ENV 499 THESIS REPORT

Impact of Right First Time (RFT) Approach on Textile Industries in Bangladesh: A Case Study
Prepared for: Mr. Alamgir Hossain Lecturer Department of Environmental Science and Management Prepared by: Raisa Najat Saif ID# 051-679-529 Department of Environmental Science and Management

North South University

Acknowledgement
While I am of course solely responsible for the contents in my research on Impact of Right First Time (RFT) Approach on Textile Industries in Bangladesh: A Case Study', I would like to thank several people for their professional assistance. This thesis arose out of two months of research. During this time I have worked with a great number of people whose contribution in the making of the thesis deserve special mention. Firstly, I would like to thank my course instructor, Mr. Alamgir Hossain, for his supervision, advice and guidance from the very early stage of this research. His assistance was absolutely invaluable. In spite of his busy work schedule he had kindly agreed to help me, and I would like to express my heartfelt gratitude for that. This paper would not have been possible without his vital encouragement, inspiration and support. I am also grateful to Mr. Abbas Uddin Shiyak, Assistant Professor of Prime Asia University, for offering valuable advice. At all stages the report has benefited tremendously from his support. I appreciate his advice, comments and willingness to discuss any questions and ideas that I have had. Particular thanks must be extended to Mr. ATM Mahbub Alam Milton, Director Operations, Masco Industries Limited, with whom I spent many hours seeking the information I needed to inform my research. I also wish to acknowledge the support of Mr. Md. Nasimul Hassan, Manager, Masco industries Limited for his generous support of information and fruitful discussion. My special appreciation goes to Mr. Biswajit Banik, Senior Executive (Dyeing), Masco Industries Limited, for his numerous fruitful discussions and providing me with all the data I needed for carrying out my research. I also wish to express my deep appreciation to the staff members of Masco Industries Limited who provided valuable input to the project I would like to express my heartiest thanks to my friend Ms. Labonya Das Nirjan for accompanying me to the factory whenever she could. My special gratitude is due to my brother in law Dr. Syed S. Amin. Without his encouragement and guidance it would have been impossible for me to finish this work. Finally I thank my family for their faith and constant support. Their support has been unconditional all these years.

Table of Contents
Chapters Page No.

1. Abstract.. .... 5 2. Background......... 6 3. Introduction................................................ 7 4. Overview of Masco Industry......... 8 5. Water situation of the World 9 6. Mud-map of Environmental Management Strategies 10 7. Drivers of global textile supply chain... 11 8. Research Area 14 9. Methodology
Quantitative Measurement............. Qualitative Measurement...

15 15

10. Results and Discussions

Flow of water in Case Plant. Flow diagram of the inputs and output.. Utility and Water Cost in May Utility, Water and Chemical Cost for two shades. Effect of Shade Reproducibility on Total Production Cost.. Non-RFT Impact on Process Cost...... Water Consumption in Masco

16 17 18 19 21 23 25

11. Win-Win situations for Masco Industry... 26 12. My Observations in Masco. 27 13. Limitations... 27

14. Recommendations... 27 15. Conclusion... 29 16. Reference..... 30

17. Appendix 17.1 Water Consumption Audit 17.2 Gas Bill of Masco 17.3 List of Chemicals and their Cost 17.4 Topping recipes 17.5 Dyeing process control 17.6 Monthly Production Report 17.7 Pictures

Abstract
Textiles play an important role in the economic life of Bangladesh. One principal problem that textile industry meets is the re-dyeing problem because the dyeing fabric does not meet the requirement of the customer. When the re-dyeing process is carried out, it leads to a loss of many resources such as water, energy, chemical and dye stuff, time, man-hour, etc. I focused on one specific textile manufacturing unit and tried to understand the status of energy, chemical and water use by conducting an audit on water and chemical consumption and also by collecting existing data from various sources in the factory. I calculated the impact of process-cost in re-dyeing brown and light grey shades. My study results show that water is used extensively in Masco industry. This puts a burden on the Water Treatment Plant as well as on the Effluent Treatment Plant and thus it is imperative to reduce water, chemical and energy usage. Right First Time is an ecoefficiency measure which when achieved, reduces the total consumption of water and energy.

