Apex Adelchi Footwear Ltd

 Introduction

“APEX” means the peak or the zenith. Apex Adelchi Footwear Limited – The leading manufacturer and exporter of leather footwear from Bangladesh to major shoe retailers in Western Europe, North America and Japan.

Apex Adechi Footwear Ltd. started their business at January 04, 1990 as Apex Footwear Ltd. Name changed to Apex Adelchi Footwear Ltd. at 2006.

AAFL pioneered the export of value added finished products export in the leather sector of Bangladesh and is also involved in the local footwear retail business trading under the “Gallerie Apex” brand. AAFL has strategic, technical and marketing alliances with Italy. Publicly listed and traded since 1993, AAFL is professionally managed, currently employs 3920 persons.

It is utilized most modern state of art machinery for production of footwear and all its manufacturing operations are automated and manual both.

This permits 20,000 Pairs of Complete shoes per day.

Most of the leather use in this factory is tanned and developed by its sister concern.

It’s now a leading footwear industry in Bangladesh, catering to the footwear needs of the global clientele.

COMPANY PROFILE

Name of the Company: APEX ADELCHI FOOTWEAR LIMITED

Date of Commencement of Business as Apex Footwear Limited: January 04, 1990
Name Change to Apex Adelchi Footwear Limited: December 27, 2006

Type of Company: Public Limited Company

VISION: “HONEST GROWTH”

Board of Directors:

 Mr. Syed Manzur Elahi –  Chairman
Mr. Syed Nasim Manzur –  Managing Director
Mr. Syed Gias Hussain –  Deputy Managing Director
Ms. Munize Manzur Khasru –  Director
Mr. Niaz Ahmed Choudhury –  Director
Mr. Adelchi Sergio –  Director
Mr. Samson H. Chowdhury –  Independent Director

Management Team:

 Mr. Syed Manzur Elahi –  Chairman
Mr. Adelchi Sergio –  President
Mr. Syed Nasim Manzur –  Managing Director
Mr. Syed Gias Hussain – Deputy Managing Director
Mr. Abdul Momen Bhuiyan –  Executive Director
Mr. S A M Yousuf –  Executive Director (Unit 02)
Mr. Razya  Rahim –  GM ( Factory )
Mr. Md. Mominul Ahsan –  Head of HR

 Mr. Dilip Kajuri  – Financial Controller

 Mr.Pradip Kanti Saha – General Manager Finance
Mr. Atiqul Islam – GM (Leather)
Mr.Md. Shahjahan – Company Secretary

   History

1990       —             January 04          –              Business Operations Started

1993       –              November 07       –              Listed on DHAKA Stock Exchange

2006       –              May 06                  –              Strategic Alliance with Italian companies

2006       –              December 27       –              Name Changed to APEX ADELCHI FOOTWEAR   LTD.

2007                                                       –              Production Capacity Reached 10,000Pairs/Day

2008                                                       –           Production Capacity Reached 15,000Pairs/Day

2010                                                       –              Celebrated 20th Anniversary

Global Market:

EuropeAsiaUKUSACanadaUAE
79.50 %12.60 %0.70 %6.80 %0.30 %0.10 %
Country Order %  
Germany30.40 %
Japan12.10 %
Italy10.30 %
France7.40 %
USA6.80 %
Czech Rep 6.50 %
Austria5.20 %
Belgium4.40 %
Netherlands4.10 %
Others 12.80 %
  100 

 

 

 

 

 

 

 

 Research & Development of New Product

DURATION: 6th February, 2012 to 17th February, 2012.

The most vital & important dept. of every factory is R & D. No factory can reach the ultimate goal, unless develop a highly sophisticated R& D dept. In harmony with other factory

R & D: By the meaning of the R&D we can get an idea about its activities. In general by this word we understand that the place/section where new product is developed or research with all problem creating during pilot production to batch production or research the longevity to comfort of any types of product. Besides these costing of the product is also calculated in R&D dept.

New product for a company can be obtained by various ways, details in given bellow:

Customer research:

It is done for product development of a company. it is done by asking various types of questions ,eg -what’s customer needs ,why they need so, why they like such types of item or products ,etc. so it is very important to research the customers for a new product development.

Market research:

It is one of the most important factors of NDP process. By market research we can earn many kinds of ongoing fashion, know what kinds of products are needed by the customers. Customers always want service and quality in their ability to buy the products.

Merchandizing:

Buyer contact with merchandiser or merchandiser contact with buyer for the product then send into PD room. The selection of PD in the middle section where the product will go for production or not in production floor or mass production all are included here.

