Term Paper Final Jia

TITLE FLY

Term Paper on

“Evaluation of Production & Operations Management System of

Department of Business AdministrationEMBA, FALL-2011

POM-601 (PRODUCTION & OPERATIONS MANAGEMENT)

Report on:“Evaluation of Production & Operations

Management System of

Supervised By::

ENGR. ASADUZAMAN CHOWDHURYDIRECTOR & COMPANY SECRETARY, BTCLCOURSE INSTRUCTORPRODUCTION & OPERATIONS MANAGEMENTDEPARTMENT OF BUSINESS ADMINISTRATIONTHE UNIVERSITY OF ASIA PACIFIC

Submitted By:

MD. JIAUR RAHMAN

10212002

Date of Submission: 14th October, 2011

LETTER OF AUTHORIZATION

October 14, 2011

ToENGR. ASADUZAMAN CHOWDHURY

TITLE PAGE

DIRECTOR & COMPANY SECRETARY, BTCLCOURSE INSTRUCTORPRODUCTION & OPERATIONS MANAGEMENTDEPARTMENT OF BUSINESS ADMINISTRATIONTHE UNIVERSITY OF ASIA PACIFIC

Sub: Declaration regarding the validity of the report.

Dear Sir,

This is my truthful declaration that the “Evaluation of Production & Operations Management System of BEXIMCO TEXTILE LTD. I have been prepared is not a copy

of any report previously made by any other students.

I also express my honest confirmation in support of the fact that the said “Term Paper”

has neither been used before to fulfill any other course related purpose nor it will be

submitted to any other person or authority in future.

Sincerely yours

MD. JIAUR RAHMAN ID-10212002

LETTER OF TRANSMITTAL

October 14, 2011

ToENGR. ASADUZAMAN CHOWDHURYDIRECTOR & COMPANY SECRETARY, BTCLCOURSE INSTRUCTORPRODUCTION & OPERATIONS MANAGEMENTDEPARTMENT OF BUSINESS ADMINISTRATIONTHE UNIVERSITY OF ASIA PACIFIC

Sub: Submission the report “Evaluation of Production & Operations Management System of BEXIMCO TEXTILE LTD.

Dear Sir,

In accordance to your advice I prepare report paper on “Evaluation of Production &

Operations Management System of BEXIMCO TEXTILE LTD. that you authorized me to

prepare, for partial fulfillment of my Production Operation Management course.

I have tried my best to follow your guidelines in every aspect of preparing this report. I collected

what I believed to be the most relevant information to make my report as descriptive and

coherent as possible.

I enjoyed preparing this report because it provided me an opportunity to increase my

knowledge about research. I hope this Term paper will fulfill all the requirements suggested by

you. I will appreciate if you kindly spend some moment from your valuable time in checking the

papers and making a positive remark about the report.

Sincerely yours

MD. JIAUR RAHMAN

ID-10212002

Acknowledgements

At first I am grateful to my almighty Allah, because I have been able to complete the report paper within the given time period.

This report was possible because of the contributions of many individuals. I want to thank, ENGR. ASADUZAMAN CHOWDHURY, an honorable Course Instructor (Production & Operations Management) of The University of Asia Pacific, for his guidance, supervision & suggestion through out of the study period of my report paper. His continuous support and re-enforcement has encouraged me to do the study work properly.

I am thankful towards all my classmates for their support and suggestion who gave us valuable opinion and honest replies, and information’s which were very essential to complete the report.

All over again I want to give my millions of thanks and my honest respect to a man who always time try to teach us new difficult things in a easy way, this man is our honorable course teacher ENGR. ASADUZAMAN CHOWDHURY.

METHODOLOGY OF THE STUDY

In order to conduct the report, I have decided to collect various types of secondary data. Data was collected by oral communication of the responsible officers. They gave me annual report and other documents.

Secondary Data

Different types of secondary data have been elaborated from both internal and external sources. The internal sources include Web site, MIS, Prior research report etc. The external sources include different books and periodicals related to the telecom sector, news letters, newspapers, magazines, journals etc.