Background
The textile and garment sector in Bangladesh fulfils a crucial role in the countrys economy. It accounts for as much as 78% of the countrys total exports. It provides jobs for 4.5 million people, accounts for 10.5% of the countrys GDP, and contributes 40% of its manufacturing output. Textiles as a whole play the most significant role in the alleviation of poverty, provision of employment to rural women and economic empowerment of women. During the dyeing process when the shade of a particular production batch does not lie within the customers tolerance; then a shading addition would be needed. This would require further dyes, chemical, time and money. By reducing the number of re-dyeing operations, a company can achieve significant savings without investing in costly machinery. When one thinks about competitiveness in this millennium, wet processed goods must be provided with consistent quality, in large quantity, adhering to delivery schedule and with right first time (RFT) performance. Textile wet processing sector is a major consumer of water and energy. Ever increasing environmental issues and energy cost are forcing towards RFT approach. When we achieve the target at first time, it reduces the total consumption of water and energy. The percentage of RFT is directly proportional increase in extra cost of the process. RFT approach became the need of the day

Introduction
Textiles play an important role in the economic life of Bangladesh. The sector, in addition to meeting the demand of fabrics and apparel domestically, contributes significantly to the textiles and clothing (T&C) export trade. At present, more than 78 per cent of the countrys export earnings come from T&C. The sector provides employment to a workforce of 4.5 million and contributes 40 per cent value addition to the manufacturing sector. (Hassan) One principal problem that textile industry meets is the re-dyeing problem because the dyeing fabric does not meet the requirement of the customer. When the re-dyeing process is carried out, it leads to a loss of many resources such as water, energy, chemical and dye stuff, time, man-hour, etc. (Tanapongpipat, Khamman, Pruksathorm, & Hunsom) When the dyeing batch is matched in first time dyeing then its called Right First Time (RFT). (Hossain, 2003) I focused on one specific textile manufacturing unit and tried to understand the status of energy, chemical and water use by conducting an audit on water and chemical consumption and also by collecting existing data from various sources in the factory. I calculated the impact of process-cost in re-dyeing brown and light grey shades. My objectives are outlined as follows: 1. To figure out opportunities to reduce production costs 2. To figure out whether the dyeing part of the industry is polluting and resource consuming in terms of water, energy and chemicals. 3. To find out the quantity of water needed to dye 1 kilogram of textiles for two different shades (light and dark). 4. To find and compare electricity, water and chemical costs for the two shades in the month of May.

Overview of Masco Industry

Masco Industries is located in Gazipur about 4 Km North from Dhaka International Airport. It is 100% Export Oriented Composite Knit Garments Industry. The main productions sections are Knitting, Dyeing and Garments. It started its journey in December 09 1999.Now it has one knitting factory, one dyeing factory and two garment manufacturing units. 80 to 85% of the raw material that Masco uses is cotton while the rest consist of polyester, viscose, etc. The fiber or raw material is converted to yarn in various spinning factories in Bangladesh. Masco buys yarn from those factories. Their first operation is knitting where the raw fabric (also known as grey fabric) is produced. The different types of machineries in the knitting division are Circular Knitting, Gear Type Raising and Flat Knit Machineries. The production capacity in this division is 5000kg/day. The product fabrics are Single Jersey, Heavy Jersey, Pique, Interlock, Drop Needle Interlock, 1X1 Rib, 2X2 Rib, Drop Needle Rib, Flat back Rib, French Terry, Fleece, Waffle, Pop Corn, Feeder & Engineering Stripe, Flat knit Plain & Tipped Collars & Cuffs, any kinds of Fancy knit fabrics. After knitting, the grey fabric goes through a process of inspection where the fabric is checked for any fault. The second operation is dyeing which is the process of imparting color to the grey fabric produced by the knitting process. The dyeing process requires a large number of steps all of which takes place in a single machine. The dyeing process is divided into 3 major parts: Pre-treatment, dyeing and After-treatment. After dyeing, the fabric goes through a process of finishing. The different types of machineries in the dyeing division are Dyeing, Finishing and Laboratory machineries. The Production Capacity in the dyeing division is12, 000 Kg/per day. Masco tries to fulfill requirements of the customers. It also meets the average standard set by the factory. Apart from this, Masco tries to comply with the Department of Environment (DoE) guideline regarding the effluent water discharged by the factory. It also tries to comply with World Bank guideline.

Water situation of the World

Of every liter of water on the earth's surface, 26 ml is fresh water. However, the actual amount of freshwater that is directly available, i.e. economically accessible for all mankind, is equivalent to 0.156 ml. The stark reality of this statistic is sufficiently explicit to make us aware of the seriousness of the situation and to act accordingly.