Buyer and merchandiser share the aesthetical problem with PD section.

Target Set up:

Set up the target according to buyer requirement what types of products they required and what types of materials, tools, machines are needed.

PD Meeting:

Section of product or design for the next target that is done by high authority of the company.

Here the products are divided according to season, festival etc. eg. Summer, winter and with various religious festival or cultural program.

Purchase and Supply Chain:

All types of materials are supplied for the production by requirements of PD.

Costing:

It is very important factor for a product development, here PD guide, specification guide for product are supplied by the PD room.

Grading:

Size grading is done in PD room for fast production running, time saving and overall save the cost of production. After grading all size then order the equipment.

Equipment Arrange:

Knives, materials, tools machines, last, mould etc. are arranged for production. At last go for mass production.

These overall procedures are centrally controlled by PD section. So, we can call PD is the heart or brain of production firm.

Design & pattern: provided by the buyer (maximum time), Often new design & pattern is made here.

Pattern grading: provided by the buyer, often grading is done in R&D.

Sample: 1/2 pair sample is also provided by the buyer.

Prototype making: R&D dept. makes a prototype of that sample by using the provided pattern of buyer.

Buyer’s Approval: prototype sample is checked by the buyer and give approval of the working procedure.

Product costing: By using graph paper R&D dept. make the consumption of the used material of the shoe. Except glue and thread most of the materials can be consumed by the graph paper.

Price negotiation: By the measured cost Apex Adelchi Footwear Ltd. bargains with the buyer for the price. By the negotiation of both sides the selling price has been fixed up.

Order sheet: After negotiations buyer give an order sheet to the factory by mentioning quantity of pairs, size color, soling material, insole materials, thread etc. in a word every specifications for development new order. Besides the order LC is also given to the factory.

 Production plan: R&D dept. makes a production plan for the newly ordered article.

Materials consumptions: By considering the quantity of order R&D dept. will make total material consumption for the order.

Pilot production: By the availability of the material as well as productions lines R&D will accomplice a pilot production in production line by direct supervision.

By this way R&D dept. has become the most vital dept. among the other dept. in Apex Adelchi Footwear ltd.

R&D dept. of Apex Adelchi Footwear ltd. has been done and still doing some extra ordinary work. For this work the factory is developing sharply. Some of important works in R&D are mentioned in below……

  • R&D has preserved properly all the article sample till Apex Adelchi Footwear ltd established.
  • R&D preserved all types material swatch. It has an extraordinary thread swatch file as well as it has every article’s swatch file.
  • R&D has preserved all patterns accordingly.
  • R&D makes immediate copy of the original pattern comes from the buyer for safety purpose.
  • R&D makes the setting pattern and skeleton pattern for productions floor also.
  • R&D has a large collection of various types of upper leather of various article.
  • R&D has some much skilled persons who are devoted to make sample to productions. If necessary they floors any time.

FUNCTION OF A SHOE DESIGN:

 They are 4 functions given as below:

  The purpose.

  The material.

  The method.

  The fashion.

CATEGORY:       

  1. Men’s close:

  Dress

  Casual

  Sports

  1. Men’s summer:

  Sandal

  Slipper

  Chaplies

  1. Ladies summer:

  Sandal

  Slipper

  Chaplies

4.   Children close

  Dress

  Casual

CATEGORY (BY DIGIT):

Category                              Digit     

Men’s ………………………1

Ladies ………………………2,3,4

Children …………………… 5 6 7 8 9

SIZE RANGE:

Men’s:      39 40 41 42 43 44

Ladies:     35 3637 38 39

Children:   21 22 23 24 25

All the size in which there are underline marks are the sample size.

  • What the name of BRAND used in APEXADELCH Footwear Ltd( unit-2)

  The name of BRAND used in APEXADELCHI footwear ltd. are given below:-

 1.Men : (i) Venturini ,      (ii) Apex Men ,   (iii) Sprint

2. Women: (i) Moochie,  (ii) Nino Rossi, (iii) Sandra Rosa, (iv) Apex Ladies

3. Kids: (i) School Brand,   (ii) Twinklers

   4. Thongs           

  • What type of LAST  used in APEXADELCHI footwear ltd .

Last observation in PD department

There are various type of last are used in PD department of APEXADELCHI footwear ltd unit(2).

The Last are gen’s Ladies and Children. All the last  discuss  are given bellow———–

1.     TELESCOPE LAST:-

  1. DIP last
  2. Parker last

 Used for SANDAL Shoe manufacture

c.SHOE LAST:-

-Used mainly for ladies Sandal and  Gen’s shoe.