LIMITATION

I have been tried my best to provide with all necessary information about Ethical mooring & corporate social responsibility of Pioneer Sweaters Ltd.. But due to the exhaustive nature of this study most secret and strategic ethics could not be brought in this report. In this field some problems were created that may be termed as limitations of the study.

Lack of availability of data

Improper combination among various departments

Time constraint

Up-to-date information were not available

Don’t give the data from their source document

Table of Contents

TITLE FLY 01

TITLE PAGE 02

LETTER OF AUTHORIZATION 03

LETTER OF TRANSMITTAL 04

ACKOWLEDGEMENT 05

EXECUTIVE SUMMARY 08

THE REPORT PROPER 10

1. INTRODUCTION PART OF THE REPORT 11

1.1 ORIGIN OF THE REPORT 11

1.2 PROBLEM AND PURPOSE 11

1.3 SCOPE 11

1.4 LIMITATIONS 11

1.5 HISTORICAL BACKGROUND 12

1.6 SOURCES AND METHODS OF COLLECTING INFORMATION 12

1.7 DEFINITIONS, INITIALISMS AND ACRONYMS 13

1.8 REPORT PREVIEW 13

THE REPORT BODY 14

2. ABOUT GRAMEENPHONE 15

2.1 LOCATION 15

2.2 VISION 15

2.3 MISSION 15

2.4 VALUES 15

2.5 OBJECTIVES 15

2.6 STRATEGIES OF GRAMEENPHONE 15

2.7 ORGANIZATIONAL STRUCTURE 16

2.8 COMPETITIVE CONDITIONS OF GRAMEENPHONE 17

2.9 INDUSTRY ANALYSIS 18

2.10 SWOT ANALYSIS FOR GRAMEENPHONE 22

2.11 CURRENT STATE OF OPERATION 23

2.12 FUTURE DIRECTIONS 23

3 FINDINGS 24

3.1 SUMMARY OF THE SURVEY OUTCOME 24

3.2 SONG DEDICATION 28

3.3 BACKGROUND MUSIC 29

3.4 BUY MUSIC FROM ONLINE STORE 30

3.5 WALKIE TALKIE 30

3.6 AGRICULTURE INFORMATION SERVICE 31

3.7 MOBILE BANKING 32

3.8 3G OR MOBILE BROADBAND 33

3.9 EDUTAINMENT (EDUCATION AND ENTERTAINMENT FOR CHILDREN) 35

3.10 MOBILE RADIO 37

3.11 MOBILE TV 39

3.12 POSSIBLE BENEFITS FROM VIDEO CONFERENCING 41

3.13 RANKING OF THE TOP RATED SERVICES 42

4 MARKETING MIX AND PROMOTIONAL PLAN 43

4.1 3G OR MOBILE BROADBAND 43

4.2 MOBILE TV 45

4.3 CHILDREN EDUCATION SERVICE (EDUTAINMENT) 47

5 RECOMMENDATIONS 49

6 CONCLUSION 50

7 APPENDIX

LIST OF TABLES

LIST OF FIGURES

8 REFERENCES / BIBLIOGRAPHY

THE REPORT BODY

Manufacturing Organization Background

BEXIMCO TEXTILE LTD.

Bextex Ltd. (the "Company") was incorporated in Bangladesh as a Public Limited Company with limited liability on 8 March 1994 and commenced commercial operation in 1995 and also went into the public issue of shares and debentures in the same year. The shares of the Company are listed in the Dhaka and Chittagong Stock Exchanges of Bangladesh.

Bextex Ltd. is the most modern composite mill in the region. Bextex Ltd. has an installed capacity of 288 high-speed air-jet looms in its weaving section and a high-tech dyeing and finishing section with a capacity of 100,000 yards of finished fabric per day. This company is located at the Beximco Industrial Park .

Bextex Ltd. has a state of the art composite knit fabric production mill, which serves the growing needs of high-quality knit garments exporters in Bangladesh. The project was set up as a state of the art knit fabric knitting, dyeing and finishing facility. During the year the Company produced and sold high quality of knit fabrics and bringing forth all the latest in hard and soft technologies in knitting, dyeing and finishing of knit fabric.