Mud-map of Environmental Management Strategies

Clean production and Eco-efficiency are two important tools in achieving Sustainable Development. Cleaner Production is about preventing waste and emissions while EcoEfficiency is about better products that have a lower ecological impact, are competitive and better meet customer needs. (Curtin University of Technology) In the early days, environmental policies were mostly reactive for example pollution control, re-use, and recovery and recycling. But these end-of-pipe technologies were costly and so gradually preventive approaches (such as waste minimization, toxic use reduction, pollution prevention, cleaner technology and cleaner production) have been adopted that avoid or minimize waste at the source. Cleaner production deals with the efficient use of materials, energy, water and other natural resources while conducting business. Eco-efficiency is an advanced version of cleaner production and a business driven philosophy while cleaner production is more of a regulation driven philosophy. The term eco-efficiency was first coined by the World Business Council for Sustainable Development. The eco-efficiency concept is close to the cleaner production concept but puts more emphasis on creating additional value for customers through environmental actions. In simple terms, this means producing more with less while improving customer service and satisfaction.

In the diagram it is also clear that the preventive approaches were mostly process oriented which is not very suitable for development. Design for Environment has proven to be more effective because the approach is to prevent pollution along the whole life-cycle of the product. This approach also identifies opportunities for environmental improvements at first source, that is, the product design phase. RFT is an eco-efficiency measure that is also a business driven philosophy.

Drivers of global textile supply chain

1. Higher Productivity: Shorter cycles, RFT performance and Robustness lead to higher productivity. A lot of energy efficient wet processing is based on right-first-time (RFT) and short cycle processing. Process times can be significantly reduced. The dyeing of cotton knits to a medium shade can be reduced from the conventional 10-12 hour to a mere 4-5 hour process. (Bhurtun, Kistamah, & Chummun) If bulk dyeing proves to be off-shade and the original recipe requires a correction (i.e. an addition) that results in extending the dyeing time, the dyers suffer a considerable financial penalty. If the color is too dark and the bulk dyeing must be stripped and redyed, this imposes further cost and penalties and often impairs the quality, physical properties and surface appearance of the dyed material. In general, the shorter the processing time under hot wet conditions in the dye bath, the lower will be the fiber degradation, all important considerations for many technical textiles. (Horrocks & Anand) Where there is close control over the color strength of the dyestuffs and consistent substrate dye-ability, it is often possible to operate so-called blind dyeing in which the computed dye recipe in the laboratory is used immediately for bulk dyeing. This shortens the time required; decreases dye house costs, increases productivity and offers rapid delivery to customers. Right first time dyeing is the goal of the dyer because this is the lowest cost dyeing system that provides quick response for customers. (Horrocks & Anand)

2. Reduced costs can be achieved by less dyestuff, less chemical, less energy and reduced stock costs. The supply chain starts from raw materials e.g. cotton to the production of textiles, to design, cutting and assemble and finally to distribution and retailing garments. When one thinks about competitiveness in this millennium, wet processed goods must be provided with consistent quality, in large quantity, adhering to delivery schedule and with right first time (RFT) performance. Textile wet processing sector is a major consumer of water and energy. Ever increasing environmental issues and energy cost are forcing towards RFT approach. Textile wet processing consumes 5-200 lit of water per kg of fabric. When we achieve the target at first time, it reduces the total consumption of water and energy. The percentage of RFT is directly proportional increase in extra cost of the process. Thus, RFT approach became the need of the day. (Jadhav & Ajmera)

3. Product Integrity: Shade Reproducibility, Color fastness, Eco-compliance can lead to product integrity. Within the batch dyeing cycle there are several important stages, each of which can have an effect on the ultimate shade and levelness. Dyes play an important role in cost competitiveness and absolute reproducibility of dyeing. Dyes are the most expensive raw materials of dyeing. Hence, it is important to maintain the following dyestuff factors: a. Proper dyestuff selection: The main criteria behind dyestuff selection should be: High quality of dye standardization i.e. negligible lot-to-lot strength variation in dyestuff supplies. This nullifies the need for the check routine for each lot as well as shade adjustments and ensures high level of reproducibility. Choice of medium affinity bi-reactive dyestuffs- Bireactive dyestuffs give a high degree of fixation (approximately 80%) as against mono-reactive dyes (approximately 60%). This accompanied with the medium affinity of dyes ensures easy wash off thus, fewer washing baths. This has an impact on the water, time and energy savings in cost effective production. Moreover, the dyes should have a proper combination of reactive groups in the bireactive system to achieve ideal and homogeneous application properties.