–          French sizing system flowed in Apexadelchi footwear ltd.

–          For men size range are(39-46).

–          For ladies size range are (35-41).

 2.     HING LAST:-

                a. DIP last

                b. Shoe last

               -Used mainly casual shoe.

3.     SCOOP BLOCK LAST:-

 Used for mainly shoe manufacture.

4.THONGE LAST;-

-Used for mainly for

Sandal shoe.

5.CHILDREN LAST;-

 a.     Kids last

Size range(21-26).

b.    Twin last

-size range(27-36)

ANDAL LAST;-

  1. Thonge last
  2. Chappal last
  3. Slipper last

  Total  area – 3360 sft

  M/C Quantity  –  06 pcs

  Sample Rack – 05 pcs

  No of Operator – 06

  Shift – General shift.

Sequence of Operation of Pattern Making.

  • Clean the Last
  • Using Masking Tape, Masking the outside of last.
  • Tangent Point marking, Middle line marking, Back height Marking, Finding the vamp point.
  • Sketch the design on last(own)
  • Flattening the masking tape on pattern paper.
  • Make upper standard.
  • Cutting the all the sectional pattern and draw stitch mark, folding mark etc.

Report on Cutting section:

Duration: 19th March, 2012 to 31st March, 2012.

Cutting department is the most import section of the industry.  The main component of the cutting section is Leather. Leather need to cut in budget. If a operator can cut maximum component from leather then company can make great profit.

Leather Defects:

Naturally leather has some defects. So it needs to cut carefully to get maximum profit. There are many types of defects in leather. Some of them given below:

►Natural matters:

  • Growth marks

 Growth marks occur in the shoulder and neck areas at right angles to the back bone line . They  are caused by wrinkles in the skin . The wrinkles are similar to those on the fore head of a man or woman and become more pronounced with age.

  • Veins:

After the skin has been tanned , vein may be visible through the surface Finish of smooth finished leather.

  • Scratches :

These are deep long scratches caused by thorng shrubs . Cattle stray out to grain in thorng and while running against the thorng the animal gets their hide scratches.

  • Flay cuts:

Skin is usually a by product of meat industry . When the skin is removed cuts occur due to careless misuse of the flaying knife . These will appear on the flesh side of the skin.

  • Tick marks:

The tick burrows its head into the skin of the animal to suck the blood and at the some time injects the animal after the tick with draws.

  • Loose grain:

These are small round depressions on the grain surface of the H/S .These small depressions innumerable and they make hides totally unsuitable.

  • Warble hole:

Many hides are found to be of a very poor quality due to old age and protracted illness. These hides are thinner and contain looser and emptier fiber texture.

  • Back bone :

   After the skin or hides has been tanned, the backbone will be visible through the         surface finish of the leather in the surface finish leather.

   ►Technical matters:

  • Thickness
  • Salt stain
  • Crack
  • Color stress
  • Elasticity
  • Shininess
  • Softness

Sequence of cutting:

Sorting

Cutting

Stamping

Quality control

Sorting:

At first we need to sort the leather. We have to check several things such as color fastness, thickness and type of grade given by tannery, key test, tape test etc. after sorting the leather we have to make consumption for every pair. Consumption of Cow leather 10-15% & Sheep leather 20-25% (based on paper). If article knife is not more than two then consumption is 10%.

Leather Grade:

Grade% of cutting area
A90-97%
B80-90 %
C70-75 %
D60-70 %

Cutting:

Mainly two types of methods followed in cutting section.

 They are given below:

      1. Tracing method

      2. Direct cutting method

Benefit of tracing method:

  • Avoid defects
  • Good production
  • Get more cutting area
  • Easy for operator
  • Can use less experience cutter

Detriment of tracing method:

  • Time consuming method
  • Budget high
  • Need more man power then direct method

Benefit of direct method:

  • Less man power
  • Good production
  • Fewer budgets
  • Good for A grade leather

Detriment of direct cutting method:

  • Need experience cutter
  • Rejection rate is high
  • Need more time for Q.C

Stamping:

Here article no. , size no. of a product is attached by stamping machine by using foil paper.

Embossing:                                                                      

Embossing is also important operation, because it will be identify to the company’s logo.

Quality Control:

To get a perfect production we need to check every single component. that why Q.C is important for shoe manufacturing. During Q.C we have to identify different types of defects which can hamper production. Many defects are not visible in leather but during lasting they came out. For this we have to recheck it on last.

