Report on Industrial Training in Bata Shoe Company Bangladesh Ltd.
Introduction Bata is a worldwide Shoe Manufacturing Company, with operations across 5 continents managed by 4 regional meaningful business units L (MBUs). Each unit benefits from synergies specific to their environment, such as product development, sourcing or marketing support. Each MBUL is entrepreneurial in nature, and can quickly adapt to changes in the Market place and seize potential growth opportunities. Bata Bangladesh
Bata Bangladesh is affiliated to the Bata Shoe Organization, the world's largest footwear manufacturing and marketing organization. Started its operation in Bangladesh in 1962, Incorporation in Bangladesh in 1972. Currently, Bata Bangladesh operates 2 manufacturing plant Tongi and Dhamrai, Bata Bangladesh is producing around 110,000 pairs of shoes daily. It has a modern tannery with the latest technological facilities to process 25,000 square feet of leather per day. The Tannery is equipped with a high-tech effluent treatment plant ensuring a pollution free environment for both workers and locality where we operate. Bata Bangladesh sells all kinds of footwear which are classified in alignment with market sectors as follows: Domestic market - under the trademarks of "Bata", "Power", "Weinbrenner" Bubblegummers", and "Marie Claire", through a countywide distribution network comprising retail stores, DSPs and independent dealers. Overseas market - under the trademarks of its customers, and also markets its own brands to sister
companies send the Middle East. Associate Business Unit This is a department in Dhamrai plant through which outsourcing is done to Bata family. Complete, partly completed and job works are done from others by this wing. Which run under the complete supervision and guidance of ABU manager. Bata office fixes some footwear industry outside their plant from where different operation, part or full of different footwear manufacturing operation is done. This is done under Bata's own quality policy. This strategy helps the company to serve there valued customer more quickly, widely and in a competitive price. About 70% of total estimated production is supplied from these ABUs. Thus this company try to rich grass root level of the shoe consumers. ABU offer three type of works i. Ready component ii. Cut to Stitch iii. Only Stitching. Those companies which supplies ready component is called Satellite. There are about 30 ABU s under Dhamrai plant. Within these 30, 10 Companies supply ready component 10 Companies supply Sole 2 Companies work only stitching operation 8 Companies Cut to stitch operation. Objectives of ABUs: i. To increase productivity with less investment ii. To supply product with a competitive price iii. To meet up high manual work content, iv. To increase the capacity of production. Selection of a factory as an ABU: There is a standard/strategy to select a factory as an ABU which is widely known as SWOT. This is an abbreviated word which means S for Strength: Man, Machine/equipments etc that is infrastructure facilities of a factory. W for Weakness: Problem faced, Unskill operators/Entrepreneur etc. O for Opportunity: Land, vehicles, expansion facilities etc. T for Threat: Risk of getting back and proper use of materials and component of BSO. Mohammadia Leather and Footwear Ltd.: This is an ABU of BATA which is about 15 minutes Rickshaw distance in north along DhakaAricha high way from Dhamrai plant. Here Cut to Stitch operation is done. All types of Weinbrenuer, gent's unlined sandal and closed shoe insole are prepared here. All type of raw materials is supplied from BATA. Machines of this unit also supplied from BATA. Only different operations are done here. These operations are also supervised by BATA officers. So quality is maintained as like as in house production. There are two section of this factoryi.
Bottom manipulation section,
ii.
ii. Upper manipulation section.
Grouping of Cutting Dice:
Group-8- Size 5-8; Gents Group-4- Size 2-4; Gents Group-3- Size 1-9; Children Group-1- Size 5-8; Infant Sequence of operation of Leather Board Cutting for Sandal insole: Leather board cutting in Hydraulic Press machine Cutting piece embossing throughout the edge Dust Cleaning Coloring (Spraying) Dying (20') Shadow spraying the edge (Dark Ked) Screen Printing (Price and Size) Hand marking for slotting Slotting Hand punch (Front middle) Check and Supply Dispatch to BATA. Sequence of operation of Insole board (Carry board) Cutting for Shoe insole: Insole board (Carry board) Cutting Shank Riveting Shank board (Half insole) skiving at the trade line Adhesive apply for shank board attaching Shank board fixing Insole Voiding Beveling at the edge Check and Supply.
Machines Used in Bottom Section: Machine Action Origin
Hydraulic Press
Cutting
Embossing
Emboss
Riveting
Attach Rivet
Torielli, Italy
Moulding
Insole Moulding
Vicevano, Italy.
Skiving
Skive at Tostuna, the edge Germany.
Beveling
Bevel at Mohrbach, the insole Germany. edge
Slotting
Make slot
Swing arm Cutting Clicking
Atom, Italy
Properties
Model: 300 MTH Serial: 4 201580 Min detectable object: >40mm Response time <ms Working Temp. 0-50째
Remark
Active
2
1 under maintenance
1
Active
1
Active
Bon-602-60/3
2
Active
BGF-8
1
Active
2
1 under maintenance
4
Active.
Model: 69-SC-9
Torielli, Italy. Atom, Italy.
Number of Machine
SE-20
Sequence of operation of Screen Printing: Print of Required design on the tracing paper Wooden Frame (14"X16") tightly fitted with Bolting Cloth (140 mesh) Sunacoat and Potassium Chloride (10:1) mixture apply on the cloth on the other side of the placement of tracing paper Dry (by Dryer) Apply lighting camera (intense light source) 10'Normal water wash of screen Drying of Screen. Printing with required color by rubber pad drying.