Good compatibility of Dyestuffs- the dyestuffs used in trichromy should be compatible i.e. they should have homogeneous affinity and reactivity. This is essential to ensure reproducible results.

b. Purity of dyestuff: There are several tests that can be routinely carried out in the dye house to ensure the dye quality and thus reproducible dyeing, they are: - i) Chemical methods, ii) Colorimetric estimation and iii) Laboratory dyeing trials. c. Chemicals & auxiliary testing; various organic and inorganic chemicals of commercial grade are used in dyeing with different classes of dyestuff. Apart from this, different auxiliarys products, viz., dispersing agents, wetting agent, de-foamers, etc., are used for specific purpose in a particular dyeing operation. These auxiliaries and chemicals should be tested for their purity and/ or performance before use in bulk dyeing. d. Water parameters: Poor water quality can affect batch and continuous dyeing processes. Dyeing defects due to water contamination include inconsistent shade, streaky dyeing, filtering, resist, poor washing off and poor fastness. e. Fabric parameters: Many impurities can be introduced into the dyeing system by cellulose fiber itself e.g. hardness, reducing agents, metal ions, etc. It is advisable to compare the fiber used in preliminary lab trials and the one used for bulk trials. f. Liquor Ratio: This is the most common cause of poor reproducibility. In most of the dye houses chemical additions are based on data provided by machinery manufacturer, on the physical dimensions of the dyeing vessel or on liquor level indications on dyeing machine itself. Experience shows that these liquor indications are erroneous (generally up to 25% as compared to actual liquor ratio) since liquor in dead volume in circulation tubes, heat exchanger, expansion tanks, etc., is often not taken into consideration. Also, wet pretreated fabric content vs. measurements with water alone lead to wrong assumptions. An error in liquor ratio (e.g. higher than anticipated), results in wrong salt concentration (less than required resulting in lower fixation of a lower exhausted amount of dye). These cumulative effects result in poor reproducibility leading to shade corrections. (Jadhav & Ajmera)

Research Area:
Use of Chemicals, Water and Electricity in Textile Industry and their Impact on Productivity and Environment.

The impacts on the environment by Masco industry have been recognized in terms of the consumption of water, chemicals and energy. The operating process of this industry consumes enormous amount of water which requires large quantities chemicals. This puts a burden on the water treatment plant and also on the ETP. Major environmental concerns in textile industry are 1. High water consumption. A Number of washing steps involved in the production process consume substantial amount of water (and energy too). 2. Color and heavy metals in the waste water, due to a variety of dyestuff and auxiliary chemicals used. 3. Workers health and safety due to VOC emissions. Number of dyestuffs, auxiliary chemical (like finishing agents) gives rise to hazardous VOC emissions. 4. Toxicity to aquatic world in receiving water bodies due to the hazardous chemicals involved in wet processing that escape through waste water. (Visvanathan, Kumar, & Han, 2000) One principle problem that textile industry meets is the re-dyeing problem because the dyeing fabric does not meet the requirement of the customer. When the re-dyeing process is carried out, it leads to a loss of many resources such as water, energy, chemical and dye stuff, time, man-hour, etc. (Tanapongpipat, Khamman, Pruksathorm, & Hunsom) This re-dyeing or Non- RFT also affects productivity, quality of fabric and deadline of delivery. Measures to achieve RFT would help Masco to improve productivity which includes reducing total cost, increasing profit margin on existing business, and generating extra capacity from same resources without capital outlay on new capacity.

Methodology
Quantitative Measurement 1. I conducted an audit on water consumption to assess water usage to dye two different shades namely brown and light grey. I used the data results to determine how much water is being wasted. I also compared water consumption of Masco and water consumption of standard Textile processing. 2. I conducted a chemical consumption audit to find out the quantity and cost of different chemicals used to dye the two shades. I used the results to compare the water, utility and chemical costs of brown and light grey shade for the month of May. 3. I collected data on monthly gas bill, production capacity of dyeing machines and groundwater pump, and monthly production of Masco to calculate utility cost per kg fabric and water cost per liter. I also collected data for calculating water, utility and chemical cost to find out the losses due to Non-RFT. 4. I conducted an audit to draw a flow diagram of the inputs and outputs during the dyeing process. Qualitative Measurement I obtained qualitative data by interviewing few experts. I interviewed two important people from whom I got insightful knowledge about my research topic. My first interview was with Mr. ATM Mahbub Alam Milton, Director Operations of Masco Industries Limited. He gave me information regarding how Masco operates and what techniques they are using. I also interviewed Mr. Md. Nasimul Hassan, Maintenance Manager of Masco Industries Limited who gave me useful knowledge about the different dyeing machines and their effectiveness.