Q.C table- 1 pcs

Materials:

Not only leather but also many type of material need to cut in cutting room. Such as lining leather, reinforcement material (PU, Casper, Cotton, and Foam), sole, insole, toe puff, stiffener, Velcro etc.

Cutting Knives:

There are two types of cutting knives for cutting the components.

  1. single edge knives

–          32 mm Gauge Thickness.

–          Blade depth starts 10mm during cutting of materials.

–          Mainly used for insole & outsole cutting.

  1. Double edge knives

–          19 mm Gauge Thickness.

–          Blade depth starts 5 mm during cutting of materials.

–          Mainly used for upper & lining cutting.

In cutting knives there are various type of marks such as pick marks, size marks, side mark, notch mark are given.

CUTTING DEPARTMENT OF APEX ADELCHI FOOTWEAR LTD. (UNIT-2)

Cutting department is a key department of APEX. Its main target is maintaining the production as per plan.

FUNCTION OF CUTTING DEPARTMENT:

Common functions are:

  Make a plan as per freezing report

  Identify the important article

  Collect knife and other materials for selected article.

  Select Leather as per requirements.

  Select M/C for particular article.

  Complete the article as per date line.

  Maintain the quality as per sample.

  Provide support to other departments.

  Maintain WIP report.

CUTTING DEPARTMENT AT A GLANCE :

  Total  area – 5000 sft

  stock area – 1000 sft

  Rack area – 300 sft

  Number of racks – 2 pcs

  Per day production – 1800 pairs (Two shifts)

  Avg.conj: 2.2 sqf

  M/C Quantity:

  • Traveling Head M/C : 03 pcs
  • Clicking Head M/C : 10 pcs
  • Stamping M/C : 05 pcs

  Shift – 2

  • 1st – 6 AM – 2 PM.
  • 2nd – 2 PM – 10 PM.

  Manpower –

  • Manager – 01
  • Senior officer – 01
  • Asst. Officer — 01
  • Staff / worker – 70

FINDINGS:

  Need More skill operators

  A knife maintenance section need for Cutting Dept.

  To ensure the availability of cutting knife on time.

  Ensure the availability of Leather on time.

  To maintain the quality need more cutting board.

  Need to motivate the operators.

Reports on Sewing Section:

Duration: 9th March,2012 to 18th  March, 2012.

SEWING DEPARTMENT:

Sewing department is a vital department for any shoe company. Sewing department tries to keep the quality as per given sample.

 FUNCTION OF SEWING DEPARTMENT:

Common functions are:

  Make a plan as per freezing report

  Identify the important article

  Collect cutting material from cutting.

  Collect all other necessary materials from store.

  Rearrange the sewing line.

  Maintain the quality as per sample.

 Complete the article as per date line.

  Provide support to other departments.

  Maintain daily production report.

SEWING DEPARTMENT AT A GLANCE:

  Total  area – 9000 sft

  stock area – 270 sft

  Per day production – 2000 pairs (Three shifts)

  M/C Quantity  —  100 pcs

  Conveyor – 3 pcs ( 37.5 meter each & 140 trays/con )

  Shift – 3

  • 1st – 6 AM – 2 PM.
  • 2nd – 2 PM – 10 PM.
  • 3rd —  General shift(08am- 4.30pm)

  Manpower –

  • Senior officer – 01
  • Officer – 03
  • Supervisor – 03
  • Worker – 390
FINDINGS:Need to motivate the operators.

Need guide for sewing M/C.

Need to ensure the toe-puff and counter on time and other materials.

Need two more supervisors.

Need maintenance for sewing section.

  Need to ensure a suitable place for keeping complete upper.

  All over need to increase involvement of supervisor during shoe production.

SL.

NO.NAME OF MACHINE

AND MODELMANUFACTURER DESCRIPTION OF

OPERATIONDEPT.

USINGREMARKS02SKIVING M/C

AV-2 MACIURLI M/C CO. SEWING11 SET03SKIVING M/C

FAY SEWING02 SET04TAP ATTACHING M/C

A-79  SEWING03 SET05SINGLE NEEDLE FLAT BED, KDD-5570

SEWING08 SET06SINGLE NEEDLE FLAT BED, KI-563-900/57  SEWING02 SET07SINGLE NEEDLE FLAT BED, KI-563  SEWING01 SET08SINGLE NEEDLE FLAT BED, KI-953  SEWING01 SET09SINGLE NEEDLE FLAT BED, KI-553  SEWING01 SET10SINGLE NEEDLE POST BED, KDD-8810  SEWING32 SET11SINGLE NEEDLE POST BED, 491-BL  SEWING04 SET12SINGLE NEEDLE POST BED, KI-1293  SEWING04 SET13SINGLE NEEDLE POST BED, KI-491  SEWING01 SET14SINGLE NEEDLE POST BED, 4180-i  SEWING01 SET15TOE PUFF M/C, PP-02

TOE PUFF ATTACHINGSEWING03 SET

SL.