Bextex Ltd. also has a cotton and polyester blended yarn-spinning mill, with 122,000 spindles is one of the largest spinning mills of the country. The mill was set up to feed the country's export oriented industries.

Bextex Ltd. produces specialized finishes of denim cloth for export in finished as well as cloth only form.

DATE OF INCORPORATION: 30 May, 1984

COMMERCIAL PRODUCTION: 1990

BUSINESS LINE:

Manufacturing and Marketing of Yarn, Woven, knit and Denim Fabrics.

LISTING STATUS: Public Listed Company.

STOCK EXCHANGE LISTING:

Dhaka and Chittagong .

AUTHORIZED CAPITAL IN BDT: 3,000 Million Taka

PAID UP CAPITAL IN BDT: 1,882.50 Million Taka

NUMBER OF SHAREHOLDERS: 37,929

NUMBER OF Woven LOOMS INSTALLED: 293

NUMBER OF Spindles INSTALLED: 119,520

NUMBER OF Denim LOOMS INSTALLED: 56

NUMBER OF Circular knit Machine INSTALLED: 30

PRODUCTION CAPACITY: 28 Million Linear Meters

NUMBER OF EMPLOYEES: 5,181

Mission

BEXTEX Ltd. is a full service vendor with strong vertically integrated production facilities as well as creative & analytical capabilities which clearly sets us apart from most other South Asian vendors.

  Vision

• Gain market leadership in high value added apparel in USA & Europe .

• Use “Innovation” & “Speed” as prime drivers, rather than cotton & cheap labour .

• Dominate these markets in high quality :

Men's, Women's , Children Shirts ( Dress & Casual )

Blouses ( formal & casual ) , Skirts, Jackets

Jeans & Casual non - denim bottoms

Knitted tops & bottoms

Information collect from POM Manager by following these questionnaire

Name of the organization:Name of the respondent:Total job length as production operation manager:Name of the section:

Discuss the Functional hierarchy of the organization:Key job responsibilities:

Major operational strategy of the organization:Currents products of the organization:

Current process flow of the products:Problems of current process flow:Suggestions or recommendations to overcome the problems:

Facility status of the organization:Suggestions or recommendations to improve the status of the organization:

Forecasting techniques followed by the organization:Inventory system of the organization:

Current supply chain strategy of the organization:

Organogram and Position of production Operation Manager

Introduction of Production Operation Manager

KAZI ABDULLA Al MAMUNSenior ManagerProduction Department

BEXIMCO TEXTILE LTD.

Duties and Responsibities of Production Operation Manager

The Production Manager is responsible for the effective and efficient planning and scheduling of personnel and equipment to reduce bottlenecks and problems.The Production Manager performs essential functions to ensure overall customer satisfaction and quality service, and establishes and maintains effective communication with employees and clients. As the Production Manager and the leader of the Production Team, he is accountable for meeting the department production and quality goals, as well as playing a key role in meeting the companywide profitability and customer satisfaction goals:

Maintain a positive department attitude and ensure that all employees under your supervision are aligned with the company goals.

Satisfaction and value for our customers. Work environment that fosters pride in being part of a

winning team and promotes personal growth. Maintain personal productivity and quality standards that make

possible attractive financial returns so that the company may

continue to provide our excellent service to our customers and ensure job security and career growth for our staff

PRODUCTION OPERATIONS

Update and maintain production schedule.

Maintain production control records and provide information to sales

representatives, customers and management with regard to delivery dates,

schedules and operating problems.

Take possession of jobs.

Assures all work entered into production follows the order entry standards and

procedures.

Approve exceptional or extraordinary jobs and specifications.

Assist with estimating.

Assures the pricing accuracy of all job tickets.

Organize workflow according to workload to meet delivery schedule and to

complete assigned jobs.

Develop, manage and maintain an automated workflow system that interfaces

order entry, prepress, and digital and print production

Coordinate and maintain the order entry standards and procedures for the

company.

