INTRODUCTION Bangladesh is blessed with textile manufacturing industry, earning foreign currency with high potential growth.

Continuous improvement is the key to flourish this industry and booming to earnings. The major contributors are the knit garment sector, so any drawbacks in their process should be identified and solved so that the factories do not loose potential their buyers. Echotex is the one of the largest RMG manufacturer in the South Asia sub-continent. So, we made an effort to seek and improve its knit fabric dyeing operations by studying their four main complains/variables: color shade variation , Gram per Square meter ( GSM ) , Bursting Strength & Shrinkage . All this data is analyzed both logically, digitally with the comparison with practically .

ORIGIN OF STUDY

The research intends to find out process status by control charts and investigate the assignable cause of variations in main variables in knit fabric dyeing process. Also to venture on their continues flow process and quality control measures those are used for a better output quantity as well as quality.

PURPOSE OF THE REPORT This report is prepared to fulfill the requirement of the course - Operations Management, as a final group project. Research has been conducted keeping in mind the course

materials covered in this subject and other related topic. The course instructor has approved the topic and materials of this report. The purpose of this study is to understand the production process and quality control measures in knit fabric dyeing in Echo Tex ltd. OBJECTIVE

PRIMARY OBJECTIVE

The main goal of this study is to see if the process in control and if the process is capable for production.

SECONDARY OBJECTIVE

Secondary objective is found out the following issues:

Establishing X bar, R, Individual quality control chart of variables. Achieving process in control by identify assignable cause of variation. Capability analysis with 1.00 Cp and Cpk index Modeling appropriate control chart for the process.

METHODOLOGY

METHODOLOGY OF THE STUDY

For this research project we have used an exploratory research. For collecting information primary sources of information are used. When we were given this term paper

on garments in RMG sector, the first question raised in our mind was from where we should start, which type of data, what type of data we need and from where we would collect them. Then we selected the company upon which we will make our term paper and we selected Echotex Ltd. as our company. The report is prepared on the extensive use of secondary data. We gathered most of our primarydata from the following places

Interview of the employee

Talking with the top level management

SECONDARY DATA

Secondary information was collected from different books and journals such as the quarterly and annual reports published, the articles of association, materials and printouts used for training purposes have also been used as a means for data and information collection. Information about these variables was also collected from publication of textile processing related journal from though internet.

RESEARCH DESIGN

For this research project we used the descriptive research design, as we want to know the variations within the variables.

SOFTWARE-DATA ANALYSIS

The research has conducted and the data have been analyzed by Minitab software for control charts and capability analysis.

LIMITATIONS

In every research program, there always remain some limitations. This project also confronted with some limitations in pursuing the term project work. The major limitation of this study is the lack of information recorded in a structured way in the variables.

SCOPE

The report covers only four of the major variables which puts the factory in a challenging position . One can do further research on the whole range of these variables of the process for better understanding.

SAMPLING PROCEDURE

To conduct our study we use different sampling methods, some informative and a good volume of numerical facts were dealt with. Face to face interview with the Deputy General Manager and factory manager, supervisor, as well as the production and quality control manager of the factory were interviewed, in order to get the in-depth picture of the true situation,

DATA COLLECTION

To conduct the study, data will be used from both primary and secondary sources. Interviewing personnel's working in the factory will be used as primary data. Observations will be also made to gather specific information about production process. Echoex brochure and different reports would be used as secondary sources.

DATA ANALYSIS PROCEDURE

For the purpose of analysis, both descriptive-analytical as well as statistical tools and materials are used. Pictures, diagrams, tables, graphs and charts are included for better interpretation.

RESEARCH TIMELINE

Preparation of Research proposal Data collection Report writing

: 7 days : 8 days : 15 days

COMPANY BACKGROUND Echotex Limited is a UK-Bangladesh joint venture company with a business nature of Knit-composite textile (comprising spinning to finished good). Echo sourcing UK limited under the prominent leadership of Mrs. Para Hamilton & Mr. Shafiqul Hassan as Chairperson & managing director respectively engaged into this business for several years. However with them there are several people who desired to form a company & agree to take all kinds of responsibilities of the company. The Metropolitan Chamber of Commerce & industry recently awarded Echotex in recognition of its contribution in saving the environment through ethical business practice. 80% of shareholding is owned by British nationals & rest is owned by Bangladeshi people. It falls under the umbrella of a group of concern.

The sister concerns are as follows: 1) Echo sourcing Limited. 2) Quality Assured Limited. 3) Equity Resources Limited. 4) Childrens Hope. 5) Stitch Right Limited.

Echotex Ltd established as a complete supply chain clothing company to combine design, manufacturing and delivery from Bangladesh to European retailers with experience of over 15 years. Echotex Ltd also started to deliver products in North America.The Immediate aim is to become a World Class supplier of merchandise in terms of quality, lead-time and unbeatable value. Echotex Ltd feeling pride in setting up state-of-the-art plants in Bangladesh with the world's best machinery in spinning, knitting, dyeing and garments production within the group. Echotex Ltd have placed significant effort in Human and IT resources and consider compliance of Ethical Aims on labour and environment as an inclusive part of our growth and business. Echotex Ltd also set up an organisation called Children's Hope for the education and health care of underprivileged children in Bangladesh over the past three years.