NO.NAME OF MACHINE

AND MODELMANUFACTURER

DESCRIPTION OF

OPERATION

DEPT.

 

USINGREMARKS16DOUBLE NEEDLE FLAT BED, 1280-i

SEWING03 SET17DOUBLE NEEDLE POST BED, KDD-8820

SEWING22 SET18DOUBLE NEEDLE FLAT BED, KI-297

SEWING01 SET19DOUBLE NEEDLE FLAT BED, KI-474

SEWING01 SET20DOUBLE NEEDLE FLAT BED, KI-471

SEWING01 SET21EYELET M/C, MIIG-PZ

EYELET MOULDINGSEWING03 SET22FOLDING M/C, RP-67

LEATHER FOLDINGSEWING03 SET23HAMMARING M/C, DS-402

HAMMARINGSEWING02 SET24HAMMARING M/C,

LOCALH.B.Q ENGINEERING

BANGLADESHHAMMARINGSEWING01 SET25TRIMMING M/C, GP-2

TRIMMINGSEWING05 SET26ZIG ZAG SEWING M/C, KDD-566H-TBCIURLIZIG ZAG SEWINGSEWING06 SET

02 SET PROBLEM27COUNTER MOULDING M/C, DS-668ACHINACOUNTER MOULDINGSEWING01 SET28COUNTER MOULDING M/C COUNTER MOULDINGSEWING03 SET29CONVEYOR, DS-709TAIWAN SEWING03 SET

Sequence of Operation of Upper Closing:

  • Article Name: Casual.
  • Size: 41
  • Upper Leather: Cow, Black, Thickness-1.3mm.
  • Lining Leather:Buffalo, Brown. Thickness: 0.9mm.

Sequence

Marking (Stitch, Skiving,  Folding etc.)

 Inspection & QC.

                                                                      Skiving.

No.

Location

Type

Thickness

Width (mm)

01

Top line

tapper

Half of materials

8-10

02

Apron

tapper

Half of materials

5

03

Vamp

tapper

Half of materials

8-10

Q/C

Attaching (using Neoprene Adhesive)

Heel Grip + Quarter lining.

Quarter lining + Vamp lining.

Stitching

No

Location

Machine

Needle System

Thread Number

Thread Color

Needle Number

Needle Point

Stitch Density

01

All lining

Flat Bed 134Sys

Double

Needle

40/3

Beige

100

LR

9 per inch

02

Apron+ vamp

Flat Bed 134System

Single Needle

40/3

Black

100

LR

,,

 Turn stitch of Apron

Use latex for all the area of upper where folding is done.

Reinforcement tape marking and fixing on top line

Folding is done on Apron and Top line of upper

Top line and Apron fitting.

Positioning the Elastic under the Upper and attach by neoprene.

Stitching

No

Position

Machine

Thread number

Needle

No

Needle Point

01

Back Part

Zigzag

40/3

100

LR

02

Decorative upper Stitch on Upper Seam

Post Bed

Double Needle

20/3

120

LR

 Back Strap attach by neoprene adhesive, Stitch and Fold.

 Attach upper and Lining by neoprene Adhesive.

 Stitch

No

Position

Machine

Thread number

Thread Color

Needle

No

Needle Point

Stitch Density

01

Top line Apron with Elastic

Flat bed Double Needle

40/3

Black

100

LR

9

Per inch.

 Reinforcement Tape 50 mm Attach on toe position.

 Toe puff attachment (ABS type, Het reactivated (55-60) ° C.

 Insert Counter Stiffener.

 Back part molding.

Lining trimming.

Edge coloring.

Thread burning.

Q/C.

Upper Complete.

Reports on Lasting and Finishing Section

Duration: 18th February,2012 to 28th  February, 2012.

LASTING DEPARTMENT:

Lasting department is a key department of APEX. Its main target is maintaining the production as per plan.

FUNCTION OF LASTING DEPARTMENT:

Common functions are:

  Make a plan as per freezing report

  Identify the important article

  Received upper form sewing section

  Count all last and make pair.