1. The rate of water and gas consumptions by the dying machines is uniform. 2. I ignored the maintenance cost of Water Treatment Plant (WTP). 3. I used estimated figures for quantity of water during rinsing.

Results and Discussion

Flow of water in Case plant

ENVIRONMENT(GROUNDWATER)
Water Water from GW pump Knit Fabric Water Treatment Plant Boiler

Dyeing processes

Effluent Treatment Plant

Waste Water

Waste Water

ENVIRONMENT (LAND)
The main source of water for Masco is ground water. Through ground water pumps, water is drawn and stored in reservoir. From reservoir, water is transported to the water treatment plants where the water is being treated so that it can be used for the dyeing process. Some of the water is transported to boiler for steam production. After completion of dyeing, the wastewater is transported to the effluent treatment plant (ETP) where the water is being treated to be released into the environment. But the ETP of Masco does not run 24 hours and so some of the waste water is released into the environment, untreated. A flow diagram of the inputs and output during dyeing process is shown in the next page.

Invatex CRA (Detergent) Albafluid C (Anti-Cleanser) HTS (Anti-foam) Sirix 2UD (to remove iron) Caustic Soda Hydrogen Peroxide

Temperature rises to 98 C. The machine is allowed to run for 45 minutes Water drained out

Water in Rinsing takes place for 5 minutes

Water in

Hot wash for 10 Bactosol SAP minutes

Water out Water Acetic acid Bio Polish EC

Water out Rinsing takes place for 5 minutes

Rinsing Temperature Water raised to 80 takes place for C and left for 5 minutes 5 min Water out

Left for one hour

Water out Water in Acetic Acid Leveling Temperature reaches 40 C and left for 10 minutes Color dosing- 30 minutes Run time: 10 minutes Salt dosing: 15 minutes Glaubers salt Run time: 30 minutes

Color

Rinsing takes place for 5 minutes

Machine runs for 1 hour

Soda Dosing: 30 minute Temp set at 65C Run time: 10 minutes

Soda Ash

Water out Run time: 20 minutes Water in Acetic acid Soaping agent Water out Water out Run time: 20 minutes water in Temp rises to Water in Run time: 98C and 20 then allowed minutes to run for 10 FRD (Fixing minutes Agent)

Water out

Water in

Utility Cost and Water Cost in May Utility Cost Cost of electricity consumed by dyeing machines

= 350KW*24hours*26days*6, 43,317taka 800 KW*24hours*26days = 2, 81,451 taka Given, Total Capacity of Dyeing machines = 350KW Monthly gas bill (May) = 6, 43,317taka Total Fabric production in May = 262069 kg Cost of 1 KW-hr/electricity energy = 6, 43,317taka 800*24*26 = 1.3 taka

Cost of steaming = 180, 0000*.90 =1,620,000 taka

Therefore, Utility cost per kg fabric = 2, 81,451 taka +1,620,000 262069 kg = 7.25 taka Capacity of 2 groundwater pump2 = 22KW each Capacity of 2 centrifugal pumps = 30KW Capacity of other pumps in WTP = 4KW Rate of GW pump = 120 m per hour Therefore, amount of water used in 1 month = 120*24*26 = 74,880 m

Water Cost in May Cost of electricity to pump water from pump 1 = 22KW*24*26*1.3 =17846 taka Cost of electricity to pump water from pump 2 =22KW*24*26*1.3 = 17846taka Chemical Cost to treat Water in Water Treatment Plant (WTP) = 13,333 taka (Given) Cost to run 2 centrifugal pumps in WTP = 30KW*1.3*24*26 = 24,336 taka

Cost to run two other pumps in WTP = 44KW*1.3*24*26 = 35,693 taka

Therefore, total water cost in one month = 17846 taka + 17846taka + 13,333 taka + 24,336 taka + 35,693 taka = 109,054 taka Cost of 1m water = 109,054 = 1.5 taka 74,880 Therefore, Cost of 1 liter = 0.0015 taka Utility, Water and Chemical Cost for two shades Brown Shade Water consumption per kg fabric = 191 liter Water consumption for 7733 kg fabric produced during the month of May = 7733*191 = 1,477,003 l Cost of 1,477,003 l = 2216 taka (in May 2009) Water consumption during topping = 115 l/kg Water consumption for 1811 kg fabric requiring topping for month of May = 115*1811 = 208, 265 l

