co. Ltd | Fabric | China |
| Prosperity Textile(H.K.) Ltd. | Fabric | Hongkong |
| Artistic Milliners (PVT) Ltd | Fabric | Pakistan |
| Artistic Denim Mill Ltd. | Fabric | Pakistan |
| Artistic Fabric and Garment Industries Pvt. Ltd. | Fabric | Pakistan |
| Soorty Enterprises (PVT) Ltd | Fabric | Pakistan |
| Foshan Blue Denim textile import and Export co l | Fabric | China |
Table 18: Local Sewing Trims Suppliers
| Supplier Name | Item Name | Country |
|---|---|---|
| YKK Bangladesh Pte Ltd | Sewing Trims | Bangladesh |
| Amann Bangladesh | Sewing Trims | Bangladesh |
| American & Efird (Bangladesh) Ltd | Sewing Trims | Bangladesh |
| Coats Bangladesh Ltd | Sewing Trims | Bangladesh |
| Etafil Accessories Ltd | Sewing Trims | Bangladesh |
| TEX ZIPPERS (BD) LIMITED. | Sewing Trims | Bangladesh |
Table 19: Global Sewing Trims Suppliers
| Supplier Name | Item Name | Country |
|---|---|---|
| Golden Cedar Elastic Webbing MFG CO.Ltd | Sewing Trims | Hongkong |
| GEM EXPORTS | Sewing Trims | INDIA |
Table 20: Local Packaging Trims Suppliers
| Supplier Name | Item Name | Country |
|---|---|---|
| GEO Accessories Ind. Ltd. | Packing Trims | Bangladesh |
| Kds Accessories Ltd (Unit -2) | Packing Trims | Bangladesh |
| M&U Packaging Ltd. | Packing Trims | Bangladesh |
| Bengal Plastics Ltd. | Packing Trims | Bangladesh |
| T & S Buttons (Bangladesh) Ltd | Packing Trims | Bangladesh |
| Next Accessories | Packing Trims | Bangladesh |
| Trim Trade | Packing Trims | Bangladesh |
Table 21: Global Packaging Trims Suppliers
| Supplier Name | Item Name | Country |
|---|---|---|
| YKK (Thailand ) Co Ltd | Packing Trims | Thailand |
| Glory Metal Products Mfg Ltd | Packing Trims | Hongkong |
Table 22: Local Finishing Trim Suppliers
| Supplier Name | Item Name | Country |
|---|---|---|
| Yunusco T&A (BD) Limited | Finishing Trims | Bangladesh |
| Methila Enterprise | Finishing Trims | Bangladesh |
Bill Of Materials
Following is a list of all the materials required to make this Harriet H&M Shirt. Also, the vendors are mentioned.
Table 23: Bill of Materials for H&M Shirt
| NAME | QUALITY DETAILS | SUPPLIER | QUANTITY |
|---|---|---|---|
| FABRIC | |||
| Woven GeorgetteMSWN8625 NL-DOFB26 | 100% Polyester / 60.0 in /100GSM / 50X50 ne | Shaoxing Yan Wu Textile Co. Ltd, China | 0.461yds |
| Fusing FU-101FUSING WOVEN WENDLER3610 WHITE 44INC | Shore to Shore Ltd, Bangladesh | 0.03 yds | |
| Button (PB/2H-H) | Plastic Material/ 2 Holes/ High/ 16L | Shore to Shore Ltd, Bangladesh | 10 pcs |
| TRIMS | |||
| Thread Trim MSTT101068MS THREAD GM | A120 – DTM | Vardhman, India | 0.25 yds |
| Brand Label CONSCIOUS 18001 MS MAIN LABEL | SS-14 BLACK | Shore to Shore Ltd, Bangladesh | 1pc |
| Size Label Conscious22000 MS SIZE LABEL | M/39 SS-14-BLACK | Shore to Shore Ltd, Bangladesh | 1pc |
| Care Label HM30012MS W/C LABEL SATIN PRINTED GREEN AW-12 | Shore to Shore Ltd, Bangladesh | 1pc | |
| PACKAGING | |||
| Sleeve Binding MSBLB114MS BELLYBAND | SS-14-CREAM | Shore to Shore Ltd, Bangladesh | 1pc |
| Tag Trim MSTGT377MS HANG TAG | SS-14 CREAM | Rainbow Arts, Bangladesh | 1 pc |
| Bag BG-00002MS PRINTED POLY BAG 9.5x14x2x1 | BAG 9.5x14x2x1 | EXPO PACKAGING INDUSTRIES, Bangladesh | 1pc |
| Box CPBX800026CS Carton Box for Packing | M L S PRINT O PACKPVT. LTD., Bangladesh | 1pc | |
Bangladesh Rmg Export In The Global Rmg Market
Table 25 shows major export destinations for RMG products of Bangladesh by Country-wise markets in value terms including the USA, Germany, the UK, and France, Spain followed by the Netherlands, Italy, Canada, and Poland for the year 2016. And among Bangladesh’s major RMG exporters countries, the compound annual growth rate of export was higher in the Netherlands, Japan, Poland, Spain, Italy, and France’s market in the last 5 years (2012-16), compared to that of the USA, Germany the UK and Canada, indicating that there have to room to realize more export share in those countries.
Table 24: Major Export Market of Bangladesh RMG Sector
| Country | 2016 (Value in US$ billion) | CAGR (Compound Average Growth Rate) (%) (2012-16) |
|---|---|---|
| USA | 5.53 | 5.17 |
| Germany | 5.09 | 7.45 |
| UK | 3.25 | 7.55 |
| France | 2.05 | 10.80 |
| Spain | 2.34 | 15.89 |
| The Netherlands | 2.27 | 37.68 |
| Italy | 1.34 | 11.02 |
| Canada | 1.07 | 1.73 |
| Poland | 0.93 | 16.39 |
| Japan | 0.90 | 16.72 |
| Rest of the world | 8.99 | 11.32 |
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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