  Collect all other materials from stores

  Complete the article as per date line.

  Maintain the quality as per sample.

  Provide support to other departments.

  Maintain WIP report.

LASTING DEPARTMENT AT A GLANCE:

  Total  area – 15752 sft

  stock area –  4000 sft

  Rack area –  300 sft

  Number of racks – 12 pcs

  Per day production –

  • Conveyor 1 : 1600 pairs
  • Conveyor 2 : 800-1000 pairs

  M/C Quantity —

  Shift – 3

  • 1st – 6 AM – 2 PM. (CONV-1)
  • 2nd – 2 PM – 10 PM. (CONV-1)
  • 3rd –  8 am -5 pm (CONV-2)

  Manpower –

  • Asst. Manager- 01
  • Senior officer- 01
  • Officer – 01
  • APO – 01
  • Supervisor – 03
  • Staff / worker – 55 per shift

FINDINGS:

  •   Need more skill operators.
  •   Need to ensure the availability of quality upper
  •   Ensure the availability lasting materials on time.
  •   Need to motivate the operators.
  •   Need to ensure a separate packing section.
  •   Need to ensure a separate preparation section.
  •   Need to ensure a suitable place for keeping last.
  •   All over need to increase involvement of supervisor/APO/in charge during shoe production

INFORMATION OF LASTING M/C:

SL.

NO.NAME OF MACHINE

AND MODELMANUFACTURER

DESCRIPTION OF

OPERATION

DEPT.

 

USINGREMARKS01Cream Toe Lasting M/C

K-78 SZCIURLITOE LASTINGLASTING01 SET02TOE REACTIVATOR M/C, LOCAL

LION FOUNDRYTOE REACTIVATINGLASTING01 SET03CREAM HEAL SEAT & SIDE LASTING M/C,

K-58-ECIURLISEAD LASTINGLASTING01 SET04STREAM & HOT AIR IRONING M/C,

DS-132 HOT AIR IRONINGLASTING01 SET05HEEL SEAT POUNDING M/C, DS-234

HEEL POUNDING &SEATINGLASTING01 SET06HEAT SETTING M/C

DS-926A-3.8M HEAT SETTINGLASTING01 SET07VOLBER ROUGHING M.C, 152 (BN)

CIURLIROUGHINGLASTING01 SET08SHOE UPPER POLISHING,  DS-171 POLISHINGLASTING04 SET09IRON FOX (BANF SOLE ASSEMBLING M/C)

P-99 (BN)CIURLISOLE PRESSINGLASTING02 SET10STREAM MACHINE ,

DS-341D BACK COUNTER GLUE ACTIVATINGLASTING01 SET11HOT AIR IRONING M/C

LOCAL HOT AIR IRONINGLASTING01 SET12HAND IRON M/C

 

LOCALH.B.Q ENGINEERING

50/2 BONOGRAM,HAND IRONINGLASTING01 SET

(02 PCS)13CEMENT ACTIVATING M/C,  DS-RS-9510

CEMENT ACTIVATINGLASTING01 SET 14CEMENT ACTIVATING M/C,   LOCAL

CEMENT ACTIVATINGLASTING01 SET 15HYDRAULIC LAST RELEASING M/C

DS-243 LAST RELEASINGLASTING01 SET 16HOT AIR GUN

LOCAL THREAD BURNINGLASTING01 SET 17Lasting Conveyor(5Levels),

CARRING LAST, SOLE ETC.LASTING03 SET

Sequence of Operation of Lasting and finishing.

Searching.

Outsole Priming using MEK.

Insole attaching at bottom of the last by using masking tape.

Complete upper insert on the upper of the last.

Back height marking, fixing by using tack.

Mulling the Upper. (Heat 90° C, time 5 sec)

Toe lasting.

Apply neoprene adhesive bottom of the insole.

Side lasting using pincer by hand.

Seat lasting.

Seat rounding

Heat setting (temp. Control 190° C, time 50 sec)

Ironing of upper.

Back height tack removing.

Cream applies on upper.               

Brushing Using Wax (hard brush)

Polisher (natural) applies by Sponge.

Brushing Using Wax (Hard and Soft)

Roughing and Scouring.

Apply PU adhesive on bottom of the lasted upper and outsole.

Drying.

Second coat apply of adhesive.

Heat reactivation (both sole and upper, temp 70° C, time 5 sec)

Out sole attach with lasted upper.