Cost of 208,265 l = 312 taka (in May 2009)

Utility Cost per kg fabric = 7.25 taka Utility cost for 7733kg fabric = 7.25 *7733 = 56,064.25 taka (May 2009) Utility cost for topping 1811 kg fabric = 7.25 *1811 = 13,129.75 taka (May 2009)

Chemical Cost per kg fabric = 45.01 taka Chemical cost for 7733 kg fabric = 348,062.33 taka (May 2009)

Chemical cost for topping 1811 kg fabric = 10497.2+9878.71+5915+3219.94 = 29,511 taka Light Grey Shade Water consumption per kg fabric = 194 liter Water consumption for 27,178 kg fabric produced during the month of May = 27,178 *194 = 5,266,792 l Cost of 5,266,792 l = 7900 taka (May 2009)

Water consumption during topping = 119 l/kg Water consumption for 1893 kg fabric requiring topping for month of May = 119*1893 = 225, 267 l Cost of 225, 267 l = 338 taka (May 2009)

Utility Cost per kg fabric = 7.25 taka Utility cost for 27,178 kg fabric = 7.25 *27,178 = 197,041 taka (May 2009) Utility cost for topping 1893 kg fabric = 7.25 *1893 = 13,724 taka

Chemical Cost per kg fabric = 24.09 taka Chemical cost for 27,178 kg fabric = 24.09 *27,178 = 654, 718 taka

Chemical cost for topping 1893 kg fabric = 1635.9+6608.6+8765.24+980+322+9926.84 = 28,239 taka

Effect of Shade Reproducibility on Total Production Cost Light grey RFT (100%) Right First Time Topping Total Cost/kg 31.6 0 31.6 Share of the total cost (%) 100 0 100

Table 1: Effect of Shade Reproducibility on Total Production Cost (Without topping) Total Production- 27,178 kg Total Cost- 859,659 taka Therefore, cost per kg = 859,659/27,178 = 31.6 taka

RFT (93%) Right First Time Topping Total

Cost/kg 31.6 22.3 54

Share of the total cost (%) 59% 41% 100

Table 2: Effect of Shade Reproducibility on Total Production Cost (With topping) Topping- 1893 kg Cost of topping- 42,301 taka Therefore, cost of topping per kg fabric = 42,301/1893 = 22.3 taka The above tables present the impact of topping light grey shades on total cost. From the table it is clear that for light grey shade, the cost of all fabric that met requirements Right First Time is 31.6 taka per kg in May. A drop in production efficiency of only 7% would mean a RFT rate of 93%. This means that 7% of the production would need some form of repair or topping and costs 22.3 taka per kg. Thus, the total cost increases from 31.6 to 54 taka by 22.3 taka per kg. The share of topping is 41% of the total cost.

Brown shade RFT (100%) Right First Time Topping Total Cost/kg 52.5 0 52.5 Share of the total cost (%) 100 0 100

Table 1: Effect of Shade Reproducibility on Total Production Cost (Without topping) Total Production- 7733 kg Total Cost- 406,342 taka Therefore, cost per kg = 406,342/7733 = 52.5 taka RFT (77%) Right First Time Topping Total Cost/kg 52.5 23.7 76.2 Share of the total cost (%) 68.9 31.1 100

Table 2: Effect of Shade Reproducibility on Total Production Cost (With topping) Topping- 1811kg Total Cost- 42,953 taka Therefore, cost of topping per kg fabric = 42,953/1811 = 23.7 taka The above table compares the impact of topping brown shade on total cost. For Brown shade, the cost per kg of all dyeing batches that matched in first time dyeing is 52.5 taka. But the production efficiency dropped by 23%. Thus, the total cost increased to 76.2 taka per kg from 52.5 taka per kg. The share of topping brown shade is 31% of the total cost. This indicates that more resources have been wasted by dyeing brown shade in the month of May.

This shows that there are several factors that curb the efficiency of the dyeing process and thus require topping operations. A few reasons could be Variations in the substrate provided Variations in the preparation of that substrate Human error Lack of people skills / training Lack of control

Machine error Working with non reproducible processes Working with non reproducible dyestuffs.