Before materials are cut a Dispatch ticket is given to cutter. Which after cutting give it with the cutting pieces. It moves with the material through out all operation and up to packing. Finally it acts as label of that consignment. This gives all necessary information. This ticket is as follows: Bangladesh Date. Ticket for Dispatching Materials Dept:................Plan:...............Pair:............ Knife: .............Trolley No: Name of Cutter:................................................... Count No............. Type of Material: Learner board insole. Light Brown. ART Materia Size Pair ART Materia Size Pair ART l l
Materia l
Checker Dept. In charge Receiver Sequence of Operation of Weinbrenner Insole: Adhesive Apply on insole covering (Vivox) and EVA sheet Drying Attaching of covering on EVA sheet Edge folding of covering Cord Stitching around the edge leaving 5mm (Thread No-10) Scouring at the bottom of lasting margin Screen printing (Price and Size) Ready to Dispatch. Quality Control Check Point in Bottom Manipulation: Is right size insole cut? Is embossing done properly? Is insole spraying done properly? Is right price and size printed? Is slotting too big? Insole board moulding pressure not too high? Is right Shank board Selected? Is the shank seated in right place? Remark: > Leather board thicknesses are not adequate in all pieces. > Some Machines are not in working condition. > Hollow type skiving is doing Counter stiffener edge instead of shallow type.
Size
Pair
> Shank is attached without marking. > Insole moulding duel time is not fixed. Upper Closing Section: Cut parts of different types of upper are stitched in this section. Some types of upper leather are cut in mis factory and some are cut in BATA. These are supplied to this factory for stitching/closing operation. All operations are done under BATA specification and procedure. All materials needed to complete these operations are also supplied from BATA. And their respective person supervises manufacturing operations. Machines used in Closing Section: Machine Action Origin
Properties
Number of Machine
Remark
Sewing
Sewing
PFAFF, Germany.
Model:438
1
Active
Sewing
Sewing
PFAFF, Germany,
Model: 1 34-35
2
Active
Sewing
Sewing
PFAFF, Germany.
Model: 242
1
Active
Sewing
Sewing
PFAFF, Germany.
Model:385
1
Active
Sewing
Sewing
PFAFF, Germany.
Model :474
2
Active
Sewing
Sewing
ADLER Germany.
Model:373
1
Active
Sewing
Sewing
PFAFF, Germany.
Model:
2
Active
Sewing
Sewing
Golden
NO-9900972
1
Active.
Sewing
Sewing
ADLER Germany.
Model:K2C7
1
Active
Sewing
Sewing
SINGER
1
Active
Sewing
Sewing
SUN STAR
I
Action
Sewing
Sewing
ADLER
1
Action
Model:267-99005C
Upper Closing Operation: Upper closing operations are done as individual requirement and specification. Remark: > During my observation for vamp and quarter joining 110 size needle is used instead of 90 size needle in ongoing Oxford shoe. > Placement of vamp and quarter of same shoes are not doing all time correct. > Production schedule is not writing in per schedule board. Quality Control Check Point for Upper Closing: Is the folding in curve area are done smoothly? Are the different uppers assembled according to marking? Is the right type of needle and thread selected? Are the eyelet holes in equal distance? Are the loose threads cut? Production Schedule: Before starring operation a production schedule is hung on the wall. Both departments can out men- production according to this schedule. But in my observation period there was no change of this board and that was for past time. It was as follows: Dept. Plan Article Pair Size Assortment Balanc Supply Remark e 5
Closing OO8 6
814-
6
7
8
9
1 0
1 1
Date
800 8 0
12 0
24 0
20 0
12 0
4 0
16.2.1 0
800 8 0
12 0
24 0
20 0
12 0
4 0
16.2.1 0
800 8 0
12 0
24 0
20 0
12 0
4 0
17.2.1 0
800 8 0
12 0
24 0
20 0
12 0
4 0
17.2.1 0
6013 „
0091 8146070
»»
00%
8146077
Cutting 0103 8546016
Observation & Recommendations: Although BATA has own production unit they are doing out sourcing. But this products quality is not as own manufactured products. Because the outside operators are not as experienced as own. So there are some matters which should need more attention and precaution. Some are as follows: For Bottom Manipulation: •S Measure to maintain proper thickness of Leather Board. •S During Screen printing operator should take adequate protection. •S Accurate pressure and duel time of insole moulding should maintain. S Before shank attaching marking must needed. S During Beveling ere protection and it can be placed in a separate place, so that it does not make noise pollution in production floor. For Upper Closing: S Folding at the round area should do more smoothly, accurately and attentively. S Quarter and vamp placement should done accurately so that eyelet facing area must be parallel. •S Proper selection of needle before use as per specification must need. S Marking for placing counter stiffener is needed. S In process quality control should take instead of quality control at the end of line. •S More attention can be given to maintain compliance of operator. Century Leather Works Ltd.: It is another ABU of Bata. They produce ready component, sole insole of different types of footwear. It is situate in Hemayatpur, Savar area. It's aria about 0.5 acres. There are four sections, insole preparation section, PVC granule preparation section, PVC sole preparation, upper and complete sandal preparation unit, hi complete shoe they supply complete shoe. They produce raw materials for PVC sole which is called PVC granules. Productivity of Insole section is about 5000 pairs per day. Sole Unit 11000 pairs per day. Complete Sandal 1000 pairs per day. Observation and Recommendation: In our visit ongoing complete sandal article is 48-49. In this Sandal there is placement mark of different straps are on the upper visible part. And the hand stitch for lasting is over that is more allowance in lasting area. But this marking should be given in flash side of upper by marking pen. And during lasting should take more precaution. Conclusion: ABU operation was a new concept of out sourcing footwear component to me. So I have got clear and very good idea, i want to give thanks to Plant Manager, Leather Factory manager, ABU Manager and everyone associate with ABU operation for their help, support and their wise suggestion, instructions. It increases my knowledge and I have got practical working experience.
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