Outsole press by machine (pressure 30-40 kg/ cm2 time 10 sec)

Chilling.

Edge cleaning.

Delasting.

Insert sock inside of the shoe.

Final thread burning.

Cream application.

Drying (at room temp, time 2 min)

Polishing with polishing wax.

Sole cleaning.

Insert foam and tissue paper.

Final inspection.

Wrapping the shoe by tissue paper.

Packaging.

 SYNTHETIC DEPARTMENT:

Duration: 29th February, 2012 to 8th March, 2012.

Synthetic department is a key department of AAFL-2.

PLANTS:

  EVA Injection Plant

  PVC Upper Injection Plant

  TPR Injection Plant

  PVC Outsole Injection Plant

EVA Injection M/C (SHOE):

  No of M/C: 01

  Model: 203

  Man Power: 14

  Productivity: 1260 p/shift

PVC Injection M/C (SHOE):

  No of M/C: 01

  Model: 980

  Man Power: 48

  Productivity: 630 p/ shift

PVC Injection M/C (Strap):

  No of M/C : 01

  Model: 970

  Man Power: 15

  Productivity: 950 p/ shift

Spray M/C:

  No of M/C : 01

  Man Power: 09

  Productivity: 600 p/ shift

PVC Injection M/C (THONG Strap):

No of M/C : 01

  Man Power: 2

  Productivity: 3000 p/ shift

SL No.

Name of

No Of

Injection

Hourly Production

Production Capacity

Daily (Prs)

Monthly
(Prs)

M/C

Station

Time (±)

Capacity (Prs)

Per Shift (Prs)

1

PVC Injection Machine 980

24

20 Sec

90

630

1890

49140

(12 Prs)

2

PVC Injection Machine 970

10

20 Sec (Mono Color)

180

1260

3780

98280

(10 Prs)

40 Sec (Bi Color)

90

630

1890

49140

3

 EVA Injection Machine 203

6

8 Min

180

1260

3780

98280

4

TPR Injection Machine 611

6

3.33 Min (Mono Color)

108

756

2268

58968

5 Min (Bi Color)

72

504

1512

39312

M/C Chart of Synthetic Department:

SL.

NO.NAME OF MACHINE

AND MODELMANUFACTURER DESCRIPTION OF

OPERATIONDEPT.

USINGREMARKS01EVA INJ. MOULDING

M/C, TK-203W-6S-DSTIEN KANG CO.

TAIWANEVA INJECTION

MOULDINGSYNTHETIC 02PVC INJ. MOULDING

M/C, TK-980C-12PTIEN KANG CO.

TAIWANINJECTION

MOULDINGSYNTHETIC 03PVC UPPER INJ. MOULDING M/C,  TK-970U-3C-10STIEN KANG CO.

TAIWANINJECTION

MOULDINGSYNTHETIC 06Cooling Tower

KST-15-RTTIEN KANG CO.

TAIWANCooling WaterSYNTHETIC01 SET07Cooling Tower

KST-15-RTTIEN KANG CO.

TAIWANCooling WaterSYNTHETIC02 SET08EVE Compound Mixing M/c,  LOCALS.S ENGINEERINGEVA Compound MixingSYNTHETIC 11Cold Mould M/c

ST-03H.K ENTERPRISEThong cold mouldingSYNTHETIC02 SET12Heating Conveyor

H.K ENTERPRISEThong HeatingSYNTHETIC 13TPR Grinding M/c

A-30TIEN KANG CO.

TAIWANTPR Cutting & GrindingSYNTHETIC  14TPR Grinding M/c

LOCALH.K ENTERPRISEPVC Cutting & GrindingSYNTHETIC  16PVC Cutting M/c

LOCALH.K ENTERPRISEPVC CuttingSYNTHETIC  17Spray Booth

PVC SPRAYSYNTHETIC  18Tray Heating Conveyor

PVC  Sandal HeatingSYNTHETIC

STORE DEPARTMENT:

Store department is one of the most important departments for any shoe company. This department carries out various duties regarding Planning & Buying, Shipment of Goods, Receiving of goods & online software.

FUNCTION OF SEWING DEPARTMENT:

Common functions are:

  Working method is FIFO.

  Receive materials and maintain ERP software

  Stock all the materials in an order.

  Maintain update report.

  Supply materials and leather as per requisition.

  Provide support to other departments.

METHODS:

There are two method used in store dept.

  FIFO – FIRST IN FIRST OUT

  LIFO – LAST IN FIRST OUT

RECEIVING OF ITEMS:

  61 % duty added on leather goods.