Non-RFT Impact on Process Cost

Non-RFT impact on process cost

100% % process cost 80% 60% 40% 20% 0% Non-RFT RFT Water(in Taka) 338 7,900 Utility(in Taka) 13,724 197,041 Light grey shade Chemical (in Taka) 28,239 654,718 Non-RFT RFT

The above table compares the water, utility and chemical costs of light grey shade for the month of May. It can be seen that in Right First Time, the cost of chemical is the highest, that is 654,718 taka while the cost of Utility is 197,041taka and among the three water is cheapest, costing only 7900 taka in May. The excess cost of water, utility and chemical for re-dyeing light grey shade is 338, 13,724 and 28,239 taka respectively.

Non RFT-Impact on process cost

100% %process cost 80% 60% 40% 20% 0% Non-RFT RFT Water(in Taka) 312 2216 Utility (in Taka) 13,130 56,064 Brown shade Chemical (in taka) 29,511 348,062 Non-RFT RFT

The above table compares the water, utility and chemical costs of brown shade for the month of May. It can be seen that in Right First Time, the cost of chemical is the highest, that is 3,48,062 while the cost of Utility is 56,064 and among the three water is cheapest, costing only 2216 taka in May. The excess cost of water, utility and chemical for redyeing brown shade is 312, 13,130 and 29,511 taka respectively. The results of the above tables indicate that Masco has sufficient room to improve their RFT. Improved RFT means that less reprocessing has to be carried out, reducing the usage of chemicals, water and energy, as well as saving time previously lost in the correction of off-shade dyeing. Improvement in the RFT also helps to reduce the wastewater volume as well as the concentrations of the pollutants in the wastewater. Water is the cheapest resource because Masco does not buy water. They only have to pay for the process cost.

Water Consumption in Masco Color Water Use in Masco, l/kg of production 191 194 Standard Water use in textile processing, l/kg of production 100 100

Brown Light grey

The figure above compares water consumption of Masco and water consumption of standard Textile processing. The standard figure for water consumption serves as a good benchmark for determining whether water use in Masco industry is excessive. While Brown shade requires 191 liters of water per kg production, light grey requires a little more, that is, 194 liters of water per kg of production. The standard amount of water required to dye a 1 kg knit fabric is 100 liters. Therefore, it is very clear that Masco industry consumes significant amount of water to dye their fabric. Liquor ratio is the volume of liquor consumed in liters per kg of fabric wet processed. (Stephenson, Shemang, & Chaoka) In Masco, each kilogram of finished textile product (brown and light grey shade) requires an average of 193 liters of water. By investing in more water and energy efficient machinery it is possible to minimize this ratio without compromising product quality. The low liquor ratio not only saves water but also allows for shorter dye cycles and saves chemical and energy. (D. Stephenson, E.M. Shemang, and T.R. Chaoka) Pollution load of the wastewater was dropped due to reduction of used dye stuff and chemicals amount.

Win-Win situation for Masco Industry

Average water cost during topping = (115+119)*0.001 = 0.117 taka per kg 2 Average utility cost during topping = 7.25 taka per kg Average chemical cost during topping = (16.3+14.9) = 15.6 taka per kg 2 Therefore, Average cost during topping = 0.117+7.25+15.6= 23 taka per kg Therefore, For Masco Industry, the average loss due to topping is TK 23 per kg fabric per month. RFT can save this money!!!! Another study was conducted by Mr. Abbas Uddin Shiyak, Assistant Professor of Prime Asia University. His study results show that for the tested companies, the average loss due to re-processing is TK 14 - 16 per kg fabric per year. The difference is because Mr. Abbas took into account many different shades while I focused in two shades only. Also he conducted the study over a period of one year while I did it for two months. The direct benefit of RFT is reducing water, chemical, and utility consumption and hence their cost. The ETP is designed based on 2 criteria: 1. Volume of wastewater 2. Load of wastewater Improvement in the RFT helps to reduce the wastewater volume as well as the concentrations of the pollutants in the wastewater. The burden on the ETP becomes less and also the size of ETP can be reduced. Therefore less space is needed for the construction of ETP and this is a very big advantage in a country where space is a constraint.

My Observations in Masco
z Masco has 13 dyeing machineries in total out of which 5 are Chinese and the rest 8 are high pressure atmospheric machines. Chinese machines are atmospheric pressure machines and thus loses there is significant steam loss through heat loss z Chinese machines do not have a reserved tank. Thus it takes lot of time to achieve the desired temperature. Hence there is considerable electricity loss as the pump has to move for longer time. z Production loss as the time between loading and unloading increases. z Liquor ratio 1: 8 used thus requiring more water and more chemicals.