Coordinate and schedule for prepress/digital training relating to the digital

standards and procedures.

Schedule, plan and conduct Morning Production Meetings.

Prepare, update, and communicate the production schedule.

Oversee all staff scheduling, time off requests and overtime.

Manage the coordination and control of all jobs/work orders.

Monitor quality, accuracy, and timeliness of all orders to ensure customer

commitments are met through production of high quality material that meets

customer delivery expectations.

Assures all staff has the resources, software applications and information to

perform their function.

Assures company website is up to date with necessary current information for the

customer.

Ensure the completion of all duties with a minimum of waste and abuse to

equipment.

Ensure employee safety training is conducted as required by Company Policy.

Perform the functions of the General Manager/Owner in the General

Manager/Owner’s absence.

Production Personnel

Initiate hiring when needed to cope with expanding workload or for replacement

of substandard employees.

Provide a positive, motivating example for employees

Conduct training or authorize training of production employees.

Conduct formal performance reviews per company policy

Initiate disciplinary measures according to company policy when needed and

dismiss production employees when all corrective attempts have failed.

Financial Control

Take all necessary actions to manage production costs and improve profitability.

Ensure inventories are conducted and accurate records are maintained.•

Advice owner on capital improvements needed to increase company productivity.

Evaluate production equipment purchases/leases and conduct cost/benefit

analyses.

Equipment and Supplies

Schedule, delegate, and ensure performance of all equipment maintenance

following maintenance procedures. Maintain maintenance logs.

Assure a backup of all work in progress and archived completed work is done in a

timely manner Coordinate and manage all inventory supplies to ensure minimum

waste and spoilage.

Receive and purchase materials

Ensure that inventories are conducted per company policy and accurate records

are maintained.

Inform the General Manager/Owner of equipment and production problems

Maintain a safe work environment and ensure the maintenance and upkeep of

the physical location

Ensure preventative maintenance of all production equipment and company vehicles.

PRODUCT DESIGN PROCESS

After identification of a priority market and generation of a set of initial ideas, the next

task is to “design” the product. Consider design as the designation of the key benefits

the product is to provide, the psychological positioning of these benefits versus

competitive products, and the fulfillment of the product promises by physical features.

Products

Yarn Products

Count - Ranging from 6 – 120

Fiber - Cotton ( super – combed, combed, carded)

CVC - 60% cotton, 40% polyester

TC - 65% polyester-35% cotton; 100% polyester both regular and sewing thread

Lyocell, Tencel, Modal, Rayon, Viscose etc.

Fabric Products

Solid Dyed

Poplins Twills

Dobbies

Oxfords

Seersuckers

Canvas

Ribstops in 100% Combed Cotton

CVC and CVS/TC

Stretch

Satten

Yarn Dyed

Ginghams Stripes

Fil-a-fils/End-on-ends

Chambrays

Seersuckers

Pinpoint

Oxfords

Dobbies

Plaids in 100% Combed Cotton

CVC and CVS/TC

Finishing

Wrinkle Free Easy Care

Peach

Chintz

Paper Touch

Teflon Coated

Water Repellent

Water Resistance

Rubberized

Stretch

Satten

Dobby Designs

Herringbones Bedford

Cords/Coteles

Waffles and various structures in 100% Combed Cotton

CVC and CVS/TC

Yarn Count

Ranging from 7 to 120

Knit Products

Jersey : In 100% Combed Cotton, CVC, CVS/TC, and Lycra mix

Polo Pique : In 100% Combed Cotton, CVC and CVS/TC

Back Pique : In 100% Combed Cotton, CVC and CVS/TC

Herringbone : In 100% Combed Cotton and CVS/TC

Popcorn : In 100% Combed Cotton and CVS/TC

Bubble Knit : In 100% Combed Cotton, CVC and CVS/TC

Crepe : In 100% Combed Cotton and CVS/TC

Engineering Stripe : In 100% Combed Cotton and CVS/TC

Feeder Stripe : In 100% Combed Cotton and CVS/TC

Auto Stripe : In 100% Combed Cotton and CVS/TC

Rib : In 100% Combed Cotton and CVS/TC

Jacquard : In 100% Combed Cotton and CVS/TC

Denim Products

Chambray : In classic indigo colours ranging from 4oz to 5.5oz/Yd2

Denim (blue) : In classic indigo colours ranging from 4oz to 15oz/ Yd2

Denim (black) : In sulfur black colour ranging from 4oz to 15oz/ Yd2

Coloured Denim : In a variety of colours - both in sulfur & reactive dyes(warp dyed)