  31 % duty added on Synthetic materials.

  No duty added for local item.

SOURCES:

  Local

  Import

  Local Supplier

DISPATCH:

  All production departments, PD and administration.

  Local suppliers.

  C.D.C.

STORE DEPARTMENT AT A GLANCE:

  Total  area – sft

  stock area – sft

  Shift – 3

  • 1st – 6 AM – 2 PM.
  • 2nd – 2 PM – 10 PM.
  • 3rd —  General shift

  Manpower –

  • Asst. Manager – 01
  • Asst. Officer – 01
  • Supervisor – 03
  • Worker –  06

  FLOW CHART OF OPERATION:

 Receiving

 Quantity checking.

Storage / Stacking

 ERP input

 Picking / Supply (As per invoice

Checking / Packing..

 Dispatch

 FINDINGS:

Need more hand for store.

Need lift support for store

Need more space for store.

                          

MAINTANANCE DEPARTMENT:

MAINTANANCE DEPARTMENT   is the vital department for a company.

Common functions are:

  Maintaining all types of machineries

Provide all kind of electrical and mechanical support

To run the production floor smoothly.

BACKUP MACHINERIES FOR POWER SUPPLY:

SL.

NO.NAME OF MACHINE

AND MODELMANUFACTURER DESCRIPTION OF

OPERATIONDEPT.

USINGREMARKS01DIESEL GENERATOR

EM-550PPERKINS

2500 SERIESPOWER GENERATIONUTILITY 02DIESEL GENERATOR

EM-220PPERKINS

POWER GENERATIONUTILITY 03AIR COMPRESSOR

JC-60HHAJUCAIAIR SUPPLYUTILITY 04AIR COMPRESSOR

AW-30008JUCAIAIR SUPPLYUTILITY 05AIR COMPRESSOR

JC-60HHAJUCAIAIR SUPPLYUTILITY01 SET06SHELLMAX STREAM BOILER,

SM-20 DL, 2 TONTHERMEXStream ProduceUTILITY01 SET07DIESEL GENERATOR

EM-44YPERKINS

POWER GENERATIONUTILITY01 SET

NOT USED08WELDING M/C

220V, 160A WELDINGUTILITY01 SET

Training and Development:

Health and OSH Awareness Program

  Fire Fighting Training & Drills

  First Aid Training & Drills

  PPE Usage Training

  Evacuation drills

  Quality Training

  Facility security briefing

  Local labour law awareness

  Skill up-gradation training

  Productivity Training

  KAIZEN Training

CSR for  Employees / Workplace

  Medical care facilities inside the Factory

  Free Immunization for  children of employees

  Free Tetanus vaccination for all female workers

  Child care facilities

  Group Life Insurance Policy for all workers

Workers Profit Participation Fu

Apex Adelchi Footwear  has adopted :

  Global Standards of Footwear Production

  Best current practices to ensure Quality Footwear.

  Ultra Violet Drying Tunnels, Micropak systems and Humidity controls in production and warehouse.

  Up-to-date product content & restriction standards including Chrome VI, PCP, Formaldehyde, Lead, VOC testing

 Industrial Safety:

  • Security is very well
  • Fire Extinguisher
  • Chemical is not close in production area
  • Posturing for awareness
  • Meeting with worker
  • Emergency stair
  • Primary treatment for worker
  • Connected with hospital
  • Pure water supply for whole industry
  • Quality food supply for worker
  • Boundaries area
  • Group insurance for worker whose work in this industry for more than six years
  • Dress, mask, glass provide for worker
  • Civil, electrical and mechanical engineer for industrial safety
  • Fire hose cabinet
  • Use split leather glove when using anti fungus spray
  • Use safety guideline for all machine

CONCLUSION:

Two months industrial training is an important part of our technological education. This training helps me to do the work by direct practice and observation. I have learnt many new industrial terms and many techniques of manufacturing.

We observed many new types of machineries. We have learnt how to deal with a buyer, quality control, costing etc. we also observed conveyer system related production and the layout of this factory.

Finally, we have learnt how to control the total working procedure and management system.

Considering my all observation about the production and management system of Apex Adelchi Footwear Ltd, it is cleared that –Apex Adelchi Footwear Ltd. is one of the leading footwear manufacturing industries in Bangladesh.

  REMARKS

After the industrial training of two months I feel that two months industrial training is not enough for our course. So authority may arrange six months internship in a company so that we can learn the footwear production, management system and labour management system properly.

Apex Adelchi Footwear Ltd