Quality control of Echotex is not achieved just by having 'zero tolerance' on each garment rather all garments are checked as cut piece, in-line 'stage inspections', in-line final inspection followed by 2.5 AQL pre-shipment inspections. Lab tests are carried out by European testing houses on fabric and garments to meet specific requirement of individual buyer.

Its strength to control the supply chain from yarn selection to shipment processingtracking and delivery, has placed them in a position where they can consider themselves to be faster on delivery, better on quality and have unbeatable value in their products than any of other competitors.

Echotex is currently employing 4000 people. It uses TALLY as accounting software. It is a garment manufacturing factory which will eventually employ up to 10000 workers. The factorys vision is to be a commercially viable green community development company with people in its heart. Its mission is to be industry role model through employing passionate people with a desire to produce the best product in the best way. Echotex is an equal opportunity employer. VISION: The companys vision is to be a unique & green commercially viable community development company with people in its heart. Mission: Its mission will be to develop as a CDC & industry role model through employing passionate people with a desire to produce the best product, in the best way for the best reason: Caring for the workforce & enriching their life. Threemajorissuesareasfollows: 1) Environmental protection 2) Compliance & ethical business practices. 3) This must be addressed to sustain fierce competition in Bangladeshs apparel business. The Factory is nominated as The GREEN APPAREL MAKER INFORMATIONATAGLANCE: (Information as per our inspection)

Project Name : ECHOTEX LIMITED . Country office: Lane 5, House 134, new DOHS, Mohakhali Dhaka. Corporate Head Quarters: The old Couch House, 25Dunster Garden UK. Factory: Chandra Pollybiddut, Kaliakoire, Gazipur. Sister concerns: Quality Assured Ltd. Equity Resources Ltd. Childrens Hope. Stitch Right Ltd. EchoSourcing Ltd. Authorized Capital: TK 10 crore Manpower: Management - Staff 250 & Worker 4000 Date of start: 1st January 2007 Premises: 1 . Garments Building: Total 42000 sft each floor of 10 storied building of which 4 floors has been completed. 2. Dye house : Total 55000 sft each floor of 2 storied building of which 1 floor is for dyeing & other is for knitting. 3. Utility building: Total 12000sft each floor of 2 storied building.

Products: T-shirts, polo shirts shorts (mens wear, children wear & womens wear). Buyers: New Look (UK), Debenhams, Fat Face, Peacock & Primark Types of ownership: Jointventure.

Markets: Echotex Ltd is 100% export oriented garments factory & its Market is international. All the buyers are foreigner. Time of changing: Echotex Ltd established in 2007.From the beginning of its establishment this garments is changing rapidly. From 2009 it becomes a great change.By making quality product, delivering fastly, Ensuring workers rights, following EU code of conduct & protecting environment. Echotex Ltd awarded in 2010 for contributing in the protection of environment. Strong supply chain helps Echotex Ltd to achieve the business goal.

Specialty of Echotex ltd. The speciality of echotex are 45 tons of knitting and dyeing unit with all European machineries. Most modern printing facility with 2.7 million pcs per year production capcity. ETP and WTP with zero discharge. Adequate space to be green factory. Workers will be paid legal minimum or above. No child labor will be allowed Adequate health and safety measures are in place and proper records are maintained 30 lines of sewing factory with 14.4 million pcs per year production capacity and most modern technology from Japan. Identified fire exits in English and local language, adequate number of fire extinguisher, three stairs, early warning system and proper evacuation system will be placed. Workers / employees will be served with lunch free of cost. Serving lunch has double benefits It saves working hours and ensures good health of workers. Full fledged medical centre with full time doctor will be in place to check health care of employees. Day care facilities for the childs of the employees will be available. Azo dyes will not used. Factory will use ball point needle as a policy in order to avoid needle holes Samples will be checked thoroughly in sample room. All fabrics will be checked prior to cutting. Each piece of cut garment will be checked after cutting and after sewing to ensure effective quality control Each garment particularly those of children wear will be passed / checked through a metal detector. Color continuity cards will be maintained to check batch to batch color standard / shading / matching etc. All colors will be checked through the light box and CDM (spectra photo meter.)

Product Mix
a) Knitted grey fabrics
Plain Single Jersey Heavy Jersey

Polo Pique Lacost(Single & Double) Rib Drop Needle 2/3 Thread Fleece (Brushed/Unbrushed) Collar & Cuff

b) Knit Garments
Product Categories: Mans wear. Womans wear. Babys wear. Kids wear. Subcategories: T-shirts. Basic T-shirts. Piqu Polo Shirts. Tank Top. Long Sleeve Turtle Neck Shirt. Shorts. Auto Stripe (Yarn Dyed). Vest, Fleece etc. Roll Neck T-Shirt. Sweet Shirt. Knitted Night Dress.

Remarks
Echotex Ltd. is a ISO 9001 : 2000 certified company , a leading house of Industries & Commerce in Bangladesh, having Printing Industry. The Location of the Industry is well placed having good communication. The right combination of the High Brow business intellect and their co-operation are leading Echotex to high-end of corporate practice to refer high end quality that is the only philosophy of Echotex. Most advanced approach in the field of strategic planning, finance, Management Information System (MIS), Human Resource Management and Compliance has made DBL faster in delivering triumphant quality to its valued customer. All the products undergo stringent quality inspection procedures at each level of production process. The fabrics are Oeko-Tex certified.