Overdyed Denim : In a variety of colours on indigo blue & sulfur black

Bull Denim : In a variety of reactive colours ranging from 10oz to 13oz/ Yd2 (piece dyed)

Stretch Denim : In classic indigo colours ranging from 4.5 oz to 13.75

oz/Yd2

Special Yarn Products

Plied Yarn, Fancy Yarn, Slub Yarn (7's to 20's), Stretch both Lycra (10's to 40's) and Spandex and other Core Spun, Multi count, Multi Twist etc.

Unique Wrinkle-Free product

CORTEK-2000

mbedded filament core, which makes it permanently wrinkle-free. no resins or chemicals are used making the fabric ecologically friendly as well as highly durable. The technology provides the soft, natural comfort of cotton and the wrinkle-free convenience and strength of synthetic fibre. Beximco is the manufacturer and exclusive licensee in bangladesh of Cortex-2000, USA.

COTRA DP 3.5 +

This is a 100% cotton fabric, which is chemically, treated in a hi-tech precure process which is safe, clean and ecologically friendly. The result achieved meets a durable press rating of dp 3.5+ (aatcc - 124). Previously, this result could only be achieved by ammonia processing which is rapidly becoming obsolete, as it is hazardous to health and environment. Beximco is the manufacturer and exclusive licensee in bangladesh of Cotra dp 3.5

YARN SPINNING

The spinning mill produces cotton , polyester , viscose yarns in special counts from 100,s, 80’s to coarser counts like 10’s , 16’s etc applied for super formal shirting products to heavy duty casual wear fabrics.

Multi twist, Multi count, Slub yarns , Grindle yarn and Melange yarns and stretch yarns using lycra are the special items required for fashion fabrics which are also produced inhouse and used for shirtings , knist and bottomweight fabrics (both denim and non denim)

The flexibility to provide a variety of yarns leading to fashion products as an end product is the key focus of mill.

FABRIC WEAVING

The Vertical infrastructure of Beximco allows the development of fabrics in a wide range of weights (counts and constructions) , colour combinations using 6 colours on the weft to create colourful patterns.

The highly sophisticated CAD software can replicate patterns , weaves and designs easily and fast. Dobbies, Voiles, Gauze fabrics , high density poplins and twills, double face colourful fabrics can all be produced in variety of loom combinations which are applied to the end product for feminine or masculine products and categories .

PROCESSING AND FINISHING

In the fabric finishing stage we have facilities to produce post mercerised, aero-finished, denim and other bottom weight fabrics using Italian Biachilani machines as well as the facilities to produce over-dyed and coated fabrics.

APPAREL MANUFACTURING

Beximco produces Mens, Womens and childrens garments in all fashion categories from superior dress shirts to regular formal shirts, casual styled garments with fashion sillhoutes and details with prints , embroideries etc and also laces and high detail cut and sew styles.

Knit , Woven , Denim and Non Denims categories are all produced in specialized factories with complicated and detailed styles.

The well qualified industrial engineering in the garment factories control the highly stylized garments which is a unique and special department for garment industry.

KNITTING MACHINE

SEWING THREAD & LABEL MANUFACTURING

Beximco is one of the rare companies that also has inhouse manufacturing facilities for Label making, sewing thread making which gives it an edge for faster turn around and changes as per the customer requirement. The sewing thread ranges in diff counts and blends and this can be used for casual or formal clothing items.

PRINTING

Beximco has its inhouse flat bed printing facility backed by screen exposing and screen making facilities. All designs and screens can be produced inhouse The printing unit can do quality placement prints in foil, flock, plastisol , rubber printing , embossed effects.