Limitations
z Time: Could have audited for more shades z Chinese machines have no proper calibration so it was difficult to obtain accurate data z Used estimated figures for water consumption in some cases because of lack of knowledge of workers.

Recommendations:
1. Non-RFT maybe caused due to selection of cheap dyes and chemicals. In such cases, the real cost of electricity, water, and chemicals in re-dyeing process are normally ignored. To achieve RFT Masco can switch to better quality dyes and chemicals even if they are expensive. 2. Masco can replace Chinese dyeing machines with high pressure machines in order to reduce heat loss. 3. Liquor ratio: Masco dyes fabric using 1:8 fabric: liquor ratio. This means for 1 kg fabric, 8 liters waster is used. One of the best ways to achieve the motto of save fuel, increase profit, help the environment is to minimize the fabric: liquor ratio. Thus a substantial reduction in water usage is possible. 4. Workers training: training of workers in Masco about water management practices will ensure reduction in water consumption.

5. Good housekeeping: Good housekeeping is essential for making sure that a business is run efficiently. In the same way, good housekeeping is also the first and most essential step to improving eco-efficiency. Housekeeping is therefore the first place a manager of Masco should look for opportunities to save resources, reduce waste and prevent pollution. 6. The companys main aim should be to reduce re-dyeing operations by increasing the process efficiency in order to save time, water, energy and chemicals.

Conclusion
The results indicate that by reducing water use and improving energy efficiency, it is possible to yield significant environmental and economic benefits. It is expected that savings from water and energy conservation measures would not only cover investment costs but would also result in a profit. Also the operating and maintenance cost of the Effluent Treatment Plant will be greatly reduced. Thus a win-win situation is created as both the industry and the environment is benefited.

Reference:
1. Visvanathan, C., Kumar, S., Priambodo,A., & Vigneswaran, S. Energy And Environmental Indicators in the Thai Textile Industry. Retrieved July 12, 2009, from http://www.serd.ait.ac.th/smi2/SMI/roadmap/Publications/Conf_Work_Smnr/Thai_textile _Visu.pdf.

2. Hassan, T.G.K.M. Untitled. Retrieved July 10, 2009 from http://www.unescap.org/tid/publication/tipub2500_pt2chap1.pdf

3. Hossain, A. (2003). An Overview of Different Eco-efficiency Measures: Paper presented in a National Workshop.

4. Visvanathan, C., Kumar, S., & Han, S., (2000). Cleaner Production in Textile Sector: Asian Scenario: Paper presented in a national workshop. Retrieved July 12, 2009, from http://www.serd.ait.ac.th/smi2/SMI/roadmap/Presentations/CP_Textile_Asia.pdf

5. Tanapongpipat, A., Khamman, C., Pruksathorm, K., & Hunsom, M. Parameters effect on the scouring process of textile industry. Retrieved July 12, 2009, from http://www.intania.com/upload/PE09.pdf

6. Curtin University of Technology. (2008). Cleaner Production at Curtin. Retrieved July 12, 2009, from http://c4cs.curtin.edu.au/c4cs/c4csecoefficiencyhome.htm

7. Bhurtun, C., Kistamah, N., & Chummun, J. Energy Saving Strategies in Textiles Industry: The Case of Mauritius. Retrieved July 26, 2009, from http://active.cput.ac.za/energy/web/icue/papers/2006/15_C_Bhurtun.pdf

8. Horrocks, A.R. & Anand, S.C. (Eds.) Handbook of Technical Textiles. England: Woodhead Publishing Limited. Retrieved July 26, 2009, from http://books.google.com.bd/books?id=pq1EhoWIAzkC&printsec=frontcover&hl=en&so urce=gbs_v2_summary_r&cad=0

9. Jadhav, A., & Ajmera. N. Cost effectiveness in textile processing. Retrieved July 26, 2009, from http://www.fibre2fashion.com/industry-article/4/316/cost-effectiveness-in-textileprocessing1.asp

Picture 1: A scale attached to dyeing machines that indicates water level in the machine

Picture 2: A 650 kg dyeing machine

Picture 3: Dyeing process going on

Picture 4: A dyeing process going on

Picture 5: Foam coming out of the machine during dyeing

Picture 6: Control Panel

Picture 7: Water Tank

Picture 8: Dyeing process

Picture 9: Knitting machine

Picture 10: Checking for Faults