EMBOIDERING

To further enhance the value addition with quality supervision of the fashion garments, the embroidery unit is encompassed within the infrastructure. Embroideries in many colours and stitch counts can be produced in special computerized machines with needles.

WASHING

We have a large capacity washing plant, which was setup with German collaboration and special distressing and finishing capabilities. We can do garment dyeing, all types of whiskering, three-dimensional effects using different resins, enzymes, bio-polishing, sandblasting, etc. We mostly produce very high fashion garments. Our technical washing experts have over the years been trained by Germans, Italians, Turkish, Chinese and Tunisian experts and have had a broad International exposure. Moreover, we have a close association with Italian washing experts, who work with us every season to develop new ranges of products.

PACKING

To complete the whole supply process from the yarn to the final garment, the packaging is an integral part at the end of the chain. Beximco has its own paper and carton making facility in order to provide the required sizes , qualities and other details that can be easily incorporated into the final shipments of the orders.

THE DESIGN PROCESS

The design process can be viewed as being made up of a managerial and Buyer

component. The managerial sub process represents a categorization of the types of

managerial decisions made in new product development. The Buyer response sub

process represents a categorization of the steps' analysts proceed through as they study

the market to help managers design new products.

Operation Strategy and Competitiveness of the Organization

Operation strategy of BEXIMCO TEXTILE LTD. states as follows:

“To be the most admired and trusted organization through excelling everything we do, following ethical business practices adding value to stakeholders.”

New Product Development Process & Industrial Design

Synopsis of Product Lines in BEXIMCO TEXTILE LTD.

Fancy Yarn Nap Yarn Tube Yarn Tape Yarn Melange Yarn

Process Analysis & Scope of Development

Scope of development:

Problem in filling section- Creation of void:The operation of the filling section is aimed at obtaining a predetermined weight of the filled plate after filling with the lead oxide mixture. The plates containing that weight pass through the quality assurance. In this view, the filling section is performing its operation quite soundly. But, the plates face problem at the process named “Sulphation”. Due to the presence of voids, the absence of active material there greatly affects the battery power and thereby the battery life. After sulphation, a lot of positive plates are being rejected due to inconsistency of active material which can’t be retained by further processing.

Facility layout & scope of development

Supply Chain Concept & Application

BEXIMCO TEXTILE LTD. has its own distribution channel. They do not depend on any other source for their distribution of batteries and other products. This enables them to cut cost from this distribution sector to reduce production cost. They have the total control over their time and place of distribution. They also ensure the on-time delivery of the products to the customers.

Forecasting System- Inventory System

BEXIMCO TEXTILE LTD. not follows any specific mathematical model to forecast demand of the products. Demand is forecasted based on the marketing report and experience of the sales and marketing department. As most of the product of RAL followed by seasonal demand, sometimes weighted average method is used for some particular type of products.

As the demand of the product increased during the summer, a great amount of stock are needed to fulfill that demands. BEXIMCO TEXTILE LTD. tries to reach appropriate level of inventory before the season of high demand.

Speed to Market Opportunities

Supply chain model based on a relationship of trust and simple, short procedures Marketing model based on affordable, quick change fashion.

Clear projection or commitment and firm booking of capacity.

Maximize design, product development capability of manufacturer, in collaborative design process.

On-spot placement of order after reviewing of designs.

Focused product development. Higher adoption rate from collection.

Vertical facility enabling quick response, which allows us to produce from Yarn to Garment in fifty days and repeats orders in thirty days, leading to reduced markdowns.

Beximco Partners with Major Retailers & International Brands

SpringfieldVAN Heusen Calvin Klein

DKNY Zara J.C. Penny

Next IZOD Arizona

H & M Geoffory Beene St. Johns Bay

Mother Care Arrow J. Ferrar

Bershka Kenneth Cole Reaction Decree

ESPIRIT CHAPS Levis

Conclusion

The objective of the report is to be familiar with real life operation situations and

observing different important parts and processes of a production system. This particular

report deals with the operation processes planning & improvement of a company in the

readymade garments industry.